Liebherr a309li - 307li - SERVICE MANUAL

Service Manual

SUBGROUP - INDEX Section

Group

Type

Modification of series

1.02.1

A 309 LI - R 317 LI

Safety instructions

1.10.1

A 309 LI - R 317 LI

Tightening torques WN 4037

1.20.1

A 309 LI - R 317 LI

Tightening torques for screw connections

1.21.1

A 309 LI - R 317 LI

Assembly instruction for cylinder (WN 4121B)

1.22.1

A 309 LI - R 317 LI

Assembly instruction for cylinder (WN 4122B)

1.24.1

A 309 LI - R 317 LI

Fuels, lubricants and other consumables

1.50.1

A 309 LI -R 317 LI

Lubricant list TE-ML 05

1.55.1

A 309 LI -R 317 LI

Lubricant list TE-ML 07

1.56.1

A 309 LI -R 317 LI

1.1 MJFCIFSS

Service Manual

1.2 MJFCIFSS

Service Manual


Modification of series Item (a)

Type of modification Modified actuation of the pressure-relief valves for slewing gear Joint control line Xab replaced by separate control lines Xa / Xb for each valve Additional orifice 126 in connection P of valve 125

Affected models A 314 Li: 11147 A 316 Li: 11152 A 316 Li industrial: 11178

Modified measuring connections Measuring connections 137 / 138 are moved from the side to the top (b)

Modified spool

A 314 Li: 11820

Spool for slewing gear (change in design from restricted to blocked outlet)

A 316 Li: 11822 A 316 Li industrial: 11823

Spool for chassis (change in design from restricted to open outlet) (c)

Modified pressure balance 244 for stick cylinder Change from pressure balance without shock absorption to pressure balance with 0.4mm shock absorption

A 314 Li: 12814 A 316 Li: 12741 A 316 Li industrial: 11846

Additional control line from control valve block connection MLS to pressure balance 244 at spring side connection LSE Modified shuttle valves 227 (a3 /b3) for boom cylinder spool Change from Ø 0.8 mm to Ø 0.6 mm (d)

(e)

Modified fan cycle

A 312 Li: 13289

Installation of coarse filter 15 in the pressure line to oil motor / radiator fan

A 314 Li: 13104

Various modifications to control valve block

A 312 Li: 16275

Tuning improved. Pressure balance 224 pilotcontrolled. Shuttle valve 107 integrated into control block. Central nozzle 109 screwed in. New slewing gear module (check valve 123 before spool 120).

A 316 Li: 13105

A 314 Li: 16215 A 316 Li: 16141 A 316 Li industrial: 16286

Modified TC valve 125 Integrated restrictor 126 and bypass line with restrictor 129

1.02.1 MJFCIFSS


Item (f)

Service Manual

Type of modification Pressure-relief valve in the gear pump / steering

Affected models A 312 - A 316 Li: 20241

Gear pump of steering system with integrated pressure control (g)

Modified electrical system Modifications: K392 (industrial shut-off) omitted, S5 with 3 push buttons, S382 modified, S263 modified, S422 added

(h)

New pilot control unit for travel working movement:

A 312 Li: 20330 A 314 Li: 20334 A 316 Li: 20340 A 316 Li in.: 20340

R 317 Li: 21205

The two individual pilot control units 2x are replaced by one pilot control unit 4x (i)

Optimised control of control valve block Regulating cylinder spool modified; control of spool of combined boom / slewing gear with shuttle valves Restrictor check valve 171 for stick cylinder is omitted

(k)

Optimisation of fine control Spool of the boom and regulating cylinder and the summary pistons modified. Installation of priority circuit "Total of boom before total of stick" with decoupling. Actuation of boom and stick spools with additional shuttle valves.

A 309 Li: 23503 A 311 Li: 23504

A 309 Li: 27110 A 311 Li: 27112

See also service information 07-11-37/2005 (l)

Speed reduction when working at 1950 rpm Omission of solenoid valve Y330 for zero boom switching from P2 during travel

A 309 Li: 27110 A 311 Li: 27112

The solenoid valve Y330 at the control oil unit is omitted. See service information 07-11-37/2005 (m)

Hydraulic slewing ring locking mechanism A hydraulically operated cylinder (via pilot control system) with a locking bolt is installed in the uppercarriage. It is used for the locking of the uppercarriage during parking and transport of the machine.

(n)

Changeover to travel operation By changing over to the 2 HL 270/290 transmission, the travel motor has also been upgraded to a DMVA 165 motor.

A 309 Li: 26392 A 311 Li: 26396 A 312 Li: 29898 A 316 Li: 28061 A 316 Li ind.: 28061 A 316 Li: 28061 A 316 Li ind.: 28061

1.02A 309 LI 20221-A 311 LI 20222-A 312 LI 12363-A 314 LI 2001-A 316 LI 2001-A 316 LI-IND 2001-R 317 LI 18161-

1.02.2 MJFCIFSS

Service Manual

Safety instructions Proper use

Safety instructions Working with the machine holds dangers to which you as the owner, machine operator or maintenance expert could be exposed. If you regularly read and observe the safety information, you can guard against dangers and accidents. This applies especially to persons, who are working on the machine only occasionally, such as for maintenance work. The following information comprises safety regulations which, if followed conscientiously, will guarantee your safety and that of other persons, as well as avoid damage to the machine. Following these regulations does not release you from the responsibility to follow all safety regulations and guidelines valid for the jobsite, as required by law or issued by trade associations. For EU countries, guideline 89/655/EEC contains the minimum safety information applicable to the operator.

1 Proper use – The hydraulic excavator is a machine with attachments (such as backhoe, grapple, bucket ) designed to loosen, take on, transport and dump soil, rocks and other materials, where the load is predominantly transported without moving the machine. Moving the machine when it is carrying a load must be carried out by observing the appropriate safety measures (see section "Notes for machine operating safety"). – Machines used for load-lifting work are subject to specific conditions and must be equipped with the stipulated safety devices (see section “Load-lifting work”). – Other or additional usage, such as for demolition or material handling work, requires special equipment and may also require special safety devices. These attachments (e.g. log grapple, demolition hammer, concrete cutter etc.) may only be attached and used with approval and in accordance with the basic machine manufacturer. – Transporting persons is not deemed to be intended use. The manufacturer is not liable for damage resulting from this action. The risk must be assumed solely by the user. – Observing the operating instructions and the inspection / maintenance instructions is also deemed to be appropriate and destined use in accordance with regulations.

2 General Safety instructions – Please familiarize yourself with the operating instructions before starting the machine. – Please verify that you have supplemental instructions and have read and understood these (this may concern special options for the machine). – Only explicitly authorized personnel may operate, maintain or repair the machine. The legal minimum age must be observed. – Use only trained or instructed personnel. Clearly define who is responsible for the operation or set up, maintenance and repair. Allow personnel to refuse unsafe instructions given by a third person. This also applies to traffic regulations. Reject unsafe instructions by third parties and/or allow your personnel to reject these. This also applies in regards to traffic regulations. – Any person still in training should only operate or work on the machine under the constant supervision and guidance of an experienced person. – Check and observe any person working or operating the machine at least periodically if they observe safety instructions and guidelines given in the Operating manual. – Wear proper work clothing when operating or working on the machine. Avoid wearing rings, watches, ties, scarves, open jackets or loose clothing. There is a danger of injury, as these items could get caught or be pulled in.The following are mandatory for certain tasks: Safety glasses, safety shoes, safety helmet, work gloves, reflecting vest, hearing protection, ...

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1.10.1

Safety instructions

Service Manual

Crushing and burn prevention – For certain tasks, safety glasses, hard hats, safety boots, work gloves, reflective vests, ear protection etc. are required. – Consult the supervisor at the job site for special safety instructions and regulations. – Always raise the safety lever before leaving the operator’s seat. – When entering or leaving the cab, do not use the steering column, the control panel or the joysticks as handholds. Inadvertent movements, which could cause accidents, should be touched off. – Never jump off the machine, always use the steps, ladders, rails and handles provided to climb off or on the machine. – Use both hands to hold on, facing the machine. – Familiarize yourself with the emergency exit through the front window. – Proceed as described in the operating instructions, if no other instructions are available for maintenance and repairs: • Place the machine on a solid and level ground and lower the work equipment to the ground. • Depressurize the hydraulic system. • Move all control levers to the neutral position. • Move the safety levers up prior to leaving the machine. • Remove the ignition key. – You must also reduce the pressure in the hydraulic system and the interior pressure of the tank prior to any operation on the hydraulic system as described in these operating instructions. – Secure all loose parts on the machine. – Never start a machine before completing a thorough inspection and check, if safety tags are missing or are illegible. – Do not complete any modifications, attachments or retrofits on the machine, which could inhibit safety, without the prior consent of the manufacturer. This also applies to the installation and adjustment of safety devices and safety valves as well as to any welding on load carrying parts.

3 Crushing and burn prevention – Never work underneath the attachment as long as it is not safely resting on the ground or properly supported. – Do not use any damaged or insufficiently supporting load carrying devices, such as ropes or chains. – Always wear work gloves when handling wire ropes. – When working on the attachment, never align bores with your fingers, always use a suitable alignment tool. – Please verify that no objects enter the fan while the Diesel engine is running. Rotating fans will swirl and throw out objects, which can damage the fan. – At or near operating temperature, the engine cooling system is hot and under pressure. Avoid contact with any components containing coolant. Danger of severe burns. – Check the coolant level only after the radiator cap on the expansion tank is cool enough to touch. Turn the cap carefully to relieve the pressure. – At or near operating temperature, the engine and the hydraulic oil are hot. Do not allow your skin to come into contact with hot oil or components containing hot oil. – Always wear safety glasses and protective gloves when handling batteries. Avoid sparks and open flames. – Never permit anyone to guide the grapple by hand. – When working on the engine area, make sure that the side doors are properly secured with the appropriate supports to prevent them from closing inadvertently. – Never work underneath the machine if it is raised with the attachment, without being properly supported from below with hardwood beams.

1.10.2

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Service Manual

Safety instructions Fire and explosion prevention

4 Fire and explosion prevention – Switch off the Diesel engine prior to filling the tank. – Routinely check the electrical system. – Have skilled personnel immediately repair all defects, such as loose connections, blown fuses and burned out light bulbs, burned or frayed cables. – Do not smoke and avoid open flames when filling the tank or loading the batteries. – Always start the Diesel engine according to the regulations in the operating instructions. – Never store flammable fluids on the machine except in appropriate storage tanks. – Regularly inspect all lines, hoses and fittings for leaks and damage. – Repair any leaks immediately and replace damaged components. – Any oil escaping from leaks can easily cause a fire. – Be certain that all clamps, guards and heat shields are properly installed to prevent vibration, rubbing and heat build up. – Do not use cold start aids (ether) near heat sources or open flames or in insufficiently ventilated areas. – Do not use ether containing starting aids to start Diesel engines with preheat system or flame glow systems. DANGER OF EXPLOSION! – Familiarize yourself with the location and use of fire extinguishers on the machine as well as the local fire reporting procedures and fire fighting possibilities.

5 Transporting the machine safely – Due to the space restrictions during transport, use only suitable transporting and lifting devices with sufficient capacity – Park the machine on a level surface and chock the chains and/or wheels. – If necessary, remove parts of the attachment during transport. – The ramp to drive onto the transporting vehicle should not exceed an inclination of 30° and be provided with a wood covering to prevent sliding. – Clean the undercarriage. The undercarriage must be swept clean, meaning, the chains / wheels must be free of snow, ice and sludge prior to driving onto the ramp. – Align the machine precisely with the loading ramp. – Attach the manual lever for sensitive driving (crawler excavator) to the driving pedals. – Note that a guide gives the necessary signals to the machine driver. – Drop the equipment in and drive it onto the loading ramp. Keep the equipment tight over the loading surface and drive it carefully onto the ramp and further into the transporting vehicle. – The superstructure must be secured with the undercarriage by using locking bolts (only for Aequipment), after loading the machine onto the low loader. – Secure the machine and the remaining equipment parts with chains and chocks against shifting according to national regulations for loading and transporting. – Release all pressure lines (as described in these operating instructions), pull the ignition key and pull the safety lever up prior to leaving the machine. – Close all cab and panel doors. – Verify that no one is located on the machine during the transport. – Investigate the travel route, specifically in reference to limits for width, height and weight prior to the transport. – Pay special attention when driving under electrical lines and bridges and when passing through tunnels. – Use the same care for unloading as for loading.

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1.10.3

Safety instructions

Service Manual

Bringing the machine safely into service

6 Bringing the machine safely into service – Before starting the machine, perform a thorough walk around inspection. – Visually check the machine for loose bolts, cracks, wear, leaks and damage. – Never start or operate a damaged machine. – Make sure to correct any problems immediately. – Verify that all hoods, covers and doors are closed, however, the locks should remain unlocked. – Verify that all safety tags are available. – Make sure that all windows, as well as the inside and outside mirrors are clean. Secure all doors and windows to prevent unintentional movement. – Be certain that no one works on or under the machine and warn any personnel in the surrounding area with the horn before starting the machine. – Before operating the machine, adjust the operator’s seat, the mirror, the arm rests and the other items to ensure comfortable and safe working conditions. – The noise protection devices on the machine must be in functional protective position during operation. – Follow the regulations effective for the relevant site. – Never start the machine without the driver’s cab.

7 Starting the machine safely – Before start up, check all indicator lights and instruments for proper function, bring all controls into neutral position and raise the safety lever. – Honk the horn briefly prior to starting the Diesel engine, in order to warn persons located near the machine. – Only start the machine from the driver’s seat. – Start the Diesel engine according to the regulations in the operating instructions, if you have not received any other instructions. – Lower the safety lever and check all indicators, gauges, warning devices and controls for their proper indication. – Only operate the Diesel engine in a well ventilated area, if the area is enclosed. Open doors and windows to ensure sufficient fresh air supply, if necessary. – Bring the engine and hydraulic oil to operating temperature. Low oil temperatures cause a slow reaction of the controls. – Check that all attachment functions are operating properly. – Carefully take the machine to an open area and check all safety-related functions.

8 Shutting down the machine safely – Only place the machine on a level and solid ground. The machine must be secured with chocks, wenn setting it on a slope, to secrure it against rolling away. – Lower the working equipment and anchor it lightly into the ground. – Move all control elements into the neutral position. Set the parking and slewing gear brake. – Switch off the Diesel engine according to the operating instructions and move the safety lever up, prior to leaving the driver’s seat. – Lock the machine, as well as all hoods, covers and doors; pull out all keys and secure the machine against any unauthorized use.

1.10.4

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Service Manual

Safety instructions Towing the machine safely

9 Towing the machine safely – Always observe the correct procedure: See chapter “Towing the machine” in this operating manual. – The machine may only be towed in exceptional circumstances, e.g. in order to move the machine away from a dangerous place. – Before pulling or towing the machine, check all cables, hooks and couplers for safety and stability. – Towing equipment must have sufficient tensile strength and must be attached to the undercarriage at the provided stops. Be aware that any damage or accidents caused by towing the machine are never covered by the manufacturer's warranty. – Never allow anyone to remain in the area of the towing devices. – During the towing procedure, keep within the required transport position, the permissible speed and distance. – After the towing procedure is completed, return the machine to its previous state. – Proceed as outlined in the operation manual when putting the machine back into service.

10 Working with the machine safely – Before starting to work, familiarize yourself with the peculiarities of the job site, the special regulations and warning signals. Part of the surrounding area includes, for example, the obstacles in the working or movement area, the load carrying capacity of the ground and required safeguards for the job site to shield it from public highway traffic. – Always keep an adequate safety distance to overhangs, edges, embankments and an unsecured substrate. – Be particularly cautious in conditions of reduced visibility and changing ground conditions. – Familiarize yourself with the location of power lines on the job site and work particularly careful in their vicinity. If necessary, inform the responsible authorities. – Maintain a safe distance from electrical overhead lines. Do not approach the line with the equipment when working near electrical overhead lines. Danger of fatal injury! Inform yourself about required safety distances. – In case of a flashover, proceed as follows: • do not move the machine or its attachment, • do not leave the operator’s platform, • warn people in the vicinity not to approach or touch the machine, • have the power turned off. – Before moving the machine, always ensure that the attachments are safely secured. – When travelling on public roads, paths or squares, observe the valid traffic regulations and, if necessary, first bring the machine into proper condition to meet federal and local highway standards. – Always turn on the lights in conditions of poor visibility or darkness. – Do not permit any passengers on the machine (except on two way excavators). – Operate the machine only when seated and with the seat belt fastened. – Report any problems or needed repairs and make sure that all required repairs are carried out immediately. – Personally make sure that no one is endangered by moving the machine. – Before starting to work, always check the brake system as outlined in the operating manual. – Never leave the operator’s seat as long as the machine is still moving. – Never leave the machine unattended while the Diesel engine is running.

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1.10.5

Safety instructions

Service Manual

Working with the machine safely – The machine must be utilized, driven and operated in such way that the stability is ensured and that there is no danger of tipping over. Only known loads may be moved with the attachments, especially in grapple operation. – The maximum approved passable incline / traverse slope of the machine depends on the attached equipment as well as the substrate. – For travel, move the uppercarriage in lengthwise direction and hold the load as close as possible to the ground. EXCEPTION: see WHEN LOADING AND UNLOADING – Adjust the travel speed to suit local conditions. – Avoid working movements which could cause the machine to tip over. – If possible, always work downhill or uphill, never sideways on a slope. – Only travel downhill at the permitted speed or you could loose control over the machine. – Only drive downhill at a low driving speed, since you may otherwise loose control of the machine. The Diesel engine must run in the upper revolution range and be reduced by selecting the low driving speed range / the lowest gear. – Before travelling downhill, always shift to a lower gear. When doing this, the Diesel engine must run at maximum RPM and the speed may only be reduced using the accelerator pedals. – When loading a truck, make sure that the truck driver leaves the cab, even if a rock protection is present. – Always use the safety devices intended for their specific use for demolition work, clearings, hoisting operations, etc. – For terrain which is difficult to gain an overview of and whenever necessary, ask for assistance of a guide. Have only one person signal you. – Only permit experienced personnel to secure loads and signal the machine operator. The guide must position himself within view of the operator or be in voice contact with him. – Depending on the attachment combination, there can be a danger of collision between the working tool and the operator’s cab, the cab protection or the boom cylinders. To avoid damage, utmost attention is required when the bucket teeth enter this range.

10.1

Safe application in material handling operation (especially when handling timber) – Particularly when working with a grapple it can be necessary to move the machine with a raised attachment and picked up load, for example when handling wood or timber. – This will shift the center of gravity of the machine upward in vertical direction. The travel behaviour of the machine will be strongly influenced, for example reduction of dynamic stability. For that reason, the following rules must be strictly observed: • Match your travel behaviour to the changed machine characteristics and surrounding conditions. • Reduce the travel speed to avoid sudden braking or steering manoeuvres. • Avoid sudden speed changes, such as braking, acceleration, changes in travel direction. • Turn the uppercarriage only if the undercarriage is stationary. • Turn the uppercarriage only after taking on the load. • Move the machine only after you have taken on the load, lifted it and turned the uppercarriage in travel position. • If the attachment is raised, there is a danger due to possible oscillating movements and falling of the picked up load. • A protective screen (FOPS) according to ISO 10262 must be attached on the front on the cab. • The protective screen (FOPS) according to ISO 10262 must be installed if there is a danger of falling objects from overhead. • Only the maximum permissible load may be picked up with the grapple.

1.10.6

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Service Manual

Safety instructions Working with the machine safely

– NOTE: The weight of absorbent material, such as wooden logs, depends on the length, the diameter and the specific weight. The existing influencing factors for a natural product, such as moisture, must be considered. – The working sequences when working with machines with grapples require special instruction and training of the machine operator. – The work application is only permitted after the machine operator has received sufficient training and practical experience.

10.2

Safe application of machines with tower elevation – Due to the tower elevation, the center of gravity of the machine will shift upward in vertical direction. The travel and work behaviour of the machine will thereby be strongly influenced, for example reduction of dynamic stability. – Due to the elevated center of gravity, the machine must be aligned in horizontal direction before starting to work. In horizontal direction, the center of gravity of the uppercarriage is above the center of the undercarriage, which reduces the danger of tipping over. – The machine can rock despite leveling and tip over! For that reason, the following rules must be strictly observed: When driving the machine: • Swing the uppercarriage parallel to the undercarriage (transport position). • Pull the attachment as close as possible to the machine. • Only then may the outriggers be retracted and the machine be driven. • Driving with loads is not permitted. • Check the roadway to ensure the ground is solid and even! Pot holes and uneven road surfaces endanger the stability of the machine. • Match your travel behaviour to the changed machine characteristics (higher center of gravity) and surrounding conditions. • Reduce the travel speed to avoid sudden braking or steering manoeuvres. • Avoid sudden speed changes, such as braking, acceleration, changes in travel direction. • Drive uphill and over obstacles only in lengthwise direction, to avoid impermissible transverse slopes of the machine. • Special care must be taken when driving through narrow passages – drive slowly! In material handling operation: • Before moving (turning) the uppercarriage from transport position, the machine must be supported and horizontally aligned. • Make sure to check the placement surface of the outriggers (load carrying capacity of ground). Sinking of an outrigger below ground level would result in devastating consequences! • Carry out all movements with increased caution. • To turn a load, move the attachment as close as possible to the machine (Caution! Oscillating grapple), while holding the load as close as possible to the undercarriage and above the ground. • Avoid abrupt slow down or acceleration of the attachment or uppercarriage. • Never lift a heavier load than stated in the load chart.

10.3

Additional notes for machines with fixed operator’s cab elevation – To enter and exit the machine, park the machine on ground, which is level in lengthwise and horizontal direction. Position the uppercarriage to the undercarriage in such a way that the steps and ladders are aligned. – Keep steps, ladders and handholds (handles) in proper condition. Make especially sure that they are free of dirt, oil, ice and snow. NOTE: To ensure that the doors open in all weather conditions, lubricate the weather strips at least every two month, or more often, if necessary, with talcum powder or silicon. Lubricate the door hinges and locks regularly.

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1.10.7

Safety instructions

Service Manual

Working with the machine safely – When entering or leaving the machine, always face the machine and use the three point support, i.e. always have two hands and one foot or two feet and one hand in contact with the entry system. – When you can reach the door handle with the free hand, open the door first before climbing higher. External influences, such as wind, can make it more difficult to open the door. For that reason, always guide the door by hand when opening the door. Make sure that the door is engaged when it is open, to prevent it from banging open or closed. – Continue to climb up and immediately sit on the operator’s seat in the cab. Then close the door and fasten the safety belt. – Proceed with the same care when exiting and climbing down as when entering and climbing up the machine. – Park the machine only on firm and level ground. Position the uppercarriage to the undercarriage in such a way that the steps and ladders are aligned. – Release the safety belt. When exiting, face the machine and use the three point support. Climb down until you can close the door safely. Always guide the door by hand when closing the door. – Finally climb down to the ground.

10.4

Protection from vibrations – The vibration impact on mobile construction machinery is usually the result of the manner of utilization. Especially the following parameters have a significant influence: • Terrain conditions: Unevenness and potholes; • Operating techniques: Speed, steering, braking, control of operating elements of the machine during travel as well as working. – The machine operator determines the vibration impact to a great part, since he himself selects the speed, the gear ratio, the working manner and the travel route. This results in a wide range of various vibration impacts for the same machine type. The full body vibration impact for the machine operator can be reduced if the following recommendations are observed: – Select the appropriate machine, equipment parts and auxiliary devices for the corresponding tasks. – Use a machine equipped with the appropriate seat (i.e. for earth moving machines, for example hydraulic excavators, a seat which meets EN ISO 7096). – Keep the seat in good order and adjust it as follows: • The seat adjustment and the suspension should be made according to the weight and the size of the operator. • Check the suspension and the adjustment mechanism regularly and make sure that the characteristics of the seat remain as specified by the seat manufacturer. – Check the maintenance condition of the machine, especially regarding: Tire pressure, brakes, steering, mechanical connections, etc. – Do not steer, brake, accelerate and shift or move and load the attachment of the machine in a jerky manner. – Match the machine speed to the travel route to avoid vibration impacts. • Decrease the speed when driving on pathless terrain; • Drive around obstacles and avoid very impassable terrain. – Keep the quality of the terrain where the machine is working and travelling in good order: • Remove large rocks and obstacles; • Fill furrows and holes; • To establish and retain suitable terrain conditions, keep machines available and allow for sufficient time. – Travel longer distances (i.e. on public roads) with suitable (medium) speed. – For machines, which are frequently used for travel, utilize special auxiliary systems for travel (if installed), which reduce the vibration for this application. If such auxiliary systems are not available, regulate the speed to keep the machine from "rocking".

1.10.8

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Service Manual

Safety instructions Safe installation and removal of attachment parts

11 Safe installation and removal of attachment parts – Equipment and attachment parts made by other manufacturers or those which do not have LIEBHERR’s general approval for installation may not be installed on the machine without prior written approval by LIEBHERR. LIEBHERR must be provided with the required technical documentation necessary for this purpose. – When installing attachment parts, which are supplied via the machine's hydraulics system, such as an attachment with cylinder movement, it must be ensured that different types of oil are not mixed together. Mixing environmentally friendly hydraulic oils made by different manufacturers as well as mixing them with mineral oils must be avoided. – Set the machine on a level and stable ground prior to any attachment and removal of equipment parts. – Lock the uppercarriage with the locking pin to the undercarriage. – Do not work under the equipment as long as it does not contact the ground or prior to being supported. – Never lie under the machine, if it is lifted by the work equipment without properly propping the machine. – Before releasing a line or bolt, you must reduce the pressure in the hydraulic system as described in these operating instructions. – Do not attempt to lift heavy parts. Use suitable lifting devices with sufficient load carrying capacity. – Do not use damaged or insufficiently sized ropes or cables. Always wear work gloves when handling wire cables. – When working on the equipment: Switch off the Diesel engine and turn the safety lever upward. Never align the holes with your fingers; use a suitable mandrel. – During repairs: Make sure that the hydraulic lines are properly attached and that all fittings and connections are properly tightened. – As soon as an attachment part is removed and supported, close off the openings in the hydraulic circuit to prevent dirt infiltration. Permit only authorized persons near the machine or the lifting device.

11.1

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

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1.10.9

Safety instructions

Service Manual

Safe maintenance of the machine

12 12.1

Safe maintenance of the machine General safety instructions – All maintenance and repair work must be carried out by suitably trained specialist technicians. – Always adhere to the prescribed testing and inspection schedule and the relevant intervals laid down in the operating manual. To properly maintain the machine, the operator must have access to a suitably equipped workshop. – The inspection and maintenance schedule clearly defines the tasks and who is authorised to carry them out. Certain work may be carried out by the machine operator (or staff of the company who owns the machine), while other tasks must be completed by specialist technicians who have been specifically trained for this type of work. – All spare parts must conform to the technical specifications laid down by the manufacturer. Original spare parts always meet these requirements. – When carrying out maintenance work, wear suitable protective clothing. Always wear suitable personal protective equipment. For certain work, you must also wear a hard hat, safety footwear, goggles and protective gloves. – During maintenance work, keep unauthorised personnel away from the machine. – If necessary, cordon off the work area. – Before starting any maintenance work or other special work on the machine, inform the operating personnel. Appoint a supervisor. – Unless stated otherwise in the operating manual, all maintenance work must be carried out after the attachment is lowered, the diesel engine is shut down while the machine is parked on level and firm ground. – While carrying out maintenance work, and especially when working under the machine, attach a warning sign "Do not start" to the ignition. Remove the ignition key and set the battery main switch to position "0". – Always retighten all screwed connections that have been loosened for maintenance and repair purposes. – If safety devices must be removed, these devices must be mounted and tested immediately after the work is completed.

12.2

Cleaning – Prior to any maintenance and repair work, clean the machine and especially all connections and screws that might be contaminated with oil, fuel or other cleaning products. Use only mild detergents and lint-free cloths. – During the first two months after commissioning (or repainting), do not clean the machine with aggressive detergents or a steam cleaner. – Do not clean the machine with flammable liquids. – Before cleaning the machine with water, steam (pressure cleaner) or other detergents: • Lubricate the slewing ring as well as all bearings and pin connections to prevent water or steam from penetrating the bearing positions. • Seal all openings where penetrating water, steam or detergent might cause damage or lead to malfunctions. Especially at risk are electric motors, electronic components, switch cabinets, plug connections and air filters. – When cleaning the engine compartment, ensure that the temperature sensor of the fire alarm and extinguishing systems are not accidentally brought into contact with the hot cleaning solution, as this could trigger an alarm and activate the extinguishing system. – After completion of the cleaning work:

1.10.10

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Service Manual

Safety instructions Safe maintenance of the machine • Remove all temporary covers. • Check all fuel, engine oil and hydraulic lines for leakage, loose connections, chaffing and damage. • Repair all detected defects. • Lubricate slewing ring as well as all bearings and pin connections to eliminate water or detergent that might have penetrated these assemblies.

12.3

Crack detection – The machines are subject to various loads and stresses, depending on the actual application, location of operation, operating hours and the ambient conditions. The various load scenarios result in service lives of the machine components that might differ from each other. This might lead to cracks or loose connections, especially on load-bearing parts. This applies in particular to machines used for loading or industrial purposes, or to machines equipped with optional equipment, such as demolition excavators. To maintain the operational safety of the machine, it must be regularly inspected for cracks, loose connections and other visible damage. – To be able to inspect the machine for cracks, it must be kept clean. – The inspections must be carried out as described in the inspection and maintenance schedule: • every 250 operating hours, by the maintenance personnel of the machine operator • every 500 operating hours by authorised specialist technicians. – We strongly recommend to carry out these inspections after the machine has been placed on a firm and level surface, and by applying various different loads in longitudinal and transverse direction by moving the attachment. Always comply with the applicable workplace safety and accident prevention regulations. – Particular care is required for the inspection of load-bearing components, in particular: • The steel structure of the undercarriage with axle and gearbox bearings, the support system, the lower slewing ring support, the tower and the slewing ring. • The steel structure of the uppercarriage with bearing block for booms and boom cylinders, the upper slewing ring support, the cab bearing, and the securing devices of the slewing gear and ballasts. • The steel components of the attachments, e.g. booms, members, quick change adapters, digging buckets and grapples. • Hydraulic cylinders, axles, steering components, bolts and pin connections, ladders, steps and securing devices. – The crack inspection is a visual inspection. To improve the reliability of the inspection, check areas where you suspect cracks or areas that are not easily accessible (e.g. at the slewing ring support) with a dye penetration test. – Immediately eliminate any detected damage. Welding work on load-bearing parts of earth moving machines, handling and transport equipment must be carried out by specialist welding technicians and according to best welding practice. If in doubt, contact the LIEBHERR customer service department to discuss the envisaged measures.

12.4

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

copyright by

MJFCIFSS

1.10.11

Safety instructions

Service Manual

Safe maintenance of the machine

12.5

Fuels and lubricants – When handling oil, grease or other chemical products, always comply with the respective safety instructions provided by the supplier. – All fuels, lubricants and replaced parts must be disposed of in a safe and environmentally friendly manner. – Handle hot fuels and lubricants with particular care to prevent injury.

12.6

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

12.7

Electrical system – Regularly inspect the electrical system. Ensure that any detected faults such as loose connections, blown fuses and light bulbs, scorched or chafed cables are eliminated without delay by specialist technicians. – Use only original fuses of the prescribed amperage.

1.10.12

copyright by

MJFCIFSS

Service Manual

Safety instructions Safe maintenance of the machine

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

12.8

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

12.9

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

copyright by

MJFCIFSS

1.10.13

Safety instructions

Service Manual

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

12.10

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

1.10.14

copyright by

MJFCIFSS

Bezeichnung Description / Dénomination

Mjfcifss!

1

Blatt/Page/Feuille:

Preloads and tightening torques for screws with metric coarse and fine threads according to DIN 13, sheet 12

bestehend aus consisting of composé

The preload forces and tightening torques compiled in the table are based on the VDI 2230, July 1986.

6

Blatt Pages Feuille

WN 4037 I

Assembly preloads FM and tightening torques MA for headless screws with metric coarse or fine threads according to DIN ISO 262 and DIN ISO 965 T2 (replaces DIN 13, part 13) and head dimensions of hexagon head bolts according to DIN EN 24014 (replaces DIN 931, part 1) or hexagon socket head cap screws according to DIN EN ISO 4762 (replaces DIN 912) Metric coarse thread Surface finish: black-chrome finished or phosphatised oiled electro-galvanized flZn according to LH standard 10021432 dry Tightening torque Thread Class Assembly preload FM in N MA in Nm for mean friction factor

M4 M5 M6 M7 M8

8.8 10.9 12.9 8.8 10.9 12.9 8.8 10.9 12.9 8.8 10.9 12.9 8.8 10.9 12.9

4 050 6 000 7 000 6 600 9 700 11 400 9 400 13 700 16 100 13 700 20 100 23 500 17 200 25 000 29 500

µG= 0.12

2.8 4.1 4.8 5.5 8.1 9.5 9.5 14.0 16.5 15.5 23.0 27 23 34 40

Metric fine thread Surface finish: black-chrome finished or phosphatised oiled electro-galvanized flZn according to LH standard 10021432 dry Tightening torque Thread Class Assembly preload FM in N MA in Nm for mean friction factor

M8x1 M9x1

M10

8.8 10.9 12.9

27 500 40 000 47 000

46 68 79

M10x1 M10x1.25

M12

8.8 10.9 12.9

40 000 59 000 69 000

79 117 135

M12x1.25 M12x1.5

M14 M16

01/2005

8.8 10.9 12.9 8.8 10.9 12.9

55 000 80 000 94 000 75 000 111 000 130 000

125 185 215 195 280 330

M14x1.5 M16x1.5

8.8 10.9 12.9 8.8 10.9 12.9 8.8 10.9 12.9 8.8 10.9 12.9 8.8 10.9 12.9 8.8 10.9 12.9 8.8 10.9 12.9 8.8 10.9 12.9

18 800 27 500 32 500 24 800 36 500 42 500 31 500 46 500 54 000 29 500 43 000 51 000 45 000 66 000 77 000 42 500 62 000 73 000 61 000 89 000 104 000 82 000 121 000 141 000

µG= 0.12

24.5 36 43 36 53 62 52 76 89 49 72 84 87 125 150 83 122 145 135 200 235 205 300 360

1.20.1

Metric coarse thread Surface finish: black-chrome finished or phosphatised oiled electro-galvanized flZn according to LH standard 10021432 dry Tightening Thread Class Assembly preload torque MA in Nm FM in N for mean friction factor

M18

8.8 10.9 12.9

94 000 135 000 157 000

µG= 0.12

280 390 460

Metric fine thread Surface finish: black-chrome finished or phosphatised oiled electro-galvanized flZn according to LH standard 10021432 dry Tightening Thread Class Assembly preload torque FM in N MA in Nm for mean friction factor

M18x1.5 M18x2

M20 M22 M24

8.8 10.9 12.9 8.8 10.9 12.9 8.8 10.9 12.9

121 000 173 000 202 000 152 000 216 000 250 000 175 000 249 000 290 000

390 560 650 530 750 880 670 960 1120

M20x1.5 M22x1.5 M24x1.5 M24x2

M27

8.8 10.9 12.9

230 000 330 000 385 000

1000 1400 1650

M27x1.5 M27x2

M30

8.8 10.9 12.9

280 000 400 000 465 000

1350 1900 2250

M30x1.5 M30x2

M33

8.8 10.9 12.9

350 000 495 000 580 000

1850 2600 3000

M33x1.5 M33x2

M36

8.8 10.9 12.9

410 000 580 000 680 000

2350 3300 3900

M36x1.5 M36x3

M39

8.8 10.9 12.9

490 000 700 000 820 000

3000 4300 5100

M39x1.5 M39x3

8.8 10.9 12.9 8.8 10.9 12.9 8.8 10.9 12.9 8.8 10.9 12.9 8.8 10.9 12.9 8.8 10.9 12.9 8.8 10.9 12.9 8.8 10.9 12.9 8.8 10.9 12.9 8.8 10.9 12.9 8.8 10.9 12.9 8.8 10.9 12.9 8.8 10.9 12.9 8.8 10.9 12.9 8.8 10.9 12.9 8.8 10.9 12.9

110 000 157 000 184 000 102 000 146 000 170 000 139 000 199 000 232 000 171 000 245 000 285 000 207 000 295 000 346 000 196 000 280 000 325 000 267 000 381 000 445 000 255 000 365 000 425 000 335 000 477 000 558 000 321 000 457 000 534 000 410 000 584 000 683 000 395 000 560 000 660 000 492 000 701 000 820 000 440 000 630 000 740 000 582 000 830 000 971 000 530 000 750 000 880 000

µG= 0.12

310 440 520 290 420 490 430 620 720 580 820 960 760 1090 1270 730 1040 1220 1110 1580 1850 1070 1500 1800 1540 2190 2560 1490 2120 2480 2050 2920 3420 2000 2800 3300 2680 3820 4470 2500 3500 4100 3430 4890 5720 3200 4600 5300

Notes: Torques indicated in drawings have precedence over those specified in the factory standards and must at all times be adhered to. For very important screw connections, we recommend applying the angle tightening method. Alternatively determine the total friction factor by carrying out a series of tests and refer to VDI 2230 or consult the technical department for the relevant tightening torques.

1.20.2

01/2005

Appendix: Angle tightening method With the angle tightening method, the bolt is turned by a defined angle , which is based on the flexible elongation of the bolt and compression of the screwed plates. Depending on the bolt size, it is preloaded by a given torque before it is inserted into the parts to be secured, so that the zero point of the angle measurement can be determined. From this zero angle o = 0, the bolt can be preloaded - irrespective of the friction factor of the thread and the contact surface by turning it by the retightening angle .

Example 1: Bolt: M14 – 10.9, grip length Lk=80mm; According to table (strength class 10.9): Pretightening torque MA = 50Nm; retightening angle

45°

Example 2: Bolt: M24 – 12.9, grip length Lk=100mm; According to table (strength class 12.9): Pretightening torque MA = 160Nm; retightening angle

01/2005

57°

1.20.3

1.20.4

01/2005

01/2005

1.20.5

1.20.6

01/2005

Service Manual

Tightening torques of screw-in studs (Ermeto)

Tightening torques 1 of screw-in studs (Ermeto) 1.1

mating material: steel (Grease well before inserting!) Type with sealing edge Thread M or G

Type

Type with EOLASTIC seal Tightening torques in Nm

Type

Light-duty series L

Thread M or G

Tightening torques in Nm

Light-duty series L

GE 06 LM A 3 C

M 10x1

18

GE 06 LM ED A 3 C

M 10x1

18

GE 06 LR A 3 C

G 1/8 A

18

GE 06 LR ED A 3 C

G 1/8 A

18

GE 08 LM A 3 C

M 12x1.5

30

GE 08 LM ED A 3 C

M 12x1.5

25

GE 08 LR A 3 C

G 1/4 A

35

GE 08 LR ED A 3 C

G 1/4 A

35

GE 10 LM A 3 C

M 14x1.5

45

GE 10 LM ED A 3 C

M 14x1.5

45

GE 10 LR A 3 C

G 1/4 A

35

GE 10 LR ED A 3 C

G 1/4 A

35

GE 12 LM A 3 C

M 16x1.5

65

GE 12 LM ED A 3 C

M 16x1.5

55

GE 12 LR A 3 C

G 3/8 A

70

GE 12 LR ED A 3 C

G 3/8 A

70

GE 15 LM A 3 C

M 18x1.5

80

GE 15 LM ED A 3 C

M 18x1.5

70

GE 15 LR A 3 C

G 1/2 A

140

GE 15 LR ED A 3 C

G 1/2 A

90

GE 18 LM A 3 C

M 22x1.5

140

GE 18 LM ED A 3 C

M 22x1.5

125

GE 18 LR A 3 C

G 1/2 A

100

GE 18 LR ED A 3 C

G 1/2 A

90

GE 22 Lm A 3 C

M 22x1.5

140

GE 22 Lm Ed A 3 C

M 26x1.5

180

GE 22 Lr A 3 C

G 3/4

180

GE 22 Lr Ed A 3 C

G 3/4 A

180

GE 28 Lm A 3 C

M 33x2.0

340

GE 28 Lm Ed A 3 C

M 33x2.0

310

GE 28 Lr A 3 C

G1A

330

GE 28 Lr Ed A 3 C

G1A

310

GE 35 Lm A 3 C

M 42x2.0

500

GE 35 Lm Ed A 3 C

M 42x2.0

450

GE 35 Lr A 3 C

G 1 1/4 A

540

GE 35 Lr Ed A 3 C

G 1 1/4 A

450

GE 42 Lm A 3 C

M 48x2.0

630

GE 42 Lm Ed A 3 C

M 48x2.0

540

GE 42 Lr A 3 C

G 1 1/2 A

630

GE 42 Lr Ed A 3 C

G 1 1/2 A

540

Heavy-duty series S

Heavy-duty series S

GE 06 SM A 3 C

M 12x1.5

35

GE 06 SM ED A 3 C

M 12x1.5

35

GE 06 SR A 3 C

G 1/4 A

55

GE 06 SR ED A 3 C

G 1/4 A

55

GE 08 SM A 3 C

M 14x1.5

55

GE 08 SM ED A 3 C

M 14x1.5

55

GE 08 SR A 3 C

G 1/4 A

55

GE 08 SR ED A 3 C

G 1/4 A

55

GE 10 SM A 3 C

M 16x1.5

70

GE 10 SM ED A 3 C

M 16x1.5

70

GE 10 SR A 3 C

G 3/8 A

90

GE 10 SR ED A 3 C

G 3/8 A

80

GE 12 SM A 3 C

M 18x1.5

110

GE 12 SM ED A 3 C

M 18x1.5

90

GE 12 SR A 3 C

G 3/8 A

90

GE 12 SR ED A 3 C

G 3/8 A

80

GE 14 SM A 3 C

M 20x1.5

150

GE 14 SM ED A 3 C

M 20x1.5

125

GE 14 SR A 3 C

G 1/2 A

150

GE 14 SR ED A 3 C

G 1/2 A

115

MJF C I F S S

1.21. 1

Tightening torques

Service Manual

of swivelling connections (Ermeto) Type with sealing edge Thread M or G

Type GE 16 SM A 3 C

M 22x1.5

Type with EOLASTIC seal Tightening torques in Nm

Type

170

GE 16 SM ED A 3 C

Thread M or G

Tightening torques in Nm

M 22x1.5

135

GE 16 SR A 3 C

G 1/2 A

130

GE 16 SR ED A 3 C

G 1/2 A

115

GE 20 SM A 3 C

M 27x2.0

270

GE 20 SM ED A 3 C

M 27x2.0

180

GE 20 SR A 3 C

G 3/4 A

270

GE 20 SR ED A 3 C

G 3/4 A

180

GE 25 SM A 3 C

M 33x2.0

410

GE 25 SM ED A 3 C

M 33x2.0

310

GE 25 SR A 3 C

G1A

340

GE 25 SR ED A 3 C

G1A

310

GE 30 SM A 3 C

M 42x2.0

540

GE 30 SM ED A 3 C

M 42x2.0

450

GE 30 SR A 3 C

G 1 1/4 A

540

GE 30 SR ED A 3 C

G 1 1/4 A

450

GE 38 SM A 3 C

M 48x2.0

700

GE 38 SM ED A 3 C

M 48x2.0

540

GE 38 SR A 3 C

G 1 1/2 A

700

GE 28 SR ED A 3 C

M 1 1/2 A

540

Tab. 2

Tightening torques of screw-in studs

GE = Straight screw-in connection (with metric thread M or pipe thread G)

2 of swivelling connections (Ermeto) 2.1

mating material: steel (Grease well before inserting!) Tightening torques

Type

Thread

Tightening torques

Type

Nm

Light-duty series

Thread

Nm

Light-duty series

WH / TH 06 LR KDS A 3 C

G 1/8 A

18

WH / TH 06 LM KDS A 3 C

M 10 X 1

18


G 1/4 A

45


M 12 X 1.5

45


G 3/8 A

45


M 14 X 1.5

55


G 1/2 A

70


M 16 X 1.5

80


G 3/4 A

120


M 18 X 1.5

100


G1A

120


M 22 X 1.5

140


G 1 1/4 A

230


M 27 X 2.0

320


G 1 1/4 A

320


M 33 X 2.0

360


G 1 1/4 A

540


M 42 X 2.0

540


G 1 1/2 A

700


M 48 X 2.0

700

Heavy-duty series

Heavy-duty series

WH / TH 06 SR KDS A 3 C

G 1/4 A

45

WH / TH 06 SM KDS A 3 C

M 12 X 1.5

45


G 1/4 A

45


M 14 X 1.5

55


G 3/8 A

70


M 16 X 1.5

80


G 3/8 A

70


M 18 X 1.5

100


G 1/2 A

120


M 20 X 1.5

125


G 3/4 A

230


M 22 X 1.5

135

1.21. 2

MJF C I F S S

Service Manual

Tightening torques of screw-in studs (Ermeto) Tightening torques

Type

Thread

Tightening torques

Type

Nm

Thread

Nm


G1A

320


M 27 X 2.0

320


G 1 1/4 A

540


M 33 X 2.0

360


G 1/4 A

700


M 42 X 2.0

540


M 48 X 2.0

700

Tab. 2

Tightening torques of swivelling connections

3 of screw-in studs (Ermeto) 3.1

mating material: steel (Grease well before inserting!)

Type VSTI

Screw-in thread M

Tightening torques Nm

Type VSTI

Screw-in thread G

Tightening torques Nm

VSTI 10X1 ED A3C

M 10 X 1

12

VSTI 1/8 ED A3C

G 1/8 A

13

VSTI 12X1.5 ED A3C

M 12 X 1.5

25

VSTI 1/4 ED A3C

G 1/4 A

30

VSTI 14X1.5 ED A3C

M 14 X 1.5

35

VSTI 3/8 ED A3C

G 3/8 A

60

VSTI 16X1.5 ED A3C

M 16 X 1.5

55

VSTI 1/2 ED A3C

G 1/2 A

80

VSTI 18X1.5 ED A3C

M 18 X 1.5

65

VSTI 3/4 ED A3C

G 3/4 A

140

VSTI 20X1.5 ED A3C

M 20 X 1.5

80

VSTI 1 ED A3C

G1A

200

VSTI 22X1.5 ED A3C

M 22 X 1.5

90

VSTI 1 1/4 ED A3C

G 1 1/4 A

450

VSTI 1 1/2 ED A3C

G 1 1/2 A

450

VSTI 26X1.5 ED A3C

M 26 X 1.5

120

VSTI 27X2 ED A3C

M 27 X 2.0

135

VSTI 33X2 ED A3C

M 33 X 2.0

225

VSTI 42X2 ED A3C

M 42 X 2.0

360

VSTI 48X2 ED A3C

M 48 X 2.0

360

Tab. 2

Tightening torques of screw-in studs

VSTI = Hexagon socket plug

MJF C I F S S

1.21. 3

Tightening torques

Service Manual

of screw-in studs (Ermeto)

1.21. 4

MJF C I F S S


Mj f c i f s s !

Assembly instruction for pistons and piston nuts (hydraulic cylinders)

1

Blatt/Page/Feuille: bestehend aus consisting of composé

6

Blatt Pages Feuille

WN 4121 B

Contents 1.

Scope of application

2.

Description

3.

Referenced documents (torque table)

1.

Scope of application This factory standard applies exclusively to the assembly of hydraulic cylinders with a thread diameter of M42 and greater. For the valid factory standard number, refer to the drawing. The standard may not be adopted or transferred to apparently similar geometries. The torques have been determined empirically and are subject to changes. The revision and release dates indicate the latest version of the factory standard. For threads with diameters smaller than M42, the applicable tightening torques are indicated in the drawings. The values in the drawings are always binding.

09 / 2005

1.22.1

2.

Description

Preparation: Clean the contact surfaces (threads contact faces between piston rod, piston and piston nut) and apply a thin layer of Gleitmo high-performance lubricating grease (ID no. 8300 004, 40 g tube) on both sides. Definitions: Pretightening torque The piston is secured with a torque wrench applied to the square/hexagon head of the assembly wrench. The position of the torque wrench must be carefully noted (see figure 1).

Figure 1 A B C

Piston Assembly wrench Torque wrench

When applying the pretightening torque, the torque wrench must point in the same direction as the assembly wrench. Proceed in the same way to tighten the piston nut, using a suitable assembly wrench.

1.22.2

09 / 2005

Turning distance: Radian measure [mm] travelled as a result of the tightening of the piston, or piston nut along the outer thread diameter, after application of the pretightening torque (see figures 2 and 3). Turning angle: Angle \°^ travelled by the piston or piston nut respectively, after application of the pretightening torque (see figures 2 and 3).

Figure 2 A Marks on the piston and piston rod thread after application of the pretightening torque B Mark on the piston rod thread C Turning angle D Turning distance E Mark on the piston after tightening

Figure 3 Marks on the piston nut and piston rod thread after application of the A pretightening torque B Mark on the piston rod thread C Turning angle D Turning distance E Mark on the piston nut after tightening 09 / 2005

1.22.3

1.22.4

09 / 2005

3.

List of tightening torques for factory standard 4121 (Assembly instructions for piston and piston nur)

Edition: 11.04.2005

The date indicates the latest version of this table. This document is not covered by the revision service. FS

Preload

4121... 071 072 073 075 079 080 091 092 093 095 096 097 098 099 111 112 113 114 115 121 123 126 127 151 152 153 171 173 174 175 176 177 179 180 181 183 201 202 203 204 205 206 207 208 209 231 232

Torque Mv [Nm] 100 100 100 100 100 100 100 100 100 100 100 100 100 100 100 100 100 100 100 150 150 150 150 150 150 150 150 150 150 150 150 150 150 150 150 200 200 200 200 200 200 200 200 200 200 200 200

09 / 2005

Piston

Piston nut

Turn.distance

Turning angle

Turns distance

Turning angle

[mm] 11 +1 21 +1 18 +1 19 +1 11 +1 18 +1 13 +1 25 +1 24 +1 13 +1 10 +1 17 +1 17 +1 24 +1 16 +1 17 +1 18 +1 19 +1 18 +1 15 +1 17 +1 14 +1 22 +1 15 +1 20 +1 20 +1 12 +2 19 +2 25 +2 25 +2 19 +2 19 +2 11 +2 20 +2 20 +2 17 +2 26 +2 27 +2 27 +2 13 +2 25 +2 23 +2 15 +2 30 +2 8 +2 17 +2

~ [°] 30 57 49 52 30 49 30 57 55 30 23 39 39 55 33 35 37 39 37 29 32 27 42 27 35 35 20 32 42 42 32 32 19 34 34 26 39 41 41 20 38 35 22 45 11 23

[mm] 21 +1 21 +1 19 +1 21 +1 21 +1 19 +1 19 +1 19 +1 19 +1 9 +1 19 +1 19 +1 18 +1 18 +1 18 +1 19 +1 19 +1 19 +1 19 +1 18 +1 18 +1 18 +1 18 +1 18 +1 18 +1 18 +1 18 +1 40 +2 16 +1 16 +1 16 +1 16 +1 25 +1 16 +1 16 +1

~ [°] 57 57 52 57 57 44 44 44 44 21 44 44 37 37 37 36 36 34 34 30 30 30 30 30 30 30 30 67 24 24 24 24 38 22 22

Thread M [mm] 42x1,5 42x1,5 42x1,5 42x1,5 42x1,5 42x1,5 50x2 50x2 50x2 50x2 50x2/SW65 50x2 50x2 50x2 56x2 56x2 56x2 56x2 56x2 60x2 60x2 60x2 60x2 65x2 65x2 65x2 68x2 68x2 68x2 68x2 68x2 68x2 68x2 68x2 68x2 68x2 76x2 76x2 76x2 76x2 76x2 76x2 76x2 76x2 76x2 85x3 85x3 1.22.5

FS

Preload

4121... 234 261 281 282 301 302 303 304 305 306 307 331 332 333 334 335 501 531

Torque Mv [Nm] 200 250 250 250 300 300 300 300 300 300 300 400 400 400 400 400 200 500

1.22.6

Piston

Piston nut

Turn.distance

Turning angle

Turns distance

Turning angle

[mm] 22 +2 20 +2 20 +2 25 +2 21 +3 18 +3 20 +3 23 +3 9 +3 24 +3 27 +3 23 +3 11 +3 27 +3 20 +3 30 +3 21 +2 34 +3

~ [°] 30 25 23 29 22 19 21 24 9 25 28 22 11 26 19 29 30 28

[mm] 10 +1 13 +1 20 +2 20 +2 20 +2 20 +2 20 +2 20 +2 -

~ [°] 12 15 21 21 21 21 19 19 -

Thread M [mm] 85x3 95x3 100x3 100x3 110x3 110x3 110x3 110x3 110x3 110x3 110x3 120x3 120x3 120x3 120x3 120x3 80x2 140x3

09 / 2005


Mj f c i f s s !

Assembly instruction for piston rod bearings with external threads (hydraulic cylinders)

1

Blatt/Page/Feuille: bestehend aus consisting of composé

4

Blatt Pages Feuille

WN 4122 B

Contents 1.

Scope of application

2.

Description

3.

Referenced documents (torque table)

1.

Scope of application This factory standard applies exclusively to the assembly of hydraulic cylinders. For the valid factory standard number, refer to the drawing. The standard may not be adopted or transferred to apparently similar geometries. The torques have been determined empirically and are subject to changes. The revision and release dates indicate the latest version of the factory standard.

09 / 2005

1.24.1

2.

Description

Preparation: Clean the threads and apply a thin layer of Gleitmo high-performance lubricating grease (ID no. 8300 004, 40 g tube) on both sides. Definitions: Pretightening torque: The piston rod bearing is secured with a torque wrench applied to the square of the assembly wrench. The position of the torque wrench must be carefully noted (see figure 1).

Figure 1 A B C

Bearing head Assembly wrench Torque wrench

When applying the pretightening torque, the torque wrench must point in the same direction as the assembly wrench.

1.24.2

09 / 2005

Turning distance: Radian measure [mm] between the bearing head outer diameter and the cylinder tube, travelled after application of the pretightening torque (see figure 2). Turning angle: Angle \°^ travelled by the bearing head after application of the pretightening torque (see figure 2).

Figure 2 A B C D E F G

Marks on the cylinder tube and the auter diameter of the bearing head after application of the pretightening torque Mark on the cylinder tube Turning angle Turning distance Mark on the bearing head after tightening Cylinder Tube Bearing head

After the bearing head and the cylinder tube have been tightened, apply a notch mark at the rod side oil connection level, using a flat chisel.

09 / 2005

1.24.3

3.

List of tightening torques for factory standard 4122

(Assembly instructions for piston and piston nur)

The date indicates the latest version of this table. This document is not covered by the revision service. .

1.24.4

NU

Preload

4122... 001 011 016 017 026 027 031 036 039 041 046 047 051 052 151

Torque Mv [Nm]

Edition: 24.01.2005

Piston rod bearing

Turning distance

Turning angle

50 100 100 100 100 100 100

7 +1 10 +1 10 +1 9 +1 10 +1 8 +1 8 +1

10 12 12 10 11 8 9

400

14 +1

6

[mm]

~ [°]

09 / 2005

Service Manual

Fuels, lubricants and other consumables General instructions regarding the change of fuel, hydraulic oils, lubricants, etc.

Fuels, lubricants and other consumables 1 General instructions regarding the change of fuel, hydraulic oils, lubricants, etc. Note! The fill volumes specified in the fuel and lubricant table in the operator manual, and in the documentation of the assemblies, as well as in the lubrication schedule in the operator's cab are only approximate values. After each oil change or refilling, check the fill level in the respective tank or unit. Note! Compliance with the instructions regarding lubrication, fill level checks and oil changes improve the reliability and prolong the service life of the machine. It is very important that the prescribed intervals for oil change are adhered to and that only products of the prescribed quality and grade are used. Note! Cleanliness during the oil change is of crucial importance. Always clean all fill screws, lids and drain plugs and the area around fill openings. When draining oil, ensure that the oil is at operating temperature. Carefully collect the old oil and dispose of it in an environmentally friendly manner. This also applies to the oil filter cartridges. Danger! When checking and/or changing lubricants and fuels: If not instructed otherwise, ensure that the machine is standing on level and firm ground and that the engine is shut down. When working inside the engine compartment, always secure the cover and doors against inadvertent closing. Before refuelling the machine, switch off the engine. Do not smoke or use naked flames.

MJF C I F S S

1.50. 1


Service Manual

General instructions regarding the change of fuel, hydraulic oils, lubricants, etc.

1.1

1.50. 2

Lubricant table Description

Medium

Symbol

Diesel engine

Engine oil

Refer to the instructions of the engine manufacturer (see Deutz manual)

Hydraulic tank

Engine oil

API-CD, APICD+SF, CCMC-D4, CCMC-D5, ACEA-E1, ACEA-E3

SAE 10W SAE 10W-30 SAE 10W-40 SAE 15W-40 SAE 20W-20 SAE 30W

Slewing gear mechanism (as stop brake)

Gear oil

API - GL -5 MIL-L 2105 B, C or D

SAE 80W90 or SAE 90

Slewing gear mechanism (as positioning slewing brake)

Gear oil

API - GL -5 MIL-L 2105 B

SAE 90 LS

Steering axle

Gear oil

API - GL -5 MIL-L 2105 B ZF TE-ML 05

SAE 90 LS

Rigid axle with multi-disc brake

Gear oil


SAE 90 LS

Rigid axle with drum brake

Gear oil


SAE 90 LS

Wheel hubs in steering and rigid axles with multi-disc and drum brakes

Gear oil


SAE 90 LS

Transmission

Gear oil

ZF TE-ML 07

SAE 10 W 30 SAE 10 W 20

Travel gear

Gear oil


SAE 80W90 or SAE 90

MJF C I F S S

Classification

Viscosity

Service Manual

Fuels, lubricants and other consumables General instructions regarding the change of fuel, hydraulic oils, lubricants, etc.

Description

Medium

Tracks and gearing of the slewing ring, bearing of the equipment

Grease

Hinges, joints, locks

Engine oil

Sealing rubber on doors and covering sections

Silicone spray or talcum powder

Tab. 1 *BI

1.1.1

Symbol

Classification

Viscosity

High-pressure grease KP2k or EP2

Consiste ncy 2 NLGI grade with lithium complex Tab. 8

MPG-A

-

-

-

-

-

-

-

-

Lubricant table =

Lubricant for building machinery and vehicles recommended by the Federation of the German Construction Industry (Hauptverband der Deutschen Bauindustrie e. V.), see brochure published by Bauverlag GmbH, Wiesbaden and Berlin regarding the use of lubricant and fuel tables.

Fuel and consumables Description

Medium

Fuel tank

Conventional diesel fuel with <= 0.5 % sulphur content

Coolant

Anticorrosion and antifreeze agent

Windscreen washer system

Conventional windscreen cleaning agent or denatured alcohol

-

Coolant of airconditioning system

R 134 a

-

Refrigeration oil in SD 7H15 a/c compressor

PLANETELF PAG SP 20 ID no. 8504414 (0.25 litre) or. 7620633 (1.0 litre)

-

Tab. 2

Symbol

Fuel and consumables

MJF C I F S S

1.50. 3


Service Manual

Specifications for fuels, lubricants and consumables

2 Specifications for fuels, lubricants and consumables 2.1

Lubricating oil for the diesel engine Refer to the instructions of the engine manufacturer (see Deutz manual): Classification

Specification

API classification (American Petrol Institute)

CG-4, CF-4, CH-4

ACEA (CCMC) classification (Association des Constructeurs Européens de l´Automobile)

E2-96 (D4), E3-96 (D5), E4-98

Tab. 3

2.1.1

Lubricating oil for the diesel engine

Oil change intervals for turbocharged engines Oil change interval depending on oil quality: Operating conditions

Sulphur content of fuel

CH-4 CG-4 CF-4 E2-96 (D4)

E3-96 (D5) E4-98 E5-99

Temperature normally not dropping below -10°C

max. 0.5 % higher than 0.5 %

250 h 125 h

500 h 250 h

below -10 °C

max. 0.5 % higher than 0.5 %

125 h -

250 h 125 h

Tab. 4

Oil change intervals

The oil change intervals of the diesel engine are based on the following criteria: – First oil and filter change after 500 operating hours, if the oil of the first filling was an oil of E3-96 grade – Subsequent filter changes after 500 operating hours – Subsequent oil changes depending on the climate, sulphur content of the fuel and oil grade, Tab. 4. – If the above number of operating hours is not reached within 12 months, change the engine oil and the oil filter at least once every year.

2.2

Fuel Diesel fuels should meet the minimum requirements of the fuel specifications named below. The sulphur content should not exceed 0.5 mass %. A higher sulphur content affects the oil change intervals and the service life of the engine.

2.2.1

Lubricity By reducing the sulphur content in diesel, the issue of lubricity has come to the fore. It has been shown that diesel fuels with the sulphur levels of maximum 0.05 %, which corresponds to the limit in the European Union, can lead to wear in the injection system (especially in distributor fuel injection pumps).

1.50. 4

MJF C I F S S

Service Manual

Fuels, lubricants and other consumables Specifications for fuels, lubricants and consumables

Branded fuels in Germany and elsewhere therefore contain lubricating additives. The lubricity of the fuel must be < 400 µm in a HFFR test (60°). The additives should be added by the supplier, who is responsible for the quality of the fuel. We advise machine operators not to add any secondary lubricity additives to the fuel.

2.2.2

Improvement of fluidity by adding petrol At outdoor temperatures below approx. 0 °C, the fluidity of summer diesel might not be sufficient, due to the separation of paraffin. This also applies to winter diesel at temperatures below approx. -15 °C. There is however diesel fuel on the market, containing additives that make it suitable for use at temperatures to -20 °C. In order to avoid malfunction at low temperatures, diesel must be mixed with normal petrol or petroleum. This approach must be considered an emergency measure and the petrol content may never exceed 30 % (volume). Do not use premium petrol for this mixture. Please note that the engine output might be reduced due to the addition of petrol. The addition of petrol should therefore be based on the actual outdoor temperature and kept as low as possible. Danger! For safety reasons, the diesel-petrol mix must be produced in the fuel tank.

Note! When filling tank, first fill in the lighter additional fuel (petrol) and than add the diesel. Run the motor until the entire fuel system is filled with the fuel mix (see Tab. 6, page 6).

Approved fuel specifications DIN EN 590 ASTM D 975 (89 a) 1D and 2D DIN EN 590 with max. 5 volume % FAME* according to draft standard prEN 14214 (formerly: DIN 51606)

MJF C I F S S

1.50. 5


Service Manual


Diesel fuel – petrol mixing ratio Outdoor temperature °C

Summer diesel fuel %

Addition of petrol %

0 to -10

70

30

-10 to -15

50

50*

-15 to -20

-

-

-20 to -25

-

-

Tab. 5

Summer diesel fuel – petrol mixing ratio Winter diesel fuel %

Addition of petrol %

Grade -15 °C

Grade -20 °C

Grade -15 °C

Grade -20 °C

0 to -10

100

100

-

-

-10 to -15

100

100

-

-

-15 to -20

70

100

30

-

-20 to -25

50

70

50*

30

Outdoor temperature °C

Tab. 6

Winter diesel fuel – petrol mixing ratio

* If an additive content of 50 % is required, use only petroleum (not standard petrol).

2.2.3

Diesel fuel additives (fluidity improvers) Fluidity improvers are widely available and help improve the fluidity of diesel at low temperatures. When using such additives, always adhere to the dosing and handling instructions of the manufacturers.

2.3 2.3.1

Hydraulic oil Mineral oil Use only motor oils that conform to the specifications and requirements below: Single grade engine oils:

API - CD / CCMC - D4 / ACEA - E1 Mercedes-Benz specifications, sheet no. 226.0 and 227.0

Multigrade engine oil:

API - CD + SF / CCMC - D5 / ACEA - E3 Mercedes-Benz specifications, sheet no. 227.5 and 228.3

Tab. 7

Engine oils to be used as hydraulic oils

Select the engine oil for use as hydraulic oil according to the following diagram.

1.50. 6

MJF C I F S S

Service Manual


Fig. 1

Engine oil for use as hydraulic oil

Warm-up instruction At temperatures to 10 °C below the indicted limit (black bar), the oil must be warmed up as follows: Start diesel engine and run it at approx. 1 / 2 the rated speed. Operate the hydraulic cylinders and motors, but do not move the cylinders to their stops. Warm-up time: approx. 10 minutes At lower temperatures: Before starting the engine, warm up the oil tank.

2.3.2

Environmentally friendly hydraulic oils Note! Do not mix different brands of environmentally friendly hydraulic oils or such oils with mineral oils (see customer service information)! LIEBHERR will fill the system before delivery, based on a list of approved oils. Before using environmentally friendly oils, you must consult LIEBHERR. The list of products recommended by LIEBHERR contains only ester-based synthetic oils with a viscosity according to ISO VG 46. Do not use vegetable oils, as they do not possess the necessary thermal stability.

2.3.3

Monitoring of hydraulic oil Note! Environmentally friendly hydraulic oils must be regularly tested by means of an oil analysis. For mineral oils, we recommend carrying out oil analyses at regular intervals. LIEBHERR recommends contracting WEAR-CHECK with these analyses, and to change the oil when indicated by the test results (see also customer service and product information). Machines in normal use: at least every 500 operating hours Machines used for dust intensive applications: at least every 250 operating hours

2.3.4

Monitoring of hydraulic oil in normal use

Fig. 2

Oil sampling from machines in normal use

MJF C I F S S

1.50. 7


Service Manual

Specifications for fuels, lubricants and consumables h

Operating hours

2

Second oil sample

1

First oil sample

3

Subsequent oil samples: every 500 operating hours

Oil change based on analysis and lab report. Interval for the change of the hydraulic oil return filter (20/5 µm): first change after 500 operating hours, then every 1000 operating hours.

2.3.5

Oil sampling from machines used for dust intensive applications:

Fig. 3

Oil sampling from machines used for dust intensive applications

h

Operating hours

2

Second oil sample

1

First oil sample

3

Subsequent oil samples: every 250 operating hours

Oil change based on analysis and lab report. Interval for the change of the hydraulic oil return filter (10 µm): first change after 500 operating hours, then every 500 operating hours.

2.3.6

Instructions for the reduction of the contamination of the hydraulic oil in machine used for dust intensive applications If the machine is normally operated with a hydraulic hammer or under similar conditions (considerable dust generation), the hydraulic oil might become more contaminated than under normal working conditions. In order to prevent premature wear of the hydraulic components, shorten the intervals between the oil changes (or oil samples respectively) and observe the following instructions: – Every 500 operating hours, replace the filter cartridge(s) in the return filter. – Use 10-µm filter cartridges instead of the standard 20 / 5-µm cartridges. – Replace the breather filter on the hydraulic tank with a 2-µm fine filter (mesh size of series filters: 7 µm). – Replace the 2-µm breather at each change of the hydraulic oil (i.e. every 500 operating hours). Note! – Machines that are delivered with a fully installed AHS 11 or AHS12 accessory kit, and machines with retrofitted kits are already equipped with 10-µm filter cartridges 2-µm breather filters. – All machines produced after approx. September 2005 have been equipped with 2-µm breather filters.

2.4

Gear oil Gear oils must conform to the following specifications: – API-GL-5 and MIL-L-2105 B, C or D respectively for viscosity grade SAE 90 Engine oils used in gearboxes must conform to the following specifications: – API-CG-4, CF-4, CF for viscosity grade SAE 20

1.50. 8

MJF C I F S S

Service Manual


For viscosity grades SAE 80 and SAE 90 according to MIL-L-2105 D, you may use an oil of viscosity grade SAE 80W90.

2.4.1

Grease and other process chemicals Process chemicals

Description / manufacturer

Grease for slewing ring / general lube points

The grease must conform to specification KP2k, consistency grade 2, NLGI grade according to DIN 51818 and DIN 51825 or EP 2 according to NF-T-60 132. The grease must consist of a lithium complex with a VKA value of minimum 2300 N according to DIN 51350 or ASTM D 2596 respectively.

Contact spray for slip rings

Cramolin ID no. 7024145

Lubricant for pistons, piston nuts, also used for the mounting of piston rod bearings and cushioning sleeves to hydraulic cylinders

Gleitmo 800 ID no. 8300004 (40g tube)

Anti-friction varnish and lubricant for LIKUFIX coupling system

Gleitmo 900 ID no. 8610227 (400 ml spray can)

Special corrosion inhibitor for mounting recesses for sealing elements at hydraulic cylinders

Castrol-Tarp ID no. 8300005 (40g tube)

Other grease: Lubricant used for the mounting of pumps to prevent fretting corrosion on spline meshes

LIEBHERR CTK special lubricant ID no. 861331301 (400g cartridge)

Coolant for air-conditioning system

R 134 A Drain and fill the system according to the instructions in this manual (air-conditioning assembly).

Refrigeration oil for a/c compressor

The SD5H14 / SD7H15 a/c compressors are factory-filled with Planetelf PAG SP 20. ID no. 8504414 (0.25 litre can) ID no. 7620633 (1.0 litre can) The compressor supplier does not permit the use of any other refrigeration oil.

Tab. 8

2.5

Grease and other process chemicals

Coolant In order to improve the quality of the cooling water, LIEBHERR diesel engines are equipped with water filter installations for Deutz engines. This ensures that the coolant is also filtered in the bypass flow where dirt and rust particles that might lead to leakage in the cooling pump are removed.

MJF C I F S S

1.50. 9


Service Manual


Outdoor temperature to

Water content in %

Content of corrosion inhibitors/antifreeze agents in %

-37 °C / -34 °F

50

50

-50 °C / -58 °F

40

60

Tab. 9

Mixing ratio water : corrosion inhibitor / antifreeze agent

The coolant must contain at least 50 volume % of corrosion inhibitor and antifreeze agent during all seasons. This protected the coolant against freezing to a temperature of -37 °C and ensures adequate protection against corrosion. In the event of loss of coolant, ensure that the additive concentration does not drop below 50 volume %. Note! Do not exceed a corrosion inhibitor and antifreeze agent concentration of 60 %! Higher concentrations tend to result in poor cooling and antifreeze protection. As part of the regular maintenance, check the mixing ratio. Note! – Change the coolant every 2 years.

Before refilling the cooling system with new coolant, ensure that it is clean and rinse it, if required.

2.5.1

Requirements regarding the fresh water quality To prepare the coolant, use clean water with as little limestone content as possible. In most cases, the local drinking water meets these requirements. Do not use sea water, brackish water, brine or industrial wastewater.

Requirements regarding the fresh water quality for coolants with corrosion inhibitors and antifreeze agents Substance

Volume

Total of alkaline earths (water hardness)

0.6 to 3.6 mmol / l (3 to 20 °d)

pH at 20 °C

6.5 to 8.5

Chloride ion content

max. 80 mg / l

Total chloride and sulphate

max. 100 mg / l

Tab. 10

1.50. 10

Max. concentration of water contaminations for use with corrosion inhibitors and antifreeze agents

MJF C I F S S

Service Manual


F

Fig. 4

Mixing ratio water : corrosion inhibitor / antifreeze agent

A % of corrosion inhibitor and antifreeze agent B Antifreeze agent to indicated temperature, according to value A

2.5.2

Approved corrosion inhibitors and antifreeze agents Concentrates

Brand

Producer

Country

Agip Antifreeze Plus

Agip Petrol S.p.A., Rome

I

Agip Langzeit-Frostschutz

Autol-Werke GmbH, Würzburg

D

Antigel DB 486

Sotragal SA, St. Priest

F

Aral Kühlerfrostschutz A

Aral AG, Bochum

D

Avia Frostschutz APN (G48-00)

Deutsche Avia-Mineralöl GmbH, Munich

D

BP Antifrost X 2270 A

Deutsche BP AG, Hamburg

D

BP Napgel C 2270 / 1

BP Chemicals LTD., London

GB

Caltex Engine Coolant DB

Caltex UK Ltd, London

GB

Caltex Extended Life Coolant


GB

Castrol Anti-Freeze O

Deutsche Castrol Vertriebs GmbH, Hamburg

D

Century F.L. Anti-Freeze

Century Oils, Hanley, Stoke-on-Tent

GB

Chevron DEX-Cool Extended Life Anti-Freeze / Coolant

Chevron Texaco, San Ramon, CA

USA

DEUTZ Kühlschutzmittel 0101 1490

Deutz Service International GmbH, Cologne

D

Esso Kühlerfrostschutz

Esso AG, Hamburg

D

Fircofin

Fuchs Mineralölwerke GmbH, Mannheim

D

Frostschutz Motorex (G48-00)

Bucher & Cie, Langenthal

CH

Frostschutz 500

Mobil Oil AG, Hamburg

D

Glacelf Auto Supra

Total Nederland N.V., The Hague

NL

Glycoshell AF 405

Shell Deutschland GmbH, Hamburg

D

Glycoshell N

Shell Deutschland GmbH, Hamburg

D

MJF C I F S S

1.50. 11


Service Manual

Specifications for fuels, lubricants and consumables Brand

Producer

Country

Glysantin (G48-00)

BASF AG, Ludwigshafen

D

Havoline XLC

Arteco, Ghent

B

Chevron DEX-Cool Extended Life Anti-Freeze / Coolant


USA

Igol Antigel Type DB

Igol France, Paris

F

Labo FP 100

Labo Industrie, Nanteree

F

Motul Anti-Freeze

Motul SA, Aubervilles

F

OMV Kühlerfrostschutzmittel

OMV AG, Schwechat

A

Organifreeze

Total Deutschland GmbH, Düsseldorf

D

OZO Frostschutz S


D

Total Antigel S-MB 486


D

Total Frostfrei


D

Castrol Anti-Freeze O


D

Wintershall Kühlerschutz

Wintershall Mineralöl GmbH, Düsseldorf

D

Tab. 11

Approved corrosion inhibitors and antifreeze agents

50:50 premixed products (water: corrosion inhibitor / antifreeze agent) Product

Producer

Country

Liebherr Anti-Freeze APN Mix ID no. 8611045

Liebherr

D

Caltex Extended Life Coolant Pre-Mixed 50/50 (ready-to-use-version)


GB

Chevron DEX-Cool Extended Life Prediluted 50/50 Anti-Freeze / Coolant


USA

Havoline XLC, 50/50

Arteco, Ghent

B

Chevron DEX-Cool Extended Life Prediluted 50/ 50 Anti-Freeze / Coolant


USA

Organicool 50/50


D

Tab. 12

1.50. 12

Approved corrosion inhibitors / antifreeze agents / 50:50 premix

MJF C I F S S

Off-Road Driveline Technology and Axle Systems

Axles for off-road vehicles

List of lubricants TE-ML 05 Lubricant classes for service fills (1)

Product groups

without

with

wet multi-disc brakes and / or multi-disk limited-slip differentials 1. Axles (exception see section 2-5) Differentialsx Wheel hubsx Stub shafts 2. Axles with hypoid drive (AP 420R; AV230; MT-C 2025; MT-C2035; MT-C2075)

ZF-Powerfluidx 05A / 05B / 05C / 05D / 05E / 05F / 05G

ZF-Powerfluidx 05C / 05D / 05E / 05F / 05G

05A / 05B / 05C / 05D

05C / 05D

---

ZF-Powerfluid 05E / 05F / 05G

ZF-Powerfluid 05A / 05B / 05C / 05D 05E / 05F / 05G

ZF-Powerfluid 05E / 05F / 05G

05A / 05B / 05C / 05D

---

3. MT-D 3105 (only oil circuit brake) MT-L 3000 (with sintered brake linings) 4. MS-T 3025, MS-T 3035, MS-T 3045, MS-T 3055, MS-T 3060x MT-T 3025, MT-T 3035, MT-T 3045 MT 2075 (old: AP 2075), MT 2085 (old: AP 2085) 5. ZF-half-shafts (planetary final drives) for tractor transmissions T-7000

(1) Refer to the following pages for approved commercial products. A lithium saponified multipurpose grease of NLGI class 2 which is mixable with mineral oil is to be used at greasing points (grease code KP2K-30 in acc. with DIN 51825 or ISO-L-XCCHB2 in accordance with ISO 6743-9). Additives of any kind added later to the oil change the oil in a manner that is unpredictable, and they are therefore not permitted. No liability of any kind will be accepted by ZF for any damage resulting from the use of such additives.

The list of lubricants TE-ML 05, Edition 01.04.2005 replaces all previous editions. The current list can be requested from any ZF after-sales service center or accessed on the Internet under www.zf.com.

09 / 2005

ZF Passau GmbH ZF Friedrichshafen AG D-94030 Passau D-88038 Friedrichshafen phone: + 49 7541 77 3505 fax: + 49 7541 77 7319

1.55.1

Continued

ZF Friedrichshafen AG / List of lubricants TE-ML 05, edition 01.04.2005

Oil change intervals Lubricant class

05A, 05B, 05C, 05D, 05E, 05F

Load class

ZF Powerfluid 05G

Oil change interval

1

1500 h

2000 h

2

1000 h

1500 h

3

500 h

1000 h

Load classes Load class 1

1.55.2

Examples of applications - Dumper - Mobile excavator with low driving-mode share (<25%)x - Wheel loader with hydrostatic drivex - Other axles without wet brakes

2

- Mobile excavator with increased driving-mode share (>25%) - Wheel loader, grader, backhoe, telescopic handlerx - T 7000 half shafts

3

- Wheel loader operated under extreme braking conditions - Mobile excavator, material-handling areasx - At ambient temperatures > 40°C

09 / 2005

Continue


Lubricant class 05A Gear oilx Viscosity grades: SAE 75W-90 / 75W-140 / 80W-90 / 80W-140 / 85W-90 / 85W-140 / 90 Manufacturer (05A)

Trade name (05A)

ADDINOL LUBE OIL GMBH, LEUNA/D ADDINOL LUBE OIL GMBH, LEUNA/D ADDINOL LUBE OIL GMBH, LEUNA/D AGIP SCHMIERTECHNIK GMBH, WÜRZBURG/D ARAL AG, BOCHUM/D ARAL AG, BOCHUM/D ARAL AG, BOCHUM/D ARMORINE S.A., LANESTER CEDEX/F AVIA MINERALÖL-AG, MÜNCHEN/D AVIA MINERALÖL-AG, MÜNCHEN/D BAYWA AG, MÜNCHEN/D BAYWA AG, MÜNCHEN/D BEIJING TONGYI PETROLEUM CH. CO. LTD., BEIJING/CN BLASER SWISSLUBE AG, HASLE-RÜEGSAU/CH BLASER SWISSLUBE AG, HASLE-RÜEGSAU/CH BLASER SWISSLUBE AG, HASLE-RÜEGSAU/CH BP INTERNATIONAL, PANGBOURNE, READING/GB BP INTERNATIONAL, PANGBOURNE, READING/GB BP INTERNATIONAL, PANGBOURNE, READING/GB BP INTERNATIONAL, PANGBOURNE, READING/GB BP INTERNATIONAL, PANGBOURNE, READING/GB BP INTERNATIONAL, PANGBOURNE, READING/GB BP INTERNATIONAL, PANGBOURNE, READING/GB BP INTERNATIONAL, PANGBOURNE, READING/GB BP INTERNATIONAL, PANGBOURNE, READING/GB BUCHER AG LANGENTHAL, LANGENTHAL/CH BUCHER AG LANGENTHAL, LANGENTHAL/CH CALPAM MINERALÖL-GMBH, ASCHAFFENBURG/D CALPAM MINERALÖL-GMBH, ASCHAFFENBURG/D CASTROL INTERNATIONAL, PANGBOURNE READING/GB CASTROL INTERNATIONAL, PANGBOURNE READING/GB CASTROL INTERNATIONAL, PANGBOURNE READING/GB CASTROL INTERNATIONAL, PANGBOURNE READING/GB CASTROL INTERNATIONAL, PANGBOURNE READING/GB CASTROL INTERNATIONAL, PANGBOURNE READING/GB CASTROL INTERNATIONAL, PANGBOURNE READING/GB CASTROL INTERNATIONAL, PANGBOURNE READING/GB CEPSA LUBRICANTS S.A., MADRID/E CEPSA LUBRICANTS S.A., MADRID/E CEPSA LUBRICANTS S.A., MADRID/E CEPSA LUBRICANTS S.A., MADRID/E CEPSA LUBRICANTS S.A., MADRID/E CEPSA LUBRICANTS S.A., MADRID/E CHEVRONTEXACO GLOBAL LUBRICANTS, SAN RAMON/USA CHEVRONTEXACO GLOBAL LUBRICANTS, SAN RAMON/USA CHEVRONTEXACO, GHENT/B CHEVRONTEXACO, GHENT/B CHEVRONTEXACO, GHENT/B CHEVRONTEXACO, SYDNEY/AUS CHEVRONTEXACO, SYDNEY/AUS CONDAT LUBRIFIANTS, CHASSE SUR RHONE/F CONDAT LUBRIFIANTS, CHASSE SUR RHONE/F DE OLIEBRON B.V., ZWIJNDRECHT/NL ENI S.P.A. REFINING & MARKETING DIVISION, ROME/I ENI S.P.A. REFINING & MARKETING DIVISION, ROME/I ENI S.P.A. REFINING & MARKETING DIVISION, ROME/I ENI S.P.A. REFINING & MARKETING DIVISION, ROME/I EXXON MOBIL CORPORATION, FAIRFAX, VIRGINIA/USA EXXON MOBIL CORPORATION, FAIRFAX, VIRGINIA/USA EXXON MOBIL CORPORATION, FAIRFAX, VIRGINIA/USA EXXON MOBIL CORPORATION, FAIRFAX, VIRGINIA/USA FALCON OIL COMPANY LTD., SHARJAH/UAE FALCON OIL COMPANY LTD., SHARJAH/UAE FL SELENIA S.P.A., VILLASTELLONE/I FL SELENIA S.P.A., VILLASTELLONE/I FL SELENIA S.P.A., VILLASTELLONE/I

ADDINOL GETRIEBEÖL GH 80W-90 ADDINOL GETRIEBEÖL GH 85W-90 ADDINOL GETRIEBEÖL GX 80 W 90 ML AUTOL HYPOID-GETRIEBEÖL SAE 80W-90 ARAL GETRIEBEOL EP PLUS 80W-90 ARAL GETRIEBEOL HYP 85W-90 ARAL GETRIEBEÖL HYP SAE 85W-140 PM 90 AVIA HYPOID 90 EP AVIA SYNTOGEAR FE 80W-90 BAYWA HYPOID GETRIEBEÖL 85W-90 BAYWA SUPER 8090 MC XIECHENG 85W-90 GEAR OIL HYPOID-GETRIEBEÖL 80W90 HYPOID-GETRIEBEÖL 85W140 HYPOID-GETRIEBEÖL 90 BP ENERGEAR DL 80W-90 BP ENERGEAR HT 80W-90 BP ENERGEAR HYPO 80W-90 BP ENERGEAR HYPO 85W-140 BP ENERGEAR HYPO 90 ENERGEAR HT 85W140 FRONTOL GETRIEBEÖL FE SAE 80W-90 FRONTOL HYPOID GETRIEBEÖL B SAE 85W-140 FRONTOL HYPOID GETRIEBEÖL B SAE 90 MOTOREX GEAR OIL UNIVERSAL 80W/90 MOTOREX GEAR OIL UNIVERSAL 85W/140 CALPAM MULTI GEAR OIL FE 80W90 CALPAM SUPER GEAR OIL 85W90 GL 5 CASTROL AF-STO 85W140 CASTROL AGRI GEAR GL5 90 CASTROL AGRI GEAR ULTRA CASTROL DYNADRIVE 80W-90 CASTROL EPX 85W-140 CASTROL EPX 90 CASTROL EPX M 90 CASTROL MULTIDRIVE 80W90 CEPSA TRANSMISIONES EP 90 CEPSA TRANSMISIONES EP MULTIG. 85W-140 CEPSA TRANSMISIONES EP MULTIGRADO 80W-90 ERTOIL EP CAMBIOS Y DIFERENCIALES SAE 90 ERTOIL EP MULT. CAMBIOS Y DIFERENCIALES 80W-90 ERTOIL EP MULT. CAMBIOS Y DIFERENCIALES 85W-140 CHEVRON RPM UNIVERSAL GEAR LUBRICANT SAE 80W-90 CHEVRON RPM UNIVERSAL GEAR LUBRICANT SAE 85W-140 GEARTEX EP-B 85W-90 GEARTEX EP-C 85W-140 MULTIGEAR 80W-90 CALTEX HYPOID LD SAE 85W-90 CALTEX HYPOID LD SAE 90 GEAR S 80W90 GEAR S 85W140 TOR SUPER GEAR OIL 80W90 AGIP ROTRA MP 85W-140 AGIP ROTRA TRUCK GEAR 85W-140 ROTRA MP 80W-90 ROTRA TRUCK GEAR 80W-90 ESSO GEAR OIL GX-D 85W-90 ESSO GEAR OIL TDL 80W-90 MOBILUBE HD-A 85W-90 MOBILUBE S 80W-90 FALCON SUPER MP GEAR OIL 85W/140 GL-5 FALCON SUPER MP GEAR OIL 80W/90 GL-5 AKCELA GEAR 135H EP (SAE 80W90) AKCELA GEAR 135H EP (SAE 85W140) AKROS EP 90 SAE 80W90

09 / 2005

1.55.3

Continued FL SELENIA S.P.A., VILLASTELLONE/I FL SELENIA S.P.A., VILLASTELLONE/I FL SELENIA S.P.A., VILLASTELLONE/I FL SELENIA S.P.A., VILLASTELLONE/I FL SELENIA S.P.A., VILLASTELLONE/I FL SELENIA S.P.A., VILLASTELLONE/I FUCHS PETROLUB AG, MANNHEIM/D FUCHS PETROLUB AG, MANNHEIM/D GENOL GMBH & CO., WIEN/A GENOL GMBH & CO., WIEN/A GINOUVES GEORGES SA, LA FARLEDE/F GINOUVES GEORGES SA, LA FARLEDE/F GREAT WALL LUBE OIL CO., BEIJING/CHINA GRUPA LOTOS SA, GDANSK/PL GULF OIL INTERNATIONAL, PITTSBURG/USA HAFA, PARIS/F HANDEL MIJ NOVIOL B.V., NIJMEGEN/NL HUILES BERLIET S.A., SAINT PRIEST/F HUILES BERLIET S.A., SAINT PRIEST/F HUILES BERLIET S.A., SAINT PRIEST/F IGOL FRANCE SA, AMIENS/F IGOL FRANCE SA, AMIENS/F JOHN DEERE, WATERLOO/USA JOHN DEERE, WATERLOO/USA KOMPRESSOL-OEL VERKAUFS GMBH, KÖLN/D KRAFFT S.A., ANDOAIN/E KUWAIT PETROLEUM R&T B.V., EUROPOORT RT/NL KUWAIT PETROLEUM R&T B.V., EUROPOORT RT/NL KUWAIT PETROLEUM R&T B.V., EUROPOORT RT/NL KUWAIT PETROLEUM R&T B.V., EUROPOORT RT/NL KUWAIT PETROLEUM R&T B.V., EUROPOORT RT/NL KUWAIT PETROLEUM R&T B.V., EUROPOORT RT/NL KUWAIT PETROLEUM R&T B.V., EUROPOORT RT/NL KUWAIT PETROLEUM R&T B.V., EUROPOORT RT/NL LIQUI MOLY GMBH, ULM/D LIQUI MOLY GMBH, ULM/D LIQUI MOLY GMBH, ULM/D LIQUI MOLY GMBH, ULM/D LIQUI MOLY GMBH, ULM/D MAROIL S.R.L. CONC. BARDAHL MANU. CO.,ALTOPASCIO/I MAZIVA ZAGREB D.O.O, ZAGREB/HR MAZIVA ZAGREB D.O.O, ZAGREB/HR MAZIVA ZAGREB D.O.O, ZAGREB/HR MAZIVA ZAGREB D.O.O, ZAGREB/HR MEGUIN GMBH & CO. KG MINERALOELWERKE, SAARLOUIS/D MEGUIN GMBH & CO. KG MINERALOELWERKE, SAARLOUIS/D MEGUIN GMBH & CO. KG MINERALOELWERKE, SAARLOUIS/D MEGUIN GMBH & CO. KG MINERALOELWERKE, SAARLOUIS/D MILLERS OILS LIMITED, BRIGHOUSE/GB MINERALÖL-RAFFIN. DOLLBERGEN, UETZE-DOLLBERGEN/D MINERALÖL-RAFFIN. DOLLBERGEN, UETZE-DOLLBERGEN/D MINERALÖL-RAFFIN. DOLLBERGEN, UETZE-DOLLBERGEN/D MINERALÖL-RAFFIN. DOLLBERGEN, UETZE-DOLLBERGEN/D MINERALÖL-RAFFIN. DOLLBERGEN, UETZE-DOLLBERGEN/D MINERALÖL-RAFFIN. DOLLBERGEN, UETZE-DOLLBERGEN/D MODRICA OIL REFINERY, MODRICA/BIH MODRICA OIL REFINERY, MODRICA/BIH MOL-LUB LTD., ALMASFUZITO/H MOL-LUB LTD., ALMASFUZITO/H MORRIS LUBRICANTS, SHREWSBURY/GB MORRIS LUBRICANTS, SHREWSBURY/GB MOTUL SA, AUBERVILLIERS CEDEX/F NEW PROCESS AG, TÜBACH/CH NOVA STILMOIL SPA, MODENA/I OEL-BRACK AG, HUNZENSCHWIL/CH OEL-BRACK AG, HUNZENSCHWIL/CH OEST, GEORG MINERALÖLWERK, FREUDENSTADT/D OEST, GEORG MINERALÖLWERK, FREUDENSTADT/D OEST, GEORG MINERALÖLWERK, FREUDENSTADT/D OMV AG, SCHWECHAT/A OMV AG, SCHWECHAT/A OMV AG, SCHWECHAT/A ORLY INTERNATIONAL G.I.E., VIEUX-THANN/F

1.55.4

ZF Friedrichshafen AG / List of lubricants TE-ML 05, edition 01.04.2005 AMBRA HYPOIDE 140 SAE 85W140 AMBRA HYPOIDE 90 SAE 80W90 ARBOR TRW 140 (SAE 85W140) ARBOR TRW 90 (SAE 80W90) TUTELA W140/M-DA SAE 85W140 TUTELA W90/M-DA SAE 80W90 TITAN GEAR HYP SAE 90 TITAN SUPERGEAR MC 80W-90 GENOL GEAR-SYN 80W-90 GENOL HYPOLUBE 80W-90 YORK 793 SAE 80W90 YORK 793 SAE 85W140 GREATWALL 85W/90 GL-5 LOTOS TITANIS GL-5 SAE 80W/90 GULF GEAR DB 85W 90 HYPOID PL SAE 80W-90 KENDALL NS-MP GEAR LUBE SAE 80W-90 RTO HD 80W-90 RTO LONGEVIA P ECO 80W-140 RTO LONGEVIA P ECO 80W-90 GEAR M 80W90 HYPOID B SAE85W90 GL-5 GEAR LUBRICANT (80W90) GL-5 GEAR LUBRICANT (85W140) KOMPRESSOL-HYPOID EW SAE 80W-90 HIDROIL EP SAE 80W-90 Q8 AUTO 12 SAE 80W-90 Q8 AXLE OIL XG SAE 80W-140 Q8 GEAR OIL XG SAE 80W-90 Q8 T 55 SAE 80W-90 Q8 T 55 SAE 85W-140 Q8 T 55 SAE 90 Q8 T 65 SAE 75W-90 Q8 TRANS XGS SAE 75W-90 HYPOID GETRIEBEÖL GL 5 SAE 80W-90 HYPOID GETRIEBEÖL GL 5 SAE 85W-140 HYPOID GETRIEBEÖL GL 5 SAE 85W-90 HYPOID GETRIEBEÖL GL 5 SAE 90W HYPOID GETRIEBEÖL TDL SAE 80W-90 BARDAHL T&D OIL 80W 90 INA HIPENOL GTL DB 90 INA HIPENOL GTL HD 80W-90 INA HIPENOL GTL HD 85W-140 INA HIPENOL TDL 80W-90 MEGOL HYPOID-GETRIEBEOEL GL 5 SAE 80W-90 MEGOL HYPOID-GETRIEBEOEL GL 5 SAE 85W-140 MEGOL HYPOID-GETRIEBEOEL GL 5 SAE 85W-90 MEGOL HYPOID-GETRIEBEOEL TDL SAE 80W-90 SYNTRAN II/MILLERS TRX 80W/90 PENNASOL HYPOID-GETRIEBEOEL GL 5 SAE 80W90 PENNASOL HYPOID-GETRIEBEOEL GL 5 SAE 85W90 PENNASOL HYPOID-GETRIEBEOEL GL 5 SAE 90 PENNASOL LONGLIFE GEAR GL 5 SAE 80W90 PENNASOL LONGLIFE GEAR GL 5 SAE 85W90 PENNASOL LONGLIFE GEAR GL 5 SAE 90 HIPOIDNO ULJE B SAE 80W90 HIPOIDNO ULJE B SAE 90 MOL HYKOMOL K 85W-90 MOL HYKOMOL KZ 80W-90 MORRIS EP 80W/90 MORRIS EP 85W/140 MOTUL TRANS MB 85W-90 HD GEAROIL SAE 90 GEARING PLUS 80W90 MIDLAND SUPER M 5 80W-90 MIDLAND SUPER M 5 85W90 OEST MEHRZWECK-GETRIEBEÖL FE SAE 80W-90 OEST MEHRZWECK-GETRIEBEÖL SPEZIAL SAE 85W-140 OEST MEHRZWECK-GETRIEBEÖL SPEZIAL SAE 85W-90 OMV GEAR OIL B SAE 85W-90 OMV GEAR OIL XD-5 SAE 80W-90 OMV UNIGEAR SAE 80W-90 ORLY AURIGA EP SAE 85W140

09 / 2005

Continued


ORLY INTERNATIONAL G.I.E., VIEUX-THANN/F PAKELO MOTOR OIL S.R.L, SAN BONIFACIO (VR)/I PAKELO MOTOR OIL S.R.L, SAN BONIFACIO (VR)/I PAKELO MOTOR OIL S.R.L, SAN BONIFACIO (VR)/I PAKELO MOTOR OIL S.R.L, SAN BONIFACIO (VR)/I PAKELO MOTOR OIL S.R.L, SAN BONIFACIO (VR)/I PAKELO MOTOR OIL S.R.L, SAN BONIFACIO (VR)/I PAKELO MOTOR OIL S.R.L, SAN BONIFACIO (VR)/I PAKELO MOTOR OIL S.R.L, SAN BONIFACIO (VR)/I PAKELO MOTOR OIL S.R.L, SAN BONIFACIO (VR)/I PAKELO MOTOR OIL S.R.L, SAN BONIFACIO (VR)/I PAKELO MOTOR OIL S.R.L, SAN BONIFACIO (VR)/I PANOLIN AG, MADETSWIL/CH PANOLIN AG, MADETSWIL/CH PANOLIN AG, MADETSWIL/CH PANOLIN AG, MADETSWIL/CH PETRO-CANADA LUBRICANTS, MISSISSAUGA/CDN PETRO-CANADA LUBRICANTS, MISSISSAUGA/CDN PETROGAL S.A., LISBOA/P PETROGAL S.A., LISBOA/P PETROGAL S.A., LISBOA/P PETROL OFISI A.S, MASLAK-ISTANBUL-TURKEY/TR PRISTA OIL AD, ROUSSE/BG PRISTA OIL AD, ROUSSE/BG PT PERTAMINA (PERSERO), JAKARTA/RI PT PERTAMINA (PERSERO), JAKARTA/RI PT PERTAMINA (PERSERO), JAKARTA/RI RAFINERIA NAFTY JEDLICZE SA, JEDLICZE/PL RAFINERIA NAFTY JEDLICZE SA, JEDLICZE/PL RAFINERIA NAFTY JEDLICZE SA, JEDLICZE/PL RAVENSBERGER SCHMIERSTOFFVERTRIEB GMBH, WERTHER/D RAVENSBERGER SCHMIERSTOFFVERTRIEB GMBH, WERTHER/D RAVENSBERGER SCHMIERSTOFFVERTRIEB GMBH, WERTHER/D RAVENSBERGER SCHMIERSTOFFVERTRIEB GMBH, WERTHER/D REPSOL LUBRICANTES, MADRID/E REPSOL LUBRICANTES, MADRID/E S.A.E.L., MADRID/E SHARJAH NATIONAL LUBE OIL CO. LTD., SHARJAH/UAE SHARJAH NATIONAL LUBE OIL CO. LTD., SHARJAH/UAE SHELL ASEOL AG, BERN 5/CH SHELL ASEOL AG, BERN 5/CH SHELL ASEOL AG, BERN 5/CH SHELL ASEOL AG, BERN 5/CH SHELL BRASIL, BARRA DA TIJUCA - RIO DE JANEIRO/BR SHELL INTERNATIONAL PETROLEUM COMP LTD, LONDON/GB SHELL INTERNATIONAL PETROLEUM COMP LTD, LONDON/GB SHELL INTERNATIONAL PETROLEUM COMP LTD, LONDON/GB SHELL INTERNATIONAL PETROLEUM COMP LTD, LONDON/GB SHELL INTERNATIONAL PETROLEUM COMP LTD, LONDON/GB SHELL INTERNATIONAL PETROLEUM COMP LTD, LONDON/GB SRS SCHMIERSTOFF VERTRIEB GMBH, SALZBERGEN/D SRS SCHMIERSTOFF VERTRIEB GMBH, SALZBERGEN/D SRS SCHMIERSTOFF VERTRIEB GMBH, SALZBERGEN/D SRS SCHMIERSTOFF VERTRIEB GMBH, SALZBERGEN/D STATOIL LUBRICANTS, STOCKHOLM/S STATOIL LUBRICANTS, STOCKHOLM/S STRUB + CO AG, REIDEN/CH SUOMEN PETROOLI OY, HAMINA/FIN SYNECO SPA, SAN GIULIANO MILANESE/I SYNECO SPA, SAN GIULIANO MILANESE/I TEDEX PRODUCTION SP.Z.O.O., TOMASZOW MAZOWIECKI/PL TEXACO BRASIL S.A., RIO DE JANEIRO/BR TOTAL LUBRIFIANTS S.A., PARIS/F TOTAL LUBRIFIANTS S.A., PARIS/F TOTAL LUBRIFIANTS S.A., PARIS/F TOTAL LUBRIFIANTS S.A., PARIS/F TOTAL LUBRIFIANTS S.A., PARIS/F TOTAL LUBRIFIANTS S.A., PARIS/F TOTAL LUBRIFIANTS S.A., PARIS/F TOTAL LUBRIFIANTS S.A., PARIS/F TOTAL LUBRIFIANTS S.A., PARIS/F TOTAL LUBRIFIANTS S.A., PARIS/F TOTAL LUBRIFIANTS S.A., PARIS/F

09 / 2005

ORLY LYRA EP PAKELO GEAR OIL EP GL-5 SAE 80W/90 PAKELO GEAR OIL EP GL-5 SAE 85W/140 PAKELO GLOBAL GEAR CBS SAE 75W/90 PAKELO GLOBAL GEAR DLS SAE 85W/140 PAKELO GLOBAL GEAR DLS SAE 85W/90 PAKELO GLOBAL GEAR SA SAE 80W/90 PAKELO GLOBAL GEAR SA SAE 85W/140 PAKELO GLOBAL GEAR SA SAE 85W/90 PAKELO GLOBAL MULTIGEAR CBS PAKELO GLOBAL MULTIGEAR CBS DLS PAKELO GLOBAL MULTIGEAR SA SAE 80W/140 PANOLIN SUPER DUTY 80W/90 PANOLIN SUPER DUTY 85W/140 PANOLIN SUPER DUTY 90 PANOLIN TOPGEAR 80W/90 TRAXON 80W-90 TRAXON 85W-140 GALP TRANSOIL HP 80W90 GALP TRANSOIL HP 85W140 GALP TRANSVEX TDL 85W140 PO UNI. KEBAN EP MAN 80W/90 PRISTA EP 85W140 PRISTA EP 90 RORED HD-A SAE80W-90 RORED HD-A SAE85W-140 RORED HD-A SAE90 HIPOL EXTRA GL-5 80W-90 HIPOL SUPER GL-5 80W-90 HIPOL SUPER GL-5 85W-90 RAVENOL HYP. EPX GETR.ÖL 85W-140 GL5 RAVENOL HYPOID EPX GETR.-OEL 80W-90 GL 5 RAVENOL HYPOID EPX GETRIEBE-OEL SAE 90 GL-5 RAVENOL SLG SPEC. LKW GETR.ÖL 80W90 CARTAGO EP SAE 90 CARTAGO EP SAE 80W90 GULF MULTIPURPOSE GEAR LUBRICANT 85W-90 SHARLU MP GEAR LUBE 80W/90 (GL-5) SHARLU MP GEAR LUBE 85W/140(GL-5) ASEOL TOPRESS 320 ASEOL TOPRESS 80W-90 ASEOL TOPRESS 85W-140 ASEOL TOPRESS 85W-90 SHELL SPIRAX A 90 SHELL SPIRAX AX 80W-90 SHELL SPIRAX AX 85W-140 SHELL SPIRAX AX 90 SHELL SPIRAX MB 90 SHELL SPIRAX MX 80W-90 SHELL SPIRAX ST 80W-140 WINTERSHALL GETRIEBEFLUID SML 80W-90 WINTERSHALL WIOLIN HYPOID-GETRIEBEÖL 80W-90 WINTERSHALL WIOLIN HYPOID-GETRIEBEÖL 85W-140 WINTERSHALL WIOLIN HYPOID-GETRIEBEÖL 90 GEARWAY G5 80W-90 GEARWAY G5 85W-140 STRUB MULTIGEAR SGO 80W-90 TEBOIL HYPOID SAE 80W-140 AMPLEX 80W90 AMPLEX 85W140 TEDEX SUPER GEAR OIL (3343ML) SAE 80W90 MULTIGEAR EP SAE 90 ANTAR EPR 90 ANTAR EPR 80W-90 ANTAR UNIVERSAL FE 80W-140 ANTAR UNIVERSAL FE 80W-90 FINA PONTONIC A 80W-140 FINA PONTONIC MDL 80W-90 FINA PONTONIC MP 80W-90 FINA PONTONIC MP 85W-140 FINA PONTONIC MP 85W-90 TOTAL EP B 80W-90 TOTAL EP B 85W-90

1.55.5

Continued TOTAL LUBRIFIANTS S.A., PARIS/F TOTAL LUBRIFIANTS S.A., PARIS/F TOTAL LUBRIFIANTS S.A., PARIS/F TOTAL LUBRIFIANTS S.A., PARIS/F TOTAL LUBRIFIANTS S.A., PARIS/F TOTAL LUBRIFIANTS S.A., PARIS/F TOTAL LUBRIFIANTS S.A., PARIS/F TOTAL LUBRIFIANTS S.A., PARIS/F UNIL S.A., SAUMUR CEDEX/F VALVOLINE EUROPE, DORDRECHT/NL VALVOLINE EUROPE, DORDRECHT/NL VALVOLINE EUROPE, DORDRECHT/NL VEEDOL INTERNATIONAL, PANGBOURNE READING/GB VEEDOL INTERNATIONAL, PANGBOURNE READING/GB YACCO, ST PIERRE LES ELBEUF/F ZELLER + GMELIN GMBH & CO., EISLINGEN/D ZELLER + GMELIN GMBH & CO., EISLINGEN/D ZELLER + GMELIN GMBH & CO., EISLINGEN/D ZEPPELIN BAUMASCHINEN GMBH, GARCHING/D ZF FRIEDRICHSHAFEN AG, FRIEDRICHSHAFEN/D

1.55.6

ZF Friedrichshafen AG / List of lubricants TE-ML 05, edition 01.04.2005 TOTAL EP-B 85W-140 TOTAL TRANSMISSION MDL 80W-90 TOTAL TRANSMISSION RS FE 80W-140 TOTAL TRANSMISSION RS FE 80W-90 TRANSELF TYPE B 80W-90 TRANSELF TYPE B 90 TRANSELF UNIVERSAL FE 80W-140 TRANSELF UNIVERSAL FE 80W-90 UNIL OPAL GEAR ZF 80W90 HIGH PERFORMANCE GEAR OIL GL-5 90 VALVOLINE STX GEAR OIL GL-5 80W-140 VALVOLINE STX GEAR OIL GL-5 80W-90 VEEDOL MULTIGEAR B SAE 90 VEEDOL MULTIGEAR C SAE 85W-140 BVX C 100 80W-90 DIVINOL GEAR OIL STO SAE 80W-90 DIVINOL HYPOID-GETRIEBEÖL SAE 85W-140 DIVINOL SYNTHOGEAR SAE 75W-90 ZEPPELIN SPEZIALGETRIEBEÖL GL-4/GL-5 80W-90 ZF-ECOFLUID X

09 / 2005

Continued


Lubricant class 05B Gear oilx Viscosity grades: SAE 75W-90 / 75W-140x Manufacturer (05B)

Trade name (05B)

AGIP SCHMIERTECHNIK GMBH, WÜRZBURG/D AGIP SCHMIERTECHNIK GMBH, WÜRZBURG/D AVIA MINERALÖL-AG, MÜNCHEN/D BP INTERNATIONAL, PANGBOURNE, READING/GB BP INTERNATIONAL, PANGBOURNE, READING/GB BUCHER AG LANGENTHAL, LANGENTHAL/CH CASTROL INTERNATIONAL, PANGBOURNE READING/GB CASTROL INTERNATIONAL, PANGBOURNE READING/GB CASTROL INTERNATIONAL, PANGBOURNE READING/GB CEPSA LUBRICANTS S.A., MADRID/E CHEVRONTEXACO, GHENT/B DE OLIEBRON B.V., ZWIJNDRECHT/NL ENI S.P.A. REFINING & MARKETING DIVISION, ROME/I EXXON MOBIL CORPORATION, FAIRFAX, VIRGINIA/USA EXXON MOBIL CORPORATION, FAIRFAX, VIRGINIA/USA FUCHS PETROLUB AG, MANNHEIM/D GINOUVES GEORGES SA, LA FARLEDE/F HAFA, PARIS/F HUILES BERLIET S.A., SAINT PRIEST/F IGOL FRANCE SA, AMIENS/F MEGUIN GMBH & CO. KG MINERALOELWERKE, SAARLOUIS/D MILLERS OILS LIMITED, BRIGHOUSE/GB MOTUL SA, AUBERVILLIERS CEDEX/F NEW PROCESS AG, TÜBACH/CH OEST, GEORG MINERALÖLWERK, FREUDENSTADT/D OMV AG, SCHWECHAT/A PAKELO MOTOR OIL S.R.L, SAN BONIFACIO (VR)/I PANOLIN AG, MADETSWIL/CH PETROGAL S.A., LISBOA/P S.A.E.L., MADRID/E SHELL INTERNATIONAL PETROLEUM COMP LTD, LONDON/GB SRS SCHMIERSTOFF VERTRIEB GMBH, SALZBERGEN/D STRUB + CO AG, REIDEN/CH SUOMEN PETROOLI OY, HAMINA/FIN SUOMEN PETROOLI OY, HAMINA/FIN TOTAL LUBRIFIANTS S.A., PARIS/F TOTAL LUBRIFIANTS S.A., PARIS/F TOTAL LUBRIFIANTS S.A., PARIS/F TOTAL LUBRIFIANTS S.A., PARIS/F VALVOLINE EUROPE, DORDRECHT/NL VALVOLINE EUROPE, DORDRECHT/NL VALVOLINE EUROPE, DORDRECHT/NL VEEDOL INTERNATIONAL, PANGBOURNE READING/GB YACCO, ST PIERRE LES ELBEUF/F

AGIP HLX, SAE 75W-90 AGIP ROTRA TRUCK GEAR S, SAE 75W-90 AVIA SYNTOGEAR FE 75W-90 EP BP ENERGEAR SHX 75W90 ENERGEAR SHX-M SAE 75W-90 MOTOREX UNISYNT TX CASTROL DYNADRIVE PLUS 75W90 CASTROL SAF-XO SAE 75W-90 SAF-XT CEPSA TRANSMISIONES EP FE+LD 75W-90 MULTIGEAR S 75W-90 TOR UNIGEAR 75W90 LD ROTRA LSX 75W-90 ESSO GEAR OIL TDL 75W-90 MOBILUBE 1 SHC 75W-90 TITAN CYTRAC HSY SAE 75W-90 YORK 896 EUROGEAR SAE 75W-90 RTO LONGEVIA PXD ECO 75W-90 SYNTHEGEAR SAE75W90 MEGOL GETRIEBEOEL TRUCK-SYNTH SAE 75W-90 SYNTRAN FE/MILLERS TRX SYNTH 75W/90 MOTUL GEAR SYNT TDL 75W-90 GEAROIL SYNTH OEST SYNTH GETRIEBEÖL SAE 75W-90 OMV UNIGEAR S SAE 75W-90 PAKELO GLOBAL MULTIGEAR TS SAE 75W/90 PANOLIN SUPER DUTY SYNTH 75W/90 GALP TRANSVEX TDL 75W90 GULF SYTHETIC GEAR LUBRICANT 75W-90 SHELL SPIRAX ASX 75W-90 WINTERSHALL GETRIEBEFLUID BOS VULCOGEAR SYNT SGX 75W-90 TEBOIL HYPOID SAE 75W-140 TEBOIL HYPOID SAE 75W-90 ANTAR EPS 75W-90 FINA PONTONIC FDL 75W-90 TOTAL TRANSMISSION SYN FE 75W-90 TRANSELF SYNTHESE FE 75W-90 SYNPOWER GEAR OIL TDL 75W-90 VALVOLINE SYNPOWER STX GL-5 75W-140 VALVOLINE SYNPOWER STX GL-5 75W-90 VEEDOL SAF 66 BVX 1000

09 / 2005

1.55.7

Continued


Lubricant class 05C Gear oil with limited-slip-additivesx Viscosity grades: SAE 80W-90 / 80W-140 / 85W-90 / 85W-140 / 90x Manufacturer (05C)

Trade name (05C)

ADDINOL LUBE OIL GMBH, LEUNA/D ADDINOL LUBE OIL GMBH, LEUNA/D ARAL AG, BOCHUM/D AVIA MINERALÖL-AG, MÜNCHEN/D AVIA MINERALÖL-AG, MÜNCHEN/D BAYWA AG, MÜNCHEN/D BLASER SWISSLUBE AG, HASLE-RÜEGSAU/CH BP INTERNATIONAL, PANGBOURNE, READING/GB BP INTERNATIONAL, PANGBOURNE, READING/GB BUCHER AG LANGENTHAL, LANGENTHAL/CH CALPAM MINERALÖL-GMBH, ASCHAFFENBURG/D CASTROL INTERNATIONAL, PANGBOURNE READING/GB CASTROL INTERNATIONAL, PANGBOURNE READING/GB CHEVRONTEXACO, GHENT/B CHEVRONTEXACO, GHENT/B CHEVRONTEXACO, SYDNEY/AUS CHEVRONTEXACO, SYDNEY/AUS CHEVRONTEXACO, SYDNEY/AUS CONDAT LUBRIFIANTS, CHASSE SUR RHONE/F CONDAT LUBRIFIANTS, CHASSE SUR RHONE/F DE OLIEBRON B.V., ZWIJNDRECHT/NL ENGEN PETROLEUM LTD., CAPE TOWN/ZA ENI S.P.A. REFINING & MARKETING DIVISION, ROME/I EXXON MOBIL CORPORATION, FAIRFAX, VIRGINIA/USA EXXON MOBIL CORPORATION, FAIRFAX, VIRGINIA/USA FL SELENIA S.P.A., VILLASTELLONE/I FL SELENIA S.P.A., VILLASTELLONE/I FL SELENIA S.P.A., VILLASTELLONE/I FUCHS PETROLUB AG, MANNHEIM/D HAFA, PARIS/F HUILES BERLIET S.A., SAINT PRIEST/F IGOL FRANCE SA, AMIENS/F JOHN DEERE, WATERLOO/USA KOMPRESSOL-OEL VERKAUFS GMBH, KÖLN/D KUWAIT PETROLEUM R&T B.V., EUROPOORT RT/NL LIQUI MOLY GMBH, ULM/D MAZIVA ZAGREB D.O.O, ZAGREB/HR MEGUIN GMBH & CO. KG MINERALOELWERKE, SAARLOUIS/D MINERALÖL-RAFFIN. DOLLBERGEN, UETZE-DOLLBERGEN/D MOL-LUB LTD., ALMASFUZITO/H NOVA STILMOIL SPA, MODENA/I OEST, GEORG MINERALÖLWERK, FREUDENSTADT/D OMV AG, SCHWECHAT/A ORLY INTERNATIONAL G.I.E., VIEUX-THANN/F PAKELO MOTOR OIL S.R.L, SAN BONIFACIO (VR)/I PAKELO MOTOR OIL S.R.L, SAN BONIFACIO (VR)/I PANOLIN AG, MADETSWIL/CH PETROGAL S.A., LISBOA/P RAVENSBERGER SCHMIERSTOFFVERTRIEB GMBH, WERTHER/D REPSOL LUBRICANTES, MADRID/E S.A.E.L., MADRID/E SHELL ASEOL AG, BERN 5/CH SHELL INTERNATIONAL PETROLEUM COMP LTD, LONDON/GB SHELL INTERNATIONAL PETROLEUM COMP LTD, LONDON/GB SRS SCHMIERSTOFF VERTRIEB GMBH, SALZBERGEN/D TEXACO BRASIL S.A., RIO DE JANEIRO/BR TOTAL LUBRIFIANTS S.A., PARIS/F TOTAL LUBRIFIANTS S.A., PARIS/F TOTAL LUBRIFIANTS S.A., PARIS/F TOTAL LUBRIFIANTS S.A., PARIS/F UNIL S.A., SAUMUR CEDEX/F VEEDOL INTERNATIONAL, PANGBOURNE READING/GB YACCO, ST PIERRE LES ELBEUF/F ZEPPELIN BAUMASCHINEN GMBH, GARCHING/D

ADDINOL GETRIEBEÖL GH 80W-90 LS ADDINOL GETRIEBEÖL GH 85W-90 LS ARAL GETRIEBEOL HYP LS 90 AVIA HYPOID 90 LS AVIA HYPOID 90 LS, 85W-90 BAYWA GETRIEBEÖL HYPOID LS 90 GETRIEBEÖL LS 85W90 BP ENERGEAR LIMSLIP 90 FRONTOL GETRIEBEÖL LS 90 MOTOREX GEAR OIL UNIVERSAL LS 80W/90 CALPAM GEAR OIL LS 90 CASTROL HYPOY LS 90 CASTROL LSX GEARTEX LS 80W-90 GEARTEX LS 85W-90 CALTEX GEAR OIL ZF SAE 80W-90 CALTEX GEAR OIL ZF SAE 85W-140 CALTEX GEAR OIL ZF SAE 90 GEAR T ( 90 ) GEAR T (80W90) TOR SUPER GEAR OIL LS 80W90 ENGEN GEARLUBE EP 90 LS - SAE 80W-90 AGIP ROTRA MP/S 85W-90 ESSO GEAR OIL LSA 85W-90 MOBILUBE LS 85W-90 AKCELA AXLEPOWER (80W90) AMBRA AXF 80W90 AMBRA STF (80W90) TITAN GEAR LS 90 HYPOID PA SAE 80W-90 RTO EP 90 GL HYPOID BPA SAE90 GL-5 GEAR LUBRICANT WITH LS ADDITIVE (85W140) KOMPRESSOL-HYPOID LS SAE 90 Q8 T 45 SAE 90 HYPOID GETRIEBEÖL GL 5 SAE 85W-90 LS INA HIPENOL GTL LS 90 MEGOL HYPOID-GETRIEBEOEL GL 5 SAE 85W-90 LS PENNASOL SPERRDIFFERENTIAL HYPOID GETRIEBEOEL LS90 MOL HYKOMOL LS 85W-90 GEARING WONDER LS SAE 85W90 OEST GETRIEBEÖL HYPOID LS 90 OMV GEAR OIL LS SAE 85W-90 ORLY TUCANA LS PAKELO UNIVERSAL GEAR EP/LS SAE 85W/140 PAKELO UNIVERSAL GEAR EP/LS SAE 80W/90 PANOLIN SUPER DUTY LS 90 GALP LS 90 RAVENOL SPERRDIFF.-GETR.-OEL LS 90 CS EP AUTOBLOCANTE SAE 85W140 GULF LS REAR AXLE OIL 80W-90 ASEOL TOPRESS LS 85W-90 SHELL SPIRAX A LS 85W-140 SHELL SPIRAX A LS 90 WINTERSHALL WIOLIN RSH GEARTEX LS 85W140 ANTAR BLS 90 FINA PONTONIC LS 80W-90 TOTAL TRANSMISSION DA 80W-90 TRANSELF BLS 90 UNIL OPAL GEAR AB-EP SAE 85W90 VEEDOL MULTIGEAR LS SAE 90 BVX LS 200 ZEPPELIN SPEZIALGETRIEBEÖL GL-5 LS 90

1.55.8

09 / 2005

Continued


Lubricant class 05D Gear oil with limited-slip-additives Viscosity grades: SAE 75W-90 / 75W-140 Manufacturer (05D)

Trade name (05D)

AGIP SCHMIERTECHNIK GMBH, WÜRZBURG/D BP INTERNATIONAL, PANGBOURNE, READING/GB BP INTERNATIONAL, PANGBOURNE, READING/GB CASTROL INTERNATIONAL, PANGBOURNE READING/GB CASTROL INTERNATIONAL, PANGBOURNE READING/GB CASTROL INTERNATIONAL, PANGBOURNE READING/GB EXXON MOBIL CORPORATION, FAIRFAX, VIRGINIA/USA SRS SCHMIERSTOFF VERTRIEB GMBH, SALZBERGEN/D TOTAL LUBRIFIANTS S.A., PARIS/F TOTAL LUBRIFIANTS S.A., PARIS/F VEEDOL INTERNATIONAL, PANGBOURNE READING/GB VEEDOL INTERNATIONAL, PANGBOURNE READING/GB

AGIP HLZ, SAE 75W-140 BP ENERGEAR SHX S 75W140 BP ENERGEAR SHX-ZR 75W-140 CASTROL SAF-X SAE 75W-140 CASTROL SAF-XJ SAE 75W-140 CASTROL SAF-XLS SAE 75W-90 MOBIL GEARLUBE VS 500 WINTERSHALL GETRIEBEFLUID BMS PLUS FINA PONTONIC MLX 75W-140 TOTAL TRANSMISSION LS 75W-140 VEEDOL SAF 22 VEEDOL SAF 44

09 / 2005

1.55.9

Continued


Lubricant class 05E Universal Tractor Transmission Oil (UTTO) Viscosity grades: SAE 20W-40 / 80W-140 Manufacturer (05E)

Trade name (05E)

CASTROL INTERNATIONAL, PANGBOURNE READING/GB CNH, BURR RIDGE/USA EXXON MOBIL CORPORATION, FAIRFAX, VIRGINIA/USA FUCHS PETROLUB AG, MANNHEIM/D MAZIVA ZAGREB D.O.O, ZAGREB/HR OMV AG, SCHWECHAT/A PAKELO MOTOR OIL S.R.L, SAN BONIFACIO (VR)/I STRUB + CO AG, REIDEN/CH

KOMATSU WBL 20W40 CASE TRANSAXLE FLUID, SAE 80W-140 MOBILFLUID 2040 TITAN UTTO ZF SAE 20W-40 INA TRANSHIDROL ZF 20W-40 OMV AUSTROMATIC ZF SAE 20W-40 PAKELO UTTO FLUID 4D SAE 20W/40 VULCOTRAC UTTO SAE 20W-40

1.55.10

09 / 2005

Continued


Lubricant class 05F Universal Tractor Transmission Oil (UTTO) Manufacturer (05F)

Trade name (05F)

76 LUBRICANTS (CONOCOPHILLIPS COMP.), HOUSTON/USA ARAL AG, BOCHUM/D AVIA MINERALÖL-AG, MÜNCHEN/D BP INTERNATIONAL, PANGBOURNE, READING/GB BP INTERNATIONAL, PANGBOURNE, READING/GB BP INTERNATIONAL, PANGBOURNE, READING/GB BP INTERNATIONAL, PANGBOURNE, READING/GB BUCHER AG LANGENTHAL, LANGENTHAL/CH CASTROL INTERNATIONAL, PANGBOURNE READING/GB CASTROL INTERNATIONAL, PANGBOURNE READING/GB CASTROL INTERNATIONAL, PANGBOURNE READING/GB CHEVRONTEXACO, GHENT/B CHEVRONTEXACO, GHENT/B ENGEN PETROLEUM LTD., CAPE TOWN/ZA EXXON MOBIL CORPORATION, FAIRFAX, VIRGINIA/USA EXXON MOBIL CORPORATION, FAIRFAX, VIRGINIA/USA EXXON MOBIL CORPORATION, FAIRFAX, VIRGINIA/USA EXXON MOBIL CORPORATION, FAIRFAX, VIRGINIA/USA FL SELENIA S.P.A., VILLASTELLONE/I FUCHS PETROLUB AG, MANNHEIM/D GINOUVES GEORGES SA, LA FARLEDE/F IGOL FRANCE SA, AMIENS/F KENDALL MOTOR OIL (CONOCOPHILLIPS C.), HOUSTON/USA KUWAIT PETROLEUM R&T B.V., EUROPOORT RT/NL KUWAIT PETROLEUM R&T B.V., EUROPOORT RT/NL OEL-BRACK AG, HUNZENSCHWIL/CH OMV AG, SCHWECHAT/A PAKELO MOTOR OIL S.R.L, SAN BONIFACIO (VR)/I PANOLIN AG, MADETSWIL/CH PETROGAL S.A., LISBOA/P RAVENSBERGER SCHMIERSTOFFVERTRIEB GMBH, WERTHER/D REPSOL LUBRICANTES, MADRID/E SHELL ASEOL AG, BERN 5/CH SHELL INTERNATIONAL PETROLEUM COMP LTD, LONDON/GB SHELL INTERNATIONAL PETROLEUM COMP LTD, LONDON/GB SRS SCHMIERSTOFF VERTRIEB GMBH, SALZBERGEN/D

76 HYDRAULIC/TRACTOR FLUID ARAL FLUID HGS 10W-30 AVIA HYDROFLUID DLZ BP OLEX GO 4926 BP TERRAC SUPER TRANSMISSION 10W-30 BP TERRAC SUPER TRANSMISSION CVT 10W-30 BP TRACTRAN TF 10 MOTOREX POLYFARM 304 CASTROL AGRI TRANS PLUS 10W-30 CASTROL AGRI TRANS PLUS CVT 10W-30 CASTROL KOMATSU UTTO 10W-30 TEXTRAN TDH TEXTRAN TDH PREMIUM ENGEN AGRIFLUID ESSO TORQUE FLUID 56 MOBIL AGRIFLUID 424 MOBILFLUID 424 MOBILFLUID 426 AMBRA MULTI G TITAN UTTO J20C YORK 676 SAE 10W30 TICMA FLUID MU SAE80W KENDALL HYKEN 052 Q8 T 2000 Q8 T 2200 MIDLAND TOU OMV AUSTROMATIC IGB SAE 10W-30 PAKELO UTTO FLUID 4D SAE 10W/30 PANOLIN JD 303 GALP TRALUB 807S RAVENOL UTTO AGRO ORION SAE 10W30 ASEOL MULTITRAC 85W SHELL DONAX TD 10W-30 SHELL DONAX TD 5W-30 WINTERSHALL HYDROFLUID N

09 / 2005

1.55.11

Continued


Lubricant class 05G Universal construction-machinery oil Manufacturer (05G)

Trade name (05G)

CATERPILLAR INC., PEORIA/USA JOHN DEERE, MANNHEIM/D ZF FRIEDRICHSHAFEN AG, FRIEDRICHSHAFEN/D

CATERPILLAR MULTIPURPOSE TRACTOR OIL (MTO) 10W-30 JOHN DEERE HY-GARD ZF-POWERFLUID

1.55.12

09 / 2005

Off-Road Driveline Technology and Axle Systems

Hydrostatic and mechanical drives and electric drive systems Product groups

List of lubricants TE-ML 07 Lubricant classes for service fills (1)

Alternative lubricant classes for service fills (1)

07B / 07D / 07E

---

07C / 07E

07D

07A / 07C / 07E

07D

Powershift transmissions AVG (2) HL Mobile mixer drives Common oil circuit for transmissionx and hydrostatic systemx P3200 PLM 7, PLM 9 Mobile mixer drives Separate oil circuits for transmissionx and hydrostatic systemx P3301, P4300, P5300, P6300, P7300 PK5300, PK6500, PK7500 Transmissions for lifting equipment RME, RMT Swing drives DR

07A / 07E

---

07D / 07E Mineral oil-based Hydraulic oil: - DIN 51524-02 (HLP) and - ISO VG 46 / 68

---

(1) Refer to the following pages for approved commercial products and low temperature limits. (2) For AVGs directly mounted on ZF axles, use gear oils in accordance with TE-ML 05 for the common oil circuit of the transmission and axle A lithium saponified multipurpose grease of NLGI class 2 which is mixable with mineral oil is to be used at greasing points (grease code KP2K-30 in acc. with DIN 51825 or ISO-L-XCCHB2 in accordance with ISO 6743-9).

Additives of any kind added later to the oil change the oil in a manner that is unpredictable, and they are therefore not permitted. No liability of any kind will be accepted by ZF for any damage resulting from the use of such additives.

Note low-temperature limits on page 2!

The list of lubricants TE-ML 07, Edition 01.04.2005 replaces all previous editions. The current list can be requested from any ZF after-sales service center or accessed on the Internet under www.zf.com.

09 / 2005

ZF Passau GmbH ZF Friedrichshafen AG D-94030 Passau D-88038 Friedrichshafenx phone: + 49 7541 77 7181 fax: + 49 7541 77 7319

1.56.1

Continued

ZF Friedrichshafen AG / List of lubricants TE-ML 07, edition 01.041

Low temperatures limits Use at outside temperatures above (3) Lubricant classes

07A

viscosity grades

- SAE 75W-90, 75W-140 - SAE 80W-85, 80W-90, 80W-140

Powershift transmissions; Mobile mixer drives with common oil circuit;x (with pump)

---

- SAE 85W-90, 85W-140, 90

Mobile mixer drives with separate oil circuit; Transmissions for lifting equipment; Swing drives; (without pump) -40°C -26°C -12°C

07C, 07D

- SAE 5W-30, 5W-40

-35°C

-40°C

07E

- SAE 75W-80, ISO VG 46 (only 07E)

-35°C

-40°C

07B, 07C, 07D

- SAE 10W-30, 10W-40

-30°C

-35°C

07B, 07C, 07D

- SAE 15W-30, 15W-40

-25°C

-30°C

07D

- SAE 20W-20

-20°C

-25°C

07B

- SAE 20W-40

-20°C

---

07D

- SAE 30

-5°C

-10°C

Hydraulic oil

- ISO VG 46

---

-10°C

- ISO VG 68

---

-5°C

(3) An even warm-up phase is needed in order to reach the minimum oil temperature required for starting the drive unit (mentioned low temperature limit). At outside temperatures below -5°C, a warm-up phase of at least 10 minutes is required, irrespective of the viscosity grade used.

1.56.2

09 / 2005

Continued


Lubricant class 07A Gear oil Viscosity grades: SAE 75W-90 / 75W-140 / 80W-85 / 80W-90 / 80W-140 / 85W-90 / 85W-140 / 90 Note: Other gear oils may be used in addition to those listed, if they satisfy the following specifications: - SAE 80W-85 / 80W-90 / 80W-140 / 85W-90 / 85W-140 / 90 - API GL-5 and MIL-L-2105 D or - MIL-PRF-2105E or - SAE J 2360 Manufacturer (07A)

Trade name (07A)

ADDINOL LUBE OIL GMBH, LEUNA/D ADDINOL LUBE OIL GMBH, LEUNA/D ADDINOL LUBE OIL GMBH, LEUNA/D AGIP SCHMIERTECHNIK GMBH, WÜRZBURG/D AGIP SCHMIERTECHNIK GMBH, WÜRZBURG/D ARAL AG, BOCHUM/D ARAL AG, BOCHUM/D ARAL AG, BOCHUM/D ARAL AG, BOCHUM/D ARMORINE S.A., LANESTER CEDEX/F AVIA MINERALÖL-AG, MÜNCHEN/D AVIA MINERALÖL-AG, MÜNCHEN/D AVIA MINERALÖL-AG, MÜNCHEN/D BAYWA AG, MÜNCHEN/D BAYWA AG, MÜNCHEN/D BEIJING TONGYI PETROLEUM CH. CO. LTD., BEIJING/CN BLASER SWISSLUBE AG, HASLE-RÜEGSAU/CH BLASER SWISSLUBE AG, HASLE-RÜEGSAU/CH BLASER SWISSLUBE AG, HASLE-RÜEGSAU/CH BP INTERNATIONAL, PANGBOURNE, READING/GB BP INTERNATIONAL, PANGBOURNE, READING/GB BP INTERNATIONAL, PANGBOURNE, READING/GB BP INTERNATIONAL, PANGBOURNE, READING/GB BP INTERNATIONAL, PANGBOURNE, READING/GB BP INTERNATIONAL, PANGBOURNE, READING/GB BP INTERNATIONAL, PANGBOURNE, READING/GB BP INTERNATIONAL, PANGBOURNE, READING/GB BP INTERNATIONAL, PANGBOURNE, READING/GB BP INTERNATIONAL, PANGBOURNE, READING/GB BUCHER AG LANGENTHAL, LANGENTHAL/CH BUCHER AG LANGENTHAL, LANGENTHAL/CH BUCHER AG LANGENTHAL, LANGENTHAL/CH BUCHER AG LANGENTHAL, LANGENTHAL/CH CALPAM MINERALÖL-GMBH, ASCHAFFENBURG/D CALPAM MINERALÖL-GMBH, ASCHAFFENBURG/D CASTROL INTERNATIONAL, PANGBOURNE READING/GB CASTROL INTERNATIONAL, PANGBOURNE READING/GB CASTROL INTERNATIONAL, PANGBOURNE READING/GB CASTROL INTERNATIONAL, PANGBOURNE READING/GB CASTROL INTERNATIONAL, PANGBOURNE READING/GB CASTROL INTERNATIONAL, PANGBOURNE READING/GB CASTROL INTERNATIONAL, PANGBOURNE READING/GB CASTROL INTERNATIONAL, PANGBOURNE READING/GB CASTROL INTERNATIONAL, PANGBOURNE READING/GB CEPSA LUBRICANTS S.A., MADRID/E CEPSA LUBRICANTS S.A., MADRID/E CEPSA LUBRICANTS S.A., MADRID/E CEPSA LUBRICANTS S.A., MADRID/E CEPSA LUBRICANTS S.A., MADRID/E CEPSA LUBRICANTS S.A., MADRID/E CEPSA LUBRICANTS S.A., MADRID/E CHEVRONTEXACO GLOBAL LUBRICANTS, SAN RAMON/USA CHEVRONTEXACO GLOBAL LUBRICANTS, SAN RAMON/USA CHEVRONTEXACO, GHENT/B

ADDINOL GETRIEBEÖL GH 80W-90 ADDINOL GETRIEBEÖL GH 85W-90 ADDINOL GETRIEBEÖL GX 80 W 90 ML AGIP ROTRA TRUCK GEAR S, SAE 75W-90 AUTOL HYPOID-GETRIEBEÖL SAE 80W-90 ARAL GETRIEBEOL EP PLUS 80W-90 ARAL GETRIEBEOL HYP 85W-90 ARAL GETRIEBEÖL HYP SAE 85W-140 ARAL GETRIEBEÖL SNA-C SAE 75W-90 PM 90 AVIA HYPOID 90 EP AVIA SYNTOGEAR FE 75W-90 EP AVIA SYNTOGEAR FE 80W-90 BAYWA HYPOID GETRIEBEÖL 85W-90 BAYWA SUPER 8090 MC XIECHENG 85W-90 GEAR OIL HYPOID-GETRIEBEÖL 80W90 HYPOID-GETRIEBEÖL 85W140 HYPOID-GETRIEBEÖL 90 BP ENERGEAR DL 80W-90 BP ENERGEAR HT 80W-90 BP ENERGEAR HYPO 80W-90 BP ENERGEAR HYPO 85W-140 BP ENERGEAR HYPO 90 ENERGEAR HT 85W140 ENERGEAR SHX-M SAE 75W-90 FRONTOL GETRIEBEÖL FE SAE 80W-90 FRONTOL HYPOID GETRIEBEÖL B SAE 85W-140 FRONTOL HYPOID GETRIEBEÖL B SAE 90 MOTOREX GEAR OIL UNIVERSAL 80W/90 MOTOREX GEAR OIL UNIVERSAL 85W/140 MOTOREX PENTA TL MOTOREX UNISYNT TX CALPAM MULTI GEAR OIL FE 80W90 CALPAM SUPER GEAR OIL 85W90 GL 5 CASTROL AF-STO 85W140 CASTROL AGRI GEAR GL5 90 CASTROL AGRI GEAR ULTRA CASTROL DYNADRIVE 80W-90 CASTROL DYNADRIVE PLUS 75W90 CASTROL EPX 85W-140 CASTROL EPX 90 CASTROL EPX M 90 CASTROL MULTIDRIVE 80W90 CEPSA TRANSMISIONES EP 90 CEPSA TRANSMISIONES EP FE+LD 75W-90 CEPSA TRANSMISIONES EP MULTIG. 85W-140 CEPSA TRANSMISIONES EP MULTIGRADO 80W-90 ERTOIL EP CAMBIOS Y DIFERENCIALES SAE 90 ERTOIL EP MULT. CAMBIOS Y DIFERENCIALES 80W-90 ERTOIL EP MULT. CAMBIOS Y DIFERENCIALES 85W-140 CHEVRON RPM UNIVERSAL GEAR LUBRICANT SAE 80W-90 CHEVRON RPM UNIVERSAL GEAR LUBRICANT SAE 85W-140 GEARTEX EP-B 85W-90

09 / 2005

1.56.3

Continued CHEVRONTEXACO, GHENT/B CHEVRONTEXACO, GHENT/B CHEVRONTEXACO, GHENT/B CHEVRONTEXACO, SYDNEY/AUS CHEVRONTEXACO, SYDNEY/AUS COGNIS DEUTSCHLAND GMBH, DÜSSELDORF/D CONDAT LUBRIFIANTS, CHASSE SUR RHONE/F CONDAT LUBRIFIANTS, CHASSE SUR RHONE/F DE OLIEBRON B.V., ZWIJNDRECHT/NL DE OLIEBRON B.V., ZWIJNDRECHT/NL ENI S.P.A. REFINING & MARKETING DIVISION, ROME/I ENI S.P.A. REFINING & MARKETING DIVISION, ROME/I ENI S.P.A. REFINING & MARKETING DIVISION, ROME/I ENI S.P.A. REFINING & MARKETING DIVISION, ROME/I ENI S.P.A. REFINING & MARKETING DIVISION, ROME/I EXXON MOBIL CORPORATION, FAIRFAX, VIRGINIA/USA EXXON MOBIL CORPORATION, FAIRFAX, VIRGINIA/USA EXXON MOBIL CORPORATION, FAIRFAX, VIRGINIA/USA EXXON MOBIL CORPORATION, FAIRFAX, VIRGINIA/USA EXXON MOBIL CORPORATION, FAIRFAX, VIRGINIA/USA EXXON MOBIL CORPORATION, FAIRFAX, VIRGINIA/USA FALCON OIL COMPANY LTD., SHARJAH/UAE FALCON OIL COMPANY LTD., SHARJAH/UAE FL SELENIA S.P.A., VILLASTELLONE/I FL SELENIA S.P.A., VILLASTELLONE/I FL SELENIA S.P.A., VILLASTELLONE/I FL SELENIA S.P.A., VILLASTELLONE/I FL SELENIA S.P.A., VILLASTELLONE/I FL SELENIA S.P.A., VILLASTELLONE/I FL SELENIA S.P.A., VILLASTELLONE/I FL SELENIA S.P.A., VILLASTELLONE/I FL SELENIA S.P.A., VILLASTELLONE/I FUCHS PETROLUB AG, MANNHEIM/D FUCHS PETROLUB AG, MANNHEIM/D FUCHS PETROLUB AG, MANNHEIM/D FUCHS PETROLUB AG, MANNHEIM/D GENOL GMBH & CO., WIEN/A GENOL GMBH & CO., WIEN/A GINOUVES GEORGES SA, LA FARLEDE/F GINOUVES GEORGES SA, LA FARLEDE/F GINOUVES GEORGES SA, LA FARLEDE/F GREAT WALL LUBE OIL CO., BEIJING/CHINA GRUPA LOTOS SA, GDANSK/PL GULF OIL INTERNATIONAL, PITTSBURG/USA HAFA, PARIS/F HAFA, PARIS/F HANDEL MIJ NOVIOL B.V., NIJMEGEN/NL HUILES BERLIET S.A., SAINT PRIEST/F HUILES BERLIET S.A., SAINT PRIEST/F HUILES BERLIET S.A., SAINT PRIEST/F HUILES BERLIET S.A., SAINT PRIEST/F IGOL FRANCE SA, AMIENS/F IGOL FRANCE SA, AMIENS/F IGOL FRANCE SA, AMIENS/F JOHN DEERE, WATERLOO/USA JOHN DEERE, WATERLOO/USA KOMPRESSOL-OEL VERKAUFS GMBH, KÖLN/D KRAFFT S.A., ANDOAIN/E KUWAIT PETROLEUM R&T B.V., EUROPOORT RT/NL KUWAIT PETROLEUM R&T B.V., EUROPOORT RT/NL KUWAIT PETROLEUM R&T B.V., EUROPOORT RT/NL KUWAIT PETROLEUM R&T B.V., EUROPOORT RT/NL KUWAIT PETROLEUM R&T B.V., EUROPOORT RT/NL KUWAIT PETROLEUM R&T B.V., EUROPOORT RT/NL KUWAIT PETROLEUM R&T B.V., EUROPOORT RT/NL KUWAIT PETROLEUM R&T B.V., EUROPOORT RT/NL LIQUI MOLY GMBH, ULM/D LIQUI MOLY GMBH, ULM/D LIQUI MOLY GMBH, ULM/D LIQUI MOLY GMBH, ULM/D LIQUI MOLY GMBH, ULM/D MAROIL S.R.L. CONC. BARDAHL MANU. CO.,ALTOPASCIO/I MAZIVA ZAGREB D.O.O, ZAGREB/HR

1.56.4

ZF Friedrichshafen AG / List of lubricants TE-ML 07, edition 01.04.2005 GEARTEX EP-C 85W-140 MULTIGEAR 80W-90 MULTIGEAR S 75W-90 CALTEX HYPOID LD SAE 85W-90 CALTEX HYPOID LD SAE 90 COGNIS EMGARD UAF 4209, SAE 75W-90 GEAR S 80W90 GEAR S 85W140 TOR SUPER GEAR OIL 80W90 TOR UNIGEAR 75W90 LD AGIP ROTRA MP 85W-140 AGIP ROTRA TRUCK GEAR 85W-140 ROTRA LSX 75W-90 ROTRA MP 80W-90 ROTRA TRUCK GEAR 80W-90 ESSO GEAR OIL GX-D 85W-90 ESSO GEAR OIL TDL 75W-90 ESSO GEAR OIL TDL 80W-90 MOBILUBE 1 SHC 75W-90 MOBILUBE HD-A 85W-90 MOBILUBE S 80W-90 FALCON SUPER MP GEAR OIL 85W/140 GL-5 FALCON SUPER MP GEAR OIL 80W/90 GL-5 AKCELA GEAR 135H EP (SAE 80W90) AKCELA GEAR 135H EP (SAE 85W140) AKROS EP 90 SAE 80W90 AMBRA HYPOIDE 140 SAE 85W140 AMBRA HYPOIDE 90 SAE 80W90 ARBOR TRW 140 (SAE 85W140) ARBOR TRW 90 (SAE 80W90) TUTELA W140/M-DA SAE 85W140 TUTELA W90/M-DA SAE 80W90 FUCHS TITAN CYTRAC SL SAE 75W-90 TITAN CYTRAC HSY SAE 75W-90 TITAN GEAR HYP SAE 90 TITAN SUPERGEAR MC 80W-90 GENOL GEAR-SYN 80W-90 GENOL HYPOLUBE 80W-90 YORK 793 SAE 80W90 YORK 793 SAE 85W140 YORK 896 GREATWALL 85W/90 GL-5 LOTOS TITANIS GL-5 SAE 80W/90 GULF GEAR DB 85W 90 EUROGEAR SAE 75W-90 HYPOID PL SAE 80W-90 KENDALL NS-MP GEAR LUBE SAE 80W-90 RTO HD 80W-90 RTO LONGEVIA P ECO 80W-140 RTO LONGEVIA P ECO 80W-90 RTO LONGEVIA PXD ECO 75W-90 GEAR M 80W90 HYPOID B SAE85W90 SYNTHEGEAR SAE75W90 GL-5 GEAR LUBRICANT (80W90) GL-5 GEAR LUBRICANT (85W140) KOMPRESSOL-HYPOID EW SAE 80W-90 HIDROIL EP SAE 80W-90 Q8 AUTO 12 SAE 80W-90 Q8 AXLE OIL XG SAE 80W-140 Q8 GEAR OIL XG SAE 80W-90 Q8 T 55 SAE 80W-90 Q8 T 55 SAE 85W-140 Q8 T 55 SAE 90 Q8 T 65 SAE 75W-90 Q8 TRANS XGS SAE 75W-90 HYPOID GETRIEBEÖL GL 5 SAE 80W-90 HYPOID GETRIEBEÖL GL 5 SAE 85W-140 HYPOID GETRIEBEÖL GL 5 SAE 85W-90 HYPOID GETRIEBEÖL GL 5 SAE 90W HYPOID GETRIEBEÖL TDL SAE 80W-90 BARDAHL T&D OIL 80W 90 INA HIPENOL GTL DB 90

09 / 2005

Continued


MAZIVA ZAGREB D.O.O, ZAGREB/HR MAZIVA ZAGREB D.O.O, ZAGREB/HR MAZIVA ZAGREB D.O.O, ZAGREB/HR MEGUIN GMBH & CO. KG MINERALOELWERKE, SAARLOUIS/D MEGUIN GMBH & CO. KG MINERALOELWERKE, SAARLOUIS/D MEGUIN GMBH & CO. KG MINERALOELWERKE, SAARLOUIS/D MEGUIN GMBH & CO. KG MINERALOELWERKE, SAARLOUIS/D MEGUIN GMBH & CO. KG MINERALOELWERKE, SAARLOUIS/D MILLERS OILS LIMITED, BRIGHOUSE/GB MILLERS OILS LIMITED, BRIGHOUSE/GB MINERALÖL-RAFFIN. DOLLBERGEN, UETZE-DOLLBERGEN/D MINERALÖL-RAFFIN. DOLLBERGEN, UETZE-DOLLBERGEN/D MINERALÖL-RAFFIN. DOLLBERGEN, UETZE-DOLLBERGEN/D MINERALÖL-RAFFIN. DOLLBERGEN, UETZE-DOLLBERGEN/D MINERALÖL-RAFFIN. DOLLBERGEN, UETZE-DOLLBERGEN/D MINERALÖL-RAFFIN. DOLLBERGEN, UETZE-DOLLBERGEN/D MODRICA OIL REFINERY, MODRICA/BIH MODRICA OIL REFINERY, MODRICA/BIH MOL-LUB LTD., ALMASFUZITO/H MOL-LUB LTD., ALMASFUZITO/H MORRIS LUBRICANTS, SHREWSBURY/GB MORRIS LUBRICANTS, SHREWSBURY/GB MOTUL SA, AUBERVILLIERS CEDEX/F MOTUL SA, AUBERVILLIERS CEDEX/F NEW PROCESS AG, TÜBACH/CH NEW PROCESS AG, TÜBACH/CH NOVA STILMOIL SPA, MODENA/I OEL-BRACK AG, HUNZENSCHWIL/CH OEL-BRACK AG, HUNZENSCHWIL/CH OEST, GEORG MINERALÖLWERK, FREUDENSTADT/D OEST, GEORG MINERALÖLWERK, FREUDENSTADT/D OEST, GEORG MINERALÖLWERK, FREUDENSTADT/D OEST, GEORG MINERALÖLWERK, FREUDENSTADT/D OMV AG, SCHWECHAT/A OMV AG, SCHWECHAT/A OMV AG, SCHWECHAT/A OMV AG, SCHWECHAT/A OMV AG, SCHWECHAT/A ORLY INTERNATIONAL G.I.E., VIEUX-THANN/F ORLY INTERNATIONAL G.I.E., VIEUX-THANN/F PAKELO MOTOR OIL S.R.L, SAN BONIFACIO (VR)/I PAKELO MOTOR OIL S.R.L, SAN BONIFACIO (VR)/I PAKELO MOTOR OIL S.R.L, SAN BONIFACIO (VR)/I PAKELO MOTOR OIL S.R.L, SAN BONIFACIO (VR)/I PAKELO MOTOR OIL S.R.L, SAN BONIFACIO (VR)/I PAKELO MOTOR OIL S.R.L, SAN BONIFACIO (VR)/I PAKELO MOTOR OIL S.R.L, SAN BONIFACIO (VR)/I PAKELO MOTOR OIL S.R.L, SAN BONIFACIO (VR)/I PAKELO MOTOR OIL S.R.L, SAN BONIFACIO (VR)/I PAKELO MOTOR OIL S.R.L, SAN BONIFACIO (VR)/I PAKELO MOTOR OIL S.R.L, SAN BONIFACIO (VR)/I PAKELO MOTOR OIL S.R.L, SAN BONIFACIO (VR)/I PANOLIN AG, MADETSWIL/CH PANOLIN AG, MADETSWIL/CH PANOLIN AG, MADETSWIL/CH PANOLIN AG, MADETSWIL/CH PANOLIN AG, MADETSWIL/CH PETRO-CANADA LUBRICANTS, MISSISSAUGA/CDN PETRO-CANADA LUBRICANTS, MISSISSAUGA/CDN PETROGAL S.A., LISBOA/P PETROGAL S.A., LISBOA/P PETROGAL S.A., LISBOA/P PETROGAL S.A., LISBOA/P PETROL OFISI A.S, MASLAK-ISTANBUL-TURKEY/TR PRISTA OIL AD, ROUSSE/BG PRISTA OIL AD, ROUSSE/BG PT PERTAMINA (PERSERO), JAKARTA/RI PT PERTAMINA (PERSERO), JAKARTA/RI PT PERTAMINA (PERSERO), JAKARTA/RI RAFINERIA NAFTY JEDLICZE SA, JEDLICZE/PL RAFINERIA NAFTY JEDLICZE SA, JEDLICZE/PL RAFINERIA NAFTY JEDLICZE SA, JEDLICZE/PL RAVENSBERGER SCHMIERSTOFFVERTRIEB GMBH, WERTHER/D

09 / 2005

INA HIPENOL GTL HD 80W-90 INA HIPENOL GTL HD 85W-140 INA HIPENOL TDL 80W-90 MEGOL GETRIEBEOEL TRUCK-SYNTH SAE 75W-90 MEGOL HYPOID-GETRIEBEOEL GL 5 SAE 80W-90 MEGOL HYPOID-GETRIEBEOEL GL 5 SAE 85W-140 MEGOL HYPOID-GETRIEBEOEL GL 5 SAE 85W-90 MEGOL HYPOID-GETRIEBEOEL TDL SAE 80W-90 SYNTRAN FE/MILLERS TRX SYNTH 75W/90 SYNTRAN II/MILLERS TRX 80W/90 PENNASOL HYPOID-GETRIEBEOEL GL 5 SAE 80W90 PENNASOL HYPOID-GETRIEBEOEL GL 5 SAE 85W90 PENNASOL HYPOID-GETRIEBEOEL GL 5 SAE 90 PENNASOL LONGLIFE GEAR GL 5 SAE 80W90 PENNASOL LONGLIFE GEAR GL 5 SAE 85W90 PENNASOL LONGLIFE GEAR GL 5 SAE 90 HIPOIDNO ULJE B SAE 80W90 HIPOIDNO ULJE B SAE 90 MOL HYKOMOL K 85W-90 MOL HYKOMOL KZ 80W-90 MORRIS EP 80W/90 MORRIS EP 85W/140 MOTUL GEAR SYNT TDL 75W-90 MOTUL TRANS MB 85W-90 GEAROIL SYNTH HD GEAROIL SAE 90 GEARING PLUS 80W90 MIDLAND SUPER M 5 80W-90 MIDLAND SUPER M 5 85W90 OEST MEHRZWECK-GETRIEBEÖL FE SAE 80W-90 OEST MEHRZWECK-GETRIEBEÖL SPEZIAL SAE 85W-140 OEST MEHRZWECK-GETRIEBEÖL SPEZIAL SAE 85W-90 OEST SYNTH GETRIEBEÖL SAE 75W-90 OMV GEAR OIL B SAE 85W-90 OMV GEAR OIL BSX SAE 75W-90 OMV GEAR OIL XD-5 SAE 80W-90 OMV UNIGEAR S SAE 75W-90 OMV UNIGEAR SAE 80W-90 ORLY AURIGA EP SAE 85W140 ORLY LYRA EP PAKELO GEAR OIL EP GL-5 SAE 80W/90 PAKELO GEAR OIL EP GL-5 SAE 85W/140 PAKELO GLOBAL GEAR CBS SAE 75W/90 PAKELO GLOBAL GEAR DLS SAE 85W/140 PAKELO GLOBAL GEAR DLS SAE 85W/90 PAKELO GLOBAL GEAR SA SAE 80W/90 PAKELO GLOBAL GEAR SA SAE 85W/140 PAKELO GLOBAL GEAR SA SAE 85W/90 PAKELO GLOBAL MULTIGEAR CBS PAKELO GLOBAL MULTIGEAR CBS DLS PAKELO GLOBAL MULTIGEAR SA SAE 80W/140 PAKELO GLOBAL MULTIGEAR TS SAE 75W/90 PANOLIN SUPER DUTY 80W/90 PANOLIN SUPER DUTY 85W/140 PANOLIN SUPER DUTY 90 PANOLIN SUPER DUTY SYNTH 75W/90 PANOLIN TOPGEAR 80W/90 TRAXON 80W-90 TRAXON 85W-140 GALP TRANSOIL HP 80W90 GALP TRANSOIL HP 85W140 GALP TRANSVEX TDL 75W90 GALP TRANSVEX TDL 85W140 PO UNI. KEBAN EP MAN 80W/90 PRISTA EP 85W140 PRISTA EP 90 RORED HD-A SAE80W-90 RORED HD-A SAE85W-140 RORED HD-A SAE90 HIPOL EXTRA GL-5 80W-90 HIPOL SUPER GL-5 80W-90 HIPOL SUPER GL-5 85W-90 RAVENOL GETR.OEL 75W-90 VSG VOLLSYNTH.

1.56.5

Continued RAVENSBERGER SCHMIERSTOFFVERTRIEB GMBH, WERTHER/D RAVENSBERGER SCHMIERSTOFFVERTRIEB GMBH, WERTHER/D RAVENSBERGER SCHMIERSTOFFVERTRIEB GMBH, WERTHER/D RAVENSBERGER SCHMIERSTOFFVERTRIEB GMBH, WERTHER/D REPSOL LUBRICANTES, MADRID/E S.A.E.L., MADRID/E S.A.E.L., MADRID/E SHARJAH NATIONAL LUBE OIL CO. LTD., SHARJAH/UAE SHARJAH NATIONAL LUBE OIL CO. LTD., SHARJAH/UAE SHELL ASEOL AG, BERN 5/CH SHELL ASEOL AG, BERN 5/CH SHELL ASEOL AG, BERN 5/CH SHELL ASEOL AG, BERN 5/CH SHELL BRASIL, BARRA DA TIJUCA - RIO DE JANEIRO/BR SHELL INTERNATIONAL PETROLEUM COMP LTD, LONDON/GB SHELL INTERNATIONAL PETROLEUM COMP LTD, LONDON/GB SHELL INTERNATIONAL PETROLEUM COMP LTD, LONDON/GB SHELL INTERNATIONAL PETROLEUM COMP LTD, LONDON/GB SHELL INTERNATIONAL PETROLEUM COMP LTD, LONDON/GB SHELL INTERNATIONAL PETROLEUM COMP LTD, LONDON/GB SHELL INTERNATIONAL PETROLEUM COMP LTD, LONDON/GB SRS SCHMIERSTOFF VERTRIEB GMBH, SALZBERGEN/D SRS SCHMIERSTOFF VERTRIEB GMBH, SALZBERGEN/D SRS SCHMIERSTOFF VERTRIEB GMBH, SALZBERGEN/D SRS SCHMIERSTOFF VERTRIEB GMBH, SALZBERGEN/D SRS SCHMIERSTOFF VERTRIEB GMBH, SALZBERGEN/D STATOIL LUBRICANTS, STOCKHOLM/S STATOIL LUBRICANTS, STOCKHOLM/S STRUB + CO AG, REIDEN/CH STRUB + CO AG, REIDEN/CH SUOMEN PETROOLI OY, HAMINA/FIN SUOMEN PETROOLI OY, HAMINA/FIN SUOMEN PETROOLI OY, HAMINA/FIN SYNECO SPA, SAN GIULIANO MILANESE/I SYNECO SPA, SAN GIULIANO MILANESE/I TEDEX PRODUCTION SP.Z.O.O., TOMASZOW MAZOWIECKI/PL TEXACO BRASIL S.A., RIO DE JANEIRO/BR TOTAL LUBRIFIANTS S.A., PARIS/F TOTAL LUBRIFIANTS S.A., PARIS/F TOTAL LUBRIFIANTS S.A., PARIS/F TOTAL LUBRIFIANTS S.A., PARIS/F TOTAL LUBRIFIANTS S.A., PARIS/F TOTAL LUBRIFIANTS S.A., PARIS/F TOTAL LUBRIFIANTS S.A., PARIS/F TOTAL LUBRIFIANTS S.A., PARIS/F TOTAL LUBRIFIANTS S.A., PARIS/F TOTAL LUBRIFIANTS S.A., PARIS/F TOTAL LUBRIFIANTS S.A., PARIS/F TOTAL LUBRIFIANTS S.A., PARIS/F TOTAL LUBRIFIANTS S.A., PARIS/F TOTAL LUBRIFIANTS S.A., PARIS/F TOTAL LUBRIFIANTS S.A., PARIS/F TOTAL LUBRIFIANTS S.A., PARIS/F TOTAL LUBRIFIANTS S.A., PARIS/F TOTAL LUBRIFIANTS S.A., PARIS/F TOTAL LUBRIFIANTS S.A., PARIS/F TOTAL LUBRIFIANTS S.A., PARIS/F TOTAL LUBRIFIANTS S.A., PARIS/F TOTAL LUBRIFIANTS S.A., PARIS/F TOTAL LUBRIFIANTS S.A., PARIS/F TOTAL LUBRIFIANTS S.A., PARIS/F TOTAL LUBRIFIANTS S.A., PARIS/F UNIL S.A., SAUMUR CEDEX/F VALVOLINE EUROPE, DORDRECHT/NL VALVOLINE EUROPE, DORDRECHT/NL VALVOLINE EUROPE, DORDRECHT/NL VALVOLINE EUROPE, DORDRECHT/NL VALVOLINE EUROPE, DORDRECHT/NL VALVOLINE EUROPE, DORDRECHT/NL VEEDOL INTERNATIONAL, PANGBOURNE READING/GB VEEDOL INTERNATIONAL, PANGBOURNE READING/GB YACCO, ST PIERRE LES ELBEUF/F YACCO, ST PIERRE LES ELBEUF/F

1.56.6

ZF Friedrichshafen AG / List of lubricants TE-ML 07, edition 01.04.2005 RAVENOL HYP. EPX GETR.ÖL 85W-140 GL5 RAVENOL HYPOID EPX GETR.-OEL 80W-90 GL 5 RAVENOL HYPOID EPX GETRIEBE-OEL SAE 90 GL-5 RAVENOL SLG SPEC. LKW GETR.ÖL 80W90 CARTAGO EP SAE 90 GULF MULTIPURPOSE GEAR LUBRICANT 85W-90 GULF SYTHETIC GEAR LUBRICANT 75W-90 SHARLU MP GEAR LUBE 80W/90 (GL-5) SHARLU MP GEAR LUBE 85W/140(GL-5) ASEOL TOPRESS 320 ASEOL TOPRESS 80W-90 ASEOL TOPRESS 85W-140 ASEOL TOPRESS 85W-90 SHELL SPIRAX A 90 SHELL SPIRAX ASX 75W-90 SHELL SPIRAX AX 80W-90 SHELL SPIRAX AX 85W-140 SHELL SPIRAX AX 90 SHELL SPIRAX MB 90 SHELL SPIRAX MX 80W-90 SHELL SPIRAX ST 80W-140 WINTERSHALL GETRIEBEFLUID AFS WINTERSHALL GETRIEBEFLUID SML 80W-90 WINTERSHALL WIOLIN HYPOID-GETRIEBEÖL 80W-90 WINTERSHALL WIOLIN HYPOID-GETRIEBEÖL 85W-140 WINTERSHALL WIOLIN HYPOID-GETRIEBEÖL 90 GEARWAY G5 80W-90 GEARWAY G5 85W-140 STRUB MULTIGEAR SGO 80W-90 VULCOGEAR SYNT SGX 75W-90 TEBOIL HYPOID SAE 75W-140 TEBOIL HYPOID SAE 75W-90 TEBOIL HYPOID SAE 80W-140 AMPLEX 80W90 AMPLEX 85W140 TEDEX SUPER GEAR OIL (3343ML) SAE 80W90 MULTIGEAR EP SAE 90 ANTAR EPR 90 ANTAR EPR 80W-90 ANTAR EPS 75W-90 ANTAR UNIVERSAL FE 80W-140 ANTAR UNIVERSAL FE 80W-90 FINA PONTONIC A 80W-140 FINA PONTONIC FDL 75W-90 FINA PONTONIC MDL 80W-90 FINA PONTONIC MP 80W-90 FINA PONTONIC MP 85W-140 FINA PONTONIC MP 85W-90 TOTAL EP B 80W-90 TOTAL EP B 85W-90 TOTAL EP-B 85W-140 TOTAL TRANSMISSION BM 75W-90 TOTAL TRANSMISSION MDL 80W-90 TOTAL TRANSMISSION RS FE 80W-140 TOTAL TRANSMISSION RS FE 80W-90 TOTAL TRANSMISSION SYN FE 75W-90 TRANSELF BM 75W-90 TRANSELF SYNTHESE FE 75W-90 TRANSELF TYPE B 80W-90 TRANSELF TYPE B 90 TRANSELF UNIVERSAL FE 80W-140 TRANSELF UNIVERSAL FE 80W-90 UNIL OPAL GEAR ZF 80W90 HIGH PERFORMANCE GEAR OIL GL-5 90 SYNPOWER GEAR OIL TDL 75W-90 VALVOLINE STX GEAR OIL GL-5 80W-140 VALVOLINE STX GEAR OIL GL-5 80W-90 VALVOLINE SYNPOWER STX GL-5 75W-140 VALVOLINE SYNPOWER STX GL-5 75W-90 VEEDOL MULTIGEAR B SAE 90 VEEDOL MULTIGEAR C SAE 85W-140 BVX 1000 BVX C 100 80W-90

09 / 2005

Continued ZELLER + GMELIN GMBH & CO., EISLINGEN/D ZELLER + GMELIN GMBH & CO., EISLINGEN/D ZELLER + GMELIN GMBH & CO., EISLINGEN/D ZEPPELIN BAUMASCHINEN GMBH, GARCHING/D ZF FRIEDRICHSHAFEN AG, FRIEDRICHSHAFEN/D

09 / 2005

ZF Friedrichshafen AG / List of lubricants TE-ML 07, edition 01.04.2005 DIVINOL GEAR OIL STO SAE 80W-90 DIVINOL HYPOID-GETRIEBEÖL SAE 85W-140 DIVINOL SYNTHOGEAR SAE 75W-90 ZEPPELIN SPEZIALGETRIEBEÖL GL-4/GL-5 80W-90 ZF-ECOFLUID X

1.56.7

Continued


Lubricant class 07B Super tractor oil (STOU) Viscosity grades: SAE 10W-30 / 10W-40 / 15W-30 / 15W-40 / 20W-40 Manufacturer (07B)

Trade name (07B)

ADDINOL LUBE OIL GMBH, LEUNA/D AGIP SCHMIERTECHNIK GMBH, WÜRZBURG/D ARAL AG, BOCHUM/D ARAL AG, BOCHUM/D AVIA MINERALÖL-AG, MÜNCHEN/D AVIA MINERALÖL-AG, MÜNCHEN/D BAYWA AG, MÜNCHEN/D BAYWA AG, MÜNCHEN/D BLASER SWISSLUBE AG, HASLE-RÜEGSAU/CH BP INTERNATIONAL, PANGBOURNE, READING/GB BP INTERNATIONAL, PANGBOURNE, READING/GB BP INTERNATIONAL, PANGBOURNE, READING/GB BUCHER AG LANGENTHAL, LANGENTHAL/CH CASTROL INTERNATIONAL, PANGBOURNE READING/GB CASTROL INTERNATIONAL, PANGBOURNE READING/GB CASTROL INTERNATIONAL, PANGBOURNE READING/GB CASTROL INTERNATIONAL, PANGBOURNE READING/GB CEPSA LUBRICANTS S.A., MADRID/E CEPSA LUBRICANTS S.A., MADRID/E CHEVRONTEXACO, GHENT/B CHEVRONTEXACO, GHENT/B CHEVRONTEXACO, SYDNEY/AUS CHEVRONTEXACO, SYDNEY/AUS CONDAT LUBRIFIANTS, CHASSE SUR RHONE/F CONDAT LUBRIFIANTS, CHASSE SUR RHONE/F DE OLIEBRON B.V., ZWIJNDRECHT/NL EXXON MOBIL CORPORATION, FAIRFAX, VIRGINIA/USA EXXON MOBIL CORPORATION, FAIRFAX, VIRGINIA/USA EXXON MOBIL CORPORATION, FAIRFAX, VIRGINIA/USA EXXON MOBIL CORPORATION, FAIRFAX, VIRGINIA/USA EXXON MOBIL CORPORATION, FAIRFAX, VIRGINIA/USA FL SELENIA S.P.A., VILLASTELLONE/I FL SELENIA S.P.A., VILLASTELLONE/I FL SELENIA S.P.A., VILLASTELLONE/I FL SELENIA S.P.A., VILLASTELLONE/I FL SELENIA S.P.A., VILLASTELLONE/I FL SELENIA S.P.A., VILLASTELLONE/I FL SELENIA S.P.A., VILLASTELLONE/I FL SELENIA S.P.A., VILLASTELLONE/I FL SELENIA S.P.A., VILLASTELLONE/I FL SELENIA S.P.A., VILLASTELLONE/I FUCHS PETROLUB AG, MANNHEIM/D FUCHS PETROLUB AG, MANNHEIM/D GENOL GMBH & CO., WIEN/A GINOUVES GEORGES SA, LA FARLEDE/F HAFA, PARIS/F HAFA, PARIS/F HANDEL MIJ NOVIOL B.V., NIJMEGEN/NL IGOL FRANCE SA, AMIENS/F INA MAZIVA RIJEKA, RIJEKA/HR KRAFFT S.A., ANDOAIN/E KUWAIT PETROLEUM R&T B.V., EUROPOORT RT/NL KUWAIT PETROLEUM R&T B.V., EUROPOORT RT/NL KUWAIT PETROLEUM R&T B.V., EUROPOORT RT/NL KUWAIT PETROLEUM R&T B.V., EUROPOORT RT/NL MAGNA INDUSTRIAL CO. LIMITED, HONG KONG/HK MEGUIN GMBH & CO. KG MINERALOELWERKE, SAARLOUIS/D MINERALÖL-RAFFIN. DOLLBERGEN, UETZE-DOLLBERGEN/D MINERALÖL-RAFFIN. DOLLBERGEN, UETZE-DOLLBERGEN/D MORRIS LUBRICANTS, SHREWSBURY/GB NOVA STILMOIL SPA, MODENA/I OEL-BRACK AG, HUNZENSCHWIL/CH OMV AG, SCHWECHAT/A ORLY INTERNATIONAL G.I.E., VIEUX-THANN/F ORLY INTERNATIONAL G.I.E., VIEUX-THANN/F PAKELO MOTOR OIL S.R.L, SAN BONIFACIO (VR)/I

ADDINOL SUPER TRAKTOR MU 1045 SAE 10W-40 AUTOL AGROTECH SAE 10W-30 ARAL SUPER TRAKTORAL 10W-40 ARAL SUPER TRAKTORAL SAE 10W-30 TRACTAVIA FE 10W-40 TRACTAVIA SPEZIAL 10W-30 BAYWA SUPER 2000 CD-MC 10W-30 BAYWA SUPER MULTISYN SL 10W-40 BLASOL STOU 10W40 BP TERRAC SUPER UNIVERSAL 10W-40 BP TERRAC UNIVERSAL 15W-30 BP TERRAC UNIVERSAL 15W-40 MOTOREX FARMER TRAC CASTROL AGRI MP 15W-30 CASTROL AGRI MP 15W-40 CASTROL AGRI MP PLUS 10W-30 CASTROL AGRI MP PLUS 10W-40 CEPSA AGRO PLUS 15W-40 ERTOIL MULTI AGRO 15W-40 MULTITEX PREMIUM 10W-40 SUPER UNIVERSAL TRACTOR OIL PREMIUM 10W-30 CALTEX SUPER TRACTOR SAE 15W-40 CALTEX SUPER TRACTOR SAE 20W-40 MAXITRACT 15W40 VICAM TP 10W40 MULTITRAC 15W30 ESSO UNIFARM 10W-30 ESSO UNIFARM 15W-40 MOBIL AGRI EXTRA 10W-40 MOBIL AGRI SUPER 10W-30 MOBIL AGRI SUPER 15W-40 AKCELA MULTI TRACTOR (SAE 10W40) AKCELA SUPER UNIVERSAL (SAE 10W30) AKCELA SUPER UNIVERSAL (SAE 15W40) AKROS MULTI VT SAE 10W30 AKROS UNIVERSAL SAE 10W30 AKROS UNIVERSAL SAE 15W40 AMBRA UNIVERSAL SAE 10W30 AMBRA UNIVERSAL SAE 15W40 AMBRA VT SPECIAL (10W40) ARBOR UNIVERSAL (SAE 15W40) TITAN HYDRAMOT 10W-40 MC TITAN HYDRAMOT MC 10W-30 GENOL TRAC-SYN 1040 YORK 743 10W40 POLYMAT SAE 10W-40 SUPER TUT SAE 15W-40 KENDALL MULTIFARM SAE 15W-30 AGRI MU SUPER 10W40 INA AGRINA 15W-30 STOU 15W40 Q8 T 1000 D SAE 10W-30 Q8 T 1000 D SAE 15W-30 Q8 T 1000 SAE 10W-30 Q8 T 1000 SAE 15W-30 OMEGA 603 SAE15W40 MEGOL SUPER TRAKTORENOEL STOU SAE 10W-30 PENNASOL SUPER TRACTOR UNIVERSALOEL STOU 10W30 PENNASOL SUPER TRACTOR UNIVERSALOEL STOU 15W30 SUPER VERSITRAC MF LUBE+ AGRILUBE UNIVERSAL 10W30 MIDLAND STOU OMV AUSTROTRAC SAE 10W-40 ORLY APOLLO SAE 15W-40 ORLY STOU LUNA PAKELO STOU FLUID SAE 15W/40

1.56.8

09 / 2005

Continued


PANOLIN AG, MADETSWIL/CH PANOLIN AG, MADETSWIL/CH PETROGAL S.A., LISBOA/P RAVENSBERGER SCHMIERSTOFFVERTRIEB GMBH, WERTHER/D REPSOL LUBRICANTES, MADRID/E SHELL ASEOL AG, BERN 5/CH SHELL INTERNATIONAL PETROLEUM COMP LTD, LONDON/GB SHELL INTERNATIONAL PETROLEUM COMP LTD, LONDON/GB SHELL INTERNATIONAL PETROLEUM COMP LTD, LONDON/GB SRS SCHMIERSTOFF VERTRIEB GMBH, SALZBERGEN/D SRS SCHMIERSTOFF VERTRIEB GMBH, SALZBERGEN/D STRUB + CO AG, REIDEN/CH SYNECO SPA, SAN GIULIANO MILANESE/I TAMOIL PETROLI S.P.A., MILANO/I TOTAL LUBRIFIANTS S.A., PARIS/F TOTAL LUBRIFIANTS S.A., PARIS/F TOTAL LUBRIFIANTS S.A., PARIS/F TOTAL LUBRIFIANTS S.A., PARIS/F TOTAL LUBRIFIANTS S.A., PARIS/F TOTAL LUBRIFIANTS S.A., PARIS/F TOTAL LUBRIFIANTS S.A., PARIS/F TOTAL LUBRIFIANTS S.A., PARIS/F TOTAL LUBRIFIANTS S.A., PARIS/F TOTAL LUBRIFIANTS S.A., PARIS/F TOTAL LUBRIFIANTS S.A., PARIS/F TOTAL LUBRIFIANTS S.A., PARIS/F TOTAL LUBRIFIANTS S.A., PARIS/F UNIL S.A., SAUMUR CEDEX/F VALVOLINE EUROPE, DORDRECHT/NL VALVOLINE EUROPE, DORDRECHT/NL VALVOLINE EUROPE, DORDRECHT/NL

09 / 2005

PANOLIN STOU 10W/30 PANOLIN STOU 15W/30 GALP UNIAGRO RAVENOL SUTO SAE 15W-30 AGRO CERES STOU SAE 15W40 ASEOL MULTITRAC SUPER 10W-30 SHELL HARVELLA T 10W-30 SHELL HARVELLA T 15W-40 SHELL HARVELLA TX 10W-40 WINTERSHALL PRIMANOL 10W-30 WINTERSHALL PRIMANOL 10W-40 SUPER TRACTOROEL UNI.10W-30 (STOU) MULTITRACTOR STOU 15W40 SUPER TRACTOR SAE 15W/40 ANTAR AGRIA GR4 SAE 10W-40 ANTAR AGRIA SUPER FM SAE 15W-40 FINA SUPER UNIVERSAL OIL MF SAE 10W-40 FINA SUPER UNIVERSAL OIL SAE 15W-30 FINA SUPER UNIVERSAL OIL SAE 15W-40 TOTAL MULTAGRI MAX SAE 10W-40 TOTAL MULTAGRI MS SAE 15W-40 TOTAL MULTAGRI SUPER 10W-30 TOTAL MULTAGRI SUPER 15W-40 TOTAL MULTAGRI SUPER SAE 15W-30 TRACTORELF ST3 SAE 15W-30 TRACTORELF ST3 SAE 15W-40 TRACTORELF ST4 SAE 10W-40 XANTHOS 10W40 VALVOLINE STOU 10W-30 VALVOLINE STOU 15W-30 VALVOLINE STOU 15W-40

1.56.9

Continued


Lubricant class 07C Engine oil Viscosity grades: SAE 5W-30 / 5W-40 / 10W-30 / 10W-40 / 15W-30 / 15W-40 Manufacturer (07C)

Trade name (07C)

ADDINOL LUBE OIL GMBH, LEUNA/D ARAL AG, BOCHUM/D AVIA MINERALÖL-AG, MÜNCHEN/D AVIA MINERALÖL-AG, MÜNCHEN/D BLASER SWISSLUBE AG, HASLE-RÜEGSAU/CH BLASER SWISSLUBE AG, HASLE-RÜEGSAU/CH BP INTERNATIONAL, PANGBOURNE, READING/GB BP INTERNATIONAL, PANGBOURNE, READING/GB CEPSA LUBRICANTS S.A., MADRID/E CEPSA LUBRICANTS S.A., MADRID/E CEPSA LUBRICANTS S.A., MADRID/E CHEVRONTEXACO GLOBAL LUBRICANTS, SAN RAMON/USA GINOUVES GEORGES SA, LA FARLEDE/F GINOUVES GEORGES SA, LA FARLEDE/F KOMPRESSOL-OEL VERKAUFS GMBH, KÖLN/D KRAFFT S.A., ANDOAIN/E KUWAIT PETROLEUM R&T B.V., EUROPOORT RT/NL KUWAIT PETROLEUM R&T B.V., EUROPOORT RT/NL LIQUI MOLY GMBH, ULM/D MEGUIN GMBH & CO. KG MINERALOELWERKE, SAARLOUIS/D NOVA STILMOIL SPA, MODENA/I PAKELO MOTOR OIL S.R.L, SAN BONIFACIO (VR)/I PAKELO MOTOR OIL S.R.L, SAN BONIFACIO (VR)/I RAVENSBERGER SCHMIERSTOFFVERTRIEB GMBH, WERTHER/D RAVENSBERGER SCHMIERSTOFFVERTRIEB GMBH, WERTHER/D REPSOL LUBRICANTES, MADRID/E SHELL ASEOL AG, BERN 5/CH SHELL INTERNATIONAL PETROLEUM COMP LTD, LONDON/GB SRS SCHMIERSTOFF VERTRIEB GMBH, SALZBERGEN/D SRS SCHMIERSTOFF VERTRIEB GMBH, SALZBERGEN/D STRUB + CO AG, REIDEN/CH SUN OIL COMPANY (BELGIUM) N.V., AARTSELAAR/B VEEDOL INTERNATIONAL, PANGBOURNE READING/GB

ADDINOL SUPER STAR MX 1547 SAE 15W-40 ARAL MULTITURBORAL SAE 15W-40 AVIA MULTI CFE PLUS 10W-40 AVILUB MULTI HDC-B 15W40 BLASOL MHP 10W40 BLASOL MHP 15W40 BP VANELLUS C6 GLOBAL PLUS SAE 10W-40 ECONO VERITAS HDE SAE 10W-40 CEPSA DIESEL TURBO SHPD 15W-40 CEPSA SUPER MULTIGRADO SHPD 15W-40 CEPSA ULTRA SHPD 15W-40 CHEVRON DELO 400 MULTIGRADE SAE 15W-40 YORK 645 SAE 15W40 YORK 740 SAE 15W40 KOMPRESSOL-ULTRALUB C SAE 15W-40 SUPERMULTIGRADO D 15W40 Q8 T 500 SAE 15W-40 Q8 T 710 SAE 15W-40 TOURING HIGH TECH DIESELSPEZIALOIL SAE 15W-40 MEGOL MOTORENOEL HD-C3 SAE 15W-40 ORION SUPER PLUS 15W40 PAKELO GOLDEN D/G SAE 15W/40 PAKELO PKO HD SUPER 4 SAE 15W/40 RAVENOL FORMEL DIESEL SUPER 15W-40 RAVENOL TURBO-C HD-C 15W-40 SUPERTURBO DIESEL SAE 15W40 ASEOL PERLA 15W-40 SHELL RIMULA X 15W-40 WINTERSHALL MULTI REKORD 15W-40 WINTERSHALL MULTI REKORD TOP, SAE 15W-40 SUPER MULTI TURBO 15W-40 FORZA SAE 15W40 VEEDOL DIESELSTAR

1.56.10

09 / 2005

Continued


Lubricant class 07D Engine oil (API CD/CE/CF-4/CF/CG-4/CH-4/CI-4/SF/SG/SH/SJ/SL or ACEA-categories A/B/E) Product groups in accordance with page 1

SAE viscosity grades

Powershift transmissions Swing drives

20W-20 / 30 / 5W-30 / 5W-40 / 10W-30 / 10W-40 / 15W-30 / 15W-40

Mobile mixer drives

10W-40 / 15W-40

Note: All mineral oil-based gear oils which satisfy the above specifications may be used.

09 / 2005

1.56.11

Continued


Lubricant class 07E Biodegradable lubricant in accordance to Environmental labels RAL-UZ 79 (Blauer Engel), VAMIL-regeling Viscosity grade: SAE 75W-80 Manufacturer (07E)

Trade name (07E)

PANOLIN AG, MADETSWIL/CH

PANOLIN BIOFLUID ZFH

Only swing drives:

Biodegradable lubricant in accordance to Environmental labels RAL-UZ 79 (Blauer Engel), VAMIL-regeling, Swedish standard 15 54 34 Viscosity grade: ISO VG 46x Manufacturer

Trade name

PANOLIN AG, MADETSWIL/CH

PANOLIN HLP SYNTH 46

Instructions on the use of biodegradable lubricants: The oil manufacturer`s change-over directives included in the product description are to be observed when change-over to biodegradable lubricants is effected.

1.56.12

09 / 2005

Service Manual


Group

Type

Special tools general

2.01.1

A 309 LI 20221A 311 LI 20222A 312 LI 12363A 314 LI 2001A 316 LI 2001A 316 LI-IND 2001R 313 LI 27752R 317 LI 18161-

Special tools for diesel engines

2.03.1


Special tools for hydraulic systems

2.05.1


Special tools for electric systems

2.06.1


Special tools for gears

2.07.1

A 309 LI 20221A 311 LI 20222A 312 LI 12363A 314 LI 2001A 316 LI 2001A 316 LI-IND 20012.1

MJFCIFSS

Service Manual R 313 LI 27752R 317 LI 18161Special tools for axles

2.08.1

A 309 LI 20221A 311 LI 20222A 312 LI 12363A 314 LI 2001A 316 LI 2001A 316 LI-IND 2001-

Assembly tools for hydraulic cylinders

2.12.1


Mounting device for piston rod bearings

2.13.1


Slotted nut wrench for slewing gear

2.14.1


Mounting device for slewing gear

2.15.1


Mounting device for travel gear

2.16.1

R 313 LI 27752R 317 LI 18161-

2.2 MJFCIFSS

Service Manual


Special tools general for maintenance and repair Picture

No.

Designation

Size

ID no.

Machi ne

1 2

Measuring neck

NW 10 NW 12

7002404 7008688

all types

4

Pressure gauge connection

R 1/2"

7002436

all types

5

Pressure gauge direct connection

R 1/2"

7002435

all types

7

High-pressure hose length

7002437

all types

7002475

8

10 11 12 13 14

Screw coupling assembly, complete

M10X1 M12X1.5 M14X1.5 M16X1.5 R 1/4"

copyright by

MJFCIFSS

5005180 7402580 5004002 7361345 7362579

Application

all types

2.01.1


Picture

Service Manual

No. 15

Designation

Size

Pressure gauge

16 17

0-1.6 bar

8042577

0-1.6 bar *

8042578

7361288

19

5002867

20

0-250 bar *

7361285

21

0-400 bar *

7500002

22

0-600 bar *

5002866

30.1 30.2 30.3 30.4 30.5 30.6

Differential pressure measuring kit, consisting of:

Machi ne all types

5002865

18

30

2.01.2

ID no.

10288229

Measuring of operating pressures of one or more hydraulic circuits. * glycerine dampened

all types

10288155

1 manual measuring device 3010

Application

Measuring of difference p between the pump and the LS pressure.

10288152

1 data cable

10288154

2 measuring cables

0-600 bar

2 pressure sensors

10288153 10288151

1 power adapter

7025273

30.7 30.8

Vehicle connecting cable not included in delivery! Pressure sensor Pressure sensor

33

Fitting

4901372

34

Measuring neck with metal cap

7002404

35

Union nut

4774002

36

Cutting ring

4774001

copyright by

MJFCIFSS

see sensors on page 7

6140626 01 6140647 01

all types

Service Manual

Picture


No.

Designation

Size

ID no.

Machi ne

Application

44

Measuring adapter

8504231

all types

Measuring of current at pump regulation

45

Adapter

9956422

all types

Measuring of the inductive pickup B12 from 3-pin (LH) to 2-pin (Deutz), in conjunction with tool no. 44

46

Measuring cable

9956436

all types

Measuring and testing of solenoid valves

60

Piezzo speed

A 2106

10286429

all types

Measuring of engine speed via pulse frequency of injection line

62

Ornel speed meter

HT 460

7006974

all types

Measuring of speed with reflective strips

63

Shimpo speed meter

DT 205

7364284

64

Strips

614063201

copyright by

MJFCIFSS

with no. 63

2.01.3


Picture

Service Manual

No.

Designation

Size Chauvin Arnoux

ID no.

65

Multimeter with digital display

70

Thermometer non-contact (infrared)

72

Thermometer with probe and sensor (magnetic)

80

Hand pump

8145666

82

Sampling valve for oil samples, alternative to hand pump 80

7019068

84

Mineral oil analysis kit *

GTH 1150

no. 1

Machi ne

Application

10018500

all types

Measuring of voltage, current and resistance in electric components and valves

10024185

all types

Monitoring of temperature of a medium / outside temperature of a unit

all types

Sampling of oil for analysis

all types

1 oil sample

7020372

8145660

85

10029626

86

7018368

6 oil samples

87

7018369

12 oil samples

4 oil samples

*Analyses carried out by WAER CHECK Germany, lab report in German 88

89

2.01.4

Bio oil analysis kit *

no. 3

*Analyses carried out by WAER CHECK Germany, lab report in German

copyright by

MJFCIFSS

7026817

7026088

all types

1 oil sample

6 oil samples

Service Manual

Picture


No.

Designation

Size

ID no.

Machi ne

Application

90

REFCO vacuum pump

RD-4

7027552

all types

Maintenance and repair of a/c system

91

ITE filling hose, blue

1,500 mm

7027553

all types

See item 90

92

ITE filling hose, yellow

1,500 mm

7027554

93

ITE filling hose, red

1,500 mm

7027555

94

ITE HGV coupling

253a

7027556

See item 90

95

ITE HGV coupling

254 a

7027557

all types

96

4-valve test fittings

M4WS5 C

7027558

all types

Maintenance and repair of a/c system

100 101 102

Dismantling tool

M37X1 M42X1.5 M48X1.5

9583459 9583521 9583522

all types

Dismantling of grapple bolts

copyright by

MJFCIFSS

2.01.5


Picture

Service Manual

No.

Designation

105

Universal Passfix puller

120

Size

ID no.

Machi ne

Application

9584738

all types

Removal of Passfix bolts

Diagnostic instrument

5010474

all types

Diagnostics of D5 WS auxiliary heating

121

Adapter cable

9614382

For connection to cable harness in right bracket

122

Adapter cable

10025620

For direct plugging to the heating device

130

Testing tool for cooling system

7029179

all types

Pressurisation of engine cooling system (leakage test)

140

Torque wrench

10045464

all types

For tightening the hose clamps

150

Hand pump with pressure gauge

10454803

all types

For leakage test of backpressure line at particle filter installation

M42X1.5 M48X1.5 M58X1.5

4-20 Nm

Scope of delivery of the Litronic measuring system Depending on the requirements, there might be a need for various additional adapters and cables, which must be ordered separately. Item

Sensors

2

OEM pressure sensor, measuring range 0 - 1000 bar, output 0 - 20 mA

3


6*

6140 624 01

4


3*

6140 625 01

2.01.6

ID no.

copyright by

MJFCIFSS

1001 8329

Service Manual


Item

Sensors

ID no.

5


6

OEM pressure sensor, measuring range -1 to +6 bar, output 4 - 20 mA (LWE)

7

MINIMESS direct connection pressure sensor, 1620 screws

6*

6140 626 01

8

MINIMESS direct connection pressure sensor, 1620 screws, angled by 90°

3*

6140 647 01

9

Pt 100 temperature sensor, measuring range -50 °C to +200 °C

1*

6140 627 01

10

MINIMESS p / t coupling, screw series 1620, G 1/4"

1*

6140 628 01

11

MINIMESS P / T coupling, screw coupling 1620, M10 x 1.5

1*

1004 1274

12

RE 4 10 measuring turbine, measuring range 1 to 10 l/min

1*

5010 031

13

RE 3 75 measuring turbine, measuring range 7.5 to 75 l/min

1*

6410 629 01

14


0*

6140 630 01

15


2*

5009 492

16

DS 03 speed sensor, measuring range 1 to 9999 rpm

1*

6140 631 01

17

Spare reflector foil kit

1*

6140 632 01

18

Magnet holder, for DS 03 speed sensor

1*

6140 633 01

19

Inductive sensor for speed measurement

1*

6140 634 01

Item

Accessory

20

Transport case for RE 3 measuring turbine

1*

6140 635 01

21

MK 12 measuring cable for the connection of the sensors, length 6 m

12*

6140 636 01

22


4*

6140 637 01

23


1*

6140 638 01

24

Power supply cable for connection to the on-board power system, length 6 m

1*

6140 639 01

25

Power supply cable for connection to the on-board power system, length 12 m

0*

6140 640 01

26

DPU 411 thermal printer with power adapter

0*

6140 641 01

27

Thermal paper rolls for DPU 411

0*

6140 642 01

28

Centronics data cable, length 2 m (for DPU 411)

0*

6140 643 01

29

RS 232 data cable, length 2 m (for connection to PC)

1*

9684 327

30

AK 12 adapter cable (for speed measurement with GLR testing instrument)

1*

6140 648 01

31

Litronic Service Program, German version (for DOS operating system)

0*

6140 646 01

32

Evaluation software (d / e / f) on CD-ROM (for Windows, 16 bit)

1*

6004 401

33

Evaluation software (d / e / f) on CD-ROM (for Windows, 32 bit)

34

Measuring adapter for current measurement A 309 - R 317 Litronic

1*

8504 231

36

Y-adapter for current measuring Junior Timer plug

1*

9956 436

37

3-to-2 pin plug adapter

1*

9956 422

1002 7591 5718 886 08

ID no.

* number of units for recommended basic equipment

copyright by

MJFCIFSS

2.01.7


2.01.8

Service Manual

copyright by

MJFCIFSS

Service Manual


Special tools for diesel engines for the maintenance and adjustment of DEUTZ diesel engines Picture

no.

Designation

Size

1a

Compression pressure tester

1b

Diagram sheets for item 1a

2

Connecting piece for compression pressure tester

3

Nozzle tester

10

V-belt measuring instrument

14

Torx too kit

ID no. 8008782

100 Units

Krikit

Machi ne

Application

all types

Measurement of compression pressure

7019856

all types

Insert at the position of the injection valve

7361236

all types

Testing of injection nozzles

7019872

all types

for measurement of V-belt tension

7014716

all types

10012817

copyright by

MJFCIFSS

2.03.1


Picture

no. 22

2.03.2

Service Manual

Designation

Size

Torx insert key kits for (long design)

ID no.

Machi ne

E 14

7019851

all types

23

E 18

7021668

24

E 20

7019852

WS 15

7019853

all types

25

Socket for injection nozzle (long design) (union nut)

30

Torque wrench

7019854

all types

32

Insert key 1/4

7019855

A 312 R 317

35

Turning key

7021680

A 312 R 317

copyright by

MJFCIFSS

Application

Service Manual

Picture


no.

Designation

Size

ID no.

Machi ne

40

Mounting device for regulating rod

7021677

all types

50

Mounting tool for coolant thermostat

7019861

A 312 R 317

54

Piston ring mounting pliers

7009319

all types

60

Dismantling tool (hooks) for crank shaft seals (front and rear)

7019858

A 312 R 317

64

Mounting tool for crank shaft seals, front (fan side)

7021676

A 312 R 317

copyright by

MJFCIFSS

Application

2.03.3


Picture

2.03.4

no.

Service Manual

Designation

Size

ID no.

Machi ne

66

Mounting tool for crank shaft seal, rear (flywheel side)

7021675

A 312 R 317

68

Mounting tool for crank shaft seal (rear)

7019859

A 309 / A 311/ R 313

70

Mounting tool for crank shaft seal (front)

10294728

A 309 / A 311 / R 313

75

Claw wrench for injection lines

10294729

A 309 / A 311 / R 313

80

Valve seal clamp

10294730

all types

WS 17

copyright by

MJFCIFSS

Application

Service Manual

Picture


no.

Designation

Size

ID no.

Machi ne

85

Turning key (multitooth) for injection pump

10294731

A 309 / A 311/ R 313

90

Wheelspin device

10294732

A 309 / A 311 / R 313

95

Wheelspin device

10294733

A 309 / A 311 / R 313

100

Adjusting bolt for MAG shafts

10294734

A 309 / A 311 / R 313

105

Removing tool for injection nozzle, in conjunction with tool no. 115

10294735

A 309 / A 311 / R 313

copyright by

MJFCIFSS

Application

2.03.5


Picture

2.03.6

no.

Service Manual

Designation

Size

ID no.

Machi ne

110

Special key for injection line

10294736

A 309 / A 311 / R 313

115

Removal tool for injection nozzle

8008803

all types

120

Indicator for dial disc

8008789

all types

copyright by

MJFCIFSS

Application

Service Manual


Special tools for hydraulic systems Picture

No.

Order no.

Model

SW 17

9359414

all types

SW 19 WS 19

9210371

To adjust primary and secondary pressure-relief valves in the control valve block

7009315

all types

To secure the adjusting screws on the hydraulik aggregates

short long

SW 10 WS 10 SW 13 SW 13 l SW 17 SW 19 SW 19 l

30

Mounting sleeve

See chapter 2.12

all types

To assemble the O-ring and stepseal ring on hydraulic cylinder pistons, variable-displacement pump pistons and variable dispacement motor regulating pistons

40

Expanding sleeve

See chapter 2.12

all types

for application, see also tool no. 40

50

Piston wrench

See chapter 2.12

all types

10

Desciption

Size

Special wrench for pressure -relief valves

11

20

Safety cap short long

21 22 23 24 25

7023492 7615515 7380629 7009316 7009317

Application

Details for manufact. see page 2.12-01

A 309 LI - R 317 LI copyright by

MJFCIFSS

2.05.1


Picture

No. 60

Service Manual

Desciption

Size

Piston wrench

SW WS

61

Order no.

Model

Application

0541333

all types

To remove and tighten piston nuts

9245656

all types

To remove and install damper pins on hydraulic cylinders with damper on piston/rod side.

all types

To dismantle the piston rod bearing from the hydraulic cylinder

See chapter 2.12

62 63 64 70

80

2.05.2

Socket wrench for threaded bushing

SW 41

Mounting tool for piston rod bearings

M16

9951120

M20

9959261

M24

9959262

WS 41

90

Filling device, complete with adapter and filling hose

W24,3 2x1/14 3,0m W24.3 2x1/14 3.0m

8145359

all types

To check and refill diaphragm and piston type accumulators

110

Rod

M6

9288234

A 900C A 904C

Used to remove and install piston of pressure balance on LSC - control valve block

120

Allen key

9922975

all types

To remove and install the check valves in connection K (with radiator bypass valve)


MJFCIFSS

Service Manual

Picture


No.

Desciption

Size

Order no.

Model

Application

135

Wrench

Ø 10 mm

10114826

A 900C A 904C

To remove the check valve 123 (LUDV system)

140

Clamping device for spool

Ø 20 mm

10017281

all types

To clamp the spool during disassembly/reassembly

Ø 25 mm

10017282

Ø 32 mm

10017283

Ø 25 mm Ø 22 mm Ø 45 mm Ø 25 mm

9951457

all types

To assemble the Glyd-ring and scraper ring on the plunger piston of the hydraulic LIKUFIX coupling

00A7. 300

7405073

all types

To retain content of hydraulic tank during repair work on the hydraulic system

160

Montagehülse

161 162 163

180

Vacuum pump complete, consisting of: pump no. 180, vacuum regulation valve no. 181 with seal, hose with filter no. 187

181

Vacuum regulation valve complete:

184 185 186

9951508 9966421 951458

10097130

Tank fitting, consisting of: GE 165 fitting Cone reducing coupling 16/85 Straight nipple

7002240 7407155 7024875


MJFCIFSS

2.05.3


2.05.4

Service Manual


MJFCIFSS

Service Manual



copyright by

MJFCIFSS

2.06.1


Picture

2.06.2

No.

Service Manual

Desciption

Size

Order no.

Model

10

To crimp contacts for MATE-NLOK 1.5mm2 leads

7367025

all types

12

To crimp contacts for MATE-NLOK 2.5mm2 connectors

7366314

all types

15

Extraction tool to remove crimped contacts from MATE-N-LOK connectors

7366655

all types

20

Socket contact for 1.5 mm2 wires for MATE-N-LOCK connectors

6202619

all types

21

Pin contact for 1.5 mm2 wires for MATE-N-LOCK connectors

6202620

22

Socket contact for 2.5 mm2 wires for MATE-N-LOCK connectors

6202591

23

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

6202592

28

Hand-held tool to crimp contacts (according to MIL-C5015, VG952234, VG 955342)

7367086

29

Crimp turret to crimp contacts DEUTSCH-type connectors with special tool no. 28

7409779

30

Tool to crimp contacts of DEUTSCH - type connectors

8503647

copyright by

MJFCIFSS

all types

all types

all types

Application

Service Manual

Picture


No. 32

Desciption

Size

Extraction tool to remove crimped contacts from DEUTSCHtype connectors

33 34 35 36 37

38

Pin contact for wires of DT connectors

Socket contact for wires of DT connectors

39

Stopfen / Plug / Bouchon

55

Extraction tool for WAGO connectors

60

Order no.

Model

Size 4

8503633

all types

Size 8 Size 12 Size 16 Size 20

8503632 8145674 8145673 8503630

Ø 0,81,0 Ø 1,02,0 Ø 2,03,0

7368251

Ø 0,81,0 Ø 1,02,0 Ø 2,03,0

7368252

7368406

Application

all types

6905271

7368405 6905272 7368253

777-310

7022773

all types

IC extraction tool

8042630

61

IC mounting tool

8042629

all types

70

Ergocrimp pliers

6004391

copyright by

MJFCIFSS

all types

To crimp contacts for wires of JPT (Tyco) connectors

2.06.3


Picture

No.

Service Manual

Desciption

Size

Order no.

Ergocrimp matrix 72

0.5-2.5 mm2

10016253

73

0.5-2.5 mm2

10016255

74

0.5-2.5 mm2

10016256

Model all types

Application To crimp contacts for leads Junior Power Timer Nr./no. 927777-3 / 927779-3 / 927846-2 Junior power Timer/EDS Nr./no. 929938-3 double spring contact no. 929940-3 flat adapter no. 963745-1 / 963746-1

80

Extraction tool

7415334

all types

To remove crimped contacts from JPT (Tyco) connectors

90

Crimp plier

10016251

all types

To crimp littlefuse contacts for leads of JPT (Tyco) connectors, see also no. 92.

92

Ergocrimp matrix

10016252

all types

In connection with no. 90 and used to crimp contacts for leads

0.5 mm2 -3.32 mm2

receptacle no. 913053/ 913065 / 913066 / 913067 / 913069 / 913079 Double spring contact no. 913071 / 913072

2.06.4

copyright by

MJFCIFSS

Service Manual


Special tools for gears for the maintenance and repair of gear systems Picture

No.

Equip ment

Description

Size

ID no.

10

Slotted nut wrench for slewing gear mechanism

SAT 225

9202820

all types

20

Mounting device

SAT 225

9202825

A 309 R 317

30

Mounting device

FAT 350/022 FAT 350/032

9981445

Rmachines

Tool used to dismantle and mount the multi-disc brake of the FAT slewing gear mechanism (drawing, see page 2.16-01)

35

Mounting device for slide ring seals

FAT 350/022 FAT 350/032

8503594

Rmachines

For the mounting of slip ring seals in FAT travel gear systems

copyright by

MJFCIFSS

Application Releasing and tightening of slotted nuts in drive/slewing gear mechanisms (SAT drawing, see page 2.1401)

2.07.1


2.07.2

Service Manual

copyright by

MJFCIFSS

Service Manual

Special tools for axles

Special tools for axles for the maintenance and repair of axles

10 11

Collet chuck for axles Chuck tip

7009536

all types

Used to top in and top out the snap ring into/from the planetary gear of the axles

Used to loosen and tighten slotted nuts in planetary gears / axles.

5 mm

8145768

6 mm

8145769

AP/APL 745/ 755

7013102

A 314 / A 316

21

AP 745 TR* AP 755 TR*

7021789

A 314 / A 316

22

AP 755 HD APL 755 HD

7014452

A 316 Industry

AP/APL 745 APL 755

7013101

A 314 / A 316

31

AP 745 TR* AP 755 TR*

7029469

A 314 / A 316

32

AP/APL 755 HD

7013920

AP/APL 745 TR* APL 755

7024975

A 316 Industry A 314 / A 316

12

20

30

35

Chuck tip

Slotted nut wrench for axles

Centring disc

Centring ring

copyright by

MJFCIFSS

In conjunction with tool no. 20-22

In conjunction with tool no. 30

2.08.1


Service Manual

40

Mounting tool

AP/APL 745 AP 745 TR*

7024127

A 314 A 314

Used to insert the cassette seal ring in the hub / axles.

APL 755 42

AP 755 TR*

7024974

A 316

44

APL 755 HD

7024973

46

AP 755 HD

7029525

A 316 Industry A 316 Industry

AP/APL 745 APL 755

7019632

AP/APL 755 HD

7024131

A 316 Industry

M 16 x 1.5

7019556

A 314 / A 316

Used to measure the pad wear at the ZP axles.

A 309 / A 312

Used to measure the pad wear at the multi-disc brake

A 316

Used to loosen and tighten the slotted nuts in the planetary housing / hub carrier

50

Slip bushing, 2-part

51

2.08.2

60

Measuring screw for pad wear

65

Measuring tool for pad wear

70

Slotted nut wrench for axles

MS-E 3060 MT-E 3060

A 314 A 316

10346444

copyright by

MJFCIFSS

Used to mount the brake piston into the hollow wheel.

Service Manual


75

Gripping piece

MS-E 3060

10354109

A 316

78

Removal insert

MS-E 3060

7011520

A 316

80

Removing tool

MS-E 3060

7026311

A 316

Used to remove the outer bearing race from the joint housing. In conjunction with tool no. 90

85

Removing tool

MS-E 3060

10353377

A 316

Used to pull the shaft seal ring and the bushing from the axle housing and the joint housing. In conjunction with tool no. 90

90

Counter piece

MS-E 3060

7026310

A 316

copyright by

MJFCIFSS

Used to remove the inner bearing race from the joint housing. In conjunction with tool no. 78

2.08.3


Service Manual

95

Mounting tool

MS-E 3060

7011527

A 316

Used to insert the outer bearing race in the joint housing.

100

Mounting tool

MS-E 3060

10353378

A 316

103

Handle

MS-E 3060

7011518

Used to insert shaft seal rings / bushings in the axle housing and the joint housing. In conjunction with tool no. 103

* = Drum brake

2.08.4

copyright by

MJFCIFSS

Service Manual

Assembly tools for hydraulic cylinders Assembly wrenches for pistons of hydraulic cylinders WN 4121

Assembly tools for hydraulic cylinders 1 Assembly wrenches for pistons of hydraulic cylinders WN 4121

Fig. 1

Assembly tool (bore for mounting bolt a)

ID no.

a

b

c

d

e

f

g

h

i

Square

9131359

52

38

75

200

10

8

8

15

60

1/2

9131362

60

44

85

200

14

10

10

15

65

1/2

9231993

68

52

100

220

14

10

10

15

70

1/2

8007364*

75

54

110

220

14

12

10

20

84

3/4

8007364*

80

54

110

220

14

12

10

20

84

3/4

8007365

88

63

120

250

14

12

10

20

90

3/4

8007366

100

78

135

260

14

14

10

20

95

3/4

9919856

115

88

150

300

14

14

10

20

105

3/4

9196978#

125

97

170

320

14

14

10

25

110

3/4

9196978#

130

97

170

320

14

18

15

25

110

3/4

8007367

145

113

185

380

14

18

15

25

120

3/4

9925117

160

125

200

420

14

18

15

25

130

3/4

9131373

175

135

215

450

14

20

19

25

135

3/4

9131376

220

156

280

500

14

30

28

40

158

3/4

0541380

85

72

110

210

11

8

8

15

210

1/2

0542336

120

100

140

240

12

8

9

152

240

1/2

0540947

124

100

150

240

12

8

9

15

240

1/2

0541379

145

125

170

280

11

8

9

15

280

3/4

0540966

160

135

185

280

12

10

9

20

280

3/4

0529897

165

140

190

280

12

10

9

20

280

3/4

Tab. 1

List of assembly wrenches (all dimensions in mm)

Note! The dimensions of the pistons and assembly wrenches and the ID numbers can be looked up in Lidos (* and # correspond to one wrench each)!

copyright by

MJFCIFSS

2.12.1


Service Manual

Assembly wrenches for piston nuts

2 Assembly wrenches for piston nuts

Fig. 2

Assembly wrenches for piston nuts

Size of piston nut ID no.

*WS hex.

WS paral.

M30X1.5 - 7006469 41 50

M42X1.5 - 7010163

M50X2 - 4129202

60 55 70

M50X2 - 9166795

9921132

1/2

9211967

65

** 1/2

9211967

1/2

9921132

1/2

9921123

1/2

9921123

M56X2 - 9921260

80

1/2

9921124

M60X2 - 4129203

80

1/2

9921124

M65X2 - 9247441

85

1/2

9921133

M68X2 - 9129554

90

1/2

9921124

M76X2 - 9970448

100

3/4

9921125

M85X3 - 9142472

110

3/4

9921125

M95X3 - 9101411

120

3/4

9921126

M100X3 - 9950036

130

3/4

9951123

M110X3 - 9129653 / 9112934

149

3/4

9921127

M120X3 - 9143685

165

3/4

9921128

M130X3 - 9125066

180

3/4

9921129

M150X3 - 9144654

210

3/4

9921131

M170X3 - 5008571

230

3/4

9921134

Tab. 2

List of piston nuts

* width over flats / ** conventional grooved socket spanner

2.12.2

** 1/2

62

M42X1.5 - 9113734

ID no. **

50

M33 X1.5 - 9226916

M42X1.5 - 9970088

Square

44

M32X1.5 - 7010262 M36X1.5 - 9875702

Slotted nut Ø

copyright by

MJFCIFSS

Service Manual

Assembly tools for hydraulic cylinders Assembly wrenches for WN 4122 piston rod bearings

3 Assembly wrenches for WN 4122 piston rod bearings

Fig. 3 ID no.

Assembly wrenches for piston rod bearings a

b

c

d

e

f

g

h

i

Square

0541665

76

0541666

87,5

62

95

72

110

210

9

6

7

15

70

1/2

210

10

8

8

15

70

1/2

0541063

92

75

115

210

12

8

8

15

75

1/2

0541064

100

80

120

210

12

10

10

15

80

1/2

0529893

110

90

130

240

12

10

10

15

90

1/2

0542005

115

95

135

240

12

8

10

15

95

1/2

0541667

125

98

150

240

12

10

9

15

98

1/2

0529894

135

110

160

260

12

8

8

15

105

1/2

0540948

140

120

160

260

12

8

8

15

110

1/2

0541661

145

120

170

280

12

10

9

15

110

1/2

0529895

145

120

170

280

12

12

13

15

120

1/2

0540949

150

130

170

280

12

12

12

20

110

3/4

0529896

170

140

200

300

12

14

13

20

110

3/4

0541378

180

160

200

300

12

10

9

20

120

3/4

Tab. 3

List of assembly wrenches

copyright by

MJFCIFSS

2.12.3


Service Manual

Assembly wrenches for version 5100 pistons

4 Assembly wrenches for version 5100 pistons

Fig. 4

Assembly wrenches for version 5100 pistons

Size of piston nut

*WS hex.

Øa for mounting bolts

M120X3

175

220

3/4

9584641

M140X3

190

240

3/4

9581705

Tab. 4

WS square

ID no.


* width over flats

4.1

Assembly wrenches for pistons

Fig. 5 ID no.

a

b

c

d

e

f

g

h

i

Square

9249886

250

204

310

600

14

30

28

30

175

3/4

9249741

260

176

330

600

19

36

35

40

180

3/4

9243215

280

206

354

650

19

36

35

40

190

3/4

Tab. 5

2.12.4

Assembly wrenches for pistons


copyright by

MJFCIFSS

Service Manual

Assembly tools for hydraulic cylinders Mounting and expanding sleeves

4.2

Assembly wrenches with hex nut for pistons

Fig. 6

Assembly wrenches with hex nut for pistons

mm

mm

mm

mm Piston largest Ø

mm

mm

mm

l

mm Piston smallest Ø

*SW 6-KT

4-KT

a

b

c

9600751

80

3/4

170

Ø110

Ø140

Ø160

525

15

85

3/4

170

Ø115

Ø140

Ø160

9602239 9600418

525

15

90

3/4

170

Ø120

Ø150

Ø160

525

15

9597668

100

3/4

170

Ø130

Ø160

Ø180

525

15

9600928

110

3/4

170

Ø160

Ø190

Ø200

525

15

9600769

120

3/4

174

Ø170

Ø200

Ø200

525

15

ID no.

Tab. 6


* width over flats

5 Mounting and expanding sleeves Piston Ø

990 mounting sleeve ID no.

991 expanding sleeve ID no.

32

9136418

9136416

32

9113100

9113099

38

9143279

9143280

40

9196902

9136417

40

9580414

9580413

45

9136419

9136417

50

9288953

9288954

63

9170510

9170512

65

9177541

9177540

70

9110556

9110402

80

9227165

9227166

copyright by

MJFCIFSS

2.12.5


Service Manual

Mounting and expanding sleeves

Tab. 7

2.12.6

Piston Ø


991 expanding sleeve ID no.

85

9998618

9110404

85

9115710

9115708

90

9227161

9227162

98

9289130

9289131

100

9998626

9110405

105

9951984

9951983

106

9583670

9583671

110

9170509

9170511

110

9960483

9960502

115

9998625

9110406

120

9998778

9110407

125

9227163

9227164

125

9960484

9960503

130

9998624

9110408

135

9285578

9285579

140

9998623

9110409

150

9998622

9110410

160

9998621

9110411

170

9107931

9110412

180

9998619

9110413

180

9107932

9110413

190

9907684

9907701

190

9280862

9280863

200

9107933

9110414

List of mounting and expanding sleeves

copyright by

MJFCIFSS

Service Manual

Assembly tools for hydraulic cylinders Mounting and expanding sleeves

Mounting sleeves used to insert pistons into cylinders

Tab. 8

Piston Ø


65

9177543

80

9231749

90

9248893

90

9248894

100

9248895

110

9248897

120

9248898

130

9248899

140

9177541

140

9952180

160

9248909

190

9281241

210

9281240

250

9951147

260

9284918

950 mounting sleeves

Note! The mounting sleeve 950 is required to restore the shape of the expanded sealing elements to suit the inside diameter of the cylinder (calibration).

Mounting sleeves used to mount the piston rod bearings on the piston rods

Tab. 9

Piston rod Ø


90

9282761

105

9287177

140

9926806

960 mounting sleeves

Note! The 960 mounting sleeve is required in order to prevent damage to sealing and guide elements.

copyright by

MJFCIFSS

2.12.7


Service Manual

Mounting and expanding sleeves

2.12.8

copyright by

MJFCIFSS

Service Manual

Mounting device for piston rod bearings Tool used to dismantle piston rod bearings in hydraulic cylinders

Mounting device for piston rod bearings 1 Tool used to dismantle piston rod bearings in hydraulic cylinders

Fig. 1

Mounting device

Thread in flange ring

Thread in bearing head M1

Thread of mounting driver M2

Length of mounting driver L

ID -no.

M12

M16

M10

250

9951120

M16

M20

M12

270

9959261

M20

M24X2

M16

290

9959262

Tab. 1

Mounting devices sizes for various flange ring threads

copyright by

MJFCIFSS

2.13.1

Mounting device for piston rod bearings

Service Manual

Tool used to dismantle piston rod bearings in hydraulic cylinders

2.13.2

copyright by

MJFCIFSS

Service Manual

Slotted nut wrench for slewing gear Tool used to remove the slotted nut in the slewing gear mechanism

Slotted nut wrench for slewing gear 1 Tool used to remove the slotted nut in the slewing gear mechanism

Fig. 1

Tab. 1

Slotted nut wrench for Sat 225 Slewing gear type

ID number

SAT 225

9202820

ID numbers of slottet nut wrenches

copyright by

MJFCIFSS

2.14.1

Slotted nut wrench for slewing gear

Service Manual

Tool used to remove the slotted nut in the slewing gear mechanism

Fig. 2

Technical drawing of slotted nut wrench

SAT

A

B

C

D

E

F

G

H

J

K

L

M

N

O

P

225

90

40

30

55

71.5+0.2

77

100

95

3.8

80

35

30

40

56

7.8

Tab. 2

Dimensions

Material: 42 CrMo 4 hardened to 800 - 950 N/mm2

2.14.2

copyright by

MJFCIFSS

Service Manual


Mounting device for slewing gear Tool used to dismantle and mount the multi-disc brake of the slewing gear mechanism SAT 225

Fig. 1

Mounting device of slewing gear mechanisms

Size

SAT 225

A

268

B

40

C

12

D

10

E

10

F

16

G

100

H

117

ID no.

9202825

Tab. 1

List of mounting device sizes

copyright by

MJFCIFSS

2.15.1


2.15.2

Service Manual

copyright by

MJFCIFSS

Service Manual


Mounting device for travel gear Tool used to dismantle and mount the multi-disc brake of the FAT 350 travel gear mechanism

Fig. 1

Tab. 1

Technical drawing of mounting device Size

FAT 350 022 / 032

A

238

B

205

C

100

D

108

E

40

F

18

G

Ø16

H

15

ID no.

9981445

Dimensions of mounting device (in mm)

copyright by

MJFCIFSS

2.16.1


2.16.2

Service Manual

copyright by

MJFCIFSS

Service Manual


Group

Type

Technical data

3.09.1

A 309 LI 20221-

Technical data

3.11.1

A 311 LI 20222-

Technical data

3.12.1

A 312 LI 12363-

Technical data

3.13.1

R 313 LI 27752-

Technical data

3.14.1

A 314 LI 2001-

Technical data

3.16.1

A 316 LI 2001A 316 LI-IND 2001-

Technical data

3.17.1

R 317 LI 18161-

Inspection and maintenance schedule

3.29.1

A 309 LI 20221A 311 LI 20222-


3.32.1

A 312 LI 12363A 314 LI 2001A 316 LI 2001A 316 LI-IND 2001-


3.38.1

R 313 LI 27752R 317 LI 18161-

3.1 MJFCIFSS

Service Manual

3.2 MJFCIFSS

Service Manual

Technical data A 309 Litronic

Technical data 1 A 309 Litronic Type 717 Typ Valid from serial number

717 20221

717 29269

General

20221

29269

Weight of basic machine with 2-point support

t

9,05

=

Weight of backhoe bucket attachment (2-point support)

t

10,82

=

Overall length (with blade support)

mm

4230

=

Overall width

mm

2550

=

Overall height without attacment

mm

3110

=

Rear reach from centre/slewing radius

mm

1600 / 1600

=

Ground clearance

mm

320

=

Break-out force at tooth

KN

44,8 / 68,5

=

Max. drawing pull (in offroad gear and max. operating pressure)

KN

71,1

Drive motor Type Power at rated speed according to DIN ISO 9249

KW

Rated speed

min

Max. torque

Nm

Oil volume in engine (filling quantity at oil change with filter)

l

-1

Oil quality/oil viscosity and oil change intervals Fuel tank capacity

l

Additional information Hydraulic system Hydraulic pump

Typ

Design Drive power of pump with power control (min. power)

KW

Max. flow

l/min

Hydraulic oil volume (oil change with filter)

l

Hydraulic oil and filter change intervals

20221

29269

BF 4 M 1012

=

63 (86 PS)

=

2000

=

352 ± 10 bei1300-1500 min-1

=

15,5

=

see groups 1.50 and 3.29

=

215

=

see group 4.02

=

20221

29269

A 8 VO 55

=

axial piston swash plate double pump

=

53

=

212

=

ca.200

=


=

Control valve block

Typ

M8/NG 20

=

Rotary connection 7 x

Typ

DDF 720

=

A 309 LI 20221copyright by

MJFCIFSS

3.09.1

Technical data

Service Manual

A 309 Litronic Hydraulic system

20221

29269


Typ

815.006

=

Boom cylinder (adjustable and gooseneck equipment) Ø piston / rod

mm

115 / 70

=

Stick cylinder with adjustable attachment Ø piston / rod

mm

90 / 60

=

Bucket cylinder Ø piston / rod

mm

80 / 50

=

Swivel cylinder

mm

90 / 50

=

Support cylinder with outrigger - blade support Ø piston / rod

mm

110 / 50

=

Regulating cylinder with boom attachment Ø piston / rod

mm

125 / 70

=

Additional cylinder

see group 7.31

=

Hydraulic pump / pilot control

Typ

Gear pump

=

Max. flow / pilot control

l/min

22

=

Hydraulic pump / brake system - swivel bearing and AS1

Typ

Gear pump

=

max. flow rate through flow distributor

l/min

53

=

Constant current for brake I residual current for swivel bearing and AS1

l/min

Hydraulic pump / fan drive (cooling)

Typ

Max. flow / fan drive (cooling) Pilot control unit / working attachment / slewing gear

2

51

=

Gear pump

=

l/min

50

=

Typ

VG - 7 - 4

=

Pilot control unit / travel drive

VG - 7 - 1

=

Pilot control unit / support

VG - 7 - 2

=

see group 6. / 7.

=

20221

29269

V

24

=

Additional information Elektrical system Operating voltage Battery capacity

Ah

2 x 92 (in series)

=

Alternator voltage / current

V/A

28 / 55

=

Starter

V / KW

24 / 4,0

=

20221

29269

Slewing gear mechanism Gearbox

Typ

SAT 225 / 220

=

Oil motor

Typ

FMF 45

=

Max. slewing speed

min-1

9,0

=

Oil volume in gearbox

l

4,4

=


=

wet multi-disc brake (negative)

=

see group 9.10

=

20221

29269

Oil quality/oil viscosity and oil change intervals Slewing gear brake

Typ

Additional information Transmission Gearbox

Typ

2 HL 70

2 HL 270

Oil motor

Typ

DMVA 108

=

3.09.2


MJFCIFSS

Service Manual


Transmission Travel speed in creeper / offroad / on-road gear

km/h


l

Oil quality/oil viscosity and oil change intervals Parking brake

Typ

Additional information Axles

20221

29269

2,5 / 5,0 / 20,0

=

3,3

3,0

1.50 u. 3.29

=


=

see group 11.08

group 11.20

20221

29269

Steering axle

Typ

212

=

Rigid axle

Typ

112

=

Oil volume in steering axle housing

l

7,3

=

Oil volume in steering axle wheel hub

l

2 x 0,8

=

Oil volume in rigid axle housing

l

8,0

=

Oil volume in rigid axle wheel hub

l

2 x 2,1

=

Oil volume in axle housing of steered rigid axle (4-wheel steering)

l

7,3

=

Oil volume in wheel hub of steered rigid axle (4-wheel steering)

l

2 x 2,0

=


=

Oil quality/oil viscosity and oil change intervals Steering axle working brake

Typ

disc brake

=

Rigid axle working brake

Typ

disc brake

=

(positive)

=

see groups 12.02 / 12.03 / 12.05

=

9.00 - 20 500 / 45 - 20

=

see group 12.54

=

20221

29269

Brake type Additional information Tyres

Zoll

Additional information Steering Hydraulic pump

Typ

Gear pump

=

Flow

l/min

39

=

Steering / steering valve

Typ

Servostat 2 / LAGS 200

LAGS 200

see group 13.20/ 13.22

see group 13.22

20221

29269

Gear pump

=

2,0

=

see group 15.05

=

Additional information

Brake system Hydraulic pump

Typ

Max. flow

l/min



MJFCIFSS

3.09.3

Technical data

Service Manual

A 309 Litronic

3.09.4


MJFCIFSS

Service Manual



718 20222

718 29170

General

20222

29170


t

10,03

=


t

11,99

=


mm

4370

=

Overall width

mm

2550

=


mm

3110

=


mm

1750 / 1750

=

Ground clearance

mm

320

=


KN

49,9 / 77,5

=


KN

71,1


KW

Rated speed

min

Max. torque

Nm


l

-1


l


Typ

Design Drive power of pump with power control (min. power)

KW

Max. flow

l/min


l


20222

29170

BF 4 M 1012

=

67 (91 PS)

=

2000

=

371 ± 10 at 1300-1500 min-1

=

15,5

=


=

215

=

see group 4.02

=

20222

29170

A 8 VO 55

=

axial piston swash plate double pump

=

57

=

212

=

ca.200

=


=

Control valve block

Typ

M8/NG 20

=


Typ

DDF 720

=


MJFCIFSS

3.11.1

Technical data

Service Manual


20222

29170


Typ

815.006

=


mm

125 / 70

=


mm

100 / 70

=


mm

90 / 60

=

Swivel cylinder

mm

90 / 50

=


mm

110 / 50

=


mm

125 / 70

=

Additional cylinder

see group 7.33

=


Typ

Gear pump

=


l/min

22

=

Hydraulic pump / brake system - swivel bearing and AS1

Typ

Gear pump

=

max. flow rate through flow distributor

l/min

53

=

Constant current for brake I residual current for swivel bearing and AS1

l/min


Typ

Max. flow / fan drive (cooling) Pilot control unit / working attachment / slewing gear

2

51

=

Gear pump

=

l/min

50

=

Typ

VG - 7 - 4

=


VG - 7 - 1

=


VG - 7 - 2

=

see group 6. / 7.

=

20222

29170

V

24

=

Additional information Elektrical system Operating voltage Battery capacity

Ah

2 x 92 (in series)

=


V/A

28 / 55

=

Starter

V / KW

24 / 4,0

=

20222

29170


Typ

SAT 225 / 220

=

Oil motor

Typ

FMF 45

=

Max. slewing speed

min-1

9,0

=


l

4,4

=


=


=

see group 9.10

=

20222

29170


Typ


Typ

2 HL 70

2 HL 270

Oil motor

Typ

DMVA 108

=

3.11.2


MJFCIFSS

Service Manual


Transmission Travel speed in creeper / offroad / on-road gear

km/h


l

Oil quality/oil viscosity and oil change intervals Parking brake

Typ

Additional information Axles

20222

29170

2,5 / 5,0 / 20,0

=

3,3

3,0

1.50 and 3.29

=


=

see group 11.08

group 11.20

20222

29170

Steering axle

Typ

262 LD

=

Rigid axle

Typ

162 LD

=


l

7,3

=


l

2 x 0,8

=


l

8,0

=


l

2 x 2,1

=

Oil volume in axle housing of steered rigid axle (4-wheel steering)

l

7,3

=

Oil volume in wheel hub of steered rigid axle (4-wheel steering)

l

2 x 2,0

=


=


Typ

disc brake

=


Typ

disc brake

=

(positive)

=

see groups 12.05 / 12.10 / 12.11

=

9.00 - 20 500 / 45 - 20

=

see group 12.54

=

20222

29170


Zoll


Typ

Gear pump

=

Flow

l/min

39

=


Typ


LAGS 200

see group 13.20/ 13.22

see group 13.22

20222

29170

Gear pump

=

2,0

=

see group 15.05

=



Typ

Max. flow

l/min



MJFCIFSS

3.11.3

Technical data

Service Manual

A 311 Litronic

3.11.4


MJFCIFSS

Service Manual



719 12363

719 29898

General

12363

29898


t

13,0

=


t

12,5 - 13,5

=


mm

4150

=

Overall width

mm

2500

=


mm

3100

=


mm

1900 / 1900

=

Ground clearance

mm

360

=


KN

64,5 / 79,1

=


KN

87

Drive motor

12363

Type Power at rated speed according to DIN ISO 9249

KW

Rated speed

min-1

Max. torque

Nm


l


l


Typ

Design Max. flow

l/min


l


29898

BF 4 M 1013 E

=

74 (100 PS)

=

1800

=

422 ± 10 at 1400 min-1

=

15,5

=


=

215

=

see group 4.04

=

12363

29898

LMV 130

=

axial piston swash plate pump

=

234

=

ca.300

=


=

Control valve block

Typ

M7/NG 20

=


Typ

DDF 720

=


Typ

815.006

=


MJFCIFSS

3.12.1

Technical data

Service Manual


12363

29898


mm

100 / 70

=


mm

110 / 70

=


mm

90 / 70

=


mm

120 / 70 - 90 / 50

=


mm

140 / 80

=

see group 7.34

=

Gear pump

=

32

=

Additional cylinder Hydraulic pump / Brake system - Servo control

Typ


l/min

Flow devider K (Brake) / R (Servo control)

2

30

Hydraulic pump

Typ

Gear pump

=


Typ

Gear pump

=

Max. flow / fan drive (cooling)

l/min

50

=

Pilot control unit / working attachment / slewing gear

Typ

VG - 7 - 4

=


VG - 7 - 1

=


VG - 7 - 2

=

see group 6. / 7.

=

12363

29898

Additional information Elektrical system Operating voltage

V

24

=

Battery capacity

Ah

2 x 92 (in series)

=


V/A

28 / 55

=

Starter

V / KW

24 / 4,8

=

12363

29898

Typ

SAT 225 / 228

=

Oil motor

Typ

FMF 45

=

Max. slewing speed

min-1

9,0

=


l

4,5

=


=


=

see group 9.10

=

12363

29898



Typ


Typ

2 HL 70

2 HL 270

Oil motor

Typ

DMVA 108

=

Travel speed in creeper / offroad / on-road gear

km/h

2,5 / 5,0 / 20,0

=


l

3,3

3,0

1.50 and 3.32

=

Oil quality/oil viscosity and oil change intervals

3.12.2


MJFCIFSS

Service Manual


Transmission

12363

29898


=

see group 11.08

group 11.20

12363

29898

Typ

262 / 51

=

Rigid axle

Typ

162 / 51

=


l

8,2

=


l

2 x 3,0

=


l

10,5 (at disc brake)

=


l

2 x 0,7 (2,0 l at disc brake)

=


=

Parking brake

Typ

Additional information Axles Steering axle


Typ

disc brake

=


Typ

drum brake (option disc brake)

=

(positive)

=

see groups 12.20 / 12.21 / 12.23

=

10.00 - 20 18.00 - 19,5 600 / 40 - 22,5

=

see group 12.54

=

12363

29898


Zoll


Typ

Gear pump

=

Flow

l/min

44

=


Typ


LAGS 200

see group 13.20/ 13.22

see group 13.22

12363

29898



Typ

Gear pump

=

Max. flow

l/min

2,0

=

see group 15.05

=



MJFCIFSS

3.12.3

Technical data

Service Manual

A 312 Litronic

3.12.4


MJFCIFSS

Service Manual

Technical data R 313 Litronic

Technical data 1 R 313 Litronic Type 636 Valid from serial number 27752 R 313 Litronic Type 636

General Weight of backhoe bucket attachment and 600 mm base plates

t

Overall length

mm

4095

Overall width (500-750 mm base plates)

mm

2500-2750

Overall height without attachment

mm

2925


mm

2215

Ground clearance

mm

435

Max. break-out force at tooth

kN

111.3 / 79.2

Max. drawing pull (in off-road gear and max. operating pressure)

kN

151

Drive motor

15.3 (16.4*)

R 313 Litronic Type 636

Type

BF 4 M 2012 C

Power at rated speed according to DIN ISO 9249

kW

73 (99 HP)

Rated speed

rpm

1800

Max. torque

Nm

422 ± 10 at 1500 rpm


l

Oil quality/oil viscosity and oil change intervals Total tank capacity

14,0 see groups 1.50 and 3.38

l

approx. 230


see group 4.03

Hydraulic system


Hydraulic pump

Type

Design

DPVO 165 Axial piston swash plate pump

Drive power of pump with power control (min. power)

kW

Drive power of pump with power control (max. power)

kW

73

Max. flow

l/min

297


l


R 313 LI 27752copyright by

MJFCIFSS

29

approx. 350 see groups 1.50 and 3.38

3.13.1

Technical data

Service Manual

R 313 Litronic Hydraulic system


Control valve block

Type

M7/NG 20-16

Rotary connection 5x

Type

DDF 520


Type

815.001


mm

110 / 70


mm

115 / 70


mm

90 / 60

Cylinder with blade support Ø piston / rod

mm

130 / 90


mm

140 / 80


Type

Gear pump


l/min

36


Type

Gear pump


l/min

39


Type

VG - 7 - 4


Type

5 TH 6 NR


see group 6

Electrical system

R 313 Li Type 636

Operating voltage

V

Battery capacity

Ah


V/A

28 / 55

Starter

V / kW

24 / 4.8

Slewing gear mechanism

2 x 92 (in series)

R 313 Li Type 636

Gearbox

Type

SAT 225 / 218

Oil motor

Type

FMF 45

Max. slewing speed

rpm

9.0


l


5.2 see groups 1.50 and 3.38

Type


3.13.2

24

Wet multi-disc brake (negative) see group 9.10


MJFCIFSS

Service Manual


Travel gear


Gearbox

Type

FAT 350

Oil motor

Type

A6 VE 55

Travel speed in standard / fast travel mode

km/h

2.4 / 5.0


l

Oil quality/oil viscosity and oil change intervals Travel brake

3.0 see groups 1.50 and 3.38

Type


Multi-disc brake see group 11.62 or 11.67

Drive


Drive

bar

Running rollers

Type/ number of rollers

D4 L / 2 X 7

D4 L

Support rollers

Type/ number of rollers

D4 L / 2 X 2

Number of base plates / chains

Units

46

Base plate width

mm

500/ 600/ 750

Specific pressure on ground (max.)

N/cm2


4.6(4.9*) / 3.9(4.2*)/ 3.2(3.4*) see group 12

* in machines with blade


MJFCIFSS

3.13.3

Technical data

Service Manual

R 313 Litronic

3.13.4


MJFCIFSS

Service Manual



635 2001

General

2001


t

11,4


t

13,4 - 15,2


mm

4235

Overall width

mm

2500


mm

3107


mm

2030 / 2030

Ground clearance

mm

348


KN

66,1 / 72,9


KN

87

Drive motor

2001

Type

BF 4 M 1013 EC


KW

Rated speed

min

Max. torque

Nm


l

80 (109 PS) -1


1800 460 ± 10 at 1400 min-1 15,5 see groups 1.50 and 3.32

Fuel tank capacity

l


290 see group 4.05

Hydraulic system

2001

Hydraulic pump

Typ

Design

LMV 130 axial piston swash plate pump

Max. flow

l/min


l


234 ca.250 see groups 1.50 and 3.32

Control valve block

Typ

M7/NG 20


Typ

DDF 720


Typ

815.006


MJFCIFSS

3.14.1

Technical data

Service Manual


2001


mm

110 / 70


mm

115 / 75


mm

100 / 70


mm

120 / 70 - 90 / 50


mm

140 / 80

Additional cylinder

see group 7.35

Hydraulic pump / Brake system - Servo control

Typ


l/min


Gear pump 32 2

30

Hydraulic pump

Typ

Gear pump


Typ

Gear pump


l/min

45


Typ

VG - 7 - 4


VG - 7 - 1


VG - 7 - 2


see group 6. / 7.

Elektrical system

2001

Operating voltage

V

24

Battery capacity

Ah

2 x 92 (in series)


V/A

28 / 55

Starter

V / KW

24 / 4,8


2001

Gearbox

Typ

SAT 225 / 218

Oil motor

Typ

FMF 45

Max. slewing speed

min-1

9,0


l

4,4



Slewing gear brake

Typ


wet multi-disc brake (negative) see group 9.10

Transmission

2001

Gearbox

Typ

2 HL 100

Oil motor

Typ

LMV 108


km/h

2,5 / 5,0 / 20,0


l


3.14.2

3,3 1.50 and 3.32


MJFCIFSS

Service Manual


Transmission

2001

Parking brake

Typ



Axles

2001

Steering axle

Typ

APL - B 745

Rigid axle

Typ

AP - B 745 TR


l

7,5


l

2 x 0,7


l

9,0 ( 10,0 l at disc brake)


l




Steering axle working brake

Typ

disc brake


Typ

drum brake (option disc brake)

Brake type

(positive)


see groups 12.28 / 12.29 / 12.31

Tyres

Zoll


10.00 - 20 18.00 - 19,5 600 / 40 - 22,5 see group 12.54

Steering

2001

Hydraulic pump

Typ

Flow

l/min

44


Typ



Gear pump

see group 13.20/ 13.22

Brake system

2001

Hydraulic pump

Typ

Max. flow

l/min


Gear pump 2,0 see group 15.05


MJFCIFSS

3.14.3

Technical data

Service Manual

A 314 Litronic

3.14.4


MJFCIFSS

Service Manual


Technical data 1 A 316 Litronic Type 715 / 716 Typ Valid from serial number

715 2001

716 2001

715 28061

716 28062

General

2001

2001

28061

28062


t

12,4

14,9

12,4

14,9


t

15,0 16,7

18,9 21,0

15,0 16,7

18,9 21,0


mm

4235

=

Overall width

mm

2500

=


mm

3125

=


mm

2230 / 2230

=

Ground clearance

mm

390

=


KN

66,8 / 90

=


KN

90

=

Drive motor

2001

Type

BF 4 M 1013 EC

=

86 (115 PS)

=

1800

=

497 ± 10 at 1350 min-1

=

15,5

=


=


KW

Rated speed

min

Max. torque

Nm


l

-1


l

2001

28061

28062

290

=


see group 4.05

=

Hydraulic system

2001

Hydraulic pump

Typ

Design

2001

28062

LMV 150 axial piston swash plate pump

Max. flow

l/min


l


270 ca.290 see groups 1.50 and 3.32

Control valve block

Typ

M7/NG 20


Typ

DDF 720

A 316 LI 2001A 316 LI-IND 2001-

28061

copyright by

MJFCIFSS

3.16.1

Technical data

Service Manual


2001

2001

28061

28062


Typ

815.006

=


mm

120 / 70

=


mm


mm

100 / 70

=


mm

120 / 70 - 90 / 50

=


mm

140 / 80

=

Additional cylinder

120 / 80

110 / 70

120 / 80

110 / 70

see group 7.36

=

Hydraulic pump / Brake system - Servo control

Typ

Gear pump

=


l/min

32

=


2

30

=


Typ

Gear pump

=


l/min

45

=


Typ

VG - 7 - 4

=

VG - 7 - 1

=

Pilot control unit / travel drive Pilot control unit / support Additional information

VG - 7 - 2

=

see group 6. / 7.

=

Elektrical system

2001

28061

28062

Operating voltage

V

24

=

=

Battery capacity

Ah

2 x 92 (in series)

=

=


V/A

28 / 55

=

=

Starter

V / KW

24 / 4,8

=

=

2001

28061

28062

28061

28062


Typ

SAT 225 / 218

Oil motor

Typ

FMF 45

Max. slewing speed

min-1

9,0


l

4,4



Slewing gear brake

Typ



Transmission

2001

Gearbox

Typ

2001

2 HL 100

2 HL 290

Oil motor

Typ

LMV 100

DMVA 108


km/h

2,5 / 5,0 / 20,0

=


l

3,3

3,0

1.50 and 3.32

=


3.16.2

copyright by

MJFCIFSS

A 316 LI 2001A 316 LI-IND 2001-

Service Manual


Transmission

2001

Parking brake

Typ

2001

28061

28062


=


see group 11.10

group 11.20

Axles

2001

2001

28061

28062

Steering axle

Typ

APL-B 755

APL-B 755 HD

MS-E 3060

Rigid axle

Typ

AP-B 755 TR

AP-B 755 HD

MT-E 3060


l


l


l

9,0 (10 l at disc brake)

10,0

12,5


l


2,0

2,5


9,0

9,5

2 x 2,0

2,5


Steering axle working brake

Typ


Typ

Brake type

=

disc brake drum brake (option disc brake)

disc brake

= disc brake

(positive)


see groups 12.36 / 12.37 / 12.39

Tyres

Zoll

see groups 12.41 / 12.42 / 12.44

= see groups 12.46 / 12.47 / 12.48

10.00 - 20 18.00 - 19,5 600 / 40 - 22,5

= =


see group 12.54

= =

Steering

2001

2001

28061

28062

Hydraulic pump

Typ

Gear pump

=

Flow

l/min

44

=


Typ

Servostat 2 / LAGZ 190

LAGZ 190


see group 13.20/ 13.24

see group 13.24

Brake system

2001

28061

Hydraulic pump A 316 LI 2001A 316 LI-IND 2001-

Typ

copyright by

MJFCIFSS

2001

Gear pump

28062 =

3.16.3

Technical data

Service Manual

A 316 Litronic Brake system

2001

Max. flow

l/min


3.16.4

copyright by

MJFCIFSS

2001

28061

28062

2,0

=

see group 15.05

=

A 316 LI 2001A 316 LI-IND 2001-

Service Manual


Technical data 1 R 317 Litronic Type 970/ 362 Valid from serial number 18161 General

R 317 Li Type 970

R 317 Type 362

Weight of backhoe bucket attachment and 600 mm track pad

t

17,6

18,7

Overall length

mm

3975

5010

Overall width (500-750mm track pad)

mm

2500.2750

=


mm

2995

=


mm

2450

=

Ground clearance

mm

470

=


KN

100,6 / 125,7

=


KN

151

=

R 317 Li Type 970

R 317 Type 362

BF 4 M 1013 EC

=

86 (115 HP)

=


kW -1

Rated speed

min

1800

=

Max. torque

Nm

491 ± 10 at 1400 min-1

=


l

15,5

=

see group 1.50 and 3.38

=


l


Type

Design

290

=

see group 4.05

=

R 317 Li Type 970

R 317 Type 362

DPVO 165

=

axial piston swash plate pump

=

Drive power of pump with power control (min. power)

kW

29

=

Drive power of pump with power control (max. power)

kW

73

=

Max. flow

l/min

297

=


l

approx. 290

=

see group 1.50 and 3.38

=

M7/NG 20-16

=

Hydraulic oil and filter change intervals Control valve block

Type


MJFCIFSS

3.17.1

Technical data

Service Manual

R 317 Litronic Hydraulic system

R 317 Li Type 970

R 317 Type 362

Rotary connection 5-way

Type

DDF 520

=

Rotary connection 1-way

Type

815.001

=


mm

125 / 70

=


mm

130 / 80

=


mm

120 / 80

=


mm

140 / 80

=


Type

Gear pump

=


l/min

36

=


Type

Gear pump

=


l/min

43

=


Type

VG - 7 - 4

=


Type

5 TH 6 NR

=

see group 6. / 7.

=

R 317 Li Type 970

R 317 Li Type 362

Additional information Electrical system Operating voltage

V

24

=

Battery capacity

Ah

2 x 92 (in series)

=


V/A

28 / 55

=

Starter

V / kW

24 / 4,8

=

R 317 Li Type 970

R 317 Li Type 362


Type

SAT 225 / 218

=

Oil motor

Type

FMF 45

=

Max. slewing speed

min-1

9.0

=


l

4,4

=


=

Wet multi-disc brake (negative)

=

see group 9.10

=

R 317 Li Type 970

R 317 Li Type 362


Type

Additional information Travel gear Gearbox

Type

F40 / FAT 350

FAT 350

Oil motor

Type

A6 VE 55

=

Travel speed max on slow speed / on fast speed

km/h

1,8 / 6,0

=


l

4,5

=


=


3.17.2


MJFCIFSS

Service Manual


Travel gear Parking brake

Type


Translation

R 317 Li Type 970

R 317 Li Type 362

multi-disc brake

=

see group 11.60 / 11.62 11.65 / 11.67

11.62 / 11.67

R 317 Li Type 970

R 317 Li Type 362

B 60 L

=

Track

bar

Track roller

Type/ Qty

B 60 L / 2 x 7

D6KL 2 x 9

Carier roller

Type/ Qty

B 60 L / 2 x 2

B 60 L / 2 x 3

Quantity of track pads

piece

44

55

Track pad width

mm

500 / 600 / 750 / 900 / 1000

600/ 900 / 1000

Ground pressure

n/cm2

5,0 / 4,3 / 3,5 / 2,7 / 2,4

3,5 / 2,4 / 2,1

see group 12

=



MJFCIFSS

3.17.3

Technical data

Service Manual

R 317 Litronic

3.17.4


MJFCIFSS

Service Manual

Inspection and maintenance schedule A 309 Litronic / A 311 Litronic

Inspection and maintenance schedule 1 A 309 Litronic / A 311 Litronic A 309:Typ 717 from serial number 20221 A 311:Typ 718 from serial number. 20222

Customer:

................................

Serial no.:

................................

Type:

................................

Operating hours:

................................

Date:

.............................

Caution! Careful maintenance can only be carried out when the machine is clean. In particular, visual inspections, such as for cracks, can only be made on a clean machine. Clean the machine before starting any maintenance work (see also the chapter Maintaining the machine safely, subheadings Cleaning and Checking for cracks). Note! The daily maintenance tasks, which the machine operator has to carry out, include a function check of the brakes (swing gear, operating and parking brake), steering and the electrical and hydraulic systems. Additionally, a visual check must be made for leaks on the engine, hydraulic system, transmission and axles.

Maintenance / inspection at operating hours

WORK TO BE CARRIED OUT A 309 / A 311 Litronic By maintenance personnel (machine operator)

By authorized expert personnel

First and only interval Repeat interval Special interval every 250 hours

Note

First and only interval Repeat interval

DIESEL ENGINE Check oil level and oil pressure in engine Check coolant level and coolant temperature Check air filter via maintenance indicator Check and drain water separator on fuel filter Drain off water and sediment on fuel tank

copyright by

MJFCIFSS

3.29.1


Service Manual

A 309 Litronic / A 311 Litronic Maintenance / inspection at operating hours




Note


Empty dust collector on air filter (shorten or extend interval as necessary) Check and clean cooler, pressure relief valve, coolant hose, fan Replace lube oil filter cartridge Replace engine oil

1)

Check oil, cooling and fuel system for leaks and condition Replace water filter cartridge (at least 1 x annually) Check and adjust throttle control Check anti-corrosion fluid / antifreeze in coolant (replace coolant every 2 years) Check condition and tension of the V-belt (using a testing device at operating temperature). (Replace every 2 years) Check / adjust valve clearance Check engine console and oil sump mounts, clamps etc. Check flexible fuel leak oil line (change at least every 2 years) Check intake system and exhaust system for leaks and for condition Replace fuel fine filter cartridge (or as necessary)

4)

Replace fuel prefilter cartridge (or as necessary)

4)

Replace main element of air filter (according to maintenance indicator / annually) Replace safety element of air filter (every third change of main element / annually)

Never clean!

Check clean air line (during filter maintenance) Check / adjust injection valves every 3000 hrs. (if performance diminishes) HYDRAULIC SYSTEM Check oil level in hydraulic tank Clean magnetic rod in return filter (daily during first 300 hrs.) Replace filter element in return filter (first time at 500 hrs.) Replace filter unit on servo oil unit Check mounting of components

3.29.2

copyright by

MJFCIFSS

2)

Service Manual






Note


Clean hydraulic oil cooler (and as necessary) Drain off water in hydraulic tank (when using environmentally friendly fluids, max. 0.1 % part of water permissible, insert bypass filter, take oil sample) Check hydraulic system for leaks and function Check / adjust servo, primary and secondary pressures Replace hydraulic oil in tank (or optimize interval with oil analysis)

2), 3)

Replace breather filters on hydraulic tank

2)

ELECTRICAL SYSTEM Check indicator lights and displays when turning on Check lighting Check acid concentration and level and cable terminals and pole ends on batteries as well as all plug connections Spray slip rings on rotary connection (if present) with Cramolin contact spray Check function of entire system and components SWING GEAR Check oil level and look for leaks Check function and action of swing gear brake Check mounting of gear and oil motor Replace gear oil (first time at 500 hrs.) SWING RING Renew lubrication on gear Renew lubrication on swing race Check mounting screws for tight seating and entry of swing gear pinion TRANSMISSION Check oil level and look for leaks Check function of gear shift and parking brake

copyright by

MJFCIFSS

3.29.3


Service Manual






Check mounting of transmission, oil motor and drive shafts Replace gear oil (first time at 500 hrs.) AXLES Check oil level and for leaks, check wheel lugs for tight seating. Check mounting tightness of axles Lubricate steering knuckle bearing (weekly / monthly, depending on application) Replace oil of differential and planetary gear, front and rear (first time at 500 hrs.) Check wear on multi-disk brake (1 x annually or as necessary) STEERING Check for leaks and function Check mounting tightness of components and steering parts OSCILLATING AXLE SUPPORT Check for leaks and function Check mounting tightness of cylinders BRAKE SYSTEM Check system for leaks Check function and action Check accumulator and brake pressure as well as control switch OPERATORS CAB + HEATER Check / refill washing fluid in windshield washer system container Check function of heater (before start of winter) Check heating system for leaks Check door and window hinges as well as locks

3.29.4

copyright by

MJFCIFSS

Note

Service Manual






Note


Check water inlet valve for function and dirt, clean if necessary AIR CONDITIONING SYSTEM Turn on air conditioning system regularly (at least 1 x every 14 days) Check condenser for contamination, blow out if necessary Check mounting screws and compressor drive belt Check dryer collector unit (moisture, fill and condition), replace if required (at least every 2 years) Clean fresh air filter (at least 1 x monthly, weekly for dust intensive use) Replace fresh air filter (shorten change interval for dust intensive use) Check mounting of air conditioning system, hose connections and electrical contacts (at least 1 x annually) UNDERCARRIAGE + UPPERCARRIAGE + ATTACHMENTS Lubricate bearing points on attachment Grease swing bearing Visually check wear condition of teeth Lubricate bearing points on undercarriage (depending on application, daily in mult-shift operation) Check parts for cracks Check mounting tightness of counterweight and tank Check tight seating of attachment pins

400 Nm

Check line and screw connections for tight seating Check cover hinges, quick connections and gas cylinders on hoods Point out appropriate use of attachment Have machine lubricated according to lubrication schedule by the machine operator and point out any operating errors. HYDRAULIC QUICK CHANGE ADAPTER Check function of visual and acoustic warning devices Check extended position of locking pins visually

copyright by

MJFCIFSS

3.29.5


Service Manual





Note


Check condition of hydraulic hoses and of wiring harness Lubricate locking pins Clean strainer MECHANICAL QUICK CHANGE ADAPTER Check extended position of locking pins visually Lubricate locking pins Tab. 1-1 1 2 3 4


Engine oil change intervals can be shortened depending on temperature, fuel and oil quality. Observe shortened maintenance intervals in dust intensive application. When using environmentally friendly hydraulic fluids, the maintenance interval is to be determined by regular analysis. Shorten the maintenance interval depending on application (e.g. dust intensive application, barrel refuelling).

Comments / defects

Date:

3.29.6

...................................... ...

Mechanic: ......................................... Customer: .........................................

copyright by

MJFCIFSS

Service Manual

Inspection and maintenance schedule A 312 Litronic - A 316 Litronic

Inspection and maintenance schedule 1 A 312 Litronic - A 316 Litronic A 312: type 719, starting with serial no. 12363 A 314: type 635, starting with serial no. 2001 A 316: type 715 / 716, starting with serial no. 2001 Customer:

................................

Serial no.:

................................

Machine type:

................................

Operating hours:

................................

Date:

.............................

Caution! Careful maintenance is only possible, if the machine is clean. Especially visual inspections, e.g. for cracks can only be carried out properly on a clean machine. Therefore clean the machine thoroughly before starting any maintenance work (see also chapter 1.10 "Save maintenance of machine", subchapters "Cleaning" and "Crack inspection"). Note! The daily maintenance tasks of the machine operator include a functional test of the brakes (slewing gear brake, working brake, parking brake), steering, electrical and hydraulic system. Also to be carried out are a daily visual inspection of the motor, hydraulic system, gearbox and axles for leakage.

Maintenance/ inspection at operating hours

WORK TO BE CARRIED OUT A 312 - A 316 Litronic by maintenance personnel (machine operator)

by authorised specialist technician

Initial and single interval Repeat interval Special interval: every 250 hours

Initial and single interval Repeat interval

Note

DIESEL ENGINE Check motor oil level and oil pressure Check coolant level and temperature Check air filter (maintenance indicator) Check and drain water separator at the fuel filter Drain water at fuel tank with bottom settlings Empty dust collecting container at air filter (shorten or extend interval, if necessary)

copyright by

MJFCIFSS

3.32.1


Service Manual

A 312 Litronic - A 316 Litronic Maintenance/ inspection at operating hours





Note

Check and clean cooler, pressure relief valve, coolant hose and fan Replace lubricating oil filter cartridge Change engine oil

1)

Check oil, coolant and fuel systems for leakage Replace water filter cartridge (at least 1 x every 12 months) Check and adjust speed adjustment Check corrosion inhibitor and antifreeze agent in coolant (change coolant every 2 years) Check condition and tension of V-belt; check at operating temperature; use gauge; replace every two years Check / adjust valve play (first time after 500 operating hours) Check motor brackets and oil pan, hose clips etc. Check flexible fuel leak-oil line (replace latest every 2 years) Check intake and exhaust systems for general condition and leaks Clean or replace the cartridge of the fuel prefilter or Separ prefilter (depending on filter type); if necessary, clean or replace at shorter intervals

4)

Replace cartridge of the fuel fine filter (shorten interval, if necessary)

4)

Replace air filter main element (based on maintenance indicator / annually) Replace air filter safety element (at every 3rd replacement of the main element / annually) Check clean air line (during maintenance of filters) Check / adjust injection nozzles (every 3000 operating hours or in the event of loss of performance) HYDRAULIC SYSTEM Check oil level in hydraulic tank Clean magnetic rod in return filter (daily during first 300 operating hours) Replace return filter cartridge (first time after 500 operating hours) Replace filter cartridge in control oil unit Check components for proper mounting

3.32.2

copyright by

MJFCIFSS

2)

Service Manual







Note

Clean hydraulic oil cooler (shorten interval, if necessary) Drain water from hydraulic tank (max. permissible water content for environmentally friendly fluids: 0.1 %; insert bypass filter, take oil sample) Check hydraulic system for leakage; complete functional test

Change hydraulic oil in tank (optimise interval by carrying out oil analyses)

2), 3)

Replace breather filter on hydraulic tank

2)

ELECTRICAL SYSTEM Check indicator lights and indicating devices upon start-up Check lighting Check acid density and level, wire terminals and terminal ports of the batteries, and all the plug connections Spray slip rights of the slewing gear connection with Cramolin contact spray Carry out functional tests of entire unit and all components SLEWING GEAR MECHANISM Check oil level; check system for leakage Carry out functional test of slewing gear brake Check gearbox and oil motor for proper mounting Change gear oil (first time after 500 operating hours) SLEWING RING Replace lubricant of the gearing Replace lubricant of the ball race Check mounting bolts for press fit; slewing gear pining meshing TRANSMISSION Check oil level; check system for leakage

copyright by

MJFCIFSS

3.32.3


Service Manual






Carry out functional test of power shift mechanism and parking brake Check gearbox, oil motor and joint shafts for proper mounting Change gear oil (first time after 500 operating hours) AXLES Check oil level; check for leaks; check wheel lugs for proper fit Check axles for proper mounting Lubricate oscillating axle bearing (weekly or monthly, depending on use) Lubricate steering knuckle bearing (weekly or monthly, depending on use) Change oil in axle housing and planetary drives (front and rear) (first time after 500 operating hours) Check multi-disc brake for wear (1 x every 12 months; shorten interval, if necessary) STEERING Check system for leakage; complete functional test Check components and steering system parts for proper mounting OSCILLATING AXLE SUPPORT Check system for leakage; complete functional test Check cylinders for proper mounting BRAKE SYSTEM Check system for tightness Carry out functional test Check pressure of accumulator and brakes; check test switches OPERATOR'S CAB + HEATING Check / add detergent solution in windscreen washer tank Carry out functional test of heating system (before start of winter season)

3.32.4

copyright by

MJFCIFSS

Note

Service Manual







Note

Check heating system for leakage Check door and window hinges as well as locks Check water inlet valve for contamination, and clean, if necessary; carry out functional test of valve AIR-CONDITIONING SYSTEM Regularly switch on air-conditioning system (at least 1 x every 14 days) Check condenser for contamination; blow clean, if necessary Check compressor mounting bolts and drive belts Check dryer-collector unit (humidity, fill level, condition); replace, if necessary; replace at least every two years Clean fresh air filter; clean at least once every month; clean once every week when operation generates lots of dust Replace fresh air filter; where operation produces lots of dust, replace more often Check air condition: proper mounting, hose connections and electric contacts; check at least once every year UNDERCARRIAGE + UPPERCARRIAGE + WORKING ATTACHMENTS Lubricate bearing points of working attachments Inspect teeth for wear Lubricate bearing points on undercarriage Lubricate daily when required due to type of use and/or shift operation Check parts for cracks Check counter weight and tank for proper mounting Check lines and screwed connections for proper fit Check panelling hinges, quick fasteners and gas pressure springs of the caps Instruct operators in the proper use of the equipment Instruct the operator in how the machine must be lubricated according to the lubricating chart and make him aware of potential operator errors

copyright by

MJFCIFSS

3.32.5


Service Manual






Note

HYDRAULIC QUICK CHANGE ADAPTER Carry out a functional test of the visual and acoustic warning systems Carry out a visual inspection of the extended locking bolts Check hydraulic hoses and wire harness Lubricate locking bolts Clean mesh filters inside the screwed connections of the hydraulic hoses MECHANICAL QUICK CHANGE ADAPTER Carry out a visual inspection of the extended locking bolts Lubricate locking bolts Tab. 1


Note: 1 The intervals for the change of the motor oil might have to be shortened, depending on the actual temperature, fuel and oil quality. 2 In the case of applications with excessive dust generation, observe shortened maintenance intervals, see group 1.50. 3 For environmentally friendly hydraulic fluids, adjust the maintenance interval on the basis of regular analyses, see group 1.50. 4 The maintenance intervals might have to be shortened, depending on the operating conditions (e.g. generation of dust, barrel fuelling).

Comments / defects

Date:

3.32.6

.........................................


copyright by

MJFCIFSS

Service Manual

Inspection and maintenance schedule R 313 Litronic / R 317 Litronic

Inspection and maintenance schedule 1 R 313 Litronic / R 317 Litronic A 313:Typ 636 from serial number 27752 A 317:Typ 790 from serial number 18161 Customer:

................................

Serial no.:

................................

Type:

................................

Operating hours:

................................

Date:

.............................

Caution! Careful maintenance can only be carried out when the machine is clean. In particular, visual inspections, such as for cracks, can only be made on a clean machine. Clean the machine before starting any maintenance work (see also the chapter Maintaining the machine safely, subheadings Cleaning and Checking for cracks). Note! The daily maintenance tasks, which the machine operator has to carry out, include a function check of the brakes (swing gear, operating and parking brake), electrical and hydraulic systems. Additionally, a visual check must be made for leaks on the engine, hydraulic system, transmission and axles.


