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
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
Modification of series
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
WH / TH 08 LR KDS A 3 C
G 1/4 A
45
WH / TH 08 LM KDS A 3 C
M 12 X 1.5
45
WH / TH 10 LR KDS A 3 C
G 3/8 A
45
WH / TH 10 LM KDS A 3 C
M 14 X 1.5
55
WH / TH 12 LR KDS A 3 C
G 1/2 A
70
WH / TH 12 LM KDS A 3 C
M 16 X 1.5
80
WH / TH 15 LR KDS A 3 C
G 3/4 A
120
WH / TH 15 LM KDS A 3 C
M 18 X 1.5
100
WH / TH 18 LR KDS A 3 C
G1A
120
WH / TH 18 LM KDS A 3 C
M 22 X 1.5
140
WH / TH 22 LR KDS A 3 C
G 1 1/4 A
230
WH / TH 22 LM KDS A 3 C
M 27 X 2.0
320
WH / TH 28 LR KDS A 3 C
G 1 1/4 A
320
WH / TH 28 LM KDS A 3 C
M 33 X 2.0
360
WH / TH 35 LR KDS A 3 C
G 1 1/4 A
540
WH / TH 35 LM KDS A 3 C
M 42 X 2.0
540
WH / TH 42 LR KDS A 3 C
G 1 1/2 A
700
WH / TH 42 LM KDS A 3 C
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
WH / TH 08 SR KDS A 3 C
G 1/4 A
45
WH / TH 08 SM KDS A 3 C
M 14 X 1.5
55
WH / TH 10 SR KDS A 3 C
G 3/8 A
70
WH / TH 10 SM KDS A 3 C
M 16 X 1.5
80
WH / TH 12 SR KDS A 3 C
G 3/8 A
70
WH / TH 12 SM KDS A 3 C
M 18 X 1.5
100
WH / TH 16 SR KDS A 3 C
G 1/2 A
120
WH / TH 14 SM KDS A 3 C
M 20 X 1.5
125
WH / TH 20 SR KDS A 3 C
G 3/4 A
230
WH / TH 16 SM KDS A 3 C
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
WH / TH 25 SR KDS A 3 C
G1A
320
WH / TH 20 SM KDS A 3 C
M 27 X 2.0
320
WH / TH 30 SR KDS A 3 C
G 1 1/4 A
540
WH / TH 25 SM KDS A 3 C
M 33 X 2.0
360
WH / TH 38 SR KDS A 3 C
G 1/4 A
700
WH / TH 30 SM KDS A 3 C
M 42 X 2.0
540
WH / TH 38 SM KDS A 3 C
M 48 X 2.0
700
Tab. 2
Tightening torques of swivelling connections
3 of screw-in studs (Ermeto) 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
Bezeichnung Description / Dénomination
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
Bezeichnung Description / Dénomination
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
Fuels, lubricants and other consumables
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
API - GL -5 MIL-L 2105 B ZF TE-ML 05
SAE 90 LS
Rigid axle with drum brake
Gear oil
API - GL -5 MIL-L 2105 B ZF TE-ML 05
SAE 90 LS
Wheel hubs in steering and rigid axles with multi-disc and drum brakes
Gear oil
API - GL -5 MIL-L 2105 B ZF TE-ML 05
SAE 90 LS
Transmission
Gear oil
ZF TE-ML 07
SAE 10 W 30 SAE 10 W 20
Travel gear
Gear oil
API - GL -5 MIL-L 2105 B ZF TE-ML 05
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
Fuels, lubricants and other consumables
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
Fuels, lubricants and other consumables
Service Manual
Specifications for fuels, lubricants and consumables
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
Fuels, lubricants and other consumables Specifications for fuels, lubricants and consumables
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
Fuels, lubricants and other consumables
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
Fuels, lubricants and other consumables Specifications for fuels, lubricants and consumables
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
Fuels, lubricants and other consumables
Service Manual
Specifications for fuels, lubricants and consumables
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
Fuels, lubricants and other consumables Specifications for fuels, lubricants and consumables
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
Caltex UK Ltd, London
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
Fuels, lubricants and other consumables
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
Chevron Texaco, San Ramon, CA
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
Total Deutschland GmbH, Düsseldorf
D
Total Antigel S-MB 486
Total Deutschland GmbH, Düsseldorf
D
Total Frostfrei
Total Deutschland GmbH, Düsseldorf
D
Castrol Anti-Freeze O
Total Deutschland GmbH, Düsseldorf
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)
Caltex UK Ltd, London
GB
Chevron DEX-Cool Extended Life Prediluted 50/50 Anti-Freeze / Coolant
Chevron Texaco, San Ramon, CA
USA
Havoline XLC, 50/50
Arteco, Ghent
B
Chevron DEX-Cool Extended Life Prediluted 50/ 50 Anti-Freeze / Coolant
Chevron Texaco, San Ramon, CA
USA
Organicool 50/50
Total Deutschland GmbH, Düsseldorf
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
ZF Friedrichshafen AG / List of lubricants TE-ML 05, edition 01.04.2005
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
ZF Friedrichshafen AG / List of lubricants TE-ML 05, edition 01.04.2005
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
ZF Friedrichshafen AG / List of lubricants TE-ML 05, edition 01.04.2005
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
ZF Friedrichshafen AG / List of lubricants TE-ML 05, edition 01.04.2005
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
ZF Friedrichshafen AG / List of lubricants TE-ML 05, edition 01.04.2005
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
ZF Friedrichshafen AG / List of lubricants TE-ML 05, edition 01.04.2005
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
ZF Friedrichshafen AG / List of lubricants TE-ML 05, edition 01.04.2005
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
ZF Friedrichshafen AG / List of lubricants TE-ML 05, edition 01.04.2005
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
ZF Friedrichshafen AG / List of lubricants TE-ML 07, edition 01.04.2005
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
ZF Friedrichshafen AG / List of lubricants TE-ML 07, edition 01.04.2005
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
ZF Friedrichshafen AG / List of lubricants TE-ML 07, edition 01.04.2005
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
ZF Friedrichshafen AG / List of lubricants TE-ML 07, edition 01.04.2005
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
ZF Friedrichshafen AG / List of lubricants TE-ML 07, edition 01.04.2005
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
ZF Friedrichshafen AG / List of lubricants TE-ML 07, edition 01.04.2005
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
ZF Friedrichshafen AG / List of lubricants TE-ML 07, edition 01.04.2005
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
SUBGROUP - INDEX Section
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
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 hydraulic systems
2.05.1
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 electric systems
2.06.1
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 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
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-
Mounting device for piston rod bearings
2.13.1
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-
Slotted nut wrench for slewing gear
2.14.1
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-
Mounting device for slewing gear
2.15.1
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-
Mounting device for travel gear
2.16.1
R 313 LI 27752R 317 LI 18161-
2.2 MJFCIFSS
Service Manual
Special tools general
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
Special tools general
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
Special tools general
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
Special tools general
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
Special tools general
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
Special tools general
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
OEM pressure sensor, measuring range 0 - 600 bar, output 0 - 20 mA
6*
6140 624 01
4
OEM pressure sensor, measuring range 0 - 60 bar, output 0 - 20 mA
3*
6140 625 01
2.01.6
ID no.
copyright by
MJFCIFSS
1001 8329
Service Manual
Special tools general
Item
Sensors
ID no.
5
OEM pressure sensor, measuring range 0 - 10 bar, output 0 - 20 mA
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
RE 3 300 measuring turbine, measuring range 15 to 300 l/min
0*
6140 630 01
15
RE 3 600 measuring turbine, measuring range 25 to 600 l/min
2*
5009 492
16
DS 03 speed sensor, measuring range 1 to 9999 rpm
1*
6140 631 01
17
Spare reflector foil kit
1*
6140 632 01
18
Magnet holder, for DS 03 speed sensor
1*
6140 633 01
19
Inductive sensor for speed measurement
1*
6140 634 01
Item
Accessory
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
MK 12 measuring cable for the connection of the sensors, length 12 m
4*
6140 637 01
23
MK 12 measuring cable for the connection of the sensors, length 18 m
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
Special tools general
2.01.8
Service Manual
copyright by
MJFCIFSS
Service Manual
Special tools for diesel engines
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
Special tools for diesel engines
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
Special tools for diesel engines
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
Special tools for diesel engines
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
Special tools for diesel engines
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
Special tools for diesel engines
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
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
Special tools for hydraulic systems
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)
A 309 LI - R 317 LI copyright by
MJFCIFSS
Service Manual
Picture
Special tools for hydraulic systems
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
A 309 LI - R 317 LI copyright by
MJFCIFSS
2.05.3
Special tools for hydraulic systems
2.05.4
Service Manual
A 309 LI - R 317 LI copyright by
MJFCIFSS
Service Manual
Special tools for electric systems
Special tools for electric systems
copyright by
MJFCIFSS
2.06.1
Special tools for electric systems
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
Special tools for electric systems
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
Special tools for electric systems
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
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
Special tools for gears
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
Special tools for axles
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
Special tools for axles
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
Special tools for axles
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
Assembly tools for hydraulic cylinders
Service Manual
Assembly wrenches for piston nuts
2 Assembly wrenches for piston nuts
Fig. 2
Assembly wrenches for piston nuts
Size of piston nut 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
Assembly tools for hydraulic cylinders
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.
List of assembly wrenches
* 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
List of assembly wrenches
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
List of assembly wrenches
* 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
Assembly tools for hydraulic cylinders
Service Manual
Mounting and expanding sleeves
Tab. 7
2.12.6
Piston Ø
990 mounting sleeve ID no.
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
950 mounting sleeve ID no.
65
9177543
80
9231749
90
9248893
90
9248894
100
9248895
110
9248897
120
9248898
130
9248899
140
9177541
140
9952180
160
9248909
190
9281241
210
9281240
250
9951147
260
9284918
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
960 mounting sleeve ID no.
