265008640-Service-Manual-L550-L580-2plus2.pdf

en

Service Manual (20

Wheel loader

(10 points)

L550 - L580 2plus2 (10

en

Service Manual (20

Wheel loader

(10 points)

L550 - L580 2plus2 (10

Address Address:

LIEBHERR-WERK BISCHOFSHOFEN GMBH Dr. Hans Liebherr – Straße 4 A – 5500 BISCHOFSHOFEN

Product ID Manufacturer: Product group: Type: Production number: Serial number:

LIEBHERR-WERK BISCHOFSHOFEN GMBH Wheel loader L550 L556 L566 L576 L580 456 454 460 457 459 16978 15653 14171 14171 14171

Document ID Order number: Author: Document version: Manual number: Owner:

1035 3357 LBH / Technical Documentation Department 01

Preface

Intended readership

Contents

This service manual is addressed to anyone whose task it is to ensure that the machines are ready for everyday use. This especially includes mechanics and workshop staff of Liebherr dealers and branches. The first chapter contains information on safety regulations and on the special tools needed for maintenance and repairs. Chapter 2 gives you an overview of all the most important technical data of the machine as a whole and its individual assemblies. Next comes the maintenance chapter, with the maintenance and inspection schedule, the testing and adjustment checklists, lubrication charts, description of maintenance tasks, testing and adjustment tasks and specifications of fuel and lubricants. The technical description of the machine is in the following chapters, structured according to fifteen function groups. The layout, function and technical data of the groups, components and parts are explained. Chapter 19 contains information on troubleshooting, the service code table and a description of the “SCULI” service software. Chapter 20 will be gradually updated with the latest options.

Instructions on use

This manual describes several types and versions of machines. The information generally applies to the types and serial numbers stated at the bottom of the page. The exception to this is information which only applies to specific types and serial numbers, which are stated at the beginning of the section concerned (for example technical data of parts). Where possible, the ID numbers of parts and components are stated in the heading. This manual is available in German, English, French, Spanish and Italian.

Working instructions

Always follow the safety regulations whenever you work on the machine. You will find a reference to this in the “General Information” section. In order to perform these tasks you need a complete set of basic tools andcertain special tools, all in perfect working order. All tasks require absolute cleanliness. Replace seals such as O-rings and surface seals during repairs.

General information

1

Product description

2

Maintenance

3

Diesel engine and pump distributor gear

4

Cooling system

5

Travel hydraulics

6

Working hydraulics

7

Steering system

8

Brake system

9

Electrical system

10

Transfer gear

11

Axles and cardan shaft

12

Machine frame and ballast weight

13

Central lubrication system

14

Coverings and access

15

Cab, heating and air-conditioning

16

Lift arms and quick-change device

17

Equipment and accessories

18

Service codes and diagnosis

19

Options

20

1 General Informations 1.0 Chapter contents 1

General Informations........................................................... 1.0-1 1.1

Safety regulations ...........................................................................1.1-1 1.1.1

Introduction...........................................................................1.1-1

1.1.2

Overview of the safety regulations .......................................1.1-2

1.2

Special tools for maintenance and repair work...............................1.2-1 Special tools in general ........................................................1.2-1

1.2.2

Special tools for Liebherr diesel engines..............................1.2-2

1.2.3

Special tools for hydraulic cylinders .....................................1.2-3

1.2.4

Special tools for electronics..................................................1.2-3

1.2.5

Special tools for axles...........................................................1.2-3

1.2.6

Special tools for the transmission.........................................1.2-5

1.2.7

Central lubrication system ....................................................1.2-5

1.2.8

Special tools for the air conditioning system ........................1.2-5

1.2.9

Special tools for cab windows ..............................................1.2-5

LBH/Version 01/10.2006/en/hd/25.01.2007

1.2.1

L550 - 456 / from 16978 L556 - 454 / from 15653 L566 - 460 / from 14171

L576 - 457 / from 14171 L580 - 459 / from 14171

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Service Manual

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General Informations

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Service Manual

General Informations Safety regulations

1.1 Safety regulations Working on the machine poses safety risks to the operator, driver or maintenance engineers. You can prevent risks and accidents by regularly reading and observing the various safety instructions. This is especially important for personnel who only occasionally work on the machine, for example, carrying out rigging or maintenance work. The safety regulations listed below, if conscientiously followed, will ensure your own safety and that of others, and will prevent the machine from being damaged. Whenever tasks which could cause danger to personnel or damage to the machine are described, the necessary safety precautions are explained in this manual. These are indicated by the headings Danger, Warning or Caution.

1.1.1

Introduction 1. The symbols below have the following meanings: Danger Risk of personal injury. Denotes an impending dangerous situation which can lead to serious injury or death if not avoided. ! Note the warning.

Warning Risk of personal injury. Denotes a potentially dangerous situation which can lead to serious injury or death if not avoided. ! Note the warning.

Caution Risk of personal injury. Denotes a potentially dangerous situation which can lead to slight injury if not avoided. ! Note the warning.

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Caution Risk of damage to the machine. Denotes actions or circumstances which may result in damage to the machine. ! Note the warning.

Note Useful information Denotes information on correctly handling the machine and the lubricants and fuels used. ! Observe the instructions.


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Service Manual

Safety regulations

2. Observance of these instructions does not exempt you from following any additional rules and guidelines that may apply The following should also be observed: – The safety rules in force at the operating site – Legally enforceable road traffic regulations – Guidelines issued by trade associations

1.1.2

Overview of the safety regulations A detailed description of these can be read in the relevant section of the safety regulations chapter in the operating manual. The following sections are included in the operating manual: 1

Introduction

2

General safety regulations

3

Proper use

4

Decals on the machine

5

Instructions on preventing crushing injuries and burns

6

Instructions on preventing fires and explosions

7

Safety instructions for start-up

8

Safety precautions during start-up

9

Instructions for safe working

10

Safety instructions for driving on slopes

11

Parking safely

12

Transporting the machine safely

13

Towing the machine safely

14

Measures for ensuring safe maintenance Safety instructions for working on machines with hydro accumulators

16

Safety instructions for welding work on the machine

17

Instructions for working safely on the working attachment

18

Safety instructions for transporting the machine by crane

19

Safe maintenance of hydraulic hoses and hose lines

20

Attachments and accessories

21

Protection against vibrations

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Service Manual

General Informations Special tools for maintenance and repair work

1.2 Special tools for maintenance and repair work 1.2.1

ID no.

Use

Anti-freeze and battery tester

7408922

All wheel loaders

24 volt vacuum pump Filling and testing device with case Manometer 0 - 40 bar Manometer 0 - 250 bar Manometer 0 - 600 bar Manometer connection High pressure hose 1500 mm High pressure hose 4000 mm Screw connection M 10 x 1 Draining hose Drain piece

7408148

All wheel loaders

Remarks For checking the acid concentration (battery charging state) and anti-freeze For preventing oil loss

8145359

All wheel loaders

For checking the hydro accumulator

7361288 5002932 5002866 7002436 7002475 7009134 5005180 7005660 7402657

All wheel loaders All wheel loaders All wheel loaders All wheel loaders All wheel loaders All wheel loaders All wheel loaders All wheel loaders All wheel loaders

Safety cap 10 mm

7009315

All wheel loaders

Safety cap 13 mm Safety cap 17 mm Safety cap 19 mm

7615515 7615589 7009317

All wheel loaders All wheel loaders All wheel loaders

Safety cap 17 mm

7622068

All wheel loaders

USB dongle

10333608

L550 - L580

Diagnostic data cable

10035410

L550 - L580

Adapter cable RS232<>USB

693190714 All wheel loaders

SDCF-03 memory card adapter

10223098

L550 - L580

Compact flash card

10223095

L550 - L580

For checking the hydraulic pressure For checking the hydraulic pressure For checking the hydraulic pressure Connection for the manometer High pressure hose for manometer High pressure hose for manometer For checking the hydraulic pressure For draining oil via a drain valve For the drain hose For securing the valves on the variable adjustment motor For securing the valves on the pumps For securing the valves on the pumps For securing the valves on the pumps For securing the valves on the control block With SERVICE authorisation For adjusting the travel hydraulics, and testing the electrical system and options For communicating with the wheel loader electronics if there is an error with the RS232 interface on the notebook. For writing to the compact flash card Blank compact flash card. Data medium for application software.

LBH/Version 01/10.2006/en/hd/25.01.2007

Description

Special tools in general


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Service Manual

Special tools for maintenance and repair work

Description

Special tools for Liebherr diesel engines ID no.

Use

Mandrel

9078118

L550 - L556 engine

Mandrel

9078119

L550 - L556 engine

Rotary angle device

0524062

L550 - L580 engine

Holder

0528464

L550 - L580 engine

Dial gauge holder

10023885

L550 - L580 engine

Compression tester Compression tester insert Adapter Claw

8008782 10012817 10297211 10117612

L550 - L580 engine L550 - L580 engine L550 - L580 engine L550 - L580 engine

Engine turner

0524045

L550 - L580 engine

Holder

0528464

L550 - L580 engine

Piston strap

8000592

L550 - L580 engine

Rotary angle device

0524062

L550 - L580 engine

Piston ring tongs

7009319

L550 - L580 engine

Extractor tool

0526855

L550 - L580 engine

Extractor tool

0528462

L550 - L580 engine

Mounting pin

0528470

L550 - L580 engine

Hook and lever

7019858

L550 - L580 engine

Inserter

10116249

L550 - L580 engine

Mounting pin

0528470

L550 - L580 engine

Inserter

10116250

L550 - L580 engine

Special spanner

10020852

L550 - L580 engine

Adapter

0524029

L550 - L580 engine

Adapter

10220689

L550 - L580 engine

Hammer puller

0524072

L550 - L580 engine

Pusher tube

10289319

L550 - L580 engine

Pusher tube

10289320

L550 - L580 engine

Mounting pin

0528472

L550 - L580 engine

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Remarks For installing the mass equalisation shafts (D 934) For installing the mass equalisation shafts (D 934) For installing and removing the cylinder head For checking projection of the cylinder bushings For checking projection of the cylinder bushings For checking the compression For checking the compression For checking the compression For checking the compression For installing and removing the pistons and rods For installing and removing the pistons and rods For installing and removing the pistons and rods For installing and removing the pistons and rods For installing and removing the piston rings For installing and removing the cylinder bushing For installing and removing the cylinder bushing For installing and removing crankshaft attachments For installing and removing the front crankshaft seal For installing and removing the front crankshaft seal For installing and removing the flywheel For installing and removing the rear crankshaft seal For installing and removing the injection line For installing and removing the pressure pipe port and injection nozzles For installing and removing the pressure pipe port and injection nozzles For installing and removing the pressure pipe port and injection nozzles For installing and removing the injection pump and roller tappet For installing and removing the injection pump and roller tappet For installing and removing the exhaust pipe

L550 - 456 / from 16978 L556 - 454 / from 15653


LBH/Version 01/10.2006/en/hd/25.01.2007

1.2.2

Service Manual


1.2.3 Description Assembly sleeve 80 mm

ID no. 9227165

Assembly sleeve 90 mm

9227161


9998624


9998622

Assembly sleeve 170 mm Expansion sleeve 80 mm

9107931 9227166

Expansion sleeve 90 mm

9227162


9110408


9110410

Expansion sleeve 170 mm Bearing head assembly spanner 70/8 mm Bearing head assembly spanner 75/12 mm

9110412

Use L550, L556 steering cylinder L566, L576, L580 steering cylinder L550, L556 lift cylinder L550, L556 tilt cylinder L566, L576, L580 lift cylinder L566, L576, L580 tilt cylinder L550, L556 steering cylinder L566, L576, L580 steering cylinder L550, L556 lift cylinder L550, L556 tilt cylinder L566, L576, L580 lift cylinder L566, L576, L580 tilt cylinder

9210219

L550, L556 steering cylinder

For fitting the piston rod bearing

9239572

L566, L576, L580 steering cylinder

For fitting the piston rod bearing

1.2.4 Description

8502956

Test probe, red Test probe, black Magnet tester Stripping and crimping pliers 0.5 – 6.0 mm2 Crimping pliers Wedge extractor tool Extraction tool size 12 for pin and bushing Extraction tool size 16 for pin and bushing Extraction tool size 20 for pin and bushing

Use

For fitting the seals For fitting the seals For fitting the seals For fitting the seals For fitting the seals For fitting the seals For fitting the seals For fitting the seals For fitting the seals

Remarks For measuring voltage, current, resistance and frequency For testing DEUTSCH connectors For testing DEUTSCH connectors For checking solenoid valves

All wheel loaders

884191214 All wheel loaders 884191114 All wheel loaders 8145743 All wheel loaders 8460263

All wheel loaders

For MATE-N-LOK connectors

8503647 7026267

All wheel loaders All wheel loaders

For DEUTSCH connectors For DEUTSCH connectors

8145674

All wheel loaders

For DEUTSCH connectors

8145673

All wheel loaders


8503630

All wheel loaders


1.2.5

Special tools for axles

Description

ID no.

Hand pump

8145835

L550 - L580 axles

Collet

7009536

L550 - L576 axles

Spring hook

8145767

L550 - L576 axles

Slip bushing 260 mm

7017559

Slip bushing 315 mm

7017556


Remarks For fitting the seals

Special tools for electronics

ID no.

Digital multimeter

LBH/Version 01/10.2006/en/hd/25.01.2007

Special tools for hydraulic cylinders

Use

Remarks For finding leaks on disc brakes For installing and removing the snap ring in the planetary drive For attaching and detaching the return springs

L556 front axle L556 rear axle L566, L576 front axle L566, L576 rear axle

L576 - 457 / from 14171 L580 - 459 / from 14171

For fitting the brake piston For fitting the brake piston

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Service Manual


Use

Remarks

7017558

L556 rear axle

For fitting ring gear carriers

7017557

L556 front axle L566, L576 rear axle


7017555

L566, L576 front axle


7017566 7011518 7017563

Handle for mounting tool Handle for various mounting tools For fitting cartridge seal ring

7011522 7013922

L550 - L576 axles L550 - L576 axles L556 rear axle L556, L566, L576 front axle; L566, L576 rear axle L556 - L576 axles L556 rear axle L556 front axle L566, L576 rear axle L566, L576 front axle L556 front axle L556, L566, L576 rear axle L566, L576, L580 front axle; L580 rear axle L556 - L580 axles L556 - L580 axles

Mounting tool

7017560

Centring bracket Groove nut spanner 111 mm

7013775 7009537

Groove nut spanner 140 mm

7011251

Groove nut spanner 169 mm Measuring screw M 16 x 1.5 Measuring screw M 16 x 1.5 Clamp fork Mounting tool Slotted nut spanner 81 mm Mounting tool (used with grip 7011518)

7013774

10017840

L550 - L576 axles

7624271

L550 axles, MT-L 3085

Mounting tool

7624272

L550 axles, MT-L 3085

Centring bracket

10008138

Socket wrench

10008139

Socket wrench

10218794

Clamp fork

10008140

L550 MT-L 3085 axles

10286181

L580 Hercules axles

10286183

L580 Hercules axles

10286186

L580 Hercules axles

Grip for seal driver and shell

10286788

L580 Hercules axles

Driver for inner lip seal

10286189

L580 Hercules axles

Driver for wear bushing with guide

10286190

L580 Hercules axles

Grooved nut socket

10286192

L580 Hercules axles

Seal holder installation tool Driver for oil bearing casings, bevel gear

10286193

L580 Hercules axles

10286194

L580 Hercules axles

Special tool kit for Hercules axles Driver for lubrication and oil seal 3“ bushing driver with guide and grip

1.2-4 o f 6

ID no.

7019556 8145771

L550 - L576 axles MT-L 3085-3105 L550 MT-L 3085 axles L556 rear axle L550 MT-L 3085 front axle L556 - L576 axles

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For fitting cartridge seal ring For groove nut spanner For fitting the grooved nuts For fitting the grooved nuts For fitting the grooved nuts For measuring wear on the brake discs For measuring wear on the brake discs For fitting the drive flange For fitting the shaft seal ring For fitting the grooved nuts on the axle shaft For fitting the dust protection axle insert For fitting the shaft seal ring axle insert For detaching the output For detaching the output For detaching the output For removing and fitting the drive pinion Contains the following items: 10286183 - 10286198 For fitting the lubrication and oil seal, to be used with grip 10286788 For installing bushing, including grip 10286788 For fitting the outer lip seal, to be used with appropriate driver For fitting the inner lip seal, to be used with grip 10286788 For installing the wear bushing For removing and fitting the grooved nuts For fitting the seal holder For installing the bearing casings, bevel gear

L550 - 456 / from 16978 L556 - 454 / from 15653


LBH/Version 01/10.2006/en/hd/25.01.2007

Description Slip bushing M 90 x 1.5 mm Slip bushing M 110 x 1.5 mm Slip bushing M 130 x 1.5 mm Handle Handle Mounting tool

Service Manual


Description Driver for grease seal and disc

ID no. 10286195

L580 Hercules axles

Rolling apparatus

10286196

L580 Hercules axles

Lifting tackle Installation tool for Lifetime seal

10286197

L580 Hercules axles

Remarks For fitting the grease seal and disc, to be used with grip 10286788 For testing the rolling torque of the wheel hubs For removing the wheel hub

10286198

L580 Hercules axles

For fitting the Lifetime seal

1.2.6 Description

Special tools for the transmission ID no.

Use

Fixing spanner

10016179

L550 - L580

Special socket

10016180

L550 - L580

Mounting tool

10016181

L550 - L580

1.2.7 Description

Remarks For loosening and tightening the grooved nut on the coupling 1 For loosening and tightening the grooved nut on the coupling 1 For removing and attaching the snap ring on the couplings

Central lubrication system ID no.

Use

BEKA Max filling press

10009239

All wheel loaders

Groeneveld filling press

10333342

All wheel loaders

Filling connection Gröneveld central lubrication data cable

7029283

All wheel loaders

7624289

All wheel loaders

7624290

All wheel loaders

Gröneveld central lubrication plug adapter

1.2.8 Description

LBH/Version 01/10.2006/en/hd/25.01.2007

Use

Remarks For quickly filling the BEKA Max reservoir For quickly filling the Groeneveld reservoir For filling the reservoir For inspecting the central lubrication system For inspecting the central lubrication system

Special tools for the air conditioning system ID no.

Use

Remarks

Vacuum pump

7027552

All wheel loaders

For evacuating the air conditioning system

4-valve test fitting

7027558

All wheel loaders

For testing, evacuating and filling the air conditioning system

Filling hose, blue 1500 mm

7027553

All wheel loaders

For the test fitting

Filling hose, yellow 1500 mm

7027554

All wheel loaders


Filling hose, red 1500 mm

7027555

All wheel loaders


Car coupling 253a

7027556

All wheel loaders


Car coupling 254a

7027557

All wheel loaders


1.2.9 Description Complete tool box with suction pads


Special tools for cab windows ID no.

10021147

Use

Remarks

All wheel loaders

For installing and removing windows

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2 Production description 2.0 Chapter contents 2

Production description......................................................... 2.0-1 2.1

Technical data ................................................................................2.1-1 Complete machine................................................................2.1-1

2.1.2

Diesel engine and pump distributor gear..............................2.1-8

2.1.3

Cooling system ...................................................................2.1-12

2.1.4

Travel hydraulics ................................................................2.1-13

2.1.5

Working hydraulics .............................................................2.1-16

2.1.6

Steering system..................................................................2.1-20

2.1.7

Brake system......................................................................2.1-22

2.1.8

Electrical system.................................................................2.1-24

2.1.9

Transmission ......................................................................2.1-25

2.1.10

Axles and cardan shaft .......................................................2.1-26

2.1.11

Machine frame and ballast weight......................................2.1-30

2.1.12

Automatic central lubrication system..................................2.1-30

2.1.13

Cab, heating and air-conditioning.......................................2.1-32

2.1.14

Lift arms and quick-change device.....................................2.1-33

2.1.15

Equipment and accessories ...............................................2.1-36

LBH/Version 01/10.2006/en/hd/30/01/2007

2.1.1


L576 - 457 / from 14171 L580 - 459 / from 14171

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Production description

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Service Manual

Production description Technical data

2.1 Technical data 2.1.1

Complete machine Wheel loader with Z lift arms

Valid for:

L550 - 456 / from 16978

The values stated refer to the standard version of the machine: – With Z lift arms (2600 mm), without hydraulic quick-change device. – With 23.5 R25 Michelin XHA tyres. – Tipping loads and weights include all lubricants, full fuel tank, ROPS/ FOPS cab and driver.

Description

Value Unit

LBH/Version 01/10.2006/en/hd/30/01/2007

Bucket capacity as per ISO 7546 Bucket width Specific material weight A Dump height at maximum lifting height and 45° tilt-out angle B Dumping height C Maximum bucket base height D Maximum bucket pivot height E Maximum bucket top edge height


3.2 2700 1.8 2882

m³ mm t/m³ mm

3500 3645 3915 5395

mm mm mm mm

F Reach at maximum lifting height and 45° tilt-out angle

1095 mm

G Digging depth H Height above cab I Height above exhaust J Ground clearance K Wheel base L Overall length Turning radius over bucket outer edge

85 3365 2985 530 3280 8220 6420

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mm mm mm mm mm mm mm

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Service Manual

Technical data

Description

Value Unit

Lifting force (SAE) Breakout force (SAE) Tipping load when straight Tipping load articulated at 37° Tipping load articulated at 40° Angle of articulation (to each side) Operating weight Tractive force Travel speed in travel range 1, forward and reverse Travel speed in travel range 2, forward and reverse Travel speed in travel range A1-2 (automatic), forward and reverse Travel speed in travel range A1-3 (automatic), forward and reverse Travel speed in travel range A2-3 (automatic), forward and reverse Sound pressure level in cab in L pA according to ISO 6396

185 125 13205 11865 11650 40 16525 122.6 0 - 10

kN kN kg kg kg ° kg kN km/h

0 - 20 km/h 0 - 20 km/h 0 - 40 km/h 0 - 40 km/h 69 dB(A)

Wheel loader with Z lift arms Valid for:

L556 - 454 / from 15653

LBH/Version 01/10.2006/en/hd/30/01/2007


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Service Manual


Description

Value Unit

Bucket capacity as per ISO 7546 Bucket width

2700 mm

Specific material weight

1.8 t/m³

A Dump height at maximum lifting height and 45° tilt-out angle

2850 mm

B Dumping height

3500 mm

C Maximum bucket base height

3645 mm

D Maximum bucket pivot height

3915 mm

E Maximum bucket top edge height

5460 mm


1160 mm

G Digging depth

85 mm

H Height above cab

3365 mm

I Height above exhaust

2985 mm

J Ground clearance

530 mm

K Wheel base

3280 mm

L Overall length

8240 mm

Turning radius over bucket outer edge

6440 mm

Lifting force (SAE)

185 kN

Breakout force (SAE)

130 kN

Tipping load when straight

14890 kg

Tipping load articulated at 37°

13350 kg


13140 kg

Angle of articulation (to each side)

LBH/Version 01/10.2006/en/hd/30/01/2007

3.6 m³

40 °

Operating weight

17270 kg

Tractive force

136.42 kN

Travel speed in travel range 1, forward and reverse

0 - 10 km/h

Travel speed in travel range 2. forward and reverse

0 - 20 km/h

Travel speed in travel range A1-2 (automatic), forward and reverse Travel speed in travel range A1-3 (automatic), forward and reverse Travel speed in travel range A2-3 (automatic), forward and reverse

0 - 20 km/h

Sound pressure level in cab in L pA according to ISO 6396

0 - 40 km/h 0 - 40 km/h 69 dB(A)


L566 - 460 / from 14171

The values stated refer to the standard version of the machine: – With Z lift arms (2920 mm), without hydraulic quick-change device. – With 26.5 R25 Michelin XHA tyres. – Tipping loads and weights include all lubricants, full fuel tank, ROPS/ FOPS cab and driver. L550 - 456 / from 16978 L556 - 454 / from 15653 L566 - 460 / from 14171

L576 - 457 / from 14171 L580 - 459 / from 14171

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2.1-3 o f 3 8


Service Manual

Technical data

Description

Value Unit

Bucket capacity as per DIN 7546 Bucket width

3000 mm


1.8 t/m³


3240 mm

B Dumping height

3900 mm


4050 mm


4360 mm


5870 mm


1180 mm

G Digging depth

100 mm

H Height above cab

3550 mm


3100 mm 565 mm

K Wheel base

3580 mm

L Overall length

8912 mm


7096 mm

Lifting force (SAE)

264 kN


200 kN


17690 kg


15850 kg


15550 kg


40 °

Operating weight

22500 kg

Tractive force

173.31 kN

Travel speed in travel range 1, forward and reverse Copyright by

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L550 - 456 / from 16978 L556 - 454 / from 15653

0 - 10 km/h


LBH/Version 01/10.2006/en/hd/30/01/2007

J Ground clearance

2.1-4 o f 3 8

4.0 m³

Service Manual


Description

Value Unit


0 - 20 km/h

Travel speed in travel range A1-2 (automatic), forward and reverse

0 - 20 km/h


0 - 40 km/h


0 - 40 km/h


69 dB(A)


L576 - 457 / from 14171

LBH/Version 01/10.2006/en/hd/30/01/2007

The values stated refer to the standard version of the machine: – With Z lift arms (2920 mm), without hydraulic quick-change device. – With 26.5 R25 Michelin XHA tyres. – Tipping loads and weights include, all lubricants, full fuel tank, ROPS/ FOPS cab and driver.

Description

Value Unit


3000 mm



4.5 m³ 1.8 t/m³


3187 mm

B Dumping height

3900 mm


4050 mm


4360 mm


5960 mm

F Reach at maximum lifting height and

1233 mm

L576 - 457 / from 14171 L580 - 459 / from 14171

Copyright by

MJFCIFSS

2.1-5 o f 3 8


Service Manual

Technical data

Description 45° tilt-out angle

Value Unit

G Digging depth

100 mm

H Height above cab

3550 mm


3100 mm

J Ground clearance

565 mm

K Wheel base

3580 mm

L Overall length

8992 mm


7110 mm

Lifting force (SAE)

264 kN


190 kN


19570 kg


17530 kg


17200 kg


40 °

Operating weight

24260 kg

Tractive force

173.3 kN


0 - 10 km/h


0 - 20 km/h


0 - 20 km/h


0 - 40 km/h


0 - 40 km/h


69 dB(A)

Wheel loader with Z lift arms L580 - 459 / from 14171


2.1-6 o f 3 8

Copyright by

MJFCIFSS

L550 - 456 / from 16978 L556 - 454 / from 15653


LBH/Version 01/10.2006/en/hd/30/01/2007

Valid for:

Service Manual


Description

Value Unit


3300 mm


1.8 t/m³


3320 mm

B Dumping height

4100 mm


4270 mm


4580 mm


6340 mm


1150 mm

G Digging depth

100 mm

H Height above cab

3550 mm


3100 mm

LBH/Version 01/10.2006/en/hd/30/01/2007

J Ground clearance

565 mm

K Wheel base

3700 mm

L Overall length

9300 mm


7420 mm

Lifting force (SAE)

250 kN


175 kN


20390 kg


18409 kg


18000 kg



5.0 m³

40 °

Operating weight

24580 kg

Tractive force

173.3 kN


0 - 10 km/h

Travel speed in travel range 2, forward

0 - 20 km/h

L576 - 457 / from 14171 L580 - 459 / from 14171

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2.1-7 o f 3 8


Service Manual

Technical data

Description and reverse

Value Unit


0 - 20 km/h


0 - 40 km/h


0 - 40 km/h


2.1.2

69 dB(A)

Diesel engine and pump distributor gear Diesel engine L550 - 456 / from 16978; ID 9080542

Description

Value Unit

Engine model

D934 S A6

Number of cylinders

4

Firing order

1-3-4-2

Capacity

6360 cm³

Cylinder bore

122 mm

Stroke

136 mm

Rated power as per ISO 9249

130 / 190 kW / PS 2000 min-1

Rated speed Maximum torque at 1500 min-1

828 Nm

Lower idle speed

900±10 min-1

Upper idle speed

2065±10 min-1

Start of delivery before TDC

See type plate °

Combustion pressure

20 - 28 bar

Injection nozzle opening pressure

315 - 340 bar

Inlet valve play (cold)

0.3 mm

Outlet valve play (cold)

0.4 mm

Direction of rotation, looking at flywheel

Anticlockwise

Number of teeth on flywheel gear

147

Control thermostat

79 °C

Longitudinal / traverse inclinability

45 / 45 °

Injectors

UP20PLD

Control

LHECU PLD

Starter operating voltage

24 V

Starter power consumption

6.6 kW

Alternator voltage output

28 V

Alternator current output

80 A

Turbocharger

KKK K27

Auxiliary power take-off transmission

1 : 1.1515

Weight

800 kg

Emission thresholds comply with

2.1-8 o f 3 8

Copyright by

MJFCIFSS

EU – RL 97/68 EC Stage IIIA

L550 - 456 / from 16978 L556 - 454 / from 15653


LBH/Version 01/10.2006/en/hd/30/01/2007

Valid for:

Service Manual


Valid for:

L556 - 454 / from 15653; ID 10116679

Description

Value Unit

Engine model

D934 L A6

Number of cylinders

4

Firing order

1-3-4-2

Capacity

7010 cm³

Cylinder bore

122 mm

Stroke

150 mm

Rated power as per ISO 9249

140 / 177 kW / PS 2000 min-1

Rated speed Maximum torque at 1300 min-1

900 Nm

Lower idle speed

900±10 min-1

Upper idle speed

2065±10 min-1

Start of delivery before TDC

See type plate °

Combustion pressure

22 - 34 bar


315 - 340 bar


0.3 mm


0.4 mm


Anticlockwise


147

Control thermostat

83 °C


45 / 45 °

Injectors

UP20PLD

Control

LH-ECU-UP/CR


24 V


6.6 kW


28 V


80 A

Turbocharger

KKK K27


1 : 1.1515

Weight

980 kg

Emission thresholds comply with LBH/Version 01/10.2006/en/hd/30/01/2007

Valid for:


L566 - 460 / from 14171; ID 9079516

Description

Value Unit

Engine model

D936 L A6

Number of cylinders

6

Firing order

1-5-3-6-2-4

Capacity

10520 cm³

Cylinder bore

122 mm

Stroke

150 mm

Rated power as per ISO 9249 Rated speed

2000 min-1

Maximum torque at 1300 min-1

1230 Nm 900±10 min-1

Lower idle speed L550 - 456 / from 16978 L556 - 454 / from 15653 L566 - 460 / from 14171

190 / 259 kW / PS

L576 - 457 / from 14171 L580 - 459 / from 14171

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MJFCIFSS

2.1-9 o f 3 8


Service Manual

Technical data

Description

Value Unit 2065±10 min-1

Upper idle speed Start of delivery before TDC

See type plate °

Combustion pressure

22 - 34 bar


315 - 340 bar


0.3 mm


0.4 mm


Anticlockwise


147

Control thermostat

83 °C


45 / 45 °

Injectors

UP20PLD

Control

LH-ECU-UP/CR


24 V


6.6 kW


28 V


80 A

Turbocharger

KKK K27


1 : 1.1515

Weight

1180 kg


L576 - 457 / from 14171; L580 - 459 / from 14171; ID 10116961

Description

Value Unit

Engine model

D936 L A6

Number of cylinders

6

Firing order

1-5-3-6-2-4

Capacity

10520 cm³

Cylinder bore

122 mm

Stroke

150 mm

Rated power as per ISO 9249 Rated speed

2000 min-1

Maximum torque at 1300 min-1

1320 Nm

Lower idle speed

900±10 min-1

Upper idle speed

2065±10 min-1

Start of delivery before TDC Combustion pressure

See type plate ° 22 – 34 bar


315 - 340 bar


0.3 mm


0.4 mm

Direction of rotation, looking at flywheel Number of teeth on flywheel gear Control thermostat Injectors Copyright by

MJFCIFSS

Anticlockwise 147 83 °C


2.1-10 o f 3 8

200 / 272 kW / PS

45 / 45 ° UP20PLD

L550 - 456 / from 16978 L556 - 454 / from 15653


LBH/Version 01/10.2006/en/hd/30/01/2007

Valid for:


Service Manual


Description

Value Unit

Control

LH-ECU-UP/CR


24 V


6.6 kW


28 V


80 A

Turbocharger

KKK K29


1 : 1.1515

Weight

1180 kg



Fuel system Valid for:

L550 - 456 / from 16978; L556 - 454 / from 15653

Description

Value Unit

Tank capacity, FULL

300 l

Tank capacity, RESERVE Valid for:

50 l

L566 - 460 / from 14171; L576 - 457 / from 14171; L580 - 459 / from 14171

Description

Value Unit

Tank capacity, FULL

400 l

Tank capacity, RESERVE

70 l

Fuel separator Description

Value Unit

Filter insert grade

10 µm

Fuel fine filter Description

Value Unit

Filtration grade

2 µm

Refuelling pump (optional) LBH/Version 01/10.2006/en/hd/30/01/2007

Description

Value Unit

Flow rate

50 l/min

Current consumption

15 A

Power

360 W

Protection class

IP 44

Max. duty cycle

15 minutes

Fuse

20 A

Max. suction height

4 m

Air filter vacuum switch Description

Value Unit

Air filter contamination vacuum switch activation point L550 - 456 / from 16978 L556 - 454 / from 15653 L566 - 460 / from 14171

L576 - 457 / from 14171 L580 - 459 / from 14171

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MJFCIFSS

50 mbar

2.1-11 o f 3 8


Service Manual

Technical data

Coupling Valid for:

L550 - 456 / from 16978; L556 - 454 / from 15653

Description

Value Unit

Type

466/233 NGT

Coupling Valid for:


Description

Value Unit

Type

345/254 NGT

Pump distributor gear L550 - 456 / from 16978; L556 - 454 / from 15653

Description

Value Unit

Type

PVG 300 B 341

Input direction

Clockwise

Output direction

Valid for:

Anticlockwise

Transmission ratio for travel hydraulics pump

0.7868

Transmission ratio for working and steering hydraulics pump

0.7868


Description

Value Unit

Type

PVG 350 B 384

Input direction

Clockwise

Output direction

2.1.3

Anticlockwise

Transmission ratio for travel hydraulics pump

0.808

Transmission ratio for working and steering hydraulics pump

0.865

Cooling system Gear pump Description

Value Unit

Capacity

14 cm³

Rotary speed at rated engine speed

3030 min-1

Gear motor Description

Value Unit

Gear motor displacement Gear motor direction of rotation (looking towards shaft) Coil resistance Copyright by

MJFCIFSS

Clockwise 175 ±10 bar

Pressure relief valve

2.1-12 o f 3 8

19 cm³

4.7 Ohm L550 - 456 / from 16978 L556 - 454 / from 15653


LBH/Version 01/10.2006/en/hd/30/01/2007

Valid for:

Service Manual


Description

Value Unit 124 ±41 Nm

Screw tightening torque Spanner size

41 mm

Temperature sensor Description

Value Unit

Measuring range

min. -30 °C max. 130 °C

Resistance at 0 °C

1000 Ohm

Resistance at 20 °C

1112 Ohm


1171 Ohm


1322 Ohm


1437 Ohm


1469 Ohm


1509 Ohm


1577 Ohm


1632 Ohm

Screw thread

M 14 x 1.5

Protection class

IP 65

Max. tightening torque

30 Nm

Plug connection

2.1.4

Bosch Jet plug, 2-pin (Gold contacts)

Travel hydraulics Variable displacement pump

Valid for:

L550 - 456 / from 16978; L556 - 454 / from 15653

Description

Value Unit

Control type

EZ

Maximum capacity

90 cm³

Flow rate at rated speed

222 l/min

Maximum swivel angle (both sides)

20 ° 2542 min-1

LBH/Version 01/10.2006/en/hd/30/01/2007

Speed (at rated speed) Power

L550

111 kW

Power

L556

122 kW

Replenishing pump capacity Replenishing pump flow rate (at rated speed)

46 l/min

Inlet restrictor ∅

1.8 mm

Travel direction solenoid voltage

24 V

Travel direction solenoid current consumption

1.1 A

Travel direction solenoid resistance

22 Ohm

Control pressure proportional valve resistance

14 Ohm

Replenishing pressure at upper idle speed High pressure at 1400 min-1 L550 - 456 / from 16978 L556 - 454 / from 15653 L566 - 460 / from 14171

19.6 cm³

L576 - 457 / from 14171 L580 - 459 / from 14171

31±1 bar 350±10 bar

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MJFCIFSS

2.1-13 o f 3 8


Service Manual

Technical data

Description

Value Unit -1

High pressure at 1200 min

290±10 bar

High pressure at 930 min-1

50±10 bar

Pressure relief and replenishing valves

470±10 bar 430±5 bar

Pressure cut-off Weight Valid for:

60 kg


Description

Value Unit

Control type

EZ

Maximum capacity

125 cm³


300 l/min

Maximum swivel angle (both sides)

20 ° 2475 min-1

Speed (at rated speed) Power

L566

160 kW

Power

L576, L580

171 kW

Replenishing pump capacity

28.3 cm³

Replenishing pump flow rate (at rated speed)

62 l/min

Inlet restrictor ∅

2.2 mm

Travel direction solenoid voltage

24 V

Travel direction solenoid current consumption

1.1 A

Travel direction solenoid resistance

22 Ohm

Control pressure proportional valve resistance

14 Ohm

Replenishing pressure at upper idle speed

34±1 bar

-1

High pressure at 1400 min

330±10 bar


230±10 bar


50±10 bar

Pressure relief and replenishing valves

470±10 bar 430±5 bar

Pressure cut-off Weight

75 kg

Valid for:

L550 - 456 / from 16978; L556 - 454 / from 15653

Description

Value Unit

Control type

EP

Maximum displacement

80 cm³

Maximum swivel angel

25 °

Minimum swivel angle

0 ° 5900 min-1

Maximum speed

489 Nm

Torque (Δp 400 bar)

2.1-14 o f 3 8

Maximum discharge valve capacity

20 l/min

Discharge valve orifice diameter

3.0 mm

Weight

34 kg

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MJFCIFSS

L550 - 456 / from 16978 L556 - 454 / from 15653


LBH/Version 01/10.2006/en/hd/30/01/2007

Variable displacement motor 1

Service Manual


Valid for:


Description

Value Unit

Control type

EP


107 cm³


25 °


0 ° 5292 min-1

Maximum speed

653 Nm

Torque (Δp 400 bar) Maximum discharge valve capacity

20 l/min


3.0 mm

Weight

47 kg

Variable displacement motor 2 Valid for:

L550 - 456 / from 16978

Description

Value Unit

Control type

EP


80 cm³


25 °


0 ° 5900 min-1

Maximum speed

489 Nm

Torque (Δp 400 bar) Weight Valid for:

34 kg

L556 - 454 / from 15653

Description

Value Unit

Control type

EP


107 cm³


25 °


0 ° 5292 min-1

Maximum speed

653 Nm

Torque (Δp 400 bar) Weight Valid for:

47 kg


LBH/Version 01/10.2006/en/hd/30/01/2007

Description

Value Unit

Control type

EP


140 cm³


25 °


0 ° 4950 min-1

Maximum speed

855 Nm

Torque (Δp 400 bar)


Maximum discharge valve capacity

10 l/min


2.0 mm

Weight

60 kg

L576 - 457 / from 14171 L580 - 459 / from 14171

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MJFCIFSS

2.1-15 o f 3 8


Service Manual

Technical data

Motor scavenging pump Description

Value Unit

Capacity

11 cm³ 3030 min-1

Speed at rated speed

2.1.5

Working hydraulics Working hydraulics pump

Valid for:

L550 - 456 / from 16978; L556 - 454 / from 15653

Description

Value Unit

Control type

LRDS

Maximum capacity

95 cm³


234 l/min 2542 min-1

Speed at rated speed Power

70 KW 22±2 bar

Flow regulator (delta p) Power controller start of regulation Weight Valid for:

180±10 bar 53 kg


Description

Value Unit

Control type

LRDS

Capacity

130 cm³


290 l/min 2312 min-1


87 kW 22±2 bar

Flow regulator (delta p) Power controller start of regulation Weight

180±10 bar 66 kg

Control block L550 - 456 / from 16978; L556 - 454 / from 15653

Description

Value Unit

Spool valve diameter

25 mm

Piston stroke, both sides

11 mm

Lift arm up/down control piston flow

240 / 160 l/min

Tilt out/in control piston flow

160 / 210 l/min

Primary pressure relief valve

360±5 bar

Secondary pressure relief valve / tilt in

380±5 bar

Secondary pressure relief valve / tilt out

380±5 bar

Secondary pressure relief valve / lift

380±5 bar

LS pressure cut-off

290±5 bar 330±5 bar

L550 L556

Pressure relief valve pre-tension

2.1-16 o f 3 8

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L550 - 456 / from 16978 L556 - 454 / from 15653

8±1 bar L566 - 460 / from 14171 L576 - 457 / from 14171 L580 - 459 / from 14171

LBH/Version 01/10.2006/en/hd/30/01/2007

Valid for:

Service Manual


Description

Valid for:

Value Unit

Float position/ride control solenoid valve resistance

30 Ohm

Weight

40 kg


Description

Value Unit

Spool valve diameter

25 mm

Piston stroke, both sides

11 mm

Lift arm up/down control piston flow

300 / 170 l/min

Tilt out/in control piston flow

180 / 200 l/min


380±5 bar

Secondary pressure relief valve / tilt-in

400±5 bar

Secondary pressure relief valve / tilt out

400±5 bar

Secondary pressure relief valve / lift

420±5 bar

LS pressure cut-off

350±5 bar

Pressure relief valve pre-tension

8±1 bar

Float position/ride control solenoid valve resistance

30 Ohm

Weight

40 kg

Pilot control device Description

Value Unit

Retaining solenoid voltage

12 V

Retaining solenoid current consumption

0.35 A

Retaining solenoid resistance

70 Ohm

Weight

5.7 kg

Pilot control solenoid valve Description

Value Unit

Current consumption

0.9 A

Resistance

30 Ohm

LBH/Version 01/10.2006/en/hd/30/01/2007

Pilot control hydro accumulator Valid for:

ID 7622 448

Description

Value Unit

Hydro accumulator volume

320 cm³

Preload pressure (nitrogen filling)

15 bar

Float position pressure switch Valid for:

ID 6905 893

Description

Value Unit

Switch type

Normally open 23±1 bar

Switch point, rising Thread L550 - 456 / from 16978 L556 - 454 / from 15653 L566 - 460 / from 14171

L576 - 457 / from 14171 L580 - 459 / from 14171

M 12 x 1.5 mm Copyright by

MJFCIFSS

2.1-17 o f 3 8


Service Manual

Technical data

Stabilisation module Valid for:

ID 1003 0852

Description

Value Unit

Control piston diameter

16 mm

Cut-off pressure (LFD off)

120±20 bar

Safety valve

330±10 bar

Restrictor check valve diameter

2.0 / 0.4 mm

Solenoid valve current consumption

0.6 A

Solenoid valve resistance

40 Ohm

Weight

13 kg

Ride control hydro accumulator Description

Value Unit

Number of hydro accumulators L550, L556

2 Qty.

Number of hydro accumulators L566, L566, L576

3 Qty.


2000 cm³


25±2 bar

Oil filling

350 cm³

Ride control pressure switch Valid for:

ID 6905 893

Description

Value Unit

Switch type

N/C 10 ±1 bar

Switch point, rising Thread

M 12 x 1.5 mm

Lift cylinder L550 - 456 / from 16978; L556 - 454 / from 15653; ID 9231 458

Description

Value Unit

Piston diameter

130 mm

Rod diameter

80 mm

Stroke length

745 mm

Minimum installation length

2.1-18 o f 3 8

1245 mm

Weight

136 kg

Lifting at rated load

5.6 seconds

Lowering empty

2.7 seconds

Piston rod bearing tightening torque (hex screws)

285 Nm

Copyright by

MJFCIFSS

L550 - 456 / from 16978 L556 - 454 / from 15653


LBH/Version 01/10.2006/en/hd/30/01/2007

Valid for

Service Manual


Valid for:

L566 - 460 / from 14171; L574 - 457 / from 14171; L580 - 459 / from 14171; ID 9959 881

Description

Value Unit

Piston diameter

150 mm

Rod diameter

80 mm

Stroke length

790 mm


1320 mm

Weight

165 kg

Lifting at rated load

5.6 seconds

Lowering empty

3.5 seconds


285 Nm

Tilt cylinder Valid for:

L550 - 456 / from 16978; L556 - 454 / from 15653; ID 9954 056

Description

Value Unit

Piston diameter

Valid for:

150 mm

Rod diameter

80 mm

Stroke length

455 mm


860 mm

Weight

127 kg

Tilting out at rated load

2.3 seconds


565 Nm

L566 - 460 / from 14171; L576 - 457 / from 14171; ID 9248 203

Description

Value Unit

Piston diameter

170 mm

Rod diameter

90 mm

Stroke length

555 mm

LBH/Version 01/10.2006/en/hd/30/01/2007


Valid for:

1050 mm

Weight

188 kg


2.0 seconds


970 Nm

L580 - 459 / from 14171; ID 9903 394

Description

Value Unit

Piston diameter

170 mm

Rod diameter

90 mm

Stroke length

555 mm



1185 mm

Weight

198 kg


2.0 seconds


970 Nm

L576 - 457 / from 14171 L580 - 459 / from 14171

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MJFCIFSS

2.1-19 o f 3 8


Service Manual

Technical data

Return suction filter Description

Value Unit

Filtration grade

10 µm

Pre-tension valve

0.3 bar

Replenishing valve

0.04 bar

Replenishing strainer

160 µm

Bypass valve

3.0 bar

Return strainer

80 µm

Bleeder filter Description

Value Unit

Filtration grade

10 μm

Inlet opening pressure

2.1.6

0.03 bar

Outlet opening pressure

0.5 bar

Thread

3/4 inch

Steering system Steering pump L550 - 456 / from 16978; L556 - 454 / from 15653; ID 5716 846

Description

Value Unit

Control type

DFR

Maximum capacity

45 cm³


111 l/min

Swivel angle

min. 0° max. 15.6° 2542 min-1


39 kW 22±2 bar

Flow regulator (delta p)

210±5 bar

Pressure cut-off Weight Valid for:

21 kg

L566 - 460 / from 14171; L576 - 457 / from 14171; L580 - 459 / from 14171; ID 5716828

Description

Value Unit

Control type

DFR

Maximum capacity

71 cm³


160 l/min

Swivel angle

min. 0° max. 15.6° 2312 min-1


56 kW 22±2 bar

Flow regulator (delta p)

210±5 bar

Pressure cut-off Weight

2.1-20 o f 3 8

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33 kg L550 - 456 / from 16978 L556 - 454 / from 15653


LBH/Version 01/10.2006/en/hd/30/01/2007

Valid for:

Service Manual


Servostat Valid for:

L550 - 456 / from 16978; L556 - 454 / from 15653; ID 1011 3336

Description

Value Unit

Displacement

Valid for:

462 cm³

Secondary pressure relief

285±10 bar

Flow booster

1 : 1.6


Description

Value Unit

Displacement

588 cm³

Secondary pressure relief

285±10 bar

Flow booster

1 : 1.6

Steering cylinder Valid for:

L550 - 456 / from 16978; L556 - 454 / from 15653; ID 9231 461

Description

Valid for:

Value Unit

Piston diameter

80 mm

Rod diameter

40 mm

Stroke length

405 mm


730 mm

Piston rod bearing tightening torque

1000 Nm

Weight

26.2 kg


LBH/Version 01/10.2006/en/hd/30/01/2007

Description

Value Unit

Piston diameter

90 mm

Rod diameter

40 mm

Stroke length

455 mm


780 mm

Piston rod bearing tightening torque

1000 Nm

Weight

29.5 kg

Steering damper hydro accumulator Valid for:

ID 7623 934

Description

Value Unit


320 cm³

Preload pressure (nitrogen filling) Oil filling


L576 - 457 / from 14171 L580 - 459 / from 14171

30 bar 180 cm³

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2.1-21 o f 3 8


Service Manual

Technical data

Emergency steering pump Valid for:

ID 1000 7930

Description

Value Unit

Capacity

11 cm³ 55±5 bar

Pressure relief valve Protection class

IP 66

Maximum current consumption

150 A

Weight

10 kg

Emergency steering pressure switch Valid for:

ID 1029 4440

Description

Value Unit

Switch type


Switching point Thread

M 12 x 1.5 mm

Emergency steering check pressure switch Valid for:

ID 1029 4440

Description

Value Unit

Switch type


Switching point Thread

2.1.7

M 12 x 1.5 mm

Brake system Brake system gear pump Description

Value Unit

Capacity

4 cm³


12.1 l/min


3030 min-1

Valid for:

L550 - 456 / from 16978; L556 - 454 / from 15653; L566 - 460 / from 14171; L576 - 457 / from 14171; ID 1029 2360

Description

Value Unit

Accumulator charge valve activation pressure

180±5 bar

Accumulator charge valve deactivation pressure

210±5 bar

Parking brake solenoid valve current consumption

0.6 A

Parking brake solenoid valve resistance

40 Ohm

Maximum service brake pressure

2.1-22 o f 3 8

95±5 bar

Pedal start angle

42°

Pedal stop angle

15°

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L550 - 456 / from 16978 L556 - 454 / from 15653


LBH/Version 01/10.2006/en/hd/30/01/2007

Compact brake valve

Service Manual


Valid for:

L580 - 459 / from 14171; ID 1029 5965

Description

Value Unit

Accumulator charge valve activation pressure

180±5 bar

Accumulator charge valve deactivation pressure

210±5 bar

Parking brake solenoid valve current consumption

0.6 A

Parking brake solenoid valve resistance

40 Ohm 70±5 bar

Maximum service brake pressure Pedal start angle

42°

Pedal stop angle

15°

Service brake hydro accumulator Valid for:

ID 1003 8487

Description

Value Unit

Number of hydro accumulators

4 Qty.


1400 cm³


95 bar

Brake light button Valid for:

ID 6905 535

Description

Value Unit

Switch type

Normally open 5±0.5 bar

Switch point, rising Thread

M 12 x 1.5 mm

Accumulator charge pressure switch Valid for:

ID 1003 6072

Description

Value Unit

Switch type

N/C 120 ±5 bar

Switching point, falling LBH/Version 01/10.2006/en/hd/30/01/2007

Thread

M 12 x 1.5 mm

Disc brake


Description

Value Unit

Gap

1.0±0.5 mm

Brake lining thickness, NEW

4.5 mm

Minimum brake lining thickness

1.0 mm

L576 - 457 / from 14171 L580 - 459 / from 14171

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MJFCIFSS

2.1-23 o f 3 8


Service Manual

Technical data

Parking brake hydro accumulator Valid for:

ID 1028 8602

Description

Value Unit


320 cm³


80 bar

Overspeed protection solenoid valve Description

2.1.8

Value Unit

Current consumption

0.9 A

Resistance

30 Ohm

Electrical system Description

Value Unit

System voltage

24 V

Battery voltage

12 V

Battery L550 - 456 / from 16978; L556 - 454 / from 15653; ID 6002 886

Description

Value Unit

Battery voltage

12 V

Battery capacity

143 Ah

Acid density of charged battery Cold test current (at -18 °C EN 60095-1) Valid for:

1.26-1.28 kg/l 950 A

L566 - 460 / from 14171; L576 - 457 / from 14171; L580 - 459 / from 14171; ID 6132 03208

Description

Value Unit

Battery voltage

12 V

Battery capacity

170 Ah

Acid density of charged battery Cold test current (at -18 °C EN 60095-1)

1.26-1.28 kg/l 1000 A

Input / Output - module Description

Value Unit

Protection class (with connector plugged in) Power supply (logical unit)

7.0 to 48.0 VDC

Operating temperature

-40 to +85 °C

Operation at ambient air pressure Weight

2.1-24 o f 3 8

IP6K9K

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500 to 1100 mbar 1.77 kg

L550 - 456 / from 16978 L556 - 454 / from 15653


LBH/Version 01/10.2006/en/hd/30/01/2007

Valid for:

Service Manual


Main electronics (master) Description

Value Unit

Protection class (with connector plugged in) Computing power

266 MHz

Power supply (logical unit)

9.0 to 60.0 VDC


-40 to +85 °C

Operation at ambient air pressure Weight

2.1.9

IP 65

500 to 1100 mbar 3.5 kg

Transmission Transmission Description

Value Unit

Number of gears

3

Transfer ratio in 1st gear

6.103

Transfer ratio in 2nd gear

3.033

Transfer ratio in 3rd gear

1.342

Weight (without oil)

285 kg

Drive shaft flange tightening torque Tightening torque Control valve block fastening screws

340 - 400 Nm 30 - 35 Nm

Gear shifting solenoid valves Description

Value Unit

Voltage

24 V 300±50 mA

Current consumption

93±6 Ohm

Resistance

Speed sensors Description

Value Unit 1050±100 Ohm

Resistance

0.3±0.2 mm

LBH/Version 01/10.2006/en/hd/30/01/2007

Distance Number of teeth on drive shaft VM 1

60

Number of teeth on drive shaft VM 2

60

Number of teeth on power take-off speed sensor

128

Gear pump Description

Value Unit

Capacity


16 cm³


40.8 l/min


2550 min-1

L576 - 457 / from 14171 L580 - 459 / from 14171

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MJFCIFSS

2.1-25 o f 3 8


Service Manual

Technical data

2.1.10

Axles and cardan shaft Front axle L550 - 456 / from 16978

Description

Value Unit

Type

MT-L 3085 -

Self-locking differential

45 %

Width

2000 mm

Differential nut tightening torque Wheel hub grooved nut tightening torque Wheel lug tightening torque Wheel lug spanner size

3.89

Wheel hub transmission

6.0 23.33 816 kg

L556 - 454 / from 15653

Description

Value Unit

Type

MT-L 3095


45 %

Width

2000 mm

Differential nut tightening torque Wheel hub grooved nut tightening torque Wheel lug tightening torque Wheel lug spanner size

700 Nm 3000+500 Nm 750 Nm 30 mm

Differential transmission

3.89


6.0

Overall transmission

23.33

Weight

924 kg

L566 - 460 / from 14171; L576 - 473 / from 14171

Description

Value Unit

Type

MT-L3105


45 %

Width

2230 mm

Differential nut tightening torque Wheel hub grooved nut tightening torque Wheel lug tightening torque

2.1-26 o f 3 8

750 Nm


Weight

Valid for:

2000+500 Nm 30 mm


Valid for:

700 Nm

700 Nm 3000+500 Nm 750 Nm

Wheel lug spanner size

30 mm


4.1


6.0


24.66

Weight

1174 kg

Copyright by

MJFCIFSS

L550 - 456 / from 16978 L556 - 454 / from 15653


LBH/Version 01/10.2006/en/hd/30/01/2007

Valid for:

Service Manual


Valid for:

L580 - 459 / from 14171

Description

Value Unit SA 197 337 43 R 175

Type Self-locking differential

45 %

Width

2230 mm

Differential nut tightening torque

1200 Nm

Wheel hub grooved nut tightening torque Wheel lug tightening torque

2000+200 Nm 750 Nm


32 mm


4.1


6.0


24.60

Weight

1180 kg

Rear axle Valid for:

L550 - 456 / from 16978

Description

Value Unit

Type

MT-L 3085 -


45 %

Width

2000 mm

Differential nut tightening torque Wheel hub grooved nut tightening torque Wheel lug tightening torque

30 mm


3.89


6.0


23.33

Weight

816 kg

L556 - 454 / from 15653

Description

Value Unit

Type

MT-L 3085

LBH/Version 01/10.2006/en/hd/30/01/2007


45 %

Width

2000 mm


1200 Nm


2000+500 Nm 750 Nm


30 mm


3.89


6.0


23.33

Weight


2000+500 Nm 750 Nm


Valid for:

700 Nm

L576 - 457 / from 14171 L580 - 459 / from 14171

816 kg

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MJFCIFSS

2.1-27 o f 3 8


Service Manual

Technical data

L566 - 460 / from 14171

Description

Value Unit

Type

MT-L 3095 -


45 %

Width

2230 mm


1200 Nm


30 mm


4.1


6.0 24.66

Swing angle

13 °

Weight

975 kg

L576 - 473 / from 14171

Description

Value Unit

Type

MT-L 3105 -


45 %

Width

2230 mm


1200 Nm


750 Nm 30 mm


4.1


6.0 24.66

Swing angle

13 °

Weight

1174 kg

L580 - 459 / from 14171

Description

Value Unit SA 197 478 37 R 118

Type Self-locking differential

45 %

Width

2230 mm


1200 Nm


1300+200 Nm 750 Nm


32 mm


4.1


6.0


24.60

Swing angle

13 °

Weight

2.1-28 o f 3 8

3000+500 Nm



Valid for:

750 Nm



Valid for:

3000+500 Nm

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MJFCIFSS

1090 kg

L550 - 456 / from 16978 L556 - 454 / from 15653


LBH/Version 01/10.2006/en/hd/30/01/2007

Valid for:

Service Manual


Front drive shaft Valid for:

L550 - 4456 / from 16978

Description

Value Unit

Min. length

1310 mm

Max. length

1500 mm

Flange tightening torque

125 Nm

Weight Valid for:

38 kg

L556 - 454 / from 15653

Description

Value Unit

Min. length

1430 mm

Max. length

1440 mm


285 Nm

Weight Valid for:

72 kg

L566 - 460 / from 14171; L576 - 457 / from 14171

Description

Value Unit

Min. length

1500 mm

Max. length

1610 mm


285 Nm

Weight Valid for:

73 kg

L580 - 459 / from 14171

Description

Value Unit

Min. length

1545 mm

Max. length

1555 mm


285 Nm

Weight

75 kg

Rear drive shaft Valid for:

L550 - 4456 / from 16978; L556 - 454 / from 15653

LBH/Version 01/10.2006/en/hd/30/01/2007

Description

Value Unit

Min. length

600 mm

Max. length

710 mm


125 Nm

Weight Valid for:

16 kg


Description

Value Unit

Min. length

765 mm

Max. length

875 mm


125 Nm

Weight


L576 - 457 / from 14171 L580 - 459 / from 14171

24 kg

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MJFCIFSS

2.1-29 o f 3 8


Service Manual

Technical data

2.1.11

Machine frame and ballast weight Ballast weight

Valid for:

L550 - 456 / from 16978

Description

Value Unit

Weight per ballast weight

614 kg

Material

GG 10

M24 10.9 screw tightening torque Valid for:

960 Nm

L556 - 454 / from 15653

Description

Value Unit


901 kg

Material

GG 10


960 Nm

L566 - 460 / from 14171

Description

Value Unit


950 kg

Material

GG 10


960 Nm

L576 - 457 / from 14171; L580 - 459 / from 14171

Description

Value Unit


1540 kg

Material

GG 10

M24 10.9 screw tightening torque

2.1.12

960 Nm

Automatic central lubrication system Central lubrication pump EP1 Description

Value Unit 120 mm³ Greases up to NLGI class 2

Transfer medium Maximum flow pressure

280 bar


min. - 35 °C max. + 80 °C

Power supply

24 V

Protection class

IP 65

Container size

2.1-30 o f 3 8

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MJFCIFSS

4 kg

L550 - 456 / from 16978 L556 - 454 / from 15653


LBH/Version 01/10.2006/en/hd/30/01/2007

Flow per stroke

Service Manual


Progressive distributor MX-F Description

Value Unit

Maximum operating pressure at input Temperature range

300 bar min. -35 °C max. +100 °C Greases up to NLGI class 2

Transfer medium

MX-F 25 Description

Value Unit

Flow per outlet

25 mm³

Flow per element

50 mm³

Piston diameter

3 mm

MX-F 45 Description

Value Unit

Flow per outlet

45 mm³

Flow per element

90 mm³

Piston diameter

4 mm

MX-F 75 Description

Value Unit

Flow per outlet

75 mm³

Flow per element

150 mm³

Piston diameter

5 mm

MX-F 105 Description

Value Unit

Flow per outlet

105 mm³

Flow per element

210 mm³

LBH/Version 01/10.2006/en/hd/30/01/2007

Piston diameter

6 mm

Central lubrication pump controller EP-1 Description


Value Unit

Default lubrication (cycles)

24 Cycles

Default cycle time 75%

40 min


30 min


20 min

L576 - 457 / from 14171 L580 - 459 / from 14171

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2.1-31 o f 3 8


Service Manual

Technical data

2.1.13

Cab, heating and air-conditioning Heating and ventilation Description

Value Unit

Rated voltage

24 V

Number of blower levels

6

Maximum fan current consumption

15.7 A

Maximum air flow

600 m³/h

Heating power

11 kW

Air conditioning system Description

Value Unit

Refrigerant

R134a

Refrigerant oil (PAG oil)

ZXL 100 PG

Coolant quantity

1250+50 g

Cooling power

9.7±10% kW

Air conditioning compressor Description

Value Unit

Type

SD7H15

Capacity

154.9 cm³ ZXL 100 PG (SP 10)

Refrigerant oil (PAG oil) Filling quantity

200 cm³

Maximum current consumption

2.63 A

Weight without oil

6.9 kg

Condenser Description

Value Unit

Maximum air flow

4000 m³/h

Heating power

9.7±1 kW 35 bar

Dryer collector unit Description

Value Unit

Contents

0.70 l

Filtration grade

7 µm

Leak test

30 bar

Dryer water consumption

16 g

Burst pressure

2.1-32 o f 3 8

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130 bar

L550 - 456 / from 16978 L556 - 454 / from 15653


LBH/Version 01/10.2006/en/hd/30/01/2007

Test pressure

Service Manual


Pressure switch Description

Value Unit

Low pressure OFF

1.5±0.5 bar

Low pressure ON

3.5 bar

High pressure OFF

25±2 bar

High pressure ON

18±1.5 bar

Evaporator Description

Value Unit

Cooling power

2.1.14

9.7 kW ±10%

Temperature sensor activation temperature

5.5

Temperature sensor deactivation temperature

4.5±10% °C

°C

Lift arms and quick-change device Lift arm

Main dimensions LBH/Version 01/10.2006/en/hd/30/01/2007

Valid for:

L550 - 456 / from 16978; L556 - 454 / from 15653

Description

Value Unit

Length 1 – bucket arm

2600 mm

Length 2 – linkage

1267 mm

Length 3 – connecting link assembly Weight of complete lift arms (without cylinder)

1380 kg

Bucket arm weight

928 kg

Linkage weight

318 kg

Weight of connecting link assembly


718 mm

L576 - 457 / from 14171 L580 - 459 / from 14171

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MJFCIFSS

56 kg

2.1-33 o f 3 8


Service Manual

Technical data

Valid for:

L566 - 460 / from 14171

Description

Value Unit


2920 mm


1267 mm

Length 3 – connecting link assembly Weight of complete lift arms (without cylinder)

2090 kg

Bucket arm weight

1345 kg

Linkage weight

508 kg

Weight of connecting link assembly Valid for:

80 kg

L576 - 457 / from 14171

Description

Value Unit


2920 mm


1401 mm

Length 3 – connecting link assembly

855 mm

Weight of complete lift arms (without cylinder)

2200 kg

Bucket arm weight

1435 kg

Linkage weight

508 kg

Weight of connecting link assembly Valid for:

718 mm

80 kg

L580 - 459 / from 14171

Description

Value Unit


3050 mm


1401 mm

Length 3 – connecting link assembly

855 mm

Weight of complete lift arms (without cylinder)

2250 kg

Bucket arm weight

1500 kg

Linkage weight

508 kg 80 kg

LBH/Version 01/10.2006/en/hd/30/01/2007

Weight of connecting link assembly

2.1-34 o f 3 8

Copyright by

MJFCIFSS

L550 - 456 / from 16978 L556 - 454 / from 15653


Service Manual


Quick-change device

Main dimensions Valid for:

L550 - 456 / from 16978; L556 - 454 / from 15653

Description

Valid for:

Value Unit

A – system connection size

1000 mm

B – width

1200 mm

H – height

820 mm

T – depth

450 mm

Weight

430 kg


Description

Value Unit 1100 mm

B – width

1370 mm

H – height

1100 mm

T – depth

620 mm

Weight

830 kg

LBH/Version 01/10.2006/en/hd/30/01/2007

A – system connection size


L576 - 457 / from 14171 L580 - 459 / from 14171

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2.1-35 o f 3 8


Service Manual

Technical data

2.1.15

Equipment and accessories Standard bucket

L550 - 456 / from 16978

Description

Value Unit

B – bucket width

2700 mm

H – height

1475 mm

L – length with teeth

1630 mm


1.8 t/m³

Bucket capacity

3.2 m³

Weight

1305 kg

Teeth – UNI-Z-2000 III Valid for:

8 Pc.

L556 - 454 / from 15653

Description

Value Unit

B – bucket width

2700 mm

H – height

1520 mm


1630 mm


1.8 t/m³

Bucket capacity

3.6 m³

Weight

1365 kg

Teeth – UNI-Z-2000 III Valid for:

8 Pc.

L566 - 460 / from 14171

Description

Value Unit

B – bucket width

3000 mm

H – height

1610 mm


1805 mm


1.8 t/m³

Bucket capacity

4.0 m³

Weight

2080 kg

Teeth – UNI-Z-2000 IV

2.1-36 o f 3 8

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MJFCIFSS

9 Pc.

L550 - 456 / from 16978 L556 - 454 / from 15653


LBH/Version 01/10.2006/en/hd/30/01/2007

Valid for:

Service Manual


Valid for:

L576 - 457 / from 14171

Description

Value Unit

B – bucket width

3000 mm

H – height

1575 mm


1905 mm


1.8 t/m³

Bucket capacity

4.5 m³

Weight

2150 kg

Teeth – UNI-Z-2000 IV Valid for:

9 Pc.

L580 - 459 / from 14171

Description

Value Unit

B – bucket width

3300 mm

H – height

1675 mm


1900 mm


1.8 t/m³

Bucket capacity

5.0 m³

Weight

2340 kg

Teeth – UNI-Z-2000 IV

9 Pc.

LBH/Version 01/10.2006/en/hd/30/01/2007

Forklift

Valid for:

L550 - 456 / from 16978; L556 - 454 / from 15653

Description

Value Unit

Prong length

1500 mm

L – Length (fork carrier + prongs)

1860 mm

K – Fork carrier width

2000 mm

H – Height (fork carrier + prongs)

1040 mm

Weight (fork carrier + prongs) Valid for:


740 kg


Description

Value Unit

Prong length

1800 mm

L – Length (fork carrier + prongs)

2220 mm

L576 - 457 / from 14171 L580 - 459 / from 14171

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MJFCIFSS

2.1-37 o f 3 8


Service Manual

Technical data

Description

Value Unit 2050 mm

H – Height (fork carrier + prongs)

1270 mm

Weight (fork carrier + prongs)

1160 kg

LBH/Version 01/10.2006/en/hd/30/01/2007

K – Fork carrier width

2.1-38 o f 3 8

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L550 - 456 / from 16978 L556 - 454 / from 15653


3 Maintenance 3.0 Chapter contents 3

Maintenance........................................................................ 3.0-1 3.1

Maintenance and inspection schedule ...........................................3.1-1

3.2

Testing and adjustment plan...........................................................3.2-1

3.3

Testing and adjustment checklists..................................................3.3-1

3.4

Lubrication chart and filling quantities ............................................3.4-1 3.4.1

Table of filling quantities .......................................................3.4-1

3.4.2

Lubrication charts .................................................................3.4-5

LBH/Version 01/10.2006/en/hd/22/02/2007

3.5


Maintenance tasks..........................................................................3.5-1 3.5.1

Preparatory tasks for maintenance ......................................3.5-1

3.5.2

Removing loose parts, dirt, ice and snow from the machine ................................................................................3.5-5

3.5.3

Checking the machine for external damage.........................3.5-6

3.5.4

Making sure the bolted connections are tight.......................3.5-6

3.5.5

Sealing leaks ........................................................................3.5-6

3.5.6

Checking the engine oil level................................................3.5-6

3.5.7

Changing the engine oil........................................................3.5-7

3.5.8

Changing the diesel engine oil filter .....................................3.5-8

3.5.9

Checking / replacing the V-ribbed belt .................................3.5-9

3.5.10

Checking / adjusting the engine valve play ..........................3.5-9

3.5.11

Checking the diesel engine heating flange ........................3.5-11

3.5.12

Greasing the ring gear on the engine starter flywheel .......3.5-12

3.5.13

Changing the engine oil separator filter insert....................3.5-12

3.5.14

Checking the bearings and condition of the engine control units ........................................................................3.5-13

3.5.15

Checking the state of sensors and cable connections .......3.5-13

3.5.16

Changing the fuel pre-filter .................................................3.5-13

3.5.17

Changing the fuel fine filter.................................................3.5-15

3.5.18

Draining off condensate from the fuel pre-filter (the corresponding service code appears) ................................3.5-16

3.5.19

Bleeding the fuel system ....................................................3.5-16

3.5.20

Draining off condensate and sediment from the fuel tank .....................................................................................3.5-18

L576 - 457 / from 14171 L580 - 459 / from 14171

Copyright by

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3.0-1 o f 4

3.0-2 o f 4

Service Manual 3.5.21

Cleaning the air filter service cap and dust extraction valve................................................................................... 3.5-19

3.5.22

Testing the air filter vacuum switch ................................... 3.5-19

3.5.23

Changing the air filter primary element when indicated by the vacuum switch ........................................................ 3.5-20

3.5.24

Changing the air filter secondary element ......................... 3.5-21

3.5.25

Checking the air intake hoses for leaks and tight fitting .... 3.5-22

3.5.26

Checking the exhaust lines for leaks and tight fitting ........ 3.5-22

3.5.27

Check the oil level in the pump distributor gear................. 3.5-23

3.5.28

Changing the splitter box oil .............................................. 3.5-24

3.5.29

Checking the soot particle filter pressure monitor for function, leaks and blockages............................................ 3.5-24

3.5.30

Checking and draining the soot particle filter condensate separator ........................................................ 3.5-25

3.5.31

Changing the soot particle filter condensate separator ..... 3.5-26

3.5.32

Cleaning the soot particle filter .......................................... 3.5-27

3.5.33

Checking the coolant antifreeze and corrosion inhibitor concentration ..................................................................... 3.5-28

3.5.34

Cleaning the cooling system.............................................. 3.5-32

3.5.35

Changing the coolant......................................................... 3.5-33

3.5.36

Checking the oil level in the hydraulic tank........................ 3.5-35

3.5.37

Draining off condensate and sediment from the hydraulic tank..................................................................... 3.5-36

3.5.38

Changing the oil in the hydraulic tank and checking the return strainer..................................................................... 3.5-36

3.5.39

Checking and cleaning the magnetic rod on the hydraulic tank..................................................................... 3.5-37

3.5.40

Changing the hydraulic tank return suction filter ............... 3.5-38

3.5.41

Changing the hydraulic tank bleeder filter ......................... 3.5-38

3.5.42

Lubricating the pilot control device solenoids, universal joints and tappets............................................................... 3.5-39

3.5.43

Testing the steering ........................................................... 3.5-39

3.5.44

Lubricating the bearing points on the steering cylinders ... 3.5-39

3.5.45

Testing the service brake and parking brake..................... 3.5-40

3.5.46

Checking the gap and wear on the parking brake linings.. 3.5-41

3.5.47

Checking the indicator lamps and lighting ......................... 3.5-42

3.5.48

Checking the batteries, fluid level and terminals ............... 3.5-43

3.5.49

Checking the transmission oil level ................................... 3.5-44

3.5.50

Changing the transmission oil............................................ 3.5-44

3.5.51

Changing the transmission oil filter.................................... 3.5-44

3.5.52

Checking the tightness of the wheels (once after 50, 100 and 250 h)................................................................... 3.5-45

3.5.53

Checking the axle oil level ................................................. 3.5-45

3.5.54

Checking the axle oil level ................................................. 3.5-46

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L550 - 456 / from 16978 L556 - 454 / from 15653


LBH/Version 01/10.2006/en/hd/22/02/2007

Maintenance

Service Manual

Maintenance 3.5.55

Changing the axle oil ..........................................................3.5-46

3.5.56

Changing the axle oil ..........................................................3.5-47

3.5.57

Lubricating the bevel gear seal ..........................................3.5-48

3.5.58

Checking and lubricating the front drive shaft ....................3.5-48

3.5.59

Checking and lubricating the rear drive shaft.....................3.5-48

3.5.60

Testing and setting the tyre pressure for the machine's use and attachments ..........................................................3.5-49

3.5.61

Lubricating the articulated bearing and the rear oscillating bearing...............................................................3.5-49

3.5.62

Checking the lubrication system grease reservoir level .....3.5-50

3.5.63

Checking the pipes, hoses and lubrication points of the lubrication system...............................................................3.5-51

3.5.64

Checking whether metered quantities are adequate at the bearing points (grease collars) of the central lubrication system...............................................................3.5-51

3.5.65

Lubricating the door hinges ................................................3.5-51

3.5.66

Cleaning the fresh air and recirculated air filter..................3.5-51

3.5.67

Changing the fresh air and recirculated air filter ................3.5-53

3.5.68

Checking the indicator beads in the dryer-collector unit ....3.5-54

3.5.69

Lubricating the lift arms and attachment ............................3.5-54

3.5.70

Checking the bucket bearing seals and the bearing bushings on the lift arms.....................................................3.5-55

3.5.71

Check the lift arms and bucket stops .................................3.5-57

3.5.72

Testing the quick-change device (optional)........................3.5-58

LBH/Version 01/10.2006/en/hd/22/02/2007

3.6


Testing and adjustment tasks .........................................................3.6-1 3.6.1

Preparing for testing and adjustment ...................................3.6-1

3.6.2

Safety precautions for testing and adjustment .....................3.6-1

3.6.3

Bringing the machine up to operating temperature ..............3.6-2

3.6.4

Checking the diesel engine speed .......................................3.6-2

3.6.5

Check the fan motor and fan control pressure relief valve .....................................................................................3.6-3

3.6.6

Calibrating the pedals...........................................................3.6-4

3.6.7

Checking the replenishing pressure of the variable displacement pump ..............................................................3.6-5

3.6.8

Checking the pressure relief and replenishing valve of the variable displacement pump...........................................3.6-5

3.6.9

Checking the pressure cut-off of the variable displacement pump ..............................................................3.6-6

3.6.10

Calibrating the block curve ...................................................3.6-7

3.6.11

Calibrating the variable displacement motors ......................3.6-8

3.6.12

Checking the engine output..................................................3.6-9

3.6.13

Checking the flow controller (delta p) of the working hydraulics pump .................................................................3.6-10

L576 - 457 / from 14171 L580 - 459 / from 14171

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3.0-3 o f 4

Maintenance

Service Manual 3.6.14

Checking the flow controller (start of delivery) of the working hydraulics pump ................................................... 3.6-10

3.6.15

Checking the secondary pressure relief valves on the control block....................................................................... 3.6-11

3.6.16

Checking the primary pressure relief valves on the control block....................................................................... 3.6-12

3.6.17

Checking the LS pressure cut-off on the control block...... 3.6-12

3.6.18

Depressurising ride control and the hydro accumulators .. 3.6-13

3.6.19

Checking the cut-off pressure in the stabilisation module ............................................................................... 3.6-13

3.6.20

Checking the nitrogen in the ride control hydro accumulator ....................................................................... 3.6-13

3.6.21

Check the pressure cut-off of the steering pump............... 3.6-14

3.6.22

Checking the flow controller (delta p) of the steering pump .................................................................................. 3.6-14

3.6.23

Checking the brake pressure of the compact brake valve................................................................................... 3.6-15

3.6.24

Checking the brake pressure at the axles ......................... 3.6-15

3.6.25

Checking the capacity of the brake accumulator............... 3.6-16

3.6.26

Checking the accumulator charge pressure ...................... 3.6-17

3.6.27

Checking the brake light pressure switch and brake lights................................................................................... 3.6-17

3.6.28

Checking the transmission shift pressure.......................... 3.6-17

3.6.29

Checking the nitrogen in the transmission hydro accumulator ....................................................................... 3.6-18

3.7

Lubricants and fuels ....................................................................... 3.7-1 Diesel fuels .......................................................................... 3.7-2

3.7.2

Lubricating oils for diesel engines ....................................... 3.7-3

3.7.3

Coolant for the diesel engine ............................................... 3.7-5

3.7.4

Hydraulic oils........................................................................ 3.7-8

3.7.5

Lubricating oils for the transmission .................................... 3.7-9

3.7.6

Grease for general lubrication points................................... 3.7-9 LBH/Version 01/10.2006/en/hd/22/02/2007

3.7.1

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Service Manual

Maintenance Maintenance and inspection schedule

3.1 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 operator 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 authorised engineers from LIEBHERR or its authorised dealers. This affects the maintenance intervals on delivery, every 500, 1000, 2000 service hours (h), and at unscheduled times.

LBH/Version 01/10.2006/en/hd/22/02/2007

You will find a list of the spare parts needed for maintenance and inspection work in the service package of the spare parts list.


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3.1-1 o f 4

Maintenance

Service Manual

Maintenance and inspection schedule

Customer: ……………………

Machine type: ………...…

Serial no.: …….…… Service hours: ………..……… Date: ………..……………

Special intervals

Every 2000

Every 1000

Every 500

Every 50

Every 10

On handover

Maintenance / inspection after service hours

z z

z z

TASKS TO BE PERFORMED By maintenance staff Once-only activity zRepeat interval As necessary 7Annually before the winter

By authorised specialist staff Once-only activity Repeat interval As necessary

Have the driver lubricate the machine in accordance with the lubrication chart and instruct him on proper maintenance Instruct the driver in the operation of all functions Remove loose parts, dirt, ice and snow from the machine Check the machine for external damage Make sure the bolted connections are tight Seal any leaks Check the hydraulic pressure according to the testing and adjustment plan

z

z

7

z

z z z

z

3.1-2 o f 4

Check the engine oil level Change the engine oil (at least once a year): CAUTION See the section on lubricants and fuels for the engine oil quality and complicating factors. Change the engine oil filter (at least once a year) Check the V-ribbed belt and replace it if necessary Check / adjust the engine valve play Check the diesel engine heating flange Lightly grease the ring gear on the engine starter flywheel Change the engine oil separator filter insert Check the bearings and and condition of the engine control units Check the state of sensors and cable connections Replace the fuel pre-filter (or in the event of a lack of output) Replace the fuel fine filter (or in the event of a lack of output) Drain off condensate from the fuel pre-filter (or if the corresponding service code appears) Bleed air from fuel system (CAUTION: do not loosen injection lines) Drain off condensate and sediment from the fuel tank Clean the air filter service cap and dust extraction valve Test the air filter vacuum switch Change the main air filter element when indicated by the vacuum switch (or every year at the latest) Clean or replace the air filter secondary element (after replacing the main element 3 times or every year at the latest) Check the air intake hoses for leaks and tight fitting Check the exhaust lines for leaks and tight fitting Check the oil level in the pump distributor gear Change the splitter box oil

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L550 - 456 / from 16978 L556 - 454 / from 15653


LBH/Version 01/10.2006/en/hd/22/02/2007

Diesel engine and pump distributor gear

Service Manual

Maintenance Maintenance and inspection schedule

Customer: ……………………

Machine type: …………… Serial no.: ……....… Service hours: …….…………

Special intervals

Every 2000

Every 1000

Every 500

Every 50

Every 10

On handover


Date: ………..……………

TASKS TO BE PERFORMED By maintenance staff Once-only activity Repeat interval As necessary 7 Annually before the winter


Diesel particle filter (optional)

Check the diesel particle filter pressure monitor for function, leaks and blockages Check and drain the diesel particle filter condensate separator Change the diesel particle filter condensate separator Clean the diesel particle filter (at least once a year):

Cooling system

7 3000

Check the coolant antifreeze concentration Clean the cooling system Replace the coolant (at least every 2 years) Working hydraulics

z

z

250

Check the oil level in the hydraulic tank Drain off condensate and sediment from the hydraulic tank Change the oil in the hydraulic tank and check the return strainer Check the oil in the hydraulic tank (affects all environmentally compatible hydraulic fluids) Check and clean the magnetic rod on the hydraulic tank Change the hydraulic tank return suction filter insert Change the hydraulic tank bleeder filter Lubricate the pilot control device solenoids, universal joints and tappets Steering system

z

z z

Test the steering Lubricate the bearing points on the steering cylinders Brake system

z

z

Check the service brake and parking brake Check the gap and wear on the parking brake linings

LBH/Version 01/10.2006/en/hd/26/02/2007

Electrical system

z

z

Check the indicator lamps and lighting Check the batteries, fluid level and terminals Transmission

z


Check the transmission oil level Change the transmission oil Change the transmission oil filter

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3.1-3 o f 4

Maintenance

Service Manual

Maintenance and inspection schedule

Customer: ………………………


Serial no.: ……....… Service hours: ………..……… Date: ………..……………

TASKS TO BE PERFORMED Special intervals

Every 2000

Every 1000

Every 500

Every 50

Every 10

On handover


By maintenance staff Once-only activity zRepeat interval As necessary 7Annually before the winter


Axles and tyres

z

Checking the tightness of the wheels (once after 50, 100 and 250 h) Checking the axle oil levels Changing the axle oil Lubricate the bevel gear seal on the front and rear axles (if necessary, for example, if used in water every day) (only applies to L580 - 459) Check and lubricate the cardan shaft(s) Check the tyre pressure Machine frame and ballast weight

z

Lubricate the articulated bearing and the rear oscillating bearing Grease the rear section cover lower hinges Lubrication system (optional)

z z

z

Check the lubrication system grease reservoir level Check the pipes, hoses and lubrication points of the lubrication system Check whether metered quantities are adequate at the bearing points (grease collars) of the central lubrication system Cab, heating and air-conditioning

Grease the cab door hinges Clean the fresh air and recirculated air filter Change the fresh air and recirculated air filter Check the indicator and filling level beads in the dryer-collector unit of the air conditioner

z

z

z

3.1-4 o f 4

Lubricate the lift arms and attachment Check the bucket bearing seals and the bearing bushings on the lift arms Check the lift arms and bucket stops Lubricate and test the quick-change device

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LBH/Version 01/10.2006/en/hd/22/02/2007


Service Manual

Maintenance Testing and adjustment plan

3.2 Testing and adjustment plan The tasks in the testing and adjustment plan may only be carried out by authorised specialist staff of LIEBHERR or its contractual agents. You can find brief instructions on performing these tasks in the section on testing and adjustment checklists.

LBH/Version 01/10.2006/en/hd/22/02/2007

Detailed instructions can be found in the section on testing and adjustment tasks.


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3.2-1 o f 2

Maintenance

Service Manual

Testing and adjustment plan


Serial no.: …….…… Service hours: …….…………

TASKS TO BE PERFORMED Special intervals

Every 2000

Every 1000

Every 500

Every 50

Every 10

On handover


Cooling system Check the fan motor and fan control pressure relief valve

Travel hydraulics Synchronise pedals Check the replenishing pressure of the variable displacement pump Check the pressure relief and replenishing valve of the variable displacement pump Check the pressure cut-off of the variable displacement pump Calibrate the block curve Calibrate the variable displacement motors Check the engine output Working hydraulics Check the flow controller (delta p) of the working hydraulics pump Check the flow controller (start of delivery) of the working hydraulics pump Check the secondary pressure relief valves on the control block Check the primary pressure relief valves on the control block Check the LS pressure cut-off on the control block Check the cut-off pressure in the stabilisation module Check the nitrogen in the ride control hydro accumulator

Steering system Check the pressure cut-off of the steering pump Check the flow controller (delta p) of the steering pump

Brake system Check the opening and closing pressure of the compact brake valve Check the brake pressure of the compact brake valve Check the capacity of the brake accumulator Check the accumulator charge pressure Check the brake light pressure switch and brake lights Transmission Check the transmission shift pressure Check the nitrogen in the transmission hydro accumulator

3.2-2 o f 2

By authorised specialist staff Once-only activity Repeat interval As necessary Diesel engine Check the diesel engine speed

Date: ………..……………

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LBH/Version 01/10.2006/en/hd/22/02/2007

Customer: ………………………

Service Manual

Maintenance Testing and adjustment checklists

3.3 Testing and adjustment checklists

LBH/Version 01/10.2006/en/hd/22/02/2007

The testing and adjustment checklists contain all testing and adjustment tasks. You can find detailed descriptions of each activity in the section on testing and adjustment tasks.


L576 - 457 / from 14171 L580 - 459 / from 14171

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3.3-1 o f 2

L550, L556 Ser. Nr.

Customer:

/

Operating hours: Type of application: Checked by:

Job site:

Check / Adjustment

2000 Bh.

1000 Bh.

Checked on date: Unit

Adjust. values

°C

58±

Value before adjust.

Value after adjust.

Adjust. point

Test point

Operating temperature Operating temperature (Temperature sensor – hydraulic oil)

5

Cooling system Cooling System (fan control) Fan at high Diesel engine RPM / Sensor unplugged

bar

110±

10

Fan at high Diesel engine RPM / Prop. solenoid valve current less

bar

220±

10

P 1

P

Diesel engine S C U L I

Adjustment - pedals Gas pedal – angle sensor Inching pedal – angle sensor Diesel engine RPM Low idle RPM High idle RPM

min

-1

900±

min

-1

2065±

10 10

Travel hydraulic Replenishing pressure At high idle RPM

1

3

G

10

2

MA

±10

4

MB

5

1

MA (MB)

bar

31±

Forward

bar

470±

Reverse

bar

470

bar

430±

High pressure relief valves

Pressure cut off High pressure Engine speed drop, max. difference to high idle RPM

min

-1

Display

30

-1

Block curve at 930 min Diesel engine RPM

min

High pressure Block curve at 1200 min

bar

930 50±

930

930

10

-1

Diesel engine RPM

min


-1

-1

bar

1200 290±

1200

1200

10

-1

Diesel engine RPM

min

High pressure

-1

bar

1400 350

1400

1400

±10

S C U L I

MA (MB)

S C U L I

MA (MB)

S C U L I

MA (MB)

S C U L I

Adjustment var. displ. motor Automatically adjustment of the variable displacement motors Engine performance at 13 km/h High pressure

L550

bar

300±

10

MA

High pressure

L556

bar

330±

10

MA

Diesel engine RPM

min

-1

1980

±30

= Blocked Machine

L550 - 456 / from 16978 L576 - 454 / from 15653

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3.3

2000 Bh.

1000 Bh.

Check / Adjustment

Unit

Adjust. values


Value after adjust.

Adjust. point

Test point

Working hydraulic Control valve block 5

3

P

±5

4

P

5

6

P

±5

5

P

10

7

P

±10

7

P

10

1

M / M1

2

2

M / LS

Secondary pressure relief valve, lift

bar

Secondary pressure rel. valve, tilt in

bar

380

Secondary pressure rel. valve, tilt out

bar

380±


380±

bar

360

290±

Control valve block LS-Pressure cut off

L550

bar

LS-Pressure cut off

L556

bar

330

bar

180±

bar

22±

bar

120±

bar

25±

Working hydraulic pump Power regulator Working hydraulic pump Flow regulator-Pressure difference Stabilization module Shut off pressure (LFD – turned off)

20

MX

Hydro accumulator LFD Pretension pressure (nitrogen filling)

2

9

9

2

P

1

P / LS

5

1

M3

±5

1

M3

2

M4 / M5

Steering system Variable displacement pump Pressure cut off

bar

210±

bar

22±

5

Variable displacement pump Flow regulator – Pressure difference

2

Brake system Compact brake valve Cut in pressure

bar

Cut out pressure

bar

Brake pressure in axles

bar

95

bar

> 50

bar

120±

180± 210

±5

Accumulator After 9 braking actions

M4 / M5

Pressure switch - brake system Switching point

5

M3

Transfer gear Transfer gear Switching pressure

bar

20±

3

P

bar

12±

2

1

Transmission - hydro accumulator Preload pressure (nitrogen filling)

Remarks:

Signature:

Check and adjust only if required

3.3

copyright by

MJFCIFSS

L550 - 456 / from 16978 L556 - 454 / from 15653

L566, L576, L580 Ser. Nr.

Customer:

/

Operating hours: Type of application: Checked by:

Job site:

Check / Adjustment

2000 Bh.

1000 Bh.

Checked on date: Unit

Adjust. values

°C

58±


Value after adjust.

Adjust. point

Test point

Operating temperature Operating temperature (Temperature sensor – hydraulic oil)

5

Cooling system Cooling System (fan control) Fan at high Diesel engine RPM / Sensor unplugged

bar

165±

Fan at high Diesel engine RPM / Prop. solenoid valve current less

bar

220±

5

P

10

1

P

Diesel engine Adjustment - pedals

S C U L I

Gas pedal – angle sensor Inching pedal – angle sensor Diesel engine RPM Low idle RPM High idle RPM

min

-1

min

-1

900± 2065

10

±10

Travel hydraulic Replenishing pressure At high idle RPM

bar

34±

bar

470±

1

3

G

10

2

MA

±10

4

MB

1

MA (MB)

High pressure relief valves Forward Reverse

bar

470

bar

430±

Pressure cut off High pressure Engine speed drop, max. difference to high idle RPM

min

-1

min

-1

5

Display

30

-1

Block curve at 930 min Diesel engine RPM High pressure

Block curve at 1200 min

bar

50

930

930

±10

-1

Diesel engine RPM

min


930

-1

bar

1200 230

1200

1200

±10

-1

Diesel engine RPM

min

High pressure

-1

bar

1400 330±

1400

1400

10

S C U L I

MA (MB)

S C U L I

MA (MB)

S C U L I

MA (MB)

S C U L I

Adjustment var. displ. motor Automatically adjustment of the variable displacement motors Engine performance at 13 km/h High pressure

L566

High pressure

L576, L580

Diesel engine RPM

bar bar min

-1

340± 350

10

MA

±10

MA

1980

±30

= Blocked Machine

L566 - 460 / ab 14171 L576 - 456 / ab 14171 L580 - 459 / ab 14171

copyright by

MJFCIFSS

3.3

2000 Bh.

1000 Bh.

Check / Adjustment

Unit

Adjust. values


Value after adjust.

Adjust. point

Test point

5

3

P

±5

Working hydraulic Control valve block Secondary pressure relief valve, lift

bar

420±

Secondary pressure rel. valve, tilt in

bar

400

Secondary pressure rel. valve, tilt out

bar

400±


4

P

5

6

P

±5

5

P

5

7

P

10

1

M / M1

2

2

M / LS

bar

380

bar

350±

bar

180±

bar

22±

bar

120±

bar

25±

Control valve block LS-Pressure cut off Working hydraulic pump Power regulator Working hydraulic pump Flow regulator-Pressure difference Stabilization module Shut off pressure (LFD – turned off)

20

MX

Hydro accumulator LFD Pretension pressure (nitrogen filling)

2

9

9

2

P

2

1

P / LS

180±

5

1

M3

±5

1

M3

2

M4 / M5

2

M4 / M5

Steering system Variable displacement pump Pressure cut off

bar

210±

bar

22±

5

Variable displacement pump Flow regulator – Pressure difference

Brake system Compact brake valve Cut in pressure

bar

Cut out pressure

bar

210


L566, L576

bar

95


L580

bar

70±

bar

> 50

M4 / M5

bar

120±

M3

±5 5

Accumulator After 9 braking actions Pressure switch - brake system Switching point

5

Transfer gear Transfer gear Switching pressure

bar

20±

3

P

bar

12±

2

1

Transmission - hydro accumulator Preload pressure (nitrogen filling)

Remarks:

Signature:

Check and adjust only if required

3.3

copyright by

MJFCIFSS

L566 - 460 / ab 14171 L576 - 457 / ab 14171 L580 - 459 / ab 14171

Maintenance

Service Manual

LBH/Version 01/10.2006/en/hd/22/02/2007

Testing and adjustment checklists

3.3-2 o f 2

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Service Manual

Maintenance Lubrication chart and filling quantities

3.4 Lubrication chart and filling quantities 3.4.1

Table of filling quantities Specifications in the medium column: – The standard lubricants and fuels required for central European climate conditions are stated here. – Before you change or top up the oil in the hydraulic system (hydraulic tank), always check if it is filled with petroleum or bio oil. – For more detailed information about the required lubricants and service fuels, see the section on lubricants and fuels. Specifications in the dosage 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 question.

LBH/Version 01/10.2006/en/hd/22/02/2007

Valid for:


L550 - 456 / from 16978

Description

Medium

Hydraulic system Total capacity

Engine oil SAE 20W - 20

240 l

Diesel engine (with filter change)


31 l

Pump distributor gear

Gear oil SAE 90

2.5 l

Cooling system Diesel engine

Coolant

45 l

Hydraulic tank


135 l

Transmission

ATF oil

11.5 l

Front axle

Gear oil SAE 90 LS

30 l

Rear axle

Gear oil SAE 90 LS

30 l

Fuel tank

Diesel

Air conditioning system

Refrigerant R 134a

L576 - 457 / from 14171 L580 - 459 / from 14171

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Dosage Unit

300 l

1250+50 g

3.4-1 o f 8

Maintenance

Service Manual

Lubrication chart and filling quantities

L556 - 454 / from 15653

Description

Medium

Dosage

Unit



240 l



31 l


Gear oil SAE 90

2.5 l

Cooling system Diesel engine

Coolant

45.0 l

Hydraulic tank


135 l

Transmission

ATF oil

11.5 l

Front axle

Gear oil SAE 90 LS

38 l

Rear axle

Gear oil SAE 90 LS

30 l

Fuel tank

Diesel


Refrigerant R 134a

300 l

1250+50 g

LBH/Version 01/10.2006/en/hd/22/02/2007

Valid for:

3.4-2 o f 8

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L550 - 456 / from 16978 L556 - 454 / from 15653


Service Manual


Valid for:

LBH/Version 01/10.2006/en/hd/22/02/2007

Valid for:


L566 - 460 / from 14171; L576 - 457 / from 14171

Description

Medium

Dosage

Unit




Gear oil SAE 90 LS

Diesel engine cooling system total capacity

Coolant

52.0 l



260 l

Hydraulic tank


135 l

Transmission

ATF oil

11.5 l

Front axle

Gear oil SAE 90 LS

47.0 l

Rear axle

Gear oil SAE 90 LS

L566: 45.0 l L576: 47.0 l

Fuel tank

Diesel


Refrigerant R 134a

43.0 l

2.5 l

400 l

1250+50 g

L580 - 459 / from 14171

Description

Medium




Gear oil SAE 90 LS

Diesel engine cooling system Total capacity

Coolant

L576 - 457 / from 14171 L580 - 459 / from 14171

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Dosage

Unit 43.0 l

2.5 l

52.0 l

3.4-3 o f 8

Maintenance

Service Manual


Description

Medium

Dosage

Unit



260 l

Hydraulic tank


135 l

Transmission

ATF oil

11.5 l

Front axle

Gear oil SAE 90 LS

48.0 l

Rear axle

Gear oil SAE 90 LS

50.0 l

Fuel tank

Diesel

400 l


Refrigerant R 134a

LBH/Version 01/10.2006/en/hd/22/02/2007

1250+50 g

3.4-4 o f 8

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Service Manual


3.4.2

Lubrication charts The lubrication chart provides an overview of the location of the maintenance points on the machine and of the maintenance intervals. You will find detailed information in the maintenance and inspection schedule, as well as in the individual descriptions in the section on maintenance tasks. For more detailed information about the required lubricants and service fuels, see the section on lubricants and fuels. For information about the required filling quantities, see the tables of filling quantities. Key: 1 = transmission 2 = front axle 3 = rear axle 1) = central lubricating rail, front section

LBH/Version 01/10.2006/en/hd/22/02/2007

2) = central lubricating rail, rear section


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3.4-5 o f 8

Maintenance

Service Manual


Symbol

L550 - 456 / from 16978; L556 - 454 / from 1565 L566 - 460 / from 14171; L576 - 457 / from 14171;

Description

Symbol

LBH/Version 01/10.2006/en/hd/22/02/2007

Valid for:

Description

General lubrication points

Lubrication

Check the oil level

Oil change

First oil change

3.4-6 o f 8

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Service Manual


LBH/Version 01/10.2006/en/hd/22/02/2007

Valid for:

Symbol

L580 - 459 / from 14171

Description

Symbol

Description

General lubrication points

Lubrication

Check the oil level

Oil change

First oil change


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3.4-7 o f 8

Maintenance

Service Manual

LBH/Version 01/10.2006/en/hd/22/02/2007


3.4-8 o f 8

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Service Manual

Maintenance Maintenance tasks

3.5 Maintenance tasks On completion of servicing, the machine should be returned to the operating position.

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.

3.5.1

Preparatory tasks for maintenance Before performing the various maintenance tasks, move the machine to maintenance position unless otherwise explicitly specified in the description. The various maintenance tasks include: – Lubricating the lift arms – Checking the oil level or changing the oil in the engine, gears, axles, hydraulic tank, etc. – Replacing filters as well as adjustment and repair work on the hydraulic system Safety precautions for maintenance Always observe the accident prevention regulations during maintenance work. Make sure that visual contact between the operator in the cab and maintenance personnel is always maintained.

Visual contact Danger There is a risk of accidents for maintenance personnel. The presence of unauthorised persons on the machine can place the maintenance personnel in extreme danger.

! Never enter a dangerous area of the machine without making your preLBH/Version 01/10.2006/en/hd/22/02/2007

sence known.

Wheel wedges

• Make sure you can be clearly seen before entering one of the machine's danger areas. • Secure the machine against rolling away with wheel wedges. Maintenance positions 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.


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3.5-1 o f 5 8

Maintenance

Service Manual

Maintenance tasks

Maintenance position 1

To move the machine into maintenance position 1 proceed as follows.

• • • • • • Maintenance position 2

Maintenance position 1 Park the machine on level ground. Lower the lift arms. Set the bucket down flat on the ground. Engage the parking brake. Turn off the diesel engine. Take out the ignition key.

To move the machine into maintenance position 2 proceed as follows.

Maintenance position 2 Park the machine on level ground. Engage the articulation lock. Lower the lift arms. Tilt the bucket out and set it down on the ground on its teeth or cutting edge. • Engage the parking brake. • Turn off the diesel engine. • Take out the ignition key. • • • •

Opening the service hatches, doors and hoods Open the door if you need to access the following units or components: – Hydraulic pumps – Hydraulic tank – Hydraulic tank shut-off valve – Air filter – Battery main switch

Engine compartment hatch 1 Engine compartment hatch 2 Handle with lock

3.5-2 o f 5 8

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3 Gas-filled springs

L550 - 456 / from 16978 L556 - 454 / from 15653


LBH/Version 01/10.2006/en/hd/22/02/2007

Opening the engine compartment hatch

Service Manual


Warning There is a risk of injury if the engine compartment door falls shut.

! Check that the gas-filled springs securely hold the hood fully open. • Open the lock with the ignition key. • Completely open the hatch 1 using the handle 2. Two gas-filled springs 3 hold the opened hatch in this position. Opening the engine compartment hatch

When the hood is open, you can access the following units: – Diesel engine – Pump distributor gear – Cooling system – Hydraulic tank

•

Engine compartment hatch and hood cable Open the engine compartment hatch.

Warning Engine parts which are in motion can cause injury. Rotating or moving engine parts, such as the fan blades or V-belts, can cause injury.

! Only open the engine compartment hood when the engine is shut down.

LBH/Version 01/10.2006/en/hd/22/02/2007

• Pull the cable 1 for unlocking the engine compartment hood until the lock is open.

Engine compartment hood 1 Engine compartment hood 2 Gas-filled springs 3 Engine compartment hatch L550 - 456 / from 16978 L556 - 454 / from 15653 L566 - 460 / from 14171

L576 - 457 / from 14171 L580 - 459 / from 14171

4 Cable lock 5 Hydraulic tank cover

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3.5-3 o f 5 8

Maintenance

Service Manual

Maintenance tasks

The lock 4 unlocks the engine compartment hood 1. The hood is automatically opened and held in position by two gas-filled springs 2.

• Turn the securing pipe 2 in the direction of the arrow (position shown). The gas-filled spring 1 is now blocked. The engine compartment hood cannot be opened. Warning There is a risk of injuries if the hood falls shut.

! Check that the gas-filled springs securely hold the hood fully open. • Check the function. • Open the hydraulic tank over 5 as required. Unlock the cover and open it. Opening the engine compartment hatch

When the hood is open, you can access the cooling system. Make sure that the cab door is closed. • When opening or closing the hood, climb onto the machine via the cab access, making sure that you have secure footing.

1 Left cooling system hood 3 Gas-filled springs 2 Right cooling system hood 4 Handle • Completely open the hood 1 and/or 2 by pulling up the handle. The hood is held in this position by the gas-filled spring 3. Warning There is a risk of injuries if the hood falls shut.

! Check that gas-filled spring holds it completely open. • Check the function.

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Cooling system hood

Service Manual


Turning off the battery main switch The battery main switch is located at the rear left of the engine compartment. For certain maintenance jobs, the battery main switch must first be turned off. Find out from the descriptions of the relevant maintenance tasks whether the battery main switch must be turned on or off. See the section on maintenance tasks. Switch on the battery main switch after completing these maintenance tasks. Caution There is a risk of damaging the electrical system. ! Do not turn off the battery main switch while the engine is running.

Battery main switch 1 Battery main switch

2 Main switch key

Danger There is a risk of accidents for maintenance personnel. If unauthorised people are on the machine it can put the maintenance personnel in extreme danger.

! For safety reasons, it is essential that the battery main switch is turned off. ! Pull out the key for safety reasons. • Turn off the battery main switch 1 by turning the key 2 to the 0 position.

3.5.2

Removing loose parts, dirt, ice and snow from the machine Make sure that the machine is in maintenance position 1.

LBH/Version 01/10.2006/en/hd/22/02/2007

Procedure Note To ensure safe machine transport and easy maintenance: Clean the machine after everyday work and before starting maintenance tasks.

! Remove any loose parts, coarse dirt, mud, ice, snow etc. •


Be careful when cleaning the machine with a high-pressure cleaner. See the section on cleaning the machine.

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Maintenance

Service Manual

Maintenance tasks

3.5.3

Checking the machine for external damage Make sure that the machine is in maintenance position 1. Procedure • Before starting up the machine, check for external damage which might impair safe operation. • Repair any damage with safety implications immediately.

3.5.4

Making sure the bolted connections are tight Make sure that: – The machine is in maintenance position 2. – The service doors and hoods are open. Procedure • Check that all bolts and screws are tight. • Tighten any loose screws or bolts with the required tightening torque.

3.5.5

Sealing leaks Make sure that: – The machine is in maintenance position 2. – The service doors and hoods are open. Procedure • • • •

3.5.6

Check the entire hydraulic system for leaks. Replace any damaged hydraulic seals. Tighten any loose hydraulic couplings. See also the section on safe maintenance of hydraulic hoses and hose lines.

Checking the engine oil level Make sure that: – The machine is in maintenance position 1. – The engine compartment hood is open. – The engine is level and has not been running for 2 - 3 minutes.

LBH/Version 01/10.2006/en/hd/22/02/2007

Procedure

Diesel engine • Pull out the dipstick 1, wipe it clean, and re-insert it. • Pull out the dipstick once again and read off the oil level. The oil level must be between the MIN and MAX markings.

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Service Manual


• If the oil level is too low: Remove the sealing cap from the filler neck 2 and top up with oil. For the oil quality, see the section on lubricants and fuels. • Clean the sealing cap, place it on the filler neck 2 and tighten it.

3.5.7

Changing the engine oil Make sure that: – The machine is in maintenance position 1. – The engine compartment hood is open. – The engine is level. – The engine is warm. – A suitable receptacle, an oil drain hose and the specified engine oil are at hand. See the table of filling quantities for the required capacity of the receptacle. Procedure

• • • • •

1 Oil drain hose 3 Oil drain valve 2 Cap Unscrew the cap of the oil drain valve on the oil pan. Screw the oil drain hose to the oil drain valve. Drain off the oil into the receptacle. Unscrew the oil drain hose. Screw the cap onto the oil drain valve.

LBH/Version 01/10.2006/en/hd/22/02/2007

When changing the engine oil and the oil filter: Change the filter as described in the section on changing the engine oil filter.

• • • • •


Diesel engine Pour the new oil into the filler neck 2 to between the MIN and MAX markings on the dipstick 1. Clean the filler cap, place it on the filler neck 2 and tighten it. Start the engine and check the oil pressure. Turn off the engine and after 1 or 2 minutes and check the oil level on the dipstick. Top up with oil if necessary.

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Maintenance

Service Manual

Maintenance tasks

3.5.8

Changing the diesel engine oil filter Make sure that: – The machine is in maintenance position 1. – The engine compartment hood is open. – The engine oil has been drained off. – A strap wrench and a suitable container are in place. – Only use genuine LIEBHERR spare parts (2 oil filter cartridges). Procedure

• Place a suitable container under the diesel engine.

• Release the filter cartridges 1 with a strap wrench and unscrew them. • Clean the seals on the filter bracket. • Lightly coat the rubber gaskets on the new oil filter cartridges with engine oil. • Screw on the new oil filter cartridge until the sealing ring touches the filter bracket. • When the sealing ring touches the filter bracket: Tighten the oil filter cartridge by a half to three-quarter turn. (Do not use a tool for tightening). • Start the diesel engine: Check the oil pressure in the engine oil pressure display (see display unit). • Shut down the diesel engine: Check the seals on the oil filters and the oil level. • After 2 to 3 minutes, check the oil level on the dipstick.

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Note Protect the V-ribbed-belt against emerging oil when changing the oil filter cartridge. ! After changing the oil filter, remove all traces of oil on the diesel engine, also behind the vibration damper so that this is not diagnosed as a leak in the leakage in the radial shaft seal at a later stage.

Service Manual


3.5.9

Checking / replacing the V-ribbed belt The V-ribbed belt is on the front of the engine, protected by a cover. The engine has a tensioning device for the V-ribbed belt. This tensions itself and requires no maintenance. Check the V-ribbed belt for wear. Checking the V-ribbed belt • Take off the V-ribbed belt guard. • Check the V-ribbed belt for damage. Damage to the V-ribbed belt can include: – Torn belt – Tears in several ribs – Lumps of rubber on the base of the belt – Accumulations of dirt and grit – Ribs coming loose from the belt base – Cracks on the back

V-ribbed belt guard

Replacing the V-ribbed belt Make sure you have a DIN 3122 D 12.5 mm (1/2") ratchet wrench and a new V-ribbed belt. • Pull back the tensioning device 5 against the spring force anticlockwise as far as it will go and take off the belt. • With the tensioning device 5 swung back, put the new belt on the pulleys of the crankshaft 6, air conditioning compressor 1, alternator 3 and deflector roller 2, 4. Then return the tensioning device 5 to the tensioning position.

Belt run

Note When changing the belt, make sure the deflector roller 2, 4 and the tensioning roller 5 move freely. If the tensioning roller or ! deflector roller is defective, replace it.

3.5.10

Checking / adjusting the engine valve play

LBH/Version 01/10.2006/en/hd/22/02/2007

Check the valve play with the engine cold. Make sure that: – The machine is in maintenance position 1. – The engine compartment hood and door are open. – You have the special cranking device, a feeler gauge and cylinder head seals ready.

Valve overlap cranking device L550 - 456 / from 16978 L556 - 454 / from 15653 L566 - 460 / from 14171

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Maintenance

Service Manual

Maintenance tasks

• Unscrew the service cap from the flywheel housing. • Remove the valve cover, attach the cranking device (ID no. 0524045) to the flywheel housing and insert a standard ratchet. • For reasons of space, use extensions on the cranking device to the rear towards the ratchet. • Turn the crankshaft in the direction of rotation until the valves of the cylinder to be adjusted overlap (see the table).

Cylinder valves A Outlet valve

E Inlet valve

Engine D 934

Engine D 936

Cylinder

Cylinder Adjust

Overlap

Adjust

4

1

6

1

2

3

2

5

1

4

4

3

3

2

1

6

5

2

3

4 LBH/Version 01/10.2006/en/hd/22/02/2007

Overlap

Checking and adjusting the inlet valve play

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Service Manual


Checking and adjusting the outlet valve play • Push a feeler gauge between the valve and the rocker arm and check the valve play. Valve play Inlet valve (cold)

0.30 mm

Outlet valve (cold)

0.40 mm

• If it is not correct: Loosen the nut on the adjusting bolt for the rocker arm and adjust it. • Tighten the counter nut to 40 Nm. • Check the adjustment again. • After checking and adjusting all the valves, put on the cylinder head covers with new seals. • Remove the cranking device.

3.5.11

Checking the diesel engine heating flange Make sure that: – The machine is in maintenance position 1. – The engine compartment hood is open. – You have an ohmmeter or a multimeter ready.

LBH/Version 01/10.2006/en/hd/22/02/2007

Procedure

• Turn off the battery main switch. • Disconnect the electric connection cable 2 on the heating flange 1. • Connect the ohmmeter or multimeter to the terminal and check the resistance (0.25 Ohm +/-10% at 20 °C). • Disconnect the electric connection cable on the heating flange. • Turn on the battery main switch


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Maintenance

Service Manual

Maintenance tasks

3.5.12

Greasing the ring gear on the engine starter flywheel The service cap is on the right side of the engine, on the flywheel housing. Make sure that: – The engine is in the maintenance position.

Starter ring gear service cap • Unscrew the service cap 1 from the flywheel housing. • Only grease the starter ring gear 2; there may not be any grease on the sensor gear ring 3. Check the ring gear and apply a light coating of standard grease if necessary. • Screw on the service cap again.

3.5.13

Changing the engine oil separator filter insert

Oil separator • Carefully clean the oil separator and the area around it. • Unscrew the oil separator cap and take it off, using a screwdriver if necessary.

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The oil separator is on the flywheel side, on the right side of the engine. Make sure that: – The engine is in maintenance position 1. – You have a genuine LIEBHERR oil separator filter insert ready.

Service Manual


3.5.14

Checking the bearings and condition of the engine control units Make sure that the machine is in maintenance position 1. Procedure • Check that the bearings are properly seated and undamaged. • If you find damaged bearings: do not start the engine, replace all the bearings

3.5.15

Checking the state of sensors and cable connections Make sure that the machine is in maintenance position 1. Procedure • Check that all the sensors and cable connections are properly seated and in good condition. • Check that none of the cables and wiring harnesses are damaged, rub or not properly fastened. If you find any damaged cables, wiring harnesses or sensors: • Do not start the engine until you have replaced the defective parts.

3.5.16

Changing the fuel pre-filter

LBH/Version 01/10.2006/en/hd/22/02/2007

On the right side of the diesel engine you can find: – The fuel pre-filter with water separator and – depending on the engine type – fuel pre-heater (optional) – Water level probe – Integrated fuel hand pump Bleeding the water of the fuel prefilter must be conducted after the water level probe activates. Make sure that: – The machine is in maintenance position 1. – The engine compartment hood is open. – You have a suitable receptacle ready. – Only use genuine LIEBHERR spare parts. (1 fuel pre-filter cartridge) Procedure Danger There is a risk of fire and explosions.

! Do not smoke. ! Avoid naked flames. ! Only work with the engine switched off and cooled down. • Place a receptacle under the fuel pre-filter. • Carefully clean the fuel pre-filter and the area around it.


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Maintenance

Service Manual

Maintenance tasks

• • • • • • • • • • • • • •

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Fuel water separator container Unscrew the water separator container 4 from the filter cartridge 3. Dispose of the old filter cartridge. Wash the water separator container and dry it with compressed air. Lightly oil the O-ring 9 of the water separator container. Screw the water separator container to the new filter cartridge until the O-ring touches the filter cartridge. Tighten the water separator container half a turn by hand. Screw in the drain plug 5. Check the filter head is clean and ensure that the thread adapter is firmly in the filter head. If the filter head is dirty: Clean the filter head. Lubricate the sealing ring 10 of the new filter cartridge with clean fuel. Fill the filter cartridge via the holes on the outside and screw it on until the sealing ring lies on the filter head. Tighten the filter cartridge 3 half a turn by hand. Reconnect the electrical connections of the water level probe 8 and the fuel preheater 7 (optional). Close the bleeder screw 6.

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Fuel prefilter cartridge • Disconnect the electrical connections of the water level probe 8 and the fuel preheater 7 (optional). • Drain the fuel: Unscrew the bleeder screw 6 and drain plug 5. • Release the filter cartridge 3 with a strap wrench or similar tools and unscrew it.

Service Manual


• Bleed the fuel system. See the section on bleeding the fuel system.

3.5.17

Changing the fuel fine filter Make sure that: – The machine is in maintenance position 1. – The engine compartment hood is open. – You have a suitable receptacle ready. – Only use genuine LIEBHERR spare parts. (1 fuel filter cartridge) Procedure Danger There is a risk of fire and explosions.

! Do not smoke. ! Avoid naked flames. ! Only work with the engine switched off and cooled down.

LBH/Version 01/10.2006/en/hd/22/02/2007

• Place a receptacle under the fuel fine filter. • Carefully clean the fuel fine filter and the area around it. • Unscrew the fuel fine filter 1. (Use a suitable filter strap) • Dispose of the old filter cartridge. • Check the filter base is clean and ensure that the thread adapter is firmly in the filter base. • If the filter base is dirty: Clean the filter base. • Lubricate the sealing ring 2 of the new filter cartridge with clean fuel. • Fill the filter cartridge and screw it on until the sealing ring lies on the filter head. • Tighten the filter cartridge 1/2 a revolution by hand with a filter wrench. • Bleed the fuel system. See the section on bleeding the fuel system.


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Maintenance

Service Manual

Maintenance tasks

3.5.18

Draining off condensate from the fuel pre-filter (the corresponding service code appears) After integrated water level probe in the fuel pre-filter activates (service code on the display), the water collector tank must be drained. Danger There is a risk of fire and explosions.


Draining the fuel pre-filter • Place a receptacle under the fuel pre-filter. If necessary attach a drainage hose. • Open the drain plug, drain the water until fuel emerges without bubbles. • When fuel emerges: Tighten the drain plug. • Bleed the fuel system. See the section on bleeding the fuel system.

3.5.19

Bleeding the fuel system Danger There is a risk of fire and explosions.

LBH/Version 01/10.2006/en/hd/22/02/2007


Bleeder screw on the head of the fuel prefilter • Unscrew the bleeder screw 1 on the head of the fuel prefilter by 2 to 3 turns.

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Service Manual


• Operate the hand pump 2. • If fuel flows out of the bleeder screw without bubbles: Tighten the bleeder screw 1. • Continue to operate the hand pump until you feel strong resistance.

Bleeder screw on the head of the fuel fine filter • Unscrew the bleeder screw 1 on the head of the fuel fine filter by 2 to 3 turns. • Operate the hand pump 2. • If fuel flows out of the bleeder screw without bubbles: Tighten the bleeder screw 1. • Continue to activate the hand pump until you feel strong resistance.

LBH/Version 01/10.2006/en/hd/22/02/2007

Bleeder screw on the crankcase • Unscrew the bleeder screw 1 on the crankcase (if present) by 2 to 3 revolutions. • Operate the hand pump 2. • If fuel flows out of the bleeder screw without bubbles: Tighten the bleeder screw 1. • Continue to activate the hand pump until you feel strong resistance. Bleeding the fuel filter with the engine bleeding function It is necessary when the fuel tank has run completely empty. When the fuel tank is empty there is air in the fuel system. You can remove some of the air from the fuel system by bleeding the fuel filter. You can bleed the air between the injection pump and the injection nozzle by activating engine bleeding mode.


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Maintenance

Service Manual

Maintenance tasks

Procedure Danger There is a risk of fire and explosions.

! Do not smoke. ! Avoid naked flames. ! Only work with the engine switched off and cooled down. • Bleed the fuel filter: See the section on bleeding the fuel filter. • Activate the engine bleeding function. Activation sequence: – Turn the ignition on – With the engine not running, press the button for 10 seconds. – All 3 LEDs on the button light up when the engine bleeding function is activated. • Turn the ignition key to position II and keep it in there until the engine starts. • Do not hold the key in the starting position for more than 20 seconds at a time. The ECU ends the engine bleeding function automatically as soon as the engine starts again. If the engine does not start: • Wait a minute and repeat the procedure. In the meantime, continue to operate the hand pump until you feel strong resistance.

3.5.20

Draining off condensate and sediment from the fuel tank Make sure that the machine is in maintenance position 1.

• Unscrew the sealing cap 1 on the drain valve 2 on the bottom of the diesel tank. • Screw the drain hose 3 onto the drain valve 2. • Drain the condensation and sediment into a suitable receptacle until clean fuel begins to flow. • Unscrew the oil drain hose. • Screw the cap 1 onto the drain valve 2 and tighten it.

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Procedure

Service Manual


3.5.21

Cleaning the air filter service cap and dust extraction valve Note If the valve is damaged, the dust extraction function is impaired and the filters become clogged more quickly.

! With the engine running at lower idle speed, you should clearly feel air pulsating at the dust extraction valve.

Make sure that: – The machine is in maintenance position 1. – The engine compartment hatch is open. – The battery main switch is switched off and the main switch key is removed. Cleaning the dust extraction valve

• Press the rubber seal on the dust extraction valve 5 several times to remove the dust from the service cap 3. • When working in dusty conditions, check and empty the dust extraction valve 5 more often. • If the dust extraction valve is damaged or stays open: • Replace the dust extraction valve. Cleaning the service cap • Open the fixing clips 4 on the service cap 3 and take the cap off. • Clean the service cap 3. • Put the service cap 3 back on the filter housing 6. The dust extraction valve 5 must face down. • Make sure the cap is placed properly on the filter housing 6. Close the fixing clips 4.

3.5.22

Testing the air filter vacuum switch

LBH/Version 01/10.2006/en/hd/22/02/2007

Make sure that: – The machine is in maintenance position 1. – You have a big enough plate available.


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Maintenance

Service Manual

Maintenance tasks

Procedure

• • • • •

3.5.23

Testing the vacuum switch Take the rain cap 1 off the intake pipe 2 of the filter housing. Start the engine. Slowly and carefully push the plate over the opening of the intake pipe. At the same time, check whether the indicator lamp in the cab lights up or the warning buzzer sounds. If you hear or see no warning signal when the intake pipe is just sealed, check the vacuum switch and the wiring, and replace it if necessary.

Changing the air filter primary element when indicated by the vacuum switch The primary element 2 should be replaced when the air filter contamination symbol field on the display unit lights up. If the air filter contamination symbol field remains lit after the primary element 2 has been serviced then the secondary element 1 must also be replaced. Make sure that: – The machine is in maintenance position 1. – The engine compartment hood is open. LBH/Version 01/10.2006/en/hd/22/02/2007

Procedure

Air filter 1 Secondary element 2 Primary element 3 Service cap

4 Fixing clips 5 Dust extraction valve 6 Air filter housing

• Open the fixing clips 4 on the service cap 3 and take the cap off. • Remove the primary element 2. To do this pull or turn the element gently upwards, downwards or to the side in order to release the seal.

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Service Manual


• Ensure that all dirt is removed from the filter housing before inserting a new filter element. The secondary element 1 should be replaced every third time the primary element 2 is replaced. • Lightly oil the seal surfaces before installing the filter elements (for the primary element 2 this is on the inside, for the secondary element 1 on the outside). Re-insert filter elements 1 and 2 and make sure that they are correctly fitted. • Clean the service cap 3 and put it on the filter housing with the dust extraction valve 5 facing down. Only when the lid completely covers the filter housing can you close the fixing clips without excessive force. • Close the fixing clips 4.

3.5.24

Changing the air filter secondary element If the air filter contamination symbol field remains lit after the primary element 2 has been serviced then the secondary element 1 must also be replaced. Change the secondary element: – After replacing the primary element three times – Otherwise, at least once a year Make sure that: – The machine is in maintenance position 1. – The engine compartment door is open. – The battery main switch is switched off and the main switch key is removed. Procedure

Air filter

LBH/Version 01/10.2006/en/hd/22/02/2007

1 Secondary element 4 Fixing clips 2 Primary element 5 Dust extraction valve 3 Service cap 6 Air filter housing • Open the fixing clips 4 on the service cap 3 and take the cap off. • Remove the secondary element 1. To loosen the seal: Pull or twist the element slightly up, down or sideways. • Ensure that all dirt is removed from the filter housing before inserting a new or cleaned filter element. • Lightly oil the seal surfaces before installing the filter elements (for the secondary element 1 this is the outside). • Re-insert the filter elements 1 make sure that it is correctly fitted. • Clean the service cap 3 and put it on the filter housing with the dust extraction valve 5 facing down. Only when the lid completely covers the filter housing can you close the fixing clips without excessive force. • Close the fixing clips 4. L550 - 456 / from 16978 L556 - 454 / from 15653 L566 - 460 / from 14171

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Maintenance

Service Manual

Maintenance tasks

3.5.25

Checking the air intake hoses for leaks and tight fitting

Turbo hose 1 between the air filter and the turbocharger You can check the air intake hose 1 for cracks from the inside after removing the air filter. It is not possible to check the air intake hose all round from outside. Make sure that: – The machine is in maintenance position 1. – The engine compartment door is open. – The battery main switch is turned off. Procedure Caution A damaged or leaky air hose will damage the engine. ! Check the air hose for cracks or pitting. • Take the service cap off the air filter housing, then take the primary and secondary elements out of the air filter housing. • Check the air hose all the way round for cracks and pitting. Use a torch to light up the hose. • Check the clip fastenings on the air intake hose.

3.5.26

Checking the exhaust lines for leaks and tight fitting Make sure that: – The machine is in maintenance position 1. – The engine compartment hood is open.

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If you find cracks or pitting on the hose: • Replace the hose.

Service Manual


Procedure

• Check that the fixing screws 1 and clip 3 on the exhaust pipe between the turbocharger and the silencer are tightly fastened and do not leak. • Check that the flexible pipe 2 of the exhaust pipe is laid straight. • Check that the spacer 3 is tight. • Check that the fastening clip 6 of the tail pipe 7 is tight.

3.5.27

Check the oil level in the pump distributor gear The dipstick 3 and the oil filling tube 2 are located in the engine compartment directly beside the hydraulic tank. Access is from above the engine on the right-hand side. Make sure that: – The machine is in maintenance position 1. – The engine compartment hood is open.

LBH/Version 01/10.2006/en/hd/22/02/2007

Procedure

Pump distributor gear • Pull out the dipstick 3, wipe it clean, and re-insert it. • Pull out the dipstick 3 once again and read off the oil level. L550 - 456 / from 16978 L556 - 454 / from 15653 L566 - 460 / from 14171

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Maintenance

Service Manual

Maintenance tasks

The oil level must be between the MIN and MAX markings. • If the oil level is too low: Remove the sealing cap from the oil filling tube 2 and top up with oil. For the oil quality, see the section on lubricants and fuels. • Clean the sealing cap for the oil filling tube 2, put it on the oil filling tube 2 on the splitter box, and then tighten it up.

3.5.28

Changing the splitter box oil Make sure that: – The machine is in maintenance position 1. – The engine compartment hood is open. – The cover plate under the engine is open. – You have a suitable oil receptacle (capacity approx. 3 l) and the drain hose with valve connection ready. – For the oil quality and quantity, see the section on lubricants and fuels.

• Pull out the dipstick 3 slightly (to read off the oil level more easily). • Unscrew the sealing cap on the oil drain valve 5 and screw the drain hose onto the oil drain valve 5. • Drain the oil into the receptacle. • Unscrew the drain hose from the oil drain valve 5 and screw on the sealing cap. • Unscrew the sealing cap from the oil filling tube 2 and top up with fresh oil. • Clean the sealing cap 2, screw it on and tighten it. • Check the oil level on the dipstick 3. The oil level must be up to the MAX mark.