WORK TO BE CARRIED OUT R 313 Litronic / R 317 Litronic By maintenance personnel (machine operator)



Note


DIESEL ENGINE Check oil level and oil pressure in engine Check coolant level and coolant temperature Check air filter via maintenance indicator Check and drain water separator on fuel filter Drain off water and sediment on fuel tank Empty dust collector on air filter (shorten or extend interval as necessary)

copyright by

MJFCIFSS

3.38.1


Service Manual

R 313 Litronic / R 317 Litronic Maintenance / inspection at operating hours




Note


Check and clean cooler, pressure relief valve, coolant hose, fan Check condition of V-belt Replace lube oil filter cartridge Replace engine oil

1)

Check oil, cooling and fuel system for leaks and condition Replace water filter cartridge (at least 1 x annually) Check and adjust throttle control Check engine bracket, oil pan mounting and clamps Check anti-corrosion fluid / antifreeze in coolant (replace coolant every 2 years) Check / adjust valve clearance, Renew valve bonnet seal Check fuel leakage oil line (replace at least every 2 years) Check intake system and exhaust system for leaks and for condition Check glow plugs, change if necessary Replace fuel fine filter cartridge (or as necessary)

4)

Replace fuel prefilter cartridge (or as necessary)

4)

Replace main element of air filter (according to maintenance indicator / annually) Replace safety element of air filter (every third change of main element / annually)

Never clean!

Check clean air line (during filter maintenance) Replace adjust injection valve (every 3000 operating hours) HYDRAULIC SYSTEM Check oil level in hydraulic tank Clean magnetic rod in return filter (daily during first 300 hrs.) Replace filter element in return filter (first time at 500 hrs.) Replace filter unit on servo oil unit Check mounting of components

3.38.2

copyright by

MJFCIFSS

2)

Service Manual






Note


Clean hydraulic oil cooler (and as necessary) Drain off water in hydraulic tank (when using environmentally friendly fluids, max. 0.1 % part of water permissible, insert bypass filter, take oil sample) Check hydraulic system for leaks and function Check / adjust servo, primary and secondary pressures Replace hydraulic oil in tank (or optimize interval with oil analysis)

2), 3)

Replace breather filters on hydraulic tank

2)

ELECTRICAL SYSTEM Check indicator lights and displays when turning on Check lighting Check acid concentration and level and wire terminals and pole ends on batteries and all plug connections Spray slip rings on rotary connection (if present) with Cramolin contact spray Check function of entire system and components SWING GEAR Check oil level and look for leaks Check function and action of swing gear brake Check mounting of gear and oil motor Replace gear oil (first time at 500 hrs.) SWING RING Check mounting screws for tight seating and entry of swing gear pinion TRAVEL GEAR Check oil level and look for leaks Check function and effectiveness of travel brake Check mounting of gear and oil motor Replace gear oil (first time at 500 hrs.)

copyright by

MJFCIFSS

3.38.3


Service Manual

R 313 Litronic / R 317 Litronic Maintenance / inspection at operating hours



By authorized expert personnel First and only interval Repeat interval

TRACK COMPONENTS Check chain tension visually, retension if necessary Clean chain (after completion of work) Check mounting of track pads and sprockets Clean and grease sliding surfaces of tensioning device Check for leaks on idlers, carrier and track rollers OPERATORS CAB + HEATER Check / refill washing fluid in windshield washer system container Check function of heater (before start of winter) Check heating system for leaks Check door and window hinges as well as locks Check water inlet valve for function and dirt, clean if necessary AIR CONDITIONING SYSTEM Turn on air conditioning system regularly (at least 1 x every 14 days) Check condenser for contamination, blow out if necessary Check mounting screws and compressor drive belt Check dryer collector unit (moisture, fill and condition), replace if required (at least every 2 years) Clean fresh air filter (at least 1 x monthly, weekly for dust intensive use) Replace fresh air filter (shorten change interval for dust intensive use) Check mounting of air conditioning system, hose connections and electrical contacts (at least 1 x annually) UNDERCARRIAGE + UPPERCARRIAGE + ATTACHMENTS Visually check wear condition of teeth Lubrication of bearing points (depending on application, daily in mult-shift operation) Check parts for cracks

3.38.4

copyright by

MJFCIFSS

Note

Service Manual






Note


Check mounting tightness of counterweight and tank Check line and screw connections for tight seating Check cover hinges, quick connections and gas cylinders on hoods Point out appropriate use of attachment Have machine lubricated according to lubrication schedule by the machine operator and point out any operating errors. HYDRAULIC QUICK CHANGE ADAPTER Check function of visual and acoustic warning devices Check extended position of locking pins visually Check condition of hydraulic hoses and of wiring harness Lubricate locking pins Clean strainer MECHANICAL QUICK CHANGE ADAPTER Check extended position of locking pins visually Lubricate locking pins Tab. 1-1 1 2 3 4


Engine oil change intervals can be shortened depending on temperature, fuel and oil quality. Observe shortened maintenance intervals in dust intensive application. When using environmentally friendly hydraulic fluids, the maintenance interval is to be determined by regular analysis. Shorten the maintenance interval depending on application (e.g. dust intensive application, barrel refuelling).

Comments / defects

copyright by

MJFCIFSS

3.38.5


Service Manual

R 313 Litronic / R 317 Litronic Date:

3.38.6

...................................... ...


copyright by

MJFCIFSS

Service Manual


Group

Type

Technical data of diesel engines

4.02.1

A 309 LI 20221A 311 LI 20222-


4.03.1

R 313 LI 27752-


4.04.1

A 312 LI 12363-


4.05.1

A 314 LI 2001A 316 LI 2001A 316 LI-IND 2001R 317 LI 18161-

4.1 MJFCIFSS

Service Manual

4.2 MJFCIFSS

Service Manual

Technical data of diesel engines Engine type: BF 4 M 2012

Technical data of diesel engines 1 Engine type: BF 4 M 2012 Installation in machines / from serial no.: Power according to DIN / ISO 9249 Max. torque (max. engine speed)

A 309-Li / 20221

A 311-Li / 20222

kW

63

67

PS

86

91

Nm

352

371

A 309-Li / 20221

A 311-Li / 20222

Operating data Design

4-cylinder - turbo

Operating method

4-stroke direct injection

Bore

mm

101

Stroke

mm

126

Displacement

3

cm

4040

Firing sequence

1-3-4-2

Compression ratio

19 : 1

Combustion pressure at starting speed

bar

30-38

Firing interval

°kW

180

Weight (dry)

kg

360

Direction of rotation (seen from flywheel)

left

Flywheel housing

SAE 4

Cooling system

Recirculation cooling

Speed range

A 309-Li / 20221

A 311-Li / 20222

2000

2000

Rated speed

min-1

High idle rpm

min-1

Low idle rpm

min

-1

Lowest operating speed

min-1

1000

-1

1500

Speed at max, engine speed

min

Settings Inlet valve play (cold) Outlet valve play (cold) Begin of delivery

+40

2100 +50

+100

850 +100

2100 850

A 309-Li / 20221 mm

A 311-Li / 20222 0,30

mm

0,50

°CA before TDC

see type plate

copyright by

MJFCIFSS

4.02.1


Service Manual

Engine type: BF 4 M 2012 Filling volumes (approx. values)

A 309-Li / 20221

Lubricating oil in standard oil pan

A 311-Li / 20222

l

max. 8,5 / min. 7,0

Lubricating oil system (filter / cooler / channels)

l

10,0

Filling volumes (for oil change with filter replacement)

l

15,5

Cooling liquid including coolant

l

15,5 (Engine alone 9,3)

Operating data

A 309-Li / 20221

A 311-Li / 20222

Coolant temperature

°C

110 max.

Thermostat opening temperature

°C

87 -103

Pressure in cooling system

bar

min. 1.4 in engine at operating temperature (coolant temperature > 110°C), measured at coolant pump outlet (connection to heating) at nominal engine speed

Lubricating oil temperature

°C

max. 140

Min. lubricating oil pressure

°C

Injection nozzles

DLLA 151PV3 190588

Injection pressure of injection nozzles: new at end of service life (3000 operating hours)

220 +8 at least 198 +8

bar bar

Max. engine inclination towards right or left

right 45 ° / left 35 °

Max. engine inclination towards front or rear

30 °

Engine wear parts

A 309-Li / 20221

A 311-Li / 20222

Fuel filter

1 unit

10 m prefilter

Fuel filter

1 unit

3 m fine filter

Oil filter

1 units

Air filter

1 unit 1 unit

Main element Safety element

V-belt

2 unit

8PK 1850 NDIN 7867 8PK 1850 NDIN 7867

Safety device: oil pressure sensor

1 unit

B16 Response pressure: 0.5 bar

Coolant temperature sensor

1 unit

B2 Response temp. 100 ±3°C

Coolant level sensor

1 unit

B3

For order numbers, see respective spare parts list and service packs

Antifreeze agent / mixing ratio

Min. temperature for protection

Water content

Antifreeze content

-37°C

50%

50%

Note! Do not exceed an antifreeze concentration of 60%, as this tends to lead to reduced protection and cooling effect!

4.02.2

copyright by

MJFCIFSS

Service Manual

Technical data of diesel engines Engine Type: BF 4 M 2012 C

Technical data of diesel engines 1 Engine Type: BF 4 M 2012 C Installation in machines / from serial no.:

R 313-Li / 27752

Power according to DIN / ISO 9249

kW PS

99

Speed at max. (engine speed)

Nm

422 (1500 rpm)

Operating data

73

R 313-Li / 27752

Design

4-cylinder turbo, intercooled

Type


Bore

mm

101

Boom

mm

126

Displacement

cm3

4038

Firing sequence

1-3-4-2

Compression ratio

19 : 1


bar

Firing interval

°kW

180

Weight (dry)

kg

380


30 - 38

left

Flywheel housing

SAE 4

Cooling system

Recirculation cooling

Speed range

R 313-Li / 27752

Rated speed

rpm

1800

High idle rpm

rpm

1900 +40

Low idle rpm

rpm

850 +100


rpm

1000

Speed at max. torque

rpm

1500

Settings

R 313-Li / 27752

Inlet valve play (cold)

mm

0.30

Outlet valve play (cold)

mm

0.50

°CA before TDC

see type plate

Begin of delivery

copyright by

MJFCIFSS

4.03.1


Service Manual

Engine Type: BF 4 M 2012 C Filling volumes (approx. values)

R 313-Li / 27752


l

max. 8.5 / min. 7.0

Lubricating oil system (filter / cooler / channels)

l

10.0


l

14.0


l

15.5 (motor only: 9.3)

Operating data

R 313-Li / 27752

Coolant temperature

°C

110 max.

Opening temperature of Thermostat (control range)

°C

87 - 103

Pressure in cooling system

bar

min. 1.4 in engine at operating temperature (coolant temperature > 110°C), measured at coolant pump outlet (connection to heating) at nominal engine speed

Lubricating oil temperature

°C

max. 140


bar

at approx. 900 rpm 0.8 bar (oil temp. 120 °C)

Injection nozzles

DLLA 151PV3 190588

Injection pressure of injection nozzles: New after 3000 operating hours

220 +8 min. 198 +8

bar bar

Max. engine inclination to

right 45 ° / left 35 °

Max. engine inclination towards front or rear

30 °

Engine wear parts, V-belts and safety devices

R 313-Li / 27752

Fuel filter

1

Coarse filter 10 m

Fuel filter

1

Fine filter 3 m

Oil filter

1

Air filter

1 1

V-belt

2

8PK 1850 NDIN 7867


1

B 16 response pressure: 0.5 bar


1

B2 response temperature 100 ±3°C


1

B3




4.03.2

Antifreeze content

Water content

Antifreeze content

-37°C

50%

50%

copyright by

MJFCIFSS

Service Manual

Technical data of diesel engines Engine Type: BF 4 M 2012 C


copyright by

MJFCIFSS

4.03.3


Service Manual

Engine Type: BF 4 M 2012 C

4.03.4

copyright by

MJFCIFSS

Service Manual

Technical data of diesel engines Engine type: BF 4 M 1013 E

Technical data of diesel engines 1 Engine type: BF 4 M 1013 E Installation in machines / from serial no.: Power according to DIN / ISO 9249 Max. torque (max. engine speed)

A 312-Li / 12363 kW

74

HP

100.7

Nm

422

Operating data

A 312-Li / 12363

Design

4-cylinder - turbo

Type


Bore

mm

108

Stroke

mm

130

Displacement

3

4764

cm

Firing sequence

1-3-4-2

Compression ratio

17.5 : 1


bar

30 - 38

Firing interval

°kW

180

Weight (dry)

kg

430 (according to DIN 70020 - A)


left

Flywheel housing

SAE 4

Cooling system

liquid-cooled

Speed range

A 312-Li / 12363

Rated speed

rpm

1800

High idle rpm

rpm

1900 +30

Low idle rpm

rpm

850 +100


rpm

1000


rpm

1400

Settings

A 312-Li / 12363


mm

0.30


mm

0.50

°CA before TDC

Preset by manufacturer and specified on type plate

Begin of delivery

copyright by

MJFCIFSS

4.04.1


Service Manual

Engine type: BF 4 M 1013 E Filling volumes (approx. values)

A 312-Li / 12363


l

11


l

approx. 15.5


l

approx. 19 (7.2 l in engine + 11.5 l in radiator and lines)

Operating data

A 312-Li / 12363

Max. lubricating oil temperature

°C

130 (in oil pan)


bar

0.8 (at oil temperature of 120° C)

Safety valve of lubricating oil pump

bar

5.25 - 6.75

Injection pressure of injection nozzles: new after 3000 operating hours

bar bar

250 +12 245 +12


30°

Max. engine inclination towards fan / flywheel

30 °


A 312-Li / 12363

Fuel filter

1


Fuel filter

1

Fine filter 3 m

Oil filter

1

Air filter

1 1


V-belt

1 1

10 x 874 10x1050


1



1



1

B3



Antifreeze content

Water content

Antifreeze content

-37°C

50%

50%


4.04.2

copyright by

MJFCIFSS

Service Manual

Technical data of diesel engines Tightening torques / oversize levels

2 Tightening torques / oversize levels Installation in models / serial no.:

A 312-Li / 12363

Screw tightening torque: Screwed connections

Tightening instructions

Cylinder head

General notes

1. stage

Pre-tighten with 50 Nm

2. stage

130 Nm

3. stage

90 degrees

According to tightening sequence

Pre-tighten with 30-40 Nm

Apply a little oil to the screw thread and head surface

Screw for V-belt pulley 1. retightening angle

60 degrees

2. retightening angle

60 degrees

Flywheel

Pre-tighten with 30 Nm 1. stage

60 degrees

2. stage

60 degrees

Oversize levels / limit values




General notes

Cylinder Normal bore

mm

108 + 0.02

Wear limit of bore

mm

108.1

Normal diameter

mm

107.785 ± 0.009

Piston height

mm

Piston class A = 71.10 B = 71.18 C = 71.26

Piston from centre of piston boss to piston crown

Piston ring groove Annular groove

Double-tapered groove

Height of 1st ring groove

mm

2.0 + 0.1 + 0.08

Height of oil ring groove

mm

3.5 + 0.04 + 0.02

1. stage

- (double-tapered groove)

mm

0.17

Axial play of piston ring 1. Limit of play of compression ring Limit of play of compression ring

copyright by

MJFCIFSS

4.04.3


Service Manual

Tightening torques / oversize levels Oversize levels / limit values Limit of play of grooved piston ring

Tightening instructions mm

0.10

Piston ring gap

4.04.4

Limit value of 1st compression ring

mm

max. 0.8

Limit value of 2nd compression ring

mm

max. 2.5

Limit value of grooved piston ring

mm

max. 1.5

copyright by

MJFCIFSS

General notes

Service Manual

Technical data of diesel engines Engine type: BF 4 M 1013 EC

Technical data of diesel engines 1 Engine type: BF 4 M 1013 EC Installation in machines / from serial no.:

A 314-Li / 2001

A 316-Li / 2001 R 317 Li / 18161 86

Power according to DIN / ISO 9249

kW

82

PS

109

115

Max. torque (max. engine speed)

Nm

458

491

A 314-Li / 2001

A 316-Li / 2001 R 317 Li / 18161

Operating data Design

4-cylinder turbo, intercooled

Type Bore

4-stroke direct injection mm

108

Stroke

mm

130

Displacement

cm3

4767

Firing sequence

1-3-4-2

Compression ratio

17.5 : 1


bar

30 - 38

Firing interval

°kW

180

Weight (dry)

kg

430 (according to DIN 70020 - A)


left

Flywheel housing

SAE 4

Cooling system

liquid-cooled

Speed range

A 316-Li / 2001 R 317 Li / 18161

A 314-Li / 2001

Rated speed

min-1

High idle rpm

min

-1

1900 +30

Low idle rpm

min-1

850 +100


min-1

1000


min-1

1400

Settings

1800

A 316-Li / 2001 R 317 Li / 18161

A 314-Li / 2001


mm

0,30


mm

0,50

°CA before TDC

Preset by manufacturer and specified on type plate

Begin of delivery

copyright by

MJFCIFSS

4.05.1


Service Manual

Engine type: BF 4 M 1013 EC

Filling volumes (approx. values)

A 316-Li / 2001 R 317 Li / 18161

A 314-Li / 2001


l

11


l

approx. 15,5


l

approx. 25 (13.5 l in engine + 11.5 l in radiator and lines)

Operating data

A 316-Li / 2001 R 317 Li / 18161

A 314-Li / 2001

Max. lubricating oil temperature

°C

125 (in oil pan)


bar

0.8 (at oil temperature of 120° C)

Safety valve of lubricating oil pump

bar

5.25 - 6.75

Injection pressure of injection nozzles: new after 3000 operating hours

bar bar

250 +12 245 +12


30°

Max. engine inclination towards fan / flywheel

30 °


A 316-Li / 2001 R 317 Li / 18161

A 314-Li / 2001

Fuel filter

1


Fuel filter

1

Fine filter 3 m

Oil filter

1

Air filter

1 1


V-belt

1 1

10 x 874 10x1050


1



1



1

B3



Antifreeze content

Water content

Antifreeze content

-37°C

50%

50%


4.05.2

copyright by

MJFCIFSS

Service Manual

Technical data of diesel engines Tightening torques / oversize levels

2 Tightening torques / oversize levels A 314-Li / 2001 A 316-Li / 2001 R 317-Li / 18161

Installation in models / serial no.:

Screw tightening torque: Screwed connections


Cylinder head

General notes

1st stage

Pre-tighten with 50 Nm

2nd stage

130 Nm

3rd stage

90 degrees

According to tightening sequence

Pre-tighten with 30-40 Nm


Screw for V-belt pulley 1st retightening angle

60 degrees

2nd retightening angle

60 degrees

Flywheel

Pre-tighten with 30 Nm 1st stage

60 degrees

2nd stage

60 degrees

Oversize levels / limit values




General notes

Cylinder Normal bore

mm

108 + 0.02

Wear limit of bore

mm

108.1

Normal diameter

mm

107.785 ± 0.009

Piston height

mm

Piston class A = 71.10 B = 71.18 C = 71.26

Piston from centre of piston boss to piston crown

Piston ring groove Annular groove

Double-tapered groove

Height of 1st ring groove

mm

2.0 + 0.1 + 0.08

Height of oil ring groove

mm

3.5 + 0.04 + 0.02

copyright by

MJFCIFSS

4.05.3


Service Manual

Tightening torques / oversize levels Oversize levels / limit values


Axial play of piston ring Limit of play of 1st compression ring

1st stage

- (double-tapered groove)

Limit of play of compression ring

mm

0.17

Limit of play of grooved piston ring

mm

0.10

Piston ring gap

4.05.4

Limit value of 1st compression ring

mm

max. 0.8

Limit value of 2nd compression ring

mm

max. 2.5

Limit value of grooved piston ring

mm

max. 1.5

copyright by

MJFCIFSS

General notes

Service Manual


Group

Type

Coupling

5.05.1

A 309 LI 20221A 311 LI 20222-

Clutch

5.10.1

A 312 LI 12363A 314 LI 2001A 316 LI 2001A 316 LI-IND 2001R 317 LI 18161-

5.1 MJFCIFSS

Service Manual

5.2 MJFCIFSS

Service Manual

Coupling Function

Coupling 1 Function The flexible coupling (torsion dampers) are installed between the diesel engine and the variable displacement pump and dampens torque impacts in the event of load changes. It is a permanent coupling and thus transmits the motor torque directly and continuously to the pump. Decoupling is not possible.

Fig. 1

Coupling built into motor

copyright by

MJFCIFSS

5.05.1

Coupling

Service Manual

Design and function of coupling

2 Design and function of coupling The flexible element 4 of the coupling 1 is fixed with screws to the flywheel 10 of the diesel engine. The four metal segments 3 of the internally toothed hub 2 are connected to the drive shaft of the double variable displacement pump 20. The segments 3 are aligned in a circle and mesh in the tooth spaces of the specially formed flexible element 4, thus positively connecting the coupling sections with each other, allowing for limited flexibility. The power from the diesel engine is applied to the double variable displacement pump 20 through the flywheel 10, the mounting bolts 7, the flexible element 4, the segments 3 and the hub 2 to the pump's drive shaft 20. Torque impacts upon start-up of the diesel engine and load fluctuations are thus compensated, as the flexible element is deformed at the moment of impact and subsequently released. Rotational vibration from the engine is also significantly dampened so that the pump 20 is only marginally affected.

Fig. 2

5.05.2

Fitting position of the coupling1

1

Coupling, complete (torsion damper)

10

Flywheel

2 3

Hub Segment

11 20

Engine intermediate housing Double variable-displacement pump

4 5

Flexible element Allen head screw

22 24

Retaining washer Hex head screw

7

Allen head screw

copyright by

MJFCIFSS

Service Manual

Coupling Installation and dismantling of the coupling

3 Installation and dismantling of the coupling 3.1

Dismantling Secure the variable-displacement pump 20 using a rope. Remove the Allen head screws 24 and the washers 22. Remove the flange-mounted double variable displacement pump 20 from the intermediate housing 11 of the diesel engine and pull it together with the hub 2 from the flexible element 4. Note! Before dismantling the coupling 1, note the position of the hub 2 at the drive shaft of the double variable displacement pump 20 and of the flexible element 4 at the flywheel 10. Remove the Allen head screws 5. Pull the hub 2 from the drive shaft of the variable displacement pump 20. Remove the hex head screws 7 and disconnect the flexible element 4 from the flywheel 10.

3.2

Installation Caution! Screws that are tightened with less than the prescribed torque might become loose and can seriously damage the coupling. Always tighten all screws with a torque wrench and apply the prescribed torque! Grease the drive shaft of the double variable displacement pump 20 with LIEBHERR CTK special lubricant, see group 1.50. Push the hub 2 onto the spline mesh section to the collar of the pump drive shaft (for correct position, see Fig. 3). Tighten the attachment screw 5 (tightening torque 70 Nm). Place the flexible element 4 in the correct position, see Fig. 3, onto the flywheel 10. Tighten the Allen screws 7 (tightening torque 50 Nm). Check the flexible element 4 for concentricity at outer edge (tolerance = 0.1 mm). Check the surface of the flexible element 4 for side-to-side wobble (tolerance = 0.05 mm). Push the drive shaft of the double variable displacement pump 20 with the mounted hub 2 into the flexible element 4 and position it on the engine intermediate housing 11. Insert and tighten the hex head screws 24 with retaining washers 22 (tightening torque 68 Nm). 7

1

Coupling, complete (torsion damper)

10

Flywheel

2

Hub

11

Engine intermediate housing

3

Segment

20

Double variable-displacement pump

4 5

Flexible element Allen head screw

22 24


7

Allen head and hex head screw

copyright by

MJFCIFSS

5.05.3

Coupling

Service Manual

Installation and dismantling of the coupling

Fig. 3

5.05.4

Sectional drawing showing position and alignment of the coupling

copyright by

MJFCIFSS

Service Manual

Clutch Design and function of coupling

Clutch 1 Design and function of coupling see Fig. 1 and Fig. 2 The flexible coupling (torsion dampers) 5 is mounted between the diesel engine and the variable-displacement pump. It dampens impacts caused by torque and load changes. It is a permanent coupling and thus transmits the motor torque directly and continuously to the pump. Decoupling is not possible. Disk 5.1 is connected with bolts to the flywheel C of the diesel engine. The hub 5.2 is guided axially by circular disks 5.3 that are riveted onto hub 5.2. The hub 5.2 can be moved radically on disk 5.1. Eight pressure springs 5.4 mounted on the reference circle provide a non-positive flexible connection between the disks 5.3 and the hub 5.2. The drive shaft 10.10 of the variable-displacement pump 10 is connected by means a spline mesh to the hub 5.2 of the torsion damper 5 (positive connection). The transmission of power from the diesel engine to the pump 10 consists of the flywheel C, the mounting bolts 7, the disk 5.1, the pressure springs 5.4, the hub 5.2 with the disks 5.3 and the drive shaft 10.10 of the pump 10. Torque impacts upon start-up of the diesel engine and load fluctuations are thus compensated, as the pressure springs 5.4 are compressed at the moment of impact and subsequently released. The rotational vibration from the engine is also significantly dampened so that the pump 10 is only marginally affected.

copyright by

MJFCIFSS

5.10.1

Clutch

Service Manual


Fig. 1

Installation position of coupling 5 (a = A 312 - 316, b = R 313 / R 317)

5

Coupling (torsion damper)

80

Holder

7 10

Allen head / hex head screw Variable-displacement pump

81

Allen head screw

11 12

Allen head screw Allen head / hex head screw

C D

Flywheel Intermediate housing / engine

2 Installation and dismantling of the coupling (see Fig. 2 on page4)

2.1

Dismantling Secure the variable-displacement pump 10 using a rope. Remove the screws 11 and 81. Remove the hex retaining washers 12. Disconnect the flange connection between the variable-displacement pump 10 and the intermediate housing B of the diesel engine, and pull the pump from the coupling 5. Note and mark the installation position of the coupling 5. Remove the mounting bolts 7. Remove the coupling 5 from the flywheel C of the diesel engine.

5.10.2

copyright by

MJFCIFSS

Service Manual

Clutch Installation and dismantling of the coupling

2.2

Installation Note!

Note! Incorrect installation might destroy the coupling 5 due to insufficient engagement of the spine mesh of the hub 5.2 and the drive shaft 10.10 of the pump. Check position A of the installed coupling (see sectional drawing, see Fig. 2). Mount the coupling 5 in its correct installation position, see Fig. 2, on the flywheel C. Screws that are tightened with less than the prescribed torque might become loose and can seriously damage the coupling. Tighten all screws with the prescribed torque, using a torque spanner! Tighten Allen screws 7 (tightening torque 46 Nm). Check the hub 5.2 for concentricity at outer edge (tolerance = 0.1 mm). Check the surface of the coupling 5 for side-to-side wobble (tolerance = 0.05 mm). Apply a little Liebherr CTK special paste onto the spine mesh of the pump drive shaft and the hub 5.2, see group 1.50. Slide the drive shaft 10.10 of the pump into the hub 5.2 and mount the pump 10 on the intermediate housing D. Screw in the Allen head screws 11 / 81 with the retaining washer 12 and the Allen head screws 81 with the retaining washer 12 and the holder 80, see Fig. 2, (tightening torque 46 Nm).

copyright by

MJFCIFSS

5.10.3

Clutch

Service Manual


Fig. 2 5 5.1

5.10.4

Sectional drawing showing position and alignment of the coupling Coupling (torsion damper) Washer

11 12

Allen head screw Retaining washer

81

Allen head screw

5.2

Hub

5.3

Washers

5.4

Pressure spring

A

Correct position and alignment of the coupling

7

Allen head screw

B

Incorrect position and alignment of the coupling

copyright by

MJFCIFSS

Service Manual

Clutch Installation and dismantling of the coupling

10 10.10

C D

Variable-displacement pump Pump drive shaft

copyright by

MJFCIFSS

Flywheel / engine Intermediate housing / engine

5.10.5

Clutch

Service Manual


5.10.6

copyright by

MJFCIFSS

Service Manual


Group

Type

Adjustment protocol

6.09.1

A 309 LI 20221-27109

Adjustment protocol

6.09.11

A 309 LI 27110-

Adjustment protocol

6.11.1

A 311 LI 20222-27111

Adjustment protocol

6.11.11

A 311 LI 27112-

Adjustment protocol

6.12.1

A 312 LI 12363-

Adjustment protocol

6.13.1

R 313 LI 27752-

Adjustment protocol

6.14.1

A 314 LI 2001-

Adjustment protocol

6.16.1

A 316 LI 2001A 316 LI-IND 2001-

Adjustment protocol

6.17.1

R 317 LI 18161-

LSC system

6.20.1


Design of hydraulic system

6.22.1

A 309 LI 20221A 311 LI 20222-

Layout of hydraulic system

6.24.1



6.27.1

R 313 LI 27752R 317 LI 18161-

Adjustment guidelines for hydraulic system

6.30.1

A 309 LI 20221A 311 LI 20222-


6.34.1

A 312 LI 12363A 314 LI 2001A 316 LI 20016.1

MJFCIFSS

Service Manual Adjustment guidelines for hydraulic system

6.37.1

R 317 LI 18161-

Hydraulic system

6.40.1

A 309 LI 20221-23502 A 311 LI 20222-23506

Hydraulic system

6.40.11

A 309 LI 23503-27109 A 311 LI 23507-27111

Hydraulic system

6.40.21

A 309 LI 27110A 311 LI 27112-

Hydraulic system

6.42.1

A 312 LI 12363-13288

Hydraulic system

6.42.13

A 312 LI 13289-29897

Hydraulic system

6.42.21

A 312 LI 29898-

Hydraulic system

6.43.1

R 313 LI 27752-

Hydraulic system

6.44.1

A 314 LI 2001-11146 A 316 LI 2001-11151 A 316 LI-IND 2001-11151

Hydraulic system

6.44.13

A 314 LI 11147-13103 A 316 LI 11152-13104 A 316 LI-IND 11152-13104

Hydraulic unit

6.44.21

A 314 LI 13104A 316 LI 13105-28060 A 316 LI-IND 13105-28060

Hydraulic unit

6.44.31

A 316 LI 28061A 316 LI-IND 28061-

Hydraulic unit

6.47.1

R 317 LI 18161-21204

Hydraulic unit

6.47.11

R 317 LI 21205-

6.2 MJFCIFSS

Service Manual

Adjustment protocol A 309 Litronic from 20221

Adjustment protocol 1 A 309 Litronic from 20221 Date:

.........................................

Mechanic:

.........................................

Customer:

Type:

.........................................

Series no.:

.........................................

Operating hours: .....................................

Checks

Measuring point Specified value

1.

Operating conditions - warming up

1.1

Oil temperature

min. 50 +10°C

1.2

Regulating rpm

2000 min-1

1.3

Max. speed

2100 +50min-1

1.4

Min. speed

770 +50min-1

2.

Pilot pressure

Test point 49 32

±1

Actual value

Possible Setting.

..................................... ....

View Comment

Set measure at valve 51.

bar

A 309 LI 20221-27109 copyright by

MJFCIFSS

6.09.1

Adjustment protocol

Service Manual

A 309 Litronic from 20221

Checks

3.

Horsepower control

3.1

at speed level 1 (low idle rpm)

3.2

3.3

6.09.2


Actual value

Possible Setting.

using adapter cable at Y50.

Measuring point 59 ( X3 )

Current

850 +25 mA

Control pressure LR

30 ±1 bar

View Comment

at power test Remove plug of Y50. Set valve to emergency setting. (Remove cotter pin and actuate lever.)

Current

<50mA

Control pressure LR

1 bar (tank pressure)

Checking regulating pressure for emergency operation

Measuring point 59 30 ±1 bar


MJFCIFSS

Service Manual


Checks

4.

Checking Function Y51

4.1

Current 200 - > 900 mA via speed steps or flow reduction kit

5.

Checking Flow reduction of pump P1

5.1

Value X


Actual value

Possible Setting.

View Comment Take measure using adapter cable at Y51.

Measuring point 57 ( X1)

Pressure: see Diagram

up to pump no. 20194344

9,3 ±0.2 mm

starting with pump no. 20194345

12,4 ±0.2 mm


MJFCIFSS

6.09.3

Adjustment protocol

Service Manual


Checks


6.

Begin of hydraulic regulation of double variabledisplacement Pump (basic setting)

Measuring point 40/41

6.1

Pump P1 Primary pressure relief valve 120 (extend bucket cylinder) reduce below begin of regulation, turn in until actuating pressure at 43 rises to 10 bar

50 ±2 bar

Actual value

Possible Setting.

View Comment Speed - low (about 1,200 min-1) Y50 / Y51 not active Y50 in emergency position (30 bar at measuring point 59) Adjust using screw 1 on pump regulator

10 bar

(for auxiliary control block, AHS ) valve 122 is in charge

6.2

Pump P2 Primary pressure relief valve 121 (retract support cylinder) reduce below begin of regulation, turn in until actuating pressure at 44 at

50 ±2 bar

Adjust using screw 2 on pump regulator

10 bar

Re-connect plug on Y 50 and Y51. Return Y50 to normal position

6.09.4


MJFCIFSS

Service Manual


Checks

7.

Checking power of the diesel engine (power test) Note: Perform this check only when necessary (e.g. when you detect reduced engine performance.


Actual value

Possible Setting.

View Comment

High idle rpm

Measuring point 41

max. fan speed 2150 min-1 approx. Pull out plug (I = 0 mA).

Disconnect Y50 and/or launch menu power test on your laptop Reduce primary relief valve 120 / 121 (retract stick cylinder) below test pressure. Turn back in until you reach test pressure again. Be careful not to lower diesel engine speed below rated speed. (Check diesel speed at B12). Pump at Qmax Control chamber

( < 50mA)

100 bar (each pump) 2000 +10min-1 Measuring points 41 and 44 = tank pressure


MJFCIFSS

6.09.5

Adjustment protocol

Service Manual


Checks

8.

Secondary pressure Primary pressure relief valve 120 / 121 screwed in


Actual value

Possible Setting.

View Comment

Measuring point 40

at upper idle speed

8.1

Operational functions - extend adjusting cylinder

380 +20 bar

Valve 129

- retract adjusting cylinder

380 +20 bar

Valve 130

- extend control cylinder

380 +20 bar

Valve 131

- retract control cylinder

380 +20 bar

Valve 132

- extend bucket cylinder

380 +20 bar

Valve 133

- retract bucket cylinder

380 +20 bar

Valve 134

Measuring point 41

8.2

6.09.6

- retract stick cylinder

380 +20 bar

Valve 127

- extend stick cylinder

380 +20 bar

Valve 128

Travel function

Measuring point 41

- Travel forward

380 +20 bar

Valve 214

- Travel reverse

380 +20 bar

Valve 215


MJFCIFSS

Service Manual


Checks

9.

10.


Primary pressure / high pressure

Measuring point 40

Primary relief valve 120 Retracting bucket cylinder

350 +10 bar

(with accessory kit AHS11 / AHS 12 Primary relief valve 122 via hammer starting function; see kit group 16.)

Measuring point 40

Primary relief valve 121 Retracting support cylinder

350 +10 bar

Primary pressure / low pressure

Measuring point 45

Primary relief valve 123

110 +20 bar

Actual value

Possible Setting.

View Comment High idle rpm

350 +10 bar Measuring point 41

High idle rpm

Extending swivel cylinder


MJFCIFSS

6.09.7

Adjustment protocol

Service Manual


Checks

11.

Slewing gear function secondary pressure

11.1

Turning

11.2

Actual value

Possible Setting.

View Comment

Measuring points 197/198

Turning right

197 200 +10 bar

Valve 191 (high pressure setting) Lock nut 1 Adjusting screw 2

Turning left

198 200 +10 bar


198 70 ±5 bar

Valve 192 (low pressure setting) Lock nut 3 Adjusting screw 4

197 70 ± 5bar


Slowing down Turning right

Turning left

6.09.8



MJFCIFSS

Service Manual


Checks

12.

Travel motor

12.1

Regulation Begin of regulation End of regulation

12.2


Actual value

Possible Setting.

View Comment Adjusting screw 213.1 on travel motor 210

Measuring point 40 / M 240 bar 340 bar

Output speed (speed) Standard machine

1500 ±25 min-1

Speeder machine

1930 ±25 min-1

on drive shaft, measured during onroad gear Qmin stop screw 212.1

Checking measurement Y Standard machine

23.8 mm

Speeder machine

26.0 mm


MJFCIFSS

6.09.9

Adjustment protocol

Service Manual


Checks

13.


Lowering speed of equipment

4 seconds approx.

Checking measurement Z of stop screw 162

5 mm

14.

Hydrostatic fan drive

14.1

Checking the fan speed Check speed while diesel engine runs at rated speed. Disconnect Y352.

Actual value

Possible Setting.

View Comment

2150 +50min-1

Hydraulic oil temperature > should be 50°C when checking fan speed.

Danger! Moving fan blades can cause serious injury to fingers and hands. Before working near the fan, switch off the engine.

6.09.10


MJFCIFSS

Service Manual

Adjustment protocol A 309 Litronic from 27110 (applicable from software version 5.12)

Adjustment protocol 2 A 309 Litronic from 27110 (applicable from software version 5.12) Date:

.........................................

Mechanic:

.........................................

Customer:

.........................................

Type:

.........................................

Series no.:

.........................................

Operating hours:

.........................................

Checks


1.

Operating conditions warming up

1.1

Oil temperature

min. 50 +10°C

1.2 1.2.1 1.2.2

Regulating rpm during work with servo OFF (on-road travel)

1800 rpm 1950 rpm

1.3 1.3.1 1.3.2 1.4

Max. speed during work with servo OFF (on-road travel) Min. speed

2.

Pilot pressure

Actual value

Possible Setting.

View Comment

1950 +40 rpm 2100 +50 rpm Set measure at valve 51.

770 +50 rpm Measuring point 49 32 ±1 bar

3.

Horsepower control

3.1


3.2

3.3



Current

850 +25 mA

Control pressure LR

30 ±1 bar

at power test Current

<50mA

Control pressure LR




Remove plug of Y50. Set valve to emergency setting. (Remove cotter pin and actuate lever.) Diagram, see page 12.


MJFCIFSS

6.09.11

Adjustment protocol

Service Manual

A 309 Litronic from 27110 (applicable from software version 5.12)

Checks 4.

Checking function Y51

4.1


5.

Checking flow reduction of pump P1

5.1

Value X

6.09.12


Actual value

Possible Setting.



Pressure: see diagram

12,4 ±0.2 mm


MJFCIFSS

Service Manual


Checks


6.

Begin of hydraulic regulation of double variable-displacement Pump (basic setting)


6.1


50 ±2 bar

Actual value

Possible Setting.

View Comment Speed - low (about 1,200 rpm) Y50 / Y51 not active Y50 in emergency position (30 bar at measuring point 59) Adjust using screw 1 on pump regulator

10 bar


6.2


50 ±2 bar


10 bar



MJFCIFSS

6.09.13

Adjustment protocol

Service Manual


Checks 7.



Actual value

Possible Setting.



max. fan speed 2150 rpm approx. Pull out plug (I = 0 mA).

Disconnect Y50 and/or launch menu power test on your laptop Reduce primary relief valve 120 / 121 (retract stick cylinder) below test pressure. Turn back in until you reach test pressure again. Be careful not to lower diesel engine speed below rated speed. (Check diesel speed at B12). Pump at Qmax. Control chamber

6.09.14

( < 50mA)

100 bar (each pump) 1800 +10rpm Measuring point 43/44 = tank pressure


MJFCIFSS

Service Manual


Checks 8.



Actual value

Possible Setting.

View Comment

Measuring point 40

at upper idle speed

8.1


380 +20 bar

Valve 129


380 +20 bar*

Valve 130


380 +20 bar

Valve 131


380 +20 bar

Valve 132


380 +20 bar

Valve 133


380 +20 bar

Valve 134

Measuring point 41 - retract stick cylinder

380 +20 bar

Valve 127


380 +20 bar

Valve 128 * adjustment to 240 bar + 1 revolution of adjusting screw = 380 bar


MJFCIFSS

6.09.15

Adjustment protocol

Service Manual


Checks 8.2

9.

6.09.16


Actual value

Possible Setting.

View Comment

Travel function

Measuring point 41

- Travel forward

380 +20 bar

Valve 214

- Travel reverse

380 +20 bar

Valve 215


Measuring point 40

High idle rpm


350 +10 bar


Measuring point 40


350 +10 bar



MJFCIFSS

Service Manual


Checks 10.



Measuring point 45


110 +20 bar

Actual value

Possible Setting.




MJFCIFSS

6.09.17

Adjustment protocol

Service Manual


Checks 11.


11.1

Turning

11.2

Actual value

Possible Setting.

View Comment


Turning right

197 200 +10 bar


Turning left

198 200 +10 bar


198 70 ±5 bar


197 70 ± 5bar



Turning left

6.09.18



MJFCIFSS

Service Manual


Checks 12.

Travel motor

12.1


12.2


Actual value

Possible Setting.




1500 ±25 rpm

Speeder machine

1930 ±25 rpm


Checking measurement Y

13.

Standard machine

23.8 mm

Speeder machine

26.0 mm


4 seconds approx.


5 mm


MJFCIFSS

6.09.19

Adjustment protocol

Service Manual


Checks 14.


14.1



Actual value

Possible Setting.

View Comment

2150 +50rpm


Danger! Moving fan blades can cause serious injury to fingers and hands. Before working near the fan, switch off the engine (observe afterrun).

6.09.20


MJFCIFSS

Service Manual



.........................................

Mechanic:

.........................................

Customer:

.........................................

Type:

.........................................

Series no.:

.........................................

Operating hours:

.........................................

Checks


1.

Operating conditions - warming up

1.1

Oil temperature

min. 50 +10°C

1.2

Regulating rpm

2000 min-1

1.3

Max. speed

2100 +50min-1

1.4

Min. speed

770 +50min-1

2.

Pilot pressure

Measuring point 49

Actual value

Possible Setting.

View Comment


32 ±1 bar


MJFCIFSS

6.11.1

Adjustment protocol

Service Manual


Checks

3.

Horsepower control

3.1


3.2

3.3

6.11.2


Actual value

Possible Setting.



Current

850 +25 mA

Control pressure LR

30 ±1 bar

View Comment


<50mA

Control pressure LR

1±2 bar (tank pressure)



Remove plug of Y50. Set valve to emergency setting. (Remove cotter pin and actuate lever.)


MJFCIFSS

Service Manual


Checks

4.

Checking Function Y51

4.1


5.

Checking Flow reduction of pump P1

5.1

Value X


Actual value

Possible Setting.

View Comment Take measure using adapter cable atY51.


Pressure: see Diagram

up to pump no. 20194344

8,8 ±0.2 mm

starting with pump no. 20194345

11,8 ±0.2 mm


MJFCIFSS

6.11.3

Adjustment protocol

Service Manual


Checks


6.

Begin of hydraulic regulation of double variabledisplacement Pump (basic setting)


6.1


60 ±2 bar

Actual value

Possible Setting.

View Comment Speed - low (about 1,200 min-1) Y50 / Y51 not active Y50 in emergency position (30 bar at measuring point 59) Adjust using screw 1 on pump regulator

10 bar


6.2



60±2 bar

10 bar


6.11.4


MJFCIFSS

Service Manual


Checks

7.



Actual value

Possible Setting.

View Comment

High idle rpm

Measuring point 41

max. fan speed 2150 min-1 approx. Pull out plug (I = 0 mA).

Disconnect Y50 and/or launch menu power test on your laptop Reduce primary relief valve 120 / 121 (retract stick cylinder) below test pressure. Turn back in until you reach test pressure again. Be careful not to lower diesel engine speed below rated speed. (Check diesel speed at B12). Pump at Qmax Control chamber

( < 50mA)

110 bar (each pump) 2000 +10min-1 Measuring points 41 and 44 = tank pressure


MJFCIFSS

6.11.5

Adjustment protocol

Service Manual


Checks

8.



Actual value

Possible Setting.

View Comment

Measuring point 40

at upper idle speed

8.1


380 +20 bar

Valve 129


380 +20 bar

Valve 130

- retract boom cylinder

380 +20 bar

Valve 131

- extend boom cylinder

380 +20 bar

Valve 132


380 +20 bar

Valve 133


380 +20 bar

Valve 134

Measuring point 41

8.2

6.11.6

- retract stick cylinder

380 +20 bar

Valve 127


380 +20 bar

Valve 128

Travel function

Measuring point 41

- Travel forward

380 +20 bar

- Travel reverse

380 +20 bar

Valve 214 Valve 215


MJFCIFSS

Service Manual


Checks

9.

10.



Measuring point 40


350 +10 bar


Measuring point 40


350 +10 bar


Measuring point 45


110 +20 bar

Actual value

Possible Setting.



High idle rpm



MJFCIFSS

6.11.7

Adjustment protocol

Service Manual


Checks

11.


11.1

Turning

11.2

Actual value

Possible Setting.

View Comment


Turning right

197 200 +10 bar


Turning left

198 200 +10 bar


198 70 ±5 bar


197 70 ± 5bar



Turning left

6.11.8



MJFCIFSS

Service Manual


Checks


12.

Travel motor

12.1

Regulation

Measuring point 40 / M

Begin of regulation

240 bar

End of regulation

340 bar

12.2

Actual value

Possible Setting.



1500 ±25 min-1

Speeder machine

1930 ±25 min-1



13.

Standard machine

23.8 mm

Speeder machine

26.0 mm


4 seconds approx.


5 mm


MJFCIFSS

6.11.9

Adjustment protocol

Service Manual


Checks

14.


14.1



Actual value

Possible Setting.

View Comment

2150 +50min-1



6.11.10


MJFCIFSS

Service Manual


Adjustment protocol 2 A 311 Litronic from 27112 (applicable from software version 5.12) Date:

.........................................

Mechanic:

.........................................

Customer:

.........................................

Type:

.........................................

Series no.:

.........................................

Operating hours:

.........................................

Checks


1.


1.1

Oil temperature

min. 50 +10°C

1.2 1.2.1 1.2.2

Regulating rpm during work with servo OFF (on-road travel)

1800 rpm 1950 rpm

1.3 1.3.1 1.3.2 1.4

Max. speed during work with servo OFF (on-road travel) Min. speed

2.

Pilot pressure

Actual value

Possible Setting.

View Comment

1950 +40 rpm 2100 +50 rpm Set measure at valve 51.

770 +50 rpm Measuring point 49 32 ±1 bar

3.

Horsepower control

3.1


3.2

3.3



Current

850 +25 mA

Control pressure LR

30 ±1 bar


<50mA

Control pressure LR




Remove plug of Y50. Set valve to emergency setting. (Remove cotter pin and actuate lever.) Diagram, see page 12.


MJFCIFSS

6.11.11

Adjustment protocol

Service Manual


Checks 4.

Checking function Y51

4.1


5.

Checking flow reduction of pump P1

5.1

Value X

6.11.12


Actual value

Possible Setting.




11,8 ±0.2 mm


MJFCIFSS

Service Manual


Checks


6.

Begin of hydraulic regulation of double variable-displacement Pump (basic setting)


6.1


60 ±2 bar

Actual value

Possible Setting.

View Comment Speed - low (about 1,200 rpm) Y50 / Y51 not active Y50 in emergency position (30 bar at measuring point 59) Adjust using screw 1 on pump regulator

10 bar


6.2


60 ±2 bar


10 bar



MJFCIFSS

6.11.13

Adjustment protocol

Service Manual


Checks 7.



Actual value

Possible Setting.



max. fan speed 2150 rpm approx. Pull out plug (I = 0 mA).

Disconnect Y50 and/or launch menu power test on your laptop Reduce primary relief valve 120 / 121 (retract stick cylinder) below test pressure. Turn back in until you reach test pressure again. Be careful not to lower diesel engine speed below rated speed. (Check diesel speed at B12). Pump at Qmax. Control chamber

6.11.14

( < 50mA)

120 bar (each pump) 1800 +10rpm Measuring point 43/44 = tank pressure


MJFCIFSS

Service Manual


Checks 8.



Actual value

Possible Setting.

View Comment

Measuring point 40

at upper idle speed

8.1


380 +20 bar

Valve 129


380 +20 bar*

Valve 130


380 +20 bar

Valve 131


380 +20 bar

Valve 132


380 +20 bar

Valve 133


380 +20 bar

Valve 134

Measuring point 41 - retract stick cylinder

380 +20 bar

Valve 127


380 +20 bar

Valve 128 * adjustment to 240 bar + 1 revolution of adjusting screw = 380 bar


MJFCIFSS

6.11.15

Adjustment protocol

Service Manual


Checks 8.2

9.

6.11.16


Actual value

Possible Setting.

View Comment

Travel function

Measuring point 41

- Travel forward

380 +20 bar

Valve 214

- Travel reverse

380 +20 bar

Valve 215


Measuring point 40

High idle rpm


350 +10 bar


Measuring point 40


350 +10 bar



MJFCIFSS

Service Manual


Checks 10.



Measuring point 45


110 +20 bar

Actual value

Possible Setting.




MJFCIFSS

6.11.17

Adjustment protocol

Service Manual


Checks 11.


11.1

Turning

11.2

Actual value

Possible Setting.

View Comment


Turning right

197 200 +10 bar


Turning left

198 200 +10 bar


198 70 ±5 bar


197 70 ± 5bar



Turning left

6.11.18



MJFCIFSS

Service Manual


Checks 12.

Travel motor

12.1


12.2


Actual value

Possible Setting.




1500 ±25 rpm

Speeder machine

1930 ±25 rpm



13.

Standard machine

23.8 mm

Speeder machine

26.0 mm


4 seconds approx.


5 mm


MJFCIFSS

6.11.19

Adjustment protocol

Service Manual


Checks 14.


14.1



Actual value

Possible Setting.

View Comment

2150 +50rpm


Danger! Moving fan blades can cause serious injury to fingers and hands. Before working near the fan, switch off the engine (observe afterrun).

6.11.20


MJFCIFSS

Service Manual



.........................................

Mechanic:

.........................................

Customer:

.........................................

Typ:

.........................................

Serial-No:

.........................................

Operating hours:

.........................................

Checks


1.

Operating conditions Warm up equipment

1.1

Oil temperature

min. 50 +10°C

1.2

Regulating rpm

1800 min-1

1.3

Max. speed

1910 +50min-1

1.4

Min. speed

770 +50min-1

2.

Pilot pressure


3.

Horsepower control

3.1

at rpm step 9 (speed max.rpm)

Measuring point 59

Current (until software 1.5) Control pressure Current (from software 1.6)

Actual value

Possible setting

View Comment

Adjusting at valve 51

using adapter cable at Y50

560 +30 mA 11 +2 bar 600 +30 mA 13 +3 bar

Control pressure Remove plug at Y50. Set valve to emergency setting. (Remove cotter pin and actuate lever.)

+2 bar

3.2

Control pressure at Power test

20

3.3

Checking regulating pressure during emergency operation

Measuring point 59 3,2 ±0,5 bar


MJFCIFSS

6.12.1

Adjustment protocol

Service Manual


Checks


4.

Checking Fine control functionY51

Measuring point 57

4.1

Fine control min. (Q.max) 100 < 280 mA

0.8 bar approx.(Tank pressure)

4.2

Fine control min. to Fine control max. 280.>.640 mA (dim. cross-section)


5.

Begin of hydraulic regulation of variable displacement pump

Measuring point 41

5.1

(basic setting) until software 1.5

65 ±2 bar

from software 1.6

50 ±2 bar

Actual value

Possible setting

View Comment Using adapter cable at Y51

Select low speed (appr.1200 min-1 Disconnect plug connection at Y50 / Y51. Adjust setting at screw 23.2.1 of pump.

Set secondary relief valve 262 (extend bucket cylinder) below begin of regulation.Screw in again until actuating pressure at 44 starts to go down. p at 59 = tankpressure

Re-connect Y50.

6.12.2


MJFCIFSS

Service Manual


Checks

6.


Actual value

Adjusting pressure difference ( p) with function extend bucket cylinder

Measuring point 41 / 45 23 +1 bar

Reduce or set pressure at valve 262 at 100-120 bar at Measuring point 41 MP. p at 57 = tank pressure

Adjustment up to 500 operating hours 24 +1 bar

Possible setting

View Comment max. rpm (step 9), button p not active (Y51 disconnected). Take readings between MP and LS. Adjust at screw 23.5.1 of pump.

Re-connect plug at Y51. 7.

Checking power of diesel engine (power test) Note: Carry out this test only when necessary (e.g. when you suspect the engine runs at reduced power). Set secondary pressure relief valves 242 (extend stick cylinder*) and 262 (extend bucket cylinder*) below test pressure. Raise again until you reach test pressure again. The rpm of the diesel engine must never drop below rated speed. (Read rpm on screen.) Difference between measuring points 41 and 44.

high idle rpm Max. fan speed 2230 min-1 approx. Pull out plug (I = 0 mA).

Measuring point 41 110 bar

1800 +10min-1

< 10 bar

* Both functions are necessary to get the max.pump flow.


MJFCIFSS

6.12.3

Adjustment protocol

Service Manual


Checks


8.

Primary pressure (safety valve)

Measuring point 41

8.1

Main relief valve 105

400 +20 bar

Actual value

Possible setting

View Comment

Set secondary relief valve 262 above adjustment pressure 105 and extend bucket cylinder. Raise pressure at pressure cut-off valve 104 until pressure gauge does not go up any more. (response pressure 105) 9.

Secondary pressure flow cut-off pressure at 104 raised (not on block).

Measuring point 45

high idle rpm

9.1 Working functions

6.12.4

-Extend boom cylinder

380 +20 bar

Valve 221

-Retract boom cylinder

380 +20 bar

Valve 222

-Retract stick cylinder

380 +20 bar

Valve 241

-Extend stick cylinder

380 +20 bar

Valve 242

-Retract bucket cylinder

380 +20 bar

Valve 261

-Extend bucket cylinder

+20

380

bar

Valve 262


MJFCIFSS

Service Manual


Checks

9.2


Actual value

Possible setting

View Comment

Travel function

Measuring point 45

-Travel forward

380 +20 bar

Valve 176

-Travel reverse

380 +20 bar

Valve 177

10.

Operating pressure p

10.1

Pressure cut-off

Measuring point 41

max. rpm (step 9) Valve 104

350 +10 bar


MJFCIFSS

6.12.5

Adjustment protocol

Service Manual


Checks

11.

11.2

Actual value

Possible setting

View Comment

Slewing gear functions Measuring point 137/138

Pressure setting at valve 125, see fig. on page 7, raised.

Turning right

137 250 +10 bar

Valve 135 (High pressure setting) Lock nut 1 Adjusting screw 2

Turning left

138 250 +10 bar


Secondary pressure

11.1


Turning

Slowing down, braking Turning right

138 90 ± 5 bar

Valve 134 (Low pressure setting) Lock nut 3 Adjusting screw 4

Turning left

137 90 ± 5bar


Valves 134 / 135

6.12.6


MJFCIFSS

Service Manual


Checks

12.

Slewing gear functions Primary pressure


Actual value

Possible setting

Measuring point 137 / 138

Turning left or right

200 ± 5 bar

13.

Travel motor

13.1

Regulation


Begin of regulation

240 bar

End of regulation

320 bar

View Comment

Carry out settings on valve 125

Adjusting screw 4.14 on travel motor


MJFCIFSS

6.12.7

Adjustment protocol

Service Manual


Checks

13.2


Actual value

Possible setting

Output speed (speed)

Measured on drive shaft, during on-road gear

Standard machine

1850 ±25 min-1

Speeder machine

2780 ±25 min-1


16,0 mm

14.


14.1

Checking fan speed Check speed while diesel engine runs at rated speed. Disconnect Y352.

View Comment

Spool 160

2230 ±50 min-1

Hydraulic oil temperature should be > 50° C during check.

Danger! Moving fan blades are a severe hazard to fingers and hands. Be sure to switch off the engine when working near the fan.

6.12.8


MJFCIFSS

Service Manual

Adjustment protocol R 313 Litronic from 27752

Adjustment protocol 1 R 313 Litronic from 27752 Date:

.........................................

Mechanic:

.........................................

Cust.:

.........................................

Type:

.........................................

Serial no.:

.........................................

Operating hours:

.........................................

Checks


1.


1.1

Oil temperature

min. 50 +10°C

1.2

Regulating rpm

1780 rpm

1.3

Max. speed

1900 +30rpm

1.4

Min. speed

770 +50rpm

2.

Pilot pressure

Measuring point 49

Actual value

Possible setting

View Comment

Set at valve 51.

32 ±1bar 3.

Horsepower control

3.1

at speed step 9 (high idle rpm)

3.2

3.3

Current Control pressure

580 +30 mA 7 +2 bar

Control pressure during power test

10+2 bar

Check of regulating pressure during emergency operation

Measure at Y50 using the adapter cable.

Measuring point 59

Remove the plug from Y50. Set valve to emergency position (remove cotter pin and tilt lever).

Measuring point 59 2.0 ±0.5bar

copyright by

MJFCIFSS

6.13.1

Adjustment protocol

Service Manual

R 313 Litronic from 27752

Checks


4.

Check of Y51 function

Measuring point 57

4.1

SF min /(Q.max.) 100 < 300 mA

max. 0.8 bar (tank pressure)

4.2

SF min. to SF.max. (300 > 760 mA) (Q.reduction)

5.

Hydraulic begin of regulation of variable displacement pump (basic setting) Set the secondary relief valve 262 (extend bucket cylinder) to a value below begin of regulation; turn in again until the actuating pressure at 44 starts to drop. p at 59 = tank pressure

Actual value

Possible setting

View Comment Measure using adapter cable at Y51.


Measuring point 41

Speed - low ( approx. 1200 rpm) Y 50 / Y 51 disconnected. Adjust at screw 8 of the pump regulator.

50 ±2bar

Re-connect the plug to Y50.

6.13.2

copyright by

MJFCIFSS

Service Manual


Checks

6.

Adjustment of the differential pressure ( -p) Extend bucket cylinder with function. Lower pressure setting or adjust the valve 262 to 100-120 bar at measuring point 41 -MP. P at 57 = tank pressure


Actual value

Possible setting

View Comment Maximum speed step (step 9). Button -p disabled (Y51 disconnected). Read value between MP and LS. Adjust at the screw 2 at the pump.

Measuring point 41 / 45 19 +1 bar Adjustment up to 500 operating hours 20 +1 bar

Re-connect plug to Y51. 7.

Checking diesel engine power (power test) Note: This test should only be carried out if you suspect problems (e.g. reduced output of diesel engine). Lower the pressure at the secondary pressure relief valves 242 (extend stick cylinder) and 262 (extend bucket cylinder) below the test pressure in the adjustment protocol. Then increase the pressure again to the test pressure. Ensure that the diesel engine speed does not drop below the rated speed (speed is indicated at engine speedometer). Difference between the measuring points 41 - 44

High idle rpm Max. fan speed approx. 1500 rpm Pull out plug (I = 0 mA).

Measuring point 41 110 bar 1800 +10rpm

<10 bar

copyright by

MJFCIFSS

6.13.3

Adjustment protocol

Service Manual


Checks

8.

Primary pressure Safety valve 105


Actual value

Possible setting

Measuring point 41 400 +20 bar

Set the secondary pressure-relief valves 262 to a value above the adjustment pressure of 105 and extend the bucket cylinder. Turn up the pressure cutoff 104 until the value shown at the pressure gauge stops to increase (response pressure 105).

6.13.4

copyright by

MJFCIFSS

View Comment

Service Manual


Checks

9.

Secondary pressure Pressure cut-off 104 screwed in (not to block)

9.1

Operational functions


Actual value

Possible setting

High idle speed

Measuring point 45

- Extend boom cylinder

380 +20 bar


380

+20

bar

- Retract stick cylinder

380

+20

bar


380 +20 bar +20


380

Extend bucket cylinder

380 +20 bar

View Comment

Valve 221 Valve 222 Valve 241 Valve 242

bar

Valve 261 Valve 262

copyright by

MJFCIFSS

6.13.5

Adjustment protocol

Service Manual


Checks

9.2

10.

6.13.6


Actual value

Possible setting

View Comment

Travel functions

Measuring point 45

Disconnect the line 210 to the brake.

Forward travel, left

380 +20 bar

Valve 211

Reverse travel, left

380 +20 bar

Valve 212

Forward travel, right

380 +20 bar

Valve 213

Reverse travel, right

380 +20 bar

Valve 214


Measuring point 41

Maximum speed step (step 9) Valve 104

(pressure cut-off)

350 +10 bar

copyright by

MJFCIFSS

Service Manual


Checks

11.

Slewing gear function Secondary pressure

11.1

Swivelling back

11.2


Actual value

Possible setting

View Comment Valve 125 screwed in


Turning right

137 250 +10 bar

Valve 134 (high-pressure setting) Lock nut 1 Adjusting screw 2

Turning left

138 250 +10 bar

Valve 135 (high-pressure setting) Lock nut 1 Adjusting screw 2

Turning right

138 90 ±5bar

Valve 135 (low-pressure setting) Lock nut 3 Adjusting screw 4

Turning left

137 90 ± 5bar

Valve 134 (low-pressure setting) Lock nut 3 Adjusting screw 4

Slowing down

copyright by

MJFCIFSS

6.13.7

Adjustment protocol

Service Manual


Checks

12.

6.13.8

Slewing gear function Primary pressure


Actual value

Possible setting

Adjust settings at valve 125.



230 +10 bar

at Y451

100%

580 mA

50%

540 mA

0%

500 mA

View Comment

copyright by

MJFCIFSS

Service Manual


Checks

13.

Regulating travel motor

13.1

Speed

13.2

13.3


Actual value

Possible setting

View Comment Measured at tumbler wheel (output speed of gearbox) at stroke stop 160.1, 160.2, 180.1, 180.2 Screw .3

Normal travel

15 ±1 rpm


15.0 mm

Fast travel mode (activated with switch S21, hare symbol)

45 ±1 rpm

Straight-ahead travel with same speed at both sides.

45 rpm

Qmin stop screw Vmin

Qmin stop Vmin

copyright by

MJFCIFSS

6.13.9

Adjustment protocol

Service Manual


Checks

14. 14.1


Actual value

Possible setting

Hydrostatic fan drive Checking the fan speed Check the speed while the diesel engine runs at rated speed and Y347 is disconnected.

1500+ 50rpm

During the fan speed check, the hydraulic oil temperature should be > 50° C.


6.13.10

copyright by

MJFCIFSS

View Comment

Service Manual



.........................................

Mechanic:

.........................................

Customer:

.........................................

Typ:

.........................................

Serial-No:

.........................................

Operating hours:

.........................................

Checks


1.


1.1

Oil temperature

min. 50 +10°C

1.2

Regulating rpm

1800 min-1

1.3

Max. speed

1900 +30min-1

1.4

Min. speed

770 +50min-1

2.

Pilot pressure


3.

Horsepower control

3.1

at speed level 9 (high idle rpm) Current (until software 1.5) Control pressure Current (from software 1.6)

Actual value

Possible setting

View Comment


Measuring point 59


560 +30 mA 11 +2 bar 600 +30 mA 13 +3 bar

Control pressure Remove plug at Y50. Set valve to emergency setting. (Remove cotter pin and actuate lever.)

+2 bar

3.2


20

3.3




MJFCIFSS

6.14.1

Adjustment protocol

Service Manual


Checks


4.


Measuring point 57

4.1


0.8 bar approx. (Tank pressure)

4.2



5.


Measuring point 41

5.1


65 ±2 bar

from software 1.6

50 ±2 bar

Actual value

Possible setting




Re-connect Y50.

6.14.2


MJFCIFSS

Service Manual


Checks

6.


Actual value





Possible setting






1800 +10min-1

< 10 bar



MJFCIFSS

6.14.3

Adjustment protocol

Service Manual


Checks

8.


8.1



Actual value

Possible setting

View Comment




9.1

Working functions 380

bar


380

+20

bar


380 +20 bar


380

+20

bar

380

+20

bar

380

+20

bar

-Retract bucket cylinder -Extend bucket cylinder

high idle rpm

Valve 221 +20


6.14.4

Measuring point 45

Valve 222 Valve 241 Valve 242 Valve 261 Valve 262


MJFCIFSS

Service Manual


Checks

9.2


Actual value

Possible setting

View Comment

Travel function

Measuring point 45

-Travel forward

380 +20 bar

Valve 176

-Travel reverse

380 +20 bar

Valve 177

10.


10.1

Pressure cut-off

Measuring point 41


350 +10 bar


MJFCIFSS

6.14.5

Adjustment protocol

Service Manual


Checks

11.

11.1

Actual value

Possible setting

View Comment

Slewing gear functions Secondary pressure



Turning

137 250 +10 bar


138 250 +10 bar


Turning right

138 120 ± 5 bar


Turning left

137 120 ± 5bar


Turning right Turning left

11.2


Slowing down, braking

from Serial no. 2001


Valves 134 / 135

6.14.6


MJFCIFSS

Service Manual


Checks

12.



Actual value

Possible setting



230 ± 10 bar

13.

Travel motor

13.1

Regulation


Begin of regulation

240 bar

End of regulation

320 bar

View Comment




MJFCIFSS

6.14.7

Adjustment protocol

Service Manual


Checks

13.2


Actual value

Possible setting



Standard machine

1780 ±25 min-1

Speeder machine

2670 ±25 min-1


16,7 mm

14.


14.1


View Comment

Spool 160

1600 ±50 min-1



6.14.8


MJFCIFSS

Service Manual



.........................................

Mechanic:

.........................................

Customer:

.........................................

Typ:

.........................................

Serial-No:

.........................................

Operating hours:

.........................................

Checks


1.


1.1

Oil temperature

min. 50 +10°C

1.2

Regulating rpm

1800 min-1

1.3

Max. speed

1900 +30min-1

1.4

Min. speed

770 +50min-1

2.

Pilot pressure


3.

Horsepower control

3.1

at speed level 9 (high idle rpm) Current (until software 1.5) Control pressure Current (from software 1.6)

Actual value

Possible setting

View Comment


Measuring point 59


560 +30 mA 11 +2 bar 600 +30 mA 13 +3 bar

Control pressure 3.2


20

3.3



A 316 LI 2001A 316 LI-IND 2001-

Remove plug at Y50. Set valve to emergency setting. (Remove cotter pin and actuate lever.)

+2 bar

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MJFCIFSS

6.16.1

Adjustment protocol

Service Manual


Checks


4.


Measuring point 57

4.1


0.8 bar approx. (Tank pressure)

4.2



5.


Measuring point 41

5.1


65 ±2 bar

from software 1.6

50 ±2 bar

Actual value

Possible setting




Re-connect Y50.

6.16.2

copyright by

MJFCIFSS

A 316 LI 2001A 316 LI-IND 2001-

Service Manual


Checks

6.


Actual value





Possible setting






1800 +10min-1

< 10 bar


A 316 LI 2001A 316 LI-IND 2001-

copyright by

MJFCIFSS

6.16.3

Adjustment protocol

Service Manual


Checks

8.


8.1



Actual value

Possible setting

View Comment




9.1

Working functions

high idle rpm


380 +20 bar

Valve 221


380 +20 bar 80 +20 bar*

Valve 222 *(only industrial equipment)

380 +20 bar

Valve 241

380 +20 bar

Valve 242

380 +20 bar

Valve 261

380 +20 bar

Valve 262

-Retract stick cylinder -Extend stick cylinder -Retract bucket cylinder -Extend bucket cylinder

6.16.4

Measuring point 45

copyright by

MJFCIFSS

A 316 LI 2001A 316 LI-IND 2001-

Service Manual


Checks

9.2


Actual value

Possible setting

View Comment

Travel function

Measuring point 45

-Travel forward

380 +20 bar

Valve 176

-Travel reverse

380 +20 bar

Valve 177

10.


Measuring point 41


10.1

Pressure cut-off

350 +10 bar

A 316 LI 2001A 316 LI-IND 2001-

copyright by

MJFCIFSS

6.16.5

Adjustment protocol

Service Manual


Checks

11.

Actual value

Possible setting



137 250 +10 bar


138 250 +10 bar


Turning right

138 120 ± 5 bar


Turning left

137 120 ± 5bar


Turning Turning right

Turning left

Slowing down, braking 11.2

View Comment


11.1




Valves 134 / 135

6.16.6

copyright by

MJFCIFSS

A 316 LI 2001A 316 LI-IND 2001-

Service Manual


Checks

12.



Possible setting



230 ± 10 bar

13.

Travel motor

13.1

Regulation

Measuring point 45 / M2

Begin of regulation

240 bar

End of regulation

320 bar

A 316 LI 2001A 316 LI-IND 2001-

Actual value

View Comment



copyright by

MJFCIFSS

6.16.7

Adjustment protocol

Service Manual


Checks

13.2


Actual value

Possible setting



Standard machine until SNo. 28060 from SNo. 28061

1860 ±25 min-1 1680 ±25 min-1

Speeder machine until SNo. 28060 from SNo. 28061

2790 ±25 min-1 2520 ±25 min-1


16,7 mm

14.


14.1


View Comment

Spool 160

1600 ±50 min-1



6.16.8

copyright by

MJFCIFSS

A 316 LI 2001A 316 LI-IND 2001-

Service Manual


Adjustment protocol 1 R 317 Litronic from 18161 Date:

.........................................

Mechanic:

.........................................

Customer:

.........................................

.........................................

Serial number:

.........................................

Operating hours:

.........................................

Actual value

Checks

Possible setting

View Comment

1.


1.1

Oil temperature

min. 50 +10°C

1.2

Regulating rpm

1800 min-1

1.3

Max. speed

1900 +30min-1

1.4

Min. speed

770 +50min-1

2.

Pilot pressure



3.

Horsepower control

Measuring point 59


3.1


3.2

3.3

Current Control pressure

500+30 mA 6+2 bar

Control pressure on Power test

10 +2 bar


Measuring point 59 2.0 ±0.5 bar


MJFCIFSS

Remove plug of Y50. Set valve to emergency setting. (Remove cotter pin and actuate lever.)

6.17.1

Adjustment protocol

Service Manual

R 317 Litronic from 18161 Actual value

Checks 4.

Checking SF function Y51

Measuring point 57

4.1

SF min.(Q. max) 100 < 300 mA

Tank pressure 0.8 bar approx.

4.2

SF min. to SF max. 300 < 760 mA (dim. cross-section)


5.

Begin of hydraulic regulation of variable displacement pump (basic setting)

Measuring point 41


50 +2 bar

Possible setting


Select low speed (appr.1200 min1)

Disconnect plug connection at Y50 / Y51. Adjust setting at screw 23.2.1 of pump.

Re-connect Y50.

6.17.2


MJFCIFSS

Service Manual

Adjustment protocol R 317 Litronic from 18161 Actual value

Checks 6.

Adjusting pressure difference ( p) with function extend bucket cylinder Reduce or set pressure at valve 262 at 100-120 bar at Measuring point 41 MP. p at 57 = tank pressure

Possible setting

Measuring point 41 / 45 19+1 bar until 500 hrs. 20+1 bar

View Comment max. rpm (step 9), button p not active (Y51 disconnected). Take readings between MP and LS. Adjust at screw 2 of pump.

Re-connect plug at Y51. Checking power of diesel engine (power test) Note: Carry out this check only when necessary (e.g. when you suspect the motor runs at reduced power. Set secondary pressure relief valves 242 (extend stick cylinder) and 262 (extend bucket cylinder) below test pressure. Raise again until you reach test pressure again.The rpm of the diesel engine must never drop below rated speed. (Read rpm on screen.) Difference between measuring points 41 and 44.

high idle rpm max. fan speed 1600 min-1 approx. Pull out plug (I = 0 mA)


1800 +10min-1

< 10 bar


MJFCIFSS

6.17.3

Adjustment protocol

Service Manual


Checks 8.

Primary pressure Main relief valve 105 Set secondary relief valve 262 above adjustment pressure 105 and extend bucket cylinder. Raise pressure at pressure cut-off valve 104 until pressure gauge does not go up any more. (response pressure 105)

9.

Secondary pressure Pressure cut-off 104 screwed in (not on block).

9.1

Working functions

6.17.4

Possible setting

Measuring point 41 400+20 bar

View Comment P

Measuring point 45

high idle rpm


380 +20 bar

Valve 221


380 +20 bar

Valve 222


380 +20 bar

Valve 241


380 +20 bar

Valve 242


380 +20 bar

Valve 261

-Extend bucket cylinder

380 +20 bar

Valve 262


MJFCIFSS

Service Manual


Checks 9.2

10.

Possible setting

View Comment

Travel functions

Measuring point 45

disconnect brake hose 210

-Travel left forward

380 +20 bar

Valve 211

-Travel left reverse

380 +20 bar

Valve 212

-Travel right reverse

380 +20 bar

Valve 213

-Travel right forward

380 +20 bar

Valve 214

Operating pressure p (pressure cut-off)


max RPM ( step 9) Valve 104


MJFCIFSS

6.17.5

Adjustment protocol

Service Manual


Checks 11.


11.1

Turning

11.2

6.17.6

Possible setting

View Comment


Valve125 raised.

Turning right

137 250 +10 bar


Turning left

138 250 +10 bar


Turning right

138 120 ± 5 bar


Turning left

137 120 ± 5bar


Slowing down, braking


MJFCIFSS

Service Manual


Checks 12.

Slewing gear functions Primary pressure Turning left or right

13.

Travel motor

13.1

Slow travel speed

Possible setting


View Comment Carry out settings on valve 125

230 +10 bar

measured on turas Hoist limit screw .3 on 160.1, 160.2, 180.1, 180.2

Normal Travel

15±1 min-1

Control measurement Y

15 mm


MJFCIFSS

6.17.7

Adjustment protocol

Service Manual


Checks 13.2

Fast travel speed (with switch S21)

14.


14.1


Possible setting

View Comment Q-min screw Vmin

45 ±1 min-1

1600 +50 min-1

Hydraulic oil temperature > should be 50° C during check.

Danger! Moving fan blades are a severe hazard to fingers and hands. Be sure to switch off motor when working near the fan.

6.17.8


MJFCIFSS

Service Manual

LSC system Basic principle - general description of functions

LSC system 1 Basic principle - general description of functions 1.1

Introduction The LIEBHERR hydraulic excavator generation of the A 312 - R 317 Litronic series is equipped with the LSC hydraulic control system (Liebherr synchronous control). It allows operators to work much faster and much more precisely, thanks to easier and simpler overall handling of the machine. The biggest advantage of the LSC system is, however, that handling and operation can be adapted much better to prevailing working conditions. The speed of the working movement is determined by the displacement of the control lever / pilot control valve, not by the load pressure. Other advantages of the LSC system: Several consumers can be handled simultaneously, without any problems, independently of load pressure and even with saturation deficits. The LSC system will adapt flow rates to the requirements of the various consumers. Pressures are adapted to the consumer with the highest load. Economic operation matched to actual application of the machine

1.2

Design of LSC system Control elements: Load-sensing control LUDV system On-board electronics Horsepower and on-demand flow control Note! For detailed information on the design of components mentioned above, please refer to the respective subgroups in the service manual.

1.3

Functional description of LSC system LSC is a servo pilot-controlled, load-sensing hydraulic system with power control and integrated LUDV system. The on-board electronics allow, in addition, to adapt pump flow rates to working and/ or consumer conditions, and to increase power control all the way up to load limit.

Load-sensing control (speed control independent of load pressure) The amount of oil supplied by the pump is adjusted by means of the flow regulator. A gauge orifice (opening at the spool) generates a pressure difference which corresponds to the spring force ( p) set at the regulator.

Flow cross-section The cross-section of the flow supplied by the pump and fed through the spool to the consumers can

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MJFCIFSS

6.20.1

LSC system

Service Manual

LUDV system be controlled by actuating the pilot-control lever. It determines the control pressure, which is proportional to the travel of the lever. In other words: Short travel of lever / pedal at the pilot control valve = low control pressure at the spool = small flow cross-section = low speed of consumer. Long travel of lever / pedal at the pilot control valve = high control pressure at the spool = large flow cross-section = high speed of consumer.

Flow rate The applicable law of hydrodynamics tells us that there is a relation between the volumes flowing through the spool, the aperture of the orifice and the corresponding difference in pressure:

High p value = high flow rate Low p value = low flow rate Values for

p are pre-set at the pump, i.e. the volume depends on the cross-section.

The on-board electronics make it possible to use a proportional solenoid valve (Y51) to lower p continuously and to adapt the speed of working movements to prevailing work conditions and consumer requirements.

2 LUDV system As part of the load-sensing system, the LUDV system is connected to a spool (gauge orifice) of the respective consumer, and a subsequent pressure balance. The load pressure of each consumer (LS signal) is measured at the pressure channel leading to the consumer. The highest measured load pressure is signalled by the pressure balance of the working pump. The p value generated by the pressure spring of the LS regulator (located near the working pump) is used as a reference p value for the system. p1 = p2´ corresponds to p1 = proportional to cross-section A2.

p2; the flow Qv1 is proportional to cross-section A1, and Qv2 is

The flow generated by the pump at the gauge orifice cross-sections A1 and A2 is proportional to these cross-sections. The p values at the gauge orifices ( p1 and p2) are equal, due to the applied pressure, see Fig. 1. If several consumers are in use and the flow from the pump Q is not sufficient to saturate the gauge orifice cross-sections, p1 and p2 are reduced. Due to the status signal p2 indicating the highest load pressure and acting on all pressure balances, the flow distribution remains unaffected by the load pressure and is determined by the operation of the controls.

6.20.2

copyright by

MJFCIFSS

Service Manual

LSC system LUDV system

Fig. 1

Principle of LUDV system

A1

Gauge orifice (spool 1)

p1

Pressure in front of pressure balance 1

A2 Dw 1

Gauge orifice (spool 2) Pressure balance of spool 1)

p2 Pp

Pressure in front of pressure balance 2 Pump pressure

Dw 2

Pressure balance of spool 2)

p1

Pressure difference between Pp and p1

F1 F2

External force applied to consumer 1 External force applied to consumer 2

p2 p3

Pressure difference between Pp and p2 Pressure difference between p1 and p1

FR

Flow regulator

PQ

Pump flow volume

p1

Load pressure at consumer 1

Qv1

Flow rate at consumer 1

p2

Load pressure at consumer 2

Qv2

Flow rate at consumer 2

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MJFCIFSS

6.20.3

LSC system

Service Manual

Horsepower control by means of proportional solenoid valve Y50

2.1

Proportional split of flow volumes Example: if a consumer 1 is operated with the required flow rate Q1 = 50 l/min, the oil volume is controlled on the basis of the requirements and made available by the variable capacity pump. If a second consumer 2 with a required flow rate Q2 = 100 l/min is added, the maximum pump flow rate Qmax = 200 l /min is split at a ratio of 200 : 250 = 0.8 onto the two consumers. This means that consumer 1 receives only Q1 = 120 l/min, while consumer 2 receives only Q2 = 80 l/min.

2.2

Performance split Performance split means the ratio between pump capacity, on the one hand, and useful and lost performance on the other. The performance of the pump is equal to the flow rate Q of the pump multiplied by the highest consumer pressure (load pressure + p). Loss in performance might be caused by volumes required by other consumers, multiplied by the corresponding differential pressure ( p at the highest load pressure). A higher loss of performance arises when a consumer is operated with a pressure cut-off valve.

2.3

Intelligent electronics Purpose of electronics: Switching functions Displaying and managing important operational data Monitoring units and safety devices Displaying error and operational status messages Controlling functions and processes Regulation and control according to current operation Proportional solenoid valves Y50 and Y51

3 Horsepower control by means of proportional solenoid valve Y50 3.1

Regulation of hydraulic performance steps Horsepower control is effected by means of the spring on the performance regulator of the pump and the current at valve Y50.

3.2

Speed preselection by means of the potentiometer R75: By turning the potentiometer R75, located at the control console, 9 speed levels for the diesel engine can be preselected. ECO: Levels 1- 8 = speed levels for various applications in the most ecologically efficient range POWER: Level 9 = Max. engine speed

6.20.4

copyright by

MJFCIFSS

Service Manual

LSC system Horsepower control by means of proportional solenoid valve Y50

Fig. 2 21

Horsepower control in LSC system Powertrain (variable-displacement pump) 235

Boom cylinder

23.2 Performance regulator (A 312 - 316) 25 Performance regulator (R 317)

R75 Potentiometer for speed adjustment U16 Excavator control (BST)

220

Y50

Spool

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MJFCIFSS

Proportional valve (LR)

6.20.5

LSC system

Service Manual

On-demand flow control If the current is smaller than 220 mA = pLR 0 bar (tank pressure), the begin of regulation is equal to the begin of basic regulation, and the performance drop of the pump is minimal. If the current increases to a value above 300 mA, the control pressure increases and the begin of regulation is after the begin of basic regulation, and the performance drop of the pump is also increased.

4 On-demand flow control Machines with a load-sensing hydraulic circuit are equipped with on-demand flow control to control pump flows. As a result, the powertrain of the working pump supplies only the amount of oil needed by the consumers. This prevents any unnecessary circulation and throttle losses.

4.1

Functional description of the on-demand flow control (see Fig. 4, page 8) If all the spools (220 - 260) are in neutral position (no control oil to spools 220 - 260), the pump supplies only the oil required for stand-by operation. The flow regulator pivots the pump back to the stop Q min. (stand-by operation = QRest at circulation pressure). Actuation of a spool (gauge orifice opens) reduces the normal ( p) between the pump and the consumer. This difference in pressure effects a shifting of the flow regulator 23.5/26 due to the pre-set pressure spring (pump pressure is reduced). The flow through the bores in the spool 220 / 260 is comparable with the flow through a gauge orifice. With increasing flow rates to the consumer, the pressure difference at the gauge orifice also increases. The balance is established when the pressure difference in the spool reaches the value at the LS regulator (pump pressure - consumer pressure in LS line).

p pre-set

The flow cross-section of each spool is dimensioned in such a way that the pressure drop is equal to the value p(LS) pre-set at the regulator when the desired nominal flow rate has been reached while the spool is fully open. If the spool 220 - 260 is shifted back to an interim position, the aperture of the gauge orifice is reduced in size, and the pressure difference p(LS) is achieved with a smaller oil volume. The pump has a tendency to maintain a constant pressure difference at all times and therefore pivots back to its initial position. If several consumers are actuated at the same time, the amount of oil required exceeds the max. capacity of the pump. The value p(LS) drops, but remains the same for all consumers, so that all flow rates are reduced by the same factor.

4.2 4.2.1

Flow regulation by means of proportional solenoid valve Y51 Working speed and fine control The proportional valve Y51 is pressurised with pilot control pressure (pst) counteracting according to the pre-set % value by means of the BST of the spring force (LS) 23.5/26 through pMLS . As a result, p is reduced. As a result, the pressure difference a smaller volume of oil.

p is smaller, and the pump can maintain the reduced

The pump pivots only to the point where the pre-set flow rate at the pump outlet is reached.

6.20.6

copyright by

MJFCIFSS

p with

Service Manual

LSC system On-demand flow control

Fig. 3

Flow regulation in the LSC system

21 Powertrain (variable-displacement pump) R76 Potentiometer / fine adjustment 23.5 Flow regulator (A 312 - 316) S382 Activating switch fine control adjustment

4.2.2

26

Flow regulator (R 317)

B33

Sensor (kit)

Y51

Proportional valve LS ( p reduction)

Adapting flow reduction to working conditions Reducing pumping capacity: I Ls < 300 mA = pMLS = 0 bar (tank pressure)

p = basic setting

Note! The working speeds can immediately be tested by means of the joysticks.

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MJFCIFSS

6.20.7

LSC system

Service Manual

Hydraulic diagram

5 Hydraulic diagram

Fig. 4

6.20.8

Hydraulic schematic: a = Pump pivots out, b = pump pivots back

1

Hydraulic tank

105

Primary pressure relief valve

21

Powertrain

220

Spool

21.1 Adjusting device 23.5 LS regulator

224 235

Pressure balance Consumer

100

Control valve block

260

Spool

102

Pressure balance / minimum flow

264

Pressure balance

103 104

Pressure balance / remaining flow Pressure cut-off valve

275

to consumer (bucket cylinder)

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Service Manual

LSC system Hydraulic diagram

copyright by

MJFCIFSS

6.20.9

LSC system

Service Manual

Hydraulic diagram

6.20.10

copyright by

MJFCIFSS

Service Manual

LSC system Hydraulic diagram

copyright by

MJFCIFSS

6.20.11

LSC system

Service Manual

Hydraulic diagram

6.20.12

copyright by

MJFCIFSS

Service Manual

Design of hydraulic system Tank arrangement

Layout of hydraulic system 1 Tank arrangement

Fig. 1 11

1.1 1.1.1

1

Hydraulic tank

11

From turbo charger / diesel engine

2 3

Breather filter Stop cock

12 B8

Check valve Hydraulic oil temperature transducer

4 5

Return filter Integrated bypass valve

B285 Hydraulic oil temperature transducer(fan control)

Hydraulic tank Purpose:

1.1.2

Hydraulic tank with filters and other components

Takes up all hydraulic oils from the entire equipment Separates inlet and return sections. Baffle oil with baffle plates on the inside. Supplies purified oil to hydraulic pumps. Reservoir for return oil, with return filters. Preload of oil volume to prevent cavitation by pressure (0.5 0.7 bar) from the turbo charger 11 of the diesel engine through the check valve 12

Filter units: Return filter 4 with two-stage glass-fibre filter element and bypass valve 5 (integrated in return filter) Breather filter 2 Filter elements: Return filter element for commissioning (factory-installed) 10 µ Return filter element for cleaning of circuit (after oil change / pump failure) 5 µ Return filter element for normal operation, two-stage20 / 5 µ, for use in dusty environments single-stage 10 µ Breather filter 2 complete, for normal operation 7 µ, for use in dusty environments 2 µ

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MJFCIFSS

6.22.1


Service Manual

Hydraulic pumps

1.1.3

Maintenance:

Oil analyses Changing hydraulic oil Replacing return filter element and breather filter Draining tank see maintenance regulations in group 3

2 Hydraulic pumps

Fig. 2

Double variable-displacement pump and gear pumps

20 Double variable-displacement pump 32 Gear pump for steering 30 Gear pump for fan drive 33 Gear pump for pilot control 31 Gear pump for low-pressure circuit and brake system

2.1 2.1.1

Double variable-displacement pump 20 Powered by: Diesel engine Via torsion dampers (flexible coupling)

2.1.2

Design: Axial piston inclined axle

2.1.3

Classification: Axial piston drive system with inclined axle

6.22.2

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MJFCIFSS

Service Manual

Design of hydraulic system Hydraulic pumps

Hydromechanic adjusting unit Regulating unit Technical data and description of functions: see double variable-displacement pump in group 7.02

2.2 2.2.1

Gear pumps 30 - 33 Pump 30 for hydraulic fan drive: Powered by diesel engine via gear system of the double variable-displacement pump 20 Supply of hydraulic fan drive For flow rate, see "Technical data" in group 3

2.2.2

Pump 31 for brake system and low-pressure circuit:

Powered by diesel engine (direct) With flow distributor Preferred volume flow for brake system (connection K) Supply of offset boom bearing and grapple rotator with remaining volume flow (connection R) For flow rate, see "Technical data" in group 3

2.2.3

Pump 32 for steering: Powered by diesel engine (direct) Supply of Servostat / steering valve For flow rate, see "Technical data" in group 3

2.2.4

Pump 33 for pilot control: Powered via gear pump 32 (flange-connected) Supply of control oil unit For flow rate, see "Technical data" in group 3

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6.22.3


Service Manual

Pilot control

3 Pilot control

Fig. 3

Pilot control units on operator's platform and control oil unit

A B

Control oil unit from start of series Control oil unit from serial no. (°)

86 87

Pilot control unit 2x, for kit Positioning brake / slewing gear

1

Hydraulic tank

Y3

Solenoid valve of servo safety shut-down

50 80

Control oil unit Pilot control unit 4x, left

Y24 Y50

Solenoid valve / creeper gear Proportional solenoid valve / power control

81 84

Pilot control unit 4x, right Pilot control unit 1x, for travel drive

Y51 Proportional solenoid valve / flow reduction P1 Y330 Solenoid valve reset pump P2

85

Pilot control unit 2x, for support

Y371 Solenoid valve / oscillating axle support

(°) Solenoid valve removed without replacement in A 309 machines from serial no. 26291 and A 311 machines from serial no. 26086, see also service information 07-11-37/2005

3.1

Purpose: Hydraulic control of all operational and travel motions of the machine by means of hand and/or foot-operated controls (pilot control valves / joystick etc.)

3.2

Design and function: Pressure generated by separate gear pump 33, see Fig. 2 Control oil unit 50 regulates, monitors, filters, stores and distributes control oil and pressure.

6.22.4

copyright by

MJFCIFSS

20

Service Manual

Design of hydraulic system Arrangement of control valve block

3.3

Solenoid valve Y3 for shutdown of the pilot control pressure to the pilot control units Solenoid valve Y24 for the control of the travel motor / creeper mode Solenoid valve Y330 used to reset Qmin of pumps P2 during travel ;Note, see Fig. 3 Solenoid valve Y371for oscillating axle support Pilot control valves 80 - 86 with regulating characteristics for comfortable operation: Pilot control unit 80 and 81 with joystick to operate slewing gear and attachments. Pilot control unit84 with foot pedal for the operation of the travel drive system Pilot control unit85 with lever to operate outrigger / blade support Pilot control unit 86 with foot pedal to operate supplementary attachment (kit) Control lines leading from the pilot control units to the control caps of the respective spools.

Maintenance: Replacing filter elements (control oil filter in control oil unit) For description, see maintenance regulations in group 3.

4 Arrangement of control valve block

Fig. 4

Compact control valve block (high-pressure circuit) and auxiliary control valve block (lowpressure circuit)

100

Compact control block (high pressure)

107

Spool / bucket cylinder

101 102

Spool / slewing gear Spool / stick cylinder

108 109

Spool / travel motor Spool / combined boom cylinder / stick cylinder

103

Spool / support cylinder

110

105

Spool / regulating cylinder

112

Auxiliary control valve block (low pressure) Spool / slewing gear

106

Spool / boom cylinder

113

Spool / grapple rotator

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6.22.5


Service Manual

Oil rotary connection

4.1

Design of the compact control valve block 100: Possibility to flange-mount more sections, e.g. another kit axle Pressure control by means of screwed-in pressure relief valves (primary and secondary valves with suction function) Suction valves for chassis Stroke limitation of spools For description of functions, see group 7.50

5 Oil rotary connection

Fig. 5 260

5.1

Oil rotary connections located in the pivot point of the upper/undercarriage Oil rotary connection for high pressure 7x

262

Oil rotary connection for low pressure 6x

Purpose: Leads through hydraulic oil from uppercarriage to undercarriage and vice versa

5.2

Design: Oil rotary connection 260 for high pressure Travel drive system, Outrigger and blade support Steering Leak oil Oil rotary connection 262 for low pressure Brake system Gear shifting Creeper gear Oscillating axle support For description, see groups 7.76 and 7.78.

6.22.6

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Service Manual

Design of hydraulic system Consumers and attachments

6 Consumers and attachments

Fig. 6

Consumers and attachments

64

Hydraulic cylinder for uppercarriage locking mechanism (*)

210

Regulating travel motor DMVA

160-250

Hydraulic cylinder for attachment and support

225

Transmission

190

Slewing gear motor FMF

(*) installed as standard in A 309 machines from serial no. 26392 and A 311 machines from serial no. 26396

6.1

Purpose: Conversion of hydraulic energy into mechanical energy

6.2 6.2.1

Classification: Cylinder 64 - 250 Hydraulic device for the transmission of pushing and/or pulling forces in linear motion with limited stroke.

6.2.2

Oil motor 190 / 210 Hydraulic device for the transmission of torque in a rotary motion.

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6.22.7


Service Manual

Hydraulic cylinder

7 Hydraulic cylinder

Fig. 7

7.1

Arrangement of consumers and working attachments

64

Hydraulic cylinder / uppercarriage locking 230 mechanism

160 170

Boom cylinder Stick cylinder

180

Bucket cylinder

240 250

Support cylinder Swivel cylinder Regulating cylinder

Design: Single-side cylinder Mechanical return Differential cylinder No end-of-travel cushioning With end-of-travel cushioning, one-end / two-end

7.2

Functional description For description of functions, see group 7.30

7.3

Classification: Single-side cylinder as: hydraulic cylinder 64 for the locking of the uppercarriage during on-road travel and transport. Differential cylinder as: Boom cylinder 160 actuates basic boom, with end-of-travel cushioning on the piston side. Stick cylinder 170 moving the stick, with cushioning at both ends. Bucket cylinder 180 moving the bucket, with end-of-travel cushioning on piston side. Support cylinder 230 moving outrigger and/or blade support, no end-of-travel cushioning Swivel cylinder 240 for the adjustment of the offset boom bearing, no end-of-travel cushioning Regulating cylinder 250 operating the hydraulic outrigger adjusting device, no end-of-travel cushioning

6.22.8

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Service Manual

Design of hydraulic system Slewing gear motor

8 Slewing gear motor

Fig. 8 190

8.1

Slewing gear motor mounted in slewing gear mechanism 195

Slewing gear motor FMF

Slewing gear mechanism SAT 225

Purpose: Slewing gear motor 190driving the slewing gear mechanism Slewing gear mechanism 195 rotating the uppercarriage

9 Travel motor

Fig. 9 210

Travel motor, flange-mounted to transmission 225

Travel motor DMVA

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Transmission 2 HL 70 / 2 HL 270

6.22.9


Service Manual

Hydraulic oil cooler

9.1

Purpose: Travel motor 210 driving the transmissions Transmission 225 for the travel of the machine

10


Fig. 10

10.1


13

Oil motor / radiator fan

B2

14

Pressure relief valve / fan motor

B285 Hydraulic oil temperature transducer (fan control)

15 30

Coarse filter / fan motor Gear pump / cooling

Y352 Proportional solenoid valve / fan

Hydraulic oil temperature transducer (fan control)

Design: Two-part cooling unit, consisting of an oil cooler for hydraulic oil (bottom), and an engine cooler for coolant / diesel engine (top) Hydrostatic fan drive, controlled by the hydraulic and coolant temperature, with high air flow rate Fan speed is controlled electronically, relative to temperature, through the proportional solenoid valve Y352 For a detailed description of the cooling unit, see group 7.20.

6.22.10

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Service Manual

Design of hydraulic system Hydraulic oil cooler

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6.22.11


Service Manual


6.22.12

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Service Manual

Layout of hydraulic system Hydraulic tank

Layout of hydraulic system 1 Hydraulic tank

Fig. 1

1.1

Hydraulic tank

1

Hydraulic tank

4

2 3

Breather filter Stop cock

5 Safety check valve K Oil level sight glass

Return filter

Purpose

Takes up all hydraulic oils from the entire equipment Separates inlet and return sections. Baffle oil with baffle plates on the inside. Supplies purified and cooled oil to the hydraulic pumps. Provides reservoir for return oil, with return filters. Preloads oil to prevent cavitation.

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6.24.1


Service Manual

Hydraulic tank

1.2

Design

Fig. 2 1

Section drawing of hydraulic tank

Hydraulic tank

A Return side

2

Breather filter

B

3 4

Stop cock Return filter

C Drain valve (collection area) D Drain valve (suction side)

5

Safety check valve

K Oil level sight glass

Suction side

Classification: Return side A with return filter 4 Suction side C with suction pipe, stop cock 3 Filter units: Return filter 4 with 2-stage fibre glass -filter element and safety check valve- 5 Filter elements: for intake (initial equipment) 10 ∑ for normal use 2-stage 20 ∑05 ∑, for use in dusty environments 10 ∑ Breather filter: for normal use 7 ∑, for use in dusty environments 2 ∑

1.3

Maintenance

Check of oil level through the oil level sighting glass K Replacement of filter elements in return and breather filter Drainage of the tank through the drain valves C and D see inspection and maintenance schedule in group 3

Note! For a detailed description of the hydraulic tank, see group 19.

6.24.2

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Service Manual

Layout of hydraulic system Hydraulic pumps

2 Hydraulic pumps 2.1

Variable-displacement pump 20

Fig. 3

Variable-displacement pump 20

20 Variable-displacement pump

23 Regulating unit

Purpose: Supply of all consumers with high pressure oil Powered by: Diesel engine Via torsion dampers (flexible coupling) Design: Axial piston powertrain Adjustable unit with swash plate Regulating unit 23 with performance regulator GLR and LS regulator Technical data and description of functions: see variable-displacement pump in group 7.05

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6.24.3


Service Manual

Hydraulic pumps

2.2

Gear pumps

Fig. 4

Gear pumps 30, 31 and 32


31 Steering pump

30 Pump for fan drive/radiator fan

32 Pump for brake and pilot control system

Pump 30 for fan drive/radiator fan Driven by variable-displacement pump 20 Supply of oil motor/fan drive, see 4. For flow rate, see technical data in group 3 Pump 31 for steering: Powered by diesel engine (flange-mounted) Supply of Servostat, see group 13.20 For flow rate see technical data in group 3 Pump 32 for brake and pilot control system: Powered by diesel engine (flange-mounted) Distribution of flow volume from the pump 32 by means of integrated flow distributor Constant flow K: Supply of braking system, see group 15.10 Residual flow: Supply of control oil unit, see group 7.42 For flow rate, see "Technical data" in group 3

6.24.4

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Service Manual

Layout of hydraulic system Compact control block

3 Compact control block

Fig. 5

3.1

Compact control block 100

Purpose: Distribution of the requested pump flow volumes to the consumers

3.2

Design: Compact control block 100 Integrated LUDV control Input section 5 spools with one pressure balance each for LUDV-control Flange-mounting option for additional sections, e.g. auxiliary way valve for accessory kits Pressure control by means of screwed-in pressure relief valves (primary and secondary valves with suction function) for attachment Suction valves for chassis Stroke limitation of the spool For a description of the functions, see group 7.60

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6.24.5


Service Manual


4 Hydraulic oil cooler 4.1

Purpose Cooling of return oil Cooled by motor-driven fan

Fig. 6 13

4.2

design of hydraulic oil cooling system

6


14

13

Blower motor

Y352 Proportional solenoid valve

Pressure-relief valve

Design Three-part cooling unit, consisting of an oil cooler 6 for hydraulic oil (centre), and an coolant cooler for the diesel engine (bottom) Temperature-controlled cooling by means of annual fans. The fans are driven by a blower motor 13 with the pressure-relief valve 14 and the proportional valve Y352. For a detailed description of the cooling unit, see group 7.20.

6.24.6

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Service Manual

Layout of hydraulic system Oil rotary connection

5 Oil rotary connection 5.1

Purpose Transfer of hydraulic oil from the uppercarriage to the undercarriage and vice versa.

5.2

Design

Oil rotary connection 320 for high pressure Travel drive, outrigger and blade support, steering and leak oil Oil rotary connection 322 for low pressure Braking system, gear shifting, creeper gear system, oscillating axle support For a detailed description, see groups 7.76 and 7.78.

Fig. 7 320

Oil rotary connection Rotary connection for high pressure

322

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Rotary connection for low pressure

6.24.7


Service Manual

Consumers / working attachments

6 Consumers / working attachments

Fig. 8

6.1


130 170

Slewing gear motor Travel motor

255 275

Stick cylinder Bucket cylinder

235

Boom cylinder

295

Support cylinder

Function and classification Conversion of hydraulic energy into mechanical energy Hydraulic device for the transmission of pushing and/or pulling forces in linear motion with limited stroke, see 6.2. Hydraulic device for the transmission of torque in a rotary motion, see 6.3.

6.2

Cylinder Design: Differential cylinder without end-of-travel cushioning with single-side or double-side end-of-travel cushioning For a description of the functions, see group 7.30

6.24.8

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Service Manual

Layout of hydraulic system Pilot control

Classification: Boom cylinder 235 moving the basic boom, with single-side end-of-travel cushioning. Stick cylinder 255 moving the bucket stick, with cushioning at both ends. Bucket cylinder 275 moving the bucket, with single-side end-of-travel cushioning. Support cylinder 295 moving the outrigger and/or blade support, no end-of-travel cushioning

6.3

Oil motor Design: Axial piston swash plate constant (with constant oil flow consumption) regulated (with variable oil flow consumption) For a description of the functions: see groups 7.24, 7.26 and 7.27 Classification: Slewing gear motor 130 with integrated control to drive the uppercarriage by means of the slewing gear mechanism constant flow consumption Travel motor 170 to drive the vehicle wheels through the transmission regulated by the travel brake valve 190

7 Pilot control 7.1

Purpose Hydraulic control of all working and travel motions of the machine by means of hand and/or footoperated controls (pilot control units, / actuators, etc.)

7.2

Design and function

Fig. 9

Control oil unit and pilot control units on the operator's platform

50 Control oil unit 80 Pilot control unit for stick and rotary movement

85 Pilot control unit / support 86 Pilot control unit for accessory kits

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6.24.9


Service Manual

Hydraulic control 81 Pilot control unit for boom and bucket move- 87 Pedal for positioning brake ment 84 Pilot control unit for chassis Pressure generated by separate gear pump 32, see 2.2 Control oil unit 50 regulates, monitors, filters, stores and distributes control oil at the required pilot pressure Proportional solenoid for the control of the variable-displacement pump 20 Solenoid valves for the shut-down of the pilot control pressure for the control of the creeper gear and oscillating axle support for the provision of the pilot control pressure for additional excavator functions (e.g. gear shifting and speed adjustment of the diesel engine) For a detailed description, see group 7.42 . Pilot control units 80 - 86 with regulating characteristic for easy excavator operation Pilot control units 80 and 81 with joystick used to operate the slewing gear and the attachments, see group 7.45 Pilot control unit 84 with pedal, used to control the chassis, see group 7.49 Pilot control unit 85 with lever, used to control the support, see group 7.48 Pilot control unit 86 with pedal, used to control the accessory kits, see group 7.47 Pedal for positioning brake 87 Control lines leading from the pilot control units to the control caps of the respective spools

7.3

Maintenance Replacing filter elements (control oil filter in control oil unit) For a detailed description, see inspection and maintenance schedule in group 3

8 Hydraulic control The LIEBHERR hydraulic excavator generation of the A 312 - R 317 Litronic series is equipped with the LSC -hydraulic control system (Liebherr synchronous control). It allows operators to work much faster and much more precisely, thanks to easier and simpler overall handling of the machine. The biggest advantage of the LSC system is, however, that handling and operation can be adapted much better to prevailing working conditions. The speed of the working movement is determined by the displacement of the control lever / pilot control valve, not by the load pressure. Other advantages of the LSC system: Several consumers can be handled simultaneously, without any problems, independently of load pressure and even with saturation deficits. The LSC system will adapt flow rates to the requirements of the various consumers. Pressures are adapted to the consumer with the highest load. Economic operation matched to actual application of the machine For a detailed description of the principle, design and function, see group 6.20

6.24.10

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Service Manual

Layout of hydraulic system Tank arrangement

Layout of hydraulic system 1 Tank arrangement

Fig. 1 11

1.1 1.1.1

1

Hydraulic tank

50

Control oil unit

2

Breather filter

B8

Temperature transducer / hydraulic oil

3

Stop cock

4

Return filter

B285 Temperature transducer / hydraulic oil (fan control) K Sight glasses for hydraulic oil level

5

Integrated bypass valve

Hydraulic tank Purpose:

1.1.2

Hydraulic tank with filters and other components

Takes up all hydraulic oils from the entire equipment Separates inlet and return sections. Baffle oil with baffle plates on the inside. Supplies purified oil to hydraulic pumps. Reservoir for return oil, with return filters. Preloads oil to prevent cavitation.

Filter units: Return filter 4 with two-stage glass-fibre filter element and bypass valve 5 (integrated in return filter)

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6.27.1


Service Manual

Hydraulic pumps Breather filter 2

1.1.3

Filter elements: Return filter element for commissioning (factory-installed) 10 µ Return filter element for cleaning of circuit (after oil change / pump failure) 5 µ Return filter element for normal operation, two-stage 20 / 5 µ, for use in dusty environments single-stage 10 µ Breather filter 2 complete, for normal operation 7 µ, for use in dusty environments 2 µ

1.1.4

Maintenance:

Changing hydraulic oil Replacing return filter element and breather filter Draining tank see maintenance regulations in group 3

2 Hydraulic pumps

Fig. 2

Variable-displacement pump with integrated or flange-connected gear pumps


31 Gear pump for fan drive

30 Gear pump for pilot control system

6.27.2

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Service Manual

Layout of hydraulic system Pilot control

2.1 2.1.1

Variable-displacement pump 20 Powered by: diesel engine Via torsion dampers (flexible coupling)

2.1.2

Design: Axial piston swash plate

2.1.3

Classification: Axial piston drive system with swash plate Hydromechanical adjusting unit Regulating unit Technical data and description of functions: see variable-displacement pump in group 7.05

2.2 2.2.1

Gear pumps 30 / 31: Pump 30 for pilot control: Driven by variable-displacement pump 20 (built in) Supply of control oil unit For flow rate, see "Technical data" in group 3

2.2.2

Pump 31 for hydraulic fan drive: Powered by variable-displacement pump (flange-connected) Supply of hydraulic fan drive For flow rate, see "Technical data" in group 3

3 Pilot control

Fig. 3

Control oil unit 50 and view of pilot control units on operator's platform

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6.27.3


Service Manual

Pilot control

50

Control oil unit

Y3

Solenoid valve / servo shutdown

80

Pilot control unit 4x, left

Y7

Solenoid valve slewing gear brake

81

Pilot control unit 4x, right

Y24

Solenoid valve / fast travel gear shifting

82

Pilot control unit 1x, for travel drive, left Pilot control unit 1x, for travel drive, right

Y50

Proportional solenoid valve / power control

Y51

Proportional solenoid valve / flow reduction

83 86

3.1

Pilot control unit 2x, for accessory kit

Purpose: Hydraulic control of all operational and travel motions of the machine by means of hand and/or foot-operated controls (pilot control valves / joystick etc.)

3.2

Design and function: Pressure generated by separate gear pump 30, see Fig. 2 Control oil unit 50 regulates, monitors, filters, stores and distributes control oil and pressure. Solenoid valve Y3 for shutdown of pilot control pressure Solenoid valve Y7 for the control of slewing gear brake Solenoid valve Y24 for the control of fast travel gear shifting Proportional solenoid valves Y50 / Y51 for the control of the variable-displacement pump 20 Pilot control valves 80 - 86 with regulating characteristics for comfortable operation: Pilot control unit 80 and 81 with joystick to operate slewing gear and attachments. Pilot control unit 82 with foot pedal for the operation of the travel drive system, left Pilot control unit 83 with foot pedal for the operation of the travel drive system, right Pilot control unit 86 with foot pedal to operate supplementary attachment (kit) Control lines leading from the pilot control units to the control caps of the respective spools

3.3

Maintenance Replacing filter elements (control oil filter in control oil unit) For description, see maintenance regulations in group 3.

6.27.4

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Service Manual

Layout of hydraulic system Arrangement of control valve block

4 Arrangement of control valve block

Fig. 4

4.1

Compact control valve block 100

100 120

Compact control valve block Spool / slewing gear

220 240

Spool / boom cylinder Spool / stick cylinder

160 180

Spool for travel, right Spool for travel, left

260


Design of the compact control valve block 100:

Integrated LUDV control Input section 5 spools 1 auxiliary axle with spool for slewing gear one pressure balance for each spool, used for LUDV control Possibility to flange-mount more sections, e.g. another kit axle Pressure control by means of screwed-in pressure relief valves (primary and secondary valves with suction function) Suction valves for chassis Stroke limitation of the spool Bleeder valves of control lids For description of functions, see group 7.52

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6.27.5


Service Manual

Oil rotary connection

5 Oil rotary connection

Fig. 5

195

5.1

Oil rotary connections located in the pivot point of the upper/undercarriage

Oil rotary connection for high pressure 5x

196

Oil rotary connection for low pressure 1x

Purpose: feeds hydraulic oil from the uppercarriage to the undercarriage and vice versa

5.2

Design: Oil rotary connection 195 for high pressure Travel drive left forward / reverse Travel drive right forward / reverse Leak oil Oil rotary connection 196 for low pressure Fast travel gear shifting For a description, see groups 7.75 and 7.77.

6.27.6

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Service Manual

Layout of hydraulic system Consumers and attachments

6 Consumers and attachments

6.1

Fig. 6


235-275

Hydraulic cylinder for attachment

200

Travel motor, A6VE, left

130

FMF slewing gear motor

201

Travel motor, A6VE right

Purpose: Convert hydraulic energy to mechanical energy

6.2 6.2.1

Classification: Cylinders 235 / 255 / 275 Hydraulic device for the transmission of pushing and/or pulling forces in linear motion with limited stroke.

6.2.2

Oil motors 130 / 200 / 201 Hydraulic device for the transmission of torque in a rotary motion.

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6.27.7


Service Manual

Hydraulic cylinder

7 Hydraulic cylinder

Fig. 7

235 255

7.1

Arrangement of consumers and working attachments

275

Boom cylinder Stick cylinder

Bucket cylinder

Design: Differential cylinder without end-of-travel cushioning with end-of-travel cushioning, one-end / two-end

7.2

Functional description For description of functions of the cylinders, see group 7.30.

7.3

Classification: Boom cylinder 235 actuates basic boom, with end-of-travel cushioning on the piston side. Stick cylinder 255 moving the stick, with cushioning at both ends. Bucket cylinder 275 moving the bucket, with end-of-travel cushioning on piston side.

6.27.8

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Service Manual

Layout of hydraulic system Slewing gear motor

8 Slewing gear motor

Fig. 8

130

8.1

Slewing gear motor mounted in slewing gear mechanism

156

FMF slewing gear motor

Slewing gear mechanism SAT 225

Purpose: Slewing gear motor 130 driving the slewing gear mechanism Slewing gear mechanism 156 rotating the uppercarriage

9

Travel motor

Fig. 9

Travel motors, installed in the travel gears 216 of the undercarriage

200

Travel motor, left

201

Travel motor, right

216

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Travel gear

6.27.9


Service Manual


9.1

Purpose Travel motors 200 / 201 driving the travel gear 216 Travel gear 216 drives the tumbler wheels and chains

10 10.1

Hydraulic oil cooler Purpose Cooling of return oil Cooled by motor-driven fan

Fig. 10 13

6 13

10.2

Design of hydraulic oil cooling system 14 Pressure-relief valve Y352 Proportional solenoid valve

Hydraulic oil cooler Blower motor

Design Three-part cooling unit, consisting of an oil cooler 6 for hydraulic oil (centre), and an coolant cooler for the diesel engine (bottom) Temperature-controlled cooling by means of annual fans. The fans are driven by a blower motor 13 with the pressure-relief valve 14 and the proportional valve Y352. For a detailed description of the cooling unit, see group 7.20.

6.27.10

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Service Manual

Layout of hydraulic system Hydraulic oil cooler

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6.27.11


Service Manual


6.27.12

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Service Manual

Adjustment guidelines for hydraulic system Arrangement of measuring points

Adjustment guidelines for hydraulic system Caution! For maintenance work on the hydraulic unit, the undercarriage and the uppercarriage of the machine must be accessed. This poses a great danger for mechanics. During all adjustment and setting procedures, strictly adhere to the general safety instructions laid down in group 1.10. Adjustment and setting by skilled and well trained personnel only.

1 Arrangement of measuring points

Fig. 1 40 41 43 44 45 49 57 59 197 198

Measuring points at variable-displacement pump LPV 20, control valve block 50 and control oil unit 100 Measuring point for high pressure of pump 1 at the control valve block 100 (connection M1) Measuring point for high pressure of pump 2 at the control valve block 100 (connection M2) Measuring point for the control chamber pressure at the pump P1 Measuring point for the control chamber pressure at the pump P2 Measuring point for low pressure at the flow distributor connection R of the gear pump 31 for the offset boom bearing and AS1 Measuring point for the pilot pressure at the control oil unit 50 (connection M) Measuring point for the flow reduction control pressure (connection X1) at the pump 20 Measuring point for the power control pressure (connection X3) at the pump 20 Measuring point for the slewing gear working pressure at the slewing gear motor 190 (connection MA for turning right) Measuring point for the slewing gear working pressure at the slewing gear motor 190 (connection MB, turning left)

Note If a AHS 1, AHS 11 or AHS 12 attachment kit is installed, the measuring point 40 for the high pressure from the pump 1 is located at the auxiliary control valve block.

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6.30.1


Service Manual

Measuring instruments / adjusting tools

2 Measuring instruments / adjusting tools 2.1

Measuring instruments You need the following measuring instruments and tools o check and/or adjust the hydraulic equipment: MS measuring system tool, tool no. 40 For pilot pressure: For high pressure:

> Pressure sensor 0 - 60 bar > Pressure sensor 0 - 600 bar

For actuating pressure:

> Pressure sensor 0 - 600 bar

plus measuring cable and accessories for the measuring of speed and temperature Alternative: Speed measurement: >Speed counter, tool no. 60 / 62 Temperature measurement: >Thermometer, tool no. 70 / 72 For pilot pressure:

> Pressure gauge 0 - 60 bar

For high pressure:




Note! For the adjustment of valves and units, use commercially available high-quality tools, for instance: ring spanners, open end spanners and Allen keys. Secure adjusting screws against tampering and unintentional interference: Use lead seal wire. Use safety caps (see tools no. 20 - 25 in group 2.05).

2.2

Instructions for adjustment / pre-conditions Note! During the warranty period, only LIEBHERR agents and mechanics may modify settings of valves and units.

2.2.1

Prior to checking and adjusting the settings of the hydraulic system, ensure that the following conditions are fulfilled: The operating temperature of the hydraulic unit (measured in the tank) must be minimum 50°C. The pressure gauges must be glycerine-filled and have an indicating accuracy of below 1% relative to the scale end value. When measuring or adjusting an actuated spool of the control valve block, ensure that the piston is fully lifted at maximum control pressure (maximum piston stroke).

6.30.2

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Service Manual

Adjustment guidelines for hydraulic system Checking and adjusting pilot pressure

Note! In the event of hydraulic failures, follow the instructions in the adjustment protocol in the prescribed sequence. The required minimum oil temperature can be obtained by actuating the 'close bucket' command while the pressure at the secondary pressure relief valve 133 is lowered (close bucket / grapple). All valves must be secured against unauthorized readjustment by safety caps.

3 Checking and adjusting pilot pressure

Fig. 2

Control oil unit located at the hydraulic tank

49 Measuring connection

51 Pressure relief valve / pilot control

50 Control oil unit Connect the pressure gauge (0-60 bar) to the measuring point 49. Run the engine at maximum speed. Compare the displayed pressure with the prescribed pressure (see adjustment protocol). If necessary, adjust the setting of the pressure relief valve 51. Proceed as follows: Remove the safety cap. Loosen the lock nut (WS 13). Use an Allen key (WS 4) to turn the adjusting screw. Turn clockwise (cw)

=

increase pressure

Turn counter-clockwise (ccw)

=

reduce pressure

Secure the adjusting screw 51 with the lock nut and replace the safety cap. Disconnect the pressure sensor or gauge and seal the measuring point 49.

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6.30.3


Service Manual

Checking the proportional solenoid valve Y50

4 Checking the proportional solenoid valve Y50 Connect the pressure gauge (0-60 bar) to the measuring point 59. Start the machine. Using a suitable adapter (tool no. 44 in group 2.01), measure the current at the valve Y50. Based on the chart, determine the required pressure and compare with the actual pressure at the measuring point 59.

Fig. 3


50

Control oil unit

Y50

59

Measuring point LR (power control)


Current OK

Pressure OK

=> Everything OK

Current OK

Pressure not OK

=> Replace proportional solenoid valve.

Current not OK

Pressure not OK

=> Search for fault in the electrical system and the horsepower control

Note! The characteristic of the solenoid valve Y50 cannot be adjusted.

4.1

Adjusting the regulating pressure for emergency operation Switch off machine. Remove the plug from the proportional solenoid valve Y50, see Fig. 3,. Remove the cotter pin and tilt the lever. Start the machine. Run the engine at maximum speed. Compare the pressure values to those in the adjustment protocol and adjust, if necessary. Proceed as follows: Remove the lock nut and turn the insert by hand. Turn clockwise (cw) = increase pressure Turn counter-clockwise (ccw)

6.30.4

=

reduce pressure

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Service Manual

Adjustment guidelines for hydraulic system Checking the proportional solenoid valve Y51 Re-set the lever to its initial position. Insert the cotter pin. Disconnect the pressure sensor or gauge and seal the measuring point 59.

5 Checking the proportional solenoid valve Y51 Connect the pressure gauge (0-60 bar) to the measuring point 57. Start the machine. Adjust the current to the proportional solenoid 51 by means of the speed step switch (positions 1 - 6) or the flow reduction (kit). Using a suitable adapter (tool no. 44 in group 2.01), measure the current at valve Y51. Based on the chart, determine the required pressure and compare with the actual pressure at the measuring point 57.

Fig. 4


50

Control oil unit

57

Measuring point LS (flow reduction)

Y51


Current OK Current OK

Pressure OK Pressure not OK

=> Everything OK => Replace proportional solenoid valve.

Current not OK

Pressure not OK

=> Search for fault in the electrical system.

Note! The characteristic of the solenoid valve Y51 cannot be adjusted.

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6.30.5


Service Manual

Checking of flow reduction of pump P1

6 Checking of flow reduction of pump P1 Note: The flow reduction of pump P1 works only properly, if the threaded stud 73 is properly inserted. The stud is factory-set and secured. Incorrect stud position results in incorrect flow reduction and malfunction of the pump. If the threaded stud 73 is screwed in too far, the powertrain cannot reach the maximum pivoting angle, i.e. flow reduction remains active even if there is no pressure at the proportional solenoid valve Y51. If the threaded stud 73 is screwed out too much, flow reduction is not possible, even when the proportional solenoid valve is activated Y51 (i.e. correct current and pressure at the valve).

6.1

Check measurement at the adjusting screw for flow reduction: Remove the safety cap 75 of the threaded stud 73. Using a calliper gauge, measure distance X between the upper edge of the threaded stud 73 and the upper edge of the screw plug 72 and compare with the prescribed value in the adjustment protocol. If necessary, loosen the lock nut 74 and adjust the distance X . Tighten the lock nut 74 and mount a new safety cap 75. R

Fig. 5 72 73

6.30.6

Adjusting screw for flow reduction of pump P1 74 75

Screw plug Threaded stud

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Seal-Lock collar nut Safety cap

Service Manual

Adjustment guidelines for hydraulic system Checking and adjusting the variable-displacement pumps

7 Checking and adjusting the variable-displacement pumps

Fig. 6 1

Adjusting screw of begin of regulation P1

2

Adjusting screw of begin of regulation P2

3

Lock nut / adjustment Y50 (basic setting / 59 emergency operation)

20 40

7.1

Measuring connections and valves

Measuring point for high pressure from pump 1 at the control valve block 100 (connection M1)

43

Measuring point for the control chamber pressure at the pump P1

44

Measuring point for the control chamber pressure at the pump P2

50

Control oil unit X1

20

Measuring point for the power control pressure (connection X3) at the pump 20

120 121

Primary pressure relief valve for pump P1 Primary pressure relief valve for pump P2

Y50


Y51


Hydraulic begin of regulation (basic setting) To check the begin of the hydraulic regulation, determine the point from which the pump is regulated from Q max to Q min. Connect pressure sensors or gauges (0-60 bar) to the measuring points 57 and 59. Disconnect the plugs at the proportional solenoid valves Y50 and Y51. Measure the pressure at the measuring points 57 and 59 (Measuring point 57 = tank pressure).

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6.30.7


Service Manual

Checking and adjusting the variable-displacement pumps Remove the cotter pin from the lever at Y50 and tilt it (emergency position). The pressure at the measuring point 59 must correspond to the prescribed value (see emergency pressure in adjustment protocol). If required, adjust the emergency pressure value at the nut 3. Connect pressure sensors or gauges (0-600 bar) to the measuring points 40 / 41 (control valve block 100). Connect pressure sensors or gauges (0-600 bar) to the measuring points 43 / 44 (p control chamber variable-displacement pump P1 / P2).

of

Start the engine. Run the diesel engine at low speed (level 2 / 3, approx. 1200 rpm).

7.1.1

Checking and adjustment of the pump P1 Fully extend the bucket or grapple cylinder. Press the pilot control unit to the stop. Lower the pressure at the primary pressure relief valve 120 to a value below the begin of regulation (p pump = p valve) and (p control chamber = p tank). Slowly screw in the primary pressure relief valve 120 until the pressure at the measuring point 43 (p control chamber) begins to rise (5 - 10 bar). Compare the pressure indicated at the measuring point 40 with the prescribed value (see basic begin of pressure regulation in adjustment protocol). If the value does not correspond to the prescribed pressure value, adjust the begin of regulation as described below. Set the primary press relief valve 120 to the basic begin of regulation (see adjustment protocol). Turn in the adjusting screw 1 at the pump P1 until p control chamber = ptank. Carefully screw out the adjusting screw 1 until p control chamber is about 5 - 10 bar below p pump pressure.

Secure the adjusting screw 1 with a lock nut. Check again the begin of regulation by reducing and increasing the pressure with the primary relief valve 120as described above.

7.1.2

Checking and adjustment of the pump P2 Fully extend the support cylinder. Press the pilot control unit to the stop. Lower the pressure at the primary pressure relief valve 121 to a value below the begin of regulation (p pump = p valve) and (p control chamber = p tank). Slowly screw in the primary pressure relief valve 121 until the pressure at the measuring point 44 (p control chamber) begins to rise (5 - 10 bar). Compare the pressure indicated at the measuring point 41 with the prescribed value (see basic begin of pressure regulation in adjustment protocol). If the value does not correspond to the prescribed pressure value, adjust the begin of regulation as described below. Set the primary press relief valve 121 to the basic begin of regulation (see adjustment protocol).

6.30.8

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Service Manual

Adjustment guidelines for hydraulic system Checking and adjusting the variable-displacement pumps Turn in the adjusting screw 2 at the pump P1 until p control chamber = ptank. Carefully screw out the adjusting screw 2 until p control chamber is about 5 - 10 bar below p pump pressure.

Secure the adjusting screw 2 with a lock nut. Check again the begin of regulation by reducing and increasing the pressure with the primary relief valve 121as described above. Connect the plugs to the proportional solenoid valves Y50 / Y51. Return the lever of Y50 to its normal position (i.e. upwards) and secure it with the cotter pin.

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6.30.9


Service Manual

Checking output power of the diesel engine (power test)

8 Checking output power of the diesel engine (power test) This test is only required, if the power output of the diesel engine is reduced.

8.1

Principle The power input of the pump can be calculated with the following formula:

If the pump is maintained at maximum pivoting angle, the power input of the powertrain is determined solely by the pressure (see adjustment protocol). This pressure value has been measured individually for each model and size of attachment, whereby secondary consumers have also been taken into consideration.

Fig. 7 20

Double variable-displacement pump A8VO Measuring point for high pressure of pump 1 at the control valve block 100 (connection M1)

120

Primary pressure relief valve for pump P1

121

Primary pressure relief valve for pump P2

41

Measuring point for high pressure of pump 2 at the control valve block 100 (connection M2)

Y50


43

Measuring point for the control chamber Y51 Proportional solenoid valve / flow reduction pressure at the pump P1 Measuring point for the control chamber Y352 Proportional solenoid valve of radiator fan pressure at the pump P2

40

44 50

6.30.10

Pump, control oil unit, control valve block and cooling unit

Control oil unit

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Service Manual

Adjustment guidelines for hydraulic system Checking output power of the diesel engine (power test)

8.2

Proceed as follows: Connect the pressure sensor or gauge (0-600 bar) to the measuring point 41 (control valve block 100). Connect a pressure sensor or pressure gauge (0-600 bar) to the measuring point 43 (pump P1) and the measuring point 44 (pump P2). Connect the speed counter (tool no. 60 in group 2.01) via B12 and LMS to the engine, using a measuring adapter (tool no. 45 /46), if necessary. Start the machine. Run the engine at maximum speed (level 9*). Lower the pressure at the primary pressure relief valve 120 / 121 (extending stick cylinder), (see Fig. 7 page 10) to a value below the test pressure (see adjustment protocol). Note: In machines equipped with kit AHS, the valve 120 is located at the auxiliary control valve block. The bore of valve 120 in the compact block 100 is sealed. Disconnect the plug at the solenoid valve Y 352 (fan). Disconnect Y50 or activate the power test menu at the laptop. Fully extend the stick or bucket cylinder. Press the pilot control units to the stop. Increase the pressure until the pressure at the measuring point 41 reaches the prescribed pressure (see adjustment protocol). Note! The pressure sensors at the measuring points 43 and 44 may only indicate the tank pressure, i.e. the pumps must be set to Qmax. Note down the speed at the speed counter or the LMS measuring device or laptop. Speed

> Regulating rpm

=> Diesel engine output OK

Speed

< Regulating rpm

=> Diesel engine output not OK

* from software version V5.12, only the speed level 8 is reached when the servo steering is switched on (through S35).

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6.30.11


Service Manual

Checking and adjusting the secondary pressure

9 Checking and adjusting the secondary pressure 9.1

Operational functions

Fig. 8 100

Control valve block with measuring connections and valves

40

Measuring point (pump P1)

127

41

Measuring point (pump P2)

128

100

Compact control block

129

120

Primary pressure relief valve of pump P1

130

Secondary relief valve / retracting regulating cylinder

121

Primary pressure relief valve of pump P2

131

Secondary relief valve / retracting boom cylinder Secondary relief valve / extending boom cylinder

132 133 134

Secondary relief valve / retracting stick cylinder Secondary relief valve / retracting stick cylinder Secondary relief valve / extending stick cylinder

Secondary relief valve / retracting bucket cylinder Secondary relief valve / extending bucket cylinder

The output of the diesel engine and the hydraulic pump must correspond to the values prescribed in the adjustment protocol. Connect the pressure sensor or gauge (0-600 bar) to the measuring point 41. Start the machine. Run the engine at maximum speed (level 9). Fully extend the stick cylinder. Press the pilot control units to the stop. Increase the pressure at the primary pressure relief valves 120 and 121 to a value above the adjusting value of the secondary pressure relief valves (see adjustment protocol), (turn in valves). Extend or retract the respective cylinder. Press the pilot control unit to the stop.

6.30.12

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Service Manual

Adjustment guidelines for hydraulic system Checking and adjusting the secondary pressure Compare the indicated pressure with the prescribed pressure (see adjustment protocol). If necessary, adjust the setting of the pressure relief valves 127 - 134. To do this, remove the safety cap and loosen the lock nut (WS 19). Using an Allen key (WS 4),turn the adjusting screw.

Turn clockwise (cw)

= increase pressure


= reduce pressure

Note! The prescribed secondary pressure at valve 130 (retracting regulating cylinder) cannot be reached from serial no. 27110. The correct adjustment of the valve 130 is to be completed as described below. Adjust the pressure at the valve 130 to 240 bar. Turn the adjusting screw of the valve 130 by 1 full revolution. The prescribed secondary pressure is reached, see adjustment protocol. Secure the adjusting screws of the valves 127 - 134 with lock nuts and replace the safety caps.

9.2

Travel functions

Fig. 9 210

Travel motor with valves Travel motor DMVA

214

Secondary relief valve / forward travel

215

Secondary relief valve / reverse travel

Run the engine at maximum speed (level 9). Preselect on-road gear. Apply the working brake (locking device engaged). Operate the travel motor 210 and move forward and back. Press the pilot control unit to the stop. Compare the indicated pressure with the prescribed pressure (see adjustment protocol). Turn the secondary pressure relief valves 214 and 215 until the prescribed pressure is reached. To do this, remove the safety caps and loosen the lock nut (WS 19). Using an Allen key (WS 6), turn the adjusting screw. Turn clockwise (cw)

=

increase pressure


=

reduce pressure

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6.30.13


Service Manual

Checking and adjusting the primary pressure (operating pressure). Adjust the primary pressure control valves 120 and 121 to the prescribed value, see description below in section 10.

10

Checking and adjusting the primary pressure (operating pressure). The output of the diesel engine and the hydraulic pump must correspond to the values prescribed in the adjustment protocol. Connect pressure sensors or gauges (0-600 bar) to the measuring points 40 / 41 (control valve block 100, (see Fig. 8 page 12)). Start the machine. Run the engine at maximum speed (level 9*). Fully extend the bucket cylinder. Press the pilot control unit to the stop. Compare the pressure indicated at the measuring point 40 with the prescribed pressure (see adjustment protocol). Turn the primary pressure relief valve 120 until the prescribed pressure is reached. To do this, remove the safety caps and loosen the lock nut (WS 19). Using an Allen key (WS 6), turn the adjusting screw. Turn clockwise (cw) Turn counter-clockwise (ccw)

= =

increase pressure reduce pressure

Fully extend the support cylinder. Press the pilot control unit to the stop. Compare the pressure indicated at the measuring point 41 with the prescribed pressure (see adjustment protocol). Turn the primary pressure relief valve 121 until the prescribed pressure is reached. To do this, remove the safety caps and loosen the lock nut (WS 19). Using an Allen key (WS 6), turn the adjusting screw. Turn clockwise (cw)

=

increase pressure


=

reduce pressure

Disconnect the pressure sensor or gauge and seal the measuring points 40 / 41. * from software version V5.12, only the speed level 8 is reached when the servo steering is switched on (through S35).

6.30.14

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Checking and adjusting the primary pressure for the offset boom bearing and the kit (low pressure)

11 Checking and adjusting the primary pressure for the offset boom bearing and the kit (low pressure)

Fig. 10 31 45

Low pressure control block and diesel engine with working and auxiliary pumps

Gear pump / brake and attachment kit AS 110 with flow distributor Measuring point for low pressure 123

Low pressure control valve block Pressure relief valve for low pressure

Connect the pressure sensor or gauge (0-600 bar) to the measuring point 45. Start the machine. Run the engine at maximum speed (level 9). Fully extend the swivel cylinder. Press the pilot control unit to the stop. Compare the indicated pressure with the prescribed pressure (see adjustment protocol). Turn the primary pressure relief valve 123 until the prescribed pressure is reached. To do this, remove the safety cap and loosen the lock nut (WS 19). Using an Allen key (WS 4),turn the adjusting screw. Turn clockwise (cw)

=

increase pressure


=

reduce pressure

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6.30.15


Service Manual

Checking and adjusting secondary pressure for slewing gear

12

Checking and adjusting secondary pressure for slewing gear

Fig. 11

12.1

Slewing gear motor with measuring points and 2-stage valves

190

Slewing gear motor

197

Measuring point, turning right

191 192

Secondary pressure relief valve, turning right Secondary pressure relief valve, turning left

198

Measuring point, turning left

Start-up pressure settings Danger! Uncontrolled rotating movement of the uppercarriage during adjusting work can lead to serious injury or damage to the equipment. Prior to carrying out any adjustment work: Apply the slewing gear brake. Lock the uppercarriage against undercarriage, using the locking mechanism. Anchor the equipment to the ground. Cordon off the machine and the danger zone (swivel range) against unauthorized access. Connect the pressure sensor or gauge (0-600 bar) to the measuring points 197 / 198. Block the uppercarriage (maximum pressure is not be reached when the uppercarriage is rotated). Start the machine. Run the engine at maximum speed. Turn the slewing with full load to the right. Press the pilot control unit to the stop. If required, check the maximum control pressure at the oil motor connection XA. Compare the pressure indicated at the measuring point 197 with the prescribed high pressure (swivelling to right, see adjustment protocol). Turn clockwise (cw) Turn counter-clockwise (ccw)

= =


Turn the slewing with full load to the left. Press the pilot control unit to the stop.

6.30.16

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Adjustment guidelines for hydraulic system Checking and adjusting secondary pressure for slewing gear If required, check the maximum control pressure at the oil motor connection XB. Compare the pressure indicated at the measuring point 198 with the prescribed high pressure (swivelling to left, see adjustment protocol).

12.2

Turn clockwise (cw)

=

increase pressure


=

reduce pressure

Setting brake pressure Disconnect and dummy both hose connections to XA and XB. Turn the slewing with full load to the right. Press the pilot control unit to the stop. Compare the pressure indicated at the measuring point 198 with the prescribed low pressure (braking right, see adjustment protocol). If necessary, loosen the lock nut 3 and adjust the pressure relief valve 192 using the adjusting screw 4. Turn clockwise (cw)

=

increase pressure


=

reduce pressure

Turn the slewing with full load to the left. Press the pilot control unit to the stop. Compare the pressure indicated at the measuring point 197 with the prescribed low pressure (braking left, see adjustment protocol). If necessary, loosen the lock nut 3 and adjust the pressure relief valve 191 using the adjusting screw 4. Turn clockwise (cw) Turn counter-clockwise (ccw)

= =


Re-connect the hose connections to XA and XB.

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6.30.17


Service Manual

Checking travel motor 210

13

Checking travel motor 210

Fig. 12

13.1

Control valve block and travel motor

3.35

Screw plug at measuring point M

40

4.14

Qmin stop

100

Measuring point for working pressure of pump P1 Control valve block

4.28

Safety cap

210

Travel motor DMVA

Setting begin of regulation (end of regulation), see Fig. 12 and see Fig. 13 Danger! Uncontrolled travel movement (brakes not properly applied!) can lead to serious injury or damage! Press the attachment into the soil. Extend all supports and immobilize the machine. Cordon off the machine and the danger zone against unauthorised access. Prior to carrying out any measurements or adjustments to the travel motor, ensure that the drive system is shut down. The output of the diesel engine and the hydraulic pump must correspond to the values prescribed in the adjustment protocol. Connect the pressure sensor or gauge (0-600 bar) to the measuring point 40 (control valve block 100 right). Remove the screw plug from the measuring point M located at to the left at the rear of the housing. Attach the screw coupling M10X1 (tool no 10 in group 2.01, with extension, is required) and connect the pressure sensor (see Fig. 12). Run the engine at maximum speed. Select (on-road gear) Run the machine against the applied brake (on-road gear). Press the pedal slowly and carefully down to rev up the travel motor. High pressure builds up at the measuring point 40. Below the begin of regulation for the engine A, no pressure may be building up at the measuring

6.30.18

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Service Manual

Adjustment guidelines for hydraulic system Checking travel motor 210 connection M, i.e. the oil motor is at minimum pivot angle.

Fig. 13

Regulating characteristic of the travel motor with begin and end of regulation

A Begin of regulation

B End of regulation

p Operating pressure M Measuring point at the travel motor

Q Engine flow consumption 41 Measuring point at the control valve block

Continue to rev up the engine to the maximum speed. Keep your eyes on both pressure sensors (at measuring points 40 and M). From the begin of regulation A the pressure at the measuring connection M must continue to increase (to about 1/2 high pressure value), i.e. the oil motor is adjusted towards the max. pivot angle. As soon as the high pressure (at measuring point 40) reaches the value of the end of regulation B, the value measured at point M rises to the high pressure value, i.e. the pressures at measuring points 40 and M are identical (see Fig. 13). If the pressure value for the end of regulation B does not correspond to the prescribed value, turn the adjusting screw 4.14, (see Fig. 12 page 18). To do this, release the adjusting screw 4.14. Using an Allen key (WS 8), turn the screw until end of regulation B is correct. Turn in

=

increase end of regulation

Turn out

=

decrease end of regulation

Note! The begin of regulation A cannot be adjusted separately.

After adjusting the end of regulation B, secure the adjusting screw 4.14 with the lock nut. Remove both pressure sensors and the screw coupling. Seal both measuring points M / 40.

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6.30.19


Service Manual

Adjusting of max. output speed / max. travel speed

14 Adjusting of max. output speed / max. travel speed Note: The maximum speed is fixed by the manufacturer by means of the maximum pivot angle of the travel motor (measurement Y, see adjustment protocol) and may not be adjusted.

Fig. 14

Qmin stop at the travel motor

210 Travel motor DMVA 3.14 Qmin stop screw

3.17 Lock nut 3.37 Safety cap

Danger! To measure the drive shaft speed, attach a reflecting strip onto the universal joint shaft and hold the speed counter in an appropriate position to the strip. Rotating wheels or universal joint shafts can lead to serious injury when touched or when loose clothing is caught by them. Only access the area below the undercarriage, if the travel motor is shut down. Mount the speed counter in the appropriate position, using auxiliary equipment (magnetic brackets, etc.). Cordon off the machine and the danger zone against unauthorised access. Prior to carrying out any measurements or adjustments to the travel motor, ensure that the drive system is shut down. To check the maximum travel speed of the machine, check the position of the screw 3.14 (measurement Y serves as guide value) and adjust it, if necessary. Remove the safety cap 3.37. Measure the distance Y between the upper edge of the adjusting screw 3.14 and the lock nut 3.17 and compare with the value in the adjustment protocol. If necessary, adjust distance Y by loosening the lock nut 3.17 and turning the screw. Tighten the lock nut 3.17. Replace the safety cap 3.37. A more accurate adjustment of the maximum pivot angle can be achieved by adjusting the speed of the universal joint shaft. Jack up the machine.

6.30.20

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Adjustment guidelines for hydraulic system Adjusting of max. output speed / max. travel speed Operate the travel motor in on-road gear at full speed. Press the pilot control unit to the stop. Apply reflecting strips (tool no. 64 in group 2.01) at the universal joint shaft. Measure the maximum speed of a universal joint shaft (connection between gear system and axle) using the HT 460 speed counter (tool no 62 / 63 in group 2.01) and compare with the prescribed speed in the adjustment protocol.

If the measured speed does not correspond to the prescribed speed, proceed as follows: Remove the safety cap 3.37. Loosen the lock nut 3.17. Turn the adjusting screw 3.14 in the respective direction. The measured drive shaft speed must correspond to the prescribed value. Turn in

=

reduce speed

Turn out

=

increase speed

Tighten the lock nut 3.17. Replace the safety cap 3.37.

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6.30.21


Service Manual

Checking and adjusting the lowering speed of the attachment

15

Checking and adjusting the lowering speed of the attachment The lowering speed of the attachment is limited by means of the stroke of the spool 106 of the boom cylinder with the adjusting screw / stroke limitation 162. The system is factory-set (for optimised lowering speed, see adjustment protocol). To check and adjust the lowering speed, proceed as described below. Danger! To measuring the lowering time, the attachment must be lowered at maximum speed to the ground. There is a serious risk of injury and damage to the equipment, if the bucket hits the ground. This test thus requires fast response by the machine operator, who must stop the movement before the bucket hits the ground. Cordon off the machine and the danger zone against unauthorised access.

Fig. 15 100 106

Stroke limitation of the boom cylinder spool 162 163

Compact control block Spool / boom cylinder

Stop screw of stroke limitation Lock nut

Start the machine. Run the engine at maximum speed (level 9). Extend the attachment. Fully extend the boom cylinder. Fully retract the boom cylinder. Press the pilot control unit to the stop. Using a stopwatch, measure the time until the bucket touches the ground. Compare the measured time with the prescribed time (see adjustment protocol). If the measured time does not correspond to the prescribed time, proceed as follows: Loosen the lock nut 163. Turn the adjusting screw 162 and repeat the test until the measured time corresponds to the prescribed time. Turn in Turn out

= =

Prolong lowering time Shorten lowering time

Tighten the lock nut 163.

6.30.22

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Service Manual

Adjustment guidelines for hydraulic system Checking fan control

16 Checking fan control

Fig. 16 13

16.1

Hydraulic radiator fan located near the diesel engine Y352 Proportional solenoid valve

Fan motor

Checking fan speed Danger! Moving fan blades are a severe hazard to fingers and hands. Before working near the fan, switch off the engine. The fan speed to be measured depends on the current temperature of coolant and hydraulic oil and the air condition. A simple way of checking the fan speed and thus the hydraulic circuit (pump / oil motor) is to disconnect the electric supply at the proportional solenoid valve Y352. This results in maximum fan speed. To check the fan speed, ensure that the temperature of the hydraulic oil is > 50 °C. Measure the hydraulic oil temperature. If the temperature of the hydraulic oil is too low, heat it up. Disconnect the cable at the proportional solenoid valve Y352 at the fan motor 13 (Fig. 16). To measure the speed with the speed counter (tool no. 62 / 63 in group 2.01), apply a reflective strip to one of the fan blades. Start the motor. Run the motor at maximum speed. Measure the maximum fan speed. Compare the measured fan speed with the prescribed speed (see adjustment protocol). Note! The fan speed cannot be adjusted. The pressure is factory-set by the manufacturer and may not be changed. The above measurement serves only to establish proper functioning. If the measurement indicates that there is a substantial difference between the actual and the specified value, check the hydraulic circuit for faults.

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6.30.23


Service Manual

Checking fan control

6.30.24

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Service Manual

Adjustment guidelines for hydraulic system Pressure check

Adjustment guidelines for hydraulic system 1 Pressure check 1.1

Arrangement of measuring points

Fig. 1

Layout of measuring points, part 1

20 41

Variable-displacement pump Measuring point for high pressure at the control block 100 (MP connection)

50 57

Control oil unit Measuring point LS pressure at the control oil unit 50 (MLS connection)

44

Measuring point for actuating pressure at the pump 20 (MA connection)

59

Measuring point LR pressure at the control oil unit 50 (MLR connection)

45

Measuring point for LS pressure at the pump 20 (LS connection) Measuring point for pilot pressure at the control oil unit 50 (M1 connection)

100

Control valve block

49

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6.34.1


Service Manual

Pressure check

Fig. 2 137

1.2 1.2.1

Layout of measuring points, part 2 Measuring point for slewing gear working 138 pressure at the slewing gear motor 130 (MA connection / pivot right)

Measuring point for slewing gear working pressure at the slewing gear motor 130 (MB connection / pivot left)

Measuring instruments / adjusting tools / safety of adjusting screws Measuring instruments The following measuring tools from group 2.01 are required for the checking and adjustment of the hydraulic system: High-pressure measuring lines Tools no. 7 or 8 For pilot pressure measurement: Pressure gauge 0 - 60 bar, tool no. 19 For high pressure measurement: Pressure gauge 0 - 600 bar, tool no. 22 For actuating pressure measurement: Pressure gauge 0 - 600 bar, tool no. 22 For differential pressure p measurement: Differential pressure gauge no. 30 For speed measurement: Tool no. 60/62/63 For temperature measurement: Tool no. 70 Alternatively, the following measuring tool can be used: LMS measuring system, tool no. 40 For pilot pressure measurement: Pressure sensor 0 - 60 bar For high pressure measurement: Pressure sensor 0 - 600 bar For actuating pressure measurement: Pressure sensor 0 - 600 bar plus measuring cables and accessories for the measuring of speed and temperature

6.34.2

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1.2.2

Adjusting tools: All adjustments to the valves / units can be made with conventional ring spanners, open-end wrenches and Allen keys.

1.2.3

Securing of the adjusting screws: To protect the adjusting screws against tampering and unintentional maladjustment, they must be secured (depending on the model): with lead seal wire with safety caps, see "Special tools" in group no 2.05

1.3

Instructions for adjustment / pre-conditions Before you start checking / adjusting the hydraulic system, be sure the following conditions are fulfilled: Measure the operating temperature of the hydraulic unit (minimum 50° C) in the tank. The pressure gauge is glycerine-damped with an indication accuracy of less than 1%. The valves must be secured with lead seal wire / caps to prevent tampering. Remember that during the guarantee period only representatives of LIEBHERR may modify settings of valves and units.


Fig. 3

Checking and adjusting pilot pressure

49

Measuring point

50

Control oil unit

51

Adjusting screw

Connect the pressure sensor or gauge (60 bar) to the measuring point 49. Operate the diesel engine at the rated speed. Compare the pressure indicated at the pressure gauge with the prescribed pressure (see adjustment protocol). If necessary, adjust the setting of pressure relief valve 51. Loosen the lock nut (WS 13).

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6.34.3


Service Manual

Adjustments at the working pump Increasing the pressure Turn the adjusting screw 51 clockwise, using an Allen key (WS 4). The pressure is increased. Reducing the pressure Turn the adjusting screw 51 anticlockwise, using an Allen key (WS 4). The pressure is reduced. After the pressure settings have been adjusted, lock the adjusting screw 51. Replace the protective cap. Remove the pressure gauge and seal the measuring point.

3 Adjustments at the working pump 3.1

Checking and adjustment of the hydraulic begin of regulation of pump 20 (basic settings)

Fig. 4

6.34.4

Adjustment of the pump 20

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Service Manual

Adjustment guidelines for hydraulic system Adjustments at the working pump

20

262

Secondary pressure relief valve

23.2.1 Adjusting screw 41 Measuring point

Y24 Y50

Solenoid valve Solenoid valve

44

Y51

Solenoid valve

Variable-displacement pump

Measuring point

The settings of the hydraulic begin of regulation must be adjusted at minimum pump rate. Before adjusting the settings, the pressure must be adjusted, so that the performance regulator = tank pressure. Disconnect the plug at the proportional solenoid valve LR (Y50 at the control oil unit 50). Connect the pressure sensor or gauge (0 - 600 bar) to the measuring point 41 (control valve block 100). Connect the pressure sensor or gauge (0 - 600 bar) to the measuring point 44 (pump 20). Lower the adjusting pressure at the secondary pressure-relief valve 262 to the begin of regulation (see adjustment protocol). Run the diesel engine at a speed of approx. 1000 rpm. Note! If the adjusting pressure cannot be reduced to a value below the begin of regulation (residual pump volume too high), set the engine speed to the lower idle speed. Extending bucket cylinder Turn out the secondary pressure-relief valve 262 and slowly turn it in again, while observing the pump pressure at the measuring point 44. At the prescribed begin of regulation (see adjustment protocol), the actuating pressure (= pump press) at the measuring point 44 must begin to drop. If necessary, adjust the control valve settings. Loosen the lock nut (WS 13). Adjust the begin of regulation to a later point Turn the adjusting screw 23.2.1 (WS 5) clockwise. Pressure is increased = later begin of regulation Adjust the begin of regulation to an earlier point Turn the adjusting screw 23.2.1 (WS 5) anticlockwise. Pressure is reduced = earlier begin of regulation Note! If the begin of regulation is adjusted correctly for minimum output, the pump's begin of regulation is correct across the entire performance regulating pressure range (GLR). After completion of the adjustment, lock and secure the adjusting screw 23.2.1. After checking or adjusting the regulating valves, adjust the secondary pressure-relief valve 262 to the previous value, see section 6. Reconnect the solenoid valves Y50/Y51 to the control oil unit, see Fig. 4.

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6.34.5


Service Manual

Adjustments at the working pump

3.2

Checking and adjusting the differential pressure ( p) between the pump pressure and the LS pressure

Fig. 5

Adjustment of the working pump, part 1

1 2

Measuring cable Pressure sensor

41 45

3

Measuring neck

23.5.1Adjusting screw

4 5

Measuring point Differential pressure measuring instrument

262

Measuring point Measuring point Pressure-relief valve

Disconnect the plug at the proportional solenoid valve Y51 at the control oil unit 50, see Fig. 1. Run the diesel engine at maximum speed. Adjust the adjusting screw of the secondary pressure-relief valve 262 (set pressure to approx. 100 - 120 bar so that oil can flow through the valve 262 ). If a pressure gauge ID no. 7025376 is used, calibrate the two pressure sensors ID no. 614062401: For this purpose, connect the differential pressure measuring instrument (connection P1/P2) through two pressure sensors (600 bar) and the measuring necks ID no. 4901372 and 7002404 at the measuring point 41 of the control block 100. Extend the bucket cylinder to the stop. Calibrate the devices at a pressure of approx. 100 - 120 bar. Connect the pressure sensor at connection P2 to the measuring point 45 and measure the differential pressure p between the measuring points 41 and 45, and compare them with the prescribed value (see adjustment protocol).

6.34.6

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Service Manual

Adjustment guidelines for hydraulic system Adjustments at the working pump

Note! If you want to use the LMS measuring system, ensure that you have two pressure sensors (600 bar) with an indication tolerance of ≥0.3 bar ready.

Fig. 6

Adjustment of the working pump, part 2

20


23.5

Load sensing regulator

23.5.1 Adjusting screw

If necessary, adjust the differential pressure setting pat flow regulator 23.5 of the variabledisplacement pump. Loosen the lock nut (WS 13). Increasing the differential pressure Turn the adjusting screw 23.5.1 with the Allen key (WS 4) clockwise. Reducing the differential pressure Turn the adjusting screw23.5.1 with the Allen key (WS 4) anticlockwise. After adjustment of the pressure settings, lock the adjusting screw 23.5.1. Readjust the secondary pressure-relief valve 262. Note! To check the dynamic behaviour of the settings, the differential pressure p can be checked again while the extended attachment is slowly lifted. The pressure measured in this process may not differ significantly from the pressure of the static measurement (difference maximum ≥1.0 bar).

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6.34.7


Service Manual

Checking the output power of the diesel engine (power test)

4 Checking the output power of the diesel engine (power test) 4.1

Principle The hydraulic output available at the outlet of the pump is measured. For this purpose, the pump is moved to its maximum pivot angle and the working pressure is slowly increased in order to push the engine to the rated speed.

Fig. 7

4.2

Output check of the diesel engine

41 242

Measuring point Secondary pressure relief valve

262


H307 S382

Indicator light Fine control switch

Procedure Connect the pressure sensor or gauge (0 - 600 bar) to the measuring point 41, see Fig. 7. Connect the pressure sensor or gauge (0 - 600 bar) to the measuring point 44 at the pump 20, see Fig. 4. Power the solenoid valve Y50, using a laptop and the relevant software and accessories (24 V). If this is not possible, power the solenoid valve Y50 with 24 V through an electrical plug connection in its vicinity, e.g. through valve Y24. To do this, remove the plug at the solenoid valve Y50, disconnect the plug from the solenoid valve Y24 and connect this plug to the solenoid valve Y50. Actuate the switch S21 (creeper gear) and remove the plug at the fan motor Y352 (motor runs at maximum speed). Lower the adjusting pressure at the secondary pressure-relief valve 242 and 262* (axle/stick and bucket cylinder) to approx. 100 bar. Run the diesel engine at its upper idle speed. Switch off the fine regulation by means of the switch S382 in the joystick , see Fig. 7, (indicator light H307 is off). Extend the stick and bucket cylinder*

6.34.8

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Service Manual

Adjustment guidelines for hydraulic system Checking the output power of the diesel engine (power test)

Note! During the build-up of the high pressure, closely monitor the control chamber pressure at the measuring point 44 of the pump. Ensure that there is no significant pressure difference ( 10 bar) to the measuring point 41 (no regulation of the pumps). Turn in the primary pressure control valve 242 and 262* until the prescribed value is reached (see adjustment protocol), while checking the speed. The output of the diesel engine is correct, if the speed does not drop below the rated speed (1800 rpm) at the preset value.

*

After completion of the diesel engine output check, reset the secondary pressure-relief valves 242 and 262 to the prescribed value, see section 6.

It is necessary to complete both movements and turn both secondary pressure-relief valves, in order to ensure that the entire pump flow volume is fed through the system.

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6.34.9


Service Manual

Adjusting pressure relief and cut-off valves

5 Adjusting pressure relief and cut-off valves

Fig. 8

5.1

Measuring points and valves at the pump and control block

20 41

Variable-displacement pump Measuring point MP

177 221

Reverse travel Extending boom cylinder

45

Measuring point MLS

222

Retracting boom cylinder

100

Control valve block

241

Retracting stick cylinder

104 105

Pressure cut-off valve Primary pressure relief valve

242 261

Extending stick cylinder Retracting bucket cylinder

170

Travel motor LMV / DMVA

262

Extending bucket cylinder

176

Forward travel ° *

A 316 to 28060 A 316 from 28061

Checking/adjusting the safety valve 105 Connect the pressure sensors / gauges to the measuring points 41 (control block 100) and 41 (variable displacement pump).

6.34.10

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Service Manual

Adjustment guidelines for hydraulic system Adjusting pressure relief and cut-off valves Run the diesel engine at its upper idle speed (fine regulation disabled tank pressure at measuring point 57, see Fig. 1). Extend the bucket / grapple cylinder to the stop. Press the pilot control unit to the stop. Increase the pressure cut-off value 104 by turning in the valve (up to max. 440 bar, or until secondary pressure-relief valve 262 responds, plus 1/2 turn). Increase the pressure at the secondary pressure-relief valve 262 until the safety valve 105 responds, but only up to max. 440 bar at the measuring point 41. Compare the pressure value with the prescribed pressure of the primary pressure-relief valve 105 and adjust, if necessary. Loosen the lock nut (WS 19).

Increasing the pressure Turn the adjusting screw clockwise, using an Allen key (WS 6). The pressure is increased. Reducing the pressure Turn the adjusting screw anticlockwise, using an Allen key (WS 6). The pressure is reduced. After completion of the adjustment, secure the stop screw with a lock nut.

5.2

Checking/adjusting the secondary pressure-relief valves 176 / 177, 221 - 262 Adjust the secondary relief valve 262 to the prescribed value. After completion of the adjustment, secure the stop screw with a lock nut. Check the other secondary pressure-relief valves 176, 177, 221, 222,241,242 and 261 by moving the respective devices to the stop. Adjust the settings, if required (measuring point 45). Loosen the lock nut (WS 19).

Increasing the pressure Turn the adjusting screw clockwise, using an Allen key (WS 6). The pressure is increased. Reducing the pressure Turn the adjusting screw anticlockwise, using an Allen key (WS 6). The pressure is reduced.

5.3

Adjusting the operating pressure (pressure cut-off valve 104) Set the operating pressure at the cut-off valve 104 to the prescribed value (measuring point 45). Loosen the lock nut (WS 17). Increasing the pressure Turn the adjusting screw clockwise, using an Allen key (WS 5). The pressure is increased.

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6.34.11


Service Manual

Checking and adjusting the secondary pressure for the slewing gear Reducing the pressure Turn the adjusting screw anticlockwise, using an Allen key (WS 5). The pressure is reduced.

Fig. 9

6.34.12

TC valve and slewing gear motor with pressure-relief valves, sample diagram

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Service Manual

Adjustment guidelines for hydraulic system Checking and adjusting the secondary pressure for the slewing gear

6.1

I

Relationship between the secondary protection and the control pressure for swivelling

II III

Relationship between high pressure and the control pressure for swivelling Relationship between the motor flow consumption (speed) and the control pressure for swivelling

1

Secondary setting, minimum value (braking)

2 3

Secondary setting (starting) Primary setting (operating pressure)

125

TC valve

130

Slewing gear motor

125.1 125.2

Valve body Lock nut

134 135

Secondary pressure-relief valve Secondary pressure-relief valve

128

Shuttle valve

137

Measuring point

128.2

Screw fitting

138

Measuring point

Adjustment of the start-up pressure, Fig. 9 Danger! Uppercarriage may execute uncontrolled rotary movements, posing a hazard to mechanics and equipment. Apply the slewing gear brake. Lock the uppercarriage against the undercarriage, using locking bolts. Anchor the equipment to the ground. Connect the pressure sensor to the measuring points 137 / 138. Block the uppercarriage (maximum pressure cannot be reached if the uppercarriage is rotating). Turn in the valve body at the TC valve 125.1 until p primary is higher than the pressure at the secondary relief valve (complete about 2 turns). Start the machine. Run the diesel engine at its upper idle speed. Press the pilot control unit for "turning left" to the stop. Compare the pressure with that in the adjustment protocol (measuring point 138). If necessary, remove the locknut 1 and adjust the settings of the pressure-relief valve 135 with the adjusting screw 2 Press the pilot control unit for "turning right" to the stop. Compare the pressure with that in the adjustment protocol (measuring point 137). If necessary, remove the locknut 1 and adjust the settings of the pressure-relief valve 134 with the adjusting screw 2

6.2

Adjusting the brake pressure Fig. 9 Disconnect and dummy both hose connections with X and Y Press the pilot control unit for "turning left" to the stop. Compare the pressure with that in the adjustment protocol (measuring point 138). If necessary, remove the locknut 3 and adjust the settings of the pressure-relief valve 135 with

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6.34.13


Service Manual

Checking the travel motor 170 the adjusting screw 4 Press the pilot control unit fort "turning right" to the stop (measuring point 137). If necessary, remove the locknut 3 and adjust the settings of the pressure-relief valve 134 with the adjusting screw 4 Re-connect the hose connections to X and Y

6.3

Adjusting the settings of the TC valve 125, Fig. 9. Turn back as many turns as turned previously. Press the pilot control unit to the stop. Turn the valve body 125.1 of the TC valve to adjust the pressure to that prescribed in the adjustment protocol.

7 Checking the travel motor 170 7.1

Adjustment of the begin of regulation (end of regulation)

Fig. 10 20

Checking the travel motor, part 1 45


Measuring point

Condition: The outputs of the diesel engine and the hydraulic pump must correspond to the prescribed values (see adjusting protocols and hydraulic pump settings in group 7.05). Run the diesel engine at its upper idle speed. Connect the pressure sensor/gauge to the measuring point 45 (pump 20), see Fig. 10. M

M2

Screw in the screw coupling assembly M10x1 (tool no. 10 in group 2.01, with extension, if required) and connect a pressure gauge / sensor. Jack up the machine and run the travel motor in on-road gear at full speed (operate pilot control unit). Take all necessary safety precautions.

6.34.14

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Service Manual

Adjustment guidelines for hydraulic system Checking the travel motor 170

Fig. 11

Checking the travel motor, part 2

3.14

Threaded stud Qmin. (A 312 and A 316*)

170.26 Begin of regulation / adjusting screw (A 314/316°)

4.14

Begin of regulation / adjusting screw (A 312 and A 316*)

M

Measuring connection (A 312 and A 316*)

M2

Measuring connection (A 314/316°)

170 Travel motor 170.17 Threaded stud Qmin (A 314/316°)

° in A 316 to 28060 ° in A 316 from 28061 Operate the brake pedal to slowly apply the working brake (4-wheel brake). High pressure builds up at the measuring point 45. At values below the motor begin of regulation (see values in the adjustment protocol on pages 7.26-03/7.27-03) there may be no pressure at the measuring connections M or M2, i.e. the oil motor must be set to its minimum pivot angle. Continue to accelerate the motor to its max. speed. Keep your eyes on the two pressure gauges (at measuring points 45 and M2).

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6.34.15


Service Manual

Checking the travel motor 170 From the moment of begin of regulation M, the pressure at the measuring connection M2 must continue to rise (to about 1/2 high pressure value). The oil motor is adjusted towards the max. pivot angle. When the high pressure (at the measuring point 45) reaches the value of the end of regulation (see pages 7.26-03/7.27-03) the pressure measured at measuring point M/M2 increases suddenly to the high pressure value, so that the pressure values at the measuring points 45 and M/M2 are the same, Fig. 12.

Fig. 12 160.1

Checking the travel motor, part 3 160.2

Stroke limitation 1

Stroke limitation 2

160.1.1 Adjusting screw of the stroke limitation 1 160.2.1 Adjusting screw of the stroke limitation 2 160.1.2 Lock nut of the stroke limitation 1

160.2.2 Lock nut of the stroke limitation 2

If the pressure value for the begin of regulation does not correspond to the prescribed value, it can be adjusted by means of the adjusting screw 4.14/170.26, see Fig. 11. Release the adjusting screw 4.14/170.26. Increasing the end of regulation Turn in the adjusting screw.

6.34.16

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Service Manual

Adjustment guidelines for hydraulic system Checking the travel motor 170 The end of regulation is increased.

Reducing the end of regulation Turn out the adjusting screw. The end of regulation is reduced. After adjustment of the end of regulation, remove both pressure gauges and the screw coupling and seal both measuring points.

7.2

Adjustment of the minimum pivot angle The minimum pivot angle is set by the threaded stud 3.14/170.17, see Fig. 11. The angle is factoryset by the manufacturer and may not be changed. The correct position of the threaded stud 3.14/170.17 can be used as a reference value after measuring of the dimensions X, Fig. 11 and comparison with the adjustment protocol.

7.3

Adjustment of the maximum output speed/maximum travel speed The maximum output speed of the oil motor is determined by the minimum flow consumption of the oil motor (Qmin) and the maximum flow rate of the spool/chassis 160. Note! The max. flow rate is factory-set by the manufacturer by means of the stroke limitation of spool 160 (value Y - see adjustment protocol or group 7.60) and may only be adjusted in exceptional circumstances. If the max. travel speed of the vehicle is unsatisfactory, the setting can be modified, provided that the measured maximum speed of the universal joint shaft (connection of transmission and axles) does not correspond to the specified value (see adjustment protocol). Adjustment of the maximum output speed: Jack up the vehicle and run it in on-road gear (pilot control valve at full throttle). Measure the maximum speed of one joint shaft, using the HT 460 speed meter (for tool, see page 2.01.07) and compare with the prescribed speed (in adjustment protocol). If the measured speed does not correspond to the prescribed speed, proceed as follows: At fully actuated pilot control unit, remove the cap nut of the chassis control axle 160 of the control valve block 100. Loosen the lock nut .2 of the stroke limitation 160.1/160.2. Reducing the speed: Turn the adjusting screw .1 in. The speed is reduced. Increasing the speed: Turn adjusting screw .1 out. The speed is increased. Repeat the adjustment on the other side of the spool 160 (forward and reverse travel). After adjustment of the speed, secure the adjusting screws 160.1/160.2 and replace the cap nuts.

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6.34.17


Service Manual

Checking the fan control system

8 Checking the fan control system

Fig. 13 13

8.1

Fan motor with proportional solenoid valve Y352

Fan motor

Proportional solenoid valve

Checking the fan speed Danger! Moving fan blades might cause serious injury to fingers and hands. Shut down the engine. Do not reach into the fan operating range until the fan blades have come to a standstill. The fan speed to be measured depends on the current temperature of coolant and hydraulic oil and the air condition. A simple way of checking the fan speed and thus the hydraulic circuit (pump / oil motor) is to disconnect the electric supply to the proportional solenoid valve Y347 (max. fan speed). The temperature of the hydraulic oil must be > 50 °C (see adjustment protocol). Measure the hydraulic oil temperature. If the temperature of the hydraulic oil is too low, heat it up. Disconnect the cable at the proportional solenoid valve Y352 at the fan motor 13 (Fig. 13). To check the fan speed with the speed counter (tool no. 62 / 63), apply a reflective strip to one of the fan blades. Introduce the pressure measuring connection into the cooling circuit (not within scope of delivery). Connect a pressure sensor. Run the diesel engine at its upper idle speed. Measure the maximum fan speed. Compare the measured fan speed with the prescribed speed (see adjustment protocol). Note! The fan speed cannot be adjusted. The pressure is factory-set by the manufacturer and may not be changed. The above measurement serves only to establish proper functioning. If the measurement indicates that there is a substantial difference between the actual and the specified value, check the hydraulic circuit for faults.

6.34.18

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Service Manual

Adjustment guidelines for hydraulic system Arrangement of measuring points

Adjustment guidelines for hydraulic system 1 Arrangement of measuring points

Fig. 1 41 44 45 49 57 59 137 138

Measuring points at variable-displacement pump DPVO 20, the control valve block 50, the control oil unit 100 and the slewing gear motor 130 Measuring point for high pressure at control valve block 100 (connection MP) Measuring point for control chamber pressure at pump20 (connection MA) Measuring point for LS pressure at pump 20 (connection X2) Measuring point for pilot pressure at control oil unit 50 (connection M1) Measuring point - LS pressure at control oil unit 50 (connection MLS) Measuring point - LR pressure at control oil unit 50 (connection MLR) Measuring point for slewing-gear working pressure at slewing gear motor130 (connection MA turn right) Measuring point for slewing-gear working pressure at slewing gear motor130 (connection MB turn left)

2 Measuring instruments / adjusting tools / safety of adjusting screws 2.1

Measuring instruments To check and/or adjust the hydraulic unit, you need the following measuring equipment and tools:

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6.37.1


Service Manual

Measuring instruments / adjusting tools / safety of adjusting screws Differential pressure gauge / kit 0 - 600 bar

Tool in group 2.01

Speed measurement Temperature measurement

Speed counter Thermometer

No. 60 or 62 No. 70

Alternative: LMS measuring system, tool no. 40 For pilot pressure:

> Pressure sensor 0 -60 bar

For high pressure:




plus measuring cables and accessories for the measuring of speed and temperature Note! If the differential pressure gauge for measuring sure gauges (examples): Pressure gauge 0 - 600 bar, tool no. 22

p is not available, use one of the following pres-

Note! For the adjustment of valves and units, use commercially available high-quality tools, for instance: ring spanners, open end spanners and Allen keys. Always secure the adjusting screws against tampering and unintentional modification: Apply lead seal wire. Use safety caps (see tools no. 20 - 25).

2.2

Instructions for adjustment / pre-conditions Note! During the warranty period, only LIEBHERR agents and mechanics may modify settings of valves and units.

2.2.1

Prior to checking and adjusting the settings of the hydraulic system, ensure that the following conditions are fulfilled: The operating temperature of the hydraulic unit (measured in the tank) must be at least 50°C. The pressure gauges must be glycerine-filled and have an indicating accuracy of below 1% relative to the scale end value. When measuring or adjusting an actuated spool of the control valve block, ensure that the piston is fully lifted at maximum control pressure (maximum piston stroke). Note! In the event of a hydraulic failure, follow the instructions in the adjustment protocol in the prescribed sequence. The required minimum oil temperature can be obtained by actuating the 'close bucket' command while the pressure at the secondary pressure relief valve 262 is lowered, (see Fig. 8, page 9). All valves must be secured against unauthorized readjustment by safety caps.

6.37.2

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Service Manual



Fig. 2

Control oil unit with valve and measuring connection

49 Measuring connection - control pressure 50 Control oil unit

51 Pressure relief valve / pilot control

Connect the pressure sensor or gauge (0-60 bar) to the measuring point 49. Run machine at maximum engine speed. Compare the displayed pressure with the prescribed pressure (see adjustment protocol). If necessary, adjust the setting of the pressure relief valve 51. Proceed as follows: Remove the safety cap. Loosen the lock nut (WS 13). Use an Allen key (WS 4) to turn the adjusting screw. Turn clockwise (cw)

= increase pressure


= reduce pressure

Secure the adjusting screw 51 with the lock nut and replace the safety cap. Remove the pressure sensor / gauge and seal the measuring point 49.

4 Checking the proportional solenoid valve Y50 Connect the pressure sensor or gauge (0-60 bar) to the measuring point 59(see Fig. 3, page 4). Start the machine. Using a suitable adapter (tool no. 44 in group 2.01), measure the current at the valve Y50. Based on the chart, determine the required pressure and compare with the actual pressure at the measuring point 59.

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6.37.3


Service Manual


Fig. 3


50

Control oil unit

59

Measuring point MLR (power control)

Y50




=> everything OK => Replace proportional solenoid valve.

Current not OK

Pressure not OK

=> Search for fault in the electrical system and the horsepower control

Note! The characteristic of the solenoid valve cannot be adjusted.

4.1

Adjusting the regulating pressure for emergency operation Switch off machine. Remove the plug from the proportional solenoid valve Y 50. Remove the cotter pin. Actuate the lever. Start the machine. Preselect the maximum engine speed. Compare the pressure values to those in the adjustment protocol and adjust, if necessary. Proceed as follows: Remove the locknut and turn the insert by hand. Turn clockwise (cw) = increase pressure Turn counter-clockwise (ccw) = reduce pressure Reset the lever to its initial position. Insert the cotter pin. Remove the pressure sensor and seal the measuring point 59.

6.37.4

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Service Manual

Adjustment guidelines for hydraulic system Checking the proportional solenoid valve Y51

5 Checking the proportional solenoid valve Y51 Connect the pressure sensor or gauge (0-60 bar) to the measuring point 57. Start the machine and run it at maximum engine speed. Change the current to the proportional solenoid valve Y51 by turning the potentiometer for fine adjustment (R76). Using a suitable adapter (tool no. 44 in group 2.01), measure the current at valve Y51. Based on the chart, determine the required pressure and compare with the actual pressure at the measuring point 57.

Fig. 4


50

Control oil unit

Y51

57

Measuring point MLS (flow reduction)




=> everything OK => Replace proportional solenoid valve.

Current not OK

Pressure not OK

=> Search for fault in the electrical system.

Note! The characteristic of the solenoid valve cannot be adjusted.

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6.37.5


Service Manual

Checking and adjusting the variable-displacement pump

6 Checking and adjusting the variable-displacement pump

Fig. 5 8

Begin of regulation / adjusting screw

57

20

Variable displacement pump DPVO

59

41

Measuring point for high pressure at con- 100 trol valve block 100 (connection MP)


44

Measuring point for control chamber pres- Y50 sure at pump20 (connection MA) Control oil unit Y51

Proportional solenoid valve / power control Proportional solenoid valve / flow reduction

50

6.1

Measuring connections and valves Measuring point for flow reduction / control pressure (connection MLS) Measuring point for the power control / pressure (connection MLR)

Hydraulic begin of regulation (basic setting) To check the begin of the hydraulic regulation, determine the point from which the pump is regulated from Q max to Q min and adjust it, if necessary. Disconnect plugs on proportional solenoid valves Y50 and Y51. Measure pressure at measuring points 57 (MLS) and 59 (MLR). Target = tank pressure. Connect the pressure sensor to the measuring point 41 (p pump - control block100). Connect the pressure sensor to the measuring point 44 (p control chamber - variable-displacement pump20). Run the diesel engine at low speed (approx. 1200 rpm). Fully close the bucket / grapple. Press the pilot control unit to the stop. Screw out the secondary pressure relief valve 262 to a position below the begin of regulation (p

pump pressure = p control chamber).

Carefully screw in the secondary relief valve 262 until p control chamber is about 5 - 10 bar below p

pump pressure.

6.37.6

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Service Manual

Adjustment guidelines for hydraulic system Checking and adjusting the variable-displacement pump Compare the pressure at the measuring point 41 (p pump pressure ) with the values in adjustment protocol. If necessary, adjust the settings using the regulating valve .

Proceed as follows: Start the machine. Run the diesel engine at low speed (approx. 1200 rpm). Fully close the bucket / grapple. Press the pilot control unit to the stop. To do this, set the secondary pressure relief valve 262 (measuring point 41) to the nominal value for begin of regulation (see adjustment protocol). Turn in the adjusting screw 8 until p pump pressure = p control chamber. Carefully turn out the adjusting screw until p control chamber is about 5 - 10 bar below p pump pressure. Secure the screw with a lock nut. Check the begin of regulation again: Reduce and increase the pressure by means of the secondary relief valve 262. Connect the plug to the proportional solenoid valve Y50 / Y51.

6.2

Checking and adjusting the differential pressure ( pressure and the LS pressure Before adjusting the differential pressure control Y50.

- p) between the pump

-p, check the begin of regulation and the horsepower

Note! As the tolerance for the differential pressure -p is very small (+1 bar), use measuring instruments with suitable accuracy. As such measuring instruments do not always determine the precise pressure value, always first test and recalibrate the pressure sensors (for detailed instructions, see operating manual of your measuring device). Connect both pressure sensors to the same pressure source (100 - 110 bar). The difference between the indicated values should not exceed 0.5 bar. In the event of a greater difference, adjust the sensors using a calibration device (if possible), or replace them.

6.2.1

Calibration of pressure sensors

Fig. 6

Diagram of calibration

A

Measuring instrument

E

Pressure sensor

B

Control valve block

F

Measuring cable

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6.37.7


Service Manual

Checking and adjusting the variable-displacement pump C D

6.2.2

P1 P2

Measuring neck (ID no. 4901372) Measuring point 41

Adjusting differential pressure

Fig. 7

Measuring connection Measuring connection

-p

Measuring connections and valves at the hydraulic pump 20, the control oil unit 50 and the control valve block100 -p

57

2

Adjusting screw

20


41

Measuring point for high pressure at con- 100 trol valve block 100 (connection MP)


44

Measuring point for control chamber pres- Y50 sure at pump20 (connection MA)


45

Measuring point for LS pressure at pump 20 Control oil unit

Y51


50

59

Measuring point for flow reduction / control pressure (connection MLS) Measuring point for the power control / pressure (connection MLR)

Disconnect the plug connection from the proportional solenoid valve Y51 (see Fig. 5) and check the pressure at the measuring point 57 (nominal pressure = tank pressure). Connect the pressure sensor to the measuring points 41 (p pump) and 45 (p LS) (see Fig. 7). Start the machine. Run the engine at maximum speed. Fully close the bucket / grapple. Press the pilot control unit to the stop. Reduce the secondary relief valve 262 to the specified value. Check the pressure difference. If necessary, adjust the differential pressure setting -p at flow regulator 2 of variable-displacement pump 20.

6.37.8

Turn clockwise (cw)

= increase differential pressure -p


= reduce differential pressure

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-p

Service Manual

Adjustment guidelines for hydraulic system Checking output power of the diesel engine (power test) Secure the adjusting screw with a lock nut. Reconnect the plug at the proportional solenoid valve Y 51.

7 Checking output power of the diesel engine (power test) 7.1

Principle The power input of the pump can be calculated with the following formula:

If the pump is maintained at maximum pivot angle, the power input of the powertrain is determined solely by the pressure (see adjustment protocol). This pressure value has been measured individually for each model and size of attachment, whereby secondary consumers have also been taken into consideration.

Fig. 8

20

Double variable-displacement pump 242 A8VO Measuring point for high pressure of 262 pump 2 at control valve block 100 (connection MP)

41

7.2

Proportional solenoid valve / cooling and measuring points at the variable-displacement pump and the control valve block

44

Measuring point for control chamber pressure at pump20 (connection MA)

100


Secondary pressure relief valve for extending stick cylinder Secondary pressure relief valve for extending bucket cylinder

Y352 Proportional solenoid valve / radiator fan

Proceed as follows: Disconnect the plug at the solenoid valve Y 352 (fan) (see Fig. 8).

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6.37.9


Service Manual

Adjusting pressure relief and cut-off valves Connect the pressure sensor (0-600 bar) to the measuring point 41 (p pump) (see Fig. 8). Connect the pressure sensor (0-600 bar) to the measuring point 44 (p LS) (see Fig. 8). Connect the speed counter. Start the machine. Run the engine at maximum speed (check maximum speed). R76 not actuated (fine adjustment disabled) Fully extend the stick cylinder and close the bucket. Press the pilot control unit to the stop. Lower the pressure at the secondary pressure relief valve 242 (extend stick cylinder - Fig. 9) and 262 (extend bucket cylinder - Fig. 9) below the test pressure in the adjustment protocol. Start the power test program at the laptop. Increase the pressure until the pressure indicated at the measuring point 41 reaches the prescribed pressure (see adjustment protocol). Control chamber pressure, pressure difference< 10 bar, pump pressure (10 bar max.) Read motor speed at speed counter. Speed

> Regulating rpm

=> Diesel engine output OK

Speed

< Regulating rpm

=> Diesel engine output not OK

8 Adjusting pressure relief and cut-off valves

Fig. 9

6.37.10

Pump 20, control valve block 100 and travel motor 200/201 with measuring connections and valves

20


212

Secondary pressure relief valve / reverse travel, left

41

Measuring point(pump pressure)

213

Secondary pressure relief valve / forward travel, right

45

Measuring point (LS pressure)

214

100


221

Secondary pressure relief valve / reverse travel, right Extend boom cylinder

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Service Manual

Adjustment guidelines for hydraulic system Adjusting pressure relief and cut-off valves

104 105

Pressure cut-off valve Safety valve

222 241

Retract boom cylinder Retract stick cylinder

200 201

Travel motor, left Travel motor, right

242 261

Extend stick cylinder Retract bucket cylinder

210 211

Brake hose 262 Secondary pressure relief valve / forward travel, left


Note! All measurements must be completed at maximum engine speed. Check the secondary pressure relief valves at the measuring point 45 (p LS). Check the pressure cut-off valve 104 and the safety valve 105 at the measuring point 41 (p pump).

8.1 8.1.1

Checking and adjusting the secondary pressure relief valves Secondary pressure relief valves for the attachment Method I (including adjustment of valve 105): Connect pressure sensors to the measuring point 41 (p pump) and to the measuring point 45 (p LS). Start the machine. Run the engine at maximum speed. R76 not actuated (fine adjustment disabled) Check tank pressure at the measuring point 57 (MLS - see Fig. 7). Fully close the bucket / grapple. Press the pilot control unit to the stop. Increase the pressure cut-off value 104 by turning it in (up to max. 440 bar, or until secondary relief valve 262 responds, plus 1/2 turn). Increase pressure at secondary relief valve 262 until safety valve 105 responds, but only up to 440 bar max. at measuring point 41 (p pump). If necessary, set the safety valve 105 (measuring point 41 - p pump) to the correct value. Adjust the secondary relief valve 262 (measuring point 45 p LS). Secure the secondary relief valve 262 with a lock nut. Activate the remaining secondary relief valves by moving the associated attachments to the stop, and adjust the settings, if necessary (measuring point 45 p LS). Check the valves of the travel motorsee 8.1.2. Adjust the operating pressure at pressure cut-off valve 104 (measuring point 41 p pump).see 8.2 Secure all valves with lock nuts. Remove the pressure sensors and seal the measuring points.

8.1.2

Secondary pressure relief valve for the travel motor Danger! During the measuring procedure, cordon off the danger zone around the machine and ensure that no persons enter it!

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6.37.11


Service Manual

Adjusting pressure relief and cut-off valves Remove the cover from the longitudinal member. Remove the hose 210 to the travel gear and seal the connection (this is required in order to travel against the applied brake). Operate one travel motor after the other in both directions. Press the pilot control unit to the stop. Check the pressure at the valves 211 - 214, compare it with the prescribed pressure (see adjustment protocol) (measuring point 45 p LS) and adjust it, if necessary. Secure the valves with lock nuts. Reconnect the hose 210 to the travel gear system. Mount the cover onto the longitudinal member.

8.2

Adjustment of the operating pressure (pressure cut-off valve 104) Connect the pressure sensor to the measuring point 41 (p pump). Start the machine. Run the engine at maximum speed. R76 not actuated (fine adjustment disabled) Fully close the bucket / grapple. Press the pilot control unit to the stop. Adjust the operating pressure (see adjustment protocol) at the pressure cut-off valve 104 . Adjust pressure cut-off valve 104 . Remove the pressure sensor and seal the measuring point. Key to slewing gear adjustment, see Fig. 10 125

TC valve

135

125.1

Valve body

135.1

2-stage pressure relief valve for turning left Lock nut

125.2 128

Lock nut Shuttle valve

135.2 135.3

Adjusting screw for start-up pressure Lock nut

128.2

Union nut / screw connection

135.4

Adjusting screw for brake pressure

130

Slewing gear motor

137

Measuring point for turning left

134

2-stage pressure relief valve for turning 138 right

134.1 134.2

Lock nut Adjusting screw for start-up pressure

134.3 134.4

Lock nut Adjusting screw for brake pressure

I

XA XB

Measuring point for turning right

Control pressure connection, turn left Control pressure connection, turn right

: Relationship between the secondary protection and the control pressure for swivelling

II : Relationship between high pressure and the control pressure for swivelling III : Relationship between the motor flow consumption (speed) and the control pressure for swivelling 1 : Secondary setting, minimum value (braking) 2 : Secondary setting (starting)

6.37.12

copyright by

MJFCIFSS

Service Manual

Adjustment guidelines for hydraulic system Checking / adjusting the secondary pressure for the slewing gear

3 : Primary setting (operating pressure)

9 Checking / adjusting the secondary pressure for the slewing gear

Fig. 10

Slewing gear motor with pressure relief valves, and TC valve, with sample diagram

copyright by

MJFCIFSS

6.37.13


Service Manual

Checking / adjusting the secondary pressure for the slewing gear

9.1

Adjustment of the start-up pressure, Fig. 10 Danger! Uppercarriage may execute uncontrolled rotary movements, posing a hazard to mechanics and equipment. Apply the slewing gear brake. Lock the uppercarriage against the undercarriage, using locking bolts. Anchor the equipment to the ground. Connect the pressure sensor to the measuring points 137 / 138. Block the uppercarriage (maximum pressure cannot be reached when the uppercarriage is rotated). Turn in the valve body at the TC valve 125.1 until p primary is higher than the pressure at the secondary relief valve (complete 2 turns approx.). Start the machine. Run the engine at maximum speed. Press the pilot control unit for 'turn left' to the stop. Compare the pressure with that in the adjustment protocol (measuring point 138). If necessary, loosen the lock nut 1 and adjust the pressure relief valve 135 with the adjusting screw 2. Press the pilot control unit for 'turn right' to the stop. Compare the pressure with that in the adjustment protocol (measuring point 137). If necessary, loosen the lock nut 1 and adjust the pressure relief valve 134 with the adjusting screw 2.

9.2

Adjusting the brake pressure Fig. 10 Disconnect and seal both hose connections to XA and XB. Press the pilot control unit for 'turn left' to the stop. Compare the pressure with that in the adjustment protocol (measuring point 138). If necessary, loosen the lock nut 3 and adjust the pressure relief valve 135 with the adjusting screw 4. Press pilot control unit 'turn right' to the stop (measuring point 137). If necessary, loosen the lock nut 3 and adjust the pressure relief valve 134 with the adjusting screw 4. Re-connect the hose connections to XA and XB.

9.3

Adjusting TC valve 125. Fig. 10 Turn out the valve body 125.1 to its initial position (i.e. turn in by the same number of rotations as used previously to turn it in). Press the pilot control unit to the stop. Turn the valve body 125.1 of the TC valve to adjust the pressure to that in the adjustment protocol.

6.37.14

copyright by

MJFCIFSS

Service Manual

Adjustment guidelines for hydraulic system Adjustment of the output speed of the travel drive system

10 Adjustment of the output speed of the travel drive system

Fig. 11

Spool 160/180 for chassis

160

Spool / chassis right

180

Spool / chassis left

160.1 160.2

Stroke limitation Stroke limitation

180.1 180.2

Stroke limitation Stroke limitation

160.3 160.4

Adjusting screw Lock nut

180.3 180.4


Note! The max. speed is factory-set by means of the spool stroke limitation (value Y - see adjustment protocol) and may only be adjusted in exceptional circumstances. If there is a problem with the maximum travel speed of the machine, the setting can be modified, provided that the maximum speed measured at the tumbler wheel does not correspond to the value in the adjustment protocol. Run the engine at maximum speed. Lift one side of the chassis, using the attachment, and run the respective travel drive at normal speed (S21 not actuated). Press the pilot control unit to the stop. Measure the maximum speed of the tumbler wheel and compare with the prescribed value in the adjustment protocol. If the measured speed does not correspond to the prescribed speed, proceed as follows: Danger! During the measuring procedure, cordon off the danger zone around the operated crawler and ensure that no persons enter it! Remove the cap nut at the control axle of travel gear 160/180 of control valve block 100. Remove the lock nut .4 of the stroke limitation and turn the adjusting screw .3 as required.

copyright by

MJFCIFSS

6.37.15


Service Manual

Adjustment of the maximum speed (Qmin stop / fast travel) Turn in

= reduce speed

Turn out

= increase speed

Repeat the adjustment on the other side of the spool (travelling forward and reverse). Check adjustment of the speed. The measured tumbler wheel speed must correspond to the prescribed value. Secure adjusting screws .3 of stroke limitation 160.1 / 160.2 / 180.1 / 180.2 with lock nuts. Replace the cap nuts.

11

Adjustment of the maximum speed (Qmin stop / fast travel) Note: The maximum speed of the travel drive can be achieved by setting the unit into fast travel mode by actuating the switch S21. In this mode, the regulating motor is set to Qmin. If the factory-set maximum speed cannot be reached, check the oil motor settings: Run the diesel motor at maximum speed. Lift one side of the chassis with the attachment. Actuate the switch S21. Run lifted travel drive in fast travel mode. Press the pilot control unit to the stop. Compare the actual speed of the tumbler wheel with the nominal speed specified in the adjustment protocol. If the actual speed is below the nominal speed, adjust the Qmin stop screw of the respective regulating motor as follows: Danger! Before making any adjustments to the travel motor, ensure that the chain is not moving. Cordon off the danger zone around the operated crawler and ensure that no persons enter it!

Fig. 12

Travel motor with travel gear system in longitudinal member and Qmin stop Vmin

Remove the cover from the longitudinal member. Release the Qmin stop screw of the travel motor. Release the lock nut. Turn the stop screw.

6.37.16

copyright by

MJFCIFSS

Service Manual

Adjustment guidelines for hydraulic system Checking the fan control system

Turn in

= reduce speed

Turn out

= increase speed

Note: When adjusting the maximum speed of the travel gear system, also check the synchronisation of the two travel motors (tracking). Adjust the two oil motors to the speed of the lower one. Secure the stop screw with a lock nut. Mount the cover onto the longitudinal member.

12 Checking the fan control system

Fig. 13 13 14

12.1

Oil motor and proportional solenoid valve / fan control with pressure relief valve

Oil motor radiator fan Pressure relief valve / fan motor

Y352 Proportional solenoid valve / radiator fan

Checking the fan speed Danger! Moving fan blades might cause serious injury to fingers and hands. Before working near the fan, switch off the engine. The fan speed to be measured depends on the current temperature of the coolant and the hydraulic oil. A simple way of checking the fan speed and thus the hydraulic circuit (pump / oil motor) is to disconnect the electric supply to the proportional solenoid valve Y347 (max. fan speed). The temperature of the hydraulic oil must be > 50 °C (see adjustment protocol). Measure the hydraulic oil temperature. If the temperature of the hydraulic oil is too low, heat it up. Disconnect the cable at the proportional solenoid valve Y352 at the fan motor 13 (Fig. 13). To check the fan speed with the speed counter (tool no. 62 / 63), apply a reflective strip to the fan blade.

copyright by

MJFCIFSS

6.37.17


Service Manual

Checking the fan control system Start the motor. Run the engine at maximum speed. Measure the maximum fan speed. Compare the measured fan speed with the prescribed speed (see adjustment protocol). Note! The fan speed cannot be adjusted. The pressure is factory-set by the manufacturer and may not be changed. The above measurement serves only to establish proper functioning. If the measurement indicates that there is a substantial difference between the actual and the specified value, check the hydraulic circuit for faults.

6.37.18

copyright by

MJFCIFSS

Service Manual

Hydraulic system A 309 from 20221 / A 311 from 20222

Hydraulic system 1 A 309 from 20221 / A 311 from 20222 Note! For a detailed description of the design and construction of the hydraulic system and the various main components see group 6.20.

Items

see group

Items

see group

1

Hydraulic tank

19.08

134

Secondary pressure relief valve / bucket cylinder B7

2

Breather filter

19.08

135

Suction valve travel motor A8

7.50

3

Stop cock

136

Suction valve travel motor B8

7.50

4

Return filter

19.08

150

Check valve

7.50

5

Bypass valve/return filter (pressure)

19.08

151

Load-holing valve

7.50

6

Oil cooler

152

Check valve

7.50

10

Cylinder / speed adjustment

153

Check valve 0.5 bar

7.50

11

from turbocharger / engine

154

Preload valve 5.5 bar

7.50

12

Check valve 0.2 bar

155

Restrictor valve

13

Oil motor radiator fan

160

Boom cylinder

7.30

14

Pressure relief l valve fan motor

161

Pipe-fracture safety

16.04

15

Coarse filter

162

Stroke limitation / spool for lifting

20

Double variable-displacem. pump

7.02

170

Stick cylinder

7.30

21

Powertrain P1

7.02

171

Restrictor check valve

7.90

22

Powertrain P2

7.02

180

Bucket cylinder

7.30

23

Regulating unit P1 + P2

7.02

181

Shut-off device / grapple operation

18.35

24

Adjustment

7.02

182

Lines leading to grapple cylinder

25

Spool

7.02

183


26

Nozzle

7.02

190

Slewing gear motor / powertrain

7.24

27

Differential piston

7.02

191

Pressure-relief l valve / turn right A

7.24

28

Opposed piston / flow reduction

7.02

192

Pressure-relief l valve / turn left B

7.24

29

Actuation device

7.02

193

Suction valve

7.24

30

Gear pump / fan drive

195

Slewing gear brake

9.20

31

Pump/low-pressure circuit- brake

196


9.10

32

Gear pump / steering with Pressure-relief l valve

197

Measuring point 'turn left'

7.24

33

Gear pump / pilot control

198

Measuring point 'turn right'

7.24

40

Measuring point pump P1

210

Regulating travel motor / powertrain

7.27

41


211

Powertrain

7.27

43

Measuring point / actuating pressure for regulation P1

212

Control piston

7.27

A 309 LI 20221-23502 A 311 LI 20222-23506

copyright by

MJFCIFSS

7.90

6.40.1

Hydraulic system

Service Manual

A 309 from 20221 / A 311 from 20222 Items

see group

Items

see group

44


213

Spool

7.27

49

Measuring point / pilot pressure

214

Secondary pressure-relief l valve / chassis forward A

7.27

50

Control oil unit

7.40

215

Secondary pressure-relief l valve / chassis reverse B

7.27

51


7.40

216

Shuttle valve

7.27

52

Pressure filter

7.40

217* Brake valve, two-end

7.27

53

Check valve

7.40

218

Brake piston

7.27

54

Accumulator

7.40

219

Check valve

7.27

57

Measuring point servo pressure (LS) Flow reduction P1

220


7.27

59

Measuring point servo pressure (LR) Power control

225

Transmission

11.08

75

Check valve P2 - reset

230

Support cylinder

7.30

76

Shuttle valve / compound circuit

231

Double load-holding valve / blade support

7.86

80

Pilot control valve left 4 x

7.45

241

to Double load-holding valve / swivel cylinder, see 6.40.9

7.82

81

Pilot control valve right 4 x

7.45

250

Regulating cylinder

7.30

84

Pilot control valve 1 x / chassis

7.49

251

Double-load back-pressure valve

7.82

85

Pilot control valve 2 x / support

7.48

260


7.78

86

Pilot control valve 2 x / adjustable boom

7.47

262


7.76

87

Positioning brake / slewing gear

9.25

300

Line leading to oscillating axles support

14.10

88

Manifold / collecting pipe

301

Line leading to gear shifting

11.08

100

Compact control valve block

7.50

302

Line leading to servostat / steering

13.10

101

Spool / slewing gear

7.50

303

Line leading to compact block Brake system

15.10

102

Spool / stick cylinder

7.50

S21

Switch / creeper gear

8.09/8.20

103


7.50

S35

Switch / pilot control

8.09/8.20

105


7.50

S63

Switch / changeover Bucket swivel bearing

8.09/8.20

106


7.50

S75

Switch / oscillating axle support

8.09/8.20

107


7.50

S263 Switch / travel direction

8.09/8.20

108

Spool / travel motor

7.50

U16

Excavator control BST

8.09/8.20

109

Spool, compound boom cylinder / stick cylinder

7.50

Y3

Solenoid valve / pilot control

8.09/8.20

110

to control valve block, low pressure

7.62

Y24

Solenoid valve / creeper gear

8.09/8.20

120

Primary pressure relief valve pump P1

7.50

Y50

Proportional solenoid valve Power control

8.09/8.20

6.40.2

copyright by

MJFCIFSS

A 309 LI 20221-23502 A 311 LI 20222-23506

Service Manual

Hydraulic system A 309 from 20221 / A 311 from 20222

Items

see group

Items

see group

121


7.50

Y51

Proportional solenoid valve / flow reduction P1

8.09/8.20

127

Secondary pressure relief valve, stick cylinder A2

7.50

Y62

Solenoid valve / travel direction

8.09/8.20

128

Secondary pressure relief valve, stick cylinder B2

7.50

Y63


8.09/8.20

129

Secondary pressure relief valve, control cylinder A5

7.50

Y262 Solenoid valve: bucket cylinder / swivel bearing

8.09/8.20

130

Secondary pressure relief valve, control cylinder B5

7.50

Y330 Solenoid valve / flow reduction P2

8.09/8.20

131

Secondary pressure relief valve / boom cylinder A6

7.50


8.09/8.20

132

Secondary pressure relief valve / boom cylinder B6

7.50

Y358 Proportional solenoid valve / speed adjustment

8.09/8.20

133

Secondary pressure relief valve / bucket cylinder A7

7.50


8.09/8.20

A 309 LI 20221-23502 A 311 LI 20222-23506

copyright by

MJFCIFSS

6.40.3

Hydraulic system

Service Manual

A 309 from 20221 / A 311 from 20222

6.40.4

copyright by

MJFCIFSS

A 309 LI 20221-23502 A 311 LI 20222-23506

Service Manual

Hydraulic system Hydraulic system 3 (low-pressure circuit)

21

Hydraulic system 3 (low-pressure circuit)

Fig. 1


Items

see group

Items

see group

1

to hydraulic tank

159

Restrictor

7.56

31

from gear pump / low-pressure circuit: brake

240

Swivel cylinder

7.30

45

Measuring point: low pressure

241

Double load-holding valve

7.82

50

from Control oil unit

260

Oil motor / grapple rotator

110

Compact control valve block, lowpressure circuit

7.56

261

Pressure relief valve

111

Input section

7.56

262


112

Spool / swivel bearing

7.56

S5L Push button: 'turn grapple left'

8.09/8.20

113


7.56

S5R Push button: 'turn grapple right'

8.09/8.20

123


7.56

S19

Button / grapple rotator

8.09/8.20

124

Pressure balance / LS - control

7.56

Y22

Solenoid valve / turn left

8.09/8.20

156

Check valve

7.56

Y23

Solenoid valve / turn right

8.09/8.20

A 309 LI 20221-23502 A 311 LI 20222-23506

copyright by

MJF C I F S S

6.40.9

Hydraulic system

Service Manual

Hydraulic system 3 (low-pressure circuit) Items 157

see group Adjustment restrictor / oil quantity, rotator

6.40.10

7.62

Items

see group

Y262 fromSolenoid valve bucket swivel bearing

copyright by

MJF C I F S S

8.09/8.20

A 309 LI 20221-23502 A 311 LI 20222-23506

Service Manual

Hydraulic system Key to diagrams I and II (high pressure circuit)

Hydraulic system 3 Key to diagrams I and II (high pressure circuit) Note! For a detailed description of the design and construction of the hydraulic system and the various main components see group 6.20.

Items

see group

Items

see group

1

Hydraulic tank

19.08

136


2

Breather filter

19.08

150

Check valve

7.50

3

Stop cock

151

Load-holing valve

7.50

4

Return filter

19.08

152

Check valve

7.50

5

Bypass valve/return filter (pressure)

19.08

153

Check valve 0.5 bar

7.50

6

Oil cooler

154


7.50

10


155

Restrictor valve

11


156

Shuttle valve Swing left (i)

12

Check valve 0.2 bar

157

Shuttle valve Swing right (i)

13


158

Shuttle valve compound stick cylinder (i)

14

Pressure relief l valve fan motor

160

Boom cylinder

7.30

15

Coarse filter

161

Pipe-fracture safety

16.04

20

Double variable-displacem. pump

7.02

162


21

Powertrain P1

7.02

170

Stick cylinder

7.30

22

Powertrain P2

7.02

180

Bucket cylinder

7.30

23


7.02

181


18.35

24

Adjustment

7.02

182

Lines leading to grapple cylinder

25

Spool

7.02

183


26

Nozzle

7.02

190


7.24

27

Differential piston

7.02

191

Pressure-relief l valve / turn right A

7.24

28

Opposed piston / flow reduction

7.02

192

Pressure-relief l valve / turn left B

7.24

29

Actuation device

7.02

193

Suction valve

7.24

30


195

Slewing gear brake

9.20

31

Pump/low-pressure circuit- brake

196


9.10

32

Gear pump / steering with Pressure-relief l valve

197


7.24

33


198


7.24

40


210


7.27

41


211

Powertrain

7.27

43


212

Control piston

7.27

A 309 LI 23503-27109 A 311 LI 23507-27111

copyright by

MJFCIFSS

7.90

6.40.11

Hydraulic system

Service Manual

Key to diagrams I and II (high pressure circuit) Items

see group

Items

see group

44


213

Spool

7.27

49


214

Secondary pressure-relief l valve / chassis forward A

7.27

50

Control oil unit

7.40

215

Secondary pressure-relief l valve / chassis reverse B

7.27

51


7.40

216

Shuttle valve

7.27

52

Pressure filter

7.40

217

Brake valve, two-end

7.27

53

Check valve

7.40

218

Brake piston

7.27

54

Accumulator

7.40

219

Check valve

7.27

57

Measuring point servo pressure (LS) Flow reduction P1

220


7.27

59

Measuring point servo pressure (LR) Power control

225

Transmission

11.08

75


230

Support cylinder

7.30

76

Shuttle valve / compound circuit

231


7.86

80

Pilot control valve left 4 x

7.45

241

to Double load-holding valve / swivel cylinder, see 6.40.9

7.82

81

Pilot control valve right 4 x

7.45

250

Regulating cylinder

7.30

84


7.49

251


7.82

85


7.48

260


7.78

86


7.47

262


7.76

87


9.25

300

Line leading to oscillating axles support

14.10

88


301

Line leading to gear shifting

11.08

100

Compact control valve block

7.50

302

Line leading to servostat / steering

13.10

101


7.50

303

Line leading to compact block Brake system

15.10

102


7.50

103


7.50

S21


8.09/8.20

105


7.50

S35


8.09/8.20

106


7.50

S63

Switch / changeover Bucket swivel bearing

8.09/8.20

107


7.50

S75


8.09/8.20

108


7.50


8.09/8.20

109

Spool, compound boom cylinder / stick cylinder

7.50

U16


8.09/8.20

110

to control valve block, low pressure

7.62

Y3


8.09/8.20

120


7.50

Y24


8.09/8.20

6.40.12

copyright by

MJFCIFSS

A 309 LI 23503-27109 A 311 LI 23507-27111

Service Manual


Items

see group

Items

see group

121


7.50

Y50


8.09/8.20

127

Secondary pressure relief valve, stick cylinder A2

7.50

Y51


8.09/8.20

128

Secondary pressure relief valve, stick cylinder B2

7.50

Y62


8.09/8.20

129

Secondary pressure relief valve, control cylinder A5

7.50

Y63


8.09/8.20

130

Secondary pressure relief valve, control cylinder B5

7.50


8.09/8.20

131

Secondary pressure relief valve / boom cylinder A6

7.50

Y330 Solenoid valve / flow reduction P2

8.09/8.20

132

Secondary pressure relief valve / boom cylinder B6

7.50


8.09/8.20

133

Secondary pressure relief valve / bucket cylinder A7

7.50


8.09/8.20

134

Secondary pressure relief valve / bucket cylinder B7

7.50


8.09/8.20

135

Suction valve travel motor A8 (i)

1.02

A 309 LI 23503-27109 A 311 LI 23507-27111

Brand, see group

copyright by

MJFCIFSS

6.40.13

Hydraulic system

Service Manual

Key to diagrams I and II (high pressure circuit)

6.40.14

copyright by

MJFCIFSS

A 309 LI 23503-27109 A 311 LI 23507-27111

Service Manual


4 Hydraulic system 3 (low-pressure circuit)

Fig. 2


Items

see group

Items

see group

1

to hydraulic tank

159

Restrictor

7.56

31

from gear pump / low-pressure circuit: brake

240

Swivel cylinder

7.30

45

Measuring point: low pressure

241


7.82

50

from Control oil unit

260


110

Compact control valve block, lowpressure circuit

7.56

261


111

Input section

7.56

262


112

Spool / swivel bearing

7.56

S5L

Push button: 'turn grapple left'

113


7.56


8.09/8.20

123


7.56

S19

8.09/8.20

124


7.56

Y22


8.09/8.20

156

Check valve

7.56

Y23


8.09/8.20

157

Adjustment restrictor / oil quantity, rotator

7.62

Y262 fromSolenoid valve bucket swivel bearing

A 309 LI 23503-27109 A 311 LI 23507-27111


copyright by

MJFCIFSS

8.09/8.20

8.09/8.20

6.40.19

Hydraulic system

Service Manual


6.40.20

copyright by

MJFCIFSS

A 309 LI 23503-27109 A 311 LI 23507-27111

Service Manual


Hydraulic system 5 Key to diagrams I and II (high pressure circuit) Note! For a description of the design of the hydraulic system with main components, see group 6.22

Items

A 309 LI 27110A 311 LI 27112-

see group

1

Hydraulic tank

2

Breather filter

19.08

3

Stop cock

19.08

4

Return filter

5

Bypass valve / return filter (pressure)

19.08

6

Oil cooler

19.08

10


11

from turbo charger / diesel engine

12

Check valve 0.2 bar

13


14


15

Coarse filter

20


21

Powertrain P1

7.02

22

Powertrain P2

7.02

23


7.02

24

Adjusting device

7.02

25

Spool

7.02

26

Nozzle

7.02

27

Differential piston

7.02

28

Opposed piston / flow limitation

7.02

29

Actuation device

7.02

30


7.02

31

Gear pump / low-pressure circuit - brake

32

Gear pump / steering with pressure-relief valve

33


40

Measuring point P1

41

Measuring point P2

43

Measuring point actuating pressure for regulation P1

44

Measuring point actuating pressure for regulation P2

46

Measuring point actuation valve 166 (k)

copyright by

MJFCIFSS

6.40.21

Hydraulic system

Service Manual


6.40.22

see group

47

Measuring point actuation valve 165 (k)

49

Measuring point for pilot pressure

50

Control oil unit

7.40

51


7.40

52

Pressure filter

7.40

53

Check valve

7.40

54

Accumulator

7.40

57

Measuring point servo pressure (LS) flow reduction P1

59

Measuring point servo pressure (LR) / power control

64

Hydraulic cylinder / uppercarriage locking mechanism (m)

75


76

Shuttle valve / combined shifting

80

Pilot control unit, left 4 x

7.45

81

Pilot control unit, right 4 x

7.45

84


7.49

85

Pilot control unit 2 x / support

7.48

86


7.47

87


9.20

88


100


7.50

101

Slewing gear spool

7.50

102

Stick cylinder spool

7.50

103

Support cylinder spool

7.50

105

Spool / regulating cylinder (k)

7.50

106

Spool / boom cylinder (k)

7.50

107


7.50

108


7.50

109

Spool / combined boom cylinder / stick cylinder (k)

7.50

110

to control valve block / low pressure

7.56

120

Prim. pressure relief valve pump P1

7.50

121

Prim. pressure relief valve pump P2

7.50

127

Secondary pressure-relief valve, stick cylinder A2

7.50

128

Secondary pressure-relief valve, stick cylinder B2

7.50

129

Secondary pressure-relief valve, regulating cylinder A5

7.50

130

Secondary pressure-relief valve, regulating cylinder B5

7.50

131

Secondary pressure-relief valve, boom cylinder A6

7.50

132

Secondary pressure-relief valve, boom cylinder B6

7.50

133

Secondary pressure-relief valve, bucket cylinder A7

134

Secondary pressure-relief valve, bucket cylinder B7

135

Suction valve travel motor A8

136


copyright by

MJFCIFSS

7.50

A 309 LI 27110A 311 LI 27112-

Service Manual


Items

A 309 LI 27110A 311 LI 27112-

see group

150

Check valve

151

Load holding valve

7.50

152

Check valve

7.50

153

Check valve 0.5 bar

7.50

154


7.50

155

Restrictor valve

156

Shuttle valve turning left Ø 0.8 mm

157

Shuttle valve turning right Ø 0.8 mm

158

Shuttle valve retracting stick cylinder Ø 0.8 mm (k)

160

Boom cylinder

7.30

161

Pipe fracture safety valve

16.04

162


165

3/2-way valve / priority switching (k)

166

Pressure reduction valve / decoupling (k)

167

Measuring point actuation valve 165 Ø 0.6 mm (k)

168

Shuttle valve extending boom cylinder Ø 0.8 mm (k)

169

Shuttle valve retracting boom cylinder Ø 0.8 mm (k)

170

Stick cylinder

7.30

171

Restrictor check valve (k)

7.90 7.30

180

Bucket cylinder

181


182

Lines to grapple cylinder

183


7.90

190


7.24

191

Pressure-relief valve / turn right A

7.24

192

Pressure-relief valve / turn left B

7.24

193

Suction valve

7.24

195

Slewing gear brake

9.20

196


9.10

197


7.24

198


7.24

210


7.27

211

Powertrain

7.27

212

Control piston

7.27

213

Spool

7.27

214

Secondary pressure-relief valve / chassis forward A

7.27

215

Secondary pressure-relief valve / chassis reverse B

7.27

216

Shuttle valve

7.27

217

Two-end brake valve

7.27

218

Brake piston

7.27

219

Check valve

7.27

copyright by

MJFCIFSS

6.40.23

Hydraulic system

Service Manual


6.40.24

see group

220


7.27

225

Transmission

11.08/11.20

230

Support cylinder

7.30

231


7.83

241

to double load-holding valve / swivel cylinder, see page 6.40.19

7.82

250

Regulating cylinder

7.30

251

Load holding valve

7.85

260


7.78

262


7.76

300

Line to oscillating axle support

14.10

301

Line to gear switching unit

11.08/11.20

302

Line to Servostat / steering

13.10

303

Line to compact block brake system

15.10

S21


8.09/8.20/8.22

S354 Switch / pilot control

8.09/8.20/8.22

S63

Solenoid valve / switchover bucket offset boom bearing

8.09/8.20/8.22

S75


8.09/8.20/8.22


8.09/8.20/8.22

U16


8.09/8.20/8.22

Y3


8.09/8.20/8.22

Y24


8.09/8.20/8.22

Y50


8.09/8.20/8.22

Y50


8.09/8.20/8.22

Y62


8.09/8.20/8.22

Y63


8.09/8.20/8.22


8.09/8.20/8.22


8.09/8.20/8.22


8.09/8.20/8.22


8.09/8.20/8.22

(k),(l)(m)change mark, see also

1.02

copyright by

MJFCIFSS

A 309 LI 27110A 311 LI 27112-

Service Manual


6 Hydraulic system 3 (low-pressure circuit)

Fig. 3


Item

see group

Item

see group

1

to hydraulic tank

159

Restrictor

7.56

31

from gear pump / low-pressure circuit - brake

240

Swivel cylinder

7.30

45

Low pressure measuring point

241


7.82

50

from control oil unit

260


110

Compact control block low pressure circuit

7.56

261


111

Input section

7.56

262


112


7.56

S5L

Push button: 'turn grapple left'

113


7.56


8.09/8.20

123

Prim. pressure relief valve

7.56

S19


8.09/8.20

124


7.56

Y22


8.09/8.20

156

Check valve

7.56

Y23


8.09/8.20

157

Adjustment restrictor / oil volume rotator

Y262 from solenoid valve changeover bucket cylinder - swivel bearing

8.09/8.20

A 309 LI 27110A 311 LI 27112-

copyright by

MJFCIFSS

8.09/8.20

6.40.29

Hydraulic system

Service Manual


6.40.30

copyright by

MJFCIFSS

A 309 LI 27110A 311 LI 27112-

Service Manual

Hydraulic system Main components and key to diagrams I and II

Hydraulic system 1 Main components and key to diagrams I and II

Fig. 1

Hydraulic tank and hydraulic pumps

1

Hydraulic tank

31

Steering pump

20 30

Hydraulic variable- displacement pump Cooling fan pump

32 50

Brake and control oil pump Control oil unit

Fig. 2

Pilot control units

80

Pilot control unit for stick and rotary movement

85

Pilot control unit for outrigger and blade support

81

Pilot control unit for boom and bucket movement

86

Pilot control unit for working movement of auxiliary attachments (hydraulic boom adjustment, hydraulic hammer, etc.)

84

Pilot control unit for travel movement

87

Pedal for positioning brake


MJFCIFSS

6.42.1

Hydraulic system

Service Manual

Main components and key to diagrams I and II

Fig. 3 130

Slewing gear motor

255

Stick cylinder

170

Travel motor

275

Bucket cylinder

235

Boom cylinder

275

Support cylinder

Fig. 4 320

6.42.2

Consumer

Rotary connections Rotary connection 7x for high-pressure oil 322

Rotary connection 6x for low-pressure oil


MJFCIFSS

Service Manual


Fig. 5


100

Control valve block

280

Spool for support cylinder

160 220

Spool for travel Spool for boom cylinder

120 540

Slewing gear control axle Control axle for grapple rotation

240

Spool for stick cylinder

41-284 Valves, etc. see next page

260

Spool for bucket cylinder


MJFCIFSS

6.42.3

Hydraulic system

Service Manual


6.42.4

Item

Designation

1

Group

Item

Designation

Group

Hydraulic tank

176

Secondary pressure-relief valve / forward travel

2

Breather filter

177

Secondary pressure-relief valve / reverse travel

3

Stop cock

185

Transmission

11.08

4

Return filter

190

Travel brake valve, complete

7.82

5

Bypass valve / return line

192

Brake piston

6

Oil cooler

193


7

Check valve 3.5 bar

7.59

194

Check valve

8


7.59

195

Changeover valve

9


196

Check valves

13

Pressure-relief valve / cooling

220


14


221

Secondary pressure-relief valve / extending

20


222

Secondary pressure-relief valve / retracting

21

Powertrain

224

Pressure balance

21.1

Adjusting unit, complete

227


23

Regulating valve

233

Distribution block

23.2

Performance regulator

235

Boom cylinder

23.5

LS regulator

237

Stop cock (in models without item 238)

23.6

Changeover valve

238

Pipe fracture safety valve (kit)

16.04

28

Check valve

240


7.59

29

Restrictor

241


30

Gear pump / cooling

242


31

Gear pump / steering

244

Pressure balance

32

Gear pump / brake, pilot control

247


41

Measuring point MP

255

Stick cylinder

7.30

44

Measuring point / actuating pressure P

260


7.59

45

Measuring point LS

261


49

Measuring point / pilot control

262


50

Control oil unit

264

Pressure balance

51


275

Bucket cylinder

52

Pressure filter

277

Shut-off device for grapple operation

53

Check valve

278


54

Accumulator

279

Restrictor check valve only with attachment/quickchange adapter

7.90

57

Measuring point Servo pressure p-lowering

280


7.59

59

Measuring point Servo pressure powercontrol

281

Plug / dummy cartridge

80

Pilot control unit, left 4x-

7.45

284

Pressure balance

81

Pilot control unit, right 4x-

7.45

295

Support cylinder

7.30

84

Pilot control unit 1x -/ travel

7.49

297

Double lowering brake valve, see page 6.42-09 and 6.42-10

7.86

7.14

7.42

7.59

7.30

7.30


MJFCIFSS

Service Manual


Item

Designation

Group

85

Pilot control unit 2x,- support

7.48

87

Valve / positioning brake

88

Collecting pipe P/T

100

Compact control block 5x-

102

Pressure balance minimum flow

402

to oscillating axle support

14.10

103

Pressure balance remaining flow

403

to gear switching device (HBGV)

11.08/ 11.30

104

Pressure cut-off valve

540


16.44

105

Primary pressure-relief valve

541

Secondary relief valve / turn right

107

Shuttle valve

542

Secondary relief valve / turn left

109

LS central nozzle

544

Pressure balance

111

Check valve

550


120


551


122

Input pressure balance

552


123

Check valve / load-holding valve

S5


8.10/8.30

125

TC valve with additional pressure level

S7

Switch / safety switch

8.10/8.30

126

Orifice 0.9 mm

S19

Switch / grapple rotator

8.10/8.30

127


S21


8.10/8.30

128

Changeover valve

S263

Switch / travelling direction

8.10/8.30

130

Slewing gear motor, complete

S35


8.10/8.30

132

Powertrain

S75

Switch / oscillating axle automatic

8.10/8.30

133

Suction valves

U16

BST excavator control system

8.10/8.30

134

pressure-relief valve with additional pressure stage

Y3

Solenoid valve / servo release

7.42

136

pressure-relief valve with additional pressure stage

Y22

Solenoid valve / turn grapple left

16.44

137


Y23

Solenoid valve / turn grapple right

16.44

138


Y24


7.42

155

Slewing gear brake

9.20

Y50

Proportional solenoid valve/LR

7.42

156


9.10

Y51

Solenoid valve/LS

7.42

160

Travel gear spool

7.59

Y62

Solenoid valve / forward travel

161

Suction valve

Y63

Solenoid valve / reverse travel

162

Suction valve

Y352

Proportional solenoid valve / oil cooling

164

Pressure balance

Y358

Proportional valve / engine speed

167


Y371

Solenoid valve / oscillating axle support

170

Travel motor, complete

172

Powertrain

173

Control cylinder / regulating unit

174

Spool / regulating unit

7.59

7.59

7.24

Item

Designation

Group

320


7.78

322


7.76

400

to brake system

15.10

401

to steering

13.10

16.44

7.42

7.27


MJFCIFSS

6.42.5

Hydraulic system

Service Manual


Fig. 6

6.42.6

Hydraulic system 1

copyright by

MJF C I F S S

Service Manual


Fig. 7

Hydraulic system 2

copyright by

MJF C I F S S

6.42.7

Hydraulic system

Service Manual


Fig. 8

100/A1 from control valve block connection A1 297

Double lowering brake valve, see also group valves 7.86

100/B1 from control valve block connection B1 320

Rotary connection

295

6.42.8

Support option 2-point outriggers

Support cylinder


MJFCIFSS

Service Manual


Fig. 9




100/B1 from control valve block connection B1 320 295 Support cylinder

Rotary connection

Fig. 10

Support option 2-point blade front or rear


MJFCIFSS

6.42.9

Hydraulic system

Service Manual

Main components and key to diagrams I and II 100/A1 from control valve block connection A1 S206

Push button / individual control of left outrigger

100/B1 from control valve block connection B1 S207

Push button / individual control of right outrigger

295

Support cylinder

S335

Push button / individual control of blade

297


Y56

Solenoid valve / individual control of blade

320

Rotary connection

Y217

Solenoid valve / individual control of left outrigger

325

Slip ring / rotary connection

Y218

Solenoid valve / individual control of right outrigger

Fig. 11

6.42.10

Support option 4-point front blade / rear outriggers with individual control

100/A1 from control valve block connection A1 S206



Push button / individual control of right outrigger Push button / individual control of blade

295

Support cylinder

S335

297


Y56



MJFCIFSS

Service Manual


320

Rotary connection

Y217

325


Y218


MJFCIFSS

Solenoid valve / individual control of left outrigger Solenoid valve / individual control of right outrigger

6.42.11

Hydraulic system

Service Manual


6.42.12


MJFCIFSS

Service Manual

Hydraulic system Key to diagrams I and II

Hydraulic system 2 Key to diagrams I and II Note! For a detailed description of the design and construction of the hydraulic system and the various main components, see group 6.24.

Key to diagram I Items

see group

1

Hydraulic tank

2 3

Items

see group

80

Pilot control unit, left 4x

7.45

Breather filter

81

Pilot control unit, right 4x

7.45

Stop cock

84

Pilot control unit 1x / travelling

7.49

4

Return filter

85

Pilot control unit 2x / support

7.48

5


87


6

Oil cooler

88P

Manifold pressure

13


88T

Collecting pipe return line

14


100

from / to control valve block

7.60

15

Coarse filter (d)

155

to slewing gear brake

9.20

20


21

Powertrain

19.10

170

Travel motor

322

to rotary connection 6x

7.76

21.1 Control cylinder

400

to brake system

15.10

23

Regulating valve

401

to steering system

13.10

23.2 Performance regulator

402


14.10

23.5 LS regulator

403

to gear shifting

11.08

23.6 Shuttle valve

S7

Safety switch

8.10/8.30

28

Check valve

S21


8.10/8.30

29

Restrictor

S35


8.10/8.30

30


S75


8.10/8.30

31



8.10/8.30

32


U16


8.10/8.30

44

Measuring point actuating pressure

Y3

Solenoid valve servo release

8.10/8.30

45

Measuring point / LS pressure

Y24


8.10/8.30

49

Measuring point / pilot pressure M1

Y50

Proportional solenoid valve LR

8.10/8.30

50

Control oil unit

Y51

Proportional solenoid valve LS control

8.10/8.30

51


Y62


8.10/8.30

52

Pressure filter

Y63


8.10/8.30

53

Check valve

Y352 Proportional solenoid valve / fan control

7.05

7.42


MJFCIFSS

8.10/8.30

6.42.13

Hydraulic system

Service Manual

Key to diagrams I and II Items

see group

Items

see group

54

Accumulator

Y358 Proportional solenoid valve / motor speed

8.10/8.30

57

Measuring point servo pressure -p reduction


8.10/8.30

59

Measuring point servo pressure LR

Index to wiring diagram II Items

6.42.14

see group

1

to hydraulic tank

6

to oil cooler

7

Check valve 3.5 bar

7.60

8


7.60

20

from the variable-displacement pump

7.05

23

to regulating valve

41

Measuring point MP

80

from pilot control unit, left 4x

7.45

81

from pilot control unit, right 4x

7.45

85

from pilot control valve / support

7.48

87

from valve / positioning brake

88P

from manifold P

88T

to collecting pipe T

100

Compact control block 5x

102


103

Pressure balance / remaining flow

104


105


107

Shuttle valve (e)

109

LS central nozzle

120


122


123

Check valve (e)

125

TC valve with additional pressure stage (e)

126

Restrictor Ø 1.5 mm

127


128

Shuttle valve

129

Restrictor (Ø 0.6 mm) (e)

130


132

Powertrain

133

Suction valve

134

Pressure-relief valve with additional pressure stage

135


7.60

7.80

7.24


MJFCIFSS

Service Manual


Items

see group

137


138


155

Slewing gear brake

9.20

156


9.10

160

Spool / chassis

7.60

161

Suction valve / reverse travel

162

Suction valve / forward travel

164

Pressure balance, directly controlled

167


170

Travel motor

172

Powertrain

173


174


176

Secondary relief valve / forward

177

Secondary relief valve / reverse

7.27

185

Transmission

11.08

190


7.27

192

Brake piston

193


194

Check valve

195

Shuttle valve

196

Check valves

220


221


222


224

Pressure balance, pilot-controlled (e)

227


233

Distribution block

7.60

235

Boom cylinder

237

Stop cock (devices without item 238)

238

Pipe-fracture safety system (kit)

240


241


242


244


247


7.30

7.60

255

Stick cylinder

7.30

260


7.60

261


262


264



MJFCIFSS

6.42.15

Hydraulic system

Service Manual


see group

275

Bucket cylinder

277


278

Lines leading to grapple

279

Restrictor check valve (QC only)

280


281


284


295

Support cylinder

297


320


7.78

322


7.76

540


16.44

541

Secondary relief valve / turning right

542

Secondary relief valve / turning left

544


550


551


552


7.30

7.60

7.30

S5L Push button / grapple rotator, left

8.10/8.30

S5R Push button / grapple rotator, right

8.10/8.30

S19


8.10/8.30

Y22

Solenoid valve / grapple rotation left

16.44

Y23

Solenoid valve / grapple rotation right

16.44

Y24

from solenoid valve / creeper gear

7.42

Y62

from solenoid valve / forward travel

8.10/8.30

Y63

from solenoid valve / reverse travel

8.10/8.30

(d)/(e), see changes in group 1.02

6.42.16


MJFCIFSS

Service Manual



Index to wiring diagram I Item

see group

1

Hydraulic tank

2

Item

see group

64

Cylinder / uppercarriage locking mechanism (m)

Breather filter

80

Pilot control unit, left 4 way

7.45

3

Stop cock

81

Pilot control unit, right 4 way

7.45

4

Return filter

84

Pilot control unit, travel 1 way

7.49

5


85

Pilot control unit 2 x, support

7.48

6

Oil cooler

87


13


88P

Manifold pressure

14


88T


15

Coarse filter

100


7.60

20


155


9.20

21

Powertrain

170

from travel engine


322

to rotary connection 6 way

7.76

23

19.10

7.05

400

to brake system

15.10

23.2 Power regulator

401

to steering

13.10

23.5 LS regulator

402


14.10

23.6 Shuttle valve

403

to gear switching unit

11.10

28

Check valve

S7

Safety switch

8.10/8.32

29

Restrictor

S21


8.10/8.32

30


S35


8.10/8.32

31


S75


8.10/8.32

32



8.10/8.32

44

Measuring point / actuating pressure

U16


8.10/8.32

45


Y3


8.10/8.32

49


Y24


8.10/8.32

50

Control oil unit

Y50


8.10/8.32

51


Y51


8.10/8.32

52

Pressure filter

Y62


8.10/8.32

Regulating valve

7.42


MJFCIFSS

6.42.21

Hydraulic system

Service Manual

Key to diagrams I and II Item

see group

Item

see group

53

Check valve

Y63


54

Accumulator


8.10/8.32

57

Measuring point / servo pressure -p reduction


8.10/8.32

59

Measuring point / servo pressure Power control


8.10/8.32

8.10/8.32

Index to wiring diagram II Item

see group

Item

see group

1

to hydraulic tank

192

Brake piston

6

to hydraulic tank

193


7

Check valve 3.5 bar

7.60

194

Check valve

8


7.60

195

Shuttle valve

20

from variable-displacement pump

7.05

196

Check valves

23

to regulating valve

220


41

Measuring point MP

221

Secondary pressure relief valve / extending

80


7.45

222

Secondary pressure relief valve / retracting

81

from pilot control unit, right 4 way

7.45

224

Pressure balance, pilot-controlled

85


7.48

227


87


233

Distribution block

88P

from manifold P

235

Boom cylinder

88T


237


100

Compact control block 5 x

238


102


240


103


241


104


242


105


244


107

Shuttle valve

247


109

LS central nozzle

255

Stick cylinder

7.30

120


260


7.60

122


261


123

Check valve

262


125

TC valve with additional pressure stage

264


6.42.22

7.60

7.80

7.60

7.30

7.60


MJFCIFSS

Service Manual


Item

see group

Item

see group

126

Restrictor (Ø 1.5 mm)

275

Bucket cylinder

127


277


128

Shuttle valve

278


129


279


130


280


132

Powertrain

281


133

Suction valve

284


134

Pressure relief valve with additional pressure stage

295

Support cylinder

135


297


137


320

Rotary connection 7 way

7.78

138


322


7.76

155

Slewing gear brake

9.20

540


16.44

156


9.10

541


160

Travel gear spool

7.60

542


161


544


162


550


164


551


167


552


170

Travel motor

S5L

Push button / grapple rotator, left

172

Powertrain


8.10/8.32

173


S19


8.10/8.32

174


Y22


16.44

176

Secondary pressure relief valve / forward travel

Y23


16.44

177

Secondary pressure relief valve / reverse travel

Y24


7.42

185

Transmission

11.20

Y62


8.10/8.32

190


7.27

Y63


8.10/8.32

7.24

7.27

7.30

7.60

7.30

8.10/8.32

(m), see changes in group 1.02


MJFCIFSS

6.42.23

Hydraulic system

Service Manual

Key to diagrams I and II

6.42.24


MJFCIFSS

Service Manual

Hydraulic system

Hydraulic system Note! For a detailed description of the design and construction of the hydraulic system and the various main components, see group 6.27.

Items

see group

Items

see group

1

Hydraulic tank

19.10

155

Slewing gear brake

9.20

2

Breather filter

19.10

156


9.10

3

Stop cock

160


7.60

4

Return filter

19.10

161

Suction valve A1, forward

7.60

5


19.10

162

Suction valve B1, reverse

7.60

6

Oil cooler

164


7.60

7

Check valve 3.5 bar

7.60

167


7.60

8


7.60

180


7.60

10


181

Suction valve A2, forward

7.60

13


182

Suction valve B2, reverse

7.60

14


184


7.60

15

Coarse filter / fan motor

195


7.77

20


7.15

196


7.75

21

Powertrain

7.15

200

Travel motor, left

7.28

22

Control cylinder

7.15

201

Travel motor, right

7.28

23

Measuring cylinder

7.15

202

Adjusting device

7.28

24

Angular lever

7.15

203

Shifting piston, oil motor adjustment

7.28

25


7.15

205

Brake valve

7.28

26

Flow regulator

7.15

206

Shuttle valve

7.28

27

Shuttle valve

7.15

207

2-way valve / brake control pressure

7.28

28

Check valve

7.15

208

Pressure reduction valve / brake pressure

7.28

29

Restrictor

7.15

211

Secondary pressure-relief valve chassis, forward left

7.28

30


212

Secondary pressure-relief valve chassis, reverse left

7.28

31


213

Secondary pressure-relief valve chassis, forward right

7.28

41

Measuring point MP (control valve block)

214

Secondary pressure-relief valve chassis, reverse right

7.28

44

Measuring point actuating pressure (variable-displacement pump)

215

Travel brake

11.67

45

Measuring point LS (variable-displacement pump)

216

Travel gear

11.62


MJFCIFSS

6.43.1

Hydraulic system

Service Manual

see group

Items 49

Measuring point control pressure M1

50

Control oil unit

51

see group

Items 220


7.60

7.42

221

Secondary pressure-relief valve A3 / extend

7.60


7.42

222

Secondary pressure-relief valve B3 / retract

7.60

52

Pressure filter

7.42

224


7.60

53

Check valve

7.42

227


7.60

54

Accumulator

7.42

233

Distribution block

57

Measuring point servo pressure (MLS) -p reduction

235

Boom cylinder

59

Measuring point servo pressure (MLR) Power control

237

Stop cock (machines without item 238)

80

Pilot control unit, left 4x

7.45

238


81

Pilot control unit, right 4x

7.45

240


7.60

82

Pilot control valve 4x / travel

7.46

241

Secondary pressure-relief valve A5 / retract

7.60

88P

Manifold pressure

242

Secondary pressure-relief valve / extend

7.60

88T


244


7.60

100


7.60

247


7.60

102


7.60

255

Stick cylinder

7.30

103


7.60

257


104


7.60

260


7.60

105


7.60

261

Secondary pressure-relief valve A4 / retract

7.60

106

Shift valve regulating motor Qmin

7.60

262

Secondary pressure-relief valve B4 / extend

7.60

107

Shuttle valve

7.60

264


7.60

108

LS main orifice

7.60

275

Bucket cylinder

7.30

109

Shuttle valve

7.60

277


120


7.60

278


122


7.60

278

Grapple cylinder

123

Check valve

7.60

279

Restrictor check valve (with QC only)

125


7.80

B335 Pressure switch / slewing gear

8.17/8.38

126

Shuttle valve Ø 0.8 mm / 0.8 mm

7.80

S17

Switch / slewing gear brake

8.17/8.38

127


7.60

S21


8.17/8.38

128


7.60

U16


8.17/8.38

130

Slewing gear motor

7.24

Y3


8.17/8.38

6.43.2

7.30

7.90


MJFCIFSS

Service Manual

Items

Hydraulic system

see group

Items

see group

132

Powertrain

7.24

Y7


8.17/8.38

133

Suction valve

7.24

Y24

Solenoid valve / fast travel

8.17/8.38

134

Pressure-relief valve with additional pressure level, right B

7.24

Y50


8.17/8.38

135

Pressure-relief valve with additional pressure level, left A

7.24

Y51


8.17/8.38

137

Measuring point / turn right


8.17/8.38

138

Measuring point / turn left


8.17/8.38

Y451 Proportional solenoid valve / slewing gear

8.17/8.38


MJFCIFSS

6.43.3

Hydraulic system

6.43.4

Service Manual


MJFCIFSS

Service Manual


Hydraulic system 1 Main components and key to diagrams I and II

Fig. 1

Hydraulic tank and hydraulic pumps

1

Hydraulic tank

31

Steering pump

20 30

Hydraulic variable displacement pump Cooling fan pump

32 50

Brake and control oil pump Control oil unit

Fig. 2

Pilot control units

80

Pilot control unit for stick and rotary movement

85

Pilot control unit for outrigger and blade support

81

Pilot control unit for boom and bucket movement

86

84

Pilot control unit for travel movement

87

Pilot control unit for working movement of auxiliary attachments (hydraulic boom adjustment, hydraulic hammer, etc.) Pedal for positioning brake

copyright by

MJFCIFSS

6.44.1

Hydraulic system

Service Manual


Fig. 3 130 170

Slewing gear motor Travel motor

255 275

Stick cylinder Bucket cylinder

235

Boom cylinder

275

Support cylinder

Fig. 4 320

6.44.2

Consumer

Rotary connections Rotary connection 7x for high-pressure oil 322

copyright by

MJFCIFSS

Rotary connection 6x for low-pressure oil

Service Manual


Fig. 5


100

Control valve block with

280

Spool for support cylinder

160 220

Spool for travel Spool for boom cylinder

120 540

Slewing gear control axle Control axle for grapple rotation

240

Spool for stick cylinder

41-284 Valves, etc. see next page

260

Spool for bucket cylinder

copyright by

MJFCIFSS

6.44.3

Hydraulic system

Service Manual


6.44.4

Item

Designation

1

group

Item

Designation

Hydraulic tank

176


2

Breather filter

177


3

Stop cock

185

Transmission

11.08

4

Return filter

190


7.82

5

Bypass valve / return line

192

Brake piston

6

Oil cooler

193


7

Check valve 3.5 bar

7.59

194

check valve

8


7.59

195

Changeover valve

9


196

Check valves

13

Pressure-relief valve / cooling

220


14


221


20


222


21

Powertrain

224

Pressure balance

21.1

Adjusting unit, complete

227


23

Regulating valve

233

Distribution block

23.2


235

Boom cylinder

23.5

LS regulator

237


7.14

group

7.59

7.30

23.6

Changeover valve

238


16.04

28

check valve

240


7.59

29

Restrictor

241


30

Gear pump / cooling

242


31


244

Pressure balance

32


247


41

Measuring point MP

255

Stick cylinder

7.30

44

Measuring point / actuating pressure P

260


7.59

45

Measuring point LS

261


49

Measuring point / pilot control

262


50

Control oil unit

264

Pressure balance

51


275

Bucket cylinder

52

Pressure filter

277


53

check valve

278


54

Accumulator

279

Restrictor check valve only with attachment/quickchange adapter

7.90

57

Measuring point Servo pressure p-lowering

280


7.59

59

Measuring point Servo pressure powercontrol

281


80

Pilot control unit, left 4x-

7.45

284

Pressure balance

81

Pilot control unit, right 4x-

7.45

295

Support cylinders

7.30

84

Pilot control unit 1x -/ travel

7.49

297

Double lowering brake valve, see page 6.42-09 and 6.42-10

7.86

7.42

copyright by

MJFCIFSS

7.30

Service Manual


Item

Designation

group

85

Pilot control unit 2x,- support

7.48

87


88

Collecting pipe P/T

100

Compact control block 5x-

102

Pressure balance minimum flow

402


14.10

103

Pressure balance remaining flow

403

to gear switching device (HBGV)

11.08/ 11.30

104


540


16.44

105


541


107

Shuttle valve

542


109

LS central nozzle

544

Pressure balance

111

check valve

550


120


551


122


552


123

Check valve / load-holding valve

S5


8.10/8.30

125


S7

Switch / safety switch

8.10/8.30

126

Orifice 0.9 mm

S19


8.10/8.30

127


S21


8.10/8.30

128

Changeover valve

S263

Switch / travelling direction

8.10/8.30

130


S35


8.10/8.30

132

Powertrain

S75


8.10/8.30

133

Suction valves

U16


8.10/8.30

134


Y3

Solenoid valve / servo release

7.42

136


Y22

Solenoid valve / turn grapple left

16.44

137


Y23

Solenoid valve / turn grapple right

16.44

138


Y24


7.42

155

Slewing gear brake

9.20

Y50

Proportional solenoid valve/LR

7.42

156


9.10

Y51

Solenoid valve/LS

7.42

160

Travel gear spool

7.59

Y62


161

Suction valve

Y63


162

Suction valve

Y352

Proportional solenoid valve / oil cooling

164

Pressure balance

Y358

Proportional valve / engine speed

167


Y371


170

Travel motor, complete

172

Powertrain

173


174


7.59

7.59

7.24

Item

Designation

group

320


7.78

322


7.76

400

to brake system

15.10

401

to steering

13.10

16.44

7.42

7.27

copyright by

MJFCIFSS

6.44.5

Hydraulic system

Service Manual


Fig. 6

6.44.6

Hydraulic system 1

copyright by

MJF C I F S S

Service Manual


Fig. 7

Hydraulic system 2

copyright by

MJF C I F S S

6.44.7

Hydraulic system

Service Manual


Fig. 8



100/B1 from control valve block connection B1 320

Rotary connection

295

6.44.8


Support cylinder

copyright by

MJFCIFSS

Service Manual


Fig. 9




100/B1 from control valve block connection B1 320 295 Support cylinder

Rotary connection

Fig. 10

Support option 2-point blade front or rear

copyright by

MJFCIFSS

6.44.9

Hydraulic system

Service Manual

Main components and key to diagrams I and II 100/A1 from control valve block connection A1 S206



Push button / individual control of right outrigger

295

Support cylinder

S335

Push button / individual control of blade

297


Y56


320

Rotary connection

Y217

Solenoid valve / individual control of left outrigger

325


Y218

Solenoid valve / individual control of right outrigger

Fig. 11

6.44.10

Support option 4-point front blade / rear outriggers with individual control

100/A1 from control valve block connection A1 S206



Push button / individual control of right outrigger Push button / individual control of blade

295

Support cylinder

S335

297


Y56

copyright by

MJFCIFSS


Service Manual


320

Rotary connection

Y217

325


Y218

copyright by

MJFCIFSS

Solenoid valve / individual control of left outrigger Solenoid valve / individual control of right outrigger

6.44.11

Hydraulic system

Service Manual


6.44.12

copyright by

MJFCIFSS

Service Manual



Key to diagram I Items

see group

1

Hydraulic tank

2

Items

see group

59

Measuring point servo pressure LR

Breather filter

80

Pilot control valve, left 4x

7.45

3

Stop cock

81

Pilot control valve, right 4x

7.45

4

Return filter

84

Pilot control valve 1 x / travelling

7.49

5


85


7.48

6

Oil cooler

87


11

from turbo charger / diesel engine

88P

Manifold pressure

12

Check valve 0.2 bar

88T


13


100


7.60

14


155


9.25

15

Coarse filter (d)

170

from travel motor

20


322

to rotary connection 6x

7.76

21

Powertrain

400

to brake system

15.10


401

to steering system

13.10

23

19.10

7.14

Regulating valve

402


14.10


403

to gear shifting

11.10

23.5 LS regulator

S7

Safety switch

8.10/8.30

23.6 Shuttle valve

S21


8.10/8.30

28

Check valve

S354 Switch / pilot control

8.10/8.30

29

Restrictor

S75

8.10/8.30

30



8.10/8.30

31

Gear pump / steering (f)

U16


8.10/8.30

32


Y3


8.10/8.30

44

Measuring point actuating pressure

Y24


8.10/8.30

45


Y50

Proportional solenoid valve / LS control

8.10/8.30

49


Y51


8.10/8.30

50

Control oil unit

Y62


8.10/8.30

51


Y63


8.10/8.30

A 314 LI 11147-13103 A 316 LI 11152-13104 A 316 LI-IND 11152-13104

7.42


copyright by

MJFCIFSS

6.44.13

Hydraulic system

Service Manual


see group

Items

see group

52

Pressure filter


8.10/8.30

53

Check valve


8.10/8.30

54

Accumulator


8.10/8.30

57

Measuring point servo pressure -p reduction

Key to diagram II Items 1

6.44.14

see group to hydraulic tank

6

to oil cooler

7

Check valve 3.5 bar

7.60

8


7.60

20

from the variable-displacement pump

7.05

23

to regulating valve

41

Measuring point MP

80

from pilot control unit, left 4x

7.45

81

from pilot control unit, right 4x

7.45

85


7.48

87


88P

from manifold P

88T


100


102


103


104


105


107

Shuttle valve (e)

109

LS central nozzle

120


122


123

Check valve (e)

125


126


127


128

Shuttle valve

129


130


132

Powertrain

7.60

copyright by

MJFCIFSS

7.80

7.24

A 314 LI 11147-13103 A 316 LI 11152-13104 A 316 LI-IND 11152-13104

Service Manual


Items

see group

133

Suction valve

134


135


137


138


155

Slewing gear brake

9.20

156


9.10 7.60

160

Spool / chassis

161


162


164


167


170

Travel motor

172

Powertrain

173


174


176

Secondary relief valve / forward travel

177

Secondary relief valve/ reverse travel

185

Transmission

11.08

190


7.27

192

Brake piston

193


194

Check valve

195

Shuttle valve

196

Check valves

220


221


222


7.27

7.60

224

Pressure balance, pilot-controlled (e)

227


233

Distribution block

235

Boom cylinder

237

Stop cock (devices without item 238)

238


240


241


242


244


247


255

Stick cylinder

7.30

260


7.60

A 314 LI 11147-13103 A 316 LI 11152-13104 A 316 LI-IND 11152-13104

7.30

7.60

copyright by

MJFCIFSS

6.44.15

Hydraulic system

Service Manual


see group

261


262


264


275

Bucket cylinder

277


278


279

Restrictor check valve (only SW)

280


281


284


295

Support cylinder

297


320


7.78

322


7.76

540


16.44

541


542


544


550


551


552


7.30

7.60

7.30


8.10/8.30


8.10/8.30

S19


8.10/8.30

Y22


16.44

Y23


16.44

Y24


7.42

Y62


8.10/8.30

Y63


8.10/8.30

(d)/(e), see changes in group 1.02

6.44.16

copyright by

MJFCIFSS

A 314 LI 11147-13103 A 316 LI 11152-13104 A 316 LI-IND 11152-13104

Service Manual

Hydraulic unit

Hydraulic unit Note! For a detailed description of the design and construction of the hydraulic system and the various main components, see group 6.24.


see group

1

Hydraulic tank

2 3

Item

see group

59


Breather filter

80


7.45

Stop cock

81


7.45

4

Return filter

84


7.49

5


85


7.48

6

Oil cooler

87


11


88P

Manifold pressure

12

Check valve 0.2 bar

88T


13


100


7.60

14


155


9.20

15

Coarse filter (d)

170

from travel engine

20


322


7.76

21

Powertrain

19.10

7.14

400

to brake system

15.10


401

to steering

13.10

23

402


14.10


403


11.10

23.5 LS regulator

S7

Safety switch

8.10/8.30

23.6 Shuttle valve

S21


8.10/8.30

28

Check valve

S35


8.10/8.30

29

Restrictor

S75


8.10/8.30

30



31

Gear pump / steering (f)

U16


8.10/8.30

32


Y3


8.10/8.30

44


Y24


8.10/8.30

45


Y50


8.10/8.30

49


Y51


8.10/8.30

50

Control oil unit

Y62


8.10/8.30

51


Y63


8.10/8.30

52

Pressure filter


Regulating valve

A 314 LI 13104A 316 LI 13105-28060 A 316 LI-IND 13105-28060

7.42

copyright by

MJFCIFSS

8.10/8.30

8.10/8.30

6.44.21

Hydraulic unit

Item

Service Manual

see group

Item

see group

53

Check valve


8.10/8.30

54

Accumulator


8.10/8.30

57



see group

1

to hydraulic tank

6

to hydraulic tank

7

Check valve 3.5 bar

7.60

8


20


23 41 80


81

Item

see group

192

Brake piston

193


194

Check valve

7.60

195

Shuttle valve

7.14

196

Check valves

to regulating valve

220


Measuring point MP

221


7.45

222



7.45

224

Pressure balance, pilot-controlled(e)

85


7.48

227


87


233

Distribution block

88P

from manifold P

235

Boom cylinder

88T


237


100


238


102


240


103


241


104


242


105


244


107

Shuttle valve (e)

247


109

LS central nozzle

255

Stick cylinder

7.30

120


260


7.60

122


261


123

Check valve (e)

262


125


264


126


275

Bucket cylinder

6.44.22

7.60

7.80

copyright by

MJFCIFSS

7.59

7.30

7.60

7.30 A 314 LI 13104A 316 LI 13105-28060 A 316 LI-IND 13105-28060

Service Manual

Item

Hydraulic unit

see group

Item

see group

127


277


128

Shuttle valve

278


129


279


130


280


132

Powertrain

281


133

Suction valve

284


134


295

Support cylinder

135


297


137


320


7.78

138


322


7.76

155

Slewing gear brake

9.20

540


16.44

156


9.10

541


160

Travel gear spool

7.60

542


161


544


162


550


164


551


167


552


170

Travel motor

172 173

7.24

7.60

7.30


8.10/8.30

Powertrain


8.10/8.30


S19


8.10/8.30

174


Y22


16.44

176


Y23


16.44

177


Y24


7.42

185

Transmission

11.10

Y62


8.10/8.30

190


7.26

Y63


8.10/8.30

7.26

(d)/(e)/(f), see changes in group 1.02

A 314 LI 13104A 316 LI 13105-28060 A 316 LI-IND 13105-28060

copyright by

MJFCIFSS

6.44.23

Hydraulic unit

6.44.24

Service Manual

copyright by

MJFCIFSS

A 314 LI 13104A 316 LI 13105-28060 A 316 LI-IND 13105-28060

Service Manual

Hydraulic unit



see group

1

Hydraulic tank

2

Item

see group

59


Breather filter

64

Cylinder / uppercarriage locking mechanism (m)

3

Stop cock

80


7.45

4

Return filter

81


7.45

5


84


7.49

6

Oil cooler

85


7.48

11


87


19.10

12

Check valve 0.2 bar

88P

Manifold pressure

13


88T


14


100


7.60

15

Coarse filter

155


9.20

20


170

from travel engine

21

Powertrain

7.05

322


7.76


400

to brake system

15.10

23

401

to steering

13.10


402


14.10

23.5 LS regulator

403


11.10

23.6 Shuttle valve

S7

Safety switch

8.10/8.32

28

Check valve

S21


8.10/8.32

29

Restrictor

S35


8.10/8.32


Regulating valve

30


S75

31



8.10/8.32

32


U16


8.10/8.32

44


Y3


8.10/8.32

45


Y24


8.10/8.32

49


Y50


8.10/8.32

50

Control oil unit

Y51


8.10/8.32

51


Y62


8.10/8.32

52

Pressure filter

Y63


8.10/8.32

A 316 LI 28061A 316 LI-IND 28061-

7.42

copyright by

MJFCIFSS

8.10/8.32

6.44.31

Hydraulic unit

Item

Service Manual

see group

Item

see group

53

Check valve


54

Accumulator


57


Y371 Solenoid valve / osc. axle support

8.10/8.32

8.10/8.32


see group

1

to hydraulic tank

6

to hydraulic tank

7

Check valve 3.5 bar

7.60

8


20


23 41 80


Item

see group

192

Brake piston

193


194

Check valve

7.60

195

Shuttle valve

7.14

196

Check valves

to regulating valve

220


Measuring point MP

221


7.45

222


7.59

81


7.45

224


85


7.48

227


87


233

Distribution block

88P

from manifold P

235

Boom cylinder

88T


237


100


238


102


240


103


241


104


242


105


244


107

Shuttle valve

247


109

LS central nozzle

255

Stick cylinder

7.30

120


260


7.60

122


261


123

Check valve

262


125

TC valve with additional pressure stage

264


126


275

Bucket cylinder

6.44.32

7.60

7.80

copyright by

MJFCIFSS

7.30

7.60

7.30

A 316 LI 28061A 316 LI-IND 28061-

Service Manual

Item

Hydraulic unit

see group

Item

see group

127


277


128

Shuttle valve

278


129


279


130


280


132

Powertrain

281


133

Suction valve

284


134


295

Support cylinder

135


297


137


320


7.78

138


322


7.76

155

Slewing gear brake

9.20

540


16.44

156


9.10

541


160

Travel gear spool

7.60

542


161


544


162


550


164


551


167


552


170

Travel motor

S5L

Push button / grapple rotator, left

172

Powertrain


8.10/8.32

173


S19


8.10/8.32

174


Y22


16.44

176


Y23


16.44

177


Y24


7.42

185

Transmission

11.20(n)

Y62


8.10/8.32

190


7.27(n)

Y63


8.10/8.32

7.24

7.27(n)

7.60

7.30

8.10/8.32

(m)/(n), see changes in group 1.02

A 316 LI 28061A 316 LI-IND 28061-

copyright by

MJFCIFSS

6.44.33

Hydraulic unit

6.44.34

Service Manual

copyright by

MJFCIFSS

A 316 LI 28061A 316 LI-IND 28061-

Service Manual

Hydraulic unit


Item

see group

Item

see group

1

Hydraulic tank

19.10

137


2

Breather filter

19.10

138


3

Stop cock

155

Slewing gear brake

9.20

4

Return filter

19.10

156


9.10

5


19.10

160


7.60

6

Oil cooler

161

Suction valve A1 / forward

7.60

7

Check valve 3.5 bar

7.60

162

Suction valve B1 / reverse

7.60

8


7.60

164


7.60

10


167


7.60

11


180


7.60

12

Check valve 0.2 bar

181


7.60

13


182


7.60

14


184


7.60

15


195


7.77

20


7.16

196


7.75

21

Powertrain

7.16

200

Travel motor, left

7.28

22

Control cylinder

7.16

201

Travel motor, right

7.28

23

Measuring cylinder

7.16

202

Adjustment

7.28

24

Elbow lever

7.16

203


7.28

25


7.16

205

Brake valve

7.28

26

Flow regulator

7.16

206

Shuttle valve

7.28

27

Shuttle valve

7.16

207


7.28

28

Check valve

7.16

208


7.28

29

Restrictor

7.16

211

Secondary pressure relief valve chassis, forward left

7.28

30


212

Secondary pressure relief valve chassis, reverse left

7.28

31


213

Secondary pressure relief valve chassis, forward right

7.28

41


214

Secondary pressure relief valve chassis, reverse right

7.28

R 317 LI 18161-21204 copyright by

MJFCIFSS

6.47.1

Hydraulic unit

Service Manual

see group

Item

see group

Item

44

Measuring point / actuating pressure (variable-displacement pump)

215

Travel brake

11.65

45


216

Travel gear

11.60

49

Measuring point / control pressure M1

220


7.60

50

Control oil unit

7.43

221

Secondary relief valve A3 / extending

7.60

51


7.43

222

Secondary relief valve / retracting

7.60

52

Pressure filter

7.43

224


7.60

53

Check valve

7.43

227


7.60

7.43

54

Accumulator

233

Distribution block

57


235

Boom cylinder

59


237


80


7.45

238


81


7.45

240


7.60

82

Pilot control unit, travel, left 2 x

7.46

241

Secondary relief valve A5 / retracting

7.60

83

Pilot control unit, travel, right 2 x

7.46

242

Secondary relief valve B5 / extending

7.60

84

Pilot control unit, travel 1 x

244


7.60

85


247


7.60

88P

Manifold pressure

255

Stick cylinder

7.30

88T


257


100

Compact control valve block 5 x

7.60

260


7.60

102


7.60

261


7.60

103


7.60

262


7.60

104


7.60

264


7.60

105


7.60

275

Bucket cylinder

7.30

106

Shift valve Qmax. variable displacement motor

7.60

277


107

Shuttle valve

7.60

278


108

LS mainmain orifice

7.60

278

Grapple cylinder

109

Shuttle valve

7.60

279


120


7.60

122


7.60

6.47.2

7.30

7.90


MJFCIFSS

Service Manual

Item

Hydraulic unit

see group

Item

see group

123

Check valve

7.60

S17

Switch slewing gear brake

8.17/8.40

125


7.80

S21


8.17/8.40

126


7.80

U16


8.17/8.40

127


7.60

Y3


8.17/8.40

128

Shuttle valve

7.60

Y7


8.17/8.40

129


7.80

Y24


8.17/8.40

130

Slewing gear motor

7.24

Y50


8.17/8.40

132

Powertrain

7.24

Y51


8.17/8.40

133

Suction valve

7.24


8.17/8.40

134

Pressure relief valve with additional pressure level, r B

7.24


8.17/8.40

135

Pressure relief valve with additional pressure level, l A

7.24


MJFCIFSS

6.47.3

Hydraulic unit

6.47.4

Service Manual


MJFCIFSS

Service Manual

Hydraulic unit


Item

see group

Item

see group

1

Hydraulic tank

19.10

137


2

Breather filter

19.10

138


3

Stop cock

155

Slewing gear brake

9.20

4

Return filter

19.10

156


9.10

5


19.10

160


7.60

6

Oil cooler

161


7.60

7

Check valve 3.5 bar

7.60

162


7.60

8


7.60

164


7.60

10


167


7.60

11


180


7.60

12

Check valve 0.2 bar

181


7.60

13


182


7.60

14


184


7.60

15


195


7.77

20


7.16

196


7.75

21

Powertrain

7.16

200

Travel motor, left

7.28

22

Control cylinder

7.16

201

Travel motor, right

7.28

23

Measuring cylinder

7.16

202

Adjustment

7.28

24

Elbow lever

7.16

203


7.28

25


7.16

205

Brake valve

7.28

26

Flow regulator

7.16

206

Shuttle valve

7.28

27

Shuttle valve

7.16

207


7.28

28

Check valve

7.16

208


7.28

29

Restrictor

7.16

211

Secondary pressure relief valve chassis, forward left

7.28

30


212

Secondary pressure relief valve chassis, reverse left

7.28

31


213

Secondary pressure relief valve chassis, forward right

7.28

41


214

Secondary pressure relief valve chassis, reverse right

7.28


MJFCIFSS

6.47.11

Hydraulic unit

Service Manual

see group

Item

see group

Item

44

Measuring point / actuating pressure (variable-displacement pump)

215

Travel brake

11.65

45


216

Travel gear

11.60

49

Measuring point / control pressure M1

220


7.60

50

Control oil unit

7.43

221

Secondary relief valve A3 / extending

7.60

51


7.43

222

Secondary relief valve / retracting

7.60

52

Pressure filter

7.43

224


7.60

53

Check valve

7.43

227


7.60

7.43

54

Accumulator

233

Distribution block

57


235

Boom cylinder

59


237


80


7.45

238


81


7.45

240


7.60

82

Pilot control unit, travel, left 4 x

7.46:11

241


7.60

84

Pilot control unit, travel 1 x

242


7.60

85


244


7.60

88P

Manifold pressure

247


7.60

88T


255

Stick cylinder

7.30

100


7.60

257


102


7.60

260


7.60

103


7.60

261


7.60

104


7.60

262


7.60

105


7.60

264


7.60

106

Shift valve Qmax. variable displacement motor

7.60

275

Bucket cylinder

7.30

107

Shuttle valve

7.60

277


108

LS mainmain orifice

7.60

278


109

Shuttle valve

7.60

278

Grapple cylinder

120


7.60

279


122


7.60

6.47.12

7.30

7.90


MJFCIFSS

Service Manual

Hydraulic unit

see group

Item

see group

Item

123

Check valve

7.60

125


7.80

S17

Switch slewing gear brake

8.17/8.40

126


7.80

S21


8.17/8.40

127


7.60

U16


8.17/8.40

128

Shuttle valve

7.60

Y3


8.17/8.40

129


7.80

Y7


8.17/8.40

130

Slewing gear motor

7.24

Y24


8.17/8.40

132

Powertrain

7.24

Y50


8.17/8.40

133

Suction valve

7.24

Y51


8.17/8.40

134

Pressure relief valve with additional pressure level, r B

7.24


8.17/8.40

135

Pressure relief valve with additional pressure level, l A

7.24


8.17/8.40


MJFCIFSS

6.47.13

Hydraulic unit

6.47.14

Service Manual


MJFCIFSS

Service Manual


Group

Type

Hydraulic pumps - dismantling, installation and initial operation

7.01.1

A 309 LI 20221A 311 LI 20222A 312 LI 12363A 314 LI 2001A 316 LI 2001A 316 LI-IND 2001R 317 LI 18161-

Double variable-displacement pump A8VO

7.02.1

A 309 LI 20221A 311 LI 20222-

LPV variable displacement pump

7.05.1


DPVO variable displacement pump

7.10.1

R 317 LI 18161-

DPVO variable-displacement pump

7.15.1

R 313 LI 27752-

Cooling unit

7.20.1


FMF hydraulic fixed displacement motor

7.24.1

A 314 LI 2001-11146 A 316 LI 2001-11151 A 316 LI-IND 2001-11151


7.24.11


7.1 MJFCIFSS

Service Manual LMV regulating motor

7.26.1

A 314 LI 2001A 316 LI 2001-28060 A 316 LI-IND 2001-28060

DMVA regulating motor

7.27.1

A 309 LI 20221A 311 LI 20222A 312 LI 12363A 316 LI 28061A 316 LI-IND 28061-

Regulating motor A6VE

7.28.1

R 313 LI 27752R 317 LI 18161-

Hydraulic cylinder

7.30.1


Hydraulic cylinder

7.34.1

A 312 LI 12363-

Hydraulic cylinder

7.35.1

A 314 LI 2001-

Hydraulic cylinder

7.36.1

A 316 LI 2001A 316 LI-IND 2001-

Control oil and regulation unit

7.40.1

A 309 LI 20221A 311 LI 20222-


7.42.1

A 312 LI 12363A 314 LI 2001A 316 LI 2001A 316 LI-IND 2001R 313 LI 27752R 317 LI 18161-

Pilot control unit 4 x

7.45.1


Pilot control unit 2 way for travel gear drive

7.46.1

R 317 LI 18161-

7.2 MJFCIFSS

Service Manual


Group

Type

Pilot control unit 4x

7.46.11

R 313 LI 27752R 317 LI 21205-

Pilot control valve 2 x

7.47.1



7.48.1



7.49.1



7.50.1

A 309 LI 20221A 311 LI 20222-

LSC control block

7.60.1



7.75.1

R 313 LI 27752R 317 LI 18161-

7.3 MJFCIFSS

Service Manual Rotary connection 6 x

7.76.1



7.77.1

R 313 LI 27752R 317 LI 18161-


7.78.1


TC valve

7.80.1


7.4 MJFCIFSS

Service Manual

Hydraulic pumps - dismantling, installation and initial Variable-displacement pump / double variable-displacement pump 20 / working hydraulics

Hydraulic pumps - dismantling, installation and initial operation Note! For a clean and nearly oil-free assembly and disassembly of the hydraulic pumps, we recommend the use of a vacuum pump (tool no. 180 - 187 in group 2.05). This pump can also be used as a compressor with a controlled low pressure of 300 - 500 mbar for ventilating the equipment. See also service information no. 06 - 03 - 22 / 2003

1 Variable-displacement pump / double variable-displacement pump 20 / working hydraulics see Fig. 1

1.1

Dismantling Close stop cock on hydraulic tank. Disconnect the suction and pressure lines from the pump 20 and 30/31 and collect the hydraulic oil in a suitable container. Dismantle the hydraulic pump 20.

