Liebherr l538 1493 Wheel Loader PDF

en Service manual
Wheel loader
L 538-1493
Document ID
Order number: 11827693
Issued: 06-2015
Version: 02
Author: LBH / Technical Documentation Department
Product ID
Manufacturer: Liebherr Machinery (DaLian) Co. Ltd.
Valid for: L 538-1493
Contact Liebherr Machinery (DaLian) Co. Ltd.

No.30, Wanli Street
Dalian
2
copyright by
L538-1493
LBH/11827693/02/211-20150615.1139/en
Preface
Notes for users

This service handbook is designed for trained specialists of the Liebherr organisa-
tion and their dealers.
This service handbook contains special knowledge for repairing Liebherr construc-
tion machines. Basic specialist knowledge on electronics, hydraulics, mechanics
and engine technology is not contained in this service handbook. Therefore speci-
alized training and qualifications are necessary. Liebherr recommends participation
in the Liebherr training program for construction machines.
In this service handbook you will find information on:
– Special tools
– Technical data
– Maintenance intervals and maintenance tasks.
– Testing and adjustment tasks
– Structure and function descriptions
– Removal and installation tasks
– Circuit diagrams, hydraulic plans and technical drawings
You will find information on controls and operation in the operating instructions. In-
formation on spare parts are in the spare parts catalogue. Please observe the local
accident prevention laws.
This document may only be duplicated, even in part, with the permission of Lieb-
herr.
Technical changes are reserved.
Warning symbols
This is the warning symbol. It warns you of poten-

tial injuries. To prevent injury or death, carry out
all the measures identified by this warning sym-
bol.
LBH/11827693/02/211-20150615.1139/en
The warning symbol always appears together with the signal words
DANGER
WARNING
CAUTION
DANGER Indicates a hazardous situation that will immedi-

ately lead to serious or fatal injury if it is not avoi-
ded.
WARNING Indicates a hazardous situation that may lead to
serious or fatal injury if it is not avoided.
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L538-1493 3
Preface Service manual
CAUTION Indicates a hazardous situation that may lead to

minor or moderate injury if it is not avoided.
ATTENTION Indicates a hazardous situation that may lead to

damage if it is not avoided.
Structure of warnings
Warnings in this document are structured as follows:
WARNING
Here you will find information about the type and source of danger.
Here you will be informed about possible consequences of not paying attention to
the warning.
u Here you will be called on to take measures to avoid the dangerous situation.
Other designations
Symbol Meaning
Note useful tips and information.
This symbol means: Carry out a task.
This symbol means: Requirements must be fulfilled.
This symbol means: Results of a task.
- This symbol indicates a list.
Symbols
LBH/11827693/02/211-20150615.1139/en
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4 L538-1493
Contents
010 Introduction 010-1

010.1 Safety instructions 010-3
010.1.1 General safety instructions 010-3
010.1.2 Instructions on preventing crushing injuries and burns 010-4
010.1.3 Instructions on preventing fires and explosions 010-4
010.1.4 Safety instructions for start-up 010-5
010.1.5 Safety precautions during start-up 010-5
010.1.6 Instructions for safe working 010-6
010.1.7 Safety instructions for driving on slopes 010-7
010.1.8 Parking safely 010-7
010.1.9 Transporting the machine safely 010-7
010.1.10 Towing the machine safely 010-8
010.1.11 Measures for ensuring safe maintenance 010-8
010.1.12 Safety instructions for maintenance work on machines with hydro
accumulators 010-11
010.1.13 Safety instructions for welding work on the machine 010-11
010.1.14 Instructions for working safely on the attachment 010-11
010.1.15 Safety instructions for transporting the machine by crane 010-12
010.1.16 Safe maintenance of hydraulic hoses and hose lines 010-12
010.1.17 Roll-over protection structure (ROPS) and falling object protection
structure (FOPS) 010-13
010.1.17.1 Preventing accidents 010-13
LBH/11827693/02/211-20150615.1139/en
010.1.17.2 Preventing injuries 010-13

010.1.18 Attachments and accessories 010-14
010.1.19 Protection against vibrations 010-14
010.1.20 See and be seen 010-15
010.1.20.1 Field of view 010-15
010.1.20.2 Measures before and during operation 010-15
010.2 Special tools for maintenance and repair work 010-16
010.2.1 Special tools, general 010-16
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Contents Service manual
010.2.2 Special tools for the diesel engine 010-16

010.2.3 Special tools for the electrical system 010-17
010.2.4 Special tools for the air conditioning system 010-18
010.2.5 Special tools for cab glazing 010-18
010.2.6 Special tools for the central lubrication system 010-18
010.3 Standards and regulations 010-20
010.3.1 Prestressing forces and tightening torques for bolts with metric
standard and fine threads 010-20
010.3.2 Assembly instructions for the piston and piston nut of the hydraulic
cylinder (WN 4121) 010-24
010.3.2.1 Range of application and purpose 010-24
010.3.2.2 Requirements and description 010-24
010.3.2.3 Amendments 010-29
010.3.2.4 Other applicable documents 010-29
010.3.2.5 Maximum adapter operating pressure 010-34
010.4 Preservation guidelines 010-36
010.4.1 General information 010-36
010.4.2 Putting the machine out of service – unknown duration 010-36
010.4.3 Putting the machine out of service 010-37
010.4.3.1 Out of service for up to 2 months 010-37
010.4.3.3 Out of service for longer than 12 months 010-39
010.4.4 Putting back into service 010-39
010.4.4.1 After being out of service for 2 months 010-39
010.4.4.3 After being out of service for longer than 12 months 010-40
020 Technical data 020-1

LBH/11827693/02/211-20150615.1139/en
020.1 Drive group 020-4

020.1.1 Engine
L538-1493/31405-; 020-4
020.1.2 Fuel tank
L538-1493/31405-; 020-5
020.1.3 Fuel level sensor
L538-1493/31405-; 020-5
020.1.4 Fuel pre-filter (separator filter)
L538-1493/31405-; 020-6
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Service manual Contents
020.1.5 Air filter vacuum switch

L538-1493/31405-; 020-6
020.1.6 Clutch
L538-1493/31405-; 020-6
020.2 Cooling system 020-7
020.2.1 Water cooler
L538-1493/31405-; 020-7
020.2.2 Fan gear pump
L538-1493/31405-; 020-7
020.2.3 Fan gear motor
L538-1493/31405-; 020-7
020.3 Working hydraulics 020-8
020.3.1 Z kinematics control valve block
L538-1493/31405-; 020-8
020.3.2 Working hydraulics pump
L538-1493/31405-; 020-8
020.3.3 P kinematics control valve block
L538-1493/31405-; 020-8
020.3.4 Pilot control hydro accumulator
L538-1493/31405-; 020-9
020.3.5 Stabilisation module (optional)
L538-1493/31405-; 020-9
020.3.6 Ride control hydro accumulator (optional)
L538-1493/31405-; 020-9
020.3.7 Z kinematics lift cylinder
L538-1493/31405-; 020-9
020.3.8 Z kinematics tilt cylinder
L538-1493/31405-; 020-10
020.3.9 P kinematics lift cylinder
L538-1493/31405-; 020-10
020.3.10 P kinematics tilt cylinder
L538-1493/31405-; 020-11
020.4 Travel hydraulics 020-12
020.4.1 Travel pump
LBH/11827693/02/211-20150615.1139/en
L538-1493/31405-; 020-12
020.4.2 Travel motor 1
L538-1493/31405-; 020-12
L538-1493/31405-; 020-12
020.5 Hydraulic components 020-14
020.5.1 Filter unit
L538-1493/31405-; 020-14
020.5.2 Breather filter
L538-1493/31405-; 020-14
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020.6 Steering system 020-15

020.6.1 Servostat
L538-1493/31405-; 020-15
020.6.2 Steering cylinder
L538-1493/31405-; 020-15
020.6.3 Emergency steering pump
L538-1493/31405-; 020-15
020.6.4 Emergency steering pressure switch B3
L538-1493/31405-; 020-16
020.6.5 Emergency steering check pressure switch B3a
L538-1493/31405-; 020-16
020.7 Brake system 020-17
020.7.1 Service brake hydro accumulator
L538-1493/31405-; 020-17
020.7.2 Brake light pressure switch B12
L538-1493/31405-; 020-17
020.7.3 Accumulator charge pressure switch B19
L538-1493/31405-; 020-17
020.7.4 Disc brake
L538-1493/31405-; 020-17
020.7.5 Parking brake hydro accumulator
L538-1493/31405-; 020-18
020.8 Electrical system 020-19
020.8.1 Central control unit (UEC3)
L538-1493/31405-; 020-19
020.8.2 Battery
L538-1493/31405-; 020-19
020.9 Transmission 020-21
020.9.1 Transmission
L538-1493/31405-; 020-21
020.9.2 Output speed sensor B1 and travel motor 2 speed sensor B2
L538-1493/31405-; 020-21
020.10 Axles and cardan shafts 020-22
LBH/11827693/02/211-20150615.1139/en
020.10.1 Front axle

L538-1493/31405-; 020-22
020.10.2 Rear axle
L538-1493/31405-; 020-22
020.10.3 Cardan shaft
L538-1493/31405-; 020-23
020.11 Steel components of the basic machine 020-24
020.11.1 Ballast weight
L538-1493/31405-; 020-24
020.12 Cab, heating and air conditioning 020-25
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020.12.1 Dryer
L538-1493/31405-; 020-25
020.12.2 Pressure switches
L538-1493/31405-; 020-25
020.12.3 Anti-icing temperature sensor
L538-1493/31405-; 020-25
020.13 Lubrication system 020-27
020.13.1 Central lubrication pump EP1
L538-1493/31405-; 020-27
030 Maintenance 030-1

030.1 Maintenance and inspection schedule 030-8
030.2 Filling quantities and lubrication chart 030-13
030.2.1 Recommended lubricants
L538-1493/31405-; 030-13
030.2.2 Recommended operating fluids
L538-1493/31405-; 030-14
030.3 Lubricants and fuels 030-15
030.3.1 General information on changing lubricants and fuels 030-15
030.3.2 Converting the hydraulic system from mineral oils to
environmentally harmless hydraulic fluids 030-15
030.3.3 Diesel fuels
L538-1493/31405-; 030-16
030.3.3.1 Specification 030-16
030.3.3.2 High sulphur content in the diesel fuel 030-16
030.3.3.3 Diesel fuel at low temperatures (winter operation) 030-17
030.3.4 Lubricating oils for diesel engines
L538-1493/31405-; 030-17
030.3.4.1 Lubricating oil quality 030-17
030.3.4.2 Lubricating oil viscosity 030-17
030.3.4.3 Lubricating oil change intervals 030-18
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030.3.5 Coolants for diesel engines

L538-1493/31405-; 030-19
030.3.5.1 General recommendations 030-19
030.3.5.2 Water (fresh water) 030-19
030.3.5.3 Coolant - Mixing ration 030-20
030.3.5.4 Permissible antifreeze and corrosion inhibitors 030-20
030.3.5.5 Corrosion inhibitors without antifreeze 030-21
030.3.6 Hydraulic oil
L538-1493/31405-; 030-21
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030.3.6.1 Liebherr hydraulic oil 030-22

030.3.6.2 Using engine oil as hydraulic oil 030-22
030.3.6.3 Warming up 030-23
030.3.6.4 Biodegradable hydraulic oils 030-23
030.3.6.5 Changing the oil, analysing the oil, changing filters 030-24
030.3.7 Lubricating oils for transmissions
L538-1493/31405-; 030-25
030.3.8 Lubricating oils for axles
L538-1493/31405-; 030-26
030.3.9 Lubrication grease and other lubricants
L538-1493/31405-; 030-27
030.3.9.1 Minimum quality requirements 030-27
030.3.9.2 Liebherr lubrication grease 030-27
030.4 Maintenance tasks 030-29
030.4.1 Safety precautions
L538-1493/31405-; 030-29
030.4.2 Preparatory tasks for maintenance 030-30
030.4.2.1 Maintenance positions
L538-1493/31405-; 030-30
030.4.2.2 Opening the service accesses
L538-1493/31405-; 030-31
030.4.2.3 Turning off the battery main switch
L538-1493/31405-; 030-33
030.4.3 Overall machine 030-34
030.4.3.1 Checking the machine for external damage
L538-1493/31405-; 030-34
030.4.3.2 Removing loose parts, dirt, ice and snow from the
machine
L538-1493/31405-; 030-34
030.4.3.3 Cleaning the machine
L538-1493/31405-; 030-34
030.4.3.4 Checking the machine for leaks
LBH/11827693/02/211-20150615.1139/en
L538-1493/31405-; 030-36
030.4.3.5 Making sure the bolted connections are tight
L538-1493/31405-; 030-36
030.4.3.6 Corrosion protection on machines that work with salt
and artificial fertilisers and exchanging VCI capsules
L538-1493/31405-; 030-36
030.4.3.7 Oil analyses
L538-1493/31405-; 030-37
030.4.4 Drive group 030-43
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030.4.4.1 Checking the engine oil level

L538-1493/31405-; 030-43
030.4.4.2 Changing the engine oil
L538-1493/31405-; 030-44
030.4.4.3 Changing the engine oil filter
L538-1493/31405-; 030-45
030.4.4.4 Checking the V-ribbed belt on the engine
L538-1493/31405-; 030-46
030.4.4.5 Changing the V-ribbed belt on the engine
L538-1493/31405-; 030-47
030.4.4.6 Checking the engine valve clearance
L538-1493/31405-; 030-49
030.4.4.7 Checking the bleeder filter of the crankcase
L538-1493/31405-; 030-51
030.4.4.8 Checking the engine heating flange
L538-1493/31405-; 030-52
030.4.4.9 Draining off condensate and sediment from the fuel
tank
L538-1493/31405-; 030-53
030.4.4.10 Draining off condensate from the Separ fuel pre-filter
L538-1493/31405-; 030-54
030.4.4.11 Draining off condensate from the fuel pre-filter
L538-1493/31405-; 030-55
030.4.4.12 Changing the Separ fuel pre-filter insert
L538-1493/31405-; 030-56
030.4.4.13 Changing the fuel pre-filter
L538-1493/31405-; 030-58
030.4.4.14 Changing the fuel fine filter
L538-1493/31405-; 030-59
030.4.4.15 Bleeding the fuel system
L538-1493/31405-; 030-60
030.4.4.16 Cleaning the air filter service cover and dust
discharge valve
L538-1493/31405-; 030-61
030.4.4.17 Checking the air suction system for leaks and tight
LBH/11827693/02/211-20150615.1139/en
fitting
L538-1493/31405-; 030-63
030.4.4.18 Cleaning or changing the main filter element
L538-1493/31405-; 030-64
030.4.4.19 Changing the air filter safety element
L538-1493/31405-; 030-67
030.4.4.20 Checking the exhaust system for leaks and tight
fitting
L538-1493/31405-; 030-68
030.4.5 Cooling system 030-69
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030.4.5.1 Checking the coolant level

L538-1493/31405-; 030-69
030.4.5.2 Checking the coolant antifreeze and corrosion
inhibitor concentration
L538-1493/31405-; 030-70
030.4.5.3 Cleaning the cooling system
L538-1493/31405-; 030-74
030.4.5.4 Changing the coolant
L538-1493/31405-; 030-75
030.4.6 Working hydraulics 030-77
030.4.6.1 Checking the oil level in the hydraulic tank
L538-1493/31405-; 030-77
030.4.6.2 Checking and cleaning the magnetic rod on the
hydraulic tank
L538-1493/31405-35974; 030-78
030.4.6.3 Checking and cleaning the magnetic rod on the
hydraulic tank
L538-1493/35975-; 030-79
030.4.6.4 Draining off condensate and sediment from the
hydraulic tank
L538-1493/31405-; 030-80
030.4.6.5 Hydraulic tank - changing the return-suction filter
L538-1493/31405-35974; 030-81
030.4.6.6 Changing the hydraulic tank return suction filter
L538-1493/35975-; 030-82
030.4.6.7 Changing the hydraulic tank breather filter
L538-1493/31405-; 030-83
030.4.6.8 Changing the oil in the hydraulic system in
accordance with oil quality and oil analysis
L538-1493/31405-; 030-84
030.4.6.9 Lubricating the solenoids, universal joints and
tappets on the pilot control unit
L538-1493/31405-; 030-86
030.4.7 Steering system 030-87
030.4.7.1 Testing the steering
L538-1493/31405-; 030-87
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030.4.7.2 Lubricating the bearing points on the steering

cylinders
L538-1493/31405-; 030-88
030.4.8 Brake system 030-88
030.4.8.1 Testing the service brake and parking brake
L538-1493/31405-; 030-88
030.4.8.2 Checking the service brake discs for wear
L538-1493/31405-; 030-89
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030.4.8.3 Checking the gap and wear on the parking brake

linings
L538-1493/31405-; 030-91
030.4.9 Electrical system 030-94
030.4.9.1 Checking the lights
L538-1493/31405-; 030-94
030.4.9.2 Checking the batteries, fluid level and terminals
L538-1493/31405-; 030-95
030.4.9.3 Changing the travel direction rocker switch and cap
(optional) on the control lever
L538-1493/31405-; 030-98
030.4.10 Transmission 030-100
030.4.10.1 Checking the transmission oil level
L538-1493/31405-; 030-100
030.4.10.2 Changing the transmission oil
L538-1493/31405-; 030-100
030.4.11 Axles and cardan shafts 030-101
030.4.11.1 Checking the axle oil levels
L538-1493/31405-; 030-101
030.4.11.2 Changing the axle oil
L538-1493/31405-; 030-102
030.4.11.3 Checking the tightening torque of the front axle
fastening bolts
L538-1493/31405-; 030-104
030.4.11.4 Checking the cardan shafts
L538-1493/31405-; 030-104
030.4.11.5 Checking the tyre pressure
L538-1493/31405-; 030-105
030.4.11.6 Checking the wheel tightness (once after 50, 100 and
250 h)
L538-1493/31405-; 030-105
030.4.12 Steel components of the basic machine 030-106
030.4.12.1 Lubricating the articulated bearing and the rear
oscillating bedding
L538-1493/31405-; 030-106
LBH/11827693/02/211-20150615.1139/en
030.4.12.2 Covering - lubricating locks and hinges

L538-1493/31405-; 030-107
030.4.13 Working attachment 030-108
030.4.13.1 Lubricating the lift arms and attachment
L538-1493/31405-; 030-108
030.4.13.2 Checking the lift arm bearing bushings
L538-1493/31405-; 030-109
030.4.13.3 Checking the lift arm bucket stops (Z kinematics)
L538-1493/31405-; 030-110
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030.4.13.4 Lubricating and testing the quick-change device

L538-1493/31405-; 030-110
030.4.14 Cab, heating and air conditioning 030-111
030.4.14.1 Cleaning the fresh and recirculated air filters
L538-1493/31405-; 030-111
030.4.14.2 Changing the fresh and recirculated air filters
L538-1493/31405-; 030-113
030.4.14.3 Checking the condition and function of the safety belt
L538-1493/31405-; 030-114
030.4.14.4 Checking and topping up the windscreen washer
reservoir
L538-1493/31405-; 030-114
030.4.14.5 Checking the seals on the driver’s cab
L538-1493/31405-; 030-115
030.4.14.6 Checking the indicator and filling level beads in the
dryer-collector unit of the air conditioner
L538-1493/31405-; 030-115
030.4.14.7 Testing the air conditioning unit
L538-1493/31405-; 030-116
030.4.15 Lubrication system 030-117
030.4.15.1 Checking the lubrication system grease reservoir
level
L538-1493/31405-; 030-117
030.4.15.2 Checking the pipes, hoses and lubrication points of
the lubrication system
L538-1493/31405-; 030-118
030.4.15.3 Checking whether metered quantities are adequate
at the bearing points (grease collars) of the
lubrication system
L538-1493/31405-; 030-118
030.5 Testing and adjustment checklist
L538-1493/31405-; 030-119
030.6 Testing and adjustment tasks 030-123
L538-1493/31405-; 030-123
LBH/11827693/02/211-20150615.1139/en

030.6.2.1 Preparatory tasks for testing and adjustment
L538-1493/31405-; 030-124
030.6.2.2 Bringing the machine up to operating temperature
L538-1493/31405-; 030-125
030.6.3 Drive group 030-126
030.6.3.1 Inch/brake pedal calibration
L538-1493/31405-; 030-126
030.6.3.2 Checking the engine speed
L538-1493/31405-; 030-126
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030.6.4.1 Fan gear motor proportional pressure relief valve
L538-1493/31405-; 030-127
030.6.5.1 Working hydraulics pump flow regulator (standby
pressure)
L538-1493/31405-; 030-129
030.6.5.2 Z kinematics control valve block secondary pressure
relief valves
L538-1493/31405-; 030-130
030.6.5.3 P kinematics control valve block secondary pressure
relief valves
L538-1493/31405-; 030-132
030.6.5.4 Working hydraulics LS pressure cut-off
L538-1493/31405-; 030-134
030.6.5.5 Stabilisation module (optional), cut-off function
L538-1493/31405-; 030-135
030.6.5.6 Ride control hydro accumulator (optional), nitrogen
filling
L538-1493/31405-; 030-136
030.6.5.7 Testing the control valve block for leakage
L538-1493/31405-; 030-139
030.6.6 Travel hydraulics 030-142
030.6.6.1 Travel pump replenishing pressure relief valve
L538-1493/31405-; 030-142
030.6.6.2 Travel pump high pressure relief valves
L538-1493/31405-; 030-144
030.6.6.3 Travel pump pressure cut-off
L538-1493/31405-; 030-146
030.6.6.4 Travel pump block curve calibration
L538-1493/31405-; 030-148
030.6.6.5 Travel motor 1 start of regulation
L538-1493/31405-; 030-149
030.6.6.6 Travel motor 2 automatic calibration
L538-1493/31405-; 030-151
LBH/11827693/02/211-20150615.1139/en
030.6.6.7 Engine output

L538-1493/31405-; 030-152
030.6.7.1 Steering system LS pressure cut-off
L538-1493/31405-; 030-153
030.6.8 Brake system 030-154
030.6.8.1 Compact brake valve, hydro accumulator charging
function
L538-1493/31405-; 030-154
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030.6.8.2 Service brake pressure

L538-1493/31405-; 030-155
030.6.8.3 Service brake hydro accumulator capacity
L538-1493/31405-; 030-156
030.6.8.4 Accumulator charge pressure switch shift pressure
L538-1493/31405-; 030-158
030.6.9.1 Repairing the Tuple Chain on the central control unit
(UEC3)
L538-1493/31405-; 030-159
030.6.9.2 Resetting the central control unit (UEC3)
L538-1493/31405-; 030-164
030.6.10.1 Transmission hydro accumulator nitrogen filling
L538-1493/31405-; 030-169
040 Drive group 040-1

040.1 Engine 040-2
040.1.1 Diesel engine overview
L538-1493/31405-; 040-2
040.1.2 Crankshaft speed sensor
L538-1493/31405-; 040-6
040.1.3 Fuel temperature sensor
L538-1493/31405-; 040-7
040.1.4 Charge air temperature sensor
L538-1493/31405-; 040-7
040.1.5 Fuel system 040-8
040.1.5.1 Overview of the fuel system
L538-1493/31405-; 040-8
040.1.5.2 Fuel pre-filter
L538-1493/31405-; 040-15
040.1.5.3 Separ fuel pre-filter
L538-1493/31405-; 040-16
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040.1.5.4 Fuel fine filter

L538-1493/31405-; 040-17
040.1.6 Air filter system 040-17
040.1.6.1 Overview of the air filter unit
L538-1493/31405-; 040-18
040.1.6.2 Air filter
L538-1493/31405-; 040-19
040.2 Coupling
L538-1493/31405-; 040-20
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050 Cooling system 050-1

050.1 Hydraulic control unit 050-2
050.1.1 Overview of the hydraulics cooling system
L538-1493/31405-; 050-2
L538-1493/31405-; 050-4
L538-1493/31405-; 050-5
050.2 Electronic control unit 050-9
050.2.1 Coolant temperature sensor
L538-1493/31405-; 050-9
050.2.2 Hydraulic oil temperature sensor
L538-1493/31405-; 050-10
L538-1493/31405-; 050-12
050.3 Cooler 050-14
L538-1493/31405-; 050-14
050.3.2 Hydraulic oil cooler
L538-1493/31405-; 050-15
050.3.3 Intercooler
L538-1493/31405-; 050-17
060 Working hydraulics 060-1

060.1 Overview of working hydraulics for z-bar kinematics
L538-1493/31405-; 060-3
060.2 Overview of working hydraulics for p kinematics
L538-1493/31405-; 060-8
060.3 Working hydraulics pump
L538-1493/31405-; 060-12
060.4 Control valve block for Z-bar kinematics
L538-1493/31405-; 060-16
060.5 Control valve block for P kinematics
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L538-1493/31405-; 060-22
060.6 Pilot control 060-27
060.6.1 Overview of the pilot control unit
L538-1493/31405-; 060-27
060.6.2 Pilot control unit
L538-1493/31405-; 060-28
060.6.3 Working hydraulics lockout solenoid valve
L538-1493/31405-; 060-33
L538-1493/31405-; 060-34
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060.7 Ride control 060-35

060.7.1 Ride control overview
L538-1493/31405-; 060-35
060.7.2 Stabilisation module
L538-1493/31405-; 060-36
060.7.3 Ride control hydro accumulator
L538-1493/31405-; 060-41
060.8 Working hydraulics cylinder 060-42
060.8.1 Hydraulic cylinders for Z kinematics 060-42
060.8.1.1 Z kinematics lift cylinder
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060.8.1.2 Z kinematics tilt cylinder
L538-1493/31405-; 060-44
060.8.2 Hydraulic cylinders for P kinematics 060-45
060.8.2.1 P kinematics lift cylinder
L538-1493/31405-; 060-46
060.8.2.2 P kinematics tilt cylinder
L538-1493/31405-; 060-47
070 Travel hydraulics 070-1

070.1 Travel hydraulics overview
L538-1493/36292-31404; 070-2
L538-1493/31405-; 070-7
070.3 Travel pump
L538-1493/31405-36291; 070-12
070.4 Travel pump
L538-1493/36292-; 070-26
070.5 Travel motors 070-41
070.5.1 Overview of the travel motors
L538-1493/31405-; 070-41
L538-1493/31405-; 070-43
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L538-1493/31405-; 070-50
080 Hydraulic components 080-1

080.1 Hydraulic tank 080-2
080.1.1 Overview of the hydraulic tank
L538-1493/31405-; 080-2
080.1.2 Filter unit
L538-1493/31405-; 080-4
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L538-1493/31405-; 080-9
090 Steering system 090-1

090.1 Steering system overview
L538-1493/31405-35802; 090-2
L538-1493/35803-; 090-6
090.3 Servostat
L538-1493/31405-; 090-10
090.4 Steering cylinder 090-14
090.4.1 Steering cylinder overview
L538-1493/35803-31404; 090-14
L538-1493/31405-; 090-16
090.4.3 Steering damper hydro accumulator
L538-1493/35803-; 090-18
090.5 Emergency steering 090-19
090.5.1 Emergency steering overview
L538-1493/31405-; 090-19
L538-1493/31405-; 090-20
090.5.3 Electronic control unit 090-22
090.5.3.1 Overview of the electronic control system
L538-1493/31405-; 090-22
090.5.3.2 Emergency steering pressure switch
L538-1493/31405-; 090-23
090.5.3.3 Emergency steering check pressure switch
L538-1493/31405-; 090-24
090.5.4 Valve block
L538-1493/31405-; 090-25
100 Brake system 100-1

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100.1 Overview of the brake system

L538-1493/31405-; 100-2
100.2 Service brake and parking brake 100-4
100.2.1 Brake system gear pump
L538-1493/31405-; 100-4
100.2.2 Compact brake valve
L538-1493/31405; 100-5
100.3 Service brake 100-12
100.3.1 Overview of the service brake
L538-1493/31405-; 100-12
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L538-1493/31405-; 100-15
100.3.3 Brake light pressure switch
L538-1493/31405-; 100-16
100.3.4 Accumulator charge pressure switch
L538-1493/31405-; 100-17
100.4 Parking brake 100-18
100.4.1 Overview of the parking brake
L538-1493/31405-; 100-18
100.4.2 Disc brake
L538-1493/31405-; 100-21
L538-1493/31405-; 100-22
110 Electrical system 110-1

110.1 Overview of the electrical system
L538-1493/31405-; 110-2
110.2 Lighting
L538-1493/31405-; 110-7
110.3 Circuit diagrams
L538-1493/31405-; 110-9
110.4.1 Overview of the electronic control system
L538-1493/31405-; 110-11
L538-1493/31405-; 110-13
110.5 Electrical components of the driver’s cab 110-18
110.5.1 Fuse and relay board
L538-1493/31405-; 110-18
110.6 Electrical components in the rear section 110-22
110.6.1 Battery installation
L538-1493/31405-; 110-22
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120 Transmission 120-1

120.1 Overview of the transmission
L538-1493/31405-; 120-2
120.2 Mechanical transmission
L538-1493/31405-; 120-3
L538-1493/31405-; 120-9
120.3.2 Output speed sensor and travel motor 2 speed sensor
L538-1493/31405-; 120-10
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120.4.1 Overview of the hydraulic control system
L538-1493/31405-; 120-11
130 Axles and cardan shafts 130-1

130.1 Axles 130-2
130.1.1 Front axle
L538-1493/31405-; 130-2
130.1.2 Rear axle
L538-1493/31405-; 130-6
130.2 Cardan shafts 130-7
L538-1493/31405-; 130-7
140 Steel components of the basic machine 140-1

140.1 Vehicle frame 140-2
140.1.1 Articulation bearing
L538-1493/31405-; 140-2
140.1.2 Articulation lock
L538-1493/31405-; 140-3
150 Working attachment 150-1

150.1 Lift arms with Z kinematics 150-2
150.1.1 Z kinematics lift arms
L538-1493/31405-; 150-2
150.1.2 Pin bearing 150-2
150.1.2.1 Z kinematics standard pin bearing
L538-1493/31405-; 150-3
150.2 Lift arms with P kinematics 150-4
150.2.1 P kinematics lift arm
L538-1493/31405-; 150-4
150.3 Z kinematics quick coupler
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L538-1493/31405-; 150-5
150.4 P kinematics quick coupler
L538-1493/31405-; 150-9
160 Cab, heating and air conditioning 160-1

160.1 Overview of the cab, heating and air conditioning unit
L538-1493/31405-; 160-3
160.2 Display and control elements 160-5
160.2.1 Electrical components in the control panel 160-5
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160.2.1.1 Overview of electrical components in the control

panel
L538-1493/31405-; 160-5
160.2.1.2 Control unit for main functions
L538-1493/31405-; 160-5
160.2.1.3 Starter switch
L538-1493/31405-; 160-8
160.2.2 Display
L538-1493/31405-; 160-9
160.2.3 Control lever
L538-1493/31405-; 160-10
160.3 Heating, ventilation, air conditioning 160-13
160.3.1 Overview of the heating, ventilation and air conditioning system
L538-1493/31405-; 160-13
160.3.2 Heating and air conditioning unit 160-16
160.3.2.1 Heater/blower unit
L538-1493/31405-; 160-16
160.3.2.2 Blower
L538-1493/31405-; 160-19
160.4 Air conditioning 160-20
160.4.1 Air conditioning (optional)
L538-1493/31405-; 160-20
160.4.2 Condenser
L538-1493/31405-; 160-23
160.4.3 Dryer
L538-1493/31405-; 160-23
160.4.4 Air conditioning pressure switch
L538-1493/31405-; 160-25
160.4.5 Evaporator
L538-1493/31405-; 160-26
190 Options 190-1

190.1 Reversible fan drive
L538-1493/31405-; 190-2
LBH/11827693/02/211-20150615.1139/en
200 Service codes, diagnosis 200-1

200.1 Malfunctions 200-2
200.1.1 Warning symbols 200-2
200.2 Troubleshooting 200-3
200.2.1 Replacing fuses 200-3
200.2.1.1 Fuses in the battery compartment 200-3
200.2.1.2 Plug-in fuses on the relay and fuse board 200-4
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22 L538-1493
010 Introduction
Contents
010.1 Safety instructions 010-3
010.1.1 General safety instructions 010-3
010.1.2 Instructions on preventing crushing injuries and burns 010-4
010.1.3 Instructions on preventing fires and explosions 010-4
010.1.4 Safety instructions for start-up 010-5
010.1.5 Safety precautions during start-up 010-5
010.1.6 Instructions for safe working 010-6
010.1.7 Safety instructions for driving on slopes 010-7
010.1.8 Parking safely 010-7
010.1.9 Transporting the machine safely 010-7
010.1.10 Towing the machine safely 010-8
010.1.11 Measures for ensuring safe maintenance 010-8
010.1.12 Safety instructions for maintenance work on machines with hydro
accumulators 010-11
010.1.13 Safety instructions for welding work on the machine 010-11
010.1.14 Instructions for working safely on the attachment 010-11
010.1.15 Safety instructions for transporting the machine by crane 010-12
010.1.16 Safe maintenance of hydraulic hoses and hose lines 010-12
010.1.17 Roll-over protection structure (ROPS) and falling object protection
structure (FOPS) 010-13
010.1.17.1 Preventing accidents
LBH/11827693/02/211-20150615.1139/en
010-13
010.1.17.2 Preventing injuries 010-13
010.1.18 Attachments and accessories 010-14
010.1.19 Protection against vibrations 010-14
010.1.20 See and be seen 010-15
010.1.20.1 Field of view 010-15
010.1.20.2 Measures before and during operation 010-15
010.2 Special tools for maintenance and repair work 010-16
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L538-1493 010-1
Introduction Service manual
010.2.1 Special tools, general 010-16

010.2.2 Special tools for the diesel engine 010-16
010.2.3 Special tools for the electrical system 010-17
010.2.4 Special tools for the air conditioning system 010-18
010.2.5 Special tools for cab glazing 010-18
010.2.6 Special tools for the central lubrication system 010-18
010.3 Standards and regulations 010-20
010.3.1 Prestressing forces and tightening torques for bolts with metric
standard and fine threads 010-20
010.3.2 Assembly instructions for the piston and piston nut of the hydraulic
cylinder (WN 4121) 010-24
010.3.2.1 Range of application and purpose 010-24
010.3.2.2 Requirements and description 010-24
010.3.2.3 Amendments 010-29
010.3.2.4 Other applicable documents 010-29
010.3.2.5 Maximum adapter operating pressure 010-34
010.4 Preservation guidelines 010-36
010.4.1 General information 010-36
010.4.2 Putting the machine out of service – unknown duration 010-36
010.4.3 Putting the machine out of service 010-37
010.4.3.3 Out of service for longer than 12 months 010-39
010.4.4 Putting back into service 010-39
010.4.4.3 After being out of service for longer than 12 months 010-40
LBH/11827693/02/211-20150615.1139/en
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010-2 L538-1493
Service manual Introduction
Safety instructions
010.1 Safety instructions
010.1.1 General safety instructions

1. Familiarise yourself with the operating manual before starting up the ma-
chine.
Make sure that you are in possession of additional instructions on any special
equipment installed on your machine, and that you have read and understood
them.
2. Only expressly authorised personnel may operate, service or repair the ma-
chine.
Observe the legal minimum ages.
3. Only trained or instructed personnel may operate the machine. Clearly assign
responsibility for operation, rigging, maintenance and repair work.
4. Clearly establish the driver’s responsibilities (also with respect to traffic regula-
tions) and authorise him to refuse to carry out unsafe instructions from third
parties.
5. Personnel undergoing training and instruction or who are not yet fully qualified
may only be allowed to work on the machine under constant supervision by an
experienced person.
6. Now and again check that your personnel are working safely and are aware of
possible dangers in observance of the operating manual.
7. Wear safe working clothes when working on the machine.
Do not wear rings, wristwatches, ties, scarves, unbuttoned jackets, loose cloth-
ing or similar garments, as they can become caught in the machinery and
cause injury.
Certain tasks require safety goggles, safety boots, hard hats, gloves, reflective
vests, ear protection etc.
8. Ask the site manager about any special safety regulations in force on the site.
9. Do not hold onto the steering column, the control panel or the control levers
when getting on or off the machine.
You might inadvertently trigger movements which could lead to accidents.
10. Never jump down from the machine. Use the steps, ladders and platforms pro-
vided for getting on and off.
11. Keep all handles, steps, rails, gangways, platforms and ladders free from oil,
grease, mud snow and ice. This reduces the risk of slipping, tripping up or fall-
ing.
12. Familiarise yourself with the emergency exit through the right cab door and/or
the rear window.
13. Unless there are other instructions, perform maintenance and repair work as
follows:
Procedure:
LBH/11827693/02/211-20150615.1139/en
• Park the machine on firm, level ground and lower the working attachment
to the ground.
• Move all control levers to neutral.
• Shut down the engine and take out the ignition key.
14. Before starting any work on the hydraulic circuit, you must also press the work-
ing hydraulics lockout button and actuate all pilot control units (joystick and
pedals) in both directions in order to reduce the control pressure and accumu-
lated pressure in the operating circuits. You must then reduce the internal tank
pressure.
15. Lock the working hydraulics to prevent accidental actuation before leaving the
driver’s cab.
Lock the working hydraulics in accordance with the instructions in the operat-
ing manual.
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L538-1493 010-3
Safety instructions
16. Secure all loose parts of the machine.

17. Never start up a machine without first making a thorough tour of inspection
and checking if any warning signs are missing or illegible.
18. Observe all signs with warnings or safety instructions.
19. Special safety apparatus must be fitted to the machine for certain applications.
If this is the case, only work with this apparatus fitted and in working order.
20. Do not make any modifications, extensions or conversions to the machine with
possible safety implications without the approval of the supplier. This also ap-
plies to installing and adjusting safety apparatus and valves, as well as to
welding load-bearing components.
21. Avoid standing near the engine while it is running. People who have a pace-
maker must not stand next to the diesel engine while it is running (minimum
distance 50 cm).
22. Do not touch live components of the solenoid controlled unit pumps on their
electrical connections.
010.1.2 Instructions on preventing crushing injuries and burns

1. Do not work under the attachment if it is not resting on the ground or suppor-
ted.
2. Do not use any ropes or chains which are damaged or which have insufficient
load bearing capacity.
Wear protective gloves when handling wire ropes.
3. When working with the attachment, never align the boreholes with your fin-
gers, instead, use a suitable mandrel for this purpose.
4. Make sure no objects come into contact with the fan when the engine is run-
ning.
Objects which fall or project into the fan will be thrown back out or destroyed
and could damage the fan.
5. When the machine is near operating temperature, the engine cooler system is
hot and pressurised.
Do not touch parts carrying cooling water.
This can lead to burns.
6. Only check the coolant level once the cap on the expansion tank has cooled
down enough to touch.
Carefully open the cap to let out excess pressure.
7. When running at or near the operating temperature, the engine oil and hy-
draulic oil are hot.
Avoid touching hot oil or parts which carry oil.
8. Wear goggles and safety gloves when working on the battery.
Avoid sparks and naked lights.
9. Never let anyone move the bucket or other working attachments into position
by hand.
10. Any time you open the engine compartment, prevent the compartment doors
LBH/11827693/02/211-20150615.1139/en
from falling shut using the struts provided.

11. Before starting up the machine, close and lock the engine compartment doors
and the battery compartment cover.
12. Never lie under the machine when it is raised using the working attachment,
unless the undercarriage is securely supported using wooden beams.
13. Avoid touching hot surfaces and liquids. This can lead to burns.
010.1.3 Instructions on preventing fires and explosions

1. When refuelling, the engine must be turned off. Switch off the auxiliary heater,
if installed.
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010-4 L538-1493
Safety instructions
2. Do not smoke. Avoid naked flames when refuelling or where batteries are be-
ing recharged.
3. Always follow the instructions in the operating manual when starting the en-
gine.
4. Check the electrical system.
Immediately eliminate all faults such as loose connections, worn cables or
burnt out fuses and bulbs.
5. Do not carry combustible fluids on the machine outside the tanks provided.
6. Regularly check all lines, hoses and bolted connections for leaks and damage.
7. Repair the leaks immediately and replace the damaged components.
Oil escaping from leaks can easily cause fires.
8. Make sure that all brackets and protective plates are properly installed to pre-
vent vibrations, abrasion and heat build-up.
9. Starting agent (ether) is a particularly dangerous fire hazard.
Never use ether starting agent near head sources, naked lights (such as ciga-
rettes) or in poorly ventilated spaces.
10. Do not use starting agents containing ethers to start diesel engines with pre-
glow or flame glow systems.
Otherwise there is a RISK OF EXPLOSION.
11. Familiarise yourself with the location and use of fire extinguishers and find out
about fire alarm and firefighting facilities on site.
010.1.4 Safety instructions for start-up

1. Each time you start up the machine, make a thorough tour of inspection.
2. Check the machine for loose bolts, cracks, wear, leaks and deliberate dam-
age.
3. Never start up a damaged machine.
4. Make sure the damage is rectified immediately.
5. Ensure that all hoods and covers are closed and locked. Check that all the
warning and instruction signs are in place.
6. Clean the windows and interior and exterior mirrors, and secure the doors and
windows against inadvertent movement.
7. Make sure no-one is working on or underneath the machine. Warn any by-
standers before you start up the machine.
8. After getting into the driver’s cab, adjust the seat, the inside and outside mir-
rors, the control lever and the safety belt so that you can work comfortably.
9. Sound insulation equipment on the machine must be in place during operation.
010.1.5 Safety precautions during start-up

1. Before starting, check that all control lamps and instruments are working prop-
erly.
LBH/11827693/02/211-20150615.1139/en
2. Move all control levers to neutral.

3. Before starting the engine, briefly sound the horn to warn anyone else in the
vicinity of the machine.
4. Only start the machine when sitting in the driver’s seat.
5. Unless otherwise instructed, start the engine in accordance with the instruc-
tions in the operating manual.
6. Start the engine and then check all display and monitoring equipment.
7. Only run the engine in enclosed spaces when there is sufficient ventilation.
If necessary, open the windows and doors to ensure adequate fresh air.
8. Run the engine until both it and the hydraulic oil are at operating temperature.
Low oil temperatures lead to sluggish performance.
9. Check that the attachment controls are working properly.
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Safety instructions
10. Carefully drive the machine to open ground and check the service brake, the
steering, the signals and lighting.
010.1.6 Instructions for safe working

1. Before starting work, familiarise yourself with the features of the site, as well
as any special regulations and warning signals.
The working environment includes obstacles in the working area and on ac-
cess roads, the firmness of the terrain and any protective barriers to prevent
the public from entering the site.
2. Always keep a safe distance from overhangs, drops, slopes and unsafe ter-
rain.
3. Be especially careful with variable terrain conditions, poor visibility and
changeable weather.
4. Find out where the supply pipes to the site are, and be especially careful when
working near them. If necessary, notify the relevant authorities.
5. Keep a safe distance away from overhead power lines.
When working near overhead power lines, keep the attachment well away
from them.
• There is a risk of FATAL INJURY.
• Find out about the safety clearances to be observed.
If the machine comes into contact with live power lines:
• Do not get out of the machine.
• If possible, move the machine to a safe distance away from the danger
area.
• Warn any bystanders not to approach or touch the machine.
• Arrange for the power to be switched off.
• Only get out of the machine when you are sure that the power line you
have touched or damaged has been switched off.
6. Before driving or working with the machine, check that the accessories are
safely stowed away.
7. When driving on public roads, paths and spaces, observe the traffic regula-
tions, and make sure the machine is in a fit condition to use public roads if this
is not already the case.
8. Always switch on the lights in darkness and poor visibility.
9. Do not take passengers on the machine.
10. Only work seated and wearing a safety belt.
11. Report any malfunctions and make sure that any necessary repairs are carried
out immediately.
12. Take personal care to ensure that no-one is endangered when the machine
starts moving.
13. Before starting work, check the brake system as instructed in the operating
manual.
14. Never get out of the driver’s seat when the machine is still in motion.
LBH/11827693/02/211-20150615.1139/en
15. Never leave the machine unattended with the engine running.
16. When driving the machine, lower the working attachment to the transport posi-
tion and carry the load as close as possible to the ground.
17. Avoid movements which could cause the machine to tip over.
If the machine does start to tip over or slide sideways, put down the attach-
ment immediately and point the machine downhill.
Wherever possible, work up or downhill and not sideways to the slope.
18. Drive carefully on rocky or slippery terrain and on slopes.
19. Only drive downhill within the permitted speed limit, otherwise you could lose
control of the machine.
The engine must be running at the rated speed and you should only reduce
the travel speed using the pedals.
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010-6 L538-1493
Safety instructions
Shift down to a lower gear before reaching the slope. Do not wait until you are
actually on it.
20. When loading a truck, insist on the driver getting out of his cab, even if it is
protected against stone impact.
21. When performing work such as demolition work, clearance and crane opera-
tion, always use the protective equipment provided for these specific tasks.
22. Have someone direct you when vision is restricted and whenever else it is
necessary.
Only let one person give you signals.
23. Only allow experienced personnel to sling loads and direct crane drivers.
The person giving directions must remain in sight of the operator or at least be
in spoken contact with him.
010.1.7 Safety instructions for driving on slopes

1. On downward slopes, always drive carefully and never at top speed, as you
could otherwise lose control over the machine.
Travel speeds:
• Never exceed the speed limits specified in the operating manual.
• Exceeding the maximum speed causes the permitted limits to be exceeded
for all rotating parts, including the drive motor, the drive shaft, all gears in-
cluding axles and ultimately the engine itself.
2. Before driving onto a slope, therefore select a travel range (gear) in which you
can safely negotiate the whole slope without endangering yourself, the ma-
chine and other people.
3. Also, take your foot off the accelerator pedal when driving onto a slope.
010.1.8 Parking safely

1. When possible, always park the machine on flat, firm ground.
If you have to park on a slope, use wheel wedges to prevent the machine from
moving.
2. If the machine has articulated steering, engage the articulation lock.
This only applies to wheel loaders with articulated steering.
3. Lower the digging attachment so that it is lightly anchored in the ground.
4. Move all control levers to the neutral position and engage the parking brake.
5. Shut down the engine in accordance with the instructions in the operating
manual.
6. Lock the working hydraulics before leaving the driver's cab.
ing manual.
7. Lock up the machine, take out all keys and secure it against unauthorised use
and vandalism.
LBH/11827693/02/211-20150615.1139/en
010.1.9 Transporting the machine safely

1. Only use suitable transport equipment and lifting gear with sufficient load ca-
pacity.
2. Park the machine on flat ground and use wedges to secure the tracks or
wheels.
3. If necessary, dismantle the working attachment for the duration of transport.
4. The ramp for driving onto the low-bed truck must not be steeper than 30° and
should be covered with wooden boards to prevent slipping.
5. Clean the machine tracks or wheels of snow, ice and mud before driving onto
the ramp.
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Safety instructions
6. Before driving on, secure the upper carriage to the undercarriage with the lock-
ing pin.
Procedure (does not apply to wheel loaders):
7. Align the machine precisely with the loading ramp.
8. Attach the hand lever to the pedals for sensitive driving.
Procedure (does not apply to wheel loaders):
9. Have someone give signals to direct the driver.
Drive carefully onto the ramp and then on to the transport vehicle itself.
10. Have wedges ready to prevent the machine from rolling back when driving on.
11. Tilt the attachment in and drive onto the ramp.
Keep the attachment close to the loading area.
12. After driving on, lower the working attachment onto the loading area.
Apply the articulation lock (this only applies to wheel loaders with articulated
steering).
13. Secure the machine and the remaining individual components against slipping
using chains and wedges.
14. Relieve the pressure lines, take out the ignition key, lock the cab door and side
panels, and get out of the machine.
15. Acquaint yourself with the route before transport, especially as regards the
width, height and weight limits you will encounter.
16. Make a special note of any overhead power lines, bridges and tunnels along
the route.
17. Apply the same care when driving off.
Procedure:
• Remove all chains and wedges.
• Start the engine in accordance with the instructions in the operating man-
ual.
• Carefully drive off the loading area using a ramp.
• Keep the attachment close to the ground.
• Have someone give you directions.
010.1.10 Towing the machine safely

1. Always observe the correct procedure as described in the operating manual.
2. The machine may only be towed in exceptional circumstances, for example to
move it away from a dangerously exposed position for repairs.
3. Before pulling or towing the machine, check that all attachments and towing
equipment are safe and secure.
4. The rope or bar used for towing must have sufficient tensile strength and be
fastened to the holes provided on the front section.
Damage or accidents resulting from towing are not covered by the manufactur-
er’s guarantee in any circumstances whatsoever.
Instructions on towing by rope:
LBH/11827693/02/211-20150615.1139/en
• Make sure no-one is near the taut rope when towing.

• Keep the rope taut and avoid kinks.
• Carefully pull the rope taut.
• Sudden jerks can cause a slack rope to tear.
5. When towing, keep to the prescribed transport position, speed limit and route.
6. When starting the machine up again, follow the instructions in the operating
manual.
010.1.11 Measures for ensuring safe maintenance

1. Never attempt maintenance and repair work unless you are qualified to do so.
copyright by
010-8 L538-1493
Safety instructions
2. Observe the prescribed periods for regular checks and inspections or those
specified in the operating manual.
A suitably equipped workshop is absolutely necessary in order to perform re-
pair work.
3. The table at the end of this operating manual states exactly who may carry
out each job.
The jobs listed under daily / weekly in the maintenance schedule can be car-
ried out by the driver or by service personnel.
The other jobs may only be carried out by suitably qualified specialist staff.
4. Spare parts must meet the technical requirements specified by the manufac-
turer. This is guaranteed if you use genuine spares. Spare parts which do not
meet the manufacturer's technical specifications can impair the safety and reli-
ability of the machine.
5. Wear safety overalls for maintenance work. Certain jobs not only require a
hard hat and safety boots, but also goggles and safety gloves.
6. Keep unauthorised persons away from the machine during maintenance.
7. Set up an extended cordon around the maintenance area as necessary.
8. Notify the operating personnel before starting repairs or other special jobs.
Nominate a supervisor.
9. Unless otherwise specified in the operating manual, carry out all mainte-
nance work on the machine on firm, level ground with the engine off.
10. Afterwards always re-tighten any bolts loosened during maintenance and re-
pair work.
11. If safety equipment has to be dismantled for rigging, maintenance and repair
work, it must be re-installed and checked as soon as the job is finished.
12. When undertaking maintenance jobs, especially under the machine, attach a
warning sign marked DO NOT SWITCH ON to the ignition where it is clearly
visible. Take out the ignition key.
13. Before starting maintenance or repairs, clean any oil, fuel or service fluids from
the machine, especially connections and bolted joints. Do not use abrasive
cleaning agents. Use fibre-free cloths.
14. Before welding, burning and sanding, clean any dust from the machine and the
area around it, and ensure adequate ventilation.
Otherwise there is a RISK OF EXPLOSION.
15. Before cleaning the machine with water, steam jet (high-pressure cleaner) or
other cleaning agents, cover or tape up all openings where water, steam and
cleaning agent may not penetrate for safety reasons.
Electric motors, control cabinets and battery compartments are at particular
risk.
Further procedure:
• Make sure that during cleaning work on the machine housings, the temper-
ature sensors for the fire alarm and extinguisher systems do not come into
contact with hot cleaning agent. Otherwise the fire extinguishing system
could be activated.
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• After cleaning, completely remove the covers and tape.

• After cleaning, check all fuel, engine oil and hydraulic oil lines for leaks,
loose connections, abrasion and damage.
• Repair any defects immediately.
16. Follow the safety instructions for the product in question when handling oil,
grease and other chemical substances.
17. Dispose of spare parts and consumables in a safe, environmentally sound
manner.
18. Take care when handling hot operating and auxiliary materials (danger of
burns and scalding).
19. Only operate combustion engines and fuel-powered heaters in sufficiently ven-
tilated rooms. Before starting the engine inside a building, make sure the room
is well ventilated. Follow the local regulations in force at the site.
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L538-1493 010-9
Safety instructions
20. Only carry out welding, burning and grinding work when it is expressly allowed.
There may be a risk of fires or explosions, for example.
21. Do not try to lift heavy parts. Only use suitable equipment with sufficient load
capacity.
Procedure:
• When replacing individual parts and larger assemblies, carefully fasten and
secure them to the lifting gear so that no danger can arise.
• Only use suitable lifting gear in perfect order, and slinging equipment with
sufficient load capacity.
Keep out from under suspended loads.
22. Do not use ropes which are damaged or of insufficient load bearing capacity.
Wear protective gloves when handling wire ropes.
23. Only allow experienced personnel to sling loads and direct crane drivers. The
person giving directions must remain in sight of the operator or at least be in
spoken contact with him.
24. When carrying out fitting work above head height, use the safety climbing aids
and working platforms provided or equivalent. Do not use parts of the machine
for climbing. Wear a safety harness when working at height. Keep all handles,
steps, rails, gangways, platforms and ladders free from dirt, snow and ice.
25. When working on the attachment (for example replacing teeth), make sure it is
properly supported. Avoid direct metal-to-metal contact.
26. Never lie under the machine when it is raised using the working attachment,
unless the undercarriage is securely supported using wooden beams.
27. Always support the machine on blocks, so that it cannot become unbalanced
by any shift in weight. Avoid metal-to-metal contact.
28. Only trained specialist staff may perform work on the chassis, brake and steer-
ing systems.
29. If you have to repair the machine on a slope, secure the wheels with wedges.
Move the working attachment to the maintenance position and engage the ar-
ticulation lock.
30. Only personnel with the requisite skills and experience may work on hydraulic
equipment.
31. Wear protective gloves when looking for leaks. Under pressure, a thin jet of liq-
uid can pierce the skin.
32. Never release hydraulic lines or bolts before setting down the working attach-
ment and shutting down the engine.
Before starting any work on the hydraulic circuit, you must also press the work-
pressure.
33. Regularly check all hydraulic oil lines, hoses and bolted connections for leaks
and visible damage. Repair all damage immediately. Oil escaping under pres-
sure can cause injury and fires.
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34. Before beginning repair work, depressurise the system sections and pressur-
ised lines (hydraulics, compressed air) which are to be opened, as instructed
in the assembly descriptions.
35. Lay and fit hydraulic and compressed air lines in the proper manner. Do not
switch the connections. Fittings, as well as the length and quality of the hose
lines, must match the manufacturer’s requirements.
Only use Liebherr spare parts.
36. Replace hydraulic hose lines at appropriate intervals, even if there are no ap-
parent defects which may impair safety.
37. Work on the machine’s electrical equipment may only be carried out by a
qualified electrician or by instructed persons under the direction and supervi-
sion of a qualified electrician, in accordance with the recognised electrical en-
gineering rules.
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010-10 L538-1493
Safety instructions
38. Only use original fuses with the stated current ratings. If there are malfunctions
in the electrical power supply, switch off the machine immediately.
39. Inspect and test the machine’s electrical equipment regularly. Immediately rec-
tify all faults, such as loose connections, scorched or worn cables or burnt out
fuses and bulbs.
40. If you have to carry out work on live components, have a second person assist
you, who can throw the emergency stop or main switch in an emergency. Cor-
don off the working area with a red and white safety chain and a warning sign.
Only use insulated tools.
41. When working on high-voltage assemblies after they have been isolated from
the power supply, short the supply cable and the components, such as capaci-
tors, with an earthing rod.
42. First, check that the isolated parts are not live, connect them to earth and then
short them. Isolate any neighbouring live parts.
010.1.12 Safety instructions for maintenance work on machines

with hydro accumulators
1. Only qualified staff may carry out work on the hydraulic and pneumatic con-
nections of the membrane accumulator.
2. Serious accidents could result from inexpert fitting and operation.
3. The hydraulic system must be depressurised before work can be carried out
on it.
4. Do not carry out any welding or soldering work on the membrane accumulator.
There is a risk of explosions.
5. The accumulator may burst during machining, resulting in the loss of the oper-
ating permit.
6. Hydro accumulators may only be filled with nitrogen, not with oxygen or air -
otherwise there is a risk of explosion.
7. The accumulator can heat up, causing burns.
8. Do not use membrane accumulators which have been damaged during trans-
portation.
9. New membrane accumulators must be filled with nitrogen before they are
used. Remove the sealing caps on the fluid side.
10. The minimum and maximum operating data are permanently marked on the
membrane accumulator. The marking must remain visible.
010.1.13 Safety instructions for welding work on the machine

1. Keep to the following procedure during welding work on the machine.
• Switch off the ignition.
• Switch off battery main switch (if available).
• Bring the ground of the welding machine as close as possible to the weld-
LBH/11827693/02/211-20150615.1139/en
ing point.
• Only specialized personnel may carry out welding.
010.1.14 Instructions for working safely on the attachment

1. Do not work under the attachment if it is not resting on the ground or suppor-
ted.
2. When replacing attachment components (decals, cutting edge, teeth etc.),
avoid metal resting on metal.
3. Do not try to lift heavy parts. Only use suitable equipment with sufficient load
capacity.
4. Always wear gloves when working with wire ropes.
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L538-1493 010-11
Safety instructions
5. Never release hydraulic lines or bolts before setting down the working attach-
ment and shutting down the engine.
Before starting any work on the hydraulic circuit, you must also press the work-
pressure.
6. Ensure that all lines and threaded couplings are reconnected and re-tightened
on completion of the job.
7. Be especially careful when removing or inserting bolts and pins made of hard-
ened steel, as they can splinter, causing serious injury.
Wear safety gloves and goggles.
Whenever possible, use special tools (such as mandrels or extractors).
010.1.15 Safety instructions for transporting the machine by

crane
1. Lower the working attachment and tilt back the loading equipment to its limit.
2. Apply the articulation lock (this only applies to wheel loaders with articulated
steering).
3. Move all control levers to the neutral position and engage the parking brake.
4. Shut down the engine in accordance with the instructions in the operating
manual.
5. Lock the working hydraulics before leaving the driver's cab.
ing manual.
6. Lock all doors, covers and hoods on the machine.
7. Only allow experienced personnel to sling loads and direct crane drivers. The
person giving directions must remain in sight of the operator or at least be in
spoken contact with him.
8. Attach the lifting tackle to the lugs and bore holes provided on the machine.
9. Make sure the lifting tackle is long enough.
10. Carefully lift the machine.
11. CAUTION Never stand under the machine when it is suspended.
12. When restarting the machine, proceed strictly according to the operating
manual.
010.1.16 Safe maintenance of hydraulic hoses and hose lines

1. Never attempt to repair hydraulic lines and hydraulic hoses.
2. All hoses, hose lines and threaded couplings must be checked regularly, at the
very least once a year, for leaks and visible signs of damage.
Replace damaged parts immediately. Oil escaping under pressure can cause
LBH/11827693/02/211-20150615.1139/en
injury and fires.

3. Even when properly stored and subjected to normal load, hoses and hose
lines are subject to natural ageing. This limits their service life.
4. Improper storage, mechanical damage and excess strain are the main causes
of damage.
5. Hose lines should not be used for longer than six years, including storage of
no longer than two years (note the date of manufacture on the hoses).
6. Using the hoses close to their maximum strain can shorten their service life
(e.g. high temperatures, frequent movement, extremely high impulse frequen-
cies and multiple shift operation).
7. Hoses and hose lines must be replaced when inspections reveal the following.
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010-12 L538-1493
Safety instructions
Criteria:
• Damage to the outer layer penetrating to the inner layer (e.g. abrasion, cuts
and cracks)
• Embrittlement of the outer layer (cracks in the hose material)
• Deformation of the natural shape of the hose or the hose line, both when
pressurised and depressurised, or at bends, e.g. layer separation, blistering
• Leaks
• Failure to observe installation requirements
• Damage or deformation of the hose fittings, which reduces the strength of
the fittings or the connection between the fitting and the hose
• Slippage of the hose out of the fitting
• Corrosion of the fitting, impairing its function and strength
• Exceeded storage time or service life
8. Only use genuine spare parts to replace hoses and hose lines.
9. Lay and fit hoses and hose lines in the proper manner. Do not switch the con-
nections.
010.1.17 Roll-over protection structure (ROPS) and falling ob-

ject protection structure (FOPS)
The machine is equipped with a certified cab that is designed to protect the driver
in the event of rolling over (ROPS) and falling objects (FOPS).
010.1.17.1 Preventing accidents

Depending on the job and the way the machine is operated, hazards can arise
even when the protective apparatus is intact. Avoid all unsafe working practices.
The roll-over protection structure cannot guarantee safety if the maximum permit-
ted total machine weight (see type plate) is exceeded.
The following modifications to the machine can lead to the maximum total weight
being exceeded:
– Using attachments that are too heavy
– Changing the working attachment
– Attachments or modifications to the machine
Never use a machine whose cab protection system (ROPS, FOPS) has been dam-
aged.
Damage to the cab can be caused by the following operations and events:
– Welding, cutting or drilling holes
– Attaching brackets
– Deformation after an accident
– Falling objects
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Structural modifications and any kind of repairs are prohibited.
010.1.17.2 Preventing injuries

The cab roll-over protection system can only protect the driver if he is wearing a
safety belt.
Any modifications to the interior of the cab, such as installing accessories, may not
impair the driver's working space.
Objects carried in the cab may not project into the driver's working space. Loose
objects must be stored securely.
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L538-1493 010-13
Safety instructions
010.1.18 Attachments and accessories

1. Attachments and accessories produced by third-party manufacturers or those
which have not been generally approved by LIEBHERR for installation or for
external fitting may not be installed or fitted on the machine without prior writ-
ten consent from LIEBHERR.
2. The appropriate technical documentation should be made available to LIEB-
HERR for this purpose.
3. When adding or converting equipment or tyres, the stability of the machine
must be tested and ensured in accordance with EN 474.
(For more information see: 020 Technical data, page 020-1)
010.1.19 Protection against vibrations

1. The vibrations to which mobile construction machines are subjected are mainly
due to the way they are used.
The following parameters in particular have a great effect:
• Terrain conditions: bumps and potholes.
• Operating methods: speed, steering, braking, use of the controls while driv-
ing and while working.
2. The amount of vibration depends to a large extent on the machine operator,
because he determines the speed, gear ratio, working methods and distance
covered.
This results in a wide range of different vibrations for the same type of ma-
chine.
3. The machine operator can reduce overall vibration by following these recom-
mendations:
• Select a suitable machine, equipment and accessories for the job.
• Use a machine equipped with a suitable seat (i.e. for earthworking ma-
chines, a seat which complies with EN ISO 7096).
• Keep the seat in good repair and adjust the position and cushioning ac-
cording to the height and weight of the driver.
• Regularly check the suspension and adjustment mechanisms of the seat
and make sure the seat is kept in the condition specified by the manufac-
turer.
• Check the service condition of the machine, especially the tyre pressure,
brakes, steering, mechanical connections etc.
• Do not steer, brake, accelerate, shift gears or load the working attachment
of the machine suddenly.
• Adjust the speed of the machine to the distance to be driven in order to re-
duce vibrations.
Slow down when driving over difficult terrain.
Drive around obstacles and avoid difficult terrain.
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• Keep the area on which the machine is operated in a tidy condition.

Remove any large rocks and obstacles.
Fill in any trenches or holes.
Have machines available to maintain good terrain and plan sufficient time
to do so.
• Travel over longer distances (e.g. public roads) at a suitable (medium)
speed.
• For machines which are often driven on open roads, use a special addition-
al system (if available) to reduce vibrations during this type of use.
If such systems are not available, control your speed to stop the machine
from rocking.
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010-14 L538-1493
Safety instructions
010.1.20 See and be seen
010.1.20.1 Field of view

As a machine driver, you gain most of your information visually when working. To
minimise risks to yourself and others while travelling and working, you must have
adequate vision. Use the visual aids attached to the machine, such as mirrors and
cameras. Take account of restrictions to your field of vision or blind spots.
You must follow national regulations relating to vision from the cab. For countries in
the European Economic Area, standard ISO 5006:2006 describes the methods for
measuring and evaluating the machine driver’s field of vision. The field of vision is
tested using standard equipment. Changes to the machine, e.g. from attaching or
converting components, must not impair the driver’s vision. If changes worsen the
field of view, a test according to ISO 5006:2006, or the regulations applicable to the
place of work, must be performed. Depending on the test result, appropriate meas-
ures must be taken. The machine driver must be informed of these changes.
010.1.20.2 Measures before and during operation

• Ensure that persons establish contact with the machine driver before ap-
proaching the machine.
• Check that the visual aids function properly, are clean and adjusted correct-
ly.
• Visual aids must be adjusted to ensure the best possible all round vision.
• Clean the visual aids and the cab windows immediately if dirt affects vision.
• Have faulty visual aids repaired or replaced as soon as possible.
• Do not use sun visors if they restrict vision.
• Observe your surroundings continuously to spot potential hazards in good
time.
• Avoid reverse travel where at all possible.
• Always try to ensure a direct view: plan the work so that your view of the
working area is not blocked.
• Where visibility is restricted or if the visual aids are faulty, always have
someone direct you. Agree hand signals and, with difficult tasks, also keep
in voice contact (e.g. via radio).
• Use lighting when visibility is poor and as required by regulations.
LBH/11827693/02/211-20150615.1139/en
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L538-1493 010-15
Special tools for maintenance and repair work
010.2 Special tools for maintenance and repair

work
010.2.1 Special tools, general
Designation ID no. Use Remark

Antifreeze and battery tester 11825984 All wheel For checking the acid concentration (battery
loaders charge level) and antifreeze
24 volt vacuum pump 7408148 All wheel For preventing oil loss
loaders
Filling and testing device with case 8145359 All wheel For checking the hydro accumulators
loaders
Pressure gauge 0 - 40 bar 7361288 All wheel For checking the hydraulic pressure
loaders
loaders
loaders
Pressure gauge connection 7002436 All wheel Connection for pressure gauge
loaders
High pressure hose 1500 mm 7002475 All wheel High pressure hose for pressure gauge
loaders
High pressure hose 4000 mm 7009134 All wheel High pressure hose for pressure gauge
loaders
Drain hose 7005660 All wheel For draining oil via a drain valve
loaders
Drain piece 7402657 All wheel For the drain hose
loaders
USB dongle 10333608 All wheel With SERVICE authorisation
loaders
Diagnostic data cable (RS-232) 9067426 All wheel For adjusting the travel hydraulics or testing
loaders the electrical system and options
RS-232<>USB adapter lead 693190714 All wheel For communicating with the wheel loader elec-
loaders tronics if the laptop does not have an RS-232
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interface.
Tab. 1: Special tools, general
010.2.2 Special tools for the diesel engine
Designation ID number Use Remarks

Engine cranking device 7090361 Engine For cranking the diesel engine at the flywheel
Arrester pin 7090360 Engine For arresting the flywheel when adjusting the
valves
Compression tester 8008782 Engine For checking the compression
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010-16 L538-1493
Designation ID number Use Remarks

Gauge 7090999 Engine Use with 7090904 for measuring the valve
depth and the cylinder bushing height above
the cylinder block surface
Piston and bushing height gauge 7090904 Engine For measuring the piston height
Piston ring tensioning belt 8000592 Engine For pushing the piston rings together during
installation of the pistons
Angle torque device 0524062 Engine For screws on cylinder head, main bearing
and big end bearing
Krikit 2 V-belt tester 8042829 Engine For testing the V-belt tension
Extractor tool 7090377 Engine For removing the front wear ring
Extractor tool 7090395 Engine For removing the front wear ring
Seal remover 7090372 Engine For removing the front crankshaft oil seal
Depth gauge 7090370 Engine For measuring the valve depth in the cylinder
head and for measuring the piston and bush-
ing height
Extractor tool 7090376 Engine For removing the rear crankshaft oil seal ring
and wear ring
Extractor tool 7090363 Engine For installing and removing the cylinder bush-
ings
Angle wrench 0524062 Engine For screws on cylinder head, main bearing
and big end bearing
Installation tool 7090903 Engine For installing the crankshaft seal
For further special tools for the diesel engine, see: “Service ADVISOR”
Tab. 2: Special tools for the diesel engine
010.2.3 Special tools for the electrical system
Designation ID no. All wheel Remark

loaders
Digital multimeter 10018500 All wheel For measuring voltage, current, resistance
loaders and frequency
Test probe, red 884191214 All wheel For measurements at plug connections
loaders
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Test probe, black 884191114 All wheel For measurements at plug connections
loaders
Solenoid tester 10028268 All wheel For testing solenoid valves
loaders
ID numbers for other tools and plug connections of the electrical system can be taken from the wiring harness
repair and diagnostic set.
Wiring harness repair and diagnosis set: Liebherr Service Documentation - General information - wiring harness
repair and diagnostic set
Tab. 3: Special electrical tools
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L538-1493 010-17
010.2.4 Special tools for the air conditioning system
Description ID no. Use Remarks

Vacuum pump 7027552 All wheel For evacuating the air conditioning system
loaders
4-valve test fitting 7027558 All wheel For testing, evacuating and filling the air con-
loaders ditioning system
Filling hose, blue 1500 mm 7027553 All wheel For the test fitting
loaders
Filling hose, yellow 1500 mm 7027554 All wheel For the test fitting
loaders
Filling hose, red 1500 mm 7027555 All wheel For the test fitting
loaders
Car coupling 253a 7027556 All wheel For the test fitting
loaders
Car coupling 254a 7027557 All wheel For the test fitting
loaders
Tab. 4: Special tools for the air conditioning system
010.2.5 Special tools for cab glazing
Description ID no. Use Remarks

Toolbox complete with suction cups 10021147 All wheel For removing and installing bonded panes
loaders
Tab. 5: Special tools for cab glazing
010.2.6 Special tools for the central lubrication system
Designation ID number Use Remark

Liebherr filling press 10009239 All wheel For quickly filling the reservoir
loaders with
Liebherr cen-
tral lubrication
system
Filling press 10333342 All wheel For quickly filling the reservoir
loaders with
LBH/11827693/02/211-20150615.1139/en
Liebherr cen-
tral lubrication
system
Liebherr filling port 7029283 All wheel For quickly filling the reservoir
loaders with
Liebherr cen-
tral lubrication
system
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010-18 L538-1493
Designation ID number Use Remark

Diagnostic cable 10008427 All wheel For diagnosing the central lubrication system
loaders with
Liebherr cen-
tral lubrication
system
Tab. 6: Special tools for the central lubrication system

LBH/11827693/02/211-20150615.1139/en
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L538-1493 010-19
Standards and regulations
010.3 Standards and regulations
010.3.1 Prestressing forces and tightening torques for bolts

with metric standard and fine threads
Item code 10650716
Version 001
Note
Note the validity of the standard.
u This standard only applies to Liebherr wheel loaders.
– Tightening torques given on drawings always take precedence over the works
standards, and must be observed.
– For important bolt connections, angle control tightening may be advantageous.
If so, the required tightening torques (joining torque, rotary angle) must be cal-
culated individually by the technical department.
– When tightening in aluminium with or without using a helicoil, the values in class
8.8 must be used. However, tightening values given on drawings are binding
and must be observed with priority.
Metric standard threads and fine threads. All specifica- Metric standard threads and fine threads. All specifica-
tions apply to bolt connections with at least one ele- tions apply to bolt connections with “no” element coated
ment coated with Dacromet 500 (bolts, washers, nuts with Dacromet 500 (bolts, washers, nuts etc.)
etc.)
Surface: Surface:
- DACROMET 500 - Black oxide or phosphate
- FLZN (zinc disc coating according to LH standard - Zinc-plated
10021432)
Tab. 7
Thread Class Prestressing Tightening tor- Thread Class Prestressing Tightening tor-
force FM in N que MA in Nm force FM in N que MA in Nm
For medium coefficient of friction µG= 0.10 For medium coefficient of friction µG= 0.12
M4 8.8 4200 2,5 M4 8.8 4050 2,8
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10.9 6200 3,7 10.9 6000 4,1

12.9 7300 4,3 12.9 7000 4,8
M5 8.8 6900 4,9 M5 8.8 4200 2,5
10.9 10100 7,3 10.9 6200 3,7
12.9 11900 8,5 12.9 7300 4,3
M6 8.8 9700 8,5 M6 8.8 9400 9,5
10.9 14300 12,5 10.9 13700 14,0
12.9 16700 14,5 12.9 16100 16,5
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M7 8.8 14200 14,0 M7 8.8 13700 15,5
10.9 20900 20,5 10.9 20100 23,0
12.9 24500 24,0 12.9 23500 27
M8 8.8 17900 20,5 M8 8.8 17200 23
10.9 26000 30 10.9 25000 34
12.9 30500 35 12.9 29500 40
M8x1 8.8 19600 22 M8x1 8.8 18800 24,5
10.9 28500 32 10.9 27500 36
12.9 33500 38 12.9 32500 43
M9x1 8.8 25500 32 M9x1 8.8 24800 36
10.9 38000 46 10.9 36500 53
12.9 4400 54 12.9 42500 62
M 10 8.8 28500 41 M 10 8.8 27500 46
10.9 4200 60 10.9 40000 68
12.9 4900 71 12.9 4700 79
M 10 x 1 8.8 32500 45 M 10 x 1 8.8 31500 52
10.9 48000 67 10.9 46500 76
12.9 56000 78 12.9 54000 89
M 10 x 1.25 8.8 30500 43 M 10 x 1.25 8.8 29500 49
10.9 45000 64 10.9 43000 72
12.9 53000 74 12.9 51000 84
M 12 8.8 41500 71 M 12 8.8 40000 79
10.9 61000 104 10.9 59000 114
12.9 71000 121 12.9 69000 135
M 12 x 1.25 8.8 46500 77 M 12 x 1.25 8.8 45000 87
10.9 68000 112 10.9 66000 125
12.9 80000 130 12.9 77000 150
LBH/11827693/02/211-20150615.1139/en
M 12 x 1.5 8.8 44000 74 M 12 x 1.5 8.8 42500 83

10.9 65000 108 10.9 62000 122
12.9 76000 125 12.9 73000 145
M 14 8.8 57000 113 M 14 8.8 55000 125
10.9 84000 165 10.9 80000 185
12.9 98000 195 12.9 94000 215
M 14 x 1.5 8.8 63000 121 M 14 x 1.5 8.8 61000 135
10.9 92000 175 10.9 89000 200
12.9 108000 205 12.9 104000 235
copyright by
L538-1493 010-21
M 16 8.8 78000 170 M 16 8.8 75000 195
10.9 115000 250 10.9 111000 280
12.9 134000 300 12.9 13000 330
M 16 x 1.5 8.8 85000 180 M 16 x 1.5 8.8 82000 205
10.9 125000 270 10.9 121000 300
12.9 147000 310 12.9 141000 360
M 18 8.8 98000 245 M 18 8.8 94000 280
10.9 140000 350 10.9 135000 390
12.9 164000 410 12.9 157000 460
M 18 x 1.5 8.8 114000 270 M 18 x 1.5 8.8 110000 310
10.9 163000 390 10.9 157000 440
12.9 191000 450 12.9 184000 520
M 18 x 2 8.8 106000 260 M 18 x 2 8.8 102000 290
10.9 151000 370 10.9 146000 420
12.9 177000 430 12.9 170000 490
M 20 8.8 126000 350 M 20 8.8 121000 390
10.9 180000 490 10.9 173000 560
12.9 210000 580 12.9 202000 650
M 20 x 1.5 8.8 144000 380 M 20 x 1.5 8.8 139000 430
10.9 206000 540 10.9 199000 620
12.9 240000 630 12.9 232000 720
M 22 8.8 157000 470 M 22 8.8 152000 530
10.9 224000 670 10.9 216000 750
12.9 260000 780 12.9 250000 880
M 22 x 1.5 8.8 177000 510 M 22 x 1.5 8.8 171000 580
10.9 255000 720 10.9 245000 820
12.9 295000 840 12.9 285000 960
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M 24 8.8 182000 600 M 24 8.8 175000 670

10.9 260000 850 10.9 249000 960
12.9 305000 1000 12.9 290000 1120
M 24 x 1.5 8.8 215000 700 M 24 x 1.5 8.8 207000 760
10.9 306000 990 10.9 295000 1090
12.9 358000 1170 12.9 346000 1270
M 24 x 2 8.8 203000 640 M 24 x 2 8.8 196000 730
10.9 290000 920 10.9 280000 1040
12.9 340000 1070 12.9 325000 1220
copyright by
010-22 L538-1493
M 27 8.8 239000 180 M 27 8.8 230000 1000
10.9 340000 1250 10.9 330000 1400
12.9 400000 1450 12.9 385000 1650
M 27 x 1.5 8.8 276000 1010 M 27 x 1.5 8.8 267000 1110
10.9 394000 1440 10.9 381000 1580
12.9 461000 1690 12.9 445000 1850
M 27 x 2 8.8 265000 940 M 27 x 2 8.8 255000 1070
10.9 375000 1350 10.9 365000 1500
12.9 440000 1550 12.9 425000 1800
M 30 8.8 290000 1190 M 30 8.8 280000 1350
10.9 415000 1700 10.9 400000 1900
12.9 485000 2000 12.9 465000 2250
M 30 x 1.5 8.8 346000 1410 M 30 x 1.5 8.8 335000 1540
10.9 493000 2000 10.9 477000 2190
12.9 576000 2340 12.9 558000 2560
M 30 x 2 8.8 332000 1370 M 30 x 2 8.8 321000 1490
10.9 472000 1940 10.9 457000 2120
12.9 553000 2270 12.9 534000 2480
M 33 8.8 360000 1600 M 33 8.8 350000 1850
10.9 520000 2300 10.9 495000 2600
12.9 600000 2700 12.9 580000 3000
M 33 x 1.5 8.8 423000 1880 M 33 x 1.5 8.8 410000 2050
10.9 603000 2670 10.9 584000 2920
12.9 705000 3130 12.9 683000 3420
M 33 x 2 8.8 410000 1750 M 33 x 2 8.8 395000 2000
10.9 580000 2500 10.9 560000 2800
12.9 680000 2900 12.9 660000 3300
LBH/11827693/02/211-20150615.1139/en
M 36 8.8 425000 2100 M 36 8.8 410000 2350

10.9 600000 3000 10.9 580000 3300
12.9 710000 3500 12.9 680000 3900
M 36 x 1.5 8.8 508000 2450 M 36 x 1.5 8.8 492000 2680
10.9 724000 3490 10.9 701000 3820
12.9 847000 4090 12.9 820000 4470
M 36 x 3 8.8 455000 2200 M 36 x 3 8.8 440000 2500
10.9 650000 3100 10.9 630000 3500
12.9 760000 3600 12.9 740000 4100
copyright by
L538-1493 010-23
M 39 8.8 510000 2700 M 39 8.8 490000 3000
10.9 730000 3800 10.9 700000 4300
12.9 850000 4500 12.9 820000 5100
M 39 x 1.5 8.8 601000 3140 M 39 x 1.5 8.8 582000 3430
10.9 857000 4470 10.9 830000 4890
12.9 1002000 5230 12.9 971000 5720
M 39 x 3 8.8 550000 2800 M 39 x 3 8.8 582000 3200
10.9 780000 4000 10.9 830000 4600
12.9 910000 4700 12.9 971000 5300
Tab. 8: Bolt prestressing forces and tightening torques
010.3.2 Assembly instructions for the piston and piston nut of

the hydraulic cylinder (WN 4121)
Version 001
Item code 10334184
010.3.2.1 Range of application and purpose

This Liebherr standard only applies in respect of hydraulic cylinders for the assem-
bly of pistons or piston nuts on the piston rod with a thread diameter of M42 and
larger. This standard describes the tightening procedure in terms of the path and
angle of torsion.
The precise tightening torque for thread diameters smaller than M42 are provided
directly in the drawing. The specifications provided in the drawing are binding.
010.3.2.2 Requirements and description

The number of the tightening value must be taken from the drawing and cannot be
inferred from supposedly similar geometry. This number can be used to locate the
angle and path of torsion in the table of tightening values. (For more information
see: Other applicable documents, page 010-29)
The tightening values are based on both empirical testing and calculation, and are
LBH/11827693/02/211-20150615.1139/en
subject to amendment. This standard distinguishes between two tightening proce-

dures, which are identified by 3-digit and 4-digit numbers.
Tightening with assembly wrench

This tightening method applies to 3-digit tightening numbers.
Preparation:
Clean all contact surfaces (thread and contact surfaces between the piston rod, the
piston and the piston nut) and apply a thin coating of Gleitmo high-performance lu-
bricating paste (ID no. 8300 004, 40 g tube) to both sides.
Term definitions:
copyright by
010-24 L538-1493
Fig. 1: Figure 1
Preload torque Mv:

Applied to the piston A using the torque wrench B via the square/hex in the assem-
bly wrench C, making sure to observe the position of the torque wrench. (see:
fig. 1, page 010-25)
Path of torsion 4:
The arc [mm] travelled by the piston or the piston nut after applying the preload
torque by tightening. (see: fig. 2, page 010-26)
Angle of torsion 5:
The angle [°] travelled by the piston or the piston nut after applying the preload tor-
que by tightening. (see: fig. 2, page 010-26)
When applying the preload torque Mv, the torque wrench B should point in the
same direction as the assembly wrench C if possible. The same procedure applies
to the piston nut, using the corresponding assembly wrench.
LBH/11827693/02/211-20150615.1139/en
copyright by
L538-1493 010-25
Fig. 2: Figure 2
1 Marking on piston and piston rod 5 Angle of torsion
thread after applying the preload
torque
2 Marking on piston rod thread 6 Marking on piston nut and piston
rod thread after applying the pre-
load torque
3 Displaced marking on piston after 7 Displaced marking on piston nut
tightening after tightening
4 Path of torsion
Tightening with hydraulic assembly unit

LBH/11827693/02/211-20150615.1139/en
This tightening method applies to 4-digit tightening numbers.

Preparation:
Clean all contact surfaces (thread and contact surfaces between the piston rod, the
piston and the piston nut) and apply a thin coating of Gleitmo high-performance lu-
bricating paste (ID no. 8300 004, 40g tube) to both sides.
Term definitions:
copyright by
010-26 L538-1493
Fig. 3: Figure 3
A Torque wrench C Torque multiplier
B Hex
Preload torque:
Applied to the piston or the piston nut using the torque wrench A via the hex B of
the torque multiplier C. (see: fig. 3, page 010-27)
Angle of torsion:
The angle [°] travelled by the piston or the piston nut after applying the preload tor-
que by tightening. (see: fig. 6, page 010-29)
Operating the assembly unit:
LBH/11827693/02/211-20150615.1139/en
Fig. 4: Figure 4
A Piston rod E Piston nut
B Piston F Adapter for piston nut
C Adapter for piston G Torque multiplier
D Adapter for piston rod H Assembly unit
See the separate operating manual for the assembly unit H. Appropriate adaptors
for the piston rod, piston and piston nut are contained in the piston parts list.
copyright by
L538-1493 010-27
Fig. 5: Maximum operating pressure embossed on the adapter
NOTICE
If the maximum operating pressure is exceeded, the adapters and the assembly
unit itself can be damaged.
u The maximum operating pressures are embossed on the adapters. If the maxi-
mum operating pressure is not specified on an adapter, it can be found in the
table of tightening values (see item 4) with the aid of the adapter identification
number. This value must then be embossed on the adapter.
u The maximum operating pressure for the adapter must be set on the hydraulic
pump of the assembly unit before tightening (see separate operating manual for
assembly unit). If two adapters with different maximum operating pressures are
used during assembly, then the lowest pressure applies. The ID number of the
assembly unit to be used can be found using the 4-digit tightening value number
from the table of tightening values (see item 4).
LBH/11827693/02/211-20150615.1139/en
copyright by
010-28 L538-1493
Fig. 6: Figure 5
A Indicator C Angle scale
B Adjusting screw
– Before tightening, the indicator A must be set using the adjusting screw B to 0°
on the angle scale C.
– The angle of torsion can be read on the angle scale. If the opening angle of the
assembly unit is not enough to achieve the specified angle of torsion, reposition
the assembly unit for another tightening procedure.
– The components must be held in the angle already tightened. Before continu-
ing, set the indicator to the last angle value.
LBH/11827693/02/211-20150615.1139/en
Repeat this procedure as often as necessary until the specified torsion value is fi-
nally achieved.
010.3.2.3 Amendments
010.3.2.4 Other applicable documents

– Table of tightening values
– Drawing referring to this Liebherr standard and the tightening number
Table of tightening values (version of 15/12/2011)
For LH standard WN 4121 (ID number - 10334184) - assembly instructions for pis-
ton and piston nut.
copyright by
L538-1493 010-29
The date indicates the latest version of the table. There is no revision.
Tightening with assembly wrench (For more information see: Tightening with as-
sembly wrench, page 010-24)
Preload tor-
No. Piston Piston nut Thread
que
Path of tor- Angle of tor- Path of tor- Angle of tor-
WN 4121.. [Nm] M [mm]
sion [mm] sion ~[°] sion [mm] sion ~[°]
071 100 11+1 30 21+1 57 42x1.5
072 100 21+1 57 21+1 57 42x1.5
073 100 18 +1
49 19 +1
52 42x1.5
074 100 16+1 44 - - 42x1.5
075 100 19 +1
52 21 +1
57 42x1.5
078 100 20+1 55 14+1 38 42x1.5
079 100 11 +1
30 21 +1
57 42x1.5
080 100 18+1 49 - - 42x1.5
081 100 15 +1
41 - - 42x1.5
091 100 13+1 30 19+1 44 50x2
092 100 25 +1
57 19 +1
44 50x2
093 100 24+1 55 19+1 44 50x2
095 100 13+1 30 19+1 44 50x2
50x2/
096 100 10+1 23 9+1 21
SW65
097 100 17+1 39 19+1 44 50x2
098 100 17+1 39 - - 50x2
099 100 24+1 55 19+1 44 50x2
101 100 10+1 23 - - 50x2
103 100 9+1 21 - - 50x2
104 100 12+1 28 - - 50x2
108 100 16+1 37 - - 50x2
111 100 16+1 33 18+1 37 56x2
112 100 17+1 35 18+1 37 56x2
LBH/11827693/02/211-20150615.1139/en
113 100 17+1 35 19+1 39 56x2

114 100 19+1 39 - - 56x2
115 100 18 +1
37 - - 56x2
116 100 19+1 39 - - 56x2
117 100 17 +1
35 - - 56x2
118 100 15+1 31 - - 56x2
119 100 17 +1
35 - - 56x2
121 150 15+1 29 19+1 36 60x2
copyright by
010-30 L538-1493
Preload tor-
que
WN 4121.. [Nm] M [mm]
123 150 17+1 32 19+1 36 60x2
125 150 18+1 34 - - 60x2
126 150 14 +1
27 - - 60x2
127 150 22+1 42 - - 60x2
128 150 20 +1
38 - - 60x2
129 150 14+1 27 19+1 36 60x2
131 150 15 +1
28 - - 60x2
132 150 17+1 32 - - 60x2
151 150 15 +1
27 19 +1
34 65x2
152 150 20+1 35 19+1 34 65x2
153 150 20 +1
35 - - 65x2
156 150 20+1 35 - - 65x2
157 150 20 +1
35 - - 65x2
171 150 12+2 20 18+1 30 68x2
172 150 21 +2
35 18 +1
30 68x2
173 150 19+2 32 18+1 30 68x2
174 150 25+2 42 18+1 30 68x2
175 150 25+2 42 18+1 30 68x2
176 150 19+2 32 18+1 30 68x2
177 150 19+2 32 18+1 30 68x2
179 150 11+2 19 18+1 30 68x2
180 150 20+2 34 18+1 30 68x2
182 150 16+2 27 18+1 30 68x2
181 150 20+2 34 - - 68x2
183 200 - - 40+2 67 68x2
184 150 16+2 27 18+1 30 68x2
185 150 23+2 39 - - 68x2
LBH/11827693/02/211-20150615.1139/en
186 150 11+2 19 - - 68x2

201 200 17+2 26 16+1 24 76x2
202 200 26 +2
39 16 +1
24 76x2
203 200 27+2 41 16+1 24 76x2
204 200 27 +2
41 16 +1
24 76x2
205 200 13+2 20 - - 76x2
206 200 25 +2
38 25 +1
38 76x2
207 200 23+2 35 - - 76x2
copyright by
L538-1493 010-31
Preload tor-
que
WN 4121.. [Nm] M [mm]
208 200 25+2 38 - - 76x2
209 200 30+2 45 - - 76x2
212 200 23 +2
35 - - 76x2
213 200 16+2 24 - - 76x2
214 200 18 +2
27 - - 76x2
215 200 21+2 32 - - 76x2
216 200 25 +2
38 - - 76x2
231 200 8+2 11 16+1 22 85x3
232 200 17 +2
23 16 +1
22 85x3
234 200 22+2 30 - - 85x3
235 200 17 +2
23 - - 85x3
236 200 15+2 20 - - 85x3
237 200 19 +2
26 - - 85x3
239 200 16+2 22 - - 85x3
240 200 17 +2
23 - - 85x3
241 200 15+2 20 - - 85x3
261 250 20+2 25 10+1 12 95x3
264 250 15+2 18 - - 95x3
265 250 24+2 29 10+1 12 95x3
267 250 24+2 29 - - 95x3
268 250 20+2 24 - - 95x3
270 250 6+1 7 - - 95x3
271 250 13+2 16 - - 95x3
281 250 20+2 23 13+1 15 100x3
282 250 25+2 29 - - 100x3
283 250 25+2 29 21+1 24 100x3
284 250 14+2 16 - - 100x3
LBH/11827693/02/211-20150615.1139/en
285 250 18+1 20 - - 100x3

287 250 22+1 25 - - 100x3
301 300 21 +3
22 20 +2
21 110x3
302 300 18+3 19 20+2 21 110x3
303 300 20 +3
21 20 +2
21 110x3
304 300 23+3 24 20+2 21 110x3
305 300 9+3
9 - - 110x3
306 300 24+3 25 - - 110x3
copyright by
010-32 L538-1493
Preload tor-
que
WN 4121.. [Nm] M [mm]
307 300 27+3 28 - - 110x3
308 300 25+3 26 - - 110x3
309 300 25 +3
26 - - 110x3
310 300 19+3 20 - - 110x3
331 400 23 +3
22 20 +2
19 120x3
332 400 11+3 11 - - 120x3
333 400 27 +3
26 - - 120x3
334 400 20+3 19 20+2 19 120x3
335 400 30 +3
29 - - 120x3
336 400 29+3 28 - - 120x3
337 400 8+1
8 - - 120x3
339 400 9+1 9 - - 120x3
363 500 17 +3
15 10 +2
9 130x3
402 600 9+3 7 - - 155x3
461 600 12 +3
9 - - 150x4
501 200 21+2 30 - - 80x2
531 500 34+3 28 - - 140x3
561 100 10+1 25 - - 45x1.5
Tab. 9
Tightening with hydraulic assembly unit (For more information see: Tightening
with hydraulic assembly unit, page 010-26)
Preload tor-
No. Piston Piston nut Assembly unit Thread
que
Max. permis-
Angle of tor- Angle of tor- sible operat-
10334184... [Nm] ID No. M [mm]
sion [°] sion [°] ing pressure
[bar]
LBH/11827693/02/211-20150615.1139/en
1000 300 27+1 8+1 94030655 670 240x4

1001 300 18+1 8+1 94030655 340 200x4
1002 300 18+1 8+1 94001888 280 150x4
1003 300 23+1 8+1 94002055 310 170x4
1004 300 21+1 8+1 94001888 280 140x4
1005 300 18+1 8+1 94030655 340 180x4
1006 300 30+1 8+1 94001888 280 150x3
1007 300 27+1 3+1 94002055 310 160x4
1008 300 31 +1
5 +1
94030655 340 180x4
copyright by
L538-1493 010-33
Preload tor-
No. Piston Piston nut Assembly unit Thread
que
Max. permis-
Angle of tor- Angle of tor- sible operat-
10334184... [Nm] ID No. M [mm]
sion [°] sion [°] ing pressure
[bar]
1009 300 20+1 - 94030655 340 200x4
1010 300 27+1 5+1 94030655 340 180x4
1011 300 18 +1
- 94030655 670 260x4
1012 300 33+1 - 94030655 270 200x4
1013 3500 24+1
- 94030655 420 290x4
1019 300 16+1 - 94002055 310 160x4
Tab. 10
010.3.2.5 Maximum adapter operating pressure
Fig. 7: Maximum operating pressure embossed on the adapter
Adapter ID no. Maximum operating

pressure [bar]
9623426 350
9634625 350
LBH/11827693/02/211-20150615.1139/en
9623427 350
9640093 270
9625264 270
9635155 300
9623428 700
Tab. 11
The maximum operating pressures are embossed on the adapters.