3.5.29

Checking the soot particle filter pressure monitor for function, leaks and blockages This equipment is optional. Make sure that: – The machine is in maintenance position 1. – The engine compartment hood is open.

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Procedure

Service Manual


1 Soot particle filter 2 Temperature sensor

3 Counterpressure line connection

Procedure • Unscrew the counterpressure line from the DPX particle filter at position 3 and blow air into it with a compressed air gun. There must be sufficient distance to the entrance of the counterpressure line, so that the counterpressure of 150 mbar or 200 mbar is only slightly exceeded. Caution First adjust the air pressure down to no more than 0.5 bar, as otherwise the electronic counterpressure monitor will be irreparably damaged. • Check the electronic counterpressure monitor while blowing in air.

3.5.30

Checking and draining the soot particle filter condensate separator

LBH/Version 01/10.2006/en/hd/22/02/2007

This equipment is optional. Make sure that: – The machine is in maintenance position 1. – The engine compartment hood is open. Procedure The condensate separator is mounted on the rear left in the engine compartment.

Main components L550 - 456 / from 16978 L556 - 454 / from 15653 L566 - 460 / from 14171

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Maintenance

Service Manual

Maintenance tasks

1 2 3 4 • • • • • • •

Filter/drain unit 5 Exhaust gas counterpressure Counterpressure line display line Condensate container 6 Data logger line Drain plug At regular intervals (daily or as required): Check the filling level of the filter/drain unit. If the condensate container is over half full with condensation water: Drain off the accumulated condensation water. To do this, open the drain plug 4 of the condensate container 3. Drain the water from the condensate container. Tighten the drain plug 4 again. Check the filter insert (visible in the sight glass) of the filter/drain unit 1 for dirt. If the filter insert is too dirty: The filter insert must be replaced.

Note The condensate separator should be completely replaced after 1000 operating hours. ! This must be done when cleaning the filter (every 1000 operating hours as prescribed).

3.5.31

Changing the soot particle filter condensate separator

LBH/Version 01/10.2006/en/hd/22/02/2007

This equipment is optional. The condensate separator must be changed when cleaning the filter (every 1000 operating hours as prescribed). Make sure that: – The machine is in maintenance position 1. – The engine compartment hood is open. The condensate separator 1 is mounted on the rear left in the engine compartment on the fuse panel.

1 Condensate separator 2 PDL data logger

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3 Fuse panel

L550 - 456 / from 16978 L556 - 454 / from 15653


Service Manual


Procedure • Release the hose connections of the counterpressure line of the condensate separator 1. • Unscrew the condensate separator 1 from the fuse panel 3. • Screw the new condensate separator 1 into the fuse panel 3 and fasten the two hose connections back onto the condensate separator.

3.5.32

Cleaning the soot particle filter This equipment is optional. The cleaning process removes oil residue from the filter module. This oil residue comes from the combustion of engine oil and is visible as white ash (metal oxide). Before cleaning, completely regenerate the particle filter (operate the wheel loader for at least 10 minutes at the maximum possible engine load to burn off any soot sediment on the filter surface). Make sure that: – The machine is in maintenance position 1. – The engine compartment hood is open. – You have a suitable extraction system or industrial vacuum cleaner.

Compressed air cleaning

Procedure Caution Running at full load makes the filter housing very hot! ! When removing and cleaning it, always wear gloves, a dust mask and goggles. • Remove the filter module by releasing the V clips. • Clean the inlet side of the filter with compressed air and a vacuum cleaning system. Caution Protect the filter module from external contamination. - Never clean the filter module with steam or cleaning agents. - Use non-oiled compressed air for cleaning. • Clean the outlet side of the filter with compressed air and a vacuum cleaning system. Aim the air jet at each channel of the outlet side, until you cannot see any more particles. • Install the filter module again.

LBH/Version 01/10.2006/en/hd/22/02/2007

Note If the machine has been idling too long to regenerate the particle filter, the filter must be burned out. ! Put it in a furnace for at least 5 hours at 680 °C or use a hot air blower.


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Maintenance

Service Manual

Maintenance tasks

3.5.33

Checking the coolant antifreeze and corrosion inhibitor concentration

Coolant equalizing reservoir 1 Filler neck 2 Cap

3 Coolant equalizing reservoir 4 Coolant level sensor

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. Make sure that: – The machine is in maintenance position 1. – You have the optical density tester kit or antifreeze tester ready. Checking the antifreeze concentration

• See the coolant temperature on the display unit. The coolant temperature should be in the bottom third of the display. • Carefully open the sealing cap on the filler neck 1. • Take a sample of the coolant and check the antifreeze concentration using the test tool. • If the antifreeze concentration is too low: Refill with pure antifreeze until the required value is attained. See the section on correcting the antifreeze concentration.

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L550 - 456 / from 16978 L556 - 454 / from 15653


LBH/Version 01/10.2006/en/hd/22/02/2007

Caution There is a danger of scalding due to coolant escaping under pressure. ! Only open the cap on the filler neck once the engine has cooled down. ! Check the coolant temperature.

Service Manual


Correcting the antifreeze concentration

1 Cooler drain valve 2 Diesel engine drain plug • If the antifreeze concentration is too low: Drain off the coolant and top up with pure antifreeze according to the following diagram.

LBH/Version 01/10.2006/en/hd/22/02/2007

Caution There is a risk of damage to the diesel engine. Too much antifreeze and corrosion protection agent impairs the cooling effect. This eventually causes damage to the diesel engine. ! Never use more than 60% antifreeze and corrosion protection agent.


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Maintenance

Service Manual

Maintenance tasks

1 Amount of pure antifreeze to be added in litres 2 Identified line - top-up quantity

3 Help line(s) – example -15 °C 4 Measured coolant freezing point in °C

5 Total capacity of cooling system in litres (example 25 litres)

Example procedure Assumption: 25 litres total filling quantity of the cooling system -15 °C coolant temperature, measured in the cooling system • In the diagram, go to the line showing the overall cooling system filling quantity 5 at 25 litres, and move vertically upwards. • Carry on along the help line 3, starting from the temperature -15 °C, and move diagonally to the bottom left. • Finally, starting from the point where the lines cross, go horizontally along the (identified) line 2 to the far left.

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L550 - 456 / from 16978 L556 - 454 / from 15653


LBH/Version 01/10.2006/en/hd/22/02/2007

Selection for antifreeze concentration

Service Manual


This gives you the topping up quantity of pure antifreeze and corrosion protection agent 1 (7.6 litres in this example) to be added in order to achieve protection down to -37 °C. • To restore the correct mixing ratio, you must drain off at least the previously calculated quantity (the top-up quantity) from the cooling system. • Top up with the correct quantity of pure antifreeze and corrosion protection agent. • The coolant previously drained off can be used if necessary to restore the required coolant level. Using anti-corrosion agent without antifreeze In exceptional cases and when outside temperatures never fall below freezing, such as tropical zones, where it is demonstrable that no approved antifreeze and corrosion protection agent is available, corrosion inhibitors 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. Checking the coolant and anti-corrosion concentration

Caution There is a danger of scalding due to coolant escaping under pressure. Only open the cap on the filler neck once the engine has cooled down. ! Check the coolant temperature. • See the coolant temperature on the display unit. The coolant temperature display should be in the bottom third of the display. • Carefully open the sealing cap on the filler neck. • Check the antifreeze concentration with a 2710 refractometer from the GEFO company.

LBH/Version 01/10.2006/en/hd/22/02/2007

Checking the mixing ratio with a refractometer

Gefro refractometer no. 2710 1 Refractometer 2 Eyepiece Brix value: The measure for soluble dry substance in a liquid. • Clean the cover and the prism carefully. • Place 1 or 2 drops of test fluid on the prism. L550 - 456 / from 16978 L556 - 454 / from 15653 L566 - 460 / from 14171

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Maintenance

Service Manual

Maintenance tasks

The fluid is distributed by closing the prism. • Look through the eyepiece 2 against a light background and focus the scale. The focus is set by turning the eyepiece 2. • Read off the value on the blue line in the eyepiece.

Conversion diagram from Brix to corrosion inhibitor concentration (%vol) • Convert the Brix value using the conversion diagram to find the actual corrosion inhibitor concentration.

3.5.34

Cleaning the cooling system

Cooling system hood 3 Gas-filled springs

Clean the cooler whenever necessary in order to ensure proper cooling. In dusty environments, check the cooler every day and clean it if necessary. Dirty cooler units result in overheating. The consequence is an audible and visual warning with simultaneous power reduction of the travel drive. Dust and other contaminants can be removed from the cooling fins with water jets, steam or compressed air. Compressed air is preferable. Make sure that: – The machine is in maintenance position 1. – The left and right cooling system hoods are open.

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L550 - 456 / from 16978 L556 - 454 / from 15653


LBH/Version 01/10.2006/en/hd/22/02/2007

1 Left cooling system hood 2 Right cooling system hood

Service Manual


Procedure

Cooling system • Swing out the condenser 1. • Swing out the fuel cooler 2. Caution Risk of damage to the cooling system Careless handling can damage the cooler fins.

! Do not use hard objects or excessive water pressure for cleaning. • • • • •

3.5.35

Clean the cooler units with compressed air, steam or water. Close the condenser 1 again. Close the fuel cooler 2 again. Close any cab doors which are open. Close the cooling system hood(s) (left/right) again.

Changing the coolant Use clean, fresh water with a Ph value between 6.5 and 8.5 and a low sulphate / chlorine content for preparing the coolant. The coolant must be prepared outside the cooling system.

LBH/Version 01/10.2006/en/hd/22/02/2007

Always dispose of any coolant which you have drained off but no longer need according to the applicable regulations. Make sure that: – The machine is in maintenance position 1. – A receptacle with a minimum capacity of 25 litres is available for the used coolant, along with a drain hose. – The mixing ratio of the new coolant must be correct. See also the section on checking the coolant antifreeze concentration. – The shut-off valves on the heating hoses are open.


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Maintenance

Service Manual

Maintenance tasks

Procedure

Cooling system 1 Filler neck 2 Coolant equalizing reservoir 3 Coolant level sensor

4 Diesel engine drain plug 5 Cooler drain valve

• See the coolant temperature on the display unit. The coolant temperature should be in the bottom third of the display. • Open the sealing cap on the filler neck 1. • Unscrew the sealing cap on the cooler drain valve 5 and unscrew the drain hose. Drain the coolant into the receptacle. • Take off the drain hose, screw the sealing cap onto the cooler drain valve 5 and tighten it. • Also drain the coolant from the diesel engine: Open the drain plug 4 and let the coolant flow into the receptacle. • Screw the drain plug 4 back in and tighten it.

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L550 - 456 / from 16978 L556 - 454 / from 15653


LBH/Version 01/10.2006/en/hd/22/02/2007

Caution There is a danger of scalding due to coolant escaping under pressure. Only open the cap on the filler neck once the engine has cooled down. ! Check the coolant temperature.

Service Manual


Cooling system equalizing reservoir

• • • • • • •

3.5.36

1 Cap 3 Filler neck 2 Coolant equalizing reservoir Top up the coolant in the equalizing reservoir 2 until you can see the coolant in the filler neck 3. Screw the cap 1 onto the filler neck 3. Start the engine. Allow the engine to run at lower idling speed. Set the heater to warm. Top up the coolant in the equalizing reservoir 2 until you can see the coolant in the filler neck 3. If the coolant level is correct: Screw the cap 1 onto the filler neck 3.

Checking the oil level in the hydraulic tank Note When using bio oil, take an oil sample every 500 hours. ! See the hydraulic oil section under lubricants and fuels.

LBH/Version 01/10.2006/en/hd/22/02/2007

Make sure that: – The machine is cold. – The machine is in maintenance position 1. – The engine compartment hood is open. Checking the hydraulic oil level

Hydraulic tank L550 - 456 / from 16978 L556 - 454 / from 15653 L566 - 460 / from 14171

L576 - 457 / from 14171 L580 - 459 / from 14171

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Maintenance

Service Manual

Maintenance tasks

The red maximum oil level marking shows the correct oil level. • Check the oil level in the sight glass 1. • If the oil level is too low: Top up with hydraulic oil. Topping up with hydraulic oil

• Connect the plug 3 to the bleeder filter (to protect against vandalism). The anti-twist lock of the bleeder filter is released. • Release the tank pre-pressure: Unscrew the bleeder filter 2 on the hydraulic tank by two turns. Note The hydraulic oil may only be poured in through the return strainer. ! For oil specifications, see the section on lubricants and fuels. • • • •

3.5.37

Open the cover 1 of the return strainer. Top up with hydraulic oil up to the oil level marking 4. Put the cover 1 on the housing and tighten it up. Screw on the bleeder filter 2 tightly and remove the connector 3 (keep it somewhere safe).

Draining off condensate and sediment from the hydraulic tank Make sure that: – The machine has not been used for at least 3 hours. – The machine is in maintenance position 1. – The engine compartment door is open. – You have a receptacle ready for water and oil.

3.5.38

Changing the oil in the hydraulic tank and checking the return strainer Make sure that: – The machine is at operating temperature. – The machine is in maintenance position 1. – The engine compartment hood and door are open. – You have a receptacle of around 200 l capacity for the used oil.

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LBH/Version 01/10.2006/en/hd/22/02/2007

Procedure • Release the tank pre-pressure: Unscrew the bleeder filter 1 on the hydraulic tank by two turns. • Unscrew the plug 2 from the drain valve. • Connect the drain hose 3 and let the water and sediment flow into the receptacle. • Take off the drain hose and screw the plug into the drain valve. • Screw in the bleeder filter 1.

Service Manual


Procedure • Release the tank pre-pressure: Unscrew the bleeder filter 1 on the hydraulic tank by two turns. • Unscrew the plug 2 from the drain valve. • Connect the drain hose 3 and let the oil flow into the receptacle. • Take off the drain hose and screw the plug into the drain valve. • Open the cover 4 of the return strainer. • Take the snap ring 5 off the return strainer. • Take out the return strainer 6 and check it for dirt (clean it if necessary).

Note Serious contamination or large metal fragments in the return strainer may indicate damage to the hydraulic system.

! In this event, locate the problem and rectify it. The hydraulic oil may only be poured in through the return strainer. • Top up with hydraulic oil up to the oil level marking 3. • Put the cover 2 on the housing and tighten it up. • Screw in the bleeder filter 1. • Start the diesel engine and let it run briefly at low idling speed. • Turn off the diesel engine and then check the oil level in the sight glass, topping up if necessary.

3.5.39

Checking and cleaning the magnetic rod on the hydraulic tank Make sure that: – The machine is in maintenance position 1. – The engine compartment hood is open.

LBH/Version 01/10.2006/en/hd/22/02/2007

Procedure

• Connect the plug 4 to the bleeder filter (to protect against vandalism). The anti-twist lock of the bleeder filter is released. • Release the tank pre-pressure: Unscrew the bleeder filter 3 on the hydraulic tank by two turns. • Unscrew the plug 2. The oil level sinks. • Release the bolts on the lid and slowly lift the lid with the magnetic rod 1. L550 - 456 / from 16978 L556 - 454 / from 15653 L566 - 460 / from 14171

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Maintenance

Service Manual

Maintenance tasks

Note Serious contamination or large metal fragments on the magnetic rod may indicate damage to the hydraulic system.

! In this event, locate the problem and rectify it. • Carefully clean the magnetic rod 1. • After cleaning: Place the O-ring and cover with the magnetic rod on the housing. • Tighten the screws on the cover. • Screw in the plug 2. • Screw on the bleeder filter 4 tightly and remove the connector 3 (keep it somewhere safe).

3.5.40

Changing the hydraulic tank return suction filter Make sure that: – The machine is in maintenance position 1. – The engine compartment hood is open. Procedure • Release the tank pre-pressure: Unscrew the bleeder filter 1 on the hydraulic tank by two turns. • Unscrew the plug 2 (the oil level sinks). • Release the bolts on the lid 3 and slowly lift the lid with the magnetic rod. • Take out the filter element 4. • Put in a new filter element. • Carefully clean the magnetic rod. • Place the O-ring and cover with the magnetic rod on the housing and tighten the screws on the cover. • Screw in the plug 2. • Screw in the bleeder filter 1. Note Serious contamination or large metal fragments in the filter element or on the magnetic rod may indicate damage to the hydraulic system.

! In this event, locate the problem and rectify it. Changing the hydraulic tank bleeder filter LBH/Version 01/10.2006/en/hd/22/02/2007

3.5.41

Make sure that: – The machine is in maintenance position 1. – The engine compartment hood is open. Procedure

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L550 - 456 / from 16978 L556 - 454 / from 15653


Service Manual


You cannot clean the bleeder filter. The bleeder filter 1 and its plastic housing must be changed at the intervals in the maintenance schedule. • Connect the plug 2 to the bleeder filter (to protect against vandalism). The anti-twist lock of the bleeder filter is released. • Unscrew the old bleeder filter. • Screw in the new bleeder filter and remove the connector 2 (keep it somewhere safe).

3.5.42

Lubricating the pilot control device solenoids, universal joints and tappets Make sure that the machine is in maintenance position 1. Procedure • Take the rubber sleeve 5 of the control lever off the retaining plate 4. • Move the control lever in the appropriate direction for better access. • Clean the retaining solenoids 1 with a brush. • Lubricate the universal joints 2 and the discs 3 with a brush. • Start the machine and check the retaining function of the solenoids. Fit the rubber sleeve of the control lever on the retaining plate.

3.5.43

Testing the steering Make sure that: – The working attachment is in the transport position. – The articulation lock is open. – There is enough space to test the steering. Procedure Warning Beware of accidents

! Do not allow anyone into the danger area while these tests are being conducted.

LBH/Version 01/10.2006/en/hd/22/02/2007

! Perform the test on level ground with no obstacles.

• Start the engine. • Without moving the machine, turn the steering in both directions and check that it is functioning properly.

3.5.44

Lubricating the bearing points on the steering cylinders Make sure that: – The machine is in maintenance position 1. – The articulation lock is engaged if possible.


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Maintenance

Service Manual

Maintenance tasks

Procedure

1 Lubrication point at base of right3 Lubrication point on the piston rod hand steering cylinder end of left-hand steering cylinder 2 Lubrication point at base of left4 Lubrication point on the piston rod hand steering cylinder end of right-hand steering cylinder • Lubricate the bearing points on the steering cylinders.

3.5.45

Testing the service brake and parking brake Make sure that there is enough room to check the service brake and parking brake. Warning Beware of running over bystanders or obstacles.

! Do not allow anyone into the danger area while these tests are being conducted.

! Perform the test on level ground with no obstacles.

1 Inch/brake pedal 3 Braking range 2 Inching range • Start the machine, and drive it forwards at around 8 km/h. • Push the inch/brake pedal all the way down. The machine must come to an abrupt stop. Checking the parking brake • Start the machine, and drive it forwards at around 5 km/h. • Press the parking brake button while travelling. The machine must come to an abrupt halt.

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LBH/Version 01/10.2006/en/hd/22/02/2007

Checking the service brake

Service Manual


3.5.46

Checking the gap and wear on the parking brake linings Friction can change the gap X1 and X2 and the thickness of the brake lining. Make sure that the machine is in maintenance position 2. Procedure

Warning There is a risk of injuries due to machine rolling away.

! Make sure that the machine is secured against rolling away when carrying out work on the parking brake.

• Secure the machine against rolling away with wheel wedges.

Disc brake (shown in open position) 1 2 3 4 5

LBH/Version 01/10.2006/en/hd/22/02/2007

• • • • • • • • • • • •


Lock nut 6 Counter nut Plug 7 Hex bolt Adjusting screw 8 X1 Gap Brake disc 9 X2 Gap Brake lining Start the diesel engine and press the button to release the parking brake. Test the brake lining thickness: If the brake linings are thinner than 1.0 mm, they must be replaced. Check the gap X1 and X2: If the gap X1 + X2 is more than 1.5 mm: Adjust the gap. Loosen the counter nut 6 and adjust the gap X1 to 0.3 mm using an allen key 7. Tighten the counter nut 6. Unscrew the sealing cap 2 and loosen the lock nut 1. Use the adjusting screw 3 to set the gap X2 to 0.3 mm. Tighten the lock nut 1. Engage the parking brake several times and test it again. Screw on the sealing cap 2 and tighten it.

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Maintenance

Service Manual

Maintenance tasks

3.5.47

Checking the indicator lamps and lighting Make sure that: – The machine is in maintenance position 1. – The machine's electrical system is switched on. Checking the indicator lamps and lighting – When you switch on the ignition, the lamps on the display unit are tested. – All symbol fields light up for three seconds.

• Switch on the ignition. • Check that the symbol fields on the display unit light up. • Check that all lights are working. Adjusting the working floodlights Note: The front working floodlights cannot be adjusted. The rear working floodlights are optional. Adjust the rear working floodlights as required: – Either for close range lighting – or for long range lighting.

1 Floodlight 4 Bracket 2 Fixing screw 5 Adjusting screw 3 Fixing screws Horizontal Y axis adjustment: • Loosen the screw 2. • Move the left and right floodlights as required. • Tighten the screw again. Vertical X axis adjustment: • Loosen the screw 5. • Move the left and right floodlights as required. • Tighten the screw again.

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L550 - 456 / from 16978 L556 - 454 / from 15653


LBH/Version 01/10.2006/en/hd/22/02/2007

Rear working floodlights

Service Manual


3.5.48

Checking the batteries, fluid level and terminals

The batteries are housed in the right ballast weight and can be accessed by opening the covers. The batteries must always be in perfect condition in order for the machine to work reliably. Make sure that: – The machine is in maintenance position 1. – The battery main switch is switched off and the main switch key is taken out. – The covers on the ballast are bolted on. Warning Batteries give off explosive gases. Battery acid is highly corrosive.

! Do not smoke. Avoid naked flames when handling, servicing or recharging batteries.

Caution Beware of sparks and explosions!

! Use a special terminal brush.

LBH/Version 01/10.2006/en/hd/22/02/2007

• Wipe the battery with a clean cloth. • Clean the terminals and the connectors. • To guarantee a good connection, check that the connectors are tight on the terminals, and tighten them if necessary. • Smear the terminals and connectors with acid-proof grease such as vaseline. At very high temperatures, the acid level in the individual cells can drop due to different rates of evaporation. • Open the plugs on each cell and check the acid level. • Check the charge using an acid density tester. • If the charge is too low (acid density below 1.26 kg/l): Recharge the batteries. If there is a risk of frost, it is important that the batteries are not discharged. Otherwise the electrolyte can freeze and irreparably damage the battery. • If the acid level is too low: Top up with distilled water to around 10 mm above the plates. L550 - 456 / from 16978 L556 - 454 / from 15653 L566 - 460 / from 14171

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Maintenance

Service Manual

Maintenance tasks

3.5.49

Checking the transmission oil level Make sure that: – The machine is in maintenance position 1. – The articulation lock is engaged. Procedure Check the oil level with the engine running and at a gear oil temperature of 20±10 °C. • Start the engine and let it run at low idling speed. • Check the oil level in the sight glasses 3 and 4. The oil level must be within the bottom sight glass 4. • If the oil level is too low: Switch off the engine and top up with the required amount of gear oil. For the oil quality, see the section gear lubricants in the lubricants and fuels section. • Repeat the check. • If the oil level is too high: Have LIEBHERR CUSTOMER SERVICE identify the problem and rectify it.

3.5.50

Changing the transmission oil Make sure that: – The machine is in maintenance position 1. – You have a sufficient quantity of the gear oil prescribed in the section on lubricants and fuels. – The oil in the gearbox is warm. – You have a suitable oil receptacle ready for disposal. Procedure

3.5.51

Changing the transmission oil filter Make sure that: – The machine is in maintenance position 1. – You have a genuine LIEBHERR oil cartridge ready. Procedure • Start the engine. Turn and steer the machine to the left as far as it will go. • Turn off the diesel engine. • Release the filter cartridge with a strap wrench and unscrew it. • Clean the seals on the filter bracket. • Lightly coat the rubber seal ring on the new oil filter cartridge with gear oil. • Screw the new filter cartridge onto the filter bracket and tighten it by hand.

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LBH/Version 01/10.2006/en/hd/22/02/2007

• Open the cap on the filler neck. • Open the plug 1 on the gearbox and drain the oil into a suitable receptacle. • Then screw the plug 1 in again. • Top up gear oil the filler neck of the plug 2. • Replace the gear oil filter as described in the separate instructions. • Check the oil level in the transmission and top it up if necessary (see the section on checking the oil level in the transmission).

Service Manual


• Check the oil level in the transmission and top it up if necessary (see the section on checking the oil level in the transmission). • Check the oil filter for leaks.

3.5.52

Checking the tightness of the wheels (once after 50, 100 and 250 h) Make sure that: – The machine is in maintenance position 1. – A torque wrench with a measuring range of over 650 Nm is available.

Procedure Note Check the tightness of the wheels according to the specified intervals. ! This one-off maintenance task scheduled for 50, 100 and 250 service hours must be performed every time the wheels are changed. • Check that the nuts on all four wheels have been tightened with the required torque of 750 Nm.

3.5.53 Valid for:

Checking the axle oil level L550 - 456 / from 16978; L556 - 454 / from 15653; L566 - 460 / from 14171; L576 - 457 / from 14171

The differential and the wheel hubs have a common oil system. Make sure that the machine is in maintenance position 1.

LBH/Version 01/10.2006/en/hd/22/02/2007

Procedure

• Open the plug 4 and check the oil level in the axle. • If the oil level is too low: Top up with the axle oil prescribed in the section on lubricants and fuels.


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Maintenance

Service Manual

Maintenance tasks

3.5.54 Valid for:

Checking the axle oil level L580 - 459 / from 14171

The differential and the wheel hubs have a common oil system. Make sure that the machine is in maintenance position 1. Procedure

• Open the plug 1 and check the oil level in the axle. • If the oil level is too low: Top up with the axle oil prescribed in the section on lubricants and fuels.

3.5.55 Valid for:

Changing the axle oil L550 - 456 / from 16978; L556 - 454 / from 15653; L566 - 460 / from 14171; L576 - 457 / from 14171

Draining oil Caution Running the engine makes the gear oil very hot! ! Always wear suitable gloves and goggles. • Open the plugs 2 and 4. • Open the plugs 1 and 3 on the wheel hubs and drain the oil into a receptacle. • Close the plugs 1 and 3 again.

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LBH/Version 01/10.2006/en/hd/22/02/2007

Make sure that: – The machine is in maintenance position 1. – You have a sufficient quantity of the axle oil prescribed in the section on lubricants and fuels. – You have a suitable oil receptacle ready for disposal.

Service Manual


Topping up oil The wheel hubs and the differential have a common oil system. This means the oil can flow back and forth between the differential and the wheel hubs. • Top up oil at the filling inlet 2 up to the plug 4. • Check the oil level at the plug 4 and top up if necessary. • Close the plugs 2 and 4 again.

3.5.56 Valid for:

Changing the axle oil L580 - 459 / from 14171

Make sure that: – The machine is in maintenance position 1. – You have a sufficient quantity of the axle oil prescribed in the section on lubricants and fuels. – You have a suitable oil receptacle ready for disposal. Draining oil

LBH/Version 01/10.2006/en/hd/22/02/2007

Caution Running the engine makes the gear oil very hot! ! Always wear suitable gloves and goggles.


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Maintenance

Service Manual

Maintenance tasks

• Open the plug 1. • Open the plugs 2 and 3 on the wheel hubs and drain the oil into a receptacle. • Close the plugs 2 and 3 again. Topping up oil The wheel hubs and the differential have a common oil system. This means the oil can flow back and forth between the differential and the wheel hubs. • Top up oil at the filling inlet 1. • Check the oil level at the filling inlet 1 and top up if necessary. • Close the plug 1 again.

3.5.57 Valid for:

Lubricating the bevel gear seal L580 - 459 / from 14171

Make sure that: – The machine is in maintenance position 1. Procedure • Lubricate at the grease fitting 1 on the front and rear axles. If necessary, such as when operating the machine in water, lubricate every day.

3.5.58

Checking and lubricating the front drive shaft Make sure that the machine is in maintenance position 1. Procedure • Lubricate the drive shaft at both universal joints. • Check the play of the drive shaft in the bearings. • Check the rubber sleeve for leaks and damage.

3.5.59

Checking and lubricating the rear drive shaft LBH/Version 01/10.2006/en/hd/22/02/2007

Make sure that the machine is in maintenance position 1. Procedure • Lubricate the drive shaft at both universal joints. • Check the play of the drive shaft in the bearings.

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Service Manual


3.5.60

Testing and setting the tyre pressure for the machine's use and attachments Make sure the air pressure in the tyres on both axles is correct for the tyre type, the way the machine is used and the working attachments fitted. The reference values can be found in the operating manual, in the technical data section. Procedure The air pressure in the tyres has a significant influence on the overall operating performance of the machine. Warning Exploding tyres can cause serious injury. If the tyre inflation equipment is incorrectly or carelessly used or if the tyre pressure is too high, the tyres may burst or the rims may come off, causing severe, or possibly even fatal injuries. ! Use a sufficiently long hose with a self-locking adapter for pumping the tyres. ! Always keep outside the danger zone when tyres are being pumped up. • Check the air pressure in all the tyres and correct it if necessary.

3.5.61

Lubricating the articulated bearing and the rear oscillating bearing Make sure that: – The machine is in maintenance position 1. – The articulation lock is engaged.

LBH/Version 01/10.2006/en/hd/22/02/2007

Lubricating the articulation bearing

Articulation bearing lubrication points 1 Top articulation bearing 2 Bottom articulation bearing • Lubricate the articulation bearing lubrication points.


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Maintenance

Service Manual

Maintenance tasks

Lubricating the rear oscillating bearing

Lubricating points on the rear oscillating bearing, right central lubrication rail 1 Rear axle oscillating bearing 2 Front axle oscillating bearing • Lubricate the lubricating points on the rear axle oscillating bearing.

3.5.62

Checking the lubrication system grease reservoir level Make sure that the machine is in maintenance position 1. Procedure

It the grease in the reservoir container is too low, all 3 LEDs on the central lubrication system button light up. Caution There is a risk of damaging the system. ! Pay attention to cleanliness when filling. • If necessary, fill the reservoir via the filling coupling 1 (fast filling) or the grease fitting 2. Grease specifications: See the lubricants and fuels listed in chapter 5.

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LBH/Version 01/10.2006/en/hd/22/02/2007

Regularly check the grease quantity in the reservoir. Stay within the minimum and maximum lubricant levels. The reservoir has a sight glass where the rubber stripper on the agitator can be seen. • Look through the sight glass to check the level in the grease reservoir.

Service Manual


3.5.63

Checking the pipes, hoses and lubrication points of the lubrication system Make sure that the machine is in maintenance position 1. Procedure • Visually examine the hose lines for defects. • In case of any defects, locate and rectify the problem.

3.5.64

Checking whether metered quantities are adequate at the bearing points (grease collars) of the central lubrication system Make sure that the machine is in maintenance position 1. Procedure • Visually examine whether metered quantities are adequate at the bearing points. • If the bearing points are not sufficiently lubricated, locate the problem and rectify it. Regularly check the grease quantity in the reservoir. See the section on checking the lubrication system grease reservoir level,

3.5.65

Lubricating the door hinges Procedure • Lubricate the door hinges with a grease gun.

3.5.66

Cleaning the fresh air and recirculated air filter Make sure that the machine is in maintenance position 1.

LBH/Version 01/10.2006/en/hd/22/02/2007

Cleaning the fresh air filter

Fresh air filter 1 Door 3 Ventilation lint filter 2 Fresh air filter • Open the door 1. • Pull out the fresh air filter 2 by the protruding lug on the bottom.


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Maintenance

Service Manual

Maintenance tasks

Fresh air filter • Clean (blow out) or replace the fresh air filter 2. • Remove the lint filter 3. • Clean (blow out or wash) the lint filter or change it if necessary.

Fresh air filter • Insert the cleaned or new filters, making sure they are correctly fitted (the arrows moulded on the filter frame point towards the air taken in). • Close the door again.

Recirculation filter

• • • • •

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1 Door 3 Recirculation filter 2 Pin Remove the pin 2. Open the door 1. Take out the recirculated air filter 3 and clean it (blow it out) or replace it. Put in a clean or new filter. Close the door again.

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LBH/Version 01/10.2006/en/hd/22/02/2007

Cleaning the recirculated air filter

Service Manual


3.5.67

Changing the fresh air and recirculated air filter Make sure that the machine is in maintenance position 1. Changing the fresh air filter

Fresh air filter 1 Door 3 Ventilation lint filter 2 Fresh air filter • Open the door 1. • Pull out the fresh air filter 2 by the protruding lug on the bottom.

Fresh air filter • Insert the new filter 1, making sure it is correctly fitted (the arrows moulded on the filter frame point towards the air taken in). • Close the door again.

LBH/Version 01/10.2006/en/hd/22/02/2007

Changing the recirculated air filter

Recirculation filter 1 Door 2 Pin • Remove the pin 2. • Open the door 1. L550 - 456 / from 16978 L556 - 454 / from 15653 L566 - 460 / from 14171

L576 - 457 / from 14171 L580 - 459 / from 14171

3 Recirculation filter

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Maintenance

Service Manual

Maintenance tasks

• Take out the recirculated air filter 3. • Put in a new filter. • Close the door again.

3.5.68

Checking the indicator beads in the dryer-collector unit The dryer-collector unit is located on the right under the cooling system hood.

Sight glass in the dryer-collector unit • Check the orange bead 2 (moisture indicator). • If the orange bead 2 has turned transparent: There is moisture in the refrigerant circuit. You must replace the dryercollector and the compressor oil and refill the system. • The white bead 1 shows the filling level of R134a refrigerant in the circuit and acts as an indicator during initial filling. The white bead 1 must be at the top of the sight glass. The filling level can vary due to temperature fluctuations. It also sinks in time due to natural leakage. This does not impair operation. If the cooling performance deteriorates, one of the causes can be a low refrigerant level. In normal circumstances, one filling lasts for three to five years.

3.5.69

Lubricating the lift arms and attachment This also applies to optional equipment, for example: – High dump bucket, timber grabber etc. Make sure that the machine is in maintenance position 2.

LBH/Version 01/10.2006/en/hd/22/02/2007

Lubricating standard lift arms and attachment

Bearing and lubrication points on the lift arms • Move the lift arms and the bucket to the position shown.

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Service Manual


• • • • •

Secure the machine against rolling away with wheel wedges. Grease all the bearing and lubrication points on the lift arms. If fitted, lubricate the quick-change device. If fitted, grease the lubrication points on the attachment. The lower bucket bearings should be lubricated daily if necessary.

Lubricating the tilt cylinder support for timber transfer This equipment is optional.

Tilt cylinder support 1 Grease fitting 3 Lubricating line 2 Distributor block • Grease the lubrication points via the grease fitting 1. The lubricant is pumped via the distributor block 2 and the lubricating lines 3 to the lubricating points. • If fitted, grease the lubrication points on the timber grabber. For detailed information on maintenance for the attachment, see the manufacturer's instructions.

3.5.70

Checking the bucket bearing seals and the bearing bushings on the lift arms Checking the bucket bearing seal The bucket bearing seal 3 prevents dirt from entering the bearing, thus increasing the lifetime of the bearing bushings.

LBH/Version 01/10.2006/en/hd/22/02/2007

Depending on the type of application, wear occurs on the sealing lips 5 and on the dirt guard 6. If the bucket bearing seal 3 is in any way damaged or worn, it must be replaced.


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Maintenance

Service Manual

Maintenance tasks

Checking the bucket bearing seal 1 Bucket bearing plate 2 Bucket arm

3 Bucket bearing seal 4 Bearing bushing

5 Sealing lips 6 Dirt guard

• Move the lift arms and the bucket to the position shown. • Clean the bucket bearing seals 3 using a steam jet. • Visually check whether the sealing lips 5 touch the sides of the lift arms and the bucket. • If there is a gap between the sealing lips 5 and the bucket arm 2 or the bucket bearing plate 1, or if the bucket bearing seal is damaged: Replace the bucket bearing seal as described in section 17.2.5. Checking the bearing bushings for wear

Replace the bearing bushings in good time to prevent damage to the material of the bucket arm.

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LBH/Version 01/10.2006/en/hd/22/02/2007

Dirt or insufficient lubrication can cause wear on the bearing bushings. The increased play between the pin and bearing bushing causes noises.

Service Manual


• Move the lift arms and the bucket to the position shown. • Gently and rapidly tilt the bucket in and out, and check the bearing points for noise and play. • If there is significant play at the bearing points or loud noise: Replace the bearing bushings as described in section 17.2.4.

3.5.71

Check the lift arms and bucket stops There are two ways to attach the equipment to the lift arms: directly or using the quick-change device. It is important that the limits stops and the sequence of stops are as specified. Failure to comply can reduce the lifetime of the equipment and the lift arms. Checking the bucket stops without a quick-change device This is how to check the bucket stops properly: • Secure the machine against rolling away (using the parking brake or wheel wedges). • Move the lift arms and the bucket to the position shown. • Retract the tilt cylinders until the bucket stops 1 touch the bucket arm. • Check the dimension 2 according to the following table. Dimensions

LBH/Version 01/10.2006/en/hd/22/02/2007

Description Dimensions L550 - L580

Dimension 1 0

Dimension 2 Unit mm 3±2

If there are deviations from the table above, contact LIEBHERR customer service about corrective action. Checking the bucket stops with a quick-change device This is how to check the bucket stops properly: • Secure the machine against rolling away (using the parking brake or wheel wedges). • Move the lift arms and the quick-change device to the position shown. • Retract the tilt cylinders until the linkage stop touches the cross tube stop. • Check the dimension 1 according to the following table.


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Maintenance

Service Manual

Maintenance tasks

Dimensions Description Dimensions L550 - L580

Dimension 1 5

±3

Dimension 2

Unit

0

mm

If there are deviations from the table above, contact LIEBHERR customer service about corrective action.

3.5.72

Testing the quick-change device (optional) Make sure that: – The lift arms have been lowered. – The working attachment is tilted in. Procedure The operation of the quick-change device can vary according to the version or the type of machine. • To check that it is working properly: Unlock the quick-change device and lock it again.

LBH/Version 01/10.2006/en/hd/22/02/2007

This prevents the locking pins from jamming and preventing the quickchange device from being released. • To make sure, check: That the quick-change device is properly locked again.

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Service Manual

Maintenance Testing and adjustment tasks

3.6 Testing and adjustment tasks 3.6.1

Preparing for testing and adjustment During the warranty period, only trained and authorised specialist staff may carry out adjustments on the machine. Make sure that: – The machine is in maintenance position 2. – The machine is at operating temperature (except when testing the air conditioning). – The adjustment data for the machine is available or known. – Seals and safety caps are at hand. – The following special tools are available. Special tools Number Description USB dongle for SCULI 1

3.6.2

ID no. 1033 3608

1

Data lead for SCULI

1003 5410

2

Manometer, 0 - 40 bar, class 1.0

7361 288

2

Manometer, 0 - 600 bar, class 1.0

5002 866

2

4000 mm test leads

7009 134

2

1500 mm test leads

7002 475

Safety precautions for testing and adjustment Always observe the accident prevention regulations during maintenance work. See the safety regulations section for measures to ensure safe maintenance. Make sure that visual contact between the operator in the cab and maintenance personnel is always maintained. Only carry out adjustments on valves etc. with the machine not running.

LBH/Version 01/10.2006/en/hd/22/02/2007

Visual contact


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Maintenance

Service Manual

Testing and adjustment tasks

3.6.3

Bringing the machine up to operating temperature During testing and adjustment, the machine must be at an operating temperature of 58±5 °C. The temperature is measured by the hydraulic oil sensor and can be seen in SCULI. Procedure • Insert a piece of card or similar material between the fuel cooler 1 and the hydraulic oil cooler 2. • Connect your laptop, start the engine and run the SCULI program. • In the variables editor in the group structure, select the Adjustment Block Curve folder. • The cooling system - temperature hydraulic oil variable shows the hydraulic oil temperature during the adjustment.

58.1

Bring the machine up to operating temperature as follows: – Run the engine at around 2000 rpm. – Activate the tilt-in function as far as it will go and hold the control lever in this position. – At the same time, move the lift arms up and down with the lever halfway out. – Operate the travel hydraulics in fixed gear 1. • Bring the machine up to operating temperature until the hydraulic oil temperature is 58±5 °C. • When working on the hydraulic system, the hydraulic oil temperature must be within the prescribed range. • After finishing the adjustment, take the piece of card out of the oil cooler.

Checking the diesel engine speed You can read the engine speed from the RPM segment indicator in the display unit or use a standard engine speed tester. The engine speed cannot be mechanically adjusted; it is determined directly by the engine control unit.

Cab display unit

Procedure • Start up the engine. • Check that the top and bottom engine speeds are correct. • If it is not correct: Calibrate the gas pedal using the SCULI program and service the engine. • Check the top and bottom idle speeds again.

3.6-2 o f 1 8

Description

Value Unit

Lower idle speed

900±10 min-1

Upper idle speed

2065±10 min-1

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LBH/Version 01/10.2006/en/hd/22/02/2007

3.6.4

Service Manual


3.6.5

Check the fan motor and fan control pressure relief valve Make the following checks on the fan motor: These tests must be performed at upper engine speed. – Test the fan according to the temperature (temperature sensor 1 or 2 disconnected). – Test the pressure relief valve 7 on the fan motor 5 (with the plug on the proportional valve disconnected).

Fan drive components 1 Hydraulic oil temperature sensor 2 Coolant temperature sensor 3 Fan pressure test connection

4 Fan gear pump 5 Fan gear motor 6 Fan proportional valve cap

7 Fan proportional valve 8 Fan proportional solenoid 9 Proportional solenoid connector

You can check the fan using the system pressure, measured at the test connection 3 of the gear pump 4. Make sure that: – The hydraulic oil temperature is less than 88 °C. – The coolant temperature is below 97 °C. If the hydraulic temperature is over 88 °C or the coolant temperature is above 97 °C, the fan speeds up. This makes it impossible to test the fan control.

LBH/Version 01/10.2006/en/hd/22/02/2007

Checking the fan according to the temperature The fan speed (system pressure) is tested here in the stated temperature range. • Connect a manometer (250 bar) to the test connection 3 on the gear pump 4. • Disconnect the hydraulic oil temperature sensor 1 or coolant temperature sensor 2. • Start the engine and bring it to top idle speed. • Check whether the pressure is correct at top engine idle speed. Valid for:

L550 - 456 / from 16978; L556 - 454 / from 15653

Description

Value Unit

Fan pressure

110±10 bar 1650 min-1

Fan speed


L576 - 457 / from 14171 L580 - 459 / from 14171

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Maintenance

Service Manual


Valid for:


Description

Value Unit

Fan pressure

175±10 bar 1400 min-1

Fan speed • If it is not correct: Check the fan motor pressure relief valve. Checking the fan motor pressure relief valve

• Connect a manometer (250 bar) to the test connection 3 on the gear pump 4. • Pull out the plug 9 on the proportional solenoid 8. • Start the engine and bring it to top idle speed. • Check whether the pressure is correct at top engine idle speed. • If it is not correct: Adjust the pressure relief valve 7 on the fan motor 5 (using the adjusting screw and a 5 mm open-end spanner - the lock nut is a round nut). Turn clockwise to increase the pressure and anticlockwise to reduce it. • Remove the cap 6. • Adjust the screw on the proportional valve. Valid for:

L550 - 456 / from 16978; L556 - 454 / from 15653

Description

Value Unit

Fan pressure

220±10 bar approx. 2050 min-1

Fan speed Valid for:


Description

Value Unit

Fan pressure

220±10 bar approx. 1600 min-1

Fan speed • Plug in the disconnected plug again.

3.6.6

Calibrating the pedals The pedals can only be calibrated using the SCULI software. During calibration, the MIN and MAX positions of the gas pedal and inch pedal are stored in the master electronics.

• Connect your laptop, turn on the start switch and run the SCULI program. • In the variables editor in the group structure, select the Adjustment Pedals folder. • Set Throttle - start adjustment to 1. • Push the gas pedal all the way down. The MIN and MAX positions of the gas pedal are stored. After 15 seconds the value automatically returns to 0 Æ and calibration is finished. • Check that Throttle - guide value is 0% when the pedal is not pressed and 100% when the pedal is pressed all the way down.

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Procedure

Service Manual


• Set Inch pedal - start adjustment to 1. • Push the inch pedal all the way down. The MIN and MAX positions of the gas pedal are stored. After 15 seconds the value automatically returns to 0 Æ and calibration is finished. • Check that Inch pedal - guide value is 0% when the pedal is not pressed and 100% when the pedal is pressed all the way down.

3.6.7

Checking the replenishing pressure of the variable displacement pump Measure the replenishing pressure at the test connection G. Procedure • • • •

Valid for:

Connect a manometer (40 bar) to the test connection G. Start the machine and let the engine run at top idling speed. Check that the replenishing pressure is correct. If it is not correct: Turn the adjusting screw on the replenishing pressure relief valve 1 until the replenishing pressure is correct.

L550 - 456 / from 16978; L556 - 454 / from 15653

Description

Value Unit 31±1 bar

Replenishing pressure Valid for:


Description


Replenishing pressure

3.6.8

Checking the pressure relief and replenishing valve of the variable displacement pump

LBH/Version 01/10.2006/en/hd/22/02/2007

The pressure relief and replenishing valves protect the variable displacement pump from pressure peaks. These can occur when braking the machine. When a pressure peak occurs, oil flows from the high pressure side via the pressure relief and replenishing valve to the low pressure side in a closed circuit. Procedure To attain the set value for the pressure relief and replenishing valves, the pressure cut-off must be set to a higher value. • Screw in the adjusting screw 1 on the pressure cut-off by one turn. • Connect a manometer (600 bar) to the test connections MA and MB. • Use SCULI to set the Inch pedal - function OFF variable to 1 Æ the inching function is disabled.


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Maintenance

Service Manual


Check the pressure relief and replenishing valve 2 for forward travel on the manometer MA. Check the pressure relief and replenishing valve 3 for reverse travel on the manometer MB. • Select fixed gear 2 and forward or reverse travel, and hold the machine in the blocked condition using the service brake. Caution Heat is quickly generated when you test the pressure relief and replenishing valves. Excessive heat can irreparably damage the pump.

! Only test the pressure relief and replenishing valves for a short time. • In the blocked condition, increase the engine speed to the maximum. • Check that the high pressure at the two pressure relief and replenishing valves is correct. • If it is not correct: Turn the adjusting screw on the pressure relief and replenishing valve until the high pressure is correct. • Loosen the adjusting screw 1 on the pressure cut-off by one turn and check the pressure cut-off. • Use SCULI to set the Inch pedal - function OFF variable back to 0 Æ the inching function is enabled.

3.6.9

Description

Value Unit

High pressure

470±10 bar

Checking the pressure cut-off of the variable displacement pump The pressure cut-off limits the maximum pressure of the variable displacement pump. When this pressure is reached, the pump flow is automatically reduced in order to maintain the maximum permitted pressure.

• Connect a manometer (600 bar) to the test connection MA. • Use SCULI to set the Inch pedal - function OFF variable to 1 Æ the inching function is disabled. • Select fixed gear 2 and forward travel, and hold the machine in the blocked condition using the service brake. • In the blocked condition, increase the engine speed to the maximum. • Check that the high pressure on the manometer MA is correct. • Check that the engine suppression is below the threshold. • If it is not correct: Turn the adjusting screw 1 on the pressure cut-off 1 until the manometer MA reaches the correct value. • Use SCULI to set the Inch pedal - function OFF variable back to 0 Æ the inching function is enabled. Description

Value Unit

High pressure

430±5 bar

Maximum engine suppression at top idle speed

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30 min-1


LBH/Version 01/10.2006/en/hd/22/02/2007

Procedure

Service Manual


3.6.10

Calibrating the block curve The block curve can only be calibrated using the SCULI software. During calibration, the current to the proportional valve on the variable displacement pump is adjusted so that the pump reaches a set pressure at a set engine speed. Procedure • Connect a manometer (600 bar) to the test connection MA. • Connect your laptop, start the engine and run the SCULI program. • In the variables editor in the group structure, select the Adjustment Block Curve folder. • Set the Inch pedal - function OFF variable to 1 Æ the inching function is disabled. • Select fixed gear 2 and forward travel, and hold the machine in the blocked condition using the service brake. • Increase the engine speed to the levels shown in the table (930 min-1, 1200 min-1, 1400 min-1) and test the high pressure. • If it is not correct: Adjust the parameter Travel pump - current at 930, 1200, 1400 rpm until the set value is reached. • Set the Inch pedal - function OFF variable back to 0 Æ the inching function is enabled.

Valid for:

L550 - 456 / from 16978; L556 - 454 / from 15653

Description

Value Unit -1

LBH/Version 01/10.2006/en/hd/22/02/2007

Valid for:

High pressure at 930 min engine speed

50±10 bar

High pressure at 1200 min-1 engine speed

290±10 bar


350±10 bar


Description

Value Unit -1


High pressure at 930 min engine speed

50±10 bar


230±10 bar


330±10 bar

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Maintenance

Service Manual


3.6.11

Calibrating the variable displacement motors The variable displacement motors are calibrated automatically by the master electronics. Automatically calibrating the variable displacement motors • Connect your laptop, start the engine and run the SCULI program. • In the variables editor in the group structure, select the Adjustment Travel motor folder. • Set the parameter Travel motor - start motor adjustment to 1. The engine speed is automatically increased to 1000 min-1. After this the motors are successively calibrated across the entire speed range. After calibration, set the parameter Travel motor - start motor adjustment back to 0.

Note: Once the automatic calibration of the motors is complete, a service code appears in the display. This can happen if the variable displacement motor current is too high or low. In this case, the variable displacement motors must be manually checked and adjusted to 600±30 mA. Setting VG max manually

Adjusting variable displacement motor 1: • In the blocked condition, slowly increase the engine speed until the manometer MA shows exactly 300 bar. • Lower the current at Travel motor - motor 1 maximal current until the manometer at M1 shows 15±5 bar less than manometer MA. • When the manometers MA and M1 show the correct levels, increase the current at Travel motor - motor 1 maximal current by 10 mA. Adjusting variable displacement motor 2: • In the blocked condition, slowly increase the engine speed until the manometer MA shows exactly 300 bar. • Lower the current at Travel motor - motor 2 maximal current until the manometer at M1 shows 15±5 bar less than manometer MA. • When the manometers MA and M2 show the correct levels, increase the current at Travel motor - motor 2 maximal current by 10 mA.

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• Connect a manometer (600 bar) to the test connection MA. • Connect a manometer (600 bar) to the test connections M1 and M2. • In the variables editor in the group structure, select the Adjustment Travel motor folder. • Set the Inch pedal - function OFF variable to 1 Æ the inching function is disabled. • Select fixed gear 1 and forward travel, and hold the machine in the blocked condition using the service brake.

Service Manual


Note: The current for both motors must be in the range of 600±30 mA. If there is any deviation, correct it using the adjusting screws 1 or 2. • Set the Inch pedal - function OFF variable back to 0 Æ the inching function is enabled. • Repeat the automatically calibration of the variable displacement motors.

3.6.12

Checking the engine output Before you check the power of the engine, you must carry out the following tasks: – Tasks in maintenance schedule (air filter, fuel filter etc.) – Check the operating pressures according to the adjustment checklist – The machine must be at operating temperature. At maximum engine power consumption, the variable displacement motor power limiting control is activated. It regulates the pivot angle of the motors so that the engine runs at rated speed. This results in a set high pressure in the closed circuit. – If the high pressure is is above the set value, the engine power is good. – If the high pressure is is below the set value, the engine power is poor. If the engine speed reaches the set value, power limiting control is working correctly. Procedure

LBH/Version 01/10.2006/en/hd/22/02/2007

• Connect a manometer (600 bar) to the test connection MA. • In the variables editor in the group structure, select the Check Dieselengine folder. • Set the Inch pedal - function OFF variable to 1 Æ the inching function is disabled. • Start the machine, select fixed gear 2 and forward travel direction. • Hold the machine with the service brake and run it at full throttle. • Slowly release the service brake until the machine moves at 13 km/h. Check that the set values are reached. • If they are not correct: Troubleshoot the engine: air filters, fuel filters etc. Troubleshoot the travel hydraulics: check the operating pressure etc.

• Set the Inch pedal - function OFF variable back to 0 Æ the inching function is enabled. Valid for:

L550 - 456 / from 16978

Description

Value Unit

High pressure

300±10 bar 1980±30 min-1

Diesel engine speed


L576 - 457 / from 14171 L580 - 459 / from 14171

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Maintenance

Service Manual


Valid for:

L556 - 454 / from 15653

Description

Value Unit

High pressure

330±10 bar 1980±30 min-1

Diesel engine speed Valid for:

L566 - 460 / from 14171

Description

Value Unit

High pressure

340±10 bar 1980±30 min-1

Diesel engine speed Valid for:

L576 - 457 / from 14171; L580 - 459 / from 14171

Description

Value Unit

High pressure

340±10 bar 1980±30 min-1

Diesel engine speed

3.6.13

Checking the flow controller (delta p) of the working hydraulics pump Make sure you have a differential pressure gauge and two pressure sensors for the range up to 600 bar. Procedure Measure the difference in pressure between the test connections P and LS. You can measure the differential pressure, for example by slowly raising the lift arms. • Connect 600 bar pressure sensors to test connections P and LS. • Start the engine and let it run at low idling speed. • Slowly raise the lift arms and check whether the differential pressure is correct. • If it is not correct: Turn the adjusting screw on the flow controller 1 until the differential pressure is correct. Description


Differential pressure

Checking the flow controller (start of delivery) of the working hydraulics pump The flow controller determines the maximum output of the variable displacement pump. At the start of delivers, the indicator on the manometer M1 moves away from 0 bar. The set value on the manometer P should be reached. Procedure • Connect a manometer (600 bar) to the variable displacement pump at test connections M1 and P. • Start the engine, tilt the bucket all the way out and move the lift arms to the bottom position. • At idle speed, raise the lift arms all the way and check that the start of delivery shown on the manometer M1 is correct. • If it is not correct: Turn the adjusting screw on the power controller 1 until the pressure is correct.

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3.6.14

Service Manual


3.6.15

Description

Value Unit

Start of regulation

180±10 bar

Checking the secondary pressure relief valves on the control block Procedure To check the secondary pressure relief valve, you must increase the setting of the LS pressure cut-off 5 and the primary pressure relief valve 3. • Screw in the adjusting screw on the LS pressure cut-off 5 on the control block by two turns. • Tighten the adjusting screw on the primary pressure relief valve 3 by two turns. • Connect a manometer (600 bar) to the test connection P on the control block. Caution The pump can be irreparably damaged if you lower the lift arms. This function has no secondary pressure relief valve. ! Do not lower the lift arms. Start the machine and let the engine run at lower idling speed. Raise the lift arms, tilt out the bucket and tilt in the bucket, each to the limit. Check that the pressure at each secondary pressure relief valve is correct. If it is not correct: Turn the adjusting screw on the secondary pressure relief valve until it is correct. • Adjust the primary pressure relief valve 3 and the LS pressure cut off 5 back to the set value. See the sections on testing the primary pressure relief valve and LS pressure cut-off.

• • • •

Valid for:

LBH/Version 01/10.2006/en/hd/22/02/2007

Valid for:


L550 - 456 / from 16978; L556 - 454 / from 15653

Description

Value Unit

Tilt-in function (2)

380±5 bar

Tilt-out function (4)

380±5 bar

Lifting function (1)

380±5 bar


Description

Value Unit

Tilt-in function (2)

400±5 bar

Tilt-out function (4)

400±5 bar

Lifting function (1)

420±5 bar

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Maintenance

Service Manual


3.6.16

Checking the primary pressure relief valves on the control block Procedure To check the primary pressure relief valve 3, you must increase the setting of the LS pressure cut-off 5. • Screw in the adjusting screw on the LS pressure cut-off 5 on the control block by two turns. • Connect a manometer (600 bar) to the test connection P. • Start the machine and let the engine run at lower idling speed. • Raise the lift arms to the limit. • Check that the pressure is correct. • If it is not correct: Turn the adjusting screw on the primary pressure relief valve 3 until the pressure is correct. • Return the LS pressure cut-off 5 to its normal value. See the section on testing the LS pressure cut-off.

Valid for:

Valid for:

3.6.17

L550 - 456 / from 16978; L556 - 454 / from 15653

Description

Value Unit

Primary valve (3)

360±5 bar


Description

Value Unit

Primary valve (3)

380±5 bar

Checking the LS pressure cut-off on the control block Procedure • • • • •

Valid for:

Valid for:

3.6-12 o f 1 8

L550 - 456 / from 16978

Description

Value Unit

LS pressure cut-off (5)

290±5 bar

L556 - 454 / from 15653

Description

Value Unit


330±5 bar


Description

Value Unit


350±5 bar

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L550 - 456 / from 16978 L556 - 454 / from 15653


LBH/Version 01/10.2006/en/hd/22/02/2007

Valid for:

Connect a manometer (600 bar) to the test connection P. Start the machine and let the engine run at lower idling speed. Raise the lift arms to the limit. Check that the pressure is correct. If it is not correct: Turn the adjusting screw on the LS pressure cut-off 5 until the pressure is correct.

Service Manual


3.6.18

Depressurising ride control and the hydro accumulators You must depressurise the system before checking and filling the hydro accumulators or making repairs to the ride control system. This is how to depressurise the ride control system: Procedure Caution: Perform the following actions in the correct sequence. • Put the machine and the lift arms in maintenance position 2. The working attachment and lift arms must lie on the ground under their own weight. • Turn off the diesel engine. • Connect a manometer (40 bar) to the test connection M4 on the front axle. • Connect the same test line to the test connection MX. The pressure can then be relieved through this line to the tank. This takes around 10 minutes. • After 10 minutes, take the test line off test connection M4 and drain the remaining fluid into a suitable receptacle. Leave the test line connected during the testing and repair work. • After servicing, remove the test line from test connection MX.

3.6.19

Checking the cut-off pressure in the stabilisation module The cut-off function limits the pressure in the hydro accumulators when ride control is deactivated. This is how to check and correct the cut-off pressure: The cut-off pressure is fixed by the spring force. This means the cut-off pressure cannot be adjusted. Procedure

LBH/Version 01/10.2006/en/hd/22/02/2007

• Connect a manometer (600 bar) to the test connection MX on the stabilisation module. • Start the diesel engine (with ride control deactivated). • With the engine idling, raise the lift arms to their full height and accumulate pressure. • Check that the high pressure on the manometer is correct (reading the highest value). • If it is not correct: Find the cause and rectify the fault.

3.6.20

Description

Value Unit

High pressure

120±20 bar

Checking the nitrogen in the ride control hydro accumulator Make sure that you have a charging and testing device with a nitrogen bottle. The hydro accumulators can only be tested or filled when they are depressurised. Note: The nitrogen chamber of the hydro accumulator has around 350 cm³ of oil in it to protect the membrane.


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Maintenance

Service Manual


Procedure • Depressurise the ride control system as described in the section on depressurising ride control and the hydro accumulators.

• Take off the cap and slightly loosen the plug 2 of the hydro accumulator using a 6 mm allen key. • Connect the charging and testing device 4 to the hydro accumulator you want to test. • Open the valve 6 and check whether the nitrogen filling is correct. • If it is not correct: Slowly open the valve 8 on the nitrogen bottle 9 until the pressure is correct. You can reduce the pressure in the hydro accumulator using the relieve valve 5. The nitrogen escapes to the open air. Description

Value

Hydro accumulator temperature

Unit

0

Nitrogen for filling the hydro accumulator Minimum hydro accumulator nitrogen filling

3.6.21

10

25

±2

23

±2

26

±2

24

±2

20 27 25

±2 ±2

30

°C

28

±2

bar

26

±2

bar

Check the pressure cut-off of the steering pump Procedure

3.6.22

Connect a manometer (600 bar) to the test connection P. Start the engine and let it run at low idling speed. Turn the steering fully to the left or right. Check that the pressure at the test connection P is correct. If it is not correct: Turn the adjusting screw on the pressure controller 2 until the pressure is correct.

Description

Value Unit

High pressure

210±5 bar

Checking the flow controller (delta p) of the steering pump Make sure you have a differential pressure gauge and two pressure sensors for the range up to 600 bar. Procedure Measure the difference in pressure between the test connections P and LS. You can only measure the differential pressure when the flow controller is activated. This is best done when slowly steering. • Fit a test connection between the hose line and the connection LS. • Connect 600 bar pressure sensors to test connections P and LS. • Start the engine and let it run at low idling speed. • Slowly steer the machine to the left or right and check whether the differential pressure on the measuring device is correct.

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LBH/Version 01/10.2006/en/hd/22/02/2007

• • • • •

Service Manual


• If it is not correct: Turn the adjusting screw on the flow controller 1 until the differential pressure is correct. Description

Value Unit 22 ±2 bar

Differential pressure

3.6.23

Checking the brake pressure of the compact brake valve The compact brake valve fills the brake accumulator until the shut-off pressure is reached. When you repeatedly press the inch-brake pedal, the pressure in the brake accumulators falls until the opening pressure is reached. The brake accumulator charging function then begins. Procedure You can check the cut-off pressure of the brake accumulator charging function using the test connection M3 on the compact brake valve. • Connect a manometer (600 bar) with a short test line to the test connection MA. • Start the engine and let it run at low idling speed. • Push the inch/brake pedal all the way down several times. • Look at the manometer M3 to check that the correct opening pressure is reached. When the opening pressure is reached, the pressure on the manometer begins to rise. The pressure then increases to the closing pressure. • Check the test connection M3 to see if the closing pressure is correct. • If it is not correct: Turn the adjusting screw 1 on the compact brake valve until the closing pressure is correct.

3.6.24

Description

Value Unit

Opening pressure

180±5 bar

Closing pressure

210±5 bar

Checking the brake pressure at the axles You can check the brake pressure on the wet disk brakes in the wheel hubs at the test connection M4 on the front axle 1 and M5 on the cut-in block 2.

LBH/Version 01/10.2006/en/hd/22/02/2007

Procedure

• • • • •


Connect manometers (600 bar) to the test connections M4 and M5. Start the engine and let it run at low idling speed. Push the inch/brake pedal all the way down. Check that the pressure on both manometers is correct. If it is not correct: Adjust the pedal stop screw 3 so that the brake pressure is correct when

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Maintenance

Service Manual


the pedal is all the way down. Remove the seal 4, loosen the counter nut and adjust the bottom screw. Valid for:

L550 - 456 / from 16978; L556 - 454 / from 15653; L566 - 460 / from 14171; L576 - 457 / from 14171

Description

Value Unit

Brake pressure with the pedal fully pressed Valid for:

L580 - 459 / from 14171

Description

Value Unit

Brake pressure with the pedal fully pressed

3.6.25

95 ±5 bar

70 ±5 bar

Checking the capacity of the brake accumulator Test the capacity of the brake accumulators 1 and 2 for the front and rear axles respectively by pressing the inch/brake pedal nine times. Before the test, the pressure in the brake accumulators must be 180 bar. After pressing the inch/brake pedal nine times, the pressure should not be below the correct level.

• Connect a manometer (600 bar) to the test connection M3 on the compact brake valve. • Connect manometers (600 bar) to the test connections M4 and M5 on the cut-in block 2. • Push the inch/brake pedal all the way down several times to lower the brake accumulator pressure to 180 bar. • Slowly press the inch/brake all the way down nine times, keeping it down the final time. • Check that the correct pressure is reached on the manometers M4 and M5. • If the brake pressure on either manometer falls below the correct level: Replace the brake accumulator if necessary. Description

Value Unit

Lower brake pressure tolerance

3.6-16 o f 1 8

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50 bar


LBH/Version 01/10.2006/en/hd/22/02/2007

Procedure

Service Manual


3.6.26

Checking the accumulator charge pressure The pressure switch generates a warning if the brake accumulator pressure is too low. When the pressure in the brake accumulators is reached, the symbol field 2 goes out and the brake system is ready for operation. Procedure You can check the switching point of the pressure switch 1 using the test connection M3 on the compact brake valve and the symbol field 2 on the display unit. • Connect a manometer (600 bar) with a short test line to the test connection MA. • Turn on the starter switch. • Gently push the inch/brake pedal to slowly lower the pressure in the brake accumulators. • Check that the symbol field 2 lights up when the correct pressure is shown on the manometer M3. • If it is not correct: Replace the brake accumulator pressure switch 1.

3.6.27

Description

Value Unit

Pressure switch activation point

120±5 bar

Checking the brake light pressure switch and brake lights This check tests the brake lights. Procedure • Turn on the starter switch. • Slowly and gently press the inch/brake pedal and watch the brake lights light up. • If the brake lights do not light up: Check the brake lights; replace the brake light pressure switch 1 if necessary.

3.6.28

Checking the transmission shift pressure Procedure

LBH/Version 01/10.2006/en/hd/22/02/2007

• • • •

Connect a manometer (40 bar) to the test connection P. Start the engine and bring it to top idle speed. Check that the pressure at the test connection P is correct. If it is not correct: The shift pressure relief valve is inside the control valve block. You can only adjust the shift pressure by adding or removing shims. For a sectional view view of the control valve block, see section on electrohydraulic pressure modulation.

Description

Value Unit 20 ±3 bar

Shift pressure


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Maintenance

Service Manual


3.6.29

Checking the nitrogen in the transmission hydro accumulator Make sure that you have a charging and testing device with a nitrogen bottle.

Procedure • Take off the cap and slightly loosen the plug 2 of the hydro accumulator using a 6 mm allen key. • Connect the charging and testing device 4 to the hydro accumulator. • Open the valve 6 and check whether the nitrogen filling is correct. • If it is not correct: Slowly open the valve 8 on the nitrogen bottle 9 until the nitrogen pressure is correct. You can reduce the pressure in the hydro accumulator using the relieve valve 5. The nitrogen escapes to the open air. Description


LBH/Version 01/10.2006/en/hd/22/02/2007

Nitrogen filling

3.6-18 o f 1 8

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Service Manual

Maintenance Lubricants and fuels

3.7 Lubricants and fuels Conscientious observance of the regulations for handling lubricants and fuels will increase the reliability and service life of the machine. It is especially important that the specified lubricant qualities are observed. You can find the various specifications about the prescribed intervals in the maintenance and inspection schedule and the lubrication chart. You can find details on lubrication, checking the oil level and changing operating fluids in the maintenance section under maintenance tasks. Follow the rules on handling lubricants and fuels, especially the environmental regulations. Filling quantities and specifications: – The filling quantities listed in the tables are only guidelines. The dipstick and level markings are always mandatory. – Each time the lubricant or fuel is replaced or topped up, check the level in the unit in question. – For more detailed information about the required lubricants, fuels and filling quantities, see the filling quantities in the lubrication chart and the section on lubricants and fuels.

Environmental protection • Always implement and observe environmental protection measures. • Observe national regulations. • Ensure that liquids can be properly disposed of before draining them.

Disposing of used materials This applies to the following types of used materials and hazardous waste: – Oils, lubricants, brake fluids, etc. – Coolant – Fuels – Filters, oil cartridges etc. – Rubber, tyres, insulating materials etc. – Batteries

LBH/Version 01/10.2006/en/hd/22/02/2007

Procedure

Note Environmental and health hazard ! Observe the local regulations for protecting the environment when disposing of used materials! • Always collect and store used materials separately in suitable containers. • Dispose of used materials properly at the official collection points.


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Maintenance

Service Manual

Lubricants and fuels

Converting the hydraulic system from petroleum to environmentally compatible hydraulic fluids For the operation of LIEBHERR earth moving machines with environmentally compatible hydraulic fluids we recommend PANOLIN HLP SYNTH 46. Machines filled at factory with environmentally compatible hydraulic fluids have an appropriate sign (CAUTION) attached to the driver's cab and hydraulic tank. Procedure for conversion: Caution Beware of damaging the machine's hydraulic system. Mixing environmentally harmless hydraulic fluids with mineral oils produces a vigorous reaction that can damage the hydraulic system.

! Do not mix environmentally harmless hydraulic fluids with mineral oil. • If you intend to convert the machine to environmentally-compatible hydraulic fluid, you must first consult LIEBHERR CUSTOMER SERVICE. • Ask LIEBHERR for the instruction sheet and conversion guidelines and be sure to follow them.

3.7.1 Specification

Diesel fuels The diesel fuels must comply with the minimum requirements of the fuel specifications prescribed as follows. Authorised fuel specifications: – DIN EN 590 – ASTM D 975 (89a) 1D and 2D Further fuel specifications only upon consultation with the Diesel Engine Development Department, LIEBHERR Machines Bulle S.A.

Sulphur content in the diesel fuel

For worldwide markets except the USA: In DIN EN 590 the maximum sulphur content is 50 mg/kg = max. 0.005 % by weight. For the USA: In ASTM D 975 (89a) 1D and 2D, the maximum sulphur content is 10 ppm.

The diesel fuel lubricating proficiency must be a max. 460 µm in accordance with the HFRR (60) test. For diesel fuels featuring a sulphur content above / more than 0.5 weight%, the oil-change intervals are to be halved. Diesel fuels featuring a sulphur content above / more than 1 weight% are not permissible.

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LBH/Version 01/10.2006/en/hd/22/02/2007

Low-sulphur diesel fuels featuring a sulphur content of below / less than 0.05 weight% are only applicable if lubricity can be ensured with the admixture of additives.

Service Manual


Note In some cases, approval may be given, depending on the quality of the diesel engine lubricating oil. ! Fuel standard ASTM D 975 does not stipulate that fuels must pass a fuellubricity test. A written confirmation of the fuel supplier must be requested. The additives should be added by the supplier in his capacity as agent responsible for fuel quality. The addition of secondary-lubricity-additives by the customer is not recommended. – A cetane number of at least 45 is required for fuels in accordance with ASTM D975. A cetane number above 50 is preferable, especially with temperatures below 0°C. Diesel fuel at low temperatures (winter operation)

Diesel fuel precipitates paraffin crystals as the temperature drops. This increases flow-resistance in the fuel filter to such an extent that a sufficient supply of fuel to the diesel engine can no longer be guaranteed. In temperate climates, cold flow is guaranteed up to: 0 °C from 15/04. to 30/09 -10 °C from 01/10. to 14/11 / 1.3. - 14.04. -20 °C from 16/11 to 29/02 according to DIN EN 590. If the cold-flow properties of the diesel fuel are insufficient or with lower ambient temperatures than -20°C, we recommend using a fuel filter heater. Other approved diesel fuels: Diesel fuel complying with DIN EN 590 with up to 5% vol. FAME.

3.7.2 Lube oil specifications

Lubricating oils for diesel engines Only high-alloy lube-oils are used nowadays for 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. Description

Specification

ACEA classification (Association des E4, E5, E6, E7 Constructeurs Européens de Caution: particle filter operation is l'Automobile) only possible with E6

LBH/Version 01/10.2006/en/hd/22/02/2007

API classification (American Petroleum Institute)

CH-4, CI-4, CJ-4 observe special oilchange interval Caution: observe the reduced oilchange interval

Lube-oil viscosity

Selection of lube-oil viscosity in accordance with the SAE-classification (Society of Automotive Engineers). The ambient temperature is definitive for the correct selection of the SAE-class. Selection of the SAE-classification gives no indication of the quality of a lube-oil. Too high a viscosity can lead to starting difficulties, and too low a viscosity could jeopardise the lubricating efficiency. The temperature ranges specified in the diagram are guidelines and can be briefly exceeded or fallen short of.


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Maintenance

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Temperature-dependent selection of the SAE-class The following engine oil is recommended (for outside temperatures of -20°C to +45°C): Liebherr Motoroil 10W-40 Specification ACEA E4 Liebherr Motoroil low ash Specification ACEA E6 Lube-oil change intervals

Changing intervals: – Oil change and filter replacement: see the maintenance and inspection schedule – Oil-change respective of climatic zone, sulphur content in the fuel and oil quality in accordance with the following table. If the prescribed operating hours (h) have not expired within one year, the diesel engine oil and filter must be replaced at least once a year.

Difficulty factors

Various difficulty factors or more difficult operating conditions reduce maintenance intervals. Difficulty factors or difficult conditions include for example.: – frequent cold-starts – sulphur content in the fuel over 0.5% – Outside operating temperatures below -10 °C Should difficulty factors or tougher operating conditions arise, oil-change and filter replacement must be carried out in accordance with the specifications in the following table. Difficulty factor

Oil quality CH-4 CJ-4 E4 E5 E6 E7

Outside temperature

Sulphur content in the fuel

Normal climate, up to -10 °C

up to 0.5%

250 h

500 h

over 0.5%

125 h

250 h

up to 0.5%

125 h

250 h

over 0.5%

not permissible

125 h

Below -10 °C

Interval

Oil-change intervals in operating hours (h)

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CI-4

Service Manual


3.7.3 General recommendations

Coolant for the diesel engine The cooling system will only function reliably if it is working under pressure. It is therefore imperative that it is kept clean and watertight, that the radiator cap valve and working valves are functioning correctly and the necessary coolant level is maintained. The corrosion inhibitor/antifreeze authorised by LIEBHERR guarantees sufficient protection against cold, corrosion and cavitation, do not corrode seals and hoses and do not foam up. Coolants which contain inadequate or ill-prepared corrosion inhibitor/ antifreeze could cause a malfunctioning of aggregates or parts in the cooling circuit as a result of cavitational or corrosive damage. Furthermore, heatinsulating sedimentation can result at heat-exchanging parts, leading to overheating, and then to malfunctioning, of the engine. Note Emulsifiable corrosion inhibition oils may are impermissible. ! In special cases, it is permissible to use corrosion inhibitors.

Water (fresh water)

Suitable water is colourless, clear, free of mechanical contamination, drinkable tap water featuring the following restricted analysis values. Sea water, brackish water, salt water and industrial waste water is not suitable. Fresh water quality Description

Value and unit

Total of alkaline earths (water hardness)

0.6 to 3.6 mmol/l (3 to 20°d)

pH value at 20 °C

6.5 to 8.0

Chloride-ion content

max. 80 mg/l

Sulphate-ion content

max. 100 mg/l

Fresh water quality when using DCA 4 Description

Value and unit

Total of alkaline earths (water hardness)

0.6 to 2.7 mmol/l (3 to 15°d)

pH value at 20 °C

6.5 to 8.0

Chloride-ion content

max. 80 mg/l

Sulphate-ion content

max. 80 mg/l

LBH/Version 01/10.2006/en/hd/22/02/2007

Water analyses can be applied for from the communal authorities responsible.


All year roundto

°C

°F

Water %

Corrosion inhibitor / antifreeze %

Outside temperature

-37

-34

50

50

Outside temperature

-50

-58

40

60

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Temperature-dependent selection of mix ratio for corrosion inhibitor/antifreeze A = ratio of corrosion inhibitor/antifreeze in the coolant as a percentage Product designation

Manufacturer

Liebherr Antifreeze Concentrate

Country

Liebherr

D

Addinol Antifreeze Super

Addinol Lube Oil GmbH, Leuna

D

Agip Antifreeze Plus

Aral AG, BochumEni S.p.A., Rome

I

Agip Langzeit-Frostschutz

Eni S.p.A., Würzburg

D

Antigel DB 486

Sotragal SA, St-Priest

F

Aral Antifreeze Extra

Aral AG, Hamburg

D

Avia Antifreeze APN G48

Avia Mineralöl AG, Munich

D

BP Isocool

BP p.l.c. London

GB

Caltex Extended Life Coolant

Chevron Texaco

*

Castrol Antifreeze NF

Castrol, London

GB

Chevron Extended Life Coolant

Chevron Texaco

*

DEUTZ Kühlerschutzmittel 0101 1490

DEUTZ Service International GmbH, Cologne

D

ESA Frostschutz G48

ESA Burgdorf

Fuchs Fricofin Kühlerfrostschutz

Fuchs Petrolub AG, Mannheim

D

Glacelf Auto Supra (antifreeze)

Total, Paris

F

GlycoShell Longlife

Shell International Petroleum Company, London

GB

GlycoShell N

Shell International Petroleum Company, London

GB

Glysantin G48

BASF AG, Ludwigshafen/Germany

D

Havoline Extendend Life Antifreeze / Coolant

Chevron Texaco

*

Havoline XLC

Arteco

B

Motorex Antifreeze Protect G48

Bucher AG, Langenthal

Motul Inugel Optimal Ultra

Motul SA, Aubervilliers Cedex

F

OMV Kühlerfrostschutz / Coolant Plus

OMV Refining & Marketing GmbH, Vienna

A

CH

CH

Do not mix products with one another! * = global / worldwide

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Corrosion inhibitor / antifreeze permitted for diesel engine cooling syst

Service Manual


Corrosion inhibitor/antifreeze premixes (50% water: 50% corrosion inhibitor/antifreeze) permitted for diesel engine cooling systems

Product designation

Manufacturer

Country

Liebherr Antifreeze Mix

Liebherr

D

Caltex Extended Life Coolant Pre-Mixed 50/50 (ready-touse version)

Chevron Texaco

*

Chevron DEX-COOL Extended Life Pre-Diluted 50/50 Antifreeze Coolant

Chevron Texaco

*

Coolelf Auto Supra -37 °C

Total, Paris

F

Havoline XLC, 50/50

Arteco

B

Havoline DEX-COOL Extended Life Pre-Diluted 50/50 Antifreeze Coolant

Chevron Texaco

*

Do not mix products with one another! * = global / worldwide Corrosion inhibitors without antifreeze

In exceptional cases and if outside temperatures constantly remain above freezing, for example in the tropics, where it can be proven that no approved corrosion inhibitor/antifreeze is available, the following may be used as coolant: Product DC4 (Diesel Coolant Additives 4) Product Caltex / Chevron / Havoline / Total When carrying out maintenance tasks, the concentration must be tested and rectified as necessary. The coolant must be changed once a year. Note The entire amount of coolant must be drained. ! When changing from corrosion inhibitor/antifreeze to pure corrosion inhibitor, or vice versa.

LBH/Version 01/10.2006/en/hd/22/02/2007

Approved water-soluble corrosion inhibitors (concentrates) for diesel engine cooling systems

Product designation

Manufacturer

Countr y

DCA 4 Diesel Coolant Additives

Fleetguard / Cummins Filtration

*

Caltex XL Corrosion Inhibitor Concentrate

Chevron Texaco

*

Chevron Heavy Duty Extended Life Corrosion Inhibitor Nitrite Free (ELC)

Chevron Texaco

*

Havoline Extended Life Corrosion Inhibitor (XLI)

Chevron Texaco

*

Total WT Supra

Total, Paris

F

Do not mix products with one another! * = global / worldwide


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Service Manual


3.7.4

Specification

Hydraulic oils

Only engine oils (mineral oils) meeting the following specifications and regulations are permitted. Description

Specification

API classification (American Petroleum Institute)

CF-4, CG-4, CH-4

ACEA classification (Association des Constructeurs Européens de E2 , E3 , E4 l'Automobile) Specifications and regulations for hydraulic oil Viscosity

The viscosity is selected according to the SAE (Society of Automotive Engineers) classification. The decisive factor for the selection of the correct SAE class is the ambient temperature. The selection of the SAE classification has no bearing on the quality of a hydraulic oil. The temperature ranges presented in the diagram are merely guidelines.

Temperature-dependent selection of the SAE-class For temperatures up to 10 °C below the specified limit: – Adjust the diesel engine to roughly half speed after starting. – Activate the hydraulic cylinders and engines and briefly move the cyliners to their stops. – Warming up takes roughly 10 minutes. At even lower temperatures: – Before starting the engine, prewarm the oil tank. Environmentally compatible hydraulic fluids

When operating LIEBHERR earth moving machines with environmentally compatible hydraulic fluids, we recommend PANOLIN HLP SYNTH 46 with the viscosity specified by LIEBHERR. Converting the hydraulic system to environmentally harmless hydraulic fluid: – See the section on conversion from mineral oils to environmentally harmless hydraulic fluids. Note Environmentally-compatible hydraulic fluids must be checked every 500 operating hours at regular intervals. ! LIEBHERR recommends that oil analysis is carried out by WEAR-CHECK.

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Warming up

Service Manual


Oil change: – At the interval stated in the maintenance and inspection schedule. – At the interval specified by WEAR-CHECK. Note Do not mix environmentally-compatible hydraulic fluid from different manufacturers or with mineral oils. ! See also the customer service information. Monitoring hydraulic oil - changing according to oil samples - analysis and laboratory report:

Oil change intervals according to sample analysis and laboratory report 1 Service hours 2 First oil sample

3.7.5

Pump distributor gear and axles

3 Second oil sample 4 Further oil samples every 500 operating hours

Lubricating oils for the transmission Gear oils must comply with the API GL-5 and MIL-L 2105 B, C or D specifications and the viscosity class SAE 90 LS *. * = Gear oil with limited slip additives for disc brakes and self-locking differentials. LS = limited slip additive: – Not required for pump distributor gears – Required for axles For the viscosity class SAE 90 LS, an oil of the viscosity class SAE 80 W 90 LS can also be used.

Transmission

An ATF oil compliant with the DEXTRON II D specification should be used as lubrication oil for the transmission.

LBH/Version 01/10.2006/en/hd/22/02/2007

Factory filling: ATF 86 AVIA-FLUID DEXRON II D

3.7.6

Description

ID no.

Quantity

ATF 86 AVIA-Fluid DEXRON II D

861012601

210 l

ATF 86 AVIA-Fluid DEXRON II D

10009964

20 l

Grease for general lubrication points This grease must meet the KP2k specification – consistency 2 of the NL GI class according to DIN 51818 and DIN 51825 or EP 2 according to NF-T-60 132. The grease must be made of a lithium complex with a four ball tester (VKA) value of at least 2300 N according to DIN 51350 or ASTM D 2596. Application: – Grease for all lubrication points (according to the lubrication schedule) – Lubricant grease for bolt fitting – Lubricant grease for automatic central lubrication systems


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Maintenance

Service Manual


Approved greases

LIEBHERR 9610 special grease is a milling-resistant, ageing-resistant lithium grease, providing protection against corrosion with excellent lubricity over a wide temperature range. Its molecular composition yields high degrees of shearing and milling stability and good flow properties in long pipes. Description

Lubricant grease for automatic central lubrication systems

ID no.

Quantity

LH 9610 special grease 861302908

400 g (cartridge)


10 kg (drum)


25 kg (drum)

Greases with high-pressure additives (EP greases) are recommended. Only use greases with the same type of saponification.

LBH/Version 01/10.2006/en/hd/22/02/2007

Note Greases with solid lubricant particles such as graphite are not suitable. ! Do not use this type of grease.

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4 Diesel engine, Splitter box 4.0 Chapter contents 4

Diesel engine, Splitter box................................................... 4.1-1 4.1

Diesel engine ..................................................................................4.1-1 4.1.1

Electrical engine components ..............................................4.1-6

4.1.2

Crankshaft flywheel speed sensors – B711/B712................4.1-7

4.1.3

Camshaft speed sensor – B713 ...........................................4.1-8

4.1.4

Coolant temperature sensor – B708 Fuel temperature sensor – B709 ......................................................................4.1-9

4.1.5

Charge air temperature sensor – B707 ..............................4.1-10

4.1.6

Charge air pressure sensor – B703 ...................................4.1-11

4.1.7

Oil pressure sensor – B701................................................4.1-12

4.2

Fuel system.....................................................................................4.2-1 4.2.1

Fuel level sensor ..................................................................4.2-2

4.2.2

Fuel pre-filter ........................................................................4.2-3

4.2.3

Fuel fine filter ........................................................................4.2-4

4.2.4

Refuelling pump (optional) ...................................................4.2-5

4.3

Air filter system ...............................................................................4.3-1 4.3.1

Air filter .................................................................................4.3-1

4.3.2

Vacuum switch .....................................................................4.3-2 Coupling..........................................................................................4.4-1

4.5

Splitter box ......................................................................................4.5-1

LBH/Version 01/10.2006/en/nk/29.01.2007

4.4


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Diesel engine, Splitter box

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Service manual

Diesel engine, Splitter box Diesel engine

4.1

Diesel engine Technical data See section 2.1

Design The diesel engine is a water-cooled, four-stroke in-line engine with pumpline-nozzle (PLD) direct injection, turbocharging and charge air cooling. The engine is fitted lengthways in the rear section and elastically supported on rubber elements. The flywheel end faces to the rear. Valid for:

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Diesel engine components / right view

LBH/Version 01/10.2006/en/nk/29.01.2007

1 2 3 4 5 6 7 8 9 10 11 12 13


Flywheel housing Flywheel Opening for cranking device Auxiliary drives Fuel pre-filter Crankcase bleeder Bleeder filter with oil separator Hand pump Cylinder head Fuel fine filter Charge air pipe Lube oil filler neck Air intake pipe

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14 Flame glow plug 15 Engine electronics (LH-ECU) 16 Air conditioning compressor 17 Alternator 18 Fuel line connections 19 Auxiliary drive 20 Engine block 21 Dipstick 22 Oil separator return line 23 Oil pan 24 Fuel pump

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Service manual

Diesel engine

Diesel engine components / left view Water pump Belt drive cover Thermostat housing Oil filter Charge air pipe Housing bleeder Turbocharger compressor

8 9 10 11 12 13

Turbocharger turbine Starter Oil cooler Cooling water supply to cooler Cooling water return from cooler Crankshaft / vibration damper

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1 2 3 4 5 6 7

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Service manual


Valid for:


Diesel engine components / right view Flywheel Flywheel housing Opening for cranking device Auxiliary drives Crankcase bleeder Bleeder filter with oil separator Cylinder head Lube oil filler neck Combustion air intake manifold Flame glow plug Air conditioning compressor Pump element with magnetic coil

13 14 15 16 17 18 19 20 21 22 23

Alternator Engine electronics (LH-ECU) Auxiliary drive Hand pump Fuel pre-filter Fuel line connections Fuel fine filter Engine bearing Oil pan Engine block Fuel pump

LBH/Version 01/10.2006/en/nk/29.01.2007

1 2 3 4 5 6 7 8 9 10 11 12


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Service manual

Diesel engine

Diesel engine components / left view Water pump Tension pulley apparatus Oil filter Air intake pipe Housing bleeder Charge air pipe Turbocharger compressor

8 9 10 11 12 13 14

Turbocharger turbine Crankcase Exhaust pipe Cooling water supply to cooler Cooling water return from cooler Thermostat housing Crankshaft / vibration damper

Design features of the diesel engine: – Water-cooled four-stroke diesel engine with pump-line-nozzle (PLD) direct injection – Turbocharger and charge air cooling – Maintenance-free gear drive for camshaft, fuel pump, lubricant pump on flywheel end and coolant pump on motor end, as well as power take-off for gear pumps – Individual cylinder heads with cast integral vortex intake duct – Replaceable wet bushings – Small number of parts due to lubricant and coolant lines integrated in crankcase – Oil spray-cooled three-ring piston made of light alloy (D934S) Oil spray-cooled three-ring piston made of monotherm steel (D934L/D936L) – Engine oil cooler – Double lube oil filter – Large, tilt-proof oil pan – 5-bearing (4-cylinder) or 7-bearing (6-cylinder) steel crankshaft with forged counterweights and diagonal “cracked” piston rods. Lead bronze triple composite bearings.

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1 2 3 4 5 6 7

Service manual


Function description Basic function The diesel engine converts the chemical energy in the fuel into kinetic energy, which it provides to the flywheel via the torsion absorber and the pump distributor gear to the travel hydraulics, working hydraulics and steering hydraulics pumps. A small portion of the power is taken off at the accessory drive side of the diesel engine to drive the gear pumps.

LBH/Version 01/10.2006/en/nk/29.01.2007

These are the single gear pump for the transmission shift pressure, and the triple gear pump for the hydrostatically driven fan, the accumulator pressure brake system and the leak oil scavenging in the variable displacement motor.


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Service manual

Diesel engine

4.1.1

Electrical engine components Design

Valid for:

L550 - 456 / from 16978; L556 - 454 / from 15653; L566 - 460 / from 14171; L576 - 453 / from 14171; L580 - 459 / from 14171;

Electrical engine components 7 Alternator – G700 8 Engine electronics (LH-ECU) – A700 9 Pump element magnetic coil Y711 – Y716 10 Water sensor on fuel pre-filter – B710 11 Oil pressure sensor – B701

12 Crankshaft 2 flywheel speed sensor – B712 13 Camshaft speed sensor – B713 14 Crankshaft 1 flywheel speed sensor – B711

LBH/Version 01/10.2006/en/nk/29.01.2007

1 Heating flange – R701 2 Starter – M700 3 Coolant temperature indicator + thermostat – B708 4 Charge air pressure sensor – B703 5 Charge air temperature sensor – B707 6 Air conditioning compressor magnetic coupling – M710

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Service manual


4.1.2

Crankshaft flywheel speed sensors – B711/B712 For safety reasons, two identical speed sensors are used on the crankshaft. The two speed sensors, B711 and B712, are attached to the engine flywheel housing and their job is to record the speed and position of the crankshaft. The first sensor (B711) is the working sensor; if it fails, the system automatically switches to the second – backup – sensor (B712). The signal voltage, whose frequency is proportional to the speed, is used for: – Controlling the fan drive – Starting the emergency steering pump check – Controlling the diesel engine – Indicating the engine speed – Power limiting control – Overspeed protection – 0-inching control

Design The speed sensors are Hall-effect sensors. Hall-effect sensors are electromagnetic components with a permanent magnet and a Hall element (Hall IC). The distance between the sensor and the flywheel ring gear is fixed. Distance “a” = 0.5 - 2 mm

Function description Speed sensor location

Basic function If a Hall-effect sensor has voltage supplied and is put vertically into a magnetic field, it provides an output voltage. This signal voltage modulates proportionally to the speed of the ring gear on the flywheel and is provided to the engine electronics as a frequency signal. Attention Never measure resistance on a Hall-effect sensor.

! Malfunctions are indicated by service codes in display. Plug assignment

LBH/Version 01/10.2006/en/nk/29.01.2007

1 Weight 2 Frequency signal (output voltage) 3 12 V power supply


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Service manual

Diesel engine

4.1.3

Camshaft speed sensor – B713 The speed sensor B713 is attached to the crankshaft housing of the engine; its job is to detect the phase of the engine while starting. If the camshaft sensor fails while the engine is running, the engine continues turning. When the engine is turned off and started again, its running is restricted. The signal voltage, whose frequency is proportional to the speed, is used for: – Controlling the diesel engine

Design The speed sensor is a Hall-effect sensors. Hall-effect sensors are electromagnetic components with a permanent magnet and a Hall element (Hall IC). The distance between the sensor and the flywheel ring gear is fixed. Distance “a” = 0.5 - 2 mm

Function description Speed sensor location

Basic function If a Hall-effect sensor has voltage supplied and is put vertically into a magnetic field, it provides an output voltage. This signal voltage modulates proportionally to the speed of the ring gear on the flywheel and is provided to the engine electronics as a frequency signal. Attention Never measure resistance on a Hall-effect sensor.

! Malfunctions are indicated by service codes in display. Plug assignment

LBH/Version 01/10.2006/en/nk/29.01.2007

1 Weight 2 Frequency signal (output voltage) 3 12 V power supply

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Service manual


4.1.4

Coolant temperature sensor – B708 Fuel temperature sensor – B709 The coolant temperature sensor B708 is attached to the thermostat housing of the engine, while the fuel temperature sensor B709 is fitted in the fuel supply line. Both have the task of signalling the temperature to the engine control unit (ECU) in the form of an electrical resistance. The ECU uses this signal for: Coolant temperature: – Indicating the coolant temperature in the cab – Controlling the fan drive – Preglow control – Engine power limiting control Coolant temperature [°C] Power reduction [%]

-100

-15

100

101

120

150

10

0

0

4

50

50

– Controlling the engine to increase the idling speed Coolant temperature [°C]

-100

-90

-40

-10

20

0

200

200

100

0

Idling speed increase [rpm] Fuel temperature: – Controlling the fan drive – Engine power limiting control Fuel temperature [°C]

-100

-5

0

75

80

85

100

Power reduction [%]

10

3

0

0

3

10

30

Design The temperature sensor is a resistance thermometer which operates with an NTC characteristic (semiconductor).

Function description Basic function The resistance in the sensor decreases as the temperature rises. The curve is not a straight line. If the sensor is defective, a temperature of -100 °C is assumed. Coolant resistance characteristic B708

Temperature (°C)

LBH/Version 01/10.2006/en/nk/29.01.2007

Coolant and fuel temperature sensor

105 100 95 90 85 80 75 70 65 60 55 50 45 40 35 30 25 20 15 10 5 0 0

3

6

9

12

15

18

21

24

27

30

33

36

39

42

45

48

51

54

57

60

Resistance (kOhm )


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Service manual

Diesel engine

4.1.5

Charge air temperature sensor – B707 The charge air temperature sensor B707 is attached to the air intake pipe of the engine and has the task of signalling the charge air temperature to the engine control unit (ECU) in the form of an electrical resistance. The ECU uses this signal for: – Controlling the fan drive – Preglow control – Engine power limiting control Charge air temperature [°C] Power reduction [%]

-100

-15

75

80

85

100

10

0

0

0

10

30

Design The temperature sensor is a resistance thermometer which operates with an NTC characteristic (semiconductor).

Function description Basic function Charge air temperature sensor

The resistance in the sensor decreases as the temperature rises. The curve is not a straight line. If the sensor is defective, a temperature of 100 °C is assumed.

Temperature (°C)

Charge air resistance characteristic B707 105 100 95 90 85 80 75 70 65 60 55 50 45 40 35 30 25 20 15 10 5 0 0

5

10

15

20

25

30

35

40

45

50

55

60

65

70

75

80

85

90

95

100

LBH/Version 01/10.2006/en/nk/29.01.2007

Resistance (kOhm )

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Service manual


4.1.6

Charge air pressure sensor – B703 The charge air pressure sensor B703 is attached to the air intake pipe of the engine and has the task of signalling the charge air pressure to the engine control unit (ECU) in the form of an electrical voltage. The ECU uses this signal for: – Engine power limiting control Power reduction (%)

Atmospheric pressure (mbar) Height above sea level* (m)

Speed (rpm) 1000

1300

1600

1900

2100

550 4850*

23.1

24.1

24.4

24.4

23.3

620 3950*

19.5

19.6

19.1

19.1

18.0

690 3100*

14.2

14.8

13.9

13.6

12.6

770 2250*

10.0

10.1

8.9

8.4

7.2

840 1550*

0.0

0.0

0.0

Design The charge air pressure sensor is an absolute pressure sensor with a membrane and an evaluation circuit. At atmospheric pressure, an absolute pressure sensor is subject to approximately 1 bar (at sea level 1030 mbar). 1 Electrical connections 2 Evaluation circuit 3 Membrane with sensor element 4 Pressure port 5 Fixing thread

Function description Basic function Cross section of speed sensor

The electrical resistance varies on the layers applied to the membrane as they change shape. This deformation due to the accumulating system pressure alters the electrical resistance and causes a change in the voltage of the resistance bridge, which has a 5 V supply.

LBH/Version 01/10.2006/en/nk/29.01.2007

This voltage is in the range of 0 to 70 mV (depending on the pressure) and is amplified in the evaluation circuit to between 0.5 and 4.5 V. Attention Never measure resistance on a pressure sensor.

! Malfunctions are indicated by service codes in display.


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Service manual

Diesel engine

4.1.7

Oil pressure sensor – B701 The oil pressure sensor B701 is attached to the crankcase of the engine and has the task of signalling the oil pressure to the engine control unit (ECU) in the form of an electrical voltage. The ECU uses this signal for: – Indication in the cab – Controlling the engine as a function of the safety curve: 300

1000

1400

1800

2100

Design The oil pressure sensor is a relative pressure sensor with a membrane and an evaluation circuit. At atmospheric pressure, a relative pressure sensor is subject to 0 bar. 1 Electrical connections 2 Evaluation circuit 3 Membrane with sensor element 4 Pressure port 5 Fixing thread

Function description

Cross section of speed sensor

Basic function The electrical resistance varies on the layers applied to the membrane as they change shape. This deformation due to the accumulating system pressure alters the electrical resistance and causes a change in the voltage of the resistance bridge, which has a 5 V supply. This voltage is in the range of 0 to 70 mV (depending on the pressure) and is amplified in the evaluation circuit to between 0.5 and 4.5 V. Attention Never measure resistance on a pressure sensor.

LBH/Version 01/10.2006/en/nk/29.01.2007

! Malfunctions are indicated by service codes in display.

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Service manual

Diesel engine, Splitter box Fuel system

4.2

Fuel system Technical data See section 2.1

Design

LBH/Version 01/10.2006/en/nk/29.01.2007

The fuel tank is located behind the right cab access.

Fuel system 1 2 3 4

Tank cap Filler strainer Fuel level sensor Distributor port

5 Intake line 6 Return line 7 Diesel engine

8 Fuel cooler 9 Drain valve 10 Fuel tank

Function description The fuel is drawn up by the fuel pump via the intake line and fuel pre-filter (water and dirt separator) and is delivered to the injection elements via a fine filter.


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Fuel system

4.2.1

Fuel level sensor Design The fuel level sensor is fitted vertically in the tank. It is connected via a lead and plugs to the display unit. The sensor tube contains two electrodes to transmit the fuel level in the tank.

Function description The fuel level sensor tube 2 contains electrodes 3 which measure the fuel level using a capacitive resistor. The electronics in the head of the fuel level sensor 1 transmit a corresponding voltage signal of 1 V – 4 V to input module 1 – A16a pin 23. Input module 1 converts the signal to a digital signal and forwards it via the master electronics to the fuel level display in the display unit A13. The fuel level sensor is earthed via input module 1 – pin 65.

Fuel level display The lower the fuel level the higher the voltage and thus the level shown on the fuel level display.

LBH/Version 01/10.2006/en/nk/29.01.2007

The “reserve” fuel level is shown by the fuel level symbol field flashing.

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4.2.2

Fuel pre-filter The fuel pre-filter protects the engine's fuel system (pump, pump elements, injection valves, valves and pistons) from dirt and water penetration.

Design The fuel pre-filter acts as both a water separator and a filter. It is fitted in the fuel intake line between the engine control unit and the fuel pump. The intake line is connected via the engine control unit (cooler) to the fuel tank. The outlet line is connected to the fuel pump. The water probe in the water collector monitors the condensate in the fuel pre-filter; if the water level is too high, it generates a service code via the engine control unit to the display unit.

Fuel pre-filter 1 Hand pump 2 Filter head 3 Filter cartridge

LBH/Version 01/10.2006/en/nk/29.01.2007

4 Water collector 5 Drain cock 6 Water sensor


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Fuel system

4.2.3

Fuel fine filter Technical data See section 2.1

The filter can be serviced without any tools. The filter can be removed and replaced by hand during a service.

Design The fuel filter is a fine filter with a water drain valve and is fitted between the fuel pump and the injection pump. It has a disposable filter cartridge which must be replaced each time it is serviced.

Fuel fine filter 1 Filter head

2 Filter cartridge

Function description The fuel fine filter protects the fuel system from contamination.

The pressure of the fuel pump forces the fuel through the filter membrane. The filtered fuel then flows through the outlet in the filter head via the fuel line to the injection pump. The water in the fuel system is separated by the impregnation of the filter insert, and then settles in the filter at the bottom. The filter can be emptied during maintenance by opening the drain valve.

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The diesel fuel is pumped under pressure from the fuel pump through the filter intake into the filter insert.

Service manual


4.2.4

Refuelling pump (optional) Technical data See section 2.1

The refuelling pump is mounted on the right of the rear section. The refuelling pump is only suitable for diesel fuel. The refuelling system is designed to assist filling the diesel fuel from the container to the fuel tank.

Design

Main components of the refuelling pump

LBH/Version 01/10.2006/en/nk/29.01.2007

1 Intake connection 2 Pressure port 3 Supply pump

4 DC motor 5 Electrical connection

Components of the refuelling pump 1 2 3 4

Snap ring Check valve Intake housing Impeller


5 6 7 8

Seal Discharge housing Feather key DC motor

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9 Electrical connection 10 Carbon brush

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Fuel system

Function description Refuelling system

Refuelling pump The refuelling pump 5 is a rotary vane pump which draws in fuel via the intake line 6 and the intake line extension 7 with suction strainer 8, from the container 9 and pumps it through the discharge line 4 to the fuel tank 3 of the machine. The refuelling pump 5 can be switched on and off using the removable key 2. The refuelling pump 5 is filled with fuel via the discharge line before it is first used. This means it is self-priming. The diesel fuel also lubricates the mechanical seals in the pump. A check valve in the intake port prevents the refuelling pump 5 from running empty. This means the pump remains self-priming. The DC motor does not have internal thermal protection; it is designed to run for a maximum of 15 minutes.

LBH/Version 01/10.2006/en/nk/29.01.2007

The external 20 amp fuse F05 (fitted in the instrument panel) protects the pump from short-circuits and overload.

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Service manual

Diesel engine, Splitter box Air filter system

4.3

Air filter system Design

Air filter system 1 Rain cap 2 Fixing clips 3 Air filter

4 Vacuum switch 5 Filtered air intake manifold 6 Fixing clips

Function description The engine takes in fresh air via the rain cap 3 and the air filter 5. The filtered air is provided to the engine via the turbocharger.

4.3.1

Air filter

LBH/Version 01/10.2006/en/nk/29.01.2007

Design

Air filter 1 Secondary element 2 Primary element 3 Service cap


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4 Fixing clips 5 Dust extraction valve 6 Air filter housing

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Air filter system

Function description Air filter unit The primary element 2 and the secondary element 1 of the dry air filter are designed to ensure maximum protection for the engine at very long service intervals. The primary element 2 with radial sealing at the filtered air connection in the filter housing 6 is subject to scheduled and non-scheduled maintenance. The secondary element 1 acts as a back-up if the primary element 2 is damaged. The secondary element 1 is not a service filter. It must be replaced if necessary. The dust extraction valve 5 automatically removes dust from the service cap 3. The tangential arrangement of the intake port sets the air into fast rotation, so that large dust particles are thrown by centrifugal force against the housing and accumulate in the service cap 3 due to the air flow. At idle speed, the accumulated dust particles in the service cap 3 are carried outside via the dust extraction valve 5 by the vibrations in the intake air. The service cap 3 must be fitted so that the dust extraction valve 5 points down. With the engine running at lower idle speed, you should clearly feel air pulsating at the dust extraction valve 5.

4.3.2

Vacuum switch (ID 6906001)

Technical data See section 2.1

Design

Vacuum switch arrangement 2 Air filter

Function description The vacuum switch 1 monitors the pressure ratio between the turbocharger and the air filter 2. If the filters are dirty (excessive vacuum) it activates the air contamination symbol field on the display unit.

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1 Vacuum switch

Service manual

Diesel engine, Splitter box Coupling

4.4

Coupling Technical data See section 2.1

Design The coupling is an elastic torsion and vibration absorber between the flywheel on the engine and the splitter box.

Position of the coupling LBH/Version 01/10.2006/en/nk/29.01.2007

1 Torsion absorber


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2 Flywheel

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Coupling

1 2 3 4

Torsion absorber assembly Hub Pressure springs Disc

5 6 7 8

Disc Fixing screw Flywheel housing Flywheel

The disc 5 is bolted to the flywheel 8 of the engine. The hub 2 is axially guided by circular discs riveted to the hub. The hub 2 can move radially on the disc 4. The springs 3 are arranged in a ring and form an elastic connection which transfers the torque between the disc 5 and the hub 2. The drive shaft of the splitter box is connected to the hub 2 by a spline shaft gearing.

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Main components of the torsion absorber

Service manual

Diesel engine, Splitter box Coupling

Function description Basic function The coupling is an elastic connection which also absorbs torque peaks between the engine and the driven splitter box. The coupling transmits the engine torque to the splitter box.

Power transmission The following components transmit the engine torque to the splitter box: – Flywheel 8 – Fixing screws 6 – Discs 4 and 5 – Pressure springs 3 – Hub 2

Damping

LBH/Version 01/10.2006/en/nk/29.01.2007

The springs 3 absorb load fluctuations and torque peaks on the engine crankshaft. The vibrations of the crankshaft are greatly reduced as torque is transmitted to the splitter box.


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LBH/Version 01/10.2006/en/nk/29.01.2007

Coupling

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Service manual

Diesel engine, Splitter box Splitter box

4.5

Splitter box Technical data See section 2.1

Design The splitter box is a single-stage spur gear transmission attached to the flywheel housing of the diesel engine.

Location of the splitter box

LBH/Version 01/10.2006/en/nk/29.01.2007

1 Working hydraulics pump 2 Steering hydraulics pump

3 Travel hydraulics pump 4 Pump distributor gear

Splitter box, rear view 1 2 3 4


Housing Dipstick Oil filler tube Pump connection for working and steering hydraulics

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5 Pump connection for travel hydraulics 6 Oil drain valve

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Service manual

Splitter box

Splitter box, front view Housing Dipstick Oil filler tube Pump connection for working and steering hydraulics

5 Oil drain valve 6 Pump connection for travel hydraulics

LBH/Version 01/10.2006/en/nk/29.01.2007

1 2 3 4

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Service manual

Diesel engine, Splitter box Splitter box

Cross section of the splitter box

LBH/Version 01/10.2006/en/nk/29.01.2007

1 2 3 4 5 6 7 8 9 10 11 12 13


Housing Stud screw Disc Hex nut O-ring Ball bearing Spur gear for working and steering pump Bearing flange O-ring Cylindrical roller bearing Bearing flange O-ring Spur gear for travel pump

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14 15 16 17 18 19 20 21 22 23 24 25

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Ball bearing O-ring Stud screw Hex nut Disc Ball bearing Cylindrical roller bearing Drive shaft Shaft seal ring Bearing flange O-ring Ball bearing

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Service manual

Splitter box

Function description Power transmission The splitter box transfers and distributes the engine torque to the hydraulic pumps for: – Travel hydraulics – Working hydraulics – Steering hydraulics

Input

LBH/Version 01/10.2006/en/nk/29.01.2007

The splitter box is directly driven by the flywheel of the engine via the elastic coupling.

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5 Cooling system 5.0 5

Cooling system.................................................................... 5.0-1 Gear pump ......................................................................................5.1-1

5.2

Gear motor......................................................................................5.2-1

5.3

Temperature sensor .......................................................................5.3-1

LBH/Version 01/10.2006/en/hd/22.02.2007

5.1


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Service manual

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Cooling system

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Service manual

Cooling system Cooling system

Design The cooling system is fitted on the rear section between the diesel engine and the driver's cab.

Cooler unit components Air conditioning condenser Diesel fuel cooler Hydraulic oil cooler Gear oil cooler Water cooler

6 Intercooler 7 Cooler support, cooler unit frame 8 Fan motor with proportional pressure relief valve 9 Fan blade

LBH/Version 01/10.2006/en/hd/22.02.2007

1 2 3 4 5


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Cooling system

Service manual

Cooling system

Cooling system components 4 5 6 7 8

Fan motor pressure line Fan pump intake line Fan pump Hydraulic tank Fan blade

9 Suction and return filter 10 Fan motor leak oil line / variable displacement motor bearing lubrication 11 Variable displacement motor 2 12 Cooler unit

LBH/Version 01/10.2006/en/hd/22.02.2007

1 Gear motor with proportional pressure relief valve 2 Fan motor in-line filter 3 Fan motor shaft seal leak oil line relief

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Function description Basic function The fan takes in air from the outside of the cooler units, and blows it over the cooling fins of the cooler units, through the engine and out again. The cooler system cools: – The engine coolant – The hydraulic oil – The engine charge air – The air conditioning condenser – The gear oil – The diesel fuel

Hydraulic fan speed control

Hydraulic plan of fan drive 1 2 3 4

Cooler unit Fan Gear motor Proportional pressure relief valve assembly

5 6 7 8 9

Triple pump Return strainer Ventilation and bleeder filter Suction and return filter Hydraulic tank

10 11 12 13 14

Bearing lubrication orifice Variable displacement motor 2 Bearing lubrication orifice Variable displacement motor 1 Collector pipe with safety valve

LBH/Version 01/10.2006/en/hd/22.02.2007

The speed of the hydrostatically driven fan depends on the engine speed (pump flow) and the fluid temperatures or the status of the air conditioning system.


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Cooling system

Service manual

Cooling system

Electric fan speed control

Block diagram of cooling system 1 2 3 4 5 6 7

Engine electronics (LH-ECU) Input module 1 Main electronics (master) Output module 1 Cooler unit Gear motor in-line filter Fan

8 Proportional pressure relief valve Y13 9 Gear motor 10 Coolant temperature sensor (B708) 11 Gear pump

12 Diesel engine 13 Charge air temperature sensor (B707) 14 Hydraulic oil temperature sensor (B8) 15 Hydraulic tank

The main electronics (master) A15 process the following parameters: – The values of the hydraulic oil temperature sensor B8 – The values of the coolant temperature sensor B708 – The values of the charge air temperature sensor B707 The signals are provided by the engine controller (LH-ECU) and input module 1 of the main electronics (master) A15 via CAN bus. The main electronics (master) A15 calculate the current for the proportional pressure relief valve Y13 and generate a signal via output module 1. When the air conditioning system is on, the main electronics (master) A15 regulate the fan current to the value set using SCULI. This current controls the proportional pressure relief valve Y13 on the gear motor and therefore the fan speed. A high temperature means a low current at the proportional pressure relief valve Y13.

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LBH/Version 01/10.2006/en/hd/22.02.2007

The fan speed is controlled by: – The charge air temperature sensor B707 in the intake pipe – The coolant temperature sensor B708 in the cooling water circuit – The hydraulic oil temperature sensor B8 in the hydraulic oil circuit – The proportional pressure relief valve Y13 on the gear motor – The status of the air conditioning system – The main electronics (master) A15

Service manual


If the hydraulic oil sensor B8 records overheating, the following functions are activated: – Above 88 °C the current to the proportional pressure relief valve Y13 is reduced to 0 mA. This turns the fan motor M1 at maximum speed. – Above 90 °C the display unit shows service code E A02A, a warning tone sounds every 10 seconds and the hydraulic oil overheating warning lamp H23 is activated. – From 90 °C to 100 °C the current to the control pressure proportional valve is reduced gradually to 40 % (tractive force reduction). If the coolant sensor B708 records overheating, the following functions are activated: – Above 97 °C the current to the proportional pressure relief valve Y13 is reduced to 0 mA. This turns the fan motor M1 at maximum speed. In addition, the display unit shows service code E A02A, a warning tone sounds every 10 seconds and the coolant overheating symbol field (H13) is activated. – From 100 °C to 105 °C the current to the control pressure proportional valve is reduced gradually to 40 % (tractive force reduction). If the charge air sensor B707 records overheating, the following functions are activated: – Above 75 °C the service code E6001 appears in the display unit, accompanied by a warning tone. The engine power is reduced in increments.

Diagram of electric current and fan speed

LBH/Version 01/10.2006/en/hd/22.02.2007

1 2 3 4


Fan speed Current to proportional valve (mA) Engine speed Fan speed (rated speed)

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5 Fan speed with no current to proportional pressure relief valve Y13 6 Fan speed at low temperature (minimum speed)

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Cooling system

Service manual

Cooling system

Tables of system pressure, electric current and fan speed Valid for:

L550 - 456 / from 14171; L556 - 454 / from 14171;

Fan control At upper engine speed Hydraulic oil up to 55 °C, coolant up to 88 °C At upper engine speed Hydraulic oil 55 - 73 °C, coolant 88 - 93 °C At upper engine speed Hydraulic oil 73 - 88 °C, coolant 93 - 97 °C Temperature sensor unplugged At upper engine speed, hydraulic oil above 88 °C, coolant above 97 °C, proportional solenoid de-energised. Also suitable for setting the pressure relief valve

System pressure

Current

Fan speed

30 bar

900 mA

500 rpm

30 - 110 bar

900 - 580 mA

500 - 1650 rpm

110 ±10 bar

580 mA

1650 rpm

220 ±10 bar

De-energised

2050 rpm

When the air conditioning system is on and the air conditioning compressor coupling is on, the current is reduced from 900 mA to 750 mA. Valid for:


Fan control At upper engine speed Hydraulic oil up to 55 °C, coolant up to 88 °C At upper engine speed Hydraulic oil 55 - 73 °C, coolant 88 - 93 °C At upper engine speed Hydraulic oil 73 - 88 °C, coolant 93 - 97 °C Temperature sensor unplugged At upper engine speed, hydraulic oil above 88 °C, coolant above 97 °C, proportional solenoid de-energised. Also suitable for setting the pressure relief valve

System pressure

Current

Fan speed

40 bar

850 mA

250 rpm

40 - 175 bar

850 - 360 mA

250 - 1400 rpm

175 ±10 bar

360 mA

1400 rpm

220 ±10 bar

De-energised

1600 rpm

LBH/Version 01/10.2006/en/hd/19.03.2007

When the air conditioning system is on and the air conditioning compressor coupling is on, the current is reduced from 850 mA to 650 mA.

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Service manual

Cooling system Gear pump

5.1 Gear pump Technical data See section 2.1

Design

Gear pump arrangement 1 Fan circuit test connection 2 Cooling system gear pump

3 Brake system gear pump 4 Motor scavenging pump

The gear pumps are fitted on the auxiliary drive of the engine and is driven by the engine at a specific transmission ratio via a spur gear.

LBH/Version 01/10.2006/en/hd/22.02.2007

The pumps are connected to each other on the shaft via actuator rings. The pumps are sealed against each other. The intake side of the cooler gear pump 2 is connected to the hydraulic tank, and the discharge side is connected to the gear motor on the fan housing.

Gear pump components 1 2 3 4


Shaft seal ring Flange Seals Bearing bushings

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5 Gears 6 Housing 7 Housing cover

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Cooling system

Service manual

Gear pump

Function description Basic function The gear pump consists of two intermeshing gears enclosed in a housing. One of the two gears is driven via the outgoing shaft (driving gear), and the other driven by the gear teeth (driven gear). The fluid taken in is injected into the gaps between the teeth and pumped outside along the housing from the intake port to the pressure port.

Pressure cut-off

LBH/Version 01/10.2006/en/hd/22.02.2007

The cooling system gear pump pressure cut-off is performed by the pressure relief valve on the gear motor.

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Service manual

Cooling system Gear motor

5.2 Gear motor Technical data See section 2.1

The gear motor is fitted to the fan housing. The gear motor drives the fan blades via a shaft. The proportional pressure relief valve attached to the gear motor controls the fan speed.

Design

Gear motor with proportional pressure relief valve

LBH/Version 01/10.2006/en/hd/22.02.2007

1 Gear motor 2 Fan drive shaft

3 Proportional pressure relief valve

Gear motor with proportional pressure relief valve 1 2 3 4 5 6

Bearing cover Seal kit Bearing bushing Gears Bearing bushing Motor housing


7 Seal kit 8 Proportional pressure relief valve connecting housing 9 Proportional pressure relief valve 10 O-ring

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O-ring Shaft Roller bearing Shaft seal ring Bearing cover

5.2-1 o f 4

Cooling system

Service manual

Gear motor

Proportional pressure relief valve 1 2 3 4 5

Pressure relief adjusting screw Counter nut Cap Electromagnet Electromagnet connection

6 7 8 9

Secondary spring Housing Secondary piston Secondary restrictor

10 11 12 13

Housing Primary spring Main piston Primary restrictor

Function description Basic function The gear motor 1 is powered by the current from the gear pump.

Diagram of fan motor 1 Gear motor 2 Proportional pressure relief valve assembly 3 Proportional pressure relief valve 4 Main piston

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P Pump intake T1 Return line to variable displacement motors (bearing flushing) T2 Relief seal (return to tank)


LBH/Version 01/10.2006/en/hd/22.02.2007

The gear motor 1 has a proportional pressure relief valve 3, which controls the speed of the gear motor and therefore the fan speed.

Service manual

Cooling system Gear motor

Pressure regulation by the proportional pressure relief valve

How the proportional pressure relief valve works When the solenoid 1 is not energised, the proportional pressure relief valve acts like a pilot-controlled pressure relief valve. The pressure acting at “P” passes through the primary restrictor 8 to the spring chamber of the main piston 7 and acts via the secondary restrictor 5 on the secondary piston 4. The pressure equalisation on the main piston 7 causes the primary spring 6 to close it. If the pressure on the secondary piston 4 becomes so high that the set force of the secondary spring 2 is exceeded, the secondary piston 4 opens, allowing oil to flow into the tank chamber. This gives rise to a difference in pressure in front of and behind the main piston 7, causing it to open. If the solenoid 1 is energised, a magnetic force is generated depending on the current. The magnetic force acts on the iron core 3, pulling it back according to the current strength. This magnetic force reduces the set spring force of the secondary spring 2 accordingly. This causes the proportional valve to open at a lower system pressure.

Fan speed regulation The proportional pressure relief valve acts as a bypass on the gear motor. LBH/Version 01/10.2006/en/hd/22.02.2007

At low temperature the bypass is almost fully open. Most of the pump flow goes through the bypass valve to the tank. The fan turns at low speed (minimum speed = dragging speed). As the temperature rises, the bypass valve closes proportionally. The gear motor turns the fan faster.

Failsafe function The failsafe function is as follows: if the power supply to the proportionally controlled pressure relief valve fails, the bypass closes. The full flow of the gear pump drives the gear motor. The fan turns at maximum speed.


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Cooling system

Service manual

LBH/Version 01/10.2006/en/hd/22.02.2007

Gear motor

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Service manual

Cooling system Temperature sensor

5.3 Temperature sensor (ID 10043264)


The temperature sensor is used for measuring the temperature of the hydraulic oil.

Design The sensor element of the temperature sensor consists of an encapsulated thin-layer nickel resistor.

Temperature sensor

Function description Temperature measurement

Temperature/resistance curve The sensor is a temperature sensor with an NTC characteristic. This means, the resistance in the sensor rises along with the temperature.

LBH/Version 01/10.2006/en/hd/22.02.2007

The resistance curve of the temperature sensor is almost linear. For the coolant and charge air temperature sensors, see the section on the ENGINE.


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Service manual

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Temperature sensor

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6 Travel Hydraulics 6.0 Chapter contents 6

Travel Hydraulics ................................................................ 6.0-1 6.0.1

Travel hydraulics – L550, L556 ............................................6.0-1

6.0.2

Travel hydraulics – L566, L576, L580 ..................................6.0-9

6.1

Variable displacement pump ..........................................................6.1-1

6.2

Variable displacement motors ........................................................6.2-1 Variable adjustment motor ...................................................6.2-3

6.2.2

Motor scavenging pump .......................................................6.2-8

LBH/Version 01/10.2006/en/dw/26/01/2007

6.2.1


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Travel Hydraulics

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Service Manual

Travel Hydraulics 6.0.1 Valid for:

Travel hydraulics – L550, L556 L550 - 456 / from 16978; L556 - 454 / from 15653

Design

LBH/Version 01/10.2006/en/dw/26/01/2007

Main components of the travel hydraulics 1 2 3 4

Hydraulic tank Variable displacement pump Overspeed protection solenoid valve Collector pipe

L550 - 456 / from 16978 L556 - 454 / from 15653

5 Oil cooler 6 Variable displacement motor 1 7 Variable displacement motor 2

8 Scavenging pump 9 Fan pump 10 Fan motor

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Travel Hydraulics

PowerPoint

Service Manual Function description

LBH/Version 01/10.2006/en/dw/26/01/2007

Basic function

Hydraulic plan of the travel hydraulics

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Service Manual

1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22

Hydraulic tank Bleeder filter Return strainer Bypass valve Return suction filter Pre-tension valve Replenishing valve with strainer Working hydraulics pump leak oil Solenoid valve block return oil Compact brake pump leak oil Control block return oil Shut-off valve Working hydraulics pump intake port Steering pump intake port Emergency steering pump intake port Hydraulic oil temperature sensor Gear pump fan Brake system gear pump Motor scavenging pump Variable displacement pump assembly Axial piston pump Travel direction valve

Travel Hydraulics

23 Servo cylinder 24 Restrictor ∅ 1.8 mm 25 Pressure relief and replenishing valve A 26 Pressure relief and replenishing valve B 27 Replenishing pressure relief valve 28 Pressure cut-off 29 Control pressure proportional valve 30 Replenishing pump 31 To working hydraulics pilot control 32 Bypass valve 33 Variable displacement motor 1 assembly 34 Axial piston drive unit 35 Check valves 36 Proportional valve and piston rod 37 Servo piston 40 Variable displacement motor 2 assembly 41 Axial piston drive unit 42 Check valves 43 Proportional valve and piston rod 44 Servo piston 45 Discharge valve

46 Pressure relief valve with orifice 47 Orifice ∅ 4.2 mm 50 Fan motor assembly 51 Main piston 52 Pressure relief and proportional valve 53 Gear motor 54 Fan blade 55 Oil cooler 56 Bypass valve 57 Collector pipe 58 Return oil from servostat Test connections: PST Control pressure / variable displacement pump G Replenishing pressure MA High pressure / forward travel direction MB High pressure / reverse travel direction M1 Servo pressure / variable displacement motor 1 M2 Servo pressure / variable displacement motor 2 P High pressure / fan

The hydrostatic travel drive operates in a closed circuit. The variable displacement pump 20 pumps oil directly to the variable displacement motors 33 and 40. The oil returning from the variable displacement motors is pumped back to the intake side of the variable displacement pump. 1st gear: At low speed or high tractive force, both motors pivot out to a wide angle. This provides a low output speed and a high torque to the motors. If the travel speed is increased, both motors pivot inwards. 2nd gear: Motor 33 is uncoupled (not turning) and at an angle of 0°. Motor 40 moves to a certain angle depending on the travel speed. 3rd gear: Motor 40 is uncoupled (not turning) and at an angle of 0°. Motor 33 moves to a certain angle depending on the travel speed. Maximum travel speed is achieved at an angle of approximately 15°.

Variable displacement pump LBH/Version 01/10.2006/en/dw/26/01/2007

The variable displacement pump operates in a closed circuit. It pumps the oil directly to the variable displacement motors. The oil flowing back from the motors is fed back to the intake side of the pump. The main electronics (master) control the pump. Depending on the operating state of the machine, the control pressure proportional valve 5 is activated by the main electronics. The proportional valve regulates the control pressure and therefore the pump flow. At high load, the pump is adjusted to a lower displacement by the reaction forces from the high pressure. The travel direction valve 3 determines the direction in which the displacement pump operates and thus the travel direction of the machine. The pressure cut-off 2 limits the maximum operating pressure within the closed circuit. The pressure relief valves 4 for forward and reverse travel direction protect the travel drive from excessive pressure peaks. L550 - 456 / from 16978 L556 - 454 / from 15653

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Travel Hydraulics

Service Manual See the detailed description in the section on the variable displacement pump. Variable displacement pump regulation The main electronics (master) control the variable displacement pump. The following parameters affect the control of the pump: – Gas pedal position – Inching function – Tractive force control – Excess hydraulic oil or coolant temperature – Engine overspeed or excessive road speed

Gas pedal position

When gas pedal is depressed, the current to the control pressure proportional valve is increased and the variable displacement pump pivots out. The control pressure proportional valve is only energised when the engine speeds exceeds 930 rpm. The current is then increased to the set value according to the engine speed.

Inching function

When the inch/brake pedal is depressed, the main electronics (master) reduce the current to the control pressure proportional valve and hydrostatic braking takes place. At excess engine speeds of 2450 rpm and above, the inching function is gradually reduced, and at 2600 rpm it is completely deactivated. This prevents engine overspeed when travelling downhill. If the inching angle sensor fails, the inching function is gradually deactivated within 20 seconds.

Tractive force adjustment

If tractive force control is activated, the main electronics (master) reduce the maximum current to the control pressure proportional valve. This restricts the tractive force to the set level. The following parameters are required for tractive force control: – The tractive force control button must be switched on – The machine must be moving forward – The machine must be in 1st gear (even with kickdown) You can use the two buttons to adjust the tractive force as required in a range of 100% to 70%.