1.2

Installation Apply CTK special paste to the gearing of the pump 20 (see group 1.50). Insert the hydraulic pump 20 into the clutch and place it on the intermediate housing/motor. Screw in the mounting bolts and tighten them with the prescribed tightening torque, see also group 5.05 / 5.10. Carefully clean all pipes and hoses and inspect them for damage. Connect the pipes and hoses to the pumps 20 / 30, as shown in the hydraulic diagram. Disconnect the leak oil line T1 from the pump 20. Fill the pump hosing through the open leak oil connection. Before starting the machine, fill the hydraulic tank to the upper fill level mark. Open the stop cock on the hydraulic tank. Check the screw fittings and lines for tightness. Make the suction hose air-tight. (Re-tighten connection and/or pipe clamps.)

copyright by

MJFCIFSS

7.01.1

Hydraulic pumps - dismantling, installation and initial

Service Manual

Gear pumps

Fig. 1

Variable-displacement pump / double variable-displacement pump and gear pumps

20 Double variable-displacement pump (A 309 - 30 Gear pump A 311) 20 Variable-displacement pump (A 312 - R 317) 31 Gear pump T1 Leak oil connection

2 Gear pumps 2.0.1

In models A 309 - A 311311, see Fig. 1 and Fig. 2 Gear pump 30 for hydraulic fan drive Gear pump 31 for brake system and low-pressure circuit Gear pump 32 for steering Gear pump 33 for pilot control system

2.0.2

In models A 312 - A 316, see Fig. 1 and Fig. 2 Gear pump 30 for hydraulic fan drive Gear pump 31 - steering Gear pump 32 for brake and pilot control system

2.0.3

In model R 317, see Fig. 1 Gear pump 30 for pilot control system Gear pump 31 for hydraulic fan drive

7.01.2

copyright by

MJFCIFSS

Service Manual

Hydraulic pumps - dismantling, installation and initial Gear pumps

Fig. 2

Variable-displacement pump / double variable-displacement pump and gear pumps

20 Double variable-displacement pump A 309 - 31 Gear pump with flow distributor A 311 20 Variable-displacement pump (A 312 - A 316) 32 Gear pump 30 Gear pump

2.1

33 Gear pump

Dismantling Close stop cock on hydraulic tank. Place suitable oil pan under hydraulic pumps. Disconnect hoses / lines at pumps. Collect hydraulic oil. Remove hydraulic pumps.

2.2

Installation Install hydraulic pumps. Connect all hoses / lines at pumps. Before starting the system, fill the hydraulic tank all the way to full mark at the top. Open the stop cock. Check the screw fittings and lines for tightness.

copyright by

MJFCIFSS

7.01.3

Hydraulic pumps - dismantling, installation and initial

Service Manual

First operation after replacement of pumps Note! Gear pumps do not require filling. To bleed the gear pumps 30, 31, 32 and 33: Loosen the screwed connections of the respective pressures hoses. Bleed the pump with the diesel engine at low idle speed until the oil runs out of the pressure connection (liquid, not oil foam). Re-tighten the connections. Check for tightness.

3 First operation after replacement of pumps and/or after use of a vacuum pump. See start-up of pumps. Run diesel engine for about 10 seconds using starter, but do not start the engine yet. Start diesel engine. Let run for about 7 minutes at low idle speed. Check oil level in hydraulic tank. Fill up, if necessary. Loosen leak oil line at variable-displacement pump, but do not disconnect. Bleed pump with diesel engine at low idle speed until oil runs out of the leak connection (collect escaping oil). Re-tighten leak oil line (not necessary with gear pumps). Run hydraulic system at full power. Run hydraulic oil to a working temperature of at least 50°C. Check settings of system's pressure relief valves. When pressures increases, remember to reduce engine speed. Also check electrical signals and settings, if necessary. See adjustment protocol and adjustment guideline, group 6. Check system for tightness.

7.01.4

copyright by

MJFCIFSS

Service Manual

Double variable-displacement pump A8VO Function

Double variable-displacement pump A8VO 1 Function

Pump 21 supplies the following consumers: Chassis, bucket cylinder, boom cylinder, stick cylinder (total) Pump 22 supplies the following consumers: Slewing gear, stick cylinder, support system The volumetric delivery of the pump is determined by the pivot angle of the respective powertrains. At the begin of regulation, each pump is set to Qmax (maximum flow). The control piston adjusts the cylinders to a smaller pivot angle. By operating the power regulator (LR regulator). the hydraulic control of the control piston can be adjusted. In a similar manner, the flow volume of pump P1 can be adjusted by means of the flow limitation.

Fig. 1

Variable-displacement pump A8VO

20

Double variable-displacement pump, complete

22

Pump P2

21

Pump P1

30


copyright by

MJFCIFSS

7.02.1


Service Manual

Function

7.02.2

copyright by

MJFCIFSS

Service Manual

Double variable-displacement pump A8VO General information

2 General information Equipment from serial number

A 309 Litronic 20221


A8VO 55

A8VO 55

2000 min-1

2000 min-1

Drive power of diesel engine (nominal power) = Pmax

63 kW

67kW

Max. input power of the pumps

59 kW

63 kW

106 l/min 20 l/min

106 l/min 20 l/min

13.5 kW

15.7 kW

60 ± 2 bar

70 ± 2 bar

Begin of regulation P1 / P2

290 bar

300 bar

Gear pump 30 / fan drive

40 l/min

40 l/min

Check measurement X (stroke limitation, flow reduction)

12.4 mm

11.8 mm

Flow from solenoid valve Y50

Flow from solenoid valve Y50

850 + 25 mA

850 + 25 mA

0 mA

0 mA

Control pressure from solenoid valve Y50

Control pressure from solenoid valve Y50

P max.

0 +1 bar

0 +1 bar

P emergency operation

30+2 bar

30+2 bar

Type of pump Input speed

Volumetric delivery per pump max. min. Hydraulic output per pump (basic operation) Begin of regulation (basic operation)

Check measurement Y (threaded stud 56 / Qmax stop) Settings and comparative values

I max I emergency operation Settings and comparative values

Tab. 1

Technical data

copyright by

MJFCIFSS

7.02.3


Service Manual

Description

3 Description The double variable-displacement pump consists of the following main components: Pump housing 1 Regulator housing 40 Actuation housing 60 Actuation device 70 Pump flange 98 for gear pump / fan drive The double variable-displacement pump A8VO is flange-connected to the diesel engine. The powertrains of the pumps P1 and P2 consisting of an input pinion, cylinder and piston are adjustable by means of the control pistons and necks. The regulator housing 40 with the integrated control piston is mounted to the rear of the pump housing 1. The actuation housing 60 with spool and regulating springs for the regulation and adjustment of the pump output is mounted on the regulator housing 40. The actuation housing 60 carries the actuation device 70 with the differential pistons of the power regulator and the spool with springs for the flow reduction of pump P1. The gear pump for the cooling system is attached to flange 98.

Fig. 2

7.02.4

Elements of the pump A8VO

copyright by

MJFCIFSS

Service Manual

Double variable-displacement pump A8VO Description

1 40

Pump housing Regulator housing

70 78

Actuation device Stroke limitation / flow limitation

60 65

Actuation housing Begin of regulation / adjusting screw

98

Flange for gear pump

from / to hydraulic tank

28

Spool / flow limitation

13

to oil motor / fan drive

29

Actuation device, complete

20

30

Gear pump / cooling

21

Double variable-displacement pump, complete Powertrain P1

43

Measuring point / actuating pressure pump 1

22

Powertrain P2

44

23

Pump regulator / actuation housing, com- 57 plete

Measuring point / actuating pressure pump 2 Measuring point MR / flow reduction control pressure

24

Pump adjustment

59

Measuring point LR / power control pressure

25

Spool

100

to control valve block

26

Nozzle

Y50

from proportional solenoid valve / power control

27

Differential piston

Y51

from proportional solenoid valve / flow limitation

Fig. 3 1

Hydraulic diagram of A8VO

copyright by

MJFCIFSS

7.02.5


Service Manual

Functional description of double variable-displacement pump

4 Functional description of double variable-displacement pump 4.1

Powertrain 21/ 22 The input pinions 2 and 3 are installed on tapered roller bearings 8 / 9 / 10 in the pump housing. The input/drive shaft 2 with spline mesh is driven directly by the diesel engine to which it is connected with a flexible coupling. The input pinion 3 and the gear 91 are driven through the helical gearing in opposite direction of rotation. The gear 91 or the input pinion 3 respectively drive the input pinion 95 of the gear pump / cooling or the input pinion 100, (see Fig. 7 page 14) (in opposite direction). The tapered roller bearing is preloaded with the slotted nuts 11 screwed into the input pinions 2 / 3. The cylinders 30 are set in motion by the conical pistons 33 connected to the input pinions 2 / 3. The centre pegs 31 act as axial and radial guide devices for the cylinders 30. The spherical heads of the centre pegs 31 and the conical piston 33 are borne by the spherical caps of the input pinions 2 / 3 and are secured with the screws 36 to the return plate 35. Each cylinder 30 rotates in radial direction on the control lens 38 with spherical sliding and sealing face. The control lens 38 is moved in vertical direction by the control piston 41 and the attached control neck 49. By placing the cylinder 30 into an incline position to the pinion axis (by means of regulating system), the piston stroke in cylinder 30 is adjusted. At each revolution of the cylinder 30, the seven pistons 33 complete a double stroke motion. The actual volumetric delivery (piston stroke x piston surface) depends on the number of strokes per minute. When not pressurised, the disc springs 32 press the cylinder 30 against the control lens 38. When the pressure increases, the hydraulic forces support the spring force, so that a sufficiently thick lubricating layer is maintained between the cylinder 30 and the control lens 38 and oil leakage is minimal, even at high pressures between the above components. The spherical heads of the piston 30 and the centre peg 31 , and the tapered roller bearings 8 - 10 are lubricated through the axial bores in the piston, centre peg and input pinion. The control lens 38 separates the pressure side from the suction side of the powertrain. The spherical surface of the control lens 38 is equipped with radially aligned kidney-shaped grooves through which the cylinder 30 is supplied through the joint suction connection (suction side) with oil from the tank. Another set of kidney-shaped grooves ensure that the pressure oil from cylinder 30 is fed to the respective pressure connection A1 (for pump P1) or A2 (for pump P2). The radial shaft seal ring 5 in the locking ring 4 seals the gap between the drive shaft 2 and the housing 1.

7.02.6

1

Pump housing

38

Control lens

2

Input pinion / drive shaft

40

Regulator housing

3

Input pinion

41

Control piston, siehe Fig. 6

4

Locking ring

49

Control neck, siehe Fig. 6

5 8

Radial shaft seal ring Tapered roller bearing

90 91

Stub shaft Gear

9

Tapered roller bearing

92

Cylindrical roller bearing

10


94

Cover

11

Slotted nut

95

Gear

30 31

Cylinder Centre peg

96 97

Deep groove ball bearing Deep groove ball bearing

32 33

Disc springs Conical piston

98 A1

Flange Pressure connection of pump P1

34 35

Piston ring Return plate

A2 S

Pressure connection of pump P2 joint suction connection P1/P2

36

Oval head screw

V

Profile of inclined axle

copyright by

MJFCIFSS

Service Manual

Double variable-displacement pump A8VO Functional description of double variable-displacement pump

Fig. 4

Powertrain of the pump A8VO

copyright by

MJFCIFSS

7.02.7


Service Manual

Functional description of double variable-displacement pump

4.1.1

Min. and max. pivot angle of the pump The maximum pivot angle max of the pump powertrain is determined by the threaded stud 56 in the regulator housing 40. In Qmax position, the hex head screw 52 of the control piston 41 touches the threaded stud 56. The position of the threaded stud 56 is factory-set and may not be modified. Dimension Y of max is used for checking purposes only, (see page 3). The minimum pivot angle min of the powertrain is determined by the stop of the piston 51 in the regulator housing 40 and cannot be modified.

Fig. 5

7.02.8

Minimum and maximum stop of the pump

40

Regulator housing

55

Allen head screw

41

Control piston

56

Threaded stud / Qmax stop

51

Piston

57

Seal-Lock collar nut

52 54

Hex head screw Cover

58

Safety cap

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MJFCIFSS

Service Manual

Double variable-displacement pump A8VO Pump regulation

5 Pump regulation 5.1

Introduction The double variable-displacement pump consists of two individually controlled pumps installed in a joint housing. Each pump is regulated independently from the other according to its performance characteristic.

5.2

Performance regulator LA, siehe Fig. 6 The performance regulator 25 is designed to adjust the flow rates of the pump in relation to the operating pressure, in line with the performance curve of the diesel engine. The pump performance is thus regulated along a hyperbolic characteristic. The pump delivers larger volumes at low pressure and smaller volumes at high pressures. The hyperbolic performance characteristic is approximated by means of the regulating springs 44 and 45/46. The operating pressure acts on the small measuring surface of the differential piston 80. The resulting force of this piston 80 is then applied through the stud 81 and the externally adjustable spring force (through the treaded stud 65) against the spring force of the regulating springs 44/45/46. When the pump is not pressurised, the powertrain is held by the regulating springs 44/45/46 at a maximum pivot angle. At a pressure below the maximum output of the pump (before begin of regulation), the pressure oil acts on the small piston surface (annular surface Fk ) of the control piston 41. As a result, the mechanical connection of the control piston 41 to the control lens 38 through the control neck 49 pushes the power train to its maximum pivot angle. The large control piston surface Fg is thereby connected to the tank side.

5.2.1

Begin of pump regulation If the total hydraulic forces exceed the spring force of the regulating springs 44/45/46, the spool 25 is moved and high pressure oil flows from the small piston surface through the nozzle 26 to the large piston surface of the control piston 41. The resulting increased force pushes the control piston 41 against the regulating springs 44/45/46. The control piston 41 thus regulates the powertrain in the direction of a smaller pivot angle, and thus towards Qmin.

5.2.2

Performance override by means of control pressure The external control pressure is fed through connection X3 onto the large measuring surface of the diffrential piston 80. The control pressure is created and controlled by the proportional solenoid valve Y50 located at the control oil unit 50, in proportion to the current fed to the valve by the U16 excavator control system. The force resulting from the high pressure and the additional control pressure acts on the spool 25 and, through the pushrod 81, also onto the regulating springs 44/45/46. The set output (i.e. max. output) of the pump isthereby adjusted to a lower value. This mechanism allows for a number of performance settings, (see Fig. 8 page 14) or (see Fig. 9 page 15). The total of the two pump outputs corresponds to the maximum available drive power.

5.2.3

Hydraulic stroke limitation of pump P1 By means of the hydraulic stroke limitation, the volumetric delivery of the pump P1 can be adjusted or limited stepleessly across the entire adjusting range from Qmax to Qmin. The desired volumetric delivery is determined by the control pressure from the proportional solenoid valve Y51 of the control oil unit through the connection X1 onto the piston 78. The hydraulic stroke limitation is overridden by the power regulator, which means that, below the power regulator characteristic, the volumetric delivery is adjusted in line with the control pressure. If the set flow volume or the operating pressure exceeds the pump characteristic, the power regulator overrides the settings and controls the volumetric delivery along the performance characteristic. When pressure is applied to the piston 78, the control bushing 79 is moved towards the spool 25, so that the spool 25 is pressed through the differential piston 80 and the pin 81 into its switching position.

copyright by

MJFCIFSS

7.02.9


Service Manual

Pump regulation As a result, the powertrain is moved in direction Qmin = smaller volumetric delivery. The volumetric delivery is proportional to the control pressure fed t connection X1. The basic setting is determined by the pressure spring 77 with the threaded stud 73.

25 Spool

60 Actuation housing

26 Nozzle

61 Measuring connection / begin of regulation ( M10x1)

38 Control lens 40 Regulator housing

63 Spring bushing 64 Pressure spring (Ø 16.2 mm)

41 Control piston 42 Spring plate

65 Threaded stud (begin of regulation) 66 Seal-Lock collar nut

43 Spring plate

67 Safety cap

44 Pressure spring (Ø 30.4 mm, regulating spring) 45 Pressure spring (Ø 21.8 mm, regulating spring)

70 Actuation device 71 Actuation housing

46 Pressure spring (Ø 22.5 mm, regulating spring)

72 Screw plug

47 Spring plate 49 Control neck

73 Threaded stud 74 Seal-Lock collar nut

50 Threaded stud 51 Piston

75 Safety cap 76 Spring plate

52 Hex head screw 54 Cover

77 Pressure spring 78 Control piston

55 Allen head screw

79 Control bushing

56 Threaded stud / Qmax stop 57 Seal-Lock collar nut

80 Spool 81 Pin

58 Safety cap

84 Screw plug (M12x1.5)

59 Screw plug M (M12x1.5)

X1 Control pressure connection MR (M14x1.5) X3 Control pressure connection LR (M14x1.5)

7.02.10

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Service Manual

Double variable-displacement pump A8VO Pump regulation

Fig. 6

Sectional drawing of power regulator LA

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7.02.11


Service Manual

Adjustment of the variable-displacement pump A8VO

6 Adjustment of the variable-displacement pump A8VO 6.1

Adjustment of the hydraulic begin of regulation and the stroke limitation / flow reduction Note! The procedure to adjust the pump settings is described in group 6 "Adjustment protocol" and "Adjustment guidelines". 1 2

Housing Input pinion / drive shaft

55 56

Allen head screw Threaded stud / Qmax stop

3 4

Input pinion Locking ring

57 58


5 6

Radial shaft seal ring O-ring

59 60

Screw plug (M12x1.5) Actuation housing

7

Snap ring

61

Measuring connection / begin of regulation ( M10x1)

8 9

Tapered roller bearing Tapered roller bearing

63 64

Spring bushing Pressure spring (Ø 16.2 mm)

10 11

Tapered roller bearing Slotted nut

65 70

Threaded stud / begin of regulation Actuation device

25

Spool

71

Actuation housing

26 30

Restrictor Cylinder

72 73


31 32

Centre peg Disc spring

74 75


33 35

Conical piston Return plate

76 77

Spring plate Pressure spring

38

Control lens

78

Control piston

40 41

Regulator housing Control piston

79 80

Control bushing Spool

42

Spring plate

81

Pin

43

Spring plate

82

Screw plug (M12x1.5)

44

Pressure spring (Ø 30.4 mm, regulating spring)

84

Threaded stud

45

Pressure spring (Ø 21.8 mm, regulating spring) Pressure spring (Ø 22.5 mm, regulating spring)

85

Seal-Lock collar nut

86

Safety cap

47 49

Spring plate Control neck

100 101

Stub shaft Gear

50

Threaded stud

102


51

Piston

103

Cover

52

Hex head screw

R1 Bleeding connection

54

Cover

R2 Oil drain screw

46

7.02.12

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Service Manual

Double variable-displacement pump A8VO Sectional drawing of the double variable-displacement pump A8VO

7 Sectional drawing of the double variable-displacement pump A8VO

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7.02.13


Service Manual

Regulating characteristic for A 309 Fig. 7


8 Regulating characteristic for A 309

Fig. 8

7.02.14

Performance characteristics of the pumps P1 / P2

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Service Manual

Double variable-displacement pump A8VO Regulating characteristic for A 311

9 Regulating characteristic for A 311

Fig. 9

Performance characteristics of the pumps P1 / P2

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7.02.15


Service Manual

Regulating characteristic for A 311

7.02.16

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MJFCIFSS

Service Manual

LPV variable displacement pump Purpose

LPV variable displacement pump 1 Purpose The LPV variable displacement pump is of the axial piston swash-plate type. Powertrain and gear pump are powered by the diesel engine via the flexible coupling (torsion damper). The variable displacement pump regulates its output according to actual requirements and, thus, provides the hydraulic pressure / volume required by the hydraulic system. The volumetric delivery of the pump is determined by the pivot angle of the swivel yoke. The angle can be changed / controlled by the regulating cylinder. Regulation is effected by the flow regulator (LS regulator ) and/or performance regulator.

Fig. 1


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7.05.1


Service Manual

General information

2 General information Machine from serial number


A 314 Litronic 2001

A 316 Litronic 2001

Pump type Input speed

LPV 130

LPV 130

LPV 150

1800 rpm

1800 rpm

1800 rpm

Drive power of diesel engine (rated power)

74 kW

80 kW

86 kW

Volumetric delivery max. min.

234 l/min 30 l/min

234 l/min 30 l/min

270 l/min 30 l/min

Hydraulic performance (basic performance)

30 kW 23 kW (*)

30 kW 23 kW (*)

27 kW 35 kW (*)

Begin of regulation (with basic settings)

65 ± 2 bar 50 ± 2 bar(*)

65 ± 2 bar 50 ± 2 bar(*)

65 ± 2 bar 50 ± 2 bar(*)

Begin of regulation (at rated output of the diesel engine)

155 bar

165 bar

155 bar

Control oil pump / radiator fan

45 l/min

45 l/min

45 l/min

Check measurement X (Q min. stop)

16.3 mm

16.3 mm

16.3 mm

Current from solenoid valve Y50, see adjustment protocols in group 6 For parameters and reference values, see adjustment protocol in group 6. Tab. 1

Technical data

(*) from software version 1.6

7.05.2

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Service Manual

LPV variable displacement pump Description

3 Description The variable displacement pump consists of three main components: Mounting plate 11 Connecting flange 13 Powertrain 1 The LPV variable displacement pump is flanged to the diesel engine with connection flange 13. Powertrain 1 / 21* consists of drive shaft, cylinder and piston. It can be adjusted / regulated by means of the swivel yoke. The pump regulation 23 consisting of the performance regulator (LR regulator) 23.2 and the flow regulator (LS regulator) 23.5 is mounted to the housing of the powertrain and connected through the pump adjustment 5 with a lever to the swivel yoke. The performance regulator 23.2 controls the pump via the performance curve (performance chart, see Fig. 13, see Fig. 14 and Fig. 15). The load-sensing regulator 23.5 is used to regulate the required oil volume by adjusting the pressure difference p. Gear pump 8 / 30* (pilot control) is screwed to mounting plate 11 and driven via the drive shaft of the variable displacement pump. The min. flow rate of the pump is pre-set by means of a stop screw.

Fig. 2 1

LPV components Powertrain (21*)

13

Connecting flange Regulating valve

5

Pump regulation

23*

8

Gear pump(30*)

23.2* Performance regulator

11

Mounting plate

23.5* Load sensing regulator

* items in hydraulic diagram

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7.05.3


Service Manual

Description

Fig. 3

7.05.4

LPV hydraulic diagram

1

to hydraulic tank

23.6 Shuttle valve

3 20

from stop cock / tank LPV pump unit

28 29

from check valve Restrictor

21

Powertrain

30


21.1 Control piston 23 Regulating valve

44 45

Measuring point / actuating pressure Measuring point / LS pressure

23.2 Performance regulator 23.5 LS regulator

50 100

from control oil unit from / to control valve block

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Service Manual

LPV variable displacement pump Functional description

4 Functional description 4.1

Powertrain, see Fig. 11 The drive shaft 1.10 is borne in the mounting plate 11 and the mounting flange 13 with needle bearings 11.3 and a roller bearing 13.3. It drives the cylinder 1.11 and the nine pistons 1.9 via the gearing. The clutch sleeve 11.31 conveys some of the driving power to the flange-mounted gear pump 8 (pilot control). Bearing of pistons 1.9 is arranged with slippers. The sliding disc 1.15 holds them on to the swivel yoke with the help of return plate 1.14 and return ball 1.13. Hydrostatic bearing by means of bores in piston 1.9 and slippers reduces high surface pressure between the rotating slippers and sliding disc 1.15 When there is no pressure, pressure springs 1.16 press cylinder 1.11 and return ball 1.13 against pilot plate 1.12. As soon as the pressure rises, the hydraulic forces add to the spring force so that an oil film is maintained, and the amount of leak oil is small. The leak oil will grease all the moving parts of the powertrain and is then lead on to the tank. For every rotary motion of the cylinder 1.11, the pistons 1.9 execute a double stroke. The length of the stroke depends on the inclination of swivel yoke 1.2. The rotary bearing of the swivel yoke is arranged via flanges 12 and the roller bearing 12.34. The rotary motion of the swivel yoke 1.2 is effected as the swivel yoke 1.2 engages with the control piston 5.10 at each axial movement of the swivel yoke 1.2. The volumetric delivery of the pump per each interval of time is determined by the piston capacity (piston diameter x stroke) and the speed of drive shaft 1.10. Pilot plate 1.12 separates the pressure side from the suction side of the powertrain. Pilot plate 1.12 has a kidney-shaped slit for suction, and a three-part slit for pressure.

4.2

Adjustment and control of the pump, see Fig. 11 There is a mechanical connection between swivel yoke 1.2 and control piston 5.10. The swivel yoke is in engagement (via the neck) with sliding block 5.30 on control piston 5.10. The axial motion of control piston 5.10, and, thus, the rotary motion (change of pivot angle) of swivel yoke 1.2, is caused by an actuating pressure controlled by regulating valve 23. In stand-by mode (i.e. all pilot control valves in neutral position), the pump supplies only min. flows (about 30 l/min - pre-set by stop screw at the factory). The pivoting motion of the pump is initiated by actuation of one or more consumers (via pilot control valves). It is the actuating pressure acting on the larger piston face plus the mechanical force of pressure spring 5.14 that effect the adjustment. Adjustment of the powertrain to a certain pivot angle depends on the following: Requirements pre-set (speed of consumers via displacement of lever / pedal at pilot control valve) Desired flow rate (e.g. when the volume is to be reduced) Working pressure (performance curve, see Fig. 13 applies from the beginning of basic regulation) see Fig. 14 and Fig. 15. The pivoting back of the pump is effected by the regulating unit of the pump, see 5.

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7.05.5


Service Manual

Pump regulation

5 Pump regulation 5.1 5.1.1

Performance regulator 23.2 with regulating piston 23.2.7, see Fig. 4 Horsepower control Pump high pressure (PHD) acts continuously on the small face s of control piston 5.10, via shuttle valve 23.6 and internal bores in valve housing 23 and the control cylinder. High pressure from the pump also acts on the central groove of regulating piston 2.7 via shuttle valve 23.6 and LS regulator 23.5. High pressure from the pump also acts on the space behind rod 2.33 via bores in housing 23 and lid 2.35. The resulting pressure is transmitted via spring plate 2.19 and push rod 2.4 to piston 2.7. At low pump pressure (below begin of regulation), spring 2.13 shifts piston 2.7 to the right, and edge S2 opens. That way, PHD (pump high pressure) acts via open control spool edge S2 on the large face S2 of control piston 5.10. Both faces S and s of control piston 5.10 are now connected to the same pump pressure so that piston 5.10 is now moved towards Qmax (max. pivot angel of pump). If the pump pressure increases and the resulting force becomes greater than the preload force of pressure spring 2.13, spool 2.7 is moved to the left, edge S closes and edge S opens so that oil can flow from large piston face S back to the tank (begin of regulation). Control piston 5.10 is pushed to the left so that the pivot angle of the pump becomes smaller. The motion of control piston 5.10 is transmitted via lever 2.6 and return piston 2.5 to regulating spring 2.11 so that preloading of spring 2.11 increases. If control piston 5.10 is shifted even further to the left, regulating spring 2.12 is preloaded as well. The pivot angle of the pump will be reduced until a balance is re-established between preloads of pressure spring 2.13, regulating springs 2.11 and 2.12 and the pump high-pressure force transmitted by rod 2.33. Over the entire range of control, each high-pressure value of the pump corresponds to a certain position of the control piston so that spool 2.7 is in a state of balance (control edges S1 and S2 closed). Regulating springs 2.11 and 2.12 define the regulating characteristics of the pump. The springs have been designed to get the regulating characteristics as close as possible to the theoretical curve at constant performance (= hyperbole). The beginning of preloading regulating springs 2.12 corresponds to the pump angle at which the slope of the regulating characteristics changes. Preloading of regulating spring 2.13 determines the begin of regulation. The max. pivot angle is determined by the final position of control piston 5.10 in the control cylinder and cannot be adjusted. The min. pivot angle is determined by the setting of Qmin stop screw 5.13.

7.05.6

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Service Manual

LPV variable displacement pump Pump regulation

Fig. 4 23

Sectional drawing of performance regulator 23.2 2.19 Spring plate

Regulating valve


2.33 Rod

2.4 2.5

Pressure rod Return piston

2.35 Lid 23.5 Load-sensing regulator

2.6

Lever

23.6 Shuttle valve

2.7 Regulating piston 2.11 Regulating spring

5.10 Control piston 5.13 Adjusting screw

2.12 Regulating spring 2.13 Pressure spring / begin of regulation

5.24 Hex nut 44 Measuring point actuating pressure

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7.05.7


Service Manual

Pump regulation

5.1.2

Stage for performance change

Fig. 5 21 21.1

Pump regulation Powertrain Control cylinder

GLR LS

Connection from LR control oil unit Connection from LS control oil unit

ST

Connection from LS control block

This stage allows to hydraulically adjust the pump regulation characteristics during operation. As soon as a pressure is connected to chamber "B" (see Fig. 4) via the regulator connection "GLR", a force is generated at the spool 2.7 which is proportional to pressure "GLR" and which shifts the spool towards "pump to Qmax". A new balance at the spool can only be established if the pressure from the pump increases. The higher the GLR pressure, the higher the pump pressure at begin of regulation. The pump regulation continues as described in 5.1 , page 6. However, the regulation characteristics in the P-Q diagram are shifted towards a higher pressure (i.e. higher performance) in order to attain a value that is proportional to the GLR pressure. The connection "GLR" receives the output pressure of the performance-regulating solenoid valve Y50 (LR valve).

7.05.8

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Service Manual


5.2 5.2.1

Load-sensing regulator 23.5 Regulation of pressure difference

P LS

This regulator adapts the flow rate of the pump to the flow consumption of the consumers to be fed. The load-sensing regulator 23.5 is installed together with the performance regulator 23.2 at the control cylinder 21.1. Piston .7 connects the channel leading to the control pistons either with tank pressure T (edge S4 open and pump pivots to Qmin), or with pump high pressure PHD (edge S3 open and pump pivots to Qmax.). The preload force of springs .13 and .14 (value for P setting) and the force resulting from the pressure in chamber PLS, acting on the working face of piston .8, shift piston .7 to Qmax. The hydraulic force resulting from the pump high pressure acting on the working face of piston .9 shifts piston .7 towards Qmin. In the neutral position of the piston, the three forces are in balance. That means, regulating piston .7 regulates so that a constant pressure difference ( P) is maintained between both chambers LS and PHD which corresponds to the preload of springs .13 and .14. And the pressure difference does not depend on the current working pressure and flow rate of the pump.

Fig. 6

Sectional drawing: load-sensing regulator 23.5

21.1

Control cylinder

23.8

Piston

23.2


23.9

Piston

23.5 23.6

Load-sensing regulator Shuttle valve

23.13 2.314

Regulating spring Regulating spring

23.7

Spool

44


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7.05.9


Service Manual

Pump regulation

5.2.2

Limitation of max. pump flow rate ( P reduction) By preselecting a certain working attachment, e.g. a hydraulic hammer, a possible flow reduction is preset at the switch S241 and the excavator control U16 is activated (both devices are installed in the right console). As a result, the chamber PST of the LS regulator 23.5 is pressurised through the regulating solenoid valve Y51. This results in an additional pressure force on the piston .7 that acts against the preload force of the regulating springs 2.11 and 2.13. That means, the pressure difference a smaller amount of oil.

P is smaller, and the pump can maintain the reduced

The pump pivots only to the point where the pre-set flow rate at the pump inlet is reached.

Fig. 7

7.05.10

Diagram: variable displacement pump

21 Powertrain 21.1 Adjustment

23.5 LS regulator 23.6 Shuttle valve

23 Regulating valve 23.2 Performance regulator

30 44

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Gear pump / pilot control Measuring point / actuating pressure

P with

Service Manual


5.3

Fine control and/or flow reduction via

Fig. 8

p reduction

Hydraulic diagram: flow reduction

21

Powertrain

235

Boom cylinder

21.1

Control cylinder

240


23.5 LS regulator 120 Spool / slewing gear

255 260

Stick cylinder Spool / bucket cylinder

130

Slewing gear motor

275

Bucket cylinder

160

Spool / chassis

280


170

Travel motor

295

Support cylinder

220


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7.05.11


Service Manual

Adjustment of LPV variable displacement pump (LR - LS)

6 Adjustment of LPV variable displacement pump (LR - LS) 6.1

Min. and max. pivot angle of the pump

Fig. 9

Min. and max. pivot angle of the variable displacement pump

5.10

Spring plate

5.29

Safety cap

5.13 5.24

Pressure spring Hex nut

5.32

Sleeve

The max. pivot angle of the powertrain of the pump is determined by the non-adjustable dead stop (collar 5.32) of control piston 5.10 in the control cylinder. That means, it cannot be adjusted from the outside. The min. pivot angle of the powertrain is determined by the stop of control piston 5.10. It can be adjusted by means of adjusting screw 5.13 (with lock nut 5.24). It has been pre-set at the factory to guarantee sufficient cooling and lubrication of the powertrain. The min. pivot angle should not be changed under normal circumstances (adjusting screw 5.13 is secured against tampering by lock nut 5.24 and safety cap 5.29).

7.05.12

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Service Manual

LPV variable displacement pump Adjustment of LPV variable displacement pump (LR - LS)

6.2

Adjustment of differential pressure of the working pump

p (LS) and begin of hydraulic regulation

The procedure to adjust the differential pressure and begin of regulation of pump 20 is described in group 6 "Adjustment protocol" and "Adjustment guideline".

Fig. 10

Adjusting begin of regulation Prb and pressure difference screw 23.2.1 and 23.5.1

p(LS) by means of adjusting

23.2.1 Adjusting screw of performance regula- 23.5.1 Adjusting screw of load-sensing regulator tor 23.2.2 Lock nut 23.5.2 Lock nut

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7.05.13


Service Manual

Sectional drawing: pump regulation 23

7 Sectional drawing: pump regulation 23 Key re. sectional drawing, see Fig. 11 2.1 2.2

7.05.14


23.2 23.5

Performance regulator Load-sensing regulator

2.4

Pressure rod

23.6

Shuttle check valve

2.5 2.6

Return piston Lever

44 5.1

Measuring point MA Adjusting screw

2.7

Spool

5.2

Lock nut

2.8

Control sleeve

5.5

Screwed connection

2.9

Spring plate

5.6

Control sleeve

2.10

Spring plate

5.7

Spool

2.11 2.12

Regulating spring Regulating spring

5.8 5.9

Piston Piston

2.13 2.14

Pressure spring / begin of regulation Spacer

5.10 2.11

Spring plate Spring plate

2.15 2.16

O-ring O-ring

5.13 5.14

Pressure spring Pressure spring

2.18

Guide sleeve

5.15

O-ring

2.19 2.20

Spring plate Lid

5.16 5.17

O-ring Guide sleeve

2.21 2.33

Allen head screw Rod

5.22 6.1

O-ring Valve insert

2.34 2.35

O-ring Lid

6.2 6.3

Sleeve Ball

2.36

Allen head screw

6.4

O-ring

23

Regulating valve

6.5

O-ring

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Service Manual

LPV variable displacement pump Sectional drawing: pump regulation 23

Fig. 11

Sectional drawing: Pump regulation

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7.05.15


Service Manual

Sectional drawing of the complete LPV pump

8 Sectional drawing of the complete LPV pump 1.0 1.1

Powertrain Pump casing

5.14 5.24

Pressure spring Hex nut

1.2

Swivel yoke

5.25

Allen head screw

1.9 1.10

Piston slipper Drive shaft

5.30 11

Sliding block End plate

1.11

Cylinder

11.3

Cylindrical needle bearing

1.12

Pilot plate

11.31

Clutch sleeve

1.13

Return ball

12

Flange

1.14

Return plate

12.34

Cylindrical needle bearing

1.15

Sliding disc

13

Connecting flange

1.16 5.

Pressure spring Adjustment (21.1*)

13.3 13.4

Cylindrical needle bearing Radial shaft seal ring

5.10 5.11

Control piston Lid

23* 23.2*

Regulating valve Performance regulator

5.12 5.13

Lid Stop screw / Qmin

23.5* 44*

LS regulator Measuring point / actuating pressure


7.05.16

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Service Manual

LPV variable displacement pump Sectional drawing of the complete LPV pump

Fig. 12

Sectional drawing of LPV variable displacement pump

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7.05.17


Service Manual

LPV 130 pump performance diagram

9 LPV 130 pump performance diagram

Fig. 13

Performance diagram of the LPV 130 variable-displacement pump in A 312 Litronic machines

H

Hyperbola for rated power

P

Power

S -1.5

to software version 1.5

(*)Qn is the rated flow rate (=volume at PO(LS)) of the respective spool

7.05.18

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Service Manual

LPV variable displacement pump LPV 130 pump performance diagram

Fig. 14


H

Hyperbola for rated power

P

Power

S -1.5



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7.05.19


Service Manual

LPV 150 pump performance diagrams

10

LPV 150 pump performance diagrams

Fig. 15

H P


S -1.5

Hyperbola for rated power Power



7.05.20

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Service Manual

DPVO variable displacement pump Purpose

DPVO variable displacement pump 1 Purpose The DPVO variable displacement pump is of the axial piston swash-plate type. Powertrain and integrated pilot-control gear pump are powered by the diesel engine via the flexible coupling (torsion damper). The variable displacement pump regulates its flow rate according to current requirements (load sensing principle) and supplies the required quantities of oil to the various consumers , (lifting / bucket / stick / travel / support / slewing gear / pivot grapple). The volumetric delivery of the pump is determined by the pivot angle of the swivel yoke. The swivel yoke is adjusted by means of the control cylinder. Regulation of the regulating cylinder is effected by the flow regulator (LS regulator ) and/or performance regulator (LR regulator).

Fig. 1


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7.10.1


Service Manual

Purpose

7.10.2

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Service Manual

DPVO variable displacement pump General information


R 317 Litronic 18161

Type of pump

DPVO 165

Input speed

1800 min-1


86 kW


297 l/min 40 l/min

Hydraulic performance (basic performance) Begin of regulation (with basic settings)

29 kW 50 ± 2 bar

Control oil pump / pilot control

36 l/min

Test value X (Q min. stop)

15.6 mm

Settings and comparative values Flow from solenoid valve Y50 P min.

180 +10 mA

P max

500 +13 mA

Settings and comparative values Flow from solenoid valve Y50 P min.

1,5 +1 bar

P max

6 +3 bar

Tab. 1

Technical data

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7.10.3


Service Manual

Description

3 Description The variable displacement pump consists of the following main components: Mounting plate 1 Connecting flange 2 Powertrain21 Pump casing 40 The DPVO variable displacement pump is flanged to the diesel engine with connection flange 2. The powertrain consists of drive shaft, cylinder and piston. It can be adjusted by means of the swivel yoke. Regulator housing 6 sits on pump casing 40. Performance regulator 25 (for regulating and adjusting pump performance) is mounted in regulator housing 6. It obtains feedback concerning the current pivot angle by means of a pin. Flow regulator 26 sits right on mounting plate 26. It controls flows and the adjustment of differential pressure p. Gear pump 30 (pilot control) sits on mounting plate 1. It is driven by means of an internal drive shaft. There is an opening in the mounting plate for the installation of an additional gear pump, if required.

Fig. 2

7.10.4

Components of the DPVO

1

Mounting plate

40

Pump casing

2

Connecting flange

44

Measuring point pSK (control chamber pressure)

3

Qmin stop screw

A1

Pressure connection

6 25

Regulator housing Performance regulator (LR)

AX T

Pressure connection locked up Leak oil connection

26

Flow regulator (LS)

FE

Pressure connection of servo oil pump

27

Shuttle valve

X2

Connection LS-pressure

28

Check valve (12 Nm)

X3

Connection to servo oil unit

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Service Manual

DPVO variable displacement pump Description

29 30

Fig. 3

Restrictor Gear pump

X4

Connection

25 26

Performance regulator Flow regulator

p -subsidence

Hydraulic schematic: DPVO

1 3

to hydraulic tank from stop cock / tank

4

Pressure spring /

27

Shuttle valve

10

Pressure spring / begin of regulation

28

Check valve

15

Connecting pin (swivel yoke)

29

Restrictor

16 20

Return piston DPVO pump unit

30 44

Gear pump / pilot control Measuring point / actuating pressure

21 22

Powertrain Control piston

45 50

Measuring point / LS pressure from / to control oil unit

23

Measuring cylinder

100

to control valve block

24

Lever (rocker)

p

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7.10.5


Service Manual

Functional description of variable displacement pump

4 Functional description of variable displacement pump 4.1

Powertrain 21, see Fig. 10 Bearing of drive shaft 5 in mounting plates 1 and mounting flange 2 is arranged by way of cylindrical roller bearing 8 and sliding bearing 10. The shaft drives cylinder 16 and the nine pistons with slipper 19 via the gearing. The toothing on the drive shaft, in addition, drives flange-mounted gear pump 30 (pilot control). Sliding disc 31 holds pistons 19 (with slippers) on swivel yoke 7, with the help of return plate 34 and return ball 33. Hydrostatic bearing by means of bores in pistons 19 reduces high surface pressure between the rotating slippers and sliding disc 31. When there is no pressure, pressure springs 35 / 36 press cylinder 16 and return ball 33 against pilot plate 17. As soon as the pressure rises, the hydraulic forces add to the spring force so that an oil film is maintained, and the amount of leak oil is small. The leak oil will grease all the moving parts of the powertrain, and is then lead on to the tank. For every rotary motion of cylinder 16, pistons 19 execute a double stroke. The length of the stroke depends on the angle of swivel yoke 7. Rotary bearing of the swivel yoke is arranged by way of roller bearing 14. The rotary motion of swivel yoke 7 is effected by means of a connection between control piston 22 and connecting link 37 at every axial motion of the piston. The volumetric delivery of the pump per each interval of time is determined by the piston capacity (piston diameter x stroke) and the speed of drive shaft 5. Pilot plate 17 separates the pressure side from the suction side of the powertrain. Pilot plate 17 has a kidney-shaped opening on the suction side, and three smaller kidney-shaped openings on the pressure side.

Fig. 4

7.10.6

Section: powertrain

16 Cylinder 17 Pilot plate

33 Return ball 34 Return plate

18 Pin

35 Spring

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Service Manual

DPVO variable displacement pump Functional description of variable displacement pump

19 Piston

4.1.1

35 Spring

Adjusting the pivot angle of the pump Connecting link 37 provides a mechanical connection between swivel yoke 7 and control piston 22. The connecting link engages into the opening on control piston 22. It is secured by means of pin 12 and roll pin 11. The axial motion of control piston 22 (and thus the rotary motion, i.e. the change of the angle of swivel yoke 7) is determined by way of the performance regulator and/or flow regulator. The LS signal generated by the consumer moves the flow regulator into the actuating position so that pump pressure can reach the control chamber - the pump pivots. The pump will pivot back as soon as the control chamber is connected to the tank by the flow regulator (no LS signal) or by the performance regulator (output too high). In standby mode (i.e. all pilot control valves in neutral position), the pump delivers only min. flows (about 40 l/min - pre-set in the factory by means of stop screw 3).

4.1.2

Min. and max. pivot angle of the pump The max. pivot angle of the powertrain of the pump is determined by the dead stop (collar 39) of control piston 22 in the control cylinder. The stop cannot be adjusted. The min. pivot angle of the powertrain is determined by stop screw 3 (with locknut 38). It has been pre-set at the factory. It is recommended not to tamper with that angle under normal circumstances.

Fig. 5 3

Adjusting the swivel yoke 22 Control piston

stop screw Q-min

7 Swivel yoke 11 roll pin

37 Connecting link 38 Locknut

12 Pin

39 Collar

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7.10.7


Service Manual

Pump regulation


Performance regulator 25 (LR) hyperbolic regulator The purpose of the performance regulator is to adapt the flow rates from the pump with respect to the pump pressure (decreasing output) to the performance curve of the diesel engine. That means, regulation of the pump performance is effected along a hyperbolic line. The pump delivers larger volumes at low pressure and smaller volumes at high pressures. The basic setting of regulating spring 10 /11 corresponds to the mechanical beginning of basic regulation. It can be switched up to load limit control via control pressure pMLR at connection X3. Pressure springs 10 / 11 switch piston 17 to the right against lever 24. This will open control edge S1, and the control chamber of control cylinder 22 will receive pump pressure pP. The pump will pivot to Qmax. The return piston has a mechanical connection with the swivel yoke in connecting pin 15.

5.1.1

Begin of pump regulation As soon as operating pressure pP in the system rises to the value of begin of regulation, the force exercised on lever 24 at measuring cylinder 23 goes up as well. Control piston 17 is moved against spring 10 and thus opens the connection between control chamber (SK) and tank (T) with the help of control edge S2. The pump pivots back. The pump pivoting back effects an axial movement of return piston 16 against pressure spring 3 by means of connecting pin 15 with the bearing pin of the swivel yoke. This leads to the line of force of measuring cylinder 23 against lever 24 being shifted in the direction of the fulcrum. The force exercised by lever 24 on piston 17 decreases so that pressure spring 10 moves piston 17 back into its neutral position. The connection between control chamber (SK) and tank (T) is interrupted. The pump remains on a constant flow rate that corresponds (with the pP still prevailing) to a constant decrease of performance.

5.1.2

Pivoting of the pump (at pressures below begin of regulation) As soon as operating pressure pP drops in the system, the force exercised by piston 23 on lever 24 will go down. Spring 10 will move piston 17 against lever 24. The connection via control edge S1 pump pressure (P) in control chamber (SK) will be opened. The pump will go to a larger pivot angle. The pivoting motion of the pump will move return piston 16 in the direction of screw plug 1. Measuring cylinder 23 will be pushed away by lever 24. The resulting force of lever 24 exercised on piston 17 goes up, i.e. there is a balance again, and piston 17 moves to closing position (S1 and S2 closed).

Fig. 6

7.10.8

View: control edges S1 and S2

10

Spring

pP

Pump pressure

11

Spring

SK

Control chamber pressure

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Service Manual

DPVO variable displacement pump Pump regulation

17

T

Control piston

Tank pressure

Sectional drawing: performance regulator 25

Fig. 7 1

Plug

12

Bushing

2 3

Threaded stud Pressure spring

13 14

Spring plate Ball

4 5

O-ring O-ring

15 16

Connecting pin (swivel yoke) Return piston

6

Regulator housing

17

Spool

7 8

Sealing nut Adjusting screw

23 24

Piston with slipper (measuring cylinder) Lever

9 10

Plug Pressure spring (begin of regulation)

pP SK

Pump pressure Control chamber pressure

11

Pressure spring

T

Tank pressure

Note! Tightening torques: Screw plug 1 / 9 = 35 Nm; sealing nut 7 = 18 Nm.

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7.10.9


Service Manual

Pump regulation

5.2

Flow regulator 26 (LS regulator) The purpose of flow regulator 26 is to adapt the flow rates of the pump to the requirements of the consumers. Flow regulator 26 is mounted on mounting plate 1. The regulator consists of piston 15 switching the connection between control chamber and tank or pump pressure, and pressure spring 4, being adjusted using adjusting screw 2 (adjustment p). Basic setting p can be reduced using control pressurepMLS at connectionX4 of the pump. This will, at the same time, reduce the flow rate of the pump. Reduction of flow rates /

p reduction/ SF

Flow regulator 26 on mounting plate 1 , connection X4 for

Fig. 8

p-reduction

1

Mounting plate

15

Control piston

2

Regulating screw

26

Flow regulator

3

Nut pP

Pump pressure

X4

Control pressure

4

Spring (Adjusting

9

Sealnut

p)

Note! Screw down flow regulator 26 all the way to stop. Tighten with 5 Nm max. Sealing nut 9 = 8 Nm; nut 3 = 120 Nm.

7.10.10

copyright by

MJFCIFSS

p -subsidence

Service Manual

DPVO variable displacement pump Pump regulation

5.3 5.3.1

Regulation of pressure difference

P LS

Standby As soon as all the consumers are closed, the flow from the pump will build up a backpressure in channel pP. Feedback concerning backpressure will be sent to piston 8. As soon as the pressure exceeds the forces of springs 4/14, control edge S2 will open. The powertrain will go on pivoting back until the spring and pressure forces at regulating piston 15 cancel out each other or the powertrain attains Qmin. Shifting piston 15 is pushed to the right by pressure spring 4. Control edge S1 opens, pump pressure gets into the control chamber, the pump goes to a large pivot angle, and the flow rate goes up.

5.3.2

Pivoting out Pressure building up at connection pLS (operation of a consumer) will increase the sum of forces acting on the spring side of piston 15, and piston 15 will switch right. Control edge S1 opens, pump pressure gets into the control chamber, the pump goes to a large pivot angle, and the flow rate goes up. The backpressure pP caused by the increasing volumes coming from the pump will now increase pressure against piston 8. As soon as it reaches the value set at spring 4, shifting piston 15 will go back to the left again until control edge S1 closes. The control chamber does not receive pP any more, but is not relieved to tank either (thanks to control edge S2 which is still closed). That means, the flow rate from the pump levels out at a constant value.

5.3.3

Pivoting back As soon as pressure pP acting on piston 8 exceeds a value made up of pLS (consumer pressure) plus spring force, piston 15 will go to the left, control edge S1 will close, control edge S2 will open, and the control chamber of the regulating cylinder will be connected to the tank for relief. The pump pivots back.

Fig. 9

Sectional drawing: load-sensing regulator

1 2

Plug Adjusting screw

12 13

Backing ring O-ring

3

Nut

4

Pressure spring(adjustment

14

Pressure spring

Piston

15 pP

Spool Pump pressure

5 6 7

Bushing Bushing

pLS LS-Druck pMLS p-Reduction

8 9

Piston Sealing nut

S1

Control edge pump pressure

S2

Control edge tank pressure

10

Backing ring

SK


p)

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7.10.11


Service Manual

Adjustment of DPVO variable displacement pump 11

T

O-ring

Tank pressure

6 Adjustment of DPVO variable displacement pump 6.1

Adjustment of differential pressure

p LS and begin of hydraulic regulation

Note! The procedure to adjust the differential pressure and begin of regulation of the pump is described in group 6 "Adjustment protocol" and "Adjustment guideline".

7.10.12

1 2

Mounting plate Connecting flange

17 18

Pilot plate Locking pin (against tampering)

3

Stop screw

19

Piston with slipper

4 5

Locking ring Drive shaft

22 30

Control piston Gear pump

6 7

Regulator housing Swivel yoke

31 32

Sliding disc Set of discs

8 9

Cylindrical roller bearing O-ring

33 34

Return ball Return plate

10

Sliding bearing

35

Pressure spring

11 12

Roll pin Pin

36 37

Pressure spring Connecting link

13 14

O-ring Cylindrical roller bearing

38 39

Hex nut Stop sleeve

15 16

Pin Cylinder with bushing

40

Pump casing

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Service Manual

DPVO variable displacement pump Adjustment of DPVO variable displacement pump

Fig. 10

Sectional drawing: DPVO

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MJFCIFSS

7.10.13


Service Manual

Regulating characteristics

7 Regulating characteristics

Fig. 11

7.10.14

Performance curve: DPVO 165

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MJFCIFSS

Service Manual

DPVO variable-displacement pump Design

DPVO variable-displacement pump 1 Design The DPVO variable-displacement pump is of the axial piston swash-plate type. The powertrain and the integrated pilot-control gear pump as well as the attached gear pump for the fan control are powered by the diesel engine via the flexible coupling (torsion damper). The variable-displacement pump regulates its flow rate according to current requirements (load sensing principle) and supplies the required quantities of oil to the various consumers, (lifting / bucket / stick / travel / support / slewing gear / pivot grapple). The variable displacement pump consists of the following main components: Powertrain 21 Pump casing 40 Mounting plate 46 Connecting flange 47 Regulator housing 49 The DPVO variable displacement pump is flange-mounted to the diesel engine with the connecting flange 47. The powertrain consists of drive shaft, cylinder and piston. It can be adjusted by means of the swivel yoke. The regulator housing 49 in mounted to the pump casing 40. The performance regulator 25 (for regulating and adjusting the pump performance) is screw-mounted in the regulator housing 49. It obtains feedback concerning the current pivot angle by means of a pin. The flow regulator 26 used to adjust the flow and the differential pressure to the regulator housing 49.

p is also screw-mounted

The gear pump 30 (pilot control) is integrated into the mounting plate 46, while the gear pump 31 (fan control) is flange-mounted to the mounting plate 46. Both pumps are driven through the powertrain.

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7.15.1


Service Manual

Design

Fig. 1

7.15.2

Components of the DPVO

25

Performance regulator (LR)

48

Qmin stop screw

26 27

Flow regulator (LS) Shuttle valve

49

Regulator housing

28 29

Check valve Restrictor

A1 AX

Pressure connection Pressure connection sealed

30 31

Gear pump / pilot control Gear pump / fan control

FE S

Pressure connection of control oil pump Suction connection

40

Pump casing

7

Leak oil connection

44

Measuring point pSK (control chamber pressure)

X2


46

Mounting plate

X3

Connection of control oil unit LR

47

Connecting flange

X4

Connection

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-p reduction

Service Manual

DPVO variable-displacement pump Technical data

2 Technical data Machine from serial number


Pump type

DPVO 165

Input speed

1800 rpm


73 kW


297 l/min 40 l/min

Hydraulic performance (basic performance) Begin of regulation (with basic settings)

29 kW 50 ± 2 bar

Control oil pump / pilot control

36 l/min

Control oil pump / fan control

39 l/min

Check measurement X (Q min. stop)

15.0 mm

Settings and comparative values: Flow from solenoid valve Y50 P min.

180+10 mA

P max.

580+30 mA

Settings and comparative values Control pressure from solenoid valve Y50 P min.

1.5 +1 bar

P max.

7 +2 bar

Tab. 1

Technical data

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7.15.3


Service Manual

Technical data

Fig. 2

7.15.4

Hydraulic diagram of DPVO

1

to hydraulic tank

25

3

from stop cock / tank

26

Flow regulator

4 10

Pressure spring / p Pressure spring / begin of regulation

27 28

Shuttle valve Check valve

13 15

to oil motor / fan drive Connecting pin (swivel yoke)

29 30

Restrictor Gear pump / pilot control

16 20

Return piston DPVO pump unit

31 44

Gear pump / fan control Measuring point / actuating pressure

21

Powertrain

45


22 23

Control piston Measuring cylinder

50 100

from/to control oil unit to control valve block

24

Lever (rocker)

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Service Manual

DPVO variable-displacement pump Functional description


Powertrain 21, see Fig. 9 The drive shaft 5 is borne in the mounting plate 46 and the mounting flange 47 with a cylindrical roller bearing 8 and a sliding bearing 10. The shaft drives the cylinder 16 and the nine pistons with slipper 19 via the gearing. The toothing on the drive shaft drives the integrated and flange-mounted gear pump 30/31. The pistons 19 with slippers are held by means of the return plate 34 and the return ball 33 on the swivel yoke 7 with the sliding disc 31. The hydrostatic bearing by means of bores in the pistons 19 reduces the high surface pressure between the rotating slippers and the sliding disc 31. If there is no pressure, the pressure springs 35 / 36 press the cylinder 16 and the return ball 33 against the pilot plate 17. As soon as the pressure rises, the hydraulic forces add to the spring force so that an oil film is maintained, while the amount of leak oil is small. The leak oil lubricates all the moving parts of the powertrain, and is then fed to the tank. For every rotary motion of the cylinder 16, the pistons 19 execute a double stroke. The length of the stroke depends on the inclination of swivel yoke 7. The swivel yoke is borne on the roller bearing 14 and can be tilted. The rotary motion of the swivel yoke 7 is effected by means of a connection between the control piston 22 and the connecting link 37 at every axial motion of the piston. The volumetric delivery of the pump per time interval is determined by the piston capacity (piston diameter x stroke) and the speed of drive shaft 5. The pilot plate 17 separates the pressure side from the suction side of the powertrain. Pilot plate 17 has a kidney-shaped opening on the suction side, and three smaller kidney-shaped openings on the pressure side.

Fig. 3

Section of powertrain

16

Cylinder

33

Return ball

17

Pilot plate

34

Return plate

18

Pin

35

Pressure spring

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7.15.5


Service Manual

Functional description 19

3.1.1

36

Piston

Pressure spring

Adjusting the pivot angle of the pump, see Fig. 9 The connecting link 37 provides a mechanical connection between the swivel yoke 7 and the control piston 22. The connecting link engages in the opening on the control piston 22. It is secured by means of the pin 12 and the roll pin 11. The axial motion of the control piston 22 (and thus the swivelling motion, i.e. the change of the angle of swivel yoke 7) is determined by way of the performance regulator and/or flow regulator. The LS signal generated by the consumer moves the flow regulator into the actuating position so that the pump pressure can reach the control chamber. As a result, the pump is swivelled out. The pump pivots back as soon as the control chamber is connected by the flow regulator (no LS signal) or by the performance regulator (output too high) to the tank. In stand-by mode (i.e. all pilot control valves in neutral position), the pump supplies only minimum flows, (see Tab. 1 on page3).

3.1.2

Min. and max. pivoting angle of the pump The max. pivot angle of the powertrain of the pump is determined by the dead stop (collar 39) of the control piston 22 in the control cylinder. The stop cannot be adjusted. The min. pivot angle of the powertrain is determined by the stop screw 48 (with lock nut 38). It is factory-set. It is recommended not to tamper with these angle settings.

Fig. 4

7.15.6

Adjusting the swivel yoke

7

Swivel yoke

37

Connecting link

11

Roll pin

38

Lock nut

12

Pin

39

Sleeve

22

Control piston

48

Qmin stop screw

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Service Manual

DPVO variable-displacement pump Pump regulation


Performance regulator 25 (LR) hyperbolic regulator The purpose of the performance regulator is to adapt the flow rates from the pump with respect to the pump pressure (decreasing output) to the performance curve of the diesel engine. As a result, the pump performance is regulated along a hyperbolic line. The pump delivers larger volumes at low pressure and smaller volumes at high pressures. The basic setting of the regulating spring 90 /91 corresponds to the mechanical begin of basic regulation. It can be switched up to load limit control via the control pressure pMLR at the connection X3. The pressure springs 90 / 91 push the spool 97 to the right against the lever 24. This opens the control edge S1; the control chamber of the control cylinder 22 receives pump pressure pP. The pump pivots to Qmax. The return piston 16 has a mechanical connection with the swivel yoke in the connecting pin 15.

4.1.1

Begin of pump regulation When the working pressure pP in the system rises to the value of the begin of regulation, the force from the measuring cylinder 23 to the lever 24 is increased. The spool 97 is shifted against the pressure spring 90 and opens, through the control edge S2, the connection from the control chamber (SK) to the tank (T). The pump pivots back. The pump pivoting back results in an axial movement of the return piston 96 against the pressure spring 83 by means of the connecting pin 95 with the bearing pin of the swivel yoke. As a consequence, the line of force of the measuring cylinder 98 against the lever 99 is shifted in the direction of the fulcrum. The force exercised by the lever 94 onto the spool 97 is reduced so that the pressure spring 90 moves the spool 97 back into its neutral position. The connection between the control chamber (SK) and the tank (T) is closed. The pump remains at a constant flow rate, which results in a constant drop in performance (at the prevailing pP).

4.1.2

Pivoting of the pump (at pressures below the begin of regulation) As soon as the operating pressure pP in the system drops, the force exercised by the piston 98 onto the lever 99 is reduced. The spring 90 shifts the spoon 97 against the lever 99. The connection through the control edge S1 pump pressure (P) in the control chamber (SK) is opened. The pump is set to a larger pivot angle. The pivoting motion of the pump moves the return piston 96 in the direction of the screw plug 81. The measuring cylinder 23 is pushed away from the fulcrum by the lever 99. The resulting force applied by the lever 99 onto the spool 97 is increased, i.e. an equilibrium is reestablished, and the piston 97 is moved to its closing position (S1 and S2 closed).

Fig. 5

Control edges S1 and S2

10

Pressure spring

pP

Pump pressure

11

Pressure spring

SK


17

Spool

T

Tank pressure

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7.15.7


Service Manual

Pump regulation

Fig. 6

Sectional drawing of performance regulator 25

26 49

Flow regulator, complete Regulator housing

91 92

Pressure spring Bushing

81 82


93 94

Spring plate Ball

83 84

Pressure spring O-ring

95 96

Connecting pin (swivel yoke) Return piston

85

O-ring

97

Spool

86 87

Regulator housing Sealing nut

98 99

Piston with slipper (measuring cylinder) Lever

88 89

Adjusting screw Screw plug

pP SK

Working pressure Control chamber pressure

90

Pressure spring (begin of regulation)

T

Tank pressure

Note! Tightening torques: Screw plug 81 / 89 = 35 Nm; sealing nut 87 = 18 Nm.

7.15.8

copyright by

MJFCIFSS

Service Manual

DPVO variable-displacement pump Pump regulation

4.2

Flow regulator 26 (LS regulator) The flow regulator 26 is used to adapt the flow rates of the pump to the requirements of the consumers. The flow regulator 26 is screw-mounted to the mounting plate 49. It consists of the following main components: 3-piece piston 63/64/65 and pressure spring 59 with adjusting screw 52. The spool 62 is held in its controlling position by the equilibrium of the pressures (pP, pLS) and the spring force of the pressure spring 59. When the pressure forces change, the control chamber is connected with the tank, or the pump pressure is applied to the control cylinder. The spring force of the pressure spring 59 and thus the setting of p can be adjusted / set by turning the adjusting screw 52.

Fig. 7

Flow regulator, inserted in regulator housing

26 49

Flow regulator, complete Regulator housing

62 63

Spool Piston

51 52

Screw plug Adjusting screw

64 65

Control sleeve Piston

56

Sealing nut

73

O-ring with backing ring

58

Lock nut

Pp

Pump pressure

59

Pressure spring (adjustment

60

Pressure spring

T

Return channel

61

Seal

X2

Connection control block-LS

X4

Connection T to tank

p)

pLS LS pressure

Note! Screw down the flow regulator 26 all the way to stop. Tighten it with 5 Nm max. Sealing nut 56 = 8 Nm; nut 58 = 120 Nm.

copyright by

MJFCIFSS

7.15.9


Service Manual

Pump regulation

4.3 4.3.1

Regulation of pressure difference

P LS

Stand-by When all consumers are closed, the flow from the pump builds up a backpressure in channel pP. The backpressure acts on the piston 63. If the pressure exceeds the forces of the pressure springs 59/60, the control edge S2 is opened, i.e. the connection between SK and T is opened. The powertrain is swivelled back until the spring forces and the pressure forces on the spool 62 are balanced, or until the powertrain is set to Qmin.

4.3.2

Pivoting out The spool 62 is pushed to the right by the pressure spring 59. The control edge S1 is opened, and the pump pressure pP is applied to the channel SK to the control chamber of the pump. The pump swivels to the large swivel angle and the pumped volume is increased. The pressure building up at the connection pLS (by means of operation of a consumer) increases the sum of the forces acting on the spring side of the spool 62, so that the spool 62 is switched to the right. The control edge S1 is opened. The pump pressure pP is applied through the channel SK to the control camber / control piston. The pump swivels to the large swivel angle. The pumped volume increases. The backpressure pP caused by the increasing pump volume is built up and acts on the piston 63. As soon as it reaches the value set at the pressure spring 59, the spool 62 is moved to the left again until the control edge S1 closes. The pressure pP ceases to act on the control chamber of the control piston, but is not released to the tank or the channel T (as the control edge S2 is still closed). As a result, the powertrain is fixed and the flow rate from the pump is levelled out at a constant value.

4.3.3

Pivoting back If the pump pressure pP at the spool 62 exceeds the total value in pLS (consumer pressure at X2) and the spring force of the pressure spring 59,

the spool 62 is pushed to the left, the control edge S1 is closed, the control edge S2 is opened, and the spool is relieved through SK to the tank. The pump pivots back.

Fig. 8

7.15.10

Control edges S1 and S2 at the flow regulator

51

Screw plug

68

Backing ring

52

Adjusting screw

72

Backing ring

56 58

Sealing nut Nut

73

O-ring

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Service Manual

DPVO variable-displacement pump Adjustment of DPVO variable displacement pump

59 60

Pressure spring (adjustment Pressure spring

62 63 64 65

p)

pP pLS

Working pressure LS pressure

Spool Piston

S1 S2

Pump pressure control edge Tank pressure control edge

Bushing Piston

SK T

Control chamber pressure Tank pressure

66

Bushing

X2

Connection at regulator housing

67

O-ring

X4

Connection at regulator housing

5 Adjustment of DPVO variable displacement pump 5.1

Adjustment of the differential pressure lation

p LS and begin of the hydraulic regu-

Note! The procedure to adjust the differential pressure and begin of regulation of the pump is described in group 6 "Adjustment protocol" and "Adjustment guideline".

4

Locking ring

22

Control piston

5 6

Drive shaft Regulator housing

30 31

Gear pump Sliding disc

7 8

Swivel yoke Cylindrical roller bearing

32 33

Set of discs Return ball

9

O-ring

34

Return plate

10 11

Sliding bearing Roll pin

35 36


12

Pin

37

Connecting link

13

O-ring

38

Hex nut

14 15

Cylindrical roller bearing Pin

39 40

Stop sleeve Pump casing

16

Cylinder with bushing

46

Mounting plate

17

Pilot plate

47

Connecting flange

18

Locking pin (against tampering)

48

Stop screw

19

Piston with slipper

100

Flange with O-ring

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7.15.11


Service Manual

Adjustment of DPVO variable displacement pump

Fig. 9

7.15.12

Sectional drawing of DPVO

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MJFCIFSS

Service Manual

DPVO variable-displacement pump Regulating characteristics

6 Regulating characteristics

Fig. 10

Performance curve of DPVO 165

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MJFCIFSS

7.15.13


Service Manual

Regulating characteristics

7.15.14

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MJFCIFSS

Service Manual

Cooling unit Function and design

Cooling unit 1 Function and design Cooling of the hydraulic oil, the coolant and the intercooling air of the diesel engine. The speed of the hydrostatically driven annular fan RL is controlled according to the cooling requirements (i.e. based on the coolant and hydraulic oil temperature). The flow rate of the hydraulic oil is not controlled. The flow rate of the engine coolant is however thermostat-controlled.

Fig. 1

Cooling unit, e.g. in three parts

6 13

Hydraulic oil cooler Blower motor

FS H

Finger guard Air scoop

14


LLK MWK

Intercooling air cooler / engine Water cooler (coolant) / engine

RL Y352

Annular fan Proportional solenoid valve

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MJFCIFSS

7.20.1

Cooling unit

Service Manual

Function and design

1.1

Cooling elements The cooling unit consists of 2 or 3 cooling elements (depending on model): In models A 309 - A 312, the cooler 6 for the hydraulic oil and the cooler 7 for the diesel engine coolant are mounted in a shared frame equipped with the necessary air baffle plates. In models A 314 - A 316 / R 313 / R 317, the cooler 6 for the hydraulic oil, the cooler for the engine coolant and the cooler for the intercooling air are mounted in a shared frame equipped with the necessary air ducting plates. The annular fan required to produce the air flow (equipped with 8 fan blades as standard) is positioned in the opening of the air duct frame. The annular fan is driven by the gear oil motor 13. The oil motor speed required to produce the necessary air flow is automatically controlled by the BST through the proportional solenoid valve Y352 at the fan motor and the necessary signals from the temperature sensors at the diesel engine and the hydraulic tank. The blower motor 13 is protected with the pressure-relief valve 14, on the proportional solenoid valve Y352, . The pressure relief valve 14 is integrated into the radiator fan circuit and is factory-set.

1.2

Fan control The hydrostatic fan drive is controlled by the hydraulic oil temperature B285 and the coolant temperature B2. The fan speed is controlled electronically, relative to the temperature, through the proportional solenoid valve Y352. Between the above minimum and maximum values, the current of the BST to the solenoid valve Y352 is nearly linear, i.e. each temperature between these two limit points corresponds to a specific current and pressure between min. and max., resulting in a specific fan speed. Note! If Y352 is disconnected, the fan switches to nnot Diagrams of the hydraulic fan control, see 2.2.

Current from BST

Valve position Y352

Fan speed

Imax

Largest opening

nmin

60 - 80 °C oil temperature and 90 - 100 °C coolant temperature

Imax - Imin

Medium opening

nmin - nmax

80 °C oil temperature and 100 °C coolant temperature

Imin

Smallest opening

nmax

Temperature 60 °C oil temperature and 90 °C coolant temperature

7.20.2

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MJFCIFSS

Service Manual

Cooling unit Function and design

Fig. 2

Components of the fan control system

1

Hydraulic tank

30

Gear pump / fan drive (A 309-316)

13 14

Oil motor / fan drive Proportional pressure-relief valve

31 B2

Gear pump / fan drive (R 313 / R 317) Temperature transducer / coolant

15

Coarse filter fan motor

B285 Temperature transducer / hydraulic oil

20

Variable-displacement pump / double variable-displacement pump


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7.20.3

Cooling unit

Service Manual

Function of the fan control

2 Function of the fan control The speed of the blower motor is controlled with the solenoid valve Y352. Depending on the oil and coolant temperature, the BST adjusts the current to the solenoid valve Y352 thus opening and closing it . The more the solenoid valve Y352 is opened, the less hydraulic oil flows to the blower motor 13 and the lower the fan speed. If the temperature of the hydraulic oil in the tank and/or coolant in the engine is equal to or below the lower limit value T Â285 (min.) or T Â2 (min.) respectively, the output current to the solenoid valve Y347 of the BST (U16) is I Y352 (max.). In this case, the pressure at the proportional solenoid valve Y352 is reduced to a low value. This has the effect that the speed of the fan is reduced to the minimum working speed n fan (min.). Surplus oil from pump 31 is returned back to tank through the pressure relief valve 14. If the temperatures increase from minimum to maximum limit value T Â285 (max.) or T Â2 (max.) respectively, the current at the solenoid valve Y352 drops continuously . The pressure in the fan drive system corresponds now to the upper nominal value. Nearly all oil from the pump 31 flows to the fan motor 13. The speed of the fan reaches its upper nominal value nfan (max.). Between the above minimum and maximum values, the current of the BST (U16) to the solenoid valve Y352 is nearly linear, i.e. each temperature between these two limit points corresponds to a specific current I and pressure p between min. and max., resulting in a specific fan speed (see diagrams). In emergency mode, i.e. in the event of a failure of the control system (I = 0 mA), the oil pressure in the hydraulic fan drive reaches the maximum value p(max.) set for the pressure relief valve 14, resulting in maximum speed of the fan n fan (max.).

Fig. 3

7.20.4

Cooling unit and fan circuit

A

Layout from start of series

B

Layout from change in series

1 6

Hydraulic tank Hydraulic oil cooler

31 100

Gear pump (in R 313 / R 317) from compact control block connection K

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Service Manual

Cooling unit Function of the fan control

7 9

2.1

B2 Temperature transducer / coolant B285 Temperature transducer / hydraulic oil

Cooler for motor coolant Annular fan

13

Blower motor

MK

Engine coolant circuit

14


U16


15

Coarse filter (from serial no. 13104)

Y352 Proportional solenoid valve

30

Gear pump (in A 309 - A 316)

Maintenance Maintenance is limited to inspection and cleaning of the cooling unit fins. After a repair on the hydraulic components (defective pump, etc.), the coarse filter 15 in the fan circuit must be inspected for contamination and replaced, if necessary.

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7.20.5

Cooling unit

Service Manual


2.2 2.2.1

Diagrams Diagram of model A 309/ A 311

Fig. 4 Y352 p

7.20.6

Temperature current and current speed and pressure to proportional solenoid valve Pressure in cooling circuit

T n

Temperature of medium (oil, coolant) Speed of annular fan

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Service Manual


2.2.2

Diagram of model A 312

Fig. 5

Temperatures current and current speed and pressure

Y352


T

Temperature of medium (oil, coolant)

p

Pressure in cooling circuit

n

Speed of annular fan

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7.20.7

Cooling unit

Service Manual


2.2.3

Diagram of model R 313

Fig. 6

7.20.8


Y352


T


p


n


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Service Manual


2.2.4

Diagram of model A 314 - R 317

Fig. 7


Y352


T


p


n


Note! Speed during emergency operation (failure of Y352): Inot = 0 mA = nmax p not a the pressure-relief valve 14 = pmax

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7.20.9

Cooling unit

Service Manual


7.20.10

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Service Manual

FMF hydraulic fixed displacement motor Function

FMF hydraulic fixed displacement motor 1 Function The FMF hydraulic fixed displacement motor is of the built-in type. Its purpose is to drive the slewing gear mechanism of the machine. The axial piston motor is of the swash plate design and sits on the slewing gear mechanism of the machine.

Fig. 1


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7.24.1


Service Manual

General information and tightening torques

2 General information and tightening torques A 314 Litronic from 2001 A 316 Litronic from 2001

Machines from serial number Type of oil motor

FMF 45 45 cm3/rev

Oil flow consumption Max. leak oil at max. working pressure Tab. 1

6 l/min

Technical data

Allen head screws 14

118 Nm

Screw plug / leak-oil connection S Pressure relief valve 134 / 135

68 Nm 100-120 Nm

Screw plug / suction valve 133.1 Measuring connection 137 / 138

250 Nm 27 Nm

Note! For the adjustment of the valves 134 / 135: see adjustment protocol and adjustment guideline in group 6.

7.24.2

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Service Manual

FMF hydraulic fixed displacement motor Design

3 Design Axial-piston oil motors are energy converters characterised by the axial alignment of the pistons in the cylinder. The oil motor 130 consists of two main components: Motor housing 12 with powertrain 132 Mounting plate 13 with suction valves 133 and pressure relief valves 134 / 135 Furthermore, there are the measuring connections 137 / 138 at the top of the mounting plate 13. The powertrain pistons 132 with slippers rotate on the swash plate. The inclined arrangement of the slide faces is responsible for the stroke of the pistons in the cylinder and, thus, the constant oil flow consumption of the oil motor. The force resulting from hydraulic pressure and piston areas generates the required torque on the output shaft.

Fig. 2

FMF fixed displacement motor

12

Housing

134

13

Mounting plate

135

130

Oil motor, complete

137

Measuring connection MA

132

Powertrain, complete

138

Measuring connection MB

133

Suction valve

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Pressure-relief valve with additional pressure stage Pressure-relief valve with additional pressure stage

7.24.3


Service Manual

Functional description


Functioning of the oil motor, see Fig. 3 and see Fig. 4 The housing 12 contains 9 pistons 5 that are arranged in a circle, parallel to output shaft 3. They run in cylinder 4, which is geared with output shaft 3. The piston ends are designed as ball joints and sit in the slippers 5.1. They are held by the return ball 8 and the return plate 7 on the fixed inclined eccentric disc 6. The hydrostatic bearing arrangement of the slippers 5.1 on thrust washer 6 (by means of bores in piston 5 and slippers 5.1) reduces the otherwise high friction between the slippers and the eccentric disc to a minimum. When there is no pressure, the pressure springs 8.1 built into the return ball 8 press the cylinder 4 against the disc cam 9. When the pressure increases, the cylinder 4 and the pilot plate 9 are balanced by hydraulic forces in such a way that the oil film at the control surface is maintained at all times, even under high loads, and the amount of leak oil is reduced to a minimum. Some of the leak oil is used to lubricate the moving parts of the powertrain and guided externally back to the tank. If pressure oil is supplied to the operating connections A or B, the respective four pistons 5 are pressurised through the kidney-shaped slots in the pilot plate 9. Another group of four pistons 5 displaces the unpressurised oil through the kidney-shaped slots in the pilot plate 9 and connection B or A to the tank. A ninth piston is situated in the area of the dead centre, i.e. at the point of return of motion. The oil acting on the four pistons on the pressure side generates a certain force determined by the pressure and the piston area. This force acts through the piston 5 and the slipper 5.1 on the eccentric disc 6. The radial component of the above force (together with the limb of the cylinder acting as a lever arm) generates a torque, which is transmitted onto the cylinder 4 and the output shaft 3. The torque can be influenced only by the applied oil pressure, i.e. high pressure = high torque. The two-way pressurisation of the oil motor (connection A or B) results in a change of direction of the torque at drive shaft 3 (left or right-hand rotation). With every rotary motion of cylinder 4, the pistons 5 complete a double stroke. The stroke of the pistons corresponds to the inclination of the eccentric disc 6 and determines the volume of oil consumed. As the oil flow consumption remains constant at all times, it is the travel / output speed of the oil motor that is changed accordingly via the spool when the oil supply changes.

7.24.4

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Service Manual

FMF hydraulic fixed displacement motor Functional description

Fig. 3

Sectional drawing of fixed displacement motor

2

Roller bearing

15

Locking ring

3 4

Output shaft Cylinder

16 17


5 5.1

Piston Slipper

18 19

O-ring O-ring

6 7

Eccentric disc Return plate

22 23

Snap ring Snap ring

8

Return ball

26

Needle bearing

8.1

Pressure spring

27

Shim

9

Pilot plate

28

Shim

10

Locking pin

29

Shim

12

Housing

30

Shim (supplied only with repair set / locking ring

13

Mounting plate

134

Pressure relief valve B with additional pressure stage

13.21

Screw plug

135


14

Allen head screw

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7.24.5


Service Manual


4.2 4.2.1

Functioning of valves on the mounting plate, see Fig. 4 Suction valves 133 The suction valves (acting as check valves) ensure that the oil motor is always properly filled (no cavitation e.g. when relief valves blow off or in the event of leaks). If a vacuum occurs at the connection A or B the cone 133.10 is pushed against the force of the spring 133.14 from its seat, and oil can flow from the connection S to the suction side A or B. This prevents cavitation in the oil motor.

4.2.2

Pressure relief valves with additional pressure level 134 and 135 These valves limit the high pressure that may arise at main connections A and B with respect to the control pressure at connections XAB.

Pressure control If the pressure increases in the slewing gear circuit in undesirable ways, damage would occur at the weakest point, e.g. screwed connections or hydraulic hoses. In order to prevent this, the system is equipped with a pre-determined breaking point. The increasing working pressure in the slewing gear circuit acts on a pressure relief valve. It limits the maximum pressure in the slewing gear circuit and its connection to a pre-set value. As high flows result in pressure on the pressure-relief valves, the machine is equipped with indirectly acting (pilot-controlled) pressure-relief valves. In these valves, a pressure-relief valve is installed as a pilot control valve to actuate a second, larger valve. The applied pressure (in A or B respectively) acts on the front face of the piston (main cone) .19 and through a small bore also on the reverse side of the piston .19, closing it. Simultaneously, the pilot control cone .20 is pressurised. The pressure spring .23 pushes the pilot control cone .20 into its closing position (static status). The pressure springs .24 and .31 serve as return devices. As soon as the pressure in the consumer circuit attains a value exceeding the set value of pressure and adjusting spring .23, pilot control cone .20 is lifted from its seat, and some oil can penetrate into the return channel. As the diameter of the boreholes in the bushing .19 differs from that of the valve insert .18, a differential pressure is built up between the front side and the rear side of the piston .19. As a result of this pressure difference, the piston .19 is shifted against the pressure spring .23, and a substantial amount of oil flows off to the non-pressurised return side 5 or the opposite side.

Additional pressure level If the pilot control valve for the actuation of the slewing gear is not actuated, the connection XAB is relieved. Stage 1 (low pressure = braking pressure - see adjustment protocol of hydraulic system) Connection XAB is connected to the tank: Pressure spring .23 has a lower pre-loading force. The pressure limitation of the relief valve 134 / 135 is set to the low value (level 1). When the pilot control unit for the slewing gear actuation is activated, the pilot control pressure is applied the piston .12 through the connection XAB respectively, the internal boreholes in the mounting plate 13 and the boreholes and the annular gap in the valve 134 / 135. Level 2 (higher pressure = pivoting pressure - see adjustment protocol of hydraulic system) Pressure spring .23 is pre-loaded a bit more by shifting piston .12, ball .21 and spring plate .11, so that there is a higher blow-off pressure. The pressure limitation of the relief valve 134 / 135 is set to the high value (level 2). Adjustment of the relief valves 134 / 135 with additional pressure level: see adjustment protocol and adjustment guideline in group 6.

7.24.6

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Service Manual


Fig. 4

Sectional drawing of mounting plate

13

Mounting plate

134.19 Piston

14

Allen head screw

134.20 Cone

133 Check valve / suction valve 133.10 Cone

134.21 Ball 134.22 O-ring

133.11 Screw plug 133.14 Pressure spring

134.23 Pressure spring 134.24 Pressure spring

133.17 O-ring

134.25 O-ring

134

Pressure relief valve / turn right A with additional pressure stage 134.10 Adjusting screw

134.26 Backing ring

134.11 Spring plate 134.12 Piston

134.28 O-ring 134.29 O-ring

134.13 Nut 134.14 Bushing*

134.30 O-ring 134.31 Pressure spring

134.15 Bushing

134.98 Seal kit

134.16 Nut

135

134.17 Bushing*

137

Pressure relief valve / turn left B with additional pressure level items .10 - 0.98, see 134 Measuring point MA / turn right

134.18 Valve seat

138

Measuring point MB / turn left

134.27 O-ring

* one piece (roller bearing)

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7.24.7


Service Manual

Maintenance and repairs

5 Maintenance and repairs Note! Liebherr oil motors do not require any maintenance whatsoever. For sealing and repair jobs, please refer to separate repair instructions "Liebherr FMF fixed displacement oil motors".

5.1

Sealing jobs on valves on mounting valve Replacement of O-ring 133.17 or spring 133.14 on the suction valves 133: Remove the screw plug 133.11 complete with the measuring connection 137 / 138. Remove the cone 133.10, the spring 133.14 and the O-ring 133.17. Check the cones 133.10 for free movement. Place the new spring or O-ring in the valve, and reassemble it. When installing the valve, tighten the screw plug 133.11 with the measuring connection 137 / 138 (tightening torque: 250 Nm).

Sealing jobs on the pressure relief valves 134 and 135 To seal the valves, use the seal kit .93. For this purpose, remove and/or dismantle the valve 134 / 135 completely, as needed. Check whether the parts are in proper working order and can be reused. Note! After having replaced the defective sealing element, reassemble it and insert it (tightening torque between 100 and 120 Nm). After the replacement of the O-rings .22, .27, .29, the response pressures of the valve must be readjusted. See adjustment guideline and protocol in group 6.

7.24.8

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Service Manual

FMF hydraulic fixed displacement motor Function

FMF hydraulic fixed displacement motor 6 Function The FMF hydraulic fixed displacement motor is of the built-in type. Its purpose is to drive the slewing gear mechanism of the machine. The axial piston motor is of the swash plate design and sits on the slewing gear mechanism of the machine.

Fig. 5


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7.24.11


Service Manual

General information and tightening torques

7 General information and tightening torques A 309 Litronic from 20221 A 311 Litronic from 20222 A 312 Litronic from 12363 A 314 Litronic from 11147 A 316 Litronic from 11152 R 317 Litronic from 18161

Machines from serial number

Type of oil motor

FMF 45 45 cm3/rev

Oil flow consumption Max. leak oil at max. working pressure Tab. 2

6 l/min

Technical data


118 Nm

Screw plug / leak-oil connection S Pressure relief valve 134 / 135

68 Nm 100-120 Nm

Screw plug / suction valve 133.1 Measuring connection 137 / 138

250 Nm 27 Nm

Note! For the adjustment of the valves 134 / 135: see adjustment protocol and adjustment guideline in group 6.

7.24.12

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Service Manual

FMF hydraulic fixed displacement motor Design

8 Design Axial-piston oil motors are energy converters characterised by the axial alignment of the pistons in the cylinder. The oil motor 130 consists of two main components: Motor housing 12 with powertrain 132 Mounting plate 13 with suction valves 133 and pressure relief valves 134 / 135 Furthermore, there are the measuring connections 137 / 138 at the top of the mounting plate 13. The powertrain pistons 132 with slippers rotate on the swash plate. The inclined arrangement of the slide faces is responsible for the stroke of the pistons in the cylinder and, thus, the constant oil flow consumption of the oil motor. The force resulting from hydraulic pressure and piston areas generates the required torque on the output shaft.

Fig. 6

FMF fixed displacement motor

12

Housing

134


13

Mounting plate

135


130

Oil motor, complete

137

Measuring connection MA

132 133

Powertrain, complete Suction valve

138

Measuring connection MB

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7.24.13


Service Manual



Functioning of the oil motor, see Fig. 7 and see Fig. 8 The housing 12 contains 9 pistons 5 that are arranged in a circle, parallel to output shaft 3. They run in cylinder 4, which is geared with output shaft 3. The piston ends are designed as ball joints and sit in the slippers 5.1. They are held by the return ball 8 and the return plate 7 on the fixed inclined eccentric disc 6. The hydrostatic bearing arrangement of the slippers 5.1 on thrust washer 6 (by means of bores in piston 5 and slippers 5.1) reduces the otherwise high friction between the slippers and the eccentric disc to a minimum. When there is no pressure, the pressure springs 8.1 built into the return ball 8 press the cylinder 4 against the disc cam 9. When the pressure increases, the cylinder 4 and the pilot plate 9 are balanced by hydraulic forces in such a way that the oil film at the control surface is maintained at all times, even under high loads, and the amount of leak oil is reduced to a minimum. Some of the leak oil is used to lubricate the moving parts of the powertrain and guided externally back to the tank. If pressure oil is supplied to the operating connections A or B, the respective four pistons 5 are pressurised through the kidney-shaped slots in the pilot plate 9. Another group of four pistons 5 displaces the unpressurised oil through the kidney-shaped slots in the pilot plate 9 and connection B or A to the tank. A ninth piston is situated in the area of the dead centre, i.e. at the point of return of motion. The oil acting on the four pistons on the pressure side generates a certain force determined by the pressure and the piston area. This force acts through the piston 5 and the slipper 5.1 on the eccentric disc 6. The radial component of the above force (together with the limb of the cylinder acting as a lever arm) generates a torque, which is transmitted onto the cylinder 4 and the output shaft 3. The torque can be influenced only by the applied oil pressure, i.e. high pressure = high torque. The two-way pressurisation of the oil motor (connection A or B) results in a change of direction of the torque at drive shaft 3 (left or right-hand rotation). With every rotary motion of cylinder 4, the pistons 5 complete a double stroke. The stroke of the pistons corresponds to the inclination of the eccentric disc 6 and determines the volume of oil consumed. As the oil flow consumption remains constant at all times, it is the travel / output speed of the oil motor that is changed accordingly via the spool when the oil supply changes.

7.24.14

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Service Manual


Fig. 7

Sectional drawing of fixed displacement motor

2 3

Roller bearing Output shaft

15 16

Locking ring Radial shaft seal ring

4

Cylinder

17

O-ring

5 5.1

Piston Slipper

18 19

O-ring O-ring

6 7

Eccentric disc Return plate

22 23

Snap ring Snap ring

8

Return ball

26

Needle bearing

8.1

Pressure spring

27

Shim

9

Pilot plate

28

Shim

10 12

Locking pin Housing

29 30

Shim Shim (supplied only with repair set / locking ring

13

Mounting plate

134


13.21

Screw plug

135

14

Allen head screw

137

Pressure relief valve B with additional pressure stage Measuring point MA / pivot right

138

Measuring point MA / turn left

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7.24.15


Service Manual


9.2 9.2.1

Functioning of valves on the mounting plate, see Fig. 8 Suction valves 133 The suction valves (acting as check valves) ensure that the oil motor is always properly filled (no cavitation e.g. when relief valves blow off or in the event of leaks). If a vacuum occurs at the connection A or B the cone 133.10 is pushed against the force of the spring 133.14 from its seat, and oil can flow from the connection S to the suction side A or B. This prevents cavitation in the oil motor.

9.2.2

Pressure relief valves with additional pressure level 134 and 135 These valves limit the high pressure that may arise at main connections A and B with respect to the control pressure at connections XA / XB.

Pressure control If the pressure increases in the slewing gear circuit in undesirable ways, damage would occur at the weakest point, e.g. screwed connections or hydraulic hoses. In order to prevent this, the system is equipped with a pre-determined breaking point. The increasing working pressure in the slewing gear circuit acts on a pressure relief valve. It limits the maximum pressure in the slewing gear circuit and its connection to a pre-set value. As high flows result in pressure on the pressure-relief valves, the machine is equipped with indirectly acting (pilot-controlled) pressure-relief valves. In these valves, a pressure-relief valve is installed as a pilot control valve to actuate a second, larger valve. The applied pressure (in A or B respectively) acts on the front face of the piston (main cone) .19 and through a small bore also on the reverse side of the piston .19, closing it. Simultaneously, the pilot control cone .20 is pressurised. The pressure spring .23 pushes the pilot control cone .20 into its closing position (static status). The pressure springs .24 and .31 serve as return devices. As soon as the pressure in the consumer circuit attains a value exceeding the set value of pressure and adjusting spring .23, pilot control cone .20 is lifted from its seat, and some oil can penetrate into the return channel. As the diameter of the boreholes in the bushing .19 differs from that of the valve insert .18, a differential pressure is built up between the front side and the rear side of the piston .19. As a result of this pressure difference, the piston .19 is shifted against the pressure spring .23, and a substantial amount of oil flows off to the non-pressurised return side 5 or the opposite side.

Additional pressure level If the pilot control valve for the actuation of the slewing gear is not actuated, the connection XA / XB is relieved. Stage 1 (low pressure = braking pressure - see adjustment protocol of hydraulic system) Connection XA and/or XB is connected to the tank. Pressure spring .23 has a lower pre-loading force. The pressure limitation of the relief valve 134 / 135 is set to the low value (level 1). When the pilot control unit for the slewing gear actuation is activated, the pilot control pressure is applied the piston .12 through the connection XA or XB respectively, the internal boreholes in the mounting plate 13 and the boreholes and the annular gap in the valve 134 / 135. Level 2 (higher pressure = pivoting pressure - see adjustment protocol of hydraulic system) Pressure spring .23 is pre-loaded a bit more by shifting piston .12, ball .21 and spring plate .11, so that there is a higher blow-off pressure. The pressure limitation of the relief valve 134 / 135 is set to the high value (level 2). Adjustment of the relief valves 134 / 135 with additional pressure level: see adjustment protocol and adjustment guideline in group 6.

7.24.16

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Service Manual


Fig. 8 13 14

Sectional drawing of mounting plate 134.19 Piston 134.20 Cone

Mounting plate Allen head screw

133 Check valve / suction valve 133.10 Cone

134.21 Ball 134.22 O-ring

133.11 Screw plug

134.23 Pressure spring

133.14 Pressure spring 133.17 O-ring

134.24 Pressure spring 134.25 O-ring

134

Pressure relief valve / turn right A with additional pressure stage 134.10 Adjusting screw

134.26 Backing ring

134.11 Spring plate

134.28 O-ring

134.12 Piston 134.13 Nut

134.29 O-ring 134.30 O-ring

134.14 Bushing* 134.15 Bushing

134.31 Pressure spring 134.98 Seal kit

134.16 Nut

135

Pressure relief valve / turn left B with additional pressure stage, items .10 - 98, see 134

134.17 Bushing*

137

Measuring point MA / turn right

134.18 Valve seat

138

Measuring point MB / turn left

134.27 O-ring

* one piece (roller bearing)

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7.24.17


Service Manual


10 Maintenance and repairs Note! Liebherr oil motors do not require any maintenance whatsoever. For sealing and repair jobs, please refer to separate repair instructions "Liebherr FMF fixed displacement oil motors".

10.1

Sealing jobs on valves on mounting valve Replacement of O-ring 133.17 or spring 133.14 on the suction valves 133: Remove the screw plug 133.11 complete with the measuring connection 137 / 138. Remove the cone 133.10, the spring 133.14 and the O-ring 133.17. Check the cones 133.10 for free movement. Place the new spring or O-ring in the valve, and reassemble it. When installing the valve, tighten the screw plug 133.11 with the measuring connection 137 / 138 (tightening torque: 250 Nm).

Sealing jobs on the pressure relief valves 134 and 135 To seal the valves, use the seal kit .93. For this purpose, remove and/or dismantle the valve 134 / 135 completely, as needed. Check whether the parts are in proper working order and can be reused. Note! After having replaced the defective sealing element, reassemble it and insert it (tightening torque between 100 and 120 Nm). After the replacement of the O-rings .22, .27, .29, the response pressures of the valve must be readjusted. See adjustment guideline and protocol in group 6.

7.24.18

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Service Manual

LMV regulating motor Function

LMV regulating motor 1 Function The axial-piston oil motor is of the swash-plate type. It is flange-mounted to the transmission of the machine. The flow from the variable-displacement pump is fed through brake valve "Connection A or B" to the oil motor and acts on the pistons of the powertrain. The pistons (moving in the axial direction inside the cylinder of the powertrain) act on the cylinder and drive shaft and generate a certain torque. The regulating and adjusting unit adjusts the pivot angle to the flow consumption of the oil motor (depending on the operating pressure). The variable flow consumption of the oil motor determines the torque and speed of the drive shaft. Both values are in inverse ratio, i.e.: Large flow consumption

=

large torque, low rpm, low speed

Small flow consumption

=

small torque, high rpm, high speed

Fig. 1

LMV regulating motor

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7.26.1


Service Manual

General information

2 General information Machine from serial number Design Oil motor

Unit

A 314-Li 2001 N

A 314-Li 2001 Speeder

A 316-Li 2001 N

A 316-Li 2001 Speeder

Type

LMV 100

LMV 100

LMV 100

LMV 140

Max. oil flow consumption

cm3/rev

100

100

100

140

Oil flow consumption min.

cm3/rev

49

49

49

49

bar

240

240

240

240

Begin of regulation (1) End of regulation Max. admissible amount of leak oil

bar

320

320

320

320

l/min

8,0

8,0

8,0

8,0

mm

11.0

11.0

11.8

14.0

rpm

1780±25

2670±25

1860±25

2790±25

86

115

82

105

380+20

380+20

380+20

380+20

Adjustable settings of oil motor A

B

C

Regulation end of oil motor Min. pivot angle Measure X (standard value), see Fig. 4 Drive shaft speed (jacked up) Travel pressure (2) Secondary pressure-relief valves

Tab. 1

bar

Technical data

(1) This value is only for orientation. It actually depends on the setting of end of regulation and the min. pivot angle Qmin. to be attained. It is not necessary to set the beginning of regulation. However, you can measure this value when you check the end-of-regulation value. See group 6.34. (2) This value depends on the friction factors in the gearbox and axles of the machine. Remember, it is a standard given only for orientation. Tolerances of up to ± 20 bar are possible. Execute checks and adjustments of values A, B and C as described in group 6.34.

7.26.2

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Service Manual

LMV regulating motor Design

3 Design The LMV regulating motor consists of the following main components: Mounting plate 100 Travel motor 170 with drive shaft Regulating unit 173 Spool / regulating unit 174 Travel brake valve 190 The travel motor consists of the motor housing with integrated drive shaft, swivel yoke, regulating and adjusting unit. The mounting plate 100 carries the secondary pressure-relief valves 176 / 177. The control cylinder 173 and the spool 174 sit directly on the travel motor 170. The brake valve 190, acting in both travel directions, is mounted directly on the mounting plate 100.

Fig. 2

Design of LMV regulating motor

100

Mounting plate

176

Secondary pressure-relief valve

170 173

Travel motor, complete Control cylinder

177 190

Secondary pressure-relief valve Brake valve, complete

174

Spool

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7.26.3


Service Manual



Functioning of powertrain, see Fig. 3 The housing 2 contains 9 pistons 77.1 that are arranged in a circle, parallel to the drive shaft 95. They run in axial arrangement in cylinder 75, which is in gear with the drive shaft 95. The piston ends are designed as ball joints and sit in the slippers 77.2. They are held in place by the swivel yoke 84 (swash plate) by the return ball 78.1 and the return plate 78.2. The hydrostatic bearing arrangement of the slippers 77.2 on the sliding disc 85 in the swivel yoke 84 (by means of bores in the piston 77.1 and the slippers 77.2) reduces the otherwise high friction between the slippers and the sliding disc to a minimum. When there is no pressure, the cylinder 75 is pressed by the pressure springs 78.2 in the return ball 78.1 against the pilot plate 79. When the pressure increases, the cylinder 75 and the pilot plate 79 are balanced by hydraulic forces in such a way that the oil film at the control surface is maintained at all times, even under high loads, and the amount of leak oil is reduced to a minimum. Some of the leak oil is used to lubricate the moving parts of the powertrain and guided externally back to the tank. If pressure oil is supplied to the operating connection "A or B", pressure is applied to four pistons through kidney-shaped slots in the pilot plate 79. Another four pistons press the non-energised oil through the kidney-shaped openings in the piston plate 79 through the connection "A or B" and the brake valve 190 (see Fig. 2) to the tank. A ninth piston is situated in the area of the dead centre, i.e. at the point of return of motion. The oil acting on the four pistons on the pressure side will generate a certain force resulting from pressure and piston area. This force acts through the piston 77.1 and the slipper 77.2 on the swivel yoke 84. The radial component of the above force (together with the limb of the cylinder acting as a lever arm) generates a torque, which is transmitted to the cylinder 75 and the drive shaft 95. For every rotary motion of cylinder 75, the pistons execute one stroke. That stroke corresponds to the inclination of swivel yoke 84 and determines the amount of oil consumed. The stroke of the pistons can be modified by changes to the angle of the swivel yoke. Speed and torque will follow and adjust to the resulting pressure. Changing the side of the oil motor that bears the pressure (connection A or B) will lead to a change of direction of the torque and drive shaft (right or left-hand rotation = travel forward or reverse, respectively). The drive shaft 95 is borne with the roller bearings 32 and 33 in the mounting plate 100 and the mounting flange 98. The gap between the housing 2 and the drive shaft 95 is sealed with the shaft seal 35 and O-ring 36 in the locking ring 97. The seal 15 seals off the contact faces of the mounting flange 98 and the housing 2 to the outside.

7.26.4

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Service Manual

LMV regulating motor Functional description

Fig. 3

Sectional drawing: travel motor / powertrain 170

2

Housing

75

5 12

Adjusting device Flange

77.1 Piston (172*) 77.2 Slipper

15 18

Seal O-ring

78.1 Return ball with pressure spring 78.2 Return plate

20 21


79 84

Pilot plate Swivel yoke

25

Allen head screw

85

Sliding disc

29

Allen head screw

87

Actuation device (174*)

32


95

Drive shaft

33


97

Locking ring Mounting flange

Cylinder (172*)

34


98

35 36


100 Mounting plate 170* Travel engine

40

Snap ring

172* Powertrain

41

Snap ring

173* Regulating unit / control cylinder (see Fig. 5)

44

Shim ring

174* Regulating unit / spool (see Fig. 6)

70

Spacer ring

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7.26.5


Service Manual

Functional description * items in hydraulic diagram

Fig. 4

4.2 4.2.1

Sectional drawing of the regulating unit of the regulating motor, actuating device and control cylinder

Functioning of the regulating unit (control cylinder), see Fig. 5 System is without pressure; or high pressure below begin of regulation When the system is without pressure, the pressure spring 14 holds the control piston 10 in the control cylinder 173 in the direction of Qmin. The pressure oil from the respective high pressure side A or B respectively, acts on the small piston surface (spring side) of the control piston 10 through the check valves 3 and the internal bores in the mounting plate 100, Fig. 7. The swivel yoke 84 is switched to small pivot angle (Qmin.) = large output speed; low oil flow consumption - low speed. This happens via the control neck with sliding block 30 that engages with the control piston 10. The travel of the control piston 10 in the direction of min. pivot angle is limited by the stop screw 13.

4.2.2

High-pressure value above begin of regulation High-pressure oil is fed through the control piston and the restrictor 20 to the large surface of the control piston 10. Due to the larger size of the effective piston surface, the control piston 10 moves the control neck with sliding block 30 of the swivel yoke 84 in the direction of the large swivel angle = smaller output speed; high oil flow consumption - high torque. The maximum pivot angle is limited by the guide ring 19 (dead stop). The hydraulic connection between the spool and the control piston is locked after a relative movement of control piston 10, and the adjustment procedure comes to an end. This happens thanks to the mechanical connection between the control piston 10 and the regulating spring .24, via the lever .25 (see Fig. 6). If high pressure attains the value in question (end of regula-

7.26.6

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Service Manual


tion), the regulating motor is at max. pivot angle. If the high pressure drops, the large surface of the control piston 10 is relieved and the powertrain is adjusted with the control piston 15 to a smaller swivel angle.

Fig. 5

Sectional drawing of the regulating unit / control cylinder 173

10

Control piston

21

Allen head screw

11 12

Lid Lid

22 23

O-ring Backing ring

13

Stop screw

25

Seal ring

14

Pressure spring

26

O-ring

15

Lock nut

27

Guide bushing

16 17

Protective cap O-ring

28 30

Circlip Sliding block

18

Backing ring

84

Swivel yoke

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7.26.7


Service Manual


Guide ring

20

Restrictor

173* Regulating unit / control cylinder


4.3 4.3.1

Functioning of the regulating unit (actuation device 87), see Fig. 5 / Fig. 6 System is without pressure; or high pressure below begin of regulation The pressure oil of the relevant high pressure side A or B acts on the spool .11 (measuring cylinder .43) of the actuation device 87, via connection G of the flanged-mounted brake valve and the internal bores in the mounting plate 100. If the high pressure value is below the begin of regulation set at the adjusting screw .41, the spring .19 pushes the spool .11 through the guide rod .13 against the right stop in the direction of the shim .21. The large piston surface of the control piston is relieved and the powertrain is set to Q min through the control piston 10.

4.3.2

High-pressure value above begin of regulation If the high pressure value rises above the pressure value for begin of regulation, the spool .11 is moved against the guide rod .13 and the adjusting spring .19. As soon as the control edge of the spool .11 opens, high pressure oil flows through the restrictor 20 to the large surface of the control piston 10. The control piston 10 pushes the swivel yoke 84 towards the larger pivot angles. The mechanical connection between the control piston and the regulating spring .24 through the lever .25 has the effect that regulating spring .24 is preloaded to a higher degree during adjustment. That means, the spool .11 is pushed into closing position after a relative movement of the control piston, and the adjustment procedure comes to an end. If high pressure attains the value in question (end of regulation), the regulating motor is at max. pivot angle. As soon as the high pressure goes down again, below begin of regulation, the spring force of the regulating spring .24 is higher again than the hydraulic force at the spool .11. That means, the powertrain is switched to a smaller pivot angle.

4.3.3

Creeper gear mode With the push button S21 on the right control desk and the solenoid valve Y24 (see hydraulic system, group 6) in the control oil unit, it is possible to maintain the oil motor constantly at max. pivot angle (creeper gear mode). When the button S21 is pushed, the pilot pressure is guided through the control connection "X" to the spool .11, which is then shifted against the pressure springs .19 and .24. That means, the high pressure is applied and immediately acts on the large face of the control piston (independent of regulation settings) so that the oil motor is switched to a large pivot angle. The machine has a great tractive power.

4.3.4

Protecting the oil motor, see Fig. 7 The two pilot-controlled pressure-relief valves .1 on the mounting plate 100 provide secondary protection for the oil motor against reaction forces from the outside and, thus, excess pressure.

7.26.8

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Fig. 6

Sectional drawing of regulating unit / actuation device 87

.01 .10

Screw Regulating valve (housing)

.24 .25

Regulation spring Lever

.11 .12

Spool Spring plate

.26 .27

Lock nut Plug

.13

Guide rod

.28

Screw plug

.14 .15

Lid Control sleeve

.29 .34

Guide Snap ring

.16 .17

Guide Lid

.35 .39

Axle Allen head screw

.18 .19

Guide sleeve Pressure spring (begin of regulation)

.41 .42

Adjusting screw Ball

.20

Seal

.43

Measuring cylinder

.21

Shim

.45

Snap ring

.22

Spring plate

.46

Pin

.23

Seal ring

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7.26.9


Service Manual


Fig. 7

7.26.10

Sectional drawing of mounting plate 100

.1

Secondary relief valve (176* travel forward)

.13

O-ring

.1

.14

O-ring

.3

Secondary relief valve (177* travel forward) Check valve (175*)

15

Allen head screw

.4

Screw plug

172* Powertrain

.10

Mounting plate

A/B

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Bores (high pressure from control valve block)

Service Manual

LMV regulating motor Maintenance and inspection

0.12 Screw plug

G

Bores (high pressure from shuttle valve 195 in brake valve


5 Maintenance and inspection 5.1

Maintenance and repair works on oil motor Liebherr oil motors do not require any maintenance whatsoever. For sealing and repair work, please refer to the separate repair instructions "LMV regulating motor". This hydraulic regulating motor has been pre-set by the manufacturer and must not be changed. In the event of malfunction of the motor, check the control function. To do this, proceed as described in the adjustment guidelines and the adjustment protocol, see group 6. Danger! For inspection, adjustment and repair work, it is necessary to access the undercarriage. This can be dangerous for technicians. There is a risk of serious injury or even death from rotating wheels and shafts, or if the machine begins to move. Always apply the parking brake. Place the attachment on the ground. Establish visual or acoustic contact with the operating personnel.

5.2

Checking oil motor for leakage Disconnect the hose L leading from the connection T1 of the oil motor to the lower rotary connection and seal the connection. Apply the machine brakes, and pressurise the oil motor to the maximum high pressure. Collect leak oil from the oil motor, in a suitable and sufficiently large container, using the hose L. Determine how much leak oil has been collected and compare this volume to the max. admissible value, (see Technical data on page 2). Oil motors producing too much leak oil should be replaced. Re-connect the hose L.

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Service Manual

Secondary pressure-relief valves 1 (176* / 177*)

Fig. 8

Leak oil connection T1 at the oil motor

6 Secondary pressure-relief valves 1 (176* / 177*) 6.1

Function The secondary pressure-relief valves 1 are of the cartridge type and screwed directly into the mounting plate of the regulating motor. They put a limit on the pressure between the oil motor and the control valve block when the spools are closed (secondary function). The high pressure in the oil motor acts on the pressure-relief valve. It limits the maximum pressure in the consumer and its connection to the pre-set value. As high flows result in pressure on the pressure valves of the hydraulic unit, the machine is equipped with indirectly responding (pilot-controlled) pressure-relief valves. In these valves, a direct-acting pressure-relief valve is installed acting as a pilot control valve to actuate a second, larger valve.

6.2

Function of pressure-relief valve, see Fig. 9 The pressure (P) built up in the consumer circuit acts on the front face of the main piston .2 and, through the bore A, also on the rear face of the main piston .2. At the same time, the pressure acts also on the pilot control cone .5. The pressure springs .3 and .6 push the main piston .2 and the pilot control cone .5 into their closing positions (static status). As soon as the pressure in the oil motor reaches a value above the adjusting value for the pressure and adjusting spring .6 (due to external forces acting on the powertrain), the pilot control cone .5 is lifted from its seat and a little oil is released into the return channel (T1). Due to the different cross-sections of the bores A in the main piston .2 and B in the valve insert .4 respectively, there is a pressure difference between the front and the spring side of the main piston .2. As a result of this pressure difference, the main piston .2 is shifted against the pressure springs .3, and a substantial amount of oil flows off to the non-pressurised return side (T2). The pressure in the system drops, and the main piston .2 is again pushed against the sealing edge at the front part of the housing .1. Furthermore, the adjusting spring .6 pushes the pilot control cone .5 against the valve insert .4, i.e. the connection between pressurised side and return side (T1/T2) is closed.

7.26.12

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Service Manual

LMV regulating motor Exploded view / sectional drawing

7

Exploded view / sectional drawing

Fig. 9

Exploded view and sectional drawing of secondary pressure-relief valve 1 (176* / 177*)

1

Valve

.24

O-ring

.1

Housing (rolled up)

.25

O-ring

.1.1 .1.2

Housing - front part Housing - back part

.26 .27

O-ring O-ring

.2

Main piston

.28

Backing ring

.3 .4

Pressure spring Valve insert

.7 .8


.5 .6

Pilot control cone Pressure spring

.10 999

Protective cover O-ring (seal kit)

A B

Bore / main cone Bore / valve insert

T1 T2

Outlet pilot control cone Outlet main cone

P

High pressure

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Service Manual

Brake valve

8 Brake valve 8.1

Function The travel brake valve is flanged to the mounting plate of the regulating travel motor 170*. During downhill travel or deceleration of the machine, it prevents insufficient filling and over-speeding of the regulating travel motor. Insufficient filling (cavitation) can become a problem when the speed of the oil motor exceeds the speed corresponding to the oil flowing in from the control block due to some sort of external drive (via axles and gearbox). In such a case, brake valve 190* restricts the return flow going back to the tank. The drive is thus slowed down hydraulically while overspeeding of the oil motor is prevented.

8.2 8.2.1

Functioning of brake valve Function of brake valve 190* during travel High-pressure oil flows through the connection A / B, the check valve 210 - 230 (196*) and the connection A / B to the mounting plate 100 where it acts on the powertrain of the oil motor 170*. The return oil from the oil motor flows via the connection A / B back to the brake valve. The check valve 210 - 230 (196*) closes so that the brake piston 20 (192*) (in closing position) is throttled via the ring gap (reduced diameter) at the end of the pistons and the shuttle valve 50 / 140 (193*) and is, thus, slowly shifted against the pressure spring 170. The brake piston opens, and the return oil can flow via the opening check valve 200 / 220 / 250 (194*) connection B to the return side (tank) of the control valve block.

8.2.2

Braking function During downhill travel or deceleration, the operating pressure (high pressure) goes down. That means, the pressure at the brake piston 20 (192*) drops as well. Pressure spring 170 pushes the brake piston 20 (192*) into braking position. The connection of the return oil from the oil motor from connection B / A to connection B / A is restricted, i.e. the oil flow (and, thus, the speed of the oil motor) is reduced. The small bores in the cone 230 let a small amount of oil flow directly to the return side in advance, and, thus, prevent a jerky slowdown, especially when the oil is cold.

7.26.14

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Service Manual

LMV regulating motor Brake valve

Fig. 10

Sectional drawing of brake valve 190*

10 20

Housing Brake piston

230 250

Valve cone Screw plug

30

Pin

300

Shuttle check valve

40 50

Valve seat Valve seat

310 999

Screw plug O-ring (seal kit)

70 100

Spring plate Screw plug

190* Brake valve

110 140

Screw plug Restrictor bolt

192* Brake piston 193* Shuttle valve

170

Pressure spring

194* Check valve

200 210

Cone Guide

195* Shuttle valve 196* Check valve

220

Pressure spring


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Service Manual

Brake valve

Fig. 11

Exploded view of brake valve

10 20

Housing Brake piston

210 220

Guide Pressure spring

30 40

Pin Valve seat

230 250

Valve cone Screw plug

50 70

Valve seat Spring plate

300 310

Shuttle check valve Screw plug

100

Screw plug

420

Screw plug

110

Screw plug

480

Hex nut

140

Restrictor bolt

490

Mounting bolt

170 200

Pressure spring Cone

999

O-ring (seal kit)


7.26.16

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Service Manual

DMVA regulating motor Design of hydraulic travel motor

DMVA regulating motor 1 Design of hydraulic travel motor The axial-piston oil motor is of the swash-plate type. It is flanged to the transmission of the machine. It consists of a motor housing with built-in powertrain, swivel yoke and a mounting plate with regulating and adjusting unit. The mounting plate features a brake valve working in both directions of travel. The mounting plate is also equipped with the secondary pressure-relief valves and the suction valves. The flow volume of the variable displacement pump is fed through connections A or B to the travel motor and acts on the piston of the powertrain. The pistons (moving in the axial direction inside the cylinder of the powertrain) act on the cylinder and drive shaft and generate a certain torque. The regulating and adjusting unit built into the mounting plate adjusts the pivot angle to the flow consumption of the oil motor (= flow consumption of the travel motor). The variable flow consumption of the travel motor determines the torque and speed of the drive shaft. Both values are in inverse ratio, i.e.: High flow consumption Qmax = high torque = low speed of travel motor Low flow consumption Qmax = low torque = high speed of travel motor The brake valve integrated into the mounting plate restricts the return flow to the control valve block or the tank respectively, while the pressure in the feed line is reduced, thus slowing down the drive. This approach prevents overspeeding of the travel motor when travelling down a slope and consequent cavitation.

Fig. 1

DMVA travel motor

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7.27.1


Service Manual

Technical data

2 Technical data Machine

A 312 Litronic /

from serial number

A 309 Litronic / A 311 Litronic 20221

Oil motor

DMVA 108

DMVA 108

12363


106.5

cm3/rev

106.5 cm3/rev

Oil flow consumption min. Standard machine Speeder

52.3 cm3/rev 38.5 cm3/rev

48.8 cm3/rev 48.8 cm3/rev

Begin of regulation (high pressure)

240 bar

240 bar

End of regulation (high pressure)

340 bar

340 bar

Max. pivot angle

22°

22°

Min. pivot angle

10,8°

10,8°

Max. permissible leak oil volume

7 l/min

7 l/min

240 bar

240 bar


Begin of regulation of the oil motor at the adjusting screw

B

Qmin. pivot angle Dimension X of the stop screw 35 (guide value) Standard machine Speeder

23.8 mm 26 mm

14.8 mm -

Drive shaft speed Standard machine Speeder

1500 rpm (±25 rpm) 1930 rpm (±25 rpm)

1850 rpm (±25 rpm) 2780 rpm (±25 rpm)

High pressure

115 bar

115 bar

Secondary pressure-relief valves

380+20 bar

380+20 bar

C

D Tab. 1

7.27.2

Technical data of the travel motor for machines A 309 Litronic to A 312 Litronic

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Service Manual

DMVA regulating motor Technical data

Machine

A 316 Litronic

from serial number

28061

Oil motor

DMVA 165


165 cm3/rev

Oil flow consumption min.

94 cm3/rev

Begin of regulation (high pressure)

190 bar

End of regulation (high pressure)

250 bar

Max. pivot angle

22°

Min. pivot angle

10,8°

Max. permissible leak oil volume

7 l/min


Begin of regulation of the oil motor at the adjusting screw

B

Qmin. pivot angle Dimension X of the stop screw 35 (guide value) Standard machine Speeder

21 mm -

Drive shaft speed

1680 rpm (±25 rpm)

Adjusting screw 92 for stroke limitation of the control axle 160 (dimension Y)

16.7 mm 12.9 mm* 115 bar

C

190 bar

High pressure D Tab. 2


380+20 bar

Technical data of the travel motor for model A 316 Litronic

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Service Manual

Design

3 Design The travel motor consists of the following main components: Powertrain 172 Mounting plate 30 Regulator 174 80

172

The housing 80 is screwed to the mounting plate 30. The mounting plate contains the secondary pressure-relief valves, the control and regulating unit and the brake valve acting in both directions of travel.

Fig. 2

7.27.4

Design of the travel motor

30

Mounting plate

172

Complete powertrain

60

Regulator, complete

176


80

Housing

177


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Service Manual

DMVA regulating motor Functional description of the travel motor

4 Functional description of the travel motor see also sectional drawing on page 7.27.21

4.1

Function of powertrain The housing 80 encloses the powertrain 172 with the drive shaft 4, cylinder 3, piston 2 with slipper, etc. Parallel to the drive shaft 4, there are nine pistons 2 arranged in a circle. They run in axial arrangement in the cylinder 3, which is in gear with drive shaft 4. The bottom ends of the pistons are designed as ball joints and sit in slippers. They are held on the swivel yoke 9 by the return ball 6 and the return plate 7 (swash plate). The hydrostatic bearing of the slipper on the sliding disc 8 of the swivel yoke 9 (through bores in the piston 2 and the slippers) reduces the high surface pressure between the slipper and the swivel yoke 9 to a minimum. When there is no pressure, the cylinder 3 is pressed by the pressure springs 13 in the return ball 6 against the pilot plate 5. When the pressure increases, the cylinder 3 and the pilot plate 5 are balanced by hydraulic forces in such a way that the oil film at the control surface is maintained at all times, even under high loads, and the amount of leak oil is reduced to a minimum. Some of the leak oil is used to lubricate the moving parts of the powertrain and guided externally back to the tank. If pressure oil is supplied to the operating connections A or B, the respective four pistons are pressurised through the kidney-shaped slots in the pilot plate 5. Another four pistons press the non-energised oil through the kidney-shaped openings in the piston plate 5 through the connection A or B to the tank. A ninth piston is situated in the area of the dead centre, i.e. at the point of return from the pressure to the suction phase. The oil acting on the four pistons on the pressure side will generate a certain force resulting from pressure and piston area. This force acts via the pistons 2 with slippers onto the swivel yoke 9. The radial component of the above force (together with the section of the cylinder acting as a lever arm) generates a torque which is transmitted onto the cylinder 3 and the drive shaft 4. Changing the side of the travel motor (connection A or B) results in a change of direction of the torque at the drive shaft 4 (clockwise or anticlockwise rotation respectively). For every rotary motion of the cylinder 3, the pistons execute a double stroke. This stroke corresponds to the inclination of the swivel yoke 9 and determines the amount of oil consumed Q.

4.2

Function of the regulating unit The sectional drawing shows the following regulating positions of the travel motor: The powertrain 172 (swivel yoke 9) is already set to a maximum swivel angle. The working pressure acts on the large piston surface of the spool 173 (minimum pressure: pressure at end of regulation), (see table on page 2 or 3, depending on machine model). The regulating piston 174 is in regulating position, i.e. the flow from the high pressure side through the check valve 52 to the large piston surface of the spool 173 and the flow from the large piston surface of the spool 173 to the tank side are blocked. The maximum swivel angle is determined by the stop of the spool 173 at the guide bushing 33. The motor remains in this position, until the high pressure drops below the pressure value at the end of regulation. Within the regulated range, the travel motor can reach any position that corresponds to a working pressure of between Qmax and Qmin. If the working pressure drops below the value at the begin of regulation, the spool 173 touches the stop screw 35, i.e. the travel motor's flow consumption capacity is lowest at high drive shaft speed, high speed and low drawing pull.

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Service Manual

Functional description of the travel motor

Fig. 3

Sectional drawing at the begin of regulation (spool)

32 Mounting plate

38 Lock nut

33 Guide bushing

42 Bolt

34 Connecting link

50 Measuring connection of the actuating pressure M

35 Stop screw

4.3

Function prior to the begin of regulation The pressure oil from the respective high pressure side A or B respectively, acts on the piston ring surface of the spool 173 through the check valves 52 and the internal bores in the mounting plate 32. The swivel yoke 9 is kept at a small swivel angle by the connecting link 34. The minimum swivel angle is limited by the stop screw 35, (see Fig. 3, page 6). The working pressure acts on the spool 174 through the check valves 52. The spool 174 is held by the preloaded adjusting spring 68 in its blocking position so that the flow from the high pressure side through the check valve 52 to the large piston surface of the spool 173 is blocked. The flow from the large piston surface of the spool 173 to the tank side is opened. The travel motor remains in this position, until the working pressure rises above the pressure value at the begin of regulation, (see table on page 2 or 3, depending on machine model).

4.4

Function from begin of regulation The spool 174 is held in the regulating position by the adjusting spring 68 and the return spring 69 (+ the working pressure acting on the shuttle check valve 195). Regulating position of the spool 174 spring force of the return spring 69 + force resulting from the working pressure on the surface difference = spring force of the adjusting spring 68. If the existing working pressure rises above the value at the begin of regulation, it acts on the surface difference Ø D - Ø d, (see Fig. 5, page 7) of the spool 174, pushing it against the adjusting spring 68. The edge of the control spool 174 opens the oil flow to the large piston surface of the spool 173. The surface difference of the spool 173 generates the necessary actuating force to swivel the powertrain in direction Qmax. As a result, the powertrain is swivelled to a large swivel angle. The push rod 67 acts as a sensing device and relieves the return spring 69, so that the force ratio between the adjusting spring 68 + return spring 69 differs from the working pressure. As a result, the spool 174 returns to its regulating position (= closed position) and the actuating procedure is completed, (see Fig. 4, page 7). At the respective working pressure (end of regulation) the powertrain is set again to the maximum swivel angle.

7.27.6

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Fig. 4

Sectional drawing of the regulator

61

Bushing

69

Pressure spring (regulating spring)

62 63

Bushing Spring plate

72 174

Ball Spool

64 65

Adjusting screw Spring plate

A B

High pressure through valve 52 Pressure to control piston 173

66

Spring plate

C

High pressure through valve 195

67 68

Push rod Pressure spring (adjusting spring)

T

to tank

Fig. 5

Magnified view of the surface difference (detail Z)

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7.27.7


Service Manual

Functional description of the travel motor

4.5

Protection The two pilot-controlled pressure-relief valves 176 / 177 protect the travel motor against overpressure (secondary protection). The suction valves (check valves) 194 prevent cavitation when the secondary pressure-relief valves 176 / 177 respond.

Fig. 6 52 173

4.6

Arrangement of the valves for pressure protection 176/177 194

Check valve Control piston

Secondary pressure-relief valves Check valve

Creeper gear mode The travel motor is kept at a maximum swivel angle (creeper gear mode) with the switch S21 (standard equipment) on the control console and the solenoid valve Y24 located on the control oil unit. When the switch S21 is actuated, the pilot control pressure from the solenoid valve Y24 acts through the control connection "X" onto the spool 174, which is then pushed against the pressure spring 68. As a result, the high pressure immediately acts on the large surface of the control piston 173 (independent of regulation settings) so that the travel motor is switched to a maximum pivot angle. The oil motor remains set to high consumption flow and the fine control of the powertrain is improved.

7.27.8

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Service Manual


4.7

Functioning of brake valve When a travel motion of the machine is initiated, the working pressure that is being built up acts through the restrictor bolt 193 (restrictor check valve) onto the brake piston 192 and pushes it against the pressure spring 48. As a result, the flow is opened on the return side A or B so that the oil is displaced to the tank. If the pressure in the feed line A or B drops, be it as a result of a steering movement or a change in load, for example during travel down a slope, the pressure in the spring chamber is reduced through the restrictor bolt 193. The brake piston 192 is put into braking position by the pressure spring 48, whereby the equilibrium of forces between the high pressure at the brake piston 192 and the pressure spring 48 determines the automatic brake function. Irregular braking of the travel motor is prevented by the check valves 196 with bypass bores, see page 7.27.21.

Fig. 7

Arrangement of the valves for the brake function

45 Valve seat

52

Check valve

46 Spring plate

192

Piston

47 Cover

193

Restrictor bolt

48 Pressure spring

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7.27.9


Service Manual


5 Maintenance and repairs Note! Liebherr oil motors do not require any maintenance whatsoever. For sealing and repair work, please refer to the separate repair instructions for DMVA regulating motors.

6 Checking and adjusting the travel motor Danger! For inspection, adjustment and repair work, it is necessary to access the undercarriage. This can be dangerous for technicians. There is a risk of serious injury or even death from rotating wheels and shafts, or if the machine begins to move. Extend the supports. Place the attachment onto the ground and lift the undercarriage from the ground, if necessary. Apply the parking brake. Establish visual or acoustic contact with the operating personnel. Note! This travel motor has been pre-set by the manufacturer and its settings should not be changed.

6.1

Checking and adjusting the begin of regulation of the travel motor The checking and adjustment of the begin of regulation of the travel motor is described in detail in group 6 "Adjustment protocols and guidelines".

6.2

Checking and adjusting of the maximum output speed / maximum travel speed (setting C) Note! The maximum output speed of the travel motor is determined by the minimum flow consumption of the oil motor and the maximum volumetric delivery of the pump. The maximum speed is factory-set by the manufacturer and may not be changed. In models A 309 and 311, the minimum flow consumption of the oil motor is only determined by the Qmin stop screw 35. In models A 312 316, the minimum flow consumption of the oil motor is determined by the Qmin stop screw 35 and the maximum flow rate at the spool (stroke limitation) for travel. If the maximum travel speed of the vehicle is unsatisfactory, the setting can be adjusted. To determine the current actual value, measure the dimension Y of the stop screw 35 (in A 309 Li and A311 Li models), or the stroke limitation of the travel spool (in A 312- 316 Li models). To determine the maximum travel speed accurately, measure the speed of the universal joint shaft (connection of gear system and axle) using a HT 460 speed meter (for tools, see group 2.01.3). Settings (see tables on pages 2 and 3).

7.27.10

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Service Manual

DMVA regulating motor Checking and adjusting the travel motor

6.3

Checking and adjusting the minimum pivot angle (setting B) The minimum pivot angle, i.e. the minimum flow consumption is determined by the stop screw 35. The angle is factory-set by the manufacturer and should not be changed. To check the position of the stop screw 35 in the mounting plate 32, use dimension X (between the stop screw 35 and the lock nut 38) as a guide value (see tables on pages 2 and 3, depending on machine model).

Fig. 8

6.4

Setting value of Qmin stop screw

32 Mounting plate

38 Lock nut

35 Stop screw

51 Protective cap

Checking travel motor for leakage Disconnect the leak oil hose to connection T1 and seal the hose. Screw a matching hose section to connection T1 on the travel motor and place the other end of the hose in a suitable oil collection container. Press the brake pedal to the stop and apply the maximum pressure to the travel motor (maximum high pressure). Measure the volume of leaked oil and compare it with the permissible volume, (see Tab. 2, page 3). If there is excessive leakage, replace the oil motor. Remove the hose section and reconnect the leak oil hose to connection T1.

Fig. 9

Connection T1 for the leakage check of the travel motor

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7.27.11


Service Manual

Hydraulic diagram of the travel motor

7 Hydraulic diagram of the travel motor

7.27.12

34

Connecting link

177

Secondary pressure-relief valve, reverse

35

Stop screw

190


52 67

Check valve Push rod

192 193

Brake piston Restrictor bolt

68

Pressure spring (adjusting spring)

194

Check valve

69


195

Shuttle valve

170 172

Travel motor, complete Complete powertrain

196 X

Check valve Connection for control pressure from solenoid valve Y24

173

Control piston

T1

Leak oil connection

174

Spool

R

Pressure/return line connection, reverse

176

Secondary pressure-relief valve, forward

V

Pressure/return line connection, forward

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Service Manual

DMVA regulating motor Hydraulic diagram of the travel motor

Fig. 10

Hydraulic diagram of the travel motor

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7.27.13


Service Manual


8 DMVA regulating motor Item

7.27.14

Item

172

Complete powertrain

44

Bolt

2

Piston with slipper

45

Valve seat

3

Cylinder with bushing

46

Spring plate

4

Drive shaft

47

Cover

5

Pilot plate

48

Pressure spring

6

Return ball

49

O-ring

7

Return plate

50

Screw cap (measuring point M)

8

Sliding disc

51

Safety cap

9

Swivel yoke

52

Check valve

10

Locking ring

173

Control piston

11

Bolt

176


12

Bolt

177


13

Pressure spring

192

Piston

14


193

Restrictor bolt

15


194

Check valve

16


195

Shuttle valve

17

Radial shaft seal ring

196

Check valve

18

O-ring

19

Snap ring

60

Regulator, complete

20

Snap ring

61

Bushing

21

Allen head screw

62

Bushing

22

Roll pin

63

Spring plate

80

Housing

64

Adjusting screw

82

O-ring

65

Spring plate

83

Cylinder pin

66

Spring plate

67

Push rod

30

Connecting plate, complete

68

Pressure spring (adjusting spring)

31

Screw plug

69


32

Mounting plate

70

Lock nut

33

Guide bushing

71

Circlip

34

Connecting link

72

Ball

35

Stop screw

73

O-ring

36

Backing ring

74

O-ring

37

O-ring

75

Allen head screw

38

Lock nut

76

Protective cap

39

Allen head screw

77

Lead seal

40

Allen head screw

78

Disc

41

Jacket ring

79

Allen head screw

42

Bolt

81

Cylinder pin

43

Roll pin

174

Spool

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Service Manual

Regulating motor A6VE Function

Regulating motor A6VE 1 Function The axial piston oil motor of the inclined axle type is inserted into the travel gear of the crawler excavator (plug-in motor). The travel motor propels the travel gear and, through the tumbler wheel, the chain. The flow from the variable-displacement pump is fed through brake valve "Connection A or B" to the oil motor and acts on the pistons of the powertrain. The pistons (moving in axial direction inside the cylinder of the powertrain) act on the cylinder and drive shaft and generate an input torque. The regulating and adjusting unit adjusts the pivot angle to the flow consumption of the oil motor (depending on the operating pressure). The variable flow consumption of the oil motor determines the torque and speed of the drive shaft. Both values are in inverse ratio, i.e.: Large flow consumption = large torque, low rpm, low speed Small flow consumption = small torque, high rpm, high speed The travel motor can be adjusted by the operator to its minimum pivot angle (electrohydraulic adjustment) (fast travel). .

Fig. 1


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7.28.1


Service Manual

Function

7.28.2

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Service Manual

Regulating motor A6VE Function

1.1

Technical data Equipment from serial number

Unit

R 313 / R 317 27752 / 18161

Regulating motor

Type

A6VE


cm3

54.8

Max. torque

Nm

349

Operating pressure

bar

350

l/min

8

Check measurement X. Qmin Stop 8 Qmax Stop 11

mm mm

approx.15.5 approx.15.5

Brake release pressure

bar

approx. 30

Secondary pressure relief valves 211-214

bar

380 +20

Max. leak oil Adjustable settings of oil motor

Tab. 1

Technical data and settings

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7.28.3


Service Manual

Description

2 Description The regulating motor 200/201 consists of two main components: Motor housing2 End plate 20 The regulating motor consist of the motor housing 2 with integrated powertrain 1. At the left and right side of the travel motor housing 2, the stop screws 8 (Qmin) and 11 (Qmax) are mounted. The motor housing 2 is equipped with a flange-mounted end plate 20. The end plate 20 includes the powertrain adjusting device 202. The brake valve 205, double stop valve 209 and the secondary pressure relief valves 211-214 are screwed into the end plate 20.

Fig. 2

7.28.4

Design of regulating motor

2

Motor housing

211

Secondary pressure relief valve, powertrain, forward left

8

Stop screw (Qmin)

212

Secondary pressure relief valve, powertrain,reverse left

11

Stop screw (Qmax)

213

Secondary pressure relief valve, powertrain, forward right

20

End plate

214

Secondary pressure relief valve, powertrain, reverse right

200 201


A B

Pressure/return line connection Pressure/return line connection

209

Double stop valve

T1

Leak oil connection

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Service Manual

Regulating motor A6VE Description

Fig. 3

Hydraulic diagram of regulating motors

50


208


100


209

Double stop valve

106

Shift valve / Qmax Regulating motors

211

Secondary pressure relief valve, powertrain, forward left

195


212

196


213

Secondary pressure relief valve, powertrain,reverse left Secondary pressure relief valve, powertrain, forward right

200

Travel motor, left

214

201

Travel motor, right

215

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Secondary pressure relief valve, powertrain, reverse right Travel brake

7.28.5


Service Manual

Description

7.28.6

202 203

Powertrain adjusting device Shifting piston / powertrain adjusting device

216 S21

Travel gear Switch (fast travel)

205 206

Brake valve Shuttle valve

Y24

Solenoid valve (fast travel)

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Service Manual

Regulating motor A6VE Functional description

3 Functional description see Fig. 3 and see Fig. 4

3.1

Powertrain The pressure oil from the hydraulic pump is fed through the pressure connection A or B respectively and through a kidney-shaped orifice in the control lens 13 to the cylinder 12. Three bores of the cylinder 12 are connected to the pressure side of the control lens 13, and three bores are connected with the return side. One bore is located at the dead centre, i.e. between the pressure and suction phase. The conical pistons 15 moving in axial direction inside the cylinder 12 are sealed by means two piston rings each. By applying oil under pressure onto the three piston surfaces, a radial force is created at the pistons 15, in turn generating a output torque at the perimeter of the drive shaft 1 . In idle mode, and during start-up, the cylinder 12 is pressed by the pressure spring 17 mounted on the centre peg 14 against the control lens 13. When the pressure increases, the cylinder 12 is balanced in such a way that the oil film at the control surface of the cylinder 12 and the control lens 13 is maintained at all times, even under high loads, and the amount of leak oil is reduced to a minimum. The leak oil lubricates the centre peg 14, the pistons 15 and the tapered roller bearings39 of the drive shaft.

3.2

Adjustment The oil motor can only be operated in two powertrain positions (on-off control).

3.2.1

Operation Switch S21 for fast travel is not actuated. The operating pressure at the high pressure side A or B is applied through the internal bores and the shuttle valve 206 in the end plate 20, the spool 24 and the restriction pin 30 onto the surface Fg of the spool 21. The powertrain is set by the control piston 21 and the control neck 22 to a large pivot angle (Qmax) = large oil volume consumption = high tractive power.

3.2.2

Fast travel Switch S21 for fast travel is actuated. The solenoid valve Y24 connected to the switch S21 is powered. As a result, the control oil of the control oil unit flows through Y24, the shift valve 106 (in the control valve block), the rotary connection 196,(see Fig. 3 on page 5) and connection X of the end plate 20 and acts on the spool 24. The spool 24 is pressed against the pressure spring 25. The operating pressure is applied through the opening edge of the control spool 24 and the control bushing 23 onto the piston surface Fk of the control piston 21, while the surface Fg is relieved by the spool 24 to the tank. The control piston 21, through the control neck 22, moves the cylinder 12 to a small pivot angle position = small oil volume consumption = high speed = low tractive power. The maximum and minimum pivot angles are set by means of the stop screws 11 and 8 respectively.

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7.28.7


Service Manual

Sectional drawings of the regulating motor

4 Sectional drawings of the regulating motor

Fig. 4

7.28.8

Sectional drawing of the regulating motor

1

Powertrain with drive shaft

12

Cylinder

2

Motor housing

13

Control lens

3

Snap ring

14

Centre peg

4


15

Piston

5 6

Back-up washer O-ring

16 17

Tuning disc (S = 3.50 4.00 mm) Pressure spring

7 8

O-ring Stop screw (Qmin)

18 19

Return plate Oval head screw

9 10

Seal-Lock collar nut O-ring

20 39

End plate Tapered roller bearing

11

Stop screw (Qmax)

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Service Manual

Regulating motor A6VE Sectional drawings of the regulating motor

20

End plate

36

Screw plug

21 22

Control piston Control neck

37 202

Double pull-off plug Adjusting device

23

Control bushing

203

Shifting piston (powertrain adjustment)

24

Spool

205

Brake valve

25

Pressure spring

206

Shuttle valve

26 27

Screw plug Restriction screw

208 209

Pressure reduction valve Double stop valve

28

Restriction screw

211

30

Restriction pin

212

Secondary pressure relief valve, chassis, forward left Secondary pressure relief valve, chassis, reverse left

32

Screw plug

213

Secondary pressure relief valve, chassis, forward right

34

Cylinder pin

214

Secondary pressure relief valve, chassis, reverse right

35

Double pull-off plug

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7.28.9


Service Manual

Sectional drawings of the regulating motor

Fig. 5

7.28.10

Sectional drawing of adjusting device

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Service Manual

Regulating motor A6VE Inspection, maintenance and adjustment

5 Inspection, maintenance and adjustment 5.1

Maintenance and repair works on oil motor Note! Hydraulic regulating motors are maintenance-free! This hydraulic regulating motor has been pre-set by the manufacturer and must not be changed. If you detect disturbances in connection with the motor, inspect the secondary protection system. Proceed according to the adjustment guideline and protocol, see group 6. For sealing and repair work, please refer to the separate repair instructions "A6VE regulating motor". Danger! Danger areas: undercarriage - crushing hazard for mechanics, if machine unintentionally starts rolling or if the chassis is moved. Park the machine on a level surface. If parked on a slope or off the road, secure the machine. Block the chassis by applying the parking brake. Place attachments on the ground. Contact operating personnel.

5.2

Check oil motor for leakage Disconnect hose L leading from the connection T1 of the oil motor to the rotary connection at the T-piece. Remove the hose and seal the open connection at the T-piece. Disconnect and seal the line 210 to the brake. Pressurise the regulating motor with maximum high pressure. Collect leak oil from the oil motor, using the hose L and a suitable and sufficiently large container. Determine how much leak oil you actually collected and compare to the max. admissible value. (see Technical data and settings on page 3) Oil motors producing too much leak oil should be replaced. After completed measurement, reconnect the hoses L and 210.

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Service Manual

Inspection, maintenance and adjustment

Fig. 6 210

7.28.12

Leak oil check at the regulating motor Brake hose from the oil motor to the multi- L disc brake T1

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Leak oil line Leak oil connection at oil motor

Service Manual

Regulating motor A6VE Double stop valve 209

6 Double stop valve 209

Fig. 7

6.1

Double stop valve 209

1

Valve cone

20

Housing / mounting plate

2 3

Pressure spring Valve seat

209

Double stop valve, complete

4

Valve cone

A

Pressure/return line connection

5 6

Pressure spring Screw plug

B R

Pressure/return line connection return line from brake valve

11

O-ring

U

from/to powertrain and pressure control

Blocking functions, see Fig. 7 and see Fig. 8 As soon as pressure is applied to the operating connection A or B , the valve cone 1 closes the connection to the respective other operating connection B or A. The oil returning from the brake valve 205 opens the valve cone 1, i.e. the oil can flow through the respective connection A or B to the control valve block. The valve thus prevents a short circuit. As soon as pressure is applied onto the operating connection A or B, the valve cone 4 opens the connection to the powertrain. The oil returning from the powertrain closes the valve cone 4, and thus the direct connection to A or B respectively. The oil is thus fed through the brake valve 205 and is restricted (slowed down).

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Service Manual

Brake valve 205

7 Brake valve 205

Fig. 8

7.1

Sectional drawing of brake valve 205

1 2

Brake piston Screw plug

6 10

Restriction screw Restriction pin

3

Pressure spring

11

O-ring

4 5

Washer Restriction screw

205 209

Brake valve, complete Double stop valve

Opening of brake piston (travel), see Fig. 8 The pressure oil from the pressurised side A or B flows via the double stop valve 209 to the control lens of the travel motor and also acts on the brake valve 205. At the same time, the pressure at the control is built up progressively at the control surface of the brake piston 1 through the edge of the control spool S1 or S2 and the restriction screw 5/6. The brake piston 1 is pressed against the pressure spring 3, opening a connection between A or B and S. The oil can now drain off through the respective return line (tank). The brake valve is now in normal travel operation position.

7.2

Closing or brake piston (hydraulic braking) If the pressure at connection A or B drops (e.g. when travelling downhill), the spring 3 presses the brake piston 1 towards its brake position. The oil flow between A or B and S is gradually restricted, preventing cavitation or overspeeding of the travel motor. When the travel movement is halted, the pressure spring 3 pushes the brake piston 1 into its neutral position, thus immediately closing the connection from A or B to S.

7.28.14

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Service Manual

Regulating motor A6VE Pressure reduction valve (brake pressure) 208

8 Pressure reduction valve (brake pressure) 208

Fig. 9

8.1

Sectional drawing of the pressure reduction valve for brake pressure 208

12

Screw plug

15

Pressure spring

13

Control bushing

16

O-ring

14

Spool

17

Disc

Releasing of multi-disc brake, see Fig. 9 When the travel motor is pressurised through connection A or B, a high pressure P is built up through the shuttle valve 206 at the pressure reduction valve 208. The piston 14 is moved, so that the high pressure is fed via the edge of control spool S3 (limited by pressure spring 15) to connection Bre and the hose, releasing the multi-disc clutch, (see Technical data and settings on page 3). If the high pressure P (travel operation) is increased at connection A or B, the control bushing 13 is pressed against the pressure spring 15. The control bushing thereby seals off the connection T to the tank. The brake pressure (Bre) in the spring chamber of the pressure spring 15 is added to the spring pressure. The applied high pressure P, the surface ratio of the control bushing 13 and the interaction between the spring force and the brake pressure ensure a constant brake release pressure at the control edge of the spool S3. If there is no pressure at connection A or B, the spring 15 presses the piston 14 and the control bushing into their normal position. The release pressure at the connection Bre is thus released directly via connection T and the internal restrictor to the tank. The release pressure is created by the pressure reduction valve 208. This prevents inadvertent release of the multi-disc brake when the machine is standing still or is travelling.

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7.28.15


Service Manual

Pressure relief valve with suction function 211 - 214

9 Pressure relief valve with suction function 211 - 214 9.1

Function and design The secondary pressure relief valves 211 - 214 are of the cartridge type and screwed directly into the mounting plate of the regulating motor. They put a limit on the pressure between the oil motor and the control valve block when the spools are closed (secondary function). In the event of an undesirable pressure rise in the circuit of an attachment, it is the weakest point of the circuit that would normally break, e.g. screwed connections or hydraulic hoses. In order to prevent this, machines are equipped with a pre-determined breaking point. The pressure increase in the hydraulic system acts on a built-in pressure relief valve. It limits the maximum pressure in the consumer and its connection to the pre-set value. As the pressure valves in the hydraulic system must be able to cater for great flows of oil, our machines are equipped with indirect (pilot-controlled) pressure relief valves for reasons of manufacture and better functioning. In these valves, a pressure relief valve is installed that works directly as a pilot control valve to actuate a second, larger valve.

9.2

Functional description The pressure (P) applied in the circuit of the consumer acts on the front face of main cone 1 and, at the same time, through the bore a on the rear face of the main piston 1. The pressure is also applied simultaneously to the pilot control cone 2. The pressure springs 9 and 3 push the main cone 1 and the pilot control cone 2 into their closing positions (static status). As soon as the pressure in the oil motor reaches a value above the adjusting value for the pressure and adjusting spring 3 (due to external forces acting on the powertrain), the pilot control cone 2 is lifted from its seat and a little oil is released into the return channel (T1). Due to the different cross-sections of the bores a in the main piston 1 and b in the rear section of the housing 4, a pressure difference between front and rear side of the main piston 1 is created. The pressure difference results in the main piston 1 being shifted against the pressure springs 9 so that a great amount of oil can drain off to the non-pressurised return side (T2). The pressure in the system drops, and the main piston 1 is again pushed against the sealing edge at the front part of the housing 8. The adjusting spring 3 pushes the pilot control cone 2 against the rear section of the housing 4, i.e. the connection between the pressurised side and the return side (T1/T2) is closed.

9.3

Suction: If there is a vacuum at the high pressure connection A or B, the higher pressure of the low pressure circuit acts on the ring face of the main cone 1. This resulting pressure difference affects the entire surface of the main cone 1 and lifts it against the force of the pressure springs 9 from its seat, so that the required oil volume can flow through A orB the respective side of the consumer.

7.28.16

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Service Manual

Regulating motor A6VE Pressure relief valve with suction function 211 - 214

Fig. 10 1

Sectional drawing of the pressure relief valve 211 - 214 6

Main cone

Adjusting screw

2

Pilot control cone

7

Lock nut

3

Pressure spring

8

Housing (front section)

4 5

Housing (rear section) Protective cap

9 10


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7.28.17


Service Manual

Pressure relief valve with suction function 211 - 214

7.28.18

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Service Manual

Hydraulic cylinder Function

Hydraulic cylinder 1 Function The LIEBHERR hydraulic cylinders are primarily used as working cylinders for the movement of attachments. Due to their design, they are classified as differential cylinders. When hydraulic oil is fed to the piston side, the cylinder is extended; when oil is fed to the piston rod side, the cylinder retracts. The maximum forces of the cylinder depend on the size and shape of the effective surfaces Extending Retracting

Piston surface Piston ring surface

and the max. admissible operating pressure, which is greater during extending than retracting. The speed of the cylinder extending or retracting depends on the amount of oil fed per interval of time, and on the surface. It is reciprocally proportional to the force, so that it is higher at retracting than at extending. LIEBHERR offers hydraulic cylinders for various fields of application that differ in stroke (length of extension), diameter (power) and cushioning system (end-of-travel cushioning). Our machines are equipped with hydraulic cylinders with and without end-of-travel cushioning. Note! As the machines feature a great range of seals, guides, pistons and cushioning equipment, it was not possible to cover all components in detail in the service manual. For details, please refer to the ET spare parts catalogue and the delivery documents.

Fig. 1

Hydraulic cylinder

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7.30.1

Hydraulic cylinder

Service Manual

Description

2 Description Hydraulic cylinders consist basically of a cylinder tube 10 with welded cylinder base and bearing bore, a screwed-in piston rod bearing 13 (acting as cylinder head) and a piston rod 8 with bearing bore and screwed-in piston 12. To seal off the pressure chambers to the inside and outside, the cylinder is equipped with O-rings and backing rings, as well as Glyd-Rimseal rings and Stepseal seal rings in the piston 12 and the piston rod bearing 13. The scraper ring in the piston rod bearing 13 protects the piston rod 8 against dirt. The guide rings on the piston 12 and in the piston rod bearing 13 guide the piston rod. For a detailed description of the sealing elements of the piston 12 and the piston rod bearing 13, see Fig. 3. For further details concerning the piston see Fig. 16, the end-of-travel cushioning see Fig. 17 and the stroke reductionsee Fig. 18.

Fig. 2

7.30.2

Exploded view of a hydraulic cylinder with various piston, cushioning and stroke shortening options.

1

Bushing

2 3

Sleeve (stroke reduction as optional 25 extra) Piston (stroke reduction as optional extra) 31

20

4

Piston nut

32

Cushioning sleeve

8

Piston rod

33

Disc

9

Cushioning sleeve

34

Cushioning pin

10

Cylinder

35

Threaded bushing

12

Piston

60

Retaining washer

13

Piston rod bearing

65

Allen head screw

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Hex head screw Circlip Screw

Service Manual

Hydraulic cylinder Description

15

Fig. 3

2.1

Radial seal ring

Sealing elements at the piston 12 and the piston rod bearing 13

9 12

Cushioning sleeve Piston

125 126

Backing ring Piston guide ring

13 25

Piston rod bearing Ring

131 132

Guide ring Backing ring

91

O-ring

133

O-ring

92 121

Seal ring Piston guide ring

134 135

Scraper ring O-ring

122

Turcon-Glyd ring

136

Rimseal ring (secondary protection)

123

O-ring

137

O-ring

124

O-ring

138

Turcon Stepseal (primary protection)

Cylinder variants, see Fig. 17 / Fig. 18 The uncushioned hydraulic cylinder (type I) is used mainly with supports and with certain (less frequently used) cylinders for working attachments such as grapple and regulating cylinders, etc. and for on-road travel. Cushioned hydraulic cylinders can be equipped with one-side and two-side end-of-travel cushioning. See type II (one-side) and/or type III and type IV (two-side). Depending on the application, cylinders might be used in conjunction with stroke reduction. The stro-

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7.30.3

Hydraulic cylinder

Service Manual

Functional description ke can be reduced either by inserting a sleeve 2 (type G) on the piston side, or by inserting a piston 3 on the piston rod side (type H). Both methods result in the desired shortening of the piston stroke.

3 Functional description 3.1 3.1.1

One-side end-of-travel cushioning Extending piston rod 8 The hydraulic oil coming from the control valve block flows through the piston-side connection of the cylinder 10 and acts on the piston 12. The piston rod is driven out and displaces the oil on the rod side back through the control valve block to the tank. Shortly before the end of the stroke is reached, the cushioning sleeve 9 is inserted into the cushioning bore of the piston rod bearing 13. When the cushioning sleeve 9 is introduced into the bore, the flow cross-section of the displaced oil is reduced. The oil is fed from the hydraulic cylinder back to the control valve block. This happens with the help of three splines sitting around the circumference of the sleeve 9. The extending motion of the piston rod is slowed down, i.e. cushioned, thanks to the strong restriction of the return oil flow.

3.1.2

Retracting piston rod 8 The hydraulic oil coming from the control valve block flows through the connection into piston rod bearing 13 and pushes against the front face of the cushioning sleeve 9 through the ring gap between the cushioning sleeve 9 and the piston rod 8 and/or the piston rod bearing 13. Through the radial bores and the splines in the cushioning sleeve 9, the oil acts on the piston 12. The piston rod retracts and displaces the oil on the piston side through the connection bore and the control valve block back to the tank.

Fig. 4

7.30.4

Sectional drawing of the hydraulic cylinder

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Service Manual

Hydraulic cylinder Functional description

3.2 3.2.1

Two-side end-of-travel cushioning, see Fig. 5 Extending piston rod 8 The hydraulic oil coming from the control valve block flows through the connection into the piston side of the cylinder and acts on the cushioning pin 31 and the piston 12 via the longitudinal slots. The piston rod 8 is extended (see 3.1, page 4).

3.2.2

Retracting piston rod 8 The hydraulic oil coming from the control valve block flows through the connection into the piston rod bearing 13 and acts on the front face of the cushioning sleeve 9 through the ring gap between the cushioning sleeve 9 and the piston rod 8. The oil acts on the piston 12 through the radial bores and splines in the cushioning sleeve 9. The piston rod retracts and displaces the oil on the piston side back to the tank. Shortly before the end of the stroke, the cushioning pin 31 is inserted into the base of the cylinder 10. When the cushioning sleeve 32 enters the cushioning bore, the flow cross-section of the displaced oil is reduced. The oil flows through two longitudinal slots arranged along the circumference of the sleeve 32 and/or the pin 34 from the hydraulic cylinder back to the control block. The retracting motion of the piston rod is slowed down i.e. cushioned, thanks to the strong restriction of the return oil flow.

Fig. 5

Partial section of end-of-travel cushioning device

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7.30.5

Hydraulic cylinder

Service Manual

Removal and installation of hydraulic cylinders

4 Removal and installation of hydraulic cylinders Caution! The dismantling and installation of a cylinder requires lifting gear such as a crane and additional personnel. When the cylinder is placed in its bearings, there is a risk of serious injury to hands and other limbs that might become caught and crushed between the cylinder and other equipment parts. To prevent accidents, the following precautionary measures must be taken: Drive the vehicle onto level and firm ground. Place the attachments and the support on the ground. Ensure that the cylinder is stopped in a suitable position for removal and installation. Switch off the diesel engine. Relieve the hydraulic pressure from pressure lines. To do this, switch on the ignition and the pilot control system and actuate the pilot control units several times to the stop. Relieve the preload of hydraulic tank by loosening the breather filter at the tank. Secure the hydraulic cylinder by attaching it to lifting tackle. Secure other loose equipment, if necessary.

4.1

Dismantling Disconnect the flange connections of the hydraulic hoses. Collect the escaping oil in a suitable container. If necessary, unscrew and remove the connection block with the pressure line from the piston rod bearing and the cylinder base. Seal the lines and hoses with cover plates, screw caps, plugs etc.

Sealing work on the machine Release and drive out the bearing pin connecting the piston rod eye to the equipment. Pull out stuck bolts using a special removal tool.

Complete dismantling Release and drive out both bearing pins from the piston rod and the cylinder tube. Pull out stuck bolts using a special removal tool.

4.2

Installation Using lifting tackle, place the hydraulic cylinder into the bearing block so that the bearing bores in the cylinder base and in the attachment component are aligned to each other. Slightly grease the bearing pin and drive/pull it in. Secure both bearing pins. Bleed hydraulic cylinder, see 4.3. Move the attachments / support to check their functions and tightness of the cylinder and the hydraulic connections.

7.30.6

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Service Manual

Hydraulic cylinder Removal and installation of hydraulic cylinders

4.3 4.3.1

Bleeding cylinder after repair Bleeding cylinder without bleeder bores Caution! After a repair of the cylinder, there is air trapped in the closed chamber. In connection with oil and high pressure, this could result in explosive ignition ("diesel effect"). This poses a serious risk to persons and property. Therefore complete the following steps: When bleeding the cylinder, never extend/retract it to the stop (to prevent maximum pressure build-up). When connecting the pressure lines and tightening the screw connections, ensure that they are air-tight. To accomplish this, connect the hose on the piston side. Completely extend cylinder slowly and carefully, at low idle rpm, so that the air on the rod side can escape completely from the cylinder. Collect escaping oil in a suitable container. When the cylinder is fully retracted, connect the line to the piston rod. Extend and retract the cylinder several times slowly and carefully, at low idle rpm, so that the remaining air in the cylinder can escape towards the tank. Re-tighten all the lines. Check the screw connections of the flanges for correct torque.

4.3.2

Bleeding of cylinders with integrated bleeder plug, see Fig. 6 Caution! The cylinder is under pressure. When you loosen and unscrew the plug 11, it is possible that residual pressure in the line pushes out the plug with great force, which can result in serious injury. Therefore carefully loosen the plug and release the oil pressure (collect oil in suitable container). Unscrew the plug 11. (New versions of this design have separate bleeder valves to which an oil discharge hose can be connected.) Insert a mini measuring connection with an oil discharge hose into the bleeder bore and keep a suitable collecting container ready. Completely extend the cylinder slowly and carefully at low idle rpm. A mixture of air and oil escapes through the hose into the container. Remove the mini measuring connection. Be sure to properly replace plug after bleeding (torque: 40 Nm).

Fig. 6

Bleeder screw at the hydraulic cylinder

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7.30.7

Hydraulic cylinder

Service Manual

Replacing seals

5 Replacing seals

Fig. 7

5.1

Partial section of the hydraulic cylinder

4

Piston nut

33

Disc

8 9

Piston rod Cushioning sleeve

121 122

Piston guide ring Turcon-Glyd ring

12 13

Piston Piston rod bearing

123 124

O-ring O-ring

20

Hex head screw

125

Backing ring

25

Snap ring

126

Piston guide ring

Dismantling Note! To disassemble and assemble the piston nut 4 and the piston 12, you need great force. Inadvertent rotation of the piston rod 8 can lead to damage to the chromium surface finish. To prevent this, complete the following steps: Lock the piston rod 8 using a suitable clamping or anti-torsion device. Avoid damaging the surface of the piston rod. Unscrew the hex head screw 20 with washer 33. Pull the piston rod bearing 13 together with the piston rod 8 and the piston 12 from the cylinder. Place the piston rod on a suitable and clean surface to prevent damage. Remove the piston guide rings 121. Remove the snap ring 25. Unscrew the piston nut 4 (if any). Attach a piston spanner and other special tools (see group 2.05) to the piston 12 . Remove the piston from the piston rod 8. Hydraulic cylinders with end-of-travel cushioning: Remove the cushioning sleeve 9. Remove the piston rod bearing 13 from the piston rod 8. Remove all sealing elements from the piston, the piston rod bearing and the cushioning system.

7.30.8

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Service Manual

Hydraulic cylinder Replacing seals

5.2 5.2.1

Assembly of sealing and guide elements on the piston Installation in piston rod bearing Carefully remove all dirt, dust, chips and other foreign matter from the parts. Check all parts for suitability for reuse. Parts that show damage to the piston rod such as dents and grooves must be replaced. Treat the seal housings with Castrol-Tarp corrosion inhibitor (40g tube - ID no. 830005). Apply a little oil to the O-ring 135 / 137 and insert it in the piston rod bearing 13. Apply a little oil to the seal rings 136 and 138 and insert them into the piston rod bearing 13, see Fig. 10 and Fig. 11. .

Note! Ensure that the seal rings 136 and 138 are installed in the correct position and direction (see flow direction of pressurised oil). Pay attention to the different features of the various seals: Turcon - Rimseal 136 (dark grey or turquoise) secondary- flexible - like rubber Turcon - Stepseal 138 (light grey) primary, see Fig. 10

Fig. 8

Pressing seal and scraper ring into kidney shape ring for assembly

13 135

Piston rod bearing O-ring

137 138

136

Rimseal Ring (secondary protection)

O-ring Turcon Stepseal (primary protection)

Press Stepseal / Rimseal into kidney shape, avoiding kinking. Place the pressed Stepseal / Rimseal over the O-ring 135 / 137 and press it into the groove, in the direction of the arrow, see Fig. 10. Compress and place the scraper ring 134 in the same fashion and insert it in its correct position, see Fig. 10.

5.2.2

Installing the piston rod bearing Caution! For certain piston guide designs, (see Fig. 9, page 10) use a mounting sleeve c (in the ET catalogue, included with no. 960) for the installation of the piston guide bearing 13. If this installation aid is not used, the sealing elements in the piston rod bearing 13 get damaged. Screw the mounting sleeve c to the piston rod 8. Slide the piston rod bearing 13 over the mounting sleeve c onto the piston rod 8. Remove the mounting sleeve c.

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7.30.9

Hydraulic cylinder

Service Manual

Replacing seals

Fig. 9 c

Mount the piston rod bearing using the mounting sleeve for special piston rod shapes Mounting sleeve, see tools in group 2.01 / 8 2.12 13

Piston rod Piston rod bearing

Slide the cushioning sleeve 9 (not required for hydraulic cylinders without end-of-travel cushioning) onto the piston rod 8.

7.30.10

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Service Manual

Hydraulic cylinder Replacing seals

Note! Distinguishing features of the seal rings 136 / 138. The various shapes of the Rimseal 136 are shown here in comparison to the Stepseal 138 ring (see Fig. 10).

)

Fig. 10

5.2.3

Distinguishing features of seal rings

136

Rimseal ring

s

Flange - inclined

138

Stepseal ring

g

Flange - straight

Colour

Rimseal Stepseal

136 => 138 =>

dark grey - polished or turquoise (new) light grey - matt

Elasticity

Rimseal Stepseal

136 => 138 =>

flexible rigid

Shape

Rimseal Stepseal

136 => 138 =>

flange inclined flange straight

Mounting to piston Note! The Turcon-Glyd ring 122 must be expanded before mounting and then returned to its normal shape, as it can otherwise not be slid over the outer edge and into the groove. To facilitate installation, we recommend to heat the Turcon-Glyd ring 122 in a water or oil bath (approx. 60°C). Apply a little oil to the O-ring 125 and the Turcon-Glyd ring 122 and place them onto the piston 12, using the mounting sleeve b and the expanding sleeve b (for special tools, see group 2.05). After installation, return the Turcon-Glyd ring 122 to its original shape, using the piston tightening strap. Insert the first backing ring 125, the O-ring 124 and the second backing ring into the piston 12. Apply Castrol Tarp to the internal piston chamber.

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7.30.11

Hydraulic cylinder

Service Manual

Mounting of the cylinder after replacement of the seals

Fig. 11

Mounting of sealing and guide elements to the piston, using the mounting sleeve a and expanding sleeve b

a b

Mounting sleeve Expanding sleeve

121 122

Piston guide ring Turcon-Glyd ring

9 12

Cushioning sleeve Piston

123 124

O-ring O-ring

13

Piston rod bearing

125

Backing ring

6 Mounting of the cylinder after replacement of the seals 6.1

Mounting of the piston and the piston nut onto the piston rod Carefully clean all contact and thread faces between the piston rod, the piston and the piston nut. Apply a thin layer of Gleitmo 800 lubricant (ID no. 8300004) to both sides (see fuels and lubricants group 1.50). Note! If components are mounted without having been treated with lubricant, the turning distance prescribed according to factory standard 4121 cannot be achieved. As the parts tend to become jammed (seizing), it is also not possible to remove the component at a later stage. Apply Gleitmo 800 lubricant (ID no. 8300004) to all components. Screw the piston 12 onto the piston rod 8. Attach a piston wrench or special tool (see group 2.05) to the piston 12.

7.30.12

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Service Manual

Hydraulic cylinder Mounting of the cylinder after replacement of the seals

Note! Mount the piston and the piston nut following the instruction in the factory standard 4121 B in group 1.22. The drawing number and the date of assembly are engraved on the cylinder. The factory standard 4121-095 is specified in the hydraulic cylinder list, see group 7.31 7.37. This information is engraved on all newly manufactured pistons. Tighten the piston 12 to the piston rod 8 according to the installation instructions, see group 1.22. Remove the piston wrench. Screw the piston nut 4 onto the piston rod 8. Tighten the piston nut 4 to the piston rod, using a suitable piston nut wrench and following the installation instructions, see group 1.22. Remove the piston nut wrench. Secure the piston nut 4 with a snap ring 25 (drill new hole, if necessary).

6.2

Mounting the cushioning sleeve 32 Cylinder with two-side end-of-travel cushioning, see Fig. 12 Clean the thread of the screw 31 (remove all grease). Apply Loctite no. 270 to the thread of the screw 31. Apply Gleitmo 800 to the shank. Secure the sleeve 32 with the screw 31 to the piston rod 8 (torque: 130 Nm).

Fig. 12

Mounting the piston-side cushioning sleeve

8

Piston rod

121

Piston guide ring

31 32

Screw Cushioning sleeve

126

Piston guide ring

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7.30.13

Hydraulic cylinder

Service Manual

Mounting of the cylinder after replacement of the seals

6.3

Mounting the piston rod in the cylinder tube Place the inside piston guide straps 121 (hard) and the outside straps 126 (soft) on the piston 12. Note: For perfect piston assembly, we offer special calibrating sleeves (mounting sleeves, see group 2.05, 2.12 for a number of piston sizes. Place the piston tightening strap and/or the mounting sleeve on the piston 12. Gently tighten the guide rings 121 and 126 to the piston. Push the piston rod 8 (complete with piston 12) carefully into the cylinder 10. Remove the piston tightening strap and/or mounting sleeve.

6.4

Mounting the piston rod bearing 8 (plug-in type)

Fig. 13

Installation of piston rod bearing

10 13

Cylinder tube Piston rod bearing

33 132

Disc Backing ring

20

Screw

133

O-ring

Mount the slightly oiled O-ring 133 and the backing ring 132. Observe the installation position of the backing 132 and the O-ring 133 (concave). Push the piston rod bearing 13 into the cylinder 10. Observe the positions of the hydraulic connections. Screw in the hex head screw or socket screw 20 (with washer 33, if any).

6.5

Mounting the piston rod bearing 8 (screw-in type) Attach the assembly wrench (special tool group 2.12) to the piston rod bearing 13. Note! Mount the piston and the piston nut following the instruction in the factory standard 4122 B in group 1.22. The factory standard 4122-017 is specified in the hydraulic cylinder list, see group 7.34 7.36. This information is engraved on all newly manufactured pistons. Tighten the piston rod bearing13 in the cylinder tube 10, following the instructions, see group 1.24.

7.30.14

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Service Manual

Hydraulic cylinder Piston rod bearing types

Fig. 14

8 10

Assembly wrenches for screw-type piston rod bearings

13

Piston rod Cylinder tube

Piston rod bearing

7 Piston rod bearing types

Fig. 15

Piston rod bearing types

D

Piston rod bearing 13, plug-in type

E

Piston rod bearing 13, screw-in type

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7.30.15

Hydraulic cylinder

Service Manual

Piston types on hydraulic cylinders

8 Piston types on hydraulic cylinders

Fig. 16

7.30.16

Piston types 12

A

Piston 12 secured with piston nut

B

Piston 12 with integrated piston nut

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Service Manual

Hydraulic cylinder End-of-travel cushioning

9 End-of-travel cushioning

Fig. 17

Options for end-of-travel cushioning and stroke reduction

Option I Option II

without end-of-travel cushioning one-side end-of-travel cushioning

Option III

two-side end-of-travel cushioning (old)

Option IV

two-side end-of-travel cushioning (new)

9

Cushioning sleeve

34

Cushioning pin

31

Screw

35

Threaded bushing

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7.30.17

Hydraulic cylinder

Service Manual

Stroke reduction 32

10

Cushioning sleeve

Stroke reduction

Fig. 18

7.30.18

Cylinder with stroke reduction

Option G

Stroke reduction with sleeve 2

Option H

Stroke reduction with piston 3

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Service Manual

Hydraulic cylinder

Hydraulic cylinder Drawing no.

Installed as

D

d

Stroke eff.

Fitting length

(in equipment)

(mm)

(mm)

(mm)

(mm)

WN 4121 No.

Boom cylinder at 29 441 1047

adjustable attachment

2

100

70

895

1410

091

29 441 1047

Gooseneck boom

2

100

70

875

1430

091

Stick cylinder at 29 748 1000


1

110

75

1050

1590

091

29 748 1000

Gooseneck boom

1

110

75

1050

1590

091

29 524 4049

Bucket cylinder

1

90

60

900

1340

073

1

140

80

700

1140

171

Regulating cylinder at 29 447 1040

hydraulic boom adjustment grapple cylinder at

29 128 1000

clamshell grab

2

70

50

350

710

(*)

29 679 1040

Multiple tine grab

5

70

50

155

485

(*)

Support cylinder at 29 187 1000

outrigger support

2

120

70

455

855

091

29 530 1049

Blade support

2

90

50

205

515

075

29 530 2049

Blade support

2

90

50

205

515

075

Boom, horizontally adjus29 513 5000

Adjustable attachment

1

110

60

640

1040

091

29 513 5000

Gooseneck boom

1

110

60

640

1040

091

D

=

Diameter of piston

d

=

Piston rod diameter

Working tolerance of hydraulic cylinder: H8

=

at cylinder diameter

f7

=

at piston rod diameter

=

with stroke reduction

=

Factory standard no. 4121 / see also page 7.30.09

=

Simple piston installation, see also page 7.30.09

*

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7.34.1

Hydraulic cylinder

7.34.2

Service Manual

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Service Manual

Hydraulic cylinder


Installed as

D

d

Stroke eff.

Fitting length

(in equipment)

(mm)

(mm)

(mm)

(mm)

WN 4121 No.



2

110

70

895

1410

091

29 443 1048

Gooseneck boom

2

110

70

895

1410

091

29 441 1049

Gooseneck boom

2

100

70

895

1410

091


Adjustable attachment

1

115

75

1050

1590

091

29 761 2000

Gooseneck boom

1

115

75

1050

1590

091

29 523 1049

Gooseneck boom

1

110

70

1050

1565

091

29 524 1049

Bucket cylinder

1

90

60

900

1340

073

29 524 4049

Bucket cylinder

1

90

60

900

1340

073

1

140

80

700

1140

171


hydraulic boom adjustment Grapple cylinder at

29 128 1000

clamshell grab

2

70

50

350

710

(*)

29 679 1040

Multiple tine grab

5

70

50

155

485

(*)


outrigger support

2

120

70

455

855

091

29 530 1049

Blade support

2

90

50

205

515

075

29 530 2049

Blade support

2

90

50

205

515

075

D

=

Diameter of piston

d

=

Piston rod diameter


=


f7

=


=


=


=


*

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7.35.1

Hydraulic cylinder

7.35.2

Service Manual

copyright by

MJFCIFSS

Service Manual

Hydraulic cylinder


Installed as

D

d

Stroke eff.

Fitting length

(in equipment)

(mm)

(mm)

(mm)

(mm)

WN 4121 No.



2

120

70

895

1420

091

29 615 1040

Industrial gooseneck boom

2

120

70

895

1420

091


adjustable and gooseneck

1

120

80

970

1500

121

29 749 1000

adjustable and gooseneck

1

120

80

970

1515

112

29 443 1040

Industrial gooseneck boom

1

110

70

895

1410

091

29 441 7040

Bucket cylinder

1

100

70

895

1410

091

1

140

80

700

1140

171


hydraulic boom adjustment Grapple cylinder at

29 128 1000

clamshell grab

2

70

50

350

710

(*)

29 679 1040

Multiple tine grab

5

70

50

155

485

(*)


outrigger support

2

120

70

455

855

091

29 530 1049

Blade support

2

90

50

205

515

075

29 530 2049

Blade support

2

90

50

205

515

075

D

=

Diameter of piston

d

=

Piston rod diameter


=


f7

=


=


=


=


*

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7.36.1

Hydraulic cylinder

7.36.2

Service Manual

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Service Manual

Control oil and regulation unit Function

Control oil and regulation unit 1 Function The control oil unit generates the servo pressure for the pilot control and the regulating pressures for the working pumps. It also generates the control pressures for the actuation of the oscillating axle support and the multidisc brake of the slewing gear.

Fig. 1

Control oil unit

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7.40.1


Service Manual

Design

2 Design The control oil unit 50 consists of a housing block with integrated oil channels and screwed-in valves. The pressure-relief valve 51 is screwed into the front part of this block. the measuring point 49 for the control pressure is also accessible from the front. The solenoid valves Y3, Y24 and Y371 are inserted from the top into the unit. The pressure accumulator 54 is mounted at the top of the unit and secured with screws. The pressure filter 52 is screwed in from the base. The control oil block also features an integrated check valve 53. To the side of the unit 50, the proportional solenoid valves Y50 and Y51 are flange-mounted to the control oil unit and are connected hydraulically. Up to the change in the series (from serial no. 27110/27112, see below), a switching solenoid valve Y330 is flange-mounted to the solenoid valve Y51 and hydraulically connected.

Fig. 2

49

7.40.2

Control oil unit with control and regulating valves, pressure-reduction valve, pressure accumulator and measuring point

50

Measuring point for control pres- Y3 sure Control oil and regulation unit Y24

51 52

Pressure-relief valve Pressure filter

Y50 Y51

53

Check valve

Y330 Solenoid valve / reset pump P2 (to serial no. 27109/27111, see also service information 07-11-37/2005)

54

Accumulator


Solenoid valve / servo release Solenoid valve / creeper gear switching Proportional solenoid valve / power control Proportional solenoid valve / LS control

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Service Manual

Control oil and regulation unit Functional description

3 Functional description (see Fig. 2, page 2)

3.1

Generation of servo pressure The control oil unit is supplied with oil via the connection P from the gear pump / pilot control system. The unit contains a pressure relief valve 51 of the cartridge type that is screwed into the unit. It limits the control pressure to a certain value (see adjustment protocols, group 6). The oil flows through the filter 52 and the check valve 53 to the accumulator 54. The accumulator 54 allows for a small number of control operations - after the diesel engine has been switched off or when the gear pump fails. The connection P1 in the circuit is located behind the filter 52. It provides control pressure to the regulating unit of the working pumps.

3.2

Function of switching solenoid valves Through internal pressure channels in the control oil unit, the pressure oil also acts on the switching solenoid valves Y3, Y24 and Y371. The flange-mounted switching solenoid valve Y330 is connected through the connection PHD to the high-pressure line (from the pump P1) of the control block. When switched, the solenoid valves Y3, Y24 and Y371 provide control pressure to the outlets A1, A2 and A3. In neutral position, the outlets are connected to the tank. Through the connection A1, the solenoid valve Y3 releases control pressure to the pilot control units. Through connection A2, the solenoid valve Y24 acts on the circuit for the control for creeper gear switching. Through the connection A3, the solenoid valve Y371 controls the oscillating axle support. Through the connection A4, the solenoid valve Y330 controls the reset of the pump during travel (omitted from serial no. 27110/27112).

3.3

Function of the proportional solenoid valves Y50 / Y51 The proportional solenoid valves Y50 and Y51 are pressurised through internal pressure channels in the control oil unit. The proportional solenoid valves for power control or flow limitation in the working pumps of the control oil unit are used to build up a pressure at their output, which is determined by the actual solenoid current. The outlet "LR" of the solenoid valve Y50 is connected to the connection "X3", which is the pressure connection to the spool of the working pumps. The proportional solenoid valve Y51 regulates the control pressure LS, which determines the limitation of the pivot angle of the working pump P1. This pressure also acts on the connection X1 of the pump regulator and reduces the spool stroke through opposed piston of the pump P1. This results in a reduction of the maximum pump flow rate.

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7.40.3


Service Manual


Characteristics of the proportional solenoid valves Y50 and Y51

Fig. 3

Regulating diagram for Y50 / Y51

The regulation characteristic illustrates the interrelation between the input current (I) of the regulating solenoids and the regulating pressure (p) at outlets LR or LS. The effect of the pressures p at the outlet LR or p at the outlet LS on the power settings and/or the limitation of the pivot angle of the respective working pumps is described in group 7. The regulation characteristic of a proportional solenoid valve can be checked by measuring a few pressure values at the outlet LR (or LS respectively) and comparing them with the solenoid current Y50 or Y51).

7.40.4

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Service Manual

Control oil and regulation unit Emergency position of the proportional solenoid valve Y50

4 Emergency position of the proportional solenoid valve Y50 In order to prevent that the control current affects the system when operated in emergency position, disconnect the plug 1 to the proportional solenoid valve Y50. By removing the cotter pin 2 and tilting the lever 3 into a horizontal position, the solenoid valve Y50 can be brought into a pre-defined emergency position.

4.1

Adjustment of the emergency position Set the regulating pressure to the desired fixed value by proceeding as follows: Connect pressure sensor to the measuring point 59. While the engine is running and the lever 3 is in a horizontal position, remove the lock nut 5 and turn the adjusting screw 4 until the desired pressure is obtained. Re-tighten the locknut 5, holding the adjusting screw 4 in its position and re-check the pressure settings.

Fig. 4 5

Normal position a and emergency position b of the regulating solenoid valve Y50

1 2

Adapter Cotter pin

5 50

Lock nut Control oil unit

3

Lever

Y50

Proportional solenoid valve / performance control

4

Adjusting nut

Y51


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7.40.5


Service Manual

Emergency position of the proportional solenoid valve Y50

7.40.6

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Service Manual

Control oil and regulation unit Purpose

Control oil and regulation unit 1 Purpose The control oil and regulation unit generates the servo pressure for the pilot control and the regulating pressures for the working pumps. This unit also provides the control pressures for the operation of the oscillating axle support and the creeper gear system of the regulating travel motor (in wheel machines) and for the operation of the multi-disc brake of the slewing gear or the fast travel gear respectively of the regulating travel motors (in track machines)

Fig. 1


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7.42.1


Service Manual

Description

2 Description The control oil unit 50 consists primarily of an aluminium block. At its front, it is equipped with a pressure relief valve 51 of the cartridge type that is screwed into the block. At the top of the unit, the solenoid valves Y3, Y7 and Y66 are integrated into the block. The measuring points 49, 57, 59 and the accumulator are also secured with screw connections to the top of the unit. At its base of the block, the proportional solenoid valves Y50 and Y51 and the pressure filter 52 are screwed in. The control oil block also features an integrated check valve 53.

2.1

Arrangement of measuring points The stationary measuring points 49, 57 and 59 are designed to measure the pressures in the control oil unit.

Measuring point 49 At this point, the current pilot pressure of the entire pilot control system is measured. See instructions on checking pressures in main group 6.

Measuring point 57 At this point, the control pressure for p-reduction, which is generated by the solenoid valve Y51 is measured. See flow reduction in group 16.20.

Measuring point 59 The control pressure for the power regulation generated by the solenoid valve Y50 is measured here, see also the basic values and power adjustments in the groups "Adjusting protocols" 6. and "Pump description" 7.05.

7.42.2

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Service Manual

Control oil and regulation unit Description

Fig. 2

Control oil unit with control and regulating valves, pressure-reduction valve, pressure accumulator and measuring points

49 50

Measuring point for control pressure Control oil and regulation unit

57 59

Measuring point ( p reduction) Measuring point (power control)

51 52

Pressure-relief valve Pressure filter

Y3 Y7

Solenoid valve / servo release Solenoid valve / slewing gear brake (track machines only)

53

Check valve

Y24

Solenoid valve / creeper gear clutch (wheel machines only) Solenoid valve / fast travel clutch (track machines only)

54

Accumulator

Y50


55 56

Dummy plate Dummy plate

Y51 Proportional solenoid valve / LS control Y371 Solenoid valve / oscillating axle support (wheel machines only)

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7.42.3


Service Manual



3.1

Generation of servo pressure The control oil unit is fed via connection P with the flow from the gear pump. The unit contains a pressure relief valve 51 of the cartridge type that is screwed into the unit. It limits the control pressure to a certain value (see adjustment protocol). The oil flows through the filter 52 and the check valve 53 to the accumulator 54. The accumulator 54 allows for a limited number of control operations after the diesel engine is switched off, or in the event of a gear pump failure. The connection P1 is located after the filter 52 . It provides control pressure to the regulating unit of the working pumps.

3.2

Function of switching solenoid valves Through pressure channels in the control oil unit, the pressure oil acts also on the switching solenoid valves Y3, Y7 and Y66 and on the regulating solenoid valves Y50 and Y51. When engaged, the solenoid valves Y3, Y24 and Y7 provide control pressure to the outlets A1, A2 and A3. In neutral position, the outlets are connected to the tank. Through the connection A1, the solenoid valve Y3 releases control pressure to the pilot control units. Through connection A2, the solenoid valve Y24 acts on the circuit for the control of the creeper speed. The solenoid valve Y7 / Y371 controls the multi-disc brake in the slewing gear or oscillating axle support through the outletA3.

3.3

Proportional solenoid valves Y50 / Y51 The proportional solenoid valves for power control or flow limitation in the working pumps of the control oil unit are used to build up a pressure at their output, which is determined by the actual solenoid current. The outlet LR of the solenoid valve Y50 is connected to the connection GLR, which is the pressure connection for the power control of the working pumps. The proportional solenoid valve Y51 regulates the control pressure p(LS), which determines the limitation of the pivot angle of the working pump. This pressure line is also linked to the connection pst of the pump regulator. Through the LS regulator, it reduces the pre-set pLS ( p reduction) and, thus, limits the maximum pump flow. This pressure is therefore referred to in the other groups of this manual as p ( Pred).

7.42.4

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MJFCIFSS

Service Manual

Control oil and regulation unit Characteristics of the proportional solenoid valves Y50 and Y51

4 Characteristics of the proportional solenoid valves Y50 and Y51

Fig. 3

Regulation diagram

a = Y50 (A 900 C); Y51 (A 900 C / A 904 C) b = Y50 (A 904 C) The regulation characteristics illustrate the interrelation between input current (I) of the regulating solenoid valves and the regulating pressure (p) at the outlets LR or LS respectively. The effect of the pressures p (GLR) at outlet LR or p ( Pred) at outlet LS on the power settings and/ or the limitation of the pivot angle of the respective working pumps is described in group 7. The regulation characteristics of a proportional solenoid valve can be checked by measuring a number of pressure values at outlet LR (or LS) relative to the solenoid current ILR in Y50 (or Iev in Y51). The measurement and subsequent adjustment of the currents ILR and IEV to fixed values can be completed with sufficient accuracy by means of the display menus (see group 8.71).

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MJFCIFSS

7.42.5


Service Manual

Emergency position of the proportional solenoid valves Y50 / Y51

5 Emergency position of the proportional solenoid valves Y50 / Y51 By removing the pin 2 and tilting the lever 3 into a horizontal position, the solenoid valves Y50 and Y51 can be brought into a pre-defined emergency position. During operation in emergency position, the connection plug 1 at the proportional solenoid valve must be unplugged in order to prevent interference by the control current.

5.1

Adjustment of the emergency position Set the regulating pressure to the desired fixed value by proceeding as follows: Connect a pressure sensor to the measuring point 59 or 57. While the engine is running and the lever 3 is in a horizontal position, remove the lock nut 5 and turn the adjusting screw 4 until the desired pressure is obtained. Re-tighten the lock nut 5, holding the adjusting screw 4 in its position and re-check the pressure settings.

Fig. 4

7.42.6

Emergency position of the regulating solenoid valves Y50 and Y51

1 2

Adapter Cotter pin

57 59

Measuring point (rp reduction) Measuring point (power control)

3 4

Lever Adjusting nut

Y50


5

Lock nut

Y51

Proportional solenoid valve / LS control

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MJFCIFSS

Service Manual

Pilot control unit 4 x Design

Pilot control unit 4 x 1 Design The two pilot control valves with joystick, (to the left and right of the operator's seat) control the working functions of lifting, stick movements, bucket cylinder movements and turning of the uppercarriage. There are four regulating pistons 12 (pressure control valves) inserted in an axial position in the housing 10, complete with pressure, return and control connections. The regulating piston 12 is operated by means of the joystick 1 with universal joint 16 and the switching disc 18. The joystick 1 can be moved freely in any direction. With each movement, it presses against one or several spring-loaded pushrods, which then switch the disc 18 attached to the joystick. The regulating piston 12 located under the disc is operated by means of the regulating spring (see Fig. 4) and the reset spring (see Fig. 4), so that a connection is established from the pressure channel P to the outlet 1 / 2 / 3 / 4. The bellows 31 protects universal joint, pushrods, guide bushing etc. against dirt.

Fig. 1

Diagram of the pilot control unit with joystick and other components

1

Joystick

16

Universal joint

10

Housing / pilot control unit

18

Switching disc

12

Regulating piston

31

Bellows

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MJFCIFSS

7.45.1


Service Manual


2 Functional description see Fig. 4 The pilot control valve is of the pressure regulating type. That means, regulating piston 12 of the pilot control valve builds up pressure on the discharge side, between pilot control valve and control valve block, and is, thus, shifted, against the pressure from pressure spring 25. When the joystick 1 is moved, the switching disc 18 pushes the pushrod 98.1 down, and the regulating spring 25 shifts the regulating piston 12. The control oil flows through the radial and axial boreholes in the regulating piston 12 from the pressure channel P through connection 1 or 2 , and from the control line to one of the control connections at the control valve block. As the spools in the control valve block are pressurised, a set pressure that is proportional to the predefined lever travel (see Fig. 2) is built up. The pressure acts on the face of the regulating piston 12 and shifts it against the regulating spring 25 until the connection with channel P is blocked. Depending on the position of the joystick 1 and the stroke travel of the pushrod 98.1, a preset pilot pressure is established, which shifts the spool 12 proportionally to the pressure increase. At a set pressure (corresponding to the end of the fine-control phase of the spool), the pushrod 98.1 moves the regulating piston 12 downwards. At this point, maximum control pressure is applied to the spool.

3 Repairs (see Fig. 4, page 5)

3.1

Dismantling of the regulating unit Pull up the bellows 31. Loosen the locknut 21. Remove the sleeve 20 with the joystick components 1 / 2. Remove the nut 17 and the switch disc 18. Remove the universal joint 16 from the housing 10. Remove the protective covers 98.5 and the lid 32. Pull the pushrod 98.1 complete with the bushing 98.2 from the housing 10. Press the pushrod 98.1 out of the bushing 98.2. Remove the O-ring 98.4 and the PDF seal 98.3 from the bushing 98.2. Press the regulating piston 12 with the pressure springs 25 and 28 as well as the spring plate 15 with disc 23 from the plate 10, pushing it upwards. Remove the disc 23* from the spring plate 15 . Pull out the regulating piston 12. Remove the pressure spring 25 with the washers 49 / 50.

3.2

Assembly of the regulating unit Prior to assembling the unit, clean all parts and check whether they are fit for re-use. 49 / 50

25

15

12

Mount the disc 23* . Insert the spring plate 15 with the preassembled regulating piston 12 and the pressure spring 25 into the housing 10 and the bushing 13. Insert a new O-ring 98.4 and PDF seal 98.3 into the bushing 98.2. Insert the pushrod 98.1 and install the bushing 98.2 with the pushrod 98.1 into the housing 10.

7.45.2

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MJFCIFSS

Service Manual

Pilot control unit 4 x Repairs Replace the lid 32 and the protective cover 98.5. Screw in the universal joint 16 (torque: 20 Nm). Screw in the switch disc 18 complete with the nut 17. Adjust pilot control unit to zero position. Screw the sleeve 20 with the joystick 1 into the nut 17 and then tighten the nut 21, ensuring that the joystick 1 is in the correct position. Pull the bellows 31 down over disc 30.

* New model II does not contain disc 23, see Fig. 3.

3.3

Pilot control valve adjustment in zero position, see Fig. 4 The switch disc 18 and the pushrod 98.1 must be set and installed in such a way that there is no play between them when the pilot control valve is not actuated. To adjust: loosen the nut 17. Turn the switch disc 18 until all four pushrods are in zero position, and there is no more play between switch disc 18. and the four pushrods 98.1. When finished, re-tighten nut 17.

Fig. 2

Diagram: c = control pressure in bar, d = lever displacement in angular degrees

Built into the machine A 309 - R 317

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MJFCIFSS

Point a

Point b

5.8 -0.3 bar

24.3 bar

7.45.3


Service Manual

Exploded view

4 Exploded view

7.45.4

Fig. 3

Pilot control valve model I until May 2004, model II from June 2004

10 12

Housing Regulating piston

98.2 98.3

Bushing PDF seal

13 15

Bushing (press-fitted) Spring plate

98.4 98.5

O-ring Protective cap

16 17

Universal joint Hex nut

140 150

Plate Bellows

18

Switching disc

160

Sleeve

23 25

Disc Pressure spring (regulating spring)

166 171

Nut Handle section

28

Pressure spring (return spring)

172

Handle section

30

Plate

173

Sensor surface

32

Cover

177

Dummy cap

49

Washer

192

Wire harness

50

Washer

80

Wire grommet

S5L/S5R button / grapple rotator

81

Bushing

S63

98

Repair kit

S263

98.1

Pushrod

S382

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MJFCIFSS

Switch / travel direction

Service Manual

Pilot control unit 4 x Sectional drawing

5 Sectional drawing

Fig. 4

Sectional drawing of the pilot control unit

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MJFCIFSS

7.45.5


Service Manual

Sectional drawing

7.45.6

140 142

Plate Retaining washer

B19R* Sensor transducer / right B19L* Sensor transducer / left

144 146

Spacer sleeve Allen head screw

S5R* S5L*

150

Bellows

160 166

Sleeve Hex head screw

S263* Switch / travel direction S382* Switch / fine adjustment (A 312 - R 317)

170 171

Handle Handle section

X15-2* Plug connection, 2-pin X80* Plug connection, 3-pin

172 173

Handle section Sensor surface

X81* Plug connection, 3-pin X342* Plug connection / 3-pin

177

Dummy cap

X909* Plug connection, 2-pin

Push button / turn grapple right Push button / turn grapple left

190

Sheet metal screw


191

Allen head screw


192 193

Wire harness Adapter

X1048* Plug connection, 12-pin X1049 Plug connection, 3-pin

200 201

Sheet metal screw Small parts kit

202

Pressure spring

*

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Installation according to machine type and serial number, see electrical system of basic machine, group 8.

Service Manual

Pilot control unit 4 x Sectional drawing

Fig. 5

Pilot control valve, right, with electrical components

Fig. 6

Pilot control valve, left, with electrical components

copyright by

MJFCIFSS

7.45.7


Service Manual

Sectional drawing

7.45.8

copyright by

MJFCIFSS

Service Manual

Pilot control unit 2 way for travel gear drive Description

Pilot control unit 2 way for travel gear drive 1 Description The travel gear operation is controlled by means of the pilot control unit with two pedals located in front of the operator seat and integrated into the pedal plate/base of the operator's cab. There are two regulating pistons 12 (pressure control valves) inserted in an axial position in the housing 10, complete with pressure, return and control connections. The regulating pistons 12 are operated by means of the pedal plate 2 that are equipped with the axle 24. The two pedals plates 2 / 3 can be moved forward and backward, thus actuating a spring-loaded pushrod via a threaded stud. This actuates the regulating piston 12 (with regulation spring and return spring) located below the above assembly, which is now opened towards the pressure channel P, outlet 1/2. The unit is equipped with a cover protecting the pushrod, guide bushing etc. against dirt.

Fig. 1

Pilot control unit 2x for travel left/right with functional diagram

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MJFCIFSS

7.46.1


Service Manual

Description of functions

2 Description of functions see Fig. 3 / Fig. 4 The pilot control unit is of the pressure regulating type. That means, regulating piston 12 of the pilot control unit builds up pressure on the discharge side, between pilot control unit and control unit block, and is, thus, shifted, against the pressure from pressure spring 25. When the pedal plate 2 is pressed down, a threaded stud 2.3 pushes the pushrod 13 down, so that the regulating spring 25 shifts the regulating piston 12. The control oil flows through the radial and axial boreholes in the regulating piston 12 from the pressure channel P through connection 1 or 2, see Fig. 4 and the control line to one of the control connections at the control valve block. As the spools in the control valve block are pressurised, a set pressure that is proportional to the predefined lever travel (see Fig. 2) is built up. The pressure acts on the face of the regulating piston 12 and shifts it against the regulating spring 25 until the connection with channel P is blocked. Depending on the position of the pedal 2/3 and the stroke travel of the pushrod 13,a preset pilot pressure is established, which shifts the spool 12 proportionally to the pressure increase. At a set pressure (corresponding to the end of the fine-control phase of the spool 12), the pushrod 13 moves the regulating piston downwards. At this point, maximum control pressure is applied to the spool 12. There is a valve insert 20 (shuttle valve) in the housing 10 between the control connections. If the pilot control unit is operated in such a way that control pressure is fed through a pressure connection the control valve bloc, the control oil system pressurises the shuttle valve 20. The ball 45 in the valve 20 closes the connection to the other control line, so that the applied pressure is available at connection 7 for other control functions (connection 7 is temporarily closed).

3 Repairs 3.1

Dismantling of the regulating unit Release the disc 47. Press out the axle 24 and remove the pedal plate 2. Remove the protective covers 30 and the screws 46 and remove the retaining plate 29. Pull the pushrod 13 with the bushing 14 from the housing 10. Press the pushrod 13 out of the bushing 14. Remove the O-ring 38 and the PDF seal 40 from the bushing 14. Press the regulating piston 12 with the pressure springs 25 and 26 as well as the spring plate 15 with disc 23 from the plate 10, pushing it up from underneath. Remove the disc 23 from the spring plate 15. Pull the regulating piston 12 from the unit. Remove the pressure spring 25 with the washers 49 / 50.

3.2

Assembly of the regulating unit Prior to assembling the unit, clean all parts and check whether they are fit for re-use. Place the washers 41 / 42, the pressure spring 25 and the spring plate 15 on the regulating piston 12. Mount the disc 23.

7.46.2

copyright by

MJFCIFSS

Service Manual

Pilot control unit 2 way for travel gear drive Repairs Insert the spring plate 15 with the preassembled regulating piston 12 and the pressure spring 25 / 26 into the housing 10 and the bushing 10.2. Insert a new O-ring 38 and PDF seal 37 in the bushing 14. Insert the pushrod 13 and install the bushing 14 with pushrod 13 in the housing 10. Place the retaining plate 29 with the pedal 2 onto the unit and secure it with the screws 46. Mount the protective covers 98.5. Position the pedal 2 in the bearing, push in the axle 24 and spring-mount the disc 47. Adjustment of pilot control unit

3.3

Adjustment of pilot control unit to zero position The pilot control unit should be adjusted in such a way that the maximum control pressure can be reached in the extreme position (stop), and the pedal can be operated in a comfortable and ergonomic position. Remove the cover 2.2 from the pedal 2.1. Loosen the lock nut 2.4 and turn the threaded stud 2.3 (see Fig. 1) until the pedals reach their new neutral / limit positions and fulfil the above requirements. Install a measuring point to measure the control pressure between the connection 1 / 2 and the connection at the respective spool / control valve block. After completed adjustment, tighten the lock nut 2.4 and replace the cover 2.2 on the pedal 2.1.

3.4

Check of shuttle valves 20 The valve insert 20 is secured with Loctite. Heat it and remove it from the housing, using an Allen key. Be careful not to lose the ball 45. Check valve for dirt and damage. Install the ball 45. Insert the seal ring 40 and the valve insert 20. Apply Loctite 572 to the valve insert and screw it in completely (torque: 10 Nm). .

Fig. 2

Diagram: Control pressure relative to pedal travel Diagram to the left: from start of series - diagram to the right: from serial no. 18915

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MJFCIFSS

7.46.3


Service Manual

Exploded view and sectional drawing

4 Exploded view and sectional drawing

7.46.4

1

Pilot control unit, complete

33

Screw plug

2 2.1

Pedal, complete Pedal

36 37

Seal plug PDF seal

2.2

Cover

38

O-ring

2.3

Threaded stud

40

Sealing ring

2.4

Hex nut

41

Washer

2.5 10R

Bushing Housing right

42 45

Washer Ball

10L

Housing left

46

Hex nut

10.2 12

Pressed-in bushing Regulating piston

47 50

Disc Screw plug

13 14

Pushrod Bushing

51

Sealing ring

15 20

Spring plate Valve insert

998

Repair kit, consisting of

23

Disc

998.1

Pushrod (item 13)

25 26

Pressure spring (regulating spring) Pressure spring (return spring)

998.2 998.3

Bushing (item 14) PDF seal (item 37)

29 30

Retaining plate Cap

998.4 998.5

O-ring (item 38) Protective cover (cap)

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MJFCIFSS

Service Manual

Pilot control unit 2 way for travel gear drive Exploded view and sectional drawing

Fig. 3

Exploded view of the pilot control units for the right and left travel gear drives

copyright by

MJFCIFSS

7.46.5


Service Manual


7.46.6

1


33

Screw plug

2 2.1

Pedal, complete Pedal

36 37

Seal plug PDF seal

2.2

Cover

38

O-ring

2.3

Threaded stud

40

Sealing ring

2.4

Hex nut

41

Washer

2.5 10R

Bushing Housing right

42 45

Washer Ball

10L 10.2

Housing left Pressed-in bushing

46 47

Hex nut Disc

12 13

Regulating piston Pushrod

50 51

Screw plug Sealing ring

14

Bushing

15 20

Spring plate Valve insert

998

Repair kit, consisting of

23 25

Disc Pressure spring (regulating spring)

998.1 998.2

Pushrod (item 13) Bushing (item 14)

26


998.3

PDF seal (item 37)

29

Retaining plate

998.4

O-ring (item 38)

30

Cap

998.5

Protective cover (cap)

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MJFCIFSS

Service Manual

Pilot control unit 2 way for travel gear drive Exploded view and sectional drawing

Fig. 4

Sectional drawing of a pilot control unit for the travel gear

copyright by

MJFCIFSS

7.46.7


Service Manual


7.46.8

copyright by

MJFCIFSS

Service Manual

Pilot control unit 4x Design

Pilot control unit 4x for travel gear drive

5 Design see Fig. 7 and Fig. 8 The travel gear operation is controlled by means of the pilot control unit with two pedals located in front of the operator seat and integrated into the pedal plate/base of the operator's cab. There are two regulating pistons 16 (pressure control valves) inserted in an axial position in the housing 3, complete with pressure, return and control connections. The regulating pistons 16 are operated by means of two pedals 20 / 25. The two pedals 20 / 25 can be moved forward and backward, thus pushing the spring-loaded pushrod 8 with the switch disc 6 and the threaded stud 18. As a result, the regulating piston 16 is actuated by the regulation spring 11.1 and the return spring 11.1, so that it is in open position (connection P - control connection 19). The pushrod, guide bushing, etc. are protected against dirt with a bellows 5.

Fig. 5

Pilot control unit 4x 82 for travel left/right with functional diagram

copyright by

MJFCIFSS

7.46.11

for travel gear drive

Service Manual


6 Functional description see Fig. 8 / Fig. 9 The pilot control unit is of the pressure regulating type. That means, regulating piston 16 of the pilot control unit builds up pressure on the discharge side, between pilot control unit and control valve block, and is, thus, shifted, against the pressure from pressure springs 11. When the pedal 20/25 is pressed down, a threaded stud 18 pushes the pushrod 8 down, and the regulating spring 25 shifts the regulating piston 16. The control oil flows through the radial and axial boreholes in the regulating piston 16 from the pressure channel P through connection 1, 2, 3 or 4, see Fig. 9 and the control line to one of the control connections at the control valve block. As the spools in the control valve block are pressurised, a set pressure that is proportional to the predefined lever travel (see Fig. 6) is built up. The pressure acts on the face of the regulating piston 16 and shifts it against the regulating spring 11.1 until the connection with channel P is blocked. Depending on the position of the switch disc 5 and the stroke travel of the pushrod 8, a preset pilot pressure is established, which shifts the spool 16 proportionally to the pressure increase. At a set pressure (corresponding to the end of the fine-control phase of the spool), the pushrod 8 moves the spool downwards. At this point, maximum control pressure is applied to the spool 12. With each actuation of the pedal 20/25, the threaded stud 18 pushes the pushrod 12 down. Simultaneously, the control oil below the pushrod 12 (fed through the check valve 14) is pressurised and flows through the nozzle 15 to the parallel-mounted pushrod 12. The restriction ensures that the control flow flowing off dampens the pedal movement. The housing 3 of the pilot control units is equipped with the shuttle valves 17 mounted between the control connections. If the pilot control unit is operated in such a way that control pressure is fed through a pressure connection the control valve block, the control oil system pressurises the shuttle valve 17. The ball 45 in the valve 17 closes the connection to the other control line, so that the applied pressure is available at connection 7 for other control functions (connection 7 is temporarily closed).

7 Repairs 7.1

Dismantling of the regulating unit Remove the screws 26 and fold the pedals 20 / 25 up. Remove the screws 41 and remove the base 27 / 28 with the pedal 20 / 25. Remove the bellows 5. Note! The regulating unit 10 and the pushrod 12 are preloaded by the spring. When dismantling and mount the devices, work at a clean workplace and proceed with the necessary caution. The regulating unit can only be ordered as a complete item. Remove the threaded studs 7.4 and pull out the pins 7.2, using the M4 screw. Loosen the screws 7.3 and remove the plate 7. Pull the hollow rod 9 with the pushrod 8 from the housing 3. Pull/push the regulating unit 10 with the spring set 11 from the housing 3.

7.46.12

copyright by

MJFCIFSS

Service Manual

for travel gear drive Repairs

7.2

Installation of regulating unit Prior to assembling the unit, clean all parts and check whether they are fit for re-use. Push the regulating unit 10 with the spring set 11 into the housing 3. Push the hollow rod 9 with the pushrod 8 into the housing 3. Position the plate 7 and secure it with the screws 7.3. Check the pushrod for free movement. Insert the switch disc 6 into the bearing of the plate 7 and push in the pins 7.2. Secure the pins 7.2 with the threaded studs 7.4. Adjustment of pilot control unit, see 7.3 Place the base 27 / 28 together with the pedal 20 / 25 onto the switch disc 6 and secure it with the screws 41 (with retaining washers 42). Fold the pedal 20 / 25 down and screw in the screws 26, holding the pedal 20 / 25 in the desired position.

7.3

Adjustment of pilot control unit to zero position Remove the cover 2.2 from the pedal 2.1. Loosen the lock nut 2.4 and turn the threaded stud 2.3 (see Fig. 5) until the pedals reach their new neutral / limit positions and fulfil the above requirements. Install a measuring point to measure the control pressure between the connection 1 / 2 and the connection at the respective spool / control valve block. After completed adjustment, tighten the lock nut 2.4 and replace the cover 2.2 on the pedal 2.1.

7.4

Check of shuttle valves 20 The valve insert 20 is secured with Loctite. Heat it and remove it from the housing, using an Allen key. Be careful not to loose the ball 45. Check valve for dirt and damage. Install the ball 45. Insert the seal ring 40 and the valve insert 20. Apply Loctite 572 to the valve insert and screw it in completely (torque: 10 Nm). .

Fig. 6

Diagram: Control pressure relative to pedal travel

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MJFCIFSS

7.46.13


Service Manual


8 Exploded view and sectional drawing

Fig. 7

7.46.14

Exploded view of pilot control unit operation

2 20

Pilot control unit, complete Left pedal

30 31

Pin Washer

25 26

Right pedal Allen head screw

32 41

Cotter pin Allen head screw

27

Base

42

Retaining washer

28

Base

copyright by

MJFCIFSS

Service Manual

for travel gear drive Exploded view and sectional drawing

Fig. 8

Exploded view of pilot control unit

2


12

Pushrod

5

Bellows

13

Return spring

6

Switch disc

14

Check valve

7 7.1

Plate, complete Bearing block

15 16

Nozzle set Regulating piston

7.2

Allen head screw

17

Shuttle valve

7.3

Pin

18

Threaded stud

7.4

Threaded stud

8 9

Pushrod Hollow rod

10 11

Regulating unit Spring set

copyright by

MJFCIFSS

7.46.15


Service Manual


Fig. 9

7.46.16

Sectional drawing of the pilot control unit

6

Switch disc

7 7.1

Plate, complete Bearing block

11.1 11.2

Regulation spring Return spring

7.2

Allen head screw

12

Pushrod

7.3

Pin

13

Return spring

7.4 8

Threaded stud Pushrod

15 16

Nozzle set Regulating piston

9 10

Hollow rod Regulating unit

17 18

Shuttle valve Threaded stud

11

Spring set

19

Control connection

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MJFCIFSS

Service Manual

Pilot control valve 2 x Description

Pilot control valve 2 x 1 Description The two pilot control valves with foot pedals, in front of the operator's seat to the left, in the running plate of the base of the operator's platform, control the operations of the accessory kit. There are two regulating pistons 12 (pressure control valves), sitting in an axial position in housing 1, complete with pressure, return and control connections. There are two pedals 2 and 3 on top, to actuate regulating piston 12. The two pedals 2 / 3 can be pressed down, and then actuate a spring-loaded pushrod via a threaded stud. This actuates regulating piston 12 underneath (with regulation spring and return spring) and, thus, opens it towards pressure channel P, outlet 1/2. There is a cover to protect pushrod, guide bushing etc. against dirt.

Fig. 1

Pilot control valve 2 x with hydraulic diagram

copyright by

MJFCIFSS

7.47.1


Service Manual


2 Functional description see Fig. 3 / Fig. 4 The pilot control valve is of the pressure regulating type. That means, regulating piston 12 of the pilot control valve builds up pressure on the discharge side, between pilot control valve and control valve block, and is, thus, shifted, against the pressure from pressure spring 25. When pedals 2 and/or 3 are actuated, threaded stud 47 presses pushrod 98.1 down and shifts regulating piston 12 via regulating spring 25. The radial and axial bores in regulating piston 12 let control oil from pressure channel P enter into connection 1 or 2 (see Fig. 4) and the control line to flow to one of the control connections on the additional axle of the control valve block. Pressurising the spools in the control block will build up a certain pressure which is proportional to the pre-defined displacement of the lever (see Fig. 2). The pressure acts on the face of regulating piston 12 and shifts it against regulating spring 25 until the connection with channel P is interrupted. Depending on how pedal 2/3 is positioned, and what the stroke of pushrod 98.1 is, there will be a certain pilot pressure, which will shift the spool proportionally. At a certain pressure (which corresponds to the end of the fine control phase of the spool), pushrod 98.1 will move regulating piston 12 down directly. At this point, the spool will receive the max. control pressure. 1

3 Repair 3.1

Dismantling the regulating unit Lift pedal 2 / 3 Remove protective covers 98.5. Remove screws 46. Remove bearing pillow block 10 complete with pedals 2 / 3. Pull pushrod 98.1 with bushing 98.2 from housing 1. Press pushrod 98.1 out of bushing 98.2. Remove O-ring 98.4 and PDF seal 98.3 from bushing 98.2. Press regulating piston 12 complete out of bearing pillow block 10 (from below), complete with pressure springs 25 and 26 and spring plate 15 with disc 23. Remove disc 23 from spring plate 15. Pull out regulating piston 12. Remove pressure spring 25 with washers 49 / 50.

3.2

Installing the regulating unit Before installation, be sure to clean all parts and check whether they are fit for re-use.

7.47.2

copyright by

MJFCIFSS

Service Manual

Pilot control valve 2 x Repair Place washers 49 / 50, pressure spring 25 and spring plate 15 on regulating piston 12. Place disc 23. Push spring plate 15 into housing 1 and bushing 16, complete with pre-installed regulating piston 12 and pressure spring 25 / 26. Install new O-ring 98.4 and PDF seal 98.3 in bushing 98.2. Insert pushrod 98.1. Install bushing 98.2 complete with pushrod 98.1 in housing 1. Bearing pillow block 10 complete with pedals 2 / 3. Screw in screws 46. Install protective covers 98.5. Adjusting pilot control valve

3.3

Pilot control valve adjustment in zero position The pilot control valve should be adjusted in such a way that the max. control pressure can be reached in the extreme position (stop), and pedals 2 / 3 can be operated in a comfortable and ergonomic position. To adjust: Loosen lock nut 48. Turn stud 47 (see Fig. 1) until the pedals reach their new neutral / end positions and fulfil the conditions as mentioned above. Install a measuring point to measure the control pressure between connection 1 / 2 and the connection at the spool / control valve block in question.

3.4

Checking shuttle valve 20 Valve insert 20 has been installed using Loctite. Heat, and remove completely from housing, using an Allen key. Be careful with ball 45. Check valve for dirt and damage. Install ball 45. Install seal 40. Apply Loctite 572 to valve insert 20 and screw in completely (torque: 10 Nm). .

Fig. 2

Diagram: c = control pressure in bar, d = Pushrod displacement in mm

A 309 - R 317 Litronic

copyright by

MJFCIFSS

Point a

Point b

5.8 -0.3 bar

24.3 bar

7.47.3


Service Manual

Exploded view

4 Exploded view

Fig. 3

7.47.4

Exploded drawing: pilot control valve

1

Housing

40

Seal ring

2 2.1

Pedal to the left Bushing

41 42

Washer Washer

3

Pedal to the right

45

Ball

3.1 10

Bushing Bearing pillow block

46 47

Hex nut Threaded stud

11 12

Pin Regulating piston

48 50

Hex nut Screw plug

13 15

Bushing (pressed in) Spring plate

51 52

Seal ring Snap ring

16

Bushing

98

Repair kit

20

Valve insert

98.1 Pushrod

23 25

Washer Pressure spring (regulating spring)

98.2 Bushing 98.3 PDF seal

26


98.4 O-ring

33

Screw plug

98.5 Protective cover

copyright by

MJFCIFSS

Service Manual

Pilot control valve 2 x Sectional drawing

5 Sectional drawing

Fig. 4

Sectional drawing

copyright by

MJFCIFSS

7.47.5


Service Manual

Sectional drawing

7.47.6

copyright by

MJFCIFSS

Service Manual


Pilot control valve 2 x 1 Description The operator controls outrigger and/or blade support operations by means of the pilot control valve and lever (on the control console, to the right). There are two regulating pistons 12 (pressure control valves), sitting in an axial position in housing 70, complete with pressure, return and control connections. There is a sort of tipping switch on top, (with lever 64) to actuate regulating piston 12. The tipping switch 3, which can move to and fro, presses with each movement against a screwed-in threaded thud which, again, presses against a spring-loaded pushrod. This actuates regulating piston 12 underneath (with regulating spring and return spring) and, thus, opens it towards pressure channel P, outlet 1 / 2. There is a cover to protect pushrod, guide bushing etc. against dirt.

Fig. 1

Pilot control valve 2 x with hydraulic diagram

copyright by

MJFCIFSS

7.48.1


Service Manual


2 Functional description The pilot control valve is of the pressure regulating type. That means, regulating piston 12 of the pilot control valve builds up pressure on the discharge side, between pilot control valve and control valve block, and is, thus, shifted, against the pressure from pressure spring 25. Upon actuation, lever 64 and tipping switch 3 act on threaded stud 18, which presses pushrod 98.1 down and, at the same time, shifts regulating 12 via regulating spring 25. The radial and axial bore in regulating piston 12 lets control oil flow from pressure channel P via connection 1 or 2 and the control line to one of the control connections of the control valve block. Pressurising the spools in the control block will build up a certain pressure which is proportional to the pre-defined displacement of the lever (see Fig. 2). The pressure acts on the face of regulating piston 12 and shifts it against regulating spring 25 until the connection with channel P is interrupted.

3 Repair 3.1

Dismantling the regulating unit Loosen hex nut 68. Unscrew lever 64 complete from tipping switch 3. Remove bellows 66. Remove screws from connecting link 90. Remove connection link. Remove threaded stud or Allen head screw 20. This will release axle 24. Press out axle 24. Lift and take out complete tipping switch 3. Remove protective covers 98.5. Remove Allen head screw 21. Lift and take out cover plate 29. Pull pushrod 98.1 with bushing 98.2 from housing 70. Press pushrod 98.1 out of bushing 98.2. Remove O-ring 98.4 and PDF seal 98.3 from bushing 98.2. Press complete regulating piston 12 out of the housing (from below), complete with pressure springs 25 and 28 and spring plate 15 with disc 23. Remove split disc 23 from spring plate 15 . Pull out regulating piston 12. Remove pressure spring 25 with washers 49 / 50.

3.2

Installing the regulating unit Before installation, be sure to clean all parts and check whether they are fit for re-use. Place washers 49 / 50, pressure spring 25 and spring plate 15 on regulating piston 12. Place split disc 23. Push spring plate 15 into housing 70 (bushing), complete with pre-installed regulating piston 12 and pressure spring 25 and pressure spring 28. Install new O-ring 98.4 and PDF seal 98.3 in bushing 98.2. Insert pushrod 98.1. Install bushing 98.2 complete with pushrod 98.1 in housing 70. Place plate 29. Screw in screws 21. Place protective covers 98.5.

7.48.2

copyright by

MJFCIFSS

Service Manual

Pilot control valve 2 x Repair Place tipping switch 3. Press in axle 24. Re-tighten threaded stud / Allen head screw 20. Screw lever 64 complete. to tipping switch 3. Re-tighten hex nut 68. Adjusting pilot control valve

3.3

Pilot control valve adjustment in zero position Stud 18 and pushrod 98.1 must be set and installed in such a way that there is no play between them when the pilot control valve is not actuated. Loosen lock nut 17. Turn stud 18 until both pushrods 98.1 are in zero position and there is no more play between screw 18 and pushrod 98.1. .

Fig. 2

Diagram: c = control pressure in bar, d = lever displacement in angular degree

A 309 - A 316 Litronic und A 309 - R 317 Litronic TCD

copyright by

MJFCIFSS

Point a

Point b

5.8 -0.3 bar

24.3 bar

7.48.3


Service Manual

Exploded view

4 Exploded view

Fig. 3

7.48.4


3 12

Tipping switch Regulating piston

52 54

Shim Shim

15 17

Spring plate Hex nut

64 65

Lever Handle

18

Threaded stud

66

Bellows

20 21

Allen head screw Allen head screw

68 70

Hex nut Housing

23 24

Split disc Axle

71 90

Bushing (pressed in) Connecting link

25


98

Repair kit

28


98.1

Pushrod

29

Cover plate

98.2

Bushing

49 50

Washer Washer

98.3 98.4

PDF seal O-ring

51*

Shim

98.5

Protective cover

*

Omitted in A 309 - 312 machines from start of series in A 314 - 316 machines from serial no. 11500 and A 309 - R 317 Litronic TCD machines from start of series

copyright by

MJFCIFSS

Service Manual

Pilot control valve 2 x Sectional drawing

5 Sectional drawing

Fig. 4

Sectional drawing: pilot control valve

copyright by

MJFCIFSS

7.48.5


Service Manual

Sectional drawing

7.48.6

copyright by

MJFCIFSS

Service Manual


Pilot control valve 1 x 1 Description The operator controls the operations of the chassis by means of a foot pedal, to the right, in front of his seat, in the running plate of the base of the operator's platform. It actuates the pilot control valve. There is a regulating piston 12 (pressure control valve), sitting in an axial position in housing 6, complete with pressure, return and control connections. There is a second pedal 2 on top to actuate regulating piston 12. This pedal (that can be pressed down) pushes down on a spring-loaded pushrod. This actuates regulating piston 12 underneath (with regulating spring 25 and return spring) and, thus, opens it towards pressure channel P (outlet A). There is a cover to protect pushrod, guide bushing etc. against dirt.

Fig. 1

Pilot control valve 1x with hydraulic diagram

copyright by

MJFCIFSS

7.49.1


Service Manual


2 Functional description Fig. 3 / Fig. 4 The pilot control valve is of the pressure regulating type. That means, regulating piston 12 of the pilot control valve builds up pressure on the discharge side, between pilot control valve and control valve block, and is, thus, shifted, against the pressure from pressure spring 25. Actuation of pedal 2 will push pushrod 98.1 down. At the same time, it will shift regulating piston 12 by means of regulating spring 25. The radial and axial bores in regulating piston 12 let control oil from pressure channel P penetrate into connection 1 and the control line, to flow on to solenoid valve 'travel forward / reverse' and to the control connections on control valve block 6. Pressurising spool 12 in housing 6 will build up a certain pressure which is proportional to the predefined displacement of the lever (Fig. 2). The pressure acts on the face of regulating piston 12 and shifts it against regulating spring 25 until the connection with channel P is interrupted. Depending on how pedal 2 is positioned, and what the stroke of pushrod 98.1 is, there will be a certain pilot pressure, shifting spool 12 proportionally. At a certain pressure (which corresponds to the end of the fine control phase of the spool), pushrod 98.1 will move regulating piston 12 down directly. At this point, the spool will receive the max. control pressure.

3 Repair 3.1

Dismantling the regulating unit Remove hex head screws 86. Remove protective cover 98.5. Remove plate 1 complete with pedal 2. Pull pushrod 98.1 with bushing 98.2 from housing 6. Press pushrod 98.1 out of bushing 98.2. Remove O-ring 98.4 and PDF seal 98.3 from bushing 98.2. Press regulating piston 12 out of housing 6 (from below), complete with pressure springs 25 and 26 and spring plate 15 with disc 23. Remove split disc 23 from spring plate 15. Pull out regulating piston 12. Remove pressure spring 25 with washers 37 / 38.

3.2

Installing the regulating unit Before installation, be sure to clean all parts and check whether they are fit for re-use. Place washers 37 / 38, pressure spring 25 and spring plate 15 on regulating piston 12. Place split disc 23. Push spring plate 15 into housing 6 and bushing 17, complete with pre-installed regulating piston 12 and pressure spring 25 and pressure spring 26. Install new O-ring 98.4 and PDF seal 98.3 in bushing 98.2. Insert pushrod 98.1. Install bushing 98.2 complete with pushrod 98.1 in housing 6. Place plate 1 in one piece. Screw in screws 86 complete with washers 85. Screw in pin 7 with retaining washer 9. Secure with cotter pin 11 (see Fig. 3). Place protective cover 98.5. Check pilot control valve for correct operation.

7.49.2

copyright by

MJFCIFSS

Service Manual

Pilot control valve 1 x Repair

Fig. 2

Diagram: c = control pressure in bar, d = lever displacement in angular degree

A 309 - A 316

copyright by

MJFCIFSS

Point a

Point b

6.5 bar

25 bar

7.49.3


Service Manual

Repair

3.3

Exploded view

Fig. 3


1 2

Plate Pedal

26 37

Pressure spring (return spring) Washer

6 7

Housing Pin

38 39*

Washer Shim ring

9

Washer

85

Retaining washer

11 12

Cotter pin Regulating piston

86 98

Hex head screw Repair kit

15 17

Spring plate Bushing (pressed in)

98.1 Pushrod 98.2 Bushing

23 25

Washer Pressure spring (regulating spring)

98.3 PDF seal 98.4 O-ring

26


98.5 Protective cover *

7.49.4

copyright by

MJFCIFSS

Omitted in A 309 - 312 machines from start of series in A 314 - 316 machines from serial no. 11500.

Service Manual

Pilot control valve 1 x Repair

3.4

Sectional drawing

Fig. 4

Sectional drawing: pilot control valve

6

Housing

37

12 15

Regulating piston Spring plate

38 Washer 98.1 Pushrod

17

Bushing (press-fitted)

98.2 Bushing

23

Disc

98.3 PDF seal

25


98.4 O-ring

26


98.5 Protective cap

copyright by

MJFCIFSS

Washer

7.49.5


Service Manual

Repair

7.49.6

copyright by

MJFCIFSS

Service Manual

Compact control block Function

Compact control block 1 Function The devices of the compact excavator models A 309 / A 311 are equipped with a built-in compact control valve block. The compact control valve blocks are designed specifically to suit the relevant task. Each control valve block contains 8 spools for working and travel functions, and the associated pressure-relief and suction valves. The geometry of the spools and the mounted regulating spring has been designed and adapted specifically to match the characteristics of the individual consumer. The control valve block is designed as a restrictor control element.

Fig. 1


copyright by

MJFCIFSS

7.50.1


Service Manual

Technical data

2 Technical data Contained in: Type

A 309 Litronic 717

Series

A 311 Litronic 718

M8-1384-00 8M8-16

Spool

Unit

101 Slewing gear Ext.

Retr.

102 Stick cylinder Ext.

Retr.

103 Support cylinder Ext.

Retr.

105 Regulating cylinder Ext.

Retr.

106 Boom cylinder

107 Bucket cylinder

Ext.

Ext.

Retr.

Retr.

Nominal block width

mm

20

20

20

20

20

20

Consumer connection

inch

3/4

3/4

3/4

3/4

3/4

1/2

Ø piston rod

mm

20

20

20

20

20

20

Piston stroke

mm

9.0

9.0

9.0

9.0

9.0

9.0

9.0

9.0

9.0

9.0

9.0

9.0

p1bar ± 0.5 mm*

bar

7.0

7.0

7.0

7.0

7.0

7.0

7.0

7.0

7.0

7.0

7.0

7.0

p2bar ± 0.5 mm*

bar

24

24

24

24

24

24

24

24

24

24

24

24

Leak oil max. at load pressure at oil temperature

3

cm /min bar °C

60 150 50

60 150 50

Unit

108 Travel motor

109 Total Boom / stick cylinder

Spool

Ext.

Retr.

Ext.

60 150 50

Retr.

Nominal block width

mm

20

20

Consumer connection

inch

3/4

3/4

Ø piston rod

mm

20

20

Piston stroke

mm

9.0

9.0

8.0

p1bar ± 0.5 mm*

bar

7.0

7.0

17

17

p2bar ± 0.5 mm*

bar

24

24

24

24


cm3/min bar °C

Tab. 1

60 150 50

60 150 50

8.0

60 150 50

Technical data

* p1 = Control pressure at begin of regulation (fine-control phase) p2 = Control pressure in final position of spool

7.50.2

copyright by

MJFCIFSS

60 150 50

60 150 50

Service Manual

Compact control block Description

3 Description 3.1

Design of the control valve block see Fig. 4 The compact control valve block 100 consists of a compact cast element. The cast element contains the following components: Spool 101-109 with spring pack 25 Primary pressure-relief valve 120 (P1) Primary pressure-relief valve 121 (P2) Secondary pressure-relief valves 127/128, 131/132, 133/134 Suction valves 135/136 Load-holding valves 151 Check valves 152 Restrictor valve 155 The block contains the control axles 101 - 109, which are adjusted to suit the respective function. Each control axle 101 - 109 contains a spool with spring pack, a control lid 13 at the top (long design) and a control lid 12 at the bottom (short design). The adjusting screw 162 (lowering speed of attachment) is integrated into the control lid 13 of the control axle 106 of the boom cylinder. The secondary pressure-relief valves 127 - 134 are screwed in parallel to the control axles 101 - 107. The control axle 108 of the travel motor includes the two suction valves 135 / 136, which are screwed in one on each side. The measuring connections for the measuring points 40 (pump P1) and 41 (pump P2) are also screwed into the control valve block 100. The load-holding valves 151, check valves152 and the restrictor valve 155 are screwed into the block 100 at the connection side. There are two additional load-holding valves 151 screwed in at the rear of the block. The check valve 153 and the preload valve154 are integrated into a separate block, which is flange-mounted to the compact control valve block 100.

copyright by

MJFCIFSS

7.50.3


Service Manual

Description

7.50.4

10

Plate

127

30

Allen head screw

128

40

Measuring point P1

129

Secondary pressure-relief valve, regulating cylinder A5

41

Measuring point P2

130

100


131

Secondary pressure-relief valve, regulating cylinder B5 Secondary pressure-relief valve, boom cylinder A6

101

Slewing gear spool

132


102


133


103


134


105 106

Regulating cylinder spool Boom cylinder spool

135 136

Suction valve, travel motor A8 Suction valve, travel motor B8

107

Bucket cylinder spool

150

Check valve

108 109

Travel motor spool Combined boom cylinder / stick cylinder spool

151 152

Load-holding valve Check valve

111 120

Auxiliary block Prim. pressure-relief valve pump P1

153 154

Check valve 0.5 bar Check valve 5.5 bar

121

Prim. pressure-relief valve pump P2

162

Stroke limitation adjusting screw

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MJFCIFSS

Secondary pressure-relief valve, stick cylinder A2 Secondary pressure-relief valve, stick cylinder B2

Service Manual


Fig. 2

Control valve block - front and rear view

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MJFCIFSS

7.50.5


Service Manual

Description 1

to tank

127


6

to oil cooler

128

10

Plate

129

20

from pump

130

Secondary pressure-relief valve, stick cylinder B2 Secondary pressure-relief valve, regulating cylinder A5 Secondary pressure-relief valve, regulating cylinder B5

40

Measuring point P1

131


41

Measuring point P2

132


100


133


101

Slewing gear spool

134

102


135

Secondary pressure-relief valve, bucket cylinder B7 Suction valve travel motor A8

103


136


105 106


150 151

Check valve Load-holding valve

107 108

Bucket cylinder spool Travel motor spool

152 153

Check valve Check valve 0.5 bar

109

154


111

Combined boom cylinder / stick cylinder spool Auxiliary block

155

Restrictor valve

120

Prim. pressure-relief valve pump P1

162

Adjusting screw

121

Prim. pressure-relief valve pump P2 * marked with P2 at control valve block ** marked with P1 at control valve block

7.50.6

copyright by

MJFCIFSS

Service Manual


Fig. 3

Diagram of control valve block

copyright by

MJFCIFSS

7.50.7


Service Manual

Description

7.50.8

10 12

Plate Control lid, bottom

105 106


13 14

Control lid, top Control lid with stroke limitation (for lowering of boom)

107 108

Bucket cylinder spool Travel motor spool

23

Spring pack, complete

109

Combined boom / stick cylinder spool

24 25

Spring pack, complete Spring pack, complete

111 120

Auxiliary block Prim. pressure-relief valve pump P1

26 27

Spring pack, complete 121 Regulating spring (various characteristics) 127

Prim. pressure-relief valve pump P2 Secondary pressure-relief valve, stick cylinder A2

28

Spring plate

128


29

Lock washer

129

30

Allen head screw

130

Secondary pressure-relief valve, regulating cylinder A5 Secondary pressure-relief valve, regulating cylinder B5

31

Allen head screw

131


32

Washer

132

33

O-ring

133

Secondary pressure-relief valve, boom cylinder B6 Secondary pressure-relief valve, bucket cylinder A7

34

O-ring

134


40 41

Measuring point for pump P1 Measuring point for pump P2

135 135

Suction valve, travel A8 Suction valve, travel B8

49 50

Bushing Threaded stud

150 151


51 52

Hex nut Washer

152 153

Check valve Check valve 0.5 bar

100 101

Compact control block Slewing gear spool

154 155

Preload valve 5.5 bar Restrictor valve

102


162

Adjusting screw

103


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MJFCIFSS

Service Manual


Fig. 4

Design of the control valve block 100

copyright by

MJFCIFSS

7.50.9


Service Manual


4 Description of functions see Fig. 5

4.1

Sectional drawing of control axles In neutral position, the lines from the pumps to the consumers, and from the consumers to the tank are closed. The flow from the pump P1 applies pressure onto the connection P2. The oil flows virtually pressurefree through the spool 108 (travel motor), the spool 107 (bucket), the spool 106 (boom cylinder), the spool 105 (regulating cylinder) and the spool 109 (combined boom/stick) to the tank channel in the block 100. The flow from the pump P2 applies pressure onto the connection P1. The oil flows virtually pressurefree through the spool 101 (slewing gear), the spool 102 (stick), the spool 103 (support) and the spool 109 (combined boom/stick) to the tank channel in the block 100. All return oil flows are fed through the internal tank channels in the control valve block and via the check valves 153 (connection K) to the hydraulic oil cooler. In the event of increased backpressure (cold oil), the oil flows through the check valve 154 and the connection T to the hydraulic tank, bypassing the oil cooler (protective function).

4.2

Working position of the control axles When a spool is moved from its neutral position, the connection P to VA/VB from the pump channel to the consumer connection is opened through fine control grooves, while the flow through the pump channel to the tank channel (free passage) is restricted. The pump pressure increases until the pressure applied to the consumer connection (load pressure) is reached. Each axle is equipped with a screwed-in load-holding valve 151,retaining the load pressure in the consumer until the pump pressure has reached the level of the load pressure. When the pump pressure has reached the level of the load pressure, oil begins to flow to the consumer, and the cylinder or oil motor is set in motion. When the spool 101 - 108 is actuated further, the connection from the pump channel to the tank channel is closed, and the connection from the consumer to the tank channel is opened, so that the return oil can flow to the tank channel. This design ensures that the entire oil flow from the pump is available to the consumer(s). The adjusting displacement of the spool is determined by the existing control pressure at the connections a1 - a8 or b1 - b8 and the pre-set spring force of the spring pack. The control pressure can be continuously adjusted, in proportion to the level motion of the respective pilot control device. The pistons of the control block are equipped with a negative control edge overlap and fine control grooves. These components ensure that the oil flow to the consumers, and thus all working and travel movements, can be controlled in small and accurate steps. Approx. 30% of the piston stroke goes to control edge overlap, while approx. 50% are assigned to the fine control range, and approx. 20% constitute the residual stroke for the complete opening of the orifice cross-section. The fine control grooves adjusted to the characteristics of the hydraulic pilot control devices allow for optimised fine control properties. The spring pack 25 installed at the upper end of the spool resets the spool to its neutral position when there is no control pressure.

7.50.10

copyright by

MJFCIFSS

Service Manual

Compact control block Description of functions

The internal leakage of a consumer connection under pressure is influenced by the length of the overlap and the play between the housing and the piston. For maximum permissible leakage volumes, (see "Technical data", page 2). For optimum bleeding of the control oil circuit, there is a hydraulic connection through the flushing grooves (restrictor) between the control caps and the upper or lower tank channel of the control valve block. This connection is only open, if the spools 101 - 109 are in neutral position.

4.3

Control lid The control lids 12/13/14 are located at the base and top of the spools 101 to 109 and secured to the compact block 100. The control oil required for the actuation of the spool is fed through the control connection a / b of the control lids12/13/14. Thanks to its customised spring characteristic, the regulating spring 27 installed at the upper end of the spools, acts as a regulating element and returns the spool to its neutral position.

4.4 4.4.1

Combined shifting and priorities Combined shifting of boom and stick cylinder The oil flow from both pumps P1 and P2 applies pressure to the connections P2 and P1 at the control valve block 100. The oil flows virtually pressure-free through all spools 101 - 109 to the tank. If the spool 106 (boom cylinder) is pressurised through connection a6 with control oil, while the combined spool 109 actuates connection b4, the combined spool 109 opens the connection to the pump side P1 so that the double pumped oil volume is available when the boom cylinder is extended. If the spool 102 (stick cylinder) is pressurised through connection a2 / b2, while the combined spool 109 actuates connection a4, the combined spool 109 opens the connection to the pump side P1 so that the double pumped oil volume is available when the stick cylinder is extended and retracted. If no other consumers are actuated, the boom and stick cylinder can now be operated with maximum pump volume. As soon as another consumer is actuated, one of the pumps P1 and P2 is not available any more, depending on the position of the spools. The boom and stick cylinders are now only supplied by one pump.

4.4.2

Shifting priorities If several consumers are operated simultaneously, the slewing gear axle 101 is first supplied with oil by the pump P2 due to the position of the spools in the control block. These two axles have thus priority over the other control axles. If the control axle 101 is not actuated, the oil flow is available to the other control axles. The control axle 102 (stick cylinder) is also given priority. The oil flow from the pump P2 is fed through the connections E1 and E2 and the restrictor valve 155 and continuously supplies the control axle 102 with hydraulic oil. This means that the stick cylinder is always operational, even when other consumers are actuated.

copyright by

MJFCIFSS

7.50.11


Service Manual


7.50.12

12

Control lid, bottom

13 14

Control lid, top 108 Control lid with stroke limitation 109

107

23

Spring pack

127


24

Spring pack

128


26

Spring pack

129

Sec. pressure-relief valve, regulating cylinder A5

27 28

Regulating spring (various cha- 130 racteristics) Spring plate 131

Secondary pressure-relief valve, regulating cylinder B5 Secondary pressure-relief valve, boom cylinder A6

29 30

Lock washer Allen head screw

132 133

Secondary pressure-relief valve, boom cylinder B6 Secondary pressure-relief valve, bucket cylinder A7

31

Allen head screw

134


32 33

Washer O-ring

135 136

Suction valve / forward travel Suction valve / reverse travel

100 101

Compact control block Slewing gear spool

150 151


111 102

Auxiliary block Stick cylinder spool

152 157

Check valve O-ring

103


158

Cone / load-holding valve

105 106


159

Pressure spring / load-holding valve

Bucket cylinder spool Travel motor spool Combined boom / stick cylinder spool

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MJFCIFSS

Service Manual


Fig. 5

Sectional drawings of working axles 1,2,3,5,6,7 and 8

F

Free passage

T

P

Pressure channel, pump side

VA/VB channel, consumer side

copyright by

MJFCIFSS

Return channel, tank side

7.50.13


Service Manual


4.5

Cooler and tank preload valves 153 / 154 The compact control block is equipped with central cooler and tank connections. The return lines are preloaded by the pressure springs of the check valves 153 / 154. The resulting back pressure at the outlet guarantees sufficient inflow in the event of negative external loads (boom down, uphill travel etc.), thus preventing cavitation. The volumes required for back-feeding are usually available from the volumes displaced by the consumer. The priority of the return flow of the oil through the cooler is implemented by means of different preloads of the valves with different pressure springs 153 (0.5 bar for tank preload) and 154 (5.5 bar for cooler protection). When the volume flow becomes greater and/or the oil viscosity is increased as the oil is cold, the resistance in the cooling circuit increases, and the additional oil volume or the volume not to be discharged by the cooler is directly fed to the tank. The valves are maintenance-free. In the event of malfunction, proceed as follows: Disconnect the hose lines from connection T / K. Unscrew the connecting pieces 17/18 of the valves 153 / 154 from the housing and inspect the valve cones 6 for contamination. If necessary, complete a function test of the valve. Note! When dismantling both valves 153 / 154, do not confuse the two pressure springs 7/8.

To reinstall the parts, complete the above steps in reverse order.

7.50.14

5 6

Valve seat Valve cone

32 33

Washer O-ring

7 8

Pressure spring (0.5 bar) Shim

55 56

Reducer O-ring

9

Pressure spring (5.5 bar)

57

Pressure spring

11 12

Valve seat Control lid, bottom

58 59

Pressure spring Spring plate

13 17

Control lid, top Connecting piece

60 61

Valve cone Valve seat

18

Connecting piece

100


19

Allen head screw

109

Combined boom / stick spool

20

O-ring

111

Auxiliary block

21 22

Backing ring O-ring

152 153

Check valve Check valve (0.5 bar)

25


154

Check valve (5.5 bar)

31

Allen head screw

155

Restrictor valve, complete

E2

External pressure connection (inlet)

P1

Pressure channel pump 1

F1

Free passage P1

P2

Pressure channel pump 2

F2

Free passage P2

S

Suction connection

K

Return connection, oil cooler side

T

Return channel, tank side

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MJFCIFSS

Service Manual


Fig. 6

Control axle 4 with auxiliary block and integrated cooler and tank preload valves

copyright by

MJFCIFSS

7.50.15


Service Manual

Primary and secondary pressure-relief valves

5 Primary and secondary pressure-relief valves 5.1

Primary pressure-relief valve 120 / 121 (pump safety valve) The primary pressure-relief valves mounted on the side of the control block limit the pressure between the pump and the control block (working and operating pressure). The pressure-relief valves 120 / 121 are of the cartridge type and inserted directly into control valve block 100. The raising system pressure in the hydraulic unit acts on the indirectly acting (pilot-controlled) valve. In these valves, a direct-acting pressure-relief valve (with valve cone and seat) acts as the pilot-control valve, generating a pulse that actuates the second, larger valve. The preload of the valve spring determines the opening pressure and can be adjusted by means of the adjusting screw located on the outside of the unit.

5.2

Secondary pressure-relief and feeder valves 127 - 134 The secondary pressure-relief valves127-134 limit the pressure between the attachments and the control block when the spools are closed (secondary function). The design and function of these valves is identical with that of the primary pressure-relief valves. The pressure settings are however significantly higher than those of the primary pressure-relief valves. The secondary pressure-relief valves also act as feeder valves. Differences in the flow rates of the oil to and from the working cylinders result in a vacuum. This might occur for instance when the stick cylinder is extended with a long stick, due to external pulling loads. In order to prevent this, the valves connect the return side with the corresponding low-pressure side so that additional oil can be taken in.

5.3 5.3.1

Description of functions Pressure limitation The pressure (P) built up in the consumer circuit acts on the front face of the main cone 3 and, through the bore D1, also on the rear surface of the main cone 3. At the same time, the pressure acts also on the pilot control cone 4. The springs 8 / 9 and 5 push the main cone 3 and the pilot control cone 4 into their closing positions (static status). As soon as the pressure in the consumer circuit exceeds the pre-set pressure of the pressure and adjusting spring 5, the pilot control cone 4 is lifted from its seat, and some oil can flow into the return channel. Due to the different cross-sections of the bores D1 in the main cone 3 and D2 in the valve insert 2, there is a pressure difference between the front and the spring side of the main cone 3. As a result of this pressure difference, the main cone 3 is shifted against the pressure springs 8 / 9, and a substantial amount of oil flows off to the non-pressurised return side T.

5.3.2

Feed If there is a vacuum in a working circuit, the higher pressure in the hydraulic tank is applied through the bore T of the housing 1 onto the ring face of the main cone 3. As a result of the pressure difference across the effective surface of the main cone 3, the main cone is pressed against the force of the pressure springs 8 / 9 so that the required amount of oil can flow through the bore T to the respective side of the consumer.

7.50.16

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MJFCIFSS

Service Manual

Compact control block Primary and secondary pressure-relief valves

Fig. 7

Primary and secondary pressure-relief valves 120-134

1

Housing

9

Pressure spring

2

Valve insert

10

Protective cap

3 4

Main cone Pilot control cone

11 12

Piston seal O-ring

5 6

Pressure spring Adjusting screw

13 14

O-ring Backing ring

7

Lock nut

15

O-ring

8

Pressure spring

16

O-ring

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MJFCIFSS

7.50.17


Service Manual

Suction valves 135/136

6 Suction valves 135/136 The suction valves (i.e. feeder valves / check valves) are mainly used in conjunction with rotating consumers. The risk of insufficient oil, i.e. cavitation, in oil motors is greatest when there are delays in the operation of the machine (downhill travel). When decelerating, the oil motor of the drive system runs idle. The pressure peaks due to the high moment of inertia during downhill travel result in activation of the brake valves while the spools are blocked. From a certain inclination, the speed of the motor (and, thus, the oil volume to be fed) is no longer determined by the aperture of the inlet orifice of the spool, but depends on the load and the grade resistance. The feeder valve provides the required volume of oil to the working connection in order to prevent cavitation.

6.1 6.1.1

Description of functions Closing position: The high pressure in channel A/B is applied through the bore D to the spring side of the main cone 3, pressing the cone against the sealing edge of the valve insert 1, so that the valve 135 / 136 / 181 / 182 is closed towards the consumer side.

6.1.2

Suction: If there is a vacuum in the working circuit, the higher pressure in the hydraulic tank acts through the bore T of the valve insert 1 onto the ring face of the main cone 3. As a result of the pressure difference across the effective surface of the main cone 3, the main cone is pressed against the force of the pressure spring 8 so that the required amount of oil can flow through the bore T to the respective side of the consumer A / B.

7.50.18

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MJFCIFSS

Service Manual

Compact control block Suction valves 135/136

Fig. 8

Suction valves 135/136

1 3

Valve insert Main cone

33 34

O-ring Backing ring

6 8

Screw Pressure spring

35 37

O-ring O-ring

31

Piston seal

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7.50.19


Service Manual

Repairs to control valve block

7 Repairs to control valve block Caution! Before carrying out any repairs on the control valve block, release the preload pressures at the tank and servo system. Switch off the diesel engine. Proceed as follows: Unscrew the breather filter on the hydraulic tank with 1 turn (slow de-pressurisation).

Release backpressures. Turn ignition key into contact position. Actuate all pilot control devices in all possible directions.

7.1

Leaks on the outside If there are leaks on control valve block, replace the seals on the screwed connections, SAE flanges, caps and valves.

7.1.1

Spool Disconnect the relevant control line. Remove the Allen head screws 30. Remove the control lid 12 or 13/14. Lift off the spring pack 23/24/25/26 and pull the respective spool101 - 109 from the housing. Note! If you wish remove more than one spool at a time, do not confuse them and ensure they are reinstalled in their original bores (observe markings, etc.). In spare spools, the axle marking A1 - A8 is engraved on the front side opposite the spring and on the shaft of the spring pack. Prior to installing the spools, check the O-rings 33 in the housing for damage (spool lid seals). Also check the spools for damage or defects (scores in surface). Install the parts by completing the above steps in reverse order. Insert the spool with care to avoid jamming. Do not use force.

7.2

Dismantling of spools 101 to 109 Caution! Before dismantling control lines: relieve pressure from hydraulic circuit. The lid 12/13/14 is spring-loaded. Risk of injury from propelled spring pack Dismantle the respective control line. Remove the screws 30. Remove the lid 12/13 with the O-ring 33. Pull the spool 101 to 109 from the control valve block 100. Remove the spring pack 26.

7.50.20

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Service Manual

Compact control block Repairs to control valve block

7.3

Installation of spools Important information for installation / replacement of pistons: The various spools are matched to suit the specific requirements of the respective operational functions (boom, stick etc.) and cannot be interchanged with each other for that reason. If you want to remove several spools at a time, reinstall them in their original bores. Usually, the bores in the control valve blocks are made for perfect fit. If this is the case with all the bores in the block, the type plate of the block shows end number "000". 'Perfect fit' indicates that the bores have ± 0 µm tolerance. This means that spools supplied for replacement usually have a tolerance of 8-10 µm, and the amount of leak oil is within the normal range. Zero-tolerance bores are marked with punched code 0. Replacement with spools as specified in the ET spare parts catalogue is possible. If one or several bores of the control block do not meet the zero tolerance standard, the actual tolerance is indicated on the type plate. To find out which bore is meant, remove the top lid of the spool in question. The marking indicating the tolerance of the bore (10 = 10) is located at the front face of the control block. In this case, it is not possible to replace the spool with a part from the spare parts catalogue, and the spool must be specially made to fit the tolerance. When ordering spare spools, please quote all information on the type plate, see also service information no. 1-14-52 / 2000. Ensure that the spool is installed in the correct position. Choose a matching spool and grease it lightly. Carefully insert it into the control valve block 100. Place the spring pack 26 on the spool. Place the lid 12/13/14 complete with the O-ring 33 onto the control block100 and secure it with the screws 30.

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7.50.21


Service Manual

Auxiliary control axles

8 Auxiliary control axles 8.1

Function The auxiliary element for the accessory kit AHS 12 is flange-mounted to the control block 100. It allows for the activation of additional working movements (hammers, scrap shear, etc.). The control axles of the auxiliary control block includes the spool with actuation elements (control lid, spring pack) required for the relevant function, and all associated secondary protection elements.

Fig. 9

7.50.22

Accessory kit AHS 12

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Service Manual


9 Description The auxiliary control valve block 115 consists of a compact cast element. The cast element contains the following components: Spool 116 Primary protection 120 Pressure-relief valve143, 144 Check valve 152 The auxiliary control axle 115 is flange-mounted to the mounting plate 10 of the control block 100. The threaded stud 47 is screwed into the auxiliary control block 115,inserted through the bores of the mounting plate 10 and secured with the nut 51. The bushing 49 is inserted into the auxiliary block and used to secure it to the mounting plate 10. The O-rings 34 seal the hydraulic connections between the mounting plate 10 and the auxiliary block 115.

Fig. 10

Auxiliary axle AHS 115

Note! When attaching an auxiliary control axle 115, ensure that it is not equipped with a primary protection 120 provided by the manufacturer. Remove the primary protection 120 from the control block 100 by turning it from the bore. Remove the dummy plug 48 from the auxiliary control axle 115. Insert the primary protection 120 in the axle 115 and screw it in. Insert the dummy plug 48 in the axle 100 and screw it in.

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7.50.23


Service Manual


Fig. 11

10

Hydraulic diagram of the auxiliary axle AHS 12

100 115

Compact control block Auxiliary control valve block

120 143

Primary pressure-relief valve Secondary pressure-relief valve with additional pressure stage

116

Spool / kit AHS 12

144


Description of functions The design and function of the auxiliary axle AHS corresponds to that of the working axles, (see "Design of the control valve block", page 3) and see page 3.

7.50.24

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Service Manual


Fig. 12

Sectional drawing of auxiliary axle AHS 12

12 13

Control lid, bottom Control lid, top

115 116

Auxiliary control valve block (low pressure) Spool AHS12

24


143

Secondary pressure-relief valve with additional pressure stage, hydraulic hammer A9

27

Regulation spring

144

Secondary pressure-relief valve, kit AHS B9

28

Spring plate

151

Load-holding valve

29 31

Lock washer Allen head screw

152 157

Check valve O-ring

32

Washer

158


33

O-ring

159

Pressure spring / load-holding valve

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7.50.25


Service Manual

Pressure and feeder valves 143 (2-step at AHS for hammer)

11

Pressure and feeder valves 143 (2-step at AHS for hammer) The pilot-controlled pressure-relief valve 143 of the consumer connection is of the cartridge type and inserted directly into control valve block 100. The valve has an additional hydraulic pressure stage and can therefore be used for two different pressure ranges. It limits the pressure between the pump, the control valve block and the working attachment (stage 1 - primary function - hammer operation) or between the working attachments and the control block when the spool is closed (stage 2 - secondary function - regulating cylinder protection). If the pressure increases in the circuit of an attachment in undesirable ways, destruction would occur at the weakest point, e.g. screwed connections or hydraulic hoses. In order to prevent that, we provide a sort of pre-determined breaking point. In our scenario, the pressure rising in the hydraulic system acts on a certain type of integrated hydraulic device. This element is referred to as a pressure-relief valve. It limits the maximum pressure in the consumer and its connections to a pre-set value. As the pressure valves in the hydraulic system must be able to cater for great flows of oil, our machines are equipped with indirect (pilot-controlled) pressure-relief valves for reasons of manufacture and better functioning. In these valves, a direct-acting pressure-relief valve acts as the pilot-control valve, generating a pulse that actuates the second, larger valve. The pressure-relief valve 143 also serves as a feeder valve. Differences in the flow rates of the oil to and from the working cylinders result in a vacuum. This might occur for instance when the regulating cylinder is extended due to external pulling loads. In such a case, the speed of the consumer would not be controlled by means of the gauge orifice diameter, but based on the loads and via the outlet edge of the spool. In order to prevent this, the valves connect the return side with the corresponding low-pressure side so that additional oil can be taken in.

Fig. 13

7.50.26

Pressure and feeder valve 143

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Service Manual

Compact control block Pressure and feeder valves 143 (2-step at AHS for hammer)

11.1 11.1.1

Description of functions Pressure limitation The pressure (P) built up in the consumer circuit acts on the front face of the main cone 5 and, through the bore D1, also on the rear surface of the main cone 5. At the same time, the pressure acts also on the pilot control cone 15. The springs 7 and 18 push the main cone 5 and the pilot control cone 15 into their closing positions (static status). As soon as the pressure in the consumer circuit exceeds the preset pressure of the pressure and adjusting spring 18, the pilot control cone 15 is lifted from its seat, and some oil can flow into the return channel. Due to the different cross-sections of the bores D1 in the bushing 6 and the ring face D2 in the valve insert 2, a pressure difference is built up between the front and rear sides of main cone 5. As a result of this pressure difference, the main cone 5 is shifted against the pressure springs 7, and a substantial amount of oil flows off to the non-pressurised return side T.

11.1.2

Additional pressure stage Stage 1 (low pressure - protection of hydraulic hammer) connection X is connected to the tank. Pre-loading of pressure spring 18 is lower. Stage 2 (higher pressure - protection of regulating cylinder) connection X receives pilot pressure. The pressure spring 18 is pre-loaded via the shifting piston 9 and the piston 8 to a higher degree, which results in a higher blow-off pressure.

11.1.3

Feed If there is a vacuum in a working circuit, the higher pressure in the hydraulic tank is applied through the bore T of the housing 1 onto the ring face of the main cone 5. As a result of the pressure difference across the effective surface of the main cone 5, the main cone is pressed against the force of the pressure springs 7 so that the required amount of oil can flow through the bore T to the respective side of the consumer.

Fig. 14

Sectional drawing: pressure and feeder valve 143

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MJFCIFSS

7.50.27


Service Manual

Pressure and feeder valves 143 (2-step at AHS for hammer)

7.50.28

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MJFCIFSS

Service Manual

LSC control block Function

LSC control block 1 Function The A 312 - R 317 Litronic machines are equipped with an LSC control system. The control unit consists of a compact control valve block with LUDV system. The control block contains five spools (working and travel functions) with the corresponding valves. There is a separate control block segment for the slewing gear drive.

Fig. 1

Example: LSC control block of model A 312 - 316

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7.60.1

LSC control block

Service Manual

General data of A 312 - A 316 Litronic control block

2 General data of A 312 - A 316 Litronic control block Contained in: Type Construction

A 312 Litronic 719

A 314 Litronic 635

A 316 Litronic 715 / 716

from sn.12363 M7-1442-20 from sn.16275 M7-1442-31

from sn. 2001 M7-1340-20 from sn.11820 M7-1340-22 from sn.11814 M7-1340-23 from sn.16215 M7-1340-31


Industry


Speeder

from sn.12363 M7-1443-20 from sn.15864 M7-1443-31

Spool

Unit

220 Boom cylinder Ext.

Retr.

from sn. 2001 M7-1433-20 from sn.12734 M7-1433-21 from sn.15964 M7-1433-31


Retr.

260 Bucket cylinder Ext.

from sn. 2001 M7-1433-20 from sn.12734 M7-1433-21 from sn.15964 M7-1433-31

160 Travel motor

Retr.

280 Support cylinder Ext.

120 Slewing gear

Retr.

Nominal block width

mm

20

20

20

20

20

20

Consumer connection A/B

()

3/4

3/4

3/4

3/4

3/4

1/2

Ø piston rod

mm

25

25

25

Piston stroke

mm

9.0

9.0

9.0

9.0

9.0

9.0

9.0

9.0

9.0

9.0

Setting value Y* A 312 - A 316 A 312 - A 316

mm

17.4 14.0

17.2 13.6

17.3 14.5

17.5 14.3

15.9 13.2

16.0 13.0

16.7 12.9

15.8 13.0

15.5 13.0

16.3 12.3

p1bar ± 0.5 mm**

bar

7.0

7.0

7.0

7.0

7.0

7.0

7.0

7.0

7.0

7.0

p2bar ± 0.5 mm***

bar

20.6

20.6

20.6

20.6

20.6

20.6

20.6

20.6

20.6

20.6

Qn (A)/Qn(B)° A 312 A 312 Speeder A 314 A 316 314/316 Speeder A 316 Industry

l/min l/min l/min l/min l/min l/min

220 220 220 220 220 300

90 90 90 90 90 70

220 220 220 220 220 300

150 150 150 150 150 110

180 180 180 180 180 225

100 100 100 100 100 175

120 200 120 120 200 150

75 75 75 75 75 220

65 65 65 65 65 190

120 120 120 120 120 120

Restr. check valve at connection a / b

Ø mm

-


cm3/min bar °C

Tab. 1 #

7.60.2

25

25

0.8#

0.8

-

60 150 50

60 150 50

60 150 50

0.8

-

0.8

60 150 50

60 150 50

60 150 50

Technical data

from index 23 = diameter 0.6 mm

sn. = Serial number

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MJFCIFSS

25

Service Manual

LSC control block General data of R 313 / R 317 Litronic control block

^

Machine A 312 from serial no. 11367, A 314 from serial no. r.12814, A 316 from serial no. 12741, A 316 Ind. 12846

3 General data of R 313 / R 317 Litronic control block Contained in: Type

R 313 Litronic 790

standard model Spool

R 317 Litronic 790

from sn. 27752 M7-1748-30 Unit

220 Boom cylinder Ext.

Retr.

from sn. 18161 M7-1466-31


Retr.

260 Bucket cylinder Ext.

mm

Consumer connection A/B

()

Ø piston rod

mm

Piston stroke

mm

9.0

9.0

9.0

9.0

9.0

Setting value Y* R 313 / R 317

mm

14.0

13.6

14.5

14.3

p1bar ± 0.5 mm**

bar

7.0

7.0

7.0

7.0

p2bar ± 0.5 mm***

bar

20.6

20.6

20.6

Qn (A)/Qn(B)° R 313 R 317

l/min

195 220

85 90

0.6

0.6

Leak oil max. at load pressure at oil temperature Tab. 2

Ø mm cm3/min

bar °C

180 Drive motor

120 Slewing gear

Retr.