If two adapters with different maximum operating pressures are used during as-
sembly, then the lowest pressure applies.
copyright by
010-34 L538-1493
If the maximum operating pressure is not specified on an adapter, it can be found

in the table with the aid of the adapter identification number. This value must then
be embossed on the adapter.
LBH/11827693/02/211-20150615.1139/en
copyright by
L538-1493 010-35
Preservation guidelines
010.4 Preservation guidelines
010.4.1 General information

All parts of a construction machine are exposed to corrosion when out of use. Cor-
rosion can be compared to wear. However, the effects can be much more serious
than mechanical wear and can significantly reduce the service life of the parts. This
means the machines and their components must be preserved according to certain
guidelines when out of use.
Generally these guidelines are based on the following time-scales:
– Putting the machine out of service – unknown duration
– Putting the machine out of service
• Out of service for up to 2 months
• Out of service for up to 12 months
• Out of service for longer than 12 months
– Putting back into service
The required measures are also scaled according to the time periods. The preser-
vation measures are not strictly standardized, and are to be shortened or length-
ened depending on necessity (e.g. because of environmental conditions).
Such conditions are, for example:
– The machine's location (e.g. in unprotected open space, in closed space, with
roof, temperature-controlled environment)
– The type of climate (e.g. extreme temperatures, storage near the sea or the
coast, etc.)
010.4.2 Putting the machine out of service – unknown duration

If the machine is out of use for a lengthy period without preservation, it must be put
back into service at intervals of no more than 14 days in order to prevent in-
creased corrosion and the resulting damage.
– All oil levels must be checked before putting into service and filled up where
necessary.
– Carry out all daily prescribed maintenance work before putting back into service
each time. Carry out all additional temporary maintenance work as per inspec-
tion plan and extra engine operating instructions, at the latest at the intended in-
tervals.
– Put machine back into service according to operating instructions and operate
until the engine and hydraulics system have reached the prescribed operating
temperature in the hydraulic tank and in the coolant circulation.
LBH/11827693/02/211-20150615.1139/en
– Activate all functions of the working and travel hydraulics and of the other hy-
draulic components, and alternately operate over a time-span of approx. 20 mi-
nutes. Hydraulic cylinders must each be extended and retracted over their full
stroke length.
– When switching off the machine, retract all the hydraulic cylinders completely if
possible, and fill up fuel tank. If the surface is soft, put the machine on wooden
blocks or similar, and secure against rolling.
– Check batteries and, if necessary, remove and recharge. Check electronic con-
tact points and grease with terminal grease if needed.
copyright by
010-36 L538-1493
010.4.3 Putting the machine out of service

Preparation activities for putting out of service:
– Put machines on horizontal, dry, solid surface and secure against rolling. Sink
working attachment to a level where the hydraulics are under no remaining
pressure.
– Before putting out of service, clean the machine while strictly following the oper-
ating instructions.
– The machine must be completely dry before preservation begins. Electronic
components and damp areas of the machine must be dried with compressed
air.
– If frost temperatures are expected during the intended out of service period,
then the fuel tank must be filled with winter fuel. Start the engine and run for a
short time so that the winter fuel flows into the fuel circulation. After running the
engine, refill the fuel tank completely.
Note
When moving a machine thus protected for loading or transport, the scraper usual-
ly removes the grease from the piston rods in the cylinders.
u If the machine is being transported, the grease on the piston rods must be re-
checked after loading and renewed if necessary.
Note
Despite preservation measures, the machine must be checked after certain time in-
tervals and if necessary greased again. The operator must judge this.
u In the case of difficult conditions (cold, heat, proximity to coast, etc.), this in-
spection should be carried out regularly (monthly).
010.4.3.1 Out of service for up to 2 months
Designation ID number Description Illustration

Optical den- 7408922 To test the battery
sity tester acid density and
the anti-freeze in
the cooling agent
WAXOYL 8504472 500 ml spray can,

120-4 anti- long-term protec-
LBH/11827693/02/211-20150615.1139/en
corrosion tion for up to 2

wax years
Ballistol 10025514 Area of application:
Spray anti- Door locks
corrosion
agent
copyright by
L538-1493 010-37
Designation ID number Description Illustration

VC1-1 cap- 8145869 Fitted in enclosed
sule from spaces: Protection
Zerust effect 30 cm, pro-
tection duration 12
months
VC2-2 cap- 10013313 Fitted in enclosed
sule from spaces: Protection
Zerust effect 60 cm, pro-
tection duration 24
months
VCI capsu- Decal is in- For entering the re-

les decal cluded placement date of
with the the VCI capsules.
VCI capsu-
les
Tab. 12: Required tools / service fluids
– Inspect the entire machine for damage and repair if necessary.

– Check the machine for paint damage and if necessary repair.
– Perform any maintenance work that would have fallen due during the out of
service period in advance.
– Because of UV radiation, synthetic materials like plastic parts, hoses, rubber
etc. must be covered with suitable equipment.
– Electronic components, contact points and plugs that are not sealed should be
protected with Waxoyl 120-4 preservation wax.
– Cover ball joints, hinges, bare parts and exposed piston rods with a thick layer
of “Waxoyl 120-4” preservation wax. (Do not preserve ball bearings with Waxo-
yl!)
– Place a dehumidification capsule in the central electrics box.
– Preserve all door and container locks with “Ballistol Spray”.
– Set battery main switch (if available) at position “0”, and remove battery after-
wards. Check acid level and if necessary offset by filling with distilled water. Al-
ways store batteries in a cool and dry room. Check battery current every 6
weeks and recharge is necessary.
– Seal exhaust outlet with air and water proof cover.
– Observe any extra guidelines for special construction equipment or special local
conditions.
010.4.3.2 Out of service for up to 12 months

Carry out all measures according to the section, “Putting out of service for up to 2
LBH/11827693/02/211-20150615.1139/en
months”.
Please also:
– Carry out an external wash of the engine.
– Let out water from the fuel tank or condensation from the engine prefilter (see
operating instructions).
– Completely fill the fuel tank with standard fuel. If the out of service period is dur-
ing winter, fill the fuel tank with winter diesel (which is suitable for temperatures
down to 22 C°). Start the engine and run for a short time so that the winter fuel
flows into the fuel circulation. After running the engine, refill the fuel tank com-
pletely.
– Check that there is sufficient (at least 50%) antifreeze and corrosion inhibitor in
the coolant (see operating instructions for guidelines).
copyright by
010-38 L538-1493
– Seal the complete machine (engine, hydraulic components, main frame, con-
tainers, running gear, axles, oscillating axle frame, work equipment etc.) with
Waxoyl 120-4 preservation wax. (Amount of preservation agent: With a litre of
Waxoyl, a preservation area of approx. 5 m2 can be treated).
The following points must be observed when putting on the corrosion inhibiting
wax:
– Keep to the drying time of 3 hours.
– Ambient temperature is at least 15 °C.
– Use protective equipment (breathing protection, protective goggles, extraction,
etc.).
– The solvents used in the corrosion inhibiting wax are inflammable! (Avoid smok-
ing and open flames).
– Resistance to cold down to a temperature of -40 °C.
– Check the machine every month and apply preservation agents if re-
quired.
010.4.3.3 Out of service for longer than 12 months

Carry out all measures according to the section, “Putting out of service for up to 12
months”.
Also required is:
– If it is planned to put a machine out of service for longer than 12 months,
then the engine manufacturer's customer service must be contacted.
– Seal air tight all openings like air filters, exhaust pipes, ventilation openings on
units and so on. The fuel tank's ventilation and bleeder filters (if available) must
stay open for safety reasons.
– Rub talcum powder into the sealing rubber of the containers and driver's cab,
and seal the doors. If there is no driver’s cab, cover the operator’s platform in a
suitable manner. Cover the driver seat and control panel using suitable materi-
als.
010.4.4 Putting back into service
010.4.4.1 After being out of service for 2 months

– Remove dehumidification capsule from the electronics box.
– Check fill levels and lubricate machines according to the operating instructions.
– Install batteries and clean and grease battery connections.
– Open exhaust outlet.
– Remove corrosion inhibiting grease.
– Let out water from the fuel tank or condensation from the engine prefilter (see
operating instructions).
– Clean the corrosion inhibiting wax off the ball joints, hinges, bare parts and ex-
LBH/11827693/02/211-20150615.1139/en
posed piston rods.

– Put the machine back into service according to the operating instructions.
– Before work with the machine, check all functions of the machine and immedi-
ately rectify any defects. Carry out a comprehensive visual inspection on the
machine.
– Activate all functions of the working and travel hydraulics and of the other hy-
draulic components, and alternately operate over a time-span of approx. 20 mi-
nutes. Hydraulic cylinders must each be extended and retracted over their full
stroke length.
Observe any extra guidelines for special construction equipment or local condi-
tions.
copyright by
L538-1493 010-39
010.4.4.2 After being out of service for 12 months

Put back into service according to the section “After being out of service for 2
months”.
The following measures must also be carried out:
– Extract an oil probe from the hydraulic oil and send it in for analysis.
– Carry out planned maintenance and inspection tasks on the machine before
putting back into service.
– Mechanically activate the external exhaust return on the engine and the engine
brake flap and check for clearance.
– Clean corrosion inhibitor wax from machine and components with steam from a
high-pressure cleaner (min. 120 °C) and with 5% cleaning agent (e.g. petrole-
um). (Careful on walk-on surfaces: there is a danger of slipping on wax re-
mains.)
– Check the engine's V-ripped belt and change if necessary.
– Carry out an engine trial run. Increase engine speed gradually to up to ¾ of the
upper idle speed, until the operating temperature is reached.
– Check oil pressure display immediately after starting the engine.
010.4.4.3 After being out of service for longer than 12 months

Put back into service according to the section “After being out of service for 12
months”.
– After a machine has been out of service for longer than 12 months, the en-
gine manufacturer's customer service must be contacted.
– Remove all covers and seals used for the preservation measures.
– Turn the engine several full turns by hand (use flywheel cranking device – see
special tools).
– Start the engine and bring up to operating temperature.
– After the engine has been brought to operating temperature, change all lubrica-
tion and operating fluids as well as the filters.
– Check the whole machine for proper functioning and inspect for leaks.
Carry out any additionally required temporary maintenance work.
LBH/11827693/02/211-20150615.1139/en
copyright by
010-40 L538-1493
020 Technical data
Contents
020.1 Drive group 020-4
020.1.1 Engine
L538-1493/31405-; 020-4
020.1.2 Fuel tank
L538-1493/31405-; 020-5
L538-1493/31405-; 020-5
L538-1493/31405-; 020-6
L538-1493/31405-; 020-6
020.1.6 Clutch
L538-1493/31405-; 020-6
020.2 Cooling system 020-7
L538-1493/31405-; 020-7
L538-1493/31405-; 020-7
L538-1493/31405-; 020-7
020.3 Working hydraulics 020-8
L538-1493/31405-; 020-8
LBH/11827693/02/211-20150615.1139/en
L538-1493/31405-; 020-8
L538-1493/31405-; 020-8
L538-1493/31405-; 020-9
L538-1493/31405-; 020-9
L538-1493/31405-; 020-9
L538-1493/31405-; 020-9
copyright by
L538-1493 020-1
Technical data Service manual

L538-1493/31405-; 020-10
L538-1493/31405-; 020-10
L538-1493/31405-; 020-11
020.4 Travel hydraulics 020-12
020.4.1 Travel pump
L538-1493/31405-; 020-12
L538-1493/31405-; 020-12
L538-1493/31405-; 020-12
020.5 Hydraulic components 020-14
020.5.1 Filter unit
L538-1493/31405-; 020-14
L538-1493/31405-; 020-14
020.6 Steering system 020-15
020.6.1 Servostat
L538-1493/31405-; 020-15
L538-1493/31405-; 020-15
L538-1493/31405-; 020-15
L538-1493/31405-; 020-16
L538-1493/31405-; 020-16
020.7 Brake system 020-17
L538-1493/31405-; 020-17
L538-1493/31405-; 020-17
LBH/11827693/02/211-20150615.1139/en

L538-1493/31405-; 020-17
020.7.4 Disc brake
L538-1493/31405-; 020-17
L538-1493/31405-; 020-18
020.8 Electrical system 020-19
L538-1493/31405-; 020-19
copyright by
020-2 L538-1493
Service manual Technical data
020.8.2 Battery
L538-1493/31405-; 020-19
020.9 Transmission 020-21
L538-1493/31405-; 020-21
020.9.2 Output speed sensor B1 and travel motor 2 speed sensor B2
L538-1493/31405-; 020-21
020.10 Axles and cardan shafts 020-22
020.10.1 Front axle
L538-1493/31405-; 020-22
020.10.2 Rear axle
L538-1493/31405-; 020-22
L538-1493/31405-; 020-23
020.11 Steel components of the basic machine 020-24
L538-1493/31405-; 020-24
020.12 Cab, heating and air conditioning 020-25
020.12.1 Dryer
L538-1493/31405-; 020-25
L538-1493/31405-; 020-25
L538-1493/31405-; 020-25
020.13 Lubrication system 020-27
L538-1493/31405-; 020-27
LBH/11827693/02/211-20150615.1139/en
copyright by
L538-1493 020-3
Drive group
020.1 Drive group
020.1.1 Engine
Valid for: L538-1493/31405-;
Fig. 8: Characteristic output/torque

1 Torque curve 4 Speed in rpm
2 Performance curve 5 Output in kW
3 Torque in Nm
Description Unit Value

Engine model John Deere CD
4045 HF286
Maximum power according to DIN/ISO 3046 kW 104
at 2400 rpm
Number of cylinders 4
Combustion method Common rail elec-
tronic high-pressure
LBH/11827693/02/211-20150615.1139/en
fuel injection
Firing order 1-3-4-2
Piston displacement cm3 4500
Cylinder bore mm 106
Stroke mm 127
Maximum torque at 1500 rpm Nm 525
Rated speed rpm 2400
Lower idling speed rpm 850±10
Upper idling speed rpm 2560±10
copyright by
020-4 L538-1493
Drive group

Inlet valve clearance (cold) mm 0.36
Outlet valve clearance (cold) mm 0.46
Direction of rotation, looking at flywheel Left
Thermostat at start of opening °C 85
Thermostat when fully open °C 97
Longitudinal/traverse inclinability ° 30 / 30
Speed regulation Electronic
Starter operating voltage V 24
Starter power consumption kW 7.8
Alternator voltage output V 27.8
Alternator current output A 100
Emission thresholds comply with EU directive 97/68
EC Stage IIIA
020.1.2 Fuel tank

Valid for: L538-1493/31405-;

Tank capacity, FULL l 225
Tank capacity, RESERVE l 30

Valid for: L538-1493/31405-;

Supply voltage V 24
Measuring principle Capacitive with inte-
grated electronics
Operating temperature -40 to +85 °C
LBH/11827693/02/211-20150615.1139/en
Measuring error ± 3%
Overall length mm 695
Start of measuring range mm 685
End of measuring range mm 50
Compressive strength bar 5
Protection class IP69
copyright by
L538-1493 020-5
Drive group

Valid for: L538-1493/31405-;

Filtration grade µm 30
Maximum flow rate l/min 10

Valid for: L538-1493/31405-;

Activation point of vacuum switch for air filter mbar 54±5
contamination
020.1.6 Clutch
Valid for: L538-1493/31405-;

Type Bowex T80 FLE-
PAC
Screw locking Loctite 241
Tightening torque of cheese-head screws on Nm 69
coupling
Tightening torque of cheese-head screws on Nm 68
coupling flange
Tightening torque of gearwheel screw Nm 86
LBH/11827693/02/211-20150615.1139/en
copyright by
020-6 L538-1493
Cooling system
020.2 Cooling system

Valid for: L538-1493/31405-;

Cooler cover pressure bar 1.2

Valid for: L538-1493/31405-;

Displacement per turn cm3 8
Flow rate at upper engine speed l/min 17.6
Speed at upper engine speed rpm 2280

Valid for: L538-1493/31405-;

Coil resistance ohms 4.5
Screw-in tightening torque Nm 124±41
LBH/11827693/02/211-20150615.1139/en
copyright by
L538-1493 020-7
Working hydraulics
020.3 Working hydraulics

Valid for: L538-1493/31405-;

Type M6-15
Spool valve diameter mm 18
Lifting function - maximum flow rate l/min 140
Lowering function - maximum flow rate l/min 60
Tilt-in function - maximum flow rate l/min 120
Tilt-out function - maximum flow rate l/min 80
3rd function A3 (optional) - maximum flow rate l/min 160
3rd function B3 (optional) - maximum flow rate l/min 100
Pretension valve bar 16±3
Weight kg 32

Valid for: L538-1493/31405-;

Type A11VO 75 LRDS
Maximum displacement per turn cm 75
3
Maximum flow rate at upper engine speed l/min 171

Power kW 51
Weight kg 45

LBH/11827693/02/211-20150615.1139/en
Valid for: L538-1493/31405-;

Type M6-15
Spool valve diameter mm 18
Lifting function - maximum flow rate l/min 140
Lowering function - maximum flow rate l/min 60
Tilt-in function - maximum flow rate l/min 140
Tilt-out function - maximum flow rate l/min 90
copyright by
020-8 L538-1493
Working hydraulics

3rd function A3 (option) - maximum flow rate l/min 160
3rd function B3 (option) - maximum flow rate l/min 100
LS working hydraulics pressure cut-off bar 350±5
LS steering system pressure cut-off bar 250±5
Pre-tension valve bar 16±3
Weight kg 32

Valid for: L538-1493/31405-;

Storage volume cm3 320
Nitrogen filling - preload pressure bar 15

Valid for: L538-1493/31405-;

Type RSM2-16
Valve spool diameter mm 16
Safety valve bar 330±10
Ride control solenoid valve Y20 - current con- A 0.6
sumption
Ride control solenoid valve Y20 - resistance ohms 40
Weight kg 13

Valid for: L538-1493/31405-;
LBH/11827693/02/211-20150615.1139/en

Oil filling (nitrogen side) cm3 350

Valid for: L538-1493/31405-;

Piston diameter mm 110
copyright by
L538-1493 020-9
Working hydraulics

Piston rod diameter mm 60
Stroke length mm 735
Minimum installation length mm 1170
Piston rod bearing tightening torque Nm 290
Piston tightening torque WN-4121-092
Lifting (loaded) 5.3 seconds
Lowering (unloaded) 4.0 seconds
Weight kg 87

Valid for: L538-1493/31405-;

Tilt-out (unloaded) 1.6 seconds
Weight kg 110

Valid for: L538-1493/31405-;

LBH/11827693/02/211-20150615.1139/en

Lifting (loaded) 5.3 seconds
Lowering (unloaded) 4.0 seconds
Weight kg 87
copyright by
020-10 L538-1493
Working hydraulics

Valid for: L538-1493/31405-;

Tilt-out (unloaded) 3.5 seconds
Weight kg 57.5
LBH/11827693/02/211-20150615.1139/en
copyright by
L538-1493 020-11
Travel hydraulics
020.4 Travel hydraulics
020.4.1 Travel pump

Valid for: L538-1493/31405-;

Type A4VG 85 EP
Series 40
Variable displacement pump - maximum dis- cm3 85
placement per turn
Variable displacement pump - maximum flow l/min 194
rate at upper engine speed
Power kW 86
Replenishing pump - displacement per turn cm3 24.5
Replenishing pump - flow rate at upper engine l/min 56
speed
Swivel restrictor diameter mm 1.8
Weight kg 77

Valid for: L538-1493/31405-;

Type A6VM 60 HA1R
Series 71
Minimum displacement per turn cm 41.5
3
Maximum displacement per turn cm3 60

Minimum angle adjustment ° 16.4
Maximum angle adjustment ° 25
Maximum output speed rpm 4560
LBH/11827693/02/211-20150615.1139/en
Output speed at Δp 400 bar Nm 395

Weight kg 28

Valid for: L538-1493/31405-;

Type A6VM 150 EP
copyright by
020-12 L538-1493
Travel hydraulics

Series 71
Maximum displacement per turn cm3 150
Minimum angle adjustment ° 0
Maximum angle adjustment ° 25
Maximum output speed rpm 4500
Output speed at Δp 400 bar Nm 968
Discharge valve - orifice diameter mm 2.0
Maximum discharge valve capacity l/min 12
Weight kg 61
LBH/11827693/02/211-20150615.1139/en
copyright by
L538-1493 020-13
Hydraulic components
020.5 Hydraulic components
020.5.1 Filter unit

Valid for: L538-1493/31405-;

Return suction filter filtration grade μm 10
Replenishing strainer filtration grade μm 160
Pre-tension valve bar 0.5
Replenishing valve bar 0.05
Return strainer filtration grade μm 80
Bypass valve bar 2.5

Valid for: L538-1493/31405-;

Breather filter filtration grade μm 2
Inlet valve bar 0.03
Outlet valve bar 0.5
Connecting thread inch 3 / 4
LBH/11827693/02/211-20150615.1139/en
copyright by
020-14 L538-1493
Steering system
020.6 Steering system
020.6.1 Servostat
Valid for: L538-1493/31405-;

Displacement cm3 462
Secondary pressure relief valves bar 310±5
Flow booster 1 : 1.6
Weight kg 8.7

Valid for: L538-1493/31405-;

Piston tightening torque Nm 300
Nut tightening torque (securing piston) Nm 150
Weight kg 27.3

Valid for: L538-1493/31405-;

LBH/11827693/02/211-20150615.1139/en
Pressure relief valve bar 55±5

Protection class IP66
Maximum current consumption A 150
Weight kg 10
copyright by
L538-1493 020-15
Steering system

Valid for: L538-1493/31405-;

Type Normally open
Type Electronic pressure
switch
Switching point bar 16±2
Connecting thread mm M12x1.5
Tightening torque Nm 25

Valid for: L538-1493/31405-;

Type Normally open
switch
Switching point bar 16±2
Connecting thread mm M12x1.5
Tightening torque Nm 25
LBH/11827693/02/211-20150615.1139/en
copyright by
020-16 L538-1493
Brake system
020.7 Brake system

Valid for: L538-1493/31405-;

Number of hydro accumulators Set of 2
Storage volume per hydro accumulator cm 750
3

Valid for: L538-1493/31405-;

Type Normally open
Switch point, rising bar 5±0.5
Thread mm M 12 x 1.5

Valid for: L538-1493/31405-;

Type Normally open
switch
Switching point, falling bar 90±5
020.7.4 Disc brake

Valid for: L538-1493/31405-;
LBH/11827693/02/211-20150615.1139/en

Gap mm 0.5+1.0
New brake lining thickness mm 4.5
Worn brake lining thickness mm 1.0
copyright by
L538-1493 020-17
Brake system

Valid for: L538-1493/31405-;

LBH/11827693/02/211-20150615.1139/en
copyright by
020-18 L538-1493
Electrical system
020.8 Electrical system

Valid for: L538-1493/31405-;

Protection class (with plug connected) IP6K9K
Operating voltage VDC 7 to 36
Operating temperature °C -40 to +70
Operation at ambient air pressure mbar 500 to 1100
Dimensions mm 268 x 221 x 90
Weight kg 3,45
Processor speed MHz 40
Programme memory MB 1
Interfaces 2 x CAN, 1 x RS232
Digital inputs 22 x digital input, 8 x
8-bit digital input, 2 x
frequency input,
Analogue inputs 3 x analogue input
0-10 V, 4 x resist-
ance input 10-2 kΩ
Digital outputs 5 x digital output
2 A, 9 x digital out-
put 3 A, 4 x digital
output 5 A
Analogue outputs 3 x PWM output 3 A
current controlled
020.8.2 Battery
Valid for: L538-1493/31405-;
LBH/11827693/02/211-20150615.1139/en

Battery voltage V 12
Battery capacity Ah 150
Acid density of charged battery kg/l 1.28
Charging current (recommended) A 14 – 15
Charging voltage (recommended) VDC 13.7 – 14.4
Cold start current (EN) A 900
Self-discharging (at 25 °C) About 4% a month
copyright by
L538-1493 020-19
Electrical system

Electrolyte Diluted sulphuric
acid
Top-up water Distilled or deminer-
alised
LBH/11827693/02/211-20150615.1139/en
copyright by
020-20 L538-1493
Transmission
020.9 Transmission
Valid for: L538-1493/31405-;

Type 319
Travel motor 1 ratio 1.55
Travel motor 2 ratio 3.83
Output speed at 40 km/h rpm 2795
020.9.2 Output speed sensor B1 and travel motor 2 speed sen-

sor B2
Valid for: L538-1493/31405-;

Type Hall sensor
Resistance at 20 °C ohms 1050±100
Teeth at output speed sensor B1 76
Teeth at travel motor 2 speed sensor B2 34
LBH/11827693/02/211-20150615.1139/en
copyright by
L538-1493 020-21
Axles and cardan shafts
020.10 Axles and cardan shafts
020.10.1 Front axle

Valid for: L538-1493/31405-;

Type 113/162
Differential locking value % 45
Track width mm 1900
Flange size mm 1920
Wheel nut spanner size mm 30
Wheel nut tightening torque Nm 650
Differential transmission ratio 3.09
Wheel hub transmission ratio 6
Overall transmission 18.54
Weight kg 720
020.10.2 Rear axle

Valid for: L538-1493/31405-;

Type 319/113/96
Differential locking value % 45
Track width mm 1900
Flange size mm 1920
Wheel nut spanner size mm 30
Wheel nut tightening torque Nm 650
Differential transmission ratio 3.09
Wheel hub transmission ratio 6
LBH/11827693/02/211-20150615.1139/en
Overall transmission 18.54

Pendulum angle per side 6°
Weight kg 840
copyright by
020-22 L538-1493

Valid for: L538-1493/31405-;

Minimum length mm 1875
Maximum length mm 2020
Weight kg 27.5
LBH/11827693/02/211-20150615.1139/en
copyright by
L538-1493 020-23
Steel components of the basic machine
020.11 Steel components of the basic machine

Valid for: L538-1493/31405-;

Weight of left ballast weight kg 1039
Weight of right ballast weight kg 798
LBH/11827693/02/211-20150615.1139/en
copyright by
020-24 L538-1493
Cab, heating and air conditioning
020.12 Cab, heating and air conditioning
020.12.1 Dryer
Valid for: L538-1493/31405-;

Filtration grade μm 7
Test pressure bar 38
Dryer water consumption g 13
Pressure relief valve, opening pressure bar 35 ±3
Burst pressure bar 100

Valid for: L538-1493/31405-;

Low pressure OFF bar 1.5±0.5
Low pressure ON bar 3.4±0.3
High pressure OFF bar 26±2
High pressure ON bar 18±1.5
Increase fan speed OFF bar 15±1
Increase fan speed ON bar 19±1

Valid for: L538-1493/31405-;

Set-up NTC resistance
Operating temperature °C -40 to +90
LBH/11827693/02/211-20150615.1139/en
Resistance at -15°C ohms 72910

Resistance at -10°C ohms 55310
Resistance at -5 °C ohms 42330
Resistance at 0 °C ohms 32670
copyright by
L538-1493 020-25

Resistance at 25°C ohms 10000
Protection class IP 68
LBH/11827693/02/211-20150615.1139/en
copyright by
020-26 L538-1493
Lubrication system
020.13 Lubrication system

Valid for: L538-1493/31405-;

Flow per stroke mm3 120
Pumped medium Grease up to NLGI
class 2
Maximum pump pressure bar 280
Operating temperature °C min. -35
max. +80
Supply voltage V 24
Protection class IP 65
Reservoir capacity kg 4
Lubricating time min 6
Cycle time h 0.5
LBH/11827693/02/211-20150615.1139/en
copyright by
L538-1493 020-27
Lubrication system
LBH/11827693/02/211-20150615.1139/en
copyright by
020-28 L538-1493
030 Maintenance
Contents
030.1 Maintenance and inspection schedule 030-8
030.2 Filling quantities and lubrication chart 030-13
L538-1493/31405-; 030-13
L538-1493/31405-; 030-14
030.3 Lubricants and fuels 030-15
030.3.1 General information on changing lubricants and fuels 030-15
030.3.2 Converting the hydraulic system from mineral oils to environmental-
ly harmless hydraulic fluids 030-15
L538-1493/31405-; 030-16
L538-1493/31405-; 030-17
L538-1493/31405-; 030-19
L538-1493/31405-; 030-21
L538-1493/31405-; 030-25
L538-1493/31405-; 030-26
L538-1493/31405-; 030-27
LBH/11827693/02/211-20150615.1139/en
030.4 Maintenance tasks 030-29

L538-1493/31405-; 030-29
030.4.2 Preparatory tasks for maintenance 030-30
L538-1493/31405-; 030-30
L538-1493/31405-; 030-31
L538-1493/31405-; 030-33
copyright by
L538-1493 030-1
Maintenance Service manual

L538-1493/31405-; 030-34
030.4.3.2 Removing loose parts, dirt, ice and snow from the
machine
L538-1493/31405-; 030-34
L538-1493/31405-; 030-34
L538-1493/31405-; 030-36
L538-1493/31405-; 030-36
030.4.3.6 Corrosion protection on machines that work with salt
and artificial fertilisers and exchanging VCI capsules
L538-1493/31405-; 030-36
L538-1493/31405-; 030-37
030.4.4 Drive group 030-43
L538-1493/31405-; 030-43
L538-1493/31405-; 030-44
L538-1493/31405-; 030-45
L538-1493/31405-; 030-46
L538-1493/31405-; 030-47
L538-1493/31405-; 030-49
L538-1493/31405-; 030-51
L538-1493/31405-; 030-52
030.4.4.9 Draining off condensate and sediment from the fuel
LBH/11827693/02/211-20150615.1139/en
tank
L538-1493/31405-; 030-53
L538-1493/31405-; 030-54
L538-1493/31405-; 030-55
L538-1493/31405-; 030-56
L538-1493/31405-; 030-58
copyright by
030-2 L538-1493
Service manual Maintenance

L538-1493/31405-; 030-59
L538-1493/31405-; 030-60
030.4.4.16 Cleaning the air filter service cover and dust dis-
charge valve
L538-1493/31405-; 030-61
030.4.4.17 Checking the air suction system for leaks and tight
fitting
L538-1493/31405-; 030-63
L538-1493/31405-; 030-64
L538-1493/31405-; 030-67
030.4.4.20 Checking the exhaust system for leaks and tight fit-
ting
L538-1493/31405-; 030-68
L538-1493/31405-; 030-69
030.4.5.2 Checking the coolant antifreeze and corrosion inhibi-
tor concentration
L538-1493/31405-; 030-70
L538-1493/31405-; 030-74
L538-1493/31405-; 030-75
L538-1493/31405-; 030-77
030.4.6.2 Checking and cleaning the magnetic rod on the hy-
draulic tank
L538-1493/31405-35974; 030-78
030.4.6.3 Checking and cleaning the magnetic rod on the hy-
draulic tank
L538-1493/35975-; 030-79
LBH/11827693/02/211-20150615.1139/en
030.4.6.4 Draining off condensate and sediment from the hy-

draulic tank
L538-1493/31405-; 030-80
L538-1493/31405-35974; 030-81
L538-1493/35975-; 030-82
L538-1493/31405-; 030-83
copyright by
L538-1493 030-3
030.4.6.8 Changing the oil in the hydraulic system in accord-

ance with oil quality and oil analysis
L538-1493/31405-; 030-84
030.4.6.9 Lubricating the solenoids, universal joints and tap-
pets on the pilot control unit
L538-1493/31405-; 030-86
L538-1493/31405-; 030-87
030.4.7.2 Lubricating the bearing points on the steering cylin-
ders
L538-1493/31405-; 030-88
030.4.8 Brake system 030-88
L538-1493/31405-; 030-88
L538-1493/31405-; 030-89
030.4.8.3 Checking the gap and wear on the parking brake lin-
ings
L538-1493/31405-; 030-91
L538-1493/31405-; 030-94
L538-1493/31405-; 030-95
030.4.9.3 Changing the travel direction rocker switch and cap
(optional) on the control lever
L538-1493/31405-; 030-98
L538-1493/31405-; 030-100
L538-1493/31405-; 030-100
030.4.11 Axles and cardan shafts 030-101
LBH/11827693/02/211-20150615.1139/en

L538-1493/31405-; 030-101
L538-1493/31405-; 030-102
030.4.11.3 Checking the tightening torque of the front axle fas-
tening bolts
L538-1493/31405-; 030-104
L538-1493/31405-; 030-104
L538-1493/31405-; 030-105
copyright by
030-4 L538-1493
030.4.11.6 Checking the wheel tightness (once after 50, 100 and
250 h)
L538-1493/31405-; 030-105
030.4.12 Steel components of the basic machine 030-106
030.4.12.1 Lubricating the articulated bearing and the rear oscil-
lating bedding
L538-1493/31405-; 030-106
L538-1493/31405-; 030-107
030.4.13 Working attachment 030-108
L538-1493/31405-; 030-108
L538-1493/31405-; 030-109
L538-1493/31405-; 030-110
L538-1493/31405-; 030-110
030.4.14 Cab, heating and air conditioning 030-111
L538-1493/31405-; 030-111
L538-1493/31405-; 030-113
L538-1493/31405-; 030-114
030.4.14.4 Checking and topping up the windscreen washer res-
ervoir
L538-1493/31405-; 030-114
L538-1493/31405-; 030-115
030.4.14.6 Checking the indicator and filling level beads in the
dryer-collector unit of the air conditioner
L538-1493/31405-; 030-115
L538-1493/31405-; 030-116
LBH/11827693/02/211-20150615.1139/en
030.4.15 Lubrication system 030-117

030.4.15.1 Checking the lubrication system grease reservoir lev-
el
L538-1493/31405-; 030-117
030.4.15.2 Checking the pipes, hoses and lubrication points of
the lubrication system
L538-1493/31405-; 030-118
030.4.15.3 Checking whether metered quantities are adequate
at the bearing points (grease collars) of the lubrica-
tion system
L538-1493/31405-; 030-118
copyright by
L538-1493 030-5

L538-1493/31405-; 030-119
030.6 Testing and adjustment tasks 030-123
L538-1493/31405-; 030-123
L538-1493/31405-; 030-124
L538-1493/31405-; 030-125
030.6.3 Drive group 030-126
L538-1493/31405-; 030-126
L538-1493/31405-; 030-126
L538-1493/31405-; 030-127
030.6.5.1 Working hydraulics pump flow regulator (standby
pressure)
L538-1493/31405-; 030-129
030.6.5.2 Z kinematics control valve block secondary pressure
relief valves
L538-1493/31405-; 030-130
030.6.5.3 P kinematics control valve block secondary pressure
relief valves
L538-1493/31405-; 030-132
L538-1493/31405-; 030-134
L538-1493/31405-; 030-135
030.6.5.6 Ride control hydro accumulator (optional), nitrogen
filling
LBH/11827693/02/211-20150615.1139/en
L538-1493/31405-; 030-136
L538-1493/31405-; 030-139
030.6.6 Travel hydraulics 030-142
L538-1493/31405-; 030-142
L538-1493/31405-; 030-144
L538-1493/31405-; 030-146
copyright by
030-6 L538-1493

L538-1493/31405-; 030-148
L538-1493/31405-; 030-149
L538-1493/31405-; 030-151
L538-1493/31405-; 030-152
L538-1493/31405-; 030-153
030.6.8 Brake system 030-154
030.6.8.1 Compact brake valve, hydro accumulator charging
function
L538-1493/31405-; 030-154
L538-1493/31405-; 030-155
L538-1493/31405-; 030-156
L538-1493/31405-; 030-158
030.6.9.1 Repairing the Tuple Chain on the central control unit
(UEC3)
L538-1493/31405-; 030-159
L538-1493/31405-; 030-164
L538-1493/31405-; 030-169
LBH/11827693/02/211-20150615.1139/en
copyright by
L538-1493 030-7
Maintenance and inspection schedule
030.1 Maintenance and inspection schedule
The following abbreviations are used in this section:

– h = service hours
Various symbols (solid or empty circles, boxes and stars) are used to indicate the
maintenance tasks, which fall into two main types.
The symbols have the following meanings:
Table with solid circle, box or star
– Responsibility for carrying out the maintenance work lies with the machine oper-
ator or his maintenance personnel.
This affects the maintenance intervals every 10 and 50 service hours (h) and
non-scheduled intervals.
The symbols have the following meanings:
Table with empty circle, box or star, or service hours (h)
– The maintenance and inspection work must be performed or supervised by au-
thorised engineers from Liebherr or its authorised dealers.
This affects the maintenance interval: on delivery and every 500, 1000, 2000,
3000 service hours (h), and at unscheduled times.
A list of the spare parts needed for maintenance and inspection work is contained
in the service package of the spare parts list.
LBH/11827693/02/211-20150615.1139/en
copyright by
030-8 L538-1493
Customer:....................Machine type:........................................... Serial no.:...................Operating hours:.....................Date:.................................
Maintenance / inspection after Tasks to be performed

service hours
By maintenance staff By authorised specialist

n Once-only activity staff
l Repeat interval o Once-only activity
ª If necessary m Repeat interval
Additional labelling
T Annually before the winter ² If necessary
Other intervals
Confirm tasks
On handover
Assistance required
All 1000 h
All 2000 h
See page
All 8-10 h
All 500 h
All 50 h
Have this task carried out exclusively by a

certified electrician
Overall machine
o l l m m m Checking the machine for external damage 030-34
l l m m m Removing loose parts, dirt, ice and snow from the machine 030-34
m m Checking the hydraulic pressure according to the testing and ad-
justment checklist
o ª Checking the machine for leaks 030-36
ª Making sure the bolted connections are tight 030-36
m m ª Perform corrosion protection on machines that are used for salt 030-36
and artificial fertilisers and exchange VCI capsules (at least once a
year)
Drive group
o l l m m m Checking the engine oil level 030-43
m m m Changing the engine oil (at least once a year): NOTE: Engine oil 030-44
quality and complicating factors (For more information see:
030.3.4 Lubricating oils for diesel engines, page 030-17)
m m m Change the engine oil filter (with every oil change) 030-45
m m m Checking the V-ribbed belt on the engine 030-46
² Changing the V-ribbed belt on the engine 030-47
m Checking the engine valve clearance 030-49
m m m Checking the bleeder filter of the crankcase 030-51
T Checking the engine heating flange 030-52
o l m m m ª Draining off condensate and sediment from the fuel tank 030-53
l m m m ª Drain off condensate from the Separ fuel pre-filter (or in the event 030-54
LBH/11827693/02/211-20150615.1139/en
of poor performance)
l l m m m ª Draining off condensate from the fuel pre-filter (regularly, or if the 030-55
corresponding service code appears)
m m m ª Change the Separ fuel pre-filter insert (or in the event of poor per- 030-56
formance)
m m m ª Changing the fuel pre-filter (or in the event of poor performance) 030-58
m m m ª Changing the fuel fine filter (or in the event of poor performance) 030-59
ª Bleed the fuel system (caution: do not disconnect the pump - RAIL 030-60
- injection valve lines).
l m m m ª Cleaning the air filter service cover and dust discharge valve 030-61
copyright by
L538-1493 030-9

service hours

Additional labelling T Annually before the winter ² If necessary
Other intervals
Confirm tasks
On handover
Assistance required
All 1000 h
All 2000 h
See page
All 8-10 h
All 500 h
All 50 h

m m m Checking the air suction system for leaks and tight fitting 030-63
m m ª Changing or changing the air filter main element (when indicated 030-64
by the vacuum switch, or at least once a year)
m ª Changing the air filter safety element (after replacing the main ele- 030-67
ment 3 times or once a year at the latest)
m m m Checking the exhaust system for leaks and tight fitting 030-68
Cooling system
o l l m m m Checking the coolant level 030-69
m m m T Checking the coolant antifreeze and corrosion inhibitor concentra- 030-70
tion
ª Cleaning the cooling system 030-74
m Change the coolant (at least every 2 years) 030-75
Working hydraulics
o l l m m m Checking the oil level in the hydraulic tank 030-77
o m m m Checking and cleaning the magnetic rod on the hydraulic tank 030-78
o m m m Checking and cleaning the magnetic rod on the hydraulic tank 030-79
m m m Draining off condensate and sediment from the hydraulic tank 030-80
m m Hydraulic tank - changing the return-suction filter 030-81
m m Changing the hydraulic tank return suction filter 030-82
m Changing the hydraulic tank breather filter 030-83
² Changing the oil in the hydraulic system in accordance with oil 030-84
quality and oil analysis (For more information see: 030.3.6 Hy-
draulic oil, page 030-21)
LBH/11827693/02/211-20150615.1139/en
m m Lubricating the solenoids, universal joints and tappets on the pilot 030-86
control unit
Steering system
o l l m m m Testing the steering 030-87
o l m m m Lubricating the bearing points on the steering cylinders 030-88
Brake system
o l l m m m Testing the service brake and parking brake 030-88
m3000h Checking the service brake discs for wear 030-89
m m Checking the gap and wear on the parking brake linings 030-91
copyright by
030-10 L538-1493

service hours

T Annually before the winter ² If necessary
Other intervals
Confirm tasks
On handover
Assistance required
All 1000 h
All 2000 h
See page
All 8-10 h
All 500 h
All 50 h

Electrical system
o l l m m m Checking the lights 030-94
m m m Checking the batteries, fluid level and terminals 030-95
m m Changing the travel direction rocker switch and cap (optional) on 030-98
the control lever
Transmission
o m m m Checking the transmission oil level 030-100
o m m Changing the transmission oil 030-100
o m m m Checking the axle oil levels 030-101
o m m Changing the axle oil 030-102
o m Checking the tightening torque of the front axle fastening bolts 030-104
m m m Checking the cardan shafts 030-104
o l m m m Checking the tyre pressure 030-105
o n m m m Checking the wheel tightness (once after 50, 100 and 250 h) 030-105
Steel components of the basic machine
o l m m m Lubricating the articulated bearing and the rear oscillating bedding 030-106
m m m ª Covering - lubricating locks and hinges 030-107
Working attachment
o l m m m ª Lubricating the lift arms and attachment 030-108
m m ª Checking the lift arm bearing bushings 030-109
LBH/11827693/02/211-20150615.1139/en
m m Checking the lift arm bucket stops (Z kinematics) 030-110

o l l m m m Lubricating and testing the quick-change device 030-110
m m m ª Cleaning the fresh and recirculated air filters 030-111
m m ª Changing the fresh and recirculated air filters 030-113
m m m ª Checking the condition and function of the safety belt 030-114
m m m Checking the condition and function of the windscreen washer sys-
tem
ª Checking and topping up the windscreen washer reservoir 030-114
copyright by
L538-1493 030-11

service hours

Additional labelling T Annually before the winter ² If necessary
Other intervals
Confirm tasks
On handover
Assistance required
All 1000 h
All 2000 h
See page
All 8-10 h
All 500 h
All 50 h

ª Checking the seals on the driver’s cab 030-115
m m m Checking the indicator and filling level beads in the dryer-collector 030-115
unit of the air conditioner (optional)
m m m Testing the air conditioning unit 030-116
Lubrication system
o l m m m Checking the lubrication system grease reservoir level 030-117
o l m m m Checking the pipes, hoses and lubrication points of the lubrication 030-118
system
o l m m m Checking whether metered quantities are adequate at the bearing 030-118
points (grease collars) of the lubrication system
LBH/11827693/02/211-20150615.1139/en
copyright by
030-12 L538-1493
Filling quantities and lubrication chart
030.2 Filling quantities and lubrication chart
Specifications in the quantity column:

– The values stated for the filling quantities in the table are only guidelines.
– The dipstick and level markings are always mandatory.
– Each time the oil is replaced or topped up, check the level in the unit in ques-
tion.
Valid for: L538-1493;

Valid for: L538-1493/31405-;
Designation Recommended lubricant Symbol Quantity

Engine (with filter change) Liebherr Motoroil 10W-40 14.7 l
Liebherr Motoroil 10W-40 low ash
Liebherr Motoroil 5W-30
Hydraulic system Liebherr Hydraulic Basic 68
Liebherr Hydraulic Basic 100
Liebherr Hydraulic HVI
Liebherr Hydraulic Plus
System capacity 180 l
Tank capacity 110 l
Transmission Liebherr Hydraulic-Gear ATF 5W-20 3.8 l
Front axle differential Liebherr Gear Basic 90LS 16.3 l
Front axle wheel hubs Liebherr Gear Basic 90LS 2.6 l
Rear axle differential Liebherr Gear Basic 90LS 15 l

LBH/11827693/02/211-20150615.1139/en
Rear axle wheel hubs Liebherr Gear Basic 90LS 2.6 l
Tab. 13: Recommended lubricants
copyright by
L538-1493 030-13
Filling quantities and lubrication chart

Valid for: L538-1493/31405-;
Designation Recommended operating fluid Symbol Quantity

Fuel tank Conventional diesel fuel with a sulphur content of 225 l
less than or equal to 0.5 %
Fuel reserve, approx. 30 l
Engine cooling system total Liebherr Antifreeze OS Mix 36 l
capacity
Liebherr Antifreeze OS Concentrate
Windscreen washer system Standard windscreen washer fluid or denatured 3.5 l

alcohol
Air conditioning system refrig- R134a 1180+20 g

erant
Refrigerant oil for air condi- ZXL 100 PG (PAG Oil) 200 cm3
tioning compressor
Tab. 14: Recommended operating fluids
LBH/11827693/02/211-20150615.1139/en
copyright by
030-14 L538-1493
Lubricants and fuels
030.3 Lubricants and fuels
030.3.1 General information on changing lubricants and fuels
Note
The filling quantities listed in the lubricant and fuel table and the lubrication chart in
the driver's cab are only guidelines.
u Each time the oil is replaced or topped up, check the level in the unit in ques-
tion.
Note
Conscientious observance of the regulations for lubrication, level testing and
changing fuels and operating fluids will increase the reliability and service life of the
machine.
It is especially important that the oil change intervals and the specified lubricant
qualities are observed.
u Note the sections on lubricants and fuels and the maintenance and inspection
schedule when using and checking lubricants and fuels.
Note
Cleanliness is essential during every oil change.
u Clean all filler plugs, filler caps and drain plugs and the area around them be-
fore opening them.
u It is advisable to wait until the oil has reached operating temperature before
draining it.
u Make sure used oil is collected and disposed of, along with the old oil filter car-
tridges, in an environmentally friendly manner.
WARNING
When checking and changing lubricants and fuels, make sure you observe the fol-
lowing instructions:
u Unless stated otherwise, carry out the work on the machine on firm, level
ground with the engine switched off.
u Before working in the engine compartment, secure the hood and side hatches
against accidentally falling down or closing.
u Only refuel the machine with the engine switched off. Do not smoke, avoid nak-
LBH/11827693/02/211-20150615.1139/en
ed lights.
u Turn the battery main switch to the 0 (off) position and take out the ignition key.
030.3.2 Converting the hydraulic system from mineral oils to

environmentally harmless hydraulic fluids
For the operation of Liebherr earth moving machines with environmentally harm-
less hydraulic fluids, we recommend Liebherr Hydraulic Plus.
copyright by
L538-1493 030-15
Machines filled at the factory with environmentally harmless hydraulic fluids

have a sign to that effect (NOTICE) attached to the driver's cab and hydraulic
tank.
Procedure for later conversion
NOTICE
Beware of damaging the machine's hydraulic system.
Mixing environmentally harmless hydraulic fluids with mineral oils produces a vigo-
rous reaction that can damage the hydraulic system.
u Never mix environmentally harmless hydraulic fluid with mineral oil.
u If you intend to convert the machine to environmentally harmless hydraulic fluid,

you must first consult Liebherr CUSTOMER SERVICE.
u It is essential that you order the instruction sheet and the conversion guide-
lines from Liebherr and that you observe them.

Valid for: L538-1493/31405-;
030.3.3.1 Specification
Diesel fuels must comply with the minimum requirements of the following specifica-
tions.
Specifications:
– DIN EN 590
– ASTM D 975-89a - 1D and 2D
– We strongly recommend using diesel fuel with a sulphur content of less than
0.1 % (1000 ppm).
030.3.3.2 High sulphur content in the diesel fuel

1. See oil change intervals according to complicating factors.
2. Diesel fuels with a sulphur content of more than 1% (10,000 mg/kg) are not
permitted.
3. For engines with external exhaust gas recirculation (eEGR): use diesel fuels
with a sulphur content of no more than 0.5% (5000 mg/kg).
4. If the diesel engine is operated using E6 engine oil and a standard oil change
interval (500 operating hours), diesel fuels with a sulphur content of more than
0.005% (50 mg/kg) may not be used.
LBH/11827693/02/211-20150615.1139/en
According to the HFRR (60) test, the maximum diesel fuel lubricity must be 460 µm
(lubricity-corrected wear scar diameter [1.4] at 60 °C).
Fuel standard ASTM D 975 does not stipulate that fuels must pass a fuel-lubricity
test. Written confirmation must be provided by the fuel supplier. Any additions
should be undertaken by the supplier as he is responsible for the quality of the fuel.
The addition of secondary lubricity additives by the customer is not recommended.
Note
u Obtain written confirmation from the supplier.
copyright by
030-16 L538-1493
A cetane number of at least 45 is required for fuels. A cetane number above 50 is

preferable, especially at temperatures below 0 °C.
030.3.3.3 Diesel fuel at low temperatures (winter operation)

Paraffin crystals form in diesel fuel as the temperature falls; these increase the flow
resistance in the fuel filter to such an extent that the fuel supply to the engine is no
longer guaranteed.
NOTICE
Danger of damage to the injection system if incorrect fuel is used.
Adding petroleum or normal petrol will damage the injection system.
u Do not add petroleum, normal petrol or any additives to the diesel fuel.
If the outside temperature falls below -20 °C:
u Use an ignition-starting device such as a fuel filter heater.
When using the machine in arctic climates:
u Use special diesel fuels with suitable flow characteristics.

Valid for: L538-1493/31405-;
030.3.4.1 Lubricating oil quality

Only high-alloy lubricating oils are used in modern diesel engines.
They are comprised of base oils which feature combined admixtures (additives).
The lubricating oil regulation for Liebherr diesel engines is based on the following
specifications and regulations.
Designation Specification
ACEA classification (Association des Con- E4, E5, E6, E7
structeurs Européens de l’Automobile)
API classification (American Petroleum In- CI-4, CI-4 Plus, CJ-4
stitute)
Note: observe the reduced oil-
change intervals
Tab. 15: Lubricating oil specifications
030.3.4.2 Lubricating oil viscosity

LBH/11827693/02/211-20150615.1139/en
Select the lubricating oil viscosity in accordance with the SAE classification (Soci-
ety of Automotive Engineers).
The ambient temperature determines the right choice of SAE class.
The selection of the SAE classification gives no indication of the quality of a lubri-
cating oil.
Oil that is too viscous can cause starting problems, while insufficient viscosity im-
pairs lubricating efficiency.
The temperature ranges detailed in the following diagram are guidelines; short-
term deviations are permissible.
copyright by
L538-1493 030-17
Fig. 13: Selection of the SAE class according to temperature
The following diesel engine oil is recommended for ambient temperatures from
-20 °C to 45 °C:
Liebherr Motoroil 10W-40, specification ACEA E4
Liebherr Motoroil 10W-40 low ash, specification ACEA E4, E6, E7
The following diesel engine oil is recommended for ambient temperatures from
-30 °C to 30 °C:
Liebherr Motoroil 5W-30, specification ACEA E4, E7
030.3.4.3 Lubricating oil change intervals

Changing intervals: (For more information see: 030.1 Maintenance and inspection
schedule, page 030-8)
Change the oil according to the climate zone, sulphur content in the fuel and oil
quality as shown in the following table.
Even if the specified number of service hours (h) is not reached in the course of a
year, the engine oil and filter should be replaced at least once a year.
Various complicating factors (harsh operating conditions) can affect the mainte-
nance interval.
Possible complicating factors are:
– Frequent cold-starts
– Sulphur content in the fuel
– Operating temperature
If complicating factors do play a role, the oil must be changed and the filter re-
placed in accordance with the specifications in the following table.
The use of diesel fuel with a sulphur content of less than 0.1% (1000 ppm) is
LBH/11827693/02/211-20150615.1139/en
strongly recommended.
Complicating factor for engines without external

Oil quality
exhaust gas recirculation (external EGR)
CI-4, CI-4
Plus, CJ-4, E6, E7
E4, E5
Sulphur content in the fuel Interval A)
Up to 0.5 % 250 h 500 h
copyright by
030-18 L538-1493
Complicating factor for engines without external

Oil quality
exhaust gas recirculation (external EGR)
0.5 % to 1.0 % 125 h 250 h
Tab. 16: Oil change intervals depending on complicating factor for engines without
external exhaust gas recirculation (external EGR)
A) Operating hours
Complicating factor for engines with external ex-

Oil quality
haust gas recirculation (external EGR)
CI-4, CI-4
Plus, CJ-4, E6, E7
E4, E5
Sulphur content in the fuel Interval A)
Up to 0.5 % 250 h 500 h
Tab. 17: Oil change intervals depending on complicating factor for engines with ex-
ternal exhaust gas recirculation (external EGR)
A) Operating hours

Valid for: L538-1493/31405-;
030.3.5.1 General recommendations

Antifreezes and corrosion inhibitors approved by Liebherr:
– Guarantee adequate protection from cold, corrosion and cavitation.
– Do not corrode seals and hoses.
– Do not foam.
Coolant is a mixture of water with corrosion inhibiting and antifreeze additives.
The cooling system only functions reliably under pressure. The cooling system
must be clean and leak-tight. The cooling shut-off and working valves must work
correctly. Maintain the required coolant level.
Coolants cause cavitation or corrosion damage in the cooling system if they con-
tain unsuitable antifreeze and corrosion inhibitors or are incorrectly prepared. Insu-
lating deposits that accumulate on components that conduct heat can lead to over-
heating and engine failure.
LBH/11827693/02/211-20150615.1139/en
Emulsifying anti-corrosion oils are prohibited.
030.3.5.2 Water (fresh water)

Water that is colourless, clear, free of mechanical contamination, drinkable tap wa-
ter featuring the following restricted analysis values is suitable.
Seawater, brackish water, brine and industrial wastewater are unsuitable.
Designation Value
Water hardness 0.6 mmol/l to 3.6 mmol/l (3 to 20°d)
copyright by
L538-1493 030-19
Designation Value
PH level at 20 °C 6.5 to 8.5
Chloride ion content maximum 80 mg/l
Sulphate ion content maximum 100 mg/l
Tab. 18: Fresh water quality
Water analyses must be requested from the communal authorities responsible.
Designation Value and unit

Water hardness 0.6 mmol/l to 2.7 mmol/l (3 to 15°d)
PH level at 20 °C 6.5 to 8.0
Chloride ion content maximum 80 mg/l
Sulphate ion content maximum 80 mg/l
Tab. 19: Fresh water quality when using DCA A)
A) Diesel coolant additives
030.3.5.3 Coolant - Mixing ration

The cooling system must contain at least 50% antifreeze and corrosion inhibitor all
year round.
Outside temperature up Mixing ratio

to
Water % Antifreeze and corrosion inhibitor %
-37 °C 50 50
-50 °C 40 60
Tab. 20: Mixing ratio of water and antifreeze/corrosion inhibitor depending on the
temperature
NOTICE
Too much antifreeze and corrosion inhibitor in the coolant.
The engine will overheat and can be damaged.
u Do not use more than 60% antifreeze and corrosion inhibitor.
LBH/11827693/02/211-20150615.1139/en
030.3.5.4 Permissible antifreeze and corrosion inhibitors
Product designation Manufacturer Contains silicates

Liebherr Antifreeze OS Concentrate Liebherr Yes
Liebherr Antifreeze OS Mix A) Liebherr Yes
Tab. 21: Permissible antifreeze and corrosion inhibitors
A) Mix = prepared mixture (50% water and 50% antifreeze/corrosion inhibitor)
copyright by
030-20 L538-1493
Note
If Liebherr coolant is not available at your location:
u Use coolant that meets the “coolant specifications for Liebherr engines” (consult
customer service).
NOTICE
Mixing different antifreeze and corrosion inhibitors can degrade the properties of
the coolant.
u Do not combine different products.
u Never mix coolants with and without silicates, as this can damage the cooling
system.
030.3.5.5 Corrosion inhibitors without antifreeze

In exceptional cases and if ambient temperatures constantly remain above
freezing point, for example in tropical regions where there is demonstrably no au-
thorised antifreeze and corrosion inhibitor available, prepare coolant by mixing wa-
ter with the following inhibitors:
– DCA 4 Diesel Coolant Additives
– Caltex XLI / Delo XLI / Texaco XLI / Havoline XLI
In this case, change the coolant annually.
When carrying out maintenance tasks, test the concentration and adjust it as nec-
essary.
NOTICE
Mixing different corrosion inhibitors can degrade the properties of the coolant.
u Do not combine different products.
u Never mix coolants with and without silicates, as this can damage the cooling
system.
If changing between corrosion inhibitor with and without antifreeze:
u Drain the coolant completely.
Product designation Manufacturer

DCA 4 Diesel Coolant Additives Fleetguard / Cummins Filtration
Caltex XLI / Delo XLI Caltex (Asia)
Texaco XLI / Havoline XLI Chevron (North and South America)
LBH/11827693/02/211-20150615.1139/en
Havoline XLI Arteco (Asia and Europe)
Tab. 22: Corrosion inhibitors without antifreeze

Valid for: L538-1493/31405-;
The following oils may be used as hydraulic oils according to the following specifi-
cations.
Maximum water content of the hydraulic fluid: < 0.1 %
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L538-1493 030-21
030.3.6.1 Liebherr hydraulic oil

Liebherr recommends the following hydraulic oils for the machine, according to the
temperature range:
Fig. 15: Liebherr hydraulic oil, selection of viscosity class according to temperature
A Ambient temperature C Operating range
B Cold start with warming-up proce-
dure
Liebherr Hydraulic Plus is suitable as a bio oil as well as for long-term use.
If Liebherr oils cannot be purchased locally, you must use engine oils as described
in the section on using “engine oil as hydraulic oil” (after consultation with customer
service).
030.3.6.2 Using engine oil as hydraulic oil

When using non-Liebherr engine oils, we recommend that the customer first ask
the oil manufacturer whether the product meets the following specifications.
Engine oils to be used as hydraulic oil must be selected according to the following
specifications:
Single-grade oils (1) API - CD / ACEA - E1

(MB 226.0 and 227.0)
Multi-grade oils (2) API - CD, CE, CF / ACEA - E2, E3, E4
(MB 227.5, 228.1, 228.3 and 228.5)
Tab. 23: Classification of engine oil for use as hydraulic oil

LBH/11827693/02/211-20150615.1139/en
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030-22 L538-1493
Fig. 16: Engine oil for use as hydraulic oil, temperature-dependent selection of the
viscosity class 5)
A Ambient temperature 1 Single-grade oils
B Cold start with warming-up proce- 2 Multi-grade oils
dure
C Operating range
030.3.6.3 Warming up
The black bar B represents ambient temperatures that are up to 20 °C lower than
the operating range C.
If the engine is cold started at ambient temperatures within the range B, the follow-
ing warming-up procedure applies to the hydraulic oil:
1. Once the engine has started, set a medium speed for the engine (at most half
of the maximum speed).
2. Carefully activate the working hydraulics. Actuate the hydraulic cylinders and
move them briefly to their stops.
3. Also activate the travel hydraulics after about 5 minutes. Warming up takes
roughly 10 minutes in total.
If you perform a cold start at even lower temperatures, observe the following warm-
up procedure: Warm the hydraulic tank before starting the engine. Then start the
warm-up procedure from point 1.
030.3.6.4 Biodegradable hydraulic oils

Bio-application means that the use of biodegradable or environmentally friendly
hydraulic oil is prescribed at the operating site of the machine.
LBH/11827693/02/211-20150615.1139/en
NOTICE
Ensure that hydraulic oils are not improperly mixed.
Mixing biodegradable ester-based hydraulic oils with each other or with mineral oils
can cause aggressive reactions. This can damage the hydraulic system.
u Do not mix biodegradable hydraulic oils from different manufacturers or different
kinds of mineral oils.
5) If the viscosity class differs: contact customer service
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L538-1493 030-23
Liebherr oils
Liebherr recommends Liebherr Hydraulic Plus for the machine.
Third-party manufacturer oils

If you are unable to purchase this oil locally, only oils based on fully saturated syn-
thetic ester (HEES) may be used after consultation with your local customer serv-
ice.
When using synthetic esters, we recommend changing the hydraulic hoses after
4000 service hours or after four years at the latest.
Vegetable oils are not permitted because of their poor resistance to high tempera-
tures.
030.3.6.5 Changing the oil, analysing the oil, changing filters
Oil change
Oil type Oil change

Not used as bio oil Bio application (only per-
Without oil analysis With oil analysisA) mitted with oil analysisA) )
(optional)
Liebherr mineral oil Every 3000 h Every 6000 h --B)
Liebherr PAO (polyalphaolefin) Every 4000 h Every 8000 h Every 8000 h
Third-party product - mineral oil Every 2000 h Every 2000 h --B)

Third-party product - fully satura- --B) --B) Every 2000 h
ted synthetic ester
Tab. 24: Oil change intervals
A) If the result of the oil analysis is positive, the oil may be used for longer. If the result of the oil analysis is nega-
tive, the oil must be changed immediately.
B) Combination not permitted
LBH/11827693/02/211-20150615.1139/en
Bio application means that the use of biodegradable or environmentally friendly

hydraulic oil is prescribed at the operating site of the machine.
If a machine is operated for less than 1000 hours a year, an oil sampling is re-
quired once a year. Hydraulic oil staying for a long time in the machine should,
however, be changed at the latest after four years (mineral oils and fully saturated
synthetic esters) and at the latest after six years (Liebherr-Plus oils).
If a machine is inactive for longer than six months, an oil analysis is required before
resuming operation.
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030-24 L538-1493
Oil analysis
Liebherr recommends having the oil analyses carried out by OELCHECK and car-
rying out an oil change according to the laboratory report:
– Yellow set for readily biodegradable hydraulic oils
– green set for mineral oils
To take an oil sample: (For more information see: Oil analyses, page 030-37)
See also customer service and product information.
Oil type Oil sample

Not used as bio oil Used as bio oil (oil
(oil analysis op- analysis prescri-
tional) bed)
Liebherr mineral oil Every 1000 h --A)
Liebherr PAO (polyalphaolefin) Every 1000 h First at 0 h then ev-
ery 1000 h
Third-party product - mineral oil First at 1000 h then --A)

every 500 h
Third-party product - fully saturated --A) First at 0 h then ev-
synthetic ester ery 500 h
Tab. 25: Oil sample
A) Combination not permitted
Changing the filter
Change return filter (only Liebherr filters are permitted)

Every 1000 h
Tab. 26: Changing filters

LBH/11827693/02/211-20150615.1139/en
Valid for: L538-1493/31405-;
Recommended lubricant Specification

Liebherr Hydraulic Gear ATF GM: Dexron II D
ZF: TE-ML 03D, 04D, 11A, 14A, 17C
If Liebherr oils cannot be purchased locally, you must use oils according to the
specifications instead (after consultation with customer service).
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L538-1493 030-25
NOTICE
Oil quality
u Mixing various types of oil is not permitted.

A Ambient temperature
The temperature ranges specified in the diagram are guidelines and can be briefly
exceeded or fallen short of.

Valid for: L538-1493/31405-;
Recommended lubricant Specification

Liebherr Gear Basic 90 LS API: GL-5
MIL-L: 2105 D
ZF: TE-ML 05C or 05D
LS = Gear oil with limited slip additives for disc brakes and self-locking differen-
tials.
For the viscosity class SAE 90 LS, an oil of the viscosity class SAE 80 W 90 LS
can also be used.
If Liebherr oils cannot be purchased locally, you must use oils according to the
specifications instead (after consultation with customer service).
NOTICE
Oil quality
u Mixing various types of oil is not permitted.
LBH/11827693/02/211-20150615.1139/en
u A minimum phosphorus content of 1900 mg/kg is required.

A Ambient temperature
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030-26 L538-1493
The temperature ranges specified in the diagram are guidelines and can be briefly
exceeded or fallen short of.

Valid for: L538-1493/31405-;
Lubrication grease is used for the automatic or manual lubrication of the machine.
The lubrication grease reaches the lubrication points via the central lubrication sys-
tem or lubrication nipples.
Examples:
– Articulated joint
– Ring gears, gearwheels
– Pins, axles and bolts
– Attachment tools
Note
The lubrication grease must be capable of being easily delivered throughout the
entire ambient temperature range.
u Only use approved lubrication greases.
u In retrofitted central lubrication systems, pay attention to the specifications for
the consistency of the lubrication grease.
030.3.9.1 Minimum quality requirements

Lubrication greases must fulfil the following minimum quality requirements.
Application Specification Designation

Standard Soap-based (lithium complex) KP 2 K (DIN 51502)
NLGI grade: 2 (DIN 51818)
VKA weld load: ≥ 6000 N (DIN 51350 / 4 – ASTM D 2596)
Cryogenic temperature Soap-based (lithium complex) KP 1 K (DIN 51502)
NLGI grade: 1 (DIN 51818 / ASTM D 2596)
VKA weld load: ≥ 5500 N (DIN 51350 / 4 – ASTM D 2596)
Tab. 29
030.3.9.2 Liebherr lubrication grease

LBH/11827693/02/211-20150615.1139/en
Liebherr recommends the following lubrication greases to achieve optimum lubrica-

tion results and for additional corrosion protection.
Application Recommended lubricant Specification Designation

Standard Liebherr Universalfett 9900 Soap-based (lithi- KPF 2 N - 25 (DIN 51502)
um complex)
VKA weld load: ≥ 6000 N (DIN 51350 / 4)
with vapour phase anti-corrosion agent
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L538-1493 030-27
Application Recommended lubricant Specification Designation

Cryogenic tem- Liebherr Universalfett Arctic Soap-based (lithi- KPFHC 1 N - 60 (DIN 51502)
perature um complex)
VKA weld load: ≥ 5500 N (DIN 51350 / 4)
Tab. 30
Fig. 21: Operating temperature of Liebherr lubrication greases

A Temperature of the lubrication ** Brief temperature peaks up to a
grease maximum of 200 °C may occur.
* Not when used in central lubrica-
tion systems
LBH/11827693/02/211-20150615.1139/en
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030-28 L538-1493
Maintenance tasks
030.4 Maintenance tasks
All work must be carried out by specialist technicians or under their supervision
and responsibility.
Specialists technicians are people who:
– Have the requisite training and experience in operating and servicing earthmov-
ing machinery
– Are familiar with the statutory accident prevention regulations and national
guidelines
– Are able to judge whether earthmoving machinery is safe to operate
– Can carry out the required work without endangering themselves or others

Valid for: L538-1493/31405-;
Fig. 22: Safety precautions
Make sure you are wearing safe working clothing.

Certain jobs not only require a hard hat and safety boots, but also goggles and
safety gloves.
The relevant safety regulations must be observed whenever maintenance, in-
spection or repair work is carried out. Local health and safety regulations, accident
prevention regulations and national laws must be observed.
(For more information see: 010.1.11 Measures for ensuring safe maintenance,
page 010-8)
LBH/11827693/02/211-20150615.1139/en
Fig. 23: Visual contact
Make sure that visual contact between the operator in the cab and maintenance
personnel is always maintained.
WARNING
Beware of accidents during maintenance
The presence of unauthorised persons on the machine can place the maintenance
personnel in extreme danger.
u Never enter a dangerous area of the machine without making your presence
known.
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L538-1493 030-29
Maintenance tasks
Fig. 24: Wheel wedges
u Use wheel wedges to prevent the machine from accidentally rolling away.
030.4.2 Preparatory tasks for maintenance

Before performing the various maintenance tasks, move the machine to the main-
tenance position unless otherwise explicitly specified in the description.
The various maintenance tasks include:
– Lubricating the lift arms and attachment
– Checking the oil level in the engine, transmission, axles, hydraulic tank, etc.
– Changing filters

Valid for: L538-1493/31405-;
The maintenance position depends on the maintenance task to be performed.
The two basic maintenance positions 1 and 2 are described below.
They enable you to access the individual maintenance points.
Maintenance position 1
To move the machine into maintenance position 1, carry out the following steps.
Fig. 25: Maintenance position 1

LBH/11827693/02/211-20150615.1139/en
u Park the machine on level ground.

u Lower the lift arms.
u Lay the bucket flat on the ground.
u Engage the parking brake.
u Turn off the engine.
u Take out the ignition key.
u Turn off the battery main switch.
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030-30 L538-1493
Maintenance tasks
Maintenance position 2
To move the machine into maintenance position 2, carry out the following steps.
Fig. 26: Maintenance position 2

u Engage the articulation lock.
u Lower the lift arms.
u Tilt the bucket out and set it down on the ground on its teeth or cutting edge.

Valid for: L538-1493/31405-;
CAUTION
Beware of injury when opening and closing hatches.
u Make sure you are standing safely when opening or closing the hatch.
Opening the engine compartment hood

When the hood is open, you can access the following components:
– Engine
– Air filter
– Hydraulic pumps
– Battery
– Battery main switch
LBH/11827693/02/211-20150615.1139/en
WARNING
Rotating parts and hot surfaces can cause injuries.
Beware of scalding when opening the engine compartment hood.
u Only open the hood when the engine is cooled and at a standstill.
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L538-1493 030-31
Maintenance tasks
Fig. 27: Opening the engine compartment hood

1 Engine compartment hood 3 Gas-filled spring
2 Handle
u Open the lock with the ignition key.
u Fully open the engine compartment hood 1 with the handle 2.
w The engine compartment hood is held in this position by two gas-filled
springs 3.
CAUTION
Beware of injury caused by the hood falling shut.
u Only open the hood when the gas-filled spring functions properly.
u Check the function.
Troubleshooting
If the gas-filled spring does not hold the hood open.
u Contact Liebherr customer service.
Opening the cooling system grille

When the protective grille is open, it is possible to access the following units:
– Cooling system
– Hydraulic tank
WARNING
LBH/11827693/02/211-20150615.1139/en
Hot surfaces can cause injury.

u Do not open the protective grille until the engine has cooled down.
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030-32 L538-1493
Maintenance tasks
Fig. 28: Opening the cooling system grille

1 Cooling system grille 2 Gas-filled spring
u Open the lock with an Allen key.
u Raise the protective grille up to the stop.
w The protective grille is held in position by a gas-filled spring.
CAUTION
Risk of injury due to the protective grille dropping.
u Only open the grille when the gas-filled spring functions properly.
u Check the function.
Troubleshooting
If the gas-filled spring does not hold the grille open.
To close the protective grille:

u Completely close the protective grille.
u Close the lock with an Allen key.

Valid for: L538-1493/31405-;
The battery main switch is located in the rear right of the battery compartment.
For certain maintenance jobs, the battery main switch must first be turned
off.
Read the descriptions of the maintenance tasks to find out whether the battery
main switch must be turned on or off.
LBH/11827693/02/211-20150615.1139/en
Turn on the battery main switch after completing these maintenance tasks.
NOTICE
Beware of damage to the electrical system.
u Never turn off the battery main switch when the engine is running.
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L538-1493 030-33
Maintenance tasks
Fig. 29: Turning off the battery main switch

1 Battery main switch 2 OFF position
u Turn the battery main switch 1 to the OFF position 2.
u Remove the key.
030.4.3 Overall machine

Valid for: L538-1493/31405-;
Make sure that the machine is in maintenance position 1.
u Before starting the machine, check it for external damage.
u Repair any damage with safety implications immediately.
030.4.3.2 Removing loose parts, dirt, ice and snow from the machine
Valid for: L538-1493/31405-;
Note
Ensure safe machine operation.
u Remove any loose parts, coarse dirt, mud, ice, snow etc.
u Carefully clean the machine with a high-pressure cleaner.

w (For more information see: Cleaning the machine, page 030-34)
LBH/11827693/02/211-20150615.1139/en

Valid for: L538-1493/31405-;
Thoroughly clean the machine of all dirt and deposits in the following situations:
– After completing each job
– Before maintenance
– Before repairs
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030-34 L538-1493
Maintenance tasks
NOTICE
Beware of corrosive materials and working environments.
Corrosion may damage the machine or impair its functions (for example when in
contact with corrosive materials or when working in corrosive environments).
u Thoroughly clean the machine at the end of the job.
Thorough cleaning prevents dirt and foreign particles from entering the machine.
Clean oil, fuel and maintenance products from all connections and bolts.
The machine must be particularly cleaned after the following jobs:
– Working in salty environments (in winter, after contact with road salt during
transport on icy roads, when working near the sea or at ports etc.)
– Working with alkaline or acidic compounds
– Working with corrosive materials (lime compounds, cement etc.)
Note
High-pressure cleaners (steam cleaners) can damage the paintwork.
u Do not use high-pressure cleaners in the first two months of using the machine
(or after a respray).
u Observe the operating instructions for the high-pressure cleaner. Note the infor-
mation on the pressure and the distance from the high-pressure nozzle to the
object to be cleaned.
Washing the machine
CAUTION
Risk of accidents from the high-pressure jet of the high-pressure cleaner.
u Wear appropriate protective clothing and safety glasses.
Electrical devices such as the emergency steering pump, refuelling pump, sensors
and electric components are not watertight.
Every time you clean the machine with a high-pressure cleaner, regrease all lubri-
cation points on the machine.
NOTICE
Beware of damaging the soundproofing mats.
The soundproofing mats can be damaged if you clean them with high pressure.
Damaged soundproofing mats increase the sound output level above that guaran-
teed by the manufacturer.
LBH/11827693/02/211-20150615.1139/en
u Do not expose soundproofing mats to water or steam jets.
NOTICE
There is a risk of damaging electrical devices.
When using a high-pressure cleaner, you may damage electrical devices such as
the emergency steering pump, refuelling pump, sensors and electrical compo-
nents.
u Do not expose electrical devices to water or steam jets.
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L538-1493 030-35
Maintenance tasks
u Wash the machine.

u Regrease all lubrication points on the machine.
Washing the engine

When washing the engine using water or steam jet, take care not to expose elec-
tronic devices such as the starter, alternator, sensors and engine control unit di-
rectly to the jet.
After cleaning, start up the engine to allow it to dry out.
NOTICE
There is a risk of damaging the engine and its electric components.
Moisture penetration can cause corrosion and electrical malfunctions.
u Do not expose devices such as the starter, alternator, sensors and engine con-
trol unit to water or steam jets.
Make sure that the following requirements are fulfilled:

q The machine is in maintenance position 1.
q The engine compartment hood is open.
u Carefully clean the engine.

Valid for: L538-1493/31405-;
q The service doors, hatches and hoods are open.
u Check the hydraulic system for leaks.
u Replace any damaged hydraulic seals.
u Tighten any loose hydraulic connections.
u (For more information see: 010.1.16 Safe maintenance of hydraulic hoses and
hose lines, page 010-12)

Valid for: L538-1493/31405-;
LBH/11827693/02/211-20150615.1139/en
q The service doors, hatches and hoods are open.

u Check that all bolts and screws are tight.
u Tighten any loose screws or bolts with the required tightening torque.
030.4.3.6 Corrosion protection on machines that work with salt and artifi-
cial fertilisers and exchanging VCI capsules
Valid for: L538-1493/31405-;
This equipment is optional.
If you carry out corrosion protection:
u See the separate operating manual “Working with salt and artificial fertilisers”.
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030-36 L538-1493
Maintenance tasks

Valid for: L538-1493/31405-;
Oil analyses are only meaningful if there has been compliance with the specific
procedure. The results of the analyses in the printed laboratory reports are not only
affected by the condition of the oil but by other factors as well.
Note the following points when taking oil samples:
– Take oil samples from clean sampling points.
– Take oil samples at operating temperature.
– Use a hand pump for sections where no pressure is built up.
– When using a hand pump, take the oil sample immediately after the machine
has come to a standstill because the dirt and abraded particles are still in sus-
pension and any water in the oil has not yet separated.
– When using the hand pump, dip the sampling hose into the middle of the oil.
– Always use the same method and take the oil sample at the same place (this
makes the values comparable with each other).
– Never take the oil sample from the filter.
– Do not take samples immediately after an oil change or after large amounts of
oil have been added.
– Fill the oil that is to be tested into a clean and dry original sample container from
the sampling kit.
– The sampling systems must be CLEAN. The exterior of the sample container,
sampling valve and sampling hose may also not come into contact with dust
and dirt, neither whilst flushing nor during sampling. This is the only way to en-
sure that unobjectionable results are obtained.
Tools required:
Quantity Description Item code

1 1 m test line 7002437
1 Hand pump with sampling hose 8145666
Tab. 31: Tools required
Oil analysis kits

Liebherr recommends having the oil analyses carried out by Oelcheck.
Oelcheck offers various methods of analysis for a wide range of components and
units. Liebherr has chosen two methods analysis that are specially adapted to the
particular requirements of our systems and components.
Green lid: Mineral oil, coolant Yellow lid: Bio oil

LBH/11827693/02/211-20150615.1139/en
Single analysis kit 8145660 7026 817

6-sample analysis kit 7018 368 7026 088
12-sample analysis kit 7018 369
Tab. 32: Available analysis kits
The analysis kits with the green lid can be used for hydraulic systems filled with
mineral oil, diesel engines, transmission and lubricating grease.
The analysis kits with the yellow lid may only be used for bio hydraulic oils. The dif-
ference in the scope of the analysis is that the water content of all bio oils has to be
tested using the comparatively expensive Karl Fischer method. However, this test
method is essential for a precise diagnosis of bio oils.
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L538-1493 030-37
Maintenance tasks
If other test laboratories are used, the oil analyses must at least include the follow-
ing data:
Test methods Measured items

Atomic emission Metal debris, additives, contaminants, iron, chrome, tin, alu-
spectroscopy (AES) minium, nickel, copper, lead, molybdenum, silver, silicon,
potassium, magnesium, boron, zinc, phosphorus, barium
Fourier transform in- Oil condition and pollution, oil oxidation, glycol, water, nitra-
frared spectroscopy tion, fuel, soot
(FTIR)
Viscosity Test at 40 °C and 100 °C, viscosity index, note on lubricity
and mixing
Analex PQ index Magnetic abrasion (information on the quantity of magnetis-
able iron debris in the oil > 5 µm)
Tab. 33: Test methods
Sending oil samples

u Label the sample container with the barcode (the red laboratory number on the
sample information form).
w This ensures that the form with the sample information is allocated to the
correct sample.
u Carefully complete the sample information form.
w The more information you provide on the machine and the oil, the more ac-
curately the diagnosis can be carried out.
u Always identify subsequent samples for the same machine with an identical
sample description.
w This ensures that the analysed values are can be logged on the printed labo-
ratory reports. This makes it easier to identify trends. Only by studying tends
is it possible to clearly identify changes of state caused by contamination,
wear, ageing and mixing with other service fluids.
u Send the sample in the oil-proof plastic bag provided.
w The self-adhesive seal ensures that the bag is firmly closed. The sample in-
formation form is protected in a separate plastic pocket on the outside.
Assessing the analysis results

There is no single element or measured value that in itself necessitates a warning
or a recommendation to change the oil. It depends on the overall analysis of the oil
sample, from the zinc content to the purity class.
LBH/11827693/02/211-20150615.1139/en
For bio hydraulic oils:

If the zinc content in the oil exceeds 300 mg/kg and other critical values are ex-
ceeded, the zinc may saponify and block the filter systems. The system may fail
completely.
Purity class:
Contamination of the hydraulic fluid directly affects the lifetime of the components.
Therefore, the following minimum purity classes are required for Liebherr earth-
moving machines:
– ISO 4406 Purity class: 21/17/14
– NAS 1638 Purity class: 8
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030-38 L538-1493
Maintenance tasks
If the values are slightly below these, they may be improved by using special filters
systems (such as stationary filters) in consultation with the manufacturer. If subse-
quent trend analyses do not show an improvement, there is no option but to
change the oil. Note that not only the oil in the hydraulic tank has to be drained, but
also as much oil as possible from the units and cylinders.
Taking oil samples

Samples can be taken from the following fluids:
– Hydraulic oil from the hydraulic system
– Engine oil from the diesel engine
– Lubricating oil from the axles
– Lubricating oil from the transmission
– Coolant from the cooling circuit
q The machine is on firm and level ground.
q A suitable collecting pan for the flushing oil is available.
q You have an analysis set ready.
WARNING
Beware of injuries from rotating engine parts, hot surfaces and hot fluids.
u Wear protective clothing
u Avoid touching hot surfaces and fluids.
u Watch out for rotating engine parts.
WARNING
Unauthorised operation of the machine can cause injury.
u Secure the machine against unauthorised operation.
Hydraulic system
The hydraulic oil sample is taken via a test connection on the variable displace-
ment pump (travel hydraulics).
LBH/11827693/02/211-20150615.1139/en
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L538-1493 030-39
Maintenance tasks
Fig. 30: Sampling point for hydraulic oil
u Start the engine and wait 3 minutes.

w The hydraulic oil is circulated.
u Engage the parking brake and secure the machine against rolling away.
u Connect the test line to the test connection G.
u Drain 0.2 l of hydraulic oil to the collecting pan.
u Fill the sample container.
u Remove the test line and seal the test connection.
Diesel engine
The engine oil sample is taken via the dipstick pipe with a hand pump.
LBH/11827693/02/211-20150615.1139/en
Fig. 31: Sampling point on the diesel engine

1 Dipstick B Oil sampling depth
A Oil level
u Start the engine and let it run for 3 minutes at medium idling speed.
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030-40 L538-1493
Maintenance tasks
w The engine oil is circulated.

u Put the machine in maintenance position 1.
CAUTION
Beware of burns from hot surfaces on the exhaust system.
u Do not touch hot surfaces.
u Insert the sampling hose through the dipstick tube to 5 cm below the oil level A.
u Fill the sample container using the hand pump.
u Put the dipstick 1 back in again.
Coolant circuit
The coolant sample is taken from the cooler.
Fig. 32: Sampling point for coolant
u Start the engine.

u Turn the heating system to the maximum temperature and wait for three mi-
nutes.
w The coolant is circulated.
CAUTION
Beware of injury due to coolant escaping under pressure
u The coolant temperature must not exceed 45 °C.
LBH/11827693/02/211-20150615.1139/en
u Wear protective clothing and safety glasses.

u Carefully open the cap.
u Carefully open the cap 1.

u Insert the sampling hose and take an oil sample.
u Close the cap 1.
Transmission
The coolant sample is taken from the transmission.
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L538-1493 030-41
Maintenance tasks
Fig. 33: Sampling point on the transmission
u Start the engine and accelerate the machine to 15 km/h.

w The oil is circulated.
CAUTION
Beware of injury from hot, pressurised oil.
u To reduce the pressure: Carefully unscrew the filling plug.
u Carefully unscrew the filling plug 1.

u Insert the sampling hose and take the oil sample.
u Close the filling plug 1 again.
Axles
The oil sample from the axles is taken from the differential with a hand pump.
LBH/11827693/02/211-20150615.1139/en
Fig. 34: Sampling point on the axles
u Start the engine and drive the machine for 3 minutes at 15 km/h.
w The oil is circulated.
copyright by
030-42 L538-1493
Maintenance tasks
CAUTION
Beware of injury from hot, pressurised oil.
u To reduce the pressure: Carefully unscrew the filling plug.
u Slowly open the filling plug 1.

u Insert the sampling hose into the differential to 5 cm below the oil level.
u Fill the sample container using the hand pump.
u Close the filling plug 1 again.
030.4.4 Drive group

Valid for: L538-1493/31405-;
q The service access is open.
q The engine is level and has been switched off for 2 or 3 minutes.
q The engine has cooled down.
Fig. 35: Checking the engine oil level

1 Cap 2 Dipstick
u Pull out the dipstick 2, wipe it clean, and re-insert it.
u Pull out the dipstick once again and read off the oil level.
LBH/11827693/02/211-20150615.1139/en
w The oil level must be between the MIN and MAX markings.
If the oil level is too low:
u Open the cap 1.
u Top up the engine oil via the cap 1 to the MAX marking. (For more information
see: 030.3.4 Lubricating oils for diesel engines, page 030-17)
u Clean the cap 1, place it on the filler neck and tighten it.
copyright by
L538-1493 030-43
Maintenance tasks

Valid for: L538-1493/31405-;
q The engine is level and warm.
q A suitable receptacle, an oil drain hose and the specified engine oil are at hand.
Draining the engine oil
CAUTION
Beware of scalding due to hot engine oil!
u Wear protective gloves.
u Avoid touching engine oil.
Fig. 36: Draining the engine oil

1 Oil drain valve 2 Oil drain hose
u Unscrew the cap of the oil drain valve 1 on the oil pan.
u Screw the oil drain hose 2 onto the oil drain valve 1.
u Drain off the oil into the receptacle.
u Unscrew the oil drain hose 2 and screw on the cap of the oil drain valve 1.
LBH/11827693/02/211-20150615.1139/en
copyright by
030-44 L538-1493
Maintenance tasks
Topping up the engine oil
Fig. 37: Topping up the engine oil

1 Filler neck 2 Dipstick
u Pour new engine oil into the filler neck 1 to between the MIN and MAX markings
on the dipstick 2. (For more information see: 030.3.4 Lubricating oils for diesel
engines, page 030-17)
u Clean the filler cap, place it on the filler neck 1 and tighten it.
u Start the engine and check the oil pressure.
u After 2 to 3 minutes, check the oil level on the dipstick 2.
w Top up with oil if necessary.

Valid for: L538-1493/31405-;
The oil filter is installed in the centre of the engine compartment.
q You have a strap wrench ready.
q You have a suitable receptacle and genuine Liebherr oil filter cartridges ready.
LBH/11827693/02/211-20150615.1139/en
copyright by
L538-1493 030-45
Maintenance tasks
Fig. 38: Changing the engine oil filter

1 Oil filter cartridge 2 Rubber seal
u Place a receptacle under the oil filter.
u Release the oil filter cartridge 1 with a strap wrench and unscrew it.
u Dispose of the oil filter cartridge 1.
u Clean the sealing faces on the filter bracket.
u Check that the filter base is clean and make sure the thread adapter is firmly
seated in the filter base.
u Fill the new oil filter cartridge 1 with clean engine oil.
u Lightly coat the rubber seal 2 on the new oil filter cartridge 1 with clean engine
oil.
u Screw on the new oil filter cartridge 1 until the seal ring touches the filter brack-
et.
u Tighten the oil filter cartridge half a turn by hand.
u Remove oil traces on the engine.
u Start the engine and check the oil pressure.
u Check that the oil filter is leak-tight.
u After 2 to 3 minutes, check the oil level on the dipstick.
w Top up with oil if necessary.

Valid for: L538-1493/31405-;
LBH/11827693/02/211-20150615.1139/en
The engine is equipped with an automatic tensioning device for the V-ribbed belt.
copyright by
030-46 L538-1493
Maintenance tasks
Fig. 39: Tensioning device stops

1 Tensioning device 3 Tensioning device stop
2 Fixed cast stops 4 V-ribbed belt
The following damage could occur on the V-ribbed belt 4:
– Broken ribs
– Cracks across several ribs
– Lumps of rubber on the belt
– Accumulated dirt or grit
– Ribs coming loose from the belt
– Cracks across the back
u Check the V-ribbed belt 4 for damage.
If damage is found:
u Replace the V-ribbed belt.
The engine is equipped with an automatic tensioning device for the V-ribbed belt.
u Conduct visual check of the stops 2 and 3.
w The tensioning device 3 stop must not be touching the cast stops 2.
If the tensioning device stop is touching one of the cast stops:
u Check the length of the V-ribbed belt and fastenings of the generator, the
clamping device, the deflecting rollers, etc.
u Start the engine.
WARNING
Risk of injury from rotating parts in the diesel engine!
LBH/11827693/02/211-20150615.1139/en
u Check V-ribbed belt and tensioning device for running noise.

If the V-ribbed belt wobbles or noises occur:
u Replace the tensioning device.

Valid for: L538-1493/31405-;
copyright by
L538-1493 030-47
Maintenance tasks
Fig. 40: Removing the guard plate and accessories

1 Separ fuel pre-filter 2 Guard plate
The guard plate 1 has to be removed to change the V-ribbed belt.
u Remove the Separ fuel pre-filter 1 from the guard plate 2.
u Remove the guard plate 2 from the engine.
Fig. 41: Changing the V-ribbed belt on the engine

1 Tensioning device 6 Deflector roller
2 Ratchet 7 Air-conditioning compressor pulley
3 Alternator pulley 8 Water pump pulley
4 Deflector roller 9 Crankshaft pulley
LBH/11827693/02/211-20150615.1139/en
5 V-ribbed belt
u Pull back the tensioning device 1 against the spring force as far as it will go and
take off the V-ribbed belt.
u Check that the tensioning device and the pulleys are in perfect condition (for ex-
ample, the tension roller bearings are in place and the pulleys are not worn).
w Replace any damaged parts.
u With the tensioning device 1 pulled back, fit a new V-ribbed belts on to the pul-
leys and bring the tensioning device back into the tensioned position.
u Reattach the guard plate and Separ fuel pre-filter.
copyright by
030-48 L538-1493
Maintenance tasks

Valid for: L538-1493/31405-;
Check the valve clearance when the engine is cold.
q The engine is cold.
q Special tool “Engine cranking device” (ID number: 7090361) is available.
q Special tool “Arrester pin” (ID number: 7090360) is available.
q A new valve cover seal is available.
Fig. 42: Removing the valve cover

1 Valve cover 3 Arrester pin
2 Engine cranking device
u Remove accessories from the valve cover 1.
u Remove the crankcase bleeding line from the valve cover.
u Remove the valve cover.
w The valves are exposed.
The engine can be turned using the engine cranking device 2 and a ratchet.
The openings for the engine cranking device 2 and the arrester pin 3 are on the
flywheel side on the right of the engine and are protected by a cover.
u Remove the cover and attach the engine cranking device.
LBH/11827693/02/211-20150615.1139/en
Fig. 43: Arrangement of the valves

1 Flywheel end E Outlet valves
2 Control system end I Inlet valves
copyright by
L538-1493 030-49
Maintenance tasks
u Turn the engine using the engine cranking device until the arrester pin engages
the flywheel.
w Cylinder 1 or 4 is in the ignition TDC.
The top dead centre between the compression stroke and the power stroke is
called the ignition TDC.
u Check the rocker arm of cylinder 1 and 4.
w Loose rocker arm = cylinder in the ignition TDC
Fig. 44: Checking and adjusting the valve clearance

1 Feeler gauge 4 Spanner
2 Counter nut 5 Rocker arm
3 Hex key
Check the valves according to the “Checking the valve clearance” table:
u Push a feeler gauge 1 between the rocker arm 5 and the valve bridge and
check the valve play.

Inlet valve mm 0.36
Outlet valve mm 0.46
Cylinder 4 3 2 1
LBH/11827693/02/211-20150615.1139/en
Valve E I E I E I E I
Cylinder 1 in igni- Check Check Check Check
tion TDC
Cylinder 4 in igni- Check Check Check Check
tion TDC
Tab. 34: Checking the valve clearance
If a required value is not reached:

u Loosen the counter nut 2 on the adjusting screw of the relevant rocker arm and
correct the setting.
u Tighten the counter nut to a torque of 27 Nm.
copyright by
030-50 L538-1493
Maintenance tasks
u Check the valve clearance again.

Once the valves have been checked and adjusted according to the table:
u Remove the arrester pin.
u Turn the engine using the engine cranking device (360°) until the arrester pin
engages in the flywheel.
u Check the rocker arm of cylinder 1 and 4.
w Loose rocker arm = cylinder in the ignition TDC
u Check the remaining valves and adjust if necessary.
After completing testing and adjustment:
NOTICE
Beware of damaging the engine.
If the engine starts while the arrester pin or the engine cranking device are attach-
ed, the engine will be damaged.
u Remove the engine cranking device.

u Remove the engine cranking device.
u Check the components and valve cover for damage.
Note
The valve cover seal may not be reused.
u Replace the valve cover seal.
u Replace the valve cover seal.

u Attach the valve cover and accessories.
u Attach the crankcase bleeding line.
u Start the engine and let it run for 3 minutes at medium idling speed.
WARNING
Rotating parts on the engine and hot surfaces can cause injuries.
u Wear protective clothing.
LBH/11827693/02/211-20150615.1139/en
u Check that valve cover and valve cover seal do not leak.

Valid for: L538-1493/31405-;
The crankcase bleeding line is designed as an open crankcase bleeding line and is
attached to the valve cap of the diesel engine.
copyright by
L538-1493 030-51
Maintenance tasks

q The engine is cold.
Fig. 45: Checking the engine bleeding system of the crankcase

1 Screwdriver 3 Hose line
2 Connector piece
The crankcase bleeding line consists of the connector piece 2 and the hose line 3.
u Remove the connector piece 2 including the hose line 3 from the valve cap with
a screwdriver 1.
The connector piece and hose line must be checked for:
– Wear
– Cracks
– Leaks
– Blockages
– Proper installation (no kinks in the hose lines, no signs of abrasion)
– Other damage
u Check the connector piece and hose line for damage and blockages.
After checking:
u Reattach the connector piece and hose line to the valve cover.

Valid for: L538-1493/31405-;
The preglow system is checked by means of a resistance measurement at the
heating flange.
LBH/11827693/02/211-20150615.1139/en
WARNING
Risk of injury due to unauthorised operation of the machine and electric shocks.
u Remove the starting key and keep it in a safe place.
copyright by
030-52 L538-1493
Maintenance tasks
Fig. 46: Removing the fuse

1 Battery main switch 2 Preglow response fuse (F010)
To avoid measuring errors, the preglow response fuse (F010) 2 must be removed
before the measurement is taken.
u Remove the preglow response fuse (F010).
u Switch on the battery main switch 1.
w The battery earth is connected to the rear section.
Fig. 47: Checking the engine heating flange

1 Test prod 4 Ohmmeter
2 Heating flange connection 5 Preglow system relay (K04)
3 Heating flange (R701) 6 Preglow response fuse (F010)
u Measure the resistance between the heating flange connection 2 and the vehi-
cle earth.
LBH/11827693/02/211-20150615.1139/en

Resistance Ω 0.7±0.2
After completing the check:

u Reattach the preglow response fuse (F010).
030.4.4.9 Draining off condensate and sediment from the fuel tank
Valid for: L538-1493/31405-;
q You have a suitable receptacle ready.
copyright by
L538-1493 030-53
Maintenance tasks
q The machine has been out of operation for at least 3 hours.
DANGER
Beware of fire
u Naked flames and smoking are prohibited.
Fig. 48: Draining off condensate and sediment from the fuel tank
1 Drain valve 3 Drain hose
2 Cap
u Place a receptacle under the fuel tank.
u Unscrew the cap 2 on the drain valve 1 on the bottom of the fuel tank.
u Screw the drain hose 3 onto the drain valve 1.
w Condensate and sediment drain off.
u Drain the condensation and sediment into a suitable receptacle until clean fuel
begins to flow.
u Unscrew the drain hose 3.
u Screw the cap 2 onto the drain valve 1 and tighten it.

Valid for: L538-1493/31405-;
LBH/11827693/02/211-20150615.1139/en

DANGER
Beware of fire
copyright by
030-54 L538-1493
Maintenance tasks
Fig. 49: Draining off condensate from the Separ fuel pre-filter
1 Bleeder screw 2 Drain valve
Note
To prevent condensate flowing back into the fuel tank:
u Open the bleeder screw in front of the drain valve.
u Place a receptacle under the Separ fuel pre-filter.

u Open the bleeder screw 1.
u Open the drain valve 2 until clean fuel flows out.
When clean fuel flows out:
u Close the drain valve 2.
u Close the bleeder screw 1 with a tightening torque of 6 Nm.

Valid for: L538-1493/31405-;
When the water level probe in the fuel pre-filter is activated (the service code is dis-
played), the water collector tank must be drained.
LBH/11827693/02/211-20150615.1139/en
DANGER
Beware of fire
copyright by
L538-1493 030-55
Maintenance tasks
Fig. 50: Draining off condensate from the fuel pre-filter

Note
u Place a receptacle under the fuel pre-filter.

u Open the drain valve 2 until clean fuel flows out.
When clean fuel flows out:
u Close the bleeder screw 1.