Overheating

If the hydraulic oil (90 - 95 °C) or the coolant (90 - 100 °C) overheats, the main electronics (master) reduce the current to the control pressure proportional valve. The current is reduced gradually to 40% of the maximum level. The control pressure proportional valve is energised normally again when the temperature falls back below the threshold.

Engine overspeed or excessive road speed

Above a certain speed in each gear, the main electronics (master) starts gradually reducing the current to the control pressure proportional valve to 200 mA. At even higher road speeds or engine or motor overspeed, the overspeed protection function is activated. The rear axle is braked using replenishing pressure from the variable displacement pump.

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LBH/Version 01/10.2006/en/dw/26/01/2007

Tractive force control is gradually disabled as the speed increases from 0.3 to 4 km/h.

Service Manual

Travel Hydraulics Variable displacement motors The variable displacement motors drive the transmission. A higher or lower torque is transferred to the transmission, depending on the pivot angle and pressure.

The flow from the displacement pump reaches the variable displacement motor via pressure connection A or B. In the process, the regulating pistons which move along the cylinder of the rotary group are subjected to pressure. The resulting force turns the drive shaft and generates a certain torque. The main electronics (master) control the motors. Depending on the operating state of the machine, the proportional valves 3 on the variable displacement motors are activated by the main electronics. This adjusts the pivot angle and displacement to the current operating condition. The discharge valve 4 in the variable displacement motor 2 is employed in the closed circuit to avoid heat build-up. In the process, oil is discharged from the low pressure side of the closed circuit and fed to the hydraulic tank. The replenishing pump replaces this oil with cooled oil. Variable displacement motor regulation

LBH/Version 01/10.2006/en/dw/26/01/2007

The main electronics (master) control the variable displacement motors. The following parameters affect the control of the motors: – Road speed – Gas pedal position – Variable displacement motor power limiting control (excessive engine suppression) – Inching function – Tempomat – Engine overspeed or excessive road speed

Road speed

The proportional valves on the motors are energised according to the speed. The lower the current at the proportional valve of the motors, the smaller the pivot angle and the displacement of the motor.

Gas pedal position

L550 - 456 / from 16978 L556 - 454 / from 15653

The gas pedal governs how the motors pivot to a smaller angle. This accelerates the machine.

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Travel Hydraulics

Service Manual

Variable displacement motor power limiting control

Power limiting control comes into affect when the engine is excessively suppressed due to load. This can occur while driving and additionally operating the working hydraulics or steering. The main electronics (master) increase the current at the proportional valve of the motors until the engine speed is back in the normal range. The motors then pivot out again.

Inching function

When the inch/brake pedal is depressed, the main electronics (master) increase the current to the motor proportional valve and hydrostatic braking takes place.

Vmax function

With the Vmax function, the motors move towards a set displacement which corresponds to the preselected speed at full throttle. This means that the road speed decreases as the engine speed is reduced. The function is only activated when travelling forward in first or second fixed gear. The current speed when the Vmax button is pressed is stored. The machine then reaches this speed at full throttle.


If the engine overrevs when travelling downhill, the motors pivot to a smaller angle. If the engine speed exceeds a critical level, overspeed protection is activated. The rear axle is braked. Overspeed protection is also activated if the variable displacement motors overrev.

During bearing flushing, fresh, cooled oil is directed to the tapered roller bearings and into the housing of the variable displacement motors. The hot oil is pumped out. The return oil from the fan motor 1 is pumped to the port U of the motors. The orifice 10 ensures that the oil is distributed evenly to both motors.

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Variable displacement motor bearing flushing

Service Manual

Travel Hydraulics The scavenging pump 2 draws oil from the connection T on both variable displacement motors. The hot oil flows to the collector pipe 7 and the oil cooler 6, and through the return suction filter 4 back to the hydraulic tank 5.

Hydraulic tank The hydraulic tank provides filtered oil for the replenishing pump of the travel hydraulics. The replenishing pump draws up oil from the hydraulic tank via the connection 1. A pre-tension valve in the return suction filter 3 preloads the suction side of the replenishing pump with a pressure of 0.5 bar. The replenishing pump is better able to draw up the oil for cold starts. This means that the pressure in the hydrostatic control circuit increases more quickly and a better drive performance is achieved. The oil returning from the travel hydraulics is directed over the oil cooler. The oil is then pumped back through the connection 2 and the return suction filter 3 to the hydraulic tank. The bleeder filter 4 compensates for pressure differences inside the hydraulic tank by providing appropriate ventilation.

LBH/Version 01/10.2006/en/dw/26/01/2007

See the detailed description in the section on the hydraulic tank.

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Service Manual

LBH/Version 01/10.2006/en/dw/26/01/2007

Travel Hydraulics

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Service Manual

Travel Hydraulics 6.0.2 Valid for:

Travel hydraulics – L566, L576, L580 L566 - 460 / from 14171; L576 - 457 / from 14171; L580 - 457 / from 14171

Design

LBH/Version 01/10.2006/en/dw/26/01/2007

Main components of the travel hydraulics 1 2 3 4

Hydraulic tank Variable displacement pump Overspeed protection solenoid valve Collector pipe


5 Oil cooler 6 Variable displacement motor 1 7 Variable displacement motor 2

8 Scavenging pump 9 Fan pump 10 Fan motor

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Travel Hydraulics PowerPoint


LBH/Version 01/10.2006/en/dw/26/01/2007

Basic function

Hydraulic plan of the travel hydraulics

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Service Manual

1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23

Hydraulic tank Bleeder filter Return strainer Bypass valve Return suction filter Pre-tension valve Replenishing valve with strainer Working hydraulics pump leak oil Solenoid valve block return oil Compact brake pump leak oil Control block return oil Shut-off valve Working hydraulics pump intake port Steering pump intake port Emergency steering pump intake port Hydraulic oil temperature sensor Gear pump fan Brake system gear pump Motor scavenging pump Variable displacement pump assembly Axial piston pump Travel direction valve Servo cylinder

Travel Hydraulics

24 Restrictor ∅ 1.8 mm 25 Pressure relief and replenishing valve A 26 Pressure relief and replenishing valve B 27 Replenishing pressure relief valve 28 Pressure cut-off 29 Control pressure proportional valve 30 Replenishing pump 31 To working hydraulics pilot control 32 Bypass valve 33 Variable displacement motor 1 assembly 34 Axial piston drive unit 35 Check valves 36 Proportional valve and piston rod 37 Servo piston 38 Discharge valve 39 Pressure relief valve with orifice 40 Variable displacement motor 2 assembly 41 Axial piston drive unit 42 Check valves 43 Proportional valve and piston rod 44 Servo piston

45 Discharge valve 46 Pressure relief valve with orifice 47 Orifice ∅ 4.2 mm 50 Fan motor assembly 51 Main piston 52 Pressure relief and proportional valve 53 Gear motor 54 Fan blade 55 Oil cooler 56 Bypass valve 57 Collector pipe 58 Return oil from servostat Test connections: PST Control pressure / variable displacement pump G Replenishing pressure MA High pressure / forward travel direction MB High pressure / reverse travel direction M1 Servo pressure / variable displacement motor 1 M2 Servo pressure / variable displacement motor 2 P High pressure / fan

The hydrostatic travel drive operates in a closed circuit. The variable displacement pump 20 pumps oil directly to the variable displacement motors 33 and 40. The oil returning from the variable displacement motors is pumped back to the intake side of the variable displacement pump. 1st gear: At low speed or high tractive force, both motors pivot out to a wide angle. This provides a low output speed and a high torque to the motors. If the travel speed is increased, both motors pivot inwards. 2nd gear: Motor 33 is uncoupled (not turning) and at an angle of 0°. Motor 40 moves to a certain angle depending on the travel speed. 3rd gear: Motor 40 is uncoupled (not turning) and at an angle of 0°. Motor 33 moves to a certain angle depending on the travel speed. Maximum travel speed is achieved at an angle of approximately 15°.

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Variable displacement pump The variable displacement pump operates in a closed circuit. It pumps the oil directly to the variable displacement motors. The oil flowing back from the motors is fed back to the intake side of the pump. The main electronics (master) control the pump. Depending on the operating state of the machine, the control pressure proportional valve 5 is activated by the main electronics. The proportional valve regulates the control pressure and therefore the pump flow. At high load, the pump is adjusted to a lower displacement by the reaction forces from the high pressure. The travel direction valve 3 determines the direction in which the displacement pump operates and thus the travel direction of the machine. The pressure cut-off 2 limits the maximum operating pressure within the closed circuit. L566 - 460 / from 14171 L576 - 457 / from 14171 L580 - 459 / from 14171

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Service Manual The pressure relief valves 4 for forward and reverse travel direction protect the travel drive from excessive pressure peaks. See the detailed description in the section on the variable displacement pump. Variable displacement pump regulation The main electronics (master) control the variable displacement pump. The following parameters affect the control of the pump: – Gas pedal position – Inching function – Tractive force control – Excess hydraulic oil or coolant temperature – Engine overspeed or excessive road speed

Gas pedal position

When gas pedal is depressed, the current to the control pressure proportional valve is increased and the variable displacement pump pivots out. The control pressure proportional valve is only energised when the engine speeds exceeds 930 rpm. The current is then increased to the set value according to the engine speed.

Inching function

When the inch/brake pedal is depressed, the main electronics (master) reduce the current to the control pressure proportional valve and hydrostatic braking takes place. At excess engine speeds of 2450 rpm and above, the inching function is gradually reduced, and at 2600 rpm it is completely deactivated. This prevents engine overspeed when travelling downhill. If the inching angle sensor fails, the inching function is gradually deactivated within 20 seconds.

Tractive force adjustment

If tractive force control is activated, the main electronics (master) reduce the maximum current to the control pressure proportional valve. This restricts the tractive force to the set level. The following parameters are required for tractive force control: – The tractive force control button must be switched on – The machine must be moving forward – The machine must be in 1st gear (even with kickdown) You can use the two buttons to adjust the tractive force as required in a range of 100% to 70%.

Overheating

If the hydraulic oil (90 - 95 °C) or the coolant (90 - 100 °C) overheats, the main electronics (master) reduce the current to the control pressure proportional valve. The current is reduced gradually to 40% of the maximum level. The control pressure proportional valve is energised normally again when the temperature falls back below the threshold.


Above a certain speed in each gear, the main electronics (master) starts gradually reducing the current to the control pressure proportional valve to 200 mA. At even higher road speeds or engine or motor overspeed, the overspeed protection function is activated. The rear axle is braked using replenishing pressure from the variable displacement pump.

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Tractive force control is gradually disabled as the speed increases from 0.3 to 4 km/h.

Service Manual

Travel Hydraulics Variable displacement motors The variable displacement motors drive the transmission. A higher or lower torque is transferred to the transmission, depending on the pivot angle and pressure.

The flow from the displacement pump reaches the variable displacement motor via pressure connection A or B. In the process, the regulating pistons which move along the cylinder of the rotary group are subjected to pressure. The resulting force turns the drive shaft and generates a certain torque. The main electronics (master) control the motors. Depending on the operating state of the machine, the proportional valves 3 on the variable displacement motors are activated by the main electronics. This adjusts the pivot angle and displacement to the current operating condition. The discharge valve 4 in the variable displacement motors 1 and 2 is employed in the closed circuit to avoid heat build-up. In the process, oil is discharged from the low pressure side of the closed circuit and fed to the hydraulic tank. The replenishing pump replaces this oil with cooled oil. Variable displacement motor regulation

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The main electronics (master) control the variable displacement motors. The following parameters affect the control of the motors: – Road speed – Gas pedal position – Variable displacement motor power limiting control (excessive engine suppression) – Inching function – Tempomat – Engine overspeed or excessive road speed

Road speed

The proportional valves on the motors are energised according to the speed. The lower the current at the proportional valve of the motors, the smaller the pivot angle and the displacement of the motor.

Gas pedal position


The gas pedal governs how the motors pivot to a smaller angle. This accelerates the machine.

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Service Manual

Variable displacement motor power limiting control

Power limiting control comes into affect when the engine is excessively suppressed due to load. This can occur while driving and additionally operating the working hydraulics or steering. The main electronics (master) increase the current at the proportional valve of the motors until the engine speed is back in the normal range. The motors then pivot out again.

Inching function

When the inch/brake pedal is depressed, the main electronics (master) increase the current to the motor proportional valve and hydrostatic braking takes place.

Vmax function

With the Vmax function, the motors move towards a set displacement which corresponds to the preselected speed at full throttle. This means that the road speed decreases as the engine speed is reduced. The function is only activated when travelling forward in first or second fixed gear. The current speed when the Vmax button is pressed is stored. The machine then reaches this speed at full throttle.


If the engine overrevs when travelling downhill, the motors pivot to a smaller angle. If the engine speed exceeds a critical level, overspeed protection is activated. The rear axle is braked. Overspeed protection is also activated if the variable displacement motors overrev.

During bearing flushing, fresh, cooled oil is directed to the tapered roller bearings and into the housing of the variable displacement motors. The hot oil is pumped out. The return oil from the fan motor 1 is pumped to the port U of the motors. The orifice 10 ensures that the oil is distributed evenly to both motors.

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Service Manual

Travel Hydraulics The scavenging pump 2 draws oil from the connection T on both variable displacement motors. The hot oil flows to the collector pipe 7 and the oil cooler 6, and through the return suction filter 4 back to the hydraulic tank 5.

Hydraulic tank The hydraulic tank provides filtered oil for the replenishing pump of the travel hydraulics. The replenishing pump draws up oil from the hydraulic tank via the connection 1. A pre-tension valve in the return suction filter 3 preloads the suction side of the replenishing pump with a pressure of 0.5 bar. The replenishing pump is better able to draw up the oil for cold starts. This means that the pressure in the hydrostatic control circuit increases more quickly and a better drive performance is achieved. The oil returning from the travel hydraulics is directed over the oil cooler. The oil is then pumped back through the connection 2 and the return suction filter 3 to the hydraulic tank. The bleeder filter 4 compensates for pressure differences inside the hydraulic tank by providing appropriate ventilation.

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Service Manual

Travel Hydraulics Variable displacement pump

6.1 Variable displacement pump Technical data See section 2.1

Design

Main components of the variable displacement pump 1 Drive shaft 2 Pump housing 3 Servo cylinder

4 Travel direction valve 5 Connection housing

The variable displacement pump is flange-mounted to the splitter box and is driven by the diesel engine via this unit. The variable displacement pump is an axial piston pump with a swash plate design. The variable displacement pump contains proportional valves for the control pressure and pressure cut-off, as well as a replenishing pressure valve, pressure relief and replenishing valve, and a replenishing pump.

LBH/Version 01/10.2006/en/dw/26/01/2007

The following diagrams illustrate the design of the variable displacement pump:


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Service Manual

Variable displacement pump

Components of the variable displacement pump, side view Drive shaft Shaft seal ring Snap ring Pump housing Servo piston Travel direction valve Control pressure proportional valve Pressure cut-off Connection housing Disc Replenishing pump housing Coupling hub

13 14 15 16 17 18 19 20 21 22 23

Bearing bushing Internal gear External gear Bearing bushing Bearing bushing Bushing Control lens Snap ring Pressure spring Bushing Cylinder

24 25 26 27 28 29 30 31 32 33 34

Piston Return ball Return plate Glide shoe Disc springs Swash plate Guide pin Pin Swash plate bearing Roller bearing Snap ring

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1 2 3 4 5 6 7 8 9 10 11 12

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Components of the variable displacement pump, servo cylinder and servo valve view Servo piston Pump housing Spring cup Pressure spring Pressure spring Turcon-Glyd seal Guide ring Solenoid

9 10 11 12 13 14 15 16

Pressure cut-off Travel direction valve Control pressure proportional valve Connection housing Pressure relief and replenishing valve Replenishing pressure relief valve Twist screw Solenoid

17 Receptacle ring 18 Adjusting screw for the pump zero position 19 Counter nut 20 Spring cup 21 Snap ring 22 Cover

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1 2 3 4 5 6 7 8


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Components of the variable displacement pump, front view 4 Restrictor 5 Plug 6 Replenishing pressure relief valve

7 Pressure relief and replenishing valve

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1 Pressure cut-off 2 Connection housing 3 Pressure relief and replenishing valve

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Service Manual


Function description Basic function

Hydraulic plan of the variable displacement pump 1 2 3 4 5

Variable displacement pump Servo cylinder Travel direction valve Restrictor Pressure relief and replenishing valve A 6 Pressure relief and replenishing valve B

7 Replenishing pressure relief valve 8 Pressure cut-off 9 Control pressure proportional valve 10 Replenishing pump 11 Suction line from replenishing pump 12 To working hydraulics pilot control 13 To the oil cooler

The variable displacement pump is designed for hydrostatic drives in a closed circuit. The pump delivers directly to the variable displacement motors. The oil flowing back from the motors is fed back to the opposite side of the pump. The main electronics (master) control the pump. Depending on the operating state of the machine, the control pressure proportional valve 9 is activated by the main electronics (master). The proportional valve regulates the control pressure and therefore the pump flow. LBH/Version 01/10.2006/en/dw/26/01/2007

At high load, the pump is adjusted to a lower displacement by the reaction forces from the high pressure. The travel direction valve determines the direction in which the displacement pump operates and the travel direction of the machine. The pressure relief and replenishing valves A and B protect the travel drive from excessive pressure peaks. At the same time, the valves act as replenishing valves for the closed circuit. The pressure cut-off limits the maximum operating pressure within the closed circuit.


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Control of the pump The main electronics (master) control the pump. Depending on the operating state of the machine, the control pressure proportional valve is activated by the main electronics. The proportional valve regulates the control pressure and therefore the pump flow. The following parameters affect the control of the pump: – Gas pedal position – Inching function – Tractive force control – Excess hydraulic oil or coolant temperature – Engine overspeed or excessive road speed

Control pressure proportional valve Depending on the operating state of the machine, the control pressure proportional valve is activated by the main electronics (master). The valve reduces the pressure in the PST channel in proportion to the magnet current. It operates largely independently of the PSP control pressure.

In the de-energised state, the PST control pressure duct is connected to the tank T. The more the current increases, the higher the control pressure. The maximum level is limited by the replenishing pressure. Depending on the current to the proportional valve 3, the control piston 2 is moved closer to or further from the regulating springs 1. This adjusts the pressure in the PST duct.

Servo piston and swash plate

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The servo piston 3 turns the swash plate 2 mounted on roller bearings and thus changes the pump flow rate of the pump.

Servo piston and swash plate

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1 Swash plate bearing 2 Swash plate

3 Servo piston 4 Cylinder with piston

As the swivel angle increases, the pump flow is increased. The drive torque is increased. When the swivel angle is reduced, the flow rate of the pump is also reduced. The drive torque is reduced. When in the zero position, the pump flow is also zero. The strong spring centring in the servo cylinder keeps the swash plate in the zero position if no control signals are present. The zero position can be mechanically adjusted.

Sectional view of the servo cylinder 1 2 3 4

Pump housing Pressure spring Servo cylinder Forward travel direction servo oil supply

5 Reverse travel direction servo oil supply 6 Pressure spring 7 Zero position adjusting screw

On traversing the zero position, the flow direction of the hydraulic oil is smoothly reversed.

Travel direction valve The travel direction valve determines the direction in which the pump swivels out.

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The travel direction valve directs the control pressure into one of the two servo chambers in the servo cylinder. The opposite chamber remains connected to the drain.

Sectional view of the travel direction valve 1 2 3 4


Forward travel direction solenoid Servo oil supply Reverse travel direction solenoid Forward travel direction servo oil supply

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5 Reverse travel direction servo oil supply 6 Servo piston

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Service Manual


Replenishing pump The replenishing pump is an internal gear pump. The replenishing pump draws up oil from the hydraulic tank. The delivery volume of the pump is proportional to the drive speed.

Front view of the replenishing pump 1 Internal gear pump

2 Suction side of the replenishing pump

The replenishing pump supplies the closed circuit with fresh, cooled oil. The replenishing pump also provides oil for the control circuit (control pressure). The maximum replenishing pressure is limited by the replenishing pressure relief valve.

Replenishing pressure relief valve

Cross section of the replenishing pressure relief valve 1 Tank outlet 2 Oil from the replenishing pump 3 Adjusting screw

4 Oil to the pressure relief and replenishing valve 5 Valve piston

Excess oil that is not fed into the closed circuit flows via the replenishing pressure relief valve to the pump housing. At the same time, this oil cools the rotary group of the variable displacement pump.

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This directly actuated pressure relief valve protects the replenishing pump against excess pressure.

Service Manual


Pressure cut-off The pressure cut-off valve limits the operating pressure in the closed circuit. When the maximum operating pressure is reached, the flow of the variable displacement pump is reduced so that the maximum operating pressure is just maintained.

Hydraulic diagram of active/inactive pressure cut-off 1 Variable displacement pump 2 Travel direction valve 3 Control pressure proportional valve

4 Pressure cut-off 5 Nozzle 6 Replenishing pump

Pressure cut-off active: when the maximum operating pressure is reached in the closed circuit, the pressure cut-off is activated. Control oil flows into the tank duct. Sufficient oil from the replenishing pump 6 can no longer flow through the nozzle 5. Up to the nozzle 5 the replenishing pressure acts; after it, only the reduced control pressure.

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Pressure cut-off inactive: the control pressure acts in the duct up to the control pressure proportional valve 3 and the pressure cut-off 4.

Sectional view of the pressure cut-off 1 2 3 4

Pressure spring Valve piston Servo oil supply Control edge

5 Tank outlet 6 Tappet 7 Low pressure / closed circuit

8 Check valve 9 Bore hole 10 High pressure / closed circuit

The operating pressure controls the valve. When the maximum operating pressure has been reached, the tappet 6 and the valve piston 2 are pushed against the pressure spring 1. The control pressure channel 3 is linked to the tank outlet 5, and servo oil drains off. The control pressure drops and the variable displacement pump swivels to a smaller flow rate. The variable displacement pump then delivers just enough oil to attain the maximum pressure.


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Pressure relief and replenishing valve The pilot-controlled pressure relief and replenishing valves prevent excess pressure from forming in the closed circuit. The high pressure from the system acts via the nozzle 6 on the pilot control piston 2. It the set value is exceeded, the pilot control piston opens. The rear piston chamber 3 is opened via the relief duct 8 to the low pressure side. The main piston 4 then opens and the high pressure oil can flow to the low pressure side 5.

Pressure relief and replenishing valve at high pressure 1 2 3 4

Pressure spring Pilot control piston Rear piston chamber Main piston

5 6 7 8

Low pressure side Nozzle High pressure Relief duct

At the same time, the valves act as replenishing valves for the closed circuit.

Pressure relief and replenishing valve during replenishment 1 Main piston 2 Pressure spring 3 Main piston control edge

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4 Replenishing oil intake 5 Closed circuit replenishment

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LBH/Version 01/10.2006/en/dw/26/01/2007

Oil leaks in the closed circuit reduce the pressure on the low pressure side. This opens the main piston and oil from the replenishing pump can flow into the closed circuit.

Service Manual

Travel Hydraulics Variable displacement motors

6.2 Variable displacement motors Function description Basic function

Variable displacement motor arrangement 1 2

Variable displacement motor 2 Variable displacement motor 1

3 4

Proportional valve Discharge valve

The variable displacement motors drive the transmission. A higher or lower torque is transferred to the transmission, depending on the pivot angle and pressure.

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The main electronics (master) control the motors. Depending on the operating state of the machine, the proportional valves 3 on the variable displacement motors are activated by the main electronics. This adjusts the pivot angle and displacement to the current operating condition.

Regulation of the variable displacement motors during acceleration 1st gear: At low speed, both motors pivot to a 25° angle. The greatest torque is transferred to the transmission. If the travel speed is increased, the motors simultaneously pivot inwards. The shift range is reached at around 6 km/h. Motor 1 moves back towards 0° and motor 2 towards 23°. Motor 1 reduces its torque and motor 2 increases its torque. L550 - 456 / from 16978 L556 - 454 / from 15653 L566 - 460 / from 14171

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Variable displacement motors

Once motor 1 reaches an angle of 0°, the coupling 1 opens in a loadfree condition. 2nd gear: In 2nd gear, only variable displacement motor 2 is active. Motor 1 is uncoupled and at an angle of 0°. As the speed is increased, motor 2 gradually reduces its angle. The next shift range is reached at around 17 km/h. Motor 1 is coupled again and moves to a wide angle. At the same time, motor 2 moves to 0°. Motor 2 is then uncoupled. 3rd gear: In 3rd gear, only variable displacement motor 1 is active. Initially, motor 1 is at an angle of 25°. In this range, the variable displacement pump takes control. At speeds higher than 23 km/h, motor 1 moves towards a smaller angle.


The return oil from the fan motor 1 is pumped to the port U of the motors. The orifice 10 ensures that the oil is distributed evenly to both motors. The scavenging pump 2 draws oil from the connection T on both variable displacement motors. The hot oil flows to the collector pipe 7 and the oil cooler 6, and through the return suction filter 4 back to the hydraulic tank 5.

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During bearing flushing, fresh, cooled oil is directed to the tapered roller bearings and into the housing of the variable displacement motors. The hot oil is pumped out.

Service Manual


6.2.1

Variable adjustment motor Technical data See section 2.1

Design

Main components of the variable displacement motor 1 Drive shaft 2 Housing 3 Discharge valve

4 Control unit 5 Regulating unit 6 Proportional valve

LBH/Version 01/10.2006/en/dw/26/01/2007

The variable displacement motor is flange-mounted on the transfer gear. The inclined axial tapered piston rotary group and the variable displacement are all integrated in the variable displacement motor.


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1 2 3 4 5 6 7 8 9 10 11 12 13

Drive shaft Snap ring Shaft seal ring U-connection Motor housing Piston Cylinder Control lens Q min adjusting screw Bolt connection Pressure spring Pressure relief valve Discharge valve

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14 15 16 17 18 19 20 21 22 23 24 25 26

Orifice Valve piston Socket-head screw Servo piston seal Servo piston Threaded pin Control pin Regulating spring 1 Connecting plate Spring cup Spring cup Regulating spring 2 Control bushing

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27 28 29 30 31 32 33 34 35 36 37 38

Control piston Proportional magnet Regulation adjusting screw Installation pin O-ring Q max adjusting screw Adjusting washer Pressure spring Centre pin Drive shaft bearing Check valve Valve insert

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Components of the variable displacement motor

Service Manual

Travel Hydraulics

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Hydraulic plan of the variable displacement motor 1 2 3 4 5 6

Variable adjustment motor Check valves Proportional valve Control piston Servo piston Discharge valve

7 8 9 10 11 M1

Orifice Pressure relief valve Bearing lubrication oil Return oil from discharge valve Housing scavenging connection Servo pressure test connection

The flow from the displacement pump reaches the variable displacement motor via pressure connection A or B. In the process, the regulating pistons which move along the cylinder of the rotary group are subjected to pressure. The resulting force turns the drive shaft and generates a certain torque. The torque at the drive shaft depends on the swivel angle and on the operating pressure in the closed circuit. The speed of the drive shaft depends on the pump flow and on the swivel angle of the variable displacement motor. – As the swivel angle decreases, the speed increases and the potential torque is reduced. – As the swivel angle increases, the torque increases and the potential speed is reduced.

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The regulation and control unit installed in the connecting housing adjusts the swivel angle of the motor. The main electronics (master) control the position of the motor.

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Electro-proportional control (EP) Depending on the energisation of the proportional magnet 7, the variable displacement motor is moved to the required angle. When the proportional magnet not energized, the motor is held at the 0° angle by the high pressure acting on the small servo piston face 2. When the proportional magnet is energised, above a certain current the control piston 6 is pushed up against the regulating springs 5 and 4. Highpressure oil flows via the control piston 6 to the large piston face 1 and the variable displacement motor moves out to a wider angle. During regulation, the control piston 3 is pushed down, increasing the tension in the regulating spring 4. This stops the regulation process if the current at the proportional magnet is not further increased. If the current is increased, the force of the two regulating springs is overcome and the motor continues moving to a wider angle. The maximum pivot angle is reached at a current of around 600 mA. The force of the proportional magnet is go great that it overcomes the spring force even at a wide pivot angle. The adjusting screw 8 is used for adjusting the regulating springs 5 (basic setting). Adjust the regulating springs 5 so that the motor is moved to a 25° angle at 600 mA on the proportional magnet. The main electronics (master) control the speed with which the variable displacement motor is moved. This means no swivel restrictors are required.

Cooling by the discharge valve The discharge valve is used in the closed circuit to avoid excessive heat build-up. In the process, oil is discharged from the low pressure side of the closed circuit and fed to the hydraulic tank. The replenishing pump replaces this oil with cooled oil. When the machine is at rest, the pressure is the same on both faces of the valve piston 4. The two return springs 5 push the valve piston 4 to the centre position. No oil is discharged in this position.

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When the machine moves, the pressure in the duct 6 or 7 increases and moves the valve piston 4 towards one of the return springs 5. The low pressure side is opened and a defined quantity of oil flows via the orifice 1 and the pressure relief valve 2 to the hydraulic tank.


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6.2.2

Motor scavenging pump Design

Scavenging pump arrangement 1 Motor scavenging pump

2 Brake system gear pump 3 Cooling system gear pump

The gear pumps are fitted on the auxiliary drive of the engine and is driven by the engine at a specific transmission ratio via a spur gear.

1 2 3 4

Flight O-ring Flange Seals

5 6 7 8

Bearing bushings Gears Housing Housing cover

Function description Scavenging from the variable displacement motor housing The pump actively draws up hot oil from the housing of the variable displacement motors and pumps it through the oil cooler to the hydraulic tank.

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Motor scavenging pump components

7 Working hydraulics 7.0 Chapter contents 7

Working hydraulics.............................................................. 7.0-1 7.0.1

Working hydraulics - L550, L556..........................................7.0-1

7.0.2

Working hydraulics - L566, L576, L580................................7.0-7

7.1

Working hydraulics pump ...............................................................7.1-1

7.2

Control block ...................................................................................7.2-1

7.3

Pilot control unit ..............................................................................7.3-1 7.3.1

Pilot control unit ....................................................................7.3-5

7.3.2

Pilot control solenoid valve ...................................................7.3-9

7.3.3

Pilot control hydro accumulator ..........................................7.3-10

7.3.4

Float position pressure switch ............................................7.3-11

7.4

Ride control.....................................................................................7.4-1 7.4.1

Ride control – L550, L556 ....................................................7.4-1

7.4.2

Ride control – L566, L576, L580 ..........................................7.4-7

7.4.3

Stabilisation module ...........................................................7.4-13

7.4.4

Hydro accumulator unit.......................................................7.4-15

7.4.5

Ride control pressure switch ..............................................7.4-17

7.5

Lift and tilt cylinders ........................................................................7.5-1 7.5.1

Lift cylinder ...........................................................................7.5-1

7.5.2

Tilt cylinder ...........................................................................7.5-3

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7.6


Hydraulic tank .................................................................................7.6-1 7.6.1

Filter unit...............................................................................7.6-3

7.6.2

Bleeder filter .........................................................................7.6-8

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Working hydraulics

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Working hydraulics 7.0.1 Valid for:

Working hydraulics - L550, L556 L550 - 456 / from 16978; L556 - 454 / from 15653

LBH/Version 01/10.2006/en/dw/05/02/2007

Design

Main components of the working hydraulics 1 2 3 4

Lift cylinder Tilt cylinder Pilot control unit Hydraulic tank

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5 Working hydraulics pump 6 Travel hydraulics variable displacement pump with replenishing pump 7 Pilot control solenoid valve

8 9 10 11 12

Pilot control hydro accumulator Compact brake valve Hydro accumulator unit Stabilisation module Control block

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7.0-1 o f 1 2

Working hydraulics

PowerPoint


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Basic function

Hydraulic diagram of the working hydraulics

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L550 - 456 / from 16978 L556 - 454 / from 15653

Service Manual

1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 20 21 22 23 24 25 26 27 28 30 31

Hydraulic tank Bleeder filter Return strainer Bypass valve Return suction filter Pre-tension valve Replenishing valve with strainer Travel pump return line Fan motor leak oil Compact brake pump leak oil Return line from oil cooler Shut-off valve Emergency steering pump intake port Replenishing pump Hydraulic oil temperature sensor Steering pump intake port Working hydraulics pump Axial piston pump Return cylinder Restrictor Servo cylinder Power regulator Restrictor Flow controller Steering pump return line Pilot control unit Tilt-out valve

Working hydraulics

32 33 34 35 36 37 38 39 40 41 42 43 44 45 46 50 51 52 53 54 55 56 57 58 59

Bucket return-to-dig solenoid Tilt-in valve Lifting valve Lift kick-out solenoid Lowering valve Float position solenoid Float position pressure switch, 26 bar Ride control pressure switch, 10 bar Stabilisation module Ride control spool valve Restrictor check valve Ride control solenoid valve Safety valve Hydro accumulator unit Check valve Control block assembly Pre-tension valve Primary pressure relief valve LS pressure cut-off Flow control valve Tilt cylinder pressure balance Tilt cylinder spool valve Lift cylinder pressure balance Lift cylinder spool valve Load valve

60 Lifting pressure relief valve 61 Restrictor check valve 62 Float position / ride control solenoid valve 63 Check valve 64 Tilt-in pressure relief valve 65 Tilt-out pressure relief valve 66 Orifice ∅ 1 mm 67 Lift cylinder 68 Tilt cylinder 69 Oil from compact brake valve (housing preheating) 70 Cut-in block 71 Overspeed protection solenoid valve 72 Pilot control solenoid valve 73 Check valve 74 Pilot control hydro accumulator Test connections: P Working hydraulics pump high pressure M1 Working hydraulics pump servo pressure LS LS signal pressure MX Ride control accumulator pressure

The working hydraulics are equipped with the following standard functions: – Working movements for the lift and tilt cylinders – Ride control – Float position – Automatic bucket return-to-dig function – Lift kick-out The working hydraulics system operates in an open circuit. The working hydraulics pump 20 draws up oil from the hydraulic tank 1 and pumps it to the control block 50. The returning oil is pumped through the return suction filter 5 back to the hydraulic tank 1. The control block is activated via the hydraulic pilot control unit. The control block contains the spool valves for the lift and tilt cylinders. The LS system in the control valve block distributes the flow of the working hydraulics pump to the consumer units independently of load. LBH/Version 01/10.2006/en/dw/05/02/2007

The ride control system attenuates the bouncing and pitching vibrations of the machine while it is travelling, thus greatly increasing comfort and safety.

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Working hydraulics

Service Manual Hydraulic tank The hydraulic tank provides filtered oil for the working hydraulics. The working hydraulics pump draws up oil from the hydraulic tank via the shut-off connection 1. The returning oil is pumped back through the connection 2 and the return suction filter 3 to the hydraulic tank. The bleeder filter 4 compensates for pressure differences inside the hydraulic tank by providing appropriate ventilation. See the detailed description in the section on the hydraulic tank.

Working hydraulics pump The working hydraulics pump draws up oil from the hydraulic tank and pumps it to the control block. The flow regulator 2 (load sensing) ensures that the working hydraulics pump only delivers as much oil from the hydraulic tank as the working hydraulics currently need. The power regulator 1 ensures that the maximum current consumption of the variable displacement pump is never exceeded. See the detailed description in the section on the working hydraulics pump.

Control block The control block contains the spool valves for the lift cylinder 3 and the tilt cylinder 4. The LS pressure relief valve 7 limits the maximum pressure of the working hydraulics pump. The primary pressure relief valve 5 additionally limits the maximum pressure of the working hydraulics pump. The secondary pressure relief valves 2 protect the hydraulic system against pressure peaks from the consumer units. The float position/ride control solenoid valve 6 is activated for the float position and ride control. See the detailed description in the section on the control block.

The working hydraulics are actuated by a separate control circuit. The spool valves in the control block 1 are hydraulically actuated by the pilot control unit 2. The variable displacement pump 5 (replenishing pump) of the travel hydraulics takes the required servo oil and pumps it through the pilot control solenoid valve 4 to the pilot control unit 2. See the detailed description in the section on the pilot control unit.

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Pilot control unit

Service Manual

Working hydraulics Ride control

The ride control system attenuates the bouncing and pitching vibrations of the machine while it is travelling, thus greatly increasing comfort and safety. The lift cylinders are connected at the base end via the control valve block 3 and the stabilisation module 2 to the hydro accumulators 1. The rod end of the lift cylinders is connected to the hydraulic tank via the float position/ride control solenoid valve 4 in the control valve block.

LBH/Version 01/10.2006/en/dw/05/02/2007

See the detailed description in the section on ride control.

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Service Manual

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Working hydraulics

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Service Manual

Working hydraulics 7.0.2 Valid for:

Working hydraulics - L566, L576, L580 L566 - 460 / from 14171; L576 - 457 / from 14171; L580 - 459 / from 14171

LBH/Version 01/10.2006/en/dw/05/02/2007

Design

Main components of the working hydraulics 1 2 3 4

Lift cylinder Tilt cylinder Pilot control unit Hydraulic tank


5 Working hydraulics pump 6 Travel hydraulics variable displacement pump with replenishing pump 7 Pilot control solenoid valve

8 9 10 11 12

Pilot control hydro accumulator Compact brake valve Hydro accumulator unit Stabilisation module Control block

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Working hydraulics PowerPoint


LBH/Version 01/10.2006/en/dw/05/02/2007

Basic function

Hydraulic diagram of the working hydraulics

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Service Manual 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 20 21 22 23 24 25 26 27 28 30 31

Hydraulic tank Bleeder filter Return strainer Bypass valve Return suction filter Pre-tension valve Replenishing valve with strainer Travel pump return line Fan motor leak oil Compact brake pump leak oil Return line from oil cooler Shut-off valve Emergency steering pump intake port Replenishing pump Hydraulic oil temperature sensor Steering pump intake port Working hydraulics pump Axial piston pump Return cylinder Restrictor Servo cylinder Power regulator Restrictor Flow controller Steering pump return line Pilot control unit Tilt-out valve

Working hydraulics 32 33 34 35 36 37 38 39 40 41 42 43 44 45 46 50 51 52 53 54 55 56 57 58 59

Bucket return-to-dig solenoid Tilt-in valve Lifting valve Lift kick-out solenoid Lowering valve Float position solenoid Float position pressure switch, 26 bar Ride control pressure switch, 10 bar Stabilisation module Ride control spool valve Restrictor check valve Ride control solenoid valve Safety valve Hydro accumulator unit Check valve Control block assembly Pre-tension valve Primary pressure relief valve LS pressure cut-off Flow control valve Tilt cylinder pressure balance Tilt cylinder spool valve Lift cylinder pressure balance Lift cylinder spool valve Load valve

60 Lifting pressure relief valve 61 Restrictor check valve 62 Float position / ride control solenoid valve 63 Check valve 64 Tilt-in pressure relief valve 65 Tilt-out pressure relief valve 66 Orifice ∅ 1 mm 67 Lift cylinder 68 Tilt cylinder 69 Oil from compact brake valve (housing preheating) 70 Cut-in block 71 Overspeed protection solenoid valve 72 Pilot control solenoid valve 73 Check valve 74 Pilot control hydro accumulator Test connections: P Working hydraulics pump high pressure M1 Working hydraulics pump servo pressure LS LS signal pressure MX Ride control accumulator pressure

The working hydraulics are equipped with the following standard functions: – Working movements for the lift and tilt cylinders – Ride control – Float position – Automatic bucket return-to-dig function – Lift kick-out The working hydraulics system operates in an open circuit. The working hydraulics pump 20 draws up oil from the hydraulic tank 1 and pumps it to the control block 50. The returning oil is pumped through the return suction filter 5 back to the hydraulic tank 1. The control block is activated via the hydraulic pilot control unit. The control block contains the spool valves for the lift and tilt cylinders. The LS system in the control valve block distributes the flow of the working hydraulics pump to the consumer units independently of load. LBH/Version 01/10.2006/en/dw/05/02/2007

The ride control system attenuates the bouncing and pitching vibrations of the machine while it is travelling, thus greatly increasing comfort and safety.


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Working hydraulics

Service Manual Hydraulic tank The hydraulic tank provides filtered oil for the working hydraulics. The working hydraulics pump draws up oil from the hydraulic tank via the shut-off connection 1. The returning oil is pumped back through the connection 2 and the return suction filter 3 to the hydraulic tank. The bleeder filter 4 compensates for pressure differences inside the hydraulic tank by providing appropriate ventilation. See the detailed description in the section on the hydraulic tank.

Working hydraulics pump The working hydraulics pump draws up oil from the hydraulic tank and pumps it to the control block. The flow regulator 2 (load sensing) ensures that the working hydraulics pump only delivers as much oil from the hydraulic tank as the working hydraulics currently need. The power regulator 1 ensures that the maximum current consumption of the variable displacement pump is never exceeded. See the detailed description in the section on the working hydraulics pump.

Control block The control block contains the spool valves for the lift cylinder 3 and the tilt cylinder 4. The LS pressure relief valve 7 limits the maximum pressure of the working hydraulics pump. The primary pressure relief valve 5 additionally limits the maximum pressure of the working hydraulics pump. The secondary pressure relief valves 2 protect the hydraulic system against pressure peaks from the consumer units. The float position/ride control solenoid valve 6 is activated for the float position and ride control. See the detailed description in the section on the control block.

The working hydraulics are actuated by a separate control circuit. The spool valves in the control block 1 are hydraulically actuated by the pilot control unit 2. The variable displacement pump 5 (replenishing pump) of the travel hydraulics takes the required servo oil and pumps it through the pilot control solenoid valve 4 to the pilot control unit 2. See the detailed description in the section on the pilot control unit.

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Pilot control unit

Service Manual


The ride control system attenuates the bouncing and pitching vibrations of the machine while it is travelling, thus greatly increasing comfort and safety. The lift cylinders are connected at the base end via the control valve block 3 and the stabilisation module 2 to the hydro accumulators 1. The rod end of the lift cylinders is connected to the hydraulic tank via the float position/ride control solenoid valve 4 in the control valve block.

LBH/Version 01/10.2006/en/dw/05/02/2007

See the detailed description in the section on ride control.


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Service Manual

LBH/Version 01/10.2006/en/dw/05/02/2007

Working hydraulics

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Service Manual


7.1 Working hydraulics pump Technical data See section 2.1

Design

Main components of the working hydraulics pump 1 Drive shaft 2 Pump housing 3 Connection housing

4 Power regulator 5 Flow controller

The working hydraulics pump is flange-mounted to the splitter box and is driven by the diesel engine via this unit. The working hydraulics pump is an axial piston pump with a swash plate design. The rotary group cylinder contains seven pistons in a circular arrangement which can move back and forward.

LBH/Version 01/10.2006/en/dw/05/02/2007

Two power regulator and a flow controller are attached to the pump housing.


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Working hydraulics

Service Manual

Working hydraulics pump

1 2 3 4 5 6 7 8 9 10 11 12 13

Drive shaft Shaft seal ring Snap ring Cover Pump housing Swash plate Glide shoe Piston Adjusting pin Q min adjusting screw Pressure spring O-ring Valve housing

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14 15 16 17 18 19 20 21 22 23 24 25 26

Control lever Restrictor Piston with roller Control bushing Sleeve Servo piston Cylindrical roller bearing Control plate Restrictor Connection housing Pressure spring Return piston Return pin

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27 28 29 30 31 32 33 34 35 36 37

L550 - 456 / from 16978 L556 - 454 / from 15653

O-ring Cylinder Q max adjusting screw Bushing Return plate Disc springs Return ball Swash plate bearing Guide pin Snap ring Cylindrical roller bearing


LBH/Version 01/10.2006/en/dw/05/02/2007

Components of the working hydraulics pump

Service Manual


Components of the regulator unit Valve piston Plug Valve insert Adjusting screw Counter nut Spring cup O-ring Regulating springs Spring cup

10 11 12 13 14 15 16 17 18

LS connection Valve piston Regulator housing Adjusting screw Counter nut Spring cup Regulating spring Spring cup Control lever

19 20 21 22 23 24 25 26

Pin Valve piston Spring cup Pressure spring Spring cup O-ring Brace Valve insert

LBH/Version 01/10.2006/en/dw/05/02/2007

1 2 3 4 5 6 7 8 9


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Working hydraulics

Service Manual



Hydraulic diagram of the working hydraulics pump 1 2 3 4 5 6 7

Rotary group Return cylinder Restrictor Servo cylinder Restrictor Power regulator Flow controller

8 9 10 11 M1 LS P

Connection to hydraulic tank Oil to control valve block LS signal from control valve block Intake connection Servo pressure test connection LS signal pressure Working hydraulics pump high pressure

The working hydraulics pump operates in an open circuit. It draws up oil directly from the hydraulic tank and pumps it to the control block. The flow of the of the working hydraulics pump is determined by the angle and speed of the pump. The governors fitted to the working hydraulics pump determine the angle of the pump and therefore the pump flow.

Pump control

LBH/Version 01/10.2006/en/dw/05/02/2007

The swash plate 1 of the working hydraulics pump is moved out by the control piston 2. The operating pressure constantly acts in the piston chamber 3. This causes the pump to swivel out.

Working hydraulics pump with control unit

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Service Manual


The swash plate is returned to its initial position by the return piston 5. Pressure oil is pumped into the piston chamber 4. The return piston is controlled by the governors fitted on the working hydraulics pump. The working hydraulics pump flow is controlled by the following governors: – Flow controller – Power regulator The operating state of the working hydraulics system governs which governor is currently activated. If the working hydraulics demand only a small amount of oil or none at all, the flow regulator restricts the working hydraulics pump to the required amount. If the set power limit is reached at a certain flow and increasing pressure, the flow regulator reduces the working hydraulics pump flow.

Flow regulation The load sensing system ensures that the working hydraulics pump only delivers as much oil from the hydraulic tank as the working hydraulics currently need.

LBH/Version 01/10.2006/en/dw/05/02/2007

When the working hydraulics are not in use, the oil flow is blocked by the spool valves in the control block and the working hydraulics pump is reduced to minimum flow (leak flow). Connection 2 is depressurised. The high pressure pushes the piston 3 against the pressure springs 1 which determine the standby pressure in the system. The control piston 3 opens the high pressure duct 4 to the duct 5 and the return cylinder reduces the pump to leak flow.

Flow controller when the working hydraulics do not need oil 1 Pressure springs 2 LS connection X 3 Control piston

4 High pressure duct 5 Duct to return cylinder 6 Flow controller

If the working hydraulics need oil, the pressure at the connection 2 increases. The pressure and force of the springs 1 move the control piston 3 against the high pressure. The duct 5 opens to the tank connection 7. The open duct relieves the return cylinder and the pump delivers the required oil quantity.


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Working hydraulics

Service Manual


Flow controller when the working hydraulics need oil 1 2 3 4

Pressure springs LS connection X Control piston High pressure duct

5 Duct to return cylinder 6 Flow controller 7 To the pump housing

Pump pressure limitation The maximum operating pressure in the system is limited by the LS pressure cut-off valve 1 in the control block. The LS pressure, which affects the flow regulator 2, is set to a particular value.

LS pressure cut-off in the control block

The power regulator controls the displacement of the working hydraulics pump according to the operating pressure, so that a specific drive power is never exceeded. The power regulator works on the principle of hyperbolic control. It regulates the pump exactly along the preset power curve 1 (flow x high pressure).

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Pump output regulation

Service Manual


Pump output diagram The operating pressure acts via the ring face 8 of piston on the control lever 11. This produces a variable levering force depending on the position of the control cylinder (flow) and acts on the externally adjustable spring 6. If the force on the lever 11 generated by the operating pressure exceeds the set spring force, the valve piston 5 is moved. Pressure oil flows through the duct 3 to the return cylinder and the working hydraulics pump displacement is reduced.

Power regulator in the control phase LBH/Version 01/10.2006/en/dw/05/02/2007

1 2 3 4 5 6


Power regulator Pressure spring Duct to return cylinder High pressure duct Valve piston Regulating spring

L576 - 457 / from 14171 L580 - 459 / from 14171

7 8 9 10 11

Tank connection Piston ring face Servo piston Piston with roller Control lever

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Working hydraulics

Service Manual

LBH/Version 01/10.2006/en/dw/05/02/2007


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Service Manual


7.2 Control block Technical data See section 2.1

Design

Main components of the control block 1 2 3 4 5 6

Closing element Lifting pressure relief valve Tilt-in pressure relief valve Pressure balances Main block housing Primary pressure relief valve

7 8 9 10

Tilt-out pressure relief valve Tilt cylinder spool valve Lift cylinder spool valve Float position / ride control solenoid valve 11 LS pressure cut-off

The control block is mounted in the front section. It consists of the main block housing 5 and the closing element 1. Additional segments for a 3rd and 4th control circuit can be installed if needed between the main block housing and the closing element.

LBH/Version 01/10.2006/en/dw/05/02/2007

The control block contains all the pressure cut-off valves and the valves for the float position and ride control.


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Working hydraulics

Service Manual


Components of the control block Main block housing Pre-tension valve Primary pressure relief valve Tilt-out replenishing valve Lowering replenishing valve

6 7 8 9 10

Closing plate Lift cylinder spool valve Counter nut Cap nut Spool valve stroke adjusting screw

11 12 13 14

Cover Pressure spring Spring cup Tilt cylinder spool valve

LBH/Version 01/10.2006/en/dw/05/02/2007

1 2 3 4 5

Components of the control block

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Service Manual


Cross section A-A of control block with spool valves for lift cylinder

LBH/Version 01/10.2006/en/dw/05/02/2007

Cross section B-B of control block with spool valves for tilt cylinder 1 2 3 4 5

Main block housing Pressure spring Cover Restrictor check valve Spool valve stroke adjusting screw 6 Cap nut


7 Counter nut 8 Float position / ride control solenoid valve 9 Control piston 10 Valve insert 11 Main piston 12 Pressure balance

L576 - 457 / from 14171 L580 - 459 / from 14171

13 14 15 16 17 18

Lifting pressure relief valve Spring cup Lift cylinder spool valve Tilt-out pressure relief valve Tilt-in pressure relief valve Tilt cylinder spool valve

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Working hydraulics

Service Manual



Hydraulic plan of the control valve block Primary pressure relief valve LS pressure cut-off Flow control valve Tilt cylinder load valve Tilt cylinder pressure balance Tilt cylinder spool valve Restrictor check valve Lift cylinder load valve Lift cylinder pressure balance Lift cylinder spool valve Lifting pressure relief valve Float position / ride control solenoid valve 13 Replenishing valve

14 15 16 17 18 19 20 21 22 23 24

Tilt-in pressure relief valve Tilt-out pressure relief valve Pre-tension valve Orifice ∅ 1.0 mm Lift cylinder connection Housing preheating connection Tank connection from stabilization module Hydraulic tank connection LS connection Working hydraulics pump connection Tilt cylinder connection

The control block contains the spool valves for the lift cylinder 10 and the tilt cylinder 6. The spool valves are supplied with oil by the pilot control unit. The restrictor check valves 7 in the control valve block allow sensitive control of the individual functions. The LS control and the pressure balances 5 and 9 divide the oil among the individual consumer units. The float position or ride control function is activated by the solenoid valve 12. Secondary pressure relief valves for each function protect the working attachment, cylinders, hose lines and the control block from overload. At the same time, the secondary pressure relief valves act as replenishing valves. The LS pressure cut-off 2 protects the working hydraulics pump from excess pressure.

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1 2 3 4 5 6 7 8 9 10 11 12

Service Manual


Working hydraulics in active state The spool valves in the control block are hydraulically actuated by the pilot control unit.

Control block in active state When the tilt-in function is actuated, oil flows from the pilot control unit to the connection a1. This pushes the spool valve 2 to the left. The spool valve 2 opens the pump duct P to the pressure balance 3 via the control notches 1. If the pump pressure exceeds the pressure at the tilt cylinder, the pressure balance in the load valve opens and oil flows through the connection A1 to the tilt cylinder. The oil returning from the tilt cylinder flows through the connection B1 and the spool valve to the tank channel T.

Working hydraulics in float position

LBH/Version 01/10.2006/en/dw/05/02/2007

In the float position, the working attachment lies on the ground under its own weight. The lift arms can move up and down freely to compensate for uneven ground.

Control block in float position L550 - 456 / from 16978 L556 - 454 / from 15653 L566 - 460 / from 14171

L576 - 457 / from 14171 L580 - 459 / from 14171

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Working hydraulics

Service Manual


At the maximum deflection of the LH control lever for lowering the lift arms, there is maximum control pressure at the connection b2. This pushes the spool valve 1 all the way to the right against the regulating spring 3 and the limit screw 2. When the spool valve 1 is in this position, the base end B2 of the lift cylinder is connected to the tank channel T.

LBH/Version 01/10.2006/en/dw/05/02/2007

The float position solenoid valve 4 is also energised. The rod ends of the lift cylinder A2 is also connected to the tank duct T. The lift arms can now move up and down freely.

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Service Manual


7.3 Pilot control unit Design

Main components of the pilot control unit 3 Pilot control unit 4 Variable displacement pump with replenishing pump 5 Overspeed protection solenoid valve

6 7 8 9

Pilot control solenoid valve Solenoid valve block Pilot control hydro accumulator Control block

LBH/Version 01/10.2006/en/dw/05/02/2007

1 Float position pressure switch, 26 bar 2 Ride control pressure switch, 10 bar


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Working hydraulics

Service Manual



Hydraulic plan of the pilot control unit 1 2 3 4

Hydraulic tank Replenishing pump Solenoid valve block Overspeed protection solenoid valve 5 Pilot control solenoid valve 6 Check valve 7 Pilot control hydro accumulator

8 Float position pressure switch, 26 bar 9 Ride control pressure switch, 10 bar 10 Pilot control unit 11 Tilt-in valve 12 Bucket return-to-dig solenoid 13 Tilt-out valve

14 15 16 17 18 19 20 21

Lifting valve Lift kick-out solenoid Lowering valve Float position solenoid Control block assembly Lift cylinder spool valve Tilt cylinder spool valve Restrictor valve

The pilot control solenoid valve 5 is installed for the safety of the machine. The working hydraulics lockout button must be activated to prevent accidental movements of the working attachment during maintenance, road travel and when the driver leaves the machine. The operation of the working hydraulics is disabled. The pilot control hydro accumulator 7 with check valve 6 on the solenoid valve block 3 allows the lift arms to be lowered or the bucket to be tilted out, even when the engine is not running. The bucket return-to-dig, lift kick-out and float position functions are controlled via retaining solenoids in the pilot control unit and proximity switches.

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The working hydraulics are actuated by a separate control circuit. The spool valves are hydraulically actuated by the pilot control unit 10. The required control oil is taken from the replenishing pump 2 of the travel hydraulics. The replenishing pressure relief valve limits the pilot control pressure to the specified level.

Service Manual


Pilot control unit The pilot control unit controls the spool valves in the control block. The control pressure increases smoothly according to the deflection of the lever. The pilot control unit contains retaining solenoids for the bucket return-to-dig, lift kick-out and float position functions. These solenoids hold the control lever in the maximum position until the solenoid current is switched off. See the detailed description in the section on the pilot control unit.

Variable displacement pump with replenishing pump The replenishing pump 1 is part of the variable displacement pump 2 of the travel hydraulics. The replenishing pump delivers oil for the following components and functions: – Travel hydraulics control circuit – Replenishing oil in the closed circuit – Pilot control of the working hydraulics – Overspeed protection (rear axle braking function) The maximum pressure of the replenishing pump is limited by the replenishing pressure relief valve. The design and functions are described in the sections on the travel hydraulics and the variable displacement pump.

Solenoid valve block The solenoid valve block 4 contains the pilot control solenoid valve 2 and the pilot control hydro accumulator 1. When the machine is started or when the starter switch is in position 1, the pilot control solenoid valve is activated automatically. Control oil flows to the pilot control unit and the working hydraulics can be operated. The hydro accumulator 1 and check valve (starter switch in position 1) allow the lift arms to be lowered and the working attachment to be tilted out, even when the engine is not running. The working hydraulics lockout button deactivates the pilot control solenoid valve. The P connection in the pilot control unit is relieved towards the hydraulic tank and the working hydraulics cannot be used. See the detailed description in the section on the pilot control unit solenoid valve.

LBH/Version 01/10.2006/en/dw/05/02/2007

Control block The control block contains the spool valves for the tilt cylinder 1 and the lift cylinder 2. The spool valves for the lift and tilt cylinders are supplied with oil by the pilot control unit. The restrictors in the control valve block allow sensitive control of the individual functions. The float position/ride control solenoid valve relieves the lift cylinder rod end to the hydraulic tank when it is activated. See the detailed description in the section on the control block.


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Working hydraulics

Service Manual

LBH/Version 01/10.2006/en/dw/05/02/2007


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Service Manual


7.3.1

Pilot control unit Technical data See section 2.1

Design

Main components of the pilot control device 1 Housing 2 Control valve 3 Electromagnetic locking

4 Control plate 5 Control lever

The pilot control device is fitted in the operating panel to the right of the driver's seat.

LBH/Version 01/10.2006/en/dw/05/02/2007

An additional pilot control unit for special functions (3rd control circuit) can be fitted on the side of the existing pilot control unit.


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Working hydraulics

Service Manual


1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20

7.3-6 o f 1 2

Pressure spring Spring sleeve O-ring Brass bushing Sealing ring O-ring Plastic bushing O-ring Tappet guide Retaining ring Electromagnet with sockets Threaded rod with universal joint Ring Tappet with universal joint Disc Lock nut Connector piece Counter nut Control lever Control plate

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21 22 23 24 25 26 27 28 29 30 31 32 33 34 35 36 37 38 39

Shim Adjusting bushing Nut Counter nut Adjusting screw Snap ring Tappet Guide bushing Tappet Retaining plates Spring cup Return spring Regulating spring Regulating piston Plug Bore hole Housing Connection 2 Connection 4

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Components of the pilot control device

Service Manual



Hydraulic plan of the pilot control unit 1 2 3 4

Lowering valve Lifting valve Tilt-out valve Tilt-in valve

5 Float position solenoid 6 Lift kick-out solenoid 7 Bucket return-to-dig solenoid

The pilot control device activates the pistons in the control block hydraulically. It works on the basis of directly controlled pressure relief valves. When the control lever is moved, it supplies oil to the appropriate connection. The pressure regulation of the valves in the pilot control device depends on: – The position of the control lever – The properties of the individual regulating springs The retaining solenoids allow each function to be electromagnetically locked. Its magnetic force holds the control lever in its end position.

LBH/Version 01/10.2006/en/dw/05/02/2007

Idle state

In the idle state, the control lever is held in the zero position by the return spring 2. The connection 6 is connected via the hole 5 to the tank connection T.

Control valve in idle state / Control valve in active state Regulating phase

When the control lever is moved, the tappet 7 pushes against the return spring 8 and the regulating spring 9. The regulating spring 9 pushes down the regulating piston 10 and closes the connection of the port 12 and the tank connection T. At the same time, the connection 12 is connected via the hole 11 to the connection P. The control phase begins as soon as the force of the regulating spring 9 and the force of the hydraulic pressure at the connection 12 are equal. The regulating piston 10 is in equilibrium. The interaction of the regulating piston 10 and the regulating spring 9 means that the pressure at the connection 12 is proportional to the stroke of the


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tappet 7 and therefore to the position of the control lever. The pressure regulation which is proportional to the position of the control lever allows the spool valves in the control block to be moved proportionally to the pressure.

Electromagnetic locking The following functions have electromagnetic locking: – Lift kick-out – Bucket return-to-dig – Float position The pressure spring 1 is attached under the tappet 3 and the spring sleeve 2. Just before the end of the stroke of the tappet and the control lever, the operator must apply additional force to tension the pressure spring 1. This shows the operator that the control lever is at its end position / maximum deflection. At the end position (maximum deflection) of the control lever, the ring 5 comes into contact with the anchor magnet 4. When the solenoid is activated, its magnetic force holds the control lever in its end position.

LBH/Version 01/10.2006/en/dw/05/02/2007

Unlocking takes place automatically by switching off the solenoid current using the proximity switch or by pulling back the control lever.

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7.3.2

Pilot control solenoid valve Technical data See section 2.1

Design

Solenoid valves in the cut-in block 1 Pilot control hydro accumulator 2 Pilot control solenoid valve

3 Overspeed protection solenoid valve 4 Solenoid valve block assembly

The cut-in block is fitted on left of the rear section beside the engine.

Function description Basic function The cut-in block includes the following components in a single housing: – Pilot control solenoid valve (working hydraulics) – Overspeed protection solenoid valve (rear axle braking function)

Pilot control solenoid valve

LBH/Version 01/10.2006/en/dw/05/02/2007

When the engine is running or when the starter switch is in position 1, the pilot control solenoid valve 5 is activated automatically. Control oil flows to the pilot control unit 1 and the working hydraulics can be operated.

Hydraulic plan of the solenoid valve block 1 2 3 4

Pilot control unit Pilot control hydro accumulator Solenoid valve block assembly Check valve

5 Pilot control solenoid valve 6 Overspeed protection solenoid valve 7 Replenishing pump

The on-road travel button deactivates the pilot control solenoid valve 5. The P connection in the pilot control unit 1 is relieved towards the hydraulic tank and the working hydraulics cannot be used. The pilot control hydro accumulator 3 with check valve 4 allows the working hydraulics to be used even when the engine is not running (starter switch in position 1). The lift arms can be lowered and the working attachment tilted out.


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7.3.3

Pilot control hydro accumulator (ID 7622 448)


Design

Components of the hydro accumulator 1 Plug 2 Membrane

3 Closing head 4 Accumulator

The elastic partition between the fluid and the nitrogen is a membrane 2, which is stretched in the accumulator 4. The closing head 3 prevents the membrane from being pressed into the inlet opening when the hydro accumulator is completely empty. The plug 1 allows the accumulator to be checked and topped up using the filling and testing device.


It has the following applications: – To act as an attenuator for pressure peaks, for example for the ride control system or steering attenuation. – As an energy reserve to supply energy when needed, for example for the brake system.

Storing pressure for the pilot control The hydro accumulator 1 allows the working hydraulics to be used even when the engine is not running (starter switch in position 1). The lift arms can be lowered and the working attachment tilted out.

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LBH/Version 01/10.2006/en/dw/05/02/2007

The purpose of the hydro accumulator is to store hydraulic energy and supply it when needed.

Service Manual


7.3.4

Float position pressure switch (ID 6905 869)


Design

Components of the pressure switch 1 Connection contact 2 Adjusting screw 3 Pressure spring

4 Switch contact 5 Membrane 6 Housing

The float position pressure switch is installed under the pilot control unit in the control line for lowering the lift arms.

Function description Basic function The membrane pressure switches are for switching electric circuits on and off. The hydraulic pressure acts via a membrane on an adjustable spring. When a set value is reached, the electric contact opens and the circuit is interrupted. This type of membrane pressure switch is known as “normally open”.

Activating the float position function LBH/Version 01/10.2006/en/dw/05/02/2007

The float position pressure switch activates the float position function.

Layout of pressure switches and solenoid valve 1 Float position / ride control solenoid valve 2 Float position pressure switch


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3 Ride control pressure switch 4 Float position retaining solenoid

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When the float position pressure switch 2 reaches a set pilot control pressure, its electrical contact closes. If the float position/ride control button is switched on, the float position/ride control solenoid valve 1 (on the control valve block) and the float position retaining solenoid 4 (in the pilot control unit) are activated. When float position retaining solenoid 4 is activated, its magnetic force holds the control lever in its end position.

LBH/Version 01/10.2006/en/dw/05/02/2007

The float position/ride control solenoid valve 1 (on the control valve block) relieves the lift cylinder rod end to the hydraulic tank. The working attachment lies on the ground under its own weight.

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7.4 Ride control 7.4.1 Valid for:

Ride control – L550, L556 L550 - 456 / from 16978; L556 - 454 / from 15653

Design

Main components of the ride control system 1 Lift cylinder 2 Control block

3 Float position / ride control solenoid valve

4 Stabilisation module 5 Hydro accumulator

The stabilisation module 4, hydro accumulator 5 and control valve block 2 are installed in the front section.


LBH/Version 01/10.2006/en/dw/05/02/2007

Basic function The wheel loader is an unsprung earth-moving machine and therefore tends towards bouncing and pitching vibrations. These vibrations are uncomfortable for the driver, reduce drive performance and machine safety. The ride control system is a hydropneumatic spring support between the lift arms and the chassis. It reduces bouncing and pitching vibrations.

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Ride control

Hydraulic diagram of the ride control system Stabilisation module Ride control spool valve Restrictor check valve Ride control solenoid valve Safety valve Hydro accumulator unit Check valve Pilot control unit

14 Lowering valve 15 Lifting valve 16 Float position pressure switch, 26 bar 17 Ride control pressure switch, 10 bar 18 Lift cylinder

19 Control block assembly 20 Lift cylinder spool valve 21 Float position / ride control solenoid valve 22 Lifting pressure relief valve 23 Replenishing valve 24 Tilt cylinder spool valve

When ride control is activated, the lift cylinders 15 are connected at the base end to the hydro accumulators 6. The hydro accumulators are filled with nitrogen and absorb pressure peaks at the base end of the lift cylinders. The lift cylinders are connected at the rod end to the hydraulic tank. This allows the lift arms to move up freely.

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6 7 8 9 10 11 12 13

Service Manual


Stabilisation module The stabilisation module protects the hydro accumulator from overload. If the pressure is too high, the stabilisation module stops the oil flow to the hydro accumulators. The solenoid valve 7 is for activating and deactivating ride control. The safety valve 2 opens if the pressure to the tank connection is too high. This protects the hydro accumulator from overload. See the detailed description in the section on the stabilisation module.

Hydro accumulator unit The stabilisation module protects the hydro accumulator 1 from overload. If the pressure is too high, the stabilisation module stops the oil flow to the hydro accumulators. The hydro accumulators absorb bouncing and pitching vibrations. The vibration damping effect is achieved using a nitrogen filling in the hydro accumulators. See the detailed description in the section on the hydro accumulator unit.

Control valve block The control block contains the spool valves for the lift cylinder 2 and the tilt cylinder 1. The lift cylinder base end is connected to the control valve block and the stabilisation module. The float position/ride control solenoid valve 3 connects the lift cylinder rod end to the hydraulic tank when it is activated. See the detailed description in the section on the control block.

Ride control pressure switch The ride control pressure switch 1 prevents ride control from being activated at the same time as the float position or lift arm lowering function.

LBH/Version 01/10.2006/en/dw/05/02/2007

When the float position or lift arm lowering function is not activated, the contact in the ride control pressure switch 1 is closed. This means that ride control can be activated.

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Ride control

Ride control deactivated When ride control is deactivated, the spool valve 2 is in the second position. Oil can flow through the check valve from the spool valve 2 to hydro accumulators 6. This means the hydro accumulators already have the load pressure of the working attachment. If the pressure is too high, the spool valve 2 blocks the connection to the hydro accumulators. This pushes the spool valve to the left into the closed position. The connection between the lift cylinder rod end and the hydraulic tank is interrupted. The pressure generated at the lift cylinder rod end prevents the working attachment from vibrating. This makes it easier to pick up material.

Hydraulic diagram with ride control deactivated 4 5 6 7

Ride control solenoid valve Safety valve Hydro accumulator unit Check valve

8 Lift cylinder 9 Float position / ride control solenoid valve 10 Lift cylinder spool valve

LBH/Version 01/10.2006/en/dw/05/02/2007

1 Stabilisation module 2 Ride control spool valve 3 Restrictor check valve

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Ride control activated Ride control can only be activated when: – The ride control button is activated – The travel speed is above 9.1 km/h (adjustable) – The contact on the ride control pressure switch is closed When ride control is activated, the float position/ride control solenoid valve 9 and the ride control solenoid valve 4 are energised. The float position/ride control solenoid valve 9 opens the lift cylinder rod end to the hydraulic tank. The ride control solenoid valve 4 directs the pressure of the hydro accumulator to the left side of the spool valve 2. This pushes the spool valve 2 right, fully opening the connection to the hydro accumulators. The safety valve 5 is installed to relieve the pressure. If there are excess pressure peaks, the safety valve opens to the hydraulic tank. If the speed falls below 9.1 km/h the two solenoid valves are switched off again. The lift arms can no longer vibrate.

LBH/Version 01/10.2006/en/dw/05/02/2007

The activation speed of 9.1 km/h can be adjusted using the SCULI software.

Hydraulic diagram with ride control activated 1 Stabilisation module 2 Ride control spool valve 3 Restrictor check valve

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4 5 6 7



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Ride control

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7.4.2 Valid for:

Ride control – L566, L576, L580 L566 - 460 / from 14171; L576 - 457 / from 14171; L580 - 459 / from 14171

Design

Main components of the ride control system 1 Lift cylinder 2 Control block

3 Float position / ride control solenoid valve

4 Stabilisation module 5 Hydro accumulator

The stabilisation module 4, hydro accumulator 5 and control valve block 2 are installed in the front section.

Function description Basic function LBH/Version 01/10.2006/en/dw/05/02/2007

The wheel loader is an unsprung earth-moving machine and therefore tends towards bouncing and pitching vibrations. These vibrations are uncomfortable for the driver, reduce drive performance and machine safety. The ride control system is a hydropneumatic spring support between the lift arms and the chassis. It reduces bouncing and pitching vibrations.


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Ride control

Hydraulic diagram of the ride control system Stabilisation module Ride control spool valve Restrictor check valve Ride control solenoid valve Safety valve Hydro accumulator unit Check valve Pilot control unit

9 Lowering valve 10 Lifting valve 11 Float position pressure switch, 26 bar 12 Ride control pressure switch, 10 bar 13 Lift cylinder

20 Control block assembly 21 Lift cylinder spool valve 22 Float position / ride control solenoid valve 23 Lifting pressure relief valve 24 Replenishing valve 25 Tilt cylinder spool valve

When ride control is activated, the lift cylinders 15 are connected at the base end to the hydro accumulators 6. The hydro accumulators are filled with nitrogen and absorb pressure peaks at the base end of the lift cylinders. The lift cylinders are connected at the rod end to the hydraulic tank. This allows the lift arms to move up freely.

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1 2 3 4 5 6 7 8

Service Manual


Stabilisation module The stabilisation module protects the hydro accumulator from overload. If the pressure is too high, the stabilisation module stops the oil flow to the hydro accumulators. The solenoid valve 7 is for activating and deactivating ride control. The safety valve 2 opens if the pressure to the tank connection is too high. This protects the hydro accumulator from overload. See the detailed description in the section on the stabilisation module.

Hydro accumulator unit The stabilisation module protects the hydro accumulator 1 from overload. If the pressure is too high, the stabilisation module stops the oil flow to the hydro accumulators. The hydro accumulators absorb bouncing and pitching vibrations. The vibration damping effect is achieved using a nitrogen filling in the hydro accumulators. See the detailed description in the section on the hydro accumulator unit.

Control valve block The control block contains the spool valves for the lift cylinder 2 and the tilt cylinder 1. The lift cylinder base end is connected to the control valve block and the stabilisation module. The float position/ride control solenoid valve 3 connects the lift cylinder rod end to the hydraulic tank when it is activated. See the detailed description in the section on the control block.

Ride control pressure switch The ride control pressure switch 1 prevents ride control from being activated at the same time as the float position or lift arm lowering function.

LBH/Version 01/10.2006/en/dw/05/02/2007

When the float position or lift arm lowering function is not activated, the contact in the ride control pressure switch 1 is closed. This means that ride control can be activated.


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Ride control

Ride control deactivated When ride control is deactivated, the spool valve 2 is in the second position. Oil can flow through the check valve from the spool valve 2 to hydro accumulators 6. This means the hydro accumulators already have the load pressure of the working attachment. If the pressure is too high, the spool valve 2 blocks the connection to the hydro accumulators. This pushes the spool valve to the left into the closed position. The connection between the lift cylinder rod end and the hydraulic tank is interrupted. The pressure generated at the lift cylinder rod end prevents the working attachment from vibrating. This makes it easier to pick up material.

Hydraulic diagram with ride control deactivated 4 5 6 7



LBH/Version 01/10.2006/en/dw/05/02/2007

1 Stabilisation module 2 Ride control spool valve 3 Restrictor check valve

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Ride control activated Ride control can only be activated when: – The ride control button is activated – At a travel speed above 9.1 km/h (adjustable) – The contact on the ride control pressure switch is closed When ride control is activated, the float position/ride control solenoid valve 9 and the ride control solenoid valve 4 are energised. The float position/ride control solenoid valve 9 opens the lift cylinder rod end to the hydraulic tank. The ride control solenoid valve 4 directs the pressure of the hydro accumulator to the left side of the spool valve 2. This pushes the spool valve 2 right, fully opening the connection to the hydro accumulators. The safety valve 5 is installed to relieve the pressure. If there are excess pressure peaks, the safety valve opens to the hydraulic tank. If the speed falls below 9.1 km/h the two solenoid valves are switched off again. The lift arms can no longer vibrate.

LBH/Version 01/10.2006/en/dw/05/02/2007

The activation speed of 9.1 km/h can be adjusted using the SCULI software.

Hydraulic diagram with ride control activated 1 2 3 4

Stabilisation module Ride control spool valve Restrictor check valve Ride control solenoid valve


5 6 7 8

Safety valve Hydro accumulator unit Check valve Lift cylinder

9 Float position / ride control solenoid valve 10 Lift cylinder spool valve

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7.4.3

Stabilisation module Technical data See section 2.1

Design

Main components of the stabilisation module 1 2 3 4

Housing Safety valve Ride control piston Lift cylinder connection

5 Hydro accumulator connection 6 Tank connection 7 Ride control solenoid valve

The stabilisation module is mounted under the steering cylinder in the front section.

LBH/Version 01/10.2006/en/dw/05/02/2007

It consists of the housing 1, which contains the safety valve 2 and the ride control piston 3. The ride control solenoid valve 7 is for activating and deactivating ride control.


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Ride control

Components of the stabilisation module 1 2 3 4 5

Plug Socket-head screw Spacer bushing Spring cup Regulating spring

6 7 8 9

Regulating spring Ride control spool valve Regulating piston Ride control solenoid valve

10 11 12 13

Outer restrictor screw Restrictor check valve Inner restrictor screw Housing


LBH/Version 01/10.2006/en/dw/05/02/2007

The stabilisation module protects the hydro accumulator from excessive pressure peaks.

Hydraulic diagram of the stabilisation module

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7.4.4

Hydro accumulator unit Technical data See section 2.1

Design

Components of the hydro accumulator unit 1 Housing 2 Stabilisation module connection

3 Hydro accumulator

The hydro accumulator unit is mounted in the front section. The hydro accumulators are mounted on the housing. The housing is connected to the stabilisation module.

L550, L556 L566, L576, L580 Hydro accumulator unit

LBH/Version 01/10.2006/en/dw/05/02/2007

Function description Function The hydro accumulator unit is connected via the stabilisation module to the base end of the lift cylinders. If the maximum pressure is reached, the stabilisation module stops the oil flow to the hydro accumulators. This protects the hydro accumulator from overload. The hydro accumulators absorb bouncing and pitching vibrations. The vibration damping effect is achieved using a nitrogen filling in the hydro accumulators.


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Ride control

Oil filling on the nitrogen side of the hydro accumulator

Cross section of the hydro accumulator 1 Plug 2 Nitrogen filling 3 Oil filling

4 Membrane 5 Closing head 6 Accumulator

LBH/Version 01/10.2006/en/dw/05/02/2007

The hydro accumulators have a small amount of oil in them to protect the membrane on the nitrogen side. When sudden pressure peaks occur, such as when driving over rough ground, the oil prevents the membrane from hitting the inside of the accumulator too hard.

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7.4.5

Ride control pressure switch (ID 6905 893)


Design



The ride control pressure switch is installed under the pilot control unit in the control line for lowering the lift arms.

Function description Basic function The membrane pressure switches are for switching electric circuits on and off. The hydraulic pressure acts via a membrane on an adjustable spring. When a set value is reached, the electric contact opens and the circuit is interrupted. This type of membrane pressure switch is known as "normally closed".

Deactivating the ride control function The ride control pressure switch prevents ride control from being activated at the same time as the float position or lift arm lowering function. LBH/Version 01/10.2006/en/dw/05/02/2007

When the float position or lift arm lowering function is not activated, the contact in the ride control pressure switch is closed. This means that ride control can be activated. When the float position or lift arm lowering function is activated, the pressure on the ride control pressure switch increases and the electrical contact in the switch opens. This prevents ride control from being activated at the same time.


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Ride control

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Working hydraulics Lift and tilt cylinders

7.5 Lift and tilt cylinders 7.5.1

Lift cylinder Technical data See section 2.1

Design

Main components of the lift cylinder 1 Rod-end cylinder bearing 2 Piston rod bearing 3 Cylinder tube

4 Piston rod 5 Piston 6 Base-end cylinder bearing

7 Hex screw

The cylinder base is welded to the cylinder tube 3. The rod-end cylinder bearing 1 is forked. The base-end cylinder bearing 6 is a lug with a bearing bushing. The piston rod bearing 2 is pushed on and screwed to the cylinder tube 3. The piston 5 and the piston rod bearing 2 are fitted with Glyd Seal, Rimseal and Stepseal sealing rings.

LBH/Version 01/10.2006/en/dw/05/02/2007

The O rings are equipped with support rings.

Function description Extension and retraction The hydraulic cylinder is a double-action cylinder with a piston at one end. The maximum forces in the cylinder depend on the maximum operating pressure and the active surfaces. When extending, the piston face is active; when retracting, the smaller ring face is active. This means the force when extending is greater than when retracting. The piston speed is inversely proportional to the force. It is faster when retracting than extending.


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Lift and tilt cylinders

Piston rod guide The piston rod is guided by the guide rings on the piston and in the piston rod bearing.

Sealing The scraper ring in the piston rod bearing prevents dirt from penetrating the piston rod.

LBH/Version 01/10.2006/en/dw/05/02/2007

The O-rings and the Glyd Seal, Rimseal and Stepseal sealing rings seal the pressure chambers inside and out.

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Working hydraulics Lift and tilt cylinders

7.5.2

Tilt cylinder Technical data See section 2.1

Design

Main components of the tilt cylinder 1 Rod-end cylinder bearing 2 Piston rod bearing 3 Cylinder tube

4 Piston rod 5 Piston 6 Base-end cylinder bearing

7 Hex screw

The cylinder base is welded to the cylinder tube 3. The rod-end cylinder bearing 1 and the base-end cylinder bearing 6 form a lug with a bearing bushing. The piston rod bearing 2 is pushed on and screwed to the cylinder tube 3. The piston 5 and the piston rod bearing 2 are fitted with Glyd Seal, Rimseal and Stepseal sealing rings.

LBH/Version 01/10.2006/en/dw/05/02/2007

The O rings are equipped with support rings.


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Lift and tilt cylinders

Function description Extension and retraction The hydraulic cylinder is a double-action cylinder with a piston at one end. The maximum forces in the cylinder depend on the maximum operating pressure and the active surfaces. When extending, the piston face is active; when retracting, the smaller ring face is active. This means the force when extending is greater than when retracting. The piston speed is inversely proportional to the force. It is faster when retracting than extending.

Piston rod guide The piston rod is guided by the guide rings on the piston and in the piston rod bearing.

Sealing The scraper ring in the piston rod bearing prevents dirt from penetrating the piston rod.

LBH/Version 01/10.2006/en/dw/05/02/2007

The O-rings and the Glyd Seal, Rimseal and Stepseal sealing rings seal the pressure chambers inside and out.

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Working hydraulics Hydraulic tank

7.6 Hydraulic tank Design

Main components of the hydraulic tank 1 Shut-off valve 2 Working hydraulics pump intake port 3 Emergency steering pump intake port 4 Steering pump intake port 5 Suction line from replenishing pump

6 7 8 9 10 11 12

Steel container Gear pump intake connection Oil level sight glass Return and suction filter Return strainer Bleeder filter Fixing panels for air filter and exhaust system

The hydraulic tank is fitted on the rear section. The fittings for fastening the exhaust and air filter are on the steel part of the hydraulic tank.


The hydraulic tank contains the oil required by the hydraulic system. It supplies oil to the travel hydraulics, working hydraulics, brake system and steering system. When the machine moves, a plate inside the hydraulic tank calms the hydraulic oil. This moderating plate divides the hydraulic tank into a return chamber and an intake chamber.


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Hydraulic tank

Filter unit The filter unit consists of the following components: 1 Return suction filter 2 Return strainer 3 Bleeder filter 4 Suction line from replenishing pump The return suction filter 1 filters the oil flowing back from the working and travel hydraulics. The oil flows from the inside outwards through the filter. At the same time the filter acts as a suction filter for the replenishing pump of the hydrostatic travel drive. The replenishing pump draws up the filtered oil via the connection 4. To prevent excessive changes of pressure inside the hydraulic tank, air must be exchanged with the atmosphere outside. The bleeder filter 2 provides the connection to the outside. To prevent contamination, the air taken in from outside passes through a fine filter. A valve with a spring provides a slight pressure inside the hydraulic tank. The return strainer 3 filters some of the oil returning from the entire hydraulic system. The filtered oil then flows back to the hydraulic tank.

LBH/Version 01/10.2006/en/dw/05/02/2007

See the detailed description in the section on the filter unit and bleeder filter.

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7.6.1

Filter unit Technical data See section 2.1

Design

Main components and connections of the filter unit 13 Return and suction filter 14 Integrated bypass valve 15 Bleeder filter

16 Return strainer 17 Filter housing 18 Suction line from replenishing pump

The filter unit is contained in the hydraulic tank. LBH/Version 01/10.2006/en/dw/05/02/2007

The steel vessel is sealed with an O-ring.


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Hydraulic tank

Components of the filter unit Filter housing Return suction filter cover Return strainer cover Duct to bypass valve Bleeder filter

6 7 8 9 10

Bypass valve Pre-tension valve Suction line from replenishing pump Replenishing strainer Return strainer

11 12 13 14 15

Return pipe Replenishing valve Filter element Magnetic rod Filter casing LBH/Version 01/10.2006/en/dw/05/02/2007

1 2 3 4 5

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Function description Basic function The return suction filter 1 acts as a return filter for oil flowing back from the working and travel hydraulics, and as a suction filter for the replenishing pump of the hydrostatic travel drive. Some of oil flowing back from the various consumer units is pumped through the return suction filter 3 back to the hydraulic tank. The bleeder filter 2 prevents inadmissible pressure changes inside the hydraulic tank. This means air can be exchanged with the atmosphere outside. Connections on the filter unit: Compact brake pump leak oil Fan motor leak oil Suction line from replenishing pump Working hydraulics pump leak oil Solenoid valve block return line Working hydraulics pump leak oil Return line from control block Return line from oil cooler

LBH/Version 01/10.2006/en/dw/05/02/2007

4 5 6 7 8 9 10 11

Basic function of the filter unit 1 Control block oil cooler connection 2 Magnetic rod 3 Return and suction filter L550 - 456 / from 16978 L556 - 454 / from 15653 L566 - 460 / from 14171

L576 - 457 / from 14171 L580 - 459 / from 14171

6 Replenishing strainer 7 Pre-tension valve 8 Return strainer

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Hydraulic tank

4 Lower chamber 5 Suction line from replenishing pump

9 Return pipe

The oil flowing back from the working and travel hydraulics is pumped through the connection 1 to the return suction filter 3. The oil flows from the inside outwards through the return suction filter 3 and is cleaned. The magnetic rod 2 attracts larger metal particles from the oil flowing past. This also increases the lifetime of the filter. The outside of the filter is connected to intake connection 5 of the replenishing pump. More oil flows from the working and travel hydraulics to the return and suction filter than is drawn up by the replenishing pump. The excess oil flows through the pre-tension valve 7 to the hydraulic tank.

Oil supply to the replenishing pump The returning oil flows from the inside outwards through the return suction filter 1. The replenishing pump of the travel hydraulics draws up some of the oil from the lower chamber 2 via the intake connection 4. The pre-tension valve 3 preloads the intake connection 4 of the replenishing pump with a pressure of 0.5 bar. The excess oil flows through the pretension valve 3 to the hydraulic tank.

Replenishing pump oil supply 1 Return and suction filter 2 Lower chamber 3 Pre-tension valve

Replenishing function 4 Suction line from replenishing pump 5 Replenishing strainer 6 Replenishing valve

If there is insufficient oil to supply the replenishing pump, it can draw up oil from the hydraulic tank. Oil flows through the replenishing strainer 5 and the replenishing valve 6 to the intake connection 4 of the replenishing pump. There may be too little oil in the filter element, for instance after it is changed.

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LBH/Version 01/10.2006/en/dw/05/02/2007

The pressure of the intake connection 4 allows the replenishing to draw up oil more easily for cold starts. This increases the pressure in the hydrostatic control circuit increases more quickly and a better drive performance is achieved.

Service Manual


Bypass valve for pressure relief The bypass valve 4 prevents excess pressure in the return system. Excess pressure can arise if the filter element 1 is dirty or if the oil is not sufficiently viscous. If a certain pressure is reached, the bypass valve 4 opens. The oil then flows through the duct 3, the bypass valve 4 and the return strainer 5 to the hydraulic tank.

Return suction filter with bypass valve and return strainer 1 Return and suction filter 2 Connections to the filter unit: 3 Duct to bypass valve

4 Bypass valve 5 Return strainer

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The return strainer 5 catches dirt particles. This prevents soiling of the hydraulic tank.


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Working hydraulics

Service Manual

Hydraulic tank

7.6.2

Bleeder filter Technical data See section 2.1

Design

Components of the bleeder filter 1 2 3 4 5

Filter housing Inlet valve Pressure spring Outlet valve Pressure spring

6 7 8 9

O-ring Fine filter O-ring Inner housing

The bleeder filter consists of an oil-resistant, corrosion-proof plastic housing in which a filter element folded in a star shape is inserted. The bleeder filter contains an inlet and outlet valve.

Function description Function

To prevent contamination, the air taken in from outside passes through the fine filter. The spring-loaded outlet valve 2 and inlet valve 3 reduce the exchange of air. This minimises the oil contamination and increases the service life of the fine filter element.

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To prevent excessive changes of pressure inside the hydraulic tank, air must be exchanged with the atmosphere outside.

Service Manual


Excess pressure in the hydraulic tank Excess pressure in the hydraulic tank can be caused by increased oil temperature or by the hydraulic cylinders retracting. At a certain excess pressure, the outlet valve 2 opens. This allows air to escape through the fine filter 1 and the opening 3.

Insufficient pressure in the hydraulic tank Insufficient pressure in the hydraulic tank can be caused by decreasing oil temperature or by the hydraulic cylinders extending.

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At a certain low pressure, the inlet valve 4 opens. This allows air to flow in through the opening 3 and the fine filter 1.


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Working hydraulics

Service Manual

LBH/Version 01/10.2006/en/dw/05/02/2007

Hydraulic tank

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8 Steering System 8.0 Chapter contents 8

Steering System.................................................................. 8.0-1 8.0

Steering system ..............................................................................8.0-1

8.1

Steering pump ................................................................................8.1-1

8.2

Servostat.........................................................................................8.2-1

8.3

Steering cylinder .............................................................................8.3-1 8.3.1

8.4

Steering damper hydro accumulator ....................................8.3-3 Emergency steering........................................................................8.4-1 Emergency steering pump ...................................................8.4-5

8.4.2

Emergency steering pressure switch ...................................8.4-7

8.4.3

Emergency steering check pressure switch .........................8.4-8

8.4.4

Valve block ...........................................................................8.4-9

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8.4.1


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Steering System

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Service Manual

Steering System

8.0 Steering system

LBH/Version 01/10.2006/en/dw/26/01/2007

Design

Main components of the steering system 1 2 3 4

Servostat Oil cooler Collector pipe Hydraulic tank

5 6 7 8

Variable displacement pump Valve block Emergency steering pump Left steering cylinder

9 Steering damper hydro accumulator 10 Right steering cylinder

The machine has articulated steering. Two steering cylinders move the front section and the rear section to each other using the articulated joint.


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Steering System PowerPoint


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Basic function

Hydraulic diagram of the steering system

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Service Manual

1 2 3 4 5 6 7 8 9 10 11 12 13 14

Steering System

Hydraulic tank Bleeder filter Return strainer Bypass valve Return suction filter Pre-tension valve Replenishing valve with strainer Travel pump return line Fan motor leak oil Compact brake pump leak oil Solenoid valve block leak oil Return line from oil cooler Shut-off valve Working hydraulics pump intake port 15 Hydraulic oil temperature sensor 16 Right steering cylinder 17 Right steering damper hydro accumulator

18 Left steering cylinder 19 Left steering damper hydro accumulator 20 Variable displacement pump 21 Axial piston pump 22 Servo cylinder 23 Return cylinder 24 Restrictor 25 Restrictor 26 Pressure cut-off 27 Flow controller 28 Working hydraulics pump return line 30 Servostat 31 Left replenishing valve 32 Left pressure relief valve 33 Right replenishing valve 34 Right pressure relief valve 35 Metering pump

36 40 41 42 43 44 45 46 47 48 50 51 52

Valve slider Valve block Check valve Check valve Variable displacement pump pressure switch B3 Emergency steering pump pressure switch B3a Emergency steering pump Electric motor Gear pump Pressure relief valve Oil cooler Collector pipe Bypass valve

Test connections: P High pressure / steering pump M High pressure / steering pump or emergency steering pump

The steering system operates in an open circuit. The variable displacement pump 20 draws up oil from the hydraulic tank 1 and pumps it through the valve block 40 to the servostat 30. The servostat supplies oil to the two steering cylinders when the steering wheel is moved. The load sensing system ensures that the pump 20 only pumps as much oil as is actually required. The emergency steering system allows steering movement if the variable displacement pump fails. The emergency steering pump 45 delivers oil via the valve block 40 to the servostat 30. The hydro accumulators 17 and 18 on the steering cylinders absorb steering movements. The absorber system in the steering cylinder prevents the front and rear sections from bumping other at full articulation.

Hydraulic tank The hydraulic tank provides filtered oil for the steering system. The variable displacement pump draws up oil from the hydraulic tank via the connection 1. The returning oil from the servostat is pumped back through the oil cooler and the connection 3 via the return suction filter 4 to the hydraulic tank. Leak oil from the variable displacement pump is directed through the connection 2 via the return strainer 5 to the hydraulic tank. The bleeder filter 6 compensates for pressure differences inside the hydraulic tank by providing appropriate ventilation. LBH/Version 01/10.2006/en/dw/26/01/2007


Variable displacement pump The pump draws up oil directly from the hydraulic tank and pumps it through the valve block to the servostat. The load sensing system ensures that the variable displacement pump only provides as much oil as the steering system currently needs. The pressure cut-off valve 2 limits the maximum pressure of the pump. See the detailed description in the section on the variable displacement pump.


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Steering System

Service Manual Valve block The valve block directs the oil from the variable displacement pump or the emergency steering pump to the servostat. The emergency steering pressure switch 1 monitors the pressure of the variable displacement pump. If the pressure at the emergency steering pressure switch 1 is too low, the emergency steering pump is automatically activated. This can happen if the diesel engine shuts down or if the variable displacement pump fails. The check valves 2 and 3 prevent the oil from flowing back to the pumps. See the detailed description in the section on the valve block.

Servostat The servostat is connected to the steering column. The steering wheel actuates the metering pump and valve slider in the servostat, causing the steering system to move. If the steering wheel is moved quickly, the flow booster system pumps some of the oil via the spool directly to the steering cylinders. This facilitates fast steering on rough terrain. When the steering wheel is moved slowly, the flow booster is not activated. All the oil is pumped through the spool and the metering pump to the steering cylinders. This facilitates sensitive steering on roads. Two pressure relief valves protect the steering cylinder and servostat from excessive pressure peaks. See the detailed description in the section on the servostat.

Steering cylinder The steering cylinders are connected to the front and rear sections. The servostat supplies oil to the steering cylinders during steering. The hydro accumulators on the steering cylinders absorb steering movements. The absorber system in the steering cylinder prevents the front and rear sections from bumping other at full articulation. See the detailed description in the section on the steering cylinder.

The emergency steering function allows the steering system to be operated if the engine or the variable displacement pump fails. The emergency steering pump is activated by the main electronics (master). See the detailed description in the section on emergency steering.

Emergency steering pump The gear pump 4 of the emergency steering pump is powered by the electric motor 2. The electric motor is switched on when necessary via the relay 1. In emergency steering mode the emergency steering pump draws up oil from the hydraulic tank and pumps it through the valve block to the servostat. The pressure relief valve 3 protects the pump from excess pressure. See the detailed description in the section on the emergency steering pump.

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Emergency steering function

Service Manual

Steering System

Steering pump

8.1 Steering pump Technical data See section 2.1

Design

Main components of the steering pump 1 Drive shaft 2 Pump housing 3 Flow controller

4 Pressure cut-off 5 Connection housing

The steering pump is an axial piston pump with a swash plate design. The steering pump is flange-mounted to the working hydraulics pump and is driven by the diesel engine via this unit.

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The pressure and flow controller attached to pump housing affect the control unit of the pump.


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Steering System

Service Manual

Steering pump

Components of the steering pump Drive shaft Snap ring Shaft seal ring Pump housing Bearing casing Swash plate Return plate Piston

9 10 11 12 13 14 15 16

Cylinder Control plate O-ring P connection Valve housing Shim Tapered roller bearing Shim

17 18 19 20 21 22 23 24

Intake connection Snap ring Support ring Pressure spring Support ring Glide shoe Return ball Tapered roller bearing

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1 2 3 4 5 6 7 8

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Service Manual

Steering System

Steering pump

Components of the steering pump Ball journal Glide shoe Servo piston Regulating spring Piston guide

6 7 8 9 10

Test connection P Plug Pressure cut-off Flow controller LS connection

11 12 13 14

Guide piston Return cylinder Glide shoe Ball journal

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1 2 3 4 5


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Steering System

Service Manual

Steering pump


Hydraulic plan of the variable displacement pump 1 2 3 4 5 6

Rotary group Servo cylinder Return cylinder Restrictor Restrictor Pressure cut-off

7 8 9 10 11 12

Flow controller High pressure test connection Oil to servostat LS signal from servostat Return line to hydraulic tank Intake connection

The steering pump operates in an open circuit. During operation, the pump delivers oil from the hydraulic tank through the valve block to the steering. The displacement of the steering pump is proportional to the input speed and the variable cylinder volume. The pressure cut-off valve 6 and flow controller 7 attached to pump housing affect the control unit of the pump. The pump control unit pivots the swash plate out of the zero position. When the swash plate pivots out, the piston stroke in the rotary group 1 increases and the pump starts delivering oil.

Control unit

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The control unit continuously regulates the steering pump flow. The angle of the swash plate 3 is changed from 0° towards 15° and vice versa.

Control unit with return cylinder and actuating cylinder

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Service Manual

Steering System

Steering pump

The system pressure constantly acts on the actuating cylinder 1. The actuating cylinder 1 pushes the swash plate 3 towards a wider angle and pump delivers oil. The return cylinder 2 moves the swash plate 3 against the actuating cylinder 1 to a smaller angle. The effective piston face of the return cylinder 2 is larger than that of the actuating cylinder 1. The oil pressure acting on the return cylinder 2 is controlled by the flow controller or pressure cut-off valve. In the pump control range, the oil pressure on the return cylinder is just enough to keep the forces of the actuating and return cylinders in equilibrium. This means the pump can maintain a specific pivot angle and pump a corresponding amount of oil.

Flow controller (load sensing) The load sensing system ensures that the variable displacement pump only provides as much oil from the hydraulic tank as the steering system currently needs. If the steering system needs oil, the load pressure at the connection 4 increases. The pressure and the force of the springs 5 push the piston 2 against the pump pressure. The duct A opens to the tank connection T. The open duct A relieves the return cylinder 3 and the pump delivers the required quantity of oil.

Flow controller during steering (pump delivers oil) Flow controller Valve piston Plug Connection X Pressure springs

6 7 T A P

Adjusting screw Pressure cut-off Pump housing return line To the return cylinder High pressure

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1 2 3 4 5


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Steering System

Service Manual

Steering pump

If the steering wheel is not moved, the load pressure at the connection 4 decreases. The pump pressure moves the piston 2 against the springs 5. The piston 2 opens the pump pressure duct P to the duct A and the return cylinder regulates the pump to the minimum flow.

Flow controller with no steering movement (pump does not deliver oil)

Pressure cut-off When the maximum operating pressure in the system has been reached, the pump moves back to the smallest angle and only delivers leak oil. The maximum operating pressure remains constant. When the pump reaches its maximum operating pressure, the piston 3 in the pressure cut-off valve 1 moves against the spring 4. This opens the duct A and pressure oil flows to the return cylinder.

Pressure cut-off valve at maximum system pressure 1 2 3 4

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Pressure cut-off Effective face Valve piston Pressure spring

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5 P A T

Adjusting screw High pressure To the return cylinder Pump housing return line

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The return cylinder moves the swash plate and regulates the pump to the smallest angle.

Service Manual

Steering System

Servostat

8.2 Servostat Technical data See section 2.1

Design

Main components of the servostat 1 Left pressure relief valve 2 Inner rotary slide valve with teeth

3 Right pressure relief valve 4 Housing with spool valve 5 Metering pump

The servostat is fastened on rubber fittings at the front under the cab. The rubber fittings prevent noise from the hydraulics from being transferred to the steel cab frame.

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The steering column meshes with the teeth of the internal rotary slider 2. The internal rotary slider in the servostat is actuated by the steering wheel and the steering column.


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Steering System

Service Manual

Servostat

Components of the servostat Closing plate Metering pump Internal gear O-ring Intermediate flange Outer valve sleeve

7 8 9 10 11 12

Internal rotary slider Flight Actuator journal Housing Needle bearing Guide ring

13 14 15 16 17

Shaft seal ring Right pressure relief valve Leaf springs Left pressure relief valve Replenishing valve

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1 2 3 4 5 6

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Service Manual

Steering System

Servostat


Hydraulic diagram of the servostat 1 2 3 4 5 6

Left replenishing valve Left pressure relief valve Right replenishing valve Right pressure relief valve Metering pump Valve slider

7 8 9 10 11

Return line to hydraulic tank Steering cylinder connection Steering cylinder connection Oil from valve block Load sensing signal

When it is actuated, the servostat directs oil from the variable displacement pump to the steering cylinders. The oil supply to the steering cylinders is precisely metered according to the speed of the steering wheel. When the steering wheel is turned, the position of the internal rotary slider is turned in relation to the outer valve sleeve. This opens the valve, allowing a certain amount of oil to flow through the metering pump to the steering cylinder.

Flow booster

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The flow booster allows the small servostat to supply oil from two cylinders. A specific portion of the flow is directed through the metering pump, and another portion is pumped through the spool directly to the cylinders.

Diagram of flow booster 1 Boost ratio 2 Turns of steering wheel


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3 Oil via the metering pump 4 Oil via the spool

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Steering System

Service Manual

Servostat

If the steering wheel is moved slowly, the entire flow is directed through the metering pump 3. The oil flowing to the steering system depends on the size of the metering pump. This allows very sensitive steering for travelling on roads. At faster steering speeds of more than 10 turns of the steering wheel per minute, additional holes in the spool open. Some of the oil flows through the metering pump 3, and more oil flows the spool 4 directly to the cylinders. The volumetric flow ration is 1:1.6. This allows very fast steering for rough terrain.

Flow regulation (load sensing) Load sensing ensures that the variable displacement pump only supplies the amount of oil currently needed by the steering system. The servostat reports the required amount of oil via the LS connection to the variable displacement pump. Steering system in inactive state

When the steering is not actuated, the duct P on the variable displacement pump 3 is blocked. The LS connection for controlling the pump is relieved via the spool to the tank connection T. The LS depressurised connection adjusts the variable displacement pump minimum flow.

Steering system in active state

When the steering is actuated, the spool 2 is moved. The connection P is connected to the connection LS and to the steering cylinder. The increase pressure at the LS connection causes the flow controller 4 to regulate the variable displacement pump 3 to the required oil quantity.

Pressure cut-off The pressure relief valves prevent excessive pressure peaks in the steering system. Pressure peaks can be caused by sudden loads while driving. Depending on the direction of the load, either the pressure relief valve 1 on the left steering cylinder or the pressure relief valve 2 for the right cylinder opens.

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The variable displacement pump 3 is adjusted until there is a specific pressure difference between the connection P and the connection LS.

Service Manual

Steering System

Servostat

When the set pressure is reached, the valve cone 6 opens against the pressure spring 4. Oil flows from the consumer unit 7 to the tank connection 5. The opening pressure of the pressure relief valve can be set using the adjusting screw 3.

Replenishing function The servostat has two replenishing valves: one for steering to the left and one for steering to the right.

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The replenishing valves prevent vacuums from forming in the steering cylinder under certain operating conditions. Oil flows through the check valve 2 from the tank duct 1 to the steering cylinder (duct 3). The pin 4 prevents the check valve 2 from moving too far from the valve insert.


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Steering System

Service Manual

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Servostat

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Service Manual

Steering System Steering cylinder

8.3 Steering cylinder Technical data See section 2.1

Design

Main components of the steering cylinder 1 Rod-end cylinder bearing 2 Piston rod bearing 3 Cylinder tube

4 Piston rod 5 Piston 6 Damper bushing

7 Base-end cylinder bearing

The cylinder base is welded to the cylinder tube 3. The rod-end cylinder bearing 1 and the base-end cylinder bearing 7 form a lug with a swivel bearing. The piston rod bearing 2 is screwed into the cylinder tube 3. The piston 5 and the piston rod bearing 2 are fitted with Glyd Seal, Rimseal and Stepseal sealing rings.

Function description LBH/Version 01/10.2006/en/dw/26/01/2007

Extension and retraction The hydraulic cylinder is a double-action cylinder with a piston at one end. The maximum forces in the cylinder depend on the maximum operating pressure and the active surfaces. When extending, the piston face is active; when retracting, the smaller ring face is active. This means the force when extending is greater than when retracting. The piston speed is inversely proportional to the force. It is faster when retracting than extending.

Piston rod guide The piston rod is guided by the guide rings on the piston and in the piston rod bearing. L550 - 456 / from 16978 L556 - 454 / from 15653 L566 - 460 / from 14171

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Steering System

Service Manual

Steering cylinder

Sealing The scraper ring in the piston rod bearing prevents dirt from penetrating the piston rod. The O-rings and the Glyd Seal, Rimseal and Stepseal sealing rings seal the pressure chambers inside and out.

Stroke end shock absorber

Stroke end shock absorber 1 Piston rod 2 Piston

3 Damper bushing 4 Damper notch

The piston rod is slowed down before it is fully retracted. Just before the piston 2 hits the cylinder base, it enters the damper bushing 3 in the cylinder base.

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The oil can only flow through the damper notch 4. This decreases the flow diameter for the displaced oil and the speed of the piston is reduced.

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Service Manual

Steering System Steering cylinder

8.3.1

Steering damper hydro accumulator Technical data See section 2.1

Design

Components of the hydro accumulator 1 Plug for test and filling valve 2 Membrane



Function description Basic function The purpose of the hydro accumulator is to store hydraulic energy and supply it when needed.

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It has the following applications: – To act as an attenuator for pressure peaks, for example for the ride control system or steering attenuation. – As an energy reserve to supply energy when needed, for example for the brake system.

Steering damper The hydro accumulators on the steering cylinders absorb steering movements when changing direction quickly. Also, the damping effect absorbs external influences on the machine, for example if the working attachment is driven against an obstacle.


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Steering System

Service Manual

Steering cylinder

Oil filling on the nitrogen side of the hydro accumulator

Cross section of the hydro accumulator 1 Plug for test and filling valve 2 Nitrogen filling 3 Oil filling

4 Membrane 5 Closing head 6 Accumulator

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The hydro accumulator has a small amount of oil in it to protect the membrane on the nitrogen side. When sudden pressure peaks occur, such as when driving on rough terrain or suddenly moving the steering wheel, the oil prevents the membrane from hitting the inside of the accumulator too hard.

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Service Manual

Steering System Emergency steering

8.4 Emergency steering Design

Main components of the emergency steering 1 Emergency steering button 2 Emergency steering check symbol field 3 Emergency steering symbol field 4 Main electronics (master) 5 Input module 1 6 Emergency steering pressure switch B3

7 Valve block 8 Emergency steering check pressure switch B3a 9 Emergency steering pump 10 Emergency steering pump relay 11 Output module 2

The emergency steering pump 9, the emergency steering pump relay 10 and the emergency steering check pressure switch 8 are mounted on the right of the rear section. The valve block 7 and the emergency steering pressure switch 6 are mounted on the left of the rear section.

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The main electronics (master) 4 are located in the cab behind the driver's seat. The input module 1 and the output module 2 are fitted in the right cab access.


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Steering System

Service Manual

Emergency steering


Functional diagram of the emergency steering 1 Emergency steering button 2 Emergency steering check symbol field 3 Emergency steering symbol field 4 Main electronics (master) 5 Input module 1 6 Emergency steering pressure switch B3

7 Valve block 8 Emergency steering check pressure switch B3a 9 Emergency steering pump 10 Emergency steering pump relay 11 Output module 2

The emergency steering system allows continued steering if the variable displacement pump or the diesel engine fails. The emergency steering pump 9 delivers oil via the valve block 7 to the servostat.

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The emergency steering pump is regulated by the main electronics (master) 4. The emergency steering check pressure switch 8, and the emergency steering pressure switch 5 provide the main electronics with the necessary signals. The emergency steering button 1 is for restarting the emergency steering pump.

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Service Manual


Pressure switch test When you switch on the ignition, the pressure switches are tested. The pressure switch is powered (24 V) via the fuse F11. When the system is OK, no signal is returned to the input module 1. This tells the main electronics (master) 2 that the pressure switch is working properly. The symbol fields 3 and 4 do not light up. If the pressure switch is defective or if there is moisture in the plug or cable, a positive signal is sent to the input module 1. If the emergency steering pressure switch 5 is defective, the emergency steering symbol field 4 lights up. If the emergency steering pressure check switch 6 is defective, the emergency steering check symbol field 3 lights up.

Function diagram of the emergency steering when the pressure switch is defective (ignition on, engine off, both pressure switches closed in the depressurised state) 1 Input module 1 2 Main electronics (master) 3 Emergency steering check symbol field 4 Emergency steering symbol field

5 Emergency steering pressure switch 6 Emergency steering check pressure switch 7 Emergency steering pump

Emergency steering check Every time the machine is started up the system performs a brief safety test. This safety test is not performed until the engine is running. This is to prevent the high current consumption of the emergency steering pump from impairing the starting procedure.

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During the safety test, the emergency steering pump is activated. The pump runs for 2 to 3 seconds. A pressure of 16 bar must be reached within this time. The contact on the emergency steering check pressure switch 6 closes. During the safety test, the emergency steering check symbol field 3 lights up. The emergency steering system is then operational and the emergency steering check symbol field goes out. If the pressure at the emergency steering check pressure switch 6 does not reach 16 bar, the check symbol field stays lit until the ignition is switched off. The safety test is interrupted after 3 seconds. The emergency steering field check symbol field indicates to the driver that the emergency steering system is defective.


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Steering System

Service Manual

Emergency steering

Activated emergency steering system

Functional diagram of the emergency steering 1 Input module 1 2 Output module 2 3 Emergency steering check pressure switch 4 Emergency steering pressure switch 5 Electric motor

6 7 8 9 10

Valve block Oil from the steering pump To servostat Emergency steering button Main electronics (master)

If the diesel engine or the steering pump 7 fails, the emergency steering function is started automatically. If the pressure drops, the emergency steering pressure switch 4 sends a signal via the input module 1 to the main electronics (master) 10. The main electronics give the start command to the output module 2 and the emergency steering pump starts pumping oil. At the same time the emergency steering symbol field lights up, accompanied by an audible signal. The emergency steering function is provided for 40 seconds. The electric motor 5 of the emergency steering pump is automatically switched off.

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The emergency steering pump can only started manually using the emergency steering button 9. This function is only available for 10 seconds if the ignition is on.

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Service Manual


8.4.1

Emergency steering pump Technical data See section 2.1

Design

Main components of the emergency steering pump 1 Relay 2 Electric motor

3 Pressure relief valve 4 Gear pump

LBH/Version 01/10.2006/en/dw/26/01/2007

The emergency steering pump is mounted on the right of the rear section.

Components of the emergency steering pump 1 2 3 4

Relay Electric motor Connector piece Sealing ring


5 6 7 8

Flange Seals Bushing Gears

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9 Housing 10 Valve housing 11 Pressure relief valve

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Steering System

Service Manual

Emergency steering

Function description Basic function The gear pump of the emergency steering pump is powered by the electric motor. The electric motor is switched on and off via a relay. The gear pump draws up oil from the hydraulic tank as needed. The oil is pumped via the valve block to the servostat. A pressure relief valve protects the pump from excess pressure.

Gear pump with pressure relief valve The gear pump 1 of the emergency steering pump is protected by a pressure relief valve. By restricting the maximum pressure, this also prevents the electric motor from consuming too much current. The system pressure pushes the valve piston 2 against the spring 3. If the maximum pressure is reached, the valve piston 2 opens. This allows hydraulic oil to flow out to the intake side of the gear pump. The maximum pressure is determined by the pressure spring 3 and the adjusting disc 4.

Emergency steering pump relay

Emergency steering pump with electric diagram 1 Relay 2 Positive current supply 3 Relay activation

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4 Output module 2 5 Electric motor 6 Main earth connection

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LBH/Version 01/10.2006/en/dw/26/01/2007

The electric motor 5 of the emergency steering pump is switched on and off via the relay 1. The relay 1 is activated by the main electronics (master) and the output module 2. The relay is designed to switch large currents.

Service Manual


8.4.2

Emergency steering pressure switch ID 1029 4440


Design



The emergency steering pressure switch 1 is mounted on the valve block 2.


Membrane pressure switches are for switching electric circuits on and off. The hydraulic pressure acts via a membrane on an adjustable spring. When a set value is reached, the electric contact closes and the circuit is closed. This type of membrane pressure switch is known as “normally open”.

Activating the emergency steering function The emergency steering pressure switch monitors the steering system pressure. If the diesel engine or the steering fails, the pressure at the emergency steering pressure switch drops. If the pressure drops, the switch contact opens. This interrupts the positive signal to the input module 1 and the emergency steering system is activated.


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Steering System

Service Manual

Emergency steering

8.4.3

Emergency steering check pressure switch ID 1029 4440


Design



The emergency steering pressure switch 2 is mounted on the emergency steering pump 1.


Membrane pressure switches are for switching electric circuits on and off. The hydraulic pressure acts via a membrane on an adjustable spring. When a set value is reached, the electric contact closes and the circuit is closed. This type of membrane pressure switch is known as “normally open”.

Activating the emergency steering function The job of the emergency steering check pressure switch is to test the emergency steering system. When the diesel engine is started, the emergency steering pump begins to pump oil. If the pressure rises to the set level, the switch contact closes. A positive signal to the input module 1 is activated and the emergency steering check is successfully completed.

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LBH/Version 01/10.2006/en/dw/26/01/2007

Basic function

Service Manual


8.4.4

Valve block Design

Components and connections on the valve block 1 Oil from the emergency steering pump 2 Oil from the variable displacement pump 3 Emergency steering pressure switch 4 Variable displacement pump check valve

5 6 7 8

To servostat Housing Steering test connection Emergency steering pump check valve

The valve block is fitted on left of the rear section.


LBH/Version 01/10.2006/en/dw/26/01/2007

The valve block connects the oil from the variable displacement pump or the emergency steering pump to the servostat.

Hydraulic plan of the valve block 1 Oil from the variable displacement pump 2 Emergency steering pressure switch 3 Oil from the emergency steering pump 4 Emergency steering pump check valve


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5 Variable displacement pump check valve 6 To servostat 7 Steering pressure test connection

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Steering System

Service Manual

Emergency steering

The emergency steering pressure switch 2 monitors the pressure of the variable displacement pump. If the pressure at the switch 2 is too low, the emergency steering pump is automatically activated. This can happen if the diesel engine fails or if the variable displacement pump pressure drops. The check valves 4 and 5 prevent oil from flowing back to the pump. Valve block during normal steering function

Valve block during normal steering function When the steering is activated, the variable displacement pump delivers oil to the connection 2 and via the check valve 4 to the servostat. The check valve 8 prevents oil from flowing back to the emergency steering pump.

Valve block during emergency steering function The emergency steering pump delivers oil to the connection 1 and via the check valve 8 to the servostat. The check valve 4 prevents oil from flowing back to the variable displacement pump.

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LBH/Version 01/10.2006/en/dw/26/01/2007

Valve block during emergency steering function

9 Brake system 9.0 Chapter contents 9

Brake system ...................................................................... 9.0-1 9.0.1 9.1

Brake system........................................................................9.0-1 Service brake ..................................................................................9.1-1

9.1.1

Brake system gear pump......................................................9.1-1

9.1.2

Compact brake valve............................................................9.1-3

9.1.3

Service brake hydro accumulator.........................................9.1-7

9.1.4

Brake light pressure switch ..................................................9.1-9

9.1.5

Accumulator charge pressure switch .................................9.1-10

9.2

Parking brake..................................................................................9.2-1 9.2.1

Disc brake.............................................................................9.2-2

9.2.2

Parking brake hydro accumulator.........................................9.2-4

9.3

Overspeed protection .....................................................................9.3-1 Overspeed protection solenoid valve ...................................9.3-3

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9.3.1


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9.0-1 o f 2

Service Manual

LBH/version 01/10.2006/en/dw/26/01/2007

Brake system

9.0-2 o f 2

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Service Manual

Brake system 9.0.1

Brake system Design

LBH/version 01/10.2006/en/dw/26/01/2007

Main components of the brake system 1 Compact brake valve 2 Front axle service brake hydro accumulator 3 Rear axle service brake hydro accumulator 4 Parking brake hydro accumulator 5 Brake system gear pump 6 Hydraulic tank

7 Rear axle 8 Pilot control solenoid valve 9 Overspeed protection solenoid valve 10 Pilot control hydro accumulator 11 Oil from the replenishing pump 12 Transmission with parking brake

13 Front axle Test connections: M3 Accumulator charge pressure M4 Front axle brake pressure M5 Rear axle brake pressure M6 Parking brake pressure

The gear pump 5 is flange-mounted on the engine. Together with the compact brake valve 1, its job is to charge the hydro accumulators of the brake system. The hydro accumulators for the service brake are fitted outside on the cab floor. The hydro accumulator for the parking brake mounted directly on the compact brake valve. The service brake is a wet disc brake mounted in the wheel hubs of both axles. The parking brake is a disc brake attached to the transmission 12.


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Brake system

Service Manual

PowerPoint


1 2 3 4 5 6 7 8 9 10 11 12

Hydraulic tank Return strainer Brake system gear pump Replenishing pump Solenoid valve block Overspeed protection solenoid valve Pilot control solenoid valve Check valve Pilot control hydro accumulator Compact brake valve assembly Accumulator charge valve Pressure balance pilot valve

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13 14 15 16 17 18 19 20 21 22 23

Check valve Inverted shuttle valve Check valve Parking brake solenoid valve Inching angle sensor Pressure control piston for st 1 circuit Pressure control piston for 2nd circuit Accumulator charge pressure switch Front axle disc brakes Front axle hydro accumulator Parking brake hydro accumulator

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24 25 26 27 28 29

Transfer gear Parking brake Brake light pressure switch Rear axle disc brakes Rear axle hydro accumulator Control valve block (housing spreheating)

Test connections: M3 Accumulator charge pressure M4 Front axle brake pressure M5 Rear axle brake pressure M6 Parking brake pressure

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Hydraulic diagram of the brake system

Service Manual

Brake system The service brake is a hydraulic 2-circuit brake system. It acts on the wet discs in the front and rear axles. The brake system gear pump 3 draws up oil from the hydraulic tank 1 and pumps it to the compact brake valve 10. The accumulator charge valve 11 in the compact brake valve fills the hydro accumulators to a specified oil pressure. When the inch/brake pedal is slightly depressed (up to 2/3 of the way down), only the hydraulic inching function is activated via the inching angle sensor 17. When the inch/brake pedal is fully depressed (in the last third), oil flows from the hydro accumulators 22 and 28 via the pressure control pistons 18 and 19 to the brake pistons in the front and rear axles. This activates the wet disc brakes. At the end of the braking procedure, the oil flows into the hydraulic tank. The parking brake 25 is opened by oil pressure and closed by spring force. When the parking brake solenoid valve 16 is energised, oil flows from the parking brake hydro accumulator 23 to the parking brake and opens the callipers.

Hydraulic tank The hydraulic tank provides filtered oil for the brake system. The gear pump draws up oil from the hydraulic tank via the connection 1. The returning oil is pumped back through the return strainer 3 to the hydraulic tank. The bleeder filter 4 compensates for pressure differences inside the hydraulic tank by providing appropriate ventilation. See the detailed description in the section on the hydraulic tank.

Brake system gear pump The brake system gear pump 2 draws up oil from the hydraulic tank and pumps it through the connection 4 to the compact brake valve. The cooling system gear pump 3 and the brake system gear pump 2 have a shared intake port. See the detailed description in the section on the brake system gear pump.

Compact brake valve with hydro accumulator LBH/version 01/10.2006/en/dw/26/01/2007

The compact brake valve performs the following tasks: – Charging the hydro accumulator – Inching function when the inch/brake pedal is slightly depressed – Braking function when the inch/brake pedal is fully depressed – Activating the parking brake via the parking brake solenoid valve


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Brake system

Service Manual

The accumulator charge valve fills the hydro accumulators 2, 3 and 4 to a specified oil pressure. The accumulator charge pressure switch 5 monitors the pressure in the hydro accumulators. When the inch/brake pedal is pressed, oil flows from the service brake hydro accumulators 3 and 4 to the wet disk brake. The contact on the brake light pressure switch 6 closes and the brake lights light up. See the detailed description in the section on the compact brake valve.

Service brake The service brake is a wet disc brake 1 mounted in the front and rear axles. The oil pressure pushes the brake discs together. The number of brake discs and the brake pressure determine the braking force.

L550, L556, L566, L576 1 Brake piston 2 Brake discs

9.0-4 o f 6

Brake discs in the axle

3 Wheel hub (Multitrac axle)

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L580 4 Differential (Hercules axle)

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LBH/version 01/10.2006/en/dw/26/01/2007

See the detailed description of the wet disc brake in the section on the axles.

Service Manual

Brake system Parking brake The parking brake is attached to the output shaft of the transmission 4 and thus acts on all four wheels.

The parking brake is opened by oil pressure and closed by spring force. When you start the engine and press the parking brake button, the solenoid valve 2 in the compact brake valve 1 is activated. Oil flows from the hydro accumulator 3 to the parking brake 5, where it acts on the brake cylinder and opens the callipers. When you press the parking brake button again or turn off the engine, the force of the springs in the brake cylinder closes the brake, thus generating the required braking torque on the brake disc. When the parking brake is closed, the LED in the parking brake button and the parking brake symbol field in the display light up. See the detailed description in the section on the parking brake.

Overspeed protection The overspeed protection prevents the engine and the variable displacement motors from overrevving, which can occur, for example, when driving downhill.

LBH/version 01/10.2006/en/dw/26/01/2007

When a set limit speed is exceeded, the overspeed protection solenoid valve 3 is activated. Oil flows from the replenishing pump 2 to the rear axle disc brake 5, causing the machine to slow down. See the detailed description in the section on overspeed protection.


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9.0-5 o f 6

Service Manual

LBH/version 01/10.2006/en/dw/26/01/2007

Brake system

9.0-6 o f 6

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Service Manual

Brake system Service brake

9.1 Service brake 9.1.1

Brake system gear pump Technical data See section 2.1

Design

Scavenging pump arrangement 1 Motor scavenging pump

2 Brake system gear pump 3 Cooling system gear pump

LBH/version 01/10.2006/en/dw/26/01/2007

The gear pumps are fitted on the accessory drive of the engine and is driven by the engine at a specific transmission ratio via a spur gear.

Brake system gear pump components 1 2 3 4 5


Driver O-ring Flange Seals Bearing bushings

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6 7 8 9

Gears Housing Housing cover Shaft seal ring

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9.1-1 o f 1 0

Brake system

Service Manual

Service brake

Function description Basic function The gear pump consists of two intermeshing gears enclosed in a housing. One of the two gears is driven via the outgoing shaft (driving gear), and the other driven by the gear teeth. The fluid taken in is injected into the gaps between the teeth and pumped outside along the housing from the intake port to the pressure port.

Oil supply for the brake system

The brake system gear pump 2 draws up oil from the hydraulic tank 4 via the internal intake duct of the cooling system gear pump 3. The oil is pumped via the discharge port to the compact brake valve 1.

Pressure cut-off

LBH/version 01/10.2006/en/dw/26.01.2007

The brake system gear pump pressure cut-off is performed by the pressure relief valve in the compact brake valve.

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Service Manual


9.1.2

Compact brake valve Technical data See section 2.1

Design This compact brake valve is attached to the cab floor. It is activated using the inch/brake pedal.

Main components of the compact brake valve Actuation pedal Inching angle sensor R1 Brake pressure adjusting screw Brake light pressure switch Compact brake valve housing

6 Accumulator charge valve 7 Parking brake solenoid valve 8 Accumulator charge pressure switch 9 Base plate

LBH/version 01/10.2006/en/dw/26/01/2007

1 2 3 4 5


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Brake system

Service Manual

Cross section of the compact brake valve 1 2 3 4 5 6 7 8 9

Pedal idle position adjusting screw Base plate Parking brake check valve Pressure balance check valve Accumulator pressure test piston Valve insert Compact brake valve housing Pilot valve actuating piston Pressure relief valve

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10 Opening/closing pressure adjusting screw 11 Inverted shuttle valve 12 Return spring for 2nd brake circuit 13 Pressure control piston for 2nd brake circuit 14 Return spring for 1st brake circuit 15 Pressure control piston for 1st brake circuit 16 Spring cup

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17 Pressure control spring 18 Brake pressure adjusting screw 19 Seal rings 20 Pressure control springs 21 Spring sleeve 22 Actuating piston 23 Actuation pedal

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Service brake

Service Manual



Hydraulic diagram of the compact brake valve 1 Parking brake solenoid valve 2 Inching angle sensor 3 Pressure control piston for 1st circuit 4 Pressure control piston for 2nd circuit 5 Inverted shuttle valve 6 Check valve 7 Pressure balance pilot valve 8 Check valve

9 10 11 12

Accumulator charge valve Flow control nozzle Gear pump P connection To the control valve block (housing preheating) 13 Accumulator charge pressure switch 14 Front axle hydro accumulator 15 Parking brake hydro accumulator

16 Parking brake connection 17 Front axle connection 18 To the overspeed protection solenoid valve 19 Brake light pressure switch 20 Rear axle hydro accumulator 21 Hydraulic tank connections M3 Accumulator charge pressure test connection

The compact brake valve is supplied with oil by a gear pump. The integrated accumulator charge valve 9 and the pilot valve 7 fill the hydro accumulator with pressure oil. If the accumulator charge cut-off pressure is reached, the accumulator charge valve 9 switches the pump flow to circulate to the connection N. LBH/version 01/10.2006/en/dw/26/01/2007

If braking causes the accumulator pressure to fall to the accumulator charge cutin pressure, the accumulator charge valve 9 switches to accumulator charging. The brake circuits of the front and rear axles are separated by the inverted shuttle valve 5. The parking brake solenoid valve 1 provides pressure oil to the disc brake.