Nominal block width

Restrictor check valve at connection a/b

160 Drive motor

20

20

20

20

20

20

3/4

3/4

3/4

3/4

3/4

1/2

25

25

25

25

25

25

9.0

9.0

9.0

9.0

13.2

13.0

14.5

14.5

12.3

7.0

7.0

7.0

7.0

7.0

20.6

20.6

20.6

20.6

20.6

20.6

250 220

150 150

210 180

90 100

125 125

125 125

140 120

0.8

0.8

-

-

0.8

0.8

0.8

60 150 50

60 150 50

60 150 50

60 150 50

60 150 50

60 150 50

Technical data

*

The setting value Y serves as reference value

**

p1 = control pressure at begin of regulation

***

p2 = control pressure in final position

°

Qn A/ Qn B = nominal flow rate at outlet A / B at

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MJFCIFSS

p = nominal value

7.60.3

LSC control block

Service Manual

General data of R 313 / R 317 Litronic control block

7.60.4

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MJFCIFSS

Service Manual

LSC control block Design of A 312 - A 316 control block

4 Design of A 312 - A 316 control block 4.1

Elements of control valve block, (see Fig. 2, page 7) Input section: Connection P for oil pump flow Connection K for return flow to hydraulic oil cooler Connection MP for pump pressure Connections MLS and LS2 for external load signal Connection LS with shuttle 107 for load signal line to pump flow regulator Check valve 7 (3.5 bar) in block for return backpressure Preload valve 8 (7 bar) in block for return as cooler bypass valve Minimum-flow pressure balance 102 (flow controller) for the stabilisation of the load pressure and relief of the LS line Pressure balance / remaining flow 103 (unloading valve) for a fast and direct response in the system Pressure cut-off valve 104 as a limiting valve for the working pressure Primary pressure-relief valve 105 to protect the system

Control and distribution area: Operating connections A1 - A5 and B1 - B5 for supply and return flows of consumers Connection T for return oil to hydraulic tank1 The control caps of the various axles with stroke limitation of spools 160 / 220 / 240 / 260 and 280; control pressure connections a1 - a5 and b1 - b5, and regulating and return spring 132 Spool 160 / 220 / 240 / 260 and 280 for the working movements of travel drive, boom, stick, bucket and support Secondary pressure-relief valve 221 / 222 / 241 / 242 and 261 / 262 to protect the consumer circuit in closed condition. Suction valves 161 and 162 to prevent cavitation in the travel drive system Pressure balance 164 / 224 / 244 / 264 and 284 for LS signal message re. compensation of the various axles Restrictor check valves 127 / 167 / 227 and 247 for the fine control of the spools 120 / 160 / 220 and 240 The auxiliary control axle is equipped with the following components as standard: slewing gear spool 120, inlet pressure balance 122, check valve 123 and restrictor check valves 127, see 17.1 Note! Additional elements with spools serving as auxiliary equipment can be flange-mounted to the compact block.

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7.60.5

LSC control block

Service Manual

Design of A 312 - A 316 control block

4.2

7.60.6

Control block for A 312 - 316 and components 7 8

Check valve (3.5 bar) Preload valve (7.0 bar)

167 220

Restrictor check valve Spool / boom cylinder

100 102

Compact control valve block 5 x Pressure balance / minimum flow

221 222

Secondary pressure-relief valve A3 Secondary pressure-relief valve B3

103


224

Pressure balance (pilot-controlled)

104


227


105


240


106

Shift valve / Qmax regulating motor

241

Secondary pressure-relief valve A5

107

Shuttle valve

242

Secondary pressure-relief valve B5

108

Restrictor (LS central nozzle)

244

Pressure balance

109 110

Restrictor check valve Mounting plate

247 260

Restrictor check valve Spool / bucket cylinder

111 120

Allen head screw Spool / slewing gear

261 262

Secondary pressure-relief valve A4 Secondary pressure-relief valve B4

122 123

Inlet pressure balance Check valve

264 280

Pressure balance Spool / support

127


281

Screw plug / dummy cartridge

134 135

Control lid Allen head screw

284 334

Pressure balance Control lid

140 160

Screw plug Spool / chassis right

369 373

Screw plug Screw plug

161 162

Suction valve Suction valve

810 811

Mounting plate Allen head screw

164

Pressure balance

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Service Manual


Fig. 2

Control valve block for A 312 - A 316 - front and rear view

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MJFCIFSS

7.60.7

LSC control block

Service Manual


7.60.8

7


164

Pressure balance (directly controlled)

8 41

Preload valve (7.0 bar) Measuring point MP

167 220

Restrictor check valve Spool / boom cylinder

45

Measuring point LS

221


100


222

Secondary pressure-relief valve / retract

102

Pressure balance / minimum flow (flow controller)

224

Pressure balance (direct / pilot-controlled*)

103

Pressure balance (remaining flow control- 227 ler)

104


240


105 106

Primary pressure-relief valve Shift valve / Qmax Regulating motor

241 242

Secondary pressure-relief valve / retract Secondary pressure-relief valve / extend

107

Shuttle valve

244


108 109

Restrictor (LS central nozzle) Restrictor check valve

247 260


120 122

Spool / slewing gear Inlet pressure balance (supply pressure balance)

261 262

Secondary pressure-relief valve / retract Secondary pressure-relief valve / extend

123

Check valve

264


127 160

Restrictor check valve Spool / travel drive

280 281

Spool / chassis left Suction valve

161 162


284


*

from index 31, see Tab. 2, pilot-controlled (directly controlled pressure balance: see items 244 / 264)

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Service Manual


Fig. 3

Hydraulic diagram of LSC control block for A 312 - A 316

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MJFCIFSS

7.60.9

LSC control block

Service Manual


Fig. 4

7.60.10

Exploded view of control block for A 312 - 316

100


169

Screw plug

102 103

Pressure balance / minimum flow (LS outlet) Residual flow pressure balance (unloading valve)

170 171

Cone / load-holding valve Pressure spring / load-holding valve

104 105

Pressure cut-off valve Primary pressure-relief valve

172 220

Screw plug Spool / boom

110 111

End plate Allen head screw

221 222

Spring plate Secondary pressure-relief valve

120

Control axle / slewing gear

223

Pressure spring

130

O-ring

224

Piston / pressure balance (pilot-controlled)

131

Spring plate

225

Screw plug

132 134

Regulation spring Control lid

227 240

Restrictor check valve Spool / stick

135

Allen head screw

242


140

Screw plug

244

160

Spool / travel drive

247

Piston / pressure balance (directly controlled) Restrictor check valve

162 164

Suction valve 260 Piston / pressure balance (directly controlled) 262

165

Spring / pressure balance

264

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Spool / bucket Secondary pressure-relief valve Piston / pressure balance (directly controlled)

Service Manual

LSC control block Design of R 317 control block

166

280

O-ring

Spool / support

167


281

Screw plug

168

Screw plug

284

Piston / pressure balance (directly controlled)

5 Design of R 317 control block 5.1

Elements of control valve block, (see Fig. 5, page 13) Input section: Connection P for oil pump flow Connection K for return flow to hydraulic oil cooler Connection MP for pump pressure Connections MLS and LS2 for external load signal Connection LS with shuttle 107 for load signal line to pump's flow regulator Check valve 7 (3.5 bar) in block for return backpressure Preload valve 8 (7 bar) in block for return as cooler bypass valve Minimum-flow pressure balance 102 (flow controller) for the stabilisation of the load pressure and relief of the LS line Pressure balance / remaining flow 103 (unloading valve) for a fast and direct response in the system Pressure cut-off valve 104 as a limiting valve for the working pressure Primary pressure-relief valve 105 to protect the system Control and distribution area: Operating connections A1 - A5 and B1 - B5 for supply and return flows of consumers Connection T for return oil to hydraulic tank1 The control caps of the various axles with stroke limitation of spools 160 / 180 / 220 / 240 and 260; control pressure connections a1 - a5 and b1 - b5, and regulating and return spring 132 Spool 160 / 180 / 220 / 240 and 260 for the working movements of travel drive, boom, stick, bucket and support Secondary pressure-relief valve 221 / 222 / 241 / 242 and 261 / 262 to protect the consumer circuit in closed condition. Suction valves 161 /181 and 162 / 182 to prevent cavitation in the travel drive system Pressure balance 164 / 184 / 224 / 244 and 264 for LS signal message re. compensation of the various axles Restrictor check valves 167 / 187 / 227 and 247 for the fine control of the spools 160 / 180 / 220 and 240 Shift valve 106 for Qmax shifting of the regulating travel motors The auxiliary control axle is equipped with the following components as standard: slewing gear spool 120, inlet pressure balance 122, check valve 123 and restrictor check valves 127, see 17.1 Note! Additional elements with spools serving as auxiliary equipment can be flange-mounted to the compact block.

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7.60.11

LSC control block

Service Manual

Design of R 317 control block

5.2

7.60.12

Control block R 317 and components 7 8

Check valve (3.5 bar) Preload valve (7.0 bar)

180 181


100 102

Compact control valve block 5 x Pressure balance / minimum flow

182 184

Suction valve Pressure balance

103


187


104


220


105


221


106

Shift valve / Qmax Regulating motor

222

Secondary pressure-relief valve B3

107

Shuttle valve

224


108

Restrictor (LS central nozzle)

227


109 110

Restrictor check valve Mounting plate

240 241

Spool / stick cylinder Secondary pressure-relief valve A5

111 120

Allen head screw Spool / slewing gear

242 244

Secondary pressure-relief valve B5 Pressure balance

122 123

Inlet pressure balance Check valve

247 260


127


261


134 135

Control lid Allen head screw

262 264

Secondary pressure-relief valve B4 Pressure balance

140 160

Screw plug Spool / chassis right

334 369

Control lid Screw plug

161 162


373 810

Screw plug Mounting plate

164

Pressure balance

811

Allen head screw

167


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MJFCIFSS

Service Manual


Fig. 5

Control valve block for R 317 - front and rear view

copyright by

MJFCIFSS

7.60.13

LSC control block

Service Manual


7.60.14

7


167


8 41

Preload valve (7.0 bar) Measuring point MP

180 181


45

Measuring point LS

182

Suction valve

100


184


102

Pressure balance / minimum flow (flow controller)

187


103

Pressure balance (remaining flow control- 220 ler)


104


221


105 106

Primary pressure-relief valve Shift valve / Qmax Regulating motor

222 224

Secondary pressure-relief valve / retract Pressure balance (pilot-controlled)

107

Shuttle valve

227


108 109

Restrictor (LS central nozzle) Restrictor check valve

240 241

Spool / stick cylinder Secondary pressure-relief valve / retract

120 122

Spool / slewing gear Inlet pressure balance (supply pressure balance)

242 244

Secondary pressure-relief valve / extend Pressure balance (directly controlled)

123

Check valve

247


127 160

Restrictor check valve Spool / chassis right

260 261

Spool / bucket cylinder Secondary pressure-relief valve / retract

161 162


262 264

Secondary pressure-relief valve / extend Pressure balance (directly controlled)

164


copyright by

MJFCIFSS

Service Manual


Fig. 6

Hydraulic diagram of LSC control valve block for R 317

copyright by

MJFCIFSS

7.60.15

LSC control block

Service Manual


Fig. 7

7.60.16

Exploded view of control valve block for R 317

100


170

102 103

Pressure balance / minimum flow (LS outlet) 171 Residual flow pressure balance (unloading valve) 172

Cone / load-holding valve Pressure spring / load-holding valve Screw plug

104


180


105 110

Primary pressure-relief valve End plate

182 184

Suction valve Piston / pressure balance (directly controlled)

111

Allen head screw

187


120 130

Spool / slewing gear O-ring

220 221

Spool / boom Spring plate

131

Spring plate

222


132

Regulation spring

223

Pressure spring

134

Control lid

224

135

Allen head screw

225

Piston / pressure balance (pilot-controlled) Screw plug

140

Screw plug

227


160


240

Spool / stick

162

Suction valve

242


164


244


165

Spring / pressure balance

247


166

O-ring

260

Spool / bucket

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MJFCIFSS

Service Manual

LSC control block Functional description (short description)

167


262


168

Screw plug

264


169

Screw plug

6 Functional description (short description) (see Fig. 3, page 9) and (see Fig. 6, page 15)

6.1

Neutral position All spools 160 / 180 / 220 / 240 / 260 and 280 are maintained in a neutral position by means of regulating and return springs 132. The connection between pump connection and consumer is closed. The connection between consumer and tank is closed. Pressure balances 164 / 184 / 224 / 244 / 264 and 284 are in a neutral position (connections are closed). Pressure balance / remaining flow 103 is open. The pre-set flushing volume is pumped from the variable displacement pump through 103 to the tank.

6.2 6.2.1

Working position, (see Fig. 16, page 29) One spool in working position Connection between sections P and P' opens, oil flows. The respective pressure balance 164/184/224/244/264/284 is pressurised and opened, while all other balances remain closed. When the spool is in its working position, oil flows through the pressure balances to the flow regulator. The pressure in the pump is increased and exceeds the load-holding function. As a consequence, the consumer is supplied oil. Pressure balance 103 closes, and the flow from the pump is now available to the consumer.

6.2.2

Several spools in working position, see figure 4 Connection between sections P and P' opens, oil flows. Pressure balances 164 to 284 are pressurised and shifted in the direction of the spring side (in proportion to the LS pressure), i.e. the consumer with the highest load pressure determines the LS pressure. The pressure balances 164 to 284 of each spool always switch to the same pressure difference ( -p), even at different load pressures. The pump is pivoted according to the oil requirements of the various consumers. The oil is fed via the control edge of the respective pressure balance and load-holding valves 170172 to section PA or PB, to the consumer connection A1 - A5 or B1 - B5 and to the consumer. The remaining flow pressure balance 103 closes. The flow from the pump is now available to the consumer. Decisive advantages of the LSC control: The pump delivers only the oil required for the individual consumers. The speeds of the consumers are determined only by the pre-selected pilot pressure on the spool. It remains constant, irrespective of the load pressure of the consumer in question.

copyright by

MJFCIFSS

7.60.17

LSC control block

Service Manual

Functional description (short description)

Fig. 8

View of compact control block from the left with sectional drawing of the a control axle

100


222

Secondary pressure-relief valve / boom

104


224


105

Prim. pressure-relief valve

240

Spool / stick

160 161

Spool / chassis right / travel drive Suction valve

241 242

Secondary pressure-relief valve Pressure-relief valve / stick

162 164

Suction valve Pressure balance, directly controlled

244 260

Pressure balance, directly controlled Spool / bucket

180

Spool / chassis left (R 317 only)

261


181

Suction valve

262

Pressure-relief valve / bucket

182

Suction valve

264


184


280

Spool / support (A only)

220

Spool / boom

284


221

Secondary pressure-relief valve *

7.60.18

copyright by

MJFCIFSS

only in A machines/R machines

Service Manual

LSC control block Input section / input element

7 Input section / input element Description The input element contains the central system functions such as the check valve 7 (cooler valve), check valve 8 (tank valve), primary pressure control (valve 105), LS pressure relief (cut-off valve 104), residual flow pressure balance 103, minimum-flow pressure balance 102 and LS central nozzle 108.

Fig. 9

Exploded drawing of the input element

1

Cone

105


2

Pressure spring

106

Shift valve / Qmax - Travel motor (R 317 only)

3 4

O-ring Screw plug

107 108

Shuttle valve LS central nozzle (Ø 1.6 mm)

5

Shim

109


6

Pressure spring

210

Valve seat

7 8

Check valve (cooler) Check valve (tank)

211 219

Restrictor bolt Valve seat

100

Compact block

275

Screw plug

102

Pressure balance / minimum flow (flow controller) Residual flow pressure balance (unloading valve)

221

Spring plate

222

Pressure spring

103 104


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MJFCIFSS

7.60.19

LSC control block

Service Manual

Input section / input element

Fig. 10

7.1

Hydraulic diagram: input section - control valve block

6 7

to oil cooler Check valve (3.5 bar)

100 102

Compact block Pressure balance / minimum flow (flow controller)

8

Check valve (7 bar)

103

Residual flow pressure balance (unloading valve)

20 26

from variable-displacement pump to LS regulator

104 105

Pressure cut-off valve Primary pressure-relief valve

41 45

Measuring point MP Measuring point LS

107 108

Shuttle valve LS central nozzle

Cooler and tank preload valves 7 / 8, (see Fig. 11, page 21) The compact control block is equipped with cooler and tank connections. The return lines are preloaded with the pressure springs 2 / 6 of the check valves 7/8. The resulting back pressure at the outlet guarantees sufficient inflow in the event of negative external loads (boom down, uphill travel etc.), thus preventing cavitation. The volumes required for back-feeding are usually available from the volumes displaced by the consumer. The priority of the return flow of the oil through the cooler is implemented by means of different preloads of the valves with different pressure springs 2 (3.5 bar for tank preload) and 6 (7 bar for cooler protection). With increasing volumetric flow, the resistance in the cooler line increases, and the additional volume of oil is fed directly to the tank after valve 8 has opened. The valves do not require maintenance. In the event of a malfunction, the valve can be removed with the screw plug, the pressure springs 2 / 6 and the cone 1 from the housing 100 for inspection (contamination, defect), testing and replacement. If there is leakage at the outside, mount a new O-ring 3. Note! When installing/removing the valves 7 and 8, ensure that the correct pressure springs 2 / 6 and shims 5 are mounted.

7.60.20

copyright by

MJFCIFSS

Service Manual


Fig. 11

Sectional drawing of inlet elements in the oil return section

1 2

Cone Pressure spring

8 25

Preload valve, complete (7.0 bar) Screw coupling / measuring point MP

3

O-ring

100

Compact block

4

Screw plug

105


5

Shim

K

Connection to oil cooler

6 7

Pressure spring Check valve, complete (3.5 bar)

P MP

connection / pump pressure Measuring connection / pump pressure

T

Tank channel

copyright by

MJFCIFSS

7.60.21

LSC control block

Service Manual


7.2

Minimum flow pressure balance / input pressure balance 102, see Fig. 12 and Fig. 13 The valve 102 (which is screwed into the block 100 from the bottom) allows a small amount of oil (approx. 0.7 l/min.) to flow continuously from the LS line to the tank. This ensures that sudden pressure increases in the LS line caused by impacts are eliminated. The valve 102 also ensure that the LS line is relieved to the tank if the consumers are not actuated (neutral position of spools). The 2-way flow limitation valve consists of an orifice and a pressure balance with regulating piston. The pressure balance keeps the pressure decrease p constant, so that the volume of outliving oil is also kept constant, irrespective of the LS pressure. The ratio p is determined by the selected cross-section of the orifice (spool). The valve cannot be adjusted and is maintenance-free. In the event of a malfunction, the valve can be removed from the housing and dismantled for inspection (contamination, spring break) or replacement. In the event external leakage, mount a new seal kit.

7.3

Remaining flow pressure balance 103, see Fig. 12 and Fig. 13 In standby mode, there is a continuous flow volume Qmin of approx. 30 l/min. When consumers are not in operation, the p ration of the valve and the additional tank preload generate a standby pressure at the pump connection MP. In this mode, the system pressure is thus approx. 35 bar (R 317-Li). The standby pressure pushes the piston 103 through the integrated channels against the spring 322. Simultaneously, the LS channel is relieved through the valve 102 to the tank. As a result, a connection between the pressure side P and the tank side T is established, and the pre-set volume of oil flows off. The valve ensures that, in the event of idle run, there is still a minimum volume flow of Qmin at standby pressure to the tank. There is thus a certain loss of power in this mode, in line with the volume flow. As soon as a consumer is actuated, the load pressure of the consumer is applied to spool 103. The pressure and spring force displace the piston 103 proportionally to the requested volume, thus reducing the outlet cross-section of the orifice in the direction of the tank. If the total amount of the consumer volumes is smaller than Qmin, the volume allotted through the gauge orifice is fed to the consumers first, due to the lower p ration of the spool. The remaining differential quantity (Qmin - total of consumer volume) continues to flow via the adjusted control edge to tank. As soon as the requested volumes exceed Qmin at one or more spool(s) (i.e. total of consumer volumes greater than Qmin), the valve 103 is closed completely, shutting off the connection to the tank side. Above this volume, the system works with the variable displacement pump according to the "closed centre" and adjust the requested volumes by means of the LS regulator. As long as the performance requested by the diameter of the gauge-orifice (at the spool) and the highest load pressure is below the pre-set power curve, the LS regulator maintains the set p ratio at a constant level. As soon as the system falls below this point, a saturation deficit occurs. The LS regulator of the pump is unable to maintain the set p ratio via the gauge orifices. The pump cannot build up the required pressure at it has already reached its maximum pivot angle. The LS regulator is disabled, and the pump delivers the highest obtainable volume given the prevailing load pressure. The valve cannot be adjusted and is maintenance-free. In the event of a malfunction, the valve 103 can be checked for contamination or defects and replaced, if necessary, by unscrewing the screw plug 275 and removing the parts 321 and 322 from the housing.

7.60.22

copyright by

MJFCIFSS

Service Manual


Fig. 12

Sectional drawing of the inlet element "residual pressure balance and pressure cut-off"

100

Compact block

211

Restrictor bolt

102

Pressure balance / minimum flow (flow controller) For details, see Fig. 13

275

Screw plug

103

Piston/pressure balance (unloading valve) 321

104


322

Pressure spring

105


LS

107

Shuttle valve

P

LS signal from the consumer with the highest load Pump pressure

108

LS central nozzle

T

Tank channel

copyright by

MJFCIFSS

Spring plate

7.60.23

LSC control block

Service Manual

Input section / input element The diagram of the inlet element with external shuttle valve 107 is only valid for A 312 units to serial no. 16275, A 314 units to serial no. 16214 and A 316 units to serial no. 16141.

Fig. 13

100 102

7.60.24

Sectional drawing of the inlet element "residual pressure balance and external shuttle valve" 16 103

1

Compact block Minimum flow pressure balance, complete Valve insert/pressure balance

104

Backing ring/pressure balance Residual flow pressure balance (unloading valve) Pressure cut-off valve

2 3

Piston/pressure balance Pressure spring/pressure balance

107 108

Shuttle valve LS central nozzle

4

Screw plug/pressure balance

211

Restrictor bolt

14

O-ring/pressure balance

321

Spring plate

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MJFCIFSS

Service Manual


15

7.4

322

O-ring/pressure balance

Pressure spring

Primary pressure-relief valve 105 (pump safety valve), see Fig. 12 The primary pressure-relief valve protects the pump against excessive pressure in the event of failure of the secondary pressure-relief valve and cut-off valve. As it is supposed to respond only in the event of an emergency, its pressure setting is significantly higher than that of the cut-off valve and system pressure. This valve is identical as regards function and design with the secondary pressure-relief valves of the control axles for boom, stick and bucket, see Fig. 27.

7.5

LS shuttle valve 107, see Fig. 12 and Fig. 13 The orifices of LS shuttle 107 limit the volumetric flow to the LS regulator of the pump. The propagation of abrupt pressure peaks to the regulator and resulting power peaks of the pump are prevented in the LS line, thanks to the interrelation between the various orifices and capacities. The pulsating of the hose and/or the compressibility of the oil volume smoothens out pressure peaks. This prevents aggressive or unwanted responses of the pump to sudden peaks, ensuring stable operating behaviour. In the event of malfunction, the valve 107 can be removed by screwing off the valve seal 210/219 and pulling out the double-sided cone 211 so that the valve can be inspected for damage or contamination and replaced, if necessary (observe correct installation position of double-sided cone).

7.6

LS central nozzle 108, see Fig. 12 and Fig. 13 The LS central nozzle acts as restrictor and dampener at the LS oil inlet in the input element. When the pressure cut-off valve 104 is actuated, the restrictor lowers the p ratio, and the cut-off valve can be used to reduce the pump volume through the pump flow regulator. The central nozzle 108 restricts the volume flowing off through the pressure cut-off line. This is particularly important where several consumers are run to their limit and the fully opened pressure balances feed oil into the LS line.

copyright by

MJFCIFSS

7.60.25

LSC control block

Service Manual


7.7

Pressure cut-off valve 104 The LS pressure cut-off valve 104 acts as a pressure controller. As soon as the pre-set pressure is reached, it reduces the volumetric delivery of the pump to Qmin. This function has priority over the pump's power and flow regulation systems. As soon as the pressure cut-off valve is actuated, loadsensing and/or power regulation are disabled. Once a consumer reaches its max. permissible operating pressure, the cut-off valve is actuated, relieving the LS signal behind the LS main nozzle in the control valve block to the tank. The LS signal to the pump cannot increase any further, and the pump regulates the flow in such a way that a maximum pump pressure of LS + is built up in the pump channel. Thanks to the pressure cut-off valve, there is still a certain pump flow volume available in the power control system. The valve 104 thus prevents that consumers connected in parallel are stopped as soon as one or more are run at their maximum limit. The valve must be regularly inspected and readjusted, if necessary (see maintenance schedule).

Fig. 14

7.60.26

Pressure cut-off valve 104

1

Valve insert

11

Backing ring

4

Adjusting screw

12

Backing ring

5

Spring plate

13

Backing ring

6 7

Pressure spring Washer

14 15

O-ring O-ring

8

Lock nut

16

O-ring

10

Circlip

104


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Service Manual

LSC control block Control and distribution area

8 Control and distribution area 8.1

Control axles, see Fig. 15 and Fig. 16 Each control axle is equipped with the necessary spool and actuation devices (control lid, regulating springs), a pressure balance and the respective control and high-pressure connections with secondary protection.

8.2

Spools 160, 180, 220, 240, 260 The geometry of the spools and their orifices have been designed and adapted specially to match the characteristics of the individual consumer. The control of the consumer in the LUDV system is independent of the load pressure. At a constant p, the volumetric flow rate is adjusted by modifying the cross-section of the gauge orifice and via the stroke of the spool. The maximum volumetric flow rate to the consumer is thus determined by the maximum possible cross-section. In the event of malfunction, check the spools 160 to 280. To do this, remove the upper control lid 134, pull out the spool and check it for damage, contamination, etc. If necessary replace it.

8.3

Dismantling of spools 160 to 260 Caution! Before dismantling control lines: relieve pressure from hydraulic circuit. Lid 134 is spring-loaded. Risk of injury Dismantle the respective control line. Remove the screws 135. Remove the lid 134 with O-ring 130. Pull the spools 160 to 280 from the control valve block 100. Remove the pressure spring 132 and the spring plate 131.

8.4

Installation of spools Important information for installation / replacement of pistons: The individual spools are matched to the specific requirements of their operational functions (boom, stick, etc.) and are not interchangeable. If you wish to remove more than one spool at a time, make sure they are re-installed in their original bores. Usually, the bores in the control valve blocks are made for perfect fit. If this is the case with all the bores in the block, the type plate of the block shows end number "000". 'Perfect fit' indicates that the bores have ± 0 µm tolerance. This means that the spools supplied for replacement usually have a tolerance range of 8-10 µm, and that the amount of leak oil is within the standard tolerance range. Zero-tolerance bores are marked with steel stamping numeral 0. Replacement with spools as specified in the ET spare parts catalogue is possible. If one or several bores of the control block do not meet the zero tolerance standard, the actual tolerance is indicated on the type plate. To find out the bores to which this applied, remove the top lid 134 of the spool in question.

copyright by

MJFCIFSS

7.60.27

LSC control block

Service Manual

Control and distribution area The tolerance is indicated on the front face /control lid of the control block (e.g. 10 = 10 µm). In this case, it is not possible to replace the spool with a part from the spare parts catalogue, and the spool must be specially made to fit the tolerance. When ordering spare spools, please quote all information on the type plate, see also service information no. 1-14-52 / 2000. Ensure that the spool is installed in the correct position. Apply a little oil to the fitting spool and carefully insert it into the control valve block 100. Place the spring plate131 and the pressure spring132 onto the spool. Insert the O-ring 130 and place the lid 134 on the control valve block 100 and secure them with the screws 135.

Fig. 15

7.60.28

Control axles with regulating springs and control lid at the control valve block

copyright by

MJFCIFSS

Service Manual

LSC control block Control and distribution area

Fig. 16

Control axles of the compact control valve block (left) and travel gear (right)

100 134

Compact control block Control lid

221/222 224

Secondary pressure-relief valves Pressure balance, pilot-controlled

160 161/162

Spool / chassis right Suction valves chassis right

227 240

Restrictor check valve Spool / stick

164


241/242


167


244**


170


247


172 180

Pressure spring / load-holding valve Spool / chassis left

260 261/262

Spool / bucket Secondary pressure-relief valves

181/182* Suction valves chassis left

264**


184*


280

Spool / support

187*


281

Screw plugs only with section support

220

Spool / boom

284**


copyright by

MJFCIFSS

7.60.29

LSC control block

Service Manual

Control lid 134 * **

in R machines only Sectional drawing, (see Fig. 19, page 32)

9 Control lid 134

Fig. 17

Control lid 134

1 2

Cap nut O-ring

167 167

Restrictor check valve / travel drive (A) Restrictor check valve / travel right (R)

3 4

Lock nut Adjusting screw / stroke limitation

187 227

Restrictor check valve / travel left (L) Restrictor check valve / boom

134

Control lid

247

Restrictor check valve / stick

140

Screw plug

Y

Setting value of stroke limitation

The control lid 134 is located on both sides of the spools 120 to 260 and is fixed to the compact block 100. The control oil required for the actuation of the spool is fed through the control connection a / b of the control lid 134. Some of the control axles have a shuttle dampening function (restrictor check valve 167 / 187 / 227 / 247) in the inlet area of the control connection. They restrict the flow of the oil displaced by the spool in the opposite control lid, thus reducing the shifting speed of the spool. This results in a smooth start of the motion of the consumer, as well as good handling and fine-control. The consumer movement is damped by the restrictor check valve 167 / 187 / 227 / 247 in the opposite control lid. The oil enters the control lid (e.g. at connection a) through the opening valve seat. The oil displaced by the spool (e.g. through connection b) closes the valve seat so that the control oil displaced must flow through the orifice of the valve. The cross-section of the orifice (and thus the shifting speed) are adjusted to suit the characteristics of the individual consumer. The restriction of the flow in the outlet to T ensures that both abrupt actuation and sudden pressure relief are effectively dampened. The control lid is also equipped with a stroke limitation 4 for the spool, so that the maximum speed of the consumer can be limited. The relevant setting are factory set (by supplier/manufacturer) and may not be changed. The adjusting screws 4 are secured with the lock nuts 3 and protected against damage by the cap nut 1. For rough adjustment, check the setting value Y. The fine adjustment of the absolute maximum vo-

7.60.30

copyright by

MJFCIFSS

Service Manual

LSC control block Control lid 134

lume to a consumer must be carried out with a flow meter on the outlet of the control block. The flushing grooves a of the spools 160 to 260 form a connection between the tank and control lid 134. Together with the tank preload of the control valve block, they ensure a continuous flow of oil when the pilot control valve is not actuated. The flushing volume is thus available for the preheating of the control oil circuit.

Fig. 18

Sectional drawing of control lid134

1 2

Cap nut O-ring

167 180

Restrictor check valve Spool / chassis left*

3 4

Lock nut Adjusting screw / stroke limitation

187 220

Restrictor check valve* Spool / boom

5

Shuttle

227


6

Orifice

240

Spool / stick

100

Control valve block

247


130 131

O-ring Spring plate

260 280

Spool / bucket Spool / support

132

Regulation spring

134

Control lid

a

Flushing groove

160

Spool / travel drive

a1-a5

Control pressure connections, bottom

160

Spool / chassis right*

b1-b5

Control pressure connections, top

*

in R machines only

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MJFCIFSS

7.60.31

LSC control block

Service Manual

Directly controlled pressure balances 164 / 184* / 244 / 264 / 284

10

Directly controlled pressure balances 164 / 184* / 244 / 264 / 284 The required flow is controlled by means of the cross-section of the opening of the respective spool shaft and the LS pressure at the pump regulator. The effect of differing load pressures in the consumers is compensated by the pressure balances connected to each spool axle and used in each control valve block. The LUDV pressure balances 164 -284 with the pressure spring 165 of each section is situated downstream of the gauge orifice of the spool. The pressure balance reports the pressure of the consumer with the highest load to the pump regulator. The pressure balance then compensates the pressure difference between load pressure and pump pressure in all consumers with a lower load. When in neutral position, the spool blocks the connection between the pump and the channel p (see Fig. 22). In this position, the pressure in the channel p and behind the load-holding valves is relieved through the piston play to nearly tank level. The consumer connections are blocked by the spool in the housing. The consumer is thus located between two oil columns.

Fig. 19

7.60.32

Directly controlled pressure balance (front view and sectional drawing) Shown here: pressure balance 164

164

Pressure balance

166

O-ring

165

Pressure spring

167

Screw plug

*

in R machines only

copyright by

MJFCIFSS

Service Manual

LSC control block Directly controlled pressure balances 164 / 184* / 244 / 264 / 284

10.1

High pressure As soon as the spool is shifted, the supply orifice of the spool opens the connection between the pump connection p and the channel p. The pressure built up in this section shifts the pressure balance and also acts through the internal channels in the pressure balance on the rear of the loadholding valves. The consumer pressure pc of the connection A acts via the channels in the spool and is available at the front of the left-hand load-holding valve. When the pump pressure p is increased above the consumer pressure pc, the load-holding valve is opened. The connection between the pump and the consumer is now established and initiates the movement. The displaced oil flows through the outlet orifice back to the tank. The secondary pressure-relief valves remain closed as long as the pressure in the consumer connection is below the pre-set pressure value.

Fig. 20

Pressure balance in high-pressure position

pc high = LS signal to pump regulator

10.2

Consumer with highest load is actuated In the event of individual movements, or if the load pressure of the consumers pc is the highest within the system, the pressure balance is fully opened. The channel p is connected to the consumer connection pc, without pressure drop. The consumer pressure is transferred through the pressure balance bores to the spring chamber of the pressure balance and subsequently to the LS line. The LS signal is transmitted to the flow regulator (LS regulator) of the variable displacement pump, and also to the spring chambers of the other LUDV pressure balances, which then block the load pressures of the other consumers against the LS line. As the LS signal is constantly regenerated by the load-holding valves, the consumer connections remain closed until the required working pressure is reached. This prevents sudden pressure drops in the event of negative (i.e. pulling) loads.

copyright by

MJFCIFSS

7.60.33

LSC control block

Service Manual

Directly controlled pressure balances 164 / 184* / 244 / 264 / 284

10.3 10.3.1

Low pressure Load-sensing regulation In the saturated area, the LUDV system operates as a pure load-sensing regulation system. The speed of the consumer is controlled independently of the load pressure, by means of the cross-section of the gauge orifice (spool). When several movements overlap, the load pressure of the consumer with the highest pressure is applied through the central LS line to the spring chambers of the other LUDV pressure balances. The resulting pressure in the channel p of this section is determined by the highest reported LS pressure (p = LS + spring force). The LUDV pressure balances automatically regulate the pressure p of the various axles by restricting the flow cross-sections to the consumer channels to the same value. As pressure p in the P channel of the block is the same everywhere, p is the same at all gauge orifices. As a consequence, the consumer speed is independent of the difference between the load pressures. As the pressure balance spring end is pressurised according to the highest load signal, it cannot open completely. As the pressure balance is only partly open, an additional pressure difference is built up, which is based on the actual load.

Fig. 21

Pressure balance in low-pressure position

d = LS = pc high e = pc low p = LS pressure (approx.) F = spring chamber R = regulating orifice

10.3.2

LUDV function The LUDV system works even in the event of a saturation deficit. In such a case, the oil volume requested by means of the sum of the open gauge-orifice cross-sections at the existing p exceeds the maximum flow rate of the pump within the boundaries of the power control. The LS regulator of the pump is no longer in a position to build up the set p by means of further pivoting the variable displacement pump. Pressure p set at the regulator collapses. In this status, the LUDV system maintains the p at the same level across all open gauge orifices. This ensures that the consumer(s) with the highest pressure is/are not shut down in the event of a saturation deficit. Instead, the speeds of all actuated consumers is reduced in proportion to the respective open cross-sections.

7.60.34

copyright by

MJFCIFSS

Service Manual

LSC control block Directly controlled pressure balances 164 / 184* / 244 / 264 / 284

When all the pressure balances are in balance, the LS system pressure is the same in all the spring chambers of the pressure balances the pressure p in front of the gauge orifices or the pressure balances of the section with the lower load corresponds to the LS pressure of the consumer with the highest load p inlet orifice = ppump - p The pat the inlet orifices of all consumers is always the same. In the event of a saturation deficit, the p is reduced but again remains the same in all consumers. The pressure differences p inlet orifices between p and each individual consumer pressure pc are regulated and automatically levelled by adapting the opening cross-section, so that the volumetric flows are split proportionally.

10.3.3

Negative load Speed control of the consumers via the aperture of the inlet orifice is not possible with negative (pulling) loads. In such a case, the consumer is controlled in relation to the actual load, via the outlet orifices.

Fig. 22

Pressure balance in position "spool closed"

a b

no LS signal LS signal

100

Control valve block

160 164

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MJFCIFSS

Spool / travel Piston

7.60.35

LSC control block

Service Manual

Pilot-controlled pressure balance 224

11

Pilot-controlled pressure balance 224 The pilot-controlled pressure balance 224 fulfils the same purposes as the directly controlled pressure balance in the LUDV system. Its function therefore corresponds to the basic functions of the directly controlled pressure balances, (see 10, page 32).

11.1

Additional properties of the pressure balances 224: Finer and more precise regulation behaviour thanks to the pilot control pistons 1 with pressure springs 2 incorporated in the pressure balance. The fast-responding pilot control pistons control the pressure signal from the high-load to the low-load consumers.

Fig. 23

7.60.36

Pilot-controlled pressure balance (front view and sectional drawing)

1 2

Pilot control piston Pressure spring

165 166


3 4

Spring plate Spring plate

168 224

Screw plug Pressure balance (pilot-controlled)

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MJFCIFSS

Service Manual

LSC control block Pilot-controlled pressure balance 224

11.1.1

Low pressure section: The pilot control piston 1 is in its initial position, i.e. it connects the current LS pressure of the consumer with the highest load pressure to the spring side of the pressure balance. The pressure balance regulates the pump pressure of the consumer with the lower load pressure to the LS pressure of the consumer.

Fig. 24

Pressure balance in low-pressure position (LS signal from consumer with highest load pressure)

1

Pilot control piston

F

Spring chamber

2 100

Pressure spring Control valve block

R pch

Regulating orifice High pressure (LS)

220

Spool

pcl

Low pressure

224

Pressure balance

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MJFCIFSS

7.60.37

LSC control block

Service Manual

Pilot-controlled pressure balance 224

11.1.2

High pressure section: The pilot control piston 1 is shifted against pressure spring 2, thus relieving the spring side of the pressure balance main piston. At the same time, the consumer with the highest load pressure is connected to the LS pressure, which in turn acts on the LS controller of the working pump.

7.60.38

Fig. 25

Pressure balance in high-pressure position (pc high = LS signal to pump regulator)

Fig. 26

Pressure balance in position "spool closed"

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Service Manual

LSC control block Pressure-relief and feeder valves

12 Pressure-relief and feeder valves see Fig. 27 The pilot-controlled pressure-relief valves 105 / 221 - 262 of the various consumer connections are all of the cartridge type and screwed directly into the control valve block 100. They limit the pressure between the pump, the control block and the working attachments and/or between the working attachments and the control block when the spools are closed (secondary function). If the pressure in the working attachment circuit exceeds the maximum permissible limit, it activates the built-in pressure-relief valve. the valve limits the maximum pressure in the consumer and the respective connection to the pre-set value. As high flows result in pressure on the pressure valves of the hydraulic unit, the machine is equipped with pilot-controlled pressure-relief valves. In these valves, a direct-acting pressure-relief valve acts as the pilot-control valve, generating a pulse that actuates the second, larger valve. The pressure-relief valves also act as feeder valves. Differences in the flow rates of the oil to and from the working cylinders result in a vacuum. This might occur for instance when the stick cylinder is extended with a long stick, due to external pulling loads. In such a case, the speed of the consumer would not be controlled by means of the gauge orifice diameter, but based on the loads and via the outlet edge of the spool. In order to prevent this, the valves connect the return side with the corresponding low-pressure side so that additional oil can be taken in.

12.1 12.1.1

Description of functions Pressure limitation The pressure (P) built up in the consumer circuit acts on the front face of the main cone 3 and, through the bore D1, also on the rear surface of the main cone 3. At the same time, the pressure acts also on the pilot control cone 4. The springs 8 / 9 and 5 push the main cone 3 and the pilot control cone 4 into their closing positions (static status). As soon as the pressure in the consumer circuit reaches a value that is above the set value of pressure and adjusting spring 5, the pilot control cone 4 is lifted from its seat and some oil enters the return channel T through the ring gap between the housing and the main cone 3. Due to the different cross-sections of the bores D1 in the main cone 3 and D2 in the valve insert 2, there is a pressure difference between the front and the spring side of the main cone 3. As a result of this pressure difference, the main cone 3 is shifted against the pressure springs 8 / 9, and a substantial amount of oil flows off to the non-pressurised return side T.

12.1.2

Feed If there is a vacuum in a working circuit, the higher pressure in the hydraulic tank is applied through the bore T of the housing 1 onto the ring face of the main cone 3. As a result of the pressure difference across the effective surface of the main cone 3, the main cone is pressed against the force of the pressure springs 8 / 9 so that the required amount of oil can flow through the bore T and the connection P to the respective side of the consumer.

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MJFCIFSS

7.60.39

LSC control block

Service Manual

Pressure-relief and feeder valves

Fig. 27

7.60.40

Pressure and feeder valve 105 / 221 - 262

1

Housing

9

2

Valve insert

10

Safety cap

3 4

Main cone Pilot control cone

11 12

Piston seal O-ring

5

Pressure spring

13

O-ring

6

Adjusting screw

14

Backing ring

7

Lock nut

15

O-ring

8

Pressure spring

16

O-ring

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MJFCIFSS

Pressure spring

Service Manual

LSC control block Feeder valves 161 / 162 / 181 / 182

13 Feeder valves 161 / 162 / 181 / 182 see Fig. 28 Feeder valves (i.e. suction valves / check valves) are mainly used in conjunction with rotating consumers. The risk of insufficient oil, i.e. cavitation, in oil motors is greatest when there are delays in the operation of the machine (downhill travel). When decelerating, the oil motor of the drive system runs idle. The pressure peaks due to the high moment of inertia during downhill travel result in activation of the brake valves while the spools are blocked. From a certain inclination, the speed of the motor (and, thus, the oil volume to be fed) is no longer determined by the aperture of the inlet orifice of the spool, but depends on the load and the grade resistance. The feeder valve provides the required volume of oil to the working connection in order to prevent cavitation.

13.1 13.1.1

Description of functions Closing position: The high pressure in channel A/B is applied through the bore D to the spring side of the main cone 3, pressing the cone against the sealing edge of the valve insert 1, so that the valve 161 / 162 / 181 / 182 is closed towards the consumer side.

13.1.2

Suction: If there is a vacuum in the working circuit, the higher pressure in the hydraulic tank acts through the bore T of the valve insert 1 onto the ring face of the main cone 3. As a result of the pressure difference across the effective surface of the main cone 3, the main cone is pressed against the force of the pressure spring 8 so that the required amount of oil can flow through the bore T to the respective side of the consumer A / B.

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MJFCIFSS

7.60.41

LSC control block

Service Manual

Feeder valves 161 / 162 / 181 / 182

Fig. 28

7.60.42

Feeder valves 161 / 162 / 181 / 182

1 3

Valve insert Main cone

33 34

O-ring Backing ring

6 8

Screw Pressure spring

35 37

O-ring O-ring

31

Piston seal

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Service Manual

LSC control block Shift valve for Qmin shifting (fast run) of the regulating motor 106 (in R models only)

14 Shift valve for Qmin shifting (fast run) of the regulating motor 106 (in R models only) The 3/2-way shift valve 106 integrated into the control valve block controls the working pressure of the travel motor and thus the Qmin / Qmax shifting of the regulating travel motors 200/201. If fast travel of the excavator is pre-selected with the switch S21 (on the right control console, see electric equipment) (regulating motor to Qmin), the switching from Qmax to Qmin and vice versa is determined by the working pressure in the travel gear circuit (travel pressure). Travel pressure 0 bar - 300 bar = regulating motor can be run at normal and fast speed (Qmax./ Qmin.). Travel pressure > 310 bar = regulating motor is automatically set to Qmax (low speed). Travel pressure <130 bar = Resetting pressure from Qmax. (low speed = normal travel) to Qmin.(high speed = fast travel).

14.1

Function The valve 106 in neutral position feeds the control oil from the control oil unit 50 connection A2 (solenoid valve Y24) through connection c to connection d and a line to connection X of the regulating motors 200/201. The maximum control pressure acts on the travel motors and pushes the powertrain to the minimum pivot angle (Qmin.= fast speed), see also functional description in group 7.28). If the travel pressure is increased (>310 bar), the shifting piston 6 is pressed against the pressure spring 4 and the connection between c - d is blocked, while the pressure at the connection X of the regulating motors 200/201 is released through connection d -L to the tank. As a consequence, the oil motor switches to Qmax = low speed, despite the pre-set fast speed. If the travel pressure drops to the level or the switching point (<130 bar) of the valve or below, the pressure spring 4 pushes the shifting piston 6 to its neutral position (connecting lines c - d) and the regulating motors are switched again to Qmin (fast travel).

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7.60.43

LSC control block

Service Manual

Shift valve for Qmin shifting (fast run) of the regulating motor 106 (in R models only)

Fig. 29

14.2

Sectional drawing of shifting valve (Qmin shifting)

1 2

Connecting piece Bushing

11 17

O-ring Backing ring

3

Piston guide

18

O-ring

4 5

Pressure spring Spring plate

50 100

from the control oil unit Compact control block

6 7

Shifting piston Piston

106 200

Shift valve, complete from/to travel motor left

8

Threaded stud

201

from/to travel motor right

Repairs In the event of malfunction, the valve 106 can be screwed out and inspection for damage and contamination.

7.60.44

copyright by

MJFCIFSS

Service Manual

LSC control block Repairs to control valve block

15 Repairs to control valve block Caution! Before carrying out any repairs on the control valve block, release the preload pressures at the tank and servo system. Switch off the diesel engine. Proceed as follows: Unscrew the breather filter on the hydraulic tank with 1 turn (slow de-pressurisation).

Release backpressures. Turn ignition key into contact position. Actuate all pilot control devices in all possible directions.

15.1

Leaks on the outside If there are leaks on the control valve block, replace the seals on the screwed connections, SAE flanges, caps and valves.

15.2

Spool Remove the control line (collect escaping oil). Remove the Allen head screws 135. Remove the control lid 134. Remove the pressure spring 132 with spring plate 131 and pull the spool from the housing. Note! If you wish to remove more than one spool at a time, do not confuse them and ensure they are reinstalled in their original bores (observe markings, etc.). In spare spools, the axle marking A1 - A5 is engraved on the front side opposite the spring and on the shaft of the spring pack. Note (see table 8.4, page 27) Prior to installing the spools, check the O-rings in the housing for damage (spool lid seals). Also check the spools for damage or defects (scores in surface). Install the parts by completing the above steps in reverse order. Insert the spool with care to avoid jamming. Do not use force.

15.3

Pressure balances and valves To repair pressure balances and valves, they must be removed from the housing. To access the suction valves 161 / 162 / 181 / 182 and the secondary pressure-relief valves 221 262, screw the respective load-holding valve 170 - 172 from the housing. When installing the valves, check the outer seal rings. Do not use seal rings that are damaged. Avoid twisting and warping. Fit seals tightly. Use correct torques to tighten the auxiliary axles, valves and screwed connections.

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7.60.45

LSC control block

Service Manual

Maintenance

15.4

Tightening torques for the valves and screw plugs of control valve block 100 Pressure balance 102

15.5

120 Nm

Nozzle 271

6.5 Nm

Pressure cut-off valve 104

25 Nm

Check valve 274

3.5 Nm

Pressure-relief valve105

120 Nm

Screw plug 275

30 Nm

LS central nozzle 108

8 Nm

Screw plug 276

60 Nm

Restrictor check valve 109 Allen head screw 111

10 Nm 70 Nm

Screw plug 278 Allen head screw 320

10 Nm 70 Nm

Allen head screw 135

10.5 Nm


10.5 Nm

Screw plug 140

20 Nm

Valve 341

20 Nm

Restrictor check valve 167/187/227/247 Screw plug 168/169

20 Nm 200 Nm

Screw plug 369 Screw plug 373

90 Nm 120 Nm

Load-holding valve 172

100 Nm

Screw plug 475

30 Nm

Suction valves 161/162/181/182 Valve seat 210/219

100 Nm 120 Nm

Screw plug 476 Screw plug 490

60 Nm 3.5 Nm

Pressure-relief valves 221 - 262 Check valve 233/234

100 Nm 10 Nm

Screw plug 811

55 Nm

Installation instructions

The contact surface must be absolutely even. Tighten the mounting bolts evenly, in a cross-wise pattern. Ensure that all contact faces of the SAE connections are clean. Pipes and hose lines must be properly laid, without any twists, warps, or tension. Observe the prescribed tightening torques for mounting bolts, screwed connections etc. (See also group 1.20 torques of screws, bolts, screw-in studs)

16 Maintenance Regularly inspect the control valve block for leaks. Regularly check the pressure cut-off valve 104 and the secondary pressure-relief valves 221 - 262 for correct settings (see maintenance instructions). To test the secondary pressure-relief valves, increase the set value of the pressure cut-off valve 104 to a value above the expected peak (see adjustment protocol and guidelines for the hydraulic system, group 6).

7.60.46

copyright by

MJFCIFSS

Service Manual

LSC control block Auxiliary control axles

17 Auxiliary control axles 17.1

Slewing gear element, see Fig. 31 Components of the element: Connections A01 and B01 for slewing-gear supply and return flows Connection LSDR for load signal to right-hand control block side Connection DRDA for pressure line to TC valve 125, see also group 7.80 Spool 120 for working movements of the uppercarriage (turning left and right) Input pressure balance 122 for priority shifting Check valve 123, preventing any effects on the slewing gear from simultaneously operated consumers with a higher load pressure Control lid 334 of the axle, limiting the stroke of the spool 120, and featuring the control pressure connections a01 and b01 as well as the regulating and return spring 332 Restrictor check valves 127 for the fine-control of the spool 120

Fig. 30

17.2

Hydraulic diagram of slewing gear element 120 with TC valve 125

Repairs to control valve block Always observe the safety notes, (see 15, page 45).

Leaks on the outside Replace the seal rings of flanges, lids and valves. Replace all screw plugs that are no longer tight.

Spool Disconnect the relevant control line. Remove the Allen head screws 335. Remove the control lid 334 (caution: the lid 334 is spring-loaded.) Remove the pressure spring 332 and pull the spool 120 from the housing. Install the parts by completing the above steps in reverse order.

Valves To repair valves, remove them from the housing. If necessary, replace them with spare parts from the ET catalogue.

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MJFCIFSS

7.60.47

LSC control block

Service Manual


Fig. 31

7.60.48

Slewing gear segment

100 120

Compact control block Spool / slewing gear segment

332 333

Pressure spring Washer

122

Inlet/supply pressure balance

334

Control lid

123 125

Check valve TC valve

335 365

Allen head screw Pressure spring

126 127

Restrictor (Ø 1.5 mm) Restrictor check valve

369 371

Screw plug Pressure spring

128 129

Shuttle valve Restrictor (Ø 1.5 mm)

372 373

O-ring Screw plug

130

Nozzle (Ø 0.9 mm)

475

Screw plug

131 132

Nozzle (Ø 1.5 mm) Cone

810 811

End plate Allen head screw

330 331

O-ring Spring plate

999

Seal kit

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Service Manual


17.3 17.3.1

Functional description of slewing gear spool Priority of slewing gear In a single-circuit LUDV system, all consumers are arranged in parallel and supplied by a single working pump. In the LUDV system, the slewing gear is always given priority. It can be controlled independently of all the other consumers. The question of priorities arises whenever the system must work with a deficit in saturation and the LUDV system automatically influences the speed of movements with respect to the degree of the actual saturation deficit. Assigning first priority to the slewing gear became necessary because most operators do not like it when the speed is automatically influenced by other movements. Automatic acceleration caused as a result of the LUDV principle is also considered unacceptable. The priority of the slewing gear during combined movements is ensured by the following measures: The module is the only consumer in the system working with a 2-way pressure balance in the supply flow to the gauge orifice. The pressure balance for the section located in front of the gauge orifice compares the load pressure LS slewing gear and the setting of the pressure balance spring with the pressure p at the gauge orifice. The p gauge orifice is maintained at a constant level (corresponding to the applied spring force), allowing for speed control that is independent of the load pressure. The volume can only be increased or reduced, and the speed thus only changed by manipulating the gauge orifice.

17.3.2

Attachment section is consumer with highest load pressure The check valve in the LS line between the module and the system ensures that the control of the slewing gear is not influenced by consumers with higher loads running at the same time. The difference between the pump pressure psystem and the working pressure p of the slewing gear element is always controlled and regulated by the preceding pressure balance, even when consumer pressures fluctuate significantly. The regulating cross-section of the pressure balance has been chosen to allow for quick responses in cases of great differences between psystem and p slewing gear and is increased/opened with decreasing pressure differences. The volumes supplied by the pump and not taken up by the slewing gear are distributed proportionally to the other active consumers according to the LUDV principle.

17.3.3

Slewing gear section is consumer with highest load The LSslewing gear is reported to the LS line of the compact control block (via the check valve) to have the highest pressure in the system. Its pressure acts on the rear of the LUDV pressure balances and the p regulator of the variable displacement pump. The volumes supplied by the pump and not taken up by the slewing gear are distributed proportionally to the other active consumers according to the LUDV principle.

17.3.4

Slewing gear torque control In order to achieve sensitive acceleration of the slewing gear, a torque control (pressure control) is required. During acceleration from standstill, the slewing gear requires only a small amount of oil. With pure LS control, this amount however generates the maximum load pressure in the slewing gear, resulting in maximum rotary acceleration. Any precise speed that is independent of the load pressure (via 2-way supply pressure balance 360) is thereby overridden by a torque control. The directly controlled torque control valve 125* allows the operator to continuously control the admissible pslewing gear with respect to pcontrol pressure and, thus, the available torque. The corresponding operating pressure is generated in proportion to the control pressure, i.e. in proportion to the angle of the pilot control valve. The operator can thus control the rotary acceleration by means of the angle of the pilot control valve. This approach allows for very sensitive means of accelerating the rotary motion.

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7.60.49

LSC control block

Service Manual


17.3.5

Loss-free acceleration The torque control valve 125 is mounted separately to the hydraulic tank. It is integrated into the LS line of the module of the pressure balance. This design ensures that the slewing gear is supplied with the quantity of oil required to build up the necessary working pressure. As soon as the pre-set pslewing gear is reached, the preceding pressure balance reduces the flow, and only supplies the amount necessary to maintain the pressure. The acceleration of the slewing gear works thus without any losses. The maximum admissible acceleration pressure at the torque control valve 125 is about 30 bar below the upper setting of the 2-step slewing gear valves in the oil motor. The secondary valves therefore do not respond, so that loss is prevented. Thanks to the torque control, the quantities supplied to the slewing gear motor increase when pslewing gear drops until the required pressure according to the pre-set p pressure spring is obtained through the gauge orifice.

17.3.6

Deceleration of the slewing gear The slewing gear is slowed down by means of the outlet orifices of the spool leading to the tank, and the pressure-relief valves leading to the motor. The minimum possible deceleration is determined by the lower pressure setting of the 2-step slewing-gear pressure valves. They have been tuned to a lower level in order to provide for smooth deceleration. Again, the following rule applies: when pcontrol pressure increases, the additional pressure stage of the secondary cartridge is increased continuously to the maximum admissible value. Both values can be adjusted independently by controlling the admissible acceleration pressure via the torque control valve and the deceleration by means of the brake valves at the motor. If the spool is in neutral position, the slewing gear is hydraulically fixed by means of the locked consumer connections A and B. The valve 125 is factory-set and cannot be adjusted. Should modifications become necessary, proceed as laid down in the adjustment protocol and guideline; see group 6. In the event of a malfunction, the valve can be removed from the housing and dismantled for inspection (contamination, spring break) or replacement.

7.60.50

copyright by

MJFCIFSS

Service Manual


Fig. 32

Sectional drawing of slewing-gear element

120 122

Spool / slewing-gear segment Inlet/supply pressure balance

372 373

O-ring Screw plug

127 130

Restrictor check valve Nozzle (Ø 0.9 mm)

475 D1

Screw plug Supply gauge orifice p-A01 or p-B01

131 132

Nozzle (Ø 1.5 mm) Cone (load-holding function)

D2 pV

Outlet orifice A01 - T or B01 - T Consumer pressure

334

Control lid

pM

Pressure in front of gauge orifice

365

Pressure spring

a01/b0 Control oil connection

369

Screw plug

A01

Consumer connection

371

Pressure spring

B01

Consumer connection

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7.60.51

LSC control block

Service Manual


7.60.52

copyright by

MJFCIFSS

Service Manual

LSC control block Kit elements for auxiliary control axles

18 Kit elements for auxiliary control axles

Fig. 33

Auxiliary control axles AS1, AHS 1, AHS 11 and AHS 12

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7.60.53

LSC control block

Service Manual

LSC auxiliary control axles

19

LSC auxiliary control axles M7 - 205

Product

Secondary valve with additional pressure stage

2 axles (AHS 1 + AHS 11)

AS1

AHS 1

AHS11

AHS 12

540 Grapple rotator

500 Boom adjusting device

510 Hydraulic hammer

500 and 510 All auxiliary attachments

Extend

Extend

Contained in:

left

Nom. block width Consumer connection

M7 - 205

Secondary valve without additional pressure stage

Unit

Spool for

M7 - 205

SX/14-1X

right

Retract

Retract

()

14 (G3/4)

20 (SAE §/4)

20 (SAE 3/4)

20 (SAE 3/4)

Ø piston rod

mm

18

25

25

25

Piston stroke

mm

8

8

11

11

11

11

11

Setting value Y A 312 - R 317

mm

15.6

15.6

17.4 14.7(^)

17.4 14.7(^

17.4 14.7(^)

17.4 14.7(^)

p1 ± 0.5 *

bar

2.0

2.0

7.0

7.0

7.0

7.0

p2

± 0.5 **

bar

23.4

23.4

20.6

20.6

20.6

20.6

Qn (A)/Qn (B)***

l/min

30

30

200

200

200

200*

Restr. check valves at connection a at connection b

mm mm

-

Max. leak oil at load pressure at oil temperature Tab. 3

1.0

-

1.0

1.0

1.0 60 150 50

60 150 50

cm3/min bar °C

see AHS 1 / AHS 11

see AHS 1 / AHS 11

List of LSC auxiliary control axles

° = when connecting to a horizontal boom movement device, the flow rate must be reduced at both sides by turning in the stop screw to Y = 15mm (top) and Y = 12 mm (bottom). # = when connecting to a regulating cylinder / hydraulic boom adjusting device, reduce the flow rate to the piston rod side to 140 l/min by turning the stop screw by 270 degrees = 0.7 mm. This reduces dimension Y to 13.5 mm. (^)= valid for models A 312 - A 316 from serial no. 13225 and model R 317 from serial no. 18161 Magnet Y22 / Y23

12 Nm

Pressure-relief valve 501 / 502 100 Nm / 511 / 512

Seal-lock collar nut 31

38 Nm

Pressure balance 504 / 514

Allen head screws 111 Allen head screws 122

70 Nm 110 Nm

Restrictor check valve 507/517 20 Nm Pressure-relief valve 541 542 90 Nm


10 Nm


Screw plug 172

100 Nm

p1 = control pressure at begin of regulation **p2 = control pressure in final position ***Qn (A) / Qn (B) = nominal flow rate at outlet A / Bat

7.60.54

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p = nominal value

160 Nm

55 Nm

at AS1

Service Manual

LSC control block LSC auxiliary control axles

19.1

Auxiliary control valve block for accessory kit AS 1 The auxiliary element 540 consists of the accessory kit AS1 for working movements by the grapple rotator, swivelling ditch cleaning bucket, quick change adapter or Likufix system and is flange-mounted to the control valve block adjacent to the slewing gear element. The above devices for movements are supplied with oil by the main working pump. The individual segment is equipped with an electromagnetic-hydraulic control of the spool. The proportional control of the spool is designed as an ON-OFF switching system. The control pressure at the connection a / b is only fed to the spring chamber of the spool 540 after the solenoids Y22 / Y23 have been switched. The spool is then fully switched over. The pressure balance 544 fulfils the same purpose as the other pressure balances in compact block 100. Adjust the stroke limitation of the spool according to the instructions in group 16.40. The design and settings of the secondary protection correspond to group 16.40.

Fig. 34

Auxiliary axle at AS1

540

Spool / auxiliary control block AS1

810

End plate

541


811

Allen head screw

542


Y22


544

Pressure balance

Y23


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7.60.55

LSC control block

Service Manual


Fig. 35

7.60.56

Auxiliary control axle AS1

540

Spool / AS 1

544

Pressure balance

541 542


Y22 Y23

Solenoid valve / grapple rotation left Solenoid valve / grapple rotation right

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Service Manual


Fig. 36 27

Sectional drawing of auxiliary control axle AS1 541



28

Pressure spring / L

542


29 30

Screw plug O-ring

544 810

Pressure balance End plate

31 32

Seal-Lock collar nut Adjusting screw / stroke limitation

811 Y22

Allen head screw Solenoid valve / grapple rotation left

33

Pressure spring

Y23


540

Spool / auxiliary control block AS1

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7.60.57

LSC control block

Service Manual


19.2

Kit elements (kits AHS 1, AHS 11 and AHS 12) For additional functions, e.g. accessory kits AHS1, AHS11 and AHS 12, more auxiliary axles can be flange-mounted to the left-hand side of the compact control block. Each control axle (auxiliary control block) is equipped with the spool and actuating devices (control load, control springs) required for the relevant function, a pressure balance and all required connections with secondary protection. It is connected hydraulically through the pressure, return and LS channels with the series block 100. The flange faces of the channels are sealed with O-rings. The geometry of the spools and their orifices has been designed and adapted specifically to match the characteristics of the individual consumer. The control of the consumer in the LUDV system is independent of the load pressure. At a constant p, the volumetric flow rate is generated by modifying the cross-section of the gauge orifice and via the stroke of the spool. The maximum volumetric flow rate to the consumer is thus determined by the maximum possible cross-section. To retrofit one or more auxiliary axles, remove the end plate 110 or 810 and mount the new axle between the block 100 and the plate 110 / 810.

19.3

Auxiliary control valve block for accessory kit AHS 1 The design of the individual segment for the working movement 'hydraulic adjustment of boom' etc. corresponds to that of the boom, stick and bucket axles of the compact block. For a description of its functions and settings, see group 16.48.

19.4

Auxiliary control valve block for accessory kit AHS 11 The design of the individual segment for the working movement 'hydraulic hammer' corresponds to that of the boom, stick and bucket axles of the compact block. Only the function 'actuate hydraulic hammer' has a 2-step secondary pressure-relief valve. For a description of its functions and settings, see group 16.52.

19.5

Auxiliary control valve block for accessory kit AHS 12 The design of the individual segment for the working movement 'hydraulic adjustment of boom hydraulic hammer / hydraulic adjustment of boom telescopic demolition stick / scrap shear / concrete crusher / sorting grapple', etc. corresponds to that of the boom, stick and bucket axles of the compact block. Only the function 'actuate hydraulic hammer' has a 2-step secondary pressure-relief valve. For a description of its functions and settings, see group 16.56.

7.60.58

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MJFCIFSS

Service Manual


100


510

Spool / hydraulic hammer, etc.

500


511

Secondary pressure-relief valve /extend cylinder, 2-step

501


512

Secondary pressure-relief valve / retract cylinder

502


514

Pressure balance

504

Pressure balance

517


507


520

Accessory kit AHS 12 consisting of Auxiliary axles AHS 1 and AHS 11

copyright by

MJFCIFSS

7.60.59

LSC control block

Service Manual


Fig. 37

7.60.60

Auxiliary control axles for AHS 1, AHS 11 and AHS 12

copyright by

MJFCIFSS

Service Manual


Fig. 38

Auxiliary axles AHS 1, AHS 11 and AHS 12

copyright by

MJFCIFSS

7.60.61

LSC control block

Service Manual


Fig. 39

Auxiliary control axles, left = AHS 1, right = AHS 11

15

Control lid

122

Allen head screw*

20

Allen head screw

500

Spool / segment AHS 1

27 28

Cone Pressure spring

501 502

Pressure and feeder valve, 1-step Pressure and feeder valve, 1-step

29 34

Screw plug O-ring

504 507

Pressure balance Restrictor check valve

70

O-ring

510

Spool / segment AHS 11

71

Screw plug

511

Pressure and feeder valve, 2-step

72

Pressure spring

512

Pressure and feeder valve, 1-step

90

Spring plate

514

Pressure balance

91 100

Pressure spring Compact block

517 520

Restrictor check valve AHS 12

110

End plate

999

Seal kit

* various lengths (depend on the number of auxiliary elements)

7.60.62

copyright by

MJFCIFSS

Service Manual

LSC control block Pressure and feeder valves 511 (2-step at AHS 11)

20 Pressure and feeder valves 511 (2-step at AHS 11) see Fig. 41 The pilot-controlled pressure-relief valve 511 of the consumer connection is of the cartridge type and inserted directly into control valve block 510. The valve has an additional hydraulic pressure stage and can therefore be used for two different pressure ranges. It limits the pressure between the pump, the control valve block and the working attachment (stage 1 - primary function - hammer operation) or between the working attachments and the control block when the spool is closed (stage 2 - secondary function - regulating cylinder protection). If the pressure in the circuit of a working attachment rises, it begins to act on the built-in hydraulic device. This element is referred to as a pressure relief valve. It limits the maximum pressure in the consumer and its connections to a pre-set value. As high flows result in pressure on the pressure valves of the hydraulic unit, the machine is equipped with indirectly responding (pilot-controlled) pressure-relief valves. In these valves, a direct-acting pressure-relief valve acts as the pilot-control valve, generating a pulse that actuates the second, larger valve. The pressure-relief valve 511 also serves as a feeder valve. Differences in the flow rates of the oil to and from the working cylinders result in a vacuum. This might occur for instance when the regulating cylinder is extended due to external pulling loads. In such a case, the speed of the consumer would not be controlled by means of the gauge orifice diameter, but based on the loads and via the outlet edge of the spool. In order to prevent this, the valves connect the return side with the corresponding low-pressure side so that additional oil can be taken in.

Fig. 40

Pressure and feeder valve 511 (2-step)

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MJFCIFSS

7.60.63

LSC control block

Service Manual

Pressure and feeder valves 511 (2-step at AHS 11)

20.1 20.1.1

Description of functions Pressure limitation The pressure P built up in the consumer circuit acts on the front face of the main cone 5 and, through the bore D1, also on the rear surface of the main cone 5. At the same time, the pressure acts also on the pilot control cone 15. The springs 7 and 18 push the main cone 5 and the pilot control cone 15 into their closing positions (static status). As soon as the pressure in the consumer circuit exceeds the pre-set pressure of the pressure and adjusting spring 18, the pilot control cone 15 is lifted from its seat, and some oil can flow into the return channel. Due to the different cross-sections of the bores D1 in the bushing 6 and the ring face D2 in the valve insert 2, a pressure difference is built up between the front and rear sides of the main cone 5. As a result of this pressure difference, the main cone 5 is shifted against the pressure springs 7, and a substantial amount of oil flows off to the non-pressurised return side T.

20.1.2

Additional pressure stage Stage 1 (low pressure - protection of hydraulic hammer) connection X is connected to the tank. Pre-loading of pressure spring 18 is lower. Stage 2 (higher pressure - protection of regulating cylinder) connection X is pressurised with pilot pressure. The pressure spring 18 is pre-loaded via the shifting piston 9 and the piston 8 to a higher degree, which results in a higher blow-off pressure.

20.1.3

Feed If there is a vacuum in a working circuit, the higher pressure in the hydraulic tank is applied through the bore T of the housing 1 onto the ring face of the main cone 5. As a result of the pressure difference across the effective surface of the main cone 5, the main cone is pressed against the force of the pressure springs 7 so that the required amount of oil can flow through the bore T and connection P to the respective side of the consumer.

Fig. 41

7.60.64

Sectional drawing of pressure and feeder valve 511

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MJFCIFSS

Service Manual

LSC control block Pressure and feeder valves 511 (2-step at AHS 11)

Fig. 42

Pressure and feeder valve with additional pressure stage (2-step)

1

Housing

27

O-ring

2 3

Valve insert Adjusting screw

28 30

O-ring Backing ring

4 5

Screw Main cone

31 32

Piston seal O-ring

6

Bushing

33

O-ring

7 8

Pressure spring Piston

34 35

Backing ring O-ring

9 10

Shifting piston Lock nut

37 511

O-ring Pressure-relief valve, 2-step, complete

11 15

Lock nut Pilot control cone

999 D1

Seal kit Bore

18

Pressure spring

D2

Ring face

21

Shim

X

Connection for control pressure

copyright by

MJFCIFSS

7.60.65

LSC control block

Service Manual

Pressure and feeder valves 511 (2-step at AHS 11)

7.60.66

copyright by

MJFCIFSS

Service Manual

Rotary connection 1 x Design

Rotary connection 1 x 1 Design The rotary connection is situated at the fulcrum between uppercarriage and undercarriage. It connects the hydraulic system of the uppercarriage with the units situated on the undercarriage. The stator 2 is mounted above the stator of the 5x rotary connection (high pressure) to the undercarriage. The rotor 1 is mounted above the rotor of the 5x rotary connection (high pressure) to the uppercarriage. The connection at the top is connected through the radial and axial bore in the stator 2 and the lines leading downwards. The two V seals 21 seal the rotary connection to the outside.

Fig. 1

Rotary connection

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MJFCIFSS

7.75.1


Service Manual

Connection and hydraulic link

2 Connection and hydraulic link Connection A

Regulating travel motors Supply from the solenoid valve Y24 to the regulating motor connection X

3 Sealing of the 1x rotary connection, see Fig. 3 and Fig. 4 To carry out sealing work, the rotary connection 30 can remain mounted in the rotary connection 20. Disconnect the hydraulic line from the top of the screw fitting 40. If necessary, remove the hex head screw 26 and remove the driver 25. Remove the nut 4 (secured with Loctite). Remove the rotor 1 from the stator 2. Remove the V-seals 12 from the nut 4 and the stator 2. Remove the thrust washers 3 and the Quad rings 11 from the rotor 1. Mount new Quad rings 11 and thrust washers 3 in the rotor 1. Remount the V-seals 12 onto the stator 2 and the nut 4. Secure the driver 25 using the hex head screw 26 and the retaining washer 27 to the rotary connection 20. Place the rotor 1 from the stator 2. Carefully remove all oil and grease from the thread of the stator 2 and the nut 4. Apply Loctite 270 to both parts. Mount the nut 4 and tighten it (tightening torque 30Nm). Connect the hydraulic line at the screw fitting 40 of the rotary connection 30.

7.75.2

copyright by

MJFCIFSS

Service Manual

Rotary connection 1 x Sealing of the 1x rotary connection, see Fig. 3 and Fig. 4

Fig. 2 1 2

Installation and dismantling of the rotary connection 20 25

Rotor Stator

Rotary connection 5x, complete Driver

3

Thrust washer

26

Allen head screw

4

Nut

27

Retaining washer

11

Quad ring

30

Rotary connection 5x, complete

12

V seal

40

Screw connection with screw fitting

copyright by

MJFCIFSS

7.75.3


Service Manual

Exploded view

4 Exploded view

Fig. 3

7.75.4

Exploded view of the rotary connection

1

Rotor

11

Quad ring

2 3

Stator Thrust washer

12 999

V seal Seal kit

4

Nut

copyright by

MJFCIFSS

Service Manual

Rotary connection 1 x Sectional drawing

5 Sectional drawing

Fig. 4

Sectional drawing of the rotary connection

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MJFCIFSS

7.75.5


Service Manual

Sectional drawing

7.75.6

copyright by

MJFCIFSS

Service Manual


Rotary connection 6 x 1 Design The rotary connection is situated at the fulcrum between uppercarriage and undercarriage. It connects the hydraulic system of the uppercarriage with the units situated on the undercarriage. The stator 2, the pipe coupling 4 and the flange 5 with the connections 1-6 are connected to the undercarriage via the stator of the 7 x rotary connection (high pressure). The rotor 1 with the connections 1-6 is fixed to the uppercarriage through the rotor of the 7 x rotary connection (high pressure). There are bores leading from line connections 1-6 of the uppercarriage to the annular chambers. They are sealed by the rotor seal 22 in the rotor 1. Every annular chamber is connected through a radial and axial bore in the stator 2 to the pipe coupling 4 and the connections of the flange 5. The two V-seals 21 prevent dirt penetrating the assembly. The lid 3 secures the rotor 1 in axial direction and also serves as an additional protection against dirt.

Fig. 1

Rotary connection

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MJFCIFSS

7.76.1


Service Manual

Connections and hydraulic connections

2 Connections and hydraulic connections Connection 1

Brake system / working brake Supply from the foot brake valve (compact brake block), connection B1, to the multi-disk brakes of the front axle

Connection 2

Transmission Supply from brake and HBGV switch block (connection A) to shift lo ok / gearbox connection P1 (travel in 2nd gear)

Connection 3

Transmission Supply from brake and HBGV switch block (connection B) to shift lo ok / gearbox connection P2 (travel in 1st gear)

Connection 4

Oscillating axle support Supply from solenoid valve Y66 to the support cylinders, connection St

Connection 5

Brake system / working brake Supply from the foot brake valve (compact brake block), connection B2, to the multi-disc brakes and/or drum brakes of the rear axle

Connection 6

Regulating travel motor / creeper gear mode Supply from solenoid valve Y24 to regulator / regulating motor connection X

3 Removal and installation 3.1

Dismantling of 6 x rotary connection for sealing work, see Fig. 2 Mark the bottom of the hydraulic lines leading to the rotary connection and disconnect them. Remove the hollow screw 6 and pull off the flange 5. Be careful with the seal washer 7. Mark the top of the hydraulic lines leading to the rotary connection and disconnect them. Remove the Allen head screws 32 with the retaining washer 33 and remove the driver 30. Remove the nut 29 and the retaining washers 28. Pull the rotary connection 25 from the rotary connection 40.

3.2

Installation of the 6 x rotary connection after sealing work, see Fig. 2 Insert the complete rotary connection 25 into the rotary connection 40 and replace the cover 44. Secure the nuts 29 complete with the washers 28 to the screws 27. Place the driver 30 on the rotary connection 40 and secure it with the Allen head screws 32 and washer 33. Place the seal washer 7 in the flange 5. Put the flange 5 on the pipe coupling 4 of the rotary connection. Pay attention to the locking pin in the coupling 4, and the bore in the seal washer 7 and the flange 5. Insert and tighten the hollow screw 6 with the tooth lock washer 9 (torque: 50 Nm). Connect all the hydraulic lines to the completed rotary connection. Pay attention to markings you made before.

7.76.2

copyright by

MJFCIFSS

Service Manual

Rotary connection 6 x Removal and installation

Fig. 2 4

Installation and dismantling of the rotary connection 28

Pipe coupling

Retaining washer

5

Flange

29

Hex nut

6 7

Hollow screw Seal washer

30 32

Driver Allen head screw

9

Tooth lock washer

33

Retaining washer

25 27

Rotary connection 6x, complete Allen head screw

40 44

Rotary connection 7x, complete Lid

copyright by

MJFCIFSS

7.76.3


Service Manual

Exploded view of previous design

4 Exploded view of previous design

Fig. 3

7.76.4

Exploded view of rotary connection

1

Rotor

9

Tooth lock washer

2

Stator

11

Allen head screw

3

Lid

12

Allen head screw

4

Pipe coupling

13

Lock washer

5 6

Flange Hollow screw

21 22

V seal Rotor seal

7 8

Seal washer Thrust washer

25 999

Rotary connection Seal kit

copyright by

MJFCIFSS

Service Manual

Rotary connection 6 x Sectional drawing of previous design

5 Sectional drawing of previous design

Fig. 4


copyright by

MJFCIFSS

7.76.5


Service Manual

Exploded view of new design

6 Exploded view of new design

Fig. 5

7.76.6


1 2

Rotor Stator

9 11

Tooth lock washer Allen head screw

3 4

Lid Pipe coupling

12 13

Allen head screw Lock washer

5

Flange

21

V seal

6

Hollow screw

22

Rotor seal

7

Seal washer

25

Rotary connection

8

Thrust washer

999 A

Seal kit modified design from 08 / 2002

copyright by

MJFCIFSS

Service Manual

Rotary connection 6 x Sectional drawing of modified design

7 Sectional drawing of modified design

Fig. 6


copyright by

MJFCIFSS

7.76.7


Service Manual

Sectional drawing of modified design

7.76.8

copyright by

MJFCIFSS

Service Manual


Rotary connection 5 x 1 Design The rotary connection is situated at the fulcrum between uppercarriage and undercarriage. It connects the hydraulic system of the uppercarriage with the units situated on the undercarriage. The stator is on the undercarriage. The rotor is held in the axial direction by the lid, which, at the same time, provides additional protection against dirt. The driving pin locks the rotor with the uppercarriage. There are cast channels leading from line connections 0 - 4 in the rotor to the annular chambers. Special seal rings (seal kit) seal them off against each other. Every annular chamber is connected to its individual connection 0 - 4 in the stator via a radial and axial bore. The two outer seal rings (seal kit) seal off the rotor to the outside. The rotary connection does not need any maintenance.

Fig. 1

Rotary connection

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MJFCIFSS

7.77.1


Service Manual

Connections and hydraulic connections

2 Connections and hydraulic connections Connection 0

Leak oil Return of the leak oil from the travel motor to the transmission

Connection 1

Connection 2

Travel motor, right Supply from the control block connection B1 to the travel motor (right, reverse motion) Travel motor, left

Connection 3

Supply from the control block connection B2 to the travel motor (left, reverse motion) Travel motor, left Supply from the control block connection A2 to the travel motor (left, forward motion)

Connection 4

Travel motor, right Supply from the control block connection A1 to the travel motor (right, forward motion)


Dismantling of 5 x rotary connection for sealing work, see Fig. 2 Remove all lines and parts that might obstruct the disassembly. Mark the hydraulic lines leading to bottom of the rotary connections 1 and 20 and disconnect them (collect escaping oil in a suitable container). Remove the L-piece 25 from the pressure line 24. Mark the hydraulic lines leading to the top of the rotary connections 1 and 20 and remove them. Remove the hex head screws 42 with the retaining washers 43. Carefully pull the rotary connection 20 from the rotary connection 1. Remove the hex head screws 17 with the retaining washer 18 and remove the driver 19. Remove the nuts 34 from the hex head screws 32 and lift off the washer 33. Pull the rotary connection 1 from the undercarriage 50.

3.2

Installation of the 5x rotary connection after sealing work, see Fig. 2 Insert the rotary connection 1 into the undercarriage. Screw the nuts 34 with the retaining washers 33 onto the hex head screws 32 and tighten them. Slide the rotary connection 20 into the rotary connection 1. Screw the hex head screws 42 with the retaining washers 43 into the cover 3 and the rotary connection 20. Secure the driver 19 to the uppercarriage, using the hex head screws 17 with the washers 18. Re-connect the hydraulic lines to the rotary connections 1 and 20 (top and bottom). Pay attention to the markings you made before. Re-install all other lines and parts you may have removed before.

7.77.2

copyright by

MJFCIFSS

Service Manual


Fig. 2

Installation position of rotary connection

1


32

Hex head screw

17 18

Hex head screw Retaining washer

33 34

Retaining washer Hex nut

19

Driver

41

Allen head screw

20


42

Hex head screw

22

Screw connection

43

Retaining washer

23

Screw connection

44

Retaining washer

24 25

Pressure line Fitting

50

Undercarriage

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MJFCIFSS

7.77.3


Service Manual

Exploded view

4 Exploded view

Fig. 3

7.77.4


3

Cover

11

Rotor

4 5

Screw plug Retaining washer

15 16*

Felt washer Screw plug

6

Hex head screw

98

Seal kit - consisting of 8 seals: 1 felt washer, 2 outer seals top / bottom, 5 inside seals

10

Stator

*

The type of screw plug has changed during the production of the series.

copyright by

MJFCIFSS

Service Manual

Rotary connection 5 x Sectional drawing

5 Sectional drawing

Fig. 4


copyright by

MJFCIFSS

7.77.5


Service Manual

Sectional drawing

7.77.6

copyright by

MJFCIFSS

Service Manual


Rotary connection 7 x 1 Design The rotary connection is situated at the fulcrum between uppercarriage and undercarriage. It connects the hydraulic system of the uppercarriage with the units situated on the undercarriage. The stator is on the undercarriage. The rotor is held in the axial direction by the lid, which, at the same time, provides additional protection against dirt. The driving pin locks the rotor with the uppercarriage. There are cast channels leading from line connections 0 - 6 in the rotor to the annular chambers. Special seal rings (seal kit) seal them off against each other. Every annular chamber is connected to its individual connection 0 - 6 in the stator via a radial and axial bore. The two outer seal rings (seal kit) seal off the rotor to the outside. The rotary connection does not need any maintenance.

Fig. 1

Rotary connection

2 Connections and hydraulic connections 2.1

Model A 309 - A 311 Litronic Connection 0

Leak oil Recycling of leak oil from travel motor and auxiliary gearbox

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MJFCIFSS

7.78.1


Service Manual

Connections and hydraulic connections Connection 1

Travel motor Supply from control block connection A8 to travel motor (reverse)

Connection 2

Support cylinders Supply from control block connection A3 to support cylinders (retract)

Connection 3

Travel motor Supply from control block connection B8 to travel motor (forward)

Connection 4

Support cylinders Supply from control block connection B3 to support cylinders (extend)

Connection 5

Steering Supply from Servostat to steering cylinder (travel, right)

Connection 6

Steering Supply from Servostat to steering cylinder (travel, left)

2.2

Model A 312 - A 316 Litronic Connection 0

Leak oil

Connection 1

Recycling of leak oil from travel motor and auxiliary gearbox Travel motor Supply from control block connection A2 to travel motor (reverse)

Connection 2

Support cylinders Supply from control block connection B1 to support cylinders (retract)

Connection 3

Travel motor Supply from control block connection B2 to travel motor (forward)

Connection 4

Support cylinders Supply from control block connection A1 to support cylinders (extend)

Connection 5

Steering

Connection 6

Supply from Servostat to steering cylinder (travel, right) Steering Supply from Servostat to steering cylinder (travel, left)

7.78.2

copyright by

MJFCIFSS

Service Manual



Dismantling of 7 x rotary connection for sealing work, see Fig. 2 Remove all lines and parts that might obstruct the disassembly. Mark the hydraulic lines leading to rotary connections 10 and 115 and disconnect them. Remove the hollow screw 117 and the tooth lock washer 118. Remove the flange 116 with the seal 117. Remove the Allen head screws 27 with the retaining washer 26 and remove the driver 25. Remove the nuts 122 and the washer 121. Pull the rotary connection 115 from the rotary connection 10. Unscrew the hex head screw 12. Lift the rotary connection 10 from the undercarriage 125.

3.2

Installation of the 7x rotary connection after sealing work, see Fig. 2 Place the rotary connection 10 in the undercarriage, engage the driving pin in the driver 19 and tighten the screws 12. Secure the driver 25 using the hex head screws 27 and the retaining washers 26 to the rotary connection 10. Insert the complete rotary connection 115 into the rotary connection 10 and replace the lid 3. Secure the nuts 122 complete with the washers 1 21 to the screws 120. Place the driver 25 on the rotary connection 10 and secure it with the Allen head screws 27 and washers 26. Secure the flange 116 and the seal 117 with the hollow screw 119 (with tooth lock washer 118) on the rotary connection 115. Observe correct position. Re-connect the hydraulic lines to the rotary connections 10 and 115 (top and bottom). Pay attention to marks you made earlier. Re-install all other lines and parts you may have removed before.

copyright by

MJFCIFSS

7.78.3


Service Manual

Removal and installation

Fig. 2

7.78.4

Installation position of rotary connection

3

Lid

115


10 12

Rotary connection 5x, complete Hex head screw

116 117

Flange Seal

17

Hex head screw

118

Tooth lock washer

18 19

Retaining washer Driver

119 120

Hollow screw Allen head screw

26 27

Retaining washer Allen head screw

121 122

Retaining washer Hex nut

125

Undercarriage

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MJFCIFSS

Service Manual

Rotary connection 7 x Exploded view

4 Exploded view

Fig. 3


3

Lid

11

Rotor

4 5


12 13

Hex head screw Stator

6 7


15* 16#

Felt washer Screw plug

10

Rotary connection

98

Seal kit - consists of 9 seals: 1 felt washer, 2 outer seals top / bottom, 7 inside seals

A

version in models A 309 - A 312 from start * of series production in machine model A 314 from serial no. 9972 in machine model A 316 from serial no. 9701

In models A 309 - A 312 from start of series production in machine model A 314 from serial no. 9972 in machine model A 316 from serial no. 9701

B

Version in models A 309 - A 311 from start # of series production in machine model A 312 - 316 from serial no. 17250

In models A 309 - A 311 from start of series production in machine model A 312 - 316 from serial no. 17250

copyright by

MJFCIFSS

7.78.5


Service Manual

Sectional drawing

5 Sectional drawing

Fig. 4

7.78.6


copyright by

MJFCIFSS

Service Manual

TC valve Purpose

TC valve 1 Purpose The directly controlled 2-stage torque control valve allows the operator to continuously control the admissible operating pressure in the slewing gear, with respect to the control pressure and, thus, the available torque. The corresponding operating pressure is generated in a proportional relation to the control pressure, i.e. the angle of the pilot control valve. That way, the operator can control the rotary acceleration via the angle of the pilot control valve and, thus, benefit from a very sensitive means of accelerating the rotary motion. For reasons of better accessibility, the torque control valve is situated on the outside of the slewing gear section, in the area of the hydraulic tank. It is connected to the pressure balances LS line of the slewing gear circuit via pressure lines. The max. admissible acceleration pressure has been pre-set on the torque control valve by the manufacturer. In order to prevent actuation of the secondary valves - and the resulting losses - the highest set value of the 2-step slewing-gear pressure valves in the oil motor is about 30 bar above the set value of the TC valve.


Pressure limitation in step 1 Pressure spring 6 is pre-loaded via guide 4 and valve body 2 and presses valve cone 8 against the sealing edge in valve insert 3 via spring sleeve 7. In its static condition (closed position), the cone blocks the connection between pressure side P and tank side T. As soon as the pressure in pressure connection P attains a value above the pre-set value of pressure spring 6, valve cone 8 will be lifted from its seat and allow oil to enter the return channel. The oil will continue to flow until the pressure goes down again, back to the pre-set value. That is when the force of the spring will push valve cone 8 back into its closed position.

2.2

Pressure limitation in step 2 (actuation of the slewing gear) When actuating and turning the slewing gear to the left or right, the pre-selected control pressure is guided to connection Pst via a shuttle check valve. Control oil flows to pilot control piston 9 via shuttle valve 11. Pilot control piston 9 acts on piston 5 and, thus, compresses pressure spring 6. That way, pre-loaded pressure spring 6 is set under higher pressure so that valve cone 8 stays longer in its closed position, i.e. even under higher operating pressure. That means, proportional to the control pressure added in connection Pst, a certain operating pressure is attained in connection P. (The ratio of 1:11 between control pressure and operating pressure is determined by the piston area of pilot control valve 9.) Shuttle valve 11 (sitting in connection Pst) throttles the control oil and, thus, prevents a jerky control behaviour of the TC valve when the control pressure goes down again. Restrictors 12 and 13, sitting in pressure connection P leading to valve cone 8 and the by-pass channel leading to tank connection T, respectively, also improve the fine-control and regulating behaviour of the valve.

copyright by

MJFCIFSS

7.80.1

TC valve

Service Manual


2.3

Setting the valve The valve has a pre-determined fixed setting. Should modifications become necessary, proceed according to adjustment protocol and guideline; see group 6. In the event of disturbances, it is possible to check the valve for dirt and/or a broken spring: remove and dismantle; if necessary, replace completely. In the event of leaks, use new seal elements. See ET spare parts list.

2.4

Repair In the event of leaks, use seal kit 40. How to proceed: Loosen locknut 10. Screw out valve body. Pull out piston 5. Install new seals on piston 5 and valve body 2. If necessary, it is also possible to dismantle valve insert 3 complete with piston 4 to check valve cone 8 for dirt and/or damage (scorings, broken spring etc.). Re-assemble valve according to sectional drawing (see Fig. 2). Valve insert 3: use torque = 25 Nm. Valve body 2 / adjusting screw: use torque = 25 Nm. Locknut 10: use torque = 40 Nm. Restrictor 12: use torque = 8 Nm. Restrictor 13: use torque = 6.5 Nm. Screw plug 22: use torque = 30 Nm.

Fig. 1

TC valve and hydraulic schematic

2

Valve body

11 Shuttle valve

8

Valve cone

12 Restrictor

9


13 Restrictor

10 Lock nut

7.80.2

copyright by

MJFCIFSS

Service Manual

TC valve Sectional drawing

3 Sectional drawing

Fig. 2

Sectional drawing and hydraulic schematic of TC valve

1 2

Housing Valve body

11 12

Shuttle valve Ø 1.2 / 0.3 mm Restrictor Ø 1.5 mm

3 4

Valve insert Piston guide

13 14

Restrictor Ø 0.9 mm Stroke stop

5 6

Piston Pressure spring

16 17

O-ring Backing ring

7

Spring sleeve

19

Backing ring

8

Valve cone

20

O-ring

9


22

Screw plug

10

Hex nut

29

O-ring

copyright by

MJFCIFSS

7.80.3

TC valve

Service Manual

Sectional drawing

7.80.4

copyright by

MJFCIFSS

Service Manual


Group

Type

Component arrangement

8.09.1

A 309 LI 20221A 311 LI 20222-


8.10.1



8.17.1

R 313 LI 27752R 317 LI 18161-

Electrical system

8.20.9

A 309 LI 20221A 311 LI 20222-

Electrical system

8.22.9

A 309 LI 29269A 311 LI 29270-

Electrical system

8.30.1


Electrical system

8.32.1


Electrical system

8.33.1

A 312 LI 29898A 316 LI 28061-

Electrical system

8.34.1

A 312 LI 31253A 316 LI 31134R 317 LI 31140-

Electrical system

8.38.1

R 313 LI 27752-

Electrical system

8.40.8

R 317 LI 18161-

8.1 MJFCIFSS

Service Manual Electric kits

8.45.1



8.70.1


Slip ring rotary connection

8.80.1


Directory of electric kits

8.100.1


8.2 MJFCIFSS

Service Manual

Component arrangement Control elements

Component arrangement 1 Control elements 1.1

Overview of operator's cab

Fig. 1

Operator's cab as seen from the operator

A126

Printed circuit board (autocheck)

S5

B19L

Sensor transducer / left pilot control unit

S8-S218 Switches, see Fig. 19

B19R

Sensor transducer / right pilot control S18-S422 Switches, see Fig. 17 unit

B40

Sensor transducer / travel


B290 B291

Sensor transducer left (kit) Sensor transducer right (kit)

S32 S44

Indicator switch, horn Hazard light switch

E8 Cigarette lighter H7-H336 Indicator lights see Fig. 17

S63 S75

H9

Horn

S263

Switch / offset boom bearing Switch / oscillating axle locking device Switch / travel direction

H10 P6-P50

Buzzer Displays / clock see Fig. 17

S439L S439R

Switch button / split blade left Switch button / split blade right

A 309 LI 20221A 311 LI 20222-

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MJFCIFSS

Push button / turn grapple

8.09.1


Service Manual

A125 printed circuit board R75

Potentiometer speed see Fig. 17

S*

Switches for various kits

S1

Pre-heating and start switch

U16


2 A125 printed circuit board

Fig. 2

A125 printed circuit board installed at the left control console behind the function box

A 125

printed circuit board potentiometer

K63-K386 Relays on the distribution board (fig. 1-23)

Fig. 3

S7

Safety switch

C

Heating

A125 printed circuit board potentiometer

H301

BST indicator light

X837

Plug connection / 8-pin

P1

Potentiometer flow limitation (P1)

X838


P2


X838-1 Plug connection / 9-pin (service)

P3


X838-2 Plug connection / 9-pin (service)

S1 X834

Code switch Plug connection / 2-pin

X838-3 Plug connection CAN bus / 2-pin X839 Screw terminal / 3-pin

X835


X973

Power socket (12V)

X836 Plug connection / 4-pin

8.09.2

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MJFCIFSS

A 309 LI 20221A 311 LI 20222-

Service Manual

Component arrangement E50 safety and power switch cabinet

3 E50 safety and power switch cabinet

Fig. 4 E50

Fig. 5

Component arrangement in E50 safety cabinet on the hydraulic tank A127

safety and power switch cabinet

printed circuit board - power (fig. 1-5)

A127 printed circuit board - power

Termina1 5Plus after ignition

F302

terminal 19Pre-heating

F303

Terminal 30EPermanent plus (input) Terminal 30APermanent plus (output)

F332 Fuse M1, Y12 (25 A) F-A to F-HFuse / option

Terminal 31Ground

Kl6-1

Relay / terminal 50

Terminal 50Engine start

K288

Relay / terminal 15

BTKP Refuelling pump (kit)

K302

Relay / pre-heating 15

F300 F301

A 309 LI 20221A 311 LI 20222-

Fuses terminal 15, terminal 30, B3, S44 (7.5 A) Fuse Y29 (7.5 A)

Fuse terminal 15, terminal 30 (50 A) K-A to K-ERelay / option Fuse K302, R60 (70 A)

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MJFCIFSS

8.09.3


Service Manual

Sensors / transducers

4 Sensors / transducers

Fig. 6

Fuel level sensor B1 (mounted on the fuel tank)

Fig. 7

Diesel engine, output side

B2 B7

Temperature sensor / engine coolant Vacuum switch / air filter

Y12 Y29

Solenoid valve / excess fuel for starting Solenoid valve / engine shut-down

B232 Temperature switch / excess fuel for starting

8.09.4

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MJFCIFSS

A 309 LI 20221A 311 LI 20222-

Service Manual

Component arrangement Sensors / transducers

Fig. 8

Coolant level sensor B3 (mounted on coolant / expansion tank)

Fig. 9

Hydraulic tank, bottom

B8

Switch / hydraulic oil temperature (indicator light)

B285

Transducer / hydraulic oil temperature (fan control)

HBGV block mounted on hydraulic tank (engine side)

Fig. 10 A

HBGV block mounted on hydraulic tank (engine side) B

HBGV block at unit A 309 from serial no. 29269, A 311 from serial no. 29170

Pressure switch / Parking brake

Y55

Solenoid valve / first gear

Y6

Solenoid valve / parking brake

Y60


Y55

Solenoid valve / first gear

B10

A 309 LI 20221A 311 LI 20222-

HBGV block at unit A 309 to serial no. 29268, A 311 to serial no. 29169

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MJFCIFSS

8.09.5


Service Manual


Fig. 11

Engine, seen from rear

B12 Transducer / engine speed

Fig. 12

B16

Compact brake block located under the operator's cab

B20 Pressure switch / accumulator pressure B60 Pressure switch / brake light

Fig. 13

8.09.6

Switch / engine oil pressure

B266

Proximity switch / oscillating axle automatic

S4

Switch / horn

Boom cylinder with pressure switch, overload warning system B21 (kit)

copyright by

MJFCIFSS

A 309 LI 20221A 311 LI 20222-

Service Manual

Component arrangement Fuses

Fig. 14

Water sensor B289 (located near fuel prefilter)

5 Fuses

Fig. 15

Component arrangement on control console, front right

F304-F339Fuses (fig. 1-16)

Fig. 16

A 309 LI 20221A 311 LI 20222-

P5

Operating hour meter

Fuses in the control console, front right

F304

15 A

External fuse / ignition switch

F305

15 A

Interior lights / cigarette lighter / clock

F306

15 A

Reserve

F312

7.5 A

Indicators

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MJFCIFSS

8.09.7


Service Manual

Fuses

8.09.8

F313 F314

5A 3A

Brake light Safety lever

F315 F316

15 A 7.5 A

Excavator control Sensor control / console

F318 F319

20 A 15 A

Heating / air-conditioning system (kit - terminal 30) Heating / air-conditioning system (kit - terminal 15)

F320

15 A

Reserve

F321

15 A

Reserve

F322

7.5 A

Voltage transformer

F325

7.5 A

Parking brake / travel

F326

15 A

Fast travel / quick change adapter

F327

15 A

Reserve

F328 F329

15 A 5A

Reserve Servo control

F330 F331

7.5 A 15 A

AHS / AS1 Reserve

F336 F337

15 A 15 A

External fuse for lighting Support / solenoid

F338

15 A

Horn

F339

20 A

A/c condenser (kit)

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A 309 LI 20221A 311 LI 20222-

Service Manual

Component arrangement Overview of control console

6 Overview of control console

Fig. 17

Control console A (front right)

Indicating elements: P6

Dial indicator / coolant temperature

P7

Dial indicator / fuel reserve

P50

Clock

Indicator lights: H7

Engine oil pressure

H167

Forward travel

H11

Pre-heating

H168

Reverse travel

H12 H13

Battery charging Air filter contamination

H175 H176

Engine overheating Oscillating axle automatic

H15

Hydraulic oil temperature

H186

Offset boom bearing

A 309 LI 20221A 311 LI 20222-

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MJFCIFSS

8.09.9


Service Manual

Overview of control console H16 H18

Overload warning system* Coolant level

H26 H196

Quick change adapter* Scrap shear / sorting grapple*

H19 H20

Indicator Parking brake

H311 H336

Oscillating axle locking mechanism Water in fuel filter

H23

Accumulator pressure

S241 S335

Hydraulic hammer Blade support

* kit

Switches, potentiometers R75 S18

Speed adjustment Overload warning system*

S19

Grapple rotator*

S343

Individual control of split blade sections (°)

S21

Creeper gear travel

S360

Acknowledgement of quick change adapter buzzer*

S42

1st gear switching

S422

Radio mute mode

S47

Quick change adapter*

* kit

Fig. 18

Control console B (front centre)

S1 S16

Pre-heating and start switch Parking brake

S92 S93

S20

Idle automatic

S284 Heating-a/c system blower (4 speeds)

S35 S74

Switch / servo control Immobiliser*

S318 A/c system* S398 Reversing switch

Rotary potentiometer / air distribution Rotary potentiometer for heating-a/c system

* kit

(°) This switch has been removed without replacement, see service information 08-08-06/2006

8.09.10

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MJFCIFSS

A 309 LI 20221A 311 LI 20222-

Service Manual


Fig. 19

Control console C (rear right)

E8

Cigarette lighter

S22

Work headlights, front, front roof light*

F307-F343Fuses, see Fig. 20 S8 Beacon*

S22-1 S61

Rear roof light* Travel light

S11

Windscreen washer system

S218

Roof window wiper*

S14

Windscreen wiper

* kit

Fig. 20

Fuses and relays, control console, rear right

F307 F308

7.5A Parking light / tail light 7.5A Right parking light / tail light

F309

7.5A Travel light, left

F310 F311

7.5A Travel light, right 15 A Windscreen wiper / washing system

F317 F323

7.5A Beacon* 15 A Work headlight, attachment*

F324

15 A Work headlight, roof*

F343

7.5A Roof window wiper*

K414

Relay interval control device*

* kit

A 309 LI 20221A 311 LI 20222-

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MJFCIFSS

8.09.11


Service Manual

Battery and battery main switch

Fig. 21

Left control console with auxiliary switches and indicator lights for 4-wheel steering

H191

Indicator light / 4-wheel steering*

S309

Rotary switch / 4-wheel steering

H192

Indicator light / dog walk steering

7 Battery and battery main switch

Fig. 22

Battery compartment in uppercarriage, front right

e

F359 Fuse permanent ground clock (3 A) G2

8.09.12

S9

Battery main switch

Batteries

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A 309 LI 20221A 311 LI 20222-

Service Manual

Component arrangement Generator / starter

8 Generator / starter

Fig. 23 G1

Diesel engine, radiator side Alternator

M1

Starter

9 Distribution board

Fig. 24

A 309 LI 20221A 311 LI 20222-

Distribution board with relays and buzzer, located at the control console, rear right

copyright by

MJFCIFSS

8.09.13


Service Manual

Distribution board H27

Warning buzzer

K375

Relay / kit*

K63 K250

Relay / indicator Relay / oscillating axle support

K386 K445

Relay / safety switch Relay / travel 4-wheel steering*

K251

Relay / hand brake (light)

Terminal 15Plus after ignition / permanent plus

K252

Relay / servo hand brake (buzzer)

Terminal 30Plus after ignition / permanent plus

K315

Relay / brake light

A

K370

Relay / terminal 15 servo

Ground

* kit

Fig. 25

Distribution board with plug connection located at the control console, rear right

X10 X11

Housing recess* 2-pin Housing recess* 2-pin

X958 X959


X12

Housing recess* 2-pin

X960


X27 X28


X961 X962


X29


X963


X952


X964


X953


X965


X954 X955


X966 X967


X956 X957


X1106 Housing recess* 4-pin

*Recesses for plugs

8.09.14

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MJFCIFSS

A 309 LI 20221A 311 LI 20222-

Service Manual

Component arrangement Seat heating

10 Seat heating

Fig. 26

Seat heating switch S389 at the front of the operator seat

11 Solenoid valves

Fig. 27

Control oil unit with solenoid valves (located on the engine side of the hydraulic tank)

Y3

Solenoid valve / pilot control pressure Y51

Y24


Y50


A 309 LI 20221A 311 LI 20222-

Proportional solenoid valve / flow limitation

Y330 Solenoid valve / pump regulation removed on machine A 309 from Sno 26291 and A 311 from Sno 27086 Y371 Solenoid valve / oscillating axle support

copyright by

MJFCIFSS

8.09.15


Service Manual

Solenoid valves

Fig. 28

Low-pressure control valve block AS1 and valve block for travel / offset boom bearing (located at fuel tank)

Y22 Y23

Solenoid valve / grapple rotator Solenoid valve / grapple rotator

Y62

Solenoid valve / travel forward

Fig. 29

Outrigger bearing at rear of undercarriage

et

Y217 Solenoid valve / left outrigger

8.09.16

Y63 Solenoid valve / grapple rotator Y262 Solenoid valve / switchover bucket offset boom bearing

Y218 Solenoid valve / right outrigger

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MJFCIFSS

A 309 LI 20221A 311 LI 20222-

Service Manual

Component arrangement Solenoid valves

Fig. 30 Y268

Auxiliary solenoid valve below the control valve block Solenoid valve / changeover AHS pilot control

Y299

Solenoid valve / AHS* additional pressure level

* kit

Fig. 31

Proportional solenoid valve / fan control Y352 (located on the oil motor / fan)

Fig. 32

Proportional solenoid valve / motor speed adjustment Y358 (located on the hydraulic tank)

A 309 LI 20221A 311 LI 20222-

copyright by

MJFCIFSS

8.09.17


Service Manual

Solenoid valves

8.09.18

copyright by

MJFCIFSS

A 309 LI 20221A 311 LI 20222-

Service Manual



Overview of operator's platform

Fig. 1

Operator's platform seen from the operator

A126

Printed circuit board (autocheck)

S1


B19L

Sensor transducer / left pilot control unit

S5


B19R

Sensor transducer / right pilot control S8-S218 Switches, see Fig. 25 unit

B40

Sensor transducer / travel


B290 B291

Sensor transducer left (kit) Sensor transducer right (kit)

S16-S398 Switches, see Fig. 23 S32 Indicator switch, horn

E8

Cigarette lighter

S44

Hazard light switch

H7-H336 Indicator lights see Fig. 21 H9 Horn

S63 S75

Switch / offset boom bearing Switch / oscillating axle locking device

H10

Buzzer

S263


P6-P50

Displays / clock see Fig. 21

S382

Switch fine adjustment ON / OFF


copyright by

MJF C I F S S

8.10.1


Service Manual

A125 printed circuit board R75 R76

Potentiometer speed see Fig. 21 Potentiometer / fine adjustment

S* U16

Switches for various kits Excavator control BST


Fig. 2

Installation of the printed circuit board A125 in the housing behind the left control console in machine model A 312 from serial no. 20432, A 314 units to serial no. 20333 and A 316 units to serial no. 20339.

A 125 Printed circuit board potentiometer K63-K386 Relays on the distribution board (fig. 1-23)

Safety switch Heating

Fig. 3

Installation of the printed circuit board A125 without housing behind the left control console (function box must be removed) in machine model A 312 from serial no. 20433, A 314 units from serial no. 20334 and A 316 units from serial no. 20340.

A 125

printed circuit board potentiometer

K63-K386 Relays on the distribution board (fig. 1-23) S7

8.10.2

S7 C

C

Heating

F

Function box

Safety switch

copyright by

MJF C I F S S


Service Manual

Component arrangement A125 printed circuit board

Fig. 4

Printed circuit board potentiometerA125in machine model A 312 from serial no. 20432, A 314 units to serial no. 20333 and A 316 units to serial no. 20339.

Fig. 5

Printed circuit board potentiometerA125in machine model A 312 from serial no. 20433, A 314 units to serial no. 20334 and A 316 units to serial no. 20340.

H301

BST indicator light

X837


P1


X838


P2 P3

Potentiometer flow limitation (P2) Potentiometer flow limitation (P3)

X838-1 Plug connection / 9-pin (service) X838-2 Plug connection / 9-pin (service)

S1

Code switch

X838-3 Plug connection CAN bus / 2-pin

V156-4 Blocking diode kit

X839

X834 X835

Plug connection / 2-pin Plug connection / 2-pin

X973 Power socket (12V) X974-4 Diode plug, 2-pin (kit)

X836



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MJF C I F S S

Screw terminal / 3-pin

8.10.3


Service Manual

E50 safety and power switch cabinet


Fig. 6

8.10.4

Installation of the fuse box and solenoid valves at the hydraulic tank

A127 Printed circuit board / power, see Fig. 7

Y63

E50

Safety and power switch cabinet

Y62


Y268 Solenoid valve changeover adjusting equipment / hammer (kit) Y299 Solenoid valve pressure reduction (kit)

Fig. 7

Printed circuit board / powerA127

KL15

Plus after ignition

F302


KL19

Pre-heating

F303

Fuses terminal 15, terminal 30, B3, S44 (7.5 A) Fuse Y29 (7.5 A)

KL30E

Permanent plus (input)

F332

Fuse M1, Y12 (25 A)

KL30A KL31

Permanent plus (output) Ground

F-A to F-HFuse / option K16-1 Relay / terminal 50

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MJF C I F S S


Service Manual


KL50 BTKP

Engine start Refuelling pump (kit)

K288 K302

F300

Fuse terminal 15, terminal 30 (50 A)

K-A to K-ERelay / option

F301

Fuse K302, R60 (70 A)

Relay / terminal 15 Relay / pre-heating 15


Fig. 8


Fig. 9


B2


Temperature sensor / engine coolant

M1

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MJF C I F S S

Starter

8.10.5


Service Manual


Fig. 10


Fig. 11


B7

Fig. 12 B8

8.10.6

Y12 Y29

Vacuum switch / air filter

Solenoid valve / excess fuel for starting Solenoid valve / engine shut-down


Switch / hydraulic oil temperature (indica- B285 Transducer / hydraulic oil temperature tor light) (fan control)

copyright by

MJF C I F S S


Service Manual


Fig. 13

HBGV block for 2 HL 70/100 in models A 312 to 29897 and A 316 to 28060 located at the basic boom bearing block

B10

Pressure switch / parking brake

Y6


Fig. 14

Y55

Fig. 15

Solenoid valve / 1st gear

HBGV block for 2 HL 270/290 in models A 312 to 29898 and A 316 to 28061 located at the basic boom bearing block Solenoid valve / 1st gear

Y60

Solenoid valve / 2nd gear

B16



B12 Transducer / engine speed


Y55

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MJF C I F S S

8.10.7


Service Manual


Fig. 16

Compact brake block located under the operator's cab

B20 Pressure switch / accumulator pressure B60 Pressure switch / brake light

8.10.8

B266

Proximity switch / oscillating axle automatic

S4

Switch / horn

Fig. 17


Fig. 18

Water sensor B289 (located near fuel prefilter)

copyright by

MJF C I F S S


Service Manual


5 Fuses

Fig. 19

Component arrangement on control console, front right

F304-F339 Fuses, (see Fig. 20 on page9)

Fig. 20

P5



F304

15 A

External fuse / ignition switch

F305 F306

15 A 15 A

Interior lights / cigarette lighter / clock Reserve

F312

7.5 A

Indicators

F313

5A

Brake light

F314 F315

3A 15 A

Safety lever Excavator control

F316

7.5 A

Sensor control / console

F318 F319

20 A 15 A


F320 F321

15 A 15 A

Reserve Reserve

F322

7.5 A

Voltage transformer

F325

7.5 A

Parking brake / travel

F326

15 A

Fast travel / quick change adapter

F327 F328

15 A 15 A

Reserve Reserve


copyright by

MJF C I F S S

8.10.9


Service Manual

Overview of control console F329

5A

Servo control

F330

7.5 A

AHS / AS1

F331 F336

15 A 15 A

Reserve External fuse for lighting

F337

15 A

Support / solenoid

F338

15 A

Horn

F339

20 A

A/c condenser (kit)


Fig. 21

8.10.10

Control console A (front right) in model A 312 to serial no. 20432, A 314 units to serial no. 20333 and A 316 units to serial no. 20339.

copyright by

MJF C I F S S


Service Manual


Fig. 22

Control console A (front right) in model A 312 from serial no. 20433, A 314 units from serial no. 20334 and A 316 units from serial no. 20340.

Indicating elements: P6

Dial indicator / coolant temperature

P7

Fuel level indicator

P50

Clock

Indicator lights: H7 H11

Engine oil pressure Pre-heating

H167 H168

Forward travel Reverse travel

H12 H13

Battery charging Air filter contamination

H175 H176

Engine overheating Oscillating axle automatic

H15

Hydraulic oil temperature

H186

Offset boom bearing

H16

Overload warning system*

H26



copyright by

MJF C I F S S

8.10.11


Service Manual

Overview of control console H18 H19

Coolant level Indicator

H196 H311

Scrap shear / sorting grapple* Oscillating axle locking mechanism

H20 H23

Parking brake Accumulator pressure

H307 H336

Fine adjustment (delta P) Water in fuel filter

S241

Hydraulic hammer

* kit

Switches, potentiometers R75

Speed adjustment

S18

Overload warning system*

S335

Blade support

S19

Grapple rotator*

S343

Individual control of split blade sections

S21

Creeper gear travel

S360

Acknowledgement of quick change adapter buzzer*

S42

1st gear switching

S422

Radio mute mode

S47


* kit

Fig. 23

8.10.12

Control console B (front centre) in model A 312 to serial no. 20432, A 314 units to serial no. 20333 and A 316 units to serial no. 20339.

copyright by

MJF C I F S S


Service Manual


Fig. 24

Control console B (front centre) in model A 312 to serial no. 20433, A 314 units from serial no. 20334 and A 316 units from serial no. 20340.

S16

Parking brake

S93

S20 S35

Idle automatic Switch / servo control

S284 Heating-a/c system blower (4 speeds) S318 A/c system*

S74

Immobiliser*

S398 Reversing switch

S92

Rotary potentiometer / air distribution

Rotary potentiometer for heating-a/c system

* kit

Fig. 25

Control console C (rear right)

E8

Cigarette lighter

S22*

Work headlights, front, front roof light

F307-F343 Fuses, see Fig. 26

S22-1

Rear roof light

S8*

S61

Travel light


Beacon

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MJF C I F S S

8.10.13


Service Manual

Battery and battery main switch S11 S14 * Kit

Windscreen washer system Windscreen wiper

S90 # S218*

Interval switch / windscreen wiper Roof window wiper

# only in models A 312 to serial no. 20432, A 314 units to serial no. 20333 and A 316 units to serial no. 20339.

Fig. 26

Fuses and relays, control console, rear right

F307

7.5A

Parking light / tail light

F308 F309

7.5A 7.5A

Right parking light / tail light Travel light, left

F310 F311

7.5A 15 A

Travel light, right Windscreen wiper / washing system

F317* F323*

7.5A 15 A

Beacon Work light / attachment

F324*

15 A

Work headlight, roof

F343* K414

7.5A

Roof window wiper Relay interval control device*

* kit


Fig. 27 e

8.10.14

Battery compartment in uppercarriage, front right

E4

Travel light, right

G2

Batteries

E15 E23

Parking light, right Indicator light, front right

S9

Battery main switch

copyright by

MJF C I F S S


Service Manual

Component arrangement Generator / starter

8 Generator / starter

Fig. 28 G1

Diesel engine, radiator side Alternator

M1

Starter


Fig. 29


H27

Warning buzzer

K375

Relay / kit*

K63

Relay / indicator

K386

Relay / safety switch


copyright by

MJF C I F S S

8.10.15


Service Manual

Distribution board K250 K251

Relay / oscillating axle support Relay / hand brake (light)

K392# Relay / industrial shut-off* KL15 Plus after ignition / permanent plus

K252 K315

Relay / servo hand brake (buzzer) Relay / brake light

KL30 A

K370


* Kit

Fig. 30

Plus after ignition / permanent plus Ground

# only in models A 312 to serial no. 27113


X10


X958


X11 X12


X959 X960


X27


X961


X28 X29


X962 X963


X952 X953


X964 X965


X954


X966


X955


X967


X956



X957


*Recesses for plugs

8.10.16

copyright by

MJF C I F S S


Service Manual

Component arrangement Additional switches

10 Additional switches

Fig. 31

Switch for release of the windscreen wiper S283 (located in the front right position on the operator's cab frame)

Fig. 32

Switch of air cushioning and seat heating at the front of the operator seat

S388


S389

Switch air cushioning

copyright by

MJF C I F S S

Switch / seat heating

8.10.17


Service Manual

Solenoid valves

11

Solenoid valves

Fig. 33 Y3

Solenoid valve / pilot control pressure

Y24


Y50


Fig. 34 Y22

8.10.18

Control oil unit with solenoid valves (located on the engine side of the hydraulic tank) Y51

Proportional solenoid valve / flow limitation Y371 Solenoid valve / oscillating axle support

Compact control block with auxiliary control axle for AS1 kit

Solenoid valve / grapple rotator left

Y23

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MJF C I F S S

Solenoid valve / grapple rotator right


Service Manual


Fig. 35

Outrigger bearing at rear of undercarriage

Y217 Solenoid valve / left outrigger *

Fig. 36

Y218 Solenoid valve / right outrigger *

Junction box and solenoid valve in undercarriage (seen from the bottom)

S272 Junction box

Y56

Solenoid valve / blade *

* for outrigger individual control resp. front blade with outrigger individual control.


copyright by

MJF C I F S S

8.10.19


Service Manual

Solenoid valves

8.10.20

Fig. 37


Fig. 38

Proportional solenoid valve / motor speed adjustment Y358 (located on the hydraulic tank)

copyright by

MJF C I F S S


Service Manual



Overview of operator's cab

Fig. 1

Operator's cab seen from the operator

A126 B19L

Printed circuit board (autocheck) P6-P50 Displays / clock siehe Fig. 15 Sensor transducer / left pilot control unit R75 Potentiometer / speed siehe Fig. 15

B19R

Sensor transducer / right pilot control unit Sensor transducer / pilot control unit Travel left

R76

Potentiometer / fine adjustment

S1


B40R

Sensor transducer / pilot control unit Travel right

S5


B290

Sensor transducer / pilot control unit Kit left

S8-S218Switch siehe Fig. 17

B291

Sensor transducer / pilot control unit Kit right

S17-S382 Switchsiehe Fig. 15

E8

Cigarette lighter

S20-S398 Switch siehe Fig. 16

B40L

H7-H307Indicator lamps siehe Fig. 15 H9 Horn

R 313 LI 27752R 317 LI 18161-

S382 S*

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MJFCIFSS

Switch fine adjustment ON / OFF Switches for various kits

8.17.1


Service Manual

A125 printed circuit board H10

U16

Buzzer



Fig. 2

A125 printed circuit board installed at the left control console behind the function box

A 125 printed circuit board potentiometer K370-K386 Relay on distribution boardsiehe Fig. 20

Fig. 3

8.17.2

S7 C

Safety switch Heating

A125 printed circuit board potentiometer

copyright by

MJFCIFSS

R 313 LI 27752R 317 LI 18161-

Service Manual

Component arrangement E50 safety and power switch cabinet

H301

BST indicator light

X837

P1 P2

Potentiometer flow limitation (P1) Potentiometer flow limitation (P2)

X838 Plug connection / 6-pin X838-1 Plug connection / 9-pin (service)

P3 S1

Potentiometer flow limitation (P3) Code switch

X838-2 Plug connection / 9-pin (service) X838-3 Plug connection CAN bus / 2-pin

X834


X839

Screw terminal / 3-pin

X835 X836

Plug connection / 2-pin Plug connection / 4-pin

X973

Power socket (12V)



Fig. 4

Component arrangement in E50 safety cabinet on the hydraulic tank

E50 safety and power switch cabinet A127 printed circuit board / powersiehe Fig. 5

Fig. 5

R 313 LI 27752R 317 LI 18161-

Y299 Solenoid valve / AHS 11 kit

A127 printed circuit board / power

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MJFCIFSS

8.17.3


Service Manual

Sensors / transducers KL15

Plus after ignition

KL19 Pre-heating KL30E Permanent plus (input)

F302

Fuses KL 15, KL 30, B3, S44 (7.5 A)

F303 F332

Fuse Y29 (7.5 A) Fuse M1, Y12 (25 A)

KL30A Permanent plus (output)

F_A - F_M Fuse / optional

KL31

Ground

K16-1 Relay / terminal 50

KL50

Engine start

K288

BTKP Refuelling pump (kit) F300 Fuse KL15, KL 30 F301

Relay / terminal 15

K302 Relay / pre-heating 15 K_A - K_E Relay / optional

Fuse K302, R60


Fig. 6


Fig. 7

Engine output side

B2

8.17.4


M1

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MJFCIFSS

Starter

R 313 LI 27752R 317 LI 18161-

Service Manual


Fig. 8


Fig. 9


B7

R 313 LI 27752R 317 LI 18161-

Y12 Vacuum switch / air filter (located at the suction pipe between the air filter and the engine)

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MJFCIFSS

Solenoid valve / excess fuel for starting (located on the housing / speed adjusting device)

8.17.5


Service Manual


Fig. 10 B8


Switch / hydraulic oil temperature (indica- B285 Transducer / hydraulic oil temperature tor light) (fan control)

Fig. 11


B12 Transducer / engine speed B16 Switch / engine oil pressure

8.17.6

G1 R60

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MJFCIFSS

Three-phase regulator Pin-type glow plugs (located at the engine)

R 313 LI 27752R 317 LI 18161-

Service Manual


Fig. 12


5 Fuses

Fig. 13


F304-F339Fuses siehe Fig. 14

Fig. 14

P5



F304 F305

15 A 15 A

External fuse / ignition switch Interior lights / cigarette lighter / clock

F306 F314

15 A 3 A

Reserve Safety lever

F315 F316

15 A 7,5 A

Excavator control Sensor control / console

R 313 LI 27752R 317 LI 18161-

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MJFCIFSS

8.17.7


Service Manual

Fuses

8.17.8

F318

20 A


F319

15 A

F320 F321

15 A 15 A

F322

7,5 A

F326 F327

15 A 15 A

Fast travel / quick change adapter Reserve

F328 F329

15 A 5 A

Reserve Servo control

F330 F331

7,5 A 15 A

AHS / AS Reserve

F336

15 A

External fuse for lighting

F338 F339

15 A 20 A

Horn A/c condenser (kit)

Reserve Reserve Voltage transformer

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MJFCIFSS

R 313 LI 27752R 317 LI 18161-

Service Manual



Fig. 15

Control console A (front right)

Indicating elements: P6 Dial indicator / coolant temperature P7

Indicator lights: H7 Engine oil pressure R 313 LI 27752R 317 LI 18161-

P50

Clock

Dial indicator fuel reserve

H18

Coolant level

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MJFCIFSS

8.17.9


Service Manual

Overview of control console H11 Pre-heating H12 Battery charging

H26 Quick change adapter* H175 Engine overheating

H13 Air filter contamination H15 Hydraulic oil temperature

H196 Scrap shear / sorting grapple* H307 Fine adjustment ( p)

H16 Overload warning system* * kit

Operation / switches, potentiometers

R75 Speed adjustment

S47

S17 S18

Slewing gear brake Overload warning system*

S19

Grapple rotator*

S241 Hydraulic hammer S360 Acknowledgement of quick change adapter buzzer* S382 Activation fine control adjustment

S21

Fast travel


* kit

Fig. 16 S20

Control console B (front centre) S284 Heating-a/c system blower (4 speeds)

Idle automatic

S74

Immobiliser*

S318 A/c system*

S92

Rotary potentiometer / air distribution

S398 Reversing switch

S93

Rotary potentiometer for heating-a/c system

* kit

8.17.10

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MJFCIFSS

R 313 LI 27752R 317 LI 18161-

Service Manual


Fig. 17 E8

Control console C (rear right) S22

Work headlights, front, front roof light*

F307-F343Fuses siehe Fig. 18

S22-1

Rear roof light*

S8 S11

Beacon* Windscreen washer system

S61 S218

Travel light Roof window wiper*

S14

Windscreen wiper

Cigarette lighter

* kit

Fig. 18

Fuses and relays, control console, rear

F307 F308

7.5 A 7.5 A

Parking light / tail light Right parking light / tail light

F309 F310

7.5 A 7.5 A

Travel light, left Travel light, right

F311

15 A

Windscreen wiper / washing system

F317 F323

7.5 A 15 A

Beacon* Work headlight, attachment*

F324

15 A

Work headlight, roof*

F343

7.5 A

Roof window wiper*

K414

A

Relay interval control device*

* kit

R 313 LI 27752R 317 LI 18161-

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MJFCIFSS

8.17.11


Service Manual

Battery and battery main switch


Fig. 19 G2

Battery compartment in uppercarriage, front right S9

Batteries

Battery main switch


Fig. 20


H27

Warning buzzer

K386

K370 K375

Relay / KL 15 servo Relay / kit*

KL15 / KL 30Plus after ignition / permanent plus C Ground

Relay / safety switch

* kit

8.17.12

copyright by

MJFCIFSS

R 313 LI 27752R 317 LI 18161-

Service Manual

Component arrangement Distribution board

Fig. 21


X10



X11



X12 X27


X959 Housing recess* 21-pin X960 Housing recess* 21-pin

X28 X29









X956 Housing recess* 21-pin *Recesses for plugs

R 313 LI 27752R 317 LI 18161-

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MJFCIFSS

8.17.13


Service Manual

Seat heating

9 Seat heating

Fig. 22

10

Solenoid valves

Fig. 23

8.17.14

Seat heating switch S389 at the front of the operator seat

Control oil unit (located at the rear of the hydraulic tank)

Y3

Solenoid valve / pilot control pressure

Y50

Y7

Solenoid valve / slewing gear brake

Y51

Y24


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MJFCIFSS

Proportional solenoid valve / power control Proportional solenoid valve / flow limitation

R 313 LI 27752R 317 LI 18161-

Service Manual


Fig. 24 Y22

Additional control valve block AS1

Solenoid valve / grapple rotator

Y23


Fig. 25


Fig. 26

Proportional solenoid valve / motor speed Y358 (located at the separating panel of the control valve block console)

R 313 LI 27752R 317 LI 18161-

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MJFCIFSS

8.17.15


Service Manual

Solenoid valves

8.17.16

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MJFCIFSS

R 313 LI 27752R 317 LI 18161-

Service Manual

Electrical system

Electrical system Item

Description

Step

Place / layout

A3 A125 A126

Radio (optional) Potentiometer board Printed circuit board (autocheck)

Operator's cab, back Left bracket Right bracket

A127

Printed circuit board: power

A134 A1017

Control: 4-wheel steering Printed circuit board: quick-change adapter

8 26/34 4/10/13/ 21a/21b/ 24/33/34/ 36/38/40/ 1a/1b/1c/ 2/3 12 38

B1 B2 B3 B7 B8 B10 B12 B16 B19L B19R B20

Transducer/fuel level - with plug Temperature sensor for motor coolant Transducer/motor coolant - with plug Vacuum switch / air filter Switch / hydraulic oil temperature Pressure switch / parking brake Transducer / motor speed Switch / motor oil pressure Sensor transducer - pilot control valve, left Sensor transducer - pilot control valve, right Pressure switch / accumulator pressure

17 20 21a 21a 21a 13 27 21a 28 28 21a

B21

Pressure switch UL

36

B26 B40 B50L B50R B60

Proximity switch / quick-change adapter Proximity switch / pilot pressure valve: travel Loudspeaker, left Loudspeaker, right Pressure switch / brake light

38 28 8 8 9

B232 B248H B248V B266 B285 B289 B290 B291

Temperature switch / excess fuel for starting Sensor for rear axle alignment Sensor for front axle alignment Proximity switch / oscillating axle automatic Transducer hydraulic oil temperature / fan control Water sensor in fuel tank Proximity switch / kit pedal Proximity switch / kit pedal

1a 12 12 33 29 21a 34 34

Fuel tank Motor, top fan side Engine compartment Suction pipe - air filter Hydraulic tank, bottom HBGV block Flywheel housing / motor Motor housing Joystick, left Joystick, right Brake block beneath operator's platform Boom cylinder section piston side Quick-change adapter Travelling pedal Cab, rear left Cab, rear right Brake block beneath operator's platform Motor Rear axle housing Front axle housing Lower brake pedal Tank Preliminary fuel filter Operators platform Operators platform

E1 E2 E3 E4 E7 E8 E9 E15

work headlight for attachments Front roof light Travel light, left Travel light, right Roof-mounted light Cigarette lighter Beacon Parking light, right

5 5 6 6 8 8 37 6

Attachment Front cab roof Revolving deck, front Revolving deck, front Cab Bracket, rear right Cab, top Revolving deck, front right

A 309 LI 20221A 311 LI 20222-

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MJFCIFSS

Electric cabinet at hydraulic tank below operator's platform Distribution board

8.20.1

Electrical system

Service Manual

Item

Description

Step

Place / layout

E16 E17 E18 E19 E20 E21 E22 E23 E24

Parking light, left Tail light, right Tail light, left Brake light, right Brake light, left Direction indicator, front left Direction indicator, rear left Direction indicator, front right Direction indicator, rear right

6 6 6 6 6 4 4 4 4

E50

Electric cabinet

E150

Rear roof light, with plug

1a/1b/1c/ 2/3/40 5

Revolving deck, front left Revolving deck, rear right Revolving deck, rear left Revolving deck, rear right Revolving deck, rear left Revolving deck, front left Revolving deck, rear left Revolving deck, front right Revolving deck, backside, to the right Hydraulic tank

F_A F_B F_C F_D F_E F_F F_G F_H F_I F_K F_L F_M F_N FRes F20/ F300 F19/ F301 F22/ F302 F303 F304 F305 F306 F307

Fuse optional Fuse optional Fuse optional Fuse optional Fuse optional Fuse optional Fuse optional Fuse optional Fuse optional Fuse optional Fuse optional Fuse optional Fuse optional Fuse, reserve Fuse A127 class 30 to class 15

_A _A _A _A _A _A _A _A _A _A _A _A 70 A _A 50A

1b 1b 1b 1b 1b 1b 1b 1b 1b 1b 1b 1b 1a 14 1a

A127, hydraulic tank A127, hydraulic tank A127, hydraulic tank A127, hydraulic tank A127, hydraulic tank A127, hydraulic tank A127, hydraulic tank A127, hydraulic tank A127, hydraulic tank A127, hydraulic tank A127, hydraulic tank A127, hydraulic tank A127, hydraulic tank Right bracket A127, hydraulic tank

Fuse A127 K302, R60

70A

2

A127, hydraulic tank

Fuse A127 class 15, class 30, S44

7.5A

1b


Fuse A127, Y29 Fuse S1 Fuse E7, E8, P50 Fuse X10 Fuse E16, E17, P6, P7, P50

7.5A 15A 15A 15A 7.5A

3 1a 8 16 6

F308

Fuse E15, E18

7.5A

6

F309

Fuse E3

7.5A

6

F310

Fuse E4

7.5A

6

F311

Fuse M3, M4

15A

7

F312 F313

Fuse S44, E21, E22, E23, E24 Fuse E19, E20

7.5A 5A

4 9

A127, hydraulic tank Right bracket Right bracket Right bracket Bracket, backside, to the right Bracket, backside, to the right Bracket, backside, to the right Bracket, backside, to the right Bracket, backside, to the right Right bracket Right bracket

8.20.2

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MJFCIFSS

Cab roof, rear

A 309 LI 20221A 311 LI 20222-

Service Manual

Electrical system

Item

Description

Step

Place / layout

F314 F315 F316 F317

Fuse S7 Fuse BST (excavator control) Fuse: servo control Fuse: beacon

3A 15A 7.5A 7.5A

14 23 28 37

F318 F319 F320 F321 F322 F323

Fuse: heating / air condition, class 30 Fuse: heating / air condition, class 15 Fuse X11 Fuse X12 Fuse T1 Fuse E1

20A 15A 15A 15A 7.5A 15A

30c 30c 16 16 8 5

F324

Fuse S22 - E2, S22-1 - E150

15A

5

F325 F326 F327 F328 F329 F330 F331 F332 F336 F337 F338 F339 F343 F356 F357 F359

Fuse S16, K251 Fuse S21 - Y24, S42 - Y55 Fuse X27 Fuse X28 Fuse S35 Fuse: kits Fuse X29 Fuse A127, M1, Y12 Fuse S61 Fuse: support Fuse H9, seat heating Fuse: a/c condenser Fuse: roof window wiper Fuse: 4-wheel steering, class 15 Fuse: 4-wheel steering, class 30 Fuse: permanent ground - clock

7.5A 15A 15A 15A 5A 7.5A 15A 25A 20A 15A 10A 20A 7.5A 10A 2A 3A

13 11 16 16 15 16 16 1a 6 35 4 30c 7 1b 1b 42

Right bracket Right bracket Right bracket Bracket, backside, to the right Right bracket Right bracket Right bracket Right bracket Right bracket Bracket, backside, to the right Bracket, backside, to the right Right bracket Right bracket Right bracket Right bracket Right bracket Right bracket Right bracket A127, hydraulic tank Right bracket Right bracket Right bracket Right bracket Right bracket A127, hydraulic tank A127, hydraulic tank Battery box

G1 G2

alternator batteries

1a 1a

diesel engine Battery box

H7 H9 H10 H11 H12 H13 H15 H16 H18 H19 H20 H23 H26 H27 H167

Indicator light: motor oil pressure horn Warning buzzer Indicator light: pre-heat Indicator light: charge Indicator light: air filter dirty Indicator light: hydraulic oil temperature Indicator light: overload warning (kit) Indicator light: coolant level Indicator light: direction indicator Indicator light: parking brake Indicator light: accumulator pressure Indicator light: quick-change adapter warning buzzer Indicator light: travel forward

21a 4 21b 2 21b 21a 21a 36 21a 4 13 21a 38 13 10

Right bracket below operator's platform Right bracket Right bracket Right bracket Right bracket Right bracket Right bracket Right bracket Right bracket Right bracket Right bracket Right bracket Right bracket Right bracket

A 309 LI 20221A 311 LI 20222-

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MJFCIFSS

8.20.3

Electrical system

Service Manual

Item

Description

Step

Place / layout

H168 H175 H176 H186 H191 H192 H196 H301 H311 H336 HRes

Indicator light: travel reverse Indicator light: motor overheating Indicator light: oscillating-axle locking device Indicator light: swivel bearing Indicator light: 4-wheel steering Indicator light: dog-walk steering mode Indicator light: sorting grapple Indicator light: error BST Indicator light: oscillating axle locked Indicator light: water in fuel filter Indicator light: reserve

10 21a 33 40 12 12 34 26 33 21a 40

Right bracket Right bracket Right bracket Right bracket Left bracket Left bracket Right bracket A125, left bracket Right bracket Right bracket Right bracket

K_A K_B K_C K_D K_E K16-1 K16-2 K63 K250 K251 K252 K288 K302 K315 K364

Relay optional Relay optional Relay optional Relay optional Relay optional Relay terminal 50 Relay, disconnected Relay: direction indicator Relay: oscillating axle automatic Relay: hand brake (indicator light H20) Relay servo - hand brake (buzzer) Relay, terminal 15 Relay: pre-heat Relay: brake light Relay to A1017

1c 1c 1c 1c 1c 1a 1a 4 33 13 13 3 2 9 38

K370 K375 K386 K393 K403 K405 K414 K445

Relay KL15, servo Relay kit - quantity Relay, safety switch S7 Relay, air-spring seat Relay: heating Relay: heating Relay: intermittent windscreen wiper Relay: travel shut-off 4-wheel steering

15 34 14 31 30a 30b 7 10

A127, hydraulic tank A127, hydraulic tank A127, hydraulic tank A127, hydraulic tank A127, hydraulic tank A127, hydraulic tank A127, hydraulic tank Right bracket Right bracket Right bracket Right bracket A127, hydraulic tank A127, hydraulic tank Right bracket Quick-change adapter board Right bracket Operator's platform, back Right bracket Operators platform Operator's platform, back Operator's platform, back Operator's platform, back Right bracket

M1 M3 M4 M60 M65 M68 M70 M71 M72

Starter Motor: windscreen washer system Motor: windscreen wiper with plug Windscreen washer system: roof (optional) blower motor Windscreen washer system: roof (optional) Motor: air-spring seat Servo motor water valve Servo motor: air diffusion

1a 7 7 7 30b 7 31 30a 30a

Diesel engine Cab, back Windscreen Cab, top Operator's platform, back Cab, top Operators platform Operator's platform, back Operator's platform, back

8.20.4

copyright by

MJFCIFSS

A 309 LI 20221A 311 LI 20222-

Service Manual

Electrical system

Item

Description

Step

Place / layout

M73

Servo motor: air diffusion

30a

Operator's platform, back

P1 P2 P3 P5 P6 P7 P50

Potentiometer flow limitation 1 Potentiometer flow limitation 2 Potentiometer flow limitation 3 Display: operating hour meter Display: motor temperature Display: fuel level Display: clock

26 26 26 19 20 17 18

Left bracket Left bracket Left bracket Right bracket, bottom Right bracket Right bracket Right bracket

R60 R75 R78-1 R78-2 RS232

Pin-type glow plug, with plug Potentiometer: speed seat heating seat heating Laptop interface

2 22 32 32 26

diesel engine Right bracket Operators platform Operators platform Left bracket

S1 S1 S4 S5L S5M S5R S7 S8

Pre-heating and start switch Code switch A125 Switch: horn H9 Push button 'turn grapple left' Y22 Push button, centre (no function) Push button 'turn grapple right' Y23 safety switch Switch: beacon

1a 26 4 25 25 25 14 37

S9 S11

battery main switch Switch: windscreen washer system M3

42 7

S14

Switch: windscreen wiper M4

7

S16 S18 S19 S20 S21 S22

Switch: parking brake Y6 Switch: overload warning system (optional) Switch: grapple rotator Y22, Y23 Switch: sensor control Switch: creeper gear Y24 Switch: work headlight E1 / roof light E2

13 36 25 28 11 5

S22-1

Switch: auxiliary headlight / roof light

5

S32 S35 S42 S44 S47 S61

Switch: direction indicator / horn Switch: servo Switch. first gear Y55 Switch: hazard light Switch: Bucket quick-change adapter (optional) Switch: lighting installation

4 15 11 4 38 6

S63 S75 S92

Switch: swivel bearing Switch: oscillating axle locking device Y371 Potentiometer: air diffusion

40 33 30a

Right bracket Left bracket Cab floor plate Pilot control valve, left Pilot control valve, left Pilot control valve, left Left bracket Bracket, backside, to the right Battery compartment Bracket, backside, to the right Bracket, backside, to the right Right bracket Right bracket Right bracket Right bracket Right bracket Bracket, backside, to the right Bracket, backside, to the right steering column Right bracket Right bracket Right bracket Right bracket Bracket, backside, to the right Pilot control valve right Right bracket Right bracket

A 309 LI 20221A 311 LI 20222-

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MJFCIFSS

8.20.5

Electrical system

Service Manual

Item

Description

Step

Place / layout

S93 S218 S241 S263 S272 S283 S284 S309 S343 S360 S388 S389 S398 S422 S439L S439R

Potentiometer: heating / air condition Switch: roof window wiper (optional) Switch: accessory kit AHS 11 / AHS 12 (optional) Switch: travel direction Junction box undercarriage Switch: windscreen wiper release Switch: four-step blower Rotary switch: 4-wheel steering Switch: individual control, back Switch: Mute switch for buzzer UL Switch: air-spring seat Switch: seat heating Reversing switch / air diffusion Switch: mute switch for radio Push button: split blade, left Push button: split blade, right

30a 7 34 10 12/35 7 30b 12 35 38 31 32 30a 8 35 35

Right bracket Bracket, backside Right bracket Pilot control valve, left Undercarriage windscreen Right bracket Left bracket Right bracket Right bracket operator seat operator seat Right bracket Right bracket Pilot control valve: support Pilot control valve: support

T1

Voltage transformer / radio

8

Left bracket

U16


Right bracket

V155 V156-2 V156-4 V171

Blocking diode: oscillating axle Blocking diode H311 - S75 Diode input quantity Blocking diode: buzzer

2/15(I)/ 20-23/2629/34 33 33 34 13

Right bracket Right bracket Right bracket Right bracket

X10 X11 X12 X27 X28 X29 X65 X66 X67-1 X67-2 X90 X196 X197 X230 X262 X262-1 X262-3 X262-4 X262-5 X262-6 X301 X304

Plug connection distribution board / 2-pin Plug connection distribution board / 2-pin Plug connection distribution board / 2-pin Plug connection distribution board / 2-pin Plug connection distribution board / 2-pin Plug connection distribution board / 2-pin Plug connection to voltage transformer / 2-pin Plug connection to voltage transformer / 2-pin Plug connection A3 power supply / 8-pin Plug connection A3 power supply / 8-pin Plug connection: heating fan motor B40 plug connection / 3-pin Plug connection / 3-pin Plug connection distribution board / 3-pin Plug connection distribution board / 8-pin Plug connection: wire harness quick-change adapter, 8-pin Plug connection: wire harness quick-change adapter, 8-pin Plug connection: wire harness quick-change adapter, 2-pin Plug connection: wire harness quick-change adapter, 2-pin Plug connection: wire harness quick-change adapter, 3-pin Plug connection: wire harness, 12-pin Plug connection: wire harness, console, 6-pin

16 16 16 16 16 16 8 8 8 8 30b 28 33 10/13 38 38 38 38 38 38 35 35

Right bracket Right bracket Right bracket Right bracket Right bracket Right bracket Right bracket Right bracket Operator's platform, left Operator's platform, left Operators platform Travelling pedal Brake pedal Right bracket Right bracket Bearing block stick Quick-change adapter Quick-change adapter Quick-change adapter Revolving deck Right bracket

8.20.6

copyright by

MJFCIFSS

A 309 LI 20221A 311 LI 20222-

Service Manual

Electrical system

Item

Description

Step

Place / layout

X404 X406 X407 X410 X411 X412 X413 X550 X834 X835 X836 X837 X838 X838-1 X838-2 X838-3 X839 X842-1 X842-2 X842-3 X856

Plug connection: work headlight / 4-pin Plug connection: transducer fuel reserve / 3-pin Plug connection: revolving deck UL 2-pin Plug-type connection distribution board / 2-pin Plug-type connection distribution board / 4-pin Plug-type connection distribution board / 2-pin Plug-type connection distribution board / 4-pin Plug connection: switch S32 / 6-pin Plug connection to A 125 / 2-pin Plug connection to A 125 / 2-pin Plug connection to A 125 / 4-pin Plug connection to A 125 / 8-pin Plug connection to A 125 / 6-pin Plug connection to A 125 / 9-pin Plug connection to A 125 / 9-pin Plug connection CAN - bus connection, 2-pin Screw terminal on A125 / 3-pin Climate plug connection / 15-pin Plug connection: console, ignition switch / 2-pin Plug connection: blocking diode / 2-pin Plug connection to BST excavator control / 40-pin

Revolving deck Revolving deck Revolving deck Right bracket Right bracket Right bracket Right bracket steering column Left bracket Left bracket Left bracket Left bracket Left bracket Left bracket Left bracket Left bracket Left bracket Right bracket Right bracket Right bracket Right bracket

X857

Plug connection to BST excavator control / 24-pin

X859 X860 X861 X862 X863 X924-1 X924-2 X950

Plug connection / 21-pin Plug connection / 6-pin Plug connection / 6-pin Plug connection / 6-pin Plug connection / 15-pin B290 plug connection / 3-pin B291 plug connection / 3-pin Plug connection: console display autocheck / 21-pin

X951

Plug connection: console display autocheck / 21-pin

X952

Plug connection: revolving deck - BST excavator control / 21pin

X953

Plug connection: revolving deck - distribution board / 21-pin

X954

Plug connection: revolving deck - BST excavator control / 21pin

X955

Plug connection: revolving deck - distribution board / 15-pin

5 17 36 38 38 38 38 4 26 26 26 26/34 26 26 26 26 34 30c 30c 33 2/15(I)/ 20-23/2629/34 21a/2223/26/28/ 34 30a/30b 30a 30a 30a 30a/30b 34 34 4/10/13/ 21a/33/ 36/38/40 4/10/13/ 21b/34/ 38/40 10-15/25/ 30c/33/ 34/40 1/4-6/12/ 13/17/ 21a/36/42 2/12/20/ 22/26/27/ 29 1a/3/4/35/ 38

A 309 LI 20221A 311 LI 20222-

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MJFCIFSS

Right bracket

Operator's platform, back Operator's platform, back Operator's platform, back Operator's platform, back Operator's platform, back below operator's platform below operator's platform Right bracket Right bracket Right bracket Right bracket Right bracket Right bracket

8.20.7

Electrical system

Service Manual

Item

Description

Step

Place / layout

X956

Plug connection: BST excavator control - distribution board / 21-pin

Right bracket

X957

Plug connection: switch - distribution board / 21-pin

X958

Plug connection: switch - distribution board / 21-pin

X959

Plug connection: fuse - distribution board / 21-pin

X960 X961

Plug connection: operator's platform - distribution board / 21pin Plug connection: display - distribution board / 21-pin

X962

Plug connection: display - distribution board / 21-pin

X963


X964


X965 X966

Plug connection: BST excavator control - distribution board / 21-pin Plug connection A 125 - distribution board / 21-pin

2/15(I)/ 20-23/26/ 28/34/43 8/11/20/ 22/25/34/ 35/ 18/28/34/ 35/36/38/ 43 15/30c/ 35/40 4/6/9/21a/ 28/33/34 2/6/13/17/ 20/21a/ 21b/33 4/10/13/ 14/21b/ 28/34/38/ 40 6/8/9/11/ 13-16/23/ 24/28/35 1a/3/4/13/ 14/16/28/ 33/43 26/34

X967 X967-1 X967-2 X968-1 X968-2 X971 X972 X973 X974-2 X974-4 X1046 X1047 X1048 X1049 X1090 X1104 X1106 X1117 X1118

Plug connection: display - distribution board / 21-pin Plug connection: wire harness - connection / 1-pin Plug connection: wire harness - connection / 1-pin Plug connection: quantity 2 / 1-pin Plug connection: quantity 3 / 1-pin Plug connection: seat adjustment / 2-pin Plug connection: seat heating / 2-pin Power socket, 12V Plug connection: blocking diode / 2-pin Plug connection: blocking diode / 2-pin Plug connection / 12-pin Plug connection B19L / 3-pin Plug connection / 12-pin Plug connection: B19R / 3-pin Plug connection / 6-pin Plug connection / -pin Plug connection / 4-pin Plug connection: 4-wheel steering, 6-pin Plug connection: blocking diode, 2-pin

8.20.8

copyright by

MJFCIFSS

8/10/12/ 14/25/28/ 32/34/43 5/6/8/37 45 43 34 34 31 32 8 33 34 10/25 28 40 28 12 35 14/15 12/14/43 13

Right bracket

Right bracket Right bracket Right bracket Right bracket Right bracket

Right bracket Right bracket Right bracket Right bracket Right bracket Operator's platform, back Operator's platform, back Right bracket Right bracket Operators platform Operators platform Left bracket Right bracket Cab, right Left bracket Pilot control valve, left Pilot control valve right Pilot control valve right below operator's platform Right bracket Right bracket Right bracket Right bracket

A 309 LI 20221A 311 LI 20222-

Service Manual

Electrical system

Item

Description

Step

Place / layout

Y3 Y6 Y12 Y20 Y22 Y23 Y24 Y28-1 Y28-2 Y29 Y50 Y51 Y55 Y56 Y62 Y63 Y217 Y218 Y229-1 Y229-2 Y262 Y268 Y294-1 Y294-2 Y299 Y330 Y352 Y358 Y371

Solenoid valve: pilot pressure Solenoid valve: parking brake Solenoid valve: excess fuel for starting magnetic clutch / a/c compressor Solenoid valve / grapple rotator Solenoid valve / grapple rotator Solenoid valve: creeper gear Solenoid valve: quick-change adapter Solenoid valve: quick-change adapter Solenoid valve: motor shut-down Proportional solenoid valve: power control Proportional solenoid valve: flow limitation Solenoid valve: first gear Solenoid valve: blade Solenoid valve: travel forward Solenoid valve: travel reverse Solenoid valve: outrigger, rear left Solenoid valve: outrigger, rear right Solenoid valve: dog-walk steering mode Solenoid valve: 4-wheel steering Solenoid valve: bucket swivel bearing Solenoid valve: flow reduction, AHS Solenoid valve: 4-wheel steering Solenoid valve: 4-wheel steering Solenoid valve: flow reduction, AHS Solenoid valve: pump regulation Proportional solenoid valve: fan control Proportional solenoid valve: motor speed with plug Solenoid valve: oscillating axle support

15 13 1a 30c 25 25 11 38 38 3 26 26 11 35 10 10 35 35 12 12 40 34 12 12 34 15 29 22 33

control oil unit HBGV block Regulator: motor diesel engine control valve block control valve block control oil unit Quick-change adapter Quick-change adapter Regulating rod: motor control oil unit control oil unit HBGV block Undercarriage Hydraulic tank Hydraulic tank Undercarriage Undercarriage Undercarriage Undercarriage Fuel tank Hydraulic tank below operator's platform below operator's platform Hydraulic tank control oil unit Fan / radiator Bulkhead control oil unit

A 309 LI 20221A 311 LI 20222-

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8.20.9

Electrical system

Service Manual

1a Power supply, board A127

8.20.10

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Service Manual

Electrical system

1b Power supply, board A127 / fuses

A 309 LI 20221A 311 LI 20222-

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8.20.11

Electrical system

Service Manual

1c Power supply, board A 127 / relay

8.20.12

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Service Manual

Electrical system

2 Pre-heating

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8.20.13

Electrical system

Service Manual

3 Motor shut-down

8.20.14

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Service Manual

Electrical system

4 Direction indicator system / horn

A 309 LI 20221A 311 LI 20222-

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8.20.15

Electrical system

Service Manual

5 Work headlight

8.20.16

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Service Manual

Electrical system

6 Lighting installation

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8.20.17

Electrical system

Service Manual

7 Windscreen wiper / washer systems

8.20.18

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Service Manual

Electrical system

8 Interior lights, radio

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8.20.19

Electrical system

Service Manual

9 Brake light

8.20.20

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Service Manual

Electrical system

10 Travel direction switch

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8.20.21

Electrical system

Service Manual

11 Creeper gear first gear

8.20.22

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Service Manual

Electrical system

12 Optional 4-wheel steering

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8.20.23

Electrical system

Service Manual

13 Parking brake

8.20.24

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Service Manual

Electrical system

14 Safety switch

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8.20.25

Electrical system

Service Manual

15 Servo

8.20.26

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Service Manual

Electrical system

16 Power supply / socket

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8.20.27

Electrical system

17 Fuel gauge

8.20.28

Service Manual

18 Clock

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19 Hour meter

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Service Manual

Electrical system

20 Motor temperature

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8.20.29

Electrical system

Service Manual

21a Indicator lights

8.20.30

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Service Manual

Electrical system

21b Autocheck / main warning buzzer / charge indicator

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8.20.31

Electrical system

Service Manual

22 Speed adjustment

8.20.32

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Service Manual

Electrical system

23 BST excavator-control power supply

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8.20.33

Electrical system

Service Manual

25 Optional: AS I

8.20.34

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Service Manual

Electrical system

26 Regulating valves

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8.20.35

Electrical system

Service Manual

27 Speed sensor

8.20.36

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Service Manual

Electrical system

28 Sensor control

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8.20.37

Electrical system

Service Manual

29 Fan control

8.20.38

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Service Manual

Electrical system

30a Heating

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8.20.39

Electrical system

Service Manual

30b Heating

8.20.40

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Service Manual

Electrical system

30c Heating

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8.20.41

Electrical system

Service Manual

31 Electrical set adjustment - seat made by Isringhausen

8.20.42

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Service Manual

Electrical system

32 Seat heating - seat made by Isringhausen

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8.20.43

Electrical system

Service Manual

33 Automatic oscillating axle locking device

8.20.44

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Service Manual

Electrical system

34 Optional AHS11 / AHS12

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8.20.45

Electrical system

Service Manual

35 Optional blade / individual control outrigger

8.20.46

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Service Manual

Electrical system

36 Optional overload warning system

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8.20.47

Electrical system

Service Manual

37 Optional beacon

8.20.48

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Service Manual

Electrical system

38 Optional bucket quick-change adapter

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8.20.49

Electrical system

Service Manual

40 Swivel bearing

8.20.50

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Service Manual

Electrical system

42 Ground

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8.20.51

Electrical system

Service Manual

43 Ground

8.20.52

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Service Manual

Electrical system

44 Ground

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8.20.53

Electrical system

Service Manual

45 Class 30 / class 15

8.20.54

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Service Manual

Electrical system


Description

Step

Location / arrangement

A3 A125 A126


Operator's cab, rear Left console Right console

A127

Printed circuit board / power

A134 A1017

Control: 4-wheel steering Printed circuit board / quick-change adapter

8 26/34 4/10/13/ 21a/21b/ 24/33/36/ 38/40/ 1a/1b/1c/ 2/3 12 38

B1 B2 B3 B7 B8 B12 B16 B19L B19R B20

Transducer / fuel level, with plug Temperature sensor / motor coolant Transducer / motor coolant, with plug Vacuum switch / air filter Switch / hydraulic oil temperature Transducer / motor speed Switch / motor oil pressure Sensor transducer / left pilot control unit Sensor transducer / right pilot control unit Pressure switch / accumulator pressure

17 20 21a 21a 21a 27 21a 28 28 21a

B21

Pressure switch / overload

36

B26 B33 B40 B50L B50R B60

Proximity switch / quick-change adapter Pressure switch / accessory kit Proximity switch / pilot pressure valve, travel Loudspeaker, left Loudspeaker, right Pressure switch / brake light

38 34 28 8 8 9

B232 B248H B248V B266 B285 B289

Temperature switch / excess fuel for starting Sensor for rear axle alignment Sensor for front axle alignment Proximity switch / oscillating axle automatic Transducer hydraulic oil temperature / fan control Water sensor in fuel tank

1a 12 12 33 29 21a

Fuel tank Motor, top fan side Engine compartment Suction pipe / air filter Hydraulic tank, bottom Flywheel housing / motor Motor housing Left joystick Right joystick Brake block beneath operator's platform Boom cylinder section piston side Quick-change adapter Near control valve block Travelling pedal Cab, rear left Cab, rear right Brake block beneath operator's platform Engine Rear axle housing Front axle housing Lower brake pedal Tank Preliminary fuel filter

E1 E2 E3 E4 E7 E8 E9 E15 E16 E17

Work light / attachment Front roof light Travel light, left Travel light, right Roof-mounted light Cigarette lighter Beacon Parking light, right Parking light, left Tail light, right

5 5 6 6 8 8 37 6 6 6

Attachment Front cab roof Revolving deck, front Revolving deck, front Cab Right console, rear Cab, top Revolving deck, front right Revolving deck, front left Revolving deck, rear right

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Electric cabinet at hydraulic tank Below operator's platform Distribution board

8.22.1

Electrical system

Service Manual

Item

Description

Step


E18 E19 E20 E21 E22 E23 E24 E50

Tail light, left Brake light, right Brake light, left Indicator light, front left Indicator light, rear left Indicator light, front right Indicator light, rear right Electric cabinet

Revolving deck, rear left Revolving deck, rear right Revolving deck, rear left Revolving deck, front left Revolving deck, rear left Revolving deck, front right Revolving deck, rear right Hydraulic tank

E150

Rear roof light, rear, with plug

6 6 6 4 4 4 4 1a/1b/1c/ 2/3/40 5

F_A F_B F_C F_D F_E F_F F_G F_H F_I F_K F_L F_M F_N FRes F20/ F300 F19/ F301 F22/ F302 F303 F304 F305 F306 F307 F308 F309 F310 F311 F312 F313 F314 F315 F316 F317 F318 F319 F320

Fuse optional Fuse optional Fuse optional Fuse optional Fuse optional Fuse optional Fuse optional Fuse optional Fuse optional Fuse optional Fuse optional Fuse optional Fuse optional Fuse, reserve Fuse A127 terminal 30 to terminal 15


1b 1b 1b 1b 1b 1b 1b 1b 1b 1b 1b 1b 1a 14 1a

A127, hydraulic tank A127, hydraulic tank A127, hydraulic tank A127, hydraulic tank A127, hydraulic tank A127, hydraulic tank A127, hydraulic tank A127, hydraulic tank A127, hydraulic tank A127, hydraulic tank A127, hydraulic tank A127, hydraulic tank A127, hydraulic tank Right console A127, hydraulic tank

Fuse A127 K302, R60

50A

2


Fuse A127 terminal 15, terminal 30, S44

7.5A

1b


Fuse A127, Y29 Fuse S1 Fuse E7, E8, P50 Fuse X10 Fuse E16, E17, P6, P7, P50 Fuse E15, E18 Fuse E3 Fuse E4 Fuse M3, M4 Fuse S44, E21, E22, E23, E24 Fuse E19, E20 Fuse S7 Fuse BST Fuse servo control Fuse beacon Fuse heating / air conditioning, terminal 30 Fuse heating / air conditioning, terminal 15 Fuse X11

7.5A 15A 15A 15A 7.5A 7.5A 7.5A 7.5A 15A 7.5A 5A 3A 15A 7.5A 7.5A 20A 15A 15A

3 1a 8 16 6 6 6 6 7 4 9 14 23 28 37 30c 30c 16

A127, hydraulic tank Right console Right console Right console Right console, rear Right console, rear Right console, rear Right console, rear Right console, rear Right console Right console Right console Right console Right console Right console, rear Right console Right console Right console

8.22.2

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Rear cab roof

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Service Manual

Item

Description

F321 F322 F323 F324 F325 F326 F327 F328 F329 F330 F331 F332 F336 F337 F338 F339 F343 F356 F357 F359

Fuse X12 Fuse T1 Fuse E1 Fuse S22 - E2, S22-1 - E150 Fuse S16, K251 Fuse S21 - Y24, S42 - Y55 Fuse X27 Fuse X28 Fuse S35 Fuse kits Fuse X29 Fuse A127, M1, Y12 Fuse S61 Fuse support Fuse H9, seat heating Fuse a/c condenser Fuse roof window wiper Fuse: 4-wheel steering, class 15 Fuse: 4-wheel steering, class 30 Fuse: permanent ground - clock

G1 G2 H7 H9 H10 H11 H12 H13 H15 H16 H18 H19 H20 H23 H26 H27 H167 H168 H175 H176 H186 H191 H192 H196 H301 H311

Electrical system

Step


16 8 5 5 13 11 16 16 15 16 16 1a 6 35 4 30c 7 1b 1b 42

Right console Right console Right console, rear Right console, rear Right console Right console Right console Right console Right console Right console Right console A127, hydraulic tank Right console Right console Right console Right console Right console A127, hydraulic tank A127, hydraulic tank Battery box

Alternator Batteries

1a 1a

Diesel engine Battery box

Indicator light / motor oil pressure Horn Warning buzzer Indicator light / pre-heating Indicator light / charging Indicator light / air filter contamination Indicator light / hydraulic oil temperature Indicator light / overload warning (kit) Indicator light / coolant level Indicator light / indicator Indicator light / parking brake Indicator light / accumulator pressure Indicator light / quick-change adapter Warning buzzer Indicator light / forward travel Indicator light / reverse travel Indicator light / motor overheating Indicator light / oscillating-axle locking device Indicator light / swivel bearing Indicator light: 4-wheel steering Indicator light: dog-walk steering mode Indicator light / sorting grapple Indicator light / error BST Indicator light / oscillating axle locked

21a 4 21b 2 21b 21a 21a 36 21a 4 13 21a 38 13 10 10 21a 33 40 12 12 34 26 33

Right console Below operator's platform Right console Right console Right console Right console Right console Right console Right console Right console Right console Right console Right console Right console Right console Right console Right console Right console Right console Left console Left console Right console A125, left console Right console

A 309 LI 29269A 311 LI 29270-

15A 7.5A 15A 15A 7.5A 15A 15A 15A 5A 7.5A 15A 25A 20A 15A 10A 20A 7.5A 10A 2A 3A

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8.22.3

Electrical system

Service Manual

Item

Description

Step


H336 HRes

Indicator light: water in fuel filter Indicator light: reserve

21a 40

Right console Right console

K_A K_B K_C K_D K_E K16-1 K16-2 K63 K250 K251 K288 K302 K315 K364

Relay, optional Relay, optional Relay, optional Relay, optional Relay, optional Relay terminal 50 Relay, disconnected Relay / direction indicator Relay / oscillating axle automatic Relay / hand brake (indicator light H20) Relay terminal 15 Relay / pre-heating Relay brake light Relay to A1017

1c 1c 1c 1c 1c 1a 1a 4 33 13 3 2 9 38

K370 K375 K386 K393 K403 K405 K414 K445 K466

Relay terminal 15, servo Relay / kit, quantity Relay / safety switch S7 Relay / air-spring seat Relay / heating Relay / heating Relay / windscreen wiper interval Relay: travel shut-off 4-wheel steering Relay horn H9

15 34 14 31 30a 30b 7 10 4

A127, hydraulic tank A127, hydraulic tank A127, hydraulic tank A127, hydraulic tank A127, hydraulic tank A127, hydraulic tank A127, hydraulic tank Right console Right console Right console A127, hydraulic tank A127, hydraulic tank Right console Quick-change adapter board Right console Operator's platform, rear Right console Operator's platform Operator's platform, rear Operator's platform, rear Operator's platform, rear Right console Right console

M1 M3 M4 M60 M65 M68 M70 M71 M72 M73

Starter Motor / windscreen washer system Motor / windscreen wiper with plug Windscreen washer system / roof (optional) Blower motor Windscreen washer system / roof (optional) Motor / air-spring seat Servo motor / water valve Servo motor / air distribution Servo motor / air distribution

1a 7 7 7 30b 7 31 30a 30a 30a

Diesel engine Operator's cab, rear Windscreen Cab, top Operator's platform, rear Cab, top Operator's platform Operator's platform, rear Operator's platform, rear Operator's platform, rear

P1 P2 P3 P5 P6 P7 P50

Potentiometer / flow limitation 1 Potentiometer / flow limitation 2 Potentiometer / flow limitation 3 Display / operating hour meter Display / motor temperature Indicator / fuel level Display / clock

26 26 26 19 20 17 18

Left console Left console Left console Right console, bottom Right console Right console Right console

R60

Pin-type glow plug, with plug

2

Diesel engine

8.22.4

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Service Manual

Electrical system

Item

Description

Step


R75 R78-1 R78-2 RS232

Potentiometer / speed Seat heating Seat heating Laptop interface

22 32 32 26

Right console Operator's platform Operator's platform Left console

S1 S1 S4 S5L S5M S5R S7 S8 S9 S11 S14 S16 S18 S19 S20 S21 S22 S22-1 S32 S35 S42 S44 S47 S61 S63 S75 S92 S93 S218 S241 S263 S272 S283 S284 S309 S360 S388 S389 S398 S422 S439L S439R

Pre-heating and start switch Code switch A125 Switch / horn H9 Push button / turning grapple to the left, Y22 Push button, centre (no function) Push button / turning grapple to the right, Y23 Safety switch Switch / beacon Battery main switch Switch / windscreen washer system M3 Switch / windscreen wipers M4 Switch / parking brake Y6 Switch / overload warning system (optional) Switch / grapple rotator Y22, Y23 Switch / sensor control Switch / creeper gear Y24 Switch / work light E1 / roof light E2 Switch / auxiliary headlight / roof light Switch / direction indicator / horn Switch servo Switch / first gear Y55 Switch / hazard light Switch / bucket quick-change adapter (optional) Switch / lighting installation Switch / swivel bearing Switch / oscillating axle locking device Y371 Potentiometer / air distribution Potentiometer / heating / air condition Switch / roof window wiper (optional) Switch / accessory kit AHS 11 / AHS 12 (optional) Switch / travelling direction Junction box, undercarriage Switch / windscreen wiper release Switch / four-step blower Rotary switch: 4-wheel steering Switch / mute switch for overload buzzer Switch / air-spring seat Switch / seat heating Reversing switch / air distribution Switch / mute switch for radio Push button: split blade, left Push button: split blade, right

1a 26 4 25 4,25 25 14 37 42 7 7 13 36 25 28 11 5 5 4 15 11 4 38 6 40 33 30a 30a 7 34 10 12/35 7 30b 12 38 31 32 30a 8 35 35

Right console Left console Cab floor plate Left pilot control unit Left pilot control unit Left pilot control unit Left console Right console, rear Battery compartment Right console, rear Right console, rear Right console Right console Right console Right console Right console Right console, rear Right console, rear Steering column Right console Right console Right console Right console Right console, rear Right pilot control unit Right console Right console Right console Right console, rear Right console Left pilot control unit Undercarriage Windscreen Right console Left console Right console Operator seat Operator seat Right console Right console Pilot control valve: support Pilot control valve: support

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8.22.5

Electrical system

Service Manual

Item

Description

Step


T1


8

Left console

U16


Right console

V155 V156-2 V156-4 V171 V181 V182

Blocking diode / oscillating axle Blocking diode H311 - S75 Diode / input quantity Blocking diode: buzzer Amplifier magnet Y22 Amplifier magnet Y23

2/15/2023/26-29/ 34 33 33 34 13 25 25

Right console Right console Right console Right console Right console, rear Right console, rear

X10 X11 X12 X27 X28 X29 X65 X66 X67-1 X67-2 X90 X196 X197 X230 X262 X262-1 X262-3 X262-4 X262-5 X262-6 X301 X304 X404 X406 X407 X410 X411 X412 X413 X550 X834 X835 X836 X837 X838 X838-1 X838-2

Plug connection distribution board / 2-pin Plug connection distribution board / 2-pin Plug connection distribution board / 2-pin Plug connection distribution board / 2-pin Plug connection distribution board / 2-pin Plug connection distribution board / 2-pin Plug connection on voltage transformer / 2-pin Plug connection on voltage transformer / 2-pin Plug connection A3 power supply / 8-pin Plug connection A3 power supply / 8-pin Plug connection / heating fan motor Plug connection B40 / 3-pin Plug connection, 3-pin Plug connection distribution board / 3-pin Plug connection distribution board / 8-pin Plug connection wire harness quick-change adapter / 8-pin Plug connection wire harness quick-change adapter / 8-pin Plug connection wire harness quick-change adapter / 2-pin Plug connection wire harness quick-change adapter / 2-pin Plug connection wire harness quick-change adapter / 3-pin Plug connection: wire harness, 12-pin Plug connection wire harness, console / 6-pin Plug connection work headlight / 4-pin Plug connection transducer fuel reserve / 3-pin Plug connection revolving deck overload / 2-pin Plug connection distribution board / 2-pin Plug connection distribution board / 4-pin Plug connection distribution board / 2-pin Plug connection distribution board / 4-pin Plug connection switch S32 / 6-pin Plug connection to A 125 / 2-pin Plug connection to A 125 / 2-pin Plug connection to A 125 / 4-pin Plug connection to A 125 / 8-pin Plug connection to A 125 / 6-pin Plug connection to A 125 / 9-pin Plug connection to A 125 / 9-pin

16 16 16 16 16 16 8 8 8 8 30b 28 33 10/13 38 38 38 38 38 38 35 35 5 17 36 38 38 38 38 4 26 26 26 26/34 26 26 26

Right console Right console Right console Right console Right console Right console Right console Right console Operator's platform, left Operator's platform, left Operator's platform Travelling pedal Brake pedal Right console Right console Bearing block Stick Quick-change adapter Quick-change adapter Quick-change adapter Revolving deck Right console Revolving deck Revolving deck Revolving deck Right console Right console Right console Right console Steering column Left console Left console Left console Left console Left console Left console Left console

8.22.6

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Service Manual

Electrical system

Item

Description

Step


X838-3 X839 X842-1 X842-2 X842-3 X856

Plug connection CAN - bus / 2-pin Screw terminal on A125 / 3-pin Plug connection air-conditioning / 15-pin Plug connection console, ignition switch / 2-pin Plug connection blocking diode / 2-pin Plug connection to BST excavator control / 40-pin

Left console Left console Right console Right console Right console Right console

X857


X859 X860 X861 X862 X863 X924-1 X924-2 X950

Plug connection, 21-pin Plug connection, 6-pin Plug connection, 6-pin Plug connection, 6-pin Plug connection, 15-pin Plug connection B290 / 3-pin Plug connection B291 / 3-pin Plug connection console display autocheck / 21-pin

X951

Plug connection console display autocheck / 21-pin

X952

Plug connection revolving deck BST excavator control / 21pin

X953

Plug connection revolving deck distribution board / 21-pin

X954


X955


X956

Plug connection BST excavator control distribution board / 21-pin

X957

Plug connection switch distribution board / 21-pin

X958


X959

Plug connection fuse distribution board / 21-pin

X960

Plug connection operator's platform distribution board / 21pin Plug connection display distribution board / 21-pin

26 34 30c 30c 33 2/15/2023/26-29/ 34 21a/2223/26/28/ 34 30a/30b 30a 30a 30a 30a/30b 34 34 4/10/13/ 21a/33/ 36/38/40 4/10/13/ 21b/34/ 38/40 10-15/25/ 30c/33/ 34/40 1/4-6/12/ 13/17/ 21a/36/42 2/12/20/ 22/26/27/ 29 1a/3/4/35/ 38 2/15 /2023/26/28/ 34/43 8/11/20/ 22/25/34/ 35/ 18/28/34/ 35/36/38/ 43 15/30c/ 35/40 4/6/9/21a/ 28/33/34 2/6/13/17/ 20/21a/ 21b/33

X961

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Right console Operator's platform, rear Operator's platform, rear Operator's platform, rear Operator's platform, rear Operator's platform, rear Below operator's platform Below operator's platform Right console Right console Right console Right console Right console Right console Right console Right console Right console Right console Right console Right console

8.22.7

Electrical system

Service Manual

Item

Description

Step


X962

Plug connection display distribution board / 21-pin

Right console

X963


X964


X965 X966

Plug connection BST excavator control distribution board / 21-pin Plug connection A 125 distribution board / 21-pin

4/10/13/ 14/21b/ 28/34/38/ 40 6/8/9/11/ 13-16/23/ 24/28/35 1a/3/4/13/ 14/16/28/ 33/43 26/34

X967 X967-1 X967-2 X968-1 X968-2 X971 X972 X973 X974-2 X974-4 X1046 X1047 X1048 X1049 X1090 X1104 X1106 X1117 X1118 Y3 Y12 Y20 Y22 Y23 Y24 Y28-1 Y28-2 Y29 Y50 Y51 Y55 Y60 Y56 Y62

8.22.8

Right console

Right console Right console Right console

Plug connection display distribution board / 21-pin Plug connection wire harness connection / 1-pin Plug connection wire harness connection / 1-pin Plug connection quantity 2 / 1-pin Plug connection quantity 3 / 1-pin Plug connection seat adjustment / 2-pin Plug connection seat heating / 2-pin Power socket, 12V Plug connection blocking diode / 2-pin Plug connection blocking diode / 2-pin Plug connection, 12-pin Plug connection B19L / 3-pin Plug connection, 12-pin Plug connection B19R / 3-pin Plug connection, 6-pin Plug connection / -pin Plug connection / 4-pin Plug connection: 4-wheel steering, 6-pin Plug connection: blocking diode, 2-pin

8/10/12/ 14/25/28/ 32/34/43 5/6/8/37 45 43 34 34 31 32 8 33 34 10/25 28 4/40 28 12 35 14/15 12/14/43 13

Right console Operator's platform, rear Operator's platform, rear Right console Right console Operator's platform Operator's platform Left console Right console Cab, right Left console Left pilot control unit Right pilot control unit Right pilot control unit Below operator's platform Right console Right console Right console Right console

Solenoid valve / pilot pressure Solenoid valve / excess fuel for starting Magnetic clutch / a/c compressor Solenoid valve / grapple rotator Solenoid valve / grapple rotator Solenoid valve / creeper gear Solenoid valve / quick change adapter Solenoid valve / quick change adapter Solenoid valve / engine shut-down Proportional solenoid valve / power control Proportional solenoid valve / flow limitation Solenoid valve / first gear Solenoid valve / parking brake Solenoid valve / blade Solenoid valve / forward travel

15 1a 30c 25 25 11 38 38 3 26 26 11 11 35 10

Control oil unit Regulator / motor Diesel engine Control valve block Control valve block Control oil unit Quick-change adapter Quick-change adapter Regulating rod / motor Control oil unit Control oil unit HBGV block HBGV block Undercarriage Hydraulic tank

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MJFCIFSS

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Service Manual

Electrical system

Item

Description

Step


Y63 Y217 Y218 Y229-1 Y229-2 Y262 Y268 Y294-1 Y294-2 Y299 Y352 Y358 Y371 Y451

Solenoid valve / reverse travel Solenoid valve / outrigger, rear left Solenoid valve / outrigger, rear right Solenoid valve: dog-walk steering mode Solenoid valve: 4-wheel steering Solenoid valve: bucket swivel bearing Solenoid valve / flow reduction, AHS Solenoid valve: 4-wheel steering Solenoid valve: 4-wheel steering Solenoid valve / flow reduction, AHS Proportional solenoid valve / fan control Proportional solenoid valve / motor speed with plug Solenoid valve/oscillating axle support Solenoid valve / combined lifting of boom

10 35 35 12 12 40 34 12 12 34 29 22 33 34

Hydraulic tank Undercarriage Undercarriage Undercarriage Undercarriage Fuel tank Near control oil unit Below operator's platform Below operator's platform Near control oil unit Fan / radiator Bulkhead Near control oil unit Near control oil unit

A 309 LI 29269A 311 LI 29270-

copyright by

MJFCIFSS

8.22.9

Electrical system

Service Manual

1a power supply, board A127

8.22.10

copyright by

MJFCIFSS

A 309 LI 29269A 311 LI 29270-

Service Manual

Electrical system

1b power supply, board A127 / fuses

A 309 LI 29269A 311 LI 29270-

copyright by

MJFCIFSS

8.22.11

Electrical system

Service Manual

1c power supply, board A 127 / relay

8.22.12

copyright by

MJFCIFSS

A 309 LI 29269A 311 LI 29270-

Service Manual

Electrical system

2 Pre-heating

A 309 LI 29269A 311 LI 29270-

copyright by

MJFCIFSS

8.22.13

Electrical system

Service Manual

3 Motor shut-down

8.22.14

copyright by

MJFCIFSS

A 309 LI 29269A 311 LI 29270-

Service Manual

Electrical system


A 309 LI 29269A 311 LI 29270-

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MJFCIFSS

8.22.15

Electrical system

Service Manual

5 Work headlight

8.22.16

copyright by

MJFCIFSS

A 309 LI 29269A 311 LI 29270-

Service Manual

Electrical system


A 309 LI 29269A 311 LI 29270-

copyright by

MJFCIFSS

8.22.17

Electrical system

Service Manual


8.22.18

copyright by

MJFCIFSS

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Service Manual

Electrical system


A 309 LI 29269A 311 LI 29270-

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MJFCIFSS

8.22.19

Electrical system

Service Manual

9 Brake light

8.22.20

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MJFCIFSS

A 309 LI 29269A 311 LI 29270-

Service Manual

Electrical system


A 309 LI 29269A 311 LI 29270-

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MJFCIFSS

8.22.21

Electrical system

Service Manual

11 Creeper gear first gear

8.22.22

copyright by

MJFCIFSS

A 309 LI 29269A 311 LI 29270-

Service Manual

Electrical system

12 Optional 4-wheel steering

A 309 LI 29269A 311 LI 29270-

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8.22.23

Electrical system

Service Manual

13 Parking brake

8.22.24

copyright by

MJFCIFSS

A 309 LI 29269A 311 LI 29270-

Service Manual

Electrical system

14 Safety switch

A 309 LI 29269A 311 LI 29270-

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8.22.25

Electrical system

Service Manual

15 Servo

8.22.26

copyright by

MJFCIFSS

A 309 LI 29269A 311 LI 29270-

Service Manual

Electrical system


A 309 LI 29269A 311 LI 29270-

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MJFCIFSS

8.22.27

Electrical system

17 Fuel gauge

8.22.28

Service Manual

18 Clock

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MJFCIFSS

19 Hour meter

A 309 LI 29269A 311 LI 29270-

Service Manual

Electrical system


A 309 LI 29269A 311 LI 29270-

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MJFCIFSS

8.22.29

Electrical system

Service Manual


8.22.30

copyright by

MJFCIFSS

A 309 LI 29269A 311 LI 29270-

Service Manual

Electrical system


A 309 LI 29269A 311 LI 29270-

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MJFCIFSS

8.22.31

Electrical system

Service Manual

22 Speed adjustment

8.22.32

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A 309 LI 29269A 311 LI 29270-

Service Manual

Electrical system


A 309 LI 29269A 311 LI 29270-

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8.22.33

Electrical system

Service Manual

25 Optional AS I

8.22.34

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MJFCIFSS

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Service Manual

Electrical system


A 309 LI 29269A 311 LI 29270-

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8.22.35

Electrical system

Service Manual

27 Speed sensor

8.22.36

copyright by

MJFCIFSS

A 309 LI 29269A 311 LI 29270-

Service Manual

Electrical system

28 Sensor control

A 309 LI 29269A 311 LI 29270-

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8.22.37

Electrical system

Service Manual

29 Fan control

8.22.38

copyright by

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A 309 LI 29269A 311 LI 29270-

Service Manual

Electrical system

30a Heating

A 309 LI 29269A 311 LI 29270-

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8.22.39

Electrical system

Service Manual

30b Heating

8.22.40

copyright by

MJFCIFSS

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Service Manual

Electrical system

30c Heating

A 309 LI 29269A 311 LI 29270-

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8.22.41

Electrical system

Service Manual

31 Electrical set adjustment / seat made by Isringhausen

8.22.42

copyright by

MJFCIFSS

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Service Manual

Electrical system

32 Seat heating / seat made by Isringhausen

A 309 LI 29269A 311 LI 29270-

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8.22.43

Electrical system

Service Manual


8.22.44

copyright by

MJFCIFSS

A 309 LI 29269A 311 LI 29270-

Service Manual

Electrical system


A 309 LI 29269A 311 LI 29270-

copyright by

MJFCIFSS

8.22.45

Electrical system

Service Manual


8.22.46

copyright by

MJFCIFSS

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Service Manual

Electrical system


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8.22.47

Electrical system

Service Manual

37 Optional beacon

8.22.48

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Service Manual

Electrical system


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8.22.49

Electrical system

Service Manual

40 Swivel bearing

8.22.50

copyright by

MJFCIFSS

A 309 LI 29269A 311 LI 29270-

Service Manual

Electrical system

42 Ground

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8.22.51

Electrical system

Service Manual

43 Ground

8.22.52

copyright by

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Service Manual

Electrical system

44 Ground

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8.22.53

Electrical system

Service Manual

45 Terminal 30 / terminal 15

8.22.54

copyright by

MJFCIFSS

A 309 LI 29269A 311 LI 29270-

Service Manual

Electrical system


Description

Step

Location/arrangement

A3 A125 A126


Operator's cab, rear Left bracket Right bracket

A127


A1017

Printed circuit board / quick change adapter

8 26/34 4/10/13/ 21a/21b/ 24/33/34/ 36/38/40/ 41 1a/1b/1c/ 2/3 38

B1 B2 B3 B7 B8 B10 B12 B16 B19L B19R B20

Transducer / fuel level, with plug Temperature sensor / motor coolant Transducer / motor coolant, with plug Vacuum switch / air filter Switch / hydraulic oil temperature Pressure switch / parking brake Transducer / motor speed Switch / motor oil pressure Sensor transducer / left pilot control unit Sensor transducer / right pilot control unit Pressure switch / accumulator pressure

17 20 21a 21a 21a 13 27 21a 28 28 21a

B21


36

B26 B40 B50L B50R B60

Proximity switch / quick-change adapter Proximity switch / pilot pressure valve, travel Loudspeaker, left Loudspeaker, right Pressure switch / brake light

38 28 8 8 9

B204 B266 B285 B290 B291

Proximity switch / industrial shut-down Proximity switch / oscillating axle automatic Transducer hydraulic oil temperature / fan control Proximity switch / kit pedal Proximity switch / kit pedal

39 33 29 34 34

Fuel tank Motor, top fan side Engine compartment Suction pipe / air filter Hydraulic tank, bottom HBGV block Flywheel housing / motor Motor housing Left joystick Right joystick Brake block beneath operator's platform Boom cylinder section piston side Quick change adapter Travelling pedal Cab, rear left Cab, rear right Brake block beneath operator's platform Attachment Lower brake pedal Hydraulic tank Operator's platform Operator's platform

E1 E2 E3 E4 E7 E8 E9 E15 E16 E17

Work light / attachment Front roof light Travel light, left Travel light, right Roof-mounted light Cigarette lighter Beacon Parking light, right Parking light, left Tail light, right

5 5 6 6 8 8 37 6 6 6

Attachment Front cab roof Revolving deck, front Revolving deck, front Cab Right bracket, rear Cab, top Revolving deck, front right Revolving deck, front left Revolving deck, rear right


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MJFCIFSS

Electric cabinet at hydraulic tank Distribution board

8.30.1

Electrical system

Service Manual

Item

Description

Step


E18 E19 E20 E21 E22 E23 E24 E50

Tail light, left Brake light, right Brake light, left Indicator light, front left Indicator light, rear left Indicator light, front right Indicator light, rear right Electric cabinet

Revolving deck, rear left Revolving deck, rear right Revolving deck, rear left Revolving deck, front left Revolving deck, rear left Revolving deck, front right Revolving deck, rear right Hydraulic tank

E150


6 6 6 4 4 4 4 1a/1b/1c/ 2/3/40 5

F_A F_B F_C F_D F_E F_F F_G F_H F_I F_K F_L F_M F_N FRes F20/ F300 F19/ F301 F22/ F302 F303 F304 F305 F306 F307 F308 F309 F310 F311 F312 F313 F314 F315 F316 F317 F318 F319 F320



1b 1b 1b 1b 1b 1b 1b 1b 1b 1b 1b 1b 1a 14 1a


Fuse A127 K302, R60

50A

2



7.5A

1b


Fuse A127, Y29 Fuse S1 Fuse E7, E8, P50 Fuse X10 Fuse E16, E17, P6, P7, P50 Fuse E15, E18 Fuse E3 Fuse E4 Fuse M3, M4 Fuse S44, E21, E22, E23, E24 Fuse E19, E20 Fuse S7 Fuse BST Fuse servo control Fuse beacon Fuse heating / air conditioning, terminal 30 Fuse heating / air conditioning, terminal 15 Fuse X11

7.5A 15A 15A 15A 7.5A 7.5A 7.5A 7.5A 15A 7.5A 5A 3A 15A 7.5A 7.5A 20A 15A 15A

3 1a 8 16 6 6 6 6 7 4 9 14 23 28 37 30c 30c 16

A127, hydraulic tank Right bracket Right bracket Right bracket Right bracket, rear Right bracket, rear Right bracket, rear Right bracket, rear Right bracket, rear Right bracket Right bracket Right bracket Right bracket Right bracket Right bracket, rear Right bracket Right bracket Right bracket

8.30.2

copyright by

MJFCIFSS

Rear cab roof


Service Manual

Item

Description

F321 F322 F323 F324 F325 F326 F327 F328 F329 F330 F331 F332 F336 F337 F338 F339 F343

Fuse X12 Fuse T1 Fuse E1 Fuse S22 - E2, S22-1 - E150 Fuse S16, K251 Fuse S21 - Y24, S42 - Y55 Fuse X27 Fuse X28 Fuse S35 Fuse kits Fuse X29 Fuse A127, M1, Y12 Fuse S61 Fuse support Fuse H9, seat heating Fuse a/c condenser Fuse roof window wiper

G1 G2

Electrical system

Step


16 8 5 5 13 11 16 16 15 24 16 1a 6 35 4 30c 7b

Right bracket Right bracket Right bracket, rear Right bracket, rear Right bracket Right bracket Right bracket Right bracket Right bracket Right bracket Right bracket A127, hydraulic tank Right bracket Right bracket Right bracket Right bracket Right bracket


1a 1a


H7 H9 H10 H11 H12 H13 H15 H16 H18 H19 H20 H23 H26 H27 H167 H168 H175 H176 H186 H196 H301 H307 H311

Indicator light / motor oil pressure Horn Warning buzzer Indicator light / pre-heating Indicator light / charging Indicator light / air filter contamination Indicator light / hydraulic oil temperature Indicator light / overload warning (kit) Indicator light / coolant level Indicator light / indicator Indicator light / parking brake Indicator light / accumulator pressure Indicator light / quick-change adapter Warning buzzer Indicator light / forward travel Indicator light / reverse travel Indicator light / motor overheating Indicator light / oscillating-axle locking device Indicator light / swivel bearing Indicator light / sorting grapple Indicator light / error BST Indicator lamp / delta P Indicator light / oscillating axle locked

21a 4 21b 2 21b 21a 21a 36 21a 4 13 21a 38 13 10 10 21a 33 40 34 26 24 33

Right bracket Below operator's platform Right bracket Right bracket Right bracket Right bracket Right bracket Right bracket Right bracket Right bracket Right bracket Right bracket Right bracket Right bracket Right bracket Right bracket Right bracket Right bracket Right bracket Right bracket A125, left bracket Right bracket Right bracket

K_A K_B K_C

Relay, optional Relay, optional Relay, optional

1c 1c 1c

A127, hydraulic tank A127, hydraulic tank A127, hydraulic tank


15A 7.5A 15A 15A 7.5A 15A 15A 15A 5A 7.5A 15A 25A 20A 15A 10A 20A 7.5A

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MJFCIFSS

8.30.3

Electrical system

Service Manual

Item

Description

Step


K_D K_E K16-1 K16-2 K63 K250 K251 K252 K288 K302 K315 K364

Relay, optional Relay, optional Relay, terminal 50 Relay, disconnected Relay / direction indicator Relay / oscillating axle automatic Relay / hand brake (indicator light H20) Relay servo / hand brake (buzzer) Relay, terminal 15 Relay / pre-heating Relay brake light Relay to A1017

1c 1c 1a 1a 4 33 13 13 3 2 9 38

K370 K375 K386 K392 K393 K403 K405 K414

Relay terminal 15, servo Relay / kit, quantity Relay / safety switch S7 Relay / optional industry shutt off Relay / air-spring seat Relay / heating Relay / heating Relay / windscreen wiper interval

15 34 14 39 31 30a 30b 7

A127, hydraulic tank A127, hydraulic tank A127, hydraulic tank A127, hydraulic tank Right bracket Right bracket Right bracket Right bracket A127, hydraulic tank A127, hydraulic tank Right bracket Quick-change adapter board Right bracket Operator's platform, rear Right bracket Right bracket Operator's platform Operator's platform, rear Operator's platform, rear Operator's platform, rear

M1 M3 M4 M60 M65 M68 M70 M71 M72 M73


1a 7 7 7b 30b 7 31 30a 30a 30a


P1 P2 P3 P5 P6 P7 P50


26 26 26 19 20 17 18

A125, left bracket A125, left bracket A125, left bracket Right bracket, bottom Right bracket Right bracket Right bracket

R60 R75 R76 R78-1 R78 -2 RS232

Pin-type glow plug, with plug Potentiometer / speed Potentiometer / fine adjustment Seat heating Seat heating Laptop interface

2 22 24 32 32 26

Diesel engine Right bracket Right bracket Operator's platform Operator's platform Left bracket

8.30.4

copyright by

MJFCIFSS


Service Manual

Electrical system

Item

Description

Step


S1 S1 S4 S5L S5R S7 S8 S9 S11 S14 S16 S18 S19 S20 S21 S22 S22-1 S32 S35 S42 S44 S45 S46 S47 S61 S63 S75 S90 S92 S93 S204 S205 S206 S207 S216 S218 S241 S263 S272 S283 S284 S335 S360 S382 S388 S389 S398

Pre-heating and start switch Code switch A125 Switch / horn H9 Push button / turning grapple to the left, Y22 Push button / turning grapple to the right, Y23 Safety switch Switch / beacon Battery main switch Switch / windscreen washer system M3 Switch / windscreen wipers M4 Switch / parking brake Y6 Switch / overload warning system (optional) Switch / grapple rotator Y22, Y23 Switch / sensor control Switch / creeper gear Y24 Switch / work light E1 / roof light E2 Switch / auxiliary headlight / roof light Switch / direction indicator / horn Switch servo Switch / first gear Y55 Switch / hazard light Switch / priotity (optional) Switch / magnet system (optional) Switch / bucket quick-change adapter (optional) Switch / lighting installation Switch / swivel bearing Switch / oscillating axle locking device Y371 Intervall switch / windshield wiper Potentiometer / air distribution Potentiometer / heating / air condition Switch / outrigger, front left Switch / outrigger, front right Switch / outrigger, rear left Switch / outrigger, rear right Push button / bypass Switch / roof window wiper (optional) Switch / accessory kit AHS 11 / AHS 12 (optional) Switch / travelling direction Junction box, undercarriage Switch / windscreen wiper release Switch / four-step blower Switch / blade (optional) Switch / mute switch for overload buzzer Switch / fine adjustment ON / OFF Switch / air-spring seat Switch / seat heating Reversing switch / air distribution

1a 26 4 25 25 14 37 42 7 7 13 36 25 28 11 5 5 4 15 12 4 34 41 38 6 40 33 7a 30a 30a 35 35 35 35 39 7b 34 10 35 7 30b 35 38 24 31 32 30a

Right bracket A125, left bracket Cab floor plate Left pilot control unit Left pilot control unit Left bracket Right bracket, rear Battery compartment Right bracket, rear Right bracket, rear Right bracket Right bracket Right bracket Right bracket Right bracket Right bracket, rear Right bracket, rear Steering column Right bracket Right bracket Right bracket Right bracket Right bracket Right bracket Right bracket, rear Right pilot control unit Right bracket Cab right Right bracket Right bracket Right bracket Right bracket Right bracket Right bracket Right bracket Right bracket, rear Right bracket Left pilot control unit Undercarriage Windscreen Right bracket Right bracket Right bracket Right bracket Operator seat Operator seat Right bracket


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MJFCIFSS

8.30.5

Electrical system

Service Manual

Item

Description

Step


T1


8

Left bracket

U16


Right bracket

V155 V156-1 V156-2 V156-3 V156-4

Blocking diode / oscillating axle Blocking diode H307 - BST Blocking diode H311 - S75 Blocking diode S14-S90 Diode / input quantity

2/20-24/ 26-29/34/ 41 33 24 33 7a 34

Right bracket Right bracket Right bracket Right bracket Right bracket

X10 X11 X12 X15-2 X27 X28 X29 X65 X66 X67-1 X67-2 X80 X81 X90 X196 X197 X230 X262 X262-1 X262-3 X262-4 X262-5 X262-6 X301 X304 X327 X342 X404 X406 X407 X410 X411 X412 X413 X550 X771 X834 X835

Plug connection distribution board / 2-pin Plug connection distribution board / 2-pin Plug connection distribution board / 2-pin Plug connection / 2-pin Plug connection distribution board / 2-pin Plug connection distribution board / 2-pin Plug connection distribution board / 2-pin Plug connection on voltage transformer / 2-pin Plug connection on voltage transformer / 2-pin Plug connection A3 power supply / 8-pin Plug connection A3 power supply / 8-pin Plug connection B19L / 3-pin Plug connection B19R / 3-pin Plug connection / heating fan motor Plug connection B40 / 3-pin Plug connection / 3-pin Plug connection distribution board / 3-pin Plug connection distribution board / 8-pin Plug connection wire harness quick-change adapter / 8-pin Plug connection wire harness quick-change adapter / 8-pin Plug connection wire harness quick-change adapter / 2-pin Plug connection wire harness quick-change adapter / 2-pin Plug connection wire harness quick-change adapter / 3-pin Plug connection wire harness, 12-pin Plug connection wire harness, console / 6-pin Plug connection wire harness / revolving deck Plug connection / 3-pin Plug connection work headlight / 4-pin Plug connection transducer fuel reserve / 3-pin Plug connection revolving deck overload / 2-pin Plug connection distribution board / 2-pin Plug connection distribution board / 4-pin Plug connection distribution board / 2-pin Plug connection distribution board / 4-pin Plug connection switch S32 / 6-pin Plug connection distribution board / 5-pin Plug connection to A 125 / 2-pin Plug connection to A 125 / 2-pin

16 16 16 25 16 16 16 8 8 8 8 28 28 30b 28 33 10/13 38 38 38 38 38 38 35 35 39 10 5 17 36 38 38 38 38 4 35 26 26

Right bracket Right bracket Right bracket Left bracket Right bracket Right bracket Right bracket Right bracket Right bracket Operator's platform, left Operator's platform, left Pilot control valve, left Pilot control valve, right Operator's platform Travelling pedal Brake pedal Right bracket Right bracket Bearing block Stick Quick change adapter Quick change adapter Quick change adapter Revolving deck Right bracket Basic boom bearing block Left bracket Revolving deck Revolving deck X Revolving deck Right bracket Right bracket Right bracket Right bracket Steering column Right bracket Left bracket Left bracket

8.30.6

copyright by

MJFCIFSS


Service Manual

Electrical system

Item

Description

Step


X836 X837 X838 X838-1 X838-2 X838-3 X839 X842-1 X842-2 X842-3 X856

Plug connection to A 125 / 4-pin Plug connection to A 125 / 8-pin Plug connection to A 125 / 6-pin Plug connection to A 125 / 9-pin Plug connection to A 125 / 9-pin Plug connection CAN - bus / 2-pin Screw terminal on A125 / 3-pin Plug connection air-conditioning / 15-pin Plug connection console, ignition switch / 2-pin Plug connection blocking diode / 2-pin Plug connection to BST excavator control / 40-pin

Left bracket Left bracket Left bracket Left bracket Left bracket Left bracket Left bracket Right bracket Right bracket Right bracket Right bracket

X857


X859 X860 X861 X862 X863 X909 X924-1 X924-2 X950

Plug connection / 21-pin Plug connection / 6-pin Plug connection / 6-pin Plug connection / 6-pin Plug connection / 15-pin Plug connection fine control / 2-pin Plug connection B290 / 3-pin Plug connection B291 / 3-pin Plug connection console display autocheck / 21-pin

X951


X952


X953


X954

Plug connection revolving deck BST excavator control / 21pin Plug connection revolving deck distribution board / 15-pin

26 26/34 26 26 26 26 34 30c 30c 33 2/20-24/ 26-29/34 21a/2224/26/28/ 34 30a/30b 30a 30a 30a 30a/30b 30a/30b 34 34 4/10/13/ 21a/33/ 36/38/40/ 41 4/10/13/ 21b/34/ 38/40/41 10-13/15/ 25/30c/ 33/34 1/4-6/9/ 13/17/ 21a/36/42 2/20/22/ 26/27/29 1a/3/4/38/ 39 2/20-24/ 28/34/41/ 43 8/11/12/ 20/22/25/ 34/35 18/28/34/ 35/36/38/ 39/41/43 10/24/30c

X955 X956


X957


X958


X959



copyright by

MJFCIFSS

Right bracket Operator's platform, rear Operator's platform, rear Operator's platform, rear Operator's platform, rear Operator's platform, rear Operator's platform, rear Below operator's platform Below operator's platform Right bracket

Right bracket Right bracket Right bracket Right bracket Right bracket Right bracket Right bracket Right bracket Right bracket

8.30.7

Electrical system

Service Manual

Item

Description

Step


X960

Plug connection operator's platform distribution board / 21pin

Right bracket

X961


X962


X963


X964


X965 X966


4/6/9/21a/ 28/33/34/ 40 2/6/13/17/ 20/21a/ 21b/24/33 4/10/13/ 14/21b/ 28/34/38/ 40/41 6/8/9/11/ 13/14/16/ 23/24/28/ 35 1a/3/4/13/ 14/28/33/ 43 26/34

X967 X967-1 X967-2 X968-1 X968-2 X971 X972 X973 X974-1 X974-2 X974-3 X974-4 Y3 Y6 Y12 Y20 Y22 Y23 Y24 Y28-1 Y28-2 Y29 Y50 Y51 Y55 Y56 Y62

8.30.8

Right bracket

Right bracket

Right bracket

Right bracket Right bracket Right bracket

Plug connection display distribution board / 21-pin Plug connection wire harness connection / 1-pin Plug connection wire harness connection / 1-pin Plug connection quantity 2 / 1-pin Plug connection quantity 3 / 1-pin Plug connection seat adjustment / 2-pin Plug connection seat heating / 2-pin Power socket, 12V Plug connection blocking diode / 2-pin Plug connection blocking diode / 2-pin Plug connection blocking diode / 2-pin Plug connection blocking diode / 2-pin

8/14/24/ 25/28/32/ 34/43 5/6/8/37 45 43 34 34 31 32 8 24 33 7a 34

Right bracket Operator's platform, rear Operator's platform, rear Right bracket Right bracket Operator's platform Operator's platform Left bracket Right bracket Right bracket Right bracket Cab, right

Solenoid valve / pilot pressure Solenoid valve / parking brake Solenoid valve / excess fuel for starting magnetic clutch / a/c compressor Solenoid valve / grapple rotator Solenoid valve / grapple rotator Solenoid valve / creeper gear Solenoid valve / quick change adapter Solenoid valve / quick change adapter Solenoid valve / engine shut-down Proportional solenoid valve / power control Proportional solenoid valve / flow limitation Solenoid valve / first gear Solenoid valve / blade Solenoid valve / forward travel

15 13 1a 30c 25 25 11 38 38 3 26 26 11 35 10

Control oil unit HBGV block Regulator / motor Diesel engine Control valve block Control valve block Control oil unit Quick change adapter Quick change adapter Regulating rod / motor Control oil unit Control oil unit HBGV block Undercarriage Hydraulic tank

copyright by

MJFCIFSS


Service Manual

Electrical system

Item

Description

Step


Y63 Y212 Y215 Y216 Y217 Y218 Y268 Y299 Y352 Y358 Y371

Solenoid valve / reverse travel Solenoid valve / industrial shut-down Solenoid valve / outrigger, front left Solenoid valve / outrigger, front right Solenoid valve / outrigger, rear left Solenoid valve / outrigger, rear right Solenoid valve / flow reduction, AHS Solenoid valve / flow reduction, AHS Proportional solenoid valve / fan control Proportional solenoid valve / motor speed with plug Solenoid valve/oscillating axle support

10 39 35 35 35 35 34 34 29 22 33

Hydraulic tank Uppercarriage Undercarriage Undercarriage Undercarriage Undercarriage Hydraulic tank Hydraulic tank Fan / radiator Control valve block panel Control oil unit


copyright by

MJFCIFSS

8.30.9

Electrical system

Service Manual


8.30.10

copyright by

MJFCIFSS


Service Manual

Electrical system



copyright by

MJFCIFSS

8.30.11

Electrical system

Service Manual


8.30.12

copyright by

MJFCIFSS


Service Manual

Electrical system

2 Pre-heating


copyright by

MJFCIFSS

8.30.13

Electrical system

Service Manual

3 Motor shut-down

8.30.14

copyright by

MJFCIFSS


Service Manual

Electrical system



copyright by

MJFCIFSS

8.30.15

Electrical system

Service Manual

5 Work headlight

8.30.16

copyright by

MJFCIFSS


Service Manual

Electrical system



copyright by

MJFCIFSS

8.30.17

Electrical system

Service Manual

7a Windscreen wiper / washer systems

8.30.18

copyright by

MJFCIFSS

only A 314 / 316 from 2001


Service Manual

Electrical system

7b Windscreen wiper/washer systems A 312 from 12363/A 314/316 from 12736


copyright by

MJFCIFSS

8.30.19

Electrical system

Service Manual


8.30.20

copyright by

MJFCIFSS


Service Manual

Electrical system

9 Brake light


copyright by

MJFCIFSS

8.30.21

Electrical system

Service Manual


8.30.22

copyright by

MJFCIFSS


Service Manual

Electrical system

11 Creeper speed


copyright by

MJFCIFSS

8.30.23

Electrical system

12

8.30.24

Service Manual

1st gear

copyright by

MJFCIFSS


Service Manual

Electrical system

13 Parking brake


copyright by

MJFCIFSS

8.30.25

Electrical system

Service Manual

14 Safety switch

8.30.26

copyright by

MJFCIFSS


Service Manual

Electrical system

15 Servo


copyright by

MJFCIFSS

8.30.27

Electrical system

Service Manual


8.30.28

copyright by

MJFCIFSS


Service Manual

Fuel gauge


Electrical system

18 Clock

copyright by

MJFCIFSS

19 Hour meter

8.30.29

Electrical system

Service Manual


8.30.30

copyright by

MJFCIFSS


Service Manual

Electrical system



copyright by

MJFCIFSS

8.30.31

Electrical system

Service Manual


8.30.32

copyright by

MJFCIFSS


Service Manual

Electrical system

22 Speed adjustment


copyright by

MJFCIFSS

8.30.33

Electrical system

Service Manual


8.30.34

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Service Manual

Electrical system

24 Fine control


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8.30.35

Electrical system

Service Manual

25 Optional AS I

8.30.36

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Service Manual

Electrical system



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8.30.37

Electrical system

Service Manual

27 Speed sensor

8.30.38

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Service Manual

Electrical system

28 Sensor control


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8.30.39

Electrical system

Service Manual

29 Fan control

8.30.40

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Service Manual

Electrical system

30a Heating


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8.30.41

Electrical system

Service Manual

30b Heating

8.30.42

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Service Manual

Electrical system

30c Heating


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8.30.43

Electrical system

Service Manual


8.30.44

copyright by

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Service Manual

Electrical system



copyright by

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8.30.45

Electrical system

Service Manual


8.30.46

copyright by

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Service Manual

Electrical system



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8.30.47

Electrical system

Service Manual


8.30.48

copyright by

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Service Manual

Electrical system



copyright by

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8.30.49

Electrical system

Service Manual

37 Optional beacon

8.30.50

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Service Manual

Electrical system



copyright by

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8.30.51

Electrical system

Service Manual

39 Optional industrial shut-down

8.30.52

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Service Manual

Electrical system

40 Reserve


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8.30.53

Electrical system

Service Manual

41 Optional magnet system

8.30.54

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Service Manual

Electrical system

42 Ground


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8.30.55

Electrical system

Service Manual

43 Ground

8.30.56

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Service Manual

Electrical system

44 Ground


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8.30.57

Electrical system

Service Manual


8.30.58

copyright by

MJFCIFSS


Service Manual

Electrical system


Description

Step


A3 A125 A126


Operator's cab, rear Left bracket Right bracket

A127


A1017

Printed circuit board / quick change adapter

8 26/34 4/10/13/ 21a/21b/ 24/33/34/ 36/38/40/ 41/47 1a/1b/1c/ 2/3 38

B1 B2 B3 B7 B8 B10 B12 B16 B19L B19R B20

Transducer / fuel level, with plug Temperature sensor / motor coolant Transducer / motor coolant, with plug Vacuum switch / air filter Switch / hydraulic oil temperature Pressure switch / parking brake Transducer / motor speed Switch / motor oil pressure Sensor transducer / left pilot control unit Sensor transducer / right pilot control unit Pressure switch / accumulator pressure

17 20 21a/47 21a/47 21a/47 13 27 21a 28 28 21a/47

B21


36

B26 B40 B50L B50R B60

Proximity switch / quick-change adapter Proximity switch / pilot pressure valve, travel Loudspeaker, left Loudspeaker, right Pressure switch / brake light

38 28 8 8 9

B204 B266 B285 B290 B291

Proximity switch / industrial shut-down Proximity switch / oscillating axle automatic Transducer hydraulic oil temperature / fan control Proximity switch / kit pedal Proximity switch / kit pedal

39 33 29 34 34

Fuel tank Motor, top fan side Engine compartment Suction pipe / air filter Hydraulic tank, bottom HBGV block Flywheel housing / motor Motor housing Left joystick Right joystick Brake block beneath operator's platform Boom cylinder section piston side Quick change adapter Travelling pedal Cab, rear left Cab, rear right Brake block beneath operator's platform Attachment Lower brake pedal Hydraulic tank Operator's platform Operator's platform

E1 E2 E2L E2R E3 E4 E7 E8 E9 E15

Work light / attachment Front roof light Front roof light left Front roof light right Travel light, left Travel light, right Roof-mounted light Cigarette lighter Beacon Parking light, right

5,46 5 46 46 6 6 8 8 37 6

Attachment Front cab roof Front cab roof Front cab roof Revolving deck, front Revolving deck, front Cab Right bracket, rear Cab, top Revolving deck, front right


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Electric cabinet at hydraulic tank Distribution board

8.32.1

Electrical system

Service Manual

Item

Description

Step


E16 E17 E18 E19 E20 E21 E22 E23 E24 E50

Parking light, left Tail light, right Tail light, left Brake light, right Brake light, left Indicator light, front left Indicator light, rear left Indicator light, front right Indicator light, rear right Electric cabinet

Revolving deck, front left Revolving deck, rear right Revolving deck, rear left Revolving deck, rear right Revolving deck, rear left Revolving deck, front left Revolving deck, rear left Revolving deck, front right Revolving deck, rear right Hydraulic tank

E150


6 6 6 6 6 4 4 4 4 1a/1b/1c/ 2/3/40 5

F_A F_B F_C F_D F_E F_F F_G F_H F_I F_K F_L F_M F_N FRes F20/ F300 F19/ F301 F22/ F302 F303 F304 F305 F306 F307 F308 F309 F310 F311 F312 F313 F314 F315 F316 F317 F318



1b 1b 1b 1b 1b 1b 1b 1b 1b 1b 1b 1b 1a 14 1a


Fuse A127 K302, R60

50A

2



7.5A

1b


Fuse A127, Y29 Fuse S1 Fuse E7, E8, P50 Fuse X10 Fuse E16, E17, P6, P7, P50 Fuse E15, E18 Fuse E3 Fuse E4 Fuse M3, M4 Fuse S44, E21, E22, E23, E24 Fuse E19, E20 Fuse S7 Fuse BST Fuse servo control Fuse beacon Fuse heating / air conditioning, terminal 30

7.5A 15A 15A 15A 7.5A 7.5A 7.5A 7.5A 15A 7.5A 5A 3A 15A 7.5A 7.5A 20A

3 1a 8 16 6 6 6 6 7 4 9 14 23 28 37 30c

A127, hydraulic tank Right bracket Right bracket Right bracket Right bracket, rear Right bracket, rear Right bracket, rear Right bracket, rear Right bracket, rear Right bracket Right bracket Right bracket Right bracket Right bracket Right bracket, rear Right bracket

8.32.2

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MJFCIFSS

Rear cab roof


Service Manual

Electrical system

Item

Description

F319 F320 F321 F322 F323 F324 F325 F326 F327 F328 F329 F330 F331 F332 F336 F337 F338 F339 F343

Fuse heating / air conditioning, terminal 15 Fuse X11 Fuse X12 Fuse T1 Fuse E1 Fuse S22 - E2, S22-1 - E150 Fuse S16, K251 Fuse S21 - Y24, S42 - Y55 Fuse X27 Fuse X28 Fuse S35 Fuse kits Fuse X29 Fuse A127, M1, Y12 Fuse S61 Fuse support Fuse H9, seat heating Fuse a/c condenser Fuse roof window wiper

Step


30c 16 16 8 5, 46 5, 46 13 11 16 16 15 24 16 1a 6 35 4 30c 7

Right bracket Right bracket Right bracket Right bracket Right bracket, rear Right bracket, rear Right bracket Right bracket Right bracket Right bracket Right bracket Right bracket Right bracket A127, hydraulic tank Right bracket Right bracket Right bracket Right bracket Right bracket

G1 G2


1a 1a


H7 H9 H10 H11 H12 H13 H15 H16 H18 H19 H20 H23 H26 H27 H167 H168 H175 H176 H186 H196 H301 H307 H311 H336

Indicator light / motor oil pressure Horn Warning buzzer Indicator light / pre-heating Indicator light / charging Indicator light / air filter contamination Indicator light / hydraulic oil temperature Indicator light / overload warning (kit) Indicator light / coolant level Indicator light / indicator Indicator light / parking brake Indicator light / accumulator pressure Indicator light / quick-change adapter Warning buzzer Indicator light / forward travel Indicator light / reverse travel Indicator light / motor overheating Indicator light / oscillating-axle locking device Indicator light / swivel bearing Indicator light / sorting grapple Indicator light / error BST Indicator lamp / delta P Indicator light / oscillating axle locked Warning lamp / water in fuel filter

21a 4 21b 2 21b 21a/47 21a/47 36 21a/47 4 13 21a/47 38 13 10 10 21a/47 33 40 34 26 24 33 33

Right bracket Below operator's platform Right bracket Right bracket Right bracket Right bracket Right bracket Right bracket Right bracket Right bracket Right bracket Right bracket Right bracket Right bracket Right bracket Right bracket Right bracket Right bracket Right bracket Right bracket A125, left bracket Right bracket Right bracket Right bracket


15A 15A 15A 7.5A 15A 15A 7.5A 15A 15A 15A 5A 7.5A 15A 25A 20A 15A 10A 20A 7.5A

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8.32.3

Electrical system

Service Manual

Item

Description

Step


K_A K_B K_C K_D K_E K16-1 K16-2 K63 K250 K251 K252 K288 K302 K315 K364

Relay, optional Relay, optional Relay, optional Relay, optional Relay, optional Relay, terminal 50 Relay, disconnected Relay / direction indicator Relay / oscillating axle automatic Relay / hand brake (indicator light H20) Relay servo / hand brake (buzzer) Relay, terminal 15 Relay / pre-heating Relay brake light Relay to A1017

1c 1c 1c 1c 1c 1a 1a 4 33 13 13 3 2 9 38

K370 K375 K386 K393 K403 K405 K414 K447 K448 K449

Relay terminal 15, servo Relay / kit, quantity Relay / safety switch S7 Relay / air-spring seat Relay / heating Relay / heating Relay / windscreen wiper interval Relay / Front roof light Relay / Rear roof light Relay / Front work light

15 34 14 31 30a 30b 7 46 46 46

A127, hydraulic tank A127, hydraulic tank A127, hydraulic tank A127, hydraulic tank A127, hydraulic tank A127, hydraulic tank A127, hydraulic tank Right bracket Right bracket Right bracket Right bracket A127, hydraulic tank A127, hydraulic tank Right bracket Quick-change adapter board Right bracket Operator's platform, rear Right bracket Operator's platform Operator's platform, rear Operator's platform, rear Operator's platform, rear Operator's platform, rear Operator's platform, rear Operator's platform, rear

M1 M3 M4 M60 M65 M68 M70 M71 M72 M73


1a 7 7 7 30b 7 31 30a 30a 30a


P1 P2 P3 P5 P6 P7 P50


26 26 26 19 20 17 18

A125, left bracket A125, left bracket A125, left bracket Right bracket, bottom Right bracket Right bracket Right bracket

R60 R75

Pin-type glow plug, with plug Potentiometer / speed

2 22

Diesel engine Right bracket

8.32.4

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MJFCIFSS


Service Manual

Electrical system

Item

Description

Step


R76 R78-1 R78 -2 RS232

Potentiometer / fine adjustment Seat heating Seat heating Laptop interface

24 32 32 26

Right bracket Operator's platform Operator's platform Left bracket

S1 S1 S4 S5L S5M S5R S7 S8 S9 S11 S14 S16 S18 S19 S20 S21 S22 S22-1 S32 S35 S42 S44 S46 S47 S61 S63 S75 S92 S93 S204 S205 S206 S207 S216 S218 S241 S263 S272 S283 S284 S335 S360 S382

Pre-heating and start switch Code switch A125 Switch / horn H9 Push button / turning grapple to the left, Y22 Push button, centre (no function) Push button / turning grapple to the right, Y23 Safety switch Switch / beacon Battery main switch Switch / windscreen washer system M3 Switch / windscreen wipers M4 Switch / parking brake Y6 Switch / overload warning system (optional) Switch / grapple rotator Y22, Y23 Switch / sensor control Switch / creeper gear Y24 Switch / work light E1 / roof light E2 Switch / auxiliary headlight / roof light Switch / direction indicator / horn Switch servo Switch / first gear Y55 Switch / hazard light Switch / magnet system (optional) Switch / bucket quick-change adapter (optional) Switch / lighting installation Switch / swivel bearing Switch / oscillating axle locking device Y371 Potentiometer / air distribution Potentiometer / heating / air condition Switch / outrigger, front left Switch / outrigger, front right Switch / outrigger, rear left Switch / outrigger, rear right Push button / bypass Switch / roof window wiper (optional) Switch / accessory kit AHS 11 / AHS 12 (optional) Switch / travelling direction Junction box, undercarriage Switch / windscreen wiper release Switch / four-step blower Switch / blade (optional) Switch / mute switch for overload buzzer Switch / fine adjustment ON / OFF

1a 26 4 25 25 25 14 37 42 7 7 13 36 25 28 11 5, 46 5, 46 4 15 12 4 41 38 6 40 33 30a 30a 35 35 35 35 39 7 34 10 35 7 30b 35 38 24

Right bracket A125, left bracket Cab floor plate Left pilot control unit Left pilot control unit Left pilot control unit Left bracket Right bracket, rear Battery compartment Right bracket, rear Right bracket, rear Right bracket Right bracket Right bracket Right bracket Right bracket Right bracket, rear Right bracket, rear Steering column Right bracket Right bracket Right bracket Right bracket Right bracket Right bracket, rear Right pilot control unit Right bracket Right bracket Right bracket Right bracket Right bracket Right bracket Right bracket Right bracket Right bracket, rear Right bracket Left pilot control unit Undercarriage Windscreen Right bracket Right bracket Right bracket Right bracket


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8.32.5

Electrical system

Service Manual

Item

Description

Step


S388 S389 S398 S422

Switch / air-spring seat Switch / seat heating Reversing switch / air distribution Switch / mute switch for radio

31 32 30a 8

Operator seat Operator seat Right bracket Right bracket

T1


8

Left bracket

U16


Right bracket

V155 V156-1 V156-2 V156-4

Blocking diode / oscillating axle Blocking diode H307 - BST Blocking diode H311 - S75 Diode / input quantity

2/20-24/ 26-29/34/ 41 33 24 33 34


X10 X11 X12 X27 X28 X29 X65 X66 X67-1 X67-2 X90 X196 X197 X230 X262 X262-1 X262-3 X262-4 X262-5 X262-6 X301 X304 X327 X404 X406 X407 X410 X411 X412 X413 X550 X771 X834 X835

Plug connection distribution board / 2-pin Plug connection distribution board / 2-pin Plug connection distribution board / 2-pin Plug connection distribution board / 2-pin Plug connection distribution board / 2-pin Plug connection distribution board / 2-pin Plug connection on voltage transformer / 2-pin Plug connection on voltage transformer / 2-pin Plug connection A3 power supply / 8-pin Plug connection A3 power supply / 8-pin Plug connection / heating fan motor Plug connection B40 / 3-pin Plug connection / 3-pin Plug connection distribution board / 3-pin Plug connection distribution board / 8-pin Plug connection wire harness quick-change adapter / 8-pin Plug connection wire harness quick-change adapter / 8-pin Plug connection wire harness quick-change adapter / 2-pin Plug connection wire harness quick-change adapter / 2-pin Plug connection wire harness quick-change adapter / 3-pin Plug connection wire harness, 12-pin Plug connection wire harness, console / 6-pin Plug connection wire harness / revolving deck Plug connection work headlight / 4-pin Plug connection transducer fuel reserve / 3-pin Plug connection revolving deck overload / 2-pin Plug connection distribution board / 2-pin Plug connection distribution board / 4-pin Plug connection distribution board / 2-pin Plug connection distribution board / 4-pin Plug connection switch S32 / 6-pin Plug connection distribution board / 5-pin Plug connection to A 125 / 2-pin Plug connection to A 125 / 2-pin

16 16 16 16 16 16 8 8 8 8 30b 28 33 10/13 38 38 38 38 38 38 35 35 39 5 17 36 38 38 38 38 4 35 26 26

Right bracket Right bracket Right bracket Right bracket Right bracket Right bracket Right bracket Right bracket Operator's platform, left Operator's platform, left Operator's platform Travelling pedal Brake pedal Right bracket Right bracket Bearing block Stick Quick change adapter Quick change adapter Quick change adapter Revolving deck Right bracket Basic boom bearing block Revolving deck Revolving deck X Revolving deck Right bracket Right bracket Right bracket Right bracket Steering column Right bracket Left bracket Left bracket

8.32.6

copyright by

MJFCIFSS


Service Manual

Electrical system

Item

Description

Step


X836 X837 X838 X838-1 X838-2 X838-3 X839 X842-1 X842-2 X842-3 X856

Plug connection to A 125 / 4-pin Plug connection to A 125 / 8-pin Plug connection to A 125 / 6-pin Plug connection to A 125 / 9-pin Plug connection to A 125 / 9-pin Plug connection CAN - bus / 2-pin Screw terminal on A125 / 3-pin Plug connection air-conditioning / 15-pin Plug connection console, ignition switch / 2-pin Plug connection blocking diode / 2-pin Plug connection to BST excavator control / 40-pin

Left bracket Left bracket Left bracket Left bracket Left bracket Left bracket Left bracket Right bracket Right bracket Right bracket Right bracket

X857


X859 X860 X861 X862 X863 X924-1 X924-2 X950

Plug connection / 21-pin Plug connection / 6-pin Plug connection / 6-pin Plug connection / 6-pin Plug connection / 15-pin Plug connection B290 / 3-pin Plug connection B291 / 3-pin Plug connection console display autocheck / 21-pin

X951


X952


X953


X954

Plug connection revolving deck BST excavator control / 21pin Plug connection revolving deck distribution board / 15-pin

26 26/34 26 26 26 26 34 30c 30c 33 2/20-24/ 26-29/34 21a/2224/26/28/ 34/47 30a/30b 30a 30a 30a 30a/30b 34 34 4/10/13/ 21a/33/ 36/38/40/ 41/47 4/10/13/ 21b/34/ 38/40/41 10-13/15/ 25/30c/ 33/34 1/4-6/9/ 13/17/ 21a/36/ 42/47 2/20/22/ 26/27/29 1a/3/4/38/ 39 2/20-24/ 28/34/41/ 43 8/11/12/ 20/22/25/ 34/35 18/28/34/ 35/36/38/ 39/41/43 10/24/30c

X955 X956


X957


X958


X959



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MJFCIFSS

Right bracket Operator's platform, rear Operator's platform, rear Operator's platform, rear Operator's platform, rear Operator's platform, rear Below operator's platform Below operator's platform Right bracket

Right bracket Right bracket Right bracket

Right bracket Right bracket Right bracket Right bracket Right bracket Right bracket

8.32.7

Electrical system

Service Manual

Item

Description

Step


X960

Plug connection operator's platform distribution board / 21pin

Right bracket

X961


X962


X963


X964


X965 X966


4/6/9/21a/ 28/33/34/ 47 2/6/13/17/ 20/21a/ 21b/24/ 33/47 4/10/13/ 14/21b/ 28/34/38/ 40/41 6/8/9/11/ 13/14/16/ 23/24/28/ 35 1a/3/4/13/ 14/28/33/ 43 26/34

X967


X967-1 X967-2 X968-1 X968-2 X971 X972 X973 X974-1 X974-2 X974-4 X1046 X1047 X1048 X1049 X1116 Y3 Y6 Y12 Y20 Y22 Y23 Y24 Y28-1 Y28-2 Y29

8.32.8

Right bracket

Right bracket

Right bracket

Right bracket Right bracket

Plug connection wire harness connection / 1-pin Plug connection wire harness connection / 1-pin Plug connection quantity 2 / 1-pin Plug connection quantity 3 / 1-pin Plug connection seat adjustment / 2-pin Plug connection seat heating / 2-pin Power socket, 12V Plug connection blocking diode / 2-pin Plug connection blocking diode / 2-pin Plug connection blocking diode / 2-pin Plug connection / 12-pin Plug connection B19L / 3-pin Plug connection / 12-pin Plug connection B19R / 3-pin Plug connection / 2-pin

8/14/24/ 25/28/32/ 34/43 5/6/8/37/ 46 45 43 34 34 31 32 8 24 33 34 24/25 28 10 28 15

Operator's platform, rear Operator's platform, rear Right bracket Right bracket Operator's platform Operator's platform Left bracket Right bracket Right bracket Cab, right Left bracket Left pilot control unit Right pilot control unit Right pilot control unit Right bracket

Solenoid valve / pilot pressure Solenoid valve / parking brake Solenoid valve / excess fuel for starting magnetic clutch / a/c compressor Solenoid valve / grapple rotator Solenoid valve / grapple rotator Solenoid valve / creeper gear Solenoid valve / quick change adapter Solenoid valve / quick change adapter Solenoid valve / engine shut-down

15 13 1a 30c 25 25 11 38 38 3

Control oil unit HBGV block Regulator / motor Diesel engine Control valve block Control valve block Control oil unit Quick change adapter Quick change adapter Regulating rod / motor

copyright by

MJFCIFSS



Service Manual

Electrical system

Item

Description

Step


Y50 Y51 Y55 Y56 Y62 Y63 Y212 Y215 Y216 Y217 Y218 Y268 Y299 Y352 Y358 Y371

Proportional solenoid valve / power control Proportional solenoid valve / flow limitation Solenoid valve / first gear Solenoid valve / blade Solenoid valve / forward travel Solenoid valve / reverse travel Solenoid valve / industrial shut-down Solenoid valve / outrigger, front left Solenoid valve / outrigger, front right Solenoid valve / outrigger, rear left Solenoid valve / outrigger, rear right Solenoid valve / flow reduction, AHS Solenoid valve / flow reduction, AHS Proportional solenoid valve / fan control Proportional solenoid valve / motor speed with plug Solenoid valve/oscillating axle support

26 26 11 35 10 10 39 35 35 35 35 34 34 29 22 33

Control oil unit Control oil unit HBGV block Undercarriage Hydraulic tank Hydraulic tank Uppercarriage Undercarriage Undercarriage Undercarriage Undercarriage Hydraulic tank Hydraulic tank Fan / radiator Control valve block panel Control oil unit


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MJFCIFSS

8.32.9

Electrical system

Service Manual


8.32.10

copyright by

MJFCIFSS


Service Manual

Electrical system



copyright by

MJFCIFSS

8.32.11

Electrical system

Service Manual


8.32.12

copyright by

MJFCIFSS


Service Manual

Electrical system

2 Pre-heating


copyright by

MJFCIFSS

8.32.13

Electrical system

Service Manual

3 Motor shut-down

8.32.14

copyright by

MJFCIFSS


Service Manual

Electrical system



copyright by

MJFCIFSS

8.32.15

Electrical system

Service Manual

5 Work headlight (on machine A312 from 20330, A 314 from 20334, A 316 from 20340 until 25765 A 316 from 25766, see page 8.32.58

8.32.16

copyright by

MJFCIFSS


Service Manual

Electrical system



copyright by

MJFCIFSS

8.32.17

Electrical system

Service Manual


8.32.18

copyright by

MJFCIFSS


Service Manual

Electrical system



copyright by

MJFCIFSS

8.32.19

Electrical system

Service Manual

9 Brake light

8.32.20

copyright by

MJFCIFSS


Service Manual

Electrical system



copyright by

MJFCIFSS

8.32.21

Electrical system

Service Manual

11 Creeper speed

8.32.22

copyright by

MJFCIFSS


Service Manual

12


Electrical system

1st gear

copyright by

MJFCIFSS

8.32.23

Electrical system

Service Manual

13 Parking brake

8.32.24

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MJFCIFSS


Service Manual

Electrical system

14 Safety switch


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MJFCIFSS

8.32.25

Electrical system

Service Manual

15 Servo

8.32.26

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MJFCIFSS


Service Manual

Electrical system



copyright by

MJFCIFSS

8.32.27

Electrical system

17 Fuel gauge

8.32.28

Service Manual

18 Clock

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MJFCIFSS

19 Hour meter


Service Manual

Electrical system



copyright by

MJFCIFSS

8.32.29

Electrical system

Service Manual

21a Indicator lights (on machine A 312 until 27112, A 314 until 27114, A 316 until 27118, A 316 Ind. until 27383 new version , see page 8.32.59

8.32.30

copyright by

MJFCIFSS


Service Manual

Electrical system



copyright by

MJFCIFSS

8.32.31

Electrical system

Service Manual

22 Speed adjustment

8.32.32

copyright by

MJFCIFSS


Service Manual

Electrical system



copyright by

MJFCIFSS

8.32.33

Electrical system

Service Manual

24 Fine control

8.32.34

copyright by

MJFCIFSS


Service Manual

Electrical system

25 Optional AS I


copyright by

MJFCIFSS

8.32.35

Electrical system

Service Manual


8.32.36

copyright by

MJFCIFSS


Service Manual

Electrical system

27 Speed sensor


copyright by

MJFCIFSS

8.32.37

Electrical system

Service Manual

28 Sensor control (on machine A 312 until 27112, A 314 until 27114, A 316 until 27118, A 316 Ind. until 27383 new version , see page 8.32.60

8.32.38

copyright by

MJFCIFSS


Service Manual

Electrical system

29 Fan control


copyright by

MJFCIFSS

8.32.39

Electrical system

Service Manual

30a Heating

8.32.40

copyright by

MJFCIFSS


Service Manual

Electrical system

30b Heating


copyright by

MJFCIFSS

8.32.41

Electrical system

Service Manual

30c Heating

8.32.42

copyright by

MJFCIFSS


Service Manual

Electrical system



copyright by

MJFCIFSS

8.32.43

Electrical system

Service Manual


8.32.44

copyright by

MJFCIFSS


Service Manual

Electrical system



copyright by

MJFCIFSS

8.32.45

Electrical system

Service Manual


8.32.46

copyright by

MJFCIFSS


Service Manual

Electrical system



copyright by

MJFCIFSS

8.32.47

Electrical system

Service Manual


8.32.48

copyright by

MJFCIFSS


Service Manual

Electrical system

37 Optional beacon


copyright by

MJFCIFSS

8.32.49

Electrical system

Service Manual


8.32.50

copyright by

MJFCIFSS


Service Manual

Electrical system



copyright by

MJFCIFSS

8.32.51

Electrical system

Service Manual

40 Reserve

8.32.52

copyright by

MJFCIFSS


Service Manual

Electrical system



copyright by

MJFCIFSS

8.32.53

Electrical system

Service Manual

42 Ground

8.32.54

copyright by

MJFCIFSS


Service Manual

Electrical system

43 Ground


copyright by

MJFCIFSS

8.32.55

Electrical system

Service Manual

44 Ground

8.32.56

copyright by

MJFCIFSS


Service Manual

Electrical system



copyright by

MJFCIFSS

8.32.57

Electrical system

Service Manual

46 (5) Work headlight (on machine A 316 from 25766)

8.32.58

copyright by

MJFCIFSS


Service Manual

Electrical system

47 (21a) Indicator lights (on A 312 from 27113, A 314 from 27115, A 316 from 27119, A 316 Ind. from 27384)


copyright by

MJFCIFSS

8.32.59

Electrical system

Service Manual

48 (28) Sensor control (on A 312 from 27113, A 314 from 27115, A 316 from 27119, A 316 Ind. from 27384)

8.32.60

copyright by

MJFCIFSS


Service Manual

Electrical system


Description

Step


A3 A 125 A 126


Operator's cab, back Left bracket Right bracket

A 127


A 1017

Printed circuit board/quick change adapter

8 26/34 4/10/13/ 21a/21b/ 24/33/34/ 36/38/40/ 41 1a/1b/1c/ 2/3 38

B1 B2 B3 B7 B8 B12 B16 B19L B19R B21

Transducer/fuel level - with plug Temperature sensor / motor coolant Transducer / motor coolant - with plug Vacuum switch / air filter Switch / hydraulic oil temperature Transducer / motor speed Switch / motor oil pressure Sensor transducer / left pilot control unit Sensor transducer / right pilot control unit Pressure switch / overload

17 20 21a 21a 21a 27 21a 28 28 36

B26 B40L B40R B50L B50R B285 B290 B291

Proximity switch / quick-change adapter Proximity switch / pilot control unit, left, travel Proximity switch / pilot control unit, right, travel Loudspeaker, left Loudspeaker, right Transducer hydraulic oil temperature / fan control Proximity switch / kit pedal Proximity switch / kit pedal

38 28 28 8 8 29 34 34

E1 E2 E3 E4 E7 E8 E9 E15 E16 E50

Work light / attachment Front roof light Travel light, left Travel light, right Roof-mounted light Cigarette lighter Beacon Parking light, right Parking light, left Electric cabinet

Attachment Front cab roof Revolving deck, front Revolving deck, front Cab Bracket, rear, right Cab, top Revolving deck, front right Revolving deck, front left Hydraulic tank

E150


5 5 6 6 8 8 37 6 6 1a/1b/1c/ 2/3 5

F_A F_B F_C F_D

Fuse optional Fuse optional Fuse optional Fuse optional

1b 1b 1b 1b

A127, hydraulic tank A127, hydraulic tank A127, hydraulic tank A127, hydraulic tank

_A _A _A _A


MJFCIFSS

Hydraulic tank Distribution board Fuel tank Motor Expansion tank Suction pipe / air filter Hydraulic tank, bottom Flywheel housing Motor housing Left joystick Right joystick Boom cylinder / piston side Quick change adapter Travelling pedal, left Travelling pedal, right Cab, rear left Cab, rear right Hydraulic tank Operators platform Operators platform

Rear cab roof

8.40.1

Electrical system

Service Manual

Item

Description

Step


F_E F_F F_G F_H F_I F_K F_L F_M F_N FRes F20/ F300 F19/ F301 F22/ F302 F303 F304 F305 F306 F307 F308 F309 F310 F311 F314 F315 F316 F317 F318 F319 F320 F321 F322 F323 F324 F326 F327 F328 F329 F330 F331 F332 F336 F337 F338 F339 F343

Fuse optional Fuse optional Fuse optional Fuse optional Fuse optional Fuse optional Fuse optional Fuse optional Fuse optional Fuse, reserve Fuse A127 terminal 30 to terminal 15

_A _A _A _A _A _A _A _A 70 A _A 50A

1b 1b 1b 1b 1b 1b 1b 1b 1a 14 1a

A127, hydraulic tank A127, hydraulic tank A127, hydraulic tank A127, hydraulic tank A127, hydraulic tank A127, hydraulic tank A127, hydraulic tank A127, hydraulic tank A127, hydraulic tank Right bracket A127, hydraulic tank

Fuse A127 K302, R60

70A

2


Fuse A127 terminal 15, terminal 30, B3, S44

7.5A

1b


Fuse A127, Y29 Fuse S1 Fuse E7, E8, P50 Fuse X10 Fuse E16, E17, P6, P7, P50 Fuse E15, E18 Fuse E3 Fuse E4 Fuse M4 Fuse S7 Fuse BST Fuse servo control Fuse servo control Fuse heating / air conditioning, terminal 30 Fuse heating / air conditioning, terminal 15 Fuse X11 Fuse X12 Fuse T1 Fuse E1 Fuse S22 - E2, S22-1 - E150 Fuse S21 - Y24 Fuse X27 Fuse X28 Fuse servo Fuse kits Fuse X29 Fuse A127, M1, Y12 Fuse S61 Fuse support Fuse H9, seat heating Fuse a/c condenser Fuse roof window wiper

7.5A 15A 15A 15A 7.5A 7.5A 7.5A 7.5A 15A 3A 15A 7.5A 7.5A 20A 15A 15A 15A 7.5A 15A 15A 15A 15A 15A 5A 15A 15A 25A 20A 15A 15A 20A 7.5A

3 1a 8 16 6 6 6 6 7 14 23 28 37 30c 30c 16 16 8 5 5 11 16 16 15 24 16 1a 6 35 4 30c 7

A127, hydraulic tank Right bracket, front Right bracket, front Right bracket, front Bracket, rear, right Bracket, rear, right Bracket, rear, right Bracket, rear, right Bracket, rear, right Right bracket, front Right bracket, front Right bracket, front Bracket, rear, right Right bracket, front Right bracket, front Right bracket, front Right bracket, front Right bracket, front Bracket, rear, right Bracket, rear, right Right bracket, front Right bracket, front Right bracket, front Right bracket, front Right bracket, front Right bracket, front Hydraulic tank Right bracket, front Right bracket, front Right bracket, front Right bracket, front Bracket, rear, right

8.40.2


MJFCIFSS

Service Manual

Electrical system

Item

Description

Step


G1 G2


1a 1a



Indicator light / motor oil pressure Horn Warning buzzer Indicator light / pre-heating Indicator light / charging Indicator light / air filter contamination Indicator light / hydraulic oil temperature Indicator light / overload warning (kit) Indicator light / coolant level Indicator light / quick-change adapter Warning buzzer Indicator light / motor overheating Indicator light / sorting grapple Indicator light / error BST Indicator lamp / delta P

21a 4 21b 2 21b 21a 21a 36 21a 38 13 21a 34 26 24

Right bracket Below operator's platform Right bracket Right bracket Right bracket Right bracket Right bracket Right bracket Right bracket Right bracket Right bracket Right bracket Right bracket A125, left bracket Right bracket

K_A K_B K_C K_D K_E K16-1 K16-2 K288 K302 K364

Relay, optional Relay, optional Relay, optional Relay, optional Relay, optional Relay, terminal 50 Relay, disconnected Relay, terminal 15 Relay / pre-heating Relay to A1017

1c 1c 1c 1c 1c 1a 1a 3 2 38

K370 K375 K386 K393 K403 K405 K414

Relay / fine control, grapple rotation Relay / kit - quantity Relay / safety switch S7 Relay / air-spring seat Relay / heating Relay / heating Relay / windscreen wiper interval

15 34 14 31 30a 30b 7

A127, hydraulic tank A127, hydraulic tank A127, hydraulic tank A127, hydraulic tank A127, hydraulic tank A127, hydraulic tank A127, hydraulic tank A127, hydraulic tank A127, hydraulic tank Quick-change adapter board Right bracket Operator's platform, back Right bracket Operators platform Operator's platform, rear Operator's platform, rear Operator's platform, rear

M1 M3 M4 M60 M65 M68 M70 M71 M72 M73


1a 7 7 7 30b 7 31 30a 30a 30a

Diesel engine Operator's cab, rear Windscreen Cab, top Operator's platform, rear Cab, top Operators platform Operator's platform, rear Operator's platform, rear Operator's platform, rear


MJFCIFSS

8.40.3

Electrical system

Service Manual

Item

Description

Step


P1 P2 P3 P5 P6 P7 P50


26 26 26 19 20 17 18

Left bracket Left bracket Left bracket Left bracket, bottom Right bracket Right bracket Right bracket

R60 R75 R76 R78-1 R78-2 RS232

Pin-type glow plug, with plug Potentiometer / speed Potentiometer / fine adjustment Seat heating Seat heating Laptop interface

2 22 24 32 32 26

Diesel engine Right bracket Right bracket Operators platform Operators platform Left bracket

S1 S1 S4 S5L S5M S5R S7 S8 S9 S11 S14 S17 S18 S19 S20 S21 S22 S22-1 S46 S47 S61 S92 S93 S218 S241 S283 S284 S360 S382 S388 S389 S398

Ignition switch Code switch A125 Switch / horn H9 Push button/turning grapple to the left, Y22 Push button, centre (no function) Push button / turning grapple to the right, Y23 Safety switch Switch / beacon Battery main switch Switch / windscreen washer system M3 Switch / windscreen wipers M4 Switch / slewing gear brake Y7 Switch / overload warning system (optional) Switch / grapple rotator Y22, Y23 Switch / sensor control Switch / rapid gear Y24 Switch / work light E1 / roof light E2 Switch / auxiliary headlight / roof light Switch / magnet system (optional) Switch / bucket quick-change adapter (optional) Switch / lighting installation Potentiometer / air distribution Potentiometer / heating / air condition Switch / roof window wiper (optional) Switch / accessory kit AHS 11 / AHS 12 (optional) Switch / windscreen wiper release Switch / four-step blower Push button / muting overload buzzer (optional) Switch / fine adjustment ON / OFF Switch / air-spring seat Switch / seat heating Reversing switch / air distribution

1a 26 4 25 25 25 14 37 42 7 7 15 36 25 28 11 5 5 41 38 6 30a 30a 7 34 7 30b 38 24 31 32 30a

Right bracket Left bracket Cab floor plate Left pilot control unit Left pilot control unit Left pilot control unit Left bracket Right bracket, rear Battery compartment Right bracket, rear Right bracket, rear Right bracket Right bracket Right bracket Right bracket Right bracket Right bracket, rear Right bracket, rear Right bracket Right bracket Right bracket, rear Right bracket Right bracket Right bracket, rear Right bracket, rear Windscreen, bottom Right bracket Right bracket Right pilot control unit Operator seat Operator seat Right bracket

8.40.4


MJFCIFSS

Service Manual

Electrical system

Item

Description

Step


S422

Switch / mute switch for radio

8

Right bracket

T1


8

Right bracket

U16


Right bracket

V155 V156-1 V156-2 V156-4

Blocking diode / oscillating axle Blocking diode H307 - BST Blocking diode H311 - S75 Diode / input quantity

2/20/2629/34/41 33 24 33 34


X10 X11 X12 X27 X28 X29 X65 X66 X67-1 X67-2 X90 X196 X197 X230 X262 X262-1 X262-3 X262-4 X262-5 X262-6 X304 X404 X406 X407 X410 X411 X412 X413 X550 X771 X834 X835 X836 X837 X838 X838-1 X838-2

Plug connection distribution board / 2-pin Plug connection distribution board / 2-pin Plug connection distribution board / 2-pin Plug connection distribution board / 2-pin Plug connection distribution board / 2-pin Plug connection distribution board / 2-pin Plug connection on voltage transformer / 2-pin Plug connection on voltage transformer / 2-pin Plug connection A3 power supply / 8-pin Plug connection A3 power supply / 8-pin Plug connection / heating fan motor Plug connection B40 / 3-pin Plug connection / 3-pin Plug connection distribution board / 3-pin Plug connection distribution board / 8-pin Plug connection / wire harness quick-change adapter / 8-pin Plug connection wire harness quick-change adapter / 8-pin Plug connection wire harness quick-change adapter / 2-pin Plug connection wire harness quick-change adapter / 2-pin Plug connection wire harness quick-change adapter / 3-pin Plug connection wire harness, console / 6-pin Plug connection work headlight / 4-pin Plug connection transducer fuel reserve / 3-pin Plug connection wire harness revolving deck / 2-pin Plug connection distribution board / 2-pin Plug connection distribution board / 4-pin Plug connection distribution board / 2-pin Plug connection distribution board / 4-pin Plug connection switch S32 / 6-pin Plug connection distribution board / 5-pin Plug connection to A 125 / 2-pin Plug connection to A 125 / 2-pin Plug connection to A 125 / 4-pin Plug connection to A 125 / 8-pin Plug connection to A 125 / 6-pin Plug connection to A 125 / 9-pin Plug connection to A 125 / 9-pin

16 16 16 16 16 16 8 8 8 8 30b 28 33 10/13 38 38 38 38 38 38 35 5 17 36 38 38 38 38 4 35 26 26 26 26/34 26 26 26

Right bracket Right bracket Right bracket Right bracket Right bracket Right bracket Right bracket Right bracket Operator's platform, left Operator's platform, left Operators platform Travelling pedal Travelling pedal Right bracket Right bracket Bearing block Stick Quick change adapter Quick change adapter Quick change adapter Right bracket Revolving deck Revolving deck Revolving deck Right bracket Right bracket Right bracket Right bracket Steering column Right bracket Left bracket Left bracket Left bracket Left bracket Left bracket Left bracket Left bracket


MJFCIFSS

8.40.5

Electrical system

Service Manual

Item

Description

Step


X838-3 X839 X842-1 X842-2 X842-3 X856

Plug connection to A 125 / CAN bus / 2-pin Screw terminal on A125 / 3-pin Plug connection air-conditioning / 15-pin Plug connection console, ignition switch / 2-pin Plug connection blocking diode / 2-pin Plug connection to BST excavator control / 40-pin

Left bracket Left bracket Right bracket Right bracket Right bracket Right bracket

X857


X859 X860 X861 X862 X863 X902 X924-1 X924-2 X950

Plug connection / 21-pin Plug connection / 6-pin Plug connection / 6-pin Plug connection / 6-pin Plug connection / 15-pin Plug connection / 9-pin Plug connection B290 / 3-pin Plug connection B291 / 3-pin Plug connection console display autocheck / 21-pin

X951


X952

Plug connection revolving deck - BST excavator control / 21pin

X953

Plug connection revolving deck - distribution board / 21-pin

X954

Plug connection revolving deck - BST excavator control / 21pin Plug connection revolving deck - distribution board / 15-pin

26 34 30c 30c 33 2/20/24/ 26-29/38/ 41 21a/2224/26/28/ 34 30a/30b 30a 30a 30a 30a/30b 4/6/42 34 34 4/10/13/ 21a/24/ 33/36/38/ 40/41 4/10/13/ 21b/34/ 38/40/41 10-13/15/ 25/30c/ 33/34 4-6/9/13/ 17/21a/ 36/42 2/20/22/ 26/27/29 1a/3/4/38/ 39 2/20-24/ 28/34/41/ 43 8/11/12/ 15/20/22/ 25/34/35 18/28/34/ 35/36/38/ 39/41/43 10/24/30c 4/6/9/21a/ 28/33/34 2/6/13/17/ 20/21a/ 21b/24/33

X955 X956


X957


X958


X959 X960

Plug connection fuse distribution board / 21-pin Plug connection operator's platform distribution board / 21pin Plug connection / display distribution board / 21-pin

X961

8.40.6

Right bracket Operator's platform, rear Operator's platform, rear Operator's platform, rear Operator's platform, rear Operator's platform, rear Basic boom bearing block Below operator's platform Below operator's platform Right bracket

Right bracket Right bracket Right bracket Right bracket Right bracket Right bracket Right bracket Right bracket Right bracket Right bracket Right bracket


MJFCIFSS

Service Manual

Electrical system

Item

Description

Step


X962


Right bracket

X963


X964


X965 X966


4/10/13/ 14/21b/ 34/38/40/ 41 6/8/9/11/ 13/14/16/ 23/24/28/ 35 1a/3/4/13/ 15/28/33/ 43 26/34

X967 X967-1 X967-2 X968-1 X968-2 X971 X972 X973 X974-1 X974-2 X974-3 X974-4 X1046 X1047 X1048 X1049 X1115 X1116 Y3 Y7 Y12 Y20 Y22 Y23 Y24 Y28-1 Y28-2 Y29 Y50 Y51 Y268 Y299 Y352

Right bracket


Plug connection display distribution board / 21-pin Plug connection wire harness connection / 1-pin Plug connection wire harness connection / 1-pin Plug connection quantity 2 / 1-pin Plug connection quantity 3 / 1-pin Plug connection seat adjustment / 2-pin Plug connection seat heating / 2-pin Power socket, 12V Plug connection blocking diode / 2-pin Plug connection blocking diode / 2-pin Plug connection blocking diode / 2-pin Plug connection blocking diode / 2-pin Plug connection / 12-pin Plug connection B19L / 3-pin Plug connection / 12-pin Plug connection B19R / 3-pin Plug connection slewing gear brake / 2-pin Plug connection slewing gear brake / 2-pin

8/14/24/ 25/28/32/ 34/43 5/6/8/37 45 43 34 34 31 32 8 24 33 7 34 24,25 28 10 28 15 15

Right bracket Operator's platform, rear Operator's platform, rear Right bracket Right bracket Operators platform Operators platform Left bracket Right bracket Right bracket Cab, right Cab, right Left bracket Left pilot control unit Right pilot control unit Right pilot control unit Below operator's platform Right bracket

Solenoid valve / pilot pressure Solenoid valve / slewing gear brake Solenoid valve / excess fuel for starting Magnetic valve / a/c compressor Solenoid valve / grapple rotator Solenoid valve / grapple rotator Solenoid valve / fast travel Solenoid valve / quick change adapter Solenoid valve / quick change adapter Solenoid valve / engine shut-down Proportional solenoid valve / power control Proportional solenoid valve / flow limitation Solenoid valve / flow reduction, AHS Solenoid valve / flow reduction, AHS Proportional solenoid valve / fan control

15 15 1a 30c 25 25 11 38 38 3 26 26 34 34 29

Control oil unit Control oil unit Regulator / motor Diesel engine Control valve block Control valve block Control oil unit Quick change adapter Quick change adapter Regulating rod / motor Control oil unit Control oil unit Hydraulic tank Hydraulic tank Fan / radiator


MJFCIFSS

Right bracket

8.40.7

Electrical system

Service Manual

Item

Description

Step


Y358

Proportional solenoid valve / motor speed with plug

22

Control valve block panel

8.40.8


MJFCIFSS

Service Manual

Electrical system



MJFCIFSS

8.40.9

Electrical system

Service Manual


8.40.10


MJFCIFSS

Service Manual

Electrical system



MJFCIFSS

8.40.11

Electrical system

Service Manual

2 Pre-heating

8.40.12


MJFCIFSS

Service Manual

Electrical system

3 Motor shut-down


MJFCIFSS

8.40.13

Electrical system

Service Manual


8.40.14


MJFCIFSS

Service Manual

Electrical system

5 Work headlight


MJFCIFSS

8.40.15

Electrical system

Service Manual


8.40.16


MJFCIFSS

Service Manual

Electrical system



MJFCIFSS

8.40.17

Electrical system

Service Manual


8.40.18


MJFCIFSS

Service Manual

Electrical system

9 Brake light


MJFCIFSS

8.40.19

Electrical system

Service Manual


8.40.20


MJFCIFSS

Service Manual

Electrical system

11 Rapid gear


MJFCIFSS

8.40.21

Electrical system

Service Manual

12 1st gear

8.40.22


MJFCIFSS

Service Manual

Electrical system

13 Parking brake


MJFCIFSS

8.40.23

Electrical system

Service Manual

14 Safety switch

8.40.24


MJFCIFSS

Service Manual

Electrical system

15 Servo swing gear brake


MJFCIFSS

8.40.25

Electrical system

Service Manual


8.40.26


MJFCIFSS

Service Manual

17 Fuel gauge

Electrical system

18 Clock


MJFCIFSS

19 Hour meter

8.40.27

Electrical system

Service Manual


8.40.28


MJFCIFSS

Service Manual

Electrical system



MJFCIFSS

8.40.29

Electrical system

Service Manual


8.40.30


MJFCIFSS

Service Manual

Electrical system

22 Speed adjustment


MJFCIFSS

8.40.31

Electrical system

Service Manual

23 Excavator-control power supply

8.40.32


MJFCIFSS

Service Manual

Electrical system

24 Excavator-control power supply


MJFCIFSS

8.40.33

Electrical system

Service Manual

25 Optional AS I

8.40.34


MJFCIFSS

Service Manual

Electrical system



MJFCIFSS

8.40.35

Electrical system

Service Manual

27 Speed sensor

8.40.36


MJFCIFSS

Service Manual

Electrical system

28 Sensor control up to serial number 21204


MJFCIFSS

8.40.37

Electrical system

Service Manual

28 Sensor control from serial number 21205

8.40.38


MJFCIFSS

Service Manual

Electrical system

29 Fan control


MJFCIFSS

8.40.39

Electrical system

Service Manual

30a Heating

8.40.40


MJFCIFSS

Service Manual

Electrical system

30b Heating


MJFCIFSS

8.40.41

Electrical system

Service Manual

30c Heating

8.40.42


MJFCIFSS

Service Manual

Electrical system



MJFCIFSS

8.40.43

Electrical system

Service Manual


8.40.44


MJFCIFSS

Service Manual

Electrical system



MJFCIFSS

8.40.45

Electrical system

Service Manual


8.40.46


MJFCIFSS

Service Manual

Electrical system



MJFCIFSS

8.40.47

Electrical system

Service Manual


8.40.48


MJFCIFSS

Service Manual

Electrical system

37 Optional beacon


MJFCIFSS

8.40.49

Electrical system

Service Manual


8.40.50


MJFCIFSS

Service Manual

Electrical system



MJFCIFSS

8.40.51

Electrical system

Service Manual

40 Reserve

8.40.52


MJFCIFSS

Service Manual

Electrical system



MJFCIFSS

8.40.53

Electrical system

Service Manual

42 Ground

8.40.54


MJFCIFSS

Service Manual

Electrical system

43 Ground


MJFCIFSS

8.40.55

Electrical system

Service Manual

44 Ground

8.40.56


MJFCIFSS

Service Manual

Electrical system



MJFCIFSS

8.40.57

Electrical system

8.40.58

Service Manual


MJFCIFSS

Service Manual

Electric kits List of kits

Electric kits 8.45A 309 LI 20221-A 311 LI 20222-A 312 LI 12363-A 314 LI 2001-A 316 LI 2001-A 316 LI-IND 2001-R 317 LI 18161-

1 List of kits Step

Kit

Page

50 51 51 51 52-1 52-2 53 54 55-1 55-2 55-3 56 57 58 59 60 61 62 63 64 a - c 65 66-1 66-2 67 68 69 70 71 72 73 74 75 76 77 78-1 78-2 79 80 81 82 83/1

List of electric units Changeover blade - outrigger/individual control AHS 11 AHS 12 AHS 12 & PRIO Refuelling pump Refuelling pump Hydraulic operator's cab elevation (lift frame) Overload warning system Magnet system control Magnet system control Magnet system control Industrial shut-off Radio system Beacon Motor stop (emergency-stop) Immobiliser Travel alarm Quick change adapter Industrial quick change adapter Air-conditioning system Auxiliary headlight equipment Accessory kit changeover valve Accessory kit changeover valve Operating hour meter Back-up alarm Fuel pre-heating Auxiliary heater Power socket Stroke limitation at hydraulic boom adjusting device Individual control (blade) License plate light Central lubrication system Emergency drain Stroke limitation (basic boom) Accessory kit changeover valve Accessory kit changeover valve fine regulation switch Stroke limitation (boom and stick) AS1 actuating device in handle, left and right Kit quantity switchable Inclinometer illumination Krüger stroke limitation part 1

8.45.3 8.45.19 8.45.21 8.45.23 8.45.25 8.45.27 8.45.29 8.45.31 8.45.33 8.45.35 8.45.37 8.45.39 8.45.41 8.45.43 8.45.45 8.45.47 8.45.49 8.45.51 8.45.53 8.45.55 8.45.57 - 8.45.59 8.65.61 8.45.63 8.45.65 8.45.67 8.45.69 8.45.71 8.45.73 8.45.75 8.56.77 8.45.79 8.45.81 8.45.83 8.45.85 8.45.87 8.45.89 8.45.91 8.45.93 8.45.95 8.45.97 8.45.99 8.45.101


MJF C I F S S

8.45.1

Electric kits

Service Manual

List of kits Step

Kit

Page

83/2 84/1 84/2 84/3 85 86/1 86/2 87 88 89 90 91 92 93 94 95 96 97/1 97/2 97/3 98 99 100 101 102 103 104 105 106 107 108 109 110 111

Krüger stroke limitation part 2 Changeover bucket tilt circuit / AHS Changeover bucket tilt circuit / AHS Changeover bucket tilt circuit / AHS Puritech particle filter Mower rake accessory kit Mower rake accessory kit Trailer coupling Joystick control Visual and acoustic back-up warning Bucket cylinder shut-off Special installation kit bore gun carriage Individual blade control Telescopic support blade Actua tion valve spool with pushbutton Timed motor stop Turn grapple with right rocker button Auxiliary indicators Auxiliary lamps Auxiliary lamps Travel direction switch in left handle Horn operation through push buttons Changeover Fuchs control Outrigger monitoring system Reversible fan Automatic oscillating axle locking device Travel alarm new Accessory kit changeover valve, new Accessory kit changeover valve, new Accessory kit changeover valve, new Stroke limitation boom and stick AS1 actuator in left and right handle A 312 - R 317 Changeover bucket tilt circuit A 309 / 311 Kit for reduction of engine speed during work power reduction Slider section operation through push buttons Turn grapple with right rocker button Individual blade / outrigger control Flow distributor emi-automatic central lubrication system Stick cylinder shut-down Automatic shut-down mechanism at the gooseneck boom Puritech particle filter AS1 accessory kit with 3 buttons - handle Xenon light

8.45.103 8.45.105 8.45.107 8.45.109 8.45.111 8.45.113 8.45.115 8.45.117 8.45.119 8.45.121 8.45.123 8.45.125 8.45.127 8.45.129 8.45.131 8.45.133 8.45.135 8.45.137 8.45.139 8.45.141 8.45.143 8.45.145 8.45.147 8.45.149 8.45.151 8.45.153 8.45.155 8.45.157 8.45.159 8.45.161 8.45.163 8.45.165 8.45.167 8.45.169

112 113 114 115 116 117 118 119 120 121

8.45.2

8.45.171 8.45.173 8.45.175 8.45.177 8.45.179 8.45.181 8.45.183 8.45.185 8.45.187 8.45.189


MJF C I F S S

Service Manual

Electric kits Key to accessory kit diagrams

2 Key to accessory kit diagrams Item

Description

Step


A3 A123 A125

Radio Printed circuit board PCB potentiometers

Left console Left console Left console

A126

PCB / autocheck

A127


A133 A1017 A1202

Printed circuit board Printed circuit board / quick-change adapter Printed circuit board / frequency conversion

8*, 57 88 26*,51,81,84, 110,115 21*,54,55,68,81, 89,97,103 1*,51,52,59,60,69,70, 71,95,100 85,119 38*,54,62 67