Valid for: L538-1493/31405-;
LBH/11827693/02/211-20150615.1139/en
q Only use genuine Liebherr spare parts.
DANGER
Beware of fire
copyright by
030-56 L538-1493
Maintenance tasks
Fig. 51: Changing the Separ fuel pre-filter

1 Bleeder screw 5 Spring packet
2 Cover 6 Fuel pre-filter insert
3 4 screws 7 Drain valve
4 Seal
Note
u Place a receptacle under the Separ fuel pre-filter.

u Carefully clean the Separ fuel pre-filter and the area around it.
When you drain off fuel:
u Open the drain valve 7.
w Fuel flows out of the pre-filter until it is empty.
u Open the screws 3 and remove the cover 2 with the seal 4.
u Take out the fuel pre-filter insert 6 along with the spring packet 5.
NOTICE
Beware of damage to the Common Rail system.
u Make sure no dirt gets into the clean side of the filter.
LBH/11827693/02/211-20150615.1139/en
u Install the new fuel pre-filter 6.

u Check the seal 4 and replace it if necessary.
u Check that the cover 2 is clean, put it on again and tighten the screws 3 cross-
wise and evenly.
u Tighten the bleeder screw 1 to a torque of 6 Nm.
copyright by
L538-1493 030-57
Maintenance tasks

Valid for: L538-1493/31405-;
DANGER
Beware of fire
Fig. 52: Changing the fuel pre-filter

1 Bleeder screw 4 Electrical connection
2 Snap ring 5 Water separator container
3 Filter cartridge 6 Drain valve
Note
u Place a receptacle under the fuel pre-filter housing.

LBH/11827693/02/211-20150615.1139/en
u Carefully clean the fuel pre-filter housing and the area around it.
u Disconnect the electrical connection 4.
u Open the bleeder screw 1 and drain valve 6.
u Unscrew the snap ring 2 and remove the filter cartridge 3.
u Unscrew the water separator container 5 from the filter cartridge 3.
u Dispose of the filter cartridge 3.
u Wash the water separator container 5 and dry it with compressed air.
u Lubricate the O-ring of the water separator tank 5 with clean fuel.
copyright by
030-58 L538-1493
Maintenance tasks
u Screw the water separator tank 5 to the new filter cartridge 3 until the O-ring
touches the filter cartridge.
u Tighten the water separator container 5 a quarter turn by hand.
u Check that the filter base is clean.
NOTICE
u Lubricate the sealing ring of the new filter cartridge 3 with clean fuel.
Note
Install the filter cartridge.
u Align the filter cartridge correctly on the base.
u Screw the new filter cartridge onto the base with the snap ring 2.
w The filter clicks into place.
u Reconnect the electrical connection 4.
u Close the bleeder screw 1.
u Bleed the fuel system. (For more information see: Bleeding the fuel system,
page 030-60)

Valid for: L538-1493/31405-;
DANGER
Beware of fire
LBH/11827693/02/211-20150615.1139/en
copyright by
L538-1493 030-59
Maintenance tasks
Fig. 53: Changing the fuel fine filter

1 Bleeder screw 3 Filter cartridge
2 Snap ring 4 Drain valve
u Place a receptacle under the fuel fine filter.
u Carefully clean the fuel fine filter and the area around it.
u Open the bleeder screw 1 and drain valve 4.
u Unscrew the snap ring 2 and remove the filter cartridge 3.
u Dispose of the filter cartridge.
u Check that the filter base is clean.
NOTICE
u Lubricate the sealing ring of the new filter cartridge 3 with clean fuel.
Note
Install the filter cartridge.
u Align the filter cartridge correctly on the base.
LBH/11827693/02/211-20150615.1139/en
u Screw the new filter cartridge onto the base with the snap ring 2.
w The filter clicks into place.
u Close the bleeder screw 1 and drain valve 4.
u Bleed the fuel system. (For more information see: Bleeding the fuel system,
page 030-60)

Valid for: L538-1493/31405-;
Bleeding the fuel filter is necessary after:
– Changing the fuel filter
– Emptying the fuel tank
copyright by
030-60 L538-1493
Maintenance tasks

q A receptacle is ready for the fuel.
DANGER
Beware of fire
Fig. 54: Bleeding the fuel system

1 Fuel fine filter bleeder screw 2 Hand pump
CAUTION
Beware of fuel spurting out.
u Wear safety glasses.
u Unscrew the fuel fine filter bleeder screw 1 by 2 or 3 turns.

u Operate the hand pump 2 until fuel comes out of the bleeder screw without bub-
bles.
u Tighten the fuel fine filter bleeder screw 1.
LBH/11827693/02/211-20150615.1139/en
u Continue to operate the hand pump until you feel strong resistance.
030.4.4.16 Cleaning the air filter service cover and dust discharge valve
Valid for: L538-1493/31405-;
Note
If the valve is damaged, the dust discharge function is impaired and the filters be-
come clogged more quickly.
u With the engine running at lower idle speed, you should clearly feel air pulsating
at the dust discharge valve.
copyright by
L538-1493 030-61
Maintenance tasks

q Appropriate protective equipment is used.
Cleaning the service cover
Fig. 55: Cleaning the service cover

1 Safety clamp 3 Service cover
2 Filter housing 4 Dust discharge valve
u Release the safety clamp 1 on the service cover 3.
u Turn the service cover 3 anticlockwise and remove it.
u Clean the service cover 3 and place it back onto the filter housing 2.
w The dust discharge valve 4 must face down.
u Turn the service cover 3 clockwise until it is locked.
u Close the safety clamp 1.
Cleaning the dust discharge valve
Note
When using the machine in dusty conditions:
u Check and empty the dust discharge valve more often.
LBH/11827693/02/211-20150615.1139/en
copyright by
030-62 L538-1493
Maintenance tasks
Fig. 56: Cleaning the dust discharge valve

1 Dust discharge valve
u Press the rubber seal on the dust discharge valve 1 several times to remove the
dust from the service cap.
If the dust discharge valve is damaged or stays open:
u Replace the dust discharge valve.
030.4.4.17 Checking the air suction system for leaks and tight fitting
Valid for: L538-1493/31405-;
q The exhaust system is cold.
LBH/11827693/02/211-20150615.1139/en
Fig. 57: Checking the air suction system for leaks and tight fitting
1 Clean air intake hose 3 Vacuum switch
2 Air filter housing 4 Untreated air intake hose
copyright by
L538-1493 030-63
Maintenance tasks
NOTICE
Damaged or leaking air intake hoses will lead to engine damage.
u Check the air intake hoses for cracks and porosity.
u Check the vacuum switch 3 for damage.

u Check the clean air intake hose 1 for cracks and porosity.
u Check the untreated air intake hose 4 for cracks and porosity.
u Check the air filter housing 2 for damage.
u Check that all the clips of the air intake system fit tightly.

Valid for: L538-1493/31405-;
NOTICE
Always carry out maintenance correctly.
Otherwise the engine may be damaged.
u Do not clean the safety element.
u Always replace the safety element.

q Suitable protective equipment is used.
Removing the main element
LBH/11827693/02/211-20150615.1139/en
Fig. 58: Removing the main element

1 Dust discharge valve 4 Main element
2 Service cover 5 Safety element
3 Lock 6 Filter housing
copyright by
030-64 L538-1493
Maintenance tasks
NOTICE
Do not use a damaged filter element
u Replace damaged filter elements.
u Release the lock 3 on the service cover 2.

u Remove the main element 4 and check it for damage before cleaning it.
Cleaning the main element
Fig. 59: Cleaning the main element

1 Main element 2 Compressed air
NOTICE
Always carry out cleaning correctly
Take care not to damage the main element.
u Do not use compressed air at too high a pressure.
u Clean the main element with clean, oil-free compressed air.
u Do not knock out the main element.
u Clean the main element 1 from the inside out with compressed air 2.
Cleaning the service cover and filter housing

LBH/11827693/02/211-20150615.1139/en
Fig. 60: Cleaning the service cover and filter housing

1 Cloth 3 Service cover
2 Filter housing 4 Safety element
copyright by
L538-1493 030-65
Maintenance tasks
NOTICE
Always carry out cleaning correctly
u Clean the filter housing with compressed air.
u Wipe with a clean cloth.
u Clean the inside of the filter housing 2 and the service cover 3 with a cloth 1.
Installing the main element
Fig. 61: Removing the main element

u Lightly oil the sealing face of the main element 4.
u Install the main element 4.
u Put the clean service cover 2, with the dust discharge valve 1 facing down, on
the filter housing 6.
u Turn the service cover 2 clockwise until it catches.
u Close the lock 3.
Note
If the air filter contamination symbol field lights up again a few service hours after
LBH/11827693/02/211-20150615.1139/en
the main element has been cleaned:

u Change the main element.
Note
If the air filter contamination remains lit after the main element has been changed:
u Change the safety element.
copyright by
030-66 L538-1493
Maintenance tasks

Valid for: L538-1493/31405-;
NOTICE
Always carry out maintenance correctly.
u Do not clean the safety element.
u Always replace the safety element.

q Appropriate protective equipment is used.
Fig. 62: Changing the air filter safety element

u Release the lock 3 on the service cover 2.
u Remove the main element 2.
LBH/11827693/02/211-20150615.1139/en
u Clean the service cover 2 and the filter housing 6 with a clean cloth.
u Remove the safety element 5.
u Lightly oil the sealing faces of the new safety element 5 and the main ele-
ment 4.
u Install the new safety element 5 and the main element 4.
u Put the service cover 2, with the dust discharge valve 1 facing down, on the
filter housing 6.
u Turn the service cover 2 clockwise until it catches.
u Close the lock 3.
copyright by
L538-1493 030-67
Maintenance tasks
030.4.4.20 Checking the exhaust system for leaks and tight fitting
Valid for: L538-1493/31405-;
q The exhaust system is cold.
CAUTION
The hot exhaust system can cause injury.
u Let the exhaust system cool down.
Fig. 63: Checking the exhaust system for leaks and tight fitting
1 Tailpipe 3 Exhaust pipe
2 Silencer
u Make a visual inspection of the exhaust system.
u Check the silencer 2 for cracks and damage.
u Check the exhaust pipe 3 for cracks and damage.
u Check the clips of the exhaust system are tight and do not leak.
u Start the engine.
LBH/11827693/02/211-20150615.1139/en
WARNING
Rotating parts on the engine and hot surfaces can cause injuries.
u Wear protective clothing.
u Check the exhaust system for leaks and escaping exhaust gas.
u Check the clips for leaks and escaping exhaust gas.
copyright by
030-68 L538-1493
Maintenance tasks
030.4.5 Cooling system

Valid for: L538-1493/31405-;
Fig. 64: Checking the coolant level

1 Cooling system grille 5 Coolant level mark
2 Cooler cap 6 Equalising reservoir
3 Cap 7 Cooler sight glass
4 Filler neck
CAUTION
Beware of scalding due to coolant escaping under pressure.
Do not open the cap on the filler neck until the engine has cooled down.
u Let the engine cool down.
u Check the coolant level in the cooler through the sight glass 7.
If no coolant is visible through the sight glass 7:
u Carefully open the cap 2.
u Top up the coolant via the cap 2.
w Coolant should now be visible in the sight glass 7.
u Close the cap 2.
u Check the coolant level in the equalising reservoir 6 using the coolant level
markings 5.
If the coolant is below the MIN marking:
LBH/11827693/02/211-20150615.1139/en
u Carefully open the cap 3 on the filler neck 4.
NOTICE
Mixing different antifreeze/corrosion inhibitors can result in damage to the cooling
system.
u Do not mix coolants with and without silicates.
u Top up with coolant via the filler neck 4.

w The coolant should now be between the coolant level markings 5.
u Close the cap 3 on the filler neck.
copyright by
L538-1493 030-69
Maintenance tasks
030.4.5.2 Checking the coolant antifreeze and corrosion inhibitor concen-

tration
Valid for: L538-1493/31405-;
Checking the antifreeze concentration

All year round, the coolant must contain at least 50% by volume of concentrated
antifreeze, but not more than 60% by volume.
This protects against freezing down to around -37 °C.
q The optical density tester or antifreeze tester is ready.
CAUTION
Beware of scalding due to coolant escaping under pressure
Fig. 65: Checking the antifreeze concentration

1 Cap 3 Coolant equalising reservoir
2 Filler neck
u Carefully open the cap 1 on the filler neck 2.
u Take a sample of the coolant and check the antifreeze concentration using the
test tool.
If the antifreeze concentration is too low:
u Refill with pure antifreeze until the required value is attained.
w (For more information see: Correcting the antifreeze concentration,
page 030-71)
LBH/11827693/02/211-20150615.1139/en
copyright by
030-70 L538-1493
Maintenance tasks
Correcting the antifreeze concentration
Fig. 66: Correcting the antifreeze concentration

1 Engine drain valve
If the antifreeze concentration is too low:
u Drain off the coolant and top up with pure antifreeze according to the following
diagram.
NOTICE
Mixing different antifreeze/corrosion inhibitors can result in damage to the cooling
system.
u Do not mix coolants with and without silicates.
NOTICE
Beware of damaging the engine.
Too much antifreeze and corrosion inhibitor impairs the cooling effect.
This eventually causes damage to the engine.
u Never use more than 60% antifreeze and corrosion inhibitor.
LBH/11827693/02/211-20150615.1139/en
copyright by
L538-1493 030-71
Maintenance tasks
Fig. 67: Correcting the antifreeze concentration

LBH/11827693/02/211-20150615.1139/en
1 Amount of pure antifreeze to 3 Guide line(s) - example 5 Total capacity of cooling sys-
be added in litres -15 °C tem in litres (example
25 litres)
2 Identified line for top-up quan- 4 Measured coolant freezing
tity point in °C
Example procedure
Assumption:
25 litres total filling quantity of the cooling system
-15 °C coolant temperature, measured in the cooling system
u In the diagram, go to the line showing the overall cooling system capacity 5 at
25 litres and follow it upwards.
copyright by
030-72 L538-1493
Maintenance tasks
u Continue along the guide line 3, starting from the temperature -15 °C, and move
diagonally left to the bottom.
u Finally, starting from the point where the lines cross, go horizontally along the
(identified) line 2 to the far left.
w This gives you the topping up quantity of pure antifreeze and corrosion inhib-
itor 1 (7.6 litres in this example) to be added in order to achieve protection
down to -37 °C.
u To restore the correct mixing ratio, you must drain off at least the previously cal-
culated quantity (the top-up quantity) from the cooling system.
u Top up with the correct quantity of pure antifreeze and corrosion inhibitor.
u The coolant previously drained off can be used if necessary to restore the re-
quired coolant level.
Using corrosion inhibitor without antifreeze

In exceptional cases and when outside temperatures never fall below freezing,
such as in tropical zones, where it is demonstrable that no approved antifreeze and
corrosion inhibitor is available, pure corrosion inhibitor may be used.
The coolant must be changed once a year.
The mixing ratio must consist of 7.5% corrosion inhibitor and 92.5% water.
The Gefo 2710 refractometer is recommended for testing.
Procedure for checking the coolant antifreeze concentration
Fig. 68: Procedure for checking the coolant antifreeze concentration
CAUTION
Beware of scalding due to coolant escaping under pressure
u Carefully open the sealing cap on the coolant equalising reservoir.

LBH/11827693/02/211-20150615.1139/en
u Check the antifreeze concentration with a Gefo 2710 refractometer.
copyright by
L538-1493 030-73
Maintenance tasks
Fig. 69: Checking the mixing ratio with a refractometer

1 Prism with cover 2 Eyepiece with scale
u Clean the cover and the prism carefully.
u Place one or two drops of coolant on the prism.
w Close the cover to distribute the fluid.
u Look through the eyepiece against a light background and focus the scale.
u Read the Brix value off the blue dividing line.
u Convert the Brix value using the conversion diagram to find the actual corrosion
inhibitor concentration.
Fig. 70: Checking the mixing ratio with a refractometer

Valid for: L538-1493/31405-;
LBH/11827693/02/211-20150615.1139/en
Clean the coolers whenever necessary in order to ensure proper cooling. In dusty
environments, check the coolers every day and clean if necessary.
Dirty cooler units result in overheating. This results in an audible and visual warn-
ing with simultaneous power reduction of the travel drive.
Dust and other dirt can be removed from the cooling fins using a high-pressure
cleaner or compressed air. Compressed air is preferable.
q The air conditioning condenser (optional) is pulled forward.
copyright by
030-74 L538-1493
Maintenance tasks
NOTICE
Beware of damage to the cooling system
Careless handling can damage the cooler fins.
u Do not use hard objects or excessive water pressure for cleaning.
Fig. 71: Cleaning the cooling system

1 Cooling system grille 2 Cooler unit
u Open the cooling system grille 1.
u Clean the cooler unit 2 with a high-pressure cleaner or compressed air.
u Close the cooling system grille 1.

Valid for: L538-1493/31405-;
Make sure the following preconditions are met:
q The machine is cold.
q The service hatches are open.
q You have a drain hose ready.
q You have a suitable collecting pan ready.
q The specified coolant is available. (For more information see: 030.2.2 Recom-
mended operating fluids, page 030-14)
Draining the coolant

LBH/11827693/02/211-20150615.1139/en
Fig. 72: Draining the coolant

1 Equalising reservoir 3 Cooler cap
2 Equalising reservoir sealing caps 4 Drain valve for coolant
copyright by
L538-1493 030-75
Maintenance tasks
CAUTION
Risk of scalding due to hot coolant escaping while under pressure.
u Let the machine cool down. Check the coolant temperature on the display unit.
u Carefully open the sealing caps.
u Open the sealing caps of the equalising reservoirs 2 and the cooler sealing
cap 3 carefully.
u Unscrew the cap of the coolant drain valve 4.
u Screw the drain hose on to the coolant drain valve 4.
u Drain the coolant into the collecting pan.
u Press the equalising reservoirs 1 away upwards.
w The equalising reservoirs 1 can be removed.
u Empty the equalising reservoir 1 and put them back in place.
u Unscrew the drain hose and screw on the sealing cap.
Filling coolant
Note
When preparing the coolant, ensure that you:
u Observe the instructions on the water quality, mixing ratio and anti-corrosion
agent. (For more information see: 030.3.5 Coolants for diesel engines,
page 030-19)
u Mix the coolant before filling it into the cooling system.
Fig. 73: Filling coolant

1 Equalising reservoir 5 Cooler sight glass
LBH/11827693/02/211-20150615.1139/en
2 Equalising reservoir sealing caps MIN Minimum coolant level

3 Cooler cap MAXMaximum coolant level
4 Water cooler
u Completely fill the water cooler 4 with coolant.
u Screw on the sealing caps 2 and 3.
u Start the engine and set the heating to the maximum temperature and the high-
est blower speed.
u Let the engine run at a low idling speed for two to three minutes.
w The coolant is circulated.
copyright by
030-76 L538-1493
Maintenance tasks
CAUTION
Risk of scalding due to hot coolant escaping while under pressure.
u Let the machine cool down. Check the coolant temperature on the display unit.
u Carefully open the sealing caps.
Coolant level in the water cooler:

u Check whether coolant is visible in the cooler sight glass 5.
If no coolant is visible in the cooler sight glass 5:
u Carefully open the cooler cap 3.
u Completely fill the water cooler 4 with coolant.
Coolant level in the equalising reservoirs:
u Carefully open the equalising reservoir sealing caps 2.
u Fill coolant in both equalising reservoirs 1 until the coolant level is between the
markings MIN and MAX.
u Check the coolant level after one hour of operation. (For more information see:
Checking the coolant level, page 030-69)
030.4.6 Working hydraulics

Valid for: L538-1493/31405-;
Checking the hydraulic oil level

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Fig. 74: Checking the hydraulic oil level

1 Maximum oil level 2 Minimum oil level
The red “OIL LEVEL - max.” 1 marking and the bottom edge 2 of the upper sight
glass show the correct oil level.
copyright by
L538-1493 030-77
Maintenance tasks
Note
Check the hydraulic oil level.
u Lower the lift arms until the lift cylinders are retracted.
u Check the oil level.

u Top up with hydraulic oil.
Topping up with hydraulic oil
Note
Top up with hydraulic oil.
u Lower the lift arms until the lift cylinders are retracted.
u Hydraulic oil may only be poured in through the return strainer.
u Oil specification: (For more information see: 030.3.6 Hydraulic oil, page 030-21)
Fig. 75: Topping up with hydraulic oil

1 Plug 3 Return strainer cover
2 Breather filter
u Insert the plug 1 in the breather filter.
w The anti-twist device of the breather filter is released.
u Unscrew the breather filter 2 on the hydraulic tank by two turns.
w The pressure in the tank is released.
u Open the cover 3 of the return strainer.
u Top up with hydraulic oil.
u Put the cover 3 on the housing and tighten it up.
LBH/11827693/02/211-20150615.1139/en
u Screw on the breather filter 2.

u Remove the plug 1 for protection against unauthorised opening, and keep it in a
safe place.
030.4.6.2 Checking and cleaning the magnetic rod on the hydraulic tank
Valid for: L538-1493/31405-35974;
copyright by
030-78 L538-1493
Maintenance tasks
Fig. 76: Checking and cleaning the magnetic rod on the hydraulic tank
1 Breather filter 3 Filter cover
2 Plug 4 Magnetic rod
u Insert the plug 2 in the breather filter 1.
u Unscrew the breather filter 1 by two turns.
u Unscrew the filter cover 3 and lift it up carefully.
u Check the magnetic rod 4 for coarse dirt and particles.
Note
Coarse dirt and particles on the magnetic rod indicate damage in the hydraulic sys-
tem.
u Check the hydraulic system for damage if the magnetic rod is very dirty.
u Carefully clean the magnetic rod 4.

u Screw on the filter cover 3 and tighten it.
u Remove the plug 2 and keep it in a safe place.
030.4.6.3 Checking and cleaning the magnetic rod on the hydraulic tank
Valid for: L538-1493/35975-;
LBH/11827693/02/211-20150615.1139/en
copyright by
L538-1493 030-79
Maintenance tasks
Fig. 77: Checking and cleaning the magnetic rod on the hydraulic tank
2 Plug 4 Magnetic rod
u Unscrew the filter cover 3 (55 mm) and carefully lift it off.
u Check the magnetic rod 4 for coarse dirt and particles.
Note
Coarse dirt and particles on the magnetic rod indicate damage in the hydraulic sys-
tem.
u Check the hydraulic system for damage if the magnetic rod is very dirty.
u Carefully clean the magnetic rod 4.

u Screw on the filter cover 3 with a tightening torque of 10 Nm.
030.4.6.4 Draining off condensate and sediment from the hydraulic tank
Valid for: L538-1493/31405-;
q The machine has not been started for at least one hour (condensate can build
up).
LBH/11827693/02/211-20150615.1139/en

Fig. 78: Positioning the machine at an incline, putting wedges in place
copyright by
030-80 L538-1493
Maintenance tasks
Note
The drain valve of the hydraulic tank is not at the lowest point of the hydraulic tank.
To be able to completely drain the condensate, the machine has to be positioned
at a slight incline.
u Position the machine at a slight incline.
u Put the wheel wedges into position.
Fig. 79: Draining off condensate and sediment from the hydraulic tank

u Unscrew the bleeder filter 1.
w The tank pre-tension is released.
u Screw off the sealing cap on the hydraulic tank drain valve 3 on the back of the
hydraulic tank.
u Screw the drain hose on to the hydraulic tank drain valve 3.
u Drain the condensation water and sediment into the collecting pan.
When clean hydraulic oil comes out:

Valid for: L538-1493/31405-35974;
LBH/11827693/02/211-20150615.1139/en

q A new return-suction filter is ready for use.
copyright by
L538-1493 030-81
Maintenance tasks
Fig. 80: Hydraulic tank - changing the return-suction filter

2 Plug
w The tank preload pressure is released.
u Unscrew the filter cover 3 and lift it up carefully.
u Take out the return suction filter and let it drip dry.
Note
If the return suction filter is stuck:
u Turn the return suction filter to loosen it.
u Check the return suction filter and magnetic rod for excessive dirt and coarse
particles.
Note
Excessive dirt and coarse particles in the return suction filter indicate damage to
the hydraulic system.
u Check the hydraulic system if the return suction filter is very dirty.
u Put in the new return suction filter.

u Clean the magnetic rod.
u Screw on the filter cover 3 and tighten it.
LBH/11827693/02/211-20150615.1139/en

Valid for: L538-1493/35975-;
q A new return suction filter is available.
copyright by
030-82 L538-1493
Maintenance tasks
Fig. 81: Changing the hydraulic tank return suction filter

2 Plug
w The tank pre-tension is released.
u Unscrew the filter cover 3 (55 mm) and carefully lift it off.
u Take out the return suction filter and let it drip dry.
Note
If the return suction filter is stuck:
u Turn the return suction filter to loosen it.
u Check the return suction filter and magnetic rod for excessive dirt and coarse
particles.
Note
Excessive dirt and coarse particles in the return suction filter indicate damage to
the hydraulic system.
u Check the hydraulic system if the return suction filter is very dirty.
u Put in the new return suction filter.

u Clean the magnetic rod.
u Screw on the filter cover 3 with a tightening torque of 10 Nm.
LBH/11827693/02/211-20150615.1139/en

Valid for: L538-1493/31405-;
The breather filter cannot be cleaned.
q A new breather filter is available.
copyright by
L538-1493 030-83
Maintenance tasks
Fig. 82: Changing the hydraulic tank breather filter

u Screw on the new breather filter.
030.4.6.8 Changing the oil in the hydraulic system in accordance with oil
quality and oil analysis
Valid for: L538-1493/31405-;
Note
To check the oil quality:
u Carry out an oil analysis. (For more information see: Oil analysis, page 030-25)

q The hydraulic oil is at operating temperature.
q The specified hydraulic oil is at hand.
Note
If a different hydraulic oil is used to the one used before:
u Make sure that the oils can be mixed. (For more information see: 030.3.2 Con-
verting the hydraulic system from mineral oils to environmentally harmless hy-
LBH/11827693/02/211-20150615.1139/en
draulic fluids, page 030-15)
copyright by
030-84 L538-1493
Maintenance tasks
Draining hydraulic oil
Fig. 83: Draining hydraulic oil

1 Breather filter 3 Cover of return strainer
2 Plug 4 Hydraulic tank drain valve
w The tank preload pressure is released.
u Unscrew the cap of the hydraulic tank drain valve 4.
CAUTION
Risk of scalding due to hot hydraulic oil.
u Avoid contact with the skin.
u Wear protective clothing (oil-proof gloves and goggles).
u Screw the drain hose on to the drain valve of the hydraulic tank 4.
u Drain the hydraulic oil into the collecting pan.
u Unscrew the return strainer cover 3.
u Take out the return strainer.
u Check the return strainer for excessive dirt and coarse particles.
Note
Excessive dirt and coarse particles in the return strainer indicate damage in the hy-
draulic system.
LBH/11827693/02/211-20150615.1139/en
u Check the hydraulic system for damage if the return strainer is very dirty.
u Clean the return strainer.

u Put in the return strainer.
copyright by
L538-1493 030-85
Maintenance tasks
Filling hydraulic oil
Fig. 84: Filling hydraulic oil

1 Cover of return strainer MIN Minimum oil level
2 Oil sight glass MAXMaximum oil level
u Fill hydraulic oil through the return strainer up to the maximum oil level MAX.
u Screw on the return strainer cover 1.
u Screw on the breather filter.
u Remove the plug and keep it in a safe place.
u Start the engine and let it run for a minute at medium idling speed.
u Actuate all the working hydraulics functions while doing this.
w The hydraulic oil is circulated.
u Move the lift arms to maintenance position 1, stop the machine and take out the
ignition key.
u Carefully unscrew the return strainer cover 1.
u Fill the hydraulic oil through the filler strainer until the oil level is between the
minimum MIN and maximum MAX.
u Screw on the return strainer cover 1.
u Check the oil level after one hour of operation. (For more information see:
Checking the oil level in the hydraulic tank, page 030-77)
030.4.6.9 Lubricating the solenoids, universal joints and tappets on the

pilot control unit
Valid for: L538-1493/31405-;
LBH/11827693/02/211-20150615.1139/en
copyright by
030-86 L538-1493
Maintenance tasks
Fig. 85: Lubricating the solenoids, universals joint and tappets

1 Universal joints and tappet 3 Lift kick-out retaining solenoid (op-
tional)
2 Float position retaining solenoid 4 Bucket return-to-dig retaining sole-
noid (optional)
u Remove the rubber sleeves on the control lever and on the additional (optional)
control lever.
u Clean the retaining solenoids with a brush.
u Clean the universal joint and tappet with a brush and lubricate.
u Fit the rubber sleeves.
u Start the engine.
u Testing the retaining solenoids
030.4.7 Steering system

Valid for: L538-1493/31405-;
q The working attachment is in the transport position.
q The articulation lock is released.
q There is enough space to test the steering.
WARNING
Beware of injuries while testing.
u Make sure there is no-one in the danger area.
LBH/11827693/02/211-20150615.1139/en
u Perform the test on level ground with no obstacles.
Fig. 86: Testing the steering
copyright by
L538-1493 030-87
Maintenance tasks
u Start the engine.

u Without moving the machine, turn the steering in both directions and check that
it is functioning properly.
030.4.7.2 Lubricating the bearing points on the steering cylinders

Valid for: L538-1493/31405-;
Fig. 87: Lubricating the bearing points on the steering cylinders

1 Right steering cylinder, ring side 3 Right steering cylinder, piston side
2 Left steering , ring side 4 Left steering cylinder, piston side
u Lubricate the bearing points on the steering cylinders.
030.4.8 Brake system

Valid for: L538-1493/31405-;
Make sure that there is enough room to check the service brake and parking brake.
LBH/11827693/02/211-20150615.1139/en
WARNING
u Perform the test on level ground with no obstacles.
copyright by
030-88 L538-1493
Maintenance tasks
Testing the service brake
Fig. 88: Testing the service brake

1 Inch/brake pedal B Braking
I Inching
u Start the machine.
u Select forward travel and drive it forwards at around 8 km/h.
u While the vehicle is moving, press the inch/brake pedal 1 all the way down.
w The machine must come to an abrupt halt.
Troubleshooting
If the braking effect is too slight or entirely absent?
Testing the parking brake

u Select forward travel and drive it forwards at around 5 km/h.
u Press the parking brake button while travelling.
w The machine must come to an abrupt halt.
Troubleshooting
If the braking effect is too slight or entirely absent?

LBH/11827693/02/211-20150615.1139/en
Valid for: L538-1493/31405-;

If the machine is subjected to very demanding use (such as frequent downhill driv-
ing), the maintenance interval must be shortened.
Note
If the braking behaviour changes:
u Check for wear.
copyright by
L538-1493 030-89
Maintenance tasks
WARNING
Longer braking distances can cause accidents.
u Replace the brake discs before they become too worn.
Note
The axle oil must be drained in order to measure the wear.
u Measure the wear when you change the oil.
Checking the front axle brake discs for wear

If the wear is measured at the service interval, it should be ascertained that the
brake discs are at least a certain minimum thickness. This ensures that the brake
discs do not become too worn by the time the next service is due.
Service hours Minimum brake disc thickness

Wear limit 5.2 mm
3000 h 5.6 mm
6000 h 5.5 mm
9000 service hours or more 5.4 mm
Tab. 35: Minimum thickness at each service interval
Make sure you have a feeler gauge ready.

u Wait 10 seconds.
w The brake system hydro accumulators are charged.
LBH/11827693/02/211-20150615.1139/en
Fig. 90: Wheel hub with plug screw

1 Oil drain plug 3 Outer disc
2 Feeler gauge 4 Brake disc
u Drain the axle oil (see section 3.5.62 on changing the axle oil).
u Open the oil drain screws 1.
u Set the feeler gauge 2 to the minimum thickness.
u Push the feeler gauge 2 into the right-hand gap between two outer discs 3.
copyright by
030-90 L538-1493
Maintenance tasks
Fig. 91: Checking the brake discs for wear
u Have a second person push the brake pedal all the way down and hold it.
u Try to pull the feeler gauge out.
If you can pull the feeler gauge out:
u The brake discs are OK.
Troubleshooting
If the feeler gauge is stuck:
u Replace the brake discs on both sides (see the service documentation, repair
instructions for Dana axles 113 and 123).
u Measure the wear on the rear axle.
u Repeat the process for the gap on the left.

u Close the plugs 1.
Checking the rear axle brake discs for wear

Measure the wear on the rear axle brake discs if the brake discs on the front axle
are worn. The brake discs on the rear axle should therefore have a minimum thick-
ness of 5.6 mm.
This ensures that the brake discs do not become too worn by the time the next in-
spection is due.
u The procedure is the same as for the front axle.
030.4.8.3 Checking the gap and wear on the parking brake linings
Valid for: L538-1493/31405-;
LBH/11827693/02/211-20150615.1139/en

q The machine is secured against rolling away. Wedges are in place.
q Automatic engine shutdown (option) is deactivated.
q You have a feeler gauge ready.
CAUTION
Beware of crushing injuries caused by unintentional closing of the parking brake
when the engine is automatically shut down.
u Deactivate the automatic engine shutdown with the Sculi diagnostics software.
u Keep all persons away from the operator's cab while work is being performed.
copyright by
L538-1493 030-91
Maintenance tasks
Fig. 92: Secure the machine against rolling away
Fig. 93: Check the gap and wear on the brake linings
1 Sealing cap 7 Brake caliper
2 Counter nut 8 Brake disc
3 Adjusting screw 9 Brake shoes
4 Guide pin s Brake lining thickness
5 Castle nut x Gap
6 Cotter pin
Preparation
LBH/11827693/02/211-20150615.1139/en
If the machine is equipped with an automatic engine shutdown system:

u Connect the Sculi diagnostic software to the machine.
u In the variables editor, select the Options folder.
u Set variable CXadAutoEngOff to 0.
w Automatic engine shutdown is deactivated.
Checking the wear on the brake linings

u Check that the thickness of the brake lining s corresponds to the required value.
copyright by
030-92 L538-1493
Maintenance tasks

Brake lining thickness s mm greater than 1.0
If the required value is reached:

u Check the gap. (For more information see: Checking the gap, page 030-93)
If the required value is not reached:
u Replace the brake shoes. (For more information see: Replacing the brake
shoes, page 030-93)
Checking the gap

u Start the engine.
u Release the parking brake.
WARNING
Beware of fatal injuries when operating or moving the machine!
u Secure the machine against rolling away. Put the wheel wedges into position.
u Keep people out of the driver's cab.
u Check that the gap x corresponds to the required value.

Gap x mm 0.5+1.0

u Adjust the gap. (For more information see: Adjusting the gap, page 030-94)
Replacing the brake shoes

u Start the engine.
WARNING
u Unscrew the cap 1.

LBH/11827693/02/211-20150615.1139/en
u Release the counter nut 2 and loosen the adjusting screw 3 by three or four
turns.
u Remove the cotter pin 6 and screw off the castle nut 5.
u Pull out the guide bolt 4.
w The brake caliper 7 can be folded away downwards.
u Fold the brake caliper 7 down.
u Put on the new brake shoes 9.
u Fold up the brake caliper 7.
u Insert the guide bolt 4 and screw on the castle nut 5.
copyright by
L538-1493 030-93
Maintenance tasks
u Insert the cotter pin 6.

u Adjust the gap. (For more information see: Adjusting the gap, page 030-94)
Adjusting the gap

u Start the engine.
WARNING
u Unscrew the cap 1.

u Unscrew the counter nut 2.
u Tighten the adjusting screw 3 until the gap is x 0.5 mm.
u Tighten the counter nut 2.
WARNING
u Make sure there is nobody under the machine.
u Close the parking brake three times and open it again.
WARNING
u Check the gap.

u Repeat the procedure.
u Screw on the cap 1.
Final tasks
If the machine is equipped with an automatic engine shutdown system:
LBH/11827693/02/211-20150615.1139/en
u Activate the automatic engine shutdown.
030.4.9 Electrical system

Valid for: L538-1493/31405-;
q The machine is parked in a safe place.
q The electrical system of the machine is switched on.
copyright by
030-94 L538-1493
Maintenance tasks
All the lights can be tested without starting the machine. Start the machine when
testing the reversing headlight.
WARNING
Beware of accidents when testing the lighting equipment with another person.
u Always maintain visual contact with the other person.
u Do not allow anyone into the danger area of the machine.
CAUTION
Beware of fires caused by the heat of the working floodlights.
u Observe the minimum interval of 1 m to persons and material.
Fig. 94: Checking the lights
u Turn on all the lights.

u Check all the lights work properly.
When checking the brake lights:
u Press the inch/brake pedal.
To check the reversing headlights:
u Select “reverse” travel direction.
u Check the reversing headlights.
If lights have to be adjusted or defective bulbs replaced:

Valid for: L538-1493/31405-;
LBH/11827693/02/211-20150615.1139/en
The batteries are installed in the right ballast weight.

The batteries must always be in perfect condition in order for the machine to work
reliably.
q The battery main switch is off.
q Safety glasses and acid-proof protective gloves are available.
copyright by
L538-1493 030-95
Maintenance tasks
Fig. 95: Battery arrangement

1 Terminals 3 Mounting plate
2 Fuse carrier 4 Batteries
WARNING
Beware of explosions and acid burns
Batteries produce explosive gases and are filled with highly corrosive acid.
u Avoid sparks.
u Do not allow acid to come into contact with your skin.
u Wear protective clothing (acid-proof gloves and safety glasses).
u Switch off the battery main switch and remove the key.
u Remove the mounting plate 3.

u Remove the electrical wires from the fuse carrier 2.
u Remove the fuse carrier 2.
u Wipe the battery with a clean cloth.
u Clean the terminals and clamps with a special terminal brush.
To ensure a good connection:
u Check that the connectors are fastened to the terminals and tighten them if nec-
essary.
u Smear the terminals and clamps with acid-proof grease such as Vaseline.
LBH/11827693/02/211-20150615.1139/en
At very high temperatures, the acid level in the individual cells can drop due to dif-
ferent rates of evaporation.
u Open the plugs on each cell and check the acid level.
w The acid level must be 10 mm above the plates.
If the acid level is too low:
u Top up with distilled water up to 10 mm above the plates.
copyright by
030-96 L538-1493
Maintenance tasks
Note
Beware of damage to the batteries in very cold weather.
The electrolyte of a discharged battery can freeze and irreparably damage the
components.
u At low ambient temperatures, check the charging condition and charge the bat-
tery at regular intervals.
u Check the charge level using an acid density tester.
Charge levels
Acid density at Charge level Battery volt- Voltage per Remark
27 °C age cell
1.28 – 1.26 100% over 12.60 over 2.10 Battery OK
1.25 – 1.24 75% 12.54 – 12.40 2.10 – 2.07
1.24 – 1.18 50% 12.40 – 12.18 2.07 – 2.03 Charge battery
1.18 > 25% 12.18 > 2.03 > Battery not OK
Tab. 36: Table of charge levels
If the charge is too low:

u Recharge the batteries.
After completing the maintenance tasks:
u Fit the mounting plate 3.
u Fit the fuse carrier 2.
WARNING
Incorrect protection of the electrical lines!
Risk of electric shock and damage to the electrical system.
u Connect the electrical lines to the correct fuse in the fuse carrier.
WARNING
Short circuit or fault in the electrical system!
Explosion or fire.
u Always fasten electrical cables to the fuse carrier with the appropriate insulating
nuts.
u Check the insulating nuts for damage and replace them if necessary.
LBH/11827693/02/211-20150615.1139/en
u Attach the electrical cables to the fuse carrier. (Insulating nut torque: 12 Nm)
Fuse assignment
Fuse Amps
F01 100
F02 100
F03 200
Tab. 37: Fuse assignment
copyright by
L538-1493 030-97
Maintenance tasks
030.4.9.3 Changing the travel direction rocker switch and cap (optional)
on the control lever
Valid for: L538-1493/31405-;
Changing the travel direction rocker switch

Make sure that the ignition is set at OFF.
Fig. 96: Control lever with rocker and seals
NOTICE
Beware of damage
The seal 2 can be damaged by a screwdriver.
In this way the functioning of the travel direction switch can be impaired.
u Use 5 mm screwdrivers (maximum).
u Insert a small screwdriver between rocker 1 and travel direction switch under
the middle axis and lever out the rocker 1.
u Check seal 2 for damage.
w The travel direction switch must be replaced when a seal 2 is damaged.
u Fit the new rocker 1 on the travel direction switch.
LBH/11827693/02/211-20150615.1139/en
Changing push button covering (option)

Make sure that the ignition set at OFF.
copyright by
030-98 L538-1493
Maintenance tasks
Fig. 97: Push button covering and buttons
u Release the two TORX screws 3 (size 8).
Note
u For easier removal of the push button covering 4, press together both grip han-
dles of the control lever.
u Pay attention to the different sizes of the push buttons 5.
u Remove push button covering 4.

LBH/11827693/02/211-20150615.1139/en
Fig. 98: Fit push button covering.
u Fit push buttons 5 in the new push button covering 4.

u Fit push button covering 4 on the control lever while paying attention to the anti-
rotation lock 6.
Note
So that the push buttons 5 do not fall out of the push button covering 4 during fit-
ting:
u Clamp the three push buttons 5 by pushing slightly from the outside inwards.
u Tighten two TORX screws 3 with 0.5 Nm.
copyright by
L538-1493 030-99
Maintenance tasks

Valid for: L538-1493/31405-;
Fig. 99: Checking the transmission oil level
u Open the filling plug 1 on the transmission.

u Check whether the oil level is at correct level (the lower edge of the filling
plug 1).
If the oil is below the required level:
u Fill gear oil up to the lower edge of the filling plug 1.
u Check the transmission for oil loss.
If the oil is at correct level:
u Close the filling plug 1.

Valid for: L538-1493/31405-;
q The transmission is at operating temperature.
q The specified gear oil is at hand.
LBH/11827693/02/211-20150615.1139/en
copyright by
030-100 L538-1493
Maintenance tasks
Fig. 100: Changing the transmission oil

1 Filling plug 2 Drain plug
CAUTION
Risk of scalding by hot, pressurised oil.
u Open the plugs carefully.
u Wear protective clothing (oil-proof gloves and safety glasses).
u Carefully open the filling plug 1.

u Carefully open the drain plug 2 and drain the oil into the collecting pan.
u Close the drain plug 2.
u Fill oil to the lower edge of the filling plug 1.
030.4.11 Axles and cardan shafts

Valid for: L538-1493/31405-;
The oil level must be checked on both axles.
q The filling plug on the left wheel hub of the front axle is in a horizontal position.
LBH/11827693/02/211-20150615.1139/en
copyright by
L538-1493 030-101
Maintenance tasks
Fig. 101: Checking the axle oil levels, the main housing and wheel hub
Checking the oil level in the main housing

u Open the filling plug 1 on the main housing of the front axle.
u Check whether the oil level is correct (at the bottom of the filling plug 1).
u Top up axle oil up to the bottom of the filling plug 1.
u Check the axle for oil loss.
If the oil level is correct:
Checking the oil levels in the wheel hubs

u Open the filling plug 2 on the left wheel hub.
u Check whether the oil level is correct (at the bottom of the filling plug 2).
u Top up axle oil up to the bottom of the filling plug 2.
u Check the axle for oil loss.
If the oil level is correct:
u Position the machine so that the filling plug on the right wheel hub of the front
axle is level.
u Repeat the procedure on the right wheel hub.
LBH/11827693/02/211-20150615.1139/en
Checking the oil levels in the rear axle

u Repeat the entire procedure on the rear axle (main housing and wheel hub).

Valid for: L538-1493/31405-;
The oil must be changed on both axles.
q The axles are at operating temperature.
copyright by
030-102 L538-1493
Maintenance tasks
q The specified axle oil is at hand.

Fig. 102: Changing the axle oil

1 Main housing filling plug 3 Wheel hub filling plug
2 Main housing drain plug 4 Wheel hub drain plug
Changing the oil in the main housing
CAUTION
u Carefully open the filling plug 1 on the central housing of the front axle.
u Carefully open the drain plug 2 on the central housing of the front axle and drain
the oil into the collecting pan.
u Repeat the procedure on the rear axle.
u Check the oil levels after 1 operating hour. (For more information see: Checking
the axle oil levels, page 030-101)
LBH/11827693/02/211-20150615.1139/en
Changing the oil in the wheel hubs

u Position the machine so that the filling plug 3 on the left wheel hub of front axle
is level.
CAUTION
copyright by
L538-1493 030-103
Maintenance tasks
u Carefully open the filling plug 3 on the left wheel hub of the front axle.
u Carefully open the drain plug 4 on the left wheel hub of the front axle and drain
the oil into the collecting pan.
u Repeat the procedure on the right wheel hub.
u Check the oil levels after 1 operating hour. (For more information see: Checking
the axle oil levels, page 030-101)
Changing the oil in the rear axle

u Repeat the entire procedure on the rear axle (main housing and wheel hub).
030.4.11.3 Checking the tightening torque of the front axle fastening bolts
Valid for: L538-1493/31405-;
q You have a torque wrench ready.
Fig. 103: Front axle fastening bolts
u Check the tightening torque of 850 Nm on all fastening bolts 1 (spanner size
36 mm) on the front axle.

Valid for: L538-1493/31405-;
LBH/11827693/02/211-20150615.1139/en
Fig. 104: Checking the cardan shafts
copyright by
030-104 L538-1493
Maintenance tasks
u Check the play of the drive shaft in the bearings.

u Check the rubber sleeve for leaks and damage.

Valid for: L538-1493/31405-;
The air pressure in the tyres significantly affects the overall operating performance
of the machine.
The tyre pressure depends on the following factors:
– The tyres used
– The purpose the machine is used for
– The attachment installed
For special uses where heavier loads may be expected, a higher tyre pressure is
recommended.
However, the tyre pressure may not be greater than the maximum permitted by
the tyre manufacturer's specifications.
q The correct tyre pressures are available.
The tyre pressures stated refer to cold tyres.
Fig. 105: Checking the tyre pressure
WARNING
Beware of injuries caused by exploding tyres or the sealing ring coming loose
Failure to act as instructed can lead to serious injury.
u Use a sufficiently long hose with a self-locking adapter for filling the tyres.
LBH/11827693/02/211-20150615.1139/en
u Keep a safe distance from the side of the tyre.
u Check the tyre pressure.

If the tyre pressure is not correct:
u Correct the tyre pressure.
030.4.11.6 Checking the wheel tightness (once after 50, 100 and 250 h)
Valid for: L538-1493/31405-;
copyright by
L538-1493 030-105
Maintenance tasks
q A torque wrench with a measuring range of over 650 Nm is available.
Note
Intervals for checking the tightness of the wheels.
u This one-off maintenance task scheduled for 50, 100 and 250 service hours
must also be performed every time the wheels are changed.
Fig. 106: Checking the wheel tightness
Designation Rating
Spanner size 30 mm
Tightening torque 650 Nm
Tab. 38: Checking the wheel tightness
u Check that all the nuts on the four wheels have been tightened with the required
torque.
030.4.12 Steel components of the basic machine
030.4.12.1 Lubricating the articulated bearing and the rear oscillating bed-
ding
Valid for: L538-1493/31405-;
LBH/11827693/02/211-20150615.1139/en
copyright by
030-106 L538-1493
Maintenance tasks
Fig. 107: Lubricating the articulated bearing and the rear oscillating bearing
1 Lubrication points on the rear os- 2 Articulation bearing lubrication
cillating bearing points
To lubricate the rear oscillating bearing:
u Grease the lubrication points 1.
To lubricate the articulation bearing:
u Grease the lubrication points 2.

Valid for: L538-1493/31405-;
LBH/11827693/02/211-20150615.1139/en
Fig. 108: Covering - lubricating locks and hinges

1 Button and locking cylinder 3 Locking mechanism
2 Lock
u Lubricate the button and locking cylinder 1 with Ballistol spray (item code
10025514).
u Lubricate the lock 2 and locking mechanism 3 with Liebherr universal grease
9900.
u Lubricate the hinges of the covering with Ballistol spray (item code 10025514).
copyright by
L538-1493 030-107
Maintenance tasks
030.4.13 Working attachment

Valid for: L538-1493/31405-;
Lift arms with Z kinematics
Fig. 109: Lift arms with Z kinematics

a Lower bucket bearing
u Grease all the bearing and lubrication points on the lift arms.
u The lower bucket bearings a should be lubricated daily in accordance with re-
quirements.
Lift arms with parallel kinematics
LBH/11827693/02/211-20150615.1139/en
Fig. 110: Lift arms with parallel kinematics

a Lower bucket bearing
copyright by
030-108 L538-1493
Maintenance tasks
u Grease all the bearing and lubrication points on the lift arms.
u The lower bucket bearings a should be lubricated daily in accordance with re-
quirements.
Lubricating the attachment

Note
Lubricate the attachment.
u Ensure that the lubricating points are easy to access. Disconnect the attach-
ment if necessary.
u For detailed information on maintenance for non-Liebherr attachments, see the
manufacturer's instructions.

Valid for: L538-1493/31405-;
Dirt or insufficient lubrication causes wear on the bearing bushings. Wear is recog-
nisable through increased play between the pin and bearing bushing or through
loud noises. Replace the bearing bushings in good time to prevent damage to the
bucket arms.
Fig. 111: Checking the lift arm bearing bushings

1 Bearing bushing 2 Lower bucket bearing
u Move the lift arms and the bucket to the position shown above.
LBH/11827693/02/211-20150615.1139/en
u Rapidly tilt the bucket in and out, and check the lower bucket bearings 2 for
noise and play.
Replace the bearing bushings if:
– There is a lot of play with the bucket bearings
– Loud noise occurs
Note
To replace the bearing bushings:
copyright by
L538-1493 030-109
Maintenance tasks

Valid for: L538-1493/31405-;
Make sure that the machine is secured against rolling away (engage parking brake,
insert wedges).
Fig. 112: Checking the lift arm bucket stops
u Start the engine.

u Raise the lift arms.
u Tilt out the bucket until the stops 1 are reached.
u Turn off the engine and take out the ignition key.
WARNING
Beware of injury from lift arms lowering.
u Do not loiter under the lift arms.
u Check the dimension X (also applies for the quick-change device).

LBH/11827693/02/211-20150615.1139/en
Dimension X mm 5±3
If dimension X deviates:
u Contact the technical customer service department.

Valid for: L538-1493/31405-;
copyright by
030-110 L538-1493
Maintenance tasks
Lubricating the quick-change device

q The working attachment is disconnected for lubricating points near the bucket
coupling, which are difficult to access.
Fig. 113: Lubricating the quick-change device

1 Lubrication nipple
u Lubricate the grease nipple 1.
Testing the quick-change device

q The engine has started.
q The lift arms have been lowered.
q The working attachment is tilted in.
WARNING
u Pay attention to the safety instructions in the operating manual.
u Unlock the quick-change device and lock it again.

w This prevents the locking pins from jamming and preventing the quick-
change device from being released.
u For safety reasons, check that the quick-change device is locked again.
030.4.14 Cab, heating and air conditioning

LBH/11827693/02/211-20150615.1139/en
Valid for: L538-1493/31405-;

copyright by
L538-1493 030-111
Maintenance tasks
Cleaning the fresh air filter
Fig. 114: Cleaning the fresh air filter

1 Door 3 Fresh air filter
2 Pre-filter
u Open the door 1.
u Open the brackets for the filters 2, 3.
u Take out the pre-filter 2 and clean it (blow it out or wash it) or replace it if neces-
sary.
u Unscrew the fresh air filter 3 at the bottom on the front lug and clean it (blow it
out).
u Put in the clean filter (making sure it is correctly fitted) and close the brackets.
u Close the door 1.
Cleaning the recirculated air filter
Fig. 115: Cleaning the recirculated air filter

1 Screw 2 Recirculated air filter
LBH/11827693/02/211-20150615.1139/en
u Remove the screw 1.

u Open the bracket.
u Take out the recirculated air filter 2 and clean it (blow it out).
u Put in the clean filter.
u Close the bracket.
copyright by
030-112 L538-1493
Maintenance tasks

Valid for: L538-1493/31405-;
Changing the fresh air filter
Fig. 116: Changing the fresh air filter

1 Door 3 Fresh air filter
2 Pre-filter
u Open the door 1.
u Open the brackets for the filters 2, 3.
u Take out the pre-filter 2 and dispose of it.
u Unscrew the fresh air filter 3 at the bottom on the front lug and dispose of it.
u Insert the new fresh air filter (making sure it is correctly fitted) and close the
holders.
u Close the door 1.
Changing the recirculated air filter

LBH/11827693/02/211-20150615.1139/en
Fig. 117: Changing the recirculated air filter

1 Screw 2 Recirculated air filter
u Remove the screw 1.
u Open the bracket.
u Take out the recirculated air filter 2 and dispose of it.
copyright by
L538-1493 030-113
Maintenance tasks
u Put in a new filter.

u Close the bracket.

Valid for: L538-1493/31405-;
Fig. 118: Checking the condition and function of the safety belt
1 Strap 3 Unlock button
2 Lug 4 Belt lock
u Check the condition and function of the driver’s safety belt.
u Replace damaged parts.
030.4.14.4 Checking and topping up the windscreen washer reservoir

Valid for: L538-1493/31405-;
The reservoir is behind the driver's cab below the grille of the cooling system.
Fig. 119: Checking and topping up the windscreen washer reservoir

LBH/11827693/02/211-20150615.1139/en
1 Cap
The filling quantity is approximately 3.5 l.
u Open the cap 1 on the reservoir.
u Top up with standard windscreen washer fluid as necessary.
NOTICE
Ice can damage the windscreen washer system.
Icing up can damage the windscreen washer system and cause it to fail.
u You must protect the windscreen washer system using antifreeze.
copyright by
030-114 L538-1493
Maintenance tasks
u Use commercially available windscreen antifreeze.

u Top up with an appropriate quantity of antifreeze before the winter starts.

Valid for: L538-1493/31405-;
Fig. 120: Checking the seals on the driver’s cab

1 Seal
u Check the condition of the seals.
u Completely replace any damaged seals.
030.4.14.6 Checking the indicator and filling level beads in the dryer-collec-
tor unit of the air conditioner
Valid for: L538-1493/31405-;
q The cooling system grille is open.
LBH/11827693/02/211-20150615.1139/en
Fig. 121: Sight glass in the dryer-collector unit

1 Indicator pearl 3 Cooling system grille
2 Filling level pearl
The filling level can vary due to temperature fluctuations. It can also sink in time
due to natural leakage.
A refrigerant level that is too low can result in inadequate cooling.
copyright by
L538-1493 030-115
Maintenance tasks
The filling level pearl 2 shows the filling level of the refrigerant R134a. The filling
level pearl 2 must float at the top of the sight glass. In normal circumstances, one
filling lasts for three to five years.
u Check the filling level by means of the filling level pearl 2.
The smaller pearl is the indicator pearl 1. The indicator pearl has been dyed a col-
our. If the colour of the indicator pearl becomes transparent, there is too much wa-
ter in the refrigerant:
u Check the indicator pearl.
If the colour of the indicator pearl has become transparent:
u Drain the system.
u Replace the dryer.
u Change the compressor oil.
u Refill the system.

Valid for: L538-1493/31405-;
q The ambient temperature is at least 20 °C.
q A temperature meter is available.
Fig. 122: Ambient temperature / outflow temperature diagram

1 Ambient temperature in °C 2 Outflow temperature in °C
LBH/11827693/02/211-20150615.1139/en
u Start the engine.

u Open cab doors for 1 minute.
w Trapped heat can escape.
u Close the cab doors.
u Switch on the air conditioning unit and set to maximum cooling.
u Set fan to level 2.
u Allow machine to run for 5 minutes at medium speed.
w Air conditioning compressor is activated and coolant is circulated.
u Measure the ambient temperature in the driver's cab and enter the value in the
diagram.
copyright by
030-116 L538-1493
Maintenance tasks
u Measure the outflow temperature at the right driver-level nozzle and enter the
value in the diagram.
u Check the intersection of the measured values in the diagram.
w The value should be within the specified range.
If the value is not within the specified range:
u Check the fresh air and recirculated air filter for contamination.
u Check the air conditioning condenser for contamination and proper functioning.
u Check the condenser fan.
u Check the dryer and replace it if necessary.
u Check the air conditioning compressor and compressor coupling.
u Check the refrigerant filling level.
030.4.15 Lubrication system
030.4.15.1 Checking the lubrication system grease reservoir level

Valid for: L538-1493/31405-;
Fig. 123: Checking the filling level of the grease reservoir

1 Central lubrication system button 4 Grease fitting
2 LEDs 5 Filling coupling (fast filling)
3 Grease reservoir 6 Fast filling pump
u Check the level in the grease reservoir 3 by sight.
w Stay within the minimum and maximum lubricant levels.
w It the amount of grease in the grease reservoir is too low, all the LEDs 2 on
the central lubrication system button 1 light up.
LBH/11827693/02/211-20150615.1139/en
NOTICE
Risk of damage when filling the system.
u Pay attention to cleanliness when filling the grease reservoir.
u Stay within the minimum and maximum lubricant levels.
To fill the grease reservoir:

u Fill the grease reservoir via the grease nipple 4.
or
For rapid filling with the fast filling pump 6, fill at the filling coupling 5.
copyright by
L538-1493 030-117
Maintenance tasks
030.4.15.2 Checking the pipes, hoses and lubrication points of the lubrica-
tion system
Valid for: L538-1493/31405-;
u Visually examine the hose lines for defects.
If there are defects:
u Find the cause and rectify it.
030.4.15.3 Checking whether metered quantities are adequate at the bear-

ing points (grease collars) of the lubrication system
Valid for: L538-1493/31405-;
u Visually examine whether metered quantities are adequate at the bearing
points.
If the lubrication at the bearing points is insufficient:
u Shorten the lubrication interval or increase the intensity of the central lubrication
system.
NOTICE
Beware of damaging the machine.
If one or more bearing points are not sufficiently lubricated:
LBH/11827693/02/211-20150615.1139/en
copyright by
030-118 L538-1493
Testing and adjustment checklist
Valid for: L538-1493/31405-;
Machine: Serial no.: Service hours: Date: Tested by:
Customer:
Location:
Tab. 39: Customer data and machine data
Adjusting point
Required value
Test point
Measured
Adjusted
1000 h
2000 h
Unit
Testing / adjustment Figure
Overall machine
Preparatory tasks for testing and adjust-
ing
Preparing for testing and adjusting ○ ○
Hydraulic system operating temperature
Bring the hydraulic oil up to operating tem-

○ ○ °C 58±5
perature
Drive group
Inch/brake pedal calibration
Calibrate the inching function ○ ○
Engine speed
Lower idling speed ○ ○ rpm 850±10
Upper idling speed ○ ○ rpm 2560±10
Cooling system
Fan gear motor proportional pressure re-
LBH/11827693/02/211-20150615.1139/en
lief valve
Pressure at upper idling speed (hydraulic oil
○ ○ bar 140±5 PK
temperature sensor disconnected)
Pressure at upper idling speed (proportional
◊ ◊ bar 175±10 1 PK
solenoid de-energised)
Travel hydraulics
Travel pump replenishing pressure relief
valve
Replenishing pressure at upper idling speed ○ ○ bar 34±2 G
copyright by
L538-1493 030-119
Adjusting point
Required value
Test point
Measured
Adjusted
1000 h
2000 h
Unit
⇒ Travel pump high pressure relief valves
Forward travel direction: High pressure at

○ ○ bar 495±10 2 MH
maximum engine speed A)
Reverse travel direction: High pressure at
○ ○ bar 495±10 3 MH
maximum engine speed A)
⇒ Travel pump pressure cut-off
High pressure at maximum engine speed ○ ○ bar 440±5 4 MH
Engine droop at upper idling speed with ac-

○ ○ rpm <50
tive pressure cut-off valve
⇒ Travel pump block curve calibration
High pressure at engine speed of 930 rpm ○ ○ bar 100±10 MH
⇒ Travel motor 1 start of regulation

MH
High pressure at servo pressure of 50±10 bar ○ ○ bar 290±10 5
M1
Travel motor 2 automatic calibration
Perform automatic calibration ○ ○ 6
Engine performance
Engine speed at high pressure of 290±5 bar ◊ rpm 2250-100 MH
Working hydraulics
Working hydraulics pump flow regulator
(standby pressure)
High pressure at lower idling speed ◊ bar 32±2 7 P

LBH/11827693/02/211-20150615.1139/en
Z kinematics control valve block secon-

dary pressure relief valves
Opening pressure for tilting in B) ○ bar 220±5 10 P
Opening pressure for tilting out B) ○ bar 220±5 11 P
Opening pressure for lifting B) ○ bar 250±5 12 P
Opening pressure for 3rd function A3 (option-

○ bar 250±5 13 P
al)
Opening pressure for 3rd function B3 (option-
○ bar 250±5 14 P
al)
copyright by
030-120 L538-1493
Adjusting point
Required value
Test point
Measured
Adjusted
1000 h
2000 h
Unit
P kinematics control valve block secon-

dary pressure relief valves
Opening pressure for tilting in B) ○ bar 220±5 10 P
Opening pressure for tilting out ○ bar 150±5 11 P
Opening pressure for lifting B) ○ bar 250±5 12 P
Opening pressure for 3rd function A3 (option-

○ bar 250±5 13 P
al)
Opening pressure for 3rd function B3 (option-
○ bar 250±5 14 P
al)
Working hydraulics LS pressure cut-off
valve
High pressure at full load ○ bar 330±5 9 P
Stabilisation module (optional), cut-off

function
Cut-out pressure when charging ○ bar 120±10 MX
Ride control hydro accumulator (option-

al), nitrogen filling
Filling pressure ○ ○ bar 25±2
Steering system
Steering system LS pressure cut-off valve
High pressure at full load ○ bar 210±5 8 P
Brake system
Compact brake valve hydro accumulator
charging function
Cut-in pressure ○ ○ bar 130±10 15 M3
Cut-out pressure ○ ○ bar 160±10 15 M3

LBH/11827693/02/211-20150615.1139/en
copyright by
L538-1493 030-121
Adjusting point
Required value
Test point
Measured
Adjusted
1000 h
2000 h
Unit
Service brake pressure
Front axle brake pressure ○ ○ bar 60±5 16 M4
Rear axle brake pressure ○ ○ bar 60±5 16 M5
Service brake hydro accumulator capacity
Residual pressure in the front axle hydro ac-

○ ○ bar >50 M4
cumulator after applying the brakes 9 times
Residual pressure in the rear axle hydro ac-
○ ○ bar >50 M5
cumulator after applying the brakes 9 times
Accumulator charge pressure switch shift
pressure
Switching pressure ○ ○ bar 90±5

M3
Transmission
Transmission hydro accumulator nitrogen
filling
Filling pressure ○ ○ bar 11±1
Remarks:
Tab. 40: Testing and adjustment checklist
A) Note: Screw in the pressure cut-off of the travel pump by one turn before testing. Follow the instructions.
B) Note: Unscrew the labelled secondary pressure relief valves by half a turn before testing. Follow the instructions.
Symbol Meaning Symbol Meaning
○ Always carry out Link to the instructions
◊ Only if necessary Sculi diagnostic software is required

LBH/11827693/02/211-20150615.1139/en
Entry field Read the values from the display
Checkbox ⇒ Machine in blocked condition
Tab. 41: Key
copyright by
030-122 L538-1493
Testing and adjustment tasks
030.6 Testing and adjustment tasks
All work must be carried out by specialist technicians or under their supervision
and responsibility.
Specialists technicians are people who:
– Have the requisite training and experience in operating and servicing earthmov-
ing machinery
– Are familiar with the statutory accident prevention regulations and national
guidelines
– Are able to judge whether earthmoving machinery is safe to operate
– Can carry out the required work without endangering themselves or others

Valid for: L538-1493/31405-;
Fig. 124: Safety precautions
Make sure you are wearing safe working clothing.

Certain jobs not only require a hard hat and safety boots, but also goggles and
safety gloves.
The relevant safety regulations must be observed whenever maintenance, in-
spection or repair work is carried out. Local health and safety regulations, accident
prevention regulations and national laws must be observed.
(For more information see: 010.1.11 Measures for ensuring safe maintenance,
page 010-8)
LBH/11827693/02/211-20150615.1139/en
Fig. 125: Visual contact
Make sure that visual contact between the operator in the cab and maintenance
personnel is always maintained.
WARNING
Beware of accidents during maintenance
The presence of unauthorised persons on the machine can place the maintenance
personnel in extreme danger.
u Never enter a dangerous area of the machine without making your presence
known.
copyright by
L538-1493 030-123
Fig. 126: Wheel wedges
u Use wheel wedges to prevent the machine from accidentally rolling away.
030.6.2 Overall machine

Valid for: L538-1493/31405-;
q Machine is in maintenance position for testing and adjustment tasks.
q The machine is at operating temperature.
q You have the specific adjustment data for the machine.
q You have seals and sealing caps ready.
q You have the necessary special tools.
Maintenance position for testing and adjustment
Fig. 127: Maintenance position for testing and adjustment
To move the machine into the maintenance position for testing and adjustment,
proceed as follows:
u Fully retract the tilt cylinder.
u Set the bucket down on the ground on its teeth or cutting edge.
LBH/11827693/02/211-20150615.1139/en

u Put the wheel wedges into position.
u Ensure that another person cannot start operating the machine.
copyright by
030-124 L538-1493
Special tools
Special tools
Number Description Item code
1 Sculi diagnostic software with the applicable authori- -
sation
1 Diagnostic data cable (RS-232) for Sculi 10035410
1 USB dongle for Sculi 10489591
1 Pressure gauge, 0-40 bar, class 1.0 7361288
2 Test line, 4000 mm 7009134
2 Test line, 1500 mm 7002475
1 Hydro accumulator testing and filling device 8460226
Tab. 42: Special tools

Valid for: L538-1493/31405-;
During testing and adjustment, the machine must be at an operating temperature
of 58±5 °C. The temperature is measured by the hydraulic oil temperature sensor
and can be seen in Sculi.
Make sure that the machine is in the maintenance position for testing and adjust-
ments.
LBH/11827693/02/211-20150615.1139/en
Fig. 128: Hydraulic oil cooler (red marking)
u Place a piece of cardboard or similar in front of the hydraulic oil cooler 1.

w The cooling capacity is reduced. This allows the operating temperature to be
attained faster.
u Start the engine.
u In the variables editor in the group structure, select the Check cooling system
folder.
copyright by
L538-1493 030-125
u During the adjustment, read the hydraulic oil temperature for the variable Hy-
drOilTemp.
Bring the machine up to operating temperature as follows:
When working on the hydraulic system, the hydraulic oil temperature must be with-
in the prescribed range (58±5 °C).
u Let the engine run at about 2500 rpm.
u Activate the tilt-in function as far as it will go and hold the control lever in this
position.
u At the same time, lower the lift arms and hold the control lever in the float posi-
tion function.
u Operate the travel hydraulics in travel range 1.
u Bring the machine up to operating temperature until the hydraulic oil tempera-
ture is 58±5 °C.
u Remove the cardboard from the hydraulic oil cooler after completing the adjust-
ment.
030.6.3 Drive group

Valid for: L538-1493/31405-;
The inch/brake pedal can only be calibrated using the Sculi software. During cali-
bration, the MIN and MAX positions of the inch/brake pedal are stored in the cen-
tral control unit.
ments.
u Switch on the ignition.
u In the variables editor, select the Pedal calibration folder.
u Set the AdjustInchpedal variable to 1.
u Press the inching-brake pedal all the way down and then release it.
The MIN and MAX positions of the inch/brake pedal are stored. After 10 seconds,
the value automatically returns to 0 and calibration is finished.
u Check that the InchpedalPosition variable is 0% when the inch/brake pedal is
not pressed and 100% when it is pressed all the way down.
LBH/11827693/02/211-20150615.1139/en

Valid for: L538-1493/31405-;
The engine speed is determined by the engine control unit and cannot be adjusted
mechanically.
You can see the engine speed in the display.
Make sure the cooling water temperature is at least 75 °C.
u Start the engine.
u Check the upper and lower idle speeds.
copyright by
030-126 L538-1493

Lower idling speed rpm 850±10
Upper idling speed rpm 2560±10
030.6.4 Cooling system

Valid for: L538-1493/31405-;
q The machine is in the maintenance position for testing and adjustment.
Fig. 129: Fan gear motor proportional pressure relief valve

1 Hydraulic oil temperature sensor PK Cooling system high pressure test
connection
2 Proportional pressure relief valve
Testing the pressure relief and proportional valve and adjusting

the rated current
CAUTION
Hot components can cause injury.
u Keep a safe distance from the engine and exhaust system.
u Unplug the hydraulic oil temperature sensor 1.

u Connect a pressure gauge (250 bar) to the high pressure test connection PK on
LBH/11827693/02/211-20150615.1139/en
the fan gear pump.

u Start the engine.
u Increase the engine speed to the upper idling speed.
u Check that the high pressure PK is correct.

High pressure PK bar 140±5
When the value is correct:

copyright by
L538-1493 030-127
u Plug in the hydraulic oil temperature sensor 1.

u Disconnect the pressure gauge from the high pressure test connection PK.
When the value is not correct:
folder.
u Change the value of the FanInenn variable.
Note
To approach the required value, you can change the value of the FanInenn varia-
ble gradually at upper idling speed.
u Click the variable and press the space bar (the line is coloured pink).
u Cursor up/down: Last digit of the value +/- 1
u Cursor left/right: Last digit of the value +/- 5
u Page up/down: Last digit of the value +/- 10
u Check and repeat the adjustment until the value is correct.

If you do not achieve the required value by changing the FanInenn variable:
u Plug in the hydraulic oil temperature sensor 1.
u Check the mechanical settings of the pressure relief and proportional valve.
(For more information see: Mechanical settings of the pressure relief and pro-
portional valve, page 030-128)
Mechanical settings of the pressure relief and proportional valve

You only need to mechanically adjust the proportional pressure relief valve if the
required value is not achieved by changing the FanInenn variable.
u Start the engine.
folder.
u Set the PWM2_Fan variable to 0 mA.
w The proportional solenoid is not energised.
Note
LBH/11827693/02/211-20150615.1139/en
The PWM2_Fan variable is automatically reset to its original value when the igni-
tion is switched OFF/ON.
u If necessary, reset the value to 0 mA when repeating the test.
u Increase the engine speed to the upper idling speed.

u Check that the high pressure PK is correct.

High pressure PK bar 175±10
copyright by
030-128 L538-1493

CAUTION
Hot components can cause injury.
u Keep a safe distance from the engine and exhaust system.
u Adjust the adjusting screw of the pressure relief and proportional valve 2.
Note
To adjust the pressure relief and proportional valve:
u Turn the adjusting screw clockwise to increase the high pressure.
u Turn the adjusting screw anticlockwise to reduce the high pressure.

u Disconnect the pressure gauge from the high pressure test connection PK.
030.6.5 Working hydraulics
030.6.5.1 Working hydraulics pump flow regulator (standby pressure)

Valid for: L538-1493/31405-;
The standby pressure only needs to be checked and adjusted if the working hy-
draulics pump or material parts of the working hydraulics pump have been re-
placed or the output of the working hydraulics is insufficient.
q Machine is in the maintenance position for testing and adjustments.
LBH/11827693/02/211-20150615.1139/en
Fig. 130: Working hydraulics pump flow regulator (standby pressure)
u Connect a pressure gauge (40 bar) to the high pressure test connection P on
the working hydraulics pump.
copyright by
L538-1493 030-129
NOTICE
The high pressure of the working hydraulics pump can irreparably damage the
pressure gauge.
u Do not operate the working attachment.
u Start the engine.

u Allow the engine to run at low idling speed.
w The standby pressure can be checked at the high pressure test connec-
tion P.
u Check that the standby pressure P is correct.

Standby pressure P bar 32±2

u Adjust the adjusting screw of the flow regulator 1.
Note
To adjust the flow regulator:
u Turning the adjusting screw clockwise increases the standby pressure.
u Turning the adjusting screw anticlockwise reduces the standby pressure.
u Repeat the procedure and adjustment until the required value is attained.
u Disconnect the pressure gauge from the high pressure test connection P.
030.6.5.2 Z kinematics control valve block secondary pressure relief

valves
Valid for: L538-1493/31405-;
To check the secondary pressure relief valves, some of them must be set to a
lower value. (For more information see: Preparatory tasks, page 030-131)
LBH/11827693/02/211-20150615.1139/en
copyright by
030-130 L538-1493
Fig. 131: Z kinematics control valve block secondary pressure relief valves
1 Secondary pressure relief valve 4 Secondary pressure relief valve
for tilting in for 3rd function A3 (optional)
for tilting out for 3rd function B3 (optional)
3 Secondary pressure relief valve P Working hydraulics pump high
for raising lift arms pressure test connection
Preparatory tasks
Unscrew the adjusting screw on the following secondary pressure relief valves by
half a turn:
u Secondary pressure relief valve for tilting in 1
u Secondary pressure relief valve for tilting out 2
u Secondary pressure relief valve for raising lift arms 3
w The opening pressure of the secondary pressure relief valves is below the
opening pressure of the LS pressure cut-off.
Testing and adjusting

u Start the engine.
u Activate the lifting, tilting out and tilting in functions, as well as the optional addi-
tional functions, as far as they will go in succession and then operate fully. Keep
the engine speed at around 1200 rpm.
LBH/11827693/02/211-20150615.1139/en
Note
The lowering function has no secondary pressure relief valve.
u The lowering function cannot be tested.
u Check that the high pressure P is correct.

High pressure P during tilting in 1 bar 220±5
High pressure P during tilting out 2 bar 220±5
copyright by
L538-1493 030-131

High pressure P during lifting 3 bar 250±5
High pressure P during 3rd function A3 4 (op- bar 250±5
tional)
High pressure P during 3rd function B3 5 (op- bar 250±5
tional)

u Turn the adjusting screw of the corresponding secondary pressure relief valve.
Note
To adjust the secondary pressure relief valves:
After completing testing and adjustment

When all the values are correct:
Screw in the adjusting screw on the following secondary pressure relief valves by
precisely half a turn:
u Secondary pressure relief valve for tilting out 2
030.6.5.3 P kinematics control valve block secondary pressure relief

valves
Valid for: L538-1493/31405-;
To check the secondary pressure relief valves, some of them must be set to a
lower value. (For more information see: Preparatory tasks, page 030-133)
LBH/11827693/02/211-20150615.1139/en

copyright by
030-132 L538-1493
Fig. 132: Control valve block secondary pressure relief valves

for tilting in for 3rd function A3 (optional)
for tilting out for 3rd function B3 (optional)
3 Secondary pressure relief valve P Working hydraulics pump high
for raising lift arms pressure test connection
Preparatory tasks
Unscrew the adjusting screw on the following secondary pressure relief valves by
half a turn:
w The opening pressure of the secondary pressure relief valves is below the
opening pressure of the LS pressure cut-off.

u Start the engine.
u Activate the lifting, tilting out and tilting in functions, as well as the optional addi-
tional functions, as far as they will go in succession and then operate fully. Keep
the engine speed at around 1200 rpm.
Note
LBH/11827693/02/211-20150615.1139/en
The lowering function has no secondary pressure relief valve.

u The lowering function cannot be tested.

High pressure P during tilting in 1 bar 220±5
High pressure P during tilting out 2 bar 150±5
High pressure P during lifting 3 bar 250±5
copyright by
L538-1493 030-133

High pressure P during 3rd function A3 4 (op- bar 250±5
tional)
High pressure P during 3rd function B3 5 (op- bar 250±5
tional)

u Turn the adjusting screw of the corresponding secondary pressure relief valve.
Note
To adjust the secondary pressure relief valves:

When all the values are correct:
Screw in the adjusting screw on the following secondary pressure relief valves by
precisely half a turn:

Valid for: L538-1493/31405-;
LBH/11827693/02/211-20150615.1139/en
copyright by
030-134 L538-1493
Fig. 133: Working hydraulics LS pressure cut-off
u Start the engine.
u Raise the lift arms as far as they will go.
u Increase the engine speed and activate the lifting function fully. Keep the engine
speed at approximately 1200 rpm.

High pressure P bar 330±5

u Adjust the working hydraulics LS pressure cut-off 1 adjusting screw.
Note
To adjust the LS pressure cut-off:
u Turning the adjusting screw clockwise increases the high pressure.
u Turning the adjusting screw anticlockwise reduces the high pressure.
LBH/11827693/02/211-20150615.1139/en


Valid for: L538-1493/31405-;
ments.
copyright by
L538-1493 030-135
Fig. 134: Stabilisation module cut-off function
u Connect a pressure gauge (600 bar) to the hydro accumulator load pressure
test connection MX on the stabilization module.
u Start the engine.
u Make sure that ride control is switched off.
u Raise the lift arms as far as they will go.
u Increase the engine speed and activate the lifting function fully. Keep the engine
speed at approximately 1200 rpm.
w The pressure shown on the pressure gauge MX increases until it reaches
the hydro accumulator load pressure and then drops again.
u Check that the highest value shown corresponds to the hydro accumulator load
pressure.

Hydro accumulator load pressure MX bar 120±10

u Check the stabilisation module for damage.
u Disconnect the pressure gauge from the hydro accumulator load pressure test
connection MX.
030.6.5.6 Ride control hydro accumulator (optional), nitrogen filling

LBH/11827693/02/211-20150615.1139/en
Valid for: L538-1493/31405-;

q A testing and filling device for hydro accumulators with a nitrogen cylinder and
pressure reducer is available.
Preparations
The ride control must be depressurised hydraulically.
copyright by
030-136 L538-1493
Fig. 135: Relieving the pressure of the ride control hydro accumulator
WARNING
Beware of injury from lift arms lowering.
u Make sure that the full weight of the lift arms rests on the ground.
u Connect the test line to the brake pressure test connection M4 on the front axle.
u Use the test line to connect the front axle brake pressure test connection M4 to
the hydro accumulator load pressure test connection MX on the stabilization
module.
u Wait 5 minutes.
w The hydraulic pressure in the hydro accumulator is relieved into the tank via
the compact brake valve.
u Disconnect the test line from test connection M4 and drain the remaining fluid
into the collecting pan.
Note
The hydro accumulator must not be under pressure during testing.
u Leave the test line connected to the test connection MX during testing.

LBH/11827693/02/211-20150615.1139/en
Fig. 136: Nitrogen filling of ride control hydro accumulator

1 Hydro accumulator ride control 8 Pressure control valve
See next page for continuation of the image legend
copyright by
L538-1493 030-137
2 Hydro accumulator plug 9 Output valve of the pressure re-

ducer
3 Nitrogen cylinder 10 Testing and filling device
4 Cylinder valve 11 Hydro accumulator filling pressure
gauge
5 Pressure reducer 12 Handwheel
6 Cylinder pressure gauge 13 Drain valve
7 Output pressure gauge
u Unscrew the protective cap on the hydro accumulator 1.
Note
The hydro accumulator 1 does not have an integrated check valve.
u Only loosen the hydro accumulator plug 2 before attaching the testing and filling
device.
u Only screw on the hydro accumulator plug 2 with the handwheel of the testing
and filling device.
u Loosen the hydro accumulator plug 2 (spanner size 6 mm).

u Screw the testing and filling device 10 on to the hydro accumulator.
w The hydro accumulator plug 2 can be opened with the handwheel 12.
u Open the hydro accumulator plug 2 with the handwheel 12.
u Check that the hydro accumulator filling pressure 11 is correct.

Filling pressure at a hydro accumulator tem- bar 23±2
perature of 0 °C
perature of 10 °C
perature of 20 °C
perature of 30 °C
If the filling pressure is too low:

u Open the cylinder valve 4 of the nitrogen cylinder 3.
u Adjust the pressure control valve 8 of the pressure reducer 5 until the required
value is reached on the output pressure gauge 7.
u Open the output valve of the pressure reducer 9.
LBH/11827693/02/211-20150615.1139/en
u Wait 2 minutes.
u Close the output valve of the pressure reducer 9.
If the filling pressure is too high:
u Release nitrogen through the drain valve 13 of the hydro accumulator 1 until the
filling pressure is correct.

u Close the hydro accumulator plug 2 with the handwheel 12.
u Remove the testing and filling device 10.
copyright by
030-138 L538-1493
u Tighten the hydro accumulator plug 2 to a tightening torque of 20 Nm.

u Check the tightness of the hydro accumulator plug 2 with a leak spray.
u Screw the protective cap on to the hydro accumulator 1.
u Disconnect the test line from the test connection MX.

Valid for: L538-1493/31405-;
Check that the leakage from the spools in the control valve block is in the tolerance
range.
Test for leaks when one of the following problems occurs:
– The lift arms come down too quickly when the bucket is loaded and the working
hydraulics are not actuated. Check the lift cylinder spool valve.
– The loaded bucket tilts out when the working hydraulics are not actuated: Check
the tilt cylinder spool valve.
– When the bucket is tilted in it starts to wobble when the machine is travelling:
Check the tilt cylinder spool valve.
Make sure the hydraulic oil and control valve block are at the correct temperature
for testing. (For more information see: Bringing the machine up to operating tem-
perature, page 030-125)
Note
The control valve must be fully warmed up to test temperature before testing.
To bring the control valve block to the test temperature:
u Bring the hydraulic oil to test temperature and then continue warming up the
machine for at least another 10 minutes.
Hydraulic oil Viscosity Test temperature

°C
Liebherr Hydraulic Basic 68 ISO VG 68 53
Liebherr Hydraulic Basic 100 ISO VG 100 62
Liebherr Hydraulic HVI ISO VG 46 44
Liebherr Hydraulic Plus ISO VG 46 44
Tab. 43: Test temperature for hydraulic oils

q The hydraulic oil is at test temperature.
LBH/11827693/02/211-20150615.1139/en
q The control valve block is at test temperature.

q Material is available for loading the bucket.
copyright by
L538-1493 030-139
Checking the lift cylinder spool (Z and P kinematics)
Fig. 137: Working hydraulics pump
u Connect a pressure gauge (250 bar) to the load sensing pressure test connec-
tion LS on the working hydraulics pump.
u Start the engine and load the bucket.
u Raise the lift arms at low idling speed until the pressure shown on the pressure
gauge LS is 160±5 bar.
Note
If the pressure is not reached:
u Pressure too low: Load the bucket more.
u Pressure too high: Load the bucket less.
LBH/11827693/02/211-20150615.1139/en
Fig. 138: Marking the position of the lift cylinder
u On the piston rod of a lift cylinder, mark the distance X = 100 mm to the piston
rod bearing.
u Wait 10 minutes.
u Measure the distance X between the piston rod bearing and the mark.
copyright by
030-140 L538-1493

The distance X must be at least mm 64
If the distance X is less than the minimum:

u Check the secondary pressure relief valves for leaks (check visually, inter-
changing if necessary).
If the distance X is more than the minimum:
u The leakage is within the tolerance range. Disconnect the pressure gauge from
the load sensing pressure test connection LS.
Checking the tilt cylinder spool (P kinematics only)
Note
For z kinematics, the tilt cylinder spool has a low-leak valve (valve to prevent leak-
age). The tilt cylinder spool can therefore not be tested with Z kinematics.
u Connect a pressure gauge (250 bar) to the load sensing pressure test connec-
tion LS on the working hydraulics pump.
u Start the engine and load the bucket.
u Move the lift arms into the transport position.
u Tilt the bucket out a little.
u Tilt in the bucket at low idling speed until the pressure shown on the pressure
LBH/11827693/02/211-20150615.1139/en
gauge LS is 160±5 bar.
Note
If the pressure is not reached:
u Pressure too low: Load the bucket more.
u Pressure too high: Load the bucket less.
copyright by
L538-1493 030-141
Fig. 140: Marking the position of the tilt cylinder
u On the piston rod of a tilt cylinder, make a mark on the piston rod bearing.
u Wait 10 minutes.
u Measure the distance X between the piston rod bearing and the mark.

The maximum distance X is mm 11
If the distance X is more than the maximum:

If the distance X is less than the maximum:
u The leakage is within the tolerance range. Disconnect the pressure gauge from
the load sensing pressure test connection LS.
030.6.6 Travel hydraulics

Valid for: L538-1493/31405-;
LBH/11827693/02/211-20150615.1139/en
copyright by
030-142 L538-1493
Fig. 141: Travel pump replenishing pressure relief valve
u Connect a pressure gauge (40 bar) to the replenishing pressure test connec-
tion G on the travel pump.
u Start the engine.
u Increase the engine speed to the upper idle speed.
u Check that the replenishing pressure G is correct.

Replenishing pressure G bar 34±2

CAUTION
u Wear safety glasses and oil-proof protective gloves.
Note
Use a vacuum pump to prevent loss of oil.
u Connect the vacuum pump on the hydraulic tank to the opening of the breather
filter.
LBH/11827693/02/211-20150615.1139/en
u Unscrew the replenishing pressure relief valve 1.

If the replenishing pressure is too low:
u Insert adjustment shims 2.
If the replenishing pressure is too low:
u Remove the adjustment shims 2.
u Screw in thereplenishing pressure relief valve 1.
copyright by
L538-1493 030-143

u Disconnect the pressure gauge from the replenishing pressure test connec-
tion G.

Valid for: L538-1493/31405-;
To check the high pressure relief valves, the pressure cut-off must be set to a
higher value. (For more information see: Preparatory tasks, page 030-144)
Fig. 142: Travel pump high pressure relief valves

1 Forward high pressure relief valve 3 Pressure cut-off
2 Reverse high pressure relief valve MH Travel pump high pressure test
connection
Preparatory tasks
u Connect a pressure gauge (600 bar) to the high pressure test connection MH
on the travel pump.
u Screw in the adjusting screw of the pressure cut-off 3 by one turn.
w The opening pressure of the pressure cut-off is above the opening pressure
of the high pressure relief valves.
LBH/11827693/02/211-20150615.1139/en

u Start the engine.
u In the variables editor, select the Block curve calibration folder.
u Set the PumpBlockManual variable to 1.
w The machine is in the blocked condition.
copyright by
030-144 L538-1493
Note
The PumpBlockManual variable is automatically reset to 0 when the ignition is
switched “OFF”/“ON”.
u If necessary, reset the variable to 1 when repeating the test.
WARNING
Beware of accidents caused by the machine pulling away unintentionally.
u Do not let people near the machine.
u Be ready to brake when increasing the engine speed.
NOTICE
A rapid increase in temperature can damage the travel pump.
u Stop the testing for a brief period.
u Select forward or reverse travel direction and increase the engine speed to the
maximum.
u Check that the high pressure MH is correct.

High pressure MH in forward travel direction 1 bar 495±10
High pressure MH in reverse travel direction 2 bar 495±10

Fig. 143: High pressure relief valve

1 Valve insert 4 Valve bearing
LBH/11827693/02/211-20150615.1139/en
2 Plug 5 Lock screw

3 Adjusting screw
CAUTION
u Wear safety glasses and oil-proof protective gloves.
copyright by
L538-1493 030-145
Note
Use a vacuum pump to prevent loss of oil.
u Connect the vacuum pump to the hydraulic tank, at the opening of the breather
filter.
u Unscrew the relevant high pressure relief valve.

u Detach the drain plug 2 from the valve insert 1.
u Unscrew the lock screw 5.
u Clamp the valve bearing 4 in a vice with protective jaws.
u Adjust the spring preload by turning the adjusting screw 3 (a quarter turn corre-
sponds to about 20 bar).
u Tighten the lock screw 5.
u Screw in the high pressure relief valve.

u Unscrew the adjusting screw of the pressure cut-off by one turn.
u Check the pressure cut-off (For more information see: Travel pump pressure
cut-off, page 030-146)

Valid for: L538-1493/31405-;
LBH/11827693/02/211-20150615.1139/en
Fig. 144: Travel pump pressure cut-off
on the travel pump.
u Start the engine.
copyright by
030-146 L538-1493

w Machine is in the blocked condition.
Note
switched OFF/ON.
WARNING
u Keep the area around the machine clear of people.
u Select forward travel direction and increase the engine speed to the maximum
engine speed.

High pressure MH bar 440±5

u Adjust the pressure cut-off 1 adjusting screw.
Note
To adjust the pressure cut-off:
u Repeat the check.
u Check that the engine droop is correct.

LBH/11827693/02/211-20150615.1139/en
Maximum engine droop rpm 50
Note
If the engine droop is too high, this indicates that there is a fault in the travel hy-
draulics (e.g. a high degree of leakage in the closed circuit or a malfunction of the
pressure cut-off).
u Check the travel hydraulics for damage.
u Disconnect the pressure gauge from the high pressure test connection MH.
copyright by
L538-1493 030-147

Valid for: L538-1493/31405-;
Fig. 145: Travel pump block curve calibration
on the travel pump.
u Start the engine.
Note
u Set the AdjustPump variable to 1.

w The engine speed is limited to 930 rpm.
u Select forward travel direction and carefully press the accelerator pedal all the
LBH/11827693/02/211-20150615.1139/en
way down.
w The engine speed is 930 rpm.

High pressure at engine speed of 930 rpm bar 100±10

u Change the value of the PumpI0930JD variable.
copyright by
030-148 L538-1493
Note
In order to approach the required value, the value of the variable can be changed
gradually while pressing the accelerator pedal.
u Click the variable and press the space bar (the line is coloured pink).
u Cursor up/down: Last digit of the value +/- 1
u Cursor left/right: Last digit of the value +/- 5
u Page up/down: Last digit of the value +/- 10

u Set the AdjustPump variable to 2 and repeat the procedure (changing the
PumpI1300JD variable).

High pressure MH at engine speed of bar 270±10
1300 rpm
PumpI1600JD variable).

1600 rpm
PumpI1900JD_EM variable).

1900 rpm
If the required values are reached:


Valid for: L538-1493/31405-;
LBH/11827693/02/211-20150615.1139/en

copyright by
L538-1493 030-149
Fig. 146: Travel motor 1 start of regulation
on the travel pump.
u Connect a pressure gauge (600 bar) to the test connection M1 on travel motor
1.
u Start the engine.
Note
WARNING
u Do not let people near the machine.
u Select forward travel direction and increase the engine speed until the high
pressure gauge MH displays approximately 350 bar.
LBH/11827693/02/211-20150615.1139/en
u Slowly reduce the engine speed until the servo pressure gauge M1 displays
50±10 bar.
u While doing so, check whether the high pressure MH is correct.

High pressure MH bar 290±10

u Adjust the adjusting screw 1 on travel motor 1.
copyright by
030-150 L538-1493
Note
For setting the start of regulation:
u Turning the adjusting screw clockwise reduces the high pressure MH.
u Turning the adjusting screw anticlockwise increases the high pressure MH.

u Disconnect the pressure gauge from the servo pressure test connection M1.

Valid for: L538-1493/31405-;
ments.
Fig. 147: Travel motor 2 automatic calibration
u Start the engine.

u In the variables editor, select the Variable displacement motor calibration
folder.
u Set the AdjustMot2 variable to 1.
w The automatic calibration is started. The engine speed and the current to the
proportional solenoid of the control piston are automatically regulated.
w Once automatic calibration is complete, the AdjustMot2 variable is reset to
0.
LBH/11827693/02/211-20150615.1139/en
w Once the automatic calibration has been completed, a service code appears.
If the service code E5022 appears:
u Automatic calibration has been successfully completed.
If a service code other than E5022 appears:
u Adjust the adjusting screw 1 on travel motor 2 in terms of the table.
Service Cause Remedy

code
503A Maximum current too low (below Unscrew the adjusting screw
560 mA)
copyright by
L538-1493 030-151
Service Cause Remedy

code
503B Maximum current too high (above Screw in the adjusting screw
680 mA)
503C Minimum current too high (above Screw in the adjusting screw
290 mA)
503D Minimum current too low (below Unscrew the adjusting screw
160 mA)
Tab. 44: Remedies and service codes
u Repeat the automatic calibration and adjustment until the automatic calibration
is successfully completed.

Valid for: L538-1493/31405-;
If the engine output is poor, the engine speed falls below the set value.
q The prescribed maintenance tasks have been performed in accordance with the
maintenance schedule.
q The operating pressures of the travel hydraulics were checked in terms of the
adjustment checklist.
Fig. 148: Checking the engine power output
u Connect a pressure gauge (600 bar) to the test connection MH.

u In the variables editor in the group structure, select the Check diesel engine
folder.
LBH/11827693/02/211-20150615.1139/en
u Set the InchOFF variable to 1.

w The inching function is deactivated.
WARNING
u Keep the area in front of the machine and right next the machine clear of peo-
ple.
u Start the engine, select fixed gear 1 and forward travel direction.
copyright by
030-152 L538-1493
u Hold the machine with the service brake and run it at full throttle.
u Slowly release the service brake and check whether the required engine speed
is reached at the set test pressure.
Machine Test pressure Engine speed limit value

L524-1355 250±5 bar 2150 rpm
L524-1585 250 ±5
bar 2150 rpm
L524-1557 250±5 bar 2150 rpm
L538-1356 290 ±5
bar 2150 rpm
L538-1493 290±5 bar 2150 rpm
Tab. 45: Engine speed limit value
If the engine speed falls below this limit value:

u Troubleshoot the engine (air filter, fuel filter etc.) or the travel hydraulics (check
the operating pressures).
Once the test has been completed:
u Reset the InchOFF variable to 0.
w The inching function is activated.
030.6.7 Steering system

Valid for: L538-1493/31405-;
q The machine is in the maintenance position for testing and adjustments (without
wedges).
LBH/11827693/02/211-20150615.1139/en
Fig. 149: Steering system LS pressure cut-off
u Start the engine.
u Raise the lift arms slightly and turn the steering wheel of the machine in one di-
rection as far as it will go.
copyright by
L538-1493 030-153
u Increase the engine speed and continue turning in. Keep the engine speed at
approximately 1200 rpm.

High pressure P bar 210±5

u Adjust the steering system LS pressure cut-off 1 adjusting screw.
Note
To adjust the LS pressure cut-off:
030.6.8 Brake system
030.6.8.1 Compact brake valve, hydro accumulator charging function

Valid for: L538-1493/31405-;
ments.
LBH/11827693/02/211-20150615.1139/en
Fig. 150: Compact brake valve, hydro accumulator charging function
u Connect a pressure gauge (600 bar) to the accumulator charge pressure test
connection M3 on the compact brake valve.
u Start the engine.
u Press the compact brake valve down as far as it will go several times until the
accumulator charge pressure M3 has dropped down to the cut-in pressure.
copyright by
030-154 L538-1493
w Once the cut-in pressure is reached, the accumulator charge pressure M3

increases again.
u Check that the cut-in pressure is correct.