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
Assembly tools for hydraulic cylinders
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
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
Mounting device for slewing gear
2.15.2
Service Manual
copyright by
MJFCIFSS
Service Manual
Mounting device for travel gear
Mounting device for travel gear Tool used to dismantle and mount the multi-disc brake of the FAT 350 travel gear 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
Mounting device for travel gear
2.16.2
Service Manual
copyright by
MJFCIFSS
Service Manual
SUBGROUP - INDEX Section
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-
Inspection and maintenance schedule
3.32.1
A 312 LI 12363A 314 LI 2001A 316 LI 2001A 316 LI-IND 2001-
Inspection and maintenance schedule
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
=
see groups 1.50 and 3.29
=
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
Rotary connection 6 x
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
=
see groups 1.50 and 3.29
=
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
A 309 LI 20221copyright by
MJFCIFSS
Service Manual
Technical data A 309 Litronic
Transmission Travel speed in creeper / offroad / on-road gear
km/h
Oil volume in gearbox
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
=
wet multi-disc brake (negative)
=
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
=
see groups 1.50 and 3.29
=
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
Additional information
A 309 LI 20221copyright by
MJFCIFSS
3.09.3
Technical data
Service Manual
A 309 Litronic
3.09.4
A 309 LI 20221copyright by
MJFCIFSS
Service Manual
Technical data A 311 Litronic
Technical data 1 A 311 Litronic Type 718 Typ Valid from serial number
718 20222
718 29170
General
20222
29170
Weight of basic machine with 2-point support
t
10,03
=
Weight of backhoe bucket attachment (2-point support)
t
11,99
=
Overall length (with blade support)
mm
4370
=
Overall width
mm
2550
=
Overall height without attacment
mm
3110
=
Rear reach from centre/slewing radius
mm
1750 / 1750
=
Ground clearance
mm
320
=
Break-out force at tooth
KN
49,9 / 77,5
=
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
20222
29170
BF 4 M 1012
=
67 (91 PS)
=
2000
=
371 ± 10 at 1300-1500 min-1
=
15,5
=
see groups 1.50 and 3.29
=
215
=
see group 4.02
=
20222
29170
A 8 VO 55
=
axial piston swash plate double pump
=
57
=
212
=
ca.200
=
see groups 1.50 and 3.29
=
Control valve block
Typ
M8/NG 20
=
Rotary connection 7 x
Typ
DDF 720
=
A 311 LI 20222copyright by
MJFCIFSS
3.11.1
Technical data
Service Manual
A 311 Litronic Hydraulic system
20222
29170
Rotary connection 6 x
Typ
815.006
=
Boom cylinder (adjustable and gooseneck equipment) Ø piston / rod
mm
125 / 70
=
Stick cylinder with adjustable attachment Ø piston / rod
mm
100 / 70
=
Bucket cylinder Ø piston / rod
mm
90 / 60
=
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 7.33
=
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.
=
20222
29170
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
=
20222
29170
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
=
see groups 1.50 and 3.29
=
wet multi-disc brake (negative)
=
see group 9.10
=
20222
29170
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
=
3.11.2
A 311 LI 20222copyright by
MJFCIFSS
Service Manual
Technical data A 311 Litronic
Transmission Travel speed in creeper / offroad / on-road gear
km/h
Oil volume in gearbox
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
=
wet multi-disc brake (negative)
=
see group 11.08
group 11.20
20222
29170
Steering axle
Typ
262 LD
=
Rigid axle
Typ
162 LD
=
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
=
see groups 1.50 and 3.29
=
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 12.05 / 12.10 / 12.11
=
9.00 - 20 500 / 45 - 20
=
see group 12.54
=
20222
29170
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
20222
29170
Gear pump
=
2,0
=
see group 15.05
=
Additional information
Brake system Hydraulic pump
Typ
Max. flow
l/min
Additional information
A 311 LI 20222copyright by
MJFCIFSS
3.11.3
Technical data
Service Manual
A 311 Litronic
3.11.4
A 311 LI 20222copyright by
MJFCIFSS
Service Manual
Technical data A 312 Litronic
Technical data 1 A 312 Litronic Type 719 Typ Valid from serial number
719 12363
719 29898
General
12363
29898
Weight of basic machine with 2-point support
t
13,0
=
Weight of backhoe bucket attachment (2-point support)
t
12,5 - 13,5
=
Overall length (with blade support)
mm
4150
=
Overall width
mm
2500
=
Overall height without attacment
mm
3100
=
Rear reach from centre/slewing radius
mm
1900 / 1900
=
Ground clearance
mm
360
=
Break-out force at tooth
KN
64,5 / 79,1
=
Max. drawing pull (in offroad gear and max. operating pressure)
KN
87
Drive motor
12363
Type Power at rated speed according to DIN ISO 9249
KW
Rated speed
min-1
Max. torque
Nm
Oil volume in engine (filling quantity at oil change with filter)
l
Oil quality/oil viscosity and oil change intervals Fuel tank capacity
l
Additional information Hydraulic system Hydraulic pump
Typ
Design Max. flow
l/min
Hydraulic oil volume (oil change with filter)
l
Hydraulic oil and filter change intervals
29898
BF 4 M 1013 E
=
74 (100 PS)
=
1800
=
422 ± 10 at 1400 min-1
=
15,5
=
see groups 1.50 and 3.32
=
215
=
see group 4.04
=
12363
29898
LMV 130
=
axial piston swash plate pump
=
234
=
ca.300
=
see groups 1.50 and 3.32
=
Control valve block
Typ
M7/NG 20
=
Rotary connection 7 x
Typ
DDF 720
=
Rotary connection 6 x
Typ
815.006
=
A 312 LI 12363copyright by
MJFCIFSS
3.12.1
Technical data
Service Manual
A 312 Litronic Hydraulic system
12363
29898
Boom cylinder (adjustable and gooseneck equipment) Ø piston / rod
mm
100 / 70
=
Stick cylinder with adjustable attachment Ø piston / rod
mm
110 / 70
=
Bucket cylinder Ø piston / rod
mm
90 / 70
=
Support cylinder with outrigger - blade support Ø piston / rod
mm
120 / 70 - 90 / 50
=
Regulating cylinder with boom attachment Ø piston / rod
mm
140 / 80
=
see group 7.34
=
Gear pump
=
32
=
Additional cylinder Hydraulic pump / Brake system - Servo control
Typ
Max. flow / pilot control
l/min
Flow devider K (Brake) / R (Servo control)
2
30
Hydraulic pump
Typ
Gear pump
=
Hydraulic pump / fan drive (cooling)
Typ
Gear pump
=
Max. flow / fan drive (cooling)
l/min
50
=
Pilot control unit / working attachment / slewing gear
Typ
VG - 7 - 4
=
Pilot control unit / travel drive
VG - 7 - 1
=
Pilot control unit / support
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)
=
Alternator voltage / current
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
=
Oil volume in gearbox
l
4,5
=
see groups 1.50 and 3.32
=
wet multi-disc brake (negative)
=
see group 9.10
=
12363
29898
Slewing gear mechanism Gearbox
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
=
Travel speed in creeper / offroad / on-road gear
km/h
2,5 / 5,0 / 20,0
=
Oil volume in gearbox
l
3,3
3,0
1.50 and 3.32
=
Oil quality/oil viscosity and oil change intervals
3.12.2
A 312 LI 12363copyright by
MJFCIFSS
Service Manual
Technical data A 312 Litronic
Transmission
12363
29898
wet multi-disc brake (negative)
=
see group 11.08
group 11.20
12363
29898
Typ
262 / 51
=
Rigid axle
Typ
162 / 51
=
Oil volume in steering axle housing
l
8,2
=
Oil volume in steering axle wheel hub
l
2 x 3,0
=
Oil volume in rigid axle housing
l
10,5 (at disc brake)
=
Oil volume in rigid axle wheel hub
l
2 x 0,7 (2,0 l at disc brake)
=
see groups 1.50 and 3.32
=
Parking brake
Typ
Additional information Axles Steering axle
Oil quality/oil viscosity and oil change intervals Steering axle working brake
Typ
disc brake
=
Rigid axle working 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
Brake type Additional information Tyres
Zoll
Additional information Steering Hydraulic pump
Typ
Gear pump
=
Flow
l/min
44
=
Steering / steering valve
Typ
Servostat 2 / LAGS 200
LAGS 200
see group 13.20/ 13.22
see group 13.22
12363
29898
Additional information
Brake system Hydraulic pump
Typ
Gear pump
=
Max. flow
l/min
2,0
=
see group 15.05
=
Additional information
A 312 LI 12363copyright by
MJFCIFSS
3.12.3
Technical data
Service Manual
A 312 Litronic
3.12.4
A 312 LI 12363copyright by
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
Rear reach from centre/slewing radius
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
Oil volume in engine (filling quantity at oil change with filter)
l
Oil quality/oil viscosity and oil change intervals Total tank capacity
14,0 see groups 1.50 and 3.38
l
approx. 230
Additional information
see group 4.03
Hydraulic system
R 313 Litronic Type 636
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
Hydraulic oil volume (oil change with filter)
l
Hydraulic oil and filter change intervals
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
R 313 Litronic Type 636
Control valve block
Type
M7/NG 20-16
Rotary connection 5x
Type
DDF 520
Rotary connection 1x
Type
815.001
Boom cylinder (adjustable and gooseneck equipment) Ø piston / rod
mm
110 / 70
Stick cylinder with adjustable attachment Ø piston / rod
mm
115 / 70
Bucket cylinder Ø piston / rod
mm
90 / 60
Cylinder with blade support Ø piston / rod
mm
130 / 90
Regulating cylinder with boom attachment Ø piston / rod
mm
140 / 80
Hydraulic pump / pilot control
Type
Gear pump
Max. flow / pilot control
l/min
36
Hydraulic pump / fan drive (cooling)
Type
Gear pump
Max. flow / fan drive (cooling)
l/min
39
Pilot control unit / working attachment / slewing gear
Type
VG - 7 - 4
Pilot control unit / travel drive
Type
5 TH 6 NR
Additional information
see group 6
Electrical system
R 313 Li Type 636
Operating voltage
V
Battery capacity
Ah
Alternator voltage / current
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
Oil volume in gearbox
l
Oil quality/oil viscosity and oil change intervals Slewing gear brake
5.2 see groups 1.50 and 3.38
Type
Additional information
3.13.2
24
Wet multi-disc brake (negative) see group 9.10
R 313 LI 27752copyright by
MJFCIFSS
Service Manual
Technical data R 313 Litronic
Travel gear
R 313 Litronic Type 636
Gearbox
Type
FAT 350
Oil motor
Type
A6 VE 55
Travel speed in standard / fast travel mode
km/h
2.4 / 5.0
Oil volume in gearbox
l
Oil quality/oil viscosity and oil change intervals Travel brake
3.0 see groups 1.50 and 3.38
Type
Additional information
Multi-disc brake see group 11.62 or 11.67
Drive
R 313 Litronic Type 636
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
Additional information
4.6(4.9*) / 3.9(4.2*)/ 3.2(3.4*) see group 12
* in machines with blade
R 313 LI 27752copyright by
MJFCIFSS
3.13.3
Technical data
Service Manual
R 313 Litronic
3.13.4
R 313 LI 27752copyright by
MJFCIFSS
Service Manual
Technical data A 314 Litronic
Technical data 1 A 314 Litronic Type 635 Typ Valid from serial number
635 2001
General
2001
Weight of basic machine with 2-point support
t
11,4
Weight of backhoe bucket attachment (2-point support)
t
13,4 - 15,2
Overall length (with blade support)
mm
4235
Overall width
mm
2500
Overall height without attacment
mm
3107
Rear reach from centre/slewing radius
mm
2030 / 2030
Ground clearance
mm
348
Break-out force at tooth
KN
66,1 / 72,9
Max. drawing pull (in offroad gear and max. operating pressure)
KN
87
Drive motor
2001
Type
BF 4 M 1013 EC
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
80 (109 PS) -1
Oil quality/oil viscosity and oil change intervals
1800 460 ± 10 at 1400 min-1 15,5 see groups 1.50 and 3.32
Fuel tank capacity
l
Additional information
290 see group 4.05
Hydraulic system
2001
Hydraulic pump
Typ
Design
LMV 130 axial piston swash plate pump
Max. flow
l/min
Hydraulic oil volume (oil change with filter)
l
Hydraulic oil and filter change intervals
234 ca.250 see groups 1.50 and 3.32
Control valve block
Typ
M7/NG 20
Rotary connection 7 x
Typ
DDF 720
Rotary connection 6 x
Typ
815.006
A 314 LI 2001copyright by
MJFCIFSS
3.14.1
Technical data
Service Manual
A 314 Litronic Hydraulic system
2001
Boom cylinder (adjustable and gooseneck equipment) Ø piston / rod
mm
110 / 70
Stick cylinder with adjustable attachment Ø piston / rod
mm
115 / 75
Bucket cylinder Ø piston / rod
mm
100 / 70
Support cylinder with outrigger - blade support Ø piston / rod
mm
120 / 70 - 90 / 50
Regulating cylinder with boom attachment Ø piston / rod
mm
140 / 80
Additional cylinder
see group 7.35
Hydraulic pump / Brake system - Servo control
Typ
Max. flow / pilot control
l/min
Flow devider K (Brake) / R (Servo control)
Gear pump 32 2
30
Hydraulic pump
Typ
Gear pump
Hydraulic pump / fan drive (cooling)
Typ
Gear pump
Max. flow / fan drive (cooling)
l/min
45
Pilot control unit / working attachment / slewing gear
Typ
VG - 7 - 4
Pilot control unit / travel drive
VG - 7 - 1
Pilot control unit / support
VG - 7 - 2
Additional information
see group 6. / 7.