B10 B19 B21 B26 B33 B36 B40 B50 B51-1 B204 B213 B214 B233 B290 B291 B294 B295 B306

Pressure switch / parking brake Handle sensor / sensor control Pressure switch / overload warning system Proximity switch quick-change adapter Pressure switch pst for AHS section Pressure switch/travel alarm Proximity switch / travel pedal Loudspeaker Piston detector Proximity switch / industrial stick Proximity switch / boom shut-down Proximity switch / boom shut-down Proximity switch / bucket cylinder movement Proximity switch / adjusting pedal left Proximity switch / adjusting pedal, right Pressure switch a/c compressor Heating thermostat Particle filter temperature sensor

13*,68 25*, 120 36*,54,118 38*,62 84,110 61,104 28*,51,81 8*,57 75 39*,56,117 79,108 72,77,79,108 90 34*,51,81,100,101 34*,51,81 64b 64b 85,119

HBGV block Left pilot control unit Boom cylinder Quick change adapt. head Near control valve block Operator's platform / front Operator's platform / front Cab Revolving deck, front right Industrial stick Stick Basic boom bearing block At stick Operator's platform / front Operator's platform / front A/c compressor Operator's platform, base Particle filter

5*,16*,65 5*,65 121 121 6*,65,74,97 6*,74,97 37*,58 6,*74,97 6*,74,97 6*,74,97 6*,74,97 6*,74,97 6*,74,97 4*,97 4*,97

Attachment Front cab roof Uppercarriage, front Uppercarriage, front Front cab roof Cab roof Cab roof Revolving deck, front right Revolving deck, front left Revolving deck, rear right Revolving deck, rear left Weight, right Weight, left Revolving deck, front left Weight, left

E1 E2 E2L E2R E3 E4 E9 E15 E16 E17 E18 E19 E20 E21 E22

Work light / attachment Auxiliary headlight / front of roof Work light, front left Work light, front right with plug Headlight uppercarriage left Headlight uppercarriage, right Beacon Parking light, right Parking light, left Rear light, right Tail light, left Brake light, right Brake light, left Indicator light, front left Indicator light, rear left


MJF C I F S S

Right console Hydraulic tank Left console Right console, rear Near fuel tank

8.45.3

Electric kits

Service Manual

Key to accessory kit diagrams Item

Description

Step

E23 E24 E30 E50 E150 E150L E150R E163 E164 E167 E169 E170 E171 E172 E172 E173 E174

Indicator light, front right Indicator light, rear right D5W5 auxiliary heater Power and safety switch cabinet Roof light Working light, rear left Work light, front right with plug License plate light Illumination Beacon for back-up warning Position light, front right in indicator Position light, front left in indicator Outline light, right Outline light, left License plate light Auxiliary indicator, right Auxiliary indicator, left

F20/F300

F319 F320

A127 E15, E18 Fuse A 127 auxiliary heating Fuse A 127 auxiliary heating Fuse A 127 timer, water vent. Fuse A127 refuelling pump Fuse A127 terminal 30 to termin. 15 Fuse Fuse A127, Y29 Fuse A127 S1 Fuse X10 Fuse E16, E17 Fuse E15, E18 Fuse E3 Fuse E4 Fuse S44,E21 - E24 Fuse S7 Fuse sensor control Fuse E9 Fuse heating / air conditioning terminal 30 Fuse heating /air cond. terminal 15 Fuse X11 / X12

F321 F322 F323 F324 F325 F326

Fuse X12 Fuse T1 Fuse E1 Fuse E2, E150 Fuse S16, S263 Fuse Y24, Y55, Y371, QC adapter

15.0 A 15.0 A 10.0 A 10.0 A 7.5 A 15.0 A

F20 F34 F35 F36 F216 F300 F301 F303 F304 F306 F307 F308 F309 F310 F312 F314 F316 F317 F318

8.45.4


4*,97 4*,97 70 1to3*,70,85,119 5*,65 121 121 74 80 89 97 97 97 97 74, 97 97

Revolving deck, front right Weight, left Hydraulic tank Hydraulic tank Rear cab roof Uppercarriage, rear Uppercarriage, rear Cap, rear Right console, front Cap, top right Revolving deck, right Revolving deck, left Uppercarriage, right Uppercarriage, left Uppercarriage, rear Uppercarriage, front right Uppercarriage, front left

50.0 A 2.0 A 25.0 A 15.0 A 7.5 A 20.0 A 70.0 A 15.0 A 7.5 A 15.0 A 15.0 A 7.5 A 7.5 A 7.5 A 7.5 A 7.5 A 15.0 A 7.5 A 7.5 A 20.0 A

1a*,95 95 70 70 70 52 1*,59,60 110 3*,59,60,95 1*,57,60 16*,60 6*,74,82,97 6*,74,97 6*,74,97 6*,74,97 4*,97 14*,60,111 28*,51,54,62,81 37*,58 30c*,64c

Left console Left console Near hydraulic tank Near hydraulic tank Near hydraulic tank Near hydraulic tank Near hydraulic tank Right control desk, rear Near hydraulic tank Right console, front Right console, front Right console, rear Right console, rear Right console, rear Right console, rear Right console Right console, front Right console, front Cab Right console, front

3.0 A 15.0 A

30c*,64c 16*,55,61,67,69,75, 83,84,87,91,101,102, 104,116 16*,84, 8*,57 5*,65 5*,65 13*,68,89,95 11*,62,103

Right console, front Right console, front Right console, front Right console, front Right console, rear Right console, rear Right console, front Right console, front A 309 LI - R 317 LI

copyright by

MJF C I F S S

Service Manual


Item

Description

Step

F327 F329 F330 F331

Fuse industrial stick Fuse industrial stick Fuse kits Fuse X29

15.0 A 15.0 A 15.0 A 15.0 A

F332 F336 F337

Fuse A127 M1, Y12 Fuse S61 Fuse kits

25.0 A 20.0 A 15.0 A

F338 F339 F340 F342 F344 F345 F346 F347 F348 F349 F351 F364

Fuse capacitor motors Fuse capacitor motors Fuse A 127 Thermoline Fuse terminal 15 A 127 Fuse terminal 15 A 127 Fuse Xenon roof light Fuse Xenon headlight, left Fuse Xenon headlight, front right Fuse Xenon headlight, rear left Fuse Xenon headlight, rear right Fuse (F_H) Fuse control (F_G)

20.0 A 20.0 A 15.0 A 15.0 A 7.5 A 15.0 A 15.0 A 15.0 A 15.0 A 15.0 A 3A 15.0 A

G1 G2

Alternator battery

H9 H10 H16 H19 H26 H27

Horn Warning buzzer overload warning system Indicator light / overload warning system Indicator light / indicator Indicator light / quick-change adapter Warning buzzer


Back-up alarm travel warning Indicator light / change of direction of fan Indicator light / Fuchs control ON Indicator light / stroke limitation ON Indicator light / forward travel Indicator light / reverse travel Indicator lamp / oscillating axle automatic Buzzer / back-up alarm Indicator light / sorting grapple Indicator light / bypass ON Indicator light / operator's cab Indicator light / operator's cab Warning light/exhaust backpressure Warning buzzer/exhaust backpressure Indicator lamp / oscillating axle locked


16*,63 15*,53,111 24*,51,81,84,98 16*,66,72,77,78, 79,84,86,88,90,91, 94,100,105,106, 108,112,117,118 1*,60 6*,74,97 35*,50,55,56,73, 92,93,114 4*,82,97,99 30c*,64c 69 71 76 121 121 121 121 121 85,119 100 1a*, 67 1a*, 70 4*,97,99 21b*,54 36*,54,118 4*,97 38*,62,63 13*,62,63,72,77, 79,108,111 61,104 102 100 83 10*,68,89 10*,68,89 33*,92,103 68,89 34*,51,84,107,110 79,108 53 53 85,119 85,119 103


MJF C I F S S

Right console, front Right console, front Right console, front Right console, front

Hydraulic tank Right console, front Right console, front Right console, front Right console, front Near hydraulic tank Near hydraulic tank Near hydraulic tank Right control desk, rear Right control desk, rear Right control desk, rear Right control desk, rear Right control desk, rear Near hydraulic tank Printed circuit board A127 Diesel engine Battery box Right console Right console Right control desk Right control desk Right control desk Right console Hydraulic tank, top Right control desk Right control console Right control console Right control desk Right control desk Right console Cap, top left Right control desk Right control desk, centre Right control desk Right control desk Right control console Right control console Right console

8.45.5

Electric kits

Service Manual

Key to accessory kit diagrams Item H315 H322 H323 H324 H328 H329 H343 H344 K1 K2 K30 K33 K63 K229 K250 K251 K261 K288 K333-1 K333-2 K334 K358 K359 K360 K362 K364 K368 K369 K370 K375 K375 K386 K392 K402 K403 K404 K405 K407-1 K407-2 K414 K436 K437 K438 K439 K455 K464 K467

8.45.6

Description

Step

Warning light shut-down bridged Warning light/changeover Indicator light / lateral adjustment Inclinometer illumination Indicator light / shut-down active Indicator light / mower rake operation Warning light / outriggers not retracted Indicator light / flow distributor

Location/arrangement 113,118 84,110 78,105,107 82 90 78,86 101 115

Relay / preliminary shut-off Krüger electronics Relay / shut-off Krüger electronics Relay/refuelling pump control circuit Relay / Thermoline A127 Relay / direction indicator Relay / changeover (K_B) Relay / oscillating axle automatic Relay / parking brake Relay / solen. valve actuation in case of bypass Relay / terminal 15 at A127 Relay / boom shut-off Relay / boom shut-off Relay / boom shut-off Relay / heating ON A127 Relay / water circuit ON A127 Relay / heater fan ON A127 Relay fan control Relay / quick change valves A1017 Relay / terminal 15 A127 Relay / terminal 15 A127 Relay / fine regulation, grapple Relay / changeover hammer / pile driver Relay / signal flow reduction AHS Relay / safety switch Relay for industrial shut-off Relay / heating Relay / heating Relay / capacitor motors Relay / blower switch Relay / travel warning mute Time relay / traction-delayed travel warning 10s. Relay / boom shut-off Step relay (autom. reset) Relay / signal flow reduction drilling slide Step relay / mower rake operation Relay / drop-out delayed Relay/changeover switch Relay / oscillating axle release Step relay / flow distributor operation

83 83 52 69 4*,97 79,95,100 33*,103 13*,68,89,95 13*,68,83,95 3*,59,95 72,77 72,77 72,77 70,87 70,87 70,87 89 38*,62 1*,60 1*,60 15*,66,78,105,111 34*,51,81,84,107,110 84,91,115 14*,60,111 56 64b 30a*,64a 64b 30b*,64b 61,104 61,104 7*,79,108 91 91 78,86 95 106 103 115

Right console Right control console Right console Right control console Right control console Right console Right control console Right control console in control box / Krüger in control box / Krüger Near fuel tank Near hydraulic tank Near hydraulic tank A127 Right console, rear Right console, rear Right console, rear Near hydraulic tank Distribution board Distribution board Distribution board Near hydraulic tank Near hydraulic tank Near hydraulic tank Left console Right console, rear Near hydraulic tank Near hydraulic tank Right console, rear Right console, rear Right console, rear Right console, rear Right console, rear Operator's platform, rear Operator's platform, rear Operator's platform, rear Operator's platform, rear Right console, rear Right console, rear Distribution board Distribution board Distribution board Distribution board Distribution board Distribution board Distribution board Distribution board A 309 LI - R 317 LI

copyright by

MJF C I F S S

Service Manual


Item

Description

Step


K471 K473 KT20 KT21

Relay inversion signal servo OFF Relay shutdown attachment Time relay / fan afterrun Time relay / direction of rotation switching

M1 M6 M52 M53 M71 M72 M73 M74-1 M74-2 M74-3

Starter Refuelling pump Coolant pump Fuel metering pump Servo motor / water valve Servo motor / air distribution Servo motor / air distribution Fan motor / condenser Fan motor / condenser Fan motor / condenser

1a*/60 52 70 87 30a*, 64a 30a*, 64a 30a*, 64a 64b 64b 64b

Engine Near fuel tank Near heating Near heating Operator's platform, rear Operator's platform, rear Operator's platform, rear Condenser blower Condenser blower Condenser blower

P1 P5-1 P5-2 P5-3 P6

Potentiometer / flow reduction A125 Operating hour meter / idle run Operating hour meter / partial load Operating hour meter / full load Display / motor temperature

26*, 51,84 67 67 67 82

Left console, bottom Near fuel tank Near fuel tank Near fuel tank Right control desk

R8 R70 R71

Thermoline rotary potentiometer rotary potentiometer

S1 S4 S5L S5R S5M S6L

Ignition switch Horn switch Push button / turning grapple to the left, Y22 Push button / turning grapple to the right, Y23 Push button, centre, optional Push button / magnet unit, grapple operation, joystick control, horn activation, oscillating axle release Push button / magnet unit, grapple operation, joystick control, horn activation Push button / bridging of horn shut-off Safety switch Switch / beacon Battery main switch Parking brake switch Switch/overload warning system Switch / grapple rotator Y22, Y23

S6R S6R S7 S8 S9 S16 S18 S19 S22 S22-1 S25 S32

111 118 102 102

69 83 83

Auxiliary headlight switch Auxiliary roof headlight switch Switch/refuelling pump ON Steering column switch

1a*, 57,60 4*,97,99 25*,62,80,96,109,120 25*,62,80,96,109,120 120 55,61,80,88,94,99, 103,104,109,112,113 , 115 55,61,80,88,94,99, 103,104,109,112, 113,115 79 14*,60,111 37*,58 42*,70 13*,62 36*,54,62,118 25*,80,96,109,113, 120 5*,65 5*,65 52 97,99


MJF C I F S S

Distribution board Distribution board Near weight Near weight

Near fuel tank At basic boom At boom Right control desk Cab floor plate Left pilot control unit Left pilot control unit Left pilot control unit Right pilot control unit Right pilot control unit Right pilot control unit Left console, bottom Keyboard of right console Battery compartment Right control desk Keyboard of right console Keyboard of right console Keyboard of right console Keyboard of right console Near fuel tank Steering column

8.45.7

Electric kits

Service Manual


Description

Step

S35 S44 S45 S46 S47 S47-1 S47-2 S59 S61 S74 S75 S78 S84-1 S92 S93 S124 S160 S204 S205 S206 S207 S213 S216 S232 S241 S247 S249 S263 S269 S270 S272

Switch servo Hazard warning lights switch Switch/priority Switch/control magnet system Key switch/activate quick change adapter Key switch/activate quick change adapter Key/activate quick change adapter Switch/refuelling pump OFF Switch / lighting installation Code key for immobiliser Switch/oscillating axle locking device Push button / emergency drain Push button / central lubrication with plug Potentiometer / air distribution Rotary switch / air-conditioning, heating Switch / activation of mower rack operation Switch / change of direction of rotation Switch/front left outrigger support Switch/front right outrigger support Switch/rear left outrigger support Switch/rear right outrigger support Switch/fuel pre-heating Switch/industrial shut-down Digital timer/auxiliary heating Switch AHS 11 / AHS 12 Key switch / Fuchs control Key switch / boom shut-off with plug Switch / travelling direction Switch in slip ring Switch in slip ring Slip-ring case

S284 S291 S291 S313 S318 S321 S335 S335-1 S335-2 S341 S343 S356 S360 S361 S379 S380

Switch / blower (4 speeds) Push button / bridging boom shut-off with plug Push button / bridging boom shut-off with plug Switch / emergency-stop Switch a/c system Switch / activate joystick steering Switch / changeover blade - outrigger Switch / front blade Switch / rear blade Float switch / refuelling pump Switch / individual control, back Switch / changeover valve with plug Switch / acknowledgement QC buzzer Switch / hydr. operator's cab elevation Switch/releasing key kits Switch / mower rake activation

8.45.8

15*,53,111 4*,97 51,81 41*,55 38*,62 63 63 52 6*,74,82,97 60 33*,103 76 75,116 30a*,64a 30a*,64a 78,86,113 102 35*,50 35*,50 35*,50 35*,50 69 39*,56,117 70 51,81,84,107,110 100 72,79,83,108,118 10*,68,89,98 68,89 68,89 35*,50,73,92,93, 101,114 30b*,64b 72,77,108 79,83 77 30b*,64b 88 35*,73,92,114 73 73 52 92,114 66,78,105,106,107 38*,62 53 94,101,112 78,86

Location/arrangement Keyboard of right console Right console Right control desk Right control desk Right control desk Right control desk Right control desk Near fuel tank Right console, rear Right console Right console Right console Right control desk Right control desk Right control desk Right control desk Right control desk Right control desk Right control desk Right control desk Right control desk Right control desk Right control desk left control desk Right control desk Right control desk Right control desk, rear Right pilot control unit rotary connection rotary connection Undercarriage Right control desk Right control desk Right control console Right control desk, rear Right control desk Right control desk Right control desk Right control desk Right control desk Near fuel tank Right control desk Right console, rear Right control desk Right console, rear Right console Right control desk


MJF C I F S S

Service Manual


Item S382 S384 S398 S405 S406 S419 S423 S424 S439L S439R S442 S443L S443R S451 S452 S457 S464

Description

Step

Switch / fine regulation OFF


24*,78,79,96,98

Switch / operating hour meter Reversing switch / heating Switch / changeover Switch / kit quantity changeover Switch / trailer coupling Key switch / bridging shut-off Push button / continuous operation AHS Push button / support pilot control unit Push button / support pilot control unit Switch / changeover blade UP/DOWN - ON/ OFF Push button / telescope blade, left rear Push button / telescope blade, right rear Bypass switch stick cylinder Switch / rotating grapple with rocker button Rocker button / magnet unit ON/OFF Switch activation / flow distributor

82 30a*,64a 84,110 81 87 90 91 92 92,114 93

Left pilot control unit or right control desk Near fuel tank Right control desk Right console Right console Right console Right console Right console Pilot control valve: support Pilot control valve: support Right console

93 93 96,113 96 55 115

Pilot control valve: support Pilot control valve: support In handle, right Right console Right console Right console

T1 T4

Voltage transformer / radio Voltage transformer / 12V / 20 A

8*,57 71

U4-1 U7 U13 U16

Central lubrication system Switching system / magnet unit Electronic box / auto-scan BST excavator control system

75,116 55 60 2*,20to29*,51,55,81, 84,110,111,115

V11 V35 V154 V155 V156-2 V156-3 V156-4

LED on A1017 Diode on A126 Blocking diode / QC warning blocking diode blocking diode blocking diode Blocking diode A125

V163-1 V163-2 V172-1 V172-2 V166 V168 V169 V173 V177 V178-1 V178-2 V179

Blocking diode / QC signal Boom shut-off signal Blocking diode / signal Y428 - Y217 Blocking diode / signal Y428 - Y218 blocking diode decay diode blocking diode Blocking diode BTKP Blocking diode signal flow distributor Blocking diode signal Servo-S7 Blocking diode signal Servo-S7 Blocking diode signal actuation Y465

62 55 63 33*,103 33*,103 62 34*,51,81,84, 110,115 72,77 72,77 93 93 81 59,95 84 52 115 111 111 118


MJF C I F S S

Left console Near fuel tank Near fuel tank Operator's cab, front Right console, front Right console, rear

Right console, rear Right console Right console, front Left console Left console Right console, rear A125 printed circuit board Right console Right console Right console Right console Right console A 127 A 125 Near fuel tank Right console Right console Right console Right console

8.45.9

Electric kits

Service Manual


Description

Step

V180 V181 V182

Blocking diode signal actuation H16 Amplifier actuation grapple turning left Amplifier actuation grapple turning right

X10 X11

Plug connection distribution board / 2-pin Plug connection on distribution board / 2-pin

X12 X15 X15-2 X20 X27 X29

Plug connection on distribution board / 2-pin Plug connection, 3-pin Plug connection, 3-pin Terminal for kit / 2-pin Plug connection, 2-pin Plug connection distribution board / 2-pin

X65 X66 X67-1 X67-2 X74

Plug connection T1 / 2-pin Plug connection T1 / 2-pin Plug connection A3 power supply / 8-pin Plug connection loudspeaker / 8-pin Plug connection S6 / 3-pin

X74-1 X95 X98 X99 X100 X101 X133-1 X143-1 X204 X206 X207 X217 X230 X262 X262-1 X296 X297 X301

Plug connection magnet unit CS / 1-pin Plug connection to S232, 4-pin Plug connection to M53, 2-pin Plug connection to M52 / 2-pin Plug connection to M52 / 2-pin Plug connection to M52 / 8-pin Plug connection to B51-1 / 2-pin Plug connection to U4-1 / 4-pin Plug connection to buzzer / 2-pin Plug connection to B36, 2-pin Plug connection to B36, 2-pin Plug connection magnet unit CS / 2-pin Plug connection on A1100, 3-pin Plug connection to quick change adapter, 8-pin Plug connection on bearing block, 8-pin Plug connection left handle / 1-pin Plug connection left handle / 1-pin Plug connection on slip ring, 12-pin

X304 X312 X313 X314 X324-1 X324-2

Plug con. to S204, S205, S206, S207, 6-pin Plug connection on slip ring, 12-pin Plug connection on slip ring, 12-pin Plug connection to electr. buzzer / 2-pin Plug connection, 2-pin Plug connection, 2-pin

8.45.10

Location/arrangement 118 120 120


16*,60 16*,55,61,67,69,75, 83,87,91,101,104, 116 16*,84 88 62,80,96,109,113 1b*,85,119 16*,63 16*,66,72,77,78,79, 84,86,88,90,91,94, 100,105,106,108, 110, 112,117,118 8*,57 8*,57 8*,57 8*,57 55,61,79,80,96,99, 103,108,109,112, 113,115 55 70 70 70 70 70 75 75,116 61,104 61,104 61,104 55 10*,13*,98 38*,63 38*,62,63 80,109 80,109 35*,50,73,87,92,93, 101,114 35*,50,73,92,93,114 68,89 68,89 68,89 61,68,89,104 61,104

Right console Right console Right console Right joystick Left console Printed circuit board A127 Right console, rear Right console, rear

Left console Left console Cab Cab Right console Right console Left console Auxiliary heating Auxiliary heating Auxiliary heating Auxiliary heating Revolving deck, front Near fuel tank Left console Right console Right console Operator's cab, front Left console Attachment Bearing block Left pilot control unit Right pilot control unit Rotary connection Right console, rear Rotary connection Rotary connection Revolving deck Revolving deck Revolving deck


MJF C I F S S

Service Manual


Item X327 X342 X358 X358-1

Description

Step

X550 X689 X738 X771 X798 X821 X822 X829 X837

Plug connection, 3-pin Plug connection to travel selection switch, 3-pin Plug connection, 2-pin Plug connection under operator's platform / 2pin Plug connection, 2-pin Plug connection magnet unit CS / 2-pin Plug connection, 5-pin Plug connection to Y354 and Y355 / 2-pin Plug connection, 5-pin Plug connection to R70, 4-pin Plug connection to R70, 4-pin Plug connection to R71, 4-pin Plug connection to R71, 4-pin Plug connection to R71, 4-pin Plug connection, 4-pin Plug connection to revolving deck CS / 2-pin Plug connection to revolving deck CS / 2-pin Plug connection power supply A1017 / 2-pin Plug connection A1017 / 4-pin Plug connection A1017 / 2-pin Plug connection to Y307 / 3-pin Plug connection, 4-pin Plug connection to S321 / 3-pin Plug connection to A123 / 5-pin Plug connection to S47 / 5-pin Plug connection / warning system blocking diode Plug connection Plug connection blocking diodes / 6-pin Plug connection Thermoline Plug connection, 5-pin Plug connection blocking diode / 3-pin Plug connection distribution board / 21-pin Plug connection distribution board / 21-pin Plug connection distribution board / 21-pin Plug connection A125 / 8-pin

X839

Plug connection / screw terminal on A125 / 3-pin

X358-2 X370 X374 X378 X379 X381 X358-1 X382 X382-1 X382-2 X404 X407 X408 X410 X411 X412 X412 X413 X413 X414 X446 X447

X842-1 X842-2 X842-3 X856

Plug connection, 15-pin Plug connection, 2-pin Plug connection blocking diode / 2-pin Plug connection BST wire harness / 40-pin

X857

Plug connection: BST excavator control / 24-pin

X859 X860

Plug connection, 21-pin Plug connection, 6-pin

Location/arrangement 39*,56,117 68,89 66 78,105,106

78,105,106 55 83 83 83 83 83 83 83 83 5*,65 36*,54,94,112,118 94,112 38*,62,94 38*,62 38*,62 88 38*,62,63, 88 88 63 63 4*,97,99 70,83 69 35*,50,73,93, 101 62 53 53 53 26*,51,81,84, 110,115 34*,51,81,84, 110,115 30c*,64c 64c,70 103 2*,20to29*,55,84,110 ,115 21to29*,51,81,84, 110,115 30*,64a/b 30a*,64a


MJF C I F S S

Industrial stick Right console Revolving deck Operator's platform Fuel tank Near attachment Right control console, rear Right control console, rear Right control console, rear At basic boom Near attachment At basic boom Near attachment Near attachment Attachment Right control console Right control console Right console, rear Right console, rear Right console, rear Right console, rear Right console, rear Right console, rear Right console, rear Right console Right console Right console Right console Near fuel tank Left console Right console, rear Right console, front Right console, front Right console, rear Left console, bottom Left console, bottom Right console Right console Right console Right console Right console Operator's platform, rear Operator's platform, rear

8.45.11

Electric kits

Service Manual

Key to accessory kit diagrams Item X861 X862 X863 X864 X891-1 X891-2 X902 X909 X914 X915 X924-2 X950

Description

Step


Plug connection, 6-pin Plug connection, 6-pin Plug connection, 15-pin Plug connection, 4-pin Plug connection at valve Y360 / 2-pin Plug connection to stick, 2-pin Plug connection, 6-pin Plug connection to H300 warning light / 3-pin Plug connection to wire harness P5 / 6-pin Plug connection on A1202 / 16-pin Plug connection to B291, 3-pin Plug connection autocheck / 21-pin

30a*,64a 30a*,64a 30*,64a/b 64c 63 63 74 100 67 67 34*,51,81 4*,10*,13*,21a*,54,6 2,68,89,97,103 4*,10*,13*,21b*,51,5 4, 55,62,68,81,89,98 10 to 13*,51,64c,68,80,84, 89,95,96,103,107,10 9,110, 111,113, 120 1until 6*,54,74,82,97, 110,118 110 1*to4*,56,60,62,63, 64c,67,74,92,97,114 2*,20until24*,55,56,8 1, 98, 111 8*,11*,50,51,62,73, 80,81,84,92,93,96, 107,109,110,113, 114, 115,120 18*,28*,50, 51,54,55,56,62,73,81 ,84,92,93,107, 110,114, 118 10*;24*,30*,64c,68,8 9,92,98,103,111, 114 4*,6*,9*,51, 74,81,97,99 2*,6*,13*,62,74,82,97 ,103 4*,10*,13*,51,55,68, 81,89,95,97,98,111 6*,8*,9*, 50,51,54,55,56,60 to 63, 66 to 69, 72 to 75,77, 78,79, 81 to 84, 86,87,88, 90 to 95,97,98,100, 101,104,105,106, 108,110,111,112, 114, 116,117,118

Operator's platform, rear Operator's platform, rear Operator's platform, rear Operator's platform, rear Attachment Attachment Lighting, front right Left console Near fuel tank Near fuel tank Auxiliary pedal, right Right console

X951

Plug connection autocheck / 21-pin

X952

Plug connection distribution board / 21-pin

X953


X954 X955

Plug connection distribution board / 21-pin Plug connection distribution board / 15-pin

X956


X957


X958


X959


X960


X961


X962


X963


8.45.12

Right console Right console, rear

Right console, rear Right console, rear Right console, rear Right console, rear Right console, rear

Right console, rear



MJF C I F S S

Service Manual


Item

Description

Step


X964


Right console, rear

X965 X966

Plug connection BST- CS A125 / 21-pin Plug connection A125 wire harness / 21-pin

X967


1*,3*,4*,60,64c,97,99 103,111 26*,34*,84,110, 115 8*,14*,51,57,60,62, 80,81,84,96,98,109, 111,113,115,120 5*,6*,57,58, 65,74,82,97 34*,81,84,110,115 34*,81,84,110,115 81 8*,57 103 34*,81,84,110, 115 84 69 69 78,105,106 70 72, 77,79,108 72, 77,79,108 72, 77,79,108 79,108 79,108 79,108 71 89 76 76 76 76 116 59,95 59,95 83 83 83 84,110 84,110 85,119 85,119 24*,25*,55,78,80, 98,107,109,120 80,98,109 10*,55,61,80,98,98, 103,104,112,115 55,98 78,86 78,86

X968-1 X968-2 X968-3 X973 X974-2 X974-4 X974-5 X979 X982 X983 X987 X988-1 X988-2 X988-3 X988-4 X988-5 X988-6 X989 X993 X998 X999-1 X999-2 X999-3 X998 X1006 X1011 X1017 X1018 X1019 X1028 X1029 X1040 X1041 X1046

Plug connection A125 CS / 1-pin Plug connection A125 CS / 1-pin Plug connection A125 CS / 1-pin Power socket, 12V Plug connection blocking diode / 2-pin Plug connection A125 CS / 2-pin Plug connection adapter CS / 1-pin Plug connection switch CS / 2-pin Plug connection switch CS / 3-pin Plug connection distribution board / 3-pin Plug connection auxiliary heating CS / 8-pin Plug connection blocking diodes / 8-pin Plug connection blocking diodes / 4-pin Plug connection blocking diodes / 3-pin Plug connection blocking diodes / 6-pin Plug connection blocking diodes / 6-pin Plug connection blocking diodes / 4-pin Socket 12V / 20 A / 12-pin Plug connection beacon / 2-pin Plug connection, 2-pin Plug connection, 1-pin Plug connection, 2-pin Plug connection, A 127 /1-pin Plug connection, 3-pin Plug terminal / 1-pin Plug connection decay diode / 3-pin Plug connection to Y237/Y238 / 4-pin Plug connection to Y237/Y238 / 2-pin Plug connection to Y354/Y355 / 4-pin Plug connection to S405 and H322 / 4-pin Plug connection solenoid valves / 4-pin Plug connection to display unit / 3-pin Plug connection for temperature sensor / 2-pin Plug connection, 12-pin

X1046-1 X1048

Plug handle extension / 6-pin Plug connection, 12-pin

X1046-1 X1050 X1051

Plug to handle switch / 3-pin Plug connection adapter switch CS / 3-pin Plug connection switch CS / 3-pin


MJF C I F S S

Right console, rear Right console, rear Right console, rear Left console, bottom Left console, bottom Left console, bottom Left console Left console, bottom Left console, bottom A125 Revolving deck Revolving deck Right console, rear Near operator's cab Right console Right console Right console Right console Right console Right console Left console Uppercarriage, rear Left console Left console Left console Near hydraulic tank Below operator's platform Near A127 Near A127 Near hydraulic tank Near hydraulic tank Near hydraulic tank Right control console, rear Right control console, rear Electric box E50 Electric box E50 Left console Right handle Right handle Right handle Right handle Right handle

8.45.13

Electric kits

Service Manual


Description

X1052 X1053 X1060 X1061 X1062 X1070-1 X1070-2 X1104 X1106 X1117 X1132 X1138 X1179 X1186 X1190 X1198 X1210 X1213 X1215 X1218 X1224 X1226 X1234 X1235 X1240 X1241

Plug connection mower rake drive CS / 4-pin Plug connection slip ring CS / 1-pin Plug connection switch / 3-pin Plug connection, 8-pin Plug connection, 3-pin Plug connection solenoid valve / 2-pin Plug connection solenoid valve / 2-pin Plug connection, 1-pin Plug connection power supply / 4-pin Plug connection 4-wheel steering / 6-pin Plug connection extension bridging / 3-pin Plug connection A127 - refuelling pump / 2-pin Plug connection to display unit / 3-pin Plug connection, 3-pin Plug connection float switch / 2-pin Plug connection for temperature sensor / 2-pin Plug connection delta p / 3-pin Plug connection decay diode / 2-pin Plug connection warning light / 2-pin Plug connection warning light / 2-pin Plug connection pressure switch / 3-pin Plug connection solenoid valves / 2-pin Plug connection adapter switch CS / 6-pin Plug connection magnet unit CS / 4-pin Plug connection adapter switch CS / 4-pin Plug connection switch CS flow distributor / 2pin Plug connection CS solenoid valve / 2-pin Plug connection switch CS flow distributor / 1pin Plug connection CS diode / 2-pin Plug connection solenoid valves / 4-pin Plug connection solenoid valves / 2-pin Plug connection switch CS / 2-pin Plug connection blocking diode / 2-pin Plug connection solenoid valve / 2-pin Plug connection switch CS / 3-pin Plug connection switch / 3-pin Plug connection solenoid valves / 4-pin Plug connection solenoid valves / 4-pin Plug connection blocking diode / 2-pin Plug connection, 21-pin

X1242 X1243 X1244 X1245 X1246 X1251 X1253 X1254 X1255 X1260 X1261 X1262 X1263 X1265 Y3 Y6 Y12 Y20 Y22

8.45.14

Step

Solenoid valve / pilot pressure Solenoid valve / parking brake Solenoid valve / excess fuel for starting Coupling/air-conditioning system Solenoid valve / grapple rotator

Location/arrangement 78,86 87 90 90 90 91 91 92,93,114 111 111 79,108 52 96,113 74,97 52 97 78 100 101 101 84 106 102 102 115 115

Right handle Distribution board Right control console Near upper carriage Y409 Bearing block Near hydraulic tank Near hydraulic tank Right control desk Right control desk Right control desk Left control desk Near hydraulic tank Right control console Engine compar., left rear Near fuel tank Uppercarriage, right Right control desk Right control console Right control console Right control console Distribution board Solenoid valves Distribution board Distribution board Right control desk Right control desk

115 115

Right control desk Right control desk

115 106 106 116 117 117 117 118 118 118 118 120

Right control desk Solenoid valves Solenoid valves Right control desk Right control desk Right control desk Right control desk Right control desk Right control desk Right control desk Right control desk Right control desk

111 13*,60 1a*,60 30c*,64c 25*,80,96,109, 113,120

Control oil unit HBGV block Diesel engine regulator Engine compartment Control valve block


MJF C I F S S

Service Manual


Item Y23 Y28-1 Y28-2 Y29 Y56 Y62 Y63 Y204 Y212 Y212-1 Y215 Y216 Y217 Y218 Y236-1 Y236-2 Y236-3 Y236-4 Y237 Y238 Y238 Y268 Y295 Y299 Y307 Y330 Y332 Y341 Y354 Y355 Y356 Y357 Y357 Y360 Y363 Y365 Y366 Y371 Y385-1 Y385-2 Y405 Y406 Y406

Description

Step



25*,80,96,109, 113,120 38*,62 38*,62 3*,59,60,95 35*,50,73,92,114 10*,68,89 10*,68,89 76 39*,56,117 118 35*,50 35*,50 35*,50,73,92,93,114 35*,50,73,92,93,114 100 100 100 100 72,77,79,83,108,118 72,79,108 83 34*,51,84,107,110 55,115 34*,51,84,107,110 88 111 66,78,105,106 53 83

Control valve block

Solenoid valve / quick change adapter Solenoid valve / quick change adapter Solenoid valve / engine shut-down Solenoid valve / changeover outrigger - blade Solenoid valve / forward travel Solenoid valve / reverse travel Solenoid valve / emergency discharge Solenoid valve/industrial shut-down Solenoid valve blocking stick lowering Solenoid valve / front left outrigger support Solenoid valve / front right outrigger support Solenoid valve / rear left outrigger support Solenoid valve / rear right outrigger support Solenoid valve/changeover Solenoid valve/changeover Solenoid valve/changeover Solenoid valve/changeover Solenoid valve / boom shut-off Solenoid valve/stroke limitation Solenoid valve/stick shut-down Solenoid valve / grapple hammer Solenoid valve / magnet unit Solenoid valve / changeover pressure limitation Proportional solenoid valve/steering Solenoid valve / pump regulation Solenoid valve / changeover valve Solenoid valve / lift frame Solenoid valve / pressure limitation pst / boom cylinder extension bridged Solenoid valve / pressure limitation pst / boom cylinder extension Solenoid valve / fan stop Solenoid valve/priority circuit Solenoid valve / change of direction of rotation Solenoid valve / industrial quick change adapter Solenoid valve/retracting Solenoid valve / cylinder retraction Solenoid valve / cylinder extension / hammer Solenoid valve / oscillating axle Solenoid valve/changeover bucket cylinder AHS Solenoid valve/changeover bucket cylinder AHS Solenoid valve / mower rack forward Solenoid valve / mower rack, reverse Solenoid valve / trailer coupling OPEN/ CLOSED


MJF C I F S S

Quick-change adapter Quick-change adapter Engine regulating rod Undercarriage Hydraulic tank Hydraulic tank Lift frame base Industrial stick Industrial stick Undercarriage Undercarriage Undercarriage Undercarriage Near control valve block Near control valve block Near control valve block Near control valve block Near hydraulic tank Near hydraulic tank Near hydraulic tank Near hydraulic tank Basic boom bearing block Near hydraulic tank Below operator's platform Control oil unit Attachment Behind cab Near hydraulic tank

83

Near hydraulic tank

102 51 102 63 101 94,101,112 94,101,112 33*,103 84,110

Near weight Near hydraulic tank Near weight Industrial stick Behind cab Hydraulic tank Hydraulic tank Control oil unit Behind cab

84,110

Behind cab

78,86 86 87

Control valve block Control valve block Uppercarriage, rear

8.45.15

Electric kits

Service Manual


Description

Y409 Y410 Y428 Y443 Y444 Y451 Y452 Y453 Y454 Y456 Y465

Item

Designation

be

beige

bl

blue

br

brown

ge

yellow

gn

green

gr

grey

rt

red

sw

black

vi

purple

ws

white

Tab. 1

Step

Solenoid valve / tilt cylinder shut-off Solenoid valve / continuous operation AHS Solenoid valve / changeover UP/DOWN - telescope OUT/IN Pipe fracture safety stop valve / regulating cylinder extending Pipe fracture safety stop valve / regulating cylinder retracting Solenoid valve / combined lifting of boom Solenoid valve AHS actuation Sol. valve control press. changeover / piston side Sol. valve control press. changeover / piston side Solenoid valve changeover control lines Block solenoid valve / boom lowering

Designation (examples)

BTKP

Refuelling pump

GND

Ground

KLxx

Terminal number

KL15

Terminal 15

KL19

Terminal 19

KL30

Terminal 30

KL50

Terminal 50

M5/M6/M8

M5/M6/M8 earth conductor screw

8.45.16

Near hydraulic tank Near hydraulic tank Undercarriage

106

Near control valve block

106


84,110 115 106

Near control valve block Near control valve block Near control valve block

106


106 118

Near control valve block Near control valve block

Cable colours

Item

Tab. 2

Location/arrangement 90 91 92

Terminal designation


MJF C I F S S

Service Manual



MJF C I F S S

8.45.17

Electric kits

Service Manual

Key to accessory kit diagrams Step 50 Item

Designation


F337

Fuse

S204 S205 S206 S207

Switch / front left outrigger support Switch / front right outrigger support Switch / rear left outrigger support Switch / rear right outrigger support

S272**

Slip-ring case

S335

Blade support switch

X301 X304 X771 X957** X958** X963**

Plug connection, 8-pin Plug connection, 6-pin Plug connection, 5-pin Plug connection, 21-pin Plug connection, 21-pin Plug connection, 21-pin

Y 56 Y215 Y216 Y217 Y218

Solenoid valve blade support Solenoid valve / front left outrigger support Solenoid valve / front right outrigger support Solenoid valve / rear left outrigger support Solenoid valve / rear right outrigger support

15 A

Fuse box in control console, front right

** in basic machine

8.45.18


MJF C I F S S

Service Manual


50 A 312 Litronic / 314 Litronic / A 316 Litronic UMSCHALTUNG SCHILD / PRATZE

EINZELSTEUERUNG 4PKT

EINZELSTEUERUNG 2PKT

DOZER BLADE / OUTRIGGER CHANGEOVER

4PT. OUTRIGGER INDIVIDUAL CONTROL

2PT. OUTRIGGER INDIVIDUAL CONTROL

COMMUTATION DE LAME DE NIVELAGE / BRAS STABILISATEUR

COMMANDE UNIQUE 4POINTS

COMMANDE UNIQUE 2POINTS


MJF C I F S S

8.45.19

Electric kits

Service Manual

Key to accessory kit diagrams Step 51 Location / arrangement

Item

Designation

A125** A126**

Compact potentiometer PCB Autocheck PCB

B40** B290** B291**

Proximity switch / travel pedal right Proximity switch / adjusting pedal left Proximity switch / adjusting pedal right

F316** F330**

Fuse / indicator instruments / overload warning system / sensor control ASH/AS1 fuse / fine adjustment

H196

Indicator light / sorting grapple

K375

Relay / changeover hammer / pile driver

P1**

Flow reduction potentiometer

S45 S241

Prio switch (not installed) Switch AHS 12

U16

Electronic box BST

V156-4 X837** X839** X857** X924-2** X951** X952** X956** X957** X958** X960** X962** X963** X966** X974-4

Blocking diode Plug connection, 8-pin / / A125 left console Screw terminal, 3-pin / / kit PCB Plug connection, 24-pin / / BST Plug connection, 3-pin / / accessory kit pedal Plug connection, 21-pin / / autocheck Plug connection, 21-pin / / revolving deck CS distribution board Plug connection, 21-pin / / CS BST distribution board Plug connection, 21-pin / / console switch distribution board Plug connection, 21-pin / / console switch distribution board Plug connection, 21-pin / / platform CS distribution board Plug connection, 21-pin / / console switch distribution board Plug connection, 21-pin / / console ignition key distribution board Plug connection, 21-pin / / CS AI 25 distribution board Plug connection, 2-pin / / / CS AI 25 diode plug

Y299

Solenoid valve pressure control

15A 15 A

** in basic machine

8.45.20


MJF C I F S S

Service Manual


51

A 312 Litronic / 314 Litronic / A 316 Litronic AHS11 AHS11 AHS11


MJF C I F S S

8.45.21

Electric kits

Service Manual


Item

Designation

A125** A126**

Compact potentiometer board Autocheck PCB

B40** B290** B291**

Proximity switch right travel pedal Proximity switch / adjusting pedal left Proximity switch / adjusting pedal right

F316** F330**

Fuse / indicator instruments / overload warning system / sensor control ASH/ AS1 fuse / fine adjustment

H196


K375


P1**


S45 S241


U16

Electronic box BST

V156-4 X837** X839** X857** X924-2** X951** X952** X956** X957** X958** X960** X962** X963** X966** X974-4

Blocking diode Plug connection, 8-pin / A125 left console Screw terminal, 3-pin / kit PCB Plug connection, 24-pin / BST Plug connection, 3-pin / accessory kit pedal Plug connection, 21-pin / autocheck Plug connection, 21-pin / revolving deck CS distribution board Plug connection, 21-pin / CS BST distribution board Plug connection, 21-pin / console switch distribution board Plug connection, 21-pin / console switch distribution board Plug connection, 21-pin / platform CS distribution board Plug connection, 21-pin / console switch distribution board Plug connection, 21-pin / console ignition key distribution board Plug connection, 21-pin / CS AI 25 distribution board Plug connection, 2-pin / CS AI 25 diode plug

Y299

Solenoid valve pressure control

15.0 A 15.0 A

** in basic machine

8.45.22


MJF C I F S S

Service Manual


51

A 312 Litronic / 314 Litronic / A 316 Litronic AHS12 AHS12 AHS12


MJF C I F S S

8.45.23

Electric kits

Service Manual


Item

Designation

A125** A126**

Compact potentiometer board Autocheck PCB

B40** B290** B291**

Proximity switch / travel pedal right Proximity switch / adjusting pedal left Proximity switch / adjusting pedal right

F316** F330**

Fuse / indicator instruments / overload warning system / sensor control ASH/AS1 fuse / fine adjustment

H196


K375


P1**


S45 S241


U16

Electronic box BST

V156-4

Blocking diode

X837** X839** X857** X924-2** X951** X952** X956** X957** X958** X960** X962** X963** X966** X974-4

Plug connection, 8-pin / A125 left console Screw terminal, 3-pin / kit PCB Plug connection, 24-pin / BST Plug connection, 3-pin / accessory kit pedal Plug connection, 21-pin / autocheck Plug connection, 21-pin / revolving deck CS distribution board Plug connection, 21-pin / CS BST distribution board Plug connection, 21-pin / console switch distribution board Plug connection, 21-pin / console switch distribution board Plug connection, 21-pin / platform CS distribution board Plug connection, 21-pin / console switch distribution board Plug connection, 21-pin / console ignition key distribution board Plug connection, 21-pin / CS A125 distribution board Plug connection, 2-pin / CS A125 diode plug

Y268 Y299 Y357

Solenoid valve / grapple / hammer Solenoid valve / pressure control Solenoid valve / priority circuit

15.0 A 15.0 A

** in basic machine

8.45.24


MJF C I F S S

Service Manual


51

A 312 Litronic / 314 Litronic / A 316 Litronic AHS12 & PRIO AHS12 & PRIO AHS12 & PRIO


MJF C I F S S

8.45.25

Electric kits

Service Manual

Key to accessory kit diagrams Step 52/1 Item

Designation


A 127**


F216

Fuse / refuelling pump

K30

Relay / refuelling pump

M6

Refuelling pump

S25 S59 S341

Switch / refuelling pump ON Switch / refuelling pump OFF Float switch / refuelling pump

20.0 A

** in basic diagram

8.45.26


MJF C I F S S

Service Manual


52/1

A 309 Litronic - R 317 Litronic BETANKUNGSPUMPE REFUELLING PUMP PUMPE DE REMPL.


MJF C I F S S

8.45.27

Electric kits

Service Manual


Designation


A 127**


F216

Fuse / refuelling pump

K30

Relay / refuelling pump

M6

Refuelling pump

S25 S59 S341

Switch / refuelling pump ON Switch / refuelling pump OFF Float switch / refuelling pump

V173

Blocking diode BTKP

X7 X1138 X1190

Plug connection on A127 (F_L) Plug connection, 2-pin / A127 refuelling pump Plug connection, 2-pin / float switch

15.0 A

** in basic diagram

8.45.28


MJF C I F S S

Service Manual


52/2

A 309 Litronic - R 317 Litronic BETANKUNGSPUMPE REFUELLING PUMP PUMPE DE REMPL.


MJF C I F S S

8.45.29

Electric kits

Service Manual


Item

Designation

F329**

Servo switch fuse

H293

Indicator light / operator's cab

S35** S361

Switch / front left outrigger support Switch / hydraulic cab elevation

X821** X822** X829**

Plug connection, 21-pin / console (switch) distribution board Plug connection, 21-pin / console (switch) distribution board Plug connection, 21-pin / revolving deck CS distribution board

Y341

Solenoid valve / cab lift frame UP and DOWN

15.0 A

** in basic diagram

8.45.30


MJF C I F S S

Service Manual


53

A 316 Litronic (IND) HYDRAULISCHE FAHRERHAUSERHÖHUNG HYDRAULIC CAB ELEVATION HYDR.P.CONTRE POIDS DEMONTABLE


MJF C I F S S

8.45.31

Electric kits

Service Manual


Item

Designation

A 126**

Autocheck PCB

B21

Pressure switch / overload warning system

H10 H16

Buzzer / overload warning system Indicator light / overload warning system

S18 S20**

Switch / overload warning system Switch / sensor control

X407**

Plug connection, 2-pin / revolving deck CS overload warning system Plug connection, 21-pin / A 126 Plug connection, 21-pin / A 126 Plug connection, 21-pin / revolving deck CS distribution board Plug connection, 21-pin / console (switch) distribution board

X950** X951** X953** X958**

** in basic diagram

8.45.32


MJF C I F S S

Service Manual


54

A 312 Litronic / A 314 Litronic / A 316 Litronic / A 316 (IND) ÜBERLASTWARNEINRICHTUNG OVERLOAD WARNING SYSTEM AVERITISSEUR DE SUCHARGE


MJF C I F S S

8.45.33

Electric kits

Service Manual


Designation

A 126**

Autocheck PCB

F337

Fuse

S6L S46

Button / magnet system Switch / magnet system

U7 U16**

Switching system / magnet system Electronic box BST

X11**

X963**

Plug connection, 2-pin / magnet system CS distribution board Plug connection, 2-pin / magnet system CS, handle / button Plug connection, 1-pin / magnet system CS, handle / button Plug connection, 2-pin / magnet system CS Plug connection, 2-pin / magnet system CS, solenoid valve CS Plug connection, 40-pin / CS BST Plug connection, 21-pin / autocheck Plug connection, 21-pin / autocheck Plug connection, 21-pin / CS BST distribution board Plug connection, 21-pin / console switch distribution board Plug connection, 21-pin / console indicator distribution board Plug connection, 21-pin / fuse distribution board

Y295**

Solenoid valve / magnet unit

X74 X74-1 X217 X370 X856** X950** X951** X956** X958** X962**


15.0 A


** in basic diagram

8.45.34


MJF C I F S S

Service Manual


55/1

A 316 Litronic (IND) STEUERUNG MAGNETANLAGE MAGNET SYSTEM CONTROL CONTROLE DE MONTAGE PLATEAU MAGNETIQUE


MJF C I F S S

8.45.35

Electric kits

Service Manual


Designation

A 126**

Autocheck PCB

F337

Fuse

S6L S46


U7 U16**

Switching system / magnet system Electronic box BST

X11**

X963**

Plug connection, 2-pin / magnet system CS distribution board Plug connection, 2-pin / magnet system CS, handle / button Plug connection, 1-pin / magnet system CS, handle / button Plug connection, 2-pin / magnet system CS Plug connection, 2-pin / magnet system CS, solenoid valve CS Plug connection, 40-pin / CS BST Plug connection, 21-pin / autocheck Plug connection, 21-pin / autocheck Plug connection, 21-pin / CS BST distribution board Plug connection, 21-pin / console switch distribution board Plug connection, 21-pin / console indicator distribution board Plug connection, 21-pin / fuse distribution board

Y295**


X74 X74-1 X217 X370 X856** X950** X951** X956** X958** X962**


15.0 A


** in basic diagram

8.45.36


MJF C I F S S

Service Manual


55/2



MJF C I F S S

8.45.37

Electric kits

Service Manual


Designation

A 126**

Autocheck PCB

F337**

Fuse

S6L S46


U7 U16**

Switching system / magnet unit Electronic box BST

X74

X963**

Plug connection, 2-pin / magnet system CS, handle / button Plug connection, 1-pin / magnet system CS, handle / button Plug connection, 2-pin / magnet system CS Plug connection, 2-pin / magnet system CS, solenoid valve CS Plug connection, 40-pin / CS BST Plug connection, 21-pin / autocheck Plug connection, 21-pin / autocheck Plug connection, 21-pin / CS BST distribution board Plug connection, 21-pin / console switch distribution board Plug connection, 21-pin / console indicator distribution board Plug connection, 21-pin / fuse distribution board

Y295


X74-1 X217 X370 X856** X950** X951** X956** X958** X962**


15.0 A


** in basic diagram

8.45.38


MJF C I F S S

Service Manual


55/3



MJF C I F S S

8.45.39

Electric kits

Service Manual


Designation


B204

Proximity switch

F337

Fuse

K392

Relay for industrial shut-shut-down

S216

Switch/industrial shut-down

X955** X958** X963**

Plug connection, 5-pin Plug connection, 21-pin Plug connection, 21-pin

Y212

Solenoid valve / industrial shut-down

15.0 A


** in basic diagram

8.45.40


MJF C I F S S

Service Manual


56

A 316 Litronic (IND) INDUSTRIEABSCHALTUNG IND. SHUTDOWN INTERRUPTION IND.ELEVABLE


MJF C I F S S

8.45.41

Electric kits

Service Manual


Designation


A3**

Radio

B50**

Loudspeaker

F304** F322**

Fuse S1 Fuse T1

S1**

Start and pre-heating switch

T1**

Voltage transformer

X65** X66** X67-1** X67-2** X963** X966** X967** X973**

Plug connection, 2-pin / T1 / 24 V Plug connection, 2-pin / T1 / 12 V Plug connection, 8-pin / A3 power supply Plug connection, 8-pin, A3 loudspeaker Plug connection, 21-pin / distribution board Plug connection, 21-pin / distribution board Plug connection, 21-pin / distribution board Power socket

15.0 A 15.0 A

** in basic diagram

8.45.42


MJF C I F S S

Service Manual


57

A 312 Litronic / A 314 Litronic / A 316 Litronic / A 316 (IND) RADIO RADIO RADIO


MJF C I F S S

8.45.43

Electric kits

Service Manual


Designation

E9

Beacon


F317** Fuse Working light / beacon

7.5 A

S8

Switch / beacon

X967** X993

Plug connection, 21-pin / console indicator distribution board Plug connection, 2-pin / console indicator distribution board

** in basic diagram

8.45.44


MJF C I F S S

Service Manual


58

A 312 Litronic / A 314 Litronic / A 316 Litronic / A 316 (IND) RUNDUMKENNLEUCHTE BEACON GIROPHARE


MJF C I F S S

8.45.45

Electric kits

Service Manual


Designation


A 127**


F300** F303**

Fuse A127 / terminal 30 to terminal 15 Fuse A127, Y29

K288**

Relay 15 A127

S313

Switch / engine shut-down

V168

Decay diode

X1006 X1011

Plug terminal, 1-pin Plug connection decay diode, 3-pin

Y29**

Solenoid valve / engine stop

50.0 A 7.5 A

** see basic diagram of electrical system

8.45.46


MJF C I F S S

Service Manual


59

A 312 Litronic / A 314 Litronic / A 316 Litronic / A 316 (IND) MOTORSTOP ENGINE STOP ARRET MOTEUR


MJF C I F S S

8.45.47

Electric kits

Service Manual


Designation


A127**


F300** F303** F304** F306** F314** F332**

Fuse terminal 30 to terminal 15 Fuse Y29 B3 External fuse S1 Fuse X10 Fuse S7 Fuse M1, Y12

K368** K369** K386**

Relay of terminal 50 Relay of terminal 15 Relay / safety switch

M1**

Starter

S1** S7** S74

Start switch / right console Safety switch / left console Code key for immobiliser

U13

Electronic box / auto-scan

X10** X955** X963** X964** X966**

Plug connection, 2-pin / distribution board Plug connection, 15-pin / revolving deck CS distribution board Plug connection, 21-pin, fuse distribution board Plug connection, 21-pin, fuse distribution board Plug connection, 21-pin, A 125 distribution board

Y6** Y12** Y29**

Solenoid valve / parking brake Solenoid valve / cold-start aid Solenoid valve / engine stop

50.0 A 7.5 A 15.0 A 15.0 A 15.0 A 25.0 A

** in basic diagram

8.45.48


MJF C I F S S

Service Manual


60

A 312 Litronic / A 314 Litronic / A 316 Litronic / A 316 (IND) WEGFAHRSPERRE IMMOBILISER ANTIVOL DE DEMARRAGE


MJF C I F S S

8.45.49

Electric kits

Service Manual


Designation


B36

Pressure switch

F320**

Fuse X11 / X12

H33

Back-up alarm

K407-1 K407-2

Relay / travel warning mute Time relay, delayed travel warning 10 sec.

S6L S6R

Push button / grapple pilot control right Push button / grapple pilot control right

X11** X74 X204 X206 X207 X324-1 X324-2 X963**

Plug connection, 2-pin / distribution board Plug connection, 3-pin / cable with button Plug connection, 2-pin / to buzzer H33 Plug connection, 2-pin / to pressure switch B36 Plug connection, 2-pin / to pressure switch B36 Plug connection, 2-pin / to buzzer H33 Plug connection, 2-pin / to buzzer H33 Plug connection, 21-pin / distribution board

15.0 A

** in basic diagram

8.45.50


MJF C I F S S

Service Manual


61

A 312 Litronic / A 314 Litronic / A 316 Litronic / A 316 (IND) FAHRWARNEINRICHTUNG TRAVEL ALARM AVERTISSEUR DE MARCHE


MJF C I F S S

8.45.51

Electric kits

Service Manual


Designation


A1017

Printed circuit board / quick-change adapter

B26

Proximity switch / bucket quick-change adapter

F316** F326**

Fuse sensor / sensor control / console Fuse creeper gear / 1st gear / oscillating axle /S

H26 H27**

Indicator light / quick-change adapter Buzzer

K364

Relay / quick-change adapter valves

S18 S47 S360

Switch / overload warning system Key switch Buzzer acknowledgement

V156-3

Quick-change adapter blocking diode

X15-2** X262 X262-1 X262-3 X262-4 X262-5 X262-6 X410 X411 X412 X413 X798 X955** X957** X958** X961** X963** X966**

Plug connection, 3-pin / to S5 Plug connection, 8-pin / to quick-change adapter Plug connection, 8-pin / on bearing block Plug connection, 8-pin / on stick Plug connection, 2-pin / on valve Y28-1 Plug connection, 2-pin / on valve Y28-1 Plug connection, 2-pin / on B26 Plug connection A 1017 power supply Plug connection key switch Plug connection A 1017 - AS1 button Plug connection, 4-pin, quick-change warning Plug connection, 3 pin / blocking diode Plug connection, 15-pin / distribution board Plug connection, 21-pin / distribution board Plug connection, 21-pin / distribution board Plug connection, 21-pin / distribution board Plug connection, 21-pin / distribution board Plug connection, 21-pin / distribution board

Y28-1 Y28-2

Solenoid valve / quick-change adapter Solenoid valve / quick-change adapter

** in basic diagram

8.45.52


MJF C I F S S

Service Manual


62

A 312 Litronic / A 314 Litronic / A 316 Litronic SCHNELLWECHSLER QUICK-CHANGE ADAPTER ADAPTEUR A CHANGEMENT RAPIDE


MJF C I F S S

8.45.53

Electric kits

Service Manual


Designation


F327**

Fuse / industrial stick quick-change adapter

H26 H27**

Quick-change indicator light Quick-change warning buzzer

S47-1 S47-2

Key switch / activate quick-change adapter Key switch / activate quick-change adapter

V154

Blocking diode / quick-change warning system

X262 X262-1 X413 X446 X447 X8911 X891-2 X955 X963**

Plug connection, 8-pin / distribution board Plug connection, 8-pin / bearing block Plug connection, 4-pin Plug connection, 5-pin / S47-1/2 Plug connection to blocking diode / quick-change warning system Plug connection, 2-pin / on valve Y360 Plug connection, 2-pin / on stick Plug connection, 15-pin / distribution board Plug connection, 21-pin

Y360

Solenoid valve / quick-change adapter

15.0 A

** in basic diagram

8.45.54


MJF C I F S S

Service Manual


63

A 316 Litronic (IND) INDUSTRIESCHNELLWECHSLER IND. QUICK-CHANGE ADAPTER ADAPT. RAPIDE INDUSTRIE


MJF C I F S S

8.45.55

Electric kits

Service Manual


Designation


B294 B295

Pressure switch / a/c compressor Heating thermostat

F318** F319** F339**

Fuse heating/air-conditioning system Kl30 Fuse heating/air-conditioning system terminal 15 Fuse capacitor motors

K402 K403** K404 K405

Relay / heating Relay / heating Relay / capacitor motors Relay / blower switch

M65** M71** M72** M73** M74-1 M74-2 M74-3

Blower motor Servo motor / water valve Servo motor / air distribution Servo motor / eversing - air distribution Fan motor / condenser Fan motor / condenser Fan motor / condenser

S92** S93** S284** S318 S398**

Potentiometer / air distribution Potentiometer / heating / air conditioning system Switch / four-step blower Switch a/c system Reversing switch / heating

X842-1** X842-2** X859** X860** X861** X862** X863** X864 X952** X955** X959** X964**

Plug connection, 15-pin Plug connection, 2-pin Plug connection, 21-pin Plug connection, 6-pin Plug connection, 6-pin Plug connection, 6-pin Plug connection, 15-pin Plug connection, 4-pin Plug connection, 21-pin Plug connection, 15-pin Plug connection, 21-pin Plug connection, 21-pin

Y20

Solenoid valve / a/c coupling

20.0 A 3.0 A 20.0 A

** in basic diagram

8.45.56


MJF C I F S S

Service Manual


64a Air-conditioning system


MJF C I F S S

8.45.57

Electric kits

Service Manual

Key to accessory kit diagrams

64b Air-conditioning system

8.45.58


MJF C I F S S

Service Manual


64c Air-conditioning system


MJF C I F S S

8.45.59

Electric kits

Service Manual


Designation


E1** E2** E 150**

Working light / attachment Auxiliary headlight (roof) / front Auxiliary headlight (roof) / rear

F323** F324**

Fuse Fuse

S22** S22-1**

Switch / auxiliary headlight Switch / auxiliary headlight

X404** X967**


15.0 A 15.0 A

** in basic diagram

8.45.60


MJF C I F S S

Service Manual


65

A 312 Litronic / A 314 Litronic / A 316 Litronic / A 316 (IND) ZUSATZSCHEINWERFER AUXILIARY HEADLIGHT PROJECTEURS SUPPLEMENTAIRES


MJF C I F S S

8.45.61

Electric kits

Service Manual


Designation


F331**

Fuse

K370 S356

Relay servo Switch / changeover valve

X29 X358 X963

Plug connection, 2-pin / distribution board Plug connection, 2-pin Plug connection, 21-pin / distribution board

Y332

Solenoid valve / changeover valve

15.0 A

** in basic diagram

8.45.62


MJF C I F S S

Service Manual


66/1

A 312 Litronic / A 314 Litronic / A 316 Litronic / A 316 (IND) ANBAUSATZ UMSCHALTSCHIEBER CHANGEOVER VALVE ACCESSORY KIT ENSEMBLE DE MONTAGE


MJF C I F S S

8.45.63

Electric kits

Service Manual


Designation


F331**

Fuse

K455

Relay / changeover valve UP, horizontal

S356

Switch / changeover valve

X29 X358-1 X358-2 X963** X983 X1226

Plug connection, 2-pin / distribution board Plug connection, 2-pin / under operator's platform Plug connection, 2-pin / fuel tank Plug connection, 21-pin / distribution board Plug connection, 3-pin / distribution board Plug connection, 2-pin / magnet system

Y332 Y443 Y444

Solenoid valve / changeover valve Check valve / boon cylinder pipe fracture safety valve Check valve / boon cylinder pipe fracture safety valve

15.0 A

** in basic diagram

8.45.64


MJF C I F S S

Service Manual


66/2

A 312 Litronic / A 314 Litronic / A 316 Litronic / A 316 (IND) ANBAUSATZ UMSCHALTSCHIEBER CHANGEOVER VALVE ACCESSORY KIT ENSEMBLE DE MONTAGE


MJF C I F S S

8.45.65

Electric kits

Service Manual


Designation


A1202

Frequency switching board

F320**

Fuse X11 / X12

G1**

Alternator

P5-1 P5-2 P5-3

Operating hour meter / idle run Operating hour meter / partial load Operating hour meter / full load

S384

Switch / operating hour meter

X11** X914 X915 X955** X963**

Plug connection, 2-pin / distribution board Plug connection, 6-pin, operating our meter CS Plug connection, 16-pin / on A 1202 Plug connection, 15-pin / distribution board Plug connection, 21-pin / distribution board

15.0 A

** in basic diagram

8.45.66


MJF C I F S S

Service Manual


67

A 312 Litronic / A 314 Litronic / A 316 Litronic / A 316 (IND) BETRIEBSSTUNDENZÄHLER HOUR COUNTER COMPTEUR HORAIRE


MJF C I F S S

8.45.67

Electric kits

Service Manual


Designation


A 126**

Autocheck PCB

F325**

Fuse S16, S263 (7.5 A)

H167** H168** H183

Indicator light / forward travel Indicator light / forward travel Electronic buzzer

K251**

Relay / hand brake (light)

S263 S269 S270

Pilot control unit switch, right Switch in slip ring Switch in slip ring

X312 X313 X314 X324-1 X342** X950** X951** X952** X959** X962** X963**

Plug connection, 12-pin / slip ring Plug connection, 12-pin / slip ring Plug connection, 2-pin / electronic buzzer Plug connection, 2-pin / electronic buzzer Plug connection, 3-pin / travel switch Plug connection, 21-pin / on A 126 Plug connection, 21-pin / on A 126 Plug connection, 21-pin / revolving deck CS BST Plug connection, 21-pin / fuse distribution board Plug connection, 21-pin / console indicator distribution board Plug connection, 21-pin / fuse distribution board

Y62** Y63**

Solenoid valve, forward travel Solenoid valve, reverse travel

** in basic diagram

8.45.68


MJF C I F S S

Service Manual


68

A 312 Litronic / A 314 Litronic / A 316 Litronic / A 316 (IND) RÜCKFAHRWARNEINRICHTUNG BACK-UP WARNING DEVICE AVERTISSEUR DE MARCHE ARRIERE


MJF C I F S S

8.45.69

Electric kits

Service Manual


Designation


A 127**


F320** F340

Fuse X11 Fuse Thermoline

K33

Relay Thermoline

R8

Thermoline

S237

Switch / fuel pre-heating

X11** X738 X963** X979 X982

Plug connection, 2-pin / distribution board Plug connection, 2-pin / Thermoline Plug connection / distribution board Plug connection, 2-pin / switch CS Plug connection, 3-pin / switch CS

15.0 A 15.0 A

** in basic diagram

8.45.70


MJF C I F S S

Service Manual


69

A 312 Litronic / A 314 Litronic / A 316 Litronic / A 316 (IND) KRAFTSTOFFVORWÄRMUNG FUEL PREHEATER PRECHAUFFE DE CARBURANT


MJF C I F S S

8.45.71

Electric kits

Service Manual

Key to accessory kit diagrams Step 70

8.45.72

Item

Designation


A127


E30 E50

D5WS auxiliary heating Power cabinet and fuse cabinet

F34 F35 F36

Fuse / auxiliary heater to ground Fuse / auxiliary heater control unit Fuse / auxiliary heater timer, water valve, heating

G2

Battery

K358 K359 K360

Relay heating ON Relay water circuit ON Relay / heater fan ON

M52 M53

Water pump Fuel metering pump

S9 S232

Battery main switch Digital timer

X95 X98 X99 X100 X101 X689 X842-2 X987

Plug connection, 4-pin / to S232 Plug connection, 2-pin / to fuel metering pump Plug connection, 2-pin / to water recirculation pump Plug connection, 2-pin / to water recirculation pump Plug connection, 8-pin / to auxiliary heater control device Plug connection, 6-pin / blocking diodes Plug connection, 2-pin / heater - auxiliary heater Plug connection, 8-pin / auxiliary heater

25.0 A 15.0 A 15.0 A


MJF C I F S S

Service Manual


70

A 312 Litronic / A 314 Litronic / A 316 Litronic / A 316 (IND) STANDHEIZUNG D5WS AUXILIARY HEATER CHAUFFAGE SUPPLEMENT SUPPLEMENTAIRE A L'ARRET


MJF C I F S S

8.45.73

Electric kits

Service Manual


8.45.74

Item

Designation


A127


F342

Fuse terminal 15

T4

Voltage transformer

X989

Power socket 12V / 20 A / 2-pin

15.0 A


MJF C I F S S

Service Manual


71

A 312 Litronic / A 314 Litronic / A 316 Litronic / A 316 (IND) STECKDOSE 12V 20A SOCKET 12V 20A PRISE 12V 20A


MJF C I F S S

8.45.75

Electric kits

Service Manual


8.45.76

Item

Designation


B214

Proximity switch / boom shut-down

F331

Fuse X29

H27

Buzzer / quick-change adapter / boom shut-down

K333-1 K333-2 K334

Relay / boom shut-down Relay / boom shut-down Relay / boom shut-down

S249 S291

Key switch with plug / boom shut-down Push button with plug / override boom shut-down

V163-1 V163-2

Blocking diode / QC signal Blocking diode / signal boom shut-down

X29 X963 X988-1 X988-2 X988-3

Plug connection, 2-pin / distribution board Plug connection, 21-pin / distribution board Plug connection, 8-pin / boom shut-down CS Plug connection, 4-pin / boom shut-down CS Plug connection, 3-pin / blocking diodes

Y237 Y238

Solenoid valve / boom shut-down Solenoid valve / boom shut-down

15.0 A


MJF C I F S S

Service Manual


72

A 312 Litronic / A 314 Litronic / A 316 Litronic / A 316 (IND) HUBBEGRENZUNG STROKE LIMITER LIMITEUR DE COURSE DE LEVAGE


MJF C I F S S

8.45.77

Electric kits

Service Manual


8.45.78

Item

Designation


F337

Fuse

S272 S335 S335-1 S335-2

Slip-ring case Blade support switch Switch front blade Switch / rear blade

X301 X304 X771 X957 X958 X963

Plug connection, 12-pin / slip rig distribution board Plug connection, 6-pin / console right Plug connection, 5-pin / distribution board Plug connection, 21-pin / distribution board Plug connection, 21-pin / distribution board Plug connection, 21-pin / distribution board

Y56 Y217 Y218

Solenoid valve / blade support, front Solenoid valve / outrigger support, rear left Solenoid valve / outrigger support, rear right

15.0 A



MJF C I F S S

Service Manual


73

A 312 Litronic / A 314 Litronic / A 316 Litronic / A 316 (IND) EINZELSTEUERUNG SCHILD / SCHILD BLADE / BLADE INDIVIDUAL CONTROL COMMANDE UNIQUE LAME / LAME


MJF C I F S S

8.45.79

Electric kits

Service Manual


8.45.80

Item

Designation


F307 F308 F309 F310 F336

Fuse E16, E17 Fuse E15, E18 Fuse E3 Fuse E4 Fuse S61

E4 E15 E18 E163

Headlight uppercarriage, right Parking light, right Tail light, left License plate light

S61

Switch / lighting installation

X902 X953 X963 X967

Plug connection, 6-pin / lighting system Plug connection, 21-pin / distribution board Plug connection, 21-pin / distribution board Plug connection, 21-pin / distribution board

7.5 A 7.5 A 7.5 A 7.5 A 20.0 A


MJF C I F S S

Service Manual


74

A 312 Litronic / A 314 Litronic / A 316 Litronic / A 316 (IND) KENNZEICHENLEUCHTE LAMP ECLAIREAGE DE LA PLAQUE D'IMMATRICULATION


MJF C I F S S

8.45.81

Electric kits

Service Manual


8.45.82

Item

Designation


B51-1

Piston detector

F320

Fuse X11

S84-1

Push button with plug / central lubrication

U4-1

Central lubrication system

X11 X133-1 X143-1 X963 X998

Plug connection, 2-pin / distribution board Plug connection, 2-pin / piston detector Plug connection, 4-pin / central lubrication system Plug connection, 21-pin / distribution board Plug connection, 3-pin / under operator's platform

15.0 A


MJF C I F S S

Service Manual


75

A 312 Litronic / A 314 Litronic / A 316 Litronic / A 316 (IND) ZENTRALSCHMIERANLAGE CENTRAL LUBRICATION SYSTEM DISP. DE GRAISSAGE CENTRALISE


MJF C I F S S

8.45.83

Electric kits

Service Manual


8.45.84

Item

Designation


F344

Fuse / emergency lowering

S78

Push button / emergency lowering

X999-1 X999-2 X999-3

Plug connection, 2-pin / fuse - switch Plug connection, 2-pin / fuse - switch Plug connection, 1-pin / switch - solenoid valve

Y204

Solenoid valve / emergency lowering

7.5 A


MJF C I F S S

Service Manual


76

A 316 Litronic (IND) NOTABLASS EMERCENCY LOWERING DESCENTE SECOURS


MJF C I F S S

8.45.85

Electric kits

Service Manual


8.45.86

Item

Designation


B214

Proximity switch / boom shut-down

F331

Fuse X29

H27

Quick-change adapter buzzer / boom shut-down

K333-1 K333-1 K334

Relay / boom shut-down Relay / boom shut-down Relay / boom shut-down

S249 S291

Key switch / boom shut-down Push button with plug / override boom shut-down

V163-1 V163-2

Blocking diode / QC signal Blocking diode / signal boom shut-down

X29 X963 X988-1 X988-2 X988-3

Plug connection, 2-pin / distribution board Plug connection, 21-pin / distribution board Plug connection, 8-pin / boom shut-down CS Plug connection, 4-pin / boom shut-down CS Plug connection, 3-pin / blocking diodes

Y237

Solenoid valve / boom shut-down

15.0 A


MJF C I F S S

Service Manual


77

A 316 Litronic (IND) HUBBEGRENZUNG SCHWENKARM STROKE LIMITER BASIC BOOM LIMITEUR DE COURSE FLECHE DE BASE


MJF C I F S S

8.45.87

Electric kits

Service Manual

Key to accessory kit diagrams Step 78/1

8.45.88

Item

Designation


F331

Fuse X29

H323

Indicator light / lateral adjustment

K370

Relay servo

S356


X29 X358-1 X358-2 X963 X983

Plug connection, 2-pin / distribution board Plug connection, 2-pin / under operator's platform Plug connection, 2-pin / fuel tank Plug connection, 21-pin / distribution board Plug connection, 3-pin / distribution board

Y332


15.0 A


MJF C I F S S

Service Manual


78/1

A 312 Litronic / A 314 Litronic / A 316 Litronic / A 316 (IND) ANBAUSATZ UMSCHALTSCHIEBER CHANGEOVER VALVE ACCESSORY KIT ENSEMBLE DE MONTAGE TIROIR D'INVERSION


MJF C I F S S

8.45.89

Electric kits

Service Manual


8.45.90

Item

Designation


F330

Fuse kits

H307

Indicator light / delta P

R76

Potentiometer / fine adjustment

S382

Switch / fine adjustment ON / OFF

U16


V156-1

Blocking diode H307 BST

X856 X857 X909 X956 X959 X961 X963 X966 X974-1

Plug connection, 40-pin / BST wire harness Plug connection, 24-pin / BST Plug connection, 2-pin / to S382 Plug connection, 21-pin / distribution board Plug connection, 21-pin / distribution board Plug connection, 21-pin / distribution board Plug connection, 21-pin / distribution board Plug connection, 21-pin / A125 wire harness Plug connection, 2-pin / blocking diode

15.0 A


MJF C I F S S

Service Manual


78/2

A 312 Litronic / A 314 Litronic / A 316 Litronic / A 316 (IND) ANBAUSATZ UMSCHALTSCHIEBER / FEINREGELUNG CHANGEOVER VALVE / FINE ADJUSTMENT ENSEMBLE DE MONTAGE TIROIR D'INVERSION / REGLAGE


MJF C I F S S

8.45.91

Electric kits

Service Manual


8.45.92

Item

Designation


B213 B214

Proximity switch boom shut-down at stick Proximity switch boom shut-down at bearing block

F331

Fuse X29

H27 H249

Buzzer / quick-change adapter / boom shut-down Indicator light / override ON

K414

Relay / boom shut-down

S6R S249

Push button override boom shut-down in right pilot control unit Key switch with plug / boom shut-down ON

X29 X74 X963 X988-1 X988-2 X988-3 X988-4 X988-5 X988-6

Plug connection, 2-pin / distribution board Plug connection, 3-pin handle right Plug connection, 21-pin / distribution board Plug connection, 12-pin / boom shut-down CS Plug connection, 4-pin / boom shut-down CS Plug connection, 3-pin / blocking diodes Plug connection, 3-pin / blocking diodes Plug connection, 3-pin / blocking diodes Plug connection, 4-pin / to B214

Y237 Y238

Solenoid valve boom shut-down / stick Solenoid valve boom shut-down / boom

15.0 A


MJF C I F S S

Service Manual


79

A 312 Litronic / A 314 Litronic / A 316 Litronic / A 316 (IND) HUBBEGRENZUNG HUB UND STIEL STROKE LIMITER AND STICK LIMITEUR DE COURSE LEVAGE ET BALANCIER


MJF C I F S S

8.45.93

Electric kits

Service Manual


8.45.94

Item

Designation


S5L S5R S6L S6R S19

Push button / left grapple rotator, left pilot control unit Push button / right grapple rotator, left pilot control unit Push button / left grapple rotator, right pilot control unit Push button / right grapple rotator, right pilot control unit Switch / grapple rotator, right console

X15-2 X296 X297 X952 X957 X966

Plug connection, 3-pin / left handle Plug connection, 1-pin / left handle Plug connection, 3-pin / handle right Plug connection, 21-pin / distribution board Plug connection, 21-pin / distribution board

Y22 Y23

Solenoid valve / left grapple rotator Solenoid valve / right grapple rotator

Plug connection, 21-pin / distribution board


MJF C I F S S

Service Manual


80

A 312 Litronic / A 314 Litronic / A 316 Litronic / A 316 (IND) BETÄTIGUNG AS1 IM GRIFF LINKS UND RECHTS GRAPPLE CONTROL IN LEFT AND RIGHT JOYSTICK CDE. AS DANS LE MANIPULATEUR GAUCHE ET DROITE


MJF C I F S S

8.45.95

Electric kits

Service Manual


Designation


A125** A126**

PCB potentiometers PCB / autocheck

Left console Right console

B40** B290** B291**

Proximity switch / travel pedal Proximity switch / kit pedal Proximity switch / kit pedal

Base plate Base plate Base plate

F316** F330**

Fuse / indicator instruments / overload warning Fuse kits

K375**


Right control console, rear

S45 S241** S406

Prio switch (not installed) Switch AHS 11 / AHS 12 Switch / kit quantity changeover

Right controle Right controle Right console

U16**

Electronic box BST

Right console

V156-4** V166

Blocking diode A125 Diode with plug

A125 A 125

X837** X839** X857** X924-2** X951** X956** X957** X958** X960** X962** X963** X966** X968-1** X968-2** X974-4**

Plug connection, 8-pin / distribution board Plug connection, 3-pin / screw terminal on A125 Plug connection, 24-pin / distribution board Plug connection, 3-pin / B291 Plug connection, 21-pin / distribution board Plug connection, 21-pin / distribution board Plug connection, 21-pin / distribution board Plug connection, 21-pin / distribution board Plug connection, 21-pin / distribution board Plug connection, 21-pin / distribution board Plug connection, 21-pin / distribution board Plug connection, 21-pin / distribution board Plug connection, 1-pin / distribution board Plug connection, 1-pin / distribution board Plug connection, 2-pin / A125 CS

Left console Left console, bottom Right console, rear below operator's platform Right console, rear Right console, rear Right console, rear Right console, rear Right console, rear Right console, rear Right console, rear Right console, rear A125 A125 Left console, bottom

15.0 A 15.0 A

Right console, front Right console, front

** item from basic diagram

8.45.96


MJF C I F S S

Service Manual


81

A 312 Litronic / A 314 Litronic / A 316 Litronic / A 316 (IND) BAUSATZMENGE UMSCHALTBAR SWITCHABLE FLOW REDUCTION REDUCTION DE DEBIT


MJF C I F S S

8.45.97

Electric kits

Service Manual


Designation


F307** F336**

Fuse E16, E17 Fuse S61

H324

Inclinometer illumination

Right control console, front

P6**

Display / motor temperature

Right controle

S61**


Right console, rear

X953** X961** X963** X967**

Plug connection, 21-pin / distribution board Plug connection, 21-pin / distribution board Plug connection, 2-pin / distribution board Plug connection, 21-pin / distribution board

Right console, rear Right console, rear Right console, rear Right console, rear

7.5 A 20.0 A

Right console, rear Right console, front


8.45.98


MJF C I F S S

Service Manual


82

A 312 Litronic / A 314 Litronic / A 316 Litronic (IND) BELEUCHTUNG NEIGUNGSMESSER ILLUMINATION INCLINOMETER ECLAIRAGE NIVEAU ELECTRONIQUEB


MJF C I F S S

8.45.99

Electric kits

Service Manual


Designation

F320**

Fuse X11 / X12

H159

Indicator light / stroke limitation ON

Right control console

K261

Relay / solenoid valve actuation in case of override

Right console, rear

S249 S291

Key switch / boom shut-down with plug Push button with plug / override boom shut-down

Right controle, rear Right control console

X11** X374 X378 X379 X689 X963 X1017 X1018 X1019

Plug connection, 2-pin / on distribution board Plug connection, 5-pin Plug connection, 2-pin / to Y354 and Y355 Plug connection, 5-pin Plug connection, 6-pin / blocking diodes Plug connection, 2-pin / distribution board Plug connection, 4-pin / to Y237 - Y238 Plug connection, 2-pin / to Y237 - Y238 Plug connection, 4-pin / to Y354 - Y355

Right console Right control console, rear Right control console, rear Right control console, rear Right console Right console, rear Near hydraulic tank Near hydraulic tank Near hydraulic tank

Y237 Y238 Y354

Solenoid valve / boom shut-down Solenoid valve / stick shut-down Solenoid valve / pressure limitation pst / boom cylinder extension override Solenoid valve / pressure limitation pst / boom cylinder extension

Near hydraulic tank Near hydraulic tank Near hydraulic tank

Y355

Location / arrangement 15.0 A

Right console, front

Near hydraulic tank


8.45.100


MJF C I F S S

Service Manual


83/1 A 312 Litronic / A 314 Litronic / A 316 Litronic (IND) HUBBEGRENZUNG KRÜGER KRUEGER STROKE LIMITER LIMITEUR DE COURSE ELECTRIQUE


MJF C I F S S

8.45.101

Electric kits

Service Manual


8.45.102

Item

Designation


A B

Krueger indicating instrument Krueger control box

K1 K2

Relay / preliminary shut-down Krüger electronics Relay / shut-down Krüger electronics

in control box / Krüger in control box / Krüger

R70 R71

Rotary potentiometer Rotary potentiometer

At basic boom At boom

X379 X381 X358-1 X382 X382-1 X382-2

Plug connection, 5-pin Plug connection, 4-pin / to R70 Plug connection, 4-pin / to R70 Plug connection, 4-pin / to R71 Plug connection, 4-pin / to R71 Plug connection, 4-pin / to R71

Right control console, rear At basic boom At basic boom At boom At boom At boom


MJF C I F S S

Service Manual


83/2

A 312 Litronic / A 314 Litronic / A 316 Litronic (IND) HUBBEGRENZUNG KRÜGER KRUEGER STROKE LIMITIER LIMITEUR DE COURSE ELECTRIQUE


MJF C I F S S

8.45.103

Electric kits

Service Manual


Designation


A125**

PCB potentiometers

Left console

F330** F331**

Fuse kits Fuse X29

H322

Warning light / changeover

Right control console DOWN

P1**

Potentiometer / flow reduction A125

Left console, bottom

S241** S405

Switch AHS 11 / AHS 12 Switch / changeover

Right controle Right console

V156-4** V169

Blocking diode A125 Blocking diode

A125 A 125

X29** X837** X839** X952** X957** X958** X963** X974-4** X1028 X1029

Plug connection, 2-pin / distribution board Plug connection, 8-pin / A125 Plug connection, 3-pin / screw terminal on A125 Plug connection, 21-pin / distribution board Plug connection, 21-pin / distribution board Plug connection, 21-pin / distribution board Plug connection, 2-pin / distribution board Plug connection, 2-pin / A125 CS Plug connection, 4-pin / to S405 and H322 Plug connection, 4-pin / solenoid valves

Right console, rear Left console, bottom Left console, bottom Right console, rear Right console, rear Right console, rear Right console, rear Left console, bottom Right control console, rear Right control console, rear

Y385-1 Y385-2

Solenoid valve / changeover bucket cylinder - AHS Solenoid valve / changeover bucket cylinder - AHS

Behind cab Behind cab

15.0 A 15.0 A



8.45.104


MJF C I F S S

Service Manual


84/1 A 312 Litronic / A 314 Litronic / A 316 Litronic (IND) UMSCHALTUNG LÖFFELKIPPKREIS / AHS SWITCHING SYSTEM BUCKET / AHS COMMUTATEUR GODET CURAGE / AHS


MJF C I F S S

8.45.105

Electric kits

Service Manual


Designation


A125**

PCB potentiometers

Left console

B33

Pressure switch pst for AHS section


F320** F321** F330** F331**

Fuse X11 / X12 Fuse X12 Fuse kits Fuse X29

H322



K375**

Relay / signal flow reduction AHS

Right console, rear

S241** S405


Right controle Right console

U16**


Right console, rear

V156-4

Blocking diode A125

A125

X12** X29** X837** X839** X856** X857** X957** X958** X963** X965** X966** X968-1** X968-2** X974-4** X1028 X1029 X1224

Plug connection, 2-pin / on distribution board Plug connection, 2-pin / distribution board Plug connection, 8-pin / A125 Plug connection, 3-pin / screw terminal on A125 Plug connection, 40-pin / BST wire harness Plug connection, 24-pin / BST Plug connection, 21-pin / distribution board Plug connection, 21-pin / distribution board Plug connection, 2-pin / distribution board Plug connection, 21-pin / BST- CS A125 Plug connection, 21-pin / A125 wire harness Plug connection, 1-pin / A125 CS Plug connection, 1-pin / A125 CS Plug connection, 2-pin / A125 CS Plug connection, 4-pin / to S405 and H322 Plug connection, 4-pin / solenoid valves Plug connection, 3-pin / pressure switch

Right console Right console, rear Left console, bottom Left console, bottom Right console Right console Right console, rear Right console, rear Right console, rear Right console, rear Right console, rear Left console, bottom Left console, bottom Left console, bottom Right control console, rear Right control console, rear Distribution board

Y268** Y299** Y385-1 Y385-2

Solenoid valve / grapple hammer Solenoid valve / changeover pressure limitation Solenoid valve / changeover bucket cylinder - AHS Solenoid valve / changeover bucket cylinder - AHS

Near hydraulic tank Near hydraulic tank Behind cab Behind cab

15.0 A 15.0 A 15.0 A 15.0 A

Right console, front Right console, front Right console, front Right console, front


8.45.106


MJF C I F S S

Service Manual


84/2

A 309 Litronic / A 311 Litronic UMSCHALTUNG LÖFFELKIPPKREIS / AHS SWITCHING SYSTEM BUCKET / AHS COMMUTATEUR GODET CURAGE / AHS


MJF C I F S S

8.45.107

Electric kits

Service Manual


8.45.108

Item

Designation


A125** A133

PCB potentiometers Printed circuit board

Left console Left console

B33



F321** F330**

Fuse X12 to kits fuse

H196** H322

Indicator light / sorting grapple Warning light / changeover

Right control desk Right control console

K375**


Right console, rear

S19** S241** S405

to switch / grapple rotator Y22, Y23 Switch AHS 11 / AHS 12 Switch / changeover

Keyboard of right console Right control desk Right console

U16**


Right console, rear

V156-4 V169


A125 A 125

X12** X29** X837** X839** X856** X857** X952** X957** X958** X963** X965** X966** X967** X968-1 X968-2 X974-4 X1028 X1029 X1224 Y268 Y299 Y385-1 Y385-2 Y451

Plug connection, 2-pin / on distribution board Plug connection, 2-pin / distribution board Plug connection, 8-pin / A125 Plug connection, 3-pin / screw terminal on A125 Plug connection, 40-pin / BST wire harness Plug connection, 24-pin / BST Plug connection, 21-pin / distribution board Plug connection, 21-pin / distribution board Plug connection, 21-pin / distribution board Plug connection, 2-pin / distribution board Plug connection, 21-pin / BST- CS A125 Plug connection, 21-pin / A125 wire harness Plug connection, 21-pin / distribution board Plug connection, 1-pin / A125 CS Plug connection, 1-pin / A125 CS Plug connection, 2-pin / A125 CS Plug connection, 4-pin / to S405 and H322 Plug connection, 4-pin / solenoid valves Plug connection, 3-pin / pressure switch Solenoid valve / grapple hammer Solenoid valve / changeover pressure limitation Solenoid valve / changeover bucket cylinder - AHS Solenoid valve / changeover bucket cylinder - AHS Solenoid valve / combined lifting of boom

Right console Right console, rear Left console, bottom Left console, bottom Right console Right console Right console, rear Right console, rear Right console, rear Right console, rear Right console, rear Right console, rear Right console, rear Left console, bottom Left console, bottom Left console, bottom Right control console, rear Right control console, rear Distribution board Near hydraulic tank Near hydraulic tank Behind cab Behind cab Near hydraulic tank

15.0 A 15.0 A



MJF C I F S S

Service Manual


84/3 A 309 Litronic / A 311 Litronic UMSCHALTUNG LÖFFELKIPPKREIS / AHS SWITCHING SYSTEM BUCKET / AHS COMMUTATEUR GODET CURAGE / AHS


MJF C I F S S

8.45.109

Electric kits

Service Manual


Designation


A133

Printed circuit board

Left console

B306

Particle filter temperature sensor

Particle filter

E50

Power and safety switch cabinet

Hydraulic tank

F351

Fuse (F_H)

H298 H299

Warning light / exhaust backpressure Warning buzzer / exhaust backpressure

Right control console Right control console

X20 X1040 X1041

Terminal for kit, 2-pin Plug connection, 3-pin / to display unit Plug connection, 2-pin / for temperature sensor

Printed circuit board A127 Electric box E50 Electric box E50

3A

Near hydraulic tank


8.45.110


MJF C I F S S

Service Manual


85

A 309 - A 316 Litronic PARTICLE FILTER PURITECH FILTRE DE PARTICULES PURITECH PARTICLE FILTER PURITECH


MJF C I F S S

8.45.111

Electric kits

Service Manual


Designation


F331**

Fuse X29

S124 S380

Switch / activation of mower rack operation Switch / mower rake activation

Right controle Right controle

X29** X963** X1050 X1051 X1052

Plug connection, 2-pin / distribution board Plug connection, 21-pin / distribution board Plug connection, 3-pin / adapter switch CS Plug connection, 3-pin / switch CS Plug connection, 4-pin / mower rake drive CS

Right console, rear Right console, rear Right handle Right handle Right handle

Y405 Y406

Solenoid valve with plug / mower rack forward Solenoid valve with plug / mower rack reverse

15.0 A



8.45.112


MJF C I F S S

Service Manual


86/1 A 312 Litronic / A 314 Litronic / A 316 Litronic (IND) ANBAUSATZ MAHKORB MOWER RAKE GODET FAUCARDEUR


MJF C I F S S

8.45.113

Electric kits

Service Manual


Designation


A1017

to quick-change adapter board

Right console, rear

F331**

Fuse X29

H329

Indicator light / mower rake operation

Right console

K438

Step relay / mower rake operation

Distribution board

S5L** S5R** S19** S124 S241** S380

Push button / turning grapple to the left, Y22 Push button / turning grapple to the right, Y23 Switch / grapple rotator Y22, Y23 Switch / activation of mower rack operation to switch AHS 11 / AHS 12 Override switch stick cylinder

Left pilot control unit Left pilot control unit Keyboard of right console Right controle Right controle In handle, right

X29** X412** X952** X957** X963** X966** X1046** X1050 X1052

Plug connection, 2-pin / distribution board to plug connection distribution board / 2-pin Plug connection, 21-pin / distribution board Plug connection, 21-pin / distribution board Plug connection, 2-pin / distribution board Plug connection, 21-pin / A125 wire harness Plug connection, 12-pin Plug connection, 3-pin / adapter switch CS Plug connection, 4-pin / mower rake drive CS

Right console, rear Right console, rear Right console, rear Right console, rear Right console, rear Right console, rear Left console Right handle Right handle

Y22** Y23** Y405

Solenoid valve / grapple rotator Solenoid valve / grapple rotator Solenoid valve with plug / mower rack forward

Control valve block Control valve block Mower rake

15.0 A



8.45.114


MJF C I F S S

Service Manual


86/2 A 312 Litronic / A 314 Litronic / A 316 Litronic (IND) ANBAUSATZ MAHKORB MOWER RAKE GODET FAUCARDEUR


MJF C I F S S

8.45.115

Electric kits

Service Manual


Designation


F320

Fuse X11 / X12

S272 S419

Slip-ring case Switch / trailer coupling

Undercarriages Right console

X11 X301 X963

Plug connection, 2-pin / on distribution board Plug connection, 12-pin / on slip ring Plug connection, 2-pin / distribution board

Right console Rotary connection Right console, rear

X1053

Plug connection, 1-pin / slip ring CS

Distribution board

Y406

Solenoid valve / trailer coupling OPEN/CLOSED

Uppercarriage, rear

15.0 A



8.45.116


MJF C I F S S

Service Manual


87

A 316 Litronic (IND) ANHANGEKUPPLUNG TRAILER COUPLING D'ATTELAGE


MJF C I F S S

8.45.117

Electric kits

Service Manual


Designation


A123


Left console

F331**

Fuse X29

S6L S6R S321

Push button / joystick control Push button / joystick control Switch / activate joystick steering

Right pilot control unit Right pilot control unit Right controle

X15 X29** X412 X413 X414

Plug connection, 3-pin Plug connection, 2-pin / distribution board Plug connection, 3-pin / to Y307 Plug connection, 3-pin / to S321 Plug connection, 5-pin / to A123

Right joystick Right console, rear Right console, rear Right console, rear Right console, rear

Y307

Proportional solenoid valve / steering

below operator's platform

15.0 A



8.45.118


MJF C I F S S

Service Manual


88

A 316 Litronic (IND) JOY-STICK LENKUNG JOYSTICK CONTROL COMMAND DU VOLANT DE DIRECTION


MJF C I F S S

8.45.119

Electric kits

Service Manual


Designation


A126**

PCB / autocheck

Right console

B10**

to pressure switch / parking brake

HBGV block

E167

Beacon for back-up warning

Cap, top right

F325**

Fuse S16, S263

H167** H168** H183

Indicator light / forward travel Indicator light / reverse travel Buzzer / back-up alarm

Right controle Right controle Cap, top left

K251**

Relay / parking brake

Right console, rear

S263** S269 S270

Switch / travelling direction Switch in slip ring Switch in slip ring

Right pilot control unit Rotary connection Rotary connection

X312 X313 X314 X324-1 X342 X950** X951** X952** X959** X962** X963** X993

Plug connection, 12-pin / on slip ring Plug connection, 12-pin / on slip ring Plug connection, 2-pin / to electr. buzzer Plug connection, 2-pin Plug connection, 3-pin / to travel selection switch Plug connection, 21-pin / autocheck Plug connection, 21-pin / autocheck Plug connection, 21-pin / distribution board Plug connection, 21-pin / distribution board Plug connection, 21-pin / distribution board Plug connection, 2-pin / distribution board Plug connection, 2-pin / beacon

Rotary connection Rotary connection Revolving deck Revolving deck Right console Right console Right console Right console, rear Right console, rear Right console, rear Right console, rear Uppercarriage, rear

Y62** Y63**

Solenoid valve / forward travel Solenoid valve / reverse travel

Hydraulic tank Hydraulic tank

7.5 A



8.45.120


MJF C I F S S

Service Manual


89

A 312 Litronic / A 314 Litronic / A 316 Litronic (IND) RÜCKFAHRWARNEINRICHTUNG OPTISCH UND AKUSTISCH BACK-UP WARNING DEVICE AVERTISSEUR DE MARCHE ARRIERE


MJF C I F S S

8.45.121

Electric kits

Service Manual


Designation


B233

Proximity switch / bucket cylinder movement

At stick

F331**

Fuse X29

H328

Indicator light / shut-down active


S423

Key switch / shut-down override

Right console

X29** X963**

Plug connection, 2-pin / distribution board Plug connection, 2-pin / distribution board

Right console, rear Right console, rear

X1060 X1061 X1062

Plug connection, 3-pin / switch Plug connection, 8-pin Plug connection, 3-pin

Right control console Uppercarriage Bearing block

Y409

Solenoid valve / tilt cylinder shut-down

Near hydraulic tank

15.0 A



8.45.122


MJF C I F S S

Service Manual


90 A 312 Li / A 314 Li / A 316 Li (IND) / R 317 Li ABSCHALTUNG LÖFFELKIPPZYLINDER


MJF C I F S S

8.45.123

Electric kits

Service Manual


Designation


F320** F331**

Fuse X11 / X12 Fuse X29

K375** K436 K437

Relay / signal flow reduction AHS Step relay (atom. reset) Relay / signal flow reduction drilling slide

Right console, rear Distribution board Distribution board

S424

Push button / continuous operation AHS

Right console

X11** X29** X957** X963** X966** X1070-1 X1070-2

Plug connection, 2-pin / on distribution board Plug connection, 2-pin / distribution board Plug connection, 21-pin / distribution board Plug connection, 2-pin / distribution board Plug connection, 21-pin / A125 wire harness Plug connection, 2-pin / solenoid valve Plug connection, 2-pin / solenoid valve

Right console Right console, rear Right console, rear Right console, rear Right console, rear Near hydraulic tank Near hydraulic tank

Y410

Solenoid valve / continuous operation AHS

Near hydraulic tank

15.0 A 15.0 A



8.45.124


MJF C I F S S

Service Manual


91

A 312 Litronic / A 314 Litronic / A 316 Litronic (IND) ANBAUSATZ BOHRLAFETTE DRILLING SLIDE ACCESSORY KIT EQUIPEMENT COMPLEMENTAIRE AFFUT


MJF C I F S S

8.45.125

Electric kits

Service Manual


Designation


F337**

Fuse kits

S272** S335** S343 S439R

Slip-ring case Switch / preselection changeover blade - outrigger Switch / individual control, back Push button / support pilot control unit

S439R

Push button / support pilot control unit

X301** X304** X955** X957** X958** X959** X963** X1104

Plug connection, 12-pin / on slip ring Plug connection, 6-pin / to S04, S205, S206, S207 Plug connection, 15-pin / distribution board Plug connection, 21-pin / distribution board Plug connection, 21-pin / distribution board Plug connection, 21-pin / distribution board Plug connection, 2-pin / distribution board Plug connection, 1-pin

Rotary connection Right console, rear Right console, rear Right console, rear Right console, rear Right console, rear Right console, rear Right controle

Y56** Y217** Y218**

Solenoid valve / changeover outrigger - blade Solenoid valve / rear left outrigger support Solenoid valve / rear right outrigger support

Undercarriages Undercarriages Undercarriages

15.0 A

Right console, front Undercarriages Right controle Right controle Pilot control valve / support Pilot control valve / support


8.45.126


MJF C I F S S

Service Manual


92

A 309 Litronic / A 311 Litronic SCHILD EINZELSTEUERUNG OPTION LAME DE NIVELAGE/BRAS STABILISATEUR OPTION DOZER BLADE/OUTRIGGER INDIVIDUAL CONTROL


MJF C I F S S

8.45.127

Electric kits

Service Manual


Designation


F337**

Fuse kits

S7** S272** S443L S443R

to safety switch Slip-ring case Push button / telescope blade, left rear Push button / telescope blade, right rear

Left console Undercarriages Pilot control valve: support Pilot control valve / support

V172-1 V172-2

Blocking diode / signal Y428 - Y217 Blocking diode / signal Y428 - Y218


X301** X304** X771** X957** X958** X963** X1104

Plug connection, 12-pin / on slip ring Plug connection, 6-pin / to S04, S205, S206, S207 Plug connection, 5-pin Plug connection, 21-pin / distribution board Plug connection, 21-pin / distribution board Plug connection, 2-pin / distribution board Plug connection, 1-pin

Rotary connection Right console, rear Left console Right console, rear Right console, rear Right console, rear Right controle

Y217** Y218** Y428

Solenoid valve / rear left outrigger support Solenoid valve / rear right outrigger support Solenoid valve / changeover UP/DOWN - telescope OUT/IN

Undercarriages Undercarriages Undercarriages

15.0 A



8.45.128


MJF C I F S S

Service Manual


93

A 312 Litronic / A 314 Litronic / A 316 Litronic (IND) TELESCOPIC SUPPORT BLADE


MJF C I F S S

8.45.129

Electric kits

Service Manual


Designation


F331**

Fuse X29

S6L S6R S379

Push button / activation horizontal adjustment Push button / activation horizontal adjustment Switch / release of push button for horizontal adjustment (right handle)

Right pilot control unit Right pilot control unit Right console

X29** X407** X408 X410** X963**

Plug connection, 2-pin / distribution board Plug connection: 2-pin, / reolving deck CS Plug connection, 2-pin / to revolving deck CS Plug connection, 2-pin / power supply A1017 Plug connection, 2-pin / distribution board

Right console, rear Right control console Right control console Right console, rear Right console, rear

Y365 Y366

Solenoid valve / cylinder retraction Solenoid valve / cylinder extension / hammer


15.0 A



8.45.130


MJF C I F S S

Service Manual


94

A 312 Litronic / A 314 Litronic / A 316 Litronic / R 317 Litronic BETÄTIGUNG SCHIEBERSEKTION ÜBER TASTER ACTUATION VALVE SPOOL WITH PUSH BUTTON COMMANDE TIROIR DE DISTRIDUTION AVEC BOUTON POUSSOIR


MJF C I F S S

8.45.131

Electric kits

Service Manual


Designation


A127**


Hydraulic tank

F20/ F300** F303** F325**

Fuse terminal 30 to terminal 15

50.0 A

A127 hydraulic tank

Fuse A127, Y29 Fuse S16, S263

7.5 A 7.5 A

Near hydraulic tank Right console, front

K251** K288** K439

Relay / parking brake Relay / terminal 15 at A127 Relay / drop-out delayed

Right console, rear Near hydraulic tank Distribution board

V168

Decay diode

A 127

X952** X962** X963** X1006 X1011

Plug connection, 21-pin / distribution board Plug connection, 21-pin / distribution board Plug connection, 2-pin / distribution board Plug terminal, 1-pin Plug connection, 3-pin / decay diode

Right console, rear Right console, rear Right console, rear Near A127 Near A127

Y29**

Solenoid valve / engine shut-down

Engine block regulating rod


8.45.132


MJF C I F S S

Service Manual


95

A 312 Li / A 314 Li / A 316 Li (IND) / R 317 Li MOTORSTOP ZEITGESTEUERT ENGINE STOP WITH TIMER ARRET MOTEUR AUTOMATIQUE


MJF C I F S S

8.45.133

Electric kits

Service Manual


Designation


A1017**


Right console, rear

S5L** S5R** S19** S45 S241** S382** S451 S452

Push button / turning grapple to the left, Y22 Push button / turning grapple to the right, Y23 Switch / grapple rotator Y22, Y23 to priority switch to switch AHS 11 / AHS 12 Switch / fine regulation OFF Rocker button / rotating grapple Switch / rotating grapple with rocker button

Left pilot control unit Left pilot control unit Keyboard of right console Right controle Right controle Right controle Left pilot control unit Right console

X15-2** X74** X952** X957** X966** X1179

Plug connection, 3-pin Plug connection, 3-pin / S6 Plug connection, 21-pin / distribution board Plug connection, 21-pin / distribution board Plug connection, 21-pin / A125 wire harness Plug connection, 3-pin / to display unit

Left console Right console Right console, rear Right console, rear Right console, rear Right control console

Y22** Y23**


Control valve block Control valve block

** item from basic diagram Z=

8.45.134

switch S382 in rocker button design with indicator light due to change of the switch from the left pilot control unit (rocker button design, see step 24 in basic machine diagram) to the right control desk.


MJF C I F S S

Service Manual


96

A 312 Litronic / A 314 Litronic / A 316 Litronic (IND) GREIFER DREHEN ÜBER RECHTEN WIPPTASTER GRAPPLE ROTATOR MECHANISME DE ROTATION


MJF C I F S S

8.45.135

Electric kits

Service Manual


Designation


A126**

PCB / autocheck

Right console

E21** E22** E23 E24 E173 E174

Indicator light, front left Indicator light, rear left Indicator light, front right Indicator light, rear right Auxiliary indicator, right Auxiliary indicator, left

Revolving deck, front left Weight, left Revolving deck, front right Weight, left Uppercarriage, front right Uppercarriage, front left

F302** F312** F338**

to fuse S44 Fuse S44,E21 - E24 Fuse capacitor motors

H9** H19**

Horn Indicator light / indicator

Right console Right controle

K63**

Relay / direction indicator

Near hydraulic tank

M70**

to motor / air-spring seat

Operator's platform

S4** S32 S44** S389**

Horn switch Steering column switch Hazard warning lights switch to switch seat heating

Cab floor plate Steering column Right console Operator seat

X550** X950** X951** X953** X955** X960** X962** X964**

Plug connection Plug connection, 21-pin / autocheck Plug connection, 21-pin / autocheck Plug connection, 21-pin / distribution board Plug connection, 15-pin / distribution board Plug connection, 21-pin / distribution board Plug connection, 21-pin / distribution board Plug connection, 21-pin / distribution board

Right console Right console Right console Right console, rear Right console, rear Right console, rear Right console, rear Right console, rear

7.5 A 7.5 A 20.0 A

A127 Right console Right console, front


8.45.136


MJF C I F S S

Service Manual


97/1 A 309 Li / A 311 Li / A 312 Li / A 314 Li / A 316 Li (IND) ZUSATZ - BLINKLEUCHTEN / BLINKANLAGE, HUPE INDICATORS, HORN CLINGOTANTS, AVERTISSEUR


MJF C I F S S

8.45.137

Electric kits

Service Manual


Designation


E3** E4** E15** E16** E17** E18** E19** E20** E23** E171 E172

Headlight uppercarriage, left Headlight uppercarriage, right Parking light, right Parking light, left Rear light, right Tail light, left Brake light, right Brake light, left to indicator light, front right Outline light, right Outline light, left

Front cab roof Cab roof Revolving deck, front right Revolving deck, front left Revolving deck, rear right Revolving deck, rear left Weight, right Weight, left Revolving deck, front right Uppercarriage, right Uppercarriage, left

F307** F308** F309** F310** F336**

Fuse E16, E17 Fuse E15, E18 Fuse E3 Fuse E4 Fuse S61

K315**

to relay / brake light

Right console, rear

P6**

to indicator / engine temperature

Right controle

S61**


Right console, rear

X953** X960** X961** X963** X967** X1186**

Plug connection, 21-pin / distribution board Plug connection, 21-pin / distribution board Plug connection, 21-pin / distribution board Plug connection, 2-pin / distribution board Plug connection, 21-pin / distribution board Plug connection, 3-pin

X1198**

Plug connection, 2-pin / for temperature sensor

Right console, rear Right console, rear Right console, rear Right console, rear Right console, rear Engine compartment, left rear Uppercarriage, right

7.5 A 7.5 A 7.5 A 7.5 A 20.0 A

Right console, rear Right console, rear Right console, rear Right console, rear Right console, front


8.45.138


MJF C I F S S

Service Manual


97/2

A 309 Litronic / A 311 Litronic ZUSATZ - LEUCHTEN / LICHTANLAGE LIGHTING SYSTEM ECLAIRAGE


MJF C I F S S

8.45.139

Electric kits

Service Manual


Designation


E3** E4** E15** E16** E17** E18** E169 E170 E171 E172

Headlight uppercarriage left Headlight uppercarriage, right Parking light, right Parking light, left Rear light, right Tail light, left Position light, front right in indicator Position light, front left in indicator Outline light, right Outline light, left

Front cab roof Cab roof Revolving deck, front right Revolving deck, front left Revolving deck, rear right Revolving deck, rear left Revolving deck, right Revolving deck, left Uppercarriage, right Uppercarriage, left

F20** F307** F308** F309** F310** F336**

to fuse terminal 30 Fuse E16, E17 Fuse E15, E18 Fuse E3 Fuse E4 Fuse S61

P6**

to indicator / engine temperature

Right controle

S61**


Right console, rear

X953** X960** X961** X963** X967**

Plug connection, 21-pin / distribution board Plug connection, 21-pin / distribution board Plug connection, 21-pin / distribution board Plug connection, 2-pin / distribution board Plug connection, 21-pin / distribution board


7.5 A 7.5 A 7.5 A 7.5 A 7.5 A 20.0 A

A127 Right console, rear Right console, rear Right console, rear Right console, rear Right console, front


8.45.140


MJF C I F S S

Service Manual


97/3

A 312 Litronic / A 314 Litronic / A 316 Litronic (IND) ZUSATZ - LEUCHTEN / LICHTANLAGE LIGHTING SYSTEM ECLAIRAGE


MJF C I F S S

8.45.141

Electric kits

Service Manual


Designation


F330**

Fuse kits

S16** S263** S382**

to parking brake switch Switch / travelling direction Switch / fine regulation OFF

Right control console Right pilot control unit Right controle

U16**


Right controle

X230** X951** X956** X959** X962** X963** X966** X1046** X1046-1 X1048** X1046-1

Plug connection, 3-pin / on A1100 Plug connection, 21-pin / autocheck Plug connection, 21-pin / distribution board Plug connection, 21-pin / distribution board Plug connection, 21-pin / distribution board Plug connection, 2-pin / distribution board Plug connection, 21-pin / A125 wire harness Plug connection, 12-pin Plug handle extension, 6-pin Plug connection, 12-pin Plug to handle switch, 3-pin

Left console Right console Right console, rear Right console, rear Right console, rear Right console, rear Right console, rear Left console Right handle Right handle Right handle

15.0 A



8.45.142


MJF C I F S S

Service Manual


98

A 312 Litronic / A 314 Litronic / A 316 Litronic (IND) SCHALTER FAHRTRICHTUNG IM LINKEN GRIFF TRAVEL DIRECTION SELECTION IN LEFT JOYSTICK INTTERRUPTEUR SENS DE MARCHE AU MANIPULATEUR GAUCHE


MJF C I F S S

8.45.143

Electric kits

Service Manual


Designation


F338**

Fuse S4, seat heating

F338**

Fuse S4, seat heating

H9**

Horn

Right console

S4** S6L S6R S32

Horn switch Push button / horn activation Push button / horn activation Steering column switch

Cab floor plate Right pilot control unit Right pilot control unit Steering column

X74 X550** X960** X964** X1048**

Plug connection, 3-pin / S6 Plug connection Plug connection, 21-pin / distribution board Plug connection, 21-pin / distribution board Plug connection, 12-pin

Right console Right console Right console, rear Right console, rear Right handle

10.0 A at 309-311 15.0 A at 312-316



8.45.144


MJF C I F S S

Service Manual


99

A 309 Li / A 311 Li / A 312 Li / A 314 Li / A 316 Li BETÄTIGUNG HUPE ÜBER TASTER HORN ACTUATION WITH PUSH BUTTON COMMANDE AVERTISSEUR AVEC BOUTON POUSSOIR


MJF C I F S S

8.45.145

Electric kits

Service Manual


Designation


A127**


Hydraulic tank

F331** F364

Fuse X29 Fuse

H158

Indicator light / Fuchs control ON


K229

Relay / changeover (K_B)

A127

S247

Key switch / Fuchs control

Right controle

X29** X963**

Plug connection, 2-pin / distribution board Plug connection, 2-pin / distribution board


X1213

Plug connection, 2-pin / decay diode


Y236-1 Y236-2 Y236-3 Y236-4

Solenoid valve / changeover Solenoid valve / changeover Solenoid valve / changeover Solenoid valve / changeover

Near control valve block Near control valve block Near control valve block Near control valve block

15.0 A 15.0 A

Right console, front Printed circuit board A127


8.45.146


MJF C I F S S

Service Manual


100 A 312 Li / A 314 Li / A 316 Li (IND) / R 317 Li UMSCHALTUNG FUCHS-STEUERUNG SWITCHING FUCHS SERVO CONTROLS COMMUTATION COMMANDE FUCHS


MJF C I F S S

8.45.147

Electric kits

Service Manual


Designation


B290**

Proximity switch / adjusting pedal left

Operator's platform / front

F320**

Fuse X11 / X12

H343

Warning light / outriggers not retracted


S272**

Slip-ring case

Undercarriages

X11** X301** X771** X963** X1215 X1218

Plug connection, 2-pin / on distribution board Plug connection, 12-pin / on slip ring Plug connection, 5-pin Plug connection, 2-pin / distribution board Plug connection, 2-pin / warning light Plug connection, 3-pin / warning light

Right console Rotary connection Left console Right console, rear Right control console Right control console

15.0 A



8.45.148


MJF C I F S S

Service Manual


101 A 312 Li / A 314 Li / A 316 Li (IND) PRATZENKONTROLLE OUTRIGGER CONTROL BRAS STABO OSATEIRS DE CONTROL


MJF C I F S S

8.45.149

Electric kits

Service Manual


Designation


F320**

Fuse X11 / X12

H90

Indicator light / change of direction of fan

Right console

KT20 KT21

Time relay / fan afterrun Time relay / direction of rotation switching

Distribution board Distribution board

S160

Switch / change of direction of rotation

Right console

X11** X963** X1234 X1235

Plug connection, 2-pin / on distribution board Plug connection, 2-pin / distribution board Plug connection, 6-pin / adapter switch CS Plug connection, 4-pin / magnet unit CS

Right console Right console, rear Right console Behind cab

Y356 Y357

Solenoid valve / fan stop Solenoid valve / change of direction of rotation

Counter weight Counter weight

15.0 A



8.45.150


MJF C I F S S

Service Manual


102 A 309 Li / A 311 Li / A 312 Li / A 314 Li / A 316 Li IND / R 317 Li LÜFTERANTRIEB REVERSIERBAR REVERSIBLE FAN DRIVE ENTRAINEMENT DU VENTILATEUR REVERSIBLE


MJF C I F S S

8.45.151

Electric kits

Service Manual


Designation


A126**

PCB / autocheck

Right console

F326**

Fuse Y24, Y55, Y371, QC adapter

H176** H311**

Indicator lamp / oscillating axle automatic Indicator lamp / oscillating axle locked


K250** K464

Relay / oscillating axle automatic Relay / oscillating axle release

Distribution board

S6L

S7** S35** S75**

Push buttons magnet unit, grapple activation, joystick steering, horn actuation, oscillating axle release Push buttons magnet unit, grapple activation, joystick steering, horn actuation to safety switch to servo switch Switch / oscillating axle locking device

Left console, bottom Keyboard of right console Right console

V155** V156-2**

Blocking diode Blocking diode


X74** X842-3** X950** X952** X959** X961** X964** X974-2** X1048**

Plug connection, 3-pin / S6 Plug connection, 2 pin / blocking diode Plug connection, 21-pin / autocheck Plug connection, 21-pin / distribution board Plug connection, 21-pin / distribution board Plug connection, 21-pin / distribution board Plug connection, 21-pin / distribution board Plug connection, 2 pin / blocking diode Plug connection, 12-pin

Right console Right console Right console Right console, rear Right console, rear Right console, rear Right console, rear Left console, bottom Right handle

Y371**

Solenoid valve / oscillating axle

Control oil unit

S6R

15.0 A


Right pilot control unit Right pilot control unit


8.45.152


MJF C I F S S

Service Manual


103 A 309 Li / A 311 Li / A 312 Li / A 314 Li / A 316 Li (IND) AUTOMATISCHE PENDELACHSVERRIEGELUNG AUTOM. OSCILLATING AXLE LOCK VERROUILLAGE AUTOMATIQUE DU PONT OSCILLANT


MJF C I F S S

8.45.153

Electric kits

Service Manual


Designation


B36 F320**

Pressure switch Fuse X11

H33

Back-up alarm

Right console

K407-1 K407-2

Relay / travel warning mute Time relay / delayed travel warning

Distribution board Distribution board

S6L

Push button / right pilot control device travel warning

Right pilot control unit

X11** X204 X206 X207 X324-1 X324-2 X963** X1048**

Plug connection, 2-pin / distribution board Plug connection, 2-pin / to buzzer H33 Plug connection, 2-pin / to pressure switch B36 Plug connection, 2-pin / to pressure switch B36 Plug connection, 2-pin / to buzzer H33 Plug connection, 2-pin / to buzzer H33 Plug connection, 21-pin / distribution board Plug connection, 12-pin, CS console, ignition switch

Right console Right console, rear Right console Right console, rear Hood Revolving deck Right console, rear Right console

15.0 A

Right pilot control unit Right console, front

** in basic machine

8.45.154


MJF C I F S S

Service Manual


104 A 309 - A 316 Li FAHRWARNEINRICHTUNG TRAVEL ALARM AVERTISSEUR DE MARCHE


MJF C I F S S

8.45.155

Electric kits

Service Manual


Designation


F331**

Fuse

H323

Indicator light / lateral adjustment

Right console

K370**

Relay servo

Right console, rear

S356


Right console

X29** X358-1 X358-2 X963** X983** X1046

Plug connection, 2-pin / distribution board Plug connection, 2-pin Plug connection, 2-pin Plug connection, 21-pin / distribution board Plug connection, 3-pin / distribution board Plug connection, 12-pin

Right console, rear below operator's platform Fuel tank Right console, rear Right console, rear Right console, rear

Y332**


Attachments

15.0 A



8.45.156


MJF C I F S S

Service Manual


105 A 309 - A 316 Li ANBAUSATZ UMSCHALTSCHIEBER CHANGEOVER VALVE ACCESSORY KIT TIROIR DIVERSION


MJF C I F S S

8.45.157

Electric kits

Service Manual


Step 106 Item

Designation

F331**


K455

Relay / changeover valve UP, horizontal

Right console, rear

S356


Right console

X29** X358-1 X358-2 X963** X983** X1226 X1245 X1246

Plug connection, 2-pin / distribution board Plug connection, 2-pin Plug connection, 2-pin Plug connection, 21-pin / distribution board Plug connection, 3-pin / distribution board Plug connection, 2-pin / solenoid valves Plug connection, 4-pin / solenoid valves Plug connection, 2-pin / solenoid valves

Right console, rear below operator's platform Fuel tank Right console, rear Right console, rear Hydraulic tank below operator's platform Hydraulic tank

Y332 Y443

Solenoid valve / changeover valve Pipe fracture safety stop valve / regulating cylinder extending Pipe fracture safety stop valve / regulating cylinder extending Solenoid valve control pressure changeover / piston side Solenoid valve control pressure changeover / rod side Solenoid valve changeover control line at regulating cylinder

Slewing boom Hydraulic tank

Y444 Y453 Y454 Y456

Location / arrangement 15.0 A


Hydraulic tank below operator's platform below operator's platform Hydraulic tank


8.45.158


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Service Manual


106 A 312 - R 317 Li ANBAUSATZ UMSCHALTSCHIEBER CHANGEOVER VALVE ACCESSORY KIT TIROIR DIVERSION


MJF C I F S S

8.45.159

Electric kits

Service Manual


Step 107 Item

Designation


F330**

Fuse

H196 H323

Indicator light / sorting grapple Indicator light / lateral adjustment


K375**


Right console, rear

S241 S356

Switch AHS 12 Switch / changeover valve


X952** X957** X958** X1046

Plug connection, 21-pin / distribution board Plug connection, 21-pin / distribution board Plug connection, 3-pin / distribution board Plug connection, 12-pin

Right console, rear Right console, rear Right console, rear Left pilot control unit

Y268** Y299**

Solenoid valve changeover Solenoid valve / additional pressure stage


15.0 A



8.45.160


MJF C I F S S

Service Manual


107 A 312 - R 317 Li ANBAUSATZ UMSCHALTSCHIEBER CHANGEOVER VALVE ACCESSORY KIT TIROIR DIVERSION


MJF C I F S S

8.45.161

Electric kits

Service Manual


Step 108 Item

Designation


B213 B214

Proximity switch boom shut-down at stick Proximity switch boom shut-down at bearing block

Attachments Attachments

F331**



H27 H249

Quick-change adapter buzzer / boom shut-down Indicator light / override ON

Right controle, rear Right controle, rear

K414

Relay / boom shut-down

Right console, rear

S249 S291

Key switch boom shut-down ON Button boom shut-down override / left pilot control unit


X29** X74 X963** X988-1 X988-2 X988-3 X988-4 X988-5 X988-6 X1132

Plug connection, 2-pin / distribution board Plug connection, 3-pin / to S6 Plug connection, 21-pin / distribution board Plug connection, 8-pin / boom shut-down Plug connection, 4-pin / boom shut-down Plug connection, 3-pin / blocking diodes Plug connection, 6-pin / blocking diodes Plug connection, 6-pin / blocking diodes Plug connection, 3-pin / to B214 Plug connection, 3-pin / extension

Right console, rear below operator's platform Right console, rear Revolving deck Attachments Right console, rear Right console, rear Right console, rear Attachments Left console, rear

Y237 Y238

Solenoid valve / stick shut-down Solenoid valve / boom shut-down


15.0 A


8.45.162


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Service Manual


108 A 312 - R 317 Li HUBBEGRENZUNG HUB UND STIEL STROKE LIMITER AND STICK LIMITEUR DE COURSE LEVAGE ET BALNCIER


MJF C I F S S

8.45.163

Electric kits

Service Manual


Step 109 Item

Designation


A1017**


Right console, rear

S5L** S5R** S6L S6R S19**

Push button / turning grapple to the left, Y22 Push button / turning grapple to the right, Y23 Push button / turning grapple to the left, Y22 Push button / turning grapple to the right, Y23 Switch / grapple rotator Y22, Y23

Left pilot control unit Left pilot control unit Right pilot control unit Right pilot control unit Keyboard of right console

X15-2** X74 X952** X957** X966** X1046 X1046-1 X1048

Plug connection, 3-pin Plug connection, 3-pin / S6 Plug connection, 21-pin / distribution board Plug connection, 21-pin / distribution board Plug connection, 21-pin / distribution board Plug connection, 12-pin / left handle Plug connection, 6-pin / handle extension Plug connection, 12-pin

Left console Right console Right console, rear Right console, rear Right console, rear Left control console Left control console Right control console

Y22** Y23**




8.45.164


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Service Manual


109 A 312 - R 317 Li BETÄTIGUNG AS1 IM GRIFF LINKS UND RECHTS GRAPPLE CONTROL IN LEFT AND RIGHT JOYSTICK CDE. AS 1 DANS MANIPULATEUR GUAUGE ET DROITE


MJF C I F S S

8.45.165

Electric kits

Service Manual


Step 110 Item

Designation


A125**

PCB potentiometers

Left console

B33



F330** F331**

to fuse Fuse X29

H322



K375**


Right console, rear

S19** S241** S405

to switch AS 1 Switch AHS 11 / AHS 12 Switch / changeover

Right controle Right controle Right console

U16**


Right console, rear

V156-4

Blocking diode A125

A125

X29** X837** X839** X856** X857** X952** X953** X954** X957** X958** X963** X965** X966** X968-1** X968-2** X974-4** X1028 X1029

Plug connection, 2-pin / distribution board Plug connection, 8-pin / A125 Plug connection, 3-pin / screw terminal on A125 Plug connection, 40-pin / BST wire harness Plug connection, 24-pin / BST Plug connection, 21-pin / distribution board Plug connection, 21-pin / distribution board Plug connection, 21-pin / distribution board Plug connection, 21-pin / distribution board Plug connection, 21-pin / distribution board Plug connection, 2-pin / distribution board Plug connection, 21-pin / BST- CS A125 Plug connection, 21-pin / A125 wire harness Plug connection, 1-pin / A125 CS Plug connection, 1-pin / A125 CS Plug connection, 2-pin / A125 CS Plug connection, 4-pin / to S405 and H322 Plug connection, 4-pin / solenoid valves

Right console, rear Left console, bottom Left console, bottom Right console Right console Right console, rear Right console, rear Right console, rear Right console, rear Right console, rear Right console, rear Right console, rear Right console, rear Left console, bottom Left console, bottom Left console, bottom Right control console, rear Right control console, rear

Y268** Y299** Y385-1 Y385-2 Y451

Solenoid valve / grapple hammer Solenoid valve / changeover pressure limitation Solenoid valve / changeover bucket cylinder - AHS Solenoid valve / changeover bucket cylinder - AHS Solenoid valve / combined lifting of boom

Near hydraulic tank Near hydraulic tank Behind cab Behind cab Behind cab

15.0 A 15.0 A



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Service Manual


110

A 309 Litronic / A 311 Litronic UMSCHALTUNG LÖFFELKIPPKREIS / AHS SWITCHING SYSTEM BUCKET / AHS COMMUTATEUR GODET CURAGE / AHS


MJF C I F S S

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Electric kits

Service Manual


Step 111 Item

Designation


F314** F329** FRes**

Fuse S7 Fuse S35 Fuse, reserve

H27**

Warning buzzer


K370** K386** K471

Relay terminal 15 servo Relay / safety switch Relay inversion signal servo OFF

Right console, rear Right console, rear Right console, rear

S7** S35**

Safety switch Switch servo shut-down

Left console Right controle

U16**


Right console, rear

V178-1 V178-2

Blocking diode signal Servo-S7 Blocking diode signal Servo-S7


X952** X956** X959** X962** X963** X964** X966** X1106 X1117

Plug connection, 21-pin / distribution board Plug connection, 21-pin / distribution board Plug connection, 21-pin / distribution board Plug connection, 21-pin / distribution board Plug connection, 2-pin / distribution board Plug connection, 21-pin / distribution board Plug connection, 21-pin / A125 wire harness Plug connection, 4-pin / power supply Plug connection, 6-pin / 4-wheel steering

Right console, rear Right console, rear Right console, rear Right console, rear Right console, rear Right console, rear Right console, rear Right control console, rear Right control console, rear

Y3** Y330**

Solenoid valve / pilot pressure Solenoid valve / pump regulation (not required during series)

Control oil unit Control oil unit

3.0 A 5.0 A

Right console, front Right console, front Right console, front


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Service Manual


111

A 309 Litronic / A 311 Litronic BAUSATZ ABSENKUNG MOTORDREHZAHL BEIM ARBEITEN / LEISTUNGSREDZIERUNG KIT LOWERING ENGINE RPM DURING WORK / POWER REDUCTION KIT REDUCTION DE PUISSNANCE


MJF C I F S S

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Electric kits

Service Manual


Step 112 Item

Designation


F331**

Fuse X29

S6L S6R S379

Push button / activation horizontal adjustment Push button / activation horizontal adjustment Switch / release of push button for horizontal adjustment (right handle)


X29** X74** X407** X408 X963** X1048**

Plug connection, 2-pin / distribution board Plug connection, 3-pin / button Plug connection, 4-pin / switch Plug connection, 4-pin / solenoid valves Plug connection, 21-pin / distribution board Plug connection, 12-pin

Right console, rear Right console, rear Right control console Right control console Right console, rear Right handle

Y365 Y366

Solenoid valve / cylinder retraction Solenoid valve / cylinder extension / hammer


15.0 A



8.45.170


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Service Manual


112 A 312 Litronic / A 314 Litronic / A 316 Litronic / R 317 Litronic BETÄTIGUNG SCHIEBERSEKTION ÜBER TASTER VALVE SPOOL ACTUATION WITH PUSH BUTTON COMMANDE TIROIR DE DISTRIDUTION AVEC BOUTON POUSSOIR


MJF C I F S S

8.45.171

Electric kits

Service Manual


Step 113 Item

Designation


A1017**


Right console, rear

S6L** S6R** S19** S124 S241** S451

Push button / turning grapple to the left, Y22 Push button / turning grapple to the right, Y23 Switch / grapple rotator Y22, Y23 Switch / rotating grapple with rocker button to switch accessory kit AHS Rocker button / rotating grapple

Right pilot control unit Right pilot control unit Keyboard of right console Right console Right console Right pilot control unit

X952** X957** X966** X1046 X1048 X1179

Plug connection, 21-pin / distribution board Plug connection, 21-pin / distribution board Plug connection, 21-pin / A125 wire harness Plug connection, 12-pin Plug connection, 12-pin Plug connection, 3-pin / to display unit

Right console, rear Right console, rear Right console, rear Right control console Right control console Right control console

Y22** Y23**




8.45.172


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Service Manual


113 A 312 Litronic / A 314 Litronic / A 316 Litronic (IND) GREIFER DREHEN ÜBER RECHTEN WIPPTASTER GRAPPLE ROTATOR MECHANISME DE ROTATION


MJF C I F S S

8.45.173

Electric kits

Service Manual


Step 114 Item

Designation


F337**

Fuse

S272** S124 S343 S439L S439R

Slip-ring case Blade support switch Switch individual control, back, optional Push button / support pilot control unit Push button / support pilot control unit

Undercarriages Right control console Right control console Right control console Right control console

X301 X304 X955 X957 X958 X959 X963 X1104

Plug connection, 12-pin / slip rig distribution board Plug connection, 4-pin / console right Plug connection, 21-pin / distribution board Plug connection, 21-pin / distribution board Plug connection, 21-pin / distribution board Plug connection, 21-pin / distribution board Plug connection, 21-pin / distribution board Plug connection, 3-pin / handle right

Right control console, rear Right control console, rear Right control console, rear Right control console, rear Right control console, rear Right control console, rear Right control console, rear Right control console, rear

Y56 Y217 Y218

Solenoid valve / blade support, front Solenoid valve / outrigger support, rear left Solenoid valve / outrigger support, rear right

Undercarriages Support cylinders Support cylinders

15.0 A



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Service Manual


114 A 309 / A 311 Litronic SCHILDEINZELSTEUERUNG PRATZE INDIVIDUAL BLADE CONTROL OUTRIGGER COMMANDE UNIQUE LAME / STABILISATEUR


MJF C I F S S

8.45.175

Electric kits

Service Manual


Step 115 Item

Designation


A125**

PCB potentiometers

Near hydraulic tank

H344

Indicator light / flow distributor


K375** K467

Relay / signal flow reduction AHS Step relay / flow distributor operation


S6L S6R S464

Left button Right button Switch activation / flow distributor operation


U16**


Right console, rear

V156-4 V177

Diode / input quantity Blocking diode signal flow reduction / flow distributor


X74 X837** X839** X856** X857** X957** X965** X966** X968-1** X968-2** X974-4** X1048 X1240 X1241 X1242 X1243 X1244

Plug connection, 3-pin / handle right Plug connection, 8-pin / A125 Plug connection, 3-pin / screw terminal on A125 Plug connection, 40-pin / BST wire harness Plug connection, 24-pin / BST Plug connection, 21-pin / distribution board Plug connection, 21-pin / BST- CS A125 Plug connection, 21-pin / A125 wire harness Plug connection, 1-pin / A125 CS Plug connection, 1-pin / A125 CS Plug connection, 2-pin / A125 CS Plug connection, 4-pin / to S405 and H322 Plug connection, 4-pin / adapter switch CS Plug connection, 2-pin / CS flow distributor Plug connection, 2-pin / CS solenoid valve Plug connection, 1-pin / CS flow distributor Plug connection, 2-pin / CS diode

Right console, rear Left console, bottom Left console, bottom Right console Right console Right console, rear Right console, rear Right console, rear Near hydraulic tank Near hydraulic tank Near hydraulic tank Right control console, rear Near hydraulic tank Near hydraulic tank Near hydraulic tank Right control console, rear Counter weight

Y295 Y452

Solenoid valve flow distributor Solenoid valve changeover AHS actuation

Counter weight Fuel tank


8.45.176


MJF C I F S S

Service Manual


115 A 309 / A 311 Litronic MENGENTEILER FLOW DISTRIBUTOR DIVISEUR DE DEBIT


MJF C I F S S

8.45.177

Electric kits

Service Manual


Step 116 Item

Designation


F320**

Fuse X11

S84-1

Push button with plug / central lubrication

U4-1

Central lubrication system

X11** X143-1 X963** X998 X1251

Plug connection, 2-pin / distribution board Plug connection, 4-pin / central lubrication system Plug connection, 21-pin / distribution board Plug connection, 3-pin / under operator's platform Plug connection, 4-pin / CS switch

15.0 A


8.45.178


MJF C I F S S

Service Manual


116 A 309 - R 317 Litronic ZENTRALSCHMIERANLAGE SEMIAUTOMATISCH SEMIAUTOMATIC CENTRAL LUBRICATION SYSTEM DISP. DE GRAISSAGE CENRALISE SEMIAUTOMATIQUE


MJF C I F S S

8.45.179

Electric kits

Service Manual


Step 117 Item

Designation


B204

Proximity switch stick cylinder shut-down

At stick

F331**

Fuse X29

S216

Button stick cylinder shut-down override

Right console

X29** X327 X963** X1254 X1255

Plug connection, 2-pin / distribution board Plug connection, 2-pin Plug connection, 21-pin / distribution board Plug connection, 2-pin / solenoid valve Plug connection, 3-pin / button

Right console, rear Attachments Right console, rear Right control console Right control console

Y212

Solenoid valve shut-down stick cylinder

Near hydraulic tank

15.0 A



8.45.180


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Service Manual


117 A 309 - A 311 Litronic STIELZYLINDERABSCHALTUNG STICK CYLINDER SHUT-DOWN ARRET PILOTAGE VERIN BALANCIER


MJF C I F S S

8.45.181

Electric kits

Service Manual


Step 118 Item

Designation


B21**


Boom cylinder bearing

F331**

Fuse

H16** H20** H315

Warning light overload warning system to indicator light parking brake Warning light shut-down override


K473

Relay shutdown attachment

Distribution board

S18 S396

Switch / overload warning system Key switch shut-down override


V179 V180

Blocking dialog signal / flow distributor control to override Blocking diode signal / H16 actuation to ground


X29** X407 X953** X958** X963** X1253 X1260 X1261 X1262 X1263

Plug connection, 2-pin / distribution board Plug connection, 2-pin / pressure switch Plug connection, 21-pin / distribution board Plug connection, 21-pin / distribution board Plug connection, 21-pin / distribution board Plug connection, 2 pin / blocking diode Plug connection, 3-pin / switch Plug connection, 4-pin / solenoid valves Plug connection, 4-pin / solenoid valves Plug connection, 2 pin / blocking diode

Right console Right console Right console Right console, rear Right console, rear Right console, rear Right console, rear Right console, rear Right console, rear Right console, rear

Y212-1 Y237 Y465

Solenoid valve blocking stick lowering Solenoid valve blocking stick lifting Solenoid valve blocking lower boom

Hydraulic tank Hydraulic tank Hydraulic tank

15.0 A



8.45.182


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Service Manual


118 A 312 - R 317 Litronic AUTOMATISCHE ABSCHALTEINRICHTUNG BEI MONOAUSLEGER AUTOMATIC SHUT-DOWN INTERRUPTION AUTOMATIQUE


MJF C I F S S

8.45.183

Electric kits

Service Manual


Step 119 Item

Designation


A133


Left console

B306

Particle filter temperature sensor

Particle filter

E50

Power and safety switch cabinet

Hydraulic tank

F351

Fuse (F_H)

H298 H299

Warning light / exhaust backpressure Warning buzzer / exhaust backpressure


X20 X1040 X1041

Terminal for kit Plug connection, 3-pin / to display unit Plug connection, 2-pin / for temperature sensor

Printed circuit board A127 Electric box E50 Electric box E50

3A

Electric box E50


8.45.184


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Service Manual


119 A 309 - A 316 Litronic ARTICLEFILTER PURITECH FILTRE DE PARTICULES PURITECH PURITECH PARTICLE FILTER


MJF C I F S S

8.45.185

Electric kits

Service Manual


Step 120 Item

Designation


A1017


Right control desk

B19L

Sensor transducer

Left pilot control unit

S5L S5M S5R S19

Push button / grapple rotator left Push button / central option Push button / grapple rotator right Switch / grapple rotator

Left pilot control unit Left pilot control unit Left pilot control unit Right control desk

V181 V182

Amplifier actuation grapple rotation left Amplifier actuation grapple rotation right

Right control desk, rear Right control desk, rear

X952 X957 X966 X1046 X1047 X1265

Plug connection, 21-pin / distribution board Plug connection, 21-pin / distribution board Plug connection, 21-pin / distribution board Plug connection, 12-pin / left handle Plug connection, 3-pin Plug connection, 12-pin

Right control desk, rear Right control desk, rear Right control desk, rear Left control desk Left pilot control unit Right control desk, rear

Y22 Y23

Solenoid valve grapple rotator left Solenoid valve grapple rotator right



8.45.186


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Service Manual


120 A 309 - A 316 Litronic AS1 / GRIFF MIT 3 TASTEN AS1 / JOYSTICK WITH 3 SWITCHES AS1 / MANIPULATEUR AVEC 3 INTERRUPTEURS


MJF C I F S S

8.45.187

Electric kits

Service Manual


Step 121

8.45.188

Item

Designation


E2L E2R E2R2 E150L E150R E150R2

Work light, left Work light, right Plug connection Work light, rear left Work light, rear right Plug connection

Attachments Attachments Attachments Roof Roof Roof

F345 F346 F347 F348 F349

Fuse Xenon roof light Fuse Xenon headlight front left Fuse Xenon headlight front right Fuse Xenon headlight rear left Fuse Xenon headlight rear right

Right control desk, rear Right control desk, rear Right control desk, rear Right control desk, rear Right control desk, rear

K420 K421 K422 K423

Relay for Xenon headlight front left Relay for Xenon headlight front right Relay for Xenon headlight rear left Relay for Xenon headlight rear right

Right control desk, rear Right control desk, rear Right control desk, rear Right control desk, rear

MP-E50

Ground bolt in E50 box to A127

Electric box E50

OPT1

Terminal 30 bolt in E50 box to A127

Electric box E50

X1012 X1013/1 X1013/2 X1013/3 X1013/4 X1013/5 X1013/6 X1013/7 X1013/8 X1013/9 X1013/10 X1013/11 X1013/12

Plug connection cab – revolving deck / 4-pin Terminal 4-pin / power supply terminal 30 Terminal 4-pin / power supply terminal 30 Terminal 4-pin / actuation for E2 Terminal 4-pin / actuation for E150 Terminal 4-pin / power supply E2 L Terminal 4-pin / power supply E2 R Terminal 4-pin / power supply E150 L Terminal 4-pin / power supply E150 R Terminal 4-pin / ground E2 Terminal 4-pin / ground E150 Terminal 4-pin / ground supply Terminal 4-pin / ground supply

Revolving deck Revolving deck Revolving deck Revolving deck Revolving deck Revolving deck Revolving deck Revolving deck Revolving deck Revolving deck Revolving deck Revolving deck Revolving deck


MJF C I F S S

Service Manual


121 A 309 - A 316 Litronic XENON - SCHEINWERFER XENON HEADLIGHTS PHARES - XENON


MJF C I F S S

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Electric kits

Service Manual


8.45.190


MJF C I F S S

Service Manual

BST excavator control system Function

BST excavator control system 1 Function The LIEBHERR hydraulic excavator generation of the Litronic series is equipped with an electrical BST excavator control system and the associated units and elements. The BST (U16) excavator control system controls the diesel engine, the hydraulic pump, the monitoring function as well as the storage of the error codes. The BST control performs the following functions for the control of the machine: Pre-heating control of the diesel engine Recording and control of the diesel engine speed Recording of the nominal value of the diesel engine speed Electrohydraulic speed adjustment Sensor control / idle automatic Warm-up phase of diesel engine Control of hydraulic fan Horsepower control Limitation of pump delivery volume Monitoring of system sensors and actuators Saving of error messages generated by the monitoring function of the system sensors

Fig. 1 20

BST excavator control system Eprom (program version (V1.2 - V5......)

U16

copyright by

MJFCIFSS

Excavator control system

8.70.1


Service Manual

Description

2 Description The BST (U16) is installed in the right console on the operator's platform. The outputs and inputs of the BST are connected to the following components: Control console (push button, indicator lights and plug-in board) B2 Transducer / coolant temperature B3 Switch / coolant level B8 Transducer / hydraulic oil temperature B12 Transducer / engine speed B16 Transducer / engine oil pressure B285Transducer / hydraulic oil temperature (fan control) Y50 Proportional solenoid valve / power control Y51 Prop. valve / volume control Y352 Proportional valve of hydraulic fan control Y358 Prop. valve hydraulic speed adjustment The listed items are installed in the diesel engine, the radiator, the right console, the hydraulic and fuel tanks as well as the control oil unit, see Fig. 2.

8.70.2

A127

printed circuit board / power

R76

B2

Temperature sensor / engine coolant U16

B3

Transducer / coolant level

B8

Switch / hydraulic oil temperature

B12

Transducer / engine speed

Y51


B16


Y352

B285

Transducer / hydraulic oil temperature (fan control)

Y358

Proportional solenoid valve / fan control Proportional solenoid valve / engine speed

R75

Potentiometer for speed adjustment

Potentiometer / fine adjustment (A 312 - R 317 only) Excavator control BST

X10-X967 Plug connections between U16 and the individual components Y50 Proportional solenoid valve / power control

copyright by

MJFCIFSS

Service Manual

BST excavator control system Description

Fig. 2

Connections of BST

copyright by

MJFCIFSS

8.70.3


Service Manual


3 Functional description The BST controls or monitors the following functions, (see "Connections of BST", page 3).

3.1

Pre-heating control of the diesel engine The glow-plug indicator light H11 and the glow-plug relay K302 are controlled by the coolant temperature sensor (B2). During the pre-heating time, the glow-plug relay K302 is actuated and the glow-plug indicator light H11 is on. Pre-heating time: Coolant temperature tK > 0°C = 6 sec. Coolant temperature tK < 0°C = 6 sec. + 0.3 x tK Example: Coolant temperature tK = - 20°C 6 sec. + 20 x 0.3

6 sec. + 6 sec. = 12 sec.

The pre-heating time is followed by the switch-off time. During the switch-off time, the relay K302 drops off and the indicator light H11 is off. Switch-off time: Coolant temperature < 0°C = 18 sec. Coolant temperature > 0°C = 16 sec. + 0.3 x tK Example: Coolant temperature tK = - 20°C 6 sec. + 20 x 0.3

6 sec. + 6 sec. = 12 sec.

The switch-off time is followed by the post glow time. During the post glow time, the relay K302 is actuated.

Post glow time: Coolant temperature tK < 0°C = 99 sec. + 4 x tK Example: Coolant temperature tK = - 20°C 99 sec. + 20 x 4

99 sec. + 80 sec. = 179 sec.

Coolant temperature tK > 0°C = 99 sec.- 1.6 x tK Coolant temperature tK = - 20°C 99 sec. + 20 x 1.6

3.2

99 sec. + 32 sec. = 67 sec. 1 min

Warm-up phase of the diesel engine The warm-up phase of the diesel engine is controlled on the basis of the measured diesel engine coolant temperature (B2). If the coolant temperature at the start is < 20°C, the BST requires minimum speed step 3. During this period, the operator can however select a higher speed step. The warm-up phase of the diesel engine is terminated as soon as the coolant temperature is> 0°C or when the set maximum phase time (3 minutes) has lapsed.

8.70.4

copyright by

MJFCIFSS

Service Manual

BST excavator control system Functional description

Fig. 3

3.3

Components of the pre-heating control system

A127


H11

Pre-heating indicator light

B2


K302

Pre-heating relay

Recording and control of the diesel engine speed The speed sensor B12 at the diesel engine transmits the actual diesel engine speed as a frequency value to the BST. With the potentiometer R75, located at the control console, the diesel engine speed can be set by the operator to 9 different speed steps. With certain working functions, the speed is automatically controlled by the BST, see 3.4 and 3.5. The speed steps can be displayed in the service menu on a laptop. The diesel engine speed is adjusted through the Bowden cable and the speed adjusting lever by the 35 electrical proportional solenoid valve Y358 and the hydraulically connected control cylinder 10, see Fig. 4. Each speed step is assigned a specific speed, which in turn corresponds to a specific frequency or current respectively.

3.3.1

Speed steps of models A 309 - A 311: Speed step

Speed (without load)

Frequency

Current from BST version 5.11

1

860 rpm

1849 Hz

400 mA

2

1010 rpm

2162 - 2182 Hz

425 mA

3

1170 rpm

2506 - 2526 Hz

450 mA

4

1330 rpm

2850 - 2870 Hz

475 mA

5

1490 rpm

3194 - 3214 Hz

520 mA

6

1650 rpm

3538 - 3558 Hz

565 mA

7

1810 rpm

3882 - 3902 Hz

625 mA

copyright by

MJFCIFSS

8.70.5


Service Manual


3.3.2

3.4

Speed step


Frequency


8

1950 rpm

4226 - 4246 Hz

685 mA

9

2120rpm

4558 Hz

820 mA

Speed steps of models A 312 - R 317: Speed step


Frequency

Current to BST version 1.2


1

860 rpm

1849 Hz

350 mA

400 mA

2

1050 rpm

2220 - 2268 Hz

380 mA

425 mA

3

1220 rpm

2613 - 2633 Hz

410 mA

450 mA

4

1360 rpm

2914 - 2934 Hz

440 mA

475 mA

5

1500 rpm

3215 - 3235 Hz

490 mA

520 mA

6

1630 rpm

3495 - 3515 Hz

540 mA

565 mA

7

1750 rpm

3753 - 3773 Hz

600 mA

625 mA

8

1840 rpm

3946 - 3966 Hz

670 mA

685 mA

9

1925 rpm

4128 Hz

780 mA

820 mA

Speed adjustment / working mode (only valid for A 309 / A 311, from software version 5.12) In the above models, the regulating speed and thus the upper idle speed (speed without load) are lowered during work by means of the switch S35 (servo ON). When the switch S35 is in this position, the automatic engine speed adjustment cannot exceed speed step 8. This means that the maximum speed of the diesel engine = upper idle speed, and the maximum regulating speed (see 3.8.1 / 3.8.2 and adjustment protocols in group 6) can only be reached, if the switch S35 is in position "servo OFF".

3.5

Speed adjustment / magnet system The switch S46 of the magnet system affects the speed step of the diesel engine through the electrohydraulic speed adjustment as follows: Magnet system off: Speed can be selected with R75 Magnet system on: Speed step 8

8.70.6

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Service Manual


Fig. 4

3.6

Speed adjustment

10 35

Regulating cylinder / engine speed Speed adjusting lever

B12 S46

Transducer / engine speed Magnet system switch (only in A 316 industrial model)

50

Bowden cable

R75 Y358

Potentiometer / speed adjustment Proportional solenoid valve / engine speed

Control of hydraulic fan The hydrostatic fan drive is controlled by the hydraulic oil temperature B285, the coolant temperature B2 and the air-conditioning system. The fan speed is controlled electronically, relative to the temperature, through the proportional solenoid valve Y352. Design and function of the fan control system, see group 7.20

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8.70.7


Service Manual


Fig. 5 B2 B285

3.7

Components of the fan control system Temperature sensor / engine coolant

Y352

Proportional solenoid valve / fan control

Transducer / hydraulic oil temperature/ fan control

Sensor control (idle automatic) The function can be activated with the sensor control switch S20. Sensors in the joystick and the foot pedals: Capacitive handle sensor in right joystick B19R Capacitive handle sensor in left joystick B19L Inductive proximity switch in foot pedal (travel) B40 (only in A models) Inductive proximity switch in right pedal (travel) B40R (only in R models) Inductive proximity switch in left pedal (travel) B40L (only in R models) Inductive proximity switch in right pedal (attachment kit) B291 Inductive proximity switch in left pedal (attachment kit) B290 These sensors are used to adjust the speed for travel, the slewing gear, the attachment and the kit to a preset speed step defined by means of the nominal speed potentiometer R75, when the hydraulic circuits are activated and provided that the sensor control is switched on. While the magnet system is switched on, the sensor control is disabled.

8.70.8

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Service Manual


Fig. 6

3.8

Components of the sensor control

A

in A models

B290

B19R

Capacitive right handle sensor

B291

B19L B40

Capacitive left handle sensor Inductive proximity switch in foot pedal (travel)

S20 R75

Sensor control switch Potentiometer / speed

B40R

Inductive proximity switch in foot pedal (travel)

R

in R machines only

B40L

Inductive proximity switch in foot pedal (travel)

Inductive proximity switch in left foot pedal (kit) Inductive proximity switch in right foot pedal (kit)

Horsepower control / power control The power is controlled with a digital PID regulator. The current values of the PID regulator are used to control the current fed to the proportional solenoid valve Y50. The solenoid valve Y50 located at the control oil unit controls the oil flow and thus the control pressure to the regulating valve of the variable-displacement / double variable-displacement pump. Depending on the speed step and the actual load of the diesel engine, the horsepower control adjusts the preset regulating rpm.

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8.70.9


Service Manual

Functional description The regulating speed can be adjusted in the service menu. The following parameters are required for the pump performance control (in CAN mode): – Number of teeth (to determine the speed in rpm) – Regulating speed values of steps 1 to 9

3.8.1

3.8.2

3.9

Regulating speeds in model A 309 / 311 Speed step


Regulating rpm

Reduction

1

860 rpm

940 rpm

0 rpm

2

1050 rpm

940 rpm

100 rpm

3

1220 rpm

920 rpm

300 rpm

4

1360 rpm

1010 rpm

350 rpm

5

1500 rpm

1200 rpm

300 rpm

6

1630 rpm

1360 rpm

270 rpm

7

1750 rpm

1500 rpm

250 rpm

8

1940 rpm

1640 rpm

200 rpm

9

2120 rpm

1780 rpm

145 rpm

Speed steps of models A 312 - R 317: Speed step


Regulating rpm

Reduction

1

860 rpm

940 rpm

0 rpm

2

1010 rpm

940 rpm

70 rpm

3

1170 rpm

1000 rpm

170 rpm

4

1330 rpm

1060 rpm

170 rpm

5

1490 rpm

1320 rpm

170 rpm

6

1650 rpm

1480 rpm

170 rpm

7

1810 rpm

1640 rpm

170 rpm

8

1950 rpm

1780 rpm

170 rpm

9

1925 rpm

1755 rpm

170 rpm

Limitation of pump delivery volume Certain work, such as the production of a fine subgrade, and certain attachments such as hammers, pile drivers, etc. requires specific volumetric settings, that are lower than those produced during normal machine operation. Otherwise, the precision work cannot be completed and the attachments cannot be operated properly. The reduction of the pump flow volumes can be controlled by means of two different signals: – for all working movements (chassis, slewing gear and equipment) by means of the switch S382 and the fine adjust potentiometer R76 (only available in model A 312 - R 317) – For additional movements only (e.g. hydraulic hammer kit AHS11) by means of the switch S241, the proximity switch B291 and the potentiometer P1, P2 or P3. The volumetric flow generated by the BST is fed to the proportional solenoid valve Y51. The solenoid valve Y51 reduces the control pressure to the AS regulator of the pump relative to the actual flow rate, thus reducing p in the pump circuit.

8.70.10

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Service Manual


3.9.1

Low flow rate

small

p reduction

normal

High flow rate

large

p reduction

low

p in system

p in system

maximum pump flow rate minimum pump flow rate

Fine adjustment (for A 312 - R 317 only) The fine adjustment function is activated/deactivated by means of the switch S382. When the fine adjustment function is on, the indicator light H307 is also on. The pump flow rate can be steplessly adjusted by means of the potentiometer R76. Note! Fine adjustment is only available in model A 312 – R 317.

3.9.2

Flow reduction through kit The pump flow rate can be further reduced by activating the respective limitation function with the inductive proximity switch B291 and adjusting the flow rate with the potentiometer P1 / P2 / P3. For a description of the function and settings of the flow reduction, see flow reduction in group 16.19 or 16.20 respectively.

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8.70.11


Service Manual


Fig. 7

8.70.12

Components of the fine adjustment / flow reduction system

A125

Potentiometer board

R76

Potentiometer / fine adjustment (A 312 - R 317 only)

B291

Inductive proximity switch in right foot pedal (kit)

S241

Switch AHS 11 / AHS 12 accessory kit

H307

Indicator light p - reduction (A 312 - R 317 only)

S382

Fine adjustment switch (A 312 - R 317 only)

P1

Flow limitation potentiometer

Y50


P2


Y51


P3


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3.10

Monitoring of system sensors and actuators The sensors and actuators of the BST excavator control system are continuously monitored. In the event of a fault or failure, the respective fault signals are recognised and stored.

3.10.1

Plug connection X838-1 (service interface) It is possible to connect a laptop to the interface X838-1 on the printed circuit board A125 to read the fault messages in the form of fault codes from the system,(see 3.11, page 14). The interface can also be used by authorised personnel (service staff) to check and adjust the parameters of the excavator control system.

3.10.2

Indicator light H301 The indicator light H301 installed near the printed circuit board A125 indicates whether a fault or error occurred in the excavator control system. Light off = no fault/error Light flashing = minor faults/errors Light continuously on = serious faults/errors

Fig. 8

Printed circuit board A125 with service interface and fault indicator light

A125

Potentiometer board

X838-1 Plug connection, 9-pin service interface

H301

Indicator light/ fault/error in BST

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8.70.13


Service Manual


3.11

Monitoring function of system sensors and actuators The following sensors and actuators are monitored by the BST excavator control system. In the event of a fault or failure, the respective fault messages are generated and stored. In the event of an input or output error, the status LEDs (BST-MAIN, H1 earth contact-H4) and the fault indicator light H301 are actuated (continuously on or flashing). If there are not fault messages, the status LEDs H1, H2, H3, H4 of the BST flash in sequence (clockwise).

Error code

Sensor / actuator

Cause / switching status

Error LED Status LED

007

Cooling water temperature sensor

Short to earth

continuous

008


Short to plus

continuous

009


Wire break

continuous

Response to fault: - The time of the pre-heating control is set to the maximum values. - The fan control output is actuated with lmin (max. fan speed)

013

Hydraulic oil temperature sensor

Short to earth

continuous

014


Short to plus

continuous

009


Wire break

continuous

Response to fault: - The fan control output is actuated with lmin (max. fan speed)

8.70.14

022

Diesel engine speed sensor

Short to earth

continuous

023


Short to plus

continuous

024


Wire break

continuous

027

LR1 amplifier

Wire fault

continuous

036

Delta-P1 amplifier

Wire fault

continuous

039

HDV amplifier

Wire fault

continuous

045

LST amplifier

Wire fault

continuous

066 067

Speed adjustment potentiometer Fine adjustment potentiometer

Wire fault Wire fault

continuous flashing

422 423

Left handle sensor Left handle sensor

Short to plus Wire fault

flashing flashing

445 446

Right handle sensor Right handle sensor

Short to plus Wire fault

flashing flashing

501

Engine oil pressure switch

Switch actuated

continuous

502

Coolant level switch

Switch actuated

flashing

503

Coolant temperature switch

Switch actuated

flashing

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Error code

Sensor / actuator

Cause / switching status

Error LED Status LED

Error code 503 is currently deduced from the temperature sensor signal (coolant temperature) (switching point 105° C.)

505

Hydraulic oil temperature switch

Switch actuated

511

Supply voltage + UB

Overvoltage >30V

513

Fan switch

Switch actuated

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flashing

flashing

8.70.15


Service Manual


8.70.16

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MJFCIFSS

Service Manual

Slip ring rotary connection Function

Slip ring rotary connection 1 Function Machines with electrical equipment in the undercarriage (e.g. pressure switches, solenoid valves, angle sensors, etc.) must be equipped with a special rotary connection for electrical power from the uppercarriage to the undercarriage. This slip ring rotary connection is screw-mounted to the 6x oil rotary connection. Depending on the requirements regarding the rotary connection, a varying number of slip rings/contact brackets and microswitches are installed.

Fig. 1


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8.80.1


Service Manual

Design

2 Design (see Fig. 3 on page3) The base flange 3, adapter ring 1 and the associated slip rings 6/9/10 are fixed to the stator of the oil rotary connection and thus permanently fixed to the undercarriage. The bearing washer 2 with the contact bracket holder 14, the shim 3 and the contact bracket 11/12 is fixed to the rotor of the oil rotary connection, and thus permanently fixed to the uppercarriage. The bearing between the stationary base flange 3 and the rotating bearing disk 2 consists of deep groove ball bearings 25. The slip rings 6/9/10 is equipped with the microswitch attachment 19 and the angle sensor 39 of the swivel angle limitation (optional). The hood 4 and the hood pipe 7 with the O-ring 24 protect the slip ring against physical impact and contamination.

Fig. 2

8.80.2

Slip ring rotary connection in uppercarriage

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Service Manual

Slip ring rotary connection Design

Fig. 3

Exploded view of slip ring rotary connection

1

Adapter ring

23

Forcing screw

2 3

Bearing washer (base plate) Base flange

24 25

O-ring Deep groove ball bearing

4

Hood, glued to hood pipe 7

26

Lock washer

5 6

Ring Slip ring

27 28

Snap ring Snap ring

7 8

Hood pipe Threaded cable gland

29 30

Lock washer Hex nut

9 10

Insulating ferrule Slip ring

31 32

Holding plate of potentiometer Notch ring

11

Contact bracket, gold-plated

33

Washer with chamfer

12

Contact bracket, nickel-plated

35

Hexagon cap nut

13

Shim

37

Washer

14 15

Contact bracket holder Cover plate

39 42

Angle gauge (optional) Pipe

17 18

Threaded rod Threaded rod

43 45

Threaded cable gland Threaded rod

19

Threaded rod

50

Hex nut

22

Microswitch attachment

55

Hex nut

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8.80.3


Service Manual


3 Functional description (see Fig. 5 on page7) The current is fed from the uppercarriage to the undercarriage and vice versa through the electrical lines that are connected to the contact brackets 11/12 and the slip rings 6/9/10 respectively. All contact brackets 11/12 are permanently pressed against the associated slip rings 6/9/10, irrespective of the position of the uppercarriage to the undercarriage, thus providing an electrical connection between the units in the uppercarriage and the undercarriage. Note! The cable assignment of the individual slip rings/contact brackets is shown in the wiring diagram in group 8 and the diagram below.

8.80.4

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Service Manual

Slip ring rotary connection Maintenance

4 Maintenance Caution! The slip ring body is easily damaged by humidity, as an oxidant layer might form on the conducting surfaces, impairing the conductivity. As a result, the electrically powered units located in the undercarriage are not supplied with sufficient power. This can lead to malfunctions. Regularly apply Cramolin contact spray to the slip ring contact surface (see inspection and maintenance schedule of group 3.), see also group 1.50. Hold the nut 35 and loosen the hexagon nut 30. Remove the hood 4 with the hood pipe. Remove oxidation from the slip ring body. Remove damaged (corroded) fork terminals. Spray Cramolin contact spray onto the slip ring contact surfaces. Mount the hood 4 with the hood pipe and secure it with the nuts 30 (hold nuts 35).

Fig. 4

4.1

Electrical connections

4 30

Hood Hex nut

35

Hex nut

X301

Plug connection slip ring / 12-pin

Adjustment of the angle sensor 39 (optional) Note! For a detailed description of the angle sensor 39 settings, see the respective kit.

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8.80.5


Service Manual

Maintenance

8.80.6

1 2

Adapter ring Bearing washer (base plate)

23 24

Forcing screw O-ring

3 4

Base flange Hood with hood pipe

25 26

Deep groove ball bearing Lock washer

5

Ring

27

Snap ring

6 8

Slip ring Threaded cable gland

28 29

Snap ring Lock washer

9

Insulating ferrule

30

Hex nut

10

Slip ring

31

Holding plate of potentiometer

11

Contact bracket, gold-plated

32

Notch ring

12

Contact bracket, nickel-plated

33

Washer with chamfer

13

Shim

35

Hexagon cap nut

14 15

Contact bracket holder Cover plate

37 39

Washer Angle sensor (optional)

16 17

Back-up washer Threaded rod

42 44

Brass pipe Brass pipe

18 20

Threaded rod FGR pipe

45 46

Threaded rod Washer

21

Countersunk screw

55

Hex nut

22

Microswitch attachment

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Service Manual

Slip ring rotary connection Maintenance

Ü

Fig. 5

Sectional drawing of slip ring

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8.80.7


Service Manual

Maintenance

Fig. 6

8

Threaded cable gland

40

Contact pin

11 12

Contact bracket, gold-plated Contact bracket, nickel-plated

41 43

Plug Threaded cable gland

34

Flat adapter

Fig. 7

8.80.8

Section A-A Slip ring rotary connection

Section B-B Slip ring rotary connection

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Service Manual

Directory of electric kits Chapter

Group

Type

Blockage 2nd gear

8.101

A 312 - A 316

Function travel left / SF function right

8.102

A 312 - A 316

Travel alarm system

8.103

A 312 - A 316

Blade support front / rear

8.104

A 312 - A 316

Dozer blade with 4-point support

8.105

A 312 - A 316

AHS12 with tool control

8.106

A 312 - A 316

Changeover high – lateral in left handle

8.107

A 312 - A 316

Changeover high – lateral in left handle

8.108

A 312 - A 316

Turning grapple in handle left and right

8.109

A 312 - A 316

Stroke limitation boom and stick Bridging button in left handle

8.110

A 312 - A 316

Mower rake

8.111

A 312 - A 316

Auxiliary heating

8.112

A 312 - A 316

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8.100.1

Service Manual

8.100.2

copyright by

MJF C I F S S

© LIEBHERR HYDRAULIKBAGGER GMBH

PROJEKT: 103281525_2_bs_hoch_seitl_im_linken_griff © LIEBHERR HYDRAULIKBAGGER GMBH


/4.A6 /5.A3


-F330.A

-F331.A

-F330.E

-F331.E

/5.F4 -F337.E /3.C8



-MP/VP.X3



/2.E6

A126



/2.E6

/2.E6





Service Manual


Group

Type


9.10.1


Slewing gear brake

9.20.1


Slewing gear brake

9.24.1

R 313 LI 27752R 317 LI 18161-

9.1 MJF C I F S S

Service Manual

9.2 MJF C I F S S

Service Manual

Slewing gear mechanism Function and design

Slewing gear mechanism 1 Function and design The slewing gear mechanism, through the attached output shaft and the internally toothed slewing ring, moves the uppercarriage against the undercarriage of the machine. The two-stage planetary gear is driven by the FMF hydraulic oil motor to which it is connected with a flange. The wet multi-disc brake integrated into the gearbox acts directly onto the gear drive. The brake is designed as a spring applied brake and is released hydraulically, i.e. when the brake system is not pressurised, the discs are pressed together by the pressure springs, so that the brake is mechanically applied. The pinion of the slewing gear mechanism is encased in a nearly tight housing containing a grease reserve for the gear greasing of the slewing ring. If regularly greased according to the maintenance schedule, the reserve is sufficiently topped up to adequately lubricate the parts.

Fig. 1

Slewing gear mechanism with oil tank

13

Oil tank

110


17

Pinion / output shaft

155

Lubrication line / lubrication system

26

Grease cap

960

Brake discs / multi-disc brake

97

Oil motor / slewing gear motor

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9.10.1


Service Manual

Technical data

2 Technical data

Machine from serial number

A 309 - A 311 Litronic 20221

Gearbox type

Sat 225 / 240


SAT 225 / 228


SAT 225 / 218

21720 min-1

Max. drive speed Max. output torque

5600 Nm

Gear ratio

1: 31.7

Weight (approx.)

130 kg


4.5 l

Oil quality

API - GL - 5

Oil viscosity (with positioning brake actuated with foot pedal)

SAE 80 W 90 / SAE 90 W (SAE 90 LS)

Brake

Hydraulically released multi-disc brake

Min. release pressure

20 bar

Max. release pressure

33 bar

Tab. 1

A 314 - A 316 Litronic 2001


Technical data

Settings and tightening torques, to be observed for installation: A)

Checking measurement of the sun gear 5 (to upper edge of the gearbox)

93.5+0.5mm

B)

Friction torque of tapered roller bearing 57 / 58

20-25 Nm

C)

Tightening torque of Allen head screws 60

49 Nm

D)


190 Nm

E)

Tightening torque of hex head screws 62

195 Nm

F)


117 Nm

G)


280 Nm

Tab. 2

9.10.2

Settings and tightening torques

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Service Manual

Slewing gear mechanism Function of slewing gear

3 Function of slewing gear see Fig. 6 The input torque is transferred from the hydraulic oil motor 97 to the sun gear 5. Through the planetary gears 10 and the planetary carrier 15, the sun gear 5 drives the sun gear 6 at the oil motor speed geared down by planetary stage I. Through the planetary gears 11 and the planetary carrier 16, the sun gear 6 drives the output shaft 17 at the oil motor speed geared down by planetary stage II. The total speed reduction is based on the gearing down of both planetary stages. As the output speed is reduced, the output torque is increased accordingly.

3.1

Function of lubricating system

Fig. 2

Output pinion / slewing ring lubrication system at slewing ear

2

Housing

150

Lubricant hose

26 146

Grease cap Distribution block

153

Lubrication nipple

The grease cap 26 on the housing 2 covers the pinion of the drive shaft all the way to the connection of the slewing ring. The cap 26 is filled with grease through the lubrication nipple 153 of the distribution block 146 of the lubrication system and the lubricant line 150. Every time the uppercarriage is rotated, grease is applied to the gearing of pinion and slewing ring.

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9.10.3


Service Manual

Maintenance

4 Maintenance 4.1

Maintenance of the gearbox The gearbox must be serviced regularly at the intervals laid down in the maintenance instructions for group 3. The regular maintenance work includes a check of the oil level, inspection for leakage and check of the gearbox and oil motor for proper mounting. The gear oil must be replaced at prescribed intervals.

4.2

Maintenance of the lubricating system The grease packing in the grease cap is replaced or replenished automatically at defined intervals from the central lubrication system, see maintenance instructions for group 3.

5 Installation and dismantling of the slewing gear mechanism see Fig. 3

Fig. 3

9.10.4

Gear oil tank with oil drain valve Fit bore of the slewing gear in the upper carriage

1 13

Hydraulic tank Oil tank

119 135

Slewing gear Valve

110

Slewing gear

136

Protective cover

115

Allen head screw

138

Oil drain hose (included in the machine toolbox)

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Service Manual

Slewing gear mechanism Repair of the gear system

118

5.1

Uppercarriage

Dismantling, see Fig. 3 Place assembly onto the floor. Release the tank pressure. Before you start dismantling, release all pressure from the control oil and brake lines. Remove the protective cap 136 of the drain valve 135. Connect the oil drain hose 138 (included in the machine toolbox) through the access bore of the revolving deck onto the drain valve 135 and drain the gear oil into a suitable container. Remove the oil drain hose 138 and replace the protective cap of drain valve 135. Remove the parts and hydraulic lines that impede the dismantling of the gearbox. Disconnect all leak oil, lubrication and brake lines at the oil motor and gearbox. Remove the screws 115 and lift the gearbox from the uppercarriage, using suitable lifting tackle.

5.2

Installation, (see Fig. 3 on page4) Apply anti-corrosion grease (Optimol Paste White ID no. 8500307) to the area around the lower centring device and the centring surface of the gearbox in the revolving deck (see Fig. 3). Observe correct position for oil discharge. Lift the gearbox into the uppercarriage. Insert the screws 115 and tighten them with the prescribed torque. Connect the leak oil, lubrication and pressure lines to the gearbox and oil motor. Remove the lid of the oil tank 13 and fill the tank with the correct oil product (see lubricant table for group 1) until the "Max." mark at the tank is reached. Close the oil tank 13. Check the gearbox for leakage and complete a function test. Check the pinion engagement in the slewing ring. Add grease through the lubrication nipple 153. Replace or replenish grease packing of the slewing ring. Check lubrication of gearing.

6 Repair of the gear system The repair procedures are described in the separate repair manual "SAT 225 - 350".

7 Sealing gearbox 7.1

Sealing of drive motor section The work described below can be completed while the gearbox is mounted.

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9.10.5


Service Manual

Sealing gearbox Remove all lines that impede access to the gearbox. The leak oil and control lines at the oil motor may remain connected. Remove the screws 62 and lift the oil motor from the gearbox. Remove the O-ring 98. Prior to the installation, clean all parts to be reused and inspect them carefully for damage. Apply a little grease or oil to the O-ring 98 before installing it. Insert the O-ring 98 into the groove of the oil motor 97. Place the oil motor 97 in the gearbox. Insert the screws 62 and tighten them with the prescribed tightening torque, see Tab. 2.

Fig. 4

62 97

Oil motor with seals and fixture attaching it to the slewing gear mechanism

98 115

Hex head screw Oil motor

O-ring Allen head screw

For installation, observe the tightening torques E and G, (see Tab. 2 on page2).

7.2

Sealing of the multi-disc brake For detailed instructions regarding the above sealing work, refer to chapter "Repair of brake" in group 9.20 "Slewing gear brake".

7.3

Sealing of output area in the gearbox To seal the output side of the gearbox (radial shaft seal rings and Nilos ring), it is necessary to fully dismantle the gearbox. For repair instructions, see document "SAT 225 - 350".

9.10.6

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Service Manual

Slewing gear mechanism Exploded view of the gearbox

8 Exploded view of the gearbox 2 5

Output shaft Sun gear

60 61


6

Sun gear

62

Hex head screw

10 11

Planetary gear Planetary gear

63 64


15

Planetary carrier

65

Retaining washer

16

Planetary carrier

66

Retaining washer

17

Output shaft

70

Snap ring

20

Sun wheel

71

Snap ring

25

Brake housing

73

Snap ring

26 30

Grease cap Annular piston

82 83

O-ring O-ring

31 35

Locking ring Thrust plate

84 86

O-ring Fitting

36 37

Inner disc Outer disc

88 89

Lip seal Lip seal

40

Disc carrier

90


43

Pressure spring

91

Nilos ring

44

Pressure spring

92

Screw-in stud

45 46

Stop washer Stop washer

93 94

Fitting Plug

47 49

Slotted nut Washer

98 900

Screw-in stud Repair kit / brake

57


910

Seal kit / swing drive

58


960

Brake disc set

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9.10.7


Service Manual

Exploded view of the gearbox

Fig. 5

9.10.8

Exploded view of the gearbox

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Service Manual

Slewing gear mechanism Sectional drawing of the gearbox

9 Sectional drawing of the gearbox 2

Output shaft

60

Allen head screw

5

Sun gear

61

Allen head screw

6

Sun gear

62

Hex head screw

10 11

Planetary gear Planetary gear

63 64


15

Planetary carrier

65

Retaining washer

16

Planetary carrier

66

Retaining washer

17 20

Output shaft Sun wheel

70 71

Snap ring Snap ring

25

Brake housing

73

Snap ring

26 30

Grease cap Annular piston

82 83

O-ring O-ring

31 35


84 86

O-ring Fitting

36 37


88 89

Lip seal Lip seal

40

Disc carrier

90


43 44


91 92

Nilos ring Screw-in stud

45 46

Stop washer Stop washer

93 94

Fitting Plug

47 49

Slotted nut Washer

98 900

Screw-in stud Repair kit / brake

57


910

Seal kit / swing drive

58


960

Brake disc set

Observe the settings and tightening torques A - F for the installation, (see Tab. 2 on page2).

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9.10.9


Service Manual

Sectional drawing

10

Sectional drawing

Fig. 6

9.10.10

Sectional drawing of slewing gear mechanism

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Service Manual

Slewing gear brake Design of the slewing gear brake

Slewing gear brake 1 Design of the slewing gear brake The slewing gear brake is designed as a holding and parking brake. Thanks to the progressive control characteristics of the brake valve, the brake can also be used as a positioning brake for the continuous slowing down of the uppercarriage. This results of course in increased wear of the multi-disc brake. It is therefore recommended to slow down the uppercarriage by means of counter-pressurisation.

1.1

Multi-disc brake The brake is integrated into the slewing gear mechanism and is applied to the gear drive. It consists of a hydraulically operated wet multi-disc brake. The brake discs 36 / 37 are mechanically pressed together by the preload of the pressure springs 43 / 44. They are released when the annular piston 30 is pressurised with pilot control pressure.

1.2

Brake valve 87 (see Fig. 2 on page2) The brake valve 87 with the pedal is located to the left of the steering column in the operator's cab. 87

K

50

88P

25

As the pressure in the chamber K is built up gradually through the brake valve 87 and the collecting pipe 88T to the tank, the brake is mechanically closed.

Fig. 1

Brake valve in the operator's cab and multi-disc brake in the slewing gear

25

Brake housing/slewing gear brake

43

Pressure spring

30

Annular piston

44

Pressure spring

36 37


87 K

Brake valve with pedal and retainer Pressure chamber / opening pressure

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MJF C I F S S

9.20.1

Slewing gear brake

Service Manual

Design of the slewing gear brake

Fig. 2

9.20.2

Components of the slewing gear brake system

50

Control oil unit

88T

Collecting pipe / return oil

87 88P

Brake valve Distributor / pilot control oil

195 196

Slewing gear brake Slewing gear mechanism

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Service Manual

Slewing gear brake Function of slewing gear brake system

2 Function of slewing gear brake system (see 3 on page4) and (see Fig. 2 on page2) When the brake valve 87 is in neutral position, the pilot control oil flows from the control oil unit 50, connection A1 and the distributor 88P through the brake valve 87 and the brake connection BR in the chamber in front of the annular piston 30 of the slewing gear brake. The opening pressure (corresponding to the pilot control pressure) pushes the annular piston 30 upwards against the pressure springs 43 / 44. This force cancels out the pressure force applied to the brake discs 36/37, so that the brake is released. When the pedal of the brake valve 87 is actuated, the line between connection SP of the valve 87 and the connection BR of the slewing gear brake is closed, relative to the pedal travel. When the pedal is pressed down further, the piston in the brake valve 87 opens the line between the connection BR of the multi-disc brake via the connection T and the collecting pipe 88T to the tank. The pressure springs 43 / 44 shift the annular piston 30 against the disc pack 36/37. The resulting pressure force generates the desired braking torque, reducing the rotational speed of the uppercarriage (outlet), i.e. the brake is being closed. At the end of the pedal travel, the pedal of the brake valve 87 engages in the retainer, so that the brake remains in the brake position (parking brake). By reducing the pressure on the pedal of the brake valve or by releasing the retainer with the foot, the piston in the brake valve 87 slides back into its neutral position, connecting the pressure chamber K of the brake with the connection A1 of the control oil unit 50, and the brake is released. Due to the spring force effect, the multi-disc brake has also a safety function: When the diesel engine is off, and the accumulator of the pilot control circuit is empty (no pilot control pressure / release pressure), the slewing gear brake is applied automatically. This occurs for example in the event of a failure of the diesel engine during working operation, or if there is a fault in the pilot control pressure circuit / pilot control components. 1* 20*

Hydraulic tank Variable displacement pump

50* 87

Control oil unit Brake valve

25 30

Brake housing/Slewing gear brake Annular piston

88P 88T

Distributor / pilot control oil Collecting pipe / return oil

30* 36

Gear pump / servo control Inner disc

195 196

Multi-disc brake Slewing gear mechanism

37

Outer disc

197

Pedal with return spring and retainer

43 44


S7 Y3

Current from safety switch Solenoid valve / pilot pressure

49

Measuring point pilot / opening pressure

* item of the hydraulic system

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9.20.3

Slewing gear brake

Service Manual

Hydraulic diagram

3 Hydraulic diagram

9.20.4

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MJF C I F S S

Service Manual

Slewing gear brake Repair of brake

4 Repair of brake

Caution! To repair the brake, the hydraulic circuit and the spring-loaded components must be accessed. This can lead to serious injury from escaping oil or crushing. Position the machine on firm and level ground. Lower the attachment to the ground. This is particularly important, if the machine is standing on a slope. Press down the pedal of the brake valve 87, so that it engages. Release the tank preload. Depressurise the pilot control/brake system.

4.1

Sealing of brake and replacement of brake discs Load noises or insufficient brake effect indicate that the brake lining surfaces are worn. Replace the brake discs without delay. Note! We recommend replacing the entire disc pack. The brake can be repaired without dismantling the gear.

4.1.1

Dismantling of oil motor and the brake housing 25 (see Fig. 5 on page8) Remove all lines that impede access to the gearbox. Remove the mounting bolts of the oil motor and pull the oil motor with the flange-connected hydraulic lines from the gearbox. Disconnect the brake line from the brake connection at the gear. Remove the Allen head screws 61. Remove the entire brake housing 25 from the sun wheel 20

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9.20.5

Slewing gear brake

Service Manual

Repair of brake

Fig. 3

4.1.2

Sectional drawing of the brake housing

20

Sun wheel / gear

66

Retaining washer

25 61

Brake housing/Slewing gear brake Allen head screw

83

O-ring

Dismantling of the brake housing 25 (see Fig. 5 on page8) Caution! The locking ring 31 and the annular piston 30 are spring-loaded. Improper opening of the brake housing 25 might result in injury from impact and crushing. Open the brake housing 25 using the matching mounting device. Proceed as follows: Place the mounting tool 200 (special tool, see group 2.07) onto the brake housing 25 and push the annular piston 30 down, using the two screws M16X120 or M16X140 respectively. Ensure that the force is applied uniformly. Remove the snap ring 73. Release the screws uniformly and remove the device 200. Remove the entire brake piston 30. Remove the pressure springs 43 / 44, the O-ring 82 and the lip seal 88 from the brake housing 25. Push the locking ring 31 from the annular piston 30 and remove the lip seal 89. Remove the front thrust plate 35, the brake discs 36 / 37 and the rear thrust plate 35 from the sun wheel 20.

4.1.3

Installation of the brake housing 25 see Fig. 5 Prior to the installation, clean all parts to be reused and inspect them carefully for damage. Mount the lower thrust plate 35 in the sun wheel 20.

9.20.6

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Service Manual

Slewing gear brake Repair of brake Insert the outer and inner discs 37 / 36 one after the other into the gearing of the sun wheel 20 and the disc carrier 40. To do this, proceed as follows: Outer disc - inner disc - outer disc, etc. Mount the front thrust plate 35 on the last outer disc. Apply a little grease to the lip seal 89 and insert it into the locking ring 31. Apply a little grease to the lip seal 88 and insert it into the brake housing 25. Apply a little grease to the O-ring 82 and mount it on the brake housing 25. Press the locking ring 31 into the annular piston 30. Insert the pressure springs 43 /44 and push the annular piston 30 onto the brake housing 25, applying uniform pressure. Using the mounting device 200, push the annular piston 30 down. Top in the snap ring 73 (ensure proper seat). Release the screws uniformly and remove the mounting device 200.

4.1.4

Mounting of the brake housing 25 and slewing gear motor (see Fig. 5 on page8) Apply a little grease to the new O-ring 83 and insert it in the groove of the brake housing 25. Insert the complete brake housing 25 into the sun wheel 20 and secure it with the screws 61 and the washers 66. Apply a little grease onto the O-ring and insert it in the groove of the oil motor. Insert the complete oil motor into the gearbox and secure it to the brake housing 25 using the mounting bolts. Observe tightening torques (see "General information" for group "Slewing gear mechanism"). Connect the line between the brake valve and the brake connection BR to the gearbox. Test brake function, (see “Function of slewing gear brake system” on page 3).

20

Sun wheel / gear

61

25


66

Retaining washer

30 31

Annular piston Locking ring

73 82

Snap ring O-ring

35 36

Thrust plate Inner disc

83 86

O-ring Screw plug

Allen head screw

37

Outer disc

88

Lip seal

40

Disc carrier

89

Lip seal

43

Pressure spring

92

Plug

44

Pressure spring

200

Mounting device (special tool)

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9.20.7

Slewing gear brake

Service Manual

Repair of brake

9.20.8

Fig. 4

Sealing and repair kit of the slewing gear brake

Fig. 5

Sectional drawing of the brake housing with mounting tool, rotated by 90°

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Service Manual

Slewing gear brake Design

Slewing gear brake The mechanical slewing gear brake is designed as a holding and parking brake. The slowing down of the uppercarriage is achieved by means of hydraulic counter-pressurisation. Caution! When the slewing gear brake is applied, its drive is blocked. When the brake is applied during a rotating motion, the components of the slewing gear circuit and drive system are exposed to excessive load and might be damaged. Therefore apply the slewing gear brake only when the uppercarriage is standing still.

1 Design 1.1

Multi-disc brake The brake is integrated into the slewing gear mechanism and acts on the gear drive. It consists of a hydraulically operated wet multi-disc brake. The brake discs 36 / 37 are mechanically pressed together by the preload of the pressure springs 43 / 44. They are released when the annular piston 30 is pressurised with pilot control pressure.

1.2

Solenoid valve Y7 The solenoid valve Y7 is integrated into the control oil unit 50. In neutral position, the solenoid valve Y7 connects the chamber K through the port A3 to the tank (brake applied). In working position, the solenoid valve connects the chamber K through port A3 to the pilot pressure oil system (brake released). As a result, the annular piston 30 is pressed by hydraulic forces against the pressure springs 43/44.

Fig. 1

Slewing gear brake in slewing gear mechanism and solenoid valve at the control oil unit

25


44

Pressure spring

30

Annular piston

50

Control oil unit

36

Inner disc

K

Pressure chamber / opening pressure

37 43

Outer disc Pressure spring

Y7


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9.24.1

Slewing gear brake

Service Manual

Design

1.3

Switch S17 The switch S17 is used to control the slewing gear function (apply-release) through the solenoid valve Y7 : – Switch down = indicator light in switch S17 on = Y7 in idle position = brake applied – Switch up = indicator light in switch S17 off = Y7 powered = brake released

Fig. 2

9.24.2

Components of the slewing gear brake system

1

Hydraulic tank

195

Slewing gear brake

50

Control oil unit

196


87

Brake valve positioning brake (optional) S17 Y7

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Switch slewing gear brake Solenoid valve slewing gear brake

Service Manual

Slewing gear brake Design

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9.24.3

Slewing gear brake

Service Manual

Design

1.4 1.4.1

Function of slewing gear brake system Standard brake system (switch S7) (see Fig. 1, page 1) and (see Fig. 3, page 7) When the switch S17 is in neutral position, the solenoid valve Y7 is powered. The solenoid valve Y7 is switched during flow-through. As a result, pilot control oil from the control oil unit 50 flows through the connection A3 and the brake connection P into the room in front of the annular piston 30 of the slewing gear brake. The opening pressure (corresponding to the pilot control pressure) pushes the annular piston 30 upwards against the pressure springs 43 / 44. This force cancels out the pressure force applied to the brake discs, so that the brake is released. If the switch S17 is actuated, the solenoid valve Y7 is now powered and the valve is switched to its neutral position. As a result, the connection P of the multi-disc brake is connected through the connection A3 and the solenoid valve Y7with the tank. The pressure springs 43 / 44 shift the annular piston 30 against the disc pack 36/37, producing the prescribed torque by means of the maximum pressure force. The excavator is now blocked (parking brake applied). Due to the spring force effect, the slewing gear brake has also a safety function: When the diesel engine is off, and the accumulator of the pilot control circuit is empty (no pilot control pressure / release pressure), the slewing gear brake is applied automatically. This occurs for example in the event of a failure of the diesel engine during working operation, or if there is a fault in the pilot control pressure circuit / pilot control components.

1.4.2

Optional brake system (positioning brake through brake valve 87) For special applications, LIEBHERR offers the "Positioning brake" kit as a slewing gear brake option. In this case, the brake described in section 1.4.1 (with S17 and Y7) is blocked,, i.e. the connection A3 is sealed and the switch S17 at the control desk is deactivated. The brake valve 87,(see Fig. 2, page 2) that is now in operation controls the positioning, holding and parking brake of the slewing gear. For details regarding the design, function and hydraulic diagram are described in detail in group 9.20.

9.24.4

1 25

Hydraulic tank Brake housing

195 196

Slewing gear brake Slewing gear mechanism

29


30 36

Annular piston Inner disc

F337 S17

Fuse slewing gear brake 15 A Switch slewing gear brake

37

Outer disc

X958

43

Pressure spring

X963

44

Pressure spring

X1115

49

Measuring point pilot control / opening pressure

X1116

50

Control oil unit

Y7

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Service Manual

Slewing gear brake Hydraulic diagram

2 Hydraulic diagram

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9.24.5

Slewing gear brake

Service Manual

Repair of brake

3 Repair of brake

Caution! To repair the brake, the hydraulic circuit and the spring-loaded components must be accessed. This can lead to serious injury from escaping oil or crushing. Position the machine on firm and level ground. Lower the attachment to the ground. This is particularly important, if the machine is standing on a slope. Actuate the switch S17 (apply brake). Release the tank preload. Depressurise the pilot control/brake system.

3.1

Sealing of brake and replacement of brake discs Load noises or insufficient brake effect indicate that the brake lining surfaces are worn. Replace the brake discs without delay. Note! We recommend replacing the entire disc pack. The brake can be repaired without dismantling the gear.

3.1.1

Dismantling of oil motor and the brake housing 25 (see Fig. 5, page 9) Remove all lines that impede access to the gearbox. Remove the mounting bolts of the oil motor and pull the oil motor with the flange-connected hydraulic lines from the gearbox. Disconnect the brake line from the brake connection at the gear. Remove the Allen head screws 61. Remove the entire brake housing 25 from the sun wheel 20

9.24.6

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Service Manual


Fig. 3

3.1.2

Sectional drawing of the brake housing

20

Sun wheel / gear

66

Retaining washer

25 61

Brake housing/slewing gear brake Allen head screw

83

O-ring

Dismantling of the brake housing 25 (see Fig. 5, page 9) Caution! The locking ring 31 and the annular piston 30 are spring-loaded. Improper opening of the brake housing 25 might result in injury from impact and crushing. Open the brake housing 25 using the matching mounting device. Proceed as follows: Place the mounting tool 200 (special tool, see group 2.07) onto the brake housing 25 and push the annular piston 30 down, using the two screws M16X120 or M16X140 respectively. Ensure that the force is applied uniformly. Remove the snap ring 73. Release the screws uniformly and remove the device 200. Remove the entire brake piston 30. Remove the pressure springs 43 / 44, the O-ring 82 and the lip seal 88 with the backing rings from the brake housing 25. Push the locking ring 31 from the annular piston 30 and remove the lip seal 89 with the backing ring. Remove the front thrust plate 35, the brake discs 36 / 37 and the rear thrust plate 35 from the sun wheel 20.

3.1.3

Installation of the brake housing 25 see Fig. 5 Prior to the installation, clean all parts to be reused and inspect them carefully for damage.

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9.24.7

Slewing gear brake

Service Manual

Repair of brake Mount the lower thrust plate 35 in the sun wheel 20. Insert the outer and inner discs 37 / 36 one after the other into the gearing of the sun wheel 20 and the disc carrier 40. To do this, proceed as follows: Outer disc - inner disc - outer disc, etc. Mount the front thrust plate 35 on the last outer disc. Apply a little grease to the lip seal 89 and insert it with backing rings into the locking ring 31. Apply a little grease to the lip seal 88 and insert it with backing rings into the brake housing 25. Apply a little grease to the O-ring 82 and mount it on the brake housing 25. Press the locking ring 31 into the annular piston 30. Insert the pressure springs 43 /44 and push the annular piston 30 onto the brake housing 25. Using the mounting device, push the annular piston 30 down, applying the force uniformly around its circumference. Top in the snap ring 73 (ensure proper seat). Remove the mounting device.

3.1.4

Mounting of the brake housing 25 and slewing gear motor (see Fig. 5, page 9) Apply a little grease to the new O-ring 83 and insert it in the groove of the brake housing 25. Insert the complete brake housing 25 into the sun wheel 20 and secure it with the screws 61 and the washer 66. Apply a little grease to the O-ring and insert it into the groove of the oil motor. Insert the complete oil motor into the gearbox and secure it to the brake housing 25 using the mounting bolts. Observe tightening torques (see "General information" for group "Slewing gear mechanism"). Connect the lines between the control oil unit connection A3 and the brake connection P. Test brake function, (see "Function of slewing gear brake system", page 4)

9.24.8

20 25

Sun wheel / gear Brake housing/slewing gear brake

61 66


30

Annular piston

73

Snap ring

31 35


82 83

O-ring O-ring

36

Inner disc

86

Screw plug

37

Outer disc

88

Lip seal

40

Disc carrier

89

Lip seal

43 44


92 200

Plug Mounting device

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Service Manual


Fig. 4

Sealing and repair kit of the slewing gear brake

Fig. 5

Sectional drawing of the brake housing with mounting tool, rotated by 90°

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MJF C I F S S

9.24.9

Slewing gear brake

Service Manual

Repair of brake

9.24.10

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MJF C I F S S

Service Manual


Group

Type

Slewing ring

10.10.1


10.1 MJF C I F S S

Service Manual

1.2 MJF C I F S S

Service Manual

Slewing ring Design

Slewing ring 1 Design The slewing ring is used as a connecting and bearing element between the undercarriage and the uppercarriage. The slewing ring consists of a single-row axial rolling bearing with a large diameter. It consists of an outer race and a geared inner race. For the bearing and connection of the races, large balls are located between the two precision bearing elements. Sealing lips protect the ball bearing against dirt. To turn the uppercarriage, the slewing gear mechanism engages with the involute teething of the inner race of the slewing ring.

Fig. 1

Location of the slewing ring in the undercarriage

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MJF C I F S S

10.10.1

Slewing ring

Service Manual

Technical data


A 309-Li 20221

A 311-Li 20222

A 312-Li 12363

Factory play

0.5 mm

0.5 mm

0.5 mm

Max. play

1.5 mm

1.5 mm

1.5 mm

Tooth backlash

1.4 mm

1.4 mm

1.4 mm

Tilting play

Weight of uppercarriage with offset boom bearing

kg

5540

6030

6300

With attachment

kg

6600 - 6800

7400 - 7600

8560 - 8620

M 16

M 16

M 16

280 Nm

280 Nm

280 Nm

R 313-Li 27752

A 314-Li 2001

A 316-Li 2001

Factory play

0.5 mm

0.5 mm

0.5 mm

Max. play

1.5 mm

1.5 mm

1.5 mm

Tooth backlash

1.4 mm

1.4 mm

1.4 mm

Tightening torques Mounting bolts Quality 10.9 Machine from serial number Tilting play

Weight of uppercarriage Without attachment

kg

6400

6950

7800

With attachment

kg

8500 - 8600

8950 - 10750

10370 - 12070 13020 - 15120*

Tightening torques Mounting bolts

M 20

M 20

M 20

Quality 10.9

560 Nm

560 Nm

560 Nm

Machine from serial number

R 317-Li 18161

Tilting play Factory play

0.5 mm

Max. play

1.5 mm

Tooth backlash

1.4 mm

Weight of uppercarriage with offset boom bearing

kg

7800

With attachment

kg

10370 - 12070

Tightening torques Mounting bolts

M 20

Quality 10.9 Tab. 1

560 Nm

Technical data

* in A 316 Industry

10.10.2

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MJF C I F S S

Service Manual

Slewing ring Functional description

3 Functional description

Fig. 2

Sectional drawing of the slewing ring

1

Outer race

4

Upper sealing lip

2 3

Inner race Ball

5 6

Lower sealing lip Connecting bore for lubrication line

During work with the machine, the slewing gear must withstand changing torques and great forces from the upper carriage. These forces and stresses are transferred through the outer race 1 attached to the uppercarriage and the ball 3 onto the toothed inner race 2 mounted on the undercarriage. The sealing lips 4 and 5 prevent dirt and dust penetrating the ball bearing. The ball races are lubricated through central lubrication lines attached to the outer race of the slewing ring. The gearing of the inner race and the drive pinion are lubricated by a grease packing on the slewing gear pinion, see also group 9. The grease in the ball race and the grease packing is automatically renewed by activating the central lubrication system at regular intervals, see also maintenance instructions for group 3.

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10.10.3

Slewing ring

Service Manual

Measuring of clearance

4 Measuring of clearance

Fig. 3

4.1 4.1.1

Measuring of tilting play a and tooth backlash b (tooth impression in lead sheet)

Tilting play measurement Factory tilting play Maximum play of a new installed bearingsee Tab. 1).

4.1.2

Maximum tilting play Maximum permissible play in the uppercarriage bearing (wear limit). Slewing rings can normally be operated until the maximum tilting play is reached. If there bearing shows signs of premature stiffness, replace the slewing ring. Exceeding of the maximum play impairs the operational reliability and safety of the machine. The slewing ring must be regularly inspected and checked for stiffness.

4.1.3

Measuring procedure: The tilting play is measured using a dial gauge and a magnetic-base holder. Caution! To attach the magnetic-base holder and/or to measure the tilting play, the technician must access the danger area between the uppercarriage and the undercarriage. In the event of incorrect machine operation, there is a risk of serious injury from crushing. Before accessing the danger area of the machine, ensure that the unit is standing on level and firm ground. – Apply the parking brake. – Apply the slewing gear brake. – Place the attachment on the ground. Move the uppercarriage into a suitable position. Mount the dial gauge in a position that is in line with the attachment on the slewing gear (see Fig. 3). Note! In order to prevent incorrect or inaccurate measurements, ensure that the magnetic-base holder is properly secured in its position. Before mounting the holder, carefully clean the respective area.

10.10.4

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Service Manual

Slewing ring Dismantling

Fill the bucket of the machine, lift it above ground level and extend it as far as possible away from the machine. Secure the machine in this position (establish visual/audible contact with the machine operator). Set the dial gauge to zero (initial value). Lift machine with attachment slightly (i.e. front wheels are slightly elevated from the ground). Secure the machine again in this position. Read measured value at the gauge. The difference between the two measured values corresponds to the tilting play of the slewing ring. In order to detect any differences in play along the ring, repeat the above measurement at various swivel angles of the uppercarriage.

4.2 4.2.1

Measuring of tooth backlash Tooth backlash corresponds to the tooth backlash occurring for various reasons when a new bearing is combined with a new pinion.

4.2.2

Measuring procedure: The tooth backlash is measured with a lead sheet of approx. 10 mm in width, 120 mm in length and 2 mm in thickness. Park the machine on level ground and release the uppercarriage locking mechanism and the slewing gear brake. Fully extend the attachment and lift it by approx. 1 metre from the ground. Insert the lead strip horizontally between the slewing gear pinion and the slewing ring so that it is placed on the centre of a tooth and swivel the uppercarriage slightly by manually moving the end of the attachment. Determine the tooth backlash as described in the example below: Tooth face A Tooth face B Tooth backlash

1.00 mm + 0.40 mm 1.40 mm

5 Dismantling

Danger! For the work described below, always comply with all applicable safety instructions! Do not stand under the suspended uppercarriage! To replacing the slewing ring, the uppercarriage must be lifted from the undercarriage. Ensure that a crane/excavator with sufficiently dimensioned lifting tackle, cables and attachments is available to lift off the uppercarriage. Place the uppercarriage on a level and firm surface and remove the supports, if necessary. Secure the undercarriage against rolling by inserting wheel chocks. Fully extend the bucket, stick and boom cylinder and fully retract the stick and the bucket. copyright by

MJF C I F S S

10.10.5

Slewing ring

Service Manual

Installation Retract the regulating cylinder so that the bottom edge of the attachment and the bottom edge of the uppercarriage are aligned to each other (level bearing surface on which the parts can be placed). Mark, disconnect and seal the lines at the top of the oil rotary connections. Collect any escaping oil, using suitable oil pans. Remove the driver of the oil rotary connections. If necessary, disconnect the lubrication line. Attach lifting tackle, cables, shackles etc. to the lifting eyes and mounting points at the top of the basic boom to secure the uppercarriage see Fig. 5. Remove the outer mounting bolts 30 and washers 40 between the slewing ring and the uppercarriage. Carefully lift the uppercarriage with the crane above the rotary connections and place it to the side of the undercarriage. Remove the mounting bolts 5 with washers 6 connecting the slewing ring to the undercarriage. Caution! Deformation or stress results in damage to the slewing ring. Always transport and store the slewing rings in horizontal position. Avoid impacts and stress when installing the ring. Lift the slewing ring from the undercarriage and place in onto a suitable surface.

6 Installation Caution! Screw connections that are unable to bear the occurring forces, due to elongation of or damage to the screws, can cause serious damage to components such as slewing rings, uppercarriages and undercarriages. Such breaks can also injure persons standing nearby. For safety reasons, all screws must thus be replaced with new ones when the slewing ring is replaced. When mounting the slewing ring, always use new screws. Carefully remove all dirt and other irregularities from the slewing ring bearing surface and the ring itself. Place the complete slewing ring onto the undercarriage, observing correct alignment, see Fig. 4. The slewing gear pinion must be properly engaged in the gearing and the passages must be aligned to the threads in the uppercarriage. Insert the mounting bolts 5 with washers 4 and tighten crosswise and at 90° angles, using a torque wrench (see Tab. 1 on page 2). Check slewing ring for free movement. Lift the complete uppercarriage including attachment and carefully position it on the slewing ring. Caution! Incorrect installation of the slewing ring might result in excessive load on the ball races and the balls. Before positioning the uppercarriage, rotate the outer race of the slewing ring to the correct position (see Fig. 4).

10.10.6

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MJF C I F S S

Service Manual

Slewing ring Installation Insert the mounting bolts 30 with washers 40 and tighten crosswise and at 90° angles according to the torque table, using a torque wrench. Lower lifting tackle and remove it from the machine. Connect the oil lines to the rotary connections, observing the marks. Mount the driver of the oil rotary connections. Connect the lubrication lines and lubricate the ball race from the central lubrication system. Start the diesel engine, check all functions of the undercarriage and inspect lines for leakage. Renew the grease packing of the slewing gear pinion, lubricate the gearing by rotating the uppercarriage or by means of the central lubrication system. Check all parts for proper lubrication. Inspect slewing ring for proper functioning and measure play (see Fig. 3).

Note! When installing a new slewing ring, remove all grease from the grease cap (housing enclosing the slewing gear pinion) and clean it carefully. Proceed with filling the grease cap with brake-in grease conforming to DIN 51350. Recommended product: Liebherr Universalfett 9900

Fig. 4

Correct alignment and position of the slewing ring

5

Hex head screw

A

Plug

6

Washer

B

Travel and main working direction

30

Hex head screw

S

Mark of non-hardened zone

40

Washer

Note! Mark S (non-hardened zone = areas outside the hardened bearing race) at the end face of the slewing ring tooth and the plug A at the outer race must be at an angle of 90° to the main working direction.

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MJF C I F S S

10.10.7

Slewing ring

Service Manual

Installation

Fig. 5

10.10.8

Correct attachment of lifting tackle for the lifting of the uppercarriage

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Service Manual


Group

Type

2 HL 70 transmission

11.08.1

A 309 LI 20221-29268 A 311 LI 20222-29169 A 312 LI 12363-29897


11.10.1

A 314 LI 2001A 316 LI 2001-28060 A 316 LI-IND 2001-28060

2 HL 270 / 290 transmission

11.20.1


HBGV block for 2 HL 70 / 100

11.30.1

A 309 LI 20221-29268 A 311 LI 20222-29169 A 312 LI 12363-29897 A 314 LI 2001A 316 LI 2001-28060 A 316 LI-IND 2001-28060


11.32.1


Travel gear F40

11.60.1

R 317 LI 18161-23449

FAT 350 travel gear system

11.62.1

R 313 LI 27752R 317 LI 23450-

Travel brake

11.65.1

R 317 LI 18161-23449

Travel brake

11.67.1

R 313 LI 27752R 317 LI 23450-

11.1 MJF C I F S S

Service Manual

11.2 MJF C I F S S

Service Manual

2 HL 70 transmission Function

2 HL 70 transmission 1 Function The 2 HL 70 transmission is attached to the undercarriage. It distributes the drive force from the flange-connected engine through the drive shafts to the input axles. The transmission is designed as a 2-speed powershift transmission. The on-road gear is switched automatically, while the off-road gear must be manually selected. The input system, shift lock and the output elements are attached to the gearbox.

Fig. 1


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11.08.1


Service Manual

Technical data


A 309Li / A 311 Li 20221 / 20222 A 309 / 311 Li Speeder

A 312 Li 12363 A 312 Li Speeder

2 HL 70

2 HL 70

Max. drive power (*)

50 kW

50 kW

Max. input torque (*)

394 Nm

394 Nm

Max. input speed (*)

2500 rpm

2500 rpm

5.00 1.29

5.00 1.29

110 kg

110 kg

Gearbox type

Gear ratio 1st gear 2nd gear Weight Oil volume in gearbox Oil viscosity Operating temperature Short-time max.

2.3 l

2.3 l

SAE 20 W-20 or SAE 10 W-30

SAE 20 W-20 or SAE 10 W-30

80 - 110° 120°

80 - 110° 120°

32 l/min approx. 30 l/min


Hydraulic control Max. control oil level of gear pump 32 Residual flow R from flow distributor

Pilot pressure of hydraulic unit and release pressure of multi-disc brake / coupling Pressure-relief valve 51

32 ± 1 bar

32 ± 1 bar

approx. 32 bar

approx. 32 bar

7 - 15 bar

7 - 15 bar

Shifting pressure of pressure switch B10

25 ± 2.5 bar

25 ± 2.5 bar

Shift lock pump pressure (pressure-relief valve 74) at max. input speed at shift speed

6 - 7 bar 2.0 - 2.6 bar

6 - 7 bar 2.0 - 2.6 bar

Switching speed (drive shaft / oil motor)

800 ± 100 rpm(+)

800 ± 100 rpm(+)

Switching speed (drive shaft / universal joint)

620 ± 80 rpm (+)

620 ± 80 rpm (+)

Measuring points 49, 65, 103, 104 Brake backpressure Pressure-relief valve 63 (Measuring point 65)

Shift lock on-road gear/off-road gear

Tab. 1

Technical data

((*)

maximum permissible value modified push button (+) at oil temperature 80°C The switching range results from the tolerance Ø orifice 77 (° ) with

11.08.2

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min /

max from pump 71.

Service Manual

2 HL 70 transmission Design

3 Design see Fig. 2 The 2 HL 100 transmission is designed as a powershift transmission with a planetary and a spur gear. The powershift transmission of the planetary drive consists of a rotating multi-disc clutch and a multidisc brake mounted in a housing attached at the top of the planetary drive. Both the clutch and the brake are applied mechanically by spring force (disc springs) and hydraulically released (control pressure). When in on-road gear, the multi-disc brake is hydraulically released, and the multi-disc clutch is mechanically engaged. In off-road gear, control pressure is applied to the clutch, which is thus disengaged, and the brake is applied by means of the spring force. The transmission is driven by an axial piston regulating motor with brake valve. For a description of the complete hydraulic system, the regulating motor and the brake valve, see groups 6 and 7. The machine is equipped with a release mechanism for towing in the event of an emergency. This mechanism allows for the simultaneous hydraulic release of the multi-disc brake and the multi-disc clutch by means of a piston that can be accessed from the outside, so that there is no power transmission between the input and the output end. When disengaged, the parking brake is disabled. The shut-off mechanism thus acts as the auxiliary release device required by law for the parking brake, as it is activated in the event of a power failure and/or missing release pressure. The hydraulic shift lock of the transmission protects the regulating motor against overspeeding when the gear is shifted from on-road to off-road. It is operated by the flow produced to pressurize a spool through a gear pump driven by the transmission. Depending on the machine speed, the spool is set to neutral or working position respectively, i.e. the preselected off-road speed cannot be chosen when the vehicle is driven at high speed. During the gear shifting, the multi-disc brake or clutch is supplied with oil so that it is released and is kept in this position by a constant control pressure. The spur gear transmission section is equipped with an oil reservoir from where oil is sucked by the gear pump. Bearings, shafts and gears are lubricated with gear oil from the oil sump (splash and centrifugal lubrication). The moving clutch parts are supplied with lubricating oil fed through lubrication channel.

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Service Manual

Design

3.1

Design of transmission

Fig. 2

11.08.4


1 2

Connecting flange / regulating motor Disc springs

7 8

3

Release mechanism

9

Shift lock Rotary-type pump for shift lock and lubrication Spur drive

4

Multi-disc clutch

5

Multi-disc brake

a

Input

6

Planetary drive

b

Output

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Service Manual

2 HL 70 transmission Functional description

4 Functional description Fig. 3 and Fig. 4

4.1 4.1.1

Summary Parking Multi-disc brake 87 and multi-disc clutch 93 applied by disc springs 90 / 91

Power circuit interrupted (ignition off)

4.1.2

Braking Switch S16 operated

4.1.3

Multi-disc brake 87 and multi-disc clutch 93 applied by disc springs 90 / 91

On-road gear Switch S42 not operated

4.1.4

Brake 87 (outside) released by control pressure, clutch 93 engaged by disc springs 91

Off-road gear Switch S42 operated

4.2 4.2.1

Brake 87 (outside) applied by disc springs 90, clutch 93 (inside) opened by control pressure

Function of parking brake Diesel engine off: – No control pressure from the control oil unit 50. – Multi-disc brake 87 and multi-disc clutch 93 (1st gear) engaged by disc springs 90 / 91.

4.2.2

Diesel engine on: – – – – –

4.2.3

Switch S16 in brake position (LED on). Brake valve Y6 in neutral position, and thus no pressure at connection A - P - B and brake 87. Multi-disc brake 87 and multi-disc clutch 93 (1st gear) engaged by disc springs 90 / 91. Pressure switch B10 closed, indicator light H20 on The machine cannot be started.

Braking machine when in motion: Incorrect operation, see 6.4: – Switch S16 in brake position (integrated lamp on). – Brake valve in neutral position. – Pressure in the piston chamber of the multi-disc brake 87 is released via the shift lock 70, connection B, switching the piston 75 connection P1, rotary connection 322, HBGV block 60 connection A, shift valve Y55 and brake valve Y6 to the backpressure valve 63. – Slow closing of the brake by piston with preloaded pressure spring of the accumulator 102, restrictor effect of the valve 100 and preload of the valve 63.

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11.08.5


Service Manual

Functional description – Preload is gradually reduced to zero. – The multi-disc clutch 93 is released via the shift lock 70 connection P2 and the HBGV block connection B – T to the accumulator.

4.3 4.3.1

Gear function and power flow On-road gear / 2nd gear (no preselection with switch S42): – Multi-disc brake 87 is released. – Multi-disc clutch 93 is closed. – The sun gear 83 and the hollow gear 86 are driven simultaneously through the engaged clutch 93 and the drive shaft 82 by the oil motor 210. – There is therefore no speed reduction by the planetary drive. The planetary carrier 85 drives the helical gear 97 via the sliding sleeve 95 and the jaw clutch 96. – The larger helical gear 98 meshing with the gear 97 rotates at a lower speed (speed reduction) and drives the axles, and thus the drive wheel of the machine, via the drive flange 99 and the flange-connected universal joint shafts.

4.3.2

Off-road gear / 1st gear (preselection with switch S42): – Multi-disc brake 87 is applied. – Multi-disc clutch 93 is disengaged. – The sun gear 83 is propelled through the drive shaft 82 by the oil motor 210. The planetary gears 84 roll on the stationary hollow gear 86 (due to applied multi-disc brake 87). – The planetary carrier 85 drives the helical gear 97 via the sliding sleeve 95 and the jaw clutch 96. – The larger helical gear 98 meshing with the gear 97 rotates at a lower speed (speed reduction) and drives the axles, and thus the drive wheel of the machine, via the drive flange 99 and the flange-connected universal joint shafts. – The second speed reduction of the planetary drive / spur drive results in a high reducing gear ratio, (see “Technical data” on page 2).

4.4 4.4.1

Function of shift lock General The shift lock 70 protects the gear system and the hydraulic motor against excessive speed, which might occur when the drive changes from on-road to off-road gear while travelling at relatively high speeds. It does however not protect the system against excessive speed during deceleration. If the input speed and thus the drive speed are above the set shifting-down point, gear switching from onroad to off-road speed is not possible. The preselected off-road gear is only released by the shift lock 70 when the shifting-down point is reached. If the input speed is below the shifting-down point, the machine is automatically shifted to the selected off-road gear. The on-road gear can be chosen at any speed.

4.4.2

Normal position of shift lock The rotary-type pump / gear pump 71 driven by the gear input shaft sucks oil from the gear sump through the internal bores and the suction filter 71.2. It produces an oil pressure, which is determined by the input speed (output speed of the oil motor) and corresponds to the pressure at the orifice 77 for the lubricating oil supply of the gear system. A part of the oil is used to lubricate the gear system, while the rest moves the shifting piston 75, or is returned by the pressure-relief valve 74 to the suction side. The pump flow, the lubricating oil orifice 77 and the characteristic of the pressure spring in the shifting piston 75 are adjusted in such away that, at input speeds below the shifting-down point, the backpressure at the orifice 77 and the resulting piston force are smaller than the spring force.

11.08.6

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Service Manual


When the piston is in this position (neutral position), oil flow from P1 B or from P2 K is possible so that the machine can be switched to on-road or off-road speed. If the off-road gear is chosen, the shifting piston 75 remains in neutral position, as the shifting pressure K and the spring force are higher than the pump pressure. It is thus possible to shift the machine up to on-road gear.

4.4.3

Leakage check valve 72 If off-road gear is preselected, the leak oil from the shifting piston 75 and the check valve 73 (at pressure side P2) is fed through the leakage check valve 72 through connection P1 to the tank. The valve 72 also blocks the control pressure to the multi-disc brake 87 when the machine is driven in on-road or off-road gear.

4.4.4

Shuttle check valve 73 If the off-road gear is preselected, the shuttle check valve 73 blocks the flow from connection P2 to P1. If the machine is in on-road gear and moves at a speed above the shifting-down point, it blocks the flow from connection P1 to P2.

4.4.5

Pressure-relief valve 74 The pressure-relief valve 74 protects the lubricating pump 71 against pressures above 6 to 8 bar. It only opens, if the machine is moving above the shifting-down point, i.e. the pressure required to operate the shifting piston 75 is determined by the backpressure at the orifice 77 for the lubricating oil supply.

4.4.6

Shifting piston 75 The shifting piston 75 acts as the actual shift lock. The flow, which is given by the input speed of the gear system, and the resulting backpressure at the orifice 77 determines the position of the shifting piston 75. Low speed low flow low backpressure shifted from on-road gear to off-road gear.

shifting piston in neutral position

machine can be

High speed high flow high backpressure shifting piston in working position machine can only be shifted to on-road gear shifting to off-road gear locked.

4.4.7

Check valve 76 The check valve 76 feeds the oil that is replaced when the shifting piston 75 is moved through P2 to the tank.

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Service Manual


4.5

Diagram of gearbox / hydraulic circuit

Fig. 3 a

11.08.8

Diagram of transmission and shift lock Output

72

Leakage check valve

b

Shut-off mechanism

73

Shuttle check valve

e B

Oil supply transmission to multi-disc brake

74 75

Pressure-relief valve Shifting piston

C

Release mechanism

76

Check valve

EB

Bleeder / multi-disc brake

77

Orifice

EK EL

Bleeder / multi-disc clutch Bleeder / release mechanism

80 87

Transmission Multi-disc brake

J

Measuring point on-road gear

90

Disc springs

K L

to multi-disc clutch Measuring point pump pressure

91 93

Disc springs Multi-disc clutch

M P1

Measuring point off-road gear from HBGV block

95 100

Piston / release mechanism Restrictor check valve

P2 60

from HBGV block from HBGV block

101 102

Restrictor check valve Accumulator

70

Shift lock

106

Shift valve

71

Lubricating oil pump

210


71.2

Suction filter (maintenance-free)

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Service Manual

2 HL 70 transmission Positions of the shift lock 70

5 Positions of the shift lock 70 5.1

Machine in on-road gear (2nd gear) (see Fig. 4 on page10)

Input speed

Control oil to connection

Function / shift lock

Function / transmission

Gear pump 71 delivers a specific oil volume

Shift speed travel motor (> 700 - 900 rpm) Drive shaft (> 540 - 700 rpm)

Pump pressure Pp max. 7.0 bar Shifting piston 75 in working position P1

Shifting pressure Sp over shuttle check valve 73 Via external line to multi-disc brake. Brake released

B

Valves 72 and 73 block the connection to point K. Point K is connected via the check valve 76 and connection P2 to the tank.

Multi-disc clutch closed. Gear ratio planetary drive = 1: 1 (2nd gear)

If the machine is in on-road gear and the speeds are above the shifting-down point, an increased pump pressure is applied to the shifting piston 75. The piston is pressed against the pressure spring and moved into working position. If the operator now preselects the off-road gear, the pressure applied to the shift lock 70 changes from connection P1 to connection P2. The shuttle check valve 73 continues to release the pressure to connection B so that shifting down is not possible. The machine remains in on-road gear. Only when the speed is reduced to below the shifting-down point (reduction of travel speed), the spring presses the piston 75 into its neutral position, i.e. the machine can now be set to off-road gear. 70

79

Oil supply / transmission

71 Lubricating oil pump 71.2 Suction filter (maintenance-free)

B K

Connection to multi-disc brake Connection to multi-disc clutch

72

Leakage check valve

P1

from HBGV block

73

Shuttle check valve

P2

from HBGV block

74 75


Pp S

Pump pressure Suction chamber / pump

76

Check valve

Sp

Shifting pressure

77 78

Orifice Connection of lubricating oil supply

T

Return / tank

Shift lock

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11.08.9


Service Manual

Positions of the shift lock 70

Fig. 4

11.08.10

Hydraulic diagram and sectional drawing of the transmission during travel in on-road gear at high speed

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Service Manual


5.2

Travel in on-road gear On-road gear (1st gear) preselected with switch S42 (see Fig. 5 on page12)

Input speed


Shift speed Travel motor (> 700 - 900 rpm) Universal joint shaft (> 540 - 700 rpm)



Gear pump 71 delivers a specific oil volume Pump pressure Pp max. 7.0 bar Spool 75 in working position P2

Shifting pressure Sp over the shifting piston 75 and the shuttle check valve 73; valve 73 also blocks connection to P1. Via external line to multi-disc brake. Brake released

B

Point K is connected via the check valve 72 and connection P1 to the tank.

Multi-disc clutch closed. Gear ratio planetary drive = 1: 1 (2nd gear) Shifting-down to 1st gear not possible; shifting down only possible when the input speed is below 800 rpm

70

78

Connection of lubricating oil supply


79 B

Oil supply / transmission Connection to multi-disc brake

72

Leakage check valve

K

Connection to multi-disc clutch

73

Shuttle check valve

P1

from HBGV block

74


P2

from HBGV block

75 76

Shifting piston Check valve

Pp S


77

Orifice

Sp

Shifting pressure

Shift lock

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MJF C I F S S

11.08.11


Service Manual


Fig. 5

11.08.12

Hydraulic diagram and sectional drawing of the transmission during travel in on-road gear – off-road gear preselected

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Service Manual


5.3

Off-road gear (1st gear) preselected with switch S42 (see Fig. 6 on page14)

Input speed


Shift speed Travel motor (< 700 - 900 rpm) Universal joint shaft (< 540 - 700 rpm)



Gear pump 71 delivers a specific oil volume Pump pressure Pp low Shifting piston 75 in neutral position P2

Shifting pressure Sp over shifting piston 75 (open edge of control spool)

K

Via external line to multi-disc brake. Clutch released Gear ratio of planetary drive = 1 : 3.87 (1st gear) Valve 72 blocks the connection to point B. Point B is connected via the shifting piston 75 (open control edge) and connection P1 to the tank.

Multi-disc brake depressurised, brake applied

70

Shift lock

79


71


B

to multi-disc brake

71.2 Suction filter (maintenance-free) 72 Leakage check valve

K P1

to multi-disc clutch from HBGV block

73 74

Shuttle check valve Pressure-relief valve

P2 Pp

from HBGV block Pump pressure

75

Shifting piston

S

Suction chamber / pump

76

Check valve

Sp

Shifting pressure

77

Orifice

T

Return / tank

78

to lubricating oil supply

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11.08.13


Service Manual


Fig. 6

11.08.14

Hydraulic diagram and sectional drawing of the transmission during travel in off-road gear

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Service Manual

2 HL 70 transmission Operation of the machine

6 Operation of the machine Fig. 7 or Fig. 8

6.1

Driving and gear shifting After gear preselection and subsequent preselection of the travel direction, the vehicle can be set into motion by pressurising the oil motor.

6.2

Preselection of gear The on-road gear is automatically selected. The 1st gear / off-road gear is preselected with the switch S42 located on the right console beside the operator's seat, see Fig. 7 or Fig. 8. Actuate the switch S42: The off-road gear (1st gear) is preselected. The indicator lamp in the switch S42 is on. The solenoid valve Y55, Fig. 14, is powered and thus in working position. The gear is automatically shifted from on-road to off-road, based on the speed through the hydraulic/ mechanical shift lock 70. In other words, the shift is not completed immediately when the switch is operated.

6.3

Preselection of travel direction Preselect the travel direction at the preselection switch S263 located in the right pilot control unit, see Fig. 7 or Fig. 8. The indicator lights H167 or H168 respectively indicate the preselected travel direction. They are integrated into the right control desk, see Fig. 7 or Fig. 8. Press the preselection switch S263 down: The indicator light H167 (forward) is on. If the pilot control unit 84, Fig. 7 or Fig. 8, is actuated, the machine travels forward. Press the preselection switch S263 up: The indicator light H168 (reverse) is on. If the pilot control unit 84, Fig. 7 or Fig. 8, is actuated, the machine travels backwards. Reversing (i.e. switching from forward to reverse motion and back) is possible in both gears.

6.4

Brakes Caution! The parking brake is designed in such a way that it cannot be operated during work. Otherwise, the machine would be damaged. During work, use only the working brake. Engage the locking device 23 of the working brake (pedal 22 to the right of the steering column), see Fig. 7 or Fig. 8.

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11.08.15


Service Manual

Operation of the machine By applying the parking brake (multi-disc brake 87) with the switch S16, Fig. 7 or Fig. 8, the machine is secured against inadvertent rolling-off when parked. By applying the parking brake, the opened pressure switch B10, Fig. 14 automatically disconnects the electric mass and connection to the solenoid valves for the travel direction preselection, so that the machine cannot be moved when the brake is applied (see also electrical system). Actuate the switch S16: the brake is applied. The indicator light H20 is on. The pressure switch B10 is released. Note! The brake is designed as a parking brake and may only be applied when the machine is standing still. When parking on slopes, we recommend securing the vehicle with wedges, in addition to the parking brake.

6.5

Parking the machine Turn the ignition key of the machine to position 0 and remove it. The clutch 87 (brake) and 93 (1st gear) is automatically engaged.

Fig. 7

11.08.16

Switch and indicator light of the models A 312 to serial no. 20329

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Fig. 8

Switch and indicator light of the models A 309 from serial no. 20221 and A 311 machines from serial no. 20222 and A 312 machines from serial no. 20330

22 23

Foot pedal / working brake Foot pedal retainer

H168 S16

Indicator light / reverse travel Switch / parking brake

84*

Travel pilot control unit

S42

Switch 1st gear

H20 H167

Indicator light of parking brake Indicator light / forward travel

S263


*

Items of hydraulic unit

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11.08.17


Service Manual

Towing of the machine

7 Towing of the machine Caution! The towing of the machine is a dangerous manoeuvre with a risk of injury to the driver and damage to the machine. The machine may only be towed if absolutely necessary, e.g. to carry out repairs at a suitable location or workshop. When towing the machine, please note: – max. towing speed = 5 km/h – max. towing distance = 10 km

7.1

Towing of machine with running diesel engine Before towing the machine, ensure that pilot control oil is fed to the transmission, so that the parking brake is released. Set the switch S16 to its neutral position. The parking brake is released. The indicator light H20 is off. If there is no battery voltage or if the electrical system fails: Turn in the T-handle screw S at the HBGV block 60, Fig. 9. The brake valve Y6 is set to working position.

7.2

Towing of machine when diesel engine is off Caution! The parking brake is disabled while the machine is being towed. When the diesel engine is shut down, the working brake can still perform a few braking manoeuvres, even if the brake accumulator is filled. When the diesel engine is off, the machine can only be steered with the emergency steering system (steering wheel is stiff). The machine may only be towed away from the danger zone but not any further! Disconnect the gear drive and brake from the output. Danger! Emergency activation requires access to the undercarriage of the machine. There is a risk of serious injury or even death to the technician, if the machine begins to move. Park the machine on a level surface and secure it with chucks against rolling away. Access the area of the undercarriage only when the machine is shut down and properly secured in its position. Adhere to the accident prevention regulations issued by the German Ground Construction Trade Association (Tiefbau-Berufsgenossenschaft) for powertrains and earth-moving equipment. Before actuating the release mechanism (piston 95), ensure that the clutch chambers are properly bled. Bleed the clutch chambers of the parking brake, gear shifting mechanism and the release mechanism as follows:

11.08.18

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Service Manual

2 HL 70 transmission Maintenance Release the bleeders EB, EK and EL of the multi-disc brake / multi-disc clutch and the release mechanism. Bleed the clutch chambers, see 9.3 and Fig. 12 by actuating the parking brake and the gear shifting mechanism (clutch chambers are filled with oil). Collect escaping oil. When bubble-free oil escapes, seal the bleeders. Turn the piston 95 of the release mechanism quickly to the stop, using an Allen key (size 12), Fig. 9,. The multi-disc brake 87 and the multi-disc clutch 93 are hydraulically released. The oil motor is disconnected from the drive system.

Fig. 9

Bottom view of HBGV block and gear system release mechanism

60 80

HBGV block Gearbox (bottom view)

95

Piston / release mechanism

S Y6

T-handle screw / emergency activation Brake valve

8 Maintenance Danger! Maintenance requires access to the undercarriage of the machine. There is a risk of serious injury or even death to the technician, if the machine begins to move. Park the machine on level ground. Secure it against uncontrolled movement. Only carry out maintenance work on the gearbox, if the machine is fully shut down and properly secured. Adhere to the accident prevention regulations issued by the German Ground Construction Trade Association (Tiefbau-Berufsgenossenschaft) for powertrains and earth-moving equipment. The service life and operating time of the gearbox depend primarily on regular and careful maintenance and servicing of the unit. It is therefore important that the following instructions are strictly followed.

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11.08.19


Service Manual

Maintenance

8.1

Oil level check Check the oil level at the intervals laid down in the inspection and maintenance schedule, see group 3. Wait 5 minutes and then carry out a oil level check: Carefully remove the screw plug at the check and filling opening 2 at the gearbox 80 and check the oil level. If the oil reaches the lower edge of the opening , it is not necessary to add oil. If the oil level is below the lower edge of the opening , add oil of the prescribed viscosity to the lower edge of the opening.

8.2

Oil change Change the oil at the intervals laid down in the inspection and maintenance schedule. When the gearbox is warm (30 - 40°C), switch off the engine and wait for 5 minutes. Then change the oil: Remove the oil discharge screw 1. Drain the oil from the gearbox 80 into the provided container. Screw in the oil discharge screw 1 (ensure that the seal ring is positioned properly). Remove the screw plug at the check and filling opening 2 at the gearbox 80. Add oil of the prescribed viscosity until it reaches the lower edge of the check and refill bore 2. Screw in the screw 2 of the gearbox 80 (ensure that the seal ring is positioned properly).

Fig. 10 1

Maintenance tasks to be carried out on the gearbox 80 2

Oil drain screw

Oil check and filling opening screw

A check of the gear shifting and parking brake function must be carried out in the course of the maintenance work. In the event of malfunctions or failures, check the pressures in the gear system as described below.

8.3

Check of gearbox Note! The inspection must be carried out while the machine is at operating temperature and the diesel engine running at high idle speed.

11.08.20

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Service Manual

2 HL 70 transmission Maintenance

8.3.1

Checking the release pressure of the clutch, see Fig. 11 Connect the pressure sensor (0-40 bar) to the measuring point 103 (multi-disc brake / connection B) or the measuring point 104 (multi-disc clutch / connection K). Preselect on-road or off-road gear and check release pressure, (see “Technical data” on page 2). A release pressure below the nominal pressure is possibly caused by a defect in the shift lock 70. If the pressure is too low, check and adjust the pressure of the pilot system. After adjustment of the pressure, remove the pressure sensor and seal the measuring point(s).

8.3.2

Checking the backpressure of the brake, see Fig. 11 Connect the pressure sensor (0-40 bar) to the measuring point 65. Apply the brake with the switch S16 and measure the pressure at the measuring point 65, (see “Technical data” on page 2). To adjust the backpressure to the nominal value, turn the adjusting screw of the backpressure valve 63 (located opposite the two solenoid valves Y6 and Y55). To do this, remove the protective cap from the valve 63, loosen the lock nut and turn the adjusting screw, until the prescribed value is reached. Turn in Turn out

= Increase pressure = Reduce pressure

After the pressure has been adjusted, tighten the sealing nut and replace the protective cap. Remove the pressure sensor and seal the measuring point.

Fig. 11

Measuring points at the transmission and HBGV block

B

Connection of multi-disc brake

65

Backpressure measuring point

K

Connection of multi-disc clutch

80

Gearbox

60 63

HBGV block Backpressure valve

103 104

Measuring point Measuring point

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11.08.21


Service Manual

Dismantling, repair and installation of the gearbox

9 Dismantling, repair and installation of the gearbox (see Fig. 13 on page24)

9.1

Dismantling of the gearbox for repair work Danger! The dismantling and installation of the gearbox requires access to the undercarriage of the machine. There is a risk of death to the technician, as limbs could become crushed. Park the machine on level ground. Secure it against uncontrolled movement. The gearbox may only be dismantled or installed if the machine is properly secured. Depressurise the hydraulic system. Always refer to the safety instructions in group 1.10. Disconnect and seal the hydraulic line to the oil motor and the gearbox (collect any escaping oil) and seal the lines. Remove the hex nuts 7 and remove the universal joint shafts 3 from the gearbox 80. In order to remove all nuts 7, it might be necessary to lift the undercarriage 9, so that the universal joint shafts 3 can be rotated by turning the wheels. Secure the gearbox 80 with suitable lifting tackle. Remove the hex head screws 54 with the washers 52. Remove the hex head screw 60 with the washer 62. Disconnect the gearbox 80 and the angle bracket 40 from the undercarriage 9 and pull it from the undercarriage 9. Remove the hex head screws 44 and disconnect the angle bracket 40 from the gearbox 80. Remove the hex head screws 22. If necessary, heat the screws 22 (secured with locking agent). Insert the oil motor 210 from the gearbox 80.

9.2

Repair of the rigid axle Note! For detailed repair instructions for the transmission, refer to the separate "Repair manual for 2 HL 70 ZP gearbox".

9.3

Installation of the gearbox after repairs Apply sealant to the flange surface of the gearbox 80 and the oil motor 210. Insert the oil motor 210 into the gearbox 80. Treat the threads of the hex head screws 22 with Omnifit 100 and tighten the hex head screws 22 (tightening torque 195 Nm). Position the angle bracket 40 in the correct position on the gearbox 80. Tighten the hex head screws 44 (torque 79 Nm).

11.08.22

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Service Manual

2 HL 70 transmission Dismantling, repair and installation of the gearbox Place the gearbox 80 with the angle bracket 40 in the undercarriage 9, using suitable lifting gear. Secure the angle bracket 40 to the undercarriage 8, using the hex head screws 54 and the washers 52 (torque 560 Nm). Secure the gearbox 80 to the undercarriage 8, using the hex head screws 60 and the washers 62 (torque 430 Nm). Secure the universal joint shaft 3 with the hex head screws 7 to the output flanges of the gearbox 80. Connect all hydraulic lines of the gearbox 80 and the oil motor 210. Remove the protective cap from the bleeders EB/EK/EL,Fig. 12, and connect a suitable hose. Release the bleeders of the multi-disc brake / multi-disc clutch and the release mechanism and repeatedly actuate the parking brake and the gear shifting mechanism to bleed the clutch chambers (clutch chambers are filled with oil). Collect escaping oil. When bubble-free oil escapes, seal the bleeders and replace the protective caps.

Fig. 12

Top view of bleeder of the gearbox (without protective cap)

EB


EK

Bleeder / multi-disc clutch

EL

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Bleeder / release mechanism

11.08.23


Service Manual


Fig. 13

11.08.24

Undercarriage with transmission

3

Universal joint shaft

52

Retaining washer

7

Hex nut

54

Hex head screw

9 22

Undercarriage Hex head screw

60 62


40 44

Angle bracket Hex head screw

80 210

Transmission, complete Oil motor with brake valve

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Service Manual

2 HL 70 transmission Components and layout

10 Components and layout

Fig. 14

Main components of the transmission control and the parking brake

32 49

Gear pump Measuring point / pilot pressure

80 210

50

Control oil unit

B10 Pressure switch

60 64

HBGV block Accumulator

P R

Control pressure connection Residual flow from flow distributor / gear pump

65 70

Backpressure measuring point Shift lock

Y6 Y55

Brake valve Shift valve

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Transmission Regulating travel motor

11.08.25


Service Manual

Hydraulic release mechanism and hydraulic accumulator

11


Fig. 15

11.08.26

Sectional drawing and diagram of hydraulic release mechanism

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Service Manual

2 HL 70 transmission Hydraulic release mechanism and hydraulic accumulator

70 87

from/to shift lock from/to multi-disc brake

103 104

Measuring point / brake B Measuring point / clutch K

93 95

from/to multi-disc clutch Piston / hydraulic release mechanism

105 106

Safety valve Shift valve

100


107

Bleeder (EB) / multi-disc brake

101 102

Restrictor check valve Accumulator

107 210

Bleeder (EL) / release mechanism Regulating motor

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11.08.27


Service Manual


11.08.28

0

Check valve, complete consisting of assemblies 1- 17

1

Drive housing (81/95*)

10

Multi-disc brake (87/89/90*)

2

Drive housing (81/95*)

11

Planetary drive (85/86*)

3

Drive (82*)

12

Spur drive (97*)

4 5

Housing (80/102*) Housing (80/102*)

13 14

Spur drive (97*) Shift lock (70*)

6 7

Oil lines Clutch (91/92/93/94*)

15 16

Shift lock (70*) Output (98/99*)

8 9

Clutch (91/92/93/94*) Multi-disc brake (87/89/90*)

17

Output (98/99*)

*

Items in sectional drawing on page 11.08.35

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Service Manual

2 HL 70 transmission Exploded view of gearbox components

12 Exploded view of gearbox components 12.1

Gearbox 0 complete, drive housing 1/2 and housing 4/5

Fig. 16

Exploded view of gear housing based on spare parts list

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11.08.29


Service Manual

Exploded view of gearbox components

12.2

Clutch 7/8 and multi-disc brake 9/10

Fig. 17

11.08.30

Exploded view of the clutch and the multi-disc brake based on spare parts list

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Service Manual


12.3

Drive 3, planetary drive 11 and spur drive 12/13

Fig. 18

Exploded views of the drive, planetary drive and spur drive based on spare parts list

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11.08.31


Service Manual


12.4

Oil lines 6 and shift lock 14/15

Fig. 19

11.08.32

Exploded views of oil lines and shift lock based on spare parts list

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12.5

Gear drive 16/17

Fig. 20

Exploded views of output end based on spare parts list

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11.08.33


Service Manual

Exploded view of gearbox components 1 2

Hydraulic tank (*) Breather filter (*)

86 87

Hollow gear Multi-disc brake (6 inner discs)

3 4

Stop cock (*) Return filter (*)

89 90

Piston Disc springs

5

Bypass valve / return line (*)

91

Disc springs

20 21

Variable displacement pump (*) Powertrain

92 93

Piston Multi-disc clutch

30

Gear pump / cooling (*)

94

Thrust plate

31

Steering pump

95

Piston

32

Pump for pilot control (*)

96

Screw plug

49

Measuring point / pilot pressure (*)

97

Helical gear

50

Control oil unit / pilot control (*)

98

Helical gear

51 52

Pressure-relief valve (*) Pressure filter (*)

99 103

Output flange Measuring point / brake B

53 54

Check valve (*) Accumulator (*)

104 210

Measuring point / clutch K Regulating motor (*)

60 63

HBGV block Backpressure-limiting valve

322 400

Rotary connection 6x (*) to compact brake block

64

Accumulator

65

A126

66

Measuring point / backpressure and release pressure Check valve

B10

from/to autocheck printed circuit board (X) Pressure switch / parking brake (X)

70 71

Shift lock, complete Gear pump

H20 K251

Indicator light of parking brake (X) Relay / parking brake (X)

71.2

Suction filter

S16

Push button / parking brake (X)

72 73

Leakage check valve Shuttle check valve

S42 Y3

Push button / off-road gear (X) Solenoid valve / pilot control (*)

74 75

Pressure-relief valve (6-8 bar) Shifting piston

Y6 Y24

Solenoid valve / parking brake (X) Solenoid valve / creeper gear (*)

76 77

Check valve Orifice

Y50 Y50

Solenoid valve / power control (X) Solenoid valve / power control (X)

80

Transmission

Y55

Solenoid valve / 1st gear (X)

81 82

Connecting flange Drive shaft

Y62 Y63

Solenoid valve / forward travel (X) Solenoid valve / reverse travel (X)

85

Planetary carrier

Y371

Solenoid valve / oscillating axle (*)

* = Items in hydraulic diagram of group 6 X = Items in electrical diagram of group 8 O = built into housing connection

11.08.34

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Service Manual

2 HL 100 transmission Function

2 HL 100 transmission 1 Function The 2 HL 100 transmission is attached to the undercarriage. It distributes the drive force from the flange-connected engine through the drive shafts to the input axles. The transmission is designed as a 2-speed powershift transmission. The on-road gear is switched automatically, while the off-road gear must be manually selected. The input system, shift lock and the output elements are attached to the gearbox.

Fig. 1


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11.10.1


Service Manual

Technical data




Gearbox type

2 HL 100

2 HL 100


110 kW

110 kW


770 Nm

770 Nm


4500 rpm

4500 rpm

5.35 1.39

5.35 1.39

125 kg

125 kg

Gear ratio 1st gear 2nd gear Weight Oil volume in gearbox Oil viscosity Operating temperature Short-time max.

3.3 l

3.3 l

SAE 20 W-20 or SAE 10 W-30

SAE 20 W-20 or SAE 10 W-30

80 - 110° 120°

80 - 110° 120°



Hydraulic control Max. control oil level of gear pump 32 Residual flow R from flow distributor

Pilot pressure of hydraulic unit and release pressure of multi-disc brake / coupling Pressure-relief valve 51

32 ± 1 bar

32 ± 1 bar

approx. 32 bar

approx. 32 bar

12.5 bar

12.5 bar

26.5 bar 25 ± 2.5 bar (°)

26.5 bar 25 ± 2.5 bar (°)

6 - 8 bar 2.0 - 2.6 bar

6 - 8 bar 2.0 - 2.6 bar


580 - 950 rpm (+)

580 - 950 rpm (+)


415 - 680 rpm (+)

415 - 680 rpm (+)

Measuring points 49, 65, 103, 104 Brake backpressure Pressure-relief valve 63 (Measuring point 65) Shifting pressure of pressure switch B10 Shift lock pump pressure (pressure-relief valve 74) at max. input speed at shift speed Shift lock on-road gear/off-road gear

Tab. 1

Technical data

(*)

maximum permissible value modified pressure switch (+) at oil temperature 80°C The switching range results from the tolerance Ø orifice 77 (° ) with

11.10.2

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min /

max from pump 71.

Service Manual

2 HL 100 transmission Design

3 Design see Fig. 2 The 2 HL 100 transmission is designed as a powershift transmission with a planetary and a spur gear. The powershift transmission of the planetary drive consists of a rotating multi-disc clutch and a multidisc brake mounted in a housing attached to the top of the planetary drive. Both the clutch and the brake are applied mechanically by spring force (disc springs) and hydraulically released (control pressure). When in on-road gear, the multi-disc brake is hydraulically released, and the multi-disc clutch is mechanically engaged. In off-road gear, control pressure is applied to the clutch, which is thus disengaged, and the brake is applied by means of the spring force. The transmission is driven by an axial piston regulating motor with brake valve. For a description of the complete hydraulic system, the regulating motor and the brake valve, see groups 6 and 7. A shut-off mechanism is installed between the planetary drive and the spur gear. This jaw clutch is operated by means of a lever attached to the gearbox. The lever is equipped with a locking mechanism. In OFF position, it interrupts the power transmission between input and output. When disengaged, the parking brake is disabled. The shut-off mechanism thus acts as the auxiliary release device required by law for the parking brake, as it is activated in the event of a power failure and/or missing release pressure. The hydraulic shift lock of the transmission protects the regulating motor against overspeeding when the gear is shifted from on-road to off-road. It is operated by the flow produced to pressurize a spool through a gear pump driven by the transmission. Depending on the machine speed, the spool is set to neutral or working position respectively, i.e. the preselected off-road speed cannot be chosen when the vehicle is driven at high speed. During the gear shifting, the multi-disc brake or clutch is supplied with oil so that it is released and is kept in this position by a constant control pressure. The spur gear transmission section is equipped with an oil reservoir from where oil is sucked by the gear pump. Bearings, shafts and gears are lubricated with gear oil from the oil sump (splash and centrifugal lubrication). The moving clutch parts are supplied with lubricating oil fed through the lubrication channel.

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11.10.3


Service Manual

Design

3.1


Fig. 2

11.10.4


1

Connecting flange / regulating motor

8

Control pressure rotary-type pump

2 3

Shifting pressure accumulator Multi-disc clutch

9 10

Spur gear drive Disc springs

4 5

Multi-disc brake Planetary drive

11 a

Restrictor valve Input

6

Shut-off mechanism

b

Output

7

Shift lock

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Service Manual


4 Functional description Fig. 3 and Fig. 4

4.1 4.1.1

Summary description Parking Multi-disc brake 87 and multi-disc clutch 93 applied by disc springs 90 / 91

Power circuit interrupted (ignition off)

4.1.2

Braking Switch S16 operated

4.1.3

Multi-disc brake 87 and multi-disc clutch 93 applied by disc springs 90 / 91

On-road gear Switch S42 not operated

4.1.4

Brake 87 (outside) released by control pressure, clutch 93 engaged by disc springs 91


4.2 4.2.1

Brake 87 (outside) applied by disc springs 90, clutch 93 (inside) opened by control pressure

Function of parking brake Diesel engine off: – No control pressure from the control oil unit 50. – Multi-disc brake 87 and multi-disc clutch 93 (1st gear) engaged by disc springs 90 / 91.

4.2.2

Diesel engine on: – – – – –

4.2.3

Switch S16 in brake position (LED on). Brake valve Y6 in neutral position, and thus no pressure at connection A - P - B and brake 87. Multi-disc brake 87 and multi-disc clutch 93 (1st gear) engaged by disc springs 90 / 91. Pressure switch B10 closed, indicator light H20 on. The machine cannot be started.

Braking machine when in motion Incorrect operation, see 6.4: – Switch S16 in brake position (integrated lamp on). – Brake valve in neutral position. – Pressure in the piston chamber of the multi-disc brake 87 is released via the shift lock 70, connection B, switching piston 75 connection P1, rotary connection 322, HBGV block 60 connection A, shift valve 62 and brake valve 61 to backpressure valve 63. – Slow closing of the brake by piston with preloaded pressure spring of accumulator 102, restrictor effect of valve 100 and preload of valve 63.

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11.10.5


Service Manual

Functional description – Preload is gradually reduced to zero. – Multi-disc clutch 93 is released via shift lock 70 connection P2 and HBGV block connection B – T to the accumulator.

4.3 4.3.1

Gear function and power flow On-road gear / 2nd gear (no preselection with switch S42): – Multi-disc brake 87 is released. – Multi-disc clutch 93 is engaged. – The sun gear 83 and the hollow gear 86 are driven simultaneously through the engaged clutch 93 and the drive shaft 82 by the oil motor 210. – There is therefore no speed reduction by the planetary drive. The planetary carrier 85 drives the helical gear 97 via the sliding sleeve 95 and the jaw clutch 96. – The larger helical gear 98 meshing with the gear 97 rotates at a lower speed (speed reduction) and drives the axles, and thus the drive wheel of the machine, via the drive flange 99 and the flange-connected universal joint shafts.

4.3.2

Off-road gear / 1st gear (preselection with switch S42): – Multi-disc brake 87 is applied. – Multi-disc clutch 93 is disengaged. – The sun gear 83 is propelled through the drive shaft 82 by the oil motor 210. The planetary gears 84 roll on the stationary hollow gear 86 (due to applied multi-disc brake 87). – The planetary carrier 85 drives the helical gear 97 via the sliding sleeve 95 and the jaw clutch 96. – The larger helical gear 98 meshing with the gear 97 rotates at a lower speed (speed reduction) and drives the axles, and thus the drive wheel of the machine, via the drive flange 99 and the flange-connected universal joint shafts. – The second speed reduction of the planetary drive / spur drive results in a high reducing gear ratio, (see “Technical data” on page 2).

4.4 4.4.1

Function of shift lock General The shift lock 70 protects the gear system and the hydraulic motor against excessive speed, which might occur when the driver changes from on-road to off-road gear while travelling at relatively high speeds. It does however not protect the system against excessive speed during deceleration. If the input speed and thus the drive speed are above the set shifting-down point, gear switching from onroad to off-road speed is not possible. The preselected off-road gear is only released by the shift lock 70 when the shifting-down point is reached. If the input speed is below the shifting-down point, the machine is automatically shifted to the selected off-road gear. The on-road gear can be chosen at any speed.

4.4.2

Normal position of shift lock The rotary-type pump / gear pump 71 driven by the gear input shaft sucks oil from the gear sump through the internal bores and the suction filter 71.2. It produces an oil pressure, which is determined by the input speed (output speed of the oil motor) and corresponds to the pressure at the orifice 77 for the lubricating oil supply of the gear system. A part of the oil is used to lubricate the gear system, while the rest moves the shifting piston 75, or is returned by the pressure-relief valve 74 to the suction side. The pump flow, the lubricating oil orifice 77 and the characteristic of the pressure spring in the shifting piston 75 are adjusted in such away that, at input speeds below the shifting-down point, the backpressure at the orifice 77 and the resulting piston force are smaller than the spring force.

11.10.6

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Service Manual


When the piston is in this position (neutral position), oil flow from P1 B or from P2 K is possible so that the machine can be switched to on-road or off-road speed. If the off-road gear is chosen, the shifting piston 75 remains in neutral position, as the shifting pressure P2 and the spring force are higher than the pump pressure. It is thus possible to shift the machine up to on-road gear.

4.4.3

Leakage check valve 72 If off-road gear is preselected, the leak oil from the shifting piston 75 and the check valve 73 (at pressure side P2) is fed through the leakage check valve 72 through connection P1 to the tank. The valve 72 also blocks the control pressure to the multi-disc brake 87 when the machine is driven in on-road or off-road gear.

4.4.4

Shuttle check valve 73 If the off-road gear is preselected, the shuttle check valve 73 blocks the flow from connection P2 to P1. If the machine is in on-road gear and moves at a speed above the shifting-down point, it blocks the flow from connection P1 to P2.

4.4.5

Pressure-relief valve 74 The pressure-relief valve 74 protects the lubricating pump 71 against pressures above 6 to 8 bar. It only opens, if the machine is moving above the shifting-down point, i.e. the pressure required to operate the shifting piston 75 is determined by the backpressure at the orifice 77 for the lubricating oil supply.

4.4.6



machine can be


4.4.7

Check valve 76 The check valve 76 feeds the oil that is replaced when the shifting piston 75 is moved through P2 to the tank.

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11.10.7


Service Manual


4.5

Diagram of gear system / hydraulic circuit

Fig. 3

11.10.8

Diagram of transmission and shift lock

a

Output

60

from HBGV block

b d

Shut-off mechanism Oil supply transmission control

70 71

Shift lock Lubricating oil pump

e B

Oil supply transmission to multi-disc brake

71.2 72

Suction filter (maintenance-free) Leakage check valve

E

Leak oil control circuit

73

Shuttle check valve

J K

Measuring point on-road gear to multi-disc clutch

74 75


L M

Measuring point pump pressure Measuring point off-road gear

76 77

Check valve Orifice

P1

from HBGV block

80

Transmission

P2 S

from HBGV block Suction chamber / pump

87 93

Multi-disc brake Multi-disc clutch

100


101


102 210

Accumulator Regulating travel motor

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Service Manual



Machine in on-road gear (2nd gear) (see Fig. 4 on page10)

Input speed





800 rpm to max. rpm

Pump pressure Pp max. 8.0 bar Shifting piston 75 in working position Shifting pressure Sp over shuttle check valve 73

P1

Via external line to multi-disc brake. Brake released

B

Valves 72 and 73 block the connection to point K Point K is connected via the check valve 76 and connection P2 to the tank

Multi-disc clutch engaged. Gear ratio planetary drive = 1: 1 (2nd gear)

If the machine is in on-road gear and the speeds are above the shifting-down point, an increased pump pressure is applied to the shifting piston 75. The piston is pressed against the pressure spring and moved into working position. If the operator now preselects the off-road gear, the pressure applied to the shift lock 70 changes from connection P1 to connection P2. The shuttle check valve 73 continues to release the pressure to connection B so that shifting down is not possible. The machine remains in on-road gear. Only when the speed is reduced to below the shifting-down point (reduction of travel speed), the spring presses the piston 75 into its neutral position, i.e. the machine can now be set to off-road gear. 70

79



B K

Connection to multi-disc brake Connection to multi-disc clutch

72 73


P1 P2


74


Pp

Pump pressure

75

Shifting piston

S

Suction chamber / pump

76

Check valve

Sp

Shifting pressure

77 78

Orifice Connection of lubricating oil supply

T

Return / tank

Shift lock

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11.10.9


Service Manual


Fig. 4

11.10.10


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Service Manual


5.2

Travel in on-road gear On-road gear (1st gear) preselected with switch S42 (see Fig. 5 on page12)

Input speed





800 rpm to max. rpm

Pump pressure Pp max. 8.0 bar Spool 75 in working position P2

Shifting pressure Sp over the shifting piston 75 and the shuttle check valve 73; valve 73 also blocks connection to P1 Via external line to multi-disc brake. Brake released

B

Point K is connected via the check valve 72 and connection P1 to the tank

Multi-disc clutch engaged. Gear ratio planetary drive = 1: 1 (2nd gear) Shifting-down to 1st gear not possible; Shifting down only possible when the input speed is below 800 rpm

70

Shift lock

78


71


79


71.2 Suction filter (maintenance-free)

B

Connection to multi-disc brake

72

Leakage check valve

K

Connection to multi-disc clutch

73 74


P1 P2


75 76


Pp S


77

Orifice

Sp

Shifting pressure

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11.10.11


Service Manual


Fig. 5

11.10.12


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Service Manual


5.3

Off-road gear (1st gear) preselected with switch S42 (see Fig. 6 on page14)

Input speed





0-800 rpm

Pump pressure Pp low Shifting piston 75 in neutral position P2


K

Via external line to multi-disc brake. Clutch released Gear ratio of planetary drive = 1 : 3.87 (1st gear) Valve 72 blocks the connection to point B Point B is connected via the shifting piston 75 (open control edge) and connection P1 to the tank

Multi-disc brake depressurised, brake applied

70

Shift lock

79


71


B

to multi-disc brake


K P1

to multi-disc clutch from HBGV block

73 74


P2 Pp

from HBGV block Pump pressure

75 76


S Sp

Suction chamber / pump Shifting pressure

77

Orifice

T

Return / tank

78


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11.10.13


Service Manual


Fig. 6

11.10.14


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Service Manual


6 Operation of the machine Fig. 7 or Fig. 8

6.1


6.2

Preselection of gear The on-road gear is automatically selected. The 1st gear / off-road gear is preselected with the switch S42 located on the right console beside the operator's seat, see Fig. 7 or Fig. 8. Actuate the switch S42: The off-road gear (1st gear) is preselected. The indicator lamp in the switch S42 is on. The solenoid valve Y55, Fig. 13, is powered and thus in working position. The gear is automatically shifted from on-road to off-road, based on the speed through the hydraulic/ mechanical shift lock 70. In other words, the shift is not completed immediately when the switch is operated.

6.3

Preselection of travel direction Preselect the travel direction at the preselection switch S263 located in the right pilot control unit, see Fig. 7 or Fig. 8. The indicator lights H167 or H168 respectively indicate the preselected travel direction. They are integrated into the right control desk, see Fig. 7 or Fig. 8. Press the preselection switch S263 down: the indicator light H167 (forward) is on. If the pilot control unit 84, Fig. 7 or Fig. 8, is actuated, the machine travels forward. Press the preselection switch S263 up: the indicator light H168 (reverse) is on. If the pilot control unit 84, Fig. 7 or Fig. 8, is actuated, the machine travels backward. Reversing (i.e. switching from forward to reverse motion and back) is possible in both gears.

6.4

Brakes Caution! The parking brake is designed in such a way that it cannot be operated during work. Otherwise, the machine would be damaged. During work, use only the working brake. Engage the locking device 23 of the working brake (pedal 22 to the right of the steering column), see Fig. 7 or Fig. 8.

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11.10.15


Service Manual

Operation of the machine By applying the parking brake (multi-disc brake 87) with the switch S16 Fig. 7 or Fig. 8, the machine is secured against inadvertent rolling-off when parked. By applying the parking brake, the opened pressure switch B10 Fig. 13 automatically disconnects the electric mass and connection to the solenoid valves for the travel direction preselection, so that the machine cannot be moved when the brake is applied (see also electrical system). Actuate the switch S16: the brake is applied. The indicator light H20 is on. The pressure switch B10 is released.

Note! The brake is designed as a parking brake and may only be applied when the machine is standing still. When parking on slopes, we recommend securing the vehicle with wedges, in addition to the parking brake.

6.5

Parking the machine Turn the ignition key of the machine to position 0 and remove it. The clutch 87 (brake) and 93 (1st gear) is automatically engaged.

Fig. 7

11.10.16

Switch and indicator light of the models A 314 to serial no. 20333 and A 316 to serial no. 20339

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Service Manual


Fig. 8

Switch and indicator light of the models A 314 from serial no. 20334 and A 316 machines from serial no. 20340

22 23

Foot pedal / working brake Foot pedal retainer

H168 S16

Indicator light / reverse travel Switch / parking brake

84*

Travel pilot control unit

S42

Switch 1st gear

H20 H167

Indicator light of parking brake Indicator light / forward travel

S263


*


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11.10.17


Service Manual


7 Towing of the machine Caution! The towing of the machine is a dangerous manoeuvre with a risk of injury to the driver and damage to the machine. The machine may only be towed if absolutely necessary, e.g. to carry out repairs at a suitable location or workshop. When towing the machine, please note: – max. towing speed = 5 km/h – max. towing distance = 10 km

7.1

Towing of machine with running diesel engine Before towing the machine, ensure that pilot control oil is fed to the transmission, so that the parking brake is released. Set the switch S16 to its neutral position. The parking brake is released. The indicator light H20 is off. If there is no battery voltage or if the electrical system fails: Turn in the T-handle screw S at the HBGV block 60, Fig. 9. The brake valve Y6 is set to working position. The machine is set to the selected gear.

7.2

Towing of machine when diesel engine is off Caution! The parking brake is disabled while the machine is being towed. When the diesel engine is shut down, the working brake can still perform a few braking manoeuvres, even if the brake accumulator is filled. When the diesel engine is off, the machine can only be steered with the emergency steering system (steering wheel is stiff). The machine may only be towed away from the danger zone but not any further! Disconnect the gear drive and brake from the output. Danger! Emergency activation requires access to the undercarriage of the machine. There is a risk of serious injury or even death to the technician, if the machine begins to move. Park the machine on a level surface and secure it with chucks against rolling away. Access the area of the undercarriage only when the machine is shut down and properly secured in its position. Adhere to the accident prevention regulations issued by the German Ground Construction Trade Association (Tiefbau-Berufsgenossenschaft) for the powertrains and earth-moving equipment. Remove the hex head screws 109, Fig. 9. Turn the lever 108 of the gear-shift fork to position OFF (in direction of arrow). Secure the lever 108 with the hex head screw 109 in its turned position.

11.10.18

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Service Manual


Fig. 9

Bottom view of HBGV block and gear system

60

HBGV block

109

Hex head screw / locking device

80

Gearbox (bottom view)

S

T-handle screw / emergency activation

108

Lever / Gear-shift fork / emergency acti- Y6 vation

Brake valve

8 Maintenance Danger! Maintenance requires access to the undercarriage of the machine. There is a risk of serious injury or even death to the technician, if the machine begins to move. Park the machine on level ground. Secure it against uncontrolled movement. Only carry out maintenance work on the gearbox, if the machine is fully shut down and properly secured. Always adhere to the safety instructions in group 1.10 "Safe maintenance of machine". The service life and operating time of the gearbox depend primarily on regular and careful maintenance and servicing of the unit. It is therefore important that the following instructions are strictly followed.