Cut-in pressure bar 130±10
u Check whether the accumulator charge pressure M3 increases up to the cut-off

pressure.

Cut-off pressure bar 160±10
If the required values are not reached:

u Adjust the adjusting screw of the pressure balance pilot valve 1.
Note
To adjust the cut-in pressure and cut-out pressure:
u Turning the adjusting screw clockwise increases the cut-in pressure and cut-out
pressure.
u Turning the adjusting screw anticlockwise reduces the cut-in pressure and cut-
out pressure.
u Disconnect the pressure gauge from the accumulator charge pressure test con-
nection M3.

Valid for: L538-1493/31405-;
ments.
LBH/11827693/02/211-20150615.1139/en
Fig. 151: Service brake pressure
copyright by
L538-1493 030-155
u Connect a pressure gauge (600 bar) to the brake pressure test connection M4
on the front axle.
on the rear axle.
u Start the engine.
u Press the compact brake valve down as far as it will go.
u Check that the brake pressure on both pressure gauges is correct.

Brake pressure bar 60±5
If the required values are not reached:

u Adjust the stop screw 1.
u Repeat the procedure and adjustment until the required values are attained.
u Disconnect the pressure gauge from the brake pressure test connection M4.

Valid for: L538-1493/31405-;
Make sure that the machine is in maintenance position for testing and adjustments.
LBH/11827693/02/211-20150615.1139/en
copyright by
030-156 L538-1493
Fig. 152: Service brake hydro accumulator capacity

1 Front axle hydro accumulator M4 Front axle brake pressure test
connection
2 Rear axle hydro accumulator M5 Rear axle brake pressure test con-
nection
M3 Accumulator charge pressure test
connection
on the front axle.
on the rear axle.
u Start the engine.
u After waiting for half a minute, turn off the engine.
w The front axle hydro accumulator 1 and the rear axle hydro accumulator 2
are charged.
LBH/11827693/02/211-20150615.1139/en
u Slowly press the compact brake valve down several times until the accumulator
charge pressure M3 is 130 bar.
u Slowly press the compact brake valve down nine times and then keep it press-
ed down.
u Check that the brake pressure shown by the pressure gauge on M4 and the
pressure gauge on M5 is above the required value.

Brake pressure at least bar 50
copyright by
L538-1493 030-157
If the required value at the front axle brake pressure test connection M4 is not
reached:
u Replace the front axle hydro accumulator 1.
If the required value at the rear axle brake pressure test connection M5 is not
reached:
u Replace the rear axle hydro accumulator 2.
nection M3.

Valid for: L538-1493/31405-;
Fig. 153: Accumulator charge pressure switch shift pressure

1 Accumulator charge pressure M3 Accumulator charge pressure test
switch connection
2 Brake system accumulator pres-
sure symbol field
u Slowly press the compact brake valve down several times until the brake sys-
LBH/11827693/02/211-20150615.1139/en
tem accumulator pressure symbol field in the display lights up.

u Check that the shift pressure M3 is correct.

Shift pressure M3 bar 90±5

u Turn off the ignition and take out the key.
u Replace the accumulator charge pressure switch 1.
u Repeat the test.
copyright by
030-158 L538-1493

u Turn off the ignition and take out the key.
nection M3.
030.6.9 Electrical system
030.6.9.1 Repairing the Tuple Chain on the central control unit (UEC3)
Valid for: L538-1493/31405-;
The tuple chain is an ordered sequence of data in the central control unit. Errors in
this order can cause the central control unit to malfunction.
The tuple chain may only be repaired if the central control unit no longer functions
or software updates are no longer possible.
To repair the tuple chain, you must make a connection via Terminal Plugin. Then
change the authorisation level to Service.
Connecting to the central control unit via Terminal Plugin and

changing the authorisation level to “Service”
Fig. 154: Connecting to the central control unit via Terminal Plugin
u Start the Sculi diagnostic software and connect to the central control unit via
LBH/11827693/02/211-20150615.1139/en
Terminal Plugin.
w The login window opens.
copyright by
L538-1493 030-159
Fig. 155: Entering testsys
u Enter testsys and press “Enter” to confirm.

w A connection is made to the central control system.
Fig. 156: Service codes screen
You can navigate in the menu bar using the numerical keys.
If service codes are present on the machine, a screen showing them appears. Use
the BACK button to return to the main screen.
u Select the BACK button.
w The main screen appears. LBH/11827693/02/211-20150615.1139/en
Fig. 157: Main screen
copyright by
030-160 L538-1493
u Highlight the PME1 Code 2 .

u Right-click to copy the PME1 Code.
u Open the CodeGen 1 function.
Fig. 158: Code Generator

1 Terminal emulator 3 Access Code
2 System Code 4 Generate function
u Right-click to insert the PME1 code in the System Code line 2. (Spaces may be
inadvertently inserted when you do this. You must delete these before generat-
ing the access code.)
u Use the Generate 4 function to generate an access code 3.
u Right-click to copy the Access Code.
u Go back to the Terminal emulator 1.
Fig. 159: Inserting the access code

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u Select the Change Level button.

w The screen for inserting the access code appears.
u Right-click to insert the access code.
u Press “Enter” to confirm.
w The level is changed to “Service” .
w You are now authorised to perform additional tasks.
copyright by
L538-1493 030-161
Repairing the Tuple Chain on the central control unit (UEC3)
Fig. 160: Make sure the level has been changed to “Service” .
u Select the NEXT CMD PAGE button.
u Select the NEXT CMD PAGE button again.
w The screen with the Tuples button appears.
Fig. 161: Screen with Tuples button
u Select the Tuples button.

w The Tuple list is displayed.
LBH/11827693/02/211-20150615.1139/en
copyright by
030-162 L538-1493
Fig. 162: Tuple list

w The screen with the REPAIR CHAIN button appears.
Fig. 163: Screen with REPAIR CHAIN button
u Select the REPAIR CHAIN button.

w The Tuple Chain is repaired.
w A text in the navigation bar confirms that the tuple chain has been repaired.
After carrying out the repair, you must check that the Tuple Chain is functioning
correctly.
w The screen with the CHECK CHAIN button appears.
LBH/11827693/02/211-20150615.1139/en
copyright by
L538-1493 030-163
Fig. 164: The CHECK CHAIN button appears
u Select the CHECK CHAIN button.

w The following text should appear. Tuple chain is OK
If this test does not appear:
u Reset the central control unit (UEC3).

Valid for: L538-1493/31405-;
Note
Resetting the central control unit deletes all the settings on the machine.
If you are unsure of what the status was when the machine was delivered, contact
the technical customer service department.
u Save the settings if possible.
The central control unit can be reset if the following conditions are met:
– If the tuple chain has been repaired, but the central control unit still does not
work.
– If the service code E3002 is shown on the display and the value of the FlagIFM-
PressureSw variable is greater than 1.
To reset the central control unit, you must establish a connection via Terminal Plu-
gin. Then change the authorisation level to Service.
LBH/11827693/02/211-20150615.1139/en
copyright by
030-164 L538-1493
Connecting to the central control unit via Terminal Plugin and

changing the authorisation level to “Service”
Fig. 165: Connecting to the central control unit via Terminal Plugin
u Start the Sculi diagnostic software and connect to the central control unit via
Terminal Plugin.
w The login window opens.
Fig. 166: Entering testsys
u Enter testsys and press “Enter” to confirm.

LBH/11827693/02/211-20150615.1139/en
w A connection is made to the central control system.
copyright by
L538-1493 030-165
Fig. 167: Service codes screen
If service codes are present on the machine, a screen showing them appears. Use
the BACK button to return to the main screen.
u Select the BACK button.
w The main screen appears.
Fig. 168: Main screen
u Highlight the PME1 Code 2 .

u Right-click to copy the PME1 Code.
u Open the CodeGen 1 function.
LBH/11827693/02/211-20150615.1139/en
copyright by
030-166 L538-1493
Fig. 169: Code Generator

1 Terminal emulator 3 Access Code
2 System Code 4 Generate function
u Right-click to insert the PME1 code in the System Code line 2. (Spaces may be
inadvertently inserted when you do this. You must delete these before generat-
ing the access code.)
u Use the Generate 4 function to generate an access code 3.
u Right-click to copy the Access Code.
u Go back to the Terminal emulator 1.
Fig. 170: Inserting the access code
u Select the Change Level button.

u Right-click to insert the access code.
LBH/11827693/02/211-20150615.1139/en
w The level is changed to “Service” .

w You are now authorised to perform additional tasks.
copyright by
L538-1493 030-167
Resetting the central control unit (UEC3)
Fig. 171: Make sure the level has been changed to “Service” .

u Select the NEXT CMD PAGE button again.
w The screen with the EXECUTE TEXT CMD button appears.
Fig. 172: Performing a reset
u Select the EXECUTE TEXT CMD button.

u Enter the following text: INIT_UEC3
w The central control unit is reset.
LBH/11827693/02/211-20150615.1139/en
w Note: The reset is not confirmed with a message. Around 30 seconds after
pressing “Enter”, you can assume that a reset has been performed.
After a reset, the machine software must be reloaded and the machine data must
be configured again.
u Switch on the battery main switch.
u Install the machine software.
u Configure the machine data.
u Carry out any tests and maintenance tasks for which values are stored in the
central control unit.
copyright by
030-168 L538-1493
If you carried out the reset because of service code E3002, you must check the
FlagIFMPressureSw variable.
u Check that the value of the FlagIFMPressureSw variable is 1.

Valid for: L538-1493/31405-;
q A testing and filling device for hydro accumulators with a nitrogen cylinder and
pressure reducer is available.
Fig. 173: Transmission hydro accumulator nitrogen filling

1 Transmission hydro accumulator 8 Pressure control valve
2 Hydro accumulator plug 9 Output valve of the pressure re-
ducer
3 Nitrogen cylinder 10 Testing and filling device
4 Cylinder valve 11 Hydro accumulator filling pressure
gauge
5 Pressure reducer 12 Handwheel
6 Cylinder pressure gauge 13 Drain valve
7 Output pressure gauge
u Unscrew the protective cap on the hydro accumulator 1.
LBH/11827693/02/211-20150615.1139/en
Note
The hydro accumulator 1 does not have an integrated check valve.
u Only loosen the hydro accumulator plug 2 before attaching the testing and filling
device.
u Only screw on the hydro accumulator plug 2 with the handwheel of the testing
and filling device.
u Loosen the hydro accumulator plug 2 (spanner size 6 mm).

u Screw the testing and filling device 10 on to the hydro accumulator.
w The hydro accumulator plug 2 can be opened with the handwheel 12.
u Open the hydro accumulator plug 2 with the handwheel 12.
copyright by
L538-1493 030-169
u Check that the hydro accumulator filling pressure 11 is correct.

perature of 0 °C
perature of 10 °C
perature of 20 °C
perature of 30 °C
If the filling pressure is too low:

u Open the cylinder valve 4 on the nitrogen cylinder 3.
u Adjust the pressure control valve 8 on the pressure reducer 5 until the output
pressure gauge 7 shows the required pressure.
u Open the output valve of the pressure reducer 9.
u Wait 2 minutes.
u Close the output valve of the pressure reducer 9.
If the filling pressure is too high:
u Release nitrogen through the drain valve 13 of the hydro accumulator 1 until the
filling pressure is correct.
u Close the hydro accumulator plug 2 with the handwheel 12.
u Remove the testing and filling device 10.
u Tighten the hydro accumulator plug 2 to a tightening torque of 20 Nm.
u Check the tightness of the hydro accumulator plug 2 with a leak spray.
u Screw the protective cap onto the hydro accumulator 1.
LBH/11827693/02/211-20150615.1139/en
copyright by
030-170 L538-1493
040 Drive group
Contents
040.1 Engine 040-2
L538-1493/31405-; 040-2
L538-1493/31405-; 040-6
L538-1493/31405-; 040-7
L538-1493/31405-; 040-7
040.1.5 Fuel system 040-8
L538-1493/31405-; 040-8
L538-1493/31405-; 040-15
L538-1493/31405-; 040-16
L538-1493/31405-; 040-17
040.1.6 Air filter system 040-17
L538-1493/31405-; 040-18
L538-1493/31405-; 040-19
040.2 Coupling
LBH/11827693/02/211-20150615.1139/en
L538-1493/31405-; 040-20
copyright by
L538-1493 040-1
Drive group Service manual
Engine
040.1 Engine

Valid for: L538-1493/31405-;
1.1 Layout
Fig. 174: Engine

1 Drain plug 7 Tensioning device
2 Oil filter 8 Auxiliary drive (gear pump)
3 Dipstick 9 Coolant return line
4 Fuel pre-filter 10 Cooling water drain valve
5 Fuel fine filter 11 Oil pan
6 Alternator
LBH/11827693/02/211-20150615.1139/en
copyright by
040-2 L538-1493
Service manual Drive group
Engine
Fig. 175: Engine

1 Crankcase 10 Turbocharger
2 High pressure fuel pump position 11 Valve cover
sensor
3 Control valve (metering unit) 12 Engine control unit
4 High pressure fuel pump 13 Cylinder head
5 Fuel temperature sensor 14 Turbocharger lubricating oil return
line
6 Starter 15 Rail pipe
7 Thermostat 16 Flywheel
8 Exhaust manifold 17 Fastening for engine bearing
9 Water pump outlet
LBH/11827693/02/211-20150615.1139/en
copyright by
L538-1493 040-3
Engine
Fig. 176: Engine

1 Cooling water temperature sensor 5 Crankshaft speed sensor
2 Rail pressure control valve plug 6 Rail pressure control valve
3 Rail pipe 7 High pressure fuel pump
4 Rail pressure sensor 8 Fuel temperature sensor
The engine is installed crosswise on the rear section and is elastically supported by
rubber elements. The flywheel end faces left.
The engine has the following design features:
– Turbocharger
– Charge air cooling
– Water-cooled, four-stroke engine with direct injection
– Maintenance-free gear drive for lubricating oil pump and auxiliary drive for gear
pump
– Light alloy pistons with oil injection cooling
– Cast crankshaft with sliding bearing
– Forged connecting rod with sliding bearing
Cylinder 1 is on the water pump side, cylinder 4 is on the flywheel side
2.1 Basic function

The integrated diesel engine is a water-cooled, four-stroke in-line engine with com-
LBH/11827693/02/211-20150615.1139/en
mon rail direct injection, turbocharger and intercooler.

The engine converts the chemical energy of the fuel into mechanical energy. This
energy is transmitted through the flywheel and the torsion absorber of the travel
and working hydraulics pumps.
A small part of the power is taken off and used for driving the following gear
pumps:
– Fan gear pump
– Brake system gear pump
copyright by
040-4 L538-1493
Engine
2.2 Documentation
Note
The operating manual and workshop manual on the engine can be found in the
John Deere Service Advisor or the Liebherr Service documentation.
u Documentation -> Diesel engines -> John Deere -> Wheel loaders -> Tier 3 -
Level III-A -> CD4045
The operating manual contains the following information:

– Motor operation
– Lubricants and fuels
– Maintenance
– Troubleshooting
– Idle position
– Technical data
– etc.
The workshop manual contains the following information:
– Repairing and adjusting the engine
– Function description
– Diagnosis
– Other aids
– Technical data
2.3 Type designation
John Deere Description

40 45 H F 2 8 6 Engine type designation
40 Number of cylinders: 40 = 4 cylinders
45 Displacement: 45 = 4.5 litres
H With turbocharger and air-to-air intercooling
F OEM (John Deere Power Systems)
2 Valves per cylinder
8 Emission stage: 8 = Tier 3
6 Manufacturer’s internal designation
Tab. 46: Description of the type designation

LBH/11827693/02/211-20150615.1139/en
copyright by
L538-1493 040-5
Engine

Valid for: L538-1493/31405-;
1 Layout
Fig. 177: Crankshaft speed sensor
The crankshaft speed sensor is on the right, in the front cover.
2 Function
The speed sensor is an inductive sensor. Inductive sensors are electromagnetic
components with a permanent magnet and coil.
The distance a between the sensor and flywheel sprocket is set to a fixed value.
A ring gear with 45 uniformly sized and spaced teeth is installed on the spur gear.
At one position there is a gap three teeth wide.
Due to the principle of induction, a sine voltage wave is generated between the
teeth. The control unit detects these waves and converts them. Each position with
the three missing teeth leads to an interruption, and is required for detecting the
upper dead centre position in cylinder 1.
The speed-proportional frequency of the generated voltage is used for the following
functions:
– Control of the injection times
– Monitoring the speed
– Load limiting function
– Overspeed protection
– Diagnostics
LBH/11827693/02/211-20150615.1139/en
copyright by
040-6 L538-1493
Engine

Valid for: L538-1493/31405-;
1 Layout
Fig. 178: Temperature sensor with symbol
2.1 Basic function

The fuel temperature sensor is installed in the high pressure fuel pump. Its job is to
signal the fuel temperature to the engine control unit in the form of electrical resist-
ance.
The temperature sensor is a resistance thermometer that uses NTC characteristics
(semi-conductor).
As the temperature increases, the measured resistance decreases. In the event of
sensor failure, a substitute temperature is used.

Valid for: L538-1493/31405-;
1 Layout
LBH/11827693/02/211-20150615.1139/en
Fig. 179: Charge air temperature sensor
2.1 Function
The charge air temperature sensor is installed on the air intake pipe of the engine
and transmits the charge air temperature to the engine control unit in the form of
electrical resistance.
copyright by
L538-1493 040-7
Engine
This signal is used by the engine control unit for the following functions:
– Controlling the fan drive
– Controlling the power reduction
The temperature sensor is a resistance thermometer that uses NTC characteristics
(semi-conductor).
As the temperature increases, the measured resistance decreases. In the event of
sensor failure, a substitute temperature is used.
040.1.5 Fuel system

Valid for: L538-1493/31405-;
1.1 Layout
Fig. 180: Fuel system

1 Fuel tank 7 Fuel pre-filter
2 Filler strainer 8 Fuel pre-delivery pump
3 Tank filler cap 9 Fuel fine filter
4 Suction pipe 10 Fuel supply line
LBH/11827693/02/211-20150615.1139/en
5 Fuel level sensor B25 11 Fuel return line

6 Separ fuel pre-filter 12 Engine
The fuel tank 1 is on the right, on the machine. The fuel level sensor B25 5 and the
suction pipe 4 are installed in the fuel tank.
The following components are attached to the engine:
– Fuel pre-filter 7
– Fuel fine filter 9
– Fuel pre-delivery pump 8
The Separ fuel pre-filter 6 is on the spur gear side on the engine guard plate.
copyright by
040-8 L538-1493
Engine
2 Function
The mechanical fuel pre-delivery pump 8 draws up fuel from the fuel tank 1 via the
Separ fuel pre-filter 6 and the fuel pre-filter 7.
The Separ fuel pre-filter and the fuel pre-filter protect the fuel system from dirt parti-
cles and water in the fuel. The water sensor in the fuel pre-filter checks whether
there is water in the fuel.
The fuel goes through the fuel fine filter 9 to the high pressure fuel pump. The high
pressure fuel pump is connected to the fuel tank via the fuel return line.
2.2.1 Fuel high pressure side
Fig. 181: Fuel high pressure side

1 High pressure fuel pump 6 Flow limiter
2 Injection nozzle 7 High-pressure distributor rail
(Common-Rail)
3 Solenoid valve 8 Rail pressure sensor
4 High pressure line to the injectors 9 High-pressure lines to the com-
mon rail
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5 Pressure relief valve

The high pressure fuel pump 1 increases the fuel pressure to the level necessary
for injection. The highly pressurised fuel is pumped through high-pressure lines 8
to the common rail 6. The common rail distributes the fuel via flow limiters 6 to the
electronic injection nozzles.
The rail pressure sensor 7 measures the pressure in the common rail.
If the fuel pressure in the common rail becomes too high, the pressure limiter 5
opens and directs the fuel back to the fuel tank via the leak line.
The engine control unit sends a specific sequence of signals to all the injection
nozzles. This controls the fuel quantity, the injection time and the injection rate for
each nozzle.
copyright by
L538-1493 040-9
Engine
If fuel enters the electronic injection nozzle, the nozzle valve is opened by the high
pressure. The fuel is injected into the cylinder. Excess fuel returns to the fuel tank
via the leak line.
2.2.2 High pressure fuel pump
Fig. 182: High pressure fuel pump

1 Leak line connection 9 Common rail
2 Leak distributor 10 High pressure fuel pump gear-
wheel
3 Fuel feed 11 Pump holder
4 Injection line connection 12 Pump housing
5 High pressure fuel pump 13 High pressure pump position sen-
sor
6 Pressure control valve 14 High pressure side outlet
7 Pump position sensor connector 15 Rail pipe connection
8 Fuel temperature sensor
The high pressure fuel pump 5 is driven by the gearwheel 10.
The fuel pre-delivery pump supplies fuel to the high pressure fuel pump. The piston
in the high pressure fuel pump pressurises the fuel.
The pressurised fuel is delivered to the injectors through the common rail 9.
Depending on the incoming sensor values and the calculations of the engine con-
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trol unit, the high pressure is built up via the pressure control valve 6.
The high pressure pump is lubricated with fuel.
The high pressure pump position sensor 13 is integrated in the pump holder. Note
the adjustment marking on the spur gear during assembly. This marking must line
up with upper dead centre (UDC) on cylinder 1. The adjustment marking can be
seen through an inspection hole.
The fuel temperature sensor 8 measures the fuel temperature in the high pressure
fuel pump.
copyright by
040-10 L538-1493
Engine
2.2.3 Pressure control valve
Fig. 183
The pressure control valve 1 is flange-mounted on the high pressure fuel pump.
The stay presses the valve ball onto the seal seat using a spring. This seals the
high-pressure side from the low-pressure side.
The force on the stay is increased by an electromagnet when the valve is triggered.
The entire stay is washed round with fuel. This is used for lubrication and dissipat-
ing the heat that is created when depressurising from high pressure to atmospheric
pressure.
Pressure control valve not triggered: Stay only pressurised by the force of the
spring. This is designed so that a pressure of approximately 100 bar is set in the
rail.
Pressure control valve triggered: Depending on the energy flow from the electro-
magnets (proportionality), the force on the stay can be increased. The valve re-
mains closed until the high pressure force, magnetic force and spring force come
into equilibrium. When equilibrium has been reached, the valve remains in the
open position allowed by the set pressure in the rail.
LBH/11827693/02/211-20150615.1139/en
copyright by
L538-1493 040-11
Engine
2.2.4 Common rail
Fig. 184: Common rail

1 High pressure line 1 7 High-pressure line (cylinder 3)
2 Fuel inlet 8 High-pressure line (cylinder 4)
3 High pressure line 2 9 Common rail pressure sensor
4 High-pressure line (cylinder 1) 10 Flow regulator
5 High-pressure line (cylinder 2) 11 Pressure accumulator
The high-pressure fuel pump delivers the fuel via two axial pistons and the pres-
sure lines 1 and 3 to the common rail.
The common rail acts as a pressure accumulator. The fuel is supplied to the injec-
tors via the flow regulators 10 and the high pressure lines.
The common rail pressure sensor 9 measures the pressure in the common rail.
The engine control unit uses this sensor to monitor the fuel pressure and control
the setting of the suction control valve on the high pressure fuel pump. If the pres-
sure in the common rail exceeds a predefined range a service code is generated.
2.2.5 Injector
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Fig. 185: Injector

1 Plug-in fuse 5 Sealing face O-ring
copyright by
040-12 L538-1493
Engine
2 Electrical connection 6 Cylinder seal

3 Magnet 7 Nozzle
4 Part number and classification 8 Fuel connection and supports for
leak oil line
High pressure is supplied continuously to the injectors through the common rail
and the flow regulators. The engine control unit uses input values and characteris-
tics to determine the duration and time of injection. The injection quantity is deter-
mined from the pressure sensor calculation and the opening duration.
80 volts are applies to the magnet 3 via the output stages of the engine control
unit. The magnetic coil raises a sealing ball against the spring force. With the aid of
the internal hydraulics, this raises the nozzle needle.
Due to different variations, injectors must be sorted into classes. This code is
saved in the engine control unit in order to calculate the ideal injection quantity.
Fig. 186: Injection process
Two injections are made for each work cycle. Depending on the engine character-
istics in the ECU, these affect the noise and exhaust emissions.
Fig. A shows the injector in the closed position. The pressure acts via the ball on
the closed solenoid valve. The hydraulic force pushes the needle down.
Fig. B shows the injector in the open position. The injector is energised. The ball is
raised by the solenoid valve. This cause a sudden decrease in the pressure on the
needle. The pressure below the needle (ring face) lists the needle up.
LBH/11827693/02/211-20150615.1139/en
copyright by
L538-1493 040-13
Engine
2.2.6 Pump position speed sensor
Fig. 187
The pump position speed sensor is installed in the high pressure pump holder
plate.
The engine continues running even if the pump position speed sensor fails. If the
engine is shut down and started again, it only starts up at limited power.
The signal generated is used for controlling the engine.
The speed sensor is an inductive sensor. Inductive sensors are electromagnetic
components with a permanent magnet and coil.
The distance a between the sensor and the ring gear is set to a fixed value.
A ring gear with 12 uniformly sized and spaced teeth is installed on the upper spur
gear. At one position there is a protrusion between the teeth.
Due to the principle of induction, a sine voltage wave is generated between the
teeth. The control unit detects these waves and converts them. Each position with
the protrusion leads to an interruption, and is required for detecting the upper dead
centre position in cylinder 1.
LBH/11827693/02/211-20150615.1139/en
copyright by
040-14 L538-1493
Engine

Valid for: L538-1493/31405-;
1 Layout
Fig. 188: Fuel pre-filter

1 Fuel inlet 5 Bleeder screw
2 Snap ring 6 Water separator container
3 Filter cartridge 7 Drain valve
4 Fuel outlet
The fuel pre-filter is mounted on the engine.
2 Function
The fuel pre-filter protects the fuel system of the engine (fuel pre-delivery pump,
pump elements, injection valves, pistons and valves) from most dirt and water in-
gress. The fuel pre-filter is installed between the Separ fuel pre-filter and the fuel
pre-delivery pump. The separated water must be regularly drained via the drain
valve 7 (see the maintenance and inspection schedule).
To ensure trouble-free operation, the water separator tank 6 must be cleaned if it
becomes dirty.
A water sensor is integrated in the drain valve. This sensor measures the water
content of the fuel which is drawn from the fuel tank.
LBH/11827693/02/211-20150615.1139/en
copyright by
L538-1493 040-15
Engine

Valid for: L538-1493/31405-;
1 Layout
Fig. 189: Separ fuel pre-filter

2 Cover 8 Collection tank
3 Bolts 9 Input
4 Seal 10 Output
5 Spring packet 11 Bleeder screw
6 Fuel pre-filter insert
2 Function
The fuel pre-filter protects the fuel system of the engine (feed pump, injection
valves, pistons and vales) from most dirt and water ingress.
The Separ fuel pre-filter acts as both a water separator and a filter. It is installed in
the suction line of the fuel system between the fuel tank and the fuel pre-filter.
The water collector contains a water sensor, which monitors the condensation in
the Separ fuel pre-filter and reports any excess water level on the display using a
service code.
LBH/11827693/02/211-20150615.1139/en
copyright by
040-16 L538-1493
Engine

Valid for: L538-1493/31405-;
1 Layout
Fig. 190: Fuel fine filter

1 Bleeder screw 3 Filter element
2 Snap ring 4 Drain valve
The fuel fine filter is mounted on the engine.
2 Function
The fuel fine filter protects the fuel system from contamination.
The diesel fuel reaches the fuel fine filter under pressure from the fuel pre-delivery
pump. The fuel enters at the fuel inlet, flows through the filter element 3 and is for-
warded to the fuel injection pump.
Water and impurities in the fuel settle to the bottom of the housing. Water and im-
purities can be drained via the drain valve 4 on the fuel fine filter.
The low-pressure fuel system can be bled using the bleeder screw 1.
The fuel fine filter must be regularly replaced (see the maintenance and inspection
schedule).
040.1.6 Air filter system

LBH/11827693/02/211-20150615.1139/en
copyright by
L538-1493 040-17
Engine

Valid for: L538-1493/31405-;
1 Layout
Fig. 191: Overview of the air filter unit

1 Intake port 7 Dust discharge valve
2 Intake port clip 8 Vacuum switch
3 Untreated air intake hose 9 Clean air intake hose clip
4 Untreated air intake hose clip 10 Clean air intake hose
5 Bushing 11 Turbocharger clip
6 Air filter 12 Engine
2 Function
For optimum combustion in the engine 12, it must be supplied with clean intake air.
The air flows through the intake port 1 and the untreated air intake hose 3 to the air
LBH/11827693/02/211-20150615.1139/en
filter 6.
The air filter cleans the air, which then passes through the clean air intake hose 10
to the cylinder block.
If the air filter is clogged or too contaminated, a vacuum is produced in the system.
The vacuum is measured by the vacuum switch 11. If the vacuum is too great, the
engine control unit triggers a warning sound and a warning symbol on the display.
copyright by
040-18 L538-1493
Engine

Valid for: L538-1493/31405-;
1 Layout
Fig. 193: Layout of air filter

1 Safety element 4 Retaining clips
2 Main element 5 Dust discharge valve
3 Service cover 6 Filter housing
2 Function
The main element 2 and the safety element 1 must be regularly replaced (see the
maintenance and inspection schedule).
The safety element 1 is used as a back-up if the main element 2 is damaged.
The safety element 1 must be replaced after the main element is replaced three
times, or as necessary.
The dust discharge valve 5 is used for automatically emptying the dust from the
service cover 3.
The tangential arrangement of the intake port sets the intake air into rotation,
where centrifugal force throws the larger dust particles are against the housing wall
and the flow of intake air deposits them in the service cap 3.
At idling speed, the collected dust particles in the service cover 3 are blown outside
via the dust discharge valve 5 by the pulsations of the intake air.
LBH/11827693/02/211-20150615.1139/en
The service cover 3 must be fitted so that the dust discharge valve 5 points down-
wards.
When the engine is running (lower idle speed), you should clearly feel air pulsating
at the dust discharge valve 5.
copyright by
L538-1493 040-19
Coupling
040.2 Coupling
Valid for: L538-1493/31405-;

(For more information see: 020.1.6 Clutch, page 020-6)
Fig. 194: Position of the coupling

1 Flywheel 5 Clutch flange
2 Gearwheel screw 6 Clutch flange cheese-head screws
3 Gearwheel 7 Clutch cheese-head screws
4 Clutch
2.1 Function
The clutch 4 acts as an elastic connection between the engine and the variable dis-
placement pump. The elastic clutch compensates for engine torque peaks. This
prolongs the service life of the variable displacement pump.
The clutch 4 is screwed onto the flywheel 1. The clutch and the gearwheel 3 are
LBH/11827693/02/211-20150615.1139/en
geared to each other.

The clutch transfers the torque from the engine to the gearwheel. The gearwheel
drives the variable displacement pump. This means that there is no rigid connec-
tion between the variable displacement pump and the engine.
The clutch flange 5 protects the clutch from dirt and supports the variable displace-
ment pump.
copyright by
040-20 L538-1493
050 Cooling system
Contents
L538-1493/31405-; 050-2
L538-1493/31405-; 050-4
L538-1493/31405-; 050-5
L538-1493/31405-; 050-9
L538-1493/31405-; 050-10
L538-1493/31405-; 050-12
050.3 Cooler 050-14
L538-1493/31405-; 050-14
L538-1493/31405-; 050-15
050.3.3 Intercooler
L538-1493/31405-; 050-17
LBH/11827693/02/211-20150615.1139/en
copyright by
L538-1493 050-1
Cooling system Service manual
Hydraulic control unit
050.1 Hydraulic control unit

Valid for: L538-1493/31405-;
A reversible fan drive can be fitted as an option. (For more information see:
190.1 Reversible fan drive, page 190-2)
1 Layout
Fig. 195: Hydraulics cooling system

1 Hydraulic tank 4 80 µm inline filter 7 Hydraulic oil cooler
2 Fan gear pump 5 Fan gear motor 8 Temperature valve
3 Travel motor 1 6 Collector pipe PK Cooling system high pressure
LBH/11827693/02/211-20150615.1139/en
test connection
Components of the hydraulics cooling system:
– Hydraulic tank (For more information see: 080.1.1 Overview of the hydraulic
tank, page 080-2)
– Collector pipe
– Fan gear pump (For more information see: 050.1.2 Fan gear pump,
page 050-4)
– Fan gear motor with fan blade (For more information see: 050.1.3 Fan gear mo-
tor, page 050-5)
copyright by
050-2 L538-1493
Service manual Cooling system
2 Function
2.1 Basic function
Fig. 196: Hydraulic diagram of the cooling system

1 Hydraulic tank 15 Brake system gear pump in- 32 Discharge in travel motor 2
take connection
2 Breather filter 16 Emergency steering pump in- 33 Travel motor 2 leak oil
take connection
3 Return strainer 17 Transmission return flow 34 Collector pipe
4 Bypass valve 18 Compact brake valve return 35 0.25 bar check valve
flow
5 Return suction filter 19 Pilot control unit return flow 36 Temperature valve
6 Pre-tension valve 20 Working hydraulics pump 37 Hydraulic oil cooler
leak oil
7 Feeding valve 21 Servostat return flow 38 80 µm inline filter
8 Strainer 22 Travel pump leak oil 40 Fan gear motor
9 9 bar check valve 23 Control valve block return 41 Gear motor
flow
10 2.5 bar bypass valve 24 Brake system gear pump 42 Proportional pressure relief
valve
11 Hydraulic oil temperature 25 Fan gear pump 43 Restrictor
sensor B8
12 Drain valve 26 Engine 44 Primary piston
13 Replenishing pump intake 30 Travel motor 1 45 Secondary piston with propor-
connection tional solenoid Y13
LBH/11827693/02/211-20150615.1139/en
14 Working hydraulics pump in- 31 Travel pump leak oil PK Cooling system high pressure
take connection
The fan gear pump 25 draws up oil from the hydraulic tank 1 and pumps it to the
fan gear motor 40.
Some of the oil returning from the fan gear motor 40 flows to travel motor 1 for
flushing the bearings. The rest of the returning oil goes to the collector pipe 34.
The return flow from the following components is collected in the collector pipe 34:
– Fan gear motor return flow
– Travel pump leak oil
– Discharged oil from travel motor 2
– Travel motor 2 leak oil
copyright by
L538-1493 050-3
The collected oil flows on to the hydraulic oil cooler 37 and from there to the filter
unit on the hydraulic tank 1.
The temperature valve 36 on the hydraulic oil cooler 37 is open when the hydraulic
oil is cold. This means most of the return oil flows past the hydraulic oil cooler 37
directly to the filter unit on the hydraulic tank 1. Because this oil is not cooled, the
hydraulic system reaches its operating temperature more quickly.
2.2 Cooling power (fan speed)

The cooling power depends on the amount of air that passes through the cooler
unit. The air flow is controlled using the fan speed.
The central control unit regulates the fan speed by energising the proportional
pressure relief valve Y13.

Valid for: L538-1493/31405-;
1 Layout
Fig. 197: Fan gear pump

1 Brake system gear pump PK Cooling system high pressure test
connection
2 Fan gear pump
The fan gear pump, together with the brake system gear pump, is fitted to the pow-
er take-off unit of the engine. LBH/11827693/02/211-20150615.1139/en
copyright by
050-4 L538-1493
Fig. 198: Exploded view of the fan gear pump

1 Nut 7 Feather key
2 Snap ring 8 Drive gear
3 Shaft seal ring 9 Gearwheel
4 Flange 10 Pump housing
5 Seals 11 Pump cover with flange
6 Bearing bushings
2 Function
The fan gear pump drives the fan gear motor.
The flow rate per rotation cannot be adjusted. The flow rate is solely determined by
the engine speed.
The fan gear pump draws up oil from the hydraulic tank and pumps it to the fan
gear motor. The oil then flows from the fan gear motor to the leak oil connection on
travel motor 1. The oil flows from travel motor 1 to travel motor 2, thereby cooling
both travel motors. The oil then flows from travel motor 2 to the collector pipe.

Valid for: L538-1493/31405-;
1 Layout
LBH/11827693/02/211-20150615.1139/en
Fig. 199: Fan gear motor

1 Gear motor 2 Proportional pressure relief valve
Y13
The fan gear motor is rigidly connected to the fan blade.
copyright by
L538-1493 050-5
Fig. 200: Sectional view of the proportional pressure relief valve

1 Adjusting screw 5 Secondary spring 9 Primary piston
2 Counter nut 6 Stay 10 Restrictor
3 Protective cap 7 Secondary piston
4 Proportional solenoid Y13 8 Primary spring
2 Function
2.1 Basic function
Fig. 201: Hydraulic diagram of the fan gear motor

1 Fan gear motor 6 Secondary piston with proportional
solenoid Y13
2 Gear motor 7 Fan gear motor leak oil
3 Proportional pressure relief valve 8 Fan gear pump
4 Restrictor 9 Travel motor 1
5 Primary piston
The fan gear motor is driven by oil from the fan gear pump 8.
LBH/11827693/02/211-20150615.1139/en
The proportional pressure relief valve 3 regulates the output speed.
copyright by
050-6 L538-1493
2.2 Output speed
Fig. 202: Proportional solenoid energised/de-energised

1 Proportional solenoid Y13 4 Secondary piston 7 Restrictor
2 Secondary spring 5 Primary spring A Pressure chamber
3 Stay 6 Primary piston
The proportional pressure relief valve regulates the output speed by directing oil
past the gear motor. The more oil that flows through the bypass, the lower the out-
put speed.
When it is not energised, the proportional pressure relief valve acts as a pilot-con-
trolled pressure relief valve.
The high pressure from the gear pump pushes against the primary piston 6. At the
same time, oil flows through the restrictor 7 to the pressure chamber A. The oil
LBH/11827693/02/211-20150615.1139/en
pressure in the pressure chamber A and the primary spring 5 keep the primary pis-
ton 6 closed.
If the high pressure exceeds the set value, it pushes the secondary piston 4
against the secondary spring 2. This lowers the pressure in the pressure cham-
ber A. The high pressure pushes the primary piston 6 against the primary spring 5.
The oil flows to the tank connection.
The central control unit energises the proportional solenoid 1 depending on the hy-
draulic oil temperature. The magnet force pushes the anchor 5 against the secon-
dary spring 2. This causes oil to flow out of the pressure chamber A to the tank
connection. The high pressure pushes the primary piston 6 against the primary
spring 5 and oil flows to the tank connection.
copyright by
L538-1493 050-7
The higher the current on the proportional solenoid 1, the further the proportional
pressure relief valve opens. This means that the higher the current on the propor-
tional solenoid, the lower the output speed.
2.3 Fail-safe function

If the proportional solenoid 1 fails, the maximum spring force acts on the secondary
piston 4. This means the maximum quantity of oil flows through the gear motor,
and the fan turns at maximum speed.
This prevents the cooling fluids from overheating if the proportional solenoid fails.
LBH/11827693/02/211-20150615.1139/en
copyright by
050-8 L538-1493
Electronic control unit
050.2 Electronic control unit

Valid for: L538-1493/31405-;
1 Layout
Fig. 203: Coolant temperature sensor B5208
The sensor element consists of an encapsulated thin-film nickel resistor.
2 Function
Fig. 204: Wiring diagram and characteristic
Temperature Resistance
0 °C 9399.0 Ω
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5 °C 7263.0 Ω
10 °C 5658.0 Ω
15 °C 4441.0 Ω
20 °C 3511.0 Ω
25 °C 2795.0 Ω
30 °C 2240.0 Ω
35 °C 1806.0 Ω
40 °C 1465.0 Ω
45 °C 1195.0 Ω
copyright by
L538-1493 050-9
50 °C 980.3 Ω
55 °C 808.8 Ω
60 °C 670.9 Ω
65 °C 559.4 Ω
70 °C 468.7 Ω
75 °C 394.6 Ω
80 °C 333.8 Ω
85 °C 283.5 Ω
90 °C 241.8 Ω
95 °C 207.1 Ω
100 °C 178.0 Ω
Tab. 47: Relationship of temperature to resistance
The central control unit measures the resistance of the temperature sensor and
calculates the temperature from it.
As the temperature increases, the sensor resistance decreases.

Valid for: L538-1493/31405-;
1 Layout
Fig. 205: Hydraulic oil temperature sensor B8
The hydraulic oil temperature sensor B8 is screwed into the hydraulic tank next to
the suction port of the replenishing pump.
LBH/11827693/02/211-20150615.1139/en
copyright by
050-10 L538-1493
2 Function
-20 °C 895 Ω
0 °C 1000 Ω
20 °C 1110 Ω
40 °C 1230 Ω
60 °C 1355 Ω
80 °C 1485 Ω
100 °C 1620 Ω
120 °C 1760 Ω
The central control unit measures the resistance of the temperature sensor and
LBH/11827693/02/211-20150615.1139/en
calculates the temperature from it.

As the temperature increases, so does the sensor resistance (PTC characteristic).
The increase is approximately linear.
copyright by
L538-1493 050-11

Valid for: L538-1493/31405-;
1 Layout
Fig. 207: Charge air temperature sensor B5205
2 Function
0 °C 9795.0 Ω
5 °C 7616.0 Ω
10 °C 5970.0 Ω
15 °C 4712.0 Ω
20 °C 3747.0 Ω
LBH/11827693/02/211-20150615.1139/en
25 °C 3000.0 Ω
30 °C 2417.0 Ω
35 °C 1959.0 Ω
40 °C 1598.0 Ω
45 °C 1311.0 Ω
50 °C 1081.0 Ω
55 °C 895.9 Ω
60 °C 746.4 Ω
copyright by
050-12 L538-1493
65 °C 624.9 Ω
70 °C 525.6 Ω
75 °C 444.4 Ω
80 °C 377.4 Ω
85 °C 321.7 Ω
90 °C 275.3 Ω
95 °C 236.6 Ω
100 °C 204.0 Ω
The ECU measures the resistance of the temperature sensor and calculates the
temperature from it.
As the temperature increases, the sensor resistance decreases.
LBH/11827693/02/211-20150615.1139/en
copyright by
L538-1493 050-13
Cooler
050.3 Cooler

Valid for: L538-1493/31405-;
1 Layout
Fig. 209: Water cooler

1 Water cooler 3 Thermostat
2 Cooler cover 4 Coolant pump
The water cooler 1 is integrated in the cooler unit.
A serpentine pipe runs through the water cooler to which the cooler fins are attach-
ed. The surface of the pipe is thereby increased and the cooling output accordingly
improved.
The cooler cover 2 and the equalising reservoirs are located at the highest point.
LBH/11827693/02/211-20150615.1139/en
2 Function
When the coolant temperature reaches 85 °C, the thermostat 3 opens. When the
coolant temperature reaches 97 °C, the thermostat is completely opened. The hot
coolant flows through the water cooler 1.
The fan draws ambient air in through the water cooler. The cooler fins transfer the
heat from the coolant into the air.
The water pump 4 draws in the cooled coolant once more.
copyright by
050-14 L538-1493
Cooler

Valid for: L538-1493/31405-;
1 Layout
Fig. 210: Hydraulic oil cooler

1 Hydraulic oil cooler 4 Hot oil to the hydraulic tank via by-
pass
2 Hot oil from the collector pipe 5 Cooled oil to the hydraulic tank
3 Temperature valve
The hydraulic oil cooler 1 is integrated in the cooler unit.
A serpentine pipe runs through the hydraulic oil cooler to which the cooler fins are
attached. The surface of the pipe is increased by the cooler fins and the cooling
output accordingly improved.
LBH/11827693/02/211-20150615.1139/en
copyright by
L538-1493 050-15
Cooler
2 Function
2.1 Basic function
Fig. 211: Hydraulic diagram of the hydraulic oil cooler

1 Hydraulic oil cooler 4 Bypass to the hydraulic tank
2 Collector pipe 5 To the hydraulic tank
3 Temperature valve
The hot oil of the travel hydraulics (leak oil and discharged oil) collects in the col-
lector pipe 2 and flows to the hydraulic oil cooler 1.
The fan draws ambient air in through the hydraulic oil cooler. The cooler fins trans-
fer the heat from the oil into the ambient air.
The cooled oil flows into the hydraulic tank 5.
2.1.1 Temperature valve

The temperature valve 3 assists the hydraulic oil in reaching operating temperature
faster.
If the oil temperature is below 55 °C, the temperature valve is open. Due to the
lower flow-rate resistance, most of the oil flows straight into the hydraulic tank via
the bypass line 4 and past the hydraulic oil cooler 1. If the oil is warmer than 55 °C,
the temperature valve closes progressively, until the entire oil quantity flows
through the hydraulic oil cooler.
LBH/11827693/02/211-20150615.1139/en
copyright by
050-16 L538-1493
Cooler
050.3.3 Intercooler
Valid for: L538-1493/31405-;
1 Layout
Fig. 212: Intercooler

1 Intercooler 3 Cooled air to the engine
2 Warm air from the turbocharger
The intercooler 1 is integrated in the cooler unit.
A pipe runs through the intercooler to which the cooler fins are attached. The sur-
face of the pipe is increased by the cooler fins and the cooling output accordingly
improved.
2 Function
The air drawn in by the turbocharger is heated by being compressed.
The warm air flows through the intercooler. The fan draws in ambient air through
the intercooler. The cooler fins transfer the heat from the charge air into the ambi-
ent air.
LBH/11827693/02/211-20150615.1139/en
The cooled charge air flows into the engine 3.
copyright by
L538-1493 050-17
Cooler
LBH/11827693/02/211-20150615.1139/en
copyright by
050-18 L538-1493
060 Working hydraulics
Contents
060.1 Overview of working hydraulics for z-bar kinematics
L538-1493/31405-; 060-3
060.2 Overview of working hydraulics for p kinematics
L538-1493/31405-; 060-8
L538-1493/31405-; 060-12
L538-1493/31405-; 060-16
L538-1493/31405-; 060-22
060.6 Pilot control 060-27
L538-1493/31405-; 060-27
L538-1493/31405-; 060-28
L538-1493/31405-; 060-33
L538-1493/31405-; 060-34
060.7 Ride control 060-35
L538-1493/31405-; 060-35
L538-1493/31405-; 060-36
LBH/11827693/02/211-20150615.1139/en
L538-1493/31405-; 060-41
060.8 Working hydraulics cylinder 060-42
060.8.1 Hydraulic cylinders for Z kinematics 060-42
L538-1493/31405-; 060-42
L538-1493/31405-; 060-44
060.8.2 Hydraulic cylinders for P kinematics 060-45
copyright by
L538-1493 060-1
Working hydraulics Service manual

L538-1493/31405-; 060-46
L538-1493/31405-; 060-47
LBH/11827693/02/211-20150615.1139/en
copyright by
060-2 L538-1493
Service manual Working hydraulics
Overview of working hydraulics for z-bar kinematics
060.1 Overview of working hydraulics for z-bar

kinematics
Valid for: L538-1493/31405-;
1 Layout
LBH/11827693/02/211-20150615.1139/en
Fig. 213: Main components of the working hydraulics for z-bar kinematics
1 Hydraulic tank 8 Servostat LS connection 15 Tilt cylinder
copyright by
L538-1493 060-3
2 Travel pump 9 Servostat oil supply LS Working hydraulics pump

load sensing pressure test
connection
3 Working hydraulics pump 10 Stabilisation module P Working hydraulics pump
high pressure test connection
4 Working hydraulics lockout 11 Ride control hydro accumula- G Replenishing pressure test
solenoid valve Y14 tor connection
5 Pilot control hydro accumula- 12 Pilot control unit MX Ride control hydro accumula-
tor tor load pressure test connec-
tion
6 Control valve block 13 Left lift cylinder
7 Compact brake valve (hous- 14 Right lift cylinder
ing preheating)
The working hydraulics consist of the following components:
tank, page 080-2)
– Working hydraulics pump (For more information see: 060.3 Working hydraulics
pump, page 060-12)
– Control valve block (For more information see: 060.4 Control valve block for Z-
bar kinematics, page 060-16)
– Pilot control (For more information see: 060.6.1 Overview of the pilot control
unit, page 060-27)
– Ride control (optional) (For more information see: 060.7.1 Ride control over-
view, page 060-35)
– Lift cylinder (For more information see: Z kinematics lift cylinder, page 060-42)
– Tilt cylinder (For more information see: Z kinematics tilt cylinder, page 060-44)
LBH/11827693/02/211-20150615.1139/en
copyright by
060-4 L538-1493
2 Function
2.1 Basic function

LBH/11827693/02/211-20150615.1139/en
Fig. 214: Diagram of the working hydraulics for z-bar kinematics

copyright by
L538-1493 060-5
1 Hydraulic tank 35 Travel pump 75 Restrictor check valve

2 Breather filter 36 Replenishing pump 76 Restrictor check valve
3 Return strainer 37 Replenishing pressure relief 77 Low leak valve relief
valve
4 Bypass valve 40 Travel motor bearing flushing 78 Low leak valve for tilting in
2
5 Return suction filter 41 Engine 79 Secondary pressure relief
valve for tilting out
6 Pre-tension valve 42 Check valve 80 Secondary pressure relief
valve for tilting in
7 Feeding valve 43 Transmission 81 Lift cylinder spool
8 Strainer 44 Check valve 82 Lift cylinder pressure balance
9 9 bar check valve 45 Pilot control hydro accumula- 83 Restrictor
tor
10 2.5 bar bypass valve 46 Working hydraulics lockout 84 Load retaining valve
solenoid valve Y14
11 Hydraulic oil temperature 50 Pilot control unit 85 Feeding valve
sensor B8
12 Drain valve 51 Valve for lowering 86 Restrictor check valve
13 Fan gear pump intake con- 52 Float position retaining sole- 87 Restrictor check valve
nection noid Y18
14 Intake port of brake system 53 Valve for lifting 88 Secondary pressure relief
gear pump valve for lifting
15 Emergency steering pump in- 54 Lift kick-out retaining solenoid 89 Pre-tension valve
take connection Y17 (optional)
16 Transmission return flow 55 Tilt-in valve 90 Compact brake valve (hous-
ing preheating)
17 Compact brake valve return 56 Bucket return-to-dig retaining 91 Servostat oil supply
flow solenoid Y9
18 Fan gear motor leak oil 57 Tilt-out valve 92 Servostat LS connection
19 Servostat return flow 60 Control valve block Z kine- 95 Tilt cylinder
matics
20 Travel pump leak oil 61 Priority valve 96 Left lift cylinder
21 Hydraulic oil cooler return 62 Restrictor 97 Right lift cylinder
flow
22 Hydraulic oil cooler bypass 63 Restrictor 100 Stabilisation module
return flow
25 Working hydraulics pump 64 Check valve 101 Ride control valve spool
26 Axial piston pump 65 LS steering pressure cut-off 102 Hydro accumulator relief
valve
27 Return piston 66 LS working hydraulics pres- 103 Ride control solenoid valve
sure cut-off Y20
28 Restrictor 67 Flow regulating valve 104 Restrictor check valve
29 Servo piston 68 Restrictor 105 Safety valve
30 Regulating lever 70 Tilt cylinder spool 106 Hydro accumulator ride con-
LBH/11827693/02/211-20150615.1139/en
trol
31 Restrictor 71 Tilt cylinder pressure balance LS Working hydraulics pump
load sensing pressure
32 Power regulator 72 Restrictor P Working hydraulics pump
high pressure
33 Dummy piston 73 Load retaining valve G Replenishing pressure
34 Flow regulator 74 Feeding valve MX Hydro accumulator ride con-
trol load pressure
The working hydraulics is an open circuit. This means that the oil returns to the
hydraulic tank 1 from the consumer. In a closed circuit, by contrast, the oil flows
directly back to the pump.
copyright by
060-6 L538-1493
The working hydraulics pump 25 draws up oil from the hydraulic tank 1 and pumps
it to the control valve block 60. The flow rate depends on the load. The priority
valve 60 in the control valve block 61 directs the oil to the working hydraulics and
steering system 91.
The spool valves in the control block valve 60 are hydraulically pushed by the pilot
control unit. The replenishing pump 36 diverts the oil required to do this. The servo
pressure is generated in the pilot control unit 50, depending on the deflection of the
control lever.
The oil flows to the consumers via the opening created by the spools when moving.
At the same time, the pressure balances generate a load sensing signal which
makes the working hydraulics pump 25 swing out.
LBH/11827693/02/211-20150615.1139/en
copyright by
L538-1493 060-7
Overview of working hydraulics for p kinematics
060.2 Overview of working hydraulics for p kine-

matics
Valid for: L538-1493/31405-;
1 Layout
Fig. 215: Main components of the working hydraulics for p kinematics
The working hydraulics consist of the following components:

tank, page 080-2)
– Working hydraulics pump
– Control valve block (For more information see: 060.5 Control valve block for P
kinematics, page 060-22)
unit, page 060-27)
– Ride control (optional) (For more information see: 060.7.1 Ride control over-
view, page 060-35)
– Lift cylinder (For more information see: P kinematics lift cylinder, page 060-46)
– Tilt cylinder (For more information see: P kinematics tilt cylinder, page 060-47)
LBH/11827693/02/211-20150615.1139/en
copyright by
060-8 L538-1493
2 Function
2.1 Basic function

LBH/11827693/02/211-20150615.1139/en
Fig. 216: Diagram of working hydraulics for P kinematics with third function and quick coupler
copyright by
L538-1493 060-9
1 Hydraulic tank 43 Transmission 88 Secondary pressure relief

valve for lifting
2 Breather filter 44 Check valve 89 Restrictor check valve
3 Return strainer 45 Pilot control hydro accumula- 90 Restrictor check valve
tor
4 Bypass valve 46 Working hydraulics lockout 91 Pre-tension valve
solenoid valve Y14
5 Return suction filter 50 Pilot control unit 95 Single installation set (op-
tional)
6 Pre-tension valve 51 Valve for lowering 96 Spool valve 3rd function
7 Feeding valve 52 Float position retaining sole- 97 Pressure compensator 3rd
noid Y18 function
8 Strainer 53 Valve for lifting 98 Restrictor
9 9 bar check valve 54 Lift kick-out retaining solenoid 99 Load retaining valve
Y17 (optional)
10 2.5 bar bypass valve 55 Tilt-in valve 100 Secondary pressure relief
valve 3rd function A3
11 Hydraulic oil temperature 56 Bucket return-to-dig retaining 101 Secondary pressure relief
sensor B8 solenoid Y9 valve 3rd function B3
12 Drain valve 57 Tilt-out valve 102 Restrictor check valve
13 Fan gear pump intake con- 60 Additional control lever 103 Restrictor check valve
nection (optional)
14 Intake port of brake system 61 Valve 3rd function a3 104 Compact brake valve (hous-
gear pump ing preheating)
15 Emergency steering pump in- 62 Control lever lock retaining 105 Connection 3rd function
take connection magnet Y62 (optional)
16 Transmission return flow 63 Valve 3rd function b3 106 Check valve
17 Compact brake valve return 65 P-Kinematics control block 107 Servostat oil supply
flow
18 Fan gear motor leak oil 66 Priority valve 108 Servostat LS connection
19 Servostat return flow 67 Restrictor 110 Quick coupler solenoid valve
Y53 (optional)
20 Travel pump leak oil 68 Restrictor 111 Quick coupler solenoid valve
LS signal Y53a (optional)
21 Hydraulic oil cooler return 69 Check valve 112 Cylinder quick coupler (op-
flow tional)
22 Hydraulic oil cooler bypass 70 LS steering pressure cut-off 113 Left tilt cylinder
return flow
25 Working hydraulics pump 71 LS working hydraulics pres- 114 Right tilt cylinder
sure cut-off
26 Axial piston pump 72 Flow regulating valve 115 Left lift cylinder
27 Return piston 73 Restrictor 116 Right lift cylinder
28 Restrictor 75 Tilt cylinder spool 120 Stabilisation module
29 Servo piston 76 Tilt cylinder pressure balance 121 Ride control valve spool
30 Regulating lever 77 Restrictor 122 Hydro accumulator relief
LBH/11827693/02/211-20150615.1139/en
valve
31 Restrictor 78 Load retaining valve 123 Ride control solenoid valve
Y20
32 Power regulator 79 Secondary pressure relief 124 Restrictor check valve
33 Dummy piston 80 Secondary pressure relief 125 Safety valve
34 Flow regulator 81 Restrictor check valve 126 Hydro accumulator ride con-
trol
35 Travel pump 82 Restrictor check valve LS Working hydraulics pump
load sensing pressure
copyright by
060-10 L538-1493
36 Replenishing pump 83 Lift cylinder spool P Working hydraulics pump

high pressure
37 Replenishing pressure relief 84 Lift cylinder pressure balance G Replenishing pressure
valve
40 Travel motor bearing flushing 85 Restrictor MX Hydro accumulator ride con-
2 trol load pressure
41 Engine 86 Load retaining valve
42 Check valve 87 Feeding valve
The working hydraulics is an open circuit. This means that the oil returns to the
hydraulic tank 1 from the consumer. In a closed circuit, by contrast, the oil flows
directly back to the pump.
The working hydraulics pump 25 draws up oil from the hydraulic tank 1 and pumps
it to the control valve block 65. The flow rate depends on the load. The priority
valve 65 in the control valve block 66 directs the oil to the working hydraulics and
steering system 107.
The spool valves in the control block valve 65 are hydraulically pushed by the pilot
control unit. The replenishing pump 36 diverts the oil required to do this. The servo
pressure is generated in the pilot control unit 50, depending on the deflection of the
control lever.
The oil flows to the consumers via the opening created by the spools when moving.
At the same time, the pressure balances generate a load sensing signal which
makes the working hydraulics pump 25 swing out.
LBH/11827693/02/211-20150615.1139/en
copyright by
L538-1493 060-11
Working hydraulics pump
Valid for: L538-1493/31405-;
1 Layout

1 Flow regulator 4 Qmin adjusting screw
2 Power regulator LS Load sensing pressure test con-
nection
3 Qmax adjusting screw P High pressure test connection
The working hydraulics pump is flange-mounted on the drive shaft of the travel
pump.
The following components are integrated in the working hydraulics pump:
– Swash plate variable displacement pump (axial piston pump)
– Flow regulator
– Power regulator
– Servo piston
– Return piston
LBH/11827693/02/211-20150615.1139/en
copyright by
060-12 L538-1493
Fig. 218: Sectional view of rotary group

1 Drive shaft 10 Restrictor 19 Piston
2 Roller bearing 11 Servo piston 20 Sliding bushing
3 Swivel plate 12 Roller bearing 21 Return plate
4 Adjusting pin 13 Restrictor 22 Glide shoe
5 Qmin adjusting screw 14 Return piston 23 Return ball
6 Compression spring 15 Control plate 24 Cup springs
7 Power regulator 16 Rotary group cylinder 25 Swivel plate bearing
8 Regulating lever 17 Adjusting pin 26 Guide wire
9 Piston with roller 18 Qmax adjusting screw
LBH/11827693/02/211-20150615.1139/en
copyright by
L538-1493 060-13
Fig. 219: Sectional view of the regulation unit

1 To the return piston 3 Dummy piston 5 Power regulator
2 Flow regulator 4 Regulating lever
2 Function
2.1 Basic function
LBH/11827693/02/211-20150615.1139/en
Fig. 220: Hydraulic diagram of the working hydraulics pump

1 Working hydraulics pump 9 Dummy piston
2 Axial piston pump 10 Flow regulator
3 Return piston 11 Working hydraulics pump intake
connection
copyright by
060-14 L538-1493
4 Restrictor 12 High pressure to the control valve

block
5 Servo piston 13 Load sensing signal for control
valve block
6 Regulating lever 14 Working hydraulics pump leak oil
7 Restrictor LS Load sensing pressure
8 Power regulator P Working hydraulics pump high
pressure
The working hydraulics pump supplies:
– The working hydraulics with oil
– The steering system with oil
The working hydraulics pump 1 is driven by the engine via the drive shaft of the
travel pump.
The working hydraulics pump draws up oil from the hydraulic tank 12 and pumps it
to the control valve block 13. The priority valve in the control valve block distributes
the oil to the working hydraulics and steering system.
The working hydraulics pump is a variable displacement pump. The flow rate de-
pends on the drive speed and the angle.
LBH/11827693/02/211-20150615.1139/en
copyright by
L538-1493 060-15
Control valve block for Z-bar kinematics
Valid for: L538-1493/31405-;
1 Layout
Fig. 221: Control valve block for Z-bar kinematics

1 Secondary pressure relief valve 7 Tilt cylinder pressure balance
for lifting
2 Secondary pressure relief valve 8 Flow regulating valve
for tilting in
3 Lift cylinder pressure balance 9 Secondary pressure relief valve
for tilting out
4 LS working hydraulics pressure 10 Low-leak valve
cut-off
5 Priority valve 11 Pre-tension valve
6 LS steering pressure cut-off
The control valve block is installed in the front section.
The control valve block has the following components and functions:
– Spool valves for the lift cylinder, tilt cylinder and 3rd function (optional) with
pressure balances
LBH/11827693/02/211-20150615.1139/en
– Low-leak valve for tilt-in function

– Working hydraulics pressure protection (working hydraulic LS pressure cut-off
and secondary pressure relief valves)
– Steering system pressure protection (steering system LS pressure cut-off)
– Feeding function
– Float position function
– Priority valve
copyright by
060-16 L538-1493
Fig. 222: Sectional view of tilt cylinder section

1 Tilt cylinder spool valve 6 Secondary pressure relief 11 Spool stroke adjusting screw
2 Feeding valve 7 Load retaining valve 12 Return spring
3 Restrictor check valve 8 Tilt cylinder pressure balance 13 Restrictor check valve
with restrictor
4 Spool stroke adjusting screw 9 Secondary pressure relief
5 Return spring 10 Low leak valve for tilting in
LBH/11827693/02/211-20150615.1139/en
Fig. 223: Sectional view of low-leak valve

1 Low-leak valve relief 3 Low leak valve for tilting in
2 Secondary pressure relief valve 4 Tilt cylinder spool valve
for tilting in
copyright by
L538-1493 060-17
Fig. 224: Sectional view of lift cylinder section

1 Lift cylinder spool valve 5 Return spring 9 Return spring
2 Feeding valve 6 Load retaining valve 10 Float position compression
spring
3 Restrictor check valve 7 Lift cylinder pressure balance 11 Float position stop pin
with restrictor
4 Spool stroke adjusting screw 8 Secondary pressure relief 12 Restrictor check valve
valve for lifting
LBH/11827693/02/211-20150615.1139/en
Fig. 225: Sectional view of LS valves

1 Tilt cylinder load retaining valve 3 LS working hydraulics pressure
cut-off
2 Flow regulating valve
copyright by
060-18 L538-1493
Fig. 226: Sectional view of priority valve

1 Priority valve 3 Restrictor
2 Restrictor 4 Regulating spring
LBH/11827693/02/211-20150615.1139/en
copyright by
L538-1493 060-19
2 Function
2.1 Basic function
Fig. 227: Hydraulic diagram of control valve block for Z-bar kinematics
1 Control valve block 23 Restrictor
2 Priority valve 24 Load retaining valve
3 Restrictor 25 Feeding valve
4 Restrictor 26 Restrictor check valve
5 Check valve 27 Restrictor check valve
6 LS steering pressure cut-off 28 Secondary pressure relief valve
for lifting
7 LS working hydraulics pressure 29 Pre-tension valve
cut-off
8 Flow regulating valve 30 Compact brake valve (housing
preheating)
9 Restrictor 31 Pilot control unit connection 3
LBH/11827693/02/211-20150615.1139/en
10 Tilt cylinder spool valve 32 Pilot control unit connection 4

11 Tilt cylinder pressure balance 33 Hydraulic tank
12 Restrictor 34 Working hydraulics pump
13 Load retaining valve 35 Servostat LS connection
14 Feeding valve 36 Working hydraulics pump LS con-
nection
15 Restrictor check valve 37 Servostat oil supply
16 Restrictor check valve 38 Pilot control unit connection 2
17 Low-leak valve relief 39 Tilt cylinder ring side
18 Low leak valve for tilting in 40 Tilt cylinder piston side
19 Secondary pressure relief valve 41 Pilot control unit connection 1
for tilting out
copyright by
060-20 L538-1493
20 Secondary pressure relief valve 42 Lift cylinder ring side

for tilting in
21 Lift cylinder spool valve 43 Lift cylinder piston side
22 Lift cylinder pressure balance
The control valve block is supplied with oil by the working hydraulics pump 34. The
load sensing signal 36 determines the flow rate of the working hydraulics pump.
When the working hydraulics are actuated, the pressure balances in the control
valve block generate the load sensing signal. When the steering system is actu-
ated, the load sensing signal is transferred from the servostat 35 via the control
valve block to the working hydraulics pump.
The priority valve 2 distributes the oil from the working hydraulics pump to the
steering system 37 and the working hydraulics. The steering system has priority of
supply.
The pilot control system applies pressure to the spools and moves them. Oil flows
through the spool to the consumers.
Except for the lowering function, all the functions are protected with secondary
pressure relief valves.
LBH/11827693/02/211-20150615.1139/en
copyright by
L538-1493 060-21
Control valve block for P kinematics
Valid for: L538-1493/31405-;
1 Layout
Fig. 228: Control valve block for P kinematics

1 Secondary pressure relief valve 6 LS steering pressure cut-off
for lifting
2 Secondary pressure relief valve 7 Tilt cylinder pressure balance
for tilting in
3 Lift cylinder pressure balance 8 Flow regulating valve
4 LS working hydraulics pressure 9 Secondary pressure relief valve
cut-off for tilting out
5 Priority valve 10 Pre-tension valve
The control valve block has the following components and functions:
– Spool valves for the lift cylinder, tilt cylinder and 3rd function (optional) with
pressure balances
– Working hydraulics pressure protection (working hydraulic LS pressure cut-off
and secondary pressure relief valves)
– Steering system pressure protection (steering system LS pressure cut-off)
– Feeding function
LBH/11827693/02/211-20150615.1139/en
– Float position function

– Priority valve
copyright by
060-22 L538-1493
Fig. 229: Sectional view of tilt cylinder section

1 Tilt cylinder spool valve 5 Secondary pressure relief 9 Spool stroke adjusting screw
2 Restrictor check valve 6 Load retaining valve 10 Return spring
3 Spool stroke adjusting screw 7 Tilt cylinder pressure balance 11 Restrictor check valve
with restrictor
4 Return spring 8 Secondary pressure relief
LBH/11827693/02/211-20150615.1139/en
Fig. 230: Sectional view of lift cylinder section

1 Lift cylinder spool valve 5 Return spring 9 Return spring
2 Feeding valve 6 Load retaining valve 10 Float position compression
spring
copyright by
L538-1493 060-23
3 Restrictor check valve 7 Lift cylinder pressure balance 11 Float position stop pin
with restrictor
4 Spool stroke adjusting screw 8 Secondary pressure relief 12 Restrictor check valve
valve for lifting
Fig. 231: Sectional view of LS valves

1 Tilt cylinder load retaining valve 3 LS working hydraulics pressure
cut-off
2 Flow regulating valve
LBH/11827693/02/211-20150615.1139/en
Fig. 232: Sectional view of priority valve

1 Priority valve 3 Restrictor
2 Restrictor 4 Regulating spring
copyright by
060-24 L538-1493
2 Function
2.1 Basic function
Fig. 233: Hydraulic diagram of control valve block for P kinematics

1 Control valve block 21 Load retaining valve
2 Priority valve 22 Feeding valve
5 Check valve 25 Secondary pressure relief valve
for lifting
6 LS steering pressure cut-off 26 Pre-tension valve
7 LS working hydraulics pressure 27 Compact brake valve (housing
cut-off preheating)
8 Flow regulating valve 28 Pilot control unit connection 3
9 Restrictor 29 Pilot control unit connection 4
10 Tilt cylinder spool valve 30 Hydraulic tank
11 Tilt cylinder pressure balance 31 Working hydraulics pump
12 Restrictor 32 Servostat LS connection
13 Load retaining valve 33 Working hydraulics pump LS con-
LBH/11827693/02/211-20150615.1139/en
nection
14 Secondary pressure relief valve 34 Servostat oil supply
for tilting out
15 Restrictor check valve 35 Pilot control unit connection 2
16 Restrictor check valve 36 Tilt cylinder piston side
17 Secondary pressure relief valve 37 Tilt cylinder ring side
for tilting in
18 Lift cylinder spool valve 38 Pilot control unit connection 1
19 Lift cylinder pressure balance 39 Lift cylinder ring side
20 Restrictor 40 Lift cylinder piston side
The control valve block is supplied with oil by the working hydraulics pump 31. The
load sensing signal 33 determines the flow rate of the working hydraulics pump.
When the working hydraulics are actuated, the pressure balances in the control
copyright by
L538-1493 060-25
valve block generate the load sensing signal. When the steering system is actu-
ated, the load sensing signal is transferred from the servostat 34 via the control
valve block to the working hydraulics pump.
The priority valve 2 distributes the oil from the working hydraulics pump to the
steering system 34 and the working hydraulics. The steering system has priority of
supply.
The pilot control system applies pressure to the spools and moves them. Oil flows
through the spool to the consumers.
Except for the lowering function, all the functions are protected with secondary
pressure relief valves.
LBH/11827693/02/211-20150615.1139/en
copyright by
060-26 L538-1493
Pilot control
060.6 Pilot control

Valid for: L538-1493/31405-;
1 Layout
LBH/11827693/02/211-20150615.1139/en
Fig. 234: Pilot control

1 Hydraulic tank 4 Pilot control hydro accumulator
2 Travel pump 5 Pilot control unit
3 Working hydraulics lockout sole- G Replenishing pressure test con-
noid valve Y14 nection
The pilot control consists of the following components:
tank, page 080-2)
– Travel pump (For more information see: 070.3 Travel pump, page 070-12) (For
more information see: 070.4 Travel pump, page 070-26)
– Pilot control unit (For more information see: 060.6.2 Pilot control unit,
page 060-28)
copyright by
L538-1493 060-27
Pilot control
– Working hydraulics lockout solenoid valve Y14 (For more information see:
060.6.3 Working hydraulics lockout solenoid valve, page 060-33)
– Pilot control hydro accumulator (For more information see: 060.6.4 Pilot control
hydro accumulator, page 060-34)
2 Function
The spools in the control valve block are moved with the pilot control in proportion
to the deflection of the control lever.
The replenishing pump in the travel pump extracts oil from the hydraulic tank and
pumps it to the pilot control unit via the working hydraulics lockout solenoid valve.
The pilot control unit generates the servo pressure from the replenishing pressure
that moves the spool in the control valve block. The servo pressure is thus propor-
tional to the deflection of the control lever. The pilot control unit also controls the
float position, lift kick-out (optional) and bucket return-to-dig functions.

Valid for: L538-1493/31405-;
1 Layout
LBH/11827693/02/211-20150615.1139/en
Fig. 235: Pilot control unit

1 Control lever 4 Retaining magnet power supply
2 Lift kick-out retaining magnet Y17 5 Float position retaining magnet
(optional) Y18
3 Bucket return-to-dig retaining
magnet Y9
The pilot control unit is installed in the driver’s cab.
The control lever 1 is attached to the pilot control unit.
copyright by
060-28 L538-1493
Pilot control
Fig. 236: Sectional view of pilot control unit

1 Tilt out valve 9 Retaining plate
2 Return spring 10 Bucket return-to-dig retaining
magnet Y9
3 Regulating spring 11 Regulating spring cup
4 Regulating spring cup 12 Retaining magnet spring bushing
5 Tappet 13 Tilt in valve
6 Universal joint 14 Retaining magnet compression
spring
7 Ball journal 15 Regulating spring
8 Control lever 16 Return spring
LBH/11827693/02/211-20150615.1139/en
copyright by
L538-1493 060-29
Pilot control
2 Function
2.1 Basic function
Fig. 237: Hydraulic diagram of pilot control unit

1 Pilot control unit 8 Tilt out valve
2 Lowering valve 9 Hydraulic tank
3 Float position retaining magnet 10 Oil from the replenishing pump
Y18
4 Lifting valve 11 Tilt cylinder spool a1 (tilt out)
5 Lift kick-out retaining magnet Y17 12 Tilt cylinder spool b1 (tilt in)
(optional)
6 Tilt in valve 13 Lift cylinder spool b2 (lift)
7 Bucket return-to-dig retaining 14 Lift cylinder spool a2 (lower)
magnet Y9
The pilot control unit generates the servo pressure that moves the spool in the con-
trol valve block. It generates the servo pressure in proportion to the deflection of
the control lever.
LBH/11827693/02/211-20150615.1139/en
copyright by
060-30 L538-1493
Pilot control
2.2 Generating servo pressure
Fig. 238: Pilot control unit not actuated / actuated

1 Tilt cylinder spool b1 (tilt in) 5 Return spring 9 Ball journal
2 Oil from the replenishing 6 Regulating spring 10 Control lever
pump
3 Tilt cylinder spool a1 (tilt out) 7 Regulating spring cup 11 Return spring
4 Tilt out valve 8 Tappet 12 Tilt in valve
When the control lever 9 is not moved, the return springs 5 and 10 hold the pilot
control unit in the zero position.
LBH/11827693/02/211-20150615.1139/en
When the control lever is moved, the ball journal presses against the tappet 8. The
tappet pushes via the regulating spring 6 against the valve 4 and opens it.
This causes oil to flow from the replenishing pump 2 through the valve 4 to the pilot
control of the spool 3. The servo pressure generated by this moves the spool and
simultaneously pushes against the valve 4. If the servo pressure is high enough, it
moves the valve 4 towards the regulating spring 6 and closes it again. This means
that the servo pressure does not continue increasing.
The further the control lever is moved, the greater the force of the regulating
spring. This means that the further the control lever is moved, the more the servo
pressure increases.
The servo pressure is thus proportional to the deflection of the control lever.
copyright by
L538-1493 060-31
Pilot control
2.3 Retaining magnets
Fig. 239: Retaining magnet not active / active

1 Control lever 4 Retaining magnet spring 7 Retaining magnet compres-
bushing sion spring
2 Retaining plate 5 Regulating spring cup 8 Bucket return-to-dig switch
3 Bucket return-to-dig retaining 6 Tilt in valve
magnet Y9
The retaining magnets are electromagnets that hold the control lever in the maxi-
mum position.
LBH/11827693/02/211-20150615.1139/en
The pilot control unit has retaining magnets for the following functions:
– Float position
– Lift kick-out (optional)
– Bucket return-to-dig
When the function is activated, the central control unit energises the corresponding
retaining magnet.
If the control lever 1 is only moved so far that the regulating spring cup 5 touches
the retaining magnet spring bushing 4, the retaining plate 2 does not yet touch the
retaining magnet 3.
Only when the spring force of the retaining magnet compression spring 7 is over-
come does the retaining plate 2 touch the retaining magnet 3. The retaining mag-
copyright by
060-32 L538-1493
Pilot control
net 3 holds the control lever in position. The valve 6 thus generates the maximum
servo pressure.

Valid for: L538-1493/31405-;
1 Layout
Fig. 241: Working hydraulics lockout solenoid valve

1 Working hydraulics lockout sole- 2 Valve block
noid Y14
The working hydraulics lockout solenoid valve is fitted in the frame of the rear sec-
tion.
2 Function
Fig. 242: Hydraulic diagram of working hydraulics lockout solenoid valve

1 Working hydraulics lockout sole- 3 Pilot control unit
noid valve Y14
2 Oil from the replenishing pump
When it is not energised, the working hydraulics lockout solenoid valve separates
the pilot control unit from the replenishing pressure. This means the working at-
tachment cannot be moved accidentally when the working hydraulics lockout is ac-
tivated or the engine is not running.
The working hydraulics lockout solenoid valve is energised in the following condi-
tions:
– You press the working hydraulics lockout button and disable the working hy-
draulics lockout when the engine is running.
LBH/11827693/02/211-20150615.1139/en
– You press and hold the working hydraulics lockout button with the engine not
running and the ignition on. This disables the working hydraulics lockout for as
long as the button is pressed. You can then tilt out the bucket and lower the lift
arms when the engine is not running. The oil required by the pilot control unit
comes from the pilot control hydro accumulator.
copyright by
L538-1493 060-33
Pilot control

Valid for: L538-1493/31405-;
1 Layout
Fig. 244: Pilot control hydro accumulator

1 Plunger 4 Membrane
2 Accumulator 5 Nitrogen chamber
3 Oil chamber 6 Plug
The pilot control hydro accumulator is attached to the pilot control solenoid valve.
The pilot control hydro accumulator is divided into two chambers by a membrane 4.
The chamber 5 is filled with nitrogen.
2 Function
The pilot control hydro accumulator enables the spools in the control valve block to
be actuated even when the engine is at a standstill. This means that the lift arms
can be lowered or the bucket tilted out when the engine is at a standstill.
When the engine is running, the oil chamber 3 is filled with oil by the replenishing
pump.
When the engine is at a standstill, the nitrogen filling 5 presses the membrane 4
against the oil.
LBH/11827693/02/211-20150615.1139/en
copyright by
060-34 L538-1493
Ride control
060.7 Ride control

Valid for: L538-1493/31405-;
1 Layout
Fig. 245: Ride control activated

1 Hydraulic tank 4 Ride control hydro accumula- MX Ride control hydro accumula-
tor tor load pressure test connec-
LBH/11827693/02/211-20150615.1139/en
tion
2 Control valve block 5 Left lift cylinder
3 Stabilisation module 6 Right lift cylinder
The ride control consists of the following components:
– Stabilisation module (For more information see: 060.7.2 Stabilisation module ,
page 060-36)
– Ride control hydro accumulator (For more information see: 060.7.3 Ride control
hydro accumulator, page 060-41)
copyright by
L538-1493 060-35
Ride control
2 Function
When driving on uneven ground, especially with loaded buckets, the machine is
subjected to bouncing and pitching vibrations. These vibrations are cushioned by
the ride control.
Ride control is only active when the following conditions are fulfilled:
– Ride control is switched on (with the ride control button).
– The travel speed is at least 9 km/h.
When the ride control is activated, the stabilisation module connects the ring side
of the lift cylinder to the hydraulic tank. This allows the lift arms to move up freely.
The stabilisation module also connects the piston side of the lift cylinder to the ride
control hydro accumulator. The ride control hydro accumulator cushions the vibra-
tions which occur when driving.

Valid for: L538-1493/31405-;
1 Layout
Fig. 246: Stabilisation module

1 Safety valve 4 Ride control solenoid valve Y20
2 Ride control valve spool MX Test connection for hydro accumu-
lator ride control load pressure
3 Hydro accumulator relief valve
The stabilisation module is fitted in the front section behind the control valve block.
LBH/11827693/02/211-20150615.1139/en
copyright by
060-36 L538-1493
Ride control
Fig. 247: Sectional view of the valve spool

1 Regulating spring 1 3 Ride control valve spool 5 Pin with hole
2 Regulating spring 2 4 Check valve 6 Safety valve
Fig. 248: Sectional view of the ride control solenoid valve

1 Regulating springs 3 Ride control solenoid valve
Y20
2 Restrictor check valve MX Test connection for hydro ac-
LBH/11827693/02/211-20150615.1139/en
cumulator ride control load

pressure
copyright by
L538-1493 060-37
Ride control
2 Function
2.1 Basic function
Fig. 249: Hydraulic diagram of the stabilisation module

1 Stabilisation module 7 Ride control hydro accumulator
2 Ride control valve spool 8 Hydraulic tank
3 Hydro accumulator relief valve 9 Lift cylinder piston side
4 Ride control solenoid valve Y20 10 Lift cylinder ring side
5 Restrictor check valve MX Ride control hydro accumulator
charge pressure
6 Safety valve
The stabilisation module fulfils the following tasks:
– Charges the ride control hydro accumulator and protects from high pressure
spikes and excess pressure
– Connects the ring side of the lift cylinder with the hydraulic tank (ride control is
activated)
– Connects the piston side of the lift cylinder with the ride control hydro accumula-
tor (ride control is activated)
LBH/11827693/02/211-20150615.1139/en
copyright by
060-38 L538-1493
Ride control
2.2 Charging and protecting the ride control hydro accumulator
Fig. 250: Stabilisation module with the ride control hydro accumulator charging / with excess pressure
1 Regulating spring 4 Ride control hydro accumula- 7 Pin with hole
tor
2 Ride control valve spool 5 Check valve 8 Safety valve
3 Lift cylinder piston side 6 Compression spring
The check valve 5 in the ride control valve spool 2 connects the piston side of the
lift cylinder 3 to the ride control hydro accumulator 4. This means the working hy-
LBH/11827693/02/211-20150615.1139/en
draulics charge the ride control hydro accumulator 4 with the operating pressure.
Charging the ride control hydro accumulator 4 is necessary so that the lift arm is
not lowered when ride control is activated.
When the cut-off pressure (maximum boost pressure) is reached, the pressure in
the ride control hydro accumulator 4 moves the ride control valve spool 2 to the
point that no more oil can flow. When the cut-off pressure is exceeded, oil drains
into the hydraulic tank through the hole 7 in the pin.
In addition, the safety valve 8 protects the ride control hydro accumulator 4 from
excess pressure and high pressure peaks.
copyright by
L538-1493 060-39
Ride control
2.3 Active ride control
Fig. 251: Ride control inactive / active

A Pressure chamber 3 Lift cylinder ring side 6 Ride control hydro accumula-
tor
1 Regulating spring 4 Ride control valve spool 7 Ride control solenoid valve
Y20
2 Hydraulic tank 5 Lift cylinder piston side 8 Ride control button
When ride control is active, the ride control solenoid valve 7 connects the ride con-
LBH/11827693/02/211-20150615.1139/en
trol hydro accumulator 6 to the pressure chamber A.

The pressure in the pressure chamber A moves the ride control valve spool 4
against the regulating spring 1. Thus, the ride control valve spool 4 connects the
ring side of the lift cylinder 3 to the hydraulic tank 4 and the piston side of the lift
cylinder 5 to the ride control hydro accumulator 6.
The lift arm can move up freely. At the same time, the gas in the ride control hydro
accumulator cushions against knocks.
copyright by
060-40 L538-1493
Ride control

Valid for: L538-1493/31405-;
1 Layout
Fig. 252: Ride control hydro accumulator

1 Plunger 5 Nitrogen chamber
2 Accumulator 6 Plug
3 Oil chamber 7 Oil filling
4 Membrane
The ride control hydro accumulator is bolted to the stabilisation module.
The ride control hydro accumulator is divided into two chambers by a membrane 4.
The chamber 5 is filled with nitrogen.
2 Function
The piston side of the lift cylinder is connected to the oil chamber 3 via the stabili-
sation module. When the machine drives over uneven ground, the lift arm rocks up
and down. These rocking movements are cushioned by the nitrogen filling 5.
The oil filling 7 prevents the membrane 4 from knocking too hard against the accu-
mulator 2.
LBH/11827693/02/211-20150615.1139/en
copyright by
L538-1493 060-41
Working hydraulics cylinder
060.8 Working hydraulics cylinder
060.8.1 Hydraulic cylinders for Z kinematics

Valid for: L538-1493/31405-;
1 Layout
LBH/11827693/02/211-20150615.1139/en
Fig. 253: Lift cylinder

1 Piston-side cylinder bearing 10 Slide rings
2 Bearing bushing 11 Support rings
3 Cylinder tube 12 Glyd Ring seal
4 Ring-side cylinder bearing 13 O-ring
5 Piston rod bearing 14 Slide rings
6 Piston rod 15 Stepseal
7 Piston 16 Rimseal
8 Nut 17 Scraper ring
9 Slide rings
copyright by
060-42 L538-1493
The piston-side cylinder bearing 1 is a link with a bearing bushing 2. The ring-side
cylinder bearing 4 is forked.
The piston 7 is bolted to the piston rod 6 and secured with the nut 8.
The piston rod bearing 5 is bolted to the cylinder tube 3.
2 Function
2.1 Basic function

The lift cylinder is a double-action hydraulic cylinder with a piston rod at one end.
The force depends on the oil pressure and the piston area. The piston area on the
piston side is larger than on the ring side. This means a greater force is achieved
when extending than when retracting.
2.2 Piston rod guide

The piston rod is guided by the slide rings on the piston and in the piston rod bear-
ing.
2.3 Seals
The piston is sealed with a Glyd Ring seal.
The piston rod bearing is sealed with a Rimseal and a Stepseal. In addition, a scra-
per ring prevents dirt from penetrating.
LBH/11827693/02/211-20150615.1139/en
copyright by
L538-1493 060-43

Valid for: L538-1493/31405-;
1 Layout

2 Bearing bushing 12 Glyd Ring seal
3 Cylinder tube 13 Support rings
LBH/11827693/02/211-20150615.1139/en
4 Ring-side cylinder bearing 14 O-rings

8 Piston 18 Rimseal
10 Slide rings
The piston-side cylinder bearing 1 is designed as a fork.
The piston-side cylinder bearing 1 and the ring-side cylinder bearing 3 are links
with a bearing bushing.
copyright by
060-44 L538-1493
2 Function
2.1 Basic function


ing.
2.3 Seals
060.8.2 Hydraulic cylinders for P kinematics

LBH/11827693/02/211-20150615.1139/en
copyright by
L538-1493 060-45

Valid for: L538-1493/31405-;
1 Layout

3 Cylinder tube 12 Glyd Ring seal
4 Ring-side cylinder bearing 13 O-ring
LBH/11827693/02/211-20150615.1139/en
7 Piston 16 Rimseal
9 Slide rings
The piston-side cylinder bearing 1 is a link with a bearing bushing 2. The ring-side
cylinder bearing 4 is forked.
copyright by
060-46 L538-1493
2 Function
2.1 Basic function


ing.
2.3 Seals

Valid for: L538-1493/31405-;
1 Layout
LBH/11827693/02/211-20150615.1139/en
Fig. 256: Tilt cylinder

2 Bearing bushing 11 Glyd Ring seal
copyright by
L538-1493 060-47

5 Bearing bushing 14 Slide rings
6 Piston rod bearing 15 Stepseal
7 Piston rod 16 Rimseal
8 Piston 17 Scraper ring
9 Nut
The piston-side cylinder bearing 1 and the ring-side cylinder bearing 4 are links
with a bearing bushing.
2 Function
2.1 Basic function

The tilt cylinder is a double-action hydraulic cylinder with a piston rod at one end.

ing.
2.3 Seals
LBH/11827693/02/211-20150615.1139/en
copyright by
060-48 L538-1493
070 Travel hydraulics
Contents
L538-1493/36292-31404; 070-2
L538-1493/31405-; 070-7
070.3 Travel pump
L538-1493/31405-36291; 070-12
070.4 Travel pump
L538-1493/36292-; 070-26
070.5 Travel motors 070-41
L538-1493/31405-; 070-41
L538-1493/31405-; 070-43
L538-1493/31405-; 070-50
LBH/11827693/02/211-20150615.1139/en
copyright by
L538-1493 070-1
Travel hydraulics Service manual
Travel hydraulics overview
Valid for: L538-1493/36292-31404;
1 Layout
LBH/11827693/02/211-20150615.1139/en
Fig. 257: Main components of the travel hydraulics

1 Hydraulic tank 7 Fan gear motor MH Travel pump high pressure
test connection
2 Travel pump 8 Collector pipe M1 Travel motor 1 servo pres-
sure test connection
copyright by
070-2 L538-1493
Service manual Travel hydraulics
3 Travel motor 2 9 Hydraulic oil cooler M2 Travel motor 2 servo pres-

4 Travel motor 1 10 Temperature valve PK Cooling system high pressure
test connection
5 Fan gear pump X1 Forward travel direction servo
pressure test connection
6 80 µm in-line filter G Replenishing pressure test
connection
The travel hydraulics consist of the following components:
tank, page 080-2)
– Travel pump (For more information see: 070.4 Travel pump, page 070-26)
– Travel motor 1 (For more information see: 070.5.2 Travel motor 1,
page 070-43)
page 070-50)
– Cooling system
LBH/11827693/02/211-20150615.1139/en
copyright by
L538-1493 070-3
2 Function
2.1 Basic function
Fig. 258: Hydraulic diagram of the travel hydraulics

1 Hydraulic tank 32 Replenishing pressure relief 59 Servo piston
valve
LBH/11827693/02/211-20150615.1139/en
2 Breather filter 33 Servo cylinder 60 Travel direction solenoid

valve Y26
3 Return strainer 34 Axial piston pump 61 Control piston with travel
range 1 solenoid Y58
4 Bypass valve 35 Swivel restrictor Ø 1.8 mm 62 Swivel restrictor
5 Return suction filter 36 Fine strainer 63 Orifice Ø 1.0 mm
6 Pre-tension valve 37 Swivel restrictor Ø 1.8 mm 64 Orifice Ø 1.0 mm
7 Replenishing valve 38 Fine strainer 65 Transmission
8 Strainer 39 Travel direction valve 66 Engine
9 9 bar check valve 39a Reverse travel direction sole- 67 Fan gear pump
noid Y3
copyright by
070-4 L538-1493
10 2.5 bar bypass valve 39b Forward travel direction sole- 68 Brake system gear pump
noid Y2
11 Hydraulic oil temperature 40 Control pressure proportional 70 Fan gear motor
sensor B8 valve Y59
12 Drain valve 41 Fine strainer 71 Gear motor
13 Working hydraulics pump 42 Check valve 72 Proportional pressure relief
suction port valve
14 Brake system gear pump suc- 43 Travel pump high-pressure 73 Restrictor
tion port sensor B45
15 Emergency steering pump 44 Pilot control, gear shifting 74 Primary piston
suction port
16 Transmission return flow 45 Travel motor 2 75 Secondary piston with propor-
tional solenoid Y13
17 Compact brake valve return 46 Axial piston pump 76 80 µm in-line filter
flow
18 Pilot control unit return flow 47 Check valve 77 Hydraulic oil cooler
19 Working hydraulics pump 48 Check valve 78 Temperature valve
leak oil
20 Servostat return flow 49 Proportional valve and control 79 Collector pipe
piston Y57
21 Control valve block return 50 Servo piston 80 0.25 bar check valve
flow
25 Travel pump 51 Discharge valve X1 Forward travel direction servo
pressure
26 Replenishing pump 52 Orifice G Replenishing pressure
27 Towing bypass valve 53 Pressure relief valve MH Travel pump high pressure
28 Shuttle valve 55 Travel motor 1 M1 Travel motor 1 servo pres-
sure
29 Pressure cut-off valve 56 Axial piston pump M2 Travel motor 2 servo pres-
sure
30 Forward travel direction high 57 Check valve PK Cooling system high pressure
pressure relief valve
31 Reverse travel direction high 58 Check valve
The travel hydraulics is a closed circuit. This means that after leaving the consum-
ers (travel motors), the oil flows directly back to the pump (travel pump).
The travel hydraulics function hydrostatically. The travel pump 25 converts the rota-
ry movement of the engine 66 into a piston stroke movement (axial piston pump).
The piston stroke pumps the oil. The travel motors also use a piston stroke move-
ment to convert the flow of oil into a rotary movement (axial piston motor). There is
no slip with this kind of drive.
Leakages in the rotary groups and the discharge 51 of travel motor 2 mean that oil
constantly flows out of the closed circuit. This oil is collected in the collector pipe 79
LBH/11827693/02/211-20150615.1139/en
and then cooled in the hydraulic oil cooler 77.

The replenishing pump 26 replaces the missing oil. The replenishing pump 26
draws up oil from the hydraulic tank 1 and pumps into the closed circuit on the low
pressure side.
The replenishing pump 26 also provides the two travel motors with oil. This oil lubri-
cates and cools the travel motors.
2.2 Travel direction

The travel direction is determined by the flow direction of the oil in the closed cir-
cuit. To change the travel direction, the high pressure and low pressure are swap-
ped. The travel pump does this by moving over the zero position in the opposite
direction.
copyright by
L538-1493 070-5
2.3 Regulation
2.3.1 Regulation of the travel pump

The travel pump is electrically and proportionally regulated. The angle is deter-
mined by the current to the control pressure proportional valve Y59. The control
pressure proportional valve Y59 is powered by the central control unit.
2.3.2 Regulation of travel motor 1

Travel motor 1 is controlled according to the high pressure. The high pressure in
the closed circuit determines the angle.