Service brake When the pedal is depressed in the first two thirds of its range, the hydraulic inching function is activated. This function is triggered by the angle sensor on the compact brake valve. If the pedal is depressed further, the pressure control pistons of the 2nd circuit control the pressure in the brake pistons in proportion to the pedal force. At the end of the braking procedure, the oil flows back to the hydraulic tank.


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Brake system

Service Manual

Service brake

If one brake circuit fails, the second remains operational due to the mechanical contact between the two pressure control pistons in the compact brake valve. The actuation force remains the same.

Parking brake When you press the parking brake button, the parking brake solenoid valve 1 is opened. The accumulator pressure acts on the cylinders of the disc brake and opens the brake.

Inching angle sensor The angle sensor attached to the compact brake valve consists of two redundant sensors. The angle sensor 1 sends an electrical signal to input module 1 and the angle sensor 2 sends a signal to the input module 2.

LBH/version 01/10.2006/en/dw/26.01.2007

When the inch/brake pedal is pressed, the current to the control pressure proportional valve (travel hydraulics pump) is reduced. The variable displacement pump reduces its flow. This hydrostatically brakes the machine.

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Service Manual


9.1.3

Service brake hydro accumulator Technical data See section 2.1

Design




Function description Basic function The purpose of the hydro accumulator is to store hydraulic energy and supply it when needed.

LBH/version 01/10.2006/en/dw/26/01/2007

It has the following applications: – To act as an attenuator for pressure peaks, for example for the ride control system or steering attenuation. – To act an energy reserve to supply energy when needed, for example for the brake system.


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Brake system

Service Manual

Service brake

Storing pressure for the service brake

Hydro accumulator arrangement 1 2 3 4

Compact brake valve Parking brake hydro accumulator Front axle hydro accumulator Rear axle hydro accumulator

5 Accumulator charge pressure switch 6 Brake light pressure switch

LBH/version 01/10.2006/en/dw/26.01.2007

The service brake hydro accumulators allow the brake to be applied a certain number of times if the service brake pump fails. Oil flows from the hydro accumulators through the compact brake valve 1 to the disc brake.

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Service Manual


9.1.4

Brake light pressure switch Technical data See section 2.1

Design



The brake light pressure switch 1 is mounted on the compact brake valve 3.

Function description Basic function Membrane pressure switches are for switching electric circuits on and off. The hydraulic pressure acts via a membrane on an adjustable spring. When a set value is reached, the electric contact closes and the circuit is closed. This type of membrane pressure switch is known as “normally open”.

Brake light switching function The job of the brake light pressure switch is to switch on the brake lights.

LBH/version 01/10.2006/en/dw/26/01/2007

When the inch/brake pedal is pressed, the pressure on the parking brake pressure switch rises. When a set level is reached, the contact closes and the brake lights are switched on.


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Brake system

Service Manual

Service brake

9.1.5

Accumulator charge pressure switch Technical data See section 2.1

Design



The accumulator charge pressure switch 2 is mounted on the compact brake valve 3.

Function description Basic function The membrane pressure switches are for switching electric circuits on and off. The hydraulic pressure acts via a membrane on an adjustable spring. When a set value is reached, the electric contact opens and the circuit is interrupted. This type of membrane pressure switch is known as “normally closed”.

Accumulator charge pressure monitoring function The job of the accumulator charge pressure switch is to monitor the accumulator charge pressure.

LBH/version 01/10.2006/en/dw/26.01.2007

If the pressure in one of the brake accumulators falls below the level set for the pressure switch, the contact closes and the accumulator charge pressure symbol field lights up. In addition, an audible signal sounds.

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Service Manual

Brake system

Parking brake

9.2 Parking brake Function description Basic function of the parking brake

Components of the parking brake 1 Compact brake valve 2 Parking brake solenoid valve 3 Parking brake hydro accumulator

4 Transfer gear 5 Disc brake

The parking brake is a spring accumulator brake. The parking brake is opened by oil pressure and closed by spring force. The parking brake is supplied with oil by the compact brake valve 1. The accumulator charge valve of the compact brake valve 1 fills the parking brake hydro accumulator 3 to a specified oil pressure. The parking brake hydro accumulator 3 provides oil pressure via the solenoid valve 2 to open the parking brake. The solenoid valve 2 is actuated using the parking brake button. When the parking brake is opened, oil flows from the hydro accumulator 3 via the solenoid valve 2 to the disc brake 5.

Function of the parking brake switch The parking brake can only be released when the engine is running. When you start the engine and press the parking brake button 2, the parking brake solenoid valve is activated. The brake pressure then acts via the open parking brake solenoid valve on the brake cylinder, and opens the parking brake against the force of the brake callipers. The parking brake symbol field 3 on the display goes out.

LBH/version 01/10.2006/en/dw/26/01/2007

When you press the parking brake button 2 again or turn off the engine, the force of the springs in the brake cylinder closes the brake, thus generating the required braking torque on the brake disc. The parking brake symbol field 3 and the LED 1 in the parking brake button light up.


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9.2-1 o f 6

Brake system

Service Manual

Parking brake

9.2.1

Disc brake Technical data See section 2.1

Disc brake components 1 2 3 4 5 6 7

Counter nut Plug Adjusting screw Anti-twist locking pin Brake callipers Dust seal Pressure pin

8 9 10 11 12 13 14

Brake disc Guide pin Lock nut Counter nut Brake pad Adjusting screw Piston seal

15 16 17 18 19 20

Brake piston Cup springs Housing Brake oil connection Rubber centring element Bleeder screw

The parking brake is a spring-loaded sliding saddle brake which acts on the brake disc 8 attached outside on the output shaft of the transmission.

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LBH/version 01/10.2006/en/dw/26/01/2007

Design

Service Manual

Brake system

Parking brake

Function description Basic function of the disc brake

Disc brake in open position The two identical brake pads 5 and the brake calliper 1 slide freely on the guide pins 4, which are fastened in the transmission housing. When the brake is applied, it clamps the brake pads 5, creating a braking torque on the brake disk 3. The clamping force is generated by the cup springs 9. The piston 8 is pushed together with the pressure pin 2 and the front brake pad 5 towards the brake disc 3. When the front brake pad 5 comes into contact with the brake disc 3, the reactive force pushes the brake callipers 1 along the guide pin 4 until the rear brake pad 5 is also pressed against the brake disc 3. The parking brake is released by tensioning the entire cup spring set 9. Oil in the pressure chamber 7 pushes the piston 8 all the way back against the force of the cup springs 9.

LBH/version 01/10.2006/en/dw/26/01/2007

Rubber fittings on the guide pin 4 push the entire brake calliper to the right until the adjusting screw 6 touches the transmission housing. This moves the rear brake pad 5 away from the brake disc 3.


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9.2-3 o f 6

Brake system

Service Manual

Parking brake

9.2.2

Parking brake hydro accumulator Technical data See section 2.1

Design





It has the following applications: – To act as an attenuator for pressure peaks, for example for the ride control system or steering attenuation. – To act an energy reserve to supply energy when needed, for example for the brake system.

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LBH/version 01/10.2006/en/dw/26/01/2007

The purpose of the hydro accumulator is to store hydraulic energy and supply it when needed.

Service Manual

Brake system

Parking brake

Storing pressure for the parking brake

Components of the parking brake 1 Compact brake valve 2 Parking brake hydro accumulator

3 Transmission with disc brake

The parking brake is closed by spring force and opened by the brake oil from the hydro accumulator 2.

LBH/version 01/10.2006/en/dw/26/01/2007

When the parking brake button is pressed, brake oil flows from the hydro accumulator and releases the parking brake. The parking brake can only be safely released when the parking brake symbol field is not lit.


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9.2-5 o f 6

Brake system

Service Manual

LBH/version 01/10.2006/en/dw/26/01/2007

Parking brake

9.2-6 o f 6

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Service Manual

Brake system Overspeed protection

9.3 Overspeed protection Design

Main components of the overspeed protection 1 Compact brake valve 2 Oil from the replenishing pump 3 Overspeed protection solenoid valve

4 Solenoid valve block 5 Rear axle

The solenoid valve block 4 is fitted on left of the rear section beside the engine.

LBH/version 01/10.2006/en/dw/26/01/2007


Hydraulic diagram of the overspeed protection system 1 Compact brake valve 2 Pressure control piston for 2nd circuit 3 Brake light pressure switch

4 Replenishing pump 5 Solenoid valve block 6 Overspeed protection solenoid valve

7 Rear axle disc brake Test connection: M5 Rear axle brake pressure

The overspeed protection prevents the engine and the variable displacement motors from overrevving, which can occur, for example, when driving downhill. When the engine or the variable displacement motors reach a set limit speed, the overspeed protection solenoid valve 6 is activated. Oil flows from the replenishing pump 4 to the rear axle disc brake 7, causing the machine to slow down.


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9.3-1 o f 4

Brake system

Service Manual

Overspeed protection

Overspeed service code If the engine or the variable displacement motors overspeed, the machine reacts as follows: – The overspeed protection solenoid valve is energised – A service code appears in the display: E 5030 Overspeed on one of the variable displacement motors E 5032 Overspeed on variable displacement motor 1 E 5031 Overspeed on variable displacement motor 2 E 600B Overspeed on diesel engine – The warning buzzer sounds for one second. – Additionally, after 3 seconds of overspeed protection being active, the service code E 5029 appears.

The brake is activated according to the intensity of overspeed. The following situations may occur: Situation A: In the event of serious overspeed, for example on a steep slope, the brake activated constantly for more than 3 seconds. The service code E 5029 appears with a short warning tone. Situation B: Once the limit speed is exceeded, the machine is automatically braked until the speed falls back below the threshold. After a short time, the limit speed is exceeded again and the brake is activated again. If the brake is activated for longer than 3 seconds, the service code E 5029 appears with a short warning tone. This also happens if the brake intervention is briefly interrupted. Situation C: The machine is briefly braked. The speed then returns to the normal range.

The service code E 5029 only appears during reckless driving, for example at full speed down steep slopes. If the service code E 5029 is found several times in the memory, it may affect the warranty on the machine, especially if any damage was caused by overspeed. The service codes are stored in the main electronics A15.

9.3-2 o f 4

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LBH/version 01/10.2006/en/dw/26/01/2007

Caution: Brake interventions with the service code E 5029 do not occur during normal operation. This service code is only generated when the machine is not operated properly.

Service Manual

Brake system Overspeed protection

9.3.1

Overspeed protection solenoid valve Technical data See section 2.1

Design

Components of the solenoid valve block 1 Pilot control hydro accumulator 2 Pilot control solenoid valve

3 Overspeed protection solenoid valve 4 Solenoid valve block assembly

The solenoid valve block is fitted on left of the rear section beside the engine.

Function description Basic function The solenoid valve block includes the following components in a single housing: – Pilot control solenoid valve (working hydraulics) – Overspeed protection solenoid valve (rear axle braking function)

Overspeed protection solenoid valve

LBH/version 01/10.2006/en/dw/26/01/2007

1 Compact brake valve 2 Oil from the replenishing pump 3 Overspeed protection solenoid valve

4 Solenoid valve block 5 Rear axle disc brake

During normal operation, the overspeed protection solenoid valve 3 is not energised. Oil can flow freely from the compact brake valve 1 through the overspeed protection solenoid valve 3 to the rear axle disc brake 5. If the engine or the variable displacement motors reach a set limit speed, the overspeed protection solenoid valve 3 is energised. Oil flows from the connection 2 (from the replenishing pump) to the rear axle disc brake 5, causing the machine to slow down.


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Brake system

Service Manual

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Overspeed protection

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10 Electrical system

10.0

Chapter contents 10

Electrical system ............................................................... 10.0-1 10.0.1 10.1

Electrical system with circuit diagrams...............................10.0-3 Electrical components...................................................................10.1-1

10.1.1

Electrical components in the cab........................................10.1-1

10.1.2

Fuse and relay board A4 ....................................................10.1-2

10.1.3

Main electronics (master) A15............................................10.1-6

10.1.4

Input modules (A16a, A16b, A16c) ..................................10.1-10

10.1.5

Output modules (A17a, A17b, A17c)................................10.1-15

10.1.6

Electrical components in the rear section.........................10.1-20

10.2

Battery installation ........................................................................10.2-1 Batteries .............................................................................10.2-2

LBH/Version 01/10.2006/en/hd/21/02/2007

10.2.1


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10.0-1 o f 1

Service Manual

LBH/Version 01/10.2006/en/hd/21/02/2007

Electrical system

10.0-2 o f 2

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Service Manual

Electrical system 10.0.1

Electrical system with circuit diagrams Design The operating voltage of the machine is 24 volts. The batteries (2 x 12 V) are connected in series. The two batteries are installed in the right ballast weight.

Components of the electrical system

The table below lists all the components of the electrical system. The entry in the step column helps you locate the component in the circuit diagrams.

LBH/Version 01/10.2006/en/hd/21/02/2007

Abbreviations: - WH = Wiring harness - LFD = Liebherr ride control - SV = Solenoid valve - PSV = Proportional solenoid valve - LED = Light-emitting diode - SH = Service hours - * Options

Machine view 1, left


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10.0-3 o f 1

Electrical system

Service Manual

LBH/Version 01/10.2006/en/hd/21/02/2007

Machine view 2, right

Machine view 3, above

10.0-4 o f 2

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Service Manual

Electrical system Function description Circuit diagrams The circuit diagrams are on pages 1 to 75. The following list contains the pages and their main functions. Overview of pages for the electrical system: 1 SYSTEM OVERVIEW L550 - L580 2 3 The circuit diagrams of the electrical system show the function sequences for the entire machine, including optional equipment. All components and connections are marked and shown with the appropriate switching code so that they are clearly identifiable. The keys also list the designations of the components. The circuit diagrams are divided into pages. The pages are also divided into individual sections. Click the links in the online documentation to skip to the relevant information.

Component designation “-”

The designations of the components and connectors are always shown with -XX..: - -XX… = Component designation, e.g. -P1 = Mechanical service hours indicator (optional)

Location code “+”

Location codes are shown with +XX. The location codes show where the components are fitted on the machine.

LBH/Version 01/10.2006/en/hd/21/02/2007

The following location codes are shown: - +B Ballast weight, general - +B1 Left ballast weight - +B2 Rear ballast weight - +F Travel drive, general - +F1 Front axle - +F2 Rear axle - +F3 Transmission - +H Rear section - +H1 Rear section hatch - +H2 Rear section below cab, right - +H3 Rear section below cab, left - +H4 Right rear section - +H5 Left rear section - +K Cab, general - +K1 Cab front instruments - +K2 Cab rear wall - +K3 Cab roof - +K4 Cab instruments in side cover, rear right - +K5 Cab instruments in side cover, rear left - +K6 Cab floor - +M Engine - +V Front section


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10.0-5 o f 3

Electrical system

Service Manual +V1 +V2 +V3

Front section Lift arm Tilt cylinder

LBH/Version 01/10.2006/en/hd/21/02/2007

-

10.0-6 o f 4

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2

1

3

4

5

6

7

8

CAN BUS 3

A

A

HEAT/AIR CON CONTROL CC01

91/92 MOTOR CONTROL LHECU

106 B

PROJ: 8920980_003

DISPLAY UNIT

SENSORS (SWITCH, SENSOR)

CAN BUS 1

45

MACHINE

INPUTMODULE 1

CAN BUS 2 C

4x CAN

1x LAN

CAN BUS 3

ACTUATORS (MAGNETICS, SOLENOID VALVES)

CAN BUS 4 4XRS232

OPTIONS (e.g. WEIGHING EQUIPMENT CENTRAL GREASING, etc.)

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. © LIEBHERR WERK EHINGEN

E

112

2xCFCard

We reserve all rights in this document and in the informa tion contained therein. Reproduction, use or disclosure to third parties without express authority is strictly forbidden. © LIEBHERR WERK EHINGEN

C

D

B

97

93

CAN CAN AIR CONDITIONING KEYPAD MAIN KEYPAD

22 OUTPUTMODULE 1 Ethernet / RS232 / CAN D

ELECTRIC LOAD (LIGHTING, WINDSCREEN WIPER, REAR REAR WINDOW HEATER

46 INPUTMODULE 2

21

E

OUTPUTMODULE 2

ELECTRIC KEYPAD FUSE AND RELAY BOARD

SENSORS

MACHINE

ACTUATORS

F

F Ersteller

0

Datum

SPL

Ausgabe

Zustand

Änderung

Datum

1

Name

Datum

Donninger J. 26.03.2007 16:16 lbhhae0 27.03.2007 09:42

2

OVERVIEW DIAGRAM ELECTRICAL SYSTEM ELECTRONICS GG6 TIER3 WHEEL LOADER

Werk Bischofshofen GmbH 3

4

5

6

Ident.Nr. ZeichNr.

8920980 460 9010 00 003 7

Anlage Ort

003 8

Blatt von

1 114

2

1

3

4

TABLE OF CONTENTS

SHEET

CUTOFF TILT CYLINDER

A

61

STARTER

8

TABLE OF CONTENTS

SHEET

TRAVEL DIRECTIONS ; HYDRAULIC PUMP ; BUZZER ; PRESSURE HIGH PRESSURE TRAVEL PUMP

54

FUNCTION WORKING BASKET

59

DISPLAY UNIT CAN BUS 3

35

FUNCTION D+ PROFILE LIGHT ; PARKING LIGHT

20


36

FOOT FLAP VMC3 MIDDLE FLAP VMC4

66

WORKING PROJECTOR REAR REAR

31

FAN MOTOR AND SENSOR ICE UP PROTECTION

64

WORKING PROJECTOR REAR CABIN

32

JOYSTICK STEERING

72

WORKING PROJECTOR FRONT CABIN XENON WORKING PROJECTOR

30

JOYSTICK STEERING

74

5

AIR CONDITIONING SYSTEM ; AMBIENT TEMPERATURE SENSOR ; SUN SENSOR

62

BMKINDEX

6


63

BMKINDEX

7

HEAD FLAP VMC5 TEMPERATURE SENSOR AUTOMATIC AIR CONDITIONING

67

BMKINDEX

8

FUEL TEMPERATURE SENSOR ; ACTIVE ; OSCILLATING

107

BMKINDEX

9

CHARGE AIR COOLER ; OIL PRESSURE SWITCH

106

BMKINDEX

10

COUNTRYSPECIFIC TYPE/EXECUTION

BMKINDEX

11

KEY ; HANDOUT CONTAINING TYPE ; COUNTING NUMBER ; SYSTEM AND PLACE

BMKINDEX

12

STEERING COLUMN SWITCH ; STOP LIGHT ; LOW BEAM ; HIGH BEAM

25

BMKINDEX

13

LHCONTROL LEVER SWITCH COMFORT CONTROL ; 3 AND 4 CONTROL CIRCUIT

51


E

7

BMKINDEX

14

GENERATOR

BMKINDEX

15

VENTILATOR CONDENSER INTEGRATED

68

BMKINDEX

16

VENTILATOR CONDENSER RETROFIT KIT

69

BMKINDEX

17

MOTOR CONTROL ; AUTOMATIC RUNOUT

47

BMKINDEX

18

EMERGENCY STEERING PUMP ; LFD ; AIR FILTER CONTAMINATION ; RIDE CONTROL

23

BRAKE ACCUMULATOR

21


24

BRAKE ACCUMULATOR

22

OUTPUT MODULE 2; BACKUP ALARM AND CAN BE SWITCHED OFF

45

CAN BUS 1

37


46

CAN BUS 2

38

PARKING BRAKE ; SPEED SENSOR CENTRAL LUBRICATION SYSTEM GROENEVELD

78

DIAGNOSTIC PLUG MOTOR CONTROL AND AIR CONDITIONING SYSTEM

70

PHASE SENSOR


D

105

6

BMKINDEX

DIESEL PREHEATING COLD WEATHER KIT 40°

82

REVERSING OBSTACLE DETECTOR GROENEVELD

ANGLE SENSOR INCH/GAS PEDAL

52

REAR AREA MONITORING VIA MONITOR AND CAMERA

PROJ: 8920980_003

B

C

5

F

WARNING BEACON ; MIRROR AND REAR WINDOW HEATER

33

INJECTION PUMP CYLINDER 13

109

FLOAT POSITION ; BUCKET RETURNTODIG LIFT KICKOUT

56

INJECTION PUMP CYLINDER 46

110

WINDSCREEN WASHER FRONT AND REAR ; HOOTER

28

79

WINDSCREEN WASHER FRONT AND REAR ; HOOTER

29

101

STAND BY AM 4 CYLINDER ENGINE

111

EP 3. AND 4. CONTROL CIRCUIT

60


102

TRAVEL RANGES ; SWIVEL ANGLE HYDRO MOTORS OVERSPEED PROTECTION

53

TANK PIPE SENSOR ; TRANSMISSION / HYDRAULIC OIL TEMPERATURE ; VENTILATOR ; COOLING WATER LEVEL

Datum

1

76

108

Ausgabe Änderung

75

ENGINE SPEED SENSOR 2

Name

Datum


2

Ident.Nr.

TABLE OF CONTENTS Werk Bischofshofen GmbH 3

ZeichNr.

4

5

D

108

55

Datum

C

105

BACKUP ALARM ; GEROTOR STEERING ; DIESEL PREHEATING

Ersteller

Zustand

4

108

ELECTRICAL DIAGRAM DIESEL ENGINE 4 AND 6 CYLINDER

B

26


ELECTRONIC IMMOBILISER

A

6

8920980 460 9010 00 003 7

21

Anlage Ort

003 8

Blatt von

2 114

E

F

2

1

3

4

TABLE OF CONTENTS

SHEET

E

WATER VALVE VMC1 RECIRCULATED AIR FLAP VMC2

GENERAL OUTLAY ELECTRIC KEYPAD

94

KEY OF SYMBOLS DIN EN613461; DIN EN613462 ; DIN EN60617

GENERAL OUTLAY MAIN KEYPAD

95

CENTRAL LUBRICATION SYSTEM LIEBHERR

77

GENERAL OUTLAY HEAT / AIR CONDITIONING SYSTEM

96

CIGARETTE LIGHTER ; ELECTRICAL SOCKET 12V ; RADIO ; LOUDSPEAKER

34

GENERAL OUTLAY HEAT / AIR CONDITIONING SYSTEM SYSTEM SIDE

97

INGITION LOCK ; BATTERIES ; GENERATOR ; MAIN FUSES

19

GENERAL OUTLAY INPUT MODULE 1

86

ADDITIONAL EQUIPMENT 1;2 QUICKCHANGE DEVICE

58


87

ADDITIONAL EQUIPMENT 1;2;3 AND 4 QUICKCHANGE DEVICE

57


88

AUXILIARY HEATER DBW 2010

80


89

AUXILIARY HEATER THERMO 90

81

GENERAL OUTLAY AIR CONDITIONING KEYPAD FLAP CONTROL

99

PROJ: 8920980_003

GENERAL OUTLAY MOTOR CONTROL 4 CYLINDER

113

GENERAL OUTLAY MOTOR CONTROL 6 CYLINDER

104

GENERAL OUTLAY MOTOR CONTROL ENGINE SIDE

93

GENERAL OUTLAY OPTION KEYPAD

98

GENERAL OUTLAY OUTPUT MODULE 1

90 91


92

83

VERSION BATTERY WIRING HARNESSES L586

84

SUPPLY INPUT MODULE 1 AND 2

41

SUPPLY INPUT MODULE 3; JOYSTICK STEERING

71

SUPPLY INPUT MODULE 3; JOYSTICK STEERING

73

SUPPLY INPUT MODULE 4; EP 3. AND 4. CONTROL CIRCUIT

50

SUPPLY MASTER SUPPLY DIAGNOSTIC PLUG

40

SUPPLY OUTPUT MODULE 1

42

SUPPLY OUTPUT MODULE 1 AND 2

43


44


48

SUPPLY OUTPUT MODULE 3; AUTOMATIC LIGHTING SHUTDOWN

49

SUPPLY KEYPADS

39

HAZARD WARNING LIGHTS

27

GENERAL OUTLAY SENSORS

103


112

GENERAL OUTLAY PROTECTIVE FOIL

100

OVERVIEW DIAGRAM ELECTRICAL SYSTEM ELECTRONICS GG6 TIER3 WHEEL LOADER

Ersteller Datum Ausgabe Änderung

Datum

1

SHEET

85

VERSION BATTERY WIRING HARNESSES 40°

Zustand

TABLE OF CONTENTS

GENERAL OUTLAY MASTER


F

8

WATER DETECTOR


D

7

22


C

6

TANK PIPE SENSOR ; TRANSMISSION / HYDRAULIC OIL TEMPERATURE ; VENTILATOR ; COOLING WATER LEVEL

A

B

5

Name

Datum


2

106

1

B

D

E

F Ident.Nr.

Werk Bischofshofen GmbH

ZeichNr.

4

114

C

TABLE OF CONTENTS 3

A

65

5

6

8920980 460 9010 00 003 7

Anlage Ort

003 8

Blatt von

3 114

2

1

3

4

5

6

7

8

TYPE / COUNTING NUMBER, SYSTEM, LOCATION CODE

A

A

TYPE / COUNTING NUMBER CIRCUITS TWISTED

M1 STARTER MOTOR ; OPERATING SUPPLY CODE

E

52 52

=B BALLAST =F TRAVEL DRIVE =H HIND CARRIAGE =K CABIN =M ENGINE =V FRONT SECTION


D

B

= SYSTEM

=K +K6 X1.S1

=K SYSTEM (CABIN) +K6 LOCATION CODE (CAB FLOOR) X1.S PLUG NAME AND PIN CONTACT

X1.B1

X1.B PLUG NAME AND SOCKET CONTACT

+K6 =K

52 PIN AM PLUG

C

CABLE GREEN OPTION

/7.E4

+LOCATION CODE

CROSS REFERENCE UP SHEET 7;E4

OPEN LINE END

+B BALLAST +B1 BALLAST LEFT +B2 BALLAST RIGHT

LETZTE MODIFICATION

+K CABIN +K1 CABIN FITTINGS +K2 CABIN REAR PANEL +K2.RH CABIN REAR PANEL RELAY RACK +K3 CAB ROOF +K4 CABIN FITTINGS SIDE COVER RIGHT REAR +K5 CABIN FITTINGS SIDE COVER LEFT REAR +K6 CAB FLOOR

+F TRAVEL DRIVE +F1 FRONT AXLE +F2 REAR AXLE +F3 TRANSMISSION


C

PROJ: 8920980_003

B

+H HIND CARRIAGE +H1 HIND CARRIAGE REAR HATCH +H2 HIND CARRIAGE UNTER CABIN RIGHT +H3 HIND CARRIAGE UNTER CABIN LEFT +H4 HIND CARRIAGE RIGHT +H5 HIND CARRIAGE LEFT

D

+M ENGINE

E

+V FRONT SECTION +V1 FRONT SECTION +V2 LIFT ARM +V3 TILT CYLINDER

F

F Ersteller Datum Ausgabe Zustand

Änderung

Datum

1

Name

Datum


2

KEY ; HANDOUT CONTAINING TYPE ; COUNTING NUMBER ; SYSTEM AND PLACE


4

5

6

Ident.Nr. ZeichNr.

8920980 460 9010 00 003 7

Anlage Ort

003 8

Blatt von

4 114

2

SHEET

SYSTEM PLACE

A3

RADIO

/34.D7

=K

A3.X1

PLUG RADIO

/34.D7

A3.X2

PLUG RADIO

A4.46.4 *

8

SYSTEM PLACE

+K3

A13.X2

PLUG DISPLAY UNIT LCD

/35.A3

=K

+K1

=K

+K3

A13a.X

DISPLAY UNIT

/35.D3

=K

+K1

/34.D7

=K

+K3

A15

MAIN ELECTRONICS MASTER

/85.B1

=K

+K2

PLUG RELAY BOARD

/30.D5

=K

+K2

A15.CAN.X

PLUG MASTER 8 POLIG

/35.B7

=K

+K2

A4.46.8 *

PLUG RELAY BOARD

/30.D8

=K

+K2

A15.COM4.X

PLUG MASTERR SUB D

/40.B6

=K

+K2

A4.Kl.15.a *

Kl.15 INPUT MODULE 4

/50.A1

=K

+K2

A15.X

PLUG MASTER 6 POLIG

/40.E1

=K

+K2

A4.X40

PLUG RELAY BOARD

/40.A4

=K

+K2

A16a

INPUTMODULE 1

/86.B1

=H

+H3

A4.X40.3a *

CONNECTION RELAY BOARD

/47.A4

=K

+K2

A16a.X1

PLUG INPUT MODULE 1

/51.C1

=H

+H3

A4.X41

PLUG RELAY BOARD

/80.E2

=K

+K2

A16a.X1.44 *

CAN CONNECTION. INPUT MODULE 1

/37.E6

=H

+H3

A4.X42

PLUG RELAY BOARD

/40.C4

=K

+K2

A16b

INPUT MODULE 2

/87.B1

=K

+K2

A4.X43

PLUG RELAY BOARD

/43.B2

=K

+K2

A16b.X1

PLUG INPUT MODULE 2

/27.A8

=K

+K2

A4.X44

PLUGRELAY BOARD

/25.D3

=K

+K2

A16b.X1.10a *

PLUG COMFORT CONTROL 3. + 4.CONTROL CIRCUIT

/51.D8

=K

+K2

A4.X44a:4 *


/79.F8

=K

+K2

A16b.X1.9a *

PLUG COMFORT CONTROL; 3. + 4.CONTROL CIRCUIT

/51.D7

=K

+K2

A4.X45

PLUGRELAY BOARD

/35.E2

=K

+K2

A16b.X2.9+10b *

PLUG COMFORT CONTROL; 3. + 4. CONTROL CIRCUIT

/51.D7

=K

+K2

A4.X46

PLUGRELAY BOARD

/30.D4

=K

+K2

A16c

INPUTMODULE 3

/88.B1

=H

+H3

A4.X47

PLUGRELAY BOARD

/33.B7

=K

+K2

A16c.X1

PLUG INPUTMODULE 3

/71.E1

=H

+H3

A4.X48

PLUGRELAY BOARD

/49.C8

=K

+K

A16d

INPUTMODULE 4

/89.B1

=H

+H3

A4.X48. *

PLUG RELAY BOARD

/69.B7

=K

+K2

A16d.X1

PLUG INPUT MODULE 4

/60.B1

=H

+H3

A4.X49

PLUG RELAY BOARD

/25.B7

=K

+K2

A17.aX1a *

PLUG CENTRAL LUBRICATION SYSTEM GROENEVELD

/78.B2

=H

+H3

A4.X50

PLUG RELAY BOARD

/27.B5

=K

+K2

A17.X2 *

PLUG QUICKCHANGE DEVICE

/57.D8

=H

+H

A4.X50.12a *


/33.B3

=K

+K2

A17a

OUTPUT MODULE 1

/90.B1

=H

+H3

A4.X51

PLUG RELAY BOARD

/20.B4

=K

+K2

A17a.X1

PLUG OUTPUT MODULE 1

/42.E7

=H

+H3

A4.X52

PLUG RELAY BOARD

/80.C3

=K

+K2

A17a.X1.43.57 *

PLUG CANCONNECTION INPUT MODULE 1

/37.B6

=H

+H3

A4.X53

PLUG RELAY BOARD

/20.D3

=K

+K2

A17a.X1.48a *

OPTION BUCKET RETURNTODIG ÜBER PUSHBUTTON SWITCH

/56.E6

=H

+H3

A4.X55

PLUG RELAY BOARD

/19.C8

=K

+K2

A17a.X1.6a *

OPTION BUCKET RETURNTODIG ÜBER PUSHBUTTON SWITCH

/56.B6

=H

+H3

A4.X56

PLUG RELAY BOARD

/19.B2

=K

+K2

A17b

OUTPUT MODULE 2

/91.B1

=H

+H3

A4.X56a *


/69.B2

=K

+K2

A17b..X1.43.57 *

PLUG CAN CONNECTION OUTPUT MODULE 2

/38.C1

=K

+K

A4.X56a:4 *


/79.B4

=K

+K2

A17b.X1

PLUG OUTPUTMODULE 2

/43.C1

=H

+H3

A4.X57

PLUG RELAY BOARD

/19.B3

=K

+K2

A17b.X1.44 *

CAN CONNECTION OUTPUT MODULE 2

/38.F1

=K

+K

A4.X58

PLUG RELAY BOARD

/27.B8

=K

+K2

A17b.X1.58 *


/38.F2

=K

+K

A9 *

IMMOBILISER

/79.D4

=K

+K2

A17b.X143a *


/38.D7

=H

+H3

A9.X *

PLUG IMMOBILISER

/79.D4

=K

+K2

A17c

OUTPUT MODULE 3

/92.B1

=H

+H3

A11

MAIN KEYPAD

/95.C3

=K

+K4

A17c.X1

PLUG OUTPUT MODULE 3

/48.E2

=H

+H3

A11.X1

PLUG MAIN KEYPAD

/35.B4

=K

+K4

A18

ELECTRIC KEYPAD

/94.B2

=K

+K4

A13

DISPLAY UNIT LCD

/35.B1

=K

+K1

A18.X1

PLUG ELECTRIC KEYPAD

/27.A2

=K

+K4

A13.X1

PLUG DISPLAY UNIT LCD

/35.B1

=K

+K1

A18.X1.1a *

AUTOMATIC LIGHTING SHUTDOWN

/49.D6

=K

+K4

PROJ: 8920980_003

FUNCTION

7

SHEET

F

BMK

6


E

5

FUNCTION

B

D

4

BMK

A

C

3


1

Ersteller Datum Ausgabe Zustand

Änderung

Datum

1

Name

Datum


2

Ident.Nr.

BMKINDEX Werk Bischofshofen GmbH 3

ZeichNr.

4

5

6

8920980 460 9010 00 003 7

Anlage Ort

003 8

Blatt von

5 114

A

B

C

D

E

F

2

SHEET

SYSTEM PLACE

A18.X1.1b *


/49.D6

=K

A18.X2

PLUGELECTRIES KEY BOARD

/25.C2

A19

OPTION KEYPAD

A19.X1

8

SYSTEM PLACE

+K4

B10

HOOTER

/28.C2

=H

+H

=K

+K4

B10.X1

PLUG HOOTER

/28.C2

=H

+H

/98.B3

=K

+K4

B10.X2

PLUG HOOTER

/28.C2

=H

+H

PLUG OPTION KEYPAD

/35.E7

=K

+K4

B10a *

PLUG HOOTER OPTION

/28.C2

=H

+H

A19.X2

PLUG CAN BUS 3

/35.F7

=K

+K4

B10a.X2 *

PLUG HOOTER OPTION

/28.C1

=H

+H

A21

AIR CON ELECTRONICS CC01 29 POLIG

/96.A2

=K

+K4

B11l

LOUDSPEAKER LEFT

/34.E7

=K

+K3

A21.X1

PLUG AIR CON ELECTRONICS CC01

/62.B3

=K

+K4

B11l.X1

PLUG LOUDSPEAKER LEFT

/34.E7

=K

+K3

A21.XB

DIAGNOSTIC PLUG AIR CONDITIONING ELECTRONICS

/70.E6

=K

+K4

B11l.X2

PLUG LOUDSPEAKER LEFT

/34.F7

=K

+K3

A21a

AIR CON ELECTRONICS CC01 42 POLIG

/97.B1

=K

+K4

B11r

LOUDSPEAKER RIGHT

/34.E8

=K

+K3

A21a.X2

PLUG AIR CON ELECTRONICS CC01

/64.B1

=K

+K4

B11r.X1

PLUG LOUDSPEAKER RIGHT

/34.E8

=K

+K3

A22

KEYPAD HEAT/ AIR CONDITIONING SYSTEM

/99.B2

=K

+K4

B11r.X2

PLUG LOUDSPEAKER RIGHT

/34.F8

=K

+K3

A22.X1

PLUG KEY BOARD HEAT/ AIR CONDITIONING SYSTEM

/39.E6

=K

+K4

B12

PRESSURE SWITCH BRAKE LIGHT

/25.E1

=H

+H3

A204

CENTRAL LUBRICATION SYSTEM GROENEVELD

/78.C5

=K

+K4

B12.X

PLUG PRESSURE SWITCH

/25.E1

=H

+H3

A204.X *


/78.C4

=K

+K4

B13

COOLING WATER LEVEL

/21.C4

=H

+H

A205 *


/78.D3

=H

+H3

B13.X

PLUG COOLING WATER LEVEL

/21.C4

=H

+H

A205.X *


/78.D3

=H

+H3

B14

TRANSMISSION TEMPERATURE

/21.C5

=F

+F3

A700C.6

MOTOR CONTROL ENGINE SIDE 6 CYLINDER

/104.A1

=M

+M

B14.X

PLUG TRANSMISSION TEMPERATURE

/21.C5

=F

+F3

A700C.6.X1

PLUG ENGINE SIDE

/105.E2

=M

+M

B15

INDUCTIVE SWITCH BUCKET RETURNTODIG

/56.C2

=V

+V3

A700C4

MOTOR CONTROL ENGINE SIDE 4 CYLINDER

/113.A1

=M

+M

B15.X

PLUG INDUCTIVE SWITCH

/56.C2

=V

+V3

A700D

MOTOR CONTROL VEHICLE SIDE

/93.B1

=M

+M

B16

BACKUP ALARM

/45.C5

=H

+H5

A700D.X2

PLUG VEHICLE SIDE

/47.E1

=M

+M

B16.X

PLUG BACKUP ALARM

/45.D5

=H

+H5

A.X1 *

PLUG CIRCULATING PUMP DBW2010

/80.E6

=B

+B2

B16a.X1 *

PLUG REVERSING OBSTACLE DETECTOR CAN BE SWITCHED OFF

/45.D5

=H

+H5

B1

SPEED SENSOR TRANSMISSION

/78.C6

=F

+F3

B16b.X *

PLUG REVERSING OBSTACLE DETECTOR CAN BE SWITCHED OFF

/45.C7

=H

+H5

B1.X

PLUG SPEED SENSOR

/78.C6

=F

+F3

B16c.X1 *

PLUG OPTIONBACKUP ALARM

/45.C5

=H

+H1

B2

SPEED SENSOR CONTROL MOTOR 1

/78.C7

=F

+F3

B17

INDUCTIVE SWITCH LIFT KICKOUT

/56.C4

=V

+V

B2.X

PLUG SPEED SENSOR CONTROL MOTOR 1

/78.C7

=F

+F3

B17.B

PLUG LIFT KICKOUT

/56.B4

=V

+V

B2a

SPEED SENSOR CONTROL MOTOR 2

/78.C8

=F

+F3

B17.X

PLUG LIFT KICKOUT

/56.B4

=V

+V

B2a.X

PLUG SPEED SENSOR CONTROL MOTOR 2

/78.C8

=F

+F3

B17.X_1


/56.C4

=V

+V

B3

PRESSURE SWITCH EMERGENCY STEERING PUMP

/23.C5

=H

+H5

B19

PRESSURE SWITCH BRAKE ACCUMULATOR

/21.C3

=K

+K6

B3.X


/23.C5

=H

+H5

B19.X

PLUGPRESSURE SWITCH

/21.C3

=K

+K6

B3a

PRESSURE SWITCH CHECK EMERGENCY STEERING PUMP

/23.C4

=H

+H4

B25

TANK PIPE SENSOR

/21.C1

=H

+H2

B3a.X


/23.C4

=H

+H4

B25.X

PLUG TANK PIPE SENSOR

/21.C1

=H

+H2

B4

AIR FILTER CONTAMINATION

/23.C6

=H

+H

B26

TEMPERATURE SENSOR ICE UP PROTECTION

/64.D5

=K

+K4

B4.X_1

PLUGPRESSURE SWITCH

/23.C6

=H

+H

B26a

TEMPERATURE SENSOR ICE UP PROTECTION

/64.D7

=K

+K4

B8

HYDRAULIC OIL TEMPERATURE SENSOR

/21.C6

=H

+H1

B27

PRESSURE SWITCH AIR CONDITIONING SYSTEM

/62.C4

=H

+H

B8.X

PLUG HYDRAULIC OIL TEMPERATURE SENSOR

/21.C6

=H

+H1

B27.X


/62.C4

=H

+H

PROJ: 8920980_003

FUNCTION

7

SHEET

F

BMK

6


E

5

FUNCTION

B

D

4

BMK

A

C

3


1


Änderung

Datum

1

Name

Datum


2

Ident.Nr.


ZeichNr.

4

5

6

8920980 460 9010 00 003 7

A

C

Ort

8

Blatt von

D

E

F

Anlage

003

B

6 114

2

SHEET

SYSTEM PLACE

B27.X.2 *


/69.D8

=H

B28

PRESSURE SWITCHRIDE CONTROL

/23.C6

B28.X


B32

8

SYSTEM PLACE

+H

B711


/108.B2

=M

+M

=K

+K

B711.X

PLUG ENGINE SPEED SENSOR 1

/108.B2

=M

+M

/23.C6

=K

+K

B712


/108.B4

=M

+M

PRESSURE SWITCH FLOAT POSITION

/56.C1

=K

+K4

B712.X

PLUG ENGINE SPEED SENSOR 2

/108.B5

=M

+M

B32.X


/56.C1

=K

+K4

B713

PHASE SENSOR

/108.B7

=M

+M

B39

AIR CON AMBIENT TEMPERATURE SENSOR

/62.D5

=K

+K6

B713.X

PLUG PHASE SENSOR

/108.B7

=M

+M

B39.X

PLUG AMBIENT TEMPERATURE SENSOR

/62.D6

=K

+K6

B.X6 *

PLUG AUXILIARY HEATER DBW2010

/80.D5

=B

+B2

B40

INTERIOR TEMPERATURE SENSOR

/67.E6

=K

+K4

C.X1 *

PLUG CIRCULATING PUMP DBW2010

/80.E6

=B

+B2

B42

SUN SENSOR AIR CONDITIONING SYSTEM

/62.D7

=K

+K1

E1

REAR LAMP LEFT

/25.E2

=B

+B1

B42.X

PLUG SUN SENSOR AIR CONDITIONING SYSTEM

/62.D7

=K

+K1

E2

INDOOR LIGHTING

/19.E7

=K

+K3

B43

INDUCTIVE SWITCH DISTRIBUTOR LH

/77.C7

=H

+H5

E2.X1

PLUG INDOOR LIGHTING

/19.E7

=K

+K3

B44

INDUCTIVE SWITCH LEVEL LH

/77.C4

=H

+H5

E2.X2

PLUGINDOOR LIGHTING

/19.E7

=K

+K3

B45

PRESSURE SENSOR HIGH PRESSURE TRAVEL PUMP

/54.C7

=H

+H4

E2.X3

PLUG INDOOR LIGHTING

/19.E7

=K

+K3

B45.X

PLUG PRESSURE SENSOR HIGH PRESSURE TRAVEL PUMP

/54.C7

=H

+H4

E3

DRIVING HEADLIGHT LEFT

/25.E4

=V

+V1

B200 *

INDUCTIVE SWITCH JOYSTICK STEERING

/72.C4

=K

+K4

E3.X

PLUG DRIVING HEADLIGHT LEFT

/25.E4

=V

+V1

B200.X *


/72.C4

=K

+K4

E3.Xa *

PLUG COUNTRYSPECIFIC TYPE/EXECUTION LEFT

/26.E3

=V

+V

B201 *

PRESSURE SWITCH JOYSTICK STEERING

/72.C2

=H

+H3

E3.Xb *

PLUG COUNTRYSPECIFIC TYPE/EXECUTION LEFT

/26.F3

=V

+V

B201.X *


/72.C2

=H

+H3

E4

DRIVING HEADLIGHT RIGHT

/25.E5

=V

+V1

B202 *

SIGNAL TRANSMITTER JOYSTICK STEERING

/71.C6

=K

+K4

E4.X

PLUG DRIVING HEADLIGHT RIGHT

/25.E5

=V

+V1

B202.X *

PLUG SIGNAL TRANSMITTER JOYSTICK STEERING

/71.C6

=K

+K4

E4.Xa *

PLUG COUNTRYSPECIFIC TYPE/EXECUTION RIGHT

/26.E6

=V

+V

B203 *

PRESSURE SWITCH CENTRAL LUBRICATION SYSTEM

/78.D5

=V

+V1

E4.Xb *

PLUG COUNTRYSPECIFIC TYPE/EXECUTION RIGHT

/26.F6

=V

+V

B203.X *


/78.E5

=V

+V1

E5

REAR LIGHT RIGHT

/25.E7

=B

+B2

B213 *

INDUCTIVE SWITCH CUTOFF TILT CYLINDER

/61.C7

=V

+V2

E6

REAR LIGHTLEFT 24V 5W

/25.E2

=B

+B1

B213.X *


/61.C7

=V

+V2

E7

REAR LIGHT RIGHT 24V 5W

/25.E6

=B

+B2

B701

OIL PRESSURE

/106.B5

=M

+M

E8

CONTEUR LIGHTLEFT 24V 4W

/25.E3

=K

+K3

B701.X

PLUG OIL PRESSURE

/106.B5

=M

+M

E9

CONTEUR LIGHT RIGHT 24V 4W

/25.E6

=K

+K3

B703

CHARGE AIR PRESSURE

/106.B2

=M

+M

E10

WORKING PROJECTOR FRONT LEFT 24V 70W

/30.E4

=K

+K3

B703.X

PLUG CHARGE AIR PRESSURE

/106.B2

=M

+M

E10.X

PLUG WORKING PROJECTOR FRONT LEFT

/30.E4

=K

+K3

B707

PLUG CHARGE AIR TEMPERATURE

/107.C7

=M

+M

E10a

WORKING PROJECTOR FRONT LEFT 24V 70W

/30.E5

=K

+K3

B707.X

PLUG CHARGE AIR TEMPERATURE

/107.C7

=M

+M

E10a..X

PLUG WORKING PROJECTOR FRONT LEFT

/30.E5

=K

+K3

B708

COOLANT TEMPERATURE

/107.C5

=M

+M

E10b *

XENON WORKING PROJECTOR

/30.E5

=K

+K3

B708.X

PLUG COOLANT TEMPERATURE

/107.C5

=M

+M

E10b.X *

PLUG XENON

/30.E5

=K

+K3

B709

FUEL TEMPERATURE

/107.C3

=M

+M

E11

WORKING PROJECTOR FRONT RIGHT

/30.E7

=K

+K3

B709.X

PLUG FUEL TEMPERATURE

/107.C3

=M

+M

E11.X

PLUG WORKING PROJECTOR FRONT RIGHT

/30.E7

=K

+K3

B710

WATER DETECTOR

/106.C7

=M

+M

E11a


/30.E7

=K

+K3

B710.X

PLUG WATER DETECTOR

/106.C7

=M

+M

E11a.X

PLUG WORKING PROJECTOR FRONT RIGHT

/30.E7

=K

+K3

PROJ: 8920980_003

FUNCTION

7

SHEET

F

BMK

6


E

5

FUNCTION

B

D

4

BMK

A

C

3


1


Änderung

Datum

1

Name

Datum


2

Ident.Nr.


ZeichNr.

4

5

6

8920980 460 9010 00 003 7

Anlage Ort

003 8

Blatt von

7 114

A

B

C

D

E

F

2

SHEET

SYSTEM PLACE

E11b *

XENON WORKING PROJECTOR

/30.E8

=K

E11b.X *

PLUG XENON

/30.E8

E12 *

WORKING PROJECTOR CAB ROOF REAR LEFT

E12.b *

8

SYSTEM PLACE

+K3

F02*


/84.C7

=H

+H

=K

+K3

F03

EMERGENCY STEERING PUMP

/19.D4

=H

+H5

/32.E3

=K

+K3

F03* *

OPTION BATTERY WIRING HARNESSES 40°

/83.C6

=H

+H5.


/32.E4

=K

+K3

F03*


/84.C6

=H

+H5

E12.b.X *

PLUG E12b

/32.D4

=K

+K3

F07

Kl.30 HAZARD WARNING LIGHTS

/19.D5

=H

+H5

E12.X *

PLUG E12

/32.E3

=K

+K3

F07*


/84.D7

=H

+H5

E12a *


/32.E4

=K

+K3

F07* *


/83.D7

=H

+H5.

E12a.X *

PLUG E12a

/32.D4

=K

+K3

F07*.X1 *

OPTION BATTERY KS 40°

/83.D7

=H

+H5.

E13 *

WORKING PROJECTOR CAB ROOF REAR RIGHT

/32.E6

=K

+K3

F07*.X1

VERSION BATTERY KS L586

/84.D7

=H

+H5

E13.b *


/32.E7

=K

+K3

F07.X1

PLUG Kl.30 HAZARD WARNING LIGHTS

/19.D5

=H

+H5

E13.b.X *

PLUG E13b

/32.D7

=K

+K3

F07.X2

PLUG Kl.30 HAZARD WARNING LIGHTS

/19.E5

=H

+H5

E13.X *

PLUG E13

/32.D6

=K

+K3

F07B

HAZARD WARNING LIGHTS Kl.15

/27.C1

=K

+K2

E13a *


/32.E7

=K

+K3

F10

DISPLAY UNIT

/35.D2

=K

+K2

E13a.X *

PLUG E13a

/32.D7

=K

+K3

F11

PRESSURE SWITCH B28; B32

/56.E1

=K

+K2

E14l

LICENCE PLATE LIGHT LEFT 24V 10W

/25.D8

=H

+H1

F12 *


/78.B3

=K

+K2

E14r

LICENCE PLATE LIGHT RIGHT 24V 10W

/25.D8

=H

+H1

F13

CONDENSER FAN

/68.B2

=K

+K2

E16

WORKING PROJECTOR REAR LEFT

/31.E4

=H

+H1

F14 *

DIESEL PREHEATING

/55.A8

=K

+K2

E16.X

PLUG WORKING PROJECTOR REAR LEFT

/31.E4

=H

+H1

F15

LH CONTROL LEVER

/51.A5

=K

+K2

E17

WORKING PROJECTOR REAR RIGHT

/31.E7

=H

+H1

F18

WINDSCREEN WIPER REAR

/28.C8

=K

+K2

E17.X

PLUG WORKING PROJECTOR REAR RIGHT

/31.E7

=H

+H1

F19

Kl.15 AIR CONDITIONING ELECTRONICS

/62.B2

=K

+K2

E200

RESERVE LIGHTING

/45.D8

=K

+K4

F19A

Kl.30 AIR CONDITIONING ELECTRONICS

/62.B1

=K

+K2

E200.X

PLUG RESERVE LIGHTING

/45.D8

=K

+K4

F20

WINDSCREEN WASHER, HOOTER

/28.C3

=K

+K2

F2

HIGH BEAM LEFT

/25.B5

=K

+K2

F21

LOW BEAM/DRIVING LIGHT

/25.B3

=K

+K2

F3

HIGH BEAMHIGH BEAM

/25.B6

=K

+K2

F22

STOP LIGHT; LIGHTING

/45.A8

=K

+K2

F4

DRIVING LIGHTLEFT

/25.B3

=K

+K2

F23 *

REVERSING OBSTACLE DETECTOR ; PARTICLE FILTER

/75.A3

=K

+K2

F5

DRIVING LIGHT RIGHT

/25.B4

=K

+K2

F24

IGNITION ON MOTOR CONTROL

/47.B4

=K

+K2

F6

PROFILE LIGHT /PARKING LIGHT LEFT

/20.C6

=K

+K2

F25

WARNING BEACON

/33.C2

=K

+K2

F7

PROFILE LIGHT/ PARKING LIGHT RIGHT

/20.C6

=K

+K2

F26

DIAGNOSTIC PLUG; IMMOBILISER

/40.C6

=K

+K2

F8

DRIVER'S SEAT; RADIO Kl.58

/19.B8

=K

+K2

F27

PROFILE LIGHT/IDENTIFICATION/CONTEUR LIGHT

/20.C8

=K

+K2

F8A

INDOOR LIGHTING;AUXILIARY HEATER

/19.B7

=K

+K2

F29

IGNITION STARTER SWITCH BYPASS

/19.B3

=K

+K2

F9

LH CONTROL LEVER OPTIONS

/51.A6

=K

+K2

F30

VOLTAGE CONVERTER (RADIO)

/34.B2

=K

+K2

F01

MAIN FUSES

/19.D2

=H

+H5

F31A

WORKING PROJECTOR FRONT LEFT

/30.B3

=K

+K2

F01* *


/83.C3

=H

+H5.

F31B


/30.B5

=K

+K2

F01*


/84.C3

=H

+H5

F32A


/31.B2

=K

+K2

F02

HEATING FLANGE

/19.D4

=H

+H

F32B


/31.B5

=K

+K2

F02* *


/83.C7

=H

+H.

F33A


/32.B2

=K

+K2

PROJ: 8920980_003

FUNCTION

7

SHEET

F

BMK

6


E

5

FUNCTION

B

D

4

BMK

A

C

3


1


Änderung

Datum

1

Name

Datum


2

Ident.Nr.


ZeichNr.

4

5

6

8920980 460 9010 00 003 7

Anlage Ort

003 8

Blatt von

8 114

A

B

C

D

E

F

2

SHEET

SYSTEM PLACE

F33B


/32.B4

=K

F34 *

REFUELLING PUMP

/55.A6

F35

MASTER

F36

8

SYSTEM PLACE

+K2

F010.X1

PLUG ACKNOWLEDGEMENTHEATING FLANGE

/19.C5

=H

+H5

=K

+K2

F010.X2

PLUG ACKNOWLEDGEMENT HEATER FLANGE

/19.D5

=H

+H5

/40.B4

=K

+K2

F208 *

DIESEL PREHEATING 40°

/82.C4

=K

+K2

MOTOR CONTROL

/47.B3

=K

+K2

F209 *

INPUT MODULE 4 LOGIC

/50.B1

=K

+K2

F38

MOTOR CONTROL LOGIC

/47.B5

=K

+K2

F210 *

Kl:15 INPUT MODULE 4

/50.B3

=K

+K2

F39 *

PRESELECTION DIAL AUXILIARY HEATER

/81.A5

=K

+K2

F213 *


/61.C2

=K

+K2

F40 *

AUXILIARY HEATER

/81.A8

=K

+K2

F216 *

AUTOMATIC RUNOUT

/47.B8

=K

+K2

F42 *

AUXILIARY HEATER NOZZLE STICK PREHEATER

/80.D2

=K

+K2

G1

BATTERY

/19.E2

=B

+B

F43

MODULES LOGIC

/41.B2

=K

+K2

G1*


/84.D3

=B

+B1

F44

INPUT MODULE 1

/41.B7

=K

+K2

G1* *


/83.D3

=B

+B1.

F45

INPUT MODULE 2

/41.B3

=K

+K2

G2

BATTERY

/19.E3

=B

+B1

F46 *

INPUT MODULE 3

/71.A3

=K

+K2

G2*


/84.D4

=B

+B1

F47

OUTPUT MODULE 1 BK1

/42.B4

=K

+K2

G2* *


/83.D4

=B

+B1.

F48

OUTPUT MODULE 1 BK1

/42.B7

=K

+K2

G3

ALTERNATOR

/19.E4

=M

+M

F49 *

OUTPUT MODULE 1

/55.E2

=K

+K2

G3*


/84.E6

=M

+M

F50 *

WORKING BASKET

/59.B1

=K

+K2

G3* *


/83.E6

=M

+M.

F51

OUTPUT MODULE 2 BK 4

/43.A6

=K

+K2

G700 *

GENERATOR OPTION

/105.B4

=M

+M

F52

OUTPUT MODULE 2 BK3

/43.A7

=K

+K2

G700

GENERATOR

/105.B3

=M

+M

F53

OUTPUT MODULE 1 DO3

/77.B2

=K

+K2

H15

BLINKER LEFT 24V 21W ORANGE

/25.E4

=V

+V1

F54

MASTER LOGIC

/40.B5

=K

+K2

H16

BLINKER RIGHT 24V 21W

/25.E5

=V

+V1

F55


/44.A4

=K

+K2

H17

BLINKER BACK LEFT 24V 21W

/25.E2

=B

+B1

F56

OUTPUT MODULE 2 BK2

/44.A7

=K

+K2

H18

BLINKER RIGHT REAR 24V 21W

/25.E7

=B

+B2

F59

OUTPUT MODULE 1 BK4

/43.A2

=K

+K2

H20

BRAKE LIGHT LEFT 24V 21W

/25.E2

=B

+B1

F60


/43.A3

=K

+K2

H21

STOP LIGHT RIGHT 24V 21W

/25.E7

=B

+B2

F61

OUTPUT MODULE 2 DO3

/45.A1

=K

+K2

H22

WARNING BEACON

/33.E3

=K

+K3

F62

OUTPUT MODULE 2 DO4

/45.A2

=K

+K2

H22.X

PLUG WARNING BEACON

/33.E3

=K

+K3

F63 *

OUTPUT MODULE 3 BK1

/48.A4

=K

+K2

H22a

OPTION BACKUP ALARM

/45.C3

=H

+H1

F64 *

OUTPUT MODULE 3 BK2

/48.A6

=K

+K2

H22a.X1 *

PLUG OPTION BACKUP ALARM

/45.C3

=H

+H1

F65 *

OUTPUT MODULE 3 BK3

/49.A1

=K

+K2

H22a.X2 *

PLUG OPTION BACKUP ALARM

/45.D3

=H

+H1

F66 *

OUTPUT MODULE 3 BK4

/49.A3

=K

+K2

H40

BUZZER

/54.C8

=K

+K2

F71

KEYPADS

/39.B2

=K

+K2

H40.X1

PLUG BUZZER

/54.C8

=K

+K2

F73 *

REAR AREA MONITORING

/76.A5

=K

+K2

H40.X2

PLUG BUZZER

/54.C8

=K

+K2

F74

MIRROR/REAR WINDOW HEATER

/33.B6

=K

+K2

H50

PROFILE LIGHT/PARKING LIGHT LEFT FRONT 24V 4W

/25.E4

=V

+V1

F75

RADIO Kl.58; ELECTRICAL SOCKET 12V

/34.B5

=K

+K2

H51

PROFILE LIGHT/PARKING LIGHT 24V 4W

/25.E5

=V

+V1

F76

RADIO

/34.B5

=K

+K2

H52

REVERSING LAMP LEFT

/25.E3

=B

+B1

F010

FEEDBACK HEATING FLANGE

/19.C5

=H

+H5

H53

REVERSING LAMP RIGHT 24V 21W

/25.E6

=B

+B2

PROJ: 8920980_003

FUNCTION

7

SHEET

F

BMK

6


E

5

FUNCTION

B

D

4

BMK

A

C

3


1


Änderung

Datum

1

Name

Datum


2

Ident.Nr.


ZeichNr.

4

5

6

8920980 460 9010 00 003 7

B

Anlage Ort

003 8

Blatt von

A

9 114

C

D

E

F

2

SHEET

SYSTEM PLACE

H54

LOW BEAM 24V 70W H7

/25.E4

=V

H55

LOW BEAM 24V 70W H7

/25.E5

H56

HIGH BEAM 24V 70W H3

H57

8

SYSTEM PLACE

+V1

K33B


/32.B6

=K

+K2

=V

+V1

K208 *

WORKING BASKET

/59.B6

=K

+K2.

/25.E4

=V

+V1

K213 *


/61.C6

=K

+K2

HIGH BEAM 24V 70W H3

/25.E5

=V

+V1

K216 *

AUTOMATIC RUNOUT

/47.D8

=K

+K2

H58 *

REVERSE WARNING LIGHT RED FLASHING

/55.C3

=B

+B1

K227 *


/82.C5

=K

+K2

H59 *

REVERSE WARNING LIGHT RED FLASHING

/55.C4

=B

+B1

K228 *


/82.C6

=K

+K2

K1

FLASHER UNIT

/27.C8

=K

+K2

K240

HAZARD WARNING LIGHTS

/27.A4

=K

+K2

K2

PROFILE LIGHT/IDENTIFICATION/CONTEUR LIGHT

/20.C7

=K

+K2

K243 *

AUXILIARY HEATER NOZZLE STICK PREHEATER

/80.D3

=K

+K2

K3

LOW BEAM

/25.B5

=K

+K2

K244

CONDENSER FAN

/68.B4

=K

+K2

K3A

HIGH BEAM

/25.B7

=K

+K2

K245

CONDENSER FAN

/69.B7

=K

+K

K5

SIMULATION D+

/20.C4

=K

+K2

K245

CONDENSER FAN

/68.B7

=K

+K2

K5a

INTERVAL WINDSCREEN WIPER FRONT

/28.B4

=K

+K1

K246 *


/49.D7

=K

+K2

K5a.X

PLUG INTERVAL WINDSCREEN WIPER FRONT

/28.C5

=K

+K1

K248 *

CONDENSER FAN

/69.B4

=K

+K2.

K8


/28.C7

=K

+K2

Kl.15 *

Kl.15 CUTOFF TILT CYLINDER

/61.B2

=K

+K2

K9

WARNING BEACON

/33.C3

=K

+K2

Kl.15.X

CONNECTION Kl.15 A4

/19.B2

=K

+K2

K01

IGNITION STARTER SWITCH BYPASS

/19.C2

=K

+K2

Kl.30.X

CONNECTION Kl.30 A4

/19.D2

=K

+K2

K04

HEATING FLANGE

/19.D6

=H

+H5

Kl.30.Xa *

Kl.30 DIESEL PREHEATING 40°

/82.B3

=K

+K2

K04* *


/83.B7

=H

+H5.

Kl.30a *

Kl.30 AUTOMATIC RUNOUT

/47.A8

=K

+K2

K04*


/84.B7

=H

+H5

L2

LED F2

/25.C6

=K

+K2

K10


/33.B7

=K

+K2

L3

LED F3

/25.C6

=K

+K2

K11


/23.C2

=H

+H4

L4

LED F4

/25.C4

=K

+K2

K11*


/84.B6

=H

+H4

L5

LED F5

/25.C4

=K

+K2

K11* *


/83.B6

=H

+H4.

L6

LED F6

/20.C6

=K

+K2

K11*.X3 *


/83.B6

=H

+H4.

L7

LED F7

/20.C7

=K

+K2

K11*.X4 *


/83.B6

=H

+H4.

L8

LED F8

/19.B8

=K

+K2

K12

RADIO; ELECTRICAL SOCKET 12V

/34.B4

=K

+K2

L8A

LED F8A

/19.B7

=K

+K2

K22

HAZARD WARNING LIGHT Kl.15

/27.C2

=K

+K2

L9

LED F9

/51.B6

=K

+K2

K22a

HAZARD WARNING LIGHTS MG

/27.C3

=K

+K2

L07B

LED F07B

/27.D1

=K

+K2

K22b

HAZARD WARNING LIGHTS MG

/27.C4

=K

+K2

L10

LED F10

/35.E2

=K

+K2

K25 *

HAZARD WARNING LIGHTS USA

/27.C5

=K

+K2

L11

LED F11

/56.E1

=K

+K2

K26 *


/27.C7

=K

+K2

L12 *

LED F12

/78.B3

=K

+K2

K31A


/30.B4

=K

+K2

L13

LED F13

/68.B3

=K

+K2

K31B


/30.B7

=K

+K2

L14 *

LED F14

/55.B8

=K

+K2

K32A


/31.B4

=K

+K2

L15

LED F15

/51.B5

=K

+K2

K32B


/31.B7

=K

+K2

L18

LED F18

/28.C8

=K

+K2

K33A


/32.B3

=K

+K2

L19

LED F19

/62.B2

=K

+K2

PROJ: 8920980_003

FUNCTION

7

SHEET

F

BMK

6


E

5

FUNCTION

B

D

4

BMK

A

C

3


1


Änderung

Datum

1

Name

Datum


2

Ident.Nr.


ZeichNr.

4

5

6

8920980 460 9010 00 003 7

Anlage Ort

003 8

Blatt von

10 114

A

B

C

D

E

F

2

SHEET

SYSTEM PLACE

L19A

LED F19A

/62.B1

=K

L20

LED F20

/28.C3

L21

LED F21

L22

8

SYSTEM PLACE

+K2

L55

LED F55

/44.B5

=K

+K2

=K

+K2

L56

LED F56

/44.B7

=K

+K2

/25.C3

=K

+K2

L59

LED F59

/43.B2

=K

+K2

LED F22

/45.B8

=K

+K2

L60

LED F60

/43.B3

=K

+K2

L23 *

LED F23

/75.B3

=K

+K2

L61

LED F61

/45.B2

=K

+K2

L24

LED F24

/47.B4

=K

+K2

L62

LED F62

/45.B3

=K

+K2

L25

LED F25

/33.C2

=K

+K2

L63 *

LED F63

/48.B4

=K

+K2

L26

LED F26

/40.D6

=K

+K2

L64 *

LED F64

/48.B6

=K

+K2

L27

LED F27

/20.C8

=K

+K2

L65 *

LED F65

/49.B2

=K

+K2

L29

LED F29

/19.C3

=K

+K2

L66 *

LED F66

/49.B3

=K

+K2

L30

LED F30

/34.B2

=K

+K2

L71

LED F71

/39.B2

=K

+K2

L31A

LED F31A

/30.C3

=K

+K2

L73 *

LED F73

/76.B5

=K

+K2

L31B

LED F31B

/30.C6

=K

+K2

L74

LED F74

/33.C6

=K

+K2

L32A

LED F32A

/31.B3

=K

+K2

L75

LED F75

/34.B5

=K

+K2

L32B

LED F32B

/31.B6

=K

+K2

L76

LED F76

/34.B6

=K

+K2

L33A

LED F33A

/32.B2

=K

+K2

L77

LED D+

/20.C4

=K

+K2

L33B

LED F33B

/32.B5

=K

+K2

M1

STARTER MOTOR

/19.E3

=M

+M

L34 *

LED F34

/55.B6

=K

+K2

M1*


/84.E5

=M

+M

L35

LED F35

/40.C4

=K

+K2

M1* *


/83.E5

=M

+M.

L36

LED F36

/47.B3

=K

+K2

M2

WINDSCREEN WIPER FRONT

/28.D4

=K

+K1

L38

LED F38

/47.B5

=K

+K2

M2.X1

PLUG WINDSCREEN WIPER FRONT

/28.D4

=K

+K1

L39 *

LED F39

/81.B5

=K

+K2

M2.X2 *

PLUG WINDSCREEN WIPER FRONT RESERVE

/28.D5

=K

+K1

L40 *

LED F40

/81.B8

=K

+K2

M3


/28.D7

=K

+K2

L42 *

LED F42

/80.D2

=K

+K2

M3.X

PLUG WINDSCREEN WIPER REAR

/28.D7

=K

+K2

L43

LED F43

/41.B2

=K

+K2

M4

WASHING PUMP FRONT

/28.D6

=K

+K1

L44

LED F44

/41.B7

=K

+K2

M4.X

PLUG WASHING PUMP FRONT

/28.E6

=K

+K1

L45

LED F45

/41.B4

=K

+K2

M5

FAN MOTOR

/64.E3

=K

+K4

L46 *

LED F46

/71.B3

=K

+K2

M5.X

PLUG FAN MOTOR

/64.D2

=K

+K4

L47

LED F47

/42.B4

=K

+K2

M6

LIEBHERR CENTRAL LUBRICATION SYSTEM

/77.C3

=H

+H5

L48

LED F48

/42.B7

=K

+K2

M6.X

PLUG LIEBHERR CENTRAL LUBRICATION SYSTEM

/77.D3

=H

+H5

L49 *

LED F49

/55.E2

=K

+K2

M7

COMPRESSOR SEAT

/19.E8

=K

+K2

L50 *

LED F50

/59.B2

=K

+K2

M7.X

PLUG COMPRESSOR SEAT

/19.E8

=K

+K2

L51

LED F51

/43.B6

=K

+K2

M8


/23.D2

=H

+H4

L52

LED F52

/43.B7

=K

+K2

M8*


/84.B5

=H

+H4

L53

LED F53

/77.B2

=K

+K2

M8* *


/83.B5

=H

+H4.

L54

LED F54

/40.C5

=K

+K2

M9

WASHING PUMP REAR

/28.D8

=K

+K4

PROJ: 8920980_003

FUNCTION

7

SHEET

F

BMK

6


E

5

FUNCTION

B

D

4

BMK

A

C

3


1


Änderung

Datum

1

Name

Datum


2

Ident.Nr.


ZeichNr.

4

5

6

8920980 460 9010 00 003 7

Anlage Ort

003 8

Blatt von

11 114

A

B

C

D

E

F

2

SHEET

SYSTEM PLACE

M9.X

PLUG WASHING PUMP REAR

/28.D8

=K

M10 *

REFUELLING PUMP

/55.E6

M11

WATER VALVE

M11.X

8

SYSTEM PLACE

+K4

OLE17 *

CONNECTION AUXILIARY HEATER

/80.D8

=K

+K2

=H

+H1

OLE18 *

PLUG RELAY BOARD

/80.E2

=K

+K2

/65.E3

=K

+K4

OLE19 *

LIGHTING S210

/59.E3

=K

+K2

PLUG WATER VALVE

/65.E2

=K

+K4

OLE20 *

LIGHTING S210

/59.E4

=K

+K2

M13 *

CONDENSER FAN

/69.D6

=H

+H3a

OLE21 *

CONNECTION AUXILIARY HEATER THERMO 90

/81.D3

=B

+B2

M13

CONDENSER FAN

/68.D7

=H

+H3

OLE22 *


/80.E7

=B

+B2

M13.X

PLUG CONDENSER FAN

/68.D7

=H

+H3

OLE23 *

REVERSING OBSTACLE DETECTOR

/75.C1

=H

+H3

M13.X *

PLUG CONDENSER FAN

/69.D6

=H

+H3a

OLE23 *

QUICKCHANGE DEVICE

/57.E7

=K

+K4

M14

RECIRCULATED AIR FLAP

/65.E7

=K

+K4

P1

WORKING HOUR METER

/20.A3

=K

+K4

M14.X

PLUG RECIRCULATED AIR FLAP

/65.E6

=K

+K4

P1.X1

PLUG WORKING HOUR METER

/20.A3

=K

+K4

M15 *

CIRCULATING PUMP DWB2010

/80.D7

=H

+H1

P1.X2

PLUG WORKING HOUR METER

/20.B3

=K

+K4

M15

FOOT FLAP

/66.E3

=K

+K4

R1

ANGLE SENSOR INCH PEDAL

/52.C3

=K

+K6

M15.X *

PLUG CIRCULATING PUMP DWB2010

/80.D7

=H

+H1

R1.X

PLUG ANGLE SENSOR

/52.C3

=K

+K6

M15.X

PLUG FOOT FLAP

/66.E2

=K

+K4

R2

DROP RESISTOR L2

/25.C6

=K

+K2

M16

MIDDLE FLAP

/66.E7

=K

+K4

R3

DROP RESISTOR L3

/25.C6

=K

+K2

M16.X

PLUG MIDDLE FLAP

/66.E6

=K

+K4

R4

DROP RESISTOR L4

/25.C4

=K

+K2

M17

HEAD FLAP

/67.E3

=K

+K4

R5

ANGLE SENSOR GAS PEDAL

/52.C7

=K

+K6

M17.X

PLUG HEAD FLAP

/67.E3

=K

+K4

R5

DROP RESISTOR L5

/25.C4

=K

+K2

M700

STARTER MOTOR

/105.B6

=M

+M

R5.X

PLUG ANGLE SENSOR

/52.C6

=K

+K6

MO1

MV MODULATION

/53.C2

=F

+F3

R6

DROP RESISTOR L6

/20.C6

=K

+K2

OLE1

SPARE LINE Kl.W

/19.C4

=K

+K2

R6a *

MIRROR HEATING

/33.E6

=K

+K3

OLE2 *


/19.D7

=K

+K2

R6a.X *

PLUG MIRROR HEATING

/33.E6

=K

+K3

OLE3 *

WORKING PROJECTOR CAB ROOFREAR

/31.A8

=K

+K2

R6b *

MIRROR HEATING

/33.E6

=K

+K3

OLE4 *

LIGHTING RFWEOA OPTIONAL

/33.E5

=K

+K2

R6b.X *

PLUG MIRROR HEATING

/33.E6

=K

+K3

OLE5 *


/51.F8

=K

+K2

R7

DROP RESISTOR L7

/20.C7

=K

+K2

OLE6 *


/51.F8

=K

+K2

R8

DROP RESISTOR L8

/19.B8

=K

+K2

OLE7 *

LOGIC OUTPUT MODULE 3

/41.D1

=K

+K2

R8A

DROP RESISTOR L8A

/19.B7

=K

+K2

OLE8 *

LOGIC INPUT MODULE 3

/42.D1

=K

+K2

R9

DROP RESISTOR L9

/51.B6

=K

+K2

OLE9 *

PLUG RELAY BOARD

/45.C8

=K

+K2

R9A *

EXCITATIONRESERVE

/20.C2

=K

+K2

OLE10 *

AUTOMATIC RUNOUT

/47.B7

=K

+K2

R9B

EXCITATION GG6

/20.C2

=K

+K2

OLE11 *

CONNECTION IMMOBILISER

/79.A4

=K

+K2

R07B

DROP RESISTOR L07B

/27.D1

=K

+K2

OLE12 *


/79.A8

=K

+K2

R10

DROP RESISTOR L10

/35.E2

=K

+K2

OLE13 *


/79.F7

=K

+K2

R10 *

DIESEL PREHEATING

/82.E5

=M

+M

OLE14 *

PLUG RELAY BOARD

/80.B3

=K

+K2

R10.X *

PLUG DIESEL PREHEATING

/82.E5

=M

+M

OLE15 *

PLUG RELAY BOARD

/80.B6

=K

+K2

R11

DROP RESISTOR L11

/56.E1

=K

+K2

OLE16 *

PLUG RELAY BOARD

/80.C7

=K

+K2

R12

REAR WINDOW HEATER

/33.E7

=K

+K2

PROJ: 8920980_003

FUNCTION

7

SHEET

F

BMK

6


E

5

FUNCTION

B

D

4

BMK

A

C

3


1


Änderung

Datum

1

Name

Datum


2

Ident.Nr.


ZeichNr.

4

5

6

8920980 460 9010 00 003 7

Anlage Ort

003 8

Blatt von

12 114

A

B

C

D

E

F

2

SHEET

SYSTEM PLACE

R12.X1

PLUG REAR WINDOW HEATER

/33.E7

=K

R12.X2

PLUG REAR WINDOW HEATER

/33.E7

R12: *

DROP RESISTOR L12

R13

8

SYSTEM PLACE

+K2

R45

DROP RESISTOR L45

/41.B4

=K

+K2

=K

+K2

R46 *

DROP RESISTOR L46

/71.B3

=K

+K2

/78.B3

=K

+K2

R47

DROP RESISTOR L47

/42.B4

=K

+K2

DROP RESISTOR L13

/68.B3

=K

+K2

R48

DROP RESISTOR L48

/42.B7

=K

+K2

R13 *

DIESEL PREHEATING

/55.E8

=M

+M

R49 *

DROP RESISTOR L49

/55.E2

=K

+K2

R13.X *

PLUG DIESEL PREHEATING

/55.E8

=M

+M

R50 *

DROP RESISTOR L50

/59.B2

=K

+K2

R14 *

DROP RESISTOR L14

/55.B8

=K

+K2

R51

DROP RESISTOR L51

/43.B6

=K

+K2

R15

DROP RESISTOR L15

/51.B5

=K

+K2

R52

DROP RESISTOR L52

/43.B7

=K

+K2

R18

DROP RESISTOR L18

/28.C8

=K

+K2

R53

DROP RESISTOR F53

/77.B2

=K

+K2

R19

DROP RESISTOR L19

/62.B2

=K

+K2

R54

DROP RESISTOR L54

/40.C5

=K

+K2

R19A

DROP RESISTOR L19A

/62.B1

=K

+K2

R55

DROP RESISTOR L55

/44.B5

=K

+K2

R20

DROP RESISTOR L20

/28.C3

=K

+K2

R56

DROP RESISTOR L56

/44.B7

=K

+K2

R21

DROP RESISTOR L21

/25.C3

=K

+K2

R59

DROP RESISTOR L59

/43.B2

=K

+K2

R22

DROP RESISTOR L22

/45.B8

=K

+K2

R60

DROP RESISTOR L60

/43.B3

=K

+K2

R23 *

DROP RESISTOR L23

/75.B3

=K

+K2

R61

DROP RESISTOR L61

/45.B2

=K

+K2

R24

DROP RESISTOR L24

/47.B4

=K

+K2

R62

DROP RESISTOR L62

/45.B3

=K

+K2

R25

DROP RESISTOR L25

/33.C2

=K

+K2

R63 *

DROP RESISTOR L63

/48.B4

=K

+K2

R26

DROP RESISTOR L26

/40.D6

=K

+K2

R64 *

DROP RESISTOR L64

/48.B6

=K

+K2

R27

DROP RESISTOR L27

/20.C8

=K

+K2

R65 *

DROP RESISTOR L65

/49.B2

=K

+K2

R29

DROP RESISTOR L29

/19.C3

=K

+K2

R66 *

DROP RESISTOR L66

/49.B3

=K

+K2

R30

DROP RESISTOR L30

/34.B2

=K

+K2

R71

DROP RESISTOR L71

/39.B2

=K

+K2

R31A

DROP RESISTOR L31A

/30.C3

=K

+K2

R73 *

DROP RESISTOR L73

/76.B5

=K

+K2

R31B

DROP RESISTOR L31B

/30.C6

=K

+K2

R74

DROP RESISTOR L74

/33.C6

=K

+K2

R32A

DROP RESISTOR L32A

/31.B3

=K

+K2

R75

DROP RESISTOR L75

/34.B5

=K

+K2

R32B

DROP RESISTOR L32B

/31.B6

=K

+K2

R76

DROP RESISTOR L75

/34.B6

=K

+K2

R33A

DROP RESISTOR L33A

/32.B2

=K

+K2

R77

DROP RESISTOR L77

/20.C4

=K

+K2

R33B

DROP RESISTOR L33B

/32.B5

=K

+K2

R701

HEATER FLANGE

/19.F6

=M

+M

R34 *

DROP RESISTOR L34

/55.B6

=K

+K2

S1

IGNITION SWITCH

/19.A3

=K

+K4

R35

DROP RESISTOR L35

/40.C4

=K

+K2

S1.X1

PLUG IGNITION SWITCH

/19.A3

=K

+K4

R36

DROP RESISTOR L36

/47.B3

=K

+K2

S1.X1.8a *


/79.A6

=K

+K4

R38

DROP RESISTOR L38

/47.B5

=K

+K2

S1.X2


/19.B4

=K

+K4

R39 *

DROP RESISTOR L39

/81.B5

=K

+K2

S1.X3


/19.B4

=K

+K4

R40 *

DROP RESISTOR L40

/81.B8

=K

+K2

S2

LH CONTROL LEVER VNR AND OPTIONS

/51.E4

=K

+K4

R42 *

DROP RESISTOR L42

/80.D2

=K

+K2

S2.1

FORWARD ; NEUTRAL ; BACKWARDS

/51.F4

=K

+K4

R43

DROP RESISTOR L43

/41.B2

=K

+K2

S2.2

KICK DOWN

/51.F5

=K

+K4

R44

DROP RESISTOR L44

/41.B7

=K

+K2

S2.3

PUSHBUTTON SWITCH OPTION 1

/51.F5

=K

+K4

PROJ: 8920980_003

FUNCTION

7

SHEET

F

BMK

6


E

5

FUNCTION

B

D

4

BMK

A

C

3


1


Änderung

Datum

1

Name

Datum


2

Ident.Nr.


ZeichNr.

4

5

6

8920980 460 9010 00 003 7

Anlage Ort

003 8

Blatt von

13 114

A

B

C

D

E

F

2

SHEET

SYSTEM PLACE

S2.4

PUSHBUTTON SWITCH OPTION 2

/51.F6

=K

S2.X

PLUG LH CONTROL LEVER VNR AND OPTIONS

/51.E5

S2a *

LH CONTROL LEVER WITH ANALOGUE SENSOR + GRIP SENSOR

S2a.X2 *

8

SYSTEM PLACE

+K4

SPLICE.X7

REVERSING LAMP

/25.D7

=H

+H4

=K

+K4

SPLICE.X8

BRAKE LIGHT

/25.F1

=H

+H4

/60.D4

=K

+K4

SPLICE.X10 *


/78.B2

=H

+H3

PLUG LH CONTROL LEVER

/60.D5

=K

+K4

SPLICE.X30 *

WORKING BASKET

/59.D4

=K

+K6

S3

STEERING COLUMN SWITCH

/25.B1

=K

+K1

SPLICE.X70 *

LH CONTROL LEVER WITH ANALOGUE SENSOR GRIP SENSOR

/60.C5

=K

+K

S3.X1

PLUGSTEERING COLUMN SWITCH

/28.E2

=K

+K1

Splice;.X1

LOGIC MODULES

/41.D2

=K

+K

S3.X2

PLUGSTEERING COLUMN SWITCH

/25.A2

=K

+K1

Splice;.X3

OPTIONS LH CONTROL LEVER

/51.D5

=K

+K

S15

BATTERY MAIN SWITCH

/19.E1

=H

+H5

Splice;.X4 *

CONDENSER FAN

/69.D4

=K

+K

S15*


/84.E2

=H

+H5

Splice;.X9

WINDSCREEN WIPER FRONT

/28.A5

=K

+K

S15* *


/83.E2

=H

+H5.

Splice;.X11 *


/33.D6

=K

+K3

S23 *

QUICKCHANGE DEVICE

/57.C7

=K

+K4

Splice;.X12 *


/33.F6

=K

+K3

S23.X1 *


/57.C7

=K

+K4

T1

VOLTAGE CONVERTER

/34.B7

=K

+K2

S23.X2 *


/57.D7

=K

+K4

T1.X

PLUG VOLTAGE CONVERTER

/34.A7

=K

+K2

S23a *

QUICKCHANGE DEVICE

/57.C6

=K

+K4

V1

FREEWHEELING DIODE K01

/19.C2

=K

+K2

S43 *

BACKUP ALARM CAN BE SWITCHED OFF

/45.A7

=K

+K4

V2 *

BLOCKING DIODE

/28.C1

=H

+H

S43.X1 *

PLUG BACKUP ALARM

/45.A7

=K

+K4

V2

FREEWHEELING DIODE k01.30

/19.C3

=K

+K2

S43.X2 *

PLUG BACKUP ALARM

/45.A7

=K

+K4

V2.X1 *

PLUG BLOCKING DIODE

/28.B1

=H

+H

S202 *

PUSHBUTTON SWITCH JOYSTICK STEERING

/72.C3

=K

+K4

V2.X2 *

PLUG BLOCKING DIODE

/28.C1

=H

+H

S204 *

REFUELLING PUMP

/55.C6

=H

+H2

V3


/34.B4

=K

+K2

S210 *

WORKING BASKET

/59.D3

=K

+K4

V8


/20.C3

=K

+K2

S210.X1 *

PLUG WORKING BASKET

/59.D3

=K

+K4

V9


/25.C5

=K

+K2

S210.X2 *

PLUG WORKING BASKET

/59.D3

=K

+K4

V10


/20.C7

=K

+K2

S212 *

RFWEOA OPTIONAL

/33.C4

=K

+K4

V11


/27.C3

=K

+K2

S212.X1 *

PLUG RFWEOA OPTIONAL

/33.B4

=K

+K4

V12

FREEWHEELING DIODE K22a

/27.C4

=K

+K2

S212.X2 *

PLUG RFWEOA OPTIONAL

/33.C5

=K

+K4

V13

FREEWHEELING DIODE K22b

/27.C4

=K

+K2

S212a *

SYMBOL RFWEOA OPTIONAL

/33.B4

=K

+K4

V14 *


/27.C6

=K

+K2

S213 *

EMERGENCY OFF 1 WORKING BASKET

/59.D7

=K

+K4

V15 *


/27.C7

=K

+K2

S213 *


/61.C4

=V

+V1

V16

FREEWHEELING DIODE K31A

/30.B5

=K

+K2

S213.X1 *

PLUG CUTOFF TILT CYLINDER

/61.C4

=V

+V1

V17

FREEWHEELING DIODE K31B

/30.B7

=K

+K2

S213.X2 *


/61.C4

=V

+V1

V18


/31.B4

=K

+K2

S214 *

EMERGENCY OFF 2 WORKING BASKET

/59.D8

=K

+K4

V19


/31.B7

=K

+K2

S216 *

EMERGENCY OFF AUTOMATIC RUNOUT

/47.C8

=K

+K3

V20


/32.B4

=K

+K2

S222

COMFORT CONTROL; 3. + 4.COMFORT CONTROL

/51.E7

=K

+K4

V21


/32.B6

=K

+K2

S222.X1 *

PLUG COMFORT CONTROL 3. + 4. CONTROL CIRCUIT

/51.E7

=K

+K4

V32


/68.B4

=K

+K2

S222.X2 *

PLUG COMFORT CONTROL 3. + 4. CONTROL CIRCUIT

/51.E8

=K

+K4

V32C

BLOCKING DIODE

/31.B7

=K

+K2

SPLICE.X2

SPLICE LOGIC MODULES

/42.C2

=K

+K2

V33


/68.B4

=K

+K2

PROJ: 8920980_003

FUNCTION

7

SHEET

F

BMK

6


E

5

FUNCTION

B

D

4

BMK

A

C

3


1


Änderung

Datum

1

Name

Datum


2

Ident.Nr.


ZeichNr.

4

5

6

8920980 460 9010 00 003 7

Anlage Ort

003 8

Blatt von

14 114

A

B

C

D

E

F

2

SHEET

SYSTEM PLACE

V33C

BLOCKING DIODE

/32.B6

=K

V34


/68.B7

V35


V36

8

SYSTEM PLACE

+K2

X2.B.50 *

PLUG CAB FLOOR X2.S.50

/69.D6

=K

+K6

=K

+K2

X2.B.51 *


/69.D7

=K

+K6

/68.B7

=K

+K2

X2.B.52 *


/69.E7

=K

+K6


/49.D7

=K

+K

X2.J

HAZARD WARNING LIGHTS EU

/27.C6

=K

+K2

V37


/49.D7

=K

+K

X2.S

PLUG CAB FLOOR

/62.C5

=K

+K6

V46 *


/80.D2

=K

+K2

X2.S* *

PLUG CAB FLOOR OPTION

/69.E8

=K

+K6

V48 *


/49.D8

=K

+K2

X2.S.50 *


/69.D6

=K

+K6

V49


/68.B7

=K

+K2

X2.S.51 *


/69.D7

=K

+K6

V50


/68.B5

=K

+K2

X2.S.52 *


/69.E7

=K

+K6

V53


/27.A3

=K

+K2

X3 *

PLUG PRESELECTION DIAL THERMO 90

/81.B1

=K

+K4

V57


/33.C8

=K

+K2

X3.J


/27.C8

=K

+K2

V58


/33.C3

=K

+K2

X4 *

PLUG PRESELECTION DIAL DBW2010

/80.B1

=K

+K4

V59


/28.C6

=K

+K2

X4.J *

JUMPER RESERVE

/20.C1

=K

+K2

V60


/25.C7

=K

+K2

X5 *

PLUG NOZZLE STICK PREHEATER DBW2010

/80.E3

=B

+B2

V80

BLOCKING DIODE

/20.B2

=K

+K2

X5.J *

JUMPER RESERVE

/20.C2

=K

+K2

V81

BLOCKING DIODE

/20.C3

=K

+K2

X6.J

JUMPER GG6

/20.C2

=K

+K2

V82

BLOCKING DIODE

/20.D3

=K

+K2

X11.ST1 *

PLUG AUXILIARY HEATER THERMO 90

/81.D5

=B

+B2

V83 *

BLOCKING DIODE

/27.D2

=K

+K2

X12.ST2 *


/81.C6

=B

+B2

V84 *

BLOCKING DIODE

/27.D2

=K

+K2

X13.ST3 *


/81.D7

=B

+B2

V85

BLOCKING DIODE

/27.D3

=K

+K2

X16.B

PLUG LIGHTING REAR HATCH

/31.D4

=H

+H

V86

BLOCKING DIODE

/27.D4

=K

+K2

X16.S

PLUG LIGHTING REAR HATCH

/31.D4

=H

+H

V87

BLOCKING DIODE

/27.D8

=K

+K2

X22a.B

PLUG CABIN

/30.D4

=K

+K4

V88 *

BLOCKING DIODE

/27.D8

=K

+K2

X22a.S

PLUG CABIN

/30.D4

=K

+K4

V89

BLOCKING DIODE

/27.C8

=K

+K2

X22b.B

PLUG WIRING HARNESS CABIN

/19.D7

=K

+K4

V100 *

BLOCKING DIODE

/57.B7

=K

+K2

X22b.S

PLUG WIRING HARNESS CAB

/19.D7

=K

+K4

V100.X1 *

PLUG BLOCKING DIODE

/57.B7

=K

+K2

X26.B

PLUG E12

/32.D3

=K

+K3

V100.X2 *

PLUG BLOCKING DIODE

/57.B7

=K

+K2

X26.S *

PLUG E12

/32.E3

=K

+K3

W1

ANTENNA

/34.D8

=K

+K3

X26a.S *

PLUG E12b

/32.E4

=K

+K3

X1.B

PLUG CAB FLOOR

/20.E3

=K

+K6

X27.B

PLUG E12a

/32.D4

=K

+K3

X1.B.64 *


/57.B8

=H

+H

X27.S *

PLUG E12a

/32.D4

=K

+K3

X1.B.65 *


/57.E8

=H

+H

X28.B

PLUGFAN MOTOR

/21.B7

=H

+H

X1.J

HAZARD WARNING LIGHTS EU

/27.C5

=K

+K2

X28.B

PLUG E13

/32.D6

=K

+K3

X1.S

PLUG CAB FLOOR

/20.D3

=K

+K6

X28.S

PLUG FAN MOTOR

/21.B7

=H

+H

X1.S.61a *


/69.C8

=K

+K

X28.S *

PLUG E13

/32.D6

=K

+K3

X2.B

PLUG CAB FLOOR

/62.C5

=K

+K6

X28a.S *

PLUG E13b

/32.E7

=K

+K3

X2.B* *

PLUG CAB FLOOR OPTION

/69.E8

=K

+K6

X29.B

PLUG E13a

/32.D7

=K

+K3

PROJ: 8920980_003

FUNCTION

7

SHEET

F

BMK

6


E

5

FUNCTION

B

D

4

BMK

A

C

3


1


Änderung

Datum

1

Name

Datum


2

Ident.Nr.


ZeichNr.

4

5

6

8920980 460 9010 00 003 7

Anlage Ort

003 8

Blatt von

15 114

A

B

C

D

E

F

2

SHEET

SYSTEM PLACE

X29.S *

PLUG E13a

/32.D7

=K

X31


/77.C5

X33

PLUG MAGNETICS PILOT CONTROL UNIT

X33.X

8

SYSTEM PLACE

+K3

X.RS232.B

PLUG DIAGNOSTIC LEAD AIR CONDITIONING ELECTRONICS

/70.B7

=K

+K

=H

+H5

XA16a.X1.58 *

CAN CONNECTION. INPUT MODULE 1

/37.E7

=H

+H3

/56.C7

=K

+K4

XB39

PLUG AMBIENT TEMPERATURE SENSOR

/62.D6

=K

+K6

PLUG MAGNETICS PILOT CONTROL UNIT

/56.C7

=K

+K4

XE14l.a *

PLUG LICENCE PLATE LIGHT ITALIAN VERSION

/25.D7

=H

+H1

X37a *

PLUG RFWEOOPTIONAL

/25.C8

=H

+H3

XE14l.a. *


/25.E7

=H

+H1

X37b *

PLUG RFWEO OPTIONAL

/25.C8

=H

+H3

XE14l.b *


/25.D7

=H

+H1

X43


/77.C7

=V

+V1

XE14r.a *


/25.D8

=H

+H1

X44 *

PLUG RELAY BOARD DIESEL PREHEATING

/82.B5

=K

+K2

XE14r.a. *


/25.E8

=H

+H1

X45.B *

PLUG CONNECTOR LINT FILTER

/69.B5

=K

+K2

XE14r.b *


/25.E8

=H

+H1

X45.S *

PLUG CONNECTOR LINT FILTER

/69.B5

=K

+K2

XMSP1

MASS GROUPING BLOCK HIND CARRIAGEFRONT LEFT

/19.D3

=H

+H2

X48.B *

PLUG EMERGENCY OFF 2 WORKING BASKET

/59.C8

=H

+H

XMSP1.e *

MASS GROUPING BLOCK HIND CARRIAGE FRONT LEFT

/59.F4

=H

+H2

X48.S *

PLUG EMERGENCY OFF 2 WORKING BASKET

/59.C8

=H

+H

XMSP1a


/31.F4

=K

+H2

X50.B *


/78.C2

=H

+H3

XMSP1b

MASS GROUPING BLOCK HIND CARRIAGE FRONTLEFT

/43.D2

=H

+H2

X50.S *


/78.C2

=H

+H3

XMSP1c


/25.F6

=H

+H2

X51.B *

PLUG EMERGENCY OFF;

/59.A7

=K

+K

XMSP1d *


/48.D3

=H

+H2

X51.S *

PLUG EMERGENCY OFF;

/59.A7

=K

+K

XMSP4.1

MASS GROUPING BLOCK HIND CARRIAGEREAR LEFT

/19.E1

=H

+H

X52.B *

PLUG REVERSING OBSTACLE DETECTOR

/75.D4

=K

+K2

XMSP4.1*


/84.D2

=H

+H

X60

DIAGNOSTIC PLUG

/40.F6

=K

+K2

XMSP4.1* *


/83.D2

=H

+H.

X60a

DIAGNOSTIC PLUG ENGINE CONTROL UNIT

/70.E2

=M

+M

XMSP4.2

MASS GROUPING BLOCK HIND CARRIAGE BACKLEFT

/19.D3

=H

+H5

X70

12V ELECTRICAL SOCKET

/34.E4

=K

+K5

XMSP4.3

MASS GROUPING BLOCK HIND CARRIAGEBACK LEFT

/19.F3

=H

+H5

X70.X1

PLUG 12V ELECTRICAL SOCKET

/34.E4

=K

+K5

XMSP6.1

MASS GROUPING BLOCK CAB REAR WALL

/19.D2

=K

+K2

X70.X2

PLUG 12V ELECTRICAL SOCKET

/34.E4

=K

+K5

XMSP6.10 *


/71.C2

=K

+K2

X71

ELECTRICAL SOCKET CIGARETTE LIGHTER

/34.E3

=K

+K4

XMSP6.11 *


/71.C4

=K

+K2

X71.X

PLUG CIGARETTE LIGHTER

/34.E3

=K

+K4

XMSP6.12 *


/57.E8

=K

+K2

X73

CIGARETTE LIGHTER

/34.F3

=K

+K4

XMSP6.13 *


/33.F7

=K

+K2

X75.B *

PLUG INTERIOR TEMPERATURE SENSOR

/67.C6

=K

+K4

XMSP6.14 *


/55.C8

=K

+K2

X75.S

PLUG INTERIOR TEMPERATURE SENSOR

/67.C6

=K

+K4

XMSP6.15 *


/81.C6

=K

+K2

X223.B *

PLUG DIESEL PREHEATING 40°

/80.F3

=K

+K2

XMSP6.16 *


/80.F1

=K

+K2

X223.S *

PLUG DIESEL PREHEATING 40°

/82.B6

=K

+K2

XMSP6.18 *


/30.F5

=K

+K2

X321a *

COUNTRYSPECIFIC TYPE/EXECUTION LEFT

/26.E2

=V

+V

XMSP6.19 *


/82.F6

=K

+K6

X321b *

COUNTRYSPECIFIC TYPE/EXECUTION RIGHT

/26.E8

=V

+V

XMSP6.2


/19.D2

=K

+K2

X700.B

PLUG MOTOR CONTROL

/105.D7

=M

+M

XMSP6.20 *


/82.F6

=K

+K6

X700.S

PLUG MOTOR CONTROL

/105.D7

=M

+M

XMSP6.21 *


/76.C5

=K

+K2

X701.B

PLUG MOTOR CONTROL

/105.D8

=M

+M

XMSP6.22 *


/75.D4

=K

+K2

X701.S

PLUG MOTOR CONTROL

/105.D8

=M

+M

XMSP6a


/28.F8

=K

+K2

X.M7a.S

PLUG DIAGNOSTIC LEAD AIR CONDITIONING ELECTRONICS

/70.B6

=K

+K2

XMSP6b


/39.B4

=K

+K2

PROJ: 8920980_003

FUNCTION

7

SHEET

F

BMK

6


E

5

FUNCTION

B

D

4

BMK

A

C

3


1


Änderung

Datum

1

Name

Datum


2

Ident.Nr.


ZeichNr.

4

5

6

8920980 460 9010 00 003 7

Anlage Ort

003 8

Blatt von

16 114

A

B

C

D

E

F

2

SHEET

SYSTEM PLACE

XMSP6c


/33.F7

=K

XMSP6d *


/45.B7

XMSP6e *


XMSP7a

8

SYSTEM PLACE

+K2

Y11a.JPT *

PLUG OPTIONAL EQUIPMENT 3

/57.C3

=V

+V

=K

+K2

Y11b *

EP 3 AND 4 CONTROL CIRCUIT

/50.C7

=V

+V1

/33.B5

=K

+K2

Y11b.JPT *

PLUG EP 3 AND 4 CONTROL CIRCUIT

/50.C7

=V

+V1

MASS GROUPING BLOCK CAB ROOF

/32.F6

=K

+K3

Y12

OPTIONAL EQUIPMENT 2

/57.C2

=V

+V

XMSP7b

MASS GROUPING BLOCK CAB ROOF

/25.F6

=K

+K3

Y12.JPT


/57.C2

=V

+V

XMSP10*


/84.F4

=M

+M

Y12a *


/50.C6

=V

+V1

XMSP12

MASS GROUPING BLOCK A4

/19.D2

=K

+K2

Y12a *


/57.C4

=V

+V

XMSP12.1 *


/47.E8

=K

+K2

Y12a.JPT *


/50.C6

=V

+V1

XMSP12.2 *


/79.C6

=K

+K2

Y12a.JPT *


/57.C4

=V

+V

XMSP63 *


/78.D4

=K

+K2

Y12b *


/50.C8

=V

+V1

XMSP200 *


/50.C2

=K

+K2

Y12b.JPT *


/50.C8

=V

+V1

XMSP201 *


/61.D4

=K

+K2

Y13

FAN MOTORINTERCOOLER

/21.C7

=H

+H

XMSP.20 *


/69.F7

=K

+K2

Y13.X

PLUG FAN MOTOR

/21.C7

=H

+H

Y2

TRAVELLING DIRECTION FORWARD

/54.C1

=H

+H

Y14

WORKING HYDRAULICS LOCKOUT

/57.C5

=H

+H

Y2.DT

PLUG TRAVELLING DIRECTION FORWARD

/54.C1

=H

+H

Y14.JPT

PLUG WORKING HYDRAULICS LOCKOUT

/57.C5

=H

+H

Y2a

TRAVELLING DIRECTION FORWARD

/54.C3

=H

+H

Y15

PWM SWIVEL ANGLE TRAVEL PUMP

/54.C5

=H

+H

Y2a.DT

PLUG TRAVELLING DIRECTION FORWARD

/54.C3

=H

+H

Y15.JPT

PLUG PWM SWIVEL ANGLE TRAVEL PUMP

/54.C5

=H

+H

Y3

TRAVELLING DIRECTION BACKWARDS

/54.C2

=H

+H

Y15a

PWM SWIVEL ANGLE TRAVEL PUMP

/54.C6

=H

+H

Y3.DT

PLUG TRAVELLING DIRECTION BACKWARDS

/54.C2

=H

+H

Y15a.JPT

PLUG PWM SWIVEL ANGLE TRAVEL PUMP

/54.C6

=H

+H

Y3a

TRAVELLING DIRECTION BACKWARDS

/54.C4

=H

+H

Y16

OVERSPEED PROTECTION

/53.C5

=H

+H

Y3a.DT

PLUG TRAVELLING DIRECTION BACKWARDS

/54.C4

=H

+H

Y16.JPT

PLUG OVERSPEED PROTECTION

/53.C5

=H

+H

Y6

TRAVEL RANGES, MODULATION

/53.C2

=F

+F3

Y17

LIFT KICKOUT

/56.C7

=K

+K4

Y6.1

TRAVEL RANGE 1

/53.C4

=F

+F3

Y18

FLOAT POSITION

/56.C7

=K

+K4

Y6.2

TRAVEL RANGE 2

/53.C2

=F

+F3

Y20

RIDE CONTROL

/23.C7

=V

+V1

Y6.3

TRAVEL RANGE 3

/53.C3

=F

+F3

Y20.JPT

PLUG RIDE CONTROL

/23.C7

=V

+V1

Y6.X

PLUG TRAVEL RANGES, MODULATION

/53.C2

=F

+F3

Y21

RIDE CONTROL

/23.C8

=V

+V1

Y9

BUCKET RETURNTODIG

/56.C7

=K

+K4

Y21.JPT

PLUG RIDE CONTROL

/23.C8

=V

+V1

Y9a

BUCKET RETURNTODIG ÜBER PUSHBUTTON SWITCH

/56.C6

=V

+V1

Y22

AIR CONDITIONING COMPRESSOR

/62.E5

=M

+M

Y9a.JPT *

PLUG BUCKET RETURNTODIG ÜBER PUSHBUTTON SWITCH

/56.C6

=V

+V1

Y22.X

PLUG AIR CONDITIONING COMPRESSOR

/62.E5

=M

+M

Y10

PARKING BRAKE

/78.C1

=H

+K6

Y50

FAN REVERSAL

/21.C8

=H

+H3

Y10.JPT

PLUG PARKING BRAKE

/78.C1

=H

+K6

Y50.AF2

PLUG FAN REVERSAL

/21.C8

=H

+H3

Y11


/57.C1

=V

+V

Y51 *

JOYSTICK STEERING LEFT

/72.C6

=H

+H3

Y11.JPT


/57.C1

=V

+V

Y51.AF2 *

PLUG JOYSTICK STEERING LEFT

/72.C6

=H

+H3

Y11a *


/50.C5

=V

+V1

Y52 *

JOYSTICK STEERING RIGHT

/72.C7

=H

+H3

Y11a *


/57.C3

=V

+V

Y52.AF2 *

PLUG JOYSTICK STEERING RIGHT

/72.C7

=H

+H3

Y11a.JPT *


/50.C5

=V

+V1

Y53

QUICKCHANGE DEVICE

/57.C8

=V

+V1

PROJ: 8920980_003

FUNCTION

7

SHEET

F

BMK

6


E

5

FUNCTION

B

D

4

BMK

A

C

3


1


Änderung

Datum

1

Name

Datum


2

Ident.Nr.


ZeichNr.

4

5

6

8920980 460 9010 00 003 7

Ort

8

Blatt von

B

C

Anlage

003

A

17 114

D

E

F

2

1

A

E


D

4

5

BMK

FUNCTION

SHEET

SYSTEM PLACE

Y53.JPT


/57.D8

=V

+V1

Y57

HYDRO MOTOR SWIVEL ANGLE 1

/53.C8

=F

+F3

Y57.DT

PLUG HYDRO MOTOR SWIVEL ANGLE 1

/53.C8

=F

+F3

Y63 *

GEROTOR STEERING

/55.C4

=H

+H3

Y63.JPT *

PLUG GEROTOR STEERING

/55.C4

=H

+H3

Y64 *

SAFETY JOYSTICK STEERING

/72.C8

=H

+H3

Y64.JPT *

PLUG SAFETY JOYSTICK STEERING

/72.C8

=H

+H3

Y65 *

WORKING BASKET TILT CYLINDER LOCKOUT

/59.E4

=V

+V1

Y65.JPT *

PLUG WORKING BASKET TILT CYLINDER LOCKOUT

/59.E4

=V

+V1

Y66 *

WORKING BASKET TILT CYLINDER LOCKOUT

/59.E5

=V

+V1

Y66.JPT *

PLUG WORKING BASKET TILT CYLINDER LOCKOUT

/59.E5

=V

+V1

Y67 *

WORKING BASKET TILT CYLINDER FINE CONTROL

/59.E6

=V

+V1

Y67.JPT *

PLUG WORKING BASKET TILT CYLINDER FINE CONTROL

/59.E6

=V

+V1

Y68 *


/61.E6

=V

+V1

Y68.JPT *


/61.E6

=V

+V1

Y711

INJECTION PUMP 1

/109.B3

=M

+M

Y712

INJECTION PUMP 2

/109.B4

=M

+M

Y713

INJECTION PUMP 3

/109.B6

=M

+M

Y714

INJECTION PUMP 4

/110.B3

=M

+M

Y715

INJECTION PUMP 5

/110.B4

=M

+M

Y716

INJECTION PUMP 6

/110.B6

=M

+M

YEP1

HYDRAULIC MOTOR 1

/53.C6

=F

+F3

YEP1.DT

PLUGHYDRAULIC MOTOR 1

/53.C6

=F

+F3

YEP2

HYDRO MOTORS 2

/53.C7

=F

+F3

YEP2.DT

PLUG HYDRAULIC MOTOR 2

/53.C7

=F

+F3

6

7

8

A

B

C

D


C

PROJ: 8920980_003

B

3

E

F


Änderung

Datum

1

Name

Datum


2

Ident.Nr.


ZeichNr.

4

5

6

8920980 460 9010 00 003 7

Anlage Ort

003 8

Blatt von

18 114

2

1

3

4

5

6

7

8

WH 2.5Q

58

15

15

50a

50a

P 0 12

A16a.X1

OLE1 Verb. 1

4

1

1

+H5 F07 10A RD

2

BK 70Q

31

RD 70Q

+H5 XMSP4.3

BK 70Q

Ausgabe Änderung

Datum

1

Name

Datum


2

+H2 XMSP1c

1

E2.X1

*

B 6

BK 2.5Q

RD 25Q

WH 2Q

+K2 M7 2

28

5

1

E2.X2

M

E

3

E2.X3

2

=K

+H2 XMSP1b

+M R701 0

M7.X

+K3 XMSP7a

BK 2Q

1

BK 2Q =K

BK 2Q

3

9

+K2 XMSP6b

7

F

IGNITION LOCK ; BATTERIES ; GENERATOR ; MAIN FUSES 4

1

+K3 E2 0

X

3


D+

M7.X

1

RD 1.5Q

+M G3

1

WH 2Q

31

/81.B6

50

2

Datum

D

1

M

B+

Kl.30.F07 RD 1.5Q

+M M1

W

/D+

* 30

1

WH 1Q

X

+B1 G2

X1.B X1.S

z

+

R.5

=K

/27.A5

*

+

Ersteller

+K4 X22b.S X22b.B

28

RD 25Q

/20.E3

BK 70Q

RD 25Q

+B G1 +H5 S15

30.1

RD 25Q

RD 70Q

A4.X55

1

RD 25Q

XMSP4.1 +H

A4.X57

1

30.2 50 +H5 K04

2 1

GND

OLE2

=H

*

ELECTRICAL SOCKET RADIO F8 /34.B3

1

1

L8

C

*

1

100A F02 +H

1

+H5 F01 100A

2

1

* 1

L8A

1

65

+H5 XMSP4.2

BK 25Q

+H2 XMSP1

2

200A F03 +H5 WH 1.5Q

1 1

+K2 XMSP6.1

BK,BK 25Q,25Q

BK 25Q

+K2 XMSP6.2

RD 25Q

2

BK 25Q

RD 25Q

MP

R8

WH 2Q

+H5 F010 5A HBR

+K6 X1.S X1.B +K6

65

V2

GND

=K

F

Zustand

1

RD 6Q

XMSP12

RD 25Q

1

R8A

T.4

GND

Kl.30.X 1

A

Verb.

L29

85

15A BU

GND

1

87

Kl. 30.F08

R29

A700D.DO2 X2 39

A700D.X2

F8

B

=K+K4X3:1

A

10A RD A

WH 2Q

K01

A700D.X2

/93.E2

A700D +M

WH 6Q

V1

A700D.DI2 X2 64

F8A

E

ENGINEECU SELECTION HEATER FLANGE

1

86

25A WH

WH 1.5Q =K+K6X1.S:65

F29

/23.B2

30

We reserve all rights in this document and in the informa tion contained therein. Reproduction, use or disclosure to third parties without express authority is strictly forbidden. © LIEBHERR WERK EHINGEN 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. © LIEBHERR WERK EHINGEN

E

/93.E2

A700D +M

E Kl. 15

ENGINEECU ACKNOWLEDGEMENT HEATER FLANGE

WH 1.5Q

Kl.15.X 1

E

T.1

39

1

T.3

64

A4 =K +K2

A4.X57

S.4

3

A4.X56

4

RD 2.5Q

Kl. 30

D

2

S1.X3

A4 =K +K2

BK 1.5Q

A9 IMMOBILISER Kl. 15

1

S1.X2

A4.X57

X1 24 A16a.UI15 A +H3 Kl 50a A16a /86.D2 ANALOGUE all-purpose Input15 CAN: INPUT MODULE 1

30

ENGINE SIDE/105.B6

C

PROJ: 8920980_003

B

30

1

0

A

1

9

2

8

1

6

5

8

5

WH 2.5Q

6

10

24

5

WH 2.5Q

+K4 S1

10

A9 Kl.15

S1.X1

/79.C6

A

1

+K6 X1.S X1.B

WH 2.5Q

1

WH 2.5Q

6

Ident.Nr. ZeichNr.

8920980 460 9010 00 003 7

Anlage Ort

003 8

Blatt von

19 114

3

4

A

A18.X2

B

A4.X49 A4 =K +K2

LED GREEN L77

10

OLD M.4 M.9

K.10

PROFILE LIGHT / PARKING LIGHT

R77

E

E

E 86

R9B

V81

220Ω

F6 86

A

F27

10A RD

C

87

A

87a

R27

GND

L27

T.7

T.8

A4.X57

A4.X57

WH 1.5Q 19 WH 1.5Q Kl.58aR

E

/25.C8

Kl.58aL /25.D2

6

19

WH 1.5Q 6

WH 1.5Q 5 WH 1.5Q

5

WH 1.5Q 4 WH 1.5Q

4

WH 1.5Q Kl.58aL /25.D3

WH 1.5Q Kl.58aL

D

*

WH 1.5Q

3

WH 1.5Q

*

/25.E4

3

8

T.6

A4.X57

3

2 2 /19.F5

D+

GND

T.5

*

+K6 X1.S X1.B

GND

A4.X57

6

5

1

A4.X53

/D+ WH 1Q


+K6 X1.S X1.B

L7

GND

WH 1Q

O.1

L6

85

87a

WH 1.5Q

87

Kl.58aR

85

/25.D6

E

WH 1.5Q

E

V82

E

R7

WH 1.5Q

X6.J 10A

R6

Kl.58aR

X5.J 10A

K2

A

V8

/25.D6


K5 X4.J 10A

3A VT

A

7

A

30

V10

Kl.58aR

A

F7

3A VT

30

/25.E5

R9A

Kl.30

/51.A4

9

=K +K2 A4.X51

5

F15.2 Kl.15

V80

PROJ: 8920980_003

+K2 XMSP6b

/51.A4

WH 1Q

BK 1Q

JUMPER X6 220Ohm/5Watt L550 L586

B

E

1

P1.X2

Kl.15 F15.1

A

2

JUMPER X5 RESERVE

A4 =K +K2

8

ELECTRIC KEYPAD CAN: /94.D3 OUTLET A6 A18 PARKING LIGHT +K4 A =K A18.PWM6 X2 3

WH 1Q

h

INFO JUMPER X4 RESERVE 0 OHM EXCITATION

D

7

1

+K4 P1

C

6

1

P1.X1

5

3

2

1

F


Änderung

Datum

1

Name

Datum


2


Ident.Nr.

FUNCTION D+ PROFILE LIGHT; PARKING LIGHT 4

5

ZeichNr.

6

8920980 460 9010 00 003 7

Anlage Ort

003 8

Blatt von

20 114

A A16a.UI4 X1 7

A16a.X1

/93.D2

A700D +M

A700D.AI11.1 X2 63

A700D.X2

/86.C5 A16a /86.D2 ANALOGUE all-purpose Input13 A16a transmisson overtemperature+H3 +H3 A16a.UI13 X1 22

A16a.X1

INPUT MODULE 1 CAN: resistor input 1 hydraulics oil temperature D A16a.RI1 X1 46

A16a.X1

8

OUTPUT MODULE 1 CAN: /90.D1 PWMOutput 6 (Bank2) A17a VENTILATOR +H3 A A17a.PWM6 X1 19

A17a.X1

OUTPUTMODULE 2 CAN: /91.D2 PWMOutput6 (Bank A17b FAN REVERSAL +H3 A A17b.PWM6 X1 19

A17b.X1

A

+H X28.B X28.S

+K6 B19 0

Q

0 sw

ge

UP

+ B

1

+H B13 0

A

+H1 B8 0

T

2

B19.X

4

1

1

+F3 B14 0

B13.X

1 1

+H Y13 0

°C

B8.X

Y13.X

1

+H3 Y50 0

2

2

C

1

2

Y50.AF2

2

BK 1.5Q

D

2

+H X28.S X28.B

BU 1Q

WH 1Q

WH 1Q

BK 1Q

BK 1Q

BK 1.5Q

2

2 B25.X

s

Y13.X

2

C

B8.X

2

+H2 B25

B14.X

1

vi

B13.X

2

gn

Y50.AF2 B19.X

1

3 1

1

2

3

B25.X

1

WH 1.5Q

1

B

WH 1.5Q

1

RD 1Q

WH 1Q

BU 1Q

PROJ: 8920980_003

2

2

BK 1.5Q

1

+H3 A16a /86.E5

+H3 A16a

EARTH TANK SENSOR EARTH CAN: INPUT MODULE 1

/86.D5

GND PRESSURE RESERVOIR BRAKE

EARTH CAN: INPUT MODULE 1

X1 32 A16a.24V

+H3 A16a

Vcc PRESSURE RESERVOIR BRAKE /86.E2 SUPPLY 24V CAN: INPUT MODULE 1

+M A700D

+H3 A16a

COOLANT LEVEL SIGNAL ENGINEECU

/93.D2

/86.C5

X1 47 A16a.RI1 D hydraulics oil temperature resistor input 2 CAN: INPUT MODULE 1

A17a.X1

A17b.X1

X1 61 A17a.GND_PWM6

+H3 A17a

EARTH VENTILATOR /90.D5 EARTH CAN: OUTPUT MODULE 1

61

A16a.X1

X2 62 A700D.AI11.2

61

A700D.X2

47

A16a.X1

X1 61 A16a.GND

62

A16a.X1

X1 65 A16a.GND

61

A16a.X1

32

E 65

E

1


D


C

RD 1Q

B

WH 1Q

WH 1Q

WH 1.5Q

19

PRESSURE RESERVOIR BRAKE

INPUT MODULE 1 CAN:

7

19

A16a.X1

37

A16a.X1

A16a +H3

ENGINEECU VCC coolant level signal

6

46

A16a.24V X1 37

INPUT MODULE 1 CAN: /86.C2 ANALOGUE all-purpose Input 4

5

22

A

4

7

A16a +H3

INPUT MODULE 1 CAN: /86.D2 ANALOGUE all-purpose Input 14 A16a TANK SENSOR +H3 A A16a.UI14 X1 23 23

/86.F2

INPUT MODULE 1 CAN: SUPPLY 24V 24V TANK SENSOR

3

63

2

1

X1 61 A17b.GND_PWM6

+H3 A17b /91.D5

EARTH FAN REVERSAL EARTH CAN: OUTPUTMODULE 2

F


Änderung

Datum

1

Name

Datum


2

TANK PIPE SENSOR ; TRANSMISSION / HYDRAULIC OIL TEMPERATURE ; Werk Bischofshofen GmbH VENTILATOR ; COOLING WATER LEVEL , BRAKE ACCUMULATOR 3

4

5

6

Ident.Nr. ZeichNr.

8920980 460 9010 00 003 7

Anlage Ort

003 8

Blatt von

21 114

WH 1Q

A16a.RI1 X1 46

A16a.X1 +H3

A17a.X1 +H3

A17b.PWM6 X1 19

A17b.X1 +H3

B

X28.B X28.S

+H3 A16a

/35.D5

X1 32 A16a.24V

=M +M +H3 A700D D pressure accumulator brake A16a =M+M/34.D2

Masse Tankgeber Masse CAN: INPUT MODUL 1

/35.E2

Supply 24V CAN: INPUT MODUL 1

X2 62 A700D.AI11.2 KÜHLWASSERSTANDS. SIGNAL MOTORECU

B13a..X2

1

BK 1.5Q

2

D

BK 1.5Q

+H3 A17a.X1

X1 47 A16a.RI1

+H3 A16a Hydrauliköltempertur

/35.B5 Widerstandseingang2 CAN: INPUT MODUL 1

+H3 A17b.X1

X1 61 A17a.GND_PWM6

+H3 A17a

/37.D5

Masse Lüfter Masse CAN: OUTPUT MODUL 1

61

+H3 A16a.X1 WH 1Q

X1 65 A16a.GND

A700D.X2

62

+H3 A16a.X1

65

+H3 A16a.X1

32

B13a.X

2

2

W160 +WL017 BU

B13a

47

1

X28.S X28.B

B13 Steckverbindung Superseal L544 L554

1

WH 1Q

WH 1Q

W160 +WL016 BK

B13a.X

2

Y50.AF2 +H3

BK 1.5Q

B13a..X2

WH 1Q

1

B8.X

2 Y13.X

C

2

2

1

+H3 Y50 2

1 °C

B8

Y13 0

1

1

T

2

B13.X

Y13.X 1

1

2

2

4

B8.X

1

61

+F3 B14

2

B19.X +K6

+H3 Y50.AF2

2

ge

2 B25.X

B13

P

2

sw

B14.X

1

2

+K6 B19

Q

B13.X 1

1

B19.X

vi

X1 61 A17b.GND_PWM6

E

+H3 A17b Masse Lüfterumkehr

/38.D5

Masse CAN: OUTPUTMODUL 2

INFORMATION FROM Ident.Nr. 8920980 Zeich.Nr. 460 9010 00 000 VALID TO SERIAL NUMBER : see attachment


A17a.PWM6 X1 19

19

A16a.X1

A

+H3

1

3

W160 +WL016 BU 1

PROJ: 8920980_003

A16a.UI13 X1 22

2

E

3

B25


D

1 gn


C

W160 +WL016 RD

B

B25.X

A700D.X2

+H3

OUTPUTMODUL 2 CAN: /38.D2 PWMAusgang6 (Bank2) A17b Lüfterumkehr

19

A16a.X1

=M

+H3

1

A16a.UI4 X1 7

+H3

8

OUTPUT MODUL 1 CAN: /37.D2 PWMAusgang6 (Bank2) A17a Lüfter

1

A16a.X1 +H3

37

A16a.X1 +H3

A16a.UI14 X1 23 23

A16a.24V X1 37

A700D.AI11.1 X2 63

INPUT MODUL 1 INPUT MODUL 1 CAN: CAN: /35.D2 analoger Universaleingang13 /35.B5 Widerstandseingang1 A16a Getriebeübertemperatur A16a Hydrauliköltempertur

46

+H3

7

W160 +WL017 RD

+H3

MOTORECU VCC KÜHLWASSERSTANDS.

22

INPUT MODUL 1 INPUT MODULE 1 CAN: CAN: =M+M/34.D2 /35.D2 analoger Universaleingang14 /35.B2 analogue all-purpose input4 A16a A16a pressure accumulator brakeA700D Tankgeber +M

6

WH 1Q

A16a +H3

5

WH 1Q

/35.E2 A

4

7

INPUT MODUL 1 CAN: Versorgung 24V 24V Tankgeber

3

63

2

1

Änderung

Datum

1

Name

Datum


2

TANK PIPE SENSOR ; TRANSMISSION / HYDRAULIC OIL TEMPERATURE ; Werk Bischofshofen GmbH VENTILATOR ; COOLING WATER LEVEL , BRAKE ACCUMULATOR 3

4

5

6

Ident.Nr. ZeichNr.

8920980 460 9010 00 003 7

F

Anlage Ort

003 8

Blatt von

22 114

WH 1Q

Änderung

Datum

1

Name

Datum

WH 1.5Q

30 30

WH 1Q 1 X1 60 A17b.GND_PWM5

+H3 A17b

EARTH emergency steering /91.D5 EARTH CAN: OUTPUTMODULE 2

+H3 A16a /86.D5

GND NLP Check EARTH CAN: INPUT MODULE 1

+H3 A16a /86.E2

/86.D5

1

1 2

2

1

Vcc NLP SUPPLY 24V CAN: INPUT MODULE 1

A700D.X2

X1 60 A16a.GND

+H3 A16a

BK 1.5Q

X1 34 A16a.24V

A16a.X1

X1 59 A16a.GND

D

+M A700D

GND NLP EARTH CAN: INPUT MODULE 1

/93.E2

X2 46 A700D.TI1.GND

A17b.X1

AIR FILTER CONTAMINATION VACUUM ENGINEECU

A17b.X1

X1 62 A17b.GND_PWM7

+H3 A17b

EARTH LFD /91.D5 EARTH CAN: OUTPUTMODULE 2

E

63

A16a.X1

Y21.JPT

62

A17b.X1

Y20.JPT

2

BK 1.5Q

A16a.X1

Vcc NLP Check SUPPLY 24V CAN: INPUT MODULE 1

59

2

60

M

B28.X

BK 1Q

BK 1Q

B4.X_1

2

60

/86.E2

2

A

33

WH 1Q

A16a

P

2

B3.X

BK 1Q

BK 1.5Q

WH 25Q

B

P

1

+V1 Y21 0

2

A

+

WH 1Q

B

Y21.JPT

1

+V1 Y20 0

Kl. 15

+

Y20.JPT 1

/56.E2

UP

+K B28

2

+H5 B3 0

UP

+H B4 0

s

B28.X

1

WH 1Q

+H4 B3a 0

B4.X_1

C

46

s

1

Ausgabe

WH 1.5Q

WH 1Q

WH 1Q

WH 1Q

WH 1.5Q

85

B3.X

C

X1 33 A16a.24V

Datum

A17b.X1

A

B

34


B3a.X

+H3 A16a.X1

Ersteller

A17b.X1

OUTPUTMODULE 2 CAN: /91.D2 PWMAusgang8 (bank A17b LFD/FLOAT POSITION +H3 A A17b.PWM8 X1 21

C

B3a.X

F

Zustand

+K6 X1.B X1.S

86

88a

+H4 M8 0

OUTPUTMODULE 2 CAN: /91.D2 PWMOutput7 (bank A17b LFD +H3 A A17b.PWM7 X1 20

21

A16a.X1

8

20

A16a.X1

ENGINEECU INPUT MODULE 1 VACUUM CAN: /93.E2 A700D AIR FILTER CONTAMINATION /86.D2 ANALOGUE all-purpose input6 A16a LFD +M +H3 A700D.TI1 A X2 60 A16a.UI6 X1 19 A700D.X2 19

18

INPUT MODULE 1 CAN: /86.C2 ANALOGUE all-purpose input3 A16a PRESSURE NLP +H3 A A16a.UI3 X1 6

7

RD 25Q

PROJ: 8920980_003

88

GND VIA EARTH STRIP

E

A16a.X1

+H4 K11


D

Kl. 30.F08

B

C

INPUT MODULE 1 CAN: /86.C2 ANALOGUE all-purpose input1 A16a PRESSURE NLP Check +H3 A A16a.UI1 X1 4

6

/19.C4

A17b.X1

5

60

OUTPUTMODULE 2 CAN: /91.D2 PWMOutput5 (bank A17b emergency steering A A17b.PWM5 X1 18

4

4

A

3

6

2

1

X1 63 A17b.GND_PWM8

+H3 A17b /91.D5

EARTH LFD EARTH CAN: OUTPUTMODULE 2

F Donninger J. 26.03.2007 16:16 lbhhae0 27.03.2007 09:42

2



4

5

6

Ident.Nr. ZeichNr.