8.1

Oil level check Check the oil level at the intervals laid down in the inspection and maintenance schedule, see group 3. Wait 5 minutes and then carry out a oil level check: Carefully remove the screw plug at the check and filling opening 2 at the gearbox 80 and check the oil level. If the oil reaches the lower edge of the opening , it is not necessary to add oil.

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11.10.19


Service Manual

Maintenance If the oil level is below the lower edge of the opening the lower edge of the opening.

8.2

, add oil of the prescribed viscosity to

Oil change Change the oil at the intervals laid down in the inspection and maintenance schedule. When the gearbox is warm (30 - 40°C), switch off the engine and wait for 5 minutes. Then change the oil: Remove the oil discharge screw 1. Drain the oil from the gearbox 80 into the provided container. Screw in the oil discharge screw 1 (ensure that the seal ring is positioned properly). Remove the screw plug at the check and filling opening 2 at the gearbox 80. Add oil of the prescribed viscosity until it reaches the lower edge of the check and refill bore 2. Screw in the screw 2 of the gearbox 80 (ensure that the seal ring is positioned properly).

Fig. 10 1

Maintenance tasks to be carried out on the transmission 80 2

Oil drain screw

Oil check and filling opening screw

A check of the gear shifting and parking brake function must be carried out in the course of the maintenance work. In the event of malfunctions or failures, check the pressures in the gear system as described below.

8.3

Check of gearbox Note! The inspection must be carried out while the machine is at operating temperature and the diesel engine running at high idle speed.

8.3.1

Checking the release pressure of the clutch, see Fig. 11 Connect the pressure sensor (0-60 bar) to the measuring point 103 (multi-disc brake / connection B) or the measuring point 104 (multi-disc clutch / connection K). Preselect on-road or off-road gear and check release pressure, (see “Technical data” on page 2). A release pressure below the nominal pressure is possibly caused by a defect in the shift lock 70. If the pressure is too low, check and adjust the pressure of the pilot system. After adjustment of the pressure, remove the pressure sensor and seal the measuring point(s).

11.10.20

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Service Manual


8.3.2

Checking the backpressure of the brake, see Fig. 11 Connect the pressure sensor (0-60 bar) to the measuring point 65. Apply the brake with the switch S16 and measure the pressure at the measuring point 65, (see “Technical data” on page 2). To adjust the backpressure to the nominal value, turn the adjusting screw of the backpressure valve 63 (located opposite the two solenoid valves Y6 and Y55). To do this, remove the protective cap from valve 63, loosen the lock nut and turn the adjusting screw, until the prescribed value is reached. Turn in

= Increase pressure

Turn out

= Reduce pressure

After the pressure has been adjusted, tighten the sealing nut and replace the protective cap. Remove the pressure sensor and seal the measuring point.

Fig. 11

Measuring points at the transmission and HBGV block

B

Connection of multi-disc brake

65

Measuring point of backpressure

K

Connection of multi-disc clutch

103

Measuring point / coupling pressure of multi-disc brake

60

HBGV block

104

Measuring point / coupling pressure of multi-disc clutch

63

Backpressure valve

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11.10.21


Service Manual


9 Dismantling, repair and installation of the gearbox (see Fig. 12 on page23)

9.1

Dismantling of the gearbox for repair work Danger! The dismantling and installation of the gearbox requires access to the undercarriage of the machine. There is a risk of death to the technician, as limbs could become crushed. Park the machine on level ground. Secure it against uncontrolled movement. The gearbox may only be dismantled or installed if the machine is properly secured. Depressurise the hydraulic system. Always refer to the safety instructions in group 1.10. Disconnect and seal the hydraulic line to the oil motor and the gearbox (collect any escaping oil) and seal the lines. Remove the hex nuts 7 and remove the universal joint shafts 3 from the gearbox 80. In order to remove all nuts 7, it might be necessary to lift the undercarriage 9, so that the universal joint shafts 3 can be rotated by turning the wheels. Secure the gearbox 80 with suitable lifting tackle. Remove the hex head screws 11. If necessary, heat the screws 11 (secured with locking agent). Remove the gearbox 80 with the plate 5 from the undercarriage 9. Remove the hex head screws 12. If necessary, heat the screws 12 (secured with locking agent). Remove the plate 5 from the gearbox 80. Remove the nuts 17 complete with the washers 18 and pull the oil motor 210 from the gearbox 80.

9.2

Repair of the rigid axle Note! For detailed repair instructions for the transmission, refer to the separate "Repair manual for 2 HL 100 ZP gearbox".

9.3

Installation of the gearbox after repairs Apply sealant to the flange surface of the gearbox 80 and the oil motor 210. Insert the oil motor 210 into the gearbox 80. Tighten the nuts 17 with the washers 18 (tightening torque 79 Nm). Place the plate 5 on the gearbox 80. Apply Omnifit 100 to the thread of the hex head screws 12, insert them with the washers 13 into the gearbox 80 and tighten them (tightening torque 430 Nm). Place the gearbox 80 with the plate 5 in the undercarriage 9, using suitable lifting gear.

11.10.22

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Service Manual

2 HL 100 transmission Dismantling, repair and installation of the gearbox Apply Omnifit 100 to the thread of the hex head screws 11 and secure the plate 5 with the gearbox 80 using the hex head screws 11 and the washers 13 to the undercarriage 8 (tightening torque 560 Nm). Secure the universal joint shaft 3 with the hex head screws 7 to the output flanges of the gearbox 80. Connect all hydraulic lines to the gearbox 80 and the oil motor 210 and bleed the system by repeatedly actuating the parking brake and the gear shift lever.

Fig. 12

Undercarriage with transmission

3


13

Washer

5

Plate

17

Hex nut

7

Hex nut

18

Washer

9 11

Undercarriage Hex head screw

80 210

Transmission, complete Oil motor with brake valve

12

Hex head screw

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11.10.23


Service Manual

Components and layout

10

Components and layout

Fig. 13

11.10.24

Main components of the transmission control and the parking brake

32

Gear pump

80

Transmission

49


210


50

Control oil unit

B10

Pressure switch

60

HBGV block

P

64

Accumulator

R

Connection for control pressure to HBGV block Residual flow from flow distributor / gear pump

65 70

Backpressure measuring point Shift lock

Y6 Y55

Brake valve Shift valve

0

Check valve, complete consisting of assemblies 1- 11

1 2

Drive housing (81/102*) Drive (82/101*)

7 8

Planetary drive (83/84/85/86*) Shut-down mechanism (95/96*)

3

Housing

9

Spur drive (97*)

4

Oil line

10

Shift lock (70*)

5

Clutch (91/92/93*)

11

Output (98/99*)

6

Multi-disc brake (87/89/90*) *

Items in sectional drawing on page 11.10.33

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Service Manual


11 Exploded view of gearbox components 11.1

Gearbox 0 complete, drive housing 1 and input 2

Fig. 14

Exploded view of gear drive system based on spare parts list

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11.10.25


Service Manual


11.2

Gear housing 3 and oil lines 4

Fig. 15

11.10.26

Exploded view of gear housing based on spare parts list

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MJF C I F S S

Service Manual


11.3

Multi-disc clutch 5 and multi-disc brake 6

Fig. 16

Exploded views of the multi-disc clutch and multi-disc brake based on the spare parts list

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11.10.27


Service Manual


11.4

Planetary drive 7, gear shut-down mechanism 8 and spur drive 9

Fig. 17

11.10.28

Exploded views of the planetary drive, shut-down mechanism and spur drive based on spare parts list

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Service Manual


11.5

Shift lock 10 and gear output 11

Fig. 18

Exploded view of the shift lock and the output based on spare parts list

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11.10.29


Service Manual

Exploded view of gearbox components 1 2

Hydraulic tank (*) Breather filter (*)

85 86

Planetary carrier Hollow gear

3 4

Stop cock (*) Return filter (*)

87 89

Multi-disc brake (5 inner discs) Piston

5

Bypass valve / return line (*)

90

Disc springs

20 21

Variable displacement pump (*) Powertrain

91 92

Disc springs Piston

30

Gear pump / pilot control (*)

93

Multi-disc clutch (10 inner discs)

31

Steering pump

94

Inner disc carrier

32

Brake system pump

95

Sliding sleeve

49

Measuring point / pilot pressure (*)

96

Jaw clutch

50

Control oil unit / pilot control (*)

97

Helical gear

51 52

Pressure-relief valve (*) Pressure filter (*)

98 99

Helical gear Output flange

53

Check valve (*)

100

54

Accumulator (*)

101

Restrictor check valve (orifice Ø 1.2 mm) O Restrictor check valve (orifice Ø 0.8 mm) O

57

Measuring point

102

Accumulator

59 63

Measuring point Backpressure-limiting valve

103 104

Measuring point / brake B Measuring point / clutch K

64 65

Accumulator Measuring point / backpressure and release pressure

210 322

Regulating motor (*) Rotary connection 6x (*)

66

Check valve

400

to compact brake block

70

Shift lock, complete

A126

71

Gear pump

B10

from/to autocheck printed circuit board (X) Pressure switch / parking brake (X)

71.2 72

Suction filter Leakage check valve

H20 K251

Indicator light of parking brake (X) Relay / parking brake (X)

73 74

Shuttle check valve Pressure-relief valve (6-8 bar)

S16 S42

Push button / parking brake (X) Push button / off-road gear (X)

75

Shifting piston

Y3

Solenoid valve / pilot control (*)

76 77

Check valve Orifice

Y6 Y24

Solenoid valve / parking brake (X) Solenoid valve / creeper gear (*)

80

Transmission

Y50

81

Connecting flange

Y51

Solenoid valve / power control (X) Solenoid valve / -p reduction (X)

82

Drive shaft

Y55

Solenoid valve / 1st gear (X)

83

Sun gear

Y62

Solenoid valve / forward travel (X)

84

Planetary gear

Y63

Solenoid valve / reverse travel (X)

Y371

Solenoid valve / oscillating axle (*)

*

= Items in hydraulic diagram of group 6

X = Items in electrical diagram of group 8 O = built into housing connection

11.10.30

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Service Manual

2 HL 270 / 290 transmission Function

2 HL 270 / 290 transmission 1 Function The 2 HL 270 / 290 transmission is attached to the undercarriage. It distributes the drive force from the flange-connected regulating travel motor through the drive shafts to the input axles. The transmission is designed as a 2-speed powershift transmission. The on-road gear is switched automatically, while the off-road gear must be manually selected. The input system, shift lock and the output elements are attached to the gearbox.

Fig. 1


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11.20.1


Service Manual

Technical data


A 309 Li / A 311 Li 29269 / 29170

A 312 Li 29898

A 316 Li 28061

Gearbox type

2 HL 270

2 HL 270

2 HL 290


110 kW

110 kW

110 kW

Input torque at P max.

650 Nm

650 Nm

650 Nm


770 Nm

770 Nm

950 Nm


3500 rpm

3500 rpm

3500 rpm

4,87 1,20

4,87 1,20

4,87 1,20

135 kg

135 kg

135 kg

3.0 l

3.0 l

3.0 l

SAE 20 W -20 or SAE 10 W-30

SAE 20 W-20 or SAE 10 W-30

SAE 20 W-20 or SAE 10 W-30

33 22 l/min

32 30 l/min

32 30 l/min

Gear ratio 1. gear 2. gear Weight Oil volume in gearbox Oil viscosity Hydraulic control Max. control oil level of gear pump / flow distributor

Pilot pressure of hydraulic unit and release pressure of multi-disc brake / coupling pressure-relief valve 51

32 ± 1 bar

32 ± 1 bar

32 ± 1 bar

approx. 32 bar

approx. 32 bar

approx. 32 bar

6 - 8 bar 2.0 - 2.6 bar

6 - 8 bar 2.0 - 2.6 bar

6 - 8 bar 2.0 - 2.6 bar


800 ± 100 rpm

800 ± 100 rpm

800 ± 100 rpm


667 ± 70 rpm

667 ± 70 rpm

667 ± 70 rpm

Measuring points 49, 63, MB, MK Shift lock pump pressure (pressurerelief valve 74) at max. input speed at shift speed Shift lock on-road gear/off-road gear

Tab. 1

Technical data

(*) maximum permissible value

11.20.2

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Service Manual

2 HL 270 / 290 transmission Design

3 Design see Fig. 2 The 2 HL 270 / 290 transmission is designed as a powershift transmission with a planetary and a spur gear. The powershift transmission of the planetary drive consists of a rotating multi-disc clutch and a multi-disc brake mounted in a housing attached at the top of the planetary drive. Both the clutch and the brake are applied by spring force (disc springs) and hydraulically released (control pressure). When in on-road gear, the multi-disc brake is hydraulically released, and the multi-disc clutch is mechanically engaged. In off-road gear, control pressure is applied to the multi-disc clutch, which is thus disengaged, and the multi-disc brake is applied by means of the spring force and the hydraulic pressure. The transmission is driven by an axial piston regulating motor with brake valve. For a description of the complete hydraulic system, the regulating motor and the brake valve, see groups 6 and 7. The hydraulic shift lock mounted on the gearbox prevents shifting down at high speeds. It is operated by the flow produced to pressurize a spool through a gear pump driven by the transmission. Depending on the machine speed, the spool is set to neutral or working position respectively, i.e. the preselected off-road speed cannot be chosen when the vehicle is driven at high speed. During gear shifting, the multi-disc brake or clutch is supplied with oil from the control valve block so that it is released and is kept in this position by a constant control pressure. Excessive speeding of the gear and oil motor in overrun conditions (rolling down a slope) is not prevented by the shift lock, but by the brake valve that is flange-mounted to the oil motor. The spur gear transmission section is equipped with an oil reservoir from where oil is sucked by the gear pump. Bearings, shafts and gears are lubricated with gear oil from the oil sump (splash and centrifugal lubrication). The moving clutch parts are supplied with lubricating oil fed through the lubrication channel. The emergency activation device is designed to disrupt the power transmission between input and output in the event of failure of the control pressure or if there is a defect at the oil motor / hydraulic circuit. This is necessary to allow for the machine to be towed in such a situation. For this purpose, press grease into the lubrication nipple at the emergency activation device, using a standard grease gun (included in machine toolbox) until the grease escapes at the pressure relief valve of the emergency activation device. The two pistons of the multi-disc brake and clutch are now released so that the output shaft can be rotated freely and towing is possible.

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11.20.3


Service Manual

Design

3.1


Fig. 2

11.20.4

Transmission 2 HL 270/290

1

Disc springs

8

Output flange

2 3

Drive shaft Multi-disc brake

9 10

Output flange Connecting flange / regulating motor

4 5

Multi-disc clutch Planetary drive

11 a

Shift lock Input

6


b

Output

7

Spur gear drive

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Service Manual

2 HL 270 / 290 transmission Functional description

4 Functional description See also diagram on page 11.20.31.

4.1

Parking Power circuit interrupted (ignition off)

4.2

Braking Multi-disc brake 87 and multi-disc clutch 93 applied by disc springs 89 / 90

Switch S16 operated

4.3

On-road gear Brake 87 released by control pressure, clutch 93 engaged by disc springs 90 closed

Switch S42 not operated

4.4


4.5

Multi-disc brake 87 (outer) and multi-disc clutch 93 (inner) applied by disc springs 89 / 90

Brake 87 applied by disc springs 90, clutch 93 opened by control pressure

Function of parking brake Diesel engine off: – No control pressure from the control oil unit 50. – Multi-disc brake 87 and multi-disc clutch 93 (1st gear) engaged by disc springs 89 / 90. Diesel engine on: – Switch S16 in brake position (indicator light in switch on). – Brake valve Y60 in neutral position, and thus no pressure at connection P - B . – Multi-disc brake 87 and multi-disc clutch 93 (1st gear) engaged by disc springs 89 / 90. – The indicator light H20 is on. – The machine cannot be started.

4.5.1

Braking the machine when in travel motion (emergency braking) The parking brake can also be used for dynamic braking. The braking power is thereby enhanced by the brake effect of the hydrostatic drive.

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11.20.5


Service Manual

Functional description Caution! The braking force cannot be controlled by the operator! This method of braking may thus only be used in an emergency, e.g. in the event of failure of the working brake.

4.6 4.6.1

Gear function and power flow On-road gear / 2nd gear (no preselection with switch S42): – Multi-disc brake 87 is released. – Multi-disc clutch 93 is engaged. – The planetary carrier 85 and the hollow gear 86 are driven simultaneously through the engaged clutch 93 and the drive shaft 82 by the oil motor 210. – There is therefore no speed reduction by the planetary drive. The planetary carrier 85 propels the spur gear 99. – The larger spur gear 99 meshing with the planetary carrier 85 rotates at a lower speed (speed reduction) and drives the axles, and thus the drive wheel of the machine, via the drive flange 100 and the flange-connected universal joint shafts.

4.6.2

Off-road gear / 1st gear (preselection with switch S42): – Multi-disc brake 87 is applied. – Multi-disc clutch 93 is disengaged. – The planetary gears 84 are propelled through the drive shaft 82 by the oil motor 210. The planetary gears 84 roll on the stationary hollow gear 86 (due to applied multi-disc brake 87). – The planetary carrier 85 propels the helical gear 99. – The larger helical gear 99 meshing with the planetary carrier 85 rotates at a lower speed (speed reduction) and drives the axles, and thus the drive wheels of the machine, via the drive flange 100 and the flange-connected universal joint shafts. – The second speed reduction of the planetary drive / spur drive results in a high reducing gear ratio.

4.7

Function of shift lock The shift lock 70 protects the gear system and the hydraulic motor against excessive speed, which might occur when the drive changes from on-road to off-road gear while travelling at relatively high speeds. If the input speed and thus the drive speed are above the set shifting-down point, gear switching from on-road to off-road speed is not possible. The preselected off-road gear is only released by the shift lock 70 when the shifting-down point is reached. If the input speed is below the shifting-down point, the machine is automatically shifted to the selected off-road gear. The on-road gear can be chosen at any speed.

4.7.1

Leakage check valve 72 If off-road gear is preselected, the leak oil from the shifting piston 75 and the check valve 73 (at pressure side K) is fed through the leakage check valve 72 through connection B to the tank. The valve 72 also blocks the control pressure to the multi-disc brake 87 when the machine is driven in on-road or off-road gear.

4.7.2

Shuttle check valve 73 If the off-road gear is preselected, the shuttle check valve 73 blocks the flow from connection K to B. If the machine is in on-road gear and moves at a speed above the shifting-down point, it blocks the flow from connection B to K.

11.20.6

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Service Manual


4.7.3

Pressure-relief valve 74 The pressure-relief valve 74 protects the lubricating pump 71 against pressures above 6 to 8 bar. The pressure required to move the shifting piston 75 is determined by the backpressure at the orifice 77 for the lubricating oil supply.

4.7.4



machine can be


4.7.5

Check valve 76 The check valve 76 feeds the oil that is replaced when the shifting piston 75 is moved through K to the tank.

4.8

Normal position of shift lock The rotary-type pump / gear pump 71 driven by the gear input shaft sucks oil from the gear sump through the internal bores and the suction filter 71.2. It produces an oil pressure, which is determined by the input speed (output speed of the oil motor) and corresponds to the pressure at the orifice 77 for the lubricating oil supply of the gear system. A part of the oil is used to lubricate the gear system, while the rest moves the shifting piston 75, or is returned by the pressure-relief valve 74 to the suction side. The pump flow, the lubricating oil orifice 77 and the characteristic of the pressure spring in the shifting piston 75 are adjusted in such away that, at input speeds below the shifting-down point, the backpressure at the orifice 77 and the resulting piston force are smaller than the spring force. When the piston is in this position (neutral position), oil flow from B B’ or from K K’ is possible so that the machine can be switched to on-road or off-road speed. If the off-road gear is chosen, the shifting piston 75 remains in neutral position, as the shifting pressure K and the spring force are higher than the pump pressure. It is thus possible to shift the machine up to on-road gear.

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11.20.7


Service Manual


4.9

Diagram of gearbox / hydraulic circuit Items in transmission diagram, (see Fig. 3 on page9)

11.20.8

a

Output

3

Lubrication nipple / emergency activation

b

Planetary drive

4

Bleeder / emergency activation

c

Spur gear drive

5

Pressure relief valve / emergency activation

d

Emergency activation

60

Valve block

B/B’/B’’ to multi-disc brake

61

Valve plunger

EB


62

Pressure valve

EK

Bleeder / multi-disc clutch

63

Measuring point / opening pressure

J Measuring point on-road gear K/K’/K’’ to multi-disc clutch

70 71


L M

Measuring point pump pressure Measuring point off-road gear

71.2 72

Suction filter (maintenance-free) Leakage check valve

MB MK

Measuring point multi-disc brake Measuring point multi-disk clutch

73 74


+P


75

Shifting piston

S T

Suction chamber / pump to tank

76 77

Check valve Orifice

Y55

Solenoid / 1st gear

80 87

Transmission, complete Multi-disc brake

Y60

Solenoid / 2nd gear

93 101

Multi-disc clutch Accumulator

102


210


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Service Manual


Fig. 3

Diagram of transmission and shift lock (shifting position = 2nd gear)

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11.20.9


Service Manual



Machine in on-road gear (2nd gear)

Input speed





800 rpm to max. speed

Pump pressure Pp max. 7.0 bar Shifting piston 75 in working position B

Shifting pressure Sp over shuttle check valve 73 Via external line to multi-disc brake. Brake released

B’

Valves 72 and 73 block the connection to point K. Point K’ is connected via the check valve 76 and connection K to the tank.

70 71

Multi-disc clutch engaged. Gear ratio planetary drive = 1: 1 (2nd gear)

79 B

Oil supply / transmission from HBGV block

71.2 Suction filter (maintenance-free)

B’

to multi-disc brake

72 73


K K’

to HBGV block from multi-disc clutch

74 75


Pp S


76 77

Check valve Orifice

Sp T

Shifting pressure Return / tank

78



If the machine is in on-road gear and the speeds are above the shifting-down point, an increased pump pressure is applied to the shifting piston 75. The shifting piston is thus pressed against the pressure spring into working position. If the operator now preselects the off-road gear, the pressure applied to the shift lock 70 changes from connection B to connection K. The shuttle check valve 73 continues to release the pressure to connection B’ so that shifting down is not possible. The machine remains in on-road gear. Only when the speed is reduced to below the shifting-down point (reduction of travel speed), the spring presses the piston 75 into its neutral position, i.e. the machine can now be set to off-road gear.

11.20.10

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Service Manual

2 HL 270 / 290 transmission Positions of the shift lock 70

Fig. 4


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11.20.11


Service Manual


5.2

Travel in on-road gear On-road gear (1st gear) preselected with switch S42 Input speed





800 rpm to max. speed

Pump pressure Pp max. 7.0 bar Spool 75 in working position K

Shifting pressure Sp over the shifting piston 75 and the shuttle check valve 73; valve 73 also blocks connection to B’. Via external line to multi-disc brake. Brake released

B

Point K’ is connected via the check valve 72 and connection B to the tank.

Multi-disc clutch engaged. Gear ratio planetary drive = 1: 1 (2nd gear) Shifting down to 1st gear not possible. shifting down only possible when the input speed is below 800 rpm

70 71

11.20.12

78 79

Connection of lubricating oil supply Oil supply / transmission


B B’

to HBGV block to multi-disc brake

73 74


K K’

from HBGV block from multi-disc clutch

75

Shifting piston

Pp

Pump pressure

76 77

Check valve Orifice

S Sp



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Service Manual


Fig. 5


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11.20.13


Service Manual


5.3

Off-road gear (1st gear) preselected with switch S42

Input speed


0-800 min-1



Gear pump 71 delivers a specific oil volume Pump pressure Pp low Shifting piston 75 in neutral position K


K’

Via external line to multi-disc brake. Clutch released Gear ratio of planetary drive = 1 : 3.87 (1st gear) Valve 72 blocks the connection to point B’. Point B’ is connected via the shifting piston 75 (open control edge) and connection B to the tank.

70

11.20.14

Multi-disc brake not pressurised Brake applied

79



B B’

to HBGV block from multi-disc brake

72

Leakage check valve

K

from HBGV block

73 74


K’ Pp

to multi-disc clutch Pump pressure

75 76


S Sp


77

Orifice

T

Return / tank

78


Shift lock

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Service Manual


Fig. 6


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11.20.15


Service Manual

Operation of the machine

6 Operation of the machine Fig. 7

6.1


6.2

Preselection of gear The on-road gear is automatically selected. The 1st gear / off-road gear is preselected with the switch S42 located on the right console beside the operator's seat, Fig. 7. Actuate the switch S42: The off-road gear (1st gear) is preselected. The indicator lamp in the switch S42 is on. The solenoid valve Y55, Fig. 8, is powered and thus in working position. The gear is automatically shifted from on-road to off-road, based on the speed through the hydraulic/ mechanical shift lock 70. In other words, the shift is not completed immediately when the switch is operated.

6.3

Preselection of travel direction Preselect the travel direction at the preselection switch S263 located in the right pilot control unit, Fig. 7. The indicator lights H167 or H168 respectively indicate the preselected travel direction. They are integrated into the right control desk, Fig. 7. Press the preselection switch S263 down: The indicator light H167 (forward) is on. When the pilot control unit 84, Fig. 7, is actuated the machine travels forward. Press the preselection switch S263 up: The indicator light H168 (reverse) is on. When the pilot control unit 84, Fig. 7, is actuated, the machine travels backward. Reversing (i.e. switching from forward to reverse motion and back) is possible in both gears.

6.4

Brakes Caution! The parking brake is designed in such a way that it cannot be operated during work. Otherwise, the machine would be damaged. During work, use only the working brake. Actuate the pedal 22 of the working brake (to the right of the steering column) until the brake is fully applied (foot pedal 22 engages in the locking device 23,, Fig. 7).

11.20.16

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Service Manual

2 HL 270 / 290 transmission Operation of the machine

By applying the parking brake (multi-disc brake 87 and clutch 93) with switch S16, the machine is secured against inadvertent rolling-off when parked, Fig. 7. Actuate the switch S16: the brake is applied. The indicator light in the switch S16 is on. The indicator light H20 is on. By applying the parking brake, the electric mass, and connection to the solenoid valves for the travel direction preselection are disconnected, so that the machine cannot be moved when the brake is applied (see also electrical system).

Note! The brake is designed as a parking brake and may only be applied when the machine is standing still. When parking on slopes, we recommend securing the vehicle with wedges, in addition to the parking brake.

6.5

Parking the machine Turn the ignition key of the machine to position 0 and remove it. The multi-disc packs 87 and 93 are closed automatically.

Fig. 7

Switches and indicator lights

22

Foot pedal / working brake

H168

Indicator light / reverse travel

23 84*

Foot pedal retainer Travel pilot control unit

S16 S42

Switch / parking brake Switch 1st gear

H20

Indicator light of parking brake

S263


H167

Indicator light / forward travel

*


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11.20.17


Service Manual


7 Towing of the machine

Caution! The towing of the machine is a dangerous manoeuvre with a risk of injury to the driver and damage to the machine. The machine may only be towed if absolutely necessary, e.g. to carry out repairs at a suitable location or workshop. To tow the machine, use a suitably dimensioned rod. Never use a cable or rope. When towing the machine, please note: – max. towing speed = 10 km/h – max. towing distance = 5 km

7.1

Towing of machine with running diesel engine Before towing the machine, ensure that pilot control oil is fed to the transmission, so that the parking brake is released. Set the switch S16 to its neutral position. The parking brake is released. The indicator light H20 is off. If there is no battery power or in the event of an electric failure, activate the emergency mode at the double solenoid valve Y60/Y55: Turn in the T-handle screw 67 at the double solenoid valve Y60/Y55. The valve plunger is pressed into its open position. The brake is released and the machine is in 2nd gear.

Fig. 8 60 67

11.20.18

Valve block Valve block, complete T-handle screw / emergency activation

Y55 Y60

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Solenoid valve / 1st gear Solenoid valve / 2nd gear parking brake

Service Manual

2 HL 270 / 290 transmission Towing of the machine

7.2

Towing of machine when diesel engine is off In this case, there is no pilot control oil at the valve block 60 required to release the parking brake. Danger! With the subsequent emergency activation for towing, the parking brake is temporarily disabled. Emergency activation requires access to the undercarriage of the machine. There is a risk of serious injury or even death to the technician, if the machine begins to move. Park the machine on level ground. Before accessing the danger area and the area of the undercarriage, secure the wheels with chucks. Access the area of the undercarriage only when the machine is shut down and properly secured in its position. Adhere to the accident prevention regulations issued by the German Ground Construction Trade Association (Tiefbau-Berufsgenossenschaft) for the powertrains and earth-moving equipment. Disconnect the solenoid valves Y6 / Y55 to disable gear switching when the emergency activation is on.

Fig. 9

7.2.1

Transmission with emergency activation of the gearbox

3


4


5


Switch on emergency activation Using the grease gun (included in machine toolbox), press normal grease into the lubrication nipple 1 until it escapes at the pressure relief valve 3. The machine can now be towed away, see 7.2.

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11.20.19


Service Manual

Maintenance Caution! When the diesel engine is shut down, the working brake can still perform a few braking manoeuvres, even if the brake accumulator is filled.

Vor

When the diesel engine is off, the machine can only be steered with the emergency steering system (steering wheel is stiff). The machine may only be towed away from the danger zone but not any further! Before setting the gearbox back to normal mode (after towing) deactivate the emergency activation! Do not lubricate the lubrication nipple 3, Fig. 9, of the emergency activation.

7.2.2

Deactivating emergency activation Open the bleeder 4 of the emergency activation. If the gear can be shifted, switch it to on-road gear (S16 not actuated - S42 not actuated). The indicator light in the switch S16 / S42 and the indicator light H20 are off. If the gearbox is dismantled, apply pilot control pressure to the connection B at the gearbox. Close the bleeder 4. Release the pressure supply at connection B or actuate S16. The multi-disc brake and the multi-disc clutch are now again operational.

8 Maintenance

Danger! Maintenance requires access to the undercarriage of the machine. There is a risk of serious injury or even death to the technician, if the machine begins to move. Park the machine on level ground. Secure it against uncontrolled movement. Only carry out maintenance work on the gearbox, if the machine is fully shut down and properly secured. Always adhere to the safety instructions in group 1.10 "Safe maintenance of machine". The service life and operating time of the gearbox depend primarily on regular and careful maintenance and servicing of the unit. It is therefore important that the following instructions are strictly followed.

8.1

Oil level check Check the oil level at the intervals laid down in the inspection and maintenance schedule, see group 3. Switch off the diesel engine. Carefully clean and remove the screw plug at the check and filling opening 10 at the gearbox 80 and check the oil level. If the oil reaches the lower edge of the opening , it is not necessary to add oil. If the oil level is below the lower edge of the opening , add oil of the prescribed viscosity to the lower edge of the opening.

11.20.20

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Service Manual

2 HL 270 / 290 transmission Maintenance

8.2

Oil change Change the oil at the intervals laid down in the inspection and maintenance schedule. When the gearbox is warm (30 - 40°C), switch off the engine and wait for 5 minutes. Then change the oil: Switch off the diesel engine. Carefully clean and remove the screw plug from the oil discharge bore 9 and the control and refill bore 10 at the gearbox 80. Drain the oil from the gearbox 80 into the provided container. Clean the screw plug of the oil discharge bore 9 and its sealing surfaces. Screw in the plug screw at the gearbox 80 (ensure that the seal ring is properly positioned) and tighten it. Add oil of the prescribed viscosity until it reaches the lower edge of the check and refill bore 10. Clean the screw plug of the check and refill bore 10 and the sealing surfaces. Screw in the plug screw at the gearbox 80 (ensure that the seal ring is properly positioned) and tighten it.

Fig. 10

9

Oil discharge bore, oil check and filling opening

80 Transmission, complete

Oil discharge bore

10 Oil check and filling opening

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11.20.21


Service Manual

Maintenance

8.3

Check of gearbox

Fig. 11

Measuring points at the gearbox and valve block

60 62

Valve block, complete Pressure valve

70 80

Shift lock Transmission, complete

63

Measuring point / opening pressure

MB MK

Measuring connection for multi-disc brake Measuring connection for multi-disc clutch

Note! The inspection must be carried out while the machine is at operating temperature and the diesel engine running at high idle speed.

8.3.1

Checking the release pressure of the discs, see Fig. 11 Connect the pressure sensor (0-60 bar) to the measuring point 63 of the valve block 60. Start the engine. Check the opening pressure, (see “Technical data” on page 2). After adjustment, remove the pressure sensors and seal the measuring points.

8.3.2

Checking the opening pressure in the piston chamber / multi-disc brake and multi-disc clutch, see Fig. 11 Connect the pressure transducer (0-60 bar) to the measuring points MB and MK . Release the parking brake with the switch S16 and measure the pressure at the measuring point MB, comparing it with the prescribed value, (see “Technical data” on page 2). 1. Select the gear with the switch S42 and measure the pressure at the measuring point MK, comparing it with the prescribed value (see “Technical data” on page 2). If the prescribed pressure is not reached, it must be assumed that there is a fault in the switch fusing system. If the pressure is OK, remove the pressure sensor.

11.20.22

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Service Manual

2 HL 270 / 290 transmission Installation, dismantling and repair

9 Installation, dismantling and repair Danger! The dismantling and installation of the gearbox requires access to the undercarriage of the machine. There is a risk of death to the technician, as limbs could become crushed. Park the machine on level ground. Secure it against uncontrolled movement. The gearbox may only be dismantled or installed if the machine is properly secured. Depressurise the hydraulic system. Always refer to the safety instructions in group 1.10.

9.1

In models A 309 - A 312

Fig. 12 12

9.1.1

Dismantling and installation of the gearbox in models A 309 - A 312 60


Hex head screw

13

Hex nut

62

Washer

40 44

Angle bracket Hex head screw

80 210

Gearbox, complete Oil motor / travel drive

52

Washer

EB

Bleeder connection B

54

Hex head screw

EK

Bleeder connection K

Dismantling of the gearbox Lift the undercarriage using suitable lifting gear or propping it up on the outrigger/blade support. Drain off gear oil, see 8.2.

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11.20.23


Service Manual

Installation, dismantling and repair

Note! To disconnect the universal joint shafts, the output shaft of the gearbox 80 must be cranked. Lift the undercarriage at the front and back (wheels off the ground). Release the parking brake with switch S16 (indicator light H20 and LED in switch are off). If there is no opening pressure: Switch on emergency activation, see 8.3.1 Remove the hex nuts 13 and remove the universal joint shafts 12 from the output flanges. By cranking the wheels of the machine, screw connections at the universal joint shaft flange connection that are normally not accessible become accessible. Apply the parking brake with switch S16 (indicator light H20 and indicator light in the switch S16 are on). Switch off the engine. Disconnect and seal all hydraulic lines from the gearbox 80 and the oil motor 210 (collect escaping oil). Secure the gearbox with suitable supports 80. Remove the hex head screws 54 with the washers 52. Remove the hex head screws 60 with the washers 62. Remove the gearbox 80 and the angle console 40 from the gearbox 80. Remove the hex head screws 22. Pull the oil motor 210 from the gearbox 80.

9.1.2

Repairs Note! For detailed repair instructions for the axle, refer to the separate "Repair manual for 2 HL 250 / 270 / 290 transmission".

9.1.3

Installation of the gearbox Apply sealant to the flange surface of the gearbox 80 and the oil motor 210. Insert the oil motor 210 into the gearbox 80. Screw in the hex head screws 22 and tighten them (torque 280 Nm). Position the angle bracket 40 in the correct position on the gearbox 80. Tighten the hex head screws 44 (torque 79 Nm). Insert the gearbox 80 with the angle bracket 40 into the undercarriage, using suitable lifting gear. Secure the angle bracket 40 to the undercarriage, using the hex head screws 54 and the washers 52 (torque 560 Nm). Secure the gearbox 80 to the undercarriage, using the hex head screws 60 and the washers 62 (torque 430 Nm). Mount the universal joint shafts 12 to the output flanges of the gearbox 80 and tighten the hex nuts 13. By cranking the wheels of the machine, screw connections at the universal joint shaft flange connection that are normally not accessible become accessible. If the emergency activation is on, deactivate it, see section 7.2.2.

11.20.24

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Service Manual

2 HL 270 / 290 transmission Installation, dismantling and repair Connect all hydraulic lines of the gearbox 80 and the oil motor 210. Release the parking brake with the switch S16 (indicator light H20 and indicator light in the switch S16 are off).

Caution! Overspeeding of the gearbox without sufficient oil can damage the gear system. Before starting the machine, check the oil level, see 8.1, and add oil, if necessary. Check all screw connections at the gearbox and the oil motor for leakage. Carefully bleed the gearbox 80, see 10.

9.2

In models A 314 - A 316

Fig. 13

9.2.1

Dismantling and installation of the gearbox in models A 314 - A 316

12


19

Hex head screw

13

Hex nut

24

Washer

14 15

Plate Washer

26 80

Nut Gearbox, complete

16 17

Hex head screw Rubber pads

210 EB

Oil motor / travel drive Bleeder connection B

18

Washer

EK

Bleeder connection K

Dismantling of the gearbox Lift undercarriage using the outrigger support system

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11.20.25


Service Manual

Installation, dismantling and repair Drain off gear oil. Note! To disconnect the universal joint shafts, the output shaft of the gearbox 80 must be cranked. Lift the undercarriage at the front and back (wheels off the ground). Release the parking brake with switch S16 (indicator light H20 and indicator light in switch are off). If there is no opening pressure: Switch on emergency activation, see 7.2.1 Remove the hex nuts 13 and remove the universal joint shafts 12 from the output flanges. By cranking the wheels of the machine, screw connections at the universal joint shaft flange connection that are normally not accessible become accessible. Apply the parking brake with switch S16 (indicator light H20 and indicator light in the switch S16 are on). Switch off the engine. Release the pressure from the system. Disconnect and seal all hydraulic lines from the gearbox 80 and the oil motor 210 (collect escaping oil). Secure the gearbox with suitable supports 80. Remove the mounting bolts 19 (secured with Omnit; heat, if necessary). Remove the washers 18 and the rubber pads 17. Remove the gearbox 80 with plate 14 from the undercarriage. Remove the mounting bolts 16 (secured with Omnit; heat, if necessary). Remove the washers 15. Remove the plate 14 from the gearbox 80. Remove the nuts 26 and the washers 24. Pull the oil motor 210 from the gearbox 80.

9.2.2

Repairs Note! For detailed repair instructions for the axle, refer to the separate "Repair manual for 2 HL 250 / 270 / 290 transmission".

9.2.3

Installation of the gearbox Apply sealant to the flange surface of the gearbox 80 and the oil motor 210. Insert the oil motor 210 into the gearbox 80. Mount the nuts 26 with the washers 24. Apply a tightening torque of 280 Nm. Place the plate 14 on the gearbox 80. Apply Omnit 100 to the mounting bolts 16 and screw them in with the washer 15. Apply a tightening torque of 430 Nm. Drive the rubber pads 17 from the top and bottom into the boreholes of the plate 14. Insert the gearbox 80 with plate 14 into the undercarriage. Apply Omnit 100 to the mounting bolts 19 and screw them in with the washer 18. Apply a tightening torque of 560 Nm.

11.20.26

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Service Manual

2 HL 270 / 290 transmission Bleeding of gearbox Start the diesel engine. Release the parking brake with the switch S16 (indicator light H20 and indicator light in the switch S16 are off). Mount the universal joint shafts 12 to the output flanges of the gearbox 80 and tighten the hex nuts 13. By cranking the wheels of the machine, screw connections at the universal joint shaft flange connection that are normally not accessible become accessible. If the emergency activation is on, deactivate it, see section 7.2.2.

Caution! Overspeeding of the gearbox without sufficient oil can damage the gear system. Before starting the machine, check the oil level, see 8.1, and add oil, if necessary. Check all screw connections at the gearbox and the oil motor for leakage. Carefully bleed the gearbox.

10 Bleeding of gearbox

Fig. 14 4

Gearbox bleeder


EB

Bleeder for multi-disc brake

EK

Bleeder for multi-disc clutch

Start the diesel engine. In models A 309 - A 312: Remove the protective cap of the bleeder EB. Place one end of a transparent bleeder hose for the hydraulic oil in a suitable collecting vessel. Connect the other end to the bleeder nozzle EB. Open the bleeder EB. In model A 316: Remove the protective cap of the bleeder EB. Place one end of a high pressure hose for the hy-

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11.20.27


Service Manual

Bleeding of gearbox draulic oil in a suitable collecting vessel. Connect the other end to the bleeder nozzle EB. Release the parking brake with switch S16, (see Fig. 7 on page17), (brake connection pressurised). If a new gearbox has been installed, also open bleeder 4 (no oil escaping here). This approach ensures that the emergency activation is in its initial position. Release the multi-disc brake for approx. 20 sec. Close both bleeders 4 and EB (in model A 316, remove the high pressure hose). In models A 309 - A 312: Remove the protective cap of the bleeder EK. Place one end of a transparent bleeder hose for the hydraulic oil in a suitable collecting vessel. Connect the other end to the bleeder nozzle EK. Open the bleeder EK. In model A 316: Remove the protective cap of the bleeder EK. Place one end of a high pressure hose for the hydraulic oil in a suitable collecting vessel. Connect the other end to the bleeder nozzle EK. Switch the machine to off-road gear, using switch S42, (see Fig. 7 on page17), (clutch connection pressurised). Release the multi-disc clutch for approx. 20 sec. Close the bleeder EK (in model A 316, remove the high pressure hose). Continue the bleeding procedure (at least 2 more times) until there is no air left in the chambers of the multi-disc brake and the multi-disc clutch. There must be no visible air bubbles in the oil when completing the last the bleeding procedure. When shifting the gear from off-road to on-road (1st to 2nd gear) at low engine speed, the travel drive must not become blocked. After completion of the bleeding procedure, close the bleeders EB and EK (in model A 316, remove the high pressure hose) and replace the protective caps.

11.20.28

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Service Manual

2 HL 270 / 290 transmission Component arrangement

11 Component arrangement

Fig. 15

Diesel engines with gear pumps and control oil unit of the various models

32

Gear pump pilot control / brake unit with flow dis- 49 tributor (residual flow for pilot control)

33


Fig. 16

50

Measuring point / control pressure Control oil unit

Valve block in the uppercarriage with solenoid valves and measuring point

60

Valve block

Y6


62 63

Pressure valve Measuring point / opening pressure

Y55

Solenoid / 1st gear

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11.20.29


Service Manual

Component arrangement 1

Hydraulic tank

90

Disc springs / multi-disc clutch

3


91

Piston / multi-disc clutch fixed

4


92

Piston / multi-disc clutch rotating

5


93

Multi-disc clutch

20

Double variable-displacement pump (*) 94 A 309 - A 311 Variable-displacement pump (*) A 312 - 95 A 316

20

Pressure spring

32

Gear pump / pilot control and brake (*)

96

Piston / emergency activation

33 49

Gear pump / pilot control (*) Measuring point / pilot pressure (*)

97 98

Counterpart / emergency activation Bolt / emergency activation

50 51

Control oil unit / pilot control (*) Pressure relief valve / pilot control

99 100

Spur gear Output flange

60 61

Valve block, complete Shifting piston

101 102

Accumulator Restrictor check valve

62

Pressure valve

210

Regulating motor (*)

63 67

Measuring point / opening pressure Emergency activation / shifting to 1st gear

322

Rotary connection 6x (*)

70 71

Shift lock, complete Gear pump

EB EK

Bleeder / brake B Bleeder / clutch K

71.2

Suction filter

MB

Measuring point / brake B

72 73


MK H20

Measuring point / clutch K Indicator light of parking brake (X)

74 75

Pressure-relief valve (6-8 bar) Shifting piston

S16 S42

Push button / parking brake (X) Push button / off-road gear (X)

76 77

Check valve Orifice

Y55 Y60

Solenoid / 1st gear (X) Solenoid / 2nd gear (X)

80

Transmission, complete

81

Connecting flange

Connections:

82

Drive shaft

B, B’, B’’ Pressure oil supply of multi-disc brake

84 85

Planetary gear Planetary carrier

K/K’/K’’ Pressure oil supply to multi-disc clutch J, M Measuring connections

86

Hollow gear

P, Pp

Pressure from control oil pump

87

Multi-disc brake

S, Sp

Suction connection (lubricating pressure)

88

Piston / multi-disc brake

T

Return connection

89

Disc springs / multi-disc brake

*

= Items in hydraulic diagram of group 6

X = Items in electrical diagram of group 8

11.20.30

Inner disc carrier

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Service Manual

HBGV block for 2 HL 70 / 100 Function

HBGV block for 2 HL 70 / 100 1 Function Machines with 2 HL 70 / 100 powershift transmissions are equipped with a transmission control system as standard. (HBGV block = hand brake and gear shift valve block) The HBGV block has the following functions: – The solenoid valve Y6 (shifting piston 20 with solenoid part 120see Fig. 2) integrated in the HBGV block 60 controls the parking brake in the transmission. – The solenoid valve Y55 (shifting piston 30 with solenoid part 20 - see Fig. 2) integrated in the HBGV block 60 controls the off-road gear clutch in the transmission. – The pressure-relief valve 63 (backpressure valve) integrated in the HBGV block 60 prevents the parking braking being suddenly applied, e.g. when the brake is closed, or in the event of a power failure. – The flange-connected pressure switch B10 mounted to the HBGV block 60 disables the travel direction control when the brake is closed, thus protecting the parking brake against an overload. – The flange-connected hydraulic accumulator 64 mounted to the HBGV block 60 protects the hydraulic circuit of the transmission control against pressure fluctuations, thus preventing disruptions in the travelling movement of the machine. It also delays the (instant) closing of the multi-disc clutches in the event of an emergency braking manoeuvre.

Fig. 1

Hydraulic diagram and HBGV block 60

60

HBGV block

66

63

Backpressure-limiting valve

B10* Pressure switch

64 65

Hydraulic accumulator Measuring point

Y55* Solenoid valve / 1st gear Y6* Solenoid valve / parking brake

Check valve

* items in electrical / hydraulic diagram

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11.30.1


Service Manual


2 Functional description Fig. 1 and Fig. 2 The HBGV block is pressurised with control pressure (from the control oil unit 50) via the check valve 66 (Fig. 2) and connection P. The control or backpressure can be measured at measuring point M of the HBGV block. The block is linked through the connections A / B and hydraulic lines to the shift lock of the distributor gear. The oil from the piston chambers of the gearbox is fed through connection T to the hydraulic tank.

2.1

Neutral position If the switches S16 and S42 in the control console are not actuated, both solenoid valves Y6 and Y55 are in neutral position, i.e. the multi-disc brake and the multi-disc clutch are not pressurised and thus closed by the disc springs. The gearbox is blocked.

2.2

Control of multi-disc brake (parking brake) When setting the switch S16 to its opening position, the solenoid valve Y6 is powered and opens. The pilot control oil flows through the solenoid valve Y55 and connection A to the shift lock/gear. The multi-disc brake is released, while the multi-disc clutch remains closed. The machine is in 2nd gear. When setting the switch S16 to its closing position, the solenoid valve Y6 is not powered and thus closes. The pilot control oil flow is blocked. The oil from the piston chamber of the multi-disc brake is fed via the shift lock/gear and connection A, solenoid valve Y55, solenoid valve Y6 and backpressure valve 63 to the tank. The multi-disc brake is closed by the disc springs.

2.3

Control of the multi-disc clutch (gear clutch for 1st gear) When the switch S42 is set to 1st gear position (= off-road gear), the solenoid valve Y55 is powered and set to its changeover position. The pilot control oil flows through the already switched solenoid valve Y6 and connection B to the shift lock/gear. At the required shift speed (monitored by the shift lock), the multi-disc clutch is opened. At the same time, the multi-disc brake is closed, as the piston chamber of the brake is depressurised via connections A and T to the tank. The machine is in 1st gear. When setting the switch S16 to its reset position, the solenoid valve Y55 is not powered and thus returns to its initial position. The pilot control oil flows through the already switched solenoid valve Y6 and connection A to the shift lock/gear. In this process, the multi-disc brake is released as the brake piston is pressurised with control pressure. The multi-disc clutch is thereby closed as the clutch chamber is depressurised via connection B, solenoid valve Y5 and connection T to the tank. The machine is in 2nd gear.

2.4

Emergency activation of the multi-disc brake To tow the machine, the parking brake must be released. If this cannot be done in the normal way, as the electrical system is dead despite running diesel engine and correct pilot pressure (i.e. Y6 not powered), the solenoid valve Y6 can be operated manually by turning the T-handle screw of the device 70 clockwise.

11.30.2

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Service Manual

HBGV block for 2 HL 70 / 100 Functional description

Fig. 2 10

Sectional drawing of the HBGV block 110

Housing

Magnetic tube

20

Piston

120

Magnetic coil

30 40

Piston Spring plate

130 160

Protective cover Collar nut

50 60

Screw plug Adjusting screw

170 180

Ball Nozzle

63

Backpressure-limiting valve

190

Protective cover

70

Manual emergency locking mechanism

260

Knurled nut

80

Pushrod

999

Seal kit

90

Pressure spring

Y6


100

Pressure spring

Y55


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11.30.3


Service Manual


2.5

Testing and adjustment of the backpressure-limiting valve 63

Fig. 3

View and sectional drawing of HBGV block (key see Fig. 1 and Fig. 2)

Remove the cover cap at the measuring point 65 and connect a pressure sensor (0-60 bar). Start the diesel engine and observe the pressure sensor. Set the switch S16 to open or push the safety lever S7 down. The parking brake is released. The buzzer is off. Set the switch S16 to close or push the safety lever S7 up. The parking brake is applied. The buzzer sounds (unless the safety lever S7 has been actuated when the switch S35 was pressed). The opening pressure (pilot control pressure) gradually drops to the value of the required backpressure (see chapter "General information" for group 11.10). If the backpressure does not reach the prescribed value: Remove the cover cap 190. Loosen the collar nut 160. Turn the adjusting screw 60 at the backpressure-relief valve 63 until the actual pressure corresponds to the nominal pressure. Turn adjusting screw 60 in.

= Increase pressure

Turn adjusting screw 60 out.

= Reduce pressure

After the pressure has been adjusted, tighten the collar nut 160 and replace the cover cap 190.

2.6

Inspection of the hydraulic tank 64 Remove the cover cap at the measuring point 65 and connect the pressure sensor. Start the diesel engine and observe the pressure sensor. Testing procedure with activation of the switch S16 or operation of the safety lever S7, see 2.5. If the hydraulic tank 64 works properly, the opening pressure gradually drops to the backpressure as regulated by valve 63. The pressure then remains at this level for a certain period of time. If the opening pressure suddenly drops to a value near 0 bar when the brake is applied, the hydraulic tank 64 is defective and must be replaced.

11.30.4

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Service Manual

HBGV block for 2 HL 270 / 290 Function and design

HBGV block for 2 HL 270 / 290 1 Function and design Machines with 2 HL 270/290 powershift transmissions are equipped with a HBGV block as standard. (HBGV block = hand brake and gear shift valve block) The HBGV block mounted to the basic boom bearing block of the revolving deck or to the hydraulic tank has the following functions: Y60 67 – Control of the transmission in off-road gear by means of the solenoid valve Y55. – The pressure-relief valve 62 installed in the HGBV block 60 protects the gearbox against damage from excessive or insufficient control pressure.

Fig. 1

Design of the HBGV block

60

HBGV block

Y60


62


B

Connection to brake / on-road gear 2nd gear

63

Measuring point

K

Connection to clutch / off-road gear 1st gear

67 Y55

T-handle for emergency operation Solenoid valve / 1st gear

P T

Connection to pilot control pressure Tank connection

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11.32.1


Service Manual


2 Functional description see Fig. 2 and Fig. 3 The HBGV block is pressurised with pilot control pressure by the gear pump / pilot control system through the connection P (at control oil unit 50). The control pressure at the HBGV block can be measured at the measuring point 63 (M). The block is linked through the connections K / B and hydraulic lines to the shift lock of the load-holding transmission. The oil from the piston chambers of the gearbox is fed through connection T to the hydraulic tank.

2.1

Neutral position If the switches S16 and S42 are not actuated, the solenoid valves Y55/Y60 are not powered. The piston 61 is thus in neutral position and the multi-disc brake (B) and the multi-disc clutch (K) of the gearbox are not pressurised and thus applied/engaged by disc springs. The parking brake is applied and the gear is locked.

2.2

Control of multi-disc brake (parking brake) Set the switch S16 to opening position to power the solenoid valve Y60. The piston 61 is shifted to position a. The pilot control oil flows through the piston 61 connection B (shift locking) the piston chamber of the multi-disc brake in the gearbox. The multi-disc brake is released, while th e multi-disc clutch remains closed. The machine is in 2nd gear. Set the switch S16 to closing position to shut off the power supply to the solenoid valve Y60. The piston 61 is shifted to its neutral position. The pilot control oil flow is blocked. The oil from the piston chamber of the multi-disc brake is fed through the shift lock / gearbox and the connection K, at the piston 61 to the tank (T). The multi-disc brake is closed by the disc springs.

2.3

Control of the multi-disc clutch (gear clutch for 1st gear) When the switch S42 is set to 1st gear position (= off-road gear), the solenoid valve Y55 is powered and the piston 61 is shifted to position b. The pilot control oil flows through the already switched solenoid valve Y60, connection K to the shift lock/gear. The solenoid valve Y60 is not powered. At the required shift speed (monitored by the shift lock), the multi-disc clutch is opened by the pilot control pressure at the connection K. At the same time, the multi-disc brake is applied, as the piston chamber of the brake is depressurised via connections B and T to the tank. The machine is thus in 1st gear. Set the switch S42 to reset position to shut off the power supply to the solenoid valve Y55. The piston 61 is shifted to its neutral position. The pilot control oil flows over the piston 61 and the connection B to the shift lock/gear. In this process, the multi-disc brake is released as the brake piston is pressurised with control pressure. The multi-disc clutch is thereby closed as the clutch chamber is depressurised via connection K, the piston 61 and THE connection T to the tank. The machine is thus in 2nd gear.

11.32.2

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Service Manual

HBGV block for 2 HL 270 / 290 Functional description

Fig. 2

Functional diagram

1 50

to hydraulic tank from control oil unit

322 S16

Rotary connection 6 x Switch / parking brake

60 61

HBGV block Piston

S42 Y55

Switch / off-road gear Solenoid valve / 1st gear

62


Y60


63

Measuring point (M)

B

Connection to brake / on-road gear

64

Piston

K

Connection to clutch / off-road gear

66 67

Pressure spring T-handle for emergency operation

P T

Connection to pilot control pressure Tank connection

185

Transmission

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11.32.3


Service Manual


Fig. 3

11.32.4

Sectional drawing of the HBGV block

60 61

HBGV block Piston / shift valve

67 68

T-handle for emergency operation Spring plate

62


Y55


64 66

Piston / pressure-relief valve Pressure spring

Y60


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Service Manual

HBGV block for 2 HL 270 / 290 Pressure-relief valve 62

3 Pressure-relief valve 62

Fig. 4

3.1

Pressure relief valve in HBGV block

Function The pressure relief valve 62 inserted in the HBGV block 60 protects the gearbox from damage caused by insufficient or excessive control pressure. It ensures that no pressure < 26 bar is applied to the gear shifting valve, so that the parking brake is applied. At an existing control pressure of > 32 bar, this pressure is reduced by the integrated pressure reduction function to 32 bar.

3.2

Testing of pressure relief valve 62 Remove the cover cap at the measuring point 63 and connect the pressure sensor. Start the diesel motor and observe the pressure sensor. Release and reapply the parking brake. This can be done with switch S16 (buzzer signal) or by turning the safety lever upwards (no buzzer signal). The opening pressure (pilot control pressure) should then gradually drop to the value of the required pressure (see chapter "General information" for group 11.20). Note! The pressure relief valve 62 is fixed by the spring pressure force 66 and cannot be adjusted.

3.3

Emergency activation of the multi-disc brake (machine in 2nd gear) If the brake cannot be released due to a fault in the electrical system, despite running diesel engine and correct pilot pressure (i.e. Y60 not powered), the solenoid valve Y60 can be operated manually. To tow the machine, the parking brake must be released. Turn in the T-handle 67 of the solenoid valve Y60, see Fig. 4. The piston 61 is mechanically moved so that the multi-disc brake is pressurised with pilot control pressure through the connection B. The machine can now be removed from the danger area.

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11.32.5


Service Manual

Pressure-relief valve 62

11.32.6

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Service Manual

Travel gear F40 Function

Travel gear F40 1 Function The three-stage planetary gear is driven by the A 6VE hydraulic oil motor. It propels the tumbler wheel attached to the gearbox and the crawler chain. The wet multi-disc brake integrated into the gearbox acts directly onto the gear drive. The brake is designed as a spring applied brake and is released hydraulically, i.e. when the brake system is not pressurised, the discs are pressed together by the pressure springs, so that the brake is mechanically applied.

Fig. 1

Travel gear F40

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11.60.1

Travel gear F40

Service Manual

General information


R 317-Li 18161

Gearbox type Input speed Output speed

F40 - 110 max. (fast travel)

5479 min-1

min. (normal travel)

1713 min-1

max. (fast travel)

49.6 min-1


15.5 min-1

Max. output torque

40,000 Nm

Max. brake torque

420 Nm

Gear ratio

1: 110.38

Weight (approx.)

228 kg


4.5 l

Oil quality

API - GL - 5

Oil viscosity

SAE 90 W SAE 80 W 90 SAE 90 LS

Brake


Min. brake release pressure

18 bar


33 bar

Settings and tightening torques, to be observed for installation: A)

Tightening torque for hex head screws 5

195 Nm

B)


620 Nm

C)


300 Nm

D)


300 Nm

E)

Tightening torque for nut 260

9000 Nm

F)


G)


46 Nm

H)

Tightening torque of screw plug 900

35 Nm

I)

Stroke of brake piston 30

3.2 mm 5.0 mm

new Wear limit resulting in a maximum permissible wear of the entire disc pack of

Items A - D (see Fig. 2) Items E - H (see Fig. 6) Items I (see Fig. 8) Tab. 1

11.60.2

34 Nm

Technical data, settings and tightening torques

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1.8 mm

Service Manual

Travel gear F40 Functional description

3 Functional description (see "Sectional drawing of the travel gear system", page 9) The output torque of the hydraulic oil motor 3 is transmitted through the spline mesh of the brake 990 and the pinion 100 to the planetary stage I (positive coupling). The pinion 100 thereby propels the planetary gear and thus the planetary carrier 10 and the pinion (sun gear) 90 positively connected to the planetary carrier at the speed reduced by the planetary stage I. The pinion (sun gear) 90 simultaneously propels the planetary gear and the planetary carrier 20 as well as the pinion (sun gear) 80 positively connected to the planetary carrier 20 at the speed reduced by the planetary stage II. The pinion (sun gear) 80 propels the planetary gears of the planetary carrier 30 and thus the hollow gear 40 (positive coupling) at the speed reduced by the planetary stage III . The total speed reduction is the sum of the reductions of the three planetary stages. As the output speed is reduced, the output torque is increased accordingly.

4 Maintenance 4.1

Maintenance of the gearbox The gearbox must be regularly serviced at the intervals laid down in the maintenance instructions in group 3. Regular maintenance includes a check of the oil level, inspection for leakage and of the gearbox, oil motor and tumbler wheel for proper mounting. The gear oil must be changed at the prescribed intervals. To change the oil, follow the instructions below (see "Installation and dismantling of the travel gear system", page 4) or refer to the operating manual. The travel gear brake must also be inspected and tested at the prescribed intervals laid down in the maintenance instructions in group 3.

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11.60.3

Travel gear F40

Service Manual

Installation and dismantling of the travel gear system

5 Installation and dismantling of the travel gear system

Fig. 2

Attachment of the travel gear with tumbler wheel and oil motor to the longitudinal member

1

Longitudinal member

7

Hex head screw

2 3

Travel gear Oil motor

8 9


4

Tumbler wheel

11

Hex head screw

5 6

Hex head screw Washer

12

Washer

Danger! To dismantle and install the gearbox, the crawler chain must be dismantled, and the hydraulic and brake systems of the machine must be interfered with, whereby the danger zone of the machine must be accessed. Before dismantling or installing the gearbox: Park the machine on a level and firm surface. If parked on a slope, secure the machine properly. Release all pressure from the hydraulic system and the brake.

5.1

Dismantling see Fig. 2 and see 5.2 Turn the gearbox until the screw plug at the front 900 is at the lowest point (position A). The second screw plug 900 is in position 9.30 o'clock. Place a suitable oil collecting container under the gearbox. Remove both screw plugs 900.

11.60.4

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Service Manual

Travel gear F40 Installation and dismantling of the travel gear system Drain the gear oil from the gearbox into the container. Insert both screw plugs 900; for tightening torque, (see Tab. 1, page 2) Remove the oil collecting container. Release the chain and remove it, see also group 12.70. Remove the hex head screws 8 and disconnect the tumbler wheel 4 from the gearbox 2. Remove the hex head screws 11 and lift off the cover 9 with the washers 12. Prior to dismantling the gearbox, release all pressure from the pressure, leak oil and brake lines. Disconnect the pressure, leak oil, lubricating and brake lines at the oil motor 3 (seal openings). 7

2

Secure the gearbox 2 with suitable lifting tackle. Mark or write down installation position of the gearbox 2. Remove the hex head screws 5 and the washers 6, and lift the gearbox 2 from the undercarriage.

Fig. 3

5.2

Oil drain position A and oil filling and checking position B

Installation see Fig. 2, see 5.2, see Fig. 4 Before installing the gearbox, ensure that it is in the correct position. Place the gearbox into the gearbox bearing of the longitudinal member. 5

6

Check the O-ring 15 at the oil motor 3 and replace it, if necessary. New O-rings must be slightly lubricated before they are placed onto the oil motor 3. Place the oil motor 3 with brake valve in the gearbox 2. Insert and tighten the hex head screws 7; for tightening torque, see Table 1, page 2. Connect the brake, leak oil and hydraulic lines to the oil motor. Mount the cover 9 and tighten the hex head screws 11 with washers 12. For tightening torque, see Table 1, page 2.

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11.60.5

Travel gear F40

Service Manual

Sealing of gearbox Turn the gearbox 2so that one of the screw plugs 900 is in horizontal position (position B), (see 5.2, page 5). The second screw plug 900 is in position 4.30 o'clock. Remove the upper screw plug 900. Add gear oil (for recommended products, see Table 1, page 2) until the level reaches the lower edge of the bore in the gearbox 2. Close both screw plugs 900; for tightening torque, (see Tab. 1, page 2). Mount the tumbler wheel 4 onto the gearbox 2 and secure it; for tightening torque, see Table 1, page 2. Tighten the hex head screws 8. Mount the chain, see group 12.70.

6 Sealing of gearbox

Fig. 4 2 3

Seal between the oil motor and the gearbox 7 15

Travel gear Oil motor

Hex head screw O-ring

Note! The work described below can be completed while the gearbox is mounted.

11.60.6

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Service Manual

Travel gear F40 Sealing of gearbox

Please note:

Prior to the installation, clean all parts to be reused and inspect them carefully for damage. Apply a little oil or grease to all sealing elements to facilitate installation.

6.1

Sealing of travel motor section Turn the gearbox until the screw plug at the front 900 is at the lowest point (position A), (see 5.2, page 5). The second screw plug 900 is in position 9.30 o'clock. Place a suitable oil collecting container under the gearbox. Remove both screw plugs 900. Drain the gear oil from the gearbox into the container. Insert both screw plugs 900; for tightening torque, (see Tab. 1, page 2). Remove the hex head screws 11 and lift off the cover 9 with the washers 12. Prior to dismantling the gearbox, release all pressure from the pressure, leak oil and brake lines. Disconnect the pressure, leak oil, lubricating and brake lines at the oil motor3 (seal openings). Remove the hex head screws 7 and pull the oil motor 3 from the gearbox 2 . Replace the O-ring 15 of the oil motor3. Place the oil motor 3 in the gearbox. Insert and tighten the hex head screws 7; for tightening torque, see Table 1, page 2. Connect the brake, leak oil and hydraulic lines to the oil motor. Mount the cover 9 and tighten the hex head screws 11 with washers 12; for tightening torque, see Table 1, page 2.

6.2

Sealing of travel brake and replacement of brake discs Note! To carry out sealing and repair work on the travel brake, the travel gear does not have to be dismantled. It is however necessary to remove the oil motor from the gearbox, see 6.1. For detailed instructions for the sealing and repair of the travel brake, refer to the repair manual F40-110, chapter 'Brake'.

6.3

Replacement of the slide ring seal Note! To replace the slide ring seal, you must first dismantle the gearbox, (see "", page 4). For detailed instructions for the sealing and repair of the travel brake, refer to the repair manual F40-110, chapter "Wheel hub and bearing".

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11.60.7

Travel gear F40

Service Manual

Exploded view of the travel gear system

7 Exploded view of the travel gear system

Fig. 5

11.60.8

Exploded view of the travel gear system

3

Oil motor

220


7 10

Hex head screw Planetary carrier (planetary stage I)

260 290

Nut Slide ring seal

15

O-ring

310

Shim

20 30

Planetary carrier (planetary stage II) Planetary carrier (planetary stage III)

320 550

Adjusting ring Circlip

40 50

Hollow gear Cover

600 800


80

Pinion

810

O-ring

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Service Manual

Travel gear F40 Sectional drawing of the travel gear system

90 100

Pinion Pinion

840 850

Allen head screw O-ring

200 210

Suspension tube Hub

900 990

Screw plug Brake see Fig. 7 and see Fig. 8

8 Sectional drawing of the travel gear system

Fig. 6

Travel gear system

Note! Observe settings and tightening torques B, F, G, H for the maintenance and repair of the travel gear system, see Table 1, page 2.

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11.60.9

Travel gear F40

Service Manual

Exploded view of the travel brake

9 Exploded view of the travel brake

Fig. 7

11.60.10

Exploded view of the travel brake

10

Carrier

90

Outer disc (steel)

20 30

Hub Piston

100 110

Inner disc (sinter) Snap ring

40 50

Cover Pressure spring

140 150

Backing ring O-ring

60 70

Pressure spring Seal

160 170

Backing ring O-ring

80

Seal

180

Backing ring

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Service Manual

Travel gear F40 Sectional view of the travel brake

10 Sectional view of the travel brake

Fig. 8

Travel brake in gearbox

Note! For setting I for the maintenance and repair of the travel brake, see Table 1, page 2.

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11.60.11

Travel gear F40

Service Manual

Sectional view of the travel brake

11.60.12

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Service Manual

FAT 350 travel gear system Design

FAT 350 travel gear system 1 Design The three-stage planetary gear is driven by the A 6VE hydraulic oil motor. It propels the tumbler wheel attached to the gearbox and the crawler chain. The wet multi-disc brake integrated into the gearbox acts directly onto the gear drive. The brake is designed as a spring applied brake and is released hydraulically, i.e. when the brake system is not pressurised, the discs are pressed together by the pressure springs, so that the brake is mechanically applied.

Fig. 1

FAT travel gear system

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11.62.1


Service Manual

Technical data


R 313-Li / R 317-Li 27752 / 23450

Gearbox type Input speed

FAT 350 P062 max. (fast travel)

5479 rpm

min. (normal travel) Output speed

1713 rpm

max. (fast travel)

49.6 rpm


15.5 rpm

Max. output torque

35,000 Nm

Max. brake torque

420 Nm

Gear ratio

1: 113

Weight (approx.)

180 kg


4.1 l

Oil quality

API - GL - 5

Oil viscosity

SAE 90 W SAE 80 W 90 SAE 90 LS

Brake



18 bar


33 bar

Settings and tightening torques, to be observed for installation: A) Check dimension for the installation of the oil motor 102

93.5+1 Nm

B)

Check dimension for the axial play at the wheel end (from end of drive shaft 35 to flange face of the lid 40

3.5 + 1 mm

C)

Friction torque of ball bearing 11

100 Nm

D)

Tightening torque for threaded stud 1.4

69 Nm* 46 Nm**

E)

Tightening torque for Allen head screws 46

F)

Tightening torque of screw plug 48

90 Nm

G)


560 Nm

H)


280 Nm

I)


560 Nm

K0) Tightening torque for hex head screws 109

117 Nm

Items A - F (see Fig. 5 on page9) and items G - K (see Fig. 2 on page4) Tab. 1

Technical data, settings and tightening torques * secured with Loctite 242 ** secured with Loctite 272

11.62.2

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Service Manual

FAT 350 travel gear system Functional description

3 Functional description (see “Sectional drawing of the travel gear system” on page 9) The output torque of the hydraulic oil motor 96 is transmitted through the spline mesh of the disc carrier 55 and the drive shaft 35 to the planetary stage I (positive coupling). The drive shaft 35, through the planetary gears 32, drives the planetary carrier 30 and thus the sun gear 25 that is positively connected to the planetary carrier 25 at the speed of the oil motor as reduced by the planetary stage I. Simultaneously, the sun gear 25, through the planetary gears 22, drives the planetary carrier 20 and thus the sun gear 15 that is positively connected to the planetary carrier 20 at the speed of the planetary stage I as reduced by stage I. The sun gear 15, through the planetary gears 5 of the connected carrier 1, drives the hollow gear 10 that is positively connected, at the speed of the planetary stage III as reduced by stage II. The total speed reduction is the sum of the reductions of the three planetary stages. As the output speed is reduced, the output torque is increased accordingly.

4 Maintenance 4.1

Maintenance of the gearbox The gearbox must be regularly serviced at the intervals laid down in the maintenance instructions in group 3. Regular maintenance includes a check of the oil level, inspection for leakage and of the gearbox, oil motor and tumbler wheel for proper mounting. The gear oil must be changed at the prescribed intervals. To change the oil, follow the instructions below see Fig. 3 or refer to the operating manual. The travel gear brake must also be inspected and tested at the prescribed intervals laid down in the maintenance instructions in group 3.

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11.62.3


Service Manual

Installation and dismantling of the travel gear system

5 Installation and dismantling of the travel gear system

Fig. 2

Attachment of the travel gear with tumbler wheel and oil motor to the longitudinal member

100 101

Longitudinal member Travel gear

106 107

Hex head screw Hex head screw

102 103

Oil motor Tumbler wheel

108 109

Lid Hex head screw

104

Hex head screw

110

Washer

105

Washer

Danger! To dismantle and install the gearbox, the crawler chain must be dismantled, and the hydraulic and brake systems of the machine must be interfered with, whereby the danger zone of the machine must be accessed. Before dismantling or installing the gearbox: Park the machine on a level surface. If parked on a slope, secure the machine properly. Release all pressure from the hydraulic system and the brake.

5.1

Dismantling see Fig. 2 and see 5.2 Turn the gear until the screw plug at the front 48 (A) is at the lowest point. The second screw plug 48 (K/E) is in position 2 o'clock. Place a suitable oil collecting container under the gearbox. Remove both screw plugs 48. Drain the gear oil from the gearbox into the container.

11.62.4

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Service Manual

FAT 350 travel gear system Installation and dismantling of the travel gear system Insert both screw plugs 48; for tightening torque, (see Tab. 1 on page2). Remove the oil collecting container. Release the chain and remove it, see also group 12.70. Remove the hex head screws 107 and disconnect the tumbler wheel 103 from the gearbox 101. Remove the hex head screws 109 and lift off the cover 108 with the washers 110. Prior to dismantling the gearbox, release all pressure from the pressure, leak oil and brake lines. Disconnect the pressure, leak oil, lubricating and brake lines at the oil motor 102 (seal openings). Remove the hex head screws and the oil motor 102 together with the brake valve from the gearbox 101 . Secure the gearbox 101 with suitable lifting tackle. Mark or write down installation position of the gearbox 101. Remove the hex head screws 104 and the washers 105, and lift the gearbox 101 from the undercarriage.

Fig. 3

5.2

Gear positions for oil discharge, refilling and inspection

48 Screw plug

E

A Oil discharge bore

K Inspection bore

Oil filling bore

Installation see Fig. 2, see Fig. 4 Caution! Screw connections that are unable to bear the occurring forces, due to elongation of or damage to the screws, can result in serious damage of components such as longitudinal members, gearboxes and chains. Such breaks can also injure persons standing nearby. For safety reasons, all screws must thus be replaced with new ones when the gearbox and the tumbler wheel are replaced. When mounting the gearbox and the tumbler wheel, always use new screws. Before installing the gearbox, ensure that it is in the correct position.

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11.62.5


Service Manual

Sealing gearbox Place the gearbox into the gearbox bearing of the longitudinal member. Insert and tighten the hex head screws 104 with washers 105; for tightening torque, see Table 1, page 2. Check the O-ring 112 at the oil motor 102 and replace it, if necessary. New O-rings 112 must be slightly lubricated before they are placed onto the oil motor 102. Place the oil motor 102 with brake valve in the gearbox 101. Insert and tighten the hex head screws 106; for tightening torque, see Table 1, page 2. Connect the brake, leak oil and hydraulic lines to the oil motor. Mount the cover 108 and tighten the hex head screws 109 with washers 110. For tightening torque, see Table 1, page 2. Turn the gearbox 101 so that one of the screw plugs 48 is in horizontal position, (see 5.2 on page5). The second screw plug 48 is in position 2 o'clock. Remove the upper screw plug 48 (K/E). Add gear oil (for recommended products, see Table 1, page 2) until the level reaches the lower edge of the bore in the gearbox 101. Close both screw plugs 48; for tightening torque, (see Tab. 1 on page2). Mount the tumbler wheel 103 onto the gearbox 101 and secure it; for tightening torque, see Table 1, page 2. Tighten the hex head screws 107. Mount the chain, see group 12.70.

6 Sealing gearbox

Fig. 4

Seal between the oil motor and the gearbox

101

Travel gear

106

Hex head screw

102

Oil motor

112

O-ring

Note! The work described below can be completed while the gearbox is mounted.

11.62.6

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MJF C I F S S

Service Manual

FAT 350 travel gear system Sealing gearbox

Before you start assembly, please note:

Prior to the installation, clean all parts to be reused and inspect them carefully for damage. Apply a little oil or grease to all sealing elements to facilitate installation.

6.1

Sealing of travel motor section Turn the gear until the screw plug at the front 48 (A), (see 5.1 on page4), is at the lowest point (position 6 o'clock). The second screw plug 48 (K/E) is in position 2 o'clock. Place a suitable oil collecting container under the gearbox. Remove both screw plugs 48. Drain the gear oil from the gearbox into the container. Insert both screw plugs 48; for tightening torque, (see Tab. 1 on page2). Remove the hex head screws 109 and lift off the cover 108 with the washers 110. Prior to dismantling the gearbox, release all pressure from the pressure, leak oil and brake lines. Disconnect the pressure, leak oil, lubricating and brake lines from the oil motor 103 (seal openings). Remove the screws 106 and pull the oil motor 102 from the gearbox 101 . Replace the O-ring 112 of the oil motor 102. Place the oil motor 102 in the gearbox. Insert and tighten the screws 106; for tightening torque, see Table 1, page 2. Connect the brake, leak oil and hydraulic lines to the oil motor. Mount the cover 108 and tighten the hex head screws 109 with washers 110; for tightening torques, Table 1, page 2.

6.2

Sealing of travel brake and replacement of brake discs Note! To carry out sealing and repair work on the travel brake, the travel gear does not have to be dismantled. It is however necessary to remove the oil motor from the gearbox, see 6.1. For instructions regarding sealing and repair work, refer to the FAT 350 P repair manual.

6.3

Replacement of slide ring seal Note! To replace the slide ring seal, you must first dismantle the gearbox, (see “” on page 4). For detailed instructions regarding the sealing and repair of the travel brake, refer to the FAT 350 P repair manual, chapter 'Sealing work at the connected carrier'.

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11.62.7


Service Manual

Sealing gearbox 1

Connected carrier (planetary stage III)

41

Stop washer

1.2 1.3

Seal plug Taper pin

42 45

L-ring O-ring

1.4

Threaded stud

46

Allen head screw

2

Snap ring

48

Screw plug

3

Stop washer

50

Thrust plate

5 6

Planetary gear Snap ring

51 52


7 10

Seal plug Sun wheel

55 56

Disc carrier Lip seal

11 15

Ball Sun gear

57 60

Lip seal Annular piston

20

Planetary carrier (planetary stage II)

61

Pressure spring (large)

21 22

Stop washer Planetary gear

62 63

Pressure spring (small) Locking ring

23 25

Snap ring Sun gear

64 70

Snap ring Slip ring seal

30

Planetary carrier (planetary stage I)

71

O-ring

31

Stop washer

72

Grooved pin

32

Planetary gear

75

Shroud ring

33 35

Snap ring Drive shaft

76 95

Circlip Planetary carrier

36 38

Circlip Ball cage

102 106

Oil motor Hex head screw

40

Lid

112

O-ring

Note! Observe settings and tightening torques A, B, C, D, E, F, and H for the maintenance and repair of the travel gear system, see Table 1, page 2.

11.62.8

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Service Manual

FAT 350 travel gear system Sectional drawing of the travel gear system

7 Sectional drawing of the travel gear system

Fig. 5

Travel gear system

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11.62.9


Service Manual

Sectional drawing of the travel gear system

11.62.10

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MJF C I F S S

Service Manual

Travel brake Function

Travel brake 1 Function The travel brake is a wet multi-disc brake that is hydraulically released and installed in each travel gear system. It acts on the gear output. To apply the brake, the pressure to the brake connection of the travel gear system 216 is blocked by the solenoid valve / travel brake valve 205. In the event of a failure of the hydraulic unit, there is no pressure available to open the travel brake 215, so that it remains applied. In both cases, pressure springs connected to a brake piston push against the brake discs and thus mechanically apply the brake (static brake function). The brake acts as a spring-applied brake with a safety function in the event of malfunction of the machine. The machine is equipped with a second brake system for the travel oil motor. The travel brake valve 205 flange-mounted to the oil motor 200 / 201 acts as a dynamic brake on the hydraulic gearbox drive. For a description of the travel brake valves 205, see group 7.90 hydraulic components).

Fig. 1

Components of the hydraulic system and brake

82 83

Pilot control unit, travel left Pilot control unit, travel right

200 201


100 160

Compact control block Spool / chassis right

205 215

Brake valve Travel brake

180


216

Travel gear

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11.65.1

Travel brake

Service Manual

Design, (see Fig. 1, page 1)

2 Design, (see Fig. 1, page 1) 2.1

Pilot control units 82 / 83 The pilot control units 82 /83 equipped with pedal ensure that the control oil flows to the spools 160 / 180 in the control valve block 100. Depending on the pedal travel, high pressure is established in the lines to the travel motors 200 / 201.

2.2

Travel motor 200 / 2001 The axial piston oil motor is designed as a plug-in motor for installation into the travel gear system 216. It is positively connected to the planetary drive and the travel gear multi-disc brake 215 in the gearbox.

2.3

Brake valve 205 Each travel motor 200 /201 is equipped with a flange-mounted brake valve. The brake piston in brake valve 205 acts on the hydraulic return line of the travel motor and prevents overspeeding of the oil motor when the machine is travelling downhill. The brake valves 205with the respective pressure pA or pB also produce the release pressure required to release the multi-disc brake. Through the connection Bre of the brake valve 205 and the hose line 210, the release pressure also acts on the brake piston of the travel brake.

2.4

Multi-disc travel brake 215 The brake discs are integrated into the travel gearbox. Pressure springs connected to the brake piston press the inner and outer discs against each other. The high friction blocks the travel gear.

3 Function of the brake system 3.1

System depressurised The travelling pedals 82 / 83 are not actuated, or there is a fault in the high pressure circuit. The pressure springs 50 / 60 push in the brake piston 30, which in turn presses the outer discs 100 (steel discs) against the inner discs 90 (sinter discs). The surface pressure between the discs, combined with the high friction factor of the sinter discs, ensures maximum brake force. The outer disc 100 is positively connected through gearing to the brake hub 20, which is also positively connected through gearing to the suspension tube A and the planetary carrier B of the gearbox. The inner disc 90 is positively connected through gearing to the carrier 10, which is positively connected through gearing to the drive shaft C of the oil motor 200 / 201. The friction between the disc surfaces pressed against each other by the pressure springs 50/60 block the drive and thus stop the machine.

3.2

Travel motor pressurised / release pressure reached If one of the two travelling pedals 82/83 is pressed down, the oil motor 200 / 201 is pressurised by the working pump with hydraulic oil. The pressure is thereby proportional to the pedal travel. The

11.65.2

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Service Manual

Travel brake Function of the brake system

pressure-reducing valve 208 converts the high pressure into release pressure for the multi-disc brake 215. The release pressure acts on piston 30, which is pressed against the springs 50/60 so that the spring force onto the brake discs is reduced. From the minimum release pressure (see also technical data in group 11.60), the pressure springs 50/60 are pressed together, so that the brake discs 90/100 are not in contact and the brake is released.

Fig. 2 10 20

Sectional view of the travel brake 110 140

Carrier Hub

Snap ring Backing ring

30

Piston

150

O-ring

40 50

Cover Pressure spring

160 170

Backing ring O-ring

60 70

Pressure spring Seal

180 A

Backing ring Suspension tube

80 90

Seal Outer disc

B C

Planetary carrier stage III Drive shaft / oil motor

100

Inner disc

D

Input pinion / gearbox

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11.65.3

Travel brake

Service Manual

Function of the brake system

11.65.4

1 160

to hydraulic tank from / to spool travel right

212 213


180 195

from / to spool travel left Rotary connection 5 x

214 215

Secondary pressure-relief valve Travel brake

196


216

Travel gear

200 201


Y24

from solenoid valve / fast travel

202

Adjusting device

203


Bre

Connection for brake control pressure/release pressure

205 206


MA MB

Measuring point for travel high pressure Measuring point for travel high pressure

207

2-way shift valve

R

Connection for high pressure, reverse travel

208

7

Leak oil connection

210

Pressure reduction valve / brake pressure Brake line

V

Connection for high pressure, forward travel

211


X

Connection for control pressure/fast travel

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Service Manual


Fig. 3

Travel motors with brake valve and travel brake in travel gearbox

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11.65.5

Travel brake

Service Manual

Repair of the travel brake Note! The brake system is filled with oil from the hydraulic unit, see group 1.50.

When the oil in the hydraulic tank is replaced with a different product (e.g. environmentally friendly hydraulic fluid), the oil in the brake system must also be replaced. This means that the oil in the brake system and associated lines must be drained. Note! Under special circumstances, e.g. when the machine is to be towed, and there is no release pressure, the brake can be released by dismantling the oil motor and turning in the two M8 x 20 screws.

4 Repair of the travel brake Caution! Prior to any inspection or adjustment work on the machine, take all safety and accident prevention measures required to protect the technician, see also the accident prevention regulations issued by the German Ground Construction Trade Association (Tiefbau-Berufsgenossenschaft).

4.1

Sealing of travel brake and replacement of brake discs To carry out sealing and repair work on the travel brake, the travel gear does not have to be dismantled from the undercarriage. It is however necessary to remove the oil motor from the gearbox. Follow the instructions in chapter "Sealing of oil motor" in group 11.60. For detailed instruction for sealing and repair work, refer to the repair manual F40-110.

11.65.6

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Service Manual

Travel brake Function

Travel brake 1 Function The travel brake is a wet multi-disc brake that is hydraulically released and installed in each travel gear system. It acts on the gear output. To apply the brake, the pressure to the brake connection of the travel gear system 216 is blocked by the solenoid valve / travel brake valve 205. In the event of a failure of the hydraulic unit, there is no pressure available to open the travel brake 215, so that it remains applied. In both cases, pressure springs connected to a brake piston push against the brake discs and thus mechanically apply the brake (static brake function). The brake acts as a spring-applied brake with a safety function in the event of malfunction of the machine. The machine is equipped with a second brake system for the travel oil motor. The travel brake valve 205 flange-mounted to the oil motor 200 / 201 acts as a dynamic brake on the hydraulic gearbox drive. For a description of the travel brake valves 205, see group 7.28 hydraulic components).

Fig. 1 82 100

Components of the hydraulic system and brake 200 201

Travel pilot control unit Compact control block


160


205

Travel brake valve

180


215

Travel brake

216

Travel gear

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11.67.1

Travel brake

Service Manual

Design, (see Fig. 1, page 1)

2 Design, (see Fig. 1, page 1) 2.1

Pilot control unit 82 When the pilot control unit 82 with pedals is actuated, control oil is fed to the travel gear spools 160 / 180 in the control valve block 100. Depending on the pedal travel, high pressure is established in the lines to the travel motors 200 / 201.

2.2

Travel motor 200 / 201 The axial piston oil motor is designed as a plug-in motor for installation into the travel gear system 216. It is positively connected to the planetary drive and the travel gear multi-disc brake 215 in the gearbox 216.

2.3

Brake valve 205 Each travel motor 200 /201 is equipped with a flange-mounted brake valve. The brake piston in brake valve 205 acts on the hydraulic return line of the travel motor and prevents overspeeding of the oil motor when the machine is travelling downhill. The brake valves 205 with the respective pressure pA or pB also produce the release pressure required to release the multi-disc brake. Through the connection Bre of the brake valve 205 and the hose line 210, the release pressure also acts on the brake piston of the travel brake.

2.4

Multi-disc travel brake 215 The brake discs are integrated into the travel gearbox. Pressure springs act on the annular piston, pressing the inner and outer discs against each other. The resulting high friction blocks the travel gear.

3 Function of the brake system 3.1

System depressurised The travelling pedals 82 / 83 are not actuated, or there is a fault in the high pressure circuit. The pressure springs 61 / 62 press against the annular piston 60. The piston in turn presses the outer discs 52 (steel discs) against the inner discs 51 (sinter discs). The surface pressure between the discs, combined with the high friction factor of the sinter discs, ensures maximum brake force. The outer disc 52 gearing ensures that it is positively connected to the connected carrier 1. The inner disc 51 is equipped with a gear and positively connected to the disc carrier 55, which in turn is positively linked through its gear with the drive shaft 35. The friction between the disc surfaces pressed against each other by the pressure springs 61/62 block the drive and thus stop the machine.

3.2

Travel motor pressurised / release pressure reached If one of the two travelling pedals 82/83 is pressed down, the oil motor 200 / 201 is pressurised by the working pump with hydraulic oil. The pressure is thereby proportional to the pedal travel. The

11.67.2

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Service Manual


pressure reducing valve 208 converts the existing high pressure into the release pressure for the multi-disc brake 215. The release pressure acts on the annular piston 60 against the force of the pressure springs 61 / 62, which means that the pressure force applied onto the brake discs is reduced. As soon as the minimum release pressure (see also technical data in group 11.60) is reached, the pressure springs 61/62 are pressed together, so that the brake discs 51/52 are not in contact and the brake is released.

Fig. 2

Sectional view of the travel brake

1 2

Connected carrier (planetary stage III) Snap ring

55 56

Disc carrier Lip seal

7 15

Seal plug Sun gear (planetary stage III)

57 60

Lip seal Annular piston

35

Drive shaft

61

Pressure spring (large)

36 50

Circlip Thrust plate

62 63

Pressure spring (small) Locking ring

51

Inner disc

64

Snap ring

52

Outer disc

pBre Brake connection

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MJF C I F S S

11.67.3

Travel brake

Service Manual


11.67.4

1 160

to hydraulic tank from / to spool travel right

212 213


180 195

from / to spool travel left Rotary connection 5 x

214 215

Secondary pressure-relief valve Travel brake

196


216

Travel gear

200 201


Y24

from solenoid valve / fast travel

202

Adjusting device

203


Bre

Connection for brake control pressure/release pressure

205 206


MA MB

Measuring point for travel high pressure Measuring point for travel high pressure

207

2-way shift valve

R

Connection for high pressure, reverse travel

208

7

Leak oil connection

210

Pressure reduction valve / brake pressure Brake line

V

Connection for high pressure, forward travel

211


X

Connection for control pressure/fast travel

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Service Manual


Fig. 3

Travel motors with brake valve and travel brake in travel gearbox

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11.67.5

Travel brake

Service Manual

Repair of the travel brake Note! The brake system is filled with oil from the hydraulic unit, see group 1.50.

When the oil in the hydraulic tank is replaced with a different product (e.g. environmentally friendly hydraulic fluid), the oil in the brake system must also be replaced. This means that the oil in the brake system and associated lines must be drained. Note! Under special circumstances, e.g. when the machine is to be towed, and there is no release pressure, the brake can be released by dismantling the oil motor and turning in the two M8 x 20 screws.

4 Repair of the travel brake Caution! Prior to any inspection or adjustment work on the machine, take all safety and accident prevention measures required to protect the technician, see also the accident prevention regulations issued by the German Ground Construction Trade Association (Tiefbau-Berufsgenossenschaft).

4.1

Sealing of travel brake and replacement of brake discs To carry out sealing and repair work on the travel brake, the travel gear does not have to be dismantled from the undercarriage. It is however necessary to remove the oil motor from the gearbox. Follow the instructions in chapter "Sealing of oil motor" in group 11.60. For detailed instruction for sealing and repair work, refer to the repair manual F350-110.

11.67.6

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Service Manual


Group

Type

Steering axle 212 with multi-disc brake

12.02.1

A 309 LI 20221-

Rigid axle 112 with multi-disc brake

12.03.1

A 309 LI 20221-

Differential for the axles 112 / 212 / 162 / 262

12.05.1

A 309 LI 20221A 311 LI 20222-

Steering axle 262 LD with multi-disc brake

12.10.1

A 311 LI 20222-

Rigid axle 162LD with multi-disc brake

12.11.1

A 311 LI 20222-

Steering axle

12.20.1

A 312 LI 12363-

Rigid axle

12.21.1

A 312 LI 12363-

Differential for 162 / 262 axles

12.23.1

A 312 LI 12363-

APL - B 745 steering axle with multi-disc brake 12.28.1

A 314 LI 2001-

AP - B 745 rigid axle with drum brake

12.29.1

A 314 LI 2001-

AP - B 745 rigid axle

12.30.1

A 314 LI 2001-

Differential for AP / APL - B 745 axles

12.31.1

A 314 LI 2001-

APL - B 755 steering axle with multi-disc brake 12.36.1

A 316 LI 2001-28060


12.37.1

A 316 LI 2001-28060


12.39.1

A 316 LI 2001-28060

APL - B 755 HD steering axle with multi-disc brake

12.41.1

A 316 LI-IND 2001-28060

AP - B 755 rigid axle with multi-disc brake

12.42.1

A 316 LI-IND 2001-28060

Differential for AP / APL - B 755 HD axles

12.44.1

A 316 LI-IND 2001-28060

MS - E 3060 steering axle

12.46.1

A 316 LI 28061A 316 LI-IND 28061-

12.1 MJF C I F S S

Service Manual MT - E 3060 rigid axle

12.47.1

A 316 LI 28061A 316 LI-IND 28061-

MS/MT - E 3060 drive unit and differential

12.48.1

A 316 LI 28061A 316 LI-IND 28061-

Tyres and spacer rings

12.54.1


Chassis / drive

12.60.1

R 313 LI 27752R 317 LI 18161-

Technical data / tightening torques

12.62.1

R 313 LI 27752-


12.64.1

R 317 LI 18161-

Wear of chassis parts

12.66.1

R 313 LI 27752R 317 LI 18161-

D4L wear limits

12.67.1

R 313 LI 27752-

Wear limits - B60

12.69.1

R 317 LI 18161-

Chain

12.72.1

R 313 LI 27752R 317 LI 18161-

Tensioning unit

12.75.1

R 313 LI 27752R 317 LI 18161-

Idler

12.78.1

R 313 LI 27752R 317 LI 18161-

Running roller

12.81.1

R 313 LI 27752R 317 LI 18161-

Support roller

12.84.1

R 313 LI 27752R 317 LI 18161-

Slide ring seal

12.86.1

R 313 LI 27752R 317 LI 18161-

12.2 MJF C I F S S

Service Manual

Steering axle 212 with multi-disc brake Function

Steering axle 212 with multi-disc brake 1 Function The steering axle transfers the axle load of the machine onto the drive wheels. The axle consists of the following main components: Differential and two axle shafts with brake as well as two joint housings with output system. The differential transmits 50% of the output power of the transmission via the universal joint shafts to the planetary drives of the wheel hubs. The axle housing contains the differential as well as the hydraulically operated wet multi-disc brake. It is applied when the brake pedal (working brake) is operated and the brake is pressurised with brake oil. For a detailed description of the brake system, see group 15.10. The steering cylinder (synchronised speed cylinder) attached to the differential of the steering axle moves the wheels through the joint housings (steering knuckles) between the two stop positions. For a detailed description of the steering cylinder, see group 13.33. The steering cylinder is mounted directly on the undercarriage (oscillating bearing). This design compensates for uneven surfaces so that all wheels of the vehicle are always in contact with the ground. During digging operation, the oscillating movement of the steering axles can be blocked by means of the two swing axle support cylinders attached to the undercarriage, see group 14.10.

Fig. 1

Steering axle 212

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12.02.1


Service Manual

General information

2 General information Equipment Unit model Serial number

A 309-Li 717 20221

Axle type

212 / 440

Design

Planetary steering axle

Total gear ratio Standard Speeder

A 309-Li 717 21648 212 / 567

13.71 13.71

Brake

Wet multi-disc brake

Oil volume in axle Differential and axle shaft Planetary drive (filling level at the check screws is binding)

7.3 l 0.8 l per side

Oil quality/viscosity

API - GL 5 / SAE 90 LS

Settings and tightening torques to be observed for installation: A

Friction torque of the joint housing bearing 322 / 327

30 -60 Nm 10 -30 Nm

B

Friction torque of the wheel bearing 329

C

Torque for the hex head screws 301

122 Nm

D


15 Nm

E

Torque for the hex head screw 304

283 Nm

F


140 Nm

G

Torque for the wheel lugs 338

460 Nm

H

Torque for the countersunk screws 340

50 Nm

I

Torque for the nuts 343

1st stage 2nd stage

120 Nm 255 -285 Nm

K

Distance B of the adjusting screw 345 to the lock nut

L

Limit gap of the brake discs 401 (gap S)

4.5 mm

M

Torque for the readjusting screws 402

5 -7 Nm

N

Checking of the multi-disc brakes: High pressure test, max. value There may be no visible pressure drop after 3 minutes.

O

Tolerance between the left and the right steering stop

0.6 - 0.7 mm

P

Torque for the Allen head screw 1 at the cylinder 4, see also group "Steering".

116 - 128 Nm

Q

Torque of the spherical end sections of the piston rod / cylinder 4 , see also group "Steering"

240 - 270 Nm

R

Torque for the joint tie rod 5 at the cylinder, see also group "Steering".

298 - 328 Nm

S

Torque for the slotted nut 6 at the joint tie rods, see also group "Steering".

260 - 290 Nm

38 ± 1 mm

50 bar

Items A - D / F - K (see Fig. 6), items E, M (see Fig. 8) Pos. L (see Fig. 2), items P - S (see Fig. 9) Tab. 1

12.02.2


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Service Manual

Steering axle 212 with multi-disc brake General information secured with Loctite 242 secured with Loctite 270

2.1

Tyre pressure The tyre pressure depends on the tyre size, tyre ply rating and brand. For details, see overview of tyres in group 12.46.

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12.02.3


Service Manual


3 Description of functions (see Fig. 6 on page 11) The input torque of the transmission is transmitted through the drive shaft to the output flange of the differential. A bevel pinion and crown wheel transfer the torque via the differential case to the differential spider with balancing and axle shaft gears, which is borne in the cage. The respective axle shaft gear transfers the torque (increased by the differential translation with pinion and crown wheel) to the joint 311 meshing with the axle shaft gear. The end section of the joint 311 meshes with the planetary gears 336. These roll off on the stationary crown gear 333. This results in a high speed reduction and thus increased power transmission onto the planetary housing 341. The planetary housing 341 propels the wheel hub 331 and the wheel stud330, thus driving the vehicle wheels with the respective power and speed (based on the total gear ratio).

4 Maintenance of the axle The axle must be serviced regularly at the intervals laid down in the service manual. All maintenance work must be completed according to the instructions in the operating manual. Inspect the brake once every 12 months for damage and wear. During the annual inspection, or if any of the following problems occur: – Reduced braking force – Reduced brake pressure – Changes in the oil level in the planetary drive – Unusual braking noises inspect the multi-disc brake for damage and wear.

4.1

Inspection of the brake for disc wear (see Fig. 2 on page 5) – Remove the two oil filling screws 326 (one screw at the front and one screw at the rear). – Apply the brake by pressing down the brake pedal. – Insert a feeler gauge (tool no. 64 in group 2.08) through the oil filling bore B to measure the gap "S" between the brake disc. The gap "S" may not be greater than 4.5 mm. If the gap is narrower (i.e. the feeler gauge cannot be inserted), replace all discs.

12.02.4

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Service Manual

Steering axle 212 with multi-disc brake Maintenance of the axle

Fig. 2

Inspection of brake discs for wear

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12.02.5


Service Manual

Dismantling, repair and installation of the steering axle

5 Dismantling, repair and installation of the steering axle 5.1

Dismantling of the steering axle for repair work, (see Fig. 3 on page 7) Danger! Prior to dismantling the steering axle, take all necessary safety measures to protect persons and machinery. Always comply with the safety instructions in the operating manual and the accident prevention regulations issued by the German Ground Construction Trade Association (Tiefbau-Berufsgenossenschaft). Block the wheels of the rigid axle 623 with chocks. If required, lift the front section of the undercarriage 620 and remove the vehicle wheels 622 from the steering axle. Disconnect the hydraulic lines to the steering cylinder and the brake line to the multi-disc brakes and seal the line openings (collect escaping oil). Loosen the hex nuts 611 and remove the universal joint shaft 610. Lift and secure the undercarriage 620. Secure the steering axle 621 with suitable lifting tackle. Remove the hex head screws 608 and remove the bracket 603 and the bushings 602. Lower the steering axle 621 and pull it from the undercarriage.

5.2

Repairs on the steering axle Note! For detailed repair instructions for the axle, refer to the separate Repair manual for Dana 212 axles.

5.3

Installation of the steering axle after repair, (see Fig. 3 on page 7) Place the steering axle 621 in the undercarriage 620, using suitable lifting gear. Check the oscillating axle bearing for proper functioning (i.e. reusability of thrust bushings 602). Place the old or new thrust bushings 602 and brackets 603 on the steering axle 621 and secure the steering axle 621 to the undercarriage, using the hex head screws 608. Lubricate the oscillating axle bearing at the lubrication nipple 604. Attach the universal joint shaft 610 with the nuts 611 to the differential of the steering axle 621. Connect the brake lines to the multi-disc brake and bleed the brake (see group 15.10). Connect the hydraulic lines to the steering cylinder and bleed the steering system (see group 13.20). Mount the vehicle wheels 622 . Lower the undercarriage and remove the chocks. Tighten the wheel lugs 338 with the prescribed torque, see table 1.

12.02.6

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Service Manual

Steering axle 212 with multi-disc brake Dismantling, repair and installation of the steering axle

Fig. 3 338

5.4

Dismantling and installation of the steering axle 608

Wheel lug

Hex head screw

601

Intermediate bushing

610


602 603

Thrust bushing Bracket

611 620

Hex nut Undercarriage

604 605

Conical lubrication nipple Plug

621 622

Steering axle Vehicle wheels

623

Rigid axle

Dismantling and installation of the axle for the inspection/replacement of the brake discs Note! For instructions on how to replace the brake discs 401 / 410 or how to seal the brake, also refer to the repair manual for Dana 212.

5.4.1

Dismantling, (see Fig. 4 on page 8) Dismantle the entire axle and remove it from the undercarriage,, (see 5.1 on page 6). Place the axle onto a suitable surface. Remove the screw plugs 108 and 326 and drain the oil from the axle shaft 303 and the differential 103. Replace the screw plugs 108 and 326. Release the steering linkage 605 from the joint housing 322 / 327. Loosen the screws 304 (with washers 305) and carefully remove the axle shaft 303 from the differen-

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12.02.7


Service Manual

Dismantling, repair and installation of the steering axle tial 103. Remove the O-ring 101. Remove the brake and counter discs 401 / 410 from the gearing of the joint 311.

5.4.2

Installation, (see Fig. 4 on page 8) Apply a little oil to the new brake and counter discs 401 / 410 and install them in alternating sequence, beginning with a counter disc 410, onto the joint 311 and install the axle shaft 303. Note! When installing the discs, ensure that the oil guide bores in the discs are properly aligned. Ensure that the connection to the oil filling and check bore (outer missing tooth) is not blocked when the counter disc 410 is mounted. Insert a new O-ring 101 into the differential 103. Observe proper alignment. Place the axle shaft 303 onto the differential 103 and secure it with the screws 304 (with washers 305). Observe the tightening torque for the screws 304,(see Tab. 1 on page 2). Attach and secure the steering linkage 605 to the joint housing 322 / 327, see group13.33 Steering cylinder. Remove the screw plugs107 and 326 and add oil of the prescribed grade through the threaded bore of the screw plug 107, until the oil level reaches the lower edge of the bore for screw plug 326. Insert screw plugs 107 (with O-ring 106) and 326. Secure the axle to the undercarriage, (see 5.3 on page 6).

Fig. 4

12.02.8

Dismantling and assembly of parts for the replacement of the brake discs

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Service Manual

Steering axle 212 with multi-disc brake Output end of the steering axle

6 Output end of the steering axle

Fig. 5

Output end of the steering axle (assembly 30)

1

Hex nut

27

Right joint housing

2 3

Screw Axle shaft

28 29

Sealing ring Tapered roller bearing

4

Hex head screw

30

Wheel stud

5 6

Washer Intermediate bushing

31 32

Wheel hub O-ring

7

Sealing ring

33

Crown gear

8

Deep groove ball bearing

34

Hollow gear carrier

9

Snap ring

35

Snap ring

10

O-ring

36

Planetary gear

11

Joint

37

Roller bearing

12 13

Thrust bushing Bushing

38 40

Wheel lug Countersunk screw

14

Screw

41

Planetary housing

15

Cover

42

Stud

16

Plug

43

Nut

17

Conical lubrication nipple

44

Snap ring

18

Upper steering knuckle bolt

45

Adjusting screw

19 20

Lower steering knuckle bolt Sealing ring

49 50

Locking plate Snap ring

21 22

Joint Left joint housing

57 59

Shim (S = 0.15 / 0.20 / 0.50) Repair kit for planetary housing

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12.02.9


Service Manual

Output end of the steering axle 23 25

Sealing ring Magnetic plug

66 67

Repair kit for left joint housing Repair kit for right joint housing

26

Plug

75 76

Washer Washer

301

Hex nut

328

Sealing ring

302 303

Screw Axle shaft

329 330

Tapered roller bearing Wheel stud

306


331

Wheel hub

307

Sealing ring

332

O-ring

308 309

Deep groove ball bearing Snap ring

333 334

Crown gear Hollow gear carrier

310

O-ring

335

Snap ring

311 312

Joint Thrust bushing

336 337

Planetary gear Bearing

313 314

Bushing Screw

338 340

Wheel lug Countersunk screw

315 316

Cover Plug

341 342

Planetary housing Stud

317


343

Nut

318 319

Upper steering knuckle bolt Lower steering knuckle bolt

344 345

Snap ring Adjusting screw

320 321

Sealing ring Joint

349 350

Locking plate Snap ring

322 323

Left joint housing Sealing ring

357 375

Shim (S = 0.15 / 0.20 / 0.50) Washer (centring ring)

326

Plug

376

Washer (lock washer)

327

Right joint housing

Note! Observe the tightening torques A, B, C, D, F, G, H, I, K for the maintenance and repair of the axles (see Fig. 6, page 11) and table 1, page 2.

12.02.10

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MJF C I F S S

Service Manual

Steering axle 212 with multi-disc brake Output end of the steering axle

Fig. 6

Output end of the steering axle

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12.02.11


Service Manual

Steering axle brake

7 Steering axle brake

Fig. 7 1

12.02.12

Working brake (assembly 40) Brake disc

8

Anti-extrusion ring

2

Adjusting screw

9

O-ring

3 4

Spring Piston

10 11

Counter disc Bleeder screw

5 6

Spring Anti-extrusion ring

12 13

Plug Pin

7

O-ring

14

Piston repair kit

101

O-ring

402

Adjusting screw

102 103

Intermediate cover Housing / differential

403 404

Spring Piston

204 205

Tapered roller bearing Shaft nut

405 406

Spring Anti-extrusion ring

207

Allen head screw

407

O-ring

303 304

Axle shaft Hex head screw

408 409

Anti-extrusion ring O-ring

305 311

Washer Joint

410 411

Counter disc Bleeder screw

325

Screw plug

412

Plug

326

Screw plug

413

Pin

401

Brake disc

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Service Manual

Steering axle 212 with multi-disc brake Steering axle brake

Fig. 8

Multi-disc brake in axle shaft

Note! Observe tightening torques E and M for the repair of the axles, see table 1, page 2.

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12.02.13


Service Manual

Steering cylinder of the steering axle

8 Steering cylinder of the steering axle

Fig. 9

Steering cylinder in differential (assembly 50)

1

Allen head screw

6

Slotted nut

4

Steering cylinder, complete, see group 13.33 Steering cylinder Joint tie rod, complete

7

Cotter pin

5

10 Differential, complete

Note! Observe tightening torques P - S for the repair of the axles, see table 1, page 2.

12.02.14

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Service Manual

Rigid axle 112 with multi-disc brake Function

Rigid axle 112 with multi-disc brake 1 Function The rigid axle transfers the axle load of the machine onto the drive wheels. The axle consists of the following main components: Differential and two output shafts with axle shaft and brake. The differential transmits 50% of the output power of the transmission via the universal joint shafts to the planetary drives. The axle shafts contain the hydraulically operated wet multi-disc brake, which is located near the connection of the differential. The brake is applied when the brake pedal (working brake) is operated and the brake is pressurised with brake oil. For a detailed description of the brake system, see group 15.10.

Fig. 1

Rigid axle 112

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MJF C I F S S

12.03.1


Service Manual

Function

12.03.2

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MJF C I F S S

Service Manual

Rigid axle 112 with multi-disc brake General information


A 309-Li 717 20221

Axle type

112 / 209

Design

Planetary rigid axle

Total gear ratio Standard Speeder Planetary drive

13.71 13.71 6.0

Brake








B


283 Nm

C


460 Nm

D


50 Nm

E


F

Limit gap of the brake discs 401 (gap S)

4.5 mm

G

Torque for the adjusting screws 402

5 - 7 Nm

H

Multi-disc brakes: High pressure test, max. value There may be no visible pressure drop after 3 minutes.

10 -30 Nm

1st stage 2nd stage

120 Nm 255 - 285 Nm

50 bar

Items A / C / D / E (see Fig. 6), item F (see Fig. 2), items B and G (see Fig. 8) Tab. 1

Technical data, settings and tightening torques secured with Loctite 242 secured with Loctite 270

2.1


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MJF C I F S S

12.03.3


Service Manual



Power flow in the rigid axle, (see Fig. 6 on page 11) The output torque of the transmission is transmitted through the universal joint shaft to the input flange of the differential. A bevel pinion and crown wheel transfer the torque via the differential housing to the balancing and axle shaft gears borne in the cage. The respective axle shaft gear transfers the torque (increased by the differential translation with pinion and crown wheel) to the axle shaft 327 meshing with the axle shaft gear. The end section of the axle shaft 326 meshes with the planetary gears 317. These roll off on the stationary crown gear 313. This results in a great speed reduction and thus increased power transmission onto the planetary housing 323. The planetary housing 323 propels the wheel hub 309 and the wheel stud 308, thus driving the vehicle wheels with the respective power and speed (based on the total gear ratio).

4 Maintenance of the axle The axle must be serviced regularly at the intervals laid down in the service manual. All maintenance work must be completed according to the instructions in the operating manual. Inspect the brake once every 12 months for damage and wear. During the annual inspection, or if following problems occur: – Reduced braking force – Reduced brake pressure – Changes in the oil level in the planetary drive – Unusual braking noises inspect the multi-disc brake for damage and wear.

4.1

Checking of discs for wear – Remove the two oil filling screws 304 (one screw at the front and one screw at the rear). – Apply the brake by pressing down the brake pedal. – Insert a feeler gauge (tool no. 64 in group 2.08 List of tools) through the oil filling bore B to measure the gap "S" between the brake disc. The gap „S“ may not be greater than 4.5 mm. If the gap is narrower (i.e. the feeler gauge cannot be inserted), replace all discs.

12.03.4

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MJF C I F S S

Service Manual

Rigid axle 112 with multi-disc brake Maintenance of the axle

Fig. 2

Inspection of brake discs for wear

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12.03.5


Service Manual

Dismantling, repair and installation of the rigid axle

5 Dismantling, repair and installation of the rigid axle 5.1

Dismantling of the rigid axle for repair work, (see Fig. 3 on page 7) Danger! Prior to dismantling the rigid axle, take all necessary safety measures to protect persons and machinery. Always comply with the safety instructions in the operating manual and the accident prevention regulations issued by the German Ground Construction Trade Association (TiefbauBerufsgenossenschaft). Block the wheels of the steering axle 604 with chocks. If required, lift the front section of the undercarriage 600 and remove the vehicle wheels 603 from the rigid axle 604. Disconnect and seal the brake line to the multi-disc brakes (collect any escaping oil). Loosen the hex nuts 615 and remove the universal joint shaft 611. Lift the undercarriage 600 and secure the rigid axle 604 with suitable lifting tackle. 625

5.2

600

Repair of the rigid axle Note! For detailed repair instructions for the axle, refer to the separate Repair manual for Dana planetary rigid axles 112.

5.3

Installation of the rigid axle after repair, (see Fig. 3 on page 7) Place the rigid axle 604 in the undercarriage 600, using suitable lifting gear. Secure the rigid axle 604 with the plate 630, the hex head screws 620 (with washer 622) and hex head screw 625 / hex lock nut 625 to the undercarriage 600. Attach the universal joint shaft 611 with the nuts 615 to the differential of the rigid axle 604. Connect the brake lines to the multi-disc brake and bleed the brake (see group 15.10). Mount the vehicle wheels 603. Lower the undercarriage 600 and remove the chocks. Tighten the wheel lugs 319 with the prescribed torque, Tab. 1 page 3.

12.03.6

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Service Manual

Rigid axle 112 with multi-disc brake Dismantling, repair and installation of the rigid axle

Fig. 3

5.4

Dismantling and installation of the rigid axle

319

Wheel lug

611


332

Washer

615

Hex nut

600 602

Undercarriage Steering axle

620 622


603 604

Vehicle wheels Rigid axle

625 630

Hex nut / lock nut Plate

Dismantling and installation of the axle for the inspection/replacement of the brake discs, (see Fig. 4 on page 8) Note! For instructions on how to replace the brake discs 401 / 410 or how to seal the brake, also refer to the repair manual for Dana planetary rigid axle 112. Dismantle the entire axle and remove it from the undercarriage, see 5.1.

5.4.1

Dismantling, see Fig. 4 Place the axle onto a suitable surface. Remove the screw plugs 108 und 304 and drain the oil from the axle shaft 301 and the differential 103. Insert and tighten the screw plugs 108 and 304. Remove the screws 303 and carefully lift the axle shaft 301 from the differential 103. Remove the Oring 101. Remove the brake and counter discs 401 / 410 from the gearing of the axle shaft 327.

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12.03.7


Service Manual


5.4.2

Installation, see Fig. 4 Apply a little oil to the new brake and counter discs 401 / 410 and install them in alternating sequence, beginning with a counter disc 410, onto the shaft 327 and install the axle shaft 301. Note! When installing the discs, ensure that the oil guide bores in the discs are properly aligned. Ensure that the connection to the oil filling and check bore is not blocked when the counter disc 410 is mounted. Insert a new O-ring 101 into the differential 103. Observe proper alignment. Place the axle shaft 301 onto the differential 103 and secure it with the screws 303 (with washers 302). Observe the tightening torque for the screws 303, see Tab. 1 page 3. Remove the screw plugs107 and 304 and add oil of the prescribed grade through the threaded bore of the screw plug 107, until the oil level reaches the lower edge of the bore for screw plug 304. Replace the screw plugs 107 and304.

Fig. 4

12.03.8

Dismantling and assembly of parts for the replacement of the brake discs

101

O-ring

303

Hex head screw

103 107

Differential housing Screw plug

304 327

Screw plug Axle shaft

108

Screw plug

401

Brake disc

301 302

Axle shaft Washer

410

Counter disc

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Service Manual

Rigid axle 112 with multi-disc brake Output end of the rigid axle

6 Output end of the rigid axle

Fig. 5

Output end of rigid axle (assembly 30)

1 2

Axle shaft Washer

16 17

Snap ring Planetary gear

3 4

Hex head screw Screw plug

18 19

Roller bearing Wheel lug

5 6


20 22

Sealing ring Countersunk screw

8

Wheel stud

23

Planetary housing

9

Wheel hub

24

Nut

10

O-ring

25

Stud

11 12

Tapered roller bearing Snap ring

26 27

Thrust washer Axle shaft

13 14


30 31

Repair kit for planetary housing Washer (centring ring)

15

Locking plate

32


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12.03.9


Service Manual

Output end of the rigid axle

301 304

Axle shaft Screw plug

317 318

Planetary gear Roller bearing

306 308

Sealing ring Wheel stud

319 320

Wheel lug Sealing ring

309

Wheel hub

322

Countersunk screw

310

O-ring

323

Planetary housing

311


324

Nut

312

Snap ring

325

Stud

313

Crown gear

326

Thrust washer

314

Hollow gear carrier

327

Axle shaft

315

Locking plate

331

Washer (centring ring)

316

Snap ring

332


Note! Observe the prescribed settings and torques A, C, D, E for maintenance and repair of the axles, (see Fig. 6 on page 11) and (see Tab. 1 on page 3).

12.03.10

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Service Manual

Rigid axle 112 with multi-disc brake Output end of the rigid axle

Fig. 6

Output end of the rigid axle

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12.03.11


Service Manual

Brake of the rigid axle

7 Brake of the rigid axle

Fig. 7

12.03.12

Working brake (assembly 40)

1 2

Brake disc Adjusting screw

8 9


3

Spring

10

Counter disc

4 5

Piston Spring

11 12

Bleeder screw Plug

6 7


13 14

Pin Piston repair kit

101 102

O-ring Intermediate cover

401 402

Brake disc Adjusting screw

103 201

Housing / differential Tapered roller bearing

403 404

Spring Piston

225

Shaft nut

405

Spring

226

Allen head screw

406

Anti-extrusion ring

301

Axle shaft

407

O-ring

302 303

Washer Hex head screw

408 409


304

Screw plug

410

Counter disc

305

Screw plug

411

Bleeder screw

327

Axle shaft

412 413

Plug Pin

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Service Manual

Rigid axle 112 with multi-disc brake Brake of the rigid axle

Fig. 8

Multi-disc brake in axle shaft

Note! Observe the tightening torques B and G for the repair of the axles, see Tab. 1 page 3.

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12.03.13


Service Manual


12.03.14

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Service Manual

Differential for the axles 112 / 212 / 162 / 262 Function

Differential for the axles 112 / 212 / 162 / 262 1 Function The differential is built into the axle housing of steering and rigid axles. It transmits the output power of the transmission to the planetary drives, adjusting the speed and torque by means of bevel pinions and the crown wheel. When negotiating bends, the differential also compensates the different forces and speeds of the planetary outputs and thus the vehicle wheels.

Fig. 1

Differential of he steering and rigid axle

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12.05.1

Differential for the axles 112 / 212 / 162 / 262 Function

12.05.2

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Service Manual

Service Manual

Differential for the axles 112 / 212 / 162 / 262 General information


A 309 /311 Li 718 / 719 20221

Axle type

112 / 212 and 162 / 262

Gear ratio

14 : 32

Settings, to be observed for installation: A Setting value of the crown wheel kits 203

/ 212

B Tooth backlash of the crown wheel kit 203

/ 212

C Bearing preload of the differential bearing 201

/ 204

213 E

Torque for the hex heads screws 206 / 207 respectively

F


or 211 / 226

/ 210

G Torque for the hex head screws 217 H Torque for the nut 218 I

/ 223

Dimension on the shaft circumference of he bevel gears 203 / 212 (e.g. 118) and on the front end of the bevel gear 203 / 212 as marked (e.g. +1) 0.18 - 0.23 mm 1 - 4 Nm 120 - 170 Ncm 24 - 26 Nm 128 - 142 Nm 145 Nm 280 - 310 Nm

Torque for the shaft nut 219

500 Nm

Items A - I (see Fig. 3 on page 7) und (see Fig. 5 on page 11) Tab. 1


Note! The differential can only be dismantled, installed and repaired together with the respective axle. Please also refer to the separate repair manual 'Dana axles 112 / 212 / 162 LD / 262 LD'. Position on steering axle Position on rigid axle secured with Loctite 242

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12.05.3


Service Manual

General information

12.05.4

Assembly 10

Assembly 20

1 2

O-ring Intermediate cover

1 2

O-ring Shim 0.15 / 0.20 / 0.40 / 0.50

3

Housing

3

Bevel gear with crown wheel kit

4 5

Cover Bleeder

4 5


6 7

O-ring Plug

6 7


8

Magnetic plug

8

Hex head screw

9 10

Thrust washer Differential gear shaft wheel

Assembly 60 1 Intermediate bushing

11 12

Pin Snap ring

2 3

Stop bushing Bracket

13 14

Thrust washer Balancing shaft gears

4


15

Differential housing

5 6

Plug Bracket, complete

16 17

Tapered roller bearing Shim 0.10 / 0.15 / 0.20 / 0.30

18 19

Spacer ring Shaft nut

20 21

Sealing ring Protective plate

22

Flange

23 24

Nut Snap ring

25

Repair kit for differential

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Service Manual

Differential for the axles 112 / 212 / 162 / 262 Differential of the steering axle

3

Differential of the steering axle

Fig. 2

Exploded view of the differential (assemblies 10 and 20) and the oscillating axle bearing (assembly 60)

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12.05.5


Service Manual


101

O-ring

211

Pin

102 103

Intermediate cover Housing

212 213

Snap ring Thrust washer

104

Cover

214

Balancing shaft gears

105 106

Bleeder Sealing ring

215 216

Differential housing Tapered roller bearing

107 108

Plug Magnetic plug

217 218

Shim 0.10 / 0.15 / 0.20 / 0.30 Spacer ring

201

O-ring

219

Shaft nut

202 203

Shim 0.15 / 0.20 / 0.40 / 0.50 Bevel gear with crown wheel kit

220 221


204 205


222 223

Flange Nut

206 207


224 314

Snap ring Axle shaft

208

Hex head screw

334

Axle shaft

209 210


349

Screw plug

Note! Observe settings and torques A, B, C, D, E, F, G, H, I, K, and Tab. 1 page 3.

12.05.6

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Service Manual

Differential for the axles 112 / 212 / 162 / 262 Differential of the steering axle

4 Differential of the steering axle

Fig. 3

Sectional drawing of the differential of the steering axle

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12.05.7


Service Manual


12.05.8

Assembly 10 1 O-ring

Assembly 20 1 Tapered roller bearing

2 3


2 3

Differential housing Axle shaft wheel

4

Cover

4

Pin

5

Bleeder

5

Snap ring

7

Plug

6

Snap ring

8

Magnetic plug

7

Thrust washer

9

Snap ring

8

Balancing shaft gears

9

Thrust washer

10

Hex head screw

11 12

Allen head screw Bevel gear with crown wheel kit

13


14

Shim 0.10 / 0.15 / 0.20

15 16

Shim 0.20 / 0.40 / 0.50 O-ring

17

Hex head screw

18 19

Nut Shaft nut

20 21


22 23

Cover Spacer ring

24

O-ring

25 26

Shaft nut Allen head screw

27 28

Flange Repair kit for differential

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Service Manual

Differential for the axles 112 / 212 / 162 / 262 Differential of the rigid axle

5 Differential of the rigid axle

Fig. 4

Differential (assemblies 10 and 20)

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12.05.9


Service Manual

Differential of the rigid axle

101

O-ring

212


102 103


213 214

Tapered roller bearing Shim 0.10 / 0.15 / 0.20

104

Cover

215

Shim 0.20 / 0.40 / 0.50

105

Bleeder

216

O-ring

107

Plug

217

Hex head screw

108 109

Magnetic plug Snap ring

218 219

Nut Shaft nut

201 202

Tapered roller bearing Differential housing

220 221


203

Axle shaft wheel

222

Cover

204 205

Pin Snap ring

223 224

Spacer ring O-ring

206 207


225 226


208 209

Balancing shaft gears Thrust washer

227 304

Flange Screw plug

210

Hex head screw

319

Axle shaft

211

Allen head screw

320

Axle shaft

Note! Observe settings and torques A, B, C, D, E, F, G, H, I, (see Fig. 5 on page 11) and Tab. 1 page 3.

12.05.10

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Service Manual


Fig. 5

Sectional drawing

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12.05.11


12.05.12

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Service Manual

Service Manual

Steering axle 262 LD with multi-disc brake Function

Steering axle 262 LD with multi-disc brake 1 Function The steering axle transfers the axle load of the machine onto the drive wheels. The axle consists of the following main components: Differential and two joint housing with axle shaft, output system and brake. The differential transmits 50% of the output power of the transmission via the universal joint shafts to the planetary drives. The joint housing contains the output / wheel hub as well as the hydraulically operated wet multi-disc brake. The brake is applied when the brake pedal (working brake) is operated and the brake is pressurised with brake oil. For a detailed description of the brake system, see group 15.10. The steering cylinder (synchronised speed cylinder) built into the differential of the steering axle moves the wheels through the joint housings (steering knuckles) between the two stop positions. For a detailed description of the steering cylinder, see group 13.33. The steering cylinder is mounted directly on the undercarriage (oscillating bearing). This design compensates uneven surfaces so that all wheels of the vehicle are always in contact with the ground. During digging operation, the oscillating movement of the steering axles can be blocked by means of the two swing axle support cylinders attached to the undercarriage, see group 14.10.

Fig. 1

Steering axle 262 LD

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12.10.1


Service Manual

General information and settings

2 General information and settings Equipment Unit model Serial number

A 311-Li 718 20222

Axle type

262 / 056

Design



13.71 13.71

Brake







Friction torque of the joint housing bearing 327 / 328

30 - 60 Nm

B


10 - 30 Nm

C


D

Torque for the hex nuts 303

E


283 Nm

F


140 Nm

20 Nm 60 - 70 Nm

G


H

Setting value B for the stop screw 332 at the joint housing 327/ 328see also group 'Steering'.

I


K


L


M


148 Nm

460 Nm 1st stage 2nd stage

120 Nm 255 - 285 Nm 40 - 50 Nm 200 Nm

N

Torque for the adjusting screw 412

5 - 7 Nm

O

Torque for the adjusting screw 414

10 - 15 Nm

P


Q

Dimension X of the disc pack 415 / 416 (see Fig. 3 on page 6)

R

Testing of multi-disc brakes High pressure test, max. value There may be no visible pressure drop after 3 minutes.

128 Nm (new) Wear limit

Items A - P (see Fig. 8 on page 13), item Q (see Fig. 3 on page 6)

12.10.2

36.2 ± 1 mm

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MJF C I F S S

21.0 mm 19.2 mm 50 bar

Service Manual

Steering axle 262 LD with multi-disc brake General information and settings

Equipment Unit model Serial number

A 311-Li 718 20222

S

Tolerance between the left and the right steering stop

0.6 - 0.7 mm

T

Torque for the Allen head screw 1 at the cylinder 4, see also group 'Steering'.

116 - 128 Nm

U

Torque of the spherical end sections of the piston rod / cylinder 4 , see also group 'Steering'

240 - 270 Nm

V

Torque for the nut at the joint tie rod 5, see also group 'Steering'.

298 - 328 Nm

W

Torque for the slotted nut 6 / joint tie rods5, see also group 'Steering'.

260 - 290 Nm

Items T - W (see Fig. 7 on page 11) Tab. 1


2.1


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12.10.3


Service Manual



Power flow in the steering axle, (see Tab. 1 on page 3) The output torque of the transmission is transmitted through the universal joint shaft to the input flange of the differential. A bevel pinion and crown wheel transfer the torque via the differential housing to the balancing and axle shaft gears borne in the cage. The respective axle shaft gear transfers the torque (increased by the differential translation with pinion and crown wheel) to the joint 315 meshing with the axle shaft gear. 315 and the

344

4 Maintenance of the axle The axle must be serviced regularly at the intervals laid down in the service manual. All maintenance work must be completed according to the instructions in the operating manual. The testing of the multi-disc brake is an integral part of the maintenance; for detailed instructions, see also chapter 'Brakes' in group 15.10. Also carry out a wear check of the brake discs 416, if any of the following problems occur: – Reduced braking force – Reduced brake pressure – Changes in the oil level in the planetary drive – Unusual braking noises To do this, the axle does not have to be removed from the undercarriage. Remove the wheels from the steering axle and drain off the oil of the planetary output gear by opening the plug screw 307. Dismantle the discs for inspection as shown in the diagram below. Note For extensive dismantling and installation work concerning the multi-disc brake, we recommend referring to the repair manual for Dana planetary steering axles 262 LD.

12.10.4

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Service Manual

Steering axle 262 LD with multi-disc brake Maintenance of the axle

Fig. 2

Dismantling of the wheel hub for inspection and/or replacement of the brake discs

301

Axle shaft

347

Nut

307 327

Screw plug Right joint housing

348 349

Planetary housing Countersunk screw

328 336

Left joint housing Locking plate

353 354

Centring ring Lock washer

337-339Hollow wheel, complete 340 O-ring

404 415

O-ring Counter disc

341

Wheel hub

416

Brake disc

342 343

Sealing ring Tapered roller bearing

417 419

Cover Screw

345

Wheel lug

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12.10.5


Service Manual


4.1

Checking of discs for wear – Remove the brake discs 416 and counter discs 415 from the brake housing (joint housing 327/328 and cover 417). – Place discs in correct sequence one onto the other and check dimension X: – For nominal dimension X in new brake discs, (see Tab. 1 on page 3). – For limit dimension X in used discs, (see Tab. 1 on page 3). – If the limit value is reached or even exceeded, replace discs 415 / 416.

Fig. 3

Dimension X for brake disc wear check

Note! When installing the discs, ensure that the oil guide bores in the discs are properly aligned. Ensure that the connection to the oil filling and check bore (outer missing tooth) is not blocked when the counter disc 415 is mounted.


Dismantling of the steering axle for repair work Danger! Prior to dismantling the rigid axle, take all necessary safety measures to protect persons and machinery. Always comply with the safety instructions in the operating manual and the accident prevention regulations issued by the German Ground Construction Trade Association (TiefbauBerufsgenossenschaft). Block the wheels of the rigid axle 623 with chocks. If required, lift the front section of the undercarriage 620 and remove the vehicle wheels 622 from the steering axle. Disconnect the hydraulic lines to the steering cylinder and the brake line to the multi-disc brakes and seal the line openings (collect escaping oil). Loosen the hex nuts 611 and remove the universal joint shaft 610. Lift the undercarriage 620 and secure the steering axle 621 with suitable lifting tackle. Remove the hex head screws 608 and remove the bracket 603 and the bushings 602. Lower the steering axle 621 and pull it from the undercarriage.

12.10.6

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Service Manual

Steering axle 262 LD with multi-disc brake Dismantling, repair and installation of the steering axle

5.2

Repairs to the steering axle Note! For detailed repair instructions for the axle, refer to the separate Repair manual for Dana 262 LD axles.

5.3

Installation of the steering axle Place the steering axle 621 in the undercarriage 620, using suitable lifting gear. Check the oscillating axle bearing for proper functioning (i.e. reusability of stop bushings 602). Place the old or new stop bushings 602 and brackets 603 on the steering axle 621 and secure the steering axle 621 to the undercarriage, using the hex head screws 608. Lubricate the oscillating axle bearing at the lubrication nipple 605. Attach the universal joint shaft 610 with new self-locking nuts 611 to the differential of the steering axle 621. Connect the brake lines to the multi-disc brake and bleed the brake (see group 15.10). Connect the hydraulic lines to the steering cylinder and bleed the steering system (see group 13.20). Mount the vehicle wheels 622 . Lower the undercarriage and remove the chocks. Tighten the wheel lugs 345 with the prescribed torque, see Tab. 1.

Fig. 4

Installation of the steering wheel in the undercarriage

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12.10.7


Service Manual

Output end of the steering axle 345

Wheel lug

608

Hex head screw

354

Centring ring

610


601


611

Hex nut

602 603

Thrust bushing Bracket

620 621


604


622

Vehicle wheels

605

Plug

623

Rigid axle

6 Output end of the steering axle

Fig. 5

12.10.8

Output end of the steering axle (assembly 30)

1

Axle shaft

30

Lower steering knuckle bolt

2

Screw

31

Nut

3 4

Hex nut Hex head screw

32 33

Adjusting screw Bearing

5

Washer

34

Planetary gear

7 8

Plug Magnetic plug

35 36

Snap ring Locking plate

9 10

Snap ring Snap ring

37 38

Hollow gear carrier Crown gear

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Service Manual

Steering axle 262 LD with multi-disc brake Output end of the steering axle

11 12

Deep groove ball bearing Sealing ring

39 40

Snap ring O-ring

13 14

Intermediate bushing O-ring

41 42

Wheel hub Sealing ring

15 16

Joint Sealing ring

43 44

Tapered roller bearing Wheel stud

17

Thrust bushing

45

Wheel lug

18

Screw

46

Stud

20

Plug

47

Nut

21


48

Planetary housing

22

Upper steering knuckle bolt

49

Countersunk screw

23

Shim (S = 0.15 / 0.20 / 0.50)

50

Repair kit for planetary housing

24 26

Sealing ring Bushing

51 56

Magnetic plug Nut

27 28

Right joint housing Left joint housing

57 60

Stud Repair kit for left joint housing

29

Joint

61

Repair kit for right joint housing

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12.10.9


Service Manual

Steering axle brake

7 Steering axle brake

Fig. 6 1

Plug

12

Adjusting screw

2 3

Bleeder screw Pin

13 14

Spring Adjusting screw

4 5

O-ring O-ring

15 16

Counter disc Brake disc

6

Outer anti-extrusion ring

17

Cover

7

Piston

19

Screw

8

Inner O-ring

20

Screw plug

9 10

Inner anti-extrusion ring Counter disc

21 22

Sealing ring Screw

11

12.10.10


Spring

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Service Manual

Steering axle 262 LD with multi-disc brake Steering cylinder of the steering axle

8 Steering cylinder of the steering axle

Fig. 7

Steering cylinder in differential (assembly 50)

1 4

Allen head screw Steering cylinder, complete, see group 13.33 Steering cylinder

6 7

Slotted nut Cotter pin

5

Joint tie rod, complete

10

Differential, complete

Note! Observe torques T - W for repairs of the axle, Tab. 1 page 3.

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12.10.11


Service Manual

Steering cylinder of the steering axle 301 302

Axle shaft Screw

339 340

Snap ring O-ring

303 307

Hex nut Plug

341 342

Wheel hub Sealing ring

309

Snap ring

343


310 311

Snap ring 40 Deep groove ball bearing

344 345

Wheel stud Wheel lug

312

Sealing ring

346

Stud

313


347

Nut

314

O-ring

348

Planetary housing

315

Joint

349

Countersunk screw

316

Sealing ring

401

Plug

317 318

Thrust bushing Screw

402 403

Bleeder screw Pin

320 321

Plug Conical lubrication nipple

404 405

O-ring O-ring

322 323

Upper steering knuckle bolt Shim (S = 0.15 / 0.20 / 0.50)

406 407

Outer anti-extrusion ring Piston

324

Sealing ring

408

Inner O-ring

326 327

Bushing Right joint housing

409 410

Inner anti-extrusion ring Counter disc

328 329

Left joint housing Joint

411 412


330 331

Lower steering knuckle bolt Nut

413 414


332

Adjusting screw

415

Counter disc

333 334

Bearing Planetary gear

416 417

Brake disc Cover

335 336


419 420

Screw Screw plug

337

Hollow gear carrier

421

Sealing ring

338

Crown gear

Note! View A of sectional drawing is turned by 90°. Observe prescribed settings and torques A - P for maintenance and repair of the axles, (see Fig. 8 on page 13) and Tab. 1 page 3.

12.10.12

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Service Manual

Steering axle 262 LD with multi-disc brake Steering cylinder of the steering axle

Fig. 8

Output system and working brake of the steering axle

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12.10.13


Service Manual

Steering cylinder of the steering axle

12.10.14

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Service Manual

Rigid axle 162LD with multi-disc brake Function

Rigid axle 162LD with multi-disc brake 1 Function The rigid axle transfers the axle load of the machine onto the drive wheels. The axle consists of the following main components: Differential and two axle shafts with drive system and brake. The differential transmits 50% of the output power of the transmission via the universal joint shafts to the planetary drives of the wheel hubs. The axle shaft contains the output / wheel hub as well as the hydraulically operated wet multi-disc brake. It is pressurised and applied when the brake pedal (working brake) is operated. For a more detailed description of the brake system, see group 15.10.

Fig. 1

Rigid axle 162 LD

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12.11.1


Service Manual

Function

12.11.2

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Service Manual

Rigid axle 162LD with multi-disc brake General information


A 311-Li 718 20222

Axle type

162 / 056

Design



13.71 13.71

Brake








B


283 Nm

C


460 Nm

D


E


F


200 Nm

G


9 - 10 Nm

H


5 - 7 Nm

I


10 - 15 Nm

K


L

Dimension X of the disc pack 421 / 422 (new) (see Fig. 3 page 6) Wear limit

M

Checking of the multi-disc brakes: High pressure test, max. value There may be no visible pressure drop after 3 minutes.

10 - 30 Nm

40 - 50 Nm 1st stage 2nd stage

120 Nm 255 - 285 Nm

219 - 242 Nm 21 mm 19.2 mm 50 bar

Items A - K (see Fig. 7 page 13), item L (see Fig. 3 page 6) Tab. 1


2.1


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12.11.3


Service Manual



Power flow in the rigid axle, (see Fig. 7 page 13) The output torque of the transmission is transmitted through the universal joint shaft to the input flange of the differential. A bevel pinion and crown wheel transfer the torque via the differential case to the differential spider with balancing and axle shaft gears, which is borne in the cage. The respective axle shaft gear transfers the torque (increased by the differential translation with pinion and crown wheel) to the axle shaft 326 meshing with the axle shaft gear. The end section of the axle shaft 326 meshes with the planetary gears 315. These roll off on the stationary crown gear 311. This results in a high speed reduction and thus increased power transmission onto the planetary housing 320. The planetary housing 320 propels the wheel hub 325 and the wheel stud307, thus driving the vehicle wheels with the respective power and speed (based on the total gear ratio).

4 Maintenance of the axle The axle must be serviced regularly at the intervals laid down in the service manual. All maintenance work must be completed according to the instructions in the operating manual. The testing of the multi-disc brake is an integral part of the maintenance; for detailed instructions, see also chapter 'Brakes' in group 15.10. Also carry out a wear check of the brake discs 422, if any of the following problems occur: – Reduced braking force – Reduced brake pressure – Changes in the oil level in the planetary drive – Unusual braking noises To do this, the axle does not have to be removed from the undercarriage. Remove the wheels from the rigid axle and drain off the oil of the planetary output gear by opening the plug screw 318. Dismantle the discs for inspection as shown in the diagram below. Note For extensive dismantling and installation work concerning the multi-disc brake, we recommend referring to the repair manual for Dana planetary rigid axles 162 LD.

12.11.4

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MJF C I F S S

Service Manual

Rigid axle 162LD with multi-disc brake Maintenance of the axle

Fig. 2

Dismantling of the wheel hub for inspection and/or replacement of the brake discs

301

Axle shaft

324


306 308

Sealing ring Wheel lug

325 331

Wheel hub Centring ring

309

O-ring

332

Lock washer

406 408

Cover O-ring

310-312Hollow wheel, complete 313 Locking plate 318

Screw plug

421

Counter disc

319

Countersunk screw

422

Brake disc

320 321

Planetary housing Thrust washer

423 425

Cover Screw

322

Nut

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12.11.5


Service Manual

Maintenance of the axle

4.1

Checking of discs for wear (see Fig. 2 page 5) – – – –

422 Place discs in correct sequence one onto the other and check dimension X: For nominal dimension X in new brake discs, (see Tab. 1 page 3) For limit dimension X in used discs, (see Tab. 1 page 3) If the limit value is reached or even exceeded, replace the discs 421 / 422.

Fig. 3

406/423

Dimension X for brake disc wear check

Note! When installing the discs, ensure that the oil guide bores in the discs are properly aligned. Ensure that the connection to the oil filling and check bore is not blocked when the counter disc 421 is mounted.

12.11.6

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Service Manual

Rigid axle 162LD with multi-disc brake Dismantling, repair and installation of the rigid axle


Dismantling of the rigid axle for repair work, see Fig. 4 Danger! Prior to dismantling the rigid axle, take all necessary safety measures to protect persons and machinery. Always comply with the safety instructions in the operating manual and the accident prevention regulations issued by the German Ground Construction Trade Association (TiefbauBerufsgenossenschaft). Lift the undercarriage 600 at the front and secure the wheels of the rigid axle 604 using chocks. If required, remove the wheels 603 from the rigid axle 604. Disconnect and seal the brake line to the multi-disc brakes (collect any escaping oil). Loosen the hex head screws 615 and remove the universal joint shaft 611. Lift the undercarriage 600 and secure the rigid axle 604 with suitable lifting tackle. Remove the hex nuts 625 and the hex head screws 620 with the washer 622. Lower the rigid axle 604 and pull it from the undercarriage 600.

5.2

Repair of the rigid axle Note! For detailed repair instructions for the axle, refer to the separate Repair manual for Dana 162 LD axles.

5.3

Installation of the rigid axle after repair, see Fig. 4 Place the rigid axle 604 in the undercarriage 600, using suitable lifting gear. Secure the rigid axle 604 with the plate 630, the hex head screws 620 (with washer 622) and hex head screw 625 / hex lock nut 625 to the undercarriage 600. Attach the universal joint shaft 611 with the screws 615 to the differential of the rigid axle 604. Connect the brake lines to the multi-disc brake and bleed the brake (see group 15.10). Mount the vehicle wheels 603 . Lower the undercarriage 600 and remove the chocks. Tighten the wheel lugs 308 with the prescribed torque, see Tab. 1.

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12.11.7


Service Manual


Fig. 4

12.11.8

Dismantling and installation of the rigid axle

308

Wheel lug

611


332

Lock washer

615

Hex nut

600 602


620 622


603 604


625 630

Hex nut Plate

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Service Manual

Rigid axle 162LD with multi-disc brake Sectional drawing of the rigid axle

6 Sectional drawing of the rigid axle

Fig. 5

Output end of rigid axle (assembly 30)

1 2


18 19

Plug Countersunk screw

3 4

Washer Screw plug

20 21


5

Screw plug

22

Wheel lug

6

Sealing ring

23

Stud

7

Wheel stud

24


8 9

Wheel lug O-ring

25 26

Wheel hub Axle shaft

10

Snap ring

27

Repair kit for planetary housing

11

Crown gear

28

Stud

12 13

Hollow gear carrier Locking plate

29 30

Hex nut Sealing ring

14

Snap ring

31

Centring ring

15 16

Planetary gear Bearing

32

Lock washer

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12.11.9


Service Manual


7 Brake of the rigid axle

Fig. 6

12.11.10


1 2

O-ring Sealing ring

14 15

Spring washer Hex head screw

3 4

Screw plug Plug

16 17

Counter disc Spring

5

Bleeder screw

19

Spring

6 7

Cover Pin

20 21

Adjusting screw Counter disc

8 9

O-ring O-ring

22 23

Brake disc Cover

10

Outer anti-extrusion ring

25

Screw

11

Piston

26

Screw

12

Inner O-ring

27

Magnetic plug

13

Inner anti-extrusion ring

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Service Manual

Rigid axle 162LD with multi-disc brake Brake of the rigid axle

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12.11.11


Service Manual


102 103

Intermediate cover Differential housing

329 330

Hex nut Sealing ring

301 302


331 332

Centring ring Lock washer

303

Washer

401

O-ring

306 307

Sealing ring Wheel stud

404 405

Plug Bleeder screw

308

Wheel lug

406

Cover

309

O-ring

407

Pin

310

Snap ring

408

O-ring

311 312


409 410

O-ring Outer anti-extrusion ring

313

Locking plate

411

Piston

314 315

Snap ring Planetary gear

412 413

Inner O-ring Inner anti-extrusion ring

316 318

Bearing Plug

414 415

Spring washer Hex head screw

319

Countersunk screw

416

Counter disc

320 321


417 418


322 323

Nut Stud

419 420


324 325

Tapered roller bearing Wheel hub

421 422

Counter disc Brake disc

326

Axle shaft

423

Cover

328

Stud

425

Hex head screw

Note!

12.11.12

A-K

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Service Manual

Rigid axle 162LD with multi-disc brake Brake of the rigid axle

Fig. 7

Output system and working brake of the rigid axle

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12.11.13


Service Manual


12.11.14

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Service Manual

Steering axle Function

Steering axle 1 Function The axle housing of the steering axle, which transfers the axle load of the machine to the drive wheels, is equipped with a built-in differential mounted between the axle supports of the steering axle. The differential transmits 50% of the output power of the transmission via the universal joint shafts to the planetary drives of the double output. For a detailed description of the differential, see group 12.23. The planetary housing contains the planetary drive as well as the hydraulically operated wet multidisc brake. It is applied when the brake pedal (working brake) is operated and the brake is pressurised with brake oil. For a detailed description of the brake system, see group 15.10. The steering cylinder (synchronised speed cylinder) attached to the differential of the steering axle moves the wheels through the joint housings (steering knuckles) between the two stop positions. For a description of the steering system and the steering cylinder, see group 13.10/13.32. The steering cylinder is mounted directly on the undercarriage (oscillating bearing). This design compensates uneven surfaces so that all wheels of the vehicle are always in contact with the ground. During digging operation, the oscillating movement of the steering axles can be blocked by means of the two swing axle support cylinders attached to the undercarriage. For a detailed description of the oscillating axle support, see group 14.10 .

Fig. 1

Steering axle 262

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12.20.1

Steering axle

Service Manual

Function

12.20.2

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Service Manual

Steering axle Technical data

2 Technical data Series Machine Machine model Serial number

Litronic A 312 719 12363

Litronic A 312 719 14296

Axle type

262/51

262/53

Design


Ratio wheel hub input : total input

17.5

Brake

Wet multi-disc brake 8,2 l

Oil volume in axle Wheel hub

3,0 l

(filling level at the check screws is binding) Oil quality/viscosity

API-GL-5/SAE 90 LS


Friction torque of the joint bearing 3.26 and 3.27

B Friction torque of the wheel bearing hub 3.47

30 - 60 Nm 10 - 30 Nm

C Tightening torque of the screws 3.18

140 Nm

D Tightening torque of the countersunk screws 3.37

50 Nm

E

initial

120 Nm

final

285 Nm

F

Tightening torque of the nuts 3.18 Tightening torque of the wheel lugs 3.44

460 Nm

G Tightening torque of the nuts 3.5

122 Nm

H Tightening torque of the screws 3.6

15 Nm

I

148 Nm

Tightening torque of the nuts 3.28

K Tightening torque of the slotted nuts/tie rod 5.1

260 - 290 Nm

L

116 - 128 Nm

Tightening torque of 5.3

M Tightening torque of the tie rod 5.1 at the piston rod

240 - 270 Nm

N Tolerance between the left and the right steering stop

0,6 - 0,7 Nm

O Tightening torque of the Allen head screws 4.11 P

Check of multi-disc brakes:

53 Nm 50 bar

High pressure test, max. value No visible pressure drop after 3 minutes Q Disc wear, see “Maintenance of the axle", page 4 Disc pack 4.9/4.10

Dimension X (new)

44.85 ≥!0.75 mm

Dimension X (worn)

40.3 mm

For items A - H, O, P and Q, see see Fig. 7 Tab. 1

2.1

Technical data


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12.20.3

Steering axle

Service Manual



Power flow in the steering axle The input torque of the transmission is transmitted through the universal joint shaft to the output flange of the differential. A bevel pinion and crown wheel transfer the torque via the differential case to the differential spider with balancing and axle shaft gears, which is borne in the cage, see Fig. 7. The respective axle shaft gear transfers the torque (increased by the differential translation with pinion and crown wheel) to the double joint drive shaft 14 meshing with the axle shaft gear. The geared joint 3.14 (double joint drive shaft) drive the planetary gears 3.31. These roll off on the stationary gear 3.32. This results in a great speed reduction and associated power transmission to the rotating planetary housing 3.36. The planetary housing drives the vehicle wheels through the wheel hub 3.47 and the wheel lugs 3.45 with the respective force and speed (based on the overall gear ratio).

4 Maintenance of the axle Danger! For maintenance work on the axles, the undercarriage of the machine must be accessed. This poses a great danger for mechanics. Always adhere to the safety instructions in group 1.10 "Safe maintenance of machine". The axle must be inspected for oil level, leakage and proper fixture regularly at preset intervals, see inspection and maintenance schedule in group 3. Regularly check the wheel lugs 3.44 for the correct tightening torque, (see Tab. 1, page 3). The steering knuckle bearing must be regularly lubricated through the lubrication nipple 3.21, while the oscillating axle support bearing must be lubricated through the nipple 124, see Fig. 3 (apply 2 grease gun strokes). For intervals, see the inspection and maintenance schedule. The lubricating oil must be changed at preset intervals laid down in the inspection and maintenance schedule. As part of the maintenance work, measure the wear of the disc brake, see Fig. 2. The testing of the multi-disc brake is an integral part of the maintenance; for detailed instructions, see also chapter 'Brakes' in group 15.10.

12.20.4

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Service Manual

Steering axle Maintenance of the axle

Fig. 2 8.1

Maintenance of the axle 3.47 Wheel hub

Plug

3.2 Seal ring 3.32 Gear

4.9 Brake discs 4.10 Counter discs

3.36 Planetary housing

X

Nominal dimension/limit dimension

3.37 Countersunk screw If the braking force is reduced or if you hear unusual noises, check the brake discs 4.9 for wear of the lining. To do this, drain the oil in the planetary drives (wheel hubs). Remove the countersunk screws 3.37, pull off the planetary housing 3.36 and pull the brake discs 4.9 with the counter discs 4.10 from the gear 3.32 (observe sequence of disc for replacement!). Check the dimension X of the complete disc pack using a calliper gauge: nominal dimension X at the new brake discs = 44.85≥0.75 mm Limit dimension X at used discs = 40.3 mm If the limit dimension is reached or exceeded, replace all brake discs 4.9 and counter discs 4.10. Note! When inserting the disc pack, ensure that the discs are in the correct sequence (oil bores must be positioned so that they are aligned in axial direction with the plug 3.1 and vertically to each other. Place the planetary housing 3.36 onto the wheel hub 3.47 and tighten the screws 3.37 (tightening torque 50 Nm). Turn the wheel until the oil level mark is in horizontal position, and add oil, see (see Tab. 1, page 3) (or operating manual) through the check screw 3.1, until it reaches the lower edge of the bore.

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12.20.5

Steering axle

Service Manual

Dismantling of the steering axle for repair work

5 Dismantling of the steering axle for repair work Danger! The dismantling and installation of the steering axle requires access to the undercarriage of the machine. There is a risk of death to the technician, as limbs could become crushed. Park the machine on level ground. Secure the lifted undercarriage with suitable props. Depressurise the hydraulic system. Always adhere to the safety instructions in group 1.10 and the accident prevention regulations issued by the German Ground Construction Trade Association (Tiefbau-Berufsgenossenschaft)

Fig. 3

Dismantling and installing the steering axle

110

Steering axle

123

Bracket

111

Rigid axle

124

Lubrication nipple

112

Vehicle wheels

125

Plug

115


127

Screw

116

Hex head screw

130

Undercarriage

If required, remove the wheels 112 from the steering axle. Disconnect the hydraulic lines to the steering cylinder and the brake line to the multi-disc brakes and seal the line openings (collect escaping oil). Loosen the hex nuts 116 and remove the universal joint shaft 115. Block the wheels of the rigid axle 111 with chocks. Lift the undercarriage 130 and secure the

12.20.6

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Service Manual

Steering axle Repairs to the steering axle steering axle 110 with suitable lifting tackle. Remove the hex head screw 127 and lower the steering axle 110 together with the holder 123.

6 Repairs to the steering axle For detailed repair instructions for the axle, refer to the separate repair manual for Dana 262 axles.

7 Installation of the steering axle Place the steering axle 110 in the undercarriage, using suitable lifting gear. Check the steering axle bearing for proper functioning (i.e. reusability of stop bushings 6). Secure the steering axle 110 together with the holder 123 to the undercarriage 130, using the screw 127. Apply lubricant to the lubrication nipple 124 and then place the plug 125 onto the nipple. Secure the universal joint shaft 115 with the hex head screws 116 to the differential of the steering axle 110. Connect the brake lines to the multi-disc brake and bleed the brake (see group 15.10). Connect the hydraulic lines to the steering cylinder and bleed the steering system. For detailed instructions, see group 13.10/13.20/13.32. Mount the vehicle wheels 112.

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12.20.7

Steering axle

Service Manual

Exploded view of the steering axle

8 Exploded view of the steering axle

Fig. 4

12.20.8

Output

1 3

Differential, see group 12.23 Output, complete

3.26 Joint housing 3.27 Joint housing

3.1

Plug

3.28 Nut

3.2

Seal ring

3.29 Stop screw

3.3

Disc

3.30 Bearing

3.4 3.5

Hex head screw Nut

3.31 Planetary gear 3.32 Gear

3.6 3.7

Screw Outer race

3.33 Hollow gear carrier 3.34 Control oil unit

3.8

Snap ring

3.35 Bearing

3.9

Snap ring

3.36 Planetary housing

3.10 Deep groove ball bearing

3.37 Countersunk screw

3.11 Seal ring 3.12 Intermediate bushing

3.38 Nut 3.39 Locking plate

3.13 O-ring

3.40 Stud

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Service Manual

Steering axle Exploded view of the steering axle

3.14 Joint 3.15 Seal ring

3.41 Snap ring 3.42 Bearing

3.16 Bearing

3.43 O-ring

3.17 Steering knuckle bolt

3.44 Nut

3.18 Screw 3.19 Cover

3.45 Wheel stud 3.47 Wheel hub

3.20 Plug

3.48 Seal ring

3.21 Conical lubrication nipple

3.49 Magnetic plug

3.22 Shim ring

3.52 Centring ring

3.23 Dust sealing ring 3.24 Spacer ring

3.53 Lock washer 3.54 Spacer ring

3.25 Steering knuckle bolt

Fig. 5

Brake

3.26 Joint shaft, left / output

4.11 Allen head screw

3.27 Joint shaft, right / output 3.32 Gear

4.12 Brake disc 4.13 Spring

3.33 Hollow gear carrier, see Fig. 4 4 Brake, complete

4.14 Adjusting screw 4.16 Pin

4.1

Bleeder screw

4.17 O-ring

4.2

Plug

4.18 Seal ring

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12.20.9

Steering axle

Service Manual

Exploded view of the steering axle 4.8 4.9

4.19 Screw plug 4.20 Piston repair kit

Ring Brake disc

4.10 Counter disc

Fig. 6

12.20.10

Steering cylinder

1

Differential, complete, see page 12.23-05 5.2

5 5.1

Steering cylinder, complete Joint tie rod

5.3

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Cylinder Allen head screw

Service Manual

Steering axle Sectional drawing of steering axle

9 Sectional drawing of steering axle

Fig. 7

Steering axle with disc brake

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12.20.11

Steering axle

Service Manual

Sectional drawing of steering axle 1

Differential, see group 12.23

3.31

Planetary gear

3 3.1

Output, complete Plug

3.32 3.33

Gear Hollow gear carrier

3.2

Seal ring

3.34

Axle shaft

3.3

Disc

3.35

Bearing

3.4

Hex head screw

3.36

Planetary housing

3.5 3.6

Nut Screw

3.37 3.38

Countersunk screw Nut

3.7 3.8

Outer race Snap ring

3.39 3.40

Locking plate Stud

3.9 3.10

Snap ring Deep groove ball bearing

3.41 3.42

Snap ring Bearing

3.11

Seal ring

3.43

O-ring

3.12 3.13


3.44 3.45

Nut Wheel stud

3.14 3.15

Joint Seal ring

3.47 3.48

Wheel hub Seal ring

3.16

Bearing

3.49

Magnetic plug

3.17

Steering knuckle bolt

3.52

Disc

3.18

Screw

3.53

Spacer ring

3.19 3.20

Cover Plug

4.1 4.2

Bleeder screw Plug

3.21 3.22

Conical lubrication nipple Shim ring

4.8 4.9

Ring Brake disc

3.23

Dust sealing ring

4.10

Counter disc

3.24 3.25

Spacer ring Steering knuckle bolt

4.11 4.12

Allen head screw Brake disc

3.26 3.27

Joint housing Joint housing

4.14 4.17

Adjusting screw O-ring

3.28 3.29

Nut Stop screw

4.20

Piston repair kit

3.30

Joint housing

Note! For settings and torques A, B, C, D, E, F, G, H, O, P, Q for the maintenance and repair of the axle, see Fig. 7 and “Technical data", page 3.

12.20.12

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Service Manual

Rigid axle Function

Rigid axle 1 Function The rigid axle is permanently screwed to the undercarriage. The axle housing of the rigid axle, which transfers the axle load of the machine to the drive wheels, is equipped with a built-in differential mounted between the axle supports of the axle. The differential transmits 50% of the output power of the transmission via the axle shafts to the planetary drives of the output units. For a detailed description of the differential, see group 12.23. The output unit contains the planetary output as well as the hydraulically operated wet multi-disc brake. It is applied when the brake pedal (working brake) is operated and the brake is pressurised with brake oil. For a detailed description of the brake system, see group 15.10.

Fig. 1

Rigid axle 162

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12.21.1

Rigid axle

Service Manual

Technical data


Litronic A 312 719 12363

Axle type

162/55

Design


Ratio wheel hug input : total input

17.5/6.0

Brake

West multi-disc brake

Oil volume in axle

Axle support/ differential/wheel hub

total 10.5. l

(filling level at the check screws is binding) Oil quality/viscosity

API-GL-5/SAE 90 LS

Settings and tightening torques to be observed for installation: A Friction torque of the wheel bearing (cover 3.10

130 - 180 Nm

B Tightening torque for the Allen head screws 3.8

220 - 240 Nm

C Tightening torque for the wheel lugs 3.13

460 Nm

D Tightening torque for the hex head screws 3.28

280 - 310 Nm

E

Tightening torque for the readjusting screws 4.4

10 - 15 Nm

F

Tightening torque for the readjusting screws 4.10

5 - 7 Nm

G Check of multi-disc brakes: High pressure test, max. value

50 bar

No visible pressure drop after 3 minutes H Disc wear, see “Maintenance of the axle", page 3 Disc pack 4.1/4.2

Dimension X (new)

44.85 ≥!0.75 mm

Dimension X (worn)

40.3 mm

For items A - F and H, see see Fig. 6 Tab. 1

2.1

Technical data


12.21.2

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Service Manual

Rigid axle Functional description


Power flow in the rigid axle See also sectional drawing Fig. 6 and drawing on page 12.23-11. The input torque of the transmission is transmitted through the universal joint shaft to the output flange of the differential. A bevel gear and crown wheel transfer the torque via the differential housing to the differential spider with balancing and axle shaft gears, which is borne in the differential housing. The respective axle shaft gear transfers the torque (increased by the differential translation with pinion and crown wheel) to the axle shaft meshing with the axle shaft gear. The geared axle shaft 3.19 drives the planetary gears 3.14. These roll off on the stationary gear 3.18. This results in a great speed reduction and associated power transmission to the rotating cover 3.10 (planetary housing). The COVER drives the vehicle wheels through the wheel hub 3.2 and the wheel lugs 3.12 with the respective force and speed (based on the overall gear ratio).

4 Maintenance of the axle

Danger! For maintenance work on the axles, the undercarriage of the machine must be accessed. This poses a great danger for mechanics. Always adhere to the safety instructions in group 1.10 "Safe maintenance of machine". The axle must be inspected for oil level, leakage and proper fixture regularly at preset intervals, see inspection and maintenance schedule in group 3. Regularly check the wheel lugs 3.13 for the correct tightening torque, (see Tab. 1 on page 2). The lubricating oil must be changed at preset intervals laid down in the inspection and maintenance schedule. The testing of the multi-disc brake is an integral part of the maintenance; for detailed instructions, see also chapter 'Brakes' in group 15.10.

Fig. 2


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12.21.3

Rigid axle

Service Manual

Dismantling of the rigid axle for repair work 8.2

Wheel hub

3.28 Hex head screw

3.4 3.9

Magnetic plug Spring washer

4.1 4.2

Brake discs Counter discs

X

Nominal dimension/limit dimension

3.10 Cover 3.20 Axle shaft

If the braking force is reduced or if you hear unusual noises, check the brake discs 4.1 for wear of the lining. For this purpose, drain the oil from the planetary gear through the magnetic plug 3.4. Remove the hex head screws 3.28 and lift of the cover 3.10 together with the wheel hub 3.2. Pull the brake discs 4.1 with the counter discs 4.2 from the axle shaft 3.20 (observe sequence of discs for possible replacement!). Check the nominal dimension X of the complete disc pack using a calliper gauge: nominal dimension X at the new brake discs = 44.85≥0.75 mm Limit dimension X at used discs = 40.3 mm If the limit dimension is reached or exceeded, replace all brake discs 4.9 and counter discs 4.10. Note! When inserting the disc pack in the cover 3.10, ensure that the discs are in the correct sequence.

Place the cover 3.10 with the wheel hub 3.2 on the axle shaft 3.20 and screw in the screws 3.28 with the spring washers 3.9 (tightening torque 280 - 310 Nm). Add prescribed oil (see “Tyre pressure", page 2 (or operating manual) at the oil filling opening (plug 3.5, see Fig. 4)) until it reached the lower edge of the bore. .

5 Dismantling of the rigid axle for repair work

Danger! The dismantling and installation of the rigid axle requires access to the undercarriage of the machine. There is a risk of death to the technician, as limbs could become crushed. Park the machine on level ground. Secure the lifted undercarriage with suitable props. Depressurise the hydraulic system. Always adhere to the safety instructions in group 1.10 and the accident prevention regulations issued by the German Ground Construction Trade Association (Tiefbau-Berufsgenossenschaft)

12.21.4

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MJF C I F S S

Service Manual

Rigid axle Repair of the rigid axle

Fig. 3

Dismantling and installing the rigid axle

110 111

Steering axle Rigid axle

117 127


112 115

Vehicle wheels Universal joint shaft

128 129

Nut Washer

116

Hex head screw

130

Undercarriage

If required, remove the vehicle wheels 112 from the rigid axle. Disconnect and seal the brake line to the multi-disc brakes (collect any escaping oil). Loosen the hex head screws 116 and remove the universal joint shaft 115. Block the wheels of the steering axle 110 with chocks. Lift the undercarriage 130 and secure the rigid axle 111 with suitable lifting tackle. Remove the hex head nuts 128 and the screws 127 and then remove the rigid axle 111 from the undercarriage 130.

6 Repair of the rigid axle For detailed repair instructions for the axle, refer to the separate repair manual for Dana 162 axles.

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12.21.5

Rigid axle

Service Manual

Installation of the rigid axle

7 Installation of the rigid axle Place the rigid axle 111 below the undercarriage and lift it. Secure the rigid axle with the hex head screws 127 and the nuts 128 to the undercarriage (tightening torque 560 Nm); lock the nuts 128. Secure the universal joint shaft 115 with the hex head screws 116 to the differential of the rigid axle 111. Connect the brake lines to the multi-disc brake and bleed the brake (see group 15.10). Mount the vehicle wheels 112.

12.21.6

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Service Manual

Rigid axle Exploded view of the rigid axle

8 Exploded view of the rigid axle

Fig. 4

Output

1 3

Differential, see group 12.23 Output, complete

3.16 Bearing 3.17 Snap ring

3.1

Planetary housing

3.18 Gear

3.2 3.3

Wheel hub Bearing

3.19 Axle shaft 3.20 Axle shaft

3.4

Magnetic plug

3.21 Hex head screw

3.5

Plug

3.22 Washer

3.6 3.7


3.23 Pin 3.24 Seal ring

3.8

Allen head screw

3.25 Plug washer

3.9 Spring washer 3.10 Cover

3.26 Plug 3.27 Bleeder screw

3.11 Seal ring

3.28 Hex head screw

3.12 Wheel stud

3.29 Thrust washer

3.13 Wheel lug

3.33 Centring ring

3.14 Planetary gear

3.34 Lock washer

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MJF C I F S S

12.21.7

Rigid axle

Service Manual

Exploded view of the rigid axle 3.15 Washer

Fig. 5

12.21.8

Brake

3.10 Cover, see Fig. 4

4.6

Piston

4 4.1

Brake, complete Brake disc

4.7 4.8

O-ring Ring

4.2 4.3

Counter disc Ring

4.9 Spring 4.10 Adjusting screw

4.4 4.5

Adjusting screw Spring

4.11 O-ring

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MJF C I F S S

Service Manual

Rigid axle Sectional drawing of the rigid axle


Fig. 6


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MJF C I F S S

12.21.9

Rigid axle

Service Manual

Sectional drawing of the rigid axle 3

Output, complete

3.22

Washer

3.1 3.2

Planetary housing Wheel hub

3.23 3.24

Pin Seal ring

3.3

Bearing

3.25

Screw plug

3.4

Magnetic plug

3.26

Plug

3.5

Plug

3.27

Bleeder screw

3.6 3.7


3.28 3.29

Hex head screw Thrust washer

3.8 3.9

Allen head screw Spring washer

3.33 3.34

Centring ring Lock ring

3.10 3.11

Cover Seal ring

4 4.1

Brake, complete Brake disc

3.12

Wheel stud

4.2

Counter disc

3.13 3.14

Nut Planetary gear

4.3 4.4

Ring Adjusting screw

3.15 3.16

Washer Bearing

4.5 4.6

Spring Piston

3.17

Snap ring

4.7

O-ring

3.18

Gear

4.8

Ring

3.19

Axle shaft

4.9

Spring

3.20 3.21


4.10 4.11

Adjusting screw O-ring

Note! For settings and torques A, B, C, D, E, F, H for the maintenance and repair of the axle, see Fig. 6 and (see Tab. 1 on page 2).

12.21.10

copyright by

MJF C I F S S

Service Manual

Differential for 162 / 262 axles Function

Differential for 162 / 262 axles 1 Function The differential is built into the axle housing of steering and rigid axles. It transmits the output power of the transmission to the planetary drives, adjusting the speed and torque by means of bevel pinions and the crown wheel. When negotiating bends, the differential also compensates the different forces and speeds of the planetary outputs and thus the vehicle wheels.

Fig. 1

Differential of the steering and rigid axle

copyright by

MJF C I F S S

12.23.1


Service Manual

Function

12.23.2

copyright by

MJF C I F S S

Service Manual

Differential for 162 / 262 axles Technical data

2 Technical data Machine Machine model Serial number

A 312 Li 719 12363

Axle type

162/51 and 262/51

Gear ratio

12 : 35

Settings to be observed for installation: A Setting value of the crown wheel kits 203

/212

B Tooth backlash of the crown wheel kit 203

/ 212

C Bearing preload of the differential bearing 201 (through nut 205 / 225 )

Torque for the hex heads screws 206 / 207 respectively

F


0.13 - 0.18 mm

/ 204

D Rolling resistance of the input pinion bearing 213 216 (increase or reduce shim thickness by 0.01 mm) E

Dimension on the shaft circumference of he bevel gears 203 / 212 (e.g. 118) and on the front / end of the bevel gear 203 212 as marked (e.g. +1)

/

or 211 / 226

/ 210

1 - 4 Nm

120 - 170 Ncm (+ / -) 60 Ncm 24 - 26 Nm 128 - 142 Nm

G Torque for the hex head screws 217

90 - 100 Nm

H Torque for the nut 218

280 - 310 Nm

I

/ 223

Torque for the shaft nut 219

500 - 570 Nm

Items A - I (see Fig. 3 on page7) and (see Fig. 5 on page11) Tab. 1


Note! The differential can only be dismantled, installed and repaired together with the respective axle. Please also refer to the separate repair manual "162 / 262 Dana axles" Position on steering axle Position on rigid axle secured with Loctite 242

copyright by

MJF C I F S S

12.23.3


Service Manual

Exploded view of the differential of the steering axle

3

12.23.4

Exploded view of the differential of the steering axle Assembly 10 1 O-ring

Assembly 20 1 O-ring

2

Intermediate cover

2

Shim 0.15 / 0.20 / 0.40 / 0.50 mm

3 4

Housing Lid

3 4

Bevel gear with crown wheel kit Tapered roller bearing

5

Bleeder

5

Shaft nut

6

Seal ring

6

Allen head screw

7

Plug

7

Allen head screw

8

Magnetic plug

8

Hex head screw

9

Thrust washer

Assembly 60

10 11

Differential gear shaft wheel Pin

1 2

Intermediate bushing Thrust bushing

12 13


3 4

Support bracket Conical lubrication nipple

14 15

Balancing shaft gear Differential housing

5

Plug

16


6

Bracket, complete

17 18

Shim 0.10 / 0.15 / 0.20 / 0.30 mm Spacer ring

19 20

Shaft nut Seal ring

21 22

Protective plate Flange

23

Nut

24 25

Snap ring Repair kit for differential

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Service Manual

Differential for 162 / 262 axles Exploded view of the differential of the steering axle

Fig. 2

Exploded view of the differential (assemblies 10 and 20) and the oscillating axle bearing (assembly 60)

copyright by

MJF C I F S S

12.23.5


Service Manual

Exploded view of the differential of the steering axle

4 Exploded view of the differential of the steering axle 101

O-ring

211

Pin

102 103


212 213


104

Lid

214

Balancing shaft gear

105

Bleeder

215


106

Seal ring

216


107 108

Plug Magnetic plug

217 218

Shim 0.10 / 0.15 / 0.20 / 0.30 mm Spacer ring

201

O-ring

219

Shaft nut

202 203

Shim 0.15 / 0.20 / 0.40 / 0.50 mm Bevel gear with crown wheel kit

220 221

Seal ring Protective plate

204 205


222 223

Flange Nut

206 207


224 314

Snap ring Axle shaft

208

Hex head screw

334

Axle shaft

209 210


349

Screw plug

Note! Observe settings and torques A, B, C, D, E, F, H, I and Table 1, page 3.

12.23.6

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MJF C I F S S

Service Manual

Differential for 162 / 262 axles Exploded view of the differential of the steering axle

Fig. 3

Sectional drawing of the differential of the steering axle

copyright by

MJF C I F S S

12.23.7


Service Manual

Exploded view of the differential of the rigid axle

5

12.23.8

Exploded view of the differential of the rigid axle Assembly 10 1 O-ring

Assembly 20 1 Tapered roller bearing

2

Intermediate cover

2


3 4

Housing Lid

3 4

Axle shaft wheel Pin

5

Bleeder

5

Snap ring

7

Plug

6

Snap ring

8

Magnetic plug

7

Thrust washer

9

Snap ring

8


9

Thrust washer

10 11

Hex head screw Allen head screw

12 13

Bevel gear with crown wheel kit Tapered roller bearing

14 15

Shim 0.10 / 0.15 / 0.20 mm Shim 0.20 / 0.40 / 0.50 mm

16

O-ring

17 18

Hex head screw Nut

19 20

Shaft nut Seal ring

21 22

Protective plate Lid

23

Spacer ring

24 25

O-ring Shaft nut

26 27

Allen head screw Flange

28

Repair kit for differential

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MJF C I F S S

Service Manual

Differential for 162 / 262 axles Exploded view of the differential of the rigid axle

Fig. 4

Differential (assemblies 10 and 20)

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MJF C I F S S

12.23.9


Service Manual

Sectional drawing of the differential of the rigid axle

6 Sectional drawing of the differential of the rigid axle 101

O-ring

212


102

Intermediate cover

213


103

Housing

214

Shim 0.10 / 0.15 / 0.20 mm

104

Lid

215

Shim 0.15 / 0.20 / 0.40 / 0.50 mm

105 107

Bleeder Plug

216 217

O-ring Hex head screw

108 109

Magnetic plug Snap ring

218 219

Nut Shaft nut

201


220

Seal ring

202 203

Differential housing Axle shaft wheel

221 222

Protective plate Lid

204 205

Pin Snap ring

223 224

Spacer ring O-ring

206 207


225 226


208


227

Flange

209 210

Thrust washer Hex head screw

304 319

Screw plug Axle shaft

211

Allen head screw

320

Axle shaft

Note! Observe settings and torques A, B, C, D, E, F, G, H, I, (see Fig. 5 on page11) and Table 1, page 3.

12.23.10

copyright by

MJF C I F S S

Service Manual

Differential for 162 / 262 axles Sectional drawing of the differential of the rigid axle

Fig. 5


copyright by

MJF C I F S S

12.23.11


Service Manual


12.23.12

copyright by

MJF C I F S S

Service Manual

APL - B 745 steering axle with multi-disc brake Function

APL - B 745 steering axle with multi-disc brake 1 Function The axle housing of the steering axle, which transfers the axle load of the machine to the drive wheels, is equipped with a built-in differential. The differential transmits 50% of the output power of the transmission via the universal joint shafts to the planetary drives of the wheel hubs. For a detailed description of the differential, see group 15.31. Due to the technical design combining a high planetary gear ratio in the wheel hub with a small bevel gear ratio in the differential, the differential is very compact, providing for great ground clearance. The wheel hub contains the planetary drive as well as the hydraulically operated wet multi-disc brake. It is pressurised and applied when the brake pedal (working brake) is operated. For a more detailed description of the brake system, see group 15.10. The steering cylinder (synchronised speed cylinder) built into the differential of the steering axle moves the wheels through the joint housings (steering knuckles) between the two stop positions. For a detailed description of the steering cylinder, see group 13.34. The steering cylinder is mounted directly on the undercarriage (oscillating bearing). This design compensates uneven surfaces so that all wheels of the vehicle are always in contact with the ground. During digging operation, the oscillating movement of the steering axles can be blocked by means of the two swing axle support cylinders attached to the undercarriage, see group 14.10.

Fig. 1

APL - B 745 steering axle

copyright by

MJF C I F S S

12.28.1


12.28.2

copyright by

MJF C I F S S

Service Manual

Service Manual

APL - B 745 steering axle with multi-disc brake Technical data


A 314 Litronic 635 2001

Axle type

A 314 Litronic 635 11308

APL - B 745

Design


Gear ratio Standard Speeder

17,52 17,52

Brake

16,62 16,62


Oil volume in axle Axle housing Planetary drive (filling level at the check screws is binding) Oil quality/viscosity

7.5 l 0.7 l per side API - GL 5 / SAE 90 LS

Settings, to be observed for installation: A

End play of the double joint drive shaft 20

0.3 - 0.6 mm

B

Clearance of the disc pack 83 / 84 (piston stroke) new at max. wear

2.5 - 2.9 mm 5.0 mm

C

Rolling resistance of the joint housing bearing 35

40 - 50 Nm

D

Rolling resistance of the wheel bearing 61/64 (new)

8 - 12 Nm

E

Torque for the slotted nut 32

F


280 Nm

G


11 Nm

H

Torque for the Allen head screws 103

32 Nm

I


420 Nm

Tightening torque of the slotted nut / tie rods, see steering cylinder

300 Nm

K

1550 + 500 Nm

Multi-disc brakes: High pressure test, max. value Max. pressure drop after 5 min. Low pressure test Visible pressure drop after 15 seconds is not permissible

120 bar 3 bar 5 bar

Items A - K, (see Fig. 7, page 11) Tab. 1

2.1

Technical data


copyright by

MJF C I F S S

12.28.3

APL - B 745 steering axle with multi-disc brake

Service Manual



Power flow in the steering axle, (see Fig. 7, page 11) The input torque of the transmission is transmitted through the drive shaft to the output flange of the differential. A bevel pinion and crown wheel transfer the torque via the differential case to the differential spider with balancing and axle shaft gears, which is borne in the cage. The respective axle shaft gear transfers the torque (increased by the differential translation with pinion and crown wheel) to the double joint drive shaft 20 meshing with the axle shaft gear. The sun gear shaft 91, which is connected through the disc carrier 92 to the double joint drive shaft 20, drives the planetary gears 95. These roll off on the stationary hollow gear 68. This results in a great speed reduction and associated power transmission to the rotating planetary carrier 94. The planetary carrier 94 drives the vehicle wheels through the wheel studs 104 with the respective force and speed (based on the overall gear ratio).

4 Maintenance of the axle Danger! For maintenance work on the axles, the undercarriage of the machine must be accessed. This poses a great danger for mechanics. Always adhere to the safety instructions in group 1.10 "Safe maintenance of machine". The axle must be serviced at the intervals laid down in the inspection and maintenance schedule, see group 3. Regularly check the wheel lugs 107 for the correct tightening torque, (see Tab. 1, page 3). The oscillating axle bearing of the steering knuckle bearing must be lubricated and lubricating oil must be changed at fixed intervals laid down in the inspection and maintenance schedule. The testing of the multi-disc brake is an integral part of the maintenance; for detailed instructions, see also chapter "Brakes" in group 15.10. The manufacturer also prescribes an annual inspection of the disc lining for wear, see Fig. 2. The above check must be carried out annually, or if one of the following problems arise: – Reduced braking force – Reduced brake pressure – Changes in the oil level in the wheel hub – Unusual braking noises

Measuring of brake lining wear Turn the wheel hub until the small screw plug M16 is at the top. Apply working brake to the stop. Remove the screw plug and screw in the measuring plug M16 (tool ID no. 7019556) to the stop; tighten it with 10 Nm. Measure and write down distance X from the screw head to the plane recess at the planetary carrier, see Fig. 2. Release the brake, turn the measuring screw further in and tighten it again with 10 Nm. Measure and write down the dimension Y from the screw head to the p plane recess at the planetary carrier. Calculate the difference between the two measurements "X" – "Y". This value corresponds to the piston stroke.

12.28.4

copyright by

MJF C I F S S

Service Manual

APL - B 745 steering axle with multi-disc brake Dismantling, repair and installation of the steering axle

Note! Limit value for piston stroke with wear = 5.0 mm If the actual value exceeds the permissible limit value, replace the entire brake disc pack.

Fig. 2

A = screw plug M 16; B = measuring screw M 16


Dismantling of the steering axle for repair work Danger! The dismantling and installation of the steering axle requires access to the undercarriage of the machine. There is a risk of death to the technician, as limbs could become crushed. Park the machine on level ground. Secure the lifted undercarriage with suitable props. Depressurise the hydraulic system. Always adhere to the safety instructions in group 1.10 and the accident prevention regulations issued by the German Ground Construction Trade Association (Tiefbau-Berufsgenossenschaft) Lift the undercarriage 5 at the front and secure the wheels of the rigid axle 12 using chocks. If required, remove the wheels 1 from the steering axle. Disconnect the hydraulic lines to the steering cylinder and the brake line to the multi-disc brakes and seal the line openings (collect escaping oil). Loosen the hex head screws 2 and remove the universal joint shaft 3. Secure the steering axle 4 with suitable lifting tackle. Loosen the hex head screw 6 and remove the universal joint shaft 13 (old bearing). Remove the hex head screws 6, the retaining washers 14 and the plate 7 (new bearing). Drive out the pin 8 (do not damage the washer 9) and lower the steering axle 4.

copyright by

MJF C I F S S

12.28.5


Service Manual


5.2

Repairs to the steering axle Note! For detailed repair instructions for the axle, refer to the separate "Repair manual for APL-B 745 ZP axles".

5.3

Installation of the steering axle Insert the steering axle 4 into the undercarriage 5, using suitable lifting tackle. Insert the washers 9 and drive in pin 8. Loosen the hex head screw 6 and screw in the universal joint shaft 13 (old bearing). Secure the plate 7 using the hex head screws 6 and the retaining washers 14 (new bearing). Lubricate the steering axle bearing at the lubrication nipple 10. Secure the universal joint shaft 3 with the screws 2 to the differential of the steering axle 4. Connect the brake lines to the multi-disc brake and bleed the brake (see group 15.10). Connect the hydraulic lines to the steering cylinder and bleed the steering system (see group 13.20). Mount the vehicle wheels 1. Lower the undercarriage and remove the chocks. Tighten the wheel lugs with the prescribed torque, see Tab. 1.

Fig. 3

12.28.6

Undercarriage with axles

1

Vehicle wheels

8

Bolt

2 3

Hex head screw Joint shaft

9 10

Spacer Lubrication nipple

4

Steering axle

11

Lock nut

5

Undercarriage

12

Rigid axle

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Service Manual

APL - B 745 steering axle with multi-disc brake Exploded view of the steering axle

6 7

13 14

Hex head screw Plate

Disc Retaining washer


Fig. 4

Steering axle (assembly 17)

.10

Axle housing

.290

Stub shaft

.30

Axle housing

.330

Snap ring

.40

Bearing bushing

.340

Bushing

.50 .90

Washer (S = 0.5 - 2.0mm) Roller bearing

.350 .550

Radial shaft seal ring Left tie rod

.100 .120

Roller bearing O-ring

.560 .600

Right tie rod Axial joint

.130 .140

Hex head screw Disc

.605 .610

Bellows Right ball joint, complete

.150

Fit bolt

.611

Left ball joint, complete

.240 .250


.620 .630

Clamp Slotted nut

.260

O-ring

.640

Cotter pin

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MJF C I F S S

12.28.7


Service Manual


Fig. 5 .10

12.28.8

Joint housing (assembly 18) Left joint housing

.130

Lubrication nipple

.10

Right joint housing

.150

Bushing

.10 .50

Slotted nut Roller bearing

.160 .170

Radial shaft seal ring Universal joint

.80 .90

Sealing cap O-ring

.200 .270

Snap ring Plug

.100

Washer (S = 1.2 - 2.0mm)

.390

Bleeder valve

.114 .120

Bearing pin Hex head screw

.480 .500

Stop washer (S = 2.0 - 6.0 mm) Stop screw

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MJF C I F S S

Service Manual


Fig. 6

Output (assembly 19)

.10 .30

Radial shaft seal ring Roller bearing

.290 .300

End washer Snap ring

.40 .50

Ring (S = 14.0 - 15.0 mm) Roller bearing

.320 .340

Thrust washer Sun gear shaft

.80

Hub

.350

Disc carrier

.90 .120

O-ring Plug

.360 .370

Snap ring Snap ring

.130 .140

O-ring Junk ring

.390 .400

Planetary carrier Planetary gear

.150 .160

Snap ring Hollow gear

.410 .420

Roller bearing Junk ring

.200

Piston

.430

Snap ring

.210 .214

Lip seal Backing ring

.480 .490

Thrust washer (S = 2.0 – 3.0 mm) O-ring

.220 .230


.500 .510

Screw plug (oil drainage) Allen head screw

.232 .238

Backing washer Pressure spring

.540 .550

Wheel stud Lock washer

.248

Lock nut

.560

Centring ring

.256 .258

Hex head screw Spring sleeve

.570 .620

Wheel lug Screw plug (measuring bore)

.270

Outer disc (S = 2.0 – 3.0 mm)

.630

O-ring

.280

Inner disc

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MJF C I F S S

12.28.9


Service Manual

Exploded view of the steering axle Item

ZP figure no.

Description

Item

ZP figure no.

Description

1

17010

Axle housing

76

19230

Backing ring

8

17340

Bushing

77

19232

Back-up washer

9

17350


78

19258

Spring sleeve

10

18160


79

19238

Pressure spring

20

18170

Double joint drive shaft

81

19256

Hex head screw

31

18010

Right joint housing

82

19248

Lock nut

32

18010

Slotted nut

83

19270

Outer disc

35

18050

Roller bearing

84

19280

Inner disc

37

18080

Sealing cap

85

19290

End washer

38

18090

O-ring

86

19150

Snap ring

39

18100

Washer

87

19320

Thrust washer

40

18114

Bearing pin

91

19340

Sun gear shaft

41

18120

Hex head screw

92

19350

Disc carrier

42

18130

Lubrication nipple

93

19300

Snap ring

43

18150

Bushing

94

19390

Planetary carrier

44

18114

Bearing pin

95

19400

Planetary gear

45

18390

Bleeder valve

96

19410

Roller bearing

60

19010


97

19420

Junk ring

61

19030

Roller bearing

98

19430

Snap ring

62

19080

Hub

99

19480

Thrust washer

63

19090

O-ring

103

19510

Allen head screw

64

19050

Roller bearing

104

19540

Wheel stud

65

19130

O-ring

105

19550

Lock washer

66

19140

Junk ring

106

19560

Centring ring

68

19160

Hollow gear

107

19570

Wheel lug

71

19040

Ring

108

19370

Snap ring

72

19200

Piston

109

19360

Snap ring

73

19210

Lip seal

110

17330

Snap ring

74

19214

Backing ring

111

17290

Stub shaft

75

19220

Lip seal

Note! Observe settings and torques A, B, C, D, E, F, G, H, I, K, see Fig. 7 and Table 1, page 3.

12.28.10

copyright by

MJF C I F S S

Service Manual

APL - B 745 steering axle with multi-disc brake Sectional drawing of steering axle


Fig. 7

Sectional drawing of steering axle(see Fig. 7, page 11)

copyright by

MJF C I F S S

12.28.11


12.28.12

copyright by

MJF C I F S S

Service Manual

Service Manual

AP - B 745 rigid axle with drum brake Function

AP - B 745 rigid axle with drum brake 1 Function The axle housing of the rigid axle, which transfers the axle load of the machine to the drive wheels, is equipped with a built-in differential. The differential transmits 50% of the output power of the transmission via the universal joint shafts to the planetary drives of the wheel hubs. For a detailed description of the differential, see group 12.31. Due to the technical design combining a high planetary gear ratio in the wheel hub with a small bevel gear ratio in the differential, the differential is very compact, providing for great ground clearance. The wheel hub contains the planetary drive as well as the hydraulically operated drum brake. It is applied when the brake pedal (working brake) is operated and the brake is pressurised with brake oil.

Fig. 1


copyright by

MJF C I F S S

12.29.1


Service Manual

Technical data


A 314 Li 635 2001

Axle type

A 314 Li 635 11308

AP-B 745

Design



17,52 17,52

Brake

16,62 16,62

Drum brake

Oil volume in axle Axle housing and planetary drive (filling level at the check screws is binding) Oil quality/viscosity

10.4 l API - GL 5 / SAE 90 LS

Settings, to be observed for installation: A

End play of the stub shaft 7 with sun gear shaft 91

0.4 - 2.0 mm

B

Rolling resistance of the wheel bearing 61/64 (new) (without sealing element)

8 - 12 Nm

C


560 Nm

D


79 Nm

E

Torque for the Allen head screws 27/28

280 Nm

F

Torque for the hex nut 31

1400 + 200 Nm

G

Torque for the self locking screw 87

69 Nm

H


33 Nm

I


420 Nm

K

Check of drum brakes 20: Residual lining thickness of the brake system (glued) min.

2 mm

Items A, B, D- K (see Fig. 6, page 9) and item C (see Fig. 2, page 4) Tab. 1

2.0.1

Technical data


12.29.2

copyright by

MJF C I F S S

Service Manual

AP - B 745 rigid axle with drum brake Functional description


Power flow in the rigid axle, see Fig. 6 The input torque of the transmission is transmitted through the universal joint shaft to the output flange of the differential. A bevel pinion and crown wheel transfer the torque via the differential case to the differential spider with balancing and axle shaft gears, which is borne in the cage. The respective axle shaft gear transfers the torque (increased by the differential translation with pinion and crown wheel) to the stub shaft 7 meshing with the axle shaft gear. The sun gear shaft 91, which is connected through the sleeve 8 to the stub shaft 7, drives the planetary gears 95. These roll off on the stationary hollow gear 68. This results in a great speed reduction and associated power transmission to the rotating planetary carrier 94. The planetary carrier drives the vehicle wheels through the wheel studs 104 with the respective force and speed (based on the overall gear ratio).

4 Maintenance of the axle Danger! For maintenance work on the axles, the undercarriage of the machine must be accessed. This poses a great danger for mechanics. Always adhere to the safety instructions in group 1.10 "Safe maintenance of machine". The axle must be services at the intervals laid down in the inspection and maintenance schedule, see group 3. Regularly check the wheel lugs 107 for the correct tightening torque, (see Tab. 1, page 2). The lubricating oil must be changed at fixed intervals laid down in the inspection and maintenance schedule. The testing of the drum brake is an integral part of the maintenance; for detailed instructions, see also chapter "Brakes" in group 15.10.


Dismantling of the rigid axle for repair work Danger! The dismantling and installation of the rigid axle requires access to the undercarriage of the machine. There is a risk of death to the technician, as limbs could become crushed. Park the machine on level ground. Secure the lifted undercarriage with suitable props. Depressurise the hydraulic system. Always adhere to the safety instructions in group 1.10 and the accident prevention regulations issued by the German Ground Construction Trade Association (Tiefbau-Berufsgenossenschaft) Lift the undercarriage at the rear and secure the wheels of the steering axle 6 using chocks. If required, remove the wheels 1 from the rigid axle 2. Disconnect the brake lines of the drum brake and seal the line openings. Loosen the hex head screws 8 and remove the universal joint shaft 5 from the differential of the

copyright by

MJF C I F S S

12.29.3


Service Manual

Dismantling, repair and installation of the rigid axle rigid axle. Secure the rigid axle 2 with suitable lifting tackle. Remove the hex head nuts 3 and the screws 4 and then remove the rigid axle 2 from the undercarriage 9.

5.2

Repair of the rigid axle Note! For detailed repair instructions for the axle, refer to the separate "Repair manual for AP-B 745 ZP axles with drum brakes".

5.3

Installation of the rigid axle Install the rigid axle 2 in the undercarriage 9, using lifting gear and secure with the hex head screws 4 and the nuts 3 to the undercarriage 9; lock the nuts 3. Secure the universal joint shaft 5 with the hex head screws 2 to the differential of the rigid axle 2. Connect the brake lines to the drum brake and bleed the brake (see group 15.10). Mount the vehicle wheels 1. Lower the undercarriage and remove the chocks. Tighten the wheel lugs with the prescribed torque, see Tab. 1.

Fig. 2

12.29.4


1

Vehicle wheels

6

Steering axle

2 3

Rigid axle Hex nut

7 8


4

Hex head screw

9

Undercarriage

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Service Manual

AP - B 745 rigid axle with drum brake Exploded view of the rigid axle

5

Drive shaft


Fig. 3

Axle housing, group 17

17010 Axle housing part I

17150 Fit bolt

17030 Axle housing part II

17240 Screw plug

17050 Washer (S = 0.10 - 2.0mm)

17250 Screw plug

17090 Roller bearing 17100 Roller bearing

17260 O-ring 17290 Stub shaft

17120 O-ring 17130 Hex head screw

17690 Sleeve 17700 Snap ring

17140 Disc

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12.29.5


Service Manual

Exploded view of the rigid axle

Fig. 4

12.29.6

Hub carrier, group 22 and drum brake, group 2 (1 = old) and (400 = new)

1

Brake (old)

350

Locking plate

10 50

Brake drum Adapter

370 400

Tension spring Brake (new)

60

Brake disc

410

Adapter

70 80

Bolt Disc spring

420 430

Wheel cylinder Allen head screw

90

Disc

440

Disc

100

Hex nut

510

Hub carrier

120 170

Countersunk screw Wheel cylinder

510 570

Slotted nut Allen head screw

180

Lock washer

580

Allen head screw

190 270

Hex head screw Brake pad

590 610

O-ring Retainer plate

340

Bolt

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Service Manual


Fig. 5

Hub carrier and output of the wheel bearings or the planetary gear, group 19

10


410

Roller bearing

30 40

Roller bearing Ring (S = 14.0 - 15.2 mm)

420 430

Junk ring Snap ring

50

Roller bearing

480

Thrust washer (S = 1.5 – 5.0 mm)

80

Hub

490

O-ring

90

O-ring

500

Screw plug

160 184

Hollow gear Locking plate

510 540

Allen head screw Wheel stud

190

Self locking screw

550

Lock washer

340

Sun gear shaft

560

Centring ring

390

Planetary carrier

570

Wheel lug

400

Planetary gear

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12.29.7


Service Manual


Item

ZP figure no.

Description

Item

Group 17

ZP figure no.

Description

Group 19

1

17010

Axle housing part I

17030

Axle housing part II

7

17290

Stub shaft

8

17690

Sleeve

9

17700

10


61

30

Roller bearing

62

80

Hub

63

90

O-ring

Snap ring

64

50

Roller bearing

Group 2

60

68

160

Hollow gear

10

1

Brake

71

40

Ring

11

10

Brake drum

86

184

Locking plate

12

40

Brake disc

87

190

Self locking screw

17

170

Wheel cylinder

91

340

Sun gear shaft

18

180

Lock washer

94

390

Planetary carrier

19

190

Hex head screw

95

400

Planetary gear

20

270

Brake pad

96

410

Roller bearing

21

340

Pin

97

420

Junk ring

22

350

Locking plate

98

430

Snap ring

23

370

Tension spring

99

480

Thrust washer

101

490

O-ring

102

500

Screw plug

Group 22 27

570 / 2 430

Allen head screw

28

580 / 2 430

Allen head screw

103

510

Allen head screw

30

10

Hub carrier

104

540

Wheel stud

31

10

Slotted nut

105

550

Lock washer

33

110

Retainer plate

106

560

Centring ring

37

90

O-ring

107

570

Wheel lug

Note! Observe the setting values and tightening torques A, B, D, E, F, G, H, I, K , see Fig. 6 , and see Tab. 1.

12.29.8

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Service Manual

AP - B 745 rigid axle with drum brake Sectional drawing of the rigid axle


Fig. 6

Sectional drawing of rigid sleeve

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12.29.9


Service Manual

Sectional drawing of the rigid axle

12.29.10

copyright by

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Service Manual

AP - B 745 rigid axle Function

AP - B 745 rigid axle 1 Function The axle housing of the rigid axle, which transfers the axle load of the vehicle to the drive wheels, is equipped with a built-in differential. The differential transfers 50% of the output power of the transmission via the universal joint shafts to the planetary drives of the wheel hubs. For a detailed description of the differential, see group 12.31. Due to the technical design combining a high planetary gear ratio in the wheel hub with a small bevel gear ratio in the differential, the differential is very compact, providing for great ground clearance. The wheel hub contains the planetary drive as well as the hydraulically operated multi-disc brake. It is applied when the brake pedal (working brake) is operated and the brake is pressurised with brake oil. For a detailed description of the brake system, see group 15.10. x

Fig. 1


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12.30.1


Service Manual

Technical data


Litronic A 314 635 2001

Axle type

Litronic A 314 635 11308

AP-B 745

Design


Gear ratio

Standard

17.52

16.62

Speeder

17.52

16.62

Brake

Multi-disc brake

Oil volume in the axle - axle housing + 2 planetary gears

11,6 l

(filling level at the check screws is binding)

Planetary output approx. 0.8 l per side


API-GL-5/SAE 90 LS

Settings and tightening torques to be observed for installation: A End play of the stub shaft 7 with sun gear shaft 91

0.4 - 2.0 mm

B Clearance of the disc pack 83 / 84 (piston stroke) new at max. wear C Rolling resistance of the wheel bearing 61 (new) (without sealing element)

2.5 - 2.9 mm 5.0 mm 8 - 12 Nm 1550+500 Nm

D Torque for the slotted nut 31 E

Tightening torque for the Allen head screws 32

280 Nm

F

Tightening torque for the lock nuts 82

11 Nm

G Tightening torque for the Allen head screws 103

32 Nm

H Tightening torque for the wheel lugs 107

420 Nm

I

560 Nm

Tightening torque for the nuts 3.18

K Check of multi-disc brakes: High pressure test, max. value

120 bar

Max. pressure drop after 5 min.

3 bar

Low pressure test

5 bar

Visible pressure drop after 15 seconds is not permissible For items A - H, seesee Fig. 7 Item I, see Fig. 3 Tab. 1

2.1

Technical data


12.30.2

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Service Manual

AP - B 745 rigid axle Functional description


Power flow in the rigid axle See also sectional drawing Fig. 7 and drawing on page 12.31-09. The input torque of the transmission is transmitted through the universal joint shaft to the output flange of the differential. A bevel pinion and crown wheel transfer the torque via the differential case to the differential spider with balancing and axle shaft gears, which is borne in the cage. The respective axle shaft gear transfers the torque (increased by the differential translation with pinion and crown wheel) to the stub shaft 7 meshing with the axle shaft gear. The sun gear 91, which is connected through the disc carrier 92 to the stub shaft 7, drives the planetary gears 95. These roll off on the stationary hollow gear 68. This results in a great speed reduction and associated power transmission to the rotating planetary carrier 94. The planetary carrier drives the vehicle wheels through the wheel studs 104 with the respective force and speed (based on the overall gear ratio).

4 Maintenance of the axle Danger! For maintenance work on the axles, the undercarriage of the machine must be accessed. This poses a great danger for mechanics. Always adhere to the safety instructions in group 1.10 "Safe maintenance of machine". The axle must be inspected for oil level, leakage and proper fixture regularly at preset intervals, see inspection and maintenance schedule in group 3. Regularly check the wheel lugs 107 for the correct tightening torque, (see Tab. 1 on page 2). The lubricating oil must be changed at preset intervals laid down in the inspection and maintenance schedule. The testing of the multi-disc brake is an integral part of the maintenance; for detailed instructions, see also chapter 'Brakes' in group 15.10. The manufacturer also prescribes regular inspections of the disc lining for wear.

Fig. 2


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12.30.3


Service Manual

Dismantling of the rigid axle for repair work 1

2

M16 screw plug

M16 measuring screw

This check should be carried out annually or if any of the following occur: – Reduced braking force – Reduced brake pressure – Changes in the oil level in the wheel hub – or unusual brake noises

Measuring of brake lining wear Turn the wheel hub until the small M16 screw plug is at the top, see Fig. 2. Apply working brake to the stop. Remove the screw plug and screw in the M16 measuring plug (tool ID no. 7019556) to the stop; tighten it with 10 Nm. Measure and write down distance X from the screw head to the plane recess at the planetary carrier, see Fig. 2. Release the brake, screw measuring screw in further and tighten it again with 10 Nm. Measure and write down distance Y from the screw head to the plane recess at the planetary carrier, see Fig. 2. Calculate the difference between the two measurements X and Y. This value corresponds to the piston stroke. Limit value for piston stroke with wear = 5.0 mm If the permissible limit value is exceeded, replace all brake discs.

5 Dismantling of the rigid axle for repair work Danger! The dismantling and installation of the steering axle requires access to the undercarriage of the machine. There is a risk of death to the technician, as limbs could become crushed. Park the machine on level ground. Secure the lifted undercarriage with suitable props. Depressurise the hydraulic system. Always adhere to the safety instructions in group 1.10 and the accident prevention regulations issued by the German Ground Construction Trade Association (Tiefbau-Berufsgenossenschaft).

12.30.4

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Service Manual

AP - B 745 rigid axle Repair of the rigid axle

Fig. 3

Dismantling and installing the rigid axle

110 111

Steering axle Rigid axle

127 128

Hex head screw Nut

112

Vehicle wheels

129

Washer

115


130

Undercarriage

117

Hex head screw

If required, remove the wheels 112 from the rigid axle 111. Disconnect and seal the brake line to the multi-disc brakes (collect any escaping oil). Loosen the hex nuts and hex head screws 117 and remove the universal joint shaft 115 from the differential of the rigid axle. Block the wheels of the steering axle 110 with chocks. Secure the rigid axle with suitable lifting tackle. Remove the hex head nuts 128, the washers 129 and the screws 127 and then remove the rigid axle 111 from the undercarriage 130.

6 Repair of the rigid axle For detailed repair instructions for the axle, refer to the separate "Repair manual for AP-B 745 ZP axles with multi-disc brakes" .

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12.30.5


Service Manual

Installation of the rigid axle after repairs

7 Installation of the rigid axle after repairs Place the rigid axle 111 with lifting gear under the undercarriage and secure it with the hex head screws 127 and the nuts 128 and washers 129 to the undercarriage (tightening torque I, see (see Tab. 1 on page 2)). Secure the universal joint shaft 115 with the hex head screws 117 to the differential of the rigid axle 111. Connect the brake lines to the multi-disc brake and bleed the brake (see description in group 15.10). Mount the vehicle wheels 112.

12.30.6

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Service Manual

AP - B 745 rigid axle Axle housing

8 Axle housing

Fig. 4

Axle housing

17 010 Axle housing part I

17 140 Washer

17 030 Axle housing part II

17 150 Fit bolt

17 050 Washer (s=0.50 - 2.0 mm) 17 090 Roller bearing

17 240 Screw plug 17 250 Screw plug

17 100 Roller bearing 17 120 O-ring

17 260 O-ring 17 290 Stub shaft

17 130 Hex head screw

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12.30.7


Service Manual

Hub carrier

9 Hub carrier

Fig. 5

12.30.8

Hub carrier

22 010 Hub carrier complete with 22 010 Slotted nut

22 090 O-ring 22 110 Retainer plate

22 050 Washer 22 070 Allen head screw

22 160 Bleeder valve

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Service Manual

AP - B 745 rigid axle Output

10 Output

Fig. 6

Output

19 010 Radial shaft seal ring

22 290 End washer

19 030 Roller bearing 19 040 Ring (14.0 - 15.0 mm)

22 300 Snap ring 22 320 Thrust washer

19 050 Roller bearing 19 080 Hub

22 340 Sun gear shaft 22 350 Disc carrier

19 090 O-ring 19 120 Plug

22 370 Snap ring 22 390 Planetary carrier

19 130 O-ring

22 400 Planetary gear

19 140 Junk ring

22 410 Cylindrical roller bearing

19 150 Snap ring

22 420 Junk ring

19 160 Hollow gear 19 200 Piston

22 430 Snap ring 22 480 Thrust washer (s=2.0 - 3.0 mm)

19 210 Lip seal

22 490 O-ring

19 214 Ring 19 230 Backing ring

22 500 Screw plug (oil drainage) 22 510 Allen head screw

19 232 Back-up washer

22 540 Wheel stud

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12.30.9


Service Manual

Output 19 238 Pressure spring

22 550 Lock washer

19 248 Lock nut

22 560 Centring ring

19 256 Allen head screw 19 258 Spring sleeve

22 570 Wheel lug 22 620 Screw plug (measuring screw)

19 270 Outer disc (s=2.0 - 3 mm)

22 630 O-ring

19 280 Inner disc

Fig. 7

12.30.10


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Service Manual

AP - B 745 rigid axle Output

Item 1

ZP figure no.

Designation

Item

ZP figure no.

Designation

17 010

Axle housing part I

79

19 238

Pressure spring

17 030

Axle housing part I

81

19 256

Allen head screw

7

17 290

Stub shaft

82

19 248

Lock nut

29

22 050

Washer

83

19 270

Outer disc

30

22 010

Hub carrier

84

19 280

Inner disc

31

22 010

Slotted nut

85

19 290

End washer

32

22 070

Allen head screw

86

19 150

Snap ring

33

22 110

Retainer plate

87

19 320

Thrust washer

36

22 160

Bleeder valve

91

19 340

Sun gear shaft

37

22 090

O-ring

92

19 350

Disc carrier

60

19 010


93

19 300

Snap ring

61

19 030

Roller bearing

94

19 390

Planetary carrier

62

19 080

Hub

95

19 400

Planetary gear

63

19 090

O-ring

96

19 410

Roller bearing

64

19 050

Roller bearing

97

19 420

Junk ring

65

19 130

O-ring

98

19 430

Snap ring

66

19 140

Junk ring

99

19 480

Thrust washer

68

19 160

Hollow gear

101

19 490

O-ring

71

19 040

Ring

102

19 500

Screw plug

72

19 200

Piston

103

19 510

Allen head screw

73

19 210

Lip seal

104

19 540

Wheel stud

74

19 214

Ring

105

19 550

Lock washer

76

19 230

Backing ring

106

19 560

Centring ring

77

19 232

Back-up washer

107

19 570

Wheel lug

78

19 258

Spring sleeve

108

19 370

Snap ring

Note! Observe settings and tightening torques A, B, C, D, E, F, G, H, see also Fig. 7 and (see Tab. 1 on page 2).

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12.30.11


Service Manual

Output

12.30.12

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Service Manual

Differential for AP / APL - B 745 axles Function

Differential for AP / APL - B 745 axles 1 Function The differential is built into the axle housing of the steering and rigid axle. They transmit the output power of the transmission to the planetary drives of the wheel hubs, adjusting the speed and torque by means of bevel pinions and the crown wheel. The differential also acts as an equalising device when the vehicle is negotiating a corner. If the mechanical connection from the transmission via the universal joint shafts, the differential, the stub shafts and the planetary drives to the vehicle wheel were rigid, such steering manoeuvres would result in great strain on the axle and excessive tyre wear. The differential balances out these forces. The torque input from the input flange to the bevel gear, crown wheel and differential cage, and from there to the balancing axles mounted in the differential cage ensures that the four balancing bevel gears attached to the balancing axles mesh with the two axle shaft gears. As a result, there is a relative shift in direction of rotation between the two stub shafts meshing with the axle shaft gears, i.e. one stub shaft rotates clockwise, while the other rotates anticlockwise, or the two stub shafts rotate at different rates. The balancing movement has however a negative effect on the traction of the machine when driving off-road over surfaces with different grip. On loose ground, ice or snow, only one wheel per axle might properly grip the surface. At the request of the customer, the machine can be equipped with a limit slip differential, which at least partly eliminates this problem.

Fig. 1

Differential of steering and rigid axle

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12.31.1


Service Manual

Technical data


A 314 Litronic 635 2001

Axle type

BK

Gear ratio

2.92

This differential is not available as a complete unit. The component parts of the differentials for the steering and the rear axle are identical. Settings to be observed for installation: A Setting value of the crown wheel kit 20 B Tooth backlash of the crown wheel kit 20

(etched onto the end side of the pinion 20.1) 0.15 - 0.25 mm 0.18 - 0.23 mm (Speeder)

C Bearing preload of the differential bearing 3 / 4

1 - 4 Nm

D Rolling resistance of the driving pinion bearing 16/19

1 - 2 Nm

E


430 Nm

F

Torque for the hex head screws 6 and the fit bolt 7

410 Nm


145 Nm

Items A - G (see Fig. 5) Tab. 1

Technical data

Note! The differential can only be dismantled, installed and repaired together with the respective axle. Please also refer to the separate repair manual "AP / APL - B 745 ZP axles".

12.31.2

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Service Manual

Differential for AP / APL - B 745 axles Exploded view of the differential

3 Exploded view of the differential

Fig. 2 10

Input (assembly 16) 210

Input flange

50

Bevel gear kit (crown wheel and bevel pinion) Washer (S = 1.0 - 1.5 mm)

220

Valance

80 110

Tapered roller bearing Ring (S = 11.6 - 12.38 mm)

270 290

Washer Hex nut

160


310

Locking plate

190


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12.31.3


Service Manual

Exploded view of the differential

Fig. 3

12.31.4

Differential (assembly 73)

10

Crown wheel

720

Differential spider

570 640

Differential cage Axle shaft gear

800 850

Allen head screw Washer

650 670

Thrust washer Balancing shaft gear

860 870

Connex heavy-duty spring pin Roll pin S

680

Thrust washer

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Service Manual

Differential for AP / APL - B 745 axles Axle housing of steering and rigid axle

4 Axle housing of steering and rigid axle

Fig. 4

Axle housing of steering and rigid axle (assembly 17)

.10

Axle housing I

.240

Screw plug

.30 .40

Axle housing II Bearing bushing

.250 .260

Screw plug Seal

.50 .90

Washer (S = 0.1 - 2.0 mm) Roller bearing

.290 .330

Stub shaft O-ring

.100

Roller bearing

.340

Bearing bushing

.120

O-ring

.350

Seal ring

.130

Hex head screw

.690

Bearing bushing

.140 .150

Washer Fit bolt

.700

Seal ring

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12.31.5


Service Manual

Sectional drawing of the differential

5 Sectional drawing of the differential Item

ZP figure no.

Designation

Item

ZP figure no.

1.1

17010

Axle housing I

16

16160


1.2

17030

Axle housing II

17

16110

Ring

2.1

17050

Washer

18

16050

Adjusting disc

2.2

17050

Washer

19

16080


3

17090


20.1

16010

Bevel pinion

4

17100


20.2

16010

Crown wheel

5

17120

O-ring

21

73850

Washer

6

17130

Hex head screw

22

73800

Allen head screw

7

17150

Fit bolt

23.1

73570

Differential cage I

8

17140

Washer

23.2

73570

Differential cage II

9

17290

Stub shaft

24

73650

Thrust washer

10

16310

Locking plate

25

73640

Axle shaft gear

11

16290

Hex nut

26

73720

Differential spider

12

16270

Washer

27

73680

Thrust washer

13

16210

Input flange

28

73670

Balancing gear

14

16220

Valance

29

73870

Roll pin "S"

15

16190


30

73860

Heavy-duty roll pin "Connex"

Designation

Note! Observe settings and torques A, B, C, D, E, F, G, , see Fig. 5 and Table 1, page 2.

12.31.6

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Service Manual

Differential for AP / APL - B 745 axles Sectional drawing of the differential

Fig. 5


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12.31.7


Service Manual


12.31.8

copyright by

MJF C I F S S

Service Manual


APL - B 755 steering axle with multi-disc brake 1 Function The axle housing of the steering axle, which transfers the axle load of the machine to the drive wheels, is equipped with a built-in differential. The differential transfers 50% of the output power of the transmission via the universal joint shafts to the planetary drives of the wheel hubs. For a detailed description of the differential, see group 12.39. Due to the technical design combining a high planetary gear ratio in the wheel hub with a small bevel gear ratio in the differential, the differential is very compact, providing for great ground clearance. The wheel hub contains the planetary drive as well as the hydraulically operated wet multi-disc brake. It is pressurised and applied when the brake pedal (working brake) is operated. For a more detailed description of the brake system, see group 15.10. The steering cylinder (synchronised speed cylinder) built into the differential of the steering axle moves the wheels through the joint housings (steering knuckles) between the two stop positions. For a detailed description of the steering cylinder, see group 13.33. The steering cylinder is mounted directly on the undercarriage (oscillating bearing). This design compensates uneven surfaces so that all wheels of the vehicle are always in contact with the ground. During digging operation, the oscillating movement of the steering axles can be blocked by means of the two swing axle support cylinders attached to the undercarriage, see group 14.10.

Fig. 1


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12.36.1


12.36.2

copyright by

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Service Manual

Service Manual

APL - B 755 steering axle with multi-disc brake Technical data


A 316 Litronic 715 2001

Axle type

APL - B 755

Design



17.52 17.52

Brake




Settings to be observed for installation: A

End play of the double joint drive shaft 20

0.3 - 0.6 mm

B


3.1 - 3.5 mm 5.0 mm

C


40 - 50 Nm

D

Rolling resistance of the wheel bearing 61/64 (new)

8 - 12 Nm

E


F


280 Nm

G


11 Nm

H


55 Nm

I


420 Nm

Tightening torque of the slotted nut / tie rods, see steering

300 Nm

K

1400 + 500 Nm


150 bar 3 bar 1 - 5 bar

Items A - K ((see Fig. 7 on page11)) Tab. 1

2.0.1

Technical data


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12.36.3


Service Manual



Power flow in the steering axle, (see Fig. 7 on page11) The input torque of the transmission is transmitted through the drive shaft to the output flange of the differential. A bevel pinion and crown wheel transfer the torque via the differential case to the differential spider with balancing and axle shaft gears, which is borne in the cage. The respective axle shaft gear transfers the torque (increased by the differential translation with pinion and crown wheel) to the double joint drive shaft 20 meshing with the axle shaft gear. The sun gear shaft 91, which is connected through the disc carrier 92 to the double joint drive shaft 20, drives the planetary gears 95. These roll off on the stationary hollow gear 68. This results in a great speed reduction and associated power transmission to the rotating planetary carrier 94. The planetary carrier 94 drives the vehicle wheels through the wheel studs 104 with the respective force and speed (based on the overall gear ratio).


Danger! For maintenance work on the axles, the undercarriage of the machine must be accessed. This poses a great danger for mechanics. Always adhere to the safety instructions in group 1.10 "Safe maintenance of machine". The axle must be regularly serviced according to the intervals laid down in the service or operating manual. Regularly check the wheel lugs 107 for the correct tightening torque, (see Tab. 1 on page3). The oscillating axle bearing of the steering knuckle bearing must be lubricated and lubricating oil must be changed at fixed intervals laid down in the maintenance instructions. The testing of the multi-disc brake is an integral part of the maintenance; for detailed instructions, see also chapter "Brakes" in group 15.10. The manufacturer also prescribes an annual inspection of the disc lining for wear, see Fig. 2. The above check must be carried out annually, or if one of the following problems arise: – Reduced braking force – Reduced brake pressure – Changes in the oil level in the wheel hub – Unusual braking noises

Measuring of brake lining wear Turn wheel hub until the small screw plug M16 is at the top, see Fig. 2. Apply working brake to the stop. Remove the screw plug and screw in the measuring plug M16 (tool ID no. 7019556) to the stop; tighten it with 10 Nm. Measure and write down distance X from the screw head to the plane recess at the planetary carrier, see Fig. 2. Release the brake, screw measuring screw in further and tighten it again with 10 Nm. Measure and write down distance Y from the screw head to the plane recess of the planetary carrier. Calculate the difference between the two measurements "X" – "Y" . This value corresponds

12.36.4

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Service Manual

APL - B 755 steering axle with multi-disc brake Dismantling, repair and installation of the steering axle to the piston stroke.


Fig. 2



Dismantling of the steering axle for repair work Danger! The dismantling and installation of the steering axle requires access to the undercarriage of the machine. There is a risk of death to the technician, as limbs could become crushed. Park the machine on level ground. Secure the lifted undercarriage with suitable props. Depressurise the hydraulic system. Always adhere to the safety instructions in group 1.10 and the accident prevention regulations issued by the German Ground Construction Trade Association (Tiefbau-Berufsgenossenschaft) Lift the undercarriage 5 at the front and secure the wheels of the rigid axle 12 using chocks. If required, remove the wheels 1 from the steering axle. Disconnect the hydraulic lines to the steering cylinder and the brake line to the multi-disc brakes and seal the line openings (collect escaping oil). Loosen the hex head screws 2 and remove the universal joint shaft 3. Secure the steering axle 4 with suitable lifting tackle. Loosen the hex head screw 6 and remove the universal joint shaft 13 (old bearing). Remove the hex head screws 6 and the plate 7 (new bearing). Drive out the pin 8 (do not damage the washer 9) and lower the steering axle 4.

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12.36.5


Service Manual


5.2


5.3

Installation of the steering axle Insert the steering axle 4 in the undercarriage 5, using suitable lifting tackle. Insert the washers 9 and drive in pin 8. Secure the pin 8 with the washer 13 and the screws 6 (old), or with the plate 7 and the screws 6 with retaining washers 14 (new). Lubricate the steering axle bearing at the lubrication nipple 10. Secure the universal joint shaft 3 with the screws 2 to the differential of the steering axle 4. Connect the brake lines to the multi-disc brake and bleed the brake (see group 15.10). Connect the hydraulic lines to the steering cylinder and bleed the steering system (see group 13.20). Mount the vehicle wheels 1. Lower the undercarriage and remove the chocks. Tighten the wheel lugs with the prescribed torque, see Tab. 1.

Fig. 3

12.36.6


1

Vehicle wheels

8

Pin

2 3


9 10

Spacer Lubrication nipple

4 5

Steering axle Undercarriage

11 12

Lock nut Rigid axle

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Service Manual


6 7

13 14


Washer Retaining washer


Fig. 4


.10 .30

Axle housing Axle housing

.260 .290

O-ring Stub shaft

0.40

Bearing bushing

.330

Snap ring

.50

Washer (S = 1.05 - 2.0 mm)

.340

Bushing

.90

Roller bearing

.350


.100 .120


.600 .605

Axial joint Bellows

.130

Hex head screw

.610

Right ball joint, complete

.140

Washer

.611

Left ball joint, complete

.150

Fit bolt

.620

Clamp

.240 .250


.630 .640

Slotted nut Cotter pin

copyright by

MJF C I F S S

12.36.7


Service Manual


Fig. 5 .10

12.36.8

Joint housing (assembly 18) Left joint housing

.130

Lubrication nipple

.10

Right joint housing

.150

Bushing

.10 .50

Slotted nut Roller bearing

.160 .170

Radial shaft seal ring Universal joint

.80 .90

Sealing cap O-ring

.200 .270

Snap ring Plug

.100

Washer (S = 0.6 - 2.0 mm)

.390

Bleeder valve

.114 .120

Bearing pin Hex head screw

.500

Stop screw

copyright by

MJF C I F S S

Service Manual


Fig. 6


.10


.290

End washer

.30 .40


.300 .320


.50 .80

Roller bearing Hub

.340 .350

Sun gear shaft Disc carrier

.90

O-ring

.360

Snap ring

.120 .130

Plug O-ring

.370 0.390

Snap ring Planetary carrier

.140 .150

Junk ring Snap ring

.400 .410

Planetary gear Roller bearing

.160 .200

Hollow gear Piston

.420 .430

Junk ring Snap ring

.210

Lip seal

.480

Thrust washer (S = 1.5 - 3.0 mm)

.214 .220

Backing ring Lip seal

.490 .500

O-ring Screw plug (oil drainage)

.230 .232

Backing ring Back-up washer

.510 .540


.238

Pressure spring

.550

Lock washer

.248

Lock nut

.560

Centring ring

.256

Hex head screw

.570

Wheel lug

.258 .270

Spring sleeve Outer disc (S = 2.0 - 3.0 mm)

.620 .630

Screw plug (measuring bore) O-ring

.280

Inner disc

copyright by

MJF C I F S S

12.36.9


Service Manual

Exploded view of the steering axle Item

ZP figure no.

Designation

Item

ZP figure no.

Designation

1

17010

Axle housing

76

19230

Backing ring

8

17340

Bushing

77

19232

Back-up washer

9

17350


78

19258

Spring sleeve

10

18160


79

19240

Hex head screw

20

18170


81

19254

Hex head screw

31

18010

Right joint housing

82

19248

Lock nut

32

18010

Slotted nut

83

19270

Outer disc

35

18050

Roller bearing

84

19280

Inner disc

37

18080

Sealing cap

85

19290

End washer

38

18090

O-ring

86

19150

Snap ring

39

18100

Washer

87

19320

Thrust washer

41

18120

Hex head screw

91

19340

Sun gear shaft

42

18130

Lubrication nipple

92

19350

Disc carrier

43

18150

Bushing

93

19300

Snap ring

44

18114

Bearing pin

94

19390

Planetary carrier

45

18390

Bleeder valve

95

19400

Planetary gear

60

19010


96

19410

Roller bearing

61

19030

Roller bearing

97

19420

Junk ring

62

19080

Hub

98

19430

Snap ring

63

19090

O-ring

99

19480

Thrust washer

64

19050

Roller bearing

103

19510

Allen head screw

65

19130

O-ring

104

19540

Wheel stud

66

19140

Junk ring

105

19550

Lock washer

68

19160

Hollow gear

106

19560

Centring ring

71

19040

Ring

107

19570

Wheel lug

72

19200

Piston

108

19370

Snap ring

73

19210

Lip seal

109

19360

Snap ring

74

19214

Backing ring

110

17330

Snap ring

75

19220

Lip seal

111

17290

Stub shaft


12.36.10

copyright by

MJF C I F S S

Service Manual



Fig. 7

Sectional drawing of steering axle

copyright by

MJF C I F S S

12.36.11


12.36.12

copyright by

MJF C I F S S

Service Manual

Service Manual

AP - B 755 rigid axle with drum brake Function

AP - B 755 rigid axle with drum brake 1 Function The axle housing of the rigid axle, which transfers the axle load of the machine to the drive wheels, is equipped with a built-in differential. The differential transfers 50% of the output power of the transmission via the universal joint shafts to the planetary drives of the wheel hubs. For a detailed description of the differential, see group 12.39. Due to the technical design combining a high planetary gear ratio in the wheel hub with a small bevel gear ratio in the differential, the differential is very compact, providing for great ground clearance. The wheel hub contains the planetary drive as well as the hydraulically operated drum brake. It is applied when the brake pedal (working brake) is operated and the brake is pressurised with brake oil.

Fig. 1



A 316 Li: 715 2001

Axle type

AP-B 755 TR

copyright by

MJF C I F S S

12.37.1


Service Manual

Technical data Machine Machine model Serial number

A 316 Li: 715 2001

Design



17,52 17,52

Brake

Drum brake

Oil volume in axle Axle housing Planetary drive (filling level at the check screws is binding)






B

Rolling resistance of the wheel bearing 61 / 64 (new) (without sealing element)

C


560 Nm

D


79 Nm

E

Torque for the Allen head screws 27/28

F


G

Torque for the self locking screw 87

69 Nm

H


33 Nm

I


420 Nm

K

Check of drum brakes 20: Residual lining thickness of the brake system (glued) min.

0.4 - 2.0 mm 8 - 12 Nm

280 Nm 1400 + 200 Nm

2 mm

Items A, B, D- K (see Fig. 6 on page9) and item C (see Fig. 2 on page4) Tab. 1

2.1

Technical data


12.37.2

copyright by

MJF C I F S S

Service Manual

AP - B 755 rigid axle with drum brake Functional description


Power transfer in the rigid axle, see Fig. 6 The input torque of the transmission is transmitted through the universal joint shaft to the output flange of the differential. A bevel pinion and crown wheel transfer the torque via the differential case to the differential spider with balancing and axle shaft gears, which is borne in the cage. The respective axle shaft gear transfers the torque (increased by the differential translation with pinion and crown wheel) to the stub shaft 7 meshing with the axle shaft gear. The sun gear shaft 91, which is connected through the sleeve 8 to the stub shaft 7, drives the planetary gears 95. These roll off on the stationary hollow gear 68. This results in a great speed reduction and associated power transmission to the rotating planetary carrier 94. The planetary carrier drives the vehicle wheels through the wheel studs 104 with the respective force and speed (based on the overall gear ratio).

4 Maintenance of the axle Danger! For maintenance work on the axles, the undercarriage of the machine must be accessed. This poses a great danger for mechanics. Always adhere to the safety instructions in group 1.10 "Safe maintenance of machine". The axle must be services at the intervals laid down in the inspection and maintenance schedule, see group 3. Regularly check the wheel lugs 107 for the correct tightening torque, (see Tab. 1 on page2). The lubricating oil must be changed at fixed intervals laid down in the inspection and maintenance schedule. The testing of the drum brake is an integral part of the maintenance; for detailed instructions, see also chapter "Brakes" in group 15.10.


Dismantling of the rigid axle for repair work Danger! The dismantling and installation of the rigid axle requires access to the undercarriage of the machine. There is a risk of death to the technician, as limbs could become crushed. Park the machine on level ground. Secure the lifted undercarriage with suitable props. Depressurise the hydraulic system. Always refer to the safety instructions in group 1.10. Lift the undercarriage at the rear and secure the wheels of the steering axle 6 using chocks. If required, remove the wheels 1 from the rigid axle 2. Disconnect the brake lines of the drum brake and seal the line openings. Loosen the hex head screws 8 and remove the universal joint shaft 5 from the differential of the rigid axle. Secure the rigid axle 2 with suitable lifting tackle.

copyright by

MJF C I F S S

12.37.3


Service Manual

Dismantling, repair and installation of the rigid axle Remove the hex head nuts 3 and the screws 4 and then remove the rigid axle 2 from the undercarriage 9.

5.2

Repair of the rigid axle Note! For detailed repair instructions for the axle, refer to the separate "Repair manual for AP-B 755 ZP axles with drum brakes".

5.3

Installation of the rigid axle Install the rigid axle 2 in the undercarriage 9, using lifting gear and secure it with the hex head screws 4 and the nuts 3 to the undercarriage 9; lock the nuts 3. Secure the universal joint shaft 5 with the hex head screws 2 to the differential of the rigid axle 2. Connect the brake lines to the drum brake and bleed the brake (see group 15.10). Mount the vehicle wheels 1. Lower the undercarriage and remove the chocks. Tighten the wheel lugs with the prescribed torque, see Tab. 1.

Fig. 2

12.37.4


1 2


6 7

Steering axle Hex nut

3 4


8 9

Hex head screw Undercarriage

5


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MJF C I F S S

Service Manual


6 Exploded view of the rigid axle Fig. 3


17010 Axle housing part I 17030 Axle housing part II

17150 Fit bolt 17240 Screw plug

17050 Washer (S = 0.10 - 2.0 mm) 17090 Roller bearing

17250 Screw plug 17260 O-ring

17100 Roller bearing 17120 O-ring

17290 Stub shaft 17690 Sleeve

17130 Hex head screw

17700 Snap ring

17140 Washer

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MJF C I F S S

12.37.5


Service Manual


Fig. 4

12.37.6

Hub carrier, group 22 and drum brake, group 2 (1 = old) and (400 = new)

1

Brake (old)

350

Locking plate

10 50

Brake drum Adapter

370 400

Tension spring Brake (new)

60

Brake disc

410

Adapter

70

Pin

420

Wheel cylinder

80

Disc springs

430

Allen head screw

90

Washer

440

Washer

100

Hex nut

510

Hub carrier

120 170

Countersunk screw Wheel cylinder

510 570

Slotted nut Allen head screw

180

Lock washer

580

Allen head screw

190

Hex head screw

590

O-ring

270

Brake pad

610

Retainer plate

340

Pin

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MJF C I F S S

Service Manual


Fig. 5

Hub carrier and output of the wheel bearings or the planetary gear, group 19

10 30


410 420

Roller bearing Junk ring

40

Ring (S = 3.4 - 5.0 mm)

430

Snap ring

50 80

Roller bearing Hub

480 490

Thrust washer (S = 1.5 - 5.0 mm) O-ring

90 160

O-ring Hollow gear

500 510

Screw plug Allen head screw

184 190

Locking plate Self-locking screw

540 550


340

Sun gear shaft

560

Centring ring

390 400

Planetary carrier Planetary gear

570

Wheel lug

copyright by

MJF C I F S S

12.37.7


Service Manual


Item

ZP figure no.

Designation

Item

Group 17 1

ZP figure no.

Designation

Group 19

17010

Axle housing part I

60

10


17030


61

30

Roller bearing

7

17290

Stub shaft

62

80

Hub

8

17690

Sleeve

63

90

O-ring

9

17700

Snap ring

64

50

Roller bearing

68

160

Hollow gear

Group 2 10

1

Brake

71

40

Ring

11

10

Brake drum

86

184

Locking plate

12

40

Brake disc

87

190

Self locking screw

17

170

Wheel cylinder

91

340

Sun gear shaft

18

180

Lock washer

94

390

Planetary carrier

19

190

Hex head screw

95

400

Planetary gear

20

270

Brake pad

96

410

Roller bearing

21

340

Pin

97

420

Junk ring

22

350

Locking plate

98

430

Snap ring

23

370

Tension spring

99

480

Thrust washer

101

490

O-ring

27

570 / 2 430

Allen head screw

102

500

Screw plug

28

580 / 2 430

Allen head screw

103

510

Allen head screw

30

10

Hub carrier

104

540

Wheel stud

31

10

Slotted nut

105

550

Lock washer

33

110

Retainer plate

106

560

Centring ring

37

90

O-ring

107

570

Wheel lug

Group 22

Note! Observe the setting values and tightening torques A, B, D, E, F, G, H, I, K , see Fig. 6 and (see Tab. 1 on page 2).

12.37.8

copyright by

MJF C I F S S

Service Manual

AP - B 755 rigid axle with drum brake Sectional drawing of the rigid axle


Fig. 6


copyright by

MJF C I F S S

12.37.9


Service Manual


12.37.10

copyright by

MJF C I F S S

Service Manual

Differential for AP / APL - B 755 axles Function

Differential for AP / APL - B 755 axles 1 Function The differential is built into the axle housing of the steering and rigid axle. They transmit the output power of the transmission to the planetary drives of the wheel hubs, adjusting the speed and torque by means of bevel pinions and the crown wheel. The differential also acts as an equalising device when the vehicle is negotiating a corner. If the mechanical connection from the transmission via the universal joint shafts, the differential, the stub shafts and the planetary drives to the vehicle wheel were rigid, such steering manoeuvres would result in great strain on the axle and excessive tyre wear. The differential balances out these forces. The torque input from the input flange to the bevel gear, crown wheel and differential cage, and from there to the balancing axles mounted in the differential cage ensures that the four balancing bevel gears attached to the balancing axles mesh with the two axle shaft gears. As a result, there is a relative shift in direction of rotation between the two stub shafts meshing with the axle shaft gears, i.e. one stub shaft rotates clockwise, while the other rotates anticlockwise, or the two stub shafts rotate at different rates. The balancing movement has however a negative effect on the traction of the machine when driving off-road over surfaces with different grip. On loose ground, ice or snow, only one wheel per axle might properly grip the surface. At the request of the customer, the machine can be equipped with a limit slip differential, which at least partly eliminates this problem.

Fig. 1

Differential of steering and rigid axle

copyright by

MJF C I F S S

12.39.1


Service Manual

Technical data


A 316 Litronic 715 / 716 2001

Axle type

BK

Gear ratio

3,18


(etched onto the end side of the pinion 20.1) 0.15 - 0.2 mm 0.18 - 0.23 mm (speeder)


1 - 4 Nm


1 - 2 Nm

E


550 Nm

F


390 Nm


145 Nm


Technical data

Note! The differential can only be dismantled, installed and repaired together with the respective axle. Please also refer to the separate repair manual "AP / APL - B 755 ZP axles".

12.39.2

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MJF C I F S S

Service Manual

Differential for AP / APL - B 755 axles Exploded view of the differential


Fig. 2 10


Input flange

50


220

Valance

80 110

Tapered roller bearing Ring (S = 10.97 - 11.36 mm)

270 290

Washer (S = 10.94 - 12.38 mm) Hex nut

160


310

Locking plate

190


copyright by

MJF C I F S S

12.39.3


Service Manual


Fig. 3

12.39.4


10

Crown wheel

720

Differential spider

570 640


800 850


650 670


860 870


680

Thrust washer

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MJF C I F S S

Service Manual

Differential for AP / APL - B 755 axles Axle housing of steering and rigid axle


Fig. 4


.10

Axle housing I

.240

Screw plug

.30

Axle housing II

.250

Screw plug

.40 .50

Bearing bushing Washer (S = 0.1 - 2.0 mm)

.260 .290

Seal Stub shaft

.90

Roller bearing

.330

O-ring

.100

Roller bearing

.340

Bearing bushing

.120 .130


.350 .690

Seal ring Bearing bushing

.140

Washer

.700

Seal ring

.150

Fit bolt

copyright by

MJF C I F S S

12.39.5


Service Manual



ZP figure no.

Designation

Item

ZP figure no.

1.1

17010

Axle housing I

16

16170


1.2

17030

Axle housing II

17

16110

Bushing

2.1

17050

Washer

18

16050

Adjusting disc

2.2

17050

Washer

19

16070


3

17090


20.1

16010

Bevel pinion

4

17100


20.2

16010

Crown wheel

5

17120

O-ring

21

73850

Washer

6

17130

Hex head screw

22

73800

Allen head screw

7

17150

Fit bolt

23.1

73570

Differential cage I

8

17140

Washer

23.2

73570


9

17290

Stub shaft

24

73650

Thrust washer

10

16310

Locking plate

25

73640

Axle shaft gear

11

16290

Hex nut

26

73720

Balancing axle

12

16270

Washer

27

73680

Thrust washer

13

16210

Input flange

28

73670

Balancing gear

14

16220

Valance

29

73870

Roll pin "S"

15

16190


30

73860


Designation


12.39.6

copyright by

MJF C I F S S

Service Manual

Differential for AP / APL - B 755 axles Sectional drawing of the differential

Fig. 5


copyright by

MJF C I F S S

12.39.7


Service Manual


12.39.8

copyright by

MJF C I F S S

Service Manual

APL - B 755 HD steering axle with multi-disc brake Function

APL - B 755 HD steering axle with multi-disc brake 1 Function The axle housing of the steering axle, which transfers the axle load of the machine to the drive wheels, is equipped with a built-in differential. The differential transfers 50% of the output power of the transmission via the universal joint shafts to the planetary drives of the wheel hubs. For a detailed description of the differential, see group 12.44. Due to the technical design combining a high planetary gear ratio in the wheel hub with a small bevel gear ratio in the differential, the differential is very compact, providing for great ground clearance. The wheel hub contains the planetary drive as well as the hydraulically operated wet multi-disc brake. It is pressurised and applied when the brake pedal (working brake) is operated. For a more detailed description of the brake system, see group 15.10. The steering cylinder (synchronised speed cylinder) built into the differential of the steering axle moves the wheels through the joint housings (steering knuckles) between the two stop positions. For a detailed description of the steering cylinder, see group 13.34. The steering cylinder is mounted directly on the undercarriage (oscillating bearing). This design compensates uneven surfaces so that all wheels of the vehicle are always in contact with the ground. During digging operation, the oscillating movement of the steering axles can be blocked by means of the two swing axle support cylinders attached to the undercarriage, see group 14.10.

Fig. 1


copyright by

MJF C I F S S

12.41.1

APL - B 755 HD steering axle with multi-disc brake Function

12.41.2

copyright by

MJF C I F S S

Service Manual

Service Manual

APL - B 755 HD steering axle with multi-disc brake Technical data


A 316 Litronic Industry 716 2001

Axle type

APL-B 755 HD

Design



17.72 -

Brake





End play of the double joint shaft 20 with sun gear shaft 91

B


2.4 - 2.8 mm 4.5 mm

C


40 - 50 Nm

D

Rolling resistance of the wheel bearing 61 (new) (without sealing elements)

10 - 15 Nm

E


F


410 Nm

G


11 Nm

0.4 - 0.6 mm

1200 - 1400 Nm

H


120 Nm

I


86 Nm

K


570 Nm

Tightening torque of the slotted nut / tie rods, see steering cylinder, group 16.34 L


340 - 360 Nm

120 bar 3 bar 1 - 5 bar

Items A - L ((see Fig. 7 on page12)) Tab. 1

2.0.1

Technical data


copyright by

MJF C I F S S

12.41.3


Service Manual



Power flow in the steering axle, (see Fig. 7 on page12) The input torque of the transmission is transmitted through the drive shaft to the output flange of the differential. A bevel pinion and crown wheel transfer the torque via the differential case to the differential spider with balancing and axle shaft gears, which is borne in the cage. The respective axle shaft gear transfers the torque (increased by the differential translation with pinion and crown wheel) to the double joint drive shaft 20 meshing with the axle shaft gear. The sun gear shaft 91, which is connected through the disc carrier 92 to the double joint drive shaft 20, drives the planetary gears 95. These roll off on the stationary hollow gear 68. This results in a great speed reduction and associated power transmission to the rotating planetary carrier 94. The planetary carrier 94 drives the vehicle wheels through the wheel studs 104 with the respective force and speed (based on the overall gear ratio).


Danger! For maintenance work on the axles, the undercarriage of the machine must be accessed. This poses a great danger for mechanics. Always adhere to the safety instructions in group 1.10 "Safe maintenance of machine". The axle must be services at the intervals laid down in the inspection and maintenance schedule, see group 3. Regularly check the wheel lugs 107 for the correct tightening torque, (see Tab. 1 on page3). The oscillating axle bearing of the steering knuckle bearing must be lubricated and lubricating oil must be changed at fixed intervals laid down in the inspection and maintenance schedule. The testing of the multi-disc brake is an integral part of the maintenance; for detailed instructions, see also chapter "Brakes" in group 15.10. The manufacturer also prescribes an annual inspection of the disc lining for wear, see Fig. 2. The above check must be carried out annually, or if one of the following problems arise: – Reduced braking force – Reduced brake pressure – Changes in the oil level in the wheel hub – Unusual braking noises

Measuring of brake lining wear Turn wheel hub until the small screw plug M16 is at the top, see Fig. 2. Apply working brake to the stop. Remove the screw plug and screw in the measuring plug M16 (tool ID no. 7019556) to the stop; tighten it with 10 Nm. Measure and write down distance X from the screw head to the plane recess at the planetary carrier, see Fig. 2. Release the brake, screw measuring screw in further and tighten it again with 10 Nm. Measure and write down distance Y from the screw head to the plane recess of the planetary carrier. Calculate the difference between the two measurements "X" – "Y" . This value corresponds

12.41.4

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Service Manual

APL - B 755 HD steering axle with multi-disc brake Dismantling, repair and installation of the steering axle to the piston stroke.


Fig. 2



Dismantling of the steering axle for repair work Danger! The dismantling and installation of the steering axle requires access to the undercarriage of the machine. There is a risk of death to the technician, as limbs could become crushed. Park the machine on level ground. Secure the lifted undercarriage with suitable props. Depressurise the hydraulic system. Always adhere to the safety instructions in group 1.10 and the accident prevention regulations issued by the German Ground Construction Trade Association (Tiefbau-Berufsgenossenschaft) Lift the undercarriage 5 at the front and secure the wheels of the rigid axle 12 using chocks. If required, remove the wheels 1 from the steering axle. Disconnect the hydraulic lines to the steering cylinder and the brake line to the multi-disc brakes and seal the line openings (collect escaping oil). Loosen the hex head screws 2 and remove the universal joint shaft 3. Secure the steering axle 4 with suitable lifting tackle. Loosen the hex head screw 6 and remove the universal joint shaft 13 (old bearing). Remove the hex head screws 6 and the plate 7 (new bearing). Drive out the pin 8 (do not damage the washer 9) and lower the steering axle 4.

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MJF C I F S S

12.41.5


Service Manual


5.2


5.3

Installation of the steering axle after repair work Insert the steering axle 4 in the undercarriage 5, using suitable lifting tackle. Insert the washers 9 and drive in the pin 8. Secure the pin 8 with the washer 13 and the screws 6 (old), or with the plate 7 and the screws 6 with retaining washers 14 (new). Lubricate the steering axle bearing at the lubrication nipple 10. Secure the universal joint shaft 3 with the screws 2 to the differential of the steering axle 4. Connect the brake lines to the multi-disc brake and bleed the brake (see group 15.10). Connect the hydraulic lines to the steering cylinder and bleed the steering system (see group 13.20). Mount the vehicle wheels 1. Lower the undercarriage and remove the chocks. Tighten the wheel lugs with the prescribed torque, see Tab. 1.

Fig. 3

12.41.6


1

Vehicle wheels

8

Pin

2

Hex head screw

9

Spacer

3

Joint shaft

10

Lubrication nipple

4

Steering axle

11

Lock nut

5

Undercarriage

12

Rigid axle

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Service Manual

APL - B 755 HD steering axle with multi-disc brake Exploded view of the rigid axle

6 7

13 14


Washer Retaining washer


Fig. 4


.10

Axle housing part I

.260

O-ring

.30 .40

Axle housing part II Bearing bushing

.290 .330

Stub shaft Snap ring

.50

Washer (S = 0.15 - 2.0 mm)

.340

Bushing

.90

Roller bearing

.350


.100

Roller bearing

.600

Axial joint

.120 .130


.605 .610

Bellows Right tie rod, complete

.140

Washer

.611

Left tie rod, complete

.150 .240

Fit bolt Screw plug

.620 .630

Clamp Slotted nut

.250

Screw plug

.640

Cotter pin

copyright by

MJF C I F S S

12.41.7


Service Manual


Fig. 5 .30

12.41.8

Joint housing (assembly 18)

.10

Left joint housing, with slotted nut

.130

Lubrication nipple

.20 .30

Right joint housing, with slotted nut Plug

.150 .160

Bushing Radial shaft seal ring

.50

Roller bearing

.170

Universal joint

.80

Sealing cap

.390

Bleeder valve

.90

O-ring

.480

Washer (S = 1.9 - 3.0 mm)

.100 .114

Washer (S = 0.6 - 2.0 mm) Bearing pin

.490 .500

Pipe Stop screw

.120

Hex head screw

.510

Separate slotted nut

copyright by

MJF C I F S S

Service Manual


Fig. 6


.10


.290

End washer

.30 .40


.300 .310


.80 .90

Hub O-ring

.320 .326

Thrust washer Allen head screw

.100 .120

Hollow gear carrier Plug

.340 .344

Sun gear shaft O-ring

.130

O-ring

.350

Disc carrier

.144

Backing ring

.380

Snap ring

.154

Backing ring

.390

Planetary carrier

.200 .210

Piston Lip seal

.392 .400

Screw plug (measuring bore) Planetary gear

.214

Backing ring

.410

Roller bearing

.230

Backing ring

.412

Washer

.232

Back-up washer

.420

Junk ring

.236 .238

Spring sleeve Pressure spring

.430 .480

Snap ring Thrust washer (1.5 - 3.0 mm)

.244

Circlip

.500

Screw plug (oil drainage)

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MJF C I F S S

12.41.9


Service Manual

Exploded view of the rigid axle .246 .248

Hex head screw Lock nut

.510 .540


.256 .270

Hex head screw Outer disc (S = 2.0 - 3.0 mm)

.550 .560

Lock washer Centring ring

.280

Inner disc

.570

Wheel lug

Item

ZP figure no.

Designation

Item

ZP figure no.

Designation

1

17010

Axle housing

76

19230

Backing ring

2

17290

Stub shaft

77

19232

Back-up washer

3

17330

Snap ring

78

19258

Spring sleeve

8

17340

Bushing

79

19240

Pressure spring

9

17350


80

19244

Circlip

10

18160


81

19246

Hex head screw

11

18150

Bushing

82

19248

Lock nut

20

18170


83

19270

Outer disc

31

18010

Right joint housing

84

19280

Inner disc

18020

Left joint housing

85

19290

End washer

32

12.41.10

18010

Slotted nut

86

19150

Snap ring

18510


87

19320

Thrust washer

35

18050

Roller bearing

88

19326

Allen head screw

37

18080

Sealing cap

89

19330

Shim

38

18090

O-ring

90

19336

Snap ring

39

18100

Washer

91

19340

Sun gear shaft

40

18114

Bearing pin

92

19350

Disc carrier

41

18120

Hex head screw

93

19380

Snap ring

42

18130

Lubrication nipple

94

19390

Planetary carrier

45

18390

Bleeder valve

95

19400

Planetary gear

60

19010


96

19410

Roller bearing

61

19030

Roller bearing

97

19412

Circlip

62

19080

Hub

98

19420

Snap ring

63

19090

O-ring

99

19430

Thrust washer

65

19130

O-ring

100

19480

Thrust washer

66

19144

Backing ring

101

19392

Screw plug

67

19154

Backing ring

102

19500

Screw plug

68

19100

Hollow gear carrier

103

19510

Allen head screw

71

19040

Bushing

104

19540

Wheel stud

72

19200

Piston

105

19550

Lock washer

73

19210

Lip seal

106

19560

Centring ring

74

19214

Backing ring

107

19570

Wheel lug

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MJF C I F S S

Service Manual



copyright by

MJF C I F S S

12.41.11

APL - B 755 HD steering axle with multi-disc brake Sectional drawing of steering axle


Fig. 7

12.41.12


copyright by

MJF C I F S S

Service Manual

Service Manual

AP - B 755 rigid axle with multi-disc brake Function

AP - B 755 rigid axle with multi-disc brake 1 Function The axle housing of the rigid axle, which transfers the axle load of the machine to the drive wheels, is equipped with a built-in differential. The differential transfers 50% of the output power of the transmission via the universal joint shafts to the planetary drives of the wheel hubs. For a detailed description of the differential, see group 12.44. Due to the technical design combining a high planetary gear ratio in the wheel hub with a small bevel gear ratio in the differential, the differential is very compact, providing for great ground clearance. The wheel hub contains the planetary output drive as well as the hydraulically operated multi-disc brake. It is applied when the brake pedal (working brake) is operated and the brake is pressurised with brake oil.

Fig. 1


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MJF C I F S S

12.42.1


Service Manual

Technical data


A 316 Li: 716 2001

Axle type

AP-B 755 HD

Design



17.72 -

Brake

Multi-disc brake





B


C

Rolling resistance of the wheel bearing 61 (new) (without sealing elements)

0.4 - 2.0 mm 2.4 - 2.8 mm 4.5 mm 10 - 15 Nm

D

Tightening torque for the nuts 3

E

Tightening torque for the slotted nut 32

F


280 Nm

G

Tightening torque for the lock nuts 82

11 Nm

H


86 Nm

I

Tightening torque for the wheel lugs 107

570 Nm

K

Check of multi-disc brakes: High pressure test, max. value Max. pressure drop after 5 min. Low pressure test Visible pressure drop after 15 seconds is not permissible

120 bar 3 bar 5 bar

560 Nm 1200 - 1400 Nm

Items A, B, C, E, K (see Fig. 7 on page11) and item D (see Fig. 3 on page5) Tab. 1

2.1

Technical data


12.42.2

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Service Manual

AP - B 755 rigid axle with multi-disc brake Functional description


Power transfer in the rigid axle, see Fig. 7 The input torque of the transmission is transmitted through the universal joint shaft to the output flange of the differential. A bevel pinion and crown wheel transfer the torque via the differential case to the differential spider with balancing and axle shaft gears, which is borne in the cage. The respective axle shaft gear transfers the torque (increased by the differential translation with pinion and crown wheel) to the stub shaft 7 meshing with the axle shaft gear. The sun gear shaft 91, which is connected through the disc carrier 92 to the stub shaft 7, drives the planetary gears 95. These roll off on the stationary hollow gear 68. This results in a great speed reduction and associated power transmission to the rotating planetary carrier 94. The planetary carrier drives the vehicle wheels through the wheel studs 104 with the respective force and speed (based on the overall gear ratio).

4 Maintenance of the axle Danger! For maintenance work on the axles, the undercarriage of the machine must be accessed. This poses a great danger for mechanics. Always adhere to the safety instructions in group 1.10 "Safe maintenance of machine". The axle must be services at the intervals laid down in the inspection and maintenance schedule, see group 3. Regularly check the wheel lugs 107 for the correct tightening torque, (see Tab. 1 on page2). The testing of the multi-disc brake is an integral part of the maintenance; for detailed instructions, see also chapter "Brakes" in group 15.10. The manufacturer also prescribes an annual inspection of the disc lining for wear, see Fig. 2. The above check must be carried out annually, or if one of the following problems arise: – Reduced braking force – Reduced brake pressure – Changes in the oil level in the wheel hub – Unusual braking noises

Measuring of brake lining wear Turn wheel hub until the small screw plug M16 is at the top, see Fig. 2. Apply working brake to the stop. Remove the screw plug and screw in the measuring plug M16 (tool ID no. 7019556) to the stop; tighten it with 10 Nm. Measure and write down distance X from the screw head to the plane recess at the planetary carrier, see Fig. 2. Release the brake, screw measuring screw in further and tighten it again with 10 Nm. Measure and write down distance Y from the screw head to the plane recess of the planetary carrier. Calculate the difference between the two measurements "X" – "Y" . This value corresponds to the piston stroke.

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12.42.3


Service Manual

Dismantling, repair and installation of the rigid axle Note! Limit value for piston stroke with wear = 4.5 mm If the actual value exceeds the permissible limit value, replace the entire brake disc pack.

Fig. 2



Dismantling of the rigid axle for repair work Danger! The dismantling and installation of the rigid axle requires access to the undercarriage of the machine. There is a risk of death to the technician, as limbs could become crushed. Park the machine on level ground. Secure the lifted undercarriage with suitable props. Depressurise the hydraulic system. Always adhere to the safety instructions in group 1.10 and the accident prevention regulations issued by the German Ground Construction Trade Association (Tiefbau-Berufsgenossenschaft). Lift the undercarriage at the rear and secure the wheels of the steering axle 6 using chocks. If required, remove the wheels 1 from the rigid axle 2. Disconnect the brake lines of the drum brake and seal the line openings. Loosen the hex head screws 8 and remove the universal joint shaft 5 from the differential of the rigid axle. Secure the rigid axle 2 with suitable lifting tackle. Remove the hex head nuts 3 and the screws 4 and then remove the rigid axle 2 from the undercarriage 9.

12.42.4

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Service Manual

AP - B 755 rigid axle with multi-disc brake Dismantling, repair and installation of the rigid axle

5.2

Repair of the rigid axle Note! For detailed repair instructions for the axle, refer to the separate "Repair manual for AP-B 755 ZP axles with multi-disc brakes".

5.3

Installation of the rigid axle Install the rigid axle 2 in the undercarriage 9, using lifting gear and secure with the hex head screws 8 and the nuts 7 to the undercarriage 9; lock the nuts 7. Secure the universal joint shaft 5 with the hex head screws 2 to the differential of the rigid axle 2. Connect the brake lines to the drum brake and bleed the brake (see group 15.10). Mount the vehicle wheels 1 . Lower the undercarriage and remove the chocks. Tighten the wheel lugs with the prescribed torque, see Tab. 1.

Fig. 3


1

Vehicle wheels

6

Steering axle

2

Rigid axle

7

Hex nut

3

Hex nut

8

Hex head screw

4 5

Hex head screw Universal joint shaft

9

Undercarriage

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12.42.5


Service Manual



Fig. 4

12.42.6


17010 Axle housing part I

17150 Fit bolt

17030 Axle housing part II 17050 Washer (S = 0.15 - 2.0 mm)

17240 Screw plug 17250 Screw plug

17090 Roller bearing

17260 O-ring

17100 Roller bearing

17290 Stub shaft

17120 O-ring

17690 Sleeve

17130 Hex head screw 17140 Washer

17700 Snap ring

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Service Manual

AP - B 755 rigid axle with multi-disc brake Exploded view of the rigid axle

Fig. 5

Hub carrier

10

Hub carrier complete with slotted nut

110

Retainer plate

70 90

Allen head screw O-ring

160 330

Bleeder valve Separate slotted nut

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MJF C I F S S

12.42.7


Service Manual


Fig. 6

12.42.8

Output of planetary gear group 19

.10


.300

Snap ring

.30 .40


.310 .320

Locking plate Thrust washer

.80 .90

Hub O-ring

.340 .344

Sun gear shaft O-ring

.100

Hollow gear carrier

.350

Disc carrier

.120

Plug

.380

Snap ring

.130

O-ring

.390

Planetary carrier

.144 .154

Backing ring Backing ring

.392 .400

Screw plug (measuring bore) Planetary gear

.200 .210

Piston Lip seal

.410 .412

Roller bearing Washer

.214

Backing ring

.420

Junk ring

.230

Backing ring

.430

Snap ring

.232

Back-up washer

.480

Thrust washer (S = 1.5 - 3.0 mm)

.238

Pressure spring

.500

Screw plug (oil drainage)

.244

Circlip

.510

Allen head screw

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Service Manual

AP - B 755 rigid axle with multi-disc brake Exploded view of the rigid axle

.248 .256

Lock nut Hex head screw

.540 .550


.270 .280

Outer disc (S = 2.0 - 3.0 mm) Inner disc

.560 .570

Centring ring Wheel lug

.290

End washer

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12.42.9


Service Manual

Exploded view of the rigid axle Item

ZP figure no.

1

17010 17030

7

17290

3

Designation

Item

ZP figure no.

Designation

Axle housing part I

80

19244

Circlip


81

19246

Hex head screw

Stub shaft

82

19248

Lock nut

17330

Snap ring

83

19270

Outer disc

8

17340

Bushing

84

19280

Inner disc

9

17350


85

19290

End washer

30

22010

Hub carrier

86

19150

Snap ring

22330


87

19320

Thrust washer

33

22070

Allen head screw

88

19326

Allen head screw

34

22110

Retainer plate

89

19330

Shim

36

22160

Bleeder valve

90

19336

Snap ring

37

19090

O-ring

91

19340

Sun gear shaft

60

19010


92

19350

Disc carrier

61

19030

Roller bearing

93

19380

Snap ring

62

19080

Hub

94

19390

Planetary carrier

63

19090

O-ring

95

19400

Planetary gear

65

19130

O-ring

96

19410

Roller bearing

66

19144

Backing ring

97

19412

Circlip

67

19154

Backing ring

98

19420

Snap ring

68

19160

Hollow gear carrier

99

19430

Thrust washer

71

19040

Bushing

100

19480

Thrust washer

72

19200

Piston

101

19392

Screw plug

73

19210

Lip seal

102

19500

Screw plug

74

19214

Backing ring

103

19510

Allen head screw

76

19230

Backing ring

104

19540

Wheel stud

77

19232

Back-up washer

105

19550

Lock washer

78

19258

Spring sleeve

106

19560

Centring ring

79

19240

Pressure spring

107

19570

Wheel lug

Note! Observe the setting values and tightening torques A, B, D, E, F, G, H, I, K , see Fig. 7 and (see Tab. 1 on page 2).

12.42.10

copyright by

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Service Manual

AP - B 755 rigid axle with multi-disc brake Sectional drawing of the rigid axle


Fig. 7


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MJF C I F S S

12.42.11


Service Manual


12.42.12

copyright by

MJF C I F S S

Service Manual

Differential for AP / APL - B 755 HD axles Function

Differential for AP / APL - B 755 HD axles 1 Function The differential is built into the axle housing of the steering and rigid axle. They transmit the output power of the transmission to the planetary drives of the wheel hubs, adjusting the speed and torque by means of bevel pinions and the crown wheel. The differential also acts as an equalising device when the vehicle is negotiating a corner. If the mechanical connection from the transmission via the universal joint shafts, the differential, the stub shafts and the planetary drives to the vehicle wheel were rigid, such steering manoeuvres would result in great strain on the axle and excessive tyre wear. The differential balances out these forces. The torque input from the input flange to the bevel gear, crown wheel and differential cage, and from there to the balancing axles mounted in the differential cage ensures that the four balancing bevel gears attached to the balancing axles mesh with the two axle shaft gears. As a result, there is a relative shift in direction of rotation between the two stub shafts meshing with the axle shaft gears, i.e. one stub shaft rotates clockwise, while the other rotates anticlockwise, or the two stub shafts rotate at different rates. The balancing movement has however a negative effect on the traction of the machine when driving off-road over surfaces with different grip. On loose ground, ice or snow, only one wheel per axle might properly grip the surface. At the request of the customer, the machine can be equipped with a limit slip differential, which at least partly eliminates this problem.

Fig. 1

Differential

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12.44.1


Service Manual

Technical data


A 316 Litronic 716 2001

Axle type

BK

Gear ratio

3.18


(etched onto the end side of the pinion 20.1) 0.15 - 0.2 mm 0.18 - 0.23 mm (Speeder)


1 - 4 Nm


1 - 2 Nm

E


550 Nm

F


390 Nm


145 Nm


Technical data

Note! The differential can only be dismantled, installed and repaired together with the respective axle. Please also refer to the separate repair manual "AP / APL - B 755 HD ZP axles".