Travel motor 2 is electrically and proportionally regulated. The angle is determined
by the current to the control pressure proportional valve Y57. The proportional
valve Y57 is powered by the central control unit.
LBH/11827693/02/211-20150615.1139/en
copyright by
070-6 L538-1493
Valid for: L538-1493/31405-;
1 Layout
LBH/11827693/02/211-20150615.1139/en
Fig. 259: Main components of the travel hydraulics

1 Hydraulic tank 7 Fan gear motor MH Travel pump high pressure
test connection
2 Travel pump 8 Collector pipe M1 Travel motor 1 servo pres-
copyright by
L538-1493 070-7
3 Travel motor 2 9 Hydraulic oil cooler M2 Travel motor 2 servo pres-

4 Travel motor 1 10 Temperature valve PK Cooling system high pressure
test connection
5 Fan gear pump X1 Forward travel direction servo
6 80 µm in-line filter G Replenishing pressure test
connection
The travel hydraulics consist of the following components:
tank, page 080-2)
– Travel pump (For more information see: 070.3 Travel pump, page 070-12)
page 070-43)
page 070-50)
– Cooling system
LBH/11827693/02/211-20150615.1139/en
copyright by
070-8 L538-1493
2 Function
2.1 Basic function
Fig. 260: Hydraulic diagram of the travel hydraulics

1 Hydraulic tank 32 Replenishing pressure relief 60 Travel direction solenoid
valve valve Y26
2 Breather filter 33 Servo cylinder 61 Control piston with travel
LBH/11827693/02/211-20150615.1139/en
range 1 solenoid Y58

3 Return strainer 34 Axial piston pump 62 Swivel restrictor
4 Bypass valve 35 Swivel restrictor Ø 1.8 mm 63 Orifice Ø 1.0 mm
5 Return suction filter 36 Fine strainer 64 Orifice Ø 1.0 mm
6 Pre-tension valve 37 Swivel restrictor Ø 1.8 mm 65 Transmission
7 Replenishing valve 38 Fine strainer 66 Engine
8 Strainer 39 Travel direction valve 67 Fan gear pump
9 9 bar check valve 39a Reverse travel direction sole- 68 Brake system gear pump
noid Y3
10 2.5 bar bypass valve 39b Forward travel direction sole- 70 Fan gear motor
noid Y2
copyright by
L538-1493 070-9
11 Hydraulic oil temperature 40 Control pressure proportional 71 Gear motor

sensor B8 valve Y59
12 Drain valve 41 Fine strainer 72 Proportional pressure relief
valve
13 Working hydraulics pump 42 Check valve 73 Restrictor
suction port
14 Brake system gear pump suc- 43 Pilot control, gear shifting 74 Primary piston
tion port
15 Emergency steering pump 45 Travel motor 2 75 Secondary piston with propor-
suction port tional solenoid Y13
16 Transmission return flow 46 Axial piston pump 76 80 µm in-line filter
17 Compact brake valve return 47 Check valve 77 Hydraulic oil cooler
flow
18 Pilot control unit return flow 48 Check valve 78 Temperature valve
19 Working hydraulics pump 49 Proportional valve and control 79 Collector pipe
leak oil piston Y57
20 Servostat return flow 50 Servo piston 80 0.25 bar check valve
21 Control valve block return 51 Discharge valve X1 Forward travel direction servo
flow pressure
25 Travel pump 52 Orifice G Replenishing pressure
26 Replenishing pump 53 Pressure relief valve MH Travel pump high pressure
27 Towing bypass valve 55 Travel motor 1 M1 Travel motor 1 servo pres-
sure
28 Shuttle valve 56 Axial piston pump M2 Travel motor 2 servo pres-
sure
29 Pressure cut-off valve 57 Check valve PK Cooling system high pressure
30 Forward travel direction high 58 Check valve
31 Reverse travel direction high 59 Servo piston
The travel hydraulics is a closed circuit. This means that after leaving the consum-
ers (travel motors), the oil flows directly back to the pump (travel pump).
The travel hydraulics function hydrostatically. The travel pump 25 converts the rota-
ry movement of the engine 66 into a piston stroke movement (axial piston pump).
The piston stroke pumps the oil. The travel motors also use a piston stroke move-
ment to convert the flow of oil into a rotary movement (axial piston motor). There is
no slip with this kind of drive.
Leakages in the rotary groups and the discharge 51 of travel motor 2 mean that oil
constantly flows out of the closed circuit. This oil is collected in the collector pipe 79
and then cooled in the hydraulic oil cooler 77.
The replenishing pump 26 replaces the missing oil. The replenishing pump 26
draws up oil from the hydraulic tank 1 and pumps into the closed circuit on the low
pressure side.
LBH/11827693/02/211-20150615.1139/en
The replenishing pump 26 also provides the two travel motors with oil. This oil lubri-
cates and cools the travel motors.

The travel direction is determined by the flow direction of the oil in the closed cir-
cuit. To change the travel direction, the high pressure and low pressure are swap-
ped. The travel pump does this by moving over the zero position in the opposite
direction.
copyright by
070-10 L538-1493
2.3 Regulation
2.3.1 Regulation of the travel pump

The travel pump is electrically and proportionally regulated. The angle is deter-
mined by the current to the control pressure proportional valve Y59. The control
pressure proportional valve Y59 is powered by the central control unit.

Travel motor 1 is controlled according to the high pressure. The high pressure in
the closed circuit determines the angle.

Travel motor 2 is electrically and proportionally regulated. The angle is determined
by the current to the control pressure proportional valve Y57. The proportional
valve Y57 is powered by the central control unit.
LBH/11827693/02/211-20150615.1139/en
copyright by
L538-1493 070-11
Travel pump
070.3 Travel pump
Valid for: L538-1493/31405-36291;
1 Layout
Fig. 261: Travel pump

1 Replenishing pump 8 Control pressure proportional
valve Y59
2 Towing bypass valve 9 Reverse travel direction solenoid
Y3
3 Forward high pressure relief valve 10 Travel direction valve
4 Replenishing pressure relief valve X1 Forward travel direction servo
5 Reverse high pressure relief valve X2 Reverse travel direction servo
pressure
6 Pressure cut-off valve G Replenishing pressure test con-
nection
7 Forward travel direction solenoid MH Travel hydraulics high pressure
LBH/11827693/02/211-20150615.1139/en
Y2 test connection
The travel pump is flange-mounted on the flywheel housing of the engine. The
working hydraulics pump is attached to the drive shaft of the travel pump.
The following components are integrated in the travel pump:
– Replenishing pump (internal gear pump)
– Replenishing pressure relief valve
– Travel direction valve
– Servo cylinder
– Control pressure proportional valve
– Pressure cut-off
– High pressure relief valve (with replenishing function)
copyright by
070-12 L538-1493
Travel pump

1 Drive shaft 8 Control lens 15 Return plate
2 Servo cylinder 9 Eccentric adjusting screw 16 Cup springs
3 Control system housing 10 Rotary group cylinder 17 Return ball
4 Travel direction valve 11 Compression spring 18 Swivel plate
5 Working hydraulics pump 12 Sliding bushing 19 Swivel plate bearing
connection flange
6 Replenishing pump 13 Piston 20 Roller bearing
7 Bearing bushing 14 Glide shoe 21 Shaft seal ring
LBH/11827693/02/211-20150615.1139/en
copyright by
L538-1493 070-13
Travel pump
Fig. 263: Sectional view of the servo cylinder

1 Glyd Ring seal 5 Compression spring 9 Forward travel direction sole-
noid Y2
2 Servo cylinder 6 Swivel restrictor 10 Travel direction valve
3 Spring cup 7 Fine strainer 11 Zero position adjusting screw
4 Compression spring 8 Reverse travel direction sole-
noid Y3
LBH/11827693/02/211-20150615.1139/en
copyright by
070-14 L538-1493
Travel pump
Fig. 264: Sectional view of front side

1 Reverse high pressure relief valve 3 Replenishing pressure relief valve
2 Forward high pressure relief valve 4 Control lens
LBH/11827693/02/211-20150615.1139/en
Fig. 265: Sectional view of replenishing pump

1 Replenishing pump 4 Towing bypass valve
2 Pressure cut-off valve 5 Stop bolt for towing bypass valve
3 Shuttle valve
copyright by
L538-1493 070-15
Travel pump
2 Function
2.1 Basic function
Fig. 266: Hydraulic diagram of travel pump (forward travel direction)

1 Travel pump 15a Reverse travel direction solenoid
Y3
2 Replenishing pump (internal gear 15b Forward travel direction solenoid
pump) Y2
3 Towing bypass valve 16 Control pressure proportional
valve Y59
4 Shuttle valve 17 Fine strainer
5 Pressure cut-off valve 18 Check valve
6 Forward high pressure relief valve 19 Pilot control, gear shifting
7 Reverse high pressure relief valve 20 Travel motor bearing flushing
8 Replenishing pressure relief valve 21 Low pressure from travel motor
9 Variable displacement pump (axial 22 High pressure to travel motor
piston pump)
10 Servo cylinder 23 Travel pump leak oil
11 Swivel restrictor Ø1.8 mm 24 Travel pump leak oil bypass
12 Fine strainer 25 Replenishing pump suction port
13 Swivel restrictor Ø 1.8 mm X1 Forward control pressure
14 Fine strainer MH High pressure
LBH/11827693/02/211-20150615.1139/en
15 Travel direction valve G Replenishing pressure

The travel pump is solely designed for operation in a closed circuit.
The travel pump consists of two pumps driven by the same drive shaft: The varia-
ble displacement pump 9, which drives the travel motors in the closed circuit, and
the replenishing pump 2, which supplies the closed circuit with fresh oil from the
hydraulic tank.
The variable displacement pump delivers the oil directly to the travel motors. The
returning oil flows directly to the suction side of the variable displacement pump
(closed circuit).
The control pressure proportional valve 16 generates the control pressure. At idling
speed, the angle is 0°. The variable displacement pump does not deliver any oil.
copyright by
070-16 L538-1493
Travel pump
The variable displacement pump does not deliver oil until the control pressure is
high enough to move it out to an angle.
2.2 Replenishing pump
Fig. 267: Replenishing pump

1 External gear 3 Drive shaft
2 Internal gear 4 Consumer
The replenishing pump draws oil from the return suction filter in the hydraulic tank.
The replenishing pump delivers the oil directly to the consumers 4:
– Pressure cut-off and control pressure proportional valve
– High pressure relief valve (replenishing function)
– Bearing flushing (For more information see: Bearing flushing (lubrication and
cooling), page 070-42)
unit, page 060-27)
– Gear shifting
Because the replenishing pump is an internal gear pump, the flow rate per revolu-
tion cannot be adjusted. The actual flow rate is determined by the engine speed
LBH/11827693/02/211-20150615.1139/en
alone.
copyright by
L538-1493 070-17
Travel pump
2.3 Replenishing pressure relief valve
Fig. 268: Replenishing pressure relief valve

1 Compression spring 3 Valve piston
2 Spring cup 4 Valve seat
The replenishing pressure relief valve:
– Protects the replenishing pump from excess pressure
– Drains excess oil that is not needed for pump control or for replenishing into the
pump housing
The valve piston 3 and the spring cup 2 are pushed against the compression
spring 1. The oil is drained into the pump housing T and back to the hydraulic tank
via the leak oil connections. This cools the variable displacement pump.
When the engine is running, oil always flows through the replenishing pressure re-
lief valve.
LBH/11827693/02/211-20150615.1139/en
copyright by
070-18 L538-1493
Travel pump
2.4 Variable displacement pump
Fig. 269: Variable displacement pump

1 Servo cylinder 8 Glide shoe
2 Swivel plate 9 Piston
3 Swivel plate bearing 10 Sliding bushing
4 Drive shaft 11 Rotary group cylinder
5 Return ball 12 Compression spring
6 Cup spring 13 Eccentric adjusting screw
7 Return plate 14 Control lens
The variable displacement pump delivers oil to the travel motor. The returning oil
flows directly to the suction side of the variable displacement pump (closed circuit).
The flow rate depends on:
– Plate angle
– Engine speed
LBH/11827693/02/211-20150615.1139/en
2.4.1 Rotary group

The rotary group cylinder 11 is rigidly connected to the drive shaft 4. The rotary
group cylinder contains nine pistons 9, which rotate along with it. The pistons slide
up and down in the sliding bushings 10 and are guided by glide shoes 8 and the
return plate 7.
The swivel plate 2 and the control lens 14 do not move.
Oil is pumped through a hole in the pistons 9 into the space between the glide
shoe and swivel plate. This means the slide shoe floats on a film of oil and slides
over the swivel plate without mechanical contact.
The rotary group also slides on a film of oil. This is produced by the leakage be-
tween the control lens and the rotary group cylinder.
copyright by
L538-1493 070-19
Travel pump
2.4.2 Swivel plate

The swivel plate 2 lies on a roller bearing, the swivel plate bearing 3, and is con-
nected by a lever to the servo cylinder 1.
If the servo cylinder is moved, the this changes the lateral angle of the swivel plate
to the drive shaft 4. The angle can be between -20° and 0° and +20°.
The tilt of the swivel plate means the pistons 9 perform a lengthways movement
axially to the drive shaft with every revolution. This lengthways movement draws up
and pumps the oil. The greater the angle, the longer the stroke and the more oil is
pumped with each revolution.
If no travel direction is selected (neutral travel direction), the angle of the swivel
plate is 0°. The pistons do not perform a stroke movement. No oil is pumped.
2.4.3 Control lens

The restoring force on the high pressure side can be adjusted using the control
lens 14. The control lens is turned with the eccentric adjusting screw 13. This
moves the recesses in the control lens and adjusts the size of the area which the
high pressure acts on.
2.5 Servo cylinder
LBH/11827693/02/211-20150615.1139/en
Fig. 270: Neutral/forward travel direction servo cylinder

1 Glyd Ring seal 6 Swivel restrictor 11 Swivel restrictor
2 Servo cylinder 7 Fine strainer 12 Zero position adjusting screw
3 Spring cup 8 Travel direction valve 13 Travel direction switch
4 Compression spring 9 Control pressure
5 Compression spring 10 Fine strainer
The servo cylinder moves the swivel plate and thus changes the flow rate of the
variable displacement pump.
copyright by
070-20 L538-1493
Travel pump
If no travel direction is selected (neutral travel direction), both chambers of the ser-
vo cylinder are relieved towards the pump housing T. The springs 4 and 5 hold the
servo cylinder 2 in the zero position (0° angle). The pump does not deliver any oil.
If a travel direction is selected, one of the two chambers of the servo cylinder 2 is
acted on by control pressure 9. The servo cylinder 2 is pushed against the com-
pression springs 4 and 5. The variable displacement pump is moved to a greater
angle. The angle depends on the amount of control pressure and on the high pres-
sure (restoring force).
The oil displaced from the depressurised side by the movement of the servo cylin-
der 2 flows into the pump housing T. The swivel restrictors 6 and 11 reduce the oil
flow and restrict the movement.
2.6 Regulation of the variable displacement pump

– Plate angle
– Engine speed
In turn, the plate angle depends on:
– Selected travel direction (travel direction valve)
– Energisation of the control pressure proportional valve
– Load (operating pressure)
2.6.1 Travel direction valve
Fig. 271: Neutral/forward travel direction valve

LBH/11827693/02/211-20150615.1139/en
1 Reverse travel direction solenoid 5 Forward travel direction solenoid

Y3 Y2
2 Return spring 6 Control pressure
3 Spring cup 7 Servo cylinder
4 Valve piston 8 Travel direction switch
The travel direction valve determines the swivel direction (+/-) and thus the direc-
tion of flow of the variable displacement pump, by the valve piston 4 directing con-
trol oil to one side of the servo cylinder 7. The valve piston 4 is moved by the two
magnets for forward travel direction 5 and reverse travel direction 1.
If no travel direction is selected (neutral travel direction) the valve piston 4 is held in
the middle position by the return springs 2. In this case, no control oil pressure acts
on the servo cylinder 7.
copyright by
L538-1493 070-21
Travel pump
2.6.2 Electrical/proportional regulation (EP regulation)
Fig. 272: Regulation with the control pressure proportional valve

1 Regulating spring 4 Control pressure proportional G Replenishing pressure
solenoid Y59
2 Control piston 5 Travel direction valve PSt Control pressure
3 Ring face 6 Servo cylinder T Pump housing
The angle of the variable displacement pump is regulated by the control pressure
proportional valve. To do so, the central control unit energises the control pressure
proportional solenoid 4 via output module 1.
The energisation of the control pressure proportional solenoid 4 depends on:
– Accelerator pedal position
– Inching function
– Excessive engine speed or road speed
– Excessive temperature of the hydraulic oil
– Speed restriction (Vmax function)
Without being energised, the regulating spring 1 and the control pressure, which is
LBH/11827693/02/211-20150615.1139/en
applied to the ring area 3, move the control piston 2. The control piston is pushed
so that the control pressure PSt flows into the pump housing T. The variable dis-
placement pump swivels back to the zero position.
If the central control unit increases the current to the control pressure proportional
solenoid 4, the solenoid pushes the control piston 2 against the regulating spring.
The control pressure duct PSt is linked to the replenishing pressure duct G. Control
pressure PSt is thus generated from replenishing pressure G.
The more current the proportional solenoid receives, the further the valve piston is
pushed.
copyright by
070-22 L538-1493
Travel pump
2.6.2.1 Accelerator pedal position

The central control unit registers that the accelerator pedal is being pressed
through the angle sensor R5 on the accelerator pedal.
If the accelerator pedal is pressed and the engine speed is above 900 rpm, the
central control unit increases the current to the control pressure proportional sole-
noid. The current is regulated according to the engine speed.
2.6.2.2 Inching function

The central control unit registers that the inching brake pedal is being pressed
through the angle sensor R1 on the inching brake pedal.
When the inching brake pedal is pressed, the central control unit reduces the cur-
rent to the control pressure proportional solenoid. The travel pump pivots in. The
machine is thereby hydrostatically braked.
2.6.2.3 Excessive engine speed or road speed

If the maximum speed permitted for the travel range is exceeded, the central con-
trol unit reduces the current to the control pressure proportional solenoid progres-
sively down to 200 mA.
2.6.2.4 Excessive temperature of the hydraulic oil

If the temperature of the hydraulic oil exceeds 90 °C, the central control unit re-
duces the current to the control pressure proportional solenoid gradually down to
40% of the maximum current (at a hydraulic oil temperature of 95 °C). The travel
pump pivots in. The power consumed is thereby reduced. The decreased power
output reduces the temperature.
The control pressure proportional solenoid is energised normally again when the
temperature is back in the normal range.
2.6.2.5 Travel pump load limiting function

If the travel pump has been moved to the maximum swivel angle and the central
control unit registers a major drop in engine speed under load, the travel pump
load limiting function is activated.
The central control unit reduces the current to the control pressure proportional sol-
enoid. The travel pump pivots in. The power consumed is thereby reduced. The
load on the engine is decreased.
2.6.3 Regulation by operating pressure

The high pressure acts on the pistons in the rotary group cylinder. The pistons rest
on the swivel plate and push it towards a smaller angle.
LBH/11827693/02/211-20150615.1139/en
copyright by
L538-1493 070-23
Travel pump
2.7 Shuttle valve and towing bypass valve
Fig. 273: Shuttle valve in forward travel direction / shuttle valve in reverse travel di-
rection / towing bypass valve open
1 High pressure to pressure cut-off 4 Towing bypass valve
2 Valve seat 5 Stop bolt
3 Valve piston
The shuttle valve always connects the pressure cut-off 1 to the high pressure side
of the closed circuit.
Depending on the travel direction, the valve piston 3 is moved so that the high
pressure side is connected to the pressure cut-off while the low pressure side is
blocked.
When the machine is towed, the travel motor is driven via the transmission. This
delivers oil from the travel motor to the travel pump. Oil can circulate through the
open towing bypass valve without driving the travel pump and therefore the engine.
To do this, the bypass valve 4 must be unscrewed to the stop bolt 5. This bypasses
the shuttle valve and connects the high and low pressure sides to each other.
2.8 Pressure cut-off
Fig. 274: Pressure cut-off not active / active

1 Valve piston 4 Spring cup 7 Oil from the replenishing
pump
2 Connecting duct 5 Regulating spring 8 High pressure from shuttle
valve
LBH/11827693/02/211-20150615.1139/en
3 To the control pressure pro- 6 Adjusting screw

portional valve Y59
The pressure cut-off limits the operating pressure in the closed circuit.
The shuttle valve always connects the pressure cut-off to the high pressure side of
the travel pump. If the high pressure 8 reaches the maximum permitted level, the
high pressure pushes the valve piston 1 against the regulating spring 5. This dis-
connects the link between the replenishing pump 7 and the control pressure pro-
portional valve 3. If the pressure continues increasing, the high pressure continues
pushing the valve piston 1 until the control pressure proportional valve 3 is connec-
ted to the pump housing T via the connecting duct 2. The control pressure falls and
the variable displacement pump moves back until the high pressure has fallen back
to the maximum permissible level.
copyright by
070-24 L538-1493
Travel pump
2.9 High pressure relief valve
Fig. 275: High pressure relief valve closed / open (excess pressure)
1 Plug 5 Replenishing compression spring
2 Lock screw 6 Valve seat
3 Valve bearing 7 Valve piston
4 Pressure relief compression spring
The high pressure relief valves protect the closed circuit from excess pressure.
The high pressure relief valves always react faster than the pressure cut-off. They
therefore primarily relieve pressure peaks such as those that arise when driving in-
to a pile of material too quickly.
The valve piston 7 is pushed against the pressure relief compression spring 4. Oil
flows from the high pressure side through the replenishing pressure duct G to the
low pressure side.
2.10 Replenishing function
Fig. 276: High pressure relief valve closed / open (replenishing)

LBH/11827693/02/211-20150615.1139/en

The replenishing function of the high pressure relief valve replaces lacking oil in the
closed circuit with replenishing oil. The oil is supplied on the low pressure side.
Oil is lost from the closed circuit due to:
– Leakage in the variable displacement pump
– Leakages in the travel motors
– Discharge in travel motor 2 (cooling)
When replenishing, the valve plate 6 is pushed against the replenishing compres-
sion spring 5. Oil flows from the replenishing pressure duct G to the low pressure
side of the closed circuit.
copyright by
L538-1493 070-25
Travel pump
070.4 Travel pump
Valid for: L538-1493/36292-;
1 Layout
Fig. 277: Travel pump

1 Replenishing pump 9 Travel pump high pressure sensor
B45
2 Towing bypass valve 10 Reverse travel direction solenoid
Y3
3 Forward high pressure relief valve 11 Travel direction valve
4 Replenishing pressure relief valve X1 Forward travel direction servo
5 Reverse high pressure relief valve X2 Reverse travel direction servo
pressure
6 Pressure cut-off valve G Replenishing pressure test con-
LBH/11827693/02/211-20150615.1139/en
nection
7 Forward travel direction solenoid MH Travel hydraulics high pressure
Y2 test connection
8 Control pressure proportional
valve Y59
The travel pump is flange-mounted on the flywheel housing of the engine. The
working hydraulics pump is attached to the drive shaft of the travel pump.
The following components are integrated in the travel pump:
– Replenishing pump (internal gear pump)
– Travel direction valve
– Servo cylinder
copyright by
070-26 L538-1493
Travel pump

– Control pressure proportional valve
– Pressure cut-off
– High pressure relief valve (with replenishing function)

1 Drive shaft 8 Control lens 15 Return plate
2 Servo cylinder 9 Eccentric adjusting screw 16 Cup springs
3 Control system housing 10 Rotary group cylinder 17 Return ball
LBH/11827693/02/211-20150615.1139/en
4 Travel direction valve 11 Compression spring 18 Swivel plate

5 Working hydraulics pump 12 Sliding bushing 19 Swivel plate bearing
connection flange
6 Replenishing pump 13 Piston 20 Roller bearing
7 Bearing bushing 14 Glide shoe 21 Shaft seal ring
copyright by
L538-1493 070-27
Travel pump
Fig. 279: Sectional view of the servo cylinder

1 Glyd Ring seal 5 Compression spring 9 Forward travel direction sole-
noid Y2
2 Servo cylinder 6 Swivel restrictor 10 Travel direction valve
3 Spring cup 7 Fine strainer 11 Zero position adjusting screw
4 Compression spring 8 Reverse travel direction sole-
noid Y3
LBH/11827693/02/211-20150615.1139/en
copyright by
070-28 L538-1493
Travel pump
Fig. 280: Sectional view of front side

1 Reverse high pressure relief valve 3 Replenishing pressure relief valve
2 Forward high pressure relief valve 4 Control lens
LBH/11827693/02/211-20150615.1139/en
Fig. 281: Sectional view of replenishing pump

1 Replenishing pump 4 Towing bypass valve
2 Pressure cut-off valve 5 Stop bolt for towing bypass valve
3 Shuttle valve
copyright by
L538-1493 070-29
Travel pump
2 Function
2.1 Basic function
Fig. 282: Hydraulic diagram of travel pump (forward travel direction)

1 Travel pump 15b Forward travel direction solenoid
Y2
2 Replenishing pump (internal gear 16 Control pressure proportional
pump) valve Y59
3 Towing bypass valve 17 Fine strainer
4 Shuttle valve 18 Check valve
5 Pressure cut-off valve 19 Pilot control, gear shifting
6 Forward high pressure relief valve 20 Travel motor bearing flushing
7 Reverse high pressure relief valve 21 Low pressure from travel motor
8 Replenishing pressure relief valve 22 High pressure to travel motor
9 Variable displacement pump (axial 23 Travel pump leak oil
piston pump)
10 Servo cylinder 24 Travel pump leak oil bypass
11 Swivel restrictor Ø1.8 mm 25 Replenishing pump suction port
12 Fine strainer 26 Travel pump suction port
13 Swivel restrictor Ø 1.8 mm 27 Travel pump high pressure sensor
B45
14 Fine strainer X1 Forward control pressure
LBH/11827693/02/211-20150615.1139/en
15 Travel direction valve MH High pressure

15a Reverse travel direction solenoid G Replenishing pressure
Y3
The travel pump is solely designed for operation in a closed circuit.
The travel pump consists of two pumps driven by the same drive shaft: The varia-
ble displacement pump 9, which drives the travel motors in the closed circuit, and
the replenishing pump 2, which supplies the closed circuit with fresh oil from the
hydraulic tank.
The variable displacement pump delivers the oil directly to the travel motors. The
returning oil flows directly to the suction side of the variable displacement pump
(closed circuit).
copyright by
070-30 L538-1493
Travel pump
The control pressure proportional valve 16 generates the control pressure. At idling
speed, the angle is 0°. The variable displacement pump does not deliver any oil.
The variable displacement pump does not deliver oil until the control pressure is
high enough to move it out to an angle.
2.2 Replenishing pump
Fig. 283: Replenishing pump

1 External gear 3 Drive shaft
2 Internal gear 4 Consumer
The replenishing pump draws oil from the return suction filter in the hydraulic tank.
The replenishing pump delivers the oil directly to the consumers 4:
– Pressure cut-off and control pressure proportional valve
– High pressure relief valve (replenishing function)
– Bearing flushing (For more information see: Bearing flushing (lubrication and
cooling), page 070-42)
unit, page 060-27)
– Gear shifting
LBH/11827693/02/211-20150615.1139/en
Because the replenishing pump is an internal gear pump, the flow rate per revolu-
tion cannot be adjusted. The actual flow rate is determined by the engine speed
alone.
copyright by
L538-1493 070-31
Travel pump
2.3 Replenishing pressure relief valve
Fig. 284: Replenishing pressure relief valve

1 Compression spring 3 Valve piston
2 Spring cup 4 Valve seat
The replenishing pressure relief valve:
– Protects the replenishing pump from excess pressure
– Drains excess oil that is not needed for pump control or for replenishing into the
pump housing
The valve piston 3 and the spring cup 2 are pushed against the compression
spring 1. The oil is drained into the pump housing T and back to the hydraulic tank
via the leak oil connections. This cools the variable displacement pump.
When the engine is running, oil always flows through the replenishing pressure re-
lief valve.
LBH/11827693/02/211-20150615.1139/en
copyright by
070-32 L538-1493
Travel pump
2.4 Variable displacement pump
Fig. 285: Variable displacement pump

1 Servo cylinder 8 Glide shoe
2 Swivel plate 9 Piston
3 Swivel plate bearing 10 Sliding bushing
4 Drive shaft 11 Rotary group cylinder
5 Return ball 12 Compression spring
6 Cup spring 13 Eccentric adjusting screw
7 Return plate 14 Control lens
The variable displacement pump delivers oil to the travel motor. The returning oil
flows directly to the suction side of the variable displacement pump (closed circuit).
– Plate angle
– Engine speed
LBH/11827693/02/211-20150615.1139/en
2.4.1 Rotary group

The rotary group cylinder 11 is rigidly connected to the drive shaft 4. The rotary
group cylinder contains nine pistons 9, which rotate along with it. The pistons slide
up and down in the sliding bushings 10 and are guided by glide shoes 8 and the
return plate 7.
The swivel plate 2 and the control lens 14 do not move.
Oil is pumped through a hole in the pistons 9 into the space between the glide
shoe and swivel plate. This means the slide shoe floats on a film of oil and slides
over the swivel plate without mechanical contact.
The rotary group also slides on a film of oil. This is produced by the leakage be-
tween the control lens and the rotary group cylinder.
copyright by
L538-1493 070-33
Travel pump
2.4.2 Swivel plate

The swivel plate 2 lies on a roller bearing, the swivel plate bearing 3, and is con-
nected by a lever to the servo cylinder 1.
If the servo cylinder is moved, the this changes the lateral angle of the swivel plate
to the drive shaft 4. The angle can be between -20° and 0° and +20°.
The tilt of the swivel plate means the pistons 9 perform a lengthways movement
axially to the drive shaft with every revolution. This lengthways movement draws up
and pumps the oil. The greater the angle, the longer the stroke and the more oil is
pumped with each revolution.
If no travel direction is selected (neutral travel direction), the angle of the swivel
plate is 0°. The pistons do not perform a stroke movement. No oil is pumped.
2.4.3 Control lens

The restoring force on the high pressure side can be adjusted using the control
lens 14. The control lens is turned with the eccentric adjusting screw 13. This
moves the recesses in the control lens and adjusts the size of the area which the
high pressure acts on.
2.5 Servo cylinder
LBH/11827693/02/211-20150615.1139/en
Fig. 286: Neutral/forward travel direction servo cylinder

1 Glyd Ring seal 6 Swivel restrictor 11 Swivel restrictor
2 Servo cylinder 7 Fine strainer 12 Zero position adjusting screw
3 Spring cup 8 Travel direction valve 13 Travel direction switch
4 Compression spring 9 Control pressure
5 Compression spring 10 Fine strainer
The servo cylinder moves the swivel plate and thus changes the flow rate of the
variable displacement pump.
copyright by
070-34 L538-1493
Travel pump
If no travel direction is selected (neutral travel direction), both chambers of the ser-
vo cylinder are relieved towards the pump housing T. The springs 4 and 5 hold the
servo cylinder 2 in the zero position (0° angle). The pump does not deliver any oil.
If a travel direction is selected, one of the two chambers of the servo cylinder 2 is
acted on by control pressure 9. The servo cylinder 2 is pushed against the com-
pression springs 4 and 5. The variable displacement pump is moved to a greater
angle. The angle depends on the amount of control pressure and on the high pres-
sure (restoring force).
The oil displaced from the depressurised side by the movement of the servo cylin-
der 2 flows into the pump housing T. The swivel restrictors 6 and 11 reduce the oil
flow and restrict the movement.
2.6 Regulation of the variable displacement pump

– Plate angle
– Engine speed
In turn, the plate angle depends on:
– Selected travel direction (travel direction valve)
– Energisation of the control pressure proportional valve
– Load (operating pressure)
2.6.1 Travel direction valve
Fig. 287: Neutral/forward travel direction valve

LBH/11827693/02/211-20150615.1139/en
1 Reverse travel direction solenoid 5 Forward travel direction solenoid

Y3 Y2
2 Return spring 6 Control pressure
3 Spring cup 7 Servo cylinder
4 Valve piston 8 Travel direction switch
The travel direction valve determines the swivel direction (+/-) and thus the direc-
tion of flow of the variable displacement pump, by the valve piston 4 directing con-
trol oil to one side of the servo cylinder 7. The valve piston 4 is moved by the two
magnets for forward travel direction 5 and reverse travel direction 1.
If no travel direction is selected (neutral travel direction) the valve piston 4 is held in
the middle position by the return springs 2. In this case, no control oil pressure acts
on the servo cylinder 7.
copyright by
L538-1493 070-35
Travel pump
2.6.2 Electrical/proportional regulation (EP regulation)
Fig. 288: Regulation with the control pressure proportional valve

1 Regulating spring 4 Control pressure proportional G Replenishing pressure
solenoid Y59
2 Control piston 5 Travel direction valve PSt Control pressure
3 Ring face 6 Servo cylinder T Pump housing
The angle of the variable displacement pump is regulated by the control pressure
proportional valve. To do so, the central control unit energises the control pressure
proportional solenoid 4 via output module 1.
The energisation of the control pressure proportional solenoid 4 depends on:
– Accelerator pedal position
– Excessive engine speed or road speed
– Excessive temperature of the hydraulic oil
– Speed restriction (Vmax function)
Without being energised, the regulating spring 1 and the control pressure, which is
LBH/11827693/02/211-20150615.1139/en
applied to the ring area 3, move the control piston 2. The control piston is pushed
so that the control pressure PSt flows into the pump housing T. The variable dis-
placement pump swivels back to the zero position.
If the central control unit increases the current to the control pressure proportional
solenoid 4, the solenoid pushes the control piston 2 against the regulating spring.
The control pressure duct PSt is linked to the replenishing pressure duct G. Control
pressure PSt is thus generated from replenishing pressure G.
The more current the proportional solenoid receives, the further the valve piston is
pushed.
copyright by
070-36 L538-1493
Travel pump
2.6.2.1 Accelerator pedal position

The central control unit registers that the accelerator pedal is being pressed
through the angle sensor R5 on the accelerator pedal.
If the accelerator pedal is pressed and the engine speed is above 900 rpm, the
central control unit increases the current to the control pressure proportional sole-
noid. The current is regulated according to the engine speed.
2.6.2.2 Inching function

The central control unit registers that the inching brake pedal is being pressed
through the angle sensor R1 on the inching brake pedal.
When the inching brake pedal is pressed, the central control unit reduces the cur-
rent to the control pressure proportional solenoid. The travel pump pivots in. The
machine is thereby hydrostatically braked.
2.6.2.3 Excessive engine speed or road speed

If the maximum speed permitted for the travel range is exceeded, the central con-
trol unit reduces the current to the control pressure proportional solenoid progres-
sively down to 200 mA.
2.6.2.4 Excessive temperature of the hydraulic oil

If the temperature of the hydraulic oil exceeds 90 °C, the central control unit re-
duces the current to the control pressure proportional solenoid gradually down to
40% of the maximum current (at a hydraulic oil temperature of 95 °C). The travel
pump pivots in. The power consumed is thereby reduced. The decreased power
output reduces the temperature.
The control pressure proportional solenoid is energised normally again when the
temperature is back in the normal range.
2.6.2.5 Travel pump load limiting function

If the travel pump has been moved to the maximum swivel angle and the central
control unit registers a major drop in engine speed under load, the travel pump
load limiting function is activated.
The central control unit reduces the current to the control pressure proportional sol-
enoid. The travel pump pivots in. The power consumed is thereby reduced. The
load on the engine is decreased.
2.6.3 Regulation by operating pressure

The high pressure acts on the pistons in the rotary group cylinder. The pistons rest
on the swivel plate and push it towards a smaller angle.
LBH/11827693/02/211-20150615.1139/en
copyright by
L538-1493 070-37
Travel pump
2.7 Shuttle valve and towing bypass valve
Fig. 289: Shuttle valve in forward travel direction / shuttle valve in reverse travel di-
rection / towing bypass valve open
1 High pressure to pressure cut-off 4 Towing bypass valve
2 Valve seat 5 Stop bolt
3 Valve piston
The shuttle valve always connects the pressure cut-off 1 to the high pressure side
of the closed circuit.
Depending on the travel direction, the valve piston 3 is moved so that the high
pressure side is connected to the pressure cut-off while the low pressure side is
blocked.
When the machine is towed, the travel motor is driven via the transmission. This
delivers oil from the travel motor to the travel pump. Oil can circulate through the
open towing bypass valve without driving the travel pump and therefore the engine.
To do this, the bypass valve 4 must be unscrewed to the stop bolt 5. This bypasses
the shuttle valve and connects the high and low pressure sides to each other.
2.8 Pressure cut-off
Fig. 290: Pressure cut-off not active / active

1 Valve piston 4 Spring cup 7 Oil from the replenishing
pump
2 Connecting duct 5 Regulating spring 8 High pressure from shuttle
valve
LBH/11827693/02/211-20150615.1139/en
3 To the control pressure pro- 6 Adjusting screw

portional valve Y59
The pressure cut-off limits the operating pressure in the closed circuit.
The shuttle valve always connects the pressure cut-off to the high pressure side of
the travel pump. If the high pressure 8 reaches the maximum permitted level, the
high pressure pushes the valve piston 1 against the regulating spring 5. This dis-
connects the link between the replenishing pump 7 and the control pressure pro-
portional valve 3. If the pressure continues increasing, the high pressure continues
pushing the valve piston 1 until the control pressure proportional valve 3 is connec-
ted to the pump housing T via the connecting duct 2. The control pressure falls and
the variable displacement pump moves back until the high pressure has fallen back
to the maximum permissible level.
copyright by
070-38 L538-1493
Travel pump
2.9 High pressure relief valve
Fig. 291: High pressure relief valve closed / open (excess pressure)
The high pressure relief valves protect the closed circuit from excess pressure.
The high pressure relief valves always react faster than the pressure cut-off. They
therefore primarily relieve pressure peaks such as those that arise when driving in-
to a pile of material too quickly.
The valve piston 7 is pushed against the pressure relief compression spring 4. Oil
flows from the high pressure side through the replenishing pressure duct G to the
low pressure side.
2.10 Replenishing function
Fig. 292: High pressure relief valve closed / open (replenishing)

LBH/11827693/02/211-20150615.1139/en

The replenishing function of the high pressure relief valve replaces lacking oil in the
closed circuit with replenishing oil. The oil is supplied on the low pressure side.
Oil is lost from the closed circuit due to:
– Leakage in the variable displacement pump
– Leakages in the travel motors
– Discharge in travel motor 2 (cooling)
When replenishing, the valve plate 6 is pushed against the replenishing compres-
sion spring 5. Oil flows from the replenishing pressure duct G to the low pressure
side of the closed circuit.
copyright by
L538-1493 070-39
Travel pump
2.11 Travel pump high pressure sensor B45

The travel pump high-pressure sensor measures high pressure in the enclosed cir-
cuit.
LBH/11827693/02/211-20150615.1139/en
copyright by
070-40 L538-1493
Travel motors
070.5 Travel motors

Valid for: L538-1493/31405-;
1.1 Layout
Fig. 293: Travel motors

1 Travel motor 1 5 Collector pipe
2 Travel motor 2 6 Travel pump high pressure
3 Replenishing pump 7 Travel pump low pressure
4 Collector pipe 8 Fan gear motor
The travel motors are flange-mounted on the transmission.
2 Function
LBH/11827693/02/211-20150615.1139/en
2.1 Basic function

The travel pump drives the travel motors in a closed circuit. This means that the oil
that drives the travel motors flows back directly to the travel pump.
To change the direction of travel, the travel pump swaps the high-pressure and
low-pressure sides. The travel motors thereby change the direction of rotation.
2.2 Regulation
Travel motor 1 is regulated by the high pressure in the closed circuit (HA control).
(For more information see: High pressure-dependent regulation (HA regulation),
page 070-47)
copyright by
L538-1493 070-41
Travel motors
Travel motor 2 is electrically and proportionally regulated (EP control). (For more
information see: Electrical/proportional regulation (EP regulation), page 070-54)
2.3 Bearing flushing (lubrication and cooling)
Fig. 294: Bearing flushing and cooling
The bearing flushing system lubricates and cools the roller bearings of the travel
motors. In addition, oil returning from the fan gear motor 7 cools the travel motors.
To flush the bearings, oil flows from the replenishing pump 3 to the connection U
on the travel motor 2 and the travel motor 1. The oil is distributed through the orifi-
ces 4 and 6 equally to both travel motors.
To cool, the return oil flows from the fan gear motor 7 to the travel motor 1. The
return oil flows from there, together with the oil for the bearing flushing, to the travel
motor 2. The oil then flows via travel motor 2 to the hydraulic oil cooler 5.
LBH/11827693/02/211-20150615.1139/en
copyright by
070-42 L538-1493
Travel motors

Valid for: L538-1493/31405-;
1 Layout
Fig. 295: Travel motor 1

1 Adjusting screw for start of regula- 4 Output shaft
tion
2 Travel direction solenoid valve 5 Qmin adjusting screw
Y26
3 Travel range 1 solenoid valve Y58 M1 Travel motor 1 servo pressure test
connection
Travel motor 1 is flange-mounted on the transmission. The speed and torque are
transmitted from there to the axles.
Travel motor 1 consists of the following components:
– Servo piston
– Swash plate variable displacement motor (axial piston motor)
– Control piston
– Travel range 1 function
LBH/11827693/02/211-20150615.1139/en
copyright by
L538-1493 070-43
Travel motors
Fig. 296: Sectional view of travel motor 1 (forward travel direction)

1 Output shaft 8 Travel direction solenoid 15 Control pin
valve Y26
2 Shaft seal ring 9 Travel range 1 solenoid Y58 16 Servo piston
3 Roller bearing 10 Control piston 17 Adjusting screw for start of
regulation
LBH/11827693/02/211-20150615.1139/en
4 Roller bearing 11 Adjusting screw for start of 18 Control lens

regulation
5 Return plate 12 Regulating spring 19 Compression spring
6 Rotary group piston 13 Spring bushing 20 Central pin
7 Rotary group cylinder 14 Return spring
copyright by
070-44 L538-1493
Travel motors
Fig. 297: Sectional view of servo piston

1 Travel range 1 solenoid Y58 7 Return spring
2 Travel direction solenoid valve 8 Spring bushing
Y26
LBH/11827693/02/211-20150615.1139/en
3 Check valve 9 Regulating spring

4 Control pin 10 Check valve
5 Servo piston 11 Control piston
6 Swivel restrictor M1 Travel motor 1 servo pressure test
connection
copyright by
L538-1493 070-45
Travel motors
2 Function
2.1 Basic function
Fig. 298: Hydraulic diagram of travel motor 1 (forward travel direction)

1 Travel motor 1 9 Orifice Ø 1.0 mm
2 Swash plate variable displacement 10 Travel motor bearing flushing
motor (axial piston motor)
3 Check valve 11 Leak oil to travel motor 2
4 Check valve 12 Low pressure to travel pump
5 Servo piston 13 Fan gear motor return flow
6 Travel direction solenoid valve 14 High pressure from travel pump
Y26
7 Control piston with travel range 1 M1 Travel motor 1 servo pressure
solenoid Y58
8 Swivel restrictor
The travel motors are driven by the travel pump in the closed circuit. This means
that the oil that drives the travel motors flows back directly to the travel pump.
To change the travel direction, the high pressure side 14 and low pressure side 12
are swapped. The travel motors thereby change the direction of rotation.
2.1.1 Output speed and output torque

The output speed depends on two factors:
– High pressure
– Swivel plate angle
– Oil quantity supplied
At a small angle, the variable displacement motor 2 has a low displacement. The
output speed is high, because only a little oil is required for each revolution. At the
LBH/11827693/02/211-20150615.1139/en
same time, the output torque is low, due to the shallow angle of the pistons to the
output shaft.
At a large angle, the variable displacement motor has a high displacement. The
output speed is low, because a lot of oil is required for each revolution. At the same
time, the output torque is high, due to the large angle of the pistons to the output
shaft.
copyright by
070-46 L538-1493
Travel motors
2.2 High pressure-dependent regulation (HA regulation)
Fig. 299: Control unit - minimum angle / regulating to a larger angle

1 Travel direction solenoid 4 Adjusting screw for start of 7 Control lens for variable dis-
valve Y26 regulation placement motor
2 Control piston 5 Regulating spring 8 Small angle Qmin
3 Ring face 6 Servo piston 9 Large angle Qmax
The angle of the variable displacement motor in travel motor 1 is determined by the
high pressure in the closed circuit. As the travel resistance increases, so does the
high pressure.
The travel direction solenoid valve 1 connects the control piston 2 to the high pres-
sure. The high pressure influences the ring area 3. If the high pressure exceeds
the set value for the start of regulation, the high pressure pushes the control pis-
ton 2 against the regulating spring 5.
The control piston 2 connects the high pressure to the servo pressure. This increa-
ses the servo pressure. The higher servo pressure moves the variable displace-
ment motor to a larger swivel angle 9. The output torque increases, the output
LBH/11827693/02/211-20150615.1139/en
speed decreases.
The rising output torque lowers the high pressure again until the regulating spring 5
pushes the control piston 2 against the high pressure, separating the high pressure
from the servo pressure.
If the high pressure decreases further, the regulating spring 5 pushes the control
piston 2 until the servo pressure flows away into the motor housing. The high pres-
sure pushes the variable displacement motor to a smaller angle 8.
copyright by
L538-1493 070-47
Travel motors
2.3 Swivel restrictor
Fig. 300: Swivel restrictor - moving to a smaller / greater angle

1 Valve seat 3 Valve piston
2 Flat section 4 Notch
The swivel restrictor prevents the variable displacement motor from moving to a
larger angle too quickly.
When moving to a larger angle, the oil flows through the notch 4 to the servo pis-
ton.
When moving to a smaller angle, the oil flows almost unhindered out of the servo
piston via the flat section 2 on the valve piston 3.

The travel direction solenoid valve always connects the control piston to the high
pressure side of the corresponding travel direction.
In reverse travel direction, the travel direction solenoid is energised. The solenoid
pushes the valve piston against the return spring.
When driving downhill, the travel motor is driven by the wheels (engine braking
mode). The travel motor then acts like a pump. High pressure and low pressure are
swapped. Without the travel direction solenoid valve, the high pressure thus pro-
duced would drive the travel pump and hence the engine.
LBH/11827693/02/211-20150615.1139/en
copyright by
070-48 L538-1493
Travel motors
2.5 Travel range 1
Fig. 301: Travel range 1 solenoid non-energised / energised

1 Travel range 1 solenoid Y58 3 Regulating spring
2 Control piston 4 Travel range down button
If travel range 1 is activated, both travel motors remain at the maximum angle. This
means the maximum output torque is available.
On travel motor 1 the travel range 1 solenoid 1 is energised. The solenoid pushes
the control piston 2 against the regulating spring 3 thereby connecting the high
pressure to the servo pressure. The high pressure pushes the variable displace-
ment motor to the maximum angle.
LBH/11827693/02/211-20150615.1139/en
copyright by
L538-1493 070-49
Travel motors

Valid for: L538-1493/31405-;
1 Layout
Fig. 302: Travel motor 2

1 Proportional valve Y57 4 Qmin adjusting screw
2 Adjusting screw for start of regula- M2 Travel motor 2 servo pressure test
tion connection
3 Output shaft
Travel motor 2 is flange-mounted on the transmission. The speed and torque are
transmitted from there to the axles.
Travel motor 2 consists of the following components:
– Servo piston
– Swash plate variable displacement motor (axial piston motor)
– Proportional valve and control piston
– Discharge function
LBH/11827693/02/211-20150615.1139/en
copyright by
070-50 L538-1493
Travel motors
Fig. 303: Sectional view of travel motor 2 (forward travel direction)

1 Output shaft 10 Orifice 19 Spring cup
2 Shaft seal ring 11 Discharge valve 20 Control piston
LBH/11827693/02/211-20150615.1139/en
3 Roller bearing 12 Servo piston 21 Proportional solenoid Y57

4 Roller bearing 13 Control pin 22 Regulation adjusting screw
5 Return plate 14 1st regulating spring 23 Qmax adjusting screw
6 Rotary group piston 15 Return spring 24 Control lens
7 Rotary group 16 Spring cup 25 Compression spring
8 Qmin adjusting screw 17 Spring bushing 26 Central pin
9 Pressure relief valve 18 2nd regulating spring
copyright by
L538-1493 070-51
Travel motors
LBH/11827693/02/211-20150615.1139/en
Fig. 304: Sectional view of servo piston

1 Discharge valve 9 Spring cup
2 Orifice 10 Control piston
3 Pressure relief valve 11 Proportional solenoid Y57
4 Servo piston 12 2nd regulating spring
5 Control pin 13 Spring bushing
6 1st regulating spring 14 Check valve
7 Return spring 15 Spring cup
8 Check valve M2 Travel motor 2 servo pressure test
connection
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070-52 L538-1493
Travel motors
2 Function
2.1 Basic function
Fig. 305: Hydraulic diagram of travel motor 2 (forward travel direction)

1 Travel motor 2 10 Orifice Ø 1.0 mm
2 Swash plate variable displacement 11 Travel motor bearing flushing
motor (axial piston motor)
3 Check valve 12 Leak oil to collector pipe
4 Check valve 13 Low pressure to travel pump
5 Proportional valve and control pis- 14 Discharged oil to collector pipe
ton Y57
6 Servo piston 15 Leak oil from travel motor 1
7 Discharge valve 16 High pressure from travel pump
8 Orifice M2 Travel motor 2 servo pressure
The travel motors are driven by the travel pump in the closed circuit. This means
that the oil that drives the travel motors flows back directly to the travel pump.
To change the travel direction, the high pressure 16 and low pressure 13 are swap-
ped. The travel motors thereby change the direction of rotation.
2.1.1 Output speed and output torque

– High pressure
– Oil quantity supplied
At a small angle, the variable displacement motor 2 has a low displacement. The
LBH/11827693/02/211-20150615.1139/en
output speed is high, because only a little oil is required for each revolution. At the
same time, the output torque is low, due to the shallow angle of the pistons to the
output shaft.
At a large angle, the variable displacement motor has a high displacement. The
output speed is low, because a lot of oil is required for each revolution. At the same
time, the output torque is high, due to the large angle of the pistons to the output
shaft.
copyright by
L538-1493 070-53
Travel motors
2.2 Electrical/proportional regulation (EP regulation)
Fig. 306: Control unit - minimum angle / regulating to a larger angle

1 Proportional solenoid Y57 5 1st regulating spring 9 Control piston
2 Regulation adjusting screw 6 Return spring 10 Large angle Qmax
3 Control lens 7 2nd regulating spring 11 Small angle Qmin
4 Piston 8 Spring cup
The angle of the variable displacement motor in travel motor 2 is determined elec-
trically and proportionally.
When the proportional solenoid 1 is not energised, the high pressure keeps the
variable displacement motor at the minimum angle.
When the proportional solenoid 1 is energised, it pushes the control piston 9
against the 2nd regulating spring 7.
The control piston 9 connects the high pressure to the servo pressure. This increa-
ses the servo pressure. The higher servo pressure moves the variable displace-
ment motor to a larger swivel angle 10. The output torque increases, the output
speed decreases.
LBH/11827693/02/211-20150615.1139/en
During regulation, the servo piston pre-tensions the 1st regulating spring 5 accord-
ing to the swivel plate angle. The 1st regulating spring acts via the spring cup 8 on
the control piston 9. If the spring force is sufficient, the 1st regulating spring 5 push-
es the control piston 9 against the force of the solenoid.
The control piston 9 thus separates the high pressure from the servo pressure
again. The angle is maintained.
If the current to the proportional solenoid 1 is increased, the variable displacement
motor moves further out.
If the current to the proportional solenoid 1 is reduced, the 1st regulating spring 5
pushes the control piston 9 until the control piston 9 connects the servo pressure to
the motor housing. The servo pressure flows away into the motor housing. The var-
copyright by
070-54 L538-1493
Travel motors
iable displacement motor moves to the smaller angle until the spring force and sol-
enoid force are in equilibrium again.
2.2.1 Supply of current

The proportional solenoid Y57 is energised by the central control unit.
The central control unit calculates the current needed. When doing so, the follow-
ing parameters are considered:
– Gear
– Accelerator pedal position, travel speed
– Controlling the maximum load
– Overspeed
Gear
In 1st gear, the proportional solenoid Y57 is always supplied with the maximum
current. This keeps the variable displacement motor at the maximum angle.
In 2nd gear, the proportional solenoid Y57 is supplied with varying current levels.
In 3rd gear, travel motor 2 is decoupled. The proportional solenoid Y57 is not ener-
gised. The variable displacement motor is at the minimum angle.
Accelerator pedal position, travel speed
In 2nd gear, the proportional solenoid Y57 is supplied with current according to the
travel speed.
The faster the machine travels, the less current is supplied to the proportional sole-
noid Y57.
Controlling the maximum load
If too much power is taken from the engine, the engine speed is suppressed.
The central control unit increases the current to the proportional solenoid Y57. This
moves the variable displacement motor to a larger angle. The output torque rises.
The power taken drops.
Overspeed
If, when travelling downhill, the engine speed is too high, the central control unit re-
duces the current to the proportional solenoid Y57. This moves the variable dis-
placement motor to a smaller angle. The hydrostatic braking effect falls.
2.3 Discharging (cooling)

LBH/11827693/02/211-20150615.1139/en
Fig. 307: Discharge valve - machine stationary / machine moving forward

1 Cap 5 Regulating spring
2 Return spring 6 Pressure relief valve piston
3 Discharge valve piston 7 Orifice
4 Spring cup 8 Travel direction switch
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L538-1493 070-55
Travel motors
Oil is constantly drained via the discharge valve and pressure relief valve from the
closed circuit. The discharged oil flows to the collector pipe.
The replenishing pump replaces the discharged oil via the high pressure relief
valves in the travel pump. The replenishing pump draws up cooled oil from the hy-
draulic tank. This protects the travel hydraulics from overheating.
The discharge valve is connected to the high pressure and low pressure sides of
the travel motor. When the machine is moving, the high pressure pushes the dis-
charge valve piston 3 against the return spring 2. The discharge valve thereby con-
nects the low pressure side to the pressure relief valve 6.
The orifice 7 of the pressure relief valve 6 determines the amount of oil that is dis-
charged. When the machine is moving, the low pressure pushes the pressure relief
valve 6 against the regulating spring 5. The oil flows through the orifice 7 and the
pressure relief valve 6 the collector pipe.
LBH/11827693/02/211-20150615.1139/en
copyright by
070-56 L538-1493
080 Hydraulic components
Contents
080.1 Hydraulic tank 080-2
L538-1493/31405-; 080-2
080.1.2 Filter unit
L538-1493/31405-; 080-4
L538-1493/31405-; 080-9
LBH/11827693/02/211-20150615.1139/en
copyright by
L538-1493 080-1
Hydraulic components Service manual
Hydraulic tank
080.1 Hydraulic tank

Valid for: L538-1493/31405-;
1 Layout
Fig. 308: Hydraulic tank

1 Steel tank 8 Working hydraulics pump intake
connection
2 Oil sight glass 9 Replenishing pump intake connec-
tion
3 Emergency steering pump intake 10 Filter cover
connection
4 Brake system gear pump intake 11 Connection for replenishing pump
connection intake connection
5 Fan gear pump intake connection 12 Breather filter
6 Hydraulic oil temperature sensor 13 Cover of return strainer
LBH/11827693/02/211-20150615.1139/en
B8
7 Drain valve
The hydraulic tank is fitted behind the driver’s cab.
The hydraulic tank consists of the following components:
– Steel tank
– Filter unit (For more information see: 080.1.2 Filter unit, page 080-4)
– Breather filter (For more information see: 080.1.3 Breather filter, page 080-9)
copyright by
080-2 L538-1493
Service manual Hydraulic components
Hydraulic tank
2 Function
2.1 Basic function
Fig. 309: Hydraulic diagram of the hydraulic tank

1 Hydraulic tank 15 Fan gear pump intake connection
2 Breather filter 16 Intake port of brake system gear
pump
3 Return strainer 17 Emergency steering pump intake
connection
4 Bypass valve 18 Transmission return flow
5 Return suction filter 19 Compact brake valve return flow
6 Pre-tension valve 20 Pilot control unit return flow
7 Feeding valve 21 Fan gear motor leak oil
8 Strainer 22 Working hydraulics pump leak oil
9 9 bar check valve 23 Servostat return flow
10 2.5 bar bypass valve 24 Travel pump leak oil
11 Hydraulic oil temperature sensor 25 Hydraulic oil cooler return flow
B8
12 Drain valve 26 Hydraulic oil cooler bypass return
flow
13 Replenishing pump intake connec- 27 Control valve block return flow
tion
14 Working hydraulics pump intake
connection
The hydraulic oil is stored in the hydraulic tank.
The hydraulic oil is cleaned in the integrated filter unit.
The breather filter compensates pressure fluctuations and maintains a slight pre-
LBH/11827693/02/211-20150615.1139/en
load pressure in the hydraulic tank.

The hydraulic tank supplies the following systems with oil:
– Cooling system (fan drive) (For more information see: 050.1.1 Overview of the
hydraulics cooling system, page 050-2)
– Working hydraulics (For more information see: 060.1 Overview of working hy-
draulics for z-bar kinematics, page 060-3) (For more information see:
060.2 Overview of working hydraulics for p kinematics, page 060-8)
– Travel hydraulics (For more information see: 070.2 Travel hydraulics overview,
page 070-7)
– Steering system (For more information see: 090.1 Steering system overview,
page 090-2)
– Brake system (For more information see: 100.1 Overview of the brake system,
page 100-2)
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L538-1493 080-3
Hydraulic tank
– Gear shifting (For more information see: 120.4.1 Overview of the hydraulic con-
trol system, page 120-11)
080.1.2 Filter unit

Valid for: L538-1493/31405-;
1 Layout
Fig. 310: Filter unit

1 Filter cover 5 Pre-tension valve
2 Bypass valve 6 Breather filter
3 Filter casing with return-suction fil- 7 Cover of return strainer
ter
4 Replenishing valve with strainer
The filter unit is contained in the hydraulic tank.
The filter unit is sealed with an O-ring to the steel container.
LBH/11827693/02/211-20150615.1139/en
The following components are integrated in the filter unit:

– Return suction filter
– Return strainer
– Pre-tension valve
– Feeding valve
– Bypass valve
copyright by
080-4 L538-1493
Hydraulic tank
Fig. 311: Sectional view of the filter unit

1 Strainer 5 Magnetic rod 9 Bypass valve
2 Feeding valve 6 Filter cover 10 Return strainer
3 Filter casing 7 Cover of return strainer 11 Replenishing pump intake
connection
4 Return suction filter 8 Breather filter 12 Pre-tension valve
LBH/11827693/02/211-20150615.1139/en
copyright by
L538-1493 080-5
Hydraulic tank
2 Function
2.1 Basic function
Fig. 312: Filter unit

1 Breather filter 11 Transmission return flow
2 Return strainer 12 Compact brake valve return flow
3 Bypass valve 13 Pilot control unit return flow
4 Return suction filter 14 Fan gear motor leak oil
5 Pre-tension valve 15 Working hydraulics pump leak oil
6 Feeding valve 16 Servostat return flow
7 Strainer 17 Travel pump leak oil
8 Replenishing pump intake connec- 18 Hydraulic oil cooler return flow
tion
LBH/11827693/02/211-20150615.1139/en
9 9 bar check valve 19 Hydraulic oil cooler bypass return

flow
10 2.5 bar bypass valve 20 Control valve block return flow
The oil flows from the hydraulic components back to the filter unit. This oil is collec-
ted and filtered in the filter unit and directed into the steel tank.
The replenishing pump 8 draws the oil directly from the return suction filter 4.
2.2 Filtering function of the return strainer

In the return strainer, impurities with a minimum size of 80 µm are filtered out of the
oil.
copyright by
080-6 L538-1493
Hydraulic tank
The oil from the following components is filtered by the return strainer:
– Transmission return flow
– Compact brake valve return flow
– Pilot control unit return flow
– Fan gear motor leak oil
– Working hydraulics pump leak oil
– Servostat return flow
– Travel pump leak oil (only if the hydraulic oil cooler is blocked)
When the bypass valve is open, the entire oil quantity flows through the return
strainer.
2.3 Filtering function of the return suction filter

LBH/11827693/02/211-20150615.1139/en
Fig. 313: Filtering function of the return suction filter

1 Magnetic rod 4 Filter casing
2 Collection chamber 5 Pre-tension valve
3 Filter element 6 Replenishing pump intake connec-
tion
In the return suction filter, impurities with a minimum size of 10 µm are filtered out
of the oil.
copyright by
L538-1493 080-7
Hydraulic tank
The oil from the following components is filtered by the return suction filter:
– Hydraulic oil cooler return flow
– Hydraulic oil cooler bypass return flow (only when the temperature valve is
open)
– Control valve block return flow
The oil flowing back flows from the collection chamber 2 past the magnetic rod 1
into the filter element 3.
The magnetic rod draws the larger metal particles out of the oil that flows past. This
keeps the return suction filter clean for longer.
The oil is forced through the filter element 3 into the filter casing 4. From there, the
replenishing pump draws it in once more. The excess oil flows through the pre-ten-
sion valve 5 into the steel tank.
2.4 Replenishing pump oil supply
Fig. 314: Replenishing pump oil supply

1 Filter casing 3 Strainer
2 Feeding valve 4 Replenishing pump intake connec-
tion
The replenishing pump draws the oil directly from the filter casing 1.
If insufficient oil flows into the filter casing 1 (e.g. if the return suction filter is
blocked), the replenishing pump draws oil from the steel tank This opens the feed-
ing valve 2 and oil is drawn in through the strainer 3.
2.5 Pre-tension valve

LBH/11827693/02/211-20150615.1139/en
Fig. 315: Pre-tension valve
The pre-tension valve 1 opens at a pressure of 0.5 bar. This causes a slight excess
pressure to develop inside the filter casing. The intake connection of the replenish-
ing pump is supplied with oil faster during cold starts. The system pressure in the
travel hydraulics builds up faster.
copyright by
080-8 L538-1493
Hydraulic tank
The filtered oil that is not required by the replenishing pump flows into the steel
tank via the pre-tension valve.
2.6 Bypass valve
Fig. 316: Bypass valve closed / open
The bypass valve 1 protects the filter unit from excessive pressure.
If insufficient oil passes through the return suction filter because the hydraulic oil is
cold or the return suction filter is very dirty, some of the oil flows via the bypass
valve 1 into the return strainer 2.
This prevents the hydraulic components being damaged.

Valid for: L538-1493/31405-;
1 Layout
LBH/11827693/02/211-20150615.1139/en
Fig. 317: Breather filter

1 Filter housing 6 O-ring
2 Inlet valve 7 Fine filter
3 Compression spring 8 O-ring
4 Outlet valve 9 Inner housing
5 Compression spring
The breather filter consists of an oil-resistant, corrosion-proof plastic housing 1
and 9, in which a fine filter 7 folded in a star shape is inserted. The breather filter
contains a spring-loaded inlet valve 2 and a spring-loaded outlet valve 4.
copyright by
L538-1493 080-9
Hydraulic tank
2 Function
2.1 Basic function
Fig. 318: Diagram of the breather filter

1 Breather filter 3 Outlet valve
2 Fine filter 4 Inlet valve
The fluctuating oil level in the steel tank causes pressure fluctuations. These pres-
sure fluctuations are compensated for by ambient air flowing in via the breather fil-
ter 1 or air flowing out of the steel tank.
The air is drawn in through the fine filter 2 to avoid contamination of the oil in the
steel tank.
The outlet valve 3 and the inlet valve 4 are spring-loaded. They only open at a cer-
tain pressure difference. This prevents a constant exchange of air. The oil is not
contaminated as quickly and does not deteriorate due to moisture in the air drawn
in.
2.2 Pressure equalisation
Fig. 319: Breather filter under excess pressure and with insufficient pressure
1 Fine filter 3 Inlet valve
2 Outlet valve 4 Opening
2.2.1 Excess pressure in the steel tank

Excess pressure in the steel tank can be caused by increased oil temperature or
LBH/11827693/02/211-20150615.1139/en
by the hydraulic cylinders retracting.

At a certain excess pressure, the outlet valve 2 opens. Air can then escape via the
fine filter 1 and the opening 4 to the outside.
2.2.2 Insufficient pressure in the steel tank

Insufficient pressure in the steel tank can be caused by decreasing oil temperature
or by the hydraulic cylinders extending.
Once the pressure falls below a certain level, the inlet valve 3 opens. Air can then
flow into the steel tank via the opening 4 and the fine filter 1.
copyright by
080-10 L538-1493
090 Steering system
Contents
L538-1493/31405-35802; 090-2
L538-1493/35803-; 090-6
090.3 Servostat
L538-1493/31405-; 090-10
090.4 Steering cylinder 090-14
L538-1493/35803-31404; 090-14
L538-1493/31405-; 090-16
L538-1493/35803-; 090-18
090.5 Emergency steering 090-19
L538-1493/31405-; 090-19
L538-1493/31405-; 090-20
090.5.3 Electronic control unit 090-22
L538-1493/31405-; 090-22
L538-1493/31405-; 090-23
LBH/11827693/02/211-20150615.1139/en
L538-1493/31405-; 090-24
090.5.4 Valve block
L538-1493/31405-; 090-25
copyright by
L538-1493 090-1
Steering system Service manual
Steering system overview
Valid for: L538-1493/31405-35802;
1 Layout
LBH/11827693/02/211-20150615.1139/en
Fig. 320: Main steering system components (steering to the left)

1 Hydraulic tank 6 Ride control P Working hydraulics pump
2 Emergency steering pump 7 Valve block P1 Steering system high pres-
copyright by
090-2 L538-1493
Service manual Steering system
3 Working hydraulics pump 8 Left steering cylinder LS Load sensing pressure test
connection
4 Control valve block 9 Right steering cylinder
5 Compact brake valve (hous- 10 Servostat
ing preheating)
The steering system consists of the following components:
tank, page 080-2)
pump, page 060-12)
– Control valve block with priority valve (For more information see: 060.4 Control
valve block for Z-bar kinematics, page 060-16)
– Servostat (For more information see: 090.3 Servostat, page 090-10)
– Steering cylinder (For more information see: 090.4.2 Steering cylinder overview,
page 090-16)
– Emergency steering (For more information see: 090.5.1 Emergency steering
overview, page 090-19)
LBH/11827693/02/211-20150615.1139/en
copyright by
L538-1493 090-3
2 Function
2.1 Basic function
LBH/11827693/02/211-20150615.1139/en
Fig. 321: Hydraulic diagram of the steering system (steer to the left)
1 Hydraulic tank 25 Working hydraulics pump 51 Electric motor M8
2 Breather filter 26 Axial piston pump 52 Gear pump
3 Return strainer 27 Return piston 53 Pressure relief valve
4 Bypass valve 28 Restrictor 54 Emergency steering check
pressure switch B3a
5 Return suction filter 29 Servo piston 55 Valve block
6 Pre-tension valve 30 Regulating lever 56 Check valve
7 Replenishing valve 31 Restrictor 57 Check valve
8 Strainer 32 Power regulator 58 Emergency steering pressure
switch B3
copyright by
090-4 L538-1493
9 9 bar check valve 33 Dummy piston 60 Servostat

10 2.5 bar bypass valve 34 Flow regulator 61 Valve spool
11 Hydraulic oil temperature 35 Travel pump 62 Metering pump
sensor B8
12 Drain valve 36 Engine 63 Secondary pressure relief
valve for steering to the left
13 Replenishing pump suction 40 Control valve block 64 Secondary pressure relief
port valve for steering to the right
14 Fan gear pump suction port 41 Priority valve 65 Left replenishing valve
15 Brake system gear pump suc- 42 Restrictor 66 Right replenishing valve
tion port
16 Transmission return flow 43 Check valve 67 Left steering cylinder
17 Compact brake valve return 44 LS steering pressure cut-off 68 Right steering cylinder
flow
18 Pilot control unit return flow 45 LS working hydraulics pres- P Working hydraulics pump
sure cut-off high pressure
19 Fan gear motor leak oil 46 Flow regulating valve P1 Steering system high pres-
sure
20 Travel pump leak oil 47 Compact brake valve (hous- LS Working hydraulics load
ing preheating) sensing pressure
21 Hydraulic oil cooler return 48 Ride control
flow
22 Hydraulic oil cooler bypass 50 Emergency steering pump
return flow
The steering system is supplied with oil via the control valve block 40 by the work-
ing hydraulics pump 25.
When steering, the servostat 60 generates a load sensing signal. This load sensing
signal activates the priority valve 41 in the control valve block and the working hy-
draulics pump via the check valve 43.
The priority valve 41 in the control valve block diverts oil from the working hydraul-
ics pump 25 from the working hydraulics to the servostat 60. The oil supply for the
steering system has priority. Only the amount of oil actually needed by the steering
system is supplied. The working hydraulics are only supplied with what is left over.
If the working hydraulics pump fails to supply the oil, the central control unit acti-
vates the emergency steering function. The electrically powered emergency steer-
ing pump 50 delivers oil to the servostat 60 to allow continued steering move-
ments.
LBH/11827693/02/211-20150615.1139/en
copyright by
L538-1493 090-5
Valid for: L538-1493/35803-;
1 Layout
LBH/11827693/02/211-20150615.1139/en
Fig. 322: Main steering system components (steering to the left)

1 Hydraulic tank 6 Ride control 11 Right steering cylinder
2 Emergency steering pump 7 Valve block 12 Servostat
3 Working hydraulics pump 8 Left steering cylinder P Working hydraulics pump
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090-6 L538-1493
4 Control valve block 9 Steering damper hydro accu- P1 Steering system high pres-
mulator (optional) sure test connection
5 Compact brake valve (hous- 10 Steering damper hydro accu- LS Load sensing pressure test
ing preheating) mulator (optional) connection
The steering system consists of the following components:
tank, page 080-2)
pump, page 060-12)
– Control valve block with priority valve (For more information see: 060.4 Control
valve block for Z-bar kinematics, page 060-16)
– Servostat (For more information see: 090.3 Servostat, page 090-10)
– Steering cylinder (For more information see: 090.4.1 Steering cylinder overview,
page 090-14)
– Emergency steering (For more information see: 090.5.1 Emergency steering
overview, page 090-19)
LBH/11827693/02/211-20150615.1139/en
copyright by
L538-1493 090-7
2 Function
2.1 Basic function
LBH/11827693/02/211-20150615.1139/en
Fig. 323: Hydraulic diagram of the steering system (steer to the left)
1 Hydraulic tank 25 Working hydraulics pump 51 Electric motor M8
2 Breather filter 26 Axial piston pump 52 Gear pump
3 Return strainer 27 Return piston 53 Pressure relief valve
4 Bypass valve 28 Restrictor 54 Emergency steering check
pressure switch B3a
5 Return suction filter 29 Servo piston 55 Valve block
6 Pre-tension valve 30 Regulating lever 56 Check valve
7 Replenishing valve 31 Restrictor 57 Check valve
8 Strainer 32 Power regulator 58 Emergency steering pressure
switch B3
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090-8 L538-1493
9 9 bar check valve 33 Dummy piston 60 Servostat

10 2.5 bar bypass valve 34 Flow regulator 61 Valve spool
11 Hydraulic oil temperature 35 Travel pump 62 Metering pump
sensor B8
12 Drain valve 36 Engine 63 Secondary pressure relief
valve for steering to the left
13 Replenishing pump suction 40 Control valve block 64 Secondary pressure relief
port valve for steering to the right
14 Fan gear pump suction port 41 Priority valve 65 Left replenishing valve
15 Brake system gear pump suc- 42 Restrictor 66 Right replenishing valve
tion port
16 Transmission return flow 43 Check valve 67 Left steering cylinder
17 Compact brake valve return 44 LS steering pressure cut-off 68 Steering damper hydro accu-
flow mulator (optional)
18 Pilot control unit return flow 45 LS working hydraulics pres- 69 Steering damper hydro accu-
sure cut-off mulator (optional)
19 Fan gear motor leak oil 46 Flow regulating valve 70 Right steering cylinder
20 Travel pump leak oil 47 Compact brake valve (hous- P Working hydraulics pump
ing preheating) high pressure
21 Hydraulic oil cooler return 48 Ride control P1 Steering system high pres-
flow sure
22 Hydraulic oil cooler bypass 50 Emergency steering pump LS Working hydraulics load
return flow sensing pressure
The steering system is supplied with oil by the working hydraulics pump 25 via the
control valve block 40.
When steering, the servostat 60 generates a load sensing signal. This load sensing
signal activates the priority valve 41 in the control valve block and the working hy-
draulics pump 25 via the check valve 43.
The priority valve 41 in the control valve block supplies the oil in the working hy-
draulics pump from the working hydraulics to the servostat 60. The oil supply for
the steering system has priority. Only the amount of oil actually needed by the
steering system is supplied. The working hydraulics are only supplied with what is
left over.
If the working hydraulics pump fails to supply the oil, the central control unit acti-
vates the emergency steering function. Here the electrically powered emergency
steering pump 50 pumps oil to the servostat and enables further steering move-
ment.
LBH/11827693/02/211-20150615.1139/en
copyright by
L538-1493 090-9
Servostat
090.3 Servostat
Valid for: L538-1493/31405-;
1 Layout
Fig. 324: Servostat

for steering to the left for steering to the right
2 Valve spool with teeth
The servostat is mounted on the cab floor with rubber elements.
The steering column meshes with the teeth 2.
LBH/11827693/02/211-20150615.1139/en
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090-10 L538-1493
Servostat
Fig. 325: Sectional view of servostat

1 Metering pump 6 Secondary pressure relief valve
for steering to the right
2 Valve spool (outer spool) 7 Steering column connection
3 Actuator ring 8 Leaf springs
4 Valve spool (inner spool) 9 Secondary pressure relief valve
for steering to the left
5 Needle bearing
LBH/11827693/02/211-20150615.1139/en
Fig. 326: Sectional view of secondary pressure relief valve

1 Plug 3 Valve piston
2 Compression spring 4 Valve seat
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L538-1493 090-11
Servostat
Fig. 327: Sectional view of feeding valve

1 Check valve 3 Hex bolt
2 Pin
2 Function
2.1 Basic function
LBH/11827693/02/211-20150615.1139/en
Fig. 328: Hydraulic plan of servostat

1 Servostat 7 Right feeding valve
2 Valve spool 8 Return line to hydraulic tank
3 Metering pump 9 Oil supply from control valve block
4 Secondary pressure relief valve 10 Load sensing signal to working hy-
for steering to the left draulics pump
5 Secondary pressure relief valve 11 Steering cylinder
for steering to the right
6 Left feeding valve 12 Steering cylinder
copyright by
090-12 L538-1493
Servostat
The servostat is supplied with oil by the working hydraulics pump via the priority
valve in the control valve block 9.
The servostat directs the oil from the working hydraulics pump to the steering cylin-
ders. While doing this, the servostat regulates the amount of oil depending on the
steering speed.
The servostat also generates a load sensing signal 10 which regulates the working
hydraulics pump.
2.2 Flow booster
Fig. 329: Flow booster

Q Pump capacity in % I Flow rate via metering pump
U Turns of steering wheel per minute II Flow rate via valve spool
The valve spool consists of a inner spool and an outer spool. Both spools are kept
in position by leaf springs.
At less than ten turns of the steering wheel per minute, the inner spool and the out-
er spool turn together and deliver the oil to the metering pump. The metering pump
delivers the oil to the steering cylinders.
At more than ten turns of the steering wheel per minute, the valve spools shift
against each other due to the greater force. This causes the valve spools to make
an additional opening through which the oil flows directly to the steering cylinders.
Up to 60% more oil flows to the steering cylinders from fast steering manoeuvres.
LBH/11827693/02/211-20150615.1139/en
copyright by
L538-1493 090-13
Steering cylinder
090.4 Steering cylinder

Valid for: L538-1493/35803-31404;
1 Layout
Fig. 330: Steering cylinder for steering to the left

1 Left steering cylinder 4 Steering damper hydro accumula-
tor (optional)
2 Steering damper hydro accumula- 5 Servostat R
tor (optional)
3 Servostat L 6 Right steering cylinder
LBH/11827693/02/211-20150615.1139/en
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090-14 L538-1493
Steering cylinder
Fig. 331: Steering cylinder

1 Piston-side cylinder bearing 9 Glyd Ring seal
6 Piston 14 Rimseal
8 Sliding ring 16 Sealing lip
The piston-side cylinder bearing 1 and the ring-side cylinder bearing 3 are de-
signed as forks.
2 Function
2.1 Basic function

The steering cylinder is a double-action hydraulic cylinder with a piston rod at one
end.
LBH/11827693/02/211-20150615.1139/en
When steering, the servostat pumps oil to the piston side or ring side of the steer-
ing cylinder.

ing.
2.3 Seals
per ring and a sealing lip prevent dirt from penetrating.
copyright by
L538-1493 090-15
Steering cylinder
2.4 Steering the machine

When steering to the left, oil flows from the servostat L connection to the ring side
of the left steering cylinder and to the piston side of the right steering cylinder. The
servostat R connection relieves the ring side of the right steering cylinder and the
piston side of the left steering cylinder into the hydraulic tank.
When steering to the right, pressure is applied to the servostat R connection and
the L connection is relieved into the hydraulic tank.
2.5 Steering damper hydro accumulator

The steering damper hydro accumulators dampen pressure peaks which occur
with sudden steering movements and fast changes in the steering direction.

Valid for: L538-1493/31405-;
1 Layout
Fig. 332: Steering cylinder for steering to the left

1 Left steering cylinder 3 Servostat R
2 Servostat L 4 Right steering cylinder
LBH/11827693/02/211-20150615.1139/en
copyright by
090-16 L538-1493
Steering cylinder
Fig. 333: Steering cylinder

1 Piston-side cylinder bearing 9 Glyd Ring seal
6 Piston 14 Rimseal
8 Sliding ring 16 Sealing lip
The piston-side cylinder bearing 1 and the ring-side cylinder bearing 3 are de-
signed as forks.
2 Function
2.1 Basic function

The steering cylinder is a double-action hydraulic cylinder with a piston rod at one
end.
LBH/11827693/02/211-20150615.1139/en
When steering, the servostat pumps oil to the piston side or ring side of the steer-
ing cylinder.

ing.
2.3 Seals
per ring and a sealing lip prevent dirt from penetrating.
copyright by
L538-1493 090-17
Steering cylinder
2.4 Steering the machine

When steering to the left, oil flows from the servostat L connection to the ring side
of the left steering cylinder and to the piston side of the right steering cylinder. The
servostat R connection relieves the ring side of the right steering cylinder and the
piston side of the left steering cylinder into the hydraulic tank.
When steering to the right, pressure is applied to the servostat R connection and
the L connection is relieved into the hydraulic tank.

Valid for: L538-1493/35803-;
1 Layout
Fig. 334: Ride control hydro accumulator

1 Plunger 5 Nitrogen chamber
2 Accumulator 6 Plug
3 Oil chamber 7 Oil filling
4 Membrane
The steering damper hydraulic accumulators are attached on the piston side of the
steering cylinder.
The steering damper hydraulic accumulators are each divided into two chambers
by a membrane 4. The chamber 5 is filled with nitrogen.
2 Function
When sudden steering movements and quick changes in the steering direction are
made, the steering damper hydraulic accumulators cushion the pressure peaks.
The oil filling 7 prevents the membrane 4 from knocking too hard against the accu-
LBH/11827693/02/211-20150615.1139/en
mulator 2 when high pressure peaks occur.
copyright by
090-18 L538-1493
Emergency steering
090.5 Emergency steering

Valid for: L538-1493/31405-;
1 Layout
Fig. 335: Emergency steering is active

1 Hydraulic tank 5 Emergency steering pressure
switch B3
2 Emergency steering pump 6 Control valve block and working
hydraulics pump
3 Emergency steering check pres- 7 Servostat
sure switch B3a
4 Valve block P1 Steering system high pressure test
connection
The emergency steering system consists of the following components:
tank, page 080-2)
– Emergency steering pump (For more information see: 090.5.2 Emergency
steering pump, page 090-20)
– Valve block (For more information see: 090.5.4 Valve block, page 090-25)
LBH/11827693/02/211-20150615.1139/en
– Electronic control unit (For more information see: Overview of the electronic
control system, page 090-22)
2 Function
The emergency steering supplies the servostat with oil for a brief time if the work-
ing hydraulics pump fails. As the emergency steering pump works electrically with
power from the vehicle battery, the emergency steering is still able to work even
when the engine is not running.
When the emergency steering is activated, the emergency steering pump draws oil
from the hydraulic tank and pumps it to the valve block. The oil then flows from the
valve block to the servostat.
copyright by
L538-1493 090-19
Emergency steering

Valid for: L538-1493/31405-;
1 Layout
Fig. 336: Emergency steering pump

1 Electric motor M8 2 Gear pump with pressure relief
valve
The emergency steering pump is installed on the right side of the vehicle on the
frame of the rear section.
The emergency steering pump consists of an electric motor 1 and a gear pump 2
with integrated pressure relief valve.
LBH/11827693/02/211-20150615.1139/en
Fig. 337: Exploded view of the gear pump with pressure relief valve
1 Connector piece 9 Pump cover
2 O-ring 10 Pressure relief valve
3 Flange 11 Valve piston
4 Seals 12 Compression spring
5 Bearing bushings 13 Adjustment shim
6 Drive gear 14 Guide pin
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090-20 L538-1493
Emergency steering
7 Gearwheel 15 Plug
8 Pump housing
2 Function
2.1 Basic function
Fig. 338: Hydraulic diagram of the emergency steering pump

1 Emergency steering pump 4 Pressure relief valve
2 Electric motor M8 5 Emergency steering pump intake
connection
3 Gear pump 6 Valve block
The emergency steering pump 1 supplies the steering system with oil if the working
hydraulics pump fails. When the emergency steering is activated, the emergency
steering pump draws oil from the hydraulic tank 5 and pumps it to the valve
block 6.
The pressure relief valve 4 protects the gear pump 3 from excess pressure and the
electric motor 2 from high current consumption.
When the steering system is not actuated and the emergency steering pump is ac-
tive, the gear pump 3 supplies the oil via the pressure relief valve 4 in the circuit.
2.2 Pump capacity and current consumption

LBH/11827693/02/211-20150615.1139/en
Fig. 339: Characteristic

Q Pump capacity at Δp I Current consumption at Δp
Δp = output pressure - input pressure (tank pressure)
copyright by
L538-1493 090-21
Emergency steering
090.5.3 Electronic control unit

Valid for: L538-1493/31405-;
1 Layout
Fig. 340: Emergency steering electronic control unit

1 Display A13 5 Emergency steering check pres-
sure switch B3a
2 Emergency steering button S10 6 Emergency steering pump relay
K011
3 Central control unit (UEC3) A6 7 Electric motor M8
4 Emergency steering pressure
switch B3
2 Function
2.1 Basic function

If the pressure in the steering system falls below 16±2 bar, the emergency steering
pressure switch 4 opens. This causes the central control unit 3 to detect a failure in
the steering system oil supply.
The central control unit 3 then activates the emergency steering relay 6 for 40 sec-
onds. In addition, the central control unit generates a warning tone and the emer-
gency steering symbol field on the display 1 lights up.
LBH/11827693/02/211-20150615.1139/en
After this, the central control unit 3 energises the emergency steering relay 6 as
long as the emergency steering button is pressed, up to a maximum of 10 sec-
onds.
2.2 Testing the pressure switches

Once the ignition is switched on, the central control unit 3 tests the emergency
steering pressure switch 4 and the emergency steering check pressure switch 5 for
a short circuit. The central control unit 3 transmits a voltage signal to the pressure
switches.
If a pressure switch or wiring is defective, a positive signal is sent back to the cen-
tral control unit 3. The central control unit 3 triggers the emergency steering symbol
copyright by
090-22 L538-1493
Emergency steering
field or the emergency steering pressure check symbol field depending on the de-
fective pressure switch.
2.3 Testing the emergency steering pump

After starting the engine, the central control unit 3 activates the emergency steering
pump for 3 seconds. Within these 3 seconds, the emergency steering pressure
check switch 5 must be subject to a pressure of 16±2 bar.
During the test, the emergency steering check symbol field lights up.
Once the pressure is reached, the emergency steering check symbol field goes
out. The emergency steering system is ready for operation.
If the pressure is not reached, the emergency steering check symbol field stays lit
until the ignition is switched off. The emergency steering system is not fully func-
tional. The machine must not be put into operation.

Valid for: L538-1493/31405-;
1 Layout
Fig. 343: Emergency steering pressure switch

1 Restrictor 4 Thin-film sensor (DMS)
2 Pressure chamber 5 Electronics
3 Metal surface 6 3-pin plug
The emergency steering pressure switch B3 is mounted on the valve block.
The emergency steering pressure switch is N/O (normally open).
2 Function
LBH/11827693/02/211-20150615.1139/en
2.1 Basic function

Oil flows into the pressure chamber 2 via the restrictor 1. Pressure peaks are ab-
sorbed by the restrictor 1.
The thin-film sensor 4 changes its resistance according to the curvature of the met-
al surface 3. When a specific resistance is reached, the electronics 5 close the
electrical contact.
copyright by
L538-1493 090-23
Emergency steering
2.2 Monitoring the steering system
Fig. 344: Equivalent diagram of emergency steering pressure switch
The emergency steering pressure switch monitors the pressure of the steering sys-
tem.
If the pressure in the steering system falls below a set value, the electronics open
the contact. The emergency steering system is activated. The emergency steering
symbol field lights up in the display.

Valid for: L538-1493/31405-;
1 Layout
Fig. 346: Emergency steering check pressure switch

The emergency steering check pressure switch B3a is mounted on the emergency
steering pump.
The emergency steering check pressure switch is N/O (normally open).
LBH/11827693/02/211-20150615.1139/en
2 Function
2.1 Basic function

Oil flows into the pressure chamber 2 via therestrictor 1. Pressure peaks are absor-
bed by the restrictor 1.
electrical contact.
copyright by
090-24 L538-1493
Emergency steering
2.2 Monitoring the emergency steering pump
Fig. 347: Equivalent diagram of emergency steering check pressure switch
The emergency steering check pressure switch monitors the pressure of the steer-
ing pump.
After starting the engine, the emergency steering system performs an automatic
check. Here the emergency steering pump is activated. If the emergency steering
pump creates enough pressure, the electronics in the emergency steering check
pressure switch close the electric contact. The central control unit registers that the
emergency steering pump is working.
During the automatic check, the emergency steering check symbol field lights up in
the display.
090.5.4 Valve block

Valid for: L538-1493/31405-;
1 Layout
Fig. 349: Valve block

1 Emergency steering pressure 4 Check valve
switch B3
2 Check valve P1 Steering system high pressure test
connection
LBH/11827693/02/211-20150615.1139/en
3 Valve block
The valve block is fitted in the frame of the rear section.
copyright by
L538-1493 090-25
Emergency steering
2 Function
Fig. 350: Oil supply: Normal operation / from emergency steering pump
1 Oil supply 5 Check valve
2 Check valve 6 Oil from the emergency steering
pump
3 Emergency steering pressure P1 Steering system high pressure test
switch B3 connection
4 To the servostat
If the oil supply fails (for example when the engine is not running), the central con-
trol unit activates the emergency steering system. The oil flows from the emergen-
cy steering pump 6 to the servostat 4.
LBH/11827693/02/211-20150615.1139/en
copyright by
090-26 L538-1493
100 Brake system
Contents
L538-1493/31405-; 100-2
100.2 Service brake and parking brake 100-4
L538-1493/31405-; 100-4
L538-1493/31405; 100-5
100.3 Service brake 100-12
L538-1493/31405-; 100-12
L538-1493/31405-; 100-15
L538-1493/31405-; 100-16
L538-1493/31405-; 100-17
100.4 Parking brake 100-18
L538-1493/31405-; 100-18
100.4.2 Disc brake
L538-1493/31405-; 100-21
L538-1493/31405-; 100-22
LBH/11827693/02/211-20150615.1139/en
copyright by
L538-1493 100-1
Brake system Service manual
Overview of the brake system
Valid for: L538-1493/31405-;
1 Layout
Fig. 351: Main components of the brake system

1 Hydraulic tank 6 Compact brake valve M3 Accumulator charge pressure
test connection
LBH/11827693/02/211-20150615.1139/en
2 Rear axle (2nd brake circuit) 7 Control valve block (housing M4 Front axle brake pressure test
preheating) connection
3 Front axle (1st brake circuit) 8 Parking brake hydro accumu- M5 Rear axle brake pressure test
lator connection
4 Disc brake 9 Service brake hydro accumu-
lator (front axle)
5 Brake system gear pump 10 Service brake hydro accumu-
lator (rear axle)
The brake system consists of the service brake and the parking brake.
The following components are part of the service brake and the parking brake (For
more information see: 100.2 Service brake and parking brake, page 100-4) :
– Hydraulic tank
copyright by
100-2 L538-1493
Service manual Brake system
Overview of the brake system
– Brake system gear pump

– Compact brake valve
The following components are also part of the service brake (For more information
see: 100.3.1 Overview of the service brake, page 100-12) :
– Service brake hydro accumulator
– Brake light pressure switch
– Accumulator charge pressure switch
– Wet disc brakes (axles)
The following components are also part of the parking brake (For more information
see: 100.4.1 Overview of the parking brake, page 100-18) :
– Disc brake
– Parking brake hydro accumulator
2 Function
The brake system gear pump draws up oil from the hydraulic tank and pumps it to
the compact brake valve. The hydraulic accumulators of the brake system are
charged via the compact brake valve.
Once the hydraulic accumulators are charged, the oil flows back into the hydraulic
tank via the control block.
The oil from the hydraulic accumulators is used for braking (engaging the service
brake or releasing the parking brake).
LBH/11827693/02/211-20150615.1139/en
copyright by
L538-1493 100-3
Service brake and parking brake
100.2 Service brake and parking brake

Valid for: L538-1493/31405-;
1 Layout
Fig. 352: Brake system gear pump

1 Brake system gear pump 2 Fan gear pump
The brake system gear pump, together with the fan gear pump, is fitted to the aux-
iliary drive of the engine.
LBH/11827693/02/211-20150615.1139/en
Fig. 353: Exploded view of the brake system gear pump

1 Actuator ring 6 Gearwheel
2 O-ring 7 Drive gear
3 Pump cover with flange 8 Pump housing
4 Seals 9 Pump cover with flange
5 Bearing bushings 10 Shaft seal ring
2 Function
The brake system gear pump supplies:
– The service brake with oil
copyright by
100-4 L538-1493
– The parking brake with oil

The brake system gear pump is driven by the engine via the drive shaft of the fan
gear pump.
The flow rate per rotation cannot be adjusted. The flow rate is solely determined by
the engine speed.
The brake system gear pump draws up oil from the hydraulic tank and pumps it to
the compact brake valve. The oil for the service brake and the parking brake is divi-
ded in the compact brake valve. If the brake system does not require any oil, the oil
flows into the hydraulic tank via the accumulator charge valve in the compact brake
valve.