8920980 460 9010 00 003 7

Anlage Ort

003 8

Blatt von

23 114

+H3

MOTORECU UNTERDRUCK LUFTFILTERVERSCHM.

A700D.X2 +M =M

7

A16a.UI6 X1 19

A17b.X1 +H3 =H

=H +H3 A17b.X1

=H+H/38.D5

X1 60 A17b.GND_PWM5 Masse Notlenkung Masse CAN: OUTPUTMODUL 2

=H +H3 A17b.X1

1

1

X1 62 A17b.GND_PWM7

X1 63 A17b.GND_PWM8

=H =H +H3 +H3 Masse LFD/Schaufelschwimmstellung Masse LFD/Schaufelschwimmstellung A17b A17b

F11 10A/RD =K+K/15.E2

=H +H3 A17b

60

2

Kl. 15.6

WH 1Q

63

M =H +H3 A17b.X1

D

UNTERDRUCK MOTORECU

62

=M+M/34.E2

2

2 29

=M A700D.TI1.GND +M A700D LUFTFILTERVERSCHM. GND

BK 1.5Q

=K +K6 X1.S

C

29

WH 1Q

BK 1Q

B28.X

2

P

46

WH 1Q

4

WH 1.5Q

30

WH 1Q

1

1

+K B28

BK 1.5Q

B4.X_1 +H

=M +M A700D.X2

4

+V1 Y21.JPT 1 +V1 Y21 0 2 Y21.JPT +V1

B28.X

2

1

BK 1.5Q

WH 25Q

+V1 Y20.JPT 1 +V1 Y20 0 2 Y20.JPT +V1

P

2

1

A17b.X1 +H3 =H

WH 1.5Q

30 WH 1Q

1

+H Splice.X6

=K +K6 X2.B X2.S +K6 =K

A17b.PWM8 X1 21

WH 1Q

+H B4

2

B3.X +H5

+H3 =H

1

B3a.X +H4

1

+H B4.X_1

P

2

P

X1.S +K6 =K

=H+H/38.D5

Masse =H+H/38.D5 CAN: OUTPUTMODUL 2

E




A17b.PWM7 X1 20

B

X2 46

=H +H4 M8

+H3 =H

A

WH 1Q

A16a.X1 +H3 =H

1

+H5 B3

2

1

WH 1Q

1

1 1

+H5 B3.X

8

INPUT MODUL 1 OUTPUTMODUL 2 OUTPUTMODUL 2 CAN: CAN: CAN: =H+H/35.D2analogue all-purpose =H+H/38.D2 input6 PWMAusgang7 (Bank2)=H+H/38.D2 PWMAusgang8 (Bank2) A16a A17b A17b LFD LFD LFD/Schaufelschwimmstellung

+H3 =H

A700D.TI1 X2 60

=M

WH 1Q

WH 1Q

A16a.X1 +H3

2

30.1 31 K11.X3 K11.X1 +H4 +H4 =H =H


A16a.UI3 X1 6

1

PROJ: 8920980_003

=H =H +H4 +H4 K11.X4 K11.X2 30.2 50 =H +H4 K11

GND über Masseband

E

+H4 B3a.X +H4 B3a


D

Kl. 30.F08

B

4

18

A16a.X1 +H3

=K+K/4.C4

A17b.X1 +H3 =H

A16a.UI1 X1 4

6

+H3

A17b.PWM5 X1 18

2

+H3 =H

6

21

OUTPUTMODUL 2 INPUT MODUL 1 INPUT MODUL 1 CAN: CAN: CAN: =M+M/34.E2 =H+H/38.C2 PWMAusgang5 (Bank2) =H+H/35.B2analogue all-purpose input1 =H+H/35.B2analogue all-purpose input3 A700D A17b A16a pressure NLP Check A16a Notlenkung Druck NLP +M

A

C

5

20

4

19

3

60

2

1

Änderung

Datum

1

Name

Datum


2



4

5

6

Ident.Nr. ZeichNr.

8920980 460 9010 00 003 7

F

Anlage Ort

003 8

Blatt von

24 114

HIGH BEAM

E

30

86

E

E

30

F4

A17b.X1

F5

7,5A BN

7,5A BN

V9

R5

L21

L4

L5

7,5A BN

V60

0

85

87a A

GND

87

R2

R3

L2

L3

GND

10

1

XMSP1c

1

E4.X

XMSP1c

WH 1.5Q

WH 1.5Q

WH 1.5Q WH 1.5Q 1 1

2

XE14l.a.

H53

2

E7

7

H21

4

H18

+B2 E5 0

XE14l.b

+K3 XMSP7b

1

+H2 XMSP1c

XE14r.b

5

X16.B X16.S

2

EXTENSION OF THE LICENCE-PLATE LIGHTING FOR THE ITALIAN VERSION

1

+H2 XMSP1c

+H4 Splice.X8 Ersteller Datum Ausgabe Datum

1

Name

Datum


2

STEERING COLUMN SWITCH ; STOP LIGHT ; LOW BEAM ; HIGH BEAM


4

5

6

Ident.Nr. ZeichNr.

8920980 460 9010 00 003 7

*

2

XE14r.a.

*

5

D

1

+H1 E14r BK,BK 1.5Q,1.5Q

WH 1.5Q

1

WH 1.5Q WH 1.5Q

WH 1.5Q

2

WH,WH 1.5Q,1.5Q

/27.E7 Kl.49

/20.E6 Kl.58aR

WH 1.5Q 1 1

6

SW 1.5Q

WH 1.5Q

3

+K3 E9

H51 H16

BK 1.5Q 4

WH 1.5Q 3

/20.E6

H55

6

5

4

WH 1.5Q 3

WH 1.5Q

1

H57

XE14r.a 1

+H1 E14l

BK 1.5Q 2 2

0

XE14r.b

XE14l.b

BK 1.5Q

0

5

BK 1.5Q

+V1 E4

4

+H X16.S X16.B

XE14l.a

BK 1.5Q

+V1 E3

3

+K4 X22b.S X22b.B

SW 1.5Q

H56

2

F.6

1

H54

1

H50

2

WH 1.5Q 2

+H4 Splice.X7

A4.X45

3

/27.E5

18 18 /20.E6

17 17

16 2

WH 1.5Q 3

WH 1.5Q

WH 1.5Q 4

3

E3.X

+K3 XMSP7a

16

19 19

/20.E5

/27.E6 WH 1.5Q 5

4

2

10

1

5

3

H15

7

X1.S X1.B

2

5 1

H52

A4.X45

* E

BK 1.5QEXTEN 6

9

2

6

*

X1.S X1.B +K6

SW 1.5Q

BK 1.5Q

BK 1.5Q

4

A4.X45 F.5

C

GND

F.1

Kl.58aL

E6

GND

BK 1.5Q

H20

A4.X45

WH 1.5Q 3

BK 1.5Q

H17

XMSP1b

Änderung

+H3 X37a

85

A

GND

F.3

SW 1.5Q

WH 1.5Q

2

5

WH 1.5Q

/20.E5

3 /20.E6 WH 1.5Q

WH 1.5Q

WH 1.5Q

Kl.58aL

Kl.49

B12.1 WH 1.5Q

+K4 X22b.S X22b.B

+K3 E8

2

B12.X

GND

A4.X44

1

+B1 E1 0

2

87

A

R4

E.3

/27.E5

/45.E8

A

R21

GND

1

P

F3

7,5A BN

X37b +H3

4

X2 4 A18.PWM7 A low beam /94.E3 OUTLET A7 CAN: ELECTRIC KEYPAD

1

+H3 B12 0

F2

K3A

1

10A RD

K3

WH 1.5Q

WH 1.5Q WH 1.5Q

F21

=K +K4 A18

/33.E4

A17b.DO3 X1 37

86

5

E

5

E

A

B12.X

X1.37

+H3

87a

A18.X2

B

OUTPUTMODULE 2 CAN: /91.F2 digital output 3 A17b REVERSING LIGHT

6

hb/lbF/A LH 0

/33.E4

K.8

L

F

Zustand

LOW BEAM / DRIVING LIGHT

A4.X49

K.6

Kl.15

PROJ: 8920980_003

R

WH 1.5Q

E

+K1 S3


D


C

A4 =K +K2

A4.X49

K.4

/20.E7

B

A4.X49

K.2

WH 1.5Q

A4.X49

X1.37

56

Kl.58aR

30

1

56a

BK 1.5Q 2 2

56b

37

49a

=K

WH 1.5Q

R

=K

BK 1.5Q

L

=K 2

=K

WH 1.5Q

3

A

WH 1.5Q

3/7 S3.X2

A16b.X1

WH 1.5Q

2

WH 1.5Q

2/7

5

/87.C2

WH 1.5Q

WH 1.5Q

WH 1.5Q

WH 1.5Q

WH 1.5Q

5/7

4

A16b.X1

8

INPUT MODULE 2 CAN: ANALOGUE universal HIGH BEAM A A16b.UI2 X1 5

A16b +K2

6

/87.C2

4/7

7

INPUT MODULE 2 CAN: ANALOGUE universal DRIVING LIGHT A A16b.UI1 X1 4

A16b +K2

A

6

5

5

8

4

4

3

4

2

1

3

Anlage Ort

003 8

Blatt von

25 114

F

2

3

6

/7.E7 Kl.49a.2

R

8

INPUT MODULE 2 CAN:

/36.B2ANALOGUE Universaleingang1 DRIVING LIGHT

/36.B2ANALOGUE Universaleingang2 HIGH BEAM

A16b +K2

49a

56b

56a

15

A4.X49

A4.X49

K.4

A4.X49

K.6

K.8 B

A4 =K +K2

56

A4.X49

K.2

5

3

A16b.X1

8

2

A16b.UI2 X1 5

6

5

4

4

A16b.X1

4

3/7

S3.X2 5/7 +K1 S3.X2 2/7 +K1 S3.X2

5

A16b +K2

A16b.UI1 X1 4

2

2 2

7

LOW BEAM / DRIVING LIGHT

HIGH BEAM

Kl.15

PROJ: 8920980_003

5

A

+K1

+K1 S3 0

E

30

E

F21 10A RD

a bc

L OR

ab

E F4 7,5A BN

F5 7,5A BN

E

A

A

87

30

E

F2 7,5A BN 87a

A

86

K3

F3 7,5A BN

85

87a

A

GND

86

K3a

87

85

A

GND C

GND

GND

H50 H54

H56

=V +V1 E3

=V 2 +V1 E4

3

4

H57

H55

H51

5

4 WH 1.5Q

5

D 31

intstall 3pin socket!

58

+V X321b 0

E

31

BK,BK 1.5Q,1.5Q 1

XMSP1c

54

54

BK 1.5Q BK 1.5Q

1

E4.X

WH,WH 1.5Q,1.5Q

5

4

1

BK 1.5Q

1

BK 1.5Q BK 1.5Q

4

3 WH 1.5Q

H16

E4.Xa

XMSP1c

3

2

5

E3.Xa

E3.X

WH,WH 1.5Q,1.5Q

2

58

1

3

+V X321b

WH 1.5Q

WH 1.5Q

/7.E5

/5.E6 4

WH 1.5Q

6

18 3 Kl.58aR.1 4 Kl.49.3 5

2

2

+V E4.Xa

1 1

18

17 17

16

19 19 3

+V E3.Xa

H15

1.5Q,1.5Q BK,BK

8JB 001 9333001 LBH ID 6200003

F.6

E4.Xb +V

/5.E5

/7.E6

Kl.49.2 5 Kl.58aL.1 4 2

+K6 +K6 X1.SX1.S

16

+K6 +K6 X1.SX1.S

E3.Xb +V

A4.X45

2

F.1

WH 1.5Q

F.3

5

54

A4.X45

1

A4.X45F.5

5

A4.X45

WH 1.5Q

2

3

3 3

4 WH 1.5Q

WH 1.5Q

+V X321a 0 31

GND

BK 1.5Q

58

3

install 3-pin socket!

5

31

WH,WH 1.5Q,1.5Q

54

WH,WH 1.5Q,1.5Q

58

WH 1.5Q

+V X321a

Abblentlicht OUTLET A7 CAN: ELECTRIESKEY BOARD

4

/39.E4

5

+K4 A18

A4.X44 E.3

WH 1.5Q

8JB 001 9333001 LBH ID 6200003

GND

HELLAint

X2 4 A18.PWM7

WH 1.5Q

A18.X2

GND

4

HELLA

1

E


D

3

L


C

3

+K1 +K1 +K1 S3.X1S3.X1S3.X1 B

4

INPUT MODULE 2 CAN:

5 S3.X2 4/7 +K1

Kl.49aR.2

Kl.49aL.2

/7.B5

A

/7.B5

1

E3.Xb

E4.Xb

F


Änderung

Datum

1

Name

Datum


2


Ident.Nr.

COUNTRYSPECIFIC TYPE/EXECUTION 4

5

ZeichNr.

6

8920980 460 9010 00 003 7

Anlage Ort

003 8

Blatt von

26 114

A18.X1

5

A4.X50

4

RD,RD 1.5Q,1.5Q

A4.X50

L.4

A4 =K +K2

RD 1.5Q RD 1.5Q

Kl.30.F07 Kl.30

6

7 ELECTRIC KEYPAD CAN: /94.C3 FLASHING SPEED INPUT A18 HAZARD WARNING LIGHT +K4 A =K A18.Flasher X1 6

/19.F5 /39.B3

*

L.3

86

8

30

A18.X1

10

A

RD 1.5Q

3

ELECTRIC KEYPAD CAN: /94.D3 OUTLET A1 A18 HAZARD WARNING LIGHT +K4 A =K A18.PWM1 X1 10

4

K240

INPUT MODULE 2 CAN: ANALOGUE universal INDICATOR SIGNAL A A16b.UI3 6 X1

A16b.X1 +K2

/87.C2

A16b +K2 A

6

3

6

2

1

V53

85

87

87a

GND WH 1.5Q

WH 1.5Q

1

L.1

A4.X50 RD 1.5Q WH 1.5Q WH 1.5Q U.3

U.4

A4.X58

4

A4.X58

8

7

11

A4.X50

L.11

V89

M.7

C E

30

86

30

K22

F07B

86

30

K22a

10A RD 87a

87

85

86

A

K22b

V11

V12

87a

87

V13

85

87a

87

X1.J 10A RD

30

86

A

K25 V14

E

85

87a

87

X2.J 10A RD

30

86

49

K26

GND

87a

87

85

GND

49a

9

6

A4.X58 U.6

E1 / H18 RIGHT REAR

WH 1.5Q

E

/25.D7

Kl.49

10

X1.S X1.B

WH 1.5Q

9

M.10 OLD M.3

D

V88

10

L.6

Kl.49

E5 / H17 LEFT REAR

A4.X51

WH 1.5Q 10

WH 1.5Q 6

A4.X50

/25.E4

8 8

7

+K6 X1.S X1.B E3 / H15 LEFT FRONT

56

Kl.49

hb/lbF/A LH 0

30

X1.S X1.B

/25.D2

R

=K +K1 S3 0

56a

L.5

WH 1.5Q

56b

WH 1.5Q 5

WH 1.5Q 12

49a

7

+K6 X1.S X1.B

A4.X50

M.12 OLD M.1

WH 1.5Q

R

A4.X51

Kl.49

5

E

GND

V87

/25.E5

2

31 GND

V86

E4 / H16 RIGHT FRONT

5

3

X3.J 10A RD

E

85

GND

WH 1.5Q 2

WH 1.5Q 3

WH 1.5Q L

0

GND

V85

GND

+K1 S3.X1

0

A

K1

V84 V83

F07bKL. 15

R07B L07B

C

V15

A

WH 1.5Q

E

A4.X51 OLD M.6

A4 =K +K2


D

L.8

A4.X50


C

PROJ: 8920980_003

WH 1.5Q

B

3

B

L

F


Änderung

Datum

1

Name

Datum


2

Ident.Nr.

HAZARD WARNING LIGHTS Werk Bischofshofen GmbH 3

ZeichNr.

4

5

6

8920980 460 9010 00 003 7

Anlage Ort

003 8

Blatt von

27 114

2

1

3

4

5

OPTION HORN OPERATION VIA PUSHBUTTON SWITCH ON LH CONTROL LEVER

WH 1.5Q

1

WH 1.5Q

WH 1.5Q WH 1.5Q

12

4

B

A4.X49

A4 =K +K2

31

WH,WH 1.5Q,1.5Q

1

+K2 XMSP6a

WH 1.5Q

WH 1.5Q

1

6

Kl.15

3 2

=K

S

BK 1.5Q

15A BU

A18.X2

86

30

E

K8

F18

V59

10

85

87

10A RD

87a

2

R20 L20

SW 1.5Q

BK 1.5Q

1

B10.X2 +H

R18

GND

L18

GND

GND

A4.X44

4

4

1

1

3

1

53

WH 1.5Q

WH 1.5Q

31b

M3.X

*

M9.X

1

1

+K2 M3

M4.X

53a

M

+K4 M9 0

M

E

2

0

2

M9.X

31

2

sw

sw

31

swbl

wsbl

+K1 M4 0

bl

+

M

2

M3.X

2

53

3

D

2

7/7

6

6

4

2

6/7

7 1 7

7

53a

2

WH 1.5Q

1

swbl

wsbl

53c

M

WH 1.5Q 0 J 1

1

53

+K1 M2 0

wash 53b

31b

bl

1

1

M3.X

1 +

WH 1.5Q 6

3

* M4.X

1/7

H

4

horn

0 1

M2.X2

4

M2.X1

3

WH 1.5Q WH 1.5Q

S3.X2

5

1

=K +H2 XMSP1a

*

E.7 WH 1.5Q

K.1

1

A4.X49

E.9

7

A4.X44

1

9

47

*

X1 47 A17b.GND_PWM2 D +H3 EARTH OPTIONS A17b /91.C5 EARTH CAN: OUTPUTMODULE 2


C

A

1

A

B10a.X2 +H

A

K.12

4

WH 1.5Q

+H B10

15

WH 1.5Q 6

1.5Q 1.5Q 1.5Q 1.5Q 1.5Q 1.5Q

1

F20

1

WH WH WH WH WH WH

WH 1.5Q

1

B10.X1

5

31b

0 K5a.X

6905155

31b Datum Ausgabe Änderung

Datum

1

Name

Datum


2

WH 1.5Q

WH 1.5Q

+K2 XMSP6a

S3.X1 Ersteller

BK 1.5Q

15

WH 1.5Q

BK 1.5Q

BK 1.5Q

J

WH 1.5Q

F

Zustand

+K1 K5a E

V2 B10a 1 +H +H V2.X2 1/1

2

A18.X1

G

Kl.15

1 1

A4 =K +K2

*

86

I

0

0 1

E

3

WH 1.5Q

25

+K6 X1.S X1.B

WH 1.5Q

PROJ: 8920980_003

SW 1.5Q 5

25

K5a.X

5

WH 1.5Q WH 1.5Q

OPT3 sw5

S3 +K1

D

V2.X1


C

ELECTRIC KEYPAD ELECTRIC KEYPAD CAN: CAN: /94.D3 OUTLET A3 /94.D3 OUTLET A4 A18 WINDSCREEN WIPER A18 WASHING PUMP REAR +K4 +K4 A A =K =K A18.PWM3 A18.PWM4 X1 12 X2 1

OUTPUTMODULE 2 CAN: /91.C2 PWMOutput2 (Array A17b OPTIONS +H3 A A17b.PWM2 X1 5

B

8

+K Splice;.X9

OPT1 sw4 OPT2 sw3

7

12

A

6

8

+K2 XMSP6a

+K2 XMSP6a

5

+K2 XMSP6a

7

1

F


Ident.Nr.

WINDSCREEN WASHER FRONT AND REAR ; HOOTER 4

5

ZeichNr.

6

8920980 460 9010 00 003 7

Anlage Ort

003 8

Blatt von

28 114

2

1

3

4

5

6

7

8

Splice.X9

A18 +K4

+K6 X1.S

+K4

S

31b

BK 1.5Q

6

12

86

30

K8 V44

10

87a

A

87

85

F18 10A RD

85

GND

87

A

87a

GND

C

GND

*

A4.X49

A4.X44

1

A4.X55 +K2

A4.X44

11

9

GND

K.1

E.9

7

BK 1.5Q

86

K271

*

E.7

6

M

M4 0

53

+K2 M3

sw

M4.X

6

6

4

4

sw

BK 1.5Q

BK 1.5Q

15 31b

S3.X1

+K2 XMSP6a

8

1

M9.X

31

BK 1.5Q

7

7

M3.X +K2

2

1

1

+K4 M9 0

2

2

J

53

0 J 1

M

2

7

31

53a

2

53b

S3.X2

1

M

2 7/7

1

3

31b

M9.X

1

+K2 XMSP6a

+K2 XMSP6a

5

E

WH 1.5Q

+K1 M2

6/7

M

53a

3

+ wsbl

swbl

bl

wsbl

1 53c

53

4

D

+K2 * M3.X

2

1 +

31b

4

1

+K2 M3.X

swbl

1

1

1

1

3

+K2 M3.X

2

4

* M4.X

bl

1/7

H

M2.X2

4

M2.X1

3

S3 +K1

WH 1.5Q

+K2 XMSP6a

7

1



12

E 30

+K2 XMSP6a

+H2 XMSP1a

B

A4 =K +K2

1

F20 15A BU

5

A4.X49

V59

0

E

A18.X2

K.12

31

6

A18.PWM4 X2 1

1

1

+K1 K5 Kl.15

PROJ: 8920980_003

A4 =K +K2

A

Kl.15

15

4

9

+K2 +K2 A4.X55 A4.X55

4 5

10

2

I 86

B10.X2 +H =H


E

*

5

3

G

0

D

1

2


C

3 2

B

1

A18.X1 =H +H B10.X1 =H +H B10

ELEKTRICKEYPAD CAN: Output A4 windscreen washer rear

A18.PWM3 X1 12

25

25

/39.D4

ELEKTRICKEYPAD CAN: /39.D4 Output A3 SWindscreen wiper A18

1

A

Änderung

Datum

1

Name

Datum


2


Ident.Nr.

WINDSCREEN WASHER FRONT AND REAR ; HOOTER 4

5

ZeichNr.

6

8920980 460 9010 00 003 7

F

Anlage Ort

003 8

Blatt von

29 114

2

1

3

4

5

6

7

8

WH 1.5Q

A

A

A4.X58 A4 =K +K2

E1

PROJ: 8920980_003

F31A

Kl. 30

E1 30

KL. 15

E2

B

oder Kl. 30

F31B

30

KL. 15

E1 A E2

E1 A E2

87a

87

10A RD

85

86

K31B

V16

10A RD

E1 A E2

A

V17

E1 A E2

87a

A

R31A

87

85

R31B GND

L31A

GND

L31B

C

XMSP7a

WH 2Q

WH 2Q

+K2 XMSP6.18

6

4

7

Datum Ausgabe Änderung

Datum

1

Name

Datum


2

3

4

5

WH 2Q 2

1

XMSP7a

E

2

E11b.X

+K2 XMSP6.18

8

2

OPTION XENON WORKING PROJECTOR Ident.Nr.

WORKING PROJECTOR FRONT CABIN XENON WORKING PROJECTOR


+K3 E11b 0

BK 2Q

E11a.X

1

2

2

OPTION XENON WORKING PROJECTOR Ersteller

ZeichNr.

6

8920980 460 9010 00 003 7

D

1

SW 1.5Q

+K3 E11a

SW 1.5Q

2

+K3 XMSP7a

1

E11b.X

1

2

E11.X

A4.46.8 +K2

4

3 1

1

+K3 E11

E11a.X

SW 1.5Q

SW 1.5Q 5

1

2

E10b.X

2

E10a..X

SW 1.5Q

WH 2Q

2 SW 1.5Q 1

1 2

2

E11.X

1

+K3 E10b 0

8

2

2

1

+K3 E10a

SW 1.5Q

+K3 XMSP7a

E10b.X

1

2

E10.X

+K4 X22a.B X22a.S

A4.46.4 +K2

BK 2Q

+K3 E10

E10a..X

G.8

3

WH 2Q

WH 2Q


1

A4.X46

G.7

4

SW 1.5Q

+K4 X22a.B X22a.S

A4.X46

G.4

8

A4.X46

G.3

7

A4.X46

4

3

X2 5 A18.PWM8 =K A +K4 WORKING PROJECTOR FRONT A18 /94.E3 OUTLET A8 CAN: ELECTRIC KEYPAD

1

A18.X2

GND

5

GND

F

Zustand

86

K31A

E10.X

E

Kl. 15

Kl. 30

E2 oder


D

Kl. 15

Kl. 30

WORKING PROJECTOR FRONT

B

C

5

U.5

Anlage Ort

003 8

Blatt von

30 114

F

2

1

3

4

5

6

7

8

A4.X58

Verb.

1

=K+K2A4.X58:7

8

OLE3 U.8

A4 =K +K2

WORKING PROJECTOR REAR AM REAR

A

E2

E1 30

oder

F32A

Kl. 30

Kl. 15

WH 1.5Q E1

Kl. 30

Kl. 15

Kl. 30

A

KL. 15

86

V32C

E2 oder

K32A

Kl. 30

F32B

KL. 15

V18

10A RD

B

E1 A E2

E1 A E2

87a

87

85

10A RD

E1 A E2

A

R32A L32A

87

85

X58

GND

/32.A7

GND


Datum

1

Name

Datum


2

10

9

WH 2Q 14

WH 2Q WH 2Q 4

BK 2Q

+H2 XMSP1a

2


ZeichNr.

4

5

6

F

3

Ident.Nr.

WORKING PROJECTOR REAR REAR 3

2

+H X16.B X16.S

E

BK 2Q

E17.X

BK 2Q Ersteller

3 2

2

2

+H2 XMSP1a

3

WH 2Q 1

+H1 E17

E16

+H X16.B X16.S

D

1

E17.X

1

E16.X

X1.S

4

E16.X

13

6

11 11 1

1

+H X16.S X16.B

1

X2 6 A18.PWM9 =K A +K4 A18 WORKING PROJECTOR REAR /94.E3 OUTLET A9 CAN: ELECTRIC KEYPAD

G.10

13

+K6 X1.S X1.B

X1.S

2

A18.X2

A4.X46

G.9

WH 2Q

+H X16.S X16.B

A4.X46

G.6

WH 2Q

+K6 X1.S X1.B

A4.X46

12

G.5

WH 2Q

A4.X46

WH 2Q

5

C

6


87a

L32B

GND

F

Zustand

B V19

R32B

GND

BK 2Q

E


D

86

K32B

2

C

PROJ: 8920980_003

A

30

E1 A E2

8920980 460 9010 00 003 7

Anlage Ort

003 8

Blatt von

31 114

4

5

6

7

7

3

+K2 A4.X58 U7

A4 =K +K2

E2 oder

F33A

Kl. 30

KL. 15

V33C

E2

86

X58

0

Kl. 15

E1 30

A

/31.C8

E1

Kl. 30

Kl. 15

WORKING PROJECTOR REAR AM CAB ROOF

Kl. 30

A

8

WH 1.5Q

2

1

oder

K33A

Kl. 30

F33B

KL. 15

V20

10A RD

B

E1 A E2

E1 A E2

87a

87

10A RD

85

E1 A E2

R33A

87a

87

85

GND GND

GND

+K3 XMSP7a Ersteller Datum Ausgabe Änderung

Datum

1

Name

Datum


2

10 10

1

1.5Q 1 2

+K3 X28a.S

E

1.5Q

2

E13.b.X

Ident.Nr.

6

F

2

ZeichNr.

5

2

BK 2Q

+K3 XMSP7a

1


1

+K3 E13.b

2

WH 2Q 12 WH 2Q

1 1 1

E13.b.X

1.5Q

X28a.S +K3

1.5Q 2

+K3 X29.S X29.B

WORKING PROJECTOR REAR CABIN 3

D

2

2

E13a.X

BK 2Q

+K3 XMSP7a

4

WORKING PROJECTOR DOUBLE

2

2

2

2

+K3 X28.S X28.B

G.12

1

+K3 E13a

SW 1.5Q

2

E13.X

A4.X46

2

11 WH 2Q

9 9

WH 2Q 1

E13a.X

2

1.5Q

+K3 X26a.S

+K3 X29.B X29.S

1

1 2

E12.b.X

+K4 X22a.B X22a.S

1

+K3 E13

BK 2Q

+K3 XMSP7a

G.11

SW 1.5Q

1

1.5Q

E13.X

=K

3

A4.X46

1

8

+K3 E12.b

1.5Q

2

SW 1.5Q

=K

X27.S X27.B

+K4 X22a.B X22a.S

+K3 X28.B X28.S

1

2

E12a.X

WORKING PROJECTOR SIMPLE

1

WH 2Q

+K3 E12a

2 2

+K3 X26.S X26.B

1 1

2

E12.X

E12.b.X

1.5Q

E12a.X

2

1

+K3 E12

X26a.S +K3

1

=K +K3 X27.B X27.S

WORKING PROJECTOR DOUBLE

2

1

E12.X

G.2

8

7 7 1

WH 2Q

+K4 X22a.B X22a.S

SW 1.5Q

=K +K3 X26.B X26.S

A4.X46

WH 2Q

G.1

1

WORKING PROJECTOR SIMPLE

+K4 X22a.B X22a.S

2

A4.X46

WH 2Q


1

C

F

Zustand

V21

L33B

BK 2Q

E

B

R33B

GND

L33A


D

86

K33B

A

PROJ: 8920980_003

A

C

30

E1 A E2

8920980 460 9010 00 003 7

Anlage Ort

003 8

Blatt von

32 114

4

ELECTRIC KEYPAD CAN: /94.D3 OUTLET A2 A18 WARNING BEACON +K4 A =K A18.PWM2 X1 11

6

7

WH 1.5Q

8

ELECTRIC KEYPAD CAN: /94.D3 OUTLET A5 A18 REAR WINDOW HEATER +K4 A =K A18.PWM5 X2 2

Option BACKUP ALARM OPTICAL OPTIONAL REVERSINGACTIVE

RD 1Q

A18.X2 =K

BK 1.5Q H.4

A4.X47

Kl. 30

A4 =K +K2

1

=K +K2 K10

E

1

S212.X1

5

9

5

86

F74

S212.X2

30

V57

87a

10A RD 87a

87

R74

85

WH 1.5Q Masse

Änderung

Datum

1

Name

Datum

2

2

WH 2.5Q +K3

+K3

R6a

R6b

0

0 2

1 1

BK 2.5Q

=K BK 2.5Q

+K2 XMSP6.13

Ident.Nr. ZeichNr.

6

E

2

R12.X2

BK 2.5Q

2

R6b.X

Splice;.X12 +K3

5

1

0

2

WARNING BEACON ; MIRROR AND REAR WINDOW HEATER 4

6

1

1

R12.X1 +K2 R12

1

2

Verb.

OLE4

WH 2.5Q

OPTION MIRROR HEATING


R6b.X

1

R6a.X

D

WH 2.5Q

WH 2.5Q

=K+K4S212.X2:9 1

R6a.X

WH 1.5Q


=K

H.2

=K

6

WH 1.5Q

+K3 Splice;.X11

BK 2.5Q

M

+K4 X22a.B X22a.S

36

WH 1.5Q REVERSING LIGHT

1

+K3 H22

X1.37

/25.A8

1

H22.X

/25.A8

X1.37

5

5

+K4 X22a.B X22a.S

WH 1.5Q

+K6

36

35

35

WH 1.5Q

+K6 X2.S X2.B +K6

A4.X47

H.1

L.10

WH 1.5Q 15

WH 1.5Q

A4.X50

L.9

+K6 X1.S

WH 1.5Q

A4.X50

R.8

10

9

8

A4.X55

A4.X47

WH 2.5Q

1

GND

GND

Ausgabe

C

L74

L25

Datum

85 GND

GND

R25

Ersteller

87

A

V58

A

86

15A BU

K9

F25

F

Zustand

+K2 XMSP6e

B

Kl. 15

10 10

9

12

PROJ: 8920980_003

30

3

S212.X2

2 1 0

WH 1.5Q

E

0 S212 +K4

1 E


D

S212a


C

A4 =K +K2

S212.X1

1

+K2 A4.X50.12a

L.12

3

B

A4.X50

A

4

A18.X1

11

A

5

2

3

WH 1.5Q

2

1

1

+K2 XMSP6c

8920980 460 9010 00 003 7

F

1 Anlage Ort

003 8

Blatt von

33 114

RD 2.5Q WH 1.5Q

8

RD 2.5Q WH 1.5Q WH 1.5Q

S.5

A4.X56

=K T1.X

5

S.9

A4.X56

9

O.5

A4.X53

5

C.7

A4.X42

7

A

7

=K 4

1

+

24V +K2

A4 =K +K2

T1

A4.X56 S.7

A4.X56

5 BK 1.5Q

6 WH 1.5Q

3 BK 1.5Q

S.3

WH 1.5Q WH 1.5Q BK 1.5Q


RD 1.5Q

+K4 X22a.B X22a.S +K4

12

+K4 X22b.S X22b.B

3

=K 7

A3.X1

=K

7

+K3 A3

1

X70.X2

E

1

Ausgabe Änderung

Datum

1

Name

Datum


1

+K3 B11l

+K3 B11r

2 B11l.X2

2

CIGARETTE LIGHTER ; ELECTRICAL SOCKET 12V ; RADIO ; LOUDSPEAKER


4

B11r.X1

1

B11l.X1

1

+

CIGARETTE LIGHTER 24V

Datum

RD <> BNRD BK <> BN

2

ELECTRICAL SOCKET 12V

Ersteller

+K3

=K RD 0.75Q

=K

W1

6 6

5

4

2

5

6

Ident.Nr. ZeichNr.

8920980 460 9010 00 003 7

1

10165605

1

1

1

BK 0.75Q

=K

RD 0.75Q +

X70.X1 +K5 X70 10165605

1

2

1 2

D

LS li 5

4

3

LS re 3

=K

1

8

R A D I O

A3.X2

+K4 X71

4 +

BK 0.75Q

BK 1.5Q

WH 1.5Q

BK 1.5Q

WH 1.5Q

IGN

8

=K

4

XMSP6a +K2

F

Zustand

C

12

O.3

GND

BK 1.5Q

L76 RD 1.5Q

L75

11

R76

BK 1.5Q

7

3

6

A4.X53

=K

11

R75

GND

*

=K

A

85

GND

R.6

=K

4

5

B A

L30

A4.X55

6

RD 1.5Q

87

+

2

WH 1.5Q

87a

=K

10A RD

4

/19.B8 F8 Kl.58

F76

10A RD

3

PROJ: 8920980_003

R30


E

V3

0

A

D

F75

K12

B

C

86

T1.X

4

15A BU

WH 1.5Q

30

F30

E

3

WH 1.5Q

E

+

2

0

E

+K2 XMSP6a

12V

WH 1.5Q

A4 =K +K2

Kl. 30

A4 =K +K2

A

BK 2.5Q

6

BK 2.5Q

5

1

4

RD 2.5Q

3

4

2

1

B11r.X2

F

Anlage Ort

003 8

Blatt von

34 114

/99.C2

/99.C2

+K4 A22 /99.C2

/99.C2

A

Ausgabe Änderung

Datum

1

Name

Datum

2

A21.X1

RD 1Q

A19.X1

A19.X1

A19.X1

A19.X1

8

L10

X1 8 A19.CAN_Low A +K4 CAN_Low A19 /98.D4 CAN_Low CAN: OPTIONS KEY BOARD

BK 1.5Q

WH 0.5Q

7

RD 1Q

A21.X1

=K

F.11


HEAT/AIR CONDITIONING SYSTEM HEAT/AIR CONDITIONING SYSTEM CAN: CAN: /96.C2 CAN1_Low OUT /96.C2 CAN1_High OUT CAN1_Low OUT CAN1_High OUT A A A21.CAN1 A21.CAN1 X1 16 X1 17

X1 7 A19.CAN_High A +K4 CAN_High A19 /98.D4 CAN_High CAN: OPTIONS KEY BOARD

X1 4 A19.CAN_Low A +K4 CAN_Low A19 /98.C4 CAN_Low CAN: OPTIONS KEY BOARD

C

D

X1 3 A19.CAN_High A +K4 CAN_High A19 /98.C4 CAN_High CAN: OPTIONS KEY BOARD

E

+K4

+K4

+K4

+K4

RD 1Q BU 1Q

8

F Ident.Nr.



3

8

A19.X2 7

11 Datum

HEAT/AIR CON CAN: CAN_High CAN_High A A22.CAN_High X1 3

=K

+K2 XMSP6c Ersteller

A21.X1

X1 13 X1 14 A21.CAN1 A21.CAN1 A A +K4 +K4 CAN1_Low INPUT CAN1_High INPUT A21 A21 /96.C2 CAN1_Low ᕮ; /96.C2 CAN1_High ᕮ; CAN: CAN: HEAT/AIR CONDITIONING SYSTEM HEAT/AIR CONDITIONING SYSTEM

=K

A4.X45

2

A21.X1

=K

WH,WH 0.5Q,0.5Q

+K2 XMSP6b

=K

R10

GND

*

=K

=K

BU 1Q

2

A13a.X +K1

1

5A LBN

A15.CAN.X

B

X1 7 A22.CAN_High A CAN_High CAN_High CAN: HEAT/AIR CON

A22.X1

=K F10

A15.CAN.X

CAN HIGH 3 A A15.CAN3H .CAN.X 7

14

A22.X1

A22.X1

E

7

8

A22.X1

HEAT/AIR CON CAN: CAN_Low CAN_Low A A22.CAN_Low X1 4

WIRING HARNESS PREPARATION COLOUR GRAPHIC DISPLAY

Kl. 15

WH 0.5Q

0.5Q BK

=K

X1 8 A22.CAN_Low A CAN_Low CAN_Low CAN: HEAT/AIR CON

+K4 A22


=K

A15 +K2 =K

17

RD 0.5Q BU 0.5Q

A4 =K +K2

A11.X1 +K4 =K

/85.C1 CAN LOW 3 A A15.CAN3L .CAN.X 2

RD 1Q

A11.X1 +K4 =K

=K

A15 +K2 =K

3

6

+K2 XMSP6a

/85.C1

2

9

A11 +K4 =K

MASTER MODULE CAN:

BU 1Q

8

/95.D4

MASTER MODULE CAN:

13

7

A11 +K4 =K

MAINKEY BOARD CAN: CAN_High CAN_High A A11.CAN_High X1 3

16

6

/95.D4

CAN BUS 3

4

=K

5

N

A

4

=K

4

3

2

3

rpm time hours

4

2

=K

PROJ: 8920980_003

STOP

MAINKEY BOARD CAN: CAN_Low CAN_Low A A11.CAN_Low X1 4

8

BU 1Q

T

/95.D4

7

X1 7 A11.CAN_High A CAN_High CAN_High CAN: MAINKEY BOARD

3

4

/95.E4

=K +K4 A11

RD 1Q

3/

F

Zustand

A13.X2 +K1 =K

A11.X1

7

4

1

A13.X1


E

2

BK 1.5Q

1/2

1/

1/1

D

MP

1

1

B

check

A11.X1

7

0

mph km/h

50

120

+K1 A13

A 12

0

40

11

1

100

90

40

10

A 13

=K

BU 1Q

1

5

30

20

=K X1 8 A11.CAN_Low A CAN_Low CAN_Low CAN: MAINKEY BOARD

=K +K4 A11

A 23

6

3

4

2

5

8

3

A

C

4

4

3

4

2

1

4

5

ZeichNr.

6

8920980 460 9010 00 003 7

Anlage Ort

003 8

Blatt von

35 114

5

A11.CAN_Low X1 4

A11.CAN_High X1 3

+K4 A22.X1

W156 +WL006 BU

A11.X1

X1 8 A22.CAN_Low CAN_Low /43.C2 CAN_Low CAN: HEIZ/KLIMA TASTATUR HEIZ/KLIMA TASTATUR CAN: /43.C2 CAN_Low A22 CAN_Low

+K4 A19.X1

A

+K4 A19.X1

X1 8 A19.CAN_Low

+K4 A19

/42.C4 GND

/41.C4

/41.C4

A21 +K4

+K4 A19

/42.C4

A21.X1

A19.X1

A21.X1

+K4 A19

CAN_High CAN_High CAN: OPTIONS TASTATUR

/42.C4

B

X1 14 A21.CAN1

+K4 A21

/41.C4

/41.D4

A21 +K4

CAN1_High IN CAN1_High IN CAN: HEIZ/KLIMAANLAGE HEIZ/KLIMAANLAGE CAN: CAN1_High OUT CAN1_High OUT

C

A21.CAN1 X1 17

A21.X1

A19.X1

X1 4 A19.CAN_Low CAN_Low CAN_Low CAN: OPTIONS TASTATUR

D

X1 3 A19.CAN_High

+K4 A19

/42.C4

CAN_High CAN_High CAN: OPTIONS TASTATUR E

A4.X45

+K2 XMSP6b

3

4

A19.X2

7

8

F.11

W156 +WL036 RD 2

W156 +WL036 BU



A15.CAN3H .CAN.X 7

A21.CAN1 X1 16

X1 7 A19.CAN_High

CAN_Low CAN_Low CAN: OPTIONS TASTATUR

CAN HIGH 3

A15..CAN.X

CAN1_Low IN CAN1_Low IN CAN: HEIZ/KLIMAANLAGE HEIZ/KLIMAANLAGE CAN: CAN1_Low OUT CAN1_Low OUT

W156 +WL045 RD

4

W156 +WL045 BU

Kl. 15 F10 5A LBN

+K4 A21

A22.CAN_High X1 3

A22.X1 +K4

A15 +K2

X1 13 A21.CAN1

+K4 A22.X1 +K4

E

A21.X1

CAN_High /43.C2 CAN_High CAN: HEIZ/KLIMA TASTATUR HEIZ/KLIMA TASTATUR CAN: /43.C2 CAN_High A22 CAN_High

A22.CAN_Low X1 4

A4 =K +K2

A15..CAN.X

+K4 A22

8

WH 0.5Q

BK 0.5Q

+K4

/33.C1 CAN LOW 3 A15.CAN3L .CAN.X 2

X1 7 A22.CAN_High

+K4 A22

11

E

+K4 A22.X1


D

W156 +WL005 RD W156 +WL005 BU


C

PROJ: 8920980_003

A11.X1

A15 +K2

7

6

/33.C1

W156 +WL010 RD

9

A11 +K4

14

8

/40.C4

17

7

A11 +K4

W156 +WL034 RD

6

/40.C4

+K2 XMSP6a

4

5

N

Master Modul CAN:

3

rpm time hours

4

3

3

2

1

2

STOP

Master Modul CAN:

2

T

W156 +WL010 BU

4

BK 1.5Q

4

1/1

B

A13.X2 +K1

/40.C4

13

0

40

1/

3/

/40.C4

MP

2 1

1/2

1

A13.X1

check

50

120

mph km/h

CAN CONNECTION 3 (C)

CAN_High CAN_High CAN: HAUPTTASTATUR HAUPTTASTATUR CAN: CAN_High CAN_High

16

A 12

0

A

W156 +WL034 BU

11

1

10

40

100 90

+K4 A11

CAN_Low CAN_Low CAN: HAUPTTASTATUR HAUPTTASTATUR CAN: CAN_Low CAN_Low

8

4

A 13

X1 7 A11.CAN_High

3

30

20

+K1 A13

+K4 A11

5

1

A 23

W156 +WL006 RD

4

3

3 2

A11.X1

X1 8 A11.CAN_Low

7

A11.X1

4

A

7

7

DISPLAY CAN

6

7

4

8

3

8

2

1

Änderung

Datum

1

Name

Datum


2


Ident.Nr.

DISPLAY UNIT CAN BUS 3 4

5

ZeichNr.

6

8920980 460 9010 00 003 7

F

Anlage Ort

003 8

Blatt von

36 114

3

4

5 MASTER MODULE CAN:

A15 +K2 =K

CAN HIGH 1 A A15.CAN1H .CAN.X 5

A15.CAN.X

A17a.X1.43.57 +H3

A16c.X1

B 2

1

A17a.X1.43.57 +H3

44

39

RD 1Q

RD 1Q

BU 1Q

38 38

X1.S X1.B

BU 1Q

PROJ: 8920980_003

CAN BUS 1

+H3 A16a /86.C5

X1 43 A16a.CAN_Low D CAN low (Res verb.) CAN low CAN: INPUT MODULE 1

X1 57 A16a.CAN_High

+H3 A16a /86.D5

CAN high (Res verb.) CAN high CAN: INPUT MODULE 1

/86.C5

A16a.X1

A16c.X1

+H3 A16a.X1.44

X1 58 A16a.CAN_High

+H3 A16a

58

58

44

A17a.CAN_High X1 57

A17a.X1

X1 44 A16a.CAN_Low D CAN low CAN low CAN: INPUT MODULE 1

+H3 A16a

/88.C5

A16c +H3

/88.D5

A16c +H3

INPUT MODULE 3 CAN: CAN high CAN high

D

A16c.CAN_High X1 57

A16c.X1

57

A16a.X1

+H3

BU 1Q

A16a.X1

8

A16a.X1

A17a.X1

RD 1Q

A700D.X2

BU 1Q

A700D.X2

A700D.CAN1H.1 X2 8

9

A700D.CAN1L.2 X2 9

CAN1 HIGH

INPUT MODULE 3 CAN: CAN low CAN low D A16c.CAN_Low X1 43

CAN high CAN high CAN: INPUT MODULE 3

RD 1Q

A700D +M

OUTPUT MODULE 1 CAN: /90.D5 CAN high A17a CAN high

/88.D5

+H3 XA16a.X1.58

E 1

/93.C6 CAN1 LOW

OUTPUT MODULE 1 CAN: /90.C5 CAN low A17a CAN low +H3 D A17a.CAN_Low X1 43

/88.C5

+H3 A16c

43

ENGINEECU CAN:

+H3 A16c

BU 1Q

ENGINEECU CAN:

CAN high /90.D5 CAN high CAN: OUTPUT MODULE 1

C

X1 58 A16c.CAN_High

1

CAN: ENGINEECU

+H3 A17a

X1 44 A16c.CAN_Low D CAN low CAN low CAN: INPUT MODULE 3

57

CAN: ENGINEECU

A16c.X1

X1 58 A17a.CAN_High

RD 1Q

/93.C6

/93.C6

A700D +M

CAN1 RES

A17a.X1

58

/93.C6

+M A700D

X1 44 A17a.CAN_Low D +H3 CAN low A17a /90.C5 CAN low CAN: OUTPUT MODULE 1

43

CAN1 LOW

A17a.X1

57


+M A700D

X2 54 A700D.CAN1R

44

A700D.X2

X2 40 A700D.CAN1L.1

54

A700D.X2

40

BU 1Q

43

E

RD 1Q

=K

BU 1Q

=K

A

5

A15.CAN.X

+K6 X1.S X1.B


D

8

MASTER MODULE CAN:

4

CAN LOW 1 A A15.CAN1L .CAN.X 4

B

C

7

/85.C1

A15 +K2 =K

OUTPUT MODULE 3

OUTPUT MODULE 1

INPUT MODULE 1

INPUT MODULE 3

A

OUTPUT MODULE 2

/85.C1

6

39

2

1

CAN high CAN high CAN: INPUT MODULE 1

/86.D5

F


Änderung

Datum

1

Name

Datum


2

Ident.Nr.

CAN BUS 1 Werk Bischofshofen GmbH 3

ZeichNr.

4

5

6

8920980 460 9010 00 003 7

Anlage Ort

003 8

Blatt von

37 114

2

+K A17b.X1.44

29

43

X1 29 A17c.CAN_Res

+H3 A17c

RESERVE /92.E2 CAN MATCHING RESISTOR CAN: OUTPUT MODULE 3

+H3 A17c.X1

58

A17c.CAN_High X1 58

59

C

59

58

X1.S X1.B

B

OUTPUT MODULE 3 CAN: /92.D5 CAN high A17c CAN high

44

A17c.X1 58

A17c.X1

57

CAN low CAN: OUTPUT MODULE 3

OUTPUT MODULE 3 CAN: /92.C5 CAN low A17c CAN low +H3 D A17c X1 44

RD 1Q

BU 1Q

43

58

A16b.CAN_High X1 57

A16b.X1

RD 1Q

BU 1Q

RD 1Q

BU 1Q

A17b.X1

X1 58 A17b.CAN_High

+H3 A17b.X143a

A17b.X1

X1 57 A17b.CAN_High

OUTPUTMODULE 2 CAN: /91.E2 CAN MATCHING RESISTOR A17b CAN END

+H3 A17b

+H3

/91.D5 A17b.CAN_Res X1 29

A17b.X1

57

CAN high CAN high CAN: OUTPUTMODULE 2

/91.D5

1

+H3 A17b

D

CAN high (CANE m. CAN high CAN: OUTPUTMODULE 2

E

29

OUTPUTMODULE 2 CAN: /91.C5 CAN low A17b CAN low (CANE m. +H3 D A17b.CAN_Low X1 43

58

44

A17b.X1

X1 44 A17b D +H3 CAN low A17b /91.C5 CAN low CAN: OUTPUTMODULE 2

A16d.CAN_High X1 57

+K A17b.X1.58

/92.C5

CAN low (CANE m. CAN_Res verb.)

6

58

A17b.X1

INPUTMODUL 4 CAN: CAN high CAN high (Res verb.)

A16d.X1

+H3 A17c

X1 43 A17c.CAN_Low D

CAN BUS 2

CAN high CAN high CAN: INPUTMODUL 4

BU 1Q

A16d.X1

/89.D5

A16d +H3

CAN: MASTER MODULE

RD 1Q

/89.C5

A16d +H3

/87.D5

A16b +K2

43

INPUTMODUL 4 CAN: CAN low CAN low (Res verb.) D A16d.CAN_Low X1 43

/89.D5

INPUT MODULE 2 CAN: CAN high CAN high (CANE m

/85.C1

57

/89.C5

+K6 X1.S X1.B

.CAN.X 6 A15.CAN2H A CAN HIGH 2

=K +K2 A15

INPUT MODULE 2 CAN: CAN low CAN low (CANE m. D A16b.CAN_Low X1 43

A16b.X1

RD 1Q

44

BU 1Q

A15.CAN.X

.CAN.X 3 A15.CAN2L A CAN LOW 2

X1 58 A16d.CAN_High

+H3 A16d

8

WH 1.5Q

1

+H3 A16d

/87.C5

A16b +K2

A16b.CAN_High X1 58

3

2

A15.CAN.X =K +K2 A15

RD 1Q

1 BU 1Q

44

A16d.X1

43


A17b..X1.43.57 +K

CAN: MASTER MODULE

1

E

/87.D5

A16b +K2

INPUT MODULE 2 CAN: CAN high CAN high

A16b.X1

/85.C1

X1 44 A16d.CAN_Low D CAN low CAN low CAN: INPUTMODUL 4

7

A17c.X1 INPUT MODULE 2 CAN: CAN low CAN low D A16b.CAN_Low X1 44

A16b.X1


D

PROJ: 8920980_003

B

A16d.X1

6

WH 1.5Q

A16b +K2

A17b..X1.43.57 +K

5

A

/87.C5

C

4

OUTPUT MODULE 3

OUTPUT MODULE 2

INPUT MODULE 1

INPUT MODULE 3

A

3

OUTPUT MODULE 1

1

ERECTION OUTPUT MODULE 3 CAN END (JUMPER) REMOVE!

F


Änderung

Datum

1

Name

Datum


2

Ident.Nr.

CAN BUS 2 Werk Bischofshofen GmbH 3

ZeichNr.

4

5

6

8920980 460 9010 00 003 7

Anlage Ort

003 8

Blatt von

38 114

2

1

3

4

5

SUPPLY ELECTRIC KEYPAD

6

7

8

SUPPLY MAINKEY BOARD

A

A

/27.A5 F07 Kl.30

Kl. 15

A4 =K +K2

E

F71

10A RD

B

R71

B

XMSP6b +K2

6

4

BK 1.5Q

WH 1.5Q

BK 1.5Q

RD 1.5Q

C.6

WH 1.5Q

WH,WH 1.5Q,1.5Q

3

A4.X42

C.4

X1 5 A18.Kl30 =K A +K4 SUPPLY A18 /94.C3 SUPPLY CAN: ELECTRIC KEYPAD

A18.X1

2

5

1

X1 1 A18.Kl15 =K A +K4 INFORMATION INPUT A18 /94.C3 INFORMATION INPUT CAN: ELECTRIC KEYPAD

A18.X1

X1 2 A18.GND =K A +K4 SUPPLY EARTH A18 /94.C3 SUPPLY EARTH CAN: ELECTRIC KEYPAD

=K +K4 A11 /95.D4

1

A11.X1

X1 1 A11.Kl15 A +24V SUPPLY CAN: MAINKEY BOARD

=K +K4 A11 /95.D4

2

C

A11.X1 A18.X1

X1 2 A11.GND A SUPPLY EARTH SUPPLY EARTH CAN: MAINKEY BOARD

D

XMSP6c +K2

XMSP6c +K2

7


Datum

1

Name

Datum


2

X1 5 A19.Kl15 A +K4 SUPPLY Kl. 15 A19 /98.D4 SUPPLY CAN: OPTIONS KEY BOARD

+K4 A22 /99.C2

BK 1.5Q

A22.X1

X1 1 A22.Kl15 A INFORMATION INPUT INFORMATION INPUT CAN: HEAT/AIR CON

/99.C2

Ident.Nr.

SUPPLY KEYPADS Werk Bischofshofen GmbH 3

+K4 A22

ZeichNr.

4

5

6

A22.X1

X1 2 A22.GND A SUPPLY EARTH SUPPLY EARTH CAN: HEAT/AIR CON

+K4 A22 /99.C2

8920980 460 9010 00 003 7

5

WH 1.5Q

A22.X1

X1 2 A19.GND A +K4 SUPPLY EARTH A19 /98.C4 SUPPLY EARTH CAN: OPTIONS KEY BOARD

E

2

A19.X1

1

A19.X1

BK 1.5Q

WH 1.5Q

X1 1 A19.Kl15 A +K4 INFORMATION INPUT A19 /98.C4 INFORMATION INPUT CAN: OPTIONS KEY BOARD

2

A19.X1

5

WH 1.5Q

Kl.15

6

/51.B6

SUPPLY HEAT/AIR CON KEY BOARD

Kl.15

/51.B6

SUPPLY OPTION KEYPAD

F

Zustand

*

WH 1.5Q

PROJ: 8920980_003

* A4.X42

1

E

GND


D

1

L71


C

XMSP6b +K2

Kl.30

A

X1 5 A22.Kl15 A SUPPLY Kl. 15 SUPPLY CAN: HEAT/AIR CON

F

Anlage Ort

003 8

Blatt von

39 114

4

5

6

7

SUPPLY MASTER MODULE

SUPPLY DIAGNOSTIC PLUG MASTER MODULE CAN:

A /85.C5

A15.COM4.X

5

A15 +K2 =K

Receive (RXD) A A15.RXD .COM4.X 2

Transmit (TXD) A A15.TXD .COM4.X 3

A15.COM4.X

=K

=K

B

A

5A HBR A

R35

R54

L35

L54

GND

A4 =K +K2

Kl. 30

PROJ: 8920980_003

A

/85.B5

A15 +K2 =K

=K

F54

10A RD

GND

E

XMSP6b +K2

C 10A RD

A4.X42

RD 0.5Q

F26

BU 0.5Q

10 BK 0.5Q

9

8


XMSP6b +K2

A

C.8

R26 L26 GND

A4.X40

10

9

RD 1.5Q

WH 1.5Q

BK 1.5Q

BK 1.5Q

D

A.9

A4.X40 A.10

A9 Kl.30

RD 1.5Q

RD 1.5Q

XMSP6b +K2

4

E

CAN: MASTER MODULE

CAN: MASTER MODULE

/85.C1 CAN: MASTER MODULE

CAN: MASTER MODULE


Datum

1

Name

Datum


2

+K2 X60

DIAGNOSTIC PLUG Ident.Nr.

SUPPLY MASTER SUPPLY DIAGNOSTIC PLUG


*9

4

I

.PWR.X 6 A15.VBat A Kl. 30

H

/85.B1

=K +K2 A15

G

2

.PWR.X 2 A15.DIGIN0 A Kl. 15

B

/85.C1

=K +K2 A15

A

/85.B1

.PWR.X 5 A15.Shield A HOUSING MASTER

/79.C6

=K +K2 A15

A15.X

IMMOBILISER Kl.30

.PWR.X 1 A15.GND A EARTH

=K +K2 A15

A15.X

5

A15.X

6

BK 1.5Q

A15.X

F

Zustand

MASTER MODULE CAN:

E

F35

1

E


D

SIGNAL Ground (S A A15.GND .COM4.X 5

A15.COM4.X

Kl. 15 E

B

C

4

Kl. 30

A4 =K +K2

MASTER MODULE CAN: /85.B5

A15 +K2 =K

A.4

A4.X40

8

3

3

2

2

1

5

ZeichNr.

6

8920980 460 9010 00 003 7

F

Anlage Ort

003 8

Blatt von

40 114

2

1

3

4

5

6

7

SUPPLY INPUT MODULE 2

8

SUPPLY INPUT MODULE 1

A

A

E

Kl. 15

A4 =K +K2

Kl. 15

Kl. 15

A4 =K +K2

E

F43

E

F45

5A VI

F44

10A RD

10A RD

B

B

R45

R44

L43

L45

L44

X

R43

GND

/42.C2

GND

5

A4.X44

XMSP6b +K2

XMSP1a +H2

6

6

+K6 X1.S X1.B

A16a.X1

XMSP1a +H2

7

D

WH 1.5Q

+K2 A16b

X1 2 A16b.24V_logic A VBatt 24V Log SUPPLY 24V CAN: INPUT MODULE 2

BK 1.5Q

WH 1.5Q

BK 1.5Q

WH 1.5Q

BK 1.5Q

WH 1.5Q

40 40

+K2 A16b /87.D2

+K2 A16b /87.E2

VBatt 24V SUPPLY 24V CAN: INPUT MODULE 2

+K2 A16b /87.E2

X1 2 A16a.24V_logic A +H3 VBatt 24V Log A16a /86.C2 SUPPLY 24V LOGICAL PART CAN: INPUT MODULE 1

SUPPLY EARTH EARTH CAN: INPUT MODULE 2

+H3 A16a /86.D2

X1 16 A16a.GND_logic A SUPPLY GND LOGIK EARTH LOGICAL PART CAN: INPUT MODULE 1

A16a.X1

X1 30 A16a.24V

+H3 A16a

VBatt 24V SUPPLY 24V CAN: INPUT MODULE 1

/86.E2

31

A16a.X1

30

A16a.X1

X1 31 A16b.GND

2

A16b.X1

X1 30 A16b.24V

31

30

16

A16b.X1

X1 16 A16b.GND_logic A EARTH LOGIK EARTH LOGICAL PART CAN: INPUT MODULE 2

X1 31 A16a.GND

+H3 A16a /86.E2

E


X

/87.C2

A16b.X1

2

A16b.X1

WH 1.5Q

WH 1.5Q

=H+H3A17c.X1:2, =K+K6X2.S:33

+K6 X1.S X1.B

BK 1.5Q

1

WH 1.5Q

XMSP6b +K2

8

16

+K Splice;.X1

41

WH 1.5Q

A.5

OLE7 Verb.

A4.X40

E.11

WH 1.5Q

S.12

41


11

A4.X56

/48.C2

E

A

C


D

A

GND

12

C

PROJ: 8920980_003

A

F


Änderung

Datum

1

Name

Datum


2

Ident.Nr.

SUPPLY INPUT MODULE 1 AND 2 Werk Bischofshofen GmbH 3

ZeichNr.

4

5

6

8920980 460 9010 00 003 7

Anlage Ort

003 8

Blatt von

41 114

2

1

3

4

5

6

7

8

SUPPLY Outputmodule 1 A

Kl. 15

Kl. 15

A4 =K +K2

Kl. 15

A

E

E

E

F47

F43 B

B

/41.B1

PROJ: 8920980_003

GND

R47

R48

L47

L48 GND

X

GND

C

A4.X44

+H3 A17a /90.D1

EARTH LOGICAL PART CAN: OUTPUT MODULE 1

44

WH 1.5Q

D BK 1.5Q

WH 1.5Q

A17a.X1

X1 3 A17a.GND A +H3 SUPPLY EARTH A17a /90.C1 EARTH CAN: OUTPUT MODULE 1

10

A17a.X1

X1 15 A17a.24V_B2 A +H3 SUPPLY 24V Bank2 A17a /90.D1 SUPPLY 24V Bank2 CAN: OUTPUT MODULE 1

17

A17a.X1

XMSP1a +H2

15

BK 1.5Q

X1 1 A17a.24V_B1 A +H3 VBatt 24V Bank1 A17a /90.B1 SUPPLY 24V BANK 1 CAN: OUTPUT MODULE 1

SUPPLY EARTH LOGICAL PART

+K6 X1.S X1.B

9

3

WH 1.5Q

A17a.X1

X1 16 A17a.GND_logic A

1

BK 1.5Q 2

A17a.X1

X1 2 A17a.24V_logic A +H3 VBatt 24V Log A17a /90.C1 SUPPLY 24V LOGICAL PART CAN: OUTPUT MODULE 1

XMSP1a +H2

44

WH 1.5Q

+K6 X1.S X1.B

8

43

/44.C2

43

WH 1.5Q

WH 1.5Q

WH 1.5Q

=K+K6X2.S:64 WH 1.5Q

Splice.X2.F43 KL. 15

42

XMSP1a +H2

42

OLE8 Verb. 1

WH 1.5Q

E.10

X1 17 A17a.GND A +H3 SUPPLY EARTH A17a /90.D1 EARTH CAN: OUTPUT MODULE 1

E

/71.C1

Kl.15

A17a.X1

A4.X44

E.8

16


+K6 X1.S X1.B

10

8

11

A4.X56 +K2 Splice.X2


E

A

R43 L43

S.11

D

10A RD

A

A

C

F48

10A RD

5A VI

SUPPLY LOGIC

SUPPLY BANK 1

SUPPLY BANK 2

F


Änderung

Datum

1

Name

Datum


2

Ident.Nr.

SUPPLY OUTPUT MODULE 1 Werk Bischofshofen GmbH 3

ZeichNr.

4

5

6

8920980 460 9010 00 003 7

Anlage Ort

003 8

Blatt von

42 114

3

4

5

6

E

F59

F60

10A RD

R52

L59

L60

L51

L52

GND

5

A4.X43

4

GND

A4.X43 D.5

A4.X42

A4.X42 WH 1.5Q

+K6 X1.S X1.B

50

+K6 X1.S X1.B

46

45

+K6 X1.S X1.B

45

C.11

WH 1.5Q

50

WH 1.5Q

B

GND

C.3

46

PROJ: 8920980_003

A

R51

WH 1.5Q

X1 28 A17a.24V_B4

X1 26 A17a.GND

+H3 +H3 A17aVBatt 24V Bk 4 zu M 2/33 (2. AST) A17a /90.E1

SUPPLY 24V Bank4 CAN: OUTPUT MODULE 1

SUPPLY EARTH /90.E1 EARTH CAN: OUTPUT MODULE 1

SUPPLY BANK 4

A17a.X1

A17a.X1

A17b.X1

X1 14 A17a.24V_B3 A +H3 A17aVBatt 24V Bk 3 zu M 2/35 (2. AST) /90.D1 SUPPLY 24V Bank3 CAN: OUTPUT MODULE 1

VBatt 24V Bk 4 /91.E2 SUPPLY 24V Bank4 CAN: OUTPUTMODULE 2

SUPPLY BANK 3

+H3 A17a.DO2 X1 35

A17a.X1

A17b.X1

X1 28 A17b.24V_B4

+H3 A17b

34

32

A17a.DO1 X1 33

8

OUTPUT MODULE 1 CAN: /90.E1 digital output2 A17a 2.AST pump2 zu M 2/14

X1 26 A17b.GND

+H3 A17b /91.E2

SUPPLY EARTH EARTH CAN: OUTPUTMODULE 2

A17b.X1

X1 12 A17b.GND A +H3 SUPPLY EARTH A17b /91.C2 EARTH CAN: OUTPUTMODULE 2

SUPPLY BANK 4

35

A17b.X1

XMSP1b +H2

7

D

E

14

A17b.DO2 X1 35

X1 12 A17a.GND A +H3 SUPPLY EARTH A17a /90.C1 EARTH CAN: OUTPUT MODULE 1

XMSP1b +H2

+H3

33

A17a.X1

OUTPUT MODULE 1 CAN: /90.E1 digital output1 A17a 2. AST Joystick zu M 2/28

12

+H3

SUPPLY SUPPLY DO2 /90.E1 SUPPLY for DIGTAL OUTPUT 2 CAN: OUTPUT MODULE 1

BK 1.5Q

2

+H3 A17a

SUPPLY SUPPLY DO1 /90.E1 SUPPLY for digital output1 CAN: OUTPUT MODULE 1

28

BK 1.5Q

A17a.X1

26

33

A17b.DO1 X1 33

XMSP1b +H2 BK 1.5Q

+H3

1

OUTPUTMODULE 2 CAN: /91.E2 digital output2 A17b 2. AST TRANSMISSION

+H3 A17a

35

XMSP1b +H2

12

OUTPUTMODULE 2 CAN: /91.E2 digital output 1 A17b 2. AST pump1

X1 34 A17a.V_DO2

BK 1.5Q

SUPPLY SUPPLY DO /91.E2 SUPPLY CAN: OUTPUTMODULE 2

A17a.X1

X1 32 A17a.V_DO1

26

+H3 A17b

VBatt SUPPLY DO1 /91.E2 SUPPLY CAN: OUTPUTMODULE 2

A17a.X1

A17a.X1

X1 34 A17b.V_DO2

+H3 A17b

A17b.X1

34

A17b.X1

X1 32 A17b.V_DO1

14

A17b.X1

32


C

28

E

A

R60

D.4


D

10A RD

R59

GND

+K6 X1.S X1.B

A E

F52

10A RD

A

B

C

F51

10A RD

A

E

51

E

A4 =K +K2

51

Kl. 15

11

A

Kl. 15

SUPPLY Outputmodule 2

3

A4 =K +K2

8

Kl. 15


7

Kl. 15

2

1

A17b.X1

X1 14 A17b.24V_B3 A +H3 VBatt 24V BK 3 A17b /91.D2 SUPPLY 24V Bank3 CAN: OUTPUTMODULE 2

SUPPLY BANK 3

F


Änderung

Datum

1

Name

Datum


2

Ident.Nr.

SUPPLY OUTPUT MODULE 1 AND 2 Werk Bischofshofen GmbH 3

ZeichNr.

4

5

6

8920980 460 9010 00 003 7

Anlage Ort

003 8

Blatt von

43 114

2

1

3

4

5

6

7

8

SUPPLY Outputmodule 2 A4 =K +K2

Kl. 15

A Kl. 15

A

E

F55

E

F56

10A RD

10A RD

A

A

E

R56

L55

L56

B

GND

A4.X43

WH 1.5Q 49

A17b.X1

X1 3 A17b.GND A +H3 SUPPLY EARTH A17b /91.C2 EARTH CAN: OUTPUTMODULE 2

BK 1.5Q

X1 15 A17b.24V_B2 A +H3 VBatt 24V Bank2 A17b /91.D2 SUPPLY 24V Bank2 CAN: OUTPUTMODULE 2

SUPPLY BANK 1

A17b.X1

D

17

WH 1.5Q

BK 1.5Q

A17b.X1

6

49

48 48

X1 1 A17b.24V_B1 A +H3 VBatt 24V Bank1 A17b /91.B2 SUPPLY 24V CAN: OUTPUTMODULE 2

SUPPLY LOGIC

+K6 X1.S X1.B

15

A17b.X1

X1 16 A17b.GND_logic A +H3 VBatt EARTH A17b /91.D2 EARTH LOGICAL PART CAN: OUTPUTMODULE 2

XMSP1b +H2

5

3

16

BK 1.5Q

WH 1.5Q

+K6 X1.S X1.B

A17b.X1

X1 2 A17b.24V_logic A +H3 VBatt 24V LOGICAL PART A17b /91.C2 SUPPLY 24V CAN: OUTPUTMODULE 2

XMSP1b +H2

4

1

Splice.X2.F43 KL. 15 WH 1.5Q

XMSP1b +H2

C

D.6

WH 1.5Q

A.12

2

A17b.X1

A4.X40

6

/42.C3

12



D

R55

GND


C

PROJ: 8920980_003

B

X1 17 A17b.GND A +H3 SUPPLY EARTH A17b /91.D2 EARTH CAN: OUTPUTMODULE 2

E

SUPPLY BANK 2

F


Änderung

Datum

1

Name

Datum


2

Ident.Nr.


ZeichNr.

4

5

6

8920980 460 9010 00 003 7

Anlage Ort

003 8

Blatt von

44 114

2

3

4

5

6

WH 1.5Q 9

C.5

5 1 =K+K4S43.X2:9

BK 1.5Q

WH 1.5Q

E200.X

D

*

1 WH 1.5Q

+K4 E200

2

+H3 A17b

VBatt DO3 /91.F2 SUPPLY CAN: OUTPUTMODULE 2

B12.1

BK 1.5Q

/25.D1

54 X1 A17b.GND_DO4

X1 38 A17b

+H3

+H3 A17b

EARTH Backup A17b EARTH /91.D5 CAN: OUTPUTMODULE 2

VBatt D04 /91.F2 SUPPLY CAN: OUTPUTMODULE 2


Datum

1

Name

Datum


+K2 XMSP6a

2

3

Ident.Nr.



5

E

9

STOP LIGHT

X1 36 A17b.V_DO3

A17b.X1

54

A17b.X1

38

A17b.X1

10

E200.X

F

Zustand

20

+K6 X1.S X1.B

20

2

B16b.X

2

1

B16.X

+H5 2 B16a.X1

C WH 1.5Q

WH,WH 1.5Q,1.5Q

OLE9 Verb.

WH 1.5Q 1

1 1

B16b.X

+H5

A4.X44

22

22

21

X2.S X2.B +K6

WH 1.5Q

21 52 52

1

+K6 X1.S X1.B BK 1.5Q

WH 1.5Q

X2.S X2.B +K6

+H5 B16

2

+H1 B16c.X1

B

+K2 XMSP6d

BK 1.5Q

53 53

+H5 B16 0

M 2

H22a.X2

B16.X

2

+H1 H22a 0

B16a.X1 1

1

WH 1.5Q

WH 1.5Q

1

S43.X2

WH 1.5Q

1

B16c.X1 +H1

L22 GND

WH 1.5Q

+K6 X1.S X1.B

10

R22

WH 1.5Q

5

A4.X42

H22a.X1

10A RD A

9

5

10

PROJ: 8920980_003

A4.X43

R

1

F22

S43.X2

1 0

S43.X1

OPTION ᕪ; Rear side/ERECTION UP bonnet

GND

36

E

L62

D.10


D

L61 GND


C

R62

=K +K4 S43 0

WH 1.5Q

B

A

R61

WH 1.5Q

A

S43.X1

A17b.X1

9

10A RD

A E

10

F62

10A RD

39

F61

+H3 A17b.DO4 39 X1

Kl. 15

BK 1.5Q

E

A4 =K +K2 WH 1.5Q

E

OUTPUTMODULE 2 CAN: Digitalausgang4 /91.F2 A17b Backup ALARM

1

Kl. 15

WH 1.5Q

A

Kl. 15

8

OPTION Back up ALARM CAN BE SWITCHED OFF

SUPPLY Outputmodule 2 A4 =K +K2

7

5

1

ZeichNr.

6

8920980 460 9010 00 003 7

F

Anlage Ort

003 8

Blatt von

45 114

2

3

4

5

6

=K +K4 S43 0

1

1

B

GND

=K +K2 XMSP6d

22

WH 1.5Q 22

A4.X44

C

1

1

20

+K6 X1.S X1.B

2

BK 1.5Q D

X1 36 A17b.V_DO3

=H +H3 A17b

54

38

=H +H3 A17b.X1

54 X1 A17b.GND_DO4

X1 38 A17b

Reserve Masse CAN: OUTPUTMODUL 2

VBatt DO3 Reserve =H+H/51.F2 Versorgung für Digitalausgang3 =H+H/51.F2 Versorgung für Digitalausgang4 CAN: CAN: OUTPUTMODUL 2 OUTPUTMODUL 2

=H +H3 A17b

=K+K/7.D1

=H +H3 A17b

+H3 A17b.X1

36

+H3 A17b.X1

B12.1.2

WH 1.5Q

BK 1.5Q

2

20

B16.X +H5

B16b.X +H5 =H

2

=H 2 +H5 B16a.X1 2

1

+H1 B16c.X1

+H5 B16 0

BK 1.5Q

52 52

53 53

H22a.X2

=H +H5 B16b.X

B16a.X1 +H5 =H

1

21

21

+K6 X2.S X2.B

X2.S X2.B +K6

1

+H5 B16 0

M 2

=K +K6 X1.S X1.B +K6 =K

1

2

+H1 H22a 0

1

B16c.X1 +H1

1

WH 1.5Q

WH 1.5Q

H22a.X1

1

=K +K6 X1.S X1.B +K6 =K

10

S43.X2

R

C.5

+H5 B16.X

A

Verb. A4.X44:5

5

10

PROJ: 8920980_003

5

S43.X1

A4.X42

=H+H/51.D5

E



9

1 0

Bremslicht

E

A4.X43

S43.X2

1

WH 1.5Q


D

GND

D.10


C

GND

F22 10A RD

=K+K4S43.X2:9

B

=K +K4 S43a S2 6905201 6002120 0

Rückfahrwarneinrichtung optisch Heckseitig/Montage auf Motorhaube

E

5

A

S43.X1 WH 1.5Q

A

A17b.X1 +H3 =H

A

WH 1.5Q

A17b.DO4 39 X1

F62 10A RD

39

F61 10A RD

A17b +H3 =H

WH 1.5Q

E

=H+H/51.F2

Kl. 15

WH 1.5Q

E

A4 =K +K2

9

Kl. 15

10

Kl. 15

OUTPUTMODUL 2 CAN: Digitalausgang4 Reserve

1

A4 =K +K2

8

Option Back up Alarm which can be switched off

Supply Outputmodule 2 A

7

5

1

Änderung

Datum

1

Name

Datum


2


Ident.Nr.

OUTPUT MODULE 2; BACKUP ALARM AND CAN BE SWITCHED OFF 4

5

ZeichNr.

6

8920980 460 9010 00 003 7

F

Anlage Ort

003 8

Blatt von

46 114

2

1

3

4

5

1

+K2 A4.X40.3a

6

7

8

+K2 Kl.30a 1

WH 1.5Q

SUPPLY LHECUUP/CR

B

C

PROJ: 8920980_003

A

A

R24

R38

L36

L24

L38

GND

GND

A4.X40

A.1

2

2

1

A

R36

GND

A.2

XMSP6c +K2

XMSP6c

2

RD 6Q

Verb.

37 37

1 5A LBN

A4.X41 +K2 B.2

A700D.X2

1

+K2 F216 5A LBN

X2 68 A700D.15

+M A700D

IGNITION ON ENGINEECU

/93.B2

3

=K +K2.RH

B

2 100 mm

RD 1.5Q

F38

10A RD

=K+K2K216:87

F24

40A OG

E

WH 1.5Q

F36

E

68

E

+K6 X1.S X1.B

Kl. 30

Kl. 15

Kl. 30

A4 =K +K2

A4.X40

A

OLE10

A4.X40

3

A.3

A

+K3 S216

C

21

WH 1.5Q

WH 1.5Q

+M A700D /93.B2

SUPPLY 30b PERFORMANCE PART ENGINEECU

+M A700D /93.C2

X2 15 A700D.31.2 EARTH PERFORMANCE PART ENGINEECU

+M A700D /93.C2

X2 2 A700D.30.2 SUPPLY 30b PERFORMANCE PART ENGINEECU

+M A700D

EARTH PERFORMANCE PART ENGINEECU

/93.C2

X2 4 A700D.30.3

+M A700D

SUPPLY 30b ELECTRONICS ENGINEECU

/93.C2

A700D.X2

0

87 10022680

10022680

87a

E 1

3

A700D.X2

X2 16 A700D.31.3

4

A700D.X2

16

A700D.X2

2

15

A700D.X2

X2 1 A700D.30.1

31

BK 1.5Q

BU 1Q

RD 1Q

BU 2.5Q

RD 2.5Q

BU 2.5Q

15

+K2 XMSP12.1 +M A700D.X2

D

+K2 K216 0

RD 2.5Q

30

57

X1.S X1.B

57

56

=K +K2.RH

56

X1.S X1.B

BU 1Q

RD 1Q

BU 2.5Q 24

+K6 X1.S X1.B

24

55

RD 2.5Q 21

54

X1.S X1.B

55

+K6 X1.S X1.B

21

54

BU 2.5Q

RD 2.5Q


+K6 X1.S X1.B

1

E


D

4

WH 1.5Q

22

XMSP6c

X2 3 A700D.31.1

+M A700D

EARTH ELECTRONICS ENGINEECU

/93.C2

OPTION LAGGING AUTOMATICS

F


Änderung

Datum

1

Name

Datum


2

Ident.Nr.

MOTOR CONTROL ; AUTOMATIC RUNOUT Werk Bischofshofen GmbH 3

ZeichNr.

4

5

6

8920980 460 9010 00 003 7

Anlage Ort

003 8

Blatt von

47 114

2

1

3

4

5

6

7

8

CONNECT WITH A4.X56.12 F43

A

F64

10A RD

10A RD

A

A

R63

R64

L63

L64

B

/41.F1

GND

A4.X41 +K2

10

8

X

A4.X41 +K2

WH 1.5Q

D

BK 1.5Q

WH 1.5Q

WH 1.5Q

BK 1.5Q

BK 1.5Q WH 1.5Q

3

29

+K6 X2.S X2.B +K6

XMSP1d +H2

29

2

28

33

+K6 X2.S X2.B +K6

XMSP1d +H2

28

1

33

+K6 X2.S X2.B +K6

WH 1.5Q

WH 1.5Q

XMSP1d +H2

A17c.X1

X1 3 A17c.GND A +H3 SUPPLY EARTH A17c /92.C2 EARTH CAN: OUTPUT MODULE 3

A17c.X1

X1 15 A17c.24V_B2 A +H3 SUPPLY 24V Bank2 A17c /92.D2 SUPPLY 24V Bank2 CAN: OUTPUT MODULE 3

17

A17c.X1

X1 1 A17c.24V_B1 A +H3 VBatt 24V Bank1 A17c /92.B2 SUPPLY 24V BANK 1 CAN: OUTPUT MODULE 3

15

A17c.X1

X1 16 A17c.GND_logic A +H3 VBatt EARTH LOGICAL PART A17c /92.D2 EARTH LOGICAL PART CAN: OUTPUT MODULE 3

3

A17c.X1

X1 2 A17c.24V_logic A +H3 VBatt 24V LOGICAL PART A17c /92.C2 SUPPLY 24V LOGICAL PART CAN: OUTPUT MODULE 3

1

A17c.X1

16

E 2

E

F63

E

C


D

E

A

GND


C

PROJ: 8920980_003

B

Kl. 15

A4 =K +K2

Kl. 15

SUPPLY Outputmodul 3

X1 17 A17c.GND A +H3 SUPPLY EARTH A17c /92.D2 EARTH CAN: OUTPUT MODULE 3

F


Änderung

Datum

1

Name

Datum


2

Ident.Nr.


ZeichNr.

4

5

6

8920980 460 9010 00 003 7

Anlage Ort

003 8

Blatt von

48 114

2

1

3

4

5

6

7

8


E

E

F66

L65

L66

GND

A4 =K +K2

B

GND

E F71 10A RD

WH 1.5Q

11

6

A4.X40

A4.X40

C

1 1

8

30

86

+K2 K246

D V48

0

+K4 A18.X1.1a

87a

87

85

1

V36

V37

WH 1.5Q

GND MP

A4.X48

I.11

I.10

MP

10

BK 1.5Q

A18.X1.1b +K4

A4.X48 I.8

A4 =K +K2

X1 1 A18.Kl15 A +K4 A18 INFORMATION INPUT /52.C3 INFORMATION INPUT CAN: ELECTRIESKEY BOARD

WH 1.5Q

A4.X48

12

C.6

A18.X1 WH 1.5Q

A4.X42

I.12

*

C.4

WH 1.5Q

4

* A4.X42

SUPPLY OPTIONS/KLIMATASTATUR

31

WH 1.5Q BK 1.5Q

5

31

+K6 X2.S X2.B +K6

30

+K6 X2.S X2.B +K6

XMSP1d +H2

4

30

WH 1.5Q


XMSP1d +H2

6

GND

X1 12 A17c.GND A +H3 SUPPLY EARTH A17c /92.C2 EARTH CAN: OUTPUT MODULE 3

A17c.X1

A17c.X1

X1 28 A17c.24V_B4

+H3 A17c

SUPPLY 24V Bank4 /92.E2 SUPPLY 24V Bank4 CAN: OUTPUT MODULE 3

26

A17c.X1

X1 14 A17c.24V_B3 A +H3 SUPPLY 24V Bank3 A17c /92.D2 SUPPLY 24V Bank3 CAN: OUTPUT MODULE 3

28

A17c.X1

12

E 14

E

+K6 X2.B X2.S

A


D

WH 1.5Q

R66

32

PROJ: 8920980_003

SUPPLY ELECTRIC KEYPAD

A

R65

32

A

B

A

10A RD

SUPPLY MAIN KEYPAD

10A RD

Kl. 15

F65

C

OUTPUT MODULE 3 CAN: /92.C2 PWMOutput1 (Bank1) A17c Vcc CUTOFF LIGHTING +H3 A A17c.PWM1 X1 4

Kl. 15

A

Kl. 15

A4 =K +K2

X1 26 A17c.GND

+H3 A17c /92.E2

OPTION AUTOMATIC LIGHTING CUTOFF (ABA)

SUPPLY EARTH EARTH CAN: OUTPUT MODULE 3

F


Änderung

Datum

1

Name

Datum


2


Ident.Nr.

SUPPLY OUTPUT MODULE 3; AUTOMATIC LIGHTING SHUTDOWN 4

5

ZeichNr.

6

8920980 460 9010 00 003 7

Anlage Ort

003 8

Blatt von

49 114

A17c.X1

OUTPUT MODULE 3 CAN: /92.C2 PWMOutput4 (Bank1) A17c 4. CONTROL CIRCUIT EP MV1 +H3 A A17c.PWM4 X1 7

A17c.X1

OUTPUT MODULE 3 CAN: /92.D2 PWMOutput5 (Bank2) A17c 4. CONTROL CIRCUIT EP MV2 +H3 A A17c.PWM5 X1 18

A17c.X1

F209 5A LBN

F210 10A RD

2

WH 1.5Q

WH 1.5Q

WH 1.5Q

WH 1.5Q

PROJ: 8920980_003

A

18


8

7

WH 6Q

A17c.X1

1

2

/89.D2

+H3 A16d /89.E2

1

1

Y12b.JPT

2

1

Y11b.JPT

2

SUPPLY 24V SUPPLY 24V CAN: INPUTMODUL 4

+H3 A16d

BK 1.5Q

BK 1.5Q

BK 1.5Q

A17c.X1

50

49

A17c.X1

E

X1 47 X1 48 X1 49 X1 50 A17c.GND_PWM2 A17c.GND_PWM3 A17c.GND_PWM4 A17c.GND_PWM9 D D D D +H3 +H3 +H3 +H3 RESERVE A17cGND 3. CONTROL CIRCUIT EP MV1 A17cGND 3. CONTROL CIRCUIT EP MV2 A17cGND 4. CONTROL CIRCUIT EP MV1 A17c /92.C5 EARTH /92.C5 EARTH /92.C5 EARTH /92.C5 EARTH CAN: CAN: CAN: CAN: OUTPUT MODULE 3 OUTPUT MODULE 3 OUTPUT MODULE 3 OUTPUT MODULE 3

SUPPLY EARTH EARTH CAN: INPUTMODUL 4

/89.E2

A17c.X1

48

A17c.X1

X1 31 A16d.GND

47

BK 1.5Q

A16d.X1

X1 30 A16d.24V

31

WH 1.5Q

A16d.X1

2

D BK 1.5Q

+H3 A16d

X1 16 A16d.GND_logic A EARTH LOGICAL PART EARTH LOGICAL PART CAN: INPUTMODUL 4

30

BK 1.5Q

A16d.X1

X1 2 A16d.24V_logic A +H3 SUPPLY EARTH A16d /89.C2 SUPPLY 24V LOGICAL PART CAN: INPUTMODUL 4

16

WH 1.5Q

A16d.X1

Y12b.JPT 1 +V1 Y12b 0

2

Y12a.JPT

2

Y11a.JPT

2 2

BK 1.5Q

2

Y11b.JPT 1 +V1 Y11b 0

57

56

Y12a.JPT 1 +V1 Y12a 0

57

WH 1.5Q

Y11a.JPT 1 +V1 Y11a 0

2

+K6 X2.S X2.B

56

BK 1.5Q

+K6 X2.S X2.B

55

54

+K6 X2.S X2.B

54

+K6 X2.S X2.B

XMSP200 +K2

1

55

WH 1.5Q


XMSP200 +K2

1

C

2

E


7

B

1


D

6

=K +K2.RH

B

C

5

*

WH 6Q

A

4

6

+K2 A4.Kl.15.a 1

3

5

2

1

F


Änderung

Datum

1

Name

Datum


2

SUPPLY INPUT MODULE 4; EP 3. AND 4. CONTROL CIRCUIT Werk Bischofshofen GmbH 3

Ident.Nr. ZeichNr.

4

5

6

8920980 460 9010 00 003 7

Anlage Ort

003 8

Blatt von

50 114

3

4

5

Kl. 15

A4 =K +K2

6

E

F9

10A RD

A

A4.X45

WH 1Q 5

B

A4.X45 F.10

F.9

INPUT MODULE 2 CAN: ANALOGUE Universal CONTROL LEVEROption1 A A16b.UI9 X1 8

/87.C2

A16b +K2

WH 1Q

A16b.X1

18

A16b.X1

*

10

9

4

A4.X44

INPUT MODULE 2 CAN: ANALOGUE Universal CONTROL LEVER BACKWARD2 A A16b.UI6 X1 19 19

INPUT MODULE 2 CAN: ANALOGUE Universal /87.D2 CONTROL LEVER FORWARD2 A16b +K2 A A16b.UI5 X1 18

WH 1Q

WH 1Q

9

A16a.X1

8

A16a.X1

XMSP6c +K2

A16b.X1

/87.C2

A16b +K2

INPUT MODULE 2 CAN: ANALOGUE Universal CONTROL LEVER Option2 A A16b.UI10 X1 9

A16b.X1

/87.C2

A16b +K2

A16b.X1

WH 1Q

7

9

6

8

7

9

10

11

12

OPT2 sw3

10

WH 1Q

2

1 0

E 1

OPT3 sw5

S222.X1

7

2

8

9

S222.X2

9

8

1

10

S222.X2

2

6

3

12

1

5

11

3

2

10

5

4

6

COMFORT CONTROL VIA 1 <> 5 3 CONTROL CIRCUIT VIA 1<> 5 AND 6 <> 2 INFO ASSEMBLY INSTRUCTIONS!

0 S2.1

S2.2

S2.3

S2.4

BK 1.5Q

V N R

WH 1.5Q

+K4 S2

2

S2.X

4

OPT1 sw4

5

1


0 S222 +K4

6

WH 1Q

WH 1Q

A16b.X1.10a +K2

5

WH 1Q

A16b.X2.9+10b +K2 WH 1Q

A16b.X2.9+10b +K2

1

A16b.X1.9a +K2

WH 1Q

WH 1Q

WH 1Q

WH 1Q

WH 1Q

BK 1Q

WH 1Q

1

D 1

WH 1Q

23

+K6 X1.B X1.S +K6

23

+K6 X1.B X1.S +K6

LH CONTROL LEVER VNR AND OPTIONS OLE5 OLE6


C

+K Splice;.X3

S222.X1

E

INPUT MODULE 2 CAN: ANALOGUE Universal CONTROL LEVER; Option3 A A16b.UI11 X1 10

WH 1Q

22

PROJ: 8920980_003

GND

E.4

22

D

L9

GND


C

L15

10

B

R9

9

F15.3

R15

/39.E8

A

Kl.15

F15.2

10A RD

/39.E3

F15

E

Kl.15

F15.1

/20.C3

INPUT MODULE 1 INPUT MODULE 1 CAN: CAN: /86.C2 ANALOGUE all-purpose Input9 /86.C2 ANALOGUE all-purpose Input10 /87.D2 A16a CONTROL LEVER FORWARD1 A16a CONTROL LEVER BACKWARD1 A16b +H3 +H3 +K2 A A A16a.UI9 A16a.UI10 X1 8 X1 9

8

A

/20.B2

8

A

7

Kl. 15

2

1

Änderung

Datum

1

Name

Datum


2

LHCONTROL LEVER SWITCH COMFORT CONTROL ; 3 AND 4 CONTROL CIRCUIT


4

5

6

Ident.Nr. ZeichNr.

Verb. Verb.

1 1

8920980 460 9010 00 003 7

=K+K4S222.X2:9 =K+K4S222.X2:10

F

Anlage Ort

003 8

Blatt von

51 114

A16b.X1

35

A16b.24V X1 35

RD 0.5Q

21

A

B

15 15

14 14 BU 0.5Q

12

2

/87.E2

A16b +K2

INPUT MODULE 2 CAN: SUPPLY 24V 24V throttle transmitter2

3

+K6 X2.B X2.S

12

11 11

BU 0.5Q

RD 0.5Q 1

BU 0.5Q

RD 0.5Q

A16b.X1

BU 0.5Q

A16a.X1

25

A16a.X1

/87.D2

A16a.UI16 X1 25

RD 0.5Q

BU 0.5Q

BU 0.5Q

A16b.X1

A16a.24V X1 39

INPUT MODULE 2 CAN: ANALOGUE Universal throttle transmitter2 A A16b.UI8 X1 21

A16b +K2

+H3

5

+K6 R5 R5.X

6

4

3

+

2

5

BK 0.5Q

D

EARTH InchPot.1 EARTH CAN: INPUT MODULE 1

16

A16b.X1

X1 67 A16a.GND

EARTH InchPot.2 EARTH CAN: INPUT MODULE 2

+H3 A16a /86.E5

EARTH throttle transmitter1 EARTH CAN: INPUT MODULE 1

63

67

A16a.X1

X1 62 A16b.GND

/87.D5

E

3

62

1

A16b.X1 +K2 A16b

BK 0.5Q

BK 0.5Q

BK 0.5Q

63

3

X1 63 A16a.GND

16

13 BK 0.5Q

13

X2.S X2.B +K6

1

/86.D5

signal

2

X2.S X2.B +K6

+H3 A16a

6

3 signal

5

2

2

4

+

2

A16a.X1

1

6

3

1

+

BK 0.5Q

R1.X

signal

R5.X

6

3 signal

2

+

+K6 R1

4

1 4

5


1


E

A16b.24V X1 34

INPUT MODULE 1 CAN: /86.E2 ANALOGUE all-purpose input16 A16a throttle transmitter1

8

C

R1.X

D

/86.F2

A16a +H3

INPUT MODULE 1 CAN: SUPPLY 24V 24V throttle transmitter1

7

3

+K6 X2.B X2.S

2

/87.E2

A16b +K2

INPUT MODULE 2 CAN: SUPPLY 24V 24V InchPotentiometer2

6

39

A16b.X1

1

PROJ: 8920980_003

C

/87.D2

A16b +K2

5

RD 0.5Q

B

INPUT MODULE 2 CAN: ANALOGUE Universal InchPotentiometer2 A A16b.UI7 X1 20

21

A16a.X1

RD 0.5Q

A16a.X1

4

20

INPUT MODULE 1 INPUT MODULE 1 CAN: CAN: SUPPLY 24V /86.D2 ANALOGUE all-purpose Input8 24V InchPotentiometer1A16a InchPotentiometer1 +H3 A A16a.24V A16a.UI8 X1 35 X1 21 35

/86.E2

A16a +H3

A

3

34

2

1

X1 63 A16b.GND

+K2 A16b /87.D5

EARTH throttler transmitter EARTH CAN: INPUT MODULE 2

F


Änderung

Datum

1

Name

Datum


2

Ident.Nr.

ANGLE SENSOR INCH/GAS PEDAL Werk Bischofshofen GmbH 3

ZeichNr.

4

5

6

8920980 460 9010 00 003 7

Anlage Ort

003 8

Blatt von

52 114

A17b.X1

OUTPUT MODULE 1 CAN: /90.D1 PWMOutput13 (Bank4) A17a oil engine1 +H3 A A17a.PWM13 X1 22

A17a.X1

8

OUTPUT MODULE 1 CAN: /90.D1 PWMOutput14 (Bank4) A17a oil engine2 +H3 A A17a.PWM14 X1 23

A17a.X1

OUTPUT MODULE 1 CAN: A /90.D1 PWMOutput8 (Bank2) A17a Swivel angle limitation. oil engine 1 +H3 A A17a.PWM8 X1 21

A17a.X1

21

A17a.X1

OUTPUTMODULE 2 CAN: /91.C2 PWMOutput1 (Bank A17b OVERSPEED PROTECTION +H3 A A17b.PWM1 X1 4

7

23

A17a.X1

OUTPUT MODULE 1 CAN: /90.C1 PWMOutput9 (Bank3) A17a cruising range1 +H3 A A17a.PWM9 X1 8

6

22

OUTPUT MODULE 1 CAN: /90.C1 PWMOutput11 (Bank3) A17a cruising range3 +H3 A A17a.PWM11 X1 10

5

4

A17a.X1

4

10

A17a.X1

11

A

OUTPUT MODULE 1 CAN: /90.C1 PWMOutput10 (Bank3) A17a cruising range2 +H3 A A17a.PWM10 X1 9 9

OUTPUT MODULE 1 CAN: /90.C1 PWMOutput12 (Bank3) A17a Modulation +H3 A A17a.PWM12 X1 11

3

8

2

1

WH 1.5Q

WH 1.5Q

WH 1.5Q

WH 1.5Q

WH 1.5Q

WH 1.5Q

WH 1.5Q

WH 1.5Q

Y6.3

Y16.JPT

YEP2.DT

1

1

2

Y57.DT

H G

E

YEP1.DT

2

H

G F

F

1

+F3 Y57

Y6.1

0 E Y6.X

1

1

2

Y57.DT

2

Y6.2

2

+H Y16

D

YEP2.DT 1 +F3 YEP2

2

MO1

YEP1.DT 1 +F3 YEP1

2

+F3 Y6

C

1

2

B

D

B

A

C

Y16.JPT Y6.X A

BK 1.5Q

BK 1.5Q

BK 1.5Q

BK 1.5Q

BK 1.5Q

BK 1.5Q

BK 1.5Q

BK 1.5Q

D

+H3 A17a

+H3 A17a

EARTH Modulation /90.C5 EARTH CAN: OUTPUT MODULE 1

EARTH TRAVEL RANGES 2 /90.C5 EARTH CAN: OUTPUT MODULE 1

X1 52 A17a.GND_PWM11

+H3 A17a

EARTH TRAVEL RANGES 3 /90.C5 EARTH CAN: OUTPUT MODULE 1

X1 46 A17b.GND_PWM1 D +H3 EARTH overspeed A17b /91.C5 EARTH CAN: OUTPUTMODULE 2

A17a.X1


+H3 A17a

A17a.X1


EARTH oil engine1 /90.D5 EARTH CAN: OUTPUT MODULE 1

+H3 A17a

EARTH oil engine2 /90.E5 EARTH CAN: OUTPUT MODULE 1

63

A17a.X1

65

A17b.X1

X1 50 A17a.GND_PWM9 D +H3 EARTH TRAVEL RANGES 1 A17a /90.C5 EARTH CAN: OUTPUT MODULE 1

64

A17a.X1

46

A17a.X1


50

A17a.X1


51

A17a.X1

52

E 53

E

C


D


C

B

PROJ: 8920980_003

B

X1 63 A17a.GND_PWM8

+H3 A17a /90.D5

Swivel angle limitation. oil engine 1 EARTH CAN: OUTPUT MODULE 1

F


Änderung

Datum

1

Name

Datum


2

TRAVEL RANGES ; SWIVEL ANGLE HYDRO MOTORS OVERSPEED PROTECTION


4

5

6

Ident.Nr. ZeichNr.

8920980 460 9010 00 003 7

Anlage Ort

003 8

Blatt von

53 114

A A17b.PWM9 X1 8

A17a.X1

A17b.X1

TRAVELLING DIRECTION Pump2 BACKWARD

A A17b.PWM10 X1 9

A17b.X1

A17b.X1

OUTPUTMODULE 2 CAN: /91.C2 PWMOutput4 (Bank A17b SWIVEL ANGLE travel pump2 +H3 A A17b.PWM4 X1 7

INPUT MODULE 1 CAN: /86.C2 ANALOGUE Output2

A16a +H3

HIGH PRESSURE TRAVEL PUMP

A A16a.UI2 X1 5

A16a.X1

OUTPUT MODULE 1 CAN: /90.D1 PWMOutput7 (Bank2) A17a BUZZER +H3 A A17a.PWM7 X1 20

A17a.X1

26 26

WH 1Q

BU 1Q

WH 1.5Q

WH 1.5Q

WH 1.5Q

WH 1.5Q

WH 1.5Q

WH 1.5Q

+K6 X1.B X1.S

B

1

C

Y15.JPT

B

2

Y15a.JPT

+

H40.X2

IP

1

+H4 B45 0

s

+K2 H40 0

+ C

A

BK 1Q

2

3

B45.X

1

Y15a.JPT 1 +H Y15a 0

2

1

1

2

Y3a.DT

1 1

+H Y15 0

2

2

1

+H Y3a 0

2

Y2a.DT

Y15.JPT

2

2

Y3.DT

1

+H Y2a 0 2

2

Y2.DT

1

+H Y3 0

Y3a.DT

2

1

+H Y2 0

Y2a.DT

1

Y3.DT

1


Y2.DT

1

H40.X1

B45.X

D

BK 1Q

20

20

+K6 X2.S X2.B +K6

RD 1Q

BK 1.5Q

BK 1.5Q

BK 1.5Q

BK 1.5Q

BK 1.5Q

BK 1.5Q

1

+H3 A17a EARTH TRAVELLING DIRECTION Pump1 FORWARD

+H3 A17a EARTH TRAVELLING DIRECTION Pump1 BACKWARD

+H3 A17b

/90.E5

/90.E5

/91.C5

EARTH CAN: OUTPUT MODULE 1


EARTH TRAVELLING DIRECTION Pump

EARTH CAN: OUTPUTMODULE 2

+H3 A17b /91.C5

EARTH TRAVELLING DIRECTION Pump

EARTH CAN: OUTPUTMODULE 2

X1 48 A17b.GND_PWM3 D +H3 EARTH travel pump A17b /91.C5 EARTH CAN: OUTPUTMODULE 2

A17b.X1

X1 49 A17b.GND_PWM4 D +H3 EARTH SWIVEL ANGLE A17b /91.C5 EARTH CAN: OUTPUTMODULE 2

A16a.X1

41

A17b.X1

X1 51 A17b.GND_PWM10

49

A17b.X1

X1 41 A16a.24V D +H3 HIGH PRESSURE travel pump A16a /86.B5 SUPPLY 24V CAN: INPUT MODULE 1

A17a.X1

62

X1 50 A17b.GND_PWM9 D

48

A17b.X1

X1 67 A17a.GNDPWM16

51

A17a.X1


50

A17a.X1

67

E 66

E


D

PROJ: 8920980_003

B

C

A

WH 1Q

A17b.X1

8

20

TRAVELLING DIRECTION Pump2

A17a.PWM16 X1 25

24

A17a.X1

TRAVELLING DIRECTION Pump1 BACKWARD

A17b +H3

OUTPUTMODULE 2 CAN: /91.C2 PWMOutput3 (Bank A17b SWIVEL ANGLE travel pump1 +H3 A A17b.PWM3 X1 6

7

5

A A17a.PWM15 X1 24

A17b +H3

6

7

TRAVELLING DIRECTION Pump1 FORWARD

A17a +H3

OUTPUTMODULE 2 CAN: /91.C2 PWMOutput10 (Ban

9

A17a +H3

5

OUTPUTMODULE 2 CAN: /91.C2 PWMOutput9 (Bank

25

A

OUTPUT MODULE 1 CAN: /90.E1 PWMOutput16 (Bank4)

4

8

OUTPUT MODULE 1 CAN: /90.D1 PWMOutput15 (Bank4)

3

6

2

1

X1 62 A17a.GND_PWM7

+H3 A17a /90.D5

EARTH BUZZER EARTH CAN: OUTPUT MODULE 1

F


Änderung

Datum

1

Name

Datum


2

TRAVEL DIRECTIONS ; HYDRAULIC PUMP ; BUZZER ; PRESSURE HIGH PRESSURE TRAVEL PUMP


4

5

6

Ident.Nr. ZeichNr.

8920980 460 9010 00 003 7

Anlage Ort

003 8

Blatt von

54 114

2

1

3

4

5

6

7

OPTION GEROTOR STEERING

+H3

+H3

A17a.V_DO4 X1 38

A17a.DO4 X1 39

A17a.X1

38

A17a.X1

OUTPUTMODULE 2 CAN: /91.D2 PWMOutput15 (Ban A17b Vcc MVGEROTOR STEERING +H3 A A17b.PWM15 X1 24

A17b.X1

39

A

OUTPUT MODULE 1 CAN: /90.F1 digital output4 A17a back up alarm . OPTICAL

OPTION FUEL PREHEATING Kl.30

A4 =K +K2 F34

Kl.15

A4 =K +K2

E

24

OUTPUT MODULE 1 CAN: /90.F1 SUPPLY for digital output4 A17a supply for digital output 4 via. A4

8

A E

F14

20A YE

15A BU

F

L34

L14 GND

A4.X42

A4.X44

1

9

GND

WH,WH 1.5Q,1.5Q

RD 2.5Q

1

1 1

0

2

2

Y63.JPT

1

+H2 S204

BK 2.5Q

+H3 Y63

BK,BK 1.5Q,1.5Q

WH 1.5Q

2

1

XMSP6.14 +K2 C

WH 2.5Q

=B +B1 H59

1

Y63.JPT

2

10 10

=B +B1 H58

2

BK 1.5Q

D

A4 =K +K2 F49

1

E

2

WH 2.5Q

BK 1.5Q

A4.X43

8

BK 1.5Q

10A RD

+M

A17b.X1

X1 54 A17a.GND_DO4

A

R49 L49

+H3 A17b

/90.D5

/91.E5


E

T


+H3 A17a EARTH back up alarm. OPTICAL

GND

R13

66

A17a.X1

0

M

M10 0

EARTH GEROTOR STEERING EARTH CAN: OUTPUTMODULE 2

Kl.15

OPTION BACKUP ALARM VISUAL REDFLASHING Ersteller Datum Ausgabe

Zustand

R14 B

WH 1.5Q

PROJ: 8920980_003

+K6 X2.B X2.S

54

E

A

R34

WH 1.5Q


D


C

WH 1.5Q

B

WH 1.5Q

A

Änderung

Datum

1

Name

Datum


2

OPTION REFUELLING PUMP


Ident.Nr.

BACKUP ALARM; GEROTOR STEERING ; DIESEL PREHEATING 4

5

ZeichNr.

6

F

8920980 460 9010 00 003 7

Anlage Ort

003 8

Blatt von

55 114

OUTPUT MODULE 1 CAN: /90.C1 PWMOutput3 (Bank1) A17a BUCKET RETURNTODIG +H3 A A17a.PWM3 X1 6

A16a.X1

2

X33.X 2

36 WH 1Q

4

6

BK 1Q

BK 1Q

BK 1Q

BK 1Q

32

33 33

3

32

3

+K6 X1.S X1.B

31

D BK 1.5Q

WH 1Q 2 2

BK 1Q

WH 1Q

WH 1Q

+V B17.B B17.X

Y18

4

3

Y17

2

2

Y9

6

+K4 X33 0

1

+V1 Y9a 0

BK 1Q

A

BK 1Q

+H3 A17a.X1.48a

BK 1Q

/23.E6

10A RD

1

F11

BK 1Q

E

WH 1Q

Kl. 15

A4 =K +K2

*

C

5

1 OPT2 sw3

OPT3 sw5

31

3

2

3

OPT1 sw4

2

2

1

3

3

1

1

5

3

1 1

X33.X

2

1

B17.X_1 + +V B17 0 Ö B17.X_1

F.7

A4.X45

36

35 35 WH 1Q

WH 1Q

34

WH 1.5Q

1

WH 1Q

OPTION BUCKET RETURNTODIG VIA PUSHBUTTON SWITCH AM LH CONTROL LEVER

34

+K6 X1.B X1.S

WH 1Q

B32.X

A

B

1

WH 1Q

27 27

B17.X B17.B +V

WH 1Q

P

E

R11

X1 11 A16a.UI12 A +H3 A16a BUCKET RETURNTODIG /86.C2 ANALOGUE all-purpose input12 CAN: INPUT MODULE 1

GND


Datum

1

Name

Datum


2

X1 66 A16a.GND

+H3 A16a /86.E5

BUCKET RETURNTODIG EARTH CAN: INPUT MODULE 1

+H3 A16a /86.D5

LIFT KICKOUT EARTH CAN: INPUT MODULE 1

+H3 A17a /90.C5

4

5

6

EARTH BUCKET RETURNTODIG

EARTH CAN: OUTPUT MODULE 1 Ident.Nr. ZeichNr.

X1 49 A17a.GND_PWM4 D +H3 A17a EARTH LIFT KICKOUT /90.C5 EARTH CAN: OUTPUT MODULE 1

8920980 460 9010 00 003 7

A17a.X1

60

A17a.X1

X1 48 A17a.GND_PWM3 D

49

48

A17a.X1

X1 64 A16a.GND

FLOAT POSITION ; BUCKET RETURNTODIG LIFT KICKOUT


A16a.X1

X1 10 A16a.UI11 A +H3 LIFT KICKOUT A16a /86.C2 ANALOGUE all-purpose input11 CAN: INPUT MODULE 1

64

A16a.X1

10

A16a.X1

11

A16a.X1

66

L11

F

Zustand

A17a.X1.6a +H3

A17a.X1

WH 1Q

36

18

A16a.24V X1 38

A17a.X1

OUTPUT MODULE 1 CAN: /90.D1 PWMOutput5 (Bank2) A17a FLOAT POSITION +H3 A A17a.PWM5 X1 18

1

B15.X + +V3 B15 0 Ö B15.X

2

+K4 B32 0

7


B32.X

A17a.X1

38

A16a.24V X1 36

INPUT MODULE 1 CAN: SUPPLY 24V 24V LIFT KICKOUT

OUTPUT MODULE 1 CAN: /90.C1 PWMOutput4 (Bank1) A17a LIFT KICKOUT +H3 A A17a.PWM4 X1 7

WH 1Q

A16a +H3

+H3 A16a.X1

Kl. 15

E

+K6 X1.B X1.S


D

PROJ: 8920980_003

B

C

/86.F2

WH 1Q

A16a.X1

INPUT MODULE 1 CAN: /86.F2 SUPPLY 24V A16a 24V BUCKET RETURNTODIG

8

6

A INPUT MODULE 1 CAN: /86.D2 ANALOGUE all-purpose input5 A16a FLOAT POSITION +H3 A A16a.UI5 X1 18

7

18

6

WH 1Q

5

7

4

WH 1Q

3

1

2

1

X1 60 A17a.GND_PWM5

+H3 A17a /90.D5

EARTH FLOAT POSITION EARTH CAN: OUTPUT MODULE 1

Anlage Ort

003 8

Blatt von

56 114

F

/87.C2

A16b.X1

A

5

9

5

9

1

10

2 BK 1.5Q

1

=K+K4S23.X2:9

+K2 XMSP6.12

EARTH Additional equipment /91.C5 EARTH CAN: OUTPUTMODULE 2

+H3 A17c

RESERVE /92.C5 EARTH CAN: OUTPUT MODULE 3

+H3 A17c /92.C5

RESERVE EARTH CAN: OUTPUT MODULE 3

Verb.

47

1

+H3 A17b

A17a.X1

X1 47 A17a.GND_PWM2 D +H3 EARTH AHS A17a /90.C5 EARTH CAN: OUTPUT MODULE 1


Datum

1

Name

Datum


2

3

Ident.Nr.

ADDITIONAL EQUIPMENT 1;2;3 AND 4 QUICKCHANGE DEVICE


5

+H X1.B.65

E 1

OLE23

EARTH Additional equipment /91.C5 EARTH CAN: OUTPUTMODULE 2

X1 51 A17c.GND_PWM10

D

+H +K6 X1.B X1.S

F22 10A X44/5

+H3 A17b

A17c.X1

X1 52 A17c.GND_PWM11

51

A17c.X1


52

A17b.X1


53

A17b.X1

63 1

A17.X2 70 mm

+K2 XMSP6.12

WH 1.5Q

BK 1.5Q

S23.X2

BK 1.5Q 2

BK 1.5Q

BK 1.5Q

BK 1.5Q

BK 1.5Q

WH 1.5Q

1

S23.X1

10

2

BK 1.5Q

Y14.JPT

0 1

1

+V1 Y53 0

2

S23a 0

2

+H A17.X2

BK 1.5Q

Y12a.JPT

1

1

2

+K4 S23 0

* S23.X2 WH,WH 1.5Q,1.5Q

Y11a.JPT

S23.X1

B

C

*

1

2

2

Y14.JPT +H Y14 0

2

Y12.JPT

2

Y11.JPT

2

Y12a.JPT 1 +V Y12a 0

2

2

1

1

+V Y12 0

Y11a.JPT 1 +V Y11a 0

2

+V Y11 0

1

1

WH,WH 1.5Q,1.5Q

WH 1.5Q

1

WH 1.5Q

1

1

63

0

+K6 X1.S X1.B +K6

X1.B.64 +H

WH 1.5Q

1

1

64

5

+K2 V100

F

Zustand

INPUT MODULE 2 CAN: ANALOGUE Universal alarm buzzer A A16b.UI12 X1 11

WH 1.5Q

WH 1.5Q

WH 1.5Q

WH 1.5Q

PROJ: 8920980_003

Y12.JPT

1

52

E

Y11.JPT


D


C

WH 1.5Q

A17a.X1

B

A16b +K2

OUTPUT MODULE 1 CAN: /90.C1 PWMOutput2 (Bank1) A17a AHS +H3 A A17a.PWM2 X1 5

8

64

A17c.X1

7

WH 1.5Q

OUTPUT MODULE 3 CAN: /92.C2 PWMOutput10 (Bank3) A17c RESERVE +H3 A A17c.PWM10 X1 9

6

11

A17c.X1

5

WH 1.5Q

A17b.X1

10

A17b.X1

OUTPUT MODULE 3 CAN: /92.C2 PWMOutput9 (Bank3) A17c RESERVE +H3 A A17c.PWM9 X1 8

11

A

OUTPUTMODULE 2 CAN: /91.C2 PWMOutput12 (Bank A17b Additional equipment2 +H3 A A17b.PWM12 X1 11

4

8

OUTPUTMODULE 2 CAN: /91.C2 PWMOutput11 (Bank A17b Additional equipment1 +H3 A A17b.PWM11 X1 10

3

9

2

1

ZeichNr.

6

SEE ASSEMBLY INSTRUCTIONS!

F

8920980 460 9010 00 003 7

Anlage Ort

003 8

Blatt von

57 114

A17a.PWM2 X1 5

A4 =K +K2

E

=H +H3 A17bMasse Zusatzausrüstung1 Masse CAN: OUTPUTMODUL 2


=H +H3 A17bMasse Zusatzausrüstung2

=H+H/38.C5


X1 47 A17b.GND_PWM2

=H +H3 A17b GND Quick change device

=H+H/38.B5

MGND CAN: OUTPUTMODUL 2

=H +H3 A17a

=H+H/37.B5

5

A4.X45

*

XMSP6a +K2

F.12

2

X1 47 A17a.GND_PWM2 Masse AHS Masse CAN: OUTPUT MODUL 1

+K4 A21

/41.B4

BK 1.5Q

D

+K4 A21.X1

X1 3 A21.Kl15

Klemme 30 Versorgung CAN: HEIZ/KLIMAANLAGE

+K4 A21

/41.B4

2

RD 2.5Q

2

+K4 A21.X1

X1 2 A21.GND

+K4 A21

Klemme 15 Klemme 15 CAN: HEIZ/KLIMAANLAGE

/41.B4

Anspeisung Masse Anspeisung Masse CAN: HEIZ/KLIMAANLAGE

E



C

1

A4.X41

X1 1 A21.Kl30 47

=H +H3 A17a.X1

47

=H +H3 A17b.X1

53

52


=H+H/38.C5

=H +H3 A17b.X1

GND

B.5

+K4 A21.X1 =H +H3 A17b.X1

B

F19 10A rt

GND

BK 1.5Q

WH 1.5Q 1

+H Y14.JPT 1 +H Y14 0 2 Y14.JPT +H

BK 1.5Q

2

BK 1.5Q

2

F19a 20A ge

2

WH 1.5Q

+V1 Y53.JPT 1 +V1 Y53 0 2 Y53.JPT +V1

1

WH 1.5Q

+V Y12.JPT 1 +V Y12 0 2 Y12.JPT +V

1

=V +V Y11.JPT 1 +V Y11 0 2 Y11.JPT +V =V

BK 1.5Q


D


C

PROJ: 8920980_003

B

F19 Kl. 15.Kl. 15

A17a.X1 +H3 =H

Speisung Klimaanlage

/25.F1

A17b.X1 +H3 =H

+H3 =H

Kl. 15

A17b.PWM2 X1 5

12

A17b.X1 +H3 =H

+H3 =H

8

A

WH 1Q

A17b.PWM12 X1 11

OUTPUT MODUL 1 CAN: =H+H/37.B2 PWMAusgang2 (Bank1) A17a AHS

7

3

A17b.X1 +H3 =H

+H3 =H

6

1

A17b.PWM11 X1 10

OUTPUTMODUL 2 CAN: =H+H/38.B2 PWMOutput2 (Bank1) A17b Squick change device

5

5

+H3 =H

10

A

OUTPUTMODUL 2 CAN: =H+H/38.C2 PWMAusgang12 (Bank3) A17b Zusatzausrüstung2

11

OUTPUTMODUL 2 CAN: =H+H/38.C2 PWMAusgang11 (Bank3) A17b Zusatzausrüstung1

4

Kl. 30

3

5

2

1

Änderung

Datum

1

Name

Datum


2


Ident.Nr.

ADDITIONAL EQUIPMENT 1;2 QUICKCHANGE DEVICE 4

5

ZeichNr.

6

8920980 460 9010 00 003 7

F

Anlage Ort

003 8

Blatt von

58 114

2

1

3

4

5

6

7

8

OPTION WORKING BASKET WH 1.5Q

WH,WH 1.5Q,1.5Q

1

WH,WH 1.5Q,1.5Q

WH,WH 1.5Q,1.5Q

8

87a

B

WH 1.5Q

+K6 X2.S X2.B

9 9

S210.X2

BK 1.5Q

5 5

WH 1.5Q

1 1

+H2 XMSP1.e

2 1 0

+K4 S213

4

22

Ausgabe Änderung

Datum

1

Name

Datum

2

Y67.JPT BK 1.5Q

+H2 XMSP1.e

2


6

WH 1.5Q 2 2 WH 1.5Q

+H X48.S X48.B

25

A16c.X1

E

X1 25 A16c.UI16

+H3 A16c

basket function Not OFF 2 /88.E1 ANALOGUE all-purpose input16 CAN: INPUT MODULE 3

F

3

ZeichNr.

4

6

X1 6 A16c.UI3 A +H3 basket function Not OFF 1 A16c /88.C1 ANALOGUE all-purpose input3 CAN: INPUT MODULE 3

Ident.Nr.

FUNCTION WORKING BASKET 3

A16c.X1 2

BK 1.5Q

+H2 XMSP1.e

1

1

1

Y66.JPT

BK 1.5Q

Verb.

OLE20

+H2 XMSP1.e

1

+V1 Y67 0

2 2

Y65.JPT

1

Verb.

1

2

WH 1.5Q

+V1 Y66 0

2

+V1 Y65 0

Y67.JPT

1

2

1

WH 1.5Q

WH 1.5Q

WH 1.5Q

WH 1.5Q =K+K4S210.X2:9

Y66.JPT

1

BK 1.5Q =K+K4S210.X2:10

Y65.JPT

+K6 X2.S X2.B +K6

6

10

S210.X2

WH 1.5Q


22

WH 1.5Q

+K6 Splice.X30

10

3

S210.X1

Datum

21

D 3

Ersteller

+K4 S214

21

6

+K4 S210 0

*

1

WH 1.5Q

3

X2.S X2.B

WH 1.5Q

S210.X1

C

1

WH 1.5Q

+H X48.B X48.S 3

BK 1.5Q 5 5

WH 1.5Q

+K6 X2.S X2.B

2

+K6 X2.S X2.B

2

WH 1.5Q

WH,WH 1.5Q,1.5Q

2

WH,WH 1.5Q,1.5Q


WH,WH 1.5Q,1.5Q

A4.X43

WH 1.5Q

WH,WH 1.5Q,1.5Q WH 1.5Q

*

30

WH 1.5Q

WH 1.5Q

PROJ: 8920980_003

GND

85

7

8

K208

7

WH 1.5Q

F

Zustand

87

L50

OLE19

E

9

A

+K6 X2.B X2.S


D

K208 * =K +K2.RH

86

+K6 X2.B X2.S

R50

C

7

WH 1.5Q

10A RD

B

A16c.X1

9

F50

A16c.X1

+K X51.S 1/1 X51.B WH,WH 1.5Q,1.5Q

E

A

WH 1.5Q

Kl. 15

A4 =K +K2

INPUT MODULE 3 CAN: /88.C1 ANALOGUE all-purpose Input9 A16c basket function Mode 2 +H3 A A16c.UI9 X1 8 8

INPUT MODULE 3 CAN: /88.C1 ANALOGUE all-purpose Input4 A16c basket function Mode 1 +H3 A A16c.UI4 X1 7

A

WH 1.5Q

8920980 460 9010 00 003 7

Anlage Ort

003 8

Blatt von

59 114

2

1

3

4

5

6

7

8

OPTION PROPORTIONAL CONTROL 3. AND 4. CONTROL CIRCUIT

A16d.X1

INPUTMODUL 4 INPUTMODUL 4 CAN: CAN: /89.C2 ANALOGUE all-purpose Input2 /89.C2 ANALOGUE all-purpose Input9 A16d 3. CONTROL CIRCUIT Aktiv A16d OPTION +H3 +H3 A A A16d.UI2 A16d.UI9 X1 5 X1 8

BK 1Q

8

WH 1Q

WH 1Q

GND

9

8

1

2

3

4

5

6

4

2

5

3

9

8

1

2

3

4

5

6

1

+K4 S2a 0

cap. sensor feed 24V

S2.X1

Ausgabe Änderung

Datum

1

Name

Datum

2

GND

GND

Out

Vcc 5V

Out

GND

Ident.Nr.


ZeichNr.

4

E

F

EP 3. AND 4. CONTROL CIRCUIT 3

CAPACITIVE

Hall sensors + SW1 feed 5V U low (V) U mid (V) U high (V) Sensor 1 0,505 2,52 4,54 Sensor 2 0,556 2,521 4,539

state off 1,4....1,6mA not active state on 2,9....3,6mA active Donninger J. 26.03.2007 16:16 lbhhae0 27.03.2007 09:42

FNR

JOYSTICK SENSOR Vcc 5V

WH 1Q

Datum

NO

SW1

C

WH 1Q

Ersteller

NC

COM

WH 1Q

+K6 X1.B X1.S +K6

WH 1Q

+K6 X1.B X1.S +K6

HALL SENSOR 1. and 2.

V N R

Vcc 24V

WH 1Q

WH 1Q

7

S2a.X2

INPUT MODUL 2

/50.D2 ANALOGUE Universal A16b JOYSTICK REVERSE2 +K2 A16b.UI6 X1 19 A16b.X1 +K2

S 0 20mA

CAN:


7 INPUT MODUL 2

/50.D2 ANALOGUE Universal A16b JOYSTICK FORWARD2 +K2 A16b.UI5 X1 18 A16b.X1 +K2

WH 1Q

INPUT MODUL 1

CAN:

INPUT MODUL 1

=H+H/48.C2 ANALOGUE Universale=H+H/48.C2 ANALOGUE Universal A16a JOYSTICK FORWARD1 A16a JOYSTICK REVERSE1 +H3 +H3 A16a.UI9 A16a.UI10 X1 8 X1 9 A16a.X1 A16a.X1 +H3 +H3

D

SW1

A4.X44 E.4

F

Zustand

BU 1Q

RD 1Q A F15.3

C

2

1

BK 1Q

FUNKTION FNR

F15.2

E F15 10A RD

BU 1Q

/6.C3

F15.1

RD 1Q

/6.B2

2

WH 1Q

Kl. 15


A4 =K +K2

CAN:

E

A16d.X1

B

+K Splice.X70

CAN:

D

PROJ: 8920980_003

A16d.X1

C

A

54

A16d.X1

INPUTMODUL 4 CAN: EARTH GND Rocker Roller Cap A16d.GND X1 54

5

WH 1Q

B

A16d.X1

/89.D5

A16d +H3

10

A16d.X1

INPUTMODUL 4 CAN: /89.C2 ANALOGUE all-purpose Input11 A16d OUTPUT Hallsensor 2 +H3 A A16d.UI11 X1 10

6

A16d.X1

INPUTMODUL 4 CAN: /89.C2 ANALOGUE all-purpose Input3 A16d OUTPUT Hall sensor 1 +H3 A A16d.UI3 X1 6

7

A16d.X1

INPUTMODUL 4 CAN: /89.C2 ANALOGUE all-purpose input4 A16d CONTROL 5V +H3 A A16d.UI4 X1 7

WH 1Q

A16d.X1

36

A16d.X1

A16d.GND X1 59

/89.C5

A16d +H3

INPUTMODUL 4 CAN: SUPPLY 5V Roller Rocker Cap D A16d.5V X1 50 50

A16d.24V V X1 36

/89.D5

A16d +H3

INPUTMODUL 4 CAN: EARTH capacitive Joystick sensor

59

/89.F2

A16d +H3

INPUTMODUL 4 CAN: /89.C2 ANALOGUE all-purpose input1 A16d capacitive Joystick sensor +H3 A A16d.UI1 X1 4 4

A

INPUTMODUL 4 CAN: SUPPLY 24V capacitive Joystick sensor

5

6

8920980 460 9010 00 003 7

Anlage Ort

003 8

Blatt von

60 114

2

1

3

4

5

6

A

+K2 Kl.15 1

BK 1Q

=K +K2.RH

+K2 XMSP201

+V1 S213 0

2

9

1

B213.X =V + +V2 B213 0 S B213.X

* 30

85

+K2 K213

1 0

0 10

*

87a

87

86

BK

WH,WH 1Q,1Q

C

BU

2

3 B213.X

S213.X2

BK 1Q

S213.X1

10

5

5

1 BN

BK 1Q


+K2 F213 7,5A HBR

1

S213.X2

3

1

9

S213.X1

1

2

2

=K +K2.RH

XMSP201 +K2

4

D

WH 1Q

1

=K XMSP201

WH 1Q

WH 1Q


WH 1Q

1

Y68.JPT

E

1

+V1 Y68 0

BK 1Q

Y68.JPT

2

2

=K +K2 XMSP201


B

WH 6Q

PROJ: 8920980_003

B

E

WH 1Q

WH,WH 1Q,1Q

WH 1Q

D

8

OPTION CUTOFF TILT CYLINDER

A

C

7

Änderung

Datum

1

Name

Datum


2

3

F Ident.Nr.