Elektrical system
2001
Operating voltage
V
24
Battery capacity
Ah
2 x 92 (in series)
Alternator voltage / current
V/A
28 / 55
Starter
V / KW
24 / 4,8
Slewing gear mechanism
2001
Gearbox
Typ
SAT 225 / 218
Oil motor
Typ
FMF 45
Max. slewing speed
min-1
9,0
Oil volume in gearbox
l
4,4
Oil quality/oil viscosity and oil change intervals
see groups 1.50 and 3.32
Slewing gear brake
Typ
Additional information
wet multi-disc brake (negative) see group 9.10
Transmission
2001
Gearbox
Typ
2 HL 100
Oil motor
Typ
LMV 108
Travel speed in creeper / offroad / on-road gear
km/h
2,5 / 5,0 / 20,0
Oil volume in gearbox
l
Oil quality/oil viscosity and oil change intervals
3.14.2
3,3 1.50 and 3.32
A 314 LI 2001copyright by
MJFCIFSS
Service Manual
Technical data A 314 Litronic
Transmission
2001
Parking brake
Typ
Additional information
wet multi-disc brake (negative) see group 11.10
Axles
2001
Steering axle
Typ
APL - B 745
Rigid axle
Typ
AP - B 745 TR
Oil volume in steering axle housing
l
7,5
Oil volume in steering axle wheel hub
l
2 x 0,7
Oil volume in rigid axle housing
l
9,0 ( 10,0 l at disc brake)
Oil volume in rigid axle wheel hub
l
2 x 0,7 (2,0 l at disc brake)
Oil quality/oil viscosity and oil change intervals
see groups 1.50 and 3.32
Steering axle working brake
Typ
disc brake
Rigid axle working brake
Typ
drum brake (option disc brake)
Brake type
(positive)
Additional information
see groups 12.28 / 12.29 / 12.31
Tyres
Zoll
Additional information
10.00 - 20 18.00 - 19,5 600 / 40 - 22,5 see group 12.54
Steering
2001
Hydraulic pump
Typ
Flow
l/min
44
Steering / steering valve
Typ
Servostat 2 / LAGS 200
Additional information
Gear pump
see group 13.20/ 13.22
Brake system
2001
Hydraulic pump
Typ
Max. flow
l/min
Additional information
Gear pump 2,0 see group 15.05
A 314 LI 2001copyright by
MJFCIFSS
3.14.3
Technical data
Service Manual
A 314 Litronic
3.14.4
A 314 LI 2001copyright by
MJFCIFSS
Service Manual
Technical data A 316 Litronic
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
Weight of basic machine with 2-point support
t
12,4
14,9
12,4
14,9
Weight of backhoe bucket attachment (2-point support)
t
15,0 16,7
18,9 21,0
15,0 16,7
18,9 21,0
Overall length (with blade support)
mm
4235
=
Overall width
mm
2500
=
Overall height without attacment
mm
3125
=
Rear reach from centre/slewing radius
mm
2230 / 2230
=
Ground clearance
mm
390
=
Break-out force at tooth
KN
66,8 / 90
=
Max. drawing pull (in offroad gear and max. operating pressure)
KN
90
=
Drive motor
2001
Type
BF 4 M 1013 EC
=
86 (115 PS)
=
1800
=
497 ± 10 at 1350 min-1
=
15,5
=
see groups 1.50 and 3.32
=
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
2001
28061
28062
290
=
Additional information
see group 4.05
=
Hydraulic system
2001
Hydraulic pump
Typ
Design
2001
28062
LMV 150 axial piston swash plate pump
Max. flow
l/min
Hydraulic oil volume (oil change with filter)
l
Hydraulic oil and filter change intervals
270 ca.290 see groups 1.50 and 3.32
Control valve block
Typ
M7/NG 20
Rotary connection 7 x
Typ
DDF 720
A 316 LI 2001A 316 LI-IND 2001-
28061
copyright by
MJFCIFSS
3.16.1
Technical data
Service Manual
A 316 Litronic Hydraulic system
2001
2001
28061
28062
Rotary connection 6 x
Typ
815.006
=
Boom cylinder (adjustable and gooseneck equipment) Ø piston / rod
mm
120 / 70
=
Stick cylinder with adjustable attachment Ø piston / rod
mm
Bucket cylinder Ø piston / rod
mm
100 / 70
=
Support cylinder with outrigger - blade support Ø piston / rod
mm
120 / 70 - 90 / 50
=
Regulating cylinder with boom attachment Ø piston / rod
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
=
Max. flow / pilot control
l/min
32
=
Flow devider K (Brake) / R (Servo control)
2
30
=
Hydraulic pump / fan drive (cooling)
Typ
Gear pump
=
Max. flow / fan drive (cooling)
l/min
45
=
Pilot control unit / working attachment / slewing gear
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)
=
=
Alternator voltage / current
V/A
28 / 55
=
=
Starter
V / KW
24 / 4,8
=
=
2001
28061
28062
28061
28062
Slewing gear mechanism Gearbox
Typ
SAT 225 / 218
Oil motor
Typ
FMF 45
Max. slewing speed
min-1
9,0
Oil volume in gearbox
l
4,4
Oil quality/oil viscosity and oil change intervals
see groups 1.50 and 3.32
Slewing gear brake
Typ
Additional information
wet multi-disc brake (negative) see group 9.10
Transmission
2001
Gearbox
Typ
2001
2 HL 100
2 HL 290
Oil motor
Typ
LMV 100
DMVA 108
Travel speed in creeper / offroad / on-road gear
km/h
2,5 / 5,0 / 20,0
=
Oil volume in gearbox
l
3,3
3,0
1.50 and 3.32
=
Oil quality/oil viscosity and oil change intervals
3.16.2
copyright by
MJFCIFSS
A 316 LI 2001A 316 LI-IND 2001-
Service Manual
Technical data A 316 Litronic
Transmission
2001
Parking brake
Typ
2001
28061
28062
wet multi-disc brake (negative)
=
Additional information
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
Oil volume in steering axle housing
l
Oil volume in steering axle wheel hub
l
Oil volume in rigid axle housing
l
9,0 (10 l at disc brake)
10,0
12,5
Oil volume in rigid axle wheel hub
l
2 x 1,0 (2,0 l at disc brake)
2,0
2,5
Oil quality/oil viscosity and oil change intervals
9,0
9,5
2 x 2,0
2,5
see groups 1.50 and 3.32
Steering axle working brake
Typ
Rigid axle working brake
Typ
Brake type
=
disc brake drum brake (option disc brake)
disc brake
= disc brake
(positive)
Additional information
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
= =
Additional information
see group 12.54
= =
Steering
2001
2001
28061
28062
Hydraulic pump
Typ
Gear pump
=
Flow
l/min
44
=
Steering / steering valve
Typ
Servostat 2 / LAGZ 190
LAGZ 190
Additional information
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
Additional information
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 R 317 Litronic
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
=
Overall height without attacment
mm
2995
=
Rear reach from centre/slewing radius
mm
2450
=
Ground clearance
mm
470
=
Break-out force at tooth
KN
100,6 / 125,7
=
Max. drawing pull (in offroad gear and max. operating pressure)
KN
151
=
R 317 Li Type 970
R 317 Type 362
BF 4 M 1013 EC
=
86 (115 HP)
=
Drive motor Type Power at rated speed according to DIN ISO 9249
kW -1
Rated speed
min
1800
=
Max. torque
Nm
491 ± 10 at 1400 min-1
=
Oil volume in engine (filling quantity at oil change with filter)
l
15,5
=
see group 1.50 and 3.38
=
Oil quality/oil viscosity and oil change intervals Fuel tank capacity
l
Additional information Hydraulic system Hydraulic pump
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
=
Hydraulic oil volume (oil change with filter)
l
approx. 290
=
see group 1.50 and 3.38
=
M7/NG 20-16
=
Hydraulic oil and filter change intervals Control valve block
Type
R 317 LI 18161copyright by
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
=
Boom cylinder (adjustable and gooseneck equipment) Ø piston / rod
mm
125 / 70
=
Stick cylinder with adjustable attachment Ø piston / rod
mm
130 / 80
=
Bucket cylinder Ø piston / rod
mm
120 / 80
=
Regulating cylinder with boom attachment Ø piston / rod
mm
140 / 80
=
Hydraulic pump / pilot control
Type
Gear pump
=
Max. flow / pilot control
l/min
36
=
Hydraulic pump / fan drive (cooling)
Type
Gear pump
=
Max. flow / fan drive (cooling)
l/min
43
=
Pilot control unit / working attachment / slewing gear
Type
VG - 7 - 4
=
Pilot control unit / travel drive
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)
=
Alternator voltage / current
V/A
28 / 55
=
Starter
V / kW
24 / 4,8
=
R 317 Li Type 970
R 317 Li Type 362
Slewing gear mechanism Gearbox
Type
SAT 225 / 218
=
Oil motor
Type
FMF 45
=
Max. slewing speed
min-1
9.0
=
Oil volume in gearbox
l
4,4
=
see groups 1.50 and 3.38
=
Wet multi-disc brake (negative)
=
see group 9.10
=
R 317 Li Type 970
R 317 Li Type 362
Oil quality/oil viscosity and oil change intervals Slewing gear brake
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
=
Oil volume in gearbox
l
4,5
=
see groups 1.50 and 3.38
=
Oil quality/oil viscosity and oil change intervals
3.17.2
R 317 LI 18161copyright by
MJFCIFSS
Service Manual
Technical data R 317 Litronic
Travel gear Parking brake
Type
Additional information
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
=
Additional information
R 317 LI 18161copyright by
MJFCIFSS
3.17.3
Technical data
Service Manual
R 317 Litronic
3.17.4
R 317 LI 18161copyright by
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
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MJFCIFSS
3.29.1
Inspection and maintenance schedule
Service Manual
A 309 Litronic / A 311 Litronic Maintenance / inspection at operating hours
WORK TO BE CARRIED OUT A 309 / A 311 Litronic By maintenance personnel (machine operator)
First and only interval Repeat interval Special interval every 250 hours
By authorized expert personnel
Note
First and only interval Repeat interval
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 pre- filter 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
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MJFCIFSS
2)
Service Manual
Inspection and maintenance schedule A 309 Litronic / A 311 Litronic
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
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
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MJFCIFSS
3.29.3
Inspection and maintenance schedule
Service Manual
A 309 Litronic / A 311 Litronic 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
First and only interval Repeat interval
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
Inspection and maintenance schedule A 309 Litronic / A 311 Litronic
Maintenance / inspection at operating hours
WORK TO BE CARRIED OUT A 309 / A 311 Litronic By maintenance personnel (machine operator)
First and only interval Repeat interval Special interval every 250 hours
By authorized expert personnel
Note
First and only interval Repeat interval
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
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MJFCIFSS
3.29.5
Inspection and maintenance schedule
Service Manual
A 309 Litronic / A 311 Litronic 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
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
Inspection and maintenance schedule
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)
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MJFCIFSS
3.32.1
Inspection and maintenance schedule
Service Manual
A 312 Litronic - A 316 Litronic 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
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
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MJFCIFSS
2)
Service Manual
Inspection and maintenance schedule A 312 Litronic - A 316 Litronic
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
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
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MJFCIFSS
3.32.3
Inspection and maintenance schedule
Service Manual
A 312 Litronic - A 316 Litronic 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
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
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MJFCIFSS
Note
Service Manual
Inspection and maintenance schedule A 312 Litronic - A 316 Litronic
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
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
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MJFCIFSS
3.32.5
Inspection and maintenance schedule
Service Manual
A 312 Litronic - A 316 Litronic 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
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
Inspection and maintenance schedule
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
.........................................