Valid for: L538-1493/31405;
1 Layout
Fig. 354: Compact brake valve

1 Pedal 6 Brake light pressure switch B12
2 Base plate 7 Stop bolt
3 Accumulator charge pressure 8 Inching angle sensor R1
switch B19
4 Parking brake solenoid valve Y10 M3 Accumulator charge pressure test
connection
5 Pressure balance pilot valve
LBH/11827693/02/211-20150615.1139/en
The base plate 2 is bolted to the floor of the driver’s cab.
copyright by
L538-1493 100-5
Fig. 355: Sectional view of the compact brake valve

LBH/11827693/02/211-20150615.1139/en
1 Pedal 10 Pressure balance pilot valve ad-

justing screw
2 Zero position stop bolt 11 Inverted shuttle valve
3 Inlet restrictor 12 Pressure regulator piston readjust-
ing spring
4 Inlet check valve 13 Pressure regulator piston for 2nd
brake circuit
5 Parking brake check valve 14 Pressure regulator piston readjust-
ing spring
6 Parking brake solenoid valve Y10 15 Pressure regulator piston for 1st
brake circuit
7 To the accumulator charge valve 16 Stop bolt
copyright by
100-6 L538-1493
8 Pressure balance pilot valve 17 Pressure regulator spring

9 Pilot valve regulating spring 18 Inching compression spring
Fig. 356: Sectional view of the accumulator charge valve

1 Inlet restrictor 3 To the pressure balance pilot
valve
2 Accumulator charge valve
2 Function
2.1 Basic function

LBH/11827693/02/211-20150615.1139/en
Fig. 357: Hydraulic diagram of the compact brake valve

1 Compact brake valve 14 Compact brake valve return flow
2 Inlet restrictor 15 Brake system high pressure gear
pump
3 Accumulator charge valve 16 Control valve block (housing pre-
heating)
4 Inlet check valve 17 Accumulator charge pressure
switch B19
5 Pressure balance pilot valve 18 Service brake hydro accumulator
(front axle)
6 Inverted shuttle valve 19 Parking brake hydro accumulator
copyright by
L538-1493 100-7
7 Parking brake check valve 20 Parking brake

8 Parking brake solenoid valve Y10 21 Front axle wet disc brake
9 Inching angle sensor R1 22 Rear axle wet disc brake
10 Pressure regulator piston for 1st 23 Brake light pressure switch B12
brake circuit
11 Restrictor 24 Service brake hydro accumulator
(rear axle)
12 Pressure regulator piston for 2nd M3 Accumulator charge pressure
brake circuit
13 Restrictor
The following functions are controlled via the compact brake valve:
– Charging the hydro accumulators
– Service brake
– Parking brake
– Brake light
– Brake system accumulator pressure symbol field
2.2 Inverted shuttle valve

The service brake hydraulic accumulators are connected to the pressure balance
pilot valve via the inverted shuttle valve. The hydraulic accumulator with the lower
pressure is always connected to the pressure balance pilot valve by the inverted
shuttle valve.
2.3 Charging the hydro accumulators
LBH/11827693/02/211-20150615.1139/en
Fig. 358: Hydro accumulator charged / charging

1 Pilot valve regulating spring 5 Inlet restrictor 9 Compression spring of accu-
mulator charge valve
2 Pressure balance pilot valve 6 Inlet check valve 10 Valve piston of pilot valve
3 Piston 7 To the parking brake
copyright by
100-8 L538-1493
4 To the service brake 8 Valve piston of accumulator

charge valve
The pressure in the hydraulic accumulators of the braking system is reduced every
time the brakes are applied (engaging the service brake or releasing the parking
brake). If the pressure drops to the cut-in pressure, the hydraulic accumulators are
charged up to the cut-out pressure again.
The cut-in pressure and the cut-out pressure depend on the pre-loaded force of the
pilot valve regulating spring 1.
The hydraulic accumulators of the brake system are charged by the brake system
gear pump.
When the hydraulic accumulators are completely charged, the accumulator charge
valve directs the oil from the brake system gear pump P to the control valve block
to preheat the housing N.
2.3.1 Charged hydro accumulators

When the hydraulic accumulators are charged up to the cut-out pressure, the sys-
tem pressure pushes the valve piston of the pilot valve 10 against the regulating
spring of the pilot valve 1.
The valve piston of the pilot valve separates the accumulator charge valve from the
system pressure and links it to the tank connection. The oil from the brake system
gear pump can therefore push the valve piston of the accumulator charge valve 8
against the compression spring of the accumulator charge valve 9. The connec-
tion N is open. The oil from the brake system gear pump P flows to the control
valve block.
2.3.2 Charging the hydro accumulators

The brake system pressure is applied to the valve piston of the pilot valve 10 via
the piston 3. If the system pressure drops to the cut-in pressure, the regulating
spring of the pilot valve 1 pushes the valve piston of the pilot valve 10 against the
system pressure.
The valve piston of the pilot valve 10 links the accumulator charge valve to the sys-
tem pressure. This results in the valve piston of the accumulator charge valve 8
being closed by the system pressure and the compression spring of the accumula-
tor charge valve 9.
The oil from the brake system gear pump P flows into the hydro accumulators via
the inverted shuttle valve or via the parking brake check valve.
2.4 Inching function

The inching angle sensor R1 is connected to the pedal. The first two thirds of the
pedal displacement only operate the inching function.
LBH/11827693/02/211-20150615.1139/en
The inching angle sensor is a two-channel sensor. It issues two mixed current sig-
nals between 4 mA and 20 mA.
During inching, the central control unit reduces the current to the control pressure
proportional solenoid. This results in the travel pump pivoting back in. The machine
is hydrostatically braked. (For more information see: Electrical/proportional regula-
tion (EP regulation), page 070-22)
copyright by
L538-1493 100-9
2.5 Service brake
Fig. 359: Service brake not applied / applied

1 Pedal 5 Connecting duct 9 Pressure regulator spring
2 Inverted shuttle valve 6 Pressure regulator piston re- 10 Inching compression spring
adjusting spring
3 Pressure regulator piston re- 7 Pressure regulator piston for
adjusting spring 1st brake circuit
4 Pressure regulator piston for 8 Connecting duct
2nd brake circuit
The first of two thirds of the pedal displacement only operate the inching function.
LBH/11827693/02/211-20150615.1139/en
The pressure regulator spring is only activated in the last third of the pedal dis-
placement.
The pressure regulator spring 9 pushes the pressure regulator piston for the 1st
brake circuit 7 and the pressure regulator piston for the 2nd brake circuit 4 against
the return springs 6 and 3. Oil flows from the hydro accumulators S1 and S2 to the
brake circuits BR2 and BR1 via the recesses in the pressure regulator pistons.
At the same time, oil flows through the connecting ducts 8 and 5 to the readjusting
springs. When the oil pressure in the brake circuits is sufficient, the oil pressure
and the readjusting springs push the pressure regulator pistons against the pres-
sure regulator spring again. The connection to the hydro accumulators is interrup-
ted again. A steady brake pressure is thereby maintained in the brake circuits, as
long as the pedal position remains unchanged.
copyright by
100-10 L538-1493
If the pedal is pushed down further, the oil pressure also increases in the brake cir-
cuits because increased oil pressure is required to push the pressure regulator pis-
tons against the pressure regulator spring again.
2.6 Parking brake

When the parking brake solenoid valve Y10 is energised, oil flows from the parking
brake hydro accumulator to the disc brake. The parking brake disengages.
2.7 Brake light

The brake light is switched on by the brake light pressure switch B12 in the 2nd
brake circuit. (For more information see: 100.3.3 Brake light pressure switch ,
page 100-16)
2.7.1 Brake system accumulator pressure symbol field

The brake system accumulator pressure symbol field is activated by the accumula-
tor charge pressure switch B19. (For more information see: 100.3.4 Accumulator
charge pressure switch, page 100-17)
LBH/11827693/02/211-20150615.1139/en
copyright by
L538-1493 100-11
Service brake
100.3 Service brake

Valid for: L538-1493/31405-;
1 Layout
LBH/11827693/02/211-20150615.1139/en
Fig. 360: Main components of the service brake

1 Hydraulic tank 5 Compact brake valve M3 Accumulator charge pressure
test connection
2 Rear axle (2nd brake circuit) 6 Control valve block (housing M4 Front axle brake pressure test
preheating) connection
3 Front axle (1st brake circuit) 7 Service brake hydro accumu- M5 Rear axle brake pressure test
lator (front axle) connection
4 Brake system gear pump 8 Service brake hydro accumu-
lator (rear axle)
Components of the service brake:
tank, page 080-2)
copyright by
100-12 L538-1493
Service brake
– Brake system gear pump (For more information see: 100.2.1 Brake system gear
pump, page 100-4)
– Compact brake valve (For more information see: 100.2.2 Compact brake valve,
page 100-5)
– Service brake hydro accumulator (For more information see: 100.3.2 Service
brake hydro accumulator, page 100-15)
– Brake light pressure switch (For more information see: 100.3.3 Brake light pres-
sure switch , page 100-16)
– Accumulator charge pressure switch (For more information see: 100.3.4 Accu-
mulator charge pressure switch, page 100-17)
– Wet disc brakes (axles) (For more information see: Service brake (wet disc
brake), page 130-4)
2 Function
2.1 Basic function

LBH/11827693/02/211-20150615.1139/en
Fig. 361: Hydraulic diagram of the brake system

1 Hydraulic tank 20 Working hydraulics pump 40 Restrictor
leak oil
2 Breather filter 21 Servostat return flow 41 Pressure regulator piston for
2nd brake circuit
3 Return strainer 22 Travel pump leak oil 42 Restrictor
4 Bypass valve 23 Hydraulic oil cooler return 43 Brake light pressure switch
flow B12
5 Return suction filter 24 Hydraulic oil cooler bypass 44 Service brake hydro accumu-
return flow lator (rear axle)
copyright by
L538-1493 100-13
Service brake
6 Pre-tension valve 25 Control valve block return 45 Control valve block (housing
flow preheating)
7 Feeding valve 26 Engine 46 Accumulator charge pressure
switch B19
8 Strainer 27 Fan gear pump 47 Service brake hydro accumu-
lator (front axle)
9 9 bar check valve 28 Brake system gear pump 48 Parking brake hydro accumu-
lator
10 2.5 bar bypass valve 30 Compact brake valve 50 Front axle wet disc brake
11 Hydraulic oil temperature 31 Inlet restrictor 51 Front axle
sensor B8
12 Drain valve 32 Accumulator charge valve 52 Disc brake
13 Replenishing pump intake 33 Inlet check valve 53 Rear axle wet disc brake
connection
14 Working hydraulics pump in- 34 Pressure balance pilot valve 54 Rear axle
take connection
15 Fan gear pump intake con- 35 Inverted shuttle valve M3 Accumulator charge pressure
nection
16 Emergency steering pump in- 36 Parking brake check valve M4 Front axle brake pressure
take connection
17 Transmission return flow 37 Parking brake solenoid valve M5 Rear axle brake pressure
Y10
18 Pilot control unit return flow 38 Inching angle sensor R1
19 Fan gear motor leak oil 39 Pressure regulator piston for
1st brake circuit
The brake system gear pump 28 draws up oil from the hydraulic tank 1 and pumps
it to the compact brake valve 30.
When the service brake hydro accumulators 44 and 47 are fully charged, the oil
flows through the accumulator charge valve 32 to the control valve block 45 and
back into the hydraulic tank 1.
If the pressure in the service brake hydraulic accumulators is too low, the pressure
balance pilot valve 34 closes the accumulator charge valve 32. The service brake
hydraulic accumulators are charged by the brake system gear pump 28.
At first, only the inching function 38 is activated when braking. When this occurs,
the travel pump pivots back in and the machine is braked hydrostatically.
If the pedal is pushed down further, oil from both service brake hydro accumula-
tors 47 and 44 flows to the wet disc brakes 50 and 53 via the two separate brake
circuits BR1 and BR2. LBH/11827693/02/211-20150615.1139/en
copyright by
100-14 L538-1493
Service brake

Valid for: L538-1493/31405-;
1 Layout
Fig. 362: Service brake hydro accumulator

The service brake hydraulic accumulators are fitted under the driver’s cab.
The service brake hydraulic accumulators are each divided into two chambers by a
membrane 4. The chamber 5 is filled with nitrogen.
2 Function
Due to the service brake hydro accumulators, the machine can be braked by en-
gaging the service brake even when the engine is not running.
The front axle is braked with the oil from one of the hydraulic accumulators; the
rear axle is braked with the oil from the other hydraulic accumulator.
The oil chamber 3 is filled with oil while the engine is running via the compact
brake valve.
When the engine is not running, the nitrogen filling 5 presses the membrane 4
against the oil. The pressure is sufficient to apply the brakes fully at least nine
times.
LBH/11827693/02/211-20150615.1139/en
copyright by
L538-1493 100-15
Service brake

Valid for: L538-1493/31405-;
1 Layout
Fig. 363: Brake light pressure switch, no contact and making contact
1 Connection contacts 5 Contact plate
2 Adjusting screw 6 Pin
3 Compression spring 7 Membrane
4 Switching contacts
The brake light pressure switch B12 is fitted to the compact brake valve and con-
nected to the 2nd brake circuit.
The brake light pressure switch is N/O (normally open). The closing pressure can
be set with the adjusting screw 2.
2 Function
2.1 Basic function

When the service brake is engaged, pressure is applied to the membrane 7. When
there is sufficient pressure, the membrane 7 pushes the pin 6 against the compres-
sion spring 3, until the contact plate 5 touches the two switching contacts 4. This
causes the two connection contacts 1 to make contact and close the circuit.
2.2 Switching on the brake light

LBH/11827693/02/211-20150615.1139/en
Fig. 364: Equivalent diagram of brake light pressure switch
The brake light pressure switch closes at a brake pressure of 5±0.5 bar. This causes
the brake light to light up when braking.
copyright by
100-16 L538-1493
Service brake

Valid for: L538-1493/31405-;
1 Layout
Fig. 365: Accumulator charge pressure switch

The accumulator charge pressure switch B19 is fitted to the compact brake valve.
The accumulator charge pressure switch is N/O (normally open).
2 Function
2.1 Basic function

Oil flows into the pressure chamber 2 via the restrictor 1. Pressure peaks are ab-
sorbed by the restrictor 1.
electrical contact.
2.2 Accumulator charge pressure monitoring

LBH/11827693/02/211-20150615.1139/en
Fig. 366: Equivalent diagram of accumulator charge pressure switch
The accumulator charge pressure switch monitors the pressure in the service
brake hydro accumulators.
If the service brake is engaged when the engine is not running, the pressure in the
service brake hydraulic accumulators is reduced without these being recharged by
the brake system gear pump.
If the brake pressure falls below a set value, the electronics open the contact. The
brake system accumulator pressure symbol field appears in the display. If the en-
gine is running, a warning buzzer sounds in addition.
copyright by
L538-1493 100-17
Parking brake
100.4 Parking brake

Valid for: L538-1493/31405-;
1 Layout
Fig. 368: Main components of the parking brake

1 Hydraulic tank 3 Brake system gear pump 5 Control valve block (housing
LBH/11827693/02/211-20150615.1139/en
preheating)
2 Disc brake 4 Compact brake valve 6 Parking brake hydro accumu-
lator
Components of the parking brake:
tank, page 080-2)
– Brake system gear pump (For more information see: 100.2.1 Brake system gear
pump, page 100-4)
– Compact brake valve (For more information see: 100.2.2 Compact brake valve,
page 100-5)
– Disc brake (For more information see: 100.4.2 Disc brake, page 100-21)
– Parking brake hydro accumulator (For more information see: 100.4.3 Parking
brake hydro accumulator, page 100-22)
copyright by
100-18 L538-1493
Parking brake
2 Function
2.1 Basic function
Fig. 369: Hydraulic diagram of the brake system

1 Hydraulic tank 20 Working hydraulics pump 40 Restrictor
leak oil
2 Breather filter 21 Servostat return flow 41 Pressure regulator piston for
2nd brake circuit
3 Return strainer 22 Travel pump leak oil 42 Restrictor
4 Bypass valve 23 Hydraulic oil cooler return 43 Brake light pressure switch
flow B12
5 Return suction filter 24 Hydraulic oil cooler bypass 44 Service brake hydro accumu-
return flow lator (rear axle)
6 Pre-tension valve 25 Control valve block return 45 Control valve block (housing
flow preheating)
LBH/11827693/02/211-20150615.1139/en
7 Feeding valve 26 Engine 46 Accumulator charge pressure

switch B19
8 Strainer 27 Fan gear pump 47 Service brake hydro accumu-
lator (front axle)
9 9 bar check valve 28 Brake system gear pump 48 Parking brake hydro accumu-
lator
10 2.5 bar bypass valve 30 Compact brake valve 50 Front axle wet disc brake
11 Hydraulic oil temperature 31 Inlet restrictor 51 Front axle
sensor B8
12 Drain valve 32 Accumulator charge valve 52 Disc brake
13 Replenishing pump intake 33 Inlet check valve 53 Rear axle wet disc brake
connection
copyright by
L538-1493 100-19
Parking brake
14 Working hydraulics pump in- 34 Pressure balance pilot valve 54 Rear axle
take connection
15 Fan gear pump intake con- 35 Inverted shuttle valve M3 Accumulator charge pressure
nection
16 Emergency steering pump in- 36 Parking brake check valve M4 Front axle brake pressure
take connection
17 Transmission return flow 37 Parking brake solenoid valve M5 Rear axle brake pressure
Y10
18 Pilot control unit return flow 38 Inching angle sensor R1
19 Fan gear motor leak oil 39 Pressure regulator piston for
1st brake circuit
The brake system gear pump 28 draws up oil from the hydraulic tank 1 and pumps
it to the compact brake valve 30.
When the parking brake hydro accumulator 48 is fully charged, the oil flows
through the accumulator charge valve 32 to the control valve block 45 and back in-
to the hydraulic tank 1.
If the pressure in the parking brake hydraulic accumulator is too low, the pressure
balance pilot valve 34 closes the accumulator charge valve 32. The parking brake
hydraulic accumulator is charged by the brake system gear pump 28.
When the parking brake is engaged, the parking brake solenoid valve Y10 37 is not
energised. The pressure chamber of the disc brake 52 is relieved towards the hy-
draulic tank. The cup springs in the disc brake generate the braking force.
The parking brake therefore functions even when engine is not running.
When the parking brake is engaged, the parking brake symbol field lights up on the
display.
When the parking brake is released, the parking brake solenoid valve Y10 is ener-
gised. Oil flows from the parking brake hydro accumulator 48 to the disc brake. The
oil pressure pushes the brake piston against the cup springs.
LBH/11827693/02/211-20150615.1139/en
copyright by
100-20 L538-1493
Parking brake
100.4.2 Disc brake

Valid for: L538-1493/31405-;
1 Layout
Fig. 371: Disc brake open

1 Cap 12 Solenoid
2 Sealing ring 13 Castle nut
3 Snap ring 14 Guide pin
4 Thrust ring 15 Brake shoe
5 Cup springs 16 Solenoid
6 Grooved ring packing 17 Dust protection ring
7 Brake piston 18 Pressure chamber
8 Brake caliper 19 Bleeder valve
9 Grooved ring packing 20 Thrust pin
10 Brake disc 21 Adjusting screw
11 Brake shoe 22 Counter nut
LBH/11827693/02/211-20150615.1139/en
The parking brake is a spring accumulator sliding caliper brake.

The parking brake is fitted to the axle input shaft of the front axle. The parking
brake also works on the rear axle via the drive shaft and the output of the transmis-
sion (drive shaft).
2 Function
2.1 Basic function

The braking force is generated by the brake disc being clamped between the brake
shoes. The friction between brake shoes and brake disc generates the braking
force.
copyright by
L538-1493 100-21
Parking brake
2.1.1 Disc brake closed (bled)

The brake caliper 8 is mounted on the guide pin 14 so that it floats.
The braking force is generated by the cup springs 5. The disc brake therefore
brakes without any additional external force, i.e. even when the engine is not run-
ning.
When the disc brake is closed, the pressure chamber 18 is relieved. The cup
springs 5 press the brake piston 7 with the brake shoe 15 against the brake
disc 10. The brake caliper 8 therefore slides on to the guide pin 14, until the brake
disc 10 is clamped between the brake shoes 11 and 15.
2.1.2 Disc brake open (ventilated)

When the disc brake is open, oil flows from the compact brake valve into the pres-
sure chamber 18. The oil pressure pushes the brake piston 7 against the cup
springs 5. The disc brake is open.

Valid for: L538-1493/31405-;
1 Layout
Fig. 372: Parking brake hydro accumulator

The parking brake hydro accumulator is bolted to the compact brake valve.
LBH/11827693/02/211-20150615.1139/en
The parking brake hydraulic accumulator is divided into two chambers by a mem-
brane 4. The chamber 5 is filled with nitrogen.
2 Function
The parking brake hydraulic accumulator can open the disc brake even when the
engine is not running (the ignition must be switched on).
The oil chamber 3 is filled with oil while the engine is running via the compact
brake valve.
When the engine is not running, the nitrogen filling 5 presses the membrane 4
against the oil. The pressure is sufficient to open the disc brake.
copyright by
100-22 L538-1493
110 Electrical system
Contents
L538-1493/31405-; 110-2
110.2 Lighting
L538-1493/31405-; 110-7
L538-1493/31405-; 110-9
L538-1493/31405-; 110-11
L538-1493/31405-; 110-13
110.5 Electrical components of the driver’s cab 110-18
L538-1493/31405-; 110-18
110.6 Electrical components in the rear section 110-22
L538-1493/31405-; 110-22
LBH/11827693/02/211-20150615.1139/en
copyright by
L538-1493 110-1
Electrical system Service manual
Overview of the electrical system
Valid for: L538-1493/31405-;

The operating voltage of the machine is 24 V. The batteries (2 x 12 V) are connec-
ted in series.
The two batteries are installed in the right ballast weight.
The following illustrations and tables contain components of the electrical system
(except for the engine).
1 Layout
Fig. 373: Machine view from left
BMK Function BMK Function

A4 Fuse and relay board Y2 Forward travel direction solenoid
valve
A6 Central control unit (UEC3) Y3 Reverse travel direction solenoid
valve
B4 Air filter contamination pres- Y14 Working hydraulics lockout solenoid
sure switch valve
B16 Audible reversing alarm Y20 Ride control solenoid valve
LBH/11827693/02/211-20150615.1139/en
M4 Front washer pump Y59 Control pressure proportional valve

M9 Rear washer pump Y60 Proportional valve coupling
Tab. 50: Components
copyright by
110-2 L538-1493
Service manual Electrical system
Fig. 374: Machine view from right

B3 Emergency steering pump pressure switch F07a Hazard warning system fuse
B3a Emergency steering pump check pressure switch K04 Preglow system relay
B25 Fuel pipe sensor K011 Emergency steering pump relay
B27 Air conditioning pressure switch M8 Emergency steering pump
F01 Main fuse (100A) S15 Battery main switch
F02 Preglow relay fuse (100A) Y26 Travel direction solenoid valve
F03 Emergency steering pump fuse (200A) Y53 Quick coupler solenoid valve
F07a Hazard warning system fuse Y53a Quick coupler solenoid valve LS signal
G2a Battery Y57 Travel motor 2 proportional solenoid
G2b Battery Y58 Travel range 1 solenoid valve
Tab. 51: Components
The emergency steering pump and the quick coupler are optional.
LBH/11827693/02/211-20150615.1139/en
copyright by
L538-1493 110-3
2.1 Earthing points
Fig. 375: Earthing points
Item num- BMK Installation location

ber
1 MP1_a, MP1_b, Front right of rear section, under the driver’s cab
MP1_h
2 MP5_a Rear section, next to the emergency steering pump
LBH/11827693/02/211-20150615.1139/en
3 MP5_b Left of rear section, under the diesel engine

4 MP6_b, MP6_c, Driver’s cab, behind the rear wall cover
MP6_d, MP6_e,
MP6_f
5 MP4_b Rear section, behind the battery main switch
6 MP4 Right of rear section, under the diesel engine
7 MP6_a Driver’s cab, on the fuse and relay board
Tab. 52
copyright by
110-4 L538-1493
2.2 Other electrical components
Fig. 376: Overview of the other electrical components

B12 Brake light pressure switch R5 Accelerator pedal angle sensor
B19 Accumulator charge pressure Y9 Retaining solenoid for bucket re-
switch turn-to-dig
K5a Front windscreen wiper motor in- Y10 Parking brake solenoid valve
terval relay
M2 Front windscreen wiper motor Y17 Retaining solenoid for lift kick-
out
M3 Rear windscreen wiper motor Y18 Float position retaining solenoid
R1 Inch/brake pedal angle sensor
Tab. 53: Other electrical components
The accelerator pedal with the accelerator pedal angle sensor R5 is located in the
driver’s cab.
The brake light pressure switch B12 and the brake accumulator pressure
switch B19 are located under the driver’s cab on the compact brake valve.
The windscreen wiper motors M2 and M3 are installed in the driver’s cab.
LBH/11827693/02/211-20150615.1139/en
The retaining solenoids for the float position Y18, bucket return-to-dig Y9 and lift
kick-out Y17 are located on the pilot control unit.
copyright by
L538-1493 110-5
2.3 Emergency steering pump relay (optional)
Fig. 377: Relays
The emergency steering pump K011 relay is on the right of the rear section, under
the cooler mount.
The emergency steering pump K011 relay controls the emergency steering pump.
The emergency steering pump is regulated by the central control unit.
LBH/11827693/02/211-20150615.1139/en
copyright by
110-6 L538-1493
Lighting
110.2 Lighting
Valid for: L538-1493/31405-;
1 Layout
Fig. 378: Overview of lighting

E1 Right rear light H17 Rear left direction indicator
E3 Left driving headlight H18 Rear left direction indicator
E4 Right driving headlight H20 Left brake light
E5 Left rear light H21 Right brake light
E6 Left tail light H22 Flashing beacon
E7 Right tail light H50 Front left marker light / parking light
E10 Front left working headlight H51 Front right marker light / parking light
E11 Front right working headlight H52 Left reversing light
E12 Rear left working headlight H53 Right reversing light
E13 Rear right working headlight H54 Left low beam
E14a Right number plate light H55 Right low beam
LBH/11827693/02/211-20150615.1139/en
E14b Left number plate light H56 Left high beam

H15 Front left direction indicator H57 Right high beam
H16 Front right direction indicator
Tab. 54: Component designations
2.1 Basic function

The lighting of the machine is controlled via the steering column switch S3 and via
switches in the driver’s cab.
The left brake light H20 and the right brake light H21 are controlled by the brake
light pressure switch B12 and brake light relay K246.
copyright by
L538-1493 110-7
Lighting
2.2 LED lighting (optional)
Fig. 379: LED lighting
Optionally, LED working headlights can be installed behind in the driver’s cab.
The light from LED working headlights is very similar to daylight. This means that
colours are easier to distinguish than in the yellow light emitted by halogen lights.
This makes it much easier to see and reduces eye fatigue.
Integrated electronics protect the LED working headlights from reverse polarity.
An integrated sensor protects the LED working headlights from overheating.
Cooling fins on the housing ensure the necessary heat dissipation.
The LED working headlights are equipped with 6 LEDs and need no maintenance.
LBH/11827693/02/211-20150615.1139/en
copyright by
110-8 L538-1493
Circuit diagrams
Valid for: L538-1493/31405-;

The circuit diagrams for the electrical system show the functional sequences for the
entire machine, including optional attachments. Options in the circuit diagrams are
shown in green. All components and connectors are correctly labelled and shown
with the appropriate symbol so that they can be clearly identified. The key contains
an additional list of the components with their designations.
The wiring diagrams can also be called up in the spare parts programme LIDOS
under electrical system assemblies. These can be opened in an e3v format via the
info button next to assembly circuit diagram.
The circuit diagrams are divided up as follows:
– Overview chart
– Contents
– Key
– BMK directory
– Circuit diagrams
– Component overviews
The circuit diagrams contain links that can be activated with a mouse click.
1.1.1 Abbreviations
Abbreviation Designation
SH Service hours
EP Electroproportional
WH Wiring harness
LED Light-emitting diode
LFD Liebherr ride control system
SV Solenoid valve
PWM Pulse width modulation (proportional output)
PSV Proportional solenoid valve
Tab. 55: Abbreviations
1.1.2 Designation of components with “-”

The components or connections are always designated with “-”, for example:
LBH/11827693/02/211-20150615.1139/en
Description Component designation

-A10 Display
Tab. 56: Example of component designation
1.1.3 Location identity with “+”

Location codes are always shown as +. The location code shows where the com-
ponent is situated in the machine.
For example:
copyright by
L538-1493 110-9
Circuit diagrams
Description Location code

+V1 Front section
Tab. 57: Example of location code
LBH/11827693/02/211-20150615.1139/en
copyright by
110-10 L538-1493
1 2 3 4 5 6 7 8
OVERVIEW PLAN L524/1355; L538/1356; L538/1493 2PLUS1

A A
A11 KEY BOARD A13 DISPLAY UNIT X61 DIAGNOSTIC PLUG

1356 00090 01 00 001
93014064_001
93014064
B B
SWITCH
SUPPLY
A21 HEAT AIR CONDITIONING SYSTEM
HEAT - AIR CONDITIONING SYSTEM

SENSORS
C C
SWITCH
TEMPERATURE SENSOR
We reserve all rights in this document and in the informa-
A4 FUSE AND RELAY BOARD

tion contained therein. Reproduction, use or disclosure
ANGLE SENSOR
PRESSURE SENSOR
to third parties without express authority is strictly
© LIEBHERR WERK BISCHOFSHOFEN
ELECTRICAL CONSUMERS
LIGHTING
WINDSCREEN WIPER A6 CENTRAL CONTROL
D WARNING BEACON D
OPTION
forbidden.
ELECTRICAL SYSTEM
COMPONENTS
Für dieses Dokument und den darin dargestellten Gegen-
stand behalten wir uns alle Rechte vor. Vervielfältigung,
Bekanntgabe an Dritte oder Verwertung seines Inhaltes
sind ohne unsere ausdrückliche Zustimmung verboten.
ENGINE
E E
SUPPLY
SUPPLY BATTERY ; GENERATOR A700D MOTOR CONTROL JD
F F
TYPE: ab: 8924766

bis: 8921847 LIEBHERR OVERVIEW PLAN SIDE: 1 61
BISCHOFSHOFEN DATE: 14.03.2013 13:56
1 2 3 4 5 6 7 8
1 2 3 4 5 6 7 8
2IN1 STEERING /53 RADIO ; VOLTAGE CONVERTER ; DRIVER'S SEAT /24

A A
DISPLAY UNIT ; DIAGNOSTIC PLUG /21 RESERVE FUSES / RELAY /36
WORKING PROJECTOR REAR /19 REVERSING OBSTACLE DETECTOR /52
WORKING PROJECTOR FRONT /18 BACK-UP ALARM ACOUSTIC CAN BE SWITCHED OFF /48
1356 00090 01 00 001
BATTERY ; MASTER SWITCH ; IGNITION SWITCH /13 BACK-UP ALARM OPTICAL FLASHING LIGHT /46
CONTROL LEVER ; ADDITIONAL EQUIPMENT ; TANK PIPE SENSOR /20 WARNING BEACON ; REAR WINDOW HEATER /26
93014064_001
LIGHTING ; INDICATOR ; HAZARD WARNING LIGHT /16 LOG PUSHER /45

93014064
B REFUELLING PUMP DIFFERENTIAL LOCK /49 BUCKET RETURN-TO-DIG ; FLOAT POSITION /29 B
BMK-INDEX /4 WINDSCREEN WIPER FRONT /17
BMK-INDEX /5 QUICK-CHANGE DEVICE /30
BMK-INDEX /6 DUST FILTER EXCESS PRESSURE SYSTEM OPTION MIRROR HEATING /35
BMK-INDEX /7 CIRCUIT DIAGRAM ENGINE /56
BMK-INDEX /8 CIRCUIT DIAGRAM ENGINE SPEED SENSOR ; SOLENOID VALVE /59
BMK-INDEX /9 CIRCUIT DIAGRAM ENGINE PRESSURE SWITCH /58
BMK-INDEX /10 CIRCUIT DIAGRAM ENGINE INJECTION VALVES /60
C C
BMK-INDEX /11 CIRCUIT DIAGRAM ENGINE TEMPERATURE SENSOR PRESSURE SENSOR /57
BMK-INDEX /12 BUZZER ; SUPPLY UEC3 /23

FUEL PREHEATING /54 TEMPERATURE AND SPEED SENSORS /32

PRESSURE SWITCH ; TEMPERATURE SENSOR ENGINE /25 OVERVIEW PLAN /1

ELECTRONIC IMMOBILISER /50 SUPPLY ENGINE CONTROL UNIT /27
TRAVELLING DIRECTION AND LIGHTING /15 PREHEAT ; INTERFACE ENGINE /47
SPEED-PEDAL ; COOLING WATER LEVEL /28 CENTRAL LUBRICATION SYSTEM /37
D D
GENERATOR ; TRAVELLING DIRECTION AND LIGHTING /14 CENTRAL CONTROL UEC3 X3 /39
MAIN KEYPAD /38 CENTRAL CONTROL UEC3 X4 /40
forbidden.
HEAT - AIR CONDITIONING SYSTEM /43 AUXILIARY HEATER THERMO 90 ST /44

REAR AND HORN /17
HORN OPERATION AND BUCKET RETURN-TO-DIG ÜBER PUSH-BUTTON SWITCH /51
INCH PEDAL /22

COUPLING ; HYDRAULIC MOTOR ; TRAVEL PUMP /33
E E
COUNTRY-SPECIFIC TYPE/EXECUTION GERMANY LUXEMBOURG SWITZERLAND /42

KEY /3
FAN REVERSAL ; RIDE CONTROL /31
ENGINE ECU - ENGINE SIDE /61
ENGINE CONTROL UNIT /41
EMERGENCY STEERING PUMP ; PRESSURE SWITCH EMERGENCY STEERING PUMP /34
OPTION PRESSURE LIMITATION COUPLING /55
F F
TYPE: ab:
bis: 0 LIEBHERR TABLE OF CONTENTS SIDE: 2 61
1 2 3 4 5 6 7 8
1 2 3 4 5 6 7 8
A TYPE / COUNTING NUMBER, SYSTEM, LOCATION CODE A
CIRCUITS TWISTED
1356 00090 01 00 001
- TYPE / COUNTING NUMBER

93014064_001
=K =K SYSTEM (CABIN)
-M1 ENGINE START OPERATING SUPPLY CODE +K6 +K6 LOCATION CODE (CAB FLOOR)
52
93014064
B -X1.S1 -X1.S PLUG NAME AND PIN CONTACT B

-X1.B1 -X1.B PLUG NAME AND SOCKET CONTACT
52
+K6
= SYSTEM =K 52 PIN AM PLUG
=B BALLAST
CABLE GREEN- OPTION
=F TRAVEL DRIVE
=H HIND CARRIAGE /7.E4 CROSS REFERENCE UP SHEET 7;E4
=K CABIN OPEN LINE END
C
=M ENGINE C
LETZTE MODIFICATION
=V FRONT SECTION
+LOCATION CODE
+B BALLAST +K CABIN
+B1 BALLAST LEFT +K1 CABIN FITTINGS
D
+B2 BALLAST RIGHT +K2 CABIN REAR PANEL D
+K3 CAB ROOF
+F TRAVEL DRIVE +K4 CABIN FITTINGS SIDE COVER RIGHT REAR
forbidden.
+F1 FRONT AXLE +K5 CABIN FITTINGS SIDE COVER LEFT REAR
+F2 REAR AXLE +K6 CAB FLOOR
+F3 TRANSMISSION
+M ENGINE
+H HIND CARRIAGE
+H1 HIND CARRIAGE REAR HATCH +V FRONT SECTION
E E
+H2 HIND CARRIAGE UNTER CABIN RIGHT
+V1 FRONT SECTION

+H3 HIND CARRIAGE UNTER CABIN LEFT +V2 LIFT ARM
+H4 HIND CARRIAGE RIGHT +V3 TILT CYLINDER
+H5 HIND CARRIAGE LEFT
F F
TYPE: ab:
bis: 0 LIEBHERR KEY SIDE: 3 61
1 2 3 4 5 6 7 8
1 2 3 4 5 6 7 8
BMK SYSTEM PLACE FUNCTION SHEET BMK SYSTEM PLACE FUNCTION SHEET
-A3 * =K +K3 RADIO /24.D6 -B10X1 =H +H2 PLUG HORN /17.E4
A A
-A3X1 =K +K3 PLUG RADIO /24.D6 -B10X2 =H +H2 PLUG HORN /17.F4
-A3X2 =K +K3 PLUG RADIO /24.E6 -B11l * =K +K3 LOUDSPEAKER LEFT /24.F7
-A6.A =K +K2 UEC3 X3 /39.B1 -B11lX1 =K +K3 PLUG LOUDSPEAKER LEFT /24.F7
1356 00090 01 00 001
-A6.AX3 =K +K2 PLUG UEC3 X3 /20.A5 -B11lX2 =K +K3 PLUG LOUDSPEAKER LEFT /24.E7
-A6.B =K +K2 UEC3 X4 /40.B1 -B11r * =K +K3 LOUDSPEAKER RIGHT /24.E6
93014064_001
-A6.B.X4/20 * =K +K2 PLUG CENTRAL CONTROL /51.B3 -B11rX1 =K +K3 PLUG LOUDSPEAKER RIGHT /24.E6
93014064
B -A6.BX4 =K +K2 PLUG UEC3 X4 /20.A7 -B11rX2 =K +K3 PLUG LOUDSPEAKER RIGHT /24.F6 B
-A6.BX4/20a =K +K2 PLUG CENTRAL CONTROL /51.B2 -B12 =V +V1 PRESSURE SWITCH STOP LIGHT /16.E1
-A9 * =K +K2 IMMOBILISER /50.B3 -B12X =V +V1 PLUG PRESSURE SWITCH /16.F1
-A9.X * =K +K2 PLUG IMMOBILISER /50.C3 -B13 =H +H COOLING WATER LEVEL /28.C7
-A11 =K +K4 CONTROL STAGE /38.A1 -B13.X =H +H PLUG COOLING WATER LEVEL /28.C7
-A11X1 =K +K4 PLUG CONTROL STAGE /38.D7 -B15 =V +V2 INDUCTIVE SENSOR BUCKET RETURN-TO-DIG /29.D6
-A13 =K +K1 DISPLAY UNIT /21.D1 -B15X =V +V2 PLUG INDUCTIVE SENSOR /29.D6
-A13X1 =K +K1 PLUG DISPLAY UNIT /21.D2 -B16 =H +H5 BACK-UP ALARM /16.E6
C C
-A13X2 =K +K1 PLUG DISPLAY UNIT /21.C3 -B16.X1.B * =H +H5 PLUG ADAPTOR /48.F4
-A21 =K +K HEAT AIR CONDITIONING SYSTEM /43.A5 -B16.X1.S * =H +H5 PLUG ADAPTOR /48.A4
-A202 * =K +K PRESELECTOR CLOCK AUXILIARY HEATER /44.C2 -B16X =H +H5 PLUG BACK-UP ALARM /16.E6
-A203 * =M +M AUXILIARY HEATER THERMO 90 /44.D4 -B17 * =V +V1 INDUCTIVE SENSOR LIFT KICK-OUT /29.D5
-A700 =M +M ENGINE ECU ( APPLIANCES SIDE ) /41.A1 -B17.X * =V +V1 PLUG INDUCTIVE SENSOR /29.E5
-A700. =M +M ENGINE ECU ( ENGINE SIDE ) /61.B1 -B17X.B * =V +V1 PLUG ADAPTOR /29.E5
-A700.X2 =M +M PLUG ENGINE ECU ( ENGINE SIDE ) /47.B6 -B17X.S =V +V1 PLUG ADAPTOR /29.D5
D D
-A700X1 =M +M PLUG ENGINE ECU ( APPLIANCES SIDE ) /27.B6 -B19 =H +H PRESSURE SWITCH SERVICE BRAKE /25.D6
-B1 =H SPEED SENSOR OUTPUT /32.E4 -B19.X =H PLUG PRESSURE SWITCH /25.D6
forbidden.
+H4 +H
-B1X =H +H4 PLUG SPEED SENSOR /32.D4 -B25 =H +H2 TANK PIPE SENSOR /20.E6
-B2 =H +H4 SPEED SENSOR HYDRAULIC MOTOR 2 /32.E5 -B25X =H +H2 PLUG TANK PIPE SENSOR /20.E6
-B2X =H +H4 PLUG SPEED SENSOR /32.E5 -B27 =H +H PRESSURE SWITCH AIR CONDITIONING SYSTEM /43.B4
-B3 =H +H4 PRESSURE SWITCH EMERGENCY STEERING PUMP MAIN CIRCUIT

/34.E4 -B27X =H +H PLUG PRESSURE SWITCH /43.B4
-B3.X =H +H4 PLUG PRESSURE SWITCH /34.D4 -B43 * =H +H3 INDUCTIVE SENSOR CYCLE /37.B6
E E
-B3a =H +H4 PRESSURE SWITCH EMERGENCY STEERING PUMP CHECK /34.E5 -B43.X =H +H3 PLUG INDUCTIVE SENSOR /37.C6
-B3a.X =H +H4 PLUG PRESSURE SWITCH /34.D5 -B44 * =H +H3 INDUCTIVE SENSOR LEVEL /37.B7
-B4 =H +H3 PRESSURE SWITCH AIR FILTER CONTAMINATION /32.D6 -B44.X =H +H3 PLUG INDUCTIVE SENSOR /37.B7
-B4X =H +H3 PLUG PRESSURE SWITCH /32.E6 -B100 * =H +H PRESSURE LIMITATION COUPLING /55.D4
-B8 =H +H4 HYDRAULIC OIL CONTROL /32.D2 -B100.X * =H +H PLUG PRESSURE SWITCH /55.D4
-B8X =H +H4 PLUG HYDRAULIC OIL CONTROL /32.D2 -B100.X_1 * =H +H PLUG PRESSURE SWITCH /55.E4
-B10 =H +H2 HORN /17.E4 -C01 =M +M PLUG INJECTION VALVES /60.B1
F F
TYPE: ab:
bis: 0 LIEBHERR BMK-INDEX SIDE: 4 61
1 2 3 4 5 6 7 8
1 2 3 4 5 6 7 8
-C01. =M +M PLUG INJECTION VALVES /60.B1 -E11b.X1 * =K +K3 PLUG ADAPTOR /18.D5
A A
-C02 =M +M PLUG NOT USED /47.B8 -E11X =K +K3 PLUG WORKING PROJECTOR RIGHT /18.E6
-C03.B =M +M PLUG INTERFACE PREHEAT /47.D7 -E12 =K +K3 WORKING PROJECTOR REAR LEFT /19.E3
-C03.S =M +M PLUG INTERFACE PREHEAT /47.D6 -E12.X =K +K3 PLUG WORKING PROJECTOR /19.E3
1356 00090 01 00 001
-C06 =M +M PLUG NOT USED ( GENERATOR ) /47.D8 -E12a =K +K3 WORKING PROJECTOR REAR LEFT /19.E3
-D01 =M +M WATER SENSOR /57.E3 -E12a.X =K +K3 PLUG WORKING PROJECTOR /19.E3
93014064_001
-D01.X =M +M PLUG WATER SENSOR /57.D3 -E13 =K +K3 WORKING PROJECTOR REAR RIGHT /19.E5
93014064
B -E1 =B +B1 TAIL LIGHT RIGHT /16.E4 -E13.X =K +K3 PLUG WORKING PROJECTOR /19.E5 B
-E2 =K +K3 INDOOR LIGHTING /24.D2 -E13a =K +K3 WORKING PROJECTOR REAR RIGHT /19.E5
-E2X1 =K +K3 PLUG INDOOR LIGHTING /24.D2 -E13a.X =K +K3 PLUG WORKING PROJECTOR /19.E5
-E2X2 =K +K3 PLUG INDOOR LIGHTING /24.E2 -E14a =H +H1 LICENCE PLATE LIGHT RIGHT /15.E6
-E2X3 =K +K3 PLUG INDOOR LIGHTING /24.E2 -E14b =H +H1 LICENCE PLATE LIGHT LEFT /15.E6
-E3 =V +V1 DRIVING HEADLIGHT LEFT /16.E8 -F1 =K +K2 FUSE QUICK-CHANGE DEVICE /30.C4
-E3.Xa * =V +V1 PLUG DRIVING HEADLIGHT OPTION /42.D5 -F2 =K +K2 HIGH BEAM LEFT /16.C7
-E3.Xb * =V +V1 PLUG DRIVING HEADLIGHT OPTION /42.B5 -F3 =K +K2 HIGH BEAM RIGHT /16.C7
C C
-E3X =V +V1 PLUG DRIVING HEADLIGHT LEFT /16.E8 -F4 =K +K2 DRIVING LIGHT RIGHT /16.C7
-E4 =V +V1 DRIVING HEADLIGHT RIGHT /16.E7 -F5 =K +K2 DRIVING LIGHT LEFT /16.C8
-E4.Xa * =V +V1 PLUG DRIVING HEADLIGHT OPTION /42.D4 -F6 =K +K2 PROFILE LIGHT LEFT ; PARKING LIGHT RIGHT ; CONTEUR LIGHT LEFT /16.C6
-E4.Xb * =V +V1 PLUG DRIVING HEADLIGHT OPTION /42.B4 -F7 =K +K2 PROFILE LIGHT RIGHT ; PARKING LIGHT LEFT ; CONTEUR LIGHT RIGHT /16.C7
-E4X =V +V1 PLUG DRIVING HEADLIGHT RIGHT /16.F7 -F8 =K +K2 FUSE DRIVER'S SEAT ; SIMULATION RADIO /24.B3
-E5 =B +B1 TAIL LIGHT LEFT /16.E4 -F8a =K +K2 INDOOR LIGHTING ; ELECTRICAL SOCKET /24.B2
-E7 =B +B1 REAR LIGHT RIGHT /16.E5 -F9 =K +K2 ADDITIONAL EQUIPMENT ; FAN REVERSAL /20.C5
D D
-E8 =K +K3 CONTEUR LIGHT LEFT /18.E2 -F01 =B +B2 SUPPLY RELAY BOARD KL.30 /13.E5
-E9 =K CONTEUR LIGHT RIGHT /18.E7 -F01.X =B CONNECTION F01 /13.E5
forbidden.
+K3 +B2
-E10 =K +K3 WORKING PROJECTOR FRONT LEFT /18.E3 -F02 =B +B2 FUSE PREHEAT /13.E6
-E10a =K +K3 WORKING PROJECTOR FRONT LEFT /18.E4 -F02.X =B +B2 CONNECTION F02 /13.E6
-E10aX =K +K3 PLUG WORKING PROJECTOR LEFT /18.E4 -F03 =B +B2 FUSE EMERGENCY STEERING PUMP /13.E6
-E10b * =K +K3 XENON WORKING PROJECTOR FRONT LEFT /18.E2 -F03.X =B +B2 CONNECTION F03 /13.E6
-E10b.X * =K +K3 PLUG XENON WORKING PROJECTOR LEFT /18.E3 -F04 =B +B2 FUSE RESERVE /13.E6
E E
-E10b.X1 * =K +K3 PLUG ADAPTOR /18.D3 -F07a =B +B2 HAZARD WARNING SYSTEM /13.C8
-E10X =K +K3 PLUG WORKING PROJECTOR LEFT /18.E3 -F07b =K +K2 HAZARD WARNING LIGHTS KL.15 /16.C3
-E11 =K +K3 WORKING PROJECTOR FRONT RIGHT /18.E6 -F10 =K +K2 DISPLAY UNIT /21.C3
-E11a =K +K3 WORKING PROJECTOR FRONT RIGHT /18.E6 -F11 =K +K2 INCH PEDAL /22.B2
-E11aX =K +K3 PLUG WORKING PROJECTOR RIGHT /18.E6 -F12 =K +K2 SUPPLY UEC3 /20.C7
-E11b * =K +K3 XENON WORKING PROJECTOR REAR RIGHT /18.E5 -F13 =K +K2 FUSE SELECTION EMERGENCY STEERING PUMP /34.B8
-E11b.X * =K +K3 PLUG XENON WORKING PROJECTOR /18.E5 -F14 =K +K2 FUSE HEAT AIR CONDITIONING SYSTEM /43.B3
F F
TYPE: ab:
1 2 3 4 5 6 7 8
1 2 3 4 5 6 7 8
-F15 =K +K2 CONTROL LEVER ; TANK PIPE SENSOR ; COOLING WATER LEVEL
/20.C7 -F76 =K +K2 12V RADIO AND ELECTRICAL SOCKET /24.B5
A A
-F16 =K +K2 FUSE STARTER SOLENOID /13.C4 -F010 =H +H5 ACKNOWLEDGEMENT PREHEAT /47.B3
-F17 =K +K2 FUSE ENGINE STOP /13.C5 -F200 * =K +K FUSE AUXILIARY HEATER /44.B6
-F18 =K +K2 WIPER AND WASHING PUMP REAR /17.B7 -F201 * =K +K FUSE AUXILIARY HEATER /44.B4
1356 00090 01 00 001
-F19 =K +K2 FUSE RESERVE /23.C1 -F202 * =K +K FUSE AUXILIARY HEATER /44.B7
-F19a =K +K2 FUSE RESERVE /36.C2 -F203 * =K +K2 FUSE REVERSING OBSTACLE DETECTOR /52.B3
93014064_001
-F20 =K +K2 WIPER AND WASHING PUMP FRONT ; HORN /17.B8 -F204 * =K +K2 FUSE REFUELLING PUMP /49.B3
93014064
B -F21 =K +K2 PROFILE LIGHT / DRIVING LIGHT /23.C2 -F211 * =K +K2 FUSE DIFFERENTIAL LOCK /49.B5 B
-F22 =K +K2 FUSE UEC3 VDC3 /23.C2 -F317 * =K +K2 FUSE 2IN1 STEERING /53.B4
-F23 =K +K2 FUSE UEC3 VDC2 /23.C3 -F321 * =K +K2 FUEL PREHEATING /54.B4
-F24 =K +K2 FUSE UEC3 VDC4 /25.B4 -G1 =M +M GENERATOR /14.E5
-F25 =K +K2 FUSE WARNING BEACON /26.B4 -G1.X1 =M +M PLUG GENERATOR /14.E5
-F26 =K +K2 DIAGNOSTIC PLUG ; UEC3 VDC1 /21.C4 -G1.X2 =M +M PLUG GENERATOR /14.E5
-F27 =K +K2 FUSE PROFILE LIGHT PARKING LIGHT /16.C8 -G1.X3 =M +M PLUG GENERATOR /14.E5
-F28 =K +K2 FUSE RESERVE /36.C2 -G1.X4 =M +M PLUG GENERATOR /14.F5
C C
-F29 =K +K2 IGNITION STARTER SWITCH BYPASS /13.C4 -G2a =B +B BATTERY 1 /13.F7
-F30 =K +K2 FUSE VOLTAGE CONVERTER /24.B8 -G2b =B +B BATTERY 2 /13.E7

-F31a =K +K2 WORKING PROJECTOR FRONT LEFT /18.C3 -H6 =B +B1 REAR LIGHT LEFT /16.E3
-F31b =K +K2 WORKING PROJECTOR FRONT RIGHT /18.C5 -H15 =V +V1 BLINKER FRONT LEFT /16.E8
-F33a =K +K2 WORKING PROJECTOR REAR LEFT /19.C2 -H16 =V +V1 BLINKER FRONT RIGHT /16.E7
-F33b =K +K2 WORKING PROJECTOR REAR RIGHT /19.C4 -H17 =B +B1 BLINKER REAR LEFT /16.E4
-F35 =K +K2 FUSE DUST FILTER EXCESS PRESSURE SYSTEM /35.C2 -H18 =B +B1 BLINKER REAR RIGHT /16.E4
D D
-F36 =K +K2 FUSE RESERVE /36.C3 -H20 =B +B1 STOP LIGHT LEFT /16.E3
-F37 =K FUSE ECU VBAT POWER /27.C3 -H21 =B STOP LIGHT RIGHT /16.E4
forbidden.
+K2 +B1
-F38 =K +K2 FUSE RESERVE /14.C2 -H22 * =K +K3 WARNING BEACON /26.E4
-F39 =K +K2 FUSE WEIGHING DEVICE /36.C4 -H22.X1 =K +K3 PLUG WARNING BEACON /26.E4
-F40 =K +K2 WORKING PROJECTOR REAR HATCH /19.C8 -H22.X2 =K +K3 PLUG WARNING BEACON /26.E4
-F41 =K +K2 FUSE RESERVE /36.C4 -H40 =K +K4 BUZZER /23.E8

-F43 =K +K2 FUSE ENGINE CONTROL UNIT KL.15 /25.B4 -H40X1 =K +K4 PLUG BUZZER /23.E8
E E
-F44 =K +K2 FUSE STOP LIGHT /25.B5 -H40X2 =K +K4 PLUG BUZZER /23.E8
-F45 =K +K2 FUSE RESERVE /14.C3 -H41 =K +K4 ALARM UNIT QUICK-CHANGE DEVICE /30.E6
-F46 =K +K2 FUSE FLASHING LIGHT /46.A4 -H42 * =K +K1 LAMP DIFFERENTIAL LOCK ON /49.B6
-F71 =K +K2 FUSE INSTRUMENT LIGHTING CONTROL STAGE /26.B7 -H42.X * =K +K1 PLUG LAMP DIFFERENTIAL LOCK ON /49.C6
-F73 =K +K2 FUSE CENTRAL LUBRICATION SYSTEM /37.B4 -H50 =V +V1 PROFILE LIGHT FRONT LEFT /16.E8
-F74 =K +K2 FUSE REAR WINDOW HEATER /35.C7 -H51 =V +V1 PROFILE LIGHT RIGHT /16.E7
-F75 =K +K2 12V RADIO /24.B4 -H52 =B +B5 REVERSING LAMP LEFT /16.E3
F F
TYPE: ab:
1 2 3 4 5 6 7 8
1 2 3 4 5 6 7 8
-H53 =B +B1 REVERSING LAMP RIGHT /16.E5 -K230 =K +K2 AUTOMATIC RUN-OUT /36.C6
A A
-H54 =V +V1 LOW BEAM LEFT /16.E8 -K231 * =K +K2 RELAY QUICK-CHANGE DEVICE /30.E3
-H55 =V +V1 LOW BEAM RIGHT /16.E7 -K232 * =K +K2 RELAY QUICK-CHANGE DEVICE /30.E2
-H56 =V +V1 HIGH BEAM LEFT /16.E8 -K243 =K +K2 WORKING PROJECTOR REAR HATCH /19.C7
1356 00090 01 00 001
-H57 * =H +H1 FLASHING LIGHT 1 /46.A2 -K245 =K +K2 CENTRAL LUBRICATION SYSTEM /37.B3
-H57 =V +V1 HIGH BEAM RIGHT /16.E7 -K246 =K +K2 HEAT AIR CONDITIONING SYSTEM /43.C3
93014064_001
-H57.X * =H +H1 PLUG FLASHING LIGHT 1 /46.B2 -K270 =K +K2 IMMOBILISER /36.C6
93014064
B -H58 * =H +H1 FLASHING LIGHT 2 /46.C2 -K271 =K +K2 HEAT AIR CONDITIONING SYSTEM /43.C2 B
-H58.X * =H +H1 PLUG FLASHING LIGHT 2 /46.C2 -M1 =M +M ENGINE START /13.E4
-H59 * =H +H1 FLASHING LIGHT 3 /46.D2 -M1_50 =K +K 50a STARTING /13.D5
-H59.X * =H +H1 PLUG FLASHING LIGHT 3 /46.E2 -M2 =K +K1 WINDSCREEN WIPER FRONT /17.E5
-H301 * =K +K4 SYMBOL 2IN1 STEERING /53.C3 -M2.X =K +K1 PLUG WINDSCREEN WIPER FRONT /17.F6
-K1 =K +K2 FLASHER UNIT /16.C5 -M3 =K +K3 WINDSCREEN WIPER REAR /17.E2
-K5 =K +K2 SIMULATION D+ /14.C6 -M3X =K +K3 PLUG WIPER REAR /17.F2
-K5a =K +K4 WIPER RELAY /17.C5 -M4 =H +H WASHING PUMP FRONT /17.E7
C C
-K5aX =K +K4 PLUG WIPER RELAY /17.B5 -M4X =H +H PLUG WASHING PUMP FRONT /17.E7
-K01 =K +K2 IGNITION STARTER SWITCH BYPASS /13.C3 -M6 * =H +H3 PUMP CENTRAL LUBRICATION SYSTEM /37.E2
-K02 =K +K2 STARTER SOLENOID /13.C6 -M6X =H +H3 PLUG PUMP /37.E2
-K03 =K +K2 ENGINE STOP /13.C7 -M7 =K +K DRIVER'S SEAT /24.E3

-K04 =H +H5 RELAY HEATER FLANGE /47.C3 -M7X =K +K PLUG DRIVER'S SEAT /24.D3
-K10 =K +K2 MIRROR HEATING ; REAR WINDOW HEATER /35.C6 -M8 =H +H4 EMERGENCY STEERING PUMP /34.E3
-K12 =K +K2 SIMULATION KL.15 /24.C3 -M9 =H +H WASHING PUMP REAR /17.E3
D D
-K15 =K +K2 LIFT KICK-OUT /29.C3 -M9X =H +H PLUG WASHING PUMP REAR /17.F3
-K18 =K BUCKET RETURN-TO-DIG /29.C4 -M10 * =H REFUELLING PUMP /49.E3
forbidden.
+K2 +H
-K25 =K +K2 HAZARD WARNING LIGHTS USA /16.C4 -M200 * =K +K4 DUST FILTER EXCESS PRESSURE SYSTEM /35.E3
-K26 =K +K2 HAZARD WARNING LIGHTS USA /16.C5 -MP1_a =H +H2 MASS GROUPING BLOCK /14.F5
-K31a =K +K2 WORKING PROJECTOR FRONT LEFT /18.C4 -MP1_b =H +H2 MASS GROUPING BLOCK /30.F5
-K31b =K +K2 WORKING PROJECTOR FRONT RIGHT /18.C6 -MP1_c =H +H2 MASS GROUPING BLOCK /33.F7
-K33a =K +K2 WORKING PROJECTOR REAR LEFT /19.C3 -MP1_d =H +H2 MASS GROUPING BLOCK /31.F7
E E
-K33b =K +K2 WORKING PROJECTOR REAR RIGHT /19.C5 -MP4_b =H +H5 MASS GROUPING BLOCK /13.F8
-K011 =H +H4 RELAY EMERGENCY STEERING PUMP /34.E2 -MP4_e =H +H2 MASS GROUPING BLOCK /13.F2
-K209 =K +K2 DUST FILTER EXCESS PRESSURE SYSTEM /35.C3 -MP5_a =H +H4 MASS GROUPING BLOCK /34.F3
-K214 * =K +K RELAY AUXILIARY HEATER /44.E2 -MP5_b =H +H4 MASS GROUPING BLOCK /13.F2
-K215 * =K +K RELAY AUXILIARY HEATER /44.E3 -MP6_a =K +K4 MASS GROUPING BLOCK /24.F1
-K228 =K +K2 BACK-UP ALARM OPTICAL /26.B5 -MP6_b =K +K4 MASS GROUPING BLOCK /23.F5
-K229 =K +K2 BACK-UP ALARM OPTICAL /36.C5 -MP6_c =K +K4 MASS GROUPING BLOCK /29.F2
F F
TYPE: ab:
1 2 3 4 5 6 7 8
1 2 3 4 5 6 7 8
-MP6_d =K +K4 MASS GROUPING BLOCK /38.F1 -R5.X =K +K6 PLUG SPEED-PEDAL /28.C3
A A
-MP6_e =K +K4 MASS GROUPING BLOCK /13.E2 -R6a * =K +K3 MIRROR HEATING LEFT /35.E5
-MP6_f =K +K4 MASS GROUPING BLOCK /13.F3 -R6a.X * =K +K3 PLUG MIRROR HEATING /35.E5
-MP6_i * =K +K2 MASS GROUPING BLOCK /30.F3 -R6b * =K +K3 MIRROR HEATING RIGHT /35.E6
1356 00090 01 00 001
-MP6_l * =K +K2 MASS GROUPING BLOCK /46.D5 -R6b.X * =K +K3 PLUG MIRROR HEATING /35.E6
-MP6_o * =K +K2 MASS GROUPING BLOCK /35.F5 -R9a =K +K2 EXCITATION 100 OHM /14.C4
93014064_001
-MP6_p * =K +K2 MASS GROUPING BLOCK /52.F3 -R9b =K +K2 EXCITATION 220 OHM /14.C5
93014064
B -MP6_r * =K +K2 MASS GROUPING BLOCK /53.F6 -R11 =K +K2 REAR WINDOW HEATER /26.E1 B
-MP6j * =H +H MASS GROUPING BLOCK /55.B6 -R11X1 =K +K2 PLUG REAR WINDOW HEATER /26.E1
-MP7_a =K +K3 MASS GROUPING BLOCK /24.F2 -R11X2 =K +K2 PLUG REAR WINDOW HEATER /26.E1
-MP7_b =K +K3 MASS GROUPING BLOCK /19.F5 -R13 * =M +M FUEL PREHEATING /54.E4
-MP7_e * =K +K2 MASS GROUPING BLOCK /50.D6 -R13.X * =M +M PLUG FUEL PREHEATING /54.E4
-MP7_k * =K +K2 MASS GROUPING BLOCK /51.F6 -R700 =M +M MATCHING RESISTOR CAN /21.B2
-MP7_m * =K +K2 MASS GROUPING BLOCK /49.F6 -R700X =M +M SPLICE /21.A2
-MP10 =M +M MASS GROUPING BLOCK /13.F4 -R701 =M +M1 HEATER FLANGE /47.E3
C C
-MP10_a =M +M MASS GROUPING BLOCK /13.E2 -S1 =K +K4 IGNITION SWITCH /13.A3
-OLE1 * =H +H CONNECTION REVERSING OBSTACLE DETECTOR /52.E5 -S1.X1 =K +K4 PLUG IGNITION SWITCH /13.A4
-OLE2 * =H +H CONNECTION REVERSING OBSTACLE DETECTOR /52.E5 -S1.X1b * =K +K4 CONNECTION IGNITION SWITCH /13.A4
-OLE3 * =H +H CONNECTION REVERSING OBSTACLE DETECTOR /52.E5 -S1.X1c * =K +K4 CONNECTION IGNITION SWITCH /13.A5
-OLE4 * =K +K2 CONNECTION BUCKET RETURN-TO-DIG /29.B4 -S1.X2 =K +K4 PLUG IGNITION SWITCH /13.B4
-OLE300 * =K +K4 LINE END /15.B6 -S1.X3 =K +K4 PLUG IGNITION SWITCH /13.B4
-OLE301 * =K +K4 LINE END /15.B5 -S2 =K +K4 CONTROL LEVER /20.E1
D D
-OLE302 * =K +K4 LINE END /15.B5 -S2X =K +K4 PLUG CONTROL LEVER /20.E1
-OLE304 =K LINE END /15.B6 -S3 =K STEERING COLUMN SWITCH /16.C1
forbidden.
+K2 +K1
-P1 =K +K1 WORKING HOUR METER /14.E7 -S3X1 =K +K1 SWITCH STEERING COLUMN SWITCH /16.C2
-P1X1 =K +K1 PLUG WORKING HOUR METER /14.E7 -S3X2 =K +K1 PLUG STEERING COLUMN SWITCH /16.C2
-P1X2 =K +K1 PLUG WORKING HOUR METER /14.F7 -S4 =K +K4 HAZARD LIGHT SWITCH /16.A3
-P03 =M +M PRESSURE SENSOR FUEL /57.E6 -S4b =K +K4 SYMBOL /16.B4

-P03.X =M +M PLUG PRESSURE SENSOR /57.D6 -S4X1 =K +K4 PLUG SWITCH /16.B3
E E
-P04 =M +M PRESSURE SENSOR ENGINE OIL /57.E8 -S4X2 =K +K4 PLUG SWITCH /16.B3
-P04.X =M +M PLUG PRESSURE SENSOR /57.E8 -S6 =K +K4 SWITCH DRIVING LIGHT /16.A7
-P05 =M +M PRESSURE SENSOR RAIL /58.D4 -S6a =K +K4 SYMBOL DRIVING LIGHT /16.B7
-P05.X =M +M PLUG PRESSURE SWITCH /58.D4 -S6X1 =K +K4 PLUG SWITCH /16.A7
-R1 =K +K6 INCH PEDAL /22.D5 -S6X2 =K +K4 PLUG SWITCH /16.A8
-R1.X =K +K6 PLUG INCH PEDAL /22.D5 -S7 =K +K4 SWITCH WORKING PROJECTOR FRONT /18.A6
-R5 =K +K6 SPEED-PEDAL /28.C4 -S7a =K +K4 SYMBOL /18.A7
F F
TYPE: ab:
1 2 3 4 5 6 7 8
1 2 3 4 5 6 7 8
-S7X1 =K +K4 PLUG SWITCH /18.A6 -S43.X2 * =K +K4 PLUG SWITCH BACK-UP ALARM /48.D5
A A
-S7X2 =K +K4 PLUG SWITCH /18.A6 -S45 =K +K4 SWITCH OPTIONAL EQUIPMENT /20.C4
-S8 =K +K4 SWITCH WORKING PROJECTOR REAR /19.A5 -S45a =K +K4 SYMBOL /20.D3
-S8a =K +K4 SYMBOL /19.B5 -S45X1 =K +K4 PLUG SWITCH /20.C4
1356 00090 01 00 001
-S8X1 =K +K4 SWITCH PLUG /19.A5 -S45X2 =K +K4 PLUG SWITCH /20.C4
-S8X2 =K +K4 SWITCH PLUG /19.A5 -S46 =K +K4 SWITCH REAR WINDOW HEATER /26.D3
93014064_001
-S9 * =K +K4 SWITCH WARNING BEACON /26.D4 -S46a =K +K4 SYMBOL /26.D2
93014064
B -S9a =K +K4 SYMBOL /26.D3 -S46X1 =K +K4 PLUG SWITCH /26.D3 B

-S9X1 =K +K4 PLUG SWITCH /26.D4 -S46X2 =K +K4 PLUG SWITCH /26.D3
-S9X2 =K +K4 PLUG SWITCH /26.D4 -S55 * =F +F1 CONTROL 100% LOCKOUT /49.D5
-S10 =K +K2 SWITCH EMERGENCY STEERING PUMP /34.D7 -S55.X1 * =F +F1 PLUG SWITCH /49.C5
-S10.X1 =K +K2 PLUG SWITCH EMERGENCY STEERING PUMP /34.D7 -S55.X2 * =F +F1 PLUG SWITCH /49.D5
-S10.X2 =K +K2 PLUG SWITCH EMERGENCY STEERING PUMP /34.D7 -S203 * =K +K4 SWITCH FAN REVERSAL /31.D2
-S10a =K +K2 SYMBOL EMERGENCY STEERING PUMP /34.E7 -S203.X1 =K +K4 PLUG SWITCH /31.D2
-S13 =K +K4 SWITCH WINDSCREEN WIPER REAR /17.C2 -S203.X2 =K +K4 PLUG SWITCH /31.D3
C C
-S13X1 =K +K4 PLUG SWITCH /17.D2 -S203a * =K +K4 SYMBOL /31.C2
-S13X2 =K +K4 PLUG SWITCH /17.C2 -S204 * =H +H2 SWITCH REFUELLING PUMP /49.C3
-S14 =K +K4 SWITCH BUCKET RETURN-TO-DIG /29.B6 -S300 * =K +K3 SWITCH WORKING PROJECTOR REAR OPTIONAL /19.B2
-S14a =K +K4 SYMBOL /29.B6 -S300.B * =K +K3 SWITCH WARNING BEACON OPTIONAL /26.D6
-S14X1 =K +K4 PLUG SWITCH /29.B6 -S300_a * =K +K3 SYMBOL WORKING PROJECTOR REAR OPTIONAL /19.B1
-S14X2 =K +K4 PLUG SWITCH /29.B6 -S300_c * =K +K3 SWITCH FLASHING LIGHT OPTIONAL /46.B7
-S15 =H +H4 BATTERY MAIN SWITCH /13.E8 -S300b * =K +K3 SYMBOL WARNING BEACON OPTIONAL /26.D8
D D
-S18 =K +K4 SWITCH FLOAT POSITION /29.B7 -S300c * =K +K3 SYMBOL FLASHING LIGHT /46.A8
-S18a =K SYMBOL /29.B7 -S317 * =K SWITCH 2IN1 STEERING /53.C4
forbidden.
+K4 +K4
-S18X1 =K +K4 PLUG SWITCH /29.B7 -S317.X1 * =K +K4 PLUG 2IN1 STEERING /53.C4
-S18X2 =K +K4 PLUG SWITCH /29.B7 -S317.X2 * =K +K4 PLUG 2IN1 STEERING /53.C4
-S22 =K +K4 SWITCH LIFT KICK-OUT /29.B5 -T1 =K +K2 VOLTAGE CONVERTER /24.B6
-S22a =K +K4 SYMBOL /29.B5 -T1X =K +K2 PLUG VOLTAGE CONVERTER /24.B6
-S22X1 =K +K4 PLUG SWITCH /29.B5 -T02 =M +M TEMPERATURE SENSOR INTAKE AIR /57.E1
E E
-S22X2 =K +K4 PLUG SWITCH /29.B5 -T02.X =M +M PLUG SENSOR /57.D1

-S23 * =K +K2 SWITCH QUICK-CHANGE DEVICE /30.B2 -T04 =M +M TEMPERATURE COOLING WATER /57.E4
-S23.X1 * =K +K2 PLUG SWITCH /30.B2 -T04.X =M +M PLUG SENSOR /57.D4
-S23.X2 =K +K2 PLUG SWITCH /30.B3 -T05 =M +M TEMPERATURE FUEL /57.E5
-S23a * =K +K1 SYMBOL /30.B2 -T05.X =M +M PLUG SENSOR /57.D5
-S43 * =K +K4 SWITCH BACK-UP ALARM /48.C4 -V1 =K +K4 BLOCKING DIODE /16.A8
-S43.X1 * =K +K4 PLUG SWITCH BACK-UP ALARM /48.C4 -V2 =K +K4 BLOCKING DIODE /16.A8
F F
TYPE: ab:
1 2 3 4 5 6 7 8
1 2 3 4 5 6 7 8
-V200 * =K +K2 ↈ QUICK-CHANGE DEVICE /30.D3 -X12.B =H +H PLUG LIGHTING REAR /16.E2
A A
-V201 * =K +K2 ↈ QUICK-CHANGE DEVICE /30.D3 -X12.S =H +H PLUG LIGHTING REAR /16.E2
-V202 * =K +K2 ↈ QUICK-CHANGE DEVICE /30.D3 -X33 =K +K4 SOLENOID VALVE PILOT CONTROL /29.E2
-X1 =K +K2 JUMPER HAZARD WARNING LIGHTS EU /16.C3 -X33X =K +K4 PLUG PILOT CONTROL /29.E2
1356 00090 01 00 001
-X1 =M +M SPLICE /57.B2 -X40 =K +K2 PLUG RELAY BOARD /13.B3

-X1.B =K +K6 PLUG CAB FLOOR /14.E5 -X40.a * =K +K2 PLUG RELAY BOARD /26.C4
93014064_001
-X1.S =K +K6 PLUG CAB FLOOR /13.B6 -X40b * =K +K2 CONNECTION RELAY BOARD /13.B3
93014064
B -X1a * =K +K2 CONNECTION KL.30 /13.D2 -X41 =K +K2 PLUG RELAY BOARD /17.C7 B
-X2 =K +K2 JUMPER HAZARD WARNING LIGHTS EU /16.C4 -X41_2 * =K +K2 CONNECTION KL.15 /17.C8
-X2 * =K +K CONNECTION KL.30 /44.A6 -X42 =K +K2 PLUG RELAY BOARD /16.B6
-X2 =M +M SPLICE /57.E7 -X42a * =K +K CONNECTION RELAY BOARD /21.E5
-X2.B =K +K6 PLUG CAB FLOOR /33.C4 -X43 =K +K2 PLUG RELAY BOARD /16.D6
-X2.S =K +K6 PLUG CAB FLOOR /33.C4 -X43_8a * =K +K2 PLUG RELAY BOARD /48.B5
-X3 =K +K2 JUMPER HAZARD WARNING LIGHTS USA /16.C6 -X43a * =K +K SPLICE AUXILIARY HEATER /43.E3
-X3 * =K +K CONNECTION KL.30 /44.A4 -X43b * =K +K SPLICE AUXILIARY HEATER /43.E3
C C
-X3 =M +M SPLICE /60.E4 -X44 =K +K2 PLUG RELAY BOARD /16.B7
-X4 =K +K2 JUMPER EXCITATION 0 OHM /14.C4 -X46 =K +K2 PLUG RELAY BOARD /18.B6
-X4 * =K +K CONNECTION KL.30 /44.A7 -X47 =K +K2 SPLICE /35.B6

-X4 =M +M SPLICE /60.E5 -X48 =K +K2 PLUG RELAY BOARD /37.D3

-X4a * =K +K SPLICE AUXILIARY HEATER /43.B8 -X49 =K +K2 PLUG RELAY BOARD /16.B5
-X4b * =K +K SPLICE AUXILIARY HEATER /43.C8 -X50 =K +K2 PLUG RELAY BOARD /16.B3
-X5 =K +K2 JUMPER EXCITATION 100 OHM /14.C4 -X50 =K +K SPLICE /18.D3
D D
-X5 =M +M SPLICE /60.B7 -X51 =K +K2 PLUG RELAY BOARD /14.D5
-X6 =K JUMPER EXCITATION 220 OHM /14.C5 -X51 =K SPLICE /18.D4
forbidden.
+K2 +K
-X8 * =K +K4 CONNECTOR /20.E5 -X52 =K +K SPLICE /18.E3
-X8.ST2 * =M +M PLUG AUXILIARY HEATER THERMO 90 /44.D5 -X53 =K +K SPLICE /18.E4
-X9 * =K +K4 CONNECTOR /20.E4 -X54 =K +K2 PLUG RELAY BOARD /30.D4
-X9 * =K +K PLUG PRESELECTOR CLOCK /44.B2 -X54 =K +K SPLICE /18.D6

-X9a * =K +K CONNECTION PRESELECTOR CLOCK /44.B3 -X55 =K +K2 PLUG RELAY BOARD /16.B3
E E
-X01 =B +B2 CONNECTION BATTERY /13.E7 -X55 =K +K SPLICE /18.D6

-X01 =M +M SPEED SENSOR CRANKSHAFT /59.D2 -X55a * =K +K CONNECTION AUXILIARY HEATER /24.D2
-X01.X =M +M PLUG SPEED SENSOR /59.D2 -X56 =K +K SPLICE /18.E6
-X02 =M +M SPEED SENSOR CAM SHAFT /59.D4 -X57 =K +K SPLICE /18.E6
-X02.X =M +M PLUG SPEED SENSOR /59.D4 -X57 =K +K2 PLUG RELAY BOARD /14.B6
-X11.B =H +H PLUG LIGHTING REAR /16.E5 -X58 =K +K2 PLUG RELAY BOARD /24.B3
-X11.S =H +H PLUG LIGHTING REAR /16.E5 -X60 =K +K4 DIAGNOSTIC PLUG /21.C7
F F
TYPE: ab:
1 2 3 4 5 6 7 8
1 2 3 4 5 6 7 8
-X70 =K +K3 12V ELECTRICAL SOCKET /24.D7 -X213 =K +K2 CONNECTION KL15 /13.C2
A A
-X70.X1 =K +K3 PLUG 12V ELECTRICAL SOCKET /24.D7 -X306 * =K +K2 PLUG RELAY BOARD /46.C4
-X70.X2 =K +K3 PLUG 12V ELECTRICAL SOCKET /24.D7 -X306.B * =H +H PLUG FLASHING LIGHT /46.D4
-X71 =K +K4 CIGARETTE LIGHTER /24.E1 -X306.S * =H +H PLUG FLASHING LIGHT /46.D4
1356 00090 01 00 001
-X71X =K +K4 PLUG CIGARETTE LIGHTER /24.E1 -X306_A * =H +H5 SPLICE /46.C3
-X81 =K +K2 SPLICE /21.B4 -X306_B * =H +H5 SPLICE /46.D4
93014064_001
-X82 =K +K4 SPLICE /30.B5 -X306_C * =H +H5 SPLICE /46.D3

93014064
B -X83 =K +K2 SPLICE /17.D6 -X307 * =K +K SPLICE /48.D5 B

-X84 =K +K2 SPLICE /21.B4 -X311a.B * =K +K3 PLUG ADAPTOR /19.A3
-X86 =K +K2 SPLICE /16.E5 -X311a.S * =K +K3 PLUG ADAPTOR /19.A3
-X87 =H +H SPLICE /16.F1 -X311b.B * =K +K4 PLUG SELECTOR /26.D5
-X87 =K +K2 SPLICE /15.B4 -X311b.S * =K +K3 PLUG ADAPTOR /26.D6
-X87 =M +M SPLICE /25.B2 -X311c.B * =K +K3 PLUG OPTION /46.C6
-X88 =M +M SPLICE /28.B5 -X311c.S1 * =K +K3 PLUG ADAPTOR /46.A7
-X89 =M +M SPLICE /27.B2 -X311c.S2 * =K +K3 SHORT-CIRCUIT PLUG /46.D7
C C
-X90 =M +M SPLICE /27.B4 -X314.KL.30 * =K +K2 CONNECTION KL.30 /52.A3
-X91 =K +K2 SPLICE /20.D7 -X321_Kl.15 * =K +K2 CONNECTION KL.15 /54.A4

-X91 * =K +K4 CONNECTOR /13.A5 -X321_MP * =K +K2 MASS GROUPING BLOCK /54.A5
-X92 =K +K2 SPLICE /20.D5 -X321a * =V +V ELECTRICAL SOCKET LEFT /42.C6

-X93 =H +H2 SPLICE /28.B2 -X321b * =V +V ELECTRICAL SOCKET RIGHT /42.C3
-X93 * =K +K4 CONNECTOR /13.B2 -X_Kl.15_W317 * =K +K2 CONNECTION KL.15 /53.A3
-X94 =M +M SPLICE /28.B3 -X_Kl.30 =K +K2 KL.30 RELAY BOARD /13.D3
D D
-X95 =M +M SPLICE /28.B4 -X_MP =K +K2 MASS GROUPING BLOCK RELAY BOARD /13.D3
-X96 =M SPLICE /28.E4 -XMSP200 * =M MASS GROUPING BLOCK /44.B5
forbidden.
+M +M
-X97 =H +H SPLICE /37.A6 -XMSP201 * =K +K MASS GROUPING BLOCK AUXILIARY HEATER /44.F1
-X97 =M +M SPLICE /28.E3 -Y0 =M +M INJECTION VALVE 0 = CYLINDER 1 /60.D2
-X98 =M +M SPLICE /28.B7 -Y1 =M +M INJECTION VALVE 1 = CYLINDER 2 /60.D3
-X99 =M +M SPLICE /32.C6 -Y2 =H +H TRAVELLING DIRECTION FORWARD /15.E3

-X101.B =K +K PLUG AIR CONDITIONING SYSTEM /43.D5 -Y2 =M +M INJECTION VALVE 2 = CYLINDER 3 /60.D4
E E
-X101.S =K +K PLUG AIR CONDITIONING SYSTEM /43.D5 -Y2X =H +H PLUG SOLENOID VALVE /15.E3
-X201 * =K +K6 SPLICE /17.E4 -Y3 =H +H TRAVELLING DIRECTION BACKWARDS /15.E4
-X202 =M +M SPLICE /21.B1 -Y3 =M +M INJECTION VALVE 3 = CYLINDER 4 /60.D5
-X203 =M +M SPLICE /21.B3 -Y3X =H +H PLUG SOLENOID VALVE /15.E4
-X203.B * =K +K PLUG REVERSING OBSTACLE DETECTOR /52.D3 -Y9 =K +K4 BUCKET RETURN-TO-DIG /29.E2
-X203.S * =K +K PLUG REVERSING OBSTACLE DETECTOR /52.D2 -Y01 =M +M INJECTION VALVE /59.D6
-X212 * =K +K2 SPLICE /51.C6 -Y01.X =M +M PLUG VALVE /59.D6
F F
TYPE: ab:
1 2 3 4 5 6 7 8
1 2 3 4 5 6 7 8
-Y10 =H +H SOLENOID VALVE PARKING BRAKE /31.D6 -Y317 * =H +H1 VALVE 2IN1 STEERING /53.E4
A A
-Y10X =H +H PLUG SOLENOID VALVE /31.D6 -Y317.X * =H +H1 PLUG VALVE /53.E4
-Y11 =V +V1 ADDITIONAL EQUIPMENT 1 /20.E7 -Y717 * =V +V1 VALVE DIFFERENTIAL LOCK /49.D7
-Y11X =V +V1 PLUG SOLENOID VALVE /20.E7 -Y717.X * =V +V1 PLUG VALVE DIFFERENTIAL LOCK /49.E7
1356 00090 01 00 001
-Y12 =V +V1 ADDITIONAL EQUIPMENT 2 /20.E8

-Y12X =V +V1 PLUG SOLENOID VALVE /20.E8
93014064_001
-Y13 =H +H SOLENOID VALVE FAN REVERSAL /33.D7

93014064
B -Y13.X =H +H PLUG VALVE /33.D7 B

-Y14 =H +H3 WORKING HYDRAULICS LOCKOUT /29.E4
-Y14.X =H +H3 PLUG SOLENOID VALVE /29.E4
-Y17 =K +K4 LIFT KICK-OUT /29.E2
-Y18 =K +K4 FLOAT POSITION /29.E3
-Y20 =V +V1 SOLENOID VALVE RIDE CONTROL /31.D7
-Y20X =V +V1 PLUG SOLENOID VALVE /31.D7
-Y22 * =M +M AIR CONDITIONING COUPLING /43.E2
C C
-Y22.X =M +M PLUG COUPLING /43.E2
-Y26 =H +H4 TRAVEL DIRECTION DETECTION /15.E5

-Y26X =H +H4 PLUG SOLENOID VALVE /15.E5

-Y50 * =H +H SOLENOID VALVE FAN REVERSAL /31.D3

-Y50.X =H +H PLUG SOLENOID VALVE /31.D3
-Y53 =V +V1 QUICK-CHANGE DEVICE UNLOCKING /30.E4
-Y53a =V +V1 QUICK-CHANGE DEVICE ACTIVE /30.E5
D D
-Y53a.X =V +V1 PLUG SOLENOID VALVE /30.F5
-Y53X =V PLUG SOLENOID VALVE /30.E4
forbidden.
+V1
-Y57 =H +H SOLENOID VALVE HYDRAULIC MOTOR 2 /33.D4
-Y57X =H +H PLUG SOLENOID VALVE /33.D4
-Y58 =H +H SOLENOID VALVE HYDRAULIC MOTOR 1 /33.D5
-Y58X =H +H PLUG SOLENOID VALVE /33.D5

-Y59 =H +H SOLENOID VALVE TRAVEL PUMP /33.D6
E E
-Y59.X =H +H PLUG SOLENOID VALVE TRAVEL PUMP /33.D6

-Y60 =H +H5 SOLENOID VALVE COUPLING MODULATION /33.D3
-Y60.X =H +H5 PLUG SOLENOID VALVE COUPLING UP /33.D3
-Y215 * =V +V1 VALVE OPTION BUCKET RETURN-TO-DIG /51.D6
-Y215.X * =V +V1 PLUG VALVE OPTION BUCKET RETURN-TO-DIG /51.D6
-Y216 * =V +V1 VALVE OPTION BUCKET RETURN-TO-DIG /51.D7
-Y216.X * =V +V1 PLUG VALVE OPTION BUCKET RETURN-TO-DIG /51.D7
F F
TYPE: ab:
1 2 3 4 5 6 7 8
1 2 3 4 5 6 7 8
WH 2.5Q
/50.B6
#56344 WH 2.5Q WH 2.5Q
WH 2.5Q =K
/50.D6
/50.D6
/24.A1
=K =K +K4 =K
A +K4 +K4 -S1.X1b +K4 CABLE INTERRUPT !!! A
1
10
-S1.X1 -S1.X1 -S1.X1
WH 2.5Q
5
8
10 5 6 8 9
#56355
#56354
WH,WH 2.5Q,2.5Q
58 15 15 50a
=K 50a
8
+K4 P 0 12
-S1.X1c
-X91
1
-S1 =K
+K6
1356 00090 01 00 001
1
-X1.S
WH 2.5Q
=K WH 2.5Q
30 30
#56352
#56352
93014064_001
1 1 2
WH 2.5Q -S1.X2 WH 1.5Q
-S1.X3
1
+K4
-X93
+K4
93014064
CABLE INTERRUPT !!! +K4

B =K =K =K =K =K =K B
=K
/50.D5
/50.D5
=K +K2 +K2 +K2 +K2 +K2
/49.A5
12
10
11
+K2 -X40 -X42 -X40 -X40 -X40
9
9
-X40b
=Kl. 15
X40.12
X40.11
X40.10
X40.9
X42.9
+A4
/16.D1
-X213 -M8
1 KL. 15
DISTRIBUTION BEDPLATE
Kl.30
KL. 15
/53.A2 E E
=K =K
C +K2 C
30 86 =K E +K2
Kl.15
30 86 30 86
=K -V1 +K2 -F16 -F17 A
A =K =K
+K2 -F29 -V4 -V5

20A +K2 +K2

-K01 A
/20.C6
25A -K02 -K03
87 85
87 85 87 85 =B 1
+B2
DISTRIBUTION BEDPLATE
DISTRIBUTION BEDPLATE GND -F07a
Kl. 30 +A4 -M10
RD 6Q =M6 151
/49.A3 1 -X1a +A4 =Y5_1 2
/52.A3 +A4
-MP
1
-V2 =M1_50A -V6 -V7
10A
-X_MP 1 GND GND +A4
1 MP
RD 6Q
D MP MP D
=K
X54.2
forbidden.
RD,RD 25Q,70Q
=B BK 70Q
+B2
RD 25Q
-X01
WH 6Q
-MP10_a -MP6_e
1 1
30
=M - =H
=B =B =B =B =B +
+M 1 +H
E M +B2 +B2 +B2 +B2 +B E
-M1 -S15
50 -F01 -F02 -F03 -F04 -G2b
0 -G2a
200A
100A
100A
0 +B
31
BK 70Q
RD 70Q
BK 16Q
RD 16Q
BK 16Q
+
/14.D4
- =B 2
BK 70Q
-F01.X -F02.X -F03.X
BK 70Q
+B2 +B2 +B2
RD 50Q
RD 16Q
RD 16Q
=M =B =B =B
+M
-MP10 1
1 1 1
/47.A3
/34.B2
-MP5_b -MP4_e -MP6_f BK 70Q 2
F -MP4_b F
TYPE: ab: 8924766

bis: 8921847 LIEBHERR BATTERY ; MASTER SWITCH ; IGNITION SWITCH SIDE: 13 61
1 2 3 4 5 6 7 8
1 2 3 4 5 6 7 8
CAN:
A /40.C5 GENERATOR D+ A
-A6.B KL 61 CHARGE CONTROL
+K2 DE21_KL61
=K A6.B.DE21
X4 34
-A6.BX4
34
1356 00090 01 00 001
+K2
=K
93014064_001
WH,WH 1.5Q,1.5Q
/43.A2
93014064
B =K =K B
+K2 +K2
-X57 -X57
6
/20.C6
X51.4
F15 - Kl. 15 =100 OHM =220 OHM
X57.5
X57.6
-V80
1 1
Kl.15
Kl. 15 =K =K
+K2 +K2
Kl. 30 -V81
-R9a -R9b
2 2
C E E =K E =K E =K E 86 30 C
=K =K =K
+K2 +K2 +K2
+K2 +K2
WH 1.5Q
+K2
-X4 -X5 -X6

-F38 -K5
A -F45 A A A A
3A NOT NOT 85 87 87a
3A
V8
EQUIPPED EQUIPPED 3A
-V82
=3A JUMPER
=3A JUMPER
=3A JUMPER
X51.2
X41.6
X42.11
GND
D GND D
LED GREEN
RD 25Q
forbidden.
/13.E3
-X41 -X42 -X51
11
6
2
+K2 +K2 =K
=K =K +K6
2
-X1.S
RD 2.5Q
WH 1.5Q
-X1.B
-G1.X3 2
=K
WH 1.5Q
+K6
-G1.X1
-G1.X2
=K =K +K1
=K
1
+K6 +K6 -P1X1
1
26
69
-X1.S -X2.S W B+ D+ 1
E =M =K E
=K +M 3 +K1
+K6 -G1 -P1
h
68
-X1.B
-G1.X4 B- 2
1
+M -P1X2
1
BK 1.5Q
BK 1.5Q
=M +K1
=H =K
=K
+H2 +K4
1 -MP1_a -MP6_d 8
F F
TYPE: ab: 8924766

bis: 8921847 LIEBHERR GENERATOR ; TRAVELLING DIRECTION AND LIGHTING SIDE: 14 61
1 2 3 4 5 6 7 8
F
E
A
D
Für dieses Dokument und den darin dargestellten Gegen- We reserve all rights in this document and in the informa-
stand behalten wir uns alle Rechte vor. Vervielfältigung, tion contained therein. Reproduction, use or disclosure
93014064_001
TYPE:
Bekanntgabe an Dritte oder Verwertung seines Inhaltes to third parties without express authority is strictly 93014064
sind ohne unsere ausdrückliche Zustimmung verboten. forbidden.
© LIEBHERR WERK BISCHOFSHOFEN © LIEBHERR WERK BISCHOFSHOFEN 1356 00090 01 00 001
1
1
ab:
bis: 0
2
2
-Y2
+H
=H
3
3
-Y2X
=H
+H
-MP1_c
+H2
=H
-Y2X
=K
-A6.BX4
+K2
+H
=H
BK 1.5Q WH 1.5Q 3 3 WH 1.5Q
4
2
2 1 16
16 X4
=K
=K
A6.B.DA10
+K6
+K6
CAN:
FORWARD (3A)
-X1.B
-X1.S
DA10_FNRforward
TRAVELLING DIRECTION
=K
+K2
/40.C2
-A6.B
-Y3
+H
=H
4
4
2
-Y3X
=H
+H
-MP1_c
+H2
=H
-Y3X
=K
-A6.BX4
+K2
+H
=H
=K
-X87
+K2
BK 1.5Q WH 1.5Q 4 4 WH 1.5Q WH 1.5Q
5
2 1 30
30 X4
=K
=K
A6.B.DA14
+K6
+K6
CAN:
-X1.B
-X1.S
BACKWARDS (6A)
DA14_FNRbackward
BISCHOFSHOFEN
TRAVELLING DIRECTION
LIEBHERR
=K
+K2
/40.C5
-A6.B
=H
-Y26
+H4
1
2
-Y26X
+H4
=H
-MP1_d
+H2
=H
-Y26X
+H4
=H
5
5
BK 1.5Q WH 1.5Q 15 15 WH 1.5Q
8
2 1
=K
=K
+K6
+K6
-X2.B
-X2.S
-OLE301
#56319
/19.A4
0
-E14a
=H
+H1
-OLE302
=K+K2-X51:10 /26.A2
BK 1.5Q WH 1.5Q #79
/16.E3
1
-OLE300
=K+K3-X311c.B:2 #56158
/46.A4
0
-E14b
=H
+H1
-OLE304
=K+K-X203.B:3
6
6
/52.A2
BK 1.5Q WH 1.5Q #78
/16.D5
1
TRAVELLING DIRECTION AND LIGHTING

Kl.31
Kl.31
/16.F4
/16.F3
7
7
SIDE:
DATE:
15
8
8
14.03.2013 13:56
61
F
E
A
D
F
E
A
D
93014064_001
TYPE:
WH 2Q
=V
-B12
Kl.15
+V1
1
1
/25.D5
P
WH 1.5Q
=V
-B12X
-B12X
=V
+V1
+V1
0
=K
-S3
+K1
2
2 1
L
RD 1.5Q -S3X1
/13.C8
3
Kl.30 3
L
R
-X87
+H
=H
WH 1.5Q 1 1
R
2
-X11.B -X11.S 2
1
49a
WH 1.5Q 1 WH 1.5Q
5
-X12.B -X12.S 5
56b
BK 1.5Q 5 5 -S3X2 WH 2Q
LH
4
4
4
0
-X12.B -X12.S
hb/lb-F/A
56a
BK 1.5Q 6 6 WH 2Q
-MP1_b
2
2
5
5
-X12.B -X12.S 5
30
BK 1.5Q 6 6 WH 2Q
2
2
2
bis: 8921847
ab: 8924766
-X11.B -X11.S
5
56
BK 1.5Q WH 2Q
-MP1_a
5
3
3
-X11.B -X11.S 3
=K
-S4
+K4
BK 1.5Q 5 5
BK 1.5Q
0-1
=K
=K
+K6
+K6
BK 1.5Q
-X1.B
-X1.S
=K
=K
-F07b
+K4
+K2
-S4X1
BK 1.5Q
10A
=K
+K4
-S4X1
-X55
8
A
E
F07b-KL. 15 4 6 8
X55.4
7
6
H52
#79
/15.C6
4
2
3
3
4 2
-X50
/15.F7
3
5
7 3 5
-X12.S
-X12.B
-X1.B
-X1.S
X50.7
E6
2 2 6 6 -X50
-X1
=EU
4
10A
1
X50.12 12 1
Kl.31
2
E
10
H20
=K
-V84
-V83
5
X50.8
1
+K2
A -K25
3 3 7 7 8
7
+K4
10 -S4X2
-X50
H17
10 -X57
-X1.B
-X1.S
/15.F7
-X12.S
-X12.B
0
3
87a 87
30
-X50 X57.3
=K BK 1.5Q
X50.10
0
=K
-S4b
+K4
0
=B =B
-E5 -E1
+B1 +B1
4
4
Kl.31
3
85
GND
H18
V14
3 3 8 8
=K
+K4
5
-X2
86 =EU
-MP6_a
10A
H21
-X1.B
-X1.S
-X11.S
-X11.B
E
BISCHOFSHOFEN
=K
LIEBHERR
2 2 9 9 WH 1.5Q
+K2
A -K26
E7
11
WH 1.5Q
-X1.B
-X1.S
-X50
-X11.S
-X11.B
87a 87
30
#78 9 -X57 WH 1.5Q

/15.C6
7
6 -X50 7
H53
=K
X50.11 X50.9
/40.B2
+K2
-A6.B
=K
/40.C5
+K2
-A6.B
X57.7
85
86
5
5
4
GND
V15
-X11.B -X11.S
4 4 -X57
=K
-A6.BX4
+K2
CAN:
4
=K
-A6.BX4
+K2
CAN:
-X12.B -X12.S X57.4

X4 1
INPUT
27 27 1 -X57 1
=K
X4 40
+K2
A6.B.DE07
40
-K1
DE07_Flasher
A6.B.DA17
2
49
-X1.B -X1.S -X57 X57.2

OUTLET (5A)
49a
=K
=K
-X86
DA17_Backlights
DISPLAY INDICATOR
REVERSING LAMP
-X49
X57.1
10 10
-V87
-X1.B -X1.S X49.9 9

=K
=K
-X49
C
31
GND
=K
/40.C2
+K2
-A6.B
-V89
X49.11 11
-V88
WH 1.5Q
WH 1.5Q
WH 1.5Q
WH 1.5Q
=USA
-X3
-B16X -B16X
=H
-MP1_c
-B16
+H5
BK 1.5Q 12 12 X49.12
A
2 1 3
1
6
6
=K
-A6.BX4
=K
+K2
CAN:
X43.3
+K6
E =K
-X2.S
-F6
+K2
-X43
X4 11
INPUT
6 11
A6.B.DE08
5A A
E
-X43 F6/R6
DE08_HighBeam
/48.A6 X43.6
DISPLAY HIGH BEAM
GND
11
-X44 X44.11
=K
-F7
+K2
5A
/48.F6 -X42
12 WH 2Q
A
E
-X44 X44.12 F7-R7 X42.4 4 WH 2Q

GND
WH 1.5Q
=K
-F2
+K2
=V
-E4
7,5A
+V1
X44.8 X44.1 -X44

0
=K
-S6a
+K4
8
LIGHTING ; INDICATOR ; HAZARD WARNING LIGHT
A
E
H16
F2-R2 1
=K
WH 1.5Q
-S6
+K4
11 11 -X44
5
GND
5
H51
7
7
=K
WH 1.5Q
-F3
12 12
+K2
7,5A
2 1 0
X44.7
4
4 7 -X44
1.5Q WH
A
E
H57
=V
F3-R3 3
-E4X
WH 1.5Q 14 14
+V1
-X44 X44.3
=K
=K
+K4
+K4
-S6X1
-S6X1
3
GND
BK 1.5Q
1
1
1 3 1
=K
-F4
WH 1.5Q 13 13
+K2
-MP1_a
7,5A
H55
2
2 9 X44.9
A
E
LOW BEAM / DRIVING LIGHT

-E4X
=V
6
2
-X1.B
-X1.S
6 2
+V1
/18.D7 -X44
GND
#58
SIDE:
DATE:
/18.D2
8
#60
=K
-F5
+K4
+K2
-S6X2
=K
7,5A
-X44
=V
X44.10
-E3
10
+V1
1
A
E
LOW BEAM / DRIVING LIGHT