CUTOFF TILT CYLINDER Werk Bischofshofen GmbH 3

ZeichNr.

4

5

6

8920980 460 9010 00 003 7

Anlage Ort

003 8

Blatt von

61 114

/96.B2

HEAT/AIR CONDITIONING SYSTEM

/96.B2

X1 2 A21.GND A SUPPLY EARTH SUPPLY EARTH CAN:


28

A21.X1

29

26

27

10

A21 +K4

/68.E8

RD 0.5Q 6 6

5 5 1

+K4 X22b.S X22b.B

C

BU 0.75Q

RD 0.75Q

WH 2.5Q

1

1 °C

2

XB39 B39.X Y22.X

B42.X +K1 B42

1

0 2

B42.X

2

WH 2.5Q

53

+K6 B39 0

1

B39.X XB39

2

4

62

+K4 X22b.S X22b.B

BU 0.5Q

BU 0.75Q

RD 0.75Q

WH 1.5Q

B

D

1

62 WH 1.5Q

+K4 A21

2

3


+K6 X2.B X2.S

F19 Kl. 15.Kl. 15

/96.B2

+K4 A21

X1 3 A21.Kl15 A CLAMP 15 CLAMP 15 CAN:

A21.X1

/96.D2

2

E

1

/62.D2

+K4 A21

61 18bar

WH 1Q

WH 1.5Q

WH 1.5Q /62.E4

X1 1 A21.Kl30 A CLAMP 30 SUPPLY CAN:

A21.X1

+K6 X2.S X2.B

H

4

F19 Kl. 15.Kl. 15

WH 1Q

RD 2.5Q

A21.X1

1

N

B27.X

A21.X1

3 P

+K6 X1.B X1.S

A21 +K4

2

F.12

2

A21.X1

/96.D2

A

CAN: SUN SENSOR SUN SENSOR A A21.PME X1 28

1

XMSP6a +K2

A21 +K4

WH 0.75Q

B.5

A4.X45

L

/96.D2

CAN: SUN SENSOR+ SUN SENSOR+ A A21.PME X1 29

WH 1Q

12

*

+H B27

A21.X1

2


5

B27.X

1

GND

A4.X41 +K2

X1.S X1.B

Kl.15

GND

A21 +K4

CAN: SENSOR_ambient temp. SENSOR_ambient temp. A A21.PME X1 27

CAN: SENSOR_ambient temp. SENSOR_ambient temp A A21.PME X1 26

1

L19

/96.D2

HEAT/AIR CONDITIONING SYSTEM HEAT/AIR CONDITIONING SYSTEM


WH 2.5Q

L19A


8

WH 2.5Q

5 WH 1Q

R19

1

E


D

A

R19A

7

+M Y22 0

REMOVE WIRE JUMPER XB39 WHEN MOUNTING B39!

/68.E2

PROJ: 8920980_003

A

+K6 X1.S X1.B

60

B

10A RD

60

F19

20A GE

A21 +K4

6

CAN: compressor clutch compressor clutch A A21.PME X1 10

A21.X1

WH 1Q

F19A

A21.X1

E


/96.C2

3

E

C

HEAT/AIR CONDITIONING SYSTEM CAN: /96.B2 SWITCH HIGH&# A21 SWITCH HIGH&# +K4 A A21.PME X1 5

Kl. 15

Kl. 30

A4 =K +K2

5

61

AIR CONDITIONING SYSTEM

A

4

Kl.15

3

53

2

1

OPTION AIR CONDITIONING AUTOMATIC

F


Änderung

Datum

1

Name

Datum


2



4

5

6

Ident.Nr. ZeichNr.

8920980 460 9010 00 003 7

Anlage Ort

003 8

Blatt von

62 114

2

1

3

4

5

6

7

8

A

A

A21.X1

A21.PME X1 21

A21.X1

+K4

A21.PME X1 20

A21.X1

HEIZ/KLIMAANLAGE CAN: Sonnensensor Sonnensensor

A21.PME X1 29

A21.X1

A21.PME X1 28

A21.X1

28

A21.X1

A21.PME X1 26

A21 +K4

29

A21.X1 +K4

A21.PMES X1 27

+K4

/41.E4

HEIZ/KLIMAANLAGE CAN: Sonnensensor+ /41.E4 A21 Sonnensensor+

WH 1Q

WH 1Q

A21.PME X1 10

+K4

A21 +K4

HEIZ/KLIMAANLAGE CAN: Fühler_Innenr.1 Fühler_Innenr.1

20

A21.X1 +K4

5

A21.X1 +K4

A21.PME X1 6 6

A21.PME X1 5

+K4

/41.D4

21

+K4

HEAT-/AIR CONDITIONING SYSTEM HEAT-/AIR CONDITIONING SYSTEM HEIZ/KLIMAANLAGE CAN: CAN: CAN: /41.D4 Sensor_ambient temp.+ /41.D4 Sensor_ambient temp. /41.D4 Fühler_Innenr.1 + A21 Sensor_ambient temp.+ A21 Sensor_ambient temp. A21 Fühler_Innenr.1 +

26

+K4

10

+K4

HEIZ/KLIMAANLAGE CAN: /41.C4 Kompressorkupplung A21 Kompressorkupplung

27

HEIZ/KLIMAANLAGE HEIZ/KLIMAANLAGE CAN: CAN: /41.B4Schalter HochNiederdruck /41.C4 Schalter Mitteldruck A21Schalter HochNiederdruck A21 Schalter Mitteldruck

W160 +WL040 BU

X1.S +K6

2

1 2

B42.X +K1

1

=M +M Y22

F19 Kl. 15.Kl. 15

2 B40.X

1

1

62

=M +M Y22.X

°C

D

2

B40

+K1 B42

2

WH 1Q

1

2 B39.X

+K1 B42.X

1

B40.X

1

B39.X 1 =H +K6 °C B39

62

W156 +WL037 BU

W156 +WL037 RD

W156 +WL038 BU

W156 +WL038 RD

3 3

2

W160 +WL040 RD

WH 1Q

=H +H Splice.X4

E



C

2

WH 1Q

WH 1Q

4

2 B27.X +H

X2.S X2.B

/24.E7

E

4 B27.X +H


D


P

+K6 X2.S X2.B

2

+K6 X2.S X2.B +K6

1

1

+H B27

1

3

W156 +WL039 BU

WH 1Q

WH 1Q

+H B27.X

1

WH 1Q 3

+H B27.X

61 61

60

+K6 X1.S

60

PROJ: 8920980_003

C

B

+K6 X1.S

W156 +WL039 RD

B

Änderung

Datum

1

Name

Datum


2



4

5

6

Ident.Nr. ZeichNr.

8920980 460 9010 00 003 7

F

Anlage Ort

003 8

Blatt von

63 114

2

1

3

4

5

6

7

8

A

A

E

A21a +K4

A21a.X2


A21a +K4

CAN: Sensor2 (icing) Sensor2 (icing) A A21a.38 X2 38

A21a.X2

38

CAN: Sensor2+ (icing) Sensor2+ (icing) A A21a.37 X2 37

B

WH 1.5Q

A21a.X2


37

A21a +K4

CAN: Sensor1 (icing) Sensor1 (icing) A A21a.36 X2 36

WH 1.5Q

A21a.X2


36

A21a +K4

CAN: Sensor1+ (icing) Sensor1+ (icing) A A21a.35 X2 35

WH 1.5Q

A21a.X2


35

42

A21a.X2

A21a +K4

CAN: diagnostics FAN diagnostics FAN A A21a.16 X2 16

WH 1.5Q

A21a +K4


16

CAN: Logic output(010V) Logic output(010V) A A21a.2 X2 2

WH 1Q

BK 2.5Q

PROJ: 8920980_003


C


D

1

+K4 M5

3

1

2

3

1 +K4 B26a

°C

°C

6

2

M5.X

+K4 B26 1

D

A21a.X2


C

A21a +K4

28

A21a.X2

B

CAN: GND FAN GND FAN A A21a.42 X2 42

RD 2.5Q

A21a +K4


WH 1Q

CAN: 24V FAN 24V FAN A A21a.28 X2 28

2


4

2

6

5

2

M

E

FAN MOTOR

F


Änderung

Datum

1

Name

Datum


2

MOTOR AND SENSOR ICE UP PROTECTION


4

5

Ident.Nr. ZeichNr.

6

8920980 460 9010 00 003 7

Anlage Ort

003 8

Blatt von

64 114

2

1

3

4

5

6

7

8

A

A

E

9

CAN: VMC2 clockwise rotation VMC2 clockwise rotation A A21a.8 X2 8

BK 0.5Q

BK 0.5Q

BK 0.5Q

12

A21a.X2

B

8

A21a +K4

BK 0.5Q

BK 0.5Q

A21a.X2


CAN: VMC2 potentiometer tap VMC2 potentiometer tap A A21a.12 X2 12

A21a.X2

CAN: VMC2 counter clockwise rotation VMC2 counter clockwise rotation A A21a.9 X2 9

A21a +K4

10

11

A21a +K4

BK 0.5Q

A21a.X2

BK 0.5Q

BK 0.5Q

A21a +K4

A21a.X2 HEAT/AIR CONDITIONING SYSTEM

CAN: VMC1 clockwise rotation VMC1 clockwise rotation A A21a.3 X2 3

BK 0.5Q

PROJ: 8920980_003

A21a.X2

A21a +K4


C


1

2

3

4

6

M14.X

6

4

5

3

4

6

3

2

2

1

1

4

M11.X

3

D

1

D

A21a.X2


C

A21a +K4

CAN: V ref VMC2 V ref VMC2 A A21a.10 X2 10


CAN: VMC1 potentiometer tap VMC1 potentiometer tap A A21a.7 X2 7 7

B


CAN: GND VMC2 GND VMC2 A A21a.11 X2 11

3


A21a.X2


A21a +K4

4

A21a.X2

CAN: VMC1 counter clockwise rotation VMC1 counter clockwise rotation A A21a.4 X2 4

A21a +K4

BK 0.5Q

A21a.X2


CAN: V ref VMC1 V ref VMC1 A A21a.5 X2 5

A21a +K4

6

A21a +K4


CAN: Masse VMC1 Masse VMC1 A A21a.6 X2 6

5


5

6

E

+K4 M11

+K4 M14

M

M

URECIRCULATED AIR FLAP VMC2

WATER VALVE VMC1

F


Änderung

Datum

1

Name

Datum


2


Ident.Nr.

WATER VALVE VMC1 RECIRCULATED AIR FLAP VMC2 4

5

ZeichNr.

6

8920980 460 9010 00 003 7

Anlage Ort

003 8

Blatt von

65 114

2

1

3

4

5

6

7

8

A

A

E

23

A21a.X2

HEAT/AIR CONDITIONING SYSTEM CAN: VMC4 clockwise rotation A21a VMC4 clockwise rotation +K4 A A21a.22 X2 22

B

BK 0.5Q

22

BK 0.5Q

BK 0.5Q

26

A21a.X2

BK 0.5Q

HEAT/AIR CONDITIONING SYSTEM CAN: VMC4 counter-clockwise rotation A21a VMC4 counter-clockwise rotation +K4 A A21a.23 X2 23

24

25

18

A21a.X2

BK 0.5Q

BK 0.5Q

BK 0.5Q

BK 0.5Q

A21a.X2

HEAT/AIR CONDITIONING SYSTEM CAN: VMC4 potentiometer tap A21a VMC4 potentiometer tap +K4 A A21a.26 X2 26

BK 0.5Q

A21a.X2

HEAT/AIR CONDITIONING SYSTEM CAN: V ref VMC4 A21a V ref VMC4 +K4 A A21a.24 X2 24

C


BK 0.5Q

A21a.X2


21

PROJ: 8920980_003

A21a.X2

HEAT/AIR CONDITIONING SYSTEM CAN: GND VMC4 A21a GND VMC4 +K4 A A21a.25 X2 25

5

1

2

3

4

6

M16.X

6

4

4

3

3

2

4

2

1

3

1

6

2

M15.X

1

D


D

A21a.X2

HEAT/AIR CONDITIONING SYSTEM CAN: VMC3 counter clockwise rotation A21a VMC3 counter clockwise rotation +K4 A A21a.18 X2 18

17


B

C

A21a.X2

20

A21a.X2

HEAT/AIR CONDITIONING SYSTEM CAN: V ref VMC3 A21a V ref VMC3 +K4 A A21a.19 X2 19 19


5

6

E

+K4 M15

+K4 M16

M

FOOT FLAP VMC3

M

MIDDLE FLAP VMC4

F


Änderung

Datum

1

Name

Datum


2


Ident.Nr.

FOOT FLAP VMC3 MIDDLE FLAP VMC4 4

5

ZeichNr.

6

8920980 460 9010 00 003 7

Anlage Ort

003 8

Blatt von

66 114

2

1

3

4

5

6

7

8

A

A

E

40

39

31

A21a.X2

WH 1Q WH 1Q

B

3

4

1

2

3

4

+K4 M17

6

2

M17.X

1

1 2

WH 1Q WH 1Q


C

1 2

BK 0.5Q

BK 0.5Q

HEAT/AIR CONDITIONING SYSTEM CAN: temp.sensor(air cond. aut.) A21a temp.sensor(air cond. aut.) +K4 A A21a.40 X2 40

BK 0.5Q

A21a.X2

BK 0.5Q

BK 0.5Q

A21a.X2


34

PROJ: 8920980_003

A21a.X2

HEAT/AIR CONDITIONING SYSTEM CAN: temp.sensor+(air cond. aut.) A21a temp.sensor+(air cond. aut.) +K4 A A21a.39 X2 39

+K4 X75.S X75.B


D

A21a.X2

HEAT/AIR CONDITIONING SYSTEM CAN: VMC5 counter clockwise rotation A21a VMC5 counter clockwise rotation +K4 A A21a.31 X2 31

30


B

C

A21a.X2

33

A21a.X2

HEAT/AIR CONDITIONING SYSTEM CAN: V ref VMC5 A21a V ref VMC5 +K4 A A21a.32 X2 32 32


5

D

1

6

+K4 B40 0

°C

E

2

M

HEAD FLAP VMC5

F


Änderung

Datum

1

Name

Datum


2

HEAD FLAP VMC5 TEMPERATURE SENSOR AUTOMATIC AIR CONDITIONING


4

5

6

Ident.Nr. ZeichNr.

8920980 460 9010 00 003 7

Anlage Ort

003 8

Blatt von

67 114

E

Zustand Ersteller

Datum

Ausgabe

Änderung Datum

1 Name Datum

BK 2.5Q

2


3

MP

4

A4.X48 A4.X48

+K6 X2.S X2.B

1,5 Ohm 70 Watt

M13.X

+H3 M13 0 M13.X

+K6 X2.B X2.S

+K2 XMSP6c

VENTILATOR CONDENSER INTEGRATED


5 6

Kl.15

A4.X56

4

87a

MP

A B

Ident.Nr. ZeichNr.

6

9

6

30 86

K245 0 V49

87 85

V34

GND

8920980

460 9010 00 003 7

WH 2.5Q

86

I.6

A4 =K +K2 I.9

I.4

3

A4.X48

/62.A4

MP I.5

V33

5

V50

WH 2.5Q

V32

85

51

GND

87

51

0

WH 2.5Q

K244

B

L13

I.7

A4 =K +K2

7

R13 87a

A4.X48

C

WH 2.5Q

30

WH 2.5Q

Kl. 15 I.3

A4.X48

50

A

I.2

15A BU

5

50

* 2

F13

I.1

E

4

52

WH 2.5Q

2

3

A

WH,WH 2.5Q,2.5Q

2

52

WH 2.5Q

A4 =K +K2

BK 2.5Q

Kl.15

X1 8 A21.PME A +K4 FAN_interior. A21 /96.C2 FAN_interior.2 + CAN: HEAT/AIR CONDITIONING SYSTEM /62.E4

A21.X1 WH 2.5Q

WH 1.5Q

PROJ: 8920980_003

B

8

D We reserve all rights in this document and in the informa tion contained therein. Reproduction, use or disclosure to third parties without express authority is strictly forbidden. © LIEBHERR WERK EHINGEN

C


1 7 8

A A

A4.X48

B

V35

GND

MP

A4.X48 C

D

M

C

E

9

F F

Anlage Ort

003 8

Blatt von

68 114

2

1

3

4

5

6

7

8

RETROFIT KIT CONDENSER FAN A

A4.X48.

=K +K2.RH

I.5

5

C

1

1

1

WH 1.5Q

WH 1.5Q 1 WH 1.5Q

M13.X 1,5 Ohm 70 Watt

1

1

4

2 2

B

M

53a 53a

E

1

WH 1Q

D

B27.X.2 +H =H

+K6 X2.B* X2.S*

C

M13.X BK 1.5Q

ONLY USE WITH FLUFF FILTER OPERATION !

3 +H B27 P

A

=H +H3a M13 0

LOCATE SPLICE CLOSE TO X2.S:1!

X2.S.51 X2.B.51

WH 1.5Q

10

WH 1.5Q

+K2 XMSP.20

+K Splice;.X4 1

A4.X48.

2

WH 1.5Q

WH 1.5Q

BK 1.5Q

WH 1.5Q


+K X1.S.61a X1.B

MP I.7

MP

X2.S.50 X2.B.50 +K6 2

WH 1.5Q

WH 1.5Q GND

10022680

0

V35

1

V34

61

87

WH 1.5Q

87a

WH 1.5Q

31

87a

A21.PME X1 10 A21.X1 +K4


X2.S.52 =M +M Y22.X

1

E

85

0

A4.X48.

+K6 X2.S X2.B +K6

87

B

B

15

X45.B

D

86

K245

X45.S

HEIZ/KLIMAANLAGE CAN: Kompressorkupplung Kompressorkupplung

30

C

WH,WH 1.5Q,1.5Q

10008761 0

/62.C2 A21 +K4

A4.X48.

V49

WH 1.5Q

=K +K2. K248

2

WH 1.5Q

2

WH 1.5Q

PROJ: 8920980_003

C

A4.X56a

*

X45.S 30

WH,WH 1.5Q,1.5Q

*

1

B GND

*

A4 =K +K2

7

R13 L13

1

A

6

+K2 X45.B

I.6

15A BU

A

F13

9

E

I.9

WH,WH 1.5Q,1.5Q

A4 =K +K2

WH 1.5Q

Kl. 15

1

A

1

=M +M Y22

F


Änderung

Datum

1

Name

Datum


2

Ident.Nr.

VENTILATOR CONDENSER RETROFIT KIT Werk Bischofshofen GmbH 3

ZeichNr.

4

5

6

8920980 460 9010 00 003 7

Anlage Ort

003 8

Blatt von

69 114

2

1

3

4

5

6

7

8

DIAGNOSTIC PLUG DIESEL ENGINE A

A

A700D.RXD X2 37

A700D.GND X2 38

A700D.X2

38

A700D.X2

/93.D6

A700D +M

DIAGNOSTIC LEAD AIR CONDITIONING SYSTEM

A700D.TXD X2 36

A700D.X2

X.M7a.S 1/2 2/2 +K2

5 3 2

/93.D6

A700D +M

ENGINEECU EMIT DIAGNOSIS

36

/93.D6

A700D +M

ENGINEECU RECEIVE DIAGNOSIS

37

ENGINEECU EARTH DIAGNOSIS

X.RS232.B +K

E

BK 0.5Q BU 0.5Q RD 0.5Q

WH 1.5Q BK 1.5Q

BK 1Q BU 1Q RD 1Q


C

*

* =K 11 12

*

22

+K4 A21.XB *29

+K4 A21.XB

1

+M X60a

3 2

WH 1Q

BK 1Q

D

A B C D E F G H I

D


C

B

PROJ: 8920980_003

B

E

10290843 0 *9

F


Änderung

Datum

1

Name

Datum


2


Ident.Nr.

DIAGNOSTIC PLUG MOTOR CONTROL AND AIR CONDITIONING SYSTEM 4

5

ZeichNr.

6

8920980 460 9010 00 003 7

Anlage Ort

003 8

Blatt von

70 114

A A16c.UI1 X1 4

A16b.UI16 X1 25

A16b.X1

A16c.X1

5

BK5 1Q

BK 1Q 2

OG

GY

WH

RD

C

5

4 signal

signal

D

BK 1Q

BK6 1Q

3

+H3 A16c /88.D1

X1 16 A16c.GND_logic A EARTH LOGICAL PART EARTH LOGICAL PART CAN: INPUT MODULE 3

+H3 A16c /88.E1

SUPPLY 24V SUPPLY 24V CAN: INPUT MODULE 3

A16b.X1

X1 31 A16c.GND

+H3 A16c

+K2 A16b


/88.E1

A16c.X1

X1 67 A16b.GND

/87.E5

E 67

A16c.X1

X1 30 A16c.24V

67

A16c.X1

31

A16c.X1

X1 2 A16c.24V_logic A +H3 SUPPLY EARTH A16c /88.C1 SUPPLY 24V LOGICAL PART CAN: INPUT MODULE 3

30

A16c.X1

16

BK 1.5Q

X2.S X2.B +K6

67

67

BK 1.5Q

WH 1.5Q

BK 1.5Q

WH 1.5Q

BK 1Q

61

X2.S X2.B +K6

6

B202.X

BK3 1Q

61

62

X2.S X2.B +K6

62

63

X2.S X2.B +K6

64

X2.S X2.B +K6

63

64

3

B202.X

+

BK

BN

BK 1.5Q

WH 1.5Q

BK 1.5Q

WH 1.5Q

B202.X

2

+K4 B202

B

BK4 1Q

BK 1Q BK2 1Q

BK 1Q BK1 1Q 1

12

/42.E1 Kl.15

1

+

2

E

XMSP6.11 +K2

1

1


D

A4.X44

B202.X


C

PROJ: 8920980_003

GND

XMSP6.10 +K2

A16c.X1

66

+K6 X2.B X2.S

L46

JOYSTICK STEERING SENSOR 2 re

66

R46

A

BK 1Q

A

/88.E1

A16c +H3

A16c.24V DO1 X1 33

WH 1.5Q

A16b.X1

JOYSTICK STEERING SENSOR 2

INPUT MODULE 3 CAN: SUPPLY 24V

33

10A RD

X56/11 F34/5A

B

A16b.24V X1 36

A16c +H3

65

F46

JOYSTICK STEERING SENSOR 1

INPUT MODULE 3 CAN: /88.C1 ANALOGUE all-purpose input1

6

E

/87.E2

A16b +K2

INPUT MODULE 2 CAN: ANALOGUE Universal

8

4

/87.F2

A16b +K2

INPUT MODULE 2 CAN: SUPPLY 24V VCC JOYSTICK STEERING

7

65

A

Kl. 15

6

4

A4 =K +K2

5

WH 1.5Q

4

25

3

36

2

1

X1 67 A16c.GND

+H3 A16cJOYSTICK STEERING SENSOR 2 re

GND JOYSTICK STEERING EARTH CAN: INPUT MODULE 2

/88.E5

EARTH CAN: INPUT MODULE 3

F


Änderung

Datum

1

Name

Datum


2

SUPPLY INPUT MODULE 3; JOYSTICK STEERING Werk Bischofshofen GmbH 3

Ident.Nr. ZeichNr.

4

5

6

8920980 460 9010 00 003 7

Anlage Ort

003 8

Blatt von

71 114

A A16c.UI2 X1 5

INPUT MODULE 3 CAN: SUPPLY 24V 24V Joystick ARMREST

A16c.24V V X1 36

A16c.X1

OUTPUTMODULE 2 CAN: /91.D2 PWMOutput13 (Bank A17b JOYSTICK STEERING LEFT +H3 A A17b.PWM13 X1 22

A16c.24V X1 37

A16c.X1

7

A17b.X1

8

OUTPUTMODULE 2 CAN: /91.D2 PWMOutput14 (Bank A17b JOYSTICK STEERING RIGHT +H3 A A17b.PWM14 X1 23

A17b.X1

OUTPUTMODULE 2 CAN: /91.E2 PWMOutput16 (Bank A17b Savety MV Joy

A

+H3 A17b.PWM16 X1 25

A17b.X1

WH 1.5Q

WH 1.5Q

68 68

60

WH 1.5Q

B

+K6 X2.B X2.S

BK 1Q BK9 1Q

C

X1 38 A16c.24V

+H3 A16c

PRESSURE standard steering1 /88.D5 EARTH CAN: INPUT MODULE 3

+H3 A16c Vcc PRESSURE standard steering 1 /88.F1

SUPPLY 24V CAN: INPUT MODULE 3

1

1

Y64.JPT

2

1 2

Y52.AF2

2

BK 1.5Q

BK 1.5Q

70

+K6

BK 1Q

X1 23 A16c.UI14 A +H3 Joystick ARMREST A16c /88.D1 ANALOGUE all-purpose Input14 CAN: INPUT MODULE 3

A16c.X1

A17b.X1

X1 65 A16c.GND

+H3 A16c /88.E5

EARTH Joystick armrest EARTH CAN: INPUT MODULE 3

A17b.X1


+H3 A17b

EARTH JOYSTICK STEERING /91.D5 EARTH CAN: OUTPUTMODULE 2

A17b.X1


+H3 A17b

EARTH JOYSTICK STEERING /91.E5 EARTH CAN: OUTPUTMODULE 2

67

E 65

A16c.X1

Y51.AF2

2

D

WH 1Q

X1 22 A16c.UI13 A +H3 Joystick activation A16c /88.D1 ANALOGUE all-purpose Input13 CAN: INPUT MODULE 3

0

2

2

0 3

1

+H3 Y64 0

BK 1.5Q

BK 1Q BK11 1Q

A16c.X1

22

A16c.X1

X1 64 A16c.GND

38

A16c.X1

+H3 Y52

70

BK 1Q 59

X2.S X2.B +K6

WH 1.5Q

X2.S X2.B +K6

69

59

BK10 1Q

2

8

8

BU

BK8 1Q

B202.X

WH 1Q

B201.X

BK 1Q

BK

Y64.JPT

1

+H3 Y51

65

0

A

Y52.AF2

1

3

S202

+

Y51.AF2

BN

69

+H3 P B201 U 0 B

+K4

B200.X 1 + +K4 B200 0 S 2 B200.X B200.X

BK 1Q


s

7

64

B202.X C

23

B201.X

7

1

BK 1Q BK7 1Q

60

WH 1Q

+K6 X2.B X2.S

64

E


D

PROJ: 8920980_003

B

C

WH 1.5Q

WH 1Q

A16c.X1

/88.F1

A16c +H3

6

25

Joystick PRESSURE standard steering 1

/88.F1

A16c +H3

5

23

A16c +H3

5

A

INPUT MODULE 3 CAN: SUPPLY 24V 24V Joystick activation

36

INPUT MODULE 3 CAN: /88.C1 ANALOGUE all-purpose Input2

4

22

3

37

2

1

X1 67 A17b.GNDPWM16

+H3 A17b /91.E5

GND Savety MV Joy EARTH CAN: OUTPUTMODULE 2

F


Änderung

Datum

1

Name

Datum


2

Ident.Nr.

JOYSTICK STEERING Werk Bischofshofen GmbH 3

ZeichNr.

4

5

6

8920980 460 9010 00 003 7

Anlage Ort

003 8

Blatt von

72 114

A16b24V Joystick activation +K2 =K A16b.24V

E F46 10A RD

INPUT MODULE 2 CAN: =K+K/49.E2

+K2 =K

X56/11 F3475A

A16b.X1 +K2 =K

E

BK 1Q 5 WH

C

BN

RD

WH

RD

6

BK 1Q BK6 1Q

6

3

3

BK 1Q

61

B

+

D

67

A16c.X1

+H3 A16c

X1 2 A16c.24V_logic A A Feed GND

=H+H3/58.C1 Supply 24V Logic part CAN: INPUT MODUL 3

Feed 24V Supply 24V CAN: INPUT MODUL 3

A16b.X1

X1 31 A16c.GND

+H3 A16c

=H+H3/58.E1

67

A16c.X1

X1 30 A16c.24V

31

A16c.X1

X1 16 A16c.GND_logic A +H3 +H3 Feed GND Logic part A16c A16c =H+H3/58.D1 GND Logic part =H+H3/58.E1 CAN: INPUT MODUL 3

30

A16c.X1

2

A16c.X1

16

BK 1.5Q

X2.S X2.B +K6

67

67

BK 1.5Q

WH 1.5Q

BK 1.5Q

WH 1.5Q

X2.B X2.S +K6

5

4 signal

signal

BK3 1Q

61

62

X2.S X2.B

62

63

X2.S X2.B

63

64 64

X2.S X2.B

A

BK4 1Q

BK 1Q 4

2

BN

BK 1.5Q

WH 1.5Q

BK 1.5Q

WH 1.5Q


=K +K4 S202 B_JOYSTICK

BK5 1Q

BK2 1Q 1

2

1

XMSP6.11 +K2 =K

+

X2.S X2.B +K6

A16c.X1

66 65

BK 1Q

BK 1Q

1

BK1 1Q

12

=H+H/19.E1 Kl.15.2

PROJ: 8920980_003

XMSP6.10 +K2 =K

X1 67 A16b.GND

+K2 A16b GNDJoystick

Feed GND MGND CAN: INPUT MODUL 3

=K+K/49.E5

steering left

MGND CAN: INPUT MODUL 2

X1 67 A16c.GND

+H3 A16c GND Joystick

=H+H3/58.E5

E

steering Sensor 2 re

MGND CAN: INPUT MODUL 3



A16c.X1

A4.X44 +K2 =K

1


D

GND

INPUT MODUL 3 CAN:

=H+H3/58.C1 analogue universal input1 A16c Joystick steering sensor 2re Vcc Joystick steering sensor 2 ree +H3 +H3 A A16c.24V DO1 A16c.UI1 X1 33 X1 4

66 65

A

B

C

A16b.UI16 X1 25

X1 36

A16b.X1 +K2

INPUT MODUL 3 CAN: Supply 24V

6 =H+H3/58.E1 A16b Joystick steering transmitter1 A16c analogue all-purpose Input16

8

4

=K+K/49.F2

INPUT MODULE 2 CAN: Supply 24V

7

33

Kl. 15

6

WH 1.5Q

A4 =K +K2

5

WH 1.5Q

A

4

25

3

36

2

1

Änderung

Datum

1

Name

Datum


2

SUPPLY INPUT MODULE 3; JOYSTICK STEERING Werk Bischofshofen GmbH 3

Ident.Nr. ZeichNr.

4

5

6

8920980 460 9010 00 003 7

F

Anlage Ort

003 8

Blatt von

73 114

WH 1Q

25

A17b.X1

A

WH 1.5Q

WH 1.5Q

WH 1.5Q

B

2

2

BK 1Q

1

1

2

2

2

3

2

2

3

1

+H3 Y64 YVENTIL_2 0

BK 1Q

A17b.X1

BK 1.5Q

BK 1.5Q

A17b.X1


A17b.X1

X1 67 A17b.GNDPWM16

+H3 A17b

+H3 MasseGNDJoystick steering right A17b =H+H/51.E5

=H+H/51.E5

67

A16c.X1

X1 23 X1 22 X1 65 X1 64 A16c.UI14 A16c.UI13 A16c.GND A17b.GND_PWM13 A +H3 A +H3 +H3 +H3 Joystick Armrest A16c Joystick activation GND Joystick armrest GND Joystick steering left A16c A16c A17b aanalogue universal input14 =H+H3/58.E5 =H+H3/58.D1 1analogue all-purpose Input13=H+H3/58.D1 3 MGND =H+H/51.D5 MGND CAN: CAN: CAN: CAN: INPUT MODUL 3 INPUT MODUL 3 INPUT MODUL 3 OUTPUTMODUL 2

65

70 70

BK 1.5Q

69

D

BK 1Q

64

A16c.X1

23

22

WH 1.5Q

WH 1Q

59

59

X2.S X2.B +K6

69

8

BK 1Q

8

0

A16c.X1

BU

+H3 Y52 0

C

7

+K4 S202

X2.S X2.B +K6

1

+H3 Y51 0

65

7

2

BK

1

2

BN

1

1

60

1 =K + +K4 B200 0 S 2

BK 1Q


X2.B X2.S +K6

60

WH 1Q

+H3 Splice.X11

BK 1Q

2

68

X2.B X2.S +K6

E

Reserve MGND CAN: OUTPUTMODUL 2

MGND CAN: OUTPUTMODUL 2



A17b.X1

23

36

A17b.X1

8

OUTPUTMODUL 2 OUTPUTMODUL 2 CAN: CAN: PWMOutput16 (Bank4) =H+H/51.E2 =H+H/51.D2 PWMOutput14 (Bank4) Reserve A17b Joystick steering right A17b +H3 +H3 A A17b.PWM16 A17b.PWM14 X1 25 X1 23

22

A16c.24V X1 37

WH 1Q

24

+H3 A16c.X1

7

OUTPUTMODUL 2 CAN: =H+H/51.D2 PWMOutput13 (Bank4) A17b Joystick steering left +H3 A A17b.PWM13 X1 22

68

PROJ: 8920980_003

6

1 Ö Servostat 26 bar


E

1 P

5

INPUT MODUL 3 CAN: =H+H3/58.F1 Supply 24V A16c 24V Joystick Armrest

Reserve

1

+H3 B201a 0

B

A16c.X1

WH 1Q

5

A16c.X1

WH 1Q

A16c.X1

D

4

INPUT MODUL 3 INPUT MODUL 3 INPUT MODUL 3 CAN: CAN: CAN: aanalogue universal-input155 =H+H3/58.F1 =H+H3/58.C1 analogue universal-input22 =H+H3/58.D1 Supply 24V A16c A16c JJoystick pressure standard steering 11 A16c 224V Joystick activation steering 22 +H3 JJoystick pressure standard +H3 +H3 A A A16c.UI2 A16c.UI15 A16c.24V V X1 24 X1 5 X1 36

A

C

3

37

2

1

Änderung

Datum

1

Name

Datum


2

Ident.Nr.

JOYSTICK STEERING Werk Bischofshofen GmbH 3

ZeichNr.

4

5

6

8920980 460 9010 00 003 7

F

Anlage Ort

003 8

Blatt von

74 114

2

1

3

4

5

6

7

8

A

A

OUTPUTMODUL 2 CAN: Digitaloutput4 Backup ALARM

/75.F2

A17b +H3

A17b.DO4 39 X1 39

Kl. 15

A4 =K +K2

E

F23

A17b.X1

10A RD A

R23

Verb.

WH 1.5Q

REVERSING OBSTACLE DETECTOR GROENEVELD

A4.X41 +K2

NOT USED

=K+K2X52.B:2

1

1

PROJ: 8920980_003

GND

C

WH 1.5Q

1

1

+K2 X52.B

B16.X

2

+H5 B16 0 2

1 2

WH 1.5Q

1

D

BK 1.5Q

+K2 XMSP6.22

RD BU YE

A17b.X1

E

54

E

B16.X


D

B

L23

Rückfahrs.


C

OLE23

B

54 X1 A17b.GND_DO4 MASSE Backup &# MASSE CAN: OUTPUTMODUL 2

+H3 A17b

/75.D5

F


Änderung

Datum

1

Name

Datum


2

REVERSING OBSTACLE DETECTOR GROENEVELD Werk Bischofshofen GmbH 3

Ident.Nr. ZeichNr.

4

5

6

8920980 460 9010 00 003 7

Anlage Ort

003 8

Blatt von

75 114

D

E We reserve all rights in this document and in the informa tion contained therein. Reproduction, use or disclosure to third parties without express authority is strictly forbidden. © LIEBHERR WERK EHINGEN

Zustand Änderung

1 1

2

F Ersteller

Datum

Ausgabe

Datum Name Datum


2

3

OLE24 OLE25

3

Verb. Verb. 1 1


4 PK RT BN BK

OG WH

PROJ: 8920980_003

C


1 4 5

A

A4 =K +K2 F73

B

1

MONITOR

5

6

REAR AREA MONITORING ÜBER MONITOR AND CAMERA

6

7

Ident.Nr. ZeichNr.

8920980

460 9010 00 003 7

8

REAR AREA MONITORING VIA MONITOR AND CAMERA Kl. 15

A

E

3A VT

A

R73 L73 B

GND

A4.X41.6 +K2 XMSP6.21 +K2 C

ELECTRONICS REAR AREA MONITORING D

E

CAMERA F

Anlage Ort

003 8

Blatt von

76 114

4

A

A17a.X1

R53

32

RD 0.5Q 1

+K6 X2.S X2.B

+K6 X2.S X2.B

B

4

RD 0.5Q A

RD 1Q

+V1 X43

C

BN

BN

WH 1.5Q

+H5 X31

1

X31

C

2

4

3

BU

2

BU

3

B

S

1

BK

B43

C

3

3

M6.X

2

2

+H5 M6 0

47

B44

M

X43

B

47

+

WH 1.5Q


2

A

9 WH 1.5Q

1

+K6 X1.S X1.B

2

BK

PROJ: 8920980_003

A4.X41 +K2 B.9

+H3 A17a /90.F1

GND central lubrication system MV PUMP EARTH CAN: OUTPUT MODULE 1

+K2 A16b /87.D2


Datum

1

Name

Datum


2

/87.D5

+K2 A16b /87.D5


Ident.Nr.

6

BK 0.5Q 42 42

BK 0.5Q X1 59 A16b.GND

+K2 A16b /87.D5

8920980 460 9010 00 003 7

59

56

Sig. DISTRIBUTOR centr. frequency input2 CAN: INPUT MODULE 2

ZeichNr.

4

A16b.X1

X1 56 A16b.FI2

GND LEVEL centr EARTH CAN: INPUT MODULE 2

E

1

A16b.X1

X1 60 A16b.GND

+K2 A16b

41

BU 0.5Q

45 45

A16b.X1

X1 22 A16b.UI13 A Sig. LEVEL centr ANALOGUE Universale CAN: INPUT MODULE 2

CENTRAL LUBRICATION SYSTEM LIEBHERR 3

+K6 X2.B X2.S

1 60

A16b.X1

+K6 X2.B X2.S

1 22

1

X1 40 A17a.GND_DO3

+K6 X2.B X2.S

2

BK 0.5Q

BU 0.5Q

44

+K6 X2.B X2.S

2

41

2

44

BK 1.5Q

2

A17a.X1

BU 0.5Q

BK 1Q

BU 1Q

D

F

Zustand

1

GND

40

E

A16b.X1

L53


D

A

A16b.24V X1 32

40

A17a.DO3 X1 37

8

INPUT MODULE 2 CAN: SUPPLY 24V VCC DISTRIBUTOR cen. l. s.

RD 0.5Q

+H3

37

B

A16b.X1

OUTPUT MODULE 1 CAN: /90.F1 digital output3 A17a VCC central lubrication unit. MV PUMP

10A RD

/87.E2

A16b +K2

33

Kl. 15

F53

7

A16b.24V X1 33

SUPPLY SUPPLY DO3 /90.F1 SUPPLY for digital output3 CAN: OUTPUT MODULE 1

E

C

INPUT MODULE 2 CAN: SUPPLY 24V VCC LEVEL central l. s.

+H3 A17a

A4 =K +K2

6

40

/87.E2

A16b +K2

X1 36 A17a.V_DO3

A

5

43

A17a.X1

36

3

43

2

1

GND DISTRIBUTOR centr. EARTH CAN: INPUT MODULE 2

F

Anlage Ort

003 8

Blatt von

77 114

A16a.FI2 X1 56

A16a.FI1 X1 55

A16a.X1

A

A16b.FI1 X1 55

A16b.X1

AUTOMATIC GREASING SYSTEM

10A RD

1

L12 1

1

*1 2

1

WH 1.5Q

2

2

*2

2

3

3

3

4

A204.X * A4.X56 +K2

2

1

X50.S X50.B +H3

4 4

GND

1

RD 1Q

WH 1.5Q

WH 1.5Q

R12:

RD 1Q

A

17

+K6 X2.S X2.B

17

B GREASING MODE

WH 1.5Q

RD 1Q

F12

RD 1Q

1

A16a.X1

/87.D5

A16b +K2

INPUT MODULE 2 CAN: frequency input1 SPEED hydro motor

55

/86.D5

A16a +H3

INPUT MODULE 1 CAN: frequency input1 SPEED hydro motor1

55

INPUT MODULE 1 CAN: frequency input2 drive rotation speed

8

1

+H3 Splice.X10

+H3 X50.S

7

E

WH 1.5Q WH 1.5Q

PROJ: 8920980_003

/86.D5

27

1

+F3 B2 0

2

+K2 XMSP63

B1.X

2

B2.X

B2a.X

1

BU 1Q

BK 1.5Q

5

8

+V1 B203 0

BU 1Q

18

7

1

1

1

18

4

P BU 1Q

2

B203.X

2

2

0

+K6 X2.B X2.S

1

Groeneveld Twin Pump A16a.X1

X1 70 A16a.GND_FI2

+H3 A16a /86.E5

EARTH output speed EARTH frequency input2 CAN: INPUT MODULE 1

69

A16a.X1

X1 46 A17a.GND_PWM1 D +H3 EARTH PARKING BRAKE A17a /90.C5 EARTH CAN: OUTPUT MODULE 1

70

E

A16b.X1

X1 69 A16a.GND_FI1

+H3 A16a /86.E5

SPEED hydro motor1 EARTH frequency input1 CAN: INPUT MODULE 1

69

6

B203.X

2

1

2

1

8

6

3

7

1

BU 1Q

D

+H3 A205

A17a.X1

2

WH 1.5Q BK 1.5Q

3

BK 1.5Q

A205.X

1

+F3 B2a 0

2

+F3 B1 0

B2a.X

1

2

1

1

B2.X

1

B1.X

2

BK,BK 1.5Q,1.5Q

BK 1.5Q 27

WH 1.5Q 26 WH 1.5Q

25

WH 1.5Q

2

Y10.JPT

25

+K6 X2.S X2.B

2

26

WH 1.5Q

1

+K6 Y10 0


1

Y10.JPT

WH 1.5Q

C

46

E


D

6

+K4 A204

Kl.15

A4 =K +K2

A17.aX1a +H3

B

5

A16a +H3

4

A17a.X1

4

OPTION GROENEVELD CENTRAL LUBRICATION SYSTEM

OUTPUT MODULE 1 CAN: /90.C1 PWMOutput1 (Bank1) A17a PARKING BRAKE +H3 A A17a.PWM1 X1 4

A

C

3

56

2

1

X1 69 A16b.GND_FI1

+K2 A16b /87.E5

EARTH SPEED hydro m. EARTH frequency input CAN: INPUT MODULE 2

F


Änderung

Datum

1

Name

Datum


2

PARKING BRAKE ; SPEED SENSOR CENTRAL LUBRICATION SYSTEM GROENEVELD


4

5

6

Ident.Nr. ZeichNr.

8920980 460 9010 00 003 7

Anlage Ort

003 8

Blatt von

78 114

5

6

INGITION LOCK WITH TRANSPONDER COIL

OLE12

S1.X1.8 PINNING OUT WITH OLE 12 CONNECT

+K4 S1.X1.8a

8

Verb.

1

=K+K2A9.X:2

WH 2.5Q

+K6 X1.S

A

30

2

S1.X3

K01

B

CAN: INPUT MODULE 1

WH 2.5Q WH 2.5Q

F29 25A WH

Kl 50a ANALOGUE universal-input15

GND MP6 CABIN

E

86

igniton lock S1.X1:6

T.3

F26 A4.X40:9

3

4

A4.X57

X1 24 A16a.UI15

=H +H3 A16a

=H+H/37.D2

24

WH 2.5Q

8

S1.X2

30

1

V1

(1) dashboard

A

(3) igniton switch

85

(5) key

Kl. 30

=K +K2 A9

Kl.30 Kl.15 GND

Operation-Key Relais 1

Relais 2

Relais 3

RD WH BK WH WH

11 14 13 1 3

C

BK 1.5Q

A9 Kl.15

XMSP12.2 +K2

1.5Q 2.5Q 1.5Q 2.5Q 2.5Q

D

WH 2.5Q WH 2.5Q

2 4

WH 1Q WH 1Q

8 10

A4 =K +K2 /5.B2

WH 1Q WH 1Q

Relais 4

11 14 13 1 3 5 2 4 6 8 10 12 7 9

A9.X

Master-Key

WH 2.5Q

XMSP12

A9 Kl.30

1

Kl.30.X 1

RD 1.5Q

1 GND

Kl. 15

87

(4) mother

/19.A1

/40.E5

(2) antenna

WH 2.5Q WH 2.5Q

1

PROJ: 8920980_003

+H3 A16a.X1

Kl.15.X 1

30

/5.C3

F15.1

E F15 10A RD

F15.2

E

A F15.3

10 pin PLUG NOT in use!

ELECTRONICS IMMOBILISER

+K4 S2

5

3

1

6

8

7

9

10

11


Datum

1

Name

Datum


2

4

A4.X44a:4 +K2

V N R

OPTION Ersteller

12

1

=K+K2A9.X:8

Ident.Nr.

ELECTRONIC IMMOBILISER Werk Bischofshofen GmbH 3

ZeichNr.

4

5

6

Verb.

460 9010 00 003 7

E.4

A4.X44:4 PINNING OUT WITHOLE 13 CONNECT

OLE13

8920980

A4.X44

1

2

WH 1Q

1

GND

4

F

Zustand

50a

1

OLE11 E

9

50a

Kl. 15


D

8

15

+K2 A4.X56a:4

S.4


C

6

15

RD 2.5Q

A4.X56 A4 =K +K2

5

P 0 12

S1

A4.X56:4 PINNING OUT WITH OLE 11 CONNECT

B

10 58

1

Verb.

WH 2.5Q

1

5

1

A

7

1

4

=K+K2A9.X:1

3

1

2

1

Anlage Ort

003 8

Blatt von

79 114

F

2

4

PRESELECTOR CLOCK

A4 =K +K2

A

120 min

5

6

E

F39

5A BN A

E

20A YE A

R40 L40

OLE14

=K

WH 2Q WH,WH 1.5Q,1.5Q

3

XMSP6.16 +K2

4

BK 2.5Q

Kl. 30

E

7

X2/1

M15.X

A4.X41 +K2

1

BK 1.5Q WH 1.5Q

OR

NOZZLE STICK PREHEATER

Verb.

1

+K2 XMSP6.16

WH,WH 1.5Q,1.5Q 1 BK 1.5Q 2

1 Ersteller Datum Ausgabe

Änderung

Datum

1

Name

Datum


2

WH 1.5Q

OLE22

Verb.

E

=K+K2OLE17:1

1

=K +K4 A21.X1

WITH CABLE (OR )CONNECT!

+B2 X5

=B+B2X5:1 RD 1.5Q BK 1.5Q WH 1.5Q BK 1.5Q

+K2 X223.B

OLE18

2

M15.X

A4.X52 C.X1

9

12

2 1

1

DBW 2010 GND

A.X1 +B2

L42

Verb.

+H1 M15 0

OLE17

30

+

M

4

+B2 B.X6

D

=B+B2OLE22:1

1

1 2 3 4 5 6

K243

V46

A 86

OLE16

87a WH 2.5Q

R42

Verb.

WH 2.5Q

10A RD

87

1

1

85

=K+K2A4.X52:7

BK,BK 1.5Q,1.5Q

RD 2.5Q

A4.X52

RD 2.5Q

7

8


A4.X52

F42

=K

C

RD,RD 2.5Q,2.5Q

A4 =K +K2

A4.X41

2

+K2 XMSP6.16

2

Verb.

A4.X41

B

WH,WH 1.5Q,1.5Q

+K2 XMSP6.16

1

GND

=K+K4X4:1

4

RD 1Q =K+K4X4:11

F

Zustand

RD 1Q BK 1.5Q

WH 1.5Q

WH 1.5Q

PROJ: 8920980_003

BK 1.5Q

GND


E

A

1

1 2 3 4 5 6 7 8 9 10 11 12

L39

B

D

A4 =K +K2

Verb.

R39

C

8

F40

P

X4 +K4

7 F8 10A Kl. 58 A4.X57/4

3

OLE15

1

X1 4 A21.PME A AUXILIARY HEATER /46.B2 AUXILIARY HEATER CAN: HEAT/AIR CONDITIONING SYSTEM

1 2 3 4

=K +K4 A21

PLUG CONNECTION FUEL PREHEATING

F Ident.Nr.

AUXILIARY HEATER DBW 2010 Werk Bischofshofen GmbH 3

ZeichNr.

4

5

6

8920980 460 9010 00 003 7

Anlage Ort

003 8

Blatt von

80 114

2

1

3

4

5

6

7

8

PRESELECTOR CLOCK Kl. 30

A

120 min

E

F39

P

Kl. 30

5A BN

11 12

8

20A YE A

R40

/19.F7

B

GND

A4.X41 +K2

7

4

PROJ: 8920980_003

X

GND

A4.X41 +K2

RD 1Q WH 2Q BK 1Q

RD 2.5Q

WH 1Q WH 1Q

XMSP6.15 +K2

1

11 12

9

+B2 X12.ST2

3 4


BK 2.5Q

C

THERMO 90

=K+K4A21.X1:4

+B2 X11.ST1

WH 1.5Q

X13.ST3

1

Verb.

OLE21

D

4

WITH CABLE (SW )CONNECT!

A21.X1

E 4

E

F40

L40

BK,BK 1Q,1Q


D

R39

A E

L39

B

C

4

1 2

A

X3 +K4

A4 =K +K2

F8 10A Kl. 58 A4.X57/4

A4 =K +K2

X1 4 A21.PME A +K4 AUXILIARY HEATER A21 /96.B2 AUXILIARY HEATER CAN: HEAT/AIR CONDITIONING SYSTEM

F


Änderung

Datum

1

Name

Datum


2

Ident.Nr.

AUXILIARY HEATER THERMO 90 Werk Bischofshofen GmbH 3

ZeichNr.

4

5

6

8920980 460 9010 00 003 7

Anlage Ort

003 8

Blatt von

81 114

2

1

3

4

5

A4 =K +K2

A

6

7

8

Kl.15

A

E

F14

PLUG CONNECTION AUXILIARY HEATER DBW 2010

15A BU A

R14 L14 GND

B

E

WH,WH 1.5Q,1.5Q

1

WH 1.5Q

PROJ: 8920980_003

WH 2.5Q

=K +K2.RH

1

F208 20A YE

2

87a

87

86

87a

0

0

K227 +K2

K228 +K2 30


87

86

C

85

30

RD 2.5Q

85

WH 2.5Q

RD 2.5Q

BK 2.5Q

RD 2.5Q

D BK 2.5Q

3

4

R10.X

2

BK 2.5Q

1

D

B

X44 +K2

RD 6Q


C

=K +K2 Kl.30.Xa 1

2/2 BK 1.5Q

WH 1.5Q

X223.S 1/2 +K2

1

2

3

4

E

R10 +M T ON +5° 0°: OFF +10° +K6 XMSP6.19

1

1

+K6 XMSP6.20

F


Änderung

Datum

1

Name

Datum


2

DIESEL PREHEATING COLD WEATHER KIT 40° Werk Bischofshofen GmbH 3

Ident.Nr. ZeichNr.

4

5

6

8920980 460 9010 00 003 7

Anlage Ort

003 8

Blatt von

82 114

E

Zustand

BK 95Q

Änderung

1 Ersteller

Datum

Ausgabe

Datum Name Datum

2

XMSP4.1* +H.

+H5. S15* 2


3

1 RD 25Q

+B1. G1* +

4

1

30.1

2 K11*.X4

1

+H5. F01* 100A 2

RD 95Q

+B1. G2* +

30

+M. M1*

5

M 50

31

K11* +H4. 30.2 50 30.1

1

+H5. F03* 200A +H. F02* 100A

2

* 2

W

+M. G3*

F

VERSION BATTERY WIRING HARNESSES 40°


6

B+

Ident.Nr. ZeichNr.

RD 6Q

M 1

WH 25Q

5 6

F07*.X1

+H5. F07* 10A RD

7

1

B

+H4. M8* 0 K11*.X3

1

1

RD 25Q

RD 25Q

4

RD,RD 25Q,6Q

RD 25Q

RD 25Q

3

RD,RD 95Q,25Q

BK 95Q

PROJ: 8920980_003

2

BK 95Q


C


1 7 8

VERSION BATTERY WIRING HARNESSES COLD WEATHER KIT 40°C

A A

+H5. K04* 30.2 50 B

31

1

C

1

2

D

* RD 25Q

E

* D+

3

31 B

F

8920980

460 9010 00 003

Anlage Ort

003 8

Blatt von

83 114

E

Zustand

BK 95Q

Änderung

1 Ersteller

Datum

Ausgabe

Datum Name Datum

2

XMSP4.1* +H

+H5 S15* 2


3

1 RD 25Q

+H4 M8* 0

+

+B1 G1*

F

4

M

1 +

+M XMSP10*

+H4 K11* 88

88a

2

1 1

+H5 F01* 100A +H5 F03* 200A

RD 95Q

*

+B1 G2*

+M M1*

5

M 50

+H F02* 100A

2 2 2

W

+M G3*

1



6

B+

RD 6Q

B WH 25Q

5 6

30.1

F07*.X1

+H5 F07* 10A RD

Ident.Nr. ZeichNr.

7

1

1

RD 25Q

RD 25Q

4

RD,RD 6Q,25Q

RD 25Q

RD 25Q

3

RD,RD 25Q,95Q

BK 95Q

PROJ: 8920980_003

2

BK 95Q


C


1 7 8

VERSION BATTERY WIRING HARNESSESL586

A A

86 +H5 K04* 30.2 50 B

85 31

1

C

*

1

2

D

RD 25Q

E

* 30 D+

3

BK 95Q

31 B

F

8920980

460 9010 00 003

Anlage Ort

003 8

Blatt von

84 114

2

1

3

4

5

6

7

8

A

A

PME MASTER GENERAL OUTLAY ON AND OUTLETS

=K +K2

A15

Module Nr.: Module name:

PME_MASTER

E


D


C

B

PROJ: 8920980_003

B

Phys. Adr.

Sheet

A15.GND A15.DIGIN0 A15.DIGIN1 A15.DIGIN2 A15.Shield A15.VBat A15.CAN4L A15.CAN3L A15.CAN2L A15.CAN1L A15.CAN1H A15.CAN2H A15.CAN3H A15.CAN4H A15.DCD A15.RXD A15.TXD A15.DTR A15.GND A15.n.c. A15.RTS A15.CTS A15.n.c. A15.DCD A15.RXD A15.TXD A15.DTR A15.GND A15.n.c. A15.RTS A15.CTS A15.n.c.

/40.E1 /40.E3

Description

EA

/40.E2 /40.E4 /35.B6 /38.C3 /37.A4 /37.A5 /38.C4 /35.B7

A15.DCD A15.RXD A15.TXD A15.DTR A15.GND A15.n.c. A15.RTS A15.CTS A15.n.c.

Plug

Pin

EARTH Kl. 15 DIGITAL 1 DIGITAL 2 HOUSING MASTER Kl. 30 CAN LOW 4 CAN LOW 3 CAN LOW 2 CAN LOW 1 CAN HIGH 1 CAN HIGH 2 CAN HIGH 3 CAN HIGH 4 Data Carrier Detec Receive (RXD) Transmit (TXD) Data Derminal Read SIGNAL Ground (S NOT USED Request to send (R Clear to send (CTS NOT USED Data Carrier Detec Receive (RXD) Transmit (TXD) Data Derminal Read SIGNAL Ground (S NOT USED Request to send (R Clear to send (CTS NOT USED

.PWR.X .PWR.X .PWR.X .PWR.X .PWR.X .PWR.X CAN CAN CAN CAN CAN CAN CAN CAN COM1 COM1 COM1 COM1 COM1 COM1 COM1 COM1 COM1 COM2 COM2 COM2 COM2 COM2 COM2 COM2 COM2 COM2

1 2 3 4 5 6 1 2 3 4 5 6 7 8 1 2 3 4 5 6 7 8 9 1 2 3 4 5 6 7 8 9

Data Carrier Detec Receive (RXD) Transmit (TXD) Data Derminal Read SIGNAL Ground (S NOT USED Request to send (R Clear to send (CTS NOT USED

COM3 COM3 COM3 COM3 COM3 COM3 COM3 COM3 COM3

1 2 3 4 5 6 7 8 9

Phys. Adr. A15.DCD A15.RXD A15.TXD A15.DTR A15.GND A15.n.c. A15.RTS A15.CTS A15.n.c. A15.TXD + A15.TXD A15.RXD + A15.n.c. A15.n.c. A15.RXD A15.n.c. A15.n.c. A15.TXD + A15.TXD A15.RXD + A15.n.c. A15.n.c. A15.RXD A15.n.c. A15.n.c.

Sheet

EA

/40.A7 /40.A8 /40.A6

Description Data Carrier Detec Receive (RXD) Transmit (TXD) Data Derminal Read SIGNAL Ground (S NOT USED Request to send (R Clear to send (CTS NOT USED Transmit Data + Transmit Data Receive Data + NOT USED NOT USED Receive Data NOT USED NOT USED Transmit Data + Transmit Data Receive Data + NOT USED NOT USED Receive Data NOT USED NOT USED Transmit Data + Transmit Data Receive Data + NOT USED NOT USED Receive Data NOT USED NOT USED

A15.TXD + A15.TXD A15.RXD + A15.n.c. A15.n.c. A15.RXD A15.n.c. A15.n.c.

Plug COM4 COM4 COM4 COM4 COM4 COM4 COM4 COM4 COM4 LAN1 LAN1 LAN1 LAN1 LAN1 LAN1 LAN1 LAN1 LAN2 LAN2 LAN2 LAN2 LAN2 LAN2 LAN2 LAN2

Pin 1 2 3 4 5 6 7 8 9

LAN3 LAN3 LAN3 LAN3 LAN3 LAN3 LAN3 LAN3

1 2 3 4 5 6 7 8

1 2 3 4 5 6 7 8 1 2 3 4 5 6 7 8

C

D

E

F


Änderung

Datum

1

Name

Datum


2

Ident.Nr.

GENERAL OUTLAY MASTER Werk Bischofshofen GmbH 3

ZeichNr.

4

5

6

8920980 460 9010 00 003 7

Anlage Ort

003 8

Blatt von

85 114

2

E

PROJ: 8920980_003

A16a.UI10 A16a.UI11 A16a.UI12 A16a.GND A16a A16a.24V A16a.24V A16a.GND_logic


D

A16a.24V A16a.24V_logic A16a.GND A16a.UI1 A16a.UI2 A16a.UI3 A16a.UI4 A16a.UI9

A16a.GND A16a.UI5 A16a.UI6 A16a.UI7 A16a.UI8 A16a.UI13 A16a.UI14 A16a.UI15


C

Sheet

Module Nr.: Module name: EA

/41.E5 /23.A3 /54.A7 /23.A4 /21.A3 /51.C1 /51.C2 /56.F4 /56.F2

/41.E6 /56.A1 /23.A6 /52.A2 /21.A5 /21.A2 /19.B6

A16a.UI16 A16a.GND A16a A16a.24V A16a.CAN_Res A16a.24V A16a.GND A16a.24V

/52.A6

A16a.24V A16a.24V A16a.24V A16a.24V A16a.24V A16a.24V A16a.24V A16a.GND

/23.E4 /23.E5 /52.A1 /56.A2 /21.A1 /56.A4 /52.A5

5

6

7

8

INPUT MODULE 1 ON AND OUTLETS

A16a

Phys. Adr.

4

A

+H3

B

3

OUTPUT MODULE 1

OUTPUT MODULE 2

A

INPUT MODULE 1

INPUT MODULE 3

1

/41.E7 /41.E8 /21.F3

B

PME1_INPUT MODULE

Description

Plug

Pin

Phys. Adr. A16a.24V A16a A16a.CAN_Low A16a.CAN_Low A16a.GND A16a.RI1 A16a.RI1 A16a.RI2

Sheet

RESERVE VBatt 24V Log RESERVE PRESSURE NLP Check HIGH PRESSURE TRAVEL PUMP PRESSURE NLP PRESSURE PRESSURE RESERVOIR BRAKE CONTROL LEVER VOR1

X1 X1 X1 X1 X1 X1 X1 X1

1 2 3 4 5 6 7 8

CONTROL LEVER REVERSE1 LIFT KICKOUT BUCKET RETURNTODIG RESERVE RESERVE RESERVE RESERVE SUPPLY GND LOGIK

X1 X1 X1 X1 X1 X1 X1 X1

9 10 11 12 13 14 15 16

A16a.RI2 A16a.5V A16a.5V A16a.5V A16a.5V A16a.GND A16a.FI1 A16a.FI2

RESERVE FLOAT POSITION LFD QUICKCHANGE DEVICE InchPotentiometer1 Transmission overtemperature TANK SENSOR Kl 50a

X1 X1 X1 X1 X1 X1 X1 X1

17 18 19 20 21 22 23 24

A16a.CAN_High A16a.CAN_High A16a.GND A16a.GND A16a.GND A16a.GND A16a.GND A16a.GND

/37.E3 /37.E5 /23.E3 /23.E4 /21.F2

Throttle transmitter1 RESERVE RESERVE RESERVE CANEND WITH PIN 43 verb. VBatt 24V SUPPLY EARTH Vcc PRESSURE RESERVOIR BRAKE

X1 X1 X1 X1 X1 X1 X1 X1

25 26 27 28 29 30 31 32

A16a.GND A16a.GND A16a.GND A16a.GND A16a.GND_FI1 A16a.GND_FI2

/21.F1 /56.F3 /52.F6

Vcc NLP Check Vcc NLP 24V InchPotentiometer1 24V BUCKET RETURNTODIG 24V TANK SENSOR 24V LIFT KICKOUT 24V Throttle transmitter1 RESERVE

X1 X1 X1 X1 X1 X1 X1 X1

33 34 35 36 37 38 39 40

EA

/54.F7 /37.E2 /37.E4 /21.A6 /21.F6

/78.A7 /78.A6

/52.F2 /56.F5

/78.F7 /78.F6

Description

Plug

Pin

HIGH PRESSURE travel pump RESERVE CAN low (Res verb.) CAN low RESERVE Hydraulic oil temperature Hydraulic oil temperature RESERVE

X1 X1 X1 X1 X1 X1 X1 X1

41 42 43 44 45 46 47 48

RESERVE RESERVE RESERVE RESERVE RESERVE RESERVE SPEED hydro motor1 Drive rotation speed

X1 X1 X1 X1 X1 X1 X1 X1

49 50 51 52 53 54 55 56

CAN high (Res verb.) CAN high GND NLP Check GND NLP GND PRESSURE RESERVOIR BRAKE HIGH PRESSURE TRAVEL PUMP EARTH InchPotentiometer1 LIFT KICKOUT

X1 X1 X1 X1 X1 X1 X1 X1

57 58 59 60 61 62 63 64

EARTH TANK SENSOR BUCKET RETURNTODIG EARTH Throttle transmitter1 RESERVE SPEED hydro motor1 EARTH Output speed

X1 X1 X1 X1 X1 X1

65 66 67 68 69 70

C

D

E

F


Änderung

Datum

1

Name

Datum


2

Ident.Nr.

GENERAL OUTLAY INPUT MODULE 1 Werk Bischofshofen GmbH 3

ZeichNr.

4

5

6

8920980 460 9010 00 003 7

Anlage Ort

003 8

Blatt von

86 114

2

E

PROJ: 8920980_003

A16b.UI10 A16b.UI11 A16b.UI12 A16b.GND A16b A16b.24V A16b.24V A16b.GND_logic


D

A16b.24V A16b.24V_logic A16b.GND A16b.UI1 A16b.UI2 A16b.UI3 A16b.UI4 A16b.UI9

A16b.GND A16b.UI5 A16b.UI6 A16b.UI7 A16b.UI8 A16b.UI13 A16b.UI14 A16b.UI15


C

Sheet

Module Nr.: Module name: EA

/41.E1 /25.A5 /25.A7 /27.A8 /51.C6 /51.C6 /51.C8 /57.A6

/41.E2 /51.C3 /51.C4 /52.A3 /52.A7 /77.F4

A16b.UI16 A16b.GND A16b A16b.24V A16b.CAN_Res A16b.24V A16b.GND A16b.24V

/71.A6

A16b.24V A16b.24V A16b.24V A16b.24V A16b.24V A16b.24V A16b.24V A16b.GND

/77.A4 /52.A4 /52.A8 /71.A5

5

6

7

8

INPUT MODULE 2 ; ON AND OUTLETS

A16b

Phys. Adr.

4

A

+K2

B

3

OUTPUT MODULE 1

OUTPUT MODULE 2

A

INPUT MODULE 1

INPUT MODULE 3

1

/41.E3 /41.E4 /77.A7

B

PME1_INPUTMODULE

Description

Plug

Pin

Phys. Adr.

RESERVE VBatt 24V Log RESERVE DRIVING LIGHT HIGH BEAM INDICATOR SIGNAL RESERVE CONTROL LEVER Option1

X1 X1 X1 X1 X1 X1 X1 X1

1 2 3 4 5 6 7 8

A16b.24V A16b A16b.CAN_Low A16b.CAN_Low A16b.GND A16b.RI1 A16b.RI1 A16b.RI2

CONTROL LEVER Option2 CONTROL LEVER; Option3 Warning buzzer RESERVE RESERVE RESERVE RESERVE EARTH LOGIK

X1 X1 X1 X1 X1 X1 X1 X1

9 10 11 12 13 14 15 16

A16b.RI2 A16b.5V A16b.5V A16b.5V A16b.5V A16b.GND A16b.FI1 A16b.FI2

RESERVE CONTROL LEVER FORWARD2 CONTROL LEVER REVERSE2 InchPotentimeter2 Throttle transmitter2 Sig. LEVEL Zentr Diesel particulate filter Diesel particulate filter

X1 X1 X1 X1 X1 X1 X1 X1

17 18 19 20 21 22 23 24

A16b.CAN_High A16b.CAN_High A16b.GND A16b.GND A16b.GND A16b.GND A16b.GND A16b.GND

JOYSTICK STEERING SENSOR 1 RESERVE RESERVE RESERVE CANEND VBatt 24V SUPPLY EARTH VCC DISTRIBUTOR Central lubrictaion system

X1 X1 X1 X1 X1 X1 X1 X1

25 26 27 28 29 30 31 32

A16b.GND A16b.GND A16b.GND A16b.GND A16b.GND_FI1 A16b.GND_FI2

VCC LEVEL Central lubrication system 24V InchPotentiometer2 24V Throttler transmitter2 VCC JOYSTICK STEERING RESERVE RESERVE RESERVE RESERVE

X1 X1 X1 X1 X1 X1 X1 X1

33 34 35 36 37 38 39 40

Sheet

EA

/38.B5 /38.B3

/78.A8 /77.F7 /38.B6 /38.B4 /77.F8 /77.F5 /52.F3 /52.F7

/71.F6 /78.F8

Description

Plug

Pin

RESERVE RESERVE CAN low (CANE m. CAN low RESERVE RESERVE RESERVE RESERVE

X1 X1 X1 X1 X1 X1 X1 X1

41 42 43 44 45 46 47 48

RESERVE RESERVE RESERVE RESERVE RESERVE RESERVE SPEED hydro motor Sig. DISTRIBUTOR central lubrication system

X1 X1 X1 X1 X1 X1 X1 X1

49 50 51 52 53 54 55 56

CAN high (CANE m CAN high GND DISTRIBUTOR central lubrication system GND LEVEL central lubrication system RESERVE EARTH InchPotentiometer2 EARTH Throttle transmitter RESERVE

X1 X1 X1 X1 X1 X1 X1 X1

57 58 59 60 61 62 63 64

EARTH Joystick & RESERVE GND JOYSTICK STEERING RESERVE EARTH SPEED Hy RESERVE

X1 X1 X1 X1 X1 X1

65 66 67 68 69 70

C

D

E

F


Änderung

Datum

1

Name

Datum


2

Ident.Nr.


ZeichNr.

4

5

6

8920980 460 9010 00 003 7

Anlage Ort

003 8

Blatt von

87 114

2

A16c

E

PROJ: 8920980_003

Sheet

6

B

Plug

Pin

Phys. Adr.

/71.A7 /72.A2 /59.F7 /59.A2 /59.A3

/71.F2

NOT USED! NOT USED! NOT USED! NOT USED! NOT USED! NOT USED! NOT USED! EARTH LOGICAL PART

X1 X1 X1 X1 X1 X1 X1 X1

9 10 11 12 13 14 15 16

A16c.RI2 A16c.5V A16c.5V A16c.5V A16c.5V A16c.GND A16c.FI1 A16c.FI2

NOT USED! NOT USED! NOT USED! NOT USED! NOT USED! Joystick activation Joystick ARMREST RESERVE

X1 X1 X1 X1 X1 X1 X1 X1

17 18 19 20 21 22 23 24

A16c.CAN_High A16c.CAN_High A16c.GND A16c.GND A16c.GND A16c.GND A16c.GND A16c.GND

/37.D7 /37.C7

A16c.UI16 /59.F8 A16c.GND A16c A16c.24V A16c.CAN_Res A16c.24V /71.F3 A16c.GND /71.F4 A16c.24V V_DO1

basket function Not OFF 2 SUPPLY EARTH NOT USED! NOT USED! CANEND WITH PIN 43 conn. SUPPLY 24V SUPPLY EARTH Vbatt SUPPLY DO1

X1 X1 X1 X1 X1 X1 X1 X1

25 26 27 28 29 30 31 32

A16c.GND A16c.GND A16c.GND A16c.GND A16c.GND_FI1 A16c.GND_FI2

/72.F5

A16c.24V DO1 A16c.24V A16c.24V A16c.24V V A16c.24V A16c.24V A16c.24V A16c.GND

JOYSTICK STEERING SENSOR 2 right NOT USED! NOT USED! 24V Joystick activation 24V Joystick ARMREST Vcc PRESSURE standard steering 1 NOT USED! NOT USED!

X1 X1 X1 X1 X1 X1 X1 X1

33 34 35 36 37 38 39 40

/72.F3 /72.F4

/71.A8 /72.A3 /72.A4 /72.F2

A16c.24V A16c A16c.CAN_Low A16c.CAN_Low A16c.GND A16c.RI1 A16c.RI1 A16c.RI2

Sheet

1 2 3 4 5 6 7 8

A16c.GND A16c.UI5 A16c.UI6 A16c.UI7 A16c.UI8 A16c.UI13 A16c.UI14 A16c.UI15

8

PME1_INPUTMODULE

X1 X1 X1 X1 X1 X1 X1 X1

/71.F1

7

INPUT MODULE 3 ON / OUTLETS

Description

EA

5

NOT USED! SUPPLY EARTH NOT USED! JOYSTICK STEERING SENSOR 2 right Joystick PRESSURE standard steering 1 Basket function Not OFF 1 Basket function Modus 1 Basket function Modus 2

A16c.UI10 A16c.UI11 A16c.UI12 A16c.GND A16c A16c.24V A16c.24V A16c.GND_logic


D

A16c.24V A16c.24V_logic A16c.GND A16c.UI1 A16c.UI2 A16c.UI3 A16c.UI4 A16c.UI9


C

Phys. Adr.

4

A


+H3

B

3

OUTPUT MODULE 1

OUTPUT MODULE 2

A

INPUT MODULE 1

INPUT MODULE 3

1

/37.D6 /37.C6

/72.F1

/71.F7

EA

Description

Plug

Pin

NOT USED! NOT USED! CAN low CAN low NOT USED! NOT USED! NOT USED! NOT USED!

X1 X1 X1 X1 X1 X1 X1 X1

41 42 43 44 45 46 47 48

NOT USED! NOT USED! NOT USED! NOT USED! NOT USED! NOT USED! NOT USED! NOT USED!

X1 X1 X1 X1 X1 X1 X1 X1

49 50 51 52 53 54 55 56

CAN high CAN high NOT USED! NOT USED! NOT USED! NOT USED! NOT USED! PRESSURE standard steering 1

X1 X1 X1 X1 X1 X1 X1 X1

57 58 59 60 61 62 63 64

EARTH Joystick armrest NOT USED! JOYSTICK STEERING SENSOR 2 re NOT USED! NOT USED! NOT USED!

X1 X1 X1 X1 X1 X1

65 66 67 68 69 70

C

D

E

F


Änderung

Datum

1

Name

Datum


2

Ident.Nr.


ZeichNr.

4

5

6

8920980 460 9010 00 003 7

Anlage Ort

003 8

Blatt von

88 114

2

1

3

4

5

6

7

8

A

A

INPUT MODULE 4 ON / OUTLETS A16d

E

PROJ: 8920980_003

A16d.24V A16d.24V_logic A16d.GND A16d.UI1 A16d.UI2 A16d.UI3 A16d.UI4 A16d.UI9

EA

B

PME1_OUTPUTMODULE

Description

Plug

Pin

Phys. Adr.

NOT USED! SUPPLY EARTH NOT USED! capacitive Joystick sensor 3. CONTROL CIRCUIT Active OUTPUT Hall sensor 1 CONTROL 5V OPTION

X1 X1 X1 X1 X1 X1 X1 X1

1 2 3 4 5 6 7 8

NOT USED! OUTPUT Hall sensor 2 NOT USED! NOT USED! NOT USED! NOT USED! NOT USED! EARTH LOGICAL PART

X1 X1 X1 X1 X1 X1 X1 X1

9 10 11 12 13 14 15 16

A16d.RI2 A16d.5V A16d.5V A16d.5V A16d.5V A16d.GND A16d.FI1 A16d.FI2

A16d.GND A16d.UI5 A16d.UI6 A16d.UI7 A16d.UI8 A16d.UI13 A16d.UI14 A16d.UI15

NOT USED! NOT USED! NOT USED! NOT USED! NOT USED! NOT USED! NOT USED! NOT USED!

X1 X1 X1 X1 X1 X1 X1 X1

17 18 19 20 21 22 23 24

A16d.CAN_High A16d.CAN_High A16d.GND A16d.GND A16d.GND A16d.GND A16d.GND A16d.GND

A16d.UI16 A16d.GND A16d A16d.24V A16d.CAN_Res A16d.24V /50.E3 A16d.GND /50.E4 A16d.24V V_DO1

NOT USED! SUPPLY EARTH NOT USED! NOT USED! WITH PIN 43 conn. SUPPLY 24V SUPPLY EARTH Vbatt DO1

X1 X1 X1 X1 X1 X1 X1 X1

25 26 27 28 29 30 31 32

A16d.GND A16d.GND A16d.GND A16d.GND A16d.GND_FI1 A16d.GND_FI2

A16d.24V DO1 A16d.24V A16d.24V A16d.24V V A16d.24V A16d.24V A16d.24V A16d.GND

NOT USED! NOT USED! NOT USED! capacitive Joystick sensor NOT USED! NOT USED! NOT USED! NOT USED!

X1 X1 X1 X1 X1 X1 X1 X1

33 34 35 36 37 38 39 40

A16d.UI10 A16d.UI11 A16d.UI12 A16d.GND A16d A16d.24V A16d.24V A16d.GND_logic


D

Sheet

Phys. Adr.


C


+H3

B

/50.E1 /60.A2 /60.B7 /60.A5 /60.A4 /60.B7 /60.A6

/50.E2

/60.A1

A16d.24V A16d A16d.CAN_Low A16d.CAN_Low A16d.GND A16d.RI1 A16d.RI1 A16d.RI2

Sheet

EA

/38.D1 /38.D1

/60.A3

/60.A8

/38.D2 /38.D2 /60.A3

Description

Plug

Pin

NOT USED! NOT USED! CAN low (Res conn.) CAN low NOT USED! NOT USED! NOT USED! NOT USED!

X1 X1 X1 X1 X1 X1 X1 X1

41 42 43 44 45 46 47 48

NOT USED! Roller Rocker Cap NOT USED! NOT USED! NOT USED! GND Rocker Roller Cap NOT USED! NOT USED!

X1 X1 X1 X1 X1 X1 X1 X1

49 50 51 52 53 54 55 56

CAN high (Res verb.) CAN high capacitive Joystick sensor NOT USED! NOT USED! NOT USED! NOT USED! NOT USED!

X1 X1 X1 X1 X1 X1 X1 X1

57 58 59 60 61 62 63 64

NOT USED! NOT USED! NOT USED! NOT USED! NOT USED! NOT USED!

X1 X1 X1 X1 X1 X1

65 66 67 68 69 70

C

D

E

F


Änderung

Datum

1

Name

Datum


2

Ident.Nr.


ZeichNr.

4

5

6

8920980 460 9010 00 003 7

Anlage Ort

003 8

Blatt von

89 114

2

A17a

E

PROJ: 8920980_003 We reserve all rights in this document and in the informa tion contained therein. Reproduction, use or disclosure to third parties without express authority is strictly forbidden. © LIEBHERR WERK EHINGEN

D


C

4

5

8

B

PME1_OUTPUTMODULE

Sheet

Description

A17a.24V_B1 A17a.24V_logic A17a.GND A17a.PWM1 A17a.PWM2 A17a.PWM3 A17a.PWM4 A17a.PWM9

/42.E4 /42.E1 /42.E5 /78.A1 /57.A5 /56.A6 /56.A7 /53.A4

VBatt 24V Bank1 VBatt 24V Log SUPPLY EARTH PARKING BRAKE AHS BUCKET RETURNTODIG LIFT KICKOUT cruising range1

X1 X1 X1 X1 X1 X1 X1 X1

1 2 3 4 5 6 7 8

A17a.24V A17a.24V A17a.CAN_Low A17a.CAN_Low A17a.GND_DO2 A17a.GND_PWM1 A17a.GND_PWM2 A17a.GND_PWM3

A17a.PWM10 A17a.PWM11 A17a.PWM12 A17a.GND A17a.24V_logic A17a.24V_B3 A17a.24V_B2 A17a.GND_logic

/53.A2 /53.A3 /53.A1 /43.E3 /43.E4 /42.E7 /42.E2

cruising range2 cruising range3 Modulation SUPPLY EARTH RESERVE VBatt 24V Bk 3 zu M 2/35 (2. AST) SUPPLY 24V Bank2 SUPPLY EARTH LOGICAL PART

X1 X1 X1 X1 X1 X1 X1 X1

9 10 11 12 13 14 15 16

A17a.GND_PWM4 A17a.GND_PWM9 A17a.GND_PWM10 A17a.GND_PWM11 A17a.GND_PWM12 A17a.GND_DO4 A17a.FI1 A17a.FI2

A17a.GND A17a.PWM5 A17a.PWM6 A17a.PWM7 A17a.PWM8 A17a.PWM13 A17a.PWM14 A17a.PWM15

/42.E7 /56.A8 /21.A7 /54.A8 /53.A8 /53.A6 /53.A7 /54.A1

SUPPLY EARTH FLOAT POSITION VENTILATOR BUZZER Swivel angle limitation. oil engine1 oil engine1 oil engine2 TRAVELLING DIRECTION Pump1 FORWARD

X1 X1 X1 X1 X1 X1 X1 X1

17 18 19 20 21 22 23 24

A17a.PWM16 A17a.GND A17a.GND_logic A17a.24V_B4 A17a.CAN_Res A17a.24V A17a.GND_DO1 A17a.V_DO1

/54.A2 /43.E2

/43.D5

TRAVELLING DIRECTION Pump1 BACKWARD SUPPLY EARTH RESERVE VBatt 24V Bk 4 zu M 2/33 (2. AST) CANEND WITH PIN 43 verb. RESERVE RESERVE SUPPLY SUPPLY DO1

X1 X1 X1 X1 X1 X1 X1 X1

25 26 27 28 29 30 31 32

A17a.DO1 A17a.V_DO2 A17a.DO2 A17a.V_DO3 A17a.DO3 A17a.V_DO4 A17a.DO4 A17a.GND_DO3

/43.D5 /43.D8 /43.D8 /77.A3 /77.B3 /55.A1 /55.A2 /77.F3

2. AST Joystick zu M 2/28 SUPPLY SUPPLY DO2 2.AST Pump2 zu M 2/14 SUPPLY SUPPLY DO3 VCC central lubrication system MV PUMP Supply digital output4 A4 Back alarm OPTICAL GND central lubrication system MV PUMP

X1 X1 X1 X1 X1 X1 X1 X1

33 34 35 36 37 38 39 40

/43.E1

7

OUTPUT MODULE 1 ON / OUTLETS

Phys. Adr.

EA

6

A


+H3

B

3

OUTPUT MODULE 1

OUTPUT MODULE 2

A

INPUT MODULE 1

INPUT MODULE 3

1

Plug

Pin

Plug

Pin

RESERVE RESERVE CAN low CAN low RESERVE EARTH PARKING BRAKE EARTH AHS EARTH BUCKET RETURNTODIG

X1 X1 X1 X1 X1 X1 X1 X1

41 42 43 44 45 46 47 48

/56.F7 /53.F4 /53.F2 /53.F3 /53.F1 /55.E2

EARTH LIFT KICKOUT EARTH TRAVEL RANGES 1 EARTH TRAVEL RANGES 2 EARTH TRAVEL RANGES 3 EARTH Modulation EARTH Back alarm OPTICAL RESERVE RESERVE

X1 X1 X1 X1 X1 X1 X1 X1

49 50 51 52 53 54 55 56

A17a.CAN_High A17a.CAN_High A17a.GND A17a.GND_PWM5 A17a.GND_PWM6 A17a.GND_PWM7 A17a.GND_PWM8 A17a.GND_PWM13

/37.D5 /37.C5

CAN high CAN high RESERVE EARTH FLOAT POSITION EARTH VENTILATOR EARTH BUZZER Swivel angle limitation, oil engine1 EARTH Oil engine1

X1 X1 X1 X1 X1 X1 X1 X1

57 58 59 60 61 62 63 64

A17a.GND_PWM14 A17a.GND_PWM15 A17a.GNDPWM16 A17a.GND A17a.GND_FI1 A17a.GND_FI2

/53.F7 /54.F1 /54.F2

EARTH Oil engine2 EARTH TRAVELLING DIRECTION Pump1 FORWARD EARTH TRAVELLING DIRECTION Pump1 BACKWARD RESERVE RESERVE RESERVE

X1 X1 X1 X1 X1 X1

65 66 67 68 69 70

Phys. Adr.

Sheet

/37.D4 /37.C4 /78.F1 /57.F5 /56.F6

/56.F8 /21.F7 /54.F8 /53.F8 /53.F6

EA

Description

C

D

E

F


Änderung

Datum

1

Name

Datum


2

Ident.Nr.

GENERAL OUTLAY OUTPUT MODULE 1 Werk Bischofshofen GmbH 3

ZeichNr.

4

5

6

8920980 460 9010 00 003 7

Anlage Ort

003 8

Blatt von

90 114

2

A17b

E


D


C

Phys. Adr.

Sheet

A17b.24V_B1 A17b.24V_logic A17b.GND A17b.PWM1 A17b.PWM2 A17b.PWM3 A17b.PWM4 A17b.PWM9

4

5

B

/44.E4 /44.E1 /44.E5 /53.A5 /28.B1 /54.A5 /54.A6 /54.A3

VBatt 24V Bank1 VBatt 24V LOGICAL PART SUPPLY EARTH OVERSPEED PROTECTION OPTIONS SWIVEL ANGLE travel pump1 SWIVEL ANGLE travel pump2 TRAVELLING DIRECTION Pump2

X1 X1 X1 X1 X1 X1 X1 X1

1 2 3 4 5 6 7 8

A17b.24V A17b.24V A17b.CAN_Low A17b A17b.GND_DO2 A17b.GND_PWM1 A17b.GND_PWM2 A17b.GND_PWM3

A17b.PWM10 A17b.PWM11 A17b.PWM12 A17b.GND A17b.24V_logic A17b.24V_B3 A17b.24V_B2 A17b.GND_logic

/54.A4 /57.A1 /57.A2 /43.E7 /43.E8 /44.E7 /44.E2

TRAVELLING DIRECTION Pump2 BACKWARD Additional equipment1 Additional equipment2 SUPPLY EARTH RESERVE VBatt 24V BK 3 VBatt 24V Bank2 VBatt EARTH

X1 X1 X1 X1 X1 X1 X1 X1

9 10 11 12 13 14 15 16

A17b.GND_PWM4 A17b.GND_PWM9 A17b.GND_PWM10 A17b.GND_PWM11 A17b.GND_PWM12 A17b.GND_DO4 A17b.FI1 A17b.FI2

A17b.GND A17b.PWM5 A17b.PWM6 A17b.PWM7 A17b.PWM8 A17b.PWM13 A17b.PWM14 A17b.PWM15

/44.E7 /23.A2 /21.A8 /23.A7 /23.A8 /72.A6 /72.A7 /55.A4

SUPPLY EARTH Emergency steering FAN REVERSAL LFD LFD/FLOAT POSITION JOYSTICK STEERING LEFT JOYSTICK STEERING RIGHT Vcc MVGEROTOR STEERING

X1 X1 X1 X1 X1 X1 X1 X1

17 18 19 20 21 22 23 24

A17b.PWM16 A17b.GND A17b.GND_logic A17b.24V_B4 A17b.CAN_Res A17b.24V A17b.GND_DO1 A17b.V_DO1

/72.A8 /43.E6

Savety MV Joy SUPPLY EARTH RESERVE VBatt 24V Bk 4 CAN END RESERVE RESERVE VBatt SUPPLY DO1

X1 X1 X1 X1 X1 X1 X1 X1

25 26 27 28 29 30 31 32

A17b.DO1 A17b.V_DO2 A17b.DO2 A17b.V_DO3 A17b.DO3 A17b A17b.DO4 A17b.GND_DO3

/43.D1 /43.D4 /43.D4 /45.F1 /25.B8 /45.F2 /45.A5

2. AST Pump1 SUPPLY SUPPLY DO 2. AST TRANSMISSION VBatt DO3 REVERSING LIGHT VBatt D04 Backup ALARM RESERVE

X1 X1 X1 X1 X1 X1 X1 X1

33 34 35 36 37 38 39 40

/43.D1

8

PME1_OUTPUTMODULE

Plug

/43.E5 /38.E6

7


Description

EA

6

A


+H3

B

3

OUTPUT MODULE 1

OUTPUT MODULE 2

A

INPUT MODULE 1

INPUT MODULE 3

1

Pin

Plug

Pin

RESERVE RESERVE CAN low (CANE m. CAN low RESERVE EARTH over rotation speed EARTH OPTIONS EARTH travel pump

X1 X1 X1 X1 X1 X1 X1 X1

41 42 43 44 45 46 47 48

/54.F6 /54.F3 /54.F4 /57.F1 /57.F2 /45.F5

EARTH SWIVEL ANGLE EARTH TRAVELLING DIRECTION EARTH TRAVELLING DIRECTION EARTH Additional equipment EARTH Additional equipment EARTH Backup RESERVE RESERVE

X1 X1 X1 X1 X1 X1 X1 X1

49 50 51 52 53 54 55 56

A17b.CAN_High A17b.CAN_High A17b.GND A17b.GND_PWM5 A17b.GND_PWM6 A17b.GND_PWM7 A17b.GND_PWM8 A17b.GND_PWM13

/38.E8 /38.D6

CAN high (CANE m. CAN high RESERVE EARTH emergency steering EARTH FAN REVERSAL EARTH LFD EARTH LFD EARTH JOYSTICK STEERING

X1 X1 X1 X1 X1 X1 X1 X1

57 58 59 60 61 62 63 64

A17b.GND_PWM14 A17b.GND_PWM15 A17b.GNDPWM16 A17b.GND A17b.GND_FI1 A17b.GND_FI2

/72.F7 /55.E4 /72.F8

EARTH JOYSTICK STEERING EARTH GEROTOR STEERING GND Savety MV Joy RESERVE RESERVE RESERVE

X1 X1 X1 X1 X1 X1

65 66 67 68 69 70

Phys. Adr.

Sheet

/38.E5 /38.D5 /53.F5 /28.D1 /54.F5

/23.E2 /21.F8 /23.E7 /23.E8 /72.F6

Description

EA

C

D

E

F


Änderung

Datum

1

Name

Datum


2

Ident.Nr.


ZeichNr.

4

5

6

8920980 460 9010 00 003 7

Anlage Ort

003 8

Blatt von

91 114

2

3

OUTPUT MODULE 3

OUTPUT MODULE 1

OUTPUT MODULE 2

A

INPUT MODULE 1

INPUT MODULE 3

1

A17c

E


D

/48.F3 /48.F1 /48.F5 /49.A7 /50.A5 /50.A6 /50.A7 /57.A3

VBatt 24V Bank1 VBatt 24V LOGICAL PART SUPPLY EARTH Vcc CUTOFF LIGHTING 3. CONTROL CIRCUIT EP MV1 3. CONTROL CIRCUIT EP MV2 4. CONTROL CIRCUIT EP MV1 RESERVE

X1 X1 X1 X1 X1 X1 X1 X1

1 2 3 4 5 6 7 8

A17c.24V A17c.24V A17c.CAN_Low A17c A17c.GND_DO2 A17c.GND_PWM1 A17c.GND_PWM2 A17c.GND_PWM3

A17c.PWM10 A17c.PWM11 A17c.PWM12 A17c.GND A17c.24V_logic A17c.24V_B3 A17c.24V_B2 A17c.GND_logic

/57.A4

RESERVE RESERVE RESERVE SUPPLY EARTH RESERVE SUPPLY 24V Bank3 SUPPLY 24V Bank2 VBatt EARTH LOGICAL PART

X1 X1 X1 X1 X1 X1 X1 X1

9 10 11 12 13 14 15 16

A17c.GND_PWM4 A17c.GND_PWM9 A17c.GND_PWM10 A17c.GND_PWM11 A17c.GND_PWM12 A17c.GND_DO4 A17c.FI1 A17c.FI2

A17c.GND A17c.PWM5 A17c.PWM6 A17c.PWM7 A17c.PWM8 A17c.PWM13 A17c.PWM14 A17c.PWM15

/48.F7 /50.A8

SUPPLY EARTH 4. CONTROL CIRCUIT EP MV2 RESERVE RESERVE RESERVE RESERVE RESERVE RESERVE

X1 X1 X1 X1 X1 X1 X1 X1

17 18 19 20 21 22 23 24

A17c.CAN_High A17c.CAN_High A17c.GND A17c.GND_PWM5 A17c.GND_PWM6 A17c.GND_PWM7 A17c.GND_PWM8 A17c.GND_PWM13

RESERVE SUPPLY EARTH RESERVE SUPPLY 24V Bank4 RESERVE RESERVE RESERVE VBatt SUPPLY DO1

X1 X1 X1 X1 X1 X1 X1 X1

25 26 27 28 29 30 31 32

A17c.GND_PWM14 A17c.GND_PWM15 A17c.GNDPWM16 A17c.GND A17c.GND_FI1 A17c.GND_FI2

RESERVE VBatt SUPPLY DO2 RESERVE VBatt SUPPLY DO3 RESERVE VBatt SUPPLY D04 RESERVE RESERVE

X1 X1 X1 X1 X1 X1 X1 X1

33 34 35 36 37 38 39 40

/49.F1 /48.F6 /48.F2

/49.F4 /49.F3 /38.B8

A17c.DO1 A17c.V_DO2 A17c.DO2 A17c.V_DO3 A17c.DO3 A17c A17c.DO4 A17c.GND_DO3

8

B

A17c.24V_B1 A17c.24V_logic A17c.GND A17c.PWM1 A17c.PWM2 A17c.PWM3 A17c.PWM4 A17c.PWM9

/49.F2

7

PME1_OUTPUTMODULE

Sheet

EA

6


Phys. Adr.

A17c.PWM16 A17c.GND A17c.GND_logic A17c.24V_B4 A17c.CAN_Res A17c.24V A17c.GND_DO1 A17c.V_DO1


C

5

A


+H3

B

4

Description

Plug

Pin

Phys. Adr.

Sheet

EA

/38.B7 /38.B7 /50.E5 /50.E6 /50.E7 /50.E8 /57.F4 /57.F3

/38.B8

Description

Plug

Pin

RESERVE RESERVE CAN low (CANE m. CAN_Res conn.) CAN low RESERVE GND CUTOFF LIGHTING GND 3. CONTROL CIRCUIT EP MV1 GND 3. CONTROL CIRCUIT EP MV2

X1 X1 X1 X1 X1 X1 X1 X1

41 42 43 44 45 46 47 48

GND 4. CONTROL CIRCUIT EP MV1 RESERVE RESERVE RESERVE RESERVE RESERVE RESERVE RESERVE

X1 X1 X1 X1 X1 X1 X1 X1

49 50 51 52 53 54 55 56

CAN high (CANE m. CAN_Res conn.) CAN high RESERVE GND 4. CONTROL CIRCUIT EP MV2 RESERVE RESERVE RESERVE RESERVE

X1 X1 X1 X1 X1 X1 X1 X1

57 58 59 60 61 62 63 64

RESERVE RESERVE RESERVE RESERVE RESERVE RESERVE

X1 X1 X1 X1 X1 X1

65 66 67 68 69 70

C

D

E

F


Änderung

Datum

1

Name

Datum


2

Ident.Nr.


ZeichNr.

4

5

6

8920980 460 9010 00 003 7

Anlage Ort

003 8

Blatt von

92 114

2

1

3

4

5

6

7

8

A

A

LH ECUUP/CR GENERAL OUTLAY ON AND OUTLETS +M A700D

LHECUUPCREXT

B

E


D


C

PROJ: 8920980_003

Phys. Addr. A700D.50 A700D.15 A700D.30.1 A700D.30.2 A700D.30.3 A700D.31.2 A700D.31.3 A700D.31.1

Sheet

Type

Description

PIN

Phys. Addr.

/47.C6

ENGINE IGNITION

STARTING ON

X2 X2

66 68

/47.F1 /47.F3 /47.F5 /47.F2 /47.F4 /47.F6

SUPPLY 30b SUPPLY 30b SUPPLY 30b EARTH EARTH EARTH

PERFORMANCE PART PERFORMANCE PART ELECTRONICS PERFORMANCE PART PERFORMANCE PART ELECTRONICS

X2 X2 X2 X2 X2 X2

1 2 4 15 16 3

X2 X2 X2

67 69 70

A700D.DI5 A700D.DI6 A700D.DI7

RESERVE RESERVE RESERVE

A700D.AI9.1 A700D.AI9.2 A700D.AI9.GND A700D.AI10.1 A700D.AI10.2 A700D.AI10.GND

GAS PEDAL CHANNEL 1 GAS PEDAL CHANNEL 1 GAS PEDAL CHANNEL 1 GAS PEDAL; CHANNEL 2 GAS PEDAL; CHANNEL 2 GAS PEDAL; CHANNEL 2

SUPPLY SIGNAL EARTH SUPPLY SIGNAL EARTH

X2 X2 X2 X2 X2 X2

35 34 33 49 48 47

COOLANT LEVEL SENSOR COOLANT LEVEL SENSOR EARTH

VCC SIGNAL

X2 X2 X2

63 62 61

A700D.AL1.REF1 A700D.AI1.05V A700D.AI1.GND

WATER FUEL WATER FUEL WATER FUEL

FUEL FUEL FUEL

X2 X2 X2

7 6 5

A700D.AI2.REF1 A700D.AI2.05V A700D.AI2.GND

COOLING WATER COOLING WATER COOLING WATER

LEVEL LEVEL LEVEL

X2 X2 X2

21 20 19

X2 X2

60 46

A700D.AI11.1 A700D.AI11.2 A700D.AI11.GND

/21.A4 /21.F4

A700D.TI1 A700D.TI1.GND A700D.DO1 A700D.DI2 A700D.DO2 A700D.DI3 A700D.DO3 A700D.DO4 A700D.DO5

/23.A5 /23.F5

AIR FILTER CONTAMINATION VACUUM AIR FILTER CONTAMINATION VACUUM

/19.B5

D+ HEATER FLANGE

GENERATOR ACKNOWLEDGEMENT

X2 X2

53 64

HEATER FLANGE FREE SOLENOID VALVE ENGINE BRAKE RESERVE

SELECTION

X2 X2 X2 X2 X2

39 65 25 11 13

/19.B6

FUEL SELECTION


Plug

Änderung

Datum

1

Name

Datum


2

3

Plug

A700D.DO5.GND A700D.DO6 A700D.DO6.GND

RESERVE FAN VALVE FAN VALVE

SELECTION EARTH

X2 X2 X2

12 27 26

A700D.DO10 A700D.DO11 A700D.DO12

FEHLERLAMPE CONTROL RESERVE

(LowSide) PREHEAT (LowSide)

X2 X2 X2

14 28 42

A700D.FO A700D.CAN1.H.2 A700D.CAN1R A700D.CAN1L.1 A700D.CAN1H.1 A700D.CAN1L.2

SIGNAL

/37.C3 /37.C2 /37.D3 /37.D2

SPEED CAN1 HIGH CAN1 RES CAN1 LOW CAN1 HIGH CAN1 LOW

X2 X2 X2 X2 X2 X2

56 40 9 8 54 10

EARTH

/70.A3 /70.A2

CAN1 GND CAN2 HIGH CAN2 LOW CAN2 RES CAN2 HIGH CAN2 LOW CAN2 GND DIAGNOSIS DIAGNOSIS

X2 X2 X2 X2 X2 X2 X2 X2 X2

45 41 23 22 55 24 59 36 37

DIAGNOSIS SUPPLY SIGNAL

EARTH

X2 X2 X2

38 50 51

A700D.GND A700D.LSB1 A700D.LSB2

/70.A1

4

EMIT RECEIVE

PIN

A700D.GND A700D.FREI1 A700D.FREI2 A700D.FREI3 A700D.FREI4

EARTH NC NC NC NC

X2 X2 X2 X2 X2

52 17 18 29 30

A700D.FREI7

NC

X2

43

A700D.FREI11 A700D.FREI5 A700D.FREI6 A700D.FREI8

NC NC NC NC

X2 X2 X2 X2

44 31 57 58

A700D.FREI9

NC

X2

32

Ident.Nr.

GENERAL OUTLAY MOTOR CONTROL ENGINE SIDE


B

Description

A700D.CAN1.GND A700D.CAN2H.2 A700D.CAN2L.1 A700D.CAN2R A700D.CAN2H.1 A700D.CAN2L.2 A700D.CAN2.GND A700D.TXD A700D.RXD

Type Sheet

5

ZeichNr.

6

8920980 460 9010 00 003 7

Anlage Ort

003 8

Blatt von

93 114

C

D

E

F

2

1

3

4

5

6

7

8

A

A

ELECTRIC KEYPAD B

E


D

Phys. Addr.


C

B

=K +K4 A18

ELECTRIC KEYPAD 10278758

TYPE Sheet

Description

A18.Kl15 A18.GND A18.CAN_High A18.CAN_Low

A A A A

/39.D2 /39.D4

INFORMATION INPUT SUPPLY EARTH CAN_High CAN_Low

A18.Kl30 A18.Flasher

A A

/39.D3 /27.A7

A18.CAN_High A18.CAN_Low

A A

A18.CAN_RES. A18.PWM1 A18.PWM2 A18.PWM3

A A A A

A18.PWM4 A18.PWM5 A18.PWM6 A18.PWM7 A18.PWM8 A18.PWM9

PLUG PIN INFORMATION INPUT SUPPLY EARTH CAN_High CAN_Low

X1 X1 X1 X1

1 2 3 4

SUPPLY SUPPLY HAZARD WARNING LIGHT FLASHING SPEED INPUT

X1 X1

5 6

CAN_High CAN_Low

CAN_High CAN_Low

X1 X1

7 8

/27.A1 /33.A3 /28.A6

CAN_RES. HAZARD WARNING LIGHT WARNING BEACON WINDSCREEN WIPER

MATCHING RESISTOR OUTLET A1 OUTLET A2 OUTLET A3

X1 X1 X1 X1

9 10 11 12

A A

/28.A7 /33.A7

WASHING PUMP REAR REAR WINDOW HEATER

OUTLET A4 OUTLET A5

X2 X2

1 2

A A A A

/20.A7 /25.D1 /30.D1 /31.E1

PARKING LIGHT OUTLET A6 Abblentlicht OUTLET A7 WORKING PROJECTOR FRONT OUTLET A8 WORKING PROJECTOR REAR OUTLET A9

X2 X2 X2 X2

3 4 5 6

C

D

ELECTRIC KEYPAD E

F


Änderung

Datum

1

Name

Datum


2

Ident.Nr.

GENERAL OUTLAY ELECTRIC KEYPAD Werk Bischofshofen GmbH 3

ZeichNr.

4

5

6

8920980 460 9010 00 003 7

Anlage Ort

003 8

Blatt von

94 114

2

1

3

4

5

6

7

8

A

B

B

E

=K +K4 A11


D

C

Phys. Addr.

MAIN KEYPAD 10278781

TYPE Sheet


A A A A

A11.Kl15 A11.GND

A A


A A

A11.CAN_RES. A11.Res. A11.Res. A11.Res.

A A A A

Description

/39.D5 /39.D7 /35.B5 /35.B4

PLUG

PIN

+24V SUPPLY EARTH CAN_High CAN_Low

SUPPLY SUPPLY EARTH CAN_High CAN_Low

X1 X1 X1 X1

1 2 3 4

24V SUPPLY EARTH

SUPPLY SUPPLY EARTH

X1 X1

5 6

CAN_High CAN_Low

CAN_High CAN_Low

X1 X1

7 8

CAN_Abschlusswid. RESERVE RESERVE RESERVE

MATCHING RESISTOR RESERVE RESERVE RESERVE

X1 X1 X1 X1

9 10 11 12

D


C

PROJ: 8920980_003

A

/35.A5 /35.A4

E

F


Änderung

Datum

1

Name

Datum


2

Ident.Nr.

GENERAL OUTLAY MAIN KEYPAD Werk Bischofshofen GmbH 3

ZeichNr.

4

5

6

8920980 460 9010 00 003 7

Anlage Ort

003 8

Blatt von

95 114

2

1

3

4

5

6

7

8

A

A

ELECTRIC KEYPAD B

E


D


C

B

ELECTRIC KEYPAD

=K +K4 A18

10278758

Phys. Addr.

TYPE

Sheet

Description

PLUG


A A A A

/39.D2 /39.D4


A18.Kl30 A18.Flasher

A A

/39.D3 /27.A7

SUPPLY SUPPLY HAZARD WARNING LIGHT FLASHING SPEED INPUT


A A

CAN_High CAN_Low


A A A A

/27.A1 /33.A3 /28.A6

A18.PWM4 A18.PWM5

A A

A18.PWM6 A18.PWM7 A18.PWM8 A18.PWM9

A A A A


PIN

X1 X1 X1 X1

1 2 3 4

X1 X1

5 6

CAN_High CAN_Low

X1 X1

7 8

CAN_RES. HAZARD WARNING LIGHT WARNING BEACON WINDSCREEN WIPER

MATCHING RESISTOR OUTLET A1 OUTLET A2 OUTLET A3

X1 X1 X1 X1

9 10 11 12

/28.A7 /33.A7

WASHING PUMP REAR REAR WINDOW HEATER

OUTLET A4 OUTLET A5

X2 X2

1 2

/20.A7 /25.D1 /30.D1 /31.E1

PARKING LIGHT Low beam

OUTLET A6 OUTLET A7 WORKING PROJECTOR FRONT OUTLET A8 OUTLET A9 WORKING PROJECTOR REAR

X2 X2 X2 X2

3 4 5 6

C

D

ELECTRIC KEYPAD E

F


Änderung

Datum

1

Name

Datum


2

Ident.Nr.

GENERAL OUTLAY ELECTRIC KEYPAD Werk Bischofshofen GmbH 3

ZeichNr.

4

5

6

8920980 460 9010 00 003 7

Anlage Ort

003 8

Blatt von

94 114

2

1

3

4

5

6

7

8

A

A

HEAT / AIR CONDITIONING SYSTEM SYSTEM SIDE

E


D

A21a


+K4


C

B

PROJ: 8920980_003

B

Phys. Adr.

Sheet

A21a.1 A21a.2 A21a.3 A21a.4 A21a.5 A21a.6 A21a.7 A21a.8

/64.B3 /65.B3 /65.A3 /65.A2 /65.A1 /65.B2 /65.B7

EA

HEAT-/ AIR CONDITIONING (INSTALLATION)

PLUG

BDescription

Pin

Phys. Adr.

Sheet /66.A5 /66.B6

not used logic output(010V) VMC1 clockwise rotation VMC1 counter clockwise rotation V ref VMC1 GND VMC1 VMC1 Potentiometer tap VMC2 clockwise rotation

not used logic output(010V) VMC1 clockwise rotation VMC1 counter clockwise rotation V ref VMC1 GND VMC1 VMC1 Potentiometer tap VMC2 clockwise rotation

1 2 3 4 5 6 7 8


VMC2 counter clockwise rotation V ref VMC2 Ground VMC2 VMC2 potentiometer tap not used not used not used diagnose fan

9 10 11 12 13 14 15 16

VMC3 clockwise rotation VMC3 counter clockwise rotation V ref VMC3 Ground VMC3 VMC3 potentiometer tap VMC4 clockwise rotation VMC4 counter clockwise rotation V ref VMC4

17 18 19 20 21 22 23 24


/65.A7 /65.A6 /65.A5 /65.B6

/64.B4

VMC2 counter clockwise rotation V ref VMC2 Ground VMC2 VMC2 potentiometer tap not used not used not used diagnose fan


/66.B3 /66.A3 /66.A2 /66.A1 /66.B2 /66.B7 /66.A7 /66.A6

VMC3 clockwise rotation VMC3 counter clockwise rotation V ref VMC3 Ground VMC3 VMC3 potentiometer tap VMC4 clockwise rotation VMC4 counter clockwise rotation V ref VMC4

EA

Description

Plug

Pin

/67.B3 /67.A4 /67.A3

Ground VMC4 VMC4 potentiometer tap not used 24V fan not used VMC5 clockwise rotation VMC5 counter clockwise rotation V ref VMC5

Ground VMC4 VMC4 potentiometer tap not used 24V fan not used VMC5 clockwise rotation VMC5 counter clockwise rotation V ref VMC5

25 26 27 28 29 30 31 32


/67.A2 /67.B2 /64.B5 /64.B6 /64.B7 /64.B8 /67.A6 /67.A7

Ground VMC5 VMC5 potentiometer tap Sensor1+ (icing) Sensor1 (icing) Sensor2+ (icing) Sensor2 (icing) Temp.Sensor+(air cond. autom.) Temp.Sensor(air cond. autom.)

Ground VMC5 VMC5 potentiometer tap Sensor1+ (icing) Sensor1 (icing) Sensor2+ (icing) Sensor2 (icing) Temp.Sensor+(air cond. autom.) Temp.Sensor(air cond. autom.)

33 34 35 36 37 38 39 40

A21a.41 A21a.42

/64.B2

not used Ground FAN

not used Ground FAN

41 42

/64.B1

C

D

E

F


Änderung

Datum

1

Name

Datum


2

GENERAL OUTLAY HEAT / AIR CONDITIONING SYSTEM SYSTEM SIDE


4

5

6

Ident.Nr. ZeichNr.

8920980 460 9010 00 003 7

Anlage Ort

003 8

Blatt von

97 114

2

1

3

4

5

6

7

8

A

B

B

E

Phys. Addr.


D

OPTION KEYPAD

+K4 A19


C

PROJ: 8920980_003

A

10278759

TYPE SHEET

BDESCRIPTION

PLUG

PIN


A A A A

/39.F2 /39.F4 /35.E7 /35.E6



X1 X1 X1 X1

1 2 3 4

A19.Kl15 A19.c.

A A

/39.F3

SUPPLY Kl. 15 n.c

SUPPLY n.c

X1 X1

5 6


A A

/35.E5 /35.E4

CAN_High CAN_Low

CAN_High CAN_Low

X1 X1

7 8


A A A A

CAN_RES. n.c. n.c. n.c.

MATCHING RESISTOR n.c. n.c. n.c.

X1 X1 X1 X1

9 10 11 12

A19.PWM4 A19.PWM5

A A

n.c. n.c.

n.c. n.c.

X2 X2

1 2


A A A A

n.c. n.c. n.c. n.c.

n.c. n.c. n.c. n.c.

X2 X2 X2 X2

3 4 5 6

C

D

E

F


Änderung

Datum

1

Name

Datum


2

Ident.Nr.

GENERAL OUTLAY OPTION KEYPAD Werk Bischofshofen GmbH 3

ZeichNr.

4

5

6

8920980 460 9010 00 003 7

Anlage Ort

003 8

Blatt von

98 114

2

1

3

4

5

6

7

8

A

A

B

E


D

Phys. Addr.


C

B

+K4 A22

10278759

TYPE SHEET

PLUG PIN

BDESCRIPTION


A A A A

/39.F5 /39.F7 /35.D5 /35.D4



X1 X1 X1 X1

1 2 3 4

A22.Kl15 A22.c.

A A

/39.F8

SUPPLY Kl. 15 n.c

SUPPLY n.c

X1 X1

5 6


A A

/35.C5 /35.C4

CAN_High CAN_Low

CAN_High CAN_Low

X1 X1

7 8


A A A A

CAN_RES. n.c. n.c. n.c.

MATCHING RESISTOR n.c. n.c. n.c.

X1 X1 X1 X1

9 10 11 12

A22.PWM4 A22.PWM5

A A

n.c. n.c.

n.c. n.c.

X2 X2

1 2


A A A A

n.c. n.c. n.c. n.c.

n.c. n.c. n.c. n.c.

X2 X2 X2 X2

3 4 5 6

C

D

CAN AIR COND. KEYPAD

E

F


Änderung

Datum

1

Name

Datum


2

GENERAL OUTLAY AIR CONDITIONING KEYPAD FLAP CONTROL


4

5

6

Ident.Nr. ZeichNr.

8920980 460 9010 00 003 7

Anlage Ort

003 8

Blatt von

99 114

2

1

3

4

5

6

7

8

A

A

B

B

PROJ: 8920980_003

C

240.00

F1 10A

F31a 10A

...


F2 7,5A

F31b 10A

HIGH BEAM LEFT


F3 7,5A

F32a 10A

HIGH BEAM RIGHT

WORKING PROJECTOR LEFT REAR HATCH

F4 7,5A

F32b 10A

E

WORKING PROJECTOR RIGHT REAR HATCH

F5 7,5A

F33a 10A

130.00

LOW BEAM RIGHT

WORKING PROJECTOR LEFT* CAB ROOF

F6 3A

F33b 10A

BOUNDARY/PARKING LIGHT LEFT

F7 3A

WORKING PROJECTOR RIGHT* CAB ROOF

F29 25A

F9

10A

F45 10A

F56 10A

FUEL PREHEATING ..................................

INPUT MODULE 2 Vcc

OUTPUT MODULE 2 BANK 2 OUTPUT MODULE 3 K11/50, Y50, Y20, Y21 Vcc DO 1

F67 10A

F27 10A PROFILE LIGHT/ PARKING LIGHT

F15 10A

F46 10A

F57 10A

F68 10A

F28 10A

LH CONTROL LEVER VNR Erreg. G3, SIMULATION D+

INPUT MODULE 3 Vcc JOYSTICK STEERING

... ...

OUTPUT MODULE 3 Vcc DO 2

WEIGHING DEVICE ...

F18 10A

F47 10A

F58 10A

F69 10A

F30 15A

Windscreen wiper motor OUTPUT MODULE 1 BANK 1 ... washing p. back;dust filter check Y10, Y14, Y9, Y17 ...


Vcc VOLTAGE CONVERTER (RADIO, 12V plug.)

F19 10A

F70 10A

F34 20A

HEAT/AIR Cond. system. Kl.15 OUTPUT MODULE 1 BANK 2 OUTPUT MODULE 2 DO 1 Y18, Y13, H40, Y57* OPM1 YEP1,YEP2,Y2,Y3

F48 10A


REFUELLING PUMP

F20 15A

F49 10A

F71

F35 10A

WIPER, WASHING PUMP front; HORN

Vcc DO4 OUTPUT MODULE 2 DO 2 RFWE OPTICAL red flashing li. OPM1 MO1, Y6.1.2.3

Vcc KEYPADS Kl.15

Vcc MASTER Kl.30

F21 10A

F50 10A

F61

F72

F38 5A

LOW BEAM HIGH BEAM

... ...

OUTPUT MODULE 2 DO 3 E1, E5 back off lights

... ...

LHECUUP/CR Vcc Controller

F22 7,5A

F51

F62 10A

F73

F39 5A

OUTPUT MODULE 1 DO 1 OUTPUT Modul2 Y51, Y52

OUTPUT MODULE 2 DO 4 B16 Backup ALARM

... ...

Uhr AUXILIARY HEATER

F52 10A

10A

F59 10A

F60 10A

10A

10A

BOUNDARY/PARKING LIGHT Ignition lock release RIGHT

PUSHBUTTON SWITCH LH CONTROL LEVERR

AIR CON/OPTION KEYPAD

Switch lighting STOP LIGHT

F07b 10A

F75 10A

F10 5A

F23 5A

F63 10A

F74 15A

F40 20A

Flashing function

RADIO Kl.58 12V ELECTRICAL SOCKET

DISPLAY UNIT ...

Puritec PARTICLE FILTER

OUTPUT MODULE 1 DO 2 REVERSING OBSTACLE DETECTOR OPM2 Y2a,Y3a,Y11,Y12

OUTPUT MODULE 3 Vcc BANK 1

REAR WINDOW HEATER MIRROR HEATING*

VCC AUXILIARY HEATER Kl.30 ...

F8 15A

F76 10A

F11 10A

F24 10A

F53 10A

F64 10A

F19A 20A

F41

compressor seat*, (RADIO) CIGARETTE LIGHTER (X70)

RADIO Kl.30

PRESSURE SWITCH B32, B28, B3, B3a

IGNITION ON ENGINE ECU

OUTPUT MODULE 1 DO 3 Y62 central lubrication sys. LH


HEAT/AIR COND. SYS. Kl. 30 Dust particle filter . ...

F12 10A

F43 5A

F8A

10A

Interior lighting Clock AUXILIARY HEATER

F54 5A

F65 10A

F25

Groeneveld centr. lubr. system Logic INPUT 1+2 ... Logic OUTPUT 1 + 2

Kl. 15 MASTER ...


WARNING BEACON

F13 15A

F55 10A

F66 10A

F26

F44 10A

M11 VENTILATOR CONDENSER INPUT MODULE 1 ... Vcc


D


LOW BEAM LEFT

F14 15A

OUTPUT MODULE 2 BANK 1 OUTPUT MODULE 3 Y16, Y53, Y15, Y15a Vcc BANK 4

D

20A

F42

10A

... ...

10A

KL. 30

DIAGNOSTIC PLUG IMMOBILISER KAT

S1

C

F36 40A F17

LED TEST

A14.B1 LHECUUP/CR A14.B2 LHECUUP/CR

F16 40A

40A

...

...

...

KL. 15

F37 ... ...

...

E

8922717_002

F


Änderung

Datum

1

Name

Datum


2

Ident.Nr.

GENERAL OUTLAY PROTECTIVE FOIL Werk Bischofshofen GmbH 3

ZeichNr.

4

5

6

8920980 460 9010 00 003 7

Anlage Ort

003 8

Blatt von

100 114

D

E We reserve all rights in this document and in the informa tion contained therein. Reproduction, use or disclosure to third parties without express authority is strictly forbidden. © LIEBHERR WERK EHINGEN

PROJ: 8920980_003

C


1

Zustand Änderung

1

2

Ersteller

Datum

Datum Name Datum

2

3

Ausgabe

27.03.2007 09:42

3

4

lbhhae0 Donninger J. 26.03.2007 16:16

4

5

5

6

ELECTRICAL DIAGRAM DIESEL ENGINE 4 AND 6 CYLINDER


6

7

Ident.Nr. ZeichNr.

8920980

460 9010 00 003 7

8

A A

B B

ENGINE D936A6 AND D934A6 WITH ENGINE ECU C

D

E

F F

Anlage Ort

003 8

Blatt von

101 114

2

1

3

4

5

6

7

8

ᑏ; COOLANT TEMPERATURE ENGINE ECU

A

A

AIR CONDITIONING COMPRESSOR +M B708

M710 <> Y22

VEHICLE SIDE

1

ENGINE SIDE

/107.C5 1

R710 <> R701

X1

ENGINE CONTROL UNIT

D+ /105.B3

GENERATOR B

+M

B

PROJ: 8920980_003

C

+M Y711 +M

/109.B3 +M /109.B4 +M /109.B6 +M /110.B3 +M /110.B4 +M /110.B6 X1 Y712 X1 Y713 X1 Y714 X1 Y715 X1 Y716 X1

/105.B6 50

M700 <> M1

1 /107.C7

CHARGE AIR TEMPERATURE

B707 +M

D

/108.B2 1

SPEED

1 /106.B2

+M B711

CHARGE AIR PRESSURE

PHASE SENSOR

B710 +M

/108.B7 1

n1

3 /106.C7

3

E

SPEED

=M +M B712

/108.B4 1

WATER DETECTOR;

n

B709 +M TEMPERATURE SENSOR FUEL 1 /107.C3

B701 1 +M /106.B5 OIL PRESSURE 1

F

2

B703 +M

1

+M B713

E

STARTER


D

INJECTION PUMP


C

G700 <> G3

2

3

F

n2 Ersteller Datum


Ausgabe Zustand

Änderung

Datum

1

Name

Datum

27.03.2007 09:42

2


Ident.Nr.

STAND BY AM 6 CYLINDER ENGINE 4

5

ZeichNr.

6

8920980 460 9010 00 003 7

Anlage Ort

003 8

Blatt von

102 114

E

Zustand

+M B707

Änderung

1 Datum


Ersteller

Datum

Name Datum

COOLANT TEMPERATURE

TEMPERATURE SENSOR FUEL

Ausgabe

27.03.2007 09:42

2

WL701

CHARGE AIR PRESSURE WH 1.94

/108.B7 1

Y715 /110.B3 +M X1

Y714 +M

ENGINE PLUG

R710

3

M710 <> Y22

M710

R710

ᑏ;

1


4 1

G700 <> G3

X1

M710 +M G700


WL700

GENERATOR

WH 1.94 2

5

2

1



6

X701.B +M

n 3 /106.C7

+M B713

R710 <> R701

+M Y713

28 27 26 25 24 23 22

21 20 19 18 17 16 15

28 27 26 25 24 23 22

21 20 19 18 17 16 15

14 13 12 11 10 9 8

7 6 5 4 3 2 1

14 13 12 11 10 9 8

7 6 5 4 3 2 1

35 34 33 32 31 30 29

42 41 40 39 38 37 36

35 34 33 32 31 30 29

42 41 40 39 38 37 36

49 48 47 46 45 44 43

56 55 54 53 52 51 50

49 48 47 46 45 44 43

56 55 54 53 52 51 50

63 62 61 60 59 58 57

70 69 68 67 66 65 64

63 62 61 60 59 58 57

70 69 68 67 66 65 64

Y716 /110.B4 +M X1

X1

/109.B4

/110.B6

X1

X1

/109.B6

5

+M X701.S

OIL PRESSURE B710 +M

/106.B5 1

n2

4

X700.S +M

1

+M B701

PHASE SENSOR

3

+M X700.B

1

/107.C5 1

/106.B2 1

+M Y712 X1

/109.B3

+M Y711

2

X700.B +M

+M B708

2

/108.B4 1

SPEED

/107.C3 1

3 2

+M B703

3

/108.B2 1

SPEED

+M X700.S

+M B709

n1 +M B712

+M B711

PROJ: 8920980_003

A

/107.C7 1


C


1 6 7

G700

/105.B3 D+

+M M700

Ident.Nr. ZeichNr.

8920980

460 9010 00 003 7

8

INJECTION PUMP; 16 ENGINE ECU A

VEHICLE PLUG

ENGINE CONTROL UNIT

B B

M700 <> M1

M700

1

/105.B6 50

C

STARTER

WATER DETECTOR;

D

1

E

F F

Anlage Ort

003 8

Blatt von

103 114

2

1

A

5

6

7

8

A

PIN

OIL PRESSURE TRANSMITTER SUPPLY (5V) OIL PRESSURE TRANSMITTER SIGNAL (0,54,5V)

X1 X1

63 49

OIL PRESSURE TRANSMITTER RESERVE RESERVE RESERVE Air intake pressure transmitter Air intake pressure transmitter

GND NC NC NC SUPPLY (5V) SIGNAL (0,54,5V)

X1 X1 X1 X1 X1 X1

35 62 48 34 61 47

Air intake pressure transmitter RESERVE RESERVE

GND NC NC

X1 X1 X1

33 60 46

A A A A A A


NC NC NC NC NC NC

X1 X1 X1 X1 X1 X1

32 59 45 31 58 44

A700C.AI8.GND A700C.TI2 A700C.TI2.GND

A A A

/107.E7 /107.E6

RESERVE Air intakte temp. transmitter Air intake temp. transmitter

NC SIGNAL GND

X1 X1 X1

30 50 36

A700C.TI3 A700C.TI3.GND A700C.TI4

A A A

/107.E5 /107.E4 /107.E3

Coolant temp. transmitter Coolant temp. transmitter Fuel temp. transmitter

SIGNAL GND SIGNAL

X1 X1 X1

51 37 52

A700C.TI4.GND A700C.POWER.PS1 A700C.TI5

A

/107.E2 /106.E7 /106.E7

Fuel temp. transmitter water detector water detector

GND SUPPLY (UBat) SIGNAL

X1 X1 X1

38 57 53

A700C.TI5.GND A700C.POWER.SPEED1

/106.E6 /108.E3

water detector Speed sensor 1

GND SUPPLY (12V)

X1 X1

A700C.SPEED1 A700C.SPEED1.GND

/108.E2 /108.E1

Speed sensor 1 Speed sensor1

SIGNAL GND

X1 X1

39 69 55

A700C.POWER.SPEED2 A700C.SPEED2 A700C.SPEED2.GND A700C.POWER.INDEX A700C.INDEX

/108.E5 /108.E4 /108.E4 /108.E7 /108.E7

Speed sensor 2 Speed sensor 2 Speed sensor 2 phase sensor phase sensor

SUPPLY(12V) SIGNAL

X1 X1 X1 X1 X1

Sheet

A700C.AI3.REF2 A700C.AI3

A A

/106.E5 /106.E4

A700C.AI3.GND A700C.AI4.REF2 A700C.AI4 A700C.AI4.GND A700C.AI5.REF3 A700C.AI5

A A A A A A

/106.E4

A700C.AI5.GND A700C.AI6.REF3 A700C.AI6

A A A

/106.E1


Description

GND SUPPLY (12V) SIGNAL

56

Type

Sheet

Description

Plug

PIN 42 24

phase sensor RESERVE RESERVE

GND NC NC

X1 X1 X1

RESERVE RESERVE Dynamo D+

NC NC Ubat

X1 X1 X1

23 25 26 64

Starting motor. KL50 RESERVE RESERVE RESERVE RESERVE RESERVE

Activation(UBat) NC NC NC NC NC

X1 X1 X1 X1 X1 X1

29 66 67 43 65 14

/109.E2 /109.E3

RESERVE RESERVE RESERVE RESERVE RESERVE RESERVE RESERVE EP CYLINDER 1 EP CYLINDER 1

NC NC NC NC NC NC NC PWM (+) PWM (GND)

X1 X1 X1 X1 X1 X1 X1 X1 X1

28 13 27 9 10 11 12 22 8

A700C.A2.HIGH.MV2 A700C.A2.LOW.MV2 A700C.A3.HIGH.MV3

/109.E4 /109.E4 /109.E5

EP CYLINDER 2 EP CYLINDER 2 EP CYLINDER 3

PWM (+) PWM (GND) PWM (+)

X1 X1 X1

21 7 20

A700C.A3.LOW.MV3 A700C.A4.HIGH.MV4 A700C.A4.LOW.MV4 A700C.B1.HIGH.MV5 A700C.B1.LOW.MV5

/109.E6

/110.E2 /110.E3

EP CYLINDER 3 RESERVE RESERVE EP ZYLINDER 4 EP ZYLINDER 4

PWM (GND) NC NC PWM (+) PWM (GND)

X1 X1 X1 X1 X1

6 19 5 18 4

A700C.B2.HIGH.MV6

/110.E4

EP ZYLINDER 5

PWM (+)

X1

17

A700C.B2.LOW.MV6 A700C.B3.HIGH.MV7 A700C.B3.LOW.MV7 A700C.B4.HIGH.MV8

/110.E4 /110.E5 /110.E6

EP ZYLINDER 5 EP ZYLINDER 6 EP ZYLINDER 6 RESERVE

PWM (GND) PWM (+) PWM (GND) NC

X1 X1 X1 X1

3 16 2 15

RESERVE

NC

X1

1

/108.E6

A700C.INDEX.GND A700C.FI1 A700C.FI1.GND A700C.FI2 A700C.FI2.GND A700C.DI1

41 68 54HS 40 70

D

/105.E2

A700C.DO9 A700C.DI9 A700C.DO13 A700C.POWER.PS1 A700C.DI8 A700C.DO8

D D D

/105.E7

A700C.DO8.GND A700C.DO7 A700C.DO7.GND A700C.CURR1.HIGH A700C.CURR1.LOW A700C.CURR2.HIGH A700C.CURR2.LOW A700C.A1.HIGH.MV1 A700C.A1.LOW.MV1

D D D

D D

A700C.B4.LOW.MV8

B

C

D

E

21 20 19 18 17 16 15

35 34 33 32 31 30 29

42 41 40 39 38 37 36

49 48 47 46 45 44 43

56 55 54 53 52 51 50

70 69 68 67 66 65 64

/106.E3 /106.E2

Phys. Addr.