12.44.2

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Service Manual

Differential for AP / APL - B 755 HD axles Exploded view of the differential


Fig. 2 10


Input flange

50


220

Valance

80 110


270 290


160

Roller bearing

310

Locking plate

190


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MJF C I F S S

12.44.3


Service Manual


Fig. 3

12.44.4


10

Crown wheel

720

Differential spider

570 640


800 850


650 670


860 870


680

Thrust washer

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Service Manual

Differential for AP / APL - B 755 HD axles Axle housing of steering and rigid axle


Fig. 4


.10

Axle housing I

.240

Screw plug

.30

Axle housing II

.250

Screw plug

.40 .50

Bearing bushing Washer (S = 0.1 - 2.0 mm)

.260 .260

Seal Stub shaft

.90

Roller bearing

.330

O-ring

.100

Roller bearing

.340

Bearing bushing

.120

O-ring

.350

Seal ring

.130 .140


.690 .700

Bearing bushing Seal ring

.150

Fit bolt

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MJF C I F S S

12.44.5


Service Manual



ZP figure no.

Designation

Item

ZP figure no.

1.1

17010

Axle housing I

16

16170


1.2

17030

Axle housing II

17

16110

Bushing

2.1

17050

Washer

18

16050

Adjusting disc

2.2

17050

Washer

19

16070


3

17090


20.1

16010

Bevel pinion

4

17100


20.2

16010

Crown wheel

5

17120

O-ring

21

73850

Washer

6

17130

Hex head screw

22

73800

Allen head screw

7

17150

Fit bolt

23.1

73570

Differential cage I

8

17140

Washer

23.2

73570


Designation

9

17290

Stub shaft

24

73650

Thrust washer

10

16310

Locking plate

25

73640

Axle shaft gear

11

16290

Hex nut

26

73720

Balancing axle

12

16270

Washer

27

73680

Thrust washer

13

16210

Input flange

28

73670

Balancing gear

14

16220

Valance

29

73870

Roll pin "S"

15

16190


30

73860



12.44.6

copyright by

MJF C I F S S

Service Manual

Differential for AP / APL - B 755 HD axles Sectional drawing of the differential

Fig. 5


copyright by

MJF C I F S S

12.44.7


Service Manual


12.44.8

copyright by

MJF C I F S S

Service Manual

MS - E 3060 steering axle Function

MS - E 3060 steering axle 1 Function The axle housing of the steering axle, which transfers the axle load of the machine to the drive wheels, is equipped with a built-in drive / differential. The differential transmits 50% of the output power of the transmission via the universal joint shafts to the planetary drives of the wheel hubs. Due to the technical design combining a high planetary gear ratio in the wheel hub with a small bevel gear ratio in the differential, the drive unit is very compact, providing for great ground clearance. The wheel hub contains the planetary drive as well as the hydraulically operated wet multi-disc brake. The brake is applied when the brake pedal (working brake) is operated and the brake is pressurised with brake oil. For a detailed description of the brake system, see group 15.10. The steering cylinder (synchronised speed cylinder) built into the axle drive housing of the steering axle moves the wheels through the joint housings (steering knuckles) between the two stop positions. For a detailed description of the steering cylinder, see group 13.34. The steering cylinder is mounted directly on the undercarriage (oscillating bearing). This design compensates uneven surfaces so that all wheels of the vehicle are always in contact with the ground. During digging operation, the oscillating movement of the steering axles can be blocked by means of the two swing axle support cylinders attached to the undercarriage, see group 14.10.

Fig. 1


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MJF C I F S S

12.46.1


Service Manual

Function

12.46.2

copyright by

MJF C I F S S

Service Manual

MS - E 3060 steering axle Technical data


A 316 Li 715 / 716 28061 / 28062

Axle type

MS-E 3060

Design


Gear ratio

16,00

Brake




Settings, to be observed for installation: A*

Axial play of double joint drive shaft 35

0.3 - 0.6 mm

B*


1.2 - 1.8 mm 6.0 mm

C*

Rolling resistance of joint housing bearing 68

40 - 50 Nm

D*

Rolling resistance of wheel bearing 99

8 - 12 Nm

E*

Tightening torque of slotted nut 54

F*


280 Nm

G*


11 Nm

H*


55 Nm

I*

Tightening torque of wheel lugs 108

460 Nm

K*

Check of multi-disc brakes: High pressure test, max. value Max. pressure drop after 5 minutes Low pressure test Visible pressure drop after 5 minutes is not permissible

100 bar 3 bar 5 bar

Tightening torque of the slotted nut / tie rods, see steering

1400 + 200 Nm

100 Nm

* Items A - K, see Fig. 10 Tab. 1

Technical data


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12.46.3


Service Manual

Description

3 Description The steering axle screw-mounted to the undercarriage consists of the following main components: – Drive unit 1, differential 2 in axle drive housing – Axle housing 3 – Joint housing 4 with axle drive housing – Output 5 – Steering 6

Fig. 2

12.46.4

Design of steering axle

1 2

Input Differential

6 7

Steering Oil discharge / oil filling opening / planetary drive

3 4

Axle housing with axle drive housing Joint housing

8 9

Oil filling control bore / axle housing Oil discharge / axle housing

5

Output

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Service Manual

MS - E 3060 steering axle Description

3.1

Design of drive unit 1 and differential 2

Fig. 3

Design of drive unit/differential

10

Crown wheel

20

Allen head screw

11

Pinion

21

Washer

12

Roller bearing

22

Differential cage

13

Disc (S=0.70-1.50mm)

23

Thrust washer

14 15

Roller bearing Ring (S=10.94-12.38mm)

24 25

Axle shaft gear Balancing shaft gear

16


26

Thrust washer

17

Protective plate

27

Balancing axle

18

Input flange

28

Heavy-duty roll pin

19

Hex nut with washer

29

Roll pin

Note! For a detailed description of the differential, see group 12.48.

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12.46.5


Service Manual

Description

3.2

Layout of the axle housing 3

Fig. 4

12.46.6

Design of axle housing

30 31

Axle housing Axle drive housing

42 43

Hex nut Axial joint

32

Clamping bush

44

Slotted nut

33 34


45 46

Tie rod (right) Ball joint

35 36

Double joint drive shaft (complete) Yoke

47 48

Hex nut Axial joint

37 38

Joint yoke Double yoke

49 110

Hex head screw O-ring

39

Joint yoke (sun gear shaft)

111

Washers

40 41

Tie rod (left) Ball joint

112

Roller bearing

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Service Manual

MS - E 3060 steering axle Description

3.3

Design of the joint housing 4

Fig. 5

Design of joint housing

30

Axle housing

59

Lubrication nipple

39 50

Joint yoke (sun gear shaft) Joint housing (complete)

60 61

Hex head screw Washer (S=0.60-2.00mm)

51

Snap ring

62

Bearing pin

52 53

Thrust washer Thrust washer

63 64

Lubrication nipple Plug

54

Slotted nut

65

Bleeder

55

O-ring

66

Bushing

56 57

Sealing cap O-ring

67 68


58

Bearing pin

69

Hex head screw

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12.46.7


Service Manual

Description

3.4

Design of output unit 5

Fig. 6

12.46.8

Design of the output unit

50

Joint housing

88

Backing ring

70 71

Planetary carrier Screw plug

89 90


72

O-ring

91

Pressure spring

74 75

Allen head screw Circlip

92 93

Spring sleeve Hex head screw

76

Planetary gear

94

Disc carrier

77

Washer

95

O-ring

78 80

Roller bearing Snap ring

96 97


81

Thrust washer (S = -1.50-3.00mm)

98

O-ring

82 83

O-ring Hollow gear

99 100

Roller bearing Spacer bushing

84

Cylinder pin

101

Hub

85

Backing ring

103


86

Lip seal

104

Allen head screw

87

Lip seal

105

Wheel stud

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Service Manual

MS - E 3060 steering axle Functional description


Power flow in the steering axle, see Fig. 10 The input torque of the transmission is transmitted through the drive shaft to the output flange of the drive system. A bevel pinion and crown wheel transfer the torque via the differential case/differential to the differential spider with balancing and axle shaft gears, which is borne in the cage. The respective axle shaft gear transfers the torque (increased by the differential translation with pinion and crown wheel) to the double joint drive shaft 35 meshing with the axle shaft gear. The sun gear 39 drives the planetary gears 76. These roll off on the stationary hollow gear 83. This leads to a high speed reduction and thus a high torque transmission to the planetary carrier 70. The planetary carrier 70, via the wheel studs 105, drives the vehicle wheels with the resulting torque and speed (resulting from the overall gear ratio).

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12.46.9


Service Manual


5 Maintenance of the axle Danger! For maintenance work on the axles, the undercarriage of the machine must be accessed, which poses a great danger for mechanics. Always adhere to the safety instructions in group 1.10 "Safe maintenance of machine". The axle must be regularly serviced according to the intervals laid down in the service or operating manual. Regularly check the wheel lugs 108 for the correct tightening torque, (see Tab. 1, page 3). The oscillating axle bearing of the steering knuckle bearing must be lubricated and lubricating oil must be changed at fixed intervals laid down in the inspection and maintenance schedule. The testing of the multi-disc brake is an integral part of the maintenance; for detailed instructions, see also chapter "Brakes" in group 15.10. The manufacturer also prescribes an annual inspection of the disc lining for wear, (see Fig. 8, page 11). The above check must be carried out annually, or if one of the following problems arise: – Reduced braking force – Reduced brake pressure – Changes in the oil level in the wheel hub – Unusual braking noises

Fig. 7

Wear assessment

Measuring of brake lining wear Caution! Escaping oil, due to a pressure build-up in the drive unit, can drive out the plug screw, causing injury. Slowly screw out the screw plug to 12 o'clock position. Turn the output (wheel hub) until the screw plug 71 is in its top position (12 o'clock).

12.46.10

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Service Manual

MS - E 3060 steering axle Maintenance of the axle Carefully loosen the screw plug 71 and remove it. The internal measuring bore 2 becomes visible. Turn the output unit until the measuring bore 2 is in the 9 o'clock position. Attach the dial gauge with magnetic stand and extension to the output unit, see Fig. 8. Insert the dial gauge 3 through the oil discharge bore and the measuring bore 2 and position it at the piston 89.

If the brake is not applied, the piston is pushed by the return spring force onto the hollow gear. Apply pressure to the brakes and measure the piston travel X with the dial gauge. Write down the measured value. Note! Piston travel with new discs = 1.2 – 1.8 mm. Limit value for piston stroke with wear = 6.0 mm. If the actual value exceeds the permissible limit value, replace the entire brake disc pack. Remove the dial gauge 3 with the magnetic stand. Mount a new O-ring on the screw plug 71 and insert it.

Fig. 8

Wear measurement at the disc pack

2 3

Measuring bore (Ø 10 mm) Dial gauge with magnetic stand

83 89

70 71

Planetary carrier Screw plug Oil filling / oil discharge bore

96/97 Disc pack X Piston travel

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MJF C I F S S

Hollow gear Piston

12.46.11


Service Manual


6 Dismantling, repair and installation of the steering axle (see Fig. 9, page 13)

6.1

Dismantling of the steering axle for repair work Danger! The dismantling and installation of the steering axle requires access to the undercarriage of the machine. There is a risk of death to the technician, as limbs could become crushed. Park the machine on level ground. Secure the lifted undercarriage with suitable props. Depressurise the hydraulic system. Always refer to the safety instructions in group 1.10. Lift the undercarriage 5 at the front and secure the wheels of the rigid axle 4 using chocks. If required, remove the wheels 1 from the steering axle. Disconnect the hydraulic lines to the steering cylinder and the brake line to the multi-disc brakes and seal the line openings (collect escaping oil). Loosen the hex head screws 2 and remove the universal joint shaft 3. Lift the undercarriage 5 and secure the steering axle 4 with suitable lifting tackle. Remove the hex head screws 6 and remove the plate 7. Drive out the bolt 8 and lower the steering axle 4.

6.2

Repairs to the steering axle Note! For detailed repair instructions for the axle, refer to the separate Repair manual for ZF axles MSE 3050/3060/3070.

6.3

Installation of the steering axle Install the steering axle 4 in the undercarriage, using lifting gear, and drive in the pin 8. Secure pin 8 with the plate 7 and the screws 6. Lubricate the steering axle bearing at the lubrication nipple 10. Secure the universal joint shaft 3 with the screws 2 to the output flange / output of the steering axle 4. Connect the brake lines to the multi-disc brake and bleed the brake (see group 15.10). Connect the hydraulic lines to the steering cylinder and bleed the steering system (see group 13.20). Mount the vehicle wheels 1. Lower the undercarriage and remove the chocks. Tighten the wheel lugs with the prescribed torque, see Tab. 1.

12.46.12

copyright by

MJF C I F S S

Service Manual

MS - E 3060 steering axle Dismantling, repair and installation of the steering axle

Fig. 9


1 2

Vehicle wheels Hex head screw

6 7


3

Joint shaft

8

Pin

4

Steering axle

10

Lubrication nipple

5

Undercarriage

11

Lock nut

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MJF C I F S S

12.46.13


Service Manual

Dismantling, repair and installation of the steering axle 30 36

Axle housing Yoke

78 82


37 38

Joint yoke Double yoke

83 85

Hollow gear Backing ring

39

Joint shaft (sun gear shaft)

86

Lip seal

50 51

Joint housing Snap ring

87 88


52

Thrust washer

89

Piston

53

Thrust washer

90

Pressure spring

54

Slotted nut

91

Pressure spring

56

Sealing cap

92

Spring sleeve

57

O-ring

93

Hex head screw

58 59

Bearing pin Lubrication nipple

94 95

Disc carrier O-ring

60 61

Hex head screw Washer (S=0.60-2.00mm)

96 97


62 63

Bearing pin Lubrication nipple

99 100


65

Bleeder

101

Hub

66 67


103 104

Radial shaft seal ring Allen head screw

68 70

Roller bearing Planetary carrier

105 106


74 75


107 108

Centring ring Wheel lug

76

Planetary gear


12.46.14

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MJF C I F S S

Service Manual

MS - E 3060 steering axle Dismantling, repair and installation of the steering axle

Fig. 10


copyright by

MJF C I F S S

12.46.15


Service Manual


12.46.16

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MJF C I F S S

Service Manual

MT - E 3060 rigid axle Function

MT - E 3060 rigid axle 1 Function The axle housing of the rigid axle, which transfers the axle load of the machine to the drive wheels, is equipped with a built-in drive / differential. The differential transmits 50% of the output power of the transmission via the universal joint shafts to the planetary drives of the wheel hubs. Due to the technical design combining a high planetary gear ratio in the wheel hub with a small bevel gear ratio in the differential, the drive unit is very compact, providing for great ground clearance. The wheel hub contains the planetary drive as well as the hydraulically operated wet multi-disc brake. It is applied when the brake pedal (working brake) is operated and the brake is pressurised with brake oil. For a detailed description of the brake system, see group 15.10. I

Fig. 1

MT - E 3060 rigid axle

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MJF C I F S S

12.47.1


Service Manual

Function

12.47.2

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Service Manual

MT - E 3060 rigid axle Technical data


A 316 Li 715 / 716 28061 / 28062

Axle type

MT-E 3060

Design


Gear ratio

Standard

Brake

16,00 Wet multi-disc brake

Oil volume in axle (filling level at the check screws is binding)

Axle housing Planetary drive

Oil quality


Settings, to be observed for installation: A*

End play of the stub shaft 36

B*

Clearance of the disc pack 96/97(piston stroke)

0.4 - 0.6 mm new at max. wear

0.7 - 1.3 mm 6.0 mm at 6 discs 6.5 mm at 7 discs

C*

Rolling resistance of the wheel hub 99

D*


E*


280 Nm

F*


8 Nm

G*


55 Nm

H*


460 Nm

I*

Check of multi-disc brakes: High pressure test, max. value Max. pressure drop after 5 minutes Low pressure test Visible pressure drop after 5 minutes is not permissible

100 bar 3 bar 5 bar

8 - 12 Nm 1400 +600 Nm

* Items A - H (see Fig. 10) Tab. 1

Technical data


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MJF C I F S S

12.47.3


Service Manual

Description

3 Description The rigid axle screw-mounted to the undercarriage consists of the following main components: – Drive unit 1, differential 2 in axle drive housing – Axle housing 3 – Hub carrier 4 – Drive unit 5

Fig. 2

12.47.4

Design of rigid axle

1

Input

5

Output

2

Differential

6

Oil discharge / oil filling opening / planetary drive

3

Axle housing with axle drive housing

7

Oil filling control bore / axle housing

4

Hub carrier

8

Oil discharge / axle housing

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Service Manual

MT - E 3060 rigid axle Description

3.1

Design of drive unit 1 and differential 2

Fig. 3

Design of the drive unit

10 11

Crown wheel Pinion

20 21


12 13

Roller bearing Disc (S=0.70-1.50mm)

22 23

Differential cage Thrust washer

14 15


24 25


16


26

Thrust washer

17 18

Protective plate Input flange

27 28

Balancing axle Heavy-duty roll pin

19

Hex nut with washer

29

Roll pin

Note! For a detailed description of the differential, see group 12.48.

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MJF C I F S S

12.47.5


Service Manual

Description

3.2

Layout of the axle housing 3

Fig. 4

12.47.6

Design of axle housing

30

Axle housing

34

Washer (S = 0.10 - 2.0mm)

31

Axle drive housing

35

O-ring

32 33

Hex head screw Roller bearing

36 37

Stub shaft Washer

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Service Manual

MT - E 3060 rigid axle Description

3.3

Design of hub carrier 4

Fig. 5

Design of hub carrier

30 50

Axle housing Hub carrier

54 55

Slotted nut O-ring

51

Sun gear shaft

56

Washer

52 53

Bleeder Plug

57

Hex head screw

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MJF C I F S S

12.47.7


Service Manual

Description

3.4

Design of output unit 5

Fig. 6

12.47.8

Design of the output unit

50

Joint housing

88

Backing ring

70 71

Planetary carrier Screw plug

89 90


72

O-ring

91

Pressure spring

74 75


92 93


76

Planetary gear

94

Disc carrier

77

Washer

95

O-ring

78 80


96 97


81

Thrust washer (S = -1.50-3.00mm)

98

O-ring

82 83

O-ring Hollow gear

99 100


84

Cylinder pin

101

Hub

85

Backing ring

103


86

Lip seal

104

Allen head screw

87

Backing ring

105

Wheel stud

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Service Manual

MT - E 3060 rigid axle Functional description


Power flow in the rigid axle, see Fig. 10 The input torque of the transmission is transmitted through the drive shaft to the output flange of the drive system. A bevel pinion and crown wheel transfer the torque via the differential case to the differential spider with balancing and axle shaft gears, which is borne in the cage. The respective axle shaft gear transfers the torque (increased by the differential translation with pinion and crown wheel) to the stub shaft 36 meshing with the axle shaft gear. The sun gear 51 drives the planetary gears 76. These roll off on the stationary hollow gear 83. This leads to a high speed reduction and thus a high torque transmission to the planetary carrier 70. The planetary carrier 70, via the wheel studs 105, drives the vehicle wheels with the resulting torque and speed (resulting from the overall gear ratio).

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12.47.9


Service Manual


5 Maintenance of the axle Danger! For maintenance work on the axles, the undercarriage of the machine must be accessed. This poses a great danger for mechanics. Always adhere to the safety instructions in group 1.10 "Safe maintenance of machine". The axle must be regularly serviced according to the intervals laid down in the service or operating manual. Regularly check the wheel lugs 108 for the correct tightening torque, (see Tab. 1, page 3). The lubricating oil must be changed at fixed intervals laid down in the inspection and maintenance schedule. The testing of the multi-disc brake is an integral part of the maintenance; for detailed instructions, see also chapter "Brakes" in group 15.10. The manufacturer also prescribes an annual inspection of the disc lining for wear, (see Fig. 8, page 11). The above check must be carried out annually, or if one of the following problems arise: – Reduced braking force – Reduced brake pressure – Changes in the oil level in the wheel hub – Unusual braking noises

Fig. 7

Wear assessment

Measuring of brake lining wear Caution! Escaping oil, due to a pressure build-up in the drive unit, can drive out the plug screw, causing injury. Slowly screw out the screw plug to 12 o'clock position. Turn the output (wheel hub) until the screw plug 71 is in its top position (12 o'clock).

12.47.10

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Service Manual

MT - E 3060 rigid axle Maintenance of the axle Carefully loosen the screw plug 71 and remove it. The internal measuring bore 2 becomes visible. Turn the output unit until the measuring bore 2 is in the 9 o'clock position. Attach the dial gauge with magnetic stand and extension to the output unit, see Fig. 8. Insert the dial gauge 3 through the oil discharge bore and the measuring bore 2 and position it at the piston 89.

If the brake is not applied, the piston is pushed by the return spring force onto the hollow gear. Apply pressure to the brakes and measure the piston travel X with the dial gauge. Write down the measured value. Mount a new O-ring on the screw plug 1 and insert it. .

Note! Piston travel with new discs = 0.7 – 1.3 mm. Limit value for piston travel with wear at 6 discs = 6.0 mm. Limit value for piston travel with wear at 7 discs = 6.5 mm. If the actual value exceeds the permissible limit value, replace the entire brake disc pack.

Fig. 8

Wear measurement at the disc pack

2

Measuring bore (Ø 10 mm)

83

3 70

Dial gauge with magnetic stand Planetary carrier

89 Piston 96/97 Disc pack

71

Screw plug Oil filling/ oil discharge bore

X

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Hollow gear

Piston travel

12.47.11


Service Manual


6 Dismantling, repair and installation of the rigid axle (see Fig. 9, page 13)

6.1

Dismantling of the steering axle for repair work Danger! The dismantling and installation of the rigid axle requires access to the undercarriage of the machine. There is a risk of death to the technician, as limbs could become crushed. Park the machine on level ground. Secure the lifted undercarriage with suitable props. Depressurise the hydraulic system. Always refer to the safety instructions in group 1.10. Lift the undercarriage 5 at the rear and secure the wheels of the steering axle using chocks. If required, remove the vehicle wheels 1 from the rigid axle . Disconnect and seal the brake line to the multi-disc brakes (collect any escaping oil). Loosen the hex head screws 2 and remove the universal joint shaft 3. Lift the undercarriage 5 and secure the rigid axle 8 with suitable lifting tackle. Loosen the hex nuts 9 and remove the hex head screws 7. Lift the rigid axle 8 from the undercarriage 5.

6.2

Repair of the rigid axle Note! For detailed repair instructions for the axle, refer to the separate "Repair manual for ZF axles MTE 3050/3060/3070".

6.3

Installation of the rigid axle after repair work Place the rigid axle 8 in the undercarriage 5, using suitable lifting gear. Screw in the hex head screw 7 and tighten it with the prescribed torque. Secure the universal joint shaft 3 with the screws 2 to the output flange / drive of the rigid axle 8. Connect the brake lines to the multi-disc brake and bleed the brake (see group 15.10). Mount the vehicle wheels 1. Lower the undercarriage and remove the chocks. Tighten the wheel lugs with the prescribed torque, see Tab. 1.

12.47.12

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MJF C I F S S

Service Manual

MT - E 3060 rigid axle Dismantling, repair and installation of the rigid axle

Fig. 9


1

Vehicle wheels

5

Undercarriage

2 3


6 7


4

Lock nut

8

Rigid axle

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MJF C I F S S

12.47.13


Service Manual

Dismantling, repair and installation of the rigid axle 6 30

Screw plug Axle housing

87 88


36 50

Stub shaft Hub carrier

89 90


51

Sun gear shaft

91

Pressure spring

54 55

Slotted nut O-ring

92 93


56

Sealing cap

94

Disc carrier

57

Hex head screw

95

O-ring

70

Planetary carrier

96

Inner disc

74

Allen head screw

97

Outer disc

75

Circlip

99

Roller bearing

76 77

Planetary gear Washer

100 101

Spacer bushing Hub

78 80


103 104

Radial shaft seal ring Allen head screw

82 83

O-ring Hollow gear

105 106


85

Backing ring

107

Centring ring

86

Lip seal

108

Wheel lug

Note! Observe settings and torques A, B, C, D, E, F, G, H, I, see Fig. 10 and Table 1, page 3.

12.47.14

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MJF C I F S S

Service Manual

MT - E 3060 rigid axle Dismantling, repair and installation of the rigid axle

Fig. 10


copyright by

MJF C I F S S

12.47.15


Service Manual


12.47.16

copyright by

MJF C I F S S

Service Manual

MS/MT - E 3060 drive unit and differential Function

MS/MT - E 3060 drive unit and differential 1 Function The drive unit and differential are integrated into the axle housing of the steering and rigid axle. They transmit the output power of the transmission to the planetary drives of the wheel hubs, adjusting the speed and torque by means of bevel pinions and the crown wheel. The differential also acts as an equalising device when the vehicle is negotiating a corner. If the mechanical connection from the transmission via the universal joint shafts, the differential, the stub shafts and the planetary drives to the vehicle wheel were rigid, such steering manoeuvres would result in great strain on the axle and excessive tyre wear. The differential balances out these forces. The torque input from the input flange to the bevel gear, crown wheel and differential cage, and from there to the balancing axles mounted in the differential cage ensures that the four balancing bevel gears attached to the balancing axles mesh with the two axle shaft gears. As a result, there is a relative shift in direction of rotation between the two stub shafts meshing with the axle shaft gears, i.e. one stub shaft rotates clockwise, while the other rotates anticlockwise, or the two stub shafts rotate at different rates. The balancing movement has however a negative effect on the traction of the machine when driving off-road over surfaces with different grip. On loose ground, ice or snow, only one wheel per axle might properly grip the surface.

Fig. 1

Differential

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MJF C I F S S

12.48.1


Service Manual

Function

12.48.2

copyright by

MJF C I F S S

Service Manual

MS/MT - E 3060 drive unit and differential Technical data


A 316 Li 715 / 716 28061 / 28062

Axle type

MT-MS

Gear ratio

3,18

This differential is not available as a complete unit. The component parts of the differentials for the steering and the rear axle are identical. Settings, to be observed for installation: A Setting value of the crown wheel kit 10/11

(etched onto the end side of the pinion 11)

B Tooth backlash of the crown wheel kit 10/11

0.12 - 0.24 mm

C Bearing preload of the differential bearing 34

1 - 4 Nm


1 - 2 Nm

E


600 Nm

F

Tightening torque for the hex head screws 49

390 Nm


145 Nm

Items A - G Tab. 1

Technical data

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MJF C I F S S

12.48.3


Service Manual

Description

3 Description The differential 2 is inserted into the axle drive housing 31. The drive 1 is also integrated into the axle drive housing. The axle housings 3 with the yoke / stub shaft connecting the output end to the input end are screwed to the left and right to the axle drive housing with the hex head screws 49.

E

12.48.4

1 2

Input Differential

21 22

Washer Differential cage

3

Axle housing

23

Thrust washer

10 11

Crown wheel Pinion

24 25


12 13


26 27

Thrust washer Balancing axle

14

Roller bearing

28

Heavy-duty roll pin

15

Ring (S=10.94-12.38mm)

29

Roll pin

16


31

Axle drive housing

17 18

Protective plate Input flange

32 33

O-ring Washer

19

Hexagon nut with washer

34

Roller bearing

20

Allen head screw

49

Hex head screw

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Service Manual

MS/MT - E 3060 drive unit and differential Description

3.1

Design of differential

Fig. 2

Design of differential

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MJF C I F S S

12.48.5


Service Manual

Dismantling, repair and installation of the differential

4 Dismantling, repair and installation of the differential Danger! The dismantling and installation of the differential requires access to the undercarriage of the machine. There is a risk of death to the technician, as limbs could become crushed. For the dismantling and installation see also group 12.46 for the steering axle and group 12.47 for the rigid axle. Park the machine on level ground. Secure the lifted undercarriage with suitable props. Depressurise the hydraulic system. Always refer to the safety instructions in group 1.10.

4.1

Repair of differential Note! The differential can only be dismantled, installed and repaired together with the respective axle. Please also refer to the separate repair manual "ZF axles MT/MS-E 3050/3060/3070". 10

Crown wheel

23

Thrust washer

11

Pinion

24

Axle shaft gear

12 13


25 26

Balancing shaft gear Thrust washer

14 15


27 28

Balancing axle Heavy-duty roll pin

16


29

Roll pin

17 18

Protective plate Output flange

30 31

Axle housing Axle drive housing

19 20

Hexagon nut with washer Allen head screw

32 33

O-ring Washer

21 22

Washer Differential cage

34 49

Roller bearing Hex head screws

Note! Observe settings and torques A, B, C, D, E, F, G, and Table 1, page 3.

12.48.6

copyright by

MJF C I F S S

Service Manual

MS/MT - E 3060 drive unit and differential Dismantling, repair and installation of the differential

Fig. 3


copyright by

MJF C I F S S

12.48.7


Service Manual

Dismantling, repair and installation of the differential

12.48.8

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MJF C I F S S

Service Manual

Tyres and spacer rings A 309 and A 311 Litronic

Tyres and spacer rings 1 A 309 and A 311 Litronic 1.1

A 309 Litronic from 20221 Type: 717 Size

Tyre type

Producer

PR

Pressure [bar]

Spacer rings

9.00-20

Amor Gard

Nokia

14

7,50

MH 2

9.00-20

8 NB 38

Mitas

14

7,50

MH 3

500/45-20

4 Wide tire

Alliance

-

6,0

-

PR

Pressure [bar]

Spacer rings

Tab. 1

1.2

Tyres and spacer rings 309


Tyre type

Producer

9.00-20

Amor Gard

Nokia

14

7,50

MH 2

9.00-20

8 NB 38

Mitas

14

7,50

MH 3

500/45-20

4 Wide tire

Alliance

-

6,00

-

Tab. 2


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MJF C I F S S

12.54.1


Service Manual

A 312 and A 314 Litronic

2 A 312 and A 314 Litronic 2.1

A 312 Litronic from 12363 Types: 719 Size

Tyre type

Producer

PR

Pressure [bar]

Spacer rings

10.00-20

8 Titan

Continental

16

9,00

-

10.00-20

8 E 91-2

Dunlop

16

7,50

MH 3

10.00-20

8 Fast-Grip

Bridgestone

14

7,00

MH 2

10.00-20

8 Amor Gard

Nokia

16

9,00

MH 2

10.00-20

8 NB 38

Mitas

16

7,50

MH 3

18.00-19,5

4XTF

Michelin

-

7,00

-

600/40 - 22,5

4 HDI 331

Alliance

-

6,00

-

600/40 – 22,5

4 TR 12

Mitas

-

6.0

-

Tab. 3

2.2


A 314 Litronic from 2001 Type 635 Size

Tyre type

Producer

PR

Pressure [bar]

Spacer rings

10.00-20

8 E 91-2

Dunlop

16

7,50

MH 2

10.00-20

8 Fast-Grip

Bridgestone

14

7,00

MH 2

10.00-20

8 Amor Gard

Nokia

16

9,00

MH 2

10.00-20

8 NB 38

Mitas

16

7,50

MH 3

10.00-20

8 R 20 XL

Michelin

-

7,75

-

18.00-19,5

4XTF

Michelin

16

7,00

-

600/40 - 22,5

4 HDI 331

Alliance

-

6,00

-

600/40 - 22,5

4 TR 12

Mitas

-

6,00

-

Tab. 4

12.54.2


copyright by

MJF C I F S S

Service Manual

Tyres and spacer rings A 316 Litronic

3 A 316 Litronic 3.1


Tyre type

Producer

PR

Pressure [bar]

Spacer rings

10.00-20

8 Titan

Continental

16

9,00

-

10.00-20

8 E 91-2

Dunlop

16

7,50

MH 3

10.00-20

8 Fast-Grip

Bridgestone

14

7,00

MH 2

10.00-20

8 Amor Gard

Nokia

16

9,00

MH 2

10.00-20

8 NB 38

Mitas

16

7,50

MH 3

10.00-20

8 Gumasol

Euromaster

-

-

MH 4

18.00-19,5

4XTF

Michelin

7,00

-

600/40 - 22,5

4 HDI 331

Alliance

-

6,00

-

600/40 - 22,5

4 TR 12

Mitas

-

6,00

-

Size

Tyre type

Producer

PR

Pressure [bar]

Spacer rings

10.00-20

8 NB 38

Mitas

16

7,50

MH 3

10.00-20

8 Gumasol

Euromaster

-

-

MH 4

Size

Tyre type

Producer

PR

Pressure [bar]

Spacer rings

10.00-20

8 Titan

Continental

16

7,75

MH4

10.00-20

8 E 91-2

Dunlop

16

7,50

MH 2

10.00-20

8 XL

Michelin

16

7,75

-

10.00-20

8 NB 38

Mitas

16

7,50

MH 4

Type: 716

Type: 715 / 716 EW

Tab. 5

Tyres and spacer rings 316Broad tire

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MJF C I F S S

12.54.3


Service Manual

A 316 Litronic

12.54.4

copyright by

MJF C I F S S

Service Manual

Chassis / drive Design

Chassis / drive 1 Design The chassis / drive consist of three main components: The chain 40 with chain link 41 and base plate 45 Tensioning unit 66 with grease tensioner 3, pressure spring 67 and idler 2 Running roller 38 Support roller 39 Chassis drive with travel gear 65 and tumbler wheel 63

Fig. 1 2

Design 45 Base plate

Idler

3 Grease tensioner 38 Running roller

62 Longitudinal member 63 Tumbler wheel

39 Support roller

65 Travel gear

40 Chain

66 Tensioning unit, complete

41 Chain link

67 Spring

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MJF C I F S S

12.60.1

Chassis / drive

Service Manual

Chain 40

2 Chain 40 2.1

Dismantling, mounting and repairing chain 40 For detailed instructions, see group 12.72.

3 Tensioning unit with idler 2 3.1

Design of tensioning unit and idler 2 See groups 12.75 and 12.78.

3.2

Dismantling and mounting tensioning unit and idler 2 Dismantle the chain 40 (see group 12.72). Dismantling and mounting tensioning unit (see group 12.75) Dismantling and installing idler (see group 12.78)

4 Running roller 38 4.1

Design of running roller 38 See group 12.81.

4.2

Dismantling idler 38 Release or remove the chain 40 (see group 12.72). Remove the screws 54see Fig. 2. Remove the idler 38 from the longitudinal member 62. Dismantling and mounting idler (see group 12.81)

4.3

Design of running roller 38 Caution! Screw connections that are unable to bear the occurring forces, due to elongation of or damage to the screws, can cause serious damage of components such as longitudinal members, running rollers and chains. Such breaks can also injure persons standing nearby. For safety reasons, all screws must thus be replaced with new ones when the running rollers are replaced. When mounting running rollers, always use new screws. Mount the running roller 38 on the longitudinal member 62 and tighten the screws 54see Fig. 2.(for tightening torque, see group 12). Mount the chain 40 (see group 12.72).

12.60.2

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MJF C I F S S

Service Manual

Chassis / drive Support roller 39

5 Support roller 39 5.1

Design of support roller 39 See group 12.84.

5.2

Dismantling of support roller Release the chain 40 (see group 12.72). Push the chain 40 upwards by inserting a piece of timber between the upper edge of the longitudinal member and the chain. Remove the screws 56see Fig. 2. Remove the support roller 39 from the longitudinal member 62. Dismantling and installing support roller (see group 12.84)

5.3

Mounting support roller Place the support roller 39 onto the bearing block of the longitudinal member 62. Insert the screws 56, see Fig. 2with the retaining washers and tighten them. Remove the piece of timber. Tighten the chain (see group 12.72).

6 Chassis drive 6.1

Design and function of travel gear 65 See groups 11.60 / 11.62.

6.2

Dismantling and mounting travel gear 65 See groups 11.60 / 11.62.

7 Maintenance of chassis parts During operation, the chassis parts must be regularly inspected at the prescribed maintenance intervals, see inspection and maintenance schedule of main group 3. Clean the chain 40 at the end of the shift. The chain tension must be checked every day (every 8 to 10 operating hours), see also group 12.72. The fixture of the base plates 45 and tumbler wheels 63 must be examined every week (every 50 operating hours), see group 12.72. The fixture of the travel gear 65, the oil motor and the running and support rollers 38 / 39 must be checked every 500 operating hours by examining the tightening torque of the fastening bolts, see groups 12.62, 12.64.

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MJF C I F S S

12.60.3

Chassis / drive

Service Manual

Maintenance of chassis parts The sliding surface of the tensioning unit (on sliding pieces and longitudinal members) must be cleaned and lubricated every 500 operating hours. The travel gear 65, the oil motor and the running and support rollers 38 / 39 must be checked every 500 operating hours for leakage.

12.60.4

1 2

Undercarriage Idler

54 Hex head screw 56 Hex head screw

3 4

Grease tensioner Lid

59 Lubrication nipple 60 Extension

5

Lid

61 USIT ring

6

Locking mechanism

62 Longitudinal member

7

Hex head screw

63 Tumbler wheel

8 Hex head screw 30 Regulating motor

65 Travel drive 66 Tensioning unit

31 Hex head screw 35 O-ring

67 Spring 68 Spring plate

38 Running roller

70 Lid

39 Support roller 40 Chain

71 Hex head screw 72 Hose

41 Chain link 42 End bolt

73 Hose 74 Hose

43 End bushing

75 Allen head screw

45 Base plate 49 Spacer ring

76 Flange halves 77 Hose

50 Allen head screw 51 Square nut

78 Hose 79 Rectangular ring

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MJF C I F S S

Service Manual

Chassis / drive Maintenance of chassis parts

Fig. 2

Chassis parts

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MJF C I F S S

12.60.5

Chassis / drive

Service Manual

Maintenance of chassis parts

12.60.6

copyright by

MJF C I F S S

Service Manual


Technical data / tightening torques Machine Type valid from serial no.

R 313 636 27752

Chain Type Number of segments

D4 L 46

Base plate Type Model Width / spec. weight on ground (15 t / 16 t * usable weight)

Base plate screws Thread Tightening torques

Three-step D4 L 500 mm / 4.6 N / cm² 4.9 N / cm² * 600 mm / 3.9 N / cm² 4.2 N / cm² * 750 mm / 3.2 N / cm² 3.4 N / cm² * 5/8“-18 UNF X16 180 ± 20 Nm + 120°

Travel gear Type Number per chain Tightening torque for mounting screws

FAT 350 1 560 Nm

Tumbler wheel Number per chain Tightening torque for mounting screws

1 560 Nm

Running roller Type Number per chain Tightening torque for mounting screws

D4 L 7 280 Nm

Support roller Type Number per chain Tightening torques of mounting screws and bolts

D4 L 2 280 Nm

Lubrication nipple (extension) Number per chain Torque Tab. 1

1 170 Nm

Technical data

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MJF C I F S S

12.62.1


12.62.2

Service Manual

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MJF C I F S S

Service Manual


Technical data / tightening torques Machine Type valid from serial no.

R 317 970 18161

R 317 362 18161

Chain Type Number of segments

B 60 L 44

B 60 L 55

Three-step B 60 L 500 mm / 5.0 N / cm² 600 mm / 4.3 N / cm² 750 mm / 3.5 N / cm² 900 mm / 2.7 N / cm² 1000 mm / 2.4 N / cm²

Three-step B 60 L 600 mm / 3.5 N / cm² 900 mm / 2.4 N / cm² 1000 mm / 2.1 N / cm²

M 20 x 1.5 740 - 840 Nm

M 20 x 1.5 740 - 840 Nm

FAT 350 1 560 Nm

FAT 350 1 560 Nm

Tumbler wheel Number per chain Tightening torque for mounting screws

1 560 Nm

1 560 Nm

Running roller Type Number per chain Tightening torque for mounting screws

B 60 7 280 Nm

D6 KL 9 280 Nm

Support roller Type Number per chain Tightening torques of mounting screws and bolts

B 60 L 2 280 Nm

B 60 L 3 280 Nm

1 170 Nm

1 170 Nm

Base plate type Type Width / specific base plate load (with hydr. boom adjusting device, 17t usable weight)

Base plate screws Thread Tightening torques Travel gear Type Number per chain Tightening torque for mounting screws

Lubrication nipple (extension) Number per chain Tightening torques of mounting screws and bolts Tab. 1

Technical Data

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MJF C I F S S

12.64.1


12.64.2

Service Manual

copyright by

MJF C I F S S

Service Manual

Wear of chassis parts Introduction

Wear of chassis parts 1 Introduction Chassis parts are subject to wear from movement, loads and contact between parts. Improper driving and manoeuvring (e.g. sudden turning, uneven loads, incorrect crossing of obstacles) results in significantly increased wear. It is therefore important that the excavators are operated according to the following basic rules: Note! – For travel over long distances, the drive system of the excavator must be at the rear. – When working in longitudinal direction using the backhoe bucket, e.g. in connection with channel digging, move the excavator in reverse direction and work across the idler. – For pipe laying work, the drive unit must be at the rear of the excavator. – When working with the front shovel or the backhoe bucket, ensure that the excavator is not elevated or tipped with a high centre of gravity. Worn chassis parts such as chain links, running rollers, idlers, support rollers, tumbler wheels, base plates, etc. must be replaced with new parts as soon as the specified wear limit is reached, see group 12.67, 12.69.

1.1

Wear of bolts and bushings Internal wear of bushings and bolts leads to an increased chain pitch. As a result, the drive wheel and the bushings fail to engage properly, so that there is increased wear at the inner and outer surfaces of the bushings as well as at the engaging surfaces of the drive wheels. The effect of internal wear can be considerably reduced by turning the bolts and bushings by 180 degrees. The time at which the bolts and bushings are to be turned must be determined as described below. It cannot be determined based on the operating hours of the machine. – Measuring of chain pitch: measure the chain pitch across at least 4 chain links. Repeat this measurement at different intervals on the chain. Divide the average measured value by 4. The result corresponds to the wear per bolt and bore. If the wear is less than approx. 3 mm, turn the bushings and bolts. If the wear exceeds approx. 5 mm, replace the bushings and bolts. – Measuring of bushings: they may not be worn by more than 3 to 3.5 mm at the outer wear limit. In order to establish the degree of wear and thus the need for replacement, it is necessary to regularly and accurately measure the chassis parts. Note! Prior to measuring, carefully clean the chassis parts or measuring points. Repeat the measurements at various locations, e.g. at the tumbler wheel, or on various parts, e.g. on the chain. Always base your assessment on the maximum wear measured. The degree of wear is calculated by comparing the measured dimension (actual value) with the corresponding dimension of the new part (nominal value), see wear limits, group 12.67, 12.69..

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MJF C I F S S

12.66.1


Service Manual

Chain links Example: Hn

= height of new part

= 126 mm

Hv H

= wear limit of part = actual height (measured height)

= 116 mm = 120 mm

Degree of wear:

Fig. 1

Calculation of the degree of wear

2 Chain links

Fig. 2

Measurement with depth gauge or ruler of bearing surface wear on chain link between the chain bearing surface and the base plate pad.

3 Chain bolts

Fig. 3

12.66.2

Measurement of inner wear of bolts and bushings using a ruler. The measurement is carried out on the tight chain and across 4 chain links.

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Service Manual

Wear of chassis parts Chain bushing

4 Chain bushing

Fig. 4

Measurement with calliper gauge of outer wear of chain bushing at point of maximum wear.

5 Base plate

Fig. 5

Measurement with depth gauge or ruler of ridge wear at base plate.

6 Idler

Fig. 6

Measurement with depth gauge of wearing surface wear of idler.

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MJF C I F S S

12.66.3


Service Manual

Running roller

7 Running roller

Fig. 7

Measurement with calliper gauge or outside calliper of wearing surface wear of running roller.

8 Support roller

Fig. 8

12.66.4

Measurement with calliper gauge or outside calliper of wearing surface wear of support roller.

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MJF C I F S S

Service Manual

D4L wear limits

D4L wear limits New Tumbler wheel

Wear limit Zv

to

tip of gear

Chain link

Chain bolt

Hn

Hv

96.0

90.0

Ln

Lv

686.8

698.8

Dn

Dv

Chain bushing

normal impact

54.2

46.3

high impact

48.9

New

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MJF C I F S S

Wear limit

12.67.1

D4L wear limits

Service Manual

Base plate

Idler

Running roller

Support roller

12.67.2

copyright by

MJF C I F S S

Hn

Hv

25

12.5

Hn

Hv

17

23.5

Dn

Dv

138

126

Dn

Dv

120

110

Service Manual

Wear limits - B60

Wear limits - B60 New Tumbler wheel

Wear limit Zv

to

Tip of gear

Chain link

Chain bolt

Chain bushing

Tab. 1

Hn

Hv

105

98

Ln

Lv

761

774

Dn

Dv

59

54

Wear limits

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MJF C I F S S

12.69.1

Wear limits - B60

Service Manual

Base plate

Idler

Running roller

Support roller

12.69.2

copyright by

MJF C I F S S

New

Wear limit

Hn

Hv

28

12.5

Hn

Hv

20

25

Dn

Dv

154

141

Dn

Dv

120

107

Service Manual

Chain Dismantling complete chain

Chain 1 Dismantling complete chain Danger! When dismantling the chain, there is a risk of the chain suddenly becoming slack, which can result in injury. There is a risk of injury from escaping grease when the chain is handled incorrectly when being released. To remove the chain, the longitudinal member must be lifted over the attachment, see Fig. 1. Persons working near the chain are thus exposed to a serious risk of injury when the member is dropped or inadvertently lowered. Never reach under the suspended longitudinal member. Keep your head away from the opening of the longitudinal member when releasing the chain. Never loosen or tighten the screws by hand, always use a suitable tool. Always wear protective goggles and gloves. Always observe the instructions below. Place the excavator on a firm level ground. Move the chain until the end bolt 42, see Fig. 3 is located in the lower third of the drive train. Place the wedge under the unit. The end bolts 42 differ from normal bolts in that they feature a larger or smaller recess and bevelled front edges, (see Fig. 4 on page3).

Fig. 1

1.1

Lifting longitudinal member using the attachment

Releasing chain, see Fig. 2 Before releasing the chain, carefully clean the chassis, in particular the area around the chain end bolts and the cover 4 on the longitudinal member. Remove all objects jammed in the chain (if necessary, move the chain back and fore). Remove the screws 8 and then remove the cap 4 from the longitudinal member. Turn the lubrication nipple 59 only by a few turns on the extension 60 (WS 27) (do not screw it out fully) so that the grease escapes at the release groove N (longitudinal groove, see Fig. 2). Press the chain towards the longitudinal member between the support rollers. After the chain has been released, immediately turn in and tighten the lubrication nipple 59 complete with the extension 60 (tightening torque 170 Nm).

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12.72.1

Chain

Service Manual

Dismantling complete chain

Fig. 2 4 8

Screw plug with release groove and lubrication nipple 60 Lubrication nipple extension (WS 27)

Lid (access to lubrication nipple) Hex head screw

59 Lubrication nipple (WS 22)

1.2

N Release groove

Opening and removing chain Note! Press the thumb screw from the inside of the chain outwards. Push out the grooved end bolts (inwards or outwards). Push out the end bolts, (see 3 on page6). Roll off the chains in the direction of travel. If required, you can now remove the idler with tensioning unit from the longitudinal member, see group 12.78. Lift the excavator and pull off the chain.

12.72.2

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Service Manual

Chain Mounting chain

Fig. 3

Direction of travel for chain dismantling

A Roll-off direction

4

F

42 End bolt

Direction of travel

Fig. 4

Lid

End bolt

N Grooved end bolt

R Thumb end bolt

2 Mounting chain Before mounting the chain, inspect the fixture of the chassis components, see also maintenance instructions for the chassis, group 12.70 Position the excavator on the rolled-out chain and secure it with chocks. Place the chain over the idler and the support roller, using a rope or cable and a pulling device (vehicle, etc.). Observe the direction of travel of the chain and the position of the base plates, see Fig. 5. Insert the end bushing rings 43. Connect the chain links and push in the end bolt 42 from the outside, (see 3 on page6). Screw in the lubrication nipple 59 with the extension 60 and the UNIT seal ring at the grease tensioner and tighten the chain with the grease gun.

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12.72.3

Chain

Service Manual

Mounting chain Note! The chain is tensioned correctly, if there is a dip of approx. 15 to 22 mm between the two support rollers, (see Fig. 7 on page5)!

Fig. 5

Direction of travel of the chain

Fig. 6

Chain tensioning with manual level grease gun

4

80 Manual grease gun

Lid

59 Lubrication nipple

82 Nozzle pipe

60 Extension

2.1

Checking chain tension Release the chain by moving fore and back. Place the measuring rod 90 onto the section between the support rollers.

12.72.4

copyright by

MJF C I F S S

Service Manual

Chain Mounting chain Measure the distance X between the measuring rod lower edge and the base plate. There must be a dip of approx. 15 to 20 mm between the support rollers. If necessary, tension the chain.

Alternative measurement: Measure the distance Y1 between the upper edge of the longitudinal member and the lower edge of the chain link beside the support roller. Measure the distance Y2 between the upper edge of the longitudinal member and the lower edge of the chain link at the centre between the support rollers. Calculate the actual dip: Deduct dimension Y2 from Y1.

Fig. 7

2.2

Chain dip of correction tensioned chain

A

Insufficiently tensioned chain

X

B 90

Correctly tensioned chain Measuring rod

Y1-Y2 Chain dip

Chain dip

Tensioning chain As the chassis is exposed to normal wear, the chain tension must be regularly checked and redesigned, if necessary. Remove the lid 4 from the longitudinal member of the undercarriage. Screw the nozzle pipe 82 from the hand grease gun 80. Connect the nozzle pipe 82 through the opening in the longitudinal member with the lubrication nipple 59 of the grease tensioner, (see Fig. 6 on page4). Fill in grease until the chain is sufficiently tensioned. Check chain tension, see Fig. 7.

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12.72.5

Chain

Service Manual

Dismantling and mounting end bolt when replacing chain

3 Dismantling and mounting end bolt when replacing chain Danger! There is a risk of injury when the hardened end bolt 42 is driven out or in with the sledge hammer, as metal might break off! When driving the end bolt out or in, always were protective goggles! Complete the process with a bolt press, (see Fig. 8 on page7), or other suitable tool. Note! Push thumb bolts from the inside of the chain towards the outside, (see Fig. 8 on page7). If available, drive them out with a suitable device. The groove bolts can be driven out from the outside to the inside or vice versa! Always secure the chain link when driving out the bolts! Drive or push out the end bolt 42. Remove the seal / spacer rings and the chain bushing.

3.1

Mounting end bolt Place the seal / spacer rings and the chain bushing in the end links of the chain and bring the chain ends together. Insert the end bolt 42 from the outside of the chain and press it in, using a bolt press.

12.72.6

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Service Manual

Chain Replacing damaged base plates

Fig. 8

Bolt press for the dismantling and mounting end bolt

4 Replacing damaged base plates Caution! Bent or loose base plates can lead to serious consequential damage to the adjacent base plates and the track chain. Regularly service the chain. For instructions, see maintenance instructions for the chassis in group 12.60. Replace damaged base plates! Loosen the mounting screws 50 and remove all damaged base plates. Clean the support face at the chain link and mount a new base plate. Tighten the mounting screws 50 crosswise and with the correct torque, using a torque spanner (see Fig. 9 on page8) (see group 12.57).

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12.72.7

Chain

Service Manual

Repair of damaged chain

Fig. 9

Replacement of damaged base plates

1-4

Tightening of base plate screws

50

Hex head screw for base plate

51

Base plate nut

5 Repair of damaged chain 5.1

Dismantling of torn chain link Using a blow torch, cut through the damaged chain link and place the chain on the ground. With the blow torch, cut off the bushings and bolts at the damaged chain link at the indicated points, see Fig. 10. Remove cut chain pieces.

Fig. 10

Torch cuts through damaged chain

44 Complete side chain link 48 Complete side chain link

12.72.8

C Fraction point at chain link D Torch cuts at chain link

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Service Manual

Chain Repair of damaged chain

5.2

Preparation for insertion of new chain link Torch-cut the front side of the bushing 43 and grind it to a smooth finish (E). Weld in the bolt stump K at the centre, using a blow torch and drive it out with a hammer (back it with the hammer G).

Fig. 11

Preparation for insertion of new chain link

44 Complete side chain link

F

43 Bushing

G Backing with hammer


H Direction of bolt drive-out

E

K Bolt stub

Grinding chain link to a plane surface

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MJF C I F S S

Burn in hole, using a blow torch

12.72.9

Chain

Service Manual

Repair of damaged chain

5.3

Insertion of new chain link Connect the compressed chain link 46 with the spacer ring 49 and one end bolt 42 to the chain link 48. Press in the end bolt 42. Mount the chain. Insert two spacer rings 49 into the chain link 46 and connect them with the end bolt 44. Close the chain by pressing in the end bolt 42. Mount the base plate, (see Fig. 9 on page8).

Fig. 12

Insertion of new chain link

42 End bolt

12.72.10

47 Drive-in direction of thumb end bolt

43 End bushing


44 Complete side chain link 46 New chain link

49 Spacer ring

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Service Manual

Tensioning unit Dismantling complete tensioning unit

Tensioning unit 1 Dismantling complete tensioning unit Remove the covers 4 and 5 from the longitudinal member 62see Fig. 2 of the undercarriage. Caution The spring 67 of the tensioning unit applies a great force through the spring plate 68 onto the locking mechanism 6. Loosening the screws 7 while the spring is prestressed can cause damage to the locking mechanism. Never loosen the screws 7 while the spring plate 68 is being supported by the locking mechanisms. Place the nozzle tube of the manual grease gun onto the lubrication nipple 59 of the grease tensioner 3. Press in grease (over-tensioning chain) until the spring plate 68 is lifted from the locking mechanisms 6. Remove the mounting bolts 7 and the locking mechanisms 6. Remove the grease gun from the lubrication nipple 59. Release and dismantle the chain (see group 12.72). Pull the idler 2 with the grease tensioner 3, the spring plate 68 and the spring 67 from the longitudinal member 62.

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12.75.1

Tensioning unit

Service Manual

Dismantling grease tensioner

Fig. 1 2 3

Assembling tensioning unit and idler 14 Backing ring 59 Lubrication nipple

Idler, complete Grease tensioner

10 Piston 11 Housing

60 Extension 61 USIT ring

12 Lip seal

67 Spring

13 Scraper ring

68 Spring plate

2 Dismantling grease tensioner Dismantle the grease tensioner only, if this is necessary for repair, etc. Screw off the extensions with the lubrication nipple and pull the piston 10 from the cylinder 11. Remove the lip seal 12 from the piston 10. Remove the scraper ring 13 from the cylinder 11.

3 Mounting grease tensioner Place the new lip seal 12, new scraper ring 13 and piston 10 in the cylinder 11. Screw in the extension 60 with the lubrication nipple 59 together with the new USIT ring 61.

12.75.2

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MJF C I F S S

Service Manual

Tensioning unit Mounting complete tensioning unit

4 Mounting complete tensioning unit Insert the spring 67 into the longitudinal member 62 and centre it on the pipe section. Insert the spring plate 68 into the sliding rails of the longitudinal member 62. The centring device at the spring plate 68 must thereby be inserted into the spring 67. Insert the idler 2 with the grease tensioner 3 into the rail of the longitudinal member 62. Mount and tighten the chain (see group 12.72). Preload the spring 67 by pressing grease into the grease tensioner 3 until the spring plate has passed the opening 5 and the locking mechanisms 6 can be mounted. Note! Ensure that the machined surface of the locking mechanism 6 faces the idler 2. The machined surface is marked with an arrow. Insert the locking mechanisms 6 and secure them with the screws 7 (tightening torque for screws 7 = 107 Nm). Remove the grease gun from the lubrication nipple 59. Danger! When releasing the chain, there is a risk of injury from escaping grease. Keep your head away from the opening of the longitudinal member when releasing the chain. Never loosen or tighten the screws by hand, always use a suitable tool. Always wear protective goggles and gloves. Loosen the extension 60 with the lubrication nipple and let the grease escape until the correct chain tension is reached, see group 12.72. Screw in the extension 60 with the lubrication nipple and tighten it (torque = 170 Nm).

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12.75.3

Tensioning unit

Service Manual

Mounting complete tensioning unit

Fig. 2

12.75.4

Tensioning unit with idler

2 3

Idler Grease tensioner

7 Hex head screw 59 Lubrication nipple (with extension)

4 5

Lid Lid

62 Longitudinal member 67 Spring

6

Locking mechanism

68 Spring plate

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Service Manual

Tensioning unit Mounting complete tensioning unit

Fig. 3

Sectional drawing of tensioning unit

4 5

Lid Lid

13 Scraper 59 Lubrication nipple

6 7

Locking mechanism Hex head screw

60 USIT ring 62 Longitudinal member

10 Piston 11 Housing

67 Spring 68 Spring plate

12 Compact seal Machine Type Serial number R 313 636 27752 R 317 362 / 790 18161

Piston Ø 10 (mm)

Free length Lo (mm)

Preloaded length L1 (mm)

Preload force kN

Spring travel L (mm)

ØS (mm)

80

423

354

85

45

38

100

442

372

140

56

49

Tab. 1

Technical data of tensioning unit

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MJF C I F S S

12.75.5

Tensioning unit

Service Manual

Mounting complete tensioning unit

12.75.6

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MJF C I F S S

Service Manual

Idler Dismantling idler

Idler 1 Dismantling idler Remove the tensioning unit with the idler from the longitudinal member in the undercarriage (see group 12.75), proceeding as follows: Remove the hex head screws 12. Disconnect the idler 11 with the two sliding pieces 7 from the housing 14.

2 Dismantling Remove the screw cap 3 and drain off the oil. Drive out the roll pins 8 and remove the sliding pieces 7 and the O-rings 6 from the axle 1. Pull the axle 1 from the idler 11. Remove the slide ring seal halves 5 from the idler 11 and the sliding pieces 7. Push out the bearing bushings 2 from the idler 11.

3 Installation Press the bearing bushings 2 into the idler 11. Insert the slide ring seal halves 5 into the idler 11 and the sliding pieces 7 (see group 12.71). Note: The slide rings must be ground in pairs. Do not confuse them!

Place the O-ring 6 and a sliding piece 7 on the axle 1 and drive in the roll pin 8. Insert the axle1 in the idler 11 and place the second O-ring 6 and sliding piece 7 on the axle 1. Drive in the second roll pin 8. Fill the idler with oil (adhere to filling instructions).

4 Mounting idler Secure the sliding pieces 7 with the hex head screws 12 to the housing 14 and tighten the screws with the correct torque. Insert the tensioning unit with the idler from the longitudinal member in the undercarriage (see group 12.75).

5 Filling instructions Turn the idler until the oil filling opening is aligned vertically. Fill in SAE 40 motor oil until the centre chamber is full. Apply compressed air to the centre chamber, to press the oil into the side chambers. Turn the idler 11 until the oil filling opening is at a 45 degree angle to the perpendicular. Add oil until it escapes through the opening 15. Apply Loctite to the screw plug 3 and screw it in together

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12.78.1

Idler

Service Manual

Filling instructions with the O-ring 4, (see Fig. 3, page 3). Filling volumne:~0.300 - 0,330 kg of SAE 40

Fig. 1 1

12.78.2

Sectional drawing of the idler

Axle

8

Roll pin Trapezoid ring

2

Bearing bushing

9

3 4

Screw plug O-ring

10 Slide ring 11 Idler

5 6

Slide ring seal O-ring

12 Hex head screw 13 Washer

7

Sliding piece

14 Housing

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Service Manual

Idler Filling instructions

Fig. 2

Exploded view of the idler

Fig. 3

Filling position of the idler

15 Oil level

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MJF C I F S S

12.78.3

Idler

Service Manual

Filling instructions

12.78.4

copyright by

MJF C I F S S

Service Manual

Running roller Dismantling

Running roller 1 Dismantling Remove the screw cap 5 and drain off the oil. Drive out the roll pin 8 on both sides of the running roller axle 10 and remove the end piece 7 from the axle. Remove the slide ring seal halves 9 from the running roller body 1 and the end piece 7. Remove the O-ring 11 from the running roller axle. Pull the running roller axle 10 from the running roller body and drive out the roll pin 8. Push the running roller bushings 4 from the running roller body.

2 Assembly Push the running roller bushings 4 into the running roller body. Insert the running roller axle 10 into the running roller body and place the seals 11 into the grooves of the running roller axle. Place the slide seal ring halves 9 into the running roller body and insert the end piece 7, (see group 12.71). Mount the end piece 7 on the running roller axle 10 and secure it with the roll pin 8. Check axial play (movability). Drive in the running roller with compressed air at approx. 6 bar and check for leakage.

3 Filling instructions Turn the roller until the oil filling opening is aligned vertically. Fill in SAE 40 motor oil until the centre chamber is full. Using compressed air, pressurize the centre chamber to press the oil into the side chambers. Turn the running roller 1 until the oil filling opening is at a 45 degree angle to the perpendicular. Add oil until it escapes through the opening 15. Apply Loctite to the screw plug 5 and tighten it. Filling volume: ~0.270kg of SAE 40

Fig. 1

Filling position of running roller

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MJF C I F S S

12.81.1

Running roller

Service Manual


12.81.2

Fig. 2

Exploded view of running roller

Fig. 3

Sectional drawing of running roller

1 4

Running roller body Running roller bushing

9 Slide ring seal 10 Running roller axle

5 6


11 O-ring 12 Trapezoid ring

7

End piece

13 Slide ring

8

Roll pin

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Service Manual

Support roller Dismantling

Support roller 1 Dismantling Remove the screw plug 6 and drain the oil. Place the support roller with the end cap10 (cap11 facing upwards) in the vice. Remove the screws 1 and then remove the cap 11. Remove the O-ring 2. Remove the Allen head screws 3 and the remove the retaining washer 4. Pull the support roller body 12 with the bushings 5 and 8 and the slip ring seal 9 from the axle 7. Remove the seal 9 from the support roller body 12 and lift off the cap 10. Press the bearing bushing 5 and the bushing 8 from the support roller body 12. Note! The axle 7 press-mounted into the end cap 10 and cannot be dismantled.

2 Installation Press the bearing bushing 5 and the bushing 8 into the support roller body 12. Mount the seal 9 in the end cap and the support roller body 12. Place and secure the support roller body 12 on the axle 7. Secure the retaining washer 4 with the Allen head screws 3 on the axle 7. Mount the O-ring 2 to the cap 11. Press the cap 11 into the support roller body 12 and secure it with the screws 1. Check axial play. Apply compressed air at approx. 6 bar to the support roller and check it for leakage. Fill oil into the support roller, observing the filling instructions below.

3 Filling instructions Ensure that the oil fill opening is at the top and in vertical position. Fill in SAE 40 engine oil until the centre chamber is full. Pressurise the centre chamber with compressed air to press the oil into the lateral chambers. Turn the support roller body 12 until the oil fill opening is at an angle of 45 degrees to the perpendicular. Fill in more oil until the oil escapes at point 15, (see Fig. 1, page 2). Replace the screw plug 6 and seal it with Loctite. Filling volume: ~0.20kg SAE 40

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12.84.1

Support roller

Service Manual


Fig. 1

Filling position of support roller

15 Oil level For the items in fig. 2 and 3, page 3.

12.84.2

1

Screw

7

Axles

2 3


8 9

Bushing Seal

4

Stop washer

10 End cap

5 6

Bearing bushing Screw plug

11 Cover 12 Support roller body

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Service Manual

Support roller Filling instructions

Fig. 2

Exploded view of the support roller

Fig. 3

Sectional drawing of support roller

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MJF C I F S S

12.84.3

Support roller

Service Manual


12.84.4

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Service Manual

Slide ring seal Design

Slide ring seal 1 Design The slide ring seal is used to seal chassis parts with a long service life and that are exposed to heavy loads. Slide ring seals consists of a pairs of slide rings and seal rings (trapezoid rings), see Fig. 2.

2 Installation instructions for slide ring seals Note! Seal rings are high-precision parts made in chilled hard iron. They are easily damaged by impact. Therefore avoid impacts and shocks to the slide rings. Do not remove the seals from the original packaging until you are ready to install them. Protect the fine-machined slide faces 1 against damage and contamination. Always install seals in pairs (as packaged). Check the seal retaining parts to ensure that they are free of dirt. All edges of the seating hole must be rounded or bevelled. Ensure that there are not burrs, (see Fig. 2 on page2). Prior to assembling the seal rings, apply a thin film of oil to the slide faces 1, using a lint-free cloth. Ensure that the trapezoid rings 3 and their seats are not contaminated with oil. To facilitate this, apply a little spirit solution (spirit / water 1:1) to the bore hole 7 and to the trapezoid ring 3. Before assembling the seal halves, wait until the spirit/water mixture has evaporated and the parts are completely dry. If necessary, clean with compressed air. Note! We advise you not to use a thick piece of string or a rope for the installation of the slip ring seals.

Press the slip ring seal into the borehole 7. Ensure that the trapezoid ring is properly positioned in the chamber radius 5 and that the slide face 1 is aligned parallel to the housing face 8.

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12.86.1

Slide ring seal

Service Manual

Installation instructions for slide ring seals

Fig. 1

3

4

Trapezoid ring

Fig. 2

12.86.2

Slide ring seal

Sectional drawing of slide ring seal

Slide ring

Correctly installed slide ring seal

1

Sliding face

5

Chamber radius

2 3

Slide face cone Trapezoid ring

6 7

Installation bevel Borehole diameter

4

Slide ring

8

Housing face

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Service Manual


Group

Type

Operating pressures of the steering system

13.05.1


Hydraulic steering system

13.10.1


Servostat

13.20.1

A 309 LI 20221-21648 A 311 LI 20222-21648 A 312 LI 12363-19111 A 314 LI 2001-19111 A 316 LI 2001-24954 A 316 LI-IND 2001-24954

Steering valve

13.22.1

A 309 LI 21649A 311 LI 21649A 312 LI 19112A 314 LI 19112-

Steering valve

13.24.1

A 316 LI 24955A 316 LI-IND 24955-

Steering cylinders

13.32.1

A 309 LI 20221A 311 LI 20222A 312 LI 12363-

Steering cylinders

13.34.1

A 314 LI 2001A 316 LI 2001A 316 LI-IND 2001-

4-wheel steering

13.50.1

A 309 LI 20221A 311 LI 20222-

13.1 MJF C I F S S

Service Manual

13.2 MJF C I F S S

Service Manual

Operating pressures of the steering system General information

Operating pressures of the steering system 1 General information Machine Series

A 309/311 Litronic

A 312/314 Litronic

A 316 Litronic

l/min

39

44

44

Adjustment pressure at pressure-relief valve 88 at flow rate 15 - 20 l/min

bar

230 +15

230+15

230+15

Adjustment pressure at primary pressure-relief valve 29 in Servostat

bar

180 +10

180 +10

180 ±10

Adjustment pressure at primary pressure-relief valve 5 in steering valve

bar

180 +10

180 +10

195 ±10

Secondary pressure relief valve 44 in Servostat

bar

240 ±10

240 ±10

240 ±10

Secondary pressure relief valve 6 in steering valve

bar

240 ±10

240 ±10

250 ±10

Unit Gear pump 31 / 32: Max. oil flow to steering pump 31/32 Adjustment pressures

Tab. 1

Technical data of machine series

Machine 4-wheel steering kit

A 309/A 311 Unit

Gear pump 32 Max. oil flow to steering pump 32

l/min

39

Adjustment pressure at pressure-relief valve 88 at flow rate 15 - 20 l/min

bar

230 +15

Adjustment pressure at primary pressure-relief valve 29 in Servostat

bar

210 +10

Adjustment pressure at primary pressure-relief valve 5 in steering valve

bar

210 +10

Secondary pressure relief valve 44 in Servostat

bar

260 ±10

Secondary pressure relief valve 6 in steering valve

bar

260 ±10

Adjustment pressures

Tab. 2

Technical data of 4-wheel steering system

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13.05.1

Operating pressures of the steering system

Service Manual

General information

13.05.2

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Service Manual

Hydraulic steering system Function

Hydraulic steering system 1 Function

Fig. 1


2 Description 2.1

Steering pump 31 / 32, see Fig. 2 31 / 32 The pump takes up hydraulic oil from the tank 1 and transfers it to the steering valve / Servostat 84. The gear pump 31 / 32 is secured by the pressure relief valve 88.

2.2

Steering valve 84, see Fig. 2 The steering valve 84 is located at the base of the steering column a and is connected to the steering wheel in the operator's cab. It contains the valve actuators (way valve), the safety valves (primary and secondary pressure relief) and the hand pump for emergency operation.

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13.10.1


Service Manual

Description

Fig. 2

Gear pump with pressure relief valve and steering column with Servostat / steering valve

31 Gear pump / steering system (A312 - 316)

84 Steering valve

32 Gear pump / steering system (A309/311)

88 Pressure relief valve A 309 / 311 from start of series A 312 - 316 from serial no. 20241 a

2.3

Steering column

Rotary connection 85, see Fig. 3 The seven-fold oil rotary connection 85 is a special connection for hydraulic oil between the uppercarriage and the undercarriage and is located at the centre of the slewing ring. Pressure oil is fed from the Servostat / steering valve 84 through the rotary connection 85 to the steering cylinder 86, while return oil flows from the steering cylinder 86 through the steering valve 84 to the tank.

2.4

Steering cylinder 86, see Fig. 3 The steering cylinder is integrated into the front axle (steering axle) differential. The steering cylinder 86 is pressurised with pressure oil by the Servostat / steering valve 84 so that the connected joint housings (steering knuckles) are moved every time the piston rod is moved in axial direction, adjusting the steering angle of the wheels.

13.10.2

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Service Manual

Hydraulic steering system Function of the steering system

Fig. 3

Rotary connection and steering cylinder

85 Rotary connection 7 x

86 Steering cylinder

3 Function of the steering system (see Fig. 6, page 7) The gear pump 31 takes up oil from the tank 1 and transfers it to the Servostat / steering valve 84 port P. When the valve actuator in the Servostat / steering valve 84 is in neutral position (neutral position of the steering wheel), oil flows through port T back to the tank1. When the steering wheel is turned to the left or right, pressure oil flows from the Servostat / steering valve 84 port L or port R and the rotary connection 85 to the corresponding side of steering cylinder 86. The hand pump (metering pump) built into the Servostat / steering valve 84 is used for metering. The return oil flows from the steering cylinder 86 through the non-pressurised side back to the tank 1. The built-in hand pump of the Servostat 84 can also be used to pressurise the steering cylinder 86 in the event of a failure of the gear pump 32 (emergency steering). By pressurising the steering cylinder 86, the piston with the piston rod is moved in the corresponding direction, thus rotating the joint housing (steering knuckles) so that the axle is steered. The integrated primary and secondary pressure relief valves of the Servostat / steering valve 84 protect the entire steering system against excess pressure. To protect the gear pump 31/32, especially when cold oil is used, it is equipped with a pressure relief valve 88.

3.1

Pressure check and adjustment of the steering system

3.2

Pressure check and adjustment of the pressure relief valve 88 at the gear pump 31 / 32, see Fig. 4 Remove the cover cap at the measuring point 83 and connect the pressure sensor or pressure gauge (600 bar). Heat the hydraulic system to operating temperature. Start and run the diesel engine at its lower idle speed (level 1).

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13.10.3


Service Manual

Function of the steering system Measure and write down the actual position of the valve adjusting screw. Move the vehicle wheels to the outer steering position. Slowly turn the steering wheel against the resistance. Measure the pressure at the pressure sensor and compare it with the prescribed pressure (see group 13.05). Loosen the lock nut at the valve 88. Turn out the adjusting screw of the valve 88 until the pressure drops at the measuring point 83 (valve 5/29 closes, the flow noises at the valve 5/29 cease, while there are now flow noises at the valve 88). Turn in the adjusting screw of the valve 88 until the pressure reaches the prescribed value (valve 88 closes, the flow noises at the valve 88 cease, while there are now flow noises at the valve 5/29). If the prescribed pressure (see group 13.05) is not reached, check the primary pressure relief valve 29 / 5 and the secondary pressure relief valves 44 / shock valve 6 in the Servostat / steering valve 84, see 3.3. If the prescribed pressure (see group 13.05) is reached, turn in the adjusting screw of the valve 88 by 180 degrees. Tighten the lock nut at the valve 88. Remove the pressure sensor or gauge 83 and mount the cover cap.

3.3

Inspection of the primary pressure relief valve 29 / 5 in the Servostat / steering valve 84 Note! – The pressure relief valve 88 has been added to the machine A 312 - 316 as an additional safety valve of the pump 31/32, see Fig. 2. – In machines with valve 88, the primary pressure relief valve 29 / 5 has already been checked before the pressure relief valve 88 is checked and adjusted. – For machines without valve 88, proceed as follows: Remove the cover cap at the measuring point 83 and connect the pressure sensor or pressure gauge (600 bar). Heat the hydraulic system to operating temperature. Start and run the diesel engine at its lower idle speed (level 1). Move the vehicle wheels to the outer steering positions (right and left). Slowly turn the steering wheel against the resistance. Measure the pressure at the pressure sensor and compare it with the prescribed pressure (see group 13.05. If the pressure is not reached at only one of the steering positions (left/right), it is likely that the secondary pressure relief valves 44 / the shock valve 6 are faulty, see 3.4. If the pressure is not reached in both steering positions, it is likely that the primary pressure relief valve 29 / 5 is faulty. Replace the primary cartridge 29 / 5 (cartridge is not adjustable), see group 13.20 / 13.22. After installation of the new cartridge, check the steering system again for correct settings. Remove the pressure sensor or gauge 83 and mount the cover cap.

13.10.4

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Service Manual


Fig. 4 5

Servostat / steering valve with primary pressure relief valve

Primary pressure relief valve in the steering valve 84

83 Measuring point for steering pressure 84 Servostat A / steering valve B 88 Pressure relief valve / pump

29

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13.10.5


Service Manual

Function of the steering system

3.4

Check of the secondary pressure relief valves 44 / shock valve 6 in the Servostat / steering valve 84 Note! The secondary pressure relief valves 44 / shock valves 6 (safety valves) are factory-set and cannot be tested or adjusted. In the event of a defect or malfunction, repair it by following the instructions for the Servostat / steering valve 84 (see groups 13.20 and 13.22).

Fig. 5 6

Secondary pressure relief valves in the Servostat and shock valves in the steering valve

Shock valve in the steering valve 84

84 Servostat A / steering valve B

44 Secondary pressure relief valve in the Servostat 84

1 5

Hydraulic tank (*) Primary pressure relief valve in the steering valve 84

85 86

6 29

Shock valve in the steering valve 84 87 Primary pressure relief valve in the Ser- 88 vostat 84

31

Steering pump A 312 - 316 (*)

32 44

Steering pump A 309 / 311 (*) Secondary pressure relief valve in the Servostat 84

L R

Preload valve 3 bar (only in A 316) Pressure relief valve A 309 / 311 from start of series A 312 - 316 from serial no. 20241 Operating connection, turning left Operating connection, turning right

83

Measuring point for steering

P

Pressure connection

84 A

Servostat

84 B1

LAGS steering valve (A 309 from 20221 A 311 from 20222 A 312 and A 314 from 19112), see group 13.22

T F

Return channel Direction of travel

84 B2

LAGZ steering valve (A 316 from 17171),see group 13.24

* items in the hydraulic diagram of group 6.

13.10.6

Rotary connection (320*) Steering cylinder

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Service Manual


Fig. 6

Diagram of the steering system with Servostat 84 A

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13.10.7


Service Manual


Fig. 7

13.10.8

Diagram of the steering system with steering valves 84/B1, 84/B2 and pressure relief valve 88

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Service Manual

Servostat Function

Servostat 1 Function The Servostat serves as a hydraulic power assisted steering with hydrostatic transmission to the steered wheels. With this system, there is thus no need for a mechanical connection between the steering wheel and the steering linkage. In the event of failure of the steering pump, the machine can be steered manually to some extent, i.e. to be towed away.

Fig. 1

Servostat

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13.20.1

Servostat

Service Manual

General information


A 309 Li 20221

A 311 Li 20222

A 312 Li 18161

Manufacturer model

Servostat 2

Type no.

8474955194

Valve settings: Pressure relief valve 29 (primary pressure) Safety valves 44 (secondary pressure) Pump rate of the hydraulic pump 82

180±10 bar 240±10 bar

180±10 bar 240±10 bar

180±10 bar 240±10 bar

180±10 bar 240±10 bar

39 l/min

39 l/min

44 l/min

44 l/min

44 l/min

Setting value for the spool (19.2)

2.3 ± 0.01mm

End play of the joint shaft (10)

0.03 mm

Breakaway torque of the steering shaft(56)

max. 8 Nm

Torque for the screws (1)

32 ± 3 Nm

Torque for the pressure relief valve (29)

30 ± 3 Nm

Torque for the filter insert (43)

12 ± 3 Nm

13.20.2

A 316-Li 2001

180±10 bar 240±10 bar

Settings and torques for the installation of the Servostat

Tab. 1

A 314 Li 2001


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Service Manual

Servostat Description

3 Description The Servostat consists of: Component

Explanation

Metering pump 8

consisting of stators 8.1 and 8.2; it delivers when turning in clockwise or anticlockwise direction.

Spool 19.2

adjusted in axial direction

Hose safety valve 44

limits the oil pressure that might occur in the lines L and R to the operating cylinder (secondary pressure)

Short circuit valve 23

the hand pump can suck up oil from the return line, if the steering is operated without hydraulic assistance

Suction valve 36

helps prevent cavitation in the steering system

TÜV check valve 31

located in the pressure connection, preventing the taking in of air in the event of a pressure line break


limits the delivery pressure of the motor-driven pump to the required maximum value (primary pressure)

Stop valve 22

prevents that the wheels are automatically returned to their initial position when the spool is in the steering end position, and also reduces pressure peaks in the piston interior

Tab. 2

3.1

Component parts of the Servostat

Metering pump The rotor 8.2 of the metering pump 8 is driven by the joint shaft 10 and is connected through the steering shaft 56 with the steering wheel. It has one tooth less than the stator, so that there is always a tooth space when the rotor is rotated. Opposite the tooth space (also known as the chamber) the tool of the rotor fits into the internal tooth of the stator. When the rotor is turned, the other teeth and chambers thus form extended suction zones and narrowed pressure zones. The centre of the rotor thereby completes a planetary movement. This movement is in the opposite direction to the rotation of the steering shaft and its angular speed is 6 times higher. The suction and pressure zones revolve around the rotor at the speed of the planetary movement. The required synchronous distribution control is achieved by the rotary movement of the spool.

3.2

Steering valve The steering valve consists of the steering housing 19.1 and the spool19.2, which is located inside the housing and can be rotated and moved in axial direction. Its barrel surface is equipped with control groves aligned in radial and axial direction. These grooves match channels in the valve bore of the housing. When the steering wheel is turned, the steering shafts transfers the movement via the centring spring and the joint shaft to the metering pump 8. The spool is connected to the pump motor through the joint shaft. The centring spring on the other hand allows for relative rotation between the steering shaft and the spool, which is used to adjust the spool in axial direction by means of the steep-pitch thread. The axial motion of the spool results in an increase of the operating pressure and the changing of direction of the oil flow. The radial motion of the spool ensures synchronous distribution control of the

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13.20.3

Servostat

Service Manual

Functional description metering pump.


4.1

Neutral position of the steering valve If the steering wheel is not turned, the spool 19.2 is in neutral position. This allows for the flow generated by the pressure oil pump to exit the pressure channel P through the left and right return channels T1 and T2 and to return from there to the oil tank. The oil in the other channels and the hand pump is not affected by this. The control channels for the operating cylinders L and R are of a closed design and do not feature a connection to the distributing grooves HP1 and HP2. The built-in safety valves 44 prevent excessive pressure peaks in the steering system, which might occur as a result of sudden impacts and loads during machine travel.

4.2

Valve in operating position When the steering wheel is turned, the joint shaft 10 is moved through the steering shaft 56 and the centring spring 52. Its gearing meshes with the internal rotor of the hand pump which then moves with the shaft. The oil pressure required in the cylinder to steer the wheels acts against the rotating movement of the rotor 8.2. As a result, the steering angle of the steering shaft becomes greater than that of the rotor 8.2 and of the spool 19.2. The spool is only rotated relative to the steering shaft if there is a simultaneous axial movement. This is achieved by means of a driving pin in conjunction with a coupling designed as a steep-pitch thread between the spool and the stop bushing. When the spool is moved inside the housing in axial direction to the left (turning of the steering wheel in anticlockwise direction), the distribution groves HP1 of the spool are opened. The oil flows from connection P through the pressurised internal chamber and the distribution grooves HP1. As the distribution control rotates, there are at any one time 3 distributing grooves of the spool connected to 3 distributing channels in the housing, which lead to the suction zone of the hand pump. From the pressure zone of the hand pump, the oil flows also through 3 assigned distributing channels to 3 distributing grooves HP2 and the annular groove L and from there to the operating cylinder. When the channel T1 is opened, the left side of the operating cylinder is connected with the return line T. To steer the vehicle through a right bend the steering wheel is turned in clockwise direction, and the valve piston is moved to the right. The following channels are thereby connected with each other. P HP1 to R

The oil downstream from the hand pump flows to the operating cylinder

L to T2

The oil expelled by the operating cylinder flows into the return channel

When steering without the assistance of the pressure oil from the motor-driven pump, e.g. when the vehicle is being towed, the operator must generate the oil pressure necessary for steering by operating the hand pump. This means that considerably more force is required to turn the steering wheel than is normally necessary when the steering is assisted by the pump 82. When the machine is standing still, it is nearly impossible for one person to apply this force, so that emergency steering is virtually impossible.

5 Inspection

13.20.4

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Service Manual

Servostat Inspection

Danger! To check the steering, the technician must enter the undercarriage. To prevent serious injury or even death, secure the machine against inadvertent or unauthorised switching on.

Note! During a steering system check, all screw connections and lines of the hydrostatic steering system must be checked for leakage, and all steering components must be inspected for proper fixture. Check the Servostat, hydraulic lines and the steering cylinder for leakage Seal leaks and retighten lines, if necessary Inspect the piston rod of the steering cylinder for damage or wear The piston rod must be covered in a thin film of oil The steering cylinder is sealed Drops forming on the steering cylinder Seal the steering cylinder

5.1

Bleeding of the steering system After the hydraulic steering circuit has been opened to remove or install a component or as a result of a fault, the steering system must be bled. Proceed as follows: Start the machine. Run the diesel motor at maximum speed. Move the steering wheel several times from one stop to the other. Test drive the vehicle on a cordoned-off area. Please note that the use of oils that tend to foam may lead to malfunction, as such oils tend to keep air trapped so that the system cannot be properly bled.

5.2

Installation and dismantling of the Servostat Note! Before dismantling the Servostat, take all measures necessary to secure and block the machine (see safety instructions in group 1.10). Label the hydraulic lines of the Servostat, disconnect them and seal the openings (collect escaping oil). Remove the M8 mounting bolts from the Servostat and the steering column and lift the Servostat from the base plate (if necessary, secure the loose steering column).

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13.20.5

Servostat

Service Manual

Inspection Note! In order to ensure proper functioning of the Servostat as part of the steering system, ensure that all components of the system and all lines are kept clean at all times, especially during installation. To prevent foreign bodies and dirt from entering the steering oil circuit, do not remove the plugs sealing the lines to the Servostat, oil pump, operating cylinder, valves, etc. until they are finally reconnected. Carefully deburr and clean all line ends and screw connections. Apply grease (with lithium or calcium complex) to the missing tooth area and mount the Servostat on the shaft 2 of the steering column. Secure the Servostat and the steering column 1 to the base plate, using the four M8 hex head screws (with washers) (torque: 25 Nm). Connect the hydraulic lines to the Servostat (observe marks). L = Pressure side of the operating cylinder when steering wheel is turned anticlockwise P = Pressure line (pump) R = Pressure side of the operating cylinder when steering wheel is turned clockwise T = Return line (to tank)

13.20.6

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Service Manual

Servostat Inspection

5.3

Commissioning of the steering system In order to prevent dirt particles in the lines entering the pressure relief valve when the system is operated for the first time, we recommend to let the steering system run for a few minutes at various engine speeds, without actually turning the steering wheel, allowing the oil to flush the system. Then turn the steering wheel several times to the right and to the left without reaching the steering lock, while the engine is run at a medium speed (until the operating temperature is reached). We recommend removing and separately cleaning the filter cartridge 43 (torque 12 Nm). Bleed the steering system, (see 5.1, page 5).

5.4

Troubleshooting In the event of malfunction, first check the oil level in the tank while the engine is running and add oil, if necessary. When oil is added to the hydraulic system, there is always a risk of contamination with dirt particles. In order to prevent malfunctions caused by dirt in the system, always pay particularly attention to cleanliness when filling oil into the system.

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13.20.7

Servostat

Service Manual

Inspection

13.20.8

1

Hex head screw

35.1 O-ring

2 3

Cover Spacer

36 Suction valve 36.1 Seal washer

3.1

Washer

36.2 Cover plate

5

O-ring

37.1 Plug

8

Rotor kit (metering pump)

38

Pressure spring

8.1 8.2

Stator Rotor

43 44

Filter Safety valve

9 10

Cover plate Joint shaft

44.4 Valve seat 44.5 Valve seat

19 Housing / valve plunger 19.1 Steering housing

44.7 Tapered plug 50.1 Stop bushing

19.2 Spool

51

21 22

51.1 Spacer plate 52 Spring carrier with centring spring

O-ring Plug

Flat spring

22.1 Pressure spring 22.4 Stop / pressure relief valve

55 56

Coupler Steering shaft

23.1 Valve cone

57

Driving pin

23.2 Seal washer

59

Axial needle bearing

23.3 Cover plate

60

Washer

23.4 Pressure spring 23.5 Valve guide

61 Backing ring 61.1 O-ring

29 30

Pressure relief valve O-ring

62 69

Spacer ring ID tag

31

TÜV check valve

70

Grooved drive stud

34 35

Plug O-ring

76 79

O-ring Flange

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Service Manual

Servostat Exploded view

6 Exploded view

Fig. 2

Exploded drawing of the Servostat

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13.20.9

Servostat

Service Manual

Exploded view

13.20.10

8

Rotor kit (metering pump)

29


8.1 8.2

Stator Rotor

31 36

TÜV check valve Suction valve

10

Joint shaft

44

Safety valve

19 Housing / valve plunger 19.1 Steering housing

52 56

Spring carrier with centring spring Steering column

19.2 Spool 22 Plug

81 82

Hydraulic tank (1*) Pump (32*)

22.1 Pressure spring

85

Oil rotary connection (320*)

22.4 Stop / pressure relief valve 23 Stop valve

86

Steering cylinder

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Service Manual

Servostat Sectional drawing of the Servostat

7 Sectional drawing of the Servostat

Fig. 3

Sectional drawing and hydraulic diagram of the Servostat

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13.20.11

Servostat

Service Manual

Exploded view of the steering column

8 Exploded view of the steering column

Fig. 4

13.20.12

Exploded view of the adjustable steering column for Servostat

1 2

Steering column Shaft

16 17

Hex nut Lock washer

3 4

Universal joint Allen head screw

18 20


5 6

Hex nut Pin

21 22

Roll pin Washer

7

Hex nut

23

Hex nut

8 9

Absorber Rotating pin

24 25

Oval head screw Base plate

10

Washer

30

Pedal (old version)

11

Hex nut

31

Washer

15

Top plate

40

Pedal (new version)

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Service Manual

Steering valve Function

Steering valve 1 Function The steering valve serves as a hydraulic power assisted steering with hydrostatic transmission to the steered wheels. It does away with a mechanical connection from the steering wheel to the steering linkage and the steering knuckles of the steering axle. In servo mode, the steering valve works with a rotor kit. In the event of failure of the steering pump, the machine can be steered manually to some extent, i.e. to be towed away. The size for servo operation is based on the total size of the rotor kit and has been chosen in such a way that the wheels can be moved from one stop to the other with 3 to 5 full turns of the steering wheel.

Fig. 1

Steering valve

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13.22.1

Steering valve

Service Manual

General information


A 309 Li / A 311Li 20221 / 20222

A 312 / A 314 19112

Steering mode

2-wheel steering

4-wheel steering

2-wheel steering

Steering mode Manufacturer model

Steering valve LAGS 200/20



Max. flow rate

50 l/min

Valve settings: Pressure-relief valve 5 (primary pressure) Shock valve 6 (secondary pressure)

180+10 bar 240 ± 10 bar

210+10 bar 260 ± 10 bar

180+10 bar 240 ± 10 bar

39 l/min

39 l/min

44 l/min

Pump rate of the hydraulic pump 31 / 32 Flow rate in servo operation Flow rate in emergency operation Pressure fluid temperature range Tab. 1

50 l/min

200

cm3/rev

20

cm3/rev

-20 to +80 °C

200

cm3/rev

200 cm3/rev

20

cm3/rev

20 cm3/rev

-20 to +80 °C

-20 to +80 °C

Technical data

3 Design The steering valve consists of: Component

Explanation

Spool 1

The spool is moved in radial direction when the steering wheel is turned.

Control sleeve 2

The control sleeve is moved in radial and axial direction when the steering wheel is turned. Barrel surface with radially and axially aligned control grooves.

Rotor kit 3

In normal mode and emergency mode, the rotor kit 3 feeds the hydraulic oil to the steering cylinders.


The valve limits the delivery pressure of the motor-driven pump to the required maximum value (primary pressure).

Shock valves 6

The shock valves limit the oil pressure that might occur in the lines L and R to the operating cylinder (secondary pressure).

Suction valve 7/8

This valve helps prevent cavitation in the steering system.

Check valve 9

This valve prevents impacts to the steering wheel in the event of excessive external forces.

Housing 24

All parts of the steering valve are encased in the housing.

Tab. 2

Component parts of the steering valve

.

13.22.2

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Service Manual

Steering valve Design

Fig. 2 1 2

Design of steering valve, diagram 7 8

Spool Control sleeve


3

Rotor kit

9

Check valve

5 6

Pressure-relief valve Shock valve

24

Valve housing

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13.22.3

Steering valve

Service Manual

Function

4 Function see Fig. 3

4.1

Servo operation Through the steering column, the spool 1 of the steering valve is rotated relatively to the steering sleeve 2. As a consequence, a number of matching channels are opened between the spool 1 and the control sleeve 2. The hydraulic oil then acts on the rotor kit 3, putting it into motion. From the rotor kit 3, the hydraulic oil flows to the steering cylinder. The rotation of the two rotors acts on the sleeve 2, which rotates together with the piston 1. The check valve 9 prevents impacts to the steering wheel by excessive external steering forces. The size of the opened channels depends on the turning speed of the steering wheel and the steering pressure. If the steering movement is halted, the spool 1 comes to a standstill, while the oil still flowing through the open channels to the rotor make the rotor and the sleeve 2 rotate further.

4.2

Neutral position By turning the steering wheel, the channel is closed. The rotor and the steering cylinder are now in the desired position. The centring spring 4 aligns the spool 1 and the sleeve 2 and keeps them in neutral position. If the steering wheel is not turned, the line between the pump connection P and the tank connection T is opened and the pump volume flow is fed to the tank at virtually no pressure. In neutral position, the connections L and R are closed. The system pressure in the steering cycle is limited by the pressure-relief valve 5. The two shock valves 6 shut off the connections L and R to the steering cylinder. If one of the shock valves 6 is opened, the escaping oil is fed through the suction valve 7/8 to the opposite side, or the leaked oil is sucked from the tank.

4.3

Emergency operation In the event of a failure of the gear pump (steering pump), the steering valve acts as a hand pump. If necessary, hydraulic oil can sucked through the suction valve 8 from the tank line, whereby the check valve 9 prevents that air is being sucked in through the pump connection P.

13.22.4

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MJF C I F S S

Service Manual

Steering valve Cross-section of steering valve

5 Cross-section of steering valve

Fig. 3

Sectional drawing of the steering valve

1

Spool

14

Spacer bolt

2 3

Control sleeve Rotor kit

15 16


4

Centring spring

19

Thrust washer

5 6

pressure-relief valve Shock valve

20 21

Drive shaft Rotor gear

7

Suction valve

23

Needle roller

8

Suction valve

24

Valve housing

9

Check valve

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13.22.5

Steering valve

Service Manual

Installation and dismantling of the steering valve

6 Installation and dismantling of the steering valve see Fig. 5

6.1

Dismantling of the steering valve Release the tank pressure. Label the hydraulic lines of the steering valve, disconnect them and seal the openings (collect escaping oil). Remove the mounting bolts M10 from the steering valve and the steering column and lift the steering valve from the base plate (if necessary, secure the loose steering column).

6.2

Installation of the steering valve Apply grease (with lithium or calcium complex) to the missing tooth area of the spool 1. Mount the steering valve onto the shaft 2 of the steering column. Secure the steering valve and the steering column 1 to the base plate, using the four M10 hex head screws (with washers) (torque: 46 Nm). Connect the hydraulic lines to the steering valve (observe marks). L = Pressure side of the operating cylinder when steering wheel is turned anticlockwise P = Pressure line (pump) R = Pressure side of the operating cylinder when steering wheel is turned clockwise T = Return line (to tank)

7 Repair of the steering valve Note! In the event of malfunction or failure of the steering valve, it may not be repaired but must be replaced for safety reasons. Replace the defective steering valve with a new one.

Leakage repair: Use the seal kit 999 and seal the steering valve according to the separate instructions "Dismantling and assembly for seal change".

8 Commissioning of the steering system During commissioning, dirt particles in the line system might enter the pressure-relief valve. Let oil flow through the system for a few minutes without turning the steering wheel, and while changing the speed of the diesel engine. Then turn the steering wheel several times to the right and to the left without reaching the steering lock, while the engine is run at a medium speed (until operating temperature is reached). Bleed the steering system.

13.22.6

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MJF C I F S S

Service Manual

Steering valve Troubleshooting

8.1

Bleeding of the steering system Caution! Air locked in the steering circuit and the steering system components can impair steering. As a consequence, unintended steering movements might occur, posing a risk to operator and machine. To prevent this, bleed the system as described below: Start the diesel engine. Move the steering wheel several times from one stop to the other. Test-drive the vehicle on a cordoned-off area.

9 Troubleshooting In the event of malfunction, first check the oil level in the tank while the engine is running and add oil, if necessary. When oil is added to the hydraulic system, there is always a risk of contamination with dirt particles. Therefore add hydraulic oil through the return filter.

10 Exploded view of the steering valve

Fig. 4

Exploded view of steering valve

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MJF C I F S S

13.22.7

Steering valve

Service Manual


11

1

Spool

14

Spacer bolt

2

Control sleeve

15

Hex head screw

3

Rotor kit

16

Cover

4 5

Centring spring Pressure-relief valve

19 20

Thrust washer Drive shaft

6

Shock valve

21

Rotor gear

7 8


23 24

Needle roller Valve housing

9

Check valve

999

Seal kit


Fig. 5

13.22.8

Exploded view of steering column

1

Steering column

16

Hex nut

2 3

Shaft Universal joint

17 18

Lock washer Hex head screw

4 5

Allen head screw Hex nut

20 21

Washer Roll pin

6

Bolt

22

Washer

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Service Manual

Steering valve Exploded view of the steering column

7 8

Hex nut Absorber

23 24

Hex nut Oval head screw

9 10

Rotating pin Washer

25 30

Base plate Pedal

11 15

Hex nut Top plate

31 40

Washer Pedal

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MJF C I F S S

13.22.9

Steering valve

Service Manual


13.22.10

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MJF C I F S S

Service Manual

Steering valve Function

Steering valve 1 Function The steering valve serves as a hydraulic power assisted steering with hydrostatic transmission to the steered wheels. It does away with a mechanical connection from the steering wheel to the steering linkage and the steering knuckles of the steering axle. In servo operation, the steering valve works with two rotor kits. In emergency mode, one rotor kit is switched off. In the event of failure of the steering pump, the machine can be steered manually to some extent, i.e. to be towed away. The size for servo operation is based on the total size of the rotor kits and is chosen in such a way that the wheels can be moved from one stop to the other with 3 to 5 full turns of the steering wheel.

Fig. 1

Steering valve

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13.24.1

Steering valve

Service Manual

General information


A 900 C-Li 14675-18087

Manufacturer model

A 904 C 16000

LAGZ 190 / 60 steering valve

Max. flow rate

50 l/min

Valve settings: Pressure-relief valve 5 (primary pressure) Shock valve 6 (secondary pressure) Pump rate of the hydraulic pump 31

180 + 8 bar 240 + 10 bar 40 l/min

Settings and torques for the installation of the steering valve Flow rate in servo operation

190 cm3/rev

Flow rate in emergency operation

60 cm3/revs

Pressure fluid temperature range

-20 to +80 °C

Tab. 1

13.24.2

Technical data

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MJF C I F S S

Service Manual

Steering valve Description

3 Description The steering valve consists of: Component

Description

Spool 1

The piston is moved in radial direction when the steering wheel is turned.

Control sleeve 2

The control sleeve is moved in radial and axial direction when the steering wheel is turned. Barrel surface with radially and axially aligned control grooves.

Rotor kits 3/10

In servo mode, the rotor kits 3/10 feed the hydraulic oil to the steering cylinders; in emergency mode, only the rotary kit 3. feeds oil.


The valve limits the delivery pressure of the motor-driven pump to the required maximum pressure (primary pressure).

Shock valves 6

The shock valves limit the oil pressure that might occur in the lines L and R to the operating cylinder (secondary pressure).

Suction valve 7/8

This valve helps prevent cavitation in the steering system.

Check valve 9

This valve prevents impacts to the steering wheel in the event of excessive external forces.

Changing piston 12

The piston switches off the rotor kit 10 in the event of an emergency

Housing 24

All parts of the steering valve are encased in the housing.

Tab. 2

3.1

Component parts of the steering valve

Control valve The control valve consists of the spool 1 and the control sleeve 2, which is located inside the spool and can be rotated and moved in axial direction. Its barrel surface is equipped with control grooves aligned in radial and axial direction. These grooves match channels in the valve bore of the housing.

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13.24.3

Steering valve

Service Manual


Fig. 2

Design of the steering valve

1 2

Spool Control sleeve

9 10

Check valve Rotor kit 2

3 5

Rotor kit 1 Pressure-relief valve

11 12

Changeover housing Changing piston

6

Shock valve

13

Pressure spring

7 8


24

Valve housing

4 Functional description see Fig. 3

4.1

Servo operation Through the steering column, the spool 1 of the steering valve is rotated relatively to the steering sleeve 2. As a consequence, a number of channels are opened between the spool 1 and the sleeve 2. The hydraulic oil then acts on the rotor kits 3 and 10, putting them into motion. From the rotor kits, the hydraulic oil flows to the steering cylinder. The rotation of the two rotors acts on the sleeve, which rotates together with the piston 1. The size of the opened channels depends on the turning speed of the steering wheel. If the steering movement is halted, the spool 1 comes to a standstill, while the oil still flowing through the open channels to the rotor let the rotor and thus the sleeve 2 rotate further.

4.2

Neutral position By turning the steering wheel, the channels are closed. The rotor and thus the steering cylinder remain in the desired position. The centring spring 4 thereby moves and then secures the spool 1 and the sleeve 2 in their neutral position. While the steering wheel is not operated, the line between port (P) and the tank connection (T) is open and the pump flow is fed at very low pressure to the tank. In neutral position, the connections L and R are closed.

13.24.4

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MJF C I F S S

Service Manual

Steering valve Sectional drawing of the steering valve

The system pressure in the steering cycle is limited by the pressure relief valve 5. The two shock valves 6 shut off the connections L and R to the steering cylinder. If one of the shock valves is opened, the escaping oil is fed through the suction valve 7/8 to the opposite side or the leaked oil is sucked from the tank respectively.

4.3

Emergency operation In the event of a failure of the hydraulic pump, the steering valve acts as a hand pump. In such a case, the supply pressure (control pressure for the changing pistons) drops to zero. The spring 13 moves the changing piston 12 into its initial position so that the chambers of the rotor kit 10 are connected to the chamber. Simultaneously, the connection between the rotor kits is blocked. The volumetric displacement of the steering unit is thus reduced by the volume of the rotor kit 10. The rotor kit 3 determines the volumetric displacement during normal operation. If necessary, hydraulic oil is sucked through the suction valve 8 from the tank line, whereby the check valve 9 prevents that air is being sucked in through the pump connection (P). In normal operation, the valve 9 prevents impacts to the steering wheel by excessive external steering forces.

5 Sectional drawing of the steering valve

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13.24.5

Steering valve

Service Manual

Installation and dismantling of the steering valve Fig. 3

Sectional drawing of the steering valve

1

Spool

13

Pressure spring

2 3

Control sleeve Rotor kit 1

14 15

Spacer bolt Hex head screw

4

Centring spring

16

Cover

5


17

Rotor gear 2

6

Shock valve

18

Washer

7

Suction valve

19

Thrust washer

8

Suction valve

20

Drive shaft

9 10

Check valve Rotor kit 2

21 22

Rotor gear 1 Splined shaft

11

Changeover housing

23

Needle roller

12

Changing piston

24

Valve housing

6 Installation and dismantling of the steering valve Note! For safety reasons, replace the valve if you experience any problems in relation to the steering valve. Leakage can be sealed with a seal kit 999 available from LIEBHERR.

6.1

Dismantling of the steering valve Note! Before dismantling the steering valve, take all measures necessary to secure and block the machine (see group 1). Label the hydraulic lines of the steering valve, disconnect them and seal the openings (collect escaping oil). Remove the M10 mounting bolts from the steering valve and the steering column and lift the steering valve from the base plate (if necessary, secure the loose steering column).

6.2

Installation of the steering valve, see Fig. 5 Note! In order to ensure proper functioning of the steering valve and the entire steering system, ensure that all components of the system and all lines are kept clean. To prevent foreign bodies and dirt from entering the steering oil circuit, do not remove the plugs sealing the lines to the steering valve, oil pump, operating cylinder, valves, etc. until they are finally reconnected. Carefully deburr and clean all line ends and screw connections. Apply grease (with lithium or calcium complex) to the missing tooth area and mount the steering valve on the shaft 2 of the steering column. Secure the steering valve and the steering column 1 to the base plate, using the four M10 hex head screws (with washers) (torque: 46 Nm).

13.24.6

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MJF C I F S S

Service Manual

Steering valve Installation and dismantling of the steering valve Connect the hydraulic lines to the steering valve (observe marks).

L = Pressure side of the operating cylinder when steering wheel is turned anticlockwise P = Pressure line (pump) R = Pressure side of the operating cylinder when steering wheel is turned clockwise T = Return line (to tank)

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13.24.7

Steering valve

Service Manual

Installation and dismantling of the steering valve

6.3

Commissioning of the steering system In order to prevent dirt particles in the lines entering the pressure relief valve when the system is operated for the first time, we recommend to let the steering system run for a few minutes at various engine speeds, without actually turning the steering wheel, allowing the oil to flush the system. Then turn the steering wheel several times to the right and to the left without reaching the steering lock, while the engine is run at a medium speed (until the operating temperature is reached). Bleed the steering system.

6.4

Bleeding of the steering system Start the diesel engine and operate the steering several times by turning the wheels from one end position to the other. Test drive the vehicle on a cordoned-off off-road area. Subsequently bleed the steering system by turning the steering wheel several times moving the wheels from one stop position to the other while the engine is on. Please note that the use of oils that tend to foam may lead to malfunction, as such oils tend to keep air trapped so that the system cannot be properly bled.

6.5

Troubleshooting In the event of malfunction, first check the oil level in the tank while the engine is running and add oil, if necessary. When oil is added to the hydraulic system, there is always a risk of contamination with dirt particles. In order to prevent malfunctions caused by dirt in the system, always pay particularly attention to cleanliness when filling oil into the system.

13.24.8

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Service Manual

Steering valve Exploded view of the steering valve

7 Exploded view of the steering valve

Fig. 4

Exploded drawing of the steering valve

1

Spool

14

Spacer bolt

2 3

Control sleeve Rotor kit 1

15 16


4

Centring spring

17

Rotor gear 2

5


18

Washer

6

Shock valve

19

Thrust washer

7 8


20 21

Drive shaft Rotor gear 1

9

Check valve

22

Splined shaft

10

Rotor kit 2

23

Needle roller

11 12

Changeover housing Changing piston

24 999

Valve housing Seal kit

13

Pressure spring

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13.24.9

Steering valve

Service Manual

Exploded view of the steering valve

7.1


Fig. 5

13.24.10

Exploded view of the adjustable steering column for Servostat

1 2

Steering column Shaft

16 17

Hex nut Lock washer

3 4

Universal joint Allen head screw

18 20


5 6

Hex nut Pin

21 22

Roll pin Washer

7

Hex nut

23

Hex nut

8 9

Absorber Rotating pin

24 25

Oval head screw Base plate

10 11

Washer Hex nut

30 31

Pedal Washer

15

Top plate

40

Pedal

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Service Manual

Steering cylinders Design and function

Steering cylinders 1 Design and function see Fig. 4 The steering cylinder is integrated into the cast housing of the differential of the steering axle. The steering cylinder is of the synchronous cylinder design (i.e. cylinder with piston rods on both sides). The two rod ends are connected by joint tie rods and ball joints to the joint housings (steering knuckles). The piston rod with the attached piston moves in axial direction, thereby moving the steering knuckles from one steering stop to the other. The connections L and R of the Servostat / steering valve of the steering system are linked through hydraulic hoses and the oil rotary connection to the left or right connection of the steering cylinder respectively, see also steering system, group 13.

Fig. 1

Steering cylinder on the steering axle

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13.32.1

Steering cylinders

Service Manual

Replacement of the steering cylinder sealing elements

2 Replacement of the steering cylinder sealing elements Note! The sealing elements can be replaced without removing the steering axle or the differential. The figures below are sections from the sectional drawing (see Fig. 4). Please also refer to the separate repair manual "Dana axles 112 / 212" or "Dana axles 162 / 262". Danger! To dismantle and mount the steering cylinder while the steering axle is built in, you must access the undercarriage of the machine. There is a risk of death to the technician, as limbs could become crushed. Park the machine on level ground. Lift the undercarriage and secure the lifted undercarriage with suitable props. Depressurise the hydraulic system. Always refer to the safety instructions in group 1.10. Adhere to the accident prevention regulations issued by the German Ground Construction Trade Association (Tiefbau-Berufsgenossenschaft).

2.1

Dismantling of steering system and removing steering cylinder from the differential see Fig. 2 Unlock and remove the slotted nuts 5.22. Disconnect the joint tie rods 5.20 with the ball joints from the joint housing 3.26 / 3.27. Heat up the joint tie rods 5.20 at the piston rod 5.5 (secured with Loctite) and screw them from the piston rod 5.5. Complete the following steps, if necessary, for example for the complete replacement of the steering cylinder 5.3: Remove the mounting screws between the steering cylinder 5.3 and the differential and pull the steering cylinder 5.3 from the differential, see also groups 12.02, 12.10, 12.20. Note! It is possible to reseal the built-in steering cylinder by proceeding as described below:

2.2

Dismantling of steering cylinder see Fig. 3 Remove the snap ring 5.1. Push the cylinder head 5.2 inwards and push the circlip 5.4 from the recess, using a pin and moving the circlip over the bore at the cylinder 5.3. Pull the cylinder head 5.2 and the piston rod 5.5 together with the piston and the sealing elements 5.6 - 5.13 from the cylinder 5.3. Remove the sealing elements from the piston 5.5. Remove the seals 5.6 - 5.8 from the cylinder 5.3.

13.32.2

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MJF C I F S S

Service Manual

Steering cylinders Replacement of the steering cylinder sealing elements

Fig. 2

Steering cylinder with steering system on the steering axle

3.26

Left joint housing

5.22

Slotted nut

5.3

Cylinder

5.23

Cotter pin

5.5 5.20

Piston rod Joint tie rod

5.24

Guard ring

Fig. 3

Section of the sectional drawing of the steering cylinder

5.1

Snap ring

5.8

Scraper ring

5.2 5.3

Cylinder head Cylinder

5.9 5.10

Seal ring Guide ring

5.4

Circlip

5.11

Guide ring

5.5

Piston rod with piston

5.12

O-ring

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13.32.3

Steering cylinders

Service Manual

Replacement of the steering cylinder sealing elements 5.6 5.7

2.3

5.13

Seal ring Backing ring

Seal ring

Mounting of steering cylinder see Fig. 3 Carefully clean all parts and remove all foreign objects. Check all parts for damage. Reuse only undamaged parts. If the piston rod is irreparably damaged (impact damage, ridges), replace it. Do not use tools with sharp edges. Before mounting components and sealing elements, treat them with hydraulic oil. Place/insert all sealing elements in the correct sequence (see Fig. 4) on/in the piston 5.5, cylinder 5.3 and cylinder head 5.2. When inserting the seal and backing rings, ensure that they are in the correct position, see Fig. 4. Place the guide piece (special tool according to repair instructions) on the piston rod 5.5 and drive the piston rod 5.5 with piston and sealing elements into the cylinder 5.3 until the piston is inserted by approx. 100 mm into the cylinder 5.3 (use a mallet, if required). Place the guide piece on the cylinder side of the piston rod 5.1. Slide the cylinder head 5.2 onto the piston rod 5.5 and push it into the cylinder 5.3 until it is flush with the cylinder edge. Insert the circlip 5.4 and ensure that the grooves of the cylinder 5.3 are aligned correctly. Using a screwdriver or lever, push the cylinder head 5.2 back to the stop at the circlip 5.4. Insert the snap ring 5.1.

2.4

Mounting of steering system see Fig. 2 Apply Loctite 242 to the thread of the tie rod 5.20. Screw the tie rod 5.20 to the stop into the piston rod 5.5 (tightening torque = 350 Nm). Ensure that the heads are facing in the same direction. Check the guard ring 5.24 of the ball joint for proper seat. Insert the tie rods 5.20 with the ball joints in the joint housing 3.26 / 3.27. Screw on the slotted nut 5.22 (tightening torque 260 - 290 Nm). Secure the slotted nuts 5.22 with the cotter pins 5.23. Note! If the wheels must be realigned, please follow the instructions in the separate repair manual "112 / 212 Dana axles" or "162 / 262 Dana axles".

13.32.4

K 5.1

Piston seal Snap ring

Z 5.8

Cylinder head seal Scraper ring

5.2 5.3

Cylinder head Cylinder

5.9 5.10

Seal ring Guide ring

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Service Manual

Steering cylinders Sectional drawing of the steering cylinder

5.4 5.5

Circlip Piston rod with piston

5.11 5.12

Guide ring O-ring

5.6

Seal ring

5.13

Seal ring

5.7

Backing ring

3 Sectional drawing of the steering cylinder

Fig. 4

Sectional drawing of the steering cylinder

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MJF C I F S S

13.32.5

Steering cylinders

Service Manual

Sectional drawing of the steering cylinder

13.32.6

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MJF C I F S S

Service Manual

Steering cylinders Design and function

Steering cylinders 1 Design and function see Fig. 5 The steering cylinder is integrated into the differential of the steering axle. The cylinder 1 and the two piston rod guides 4 and 20 are mounted in the cast housing of the axle housing. The steering cylinder is of the synchronous cylinder design (i.e. cylinder with piston rods on both sides). The two rod ends are connected by the tie rods 24 and the ball joints to the joint housings 30 (steering knuckles). The piston rod 8 with the attached piston 9 moves in axial direction, thereby moving the steering knuckles from one steering stop to the other. The connections L and R of the Servostat / steering valve of the steering system are linked via hydraulic hoses and the oil rotary connection to the left or right connection of the steering cylinder respectively, see also steering system, group 13.

Fig. 1


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MJF C I F S S

13.34.1

Steering cylinders

Service Manual

Replacement of the steering cylinder sealing elements

2 Replacement of the steering cylinder sealing elements Note! The sealing elements can be replaced without removing the steering axle or the differential. The figures below are sections from the sectional drawing (see Fig. 5). Please also refer to the separate repair manual "APL-B 745 / APL-B 755 ZP planetary axles". Danger! To dismantle and mount the steering cylinder while the steering axle is built in, you must access the undercarriage of the machine. There is a risk of death to the technician, as limbs could become crushed. Park the machine on level ground. Lift the undercarriage and secure the lifted undercarriage with suitable props. Depressurise the hydraulic system. Always refer to the safety instructions in group 1.10. Adhere to the accident prevention regulations issued by the German Ground Construction Trade Association (Tiefbau-Berufsgenossenschaft).

2.1

Dismantling

Fig. 2


1

Cylinder

23

Axial joints

8

Piston rod

24

Tie rod

17

Washers

26

Stop ring

20

Guide

28

Slotted nut

21

Hex head screw

31

Axle housing

Unlock and remove the slotted nuts 28. Disconnect the tie rods 24 with ball joints from the joint housings. Move the stop ring 26 along the piston rod 8. Warm up the connection of the right tie rod 24 to the piston rod (secured with Loctite).

13.34.2

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MJF C I F S S

Service Manual

Steering cylinders Replacement of the steering cylinder sealing elements Disconnect the axial joints 23 from the piston rod 8. Remove the stop ring 26. Remove the hex head screws 21. Pull the guide 20 from the axle housing 31 and the piston rod 8 (hold washers 17). Pull the piston rod 8 from the cylinder 1. Remove the sealing elements from the piston 9 and the piston rod guides 4 and 20 (see Fig. 5). If required, pull the cylinder 1 and the guide 4 from the axle housing. Check the O-rings 2, 3 and 5 and reuse, if possible.

2.2

Installation, see Fig. 5

Fig. 3

Section of the sectional drawing of the steering cylinder

1

Cylinder

4

Guide

9

Piston rod with piston

Carefully clean all parts and remove all foreign objects. Check all parts for damage. Reuse only undamaged parts. If the piston rod is irreparably damaged (impact damage, ridges), replace them. Do not use tools with sharp edges. Before mounting components and sealing elements, treat them with hydraulic oil. Mount all sealing elements in the correct sequence (see Fig. 4) on the cylinder 1, in the guides 4 and 20 and on the piston 9. Insert the guide 4 and the cylinder 1 in the axle housing 31. Mount the complete piston rod 8, using a piston tightening strap or a special slip bushing. Place all previously removed washers 17 in the guide 20, using grease as an adhesive. Note! For new cylinders or guides 4 and 20, first determine the number of washers required (see repair manual "APL-B 745 / APL-B 755 ZP planetary axles").

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13.34.3

Steering cylinders

Service Manual

Exploded view Mount the guide 20 and secure it with the screws 21 (tightening torque 190 Nm). Apply a little grease onto the stop ring 26 and the O-ring 27 and slide them onto the piston rod 8. Note! The thickness of the stop ring 26 determines the steering angle. The permissible maximum steering angle of the wheel is prescribed by the manufacturer and may not be exceeded. If the wheels must be realigned, please follow the instructions in the separate repair manual "APLB 745 / APL-B 755 ZP planetary axles". Screw the complete tie rod 24 with the axial joint 23 (thread treated with Loctite 242) into the piston rod 8 to the stop (ensure that the heads are facing in the same direction). Tighten the axial joints 23 (torque = 350 Nm) Insert the tie rods 24 with the ball joints in the joint housings 30 and secure them with the slotted nuts 28 (tightening torque 300 Nm). Secure the slotted nuts 28 with the cotter pins 29.

3 Exploded view

Fig. 4

13.34.4

Exploded drawing of the steering valve

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Service Manual

Steering cylinders Sectional drawing

10

Cylinder

400

Stop ring

30 70

O-ring Guide

460 550

O-ring Tie rod (left)

80

O-ring

560

Tie rod (right)

150

Scraper ring

600

Axial joint

160

Lip seal

605

Bellows

170 240

Piston rod with piston Seal ring

610 611

Right ball joint Left ball joint

250 280

Scraper Washer

620 630

Clamp Slotted nut

320 350

Guide Hex head screw

640 700

Cotter pin Axle housing

4 Sectional drawing

Fig. 5

Sectional drawing of the steering cylinder and the axial joint

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MJF C I F S S

13.34.5

Steering cylinders

Service Manual

Sectional drawing

13.34.6

Item

ET item

1

10

2 4

Designation

Item

ET item

Designation

Cylinder

21

350

Hex head screw

30

O-ring

23

600

Axial joint

70

Guide

24

550

Right tie rod

5

80

O-ring

560

Left tie rod

6

250

Scraper ring

610

Right ball joint

7

160

Lip seal

611

Left ball joint

8

170

Piston rod

620

Clamp

25

9

180

Piston

26

400

Stop ring

15

240

Sealing ring

27

460

O-ring

16

150

Scraper

28

17

280

Washer, of various thickness

29

20

320

Guide

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MJF C I F S S

Right /left joint housing 700

Axle housing

Service Manual

4-wheel steering Function

4-wheel steering 1 Function Four-wheel steering allows you to use and manoeuvre the machine in confined spaces. In order to access loading bays with ease, the steering can be switched over to crab steer mode. In this mode, the wheels of the rear axle are moved in the same direction (i.e. parallel) to those of the front axle.

Fig. 1

Steered front and rear axle wheels with 4-wheel steering valve

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13.50.1

4-wheel steering

Service Manual

Description

2 Description 2.1

Steering pump 32 The hydraulic pump 32 is a gear pump and is flange-mounted to the diesel engine. The pump sucks hydraulic oil from the tank and feeds it through the steering valve 92 and the steering valve 84 to the respective side of the steering cylinder. For additional protection, the pump 32 is equipped with the flange-mounted pressure-relief valve 88.

2.2

Steering valve 84 The steering valve 84 is located at the base of the steering column and is connected to the steering wheel in the operator's cab. It contains the valve actuators (way valve), the safety valves (primary and secondary pressure relief) and the hand pump for emergency operation. The oil is pumped from the pump 32 through the pressure port P to the steering valve. When the steering wheel is turned, the working connection L or R, through the rotary connection 260, pressurises the respective components in the undercarriage, including the shift valve 94 and the steering cylinder 86-1/ 86-2,. For details, see the description of functions of the various components. The return oil flows through the tank connection T back to the tank.

Fig. 2 a

Gear pump, steering column and steering valve 84 Steering valve

Steering column

32 Gear pump / steering

2.3

88 Pressure-relief valve

Steering valve 92 for centring The steering valve 92 located below the operator's cab base plate ensure that the wheels are automatically reset to their neutral position (centred) before a different steering mode is selected. The 6/3-way valve is an electro hydraulic valve containing the solenoids Y294-1 and Y294-2. The main valve is operated through a pilot control valve pressurised with control pressure. The steering control A134 powers the respective solenoids Y294-1 and Y294-2. The wheels are the automatically moved by steering pump to their neutral position.

13.50.2

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Service Manual

4-wheel steering Description

2.4

Shift valve 94 for the switching between steering modes The steering cylinder 86-1 / 86-2 is operated via the shift valve 94 equipped with the solenoids Y2291 and Y229-2 and mounted in the undercarriage. The steering control A134 powers the respective solenoids Y229-1 and Y229-2. The steering cylinders 86-1 and 86-2 are then pressurised with hydraulic oil, and the wheels are turned parallel to each other or in opposite directions respectively.

2.5

Load-holding valve 98 The load-holding valve 98 protects the rear axle against pressure peaks that might occur when external forces interfere with the system. The vehicle meets the TUEV requirements for travel on public roads.

Fig. 3

2.6

6/3-way shift valve in upper carriage and 4/3-way shift valve and load-holding valve in undercarriage

92

6/3-way shift valve (wheel centring)

Y229-1 Solenoid shift valve for crab steer mode

94

4/3-way shift valve (changeover)

Y229-2 Solenoid shift valve for 4-wheel steering

98

Load-holding valve

Y294-1 Solenoid shift valve for wheel centring Y294-2 Solenoid shift valve for wheel centring

Rotary connection 260 The seven-fold oil rotary connection is a special connection for hydraulic oil between the uppercarriage and the undercarriage and is located at the centre of the slewing ring.

2.7

Steering cylinders 86-1 / 86-2 The steering cylinders 86-1/86-2 are integrated into the differential of the front and rear axles. They are actuated with pressure oil from the steering valve 84, so that the steering knuckles are moved with every axial movement of the piston rod to which they are connected. As a result, the steering angle of the vehicle wheels is changed.

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13.50.3

4-wheel steering

Service Manual

Description

Fig. 4 86-1 86-2

2.8

Rotary connection, slip ring rotary connection and steering cylinders 260 265

Front axle steering cylinder Rear axle steering cylinder

Rotary connection 7 x Slip ring rotary connection 9x

Electronic control system A 134 The components of the 4-wheel steering system are controlled and monitored by the steering system A134 in the electronic box, (see 7, page 26). When switching from one steering mode to another, the box A134 controls the centring of the wheels (return to neutral position).

Fig. 5

2.9

Electronic steering system A134, mounted to the revolving desk below the operator's cab

Rotary switch S309 and indicator lights H191 / 192 The steering mode can be preselected by means of the rotary switch S309 located in the left control console. The indicator lights H191 / H192 indicate the selected mode to the machine operator.

13.50.4

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Service Manual

4-wheel steering Operation of the 4-wheel steering

Fig. 6

Rotary switch and indicator lights

H191

Indicator light / 4-wheel steering

H192

Crab steer indicator light

S309

Selection switch for 2-wheel/4-wheel/ crab steer mode

3 Operation of the 4-wheel steering Apart from standard 2-wheel steering, machine is equipped with two additional steering modes. Steering mode

Characteristics

2-wheel steering

Front axle steering. Steering movement when turning to left=Front axle left Steering movement when turning to right=Front axle right Rear axle steering is blocked.

4-wheel steering

When the steering wheel is turned, the front and rear wheels are moved in opposite directions. Steering movement when turning to left=Front axle left = Rear axle right Steering movement when turning to right=Front axle right = Rear axle left The turning circle is smaller.

Crab steer mode

When the steering wheel is turned, the front and rear wheels are moved in the same direction, i.e. parallel. Steering movement when turning to left=Front axle left = Rear axle left Steering movement when turning to right=Front axle right = Rear axle right The machine can now move sideward.

Tab. 3-1

Characteristics and advantages of the available steering modes

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13.50.5

4-wheel steering

Service Manual

Operation of the 4-wheel steering

3.1

Switching to desired steering mode (steering mode preselection) Danger! For safety reasons, the steering modes "4-wheel" and "crab steer" may not be used when travelling on public roads. When travelling on public roads, use only 2-wheel steering.

3.1.1

Start conditions for steering mode preselection To switch to a particular steering mode, ensure that the following conditions are fulfilled: – Diesel engine is running. – The travelling direction switch S263 is in neutral position 0. – The lever of the safety switch S7 is pushed down. – The servo steering switch S35 is on. Note! – To switch from one steering mode to another, the wheels of both axles must be aligned to their neutral position (centred). This can be done with suitable manoeuvres carried out by the operator. – Alternatively, the machine can align the wheels automatically one after the other. If the machine is placed on uneven ground, this might however not be possible. If necessary, relieve the axles, using the supports or the attachment. If the machine is switched to a different steering mode while the start conditions, see 3.1.1 are not met, the command is ignored and the buzzer H27(at the rear of the right control console) is activated for short period. The machine remains in its current steering mode. If the start conditions are subsequently met, the preselection switch S309 must be actuated again in order to start the changeover procedure. Normally, the rear axle is aligned first, while the front wheels are trailing. The machine subsequently aligns the front wheels (monitored with proximity switches B248-H / B248-V) When switching from 4-wheel steering or crab steer mode to 2-wheel steering, the front axle is not aligned separately.

3.1.2

Switching to 4-wheel steering Ensure that the above start conditions are met. Turn the switch S309 to position 1. The machine cannot be moved (travel lock). A audible warning signal is issued, and the indicator light H191 flashes while the wheels are being aligned. When this process is completed, the indicator light is permanently on. 4-wheel steering is now enabled, and the travel lock is released.

3.1.3

Switching to crab steering Ensure that the above start conditions are met. Turn the switch S309 to position 2. The machine cannot be moved (travel lock). A audible warning signal is issued, and the indicator light H192 flashes while the wheels are being aligned. When this process is completed, the indicator light is permanently on. crab steer mode is now enabled, and the travel lock is released.

3.1.4

Switching to 2-wheel steering Ensure that the above start conditions are met.

13.50.6

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Service Manual

4-wheel steering Operation of the 4-wheel steering Turn the switch S309 to position 0. The machine cannot be moved (travel lock). A audible warning signal is issued, and the two indicator lights H191 and H192 are flashing while the wheels are being aligned. When this process is completed, the light is off. 2-wheel steering is now enabled, and the travel lock is released.

Note! – If one of the above start conditions is interfered with while the steering is being switched over, the changeover process is aborted. – This results in an error and is indicated by the alternating flashing of the two indicator lights H191 and H192. In this status, the travel lock is released, and the steering is reset to 2-wheel steering. – The desired steering mode can be selected again after the start conditions are met.

Caution! In the event of an error, the steering angle of the rear axle might not correspond to the selected steering mode. This might result in unexpected movements of the machine. Therefore, turn the switch S309 to position 0 and restart the changeover procedure.

Fig. 7

Operator's cab with safety switch, servo switch, travelling direction switch, preselection switch and steering mode indicator lights

H191 Indicator light / 4-wheel steering

S35

H192 Indicator light / crab steer mode S7 Safety switch with lever

S263 Switch / travel direction S309 Selection switch for 4-wheel/crab steer mode

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Switch / servo control

13.50.7

4-wheel steering

Service Manual


4 Function of the steering system Note! In the following chapter, the steering functions are described for steering to the right. They apply accordingly to steering to the left. For information regarding the settings of the pressure-relief valves of the steering system, refer to group 13.10. The function of the steering valve 84 is described in group 13.22.

4.1

Neutral position Steering wheel not turned, switch S309 in position 0 Shift valves 92 and 94 in neutral position The oil is fed by the gear pump 32 through the valve 92 connection P-T and the steering valve 84 connection P-T and flows back to the tank 1.

13.50.8

1

from/to tank

A134

31

Gear pump / low-pressure circuit + brake

B248-H Proximity switch rear axle

32

B248-V Proximity switch front axle

33

Gear pump / steering with pressurerelief valve Gear pump / pilot control

MP2

Ground connection

50 83

from the control oil unit Measuring point for steering pressure

S309 U16

Selection switch / 4-wheel steering Excavator control BST

84 86-1

Steering valve Front axle steering cylinder

Y229-1 Solenoid shift valve for crab steering Y229-2 Solenoid shift valve for 4-wheel steering

4-wheel steering control

86-2

Rear axle steering cylinder

Y294-1 Solenoid shift valve for wheel centring

88P 88T

Distributor Collecting pipe


92 94

6/3-way shift valve 4/3-way shift valve

98

Load-holding valve

260


265

Slip ring rotary connection 9x

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Service Manual

4-wheel steering Function of the steering system

Fig. 8

4-wheel steering in neutral position

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13.50.9

4-wheel steering

Service Manual


4.2

2-wheel steering Steering wheel turned to right, switch S309 in position 0 Shift valves 92 and 94 in neutral position The oil is fed by the gear pump 32 through the valve 92 connection P-T, the steering valve 84 connection P- R, the shift valve 92 connection A (blocked), the rotary connection 260 connection 5, and the shift valve 94 connection T-P to the right port of the steering cylinder 86-1. The wheels of the front axle are moved to the right, and the vehicle travels to the right. The return oil flows from the left side of the steering cylinder 86-1 through the rotary connection 260 connection 6 and the steering valve 84 connection L - T to the tank 1. The wheels of the rear axle are not steered. 1

from/to tank

A134

31

Gear pump / low-pressure circuit + brake Gear pump / steering with pressurerelief valve


Gear pump / pilot control from the control oil unit

MP2 S309

Ground connection Selection switch / 4-wheel steering Excavator control BST

32 33 50

13.50.10



83

Measuring point for steering pressure

U16

84 86-1



86-2 88P

Rear axle steering cylinder Distributor


88T 92

Collecting pipe 6/3-way shift valve

94

4/3-way shift valve

98 260

Load-holding valve Rotary connection 7 x

265


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Service Manual


Fig. 9

2-wheel steering

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13.50.11

4-wheel steering

Service Manual


4.3

4-wheel steering Steering wheel turned to right, switch S309 in position 1 The shift valve 92 is in neutral position. The solenoid valve Y229-2 is powered (shift valve 94 in working position I), the indicator light H191 is on. The oil is fed by the gear pump 32 through the valve 92 connection P-T, the steering valve 84 connection P- R, the shift valve 92 connection A (blocked), the rotary connection 260 connection 5, the shift valve 94 connection T-B and the load-holding valve 98 connection V1-C1 to the right port of the steering cylinder 86-2. The wheels of the rear axle are moved to the left. The built up pressure opens the stop valve of the load-holding valve 98. The displaced oil from the left side of the steering cylinder 86-2 is fed through the load-holding valve 98 connection C2- V2, and the valve 94 connection A-P, pressurising the right connection of the steering cylinder 86-1. The wheels of the front axle are moved to the right, and the vehicle travels to the right. The return oil flows from the left side of the steering cylinder 86-1 through the rotary connection 260 connection 6 and the steering valve 84 connection L - T to the tank 1. 1 31 32 33 50

13.50.12

from/to tank Gear pump / low-pressure circuit + brake Gear pump / steering with pressurerelief valve Gear pump / pilot control from the control oil unit

A134 4-wheel steering control B248-H Proximity switch rear axle B248-V Proximity switch front axle MP2 S309

Ground connection Selection switch / 4-wheel steering Excavator control BST

83


U16

84 86-1



86-2 88P



88T 92


94

4/3-way shift valve

98 260


265


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Service Manual


Fig. 10

4-wheel steering

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13.50.13

4-wheel steering

Service Manual


4.4

Crab steering Steering wheel turned to right, switch S309 in position 2 The steering valve 92 is in neutral position and the shift valve 94 is in working position II. The indicator lamp H192 is on. The oil is fed by the gear pump 32 through the valve 92 connection P-T, the steering valve 84 connection P- R, the shift valve 92 connection A (blocked), the rotary connection 260 connection 5, the shift valve 94 connection T-B and the load-holding valve 98 connection V2-C2 to the left port of the steering cylinder 86-2. The wheels of the rear axle are moved to the right. The built up pressure opens the stop valve of the load-holding valve 98. The displaced oil from the right side of the steering cylinder 86-2 is fed through the valve 98 connection C1- V1, and the valve 94 connection B-P, pressurising the right connection of the steering cylinder 86-1. The wheels of the front axle are moved to the right, and the vehicle travels to the right. The return oil flows from the left side of the steering cylinder 86-1 through the rotary connection 260 connection 6 and the steering valve 84 connection L - T to the tank 1.

1 31 32

13.50.14

from/to tank Gear pump / low-pressure circuit + brake Gear pump / steering with pressurerelief valve

A134 4-wheel steering control B248-H Proximity switch rear axle B248-V Proximity switch front axle

33 50

Gear pump / pilot control from the control oil unit

MP2 S309

83 84

Measuring point for steering pressure Steering valve

U16 Excavator control BST Y229-1 Solenoid shift valve for crab steering

86-1

Front axle steering cylinder

Y229-2 Solenoid shift valve for 4-wheel steering

86-2 88P



88T 92


94

4/3-way shift valve

98 260


265


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Ground connection Selection switch / 4-wheel steering

Service Manual


Fig. 11

Crab steering

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13.50.15

4-wheel steering

Service Manual


4.5 4.5.1

Reset (centring) of wheels prior to switching to a different steering mode Centring from 2-wheel steering mode after steering to the right The steering wheel is not turned. The start conditions, (see 3.1.1, page 6), are met. The proximity switch B248-V sends a signal to A134 (steering cylinder 86-1 not in neutral position). The solenoid Y294-2 is powered through the steering control system A134. The shift valve 92 is in working position II and the shift valve 94 is in neutral position. The oil is fed by the gear pump 32 through the valve 92 connection P-B and the rotary connection 260 connection 6 and flows to the left port of the steering cylinder 86-1. The wheels of the front axle are aligned for forward travel (centre position). The return oil from the right side of the steering cylinder 86-1 flows through the valve 94 connection P-T, the rotary connection 260 connection 5 and the valve 92 connection A-T1 back to the tank 1.

1

from/to tank

A134

31



32

13.50.16



33


MP2

Ground connection

50 83


S309 U16


84 86-1



86-2



88P 88T



92 94


98 260


265


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Service Manual


Fig. 12

Centring from 2-wheel steering mode

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13.50.17

4-wheel steering

Service Manual


4.5.2

Centring from 4-wheel steering mode after steering to the right The steering wheel is not turned. The start conditions, (see 3.1.1, page 6), are met. The proximity switches B248-H and B248-V send a signal to A134 (steering cylinders 86-1 and 86-2 not in neutral position). The solenoids Y229-2 and Y294-2 are powered through the steering control system A134. The shift valve 92 is in working position II and the shift valve 94 is in working position.I. The oil is fed by the gear pump 32 through the valve 92 connection P-B and the rotary connection 260 connection 6 and flows to the left port of the steering cylinder 86-1. The displaced oil from the right side of the steering cylinder 86-1 is fed through the valve 94 connection P-A, and the valve 98 connection V2 - C2, pressurising the left connection of the steering cylinder 86-2. The built up pressure opens the stop valve of the load-holding valve 98. The return oil from the right side of the steering cylinder 86-2 flows through the valve 98 connection C1 - V1, valve 94 connection B-T, the rotary connection 260 connection 5 and the valve 92 connection A-T1 back to the tank 1. The wheels of the rear axle are aligned for forward travel (centre position). The proximity switch B248-H sends a signal to A134 (steering cylinder 86-2 is in neutral position). The solenoid Y229-2 is not powered through the steering control system A134. The shift valve 94 is set to its neutral position. The oil is fed by the gear pump 32 through the valve 92 connection P-B and the rotary connection 260 connection 6 and flows to the left port of the steering cylinder 86-1. The return oil from the right side of the steering cylinder 86-1 flows through the valve 94 connection P-T, the rotary connection 260 connection 5 and the valve 92 connection A - T1 back to the tank 1. The wheels of the front axle are aligned for forward travel (centre position).

1

from/to tank

A134

31



32

13.50.18



33


MP2

Ground connection

50 83


S309 U16


84 86-1



86-2



88P

Distributor

88T

Collecting pipe

92 94


98

Load-holding valve

260


265


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Service Manual


Fig. 13

Centring from 4-wheel steering mode after steering to the right

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13.50.19

4-wheel steering

Service Manual


4.5.3

Centring from crab steering mode after steering to the right The steering wheel is not turned. The start conditions, (see 3.1.1, page 6), are met. The proximity switches B248-H and B248-V send a signal to A134 (steering cylinders 86-1 and 86-2 not in neutral position). The solenoids Y229-1 and Y294-2 are powered through the steering control system A134. The shift valve 92 is in working position II and the shift valve 94 is in working position II. The oil is fed by the gear pump 32 through the valve 92 connection P-B and the rotary connection 260 connection 6 and flows to the left port of the steering cylinder 86-1. The displaced oil from the right side of the steering cylinder 86-1 is fed through the valve 94 connection P-B, and the valve 98 connection V1 - C1, pressurising the right connection of the steering cylinder 86-2. The built up pressure opens the stop valve of the load-holding valve 98. The return oil from the left side of the steering cylinder 86-2 flows through the valve 98 connection C2 - V2, valve 94 connection A-T, the rotary connection 260 connection 5 and the valve 92 connection A - T1 back to the tank 1. The wheels of the rear axle are aligned for forward travel (centre position). The proximity switch B248-H sends a signal to A134 (steering cylinder 86-2 is in neutral position). The solenoid Y229-1 is not powered through the steering control system A134. The shift valve 94 is set to its neutral position. The oil is fed by the gear pump 32 through the valve 92 connection P-B and the rotary connection 260 connection 6 and flows to the left port of the steering cylinder 86-1. The return oil from the right side of the steering cylinder 86-1 flows through the valve 94 connection P-T, the rotary connection 260 connection 5 and the valve 92 connection A - T1 back to the tank 1. The wheels of the front axle are aligned for forward travel (centre position).

1

from/to tank

A134

31



32

13.50.20



33


MP2

Ground connection

50 83


S309 U16


84 86-1



86-2



88P

Distributor

88T

Collecting pipe

92 94


98

Load-holding valve

260


265


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Service Manual


Fig. 14

Centring of wheels from crab steer mode

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13.50.21

4-wheel steering

Service Manual

Components and hydraulic lines Note! For details regarding the pressure settings of the steering system, refer to group 13.10.

5 Components and hydraulic lines

Fig. 15

13.50.22

Components in uppercarrige

1

Hydraulic tank

88T

Collecting pipe

32

Gear pump

92

6/3-way shift valve (wheel centring)

83


260

Rotary connection

84

Steering valve

Y294-1 Solenoid

88P

Distributor

Y294-2 Magnet

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Service Manual

4-wheel steering Components and hydraulic lines

Fig. 16

Components in undercarriage

86-1

Front steering cylinder

260

Rotary connection

86-2

Rear steering cylinder

265


94

4/3-way shift valve (steering changeover)

Y294-1 Solenoid

98

Load-holding valve

Y294-2 Solenoid

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13.50.23

4-wheel steering

Service Manual

Electrical system

6 Electrical system

Fig. 17

13.50.24

Electrical components in uppercarriage

A127


KS

A134 F356

4-wheel steering control Fuse / 4-wheel steering, terminal 15

S309 Selection switch / 4-wheel steering X1117 Plug connection / 4-wheel steering, 6pin

Wire harness of potentiometer board A125

F357

Fuse / 4-wheel steering, terminal 30


H191 H192

Indicator light / 4-wheel steering Crab steer indicator light


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Service Manual

4-wheel steering Electrical system

Fig. 18

265

Electrical components in undercarriage

X1090 Plug connection / 6-pin



Y294-1 Solenoid / crab steer mode


Y229-2 Solenoid / 4-wheel steering

S272

Junction box / undercarriage

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13.50.25

4-wheel steering

Service Manual

Block diagram of 4-wheel steering

7 Block diagram of 4-wheel steering

Fig. 19

13.50.26

Block diagram

A134


K370


A125

Potentiometer board

K445

Relay / travel shut-off /4-wheel steering

A126 A127

Printed circuit board (auto check) Printed circuit board / power

MP V S35

Ground connection / distribution board Servo switch


S263



S272

Junction box / undercarriage

F314

Fuse S7

S309

Selection switch / 4-wheel steering

F356 F357

Fuse / 4-wheel steering, terminal 15 RS232 Laptop interface Fuse / 4-wheel steering, terminal 30 Y229-1 Solenoid shift valve for crab steering

H27 H191

Warning buzzer Indicator light / 4-wheel steering

Y229-2 Solenoid shift valve for 4-wheel steering Y294-1 Solenoid shift valve for wheel centring

H191 K252

Crab steer indicator light Relay / servo


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Service Manual

4-wheel steering Fault messages

Note! For a detailed wiring diagram, refer to step 12 and the respective electrical system diagram in group 8.20.

8 Fault messages 8.1

No response when the selection switch S309 is actuated; a short audible signal is issued Start conditions for the changeover of the steering are not fulfilled, (see 3.1.1, page 6). Fulfil the start conditions, activate the selection switch S309 again and set it to the desired steering mode. Wait, until the changeover process is completed.

8.2

The indicator lights H191 / H192 flash alternately, and the warning buzzer H27 issues signals at short intervals The changeover process has been aborted, possibly due to non-compliance with the start conditions, (see 3.1.1, page 6): S35 is off, S7 is in top position, S263 is set to V/R, ignition is off Fulfil the start conditions, activate the selection switch S309 again and set it to the desired steering mode. Wait until the changeover process is completed.

8.3

One of the two indicator lights H191 / H192 flashes or both flash together. The wheels of the axles are moving: centre contact of the rear axle not found, i.e. wire break or proximity switch B248-H defective The wheels of the front axle are moving, while the wheels of the rear axle are standing still.: centre contact of the front axle not found, i.e. wire break or proximity switch B248-V defective The wheels of both axles are at the right or left steering stop Solenoid Y294-1 or Y294-2 defective, or wire break

8.4

The wheels of the rear axle are not being aligned. The wheels of the front axle are moving from one side to the other, and the wheels of the rear axle are not in centre position Solenoid Y229-1 or Y229-2 defective, or wire break

8.5

4-wheel steering activated, indicator light H191 not on, or crab steer mode activated; indicator light H1921 not on Switch off ignition for approx. 3 seconds, and restart the engine. Both lights must be on for 1 second (lamp check). If the lights are not on: Indicator lightH191 / H192 defective, or wire break

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13.50.27

4-wheel steering

Service Manual

Fault messages

13.50.28

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Service Manual


Group

Type

Oscillating axle support with automatic control 14.10.1


Support cylinders


14.20.1

14.1 MJF C I F S S

Service Manual

14.2 MJF C I F S S

Service Manual

Oscillating axle support with automatic control Function

Oscillating axle support with automatic control 1 Function The oscillating axle support is a hydraulic locking mechanism designed to eliminate the oscillating motion of the steering axle. During work, the oscillating steering axle is blocked with two support cylinders in order to improve the stability of the machine. When these cylinders are pressurised with control from the pilot system through a solenoid valve and the rotary connection, the two stop valves (hydraulically controlled check valves) are opened. The piston in the cylinder can thus follow the oscillating motion of the axle.

Fig. 1

Support cylinder attached to the undercarriage

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14.10.1

Oscillating axle support with automatic control

Service Manual

Design of the oscillating axle support mechanism

2 Design of the oscillating axle support mechanism 2.1

Support cylinder 1, (see Fig. 2 on page2) / Fig. 7 The support cylinders 1 with screwed-in stop valve 5 are located to the right and left above the steering axle on the undercarriage. The plunger pistons in the cylinders 2 block and release the oscillating motion of the steering axle. When in blocking position (solenoid valve Y371 is not powered), the stop valves 5 close the cylinder chambers, i.e. the piston 2 is positioned between the axle and the oil column in the cylinder chamber. When the stop valves 5 are open (solenoid valve Y371 is powered), the cylinder chambers are connected to each other, i.e. the pistons follow the oscillating motion of the steering axle. The cylinders are continuously fed with a little oil (1 to 2 l/min) by the pilot system through the restrictor (0.5 mm) in the unlocking piston of the stop valve 5 in the cylinder chamber. To prevent the steering axle from oscillating when the supports are engaged (compression by air content in oil), the connecting line between the two cylinders 1 is equipped with restrictors 20, the check valve 11 and the accumulator 24. The check valve 11 produces a return pressure to the tank and thus to the pressure accumulator 24 to minimum 6 bar. This means that the unloaded piston is continuously pressed against the axle as long as the oscillating axle is locked. The cylinder 1 and the associated lines must be inspected for proper connection and leakage at the prescribed intervals, see maintenance instructions in group 3.

Fig. 2

14.10.2

Undercarriage with support cylinders and main components

1

Support cylinder, complete

5

2

Piston

10 Undercarriage

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Stop valve

Service Manual

Oscillating axle support with automatic control Design of the oscillating axle support mechanism

2.2

Rotary connections 320 / 322 The six-fold oil rotary connection 322 is mounted on the seven-fold rotary connection 320 (high-pressure connection). Control oil is fed from the solenoid valve Y371 through the oil rotary connection 322 to the stop valve 5 of the support cylinders.

2.3

Solenoid valve Y371 The solenoid valve Y371 is integrated into the control oil unit 50 of the pilot control system. It consists of a hydraulic 3/2 way valve with electric actuator. When in working position, the solenoid valve Y371 is open, allowing control oil to flow to the stop valves 5. In neutral position, it blocks the control oil flow and thereby relieves the stop valve 5 to the tank.

Fig. 3

Control oil unit and rotary connection

50

Control oil unit

320

Rotary connection 7 x for high pressure

A Control oil unit for model A 309 / 311 from start of series B Control oil unit for model A 309 / 311 from change of series, see hydraulic unit

322 Rotary connection 6 x for low pressure (*) C Control oil unit for model A 312 - 316 Y371 Solenoid valve for oscillating axle support

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MJF C I F S S

14.10.3


Service Manual

Operation of oscillating axle support

Fig. 4

Operator's platform with rotary switches, proximity switches and indicator lights

B266

Proximity switch of oscillating axle automa- S7 tic

H176

Indicator light of automatic support

H311

Indicator light / oscillating axle locked

S75

Switch safety lever Rotary switch of oscillating axle support

3 Operation of oscillating axle support 3.1

Releasing oscillating axle locking system The safety lever S7 is turned down. Turn the switch S75 to position 0. The indicator lights H176 and H311 are off. Note! For safety reasons, the oscillating axle cannot be released if there is a certain load on the axle (high load forces due to loads attached at right angles to the travel direction). Before the oscillating axle locking system is released, swivel the uppercarriage into travel direction or otherwise change the kinematics of the equipment. Operating status:

14.10.4

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Service Manual

Oscillating axle support with automatic control Operation of oscillating axle support

– Oscillating axle is released (oscillating freely). – Low stability – Only for travel operation without load or with load aligned in travel direction

3.2

Locking oscillating axle The safety lever S7 is turned down. Turn the switch S75 to position 1. The indicator light H311 is on. Operating status: – The oscillating axle is permanently locked. – High stability – for travel with load – Preferred mode for excavator operation

3.3

Oscillating axle support automatic Danger! If the oscillating axle automatic is on (rotary switch S75 in position A), the oscillating axle is automatically released when the working brake is released. This results in a lower stability. If a load is taken up and the uppercarriage is swivelled, the machine might tip over. This can result in serious injury or even death to the machine operator or the person in charge of attaching loads. Prior to taking up a load, switch off the oscillating axle automatic and permanently lock the oscillating axle (rotary switch S75 in position I). Only then travel with the machine with attached load (e.g. filled digging tool, load suspended on safety hook). The safety lever S7 is turned down. Turn the switch S75 to position A. The indicator lamp H176 is on. Operating status: – The oscillating axle is locked while the working brake is applied. This results in higher stability. – When the working brake is released, the oscillating axle is oscillating freely. This results in reduced stability. – Suitable for operation with frequent changes between travel and excavator operation (travel without load, or load swivelled in travel direction)

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14.10.5


Service Manual

Function of the oscillating axle support mechanism

4 Function of the oscillating axle support mechanism (see Fig. 7 on page11)

4.1 4.1.1

Oscillating function Permanent When the rotary switch S75 is turned to position 0 (indicator light H311 is off), the solenoid valve Y371 is powered and moved to working position. The control connection St at the stop valve 5 is pressurised with pilot control pressure through the solenoid valve Y371 and the rotary connection 322. The valve cone of the stop valve 5 is lifted from the seat so that the two support cylinders are connected to each other through the connection P at the cylinder 1 and the connected lines. The oscillating axle is opened.

4.1.2

Automatic By turning the rotary switch S75 to position A (indicator light H176 on) and releasing the working brake, the solenoid valve Y371 is powered and moved into its working position. The control connection St at the stop valve 5 is pressurised with pilot control pressure through the solenoid valve Y371 and the rotary connection 322. The valve cone of the stop valve 5 is lifted from its seat so that the two support cylinders are connected to each other. As a consequence, the oscillating axle is released. If the working brake (wheel brake) is applied, the solenoid valve Y371 is not powered (due to signal from proximity switch B266 - Fig. 4), i.e. the solenoid valve Y371) returns to its neutral position, thus locking the oscillating axle see 4.2.2.

4.2 4.2.1

Support function Permanent When the rotary switch S75 is turned to position 0 (indicator light H311 is on, the solenoid valve Y371 is not powered and moved to neutral position. The pressure is released to the tank from the control connection St at the stop valve 5 through the solenoid valve Y371 and the rotary connection 322.

4.2.2

Automatic By turning the rotary switch S75 to position A (indicator light H176 on) and applying the working brake, the solenoid valve Y371 is deactivated (not powered) and moved into its neutral position. The pressure is released to the tank from the control connection St at the stop valve 5 through the solenoid valve Y371 and the rotary connection 322. If the working brake (wheel brake) is released, the solenoid valve Y371 is automatically powered (due to signal from proximity switch B266 - Fig. 4), i.e. the solenoid valve Y371 returns to its neutral position, thus releasing the oscillating axle see 4.2.2.

5 Bleeding of the system As the cylinders are permanently flushed with control oil (operating mode "oscillating axle unlocked"),

14.10.6

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Service Manual

Oscillating axle support with automatic control Bleeding of the system

the system is automatically bled. Separate bleeding is thus not necessary. After a repair, first fill the cylinder 1 with oil. Then insert the stop valve 5, connect the lines, and turn the switch S75 (see Fig. 4) to position 0 (oscillating axle unlocked). Let the diesel engine idle for some time (minimum 5 minutes) to let oil flow through the stop valve (flushing). Complete a functional test, (see 6 on page8).

Fig. 5

Hydraulic connections with oscillating axle support

1

Cylinder

24

Accumulator

5 11

Stop valve Check valve

320 322

Rotary connection 7 x Rotary connection 6 x

20

Restrictor

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14.10.7


Service Manual

Functional test

6 Functional test Ensure that the front axle is unlocked (switch S75 in position 0 - Fig. 4), support the machine with its working attachment and lift one wheel of the front axle from the ground. Lock the axle (switch S75 in position I) and apply a load. Check whether there is any play between the piston 2 of the support cylinder without load 1 and the oscillating bridge (visual inspection). The loaded piston 2 of the support cylinder may not move inwards. If necessary, repeat the bleeding process,(see 5 on page6). If required, check the valve cone in the stop valve 5. Complete the above functional test on both support cylinders 1.

Fig. 6

14.10.8

Functional test of the locked oscillating axle

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Service Manual

Oscillating axle support with automatic control Functional test

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14.10.9


Service Manual

Hydraulic diagram

7 Hydraulic diagram

14.10.10

1 2

Cylinder Piston

H176 H311

Indicator light of oscillating axle automatic Indicator light / oscillating axle locked

5

Stop valve

K250

Relay / oscillating axle automatic

11

Check valve 6 bar preload

S35

Switch / servo control

20


S75

Rotary switch of the automatic oscillating axle Oscillating axle support

24 32

Diaphragm accumulator V155 Blocking diode S75-K250 Gear pump / brake and pilot control V156-2 Blocking diode S75-H311 unit (312 – 316)

33

Gear pump/pilot control unit (309311)

X197

49 50

Measuring point for pilot pressure Control oil unit

X842-3 Plug connection A1001 - B266 / 2-pin X856 Plug connection to BST / 40-pin

170 302

Leak oil line from travel motor Line to steering system (309-311)

X857 X950

Plug connection B266 / 3-pin

Plug connection to BST / 24-pin Plug connection indicator check / 21-pin

320


X952

Plug connection revolving deck BST / 21-pin

322


X956

Plug connection BST distributor / 21-pin

400

Line to brake system (312-316)

X957

Plug connection switch distributor / 21-pin

A126 B266

Printed circuit board (autocheck) Proximity switch / brake pedal

X958 X960

Plug connection switch distributor / 21-pin Plug connection operator's platform distributor / 21-pin

C D

X961 X963

Plug connection indicator distributor / 21-pin Plug connection fuse distributor / 21-pin

F316

Version in models A 309 / A 311 Version in models A 312 to serial no. 20329 / A 314 to serial no. 20333 / A 314 to serial no. 20339 Fuse servo steering / 15 A

X964

Plug connection fuse distributor / 21-pin

F326 F329

Fuse S75 / 15 A Fuse S35 / 5 A

X974-2 Plug connection blocking diode / 2-pin Y371 Solenoid valve / oscillating axle support

C

in models A 309 and A 311

D

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in models A 312 to serial no. 20329 A 314 to serial no. 20333 and A 316 to serial no. 20339

Service Manual

Oscillating axle support with automatic control Hydraulic diagram

Fig. 7

Diagram of electric and hydraulic system for automatic oscillating axle support

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MJF C I F S S

14.10.11

Oscillating axle support with automatic control Hydraulic diagram

14.10.12

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MJF C I F S S

Service Manual

Service Manual

Support cylinders Design

Support cylinders 1 Design The support cylinders are attached to the right and left on the undercarriage above the steering axle. They are designed as single-acting cylinders (plunger cylinders). The steering and oscillating axle touches the curved front face of the two pistons 2. When the machine is in working position, it is supported by the pistons 2, which are resting on oil columns in the cylinder 1. To release the axle so that it can oscillate, the stop valves 5 (hydraulically operated check valves) screwed into the cylinder base are opened, so that the pistons 2 can follow the oscillating motion of the axle.

Fig. 1

Main components of support cylinder

1

Cylinder

2

Piston

5

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Stop valve

14.20.1

Support cylinders

Service Manual

Function of support cylinder

2 Function of support cylinder see Fig. 6 In the cylinder 1, the piston 2 is axially guided by means of the two guide rings 15. The cylinder is sealed by means of a Turcon-Stepseal ring 12. It is protected against penetrating dirt with a special scraper ring 10. The stop valve 5 is pressurised with pilot pressure through the connection St in the cylinder 1 and depressurised to the tank. When the valve 5 is in locking position, the valve cone 31 is closed, so that the piston 2 is blocked in its position by the oil in the cylinder chamber. When the valve 5 is opened, the oil escapes through the valve 5 and the line connected to port P from the cylinder chamber, as soon as the piston 2 is moved in axial direction. The oil then flows into the support cylinder on the other side of the undercarriage.

Fig. 2

14.20.2

Exploded view of the support cylinder 1

1 2

Cylinder Piston

13 15

O-ring Guide ring

5 10

Stop valve Special scraper ring

801 999

Corrosion inhibitor Tarp Seal kit

12

Turcon-Stepseal ring

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Service Manual

Support cylinders Function of the stop valve

3 Function of the stop valve 3.1

Blocking position The control oil connection ST is not under pressure. The release piston 11 is pressed upwards by the pressure spring 16. The hydraulic pressure produced in the cylinder chamber as the oscillating axle presses against the plunger of the support cylinder presses the valve cone 31 upwards. The cone thereby fully closes the connection P to the other support cylinder. The ball 18 closes the connection P – ST.

3.2

Release position The release piston 11 is pressurised through the solenoid valve Y371 (see group 14.10), and the connection St with pilot control pressure. As a result, it is pushed down against the valve cone 31. When the cylinder is fully or nearly load-free, the valve cone 31 is lifted slightly from its seat. When the cylinder carries a load (e.g. due to a load that is suspended at right angles to the travel direction of the machine), the valve cone 31 is only lifted from its seat by the release piston 11 after the load pressure on the respective support cylinder is below 420 bar. When there is some oscillating motion by the steering axle, the oil can escape from the cylinder chamber through the valve cone 31 and connection P and/or then flows into the support cylinder at the other side of the undercarriage. A little pilot control oil flows through the restrictor 14, the check valve 17 / 18 and the bore C into the connecting line and thus continuously refills the pressure accumulator of the system.

Fig. 3

Sectional drawing of the stop valve

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14.20.3

Support cylinders

Service Manual

Maintenance 5

Stop valve, complete

24

Backing ring

11 14

Release piston Restrictor

26 27

O-ring O-ring

16

Pressure spring

31

Valve cone

17

Pressure spring

32

Spring plate

18

Ball

33

Pressure spring

21 22

Connector screw O-ring

34 35

Snap ring Valve housing

23

O-ring

4 Maintenance The regular maintenance of the support cylinder includes a visual inspection of the cylinder for leakage and proper mounting at predefined intervals, see maintenance instructions in group 3.

14.20.4

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Service Manual

Support cylinders Installation and dismantling of support cylinder

5 Installation and dismantling of support cylinder 5.1

Dismantling Slightly lift the undercarriage with the attachment so that the steering axle is oscillating freely. Release the tank preload. Disconnect and seal the hydraulic lines of the support cylinder 1. Loosen the mounting bolts 22 and remove the support cylinder from the undercarriage.

5.2

Installation Place the support cylinder 1 against the undercarriage 10 and secure it with the hex head screw 30 (with washers 29) to the undercarriage. Align it properly (tightening torque for the screws 30 = 960 Nm) Connect the hydraulic lines to the cylinders. Flush the oscillating axle support mechanism so that it is automatically bled, and complete a functional test, see group 14.10.

Fig. 4 1 10

Installation of the support cylinders to the undercarriage 29 30

Support cylinder Undercarriage

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14.20.5

Support cylinders

Service Manual

Sealing the support cylinders

6 Sealing the support cylinders (see Fig. 6, page 9) Note! To seal the support cylinder, you need a "Support cylinder seal kit" and a "Stop valve seal kit". Do not use pointed or sharp-edged tools to dismantle or mount the sealing elements. To seal the support cylinders, proceed as follows:

6.1

Dismantling of the support cylinder Remove the entire support cylinder from the undercarriage, see Fig. 4. Screw the stop valve 5 from the cylinder 1. If required, remove the backing ring 24 and the O-rings 23 and 27. Push the piston 2 from the cylinder and inspect it for damage and scoring. Remove the scraper ring 10, the Turcon-Stepseal ring 12 and the O-ring 13 from the cylinder 1.

6.2

Installation of the support cylinder Clean all parts carefully and remove all foreign particles. Inspect all components and sealing elements for damage. Reuse only undamaged parts. Apply Tarp corrosion inhibitors 801 (see group 1.50) to the gap between the guide ring 15 and the scraper ring 10. Before mounting them, wet all parts with hydraulic oil. Insert the O-ring 13 into the groove of the cylinder 1. Note! When squeezing the Turcon-Stepseal ring 12, avoid kinking. Squeeze the new Turcon-Stepseal ring 12, see Fig. 5. Insert the Turcon-Stepseal ring 12 into the cylinder 1, ensuring that it is in the correct position, see detail Z, (see Fig. 6, page 9). Expand the Turcon ring 12 in the cylinder 1 and place it on the inserted O-ring 13.

14.20.6

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Service Manual

Support cylinders Sealing the support cylinders

Fig. 5 1

Correct installation of the Turcon-Stepseal ring 12 Turcon-Stepseal ring

Cylinder

13 O-ring Insert the new scraper ring 10, see detail Z(see Fig. 6, page 9). Carefully push the piston 2 into the cylinder 1. Place the O-rings 23 / 26 and the backing ring 24 onto the stop valve 5. If required, replace the O-rings 22 and 27 after removing the connecting screw 21 (torque 160 Nm). Screw the compete stop valve 5 into the cylinder 1 (torque 300 Nm) Mount the support cylinder 1 onto the undercarriage, complete a functional test and connect the lines to the stop valve and the support cylinder. Complete a leakage and function test of the stop valve, see group 14.10.

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14.20.7

Support cylinders

Service Manual

Sectional drawing

7 Sectional drawing

14.20.8

1 2

Cylinder Piston

21 22

Connector screw O-ring

5

Stop valve

23

O-ring

10 11

Special scraper ring Release piston

24 26

Backing ring O-ring

12

Turcon-Stepseal ring

27

O-ring

13

O-ring

31

Valve cone

14

Restrictor

32

Spring plate

15

Guide ring

33

Pressure spring

16

Pressure spring

34

Snap ring

17 18

Pressure spring Ball

35

Valve housing

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Service Manual

Support cylinders Sectional drawing

Fig. 6

Sectional drawing of the support cylinder and the stop valve

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MJF C I F S S

14.20.9

Support cylinders

Service Manual

Sectional drawing

14.20.10

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MJF C I F S S

Service Manual


Group

Type

Operating pressures of the brake system

15.05.1


Hydraulic brake system

15.10.1


Compact brake block

15.20.1


15.1 MJF C I F S S

Service Manual

15.2 MJF C I F S S

Service Manual

Operating pressures of the brake system General information

Operating pressures of the brake system 1 General information

Machine Series

Einheit



A 312 - 316 Litronic from 2001

Gear pump 31 / 32 Brake oil max.

l/min

2

2

bar

125 ±5

125 ±5

Shut-off pressure

bar

±5

150 ±5

Switching range

bar

20 +15

20 +15

Shifting pressure of pressure switch B20 abate rise

bar

100 ±5 125 ±5

100 ±5 125 ±5

Accumulator charging valve 5 in compact brake block 4 Switch-on pressure

150

Brake system Brake pressure in front and rear brake circuits (measuring point 25 / 26)

bar


bar

5

5

Rated flow

cm3

700

700

Filling pressure (nitrogen)

bar

40

40

Max. permissible pressure

bar

180

180

50+5

55 +5

75 +10

Accumulators 14 and 15

Tab. 1

Technical data

Einheit


l/min

2

Switch-on pressure

bar

150 ±5

Shut-off pressure

bar

185 ±5

Switching range

bar

35 +15

Machine Series Gear pump 31 / 32 Brake oil max. Accumulator charging valve 5 in compact brake block 4

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15.05.1

Operating pressures of the brake system

Service Manual

General information Machine Series

Einheit

Shifting pressure of pressure switch B20 abate

bar

A 316 Litronic from 28061 100 ±5 125 ±5

rise Brake system Brake pressure in front and rear brake circuits (measuring point 25 / 26)

bar

75 +10


bar

5

cm3

1000

Accumulators 14 and 15 Rated flow

15.05.2

Filling pressure (nitrogen)

bar

45

Max. permissible pressure

bar

200

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Service Manual

Hydraulic brake system Function

Hydraulic brake system 1 Function The LIEBHERR hydraulic excavators are equipped with hydraulic dual-circuit brake systems. This working brake is charged by the gear pump 31/32 and the accumulator charging valve in the compact brake block 4. The charge pressure is then available at the brake valve of the working brake, which is also integrated in the compact brake block. When the pedal 11 is pressed down, the brake valve pressurises the brake circuit of the steering axle (multi-disc brakes 20) and the rigid axle (multi-disc and drum brakes 21/22). At maximum operation, the retainer of the brake pedal 11 is locked. The brake is now fully applied. This is the only brake function (parking brake) that may be used during work.

Fig. 1


4

Compact brake block

22

Drum brake, rear

11

Foot pedal / working brake

31

Gear pump with flow distributor

20

Multi-disc brake, front

32

Gear pump with flow distributor

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15.10.1


Service Manual

Design of brake system 21

H23

Multi-disc brake, rear

Indicator light / accumulator charging pressure

2 Design of brake system 2.1

Gear pump 31 / 32: The gear pump 31/32 with the flow distributor is driven directly by the diesel engine. It takes up hydraulic oil from the tank and feeds a constant oil volume of approx. 2 litres to the connection K to the compact brake block 4.

Fig. 2 4

Gear pumps flange-mounted to the diesel engine 31 Gear pump with flow distributor for low-pressure circuit and brake system (A309/311)


27 Measuring point / accumulator pressure

2.2

32 Gear pump with flow distributor for pilot control and brake system (A312-316) K Connection for constant flow of the flow distributor

Compact brake block 4, see Fig. 3 and Fig. 5 The accumulator charging valve 5, the double check valve 9 and the brake valve 10 are integrated into the compact brake block 4. The accumulator charging valve 5 keeps the pressure in the system with the accumulators 14 and 15 at a predefined level. When the charging pressure / shut-off pressure (see operating pressures, group 15.05) is reached, the valve 5 with the pressure balance 6 and the pressure regulator 7, see Fig. 10 automatically feed the flow from the gear pump 31 / 32 back to the tank 1 or lowers the constant flow rate to the level of the additional pressure to the connected brake accumulators 14 and 15. This charging/accumulator pressure is then available at the brake valve 10. The brake valve 10 is mechanically shifted via the linkage when the brake pedal 11 is operated. As a consequence, the brake pressure, which is proportional to the pedal travel, is fed through the connections B1 and B2 on the compact brake block 4 and the rotary connection 322 to the brakes of the axles, so that the brakes

15.10.2

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Service Manual

Hydraulic brake system Design of brake system

are applied. If there is sufficient accumulator pressure, the pressure switch B20 opens an electrical circuit when a predefined value is reached (see operating pressures group, 15.05). The indicator light H23 on the control desk is switched off, see Fig. 1. This indicates that the brake system is ready for operation. When the brake is actuated, the pressure switch B60 acts as a brake light switch and closes the electrical circuit when a predefined value is reached (see operating pressures, group 15.05), so that the brake lights of the machine are switched on. The proximity switch B266 for the oscillating axle automatic is installed near the linkage of the brake pedal 11 and the brake valve 10 (see also description in group 14).

2.3

Accumulator The accumulators 14 and 15 - located below the operator's platform and near the compact brake block 4 - fulfil an important safety function. In the event of a failure of the pump 31 / 32, or if the diesel engine is off, the machine can be brought to a halt by the accumulated pressure.

Fig. 3

Compact brake block with pressure accumulator below the operator's platform

4


14

Brake accumulator of the brake circuit of the steering axle

5

Accumulator charging valve

15

Brake accumulator of the brake circuit of the rigid axle

6

Pressure balance

10

Brake valve

B20 Pressure switch / accumulator pressure

11

Brake pedal

B60 Pressure switch / brake light

12

Locking lever (for brake working position) B266 Proximity switch / oscillating axle automatic

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15.10.3


Service Manual


2.4

Multi-disc brakes 20 and 21, or drum brake 22 respectively, (see Fig. 4, page 4) The axles of the various machines are equipped with brakes of the same or of different types. The steering axle is always equipped with a multi-disc brake. The rigid axle of the machine might feature a multi-disc brake or a drum brake. When the brake is applied with the brake pedal 11, the brake pistons and cylinders of the brakes 20 / 21 / 22 in the axles are pressurised with oil through the brake valve 10. When the multi-disc brakes are pressed together, or when the brake pads are pressed against the drum, the resulting friction slows down the vehicle.

Fig. 4

Multi-disc brake 20/21 and drum brake 22

3 Function of the brake system see Fig. 5 and Fig. 10.

3.1

System not pressurised, or switch-on pressure reached The gear pump 31/32 with flow distributor feeds the hydraulic oil through connection “K“ directly to the compact brake block 4 connection “P“. The hydraulic oil flows via the internal channels, the check valve 8 and the connections S1/S2 into the connected brake accumulators 14 and 15. The pressure in the accumulator circuit is thus increased. The accumulator charge pressure is applied through the check valve 8 to the pilot control piston 135 of the pressure regulator and through the channels in the housing and the edges of the piston 72 to the two front faces of the pressure balance 6. The pump 31 / 32 feeds the accumulator circuit through the double check valve 9 until the force resulting from the charging pressure exceeds the preload force of the adjusting spring 51.

3.2

System charged, shut-off pressure reached The piston 72 pushes against the spring 51, shuts off the supply from the connection P to the springfacing surface of the pressure balance 6 and also relieves this surface to the connection T. The pressure balance 6 is shifted towards the pressure spring 56 and opens the P channel to the tank through connection N. That means, the pump flow flows at low

-p through accumulator charging valve 5 to the tank.

The check valve 8 closes. The pilot control piston 135 stabilises the shut-off function, as it has a larger effective surface than the spool 72.

15.10.4

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Service Manual

Hydraulic brake system Function of the brake system

When the working brake is operated, or if there is internal leakage at the accumulator charging valve, the accumulator charge pressure drops from its maximum level (shut-off pressure) to its minimum level (switch-on pressure). The spring force of the adjusting spring 51 now exceeds the force of the pilot 135. As a result, pressure regulator 7 is reset to its initial position so that connection "T" is closed and connection "P" is opened towards the accumulator circuit and pressure balance 6 (spring side). The pressure balance closes connection "P-N". The system is again charged. The switching pressure difference / switching range (see operating pressures, group 15.05) between the switch-on and the shut-off pressure results from the surface difference of the pilot control piston 135 and spool 72.

3.3

Applying working brake By pressing down the brake pedal 11 (located to the right in the operator's cab), see Fig. 1, the linkage attached to the pedal presses down regulation springs 57 and 58. The brake piston 64 is moved inwards, so that the force applied to the pedal actuates the build-up of a proportional hydraulic brake pressure in the first brake circuit. The brake pressure of the first brake circuit shifts the brake piston 63 with the same force that is applied to the brake piston 64. After a short stroke, the pin 81 pushes the brake piston 63 against the pressure spring 52 As the pistons 63 and 64 are moved from their neutral position inwards against the pressure springs 52/53, the lines from connections B1 and B2 to connection T are closed first by means of the control edges. Subsequently, the accumulator pressure is applied through connections B1 and B2 and the rotary connection 322 to the multi-disc brakes 20 / 21/22 of the axle. As a consequence, the brakes are applied. If the force applied onto the pedal is constant, the brake pistons 63 and 64 are set in a control position, keeping the brake pressure constant, i.e. the supply from the respective accumulator circuit and the outlet to the tank are closed. If the force applied onto the pedal is reduced, the control edges of brake pistons 63 / 64 open the connection to the tank, so that the brake pressure is reduced until an equilibrium of forces is established above and below the pistons 63 / 64. When the brake pedal 11 and the brake piston 63 / 64 return to their initial position, the brakes 20 / 21 / 22 are released to the tank.

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15.10.5


Service Manual


15.10.6

4 6

Compact brake block Pressure balance

38 50

Piston/pressure balance Pressure spring / pilot control piston

7 8

Pressure regulator Check valve

51 52

Pressure spring / accumulator pressure Pressure spring / brake piston return

9

Double check valve

53

Pressure spring / brake piston return

10 11

Foot brake valve Foot brake pedal with housing

56 57

Pressure spring / pressure balance Pressure spring / brake pressure

14

Brake accumulator / front brake circuit

58

Pressure spring / brake pressure

15

Brake accumulator / rear brake circuit

63

Brake piston

20

Multi-disc brake / steering axle

64

Brake piston

21

Multi-disc brake / rigid axle

72

Spool

22

Drum brake / rigid axle

81

Pin

25 26

Measuring point / front brake pressure Measuring point / rear brake pressure

102 131

Threaded bolt Sleeve

27 31

Measuring point / accumulator pressure 132 Gear pump / low pressure relay and 135 brake system (A 309/311)

Bushing Pilot control piston

32

Gear pump / pilot control and brake system (A 312- 316)

322

Rotary connection

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Service Manual

Hydraulic brake system Function of the brake system

Fig. 5

Sectional drawing of the compact brake block with hydraulic lines

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15.10.7


Service Manual

Bleeding of the brake system

Note! The brake system is filled with oil from the hydraulic unit, see group 1.50.

When the oil in the hydraulic tank is replaced with a different product (e.g. environmentally friendly hydraulic fluid), the oil in the brake system must also be replaced. This means that the oil in the brake system must be drained through the bleeder screws at the wheels. Minimum drain volume: 0.5 l per axle. The accumulators might have to be charged several times by repeated starting of the diesel engine. Note! Do not drain the oil while the engine is on, as the accumulators are otherwise not emptied.

4 Bleeding of the brake system Caution! After the brake circuit has been opened for repair work, the piston chamber/cylinder in the axles and the line to the brake must be bled.

Fig. 6

Different location of bleeder valve in models A 309 and A 311 - 316. A

B Dust cap

Bleeder valve

Start diesel engine and let it run for approx. 2 minutes. Switch off the engine. Remove the dust cap B from the bleeder valve A and connect the bleeder hose. Immerse the other hose end into a glass container half filled with hydraulic oil. Open the bleeder valve A. Press down brake pedal and lock in place, if necessary. Close bleeder valve A again. Repeat this procedure (opening valve, operating brake, closing valve) until the oil flowing out is not foaming. Disconnect the bleeder hose and replace the dust cap B on bleeder valve A again.

15.10.8

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Service Manual

Hydraulic brake system Inspection and adjustment of the brake system settings

5 Inspection and adjustment of the brake system settings 5.1

Important adjustment notes Note! Please note that all work on the brake system must be carried out by technicians who are authorised by LIEBHERR. The pressure adjustments must be made at operating temperature of the hydraulic oil. To adjust the pressure, use only glycerine damped pressure sensors with an accuracy of at least 1% of the scale full scale value. Caution! Prior to any inspection or adjustment work on the machine, take all safety and accident prevention measures required to protect the technician, see also the accident prevention regulations issued by the German Ground Construction Trade Association (Tiefbau-Berufsgenossenschaft).

5.2

Layout of measuring points 25, 26 and 27 Note! The location of the measuring points 25 and 26 in the undercarriage is similar to that shown for model A 312.

Fig. 7

5.2.1

Measuring points for the brake pressure in the undercarriage and measuring point of the accumulator pressure at the connection K of the flow distributor.

25

Measuring point / front brake pressure

26

Measuring point / rear brake pressure

27

Measuring point / accumulator pressure

Measuring point 25 Used to check the brake pressure in the front brake circuit.

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MJF C I F S S

15.10.9


Service Manual

Inspection and adjustment of the brake system settings

5.2.2

Measuring point 26 Used to check the brake pressure in the rear brake circuit.

5.2.3

Measuring point 27 at the flow distributor of the pump 31/32, (see Fig. 7, page 9) Used to check the switch-on and the shut-off pressure, the accumulator pressure and the switching pressure of the pressure switch B20.

5.3

Checking of the switch-on and the shut-off pressure of the accumulator charging valve 5, and of the switching pressure of the pressure switch B20.

Fig. 8

Compact brake block 4 below the operator's platform

4

Compact brake block

74

Adjusting screw

16 17

Fork head Lock nut

75 102

Lock nut Threaded bolt

18

Bolt

B20

Pressure switch / accumulator pressure

Connect the 0-600 bar pressure sensor to measuring point 27 and check the following values:

5.3.1

Switch-on and shut-off pressure of the charging valve 5 Start the diesel engine and recharge the unit. The pressure at the measuring point 27 must rise all the way to the shut-off value specified. See operating pressures, group 15.05. The accumulator valve 5 is now switched, so that the system is depressurised at the measuring point 27. Repeatedly press down foot brake pedal 11 (see Fig. 3, page 3) until the system is recharged or the switch-on pressure is reached. The pressure at measuring point 27 rises again to the level of the shut-off pressure. To check the switch-on pressure, remove pressure switch B20, mount a M10 X 1 screw coupling assembly and connect a 0-600 bar pressure sensor. If required, loosen the lock nut 75 and adjust the switch-on and switch-off pressures to the prescribed value by turning the adjusting screw 74 (see operating pressures, group 15.05).

15.10.10

Turn in

= Increase pressure

Turn out

= Reduce pressure

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Service Manual

Hydraulic brake system Inspection and adjustment of the brake system settings

5.3.2

Switching pressure of pressure switch B20 Connect pressure sensor to measuring point 27. Shut down the diesel engine, leave the ignition on and reduce the brake pressure by repeatedly operating the foot pedal. The indicator light H23, (see Fig. 1, page 1) in the control desk is on. Connect the pressure sensor to the measuring point 27. Start the diesel engine and observe the pressure sensor and the indicator light H23. When the prescribed switching pressure is reached (see operating pressures, group 15.05), the indicator light H23 must switch off. If defective, replace the pressure switch B20.

5.4

Checking brake pressure of working brake

Fig. 9

Brake pedal and operating linkage of the brake valve at the compact brake block

4

Compact brake block

17

Lock nut

11 12

Foot brake pedal Locking lever

18 29

Bolt Stop screw, rear

13

Stop screw, front

102

Threaded bolt

16

Fork head Connect pressure sensor (0 - -600 bar) to measuring points 25 and 26, see Fig. 7. Start the diesel engine. Press down the foot brake pedal 11 and lock it. The actual brake pressure, as shown at the pressure sensor, must correspond to the respective value in the list of operating pressures, see group 15.05.

To adjust the brake pressure, modify the linkage length as follows: 12 Adjust stop screw 13 so that there is only minimum play between the locked pedal and the upper edge of the screw. While the pedal 11 is engaged, loosen the lock nut 17 and turn the threaded rod 102 so that the pressure measured at the measuring points 25 and 26, Fig. 7 corresponds to the prescribed pressure. Re-tighten the lock nut 17.

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15.10.11


Service Manual

Inspection and adjustment of the brake system settings Disengage the pedal 11. Unlock and drive out the pin 18 (Ø 10 mm) inserted between the fork head 16 and the pedal lever, and insert a Ø 9 mm pin (drill bore, if necessary). Loosen and adjust the stop screw 29 until there is no play between the fork head 16 and the inserted pin. Secure the stop screw 29 with a lock nut. Remove the Ø 9 mm adjusting pin and re-insert and lock the original Ø 10 mm pin 18. The threaded rod is now correctly pre-stressed (1 mm). After the adjustment is completed, check whether the measuring points 25 and 26 remain without pressure when the pedal 11 is not pressed. If required, readjust the position of stop screw 29.

5.4.1

Checking of the brake accumulators 14 and 15, (see Fig. 3, page 3) Connect pressure sensor (0-600 bar) to the measuring point 27 (see Fig. 7, page 9). Connect pressure sensor (0-600 bar) to the measuring points 25 and 26, see Fig. 7. Start the diesel engine. Charge the system all the way up to shut-off pressure. Shut down the diesel engine and slowly press down foot brake pedal 11 Fig. 3 - at least ten times, with short intervals. Having done that 10 x, the brake pressure at measuring points 25 and 26 Fig. 7 should not drop below 50 bar filling pressure. If it happens anyway, there is most probably a problem with accumulators 14 / 15. Release the pressure from the system and install new accumulators. Remove the pressure sensor, and seal the measuring points 25, 26 and 27.

15.10.12

1

Hydraulic tank

28

Diesel engine

4

Compact brake block

31

5

Accumulator charging valve

32

Gear pump / low pressure circuit and brake (A309-311) Gear pump / pilot control and brake system (A312-316)

6 7

Pressure balance Pressure regulator

38 51

Piston Pressure spring / accumulator pressure

8

Check valve

57


9

58


10

Shuttle check valve / double check valve Foot brake valve

63

Brake piston

11

Brake pedal

64

Brake piston

14

Brake accumulator / front brake circuit

72

Spool

15

Brake accumulator / rear brake circuit

135


20 21

Multi-disc brake / steering axle Multi-disc brake / rigid axle

322 B20

Rotary connection 6 x Pressure switch / accumulator charge pressure

22 25

Drum brake / rigid axle Measuring point / front brake circuit

B60 E19

Pressure switch / brake light Right brake light

26

Measuring point / rear brake circuit

E20

Left brake light

27

Measuring point / accumulator charge pressure

H23

Indicator light / accumulator charging pressure

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Service Manual

Hydraulic brake system Hydraulic diagram

6 Hydraulic diagram

Fig. 10


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MJF C I F S S

15.10.13


Service Manual

Hydraulic diagram

15.10.14

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Service Manual

Compact brake block Design

Compact brake block 1 Design (see Fig. 3 on page4) The compact brake block 4 includes the accumulator charging valve 5 and the brake valve 10. Other components required for its proper functioning are connected via hydraulic lines of hoses to the block 4. The brake valve 10 is actuated mechanically with a brake pedal via elbow levers and threaded bolts. When the brake is operated, it pressurises the multi-disc or drum brakes of the axles through two different brake circuit containing oil, which is taken from the respective accumulator circuits.

Fig. 1

Compact brake block 4

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15.20.1

Compact brake block

Service Manual

Functional description of the accumulator charging valve 5

2 Functional description of the accumulator charging valve 5 (see Fig. 6 on page7) The accumulator charging valve 5 or the pressure shut-off valve ensures that the pressure in the brake accumulator is kept at the preset level. This is achieved by means of a switching logic where the brake system is recharged to the shut-off pressure level when the pressure drops below the switchon level.

2.1

Charging pressure at the accumulator charging valve 5 During the charging process, the constant oil flow from the gear pump flows from the connection P to the check valve 8 and the double check valve 9 to the accumulator circuit. Simultaneously, the oil acts on the piston 38 of the pressure balance 6 and the spool 72 on the spring side of the pressure balance 6. As a result, the oil flow to the return side (connection N) is blocked, until the pump pressure is greater than the spring pressure at the pressure regulator 7 across the surface of the pilot control piston 135. The pilot control piston 135 shifts the spool 72 against the adjusting spring 51. The spring prevents that the pump pressure P acts on the spring side surface of the piston 38 and thus relieves the spring chamber of the pressure balance 6 to the tank T. The piston 38 is now shifted, and the oil is fed from the connection P via the connection N to the tank 1. The check valve 8 closes. The resulting force of the accumulator pressure acting on the adjusting spring 51 stabilises the shut-down function. The charging process is completed, and the pump flow can now flow through the charging valve at a relatively low -p.

2.2

Shifting pressure difference (shifting range) The shifting pressure difference is the result of the difference surfaces at the pilot control pistons 135 and the spool 72. The upper switching point (shut-off pressure) is reached, when the T edge (line to T) is opened; the lower switching point is however only reached, when the P edge (line to P is opened). If the pressure in the accumulator circuit drops below the lower switching point (switch-on point) the spool 72 is pushed by the pressure spring 51 into its basic position. As a result, pressure is applied to the spring side face of the pressure balance 6. The piston 38 blocks the connection P-N and the gear pump 33 pumps the oil again into the accumulator circuit.

15.20.2

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Service Manual

Compact brake block Connections at the compact brake block

3 Connections at the compact brake block

Fig. 2

Views W, X, Y, and Z of the compact brake block

Connections: Connection P

from pump

Connection N and T to tank Connection B1

to multi-disc brake / steering axle

Connection B2 Connection DS1

to multi-disc brake or drum brake / rigid axle Pressure switch / brake light (B60*)

Connection DS2

Pressure switch / accumulator pressure (B20*)

* item in electrical diagram

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15.20.3

Compact brake block

Service Manual

Connections at the compact brake block

Fig. 3

1

to hydraulic tank

31

from gear pump with flow distributor (A 309311)

4

Compact brake block

32

from gear pump with flow distributor (A 312316

5 6

Accumulator charging valve Pressure balance, complete

38 51

Piston / pressure balance Pressure spring / accumulator pressure

7

Pressure regulator

57


8

Check valve

58


9

Double check valve

63

Brake piston

10 11

Brake valve, complete Brake pedal

64 72

Brake piston Spool

14

to brake accumulator / steering axle 88 circuit to brake accumulator / rigid axle cir- 135 cuit to brake cylinders / steering axle with 999 multi-disc brake

15 20

21

15.20.4

Hydraulic diagram of compact brake block

to brake cylinders / rigid axle with multi-disc brake

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MJF C I F S S

to collecting pipe Pilot control piston Seal kit, complete, consisting of bellows, radial shaft seal ring and various backing and O-rings

Service Manual

Compact brake block Sectional drawing

22 27

to brake cylinders / rigid axle with B20 Pressure switch / accumulator pressure drum brake Measuring point / accumulator pres- B60 Pressure switch / brake light* sure

4 Sectional drawing In A 312 Li from 12363, A 314 Li from 2001, A 316 Li from 2001

Fig. 4

Sectional drawing of compact brake block from start of series production

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15.20.5

Compact brake block

Service Manual

Sectional drawing

Fig. 5

15.20.6

Exploded view of compact brake block from start of series production

4

Compact brake block

64

Brake piston

5 6

Accumulator charging valve Pressure balance, complete

66 72

Screw plug Spool

7

77

Screw plug

8

Pressure control element, complete Check valve

78

Snap ring

9

Double check valve

81

Pin

10

Foot brake valve, complete

102

Threaded bolt

14

Spring plate

112

Screw plug

15 22

Washer Washer

130 131

Valve insert, complete Sleeve

24 31

Pipe Spring plate

132 133

Bushing Sleeve

38

Piston

134

Check valve

39 49

Spring plate Pressure spring

135 141

Pilot control piston Pressure switch

50 51


142 144

Seal ring Pressure switch

52 53


163 165

Reducer Screw plug

56

Pressure spring

166

Reducer

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Service Manual

Compact brake block Sectional drawing

57 58


999 B20

Seal kit, complete Pressure switch / accumulator pressure*

63

Brake piston

B60 *

Pressure switch / brake light* Item in electric diagram

5 Sectional drawing In A 309 Li from 20221, A 309 Li from 20221, A 312 Li from 18335, A 314 Li from 18337, A 316 Li from 18339, A 316 Li Ind. 18374

Fig. 6

Sectional drawing of compact brake block from start of series production

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15.20.7

Compact brake block

Service Manual

Sectional drawing

15.20.8

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Service Manual


Group

Type

Pipe fracture safety valve for boom cylinders

16.04.1


Pipe fracture safety valve for stick cylinder

16.06.1


Pipe fracture safety valve for regulating cylinder

16.10.1


Overload warning system

16.12.1


Hydraulic quick change adapter

16.16.1


Flow reduction

16.19.1

A 309 LI 20221A 311 LI 20222-

16.1 MJF C I F S S

Service Manual Flow reduction

16.20.1


LIKUFIX Hydraulic Coupling System

16.24.1


Hydraulic hammers

16.30.1


Accessory kit AS1

16.44.1


Accessory kit AHS 1

16.48.1



16.52.1



16.54.1

A 309 LI 20221A 311 LI 20222-


16.56.1


16.2 MJF C I F S S

Service Manual


Group

Type

Accessory kit AHS 11 / AHS 12 with Tool Control

16.57.1


Accessory kit AHS 12 with changeover valve

16.58.1


Individual control

16.60.1

A 312 LI A 314 LI A 316 LI A 316 LI-IND

Kit for control switch-over

16.62.1

A 309 LI 20221-23701 A 311 LI 20222-23253


16.62.21

A 309 LI 23702A 311 LI 23254-


16.64.1


Dozer blade

16.66.1


Hydraulic cab elevation system

16.70.1


Speeder kit

16.74.1

A 312 LI 12363A 314 LI 2001A 316 LI 2001A 316 LI-IND 200116.3

MJF C I F S S

Service Manual Generator drive accessory kit

16.86.1

16.4 MJF C I F S S

A 316 LI-IND 2001-

Service Manual

Pipe fracture safety valve for boom cylinders Function

Pipe fracture safety valve for boom cylinders 1 Function The pipe fracture safety valve is installed directly at the pressure connection of the boom cylinder (piston side). The pipe fracture safety valve works independently of the load, pressure and adjusting pressure. It protects the entire equipment against damage from pipe fracture. The pipe fracture safety valve consists of a housing, a control piston (stop valve), the pilot piston required for actuation and a check valve (bypass of stop valve). The pressure-relief valve in the housing is responsible for secondary protection. In the event of a line break, the valve prevents uncontrolled lowering of equipment and/or the lifted load. The pipe fracture safety valve blocks the corresponding cylinder connection when the control pressure connection is not pressurised (without any leak oil).

Fig. 1

Pipe fracture safety valves at the boom cylinder (example of A 312 - R 317 model)

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16.04.1


Service Manual


2 Functional description Sectional drawing, see Fig. 2, hydraulic diagrams, see Fig. 7 and Fig. 8.

2.1

Extending cylinder 160 / 235 The hydraulic oil flows now from the control block 100 connection A3 / A6 to the valve 238 connection V2. The sleeves 12 and 42 (check valves) are shifted, and the pressure oil pressurises the piston side of the cylinder through connection C2. The cylinder 160/235 is extended. The return oil from the rod side flows through the connection B3 / A6 of the control block 100 to the tank. When the working movement is completed, the check valve 8 closes again. The return line is blocked, i.e. the load is held without any leak oil.

2.2

Pressure control The secondary pressure control is based on the application of pressure onto the cone 29.7 through the filter insert 30. In the event of pressure peaks, the cone 29.7 is shifted against the preloaded pressure spring 29.6, which results in a relief of the piston side. The oil escapes partly through the restrictor check valve 23, see Fig. 2 and Fig. 8 and pressurises, at the same time, the piston 3, which then shifts the piston 7(see Fig. 2 on page3). More oil flows from the piston side through the open valve 7 and the connection V2 to the control block 100 and the secondary pressure-relief valve 131/ 221 (boom cylinder 160/235 extending). The valve 131 / 221 opens to allow the oil to flow back to the tank.

2.3

Retracting cylinder 160 / 235 The pilot pressure at the control valve block 100, connection b3/b6, used to actuate the pilot control piston 106/220 for working movement "Lowering attachment", pressurises at the same time the restrictor check valve 23 and the pilot piston 3 through connection Pil. The pilot 3 presses against valve plunger 7.7 and, thus, shifts it against the pressure spring 7.5. After a short stroke, the sleeve 42 finds purchase on valve guide 7.1, and the leak oil free shut-off device is opened. The hydraulic oil flows now from the control block 100 connection B3 to the rod-side connection V2. The cylinder 160/235 is retracted. The oil from the piston room flows via connections C2 and V2 to the control valve block, and from there back to the hydraulic tank. Simultaneously, oil is fed from the variable-displacement pump through the respective connection in the control block to the rod side of the cylinder 160/235.

Key of sectional drawing, see Fig. 2

16.04.2

1

O-ring

14

Spring guide

2

Slide ring

15

O-ring

3

Pilot piston

16

Backing ring

4

Housing

17

Screw plug with O-ring

5 7

Screw plug with O-ring Pilot control piston, complete

19 23

Screw plug with O-ring Restrictor check valve

7.1

Valve guide

27

Protective cap

7.2 7.3

Adjusting screw Protective cap

29 Pressure-relief valve, complete 29.1 Valve guide

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Service Manual

Pipe fracture safety valve for boom cylinders Sectional drawing

7.4 7.5

Seal ring Pressure spring

29.2 Adjusting screw 29.3 Lock nut

7.6 7.7

Valve cone Valve plunger

29.4 Spring guide 29.5 Seal ring

7.8 8

O-ring Check valve, complete

29.6 Pressure spring 29.7 Valve cone

8.1

Valve guide

30

Filter cartridge

8.2 9

Cone O-ring

31 40

Screw plug with seal ring Slide ring

10 11

Slide ring O-ring

41 42

O-ring Valve seat (sleeve)

12

Valve seat (sleeve)

43

Pressure spring

13

Pressure spring

44

Spring guide

3 Sectional drawing

Fig. 2

Sectional drawing of pipe fracture safety valve

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16.04.3


Service Manual

Repair and sealing of valve 238

4 Repair and sealing of valve 238 .

Danger! Defective valves can pose a serious risk to persons and property in the danger area. For safety reasons, it is forbidden to repair pipe fracture safety valves. Always replace pipe fracture safety valves with all associated parts, and install only new valves supplied and preset by the manufacturer. Return defective valves to the manufacturer, indicating the problem or damage you have observed.

4.1

Sealing work In the event of external leakage of the valves, the valves may only be resealed, if this work does not require the dismantling or the valve. To reseal the valve, use only the seal kit provided by the manufacturer.

4.2

Assembly and dismantling of the pipe fracture safety valves Danger! The dismantling, installation or sealing of the valves requires workers to access the danger area of the machine. This bears risks for the mechanic, as equipment might move uncontrolled when a valve/hydraulic circuit is opened. Never open the hydraulic circuit of the pipe fracture safety valves while the circuit is pressurised. Place the unloaded attachment on the ground (piston side of the cylinder must be fully depressurised) Release the tank pressure. Depressurise the pipe fracture safety valve(s) by actuating the pilot control device for lifting and lowering to the stop and holding it in this position while the diesel engine is off (ignition and pilot control system on). After the hydraulic circuit of the valves 238 is opened, certain problems might occur caused by air in the control circuit. The circuit must therefore be bled (collect escaping oil), see 4.3.

4.3

Bleeding of pipe fracture safety valve 238, see Fig. 3 If the measuring neck 52 is not available: Remove the screw plug from the connections Pil and T. Screw the M12x1.5 screw coupling (tool no. 11 from group 2.01) into the bores. Remove the protective cap from the measuring neck 52 at the connections Pil and T. Install the Minimess high pressure hose between the connection Pil and connection T. Start the engine. Actuate the boom cylinder to retract it (keep pilot control unit pushed forward). The control circuit is bled. Lower the unloaded attachment onto flat and firm ground. Release the tank pressure and the load-holding valve(s) by actuating the pilot control device for lowering to the stop and holding it in this position while the diesel engine is off (ignition and pilot control system on).

16.04.4

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Service Manual

Pipe fracture safety valve for boom cylinders Repair and sealing of valve 238 Remove the measuring hose and screw coupling. Screw in the screw plug 13 at the connections Pil and T.

Fig. 3 52

Screw coupling for the bleeding of the hydraulic circuit and the pipe fracture safety valve 238

Screw coupling

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MJF C I F S S


16.04.5


Service Manual

Inspection and testing of pipe fracture valves

5 Inspection and testing of pipe fracture valves Danger! The inspection and testing of the pipe fracture safety valves require access to the danger area of the machine. There is a risk to life and limb for mechanics from uncontrolled machine movements. Park the machine on a level surface. Secure it against uncontrolled movement. Only carry out inspections, if the machine is fully shut down and properly secured. Before opening the hydraulic circuit release all pressure from the hydraulic system. Adhere to the accident prevention regulations issued by the German Ground Construction Trade Association (Tiefbau-Berufsgenossenschaft) for the powertrains and earth-moving equipment. Valves 238 have been pre-set by the manufacturer. The setting cannot be changed and is secured by means of a lead seal. Missing seals / protective caps are proof that the original settings have been tampered with. The readjustment of the pipe fracture safety valve settings is not permitted for safety reasons. Should a subsequent inspection reveal that the settings are incorrect, remove the defective valves and replace them with new valves preset by the manufacturer. Return defective valves to the manufacturer, indicating the problem or damage you have observed.

5.1

Pressure check, see Fig. 4 Place attachments on the ground. Switch off the engine. Release the pressure from the valve. Remove the plug 5 at the connection E and drain the pressure oil through the bleeding connection 52 and a measuring hose (collect escaping oil). Insert the measuring connection 52 (1/4" tool, ID no. 7362579) into the connection E of the two valves 238. In machines that are equipped with an overload warning system, insert the connection only in the valve 238 of the left boom cylinder. Instead of a measuring connection 52, you may connect a measuring hose and a measuring Tpiece to the bleeding connection 52, see group 2.01. Items 33, 34, 35, 36. Remove the cap from the measuring point 40 / 41 (at the control block 100) and connect a Minimess hose between the measuring points 40 / 41 and 52 (in connection E). Connect a pressure sensor (600 bar) with measuring connection (1.5 - 2.5 m) to the other measuring connection 52 of the valve 258 (connection E). Turn the secondary pressure-relief valve 131/221 (spool 106/220) to extend the boom cylinder to minimum 150 bar. Reduce the pressure, so that the oil can flow through connection V2 of valve 238. Fully pressurise the bucket and grapple cylinder to reach maximum pressure. Turn in the secondary pressure valve 133/262 (spool 107/260) for extending the bucket cylinder, (increase the pressure above the prescribed adjusting pressure of the valve = 410 + 10 bar). Slowly turn in the pressure cut-off valve 104 (A 312- R 317) or the primary pressure-relief valve 120/122 (A 309 - A 311) and listen for pressure sounds. When the secondary pressure-relief valve 29, (see Fig. 2 on page3), opens, a hissing sound is audible.

16.04.6

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Service Manual

Pipe fracture safety valve for boom cylinders Inspection and testing of pipe fracture valves The pressure indicated at the measuring point 52 must correspond to the prescribed adjusting pressure of the valve. If the prescribed adjusting pressure is not reached in the above test, replace the entire pipe fracture safety valve. Remove the hose line. Readjust the secondary pressure-relief valve, see adjustment protocol in group 6, and remove the pressure gauge.

Fig. 4

Measuring points at the pipe fracture safety valves and at the respective pressure-relief valves at the control blocks

40

Measuring point P1 (A 309 - A 311)

122

Primary pressure-relief valve (A 309/ 311 with AHS)

41

Measuring point MP (A 312 - R 317)

131

52

Measuring neck

133

100


220

Secondary pressure-relief valve / extending boom cylinder Secondary pressure-relief valve / extending bucket cylinder Boom cylinder spool ( 312 - 317)

104

Pressure cut-off valve (A 312 - R 317)

221

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Secondary pressure-relief valve / extending boom cylinder

16.04.7


Service Manual


5.2

106 107

Spool / boom cylinder Spool / bucket cylinder

238 260

120

Primary pressure-relief valve (A 309/ 311) 262

Pipe fracture safety valve Bucket cylinder spool ( 312 - 317) Secondary pressure-relief valve / extending bucket cylinder

Check for leakage In principle, there should be no leak oil at the pipe fracture safety valves. New valves might however show some leakage, caused by internal drop leakage, so that the pressure might drop slightly within the first 10 seconds. Subsequently, the leakage gap is sealed and leakage is prevented. Fully extend the attachment with attached load. Note! For this test, the attached load may not exceed half of the maximum load capacity.

The load may not be greater than half the maximum load capacity

At operating temperature (approx. 50°C), fully lift the attachment and hold it in this position. The load may not drop by more than 100 mm within the first 10 seconds (according to ISO 8643). If the drop is greater, there is a problem with the hydraulic unit or the valve. Inspect the valve to locate and identify the problem. Danger! The inspection of the valves requires access to the danger area of the machine. This bears risks for the mechanic, as equipment might move uncontrolled when a valve/hydraulic circuit is opened. Extend the attachment so that the valve can be accessed. Lift the attachment slightly (by approx. 20 cm). Switch off the diesel engine and release the tank pressure. Place an oil pan under the valve to collect the leak oil. Remove the line to the high pressure connection V2, (see Fig. 4 on page7). Measure the leak oil escaping at the valve. If the leak oil volume exceeds 5 cm3 within 5 minutes, it is likely that the valve seat has been damaged. In this case, replace the valve, (see 4.2 on page4).

16.04.8

50

to control oil unit

160

Boom cylinder

52 88T

Bleeding and measuring connection Collecting pipe

235 238

Boom cylinder Pipe fracture safety valve

100

Control valve block

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Service Manual

Pipe fracture safety valve for boom cylinders Hydraulic connections and links

6 Hydraulic connections and links 6.1

Models A 309 - A 311

Fig. 5

Hydraulic connections and lines in models A 309 - 311

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MJF C I F S S

16.04.9


6.2

Models A 312 - R 317

Fig. 6

16.04.10

Hydraulic connections and lines in models A 312 – R 317

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MJF C I F S S

Service Manual

Service Manual


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MJF C I F S S

16.04.11


Service Manual

Hydraulic connections and links

Components of hydraulic diagram, see Fig. 7

16.04.12

1

to hydraulic tank

130

to slewing gear motor

6

to hydraulic oil cooler

131


20


132


40

Measuring point P1

160

Boom cylinder

50

to control oil unit

162

Stroke limitation / boom cylinder

52

Bleeding and measuring connection

238


81/1 from right pilot control unit / connection 1 (lowering attachment)

238.7

Control piston

81/3 from right pilot control unit / connection 3 (lifting attachment) 100 Control valve block

238.8

Check valve

106

238.29 Pressure-relief valve 238.30 Filter


238.23 Restrictor check valve

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Service Manual

Pipe fracture safety valve for boom cylinders Hydraulic diagram of pipe fracture safety system

7 Hydraulic diagram of pipe fracture safety system 7.1

Models A 309 - A 311

Fig. 7

Diagram of the hydraulic system of the pipe fracture safety system for the boom cylinder, models A 309 - A 311

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MJF C I F S S

16.04.13


Service Manual

Hydraulic diagram of pipe fracture safety system

Components of hydraulic diagram, see Fig. 8 1

to hydraulic tank

221


6

to hydraulic oil cooler

222


20


224

Pressure balance

23

to pump regulator

227


41 50

Measuring point MP to control oil unit

235 238

Boom cylinder Pipe fracture safety valve

52

Bleeding and measuring connection

238.7

Control piston

81/1 from right pilot control unit / connection 1 (lowering attachment)

238.8

Check valve

81/3 from right pilot control unit / connection 3 (lifting attachment)

238.23 Restrictor check valve

100

238.29 Pressure-relief valve

220

16.04.14

Control valve block

238.30 Filter


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MJF C I F S S

Service Manual


7.2

Models A 312 - R 317

Fig. 8

Diagram of the hydraulic system of the pipe fracture safety system for the boom cylinder, models A 312 - R 317

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MJF C I F S S

16.04.15


16.04.16

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MJF C I F S S

Service Manual

Service Manual

Pipe fracture safety valve for stick cylinder Function

Pipe fracture safety valve for stick cylinder 1 Function The pipe fracture safety valve is installed directly at the pressure connection of the stick cylinder (piston and rod side). The pipe fracture safety valve works independently of the load, pressure and adjusting pressure. It is used to protect the stick cylinder and the attached bucket stick with equipment against damage from a pipe fracture. The pipe fracture safety valve consists of a housing, a control piston (stop valve), the pilot piston required for actuation and a check valve (bypass of stop valve). The pressure-relief valve in the housing is responsible for secondary protection. In the event of a line break, the valve prevents uncontrolled lowering of equipment and/or the lifted load. The pipe fracture safety valve blocks the corresponding cylinder connection when the control pressure connection is not pressurised (without any leak oil).

Fig. 1

The pipe fracture safety valve at the stick cylinder (example of pipe fracture safety at both ends)

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16.06.1


Service Manual


2 Functional description Sectional drawing, see Fig. 2, hydraulic diagrams see Fig. 7 and Fig. 8 and Fig. 9.

2.1 2.1.1

Single-side pipe fracture safety valve (A 309 - R 317) Extending cylinder 170 / 255 The pilot pressure at the control block 100 connection b2/b5 used to actuate the spool 102/240 for working movement "extending stick cylinder" applies pressure to the pilot piston 3 of the rod-side valve 258. This pressure is applied through the connection Pil and the restrictor check valve 23. The pilot 3 presses against valve plunger 7.7 and, thus, shifts it against the pressure spring 7.5. After a short stroke, the sleeve 42 finds purchase on valve guide 7.1, and the leak oil free shut-off device is opened. The hydraulic oil flows from the control block 100 connection B2/B5 to the piston-side connection of the cylinder 170/255. The return oil from the piston side flows through the connections C2 and V2 of the open valve 258 and the connection A2/A5 of the control block 100 to the tank (in A 309/311, the oil also flows through the restrictor check valve 171). The cylinder 255 is extended. When the working movement is completed, the check valve 8 closes again. The return line is blocked, i.e. the load is held without any leak oil.

2.1.2

Pressure control The secondary pressure control is based on the application of pressure onto the cone 29.7 through the filter insert 30. In the event of pressure peaks, the cone 29.7 is shifted against the preloaded pressure spring 29.6, which results in a relief of the piston rod side. The oil escapes partly through the restrictor check valve 23, see Fig. 7 and Fig. 8 and pressurises, at the same time, the piston 3, which then shifts the piston 7(see Fig. 2 on page5). More oil flows from the piston rod side through the open valve 7 and the connections C2 and V2 to the control block 100 and the secondary pressure-relief valve 127/241 (stick cylinder 170/255 retracting). The valve 127 / 241 opens to allow the oil to flow back to the tank.

2.1.3

Retracting cylinder 170 / 255 The pilot control pressure at the control pressure 100 connection a2/a5 acts on the spool 102/240 for the working movement "retracting stick cylinder". The hydraulic oil flows from the control block 100 connection A2/A5 (in A309/311: also through the restrictor check valve 171) to the rod-side valve 258 connection V2. The sleeves 12 and 42 (check valves) are shifted, and the pressure oil pressurises the piston side of the cylinder through connection C2. The return oil from the piston side flows through the connection B2/B5 of the control block 100 to the tank. The cylinder 170 / 255 is retracting. When the working movement is completed, the check valve 8 closes again. The return line is blocked, i.e. the load is held without any leak oil.

2.2 2.2.1

Double-side pipe fracture safety valve (A 312 - R 317 only) Extending cylinder 255 The pilot pressure at the control block 100 connection b5 used to actuate the spool 240 for working movement "extending stick cylinder" applies pressure to the pilot piston 3 of the rod-side valve 258. This pressure is applied through the connection Pil and the restrictor check valve 23. The pilot 3 presses against valve plunger 7.7 and, thus, shifts it against the pressure spring 7.5. After a short stroke, the sleeve 42 finds purchase on valve guide 7.1, and the leak oil free shut-off device

16.06.2

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Service Manual

Pipe fracture safety valve for stick cylinder Functional description

is opened. The hydraulic oil now flows from the control block 100 connection B5 to the piston-side valve 258 connection V2. The sleeves 12 and 42 (check valves) are shifted, and the pressure oil pressurises the piston side of the cylinder through connection C2. The cylinder 255 is extended. The return oil from the piston side flows through the connections C2 and V2 of the open valve 258 and the connection A5 of the control block 100 to the tank. When the working movement is completed, the check valve 8 closes again. The return line is blocked, i.e. the load is held without any leak oil.

2.2.2

Pipe fracture safety valve at piston side The secondary pressure control is based on the application of pressure onto the cone 29.7 through the filter insert 30. In the event of pressure peaks, the cone 29.7 is shifted against the preloaded pressure spring 29.6, which results in a relief of the piston side. The oil escapes partly through the restrictor check valve 23(see Fig. 8 on page14) and pressurises, at the same time, the piston 3, which then shifts the piston 7(see Fig. 2 on page5). In a next step, more oil from the cylinder piston side flows via V2 to the control valve block 100 and the secondary relief valves 242 (stick cylinder 255 extending). The valve 242 opens to allow the oil to flow back to the tank.

2.2.3

Retracting cylinder 255 The pilot pressure at the control block 100 connection a5 used to actuate the spool 240 for working movement "retracting stick cylinder" applies pressure to the pilot piston 3 of the piston-side valve 258. This pressure is applied through the connection Pil and the restrictor check valve 23. The pilot 3 presses against valve plunger 7.7 and, thus, shifts it against the pressure spring 7.5. After a short stroke, the sleeve 42 finds purchase on valve guide 7.1, and the leak oil free shut-off device is opened. The hydraulic oil now flows from the control block 100 connection A5 to the piston-side valve 258 connection V2. The sleeves 12 and 42 (check valves) are shifted, and the pressure oil pressurises the piston side of the cylinder through connection C2. The cylinder 255 is retracted. The return oil from the piston side flows through the connections C2 and V2 of the open valve 258 and the connection B5 of the control block 100 to the tank. When the working movement is completed, the check valve 8 closes again. The return line is blocked, i.e. the load is held without any leak oil.

2.2.4

Pipe fracture safety valve at rod side The secondary pressure control is based on the application of pressure onto the cone 29.7 through the filter insert 30. In the event of pressure peaks, the cone 29.7 is shifted against the preloaded pressure spring 29.6, which results in a relief of the piston side. The oil escapes partly through the restrictor check valve 23(see Fig. 8 on page14) and pressurises, at the same time, the piston 3, which then shifts the piston 7(see Fig. 2 on page5). More oil from the rod side flows through V2 to the control block 100 and the secondary pressure-relief valves 241 (retracting stick cylinder 255) or the secondary pressure-relief valve 241 (retracting stick cylinder 255). The valve 241 opens to allow the oil to flow back to the tank.

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16.06.3


Service Manual


Key of sectional drawing, see Fig. 2

16.06.4

1

O-ring

14

Spring guide

2 3

Slide ring Pilot piston

15 16

O-ring Backing ring

4

Housing

17


5


19


7

Pilot control piston, complete

27

Protective cap

7.1 7.2

Valve guide Adjusting screw

29 Pressure-relief valve, complete 29.1 Valve guide

7.3

Protective cap

29.2 Adjusting screw

7.4 7.5

Seal ring Pressure spring

29.3 Lock nut 29.4 Spring guide

7.6

Valve cone

29.5 Seal ring

7.7 7.8

Valve plunger O-ring

29.6 Pressure spring 29.7 Valve cone

8 8.1

Check valve, complete Valve guide

30 31

Filter cartridge Screw plug with seal ring

8.2

Cone

40

Slide ring

9 10

O-ring Slide ring

41 42


11 12


43 44

Pressure spring Spring guide

13

Pressure spring

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Service Manual

Pipe fracture safety valve for stick cylinder Sectional drawing

3 Sectional drawing

Fig. 2

Sectional drawing of pipe fracture safety valve

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16.06.5


Service Manual

Repair and sealing of valve 258

4 Repair and sealing of valve 258 .

Danger! Defective valves can pose a serious risk to persons and property in the danger area. For safety reasons, it is forbidden to repair pipe fracture safety valves. Always replace pipe fracture safety valves with all associated parts, and install only new valves supplied and preset by the manufacturer. Return defective valves to the manufacturer, indicating the problem or damage you have observed.

4.1

Sealing work In the event of external leakage of the valves, the valves may only be resealed, if this work does not require the dismantling of the valve. To reseal the valve, use only the seal kit provided by the manufacturer.

4.2

Assembly and dismantling of the pipe fracture safety valves Danger! The dismantling, installation or sealing of the valves requires workers to access the danger area of the machine. This bears risks for the mechanic, as equipment might move uncontrolled when a valve/hydraulic circuit is opened. Never open the hydraulic circuit of the pipe fracture safety valves while the circuit is pressurised. Place the unloaded attachment on the ground (piston side of the cylinder must be fully depressurised) Release the tank pressure. Depressurise the pipe fracture safety valve(s) by actuating the pilot control device for lifting and lowering to the stop and holding it in this position while the diesel engine is off (ignition and pilot control system on). After the hydraulic circuit of the valves 258 is been opened, certain problems might occur caused by air in the control circuit. The circuit must therefore be bled (collect escaping oil), see 4.3.

4.3

Bleeding of pipe fracture safety valve 258, see Fig. 3 Remove the protective cap from the measuring neck 52 at the connections Pil and T. If the measuring neck 52 is not available: Remove the screw plug from the connections Pil and T. Screw the M12x1.5 screw coupling (tool no. 11 from group 2.01) into the bores. Install the Minimess high pressure hose between the connection Pil and connection T. Actuate the boom cylinder to retract it (keep pilot control unit pushed forward). The control circuit is bled. Lower the unloaded attachment onto flat and firm ground. Release the tank pressure and the load-holding valves by actuating the pilot control device for lowering to the stop and holding it in this position while the diesel engine is off (ignition and pilot control system on). Remove the measuring hose and screw coupling.

16.06.6

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Service Manual

Pipe fracture safety valve for stick cylinder Repair and sealing of valve 258 Screw in the screw plug 13 at the connections Pil and T.

Fig. 3

Screw coupling for the bleeding of the hydraulic circuit and the pipe fracture safety valve

52

Screw coupling

255

Stick cylinder

170

Stick cylinder

258


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16.06.7


Service Manual


5 Inspection and testing of pipe fracture valves Danger! The inspection and testing of the pipe fracture safety valves require access to the danger area of the machine. There is a risk to life and limb for mechanics from uncontrolled machine movements. Park the machine on a level surface. Secure it against uncontrolled movement. Only carry out inspections, if the machine is fully shut down and properly secured. Before opening the hydraulic circuit release all pressure from the hydraulic system. Adhere to the accident prevention regulations issued by the German Ground Construction Trade Association (Tiefbau-Berufsgenossenschaft) for the powertrains and earth-moving equipment. Valves 258 have been pre-set by the manufacturer. The setting cannot be changed and is secured by means of a lead seal. Missing seals / protective caps are proof that the original settings have been tampered with. The readjustment of the pipe fracture safety valve settings is not permitted for safety reasons. Should a subsequent inspection reveal that the settings are incorrect, remove the defective valves and replace them with new valve preset by the manufacturer. Return defective valves to the manufacturer, indicating the problem or damage you have observed.

5.1

Pressure check, see Fig. 4 Place attachments on the ground. Switch off the engine. Release the pressure from the valve. Remove the plug 5 at the connection E and drain the pressure oil through the bleeding connection 52 and a measuring hose (collect escaping oil). Measuring connection 52 (1/4", tool ID no. 7362579) in the connection E of the two valves 258, instead of a additional measuring connection 52, you may connect a measuring hose and a measuring T-piece to the bleeding connection 52, see group 2.01. Items 33, 34, 35, 36. Remove the cap from the measuring point 40 / 41 (at the control block 100) and connect a Minimess hose between the measuring points 40 / 41 and 52 (in connection E). Connect a pressure sensor (600 bar) with measuring connection (1.5 - 2.5 m) to the other measuring connection 52 of the valve 258 (connection E). Turn out the secondary pressure-relief valve 127 /128 or 241/242 (spool 102/240) for the stick cylinder by minimum 150 bar. Reduce the pressure, so that the oil can flow through the connection V2 of the valve 258. Fully pressurise the bucket and grapple cylinder to reach high pressure. Turn in the secondary pressure valve 133/262 (spool 107/260) for extending the bucket cylinder, (increase the pressure above the prescribed adjusting pressure of the valve = 410 + 10 bar). Slowly turn in the pressure cut-off valve 104 (A 312- R 317) or the primary pressure-relief valve 120/122 (A 309 - A 311) and listen for pressure sounds. When the secondary pressure-relief valve 29, (see Fig. 2 on page5), opens, a hissing sound is audible. The pressure indicated at the measuring point 52 must correspond to the prescribed adjusting pressure of the valve.

16.06.8

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Service Manual

Pipe fracture safety valve for stick cylinder Inspection and testing of pipe fracture valves If the prescribed adjusting pressure is not reached in the above test, replace the entire pipe fracture safety valve. Remove the hose line. Readjust the secondary pressure-relief valve, see adjustment protocol in group 6, and remove the pressure gauge.

Fig. 4

A A

Measuring points at the pipe fracture safety valves and at the respective pressure-relief valves at the control blocks

Pipe fracture safety valve, single side (A 127 309 - R 317) Pipe fracture safety valve, double side 128 (A 312 - R 317)

Secondary pressure-relief valve / extending stick cylinder Secondary pressure-relief valve / extending stick cylinder

5

Screw plug

133

Secondary pressure-relief valve / extending bucket cylinder

40 41

Measuring point P1 (A 309 - A 311) Measuring point MP (A 312 - R 317)

170 240

Stick cylinder Spool of stick cylinder (312 - 317)

52

Measuring neck

241

100


242

104

Pressure cut-off valve (A 312 - R 317)

255

Secondary pressure-relief valve / retracting stick cylinder Secondary pressure-relief valve / extending stick cylinder Stick cylinder

102 107

Spool of stick cylinder (A 309 - 311) Bucket cylinder spool (A 309 - 311)

258 260

Pipe fracture safety valve Bucket cylinder spool (312 - 317)

120

Primary pressure-relief valve (A 309 – A 262 311) Primary pressure-relief valve (A 309/ 311 with AHS)

122

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Secondary pressure-relief valve / extending bucket cylinder

16.06.9


Service Manual


6 Hydraulic connections and links 6.1

Single-side pipe fracture safety valve, models A 309 - A 311

Fig. 5

16.06.10

Hydraulic connections and lines in models A 309 - 311

52

Bleeding connection / Minimess

170

Stick cylinder

88T 100

Collecting pipe Compact control block

258


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Service Manual

Pipe fracture safety valve for stick cylinder Hydraulic connections and links

6.2

Single-side and double-side pipe fracture safety valve, models A 312 - R 317

Fig. 6

Hydraulic connections and lines in models A 312 – R 317

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16.06.11


Service Manual


Components in hydraulic diagram, see Fig. 7 and Fig. 8 and Fig. 9 1

Hydraulic tank

170

Stick cylinder

6 20

to hydraulic oil cooler from variable-displacement pump

171 240

Restrictor check valve / stick cylinder Spool / stick cylinder

23

to pump regulator

241

Secondary pressure-relief valve / retracting stick cylinder

41

Measuring point P2 (A 309 - A 311)

242

Secondary pressure-relief valve / extending stick cylinder

41

Measuring point MP (A 312 - R 317)

244

Pressure balance

50

Screw coupling (install for measurement)

247


52

Measuring and bleeding connection

255

Stick cylinder

80/1

from left pilot control unit / connection 1 258 (retracting stick cylinder) from left pilot control unit / connection 3 258.7 (extending stick cylinder)

80/3

16.06.12

Pipe fracture safety valve Control piston

100 102

Control valve block Spool / stick cylinder

258.8 Check valve 258.23 Restrictor check valve

127

Secondary pressure-relief valve / retrac- 258.29 Pressure-relief valve ting stick cylinder

128

Secondary pressure-relief valve / exten- 258.30 Filter ding stick cylinder

130

to slewing gear motor

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Service Manual

Pipe fracture safety valve for stick cylinder Hydraulic diagram of pipe fracture safety system

7 Hydraulic diagram of pipe fracture safety system 7.1

Single-side pipe fracture safety valve, models A 309 - A 311

Fig. 7

Diagram of the hydraulic system of the pipe fracture safety system for the stick cylinder, models A 309 - A 311

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16.06.13


Service Manual


7.2

Single-side pipe fracture safety valve, models A 312 - R 317

Fig. 8

16.06.14

Diagram of the hydraulic system of the pipe fracture safety system for the stick cylinder, models A 312 - R 317

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Service Manual

Pipe fracture safety valve for stick cylinder Hydraulic diagram of pipe fracture safety system

7.3

Double-side pipe fracture safety valve, models A 312 - R 317

Fig. 9

Diagram of the hydraulic system of the pipe fracture safety system for the stick cylinder, models A 312 - R 317

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16.06.15


Service Manual


16.06.16

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Service Manual

Pipe fracture safety valve for regulating cylinder Function

Pipe fracture safety valve for regulating cylinder 1 Function The two load-holding valves used as pipe fracture safety valves are installed directly at the pressure connections of the regulating cylinder. In the event of a pipe break, the valves prevent uncontrolled lowering of the equipment and/or the attached load. The pipe fracture safety valves block the corresponding cylinder connection when the control pressure connection is not pressurised (without leak oil). The load-holding valve described here is outlet pressure compensated, i.e. the pressure limitation and actuation function is independent of the load pressure at the outlet connection V2. The load-holding valve consists of a housing, a control piston (stop valve), the pilot piston required for actuation and a check valve (bypass of stop valve).

Fig. 1

Pipe fracture safety valve at the regulating cylinder

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16.10.1


Service Manual


2 Functional description see sectional drawing on page 3 and hydraulic diagram on page 11.

2.1

Extending cylinder 515 The pilot control pressure at the auxiliary control block 500 connection b6 used to operate the spool 500 for working movement "extending regulating cylinder" also pressurises the pilot piston 50 of the load-holding valve 517 (piston rod side) through the connection Pil, the filter 60 and the nozzle 61. The pilot piston 50 in the valve 517 presses against the valve plunger 51 and pushes it against the pressure spring 54. After a short stroke, the sleeve 57 finds purchase on valve guide 52, and the leak oil free shut-off device is opened. The hydraulic oil now flows from the auxiliary control block 500 connection B6 to the valve 516 connection V2. The sleeves 57 is shifted, and pressure oil pressurises the piston side of the cylinder through connection C2. The cylinder 515 is extended. The oil in the piston rod chamber flows through the open valve 517 connections C2 and V2 to the spool 500 and from there back to the hydraulic tank. When the working movement is completed, the sleeve 57 is closed (check valve). The return line is blocked, i.e. the load is held without any leak oil. When the working movement "extending regulating cylinder" is completed, the control pressure at the connection Pil drops and the valve 517 is also closed without leak oil..

2.2

Retracting cylinder 515 The pilot control pressure at the auxiliary control block 500 connection a6 used to operate the spool 500 for working movement "retracting regulating cylinder" also pressurises the pilot piston 50 of the load-holding valve 516 (piston side) through the connection Pil, the filter 60 and the nozzle 61. The pilot piston 50 in the valve 516 presses against the valve plunger 51 and pushes it against the pressure spring 54. After a short stroke, the sleeve 57 finds purchase on valve guide 52, and the leak oil free shut-off device is opened. The hydraulic oil now flows from the auxiliary control block 500 connection A6 to the valve 517 connection V2. The sleeves 57 is shifted, and pressure oil pressurises the piston side of the cylinder through connection C2. The cylinder 515 is retracted. The oil in the piston chamber flows through the open valve 516 connections C2 and V2 to the spool 500 and from there back to the hydraulic tank. When the working movement is completed, the sleeve 57 is closed (check valve). The return line is blocked, i.e. the load is held without any leak oil. When the working movement "retracting regulating cylinder" is completed, the control pressure drops and the valve 516 is closed without leak oil.

2.3

Pressure control The secondary pressure control is based on the application of high pressure on the valve plunger 51, which pushes against the adjustable pressure spring 54. In the event of pressure peaks, the valve plunger 51 is shifted against the preloaded pressure spring 54, thus opening the connection for the oil from the cylinder chamber to the connection V2. The oil can flow to the auxiliary control block 500 and secondary pressure-relief valve 501 (retracting regulating cylinder 515), or the secondary pressure-relief valve 502 (extending regulating cylinder 515). The valve 501 / 502 opens to allow the oil to flow back to the tank. The pressure peak in the cylinder chamber are reduced.

16.10.2

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Service Manual

Pipe fracture safety valve for regulating cylinder Functional description

Fig. 2

Sectional drawing of the load-holding valve

1

Housing

35

Backing ring

2

Slide ring

36

Seal washer

3

O-ring

41

O-ring

5 6

O-ring Screw plug

42 50

O-ring Pilot piston

8

Screw plug

51

Valve plunger

9

O-ring

52

Valve guide

10

Backing ring

53

Valve cone

11 12

Screw plug O-ring

54 55

Pressure spring Adjusting screw

13

Screw plug

56

Protective cap

14

O-ring

57

Valve seat (sleeve)

21

USIT ring

58

Pressure spring

30

Slide ring

59

Spring guide

32

Slide ring

60

Filter

33 34

O-ring O-ring

61

Nozzle (Ø 0.6 mm)

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16.10.3


Service Manual

Repair and sealing of valve 516 / 517

3 Repair and sealing of valve 516 / 517 .

Danger! Defective valves can pose a serious risk to persons and property in the danger area. For safety reasons, it is forbidden to repair load-holding valves. Always replace load-holding valves with all associated parts, and install only new valves supplied and preset by the manufacturer. Return defective valves to the manufacturer, indicating the problem or damage you have observed.

3.1

Sealing work In the event of external leakage of the valves, the valves may only be resealed, provided that this does not require the dismantling of the valve. To reseal the valve, use only the seal kit provided by the manufacturer.

3.2

Mounting and dismantling of the pipe fracture safety valves Danger! The dismantling, installation or sealing of the valves requires workers to access the danger area of the machine. This bears risks for the mechanic, as equipment might move uncontrolled when a valve/hydraulic circuit is opened. Never open the hydraulic circuit of the load-holding valves while the circuit is pressurised. Place the unloaded attachment on the ground (piston side of the cylinder must be fully depressurised). Release the tank pressure. Depressurise the load-holding valve(s) by actuating the pilot control device for lifting and lowering to the stop and holding it in this position while the diesel engine is off (ignition and pilot control system on). After the hydraulic circuit of the valves 516/517 is opened, certain problems might occur caused by air in the control circuit. The circuit must therefore be bled (collect escaping oil), see 3.3.

3.3

Bleeding of the load-holding valve 516 / 517, see Fig. 3 Remove the protective cap from the measuring neck 52 at the connections Pil and T. If the measuring neck 52 is not available: Remove the screw plug from the connections Pil and T. Screw the M12x1.5 screw coupling (tool no. 11 from group 2.01) into the bores. Install the Minimess high pressure hose between the connection Pil and connection T. Actuate the boom cylinder to retract it (keep pilot control unit pushed forward). The control circuit is bled. Lower the unloaded attachment onto flat and firm ground. Release the tank pressure and the load-holding valve(s) by actuating the pilot control device for lifting and lowering to the stop and holding it in this position while the diesel engine is off (ignition and pilot control system on). Remove the measuring hose and screw coupling.

16.10.4

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Service Manual

Pipe fracture safety valve for regulating cylinder Repair and sealing of valve 516 / 517 Screw in the screw plug at the connections Pil and T.

Fig. 3

Screw coupling for the bleeding of the hydraulic circuit and the load-holding valve

52

Screw coupling

516

Load holding valve

515

Regulating cylinder

517

Load-holding valve

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16.10.5


Service Manual

Testing of load-holding valve(s)

4 Testing of load-holding valve(s) Danger! The inspection and testing of the load-holding valves require access to the danger area of the machine. There is a risk to life and limb for mechanics from uncontrolled machine movements. Park the machine on a level surface. Secure it against uncontrolled movement. Only carry out inspections, if the machine is fully shut down and properly secured. Before opening the hydraulic circuit release all pressure from the hydraulic system. Adhere to the accident prevention regulations issued by the German Ground Construction Trade Association (Tiefbau-Berufsgenossenschaft) for the powertrains and earth-moving equipment. The valves 516 / 517 have been pre-set by the manufacturer. The settings cannot be changed and are secured by means of lead seals. Missing seals / protective caps are proof that the original settings have been tampered with. The readjustment of the pipe fracture safety valve settings is not permitted for safety reasons. Should a subsequent inspection reveal that the settings are incorrect, remove the defective valves and replace them with new valve preset by the manufacturer. Return defective valves to the manufacturer, indicating the problem or damage you have observed.

4.1

Pressure check Due to the high adjustment pressure, it is not possible to check the pressure.

16.10.6

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Service Manual

Pipe fracture safety valve for regulating cylinder Hydraulic connections and links

5 Hydraulic connections and links

Fig. 4 1

Exploded view from ET list 500

Hydraulic tank

from auxiliary control valve block (low pressure)

52

Screw coupling at connection Pil and T

515

Regulating cylinder

86

from auxiliary pilot control unit

516 517

Load-holding valve, piston side Load-holding side, piston rod side

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16.10.7


Service Manual


Components in hydraulic diagram, see Fig. 5

16.10.8

1

to hydraulic tank

86

from auxiliary pilot control unit

6 20

to oil cooler from variable-displacement pump

100 104

Control valve block Pressure cut-off valve

23

to pump regulator

500

Auxiliary control axle with spool for regulating cylinder

41

Measuring point MP for pump pressure

501

Secondary pressure-relief valve / retracting regulating cylinder

48

Bleeding opening for connection Pil and T 502

Secondary pressure-relief valve / extending regulating cylinder

49

Pressure balance

50

Retrofitted measuring point for load pres- 504 sure at connection E Pilot piston 515

51

Valve plunger / main valve

54 57

Pressure spring Sleeve / check valve

60 61

Filter Nozzle

Regulating cylinder

516

Load-holding valve, piston side

517

Load-holding side, piston rod side

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Service Manual

Pipe fracture safety valve for regulating cylinder Hydraulic diagram

6 Hydraulic diagram

Fig. 5

Hydraulic diagram of pipe fracture safety valve, regulating cylinder

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16.10.9

Pipe fracture safety valve for regulating cylinder Hydraulic diagram

16.10.10

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Service Manual

Service Manual

Overload warning system Function

Overload warning system 1 Function Machines used for lifting loads (lifting, transporting and lowering loads attached to the machine with lifting tackle such as chains, cables, etc.) where personnel other than the machine operator are required to attach and release the loads, are subject to certain safety regulations laid down in the European standard EN 474-5. Lifting operations also include lifting and lowering of pipelines, shaft rings and vessels.

Fig. 1

Equipment options of the overload warning system

A

Overload warning system with pipe-fracture safety, e.g. in model A 309 / 311

B

Overload warning system with pipe-fracture safety, e.g. in model A 312 - R 317

D

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Overload warning system with pipe-fracture safety, e.g. in model A 312 - R 317

16.12.1


Service Manual

Function Danger! The machine may only be used for lifting operations, if it is equipped with the necessary safety devices and when these devices are in proper working order, see 1.1. The overload warning system disables the machine as soon as a set load moment is exceeded. The operator is thereby informed of the cause of the shut-down. When operating the machine to lift loads, always adhere to the relevant safety and accident prevention regulations. If the warning system is disabled or its signals (buzzer sound and indicator light) are ignored, there is a risk of serious injury or even death to the machine operator. A copy of the load lift chart must be available in the operator's cab. Before carrying out any lifting operation, always enable the overload warning system. At the start of each shift, test the overload warning system: Fully extend the boom cylinder (max. operating pressure is built up) A visual and acoustic warning signal must be emitted. As soon as the warning symbol for load moment is on, reduce the reach of the boom. Machines used to lift loads must undergo an annual load test, (see 1.4 on page3). Defective machines may not be used to lift loads. The unit must be repaired by specialist technicians and tested according to the testing and adjustment guidelines.

1.1

Safety devices for load lifting operation Lifting tackle: – safe attachment of a load – Lift hooks attached to the machine instead of a digging bucket, or safety hooks welded to the digging bucket are deemed safe. Overload warning system: – If the actual load reaches or exceeds the permissible load according to the load lift chart, the overload warning system must generate a visual and audible alarm signal to the machine operator. Pipe fracture safety valve: – This valve is flange-mounted to the boom cylinder connection on the piston side. The pipe fracture safety valve must conform to the requirements laid down in ISO 8643.

1.2

General – If the maximum permissible load is reached or exceeded, the overload warning system notifies the machine operator with a warning light H16 located on the control console (see Fig. 2) and an audible signal from the buzzer H10. – As a rule, only loads with a known weight might be lifted, so that the suitability of the machine for the task can be determined by means of the load lift chart. – The load lift values in the chart correspond to max. 75% of the tip load or 87% of the hydraulic lifting power according to ISO 10567 – In machines equipped with a backhoe bucket attachment (including bucket cylinder, change lever and connecting link), the values are applicable to the tip of the stick. If the oscillating axle is closed, and the machine is standing on a level ground, the load can be swivelled by 360°. – If the bucket cylinder, change lever and connecting link are removed, the values are increased by the values that apply to the above parts of equipment. – If a quick change adapter is used, the values are reduced by the 110 kg for SWA 33 and 190 kg for SWA 48.

16.12.2

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Service Manual

Overload warning system Function

– For industrial equipment, the values at the lift hook apply, and loads can be swivelled by 360° if the oscillating axle is closed and the machine is standing on firm and level ground. – The load values also depend on any attached tools, such as grapples, etc.

1.3

Start-up The overload warning system may only be used in connection with the lifting of loads. Activate the warning system with the switch S18 (see Fig. 2). Before the initial start-up of the warning system, adjust it according to the instructions in the adjustment guidelines. All moving parts of the warning system must be regularly inspected for unobstructed movement and lubricated.

1.4

Load test Proceed as described below: Determine the test load by multiplying the load-bearing capacity according to the table for swivelled loads (no support) or traverse extension by factor 1.33 and adding 150 kg. Attach a test load to the machine at the prescribed extension (see table), taking into account any other attached bucket or tool (grapple, etc.). Carefully swivel the uppercarriage with the attached load (suspended to just above the ground) by 360°. Ensure that the machine does not tip over. One wheel or a section of the track might be lifted off the ground. The warning system must be triggered. The settings of the warning system must be inspected at least once every year by a specialist technician and adjusted according to the adjustment protocol and guidelines. Note! Deactivate the overload warning system when working with a digging bucket, as the great force used for such operations would constantly trigger the overload warning system. Press the switch S18. Overload warning system is deactivated. LED in the switch is off.

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16.12.3


Service Manual

Design and function

2 Design and function

Fig. 2

Switch and indicator light in the front right control console

H16Indicator light

S360 Switch / buzzer acknowledgement

S18 Switch / overload warning system – The switch S18 is located in the control console. Press the switch S18. The indicator light in the switch is off. Overload warning system is activated. – A constant pressure switch B21 with measuring point 66 is located at the pipe fracture safety valve or directly at the boom cylinder 160/235. – When the maximum load-bearing capacity is reached , i.e. load pressure in the boom cylinder = switching pressure, e.g. 141 bar - (punched into the plate B), (see Fig. 4 on page7). The pressure switch B21 makes electrical contact to the indicator light H16 and the buzzer H10. The indicator light H16 is on (visual signal). The buzzer H10 emits an acoustic signal. – The switching pressure is set at the pressure switch B21 and depends on the machine model.

16.12.4

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Service Manual

Overload warning system Overload warning system with hydraulic connections

3 Overload warning system with hydraulic connections

Fig. 3

Installation of an overload warning system at the boom cylinders

52

Measuring connection

238

160 235

Boom cylinder Boom cylinder

B21 Pressure switch (*)


Switching pressure (machine-specific)

4 Setting instructions Remove the cover cap at the measuring connection 52 and connect a pressure sensor/gauge in such a way that the dial is visible from the operator's cab. Switch on the warning system by actuating the switch S18. Open the stop cock (if any) between the warning system and the boom cylinder connection. Move the boom cylinder 160/235 to it upper stop to check whether the warning system's pressure switch B21 is working properly (indicator light H16 and buzzer H10, see Fig. 2, on). Carefully actuate the right pilot control unit (extending boom cylinder) to establish the prescribed switching pressure (embossed in the plate B of the switch B21), see Fig. 4. The value embossed at the pressure switch is binding.

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16.12.5


Service Manual

Setting instructions

4.1

Example: Machine Attachment*

A 309

A 311

A 312

R 313

A 314

A 316 and A 316 Ind.

317

-

-

169-5

-

-

178-5

141-5

161-5

-

141-5

145-5

-

-

-

175-5

-

-

-

138-5

146-5

-

-

-

150-5

-

with gooseneck boom

-

-

with gooseneck boom (with 2-point or blade support)

-

with gooseneck boom (with 2-point/4-point or blade support)

-

with gooseneck boom (horizontally adjustable)

-

Pressures in bar with hydraulic boom adjustment with hydraulic boom adjustment (with 2-point or blade support)

132-5

with hydraulic boom adjustment (vertical and horizontal) with hydraulic boom adjustment (with 4-point or blade and outrigger support)

-

167-5

-

-

177-5

159-5

-

147-5

145-5

-

-

-

-

147-5

150-5

-

-

-

170-5

-

-

Note! * This table contains only examples of standard machines. For other situations, refer to the pressure tables for the respective machine model or contact our technical department. For machines with retrofitted overload warning system: The switching pressure is indicated in the enclosed installation drawing (pressure table) and embossed in the plate B, arrow see Fig. 4. If the warning system fails to emit a signal when the prescribed limit pressure is reached, the switching pressure can be corrected at the respective pressure switch B21: Remove the cap K (if any). Loosen the self-locking screw SS of the pressure switch B21. Turn the adjusting screw ES with a suitable screwdriver to adjust the switching pressure: Turn clockwise Increase switching pressure Turn anticlockwise Reduce switching pressure Secure the adjusting screw ES with the self-locking screw SS . Replace the cap K (if any). If the warning system is only triggered at a higher pressure, the switching point (pressure) must be adjusted again. A lower switching pressure is permissible.

16.12.6

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Service Manual

Overload warning system Setting instructions

Fig. 4

B21

Pressure switch with adjusting device and pressure indication

Pressure switch

B

Plate (with switching pressure*)

K ES

Protective cap Adjusting screw / switching point

SS

Self-locking screw

(*)

Switching pressure (machine-specific)

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16.12.7


Service Manual

Setting instructions

16.12.8

66

Measuring connection

H16

Indicator light

100 100

A5 control block / connection B5 control block / connection

S18 S20

Switch / overload warning system to sensor control switch

160

Boom cylinder (A 309/A 311)

X407

161

Pipe fracture safety valve (A 309/A 311) X950


233

Distribution block / boom cylinder

X951

Plug connection, 21-pin

235 238

Boom cylinder (A 312 - R 317) Pipe fracture safety valve (A 312 - R 317)

X953 X958


A126 B21

Printed circuit board (autocheck) Constant pressure switch

A

Electrical system / basic machine

H10

Buzzer

B

Electrical system / kit

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Service Manual

Overload warning system Hydraulic and electric diagram

5 Hydraulic and electric diagram

Fig. 5

Hydraulic and electric diagram of the overload warning system

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16.12.9


Service Manual

Hydraulic and electric diagram

16.12.10

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Service Manual

Hydraulic quick change adapter Function

Hydraulic quick change adapter 1 Function If several different attachments are to be used in short sequence, we recommend using a hydraulic quick change adapter, as this helps to reduce the set-up time for the bucket. The relevant parts are available as an accessory kit. It contains all mechanical, hydraulic and electrical components for the operation of the equipment. The locking and release function of the quick change adapter are operated through the hydraulic circuit for the grapple rotator (AS1). Note! For the safe operation of the attached working tools, always adhere to the instructions in the separate operating and maintenance manual for hydraulic/mechanical quick change adapters.

Fig. 1


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16.16.1


Service Manual

Design of quick change adapter

2 Design of quick change adapter see Fig. 2 The hydraulic quick change adapter consists of the following main components: – Quick change unit 10 – Locking unit 20 – Cylinder 30 – Covering parts 50 – Securing flaps 60 – Low pressure block 110 or auxiliary control axle 540 – Solenoid valves Y28-1,Y28-2 – Control elements S5L/S5R, S19, S47, see Fig. 4 and associated wire harnesses To secure the adapters when closed, they are equipped with two single-acting solenoid valves Y281 and Y28.2 in connections at the piston and the piston rod ends of the locking cylinder. The quick change adapter is operated through the AS1 (grapple rotator). In models A 309 - A 311: screw-mounted to the fuel tank above the spool 113 of the low pressure block 110 (offset boom bearing / grapple rotator). For pressure protection, a pressure-relief valve 123 is screwed into the low pressure block 110 and set to 110 bar; for details, see adjustment protocol for the hydraulic unit, group 6.09 / 6.11. In models A 312 - R 317: flange-mounted above the auxiliary control axle 540 to the slewing gear axle 120 of the control block 100. For pressure protection, the pressure-relief valves 541/542 are screwed into the auxiliary control block 540 and set to 120 bar; for details, see the instructions for settings and check of the "AS1" accessory kit or the tilting bucket, group 16.44. To protect the locking unit 20 against dirt or damage, the system is equipped with covering parts 50.

16.16.2

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Service Manual

Hydraulic quick change adapter Design of quick change adapter

Fig. 2

Main components and drive system of the hydraulic quick change adapter

10

Quick change adapter

123


20 50

Locking unit Covering parts

540 541

Spool of hydraulic drive Secondary relief valve / retracting cylinder

100


542

110

Low pressure block

Y22

Secondary relief valve / extending cylinder Solenoid valve / locking adapter

113

Spool of hydraulic drive

Y23

Solenoid valve / releasing adapter

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16.16.3


Service Manual

Design of quick change adapter

Fig. 3 10

16.16.4

Design of hydraulic quick change adapter Quick change adapter

100

Heavy-duty roll pin

20

Locking unit

B26

Proximity switch with plug

30

Hydraulic cylinder

Y28-1

2/2-way valve

50 60

Covering parts Securing flap

Y28-2

2/2-way valve

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Service Manual

Hydraulic quick change adapter Functional description

3 Functional description see Fig. 10

3.1

Working position – quick change adapter locked To attach a working tool (bucket, etc.), actuate the switch S19 and the button S47 together with the push button S5L (indicator lights in the switches are on). Press the left push button S5L - in the left joystick 80 to power the solenoid valve Y22, the button S47 and the solenoids Y28-1/Y28-2 (via A 1017). As long as S5L remains pushed down, S47 can be released (holding function). The oil of the gear or working pump flows from the low pressure block 100 connection B2 , or from the auxiliary control axle 540 connection B02 through the strainer 33 to the way valve Y28-2 in flowthrough position. The oil applies pressure to the piston side of the locking cylinder 24 via the connection B-B´. The return oil from the piston rod side flows through the way valve Y28-1 connection A´-A and connection A2 /A02 of the block 110/540 to the tank. The cylinder 30 is extended, pressing the two locking bolts 21 outwards (through levers). The tool is now bolted to the quick change unit 10. When the left push button S5L is released, the power supply to the solenoids Y28-1/Y28-2 is discontinued and the way valves are switched to blocking position. The blocking valves Y28-1/Y28-2 protect the locking mechanism against release by inadvertent operation of the push button S5R. Actuate the switch S19 (indicator light in the switch is off). In the event of inadvertent retraction of the locking bolts 21, for whatever reason, the proximity switch B26 is triggered and an electrical signal is sent to the buzzer H10 and the indicator light H26 (locking bolts retracted). The machine operator is thus made aware by an acoustic and a visual signal of the imminent danger. In the event of such a signal, work must be immediately interrupted and the problem must be rectified.

3.2

Changing position – quick change adapter released To remove a working tool (bucket, etc.), actuate the switch S19 and the button S47 together with the push button S5R (indicator lights in the switches are on). Press the right push button S5R - in the right joystick 80 to power the solenoid valve Y23, the button S47 and the solenoids Y28-1/Y28-2 (via A 1017). As long as S5R remains pushed down, S47 can be released (holding function). The oil of the gear or working pump flows from the low pressure block 100 connection A2 , or from the auxiliary control axle 540 connection A02 through the strainer 33 to the way valve Y28-1 in flowthrough position. The oil applies pressure to the piston rod side of the locking cylinder 21 via the connection A-A´. The return oil from the piston side flows through the way valve Y28-2 connection B´-B and connection B2 /B02 of the block 110/540 to the tank. The cylinder 30 is retracted, pulling with it the pins 21, so that the attached tool is released. When the pins 21 are retracted, the proximity switch B26 is activated. The buzzer H10 and the indicator light H26 are activated, indicating that the quick change adapter is released. Release the right push button S5R. Attach a new tool, or deactivate the switch S19 (indicator light in the switch is off). Note! For load-lifting work without digging bucket, the pins of the quick change adapter must be retracted. The buzzer H10 can be set to mute by means of S360.

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16.16.5


Service Manual

Operation of the quick change adapter

4 Operation of the quick change adapter

Fig. 4 80


S19

Switch / quick change adapter

H26 S5L

Indicator light / quick change adapter Push button / locking quick change adapter Push button / releasing quick change adapter

S47 S360

Switch / quick change adapter Switch / buzzer acknowledgement

S5R

4.1

Control elements

Switch S19 S19 Press the switch. The auxiliary equipment is activated. The indicator lamp in the switch is on. Press the switch again. The auxiliary equipment is deactivated. The indicator lamp in the switch is off.

16.16.6

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Service Manual

Hydraulic quick change adapter Operation of the quick change adapter

4.2

Button S47 Press the button S47 to activate the quick change adapter. The lock pin can now be operated. Press and hold the button, until the button S5L/S5R is actuated (holding function activated). The quick change adapter is activated. The indicator light in the button S47 is on. To change the direction of movement of the lock pin, press and hold the button S47 again.

4.3

Button S5L / S5R Actuate the push buttons S5L and S5R to lock and unlock the tool. Press and hold the buttonS5R. The lock pins are retracted, releasing the tool. The indicator light H26 is on and the buzzer H10 emits a warning sound. Press and hold the buttonS5L. The lock pins are extended. The indicator light H26 is off and the buzzer H10 is switched off.

4.4

Indicator light H26 The indicator light H26 shows the current operating status of the quick change adapter: – The quick change adapter is released / the lock pins are retracted. The indicator light H26 is on. The buzzer H10 emits a warning sound. – The quick change adapter is locked / the lock pins are fully extended. The indicator light H26 is off. The buzzer H10 is off.

4.5

Switch S360 (buzzer acknowledgement) In machines with built-in and activated overload warning system, the warning signal of the buzzer H10 can be set to mute with switch S360 to prevent unnecessary distraction. Press the switch S360. The indicator lamp in the switch is on. The buzzer H10 is off. The indicator light H26 is on. The buzzer H10 only emits a warning signal after the lock pins have been extended again.

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16.16.7


Service Manual

Maintenance instructions

5 Maintenance instructions The filter disc 35 must be regularly inspected for dirt and cleaned, if necessary. The inspection interval depends on the frequency of use of the quick change adapter but may not exceed 2000 operating hours. In the process of this inspection, also check the pins, levers and bearings of the quick change adapter for wear. Replace any damaged parts. Remove the screws 51 and then remove the cap 50 from the quick change adapter. Remove the screw connections and hydraulic hoses at the piston rod and the piston sides of the hydraulic cylinder 30. Unscrew the external support body 36, using a suitable tool (e.g. a thumb tack). Remove and inspect the filter disc 35 and clean or replace it, if necessary. Place the filter disc 35 onto the inner internal support body 34 and mount the external support body 36. Connect the screw connections and hydraulic hoses at the hydraulic cylinder 30. Secure the lid 50 to the quick change adapter, using the screws 51.

Fig. 5

16.16.8

Cleaning mesh filter

30

Cylinder

36

External support body

34 35

Internal support body Filter disc

50 51

Lid / covering parts Hex head screw

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Service Manual

Hydraulic quick change adapter Adjustment of the proximity switch B26 settings

6 Adjustment of the proximity switch B26 settings In the event of a malfunction of the warning system, check the distance of the proximity switch B26 to the lock pin 21 and adjust it, if necessary. Retract the lock pin 21. Loosen the lock nut 90. Turn in the proximity switch B26 to the stop at the pin 21. Turn back the switch B26 by one full revolution = distance of 1 mm (tolerance ±0.3 mm is permissible). Tighten the lock nut 90 again. After this adjustment, carry out a functional test of the switch B26 by extending and retracting the lock pins 21.

Fig. 6

21 90

Locking unit with proximity switch

B26

Lock pin Lock nut

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Proximity switch

16.16.9


Service Manual

Sealing elements bearing head / piston

7 Sealing elements bearing head / piston

Fig. 7 r

16.16.10

Sealing kit bearing head / piston

36

Bearing head

75

Piston rod bearing

70 71

Double scraper ring O-ring

76 77

Piston guide ring O-ring

72

O-ring

78

Turcon AQ seal

73

Backing ring

998

Seal kit / piston

74

Seal ring (Zurcon-L-Cup)

999

Seal kit / bearing head / piston

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Service Manual

Hydraulic quick change adapter Exploded view of quick change adapter

8 Exploded view of quick change adapter

Fig. 8

Exploded view of quick change adapter

20

Locking unit

33

Filter disc

21

Pin

36

Bearing head

22

Left lever

38

Hex nut

23 24

Right lever Pin

39 40

Retaining washer Piston rod

25 26

Heavy-duty roll pin Heavy-duty roll pin

41 42

Piston Screw plug

30

Cylinder

L

Parts are secured with Loctite 243

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16.16.11


Service Manual

Hydraulic diagrams with electrical components

9 Hydraulic diagrams with electrical components 9.1

Quick change adapter in models A 309 - A 311 1

16.16.12

A1017 Printed circuit board / quick change adapter

to hydraulic tank

10

Quick change unit

B26

Proximity switch

20

Locking unit

H10

Warning buzzer

21

Lock pin

H26

Indicator light

30

Cylinder

K364

Quick change relay

31

from gear pump / low pressure Residual flow distributor

S5L

Push button/auxiliary activation left, or locking quick change adapter

33

Filter disc

S5R

45

Low pressure measuring point

S19

Push button/auxiliary activation right, or releasing quick change adapter Switch / auxiliary activation

80 110

Left pilot control unit Low pressure control block

S47 S360

Push button Switch / buzzer acknowledgement

111

Input section

X262

Plug connections, see electric diagrams

112


X411

113

Spool grapple rotator / quick change adapter

X412

Plug connection, see electric diagrams Plug connection, see electric diagrams

123


X413

Plug connection, see electric diagrams

156 157

Check valve Adjustment restrictor / oil volume

Y22 Y23

Solenoid / locking adapter Solenoid / releasing adapter

158

Shuttle valve

Y28-1 Y28-2

Solenoid / seat valve rod side Solenoid / seat valve piston side

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Service Manual

Hydraulic quick change adapter Hydraulic diagrams with electrical components

Fig. 9

Hydraulic diagram with electric components, models A 309 - A 311

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16.16.13


Service Manual

Hydraulic diagrams with electrical components

9.2

Quick change adapter in models A 312 - R 317 10

16.16.14

20

Locking unit

A1017 Printed circuit board / quick change adapter B26 Proximity switch

21

Lock pin

H10

Quick change unit

Warning buzzer

30

Cylinder

H26

Indicator light

33

Filter disc

K364

Quick change relay

80


S5L

88P

from pressure manifold

S5R

Push button/auxiliary activation left, or locking quick change adapter Push button/auxiliary activation right, or releasing quick change adapter

S19

88T

to collecting pipe return line

120 540

Spool / slewing gear S47 Spool of hydraulic drive grapple rotator / S360 quick change adapter

Push button Switch / buzzer acknowledgement

541

Secondary pressure-relief valve / retrac- X262 ting cylinder

Plug connections, see electric diagrams

542

Secondary pressure-relief valve, exten- X411 ding cylinder


544

Pressure balance

X412


X413 Y22

Plug connection, see electric diagrams Solenoid / locking adapter

Y23

Solenoid / releasing adapter

Y28-1 Y28-2


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Switch / auxiliary activation

Service Manual

Hydraulic quick change adapter Hydraulic diagrams with electrical components

Fig. 10

Hydraulic diagram with electric components, models A 312 - R 317

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16.16.15


Service Manual

Electrical system

10

Electrical system

Fig. 11

11

Exploded view of electrical system

A1017 Printed circuit board / quick change adapter

X262-4

B26

Proximity switch of quick change adapter

X262-5

H26

Indicator light quick change adapter

X262-6 Plug-type connection at B26 / 3-pin

S47

Push button / quick change adapter

X798

Plug connection blocking diode / 3-pin

S360 Switch / buzzer acknowledgement X262-1 Plug connection / 8-pin

Y28-1 Y28-2

Solenoid / seat valve Solenoid / seat valve

X262-3 Plug connection / 8-pin

100 101

Cable harness of revolving deck Cable harness of quick change adapter

Electric diagram of hydraulic quick change adapter For the electrical diagrams of the hydraulic quick change adapter, please refer to the electrical documentation of the attachments and basic machine of the respective model in group 8.

16.16.16

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Service Manual

Flow reduction Function

Flow reduction 1 Function Certain attachments such as hammers, etc. require specific flow rates and volumes that are lower than those generated normally by the machine. Otherwise, these attachments might not work properly. The flow reduction can be easily adjusted by the operating personnel to suit any connected attachment. With the AHS 12 accessory kit, preset flow reductions can be activated.

Fig. 1

Attachments such as hydraulic hammers, sorting grapples, and various auxiliary cylinders

Note! The flow reduction must conform to the maximum permissible oil volume as specified by the manufacturer of the attachment (e.g. hydraulic hammer). Factory-set AHS 12 accessories are configured for a maximum oil flow for hammers of approx. 65 l/min.

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16.19.1

Flow reduction

Service Manual

Function

2 Function

Fig. 2

Operator's cab with printed circuit board, pilot control device, switch kit, proportional solenoid valve and pump regulator

21

Pump P1

A125 Potentiometer board

50 70

Control oil unit Actuation device / pump regulator

B290 Proximity switch / flow reduction S241 Switch / AHS 12 kit

78

integrated spool/stroke limitation

Y51

86

Pilot control device / kit


The desired or required oil flow volume is determined by the current fed to the proportional solenoid valve Y51 and the proportional actuation pressure to the spool 78 of the actuation device 70 of the variable-displacement pump P1. It determines the flow reduction (stroke limitation of pump P1), resulting from the additional force applied to the spool of the pump regulator. The solenoid current (in mA) from BST (U16) to the proportional solenoid valve Y51 is preset at the respective potentiometer P1 / P2 / P3 and determines the proportional control pressure at the outlet LS of the proportional solenoid valve Y51. The start signal for the flow reduction is preselected by the operator by means of the switch S241 (position 2) and the process is initiated with the proximity switch B290. The pump P1 is pivoted to a smaller angle (irrespective of the working pressure of the pump), see also group 7.02, stroke limitation in Service Manual 1 - 7. As a result, the oil flow volume to the attachment is reduced.