9
2 10 9
=V
X44.2
10
-X1.B
-X1.S
+V1
-X44 =K
-E3X
2
=V
GND
=K
WH 1.5Q
16
16 16
H54
+V1
-E3X
+K4
+K4
1
-S6X2
BK 1.5Q 2 -V1
3
2
5
1
=K
-F27
WH 1.5Q 15 15
+K2
8
8
10A
-MP1_a
Kl.30
3 3 X42.3
4
A
E
H56 H50
WH 1.5Q 17 17 -X42
Kl.15
4
GND
H15
WH 1.5Q
-V2
18 18
+K4
2
=K 1
5
14.03.2013 13:56
/31.C3
61
/23.E2
/31.E3
F
E
A
D
F
E
A
D
93014064_001
TYPE:
1
1
WH 1.5Q
WH 1.5Q
-M3X
1
53a
0
=K
-S13
+K4
sw-bl
1
=K
M
+K4
2 1 0
=K
+K3
-MP6_a
-M3X 2
31
-M3X
=K
=K
53
3
+K4
+K4
sw
-S13X1
-S13X1
7
1.5Q BK 2 68 68
bl
3
2
3 3 2
=K
=K
2
2
+K6
+K6
-X2.B
-X2.S
6
6
4
-M3X
=K
+K3
31b
bis: 8921847
ab: 8924766
ws-bl
5
7
4 5 7
=K
/26.A2 /26.A2
-M3
+K3
9
10 9
10
/18.B7 /18.A7
=K
=K
+K4
+K4
-S13X2
-S13X2
0
-M9
+H
=H
WH 1.5Q
01
01
-M9X
=H
+H
-MP1_c
+H2
=H
0J 1
-M9X
+H
=H
3
3
BK 1.5Q
-
+
9
2
2 1
1
WH 1.5Q
0
wash
HOOTER
-S3
-B10
+H2
+K1
=H
=K
+H2
=H
=K
+K6
+H2
-B10X2
+H2
=H
=H
-B10X1
-MP1_a
-X1.S
BK 1.5Q 19 19
6
2
1 1 31b 15 J 53 53b 53c H
=K
+K6
-X1.B
4 6 7 1 7 6 1
1
6
7
4
4
7
6
=K
=K
+K1
+K1
-X201
4 -S3X1
-S3X2
WH 1.5Q
/51.C3
WH 1.5Q
BISCHOFSHOFEN
LIEBHERR
WH 1.5Q
WH 1.5Q
5
5
WH 1.5Q
WH 1.5Q
=K
-K5a
+K4
0
-K5aX
=K
=K
+K4
-M2
+K1
I
-M2.X
=K
=K
-K5aX
+K4
+K1
ws-bl WH 1.5Q 3
*
86
31b
6
3 2
4 6 2
31b
=K
-M2.X
=K
-MP6_a
+K4
+K1
bl
=K
WH 1.5Q
15
-MP6_a
+K4
-M2.X
3
sw 3 5
53
BK 1.5Q
31
S
1
5 4
8
31
2 1 4
10
6
6
WH 1.5Q
M
-M2.X
=K
+K1
sw-bl WH 1.5Q
1
1
53a
=K
-X83
+K2
WH 1.5Q
0
-M4
+H
=H
67 67 WH 1.5Q
-M4X
=H
+H
-MP1_c
=K
=K
+H2
=H
-M4X
+H
=H
+K6
+K6
BK 1.5Q WH 1.5Q
-X2.B
-X2.S
-
+
2 1
1
10
WINDSCREEN WIPER FRONT , REAR AND HORN
WH,WH 1.5Q,1.5Q
7
7
=K
=K
-F18
+K2
+K2
-X41
1 X41.1
10A
KL. 15
A
E
2 X41.2
/35.B3
WH 1.5Q
Kl.15
=K
+K2
-X41
SIDE:
GND
DATE:
=K
-F20
+K2
/55.B5
-X41_2
15A
12 X41.12
A
E
17
=K
+K2
-X41
8
8
GND
KL. 15
14.03.2013 13:56
61
F
E
A
D
1 2 3 4 5 6 7 8
=K =K WH 1.5Q
/17.C2
+K4 +K4 WH 1.5Q
/19.A6
A -S7X1 -S7X2 A
9
1
1 9
=K =K
+K4
1 0 +K4
WH 1.5Q
-S7 -S7a
0
1356 00090 01 00 001
5 10
10
-S7X1 -S7X2
93014064_001
BK 1.5Q
+K4 +K4 /19.B6
BK 1.5Q
=K =K /17.D2
93014064
B =K =K B
11
+K2 +K2
2
-X46 -X46
X46.11
X46.2
Kl.30
Kl.15
Kl.30
Kl.15
=AS + DB FRONT E1 E2
E1 E2 =AS + DB FRONT
30 86 30 86
C =K E =K
E C
Kl. 30 KL. 15 =K Kl. 30 KL. 15
=K
+K2 +K2 +K2
+K2
-F31a -K31a -F31b

-K31b
E1 A E2 E1 A E2
E1 A E2 E1 A E2 A
V16
10A A 87a 87 85 10A
V17
87a 87 85
/16.E8
/16.E7
A
A
GND GND
#60
#58
X46.10
X46.5
X46.6
X46.9
GND
GND
D D
-X46 -X46 -X46 -X46

WH 1.5Q 5
WH 1.5Q 6
WH 1.5Q 9
WH 1.5Q 10
forbidden.
+K2 +K2 +K2 +K2

=K =K =K =K =K =K
+K3 +K3
1
1
=K -E10b.X1 =K =K =K -E11b.X1 =K =K
+K3 +K3 +K3 +K3 +K3 +K3
-E10b.X -E10X -E10aX -E11b.X -E11X -E11aX
3
3
1
1
1 1 1 1 1 1 1 1
3 3
=K =K =K =K =K =K =K =K
+K3 +K3 +K3 +K3 +K3 +K3 +K3 +K3
E -E8 -E10b -E10 -E10a -E11b -E11 -E11a -E9 E
0 2 0 2 2 0 2 0 0 2 2 0 2 0 0 2
-E10b.X -E10X -E10aX -E11b.X -E11aX
2
2
2
2
-E11X
+K3 +K3 +K3 +K3 +K3
+K3
=K -E10b.X1 =K =K =K -E11b.X1 =K
=K
2
2
+K3 +K3
BK 1.5Q
BK 1.5Q
BK 1.5Q
BK 1.5Q
=K =K
=K =K =K =K =K =K
+K3 +K3 +K3 +K3 +K3 +K3
-MP7_a 3 -MP7_a 4 -MP7_a 5 -MP7_a 6 -MP7_a 7 -MP7_a 2
F F
TYPE: ab: 8924766

bis: 8921847 LIEBHERR WORKING PROJECTOR FRONT SIDE: 18 61
1 2 3 4 5 6 7 8
1 2 3 4 5 6 7 8
WH 1.5Q
-X311a.S -X311a.B
3 WH 1.5Q
/18.A7
A WH 1.5Q A
=K /20.D4
1 =K
+K3
9
1
5
9
1
+K4
-S300.X1 1 5 9 -S300.X2 -S8X1 1 9
=K =K =K
2 1 0 #56319
+K3 /15.A5 +K4
1 0 +K4
-S300 2
-S300_a -S8 -S8a
1356 00090 01 00 001
0 0
RD 1.5Q
WH 1.5Q
5
3 10 -S8X1 5 10-S8X2
-S300.X1 -S300.X2
+K4 +K4
93014064_001
5
4
10
10
+K3 =K =K BK 1.5Q
=K /20.D4
93014064
6 BK 1.5Q
B /18.B7 B
WH,WH 1.5Q,1.5Q =K =K
+K2 +K2
12
10
12
-X50 -X50
2
5
1
X46.12
X47.10
X47.12
X46.1
X50.5
X50.2
Kl. 30
Kl.30
Kl.15
Kl.30
Kl.15
V33c
=AS + DB REAR
E1 E2 =AS + DB REAR E
RD 1.5Q
C E1 E2 C
30 86
E
30 86 30 86 =K
=K E =K Kl. 30 KL. 15 =K =K +K2
Kl. 30 KL. 15 =K
+K2
+K2 +K2 +K2 -F40

+K2
A
-F33a -F33b -K33b -K243 10A
E1 A E2 E1 A E2
-K33a E1 A E2
A E1 A E2
V20 10A
87a 87 85
V21
V46
10A A 87a 87 85 87a 87 85
A A
GND GND GND

-V38 -V39
MP MP
X41.9
X50.1
X50.3
GND
X46.3
X46.4
D D
X46.7
X46.8
GND GND
forbidden.
-X46 -X46 -X46 -X46 -X50 -X41

3
9
+K2 +K2 +K2 +K2 +K2 +K2
=K =K =K =K =K =K
WH 1.5Q
WH 1.5Q
WH 1.5Q
WH 1.5Q
=K =K
=K =K =K =K +K6 +K6
51
52
+K3 +K3 +K3 +K3 -X2.S -X2.S
-E12.X -E12a.X -E13.X -E13a.X
1
1
E E
1 1 1 1
=K =K =K =K
+K3 +K3 +K3 +K3
-E12 -E12a -E13 -E13a
0 2 0 2 0 2 0 2
-E12.X -E12a.X -E13.X -E13a.X
2
+K3 +K3 +K3 +K3

BK 1.5Q
BK 1.5Q
BK 1.5Q
BK 1.5Q
=K =K =K =K
=K =K
=K =K
+K3 +K3
+K3 +K3
-MP7_a 8 -MP7_a 9
F -MP7_a 10 -MP7_b 1 F
TYPE: ab: 8924766

bis: 8921847 LIEBHERR WORKING PROJECTOR REAR SIDE: 19 61
1 2 3 4 5 6 7 8
1 2 3 4 5 6 7 8
CAN: CAN: CAN: CAN: CAN: CAN: CAN: CAN: CAN:

INPUT /39.C2 INPUT /39.C5 INPUT /39.D2 INPUT /39.C5 INPUT /40.D2 INPUT /39.C5 INPUT /39.C5 OUTLET (3A) /40.C2 OUTLET (3A) /40.C2
A BACKWARDS NO -A6.A BACKWARDS NC -A6.A FORWARD NC -A6.A FORWARD NO -A6.APUSH-BUTTON SWITCH OPTION -A6.B
1 SIGNAL CLAMP 15 -A6.A TANK PIPE SENSOR -A6.A OPTION 2 -A6.B OPTION 3 -A6.B A
DE05_FNRbackNO +K2 DE03_FNRbackNC +K2 DE02_FNRforwNC +K2 DE04_FNRforwNO +K2 DE12_Option1 +K2 DE00_KL15 +K2 E2_Fuel +K2 DA08_Option2 +K2 DA09_Option3 +K2
A6.A.DE05 =K A6.A.DE03 =K A6.A.DE02 =K A6.A.DE04 =K A6.B.DE12 =K A6.A.DE00 =K A6.A.E2 =K A6.B.DA08 =K A6.B.DA09 =K
10 X3 29 X3 19 X3 39 X3 22 X4 38 X3 28 X3 8 X4 10 X4
-A6.AX3 -A6.AX3 -A6.AX3 -A6.AX3 -A6.BX4 -A6.AX3 -A6.AX3 -A6.BX4 -A6.BX4
10
29
19
39
22
38
28
10
+K2 +K2 +K2 +K2 +K2 +K2 +K2 +K2 +K2
1356 00090 01 00 001
=K =K =K =K =K =K =K =K =K
93014064_001
93014064
B CAN: CAN:
B
INPUT /40.C5 INPUT /40.B2
PUSH-BUTTON SWITCH OPTION 2-A6.B PUSH-BUTTON SWITCH OPTION 3-A6.B KL. 15
DE13_Option2 +K2 DE14_Option3 +K2
A6.B.DE13 =K A6.B.DE14 =K
-A6.BX4 32 X4 -A6.BX4 3 X4
+K2 +K2
32
3
=K =K =K E =K E E
+K2 +K2 =K
-F9 -F15 +K2
A A -F12 A
10A 10A 10A
C =K C
+K4
-S45X1 -S45X2
9
1
1 9
=K
WH 1.5Q
WH 1.5Q
WH 1.5Q
WH 1.5Q
WH 1.5Q
WH 1.5Q
Kl.15
Kl.15
1 0
WH 1Q
WH 1Q
WH 1Q
WH 1Q
WH 1Q
WH 1Q
WH 1Q
WH 1Q
+K4
WH 1Q
X43.2
X43.4
X43.7
X43.8
-S45
X58.4
GND GND GND
/14.C6
/13.C7
-V22
5 10
*
-S45X1 -S45X2 MP =K =K =K
10
=K
+K4 +K6 +K6 +K6
21
22
23
+K4 -X58
=K WH,WH 1Q,1Q
-X43 -X43 -X43 * -X43 +K2 -X1.S -X1.S -X1.S
4
-S45a
+K2 +K2 -X1.B -X1.B -X1.B
21
/48.B5 =K
22
23
D 0 D
WH 1.5Q
=K =K -X91 +K6 +K6 +K6
WH 1Q CAN: Kl.15 =K =K =K
20
-X1.S /34.B5
-X92 SUPPLY /39.C5 Kl.15
forbidden.
/28.A7
/19.B6
/30.C3
/30.A3
/19.A6
EARTH TANK PIPE SENSOR -A6.A -X1.B
WH 1.5Q
WH 1.5Q
WH 1.5Q
Kl.15 Kl.15
20
/31.C2 /32.B7
1Q WH +K2 Kl.15
/34.B6
1Q WH BK 1Q A6.A.E6_GND =K Kl.15
/25.B6
37 X3 =H
=K -A6.AX3 +H2
37
+K4 -B25X =V =V
3
1
+K2
1 3
10
12
11
-S2X +V1 +V1

4
7
9
1
=K
=K -Y11X -Y12X
1
4 2 5 3 1 6 8 7 9 10 11 12 CABLE INTERRUPT !!! =H gn vi
=V =V
=K 1 1 +K6 +H2 1 1
+V1 +V1
37
V N R
+K4 -X1.S -B25 -Y11 -Y12
E E
-X8
-X9
+K4
+K4
=K
=K
-S2 Q
-X1.B 0 0
37
+K6 2 2
SW4 SW5 SW3 sw ge
=K -Y11X -Y12X
2
2 4 +V1 +V1
#56346
#56349
-B25X =V =V
BK 1.5Q
BK 1.5Q
+H2
BK 1.5Q
=H
=K =H =H
/50.D5
/50.D5
+K4 +H2 +H2

-MP6_d 7 BK 1.5Q -MP1_a 7 -MP1_a 8
F F
TYPE: ab: 8924766

bis: 8921847 LIEBHERR CONTROL LEVER ; ADDITIONAL EQUIPMENT ; TANK PIPE SENSOR SIDE: 20 61
1 2 3 4 5 6 7 8
1 2 3 4 5 6 7 8
CAN: CAN: CAN: CAN: CAN: CAN: CAN: CAN:

CAN BUS /41.B2 CAN BUS /41.B2 CAN BUS /39.D2 CAN BUS /39.C5 PIN = EARTH /39.B2 DIAGNOSTIC PLUG /39.C2 DIAGNOSTIC PLUG /39.C2 DIAGNOSTIC PLUG /39.B2
A LOW -A700 HIGH -A700 HIGH2 -A6.A LOW2 -A6.A BOOTSTRAP -A6.A RS-232 UEC3 -A6.A RS-232 UEC3 -A6.A RS-232 UEC3 -A6.A A
+M +M +K2 +K2 +K2 +K2 +K2 +K2
A700.5 =M A700.Can =M A6.A =K A6.A.CAN2L =K A6.A.BSL_C2 =K A6.A =K A6.A.RxD =K A6.A.TxD =K
B1 X1 A1 X1 22 X3 32 X3 2 X3 12 X3 11 X3 1 X3
-A700X1 =M -A700X1 -A6.AX3 -A6.AX3 -A6.AX3 -A6.AX3 -A6.AX3 -A6.AX3
B1
A1
1
11
22
32
12
BU 1Q
+M
BU 0.5Q
RD 0.5Q
+M +M +K2 +K2 +K2 +K2 +K2 +K2
1
-R700
RD
BU
1356 00090 01 00 001
=M =M =K =K =K =K =K =K
-X202 -X203
BU 1Q
RD 1Q
-W157.WL017 +K
-W157.WL017 +K
=K =K
93014064_001
RD 1Q
+K6 +K6
-X2.B
10
11
-X2.B
93014064
B -X2.S -W157.WL008 +K RD
B
-X2.S -X84
11
10
+K6
+K6
=K -W157.WL009 +K RD -W157.WL008 +K BU
=K -X81
-W157.WL009 +K BU
KL. 15 KL. 15 Kl.30 Kl. 30

3
2 4 A
2-3
1
20 30 A
=K
WH 1.5Q
1.5Q
1.5Q
1.5Q
1.5Q
1.5Q
1-3
2Q
1Q
1Q
E
10
E +K4
40
A
100
110 1-2 MP =K =K
WH
BU
WH
WH
WH
WH
RD
90
BK
check
+K2 -MP6_c 6
=K mph
+K2
50
40
120
2
0
km/h
-A13X2
1
C +K1 -F10 C
/50.B6
1 A -F26
-A13 +K1 3A
A
1/
4
1/2
3/
4
=K 15A =K
T
+K4
1/1
STOP
G
C
B
A
H
D
E
F
rpm
I
time
N
-X60
#56342
hours
1 2 3 4 5 6 7 8 9
-A13X1 -A13X1 -A13X1 -A13X1

1
+K1 +K1 +K1 +K1 *9

=K =K =K =K
X42.2
X42.1
X43.5
GND GND
D D
-X43 -X42
1
5
WH 1.5Q
DOUBLE LIMIT STOP
+K2 +K2
forbidden.
=K =K
RD
BU
-X42a
1
+K
=K
-W157.WL007 +K
-W157.WL007 +K
WH 2Q
BK 0.5Q
WH 0.5Q
BK 1.5Q
E E
=K
CAN_HIGH
CAN_LOW
+K2
30
-A6.AX3
30 X3
A6.A.+27VDC_1 =K
=K =K VBAT1 +K2
+K4
/38.B7
/38.B8
+K4 VOLTAGE 1 UEC3 -A6.A

-MP6_b 7 -MP6_b 8 SUPPLY /39.C5
CAN:
F F
TYPE: ab: 8924766

bis: 8921847 LIEBHERR DISPLAY UNIT ; DIAGNOSTIC PLUG SIDE: 21 61
1 2 3 4 5 6 7 8
F
E
A
D
93014064_001
TYPE:
1
1
ab:
bis: 0
2
2
KL. 15
=K
+K2
-F11
3A
2 X58.2
A
E
=K
+K2
-X58
GND
3
3
RD,RD 0.5Q,0.5Q
4
4
=K
-A6.A
/39.D2
+K2
CAN:
18
BISCHOFSHOFEN
X3 18
LIEBHERR
A6.A.E1
=K
=K
+K6
+K2
-R1
E1_Inchsensor2
CURRENT INPUT
=K
+K4
=K
-R1.X
1
-R1.X
=K
+K6
+K6
-A6.AX3
BK 0.5Q RD 0.5Q
INCH ANGLE SENSOR 2
2
-
9
2 1
-MP6_c
4
BU 0.5Q
4
signal
3
signal
5
5
BU 0.5Q
=K
-A6.A
/39.C2
+K2
=K
+K4
6
=K
-R1.X
+K6
BK 0.5Q RD 0.5Q
5
+
8
5 6
-MP6_c
CAN:
8
X3 8
A6.A.E0
=K
+K2
E0_Inchsensor1
CURRENT INPUT
-A6.AX3
INCH ANGLE SENSOR 1
6
6
INCH PEDAL
7
7
SIDE:
DATE:
22
8
8
14.03.2013 13:56
61
F
E
A
D
1 2 3 4 5 6 7 8
A CAN: CAN: CAN: CAN: CAN: CAN: A

SUPPLY /40.C5 SUPPLY /40.C2 SUPPLY /40.C5 SUPPLY /39.D5 INPUT /39.C5 OUTLET (2A) /40.B5
VOLTAGE 2 UEC3 -A6.B VOLTAGE 3 UEC3 -A6.B EARTH UEC3 -A6.B EARTH UEC3 -A6.A RESERVE -A6.A BUZZER -A6.B
VBAT2 +K2 VBAT3 +K2 +K2 +K2 AD3_Reserve +K2 DA00_Buzzer +K2
A6.B.+27VDC_2 =K A6.B.+27VDC_3 =K A6.B.SGND =K A6.A.SGND =K A6.A.DAE3 =K A6.B.DA00 =K
35 X4 6 X4 31 X4 40 X3 33 X3 28 X4
1356 00090 01 00 001
-A6.BX4 -A6.BX4 -A6.BX4 -A6.AX3 -A6.AX3 -A6.BX4
31
35
40
33
28
+K2 +K2 +K2 +K2 +K2 +K2
=K =K =K =K =K =K
93014064_001
93014064
B B
WH 1.5Q
KL. 15 KL. 15
E E E E
=K =K =K =K
+K2 +K2 +K2 +K2
-F19 A
-F21 A -F22 -F23
A A
10A 15A 15A 15A =K
C +K6 C
28
-X1.S
X41.5
X44.2
X40.5
X43.9
GND GND GND GND

-V24
BK 2.5Q
BK 2.5Q
WH 1.5Q
-X44 -X40 -X43
4
WH 2Q
WH 2Q
+K2 +K2 +K2
D D
=K =K =K
WH 2Q
WH 2Q
WH 2Q
forbidden.
Kl.15
=K
/16.B8
E +K4 E
-H40X1
1
=K +
+K4 3
-H40
-
0
-H40X2
1
+K4
=K
BK 1.5Q
=K =K =K
+K4 +K4 +K4
F -MP6_b 3 -MP6_b 4 -MP6_b 5 F
TYPE: ab: 8924766

bis: 8921847 LIEBHERR BUZZER ; SUPPLY UEC3 SIDE: 23 61
1 2 3 4 5 6 7 8
1 2 3 4 5 6 7 8
/44.A1
/13.A3
A RD 2.5Q A
WH 2.5Q
BK 2.5Q
=K =K =K =K
+K2 +K2 +K2 +K2
-X58 -X51 -X58 -X58
1356 00090 01 00 001
7
1
1
93014064_001
X58.1
X51.1
X58.5
X58.7
=K
+K2
93014064
B -T1X B
1
4 1 Kl.30
+ -
=K 24V
+K2
-T1 E
E E 12V
E E 30 86 =K =K + - + - =K
=K =K 0
=K +K2 +K2 3 2 6 5 +K2
+K2 +K2 +K2 -T1X
-F75 -F76 -F30
5
-F8a -F8 -K12 A A +K2 =K A
V3
A A 10A 10A 15A
10A 15A 87a 87 85 =K +K4
-MP6_b 9
WH 1.5Q
C C
WH 1.5Q
BK 1.5Q
WH 1.5Q
GND
X55.8
X55.5
X55.6
X55.7
X51.3
BK 1.5Q
GND GND
X58.3
X58.8
X42.12
WH 1.5Q
WH 1.5Q
-X70.X2
-X51 -X58 -X58 =K -X42
8
12
=K+K-X9:1 -X55 -X55 +K3
+K2 +K2 +K2 +K2
+K2 +K2 =K -X70.X1
1
=K =K =K =K
D =K =K +K3 1 D
WH 2.5Q
WH 1.5Q =K 2
-A3X1 + -
4
7
8
+K3
=K 7 4 8 -X70
forbidden.
+K3 =K IGN + -
-E2X1 =K +K3
1
1 +K -A3 R A D I O
=K -M7X
1
+ LS re - + LS li -
=K +K3 1 -A3X2
3 4 5 6
+K4 -E2 +K3
6
=K
-X71X =K
2
1
WH 1Q WH 1Q
1 2 2 3 +K WH 1Q WH 1Q
M
BK 1.5Q
+ - -M7
-X71 -E2X2 -E2X3
1
=K =K
E +K3 +K3 +K3 +K3 E
=K =K -B11rX1 -B11lX2
1
2
-M7X 1 + 2
2
-
BK 1.5Q
+K =K 0
=K +K3 -B11l
BK 2.5Q
-B11r +K3
0 =K
2 + -
=K =K =K 1
-B11rX2 -B11lX1
1
+K4 +K3 +K4
-MP6_a 1 -MP7_a 1 -MP6_a 2 +K3 +K3
F =K =K F
TYPE: ab: 8924766

bis: 8921847 LIEBHERR RADIO ; VOLTAGE CONVERTER ; DRIVER'S SEAT SIDE: 24 61
1 2 3 4 5 6 7 8
1 2 3 4 5 6 7 8
CAN: CAN: CAN: CAN:

A ENGINE /41.B2 SUPPLY /40.C5 PRESSURE SWITCH /39.C2 INPUT /39.C2 A
INFO KL.15 -A700 VOLTAGE 4 UEC3 -A6.B SERVICE BRAKE -A6.A RESERVE -A6.A
/20.D7
+M VBAT4 +K2 KL. 15 KL. 15 AD4_SysBreakPS +K2 E5_Reserve +K2
A700.6 =M A6.B.+27VDC_4 =K A6.A.DAE4 =K A6.A.E5 =K
B2 X1 36 X4 4 X3 7 X3
Kl.15
-A700X1 -A6.BX4 -A6.AX3 -A6.AX3
B2
36
7
E E E
1356 00090 01 00 001
+M +K2 +K2 +K2

=K =K =K
=M =K =K =K
+K2 +K2 +K2
-F24 -F43 -F44
93014064_001
A A A
93014064
-X87
B +M B
=M 15A 10A 10A
WH 1.5Q
WH 1.5Q
WH 1.5Q
X43.11
X43.12
X42.7
GND GND GND
-X43 -X43 -X42
11
12
7
+K2 +K2 +K2
WH 1.5Q
WH 1.5Q
C =K =K =K C
=K =K =K =K =K
+K6 +K6 +K6 +K6 +K6
31
29
30
70
32
-X1.S -X2.S -X1.S -X1.S -X1.S

-X1.B -X2.B -X1.B -X1.B
31
30
70
29
+K6 +K6 +K6 +K6

WH 2Q =K =K =K =K
WH 1.5Q
WH 1.5Q
D D
Kl.15
=H
+H
WH 1.5Q
forbidden.
-B19.X
C
/16.D1
WH 1.5Q C
sw
=H
s
+H
-B19 UP
- +
bl bn
B A
-B19.X
A
E +H E
=H
BK 1.5Q
=H
+H2
-MP1_c 7
F F
TYPE: ab: 8924766

bis: 8921847 LIEBHERR PRESSURE SWITCH ; TEMPERATURE SENSOR ENGINE SIDE: 25 61
1 2 3 4 5 6 7 8
1 2 3 4 5 6 7 8
CAN:
/17.D2
/17.C2
/35.B8
/35.B6
/15.A5
=K SUPPLY /38.B2
+K2 VOLTAGE -A11
10
-X51 -X51 +K4
9
A A11.Kl15 =K A
X51.10
X51.9
1 X1
-A11X1
1
Kl. 30 KL. 15 +K4
=K
1356 00090 01 00 001
E E
=K 30 86 =K
+K2 =K +K2
93014064_001
-F25 +K2 -F71

A A
-K228 10A
93014064
B 87a 87 85 B
V45
WH 2.5Q
BK 1.5Q
WH 1.5Q
WH 1.5Q
WH 1.5Q
10A
GND
-V40 -V41
MP MP
X41.3
X41.4
X40.3
X40.6
X51.11
X51.12
GND GND
-X51 -X41 -X41
12
4
C -X40.a -X40 -X40 +K2 +K2 +K2 C
+K2 +K2 =K =K =K
=K =K
WH 1.5Q
WH 1.5Q WH 1.5Q
-X311b.B -X311b.S
=K =K 3 =K
=K
+K4 +K4 +K3
+K4 =K
-S46X1
-S46a -S9a
-S46X2
1 -S300b
-S9X1 +K3
9
1
9
1
1
0 0 0
1 9 1 9 -S300.X2 9 5 1 -S300.X1
=K =K
1 0 +K4
1 0 0 1 2 =K
D +K4 1 -S300.B D
-S9 2 +K3
-S46
-S300
7026343 5
forbidden.
5 10 5 10 10 3
-S300.X2 -S300.X1
-S9X1
5
10
-S46X1 -S46X2 4
5
10
10
3
+K3
+K4 +K4
=K
=K =K 6
=K BK 1.5Q
+K2 =K
1
-R11X1
+K3
1
=K -H22.X1
1
+K2 =K 1
E -R11 E
+K3
-H22
2
M
-R11X2
1
+K2 2
=K -H22.X2
1
BK 2.5Q
+K3
BK 1.5Q
=K
BK 1.5Q
=K
+K4
6 2 7
F -MP6_d -MP7_b -MP6_c F
TYPE: ab: 8924766

bis: 8921847 LIEBHERR WARNING BEACON ; REAR WINDOW HEATER SIDE: 26 61
1 2 3 4 5 6 7 8
1 2 3 4 5 6 7 8
A CAN: CAN: CAN: CAN: CAN: CAN: CAN: A

/41.C5 SUPPLY /41.D5 SUPPLY /41.D5 SUPPLY /41.D5 SUPPLY /41.D5 SUPPLY /41.D5 SUPPLY /41.D5 SUPPLY
-A700 PLUS KL.30 -A700 PLUS KL.30 -A700 PLUS KL.30 -A700 PLUS KL.30 -A700 EARTH -A700 EARTH -A700 EARTH
+M +M +M +M +M +M +M
=M A700.41 =M A700.44 =M A700.45 =M A700.48 =M A700.42 =M A700.43 =M A700.46
X1 L1 X1 L4 X1 M1 X1 M4 X1 L2 X1 L3 X1 M2
1356 00090 01 00 001
-A700X1 -A700X1 -A700X1 -A700X1 -A700X1 -A700X1 -A700X1
L1
M1
L4
M4
L2
L3
M2
+M +M +M +M +M +M +M
=M =M =M =M =M =M =M
93014064_001
93014064
RD 2Q
RD 2Q
RD 2Q
RD 2Q
B B
BK 2Q
BK 2Q
BK 2Q
-X89
Kl. 30 -X90
E
=K
+K2
RD 2.5Q
RD 2.5Q
C -F37 A C
20A
=K =K =K =K =K
+K6 +K6 +K6 +K6 +K6

24
25
34
35
36
-X1.B -X1.B -X1.B -X1.B -X1.B
-X1.S -X1.S -X1.S -X1.S -X1.S

24
25
34
35
36
+K6 +K6 +K6 +K6 +K6
X40.7
X40.8
=K GND =K =K =K =K
D D
7
-X40 -X40
+K2 +K2
forbidden.
=K =K
BU 2.5Q
BU 2.5Q
BU 2.5Q
RD 2.5Q
RD 2.5Q
E E
=K =K =K
+K4 +K4 +K4
3 -MP6_d 4 -MP6_d 5 -MP6_d
F F
TYPE: ab: 8924766

bis: 8921847 LIEBHERR SUPPLY ENGINE CONTROL UNIT SIDE: 27 61
1 2 3 4 5 6 7 8
1 2 3 4 5 6 7 8
CAN: CAN: CAN: CAN: CAN:

SELECTION /41.B2 SPEED-PEDAL /41.B2 SPEED-PEDAL /41.D2 SELECTION /41.B5 SWITCH ON /41.D2
PLUS 1 -A700 ANALOG 1 -A700 ANALOG 2 -A700 PLUS 2 -A700 COOLING WATER LEVEL -A700
/20.D7
A +M +M +M +M +M A
A700.3 =M A700.4 =M A700.23 =M A700.26 =M A700.21 =M
-A700X1 A3 X1 -A700X1A4 X1 -A700X1F3 X1 -A700X1 G2 X1 F1 X1
Kl.15
+M =H +M +M +M =M -A700X1
F1
A3
A4
F3
G2
=M +H2 =M 0.75Q =M =M +M +M
-X93 -X94 -X95 -X88 =M
1356 00090 01 00 001
RD 1Q
WH 0.75Q
BU 1Q
RD 1Q
BU 1Q
=K =K =K =K
+K6 +K6 +K6 +K6
41
40
38
39
-X1.B -X1.B -X1.B -X1.B
93014064_001
-X1.S -X1.S -X1.S -X1.S =M =K
41
38
39
40
+M +K6
93014064
+K6 +K6 +K6 +K6
59
B -X98 -X1.S B
=K =K =K =K
BU 1Q BU 1Q -X1.B
59
RD 1Q RD 1Q +K6
WH 1.5Q
=K
=K =K =H
+K6 +K6 +H
-R5.X -B13.X
1
-R5.X
C
A
D
F
C =H 1
C D F A
C
+
0-5V
signal signal
+ +H
=K 0-5V
-B13
+K6
A A
-R5 ° °
- 0°-360° 0°-360° -
2
B
E
-B13.X
2
-R5.X E -R5.X
B
+H
+K6 +K6
=K =K =H
D D
BK 1Q
BK 1Q
forbidden.
=K =K
+K6 +K6
44
45
-X1.S -X1.S
-X1.B -X1.B
44
45
-X96
-X97
WH 0.75Q
WH 0.75Q
E E
=M =M
+M +M
G3
C3
-A700X1 -A700X1
X1 C3 X1 G3 WH 1.5Q
=M A700.11 =M A700.27
+M +M
-A700 EARTH 1 -A700 EARTH 2
/41.C2 SELECTION /41.B5 SELECTION
CAN: CAN:
F F
TYPE: ab:
bis: 0 LIEBHERR SPEED-PEDAL ; COOLING WATER LEVEL SIDE: 28 61
1 2 3 4 5 6 7 8
1 2 3 4 5 6 7 8
/30.A4
CAN:
OUTLET (5A) /40.C5
-A6.B
WORKING HYDRAULICS LOCKOUT
DA15_AHS +K2 WH 1.5Q
/30.A3
A A6.B.DA15 =K A
39 X4 WH 1.5Q WH 1.5Q
/31.C3
-A6.BX4
39
NOT APPLICABLE
+K2 =K =K =K
=K +K4 +K4 +K4
WH 1.5Q
WH 1.5Q
WH 1.5Q
WH 1.5Q
WH 1.5Q
-S22a -S14a -S18a
-OLE4
1356 00090 01 00 001
0 0 0
=K =K =K
+K4 +K4 +K4
-S18X2
=K -S22X1 -S22X2 -S14X1 -S14X2 -S18X1
9
1
1
93014064_001
+K2 1 9 1 9 1 9
=K =K =K
10
-X49 -X49 -X49 -X49 -X49 -X49
4
8
5
1
93014064
1 0 1 0 1 0
B +K4 +K4 +K4 B
#56328
-S22 -S14 -S18
X49.10
X49.1
X49.8
X49.3
X49.4
X49.5
5 10 5 10 5 10
-S22X1
/51.B7
-S22X2 -S14X1 -S14X2 -S18X1
10
10
10
+K4 -S18X2
=K +K4 +K4
=K =K
BK 1.5Q BK 1.5Q
/31.E3
30 86 30 86
BK 1.5Q
=K /30.C3
=K
C +K2 +K2 C
-K15 -K18
V56
V55
87a 87 85 87a 87 85
=K =K =K
+K6 +K6 +K6

51
46
50
53
GND GND -X1.S -X1.S -X1.S
-X1.B -X1.B -X1.B
51
50
46
53
+K6 +K6 +K6
=K =K =K
X49.2
X49.7
X49.6
-V26 -V27 -V28
MP MP MP
D D
1
-X49 -X49 -X49 -B17X.S
2
6
+K2 +K2 +K2 =V
-B17X.B
1 1
=K =K =K =K +V2
1
forbidden.
33 +K6 -B17.X -B15X

1 1
-X1.S =V + =V +
WH 1.5Q
WH 1.5Q
WH 1.5Q
-X1.B +V1 +V2

33
+K6 -B17 -B15

=K =K
+K4 =H
Ö 2 - Ö 2 -
2
3
1
-X33X +H3 3 3
-B17.X -B15X
-Y14.X
3
=K
1
1 2 3 +V2
=H
WH 1Q
BK 1Q
+K4 1
3
+H3 -B17X.B =V
-X33 Y9 Y17 Y18 -Y14
E -B17X.S E
3
0 0 +V1
4 5 6
2
WH 1.5Q
-X33X -Y14.X =V
WH 1Q
WH 1Q
BK 1Q
BK 1Q
4
+K4
=K
=H
BK 1.5Q
BK 1.5Q
BK 1.5Q
+H2
-MP1_d 4 9 2
=K -MP1_a -MP1_b
+K4 2 5 3
-MP6_c -MP6_c -MP6_c
F F
TYPE: ab: 8924766

bis: 8921847 LIEBHERR BUCKET RETURN-TO-DIG ; FLOAT POSITION SIDE: 29 61
1 2 3 4 5 6 7 8
F
E
A
D
93014064_001
TYPE:
1
1
ab:
=K
-S23
+K2
=K
-S23a
+K1
bis: 0
2
2
0
=K
-K232
+K2
1 0 2
87a
=K
+K2
-S23.X1
=K
+K2
-S23.X1
1
WH 1.5Q 1
87
30
3
3
7
=K
-MP6_i
+K2
85
86
BK 1.5Q BK 1.5Q WH 1.5Q
/20.D4 /20.D4
1
BK 1.5Q 9 10 WH 1.5Q
10
/29.C7 /29.A7
9 -S23.X2
-S23.X2
0
=K
-V202
+K2
=K
+K2
-K231
WH 1.5Q
WH 1.5Q
3
3
WH,WH 1.5Q,1.5Q
87a
=K
+K2
-V201
WH 1.5Q
87
30
1
=K
=K
-MP6_i
+K2
-V200
+K2
85
86
BK 1.5Q WH 1.5Q
1
2
2
5A
=K
+K2
-F1
=K
-X44
+K2
WH 1.5Q 6 X44.6 X44.5 WH,WH 1.5Q,1.5Q

/29.A3
A
E
5
=K
4
4
+K2
-X44
0
=V
-Y53
+V1
GND
WH 1.5Q
-Y53X
-V90
-Y53X
=K
=K
F1-R1
+K6
-X54
-X1.S
+K2
2
1
BK 1.5Q 49 4 X54.4 X54.1
BISCHOFSHOFEN
2 1 49 1
LIEBHERR
=K
=K
+K6
+K2
-X54
-X1.B
=H
3 -MP1_b
+H2
0
=V
-Y53a
+V1
WH 1.5Q
WH 1.5Q
5
5
-Y53a.X
-Y53a.X
=K
+K6
-X2.S
2
BK 1.5Q 1 42
2 1 42
=K
+K6
-X2.B
=K
+K4
-X82
48 WH,WH 1.5Q,1.5Q
1 -MP1_b
+H2
=H
=K
+K6
-X1.S
=K
/40.D2
+K2
-A6.B
WH 1.5Q
=K
+K4
-H41
WH 1.5Q
6
6
=K
4
-A6.BX4
+K2
CAN:
BK 1.5Q
1
INPUT
X4 21
21
2
A6.B.DE09
=K
DE09_Buzzer
+K4
BUZZER SIGNAL
-MP6_c
QUICK-CHANGE DEVICE
7
7
SIDE:
DATE:
30
8
8
14.03.2013 13:56
61
F
E
A
D
1 2 3 4 5 6 7 8
CAN: CAN: CAN: CAN:

INPUT /40.D2 DIGTAL OUTPUT /40.C5 OUTLET (3A) /40.C2 OUTLET (3A) /40.C2
A -A6.B
PUSH-BUTTON SWITCH FAN REVERSAL FAN REVERSAL -A6.B PARKING BRAKE -A6.B RIDE CONTROL -A6.B A
DE16_FanReverse +K2 DA06_FanReverse +K2 DA12_FNRparkbreak +K2 DA13_LFD +K2
A6.B.DE16 =K A6.B.DA06 =K A6.B.DA12 =K A6.B.DA13 =K
23 X4 37 X4 7 X4 9 X4
-A6.BX4 -A6.BX4 -A6.BX4 -A6.BX4
23
37
9
+K2 +K2 +K2 +K2
1356 00090 01 00 001
=K =K =K =K
93014064_001
WH 1.5Q
WH 1.5Q
WH 1.5Q
WH 1.5Q
93014064
B B
=K =K =K
+K6 +K6 +K6
43
56
57
-X1.S -X1.S -X1.S
-X1.B -X1.B -X1.B
43
56
57
+K6 +K6 +K6
/20.D5 =K =K =K
/29.A7
/16.A8
C C
WH 1.5Q
Kl.15
WH 1.5Q
WH 1.5Q
=K
+K4
-S203a
0
=K =K
+K4 =H =H =V
+K4
-S203.X2 +H +H +V1
-S203.X1
5
-Y50.X -Y10X -Y20X

1
1
=K 5 9 =H =V
=H 1 +H 1 +V1 1
+K4 0 1 -Y10 -Y20
+H
D -S203 D
-Y50 0 0
2 2
2 -Y10X -Y20X
2
1 10
forbidden.
-Y50.X +H +V1
2
-S203.X1 -S203.X2
1
10
+H =H =V
+K4 +K4
=H
=K =K
BK 1.5Q
BK 1.5Q
BK 1.5Q
E E
/29.C7
/16.B8
=H =H =H
+H2 +H2 +H2
-MP1_c 2 -MP1_c 3 -MP1_d 1
F F
TYPE: ab: 8924766

bis: 8921847 LIEBHERR FAN REVERSAL ; RIDE CONTROL SIDE: 31 61
1 2 3 4 5 6 7 8
1 2 3 4 5 6 7 8
A A
CAN: CAN: CAN: CAN: CAN:
INPUT /39.B5 EARTH /39.C5 INPUT /39.C2 SPEED /39.C2 SWITCH ON /41.C2
/20.D7
HYDRAULIC OIL TEMPERATURE-A6.A HYDRAULIC OIL TEMPERATURE-A6.A SPEED OUTPUT -A6.A ENGINE 2 -A6.A AIR FILTER CONTAMINATION -A700
E4_HydrOilTemp +K2 +K2 UDE0_MachineSpeed +K2 UDE1_Mot2 +K2 +M
A6.A.E4 =K A6.A.E4_GND =K A6.A.UDE0 =K A6.A.UDE1 =K A700.17 =M
Kl.15
1356 00090 01 00 001
26 X3 36 X3 5 X3 15 X3 E1 X1
-A6.AX3 -A6.AX3 -A6.AX3 -A6.AX3 -A700X1
E1
26
36
15
+K2 +K2 +K2 9 -MP6_d +K2 10 -MP6_c +M
93014064_001
=K =K =K +K4 =K +K4 =M
=K =K
WH 0.75Q
WH 1.5Q
WH 1.5Q
WH 1.5Q
93014064
RD 1Q
BU 1Q
RD 1Q
BU 1Q
B B
=K =K =K =K =K =K =K
+K6 +K6 +K6 +K6 +K6 +K6 +K6
61
62
64
63
66
65
60
-X1.S -X1.S -X1.S -X1.S -X1.S -X1.S -X1.S
-X1.B -X1.B -X1.B -X1.B -X1.B -X1.B -X1.B
61
62
64
63
66
65
60
+K6 +K6 +K6 +K6 +K6 +K6 +K6
=K =K =K =K =K =K =K
C C
WH 1.5Q
WH 1.5Q
RD 1Q
BU 1Q
RD 1Q
BU 1Q
=M
+M
-X99
WH 1.5Q
WH 1.5Q
D D
forbidden.
=H =H
+H4 =H =H +H3
-B4X
1
-B8X +H4 +H4
1
=H 1
1 =H -B1X =H -B2X
1
1
=H +H3
+H4 +H4 1 +H4 1
-B4 P
-B8 °C -B1 -B2
0 0 2
2 2 2
-B4X
2
-B8X -B1X -B2X
2
2
E +H4 +H4 +H4 +H3 E
=H =H =H =H
F F
TYPE: ab: 8924766

bis: 8921847 LIEBHERR TEMPERATURE AND SPEED SENSORS SIDE: 32 61
1 2 3 4 5 6 7 8
1 2 3 4 5 6 7 8
A A
CAN: CAN: CAN: CAN: CAN: CAN:
OUTLET 3A /40.D2 MODULATION /40.C5 PWM (0-3A) /40.C2 OUTLET (2A) /40.C5 PWM (0-3A) /40.C2 PWM (0-3A) /40.B5
RESERVE -A6.B COUPLING -A6.B ENGINE 2 EP -A6.B ENGINE 1 Q MAX -A6.B TRAVEL PUMP EP -A6.B VENTILATOR -A6.B
DA11_Reserve +K2 DA16_Modulation +K2 PWM1_Mot2 +K2 DA02_HydraulicEngine +K2 PWM0_Pump +K2 PWM2_Fan +K2
A6.B.DA11 =K A6.B.DA16 =K A6.B.PA1 =K A6.B.DA02 =K A6.B.PA0 =K A6.B.PA2 =K
1356 00090 01 00 001
18 X4 38 X4 15 X4 29 X4 5 X4 25 X4
-A6.BX4 -A6.BX4 -A6.BX4 -A6.BX4 -A6.BX4 -A6.BX4
18
38
15
29
25
+K2 +K2 +K2 +K2 +K2 +K2
93014064_001
=K =K =K =K =K =K
93014064
B B
WH 1.5Q
WH 1.5Q
WH 1.5Q
WH 1.5Q
WH 1.5Q
WH 1.5Q
=K =K =K =K =K =K
+K6 +K6 +K6 +K6 +K6 +K6
69
70
4
3
1
-X1.S -X1.S -X2.S -X2.S -X2.S -X2.S
-X1.B -X2.B -X2.B -X2.B -X2.B
1
70
4
+K6 +K6 +K6 +K6 +K6
C =K =K =K =K =K C
WH 1.5Q
WH 1.5Q
WH 1.5Q
WH 1.5Q
WH 1.5Q
D =H =H =H =H =H D
+H5 +H +H +H +H
-Y60.X -Y57X -Y58X -Y59.X -Y13.X
1
1
=H =H =H =H =H
forbidden.
+H5 1 +H 1 +H 1 +H 1 +H 1
-Y60 -Y57 -Y58 -Y59 -Y13
0 0 0 0 0
2 2 2 2 2
-Y60.X -Y57X -Y58X -Y59.X -Y13.X
2
2
+H5 +H +H +H +H
=H =H =H =H =H
BK 1.5Q
BK 1.5Q
BK 1.5Q
BK 1.5Q
BK 1.5Q
E E
=H =H =H =H =H
+H2 +H2 +H2 +H2 +H2
-MP1_b 6 -MP1_b 8 -MP1_b 10 -MP1_b 9 -MP1_c 1
F F
TYPE: ab: 8924766

bis: 8921847 LIEBHERR COUPLING ; HYDRAULIC MOTOR ; TRAVEL PUMP SIDE: 33 61
1 2 3 4 5 6 7 8
1 2 3 4 5 6 7 8
A A
CAN: CAN: CAN: CAN: KL. 15 KL. 15

1356 00090 01 00 001
OUTLET (2A) /40.D2 PRESSURE SWITCH /39.B2 PRESSURE SWITCH /39.C2 PUSH-BUTTON SWITCH /40.C2
EMERGENCY STEERING PUMP -A6.B MAIN CIRCUIT NLP -A6.A CHECK NLP -A6.A EMERGENCY STEERING PUMP -A6.B
/20.D7
/20.D7
/13.F6
DA01_NLP +K2 AD0_1_NLPmainPS +K2 AD1_1_NLPcheckPS +K2 DE15_Notlenkpumpe +K2
=K =K =K =K E
93014064_001
A6.B.DA01 A6.A.DAE0 A6.A.DAE1 A6.B.DE15

=K
17 X4 3 X3 13 X3 13 X4
+K2
Kl.15
Kl.15
93014064
-A6.BX4 -A6.AX3 -A6.AX3 -A6.BX4

17
13
13
B -F13 B
+K2 +K2 +K2 +K2 A
10A
=K =K =K =K
=K =K =K =K =K
+K6 +K6 +K6 +K6 +K6
16
5
7
-X2.S -X2.S -X2.S -X2.S -X2.S
-X2.B -X2.B -X2.B -X2.B -X2.B
5
16
X58.6
WH 1.5Q
+K6 +K6 +K6 +K6 +K6 GND
=K =K =K =K =K
C C
-X58
6
+K2
=K
WH 1.5Q
WH 1.5Q
WH 1.5Q
WH 1.5Q
WH 1.5Q
WH 1.5Q
WH 1.5Q
RD 50Q
RD 50Q
-S10.X2
=K
+K2
D -S10.X1 D
9
=K 5 9
+K2
forbidden.
0 1
=H =H -S10
+H4 +H4
-B3.X -B3a.X
C
C
rt 1 10
C C =K
50 30.2 =H
sw sw
-S10.X1
1
=H =H
10
+ s s +K2
+H4 =H +H4 +H4 +K2
-S10.X2
-S10a
M UP UP
-K011 +H4 =K
-B3 -B3a 0
-M8 - + - +
0 - bl bn bl bn
E 31 30.1 B A B A E
-B3.X -B3a.X
B
B
A
A
sw
BK 1.5Q
+H4 +H4
=H =H
BK 1.5Q
BK 1.5Q
BK 50Q
=H =H =H =H =K
+H2 +H4 +H2 +H2 +K4
-MP1_d 3 1 -MP5_a -MP1_d 9 -MP1_d 10 10 -MP6_d
F F
TYPE: ab: 8924766

bis: 8921847 LIEBHERR EMERGENCY STEERING PUMP ; PRESSURE SWITCH EMERGENCY STEERING PUMP SIDE: 34 61
1 2 3 4 5 6 7 8
F
E
A
D
93014064_001
TYPE:
1
1
2
2
bis: 8921847
ab: 8924766
Kl. 30
=K
-F35
10A
+K2
10 X42.10
A
E
=K
+K2
-X42
GND
=K
+K2
=K
+K4
-M200
-K209
3
3
=K
+K2
-X51
5 X51.5 X51.7
M
1
7
87a 87
30
=K
+K2
-X51
=K
+K2
-X51
X51.6 Kl.15
/17.D7
6
85
86
GND
V54
4
4
BISCHOFSHOFEN
LIEBHERR
5
5
=K
-R6a
+K3
-R6a.X
=K
+K3
=K
-R6a.X
+K3
=K
-MP6_o
+K2
BK 2.5Q
2
1
1
2 1
WH 2.5Q
=K
-R6b
+K3
=K
-R6b.X
+K3
-R6b.X
=K
+K3
=K
-MP6_o
+K2
BK 2.5Q 1
X47.1
=K
6
6
+K2
-K10
2
1
2 1
=K
+K2
-X47
2 X47.2
87a 87
30
=K
+K2
-X47
OPTION MIRROR HEATING

=K
-X47
+K2
X47.4 WH 1.5Q
/26.A2
4
85
86
GND
V57
DUST FILTER EXCESS PRESSURE SYSTEM
=K
-F74
+K2
7
7
15A
A
E
KL. 15
GND
SIDE:
DATE:
WH 2.5Q
/26.A1
35
8
8
14.03.2013 13:56
61
F
E
A
D
F
E
A
D
93014064_001
TYPE:
1
1
=K
-F19a
+K2
15A
Kl. 30
X40.4
A
E
GND
2
2
X42.5
=K
-F28
+K2
10A
X42.6
bis: 8921847
ab: 8924766
A
E
GND
X40.1
=K
-F36
+K2
A
E
X40.2
3
3
GND
5A
=K
-F39
+K2
X41.7
A
E
X41.8
GND
=K
4
4
+K2
-F41
10A
X41.11
A
E
GND
BISCHOFSHOFEN
LIEBHERR
Kl. 30
=K
-K229
+K2
49
49a
5
5
X55.3 X55.2
X55.1
C
31
31
49a
=K
-K230
+K2
49
X47.7 X47.11
X47.9
X47.3
X47.5
6
6
15
87
30
87a
31
=K
0
-K270
+K2
NOT USED FUSES / RELAY
CAN LOW X54.5

X54.10 CAN LOW 120Ohm
1
Antenne1 High Side

X54.8
2
X54.11 +Ub CAN HIGH

X54.9
3
GND
Antenne 2
7
7
n.c.
X54.7
5
GND
X54.3
SIDE:
DATE:
X54.12
7
1
X54.6
2
5
36
9
3
8
8
14.03.2013 13:56
61
F
E
A
D
1 2 3 4 5 6 7 8
=H
+H
-X97
A A
=K =K CAN: CAN: CAN:
+K2 +K2 OUTLET (2A) /40.B5 CENTRAL LUBRICATION SYSTEM/39.C2 CENTRAL LUBRICATION SYSTEM/39.D2
-X48 -X48 -A6.A -A6.A
6
CENTRAL LUBRICATION SYSTEM-A6.B CYCLE SIGNAL LEVEL
DA03_OPT_CentralLuric +K2 AE5_CLUTacts +K2 AE6_CLULevel +K2
=K =K
WH 1.5Q
A6.B.DA03 =K A6.A.DAE5 A6.A.DAE6
1356 00090 01 00 001
27 X4 14 X3 24 X3
X48.9
X48.6
-A6.AX3 -A6.AX3
14
24
-A6.BX4
27
WH 1.5Q
WH 1.5Q
WH 1.5Q
+K2 +K2 +K2
93014064_001
KL. 15 =K =K =K
93014064
WH 1.5Q
B =H B
WH 1.5Q
=H
+H3 +H3
-B43.X
A
30 86
-B44.X
A
A
=K =K E A
+K2 +K2 =K =K =K
-K245 -F73 +K6 +K6 =H +K6
17
18
1 =H 1
20
V49
87a 87 85 A -X2.B -X2.S +H3 + 2 -X2.S + 2
10A +H3
-X2.S -X2.B -B43 -X2.B
17
18
-B44
20
GND +K6 +K6 +K6
=K =K 0 =K 0
-V34 -V35 S - S -
4 3 4 3
WH 1.5Q
WH 1.5Q
C MP MP C
WH 1.5Q
C B C B
X41.10
-B43.X
B
-B44.X
B
X48.7
X48.5
+H3
GND
+H3
=H =H
-X48 -X41
5
10
+K2 +K2
=K =K
=K
+K6
19
D -X2.S D
-X2.B
19
+K6
forbidden.
=K
BK 1.5Q
BK 1.5Q
WH,WH 1.5Q,1.5Q
1 4
WH 1.5Q
=H
M
+H3
-M6
E E
0
2 3
-M6X
2
+H3
BK 1.5Q
=H
=H =H =H
+H2 +H2 +H2
-MP1_d 7 -MP1_d 5 -MP1_d 6
F F
TYPE: ab: 8924766

bis: 8921847 LIEBHERR CENTRAL LUBRICATION SYSTEM SIDE: 37 61
1 2 3 4 5 6 7 8
1 2 3 4 5 6 7 8
MAIN KEYPAD
A A
CAN: CAN:
/21.E1
/21.E2
=K CAN BUS /39.D2 CAN BUS /39.C5
+K4 HIGH1 -A6.A LOW1 -A6.A
-A11 +K2 +K2
1356 00090 01 00 001
=K =K
CAN_HIGH
CAN_LOW
A6.A.CAN1H A6.A.CAN1L
Phys. Addr. TYP BLATT BESCHREIBUNG STECKER PIN 21 X3 31 X3
93014064_001
-A6.AX3 -A6.AX3
21
31
A11.Kl15 /26.A8 VOLTAGE SUPPLY X1 1 +K2 +K2
93014064
A11.GND /38.D2 EARTH SUPPLY X1 2 =K =K

B B
A11.CAN_High /38.D8 HIGH CAN BUS X1 3
BU 0.5Q
RD 0.5Q
A11.CAN_Low /38.D7 LOW CAN BUS X1 4
A11.Kl15 VOLTAGE SUPPLY X1 5

A11.GND EARTH SUPPLY X1 6
A11.CAN_High /38.C8 HIGH CAN BUS X1 7 =K =K

+K4 +K4
A11.CAN_Low /38.C7 LOW CAN BUS X1 8
-A11X1 -A11X1
7
A11.CAN_RES. MATCHING RESISTOR CAN BUS X1 9 X1 8 X1 7
C =K A11.CAN_Low =K A11.CAN_High C
A11.Res. NOT USED X1 10
+K4 +K4
A11.Res. NOT USED X1 11 LOW HIGH
RD 1.5Q
BU 1.5Q
-A11 -A11
A11.Res. NOT USED X1 12 /38.C2 CAN BUS /38.C2 CAN BUS

CAN: CAN:
CAN: CAN:
CAN BUS /38.B2 CAN BUS /38.B2
LOW -A11 HIGH -A11
+K4 +K4
A11.CAN_Low =K A11.CAN_High =K
4 X1 3 X1
D D
-A11X1 -A11X1
3
+K4 +K4
=K =K
forbidden.
CAN:
SUPPLY /38.B2
EARTH -A11
+K4
=K
A11.GND
2 X1
-A11X1
2
E +K4 E
=K
BK 1.5Q
=K
+K4
-MP6_d 1
F F
TYPE: ab: 8924766

bis: 8921847 LIEBHERR MAIN KEYPAD SIDE: 38 61
1 2 3 4 5 6 7 8
1 2 3 4 5 6 7 8
CENTRAL CONTROL UEC 3 X3

A A
1356 00090 01 00 001
=K -A6.A Modul Nr.:

93014064_001
+K2 Modulname: 8920505_A

93014064
B B
Phys. Adr. Blatt EA Beschreibung Stecker Pin Phys. Adr. Blatt EA Beschreibung Stecker Pin
A6.A.TxD /21.A8 RS-232 UEC3 DIAGNOSTIC PLUG 1 A6.A.VCC_EXT SUPPLY SENSORS OUTLET 200mA 5V 25
A6.A.BSL_C2 /21.A6 BOOTSTRAP PIN = EARTH 2 A6.A.E4 /32.A2 HYDRAULIC OIL TEMPERATURE INPUT 26
A6.A.DAE0 /34.B4 MAIN CIRCUIT NLP PRESSURE SWITCH 3 A6.A.E6 RESERVE INPUT 27
A6.A.DAE4 /25.A6 SERVICE BRAKE PRESSURE SWITCH 4 A6.A.E2 /20.A7 TANK PIPE SENSOR INPUT 28
A6.A.UDE0 /32.A4 SPEED OUTPUT INPUT 5 A6.A.DE03 /20.A2 BACKWARDS NC INPUT 29
A6.A.E3 RESERVE INPUT 6 A6.A.+27VDC_1 /21.F4 VOLTAGE 1 UEC3 SUPPLY 30
A6.A.E5 /25.A7 RESERVE INPUT 7 A6.A.CAN1L /38.A7 LOW1 CAN BUS 31
A6.A.E0 /22.A5 INCH ANGLE SENSOR 1 CURRENT INPUT 8 A6.A.CAN2L /21.A5 LOW2 CAN BUS 32
A6.A.DE06 /51.A6 INDUCTIVE SWITCH OPTION 9 A6.A.DAE3 /23.A7 RESERVE INPUT 33

C C
A6.A.DE05 /20.A1 BACKWARDS NO INPUT 10 A6.A.DAE7 /43.A2 AIR CONDITIONING COMPRESSOR ACTIVE 34
A6.A.RxD /21.A7 RS-232 UEC3 DIAGNOSTIC PLUG 11 A6.A.SGND SUPPLY SENSORS EARTH 35
A6.A /21.A7 RS-232 UEC3 DIAGNOSTIC PLUG 12 A6.A.E4_GND /32.A3 HYDRAULIC OIL TEMPERATURE EARTH 36
A6.A.DAE1 /34.B6 CHECK NLP PRESSURE SWITCH 13 A6.A.E6_GND /20.D6 EARTH TANK PIPE SENSOR SUPPLY 37
A6.A.DAE5 /37.A6 CYCLE SIGNAL CENTRAL LUBRICATION SYSTEM 14 A6.A.DE00 /20.A6 SIGNAL CLAMP 15 INPUT 38
A6.A.UDE1 /32.A5 ENGINE 2 SPEED 15 A6.A.DE04 /20.A4 FORWARD NO INPUT 39
A6.A.E3_GND EARTH RESERVE SUPPLY 16 A6.A.SGND /23.A7 EARTH UEC3 SUPPLY 40
A6.A.E5_GND EARTH RESERVE SUPPLY 17

A6.A.E1 /22.A4 INCH ANGLE SENSOR 2 CURRENT INPUT 18
A6.A.DE02 /20.A3 FORWARD NC INPUT 19
A6.A.DE01 RESERVE INPUT 20
D A6.A.CAN1H /38.A6 HIGH1 CAN BUS 21 D
A6.A /21.A4 HIGH2 CAN BUS 22
A6.A.DAE2 /55.A5 COUPLING PRESSURE LIMITATION 23
forbidden.
A6.A.DAE6 /37.A7 LEVEL CENTRAL LUBRICATION SYSTEM 24

E E
F F
TYPE: ab: 8924766

bis: 8921847 LIEBHERR CENTRAL CONTROL UEC3 X3 SIDE: 39 61
1 2 3 4 5 6 7 8
1 2 3 4 5 6 7 8
CENTRAL CONTROL UEC 3 X4

A A
1356 00090 01 00 001
=K -A6.B Modul Nr.:

+K2 Modulname: 8920505_B
93014064_001
93014064
B Phys. Adr. Blatt EA Beschreibung Stecker Pin Phys. Adr. Blatt EA Beschreibung Stecker Pin B
A6.B.DE07 /16.A5 DISPLAY INDICATOR INPUT 1 A6.B.PA2 /33.A7 VENTILATOR PWM (0-3A) 25
A6.B.DE10 WORKING BASKET MODUS 1 2 A6.B.DA05 RESERVE OUTLET (3A) 26
A6.B.DE14 /20.B4 PUSH-BUTTON SWITCH OPTION 3 INPUT 3 A6.B.DA03 /37.A5 CENTRAL LUBRICATION SYSTEM OUTLET (2A) 27
A6.B.DE18 WORKING BASKET NOT OFF 2 4 A6.B.DA00 /23.A8 BUZZER OUTLET (2A) 28
A6.B.PA0 /33.A6 TRAVEL PUMP EP PWM (0-3A) 5 A6.B.DA02 /33.A5 ENGINE 1 Q MAX OUTLET (2A) 29
A6.B.+27VDC_3 /23.A5 VOLTAGE 3 UEC3 SUPPLY 6 A6.B.DA14 /15.A4 BACKWARDS (6A) TRAVELLING DIRECTION 30
A6.B.DA12 /31.A6 PARKING BRAKE OUTLET (3A) 7 A6.B.SGND /23.A6 EARTH UEC3 SUPPLY 31
A6.B.DA08 /20.A8 OPTION 2 OUTLET (3A) 8 A6.B.DE13 /20.B3 PUSH-BUTTON SWITCH OPTION 2 INPUT 32
A6.B.DA13 /31.A7 RIDE CONTROL OUTLET (3A) 9 A6.B.DE17 WORKING BASKET NOT OFF 1 33
A6.B.DA09 /20.A8 OPTION 3 OUTLET (3A) 10 A6.B.DE21 /14.A6 KL 61 CHARGE CONTROL GENERATOR D+ 34
C C
A6.B.DE08 /16.A6 DISPLAY HIGH BEAM INPUT 11 A6.B.+27VDC_2 /23.A4 VOLTAGE 2 UEC3 SUPPLY 35
A6.B.DE11 WORKING BASKET MODUS 2 12 A6.B.+27VDC_4 /25.A3 VOLTAGE 4 UEC3 SUPPLY 36
A6.B.DE15 /34.B7 EMERGENCY STEERING PUMP PUSH-BUTTON SWITCH 13 A6.B.DA06 /31.A4 FAN REVERSAL DIGTAL OUTPUT 37
A6.B.DE19 JOYSTICK STEERING ACTIVE 14 A6.B.DA16 /33.A3 COUPLING MODULATION 38

A6.B.PA1 /33.A4 ENGINE 2 EP PWM (0-3A) 15 A6.B.DA15 /29.A3 WORKING HYDRAULICS LOCKOUT OUTLET (5A) 39
A6.B.DA10 /15.A4 FORWARD (3A) TRAVELLING DIRECTION 16 A6.B.DA17 /16.D5 REVERSING LAMP OUTLET (5A) 40
A6.B.DA01 /34.B2 EMERGENCY STEERING PUMP OUTLET (2A) 17

A6.B.DA11 /33.A2 RESERVE OUTLET 3A 18
A6.B.DA04 RESERVE OUTLET (2A) 19
A6.B.DA07 /51.A3 OPTION 1 OUTLET (3A) 20
A6.B.DE09 /30.A6 BUZZER SIGNAL INPUT 21
D A6.B.DE12 /20.A5 PUSH-BUTTON SWITCH OPTION 1 INPUT 22 D
A6.B.DE16 /31.A2 PUSH-BUTTON SWITCH FAN REVERSAL INPUT 23
A6.B.DE20 RESERVE INPUT 24
forbidden.
E E
F F
TYPE: ab: 8924766

bis: 8921847 LIEBHERR CENTRAL CONTROL UEC3 X4 SIDE: 40 61
1 2 3 4 5 6 7 8
1 2 3 4 5 6 7 8
ENGINE CONTROL UNIT ( APPLIANCES SIDE )

A A
=M -A700 Modul Nr.:

1356 00090 01 00 001
+M Modulname: JD-ECU_STUFE 3
93014064_001
Phys. Adr. Blatt EA Beschreibung Stecker Pin F2 F3 EA G1 G2 G3

93014064
B A700.Can /21.A3 HIGH CAN BUS 0 A1 A700.25 Frequency 3 Frequency 3 0 G1 B

A700.2 5 FREE 0 A2 A700.26 /28.A5 PLUS 2 SELECTION 0 G2
A700.3 /28.A2 PLUS 1 SELECTION 0 A3 A700.27 /28.F4 EARTH 2 SELECTION 0 G3
A700.4 /28.A3 ANALOG 1 SPEED-PEDAL 0 A4 A700.28 15 PU750 ANALOG 0 G4
A700.5 /21.A2 LOW CAN BUS 0 B1 A700.29 FREQUENCY 2 0 H1
A700.6 /25.A2 INFO KL.15 ENGINE 0 B2 A700.30 FREQUENCY - 0 H2
A700.7 Switsch in 9 PD FREE 0 B3 A700.31 LOW CAN BUS 2 0 H3
A700.8 PU750 ANALOG 6 0 B4 A700.32 8 PD ANALOG 0 H4
0 J1
A700.9 SINK DRIVER 3 0 C1 A700.33 3 PU SWITCH ON
0 J2
A700.10 SINK DRIVER 1 0 C2 A700.34 6 PD SWITCH ON
0 J3
A700.11 /28.F3 EARTH 1 SELECTION 0 C3 A700.35 HIGH CAN BUS 2
0 J4
A700.12 2 PD ANALOG 0 C4 A700.36 5 PWM DRIVER 5
C 0 K1 C
A700.13 SINK PWM FREQUENCY OUT 0 D1 A700.37 8 PU SWITCH ON
0 K2
A700.14 SINK DRIVER 2 0 D2 A700.38 SCREEN CAN BUS
0 K3
A700.15 12 PU750 ANALOG 0 D3 A700.39 FREE

0 K4
A700.16 5PD SWITCH ON 0 D4 A700.40 PWM DRIVER 4
0 E1 0 L1
A700.17 /32.A7 AIR FILTER CONTAMINATION SWITCH ON A700.41 /27.A1 PLUS KL.30 SUPPLY
0 E2 0 L2
A700.18 FREE A700.42 /27.A5 EARTH SUPPLY
0 E3 0 L3
A700.19 7 PU SWITCH ON A700.43 /27.A6 EARTH SUPPLY
0 E4 0 L4
A700.20 10 PD SWITCH ON A700.44 /27.A2 PLUS KL.30 SUPPLY
0 F1 0 M1
A700.21 /28.A7 COOLING WATER LEVEL SWITCH ON A700.45 /27.A4 PLUS KL.30 SUPPLY
0 F2 0 M2
A700.22 PD SWITCH ON A700.46 /27.A7 EARTH SUPPLY
0 F3 0 M3
A700.23 /28.A4 ANALOG 2 SPEED-PEDAL A700.47 PWM DRIVER 7
D 0 F4 0 M4 D
A700.24 4 PD ANALOG A700.48 /27.A5 PLUS KL.30 SUPPLY
forbidden.
E E
F F
TYPE: ab: 8924766

bis: 8921847 LIEBHERR ENGINE CONTROL UNIT SIDE: 41 61
1 2 3 4 5 6 7 8
F
E
A
D
93014064_001
TYPE:
1
1
2
2
bis: 8921847
ab: 8924766
31
58
54
3
3
+V
=V
-X321b
WH,WH 1.5Q,1.5Q
WH,WH 1.5Q,1.5Q
BK,BK 1.5Q,1.5Q
-E4
+V1
=V
=V
H16
5 11 11
5
5 5
=V
=V
H51
4 12 12
4
4
5 4
4 4
=V
-MP1_a
+H2
=H
=V
=V
+V1
-E4X
H57
WH 1.5Q 3 14 14
=V
3
BK 1.5Q BK 1.5Q 1 3 3
=V
=V
4
1
1 1 WH 1.5Q 2 13 13
=V
+V1
H55
2 2
2
BISCHOFSHOFEN
=V
+K6
+K6
-E4.Xa
+V1
-E4X
+V1
=V
+V1
LIEBHERR
-E4.Xb
-X1.B
-X1.S
-E4.Xb
-E4.Xa
+V1
-E3
+V1
=V
+V1
=H
+K6
+K6
-MP1_a
+H2
-E3.Xb
-X1.B
-X1.S
2
=V
-E3X
+V1
=V
-E3.Xa
+V1
=V
+V1
-E3X
H54
WH 1.5Q 2 16 16
=V
1
BK 1.5Q BK 1.5Q 1 2 2
=V
=V
1 1
5
5
WH 1.5Q 3 15 15
=V
+V1
3 3
=V
-E3.Xa
=V
H56 H50
17 17
-E3.Xb
4
+V1
4 4
=V
5
=V
H15
5 18 18
5 5
=V
WH,WH 1.5Q,1.5Q
+V
=V
-X321a
6
6
BK,BK 1.5Q,1.5Q
WH,WH 1.5Q,1.5Q
54
58
31
COUNTRY-SPECIFIC TYPE/EXECUTION
GERMANY LUXEMBOURG SWITZERLAND
7
7
SIDE:
DATE:
42
8
8
14.03.2013 13:56
61
F
E
A
D
F
E
A
D
93014064_001
TYPE:
WH 2.5Q
1
1
=K
-A6.AX3
+K2
WH 2.5Q
34
34 X3
ACTIVE
A6.A.DAE7
CAN:
-Y22
+M
=M
AE7_CC01_Klimastr
-V42
X55.11
=K
+K2
MP
-K271
AIR CONDITIONING COMPRESSOR
=M
+M
=K
+K2
=K
-X55
+K2
X55.12 X55.10
/39.C5
-A6.A
-Y22.X
9 9 12 WH 2.5Q
10
87a 87
30
1
=K
=K
=K
MP
+K6
+K6
+K2
-X55
-X2.B
-X2.S
-V43
X55.9
2
2
=K
85
86
GND
-X55
+K2
V44 WH,WH 1.5Q,1.5Q

/14.B5
9
bis: 8921847
ab: 8924766
X48.10
=K
-V36
+K2
-K246
MP
=K
-X48
+K2
WH 2.5Q 11 X48.11 X48.12 WH 2.5Q

12
87a 87
30
=K
MP
+K2
-X48
=K
-X48
+K2
-V37
X48.8 WH 2.5Q
=K
+K
-X43a
8
85
86
/44.F2
GND
1 V48
3
3
=K
+K
-X43b
CABLE
INTERRUPT
/44.E2
1
-V23
20A
=K
-F14
+K2
MP
WH 2.5Q 1 X43.1
A
E
=K
+K2
-X43
KL. 15
GND
-B27
+H
=H
4
4
P
L
=K
=K
-B27X
-B27X
+K6
+K6
-X2.S
-X2.B
=H
+H
+H
=H
WH 2.5Q WH 2.5Q 34 34
N
3
36 36 2.5Q WH 4 3
=K
=K
+K6
+K6
H
-X2.B
-X2.S
BISCHOFSHOFEN
LIEBHERR
18bar
1
WH 2.5Q 2
BK 2.5Q
2
-MP6_d
WH 2.5Q
5
5
2
3
4
-X101.B
1
3
2
4
-A21
Kl.15
Kl.31
14 - nc.
COUPLING
13 - nc.
BLOWER SWITCH' 4
12 - nc.
NTC
11 - nc.
ELECTRONICS
1
4
Stufe4
ICE UP PROTECTION
6
6
10
Stufe3
9
Stufe2
8 - NTC
Stufe1 1
S4
0-1-2-3-4
7 - NTC
HEAT - AIR CONDITIONING SYSTEM
6 - NTC
SWITCH AIR CON 2
AC
5 - NTC
Kl.15 1
S1 4 - COUPLING
7
7
AC
3 - AC
PRINTED CIRCUIT BOARD 2 - nc.
1 - Kl.31
3
AC A1
SIDE:
DATE:
5 - Kl.31
Kl.31
4 - Stufe4
Kl.15 1
43
X2
3 - Stufe3
M
8
8
FAN MOTOR
CABLE INTERRUPT
2 - Stufe2
1 -X4a
/44.F3 /44.E3
CONTROL STAGE -X4b 1
1 - Stufe1
M1
14.03.2013 13:56
61
F
E
A
D
F
E
A
D
93014064_001
TYPE:
WH 1Q
1
1
+K
=K
-A202
=K
-MP6_s
+K2
+K
=K
-X9
BK 1Q WH,WH 1Q,1Q WH 1.5Q
H3
/24.A1
4
1
85
86
=K
P2
-MP6_s
+K2
=K
+K
-X9
BK 1Q
3
12
12
87
30
10
/43.F3
7
23:59
=K
+K
87a
-X9
H1
WH 2.5Q BK 1Q
/43.F3
ab:
4
2
4
bis: 0
2
2
+K
=K
0
+K
=K
-K214
-X9
11
11
WH 1Q
8
2
=K
-MP6_s
8
+K2
2
BK 1Q -X9
+K
5
85
86
=K
87
30
/43.B8
87a
3
3
WH 2.5Q
/43.C8
WH 1Q
WH 1Q
+K
=K
0
-K215
=K
+K
+K
=K
-X318.B
-X318.S
ws 0,75Q WH 1Q
4 4
sw 0,75Q 3 3 WH 1Q
=K
+K
+K
=K
RD 1Q
4
4
-X318.B
-X318.S
0
=M
+K
=K
-F201
5A
+M
4
3
-X8.ST2 RD 6Q
1
4
3
1
BISCHOFSHOFEN
-X3
LIEBHERR
+K
-A203
+M
=M
=K
11
+K
=K
-X8.ST2
-X318.B
-X318.S
1
br 2,5Q BK 2.5Q
9
9 2 2
=K
+K2
ge ge
10
5
5
-MP6_s
1
+K
=K
-X8.ST2
-X318.B
-X318.S
1
CONNECTION KL.30
rt 2,5Q
E
br rt
X2
12
12 1 1
2
12
br br
8
2
0
+K
=K
-F200
X4
M2
20A
=K
+K
+K
=K
-X318.B
-X318.S
sw sw RD 2.5Q RD 6Q
M
5
1
1
1
5 5
bl bl -X2
6
+K
1
=K
bl 0,75Q
X1
M1
br ws/bl
X10
6
7
6
2
-X8.ST2
+M
=M
1
Vi vi 1
2
1
THERMO 90 ST
2
AUXILIARY HEATER
B3
X6
Vi vi/bl
CONNECTION KL.30
11
-X8.ST2
gr gr
rt-ge 0,75Q
3
6
6
X6
B1
gr or
10
2
gn
7
7
or
9
-X8.ST2
-X318.B
1
0
gr 0,75Q
+K
=K
-F202
X5 7 8
B2
20A
gn gn RD 6Q
4
2
1
1
-X4
-X8.ST2
-X318.B
X1
vi 0,75Q +K
5
5 7 =K
X13
SIDE:
DATE:
Y1
bl
1
-X8.ST2
-X318.B
br gr-ws 0,75Q
2
2 6
44
CONNECTION KL.30
X5
8
8
RD 2.5Q
14.03.2013 13:56
61
F
E
A
D
1 2 3 4 5 6 7 8
SWITCH TOP:
A S9 S18 S14 S22 S45 S203 A
SYMBOL: SYMBOL: SYMBOL: SYMBOL: SYMBOL: SYMBOL:

1356 00090 01 00 001
6000848 6000861 6000849 6905269 6002120 6905923

93014064_001
SWITCH: SWITCH: SWITCH: SWITCH: SWITCH: SWITCH:

6905702 6905702 6905702 6905702 6905702 7027880
93014064
B B
SERIES
S4 S6 S7 S8 S13 S46 OPTION

C C
6000846 10801495 6000844 6000843 6002119 6905083,
SWITCH: SWITCH: SWITCH: SWITCH: SWITCH: SWITCH:

6004446 6905702 6905702 6905865 6905702
6905861
D D
SWITCH BOTTOM:
forbidden.
S23 S43 S58 S300 S10 H42 S301
R A

6905320 6905201 6905702 6905702 6905264 606760908 /
E E
10018876
SWITCH: SWITCH: SWITCH: SWITCH: SWITCH: SIGNAL -
10665273 6905928 6905702 6905702 7027880 SENSOR
6002138
SWITCH:
6905702
F F
TYPE: ab:
bis: 0 LIEBHERR LOG PUSHER SIDE: 45 61
1 2 3 4 5 6 7 8
F
E
A
D
93014064_001
TYPE:
0
0
0
-H59
-H57
-H58
=H
=H
=H
1
1
+H1
+H1
+H1
ab:
-H59.X
-H58.X
-H57.X
=H
=H
=H
+H1
+H1
+H1
bis: 0
2
2
1
1
1
ws
ws
ws
1 1 1
br
br
br
2
2
2
2 2 2
3
3
3
gn
gn
gn
3 3 3
WH 1Q
WH 1Q
WH 1Q
ge
ge
ge
BK 1Q
BK 1Q
BK 1Q
WH 1Q
WH 1Q
WH 1Q
-X306_A
+H5
=H
WH 1Q WH 1Q
3
3
-X306_C
WH 1Q WH 1Q
-X306_B
BK 1Q BK 1Q
#56158
/15.A6
WH 1Q
4
4
=K
=K
+K6
+K6
-X2.S
-X2.B
-X306.B
-X306.S
=H
+H
+H
=H
WH 1Q
44 44 1 1
BK 1Q
=K
-F46
+K2
3A
1 X42.8
BISCHOFSHOFEN
A
E
KL. 15
LIEBHERR
=K
+K2
-X306
=K
=K
+K6
+K6
-X2.S
-X2.B
-X306.B
-X306.S
=H
+H
+H
=H
BK 1Q
GND
43 43 2 2
WH 1Q
WH 1Q
WH 1Q
=K
-MP6_l
+K2
5
5
BK,BK 1Q,1Q
1
BK 1Q
WH 1Q
6
4
5
2
3
1
-X311c.B
6
6
FLASHING LIGHT
BACK-UP ALARM OPTICAL
6
4
5
2
3
7
7
6
4
5
2
3
1
-X311c.S1
-X311c.S2
SIDE:
DATE:
-S300_c
0
=K
-S300c
+K3
-S300.X2
-S300.X2 9
10 9
10
46
3 5
3
5
8
8
1
=K
+K3
=K
-S300.X1
+K3
0 1 2
7
1 -S300.X1
14.03.2013 13:56
61
F
E
A
D
F
E
A
D
93014064_001
TYPE:
1
1
ab:
bis: 0
2
2
-K04
+H5
=H
=M
-R701
+M1
*
WH 16Q RD 16Q
/13.F6
1
30.1
30.2 50
-MP1_c
+H2
=H
31
BK 1.5Q
3
3
10A
+H5
-F010
179
=H
WH 6Q
1
4
4
WH 1.5Q
WH 1.5Q
BISCHOFSHOFEN
LIEBHERR
C03
5
5
H4
A
H4 X2
PREHEAT
=M
+M
CONNECTION ZU UNIT
A700.X2.32
SELECTION
CAN:
-A700.X2
=M
+M
/61.C5
A A
-A700.
5429
=M
+M
+M
=M
6
6
-C03.B
-C03.S
B B A2
A
A2 X2
5413
PREHEAT
=M
+M
+M
=M
=M
+M
A700.X2.2 5
CAN:
PREHEAT ; INTERFACE ENGINE

-C03.B
-C03.S
ACKNOWLEDGEMENT
-A700.X2
=M
+M
/61.B2
/47.B5
C C
-A700.
5050
=M
+M
+M
=M
-C03.B
-C03.S
7
7
A
SIDE:
DATE:
=M
+M
-C02
B
47
=M
+M
-C02
8
8
=M
+M
-C06
C
1 5412
=M
+M
-C02
14.03.2013 13:56
61
F
E
A
D
F
E
A
D
93014064_001
TYPE:
1
1
ab:
bis: 0
2
2
3
3
=K
-S43
+K4
4
4
0 1
=K
+H5
+K4
-B16.X1.B
=H
-S43.X1
WH 1.5Q 32 32 WH 1.5Q
=K
=K
=K
+K4
+K6
+K6
-X2.S
-X2.B
1 7 WH 1.5Q WH 1.5Q 1
=K
=K
+K6
+K6
5
5 30 30
-X2.B
-X2.S
BISCHOFSHOFEN
=H
+H5
LIEBHERR
=K
=K
+K4
+K4
-S43.X2
-S43.X1 -S43.X2
WH 1.5Q
-B16.X1.S
10 9
10
#56157
=K+K4-S43.X2:9 /20.D7
-X43_8a
5
5
+K2
=K
=K
=K
+H5
+K6
+K6
-B16.X1.B
-X2.S
-X2.B
=H
+K
=K
BK 1.5Q -X307
BK 1.5Q 33 33 BK 1.5Q BK 1.5Q BK 1.5Q 2

2 31 31
=K
=K
=H
+K6
+K6
+H5
-X2.B
-X2.S
-B16.X1.S
/16.E6
/16.E6
6
6
CAN BE SWITCHED OFF

BACK-UP ALARM ACOUSTIC
7
7
SIDE:
DATE:
48
8
8
14.03.2013 13:56
61
F
E
A
D
F
E
A
D
93014064_001
TYPE:
1
1
ab:
bis: 0
2
2
-M10
+H
=H
-S204
+H2
=H
0
20A
=K
-F204
+K2
WH 2.5Q RD 2.5Q RD 6Q
M
/13.D2
1
1
2
2
3
3
4
4
BISCHOFSHOFEN
LIEBHERR
-S55
+F1
0
=K
+K2
7,5A
-F211
5
5
=F
=F
-S55.X2
+F1
=F -S55.X1
+F1
WH 1.5Q WH 6Q
/13.B2
1
1
2
2
1 1
WH 1.5Q
6
6
=K
-H42
+K1
=K
-MP7_m
+K2
=K
-H42.X
-H42.X
=K
+K1
+K1
BK 1.5Q
1
1
10 9
REFUELLING PUMP DIFFERENTIAL LOCK
0
=V
-Y717
+V1
7
7
=K
-MP7_m
+K2
=V
-Y717.X
-Y717.X
=V
+V1
+V1
2
1
BK 1.5Q WH 1.5Q
/51.C2
2
2 1
SIDE:
DATE:
49
8
8
14.03.2013 13:56
61
F
E
A
D
F
E
A
D
93014064_001
TYPE:
1
1
ab:
bis: 0
2
2
=K
-A9
+K2
Relais 4
Relais 3
Relais 2
Relais 1
GND
Kl.15
Kl.30
9
7
6
5
3
8
2
4
11
13
14
12
10
3
3
3
1
8
4
10
11
13
14
-A9.X
+K2
=K
4
4
BISCHOFSHOFEN
LIEBHERR
RD 2Q
WH 1.5Q
WH 1.5Q
WH 2.5Q
WH 2.5Q
WH 2.5Q
WH 2.5Q
BK 2.5Q
WH 2.5Q
5
5
/20.F4
#56346
/20.F5
#56349
/13.B5
#56352
/13.B5
#56352
/13.A2
#56354 #56342
/21.C5
/13.A2
#56355 #56344
/13.A2
6
6
=K
-MP7_e
+K2
ELECTRONIC IMMOBILISER
1
7
7
SIDE:
DATE:
50
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8
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61
F
E
A
D
1 2 3 4 5 6 7 8
HORN OPERATION ÜBER PUSH-BUTTON SWITCH AM CONTROL LEVER EXTRA EQUIPEMENT

A BUCKET RETURN-TO-DIG ÜBER PUSH-BUTTON SWITCH A
CAN: CAN:
OUTLET (3A) /40.D2 OPTION /39.C2
OPTION 1 -A6.B INDUCTIVE SWITCH -A6.A
/29.B4
DA07_Option1 +K2 DE06_BucketReturn +K2
=K =K
1356 00090 01 00 001
A6.B.DA07 A6.A.DE06
20 X4 9 X3
#56328
-A6.BX4 -A6.AX3
20
9
93014064_001
-A6.BX4/20a +K2 -A6.B.X4/20 +K2
1
+K2 =K +K2 =K
93014064
=K =K
B B
WH 1.5Q
WH 1.5Q
WH 1.5Q
WH 1Q
=K
+K2
/49.A7
/17.F4
WH 1.5Q -X212
C C
WH 1.5Q
WH 1.5Q
=V =V
+V1 +V1
-Y215.X -Y216.X
1
=V =V
+V1 1 +V1 1
D -Y215 -Y216 D
0 0
2 2
forbidden.
-Y215.X -Y216.X
2
+V1 +V1
=V =V
BK 1.5Q
BK 1.5Q
E E
=K =K
+K2 +K2
-MP7_k 1 -MP7_k 2
F F
TYPE: ab:
bis: 0 LIEBHERR HORN OPERATION AND BUCKET RETURN-TO-DIG SIDE: 51 61
ÜBER PUSH-BUTTON SWITCH
1 2 3 4 5 6 7 8
F
E
A
D
93014064_001
TYPE:
1
1
ab:
bis: 0
2
2
3 3 WH 1Q
/15.A6
=K
+K
+K
=K
BU
-X203.S
-X203.B
10009008 0
=K
-F203
+K2
=K
-MP6_p
+K2
2 2 1 1 RD 1Q RD 6Q
/13.D2
1
1
=K
+K
+K
=K
=K
+K
+K
=K
3
3
RD
-X203.B
-X203.S
-X203.S
-X203.B
5A
-X314.KL.30
+K2
=K
YE
4
4
BISCHOFSHOFEN
LIEBHERR
=K+K-X203.S:2
=K+K-X203.S:3
=K+K-X203.S:1
RED
5
5
BLUE
YELLOW
6
6
REVERSING OBSTACLE DETECTOR
7
7
SIDE:
DATE:
52
8
8
14.03.2013 13:56
61
F
E
A
D
F
E
A
D
93014064_001
TYPE:
1
1
/13.C2
ab:
bis: 0
2
2
1
=K
-X_Kl.15_W317
+K2
0
=K
+K4
-H301
3
3
A
WH 6Q
=K
-S317
+K4
-Y317
=H
+H1
0 1
0
=K
-F317
+K2
-Y317.X
-Y317.X
=K
=K
=K
=K
+K6
+K6
+K4
+K4
-X2.B
-X2.S
=H
=H
+H1
+H1
-S317.X1
-S317.X1
WH 1.5Q
4
4
1
1
1
2
2
2 1 59 59 1 5
10 9
9
10
=K
=K
10A
+K4
+K4
BISCHOFSHOFEN
-S317.X2
-S317.X2
LIEBHERR
=K
=K
+K6
+K6
-X2.B
-X2.S
BK 1.5Q
60 60
5
5
-MP6_r
=K
+K2
BK 1.5Q
1
-MP6_r
=K
+K2
BK 1.5Q
6
6
2IN1 STEERING
7
7
SIDE:
DATE:
53
8
8
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61
F
E
A
D
F
E
A
D
93014064_001
TYPE:
1
1
ab:
bis: 0
2
2
3
3
4
4
0
15A
=K
+K2
-F321
-R13
+M
=M
-R13.X
+M
=M
WH 2.5Q WH 6Q
1
1 1
T
BK 2.5Q
BISCHOFSHOFEN
2 -X321_Kl.15
LIEBHERR
+K2
=K
1
-X321_MP
+K2
5
5
=K
6
6
FUEL PREHEATING
7
7
SIDE:
DATE:
54
8
8
14.03.2013 13:56
61
F
E
A
D
F
E
A
D
93014064_001
TYPE:
1
1
ab:
bis: 0
2
2
3
3
4
4
-B100
+H
=H
=H
+H
-B100.X_1
-
bl
B
B
UP
-B100.X
+H
=H
WH 1.5Q 22 22 WH 1.5Q 23
BISCHOFSHOFEN
sw
bn
s
A
C
+
A C
23 X3
LIEBHERR
=K
A6.A.DAE2
COUPLING
+K2
CAN:
AD2_1_Reserve
WH 1.5Q 21 21 WH 1.5Q
/17.D8
-A6.AX3
PRESSURE LIMITATION
BK 1.5Q 23 23 BK 1.5Q
=K
=K
=K
+K2
+K6
+K6
/39.D2
-A6.A
-X2.B
-X2.S
5
5
-MP6j
+H
=H
6
6
OPTION PRESSURE LIMITATION COUPLING
7
7
SIDE:
DATE:
55
8
8
14.03.2013 13:56
61
F
E
A
D
F
E
A
D
93014064_001
TYPE:
1
1
ab:
bis: 0
2
2
3
3
4
4
BISCHOFSHOFEN
LIEBHERR
5
5
6
6
CIRCUIT DIAGRAM ENGINE

4,5l Power Tech
7
7
SIDE:
DATE:
56
8
8
CIRCUIT DIAGRAM - ENGINE
14.03.2013 13:56
61
F
E
A
D
1 2 3 4 5 6 7 8
CAN: /47.B5 CAN: /47.B5 CAN: /47.B5 CAN: /47.B5 CAN: /47.B5 CAN: /47.B5 CAN: /47.B5 CAN: /47.B5
INTAKE AIR /61.C2 /61.C2 WATER SEPARATOR /61.C2 COOLING WATER /61.C2 FUEL /61.D2 FUEL /61.C2 /61.D2 ENGINE OIL /61.C2
A TEMPERATURE -A700. SELECTION 2- -A700. SENSOR -A700. TEMPERATURE -A700. TEMPERATURE -A700. PRESSURE SENSOR -A700. SELECTION 2+ -A700. PRESSURE SENSOR -A700. A
A +M A +M A +M A +M A +M A +M A +M A +M
A700.X2.10 =M A700.X2.14 =M A700.X2.6 =M A700.X2.12 =M A700.X2.24 =M A700.X2.7 =M A700.X2.23 =M A700.X2.3 =M
C2 X2 D2 X2 B2 X2 C4 X2 F4 X2 B3 X2 F3 X2 A3 X2
-A700.X2 -A700.X2 -A700.X2 -A700.X2 -A700.X2 -A700.X2 -A700.X2 -A700.X2
C2
D2
B2
C4
F4
B3
F3
A3
+M +M +M +M +M +M +M +M
1356 00090 01 00 001
=M =M =M =M =M =M =M =M
5414A
93014064_001
-X1
93014064
B B
0.75Q
0.75Q
0.75Q
0.75Q
0.75Q
0.75Q
0.75Q
1Q
C C
5414G
5414D
5414C
5414E
5414B
5416A
5414F
5463
5453
5461
5428
5469
5467
D D
forbidden.
=M =M =M =M =M =M
+M +M +M +M +M +M
-T02.X -D01.X -T04.X -T05.X -P03.X -P04.X
C
A
A
A A A A C C
=M =M =M =M =M =M
+M +M +M +M s s
+M +M
°C °C °C P P
-T02 -D01 200k -T04 -T05 I I

-P03 -P04
- + - +
B B B B A B A B
E -T02.X -D01.X -T04.X -T05.X -P03.X -P04.X E
B
B
A
A
+M +M +M +M +M +M
=M =M =M =M =M =M
0.75Q 0.75Q -X2 0.75Q
5416B 5416C
0.75Q
0.75Q
0.75Q
0.75Q
F F
TYPE: ab:
bis: 0 LIEBHERR CIRCUIT DIAGRAM ENGINE SIDE: 57 61
TEMPERATURE SENSOR PRESSURE SENSOR
1 2 3 4 5 6 7 8
F
E
A
D
93014064_001
TYPE:
1
1
ab:
bis: 0
2
2
3
3
WH 1Q E2
A
E2 X2
5427
=M
+M
A700.X2.18
CAN:
SELECTION 1-
-A700.X2
=M
+M
/47.B5
/61.D2
-A700.
-P05
+M
=M
4
4
A
-P05.X
=M
+M
-
-P05.X
+M
=M
A 1Q E3
A
IP
s
B
+
B C
E3 X2
5475
=M
+M
A700.X2.19
CAN:
COMMON RAIL
BISCHOFSHOFEN
PRESSURE SENSOR
LIEBHERR
-A700.X2
=M
+M
/47.B5
/61.D2
-A700.
5
5
1Q D3
A
D3 X2
5946
=M
+M
A700.X2.15
CAN:
SELECTION 1+
-A700.X2
=M
+M
/47.B5
/61.D2
-A700.
6
6
PRESSURE SWITCH
CIRCUIT DIAGRAM ENGINE
7
7
SIDE:
DATE:
58
8
8
14.03.2013 13:56
61
F
E
A
D
1 2 3 4 5 6 7 8
A A
CAN: /47.B5 CAN: /47.B5 CAN: /47.B5 CAN: /47.B5 CAN: /47.B5 CAN: /47.B5
CRANKSHAFT + /61.C2 CRANKSHAFT - /61.D2 CAM SHAFT - /61.D2 CAM SHAFT + /61.C2 INJECTION PUMP + /61.C5 INJECTION PUMP - /61.C5
SPEED SENSOR -A700. SPEED SENSOR -A700. SPEED SENSOR -A700. SPEED SENSOR -A700. SOLENOID VALVE -A700. SOLENOID VALVE -A700.
+M +M +M +M +M +M
1356 00090 01 00 001
A A A A A A
A700.X2.8 =M A700.X2.16 =M A700.X2.20 =M A700.X2.4 =M A700.X2.29 =M A700.X2.30 =M
B4 X2 D4 X2 E4 X2 A4 X2 H1 X2 H2 X2
93014064_001
-A700.X2 -A700.X2 -A700.X2 -A700.X2 -A700.X2 -A700.X2
H1
B4
D4
E4
A4
H2
+M +M +M +M +M +M
93014064
=M =M =M =M =M =M
B B
0.75Q
0.75Q
0.75Q
0.75Q
0.75Q
0.75Q
C C
5447
5448
5443
5445
5424
5419
=M =M
+M +M =M
=M-X01.X =M-X02.X +M
A
A
D -Y01.X D
1
+M A +M A
=M
-X01 -X02 +M 1
-Y01
0 0
forbidden.
B B 0
-X01.X -X02.X 2
B
+M +M -Y01.X
2
=M =M +M
=M
E E
F F
TYPE: ab:
SPEED SENSOR ; SOLENOID VALVE
1 2 3 4 5 6 7 8
1 2 3 4 5 6 7 8
A CAN: /47.B5 CAN: /47.B5 CAN: /47.B5 CAN: /47.B5 CAN: /47.B5 CAN: /47.B5 CAN: /47.B5 A
VALVE 0- /61.D2 VALVE 1- /61.D2 VALVE 2- /61.C2 VALVE 3- /61.C2 VALVE 1,3,5+ /61.B5 VALVE 0,2,4+ /61.B5 /61.D2
INJECTION NOZZLE -A700. INJECTION NOZZLE -A700. INJECTION NOZZLE -A700. INJECTION NOZZLE -A700. INJECTION NOZZLE -A700. INJECTION NOZZLE -A700. SCREEN -A700.
A +M A +M A +M A +M A +M A +M A +M
A700.X2.17 =M A700.X2.21 =M A700.X2.13 =M A700.X2.9 =M A700.X2.26 =M A700.X2.25 =M A700.X2.22 =M
E1 X2 F1 X2 D1 X2 C1 X2 G2 X2 G1 X2 F2 X2
1356 00090 01 00 001
-A700.X2 -A700.X2 -A700.X2 -A700.X2 -A700.X2 -A700.X2 -A700.X2

E1
F1
D1
C1
G1
1Q G2
F2
+M +M +M +M +M +M +M
1Q
1Q
1Q
1Q
1Q
=M =M =M =M =M =M =M
93014064_001
-X5 0.75Q
93014064
5410A
B B
5493
5498
5495
5499
5496
5491
=M =M =M =M =M =M
+M +M +M +M +M +M
-C01 -C01 -C01 -C01 -C01 -C01
7
1
-C01. -C01. -C01. -C01. -C01. -C01.