63 62 61 60 59 58 57

Typ

28 27 26 25 24 23 22

7 6 5 4 3 2 1

*70/70

153


Plug

Phys. Addr.

14 13 12 11 10 9 8

E


D

4

+M A700C.6

B

C

3

F

F Ersteller Datum


Ausgabe Zustand

Änderung

Datum

1

Name

Datum

27.03.2007 09:42

2


Ident.Nr.

GENERAL OUTLAY MOTOR CONTROL 6 CYLINDER 4

5

ZeichNr.

6

8920980 460 9010 00 003 7

Anlage Ort

003 8

Blatt von

104 114

2

1

3

4

5

6

7

8

A

/19.E4

VEHICLE SIDE

A

B

E

+M G700

D+

W

+M G700

G 3~ B+

B

D+

W

+M M700

G 3~ B+

10 80A

B

30

WH 1.94

50

M 31

6,6kW

15 100A

C

/104.B6

A700C.6.X1

X1 64 A700C.DI1 D DYNAMO ( Generator ) D+ Ubat MOTORECU

+M A700C.6 /104.B6

2 1

+M X701.B X701.S +M

2

1

2 2

+M X701.B X701.S +M

WH 1.94

1

+M X700.B X700.S +M

D

29

WH 1.94

WH 0.96

A700C.6.X1

64

WH 0.96

+M A700C.6

64

A700C.6.X1

+M X700.B X700.S +M

WH AWG14

1

WL700


D

WL701


C

PROJ: 8920980_003

X

B

X1 29 A700C.DO9 D Starter. KL50 Activation (UBat) MOTORECU

E

F

F Ersteller Datum


Ausgabe Zustand

Änderung

Datum

1

Name

Datum

27.03.2007 09:42

2

Ident.Nr.

STARTER, GENERATOR Werk Bischofshofen GmbH 3

ZeichNr.

4

5

6

8920980 460 9010 00 003 7

Anlage Ort

003 8

Blatt von

105 114

2

1

3

4

5

6

7

8

A

A

CHARGE AIR PRESSURE

OIL PRESSURE

p

+M B701

U

Q

p

E

3

BK

BK

3

2

1 2

B701.X

IN+

OUT

2

3

1 1

2

1

GND

3 3

PROJ: 8920980_003

IN+

OUT

2

B

12K

0,5 4,5V

B710.X

/104.B2

X1 33 A700C.AI5.GND A Charge air pressure sensor GND MOTORECU

X1 61 A700C.AI5.REF3 A Charge air pressure sensor SUPPLY (5V) MOTORECU

+M A700C.6 /104.B2

X1 49 A700C.AI3 A Oil pressure sensor SIGNAL (0,54,5V) MOTORECU

+M A700C.6 /104.D2

X1 39 A700C.TI5.GND

WH 0.96

X1 53 A700C.TI5

WATER DETECTOR GND MOTORECU

WATER DETECTOR SIGNAL MOTORECU

D

57

53

A700C.6.X1

WH 0.96

WH 0.96

X1 63 A700C.AI3.REF2 A Oil pressure sensor Supply (5V) MOTORECU

39

WH 0.96 63

WH 0.96

X1 35 A700C.AI3.GND A Oil pressure sensor GND MOTORECU

49

A700C.6.X1

35

WH 0.96

WH 0.96

X1 47 A700C.AI5 A Charge air pressure sensor SIGNAL (0,54,5V) MOTORECU

61

47

WH 0.96

+M A700C.6

33

A700C.6.X1

WH 0.96

C


D

B703.X


C

GND

R

3

0,5 4,5V 1

+M B710

U

2

+M B703

B

0 10 bar / g

1

0,5 4,5 bar / a

WATER DETECTOR

X1 57 A700C.POWER.PS1

E

WATER DETECTOR SUPPLY (UBat) MOTORECU

F

F Ersteller Datum


Ausgabe Zustand

Änderung

Datum

1

Name

Datum

27.03.2007 09:42

2

CHARGE AIR COOLER ; OIL PRESSURE SWITCH, WATER DETECTOR


4

5

6

Ident.Nr. ZeichNr.

8920980 460 9010 00 003 7

Anlage Ort

003 8

Blatt von

106 114

2

1

3

4

5

6

7

8

A

A

E

+M B708

+M B707

B708.X

B

R

2

B707.X

2

1 1

1

B709.X

30° 130°C

R

2 2

PROJ: 8920980_003

30° 130°C

R 1

1

2

+M A700C.6 /104.D2

+M A700C.6 /104.D2

X1 37 A700C.TI3.GND A COOLANT TEMP. SENSOR GND MOTORECU

+M A700C.6 /104.D2

WH 0.96

D

50

WH 0.96

X1 51 A700C.TI3 A COOLANT TEMP. SENSOR SIGNAL MOTORECU

36

A700C.6.X1

51

A700C.6.X1

WH 0.96

WH 0.96

X1 52 A700C.TI4 A FUEL TEMP. SENSPR SIGNAL MOTORECU

37

WH 0.96

X1 38 A700C.TI4.GND A FUEL TEMP. SENSOR GND MOTORECU

52

A700C.6.X1

38

WH 0.96


C


D

+M B709


2

30° 130°C

B

C

COOLANT TEMPERATURE

1

FUEL TEMPERATURE

X1 36 A700C.TI2.GND A AIR INTAKE TEMP. Sensor GND MOTORECU

X1 50 A700C.TI2 A AIR INTAKE TEMP. Sensor SIGNAL MOTORECU

E

F

F Ersteller Datum


Ausgabe Zustand

Änderung

Datum

1

Name

Datum

27.03.2007 09:42

2


Ident.Nr.

FUEL TEMPERATURE SENSOR ; AKTIVE ; OSCILLATING 4

5

ZeichNr.

6

8920980 460 9010 00 003 7

Anlage Ort

003 8

107

Blatt von

114

2

1

3

4

5

6

7

8

A

A

E

GND

SIGNAL

1

2

B713.X

B

U+

3 3

U+

3

2

2

X

1

SIGNAL

B712.X

3

2

GND

1

3

U+

3

2

2 1

PROJ: 8920980_003

SIGNAL

n

+M B713

X

/104.E2

X1 41 A700C.SPEED1.GND ENGINE SPEED Sensor1 GND MOTORECU

ENGINE SPEED Sensor 1 SIGNAL MOTORECU

ENGINE SPEED Sensor 1 SUPPLY (12V) MOTORECU

+M A700C.6 /104.E2

X1 40 A700C.SPEED2.GND ENGINE SPEED Sensor 2 GND MOTORECU

X1 54 A700C.SPEED2 ENGINE SPEED Sensor 2 SIGNAL MOTORECU

ENGINE SPEED Sensor 2 SUPPLY (12V) MOTORECU

+M A700C.6

WH 0.96

X1 42 A700C.INDEX.GND

X1 56 A700C.INDEX

PHASE SENSOR GND MOTORECU

PHASE SENSOR SIGNAL MOTORECU

/104.B6

D

70

56

A700C.6.X1

WH 0.96

WH 0.96

X1 68 A700C.POWER.SPEED2

42

WH 0.96 68

54

WH 0.96

WH 0.96

A700C.6.X1

X1 69 A700C.POWER.SPEED1

40

WH 0.96

X1 55 A700C.SPEED1

69

55

WH 0.96

+M A700C.6

41

A700C.6.X1

WH 0.96

C


D

GND

1

PHASE SENSOR

n

+M B712

X

B711.X


C

n

+M B711

B


1


X1 70 A700C.POWER.INDEX

E

PHASE SENSOR SUPPLY (12V) MOTORECU

F

F Ersteller Datum


Ausgabe Zustand

Änderung

Datum

1

Name

Datum

27.03.2007 09:42

2

ENGINE SPEED SENSOR 1, ENGINE SPEED SENSOR 2, PHASE SENSOR


4

5

6

Ident.Nr. ZeichNr.

8920980 460 9010 00 003 7

Anlage Ort

003 8

Blatt von

108 114

2

1

3

4

5

6

7

8

A

A

INJECTION PUMP 1

+M Y711

E

+M Y713

X2

X1

B

X2

X1

X2

IP CYLINDER 1 PWM (+) MOTORECU

IP CYLINDER 1 PWM (GND) MOTORECU

+M A700C.6 /104.D6

X1 7 A700C.A2.LOW.MV2



+M A700C.6 /104.D6

WH 1.23

WH 1.23

X1 21 A700C.A2.HIGH.MV2

D

6

20

WH 1.23

A700C.6.X1

7

WH 1.23


/104.D6

A700C.6.X1

8


21

WH 1.23

+M A700C.6

22

A700C.6.X1

WH 1.23

C


D

X1


C

+M Y712

PROJ: 8920980_003

B

INJECTION PUMP 3

INJECTION PUMP 2





E

F

F Ersteller Datum


Ausgabe Zustand

Änderung

Datum

1

Name

Datum

27.03.2007 09:42

2

Ident.Nr.

INJECTION PUMP CYLINDER 13 Werk Bischofshofen GmbH 3

ZeichNr.

4

5

6

8920980 460 9010 00 003 7

Anlage Ort

003 8

Blatt von

109 114

2

1

3

4

5

6

7

8

A

A

INJECTION PUMP 5

INJECTION PUMP 4

+M Y714

E

+M Y716

X2

X1

B

X2

X1

X2



+M A700C.6 /104.E6

X1 3 A700C.B2.LOW.MV6



+M A700C.6 /104.E6

WH 1.23

WH 1.23

X1 17 A700C.B2.HIGH.MV6

D

2

16

WH 1.23

A700C.6.X1

3

WH 1.23


/104.D6

A700C.6.X1

4


17

WH 1.23

+M A700C.6

18

A700C.6.X1

WH 1.23

C


D

X1


C

+M Y715

PROJ: 8920980_003

B

INJECTION PUMP 6



EP ZYLINDER 6 PWM (+) MOTORECU

EP ZYLINDER 6 PWM (GND) MOTORECU

E

F

F Ersteller Datum


Ausgabe Zustand

Änderung

Datum

1

Name

Datum

27.03.2007 09:42

2

Ident.Nr.

INJECTION PUMP CYLINDER 46 Werk Bischofshofen GmbH 3

ZeichNr.

4

5

6

8920980 460 9010 00 003 7

Anlage Ort

003 8

Blatt von

110 114

2

1

3

4

5

6

7

8

ᑏ; COOLANT TEMPERATURE ENGINE ECU

A


A

B708 1

VEHICLE SIDE

M710 <> Y22 1

ENGINE SIDE

R710 <> R701

X1

ENGINE CONTROL UNIT GENERATOR

PROJ: 8920980_003

C

ENGINE SPEED SENSOR


Y711

n1

Y713

X1

Y714

X1

CHARGE AIR TEMPERATURE 1 1

B707

D

B713

n CHARGE AIR PRESSURE 1

ENGINE SPEED SENSOR

B712

3

OIL PRESSURE SWITCH

2

1

B703

1

B701

3

n2

1

2

3

E

B710

WATER DETECTOR 1 B709

50

TEMPERATURE SENSOR FUEL

F

STARTER Ersteller Datum Ausgabe Zustand

X1

Y712

PHASE SENSOR


E

X1

B711

1

D

B

INJECTION PUMP 14

1

C

G700 <> G3

D+

B

Änderung

Datum

1

Name

Datum


2

Ident.Nr.



F

M700 <> M1

4

5

ZeichNr.

6

8920980 460 9010 00 003 7

Anlage Ort

003 8

Blatt von

111 114

E

Zustand

1

1

1 1

3

1

1

PROJ: 8920980_003

1

B

1


C


n1

3

3 2

2

Änderung Datum

1 Name

Y712

Y711

n2

Ersteller

Datum

Ausgabe

Datum

lbhhae0 27.03.2007 09:42

2

ENGINE SPEED SENSOR

B713

OIL PRESSURE SWITCH

3

21 20 19 18 17 16 15

28 27 26 25 24 23 22

21 20 19 18 17 16 15

7 6 5 4 3 2 1

R710 <> R701

ᑏ;

14 13 12 11 10 9 8

Y713

R710 X1

Donninger J. 26.03.2007 16:16

4

7 6 5 4 3 2 1

ENGINE SIDE

M710 <> Y22

M710

G700


5

49 48 47 46 45 44 43

63 62 61 60 59 58 57

70 69 68 67 66 65 64

63 62 61 60 59 58 57

70 69 68 67 66 65 64

4

35 34 33 32 31 30 29

56 55 54 53 52 51 50

49 48 47 46 45 44 43

56 55 54 53 52 51 50

3

42 41 40 39 38 37 36

35 34 33 32 31 30 29

42 41 40 39 38 37 36

Y714 28 27 26 25 24 23 22

2

14 13 12 11 10 9 8

X1

X1

A

X1

X1

1 5 6

GENERATOR



6

7

G700 <> G3 M700 <> M1

G700 M700

PHASE SENSOR

Ident.Nr. ZeichNr.

8920980

460 9010 00 003 7

8

ENGINE ECU

INJECTION PUMP 14 A

VEHICLE SIDE

ENGINE CONTROL UNIT

ENGINE SPEED SENSOR B

B711

1

B712 D+

50

C

STARTER

n WATER DETECTOR

1

B701

D

CHARGE AIR PRESSURE

1

B703

COOLANT TEMPERATURE

B708

TEMPERATURE SENSOR FUEL E

B709


B707

F F

Anlage Ort

003 8

Blatt von

112 114

2

1

A

5

6

7

8

A

PLUG

Description

Typ

A700C.AI3.REF2 A700C.AI3

A A

OIL PRESSURE SWITCH OIL PRESSURE SWITCH

SUPPLY (5V) SIGNAL (0,54,5V)

X1 X1

63 49


A A A A A A

OIL PRESSURE SWITCH RESERVE RESERVE RESERVE CHARGE AIR COOLER CHARGE AIR COOLER

GND NC NC NC SUPPLY (5V) SIGNAL (0,54,5V)

X1 X1 X1 X1 X1 X1

35 62 48 34 61 47

A700C.AI5.GND A700C.AI6.REF3 A700C.AI6

A A A

CHARGE AIR COOLER RESERVE RESERVE

GND NC NC

X1 X1 X1

33 60 46


A A A A A A


NC NC NC NC NC NC

X1 X1 X1 X1 X1 X1

32 59 45 31 58 44

A700C.AI8.GND A700C.TI2 A700C.TI2.GND

A A A

RESERVE Charge air temperature sensor Charge air temperature sensor

NC SIGNAL GND

X1 X1 X1

30 50 36

A700C.TI3 A700C.TI3.GND A700C.TI4

A A A

Coolant temperature sensor Coolant temperature sensor Fuel temperature sensor

SIGNAL GND SIGNAL

X1 X1 X1

51 37 52

A700C.TI4.GND A700C.POWER.PS1 A700C.TI5

A

Fuel temperature sensor WATER SENSOR WATER SENSOR

GND SUPPLY (UBat) SIGNAL

X1 X1 X1

38 57 53

A700C.TI5.GND A700C.POWER.SPEED1

WATER SENSOR ENGINE SPEED SENSOR1

GND SUPPLY (12V)

X1 X1

A700C.SPEED1 A700C.SPEED1.GND

ENGINE SPEED SENSOR 1 ENGINE SPEED SENSOR; 1

SIGNAL GND

X1 X1

39 69 55

A700C.POWER.SPEED2 A700C.SPEED2 A700C.SPEED2.GND A700C.POWER.INDEX A700C.INDEX

ENGINE SPEED SENSOR 2 ENGINE SPEED SENSOR 2 ENGINE SPEED SENSOR 2 PHASE SENSOR PHASE SENSOR

SUPPLY (12V) SIGNAL

X1 X1 X1 X1 X1

GND SUPPLY (12V) SIGNAL

PIN

Phys. Addr.

41 68 54 40 70 56

Type

Description

Sheet

Plug

PIN

A700C.INDEX.GND A700C.FI1 A700C.FI1.GND

PHASE SENSOR RESERVE RESERVE

GND NC NC

X1 X1 X1

A700C.FI2 A700C.FI2.GND A700C.DI1

RESERVE RESERVE GENERATOR D+

NC NC Ubat

X1 X1 X1

23 25 26 64

STARTER. KL50 RESERVE RESERVE RESERVE RESERVE RESERVE

SELECTION (UBat) NC NC NC NC NC

X1 X1 X1 X1 X1 X1

29 66 67 43 65 14

RESERVE RESERVE RESERVE RESERVE RESERVE RESERVE RESERVE EP CYLINDER 1 EP CYLINDER 1

NC NC NC NC NC NC NC PWM (+) PWM (GND)

X1 X1 X1 X1 X1 X1 X1 X1 X1

28 13 27 9 10 11 12 22 8

A700C.A2.HIGH.MV2 A700C.A2.LOW.MV2 A700C.A3.HIGH.MV3

EP CYLINDER 2 EP CYLINDER 2 RESERVE

PWM (+) PWM (GND) NC

X1 X1 X1

21 7 20

A700C.A3.LOW.MV3 A700C.A4.HIGH.MV4 A700C.A4.LOW.MV4 A700C.B1.HIGH.MV5 A700C.B1.LOW.MV5

RESERVE RESERVE RESERVE EP CYLINDER 3 EP CYLINDER 3

NC NC NC PWM (+) PWM (GND)

X1 X1 X1 X1 X1

6 19 5 18 4

A700C.B2.HIGH.MV6

EP CYLINDER 4

PWM (+)

X1

17

A700C.B2.LOW.MV6 A700C.B3.HIGH.MV7 A700C.B3.LOW.MV7 A700C.B4.HIGH.MV8

EP CYLINDER 4 RESERVE RESERVE RESERVE

PWM (GND) NC NC NC

X1 X1 X1 X1

3 16 2 15

A700C.B4.LOW.MV8

RESERVE

NC

X1

1

D

A700C.DO9 A700C.DI9 A700C.DO13 A700C.POWER.PS1 A700C.DI8 A700C.DO8

D D D

A700C.DO8.GND A700C.DO7 A700C.DO7.GND A700C.CURR1.HIGH A700C.CURR1.LOW A700C.CURR2.HIGH A700C.CURR2.LOW A700C.A1.HIGH.MV1 A700C.A1.LOW.MV1

D D D

D D

42 24

B

C

D

E

35 34 33 32 31 30 29 21 20 19 18 17 16 15

42 41 40 39 38 37 36

49 48 47 46 45 44 43

56 55 54 53 52 51 50

70 69 68 67 66 65 64

63 62 61 60 59 58 57

153

28 27 26 25 24 23 22

7 6 5 4 3 2 1

*70/70


Sheet

Phys. Addr.

14 13 12 11 10 9 8

E


D

4

+M A700C4

B

C

3

F


Änderung

Datum

1

Name

Datum


2


Ident.Nr.

GENERAL OUTLAY MOTOR CONTROL 4 CYLINDER 4

5

ZeichNr.

6

8920980 460 9010 00 003 7

Anlage Ort

003 8

Blatt von

113 114

2

1

CODE LETTER STABE

3

CODE LETTER S

= SYSTEM

4

5

KIND OF EQUIPMENT DIN EN613462

6

7

DENOTATION EXTRACTED OF DIN 72552

CLAMP SIGNAL

SIFUSES

A

U

UNDER CARRIAGE

D

REVOLVING STAGE

A

BOOM

F

CARRIAGE (CRAWLER CRANE)

M

MOTOR

E


D


C

PROJ: 8920980_003

B

F

+ INSTALLATION LOCATION UNDER CARRIAGE H

CAB

F

VEHICLE

S

SWITCH CABINET

M

B

APPROXIMATION, SENSOR, SWITCH TACHO SENSOR, TEMPERATURE SENSOR PRESSURE SENSOR,SWITCH, SENSOR

K D A

CARRIGE

S

SWITCH CABINET

M

MOTOR

+

=

U

+

H

Ausgabe Änderung

Datum

1

Name

Datum

RETURN WIRE TO BATTERY,PLUS VIA SWITCH / RELAY (SWITCHED PLUS) RETURN WIRE FROM BATTERIE, MINUS / GROUND DIRECT

F

FUSES, FI, CIRCUIT BREAKER

31b

RETURN WIRE TO BATTERY, MINUS / GROUND VIA SWITCH / RELAY (SWITCHED MINUS)

G

DYNAMOS, GENERATORS, BATTERIES LAMPS , ANNOUNC.

SWITCHING RELAY, TIME RELAY, CONTACTOR RELAY I/OMODULE, UEAMODULE, ABVELECTRONICS, TRANSISTOR, ELECTRONIC VALVES INDUCTORS

GREY

GRAU

3

VT

VIOLET

VIOLETT

5

LB

LIGHT BROWN

BEIGE

7,5

BN

BROWN

BRAUN

10

RD

RED

ROT

15

BU

BLUE

BLAU

YE

YELLOW

GELB

50

STARTER, STARTER CONTROL UNIT; DIRECT

30

GN

GREEN

GRÜN

50e; 50f

START LOCK RELAY, INPUT;OUTPUT

52

TAG SIGNAL WIPER MOTOR

B

WIRE COLOURS DIN IEC 757

N

TRANSDUCER

54

STOPLIGHT

P

BUZZER, CLAMP, SPEAKERS, CLOCK, TACHOGRAPH, PRINTER, VOLTMETER, WATTMETER,

54g

TAG SIGNAL ( COMPRESSED AIR VALVE )

Q

POWER SWITCH RELAY ( FOR LOAD ) BREAKER, MOTOR STARTER, TYRISTOR

55

FOG LAMP

56,a,b,d

HEADLIGHT

57,a,L,R

PARKING LIGHT

58,b,c,d,L,R

LIMITATION,END,LICENSE PLATE AND DEVICE LIGHTS

61

C

RESISTORS, DIODES SWITCH, KEYPAD( WITHOUT DISPLAY ), MOUSE

T

LSBBUS SENSOR, ANTENNA, TELEPHONE SET POWER TRANSFORMER, RECTIFIER, RADIO

U

ISOLATOR

V

FILTER

W

COLLECTING ELECTRODE, CABLE, CABLE LOOP, INFORMATION BUS OPTICAL FIBER, DUCT ( RING WHEEL TRANSDUCER ) CONNECTOR ( ELECTRICAL ), PLUG, CLAMP, TERMINAL BLOCK, TERMINAL STRIP, CONNECTION TERMINAL STRIP ADD. PART

GY

20

MOTORS

Z

2

FLASHER UNIT

M

VALVES

A

FARBEN

49

53,a,b,c,e,i

Y

COLOURS

ALT

COLOURS

FARBEN

gr

GY

GREY

GRAU

vi

VT

VIOLET

VIOLETT

rs

PK

PINK

ROSA

br

BN

BROWN

BRAUN

rt

RD

RED

ROT

GENERATOR CONTROL

bl

BU

BLUE

BLAU

72

ALARM SWITCH,(ALL AROUND, INDICATOR LAMP)

ge

YE

YELLOW

GELB

75

RADIO, CIGARETTE LIGHTER

gn

GN

GREEN

GRÜN

76

SPEAKERS

sw

BK

BLACK

SCHWARZ

B+,B

BATTERY, PLUS,MINUS

or

OG

ORANGE

ORANGE

D+,D

DYNAMO, PLUS,MINUS

ws

WH

WHITE

WEISS

DF,DF1,DF2

DYNAMO, FIELD, FIELD1, FIELD2

D

E

BEXAMPLE FOR SIGNAL CROSS-REFERENCE

EINSTALLATION LOCATION

Datum

30b 31

EXAMPLE FOR EQUIPMENT LABELING SYSTEM

INPUT OF BATTERY PLUS, DIRECT

FLOURESCENT LAMP, LAMP, BULB, LIGHT FIXTURE HEADLIGHTS, RUNNING LIGHT, HEATING

X

=

30

E

S

CARRIAGE

SWITCHED PLUS BEHIND BATTERY (OUTPUT IGNITION[DRIVE]SWITCH)

CAPACITOR

R

CABIN

15

C

L

+ INSTALLATION LOCATION REVOLVING STAGE / CARRIAGE

Ersteller

Zustand

KEYPAD UNIT, BRACE UNIT, MONITOR, ENGINE CONTROL UNIT

K

MOTOR

A

A

H

8

AKIND OF EQUIPMENT

ZNUMBERING

K

53

:

ACONNECTION

:

30


2

SFUSE

or

30b.F390

4

5

FUSE

SIGNAL

+24V.L1

KEY OF SYMBOLS DIN EN613461; DIN EN613462 ; DIN EN60617


SIGNAL

6

Ident.Nr. ZeichNr.

8920980 460 9010 00 003 7

F Anlage Ort

003 8

Blatt von

114 114

Service Manual

Electrical system Electrical components

10.1 Electrical components 10.1.1

Electrical components in the cab The main electrical/electronic components are located on the cab rear wall

Design The following components are fitted on the cab rear wall: - Fuse and relay board - Voltage converter - Main electronics (master) - Input module - Warning buzzer - Diagnostic plug - Optional components

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The electrical and electronic components are mounted under the covering on the cab rear wall.

Components on the rear cab wall 1 Warning buzzer H40 (behind cover) 2 Diagnostic plug 3 Main electronics (master) A15


4 5 6 7

Voltage transformer T1 Rear wiper motor M3 Relay and fuse board A4 Relay base fixing (optional)

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8 Input module 2 A16b 9 Connector X1 10 Connector X2

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10.1-1 o f 1

Electrical system

Service Manual

Electrical components

10.1.2

Fuse and relay board A4 (ID no. 10290014)

LBH/Version 01/10.2006/en/hd/21/02/2007

Design

Fuse and relay board A4

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Service Manual


LBH/Version 01/10.2006/en/hd/21/02/2007

F1 F2 F3

10 A terminal 15 reserve 7.5 A terminal 15 left high beam 7.5 A terminal 15 right high beam F4 7.5 A terminal 15 left low beam F5 7.5 A terminal 15 right low beam F6 3 A terminal 30 left profile light / parking light F7 3 A terminal 30 right profile light / parking light F07b 10 A terminal 15 hazard lights F8 15 A terminal 58 compressor seat, seat heater* F8a 10 A terminal 58 interior lighting, radio, cigarette lighter (X70) F9 10 A terminal 15 LH control lever button, air conditioning keypad, optional keypad F10 5 A terminal 15 display unit F11 10 A terminal 15 pressure switches B32, B28, B3, B3a F12 20 A terminal 15 reserve F13 20 A terminal 15 reserve F14 15 A terminal 15 fuel preheating F15 10 A terminal 15 S2 LH control lever; tank pipe sensor; terminal 15 master; engine stop relay; alternator excitation F16 40 A terminal 15 (MAXI fuse) F17 40 A terminal 15 (MAXI fuse) F18 10 A terminal 15 washer pump, rear wiper motor F19 10 A terminal 15 heater, B27 air conditioning F19A 20 A terminal 30 heater, air conditioning F20 15 A terminal 15 front wiper, washer pump, horn F21 10 A terminal 15 driving light, high beam F22 7.5 A terminal 15 brake lights, switch illumination F23 15 A terminal 15 reserve F24 10 A terminal 15 ignition ON, engine ECU F25 10 A terminal 30 flashing beacon F26 10 A terminal 30 diagnostic plug F27 10 A terminal 30 profile light / parking light F28 10 A terminal 30 reserve F29 25 A terminal 30 ignition starter switch relief F30 15 A terminal 30 voltage converter, radio, 12 V socket F31a 10 A terminal 30/15 working floodlight + double beam, front left F31b 10 A terminal 30/15 working floodlight + double beam, front right


F47 10 A terminal 15 output module 1 bank 1 - Y9, Y10, Y14, Y17 F48 10 A terminal 15 output module 1 bank 2 - H40, Y13, Y18, Y57 F49 10 A terminal 15 output module 1 bank 3 - YMo1, Y6.1, Y6.2, Y6.3 Y11, Y12 F50 10 A terminal 15 output module 1 bank 4 - Y2, Y3, YEP1, YEP2 F51 10 A terminal 15 output module 1 DO1 supply - OP M2 - Y51, Y52 F52 10 A terminal 15 output module 1 DO2 supply - OP M2 - Y2a, Y3a, Y11, Y12 F53 10 A terminal 15 output module 1 DO3 supply Y62 central lubrication system F54 5 A terminal 15 master control A15 supply F55 10 A terminal 15 output module 2 bank 1 - Y16, Y53, Y15 F56 10 A terminal 15 output module 2 bank 2 - K11/50, Y50, Y20, Y21 F57 10 A terminal 15 output module 2 bank 3 - Y11, Y12 F58 10 A terminal 15 output module 2 bank 4 - reserve F59 10 A terminal 15 output module 2 DO1 supply - OP M1 - YEP1, YEP2, Y2, Y3 F60 10 A terminal 15 output module 2 DO2 supply - OP M1 Y6.1.2.3 F61 10 A terminal 15 output module 2 DO3 supply - E1, E5 F62 10 A terminal 15 output module 2 DO4 supply - B16 F63 10 A terminal 15 output module 3 bank 1 - reserve F64 10 A terminal 15 output module 3 bank 2 - reserve F65 10 A terminal 15 output module 3 bank 3 - reserve F66 10 A terminal 15 output module 3 bank 4 - reserve F67 10 A terminal 15 output module 3 DO1 supply F68 10 A terminal 15 output module 3 DO2 supply F69 10 A terminal 15 output module 3 DO3 supply F70 10 A terminal 15 output module 3 DO4 supply F71 10 A terminal 15 keypad supply F72 30 A terminal 15 reserve F73 10 A terminal 15 reserve F74 15 A terminal 15 rear window heater, heated mirror* F75 10 A terminal 30 radio IGN,

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K209 Dust filter excess pressure system relay K228 Visual back-up alarm relay K229 Visual back-up alarm relay K230 Automatic run-off relay K240 Power hazard light relay K241 Reserve K242 Reserve K243 Reserve K244 Reserve K245 Reserve K246 Reserve K270 Immobiliser relay K271 Return-to-dig relay M3 R9b Alternator exciter resistance 220 Ω S1 Safety test button V1 Extinguishing diode K01 V2 Extinguishing diode K01/87 V3 Extinguishing diode K12 V4 Extinguishing diode K02 V5 Extinguishing diode K03 V6 Extinguishing diode K02/87 V7 Extinguishing diode K03/87 V8 Extinguishing diode K5 V9 Extinguishing diode K3 V10 Extinguishing diode K2 V11 Extinguishing diode K22 V12 Extinguishing diode K22a V13 Extinguishing diode K22b V14 Extinguishing diode K25 V15 Extinguishing diode K26 V16 Extinguishing diode K31a V17 Extinguishing diode K31b V18 Extinguishing diode K32a V19 Extinguishing diode K32b V20 Extinguishing diode K33a V21 Extinguishing diode K33b V22 Extinguishing diode F9 reserve V23 Extinguishing diode F14 preheating V24 Extinguishing diode F19 heater blower, air conditioning V25 Extinguishing diode F72 reserve V29 Extinguishing diode K240/87 V30 Extinguishing diode K241/87 V31 Extinguishing diode K242/87 V32 Extinguishing diode K244/87a V32c Reversing light blocking diode V33 Extinguishing diode K244/87 V33c Reversing light blocking diode V34 Extinguishing diode K245/87a V35 Extinguishing diode K245/87 V36 Extinguishing diode K246/87a V37 Extinguishing diode K246/87 V38 Extinguishing diode K243/87a V39 Extinguishing diode K243/87 V40 Extinguishing diode K228/87a V41 Extinguishing diode K228/87 V42 Extinguishing diode K271/87a V43 Extinguishing diode K271/87

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Electrical system

Service Manual


F32a 10 A terminal 30/15 working floodlight rear left (rear hatch) F32b 10 A terminal 30/15 working floodlight rear right (rear hatch) F33a 10 A terminal 30/15 working floodlight rear left (cab door)* F33b 10 A terminal 30/15 working floodlight rear right (cab door)* F34 20 A terminal 30 refuelling pump* F35 10 A terminal 30 master control supply A15 F36 40 A terminal 30 engine control unit supply A14 LH-ECU (output) F37 40 A terminal 30 reserve F38 5 A terminal 30 engine control unit supply A14 LH-ECU (output) F39 20 A terminal 30 engine compartment lighting, auxiliary heater clock F40 20 A terminal 30 auxiliary heater control F41 20 A terminal 30 reserve F42 20 A terminal 30 reserve F43 5 A terminal 15 input module 1+2 logic F44 10 A terminal 15 input module 1 supply F45 10 A terminal 15 input module 2 supply F46 10 A terminal 15 input module 3 supply

terminal 58, 12 V socket F76 10 A terminal 30 radio + K01 Ignition starter switch relief relay terminal 15 K02 Starter solenoid relay* K03 Engine stop relay* K1 Direction indicator relay K2 Profile light, parking light relay K3 Low beam / driving light relay K3a High beam relay K5 Relay terminal 15 K8 Rear windscreen wiper and washer pump relay K9 Flashing beacon relay K10 Mirror/rear window heater relay K12 Radio / 12 V socket relay terminal 58 K22 Hazard lights relay terminal 15 K22a Relay S4 H16, H18 K22b Relay S4 H15, H17 K25 John Deere (USA) hazard light relay K26 John Deere (USA) hazard light relay K31a Left working floodlight + double beam relay, front left K31b Right working floodlight + double beam relay, front right K32a Left working floodlight + double beam relay, rear left K32b Right working floodlight + double beam relay, rear right

V44 V45 V46 V48 V49 V50 V51 V52 V53 V54 V57 V58 V59 V60 V81 V82 V83 V84 V85 V86 V87 V88 V89 V90 V99

Extinguishing diode K271 Extinguishing diode K228 Extinguishing diode K243 Extinguishing diode K246 Extinguishing diode K245 Extinguishing diode K244 Extinguishing diode K242 Extinguishing diode K241 Extinguishing diode K240 Extinguishing diode K209 Extinguishing diode K10 Extinguishing diode K9 Extinguishing diode K8 Extinguishing diode K3a Alternator excitation blocking diode Alternator excitation blocking diode Direction indicator blocking diode Direction indicator blocking diode Direction indicator blocking diode Direction indicator blocking diode Direction indicator blocking diode Direction indicator blocking diode Direction indicator blocking diode Hydraulic quick change device blocking diode Direction indicator blocking diode

* Options


However, the other electrical and electronic components are powered via the relay and fuse board.

Working floodlight fuse function The function of the working floodlights can be selected by plugging the fuses F31A, F31B, F32A, F32B, F33A and F33B: - When the fuses are plugged to terminal 30 the working floodlights work as soon as the main switch is turned ON. - When the fuses are plugged to terminal 15 the working floodlights only work when the ignition is turned ON. You can also choose a mixed function, for example by plugging the front working floodlights to terminal 15 and the rear floodlights to terminal 30.

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LBH/Version 01/10.2006/en/hd/21/02/2007

The relay and fuse board houses and connects the electrical components. The relay and fuse board does not have a control function.

Service Manual


Fuse test The fuses on the relay and fuse board are divided into three categories. - Fuses for power supply from terminal 30 - Fuses for power supply from terminal 15 - Fuses to protect various functions (e.g. low beam, profile lights / parking light) Each fuse has an LED and can be tested by pressing the button S1. The fuse test depends on the electrical status. Only the fuses of the activated circuit can be tested: - When the main switch is on (terminal 30) only the LEDs on terminal 30 power supply fuses light up when the button S1 is pressed. - When the main ignition is on (terminal 15) the LEDs on terminal 30 and terminal 15 power supply fuses light up when the button S1 is pressed. - The LEDs to protect the various functions only light up when the corresponding function is activated.

LBH/Version 01/10.2006/en/hd/21/02/2007

If an LED does not light up, the fuse is defective.


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Electrical system

Service Manual


10.1.3

Main electronics (master) A15 ID no. 10223177


The main electronics (master) A15 are located on the cab rear wall.

Design

Main electronics (master) A15 1 Cover fixing thread 2 Status display LEDs 3 Slot 1 (CF1) for memory card with application software 4 Memory card status LEDs

5 6 7 8 9

Slot 2 (CF2) (optional) Main electronics (master) A15 Green system status LED Ventilation and bleeder screw Cover for Compact Flash (CF) memory card slot

Function description Basic function The main electronics (master) is the “brain” of the machine control system.

The application software in the main electronics (master) strictly follows the following time cycles: - Fetch all input data from the CAN/external modules - Perform all calculations in the application software with the input data; calculate the output data - Generate output data for connected external/CAN modules, which convert the commands into actions (for example activating a solenoid valve via one of the output modules)

Memory card The application software is stored on the memory card in slot 1 (CF1). 1 128 MB capacity memory card 2 ID no. of memory card including current software 3 Current software INDEX 4 Production date Each time the system is started up (ignition switched on), the application software on the memory card in slot 1 (CF1) is tested and (if there are changes) an update is performed. 128 MB memory card

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The main electronics (master) controls and monitors all connected CAN or external modules.

Service Manual


The data on the memory card takes priority. The system cannot be operated without a memory card.

How the status LEDs work

Status display LEDs

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Status list Status

Description

On

LED activation test

Directly after the main electronics (master) are switched on, an automatic LED test is performed. The system is started.

Off

Off

Booting

The system is started and waits for all the conditions, such as the presence of CAN modules in the system, to be met.

Flashes (1 s on, 1 s off)

Off

Running

The system is running fully in normal operation

Off

Flashes (0.2 s. on, 0.2 s. off)

Critical

Flashes (1 s on, 1 s off)

On

CAN download

On

Flashes (0.2 s. on, 0.2 s. off)

ALARM

The entire control system has been shut down due to an error with ALARM priority. The application software is stopped and the machine cannot be operated.

Flash in time (0.2 s. on, 0.2 s. off)

FATAL

The entire control system has been shut down due to a fatal error. The application software is stopped and the machine cannot be operated.

Flash in time (1 s on, 1 s off)

Power down

The system has been shut down due to a power down command. The machine cannot be operated.

Power off

The system has been completely shut down. The machine cannot be operated.

LED “B“ Green

LED “A“ Orange

On

Flash alternately (1 s on, 1 s off) Off

On


The entire control system has been shut down due to a critical error. The application software is stopped and the machine cannot be operated. Download of required software to a CAN module is in progress. The application software has not yet been started. The machine cannot yet be operated.

Flash Part of the main electronics software is being updated. The machine cannot programming be operated until this has been completed. Flash erase

Part of the MASTER's internal FLASH memory is being deleted (prior to reprogramming)

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Electrical system

Service Manual


How the memory card LEDs work The LEDs show the status of and communication between the memory card and the control unit. - LED 1 indicates that the memory card CF1 is plugged in. - LED 3 indicates that the memory card CF2 is plugged in. - LED 2 lights up or flickers when the memory card CF1 is communicating with the control unit. - LED 4 lights up or flickers when the memory card CF2 is communicating with the control unit. Memory card status LEDs

How the system status LEDs work The LED 3 lights up to signal the power supply for the main electronics (master).

System status LED

Main electronics (master) connectors 1 2 3 4 5 6

10.1-8 o f 8

PWR_X power supply connector CAN_X CAN connector LAN 1 connector (unassigned) LAN 2 connector (unassigned) LAN 3 connector (unassigned) Main electronics (master)

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7 COM1_X COM 1 connector (unassigned) 8 COM2_X COM 2 connector (unassigned) 9 COM3_X COM 3 connector (unassigned) 10 COM4_X COM 4 connector (unassigned)

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LBH/Version 01/10.2006/en/hd/21/02/2007

Main electronics (master) connectors

Service Manual


Plug assignment 6-pin Deutsch connector 1 Earth (ground) 2 Terminal 15 from fuse F54 3 Unassigned

4 Unassigned 5 Housing earth 6 Terminal 30 from fuse F35

PWR_X connector 8-pin Deutsch connector 1 2 3 4

CAN 4 low CAN 3 low CAN 2 low CAN 1 low

5 6 7 8

CAN 1 high CAN 2 high CAN 3 high CAN 4 high

5 6 7 8 9

Earth (GND) Standby (DSR) Transmitter activation (RTS) Transmission standby (CTS) Incoming call (RI)

CAN_X connector 9-pin SUB-D connector Reception signal level (DCD) Reception data (RXD) Transmission data (TXD) Terminal operational (DTR)

LBH/Version 01/10.2006/en/hd/21/02/2007

COM4_X connector

1 2 3 4


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Electrical system

Service Manual


10.1.4

Input modules (A16a, A16b, A16c) ID no. 10046435


The input modules are located under the left cab access and in the cab, and are arranged as follows: 1 Left rear section 2 Output module 3 A17c (optional) 3 Input module 3 A16c (optional) 4 Input module 1 A16a 5 Output module 2 A17b 6 Output module 1 A17a Input module 2 A16b in the cab on the rear wall

Module layout

Design

1 Input module 2 Ventilation and bleeder screw with Goretex membrane

3 Connector 4 Type plate

Function description The input modules have the following functions: 1 Power supply for switches and sensors 2 Converting analogue and digital signals to CAN bus messages 3 Forwarding the converted signals via CAN bus to the main electronics (master) The only difference between the input modules is their address. The input modules 1 A16a and 2 A16b must be plugged in and operational for the system to work.

10.1-10 o f 1 0

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Input module

Service Manual


Input module connector assignment

Input module connectors 1 24 V sensor supply 2 CAN interface with logic supply 3 16 analogue universal inputs

LBH/Version 01/10.2006/en/hd/21/02/2007

Input module 1 connector A16a.X1:


4 Frequency test inputs 5 Earth 6 5 V sensor supply

Plug connector, 70-pin Deutsch DRC 1 Spare 2 24 V power supply, logical unit 200 mA 3 Spare 4 Emergency steering pump pressure test 5 Spare 6 Emergency steering pump pressure 7 Brake accumulator pressure 8 Control lever forward 1 9 Control lever back 1 10 Lift kick-out 11 Bucket return-to-dig 12 Spare 13 Spare 14 Spare 15 Spare 16 Logical unit supply earth 17 Spare 18 Float position 19 Ride control (LFD) 20 Quick-change device switch 21 Inch pedal angle sensor 1 22 Transmission overheating 23 Tank sensor 24 Terminal 50a 25 Gas pedal angle sensor 1 26 Spare 27 Spare 28 Spare 29 CAN end connected to pin 43 30 Terminal 30 power supply 31 Earth 32 Power supply for service brake accumulator B19

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36 Power supply for bucket returnto-dig 37 Power supply for tank sensor 38 Power supply for lift kick-out 39 Power supply for gas pedal angle sensor 1 40 Spare 41 Spare 42 Spare 43 CAN low (CAN-E connected to CAN_Res) 44 CAN low 45 Spare 46 Hydraulic oil temperature 47 Hydraulic oil temperature 48 Spare 49 Spare 50 Spare 51 Spare 52 Spare 53 Spare 54 Spare 55 Variable displacement motor speed 1 56 Output speed 57 CAN high (CAN-E connected to CAN_Res) 58 CAN high 59 Spare 60 Spare 61 Spare 62 Spare 63 Earth for inch pedal angle sensor 1 64 Earth for lift kick-out 65 Earth for tank sensor

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10.1-11 o f 1 1

Electrical system

Service Manual


33 Spare 34 Spare 35 Power supply for inch pedal angle sensor 1

10.1-12 o f 1 1

Earth for return-to-dig Earth for gas pedal angle sensor 1 Spare Earth for variable displacement motor speed 1 70 Earth for output speed

Plug connector, 70-pin Deutsch DRC 1 Spare 2 24 V power supply, logical unit 200 mA 3 Spare 4 Driving light 5 High beam 6 Indicator signal 7 Spare 8 Control lever option 1 9 Control lever option 2 10 Control lever option 3 11 Warning buzzer 12 Spare 13 Spare 14 Spare 15 Spare 16 Logical unit supply earth 17 Spare 18 Control lever forward 2 19 Control lever reverse 2 20 Inch pedal angle sensor 2 21 Gas pedal angle sensor 2 22 Central lubrication system filling level signal B44 23 Particle filter (optional) 24 Particle filter (optional) 25 Joystick steering sensor 1 26 Spare 27 Spare 28 Spare 29 CAN end connected to pin 43 30 24 V power supply 31 Earth supply 32 Power supply for central lubrication system cycles inductive switch B43 33 Power supply for central lubrication system filling level inductive switch B44 34 Power supply for inch pedal angle sensor 2 35 Power supply for gas pedal angle sensor 2

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36 Power supply for joystick activation 37 Spare 38 Spare 39 Spare 40 Spare 41 Spare 42 Spare 43 CAN low (CAN-E connected to CAN_Res) 44 CAN low 45 Spare 46 Spare 47 Spare 48 Spare 49 Spare 50 Spare 51 Spare 52 Spare 53 Spare 54 Spare 55 Variable displacement motor speed 2 56 Central lubrication system cycle signal B43 57 CAN high (CAN-E connected to CAN_Res) 58 CAN high 59 Earth for central lubrication system cycles B43 60 Earth for central lubrication system filling level inductive switch B44 61 Spare 62 Earth for inch pedal angle sensor 2 63 Earth for gas pedal angle sensor 2 64 Spare 65 Earth for arm rest joystick 66 Spare 67 Earth for joystick steering, left 68 Spare 69 Earth for variable displacement motor speed 2 70 Spare

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LBH/Version 01/10.2006/en/hd/21/02/2007

Input module 2 connector A16b.X1:

66 67 68 69

Service Manual


LED indication

LEDs behind the bleeder screw 1 Input module ventilation opening 2 Green LED

After the ignition is switched on, the following conditions may be shown: Status Description Green LED flashes slowly

Module ready, waiting to receive the first message on the CAN bus

Green LED flickers/lights up

CAN bus communication active, normal control

Red LED flickers/lights up

Error frames detected on CAN bus. Defect on the CAN bus (e.g. wiring error, loose contact, no terminating resistor) Normal control may not be possible

LBH/Version 01/10.2006/en/hd/21/02/2007

Module status display

3 Orange LED 4 Red LED


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Electrical system

Service Manual


Addressing the input and output modules

Ventilation and bleeder opening 1 Input module ventilation opening 2 Green LED 100s display 3 Button Addressing procedure

4 Orange LED 10s display 5 Red LED 1s display 6 5 V sensor supply

A module must be addressed when it is replaced or installed. The input modules are delivered with the default address 45. The address is required in order to identify CAN bus messages. - Input module (sender) - Output module (receiver) Addressing is performed as follows: Connect the module Remove the ventilation and bleeder screw Unplug the PWR.X connector on the main electronics (master) Press the button 3 Switch on the ignition and keep the button pressed until the LEDs start flashing

Note: If you release the button too quickly, the module is in download mode for the outer core (orange flashes once, red flashes once). In this case, switch the module off and try again. The flashing LEDs indicate the module number (address): - The green LED flashes to indicate the 100s of the module number (1x = 100, 2x = 200) - The orange LED flashes to indicate the 10s of the module number (1x = 10, 2x = 20) - The red LED flashes to indicate the 1s of the module number (1x = 1, 2x = 2) Example: 1x green, 3x orange, 10x red = 130 All three LEDs briefly flash between each repeat of the number display. Changing the module number (address):

10.1-14 o f 1 4

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LBH/Version 01/10.2006/en/hd/21/02/2007

• • • • •

Service Manual


Press the button again to increase the module number by one. Four numbers are available for each module; after the last one it starts with the first one again. Addressing the input modules: Address

Setting after replacement

Status function

Input module 1 A16a

45

No

Yes

Input module 2 A16b

46

Yes

Yes

Input module 3 A16c (optional)

47

Yes

No

Component

10.1.5

Output modules (A17a, A17b, A17c) ID no. 10046438


The output modules are located under the left cab access and are arranged as follows: 1 Left rear section 2 Output module 3 A17c (optional) 3 Input module 3 A16c (optional) 4 Input module 1 A16a 5 Output module 2 A17b 6 Output module 1 A17a

Design

LBH/Version 01/10.2006/en/hd/21/02/2007

Module layout

Output module


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Electrical system

Service Manual


1 Output module 2 Ventilation and bleeder screw with Goretex membrane

3 Connector 4 Type plate

Function description The output modules have the following functions: - Converting digital input signals (CAN bus messages) from the main electronics (master) into analogue commands. - Controlling the consumer units via terminal equipment. The power supply for the terminal equipment is divided as follows: - Activation via banks, which consist of 4 terminal devices and have a single power source (fuse). - Direct activation from a fuse, where individual terminal devices are powered directly by a corresponding fuse. - Indirect activation from a fuse, where individual terminal devices are powered by a corresponding fuse via an upstream module. This configuration is required for switching off outputs in safety-critical states.

Output module connector assignment

1 2 3 4 5

Output module 1 connector A17a.X1:

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Internal 0 Ohm jumper 24 V power supply Logic earth connection Bank 1 power outputs (1.3 A) Bank 2 power outputs (1.3 A)

6 7 8 9 10 11

Bank 4 power outputs (1.3 A) Bank 3 power outputs (1.3 A) Frequency test inputs Earth for power outputs Positive-switching outputs (8 A) CAN interface

Plug connector, 70-pin Deutsch DRC 1 Bank 1 power supply (16 A) 2 24 V power supply, logical unit 200 mA 3 Power earth 4 Bank 1 power output for parking brake Y10 5 Bank 1 power output for working hydraulics lockout Y14 6 Bank 1 power output for bucket return-to-dig Y9 7 Bank 1 power output for lift kick-

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30 31 32 33 34 35 36 37

Spare Spare Digital 1 power supply (8 A) Digital 1 switching output (8 A) Digital 2 power supply (8 A) Digital 2 switching output (8 A) Digital 3 power supply (8 A) Digital 3 switching output (8 A) central lubrication M6 38 Digital 4 power supply (8 A) 39 Digital 4 switching output (8 A)

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LBH/Version 01/10.2006/en/hd/21/02/2007

Output module connectors

Service Manual


out Y17 8 Bank 3 power output for AVG coupling 1 Y6.1 9 Bank 3 power output for AVG coupling 2 Y6.2 10 Bank 3 power output for AVG coupling 3 Y6.3 11 Bank 3 power output for AVG modulation YMo1 12 Power earth 13 24 V power supply, logical unit 200 mA (reserve) 14 Bank 3 power supply (16 A) 15 Bank 2 power supply (16 A) 16 Logical unit earth 17 Power earth 18 Bank 2 power output for float position Y18 19 Bank 2 power output for cooling system fan Y13 20 Bank 2 power output for warning buzzer H40 21 Bank 2 power output for swivel restrictor Y57 22 Bank 4 power output for variable displacement motor 1 YEP1 23 Bank 4 power output for variable displacement motor 2 YEP2 24 Bank 4 power output for forward travel direction Y2 25 Bank 4 power output for reverse travel direction Y3 26 Power earth 27 Spare 28 Bank 4 power supply (16 A) 29 CAN terminating resistor to CAN_High

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Output module 2 connector A17b.X1:


40 41 42 43 44 45 46 47 48 49 50 51 52 53 54 55 56 57 58 59 60 61 62 63 64 65 66 67 68 69 70

back-up alarm H58, H59 Earth for central lubrication M6 Spare Spare CAN low input CAN low output Spare Earth for parking brake Y10 Earth for working hydraulics lockout Y14 Earth for return-to-dig Y9 Earth for lift kick-out Y17 Earth for AVG coupling 1 Y6.1 Earth for AVG coupling 2 Y6.2 Earth for AVG coupling 3 Y6.3 Earth for modulation Mo1 Earth for back-up alarm H58, H59 Spare Spare CAN high input CAN high output Spare Earth for float position Y18 Earth for fan Y13 Earth for warning buzzer H40 Earth for swivel restrictor Y57 Earth for variable displacement motor 1 YEP 1 Earth for variable displacement motor 2 YEP 2 Earth for travel direction pump 1 Y2 Earth for travel direction pump 1 Y3 Spare Spare Spare

Plug connector, 70-pin Deutsch DRC 1 Bank 1 power supply (16 A) 2 24 V power supply, logical unit 200 mA 3 Power earth 4 Bank 1 power output for overspeed protection Y16 5 Bank 1 power output for option 6 Bank 1 power output for travel pump control Y15 7 Bank 1 power output for travel pump control Y15a (L586 only) 8 Bank 3 power output for forward travel direction Y2a (L586 only) 9 Bank 3 power output for reverse travel direction Y3a (L586 only) 10 Bank 3 power output for additional equipment 1 Y11 11 Bank 3 power output for additional equipment 2 Y12 12 Power earth

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36 Digital 3 power supply (8 A) 37 Digital 3 switching output (8 A) reversing light 38 Digital 4 power supply (8 A) 39 Digital 4 switching output (8 A) back-up alarm 40 Power earth reserve 41 Power supply for 24 V sensor reserve 42 Power supply for 24 V sensor reserve 43 CAN low input 44 CAN low output 45 Power earth reserve 46 Power earth for overspeed protection Y16 47 Power earth for options 48 Power earth for travel pump 1 Y15 49 Power earth for travel pump 2

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Electrical system

Service Manual


13 24 V power supply, logical unit 200 mA (reserve) 14 Bank 3 power supply (16 A) 15 Bank 2 power supply (16 A) 16 Logical unit earth 17 Power earth 18 Bank 2 power output for emergency steering relay K11 19 Bank 2 power output for fan reversal Y50 20 Bank 2 power output for ride control Y20 21 Bank 2 power output for float position Y21 22 Bank 4 power output for joystick steering, left Y51 23 Bank 4 power output for joystick steering, right Y52 24 Bank 4 power output for gerotor steering (2-in-1) Y63 25 Bank 4 power output for joystick steering safety valve Y64 26 Power earth 27 Logical unit earth reserve 28 Bank 4 power supply (16 A) 29 CAN terminating resistor to CAN_High 30 Power supply for 24 V frequency sensor reserve 31 Power earth reserve 32 Digital 1 power supply (8 A) 33 Digital 1 switching output (8 A) 2 pump control 1 34 Digital 2 power supply (8 A) 35 Digital 2 switching output (8 A) 2 transmission control

Y15a 50 Power earth for travel direction pump 2 Y2a 51 Power earth for travel direction pump 2 Y3a 52 Power earth for additional equipment 1 Y11 53 Power earth for additional equipment 2 Y12 54 Power earth for reserve back-up alarm 55 Frequency input 1 reserve 56 Frequency input 2 reserve 57 CAN high input 58 CAN high output 59 Power earth reserve 60 Power earth for emergency steering relay K11 61 Power earth for fan reversal Y50 62 Power earth for LFD 63 Power earth for LFD 64 Power earth for joystick steering, left Y51 65 Power earth for joystick steering, right Y52 66 Power output for gerotor steering (2-in-1) Y63 67 Power output for joystick steering safety valve Y64 68 Power earth reserve 69 Earth for frequency input 1 reserve 70 Earth for frequency input 2 reserve

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LED indication

LEDs behind the bleeder screw

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Service Manual


1 Output module ventilation opening 2 Green LED

Module status display

3 Orange LED 4 Red LED

After the ignition is switched on, the following conditions may be shown: Status Description Green LED flashes slowly

Module ready, waiting to receive the first message on the CAN bus

Green LED flickers/lights up

CAN bus communication active, normal control

Red LED flickers/lights up

Error frames detected on CAN bus. Defect on the CAN bus (e.g. wiring error, loose contact, no terminating resistor) Normal control may not be possible

Addressing the input and output modules

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Ventilation and bleeder opening 1 Output module ventilation opening 2 Green LED 100s display 3 Button Addressing procedure

4 Orange LED 10s display 5 Red LED 1s display 6 5 V sensor supply

A module must be addressed when it is replaced or installed. The output modules are delivered with the default address 21. The address is required in order to identify CAN bus messages. - Input module (sender) - Output module (receiver) Addressing is performed as follows: • Connect the module • Remove the ventilation and bleeder screw


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Electrical system

Service Manual


• Unplug the PWR.X connector on the main electronics (master) • Press the button 3 • Switch on the ignition and keep the button pressed until the LEDs start flashing Note: If you release the button too quickly, the module is in download mode for the outer core (orange flashes once, red flashes once). In this case, switch the module off and try again. The flashing LEDs indicate the module number (address): - The green LED flashes to indicate the 100s of the module number (1x = 100, 2x = 200) - The orange LED flashes to indicate the 10s of the module number (1x = 10, 2x = 20) - The red LED flashes to indicate the 1s of the module number (1x = 1, 2x = 2) Example: 1x green, 3x orange, 10x red = 130 All three LEDs briefly flash between each repeat of the number display. Changing the module number (address): Press the button again to increase the module number by one. Four numbers are available for each module; after the last one it starts with the first one again. Addressing the input modules: Address


Status function

Output module 1 A17a

22

Yes

Yes

Output module 2 A17b

21

No

Yes

Output module 3 A17c (optional)

23

Yes

No

Component

10.1.6

Electrical components in the rear section

Components on the rear left of the rear section K04 B16 F01 F03

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Preglow relay Back-up alarm (optional) 100 A main fuse 200 A emergency steering pump fuse

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F02 60 A preglow fuse F07 10 A hazard warning system fuse F010 5 A heating flange feedback fuse

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LBH/Version 01/10.2006/en/hd/21/02/2007

Components on the rear left of the rear section

Service Manual


How the relay K04 works The relay K04 controls the intake air pre-heating flange.

LBH/Version 01/10.2006/en/hd/21/02/2007

The preglow system is controlled by the engine electronics A700D and depends on the following criteria: - Coolant temperature - Intake air temperature


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Electrical system

Service Manual

LBH/Version 01/10.2006/en/hd/21/02/2007


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Service Manual

Electrical system Battery installation

10.2 Battery installation The electrical system operates at 24 volts.

Design

Battery arrangement 1 Connecting cable from fuses to consumers 2 Fuses in the rear section 3 Connecting cable from battery to main switch 4 Connecting cable from main switch to vehicle earth 5 Main switch

6 Earth point on machine frame 7 Connecting cable from battery (+) to the consumers 8 Connecting cable from battery 1 (+) to battery 2 (-) 9 Batteries 1 and 2 in the left ballast weight 10 Electrical consumers

The batteries are installed in the left ballast weight. The two batteries are connected in series. The battery main switch S1 is installed in the rear left of the engine compartment and disconnects the battery circuit (-) from the vehicle earth. LBH/Version 01/10.2006/en/hd/21/02/2007

The following components are powered directly by the battery. - M1 Starter - G3 Alternator - A4 Voltage converter - F01 100 A main fuse - F02 60 A preglow fuse - F03 200 A fuse for emergency steering pump - F07 10 A fuse for hazard lights


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Electrical system

Service Manual

Battery installation

10.2.1

Batteries (ID 6002886, 613203208)


Apart from the terminals, the batteries require no maintenance during normal operation.

Battery arrangement 1 Battery 2 Back-ignition protection

3 Drip catcher

The battery has a gas escape mechanism and is equipped with back-ignition protection and a drip catcher.

LBH/Version 01/10.2006/en/hd/21/02/2007

The free channels must be sealed with dummy plugs.

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11 Transmission 11.0 Chapter contents 11

Transmission..................................................................... 11.0-1 11.0

Transmission.................................................................................11.0-1

11.1

Mechanical transmission ..............................................................11.1-1

11.2

Electronic control unit ...................................................................11.2-1 11.2.1

Main electronics (master) ...................................................11.2-1

11.2.2

Main wiring harness (including transmission) ....................11.2-4

11.2.3

Gear shifting solenoid valves .............................................11.2-5

11.2.4

Speed sensor .....................................................................11.2-6

11.3

Hydraulic control ...........................................................................11.3-1 Control valve block .............................................................11.3-3

11.3.2

Gear pump..........................................................................11.3-5

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11.3.1


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Transmission

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Transmission

11.0 Transmission Design

Main components of the transmission system 1 A11 control unit 2 Transmission 3 Gear pump

4 Oil cooler 5 Main electronics (master)

The transmission system consists of the gearbox including the control valve block, the main electronics (master), the control unit A11, the hydraulic supply system and the oil cooler. LBH/Version 01/10.2006/en/nk/30/01/2007

The gearbox is elastically mounted in the rear section of the wheel loader. The control valve block is bolted on the gearbox from above. The main electronics (master) are located on the rear wall of the cab behind the driver's seat. The control unit A11 is located on the panel in the right of the cab. The gear pump which supplies the gearbox with control and lubrication oil is connected to the wheel drive of the engine. The oil cooler is in the cooling system between the cab and the engine.


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Transmission

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Transmission Mechanical transmission

11.1 Mechanical transmission Technical data See section 2.1

LBH/Version 01/10.2006/en/nk/30/01/2007

Design

Cross section of the transmission (note: the drive shaft 2 with the coupling 2 is shown turned upwards to make it easier to see) 1 Transmission housing 2 Variable displacement motor 2 drive shaft 3 Coupling 2 4 Variable displacement motor 1 drive shaft


5 6 7 8 9 10

Coupling 3 Coupling 1 Rear axle drive shaft flange Oil strainer Power take-off shaft Front axle drive shaft flange

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11 12 13 14 15

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Coupling 1 lube oil duct Coupling 3 lube oil duct Coupling 2 lube oil duct Oil filter Control valve block

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Transmission

Service Manual

Mechanical transmission

The gearbox is elastically mounted in the rear section of the wheel loader and is driven by two variable displacement motors. The motors drive the two input shafts 2 and 4, which transfer the torque to the coupling sets 3, 5 and 6. The hydraulically actuated couplings consist of an inside-geared coupling cage, an outside-geared coupling hub, discs, piston, press plate and return springs. The outside-geared steel discs and inside-geared friction discs are arranged alternately. The outside-geared discs are connected to the coupling cage and the inside-geared discs are connected to the coupling hub in such a way that they cannot twist. The hub and the friction discs turn freely with the input shafts when the coupling is not actuated. When the travel range is shifted, oil is directed from the solenoid valve in the control valve block 15 through the appropriate duct to the coupling valve. As soon as the coupling valve is actuated, oil flows through the duct to the corresponding coupling piston. The oil pressure pushes the piston and discs against the press plate. When the steel and friction discs are pressed together, they connect the coupling cage and hub so that they turn together. When the coupling is closed, power is transmitted from the oil motor to the output shaft. The two drive shafts to the front and rear section are connected to the flanges of the output shaft 7 and 10. When the coupling is open, the return springs push the coupling piston back. The oil in front of the piston escapes through the coupling valve and holes in the coupling piston to the oil sump. The oil sump is fitted in transmission housing 1.

LBH/Version 01/10.2006/en/nk/30/01/2007

A pump fitted to the engine draws the gear oil is through pipes out of the sump. The oil strainer 8 is fitted on the intake port of the oil sump. The gear oil is pumped back through a filter into the transmission. Some of the oil is directed through the oil cooler. The cooled oil is pumped to the transmission lubrication system.

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Arrangement of shafts, gears and couplings in the transmission Motor 1 drive shaft Shaft 1 drive gear Coupling 3 Intermediate shaft power takeoff gear 5 Motor 2 drive shaft 6 Shaft 2 drive gear 7 Coupling 2 LBH/Version 01/10.2006/en/nk/30/01/2007

1 2 3 4

8 Variable displacement motor 2 input 9 Coupling 1 10 Intermediate shaft drive gear 11 Intermediate shaft 12 Variable displacement motor 1 input 13 Shaft 1 drive gear 14 Power take-off shaft

These are the basic functions of the 2plus2 transmission: – Increasing the input torque of the two variable displacement motors – Shifting gear without reducing tractive force – Increasing the speed range through 3 travel ranges – Distributing torque to the front and rear axles


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Transmission

Service Manual


The 3 gears 1st gear In first gear, the couplings K1 and K2 are closed. The torques from both variable displacement motors are used to provide maximum tractive force. Input shaft 1 The power from motor 1 is transferred directly via the input shaft 1 to the drive gear of the intermediate shaft 3. The closed coupling K1 transfers the torque of the intermediate shaft 3 to the output shaft 4. Input shaft 2 The power from motor 2 is transferred via the input shaft 2 to the coupling K2 and the output gear of the input shaft 2. The power is then transferred via the output gears of the intermediate shaft 3 to the output shaft 4. The power of both motors is accumulated in the intermediate shaft 3. The power flow is shown in the adjacent graph.

2nd gear In 2nd gear, the coupling K1 is opened and the motor 1 pivots to 0°. At the same time, motor 2 pivots to a wider angle. Input shaft 1 Motor 1 pivots to 0° and the coupling K1 is opened. Input shaft 2 The power from motor 2 is transferred via the input shaft 2 to the coupling K2 and the output gear of the input shaft 2. The power is then transferred via the output gears of the intermediate shaft 3 to the output shaft 4.

LBH/Version 01/10.2006/en/nk/30/01/2007

The power flow is shown in the adjacent graph.

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3rd gear In 3rd gear, the coupling K3 is closed and the coupling K2 is opened. The full torque is transferred during shifting. Input shaft 1 The power from motor 1 is transferred via the input shaft 1 and the coupling K3 to the output gear of the input shaft 1. The power is then transferred via the output gears of the intermediate shaft 3 to the output shaft 4. Input shaft 2 After the coupling K3 closes, motor 2 pivots to 0° and the coupling K2 is opened.

LBH/Version 01/10.2006/en/nk/30/01/2007

The power flow is shown in the adjacent graph.


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Transmission

Service Manual

LBH/Version 01/10.2006/en/nk/30/01/2007


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Transmission Electronic control unit

11.2 Electronic control unit 11.2.1

Main electronics (master) (ID 10223177) For a detailed description of the main electronics (master), see section 10.1.3.

Design The main electronics (master) are attached to the rear trim of the cab under a plastic cover and contains a flash card with the current machine software.

Main electronics (master)

Function description Basic function The main electronics (master) is the “brain” of the machine control system. The main electronics (master) controls and monitors all connected CAN or external modules. The application software in the main electronics (master) strictly follows the following time cycles: – Fetch all input data from the CAN/external modules – Perform all calculations in the application software with the input data; calculate the output data – Generate output data for connected external/CAN modules, which convert the commands into actions (for example activating a solenoid valve via one of the output modules) A laptop can be connected to the master via a serial interface.

LBH/Version 01/10.2006/en/nk/30/01/2007

Using the SCULI software, the service engineer can make settings, perform diagnosis and view operating data in the main electronics.


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Transmission

Service Manual

Electronic control unit

Block diagram of transmission Gas pedal LH control lever Input module 1 Input module 2 Main electronics (master) Display unit Control unit

8 9 10 11 12 13

Output module 1 Gear shifting solenoid valves 2plus2 gearbox Output speed sensor Thermostat Motor 2 speed sensor

14 15 16 17 18

Motor 1 speed sensor Solenoid valve Y6.1 Solenoid valve Y6.2 Solenoid valve Y6.3 Solenoid valve Y6.mo

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1 2 3 4 5 6 7

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Selecting travel ranges When the electrical system is turned on, travel range A1-3 is automatically selected. The transmission remains in neutral until the parking brake is released and the travel direction is selected. Other travel ranges can be selected by pressing the “Shift Up” (1) or “Shift Down” (2) buttons on the control unit A11. The selected travel range is indicated on the display. The following travel ranges can be selected: A2 - 3

– Automatic travel range 2nd and 3rd gear

A1 - 3

– Automatic travel range 1st to 3rd gear

A1 - 2

– Automatic travel range 1st and 2nd gear

2

– Fixed 2nd gear

1

– Fixed 1st gear

T

– Tempomat

N

– Neutral

Gearshift strategy The controller constantly monitors the speed signals and the pump and motor positions, and selects the most suitable gear in the automatic travel ranges. The travel ranges can be changed at any speed. If the speed is too high for the new travel range, the controller slows the machine by changing the current to the pump and the variable displacement motor(s). When the speed is appropriate for the new travel range after hydrostatic braking, the travel range automatically changes. Control unit A14

Maximum speed Vmax If the task in hand required a reduced maximum speed, you can reduce the maximum speed by pressing the button 3. This function is only available when travelling forward in fixed gears 1 and 2. The current speed when the Vmax button is pressed is stored. The machine then reaches this speed at full throttle. If the Vmax button is pressed when the machine is not moving, the minimum speed for the gear is stored. – 1st gear approx. 4 km/h – 2nd gear approx. 10 km/h The Vmax function is deactivated when you press the Vmax button again or change the travel range.

LBH/Version 01/10.2006/en/nk/30/01/2007

If reverse travel direction is selected, the master shifts to automatic travel range A1-3 and the Vmax function is deactivated.


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Transmission

Service Manual


Kick-down The kick-down function allows manual shifting to first gear. Kick-down shifting is used in the following situations: – Slowing the machine down when approaching the pile. The kick-down function hydrostatically brakes the machine, and it shifts down to 1st gear. – Before driving onto a steep slope, you can use the kick-down function to shift to 1st gear. – When you select the travel direction, the machine drives off in 2nd gear. If steep terrain prevents this, you can use the kick-down function to shift straight to 1st gear. When you press the lick-down button 2 on the LIEBHERR control lever 1, the machine is automatically hydrostatically braked and is shifted down to 1st gear. At high travel speeds, the machine automatically shifts to 2nd gear, and then to 1st gear. – At low travel resistance, 1st gear remains selected for 10 seconds. During acceleration, the transmission automatically shifts to 2nd gear. – While pushing into the pile, first gear remains selected as long as the resistance is high. In kick-down mode, the maximum travel speed is 10 km/h. Kick-down mode can be deactivated early by pressing the travel direction switch 3.

11.2.2

Main wiring harness (including transmission) Design The main wiring harness is connected to the right side of the transmission using a Cannon plug.


LBH/Version 01/10.2006/en/nk/30/01/2007

The Cannon plug is water- and dust-tight. Five lugs around its circumference prevent it from being plugged in incorrectly.

Plug for electrical transmission control

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Plug assignment

11.2.3

Pin

Colour

Function

A

Red

Modulation solenoid valve

B

Green

Coupling 2 solenoid valve

C

Blue


D

Yellow


E

White

Weight

Gear shifting solenoid valves Technical data See section 2.1

Design The transmission control valves are actuated by four solenoid valves. These are installed on the left of the control valve block.

2plus2 transmission control valve block 1 Solenoid valve Y6.1 2 Solenoid valve Y6.2

3 Solenoid valve Y6.3 4 Solenoid valve Y6.mo

Function description LBH/Version 01/10.2006/en/nk/30/01/2007

Basic function Once a solenoid valve is actuated, its function is triggered by applying pressure to its associated hydraulic valve.


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Transmission

Service Manual


11.2.4

Speed sensor (ID 7009274)


Design The input and output speeds of the transmission are recorded by speed sensors and monitored by the main electronics (master).

Speed sensors on the transmission 1 Variable displacement motor 2 speed sensor 2 Power take-off speed sensor

3 Variable displacement motor 1 speed sensor


LBH/Version 01/10.2006/en/nk/30/01/2007

The sensors generate an AC signal with a frequency proportional to the speed and number of teeth of the corresponding gear. This signal is recorded by the main electronics (master) and converted to the speed.

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Transmission Hydraulic control

11.3 Hydraulic control Function description Basic function

LBH/Version 01/10.2006/en/nk/30/01/2007

Diagram of the hydraulic gearbox control unit 1 2 3 4 5 6 7 8 9

Variable displacement motor 1 Variable displacement motor 2 Coupling 2 Coupling 3 Coupling 1 Lubrication oil supply Gear pump Filter Hydro accumulator


10 11 12 13 14 15 16

Oil cooler Bypass valve filter Pressure relief valve Safety valve Cooler bypass valve Pressure reducing valve Modulation solenoid valve Y6.mo 17 Coupling modulation valve 2

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18 Coupling modulation valve 1 and 3 19 Solenoid valve Y6.3 20 Solenoid valve Y6.1 21 Coupling valve 3 22 Coupling valve 1 23 Solenoid valve Y6.2 24 Coupling valve 2 P Test connection

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Transmission

Service Manual

Hydraulic control

The gear pump 7 draws up oil from the sump via a strainer. The oil sump is fitted in the transmission housing. The oil is pushed through the filter 8. The bypass valve 11 protects the filter from overload. This valve opens at a differential pressure of 4.5 bar. The hydro accumulator 9 is charged with gear oil. Some of the oil flows through the pressure reducing valve 15 to the four solenoid valves. The rest of the oil flows through the gear switching pressure relief valve 12 to the gear oil cooler 10. The pressure relief valve is set to 20±3 bar. The pressure relief valve is adjusted using discs. The operating pressure of the gearbox control unit is measured at the test point P. The pressure reducing valve 15 reduces the oil pressure for actuating the coupling valves from 20 to 9 bar. The bypass valve 14 protects the gear oil cooler from hydraulic overload. This opens at a differential pressure of 4 bar. Oil not used for lubricating the couplings flows through the lubricating oil pressure limiting valve 13 to the oil sump. The lubrication oil pressure limiting valve opens at 4 bar.

LBH/Version 01/10.2006/en/nk/30/01/2007

The cooled oil is pumped to the transmission lubrication system.

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11.3.1

Control valve block

LBH/Version 01/10.2006/en/nk/30/01/2007

Design

Cross section of the control valve block


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Transmission

Service Manual

Hydraulic control

1 2 3 4 5 6

Pressure relief valve Bypass valve filter Valve piston stop Cooler bypass valve Pressure reducing valve Coupling modulation valve 1 and 3

7 Coupling valve 2 8 Coupling 2 solenoid valve Y6.2 9 Modulation solenoid valve Y6.mo 10 Canon plug 11 Coupling 1 solenoid valve Y6.1 12 Coupling 3 solenoid valve Y6.3

13 14 15 16 17

Coupling valve 3 Coupling valve 1 Separator plate Separator plate Control valve block housing

Function description Basic function The control valve block directs oil to the various consumers in the transmission. Some are hydrostatically controlled, others electrohydrostatically. The oil pressure, cooling and lubrication are hydraulically controlled. The couplings and the pressure modulation are electrohydraulically controlled. The solenoid valves receive control impulses from the main electronics (master). The solenoid valves open and direct the pressure oil to the valve of the actuated coupling and control the pressure modulation. Shifting gears

The illustration here shows the two modulation valves (the sectional view of the control valve block only shows one modulation valve). The modulation valve 2 for coupling 2 is held in place by the plug 1. Position 3 is the solenoid valve Y6.mo for the modulation. Component 4 is the modulation valve for coupling 1 and 3. Pressure modulation is required for smooth gear shifting. When a gear is selected, oil is directed to the corresponding coupling valve. The coupling valve is actuated and the oil flows unchecked through the modulation valve and the coupling valve into the coupling. This is called the rapid fill phase. During the rapid fill phase, the coupling pads should be quickly brought into contact, but without the coupling closing. This accelerates the shifting process. A few milliseconds after the solenoid valve shifts a gear, the modulation valve is energised and the oil is directed via a restrictor to the coupling. The oil flow to the coupling is metered, and the pressure in the coupling accumulates slowly and in a controlled manner. This is called the modulation phase.

The actuated variable displacement motor pivots to an angle of 0° with the required speed. The variable displacement motor is then set to the correct angle. The motor is synchronised before the torque is transferred, thus ensuring smooth shifting.

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LBH/Version 01/10.2006/en/nk/30/01/2007

Shortly afterwards, the modulation valve is deactivated. The coupling pressure has now exceeded the force of the coupling springs and the coupling is closed.

Service Manual


Increase in coupling pressure during gear shifting 1 Travel range preselection 2 Rapid fill phase

3 Modulation phase 4 Shifting complete

The above graph shows how the pressure changes during a gearshift. The complete shifting operation only takes around 200 milliseconds, and can therefore not be recorded using conventional test equipment.

11.3.2

Gear pump Technical data See section 2.1

Design

LBH/Version 01/10.2006/en/nk/30/01/2007

Components of the gear pump 1 2 3 4

Snap ring Shaft seal ring Flange Seals

5 6 7 8

Bearing bushings Gears Housing Housing cover

The gear pump is attached to the front of the engine. It is driven at a set ratio via the spur gear transmission of the engine.


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Transmission

Service Manual

Hydraulic control

Function description Basic function The gear pump draws up oil from the transmission. Depending on the speed, the oil flows from the transmission control valve block.

Pressure cut-off

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A pressure relief valve in the transmission control valve block protects the system from excess pressure.

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12 Axles, Drive shafts 12.0 Chapter contents 12

Axles, Drive shafts ............................................................ 12.0-1 12.1

Axles – L550 - L576 2plus2 ..........................................................12.1-1

12.2

Axles – L580 2plus2 .....................................................................12.2-1

12.3

Drive shafts ...................................................................................12.3-1 Front drive shaft..................................................................12.3-1

12.3.2

Rear drive shaft ..................................................................12.3-2

LBH/Version 01/10.2006/en/nk/01/02/2007

12.3.1


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Axles, Drive shafts

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Service Manual

Axles, Drive shafts Axles – L550 - L576 2plus2

12.1 Axles – L550 - L576 2plus2 Valid for:

L550 - 456 / from 16978; L566 - 460 / from 14171 L556 - 454 / from 15653; L576 - 457 / from 14171


Design

Main components of the axle 1 Axle casing 2 Self-locking differential

3 Drive shaft flange 4 Wheel hubs

LBH/Version 01/10.2006/en/nk/01/02/2007

The axle consists of the differential with the tapered gear and self-locking differential 2, as well as the planetary drive in the wheel hub 4. The wheel hub also contains the service brake, which is a wet disc brake. The axle casing 1 contains the tapered roller bearing for the wheel hubs.

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Axles, Drive shafts

Service Manual

Axles – L550 - L576 2plus2

Cross-section of the wheel hub Retaining pin Cover M75x1.5 grooved nut O-ring Wheel flange Brake piston return springs Sealing ring Brake housing Brake piston seals Brake piston

11 Screw for measuring wear on the brake discs 12 Brake discs 13 Ring gear 14 Planetary gear 15 Planetary carrier 16 Sun gear shaft 17 Axle casing housing 18 Oil drain plug

LBH/Version 01/10.2006/en/nk/01/02/2007

1 2 3 4 5 6 7 8 9 10

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Service Manual


Sectional view of the differential 1 2 3 4 5 6 7

Half shaft Axle shaft housing Housing cover Differential housing Bevel gear Pressure rings Compensating tapered gear

8 9 10 11 12 13

Axle tapered gear Compensation axle Axle input shaft Drive flange Shaft seal ring Dust protection ring


LBH/Version 01/10.2006/en/nk/01/02/2007

These are the basic functions of the axle: – Increasing and transferring the drive torque – Transferring the vertical device forces to the wheels The gear output torque is transmitted via the drive shaft to the axle input shaft. The torque is increased to the wheel torque by the ratio of the tapered gear in the differential housing and that of the planetary drives in the wheel hubs. The input speed is reduced to the wheel speed accordingly. The vertical operating load of the machine is transmitted from the rear section via the screwed connection to the axle casing. The axle casing transmits this load to the wheel hubs so that the machine is supported by the wheels.

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Axles, Drive shafts

Service Manual


Sectional view of the differential 1 2 3 4 5

Axle input shaft Crown wheel Differential housing Output shafts Axle tapered gear

6 7 8 9

Pressure rings Compensation axle Compensating tapered gear Disc brakes

Speed balance of the left and right wheels When turning a corner, the left and right wheels cover different distances. The speeds of the two wheels are then different. The correct speed for each wheel is induced by the rolling condition.

The spreading force is generated by the transfer of the differential torque from the two pressure rings 6 to the compensation axles 7, which are loosely guided on diagonal surfaces. It produces a load-dependent locking torque in the disc brakes, which is always in equal proportion to the input torque. This ratio, expressed as a percentage, is called the locking value.

Self-locking function The disc brakes 9 on the left and right of the axle tapered gears 5 counteract the relative movement between the axle tapered gear 5 and the differential housing 3 with a braking force proportional to the rotary speed. This braking torque has a blocking action and increases the torque on the side with a firm hold on the ground. The braking torque thus compensates for the insufficient support from the side with poor hold. The disc brake consists of outer discs which are mounted in the differential housing and of non-twisting inner discs linked to the axle tapered gears.

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The axle input shaft 1 determines the average speed of the two power takeoff shafts 4 via the crown wheel 2. The crown wheel drives the differential housing 3 and thus the four facing compensation tapered gears 8 of the differential. These rest on the tooth faces of the adjacent axle tapered gears 5 and thus drive the output shafts 4. The compensation tapered gears 8 have a balancing function and turn about their own axes to compensate for various wheel torques. The speed reduction of one wheel is compensated by the increased speed of the other wheel.

Service Manual


Service brake function

Sectional view of the wheel hub 1 2 3 4 5

Wheel flange Brake housing Brake piston Brake piston seals Brake piston return springs

6 Screw for measuring wear on the brake discs 7 Brake piston guide pin 8 Brake discs 9 Ring gear 10 Planetary carrier

The service brake is a wet disc brake fitted in the wheel hubs. When pressure oil acts on the brake piston 3 the outer and inner discs 8 press against the limit stop of the ring gear 9. The inner discs mesh with the planetary carrier 10 so that they cannot slip. The outer discs mesh with the brake housing 2 and remain stationary. When the discs press together, the wheel torque is taken up by the brake housing. When it is not actuated, the brake piston 3 is held back by the return springs 5. The brake discs lose contact and the drag torque is minimised.

Wheel fastening The wheels are fastened onto the flanges of the wheel hubs by wheel nuts. They are centred by the spherical collar nuts.

Axle lubrication The axle has a shared oil system. This means the oil chambers in the differential and the wheel hubs are connected. Oil drain plugs are fitted on the wheel hubs and differential housing. LBH/Version 01/10.2006/en/nk/01/02/2007

The differential and the wheel hubs are always filled and the level checked using the filler screw on the differential housing

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Service Manual

LBH/Version 01/10.2006/en/nk/01/02/2007


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Service Manual

Axles, Drive shafts Axles – L580 2plus2

12.2 Axles – L580 2plus2 Valid for:

L580 - 459 / from 14171


Design

Main components of the axle 1 Self-locking differential 2 Axle casing

3 Wheel hub

LBH/Version 01/10.2006/en/nk/01/02/2007

The axle consists of the differential with the tapered gear and self-locking differential 1, as well as the planetary drive in the wheel hub 3. The wheel hub also contains the service brake, which is a wet disc brake. The axle casing 2 contains the tapered roller bearing for the wheel hubs.

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Service Manual

Axles – L580 2plus2

Cross-section of the wheel hub Ring gear Planetary gear Planetary pinion / cover Planetary bearing Thrust washer

6 7 8 10

Sun gear Press plate Hub Double seal ring with supports and O-rings

11 Axle 12 Axle casing 13 Seal holder

LBH/Version 01/10.2006/en/nk/01/02/2007

1 2 3 4 5

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LBH/Version 01/10.2006/en/nk/01/02/2007

Sectional view of the differential 1 2 3 4 5 6 7

Groove nut Shims Housing cover Differential holder Differential housing Crown wheel Pressure ring

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8 9 10 11 12 13 14

Seal screw Axle tapered gears Brake discs Central element Bevel gear Tapered gear seal Grease seal

15 16 17 18 19 20 21

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Pressure disc V sealing ring Tapered gear nut Drive flange Seal cartridge O-ring Wear sleeve

12.2-3 o f 6

Axles, Drive shafts

Service Manual


Function description Basic function These are the basic functions of the axle: – Increasing and transferring the drive torque – Transferring the vertical device forces to the wheels The gear output torque is transmitted via the drive shaft to the axle input shaft. The torque is increased to the wheel torque by the ratio of the tapered gear in the differential housing and that of the planetary drives in the wheel hubs. The input speed is reduced to the wheel speed accordingly.

LBH/Version 01/10.2006/en/nk/01/02/2007

The vertical operating load of the machine is transmitted from the rear section via the screwed connection to the axle casing. The axle casing transmits this load to the wheel hubs so that the machine is supported by the wheels.

Sectional view of the differential

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1 2 3 4 5

Axle input shaft Differential housing Crown wheel Pressure ring Compensation axle

6 7 8 9

Compensating tapered gear Brake discs Axle tapered gears Bevel gear

Speed balance of the left and right wheels When turning a corner, the left and right wheels cover different distances. The speeds of the two wheels are then different. The correct speed for each wheel is induced by the rolling condition. The axle input shaft 1 determines the average speed of the two power takeoff shafts 1 via the crown wheel 3. The crown wheel drives the differential housing 2 and thus the four facing compensation tapered gears 6 of the differential. These rest on the tooth faces of the adjacent axle tapered gears 8 and thus drive the output shafts 1. The compensation tapered gears 6 have a balancing function and turn about their own axes to compensate for various wheel torques. The speed reduction of one wheel is compensated by the increased speed of the other wheel.

Self-locking function The disc brakes 7 on the left and right of the axle tapered gears 8 counteract the relative movement between the axle tapered gear 8 and the differential housing 2 with a braking force proportional to the rotary speed. This braking torque has a blocking action and increases the torque on the side with a firm hold on the ground. The braking torque thus compensates for the insufficient support from the side with poor hold.

LBH/Version 01/10.2006/en/nk/01/02/2007

The disc brake consists of outer discs which are mounted in the differential housing and of non-twisting inner discs linked to the axle tapered gears. The spreading force is generated by the transfer of the differential torque from the two pressure rings 4 to the compensation axles 5, which are loosely guided on diagonal surfaces. It produces a load-dependent locking torque in the disc brakes, which is always in equal proportion to the input torque. This ratio, expressed as a percentage, is called the locking value.

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Service Manual


Service brake function

Sectional view of the wheel hub 1 Axle housing 2 Plug 3 Retainer plate / outer discs

4 Inner discs 5 Return springs 6 Brake piston

The service brake is a wet disc brake fitted in the axle casing. When pressure oil acts on the brake piston 6 the outer discs 3 and inner discs 4 press against the retainer plate 3. The inner discs mesh with the axle and turn along at high speed with the drive shaft. The outer discs 3 mesh with the axle housing 1 and remain stationary. When the discs press together, the wheel torque, reduced by the ratio of the planetary final drive, is taken up by the axle housing. When it is not actuated, the return springs 5 push back the brake piston 6. The brake discs lose contact and the braking torque is minimised.

The wheels are fastened onto the flanges of the wheel hubs by wheel nuts with rotating cups.

Axle lubrication The axle has a shared oil system. This means the oil chambers in the differential and the wheel hubs are connected. Oil filler and drain plugs are fitted on the wheel hubs and differential housing.

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Wheel fastening

Service Manual

Axles, Drive shafts Drive shafts

12.3 Drive shafts 12.3.1

Front drive shaft Technical data See section 2.1

Design

Components of the drive shaft 1 2 3 4

Flange Universal joint Shaft driver Hub liner

5 6 7 8

Connector tube Pin driver Universal joint Flight ring

9 Universal joint 10 Flange

The drive shaft has one universal joint at the output of the transmission, a universal joint at the input of the front axle and a slider to compensate the length.

Function description Function

LBH/Version 01/10.2006/en/nk/01/02/2007

The drive shaft transfers the torque from the transmission to the front axle. The universal joints at either end of the drive shaft allow it to compensate the angle between the drive and the power take-off. The angle needs to be compensated due to the articulated steering. The universal joint and connector tube can be displaced axially to mesh together. This compensates the length. Tolerances in assembly and slight movements during operation make this necessary.

Uniformity of torque transmission On drive shafts with simple universal joints, the connector tube between the two universal joints rotates unevenly. This is the case whenever the universal joint has to compensate for an angle. This occurrence is prevented by using a double cardan shaft. The connector tube turns evenly.


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Axles, Drive shafts

Service Manual

Drive shafts

12.3.2

Rear drive shaft Technical data See section 2.1

Design

Components of the drive shaft 1 Flange 2 Universal joint 3 Shaft driver

4 Hub liner 5 Connector tube 6 Pin driver

7 Universal joint 8 Flange

The drive shaft is equipped with two universal joints and a slider.

Function description Function The drive shaft transfers the torque from the transmission to the rear axle. The universal joints at either end of the drive shaft allow it to compensate the angle between the drive and the power take-off. The universal joint and connector tube can be displaced axially to mesh together.

LBH/Version 01/10.2006/en/nk/01/02/2007

This compensates the length. Tolerances in assembly and slight movements during operation make this necessary.

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13 Machine frame, Ballast weight 13.0 Chapter contents 13

Machine frame, Ballast weight .......................................... 13.0-1 Machine frame ..............................................................................13.1-1

13.2

Articulation bearing .......................................................................13.2-1

13.3

Oscillating axle mount...................................................................13.3-1

13.4

Articulation lock.............................................................................13.4-1

13.5

Ballast weight................................................................................13.5-1

LBH/Version 01/10.2006/en/nk/26/01/2007

13.1


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LBH/Version 01/10.2006/en/nk/26/01/2007

Machine frame, Ballast weight

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Service Manual

Machine frame, Ballast weight Machine frame

13.1 Machine frame Design The machine frame consists of the front section and the rear section. These are connected by the articulation bearing.

Main components of the machine frame 1 Front section 2 Rear section

3 Oscillating bearing

4 Articulation bearing

Function description LBH/Version 01/10.2006/en/nk/26/01/2007

Basic function The machine frame transfers the forces of the lift arms to the axles. The frame carries all the most important components of the machine, such as the engine, cab and transmission.


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13.1-1 o f 2


Service Manual

LBH/Version 01/10.2006/en/nk/26/01/2007

Machine frame

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Service Manual

Machine frame, Ballast weight Articulation bearing

13.2 Articulation bearing Design The articulation bearing is installed between the front and rear sections.

Location of the articulation bearing 1 Front section

2 Rear section

3 Articulation bearing

Main components of the articulation bearing

LBH/Version 01/10.2006/en/nk/26/01/2007

1 2 3 4 5

Pressure flange Cylinder screw Bushing Bearing cover Shims

6 7 8 9 10

Swivel bearing Cone tension element Shaft seal ring Cylinder screw Bearing pin

Function description Basic function The articulation bearing connects the front and rear sections. It allows steering of the machine by articulating the machine frame to the left or right.


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Articulation bearing

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Machine frame, Ballast weight Oscillating bearing

13.3 Oscillating axle mount Design The oscillating axle mount is installed between the front and rear sections.

Location of the oscillating axle mount 1 Front section 2 Rear section

3 Oscillating bearing

4 Oscillating axle frame

Main components of the oscillating axle mount LBH/Version 01/10.2006/en/nk/26/01/2007

1 2 3 4 5


Pressure flange Cylinder screw Bushing Bearing cover Shims

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6 7 8 9 10

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Swivel bearing Cone tension element Shaft seal ring Cylinder screw Bearing pin

13.3-1 o f 2


Service Manual

LBH/Version 01/10.2006/en/nk/26/01/2007

Oscillating bearing

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Service Manual

Machine frame, Ballast weight Articulation lock

13.4 Articulation lock Design The articulation lock is fitted between the front and rear sections.

Articulation lock 1 Locking bar 2 Pin

3 Spring clip


LBH/Version 01/10.2006/en/nk/26/01/2007

The articulation lock arrests the articulated joint of the machine. This means the steering is blocked, for example when transporting the machine.


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LBH/Version 01/10.2006/en/nk/26/01/2007

Articulation lock

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Service Manual

Machine frame, Ballast weight Ballast weight

13.5 Ballast weight Technical data See section 2.1

Design The ballast weight consist of two parts. They are bolted on the left and right sides on the back of the rear section.

Ballast weight layout 2 Right rear section

LBH/Version 01/10.2006/en/nk/26/01/2007

1 Left rear section


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Ballast weight

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14 Central lubrification system 14.0 Chapter contents 14

Central lubrification system ............................................... 14.0-1 14.1

Manual central lubrication.............................................................14.1-1

14.2

LIEBHERR automatic central lubrication system (optional) .........14.2-1 Central lubrication pump EP-1 ...........................................14.2-4

14.2.2

Progressive distributor MX-F..............................................14.2-5

14.2.3

Central lubrication pump controller EP-1 and operation ....14.2-8

LBH/Version 01/10.2006/en/hd/30/01/2007

14.2.1


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Service Manual

LBH/Version 01/10.2006/en/hd/30/01/2007

Central lubrification system

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Service Manual

Central lubrification system Manual central lubrication

14.1 Manual central lubrication Design

Lubricating rail on the front section 1 Lift arms, top left 2 Lift arms, top right 3 Tilt cylinder, top

4 Tilt cylinder, bottom 5 Right steering cylinder, base end 6 Left steering cylinder, base end

Lubricating rail on the rear section 1 Oscillating axle frame, front 2 Oscillating axle frame, rear

3 Right steering cylinder, rod end

LBH/Version 01/10.2006/en/hd/30/01/2007

Function description Basic function The two central lubricating rails are for lubricating points which are difficult to access.


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LBH/Version 01/10.2006/en/hd/30/01/2007

Manual central lubrication

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Service Manual

Central lubrification system Automatic central lubrication system

14.2 LIEBHERR automatic central lubrication system (optional) Design

Components of the central lubrication system 1 2 3 4 5 6 7

Central lubrication pump Rapid fill coupling Agitator Transparent reservoir Level sensor connection Grease fitting Pressure relief valve

8 Grease fitting for manual lubrication 9 Main supply line 10 Main progressive distributor MX-F 11 Secondary progressive distributor 12 Lubricant supply lines 13 Lubrication points

LBH/Version 01/10.2006/en/hd/30/01/2007

The central lubrication pump is located under the left cab access. The distributors are arranged centrally to the respective lubrication points. The central lubrication pump and the progressive distributors provide the specified quantity of grease to the connected lubrication points.


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Service Manual

Automatic central lubrication system

Valid for:

L550 - 456 / from 16978; L556 - 454 / from 15653

Overview of lubrication points 3 Main progressive distributor 4 6x secondary progressive distributor

5 6x secondary progressive distributor

LBH/Version 01/10.2006/en/hd/30/01/2007

1 Central lubrication pump 2 Inductive switch for lubrication cycles

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Valid for:

L566 - 460 / from 14171; L576 - 457 / from 14171; L580 - 459 / from 14171;

Overview of lubrication points 1 Central lubrication pump 2 Inductive switch for lubrication cycles

3 Main progressive distributor 4 6x secondary progressive distributor

5 6x secondary progressive distributor

Function description Progressive lubrication The automatic central lubrication system is a progressive system. It lubricates progressively, i.e. all lubricating points in succession.

LBH/Version 01/10.2006/en/hd/30/01/2007

The main distributor is fitted with an inductive switch, which signals the lubrication cycles to the main electronics (master).

Overall system The electrically powered central lubrication pump pumps the grease to the main progressive distributor, which distributes it to the secondary progressive distributors. The secondary progressive distributors pump the grease to the lubrication points. The main electronics (master) control the lubrications cycles and pauses of the central lubrication pump.

Safety function – The pressure relief valve on the central lubrication pump monitors lubrication. If a lubrication point receives no grease from the distributor, the progressive distributor is blocked. The pressure in the central lubricating system increases. If the pressure rises above the permitted limit, grease escapes from the pressure relief valve. During this time, there are no impulses (lubrication cycles) for the main electronics (master).


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Service Manual


– If the lubrication cycles are not performed in a specified time, the main electronics (master) switch off the lubrication system. The driver is notified by the flashing LEDs on the central lubrication button and a service code.

14.2.1

Central lubrication pump EP-1 Technical data See section 2.1

1 2 3 4 5 6

14.2-4 o f 1 0

DC motor Pump housing Cam Level sensor (inductive) Transparent reservoir Agitator

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7 8 9 10 11

Strainer Transfer piston Check valve Pressure relief valve Pressure ring

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LBH/Version 01/10.2006/en/hd/30/01/2007

Central lubrication pump EP-1

Service Manual


Function description Pump action A DC motor 1 continually drives the cam 3 with a pressure ring 11. The cam raises and lowers the transfer piston 8. This provides the suction and pumping action of the transfer piston. The built-in check valve 9 prevents the pumped medium from being sucked back out of the main supply line. The agitator 6 pushes the lubricant out of the transparent reservoir 5 through a strainer 7 to the pump housing 2. This eliminates air bubbles in the grease.

Checking the grease quantity When all three LEDs on the central lubrication button light up, there is insufficient grease. This condition is reported by the level sensor. The reservoir is a transparent cylinder, in which the rubber stripper on the agitator can be seen. This allows you to check the grease level.

Filling The reservoir can be filled via the tapered grease fitting using a standard lubrication pump or via the rapid fill coupling using the grease gun.

Safety function The pressure relief valve 10, which is set to 280 bar, prevents excess pressure in the line system.

14.2.2

Progressive distributor MX-F Technical data See section 2.1

Design The progressive distributors are manufactured with variable discs. The advantage of this is that the distributors can be extended or reduced according to the number of lubrication points. The flow per stroke depends on the piston diameter. The progressive distributor needs at least three pumping elements in order to work properly.

LBH/Version 01/10.2006/en/hd/30/01/2007

The distributors must always be installed horizontally.


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Service Manual


Main progressive distributor 1 Start element 2 Middle element with actuator piston and inductive switch for lubrication cycles 3 Inductive switch housing

4 Middle element 5 Inductive switch for lubrication cycles 6 Inductive switch LED 7 End element

Secondary progressive distributor 1 Start element (without piston) 2 Middle element with flow engraved 3 Screw connection

4 Connecting line 5 Dummy plug 6 End element

Linkage with gears connects the elements to the distributor blocks.

LBH/Version 01/10.2006/en/hd/30/01/2007

O-rings are installed as seals between the elements.

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Service Manual



Piston positions of the progressive distributor MX-F A - C Piston positions

I - III Pistons

1 - 6 Grease duct outlets

The progressive distributors act hydraulically and distribute the lubricant in series to each outlet. The lubricant flows via the entrance of the distributor through all the distributor discs to the piston I (piston position A). The piston pushes to the left and presses the lubricant out of the left pressure chamber of the piston to the outlet 1 (piston position B). Pistons II and III then pump the lubricant to the outlets 2 and 3. After piston III moves, the lubricant flows to the left side of piston I (piston position C). The piston I pushes to the right and presses the lubricant out of the right pressure chamber of the piston to the outlet 4. Pistons II and III then pump the lubricant to the outlets 5 and 6. After piston II moves, the lubricant again flows to the right side of piston I (piston position A) and a new cycle of the progressive distributor begins. This function is repeated as long as lubricant is pumped to the distributor. Malfunctions Malfunctions can occur in the lubricant lines or inside the distributor. Malfunctions include: – Clogged lubricant lines – Twisted bearing casings These prevent the flow of lubricant, and thus block the distributors. LBH/Version 01/10.2006/en/hd/30/01/2007

When the distributor is blocked, lubricant flows out of the pressure relief valve on the central lubrication pump.


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Service Manual


14.2.3

Central lubrication pump controller EP-1 and operation Technical data See section 2.1

Function description Basic function The central lubrication pump EP-1 is regulated by the main electronics (master). It is operated via CAN bus from the control unit to the main electronics (master) and output module 1 A17a.

Central lubrication system control 1 Central lubrication pump 2 Grease level sensor 3 Central lubrication button and LEDs 4 CAN bus connections 5 Main electronics (master)

6 7 8 9

Power supply from fuse F53 Output module 1 A17a Input module 2 A16b Inductive switch for lubrication cycles 10 Central lubrication pump power supply

If the ignition is switched off or the parking brake is engaged, the main electronics (master) stop lubrication. The remaining cycles are stored and after the engine is started or the parking brake released, lubrication is continued at the point where it was interrupted.

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LBH/Version 01/10.2006/en/hd/30/01/2007

The feedback from the grease level sensor 2 and the lubrication cycle inductive switch 9 comes via the input module 2 A16b to the main electronics (master).

Service Manual


Non-scheduled lubrication intensity (cycle settings) The following settings can be made with the central lubrication button: – Press briefly for less than 2 seconds: non-schedule lubrication – Hold down for more than 2 seconds: set lubrication intensity 75%, 100%, 125% The LEDs show the following states when the ignition is switched on. – LED 1 - 75% lubrication (light-duty operation) – LED 2 - 100% lubrication (medium-duty operation) – LED 3 - 125% lubrication (heavy-duty operation) – LEDs 1 + 2 + 3 flash & service code – system fault – LEDs 1 + 2 + 3 light up – grease has reached minimum level – LED 1 or 2 or 3 flashes – indicates lubrication intensity during operation: 75 / 100 / 125%

Adjusting the lubrication intensity Press the central lubrication button for more than 2 seconds to switch to setting mode. With each further press of the button, the mode is switch up one level; after the highest mode it returns to the first. 75% - 100% - 125% - 75%.....

Non-scheduled lubrication Using the central lubrication system button, you can perform non-scheduled lubrication at any time when the ignition is switched on, even when the parking brake is engaged (with the set lubrication and cycle time). The pump motor switches off after the set number of cycles and the set cycle time begins.

Lubrication sequences A Lubrication (cycles) 1 Light-duty lubrication sequence

2 Medium-duty lubrication sequence

3 Heavy-duty lubrication sequence

LBH/Version 01/10.2006/en/hd/30/01/2007

Fault in the system (cycle error) The cycles are checked with a set time. Each completed cycle resets this time. If there is no cycle within the set time, the system is stopped – LEDs 1, 2 and 3 flash and the service code E2017 appears.

Grease reservoir level too low The LEDs in the central lubrication button light up if the grease supply in the reservoir falls too low. The all three LEDs stay on until the grease is topped up. The driver can also check the grease level by looking at the reservoir.


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Service Manual


Filling the reservoir The tapered grease fitting 3 can be used to fill the reservoir. For fast filling, the rapid filler pump 1 on coupling 2 can be used.

Fast filling with cartridge 1 Rapid filler pump

2 Quick coupling 3 Grease fitting

LBH/Version 01/10.2006/en/hd/30/01/2007

Grease specifications: see the section on lubricants and fuels in the maintenance chapter.

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15 Covering, access 15.0 Chapter contents 15

Covering, access............................................................... 15.0-1 Coverings......................................................................................15.1-1

15.2

Cab access ...................................................................................15.2-1

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15.1


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Covering, access

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Service Manual

Covering, access Covering

15.1

Covering Design

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Covering components 1 Front left and right mud guards 2 Cooler hood 3 Rear left and right mud guards


4 Engine hood 5 Rear section 6 Rear lower covering

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7 Front lower covering 8 Plastic lid

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Covering, access

Service Manual

Covering

Front mud guard 1 Front mud guard

2 Front section

The two front mud guards 1 are each fastened with three bolts to the front section 2.

1 Rear right mud guard 2 Rear section

3 Rear left mud guard

The two rear mud guards 1 and 3 are each fastened with two bolts to the access, the rear section 2 and the ballast weight.

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Rear mud guard

Service Manual


Engine hood and rear section 1 Cooler support 2 Engine hood 3 Rear cover

4 Rear section 5 Cooler panel

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The engine hood 2 is fastened to the cooler support 1 with two screws. The hood can be lifted up with the aid of two gas-filled springs. The rear cover 3 is fastened to the rear section of the machine 4 with four bolts.

Rear lower covering 1 Rear section 2 Cover

3 Hinge

The cover 2 is fastened to the underside of the rear section 1 with four bolts and can be opened downward via the hinge 3.


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Covering, access

Service Manual

Covering

Front lower covering 1 Cover 2 Rear section

3 Hinge

The cover 1 is fastened to the underside of the rear section 2 with four bolts and can be opened downward via the hinge 3.

1 Cooler hood 2 Cooler support

3 Cooler panel

The cooler hood 1 is fastened with one bolt each to the cooler support 2 and the cooler panel 3.

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Cooler hood

Service Manual


Cover 1 Plastic lid

2 Front section

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The plastic lid 1 is fastened with four bolts to the front of the front section 2.


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Covering, access

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Covering

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Service Manual

Covering, access Cab access

15.2

Cab access The handrails on the cab access help you get in and out of the cab and protect you from falling off.

Design

Cab access 1 Cab access 2 Tool box

3 Cab access handrail 4 Wheel box handrail

The left side of the cab access 1 is fastened to the rear section with three bolts. The bottom rung is connected by two rubber brackets to the access. The underside of the cab access is designed to leave space for the input and output modules, and for the electric central lubrication pump (special equipment). A toolbox 2 is welded between the steps.

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The handrails 3 are each fastened to the access and wheel box with four screws.


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Covering, access

Service Manual

Cab access

Access and exit aids 1 Wheel box handrail 2 Cab access

3 Cab access handrail

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The cab access is fastened to the rear section with three bolts. The wheel box handrail is fastened with two bolts each to the access and rear mud guard. The cab access handrail is fastened to cab access with two bolts.

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16 Cab, heating, air conditioning 16.0 Chapter contents 16

Cab, heating, air conditioning............................................ 16.0-1 16.0.1 16.1

Cab, heating and air-conditioning.......................................16.0-1 Instrument panel ...........................................................................16.1-1

16.1.1

Display unit A13..................................................................16.1-1

16.1.2

Control units A11, A18 and A22 .........................................16.1-4

16.1.3

Main function control unit (CAN bus) A11 ..........................16.1-5

16.1.4

Air conditioning control unit (CAN bus) A22 .......................16.1-6

16.1.5

Option control unit (CAN bus) A19 .....................................16.1-6

16.1.6

Electrical control unit A18 ...................................................16.1-8

16.1.7

LIEBHERR control lever ...................................................16.1-11

16.2

Heating, ventilation, air conditioning.............................................16.2-1 16.2.1

Heating/air conditioning unit ...............................................16.2-2

16.2.2

Blower.................................................................................16.2-3

16.3

Air conditioning system.................................................................16.3-1 Air conditioning compressor ...............................................16.3-4

16.3.2

Condenser ..........................................................................16.3-5

16.3.3

Dryer collector unit..............................................................16.3-6

16.3.4

Pressure switch ..................................................................16.3-8

16.3.5

Evaporator ..........................................................................16.3-9

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Cab, heating, air conditioning

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Service Manual

Cab, heating, air conditioning 16.0.1

Cab, heating and air-conditioning Design The cab is a safety cab which has been tested and approved according to the ROPS/FOPS specifications. It is elastically supported on the rear section. The cab is equipped with heating, ventilation and air conditioning. The cab can be accessed from the left side of the machine via the steps and the door. The right window can be used as an exit in emergencies.

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View of driver's cab 1 2 3 4 5 6

Radio speaker Sun visor Interior lights with switch Interior mirror Radio compartment Heater/ventilation/air-conditioning outlet nozzles (9 in total) 7 Inch/brake pedal with angle sensor 8 Steering column switch 9 Adjustable steering column with steering wheel


10 11 12 13 14 15 16 17

Steering column adjustment lever Gas pedal angle sensor Adjustable LH control lever panel Display unit LIEBHERR control lever Panel adjustment pedal Window opener lever Control lever fitting for optional working functions 18 Right control panel with control units

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19 20 21 22 23 24 25 26 27

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Socket/cigarette lighter Ashtray Ignition switch Adjustable arm rest Mechanical service hours counter Diagnostic plug Glove compartment Fuse box Driver’s seat

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Service Manual

Driver's cab, outside view from right 1 Right side of cab 2 Fresh air filter 3 Heating and airconditioning housing

4 Air conditioning system expansion valve 5 Heater water connections 6 Valve and water valve control motors

Function description ROPS/FOPS strength The driver's cab complies with the ROPS/FOPS regulations. ROPS (Roll Over Protective Structure) takes into account mechanical rigidity in the event of the machine rolling over.

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FOPS (Falling Object Protective Structure) governs the rigidity of the cab when object fall onto it.

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Service Manual

Cab, heating, air conditioning Instrument panel

16.1 Instrument panel All important operating, display and control elements are arranged ergonomically on the instrument panel. The display unit 2, which indicates the operating condition of the wheel loader, is located in the upper field of view, slightly to the right of centre. The LH control lever is in a separate console, which can be adjusted back and forth using a foot pedal. The controls are arranged in the right-hand control panel. The fuses are on the left behind the driver’s seat.

Design

Instrument panel 1 Electrical control unit A18 2 Main control unit CAN bus A11 3 Air conditioning control unit CAN bus A22

16.1.1

4 Additional functions control unit CAN bus (optional) A19 5 Switch for additional options

Display unit A13 The display unit A13 is on the front right A pillar.

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Design The display unit A13 consists of: – LCD indicators – Symbol fields – Segment displays The LCD display 21 contains segment displays for: – Clock – Service codes – Engine speed – Service hours


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Instrument panel

The LCD display 26 contains segment displays for: – Tractive force adjustment – Current travel range Symbol fields for: – Warning messages – Travel direction – Travel ranges Segment fields for: – Fuel supply – Engine oil pressure – Coolant temperature – Travel speed Each symbol field is either red, yellow, green or orange. The 9-pin plug connector for communication with the electronic controller A1 (CPU) is attached to the rear.

1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18

Travel speed display P6 Emergency steering check symbol field H24 Emergency steering symbol field H8 Brake system accumulator pressure symbol field H19 Joystick steering symbol field H27 Gear oil overheating symbol field H14 Forward travel direction symbol field H3 Working hydraulics lockout symbol field H5 Reverse travel direction symbol field H9 Hydraulic oil overheating symbol field H23 Automatic travel range 2-3 symbol field H35 Automatic travel range 1-3 symbol field H34 Automatic travel range 1-2 symbol field H33 Fixed gear 2 symbol field H31 Fixed gear 1 symbol field H30 Tempomat T symbol field H29 Neutral position N symbol field H32 Parking brake symbol field H11

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19 Air filter contamination symbol field H7 20 Preglow monitor symbol field H2 21 Segment display for engine speed, time, operating hours segment and service codes P7 22 Battery charge control symbol field H6 23 High beam symbol field H12 24 Direction indicator symbol field H10 25 Stop symbol field H36 26 Display for tractive force adjustment, current travel range, fan reversal H37 27 Overspeed protection indicator H38 28 Fuel supply symbol field H1 29 Fuel supply display P2 30 Engine overheating and coolant level symbol field H13 31 Coolant temperature display P3 32 Engine oil pressure symbol field H4 33 Engine oil pressure display P5

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Display unit A13

Service Manual


Function description Plug assignment Connector A13.X1

SUB-D / 9-pin male (communication with master electronics A15) Earth +24 V power supply CAN bus CAN_L CAN bus CAN_H +5 V power supply

6 7 8 9

Earth Unassigned +5 V terminal 1 Indicator signal

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1 2 3 4 5


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Service Manual

Instrument panel

16.1.2

Control units A11, A18 and A22 The control units A11, A18, A19 (optional) and A22 are fitted in the instrument panel on the right.

Design The controls consist of the following units: – Electric control unit A18 - controlled via digital connection – Main function control unit A11 - controlled via a CAN bus – Air conditioning control unit A22 - controlled via a CAN bus – Option control unit A19 - controlled via a CAN bus. With strip inserts to show the various symbols. Backlit membrane keypads with buttons (function symbol and LEDs)

1 Electric control unit A18 - controlled via digital connection 2 Hazard warning system button S4 3 Parking light/driving light button S6 4 Flashing beacon button S9 5 Front/rear working floodlights button S8 6 Rear window heater button S55 7 Rear windshield wiper and washer system button S13 10 Main function control unit A11 - controlled via a CAN bus 11 Parking brake button S17 12 Ride control (LFD system) button S16 13 Working hydraulics lockout button S19 14 Bucket return-to-dig button S14 15 Travel range up button S27 16 Travel range down button S28 17 Increase tractive force button S32 18 Reduce tractive force button S33 19 Engine speed, clock and service hours button S30 20 Display unit brightness control button S31

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21 22 23 24 25 26 27 28 29 30 31 40 41 42 43 44 45 46

Increase fan speed button S38 Temperature down button S40 Decrease fan speed button S34 Temperature up button S39 Defrost button S47 Fresh/circulated air button S44 Central lubrication system button (optional) S50 Tempomat button S29 Emergency steering button S10 Lift kick-out button S22 Float position button S18 Air conditioning control unit A22 - controlled via a CAN bus Blower duct selector button (footwell) S41 Blower duct selector button (head area) S43 Blower duct selector button (middle area) S42 Air conditioning ECO mode button S45 Air conditioning auto mode button S46 Spare button S??

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Control unit A11

Service Manual


Basic function The control units operate the various machine functions. The control units are connected via CAN bus and digitally to the main electronics (master) A15 and the relay and fuse board A4. The control unit A18 works as soon as the main switch is turned on (terminal 30). The buttons and switches can be programmed. The control units A11, A19 (optional) and A22 work when the ignition is turned on (terminal 15). The control units must be set to the correct CAN bus address.

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 up. (See section 10.1.3 on the main electronics (master) A15).

16.1.3

Main function control unit (CAN bus) A11 Function description The main function control unit A11 is connected via CAN bus to the main electronics (master) A15. The main function control unit A11 works as soon as the ignition is turned on (terminal 15). When a button is pressed, a signal is sent via CAN bus to the main electronics (master) A15. The buttons have LEDs, which can signal the following conditions: – All three LEDs on or off – button with switch function – All three LEDs only light up when the button is pressed – button with push function – The LEDs go on or off individually each time the button is pressed – button with control function The functions of each button are described in the operating manual for each machine: “Operating the control units”.

Function test LBH/Version 01/03.2006/en/hd/30.01.2007

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 up. (See section 10.1.3 on the main electronics (master) A15).


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Instrument panel

Plug assignment Connector A11/X1

Deutsch / 12-pin male (communication with main electronics (master) A15 1 +24 V power supply F71 (connected to pin 5) 2 Earth (connected to pin 6) 3 CAN bus CAN_High 1 4 CAN bus CAN_Low 1 5 +24 V power supply (connected to pin 1)

16.1.4

6 7 8 9 10 11 12

Earth (connected to pin 2) CAN bus CAN_High 2 CAN bus CAN_Low 2 Terminating resistor Unassigned Unassigned Unassigned

Air conditioning control unit (CAN bus) A22 Function description The heating and air conditioning control unit A22 is connected via CAN bus to the main electronics (master) A15. The air conditioning control unit A22 works as soon as the ignition is turned on (terminal 15). When a button is pressed, a signal is sent via CAN bus to the main electronics (master) A15. The buttons have LEDs, which can signal the following conditions: – All three LEDs on or off – button with switch function – All three LEDs only light up when the button is pressed – button with push function The functions of each button are described in the operating manual for each machine: “Operating the control units”.

Plug assignment Deutsch / 12-pin male (electrical function control) 1 2 3 4 5

Data input F71 Earth CAN_High 1 CAN_Low 1 +24 V power supply (terminal 15) - F09 6 Unassigned

16.1.5

7 8 9 10 11 12

CAN_High 2 CAN_Low 2 120 Ω terminating resistor Unassigned Unassigned Unassigned

Option control unit (CAN bus) A19 Function description The option control unit A19 is connected via CAN bus to the main electronics (master) A15. The option control unit A19 works as soon as the ignition is turned on (terminal 15). When a button is pressed, a signal is sent via CAN bus to the main electronics (master) A15. The buttons have LEDs, which can signal the following conditions: – All three LEDs on or off – button with switch function – All three LEDs only light up when the button is pressed – button with push function

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Connector A22/X1

Service Manual


The functions of each button are described in the operating manual for each machine: “Operating the control units”. NOTE: when replacing or installing a new option control unit A19, it must be addressed. The address is required in order to identify CAN bus messages.


Deutsch / 12-pin male (electrical function control) 1 2 3 4 5

Data input F71 Earth CAN_High 1 CAN_Low 1 +24 V power supply (terminal 15) - F09 6 Unassigned

7 8 9 10 11 12

CAN_High 2 CAN_Low 2 120 Ω terminating resistor Unassigned Unassigned Unassigned

Addressing a control unit The control unit must be addressed after it is installed. Addressing is performed as follows: • Connect the control unit • On the main electronics (master), unplug the PWR_X power supply connector or remove fuses F35 and F54 • Press buttons 1, 2 and 3 • Switch on the ignition and keep buttons pressed until the LEDs start flashing The flashing LEDs indicate the module number (address): – The LEDs in button 1 show the 100s (1x = 100, 2x = 200) – The LEDs in button 2 show the 10s (1x = 10, 2x = 20) – The LEDs in button 3 show the 1s (1x = 1, 2x = 2) Example: 9x LEDs in button 2, 3x LEDs in button 3 = 93 The LEDs in all three LEDs briefly flash between each repeat of the number display. Changing the address:

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Option control unit A19

Press button 3 once to increase the current address number by 1. The option control unit A19 has five selectable addresses. After you reach the highest address by pressing button 3 the control unit returns to the lowest address. Addressing the control units: Address


Status function

Main function control unit A11

97

No

Yes

Air conditioning control unit A22

93

No

No

Option control unit A19

94

Yes

No

Component


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Service Manual

Instrument panel

16.1.6

Electrical control unit A18 Function description The electric control unit A18 is digitally connected to the relay and fuse board A4. When a button is pressed, a digital signal is generated and the relays or solenoid valves are actuated. The LEDs are arranged on the buttons as shown. In the direction of travel, LED 1 at the front, LED 2 in the middle and LED 3 at the back. When a function is activated, the status is shown by one or more of the LEDs. Each button has seven function (modes), which can be set as required. The functions of each button are described in the operating manual for each machine: “Operating the control units”.

Setting the button functions The mode can be set independently for the buttons/outputs 2 to 6. Electrical control unit A18

Activating the mode setting To go to the mode setting function, the following conditions must be met: – The three buttons 2, 4 and 6 must be simultaneously pressed. – The ignition (terminal 15) must be turned on and the three buttons 2, 4 and 6 pressed for at least 5 seconds. After mode setting is activated, the LEDs in the assigned buttons should indicate the modes currently used. When the keypad is in mode setting mode, all outputs are deactivated (and remain so until normal mode is restored). The following standard settings are shown (without options): Mode

LED 1

LED 2

LED 3

1

4 - cannot be changed

ON

OFF

OFF

2

4

ON

OFF

OFF

3

5

ON

OFF

ON

4

4

ON

OFF

OFF

5

3

OFF

ON

ON

6

1

OFF

OFF

ON LBH/Version 01/03.2006/en/hd/30.01.2007

Button

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Service Manual


The following settings are possible: Mode

Description

Function available with terminal 30

Action when terminal 15 is turned off

Action when terminal 15 is turned on

1

Switches the output OFF when the ignition is turned off, always OFF when the ignition is turned on

NO

OFF

OFF

2

Switches the output OFF when the ignition is turned off, always ON when the ignition is turned on

NO

OFF

ON

3

Act as normal switch to terminal 15

NO

OFF

Restore state when terminal 15 is turned off

4

Act as latching switch to terminal 30

YES

5

Switches output OFF when ignition is turned off, function available with terminal 30, retains terminal 30 status when ignition is turned on

YES

OFF

No reaction (terminal 30 state remains)

6

Switches output OFF when ignition is turned off, function available with terminal 30, always ON ignition is turned on

YES

OFF

ON

7

Switches output OFF when ignition is turned off, function available with terminal 30, restores switch-off state when ignition is turned on

YES

OFF

Restore state when terminal 15 is turned off

No reaction (terminal No reaction (terminal 15 state remains) 30 state remains)

Press the button to switch the current mode (increase number by one, return to lowest number after highest). The LEDs immediately indicate the altered mode. After a button is pressed to change the mode, the new configuration is immediately stored in the EEPROM. If no button is pressed within 30 seconds or terminal 15 is switched off, the keypad returns to normal mode.

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The settings are indicated as follows:


Mode

LED 1

LED 2

LED 3

1

OFF

OFF

ON

2

OFF

ON

OFF

3

OFF

ON

ON

4

ON

OFF

OFF

5

ON

OFF

ON

6

ON

ON

OFF

7

ON

ON

ON

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Service Manual

Instrument panel


Deutsch / 12-pin male (electrical function control) 1 +24 V power supply (terminal 15) - F71 2 Earth 3 CAN_High 1 (not used) 4 CAN_Low 1 (not used) 5 +24 V power supply (terminal 30) - F07 6 Digital input (flashing frequency)

Connector A18/X2

7 8 9 10 11

CAN_High 2 (not used) CAN_Low 2 (not used) 120 Ω terminating resistor Switching output (hazard lights) Switching output (flashing beacon) 12 Switching output (windscreen wipers)

Deutsch / 6-pin male (electrical function control) 4 Switching output (low beam) 5 Switching output (front working floodlight) 6 Switching output (rear working floodlight)

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1 Switching output (rear washer pump) 2 Switching output (heated rear window/mirror) 3 Switching output (parking light)

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Service Manual


16.1.7

LIEBHERR control lever The LIEBHERR control lever (LH control lever) contains the switch 5 for preselecting the travel direction, the switch 2 for the kick-down function and the buttons 3 and 4 for additional functions. The LH control lever also controls the movements of the working attachment via the lift and tilt cylinders. It is connected to the main electronics (master) via input module 1 and input module 2.

Design

Control lever with switch 1 LH control lever 2 Kick-down button 3 Additional equipment button

4 Additional equipment button 5 Travel direction switch

Function description Basic function When the electrical system is switched on, the automatic travel range A1-3 is selected and the travel drive is set to neutral N. Both are indicated by the LC display (H34) and the symbol field N (H32). The travel direction switch 5 must be moved to neutral N after the parking brake is released before a travel direction can be preselected.

Switching travel direction You can switch travel direction using the button 5 on the LH control lever. LBH/Version 01/03.2006/en/hd/30.01.2007

The solenoid valves for forward and reverse travel direction can only be activated after the parking brake is released. The travel direction is shifted to neutral by closing the parking brake or shifting the travel direction switch to neutral N (middle position).

Kick-down shifting Briefly touch the Up button 2 to trigger the command to shift to 1st gear. The gear can shift up 10 seconds after the kick-down button is released.

Additional function buttons (optional) If an option is installed or retrofitted, the buttons 3 and 4 can be used to operate it.