Mechanic: ......................................... Customer: .........................................
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.
Maintenance / inspection at operating hours
WORK TO BE CARRIED OUT R 313 Litronic / R 317 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 Empty dust collector on air filter (shorten or extend interval as necessary)
copyright by
MJFCIFSS
3.38.1
Inspection and maintenance schedule
Service Manual
R 313 Litronic / R 317 Litronic Maintenance / inspection at operating hours
WORK TO BE CARRIED OUT R 313 Litronic / R 317 Litronic By maintenance personnel (machine operator)
First and only interval Repeat interval Special interval every 250 hours
By authorized expert personnel
Note
First and only interval Repeat interval
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 pre- filter 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
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MJFCIFSS
2)
Service Manual
Inspection and maintenance schedule R 313 Litronic / R 317 Litronic
Maintenance / inspection at operating hours
WORK TO BE CARRIED OUT R 313 Litronic / R 317 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
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.)
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MJFCIFSS
3.38.3
Inspection and maintenance schedule
Service Manual
R 313 Litronic / R 317 Litronic Maintenance / inspection at operating hours
WORK TO BE CARRIED OUT R 313 Litronic / R 317 Litronic By maintenance personnel (machine operator)
First and only interval Repeat interval Special interval every 250 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
Inspection and maintenance schedule R 313 Litronic / R 317 Litronic
Maintenance / inspection at operating hours
WORK TO BE CARRIED OUT R 313 Litronic / R 317 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
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
Inspection and maintenance schedule
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
Inspection and maintenance schedule
Service Manual
R 313 Litronic / R 317 Litronic Date:
3.38.6
...................................... ...
Mechanic: ......................................... Customer: .........................................
copyright by
MJFCIFSS
Service Manual
SUBGROUP - INDEX Section
Group
Type
Technical data of diesel engines
4.02.1
A 309 LI 20221A 311 LI 20222-
Technical data of diesel engines
4.03.1
R 313 LI 27752-
Technical data of diesel engines
4.04.1
A 312 LI 12363-
Technical data of diesel engines
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
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MJFCIFSS
4.02.1
Technical data of diesel engines
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
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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
4-stroke direct injection
Bore
mm
101
Boom
mm
126
Displacement
cm3
4038
Firing sequence
1-3-4-2
Compression ratio
19 : 1
Combustion pressure at starting speed
bar
Firing interval
°kW
180
Weight (dry)
kg
380
Direction of rotation (seen from flywheel)
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
Lowest operating speed
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
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MJFCIFSS
4.03.1
Technical data of diesel engines
Service Manual
Engine Type: BF 4 M 2012 C Filling volumes (approx. values)
R 313-Li / 27752
Lubricating oil in standard oil pan
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
14.0
Cooling liquid including coolant
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
Min. lubricating oil pressure
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
Safety device: oil pressure sensor
1
B 16 response pressure: 0.5 bar
Coolant temperature sensor
1
B2 response temperature 100 ±3°C
Coolant level sensor
1
B3
Main element Safety element
For order numbers, see respective spare parts list and service packs
Antifreeze agent / mixing ratio
4.03.2
Antifreeze content
Water content
Antifreeze content
-37°C
50%
50%
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MJFCIFSS
Service Manual
Technical data of diesel engines Engine Type: BF 4 M 2012 C
Note! Do not exceed an antifreeze concentration of 60%, as this tends to lead to reduced protection and cooling effect!
copyright by
MJFCIFSS
4.03.3
Technical data of diesel engines
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
4-stroke direct injection
Bore
mm
108
Stroke
mm
130
Displacement
3
4764
cm
Firing sequence
1-3-4-2
Compression ratio
17.5 : 1
Combustion pressure at starting speed
bar
30 - 38
Firing interval
°kW
180
Weight (dry)
kg
430 (according to DIN 70020 - A)
Direction of rotation (seen from flywheel)
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
Lowest operating speed
rpm
1000
Speed at max. torque
rpm
1400
Settings
A 312-Li / 12363
Inlet valve play (cold)
mm
0.30
Outlet valve play (cold)
mm
0.50
°CA before TDC
Preset by manufacturer and specified on type plate
Begin of delivery
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4.04.1
Technical data of diesel engines
Service Manual
Engine type: BF 4 M 1013 E Filling volumes (approx. values)
A 312-Li / 12363
Lubricating oil in standard oil pan
l
11
Filling volumes (for oil change with filter replacement)
l
approx. 15.5
Cooling liquid including coolant
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)
Min. lubricating oil pressure
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
Max. engine inclination towards right or left
30°
Max. engine inclination towards fan / flywheel
30 °
Engine wear parts, V-belts and safety devices
A 312-Li / 12363
Fuel filter
1
Coarse filter 10 m
Fuel filter
1
Fine filter 3 m
Oil filter
1
Air filter
1 1
Main element Safety element
V-belt
1 1
10 x 874 10x1050
Safety device: oil pressure sensor
1
B 16 response pressure: 0.5 bar
Coolant temperature sensor
1
B2 response temperature 100 ±3°C
Coolant level sensor
1
B3
For order numbers, see respective spare parts list and service packs
Antifreeze agent / mixing ratio
Antifreeze content
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!
4.04.2
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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
Tightening instructions
Apply a little oil to the screw thread and head surface
Apply a little oil to the screw thread and head surface
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
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4.04.3
Technical data of diesel engines
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
Combustion pressure at starting speed
bar
30 - 38
Firing interval
°kW
180
Weight (dry)
kg
430 (according to DIN 70020 - A)
Direction of rotation (seen from flywheel)
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
Lowest operating speed
min-1
1000
Speed at max. torque
min-1
1400
Settings
1800
A 316-Li / 2001 R 317 Li / 18161
A 314-Li / 2001
Inlet valve play (cold)
mm
0,30
Outlet valve play (cold)
mm
0,50
°CA before TDC
Preset by manufacturer and specified on type plate
Begin of delivery
copyright by
MJFCIFSS
4.05.1
Technical data of diesel engines
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
Lubricating oil in standard oil pan
l
11
Filling volumes (for oil change with filter replacement)
l
approx. 15,5
Cooling liquid including coolant
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)
Min. lubricating oil pressure
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
Max. engine inclination towards right or left
30°
Max. engine inclination towards fan / flywheel
30 °
Engine wear parts, V-belts and safety devices
A 316-Li / 2001 R 317 Li / 18161
A 314-Li / 2001
Fuel filter
1
Coarse filter 10 m
Fuel filter
1
Fine filter 3 m
Oil filter
1
Air filter
1 1
Main element Safety element
V-belt
1 1
10 x 874 10x1050
Safety device: oil pressure sensor
1
B 16 response pressure: 0.5 bar
Coolant temperature sensor
1
B2 response temperature 100 ±3°C
Coolant level sensor
1
B3
For order numbers, see respective spare parts list and service packs
Antifreeze agent / mixing ratio
Antifreeze content
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!
4.05.2
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
Tightening instructions
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
Apply a little oil to the screw thread and head surface
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
Tightening instructions
Apply a little oil to the screw thread and head surface
Apply a little oil to the screw thread and head surface
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
Technical data of diesel engines
Service Manual
Tightening torques / oversize levels Oversize levels / limit values
Tightening instructions
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
SUBGROUP - INDEX Section
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
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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
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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
Retaining washer Hex head screw
7
Allen head and hex head screw
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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
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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.
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5.10.1
Clutch
Service Manual
Installation and dismantling of the coupling
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).
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5.10.3
Clutch
Service Manual
Installation and dismantling of the coupling
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
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MJFCIFSS
Service Manual
Clutch Installation and dismantling of the coupling
10 10.10
C D
Variable-displacement pump Pump drive shaft
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MJFCIFSS
Flywheel / engine Intermediate housing / engine
5.10.5
Clutch
Service Manual
Installation and dismantling of the coupling
5.10.6
copyright by
MJFCIFSS
Service Manual
SUBGROUP - INDEX Section
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
A 312 LI 12363A 314 LI 2001A 316 LI 2001A 316 LI-IND 2001R 317 LI 18161-
Design of hydraulic system
6.22.1
A 309 LI 20221A 311 LI 20222-
Layout of hydraulic system
6.24.1
A 312 LI 12363A 314 LI 2001A 316 LI 2001A 316 LI-IND 2001-
Layout of hydraulic system
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-
Adjustment guidelines for hydraulic system
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
Measuring point Specified value
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
A 309 LI 20221-27109 copyright by
MJFCIFSS
Service Manual
Adjustment protocol A 309 Litronic from 20221
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
Measuring point Specified value
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
A 309 LI 20221-27109 copyright by
MJFCIFSS
6.09.3
Adjustment protocol
Service Manual
A 309 Litronic from 20221
Checks
Measuring point Specified value
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
A 309 LI 20221-27109 copyright by
MJFCIFSS
Service Manual
Adjustment protocol A 309 Litronic from 20221
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.