1
7
+M +M +M +M +M +M
=M =M =M =M =M =M
C C
0.75Q
0.75Q
1Q
1Q
1Q
1Q
1Q
1Q
1Q
1Q
D D
forbidden.
-Y0 -Y1 -Y2 -Y3

+M +M +M +M
=M =M =M =M
E E
-X4
-X3
F F
TYPE: ab:
INJECTION VALVES
1 2 3 4 5 6 7 8
1 2 3 4 5 6 7 8
A A
1356 00090 01 00 001
93014064_001
=M -A700. Modul Nr.:

+M Modulname: JD-ECU_STUFE 3_MOTOR
93014064
B B
Phys. Adr. Blatt EA Beschreibung Stecker Pin F2 F3 EA G1 G2 G3
A700.X2.Can INJECTION NOZZLE VALVE 5- 0 A1 A700.X2.25 /60.A7 INJECTION NOZZLE VALVE 0,2,4+ 0 G1
A700.X2.2 5 /47.A7 ACKNOWLEDGEMENT PREHEAT 0 A2 A700.X2.26 /60.A6 INJECTION NOZZLE VALVE 1,3,5+ 0 G2
A700.X2.3 /57.A8 PRESSURE SENSOR ENGINE OIL 0 A3 A700.X2.27 0 G3
A700.X2.4 /59.A5 SPEED SENSOR CAM SHAFT + 0 A4 A700.X2.28 0 G4
A700.X2.5 INJECTION NOZZLE VALVE 4- 0 B1 A700.X2.29 /59.A6 SOLENOID VALVE INJECTION PUMP + 0 H1
A700.X2.6 /57.A4 SENSOR WATER SEPARATOR 0 B2 A700.X2.30 /59.A7 SOLENOID VALVE INJECTION PUMP - 0 H2
A700.X2.7 /57.A6 PRESSURE SENSOR FUEL 0 B3 A700.X2.31 0 H3
A700.X2.8 /59.A2 SPEED SENSOR CRANKSHAFT + 0 B4 A700.X2.32 /47.A6 SELECTION PREHEAT 0 H4
C C
A700.X2.9 /60.A5 INJECTION NOZZLE VALVE 3- 0 C1
A700.X2.10 /57.A2 TEMPERATURE INTAKE AIR 0 C2
A700.X2.11 0 C3
A700.X2.12 /57.A5 TEMPERATURE COOLING WATER 0 C4

A700.X2.13 /60.A4 INJECTION NOZZLE VALVE 2- 0 D1

A700.X2.14 /57.A3 SELECTION 2- 0 D2
A700.X2.15 /58.A6 SELECTION 1+ 0 D3

A700.X2.16 /59.A3 SPEED SENSOR CRANKSHAFT - 0 D4
A700.X2.17 /60.A2 0 E1
INJECTION NOZZLE VALVE 0-
A700.X2.18 /58.A4 0 E2
SELECTION 1-
A700.X2.19 /58.A5 0 E3
PRESSURE SENSOR COMMON RAIL
D A700.X2.20 /59.A4 0 E4 D
SPEED SENSOR CAM SHAFT -
A700.X2.21 /60.A3 0 F1
INJECTION NOZZLE VALVE 1-
A700.X2.22 /60.A8 0 F2
SCREEN
/57.A7
forbidden.
A700.X2.23 SELECTION 2+ 0 F3
A700.X2.24 /57.A6 TEMPERATURE FUEL 0 F4
E E
F F
TYPE: ab:
bis: 0 LIEBHERR ENGINE ECU - ENGINE SIDE SIDE: 61 61
1 2 3 4 5 6 7 8
Circuit diagrams
LBH/11827686/02/211-20150615.1106/en
copyright by
110-10

Valid for: L538-1493/31405-;
1 Layout
Fig. 381: Overview of the electronic control system
BMK Component CAN line

A6 Central control unit (UEC3)
A11 Control unit 1
A13 Display 1
A700 Engine control unit 2
X60 Diagnostic plug 2
Tab. 58: Components
The central control unit (UEC3) A6 is mounted behind the rear wall cover.
LBH/11827693/02/211-20150615.1139/en
The engine control unit A700 is mounted on the engine.

The diagnostic plug X60 is fitted on the rear wall of the driver’s cab.
The display A13 is mounted inside the driver’s cab, within the field of vision.
The control unit A11 is mounted on the control panel.
2 Function
2.1 Basic function

The central control unit (UEC3) A6 electronically controls the machine.
The central control unit is connected via the CAN lines with the CAN users. All the
CAN users on a CAN line are connected in series.
copyright by
L538-1493 110-11
At then end of each CAN line there is a 120 Ω resistor. This resistor is normally
integrated in the CAN users and can be activated by bridging an electric connec-
tion (jumper).
The sensors and actuators are directly connected to the central control unit via the
plug connections X3 and X4.
The terminating resistor for CAN line 1 is installed in the display.
The terminating resistor for CAN line 2 (R700) is installed in the wiring harness
near the engine.
The two terminating resistors at the control unit end of CAN lines 1 and 2 are in-
stalled in the central control unit (UEC3).
2.2 Diagnostic plug
Fig. 382: Diagnostic plug
Pin assignment of diagnostic plug X60

Pin Description
A Earth
B Power supply (terminal 30, fuse F26)
C Connected to CAN high of CAN line 2
D Connected to CAN low of CAN line 2
E Spare
F Earth (bootstrap)
G RS-232 (UEC3)
H RS-232 RxD (UEC3)
J RS-232 TxD (UEC3)
Tab. 59: Pin assignment of diagnostic plug X60

LBH/11827693/02/211-20150615.1139/en
The diagnostic plug X60 is connected to the central control unit A6. Data can be
evaluated with the Sculi diagnostic software via this connection.
The diagnostic plug X60 is connected to CAN line 2. The data from the diesel en-
gine can be evaluated with the Service Advisor diagnostic software via this connec-
tion.
The diagnostic plug is not an active CAN user.
copyright by
110-12 L538-1493

Valid for: L538-1493/31405-;
(For more information see: 020.8.1 Central control unit (UEC3), page 020-19)
1 Layout
Fig. 383: Central control unit (UEC3)

1 Connector X3 3 Ventilation and bleeder valve
LBH/11827693/02/211-20150615.1139/en
2 Housing 4 Connector X4
The central control unit (UEC3) is fitted below the covering on the rear wall of the
cab, behind the driver’s seat.
The central control unit is equipped with the plug connections X3 and X4 for com-
municating with the various components.
2 Function
2.1 Basic function

The central control unit (UEC3) controls and monitors all the electronic components
that are connected to it.
copyright by
L538-1493 110-13
All the input and output data is processed in cycles according to the following
schedule:
– Collecting all input data from the electronic components
– Putting the input data into the application software
– Calculating the output data
– Sending the output data to the connected electronic components. Commands
that are received are converted into actions.
The connectors X3 and X4 serve as the connecting elements between the machine
and the central control unit.
2.2 Connector X3
Fig. 384: Connector X3
Pin Physical address Function Pin Physical address Function

1 A6.A.TxD Diagnostic plug (RS-232) 21 A6.A.CAN1H CAN BUS 1 (High)
2 A6.A.BSL_C2 Earth (bootstrap) 22 A6.A.CAN2H CAN BUS 2 (High)
3 A6.A.DAE0 Analogue digital input (10 bits) 23 A6.A.DAE2 Analogue digital input (10 bits)
5 A6.A.UDE0 Frequency input 25 A6.A.VCC_EXT Voltage output (5 VDC /
200 mA)
6 A6.A.E3 Resistance input 26 A6.A.E4 Resistance input
7 A6.A.E5 Resistance input 27 A6.A.E6 Resistance input
8 A6.A.E0 Analogue input (0 – 10 V) 28 A6.A.E2 Analogue input (0 – 10 V)
LBH/11827693/02/211-20150615.1139/en
9 A6.A.DE06 Digital input 29 A6.A.DE03 Digital input

10 A6.A.DE05 Digital input 30 A6.A.+27VDC_1 Power supply terminal 30
11 A6.A.RxD Diagnostic plug (RS-232) 31 A6.A.CAN1L CAN BUS 1 (Low)
12 A6.A Diagnostic plug (RS-232) 32 A6.A.CAN2L CAN BUS 2 (Low)
15 A6.A.UDE1 Frequency input 35 A6.A.SGND Voltage output ground
16 A6.A.E3_GND Resistance input (ground) 36 A6.A.E4_GND Resistance input (ground)
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110-14 L538-1493

17 A6.A.E5_GND Resistance input (ground) 37 A6.A.E6_GND Resistance input (ground)
18 A6.A.E1 Analogue input (0 – 10 V) 38 A6.A.DE00 Power supply terminal 15
19 A6.A.DE02 Digital input 39 A6.A.DE04 Digital input
20 A6.A.DE01 Digital input 40 A6.A.SGND Earth
Tab. 60: Connector X3
2.3 Connector X4
Fig. 385: Connector X4

1 A6.B.DE07 Digital input 21 A6.B.DE09 Digital input
5 A6.B.PA0 PWM output 25 A6.B.PA2 PWM output
6 A6.B.+27VDC_3 Power supply 3 26 A6.B.DA05 Digital output (3A)
7 A6.B.DA12 Digital output (3A) 27 A6.B.DA03 Digital output (2A)
LBH/11827693/02/211-20150615.1139/en

11 A6.B.DE08 Digital input 31 A6.B.SGND Ground
15 A6.B.PA1 PWM output 35 A6.B.+27VDC_2 Power supply 2
16 A6.B.DA10 Digital output (3A) 36 A6.B.+27VDC_4 Power supply 4
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L538-1493 110-15

Tab. 61: Connector X4
2.4 Power supply of outputs
Power supply of outputs

Power supply Output Physical address Pin
Power supply 1 (A6.A.+27VDC_1) Digital output (2A) A6.B.DA00 X4.28
Digital output (2A) A6.B.DA01 X4.17
PWM output A6.B.PA2 X4.25
LBH/11827693/02/211-20150615.1139/en
Tab. 62: Power supply of outputs
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110-16 L538-1493
2.5 Power supply of inputs
Power supply of inputs

Power supply Input Physical ad- Pin
dress
Voltage output 5 VDC / 200 mA Resistance input A6.A.E3 X3.6
(A6.A.VCC_EXT)
Resistance input A6.A.E4 X3.26
Frequency input A6.A.UDE0 X3.5
Frequency input A6.A.UDE1 X3.15
Tab. 63: Power supply of inputs

LBH/11827693/02/211-20150615.1139/en
copyright by
L538-1493 110-17
Electrical components of the driver’s cab
110.5 Electrical components of the driver’s cab

Valid for: L538-1493/31405-;
Fig. 386: Fuse and relay board
Fuse Amps Component Fuse Amps Component

LBH/11827693/02/211-20150615.1139/en
S1 Fuse test switch F24 15 A Power supply for UEC3 (VBAT4)

F1 5A Quick coupler F25 10 A Flashing beacon
Left high beam Power supply for central control unit
F2 7.5 A F26 15 A
(VBAT1), diagnostic plug
F3 7.5 A Right high beam F27 10 A Marker light, parking light
F4 7.5 A Right low beam F28 10 A Spare
F5 7.5 A Left low beam F29 25 A Ignition switch release
F6 5A Left marker lights F30 15 A Voltage transformer
F7 5A Right marker lights F31a 10 A Front left working headlight
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110-18 L538-1493
Fuse Amps Component Fuse Amps Component

F07B 10 A Hazard warning function, terminal 15 F31b 10 A Front right working headlight
F8 15 A Driver’s seat F33a 10 A Rear left working headlight
F8A 10 A 24 volt socket, interior lighting F33b 10 A Rear right working headlight
F9 10 A Fan reversal F35 10 A Dust filter overpressure unit
F10 3A Display F36 Spare
F11 3A Inch/brake pedal F37 20 A Engine control unit terminal 30
Power supply for central control unit Spare
F12 10 A F38 3A
(UEC3)
F13 10 A Emergency steering pump activation F39 5A Weighing device (optional)
F14 20 A Heating / air conditioning F40 10 A Rear hatch working headlight
Control lever, fuel pipe sensor, cooling Spare
F15 10 A F41 10 A
water level sensor
F16 20 A Starter F43 10 A Engine control unit terminal 15
F17 Spare, engine stop F44 10 A Brake light
Rear windscreen wiper motor, rear wash- Spare
F18 10 A F45 3A
er pump
F19 10 A Spare F46 3A Flashing warning light
F19A 15 A Spare F71 10 A Dashboard lights, control unit
Front wiper motor, front washer pump,
F20 15 A F73 10 A Central lubrication system
horn
F21 15 A Marker lights and low beam F74 15 A Rear window heater
F22 15 A Power supply for UEC3 (VBAT3) F75 10 A Radio
F23 15 A Power supply for UEC3 (VBAT2) F76 10 A Radio, socket
Tab. 64: Fuses
Relay Component Relay Component

K01 Ignition switch release (terminal 15 relay) K31b Front right working headlight
K1 Indicator sensor K33a Rear left working headlight
K02 Starter K33b Rear right working headlight
K03 Engine stop K209 Dust filter overpressure unit (optional)
LBH/11827693/02/211-20150615.1139/en
K5 Simulation D+ K228 Flashing reversing alarm (optional)

K5a Wiper relay K229 Flashing reversing alarm (optional)
K10 Mirror heater, rear window heater K230 Spare
K12 Simulation terminal 15, radio K243 Rear hatch working headlight
K15 Lift kick-out K245 Central lubrication system
K18 Bucket return-to-dig K246 Heating / air conditioning
K25 US hazard warning system K270 Immobiliser
K26 US hazard warning system K271 Heating / air conditioning
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L538-1493 110-19
Relay Component Relay Component

K31a Front left working headlight
Tab. 65: Relay
Jumper Amps Ω Function

X1 10 A EU hazard warning system
X2 10 A EU hazard warning system
X3 US hazard warning system
X4 0Ω Jumper (not assigned)
X5 100 Ω Jumper (not assigned)
X6 3A 220 Ω Exciter jumper R9b
Tab. 66: Jumper
Resistance Ω Function
R9a 100 Ω Spare exciter
R9b 220 Ω Exciter
Tab. 67: Resistors
2 Function
2.1 Basic function

The relay and fuse board carries and connects the electrical components.
The electrical and electronic components are powered via the relay and fuse
board.
2.2 Working headlight safety functions
LBH/11827693/02/211-20150615.1139/en
Fig. 387: Working headlight safety functions
Fuse Function Fuse Function

F31A Front left working headlight F33A Rear left cab roof working headlight
F31B Front right working headlight F33B Rear right cab roof working headlight
Tab. 68: Working headlight safety functions
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110-20 L538-1493
The function of the working headlights can be selected by connecting the fuses
F31A, F31B, F33A and F33B:
– When the fuses are connected to terminal 30, the working headlights already
function when the battery main switch is switched on.
– When the fuses are connected to terminal 15, the working headlights do not
function until the ignition is switched on.
A mixed function is also possible, for example with the front working headlights on
terminal 15 and the rear working headlights on terminal 30.
2.3 Fuse test

The fuse test is only used for quick diagnosis of the fuses. In the event of a fault,
the fuses should be tested using a multimeter.
The fuses on the relay and fuse board are divided into three categories.
– Fuses for the power supply from terminal 30.
– Fuses for the power supply from terminal 15.
– Fuses for protecting various functions (e.g. low beam, profile light, parking light).
Note
The fuse test only works if a function of the fuse to be tested is active.
u Take this into account when testing the fuses.
Each fuse has an LED and can be tested by pressing the button S1.
If an LED does not light up, the fuse is defective.
The testing of the fuses depends on the status of the electrical system.
You can only test the fuses in the active circuit:
– When the battery main switch is on (terminal 30), only the LEDs of the terminal
30 power supply fuses light up when you press the button S1.
– When the ignition is on (terminal 15), the LEDs of the fuses for power supply
from terminal 30 and terminal 15 light up when you press the button S1.
– The LEDs of the fuses to protect the various functions only light up when the
corresponding function is activated.
LBH/11827693/02/211-20150615.1139/en
copyright by
L538-1493 110-21
Electrical components in the rear section
110.6 Electrical components in the rear section

Valid for: L538-1493/31405-;
1 Layout
The electrical system voltage is 24 V.
Fig. 388: Battery installation

F01 Main fuse (terminal 30) G2a Battery
F02 Preglow system fuse G2b Battery
F03 Emergency steering pump fuse M1 Starter
F07a Hazard warning system fuse Mp1_d Earthing point
G1 Alternator S15 Battery main switch
LBH/11827693/02/211-20150615.1139/en
Tab. 69: Component designations
The batteries G2a and G2b are installed in the right ballast weight.
2.1 Function
The battery main switch S15 connects the battery earth with the vehicle earth.
The following components are powered directly by the battery:
– Main fuse F01 (100 A)
– Preglow relay fuse F02 (100 A)
– Emergency steering pump fuse F03 (200 A)
– Hazard warning system fuse F07a (10 A)
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110-22 L538-1493
– Alternator G1
– Starter M1
2.2 Battery
Fig. 389: Battery and fuse holder

1 Battery 4 Electrical line
2 Threaded pin 5 Insulating nut
3 Fuse insert 6 Fuse carrier
The battery 1 consists of six cells, each with 2 volts. Two batteries are installed in
the machine. These are connected in series and can produce an operating voltage
of 24 volts.
The batteries are connected to the electrical lines through the fuse holder 6. The
electric lines are attached to the fuse holder with insulating nuts 5 (tightening tor-
que 12 Nm).
The insulating nut 5 fastens the electrical cable via a threaded pin 2 to the fuse. At
the same time, the insulating nut separates the electrical cable from the threaded
pin. This separation is necessary, as otherwise, the function of the fuse is disabled.
Note
The insulating nut ensures that the electrical cable is separated from the threaded
pin. Without this separation, the electrical cable would be directly connected to the
positive terminal of the battery. The fuse would be bypassed and therefore useless.
u Always fasten electrical cables to the fuse carrier with the appropriate insulating
nuts.
u Check the insulating nuts for damage and replace them if necessary.
LBH/11827693/02/211-20150615.1139/en
Charge levels
Acid density at Charge level Battery volt- Voltage per Remark
27 °C age cell
1.28 1.26 100% over 12.60 over 2.10 Battery OK
1.25 1.24 75% 12.54 12.40 2.10 2.07
1.24 1.18 50% 12.40 12.18 2.07 2.03 Charge battery
1.18 > 25% 12.18 > 2.03 > Battery not OK
Tab. 70: Table of charge levels
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L538-1493 110-23
If the machine is not started for 4 weeks, there is a risk of sulphate formation and
storage deterioration on the battery. During longer standstill periods, the charge
level must be regularly checked and the battery must be re-charged if necessary.
If the charge level falls below 50%, there is a risk of permanent damage to the bat-
tery.
2.3 Self-discharge of the battery

Even if the battery is not connected to any consumers, after a certain time it will be
flat. This phenomenon is called self-discharge and is caused by chemical process-
es in the battery. The rate of self-discharge depends on the temperature, the acid-
to-weight ratio and the battery technology.
LBH/11827693/02/211-20150615.1139/en
copyright by
110-24 L538-1493
120 Transmission
Contents
L538-1493/31405-; 120-2
L538-1493/31405-; 120-3
L538-1493/31405-; 120-9
L538-1493/31405-; 120-10
L538-1493/31405-; 120-11
LBH/11827693/02/211-20150615.1139/en
copyright by
L538-1493 120-1
Transmission Service manual
Overview of the transmission
Valid for: L538-1493/31405-;
1 Layout
Fig. 390: Transmission

1 Rear axle 5 Cardan shaft flange
2 Speed sensor for travel motor 2 6 Output speed sensor B1
B2
3 Mechanical transmission 7 Connection flange for travel motor
1
4 Connection flange for travel motor
2
The mechanical transmission 3 is flange-mounted on the rear axle 1. The transmis-
sion is joined to the front axle via the cardan shaft flange 5 and the cardan shaft.
The transmission consists of the following components:
– Mechanical transmission
– Electronic control unit
– Hydraulic control unit (For more information see: 120.4.1 Overview of the hy-
draulic control system, page 120-11)
LBH/11827693/02/211-20150615.1139/en
2 Function
The transmission performs the following functions:
– Combining the power of the two travel motors
– Changing gear without losing tractive force
– Adjusting the speed and output torque in 3 travel ranges
– Distributing the torque between the front and rear axles
copyright by
120-2 L538-1493
Service manual Transmission
Mechanical transmission
Valid for: L538-1493/31405-;
1 Layout
LBH/11827693/02/211-20150615.1139/en
Fig. 391: Sectional view of the transmission (view from below)
copyright by
L538-1493 120-3
1 Connection flange for travel 9 Clutch cup springs 17 Roller bearing

motor 1
2 Cardan shaft flange 10 Clutch piston 18 Intermediate shaft
3 Shaft seal ring 11 Roller bearing 19 Lubricating line
4 Ball bearing 12 Pressure chamber 20 Output shaft
5 Lubricating line 13 Clutch 21 Rear axle connecting flange
6 Roller bearing 14 Gearwheel with clutch cage 22 Output gear
7 Cup springs 15 Intermediate gearwheel 23 Output speed sensor
8 Connection flange for travel 16 Ball bearing F Forward travel direction
motor 2
The transmission is fitted to the rear axle 21. The output shaft 20 is connected to
the input shaft of the rear axle.
The output shaft 20 is connected to the front axle via the cardan shaft.
2 Function
2.1 Basic function
Fig. 392: Diagram of the transmission

1 Transmission 8 Gearwheel with clutch cage
2 Travel motor 1 drive shaft 9 Travel motor 2 drive shaft
3 Travel motor 1 drive gear 10 Travel motor 2 drive gear
4 Output gear 11 Clutch
5 Output shaft 12 Clutch piston
6 Intermediate gearwheel 13 Travel motor 1
7 Intermediate shaft 14 Travel motor 2
The output shaft 5 transfers the drive torque and drive speed of the travel motors to
the front and rear axles.
Travel motor 1 drives the output shaft directly.
Travel motor 2 drives the output shaft via the clutch 11. Travel motor 2 can there-
LBH/11827693/02/211-20150615.1139/en
fore be disengaged from the travel drive.

The clutch is closed with spring power and opened hydraulically with oil from the
replenishing pump.
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120-4 L538-1493
2.2 Clutch
LBH/11827693/02/211-20150615.1139/en
Fig. 393: Sectional view of closed / open clutch

1 Outer discs 8 Pressure piston
2 Inner discs 9 Coupling hub
3 Roller bearing 10 Pressure piston return spring
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L538-1493 120-5
4 Clutch cup springs 11 Pressure plate

5 Clutch piston 12 Gearwheel with clutch cage
6 Pressure chamber 13 Ball bearing
7 Separator plate 14 Intermediate shaft
The clutch is opened hydraulically. (For more information see: 120.4.1 Overview of
the hydraulic control system, page 120-11)
When the clutch is opened, the replenishing pump fills the pressure chamber 6 with
oil. The oil pressure pushes the clutch piston 5 against the cup springs 4. This cau-
ses the return springs 10 to move the pressure piston 8 and the roller bearing 3 on
the intermediate shaft 14.
This relieves the pressure on the discs. The gearwheel with the clutch cage 12 can
be turned independently of the intermediate shaft 14. Travel motor 2 is disengag-
ed.
When the clutch is closed, the oil is drained out of the pressure chamber 6. The
cup springs 4 push the clutch piston 5, together with the roller bearing 3 and the
pressure piston 8, against the discs.
The outer discs 1 and inner discs 2 are arranged alternately. The outer discs 1 are
connected by lugs to recesses in the clutch cage 12. The inner discs 2 mesh with
the coupling hub 9.
The clutch piston 5 clamps the discs between the pressure piston 8 and the pres-
sure plate 11. The gearwheel 12 and intermediate shaft 14 are connected by the
friction between the discs. Travel motor 2 drives the intermediate shaft 14.
2.3 Gears
Three gears are available. The gear is selected by the central control unit and en-
gaged. (For more information see: 120.3.1 Overview of the electronic control sys-
tem, page 120-9)
1st gear
LBH/11827693/02/211-20150615.1139/en
Fig. 394: 1st gear
Component Position Condition

Clutch 3 Closed
Clutch solenoid valve Y60 4 Energised
Travel motor 1 1 At the maximum angle
Travel motor 2 2 At the maximum angle
Tab. 71: 1st gear
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120-6 L538-1493
When 1st gear is engaged, both travel motors are moved to the maximum angle.
This allows both travel motors to provide the highest possible output torque. Maxi-
mum tractive force is available.
In 1st gear, the travel speed is entirely dependent on the flow of the travel pump.
2nd gear
Fig. 395: 2nd gear

Clutch 3 Closed
Clutch solenoid valve Y60 4 Energised
Travel motor 1 1 Regulates according to high pressure
Travel motor 2 2 Electro-proportional control
Tab. 72: 2nd gear
When 2nd gear is engaged, the angle of travel motor 1 is regulated hydraulically
and the angle of travel motor 2 is regulated electrically and proportionally.
This enables higher travel speeds to be reached.
3rd gear
LBH/11827693/02/211-20150615.1139/en
Fig. 396: 3rd gear

Clutch 3 Open
Clutch solenoid valve Y60 4 De-energised
Travel motor 1 1 Regulates according to high pressure
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L538-1493 120-7

Travel motor 2 2 At the minimum angle
Tab. 73: 3rd gear
When 3rd gear is engaged, the clutch is open. Travel motor 2 is disengaged and
kept at the minimum angle. Travel motor 1 drives the machine on its own. The an-
gle of travel motor 1 is regulated hydraulically.
Because travel motor 2 does not consume any oil, considerably more oil is availa-
ble to travel motor 1. This allows the maximum speed to be reached.
LBH/11827693/02/211-20150615.1139/en
copyright by
120-8 L538-1493

Valid for: L538-1493/31405-;
1 Layout
Fig. 397: Electronic transmission control unit

1 Accelerator pedal angle sensor R5 6 Central control unit (UEC3) A6
2 Travel direction switch S2 7 Clutch solenoid valve Y60
3 Display A13 8 Clutch pressure switch B100
4 Control unit A11 9 Travel motor 2 speed sensor B2
5 Engine control unit (ECU) A700 10 Output speed sensor B1
2 Function
2.1 Basic function

The transmission is controlled by the central control unit. (For more information
see: 110.4.2 Central control unit (UEC3), page 110-13)
LBH/11827693/02/211-20150615.1139/en
2.2 Gear selection

Three gears are available. (For more information see: Gears, page 120-6)
The gear is selected by the central control unit and engaged.
The central control unit uses the following parameters to calculate the most suita-
ble gear:
– Travel range selected
– Travel speed
– Current to the control pressure proportional valve Y59 on the travel pump
– Current to the proportional valve Y57 on travel motor 2
– Speed from the output speed sensor B1 and from the travel motor 2 speed sen-
sor B2
copyright by
L538-1493 120-9
2.3 Travel ranges

You can use the control unit to select three travel ranges. The selected travel
range is indicated on the display. When you switch on the ignition, travel range A
1-3 is always activated.
The central control unit selects the gear according to the travel range.
Display Travel range Control

Automatic travel range 1st The central control unit automatically selects
to 3rd gear between 1st, 2nd and 3rd gear.
Automatic travel range 1st The central control unit automatically selects
to 2nd gear between 1st and 2nd gear.
Fixed gear 1 The central control unit holds the machine in

1st gear.
Tab. 74: Travel ranges

Valid for: L538-1493/31405-;
1.1 Assembly
Fig. 398: Equivalent diagram of the speed sensors
The output speed sensor B1 and travel motor 2 speed sensor B2 are Hall sensors.
2 Function
If the teeth of the gear wheel move past the speed sensor, this generates an alter-
nating voltage signal. The frequency of this alternating voltage signal is proportion-
al to the speed. The signal is sent to the central control unit.
2.2 Output speed sensor

LBH/11827693/02/211-20150615.1139/en
The output speed sensor B1 measures the speed of the output gear wheel.
2.3 Travel motor 2 speed sensor

The travel motor 2 speed sensor B2 measures the speed of the travel motor 2 out-
put gear wheel. This enables the central control unit to monitor whether travel mo-
tor 2 has been disengaged.
copyright by
120-10 L538-1493
120.4 Hydraulic control unit

Valid for: L538-1493/31405-;
1 Layout
Fig. 399: Main components of the transmission

1 Filter unit 5 Clutch solenoid valve Y60 9 Transmission hydro accumu-
lator
2 Travel pump 6 Flushing orifice Ø 0.8 mm 10 Transmission
3 Pilot control 7 Modulation orifice Ø 0.8 mm G Replenishing pressure test
connection
4 Clutch pressure switch B100 8 Modulation orifice Ø 0.6 mm K Clutch shift pressure test con-
nection
LBH/11827693/02/211-20150615.1139/en
copyright by
L538-1493 120-11
2 Function
2.1 Basic function
Fig. 400: Hydraulic diagram of the transmission with the clutch closed in 1st and 2nd gear
1 Hydraulic tank 17 Compact brake valve return 37 Pilot control
flow
2 Breather filter 18 Pilot control unit return flow 38 Solenoid valve coupling Y60
3 Return strainer 19 Gear motor fan leak oil 39 Coupling pressure switch
B100
4 Bypass valve 20 Working hydraulics pump 40 Flushing orifice Ø 0.8 mm
leak oil
5 Return suction filter 21 Servostat return flow 41 Modulation orifice Ø 0.8 mm
6 Pre-tension valve 22 Travel pump leak oil 42 Check valve
7 Feeding valve 23 Hydraulic oil cooler return 43 Modulation orifice Ø 0.6 mm
flow
8 Strainer 24 Hydraulic oil cooler bypass 44 Hydro accumulator transmis-
return flow sion
9 9 bar check valve 25 Control valve block return 45 Transmission
flow
10 2.5 bar bypass valve 30 Travel pump 46 Coupling piston
11 Hydraulic oil temperature 31 Replenishing pump 47 Coupling
LBH/11827693/02/211-20150615.1139/en
sensor B8
12 Drain valve 32 Replenishing pressure relief 48 Output shaft
valve
13 Working hydraulics pump in- 33 Travel motor bearing flushing 50 Travel motor 1
take connection
14 Gear pump fan intake con- 34 Engine 51 Travel motor 2
nection
15 Gear pump brake system in- 35 Check valve G Replenishing pressure
take connection
16 Emergency steering pump in- 36 Check valve K Shift pressure of coupling
take connection
copyright by
120-12 L538-1493
The replenishing pump 31 delivers oil to the clutch solenoid valve 38. The oil from
the replenishing pump opens the clutch 47.
In 3rd gear, the clutch 47 is opened. The clutch solenoid valve 38 is not energised.
The oil from the replenishing pump 31 is restricted by the flushing orifice 40 and
accumulates. The pressure of the accumulated oil opens the clutch 47 against the
force of the cup springs.
2.2 Pilot flow (preheating the clutch)

In 3rd gear, the clutch is opened. This causes the oil from the flushing orifice to ac-
cumulate.
Oil constantly flows from the flushing orifice to the hydraulic tank. The oil warms up
the clutch piston. This improves the gear change.
2.3 Gear change - Opening the clutch
Fig. 401: 3rd gear - clutch open

1 Hydraulic tank 8 Clutch solenoid valve Y60
2 Transmission hydro accumulator 9 Coupling pressure switch B100
3 Modulation orifice Ø 0.6 mm 10 Travel motor 1
4 Check valve 11 Travel motor 2
5 Modulation orifice Ø 0.8 mm 12 Clutch piston
6 Flushing orifice Ø 0.8 mm 13 Clutch
7 Replenishing pump
When changing up from 2nd to 3rd gear, the clutch 13 is opened. To do this, the
central control unit switches off the current to the clutch solenoid valve 8. The
clutch solenoid valve 8 connects the replenishing pump 7 to the clutch piston 12.
The oil flows through the clutch piston 12 and is restricted by the flushing orifice 6
so that it accumulates. The accumulated replenishing pressure pushes the clutch
piston 12 against the cup springs and thereby opens the clutch 13.
Travel motor 2 11 is disconnected from the drive train.
LBH/11827693/02/211-20150615.1139/en
copyright by
L538-1493 120-13
2.4 Gear change - Closing the clutch
Fig. 402: 1st and 2nd gear - clutch closed

1 Hydraulic tank 8 Clutch solenoid valve Y60
2 Transmission hydro accumulator 9 Clutch pressure switch B100
3 Modulation orifice Ø 0.6 mm 10 Travel motor 1
4 Check valve 11 Travel motor 2
5 Modulation orifice Ø 0.8 mm 12 Clutch piston
6 Flushing orifice Ø 0.8 mm 13 Clutch
7 Replenishing pump
When changing down from 3rd to 2nd gear, the clutch 13 is closed. To do this, the
central control unit energises the clutch solenoid valve 8. The clutch solenoid
valve 8 separates the replenishing pump 7 from the clutch piston 12 and connects
the clutch piston 12 with the hydraulic tank 1.
This causes the cup springs in the clutch to push the oil out of the clutch piston 12
and close the clutch 13.
To ensure gears are changed smoothly, the clutch is closed in two steps:
1. Rapid draining
2. Modulation
After the shifting the clutch solenoid valve 8, rapid draining occurs. As the preload
pressure in the transmission hydro accumulator 2 is only 11±1 bar, the oil initially
flows into the transmission hydro accumulator 2. Accordingly, a large amount of oil
flows out of the clutch in a short time. Just a short time is needed to overcome the
idle path of the clutch piston 12.
When the transmission hydro accumulator 2 has been filled, the modulation phase
starts. The oil must flow through the modulation orifice 5 and the modulation ori-
fice 3 and therefore flows more slowly. The clutch therefore closes more slowly.
The clutch is engaged smoothly.
During the modulation phase, the pressure in the clutch piston 12 sinks below the
preload pressure in the transmission hydro accumulator 2. The pressure in the
transmission hydro accumulator 2 thereby closes the check valve 4. The oil from
LBH/11827693/02/211-20150615.1139/en
the clutch can continue draining into the hydraulic tank via the modulation orifice 5.
The pressure in the transmission hydro accumulator 2 is relieved into the hydraulic
tank 1 via the modulation orifice 3.
copyright by
120-14 L538-1493
130 Axles and cardan shafts
Contents
130.1 Axles 130-2
130.1.1 Front axle
L538-1493/31405-; 130-2
130.1.2 Rear axle
L538-1493/31405-; 130-6
130.2 Cardan shafts 130-7
L538-1493/31405-; 130-7
LBH/11827693/02/211-20150615.1139/en
copyright by
L538-1493 130-1
Axles and cardan shafts Service manual
Axles
130.1 Axles
130.1.1 Front axle

Valid for: L538-1493/31405-;
1 Layout
Fig. 403: Front axle

1 Wheel hub 3 Parking brake
2 Axle casing 4 Main housing
The self-locking differential is inside the main housing 4.
The service brake is built into the axle casings 2.
2 Function
2.1 Basic function

LBH/11827693/02/211-20150615.1139/en
The axle transfers all the power and torque to the wheels.
The axle input shaft transfers the torque to the crown wheel on the differential
housing with a certain transmission ratio. The output shaft transmits the torque to
the planetary gears in the wheel hubs. The planetary gear transfers the torque in
turn.
copyright by
130-2 L538-1493
Service manual Axles and cardan shafts
Axles
2.2 Self-locking differential
Fig. 404: Sectional view of self-locking differential

1 Differential bearing 6 Compensation axle
2 Main housing 7 Axle tapered gear
3 Differential housing 8 Self-locking differential discs
4 Crown wheel 9 Tapered roller bearing
5 Compensation tapered gear
2.2.1 Speed balance

The self-locking differential transmits engine speed and torque to the left wheel and
the right wheel.
The axle input shaft with the tapered gear transmits the torque to the crown
LBH/11827693/02/211-20150615.1139/en
wheel 4. The crown wheel 4 is rigidly connected to the differential housing 3. The
differential housing 3 rotates with the compensation axle 6 and the four compensa-
tion tapered gears 5 around the output shafts. The compensation tapered gears 5
move the axle tapered gears 7 and thus drive the output shaft.
If one wheel turns faster than the other (e.g. when cornering), the speed difference
between the left and right output shafts is compensated for by the compensation
tapered gears 5 rotating around the compensation axle 6.
The wheel with the higher speed rotates faster than the differential housing. The
wheel with the lower speed rotates by the same amount more slowly than the dif-
ferential housing.
Both wheels transmit the same torque.
copyright by
L538-1493 130-3
Axles
2.2.2 Self-locking function

The self-locking differential discs 8 have a non-twisting tooth connection alternately
with the differential housing 3 and the axle tapered gear 7 but can move axially.
The axle tapered gear 7 on the output shaft can also move axially.
If a difference in the torque occurs between the left and right output shaft, the axle
tapered gear 7 slips onto the side with the lower torque in the direction of the differ-
ential housing due to the inclination of the tooth face and clamps down on the self-
locking differential discs 8. The clamping force is higher, the greater the torque dif-
ference between the two output shafts.
The resulting frictional force connects the differential housing 3 with the axle ta-
pered gear 7 and equalises the output speed and output torque once more with the
input speed and input torque.
2.3 Service brake (wet disc brake)
Fig. 405: Sectional view of disc brake

1 Main housing 7 Brake piston
2 Differential bearing 8 Return spring
3 Pressure plate 9 Return pin
4 Axle casing 10 Actuator ring
LBH/11827693/02/211-20150615.1139/en
5 Inner disc 11 Output shaft

6 Outer disc A Pressure chamber
The service brake is a wet disc brake. A braking unit is built into both axle casings.
The inner discs 5 have a non-twisting tooth connection with the actuator ring 10 but
can move axially. The actuator ring 10 is connected to the output shaft.
The outer discs 6 have a non-twisting tooth connection with the axle casing 4 but
can move axially.
When braking, oil is directed to the pressure chamber A. The oil pressure moves
the brake piston 7 against the readjusting springs 8 and clamps the brake plates
between it and the pressure plate 3. The resulting friction between the inner discs 5
and outer discs 6 brakes the output shaft 11.
copyright by
130-4 L538-1493
Axles
When the brake is released, the oil is drained out of the pressure chamber A. The
readjusting springs 8 retract the brake pistons 7. The brake discs are relieved and
can turn freely.
(For more information see: 100.3.1 Overview of the service brake, page 100-12)
2.4 Wheel hub
Fig. 406: Sectional view of wheel hub

1 Axle casing 7 Ring gear
2 Output shaft 8 Planetary pinion
3 Shaft seal ring 9 Planetary carrier
4 Cartridge seal ring 10 Spherical roller bearing
5 Hub 11 Sliding washer
6 Ring gear carrier 12 Cylindrical roller bearing
There is a planetary gear in the wheel hub. The planetary gear reduces the speed
and increases the torque.
LBH/11827693/02/211-20150615.1139/en
The sun gear on theoutput shaft 2 drives the planetary pinions 8. The planetary
pinions 8 rest against the ring gear 7. This causes the planetary carrier 9 and the
wheel hub 5 to rotate.
The ring gear 7 is connected to the axle casing 1 via the ring gear carrier 6 and
accordingly does not rotate.
copyright by
L538-1493 130-5
Axles
130.1.2 Rear axle

Valid for: L538-1493/31405-;
1 Layout
Fig. 407: Rear axle

1 Wheel hub 4 Oscillating bearing
2 Axle casing 5 Transmission
3 Main housing
The self-locking differential is inside the main housing 3.
The service brake 2 is built into the axle casings.
2 Function
The functions of the rear axle correspond with the functions of the front axle. (For
more information see: Function, page 130-2) LBH/11827693/02/211-20150615.1139/en
copyright by
130-6 L538-1493
Cardan shafts
130.2 Cardan shafts

Valid for: L538-1493/31405-;
1 Layout
Fig. 408: Components of cardan shaft

1 Transmission connecting 4 Seal 7 Front axle connecting flange
flange
2 Universal joint 5 Shaft actuator
3 Extendable shaft with teeth 6 Universal joint
The cardan shaft comprises two universal joints, two connecting flanges and an ex-
tendable shaft.
2 Function
The cardan shaft connects the transmission and the front axle.
The universal joints can compensate for a misalignment of the cardan shaft flanges
with each other (angle compensation).
The cardan shaft is telescopic. The cardan shaft is retracted when steering the ma-
chine.
LBH/11827693/02/211-20150615.1139/en
copyright by
L538-1493 130-7
Cardan shafts
LBH/11827693/02/211-20150615.1139/en
copyright by
130-8 L538-1493
140 Steel components of the basic
machine
Contents
140.1 Vehicle frame 140-2
L538-1493/31405-; 140-2
L538-1493/31405-; 140-3
LBH/11827693/02/211-20150615.1139/en
copyright by
L538-1493 140-1
Steel components of the basic machine Service manual
Vehicle frame
140.1 Vehicle frame

Valid for: L538-1493/31405-;
1 Layout
Fig. 409: Articulation bearing

1 Front section 7 Bearing cover
2 Pressure flange 8 Radial seal
3 Bearing pin 9 Swivel bearing
4 Tensioner 10 Shim
5 Spacer 11 Rear section
6 Lubrication nipple
The articulation bearing is fitted between the front section 1 and rear section 11.
2.1 Function
The articulation bearing connects the front and rear sections. It allows the machine
LBH/11827693/02/211-20150615.1139/en
to be steered by articulating the vehicle frame to the left or right.

The bearing has no play between the front and rear sections.
The bearing is fastened by the bearing covers 7 bolted onto both sides. The bear-
ing pins 3 are held firmly in place in the bearing holes of the rear and front sections
by tensioners 4.
The radial seals 8 protect the bearing points from dirt.
copyright by
140-2 L538-1493
Service manual Steel components of the basic machine
Vehicle frame

Valid for: L538-1493/31405-;
1 Layout
Fig. 410: Engaging the articulation lock

1 Split pin a Articulation lock engaged
2 Bracket b Articulation lock released
3 Locking bar
The articulation lock is fitted between the front and rear sections.
2 Function
The articulation lock creates a rigid connection between the front and rear sections.
Steering is no longer possible.
This means the steering is blocked, for example, when transporting the machine or
for maintenance.
LBH/11827693/02/211-20150615.1139/en
copyright by
L538-1493 140-3
Steel components of the basic machine Service manual
Vehicle frame
LBH/11827693/02/211-20150615.1139/en
copyright by
140-4 L538-1493
150 Working attachment
Contents
150.1 Lift arms with Z kinematics 150-2
L538-1493/31405-; 150-2
150.1.2 Pin bearing 150-2
L538-1493/31405-; 150-3
150.2 Lift arms with P kinematics 150-4
L538-1493/31405-; 150-4
L538-1493/31405-; 150-5
L538-1493/31405-; 150-9
LBH/11827693/02/211-20150615.1139/en
copyright by
L538-1493 150-1
Working attachment Service manual
150.1 Lift arms with Z kinematics

Valid for: L538-1493/31405-;
1 Layout
Fig. 411: Z kinematics lift arms

1 Front section pin bearing 4 Linkage 7 Tilt cylinder
2 Lift arm 5 Connecting link 8 Bucket return-to-dig inductive
sensor B15
3 Lift cylinder 6 Working attachment pin bear-
ing
2 Function
LBH/11827693/02/211-20150615.1139/en
By extending the lift cylinder, the lift arm is lifted.

By extending the tilt cylinder, the working attachment is tilted in.
150.1.2 Pin bearing
copyright by
150-2 L538-1493
Service manual Working attachment

Valid for: L538-1493/31405-;
1 Layout
Fig. 412: Z kinematics standard pin bearing

1 Bearing pin retainer 4 Radial seal
2 Bearing pin with securing lug 5 Lifting arm
3 Counter bearing 6 Bearing bushing
2 Function
The lift arms are connected by a pin bearing to the following components:
– Front section
– Lift cylinder
– Linkage
LBH/11827693/02/211-20150615.1139/en
copyright by
L538-1493 150-3
Lift arms with P kinematics
150.2 Lift arms with P kinematics

Valid for: L538-1493/31405-;
1 Layout
Fig. 413: P kinematics lift arm

1 Front section pin bearing 5 Connecting link, front 9 Connecting link, rear
2 Lifting arm 6 Front linkage 10 Bucket return-to-dig inductive
sensor B15
3 Lift cylinder 7 Tilt cylinder
4 Quick coupler 8 Rear linkage
2 Function
LBH/11827693/02/211-20150615.1139/en
By extending the lift cylinder, the lift arm is lifted.

By extending the tilt cylinder, the working attachment is tilted out.
copyright by
150-4 L538-1493
Z kinematics quick coupler
Valid for: L538-1493/31405-;
1 Layout
Fig. 414: Unactuated quick coupler

1 Locking pin 6 Quick coupler solenoid valve Y53
2 Locking indicator 7 Quick coupler solenoid valve LS
signal Y53a
3 Hydraulic cylinder quick coupler 8 Control valve block (working hy-
draulics LS connection)
4 Backing plate 9 Hydraulic tank
5 Device support 10 Control valve block (high pressure
working hydraulics connection)
2 Function
2.1 Basic function

With the quick coupler, the working attachment (bucket, forklift, etc.) can be attach-
ed and removed without additional tools.
LBH/11827693/02/211-20150615.1139/en
copyright by
L538-1493 150-5
2.2 Hydraulics
Fig. 415: Quick coupler unactuated / unlocked / locked

1 Control valve block (working 4 Quick coupler solenoid valve I Unlock quick coupler button
hydraulics LS connection) LS signal Y53a
2 Control valve block (high 5 Quick coupler solenoid valve II Lock quick coupler button
pressure working hydraulics) Y53
3 Hydraulic tank 6 Hydraulic cylinder quick cou-
pler
When the quick coupler is not actuated, the quick coupler solenoid valve 5 and the
quick coupler solenoid valve LS signal 4 are not energised. The quick coupler sole-
noid valve 5 connects the piston side of the hydraulic cylinder 6 with the high pres-
sure of the working hydraulics 2. As the high pressure of the working hydraulics is
always on the piston side, the quick coupler can not be unlocked unintentionally.
When the quick coupler is unlocked, the quick coupler solenoid valve 5 and the
quick coupler solenoid valve LS signal 4 are energised. The quick coupler solenoid
valve 5 connects the ring side of the hydraulic cylinder 6 with the high pressure of
the working hydraulics 2. Thequick coupler solenoid valve LS signal 4 also con-
nects the high pressure of the working hydraulics 2 with the LS connection of the
working hydraulics 1 and thus generates a load sensing signal. The load sensing
signal causes the working hydraulics pump to swing out. The hydraulic cylinder 6
pulls in the two locking pins. The quick coupler unlocks.
When the quick coupler locks, only the quick coupler solenoid valve LS signal 4 is
energised. The quick coupler solenoid valve 5 connects the piston side of the hy-
draulic cylinder 6 with the high pressure of the working hydraulics 2. Thequick cou-
pler solenoid valve LS signal 4 also connects the high pressure of the working hy-
draulics 2 with the LS connection of the working hydraulics 1 and thus generates a
load sensing signal. The load sensing signal causes the working hydraulics pump
to swing out. The hydraulic cylinder 6 extends the two locking pins. The quick cou-
LBH/11827693/02/211-20150615.1139/en
pler locks.
copyright by
150-6 L538-1493
2.3 Electrics
Fig. 416: Wiring diagram of quick coupler

A17a Output module 1 K232 Latching function relay
F1 Quick coupler fuse (5A) MP6_f Cab, rear wall earth point
H40 Buzzer Y53 Quick coupler solenoid valve
KL15 Voltage at terminal 15 Y53a Quick coupler solenoid valve LS signal
KL30 Voltage at terminal 30 S23 Quick coupler button
K231 Unlock quick coupler relay
Tab. 75: Electrics
The electrics of the quick coupler are supplied with voltage via the fuse F1.
The quick coupler can be locked or unlocked using the quick coupler S23 button.
LBH/11827693/02/211-20150615.1139/en
2.3.1 Unlocking the quick coupler

When the quick coupler S23 button is in the 1 position, the quick coupler is un-
locked. The quick coupler S23 button supplies the unlock quick coupler relay K231
and the quick coupler solenoid valve LS signal Y53a with voltage.
The quick coupler solenoid valve LS signal Y53a generates a load sensing signal.
The load sensing signal causes the working hydraulics pump to swing out. This
provides sufficient pressure for the hydraulic cylinder to retract.
The quick coupler solenoid valve Y53 is supplied with voltage via the unlock quick
coupler relay K231. This directs hydraulic oil to the ring side of the hydraulic cylin-
der. The hydraulic cylinder retracts. At the same time, the buzzer H40 is activated.
copyright by
L538-1493 150-7
The latching function relay K232 ensures that the quick coupler solenoid valve Y53
and the buzzer H40 remain active even when the quick coupler S23 button is re-
leased.
The quick coupler solenoid valve LS signal Y53a is only active when the quick cou-
pler S23 button is actuated.
2.3.2 Locking the quick coupler

When the quick coupler S23 button is in the 2 position, the quick coupler is locked.
The quick coupler S23 button supplies the latching function relay K232 and the
quick coupler solenoid valve LS signal Y53a with voltage.
provides sufficient pressure for the hydraulic cylinder to extend.
As soon as the latching function relay K232 is supplied with voltage, the latching
function relay is deactivated. This interrupts the voltage supply to the quick coupler
solenoid valve Y53. Hydraulic oil is directed to the piston side of the hydraulic cylin-
der. The hydraulic cylinder extends. At the same time, the buzzer H40 is deactiva-
ted.
LBH/11827693/02/211-20150615.1139/en
copyright by
150-8 L538-1493
P kinematics quick coupler
Valid for: L538-1493/31405-;
1 Layout
Fig. 417: Unactuated quick coupler

1 Locking pin 6 Quick coupler solenoid valve Y53
2 Locking indicator 7 Quick coupler solenoid valve LS
signal Y53a
3 Hydraulic cylinder quick coupler 8 Control valve block (working hy-
draulics LS connection)
4 Backing plate 9 Hydraulic tank
5 Device support 10 Control valve block (high pressure
working hydraulics connection)
2 Function
2.1 Basic function

With the quick coupler, the working attachment (bucket, forklift, etc.) can be attach-
ed and removed without additional tools.
LBH/11827693/02/211-20150615.1139/en
copyright by
L538-1493 150-9
2.2 Hydraulics
Fig. 418: Quick coupler unactuated / unlocked / locked

1 Control valve block (working 4 Quick coupler solenoid valve I Unlock quick coupler button
hydraulics LS connection) LS signal Y53a
2 Control valve block (high 5 Quick coupler solenoid valve II Lock quick coupler button
pressure working hydraulics) Y53
3 Hydraulic tank 6 Hydraulic cylinder quick cou-
pler
When the quick coupler is not actuated, the quick coupler solenoid valve 5 and the
quick coupler solenoid valve LS signal 4 are not energised. The quick coupler sole-
noid valve 5 connects the piston side of the hydraulic cylinder 6 with the high pres-
sure of the working hydraulics 2. As the high pressure of the working hydraulics is
always on the piston side, the quick coupler can not be unlocked unintentionally.
When the quick coupler is unlocked, the quick coupler solenoid valve 5 and the
quick coupler solenoid valve LS signal 4 are energised. The quick coupler solenoid
valve 5 connects the ring side of the hydraulic cylinder 6 with the high pressure of
the working hydraulics 2. Thequick coupler solenoid valve LS signal 4 also con-
nects the high pressure of the working hydraulics 2 with the LS connection of the
working hydraulics 1 and thus generates a load sensing signal. The load sensing
signal causes the working hydraulics pump to swing out. The hydraulic cylinder 6
pulls in the two locking pins. The quick coupler unlocks.
When the quick coupler locks, only the quick coupler solenoid valve LS signal 4 is
energised. The quick coupler solenoid valve 5 connects the piston side of the hy-
draulic cylinder 6 with the high pressure of the working hydraulics 2. Thequick cou-
pler solenoid valve LS signal 4 also connects the high pressure of the working hy-
draulics 2 with the LS connection of the working hydraulics 1 and thus generates a
load sensing signal. The load sensing signal causes the working hydraulics pump
to swing out. The hydraulic cylinder 6 extends the two locking pins. The quick cou-
LBH/11827693/02/211-20150615.1139/en
pler locks.
copyright by
150-10 L538-1493
2.3 Electrics
Fig. 419: Wiring diagram of quick coupler

A17a Output module 1 K232 Latching function relay
F1 Quick coupler fuse (5 A) MP6_f Cab, rear wall earth point
H40 Buzzer Y53 Quick coupler solenoid valve
KL15 Voltage at terminal 15 Y53a Quick coupler solenoid valve LS signal
KL30 Voltage at terminal 30 S23 Quick coupler button
K231 Unlock quick coupler relay
Tab. 76: Electrics
The electrics of the quick coupler are supplied with voltage via the fuse F1.
The quick coupler can be locked or unlocked using the quick coupler S23 button.
LBH/11827693/02/211-20150615.1139/en
2.3.1 Unlocking the quick coupler

When the quick coupler S23 button is in the 1 position, the quick coupler is un-
locked. The quick coupler S23 button supplies the unlock quick coupler relay K231
and the quick coupler solenoid valve LS signal Y53a with voltage.
provides sufficient pressure for the hydraulic cylinder to retract.
The quick coupler solenoid valve Y53 is supplied with voltage via the unlock quick
coupler relay K231. This directs hydraulic oil to the ring side of the hydraulic cylin-
der. The hydraulic cylinder retracts. At the same time, the buzzer H40 is activated.
copyright by
L538-1493 150-11
The latching function relay K232 ensures that the quick coupler solenoid valve Y53
and the buzzer H40 remain active even when the quick coupler S23 button is re-
leased.
The quick coupler solenoid valve LS signal Y53a is only active when the quick cou-
pler S23 button is actuated.
2.3.2 Locking the quick coupler

When the quick coupler S23 button is in the 2 position, the quick coupler is locked.
The quick coupler S23 button supplies the latching function relay K232 and the
quick coupler solenoid valve LS signal Y53a with voltage.
provides sufficient pressure for the hydraulic cylinder to extend.
As soon as the latching function relay K232 is supplied with voltage, the latching
function relay is deactivated. This interrupts the voltage supply to the quick coupler
solenoid valve Y53. Hydraulic oil is directed to the piston side of the hydraulic cylin-
der. The hydraulic cylinder extends. At the same time, the buzzer H40 is deactiva-
ted.
LBH/11827693/02/211-20150615.1139/en
copyright by
150-12 L538-1493
160 Cab, heating and air condition-
ing
Contents
160.1 Overview of the cab, heating and air conditioning unit
L538-1493/31405-; 160-3
160.2 Display and control elements 160-5
160.2.1 Electrical components in the control panel 160-5
160.2.1.1 Overview of electrical components in the control pan-
el
L538-1493/31405-; 160-5
L538-1493/31405-; 160-5
L538-1493/31405-; 160-8
160.2.2 Display
L538-1493/31405-; 160-9
L538-1493/31405-; 160-10
160.3 Heating, ventilation, air conditioning 160-13
160.3.1 Overview of the heating, ventilation and air conditioning system
L538-1493/31405-; 160-13
160.3.2 Heating and air conditioning unit 160-16
L538-1493/31405-; 160-16
160.3.2.2 Blower
L538-1493/31405-; 160-19
LBH/11827693/02/211-20150615.1139/en
160.4 Air conditioning 160-20

L538-1493/31405-; 160-20
160.4.2 Condenser
L538-1493/31405-; 160-23
160.4.3 Dryer
L538-1493/31405-; 160-23
L538-1493/31405-; 160-25
copyright by
L538-1493 160-1
Cab, heating and air conditioning Service manual
160.4.5 Evaporator
L538-1493/31405-; 160-26
LBH/11827693/02/211-20150615.1139/en
copyright by
160-2 L538-1493
Service manual Cab, heating and air conditioning
Overview of the cab, heating and air conditioning unit
160.1 Overview of the cab, heating and air condi-

tioning unit
Valid for: L538-1493/31405-;
1 Layout
Fig. 420: Driver’s cab

1 Heating, ventilation, air-condition- 14 Adjustable arm rest
ing outlet nozzles
2 Interior mirror 15 Control lever
3 Sun visor 16 Additional control lever (optional)
4 Display A13 17 Control unit A11
5 Radio installation 18 Starter switch S1
6 Switch panel 19 Switch panel
7 Interior lighting 20 “Heater/ventilation/air-condition-
ing” control unit
8 Inch/brake pedal 21 Service hours counter (optional)
LBH/11827693/02/211-20150615.1139/en
9 Steering column switch S3 22 Cigarette lighter socket X71

10 Steering wheel 23 Diagnostic plug X60
11 Steering wheel hub for steering 24 Fuse box
wheel height adjustment (optional)
12 Steering wheel adjustment lever 25 Driver’s seat
13 Accelerator pedal R5
2.1 Basic function

The driver’s cab is mounted on a flexible bearing on the rear section.
The driver’s cab is equipped with warm water heating. Optionally, an air condition-
ing unit can be also installed.
copyright by
L538-1493 160-3
Overview of the cab, heating and air conditioning unit
The entry to the cab is via the access and the door on the left.
The right window is also an emergency exit.
2.2 Strength according to ROPS/FOPS

The cab is a safety cab which is tested and approved in accordance with ROPS/
FOPS.
ROPS (roll over protective structure) refers to mechanical rigidity in the event of the
vehicle falling over.
FOPS (falling object protective structure) refers to the rigidity of the cab on the
event of objects falling onto it.
LBH/11827693/02/211-20150615.1139/en
copyright by
160-4 L538-1493
Display and control elements
160.2 Display and control elements
160.2.1 Electrical components in the control panel
160.2.1.1 Overview of electrical components in the control panel

Valid for: L538-1493/31405-;
1 Layout
Fig. 421: Control panel

1 Control unit A11 5 Cigarette lighter socket X70
2 Temperature control knob 6 Air conditioning switch (optional)
3 Blower motor control knob 7 Starter switch S1
4 Air distribution control knob
2 Function
The control unit 1 has its own CAN address and communicates with the central
control unit.
Use the temperature knob 2 to regulate the temperature in the cab.
Use the blower motor knob 3 to regulate the blower motor speed.
Use the air distribution knob 4 to regulate the air distribution in the cab.
LBH/11827693/02/211-20150615.1139/en
External devices requiring a 12 volt power supply can be connected to the cigarette
lighter socket 5.
The machine can be put into operation with the starter switch 7.

Valid for: L538-1493/31405-;
The control unit has buttons. The buttons are used to activate and deactivate vari-
ous functions on the machine. When a function is activated, one or more LEDs
light up correspondingly.
copyright by
L538-1493 160-5
1 Layout
Fig. 422: Control unit

1 Control unit 3 LED
2 Button 4 Symbol
Button Designation Button Designation

Parking brake A) DISP MODE B)
Display brightness adjust- Working hydraulics lockout C)

ment
Higher travel range Lower travel range
Vmax (speed restriction) Central lubrication system

(optional)
Ride control (optional) C)

LBH/11827693/02/211-20150615.1139/en
Tab. 77: Buttons on the control unit
A) The parking brake is automatically activated when the engine is started.

B) For switching the display between engine speed (rpm), service hours (hours)
and clock (time). Press the button for 5 seconds to change between summer
and winter time.
C) The setting remains stored after the ignition is switched off.
2 Function
The control unit for main functions is linked to the central control unit via a CAN
bus (CAN line 1).
copyright by
160-6 L538-1493
The control unit A11 functions as soon as the ignition is turned on (terminal 15).
When a button is pressed, a signal is sent via CAN bus to the central control unit.
The buttons have LEDs, which can signal the following conditions:
Button with switch function: all three LEDs ON or OFF
Button with touch function: all three LEDs only light up when the button is press-
ed
Button with control function: the LEDs go on or off individually each time the
button is pressed
The functions of each button are described in the operating manual for the ma-
chine in question.
2.2 Function test

When the ignition is turned on, all the LEDs light up for the duration of the test.
If there is a fault or failure in a module (CAN bus module) the LEDs remain lit after
the test (safety-critical condition). In this case, the system cannot be started.
2.3 Plug assignment
Fig. 423: Plug A11/X1

1 +24 V power supply F71 (connec- 7 CAN bus CAN High 2
ted to pin 5)
2 Earth (connected to pin 6) 8 CAN bus CAN Low 2
3 CAN bus CAN High 1 9 Terminating resistor
4 CAN bus CAN Low 1 10 Unassigned
5 Unassigned 11 Unassigned
6 Unassigned 12 Unassigned
LBH/11827693/02/211-20150615.1139/en
copyright by
L538-1493 160-7

Valid for: L538-1493/31405-;
1 Layout
Fig. 424: Starter switch

1 Starter switch S1 3 Electrical connections
2 Starter switch positions 4 Equivalent circuit diagram
The starter switch 1 is on the right, fitted in the control panel.
2.1 Basic function

The machine can be started with the starter switch. The starter switch has four po-
sitions.
2.2 Position P (terminal 58)

In position P the connection 30 on the starter switch is coupled with the connec-
tion 58.
In this position, when the battery main switch is ON, the following functions are ac-
tivated:
– Radio
– 12 volt socket
– Driver's seat compressor (optional)
LBH/11827693/02/211-20150615.1139/en
– Cigarette lighter socket

– Interior lighting for cab
– Door contact switch (optional)
– Working headlights (on default setting)
2.3 Position 0 (terminal 30)

In position 0 the connection 30 on the starter switch is not connected.
This is also the ignition OFF position. In this position the machine is not in opera-
tion.
In this position, when the battery main switch is ON, terminal 30 is activated.
copyright by
160-8 L538-1493
2.4 Position 1 (terminal 15 and terminal 58)

In position 1 the connection 30 on the starter switch is coupled with the connec-
tions 15 and 58.
This is also the ignition ON position.
In this position, when the battery main switch is ON, terminals 15 and 58 are acti-
vated.
When the starter switch is turned to position 1, these are some of the functions that
are activated:
– The central control unit is booted up. A system check is performed.
– The preglow system is started.
Before the starter switch is turned from position 1 to position 2, booting up of the
central control unit and the preglow process must have been completed. This takes
5 to 10 seconds.
2.5 Position 2 (terminal 15 and terminal 50)

In position 2 the connection 30 on the starter switch is coupled with the connec-
tions 15 and 50.
In this position, when the battery main switch is ON, a signal is sent to the central
control unit. The engine starts.
After the starter switch is released in position 2, spring force automatically moves it
to position 1.
To prevent damage to the engine, position 2 should be activated for a maximum of
15 seconds. Wait 1 minute between starting attempts.
160.2.2 Display
Valid for: L538-1493/31405-;
1 Layout
The display (A13) shows the status icons and warning symbols of the machine.
LBH/11827693/02/211-20150615.1139/en
Fig. 425: Display
copyright by
L538-1493 160-9
2 Function
2.1 Symbols in the display

For further information on the symbols in the display, see: Operating manual
2.2 Plug assignment
Fig. 426: Plug assignment (plug A13.X1 / SUB-D)
The display (A13) is linked to the central control unit via 9-pin plug connector (plug
A13.X1 / SUB-D).
Pin Function Pin Function

1 Earth 6 No function
2 Supply voltage (terminal 15, 7 Supply voltage (terminal 30, fuse F10)
fuse F10)
3 CAN-Low 8 Terminating resistor
4 CAN-High 9 Terminating resistor
5 No function
Tab. 78: Plug assignment
At the back of the display, there is a plug connector (plug A13.X2) for the earth
connection to the housing.

Valid for: L538-1493/31405-;
The control lever (S2) includes the travel direction switch and buttons for other
functions.
Buttons for additional functions can be installed on the top. The control lever also
controls the movements of the working attachment (lift and tilt cylinders).
LBH/11827693/02/211-20150615.1139/en
copyright by
160-10 L538-1493
1 Layout
Fig. 427: Control lever with equivalent circuit diagram

1 Travel direction switch 4 Additional equipment 2 button
2 Control lever 5 Additional equipment 1 button
3 Additional equipment 3 button
2 Function
2.1 Basic function

After the electrical system has been turned on, the travel drive is set to neutral “N”.
This is shown in the display.
After the parking brake is released, the travel direction switch 1 must be set to neu-
tral “N” before a travel direction can be selected.
2.2 Switching the travel direction

Select forward or reverse using the travel direction switch 1.
The forward or reverse travel direction solenoid valves can only be activated when
the parking brake is released.
The travel direction is switched to neutral by closing the parking brake or by switch-
ing the travel direction 1 switch to neutral “N” (middle position).
2.3 Additional equipment button (optional)

If additional equipment is installed or will be installed later, the buttons 3, 4 and 5
can be used to control additional functions.
2.4 Plug assignment

Deutsch / 12-pin male
LBH/11827693/02/211-20150615.1139/en
Fig. 428: Plug S2.X

1 Supply voltage 7 Additional equipment button
copyright by
L538-1493 160-11
2 Forward travel direction switch sig- 8 Additional equipment supply

nal 1
3 Reverse travel direction switch 9 Additional equipment supply
signal 2
4 Forward travel direction switch sig- 10 Additional equipment button
nal 2
5 Reverse travel direction switch 11 Additional equipment supply
signal 1
6 Earth 12 Additional equipment button
For reasons of safety, two signals must be transmitted for each travel direction.
Travel direction Active signal Active signal

Neutral Forward direction switch sig- Reverse direction switch sig-
nal 1 nal 1
Forward travel direc- Forward direction switch sig- Reverse direction switch sig-
tion nal 2 nal 1
Reverse travel direc- Reverse direction switch sig- Forward direction switch sig-
tion nal 2 nal 1
Tab. 79: Travel direction output signals
LBH/11827693/02/211-20150615.1139/en
copyright by
160-12 L538-1493
Heating, ventilation, air conditioning
160.3 Heating, ventilation, air conditioning
160.3.1 Overview of the heating, ventilation and air condition-

ing system
Valid for: L538-1493/31405-;
1 Layout
The driver’s cab is equipped with warm water heating. Optionally, an air condition-
ing unit can be also installed.
LBH/11827693/02/211-20150615.1139/en
Fig. 429: Overview of the heating, ventilation and air conditioning system
1 Expansion valve 8 Coolant forward flow from the en-
gine
2 Heater/blower unit 9 Coolant return flow from the heat-
ing and air conditioning unit
3 Engine 10 Low pressure line from the expan-
sion valve
4 Air conditioning compressor 11 High pressure line from the air
conditioning compressor
5 Dryer 12 High pressure line from the con-
denser
copyright by
L538-1493 160-13
6 Air conditioning pressure switch 13 High pressure line from the dryer
and collector unit
7 Condenser
2 Basic function
The expansion valve 1 is attached to the heater/blower unit 2.
The heater/blower unit is fitted on the right of the driver’s cab.
The air conditioning compressor 4 is attached to the engine 3.
The dryer 5 and the condenser 7 are located in the cooler mount. The air condition-
ing pressure switch 6 is attached to the dryer.
The driver’s cab is equipped with warm water heating.
Optionally, an air conditioning unit can be also installed.
2.2 Air filters in the driver’s cab

The air drawn in is filtered by the pre-filter, the fresh air filter and the recirculated air
filter. The heater/blower unit distributes the filtered air through the outlet nozzles in-
to the interior of the cab.
2.2.1 Pre-filter and fresh air filter
Fig. 430: Pre-filter and fresh air filter

1 Maintenance access 3 Fresh air filter
2 Pre-filter
The pre-filter 2 and the fresh air filter 3 are located on the right, on the outside of
the driver’s cab.
Both filters must be replaced or cleaned regularly. (See the maintenance and in-
spection schedule.)
LBH/11827693/02/211-20150615.1139/en
copyright by
160-14 L538-1493
2.2.2 Recirculated air filter
Fig. 431: Recirculated air filter

1 Screw on holder for recirculated 2 Recirculated air filter
air filter
The recirculated air filter 2 is on the right, inside the driver’s cab.
In recirculation mode, the air is drawn in through the recirculated air filter.
The recirculated air filter must be replaced or cleaned regularly. (See the mainte-
nance and inspection schedule.)
2.2.3 Air conditioning troubleshooting
Malfunction Cause Remedy

The air conditioning compressor Cab filter is dirty Clean the cab filter
is switched off for long phases
Blower speed is too low Increase the blower
and only switched on for short
speed
phases
Evaporator is iced up Check the evapora-
tor
Evaporator fins are dirty Clean the cab evap-
orator fins
The air conditioning compressor Recirculating/fresh air Set the flap to recir-
is switched on for long phases flap is set to fresh air culating air
and only switched off for short
Heating is switched on Switch off heating
phases, it however fails to cool
Outlet nozzles at the Point the outlet noz-
front are pointed towards zles in the direction
the windscreen of the driver
LBH/11827693/02/211-20150615.1139/en
Air conditioning compressor Too much refrigerant in Correct the refriger-

does not run smoothly the air conditioning circuit ant level
Air in the air conditioning Evacuate and refill
circuit the air conditioning
unit
Valve plates in the air Check the valve
conditioning compressor plates
are defective
copyright by
L538-1493 160-15
Malfunction Cause Remedy

High-pressure switch switches Too much refrigerant in Correct the refriger-
off the air conditioning circuit ant level
unit
Condenser blocked Check the condens-
er
Low-pressure switch switches off Not enough refrigerant in Correct the refriger-
the air conditioning circuit ant level
Expansion valve blocked Check the expan-
sion valve
Bubbles in the sight glass Too much refrigerant in Correct the refriger-
Not enough refrigerant in Correct the refriger-
Not enough cooling Not enough refrigerant in Correct the refriger-
unit
Expansion valve blocked Check the expan-
sion valve
Condenser blocked Check the condens-
er
Valve plates in the air Check the valve
conditioning compressor plates
are defective
Tab. 80: Air conditioning troubleshooting table
160.3.2 Heating and air conditioning unit

Valid for: L538-1493/31405-;
The heater/blower unit is mounted in the right side of the cab.
LBH/11827693/02/211-20150615.1139/en
copyright by
160-16 L538-1493
1 Layout
Fig. 432: Layout of the heater/blower unit

1 Valve actuator rod 8 Air conditioning switch (optional)
2 Adjustable footwell air connection 9 Blower control knob
3 Air connection to driver-level noz- 10 Flap and air distribution control
zles knob
4 Air connections to front and right 11 Flap control bowden cable
side windows
5 Air connection to cab roof 12 Connection cable for blower regu-
lator and air conditioning control
switch
6 Water valve bowden cable 13 Regulator unit
7 Heating temperature control knob
LBH/11827693/02/211-20150615.1139/en
2 Function
2.1 Basic function

The heat exchanger of the heater/blower unit is supplied with hot water from the
engine cooling system.
Regulation takes place using the heating and ventilation control unit and a me-
chanically operated water valve.
The water valve controls the heater output.
The air flow is controlled using the various speeds of the blower.
copyright by
L538-1493 160-17
2.2 Regulating the air distribution (flap control)

The driver can adjust the air flaps manually as required, using the heating/ventila-
tion control unit.
The three flaps in the heater/blower unit are controlled using knobs.
2.3 Regulating the temperature

The temperature can be adjusted progressively.
Fig. 433: Regulating the temperature
Turn the temperature knob to the required position:

– The blue range is cool.
– The red range is warm.
2.4 Adjusting the blower

Use the blower knob to switch the blower on and off.
Fig. 434: Adjusting the blower
Blower levels:
– Level 0 – OFF position
– Level 1 to 4 – from low to high air flow
2.5 Adjusting the air distribution

LBH/11827693/02/211-20150615.1139/en
Fig. 435: Adjusting the air distribution
copyright by
160-18 L538-1493
Switch positions for air distribution:

– Position a - head and feet
– Position b - feet
– Position c - head
160.3.2.2 Blower
Valid for: L538-1493/31405-;
1 Layout
Fig. 436: Blower

1 Blower 4 Air intake
2 Blower wiring harness 5 Air outlet
3 Motor
The blower is part of the heater/blower unit.
2 Function
The blower is a 4-speed radial fan for ventilation, heating and air conditioning in the
driver’s cab.
The fan draws the air through the axial air intake 4 and blows it through the radial
air outlet 5 to the heat exchanger of the heater.
The air flow is regulated by changing the blower speed.
Regulation and control take place using the heating/ventilation control unit. On lev-
el 0, the blower is switched off. Level 4 is for maximum air flow.
LBH/11827693/02/211-20150615.1139/en
copyright by
L538-1493 160-19
Air conditioning
160.4 Air conditioning

Valid for: L538-1493/31405-;
1 Layout
Fig. 437: Components of the air conditioning system

1 Expansion valve 6 Pressure side filling coupling
LBH/11827693/02/211-20150615.1139/en
2 Evaporator in the heater/blower 7 Condenser

unit
3 Temperature sensor B26 in the 8 Air conditioning pressure switch
evaporator for anti-icing B27
4 Air conditioning compressor (with 9 Dryer
magnetic coupling Y22)
5 Suction side filling coupling
copyright by
160-20 L538-1493
Air conditioning
2 Function
2.1 Basic function
Fig. 438: Refrigerant circuit

1 Air conditioning compressor 9 Evaporator
2 Magnetic coupling 10 Blower
3 Condenser 11 Expansion valve
4 Fan A Liquid/gaseous refrigerant, high
pressure
5 Air conditioning pressure switch B Liquid refrigerant, high pressure
B27
6 Dryer C Liquid/gaseous refrigerant, low
pressure
7 Sight glass D Gaseous refrigerant, low pressure
8 Temperature sensor
The air conditioning compressor 1 draws in the refrigerant in gas form and increa-
ses its energy level (pressure and thermal energy).
The heat thus generated is transferred to the condenser 3. The heat dissipation
lowers the energy potential.
The cooled refrigerant liquefies. This change of state further reduces the energy in
it.
The refrigerant, which still has bubbles in it, passes into the dryer 6, where it is fil-
LBH/11827693/02/211-20150615.1139/en
tered and dried, and then, with the bubbles removed, passes to the expansion
valve 11 on the evaporator 9.
The liquid, pressurised refrigerant is sprayed through the expansion valve 11 into
low-pressure evaporator 9.
This allows the refrigerant to expand. The expansion reduces the pressure energy
in the refrigerant and very quickly cools the evaporator 9.
The evaporator 11 is exposed to hot air from the cab and transfers the heat to the
refrigerant. This thermal exchange cools the cab air and heats the refrigerant.
The heated refrigerant evaporates and turns to gas. This change of state requires
additional energy from the (warm) evaporator, which further reduces the tempera-
ture.
copyright by
L538-1493 160-21
Air conditioning
2.2 Temperature control

The temperature is regulated by cyclical activation and deactivation of the magnet-
ic coupling 2 of the air conditioning compressor 1 during operation, or by mixing hot
air from the heater, as for example in defrost mode.
The frequency of switching on and off is controlled by the temperature sensor 8 in
the compressor 9.
The temperature sensor 8 is a capillary tube with a switch contact. The switch con-
tact interrupts the power supply to the magnetic coupling.
The temperature is also regulated by the expansion valve 11. The pressure and
temperature are recorded at the evaporator outlet and the injection quantity is pre-
cisely metered.
These monitoring elements prevent the evaporator from icing up.
2.3 Operation
Fig. 439: Air conditioning mode
When the switch 1 is pressed, the magnetic coupling is energised by the air condi-
tioning compressor and the LED 2 lights up.
When the switch 1 is pressed again, the electrical circuit to the magnetic coupling
from the air conditioning compressor is interrupted and the LED 2 goes out.
2.4 Defrost mode

When the windows are misted up, the cab air must be dried. This is done by oper-
ating the air conditioning and the heater at the same time. The cab air can absorb
more moisture when it is heated. The air flowing past the cold evaporator releases
the moisture in the form of condensation.
LBH/11827693/02/211-20150615.1139/en
copyright by
160-22 L538-1493
Air conditioning
160.4.2 Condenser
Valid for: L538-1493/31405-;
1 Layout
Fig. 440: Condenser with connections

1 Condenser 4 Fastener
2 Refrigerant intake (from air condi- 5 Condenser holding frame
tioning compressor)
3 Refrigerant outlet (to dryer) 6 Swivel bearing for cleaning
The condenser is part of the cooling system.
2 Function
2.1 Basic function

The condenser 1 consists of a serpentine-shaped heating coil that is rigidly con-
nected to fins. A large cooling surface and a good transfer of heat is thereby ach-
ieved. The condenser works as a heat exchanger between the ambient air and the
refrigerant.
The condenser is subjected to forced ventilation by the fan of the cooling system.
LBH/11827693/02/211-20150615.1139/en
The refrigerant, which has been compressed by the compressor and thereby signif-
icantly heated, flows in a gaseous state into the condenser and is cooled down
there. The refrigerant condenses while cooling down and becomes liquid.
Cooling down and liquefaction keep the pressure of the refrigerant on the high
pressure side (the air conditioning compressor side) low.
The refrigerant flows from the condenser to the dryer.
160.4.3 Dryer
Valid for: L538-1493/31405-;
(For more information see: 020.12.1 Dryer, page 020-25)
copyright by
L538-1493 160-23
Air conditioning
1 Layout
Fig. 441: Dryer

1 Dryer 4 Intake (from condenser)
2 Sight glass 5 Outlet (to expansion valve)
3 Air conditioning pressure switch 6 Pressure relief valve
2 Function
The condenser is installed downstream from the dryer 1. The dryer acts as a refrig-
erant equalising and supply reservoir in the refrigerant circuit.
Liquid refrigerant flows from the condenser to the dryer. It is collected there and
then flows through the dryer, bubble-free, towards the expansion valve.
In different operating conditions, such as the thermal load on the evaporator or the
condenser and at different the engine speeds, different amounts of refrigerant are
pumped through the circuit.
The dryer absorbs moisture that penetrates the refrigerant circuit during assembly.
Swarf worn from the compressor, assembly dirt and similar contamination also ac-
cumulate in the circuit.
When there are high levels of moisture in the system, this can cause corrosion and
malfunctions.
The dryer contains desiccant granulate to absorb the moisture in the refrigerant. It
absorbs contamination such as acid and dirt particles. Filters are mounted on the
end of the dryer to prevent dryer granulate entering the refrigerant circuit.
LBH/11827693/02/211-20150615.1139/en
The dryer can only take up a limited amount of moisture. If the refrigerant circuit is
opened several times or for a lengthy period, the dryer takes up moisture from the
ambient air. The maximum amount of moisture will be reached faster and the dryer
will have to be replaced earlier.
A pressure relief valve 6 is fitted to protect against excess pressure. If the pressure
at the dryer exceeds 34±4 bar, the pressure relief valve opens and the pressure dis-
sipates from the dryer.
copyright by
160-24 L538-1493
Air conditioning

Valid for: L538-1493/31405-;
1 Layout
Fig. 442: Air conditioning pressure switch with equivalent circuit diagram
A High and low pressure monitor B Increase fan speed pressure
pressure switch switch
The air conditioning pressure switch (B27) is attached to the dryer of the air condi-
tioning circuit.
The air conditioning pressure switch consists of two pressure switches that are ac-
tivated by the same pressure level.
2 Function
2.1 Basic function

The high and low pressure monitor pressure switch A monitors the pressure in the
air conditioning circuit. If the pressure is too low or too high, it deactivates the mag-
netic coupling and thereby the air conditioning compressor.
If the pressure is too low or too high, there is a risk of damaging the components of
the air conditioning circuit.
The increase fan speed pressure switch B has no function in this type of machine.
Designation Unit Value

Low pressure OFF bar 1.5±0.5
Low pressure ON bar 3.4±0.3
High pressure OFF bar 26±2
High pressure ON bar 18±2
LBH/11827693/02/211-20150615.1139/en
Tab. 81: Switch pressures
2.2 Monitoring high and low pressure

The high and low pressure monitor pressure switch A at pins 3 and 4 protects the
air conditioning circuit from pressure that is too high or too low.
Monitoring low pressure:
If the pressure falls below 1.5±0.5 bar, the pressure switch opens. The central con-
trol unit detects the opening of the pressure switch and deactivates the magnetic
coupling.
When the pressure rises back above 3.5±0.5 bar, the pressure switch is reset and
the contact is closed again.
copyright by
L538-1493 160-25
Air conditioning
Insufficient pressure may be caused by:

– A leakage in the air conditioning circuit
– Not enough refrigerant
– Moisture in the air conditioning circuit
– etc.
Monitoring high pressure:
If the pressure rises above 25±2 bar, the pressure switch opens. The central control
unit detects the opening of the pressure switch and deactivates the magnetic cou-
pling.
When the pressure falls back below 18±1.5 bar, the pressure switch is reset and the
contact is closed again.
Excess pressure may be caused by:
– Air in the air conditioning circuit
– Too much refrigerant in the air conditioning circuit
– Insufficient cooling at the condenser (dirt, defective fan control)
– The filter in the dryer is dirty or saturated.
– The expansion valve may be iced up (too much moisture in the refrigerant) or
dirty (blocked).
– etc.
160.4.5 Evaporator
Valid for: L538-1493/31405-;
1 Layout
LBH/11827693/02/211-20150615.1139/en
Fig. 443: Evaporator with expansion valve

1 Holder (for fastening the air condi- 4 Evaporator
tioning hoses)
2 Expansion valve 5 Temperature sensor in the evapo-
rator (anti-icing protection)
3 Air conditioning sealing rings
The evaporator 4 is integrated in the heating and air conditioning unit and forms
part of the refrigerant circuit. The heating and air conditioning unit is installed in the
driver’s cab, on the right.
copyright by
160-26 L538-1493
Air conditioning
2 Function
2.1 Basic function

The evaporator 4 acts as a heat exchanger to cool the cab air.
The pressurised refrigerant is injected into the evaporator via the expansion
valve 2. The refrigerant evaporates as a result of the drop in pressure that devel-
ops.
Energy is required for evaporation. The evaporator takes this energy from the am-
bient air in the form of thermal energy. This significantly cools down the air. The
cooled air is conducted into the driver’s cab via nozzles.
Cooling the air down reduces the moisture in the air. This moisture settles on the
evaporator in the form of condensation water. This condensation water also ab-
sorbs the suspended solids contained in the air. The evaporator not only cools and
dehumidifies the air but also cleans it at the same time, which results in a markedly
improved interior environment when the air conditioning system operates.
The temperature sensor protects the evaporator from excessively cold tempera-
tures and icing up.
LBH/11827693/02/211-20150615.1139/en
copyright by
L538-1493 160-27
Air conditioning
LBH/11827693/02/211-20150615.1139/en
copyright by
160-28 L538-1493
190 Options
Contents
L538-1493/31405-; 190-2
LBH/11827693/02/211-20150615.1139/en
copyright by
L538-1493 190-1
Options Service manual
Reversible fan drive
Valid for: L538-1493/31405-;
1 Layout
Fig. 444: Reversible fan drive

1 Hydraulic tank 5 Travel motor 1 9 Hydraulic oil cooler
2 80 µm in-line filter 6 Fan reversal solenoid valve 10 Temperature valve
Y50
3 Pressure relief and propor- 7 Fan gear motor PK Cooling system high pressure
tional valve test connection
4 Fan gear pump 8 Collector pipe
Reversible fan drive components:
tank, page 080-2)
LBH/11827693/02/211-20150615.1139/en
– Collector pipe
– Fan gear pump (For more information see: 050.1.2 Fan gear pump,
page 050-4)
– Fan gear motor with fan blade
– Fan reversal solenoid valve Y50
– Pressure relief proportional valve Y13
copyright by
190-2 L538-1493
Service manual Options
2 Function
Fig. 445: Hydraulic diagram of reversible fan drive

1 Hydraulic tank 15 Brake system gear pump in- 31 Restrictor
take connection
2 Breather filter 16 Emergency steering pump in- 32 Primary piston
take connection
3 Return strainer 17 Transmission return flow 33 Secondary piston with propor-
tional solenoid Y13
4 Bypass valve 18 Compact brake valve return 34 0.25 bar check valve
flow
5 Return suction filter 19 Pilot control unit return flow 35 Fan reversal solenoid valve
Y50
6 Pre-tension valve 20 Working hydraulics pump 36 Fan gear motor
leak oil
7 Feeding valve 21 Servostat return flow 37 Hydraulic oil cooler
8 Strainer 22 Travel pump leak oil 38 Temperature valve
9 9 bar check valve 23 Control valve block return 39 Collector pipe
flow
10 2.5 bar bypass valve 24 Engine 40 Travel pump leak oil
11 Hydraulic oil temperature 25 Fan gear pump 41 Discharge in travel motor 2
sensor B8
12 Drain valve 26 Brake system gear pump 42 Travel motor 2 leak oil
13 Replenishing pump intake 27 80 µm in-line filter 43 Travel motor 1
connection
LBH/11827693/02/211-20150615.1139/en
14 Working hydraulics pump in- 30 Pressure relief and propor- PK Cooling system high pressure
take connection tional valve
When fan reversal is activated, the central control unit energises the fan reversal
solenoid valve 35. This swaps the pressure side and the tank side of the fan gear
motor 36. The fan gear motor turns in the opposite direction.
The fan speed is controlled via the pressure relief proportional valve 30. The pres-
sure relief proportional valve for the reversible fan drive is identical to the pressure
relief proportional valve in the fan gear motor when fitted as a standard fan drive.
(For more information see: Output speed, page 050-7)
copyright by
L538-1493 190-3
Options Service manual
LBH/11827693/02/211-20150615.1139/en
copyright by
190-4 L538-1493
200 Service codes, diagnosis
Contents
200.1 Malfunctions 200-2
200.1.1 Warning symbols 200-2
200.2 Troubleshooting 200-3
200.2.1 Replacing fuses 200-3
200.2.1.1 Fuses in the battery compartment 200-3
200.2.1.2 Plug-in fuses on the relay and fuse board 200-4
LBH/11827693/02/211-20150615.1139/en
copyright by
L538-1493 200-1
Service codes, diagnosis Service manual
Malfunctions
200.1 Malfunctions
200.1.1 Warning symbols

The following table contains explanations of warning symbols, causes and rem-
edies.
Symbol in the display Meaning Cause Remedy

Engine oil pressure too Engine oil pressure too Turn off the machine, check the oil
low low level, check the service code, trou-
bleshoot according to the engine
workshop manual
Coolant temperature Coolant temperature Clean the cooling system, check the
too high above 100 °C service code, check the coolant lev-
el, troubleshoot according to the en-
gine workshop manual
Fuel level too low Fuel tank is empty Refuel, check the service code,
check the fuel level sensor
Brake accumulator Service brake not work- Check the service code, check the
pressure too low ing correctly brake pressures according to testing
and adjustment checklist
Emergency steering Emergency steering Check the service code, check the
check not successfully check failed electrical and hydraulic system of the
completed emergency steering pump
Emergency steering Steering pump failed, Check the service code, check the
lights up when a steer- steering only possible steering system
ing pump fault occurs with emergency steer-
ing pump
Hydraulic oil tempera- Hydraulic oil tempera- Clean the cooling system, check the
ture too high ture above 95 °C service code, check the hydraulic
system
Battery not charging Fault in the electrical Check the service code, check the
system batteries, check the alternator, check
the wiring
Switch off the machine Fault on the machine Check the service code
LBH/11827693/02/211-20150615.1139/en
Air filter contamination Air filter is dirty Check the service code, change or
clean the air filter, check the air in-
take system
Tab. 82: Warning symbols
copyright by
200-2 L538-1493
Service manual Service codes, diagnosis
Troubleshooting
200.2 Troubleshooting
200.2.1 Replacing fuses
NOTICE
Beware of damage to the electrical system.
u In order to prevent damage to the electrical system, only use fuses with the cor-
rect rating.

q The electrical circuit has been checked before changing the fuse.
q The battery main switch of the machine is turned off.
WARNING
Beware of electrocution!
If you touch live parts you can be electrocuted.
u Switch off the machine’s electrical system before working on live components.
u The battery main switch must be turned off for reasons of safety.
200.2.1.1 Fuses in the battery compartment

If you need to access the fuses:
u Open the engine compartment hood.
Fig. 446: Fuses in the battery compartment

LBH/11827693/02/211-20150615.1139/en
Fuse Value Unit Designation/function

Hazard warning system, electrical sys-
1 F07a 10 A
tem button
2 F010 5 A Feedback info, heating flange
3 F01 100 A Main fuse
4 F02 100 A Preglow
5 F03 200 A Emergency steering pump
Tab. 83: Fuses in the battery compartment
copyright by
L538-1493 200-3
Troubleshooting
u Replace the blown fuse with a new one (of the same rating).
u Tighten the fuse holder insulating nut to 12 Nm.
200.2.1.2 Plug-in fuses on the relay and fuse board

The circuit board with the relays and plug-in fuses is located behind the operator’s
seat.
Each fuse has an LED so that you can test it.
Fig. 447: Plug-in fuses on the relay and fuse board

1 Screw 3 Relay and fuse board
2 Cover 4 LED TEST button
To check the plug-in fuses:
u Remove the cover 2.
u Press the button 4.
w If the fuse is intact, the corresponding LED lights up.
Note
Check the fuses.
u To check the fuses F2 to F7, the consumer unit must be switched on.
u Switch the ignition off again.

u Use the table below to identify the defective fuse.
LBH/11827693/02/211-20150615.1139/en
u Take out the defective fuse and replace it with a new one.

F1 5 A Quick coupler
F2 7.5 A Left high beam
F3 7.5 A Right high beam
F4 7.5 A Right low beam
F5 7.5 A Left low beam
F6 5 A Left marker lights
copyright by
200-4 L538-1493
Service manual Service codes, diagnosis
Troubleshooting

F7 5 A Right marker lights
F07b 10 A Hazard warning lights
F8 15 A Compressor seat
F8a 10 A Interior lighting
F9 10 A Fan reversal
F10 3 A Display
F11 3 A Inch pedal
F12 10 A Control unit UEC3, VDC1
F13 10 A Emergency steering pump
F14 20 A Heating/air conditioning system
F15 10 A Control lever
F16 20 A Starter solenoid
F17 max.40 A Engine stop
F18 10 A Rear wiper/washer pump
F19 10 A Spare
F19a 15 A Spare
F20 15 A Front wiper/washer pump, horn
F21 15 A Driving lights
F25 10 A Flashing beacon
F26 15 A Diagnostic plug
F27 10 A Marker lights/parking light
F28 10 A Spare
F29 25 A Starter switch bypass
F30 15 A Voltage transformer
F31a 10 A Front left working headlight
F31b 10 A Front right working headlight
LBH/11827693/02/211-20150615.1139/en
F33a 10 A Rear left working headlight

F33b 10 A Rear right working headlight
F35 10 A Dust filter
F36 40 A Spare
F37 20 A Engine control unit
F38 3 A Spare
F39 5 A Weighing device
F40 10 A Rear working headlights
F41 10 A Spare
copyright by
L538-1493 200-5
Troubleshooting

F43 10 A Engine control unit
F44 10 A Brake light
F45 3 A Spare
F46 3 A Reverse warning
F71 10 A Switch illumination
F73 10 A Central lubrication system
Rear window heater and mirror heater (op-
F74 15 A
tional)
F75 10 A 12V for radio, terminal 30
F76 10 A 12V for radio and 12V socket
Tab. 84: Plug-in fuses on the relay and fuse board
LBH/11827693/02/211-20150615.1139/en
copyright by
200-6 L538-1493

Liebherr l538 1493 Wheel Loader PDF

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Liebherr l538 1493 Wheel Loader PDF

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en Service manual

Contact Liebherr Machinery (DaLian) Co. Ltd.

Notes for users

This is the warning symbol. It warns you of poten-

DANGER Indicates a hazardous situation that will immedi-

CAUTION Indicates a hazardous situation that may lead to

ATTENTION Indicates a hazardous situation that may lead to

This symbol means: Carry out a task.

This symbol means: Requirements must be fulfilled.

This symbol means: Results of a task.

- This symbol indicates a list.

010 Introduction 010-1

010.1.17.2 Preventing injuries 010-13

010.2.2 Special tools for the diesel engine 010-16

020 Technical data 020-1

020.1 Drive group 020-4

020.1.5 Air filter vacuum switch

020.6 Steering system 020-15

020.10.1 Front axle

030 Maintenance 030-1

030.3.5 Coolants for diesel engines

030.3.6.1 Liebherr hydraulic oil 030-22

030.4.4.1 Checking the engine oil level

030.4.5.1 Checking the coolant level

030.4.7.2 Lubricating the bearing points on the steering

030.4.8.3 Checking the gap and wear on the parking brake

030.4.12.2 Covering - lubricating locks and hinges

030.4.13.4 Lubricating and testing the quick-change device

030.6.2 Overall machine 030-124

030.6.4 Cooling system 030-127

030.6.6.7 Engine output

030.6.8.2 Service brake pressure

040 Drive group 040-1

040.1.5.4 Fuel fine filter

050 Cooling system 050-1

060 Working hydraulics 060-1

060.7 Ride control 060-35

070 Travel hydraulics 070-1

070.5.3 Travel motor 2

080 Hydraulic components 080-1

080.1.3 Breather filter

090 Steering system 090-1

100 Brake system 100-1

100.1 Overview of the brake system

100.3.2 Service brake hydro accumulator

110 Electrical system 110-1

120 Transmission 120-1

120.4 Hydraulic control unit 120-11

130 Axles and cardan shafts 130-1

140 Steel components of the basic machine 140-1

150 Working attachment 150-1

160 Cab, heating and air conditioning 160-1

160.2.1.1 Overview of electrical components in the control

190 Options 190-1

200 Service codes, diagnosis 200-1

010.2.1 Special tools, general 010-16

010.1 Safety instructions

010.1.1 General safety instructions

16. Secure all loose parts of the machine.

010.1.2 Instructions on preventing crushing injuries and burns

from falling shut using the struts provided.

010.1.3 Instructions on preventing fires and explosions

010.1.4 Safety instructions for start-up