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Service Manual

Instrument panel

Plug assignment Connector S2

12-pin Deutsch 7 Kick-down switching signal 8 Kick-down power supply (+) F9 9 Additional equipment power supply (+) F9 10 Additional equipment switching signal 11 Additional equipment power supply (+) F9 12 Additional equipment switching signal

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1 Power supply (+) F15 2 Reverse travel direction constant signal 3 Reverse travel direction switching signal 4 Forward travel direction switching signal 5 Forward travel direction constant signal 6 Earth

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Service Manual

Cab, heating, air conditioning Heating, ventilation, air conditioning

16.2 Heating, ventilation, air conditioning Technical data See section 2.1

The driver's cab is equipped with a hot water heater and an air conditioning system. Optionally, automatic air conditioning is available. The intake air is filtered through three serviceable dry filter cartridges and directed to the adjustable air flow nozzles in the cab through the heating/air conditioning unit.

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Design

Heater/air conditioner 1 2 3 4 5

Fresh air filter service cover Heater/air conditioner covering Fresh air filter (pre-filter) Fresh air intake slots Fresh air filter (fine filter)


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6 7 8 9

Heating/air conditioning unit Driver's cab Recirculation filter Circulated air filter cover

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Service Manual

Heating, ventilation, air conditioning

16.2.1

Heating/air conditioning unit The heating/air conditioning unit is housed in the right side of the cab.

Design

1 Servo motor for footwell nozzles 2 Servo motor for middle nozzles 3 Servo motor for windscreen/head area nozzles 4 Flap control housing 5 Heat exchanger 6 Air-conditioning evaporator

16.2-2 o f 4

7 Heating/air conditioning blower 8 Heating/air conditioning control electronics (A21) 9 Fresh/recirculated air flap 10 Fresh/recirculated air flap servo motor 11 Water valve servo motor

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12 Water valve 13 Head area ventilation connection 14 Footwell ventilation connection 15 Middle ventilation connection 16 Front and side window ventilation connection

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Heating/air conditioning unit layout

Service Manual

Cab, heating, air conditioning Heating, ventilation, air conditioning

Function description How the heater works The heating and air conditioning control electronics (A21) are connected via CAN bus to the heating/air conditioning control unit. The heat exchanger is supplied with hot water from the engine cooling system. It is regulated using an electrically controlled water valve. The water valve controls the heating power. The intake air can be controlled using the fresh/recirculated air flap. The airflow is regulated using the various blower speed levels on the heating/ air conditioning system. When the air conditioning is in automatic mode, the speed levels are automatically controlled by the heating/air conditioning control electronics.

Flap control The driver can set the flaps manually as required, using the heating/air conditioning control unit. When the air conditioning is in automatic mode, the flaps are automatically controlled by the heating/air conditioning control electronics.

16.2.2

Blower The blower is part of the heating and ventilation unit.

Design The blower is a 6-speed radial fan for ventilation, heating and air conditioning in the cab.

Function description Basic function The blower sucks air (axial intake) 4 through the fresh/recirculated air duct and blows it out of the radial outlet 5 to the evaporator and through the heat exchanger. The air flow is regulated by changing the blower speed. LBH/Version 01/03.2006/en/hd/30.01.2007

It is operated and regulated using the air conditioning control unit. At level 0 the blower is switched off. Level 6 is maximum air flow.


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Service Manual

LBH/Version 01/03.2006/en/hd/30.01.2007

Heating, ventilation, air conditioning

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Service Manual

Cab, heating, air conditioning Air conditioning system

16.3 Air conditioning system Technical data See section 2.1

Design

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Components of the air conditioning system 1 Expansion valve 2 Heat exchanger in the heating/air conditioning unit


3 Compressor (with magnetic coupling Y22) 4 Condenser

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5 Pressure switch B27 6 Dryer collector unit

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Function description Basic cooling function

Diagram of cooling circuit 1 2 3 4 5 6 7

Air conditioning compressor Magnetic coupling Condenser Fan Pressure switch Dryer collector unit Sight glass

8 Heater/air conditioning control electronics 9 Temperature sensors 10 Condensation tray 11 Evaporator 12 Blower 13 Expansion valve

a b c d

Liquid refrigerant, high pressure Liquid/gaseous refrigerant, high pressure Liquid/gaseous refrigerant, low pressure Gaseous refrigerant, low pressure

The air conditioning compressor 1 draws in the refrigerant in gas form and increases its energy level (pressure and thermal energy).

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 collector unit 6, where it is filtered and dried, and then, with the bubbles removed, through the rising pipe to the expansion valve 13 on the evaporator. The liquid, pressurised refrigerant is sprayed through the expansion valve 13 into the depressurised evaporator 11.

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The heat thus generated is transferred to the condenser 3. The heat dissipation lowers the energy potential.

Service Manual


This allows the refrigerant to expand. The expansion reduces the pressure energy in the refrigerant and very quickly cools the evaporator. 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 temperature.

Temperature regulation The temperature is regulated by the cyclical activation and deactivation of the magnetic coupling 2 of the air conditioning compressor during operation, or by mixing hot air from the heater, as for example in defrost mode. The frequency of switching is controlled by the temperature sensors in the evaporator and the program in the heating/air conditioning control electronics (see the technical data). The temperature is also regulated at the expansion valve. The pressure and temperature are recorded at the evaporator outlet and the injection quantity is precisely metered. These monitoring elements prevent the evaporator from icing up.

Defrost mode

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When the windows are misted up, the cab air must be dried. This is done by operating 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 cool evaporator releases the moisture in the form of condensation.


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16.3.1

Air conditioning compressor Technical data See section 2.1

Design

Sectional view of the compressor 1 2 3 4

Intake connection Discharge connection Oil filler plug Magnetic coupling

5 6 7 8

Swash plate Piston Outlet valve Inlet valve

The air conditioning compressor with its magnetic coupling 4 is attached to the engine and driven by a V-ribbed belt. The compressor is equipped with an axial piston rotary group 6, a swash plate 5 and flap valves.

Basic function The refrigerant compressor acts as a pump which draws in the gaseous refrigerant from the evaporator, compresses it and pumps it to the condenser. It is bidirectional, which means that the refrigerant compressor can be used for both directions of rotation.

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Functions of the compressor oil There are the main functions of the compressor oil: – Reducing friction, wear and noise – Hydrostatic transmission of force to the various components of the air conditioning compressor – Dissipating heat – Increasing density – Lubricating the drive components (piston, shaft seal, bearing)

Magnetic coupling The pulley runs freely on the compressor shaft and is permanently driven by the V-ribbed belt. The power transmission between the pulley and the compressor shaft is controlled by a magnetic coupling 4. This is activated by the temperature switch in the evaporator or the pressure switch on the dryer collector unit. By periodic activation of the compressor, the evaporator is kept at a temperature of between +1 °C (uncoupling) and +4 °C (coupling), this preventing the air conditioning unit from icing up. If the pressure rises above 24 bar or below 2 bar on the pressure side of the compressor, it is also uncoupled.

16.3.2

Condenser Technical data See section 2.1

Design

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The condenser is part of the cooling system.

Condenser with connections 1 Intake 2 Outlet 3 Retaining frame


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4 Condenser 5 Cleaning access cover

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Function description Basic function The forced ventilation condenser directs the heat output of the refrigeration circuit to the ambient air and in the process condenses the gaseous refrigerant. When the air conditioning system is switched on, the cooling system fan speed is automatically increased.

16.3.3

Dryer collector unit Technical data See section 2.1

Design The dryer collector unit is located under the left cab access. It is connected to the outlet of the condenser and the intake of the evaporator.

Cross section of the dryer filter 3 Filter element 4 Dryer granules

Function description Basic function The refrigerant, which is cooled but still has bubbles in it, passes from the condenser to the dryer collector unit. The circulation pressure forces the refrigerant inside through the filter element 3 and the dryer granules 4. The bubbles are removed from the refrigerant and it passes through the rising pipe 2 to an outlet port connected by a hose to the expansion valve of the evaporator.

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1 Sight glass with indicator beads 2 Rising pipe

Service Manual


Sight glass

Sight glass 1 White filling level bead

2 Orange moisture indicator bead

The sight glass is located in the upper third of the dryer collector unit. The sight glass has the following purposes: – Checking when filling the system – Checking the refrigerant level during operation – Checking the moisture content of the refrigerant – Checking contamination of the refrigerant circuit Sight glass functions

Checking when filling the system – When completely filling the system, it is necessary to top up with gaseous refrigerant on the intake side when the system is switched on. When doing this, watch the level indicator bead 1 in the sight glass. As soon as it floats on the refrigerant to the top of the sight glass, stop adding refrigerant. Checking the refrigerant level during operation – Once the system has been running for about five minutes (to allow the refrigerant to distribute), the white level indicator bead should be near the top of the sight glass. As the engine speed increases, the level rises slightly. The refrigerant should flow through the sight glass with no visible bubbles during operation. If gas bubbles appear, it is normally due to insufficient refrigerant in the system. Sometimes the refrigerant is not sufficiently condensed due to insufficient heat extraction at the condenser (contamination), which can result in bubbles in the sight glass. Checking the moisture content of the refrigerant – There is a small orange indicator bead 2 in the sight glass. If it turns light grey, there is too much moisture in the system.

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In this case the system must be completely drained and evacuated. The oil in the compressor must also be replaced. The entire dryer collector unit must be replaced too. Checking contamination of the refrigerant circuit – A sudden change of colour in the sight glass indicates a problem in the system. A change in colour is normally caused by overheating in the refrigerant circuit. This is normally due to internal or external contamination.


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16.3.4

Pressure switch (ID 10014164)


Design

Dryer 1 Pressure switch

2 Dryer collector unit

The pressure switch is attached to the dryer collector unit in the air conditioning circuit.

Function description Basic function The pressure switch monitors the pressure in the cooling circuit. It deactivates the magnetic coupling and therefore the compressor if the pressure is too low or too high. This prevents the compressor from running dry if there is too little refrigerant (insufficient pressure).

Excess pressure may be caused by: – Too much refrigerant in the circuit – Excess temperature due to a dirty condenser or defective fan control – The filter in the dryer collector unit may be very dirty – The expansion valve may be iced up (too much moisture in the refrigerant) or dirty (blocked).

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Deactivation is also necessary when the pressure is too high. This prevents damage to components in the system.

Service Manual


16.3.5

Evaporator Technical data See section 2.1

Design

Evaporator with expansion valve 1 Hose fitting holder 2 Expansion valve

3 Air conditioning system sealing rings 4 Evaporator

The evaporator is fitted in the heater/air conditioner and is part of the refrigerant circuit. The heating/air conditioning unit is housed in the right side of the cab.

Function description Basic function The evaporator is a heat exchanger which cools the cab air.

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The pressurised refrigerant, which is cooled and liquefied by the condenser, is sprayed through the expansion valve 2 into the evaporator 4, where there is a vacuum. The drop in pressure allows the refrigerant to expand. The expansion causes a great drop in the thermal energy. The refrigerant is cooled. The thermal energy taken from the cab air via the fins on the evaporator 4 evaporates the refrigerant.


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17 Lift arms and quick-change device 17.0 Chapter contents 17

Lift arms and quick-change device.................................... 17.1-1 17.1

Lift arms ........................................................................................17.1-1

17.2

Pin bearing....................................................................................17.2-1 Standard bearing ................................................................17.2-1

17.2.2

Bucket bearing....................................................................17.2-2

17.2.3

Removing the pin bearings.................................................17.2-3

17.2.4

Changing the bushings.......................................................17.2-4

17.2.5

Assembling the bucket bearing ..........................................17.2-5 Quick change device (optional) ....................................................17.3-1

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17.3

17.2.1


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Lift arms and quick-change device Lift arms

17.1 Lift arms Technical data See section 2.1

Design

Main components of the Z lift arms 1 Connecting link 2 Linkage 3 Contact face for linkage

4 Bucket return-to-dig proximity switch 5 Tilt cylinder 6 Bucket arm

7 Lift cylinder 8 Bucket stops 9 Bucket bearing

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The lift arms are fitted on the front section of the machine. The lift arms are designed with Z-bar kinematics. This means that the tilt cylinder, linkage and connecting link form a Z shape. The Z shape can be seen from the right side. Parallel load movement is not guaranteed with lift arms with Zkinematics. Two lift cylinders and a tilt cylinder are attached to the lift arms.

Z kinematics

The lift arms are bolted to the front section via the bucket arm bearings and the cylinder bearings on the base of the cylinder. The bearing points on the lift arms have seals to protect them against dirt and corrosion. The lift cylinders are mounted at the piston rod end on the bucket arm and at the cylinder base end on the front section. The tilt cylinder is mounted at the piston rod end on the linkage and at the cylinder base end on the front section. The mechanical bucket return-to-dig device is mounted on the tilt cylinder.


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Lift arm

Function description Basic function Movements of the bucket arm

The lift arms bear and move the attached equipment or implement.

Bucket arm movement The bucket arm is raised or lowered by extending or retracting the lift cylinders. You can find details on this in the section on the working hydraulics. Movements of the working attachment

Bucket movement The bucket is tilted in or out by extending or retracting the tilt cylinder.

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You can find details on this in the section on the working hydraulics.

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Service Manual

Lift arms and quick-change device Pin bearing

17.2 Pin bearing 17.2.1

Standard bearing Design The standard bearings on the lift arms have a pin bearing seal. The following section describes the standard bearing sealing on the lift arms.

Main components of the standard bearing 4 Welded threaded bushing 5 Pin fastening screw 6 Pin fixing disc

7 Pin with lug 8 Bearing bushing 9 Radial seal

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1 Bucket arm 2 Grease fitting 3 Front section


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Pin bearing

17.2.2

Bucket bearing Design

Sectional view of the bucket arm bearing 4 Welded threaded bushing 5 Pin fastening screw 6 Pin fixing disc

7 Pin with lug 8 Bearing bushing 9 Special radial seal

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1 Bucket arm 2 Grease fitting 3 Bucket bearing plate

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Function description Basic function The bucket base and bushings are protected from corrosive or abrasive material by a special radial sealing ring. If this material penetrates the bearing it can increase wear and enlarge the play. If the bearing is loose, the friction will cause increased wear despite lubrication. The radial seal is installed on both sides of the bushing between the bucket arm and bearing plates. The radial seal is held in place by the bearing pin. The steel ring is positioned parallel to the contact faces of the bucket arm and bearing plate and prevents the lip seal ring from being damaged by the forces acting on the bucket bearing. Axial clearance between the bearing journals of the bucket arm and the bearing plate ensures that the bearing moves smoothly and is perfectly sealed.

17.2.3

Removing the pin bearings Design

Extractor hammer

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There are many ways to remove a pin. One tried-and-tested method is to use the extractor hammer shown above. The tool is easy to make and the pin is not damaged when removed. The extractor hammer consists of a round rod with an M36 thread on both ends, two machined faces for an open-ended wrench, the hammer head and two nuts. The first nut has a flange to prevent damage to the nuts.

Procedure • Put the machine in maintenance position 1. • Screw the round rod into the extractor thread of the pin. • Push the hammer onto the rod and tighten the nuts. • Remove the retaining screw. • Knock out the pin.


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Pin bearing

17.2.4 Welding processes

Changing the bushings This section describes how to change the bushings on the bucket bearing. The method for other bearings is similar.

Procedure • Put the machine in maintenance position 1. • Remove the pin as described in 17.2.3. • Start the machine and drive in reverse. • Drive the machine to a suitable place for repairs. • Slightly raise the lift arms and securely support them. • Switch off the engine and pull out the key. • Turn off the battery main switch. To make it easier to remove the steel bucket bushings, we recommend welding several lengthways seams around the bushing. The advantage of this is that when the bushing cools down it becomes smaller in diameter and thus easier to push out of the hole. • Perform the welding in accordance with the safety instructions for welding on the machine (see the operating manual). • Attach the earth lead of the welding equipment as close as possible to the welding position. • Weld on the inside of the bushing. Leave a distance of 10 mm between the ends of the bushing and the welds (see illustration).

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• Let the bushing cool down after welding.

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Service Manual


Pushing out the bushing using the extraction device

You can push out all the bushings on the lift arms using the appropriate pushing tool. Position a steel washer in the bushing, flush and slightly below centre. Use a threaded rod and a hydraulic ram to push the bushing out of the hole.

Procedure • Assemble the hydraulic ram 1, the pusher 2, the threaded rod 3 and the pushing washer 6 (illustrated).

Pushing tool • Fix the threaded rod with a nut. • Carefully push the bushing out of the hole. There are two ways to fit a new bushing: – Using a press – By shrinking it using liquid nitrogen Caution Be very careful when handling liquid nitrogen. If using liquid nitrogen, carefully follow the safety instructions for handling it. ! Read and follow the safety instructions.

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17.2.5

Assembling the bucket bearing Make sure that: – The holes in the bucket are lined up with the holes in the arm – All parts to be assembled are clean

Procedure • Prepare the pin bearing seal.


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Pin bearing

Main components of the pin bearing seal

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1 Steel ring 4 Mounting screw 2 Lip seal ring 5 O-ring 3 Protection and installation ring Mz Assembly condition • Screw in the mounting screw 4. This moves the protection and installation ring 3. • Using a screwdriver, push the lip seal ring 2 (see illustration Mz) into the grooves of the protection and installation ring 3. • Grease the O-ring 5 well.

Sectional view of the bucket arm bearing 1 Bucket arm 2 Bucket bearing plates

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3 Pin with lug 4 Retaining pin with washer

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5 Radial sealing rings

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• Grease the pins, bushings and holes. • Push in the pin until it is flush with the inside of the hole. • Push the pin bearing seal between the bearing arms of the bucket arm and the bucket bearing plate. • Push in the pin until it is flush with the inside of the bucket arm. • Push the second pin bearing seal between the bearing arms of the bucket arm and the bucket bearing plate. • Drive the pin completely through the bearing hole. • Remove the mounting screws from the sealing rings and free the sealing lips by moving the mounting rings. • Push the bucket to the left or right using a crowbar. • Check that the axial clearance between the bearing journals of the bucket arm and bucket bearing plate is 3.2 mm. • Secure the pin with the pin fixing screw 2 and washer 1.

Pin fastening

The illustration shows gaps between the pin lug 4 and the disc 1, and between the pin lug and the bushing 3. This allows the pin to move slightly, preventing it from jamming in the fixed bearing (steel to steel).

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Caution Dirt, water and other corrosive substances may wear or corrode the bearing pin, surfaces or hole. Wear and corrosion will irreparably damage the bearing. ! Before you install the pin bearing seal, check the maximum axial clearance!


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Pin bearing

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Lift arms and quick-change device Quick change device (optional)

17.3 Quick change device (optional) Technical data See section 2.1 The quick-change device is fitted to the lift arms of the machine. It is used for quickly changing the various attachments on the lift arms. The different versions are operated differently. You can find detailed operating instructions in the operating manual.

Design

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Main components of the quick-change device 1 Hydraulic quick-change device 2 Grease fitting 3 Left locking pin

4 Hydraulic lines 5 Hydraulic cylinder 6 Right locking pin

7 Mechanical indicator 8 Cover

The quick change device also has brackets for attaching and holding the working attachment. The hydraulic lines 4 lead to the hydraulic cylinder 5 via bulkhead fittings. The hydraulic cylinder and the locking pins are fitted in a bracket and protected from dust and damage by a cover 8.


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Quick change device (optional)

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18 Equipment and accessories 18.0 Chapter contents 18

Equipment and accessories .............................................. 18.0-1 18.1

Loading bucket .............................................................................18.1-1

18.2

Forklift ...........................................................................................18.2-1

18.3

Connection sizes – L550 / L556 ...................................................18.3-1 18.3.1

Buckets - direct attachment................................................18.3-2

18.3.2

Buckets - quick-change device...........................................18.3-3

18.3.3

Dimensions - Z kinematics, direct attachment ...................18.3-4

18.4

Connection sizes – L566 / L576 / L580 ........................................18.4-1 Buckets - direct attachment................................................18.4-2

18.4.2

Buckets - quick-change device...........................................18.4-3

18.4.3

Dimensions - Z kinematics, direct attachment ...................18.4-4

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18.4.1


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Equipment and accessories Bucket

18.1 Loading bucket Technical data See section 2.1 The loading bucket is one of many different attachments that can be fitted to the lift arms. The bucket is normally fitted directly to the lift arms. If the lift arms are fitted with an optional quick change device, the bucket is attached to that. The following section describes the loading bucket with teeth.

Design The bottom cutting edge varies according to the application. The various designs include: – Welded tooth holder with plug-in teeth – Four-section, reversible undercut blade

Bucket with teeth 1 Tooth 2 Tooth holder

3 Bottom cutting edge 4 Locking pin

The tooth 1 is plugged into the holder 2 and secured with a crosswise locking pin 4.

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The tooth holder 2 is welded to the bottom cutting edge 3.


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Bucket

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Equipment and accessories Forklift

18.2 Forklift Technical data See section 2.1 The forklift is one of many different attachments that can be fitted to the lift arms. The forklift is mounted either directly on the lift arms or onto the optional quick change device. The following section describes the forklift with adjustable prongs.

Design The forklift consists of the fork carrier and adjustable fork prongs.

Forklift 1 Fork carrier

2 Fork prongs

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The fork prongs 2 are attached to the fork carrier 1 and are secured against slipping with the fork lock on the upper fork hook.


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Forklift

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Equipment and accessories Connection sizes

18.3 Connection sizes – L550 / L556 General information: The connection sizes provide information when fitting equipment not supplied by Liebherr. This is defined as any equipment not bought from Liebherr. Note that all genuine Liebherr equipment is optimally designed for used with the machines. This means that equipment not supplied by Liebherr can impair the operation of the wheel loader and the machine cannot be guaranteed to work in the best manner. Also, equipment not supplied by Liebherr which is poorly or inadequately designed may damage the machine. Liebherr accepts no liability for damage caused by equipment which it does not supply. When fitting attachments, check that the stability described in EN 474 is maintained. Furthermore, the maximum axle loads and total weight of the machine (see the type plate) may not be exceeded.

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Equipment not manufactured according to the Liebherr connection sizes must be inspected and approved by the specialist department at Liebherr.


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Connection sizes

Buckets - direct attachment

This drawing may not be copied, reproduced or made accessible to third parties without our permission. Violation of this will lead to claims for compensation and, if deliberate, is punishable by law. All information in this drawing must be kept confidential.

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18.3.1

Service Manual

Equipment and accessories Connection sizes

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18.3.2

Buckets - quick-change device



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Connection sizes

Dimensions - Z kinematics, direct attachment


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18.3.3

Service Manual

Equipment and accessories Attachment handbook

18.4 Connection sizes – L566 / L576 / L580 General information: The connection sizes provide information when fitting equipment not supplied by Liebherr. This is defined as any equipment not bought from Liebherr. Note that all genuine Liebherr equipment is optimally designed for used with the machines. This means that equipment not supplied by Liebherr can impair the operation of the wheel loader and the machine cannot be guaranteed to work in the best manner. Also, equipment not supplied by Liebherr which is poorly or inadequately designed may damage the machine. Liebherr accepts no liability for damage caused by equipment which it does not supply. When fitting attachments, check that the stability described in EN 474 is maintained. Furthermore, the maximum axle loads and total weight of the machine (see the type plate) may not be exceeded.

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Equipment not manufactured according to the Liebherr connection sizes must be inspected and approved by the specialist department at Liebherr.


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Cab access

Buckets - direct attachment


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18.4.1

Service Manual

Equipment and accessories Attachment handbook

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18.4.2

Buckets - quick-change device



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Cab access

Dimensions - Z kinematics, direct attachment


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18.4.3

19 Service Codes, Diagnose Chapter contents 19

Service Codes, Diagnose ................................................... 19.0-1 19.0

Malfunctions...................................................................................19.0-1 Service codes indicated on the display unit (A13) .................19.0-1

19.0.2

Audible and visual warning signals.......................................19.0-2

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Service Codes, Diagnose

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Malfunctions

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L550 - 456 / from 16978 L556 - 454 / from 15653


Service Manual

Service Codes, Diagnose Malfunctions

19.0 Malfunctions Warning and error messages – Various faults are indicated by the corresponding symbol fields (visually) or by display instruments on the instrument panel. – Some warning functions are accompanied by audible warning signals. Finding and eliminating errors and malfunctions – Faults can often be traced back to incorrect operation or servicing of the machine. Therefore, carefully read the appropriate section of the operating manual each time a fault occurs. – Analyse the cause of the fault and correct it immediately.

19.0.1

Service codes indicated on the display unit (A13) The main electronics (master) monitor many of the machine’s functions. It monitors for short circuits, cable rupture, external voltage and incorrect input and output signals. In addition, the main electronics (master) continuously check the program sequence and communication with the display unit.

Display unit Service code display

STOP indicator

LBH/Version 01/10.2006/en/hd/29/03/2007

If a fault occurs while you are setting up or operating the machine, it is shown on the display unit and stored in the error memory.

Error indicator


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Service Manual

Malfunctions

Service code display The service codes are classed in the following groups: – CRITICAL: This is a fault which only concerns the main electronics (master). – ERROR: This is a fault in the various electrical components or wiring. – ERROR Motor This is a fault in the various electrical components or wiring. – WARNING: This is information on the condition of the power supply, CAN bus or diesel engine. The following must be taken into account: – The service codes “CRITICAL” and “ERROR” are shown in segment field 1 of the display unit and stored in the service code memory. – The service codes “ERROR Motor” and “WARNING” are not shown in the display unit but are stored in the service code memory. – A warning tone accompanies all service codes (CRITICAL and ERROR)

Effects of a fault Every malfunction has a defined effect. This is specified in the “Effect” column of the service code table. If errors occur which can damage the machine, the entire machine is shut down. Neutral travel direction is automatically selected and the machine coasts to a halt. Make a note of the service code, as it may disappear from the segment field of the display unit when the ignition is switched off. Analyse and rectify the fault.

List of abbreviations LFD LH-ECU PWM RAM REF sec t

LBH/Version 01/10.2006/en/hd/29.03.2007

Ubat V

Liebherr ride control system Liebherr engine control unit (A700D) Pulse width modulated outputs (proportional solenoid) Memory Reference (comparison) Seconds Fault time; how long a fault must be active to trigger a service code Battery power supply (terminal 30) Volts

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Service Manual


LBH/Version 01/10.2006/en/hd/29/03/2007

Malfunctions

CRITICAL This kind of malfunction is accompanied by a 1-second warning tone Service Effect Cause Remedy code The entire control system Turn the ignition off and on C1002 has been shut down due to again; if the problem persists, a critical error. System fault contact the manufacturer. The entire control system Turn the ignition off and on again; if the problem persists, C1003 has been shut down due to a critical error. System fault contact the manufacturer. The entire control system Turn the ignition off and on C1004 has been shut down due to again; if the problem persists, a critical error. System fault contact the manufacturer. The entire control system Turn the ignition off and on again; if the problem persists, C1005 has been shut down due to a critical error. System fault contact the manufacturer. The entire control system Turn the ignition off and on C100E has been shut down due to again; if the problem persists, System fault a critical error. contact the manufacturer. The entire control system Turn the ignition off and on C1014 has been shut down due to again; if the problem persists, a critical error. System fault contact the manufacturer. The entire control system Turn the ignition off and on again; if the problem persists, C101C has been shut down due to a critical error. System fault contact the manufacturer. The entire control system Turn the ignition off and on C101F has been shut down due to again; if the problem persists, System fault a critical error. contact the manufacturer. The entire control system Copy software (see label) onto C1025 has been shut down due to a critical error. Invalid boot card (CF1) the card again The entire control system Copy software (see label) onto C1033 has been shut down due to Invalid boot card (CF1) the card again a critical error. The entire control system Copy software (see label) onto C103E has been shut down due to a critical error. Invalid boot card (CF1) the card again The entire control system Copy software (see label) onto C104A has been shut down due to the card again a critical error. Invalid boot card (CF1) The entire control system Copy software (see label) onto C104B has been shut down due to Invalid boot card (CF1) the card again a critical error. The entire control system Copy software (see label) onto C104C has been shut down due to a critical error. Invalid boot card (CF1) the card again The entire control system Copy software (see label) onto C104D has been shut down due to the card again a critical error. Invalid boot card (CF1) The entire control system Copy software (see label) onto C104E has been shut down due to Invalid boot card (CF1) the card again a critical error. The entire control system Copy software (see label) onto C104F has been shut down due to the card again a critical error. Invalid boot card (CF1) The entire control system Copy software (see label) onto C1050 has been shut down due to Invalid boot card (CF1) the card again a critical error.


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Service Manual

CRITICAL This kind of malfunction is accompanied by a 1-second warning tone Service Effect Cause Remedy code The entire control system Copy software (see label) onto C1051 has been shut down due to Invalid boot card (CF1) the card again a critical error. The entire control system Copy software (see label) onto C1052 has been shut down due to the card again a critical error. Invalid boot card (CF1) The entire control system Copy software (see label) onto C1053 has been shut down due to Invalid boot card (CF1) the card again a critical error. The entire control system Copy software (see label) onto C1054 has been shut down due to a critical error. Invalid boot card (CF1) the card again The entire control system Copy software (see label) onto C1055 has been shut down due to the card again a critical error. Invalid boot card (CF1) The entire control system Copy software (see label) onto C1056 has been shut down due to Invalid boot card (CF1) the card again a critical error. The entire control system Copy software (see label) onto C1057 has been shut down due to the card again a critical error. Invalid boot card (CF1) The entire control system Copy software (see label) onto C1058 has been shut down due to Invalid boot card (CF1) the card again a critical error. The entire control system Copy software (see label) onto C1059 has been shut down due to a critical error. Invalid boot card (CF1) the card again The entire control system Copy software (see label) onto C105A has been shut down due to the card again a critical error. Invalid boot card (CF1) The entire control system Copy software (see label) onto C105C has been shut down due to Invalid boot card (CF1) the card again a critical error. The entire control system Copy software (see label) onto C105E has been shut down due to a critical error. Invalid boot card (CF1) the card again The entire control system Copy software (see label) onto C105F has been shut down due to the card again a critical error. Invalid boot card (CF1) The entire control system Copy software (see label) onto C1060 has been shut down due to a critical error. Invalid boot card (CF1) the card again The entire control system Copy software (see label) onto C1061 has been shut down due to the card again a critical error. Invalid boot card (CF1) The entire control system Copy software (see label) onto C1063 has been shut down due to Invalid boot card (CF1) the card again a critical error. The entire control system Copy software (see label) onto C1064 has been shut down due to a critical error. Invalid boot card (CF1) the card again The entire control system Copy software (see label) onto C1065 has been shut down due to the card again a critical error. Invalid boot card (CF1) The entire control system Copy software (see label) onto C1066 has been shut down due to Invalid boot card (CF1) the card again a critical error.

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LBH/Version 01/10.2006/en/hd/29.03.2007

Malfunctions

Service Manual


LBH/Version 01/10.2006/en/hd/29/03/2007

Malfunctions

CRITICAL This kind of malfunction is accompanied by a 1-second warning tone Service Effect Cause Remedy code The entire control system Copy software (see label) onto C106D has been shut down due to Invalid boot card (CF1) the card again a critical error. The entire control system Copy software (see label) onto C106E has been shut down due to the card again a critical error. Invalid boot card (CF1) The entire control system Copy software (see label) onto C1070 has been shut down due to Invalid boot card (CF1) the card again a critical error. The entire control system Copy software (see label) onto C1071 has been shut down due to a critical error. Invalid boot card (CF1) the card again The entire control system Copy software (see label) onto C1072 has been shut down due to the card again a critical error. Invalid boot card (CF1) The entire control system Copy software (see label) onto C1073 has been shut down due to Invalid boot card (CF1) the card again a critical error. The entire control system Copy software (see label) onto C1074 has been shut down due to the card again a critical error. Invalid boot card (CF1) The entire control system Check that the CAN modules and C2002 has been shut down due to software board have the right ID Invalid CAN module type a critical error. numbers Two CAN modules with the same module number but different serial numbers have been detected on a C200E The entire control system has been shut down due to CAN bus; CAN module production a critical error. Replace the CAN module error Check the power supply to the The entire control system CAN module F35, check the C200F has been shut down due to An essential CAN module has not CAN wiring; then replace the a critical error. reported on the CAN bus CAN module The entire control system Turn the ignition off and on C2010 has been shut down due to again; if the problem persists, System fault a critical error. contact the manufacturer. The entire control system Check the CAN bus connection, C2011 has been shut down due to None of the modules on a CAN line check the power supply to the a critical error. have reported on the CAN bus modules The entire control system Check the CAN bus connection, C2012 has been shut down due to None of the modules on a CAN line check the power supply to the have reported on the CAN bus a critical error. modules The entire control system Turn the ignition off and on C2014 has been shut down due to again; if the problem persists, a critical error. System fault contact the manufacturer. The entire control system Turn the ignition off and on again; if the problem persists, C2015 has been shut down due to a critical error. System fault contact the manufacturer. The entire control system Turn the ignition off and on C2017 has been shut down due to again; if the problem persists, System fault a critical error. contact the manufacturer. The entire control system Turn the ignition off and on C2019 has been shut down due to again; if the problem persists, a critical error. System fault contact the manufacturer. The entire control system Turn the ignition off and on again; if the problem persists, C201A has been shut down due to a critical error. System fault contact the manufacturer.


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Service Manual

CRITICAL This kind of malfunction is accompanied by a 1-second warning tone Service Effect Cause Remedy code The entire control system Turn the ignition off and on C202A has been shut down due to again; if the problem persists, System fault a critical error. contact the manufacturer. The entire control system Check that the CAN modules and C202B has been shut down due to Data has been received on the CAN software board have the right ID bus from an undefined CAN module numbers a critical error. The entire control system Turn the ignition off and on C202C has been shut down due to again; if the problem persists, System fault a critical error. contact the manufacturer. Check the power supply to the The entire control system CAN modules F24, F38, F43, C202D has been shut down due to An essential CAN module has failed F71, check the CAN wiring; then a critical error. on the CAN bus replace the CAN module The entire control system Check that the CAN modules and C2033 has been shut down due to Data has been received on the CAN software board have the right ID bus from an undefined CAN module numbers a critical error. The entire control system Turn the ignition off and on C2034 has been shut down due to again; if the problem persists, a critical error. System fault contact the manufacturer. The entire control system Turn the ignition off and on C2039 has been shut down due to again; if the problem persists, System fault a critical error. contact the manufacturer. The entire control system Turn the ignition off and on C203D has been shut down due to again; if the problem persists, a critical error. System fault contact the manufacturer. The entire control system Check the CAN bus connection, C203E has been shut down due to All the modules on a CAN line have check the power supply to the failed during operation. a critical error. modules The entire control system Turn the ignition off and on C2040 has been shut down due to again; if the problem persists, System fault a critical error. contact the manufacturer. The entire control system An attempt was made to reactivate a C2043 has been shut down due to CAN module during a timeout; this is a critical error. not permitted Turn the ignition off and on again Turn the ignition off and on The entire control system again; if the problem persists, C205A has been shut down due to A critical error in a CAN module replace the CAN module a critical error. caused the system to shut down. according to the error stack. Turn the ignition off and on The entire control system again; if the problem persists, C205C has been shut down due to A critical error in a CAN module replace the CAN module a critical error. caused the system to shut down. according to the error stack. The entire control system Turn the ignition off and on C205D has been shut down due to again; if the problem persists, a critical error. Error downloading to a CAN module contact the manufacturer. The entire control system Turn the ignition off and on again; if the problem persists, C205E has been shut down due to a critical error. Error downloading to a CAN module contact the manufacturer. The entire control system Turn the ignition off and on C2062 has been shut down due to again; if the problem persists, Error downloading to a CAN module contact the manufacturer. a critical error. The entire control system Turn the ignition off and on C2063 has been shut down due to again; if the problem persists, a critical error. Error downloading to a CAN module contact the manufacturer. The entire control system Turn the ignition off and on again; if the problem persists, C2064 has been shut down due to a critical error. Error downloading to a CAN module contact the manufacturer.

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LBH/Version 01/10.2006/en/hd/29.03.2007

Malfunctions

Service Manual


LBH/Version 01/10.2006/en/hd/29/03/2007

Malfunctions

CRITICAL This kind of malfunction is accompanied by a 1-second warning tone Service Effect Cause Remedy code The entire control system Copy software (see label) onto C2065 has been shut down due to A CAN download file could not be found on the boot card. the card again a critical error. The entire control system Turn the ignition off and on again; if the problem persists, C2067 has been shut down due to a critical error. Error downloading to a CAN module contact the manufacturer. The entire control system Turn the ignition off and on C2069 has been shut down due to again; if the problem persists, Error downloading to a CAN module contact the manufacturer. a critical error. The entire control system Turn the ignition off and on C3003 has been shut down due to Main electronics (master) system again; if the problem persists, a critical error. error contact the manufacturer. The entire control system Turn the ignition off and on again; if the problem persists, C3004 has been shut down due to Main electronics (master) system error a critical error. contact the manufacturer. The entire control system Turn the ignition off and on C3005 has been shut down due to Main electronics (master) system again; if the problem persists, error a critical error. contact the manufacturer. Turn the ignition off and on The entire control system again; if the problem persists, C3009 has been shut down due to Main electronics (master) system replace the main electronics a critical error. error (master). The entire control system Turn the ignition off and on C300A has been shut down due to Main electronics (master) system again; if the problem persists, a critical error. error contact the manufacturer. Turn the ignition off and on The entire control system again; if the problem persists, C300B has been shut down due to Main electronics (master) system replace the main electronics a critical error. error (master). The entire control system Turn the ignition off and on C3015 has been shut down due to Main electronics (master) system again; if the problem persists, a critical error. error contact the manufacturer. The entire control system Turn the ignition off and on again; if the problem persists, C3016 has been shut down due to Main electronics (master) system error a critical error. contact the manufacturer. The entire control system Turn the ignition off and on C3017 has been shut down due to Main electronics (master) system again; if the problem persists, error a critical error. contact the manufacturer. The entire control system Turn the ignition off and on again; if the problem persists, C3018 has been shut down due to Main electronics (master) system error a critical error. contact the manufacturer. The entire control system Turn the ignition off and on C3022 has been shut down due to Main electronics (master) system again; if the problem persists, error a critical error. contact the manufacturer. Turn the ignition off and on The entire control system again; if the problem persists, C3023 has been shut down due to Main electronics (master) system replace the main electronics a critical error. error (master). Turn the ignition off and on The entire control system again; if the problem persists, C3024 has been shut down due to Main electronics (master) system replace the main electronics a critical error. error (master). The entire control system Turn the ignition off and on again; if the problem persists, C3028 has been shut down due to Main electronics (master) system error a critical error. contact the manufacturer.


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Service Manual

Malfunctions

CA024

The entire control system has been shut down due to a critical error.

Turn the ignition off and on Invalid correction values found in the again; the correction check sum memory. is automatically corrected.

CA029



CA02A



CA02B



CA02C



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LBH/Version 01/10.2006/en/hd/29.03.2007

CRITICAL This kind of malfunction is accompanied by a 1-second warning tone Service Effect Cause Remedy code The entire control system Turn the ignition off and on C3029 has been shut down due to Main electronics (master) system again; if the problem persists, error a critical error. contact the manufacturer. The entire control system Turn the ignition off and on again; if the problem persists, C302A has been shut down due to Main electronics (master) system error a critical error. contact the manufacturer. The entire control system Turn the ignition off and on C302B has been shut down due to Main electronics (master) system again; if the problem persists, error a critical error. contact the manufacturer. The entire control system Turn the ignition off and on C302C has been shut down due to Main electronics (master) system again; if the problem persists, a critical error. error contact the manufacturer. The entire control system Turn the ignition off and on again; if the problem persists, C302D has been shut down due to Main electronics (master) system error a critical error. contact the manufacturer. The entire control system Turn the ignition off and on C6021 has been shut down due to Main electronics (master) system again; if the problem persists, error a critical error. contact the manufacturer. The entire control system Turn the ignition off and on again; if the problem persists, CA002 has been shut down due to Main electronics (master) system error a critical error. contact the manufacturer. The entire control system Turn the ignition off and on CA005 has been shut down due to Main electronics (master) system again; if the problem persists, error a critical error. contact the manufacturer. The entire control system Turn the ignition off and on CA008 has been shut down due to Main electronics (master) system again; if the problem persists, a critical error. error contact the manufacturer. The entire control system Turn the ignition off and on again; if the problem persists, CA009 has been shut down due to Main electronics (master) system error a critical error. contact the manufacturer. The entire control system Turn the ignition off and on CA00A has been shut down due to Main electronics (master) system again; if the problem persists, error a critical error. contact the manufacturer. The entire control system Turn the ignition off and on CA00B has been shut down due to Main electronics (master) system again; if the problem persists, a critical error. error contact the manufacturer. The entire control system Turn the ignition off and on again; the correction file is CA01E has been shut down due to Invalid correction file found on the boot card a critical error. generated correctly.

Service Manual


CRITICAL This kind of malfunction is accompanied by a 1-second warning tone Service Effect Cause Remedy code CA047

CA048

The entire control system has been shut down due to a critical error. The entire control system has been shut down due to a critical error.

Invalid correction check sum Invalid retain value check sum


A critical error in a CAN module caused the system to shut down.

C205C


A critical error in a CAN module caused the system to shut down.

LBH/Version 01/10.2006/en/hd/29/03/2007

C205A

Turn the ignition off and on again; the correction check sum is automatically corrected. Turn the ignition off and on again; the retain variable check sum is automatically corrected. Turn the ignition off and on again; if the problem persists, replace the CAN module according to the error stack. Turn the ignition off and on again; if the problem persists, replace the CAN module according to the error stack.


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Service Manual

Malfunctions

E2003

E2013

E2016

E2017

E2018 E201A

E201B

E201C E201D E201E

E201F E2020

Emergency steering: Emergency steering pump pressure switch check closed without check

No emergency steering function The output of the travel pump is reduced Brake system accumulator pressure symbol field H19 lights up, after 2 minutes warning beep sounds constantly, travel direction cannot be selected All three LEDs on the control unit switch light up, central lubrication system does not work

Check emergency steering pressure switch B3 and wiring Check emergency steering pressure switch B3 and wiring Check emergency steering pressure switch B3a and wiring

Hydraulic oil temperature: temperature above 95 °C

Check emergency steering pressure switch B3a and wiring Clean cooling system, check fan pressure (fan speed), hydraulic oil temperature switch B8 (at 20 °C - 1112 Ω)

Brake accumulator pressure: pressure too low

Check accumulator pressure switch B19 (switching point 120 bar), wiring, accumulator charge valve, gear pump

Central lubrication system: electrical fault at output (cable rupture) of grease line fault Gyrator steering (2 in 1 steering): Signal at output does not correspond to the activation (fault current)

Gyrator steering (2-in-1) deactivated Enabled options have no Incorrect options enabled function Variable displacement motor 1 (YEP1), variable displacement motor 2 (YEP2), forward travel direction (Y2), reverse travel Output module 1 / bank 4: no power direction (Y3) have no function supply. Wiring or fuse defective No travel range function

Remedy

Check distributor, grease lines and lubrication points

Check the wiring Enable correct options

Check fuse F59 or wiring

Output module 1 / bank 3: no power supply. Wiring or fuse defective




No joystick gyrator steering (2-in-1) function Travel direction and additional equipment do not work (driving only possible at reduced speed) Parking brake, working hydraulics lockout, bucket return-to-dig and lift kick-out do not work





Float position and cooling system fan do not work



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LBH/Version 01/10.2006/en/hd/29.03.2007

ERROR This kind of malfunction is accompanied by a 1-second warning tone Service Effect Cause code Emergency steering pressure switch E2000 No emergency steering is closed even though the engine is function not running Emergency steering pressure switch E2001 No emergency steering does not switch after the engine function starts Emergency steering: Check failed (B3a emergency steering pump E2002 No emergency steering check pressure switch did not function switch)

Service Manual


ERROR This kind of malfunction is accompanied by a 1-second warning tone Service Effect Cause code Emergency steering, fan E2022 reversal, ride control and Output module 2 / bank 2: no power float position do not work supply. Wiring or fuse defective Output module 1: return voltage measured at an output (bank 3) E2023 although it is not activated - wiring or No travel range function module 1 defective E2024 No travel direction function


Output module 1, check wiring to gearbox Y6.1, Y6.2, Y6.3, YMo1 or check output module 1 Output module 1, check wiring to Output module 1: return voltage variable displacement pump Y2, measured at control output (bank 4) Y3 or wiring to variable although it is not activated - wiring or displacement motors YEP1, module 1 defective YEP2 or output module 1 Output module 2, check wiring to Output module 2: return voltage variable displacement pump Y2a, measured at an output (bank 3) Y3a or wiring to additional although it is not activated - wiring or equipment Y11, Y12 or output module 2 defective module 2

E2025

No travel direction and additional equipment function

E2026

No joystick gyrator steering (2-in-1) function

Output module 1, check wiring to module 2 or output module 1

E2048

The ride control system does not work

Enable correct option Joystick steering pressure switch B201; check wiring or input module 3 Ride control: set activation and deactivation speeds correctly (SCULI)

E2049

Automatic lighting shutdown Faulty activation of power supply does not work terminal 15 (optional) - fault current

Check output module 3, wiring or relay K246

E204A

Functions activated via terminal 15 do not work

Faulty activation of power supply terminal 15 (optional) - interruption

Check output module 3, wiring or relay K246

E204B

All three LEDs on the control unit switch light up STOP symbol field H24 flashes, no emergency steering function available STOP symbol field H8 flashes, no emergency steering function available Brake system accumulator pressure symbol field H19 lights up, condition of the service brake cannot be detected

Central lubrication system: filling level low

E2046 E2047

E3000 E3001 LBH/Version 01/10.2006/en/hd/29/03/2007

Remedy

E3002

E3003 E3004 E3005

Output module 1: fault current/short circuit at output 33 (bank 4,) - wiring or module 2 defective Back-up alarm: options incorrectly No back-up alarm function enabled, more than one option available enabled per output Joystick steering: pressure switch check failed; fault in pressure switch No joystick steering function or wiring Ride control: speed limits incorrectly set

Emergency steering pump check pressure switch: shorted to earth Emergency steering pump pressure switch: shorted to earth

Brake accumulator pressure switch: shorted to earth

No float position available

Bucket float position pressure switch: shorted to earth

None

Inching angle sensor: channel 1 over current >20 am

None

Inching angle sensor: channel 1 undercurrent <4 am


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Top up central lubrication system Emergency steering pump check pressure switch B3a; check wiring or input module 1 Emergency steering pump pressure switch B3; check wiring or input module 1 Brake accumulator pressure switch B19; check wiring or input module 1 Float position pressure switch B32; check wiring or input module 1 Inching angle sensor R1; check wiring or input module 1 Inching angle sensor R1, power supply F44, check wiring or input module 1

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Service Manual

Malfunctions

ERROR This kind of malfunction is accompanied by a 1-second warning tone Service Effect Cause code

Remedy

E3006

Travel direction cannot be selected

Travel direction switch: forwards signal channel 1 shorted to earth

Travel direction switch S2a; check wiring or input module 1

E3007


Travel direction switch: reverse signal channel 1 shorted to earth


E3009 E300B E300C E300D E300E E300F

E3010

E3011

No lift kick-out available

Lift kick-out inductive switch: shorted Lift kick-out inductive switch B17; to earth check wiring or input module 1 Bucket return-to-dig inductive Bucket return-to-dig inductive switch B15; check wiring or input switch: shorted to earth module 1

No bucket return-to-dig available Fuel level cannot be detected - minimum filling level displayed Fuel level cannot be detected - minimum filling level displayed

Fuel level sensor: under voltage <1 V

Fuel level sensor B25; check wiring or input module 1

Fuel level sensor: over voltage >4 V

Fuel level sensor B25; check wiring or input module 1

Engine cannot be started

Ignition switch: Start signal T. 50a shorted to earth

Ignition switch S1; check wiring or input module 1

None

Gas pedal angle sensor: channel 1 over current >20 am Gas pedal angle sensor: channel 1 undercurrent <4 am

Gas pedal angle sensor R5; check wiring or input module 1 Gas pedal angle sensor R5, power supply F44, check wiring or input module 1

Hydraulic oil temperature sensor: shorted to earth

Hydraulic oil temperature sensor B8; check wiring or input module 1

None Hydraulic oil overheating symbol field H23 lights up, fan running at high speed, driving only possible in fixed gear 1 or 2 Hydraulic oil overheating symbol field H23 lights up, fan running at high speed, driving only possible in fixed gear 1 or 2

E3012

Continued driving is only possible in fixed gear 2

Variable displacement motor 1 speed sensor: shorted to earth

E3013


Variable displacement motor 1 speed sensor: Interruption

Hydraulic oil temperature sensor B8; check wiring or input module 1 Variable displacement motor 1 speed sensor B2; check wiring or input module 1 Variable displacement motor 1 speed sensor B2; check wiring or input module 1

E3014


Power take-off speed sensor: shorted to earth

Power take-off speed sensor B1; check wiring or input module 1

E3015


Power take-off speed sensor: Interruption

No driving light available

Driving light response: shorted to earth

No high beam available

High beam response: shorted to earth

Power take-off speed sensor B1; check wiring or input module 1 Steering column switch S3, relay K3; check wiring or input module 2 Steering column switch S3, relay K3a; check wiring or input module 2

None

Indicator signal response: input of input module shorted to earth

No ride control function

Ride control pressure switch: shorted to earth

E3016 E3017 E3018 E3019

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Hydraulic oil temperature sensor: Interruption

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Input module 2, check fault in wiring H15, H16, H17, H18 Ride control pressure switch B28; check wiring or input module 1

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LBH/Version 01/10.2006/en/hd/29.03.2007

E3008

Service Manual


ERROR This kind of malfunction is accompanied by a 1-second warning tone Service Effect Cause code E301A


Travel direction switch: forwards signal channel 2 shorted to earth


E301B


Travel direction switch: reverse signal channel 2 shorted to earth


None

Inching angle sensor: channel 2 over current >20 am

None

Inching angle sensor: channel 2 undercurrent <4 am

Inching angle sensor R1; check wiring or input module 2 Inching angle sensor R1, check power supply F45, wiring or input module 2

None

Gas pedal angle sensor: channel 2 over current >20 am

None

Gas pedal angle sensor: channel 2 undercurrent (<4 am)

Gas pedal angle sensor R5; check wiring or input module 2 Gas pedal angle sensor R5, check power supply F45, wiring or input module 2

Kick-down function not available

Kick-down button: shorted to earth

Kick-down button S2b; check wiring or input module 2

No option 1 function

Option 1 button: shorted to earth

Option 1 button S2c; check wiring or input module 2

No option 2 function

Option 2 button: shorted to earth

Option 2 button S2d; check wiring or input module 2

No warning buzzer function

Warning buzzer: shorted to earth

Warning buzzer H40; check wiring or input module 2

E3024

No central lubrication function

Central lubrication system (filling level) inductive switch: shorted to earth

Central lubrication system (filling level) inductive switch B44; check wiring or input module 2

E3025

Particle filter cannot be monitored

Particle filter: input 1 electrical fault (shorted to earth)

Input module 2, fault in sensor, check data logger wiring

E3026

Particle filter cannot be monitored

Particle filter input 2 electrical fault (shorted to earth)

E3027

Joystick steering not available

E3028


E301C E301D E301E E301F E3020 E3021 E3022 E3023

E3029 LBH/Version 01/10.2006/en/hd/29/03/2007

Remedy

E302A

Driving is not possible Driving is not possible

E302B

Central lubrication system not available

E302C

Central lubrication system not available

E302D


E302E



Input module 2, fault in sensor, check data logger wiring Joystick steering signal encoder Joystick steering signal encoder: left B202; check wiring or input signal over current >20 am module 2 Joystick steering signal encoder Joystick steering signal encoder: left B202; check wiring or input signal undercurrent <4 am module 2 Variable displacement motor 2 Variable displacement motor 2 speed sensor B2a; check wiring speed sensor: shorted to earth or input module 2 Variable displacement motor 2 Variable displacement motor 2 speed sensor B2a; check wiring speed sensor: Interruption or input module 2 Central lubrication system Central lubrication system (cycles) (cycles) inductive switch B43; inductive switch: shorted to earth check wiring or input module 2 Central lubrication system Central lubrication system (cycles) (cycles) inductive switch B43; inductive switch: Interruption check wiring or input module 2 Joystick steering signal encoder Joystick steering signal encoder: B202; check wiring or input right signal over current >20 am module 3 Joystick steering signal encoder Joystick steering signal encoder: B202; check wiring or input right signal undercurrent <4 am module 3

L576 - 457 / from 14171 L580 - 459 / from 14171

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19.0-13 o f 1 3


Service Manual

Malfunctions

Remedy

E302F


Joystick steering pressure switch: shorted to earth

Joystick steering pressure switch B201a; check wiring or input module 3

E3031

Basket mode - emergency off function not available

Basket mode emergency off: input signal 1 shorted to earth

Input module 3, fault in sensor, check wiring

E3032

Basket mode - emergency off function not available Basket mode function not available Basket mode function not available

Basket mode emergency off: input signal 2 shorted to earth Basket mode: input signal 1 shorted to earth Basket mode: input signal 2 shorted to earth

Input module 3, fault in sensor, check wiring Input module 3, fault in sensor, check wiring Input module 3, fault in sensor, check wiring

E3035


Joystick steering button: shorted to earth

E3036


Joystick steering inductive switch: shorted to earth

Joystick steering button S202; check wiring or input module 3 Joystick steering inductive switch B200; check wiring or input module 3

E3037

Continued driving is only possible in fixed gear 1 or 2

None

Gear oil temperature sensor: fault current Pump: pressure sensor shorted to earth Pump: pressure sensor power interruption

Check output module 1 or wiring Check pressure sensor BXXX and wiring Check pressure sensor BXXX and wiring

Option not available

LH control lever: capacitive grip sensor shorted to earth

Check grip sensor, wiring or control unit


LH control lever: power interruption to capacitive proximity switch

Check proximity switch, wiring or control unit


LH control lever: direction potentiometer 1 shorted to earth

Check potentiometer, wiring or control unit


LH control lever: direction potentiometer 1 power interrupted



LH control lever: direction potentiometer 2 shorted to earth



LH control lever: direction potentiometer 2 power interrupted



LH control lever: button 1 shorted to supply voltage

Check button 1, wiring or control unit


LH control lever: implausible status button signal


LH control lever: button 2 shorted to supply voltage Travel pump: pressure sensor detected


E3033 E3034

E3039 E303A E304F E3050 E3051 E3052 E3053 E3054 E3055 E3056 E3059 E305A E4000

E4001 E4002

None

Option not available None Parking brake symbol field H11 flashes, parking brake cannot be released, driving not possible Parking brake symbol field H11 flashes, parking brake cannot be released, driving not possible

Parking brake: short circuit at output

Parking brake solenoid valve Y10; check wiring or output module 1

Parking brake: interruption at output

Parking brake solenoid valve Y10; check wiring or output module 1

Working hydraulics lockout cannot be lifted

Working hydraulics lockout: short circuit at output

Working hydraulics lockout solenoid valve Y14; check wiring

19.0-14 o f 1 4

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None

L550 - 456 / from 16978 L556 - 454 / from 15653


LBH/Version 01/10.2006/en/hd/29.03.2007


Service Manual



Remedy or output module 1

E4003

Working hydraulics lockout cannot be lifted

Working hydraulics lockout: interruption at output

E4004

No bucket return-to-dig available

Bucket return-to-dig: short circuit at output

No lift kick-out available

Lift kick-out: short circuit at output

No float position available

Float position: short circuit at output

Fan turns at full speed

Fan: short circuit at output

Fan turns at full speed Fan turns at full speed

Fan: interruption at output Fan: fault current at output Fan: the measured return current at output does not match the output current

E4006 E4008 E400A

E400B E400C E400D E400E E4010 E4011 E4012 E4013

LBH/Version 01/10.2006/en/hd/29/03/2007

E4014

E4015

E4016 E4017 E4018

Fan turns at full speed No warning buzzer function Possible gearbox damage, coupling damage during longer trips Possible gearbox damage, coupling damage during longer trips Automatic range A2-3 activated (1st gear blocked), kick-down not possible Automatic range A2-3 activated (1st gear blocked), kick-down not possible Fixed gear 1 is activated and variable displacement motor 1 is set to a wide angle to prevent overspeed Fixed gear 1 is activated and variable displacement motor 1 is set to a wide angle to prevent overspeed Continued driving is only possible in fixed gear 1 or 2 or automatic range A1-2 Continued driving is only possible in fixed gear 1 or 2 or automatic range A1-2 Sudden shifting


Warning buzzer: short circuit at output Swivel angle restriction: short circuit at output Swivel angle restriction: interruption at output

Working hydraulics lockout solenoid valve Y14; check wiring or output module 1 Bucket return-to-dig solenoid valve Y9; check wiring or output module 1 Lift kick-out solenoid valve Y17; check wiring or output module 1 Float position solenoid valve Y18; check wiring or output module 1 Fan motor proportional valve Y13; check wiring or output module 1 Fan motor proportional valve Y13; check wiring or output module 1, check power supply F48 Check wiring or output module 1 Fan motor proportional valve Y13; check wiring or output module 1 Warning buzzer H40; check wiring or output module 1 Swivel angle restriction solenoid valve Y57; check wiring or output module 1 Swivel angle restriction solenoid valve Y57; check wiring or output module 1

Coupling 1: interruption at output

Coupling 1 solenoid valve Y6.1; check wiring or output module 1 Coupling 1 solenoid valve Y6.1; check power supply F60, wiring or output module 1

Coupling 2: short circuit at output

Coupling 2 solenoid valve Y6.2; check wiring or output module 1



Coupling 2 solenoid valve Y6.2; check power supply F60, wiring or output module 1





Modulation: short circuit at output

Modulation solenoid valve Y6.4; check wiring or output module 1

L576 - 457 / from 14171 L580 - 459 / from 14171

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Service Manual

Malfunctions


E401A

E401B

Modulation solenoid valve Y6.4; check wiring or output module 1 Variable displacement motor 1 Fixed gear 2 activated, kick- Variable displacement motor 1: short proportional valve YEP1; check down not possible circuit at output wiring or output module 1 Variable displacement motor 1 solenoid valve YEP1; check Fixed gear 2 activated, kick- Variable displacement motor 1: power supply F59, wiring or down not possible interruption at output output module 1

Sudden shifting

Modulation: interruption at output

E401C

Fixed gear 2 activated, kick- Variable displacement motor 1: fault down not possible current at output

E401D

Fixed gear 2 activated, kickdown not possible Fixed gear 1 is activated and variable displacement motor 1 is set to a wide angle to prevent overspeed Fixed gear 1 is activated and variable displacement motor 1 is set to a wide angle to prevent overspeed Fixed gear 1 is activated and variable displacement motor 1 is set to a wide angle to prevent overspeed Fixed gear 1 is activated and variable displacement motor 1 is set to a wide angle to prevent overspeed

E401E

E401F

E4020

E4021

E4022 E4023 E4024 E4025

Only reverse travel possible Only reverse travel possible Only forward travel possible Only forward travel possible

E4026

No rear axle brake available at overspeed

E4027

No rear axle brake available at overspeed

E4028

Quick change device not available

E402A

Driving is not possible

19.0-16 o f 1 6

Variable displacement motor 1: the measured return current at output does not match the output current

Check wiring or output module 1 Variable displacement motor 1 proportional valve YEP1; check wiring or output module 1

Variable displacement motor 2 Variable displacement motor 2: short proportional valve YEP2; check wiring or output module 1 circuit at output Variable displacement motor 2 solenoid valve YEP2; check Variable displacement motor 2: power supply F59, wiring or interruption at output output module 1 Variable displacement motor 2: fault current at output

Variable displacement motor 2 proportional valve YEP2; check wiring or output module 1

Variable displacement motor 2: the measured return current at output does not match the output current

Variable displacement motor 2 proportional valve YEP2; check wiring or output module 1 Forward travel direction solenoid Forward travel direction (pump 1): valve Y2; check wiring or output short circuit at output module 1 Forward travel direction solenoid Forward travel direction (pump 1): valve Y2; check wiring or output interruption at output module 1 Reverse travel direction solenoid Reverse travel direction (pump 1): valve Y3; check wiring or output short circuit at output module 1 Reverse travel direction solenoid Reverse travel direction (pump 1): valve Y3; check wiring or output interruption at output module 1 Overspeed protection solenoid Overspeed protection: short circuit valve Y16; check wiring or output at output module 2 Overspeed protection solenoid Overspeed protection: interruption at valve Y16; check wiring or output output module 2 Quick-change device solenoid Quick-change device: short circuit at valve Y53; check wiring or output output module 2 Control pressure proportional Control pressure (pump 1): short valve Y15; check wiring or output circuit at output module 2

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L550 - 456 / from 16978 L556 - 454 / from 15653


LBH/Version 01/10.2006/en/hd/29.03.2007

E4019

Remedy

Service Manual


ERROR This kind of malfunction is accompanied by a 1-second warning tone Service Effect Cause code Driving is not possible

Control pressure (pump 1): interruption at output

Control pressure proportional valve Y15; check wiring or output module 2


Control pressure (pump 1): fault current at output

Check wiring or output module 2


Control pressure (pump 1): the measured return current at output does not match the output current


Control pressure (pump 2): short circuit at output


Control pressure (pump 2): interruption at output

Control pressure proportional valve Y15; check wiring or output module 2 Control pressure proportional valve Y15a; check wiring or output module 2 Control pressure proportional valve Y15a; check wiring or output module 2


Control pressure (pump 2): fault current at output

Check wiring or output module 2


Control pressure (pump 2): the measured return current at output does not match the output current

E4032

No emergency steering available

Emergency steering: short circuit at output

E4033

No emergency steering available

Emergency steering: interruption at output

Control pressure proportional valve Y15a; check wiring or output module 2 Emergency steering pump relay K11; check wiring or output module 2 Emergency steering pump relay K11; check wiring or output module 2

No fan reversal available

Fan reversal: short circuit at output

Fan reversal solenoid valve Y50; check wiring or output module 2

No fan reversal available

Fan reversal: interruption at output

Fan reversal solenoid valve Y50; check wiring or output module 2

No ride control available

Ride control: short circuit at output

Ride control solenoid valve Y20; check wiring or output module 2

No ride control available

Ride control: interruption at output

E4038

No ride control and float position available

Float position / ride control: short circuit at output

E4039

No ride control and float position available

Float position / ride control: interruption at output

E403A

Forward travel direction (pump 2): Only reverse travel possible short circuit at output

E403B

Forward travel direction (pump 2): Only reverse travel possible interruption at output

E403C

Reverse travel direction (pump 2): Only forward travel possible short circuit at output

E403D

Reverse travel direction (pump 2): Only forward travel possible interruption at output

E403E

Additional equipment 1 cannot be activated

E402B E402C E402D E402E E402F E4030 E4031

E4034 E4035 E4036 E4037

LBH/Version 01/10.2006/en/hd/29/03/2007

Remedy


Additional equipment 1: short circuit at output

L576 - 457 / from 14171 L580 - 459 / from 14171

Ride control solenoid valve Y20; check wiring or output module 2 Float position / ride control solenoid valve Y21; check wiring or output module 2 Float position / ride control solenoid valve Y21; check wiring or output module 2 Forward travel direction solenoid valve Y2a; check wiring or output module 2 Forward travel direction solenoid valve Y2a; check wiring or output module 2 Reverse travel direction solenoid valve Y3a; check wiring or output module 2 Reverse travel direction solenoid valve Y3a; check wiring or output module 2 Additional equipment 1 solenoid valve Y11; check wiring or output module 2

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19.0-17 o f 1 7


Service Manual

Malfunctions


Remedy

No joystick gyrator steering (2-in-1) function Travel direction and additional equipment do not work (driving only possible at reduced speed)

Additional equipment 2 solenoid valve Y12; check wiring or output module 2 Joystick steering left proportional Joystick steering, left: short circuit at valve Y51; check wiring or output output module 2 Joystick steering right Joystick steering, right: short circuit proportional valve Y52; check at output wiring or output module 2 Gyrator steering solenoid valve Gyrator steering (2-in-1): short circuit Y63; check wiring or output at output module 2 Gyrator steering solenoid valve Gyrator steering (2-in-1): interruption Y63; check wiring or output at output module 2 Output module 1: return voltage Output module 1 pin 33, check measured at control output bank 4 although it is not activated - wiring or wiring to module 2 or output module 2 defective module 2 Output module 1: return voltage Output module 1 pin 35, check measured at control output bank 3 although it is not activated - wiring or wiring to module 2 or output module 2 defective module 2

E404C

No central lubrication function

Output module 1: Central lubrication system: fault current/short circuit wiring or module 1 defective

Output module 1, check wiring to central lubrication system M6 or output module 1

E404E

No flashing back-up alarm function

Output module 1, check wiring to lamps H58, H59 or output module 1

No travel direction function

Output module 1: Flashing back-up alarm: fault current/short circuit wiring or module 1 defective Output module 1: return voltage measured at control output bank 4 although it is not activated - wiring or module 1 defective

Output module 2 pin 33, check wiring to module 1 or output module 1

No travel range function

Output module 2: Control output bank 3 : fault current/short circuit wiring or module 1 defective

Output module 2 pin 35, check wiring to module 1 or output module 1

E4054

Reversing light does not work

Reversing light,: short circuit

Output module 2, fault in consumer E1, E5 or check wiring

E4056

Back-up alarm does not work

Back-up alarm: short circuit

E4058

Comfort control does not work

Comfort control fault at output (over current / short circuit)

E405A

Option output: electrical fault at output

Electrical fault in consumer or wiring - option does not work

E405B

No joystick steering available

Joystick steering safety shutdown: short circuit at output

E405C


Joystick steering safety shutdown: interruption at output

E405D


Joystick steering, left: undercurrent at output

E4040


E4042


E4044


E4046

No Gyrator steering (2-in-1) available

E4047

No Gyrator steering (2-in-1) available

E404A

E4050

E4052

19.0-18 o f 1 8

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Output module 2, fault in consumer B16 or check wiring Output module 3, fault in consumer Y11, Y12 or check wiring Check consumer or wiring Joystick steering safety shutdown solenoid valve Y64; check wiring or output module 2 Joystick steering safety shutdown solenoid valve Y64; check wiring or output module 2 Joystick steering left proportional valve Y51; check wiring or output module 2

L550 - 456 / from 16978 L556 - 454 / from 15653


LBH/Version 01/10.2006/en/hd/29.03.2007

E4048

Additional equipment 2: short circuit at output

Service Manual


ERROR This kind of malfunction is accompanied by a 1-second warning tone Service Effect Cause code E405E E405F E4060


E4061

No joystick steering available No joystick steering available

E4062 E4076 E4077 E4078 E4079 E407A E407B E407C E407D E407E

LBH/Version 01/10.2006/en/hd/29/03/2007

No joystick steering available No joystick steering available

E407F E4080 E4081 E4082 E4083

Option not available Option not available Option not available Option not available Option not available Option not available Option not available Option not available Option not available Option not available Option not available Option not available Option not available Option not available


Remedy

Joystick steering left proportional Joystick steering, left: over current at valve Y51; check wiring or output output module 2 Joystick steering, left: discrepancy at output Check output module 2 Joystick steering right Joystick steering, right: undercurrent proportional valve Y52; check at output wiring or output module 2 Joystick steering right Joystick steering, right: over current proportional valve Y52; check at output wiring or output module 2 Joystick steering, right: discrepancy Output module 2 at output Direction 1 output signal (3rd control circuit) - electrical fault at output (undercurrent) Check wiring and consumers Direction 1 output signal (3rd control circuit) - electrical fault at output (over current) Check wiring and consumers Direction 1 output signal (3rd control circuit) - electrical fault at output (deviation) Check wiring and consumers Direction 1 output signal (3rd control circuit) - electrical fault at output (short circuit) Check wiring and consumers Direction 2 output signal (3rd control circuit) - electrical fault at output Check wiring and consumers (undercurrent) Direction 2 output signal (3rd control circuit) - electrical fault at output (over current) Check wiring and consumers Direction 2 output signal (3rd control circuit) - electrical fault at output (deviation) Check wiring and consumers Direction 2 output signal (3rd control circuit) - electrical fault at output Check wiring and consumers (short circuit) Direction 1 output signal (4th control circuit) - electrical fault at output (undercurrent) Check wiring and consumers Direction 1 output signal (4th control circuit) - electrical fault at output Check wiring and consumers (over current) Direction 1 output signal (4th control circuit) - electrical fault at output (deviation) Check wiring and consumers Direction 1 output signal (4th control circuit) - electrical fault at output (short circuit) Check wiring and consumers Direction 2 output signal (4th control circuit) - electrical fault at output Check wiring and consumers (undercurrent) Direction 2 output signal (4th control circuit) - electrical fault at output (over current) Check wiring and consumers

L576 - 457 / from 14171 L580 - 459 / from 14171

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MJFCIFSS

19.0-19 o f 1 9


Service Manual

Malfunctions

Remedy

Check wiring and consumers Check wiring and consumers

E4086


Additional equipment 3: electrical fault at output (surge/short circuit)

Check solenoid valve Y11a or wiring

E4087


Additional equipment 4: electrical fault at output (surge/short circuit)

Check solenoid valve Y12a or wiring

Travel slow or impossible

Variable displacement motor synchronisation complete

Engine speed cannot be changed, driving not possible

Gas pedal angle sensor: different values from sensors 1 and 2

Synchronise variable displacement motors again Gas pedal angle sensor R5: check redundant signals (maximum current difference ±10%), check power supply F44, F45 Inching angle sensor R1: check redundant signals (maximum current difference ±10%), check power supply F45 Clean cooling system, check fan pressure (fan speed), gear oil temperature switch B14 (switching point 120 °C), oil level

E5022

E5026

E5027

E5028

No inching function available Speed limited to 20 km/h, driving only possible in 1st or 2nd gear

E5029 No immediate reaction E502A

E502B

E502C E5034

Driving only possible in 1st gear

No kick-down function available No inching function available Engine damage

E5035

Travel direction selection cannot be clearly detected

E5036

The motor retains the old value

E5037


E5038


19.0-20 o f 2 0

Inching angle sensor: different values from sensors 1 and 2 Gear oil temperature sensor triggered: gear oil temperature above 120 °C, oil level too high or temperature switch defective Rear axle brake fault: rear axle brake activated for longer than 3 seconds at a time or for more than 16 % intermittently Transfer gear speed sensor, implausible signal: power take-off speed does not match variable displacement motor speed (monitoring only in 1st gear) Kick-down button is pressed longer than 10 sacs. (or jammed) after ignition or pressed longer than 2 minutes (or jammed) in normal operation Inching angle sensor constantly less than 100 % for longer than 2 minutes (inch pedal dirty)

Check rear axle brake solenoid valve Y16 for faults Transfer gear speed sensor B1; check wiring, coupling 1 or 2 or switching pressure

Check kick-down button

Clean the inch pedal so that it moves properly Check engine oil pressure, fault Engine oil pressure too low: Fault in in pressure sensor B701 or pressure sensor or wiring wiring Travel direction switch S2a, Travel direction switch: invalid check power supply F15 or wiring switching condition Adjust variable adjustment motor Variable displacement motor 1 control range (loosen adjusting balance 1 maximum current too low screw) Adjust variable adjustment motor Variable displacement motor 1 control range (tighten adjusting balance 1 maximum current too high screw) Adjust variable adjustment motor Variable displacement motor 1 control range (tighten adjusting balance 1 minimum current too high screw)

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L550 - 456 / from 16978 L556 - 454 / from 15653


LBH/Version 01/10.2006/en/hd/29.03.2007

ERROR This kind of malfunction is accompanied by a 1-second warning tone Service Effect Cause code Direction 2 output signal (4th control E4084 circuit) - electrical fault at output Option not available (deviation) Direction 2 output signal (4th control E4085 circuit) - electrical fault at output Option not available (short circuit)

Service Manual


ERROR This kind of malfunction is accompanied by a 1-second warning tone Service Effect Cause code E5039

Variable displacement motor balance 1 minimum current too low

E5042


E5043


Joystick steering: redundant input signals outside tolerance Joystick steering: safety shutdown due to excessive discrepancies in joystick signals

E503B E503C E503D E503E

E503F

E5040

E5041

E5054 LBH/Version 01/10.2006/en/hd/29/03/2007

Adjust variable adjustment motor 1 control range (loosen adjusting screw) Adjust variable adjustment motor The motor retains the old Variable displacement motor 2 control range (loosen adjusting value balance 2 maximum current too low screw) Adjust variable adjustment motor The motor retains the old Variable displacement motor 2 control range (tighten adjusting value balance 2 maximum current too high screw) Adjust variable adjustment motor The motor retains the old Variable displacement motor 2 control range (tighten adjusting value balance 2 minimum current too high screw) Adjust variable adjustment motor The motor retains the old Variable displacement motor 2 control range (loosen adjusting value balance 2 minimum current too low screw) Driving only possible in fixed Difference between variable Check coupling 1, check wiring gear 1, kick-down not displacement motor speed 1 and and speed sensors B1, B2 possible take-off speed in 1st gear Driving only possible in fixed gear 1, variable displacement motor 1 only controls from 50 - 100 %, Difference between variable variable displacement motor displacement motor speed 2 and Check coupling 2, check wiring and speed sensors B1, B2a 2 is at 0°, coupling 2 is open take-off speed in 1st gear Driving only possible in fixed gear 1, variable displacement motor 1 only controls from 50 - 100 %, Difference between variable Check coupling 2, check wiring variable displacement motor displacement motor speed 2 and and speed sensors B1, B2a 2 is at 0°, coupling 2 is open take-off speed in 2nd gear Automatic range A2-3 Difference between variable Check coupling 3, check wiring deactivated (3rd gear displacement motor speed 1 and blocked) take-off speed in 3rd gear and speed sensors B1, B2 The motor retains the old value

E503A

E5055 E5056

E6000

E6001 E6002

Remedy

Option still available Option not available Option not available Coolant temperature symbol field (H13) flashes, STOP symbol field lights up, continuous warning buzzer sounds Warning buzzer sounds intermittently, engine has reduced power Warning buzzer sounds intermittently, engine has reduced power


Input module 2, synchronise tolerance, check sensor signals Input module 2, synchronise tolerance, check sensor signals

LH control lever: potentiometer outside tolerance range LH control lever: function deactivated due to excessive potentiometer discrepancy

Check wiring, replace potentiometer

LH control lever: potentiometer power supply too low

Check module, wiring or potentiometer

Check wiring and potentiometer

Clean cooling system, check fan speed, coolant temperature Coolant temperature above 100 °C sensor B708, thermostat in engine for more than 3 seconds Clean cooling system, check fan Charge air temperature above 75 °C speed, charge air temperature for more than 3 seconds sensor B707 Clean cooling system, check fan Fuel temperature above 75 °C for speed, fuel temperature sensor more than 10 seconds B709

L576 - 457 / from 14171 L580 - 459 / from 14171

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19.0-21 o f 2 1


Service Manual

Malfunctions

ERROR This kind of malfunction is accompanied by a 1-second warning tone Service Effect Cause code Warning buzzer sounds E6003 intermittently, engine has reduced power Water in fuel pre-filter Engine oil pressure symbol field (H4) lights up, STOP E6004 symbol field (H36) lights up, continuous warning buzzer after 10 sec. Engine oil pressure too low

E6008

Air filter contamination Air filter contamination: vacuum symbol field (H7) lights up switch switched Coolant temperature symbol field (H13) and STOP symbol field light up, continuous warning buzzer Coolant level too low sounds

E600B

Risk of damage to the engine

Engine overspeed: too high while driving downhill > 2500 rpm

E600C

Calculation error depends on the fault

Always given for an additional service code

E600D E600E E600F

Engine shuts down Engine not running smoothly Engine shuts down

E6010 Engine has reduced power E6011 E6012 E6016

E6017

EA005 EA006 EA007

Engine has reduced power

Check coolant level, check coolant level sensor B13, check power supply F36 Brake machine while driving downhill Depends on the fault. - (see additional code in the error memory)

Emergency engine shutdown: speed sensors 1 and 2 defective Check speed sensor B711, B712 Faulty injector (pump element Check injector (pump element solenoid) solenoid), wiring Check engine control unit, check Engine electronics detected internal wiring, check power supply F36 error Power reduction can be triggered by: coolant temperature, charge air temperature, fuel temperature, altitude Engine power reduction active (atmospheric pressure) Engine altitude power reduction active (from 2250 m above sea level) None Depends on the fault. - (see Always given for an additional additional code in the error service code memory)

Calculation error depends on the fault Charge control symbol field (H6) lights up, parking brake Alternator not supplying power cannot be released Calculation error, engine module sent internal error code. - This is Calculation error depends shown in the display unit instead of on the fault the engine service code CAN bus: display unit timeout , hardware defective, fault in CAN No display unit function wiring CAN bus: air conditioning controller Air conditioning controller timeout, hardware defective, fault in does not work CAN wiring CAN bus: output module 3 timeout, Output module 3 does not hardware defective, error in CAN work wiring

19.0-22 o f 2 2

Drain water from fuel pre-filter, check pre-filter water detector B710 Check oil level, engine oil pressure (2 bar at 1000 rpm, 3 bar at 2100 rpm), pressure relief valve, engine oil pressure sensor B701, wiring Replace/clean air filter, check air filter contamination vacuum switch B4, wiring

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Check alternator G3 or wiring Depends on the fault. - (see additional code in the error memory) Check display unit A13 power supply F11 or CAN wiring Check air conditioning controller A21 power supply F19, F19a or CAN wiring Check output module 3 (A17c) or CAN wiring

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LBH/Version 01/10.2006/en/hd/29.03.2007

E6006

Remedy

Service Manual


LBH/Version 01/10.2006/en/hd/29/03/2007

ERROR This kind of malfunction is accompanied by a 1-second warning tone Service Effect Cause code CAN bus: input module 3 timeout, EA008 Input module 3 does not hardware defective, error in CAN work wiring CAN bus: air conditioning control EA010 Air conditioning control unit unit timeout, hardware defective, does not work fault in CAN wiring CAN bus: option control unit timeout, EA011 Option control unit does not hardware defective, fault in CAN work wiring EA020


EA021


EA023


EA024


EA025


EA026


EA027


EA028


EA029


EA02A


EA02B

Calculation error depending on the fault

EA02C

Calculation error depending on the fault


Remedy Check input module 3 (A16c) or CAN wiring Check air conditioning control unit A22 power supply F9or CAN wiring

Check option control unit A19 or CAN wiring Depends on the fault. - (see Calculation error, option input additional code in the error module 1 sent an internal error code memory) Depends on the fault. - (see Calculation error, option output additional code in the error module 1 sent an internal error code memory) Depends on the fault. - (see Calculation error, option keypad additional code in the error module sent an internal error code memory) Depends on the fault. - (see Calculation error, main keypad additional code in the error module sent an internal error code memory) Depends on the fault. - (see Calculation error, display unit additional code in the error module sent an internal error code memory) Depends on the fault. - (see Calculation error, output module 2 additional code in the error sent an internal error code memory) Depends on the fault. - (see Calculation error, output module 1 additional code in the error sent an internal error code memory) Depends on the fault. - (see Calculation error, input module 2 additional code in the error sent an internal error code memory) Depends on the fault. - (see Calculation error, input module 1 additional code in the error sent an internal error code memory) Depends on the fault. - (see Calculation error, master unit additional code in the error module sent an internal error code memory) Depends on the fault. - Check power soppy F36 (see additional CAN module calculation error code in the error memory) Depends on the fault. - (see additional code in the error General calculation error memory)

L576 - 457 / from 14171 L580 - 459 / from 14171

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19.0-23 o f 2 3


Service Manual

Malfunctions

E4976C

No direct effect

CAN communication was resynchronised CAN driver problem in ECU

Check the ECU A700D engine control unit

E4976D

No direct effect

CAN communication timeout CAN driver problem in ECU


E49638

Construction machine CAN timeout Emergency operation: engine when requesting global process running at lower idle speed CAN bus connection problem or master unit A15 defective

Check cables, plugs, master

E49639

Construction machine CAN timeout Emergency operation: engine receiving total output data CAN bus connection problem or running at lower idle speed master unit A15 defective


E4963A

Construction machine CAN timeout Emergency operation: engine while sending messages running at lower idle speed CAN bus connection problem or master unit A15 defective


E4963B

Construction machine CAN Emergency operation: engine passive error CAN bus connection problem or running at lower idle speed master unit A15 defective


E4963C

Construction machine CAN bus off Emergency operation: engine CAN bus connection problem or running at lower idle speed master unit A15 defective


E4969C

CAN AMET timeout while requesting Emergency operation: engine global process running at lower idle speed CAN bus connection problem or master unit A15 defective


E4969D

CAN AMET timeout receiving total Emergency operation: engine output data running at lower idle speed CAN bus connection problem or master unit A15 defective


E4969E

CAN AMET timeout while sending Emergency operation: engine messages CAN bus connection problem or running at lower idle speed master unit A15 defective


E4969F

CAN AMET passive error Emergency operation: engine CAN bus connection problem or running at lower idle speed master unit A15 defective


E496A0

CAN AMET bus off Emergency operation: engine CAN bus connection problem or running at lower idle speed master unit A15 defective


E49764

No direct effect

CAN communication status CAN A cannot connect at 125kB CAN driver problem in ECU


E49765

No direct effect



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ERROR Motor This kind of malfunction is accompanied by a 1-second warning tone Service Effect Cause Remedy code

Service Manual


ERROR Motor This kind of malfunction is accompanied by a 1-second warning tone Service Effect Cause Remedy code E49766

No direct effect



E49767

No direct effect

CAN communication status CAN A cannot connect at 1MB CAN driver problem in ECU


E49768

No direct effect

CAN communication status CAN B cannot connect at 125kB CAN driver problem in ECU


E49769

No direct effect



E4976A

No direct effect



E4976B

No direct effect

CAN communication status CAN B cannot connect at 1MB CAN driver problem in ECU


CAN communication – could not detect actual CAN A baud rate

Check the ECU A700D engine control unit Master unit A15 Input module 1 Output module 1

LBH/Version 01/10.2006/en/hd/29/03/2007

E4976E

No direct effect

E4976F

No direct effect

CAN communication – could not detect actual CAN B baud rate

Check the ECU A700D engine control unit Master unit A15 Input module 1 Output module 1

E497C8

Engine cannot be started, or engine shut down

Internal error – stack overflow Internal engine control unit error

Turn the ignition off and on again; if the problem persists, replace the ECU A700D engine control unit.

E497C9


Internal error – exception Internal engine control unit error


E497CA


Internal error – program test Internal engine control unit error


E497CB


Internal error – RAM test Internal engine control unit error


E497CC

No direct effect

Turn the ignition off and on again; Internal error – error memory overflow if the problem persists, replace the ECU A700D engine control unit.

E497CD

No direct effect

Internal error – computing time test


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Service Manual

Malfunctions

E497CE

The error that occurred cannot be displayed

Internal error – error index too high


E4982C


Error accessing EEPROM Internal engine control unit error


E4982D


Parameter memory check sum fault Internal engine control unit error


E4982E


Invalid parameter memory in EEPROM Internal engine control unit error


E4982F

No direct effect

ECU page check sum fault Internal engine control unit error


E49830

No direct effect

NMI page check sum fault Internal engine control unit error


E49831

No direct effect

Work data page check sum fault Internal engine control unit error


E49832

No direct effect

Load collective check sum fault Internal engine control unit error


E49833

No direct effect

Load collective structure value has changed Internal engine control unit error


E49834

No direct effect

EEPROM does not have enough space for the load collective Internal engine control unit error


E49835

No direct effect

Permanent data check sum fault


E49890


Supply voltage too low (<9V)

Check the on-board circuit (battery, alternator, wiring, connectors)

E49891

Engine cannot be started, or engine shut down Supply voltage too high (>33V) Communication only possible with diagnostic tools

Check the on-board circuit (battery, alternator, wiring, connectors)

E49892

Engine shutdown Digital output shorted to supply Communication only possible voltage with diagnostic tools Defective line or component

Check the wiring and ECU A700D engine control unit If the problem cannot be rectified: Replace the ECU A700D engine control unit

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Service Manual



E49893

E49894


E49895

Engine shutdown 12V reference fault: voltage too low Communication only possible (<10V) with diagnostic tools Defective line or component

Check the on-board circuit (battery, alternator, wiring, connectors) with reference to PS1

E49896

Engine shutdown 12V reference fault: voltage too high Communication only possible (>14V) with diagnostic tools Defective line or component


E499BD

Power curve internally restricted

Offset on full-load curve Internal engine control unit error

New data record or replace the ECU A700D engine control unit

E499BF

Injector class 3 is used as a replacement

Incorrect pump code (pump code is wrong on at least one element) Internal engine control unit error

Check and modify pump code

E49B4C

Higher speed is used

Speed recording error Check the ECU A700D wiring to Maximum speed difference between the speed sensor and check the transmission and odometer is too high speed sensor

No direct effect

Insufficient alternator voltage when engine is not running Defective wiring from engine control unit to alternator, defective alternator or broken V belt

Check the wiring from the ECU A700D engine control unit to the alternator and check the ECU A700D engine control unit

No direct effect

Excess alternator voltage when engine is not running Defective wiring from engine control unit to alternator, defective alternator or broken V belt


No direct effect

Insufficient alternator voltage when engine is running Defective wiring from engine control unit to alternator, defective alternator or broken V belt


No direct effect

Excess alternator voltage when engine is running Defective wiring from engine control unit to alternator, defective alternator or broken V belt


No direct effect

Alternator voltage insufficiently different to supply voltage Defective wiring from engine control unit to alternator, defective alternator or broken V belt


E49BB0

E49BB1

E49BB2 LBH/Version 01/10.2006/en/hd/29/03/2007

Check the wiring and ECU A700D engine control unit If the problem cannot be rectified: Replace the ECU A700D engine control unit

Error releasing power outputs Engine shutdown Power outputs cannot be activated or All digital outputs switched off deactivated

E49BB3

E49BB4


Error on PS1 Engine control unit supply voltage PS1 defective

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Service Manual

Malfunctions

E49BB5

No direct effect

Alternator voltage excessively different to supply voltage Defective wiring from engine control unit to alternator, defective alternator or broken V belt

E49ED0

External exhaust gas recirculation 1 not activated

Exhaust gas recirculation fault Short circuit to earth or cable rupture Output and feedback values do not match

Check the wiring harness, connectors, EGR valve, ECU A700D engine control unit

E49ED1


Exhaust gas recirculation fault Shorted to supply voltage Output and feedback values do not match


E49ED2


Exhaust gas recirculation fault Hardware fault Transistor status does not match feedback value



Exhaust gas recirculation fault Negative control deviation Target less than actual value, controlled PWM goes towards minimum



Exhaust gas recirculation fault Positive control deviation Target greater than actual value, controlled PWM goes towards maximum



Exhaust gas recirculation fault Current too high (switched off) – current higher than permitted minimum value although not energised Threshold violation when switched off



Exhaust gas recirculation fault Current too low (activated state) – current less than permitted minimum value Threshold violation


E49ED7


Exhaust gas recirculation fault Current too high (activated state) – current higher than permitted maximum value Threshold violation


E49EDB


Exhaust gas recirculation fault EGR open without activation “Open” status is read even without activation


E49EDC


Exhaust gas recirculation fault EGR closed without activation “Closed” status is read even without activation


E49ED3

E49ED4

E49ED5

E49ED6

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Service Manual


ERROR Motor This kind of malfunction is accompanied by a 1-second warning tone Service Effect Cause Remedy code Air flap not activated

Air flap fault Short circuit to earth or cable rupture Output and feedback values do not match

Check the wiring harness, connectors, air flap, ECU A700D engine control unit

Air flap not activated

Air flap fault Shorted to supply voltage Output and feedback values do not match



Air flap fault Hardware fault Transistor status does not match feedback value



Air flap fault Negative control deviation Target less than actual value, controlled PWM goes towards minimum



Air flap fault Positive control deviation Target greater than actual value, controlled PWM goes towards maximum



Air flap fault Current too high (switched off) – current higher than permitted minimum value although not energised Threshold violation when switched off



Air flap fault Current too low (activated state) – current less than permitted minimum value Threshold violation


E49F3B


Air flap fault Current too high (activated state) – current higher than permitted maximum value Threshold violation


E4A060


Starter fault Short circuit to earth or cable rupture

Check the wiring harness, connectors, starter, ECU A700D engine control unit

E4A061


Starter fault Shorted to supply voltage

Check the wiring harness, connectors, starter, ECU A700D engine control unit

E4A18C

Preglow and afterglow phases fail

Heating flange 1 fault Short circuit to earth or cable rupture Output and feedback values do not match

Check the wiring harness, connectors, heating flange/glow plug unit, external relay, ECU A700D engine control unit

E49F34

E49F35

E49F36

E49F37

E49F38

E49F39

LBH/Version 01/10.2006/en/hd/29/03/2007

E49F3A


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Service Manual

Malfunctions

E4A18D


Heating flange 1 fault Shorted to supply voltage Output and feedback values do not match


E4A18E


Heating flange 1 fault Hardware fault Transistor status does not match feedback status



Heating flange 1 fault Negative control deviation Target less than actual value, controlled PWM goes towards minimum



Heating flange 1 fault Positive control deviation Target greater than actual value, controlled PWM goes towards maximum



Heating flange 1 fault Current too high (switched off) – current higher than permitted minimum value although not energised Threshold violation when switched off



Heating flange 1 fault Current too low (activated state) – current less than permitted minimum value Threshold violation



Heating flange 1 fault Current too high (activated state) – current higher than permitted maximum value Threshold violation



Heating flange 1 fault No voltage in heating element A low level is read despite activation – the external relay has not switched correctly


E4A198


Heating flange 1 fault Voltage in heating element A high level is read despite no activation – the external relay has not switched correctly


E4A1F0


Heating flange 2 fault Short circuit to earth or cable rupture Output and feedback values do not match


E4A18F

E4A190

E4A191

E4A192

E4A193

E4A197

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Service Manual


ERROR Motor This kind of malfunction is accompanied by a 1-second warning tone Service Effect Cause Remedy code E4A1F1


Heating flange 2 fault Shorted to supply voltage Output and feedback values do not match


E4A1F2


Heating flange 2 fault Hardware fault Transistor status does not match feedback status



Heating flange 2 fault Negative control deviation Target less than actual value, controlled PWM goes towards minimum



Heating flange 2 fault Positive control deviation Target greater than actual value, controlled PWM goes towards maximum



Heating flange 2 fault Current too high (switched off) – current higher than permitted minimum value although not energised Threshold violation when switched off



Heating flange 2 fault Current too low (activated state) – current less than permitted minimum value Threshold violation



Heating flange 2 fault Current too high (activated state) – current higher than permitted maximum value Threshold violation



Heating flange 2 fault No voltage in heating element A low level is read despite activation – the external relay has not switched correctly



Heating flange 2 fault Voltage in heating element A high level is read despite no activation – the external relay has not switched correctly


Afterglow phase failure

Turbocharger fault Short circuit to earth or cable rupture Output and feedback values do not match

Check the wiring harness, connectors, turbocharger solenoid valve, ECU A700D engine control unit

E4A1F3

E4A1F4

E4A1F5

E4A1F6

E4A1F7

LBH/Version 01/10.2006/en/hd/29/03/2007

E4A1FB

E4A1FC

E4A254


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Service Manual

Malfunctions


Turbocharger fault Shorted to supply voltage Output and feedback values do not match



Turbocharger fault Hardware fault Transistor status does not match feedback status



Turbocharger fault Negative control deviation Target less than actual value, controlled PWM goes towards minimum



Turbocharger fault Positive control deviation Target greater than actual value, controlled PWM goes towards maximum



Turbocharger fault Current too high (switched off) – current higher than permitted minimum value although not energised Threshold violation when switched off



Turbocharger fault Current too low (activated state) – current less than permitted minimum value Threshold violation


E4A25B


Turbocharger fault Current too high (activated state) – current higher than permitted maximum value Threshold violation


E4A2B8

Turbocharger fault Short circuit to earth or cable rupture Turbocharger is not activated Output and feedback values do not match


E4A2B9

Turbocharger fault Shorted to supply voltage Turbocharger is not activated Output and feedback values do not match


E4A2BA

Turbocharger fault Hardware fault Turbocharger is not activated Transistor status does not match feedback status


E4A2BB

Turbocharger fault Negative control deviation Turbocharger is not activated Target less than actual value, controlled PWM goes towards minimum


E4A255

E4A256

E4A257

E4A258

E4A259

E4A25A

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E4A2BC

Turbocharger fault Positive control deviation Turbocharger is not activated Target greater than actual value, controlled PWM goes towards maximum


E4A2BD

Turbocharger fault Current too high (switched off) – current higher than permitted Turbocharger is not activated minimum value although not energised Threshold violation when switched off


E4A2BE

Turbocharger fault Current too low (activated state) – Turbocharger is not activated current less than permitted minimum value Threshold violation


E4A2BF

Turbocharger fault Current too high (activated state) – Turbocharger is not activated current higher than permitted maximum value Threshold violation


E4A31C


Exhaust gas recirculation fault Short circuit to earth or cable rupture Output and feedback values do not match


E4A31D


Exhaust gas recirculation fault Shorted to supply voltage Output and feedback values do not match


E4A31E


Exhaust gas recirculation fault Hardware fault Transistor status does not match feedback value



Exhaust gas recirculation fault Negative control deviation Target less than actual value, controlled PWM goes towards minimum



Exhaust gas recirculation fault Positive control deviation Target greater than actual value, controlled PWM goes towards maximum



Exhaust gas recirculation fault Current too high (switched off) – current higher than permitted minimum value although not energised Threshold violation when switched off


LBH/Version 01/10.2006/en/hd/29/03/2007

E4A31F

E4A320

E4A321


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Service Manual

Malfunctions


Exhaust gas recirculation fault Current too low (activated state) – current less than permitted minimum value Threshold violation


E4A323


Exhaust gas recirculation fault Current too high (activated state) – current higher than permitted maximum value Threshold violation


E4A327


Exhaust gas recirculation fault EGR open without activation "Open" status is read even without activation


E4A328


Exhaust gas recirculation fault EGR closed without activation “Closed” status is read even without activation


No direct effect

Engine speed output fault Short circuit to earth or cable rupture Output and feedback values do not match

Check the wiring harness, connectors, connected module

E4A705

No direct effect

Engine speed output fault Shorted to supply voltage Output and feedback values do not match

Check the wiring harness, connectors, connected module

E4A768

No direct effect

Cylinder A1 fault Incorrect current measurement or cable rupture

Check the wiring harness, connectors, solenoid valve, ECU A700D engine control unit

E4A769

No direct effect

Check the wiring harness, Cylinder A1 fault connectors, solenoid valve, ECU Excess low side current (earth switch) A700D engine control unit

E4A76A

No direct effect

Cylinder A1 fault Excess high side current (positive switch)


E4A76B

No direct effect

Cylinder A1 fault Excess high side current on free wheel cylinder


E4A76C

No direct effect

Cylinder A1 fault No flight time measured

Replace the ECU A700D engine control unit

E4A76D

No direct effect

Cylinder A1 fault Flight time too short


E4A76E

No direct effect

Cylinder A1 fault Flight time too long


E4A76F

No direct effect

Cylinder A1 fault No rise time measured


E4A322

E4A704

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LBH/Version 01/10.2006/en/hd/29/03/2007

ERROR Motor This kind of malfunction is accompanied by a 1-second warning tone Service Effect Cause Remedy code E4A770

No direct effect

Cylinder A1 fault Rise time too long


E4A7CC

No direct effect



E4A7CD

No direct effect


E4A7CE

No direct effect



E4A7CF

No direct effect



E4A7D0

No direct effect



E4A7D1

No direct effect



E4A7D2

No direct effect



E4A7D3

No direct effect



E4A7D4

No direct effect



E4A830

No direct effect



E4A831

No direct effect


E4A832

No direct effect



E4A833

No direct effect



E4A834

No direct effect



E4A835

No direct effect



E4A836

No direct effect




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Service Manual

Malfunctions

E4A837

No direct effect



E4A838

No direct effect



E4A894

No direct effect



E4A895

No direct effect


E4A896

No direct effect



E4A897

No direct effect



E4A898

No direct effect



E4A899

No direct effect



E4A89A

No direct effect



E4A89B

No direct effect



E4A89C

No direct effect



E4AA88

No direct effect

Cylinder B1 fault Incorrect current measurement or cable rupture


E4AA89

No direct effect

Check the wiring harness, Cylinder B1 fault connectors, solenoid valve, ECU Excess low side current (earth switch) A700D engine control unit

E4AA8A

No direct effect

Cylinder B1 fault Excess high side current (positive switch)


E4AA8B

No direct effect

Cylinder B1 fault Excess high side current on free wheel cylinder


E4AA8C

No direct effect

Cylinder B1 fault No flight time measured


E4AA8D

No direct effect

Cylinder B1 fault Flight time too short


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Service Manual


LBH/Version 01/10.2006/en/hd/29/03/2007

ERROR Motor This kind of malfunction is accompanied by a 1-second warning tone Service Effect Cause Remedy code E4AA8E

No direct effect

Cylinder B1 fault Flight time too long


E4AA8F

No direct effect

Cylinder B1 fault No rise time measured


E4AA90

No direct effect

Cylinder B1 fault Rise time too long


E4AAEC No direct effect



E4AAED No direct effect


E4AAEE No direct effect



E4AAEF

No direct effect



E4AAF0

No direct effect



E4AAF1

No direct effect



E4AAF2

No direct effect



E4AAF3

No direct effect



E4AAF4

No direct effect



E4AB50

No direct effect



E4AB51

No direct effect


E4AB52

No direct effect



E4AB53

No direct effect



E4AB54

No direct effect




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Service Manual

Malfunctions

E4AB55

No direct effect



E4AB56

No direct effect



E4AB57

No direct effect



E4AB58

No direct effect



E4ABB4

No direct effect



E4ABB5

No direct effect


E4ABB6

No direct effect



E4ABB7

No direct effect



E4ABB8

No direct effect



E4ABB9

No direct effect



E4ABBA No direct effect



E4ABBB No direct effect



E4ABBC No direct effect



E4AED4

Engine shutdown

Injection system fault Cylinder fault More than the permitted number of solenoid valves have failed


Engine shutdown

Injection system fault Injection overlap to bank A Distance between the current tooth and the next tooth on bank A is more than 540° crankshaft angle

Check the start and duration of injection

E4AED5

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Service Manual



Engine shutdown

Injection system fault Injection overlap to bank B Distance between the current tooth and the next tooth on bank A is more than 540° crankshaft angle

No direct effect

Injection system fault High side short circuit to earth on bank Check the wiring harness, A connectors, solenoid valve, ECU Excess high side PWM current on all A700D engine control unit injectors on bank A

No direct effect

Injection system fault High side short circuit to earth on bank Check the wiring harness, B connectors, solenoid valve, ECU Excess high side PWM current on all A700D engine control unit injectors on bank B

No direct effect

Injection system fault High side short circuit to supply voltage on bank A Excess high side FREEcurrent on all injectors on bank A


E4AEDA No direct effect

Injection system fault High side short circuit to supply voltage on bank B Excess high side FREEcurrent on all injectors on bank B


E4AEDB No direct effect

Injection system fault Low side short circuit to earth on bank Check the wiring harness, A connectors, solenoid valve, ECU On at least one injector on bank A A700D engine control unit Rise time too long or cannot be measured

E4AEDC No direct effect

Injection system fault Low side short circuit to earth on bank Check the wiring harness, B connectors, solenoid valve, ECU On at least one injector on bank B A700D engine control unit Rise time too long or cannot be measured

E4AEDD No direct effect

Injection system fault Low side short circuit to supply voltage Check the wiring harness, on bank A On at least one injector on bank A connectors, solenoid valve, ECU Excess low side current, excess high A700D engine control unit side free current on all other injectors in this bank

E4AEDF No direct effect

Injection system fault Low side short circuit to supply voltage on bank B Check the wiring harness, On at least one injector on bank B connectors, solenoid valve, ECU Excess low side current, excess high A700D engine control unit side free current on all other injectors in this bank

E4AED6

E4AED7

E4AED8

LBH/Version 01/10.2006/en/hd/29/03/2007

E4AED9


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Check the start and duration of injection

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Service Manual

Malfunctions

Engine shutdown

Overspeed fault Overspeed from speed sensor 2 – safety limit exceeded

Check engine operation (overspeed due to thrust mode), check ECU A700D engine control unit

No direct effect

Overspeed fault Overspeed from speed sensor 1 – warning limit exceeded


No direct effect

Overspeed fault Overspeed from speed sensor 2 – warning limit exceeded


E4AF3A

Engine shutdown

Overspeed fault Overspeed from speed sensor 1 – safety limit exceeded


E4AF9C


Synchronisation error Turn the ignition off and on again; Synchronisation lost while engine was check the engine speed and phase running; gap not detected sensor


Synchronisation error Distance between gap (engine speed sensor) and phase sensor signal too great

Turn the ignition off and on again; check the engine speed and phase sensor

E4AF9E


Synchronisation error Incorrect number of teeth – during the synchronisation phase, the number of teeth measured between successive gaps is not as specified

Turn the ignition off and on again; check the engine speed sensor

E4AF9F


Synchronisation error Synchronisation not possible – speed too low during synchronisation phase

Turn the ignition off and on again; check the engine speed and phase sensor

E4AFA0


Synchronisation error Faulty camshaft wheel index counter – Turn the ignition off and on again; the additional tooth of the Bosch check the engine speed and phase camshaft wheel is not measured at sensor the right place

E4B000

Emergency shutdown at the same time as redundant sensor (1 or 2) fails; otherwise engine speed recorded by redundant sensor

Engine speed sensor 1 fault Signal from impulse recorder lost

Check distance of engine speed sensor to flywheel (0.5 – 2.0 mm), check wiring to engine speed sensor, check engine speed sensor

E4B001


Engine speed sensor 1 fault Engine speed sensor does not provide a signal


E4AEFB

E4AF38

E4AF39

E4AF9D

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LBH/Version 01/10.2006/en/hd/29/03/2007


E4B002


Engine speed sensor 1 fault Invalid signal difference – engine speed measurement gradient too steep


E4B003


Engine speed sensor 1 fault Frequency too high (implausible value)


E4B004


Engine speed sensor 1 fault Impulse sensor polarity reversed – engine speed sensor incorrectly fitted or wrongly configured in the ECU A700D engine control unit

Check the installation of the engine speed sensor; check the ECU A700D engine control unit

E4B005


Engine speed sensor 1 fault Incorrect measurement (different measurement to the other sensor)


E4B064


Engine speed sensor 2 fault Signal from impulse recorder lost


E4B065


Engine speed sensor 2 fault Engine speed sensor does not provide a signal


E4B066


Engine speed sensor 2 fault Invalid signal difference – engine speed measurement gradient too steep


E4B067


Engine speed sensor 2 fault Frequency too high (implausible value)



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Service Manual

Malfunctions

E4B068


Engine speed sensor 2 fault Impulse sensor polarity reversed – engine speed sensor incorrectly fitted or wrongly configured in the ECU A700D engine control unit


E4B069


Engine speed sensor 2 fault Incorrect measurement (different measurement to the other sensor)


E4B0C8

No effect when engine is running

Phase sensor fault Signal from impulse recorder lost

Check distance of phase sensor to flywheel (0.5 – 2.0 mm), check wiring to phase sensor, check phase sensor

E4B0CC

No effect when engine is running

Phase sensor fault Phase sensor polarity reversed – Check the installation of the engine phase sensor incorrectly fitted or speed sensor; check the ECU wrongly configured in the ECU A700D A700D engine control unit engine control unit

E4B0CD


Phase sensor fault Incorrect measurement (different measurement to the other sensor)


E4B1F4

Replacement sensor value is used. The error disappears when the measured value is in the defined range

Coolant level sensor fault Short circuit to earth or cable rupture

Check the wiring and the ECU A700D engine control unit / sensor

E4B1F5


Coolant level sensor fault Sensor signal: shorted to supply voltage


E4B1F6


Coolant level sensor fault Sensor supply voltage: cable rupture or shorted to earth


E4B1F7


Coolant level sensor fault Sensor supply voltage: shorted to supply voltage


E4B1F8

Reduced power or no reaction, depending on the configuration and sensor

Check the medium for range Coolant level sensor fault violation; repair any mechanical Signal outside permitted range (limit 1) problems

E4B1F9


Check the medium for range Coolant level sensor fault violation; repair any mechanical Signal outside permitted range (limit 2) problems

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Service Manual


LBH/Version 01/10.2006/en/hd/29/03/2007

ERROR Motor This kind of malfunction is accompanied by a 1-second warning tone Service Effect Cause Remedy code E4B44C


Air filter pressure sensor 2 fault Short circuit to earth or cable rupture


E4B44D


Air filter pressure sensor 2 fault Sensor signal: shorted to supply voltage


E4B44E


Air filter pressure sensor 2 fault Sensor supply voltage: cable rupture or shorted to earth


E4B44F


Air filter pressure sensor 2 fault Sensor supply voltage: shorted to supply voltage


E4B450


Check the medium for range Air filter pressure sensor 2 fault violation; repair any mechanical Signal outside permitted range (limit 1) problems

E4B451



E4B4B0


Charge air pressure sensor fault Short circuit to earth or cable rupture


E4B4B1


Charge air pressure sensor fault Sensor signal: shorted to supply voltage


E4B4B2


Charge air pressure sensor fault Sensor supply voltage: cable rupture or shorted to earth


E4B4B3


Charge air pressure sensor fault Sensor supply voltage: shorted to supply voltage


E4B4B4


Check the medium for range Charge air pressure sensor fault violation; repair any mechanical Signal outside permitted range (limit 1) problems

E4B4B5


Check the medium for range Charge air pressure sensor fault violation; repair any mechanical Signal outside permitted range (limit 2) problems

E4B514


Oil pressure sensor fault Short circuit to earth or cable rupture


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Service Manual

Malfunctions

E4B515


Oil pressure sensor fault Sensor signal: shorted to supply voltage


E4B516


Oil pressure sensor fault Sensor supply voltage: cable rupture or shorted to earth


E4B517


Oil pressure sensor fault Sensor supply voltage: shorted to supply voltage


E4B518


Check the medium for range Oil pressure sensor fault violation; repair any mechanical Signal outside permitted range (limit 1) problems

E4B519


Check the medium for range Oil pressure sensor fault violation; repair any mechanical Signal outside permitted range (limit 2) problems

E4B5DC


Air filter pressure sensor 1 fault Short circuit to earth or cable rupture


E4B5DD


Air filter pressure sensor 1 fault Sensor signal: shorted to supply voltage


E4B5DE


Air filter pressure sensor 1 fault Sensor supply voltage: cable rupture or shorted to earth


E4B5DF


Air filter pressure sensor 1 fault Sensor supply voltage: shorted to supply voltage


E4B5E0



E4B5E1



E4B708


Ambient pressure sensor fault Short circuit to earth or cable rupture


E4B709


Ambient pressure sensor fault Sensor signal: shorted to supply voltage


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LBH/Version 01/10.2006/en/hd/29.03.2007


Service Manual


LBH/Version 01/10.2006/en/hd/29/03/2007

ERROR Motor This kind of malfunction is accompanied by a 1-second warning tone Service Effect Cause Remedy code E4B70A


Ambient pressure sensor fault Sensor supply voltage: cable rupture or shorted to earth


E4B70B


Ambient pressure sensor fault Sensor supply voltage: shorted to supply voltage


E4B70C


Check the medium for range Ambient pressure sensor fault violation; repair any mechanical Signal outside permitted range (limit 1) problems

E4B70D


Check the medium for range Ambient pressure sensor fault violation; repair any mechanical Signal outside permitted range (limit 2) problems

E4B76C


Air filter pressure switch 2 fault Signal line shorted to earth

E4B76D


Air filter pressure switch 2 fault Check the wiring and the ECU Short circuit to supply voltage or signal A700D engine control unit / sensor line broken.

E4B76E


Air filter pressure switch 2 fault Signal line shorted to supply line


E4B76F


Air filter pressure switch 2 fault, signal line shorted to supply line


E4B770


Air filter pressure switch 2 fault Monitoring threshold 1 exceeded or fallen below; medium no longer in normal operating state

Check the medium for range violation; repair any mechanical problems

E4B771




E4B7D0


Air filter pressure switch 1 fault Signal line shorted to earth


E4B7D1


Air filter pressure switch 1 fault Check the wiring and the ECU Short circuit to supply voltage or signal A700D engine control unit / sensor line broken.


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Service Manual

Malfunctions

E4B7D2


Air filter pressure switch 1 fault Signal line shorted to supply line


E4B7D3


Air filter pressure switch 1 fault, signal line shorted to supply line


E4B7D4




E4B7D5




E4B834


Water in fuel filter sensor Signal line shorted to earth


E4B835


Water in fuel filter sensor Check the wiring and the ECU Short circuit to supply voltage or signal A700D engine control unit / sensor line broken

E4B836


Water in fuel filter sensor Signal line shorted to supply line


E4B837


Water in fuel filter sensor Signal line shorted to supply line voltage


E4B838


Water in fuel filter sensor Monitoring threshold 1 exceeded or fallen below; medium no longer in normal operating state


E4B839


Water in fuel filter sensor Monitoring threshold 2 exceeded or fallen below; medium no longer in normal operating state


E4B898


Exhaust temperature sensor fault Signal line shorted to earth


E4B899


Exhaust temperature sensor fault Check the wiring and the ECU Short circuit to supply voltage or signal A700D engine control unit / sensor line broken.

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L550 - 456 / from 16978 L556 - 454 / from 15653


LBH/Version 01/10.2006/en/hd/29.03.2007


Service Manual


LBH/Version 01/10.2006/en/hd/29/03/2007

ERROR Motor This kind of malfunction is accompanied by a 1-second warning tone Service Effect Cause Remedy code E4B89A


Exhaust temperature sensor fault Signal line shorted to supply line


E4B89B


Exhaust temperature sensor fault Signal line shorted to supply line voltage


E4B89C


Exhaust temperature sensor fault Monitoring threshold 1 exceeded or fallen below; medium no longer in normal operating state


E4B89D


Exhaust temperature sensor fault Monitoring threshold 2 exceeded or fallen below; medium no longer in normal operating state


E4B8FC


Oil temperature sensor fault Signal line shorted to earth


E4B8FD


Oil temperature sensor fault Check the wiring and the ECU Short circuit to supply voltage or signal A700D engine control unit / sensor line broken.

E4B8FE


Oil temperature sensor fault Signal line shorted to supply line


E4B8FF


Oil temperature sensor fault Signal line shorted to supply line voltage


E4B900


Oil temperature sensor fault Monitoring threshold 1 exceeded or fallen below; medium no longer in normal operating state


E4B901


Oil temperature sensor fault Monitoring threshold 2 exceeded or fallen below; medium no longer in normal operating state


E4B960


Fuel temperature sensor fault Signal line shorted to earth


E4B961


Fuel temperature sensor fault Check the wiring and the ECU Short circuit to supply voltage or signal A700D engine control unit / sensor line broken.


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Service Manual

Malfunctions

E4B962


Fuel temperature sensor fault Signal line shorted to supply line


E4B963


Fuel temperature sensor fault Signal line shorted to supply line voltage


E4B964


Fuel temperature sensor fault Monitoring threshold 1 exceeded or fallen below; medium no longer in normal operating state


E4B965


Fuel temperature sensor fault Monitoring threshold 2 exceeded or fallen below; medium no longer in normal operating state


E4B9C4


Charge air temperature sensor fault Signal line shorted to earth


E4B9C5


Charge air temperature sensor fault Check the wiring and the ECU Short circuit to supply voltage or signal A700D engine control unit / sensor line broken

E4B9C6


Charge air temperature sensor fault Signal line shorted to supply line


E4B9C7


Charge air temperature sensor fault Signal line shorted to supply line voltage


E4B9C8


Charge air temperature sensor fault Monitoring threshold 1 exceeded or fallen below; medium no longer in normal operating state


E4B9C9


Charge air temperature sensor fault Monitoring threshold 2 exceeded or fallen below; medium no longer in normal operating state


E4BA28


Coolant temperature sensor fault Signal line shorted to earth


E4BA29


Coolant temperature sensor fault Check the wiring and the ECU Short circuit to supply voltage or signal A700D engine control unit / sensor line broken.

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LBH/Version 01/10.2006/en/hd/29.03.2007


Service Manual


LBH/Version 01/10.2006/en/hd/29/03/2007

ERROR Motor This kind of malfunction is accompanied by a 1-second warning tone Service Effect Cause Remedy code E4BA2A


Coolant temperature sensor fault Signal line shorted to supply line


E4BA2B


Coolant temperature sensor fault Signal line shorted to supply line voltage


E4BA2B


Coolant temperature sensor fault Monitoring threshold 1 exceeded or fallen below; medium no longer in normal operating state


E4BA2C


Coolant temperature sensor fault Monitoring threshold 2 exceeded or fallen below; medium no longer in normal operating state


E4BA8C


Internal temperature sensor fault Signal line shorted to earth


E4BA8D


Internal temperature sensor fault Check the wiring and the ECU Short circuit to supply voltage or signal A700D engine control unit / sensor line broken.

E4BA8E


Internal temperature sensor fault Signal line shorted to supply line


E4BA8F


Internal temperature sensor fault Signal line shorted to supply line voltage


E4BA90


Internal temperature sensor fault Monitoring threshold 1 exceeded or fallen below; medium no longer in normal operating state


E4BA91


Internal temperature sensor fault Monitoring threshold 2 exceeded or fallen below; medium no longer in normal operating state



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Service Manual

Malfunctions

WARNING This kind of malfunction is accompanied by a 1-second warning tone The service codes are not shown on the display unit. Service Effect Cause code L550 - L580 no travel E2019 function, L586 restricted Machine type not defined - L566 selected by default travel

E2028 E2029 E202A E202B E202C E202D E202E E202F E2030 E2031 E2032 E2033 E2034 E2035 E2036 E2037 E2038 E2039 E203A

Selecting machine type Check output module 1, Parking brake: faulty activation (fault Greeneville central lubrication current) system or wiring

Note! The parking brake cannot be activated Note! The working hydraulics lockout cannot be Working hydraulics lockout: faulty activation (fault current) activated

Check output module 1 or wiring

Note! Bucket return-to-dig is permanently activated Note! Lift kick-out is permanently activated Note! Float position is permanently activated Note! Fan turns at incorrect speed Note! Warning buzzer is permanently activated Note! Swivel angle restriction is permanently activated Note! Coupling 1 is permanently activated Note! Coupling 2 is permanently activated Note! Coupling 3 is permanently activated Note! Modulation solenoid valve is permanently activated Note! Variable displacement motor 1 proportional valve is permanently activated Note! Variable displacement motor 2 proportional valve is permanently activated Note! Forward travel direction (pump 1) is permanently activated Note! Reverse travel direction (pump 1) is permanently activated

Bucket return-to-dig: faulty activation (fault current) Check output module 1 or wiring Lift kick-out: faulty activation (fault Check output module 1 or wiring current) Float position: faulty activation (fault Check output module 1 or wiring current)

Note! Overspeed protection is permanently activated Note! Control pressure proportional valve (pump 1) is permanently activated Note! Control pressure proportional valve (pump 2) is permanently activated

Fan: faulty activation (fault current) Warning buzzer: faulty activation (fault current) Swivel angle restriction: faulty activation (fault current) Coupling 1: faulty activation (fault current) Coupling 2: faulty activation (fault current) Coupling 3: faulty activation (fault current)

Check output module 1 or wiring Check output module 1 or wiring Check output module 1 or wiring Check output module 1 or wiring Check output module 1 or wiring

Modulation: faulty activation Yom (fault current)


Variable displacement motor 1: faulty activation (fault current)


Variable displacement motor 2: faulty activation (fault current)


Forward travel direction (pump 1): faulty activation (fault current)


Reverse travel direction (pump 1): faulty activation (fault current)


Overspeed protection: faulty activation (fault current)


Control pressure (pump 1): faulty activation (fault current)


Control pressure (pump 2): faulty activation (fault current)


Note! Emergency steering is Emergency steering: faulty permanently activated activation (fault current)

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LBH/Version 01/10.2006/en/hd/29.03.2007

E2027

Remedy

Service Manual


WARNING This kind of malfunction is accompanied by a 1-second warning tone The service codes are not shown on the display unit. Service Effect Cause code Note! Fan reversal is Fan reversal: faulty activation (fault E203B permanently activated current) Note! Ride control is Ride control: faulty activation (fault E203C permanently activated current) Note! Ride control / float E203D position is permanently Ride control / float position: faulty activation (fault current) activated Note! Forward travel E203E direction (pump 2) is Forward travel direction (pump 2): faulty activation (fault current) permanently activated Note! Reverse travel E203F direction (pump 2) is Reverse travel direction (pump 2): permanently activated faulty activation (fault current)

Check output module 2 or wiring Check output module 2 or wiring Check output module 2 or wiring Check output module 2 or wiring Check output module 2 or wiring

E2040

Note! Additional equipment 1 is permanently activated

Additional equipment 1: faulty activation (fault current)


E2041

Note! Additional equipment 2 is permanently activated



E2042

Note! Joystick steering left is permanently activated

Joystick steering, left: faulty activation (fault current)


E2043

Note! Joystick steering right is permanently activated

Joystick steering, right: faulty activation (fault current)


E2044

Note! Gyrator steering (2-in- Gyrator steering (2-in-1): faulty 1) is permanently activated activation (fault current)


E2045


Joystick steering safety shutdown: faulty activation (fault current)


E2058




E2059




E5023

Engine does not take up fuel

Gas pedal angle sensor: synchronisation not completed

Synchronise gas pedal angle sensor R5

E5024

No inching function available

Inch pedal angle sensor: synchronisation not completed

Synchronise inching angle sensor R1

Couplings open --> driving is not possible, no hydrostatic brake effect No inching function available

Variable displacement motor synchronisation not completed or not concluded with parameters Inch function was deactivated using parameters Variable displacement motor 2 overspeed (in 3rd gear) - motor 2 runs at over 1500 rpm although coupling 2 is open in 3rd gear Variable displacement motor 1 overspeed (in 2nd gear) - motor 1 runs at over 1500 rpm although coupling 1 or 3 is open in 2nd

Finish variable displacement motor synchronisation, reset parameters

E5025

LBH/Version 01/10.2006/en/hd/29/03/2007

Remedy

E502D E502E

None E502F

E5030 E5031

Inching function activation Check variable displacement motor 2 speed Check variable displacement motor 1 speed

None Machine switches to neutral, driver can select travel Motor protection active: speed direction again after speed is reduced sensor overspeed

Check conditions of use - check fault in speed sensor B2a or B2b or wiring

Machine switches to neutral, Variable displacement motor 2 driver can select travel speed sensor: overspeed

Check conditions of use, variable displacement motor 1 speed


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Service Manual

Malfunctions

WARNING This kind of malfunction is accompanied by a 1-second warning tone The service codes are not shown on the display unit. Service Effect Cause code direction again after speed is reduced E5032

E5033 E6009 E600A E6018 E6026

Machine switches to neutral, driver can select travel direction again after speed Variable displacement motor 1 is reduced speed sensor: overspeed Overspeed - engine/pump damage Batteries overheating, electrical components may fail Engine difficult to start CAN failure Battery charge symbol field (H6) lights up

Engine speed too high On-board voltage too high On-board voltage too low CAN failure due to insufficient battery voltage, below 8 V for longer than 100 ms Battery voltage below 25 V despite engine running longer than 5 minutes

Remedy sensor B2a or wiring

Check conditions of use, variable displacement motor 1 speed sensor B2 or wiring Check conditions of use, instruct driver on driving on slopes, check engine speed Check alternator or engine electronics Check battery, wiring or engine electronics, check power supply F36 Check battery voltage Check the alternator

LBH/Version 01/10.2006/en/hd/29.03.2007

WARNING diesel engine This kind of malfunction is accompanied by a 1-second warning tone Service Effect Cause Remedy code Batteries overheating, Check alternator or engine E6009 electrical components On-board voltage too high electronics may fail Check battery, wiring or engine E600A Engine difficult to start On-board voltage too low electronics

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Service Manual


19.0.2

Audible and visual warning signals The following table contains the warning signals which have an additional audible tone or which are only displayed visually, along with their causes and remedies. There are four different audible warning signals: – – – –

Continuous tone Interval tone 1/10 (1 second tone followed by 10 second pause) Interval tone 2/3 (2 second tone followed by 3 second pause) Single 1 second beep

Warning signal Service code E A02A Interval tone 1/10 Coolant temperature symbol field (H13) flashes Service code E A02A, E 6000, E 6012 Coolant temperature symbol field (H13) flashes, STOP symbol field lights up Continuous warning buzzer

Cause

Remedy

Coolant temperature above 97 °C (B708)

Cleaning the cooling system Check the fan speed

Coolant temperature above 104 °C (B708)

Cleaning the cooling system Check the fan speed

Error in the cooling or electrical system

Check the temperature sensor B708, <> 2500 Ω at 20 °C check the diesel engine thermostat

Service code E 6008, E6012 Coolant temperature symbol field (H13) lights up The STOP symbol field lights up Continuous warning buzzer

Coolant level too low (B710)

Checking the coolant level

Fault in the electrical system

Check the coolant level transmitter B710

Hydraulic oil overheating symbol field Hydraulic oil temperature above 90 °C Cleaning the cooling system (H23) lights up (B8) Check the fan speed

LBH/Version 01/10.2006/en/hd/29/03/2007

Hydraulic oil temperature above 95 °C Cleaning the cooling system (B8) Check the fan speed Service code E A02A Check the temperature sensor B8, <> Hydraulic oil overheating symbol field 1112 Ω at 20 °C (H23) lights up Check the wiring Interval tone 1/10 Fault in the cooling / hydraulic / Check the working hydraulics pressure The output of the travel pump is electrical system relief valves (control valve block) reduced Check the travel hydraulics pressure relief valves (variable adjustment pump)

Service code E 2002 Emergency steering check symbol field (H24) lights up

Emergency steering pump check not successfully completed (B3a) Error in the electrical / hydraulic system

Check the emergency steering pump Check the pressure switch B3a Check the wiring Check the emergency steering pump pressure

Emergency steering function activated Check the steering pump due to failure of steering pump (B3) Service code E 2001 Emergency steering symbol field (H8) lights up Error in the electrical / hydraulic Warning buzzer 40 second tone system


L576 - 457 / from 14171 L580 - 459 / from 14171

Check the pressure switch B3 Check the steering pump standby pressure

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Service Manual

Malfunctions

Warning signal Service code E 6004, E 5034, E A02A, E 6012 Engine oil pressure symbol field (H4) lights up Stop symbol field (H36) lights up After 10 seconds continual warning buzzer Service code E 5028 Gear oil overheating symbol field (H14) lights up Driving is only possible at reduced speed (approx. 20 km/h)

Cause Remedy Insufficient engine oil pressure (B701) Check the oil level Error in the diesel engine lubricating Check the pressure relief valve oil supply Fault in the electrical system

Check the pressure switch B701 Check the wiring

Gear oil temperature over 120 °C (B14) Oil level too high

Clean the gear oil cooler Check the fan speed Correct the oil level

Fault in the electrical system

Check the thermo switch B14 Check the wiring Start the engine: the brake accumulators are filled while the engine runs Check the pressure switch B19 Check the wiring Check the accumulator charge valve Check the gear pump

Service code E 2016 Accumulator charge pressure symbol field (H19) lights up No travel direction can be selected after 2 minutes continual warning buzzer

Brake accumulator pressure too low (B19)

Service code E 6016 Battery charge symbol field (H6) lights up The parking brake cannot be released

Torn V-belt

Fit a new V-belt

Defective alternator

Service the alternator Check the wiring to the main electronics

Error in the electrical / hydraulic system

Service code segment display (P7) shows the service code, single 1 second beep

LBH/Version 01/10.2006/en/hd/29.03.2007

See the service code tables

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265008640-Service-Manual-L550-L580-2plus2.pdf

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