Measuring point Specified value
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
A 309 LI 20221-27109 copyright by
MJFCIFSS
6.09.5
Adjustment protocol
Service Manual
A 309 Litronic from 20221
Checks
8.
Secondary pressure Primary pressure relief valve 120 / 121 screwed in
Measuring point Specified value
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
A 309 LI 20221-27109 copyright by
MJFCIFSS
Service Manual
Adjustment protocol A 309 Litronic from 20221
Checks
9.
10.
Measuring point Specified value
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
A 309 LI 20221-27109 copyright by
MJFCIFSS
6.09.7
Adjustment protocol
Service Manual
A 309 Litronic from 20221
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
Valve 192 (high pressure setting) Lock nut 1 Adjusting screw 2
198 70 ±5 bar
Valve 192 (low pressure setting) Lock nut 3 Adjusting screw 4
197 70 ± 5bar
Valve 191 (low pressure setting) Lock nut 3 Adjusting screw 4
Slowing down Turning right
Turning left
6.09.8
Measuring point Specified value
A 309 LI 20221-27109 copyright by
MJFCIFSS
Service Manual
Adjustment protocol A 309 Litronic from 20221
Checks
12.
Travel motor
12.1
Regulation Begin of regulation End of regulation
12.2
Measuring point Specified value
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
A 309 LI 20221-27109 copyright by
MJFCIFSS
6.09.9
Adjustment protocol
Service Manual
A 309 Litronic from 20221
Checks
13.
Measuring point Specified value
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
A 309 LI 20221-27109 copyright by
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
Measuring point Specified value
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
at speed level 1 (low idle rpm)
3.2
3.3
using adapter cable at Y50.
Measuring point 59 ( X3 )
Current
850 +25 mA
Control pressure LR
30 ±1 bar
at power test Current
<50mA
Control pressure LR
1 bar (tank pressure)
Checking regulating pressure for emergency operation
Measuring point 59 30 ±1 bar
Remove plug of Y50. Set valve to emergency setting. (Remove cotter pin and actuate lever.) Diagram, see page 12.
A 309 LI 27110copyright by
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
Current 200 - > 900 mA via speed steps or flow reduction kit
5.
Checking flow reduction of pump P1
5.1
Value X
6.09.12
Measuring point Specified value
Actual value
Possible Setting.
View Comment Take measure using adapter cable at Y51.
Measuring point 57 ( X1)
Pressure: see diagram
12,4 ±0.2 mm
A 309 LI 27110copyright by
MJFCIFSS
Service Manual
Adjustment protocol A 309 Litronic from 27110 (applicable from software version 5.12)
Checks
Measuring point Specified value
6.
Begin of hydraulic regulation of double variable-displacement 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 rpm) 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
A 309 LI 27110copyright by
MJFCIFSS
6.09.13
Adjustment protocol
Service Manual
A 309 Litronic from 27110 (applicable from software version 5.12)
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.
Measuring point Specified value
Actual value
Possible Setting.
View Comment High idle rpm
Measuring point 40/41
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
A 309 LI 27110copyright by
MJFCIFSS
Service Manual
Adjustment protocol A 309 Litronic from 27110 (applicable from software version 5.12)
Checks 8.
Secondary pressure Primary pressure relief valve 120 / 121 screwed in
Measuring point Specified value
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 - retract stick cylinder
380 +20 bar
Valve 127
- extend stick cylinder
380 +20 bar
Valve 128 * adjustment to 240 bar + 1 revolution of adjusting screw = 380 bar
A 309 LI 27110copyright by
MJFCIFSS
6.09.15
Adjustment protocol
Service Manual
A 309 Litronic from 27110 (applicable from software version 5.12)
Checks 8.2
9.
6.09.16
Measuring point Specified value
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
Primary pressure / high pressure
Measuring point 40
High idle rpm
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
350 +10 bar Measuring point 41
A 309 LI 27110copyright by
MJFCIFSS
Service Manual
Adjustment protocol A 309 Litronic from 27110 (applicable from software version 5.12)
Checks 10.
Measuring point Specified value
Primary pressure / low pressure
Measuring point 45
Primary relief valve 123
110 +20 bar
Actual value
Possible Setting.
View Comment High idle rpm
Extending swivel cylinder
A 309 LI 27110copyright by
MJFCIFSS
6.09.17
Adjustment protocol
Service Manual
A 309 Litronic from 27110 (applicable from software version 5.12)
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
Valve 192 (high pressure setting) Lock nut 1 Adjusting screw 2
198 70 ±5 bar
Valve 192 (low pressure setting) Lock nut 3 Adjusting screw 4
197 70 ± 5bar
Valve 191 (low pressure setting) Lock nut 3 Adjusting screw 4
Slowing down Turning right
Turning left
6.09.18
Measuring point Specified value
A 309 LI 27110copyright by
MJFCIFSS
Service Manual
Adjustment protocol A 309 Litronic from 27110 (applicable from software version 5.12)
Checks 12.
Travel motor
12.1
Regulation Begin of regulation End of regulation
12.2
Measuring point Specified value
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 rpm
Speeder machine
1930 ±25 rpm
on drive shaft, measured during onroad gear Qmin stop screw 212.1
Checking measurement Y
13.
Standard machine
23.8 mm
Speeder machine
26.0 mm
Lowering speed of equipment
4 seconds approx.
Checking measurement Z of stop screw 162
5 mm
A 309 LI 27110copyright by
MJFCIFSS
6.09.19
Adjustment protocol
Service Manual
A 309 Litronic from 27110 (applicable from software version 5.12)
Checks 14.
Hydrostatic fan drive
14.1
Checking the fan speed Check speed while diesel engine runs at rated speed. Disconnect Y352.
Measuring point Specified value
Actual value
Possible Setting.
View Comment
2150 +50rpm
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 (observe afterrun).
6.09.20
A 309 LI 27110copyright by
MJFCIFSS
Service Manual
Adjustment protocol A 311 Litronic from 20222
Adjustment protocol 1 A 311 Litronic from 20222 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
Measuring point 49
Actual value
Possible Setting.
View Comment
Set measure at valve 51.
32 ±1 bar
A 311 LI 20222-27111 copyright by
MJFCIFSS
6.11.1
Adjustment protocol
Service Manual
A 311 Litronic from 20222
Checks
3.
Horsepower control
3.1
at speed level 1 (low idle rpm)
3.2
3.3
6.11.2
Measuring point Specified value
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 Current
<50mA
Control pressure LR
1±2 bar (tank pressure)
Checking regulating pressure for emergency operation
Measuring point 59 30 ±1 bar
Remove plug of Y50. Set valve to emergency setting. (Remove cotter pin and actuate lever.)
A 311 LI 20222-27111 copyright by
MJFCIFSS
Service Manual
Adjustment protocol A 311 Litronic from 20222
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
Measuring point Specified value
Actual value
Possible Setting.
View Comment Take measure using adapter cable atY51.
Measuring point 57 ( X1)
Pressure: see Diagram
up to pump no. 20194344
8,8 ±0.2 mm
starting with pump no. 20194345
11,8 ±0.2 mm
A 311 LI 20222-27111 copyright by
MJFCIFSS
6.11.3
Adjustment protocol
Service Manual
A 311 Litronic from 20222
Checks
Measuring point Specified value
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
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
(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
Adjust using screw 2 on pump regulator
60±2 bar
10 bar
Re-connect plug on Y 50 and Y51. Return Y50 to normal position
6.11.4
A 311 LI 20222-27111 copyright by
MJFCIFSS
Service Manual
Adjustment protocol A 311 Litronic from 20222
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.
Measuring point Specified value
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
A 311 LI 20222-27111 copyright by
MJFCIFSS
6.11.5
Adjustment protocol
Service Manual
A 311 Litronic from 20222
Checks
8.
Secondary pressure Primary pressure relief valve 120 / 121 screwed in
Measuring point Specified value
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
- retract boom cylinder
380 +20 bar
Valve 131
- extend boom 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
6.11.6
- 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
- Travel reverse
380 +20 bar
Valve 214 Valve 215
A 311 LI 20222-27111 copyright by
MJFCIFSS
Service Manual
Adjustment protocol A 311 Litronic from 20222
Checks
9.
10.
Measuring point Specified value
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
A 311 LI 20222-27111 copyright by
MJFCIFSS
6.11.7
Adjustment protocol
Service Manual
A 311 Litronic from 20222
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
Valve 192 (high pressure setting) Lock nut 1 Adjusting screw 2
198 70 ±5 bar
Valve 192 (low pressure setting) Lock nut 3 Adjusting screw 4
197 70 ± 5bar
Valve 191 (low pressure setting) Lock nut 3 Adjusting screw 4
Slowing down Turning right
Turning left
6.11.8
Measuring point Specified value
A 311 LI 20222-27111 copyright by
MJFCIFSS
Service Manual
Adjustment protocol A 311 Litronic from 20222
Checks
Measuring point Specified value
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.
View Comment Adjusting screw 213.1 on travel motor 210
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
13.
Standard machine
23.8 mm
Speeder machine
26.0 mm
Lowering speed of equipment
4 seconds approx.
Checking measurement Z of stop screw 162
5 mm
A 311 LI 20222-27111 copyright by
MJFCIFSS
6.11.9
Adjustment protocol
Service Manual
A 311 Litronic from 20222
Checks
14.
Hydrostatic fan drive
14.1
Checking the fan speed Check speed while diesel engine runs at rated speed. Disconnect Y352.
Measuring point Specified value
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.
6.11.10
A 311 LI 20222-27111 copyright by
MJFCIFSS
Service Manual
Adjustment protocol A 311 Litronic from 27112 (applicable from software version 5.12)
Adjustment protocol 2 A 311 Litronic from 27112 (applicable from software version 5.12) 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 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
at speed level 1 (low idle rpm)
3.2
3.3
using adapter cable at Y50.
Measuring point 59 ( X3 )
Current
850 +25 mA
Control pressure LR
30 ±1 bar
at power test Current
<50mA
Control pressure LR
1 bar (tank pressure)
Checking regulating pressure for emergency operation
Measuring point 59 30 ±1 bar
Remove plug of Y50. Set valve to emergency setting. (Remove cotter pin and actuate lever.) Diagram, see page 12.
A 311 LI 27112copyright by
MJFCIFSS
6.11.11
Adjustment protocol
Service Manual
A 311 Litronic from 27112 (applicable from software version 5.12)
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
6.11.12
Measuring point Specified value
Actual value
Possible Setting.
View Comment Take measure using adapter cable at Y51.
Measuring point 57 ( X1)
Pressure: see diagram
11,8 ±0.2 mm
A 311 LI 27112copyright by
MJFCIFSS
Service Manual
Adjustment protocol A 311 Litronic from 27112 (applicable from software version 5.12)
Checks
Measuring point Specified value
6.
Begin of hydraulic regulation of double variable-displacement 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
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
(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
60 ±2 bar
Adjust using screw 2 on pump regulator
10 bar
Re-connect plug on Y 50 and Y51. Return Y50 to normal position
A 311 LI 27112copyright by
MJFCIFSS
6.11.13
Adjustment protocol
Service Manual
A 311 Litronic from 27112 (applicable from software version 5.12)
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.