16.19.2

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Service Manual

Flow reduction Adjustment of pump flow volume

3 Adjustment of pump flow volume 3.1

Diagram for the determination of the required control pressure

Fig. 3

Diagram for the adjustment of the desired pump flow rate

b

QP1 Pump flow rate pump P1

PY51 Control pressure from valve Y51 to pump connection X1

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16.19.3

Flow reduction

Service Manual

Adjustment of pump flow volume

3.2

Example of calculation of the control current/control pressure by means of the diagram For its HM 190 model, the hammer manufacturer Krupp specifies an oil flow rate between 50 and 90 l/min, see also group 16.30. Based on these specifications, the maximum permissible flow volume of pump P1 must be set to a reduced pump flow. The corresponding current to the proportional solenoid valve Y51 or the corresponding control pressure from the solenoid valve Y51 to the pump P1 respectively are indicated in the diagram with an arrow. In the above case, based on a required oil flow rate of 75 l/min, a current of 0.41 A (410 mA) / control pressure of approx. 14.5 bar is required in an A 309 / A 311 model. The control pressure is thereby the determining setting. The current value must be regarded as a guide value only.

3.3

Measurement and adjustment of the reduced pump flow rate Note! In order to achieve correct values, check the basic settings of the machine (for settings and values, see adjustment protocol). To accurately adjust the flow reduction to the required value, the operator must measure the oil flow at the consumer, using a measuring turbine and suitable gauge (LMS system). An initial adjustment (rough adjustment) can be made without any need for dismantling, based on the flow diagram and guide values (see Fig. 3, page 3) and by following the instructions below.

Fig. 4 50 Y51

Operator's cab with pilot control device/kit, potentiometer board and control oil unit with proportional solenoid valve / flow reduction A125 Potentiometer board K Console

Control oil unit Proportional solenoid valve

S

16.19.4

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Clamping mechanism

Service Manual

Flow reduction Adjustment of pump flow volume

The printed circuit board A125 is located behind the left control console and can be accessed as follows: Move the operator seat to the front stop position. Release the clamping mechanism S at the console K. Remove the console K from the operator's cab.

3.3.1

Adjustment procedure

Fig. 5

Adjustment of the control pressure from the proportional solenoid valve to the pump by means of the adjusting screw of the potentiometer Measuring point for control pressure at the pump

A125 Potentiometer board P1 Potentiometer / flow volume 1

20 21

Double variable-displacement pump Pump P1

P2 P3

57

Measuring point / servo pressure flow reduction

Potentiometer / flow volume 2 Potentiometer / flow volume 3

Connect the pressure sensor (0-60 bar) to the measuring point 57. Run the diesel motor at maximum speed. Set the switch S241 to position 2 (hammer icon is illuminated). Press the pedal of the pilot control device 86 (hammer operation),see Fig. 4, to the stop. Using a screwdriver, turn the adjusting screw of the potentiometer P1 / P2 / P3 until the pressure value measured at the measuring point 57 corresponds to the value determined from the diagram (see Fig. 3, page 3). After adjustment, remove the pressure sensor and seal the measuring point. Mount the console K and readjust the position of the operator seat. Note! If the adjustment of the flow rate is completed with a measuring turbine, there is no need to refer to the diagram, (see Fig. 3, page 3), as any adjustment made to the potentiometer can be directly observed at the turbine. Prior to adjusting the flow reduction with a measuring turbine, ensure that the basic machine settings are OK.

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16.19.5

Flow reduction

Service Manual

Adjustment of pump flow volume

16.19.6

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Service Manual

Flow reduction Function

Flow reduction 1 Function Certain attachments such as hammers, pile drivers, etc. require specific flow values that are lower than those generated under normal operating conditions. Otherwise, these attachments might not work properly. This means that the maximum pump flow rate must be reduced. Operating personnel should be in a position to easily and efficiently adjust the flow to the level required for the attachment. The accessory kits AHS 11 / AHS 12, see group 16.48 or 16.50, allow for the reduction of the flow rate of the machine, so that it can be used together with various attachments. D

Fig. 1

Attachments such as hydraulic hammer, sorting grapple and additional consumer

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16.20.1

Flow reduction

Service Manual

General description and function of the flow reduction

2 General description and function of the flow reduction 2.1

Flow reduction The flow to the consumer is calculated on the basis of the maximum oil volume that can be fed to the consumer at the chosen settings. The flow reduction is achieved by reducing the spring force at the LS regulator. To do this, a control pressure must be built up that acts against the spring force. The pressure results in a reduction of the normal spring force (for pressure, see adjustment protocol in group 6). The flow reduction is thus based on the following principle: -p. Flow rate Q in l/min = cross-section A of the restrictor (spool opening) x Regular The

-p (= 23+1 bar) maximum flow rate.

-p is reduced by means of the proportional valve Y51 that is part of the control oil unit 50.

The necessary control pressure of for example 23 - 16 bar = 7 bar determines the residual flow volume of the pump In machines that are equipped with the AHS 11 or AHS 12 accessory kit, a pressure and flow reduction can be achieved, see also group 16.48 and 16.50. By setting the switch S241, at the control desk, to the positions 0 / 1 / 2 the pressure and/or flow rate are reduced. The flow reduction is actuated by means of the signal to the relays K375 and U16. The excavator control U16 then powers the solenoid valve Y51 with a defined current, which is adjusted at the respective potentiometer P1 / P2 / P3. The settings of the potentiometer P1 / P2 / P3 (located on the printed circuit board A125) can be adjusted as follows:

3 Adjustment of flow reduction settings Note! In order to ensure correct adjustment, first check the basic settings of the machine, see adjustment protocol or guidelines in group 6.) Also check the settings of the stroke limitation of the spool / auxiliary axle (dimension Y), see group 7.60. To accurately adjust the flow reduction to the required value, the operator must measure the oil flow at the consumer, using a measuring turbine and suitable gauge (LMS system). An initial adjustment (rough adjustment) can be made without any need for dismantling, based on the flow diagram and guide values (see Fig. 5, page 6) and by following the instructions below. The values in the table are average values of a series of measurements. They might deviate slightly from machine to machine, i.e. the average value pMLS in the table ± 0.5 bar (or ± 5%) applies. The flow rates prescribed by the manufacturers of the working tools (hydraulic hammer, etc.) are compiled in a diagram in group 16.30, where you can also determine the control pressure at the measuring point MLS that corresponds to the required flow rate.

16.20.2

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Service Manual

Flow reduction Adjustment of flow reduction settings

3.1 3.1.1

Position of the printed circuit board A 125 with potentiometers P1/P2/P3 in models A 312 to 20432, A 314 to 20333 and A 316 to 20339

Fig. 2

Operator's cab with pilot control device/kit, potentiometer board and control oil unit with proportional solenoid valve / flow reduction

50 57

Control oil unit Measuring point MLS (flow reduction)

A125 Potentiometer board B291 Proximity switch / sensor control

86


D

Cover/electric cabinet

EK Electric cabinet S241 Switch AHS 11 / AHS 12 accessory kit Y51


The printed circuit board A125 is located in the electric cabinet behind the left control console and can be accessed as follows: Move the operator seat to the front stop position. Remove the screws and lift the cover D from the electric cabinet EK.

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16.20.3

Flow reduction

Service Manual

Adjustment of flow reduction settings

3.1.2

In models A 309 / A 311 and R 317 from start of series, A 312 from 20433, A 314 from 20334 and A 316 from 20340

Fig. 3

Operator's cab with pilot control device/kit, potentiometer board and control oil unit with proportional solenoid valve / flow reduction

50

Control oil unit

A125

Potentiometer board

57

Measuring point MLS (flow reduction)

B291

Proximity switch / sensor control

86


K S

Console / function box Clamping mechanism

S241 Y51

Switch AHS 11 / AHS 12 accessory kit Proportional solenoid valve / flow reduction

The printed circuit board A125 is located behind the left control console and can be accessed as follows: Move the operator seat to the front stop position. Release the clamping mechanism S at the console K. Remove the console K from the operator's cab.

3.2

Adjustment procedure, see Fig. 2, see Fig. 3 and Fig. 4 Connect the pressure sensor (0-60 bar) to the measuring point 57. Run the diesel motor at maximum speed. Set the switch S241 to position 2 (hammer icon is illuminated). Press the pedal of the pilot control device 86 (hammer operation),see Fig. 2, to the stop. Using a screwdriver, turn the adjusting screw of the potentiometer P1 / P2 / P3 until the pressure value measured at the measuring point 57 corresponds to the value determined from the diagram (see Fig. 5, page 6).

16.20.4

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Service Manual

Flow reduction Adjustment of flow reduction settings After adjustment, remove the pressure sensor and seal the measuring point. Mount the console K and readjust the position of the operator seat.

Fig. 4

Adjustment of the desired flow rate by means of a potentiometer

Note! If the adjustment of the flow rate is completed with a measuring turbine, there is no need to refer to the diagram, (see Fig. 5, page 6), as any adjustment made to the potentiometer can be directly observed at the turbine. Prior to adjusting the flow reduction with a measuring turbine, ensure that the basic machine settings are OK.

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16.20.5

Flow reduction

Service Manual

Diagram for flow reduction in A 312 – R 317 (Y51)

4 Diagram for flow reduction in A 312 – R 317 (Y51)

Fig. 5

4.1

Diagram for flow reduction for hammer operation with A 312 – R 317

Example for the determination of the control pressure for a HM350 hydraulic hammer from diagram For its HM 350 model, the hammer manufacturer Krupp specifies an oil flow rate between 60 and 100 l/min, see also group 16.30. Based on these specifications, the maximum permissible flow volume of the pump must be set to a reduced pump flow. To determine the control pressure of the proportional solenoid valve Y51 follow the arrow in the diagram. In the above example, where the required oil flow is 80 l/min (average value) in model A 312 - A 316, the control pressure is approx. 16.5 bar.

16.20.6

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Service Manual

LIKUFIX Hydraulic Coupling System Task

LIKUFIX Hydraulic Coupling System 1 Task The newly developed LIKUFIX hydraulic coupling system allows for the automatic coupling of hydraulic lines together with the hydraulic quick change adapter. The operator therefore does not have to connect or disconnect the hydraulic lines of working tools. System requirements for hydraulic excavators: – Original Liebherr quick change adapter SWA – Recommended kits in AHS 11/12 basic unit (required for the operation of hammers, sorting grapple, shears, etc.) – AHS lines mounted to basic boom and AHS boom. Mountable working tools: – Ditch cleaning bucket 2x45°, 2x50° swivelling – Clamshell grab / multiple tine grab – Sorting grapple – Hydraulic hammer – Shear – Plate vibrator – etc.

Fig. 1

LIKUFIX coupling system

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16.24.1


Service Manual

Design of LIKUFIX hydraulic coupling system

2 Design of LIKUFIX hydraulic coupling system

Fig. 2

2.1

16.24.2

LIKUFIX coupling system with attachments

1

Protective cover at the quick change adapter 4

2

Protective cover at the working tool

3

LIKUFIX hydraulic coupling at quick change adapter

5

LIKUFIX hydraulic coupling at the working tool Alternative hydraulic coupling at the working tool

Design of the LIKUFIX coupling system mounted to quick change adapter 33 / 48

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Service Manual

LIKUFIX Hydraulic Coupling System Design of LIKUFIX hydraulic coupling system

Fig. 3

2.1.1

LIKUFIX 33 / 48 accessory kit

Design, see Fig. 4 The coupling housing 10 is secured with the Allen head screws 21/22 to the quick change adapter. The coupling sleeves 60/70 are inserted into the coupling housing, and are secured by means of the retaining plates 80 or tie-down devices 90/100 and the Allen head screws 81. The fixture includes a locking plate 110 preventing inadvertent turning of the union nuts of the hydraulic hoses. The guide bushings 50 are press-mounted into the housing 10 and ensure proper alignment of the coupling to the counterpart at the attachment. The protective cover 30 protects the LIKUFIX hydraulic coupling system against dirt and damage from impacts. When the coupling is not in use, or when attachments without mating plates are used, it is inserted into the guides provided at the coupling housing 10.

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16.24.3


Service Manual


2.2

Exploded drawing of LIKUFIX mounted to quick change adapter

Fig. 4

16.24.4

LIKUFIX mounted to quick change adapter

10

Coupling housing

80

Retaining plate

21

Allen head screw

81

Allen head screw

22

Allen head screw

82

Retaining washer

30

Protective cover

90

Tie-down device

50

Guide bushing

100

Tie-down device

60 70

Coupling sleeve Coupling sleeve

110

Locking plate

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Service Manual


2.3

Design of LIKUFIX coupling system mounted to the attachments

Fig. 5

2.3.1

LIKUFIX mounted to attachment

Design, see Fig. 6 The coupling system can be mounted onto various attachments. The coupling plugs 10/20 see Fig. 5 are inserted into the coupling housing 10 and then secured with the holders 80/90 and Allen head screws 81, see Fig. 4. The plungers 50 are inserted in to the housing see Fig. 4 of the attachment and secured with screws. They are used to compensate the applied operating pressure in the coupling system, ensuring that the two coupling housings 10 are pressed against each other with increasing force when the pressure is increased. The pressure springs 40 are secured with the Allen head screws 41/42 to the coupling housing 10. Thanks to this floating bearing, the pressure springs 40 compensate strains that might occur during the coupling procedure. The guide bolts 20 are secured with the Allen head screws 21 to the connection side of the housing 10. They ensure proper alignment of the coupling halves during the coupling procedure. During coupling, the guide bolts 20 are inserted into the guide bushings 50, see Fig. 4 at the quick change side of the housing. They also prevent the housing 10 from being shifted horizontally. The protective cover 30 protects the LIKUFIX hydraulic coupling system against dirt and damage from impacts. When the coupling system is not in use, the cover is placed on the guide bolts 20 at the coupling housing 10.

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16.24.5


Service Manual


2.4

Exploded drawing of LIKUFIX mounted to an attachment

Fig. 6

16.24.6

LIKUFIX for attachments

10

Coupling housing

80

Retaining plate

20 21

Guide bolt Allen head screw

81 82


30 40

Protective cover Pressure spring

90 91

Tie-down device Allen head screw

41 42


92 100

Retaining washer Tie-down device

50

Plunger

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Service Manual


2.5

Assembly drawing of LIKUFIX

Fig. 7

The attachment-specific LIKUFIX 33 / 48 accessory kit 20 is inserted into the housing 10 and secured with screws

10 LIKUFIX 48 for digging bucket 11 Hex head screw

41 Hex head screw 42 Retaining washer

12 Retaining washer 20 LIKUFIX (accessory kit)

43 Washer 80 Stop

30 Protective cover 40 Cover

81 Allen head screw 90 Plug

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16.24.7


Service Manual

Function of LIKUFIX hydraulic coupling system

3 Function of LIKUFIX hydraulic coupling system 3.1

Description of functions, see Fig. 20 The basic function of the LIKUFIX hydraulic coupling system corresponds to that of the hydraulic quick change adapter, see group 16.18.

3.1.1

Check valves Y 376-1 / Y 376-2 Die Sperrventile sind in den Hydraulikkreislauf des Anbausatzes AS1 installiert. They block off the oil flow channels when the attachment is removed. Beim Betätigen des Schnellwechslers über Drucktaste S5R/S5L werden die Magnetventile Y376-1 und Y376-2 bestromt und sperren den Öldurchfluss zu den Anschlüssen E und D am LIKUFIX. Der Ölkreislauf beim Koppeln bzw.Entkoppeln ist somit drucklos.Nicht Bestromt sind sie geöffnet, so dass das Öl zu den Anschlüssen E und D gelangen kann. T

Fig. 8

A Working line (high pressure)

Y376-1 solenoid valve rotating grab right

B Working line (high pressure) E Hydraulic line rotating grab left

Y376-2 solenoid valve rotating grab left

E

16.24.8

Check valves mounted on boom

Hydraulic line rotating grab right

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Service Manual

LIKUFIX Hydraulic Coupling System Function of LIKUFIX hydraulic coupling system

3.1.2

Relief valves Y 387-1 / Y 387-2 The relief valves are integrated into the high-pressure lines of the AHS 11/AHS 12 accessory kit. They ensure that the pressure lines can be opened to the tank so that the pressure is released when the LIKUFIX coupling system is disconnected. By pressing the S5R/S5L button of the quick change adapter, the solenoid valves Y 387-1 and Y 387-2 are powered, opening the fluid flow so that the fluid pressure in line A or B is released through the restrictor 40 to the tank.

3.1.3

Inspection of relief valves Disconnect attachment. Press left and/or right AHS pedal. Quick change mechanism is operated. Pressure is released through valves Y387-1 or 387-2 respectively (hissing noise). Watch high-pressure hoses A and B for pulsating movements. Note! When the S5L or S5R button is activated, all 6 solenoid valves Y 28-1/Y28-2 (quick change adapter activation) Y376-1,Y376-2 (check valves) and Y 387-1, Y 387-2 (relief valves) are powered in parallel.

Fig. 9

In models manufactured before 08/2003, the relief valves Y387-1/Y387-2 are mounted at the tank 1.

40 Restrictor X262-3 Plug connection

Y376-1 Check valves Y376-2 Check valves

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16.24.9


Service Manual


Fig. 10

16.24.10

In models manufactured after 08/2003, the relief valves Y387-1/Y387-2 are mounted at the control valve block 100.

40

Restrictor

X262-3 Plug connection

100

Control valve block - connections

Y387-1 Relief valve Y387-2 Relief valve

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Service Manual


3.2

Function of the plunger cylinders 50

Fig. 11

3.2.1

Hydraulic connections of the plunger cylinders at the attachment and changeover valve

10

Coupling plug

60

Changeover valve

20

Coupling plug

90

Mount plug

50

Plunger cylinder

Control of the plunger cylinders 50 The plunger cylinders 50 are controlled and operated through the working line A (in other attachments: through working lines A and B). The operating pressure built up in the couplings repels the coupled plates from each other. The plunger cylinders counteract this force. For rotating grab attachments, the force of the spring plate package 50 is sufficient, see Fig. 12. If a high-pressure circuit is used, the plungers must be operated in addition to the spring plate kit. The disc springs 50, see Fig. 12 mounted in the plunger ensure that the coupling plates 10 are properly held together by applying pressure provided by the working line A . The correct number of disc springs 50, combined with the required pressure from line A produce the required counterforce. The surfaces are calculated in such a way that the coupling plates are pressed together. While the coupling is closed, the plates are thus pressed against each other and cannot be separated by the applied working pressure in the couplings 10/20. Note! The additional control of the plunger cylinders 50 is only required for certain attachments. In plunger cylinders with a low working pressure, mount plug 90. When using couplings E and D (rotating grab), we recommend filling the plunger cylinders 50 to one third with oil.

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16.24.11


Service Manual


3.3

Exploded drawing of plunger

Fig. 12

16.24.12

Plunger (X = observe correct alignment and position of disc springs).

10

Plunger cylinder

31

Circlip

11

O-ring

50

Disc spring

12 20

Scraper ring Piston

990 991

Mounting sleeve for Glyd ring Expanding sleeve for Glyd ring

21

Turcon-Glyd ring

992

22

O-ring

993

Mounting sleeve (insertion aid for piston into cylinder) Mounting sleeve for scraper ring

30

Thrust plate

999

Cylinder seal kit

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Service Manual


Fig. 13

A = decoupled; B = coupled (offset due to conversion of radial movement of the quick change adapter linear movement of the coupling plate).

1

High pressure hose from A or B

2

Disc spring pack

3

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Plunger cylinder

16.24.13


Service Manual

Coupling sleeves / coupling plugs

4 Coupling sleeves / coupling plugs 4.1

Coupling/decoupling, see Fig. 14 to see Fig. 17 When connecting the coupling sleeves and plugs together, the plug 10/20 can be inserted into the sleeve 60/70 until it touches the collar. In the process, valve 10.4 of the coupling plug is pushed inward by valve 60.2 of the coupling sleeve 60/70. As soon as the coupling housing is closed, and the coupling plug 10/20 is fully inserted into the coupling sleeve 60/70, the oil flow channel through the coupling is opened, allowing for oil flow to the consumer and/or the tank. The O-rings 60.11 and 60.12 act as seals for the valve 60.2. When decoupling the system, the housings 10.1/60.1 are decoupled. The valves 10.4/60.6 are closed by the pressure springs 60.4/60.8 . The flow channel is thus blocked, so that no fluid can escape. The dust cover 60.7 at the coupling sleeve 60/70 prevents dirt and dust penetrating the decoupled device. The O-rings 60.11/12/13 at the coupling sleeve 60/70 act as seals for the valve 60.2 so that no oil can escape. The profile ring 10.3 at the coupling plug 10/20 also protects the valve 10.4 against dirt and dust and provide a seal for the valve, similar to the O-rings 10.7and 10.8.

Fig. 14

10 20

16.24.14

Coupling plug and coupling sleeve

60 70

Coupling plug M24X1,5 Coupling plug M36X2

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Coupling sleeve M24X1,5 Coupling sleeve M36X2

Service Manual

LIKUFIX Hydraulic Coupling System Coupling sleeves / coupling plugs

4.2

Sectional drawing of coupling sleeves / plugs

Fig. 15

10 .4

A = coupling open; B = coupling closed

60 .2

Coupling plug M24X1,5 Valve

Coupling sleeve M24X1,5 Valve

.6

Spring

.4

Spring

20

Coupling plug M36X2

.6

Valve cover

.7

Dust cover

.8

Spring

70

Coupling sleeve M36X2

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Service Manual

Coupling sleeves / coupling plugs

Fig. 16

16.24.16

Sectional drawing of coupling sleeve

60

Coupling sleeve M24X1.5

.7

Dust cover

70 .1

Coupling sleeve M36X2 Housing

.8 .9

Spring Adapter

.2 .3

Valve Valve seat

.10 .11

Retainer O-ring

.4 .5

Spring Guide

.12 .13

O-ring O-ring

.6

Valve cover

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Service Manual

LIKUFIX Hydraulic Coupling System Coupling sleeves / coupling plugs

Fig. 17

Sectional drawing of coupling plug

10 20

Coupling plug M24X1.5 Coupling sleeve M36X2

.4 .5

Valve Valve seat

.1 .2

Plug housing Adapter

.6 .7

Spring O-ring

.3

Profile ring

.8

O-ring

Note! O-ring 8 might become dislodged and flushed away during coupling procedures. If this O-ring is found on the surface of the coupling plug: Remove the O-ring. The O-ring acts only as a seal to prevent oil leakage during the replacement of the profile rings .3.

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16.24.17


Service Manual

Mounting and dismantling of working tools

5 Mounting and dismantling of working tools Note! The LIKUFIX quick change adapter is operated as described in group 16.15 Hydraulic quick change adapter. Please observe the following additional instructions: Before mounting the equipment, remove the protective covers of the quick change adapter and the working tool. Keep the coupling housings 3 and 4 clean at all times. Before mounting the attachment, inspect the coupling parts for contamination and dirt. If necessary, brush off dirt and dust, and clean the coupling parts and sealing faces with a clean cloth and oil. The coupling parts are treated with Gleitmo 900 spray at the factory. This protective treatment should be repeated when necessary. Slowly connect or disconnect the hydraulic couplings to/from the respective attachment. Tilt the quick change adapter at the attachment so that the coupling plates can easily be connected due to the weight of the working tool. Extend locking bolt. If the plates cannot be easily connected to each other, check whether a foreign object (stone, etc.) is jammed between the parts. If this is the case, clean the coupling parts to prevent damage by subsequent coupling. Adjust the oil level and pressure to the attached tool. After completion of the work, and especially before transport, mount the protective covers.

Fig. 18

3

16.24.18

LIKUFIX during coupling

Coupling housing upper section at the quick change adapter

4

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Coupling housing lower part at the attachment e.g. grapple

Service Manual

LIKUFIX Hydraulic Coupling System Removal of attachments in the event of failure of the hydraulic or electric system

6 Removal of attachments in the event of failure of the hydraulic or electric system

Fig. 19

Removal of attachment

Place attachment onto a level surface. Secure it and ensure that it is properly balanced. Release pressure from hydraulic circuit. Remove hex head screws 41. Remove cover 40. Remove Allen head screws 21 and 22. Remove Allen head screws 23. Release hose brackets. you should now be able to pull out the hoses. Pull coupling system forward. Pull coupling system forward until the cover of the quick change adapter is accessible. Remove the securing screws of the cover. Remove the cover. Disengage quick change adapter mechanism (locking device). Relief the base side of the locking cylinder. Push the bolt of the quick change adapter inwards and carefully disconnect the attachment including LIKUFIX coupling from the quick change adapter. Note! In the event of a cable break in the lines supplying valves Y28-1 and Y28-2, power the lines with 24V using an auxiliary cable.

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16.24.19


Service Manual

Hydraulic and electric units

7 Hydraulic and electric units Key to hydraulic diagram 3

LIKUFIX part at quick change adapter

540


4

LIKUFIX part at attachment

541

Secondary relief valve / rotation right

10/20 40

Coupling plug Restrictor

542 544

Secondary relief valve / rotation left Pressure balance

60/70

Coupling sleeve

550


80

Pilot control valve left

S5L

Push button / grapple rotator left

88P

Manifold P

S5R

Push button / grapple rotator right

88T 110

Collecting pipe T Low pressure-control valve block

S19 Y22

Button / grapple rotator Solenoid valve / Grapple rotation left

113

Spool grapple rotator

Y23

Solenoid valve / Grapple rotation right

120


Y28-1


156

Check valve

Y28-2

157 158

Adjusting restrictor Two way check valve

Y376-1 Check valve on base side Y376-2 Check valve on boom side

515 517

Hydraulic hammer Additional consumer

Y387-1 Relief valve Y387-2 Relief valve 10*

Hydraulic quick change device (kit) see group 16.15

Key to electric diagram B26

Proximity switch of quick change adapter X262-1 Plug-type connection, 8-pin or 3-pin

X263-3 Plug-type connection / 2-pin

X262-2 Plug-type connection, 8-pin or 3-pin X262-3 Plug-type connection, 8-pin or 3-pin

X452-2 Plug-type connection to SV Y376-2 Y28-1 Solenoid valve of quick change device

X262-4 Plug-type connection at valve 28-1/2pin X262-5 Plug-type connection at valve Y28-2/2pin X262-6 Plug-type connection at B26 / 3-pin

Y28-2

Y376-2 Check valve grapple rotator cycle

X263-1 Plug-type connection / 2-pin X263-2 Plug-type connection / 2-pin

Y387-1 Solenoid valve for LIKUFIX relief Y387-2 Solenoid valve for LIKUFIX relief

X452-1 Plug-type connection to SV Y376-1

Y376-1 Check valve grapple rotator cycle

A B26 als Öffner B B26 als Schließer C Option mit Sure Seal-Stecker B26 als Schließer

16.24.20

Solenoid valve of quick change device

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Service Manual

LIKUFIX Hydraulic Coupling System Hydraulic and electric units

.

Fig. 20

Hydraulic diagram of LIKUFIX

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16.24.21


Service Manual

Hydraulic and electric units

Fig. 21

16.24.22

Electric diagram of LIKUFIX

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Service Manual

LIKUFIX Hydraulic Coupling System Connection options for LIKUFIX system

8 Connection options for LIKUFIX system

Fig. 22

Universal interface for member / attachment

A Actuation of P1(G1) Optional switching of control

a

View: in driving direction, right side

A Actuation of P2(G2)

b

Operator's cab

C Hammer return line D Actuation of D1

c d

In wheel models In track models

E

x y

View: against driving direction, from front View: in driving direction, from rear

Actuation of D2

Left

Right

Coupling

Actuation

E

D2

B

Function Rotate grab to left Lock quick change adapter

G2


P2

Close pressure (AHS) circuit of grab/shear

Coupling

Actuation

D

D1

A

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Function Rotate grab to right Release quick change adapter

G1

Retract bucket cylinder

P1

Open pressure (AHS) circuit of hammer advance line grab/shear

16.24.23


Service Manual

Connection options for LIKUFIX system Left Coupling

Right Actuation

C

Function

Coupling

Actuation

Function

Hammer return line/ leak oil

The following principle applies: Movement to the right = pressure in right line, and vice versa

Left Coupling

Right Actuation

Function

Coupling

Actuation

Function

G1

Open pressure (AHS) circuit of hammer advance line grab/shear

P1

Retract bucket cylinder

With optional "switching of AHS control with bucket function" kit. B

G2

Close pressure (AHS) circuit of grab/shear

P2


A

Note! The hammer advance line can be placed to the right (P1) or the left (P2) side. By default, the hammer return line is positioned to the right, with the option to position it to the left.

16.24.24

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Service Manual

LIKUFIX Hydraulic Coupling System Connection options for LIKUFIX system

Fig. 23

Hydraulic diagrams for the various attachments

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16.24.25


Service Manual

Maintenance and cleaning

Fig. 24

Hydraulic diagrams for the various attachments

a

Supply line to plunger

d

Mill, pile driver, plate vibrator without rotator and separator (2 directions of rotation)

b

Grab, concrete pulverizer, shear, sorting grapple

e

Hydraulic hammer without swivel bearing (mill 1 direction of rotation)

c

Vibrator plate with rotator, Hydraulic hammer with swivel bearing

f

Ditch cleaning bucket, tilting bucket, compactor, spreader (no need for additional hydraulic pressure at the disk springs)

9 Maintenance and cleaning The LIKUFIX hydraulic coupling system is virtually maintenance-free. We recommend regular cleaning of the system and lubrication of the guide elements with Gleitmo 900. This treatment prevents caking of dirt and icing up in winter. With regular cleaning, the seals of the system have a long service life.

16.24.26

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Service Manual

LIKUFIX Hydraulic Coupling System Troubleshooting

10 Troubleshooting 10.1

Coupling system leaking :

Note! After decoupling, the parts might be covered in a thin film of oil. This is normal and does not indicate a leak. In the event of substantial leakage, check the system to find the defective coupling. There is an increased risk of leakage at older coupling plugs and after prolonged operation. Replace seals and the coupling will regain their original state.

10.2

Foreign object in coupling sleeve: The coupling sleeve is mounted into the quick change adapter housing, see Fig. 16: Shut down engine. Examine coupling sleeves to see whether a foreign object is caught in them. Carefully remove the object, push in the dust cover .7 using a screwdriver and flush out the object. If the object cannot be removed, replace the coupling. Note! Always shut down the engine before removing a foreign object! When pushing the dust covers .7 into the coupling sleeves, oil might escape. Place a suitable receptacle under the sleeves.

10.3

Leakage at coupling sleeve: Complete a visual inspection of the coupling: Place oil pan under the leakage to collect the leak oil. Disconnect LIKUFIX system. Clean coupling plates. Pressurise one circuit after the next. Caution! Risk of damage to eyes from escaping oil when the couplings are pressurised. Keep a safe distance from the coupling system. Complete a visual inspection of all couplings,. If oil escapes under pressure from the gap between the dust cover .7 and the valve .2, the coupling is likely to be leaking. Check the seal ring in valve .2 for damage. Also check whether a foreign object has been jammed in the coupling. Complete a visual inspection of the inside of the coupling: Switch off the engine. Push in the dust cover .7, using a screwdriver.

copyright by

MJF C I F S S

16.24.27


Service Manual

Troubleshooting If the leak cannot be rectified, replace the coupling. Note! If there is no visible leakage at the coupling sleeves, the coupling plugs must be examined.

10.4

Leakage at coupling plug: If oil escapes at the sleeves, while no pressure is applied, so that the oil slowly drips from the sleeve, the problem is likely caused by a leaking coupling plug. Note! In the event of a leak at the coupling plug, the escaping oil see Fig. 25 tends to distribute itself in the entire front section of the coupling sleeve. During the coupling process, the oil is squirted by the leaking coupling plug into the spring space, so that drops form at the decoupled sleeve.

Fig. 25

10.5

Oil-filled section of the coupling sleeve

Identification of the leaking coupling plug: Remove all oil and grease from the coupling plates (use brake cleaner). Connect attachment. Pressurise all lines. Immediately decouple the device. Check coupling plates. Oil film around the coupling sleeve of the leaking plug Replace seal ring at defective coupling plug

16.24.28

copyright by

MJF C I F S S

Service Manual

LIKUFIX Hydraulic Coupling System Instructions for the replacement of the coupling plug seal

11 Instructions for the replacement of the coupling plug seal Using a screwdriver, press valves 4 down, one after the other, and examine the profile ring 3 for wear and tear. If necessary, replace the profile ring as described below.

Fig. 26

Instructions for the seal replacement

Fig. 27

Instructions for the seal replacement

Using a screwdriver, push valve 4 of the coupling plug 10/20 down (approx. 2 cm) and remove the defective profile ring 3 with a pointed implement. Squeeze new seal ring 3 and place it on the valve with the open side facing down. Push valve 4 down into the groove, place the screwdriver onto the centre of the valve surface and remove your hand. Let seal ring 3 expand in the groove, using the thumb to control the movement. Remove the screwdriver. Check whether the valve 4 can be moved up. If this is not the case, readjust the seal ring 3 by pressing it in further until valve 4 can be moved.

copyright by

MJF C I F S S

16.24.29


Service Manual

Instructions for the replacement of the coupling plug seal

16.24.30

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MJF C I F S S

Service Manual

Hydraulic hammers Function

Hydraulic hammers 1 Function The hydraulic hammer is used in connection with road works, demolition tasks and in quarries for the compaction, opening, breaking up or crushing of mineral material. A hammer can be connected to any LIEBHERR hydraulic excavator. Ensure however that the hydraulic output of the hammer (pressure and oil flow volume) is within the range of the actual output capacity of the excavator. For details, see data sheets 16.30-03 to 16.30-14 m

Fig. 1

Hydraulic hammers

copyright by

MJF C I F S S

16.30.1

Hydraulic hammers

Service Manual

Operating and maintenance instructions

2 Operating and maintenance instructions Note! When using a hammer, there is an ever present risk of a dusty environment, which might affect the hydraulic oil in the excavator, so that it might be contaminated more than normal. This in turn can cause excessive wear of components of the hydraulic unit (in particular of the pump parts). When using a hydraulic hammer with a LIEBHERR excavator, LIEBHERR requests the operator to adhere to the following instructions: – Change the hydraulic oil every 500 operating hours. – Replace the standard cartridge in the return filter/ hydraulic tank (20 / 5 µm) with a 10 µm cartridge. – This fine filter cartridge (10 µm) must be replaced every 500 operating hours. – the breather filter / hydraulic tank (7 µm*) must be replaced with a 2 µm fine filter. – This fine filter cartridge (2 µm) must be replaced each time the hydraulic oil is changed (i.e. every 500 operating hours). – When changing the hydraulic oil, clean the hydraulic tank and drain off the oil from all hydraulic cylinders. – After refilling of the system, insert a the cleaning cartridge (5 µm) in the return filter, which must be replaced after 50 operating hours by a fine filter cartridge (10 µm). – Regularly check the hydraulic oil for contamination (laboratory oil analysis). Hineri

Note! * From approx. Sept. 2005 all machines have been equipped with the 2 µm fine filter as standard. In machines purchased after this date, there is thus no need to replace the filter cartridge when first using the hammer attachment.

3 Equipment supplied by hammer manufacturers Note! The following equipment is offered by hammer manufacturers. Please note that the respective supplier is responsible for service, warranty, etc. Equipment available from hammer manufacturers: – Hydraulic hammer – Tool (e.g. chisel) – Device retainer / connecting part for excavator Parts available from LIEBHERR: – Accessory kit for the attachment of hydraulic hammers to basic machines (e.g. AHS 11 / AHS 12) – Lines for the hydraulic hammers at the basic boom, standard boom and adjustable gooseneck boom – Lines for hydraulic hammers at the bucket stick Functional description and diagram with pressure settings for the accessory kits AHS 11 and AHS 12. The following tables list the hammer models recommended by LIEBHERR for use with its excavator models.

16.30.2

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MJF C I F S S

Service Manual

Hydraulic hammers ATLAS - COPCO hydraulic hammers

4 ATLAS - COPCO hydraulic hammers 4.1

SB and TEX Type Product

SB 450

Tex 400 H

Tex 600 H

Tex 700 H

Unit Effective weight (1)

kg

419

412

665

715

Oil flow

l/min

50-100

50-100

52-105

55-120

Operating pressure / hammer

bar

150

150

150

140

Adjustment pressure of machine see AHS 11 / AHS 12

bar

170

170

170

170

right

NB

NB

left

A 309 Litronic

X

X

A 311 Litronic

X

X

A 312

X

X

Return (2) Attachable to machine types:

A 314

X

A 316

X

R 317

X

Tab. 1

Technical data

1) 2)

including standard chisel and suspension kit seen from operator seat

NB

no details in brochure

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16.30.3

Hydraulic hammers

Service Manual

ATLAS - COPCO hydraulic hammers

4.2

MB (former Krupp HM) Previous type Product

HM 190

New type Product

Unit

HM 350

HM 580

MB 500

MB 800

Effective weight (1)

kg

300

535

830

Oil flow

l/min

50-90

60-100

70-120


bar

130

160

170


bar

150

180

190

right

right

right

A 309 Litronic

X

X

A 311 Litronic

X

X

A 312 Litronic

X

X


Tab. 2

16.30.4

A 314 Litronic

X

A 316 Litronic

X

R 317 Litronic

X

Technical data 1)

including standard chisel and suspension kit

2)

seen from operator seat

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Service Manual

Hydraulic hammers EURORAM hydraulic hammers

5

EURORAM hydraulic hammers Type Product

Unit

RM 90

RM 115


kg

625

875

Oil flow

l/min

60-95

85 - 115


bar

145

160


bar

170

180

NB

NB

Return (2) Attachable to machine types: A 309 Litronic

X

A 311 Litronic

X

A 312 Litronic

X

A 314 Litronic

X

A 316 Litronic

X

R 317 Litronic

X

Tab. 3

Technical data 1)


2) NB

seen from operator seat no details in brochure

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16.30.5

Hydraulic hammers

Service Manual

FRD hydraulic hammers

6

FRD hydraulic hammers Type Product

Unit

HB 10G

HB 15G


kg

785

1100

Oil flow

l/min

70-90

90-120


bar

160

170


bar

180

190

right

right


X

A 311 Litronic

X

A 312 Litronic

X

A 314 Litronic

X

A 316 Litronic

X

X

R 317 Litronic

X

X

Tab. 4

16.30.6

Technical data 1)


2)


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Service Manual

Hydraulic hammers INDECO hydraulic hammers

7

INDECO hydraulic hammers Type Product

Unit

MES 1200

MEST 1500

MES 1750


kg

600

780

950

Oil flow

l/min

60-90

80-125

85-115


bar

120

130

130


bar

140

150

150

right

right

right

A 314 Litronic

X

X

A 316 Litronic

X

X

R 317 Litronic

X

X


X

A 311 Litronic

X

A 312 Litronic

X

Tab. 5

Technical data 1)


2)


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16.30.7

Hydraulic hammers

Service Manual

NPK hydraulic hammers

8 NPK hydraulic hammers Type Product

Unit

H4 XE


kg

565

Oil flow

l/min

50-80


bar

110

Adjustment pressure of machine, see AHS 11 / AHS 12

bar

130

Return (2)

right

Attachable to machine types: A 309 Litronic

X

A 311 Litronic

X

A 312 Litronic

X

A 314 Litronic A 316 Litronic R 317 Litronic Tab. 6

16.30.8

Technical data 1)


2)


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Service Manual

Hydraulic hammers RAMMER hydraulic hammers

9 RAMMER hydraulic hammers Type Product

S25

S26 N

S29C/

E64/

Unit


kg

425

540

820

1000

Oil flow

l/min

50-150

60-135

60-120

70-130


bar

180

175

200

190

Adjustment pressure of machine, see AHS 11 / AHS 12

bar

200

205

220

220

left

left

left

left

A 309 Litronic

X

X

A 311 Litronic

X

X

A 312 Litronic

X

X

X

A 314 Litronic

X

X

A 316 Litronic

X

X

X

R 317 Litronic

X

X

X


Tab. 7

Technical data 1) 2)


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MJF C I F S S

16.30.9

Hydraulic hammers

Service Manual

Ingersoll hydraulic hammers

10 Ingersoll hydraulic hammers Type Product

130

270 C


kg

370

695

Oil flow

l/min

70-110

90-130


bar

170

110


bar

190

130

left

left


X

A 311 Litronic

X

A 312 Litronic

X

A 314 Litronic

X

A 316 Litronic

X

R 317 Litronic

X

Tab. 8


16.30.10


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Service Manual

Hydraulic hammers TABE and Stanley hydraulic hammers

11 TABE and Stanley hydraulic hammers Producer Type Product

Tabe AGB 370

Stanley MB 875


kg

390

875

Oil flow

l/min

65-80

80-115


bar

130

125


bar

150

160

NB

right


X

A 311 Litronic

X

A 312 Litronic

X

A 314 Litronic

X

A 316 Litronic

X

R 317 Litronic

X

Tab. 9



NB

no details in brochure

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16.30.11

Hydraulic hammers

Service Manual

WIMMER hydraulic hammers

12 WIMMER hydraulic hammers Type Product

W 440

W 550


kg

600

1150

Oil flowl/min

l/min

60-100

70-130


bar

130

135


bar

150

180

left

left

A 309 Litronic

X

X

A 311 Litronic

X

X

A 312 Litronic

X

X

A 314 Litronic

X

A 316 Litronic

X

R 317 Litronic

X


Tab. 10


16.30.12

X


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Service Manual

Accessory kit AS1 Function

Accessory kit AS1 1 Function Auxiliary attachments that can be connected to the hydraulic excavator often require special components, hydraulic lines and hoses for control and drive purposes. These parts have been combined in accessory kits. As there is a wide range of different auxiliary attachments for excavators, we offer a number of different accessory kits to suit the equipment. The accessory kit AS1 described below is needed when the following attachments are to be used with the excavator: Examples: – A Hydraulic grapple rotator – B Ditch cleaning bucket, with swivel hydraulics – C Hydraulic quick-change adapter

Fig. 1

Attachments for AS1

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16.44.1

Accessory kit AS1

Service Manual

General information

2 General information Attachments and associated pressure relief valve Secondary pressure relief valve 541 / 542 (This valve limits the operating pressure and, thus, the operating pressure at measuring point 45) at the auxiliary control axle 540

120 +10 bar

Primary pressure relief valves 551 / 552 (primary protection for oil motor 550 / grapple rotator)

100 +10 bar

Secondary pressure relief valves 562/563 (secondary protection for cylinder 560 / tilting bucket, old model)

500 ±20 bar

Secondary pressure relief valves 566/567 (secondary protection for cylinder 560 / tilting bucket, new model)

350 ±20 bar

Tightening torques of mounting screws and bolts (Allen head screws) of auxiliary axle 540

55 Nm

Max. flow rate at spool 540 via limitation of stroke of spool

30 l/min

Stroke limitation of spool 540 Measure Y of the stop screw 540.1 Measure Y of the stop screw 540.2

Tab. 1

16.44.2

Pressure limit (in bar)

Technical data

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MJF C I F S S

17.0 mm 17.0 mm

Service Manual

Accessory kit AS1 Description of design and operation

3 Description of design and operation The kit AS1 enables the operator to move the grapple to the right and left or to swivel the tilting bucket into the desired position. To do this, the switch S19 must be pressed and the two buttons S5L/S5R in the left pilot control unit 80 must be actuated. Push the buttons S5L/S5R to lock and release the attachment by means of the hydraulic quick-change adapter. These additional functions are controlled by means of the auxiliary axle 540 attached to the slewing gear element 120. The auxiliary axle controls the flow rate between the working pump and the connected consumer.

Fig. 2 80

Control devices of AS1 S5L Button for actuation of grapple / bucket / quick-change adapter


S5R Button for actuation of grapple / bucket / quick-change adapter S19

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Switch / preselection / kit AS1

16.44.3

Accessory kit AS1

Service Manual

Functioning of the accessory kit

Fig. 3

Auxiliary control axle AS1 flange-mounted to the slewing gear axle of the compact block

100 540

Control valve block Spool / AS1

542 Y22

Pressure-relief valve connection B02 Solenoid valve / grapple rotation left

541

Pressure-relief valve connection A02

Y23


4 Functioning of the accessory kit see Fig. 7

4.1

Neutral position, see Fig. 7 The solenoids Y22 / Y23 are not powered. There is no pressure applied to the spool 540, and the control lines leading to the tank are relieved. The variable displacement pump 20 is in stand-by position and/or is available to other consumers.

4.2

Pressurisation of consumers 550, 560, 570 Actuate the push button S19 (on the control desk, to the right) to switch on the electrical system of the accessory kit. The integrated indicator light in the switch S19 is on. Press the left button S5L or the right button S5R in the joystick of the left pilot control unit 80 to power the solenoid Y22 or Y23 of the auxiliary control axle and to shift the spool 540 with maximum control pressure into the working position ("black/white switching"). The pump 20 swivels to the cross-section pre-set at the spool 540, provided that the set volume is greater than the volume Qmin of the pump. The oil flows from the control block 100 through the slewing gear axle 120 and the auxiliary control axle 540 connection "A02" or "B02" to the connected consumer.

16.44.4

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MJF C I F S S

Service Manual

Accessory kit AS1 Pressure check and adjustment

4.2.1

Oil circuit with grapple Oil from the connection "A02" or "B02" of the auxiliary control axle 540 flows to the oil motor 550 of the grapple rotator for right/left rotation. The oil motor 550 turns the grapple attached by means of a slewing ring to the right or to the left. To increase the torque at the grapple rotator, a second a oil motor 550 is installed. The return oil from the oil motor 550 flows through the connection "B02" or "A02" or the auxiliary control axle 540 to the control block 100. The double-acting pressure relief valve 551 secures the oil motor 550. If the solenoids Y22 / Y23 of the auxiliary control axle 540 are switched to their neutral position during a rotary motion, the oil motor acts as a pump. The resulting excess pressure in the line L or R is released through the pressurerelief valve 551/552.

4.2.2

Oil circuit with tilting bucket Oil from the connection "A02" for swivelling to the right or "B02" for swivelling to the left of the auxiliary control axle 540 flows through the double check valve 561 connection "V1-C1" or "V2 - C2" to the cylinder 560 (piston or rod side). Pressure is built up, opening the hydraulic double check valve 561 towards the return side. The cylinder 560 is extended or retracted and the bucket is turned into the desired horizontal position by means of a special mechanism. The return oil from the cylinder 560 flows through the open double check valve 561 connection "C2V2" or "C1-V1" and the connection "B02" or "A02" of the auxiliary control axle 540 to the control block 100. The pressure-relief valves 541 / 542 integrated into the auxiliary control axle 540 limit the pressure at the tilting bucket. In machines with attached tilting bucket, the pressure is controlled by means of the secondary pressure-relief valves 562 / 563 in the double check valve 561.

4.2.3

Oil circuit with quick-change adapter Oil from the connection "A02" for the retracting (releasing) of the locking cylinder 570 or "B02" for the extending (locking) of the locking cylinder 570 in the auxiliary control axle 540 flows through the solenoid valves Y28-1 / Y28-2 to the cylinder 570 (piston or rod side respectively). The seat valves are protected against dirt by the filters 572. The return oil from the cylinder 570 flows through the powered seat valve Y28-1 / Y28-2 and the connection "B02 or A02" in the auxiliary control axle 540 to the control block 100. The pressure-relief valves 541 / 542 integrated into the auxiliary control axle 540 limit the pressure at the quick-change adapter.

5 Pressure check and adjustment 5.1

Important adjustment notes – Pressure settings at operating temperature and engine speed step 8. – Use suitable pressure sensors and gauges. – During the warranty period, only employees and agents of LIEBHERR are allowed to carry out adjustment works. – The pressure-relief valves must be equipped with protective caps.

copyright by

MJF C I F S S

16.44.5

Accessory kit AS1

Service Manual

Pressure check and adjustment

5.2

Checking of the pressure-relief valves 541 / 542 Remove the protective cap at the measuring point 45. Connect a measuring sensor / gauge (600 bar). Close the stop cocks and remove and pressure connections (seal). 541 /542 Proceed as follows: Loosen the lock nut. Use a WS 6 Allen key to turn the adjusting screw. Turn screw in Increase pressure Turn screw out Reduce pressure When the adjustment is completed, re-tighten lock nut. Remove the pressure sensor and seal the measuring point 45.

Fig. 4

16.44.6

Measuring point for LS pressure, control block and auxiliary control axle with secondary pressure-relief valves .

20


540

Auxiliary control axle / AS1

45 100

Measuring point LS Control valve block

541 542

Pressure-relief valve Pressure-relief valve

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Service Manual


5.3

Inspecting double-acting primary pressure relief valve 551 / 552 (not applicable for tilting bucket and quick-change adapter) Remove the protective cap at the measuring point 45. Connect a measuring sensor / gauge (600 bar). Lock grapple rotator. Actuate the solenoid Y22 / Y23 on both sides. Compare the pressure at the pressure sensor with the prescribed pressure, see Tab. 1. Note! The secondary pressure relief valves 551 / 552 are factory-set and can be checked for correct pressure settings only at considerable expense. If required, adjust the pressure by inserting or removing washers between the pressure spring and the screw cap in the pressure-relief valve 551 / 552. Alternatively, replace the entire valve. Remove the pressure sensor and seal the measuring point.

Fig. 5 A B

Oil motor with shock valves and tilting bucket with twin/double check valve 561 562

Shock valve Shock valve

Double check valve Pressure-relief valve, swivelling to left

C

for old tilting bucket models

563

Pressure-relief valve, swivelling to right

D 550

for new tilting bucket models Oil motor / grapple rotator

565 566

Double check valve Pressure-relief valve, swivelling to left

551

Pressure-relief valve / turning left

567

Pressure-relief valve, swivelling to right

552

Pressure-relief valve / turning right

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MJF C I F S S

16.44.7

Accessory kit AS1

Service Manual


5.4

Inspection of the secondary pressure relief valves 562 / 563 / 566 / 567 (only in AS1 kit for tilting bucket) Note! The tilting bucket design has been improved during the production of the series. The stop valve (twin check valve 561 has been changed to a double check valve 565. The secondary pressure relief valves 562 / 563 / 566 / 567, see Fig. 5 are factory-set and can be checked for correct pressure settings only at considerable expense. Inspection must be limited to the condition of the pressure springs of the relief valves 562 / 563 / 566 / 567 (setting and break). Caution! Risk of injury to eyes and hands from preload of the spring in the valves 562 / 563 / 566 / 567. In type C units, carefully screw out the screw at the valve 562 / 563 and remove the cover. In type D units, carefully remove the screw plug of the valve 566 / 567. Check the valve for damage. Reassemble the valve 561 / 565. If required, replace the entire valve.

5.5

Adjusting the flow of the spool 540 (rotating speed of grapple)

Fig. 6

16.44.8

Compact control block, auxiliary control axle AS1 with stroke limitation of the spool

100

Control valve block

540.1

Stroke limitation of spool, top

540

Auxiliary control axle

540.2 .1

Stroke limitation spool, bottom Stop screw

.2

Stop screw

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Service Manual


– The speed of the grapple is determined by the max. oil volume flowing at spool 540. – The value has been pre-set at the factory (stroke limitation 540.1 or 540.2) and should not be tampered with. – Measure Y serves as a reference value for the prescribed setting.see Tab. 1 For certain applications, it is possible to change the flow rate and, thus, the rotating speed of the grapple. To do this, turn the stop screw 1. Loosen the lock nut .2 of the stroke limitation 540.1/540.2. Turning out the stop screw .1 /stroke limitation to increase the speed. Turning in the stop screw .1 /stroke limitation to reduce the speed. (Possible only to a certain degree because pump's Q.min volume play a certain role as well.) When the desired speed is set, secure the stop screws .1 with the lock nut .2.

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16.44.9

Accessory kit AS1

Service Manual


5.6

5.6.1

5.6.2

5.6.3

16.44.10

Hydraulic unit AS1 (basic diagram) 1 6

to hydraulic tank to hydraulic oil cooler

120 540

Spool / slewing gear Spool / AS1

20 23

Variable-displacement pump Pump regulator (A 312-316)

541 542

Pressure-relief valve connection A02 Pressure-relief valve connection B02

26

Pump regulator (R 317)

544

Pressure balance

41

Measuring point MP

S5L

Press push button

45

Measuring point LS

S5R Press push button

50


S19

Switch / kit AS1

88

P from distribution block

Y22

Solenoid valve

88


Y23

Solenoid valve

100

Control valve block

Hydraulic system - turning grapple attachment 550

Oil motor

552

551

Pressure-relief valve / turning right

Pressure-relief valve / turning left

Hydraulic system tilting bucket attachment 560

Cylinder / swivelling bucket

563

Pressure-relief valve, rod side

561 562

Double check valve Pressure-relief valve, piston side

564

Restrictor

Hydraulic system quick-change adapter 570 571

Locking cylinder Seat valve

572

Filter disc

Y28-1 Y28-2

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MJF C I F S S

Solenoid / seat valve Solenoid / seat valve

Service Manual


Fig. 7

Hydraulic diagram of the AS1 kit

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16.44.11

Accessory kit AS1

Service Manual

Electrical system

6 Electrical system For electric diagrams of the AS1 kit, please refer to the electrical system of the basic machines A 312 - A 316 and R 317.

16.44.12

copyright by

MJF C I F S S

Service Manual

Accessory kit AHS 1 Function

Accessory kit AHS 1 1 Function Auxiliary attachments that can be connected to the machine often require special components, hydraulic lines and hoses for control and drive purposes. These parts have been combined in accessory kits. As there is a wide range of different auxiliary attachments for machines, we offer a number of different accessory kits to suit the equipment. The accessory kit AHS 1 described here allows for the following functions when an auxiliary attachment is connected to the machine: – Auxiliary control axle without pressure and flow reduction of the high-pressure connections: • e.g. fir attachment of a hydraulic boom adjustment unit

Fig. 1

Auxiliary cylinder, e.g. regulating cylinder A for hydraulic boom adjustment unit

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MJF C I F S S

16.48.1

Accessory kit AHS 1

Service Manual

General information

2 General information Attachments and associated pressure-relief valves Pressure cut-off valve 104 (this valve limits the LS pressure and thus the operating pressure at the control block 100) Secondary pressure relief valves 501/502 (for cylinder 515) (in the auxiliary control axle 500) Stroke limitation of the spool Piston 500 Dimension Y of stop screw 500.1 for the retraction of the cylinder Dimension Y of stop screw 500.2 for the extension of the cylinder

16.48.2

primary

secondary

350 +10 bar 380 +20 bar

16.3 mm (from serial no. 14517 = 14.7 mm) 17.4 mm (from serial no. 14517 = 14.9 mm)

For more information on the auxiliary axle AHS1, see 7.60.55. Tab. 1


Technical data

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Service Manual

Accessory kit AHS 1 Operation

3 Operation The accessory kit AHS 1 enables the operator to operate the working attachment (consumer) for hydraulic boom adjustment. Note! To ensure proper use and functioning of the accessory kit AHS 1, the connected units must be operated according to the instructions in this manual:

Danger! When the regulating cylinder is retracted and the attachment is in a particular position, the digging bucket might reach the operator's cab, posing a serious risk to the operator and the machine.

Fig. 2

Operator's platform with pilot control unit 86 for the kit

Operation of the boom regulating cylinder Press down the right pedal of the pilot control unit 86. The boom regulating cylinder is extended, i.e. the attachment is moved upwards. Press down the left pedal of the pilot control unit 86. The boom regulating cylinder is retracted, i.e. the attachment is moved down.

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16.48.3

Accessory kit AHS 1

Service Manual



Important adjustment notes: Heat the hydraulic oil to operating temperature. Run the diesel motor at maximum speed. To adjust the pressure, use suitable pressure sensors/gauges. Note! Please note that, during the warranty period, all work on the valves must be carried out by LIEBHERR technicians. The pressure-relief valves must be protected against unauthorised manipulation with safety caps.

Fig. 3 120

16.48.4

Variable displacement pumps with measuring point LS and compact control valve block with measuring point MP and auxiliary axle AHS1.

20

Variable displacement pump (LPV or DPVO)

104


41

Measuring point MP for pump pressure

500

Auxiliary control axle with spool for auxiliary cylinder (regulating cylinder)

45

Measuring point LS for LS pressure

501

100

Control valve block

502

Secondary pressure-relief valve / retract regulating cylinder Secondary pressure-relief valve / extend regulating cylinder

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MJF C I F S S

Service Manual

Accessory kit AHS 1 Pressure check and adjustment

4.2

Checking and adjustment of the secondary pressure relief valve 501 / 502 at the auxiliary control axle 500 Connect the pressure sensor/gauge to measuring points 41 and45, see Fig. 3. Extend and retract the cylinder 517 to the stop by pressing the right and left pedal. Screw in the pressure cut-off valve 104. The pressure must be above the adjustment pressure of the secondary pressure relief valves 501 / 502. Check the adjustment pressure of the secondary pressure-relief valves 501 / 502. Turn the adjusting screw at the secondary pressure relief valve 501 / 502 until the pressure sensor/gauge at the measuring point 45 indicates the nominal pressure, Table 1, page 2.

4.3

Adjustment of the pressure cut-off valve 104 Extend the bucket cylinder to the stop Turn out the adjusting screw of the pressure cut-off valve 104 until the prescribed nominal pressure,see Tab. 1, is indicated at the pressure/gauge at the measuring point 41. Remove the pressure sensor / gauge and seal the measuring point 41 / 45.

4.4

Adjustment of the stoke limitation of the spool 500

Fig. 4

Stroke limitation of the spool 500

100


1.1

Stop screw

500


1.2

Lock nut

1.3

Safety cap

500.1 Stroke limitation / retract regulating cylinder 500.2 Stroke limitation / extend regulating cylinder

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16.48.5

Accessory kit AHS 1

Service Manual

Pressure check and adjustment Note! The stroke of the spool 500 for maximum oil flow is factory-set by means of the stroke limiters 500.1 / 500.2 and should not be modified. The dimension Y, see Tab. 1 serves as a reference value for the prescribed settings. If dimension Y does not correspond to the prescribed value, adjust the stroke limiter as follows: Remove the safety cap 1.3. Loosen the lock nut 1.2. Turn the stop screw 1.1 until dimension Y is reached. Re-tighten the lock nut 1.2. Replace the safety cap 1.3.

16.48.6

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Service Manual

Accessory kit AHS 1 Components and hydraulic lines


Fig. 5

Hydraulic connections of AHS 1 kit

1

Hydraulic tank

500

50

from the control oil unit

501

86

Pilot control unit 2x, with pedal

502

88P

Distributor

88T

Collecting pipe

B290 Proximity switch / sensor control (kit)

100 104

Compact control block Pressure cut-off valve

B291 Proximity switch / sensor control (kit)

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Spool of auxiliary cylinder(e.g. regulating cylinder) Secondary pressure relief valve / cylinder 515 retracting Secondary pressure relief valve / extend cylinder 515

16.48.7

Accessory kit AHS 1

Service Manual

Hydraulic system

6 Hydraulic system

16.48.8

1 6

from / to hydraulic tank to oil cooler

100 104


20


500

Regulating cylinder spool

23

Regulating valve

501

Secondary pressure relief valve / cylinder 515 retracting

30


502

Secondary pressure relief valve / extend cylinder 515

41 45


504 507


50


515

Regulating cylinder / hydr. boom adjusting device

86 88P

Pilot control unit 2x, with pedal Distributor

516 517

Load-holding valve, piston side Load-holding side, piston rod side

88T

Collecting pipe

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Service Manual

Accessory kit AHS 1 Hydraulic system

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16.48.9

Accessory kit AHS 1

Service Manual

Hydraulic system

16.48.10

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MJF C I F S S

Service Manual


Accessory kit AHS 11 1 Function Auxiliary attachments that can be connected to the machine often require special components, hydraulic lines and hoses for control and drive purposes. These parts have been combined in accessory kits. As there is a wide range of different auxiliary attachments for machines, we offer a number of different accessory kits to suit the equipment. The AHS 11 accessory kit described below enables operators to use an auxiliary attachment and to supply it through an auxiliary control axle. – Auxiliary control axle located beside the main control valve block with pressure and flow reduction for a high-pressure connection: • used for example in connection with the attachment of a hydraulic hammer. – Auxiliary control axle without pressure and flow reduction of the two high-pressure connections: • used for example in connection with the attachment of a sorting grapple, a horizontally movable boom or an offset boom bearing

Fig. 1

Auxiliary attachments available for basic machine (examples)

A Hydraulic hammer

B Sorting grapple

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16.52.1


Service Manual

General information

2 General information Attachments and associated pressure-relief valves Pressure cut-off valve 104 (This valve limits the LS pressure) in control valve block 100

Pressure limit (in bar) primary

secondary

350 +10 bar

Secondary pressure-relief valve with additional pressure stage 511 Stage 1 (hydraulic hammer 535) Stage 2 (extend cylinder 537) (in the auxiliary axle 510)

200 +10 bar (*) 380 +20 bar (**) 380 +20 bar

Secondary pressure-relief valves 522 for the retraction of the cylinder537 (in the auxiliary axle 510) Stroke limitation of the spool Piston 510 dimension Y of stop screw 510.1 Dimension Y of stop screw 510.2

17.4 mm (15 mm***) from serial no. 14517 = 14.7 (11.5 mm***) 16.3 mm (12 mm***) from serial no. 14517 = 14.7 (11.0 mm***)

Return flow - backpressure

(*)

Oil flow rate required for hammer operation

(*)

Factory settings Current at proportional solenoid valve Y51

640 mA (*)

Control pressure at the pump P1 via proportional solenoid valve Y51

17+1 bar (*)

Tab. 1

Technical data

(*) Always observe the instructions and specifications of the hammer manufacturer, see also group 16.30. (**) In machines with the auxiliary attachments "45° offset boom bearing" or "horizontal boom movement", the secondary pressure-relief valve 537 controlling the flow at the piston side of the cylinder 512 is set to 200 bar and acts as a primary pressure relief valve. (***) In machines with the auxiliary attachments "45° offset boom bearing" or "horizontal boom movement", the flow volume of the auxiliary control axle 510 for the cylinder 537 is reduced by means of the stroke limitation 510.1 / 510.2.

16.52.2

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Service Manual

Accessory kit AHS 11 Function and operation

3 Function and operation The accessory kit AHS 11 enables the operator to control an auxiliary attachment (consumer) by means of the auxiliary pilot control unit 86 and to reduce the pressure and oil flow by operating the switch S241. Note! To ensure proper use and functioning of the accessory kit AHS 11, the connected units must be operated according to the instructions in this manual:

Fig. 2 86

Operator's cab with pilot control device, switch and indicator lamp for the accessory kit H196 Sorting grapple indicator lamp

Pilot control device of kit

S241 Switch AHS11 Actuate the switch S241 to preselect the desired attachment and thus activate the required pressure and flow reduction by means of the solenoid valve Y299. Operation of the sorting grapple: Set the switch S241 to position 1. The indicator lamp in the switch is off. The indicator lamp H196 is on. Unreduced flow rate and maximum permissible pressure (stage 2) on the sorting grapple cylinder (via spool 510). Press down the right pedal of the pilot control unit 86. Sorting grapple cylinder is extended, and the sorting gripper is closed. Press down the left pedal of the pilot control unit 86. Sorting grapple cylinder is retracted, and the sorting gripper is opened.

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16.52.3


Service Manual

Function and operation Operation of the hydraulic hammer: Set the switch S241 to position 2. The indicator lamp in the switch is on. The indicator lamp H196 is not on. Reduced flow rate and lower pressure (stage 1) on the hydraulic hammer (via spool 510). Left pedal of the pilot control unit 86 (no function assigned in connection with hydraulic hammer; for sorting grapple, etc.: no pressure or flow reduction at connection A6). Press down the right pedal of the pilot control unit 86. Hydraulic hammer is pressurised.

16.52.4

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Service Manual




Fig. 3 120

Variable displacement pumps with measuring point LS and compact control valve block with measuring point MP and auxiliary axle AHS11

20


104

41

Measuring point MP for pump pres- 510 sure

Auxiliary control axle AHS 11 with spool

45

Measuring point LS for LS pressure 511

Secondary pressure-relief valve with additional pressure stage / extending cylinder 537 or hammer

100


512


Secondary pressure relief valve / retracting cylinder 537 or pile driver

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16.52.5


Service Manual


Fig. 4

4.2

Secondary pressure-relief valve with additional pressure stage

10

Adjusting screw

15

Lock nut

11 12

Adjusting screw Shifting piston

30 33

Bushing Valve seat

13

Piston

511

Secondary pressure-relief valve, complete

14

Lock nut

X

Control pressure connection

Checking and adjustment of the secondary pressure relief valve 511 Connect the pressure sensor/gauge to measuring points 41 and 45. Screw in the pressure cut-off valve 104. The pressure must be above the adjustment pressure of the secondary pressure relief valve 511. Disconnect the control line from the additional pressure stage of the pressure relief valve 511. Seal the control hose but keep the pressure-relief valve connection open (risk of pressure buildup by leak oil at the control pressure connection X -). Disconnect the pressure line from the hammer and seal it. Only required, if a hydraulic hammer is to be attached.

4.2.1

Adjustment of pressure stage 2 (higher pressure level) Loosen the lock nut 15 and block the shifting piston 12 by screwing in the adjusting screw 11. Press down the right pedal to pressurise the hydraulic hammer 535 with maximum permissible pressure or to extend the cylinder537 to its stop. Loosen the lock nut 14 and turn the adjusting screw 10 at the pressure-relief valve 511 until the pressure sensor indicates the nominal pressure for stage 2, see Table 1, page 2, is indicated at the pressure sensor/gauge at the measuring point 45. Re-tighten lock nut 14. Reset the system to pressure stage 1.

4.2.2

Adjustment of pressure stage 1 (lower pressure level) Pressurise the hydraulic hammer 535 to the limit value. Turn the adjusting screw 11 at the pressure-relief valve 511 until the pressure sensor/gauge

16.52.6

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Service Manual

Accessory kit AHS 11 Pressure check and adjustment (measuring point 45) indicates the nominal pressure, see Tab. 1. Tighten the lock nut 15. Reconnect the control line to the connection X.

4.3

Checking and adjustment of the secondary pressure relief valve 512

Fig. 5 20

Auxiliary control axle AHS 11 with secondary pressure-relief valves 511 and 512 Variable displacement pump (LPV 104 or DPVO) Measuring point MP for pump pres- 510 sure

41 45


100

Control valve block

512

Pressure cut-off valve Auxiliary control axle AHS 11 with spool Secondary pressure-relief valve with additional pressure stage / extend cylinder 537 or hammer Secondary pressure relief valve / retracting cylinder 537 or pile driver

Fully retract the cylinder 537 to the stop by pressing down the left pedal. Turn the adjusting screw at the secondary pressure-relief valve 512 until the pressure sensor/gauge at the measuring point 45 indicates the nominal pressure, Table 1, page 2.

4.4

Adjustment of the pressure cut-off valve 104 Extend the bucket cylinder to the stop Turn out the adjusting screw of the pressure cut-off valve 104 until the prescribed nominal pres-

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16.52.7


Service Manual

Pressure check and adjustment sure,see Tab. 1, is indicated at the pressure/gauge at the measuring point 41. Remove the pressure sensor / gauge and seal the measuring point 41 / 45.

4.5


Fig. 6 100

Stroke limitation of the spool 510 Compact control block

510 Hydraulic hammer/cylinder spool 510.1 Stroke limitation / cylinder retraction

1.1

Stop screw

1.2 1.3

Lock nut Safety cap

510.2 Stroke limitation / hydraulic hammer / cylinder extension Note! The stroke of the spool 510 for maximum oil flow is factory-set by means of the stroke limiters 510.1 / 510.2 and should not be modified. The dimension Y, see Tab. 1 serves as a reference value for the prescribed settings. If dimension Y does not correspond to the prescribed value, adjust the stroke limiter as follows: Remove the safety cap 1.3. Loosen the lock nut 1.2. Turn the stop screw 1.1 until dimension Y is reached. Re-tighten the lock nut 1.2. Replace the safety cap 1.3.

16.52.8

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Service Manual



Fig. 7

Hydraulic connections AHS 11

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16.52.9


Service Manual

Hydraulic system

6 Hydraulic system

16.52.10

1

from / to hydraulic tank

510

6

to oil cooler

511

20


512

23

Regulating valve

514

Pressure balance

30

Gear pump / cooling

517


41

Measuring point MP

535

Hydraulic hammer

45

Measuring point LS

536

Pile driver

50


537

Cylinder (auxiliary device)

86 88P

Pilot control unit 2x, with pedal Distributor

538 Stop cock B290 Proximity switch / sensor control (kit)

88T 100


B291 Proximity switch / sensor control (kit) Y62 Solenoid valve / travel

104


Y63 Solenoid valve / travel Y299 Solenoid valve / secondary pressure hammer

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Spool / hydraulic hammer / cylinder / pile driver Secondary pressure-relief valve / retract hydraulic hammer 535 cylinder 537 Secondary pressure relief valve / extend cylinder 537

Service Manual


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16.52.11


Service Manual

Electrical system

7 Electrical system The electrical diagram of the AHS 11 accessory kit is shown in section 34 of groups 8.20 / 8.30 / 8.32 / 8.40, electrical equipment of basic machine.

16.52.12

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Service Manual


Accessory kit AHS 12 1 Function Auxiliary attachments that can be connected to the machine often require special components, hydraulic lines and hoses for control and drive purposes. These parts have been combined in accessory kits. As there is a wide range of different auxiliary attachments for machines, we offer a number of different accessory kits to suit the equipment. The AHS 12 accessory kit described below enables operators to use two different auxiliary attachments and to supply them through two separate control axles: – one control axle in the main control valve block without pressure and flow reduction of the highpressure connections: • used for example in connection with the attachment of a hydraulic boom adjusting device (vertical), a horizontally adjustable boom or an offset boom bearing – one auxiliary control axle at the main control valve block with pressure and flow reduction of a high-pressure connection: • used for example in connection with the attachment of a hydraulic hammer. – the auxiliary control axles without pressure and flow reduction of both high-pressure connections: • used for example in connection with the attachment of a sorting grapple, a concrete crusher. As both functions are controlled with the same pilot control device (pedal), they cannot be operated simultaneously.

Fig. 1


A Hydraulic boom adjusting device B Hydraulic hammer

C Sorting grapple

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16.54.1


Service Manual

General information

2 General information Attachments and associated pressure-relief valves Primary pressure-relief valve 122 (valve limiting the working pressure of the pump P1 at the measuring point 40) in the control valve block 100 Secondary pressure-relief valve with additional pressure stage 511 Stage 1 (hydraulic hammer 535) Stage 2 (extend cylinder 537) (in the auxiliary axle 510) Secondary pressure-relief valves 512 for the retracting of cylinder537 (in the auxiliary axle 510)


secondary

350 +10 bar

150 +10 bar (*) 380 +20 bar 380 +20 bar (200 bar **)

Current at proportional solenoid valve Y51

640 mA


23+1 bar

Tab. 1

Technical data

(*) Always observe the instructions and specifications of the hammer manufacturer, see also group 16.30. (**) In machines with the auxiliary attachments "45° offset boom bearing" or "horizontal boom adjustment", the secondary valve 515 controlling the flow at the piston side of the cylinder 537is set to 200 bar and acts as a primary pressure-relief valve.

16.54.2

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Service Manual

Accessory kit AHS 12 Function and operation

3 Function and operation The accessory kit AHS 12 allows the machine operator to control the connected auxiliary attachments (consumers) by means of the auxiliary pilot control device 86. The desired consumers and the required pressure and flow reduction can be preselected by means of switch S241. Note! To ensure proper use and functioning of the accessory kit AHS 12, the connected units must be operated according to the instructions in this manual:


Fig. 2 86

Operator's cab with pilot control device, switch and indicator lamp for the accessory kit H196 Sorting grapple indicator lamp


S241 Switch AHS12 Actuate the switch S241 to preselect the desired attachment and thus activate the required pressure and flow reduction by means of the solenoid valve Y268 and Y299. Operation of the boom regulating cylinder Set switch S241 to position 0 (not actuated) The LED in the switch is off. The indicator lamp H196 is not on. Unreduced flow rate and maximum permissible pressure on the boom regulating cylinder (via spool 106).

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16.54.3


Service Manual

Pressure check and adjustment Press right pedal to the stop. The boom regulating cylinder is extended, i.e. the attachment is moved upwards. Press left pedal to the stop. The boom regulating cylinder is retracted, i.e. the attachment is moved down. Operation of the sorting grapple: Set the switch S241 to position 1. The LED in the switch is off. The indicator lamp H196 is on. Unreduced flow rate and maximum permissible pressure on the sorting grapple cylinder (via spool 510). Press right pedal to the stop. Sorting grapple cylinder is extended, and the sorting gripper is closed. Press left pedal to the stop. Sorting grapple cylinder is retracted, and the sorting gripper is opened. Operation of the hydraulic hammer: Set the switch S241 to position 2. The LED in the switch is on. The indicator lamp H196 is not on. Reduced flow rate and lower pressure on the hydraulic hammer (via spool 510). Combined shifting for lowering and lifting of boom. Left pedal (no function). Press right pedal to the stop. Hydraulic hammer is pressurised. Note: When the switch S241 is in position 2 ("hydraulic hammer" position), the pressure-relief valve 511 (with additional pressure stage) is set to the reduced pressure value. The pressure relief valve 511 for the pressure stage 1 must be set to the maximum permissible working pressure for the hammer (specified by the hammer manufacturer), (see "Technical data", page 2). The potentiometer P1/P2 /P3 must be set to the permissible oil volume as specified by the hammer manufacturer, see also group 16.19, flow reduction.


Important adjustment notes: Heat the hydraulic oil to operating temperature. Run the diesel motor at maximum speed. To adjust the pressure, use suitable pressure sensors/gauges. Note! Please note that, during the warranty period, all work on the valves must be carried out by LIEBHERR technicians. The pressure-relief valves must be protected against unauthorised manipulation with lead seal wire or safety caps.

16.54.4

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Service Manual


Fig. 3 120

Compact control block with auxiliary axle AHS12

40

Measuring point for pump pressure

510

Hydraulic hammer/cylinder spool

100


511

Activate the secondary pressure-relief valve of the hydraulic hammer / extend cylinder

122

Primary pressure-relief valve P1

512


Fig. 4

Secondary pressure-relief valve 511 with additional pressure stage

10

Adjusting screw

15

Lock nut

11

Adjusting screw

30

Bushing

12

Shifting piston

33

Valve seat

13

Piston

511

14

Lock nut

X

Secondary pressure-relief valve, complete Control pressure connection

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16.54.5


Service Manual


4.2

Checking and adjustment of the secondary pressure relief valve 511 Connect the pressure sensor/gauge to measuring point 40. Turn in the primary relief valve 122. The pressure must be above the adjustment pressure of the secondary pressure-relief valve 511 / 512. Disconnect the control line from the additional pressure stage of the pressure relief valve 511. Seal the control hose but keep the pressure-relief valve connection open (risk of pressure buildup by leak oil at the control pressure connection X -). Disconnect the pressure line from the hammer and seal it. Only required, if a hydraulic hammer is to be attached.

4.2.1

Adjustment of pressure stage 2 (higher pressure level) Loosen the lock nut 15 and block the shifting piston 12 by screwing in the adjusting screw 11. Press down the right pedal to pressurise the hydraulic hammer 535 or the cylinder 537 with the maximum permissible pressure. Loosen the lock nut 14 and turn the adjusting screw 10 at the pressure-relief valve 511 until the pressure sensor indicates the nominal pressure for stage 2, Table 1, page 2. Tighten the lock nut 14.

4.2.2

Adjustment of pressure stage 1 (lower pressure level) Press down the right pedal to pressurise the hydraulic hammer 535 or the cylinder537 with the maximum permissible pressure. Turn the adjusting screw 11 at the pressure-relief valve 511 until the pressure sensor/gauge (measuring point 40) indicates the nominal pressure, see Tab. 1. Tighten the lock nut 15. Reconnect the control line to the connection X.

4.3

Checking and adjustment of the secondary pressure relief valve 512

Fig. 5

16.54.6

Auxiliary axle AHS 12 with primary and secondary pressure-relief valves

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Service Manual

Accessory kit AHS 12 Flow reduction of pump P1

40

Measuring point for AHS 12 working pres- 510 sure

100

Control valve block

511

122

Primary pressure-relief valve P1

512

Hydraulic hammer/cylinder spool Activate the secondary pressure-relief valve of the hydraulic hammer / extend cylinder Secondary pressure-relief valve / retract cylinder

Fully retract the cylinder 537 to the stop by pressing down the left pedal. Turn the adjusting screw at the secondary pressure-relief valve 512 until the pressure sensor indicates the nominal pressure, Table 1, page 2.

4.4

Adjustment of primary pressure-relief valve 122, see Fig. 5 Move the bucket cylinder to the stop and adjust the primary pressure-relief valve 122 to the required pressure (measured at measuring point 40) by turning the adjusting screw, see Tab. 1. Remove the pressure sensor / gauge and seal the measuring point 40.

5 Flow reduction of pump P1 The flow reduction function is implemented in conjunction with the potentiometers P1 - P3 on the printed circuit board A125 by means of the excavator control system U16 and the solenoid valve Y51, see group 16.19. Men

Fig. 6

The printed circuit board with the potentiometers is located behind the left control console


P1

Potentiometer / flow volume 1

P2 P3

Potentiometer / flow volume 2 Potentiometer / flow volume 3

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16.54.7


Service Manual

Adjustment of flow reduction Note! The flow reduction options are used to allocate preset reduced pump flow volumes to the connected attachment (e.g. hydraulic hammer). The flow reduction is set by the technician at the potentiometers P1 - P3 on the board A125. .

Fig. 7

Potentiometer board, switch and pilot control device for kit in operator's cab Proportional solenoid valve for flow reduction at the control oil unit Measuring point for control pressure/flow reduction of pump P1

20



21

Pump P1

S241 Kit switch

50

Control oil unit

Y51

57

Measuring point for flow reduction

K

Proportional solenoid valve / flow reduction Console

86


S

Clamping mechanism

6 Adjustment of flow reduction The printed circuit board A125 is located behind the left control console and can be accessed as follows: Move the operator seat to the front stop position. Release the clamping mechanism S at the console K. Remove the console K from the operator's cab. For detailed instructions on how to adjust the various flow reductions, refer to group16.19, flow reduction.

16.54.8

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Service Manual



Fig. 8


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16.54.9


Service Manual

Hydraulic system

8 Hydraulic system 1 20

to tank Double variable-displacement pump

109 120

Combined boom / stick cylinder spool Dummy cartridge / screw plug

40

Measuring point P1

121

Primary pressure-relief valve pump P2

41 50

Measuring point P2 from the control oil unit

122 150

Primary pressure-relief valve pump P1 Check valve

76

Shuttle valve of combined shifting of stick 151

78

Shuttle valve of combined shifting of boom

152

Check valve

86

Pilot control unit two-fold, with pedal

250

Regulating cylinder / hydr. boom adjusting device

88P 88T


251 510

Double load-holding valve Auxiliary spool AHS 12

100


511

101

Slewing gear spool

512

Secondary pressure-relief valve / extend cylinder 517 or hammer Secondary pressure relief valve / retract cylinder 537

102


535

Hydraulic hammer

103 105

Support cylinder spool Regulating cylinder spool

537

Sorting grapple cylinder

106 107

Boom cylinder spool Bucket cylinder spool

S241 AHS 12 switch Y268 Solenoid valve / changeover cylinder hammer

108

Travel motor spool

Y299 Solenoid valve / pressure limitation of hammer / combined shifting to lower boom

*

marked with P2 at the control valve block

** marked with P1 at the control valve block

16.54.10

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Load-holding valve

Service Manual


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MJF C I F S S

16.54.11


Service Manual

Electrical system

9 Electrical system The electrical diagram of the AHS 12 accessory kit is shown in section 34 of group 8.20, electrical equipment of basic machine.

16.54.12

copyright by

MJF C I F S S

Service Manual


Accessory kit AHS 12 1 Function Auxiliary attachments that can be connected to the machine often require special components, hydraulic lines and hoses for control and drive purposes. These parts have been combined in accessory kits. As there is a wide range of different auxiliary attachments for machines, we offer a number of different accessory kits to suit the equipment. The AHS 12 accessory kit described below enables operators to use two different auxiliary attachments and to supply them through two separate auxiliary control axles: – first auxiliary control axle, located at the main control valve block without pressure and flow reduction for the high-pressure connections: • used for example in connection with the attachment of a hydraulic boom adjusting device (vertical), a horizontally adjustable boom or an offset boom bearing – second auxiliary control axle without pressure/flow reduction for a high-pressure connection: • used for example in connection with the attachment of a hydraulic hammer. – second auxiliary control axle without pressure/flow reduction for both high-pressure connections: • used for example in connection with the attachment of a sorting grapple, a concrete crusher. As both functions are controlled with the same pilot control unit (pedals), they cannot be operated simultaneously.

Fig. 1


A Hydraulic boom adjusting device

C Sorting grapple

B Hydraulic hammer

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MJF C I F S S

16.56.1


Service Manual

General information

2 General information Attachments and associated pressure-relief valves Pressure cut-off valve 104 (This valve limits the LS pressure) in control valve block 100


secondary

350 +10 bar 380 +20 bar

Secondary pressure relief valves 501/502 for regulating cylinder 525 extension and retraction (in the auxiliary axle 500) Secondary pressure-relief valve with additional pressure stage 511 Stage 1 (hydraulic hammer 535) Stage 2 (extend cylinder 537) (in the auxiliary axle 510)

180 +10 bar (*) 380 +20 bar 380 +20 bar 200 bar (**)

Secondary pressure-relief valves 512 for the retraction of the cylinder537 (in the auxiliary axle 510) Stroke limitation of spool 500 Dimension Y of stop screw 500.1 Dimension Y of stop screw 500.2 Stroke limitation of spool 510 Dimension Y of stop screw 510.1 Dimension Y of stop screw 510.2

16.8 mm (from serial no. 14517 = 14.7 mm) 16.8 mm (from serial no. 14517 = 14.7 mm) 17.4 mm (15 mm***) from serial no. 14517 =14.7 mm (12 mm***) 16.3 mm (12 mm***) from serial no. 14517 =14.7 mm (10.5 mm***)

Return flow - backpressure

(*)

Oil flow rate required for hammer operation

(*)

Factory settings Current at proportional solenoid valve Y51

640 mA (*)


17+1 bar (*)

Tab. 1

Technical data

(*)

Always observe the instructions and specifications of the hammer manufacturer, see also group 16.30.

(**)

In machines with the auxiliary attachments "45° offset boom bearing" or "horizontal boom movement", the secondary pressure-relief valve 512 controlling the flow at the piston side of the cylinder 537 is set to 200 bar and acts as a primary pressure relief valve.

(***) In machines with the auxiliary attachments "45° offset boom bearing" or "horizontal boom movement", the flow volume of the auxiliary control axle 510 for the cylinder 537 is reduced by means of the stroke limitation 510.1 / 510.2.

16.56.2

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Service Manual

Accessory kit AHS 12 Operation

3 Operation The accessory kit AHS 12 allows the machine operator to control the connected auxiliary attachments (consumers) by means of the auxiliary pilot control unit 86. The desired consumers and the required pressure and flow reduction can be preselected by means of switch S241. Note! To ensure proper use and functioning of the accessory kit AHS 12, the connected units must be operated according to the instructions in this manual:


Fig. 2 86

Operator's cab with pilot control unit, switch and indicator lamp for the accessory kit H196 Sorting grapple indicator lamp

Pilot control unit of kit

S241 Switch AHS12 Actuate the switch S241 to preselect the desired attachment and thus activate the required pressure and flow reduction by means of the solenoid valves Y268 and Y299.

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16.56.3


Service Manual

Operation Operation of the boom regulating cylinder Set the switch S241 to position 0 (not actuated). The indicator lamp in the switch is off. The indicator lamp H196 is not on. Unreduced flow rate and maximum permissible pressure on the boom regulating cylinder (via spool 500). Press down the right pedal of the pilot control unit 86. The boom regulating cylinder is extended, i.e. the attachment is moved upwards. Press down the left pedal of the pilot control unit 86. The boom regulating cylinder is retracted, i.e. the attachment is moved down. Operation of the sorting grapple: Set the switch S241 to position 1. The indicator lamp in the switch is off. The indicator lamp H196 is on. Unreduced flow rate and maximum permissible pressure (stage 2) on the sorting grapple cylinder (via spool 510). Press down the right pedal of the pilot control unit 86. Sorting grapple cylinder is extended, and the sorting gripper is closed. Press down the left pedal of the pilot control unit 86. Sorting grapple cylinder is retracted, and the sorting gripper is opened. Operation of the hydraulic hammer: Set the switch S241 to position 2. The indicator lam in the switch is on. The indicator lamp H196 is not on. Reduced flow rate and lower pressure (stage 1) on the hydraulic hammer (via spool 510). Left pedal of the pilot control unit 86 (no function assigned in connection with hydraulic hammer; for sorting grapple, etc.: no pressure or flow reduction at connection B7). Press down the right pedal of the pilot control unit 86. Hydraulic hammer is pressurised.

16.56.4

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Service Manual




Fig. 3 120

Variable displacement pumps with measuring point LS and compact control valve block with measuring point MP and auxiliary axles AHS12

20


500

41



45


100


510

Secondary pressure relief valve / retract cylinder 525 Auxiliary control axle AHS 11 with spool

104


511

Secondary pressure-relief valve with additional pressure stage / extend cylinder 537 or hammer

512

Secondary pressure relief valve / retracting cylinder 537 or pile driver


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16.56.5


Service Manual


Fig. 4

4.2

Secondary pressure-relief valve with additional pressure stage

10 11

Adjusting screw Adjusting screw

15 30

Lock nut Bushing

12 13

Shifting piston Piston

33 511

Valve seat Secondary pressure-relief valve,complete

14

Lock nut

X

Control pressure connection

Checking and adjustment of the secondary pressure relief valve 511 Connect the pressure sensor/gauge to measuring points 41 and 45. Screw in the pressure cut-off valve 104. The pressure must be above the adjustment pressure of the secondary pressure relief valve 511. Disconnect the control line from the additional pressure stage of the pressure relief valve 511. Seal the control hose but keep the pressure-relief valve connection open (risk of pressure buildup by leak oil at the control pressure connection X -). Disconnect the pressure line from the hammer and seal it. Only required, if a hydraulic hammer is to be attached.

4.2.1

Adjustment of pressure stage 2 (higher pressure stage) Loosen the lock nut 15 and block the shifting piston 12 by screwing in the adjusting screw 11. Press down the right pedal to pressurise the cylinder 537. Loosen the lock nut 14 and turn the adjusting screw 10 at the pressure-relief valve 511 until the pressure sensor/gauge indicates the nominal pressure for stage 2, see Table 1, page 2. Tighten the lock nut 14.

4.2.2

Adjustment of pressure stage 1 (lower pressure stage) Pressurise the hydraulic hammer 535 to the limit value. Loosen the lock nut 15 and turn the adjusting screw 11 at the pressure-relief valve 511 until the pressure sensor/gauge indicates the nominal pressure for stage 1, see Table 1, page 2. Re-tighten lock nut 15. Reconnect the control line to the connection X.

16.56.6

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4.3

Checking and adjustment of the secondary pressure relief valve 501 / 502 / 512

Fig. 5

Variable displacement pumps and auxiliary axles AHS 12 (AHS1 and AHS 11) with secondary pressure-relief valves

20


500

41



45


Secondary pressure relief valve / retract cylinder 525

100

Control valve block

510


104


511

Secondary pressure-relief valve with additional pressure stage / extend cylinder 537 or hammer Secondary pressure relief valve / retracting cylinder 537 or pile driver

512


Move the cylinders 525 and 537 to the stop. Check the adjustment pressure of the secondary pressure-relief valves 501 / 502 / 512. Turn the adjusting screw at the secondary pressure relief valve 501 / 502 / 512 until the pressure sensor/gauge at the measuring point 45 indicates the nominal pressure, see Table 1, page 2.

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Service Manual


4.4

Adjustment of the pressure cut-off valve 104 (see Fig. 5, page 7) Extend the bucket cylinder to the stop Turn out the adjusting screw of the pressure cut-off valve 104 until the prescribed nominal pressure,see Tab. 1, is indicated at the pressure/gauge at the measuring point 41. Remove the pressure sensor / gauge and seal the measuring point 41 / 45.

4.5

Adjustment of the stroke limiter of the spools 500 and 510

Fig. 6 100

Stroke limiter of the spool 500 and 510 Compact control block

500 Spool / regulating cylinder 500.1 Stroke limitation / retract regulating cylinder

1.1

Stop screw

1.2 1.3

Lock nut Safety cap

500.2 Stroke limitation / extend regulating cylinder 510 Hydraulic hammer/cylinder spool 510.1 Stroke limitation / cylinder retraction 510.2 Stroke limitation / hydraulic hammer / cylinder extension Note! The stroke of the spool 500 / 510 for maximum oil flow is factory-set by means of the stroke limiters 500.1 / 500.2 / 510.1 / 510.2 and should not be modified. The dimension Y, see Tab. 1 serves as a reference value for the prescribed settings. If dimension Y does not correspond to the prescribed value, adjust the stroke limiter as follows: Remove the safety cap 1.3. Loosen the lock nut 1.2. Turn the stop screw 1.1 until dimension Y is reached. Re-tighten the lock nut 1.2. Replace the safety cap 1.3.

16.56.8

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Service Manual



Fig. 7


1

Hydraulic tank

B290

50 86

Control oil unit Pilot control unit 2x, with pedals

B291 Proximity switch / sensor control X924-1 Plug connection, 3x

88P

Distributor

X924-2 Plug connection, 3x

88T

Collecting pipe

Y62

Solenoid valve / travel

100 500

Compact control block Spool / regulating cylinder

Y63 Y268

510

Spool / hydraulic hammer / cylinder / pile driver

Y299

Solenoid valve / travel Solenoid valve / changeover regulating cylinder - hammer Solenoid valve / secondary pressure hammer

511

Secondary pressure relief valve with additional pressure stage / hydr. hammer - cyl.

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Proximity switch / sensor control

16.56.9


Service Manual

Hydraulic system

6 Hydraulic system 1

Hydraulic tank

510


6

to oil cooler

511

Secondary pressure-relief valve with additional pressure stage / retract hydraulic hammer 535 cylinder 537

20


512

23

Regulating valve

514

Secondary pressure relief valve / extend cylinder 537 Pressure balance

30

Gear pump / cooling

517


41

Measuring point MP

525

Regulating cylinder

45

Measuring point LS

526

Load-holding valve (piston side)

50


527

Load-holding valve (rod side)

86

Pilot control unit 2x, with pedals

535

Hydraulic hammer

88P 88T


536 537

Pile driver Cylinder (auxiliary device)

100 104


538 Stop cock B290 Proximity switch / sensor control (kit)

500 501

Spool / regulating cylinder Secondary pressure-relief valve / retract regulating cylinder 525 Secondary pressure-relief valve / extend regulating cylinder 525

B291 Proximity switch / sensor control (kit) S241 AHS 12 switch


Y63 Solenoid valve / travel Y268 Solenoid valve / changeover regulating cylinder - hammer

502 504 507

Y62

Solenoid valve / travel

Y299 Solenoid valve / secondary pressure hammer

16.56.10

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Service Manual


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16.56.11


Service Manual

Electrical system

7 Electrical system The electrical diagram of the AHS 12 accessory kit is shown in section 34 of groups 8.20 / 8.30 / 8.32 / 8.40, electrical equipment of basic machine.

16.56.12

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Service Manual

Accessory kit AHS 11 / AHS 12 with Tool Control Function

Accessory kit AHS 11 / AHS 12 with Tool Control 1 Function Auxiliary attachments that can be connected to the machine often require special components, hydraulic lines and hoses for control and drive purposes. These parts have been combined in accessory kits. As there is a wide range of different auxiliary attachments for machines, we offer a number of different accessory kits to suit the equipment. The accessory kits AHS 11 and AHS 12 described below are required for the installation of the following auxiliary attachments to a machine: – Hydraulic hammer – Telescopic demolition stick – Scrap shear – Concrete crusher – Sorting grapple

Fig. 1

Machine with adjusting equipment and sorting grapple and hydraulic hammer

A Hydraulic boom adjusting device B Hydraulic hammer

C Sorting grapple

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Service Manual

General information

2 General information Attachments and associated pressure relief valve Pressure cut-off valve 104 (this valve limits the LS pressure and thus the operating pressure at the measuring point 41 in the control block 100) Secondary pressure relief valves 511/512 Low-pressure (basic settings) High pressure (proportional valve Y414 with max. current)

primary

secondary

350 +10 bar

100 +10 bar 380 +20 bar

Flow rate at the outlet A / B Extending: Retracting:

200 l/min 200 l/min

Stroke limitation of the spool Piston 510 dimension Y of stop screw 510.1 Measure Y of the stop screw 510.2

14.2 mm 14.2 mm

Tab. 1

16.57.2


Technical data

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Service Manual

Accessory kit AHS 11 / AHS 12 with Tool Control Design

3 Design The accessory kit includes the following components: – Pilot control unit 86 – Auxiliary control axle 500 (only with AHS 12) – Auxiliary control axle 510 with pressure relief valves 511 (bottom) and 512 (top) – Proportional valve Y414 for the pressure limitation of the control axle of the hydraulic hammer – Proportional valve Y463 / Y464 for the flow limitation of the control axle of the hydraulic hammer The auxiliary control axle 500/ 510 are flange-connected to the control valve block 100. The proportional solenoid valve Y414 is screw-mounted to the hydraulic tank 1 below the solenoid valve for forward/reverse travel. The two proportional solenoid valves Y463 / Y464 are mounted near the control block. The switch S241 for flow limitation and the control of the Tool Control A156 (ESX) are integrated into the control desk (front right). The keyboard unit A155 is mounted above the control desk (front right), see Fig. 5. The pilot control unit 86 is equipped with pedals for the control of the attachment and is mounted in the front left section of the operator's cab. The solenoid valve Y268 used to change over from the boom adjustment to hammer operation is located at the tank.

Fig. 2

Hydraulic unit AHS 12 with Tool Control

1

Hydraulic tank

Y62


86


Y62


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Service Manual


Control valve block

Y268 Solenoid valve / changeover regulating cylinder / hammer Y414 Prop. valve pressure reduction

500

Auxiliary control axle regulating cylinder

510 511

Auxiliary control axle / hydraulic hammer Y463 Prop. valve / flow reduction Pressure relief valve with additional pres- Y464 Prop. valve / flow reduction sure stage

512


4 Functional description The accessory kits AHS 11 / AHS 12 allow the operator to work with two completely different attachments (consumers) using a single kit type: – Standard consumer, not requiring pressure and/or flow reduction – One consumer requiring pressure and/or flow reduction Note! To ensure proper use and functioning of the accessory kit AHS 12 / AHS 11, the connected units must be operated according to the instructions in this manual: Incorrect pressure or flow reduction settings may result in damage to the attachment (e.g. hydraulic hammer or reduced tool performance (e.g. mill). The pressure and flow reduction settings must be made at service level 2/3. Adjustment of pressure and flow reduction settings, see 6.

16.57.4

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Service Manual

Accessory kit AHS 11 / AHS 12 with Tool Control Functional description

4.1

Functional description of proportional pressure relief valve Y414 This valve allows you to steplessly adjust the system pressure to be restricted, in proportion to an electric nominal value. At nominal value 0 or in the event of a power failure, the minimum pressure is established. To adjust the system pressure (high pressure), enter the required nominal value in the ESX control system. The solenoid coil 14 is subsequently powered with the set nominal current. The proportional solenoid valve converts the current into a mechanical force, moving the armature bar and with it the valve cone 16. The valve cone 16 is pressed against the valve seat 15, blocking the flow between connection P and T1. If the hydraulic pressure acting on the valve cone 16 exceeds the magnetic force, the valve cone opens the connection to the tank, thus limiting the pressure.

Fig. 3

Sectional drawing of proportional pressure relief valve Y414

14

Magnetic coil

15

Valve seat

16

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Valve cone

16.57.5


Service Manual


4.2

Functional description of secondary pressure relief valve 511 / 512 The pressure P built up in the consumer circuit acts on the front face of the main cone 5 and, through the bore B1, also on the rear surface of the main cone 5. The main cone 5 and the pilot control cone 4 are kept in a position that closes the valve, due to the surface difference between B3 and B4 that are exposed to the same pressure P. The springs 11 and 3 are used to adjust the main cone 5 and the pilot control cone 4. As soon as the pressure in the consumer circuit reaches a value exceeding the set value of the pressure and adjusting spring 3, the pilot control cone 4 is lifted from its seat, and some oil can penetrate through the valve Y414 connection (T1) to the tank. Due to the different diameters of the bore B1 in the bushing 12 and the ring face B2 in the adjusting screw 6, a pressure difference is built up between the front side and the rear side of the main cone 5. As a result, the main cone 5 is lifted, opening the connection T to the tank. Any excess pressure is thus released to the tank (secondary relief).

4.2.1

Proportional pressure control In order to achieve proportional pressure control, the pressure (P) in the consumer circuit is controlled by valve Y414 via the connection Y in the pressure relief valve 511 / 512. The minimum and maximum pressure settings (as set in the menu) are controlled relative to the current (which in turn is controlled by the ESX), (see "", page 10). The later valve Y414 is opened via T1, when the operating pressure increases. When the valve Y414 opens the connection to T1, the pressure of the column in the pressure relief valve is reduced in proportion to the actual current through the valve. The main cone 5 is thus lifted from its seat and the oil flow channel P - T is opened. The pressure set in the menu is established.

16.57.6

1

Adjusting screw

12

Bushing

2

Lock nut

14

Magnetic coil

3

Pressure spring

15

Valve seat

4 5

Pilot control cone Main cone

16 511

Valve cone Secondary pressure relief valve

6

Screw plug

512


7

Housing

Y414 Prop. solenoid valve

11

Pressure spring

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Service Manual

Accessory kit AHS 11 / AHS 12 with Tool Control Functional description

Fig. 4

Function of pressure control system

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16.57.7


Service Manual


Fig. 5 86

Pilot control unit and menu display on the screen H196 Sorting grapple indicator lamp


A155 Tool Control keyboard

16.57.8

S241 Switch AHS12

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Service Manual

Accessory kit AHS 11 / AHS 12 with Tool Control Operation

5 Operation 5.1

Operating working tool Operation of the boom regulating cylinder Set the switch S241 to position 0 (not actuated). The indicator lamp in the switch is off. The indicator lamp H196 is not on. Unreduced flow rate and maximum permissible pressure on the boom regulating cylinder (via spool 500). Tool Control is disabled (pressure and flow reduction are not possible). Press down the right pedal of the pilot control unit 86. The boom regulating cylinder is extended, i.e. the attachment is moved upwards. Press down the left pedal of the pilot control unit 86. The boom regulating cylinder is retracted, i.e. the attachment is moved down. Operating the sorting grapple or hydraulic hammer: Set the switch S241 to position 1. The indicator lamp in the switch is on. The indicator lamp H196 is on. Tool Control is enabled (pressure and flow reduction are possible) Select the desired working tool on the screen, (see 5.2, page 9) e.g. for sorting grapple cylinder (through spool 510). The pressure and flow settings made by the LIEBHERR/dealer technician and the chosen name of the working tool are shown in the Tool Control screen. Press down the right pedal of the pilot control unit 86. The sorting grapple cylinder is extended at the set speed and pressure, i.e. the sorting grapple closes. Press down the left pedal of the pilot control unit 86. The sorting grapple cylinder is retracted at the set speed and pressure, i.e. the sorting grapple opens.

5.2

Selecting working tools on the Tool Control screen A155 see Fig. 5 The horizontal arrow on the screen indicates the currently active option (working tool) and the currently applied settings in %, see Fig. 6. In the example shown here, option 1 is active. Move the cursor (black frame) to another preset option (no. 1 to 10) and press the Menu button to activate it. Press the arrow buttons UP and/or DOWN. The black frame indicates the selected option. Press the Menu button. Your selection is confirmed. The arrow moves to the selected number, and the option is activated (here: option 3). The working tool can be operated at reduced oil pressure / reduced flow rate.

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Service Manual

Operation Note! On request, LIEBHERR and the customer service department shall label the options with the name of the associated tool, e.g. "hammer" or "grapple". The working tool can only be operated by means of Tool Control. If you wish to operate a working tool without reduction, select the option with maximum values (EV1, EV2 and EV6 at 100 % level).

Fig. 6

16.57.10

Keyboard unit A155 with "Tool Control" screen

EV1 Oil volume 1 EV1 Oil volume 2

F2 F3

DOWN arrow button UP arrow button

EV2 Pressure

F4

"Menu" button

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Service Manual

Accessory kit AHS 11 / AHS 12 with Tool Control Pressure check and adjustment


Important adjustment notes: Heat the hydraulic oil to operating temperature. Run the diesel motor at maximum speed. To adjust the pressure, use suitable pressure sensors. Note! Please note that, during the warranty period, all work on the valves must be carried out by LIEBHERR technicians. The pressure relief valves must be protected against unauthorised manipulation with lead seal wire or safety caps.

6.2

Adjustment of the pressure reduction system (low pressure) Connect the pressure sensor to the measuring point 45, see Fig. 7. Remove the 4 screws at the rear of the keyboard unit A155 and remove the lid of the housing. Pull the cable with the interface X1252, see Fig. 11, from the housing. Insert the service plug at the interface provided X1252. Select speed step 8. In menu "Option 1", set EV6 to 0%. Operate the left pedal 86. Check the low pressure at the measuring point 45 (basic settings), see Tab. 1. If the prescribed pressure is not reached, adjust the secondary pressure-relief valve512: Turn the adjusting screw clockwise, using an Allen key: the pressure is increased. Turn the adjusting screw anticlockwise, using an Allen key: the pressure is reduced. Operate the right pedal 86 and check the pressure at the measuring point 45. If the prescribed pressure is not reached, adjust the secondary pressure-relief valve511: Turn the adjusting screw clockwise, using an Allen key: the pressure is increased. Turn the adjusting screw anticlockwise, using an Allen key: the pressure is reduced. Operate the right pedal 86 and check the pressure at the measuring point 45. Compare the pressures: they must correspond.

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Service Manual


Fig. 7

6.3

Adjusting points and operation

20

Variable-displacement pump LPV / DPVO

104


41 45


500 510

Spool / regulating cylinder Hydraulic hammer/cylinder spool

86


511

100


512

Secondary pressure relief valve with additional pressure level / hammer / additional consumer Secondary pressure relief valve with additional pressure level hammer / additional consumer

Adjustment of pressure reduction system (high pressure) Set the pressure cut-off valve 104 to 400 bar. Connect a pressure sensor to the measuring point 45, see Fig. 7. Run the diesel engine at its upper idle speed. In menu "opt.1", set EV6 to 100%. Operate left or right pedal. Check the high pressure, see Tab. 1, at the measuring point 45. If the prescribed high pressure is not reached: Turn the adjusting screw 20 at the proportional valve Y414 until the prescribed high pressure is reached. Turn the adjusting screw 20 clockwise, using an Allen key: the pressure is increased.

16.57.12

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Service Manual

Accessory kit AHS 11 / AHS 12 with Tool Control Pressure check and adjustment Turn the adjusting screw 20 anticlockwise, using an Allen key: the pressure is reduced. Compare the high pressure values of the right and the left foot pedal. the two measured pressures must be identical. Switch off the engine. Disconnect the service plug. Place the cable with the interface X1252 in the housing of the keyboard unit A155. Mount the lid and tighten the screws (first tighten right bottom screw in the internal clip).

Fig. 8

1 20

Foot pedal in the operator's cab and proportional solenoid valve attached to the hydraulic tank

86 Secondary pressure relief valve Y414 Prop. solenoid valve

Hydraulic tank Adjusting screw

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Service Manual


6.4

Adjustment of the pressure cut-off valve 104, see Fig. 7 Run engine at step 8. Connect a pressure sensor to the measuring point 41. Move the bucket cylinder to the stop and adjust the pressure cut-off valve 104 to the required pressure (see Tab. 1, page 2) by turning the adjusting screw. Remove the pressure sensor and seal the measuring point.

6.5


Fig. 9

100 500

Stroke limitation of the spool 510

Compact control block Spool / regulating cylinder

500.1 Stroke limitation / retracting regulating cylinder

1.1 1.2

Stop screw Lock nut

1.3

Safety cap

500.2 Stroke limitation / extending regulating cylinder 510

Spool / hydraulic hammer/cylinder spool

510.1 Stroke limitation / retracting cylinder 510.2 Stroke limitation / hydraulic hammer / extending cylinder

The stroke of the spool 510 for maximum oil flow is factory set by means of the stroke limitation 510.1 / 510.2 and should not be modified. The dimension Y, (see Tab. 1, page 2) serves as a reference value for the prescribed settings. If dimension Y does not correspond to the prescribed value, adjust the stroke limiter as follows: Remove the protective cap 1.3, loosen the lock nut 1.2 and turn the stop screw 1.1 until dimension Y is reached. Tighten the lock nut 1.2 and mount the safety cap 1.3.

16.57.14

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Service Manual

Accessory kit AHS 11 / AHS 12 with Tool Control Pressure check and adjustment

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16.57.15


Service Manual

Hydraulic diagram

7 Hydraulic diagram Items in hydraulic diagram, (see Fig. 10, page 17) 1 6

514 517


20


525

Regulating cylinder

23 41

Pump regulator Measuring point MP

526 527

Load holding valve Load holding valve

45

Measuring point LS

535

Hydraulic hammer

50


536

Pile driver

86


537

Shear

88P

Distributor

538

Stop cock

88T 90

Collecting pipe Shuttle valve

535 536

Hydraulic hammer Pile driver

100 104

Compact control block 5 x Pressure cut-off valve

537 538

Shear Stop cock

500 501

Auxiliary spool / regulating cylinder Secondary pressure relief valve / retrac- A155 ting cylinder 525

502

Secondary pressure relief valve / exten- A156 ding cylinder 537

504 507


S241 Y268

AHS 11 / AHS 12 switch Solenoid valve changeover auxiliary axle 500/ 501

510

Auxiliary spool / hammer or additional consumer

Y414

Prop.solenoid valve / pressure limitation

511

Secondary pressure relief valve with additional pressure level / hammer / additional consumer Secondary pressure relief valve with additional pressure level / additional consumer

Y463

Prop.solenoid valve flow reduction hammer control axle

Y464

Prop.solenoid valve flow reduction hammer control axle

512

16.57.16

to tank to oil cooler

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Keyboard unit ESX control

Service Manual

Accessory kit AHS 11 / AHS 12 with Tool Control Hydraulic diagram

Fig. 10

Hydraulic diagram of AHS 11 with Tool Control

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16.57.17


Service Manual

Electrical system

8 Electrical system

Fig. 11

Electrical system of AHS 12 accessory kit with Tool Control

A155

Keyboard unit / display with plug X1 and X3

X974-4 Plug

A156 S241

ESX control unit with plug X1 Switch AHS12

X1252 CanBus interface Y268 Solenoid valve / changeover auxiliary axle 500/ 501

X11

Plug

Y299

Plug connection to solenoid valve

X414 X463

Plug Plug

Y414 Y463

Prop.solenoid valve / pressure limitation Prop.solenoid valve / flow limitation Hammer control axle

X464

Plug

Y464

Prop.solenoid valve / flow limitation Hammer control axle

The electric diagram of the accessory kit is included in group 8.106.

16.57.18

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Service Manual

Accessory kit AHS 12 with changeover valve Function

Accessory kit AHS 12 with changeover valve 1 Function Auxiliary attachments that can be connected to the machine often require special components, hydraulic lines and hoses for control and drive purposes. These parts have been combined in accessory kits. As there is a wide range of different auxiliary attachments available for machines, we offer a number of different accessory kits to suit the equipment. The accessory kit AHS 12 with changeover valve accessory kit described below enables operators to use three different auxiliary attachments and to supply them through two separate auxiliary control axles: – first auxiliary control axle, located beside the main control valve block without pressure and flow reduction for the high-pressure connections: • used for example in connection with the attachment of a hydraulic boom adjusting device (vertical) and a horizontally adjustable boom. – second auxiliary control axle without pressure/flow reduction for a high-pressure connection: • used for example in connection with the attachment of a hydraulic hammer. – second auxiliary control axle without pressure/flow reduction for both high-pressure connections: • used for example in connection with the attachment of a sorting grapple, a concrete crusher, etc. – one solenoid valve for the changeover of the high-pressure connections of the first auxiliary control axle from vertically to horizontally adjustable boom As all functions are controlled with the same pilot control device (pedal), they cannot be operated simultaneously.

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16.58.1


Service Manual

General information Fig. 1

Application options with kit AHS12 with changeover valve

A Cylinder for hydr. boom adjustment (vertical) C Example: Hydraulic hammer B Cylinder for hydr. boom adjustment (horizon- C Example: Sorting grapple tal)

2 General information Attachments and associated pressure-relief valves Pressure cut-off valve 104 (This valve limits the LS pressure) in control valve block 100 Secondary pressure relief valves 501/502 for regulating cylinder 525 / 545 extension and retraction (in the auxiliary axle 500) Stroke limitation of spool 500 Dimension Y of stop screw 500.1 Dimension Y of stop screw 500.2

Tab. 1


secondary

350 +10 bar 380 +20 bar

16.8 mm (from serial no. 14517 = 14.7 mm) 16.8 mm (from serial no. 14517 = 14.7 mm)

Technical data

Note! The settings for the valves of the AHS 12 accessory kit are documented in detail in group 16.56.

16.58.2

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Service Manual

Accessory kit AHS 12 with changeover valve Operation

3 Operation The accessory kit AHS 12 with changeover valve allows for the operation of working attachments (consumers) used for the vertical and horizontal adjustment of the boom as well as of other connected auxiliary attachments, by means of the auxiliary pilot control unit 86. The desired consumers and the required pressure and flow reduction can be preselected by means of switch S241. In addition, it is possible to preselect the direction of movement of the boom (up/down, left/right) by means of switch S356. Note! For a detailed description of the functions and operation of the AHS 12 kit, refer to group 16.56. To ensure proper use and functioning of the accessory kit AHS 12 with changeover valve, the connected units must be operated according to the instructions in this manual:

Fig. 2 86

Operator's cab with pilot control device, switch and indicator lamp for the accessory kit H196 Sorting grapple indicator lamp S241 Switch AHS12


S356 Switch/changeover valve Actuate switches S241 and S356 to preselect the desired attachment and activate it through the solenoid valve Y332. Operation of the boom regulating cylinder 252 (vertical): Set the switch S241 to position 0 (not actuated). The indicator lamp in the switch is off. The indicator lamp H196 is not on.

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16.58.3


Service Manual

Operation Set the switch S356 to position 0 (not actuated). The indicator lamp in the switch is off. Unreduced flow rate and maximum permissible pressure on the boom regulating cylinder (via spool 500). Press down the right pedal of the pilot control unit 86. The boom regulating cylinder is extended, i.e. the attachment is moved upwards. Press down the left pedal of the pilot control unit 86. The boom regulating cylinder is retracted, i.e. the attachment is moved down. Operation of the boom regulating cylinder 545 (horizontal): Set the switch S241 to position 0. The indicator in the switch is off. The indicator lamp H196 is not on. Switch S356 is actuated. The indicator lamp in the switch is off. Unreduced flow rate and maximum permissible pressure on the boom regulating cylinder (via spool 500). Press down the right pedal of the pilot control unit 86. The regulating cylinder (vertical) 545 is retracted, i.e. the boom is swivelled to the right. Press down the left pedal of the pilot control unit 86. The regulating cylinder (vertical) 545 is extended, i.e. the boom is swivelled to the left.

16.58.4

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Service Manual

Accessory kit AHS 12 with changeover valve Function

4 Function 4.1

Operation of the boom regulating cylinder 525 (horizontal): Set switch S241 to position 0 (not actuated). The indicator lamp in the switch is off. The indicator lamp H196 is not on. Set switch S356 to position 0 (not actuated). The indicator lamp in the switch is off. The solenoid valve Y332 is in neutral position.

4.1.1

Extending By pressing down the right pedal of the pilot control unit 86, the control oil is fed from connection 1 through the solenoid valve Y268 connection P1-A1 to the auxiliary control axle 500 connection b6. The spool 500 feeds high-pressure oil from the working pump 20 through connection B6 and the solenoid valve Y332 connection A2 - B2 and the load-holding valve 526 connection V2-C2 to the piston side of the regulating cylinder 525. The control oil is then fed through the T-piece at the connection b6 and the solenoid valve Y444 connection T-A to the load-holding valve 527 connection Pil. The valve 527 is opened, releasing return oil from the piston rod side of the cylinder 525 through connection C2-V2 of the valve 527, connection B1-A1 of the solenoid valve Y332, connection A6 of the control valve block 100 and the spool 500 to the tank. The cylinder is extended, moving the attachment upwards.

4.1.2

Retracting By pressing down the left pedal of the pilot control unit 86, the control oil is fed from connection 2 through the solenoid valve Y268 connection P2-B1 to the auxiliary control axle 500 connection a6. The spool 500 feeds high-pressure oil from the working pump 20 through connection A6 and the solenoid valve Y332 connection A1 - B1 and the load-holding valve 527 connection V2-C2 to the piston rod side of the regulating cylinder 525. The control oil is then fed through the T-piece at the connection a6 and the solenoid valve Y443 connection T-A to the load-holding valve 526 connection Pil. The valve 526 is opened, releasing return oil from the piston side of the cylinder 525 through connection C2-V2 of the valve 526, connection B2-A2 of the solenoid valve Y332, connection B6 of the control valve block 100 and the spool 500 to the tank. The cylinder is retracted, moving the attachment downwards.

4.2

Operation of the boom regulating cylinder 545 (horizontal): Set switch S241 to position 0 (not actuated). The indicator lamp in the switch is off. The indicator lamp H196 is not on. Set switch S356 to ON (active). The indicator lamp in the switch is on. The solenoid valve Y332 is in working position.

4.2.1

Extending By pressing down the left pedal of the pilot control unit 86, the control oil is fed from connection 2 through the solenoid valve Y268 connection P2-B1 to the auxiliary control axle 500 connection a6. The spool 500 feeds high-pressure oil from the working pump 20 through connection A6 and the solenoid valve Y332 connection A1 - C1 and the load-holding valve 546 connection V2-C2 to the piston side of the regulating cylinder 545. Control oil is fed through an internal line with restrictor to a stop valve in the load-holding valve 546 located at the piston rod side. The valve 546 is opened, releasing return oil from the piston rod side of the cylinder 545 through connection C1-V1 of the valve 546, connection C2-A2 of the solenoid valve Y332, connection B6 of the control valve block 100 and the spool 500 to the tank. The cylinder is

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MJF C I F S S

16.58.5


Service Manual

Function extended, moving the attachment to the left.

4.2.2

Retracting By pressing down the right pedal of the pilot control unit 86, the control oil is fed from connection 1 through the solenoid valve Y268 connection P1-A1 to the auxiliary control axle 500 connection b6. The spool 500 feeds high-pressure oil from the working pump 20 through connection B6 and the solenoid valve Y332 connection A2 - C2 and the double load-holding valve 546 connection V1-C1 to the piston side of the regulating cylinder 545. Control oil is fed through an internal line with restrictor to a stop valve in the load-holding valve 546 located at the piston side. The valve 546 is opened, releasing return oil from the piston side of the cylinder 545 through connection C2-V2 of the valve 546, connection C1-A1 of the solenoid valve Y332, connection A6 of the control valve block 100 and the spool 500 to the tank. The cylinder is retracted, moving the attachment to the right.

4.3

Stop function of solenoid valves Y443 and Y444 To prevent that the attachment is inadvertently extended or lowered, the solenoid valves Y443 and Y444 have been installed. They act as stop valves in the hydraulic circuit of the regulating cylinder 525. If the switch S356 is activated (indicator lamp in switch is on), the two solenoid valves Y443 and Y444 are switched from neutral to blocking position. The connections Pil of the load-holding valves 526 and 527 are thus opened through the valves Y443 and Y444 connection A-P to the tank. This prevents internal pressure build-up at the control piston of the load-holding valves 526 and 527.

16.58.6

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MJF C I F S S

Service Manual

Accessory kit AHS 12 with changeover valve Pressure check and adjustment

5 Pressure check and adjustment Note! For a detailed description of testing procedures and pressure adjustments, see AHS 12, group 16.56.

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MJF C I F S S

16.58.7


Service Manual

Components and hydraulic lines

6 Components and hydraulic lines 6.1

Boom regulating cylinder without stop valves (early machines of series)

Fig. 3

Hydraulic lines of the kit with changeover valve and without hydraulic stop valves

Key to diagrams on pages 16.62.08 and 16.62.09 546

16.58.8

1

Hydraulic tank

545

255

Stick cylinder 7

546

500


525

Regulating cylinder (vertical movement)

Y332 Solenoid valve / changeover valve

526 527

Load-holding valve (piston side) Load-holding valve (rod side)

Y443 Stop valve for cylinder retracting Y444 Stop valve for cylinder extending

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MJF C I F S S

Regulating cylinder (horizontal movement) Double load-holding valve

Service Manual

Accessory kit AHS 12 with changeover valve Components and hydraulic lines

6.2

Boom regulating cylinder with stop valve (later machines of series)

Fig. 4

Hydraulic lines of the kit with changeover valve and with hydraulic stop valves

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MJF C I F S S

16.58.9


Service Manual

Hydraulic system

7 Hydraulic system 1 20

from / to hydraulic tank Variable-displacement pump

514 517


23

Regulating valve

525

Regulating cylinder

41 45


526 527

Load-holding valve (piston side) Load-holding valve (rod side)

50


535

Hydraulic hammer

86

Pilot control unit 2x, with pedal

536

Pile driver

88P

Distributor

537

Cylinder (auxiliary device)

88T

Collecting pipe

538

Stop cock

100


545

Regulating cylinder (horizontal movement)

104 500

Pressure cut-off valve Spool / regulating cylinder

546


501

Secondary pressure-relief valve / retrac- S241 Switch / changeover regulating cylinder ting reg. cyl. 525 / extending reg. cyl. 545 hydraulic hammer Secondary pressure-relief valve / exten- S356 Switch / changeover of boom adjustment ding reg. cyl. 525 / retracting reg. cyl. 545 horizontal - vertical

502 504

Pressure balance

Y268 Solenoid valve / changeover regulating cylinder - hammer

507


510


Y299 Solenoid valve / secondary pressure hammer Y332 Solenoid valve / changeover valve

511

Secondary pressure-relief valve / extend hydraulic hammer cylinder 535 cylinder 537

512

Secondary pressure relief valve / cylinder Y444° Stop valve for cylinder extending 537 retracting

Y443° Stop valve for cylinder retracing

°

16.58.10

copyright by

MJF C I F S S

The valve is not built into all machines (subsequently added to machine equipment).

Service Manual

Accessory kit AHS 12 with changeover valve Hydraulic system

Fig. 5

Hydraulic diagram of the changeover valve kit

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MJF C I F S S

16.58.11


Service Manual

Electrical system

8 Electrical system

Step 66 / 78# Item F331** K455 S356 X29** X358-1 X358-2 X963** X983 X1226 Y332 Y443° Y444°

16.58.12

Description


Fuse kits Relay/changeover switch Switch/changeover valve Plug connection distribution board / 2-pin Plug connection / 2-pin Plug connection / 2-pin Plug connection distribution board / 21-pin Plug connection solenoid valves / 3-pin Plug connection A125 CS / 2-pin Solenoid valve / changeover valve Stop valve/ regulating cylinder extending Stop valve/ regulating cylinder retracting

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15.0 A

Right console, front Right control console Right control desk Right console, rear Below operator's platform Fuel tank Right console, rear Right console, rear Left console, bottom Basic boom Hydraulic tank Hydraulic tank

Service Manual

Accessory kit AHS 12 with changeover valve Electrical system

** in basic diagram # For other options of kit layout changeover valve, see group 8.45.

copyright by

MJF C I F S S

°

The item is not built into all machines (subsequently added to machine equipment).

16.58.13


Service Manual

Electrical kit step 66 / 78

9 Electrical kit step 66 / 78

Fig. 6

16.58.14

Electrical kit for changeover valve, see also step 66 / 78 in group 8.45, electrical kits.

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MJF C I F S S

Service Manual

Individual control Function

Individual control 1 Function On request, the machine can be equipped with individual control system for the 2-point or 4-point outrigger support. This allows for the separate control of each support leg, so that the machine can be brought into a horizontal position even on a slope or on uneven ground. The pressure in the individual support cylinders is thereby controlled by means of the "outrigger support" function.

Fig. 1

Hydraulic excavator with 4-point outrigger support

copyright by

MJF C I F S S

16.60.1

Individual control

Service Manual

Design

2 Design The kit for individual control consists of a number of operating elements, solenoid valves and hydraulic and electrical connections. The operator can select the respective individual control systems by means of switches S204 - S207. This switch is integrated into the right-hand control console in the operator's cab. The pilot control unit 85 with which the extension and retraction of the outrigger support is controlled is also installed in this console. The support cylinder 295 is controlled by means of the solenoid valves Y215 - Y218 located in the undercarriage. The electrical connections from the uppercarriage to the undercarriage are fed through the rotary connection 325. The rotary connection 325 is installed on the 6x rotary connection 322 with which all models are equipped. The two rotary connections 320 (high pressure) and 322 (low pressure) are connected to each other with screws and attached to a bracket mounted in the undercarriage. The junction box S272 is mounted in the undercarriage. From this point, all electrical lines of the system in the undercarriage are supplied. The support cylinder 295 with attached double lowering brake valves 297 are secured with bolts to the steel structure of the undercarriage.

Fig. 2

85

16.60.2

Pilot control unit and switch for individual outrigger control

Pilot control unit

S204

Individual control system switch

S205


S206


S207


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Service Manual

Individual control Design

Fig. 3

Rotary connections, slip ring connection and solenoid valves in the undercarriage

320

Rotary connection (high pressure)

Y215

Solenoid valve Individual control of front left outrigger

322

Rotary connection (low pressure)

Y216

Solenoid valve Individual control of front right outrigger

325


Y217

Solenoid valve Individual control of rear left outrigger Solenoid valve Individual control of rear right outrigger

Y218

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MJF C I F S S

16.60.3

Individual control

Service Manual


3 Functional description see Fig. 4 and see Fig. 5 When in neutral position, the solenoid valves Y215 - Y218 close the pressure connection B; as a result, the oil flow from the pump through the spool 280 and the rotating connection 320 to the support cylinders 295 is thus blocked. By pressing the respective switch S204 - S207, the desired outrigger foot can be selected. When pressed, the indicator light in the respective button S204 -S207 is on. The solenoid valves Y215- Y218 are powered through the switches S204 - S207 via the slip ring rotary connection 325. If the lever of the pilot control unit 85 located in the right control console is now moved forward or back, oil flows from the pump and the spool 280 through the connections 2/ 4 of the 7x rotary connection 320 and the solenoid valves Y215 - Y218 to the support cylinders 295 in the undercarriage. The solenoid valves that have not been actuated seal the other cylinders so that no oil is fed to them. The pressure generated in this process opens the flange-mounted double lowering brake valve 297. The respective support cylinder 295 is now retracted or extended. The return oil from the piston or rod side of the cylinder flows through the valve 297 back to the tank. The valve 297 seals the extending support cylinder against the spool 280.

100

16.60.4

S206

Switch / individual outrigger control, left

100

A1 from control valve block connection A1 B1 from control valve block B1

S207

Switch / individual outrigger control, right

295

Support cylinder

Y217

Solenoid valve Individual control of rear left outrigger

297

Double lowering brake valve

Y218

Solenoid valve Individual control of rear right outrigger

320


325


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MJF C I F S S

Service Manual

Individual control Functional description

Fig. 4

Hydraulic diagram of support option with 2-point support and individual control

copyright by

MJF C I F S S

16.60.5

Individual control

Service Manual


16.60.6

100

A1 from control valve block connection A1

S205

Switch / individual control of front right outrigger

100

B1 from control valve block B1

S206

295

Support cylinder

S207

Switch / individual control of rear left outrigger Switch / individual control of rear right outrigger

297


Y215

Solenoid valve Individual control of front left outrigger

320


Y216


325


Y217


S204

Switch / individual control of front left outrigger

Y218


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MJF C I F S S

Service Manual

Individual control Functional description

Fig. 5

Hydraulic diagram of support option with 4-point support and individual control

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MJF C I F S S

16.60.7

Individual control

Service Manual


Fig. 6

16.60.8

Electrical system of individual control

F337 S204

Fuse (15 A) (front control console) Individual control system switch

X771 X957


S205 S206

Individual control system switch Individual control system switch

X958 X963


S207


Y61

S272

Junction box

Y215

Solenoid valve / changeover (without function with individual control) Solenoid valve Individual control of front left outrigger

S335

Changeover switch Y216 (without function with individual control)

X301


Y217


X304


Y218


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MJF C I F S S


Service Manual

Individual control Electric diagram of individual control system

4 Electric diagram of individual control system

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MJF C I F S S

16.60.9

Individual control

Service Manual

Electric diagram of individual control system

16.60.10

copyright by

MJF C I F S S

Service Manual

Kit for control switch-over Function

Kit for control switch-over A 309 up to serial no. 23701 A 311 up to serial no. 23253

1 Function This kit allows the operator to control the auxiliary attachment with the foot pedal or with the joystick. To install the kit, a number of units, hydraulic lines and hoses required for the switch-over of the control are required. These parts are included in the switch-over of control kit.

Fig. 1

Pilot control units for bucket movement and kit

81 Pilot control unit for boom and bucket move- 86 Pilot control unit with pedals ment with joystick e

Tilt bucket inwards

f

Tilt bucket outwards

m Operate hydraulic hammer / close sorting grapple n Open sorting grapple

after switch-over:

after switch-over:

e

Operate hydraulic hammer / close sorting grapple

m Tilt bucket inwards

f

Open sorting grapple

n

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MJF C I F S S


16.62.1


Service Manual

Operation

2 Operation Caution! Always take into account that operating procedures might change after a switch-over. Ensure that all operating staff are familiar with the operating behaviour of the machine after switch-over and that the respective instructions are included in the manual. Attach a warning sign at a clearly visible location at the machine.

Fig. 2

81 86

Operator's cab with pilot control devices, switches and indicator lamps for the switch-over kit Pilot control unit with joystick Pilot control unit with pedals

H196 H322

Sorting grapple indicator lamp Indicator light / control switch-over

S241

Switch AHS12

S405

Key switch / control switch-over

Using the switch S241 and the key switch S405, preselect the operating method for the attachment and activate it by means of the solenoid valves Y268 and Y385-1 / Y385-2.

2.1

Operation of bucket cylinder 180 and boom regulating cylinder 525: Set switch S241 to position 0 (not actuated). The indicator lamp in the switch is off. The indicator lamp H196 is not on. Set the key switch S405 to position A or B (switch-over not possible) Unreduced flow rate and maximum permissible pressure on the boom regulating cylinder (via spool 105). Push the joystick of the pilot control unit 81 to the right. The bucket cylinder is retracted, i.e. the bucket is tilted outwards

16.62.2

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MJF C I F S S

Service Manual

Kit for control switch-over Operation Push the joystick of the pilot control unit 81 to the left. The bucket cylinder is extended, i.e. the bucket is tilted inwards Press down the right pedal of the pilot control unit 86. The boom regulating cylinder is extended, i.e. the attachment is moved upwards. Press down the left pedal of the pilot control unit 86. The boom regulating cylinder is retracted, i.e. the attachment is moved down.

2.2

Operation of bucket cylinder 180 and shears / sorting grapple 537 (standard): Set the switch S241 to position 1. The indicator lamp in the switch is off. The indicator lamp H196 is on. Set the key switch S405 to position A. The indicator lamp H196 is not on. Unreduced flow rate and maximum permissible pressure on the sorting grapple cylinder (via spool 510). Push the joystick of the pilot control unit 81 to the right. The bucket cylinder is retracted, i.e. the bucket is tilted outwards Push the joystick of the pilot control unit 81 to the left. The bucket cylinder is extended, i.e. the bucket is tilted inwards Press down the right pedal of the pilot control unit 86. The cylinder of the sorting grapple / shears is extended (sorting grapple / shears closed) Press down the left pedal of the pilot control unit 86. The cylinder of the sorting grapple / shears is retracted (sorting grapple / shears opened)

2.3

Operation of bucket cylinder 180 and shears / sorting grapple 537 (after switch-over): Set the switch S241 to position 1. The indicator light at the switch is not on (as shown in section 2.2) The indicator lamp H196 is on. Set the key switch S405 to position B The indicator lamp H322 is on. Unreduced flow rate and maximum permissible pressure on the sorting grapple cylinder (via spool 510). Push the joystick of the pilot control unit 81 to the right. The cylinder of the sorting grapple / shears is retracted (sorting grapple / shears opened) Push the joystick of the pilot control unit 81 to the left. The cylinder of the sorting grapple / shears is extended (sorting grapple / shears closed) Press down the right pedal of the pilot control unit 86. The bucket cylinder is extended, i.e. the bucket is tilted inwards Press down the left pedal of the pilot control unit 86. The bucket cylinder is retracted, i.e. the bucket is tilted outwards

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MJF C I F S S

16.62.3


Service Manual

Operation

2.4

Operation of bucket cylinder 180 and hydraulic hammer 535 (standard): Set the switch S241 to position 2. The LED in the switch is on. The indicator light H196 at the switch is not on (as shown in section 2.5) Set the key switch S405 to position A The indicator lamp H196 is not on. Reduced flow rate and lower pressure on the hydraulic hammer (via spool 510). Push the joystick of the pilot control unit 81 to the right. The bucket cylinder is retracted, i.e. the bucket is tilted outwards Push the joystick of the pilot control unit 81 to the left. The bucket cylinder is extended, i.e. the bucket is tilted inwards Press down the right pedal of the pilot control unit 86. The hydraulic hammer is pressurised. Press down the left pedal of the pilot control unit 86. no function assigned

2.5

Operation of bucket cylinder 180 and hydraulic hammer 535 (after switchover): Set the switch S241 to position 2. The LED in the switch is on. The indicator lamp H196 is not on. Set the key switch S405 to position B The indicator lamp H322 is on. Reduced flow rate and lower pressure on the hydraulic hammer (via spool 510). Push the joystick of the pilot control unit 81 to the right. The hydraulic hammer is pressurised. Push the joystick of the pilot control unit 81 to the left. no function assigned Press down the right pedal of the pilot control unit 86. The bucket cylinder is extended, i.e. the bucket is tilted inwards Press down the left pedal of the pilot control unit 86. The bucket cylinder is retracted, i.e. the bucket is tilted outwards

16.62.4

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MJF C I F S S

Service Manual

Kit for control switch-over Function of switch-over / control

3 Function of switch-over / control Note! For the regular functions of the accessory kit AHS 12 that can be activated with switch S241, please refer to group 16.54.

3.1

Operation of sorting grapple / shears and hydraulic hammer with pilot control unit 86 (pedals) Operation of bucket cylinder with pilot control unit 81 (joystick) Set the switch S241 to position 1. The solenoid valve Y268 is in working position. Set the key switch S405 to position A. The solenoid valves Y385-1 / Y385-2 are in neutral position. The solenoid valve Y262 is in neutral position.

3.1.1

Extending/ pressurising hammer When the right pedal of the pilot control unit 86 is pressed down, control oil is fed from connection 1 through the solenoid valve Y268 connection P1-A2 and through the solenoid valve Y385-1 connection 3-4 to the auxiliary control axle 510 connection a9. The spool 510 feeds high-pressure oil from the working pump 20 through the connection A9 to the hydraulic hammer 535 or the piston side of the cylinder 537 respectively. The hydraulic hammer / the cylinder is extended, moving the attachment. When the joystick of the pilot control unit 81 is pushed to the left, control oil is fed from connection 4 through the solenoid valve Y262 connection P2-B1 and through the solenoid valve Y385-1 connection 2-1 to the control valve block 100 connection a7. The spool 107 feeds high-pressure oil from the working pump 20 through the connection A7 to the piston side of the bucket cylinder 180. The cylinder is extended; the bucket is tilted inwards.

3.1.2

Retracting When the left pedal of the pilot control unit 86 is pressed down, control oil from connection 2 is fed through the solenoid valve Y268 connection P2-B2, the solenoid valve Y299 connection P2-B2 and the solenoid valve Y385-2 connection 3-4 to the auxiliary control axle 510 connection b9. The spool 510 feeds high-pressure oil from the working pump 20 through the connection B9 to the rod side of the cylinder 537. The cylinder is retracted, moving the attachment. When the joystick of the pilot control unit 81 is pushed to the left, control oil is fed from connection 2 through the solenoid valve Y262 connection P1-A1 and through the solenoid valve Y385-2 connection 2-1 to the control valve block 100 connection b7. The spool 107 feeds high-pressure oil from the working pump 20 through the connection B7 to the rod side of the bucket cylinder 180. The cylinder is retracted; the bucket is tilted outwards.

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MJF C I F S S

16.62.5


Service Manual

Function of switch-over / control

3.2

Operation of sorting grapple / shears and hydraulic hammer with pilot control device 81 (joystick) Operation of bucket cylinder with pilot control unit 86 (pedals) Set the switch S241 to position 1. The solenoid valve Y268 is in working position. Set the key switch S405 to position B. The solenoid valves Y385-1 / Y385-2 are in working position. The solenoid valve Y262 is in neutral position.

3.2.1

Extending/ pressurising hammer When the joystick of the pilot control unit 81 is pushed to the left, control oil is fed from connection 4 through the solenoid valve Y262 connection P2-B1 and through the solenoid valve Y385-1 connection 2-4 to the auxiliary control axle 510 connection a9. The spool 510 feeds high-pressure oil from the working pump 20 through the connection A9 to the hydraulic hammer 535 or the piston side of the cylinder 537 respectively. The hydraulic hammer 535 / the cylinder 537 is extended, moving the attachment. When the right pedal of the pilot control unit 86 is pressed down, control oil is fed from connection 1 through the solenoid valve Y268 connection P1-A2 and through the solenoid valve Y385-1 connection 3-1 to the auxiliary control axle 100 connection a9. The spool 107 feeds high-pressure oil from the working pump 20 through eh connection A7 to the piston side of the bucket cylinder 180. The cylinder is extended; the bucket is tilted inwards.

3.2.2

Retracting When the joystick of the pilot control unit 81 is pushed to the right, control oil is fed from connection 2 through the solenoid valve Y262 connection P1-A1 and through the solenoid valve Y385-2 connection 2-4 to the auxiliary control axle 510 connection b9. The spool 510 feeds high-pressure oil from the working pump 20 through the connection B9 to the rod side of the cylinder 537. The cylinder is retracted, moving the attachment. When the left pedal of the pilot control unit 86 is pressed down, control oil from connection 2 is fed through the solenoid valve Y268 connection P2-B2, the solenoid valve Y299 connection P2-B2 and the solenoid valve Y385-2 connection 3-1 to the control valve block 100 connection b7. The spool 107 feeds high-pressure oil from the working pump 20 through the connection B7 to the rod side of the bucket cylinder 180. The cylinder is retracted; the bucket is tilted outwards.

3.3

Pressure reduction at auxiliary control valve block, and combined shifting when boom is lowered Set the switch S241 to position 2. The solenoid valve Y268 is in working position. The solenoid valve Y299 is in working position. When the switch S241 is in this position, the control oil line from the control oil unit 50 / P1 to the pressure boost cartridge of the valve 511 and through the solenoid valve Y299 connection B1/A2 is blocked, and the line from the valve 511 through the solenoid valve Y299 connection A2-T to the tank is relieved. As a result, the pressure for the hydraulic hammer is reduced. When the switch S241 is in position 2, the control oil line from the control line to the connection b6 (function "lower boom") through the solenoid valve Y299 connection A1/P1, the shuttle valve 78 and the line to the control valve block 100 connection b4 is established. The spool 109 is moved, allowing for the combined shifting of booms. In this case, the control oil line from the pilot control unit 86 connection 2 through the solenoid valve Y268 connection P2-B2, the solenoid valve Y299 connection P2-B2 and the solenoid valve Y385-2

16.62.6

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MJF C I F S S

Service Manual

Kit for control switch-over Pressure check and adjustment

connection 3-1 to the control valve block 100 connection b7 is blocked. This has a negative effect on the control of the machine (S405 in position B), as the bucket cylinder can now only be extended but not retracted.

4 Pressure check and adjustment Note! For a description of the valve and stroke limiter settings in auxiliary axle AHS 12, refer to group 16.54.

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MJF C I F S S

16.62.7


Service Manual

Components and hydraulic lines A 309 up to serial no. 23701 and A 311 up to serial no. 23253

5 Components and hydraulic lines A 309 up to serial no. 23701 and A 311 up to serial no. 23253

Fig. 3

16.62.8

Hydraulic connections of control switch-over kit

1

Hydraulic tank

B33

Pressure switch flow reduction

50 78

Control oil unit Shuttle valve / combined shifting

Y22 Y23

Solenoid valve / grapple rotator left Solenoid valve / grapple rotator left

79

Shuttle valve / pressure switch

Y62


81

Pilot control unit with joystick

Y63

Solenoid valve / travel reverse

86

Pilot control unit with pedals

Y262

Solenoid valve / switch-over bucket offset boom bearing

100


Y268

Solenoid valve / changeover regulating cylinder - hammer

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Service Manual

Kit for control switch-over Components and hydraulic lines A 309 up to serial no. 23701 and A 311 up to serial no. 23253

105


106

Boom cylinder spool

107


109


510


511

Secondary pressure relief valve with additional pressure stage / retract hydr. hammer cyl.

Fig. 4

Y299

Solenoid valve / secondary pressure hammer Y385-1 Solenoid valve changeover bucket cyl. AHS Y385-2 Solenoid valve changeover bucket cyl. AHS


copyright by

MJF C I F S S

16.62.9


Service Manual

Hydraulic diagram of the kit

6 Hydraulic diagram of the kit 546

1

to hydraulic tank

510

Spool / hydraulic hammer / cylinder

20

from double variable-displacement pump

511

Secondary pressure-relief valve / extend hydraulic hammer 535 cylinder 537

40

Measuring point P1

512


50


535

Hydraulic hammer

78


537

Cylinder (auxiliary activation, e.g. sorting grapple)

79

Shuttle valve / pressure switch B33

81

Pilot control unit 4x, with joystick

B33


86 88P

Pilot control unit 2x, with pedals Distributor

S63 S241

Switch / offset boom bearing Switch / changeover regulating cylinder - hydraulic hammer

88T

Collecting pipe

S263


100 105

Compact control block Regulating cylinder spool

S405 Y62

Key switch / control switch-over Solenoid valve / travel forward

106 107

Boom cylinder spool Bucket cylinder spool

Y63 Y262

Solenoid valve / travel reverse Solenoid valve / switch-over bucket offset boom bearing

109


Y268


122


Y299

180

Bucket cylinder

250

Regulating cylinder

251


*

16.62.10

Solenoid valve / secondary pressure hammer Y385-1 Solenoid valve / changeover bucket cyl. - AHS Y385-2 Solenoid valve / changeover bucket cyl. - AHS


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MJF C I F S S

Service Manual

Kit for control switch-over Hydraulic diagram of the kit

copyright by

MJF C I F S S

16.62.11


Service Manual

Electrical system

7 Electrical system B33



H322

Warning light / switch-over


S405

Switch / changeover

Right console

X12** X29** X957** X1029 X1224

Plug connection distribution board / 2-pin Plug connection distribution board / 2-pin Plug connection distribution board / 21-pin Plug connection solenoid valves / 4-pin Plug connection to B33 / 3-pin

Right console Right console, rear Right console, rear Right control console, rear Distribution board

Y385-1 Y385-2

Solenoid valve / changeover bucket cylinder- AHS Solenoid valve / changeover bucket cylinder - AHS

Near fuel tank Near fuel tank

** position from basic diagram

16.62.12

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MJF C I F S S

Service Manual

Kit for control switch-over Electrical system

Fig. 5

Electrical system of switch-over control kit

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MJF C I F S S

16.62.13


Service Manual

Electrical system Step 84/2# Item

Description


A125**

PCB potentiometers

Left console

B33



F321** F330** F331**

Fuse X12 Fuse kits Fuse X29

H322



K375**


Right console, rear

S241** S405


Right control desk Right console

U16**


Right console, rear

V156-4

Blocking diode A125

A125


Plug connection on distribution board / 2-pin Plug connection distribution board / 2-pin Plug connection A125 / 8-pin Plug connection / screw terminal on A125 / 3-pin Plug connection BST wire harness / 40-pin Plug connection BST excavator control / 24-pin Plug connection distribution board / 21-pin Plug connection distribution board / 21-pin Plug connection distribution board / 2-pin Plug connection BST- CS A125 / 21-pin Plug connection A125 wire harness / 21-pin Plug connection A125 CS / 1-pin Plug connection A125 CS / 1-pin Plug connection A125 CS / 2-pin Plug connection to S405 and H322 / 4-pin Plug connection solenoid valves / 4-pin Plug connection pressure switch / 3-pin


Y268** Y299** Y385-1 Y385-2

to solenoid valve / grapple hammer to solenoid valve secondary pressure hammer Solenoid valve / changeover bucket cylinder - AHS Solenoid valve / changeover bucket cylinder - AHS

Near hydraulic tank Near hydraulic tank Behind cab Behind cab

15.0 A 15.0 A 15.0 A

** position from basic diagram # see also electric kits in group 8.45

16.62.14

copyright by

MJF C I F S S


Service Manual


copyright by

MJF C I F S S

16.62.15


Service Manual

Electrical system

16.62.16

copyright by

MJF C I F S S

Service Manual


Kit for control switch-over A 309 from serial no. 23702 A 311 from serial no. 23254

8 Function This kit allows the operator to control the auxiliary attachment with the foot pedal or with the joystick. To install the kit, a number of units, hydraulic lines and hoses required for the switch-over of the control are required. These parts are included in the switch-over of control kit.

Fig. 6



Tilt bucket inwards

f



after switch-over:

after switch-over:

e

Operate hydraulic hammer / close sorting grapple

m Tilt bucket inwards

f


n

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MJF C I F S S


16.62.21


Service Manual

Operation


Fig. 7

Operator's cab with pilot control devices, switches and indicator lamps for the switch-over kit

81


H196

Sorting grapple indicator lamp

86


H322

Indicator light / control switch-over

S241 S405

Switch AHS12 Key switch / control switch-over


9.1

Operation of bucket cylinder 180 and boom regulating cylinder 525: Set switch S241 to position 0 (not actuated). The indicator lamp in the switch is off. The indicator lamp H196 is not on. Set the key switch S405 to position A or B (switch-over not possible) Unreduced flow rate and maximum permissible pressure on the boom regulating cylinder (via spool 105). Push the joystick of the pilot control unit 81 to the right.

16.62.22

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MJF C I F S S

Service Manual

Kit for control switch-over Operation The bucket cylinder is retracted, i.e. the bucket is tilted outwards Push the joystick of the pilot control unit 81 to the left. The bucket cylinder is extended, i.e. the bucket is tilted inwards Press down the right pedal of the pilot control unit 86. The boom regulating cylinder is extended, i.e. the attachment is moved upwards. Press down the left pedal of the pilot control unit 86. The boom regulating cylinder is retracted, i.e. the attachment is moved down.

9.2


9.3

Operation of bucket cylinder 180 and shears / sorting grapple 537 (after switch-over): Set the switch S241 to position 1. The indicator light in the switch is not on (as shown in section 9.2) The indicator lamp H196 is on. Set the key switch S405 to position B The indicator lamp H322 is on. Unreduced flow rate and maximum permissible pressure on the sorting grapple cylinder (via spool 510). Push the joystick of the pilot control unit 81 to the right. The cylinder of the sorting grapple / shears is retracted (sorting grapple / shears opened) Push the joystick of the pilot control unit 81 to the left. The cylinder of the sorting grapple / shears is extended (sorting grapple / shears closed) Press down the right pedal of the pilot control unit 86. The bucket cylinder is extended, i.e. the bucket is tilted inwards Press down the left pedal of the pilot control unit 86. The bucket cylinder is retracted, i.e. the bucket is tilted outwards

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MJF C I F S S

16.62.23


Service Manual

Operation

9.4

Operation of bucket cylinder 180 and hydraulic hammer 535 (standard): Set the switch S241 to position 2. The LED in the switch is on. The indicator light H196 is not on (as shown in section 9.5) Set the key switch S405 to position A The indicator lamp H196 is not on. Reduced flow rate and lower pressure on the hydraulic hammer (via spool 510). Push the joystick of the pilot control unit 81 to the right. The bucket cylinder is retracted, i.e. the bucket is tilted outwards Push the joystick of the pilot control unit 81 to the left. The bucket cylinder is extended, i.e. the bucket is tilted inwards Press down the right pedal of the pilot control unit 86. The hydraulic hammer is pressurised. Press down the left pedal of the pilot control unit 86. no function assigned

9.5


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Service Manual


10 Function of switch-over / control Note! For the regularly functions of the accessory kit AHS 12 that can be activated with switch S241, please refer to group 16.54.

10.1

Operation of sorting grapple / shears and hydraulic hammer with pilot control unit 86 (pedals) Operation of bucket cylinder with pilot control unit 81 (joystick) Set the switch S241 to position 1. The solenoid valve Y268 is in working position. Set the key switch S405 to position A. The solenoid valves Y385-1 / Y385-2 are in neutral position. The solenoid valve Y262 is in neutral position.

10.1.1

Extending/ pressurising hammer When the right pedal of the pilot control unit 86 is pressed down, control oil is fed from connection 1 through the solenoid valve Y268 connection P1-A2 and through the solenoid valve Y385-1 connection 3-4 to the auxiliary control axle 510 connection a9. The spool 510 feeds high-pressure oil from the working pump 20 through the connection A9 to the hydraulic hammer 535 or the piston side of the cylinder 537 respectively. The hydraulic hammer / the cylinder is extended, moving the attachment. When the joystick of the pilot control unit 81 is pushed to the left, control oil is fed from connection 4 through the solenoid valve Y262 connection P2-B1 and through the solenoid valve Y385-1 connection 2-1 to the control valve block 100 connection a7. The spool 107 feeds high-pressure oil from the working pump 20 through the connection A7 to the piston side of the bucket cylinder 180. The cylinder is extended; the bucket is tilted inwards.

10.1.2

Retracting When the left pedal of the pilot control unit 86 is pressed down, control oil from connection 2 is fed through the solenoid valve Y268 connection P2-B2, the solenoid valve Y299 connection P2-B2 and the solenoid valve Y385-2 connection 3-4 to the auxiliary control axle 510 connection b9. The spool 510 feeds high-pressure oil from the working pump 20 through the connection B9 to the rod side of the cylinder 537. The cylinder is retracted, moving the attachment. When the joystick of the pilot control unit 81 is pushed to the left, control oil is fed from connection 2 through the solenoid valve Y262 connection P1-A1 and through the solenoid valve Y385-2 connection 2-1 to the control valve block 100 connection b7. The spool 107 feeds high-pressure oil from the working pump 20 through the connection B7 to the rod side of the bucket cylinder 180. The cylinder is retracted; the bucket is tilted outwards.

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MJF C I F S S

16.62.25


Service Manual

Function of switch-over / control

10.2

Operation of sorting grapple / shears and hydraulic hammer with pilot control device 81 (joystick) Operation of bucket cylinder with pilot control unit 86 (pedals) Set the switch S241 to position 1 or 2. The solenoid valve Y268 is in working position. Set the key switch S405 to position B. The solenoid valves Y385-1 / Y385-2 are in working position. The solenoid valve Y262 is in neutral position.

10.2.1

Extending / pressurising hammer When the joystick of the pilot control unit 81 is pushed to the left, control oil is fed from connection 4 through the solenoid valve Y262 connection P2-B1 and through the solenoid valve Y385-1 connection 2-4 to the auxiliary control axle 510 connection a9. The spool 510 feeds high-pressure oil from the working pump 20 through the connection A9 to the hydraulic hammer 535 or the piston side of the cylinder 537 respectively. The hydraulic hammer 535 / the cylinder 537 is extended, moving the attachment. When the right pedal of the pilot control unit 86 is pressed down, control oil is fed from connection 1 through the solenoid valve Y268 connection P1-A2 and through the solenoid valve Y385-1 connection 3-1 to the auxiliary control axle 100 connection a9. The spool 107 feeds high-pressure oil from the working pump 20 through the connection A7 to the piston side of the bucket cylinder 180. The cylinder is extended; the bucket is tilted inwards.

10.2.2

Retracting When the joystick of the pilot control unit 81 is pushed to the right, control oil is fed from connection 2 through the solenoid valve Y262 connection P1-A1 and through the solenoid valve Y385-2 connection 2-4 to the auxiliary control axle 510 connection b9. The spool 510 feeds high-pressure oil from the working pump 20 through the connection B9 to the rod side of the cylinder 537. The cylinder is retracted, moving the attachment. When the left pedal of the pilot control unit 86 is pressed down, control oil from connection 2 is fed through the solenoid valve Y268 connection P2-B2, the solenoid valve Y299 connection P2-B2 and the solenoid valve Y385-2 connection 3-1 to the control valve block 100 connection b7. The spool 107 feeds high-pressure oil from the working pump 20 through the connection B7 to the rod side of the bucket cylinder 180. The cylinder is retracted; the bucket is tilted outwards.

10.3

Pressure reduction at auxiliary control valve block, and combined shifting when boom is lowered Set the switch S241 to position 2. The solenoid valve Y268 is in working position. The solenoid valve Y299 is in working position. The solenoid valve Y457 is in working position. When the switch S241 is in this position, the control oil line from the control oil unit 50 / P1 to the pressure boost cartridge of the valve 511 and through the solenoid valve Y299 connection B1/A2 is blocked, and the line from the valve 511 through the solenoid valve Y299 connection A2-T to the tank is relieved. As a result, the pressure for the hydraulic hammer is reduced. When the switch S241 is in position 2, the control oil line from the control line to the connection b6 (function "lower boom") through the solenoid valve Y299 connection A1/P1, the shuttle valve 78 and the line to the control valve block 100 connection b4 is established. The spool 109 is moved, allowing for the combined shifting of booms.

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MJF C I F S S

Service Manual

Kit for control switch-over Pressure check and adjustment


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MJF C I F S S

16.62.27


Service Manual

Components and hydraulic lines A 309 from serial no. 23702 and A 311 from serial no. 23254

12

Components and hydraulic lines A 309 from serial no. 23702 and A 311 from serial no. 23254

Fig. 8

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MJF C I F S S

Service Manual

Kit for control switch-over Components and hydraulic lines A 309 from serial no. 23702 and A 311 from serial no. 23254

1

Hydraulic tank

B33


50 78

Control oil unit Shuttle valve / combined shifting

Y22 Y23

Solenoid valve / grapple rotator left Solenoid valve / grapple rotator left

79

Shuttle valve / pressure switch

Y62


81


Y63


86


Y262


100


Y268


105


Y299

Solenoid valve / secondary pressure hammer

106

Boom cylinder spool

Y385-1 Solenoid valve changeover bucket cyl. AHS

107


109


Y385-2 Solenoid valve changeover bucket cyl. AHS Y451 Solenoid valve switch-over buzzer / boom

510 511

Hydraulic hammer/cylinder spool Secondary pressure relief valve with additional pressure stage / retract hydr. hammer cyl.

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Service Manual

Hydraulic system Fig. 9

13


Hydraulic system 546

1

to hydraulic tank

510

Spool / hydraulic hammer / cylinder

20

from double variable-displacement pump

511

Secondary pressure-relief valve / extend hydraulic hammer 535 cylinder 537

40

Measuring point P1

512


50


535

Hydraulic hammer

78


537


79

Shuttle valve / pressure switch B33

81 86

Pilot control unit 4x, with joystick Pilot control unit 2x, with pedals

B33 S63

Pressure switch flow reduction Switch / offset boom bearing

88P

Distributor

S241

Switch / changeover regulating cylinder - hydraulic hammer

88T 100


S263 S405

Switch / travel direction Key switch / control switch-over

105 106


Y62 Y63

Solenoid valve / travel forward Solenoid valve / travel reverse

107


Y262


109


Y268

122


Y299

Solenoid valve / changeover regulating cylinder - hammer Solenoid valve / secondary pressure hammer

180

Bucket cylinder

Y385-1 Solenoid valve / changeover bucket cyl. - AHS

250

Regulating cylinder

251


Y385-2 Solenoid valve / changeover bucket cyl. - AHS Y451 Solenoid valve switch-over buzzer / boom

*

16.62.30


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Service Manual

Kit for control switch-over Hydraulic system

copyright by

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16.62.31


Service Manual

Electrical system

14

Electrical system B33



H322



K375**

Relay / signal flow reduction kit AHS

Right console, rear

S405

Switch / changeover

Right console

X12** X29** X952**

Right console Right console, rear Right console, rear

X957** X1029 X1224

Plug connection distribution board / 2-pin Plug connection distribution board / 2-pin Plug connection revolving deck BST excavator control / 21-pin Plug connection distribution board / 21-pin Plug connection solenoid valves / 4-pin Plug connection to B33 / 3-pin

Right console, rear Right control console, rear Distribution board

Y268 Y299 Y385-1 Y385-2 Y451

Solenoid valve / changeover adjustable boom - hammer Solenoid valve / additional pressure stage Solenoid valve / changeover bucket cylinder - AHS Solenoid valve / changeover bucket cylinder - AHS Solenoid valve switch-over buzzer / lower boom

Near control valve block Near control valve block Near fuel tank Near fuel tank Near control valve block


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MJF C I F S S

Service Manual


Fig. 10


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MJF C I F S S

16.62.33


Service Manual


Description


A125**

PCB potentiometers

Left console

B33



F321** F330** F331**

Fuse X12 Fuse kits Fuse X29

H196** H322

Indicator light / sorting grapple Warning light / switch-over


K375**


Right console, rear

S19/5** S241** S405

to switch AS1 Switch AHS 11 / AHS 12 Switch / changeover

Right control desk Right control desk Right console

U16** V156-4

BST excavator control system Blocking diode A125

Right console, rear A125


Plug connection on distribution board / 2-pin Plug connection distribution board / 2-pin Plug connection A125 / 8-pin Plug connection / screw terminal on A125 / 3-pin Plug connection BST wire harness / 40-pin Plug connection BST excavator control / 24-pin Plug connection distribution board / 21-pin Plug connection distribution board / 21-pin Plug connection distribution board / 2-pin Plug connection BST- CS A125 / 21-pin Plug connection A125 wire harness / 21-pin Plug connection A125 CS / 1-pin Plug connection A125 CS / 1-pin Plug connection A125 CS / 2-pin Plug connection to S405 and H322 / 4-pin Plug connection solenoid valves / 4-pin Plug connection pressure switch / 3-pin


Y268** Y299** Y385-1 Y385-2 Y451

to solenoid valve / grapple hammer to solenoid valve / pressure reduction Solenoid valve / changeover bucket cylinder - AHS Solenoid valve / changeover bucket cylinder - AHS Solenoid valve switch-over buzzer / boom

Near control valve block Near control valve block at fuel tank at fuel tank Near control valve block

15.0 A 15.0 A 15.0 A


16.62.34

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MJF C I F S S


Service Manual


copyright by

MJF C I F S S

16.62.35


Service Manual

Electrical system

16.62.36

copyright by

MJF C I F S S

Service Manual


Kit for control switch-over 1 Function This kit allows the operator to control the auxiliary attachment with the foot pedal or with the joystick. To install the kit, a number of units, hydraulic lines and hoses required for the switch-over of the control are required. These parts are included in the switch-over of control kit.

Fig. 1



Tilt bucket inwards

f



after switch-over: e Operate hydraulic hammer / close sorting grapple

after switch-over: m Tilt bucket inwards

f

n



copyright by

MJF C I F S S


16.64.1


Service Manual

Operation


Fig. 2

81 86

Operator's cab with pilot control devices, switches and indicator lamps for the switch-over kit Pilot control unit with joystick Pilot control unit with pedals

H196 H322

Sorting grapple indicator lamp Indicator light / control switch-over

S241

Switch AHS12

S405

Key switch / control switch-over


2.1

Operation of bucket cylinder 180 and boom regulating cylinder 525: Set switch S241 to position 0 (not actuated). The indicator lamp in the switch is off. The indicator lamp H196 is not on. Set the key switch S405 to position A or B (switch-over not possible) Unreduced flow rate and maximum permissible pressure on the boom regulating cylinder (via spool 500). Push the joystick of the pilot control unit 81 to the right. The bucket cylinder is retracted, i.e. the bucket is tilted outwards

16.64.2

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MJF C I F S S


Service Manual

Kit for control switch-over Operation Push the joystick of the pilot control unit 81 to the left. The bucket cylinder is extended, i.e. the bucket is tilted inwards Press down the right pedal of the pilot control unit 86. The boom regulating cylinder is extended, i.e. the attachment is moved upwards. Press down the left pedal of the pilot control unit 86. The boom regulating cylinder is retracted, i.e. the attachment is moved down.

2.2


2.3

Operation of bucket cylinder 275 and shears / sorting grapple 537 (after switch-over): Set the switch S241 to position 1. The indicator light in the switch is not on (as shown in section 2.2) The indicator lamp H196 is on. Set the key switch S405 to position B The indicator lamp H322 is on. Unreduced flow rate and maximum permissible pressure on the sorting grapple cylinder (via spool 510). Push the joystick of the pilot control unit 81 to the right. The cylinder of the sorting grapple / shears is retracted (sorting grapple / shears opened) Push the joystick of the pilot control unit 81 to the left. The cylinder of the sorting grapple / shears is extended (sorting grapple / shears closed) Press down the right pedal of the pilot control unit 86. The bucket cylinder is extended, i.e. the bucket is tilted inwards Press down the left pedal of the pilot control unit 86. The bucket cylinder is retracted, i.e. the bucket is tilted outwards


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MJF C I F S S

16.64.3


Service Manual

Operation

2.4

Operation of bucket cylinder 275 and hydraulic hammer 535 (standard): Set the switch S241 to position 2. The LED in the switch is on. The indicator light H196 is not on (as shown in section 2.5) Set the key switch S405 to position A The indicator lamp H196 is not on. Reduced flow rate and lower pressure on the hydraulic hammer (via spool 510). Push the joystick of the pilot control unit 81 to the right. The bucket cylinder is retracted, i.e. the bucket is tilted outwards Push the joystick of the pilot control unit 81 to the left. The bucket cylinder is extended, i.e. the bucket is tilted inwards Press down the right pedal of the pilot control unit 86. The hydraulic hammer is pressurised. Press down the left pedal of the pilot control unit 86. no function assigned

2.5


16.64.4

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MJF C I F S S


Service Manual


3 Function of switch-over / control Note! For the regular functions of the accessory kit AHS 12 that can be activated with switch S241, please refer to group 16.56.

3.1

Operation of sorting grapple / shears and hydraulic hammer with pilot control unit 86 (pedals) Operation of bucket cylinder with pilot control unit 81 (joystick) Set the switch S241 to position 1. The solenoid valve Y268 is in working position. Set the key switch S405 to position A. The solenoid valves Y385-1 / Y385-2 are in neutral position.

3.1.1

Extending/ pressurising hammer When the right pedal of the pilot control unit 86 is pressed down, control oil is fed from connection 1 through the solenoid valve Y268 connection P1-A2 and through the solenoid valve Y385-1 connection 3-4 to the auxiliary control axle 510 connection a7. The spool 510 feeds high-pressure oil from the working pump 20 through the connection A7 to the hydraulic hammer 535 or the piston side of the cylinder 537 respectively. The hydraulic hammer / the cylinder is extended, moving the attachment. When the joystick of the pilot control unit 81 is pushed to the left, control oil is fed from connection 4 through the solenoid valve Y385-2 connection 2-1 to the control valve block 100 connection b4. The spool 260 feeds high-pressure oil from the working pump 20 through the connection B4 to the piston side of the bucket cylinder 275. The cylinder is extended; the bucket is tilted inwards.

3.1.2

Retracting When the left pedal of the pilot control unit 86 is pressed down, control oil is fed from connection 2 through the solenoid valve Y268 connection P2-B2 and through the solenoid valve Y385-2 connection 3-4 to the auxiliary control axle 510 connection b7. The spool 510 feeds high-pressure oil from the working pump 20 through the connection B7 to the rod side of the cylinder 537 or the pile driver 537 respectively. The cylinder is retracted, moving the attachment, or operating the pile driver. When the joystick of the pilot control unit 81 is pushed to the left, control oil is fed from connection 2 through the solenoid valve Y385-1 connection 2-1 to the control valve block 100 connection a4. The spool 260 feeds high-pressure oil from the working pump 20 through the connection A4 to the rod side of the bucket cylinder 275. The cylinder is retracted; the bucket is tilted outwards.


copyright by

MJF C I F S S

16.64.5


Service Manual


3.2

Operation of sorting grapple / shears and hydraulic hammer with pilot control device 81 (joystick) Operation of bucket cylinder with pilot control unit 86 (pedals) Set the switch S241 to position 1. The solenoid valve Y268 is in working position. Set the key switch S405 to position B. The solenoid valves Y385-1 / Y385-2 are in working position.

3.2.1

Extending/ pressurising hammer When the joystick of the pilot control unit 81 is pushed to the left, control oil is fed from connection 2 through the solenoid valve Y385-1 connection 2-4 to the auxiliary control axle 510 connection a7. The spool 510 feeds high-pressure oil from the working pump 20 through the connection A7 to the hydraulic hammer 535 or the piston side of the cylinder 537 respectively. The hydraulic hammer 535 / the cylinder 537 is extended, moving the attachment. When the right pedal of the pilot control unit 86 is pressed down, control oil is fed from connection 1 through the solenoid valve Y268 connection P1-A2 and through the solenoid valve Y385-1 connection 3-1 to the control valve block 100 connection a4. The spool 260 feeds high-pressure oil from the working pump 20 through the connection A4 to the piston side of the bucket cylinder 275. The cylinder is extended; the bucket is tilted inwards.

3.2.2

Retraction of attachment/pressurisation of pile driver When the joystick of the pilot control unit 81 is pushed to the right, control oil is fed from connection 4 through the solenoid valve Y385-2 connection 2-4 to the auxiliary control axle 510 connection b7. The spool 510 feeds high-pressure oil from the working pump 20 through the connection B7 to the rod side of the cylinder 537. The cylinder is retracted, moving the attachment, or operating the pile driver. When the left pedal of the pilot control unit 86 is pressed down, control oil from connection 2 is fed through the solenoid valve Y268 connection P2-B2, the solenoid valve Y299 connection P2-B2 and the solenoid valve Y385-2 connection 3-1 to the control valve block 100 connection b7. The spool 107 feeds high-pressure oil from the working pump 20 through the connection B7 to the rod side of the bucket cylinder 275. The cylinder is retracted; the bucket is tilted outwards.

3.3

Pressure reduction at auxiliary control valve block, and combined shifting when boom is lowered Set the switch S241 to position 2. The solenoid valve Y268 is in working position. The solenoid valve Y299 is in working position. When the switch S241 is in this position, the control oil line from the control oil unit 50 / P1 to the pressure boost cartridge of the valve 511 and through the solenoid valve Y299 connection P-A is blocked, and the line from the valve 511 through the solenoid valve Y299 connection A-T to the tank is relieved. As a result, the pressure for the hydraulic hammer is reduced.


16.64.6

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MJF C I F S S


Service Manual

Kit for control switch-over Components and hydraulic lines


Fig. 3


1 50

Hydraulic tank Control oil unit

Y62 Y63

Solenoid valve / travel forward Solenoid valve / travel reverse

81


Y268


86


Y299

Solenoid valve / secondary pressure hammer

100



260



510


511

Secondary pressure relief valve with additional pressure stage / extend hydr. hammer cyl.


copyright by

MJF C I F S S

16.64.7


Service Manual

Hydraulic system

6 Hydraulic system 1

to hydraulic tank

512

Retracting secondary pressure relief valve / cylinder 537

20


514

Pressure balance

41 45


517 525

Restrictor check valve Regulating cylinder

50 81

from the control oil unit Pilot control unit 4x, with joystick

526 527

Load-holding valve Load-holding valve

86

Pilot control unit 2x, with pedals

535

Hydraulic hammer

88P

Distributor

537


88T 100


B33 S63

Pressure switch flow reduction Switch / offset boom bearing

104


S241

260


S263

Switch / changeover regulating cylinder - hydraulic hammer Switch / travel direction

275

Bucket cylinder

S405

500

Spool / regulating cylinder / Y62 cylinder Secondary pressure-relief valve / retract Y63 regulating cylinder 525

501 502


504

Secondary pressure-relief valve / extend regulating cylinder 525 Pressure balance

Y268

507


Y299

510

Spool / hydraulic hammer / cylinder Secondary pressure-relief valve / extend hydraulic hammer 535 cylinder 537

Y385-1 Solenoid valve / changeover bucket cyl. - AHS Y385-2 Solenoid valve / changeover bucket cyl. - AHS

511

16.64.8

Y262

Key switch / control switch-over Solenoid valve / travel forward

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MJF C I F S S

Solenoid valve / switch-over bucket offset boom bearing Solenoid valve / changeover regulating cylinder - hammer Solenoid valve / secondary pressure hammer


Service Manual

Kit for control switch-over Hydraulic system


copyright by

MJF C I F S S

16.64.9


Service Manual

Electrical system

7 Electrical system B33



H322



S405

Switch / switch-over

Right console

X12** X29** X957** X1029 X1224

Plug connection distribution board / 2-pin Plug connection distribution board / 2-pin Plug connection distribution board / 21-pin Plug connection solenoid valves / 4-pin Plug connection to B33 / 3-pin

Right console Right console, rear Right console, rear Right control console, rear Distribution board

Y385-1 Y385-2 Y451

Solenoid valve / changeover bucket cylinder - AHS Solenoid valve / changeover bucket cylinder - AHS Solenoid valve switch-over buzzer / boom

Near fuel tank Near fuel tank Near fuel tank


16.64.10

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MJF C I F S S


Service Manual


Fig. 4



copyright by

MJF C I F S S

16.64.11


Service Manual


Description


A125**

PCB potentiometers

Left console

F330** F331**

Fuse kits Fuse X29

H322



P1**



S241** S405


Right control desk Right console

U16**


Right console, rear

V156-4 V169


A125 A125

X29** X837** X839** X952** X957** X958** X963** X974-4** X1028 X1029

Plug connection distribution board / 2-pin Plug connection A125 / 8-pin Plug connection / screw terminal on A125 / 3-pin Plug connection distribution board / 21-pin Plug connection distribution board / 21-pin Plug connection distribution board / 21-pin Plug connection distribution board / 2-pin Plug connection A125 CS / 2-pin Plug connection to S405 and H322 / 4-pin Plug connection solenoid valves / 4-pin

Right console, rear Left console, bottom Left console, bottom Right console Right console, rear Right console, rear Right console, rear Left console, bottom Right control console, rear Right control console, rear

Y385-1 Y385-2

Solenoid valve / changeover bucket cylinder - AHS Solenoid valve / changeover bucket cylinder - AHS

Behind cab Behind cab

15.0 A 15.0 A



16.64.12

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MJF C I F S S


Service Manual



copyright by

MJF C I F S S

16.64.13


Service Manual

Electrical system

16.64.14

copyright by

MJF C I F S S


Service Manual

Dozer blade Function

Dozer blade 1 Function Machines with 2-point or 4-point support can be equipped with an optional dozer blade. This blade is designed only for the purpose of grading work and may not be used as a support device. It can only be attached at the front, if no support or outrigger is mounted at that position. Lowering the dozer blade does not improve the stability of the machine, and does therefore not increase its load capacity.

Fig. 1

4-point outrigger support with dozer blade at the undercarriage

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MJF C I F S S

16.66.1

Dozer blade

Service Manual

Technical data

2 Technical data Machine

A 312 - A 316 Li

Adjusting pressure at the pressure-relief valve 304 Tab. 1

240 ± 5 bar

Adjusting pressure for the dozer blade cylinder

3 Design (see Fig. 3 on page4) The dozer blade equipped with these devices (cylinder, beam, etc.) is designed exclusively for grading work. The pressure at the piston side in the cylinder is limited by the additional pressure-relief valve 304. To actuate the dozer blade, the hydraulic cylinder 395 is pressurised through the oil circuit of the support cylinder. The support cylinder is switched over from working movement to dozer blade operation by means of the 6-way solenoid valve Y56 in the undercarriage. The hydraulically releasable check valve 302 is installed in the hydraulic circuit at the rod side. It secures the dozer blade against inadvertent lowering if there is a leakage.

4 Description of functions, Fig. 9 and Fig. 10 4.1

Outrigger support When the pilot control unit 85 (Fig. 2) is moved forward or back, the spool / support is pressurised with control oil. The hydraulic oil flows from the pump through the control block 100 the connection A1, the rotary connection 320 and the solenoid valve Y56 connection A2 - B2 or A1 - B1 to the double lowering brake valves 297 and the support cylinders 295. Depending on whether the oil reaches the rod or the piston side of the cylinder, the outrigger support is retracted or extended.

4.2

Working movement of the dozer blade By actuating the additional switch S335 located in the right control console, the solenoid valve Y56 is powered and the support cylinder 295 changes over from working movement to dozer blade 395.

4.2.1

Extending cylinder 395 When the pilot control unit 85 (Fig. 2) is pushed forward, oil flows from the control block 100 connection A1 through the rotary connection 320 to the solenoid valve Y56 connection A1 - C1. From connection C1, the oil flows through the hydraulically releasable check valve 302 connection V1 - C1 to the piston side of the dozer blade cylinder 395. High pressure is built up, opening the hydraulically releasable check valve 302. The cylinder 395 is extended and pushes the dozer blade down. The return oil from the rod side flows through the open check valve 302 connection C2 - V2, the solenoid valve Y56 connection C2 - A2, the rotary connection 320 and the control block 100 connection B1 back to the tank.

16.66.2

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Service Manual

Dozer blade Operation of dozer blade

4.2.2

Retracting cylinder 395 When the pilot control unit 85 (Fig. 2) is pushed back, oil flows from the control block 100 connection B1 through the rotary connection 320 to the solenoid valve Y56 connection A2 - C2. From connection C1, the oil flows through the hydraulically releasable check valve 302 connection V2 - C2 to the rod side of the dozer blade cylinder 395. The cylinder 395 is retracted and lifts the dozer blade up. The return oil from the piston side flows through the check valve 302 connection C1 - V1, the solenoid valve Y56 connection C1 - A1, the rotary connection 320 and the control block 100 connection A1 back to the tank.

5 Operation of dozer blade Select the dozer blade by means of switch S335. Press the switch S335. The indicator light in the switch is on. Push the pilot control unit 85 forward (a): the dozer blade is lowered Push the pilot control unit 85 back (b): the dozer blade is lifted

Fig. 2

Pilot control unit and switch for the dozer blade located in the right control console

a

Lowering dozer blade

85

b

Lifting dozer blade

S335 Switch / dozer blade

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MJF C I F S S


16.66.3

Dozer blade

Service Manual

Operation of dozer blade

Fig. 3

16.66.4

Hydraulic unit / dozer blade

302

Hydraulically releasable check valve

325


304


395

Dozer blade cylinder

320


Y56

Solenoid valve 6x

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MJF C I F S S

Service Manual

Dozer blade Exploded view / sectional drawing of Y56

6 Exploded view / sectional drawing of Y56

Fig. 4

Exploded view of solenoid valve Y56

Fig. 5

Sectional drawing of solenoid valve Y56

1 2 3

Way valve 6x 10 Pressure reducing valve (switching pressure 11 reduction) Way valve / magnet 12

7

Allen head screw

A1/A2 Connection / control valve block

8

Allen head screw

B1/B2 Connection / support cylinder

9

Allen head screw

C1/C2 Connection / dozer blade cylinder

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MJF C I F S S

Lock washer Lock washer O-ring

16.66.5

Dozer blade

Service Manual

Testing of pressure-relief valve 304

7 Testing of pressure-relief valve 304 Danger! To adjust the pressure-relief valve, it is necessary to access the undercarriage of the machine. There is a risk of death to the technician, as he could be crushed under the machine. Park the machine on level ground. Secure it against uncontrolled movement. Access the danger area only when the machine is shut down and properly secured in its position. Always refer to the safety instructions in group 1.10.

Fig. 6

Pressure-relief valve and measuring point at the control block

41

Measuring point

100

A1/B1 from control valve block

304


Remove the cap from the measuring point 41 at the control block 100 and connect the pressure sensor. Carefully fully extend the dozer blade (lower it to firm ground). Read the pressure at the measuring point 41. Caution! The pressure at the piston side in the cylinder 395 is limited by the pressure-relief valve 304. Excessive pressure applied for the extending of the cylinder 395 can lead to damage to the blade and the undercarriage. The indicated pressure may not exceed the prescribed limit pressure, see Tab. 1. If required, adjust the valve 304 to the correct pressure. Remove the protective cap 21. Loosen the lock nut and adjust the settings by turning the adjusting screw 19. Turn adjusting screw 19 out. Pressure is reduced Turn adjusting screw 19 in. Pressure is increased After adjustment, secure the adjusting screw with the lock nut. Remove the pressure sensor and seal the measuring point 41.

16.66.6

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Service Manual

Dozer blade Sectional drawing of hydraulically releasable check valve 302

Fig. 7

Sectional drawing of pressure-relief valve

19

Adjusting screw

21

Protective cover

304

Pressure-relief valve, complete

8 Sectional drawing of hydraulically releasable check valve 302

Fig. 8

Sectional drawing of check valve

1

Housing

7

Screw plug

2

Valve insert

8

Pressure spring

3

Control piston

9

Seal ring

4 6

Pushrod Valve cone

999

Seal kit

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MJF C I F S S

16.66.7

Dozer blade

Service Manual

Hydraulic diagram

9 Hydraulic diagram 9.1

at 2-point undercarriage, model A 316

Fig. 9

16.66.8

Hydraulic diagram of dozer blade with 2-point support

100

from compact control block

320


295

Support cylinder / outriggers

325


297


395

Dozer blade cylinder

302


S335 Switch / changeover blade - outrigger

304


Y56

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MJF C I F S S

Solenoid valve 6x

Service Manual

Dozer blade Hydraulic diagram

9.2

at 4-point undercarriage, model A 316

Fig. 10

Hydraulic diagram of dozer blade with 4-point support

100 295

from compact control block Support cylinder / outriggers

320 325

297 302

Double stop valve Hydraulically releasable check valve

395 Dozer blade cylinder S335 Switch / changeover blade - outrigger

304


Y56

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MJF C I F S S

Rotary connection 7x Slip ring / rotary connection

Solenoid valve 6x

16.66.9

Dozer blade

Service Manual

Electrical system

10

Electrical system

Fig. 11 F337

16.66.10

Electrical system in upper and undercarriage Fuse (15 A)

X771

S272

Junction box

X957


S335

Switch / dozer blade - outrigger

X958



X301


X963


X304


Y56

Solenoid valve 6x

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MJF C I F S S

Service Manual

Dozer blade Electrical diagram

11 Electrical diagram

Fig. 12

Electrical diagram of switchover system blade - outrigger, see basic diagram step 35

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MJF C I F S S

16.66.11

Dozer blade

Service Manual

Electrical diagram

16.66.12

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MJF C I F S S

Service Manual

Hydraulic cab elevation system Function

Hydraulic cab elevation system 1 Function The hydraulic operator's cab elevation kit has been developed specifically for machines that are used mainly in industrial operations such as timber, bulk and scrap movement and loading. The operator can adjust the elevation above ground of the cab, in order to have the best possible view during operation (eye level more than 4.5 m above ground). Danger! When working on the elevated cab, operators and technicians are exposed to a high risk of injury. When the cab is elevated, the machine may only be used on level ground free of obstacles, so that the stability of the machine is not in any way compromised. Lift or lower the cab only when the machine is standing still. Ensure that no persons are standing in the operating range of the cab elevation system.

Fig. 1

Hydraulic operator's cab elevation

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MJF C I F S S

16.70.1


Service Manual

Technical data

2 Technical data Machine: Type: Serial number:

A 316 Litronic Industry 716 2001

Volumetric flow rates at rated speed (1800 rpm) of the diesel engine Variable-displacement pump 20

270 l/min

Flow volume / spool connection A Flow volume / spool connection B Setting value Y (bottom) Setting value Y (top)

14 l/min 32 l/min 16 mm 17 mm

Setting values of the valves Secondary pressure-relief valve 601 for working pressure of cab elevation system These valves act as primary valves (measuring point 41).

100+10 bar

Secondary pressure-relief valve 602 for working pressure of cab elevation system These valves act as primary valves (measuring point 41).

150+10 bar

Tab. 1

Technical data

Caution! An incorrectly set proximity switch of the stick shut-down can lead to injury to the operator and damage to the operator's cab. Adjust the proximity switch of the stick cylinder shut-down so that the stick with grapple cannot damage the cab when the latter is at its maximum height, the boom is fully extended and the cab lift frame is adjusted horizontally. Prior to commissioning of the hydraulic cab elevation system, read the operating manual and the safety instructions for group 1.10. The cab elevation system should only be operated when the diesel engine is running at its nominal speed.

16.70.2

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MJF C I F S S

Service Manual

Hydraulic cab elevation system Design

3 Design Fig. 2 - 4 The hydraulic operator's cab elevation consists of the following main components: – Cab lift frame 70 - 78 – Pilot control unit of cab elevation system 90 – Additional control block 600 – Cylinder for cab elevation 615 – Restrictor check valve / pipe fracture safety valve 619 – Hydraulic accumulator 620 – Block ball valve of emergency lowering system in the operator's cab 621 (from serial no. 2001) – Block ball valve of emergency lowering system behind the operator's cab 622 (from serial no. 2001) – Load holding / lowering brake valve 623 – Solenoid valve of emergency lowering system Y204 (from serial no. 12390) – Switch of emergency lowering system S78 (from serial no. 12390) To lift / lower the operator's cab, the hydraulic cylinders 615 are pressurised, so that the cab is lifted on the lift frame. The oil flow required for this is produced by the variable-displacement pump 20 driven directly by the diesel engine. The oil flow to the cylinders 615 is controlled with the pilot control unit 90 and the additional control block 600. Other valves (pressure-relief valves 601 and 602, load holding / lowering brake valve 623) are designed to enhance the safety of the operator and the machine. The restrictor check valves 619 built into the cylinders 615 prevent sudden lowering of the cab in the event of a pipe break.

Fig. 2

Cab lift frame

70 Support 72 Beam

76 Left strut 78 Carrier

74 Right strut

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MJF C I F S S

16.70.3


Service Manual

Design

Fig. 3

16.70.4

Pilot control of hydraulic cab elevation system

1

Hydraulic tank

100


80

Pilot control valve left / stick

600

90

Pilot control unit of cab elevation system

623

Additional control block / operator's cab adjustment Load holding / lowering brake valve

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MJF C I F S S

Service Manual


Fig. 4

Components of the hydraulic operator's cab elevation

20


619

Restrictor check valve / pipe fracture safety valve

100 600

Compact control block Additional control block

620 623

Hydraulic accumulator Load holding / lowering brake valve

615

Cylinder

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MJF C I F S S

16.70.5


Service Manual

Design

Fig. 5

100 600

3.1

623

Compact control block Additional control block

Load holding / lowering brake valve

Control devices in operator's cab

Fig. 6 90

16.70.6

Installation position of the additional control block and the load holding / lowering brake valve

Control devices in the left control console for the hydraulic cab elevation system Pilot control unit of cab elevation system

S78

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MJF C I F S S

Button for emergency lowering (from serial no. 12390, see Fig. 9)

Service Manual


Fig. 7

Installation position of the accumulator, restrictor check valves and cylinders in the support

615

Cylinder for cab elevation system

619


620

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MJF C I F S S

Hydraulic accumulator

16.70.7


Service Manual



Neutral position The pilot control unit 90 is not actuated, and the spool 600 is in its neutral position. The variable-displacement pump 20 driven directly by the diesel engine takes up the hydraulic oil from the tank 1 and is fed to the control block 100 in stand-by mode. In this operating state, the system pressure is set to approx. 30 to 35 bar and acts on the spool 600.

4.2

Lifting operator's cab (extending cylinder 615) If the pilot control unit 90 in the left console is pushed back, the spool in the additional control block 600 is switched through the line b03. Oil flows from the variable-displacement pump 20 over the control edge of the piston and pressurises the pressure balance. The pressure balance is switched, so that the oil can flow through the spool, the line B03, the load holding / lowering brake valve 623 and the restrictor check valve / pipe fracture safety valve 619 to the piston side of the cylinder 615. The variable-displacement pump 20 is swivelled according to the oil requirements (actuation of the pilot control unit). The return oil from the rod side flows through the line A03 of the control block 100 to the hydraulic tank 1. The operator's cab is lifted as long as the pilot control unit 90 is actuated, or until the maximum height is reached.

4.3

Lowering operator's cab (retracting cylinder 615) If the pilot control unit 90 in the left console is pushed forward, the spool in the additional control block 600 is switched through the line a03 and the load holding / lowering brake valve 623 is opened. Oil flows over the control edge of the spool and pressurises the pressure balance. The pressure balance is switched, so that the oil flows through the spool and the line A03, to the rod side of the cylinder 615. The variable-displacement pump 20 is swivelled according to the oil requirements (actuation of the pilot control unit). The oil from the piston side flows through the orifice of the restrictor check valve / pipe break safety valve 619 through the open load holding / lowering brake valve 623, the line B03, the spool and the control block 100 to the hydraulic tank 1. The operator's cab is lowered as long as the pilot control unit 90 is actuated or until the lower limit position is reached.

4.4

Emergency operation In the event of a failure of the diesel engine or the control system of the adjustable operator's cab, it can be lowered manually. There are three methods of emergency lowering:

16.70.8

copyright by

MJF C I F S S

Service Manual

Hydraulic cab elevation system Functional description

4.4.1

Emergency lowering system from serial no. 2001, see Fig. 8 In the event of a failure of the diesel engine or the hydraulic system, the operator's cab can be lowered by means of the emergency lowering system (block ball valve 621 and 622). With the emergency lowering system, the operator's cab is lowered by operating the lever of the block ball valve 621 in the bottom right corner or with the lever of the block ball valve 622 located at the rear of the lift frame support. The piston side of the cylinder 615 is connected to the hydraulic tank 1, and the cab is lowered.

Fig. 8

Emergency lowering system from serial no. 2001

1

Hydraulic tank

621

Block ball valve of emergency lowering system in operator's cab

88P

Distributor of control block

622

Block ball valve of emergency lowering system at support

88T

Collecting pipe / tank

Caution! When the block ball valve is opened, the cab can still be lifted, but will automatically be lowered again. Such uncontrolled movement can cause injury to the operator or damage to the cab. To prevent this, complete the following steps: After lowering the cab, always return the lever of the block ball valve 621 / 622 to its initial position.

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MJF C I F S S

16.70.9


Service Manual


4.4.2

Emergency lowering system from serial no. 12390, see Fig. 9 In the event of a failure of the diesel engine or the hydraulic system, the operator's cab can be lowered by means of the emergency lowering system (button S78, solenoid valve Y204). The cab can be lowered by pressing the button S78 located in the left control console in the operator's cab. It can also be lowered by a person standing beside the machine by actuating the emergency valve Y204 at the support of the lift frame. Screw in the handle A of the emergency valve Y204 until the cab is fully lowered, see Fig. 9.

Fig. 9

Emergency lowering system from serial no. 12390

1

Hydraulic tank

S78

90

Pilot control unit of cab elevation system

Y204 Solenoid valve / emergency lowering system

Button / emergency lowering system

Caution! When the block ball valve is opened, the cab can still be lifted, but will automatically be lowered again. Such uncontrolled movements can cause injury to the operator or damage to the cab. To prevent this, complete the following steps: After lowering the cab, return the handle A of the solenoid valve Y204 to its initial position.

16.70.10

copyright by

MJF C I F S S

Service Manual

Hydraulic cab elevation system Functional description

Fig. 10

Y204 A

Installation position of the emergency valve at the support

Solenoid valve / emergency lowering system Handle of mechanical emergency lowering system

E

Connection from the cylinders 615

T

to hydraulic tank

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MJF C I F S S

16.70.11


Service Manual


5 Pressure check and adjustment Danger! Repair work requires access to the danger area of the elevated cab. There is a risk of death to the technician, as limbs could become crushed. Park the machine on level ground. If at all possible, carry out all repair and maintenance work on the operator's cab, the lift frame and the hydraulic system when the cab is lowered. If this is not possible, proceed as follows: Secure the lift frame to prevent lowering of the cab, using suitable propping material and supports. Depressurise the hydraulic system. Always refer to the safety instructions in group 1.10. Please note that all works on the valves must be carried out by technicians who are authorised by LIEBHERR. The pressure adjustments must be made at operating temperature of the hydraulic oil and at the rated speed.

5.1

Additional control block

Fig. 11

Installation of additional control block

41

Measuring point MP

600.2 Adjusting screw (size 6 Allen key)

100


601

Pressure-relief valve / lowering cab

602

Pressure-relief valve / lifting cab

600 Additional control block 600.1 Lock nut (WS 22)

16.70.12

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MJF C I F S S

Service Manual

Hydraulic cab elevation system Pressure check and adjustment

5.2 5.2.1

Settings of additional control block 600 Adjustment of the stroke limitation of the spool Remove the control lines at the bottom and top at connection a03 / b03 (SW 19) and seal them. Loosen the lock nuts 600.1. Turn in the adjusting screws 600.2 using an Allen key (size 6) until dimension Y is reached (upper edge of lock nut / connection to upper edge of adjusting screw), (see Tab. 1 on page 2). Re-tighten lock nuts 600.1. Mount the control lines a03 / b03 at the top and bottom.

5.2.2

Testing and adjustment of the pressure-relief valves 601/602 Connect the pressure sensor/gauge (600 bar) to the measuring point 41. Extend the cylinder 615 to the stop. Check the pressure and if necessary adjust it as follows: Remove the protective caps of the pressure-relief valves 602. Release the lock nuts (WS 17) at the pressure-relief valves 602. Extend the cylinder 615 to the stop. Turn the adjusting screw with the Allen key (size 5) until the prescribed pressure is shown at the pressure gauge / sensor, (see Tab. 1 on page2). Adjust the pressure for the retraction of the cylinder 615 at the valve 601. When the adjustment is completed, re-tighten the lock nuts. Mount the protective caps. Remove the pressure sensor / gauge and seal the measuring point 41.

Fig. 12

Sectional drawing of the additional control valve

600

Additional control block

601

Pressure-relief valve / lowering cab

600.1

Lock nut (WS 22)

602


600.2

Adjusting screw (size 6 Allen key)

604

Pressure balance

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MJF C I F S S

16.70.13


Service Manual

Hydraulic unit of the operator's cab elevation

6 Hydraulic unit of the operator's cab elevation

16.70.14

1 6

Hydraulic tank to oil cooler

600 601

Additional control block Pressure-relief valve / lowering cab

20


602


23 30

Regulating valve / pump Gear pump / cooling

604 615

Pressure balance Cylinder for cab elevation system

41

Measuring point / pump pressure

618


45


619


50 80

from control oil unit 620 Pilot control valve, left slewing gear / stick 621

88P

Distributor of control block

622

88T 90

Collecting pipe / tank Pilot control unit of cab elevation system

623 T16

Load holding / lowering brake valve Connection to hydraulic tank

100


S78

Button for emergency lowering system (from serial no. 12390)

104


Y204 Solenoid valve of emergency lowering system (from serial no. 12390)

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MJF C I F S S

Hydraulic accumulator Block ball valve of emergency lowering system (in operator's cab from serial no. 2001) Block ball valve of emergency lowering system (at the rear of support, from serial no. 2001)

Service Manual

Hydraulic cab elevation system Hydraulic unit of the operator's cab elevation

Fig. 13

Hydraulic diagram of cab elevation system

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MJF C I F S S

16.70.15


Service Manual

Electrical system of hydraulic operator's cab elevation system

7 Electrical system of hydraulic operator's cab elevation system

Fig. 14 A127 F344

16.70.16

Electrical system of the hydraulic operator's cab elevation system from serial no. 12390 Printed circuit board / power Fuse emergency lowering system

X909-1 Plug connection, 2-pin X909-2 Plug connection, 2-pin

KL 31 Earth connection terminal

X909-3 Plug connection, 2-pin

S78

Emergency cab lowering system symbol

Y78

X9

Plug connection on board A127

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MJF C I F S S

Button / emergency lowering system

Service Manual

Hydraulic cab elevation system Electrical system of hydraulic operator's cab elevation system

Fig. 15

Electrical system of the hydraulic operator's cab elevation system from serial no. 12390

F344

Fuse emergency lowering system

X909-1 Plug connection, 2-pin

S78 Y204

Button / emergency lowering system Solenoid valve / emergency lowering system

X909-2 Plug connection, 2-pin X909-3 Plug connection, 2-pin

copyright by

MJF C I F S S

16.70.17


Service Manual

Electrical system of hydraulic operator's cab elevation system

16.70.18

copyright by

MJF C I F S S

Service Manual

Speeder kit Function of Speeder kit

Speeder kit 1 Function of Speeder kit On request, the Liebherr models A 312 - 316 Litronic are available as Speeder models. These models can travel at considerably higher travel speeds.

2 Design 2.1

170 Travel motor

Fig. 1

Travel motor

3.14 Threaded stud (A 314 / 316) 17 Threaded stud (A 312)

170

Travel motor

The minimum pivot angle is set by the threaded stud 17/3.14. The angle is factory-set by the manufacturer and may not be changed. The correct position of the threaded stud 17/3.14 in the housing can be determined by checking dimension X, see Fig. 1 and pages 7.26.2 and 7.27.2 / 7.27.3 (standard value).

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MJF C I F S S

16.74.1

Speeder kit

Service Manual

Design

2.2

Control block 100 with control axle 160 chassis

Fig. 2 100 160.2

Control block with control axle 160.1.1 Adjusting screw 160.1.2 Lock nut

Control valve block Stroke limitation

In Speeder models, a machine-specific control block 100 is equipped with a control axle 160 that has been designed specifically for higher travel speeds (for control block no., see type plate and group 7.60). If there is a problem with the max. travel speed of the machine, the setting can be modified, if the actual max. speed of the universal joint shaft (connection between - gearbox and axles) is not in line with the value stated in the adjustment protocol (see group 6.

2.3

Adjustment of max. output speed / max. travel speed Danger! The inspection and testing of universal joint shaft speed require access to the undercarriage of the machine. There is a risk of serious injury or even death to the technician, if the machine begins to move. Park the machine on level ground. Extend the supports. Place the attachment on the ground and lift the undercarriage from the ground, if necessary. Establish visual or acoustic contact with the operating personnel. Always adhere to the safety instructions in group 1.10 "Safe maintenance of machine". Note! The maximum flow volume is factory-set by the stroke limitation of the spool 160 (dimension Y, see also adjustment protocol in group 6 and the control block in group 7.60) and may not be changed. In the event of an exceptional case where correction is required, proceed as follows: Jack up the vehicle and run it in on-road gear (pilot control unit at full throttle).

16.74.2

copyright by

MJF C I F S S

Service Manual

Speeder kit Design Measure the maximum speed of a joint shaft with a HT 460 speedometer (tool group 2.01) and compare with the prescribed speed, see adjustment protocol or pages 7.26.2 / 7.27.2 / 7.27.3.

If the measured speed does not correspond to the prescribed speed, proceed as follows: At fully actuated pilot control unit, remove the cap nut of the chassis control axle 160 of the control valve block 100. Loosen the lock nut .2 of the stroke limitation 160.1/160.2. Reduce the universal joint shaft speed. Turn the adjusting screw .1 in. The speed is reduced. Increase the universal joint shaft speed. Turn adjusting screw .1 out. The speed is increased. Note! If the speed does not increase despite turning in the adjusting screw 1, the spool is not fully actuated. Check the prescribed pilot control pressure at the control caps of the control axle 160 and eliminate the error, if required (e.g. restrictor check valve defective). Repeat the adjustment on the other side of the spool 160 (forward and reverse travel). After adjustment of the correct speed, secure the adjusting screws 160.1/160.2 with the lock nuts .2 (hold adjusting screw .1 firm). Replace the cap nuts.

Fig. 3

Adjusting of max. output speed / max. travel speed

160.1 Stroke limitation

.1

Adjusting screw

160.2 Stroke limitation

.2

Lock nut

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16.74.3

Speeder kit

Service Manual

Design

16.74.4

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MJF C I F S S

Service Manual

Generator drive accessory kit Function

Generator drive accessory kit 1 Function The generator drive accessory kit includes all main components required for the operation of a magnet system. Magnet systems are used in conjunction with the conventional load lifting magnet tool to take up, load and sort ferromagnetic parts, i.e. all iron parts up to a certain alloy content. The A 316 industrial mobile excavator thereby serves as a support and energy supply unit. The generator is driven hydraulically. The hydraulic energy of a gear pump drives the oil motor, which in turn propels the AC generator. The electrical energy is used to generate a magnetic field at the load lifting magnet. The necessary components are added to the installed accessory kit by LIEBHERR, your dealer or the supplier of the generator unit.

Fig. 1 400

A 316 machine with generator and load lifting magnet Generator with hydraulic drive unit

402

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MJF C I F S S

Load lifting magnet

16.86.1

Generator drive accessory kit

Service Manual

Technical data

2 Technical data Description

Generator 10 kW from serial no. 2001

Generator 10 kW from serial no. 18429

1841

2008

28

28

l/min.

51,5

56,2

min-1

3000 + 50

3150 + 50

16

16

7 - 15

7 - 15

bar bar

15 190

15 190+5

bar

35

-

Gear pump 36: Drive speed

rpm 3

Volumetric delivery

cm

Flow rate Axial piston - fixed-displacement motor 430: Output speed

3

Flow consumption

cm

Pressure balance 413: -p Solenoid pressure relief valve Y295: Minimum pressure Maximum pressure Restrictor check valve 417: Back pressure Tab. 1

Data of the components

3 Design and function of the generator drive system 3.1 3.1.1

Arrangement of the units to serial no. 18428 (old model) Gear pump 36, (see Fig. 3, page 4) The gear pump 36 is driven directly by the diesel engine and feeds hydraulic oil to the connection A of the pressure relief valve 411 and through the connection A-A of the solenoid valve 410 to the oil motor 430.

3.1.2

Generator 400 and oil motor 430, (see Fig. 3, page 4) The generator 400 and the oil motor 430 are mounted on the bearing block 408 in the uppercarriage. This block is located behind the operator's cab or the lift frame respectively (in models with elevated operator's cab). The axial piston oil motor 430 propels the generator 400 via a flexible coupling.

3.1.3

Pressure balance 413 The pressure balance 413 is used to control the flow rate to the oil motor 430. The pressure balance 413 is screwed into the housing body 410. The fixed orifice (gauge orifice) 415 generates a pressure difference ( -p), which can be controlled by means of the pressure balance 413 . The volume flow from the pump 36 to the oil motor 430 is proportional to the adjusted value -p. The drive speed resulting from the actual volume flow to the oil motor 430 is relevant for the adjustment of the -p value, (see Tab. 1, page 2).

16.86.2

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MJF C I F S S

Service Manual

Generator drive accessory kit Design and function of the generator drive system

3.1.4

Solenoid pressure relief valve Y295 The solenoid pressure relief valve Y295 is used as a 2-stage pressure relief valve for the regulation of the working pressure at the oil motor 430. The valve Y295 is screwed into the housing body 411. If the valve Y295 is activated (powered) by means of the switch S46 , the solenoid Y295 switches the piston to the higher pressure level (maximum pressure, see Tab. 1). The pump flow volume is fed to the oil motor at the set working pressure. If the valve Y295 is deactivated by means of the switch S46 (power off), the solenoid Y295 switches the piston in the valve to the lower pressure level (minimum pressure, see Tab. 1). As a result, the oil from the gear pump 36 flows through the valve Y295 and the housing 411 / control valve block 420 to the tank 1.

3.1.5

Check valve 416 and restrictor check valve 417 The check valve 416 allows for the take-up of oil and prevents cavitation in the oil motor during the afterrun of the generator 400 when the generator drive is switched off 430. 417

Fig. 2

, (see Tab. 1, page 2)

Pump, pressure balance, pressure relief valve and oil motor of the generator drive system

36

Gear pump

417


400

Generator

418

Measuring point / working pressure

408 413

Bearing block Pressure balance

419 430

Measuring point / return pressure Axial piston - oil motor

416

Check valve

Y295

Solenoid pressure relief valve

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16.86.3


Service Manual

Design and function of the generator drive system

3.2 3.2.1

Arrangement of the units from serial no. 18429 (new model) Gear pump 36, generator 400 and oil motor 430. The gear pump 36 is driven directly by the diesel engine and feeds hydraulic oil to the connection P - A in the control block 420 to the oil motor 430. The design and functions of the components 400 and 430 correspond to those described above, see 3.1.2.

3.2.2

Control valve block 420 The control block 420 installed between the pump 36 and the oil motor 430 includes a pressure balance 413 and the solenoid pressure relief valve Y295. The design and functions of the components 413 and Y295 correspond to those described above, see 3.1.3. .

Fig. 3

16.86.4

Pump, control block and oil motor of the generator drive system

36

Gear pump

418


400 408

Generator Bearing block

420 430

Control valve block Oil motor

413

Pressure balance

Y294


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Service Manual

Generator drive accessory kit Design and function of the generator drive system

3.3

Switch S46 magnet system (for both versions) The generator drive and the magnet system are switched on and off with the switch S46 located in the right front control console. When then generator drive is switched off, the solenoid pressure relief valve Y295 is set to the lower pressure level (minimum pressure,see Tab. 1). After the magnet system is switched on, the device is automatically switched as follows: The motor speed is increased to minimum level 8. The sensor control / idle automatic is disabled. The solenoid pressure relief valve Y295 is set to the higher pressure level (maximum pressure,see Tab. 1).

3.4

S6L push button of magnet system (for both versions) The load lifting magnet is activated and deactivated with the left push button S6L in the right joystick. Press the push button S6L. The magnet is activated. Press the push button S6L again. The magnet is deactivated.

Fig. 4

S6L

3.5

Switches and push buttons of the magnet system

S46

Push button of magnet

Switch to activate magnet system

Switch S457 (in special customised models only) At the request of the customer, the magnet system can be controlled by means of the rocker switch S457 in the left joystick. The switch S382 in the left joystick is included as standard in the right control condole and is used for fine adjustment, (see Fig. 5, page 6) The load lifting magnet is activated and deactivated with the rocker switch S457 in the left joystick. Press the rocker switch S457 up. The magnet is activated. Press the rocker switch S457 down.

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16.86.5


Service Manual

Setting instructions The magnet is deactivated.

Fig. 5 S46 S382

Switches, rocker switch/load lifting magnet and switch/fine control in special version S457

Magnet system switch Fine control switch

Magnet system rocker switch

4 Setting instructions The following instructions apply to both versions of the control! Note! Before checking and adjusting the pressure and the input speed of the oil motor / generator drive, ensure that the unit has reached an operating temperature of at least 50°C. For operating pressures, flow rates and speed, see section "2. Technical data".

4.1

Adjustment of solenoid pressure relief vale Y295, see Fig. 6 Connect the pressure sensor or gauge (600 bar) to the measuring point 418. Write down the current position of the adjusting restrictor (sleeve) of the restrictor check valve 417. Close the restrictor check valve 417 by turning in the adjusting restrictor (in old generator drive model), see Fig. 6. Disconnect the pressure line from the A to the oil motor 430, (see Fig. 11, page 13) and seal the pressure line with a screw plug / plug (in new generator drive model). Activate the generator drive by actuating the switch S46. The system is set to pressure level II (high pressure level). The current pressure is indicated at the measuring point 418. If required, adjust the maximum pressure to the prescribed value, (see Tab. 1, page 2) by turning the adjusting screw 5 at the pressure relief valve Y295: Remove the cap nut 5 (WS 13). Loosen the lock nut 7 (WS 13) at the pressure relief valve Y295. Turn in the adjusting screw 6 (wrench size 7) = increase pressure; turn out the adjusting screw 6

16.86.6

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Service Manual

Generator drive accessory kit Setting instructions = reduce pressure.

Note! It is not necessary to adjust the minimum pressure. Do not turn the Allen adjusting screw 6. After the adjustment is completed, tighten the lock nut 7. Adjustment of old generator drive system: Open and readjust the restrictor check valve 417, see Fig. 2, see Tab. 1. Adjustment of new generator drive system: Deactivate the generator drive system. Remove the screw / plug and the pressure line from the connection P to the oil motor 430. Remove the pressure sensor / gauge.

Fig. 6

4.2

Pressure relief valve and measuring point for the adjustment of the pressure settings in different installation models

A

Model with old generator drive system

B

Model with new generator drive system

5

Cap nut

417


6 7


418 430

Measuring point / working pressure Oil motor

400

Generator

Y295


Adjustment of the pressure balance 413 The volume flow from the pump 36 to the oil motor 430 is determined by the pressure balance 413. The necessary drive speed of the generator results from the volume determined by the pressure balance (volume results from the cross-section of the fixed restrictor 415 and the adjustable spring of the volume distributor) and the flow consumption 430. The prescribed drive speed of the oil motor 430 = drive speed of the generator 400 can be adjusted by measuring the speed at the coupling and turning the adjusting screw 2 at the pressure balance 413.

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16.86.7


Service Manual

Setting instructions Caution! The rotating coupling and generator shaft might cause serious injury to hands and fingers. Before removing the guard 403 , switch off the generator drive system and take the necessary safety measures by establishing visual or audible contact with the operator. Deactivate the magnet system with the switch S46. Remove the guard 403. Apply reflecting strips to the rubber element of the coupling 404, see Fig. 7. Activate the generator drive by actuating the switch S46. Measure the drive speed of the generator 400 using a suitable speed meter or LMS system. If required, adjust the speed by means of the adjusting screw 2: Loosen the lock nut 3. Turn in the screw 2 = increase drive speed; turn out the screw 2 = reduce drive speed. After the adjustment is completed, tighten the lock nut 3. Deactivate the generator drive by actuating the switch S46.

Fig. 7

4.3

Application of the measuring strip to the coupling 4 and adjusting screw at the pressure balance 412

A

Model with old generator drive system

B

Model with new generator drive system

2

Adjusting screw

403

Guard

3

Lock nut

404

Coupling

400

Generator

413

Pressure balance

Adjustment of the restrictor check valve 417 The return back pressure of the oil from the oil motor 430 must be adjusted at the restrictor check valve 417 as follows: Connect the pressure sensor or gauge (600 bar) to the measuring point 419. Write down the current position of the adjusting restrictor (sleeve) of the restrictor check valve 417. Activate the generator drive by actuating the switch S46.

16.86.8

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Service Manual

Generator drive accessory kit Hydraulic unit of the generator drive system (old model) Adjust the restrictor check valve 417 by turning the adjusting restrictor in such a way that the prescribed back pressure is reached at the measuring point 419, (see Tab. 1, page 2). Deactivate the generator drive by actuating the switch S46. Remove the pressure sensor / gauge.

5 Hydraulic unit of the generator drive system (old model)

Fig. 8

Hydraulic connections of the generator drive (old model)

1

Hydraulic tank

416

Check valve

36 400

Gear pump Generator

417 418

Restrictor check valve Measuring point / working pressure

410 411

Housing body / pressure balance Housing body / pressure-relief valve

419 430

Measuring point / return pressure Axial piston - oil motor

413

Pressure balance

Y295


415

Restrictor

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16.86.9


Service Manual

Hydraulic diagram of the generator drive system (old version)

6 Hydraulic diagram of the generator drive system (old version) Item

see group

1

Hydraulic tank

31


32

Gear pump / brake and pilot control unit

36 400

Item

see group

414


13.10

415


15.12 6.24/6.27

416

Check valve

Gear pump

417


Generator

418


410

Housing body / pressure balance

419

Measuring point / return pressure

411

Housing body / pressure-relief valve

430

Axial piston - oil motor

413

Pressure balance

Y295 Solenoid pressure relief valve

16.86.10

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Service Manual

Generator drive accessory kit Hydraulic diagram of the generator drive system (old version)

Fig. 9

Hydraulic diagram of the generator drive system (old version)

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16.86.11


Service Manual

Sectional drawing of the control valve block 420 (new generator drive system)

7 Sectional drawing of the control valve block 420 (new generator drive system)

Fig. 10

16.86.12

Control block with pressure balance, solenoid pressure relief valve and restrictors

2

Adjusting screw (internal hex head 5 mm)

423

Check valve

3

Lock nut (WS 17)

424


5

Cap nut

425


413

Pressure balance, complete

Y295 Solenoid pressure-relief valve

420


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Service Manual

Generator drive accessory kit Hydraulic unit of the generator drive system (new version)

8 Hydraulic unit of the generator drive system (new version)

Fig. 11

Hydraulic connections of the generator drive (new model)

1 36

Hydraulic tank Gear pump

420 425

Control valve block Minimess damping line (length 600 mm, function-relevant)

400

Generator

430 433

Oil motor Spacer*

413 418

Pressure balance Measuring point

434 Y295

Pipe seal* Solenoid pressure relief valve

*

(only for installations without generator)

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16.86.13


Service Manual

Hydraulic diagram of the generator drive system (new version)

9 Hydraulic diagram of the generator drive system (new version) Item

see group

1

Hydraulic tank

31


32

Gear pump / brake and pilot control unit

36 400

Item

see group

423

Check valve

13.10

424


15.12

425


Gear pump

430

Axial piston - oil motor

Generator

433

Spacer*

413

Pressure balance

434

Pipe seal*

418

Measuring point

Y295 Solenoid valve

420

Pilot control unit, complete *

16.86.14

only for installations without generator

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Service Manual

Generator drive accessory kit Hydraulic diagram of the generator drive system (new version)

Fig. 12

Hydraulic diagram of the generator drive system (new version)

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16.86.15


Service Manual

Electrical system of the generator drive

10


Fig. 13

16.86.16

Different versions of the electrical system / generator drive

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Service Manual

Generator drive accessory kit Electrical system of the generator drive

Fig. 14

Versions "load lifting magnet actuation in the left joystick"

S6R

Push button, not assigned

X90

Plug connection (heating), 2-pin

S6L S46

Push button magnet system ON / OFF Switch to activate magnet system

X217 X370


S382

Fine control switch

X958


S457 U7

Rocker switch magnet unit ON/OFF Magnet unit switching unit

X1046 Plug connection, 12-pin X1047 Plug connection (B19L), 3-pin

X15-2


X1048 Plug connection, 12-pin

X74


X1048-1Plug connection, 6-pin

X74-1


Y295

X80

Plug connection (B19L), 3-pin

Solenoid valve

Note! For the electrical diagrams of the accessory kit, see group 8.45, sectional drawing 55.

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16.86.17


Service Manual


16.86.18

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Service Manual


Group

Type

Passfix bolts

18.15.1

A 309 LI 20221A 311 LI 20222-

18.1 MJF C I F S S

Service Manual

1.2 MJF C I F S S

Service Manual

Passfix bolts Function

Passfix bolts 1 Function Certain bearings of the attachments of the compact excavator models A 309 and A 311 are equipped with Passfix bolts. They reduce wear at the bearing points.

Fig. 1

Passfix bolts A / B at the attachment

A General bearing points with Passfix bolts

B Main bearing points Machine model A 309 from serial no. 20221 and model A 311 from serial no. 20222 with Passfix bolts. Machine model A 309 from serial no. 27369 and model A 311 from serial no. 27373 with tab/locking nut bolts.

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18.15.1

Passfix bolts

Service Manual

Design

2 Design

Fig. 2

Parts of the Passfix bolt

1 2

Bolt Clamping bush

3

Clamping washer

4 5

Nordlock retaining washer Clamping screw

The clamping bushes 2 are pressed with the clamping screws 1 and the clamping washers 3 onto the cone-shaped bolt ends 1. The cone-shaped and slit clamping bushes 2 are thereby expanded and thus pressed against the wall of the bearing bore. This effectively prevents play between the bearing bore at the fixed bearing. To ensure a long service life and best operation, the attachment and cylinder bearings must be properly installed, (see 4.2, page 4), and regularly inspected (check of tightening torque).

3 Maintenance Check the clamping screws after approx. 50 operating hours after the first start-up of the attachment. Check the torque (400 Nm) and retighten, if necessary. Subsequently, check the tightening torque every 500 operating hours.

18.15.2

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Service Manual

Passfix bolts Dismantling and mounting of Passfix bolts

4 Dismantling and mounting of Passfix bolts 4.1

Dismantling

Fig. 3 6 7

Removal tool and dismantling procedure A and B 8

Adapter Removing tool

Removal screw

Remove the clamping screw 5, the retaining washer 4 and the clamping washer 3 at both sides. Insert the removal tool 7 included in the machine toolbox (see also tool group 2.01) into the clamping bush 2 using the adapter 6, if necessary (depending on the size of the clamping bush 2). Turn the removal screw 8 to the stop. Tighten the removal screw 8 by holding the removal tool 7 with a suitable spanner so that the bolt 1 and the clamping bush 2 are tensioned (A). Tap the head of the removal screw 8 with a hammer (B). The clamping bush 2 should become loose. If the clamping bush 2 is not loose, tighten the removal screw 8 further and tap it again with a hammer. Repeat the procedure at the other side.

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18.15.3

Passfix bolts

Service Manual

Dismantling and mounting of Passfix bolts

4.2

Mounting Note! For assembly, the bore near the clamping bush 2, the clamping bush and the conical surface of the bolt 1 must be free of any grease or oil.

Fig. 4

Alignment of the Passfix bolts during mounting

1 2

Bolt Clamping bush

4 5

Nordlock retaining washer Clamping screw

3

Clamping washer

6

Bearing bore / fixed bearing

Insert the bolt 1 into the attachment and bearing and align it evenly. Insert clamping bushes 2 at both sides. The bolt must be centred. If aligned correctly, there is a gap of 5 to 7 mm between the bush edge and the outer edge of the bolt. If the distance is < 5 mm or > 7 mm, the bolt is not correctly aligned and its position must be adjusted. Note! Insert the clamping bush 2 in such a way that the slots in the bush are at the bottom (to prevent corrosion). Mount the clamping screw 5, the retaining washer 4 and the clamping washer 3. Tighten the clamping screws 5 at both sides by hand. Ensure that the bolt 1 remains properly cantered. The clamping bushes 2 must be tensioned. Using a torque spanner, tighten the clamping screws 5 one after the other (tightening torque 400 Nm).

18.15.4

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Service Manual


Group

Type

Tank arrangement

19.10.1


19.1 MJFCIFSS

Service Manual

1.2 MJFCIFSS

Service Manual

Tank arrangement Function

Tank arrangement 1 Function The hydraulic and fuel tanks are installed in the uppercarriage of the machine and serve as reserve tanks for the fuel and the hydraulic oil. The hydraulic and fuel tank are two separate components. The fuel tank is mounted on the right side of the uppercarriage. For the design of the fuel tank, see also Design of fuel tank", page 10. The hydraulic tank is mounted on the left side of the uppercarriage. For the design and function of the hydraulic tank, see also Design and function of the hydraulic tank", page 2. The design and function of the return filter protection system integrated into the hydraulic tank are described in chapter Hydraulic oil return filter 4", page 7.

1

2

Fig. 1

1

Tank arrangement

2

Fuel tank

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Hydraulic tank

19.10.1

Tank arrangement

Service Manual

Design and function of the hydraulic tank

2 Design and function of the hydraulic tank 2.1

Hydraulic tank See also Fig. 3, Fig. 4 and Fig. 5. The hydraulic tank contains hydraulic oil used in the machine. The separating and baffle plates inside the tank baffle the oil inside the tank when the excavator is moving and separate the tank into different sections: The suction room A, from where the baffled and foam-free oil is taken up by the hydraulic pumps through the connection and the stop cock 3. The return, collection and baffling section B, in which all return and leak oil is collected through the connections T1 - T21, TL and TV. (When a generator is attached, the respective oil pump sucks oil through the pipe E from the suction room A) The oil level in the tank is indicted by the two oil level gauges 50 (O/U or Maximum/Minimum). The correct oil level is indicated when the excavator is in a horizontal position: after all working cylinders have been retracted and the oil level does not exceed the upper limit mark (O or Maximum) and after all working cylinders have been extended and the oil level does not drop below the lower oil level mark (U or Minimum). Drain off condensate and oil (for oil change) through the two oil drain pieces C. Observe the prescribed intervals in the maintenance instructions. Dispose of the drained condensate (contaminated with oil) and the spent oil according to the statutory requirements. The large opening with lid D allows for proper access to the inside of the tank for cleaning purposes. When adding or changing oil, always pour it through the return filter 4, which is accessible after the lid has been opened 4.1, see Fig. 6. The hydraulic tank is preloaded by the turbo charger of the diesel engine through the preload valve 45 ( 0.2 bar). For repair work on the hydraulic pumps, the stop cock 3 mounted on the suction connection of the tank can be closed, so that no oil from the tank can flow to the pumps. The hydraulic tank is equipped with two screwed-in oil temperature sensors. The hydraulic oil temperature sensor B8 is triggered when the oil temperature reaches 95 100 °C and issues a negative signal to the indicator light H15, warning the driver. Switch off the engine, identify the problem (radiator dirty?) and eliminate it. High or low oil temperatures change the resistance value of the hydraulic oil temperature sensor B285, which the issues a signal to the excavator control system U16 that controls the fan of the engine and oil cooling system, see also assembly 8.70.

19.10.2

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Service Manual

Tank arrangement Design and function of the hydraulic tank

2.2

Breather filter 2

Fig. 2

Hydraulic tank with filter

1

Hydraulic tank, complete

2

Breather filter

4

Return filter, complete

The breather filter 2 mounted on the top of the hydraulic tank 1 protects the tank against overpressure or underpressure that might otherwise occur due to the constantly changing oil volume during operation. If a low pressure value of 0.03 bar is reached, air enters the system through the breather part of the filter. Due to its spring preload, the breather part generates a tank lead pressure of 1.0 bar. If the tank pressure rises above this value, the valve is opened to release the excessive air pressure. The filter element has a mesh size of 7 m (for machines operated in dusty environments, use 2 m filter element) and prevents that dirt enters the tank when it is bled. The filter must be changed regularly, see maintenance schedule.

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19.10.3

Tank arrangement

Service Manual


Fig. 3

19.10.4

Hydraulic tank, connections part 1

2

Breather filter

E

Suction pipe for generator drive

3 4

Stop cock Return filter, complete

T4 T8

Return line from control valve block Radiator return line

5

Check valve

T11

A

Suction chamber

T15

Return line / leak oil variable-displacement pump Return line / control oil unit connection T

B

Return and collecting chamber

TL

Return line / control oil unit connection TL

D

Cleaning opening

TV

Return line / control oil unit connection TV

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Service Manual


Fig. 4

Hydraulic tank, connections part 2

1


C T1

Drainage and oil discharge piece T9 Return line / pipe fracture safety valves of T10 boom cylinder

Return line / attachment kit AS1 Return line / solenoid valve - travel

T1'

Return line / pipe fracture safety valves of T13 stick cylinder

Return line / hydraulic hammer

T1''

Return line / pipe fracture safety valves of T16 reg. cylinder Return line / leak oil variable-displaceT17 ment pump

Reserve

T2

T7

Return line / collecting pipe operator's platform

Return line / speed adjustment

T3

Return line / leak oil rotary connection

T18

Return line / TC valve

T5 T6

Return line / brake system Return line / steering system

T20 T21

Return line / HBGV block Reserve

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19.10.5

Tank arrangement

Service Manual


Fig. 5

19.10.6


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Service Manual


2.3

1


85

Lid

1/45 1/46

Check valve (tank lead pressure) Reducing piece

86 87

Seal Washer

1/50

Hose from turbo charger

88

Hex head screw

2 2/36

Breather filter, complete Seal ring

97 98

Reduction fitting Drain valve

2/37 2/38

Adapter Breather filter

99 100

Seal ring Seal ring

3

Stop cock, complete

200

Air filter

3/100

Suction pipe

B7

Vacuum switch / air filter

3/101

Seal ring

B8

Transducer / hydraulic oil temperature

3/102 3/103


B285 E50

Oil temperature sensor / fan control Power and fuse cabinet

4

Return filter, complete

Y3


4/41

Return filter, see Fig. 6

Y24


4/42

Retaining washer

Y50

4/43

Hex head screw

Y51

4/45

Fibreglass cartridge

Y62

Proportional solenoid valve / power control LR Proportional solenoid valve / flow limitation LS Solenoid valve / forward travel

4/46 10

Protective cylinder Mounting bolt / tank

Y63 Y358

Solenoid valve / reverse travel Proportional solenoid valve / engine speed

50

Oil level sight glass

Y371


51

Measuring coupling (for tank pressure or LMS temperature measurement)

Hydraulic oil return filter 4 see Fig. 6 The hydraulic tank is equipped with a magnet return filter 4 that is easily accessible, see also Fig. 6. To remove abrasion debris and dirt from the return oil of the attachments, it is fed through a two-stage filter cartridge 4.20 (mesh size 20/5 m). For machines operated in dusty environments, use cartridges of mesh size 10 m. The standard filter cartridge consists of 2 segments. The lower segment has a mesh size of 20 m, while the upper segment has a mesh size of 5 m. The filter fleece is made of fibreglass and is folded a sinusoidal shape. The fibreglass fleece is reinforced with a wire mesh. It is also supported by the perforated sheet metal cylinder along its circumference that helps the filter withstand the high radial forces that occur when large volumes of oil flow through it. The return oil flows from the centre outwards through the fleece. Suspended particles and abrasion debris is removed from the oil and collects in the filter fleece. The magnetic rod 4.8 removes all suspended metal particles from the oil. These particles then collect around the rod, held in place by magnetic force. The filter cartridge is protected by a bypass valve 5 in the receptacle 4.6. In the event of malfunction of the filter, which can occur if extremely cold oil is fed through or if the filter is blocked by dirt (filter surface of approx. 17000 cm2 blocked by dirt particles), there is a risk of backpressure in the filter chamber. If this pressure exceeds the opening pressure of 3 bar (determined by the spring force of the pressure spring 5.1), the closing angle 5.2 is shifted so that unfiltered oil escapes upwards through the protective cylinder 1.2 with bore to the suction section.

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19.10.7

Tank arrangement

Service Manual

Maintenance

3 Maintenance 3.1

Maintenance tasks on hydraulic tank See also maintenance instructions of group 3. Note! Modern standard maintenance procedures always include regular oil analyses in order to determine whether the hydraulic oil must be changed. Check the oil with an oil analysis kit, see group 2.01, and change it, if indicated. Otherwise, adhere to the prescribed oil change intervals in the maintenance instructions group 3.. For machines operated in extremely dusty environments, shorten the maintenance intervals. Warning! Risk of injury from pressurised hydraulic oil. Before carrying out any maintenance or repair work on the hydraulic tank or the hydraulic system, shut down the diesel engine and carefully release the pressure from the hydraulic tank by opening the breather filter 2.38. The magnetic rod 4.5 must be cleaned regularly according to the maintenance schedule. In new excavators, clean the rod daily to remove metal abrasion particles. Regularly change the filter cartridge 4.20, see maintenance instructions group 3. (Never reuse filter cartridges). To change the cartridge, remove the screws 4.43. Remove the lid with handle 4.1 together with the receptacle 4.6. Clean the magnetic rod 4.8 with a soft clean cloth. To replace the filter cartridge 4.20, remove the old cartridge with the bracket and dispose of it according to the statutory regulations. When inserting the new filter cartridge, ensure that the seal rings 4.21 and 4.22 are properly installed. Insert the filter cartridge 4.20 with the seal ring 4.21 in the tank connection (bottom end), see sectional drawing Fig. 6. Replace the lid with handle 4.1 and tighten the screws 4.43 (with the washers 4.42). After completion of the maintenance or repair work, tighten the breather filter 2.38. Start the diesel engine and test the hydraulic functions.

19.10.8

copyright by

MJFCIFSS

Service Manual

Tank arrangement Maintenance

Fig. 6 1 1.1

Return filter 4.7 4.8

Hydraulic tank, complete Tank connection

Roll pin Magnetic rod

1.2

Protective cylinder

4.20 Fibreglass filter cartridge

4 4.1

Return filter, complete Lid with handle

4.21 O-ring 4.22 O-ring

4.2 4.3

Flat gasket Roll pin

4.42 Retaining washer 4.43 Hex head screw

4.4 4.5

Spacer tube Rod

5 5.1

Check/bypass valve, complete Pressure spring

4.6

Receptacle

5.2

Valve sleeve

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19.10.9

Tank arrangement

Service Manual

Design of fuel tank

4 Design of fuel tank

3 1

4

Fig. 7

19.10.10

Design of fuel tank

1

Supply line to filter unit

40

Water drain valve

2

Fuel tank, complete

41

Seal ring

3

Return line from injection pump

46

Transducer fuel level (B1)

4 11

Internal lines Mounting bolts

48 49


21

Tank lid

60

TC valve / slewing gear

22

Strainer

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Service Manual

Tank arrangement Design of fuel tank

4.1

Fuel tank The fuel tank 2 is the fuel reservoir of the diesel engine. The fuel is fed through a line in the tank, leading from the bottom of the tank upwards and then through the filter unit to the injection system of the engine. From the injection system, the fuel flows through an internal line and down to the fuel tank. To refuel the machine, open the tank lid 21 and add fuel through the strainer 22. The fuel level in the tank 2 is monitored by a fuel level transducer 46 (B1) that sends and electric signal (resistance value) to the fuel level indicator P7 in the control panel of the operator's cab. Condensate collecting in the tank must be drained off at prescribed intervals, see maintenance instructions group 3. This is done with the drain valve 40 located at the bottom of the tank. If necessary, the tank can also be emptied that way, by removing the valve 40 and the seal cap 21.

4.2

Tubular-type sensor The tubular-type sensor B1 consists of a vertical tube in which 7 magnetic floats are placed one on top of the other. These floats are held at defined distances to each other and switch different reed contacts that correspond to specified fuel levels. Due to fuel in the tube and the physical properties of the currently switched contacts (parallel circuit with resistors), switching points with different resistance values are achieved (see values in Fig. 8). The resistance values thus vary, depending on whether the tank is full, half empty or empty, and the respective level is indicated by the fuel level indicator P7 and converted into analog values in the display field.

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19.10.11

Tank arrangement

Service Manual

Design of fuel tank

4.2.1

Tubular-type sensor for model A 309 / 311 to serial no. 31389, A 312 to serial no. 31398

Fig. 8

19.10.12

Switching points of tubular-type sensor

1

O-ring

6

3rd switching point (5/8 full; 29 Ohm)

2

Magnet

7

4th switching point (1/2 full; 35 Ohm)

3

Adjusting ring, secured with screw

8


4 5

1st switching point (full; 19 Ohm) 2nd switching point (3/4 full; 25 Ohm)

9 10

6th switching point (1/4 full; 54 Ohm) 7th switching point (reserve; 70 Ohm)

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Service Manual


4.2.2

Tubular-type sensor for model A 309 / 311 from serial no. 31390, model A 312 from 31399

Fig. 9


1 2

O-ring Magnet

7 8

3rd switching point (1/2 full; 29 Ohm) 4th switching point (3/8 full; 35 Ohm)

3


9


4

1st switching point (full; 11 Ohm)

10

6th switching point (reserve; 54 Ohm)

5

2nd switching point (3/4 full; 19 Ohm)

11


6


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19.10.13

Tank arrangement

Service Manual

Design of fuel tank

4.2.3

Tubular-type sensor for models A 314, A 316 and R 317 to serial no. 31402

Fig. 10

19.10.14


1

O-ring

6


2 3

Magnet Adjusting ring, secured with screw

7 8

4th switching point (1/2 full; 35 Ohm) 5th switching point (3/8 full; 43 Ohm)

4 5

1st switching point (full; 19 Ohm) 2nd switching point (3/4 full; 25 Ohm)

9 10

6th switching point (1/4 full; 54 Ohm) 7th switching point (reserve; 70 Ohm)

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Service Manual


4.2.4

Tubular-type sensor for models A 314, A 316 and R 317 from serial no. 31403

Fig. 11 1

Switching points of tubular-type sensor 7

O-ring


2

Magnet

8


3


9


4

1st switching point (full; 11 Ohm)

10


5


11


6


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19.10.15

Tank arrangement

Service Manual

Design of fuel tank

19.10.16

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Service Manual


Group

Type

Heating / air-conditioning system

17.30.1


17.1 MJF C I F S S

Service Manual

1.2 MJF C I F S S

Service Manual



Technical data

Page

17.30.3

Design and function

Page

17.30.5

Cooling circuit diagram

Page

17.30.8

Heating/air-conditioning circuit

Page

17.30.9

Operation of air-conditioning system

Page 17.30.11


Page 17.30.14

Maintenance

Page 17.30.18

Fault diagnosis

17.30Page 17.30.27

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17.30.1


Service Manual

Notes

1 Notes

17.30.2

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Service Manual

Heating / air-conditioning system Technical data

2 Technical data Device Series

A 309 - R 317 Litronic

Complete air-conditioning system Manufacturer

Wölfle GmbH

Type

R134a/air

Rated voltage

24 V DC

Refrigerant

R134a

Coolant oil

PAG

Air conditioning unit: Rated voltage

24 V

Max. air circulation rate

1050 m3/h (blower on)

Cooling performance

4,7 kW

Heating performance

9.0 kW

Blower steps

4

Max. current consumption

13.5 A

Compressor unit: Rated voltage

24 V

Max. air circulation rate

1500 m3/h

Heating performance

10.5 kW

Blower steps

1

Max. current consumption

12 A

Compressor: Type

Seltec TM - 15 HD

Rated voltage

24 V

Max. speed

6000 rpm

Flow rate

147 cm3

Direction of rotation

rotating clockwise or anticlockwise

Refrigerant

R134a

Oil

ZXL 100 PG (PAG oil)

Filling volume

150 cm3

Weight without oil

7 kg

Max. power consumption

48 W

Filter dryer: Capacity

0.7 l

Filter effect

up to particle size >6 ∑m

Water absorption in drying cartridge

16 g

Weight

1 kg

Leak test

35 bar

Bursting strength test

130 bar

Max. leak rate

5 g R134a/year

Refrigerant:

*

Type

R134a

Filling volume

1 000 g serial machine* 1 800 g operator's cab elevation*

The following parameters are crucial: ambient air temperature, operating pressure and filling level in sight glass.

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17.30.3


Service Manual

Purpose

3 Purpose The air-conditioning system is designed to help increase or reduce the temperature and air humidity in the operator's cab. The adjustment must be made independently from the actual ambient conditions.

4 Mode of operation

Fig. 1 M74-1

Air-conditioning system, part 1

1

Refrigeration compressor

M74-1 Fan motor

3

Fluid tank

M74-2 Fan motor

4 6

Dryer insert Sight glass

M74-3 Fan motor Y20 Electromagnetic clutch

B294

Pressure switch

The compressor 1 compresses the gaseous R134a refrigerant. In this process, the refrigerant is heated while being liquefied before it flows through the condenser 2 (heat exchanger). The heat is extracted from the refrigerator flowing through the condenser 2 by the air flow from the cooler blower M74-1/M74-2/M74-3. The liquefied coolant flows into the liquid tank 3 and then through the dryer insert 4 and the sight glass 6 to the expansion valve 7 (relief valve). The pressurised coolant is depressurised by means of the expansion valve. Due to the pressure drop, the refrigerant evaporates and extracts heat from the air in the operator's cab through the fins of the evaporator 8. The fan M65 blows cold air through the outlets back into the operator's cab. This results in a lower room temperature. The unit is also used to heat the cab during cold weather. The turning knob S284 allows for the adjustment of the heating performance at 4 levels.

17.30.4

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Service Manual

Heating / air-conditioning system Design and function

Fig. 2 M74-1

Air-conditioning system, part 2

7 8

Expansion valve Evaporator

M65 M72

Evaporator blower Servo motor

14

Heat exchanger for heating

M74

Condenser blower

5 Design and function See also Fig. 3. The air-conditioning system consists of 3 main components that are connected to each other with hoses: – The a/c compressor 1 with electromagnetic clutch Y20 is powered by the diesel engine through V-belts and is located near the diesel engine / the fan side. – The high-pressure area of the unit is located near the roof behind the operator's cab and consists of a condenser 2, liquid tank 3 with dryer insert 4, sight glass 6 and pressure switch B294, see also figure on page 17.50-11 and Fig. 13. The fan motors M74-1, M74-1, M74-3 remove the heat from the unit. – The low-pressure area of the unit is located inside the operator's cab, below the seat and consists of a combined heating/air-conditioning unit. The combined heating/air-conditioning unit includes the evaporator 8, the heat exchanger of the heating system 14 and the expansion valve 7. The evaporator 8 and the heat exchanger of the heating system 14 (water) are combined in a battery unit. The cooling water of the diesel engine is fed through hoses to the heat exchanger and forms a separate circuit. The thermostat B295 protects the evaporator 8 against icing. If the thermostat is triggered: • the magnetic clutch of the compressor 1 is switched off, • the condenser blower M74 is stopped and • the evaporator blower M65 remains on.

5.1

Cooling compressor 1 The cooling compressor 1 compresses the coolant in the circuit.

5.2

Condenser 2 In the air-filled fin condenser 2 the heat in the circuit is dissipated into the ambient air and the gase-

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17.30.5


Service Manual

Design and function ous refrigerant becomes liquid under pressure.

5.3

Liquid tank 3 The condenser 2 is located behind the liquid tank 3 where the liquid refrigerant is collected. This ensures that only liquid refrigerant without air bubbles reaches the expansion valve 7.

5.4

Dryer insert 4 Due to its chemical properties, the R134a refrigerant can only absorb very little water. At evaporation temperatures below 0°C, any residual water is normally eliminated in the form of ice at the valve, leading to unit failure. High humidity in the system can also cause corrosion. To prevent drying agent from entering the circuit, a number of sieves or filters are installed at the outlet end of the dryer 4. They remove contaminants such as acidic substances and dirt particles. The design of the solid body insert allows for efficient multi-layer drying.

5.5

Sight glass 6 During operation, the liquid refrigerant must flow through the sight glass 6 in front of the expansion valve 7 without any visible air bubbles.

5.6

Expansion valve 7 The expansion valve 7 acts as a thermostatic pressure-relief valve.

5.7

Evaporator 8 The evaporator 8 consists of an air-filled fan air cooling unit. The warm air is moved through the fins of the evaporator 8, so that heat dissipates through the fins and pipe walls to the refrigerant. The refrigerant evaporates and thus becomes gaseous.

5.8

Safety devices When the maximum pressure is reached at the high-pressure side, the pressure switch B294, see electrical diagrams Fig. 15, Fig. 16 and Fig. 17, the cooling compressor 1 are switched off through the electromagnetic clutch Y20. This feature is designed to prevent damage to the machine.

5.9

Lubricants The lubricant in the compressor 1 reduces friction and wear. It also facilitates heat dissipation and reduces leakage, noise and the transportation of abrasive particles. Due to the rotary movement of the compressor 1, the oil used as a lubricant for the compressor is transferred into the refrigerant circuit. The oil in the refrigeration system should amount to approx. 10% of the refrigeration volume. To reach this level, it might be necessary to add oil.

17.30.6

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Service Manual


5.10

Refrigerant The system is filled with R134a. As the coolant circuit of the air-conditioning system is not completely closed (reason: flexible connecting hoses from the compressor to the condenser and evaporator), there might be a need to add refrigerant from time to time. Within the circuit, the refrigerant constantly changes its physical state: – in the evaporator, it changes from liquid to gaseous, – in the condenser, it changes from gaseous to liquid. The refrigerant must meet a number of requirements. It must for example have a small vapour volume and a low condensation pressure.

5.11

Repair work For repair work on components in the cooling circuit, the R134a refrigerant must be drained off into a suitable container, see “Evacuating system and leakage check", page 16. The refrigerant can be cleaned and reconditioned by the refrigerant manufacturer. If you have access to an a/c service unit, see also Fig. 9, you can recycle the refrigerant safely.

5.12

Leak test Before carrying out a pressure and leak test, we recommend filling refrigerant vapour at a pressure of 1 bar and then to increase the pressure to the prescribed test pressure of 35 bar by adding dry nitrogen. Please ensure that the nitrogen used to pressurise the system is fed to the system through a reduction valve on the gas bottle. A drop in pressure indicates that there is a leak. There are various methods to locate the leak. A simple method consists of applying foam to the pipelines and devices in question, or immersing them in water. Alternatively, leaks can be detected with chemical or electrical methods. – Electronic leak detectors can find leaks of as little as 1 g/year.

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17.30.7


Service Manual

Design and function

Fig. 3

17.30.8

Diagram of the cooling circuit of the air-conditioning system

1 2

A/c compressor Condenser

9 Temperature sensor B294 Pressure switch

3

Liquid tank

B295 Electr. thermostat

4 6


M65 Blower motor M74 Fan motor

7 8

Expansion valve Evaporator

Y20

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Magnetic clutch

Service Manual


Fig. 4

Heating/air-conditioning circuit

13

Heating/ air-conditioning unit, complete

M65 Blower motor

14 19

Heat exchanger for heating Water valve

M71 Servo motor / water valve

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17.30.9


Service Manual

Design and function

Fig. 5

17.30.10

A/c system circuit

1

A/c compressor

14

Heat exchanger for heating

2 3

Condenser Liquid tank

B294 B295

Pressure switch Electr. thermostat

4

Dryer insert

M65

Blower motor

6

Sight glass

M74-1 Fan motor

7

Expansion valve

M74-2 Fan motor

8

Evaporator

M74-3 Fan motor

13

Heating/ air-conditioning unit

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Service Manual

Heating / air-conditioning system Operation of air-conditioning system

6 Operation of air-conditioning system The air-conditioning system is designed for cooling, heating and fan operation. The cooled or heated air flows through the outlets to the left and right behind the operator's seat and through the openings below the seat and near the windscreen into the operator's cab.

Fig. 6

Air outlet

Fig. 7

Control elements of the air-conditioning system

S92

Rotary potentiometer for air distribution control

S318

Air-conditioning switch

S93

Rotary potentiometer for heating/airconditioning control

S398

Switch for the assignment of the blower motor (change of direction of air flow from rear to front)

S284

Switch for blower level 1 – 4/ warm – cold

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17.30.11


Service Manual

Operation of air-conditioning system

Fig. 8

6.1

Control and actuating elements of the air-conditioning system

B295

Electr. thermostat with temperature sen- K405 sor

K402 K403

Relay for heating Relay for heating

K404

Relay of condenser motors M74-1 to M74-3

M71 M73

Relay for blower switch S284 Servo motor / water valve Servo motor for the reversal of the air distribution system

A/c operation For air-conditioning operation, the supply of diesel engine coolant must be discontinued by closing the water valve 19 by means of the rotary potentiometer S93 and the servo motor M71. Start the diesel engine and then switch on the air-conditioning system with the switch S318, Fig. 7. In order to prevent unnecessary heating up of the cold air through the windscreen, we recommend closing the outlet at the control console. Adjust the cold air temperature in the operator's cab with the rotary potentiometer S93 (thermostat controller), Fig. 7. The rotary potentiometer S92 and the servo motor M72 allow for the stepless adjustment of the a/c air distribution in the cab.

6.2

Heating operation The water flow through the heat exchanger 14 can be adjusted by means of the rotary potentiometer S93, Fig. 7, and the servo motor M71. Setting maximum heating output: Turn the turning knob to the right stop. Max. heat level Switching off heating: Turn the turning knob to the left stop. No neat

17.30.12

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Service Manual

Heating / air-conditioning system Operation of air-conditioning system

The air-conditioning system can be used at any time in the year to dehumidify the air in the cab. It can also be operated for that purpose together with the heating The rotary potentiometer S92 and the servo motor M72 allow for the stepless adjustment of the heating air distribution in the cab.

6.3

Fan operation Close the water supply with of the rotary potentiometer S93, Fig. 7. The heated/air-conditioned air volume supplied to the cab can be adjusted by means of the rocker switch S284 for the heater fan (4 speeds). Actuate the reversing switch S398 to change the direction of rotation of the fan motor by means of the servo motor M73 so the heated/conditioned air is supplied through the outlet at the windscreen rather than through the outlets at the back of the operator's cab. Note! For care and maintenance instructions for the air-conditioning system and instruction on the handling of the refrigerant, see chapter “Maintenance", page 18.

6.4

Air-conditioning system service device This device has been designed for the evacuation, recycling (cleaning, drying) and collecting of refrigerant in suitable containers (see page 16).

Fig. 9

Air-conditioning system service device

Note! For operating instructions, see the manual issued by the manufacturer.

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17.30.13


Service Manual


7 Installation instructions 7.1

Compressor New refrigeration compressors are filled with 150 cm3 of PAG-TL and nitrogen (N2). To distribute the oil in the compressor, rotate it a number of times up and down before installing it. Secure the compressor in such a way that the housing is not under stress. Remove the plastic cover from the low-pressure side of the compressor and carefully release the nitrogen! Caution! The special oil in the compressor might react with moisture contained in the air. When installing the compressor, ensure that the individual components remain sealed for as long as possible! Ensure that all components have the same temperature! Do not let compressor oil escape from the unit!

7.2

Filter dryer The filter dryer, which is also referred to as the collection dryer, consists of a collector, a dryer and a filter unit as well as a sight glass. It is of compact design. New dryers are clean, dry and sealed air-tight.

8 Handling of refrigerant If the refrigeration circuit is opened, refrigerant escapes in liquid or gaseous form. The higher the pressure in the system, the more refrigerant escapes. Caution! Refrigerant can cause serious injury to eyes and other parts of the body from frostbite! Wear protective goggles! Evaporating refrigerant can result in very low temperatures, which can cause localised frostbite! Avoid skin contact with liquid refrigerant! Refrigerants are good solvents for grease and oil. When in contact with the skin, they remove the protective film, causing damage to the skin! Wear suitable protective gloves! Danger! All refrigerants, with the exception of R11 and R113, displace oxygen in the atmosphere. Risk of suffocation! Handle refrigerants only in well-ventilated rooms! R 134a is heavier than air. Do not handle refrigerants when standing in a pit. Refrigerants are flammable and can be set on fire by glowing cigarette ash. The substances released by combustion are toxic and must not be inhaled! Do not smoke when handling refrigerants!

17.30.14

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Service Manual

Heating / air-conditioning system Handling of refrigerant

Warning! Misuse of refrigerant! Refrigerants have a narcotic effect and displace oxygen. Therefore do not inhale refrigerant vapours! Misuse of the substance can be fatal! Refrigeration systems are under pressure! The liquid or gaseous refrigerant in the refrigeration unit is under pressure. This fact must be taken into consideration when carrying out repair work on the system. Immediately seals any leaks on the refrigeration unit! Leaks do not only reduce the output rate of the unit, but might also cause dangerously high concentrations of gaseous refrigerant in the air. During filling and repair work, do not let refrigerant escape into the ambient air, but collect it in a special recycling container! If refrigerant escapes from the unit in a closed room, a high concentration of the substance in the air might be built up, endangering the health and safety of people due to the narcotic effect of the substance. Before carrying out any repair work on refrigeration systems, collect the refrigerant in the recycling container where it can be safely stored. After completion of the repair work and reconditioning of the refrigerant, it can be returned to the system. Alternatively, it can be returned to the supplier. Handle refrigerants only in well-ventilated rooms! To prevent the risk of high concentrations of refrigerant in a room, always ensure proper ventilation. Under certain circumstances, it might not be sufficient to open doors and windows, and it might be necessary to operate an extractor system that extracts the air near the point where the refrigerant escapes or at floor level. In the event of a sudden rise in refrigerant concentration in the air (e.g. after a pipeline rupture), immediately leave the room and only enter it after it has been properly ventilated! All refrigerants, with the exception of R11 and R113 pose a special risk to the health and safety of persons as they displace the oxygen in the air (risk of suffocation). If there is a risk of high refrigerant concentrations in the air, use respiratory equipment with separate oxygen supply! Filter masks with A-type filters (for solvents) do not provide sufficient protection and may only be used in rooms where the refrigerant concentration in the air does not exceed 0.5 vol. % (see respiratory protection sheet). As refrigerant vapours are heavier than air, there is a particular risk of high concentrations in pits and shafts. If you are not sure whether there is dangerous amount of refrigerant in the ambient air, use respiratory equipment with oxygen supply that is independent of the ambient air! Welding and soldering work on the refrigeration unit must be carried out in well-ventilated rooms! When refrigerant is combusted in the flame of the soldering iron or the arc of the welding machine, toxic substance are released that must not be inhaled! Before carrying out any welding or soldering work on the refrigeration unit, drain the refrigerant from the respective section of the unit and remove all residue by blowing out the lines and components with air or nitrogen! The substances produced when refrigerant is exposed to heat are not only toxic but also highly corrosive, causing damage to pipelines and other unit parts. In the case of chlorinated refrigerants, the decomposition products include hydrogen chloride, hydrogen fluoride and elementary chlorine. Under certain circumstances, highly toxic phosgene might be produced! When halogenated fluorocarbons are burnt, hydrogen fluoride might be produced.

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Service Manual

Filling instructions An acrid smell indicates that the refrigerant is decomposing due to overheating. Immediately leave the room, air it or wear a filter mask / respiratory filter B (acidic gases)! Please note that the dangerous decomposition products listed above are already in the air when the acrid smell occurs. Do not inhale these substances, as they can cause serious damage to the respiratory passages, the lung and other organs. The decomposition products are effectively removed by a filter mask with respiratory filter B (acidic gases). Always observe the user instructions of the filter!

8.1

First aid In the event of contact with eyes or mucous membranes, rinse the affected are with plenty of water and consult an ophthalmologist. In the event of contact with skin, remove all contaminated clothing and rinse the affected area with plenty of water. After inhalation of highly concentrated refrigerant vapours, remove the casualty to fresh air and keep at rest. Consult doctor. In the event of respiratory difficulties, administer oxygen. In case of respiratory arrest, resuscitate the casualty.

8.1.1

Instructions for doctor The inhalation of refrigerant vapours can cause drowsiness or unconsciousness. Refrigerants sensitise the heart against the effect of catecholamine, thus prohibiting the administration of adrenaline and similar substances. After inhalation of refrigerant decomposition products, there is an increased risk of lung oedema even after a prolonged latency period.

9 Filling instructions Ensure that your refrigerant is suitable for the refrigeration unit you wish to operate. For this purpose, carefully read the instruction signs on the various air-conditioning system components (compressor, dryer housing, etc.). The filling valves, pressure gauge battery and vacuum pump may only be used to add R134A/PAG (polyalkylene glycol oils) to air-conditioning systems. Refilling of refrigerant oil is normally only necessary in units that contain more than 2 kg of refrigerant. Caution! Do not mix the above substances with other refrigerant or oils as this could damage the air-conditioning system. Before connecting the quick-release couplings, ensure that the valves of the test pressure gauges are fully closed (turn pressure gauge valves clockwise). The centre fitting connection for the vacuum pump or filling bottle is thus closed.

10

Evacuating system and leakage check Connect the filling hoses to the quick-release couplings. Open both filling hoses. Run the vacuum pump for approx. 30 minutes to remove the refrigerant from the system. The pressure indicated at the blue pressure gauge (low-pressure gauge) is gradually reduced to 1 bar. Use a high-performance pump. Close the pressure gauge valve and check whether the pressure changes. If the pressure remains constant, there are no major leaks.

17.30.16

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Service Manual

Heating / air-conditioning system Filling of unit with refrigerant Disconnect the pump and connect the refrigerant bottle. Open the bottle valve and the red pressure gauge valve (high-pressure side) so that a small amount of refrigerant (approx. 100 g) can flow into the system (weigh the amount, if possible). Check all connections for leakage, using a leak detector (suitable for R134a) or a leak detection spray.

Fig. 10 1

Filling hoses and dryer container 2

Low-pressure line (blue)

High-pressure line (red)

11 Filling of unit with refrigerant Note! To fill the unit with refrigerant, use only bottles with one or two connections and a riser pipe.

11.1

Filling of liquid refrigerant when engine is off Bottles equipped with one connection must be placed upside down for liquid filling. To measure the filled amount of liquid, weigh the bottle before and after the filling process. Close the pressure gauge valve and connect the refrigerant bottle (yellow hose). Open the high-pressure valve (red). Wait until the pressure indicated at the gauge is constant. Close the red tap and place the bottle in an upright position. Before switching on the system, close the high-pressure gauge valve (red).

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Service Manual

Maintenance

11.2

Filling of gaseous refrigerant when engine is on The filling process must be completed with the addition of gaseous refrigerant while the compressor is running. The refrigerant must thereby be added in gaseous form through the open low-pressure gauge valve (blue). During the filling process, continuously weigh the refrigerant bottle. The filling process is completed when refrigerant flows through the sight glass of the dryer and does not contain gas bubbles. Close the low-pressure gauge valve (blue). Check the unit for leakage and proper operation and disconnect the filling devices.

12 Maintenance Important: The air-conditioning system should be switched on at least once every 3 months in order to lubricate rotating parts and prevent seizing of the compressor. The air-conditioning system must be serviced every year, preferably at the beginning of the hot season, by a specialist workshop. All services must be recorded in line with our warranty policy. The following maintenance tasks must be carried out at the beginning, middle and end of the cooling period: Check the V-belt tension and compressor fixture. Check the refrigerant level in the system. When the engine is on, the refrigerant must flow without air bubbles through the sight glass of the liquid tank (dryer).

Fig. 11 1

Sight glass 2

Floating ball (white)

Indicator bead

The refrigerant level is OK, if the floating ball is visible at the top of the sight glass. The refrigerant level is too low, if the floating ball is visible at the bottom of the sight glass. In this case, contact the customer service or identify the cause and eliminate it. Subsequently add refrigerant to the correct level. After the engine has been switched off, the liquid level in the tank should drop slightly in order to prevent overfilling of the unit. The indicator bead in the sight glass indicates the moisture content of the drying agent 4. indicator bead: blue = agent is dry The collector-dryer unit 3/4 is in proper working order. indicator bead: pink = agent is moist The collector-dryer unit must be replaced.

17.30.18

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Service Manual

Heating / air-conditioning system Cleaning of the compressor

The dryer tank should be replaced at each service, or at least every 2 years, as moisture in the agent and the formation of acids can damage the air-conditioning system. The dryer is installed in the compressor unit, see also Fig. 1.

13 Cleaning of the compressor The fins of the compressor must be cleaned with great care and without undue pressure, as they might otherwise be bent and damaged, preventing air flow through the compressor. The annual inspection at your service workshop should be carried out at the beginning of the cooling period and must be recorded in a service log.

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Service Manual

Air condition components

14 Air condition components

Fig. 12 13

17.30.20

A/c compressor 1 with bracket and V-belt tensioning device

1

A/c compressor

B294

Pressure switch

2

Condenser

B295

Electr. thermostat

3

Liquid tank

K402

Relay for heating

4 6


K403 K404

Relay for heating Relay for motors M74

8

Evaporator

K405

Relay for blower

13

Heating/ air-conditioning unit

M65

Blower motor

14 B294

Heat exchanger for heating Pressure switch

M72 M73

Air distribution servo motor Reversing servo motor

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Service Manual

Heating / air-conditioning system Air condition components

Fig. 13 13

2 3/4

Condenser with dryer, sight glass and pressure switch 6 B294

Condenser Dryer

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Sight glass Pressure switch

17.30.21


Service Manual

Air condition components

Fig. 14 13

17.30.22

Units of the air-conditioning system

8 14

Evaporator Heat exchanger

K404 K405

Relay for motors M74 Relay for blower

B295 K402

Thermostat Relay for heating

M65 M72

Blower motor Air distribution servo motor

K403

Relay for heating

M73

Reversing servo motor

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Service Manual

Heating / air-conditioning system Electrical diagrams

15 Electrical diagrams B294 B295

Pressure switch of a/c compressor Thermostat of heating

F318** F319**

Fuse (20 A) of heating/air-conditioning system terminal 30 Fuse (3 A) of heating/air-conditioning system terminal 15

F339**

Fuse (20 A) of condenser motors

K402

Relay for heating

K403**

Relay for heating

K404

Relay for condenser motors

K405

Relay for blower switch

M65** M71**

Blower motor Water valve servo motor

M72** M703**

Air distribution servo motor Reversing servo motor

M74-1

Condenser fan motor

M74-2 M74-3

Condenser fan motor Condenser fan motor

S92**

Air distribution potentiometer

S93** S284**

Heating/air-conditioning potentiometer Blower switch (4 speeds)

S318

Air-conditioning switch

S398**

Air distribution reversing switch

X842-1** Plug connection, 15-pin X842-2** Plug connection, 2-pin X859**


X860**


X861**


X862** X863**


X864


X952**


X955**


X959**


X964**


Y20

Solenoid valve / a/c clutch

** in basic diagram

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17.30.23


Service Manual

Electrical diagrams

Fig. 15

17.30.24

Air-conditioning system

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Service Manual

Heating / air-conditioning system Electrical diagrams

Fig. 16


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17.30.25


Service Manual

Electrical diagrams

Fig. 17

17.30.26


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Service Manual

Heating / air-conditioning system Troubleshooting

16 Troubleshooting Fault

Cause

Remedy

A/c system fails to cool

Faulty electrical connections

Check the connections of the magnetic clutch, switches, relays, temperature sensors and control unit.

Air temperature sensor defective*

Replace.

Icing protection temperature transducer defective*

Replace B295 (electrical thermostat only).

Rotary potentiometer defective

Replace S93 (electrical thermostat only).

Relay defective

Replace K404.

Fuse defective

Replace F318/F319.

Compressor shut down after exceeding of max. operating pressure

Clean compressor. Carry out function test of condenser blower F339.

Filter dryer blocked*

Exchange filter dryer.

Excessive refrigerant in the system*

Extract refrigerant.

Compressor shut down after pressure dropped below min. operating pressure

Check system for leaks; add refrigerant, if necessary.

Compressor magnetic clutch defective

Replace coil Y20.

V-belt broken

Replace V-belt.

Evaporator iced, check electrical control unit*

Adjust icing protection limit temperature settings of the thermostat (only with mechanical thermostat).

System cools only for a short time Tab. 1

Troubleshooting

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Service Manual

Troubleshooting Fault

Cause

Remedy

Cooling effect insufficient

Insufficient air flow rate

Clean fins in front of the evaporator and condenser.

Insufficient refrigerant in system*

Add refrigerant until it is visible without bubbles in the sight glass.

Expansion valve blocked*

Clean or replace expansion valve.

Expansion valve iced over, excessive moisture in system*

Filter dryer moisture indicator red. Replace filter dryer.

Filter dryer partly blocked (indicated by ice on the dryer)*

Exchange filter dryer.

Air in refrigerant circuit at increased pressure values, bubbles visible in sight glass*

Evacuate and refill system.

Ball bearing of compressor worn*

Replace ball bearing.

Magnetic clutch defective*

Replace magnetic clutch Y20.

Insufficient oil in compressor*

Refill oil.

V-belt worn

Replace V-belt.

V-belt loose

Tighten V-belt.

Loud noise from compressor

Whistling noise from Vbelt Tab. 1 *

17.30.28

Troubleshooting

The tasks marked with an asterisk must be carried out by a specialist refrigeration technician!

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Liebherr a309li - 307li - SERVICE MANUAL

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