Measuring point Specified value
Actual value
Possible Setting.
View Comment High idle rpm
Measuring point 40/41
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
A 311 LI 27112copyright by
MJFCIFSS
Service Manual
Adjustment protocol A 311 Litronic from 27112 (applicable from software version 5.12)
Checks 8.
Secondary pressure Primary pressure relief valve 120 / 121 screwed in
Measuring point Specified value
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 - retract stick cylinder
380 +20 bar
Valve 127
- extend stick cylinder
380 +20 bar
Valve 128 * adjustment to 240 bar + 1 revolution of adjusting screw = 380 bar
A 311 LI 27112copyright by
MJFCIFSS
6.11.15
Adjustment protocol
Service Manual
A 311 Litronic from 27112 (applicable from software version 5.12)
Checks 8.2
9.
6.11.16
Measuring point Specified value
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
Primary pressure / high pressure
Measuring point 40
High idle rpm
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
350 +10 bar Measuring point 41
A 311 LI 27112copyright by
MJFCIFSS
Service Manual
Adjustment protocol A 311 Litronic from 27112 (applicable from software version 5.12)
Checks 10.
Measuring point Specified value
Primary pressure / low pressure
Measuring point 45
Primary relief valve 123
110 +20 bar
Actual value
Possible Setting.
View Comment High idle rpm
Extending swivel cylinder
A 311 LI 27112copyright by
MJFCIFSS
6.11.17
Adjustment protocol
Service Manual
A 311 Litronic from 27112 (applicable from software version 5.12)
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
Valve 192 (high pressure setting) Lock nut 1 Adjusting screw 2
198 70 ±5 bar
Valve 192 (low pressure setting) Lock nut 3 Adjusting screw 4
197 70 ± 5bar
Valve 191 (low pressure setting) Lock nut 3 Adjusting screw 4
Slowing down Turning right
Turning left
6.11.18
Measuring point Specified value
A 311 LI 27112copyright by
MJFCIFSS
Service Manual
Adjustment protocol A 311 Litronic from 27112 (applicable from software version 5.12)
Checks 12.
Travel motor
12.1
Regulation Begin of regulation End of regulation
12.2
Measuring point Specified value
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 rpm
Speeder machine
1930 ±25 rpm
on drive shaft, measured during onroad gear Qmin stop screw 212.1
Checking measurement Y
13.
Standard machine
23.8 mm
Speeder machine
26.0 mm
Lowering speed of equipment
4 seconds approx.
Checking measurement Z of stop screw 162
5 mm
A 311 LI 27112copyright by
MJFCIFSS
6.11.19
Adjustment protocol
Service Manual
A 311 Litronic from 27112 (applicable from software version 5.12)
Checks 14.
Hydrostatic fan drive
14.1
Checking the fan speed Check speed while diesel engine runs at rated speed. Disconnect Y352.
Measuring point Specified value
Actual value
Possible Setting.
View Comment
2150 +50rpm
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 (observe afterrun).
6.11.20
A 311 LI 27112copyright by
MJFCIFSS
Service Manual
Adjustment protocol A 312 Litronic from 12363
Adjustment protocol 1 A 312 Litronic from 12363 Date:
.........................................
Mechanic:
.........................................
Customer:
.........................................
Typ:
.........................................
Serial-No:
.........................................
Operating hours:
.........................................
Checks
Measuring point Specified value
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
Measuring point 49 32 ±1 bar
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
A 312 LI 12363copyright by
MJFCIFSS
6.12.1
Adjustment protocol
Service Manual
A 312 Litronic from 12363
Checks
Measuring point Specified value
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)
Pressure: see diagram
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
A 312 LI 12363copyright by
MJFCIFSS
Service Manual
Adjustment protocol A 312 Litronic from 12363
Checks
6.
Measuring point Specified value
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.
A 312 LI 12363copyright by
MJFCIFSS
6.12.3
Adjustment protocol
Service Manual
A 312 Litronic from 12363
Checks
Measuring point Specified value
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
A 312 LI 12363copyright by
MJFCIFSS
Service Manual
Adjustment protocol A 312 Litronic from 12363
Checks
9.2
Measuring point Specified value
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
A 312 LI 12363copyright by
MJFCIFSS
6.12.5
Adjustment protocol
Service Manual
A 312 Litronic from 12363
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
Valve 134 (High pressure setting) Lock nut 1 Adjusting screw 2
Secondary pressure
11.1
Measuring point Specified value
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
Valve 135 (Low pressure setting) Lock nut 3 Adjusting screw 4
Valves 134 / 135
6.12.6
A 312 LI 12363copyright by
MJFCIFSS
Service Manual
Adjustment protocol A 312 Litronic from 12363
Checks
12.
Slewing gear functions Primary pressure
Measuring point Specified value
Actual value
Possible setting
Measuring point 137 / 138
Turning left or right
200 ± 5 bar
13.
Travel motor
13.1
Regulation
Measuring point 45 / M
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
A 312 LI 12363copyright by
MJFCIFSS
6.12.7
Adjustment protocol
Service Manual
A 312 Litronic from 12363
Checks
13.2
Measuring point Specified value
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
Checking measurement Y
16,0 mm
14.
Hydrostatic fan drive
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
A 312 LI 12363copyright by
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
Measuring point Specified value
1.
Operating conditions Warm up equipment
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
Measuring point Specified value
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.
Pressure: see diagram
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
Adjustment protocol R 313 Litronic from 27752
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
Measuring point Specified value
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
R 313 Litronic from 27752
Checks
8.
Primary pressure Safety valve 105
Measuring point Specified value
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
Adjustment protocol R 313 Litronic from 27752
Checks
9.
Secondary pressure Pressure cut-off 104 screwed in (not to block)
9.1
Operational functions
Measuring point Specified value
Actual value
Possible setting
High idle speed
Measuring point 45
- Extend boom cylinder
380 +20 bar
-Retract boom cylinder
380
+20
bar
- Retract stick cylinder
380
+20
bar
-Extend stick cylinder
380 +20 bar +20
-Retract bucket cylinder
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
R 313 Litronic from 27752
Checks
9.2
10.
6.13.6
Measuring point Specified value
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
Operating pressure p
Measuring point 41
Maximum speed step (step 9) Valve 104
(pressure cut-off)
350 +10 bar
copyright by
MJFCIFSS
Service Manual
Adjustment protocol R 313 Litronic from 27752
Checks
11.
Slewing gear function Secondary pressure
11.1
Swivelling back
11.2
Measuring point Specified value
Actual value
Possible setting
View Comment Valve 125 screwed in
Measuring points 137/138
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
R 313 Litronic from 27752
Checks
12.
6.13.8
Slewing gear function Primary pressure
Measuring point Specified value
Actual value
Possible setting
Adjust settings at valve 125.
Measuring point 137 / 138
Turning left or right
230 +10 bar
at Y451
100%
580 mA
50%
540 mA
0%
500 mA
View Comment
copyright by
MJFCIFSS
Service Manual
Adjustment protocol R 313 Litronic from 27752
Checks
13.
Regulating travel motor
13.1
Speed
13.2
13.3
Measuring point Specified value
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
Checking measurement Y
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
R 313 Litronic from 27752
Checks
14. 14.1
Measuring point Specified value
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.
Danger! Moving fan blades can cause serious injury to fingers and hands. Before working near the fan, switch off the engine.
6.13.10
copyright by
MJFCIFSS
View Comment
Service Manual
Adjustment protocol A 314 Litronic from 2001
Adjustment protocol 1 A 314 Litronic from 2001 Date:
.........................................
Mechanic:
.........................................
Customer:
.........................................
Typ:
.........................................
Serial-No:
.........................................
Operating hours:
.........................................
Checks
Measuring point Specified value
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
1900 +30min-1
1.4
Min. speed
770 +50min-1
2.
Pilot pressure
Measuring point 49 32 ±1 bar
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
Adjusting at valve 51
Measuring point 59
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
A 314 LI 2001copyright by
MJFCIFSS
6.14.1
Adjustment protocol
Service Manual
A 314 Litronic from 2001
Checks
Measuring point Specified value
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)
Pressure: see diagram
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.
6.14.2
A 314 LI 2001copyright by
MJFCIFSS
Service Manual
Adjustment protocol A 314 Litronic from 2001
Checks
6.
Measuring point Specified value
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 1600 min-1 approx. Pull out plug (I = 0 mA).
Measuring point 41 130 bar
1800 +10min-1
< 10 bar
* Both functions are necessary to get the max.pump flow.
A 314 LI 2001copyright by
MJFCIFSS
6.14.3
Adjustment protocol
Service Manual
A 314 Litronic from 2001
Checks
8.
Primary pressure (safety valve)
8.1
Main relief valve 105
Measuring point Specified value
Actual value
Possible setting
View Comment
Measuring point 41 400 +20 bar
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).
9.1
Working functions 380
bar
-Retract boom cylinder
380
+20
bar
-Retract stick cylinder
380 +20 bar
-Extend stick cylinder
380
+20
bar
380
+20
bar
380
+20
bar
-Retract bucket cylinder -Extend bucket cylinder
high idle rpm
Valve 221 +20
-Extend boom cylinder
6.14.4
Measuring point 45
Valve 222 Valve 241 Valve 242 Valve 261 Valve 262
A 314 LI 2001copyright by
MJFCIFSS
Service Manual
Adjustment protocol A 314 Litronic from 2001
Checks
9.2
Measuring point Specified value
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
A 314 LI 2001copyright by
MJFCIFSS
6.14.5
Adjustment protocol
Service Manual
A 314 Litronic from 2001
Checks
11.
11.1
Actual value
Possible setting
View Comment
Slewing gear functions Secondary pressure
Measuring point 137/138
Pressure setting at valve 125, see fig. on page 7, raised.
Turning
137 250 +10 bar
Valve 135 (High pressure setting) Lock nut 1 Adjusting screw 2
138 250 +10 bar
Valve 134 (High pressure setting) Lock nut 1 Adjusting screw 2
Turning right
138 120 ± 5 bar
Valve 134 (Low pressure setting) Lock nut 3 Adjusting screw 4
Turning left
137 120 ± 5bar
Valve 135 (Low pressure setting) Lock nut 3 Adjusting screw 4
Turning right Turning left
11.2
Measuring point Specified value
Slowing down, braking
from Serial no. 2001
from Serial no. 11147
Valves 134 / 135
6.14.6
A 314 LI 2001copyright by
MJFCIFSS
Service Manual
Adjustment protocol A 314 Litronic from 2001
Checks
12.
Slewing gear functions Primary pressure
Measuring point Specified value
Actual value
Possible setting
Measuring point 137 / 138
Turning left or right
230 ± 10 bar
13.
Travel motor
13.1
Regulation
Measuring point 45 / M
Begin of regulation
240 bar
End of regulation
320 bar
View Comment
Carry out settings on valve 125
Adjusting screw 87.14 on travel motor
A 314 LI 2001copyright by
MJFCIFSS
6.14.7
Adjustment protocol
Service Manual
A 314 Litronic from 2001
Checks
13.2
Measuring point Specified value
Actual value
Possible setting
Output speed (speed)
Measured on drive shaft, during on-road gear
Standard machine
1780 ±25 min-1
Speeder machine
2670 ±25 min-1
Checking measurement Y
16,7 mm
14.
Hydrostatic fan drive
14.1
Checking fan speed Check speed while diesel engine runs at rated speed. Disconnect Y352.
View Comment
Spool 160
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 the engine when working near the fan.
6.14.8
A 314 LI 2001copyright by
MJFCIFSS
Service Manual
Adjustment protocol A 316 Litronic from 2001
Adjustment protocol 1 A 316 Litronic from 2001 Date:
.........................................
Mechanic:
.........................................
Customer:
.........................................
Typ:
.........................................
Serial-No:
.........................................
Operating hours:
.........................................
Checks
Measuring point Specified value
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
1900 +30min-1
1.4
Min. speed
770 +50min-1
2.
Pilot pressure
Measuring point 49 32 ±1 bar
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
Adjusting at valve 51
Measuring point 59
using adapter cable at Y50
560 +30 mA 11 +2 bar 600 +30 mA 13 +3 bar
Control pressure 3.2
Control pressure at Power test
20
3.3
Checking regulating pressure during emergency operation
Measuring point 59 3,2 ±0,5 bar
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
copyright by
MJFCIFSS
6.16.1
Adjustment protocol
Service Manual
A 316 Litronic from 2001
Checks
Measuring point Specified value
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)
Pressure: see diagram
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.
6.16.2
copyright by
MJFCIFSS
A 316 LI 2001A 316 LI-IND 2001-
Service Manual
Adjustment protocol A 316 Litronic from 2001
Checks
6.
Measuring point Specified value
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 1600 min-1 approx. Pull out plug (I = 0 mA).
Measuring point 41 130 bar
1800 +10min-1
< 10 bar
* Both functions are necessary to get the max.pump flow.
A 316 LI 2001A 316 LI-IND 2001-
copyright by
MJFCIFSS
6.16.3
Adjustment protocol
Service Manual
A 316 Litronic from 2001
Checks
8.
Primary pressure (safety valve)
8.1
Main relief valve 105
Measuring point Specified value
Actual value
Possible setting
View Comment
Measuring point 41 400 +20 bar
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).
9.1
Working functions
high idle rpm
-Extend boom cylinder
380 +20 bar
Valve 221
-Retract boom cylinder
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
Adjustment protocol A 316 Litronic from 2001
Checks
9.2
Measuring point Specified value
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
Measuring point 41
max. rpm (step 9) Valve 104
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
A 316 Litronic from 2001
Checks
11.
Actual value
Possible setting
Measuring point 137/138
Pressure setting at valve 125, see fig. on page 7, raised.
137 250 +10 bar
Valve 135 (High pressure setting) Lock nut 1 Adjusting screw 2
138 250 +10 bar
Valve 134 (High pressure setting) Lock nut 1 Adjusting screw 2
Turning right
138 120 ± 5 bar
Valve 134 (Low pressure setting) Lock nut 3 Adjusting screw 4
Turning left
137 120 ± 5bar
Valve 135 (Low pressure setting) Lock nut 3 Adjusting screw 4
Turning Turning right
Turning left
Slowing down, braking 11.2
View Comment
Slewing gear functions Secondary pressure
11.1
Measuring point Specified value
from Serial no. 2001
from Serial no. 11152
Valves 134 / 135
6.16.6
copyright by
MJFCIFSS
A 316 LI 2001A 316 LI-IND 2001-
Service Manual
Adjustment protocol A 316 Litronic from 2001
Checks
12.
Slewing gear functions Primary pressure
Measuring point Specified value
Possible setting
Measuring point 137 / 138
Turning left or right
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
Carry out settings on valve 125
Adjusting screw 87.41 on travel motor
copyright by
MJFCIFSS
6.16.7
Adjustment protocol
Service Manual
A 316 Litronic from 2001
Checks
13.2
Measuring point Specified value
Actual value
Possible setting
Output speed (speed)
Measured on drive shaft, during on-road gear
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
Checking measurement Y
16,7 mm
14.
Hydrostatic fan drive
14.1
Checking fan speed Check speed while diesel engine runs at rated speed. Disconnect Y352.
View Comment
Spool 160
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 the engine when working near the fan.
6.16.8
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A 316 LI 2001A 316 LI-IND 2001-
Service Manual
Adjustment protocol R 317 Litronic from 18161
Adjustment protocol 1 R 317 Litronic from 18161 Date:
.........................................
Mechanic:
.........................................
Customer:
.........................................
.........................................
Serial number:
.........................................
Operating hours:
.........................................
Actual value
Checks
Possible setting
View Comment
1.
Operating conditions warming up
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
Measuring point 49 32 ±1 bar
Set measure at valve 51.
3.
Horsepower control
Measuring point 59
using adapter cable at Y50.
3.1
at speed level 1 (low idle rpm)
3.2
3.3
Current Control pressure
500+30 mA 6+2 bar
Control pressure on Power test
10 +2 bar
Checking regulating pressure during emergency operation
Measuring point 59 2.0 ±0.5 bar
R 317 LI 18161copyright by
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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)
Pressure: see diagram
5.
Begin of hydraulic regulation of variable displacement pump (basic setting)
Measuring point 41
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
50 +2 bar
Possible setting
View Comment Take measure using adapter cable at Y51.
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
R 317 LI 18161copyright by
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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)
Measuring point 41 110 bar
1800 +10min-1
< 10 bar
R 317 LI 18161copyright by
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6.17.3
Adjustment protocol
Service Manual
R 317 Litronic from 18161 Actual value
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
-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
380 +20 bar
Valve 262
R 317 LI 18161copyright by
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Service Manual
Adjustment protocol R 317 Litronic from 18161 Actual value
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)
Measuring point 41 350 +10 bar
max RPM ( step 9) Valve 104
R 317 LI 18161copyright by
MJFCIFSS
6.17.5
Adjustment protocol
Service Manual
R 317 Litronic from 18161 Actual value
Checks 11.
Slewing gear functions Secondary pressure
11.1
Turning
11.2
6.17.6
Possible setting
View Comment
Measuring points 137/138
Valve125 raised.
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
138 120 ± 5 bar
Valve 135 (Low pressure setting) Lock nut 3 Adjusting screw 4
Turning left
137 120 ± 5bar
Valve 134 (Low pressure setting) Lock nut 3 Adjusting screw 4
Slowing down, braking
R 317 LI 18161copyright by
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Service Manual
Adjustment protocol R 317 Litronic from 18161 Actual value
Checks 12.
Slewing gear functions Primary pressure Turning left or right
13.
Travel motor
13.1
Slow travel speed
Possible setting
Measuring point 137 / 138
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
R 317 LI 18161copyright by
MJFCIFSS
6.17.7
Adjustment protocol
Service Manual
R 317 Litronic from 18161 Actual value
Checks 13.2
Fast travel speed (with switch S21)
14.
Hydrostatic fan drive
14.1
Checking fan speed Check speed while diesel engine runs at rated speed. Disconnect Y352.
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
R 317 LI 18161copyright by
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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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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
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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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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
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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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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
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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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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
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6.20.9
LSC system
Service Manual
Hydraulic diagram
6.20.10
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Service Manual
LSC system Hydraulic diagram
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6.20.11
LSC system
Service Manual
Hydraulic diagram
6.20.12
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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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6.22.1
Design of hydraulic system
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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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
Design of hydraulic system
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
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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
Design of hydraulic system
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
Design of hydraulic system
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
Design of hydraulic system
Service Manual
Hydraulic oil cooler
9.1
Purpose: Travel motor 210 driving the transmissions Transmission 225 for the travel of the machine
10
Hydraulic oil cooler
Fig. 10
10.1
Hydraulic oil cooler
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
Design of hydraulic system
Service Manual
Hydraulic oil cooler
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
Layout of hydraulic system
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
Layout of hydraulic system
Service Manual
Hydraulic pumps
2.2
Gear pumps
Fig. 4
Gear pumps 30, 31 and 32
20 Variable-displacement pump
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
Layout of hydraulic system
Service Manual
Hydraulic oil cooler
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
Hydraulic oil cooler
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
Layout of hydraulic system
Service Manual
Consumers / working attachments
6 Consumers / working attachments
Fig. 8
6.1
Consumers and attachments
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
Layout of hydraulic system
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
Layout of hydraulic system
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
20 Variable-displacement pump
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
Layout of hydraulic system
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
Spool / bucket cylinder
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
Layout of hydraulic system
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
Consumers and attachments
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
Layout of hydraulic system
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
Layout of hydraulic system
Service Manual
Hydraulic oil cooler
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
Layout of hydraulic system
Service Manual
Hydraulic oil cooler
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
Adjustment guidelines for hydraulic system
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:
> Pressure gauge 0 - 600 bar
For actuating pressure:
> Pressure gauge 0 - 600 bar
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
Adjustment guidelines for hydraulic system
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
Checking the proportional solenoid valve Y50
50
Control oil unit
Y50
59
Measuring point LR (power control)
Proportional solenoid valve / 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
Checking the proportional solenoid valve Y51
50
Control oil unit
57
Measuring point LS (flow reduction)
Y51
Proportional solenoid valve / flow reduction
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
Adjustment guidelines for hydraulic system
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
Proportional solenoid valve / power control
Y51
Proportional solenoid valve / flow reduction
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
Adjustment guidelines for hydraulic system
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
Adjustment guidelines for hydraulic system
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
Proportional solenoid valve / power control
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
Adjustment guidelines for hydraulic system
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
Turn counter-clockwise (ccw)
= 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
Turn counter-clockwise (ccw)
=
reduce pressure
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6.30.13
Adjustment guidelines for hydraulic system
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
Turn counter-clockwise (ccw)
=
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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Service Manual
Adjustment guidelines for hydraulic system
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
Turn counter-clockwise (ccw)
=
reduce pressure
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6.30.15
Adjustment guidelines for hydraulic system
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)
= =
increase pressure reduce pressure
Turn the slewing with full load to the left. Press the pilot control unit to the stop.
6.30.16
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Service Manual
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
Turn counter-clockwise (ccw)
=
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
Turn counter-clockwise (ccw)
=
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)
= =
increase pressure reduce pressure
Re-connect the hose connections to XA and XB.
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6.30.17
Adjustment guidelines for hydraulic system
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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MJFCIFSS
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
Adjustment guidelines for hydraulic system
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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Service Manual
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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MJFCIFSS
6.30.21
Adjustment guidelines for hydraulic system
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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MJFCIFSS
6.30.23
Adjustment guidelines for hydraulic system
Service Manual
Checking fan control
6.30.24
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MJFCIFSS
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
Adjustment guidelines for hydraulic system
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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MJFCIFSS
Service Manual
Adjustment guidelines for hydraulic system Checking and adjusting pilot pressure
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.
2 Checking and adjusting pilot pressure
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
Adjustment guidelines for hydraulic system
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
Adjustment guidelines for hydraulic system
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
Variable-displacement pump
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
Adjustment guidelines for hydraulic system
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
Secondary pressure relief valve
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
Adjustment guidelines for hydraulic system
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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MJFCIFSS
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
Adjustment guidelines for hydraulic system
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
Adjustment guidelines for hydraulic system
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
Variable-displacement pump
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
Adjustment guidelines for hydraulic system
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
Adjustment guidelines for hydraulic system
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
Adjustment guidelines for hydraulic system
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:
> Pressure sensor 0 - 600 bar
For actuating pressure:
> Pressure sensor 0 - 600 bar
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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MJFCIFSS
Service Manual
Adjustment guidelines for hydraulic system Checking and adjusting pilot pressure
3 Checking and adjusting pilot pressure
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
Turn counter-clockwise (ccw)
= 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
Adjustment guidelines for hydraulic system
Service Manual
Checking the proportional solenoid valve Y50
Fig. 3
Checking the proportional solenoid valve Y50
50
Control oil unit
59
Measuring point MLR (power control)
Y50
Proportional solenoid valve / power control
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 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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MJFCIFSS
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
Checking the proportional solenoid valve Y51
50
Control oil unit
Y51
57
Measuring point MLS (flow reduction)
Proportional solenoid valve / flow reduction
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 cannot be adjusted.
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6.37.5
Adjustment guidelines for hydraulic system
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)
Compact control block
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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MJFCIFSS
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
Adjustment guidelines for hydraulic system
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
Variable displacement pump DPVO
41
Measuring point for high pressure at con- 100 trol valve block 100 (connection MP)
Compact control block
44
Measuring point for control chamber pres- Y50 sure at pump20 (connection MA)
Proportional solenoid valve / power control
45
Measuring point for LS pressure at pump 20 Control oil unit
Y51
Proportional solenoid valve / flow reduction
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
Turn counter-clockwise (ccw)
= 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
Compact control block
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
Adjustment guidelines for hydraulic system
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
Variable displacement pump DPVO
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
Compact control block
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
Extend bucket cylinder
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
Adjustment guidelines for hydraulic system
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
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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
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6.37.13
Adjustment guidelines for hydraulic system
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
Adjusting screw Lock nut
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
Adjustment guidelines for hydraulic system
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
Adjustment guidelines for hydraulic system
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
Restrictor check valve
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
Slewing gear mechanism
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
Measuring point pump P2
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
Measuring point / actuating pressure for regulation P2
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
Pressure-relief valve
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
Restrictor check valve
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
Rotary connection 7 x
7.78
86
Pilot control valve 2 x / adjustable boom
7.47
262
Rotary connection 6 x
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
Spool / support cylinder
7.50
S35
Switch / pilot control
8.09/8.20
105
Spool / regulating cylinder
7.50
S63
Switch / changeover Bucket swivel bearing
8.09/8.20
106
Spool / boom cylinder
7.50
S75
Switch / oscillating axle support
8.09/8.20
107
Spool / bucket cylinder
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
Primary pressure relief valve pump P2
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
Solenoid valve / travel direction
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
Y352 Proportional solenoid valve / fan
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
Y371 Solenoid valve / oscillating axle support
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
Hydraulic system 3 (low-pressure circuit)
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
Pressure relief valve
112
Spool / swivel bearing
7.56
S5L Push button: 'turn grapple left'
8.09/8.20
113
Spool / grapple rotator
7.56
S5R Push button: 'turn grapple right'
8.09/8.20
123
Primary pressure relief valve
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
Suction valve travel motor B8
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
Preload valve 5.5 bar
7.50
10
Cylinder / speed adjustment
155
Restrictor valve
11
from turbocharger / engine
156
Shuttle valve Swing left (i)
12
Check valve 0.2 bar
157
Shuttle valve Swing right (i)
13
Oil motor radiator fan
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
Stroke limitation / spool for lifting
21
Powertrain P1
7.02
170
Stick cylinder
7.30
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
Restrictor check valve
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
Slewing gear mechanism
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
Measuring point pump P2
211
Powertrain
7.27
43
Measuring point / actuating pressure for regulation P1
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
Measuring point / actuating pressure for regulation P2
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
Pressure-relief valve
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
Restrictor check valve
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
Rotary connection 7 x
7.78
86
Pilot control valve 2 x / adjustable boom
7.47
262
Rotary connection 6 x
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
103
Spool / support cylinder
7.50
S21
Switch / creeper gear
8.09/8.20
105
Spool / regulating cylinder
7.50
S35
Switch / pilot control
8.09/8.20
106
Spool / boom cylinder
7.50
S63
Switch / changeover Bucket swivel bearing
8.09/8.20
107
Spool / bucket cylinder
7.50
S75
Switch / oscillating axle support
8.09/8.20
108
Spool / travel motor
7.50
S263 Switch / travel direction
8.09/8.20
109
Spool, compound boom cylinder / stick cylinder
7.50
U16
Excavator control BST
8.09/8.20
110
to control valve block, low pressure
7.62
Y3
Solenoid valve / pilot control
8.09/8.20
120
Primary pressure relief valve pump P1
7.50
Y24
Solenoid valve / creeper gear
8.09/8.20
6.40.12
copyright by
MJFCIFSS
A 309 LI 23503-27109 A 311 LI 23507-27111
Service Manual
Hydraulic system Key to diagrams I and II (high pressure circuit)
Items
see group
Items
see group
121
Primary pressure relief valve pump P2
7.50
Y50
Proportional solenoid valve Power control
8.09/8.20
127
Secondary pressure relief valve, stick cylinder A2
7.50
Y51
Proportional solenoid valve / flow reduction P1
8.09/8.20
128
Secondary pressure relief valve, stick cylinder B2
7.50
Y62
Solenoid valve / travel direction
8.09/8.20
129
Secondary pressure relief valve, control cylinder A5
7.50
Y63
Solenoid valve / travel direction
8.09/8.20
130
Secondary pressure relief valve, control cylinder B5
7.50
Y262 Solenoid valve: bucket cylinder / swivel bearing
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
Y352 Proportional solenoid valve / fan
8.09/8.20
133
Secondary pressure relief valve / bucket cylinder A7
7.50
Y358 Proportional solenoid valve / speed adjustment
8.09/8.20
134
Secondary pressure relief valve / bucket cylinder B7
7.50
Y371 Solenoid valve / oscillating axle support
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
Hydraulic system Hydraulic system 3 (low-pressure circuit)
4 Hydraulic system 3 (low-pressure circuit)
Fig. 2
Hydraulic system 3 (low-pressure circuit)
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
Pressure relief valve
112
Spool / swivel bearing
7.56
S5L
Push button: 'turn grapple left'
113
Spool / grapple rotator
7.56
S5R Push button: 'turn grapple right'
8.09/8.20
123
Primary pressure relief valve
7.56
S19
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
157
Adjustment restrictor / oil quantity, rotator
7.62
Y262 fromSolenoid valve bucket swivel bearing
A 309 LI 23503-27109 A 311 LI 23507-27111
Button / grapple rotator
copyright by
MJFCIFSS
8.09/8.20
8.09/8.20
6.40.19
Hydraulic system
Service Manual
Hydraulic system 3 (low-pressure circuit)
6.40.20
copyright by
MJFCIFSS
A 309 LI 23503-27109 A 311 LI 23507-27111
Service Manual
Hydraulic system Key to diagrams I and II (high pressure circuit)
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
Cylinder / speed adjustment
11
from turbo charger / diesel engine
12
Check valve 0.2 bar
13
Oil motor radiator fan
14
Pressure relief valve / fan motor
15
Coarse filter
20
Double variable-displacement pump
21
Powertrain P1
7.02
22
Powertrain P2
7.02
23
Regulating unit P1 + P2
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
Gear pump / fan drive
7.02
31
Gear pump / low-pressure circuit - brake
32
Gear pump / steering with pressure-relief valve
33
Gear pump / pilot control
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
Key to diagrams I and II (high pressure circuit) Items
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
Pressure-relief valve
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
Check valve P2 - reset
76
Shuttle valve / combined shifting
80
Pilot control unit, left 4 x
7.45
81
Pilot control unit, right 4 x
7.45
84
Pilot control valve 1 x / chassis
7.49
85
Pilot control unit 2 x / support
7.48
86
Pilot control valve 2 x / adjustable boom
7.47
87
Positioning brake / slewing gear
9.20
88
Manifold / collecting pipe
100
Compact control block
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
Spool / bucket cylinder
7.50
108
Spool / travel motor
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
Suction valve travel motor B8
copyright by
MJFCIFSS
7.50
A 309 LI 27110A 311 LI 27112-
Service Manual
Hydraulic system Key to diagrams I and II (high pressure circuit)
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
Preload valve 5.5 bar
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
Stroke limitation / spool for lifting
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
Shut-off device / grapple operation
182
Lines to grapple cylinder
183
Restrictor check valve
7.90
190
Slewing gear motor / powertrain
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
Slewing gear mechanism
9.10
197
Measuring point, turning left
7.24
198
Measuring point, turning right
7.24
210
Regulating travel motor / powertrain
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
Key to diagrams I and II (high pressure circuit) Items
6.40.24
see group
220
Restrictor check valve
7.27
225
Transmission
11.08/11.20
230
Support cylinder
7.30
231
Double load-holding valve / blade support
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
Rotary connection 7 x
7.78
262
Rotary connection 6 x
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
Switch / creeper gear
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
Switch / oscillating axle support
8.09/8.20/8.22
S263 Switch / travel direction
8.09/8.20/8.22
U16
Excavator control BST
8.09/8.20/8.22
Y3
Solenoid valve / pilot control
8.09/8.20/8.22
Y24
Solenoid valve / creeper gear
8.09/8.20/8.22
Y50
Proportional solenoid valve / power control
8.09/8.20/8.22
Y50
Proportional solenoid valve / flow reduction P1
8.09/8.20/8.22
Y62
Solenoid valve / travel direction
8.09/8.20/8.22
Y63
Solenoid valve / travel direction
8.09/8.20/8.22
Y262 Solenoid valve: bucket cylinder / swivel bearing
8.09/8.20/8.22
Y352 Proportional solenoid valve / fan
8.09/8.20/8.22
Y358 Proportional solenoid valve / speed adjustment
8.09/8.20/8.22
Y371 Solenoid valve / oscillating axle support
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
Hydraulic system Hydraulic system 3 (low-pressure circuit)
6 Hydraulic system 3 (low-pressure circuit)
Fig. 3
Hydraulic system 3 (low-pressure circuit)
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
Double load-holding valve
7.82
50
from control oil unit
260
Oil motor / grapple rotator
110
Compact control block low pressure circuit
7.56
261
Pressure-relief valve
111
Input section
7.56
262
Pressure-relief valve
112
Spool / slewing gear
7.56
S5L
Push button: 'turn grapple left'
113
Spool / grapple rotator
7.56
S5R Push button: 'turn grapple right'
8.09/8.20
123
Prim. pressure relief valve
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
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
Hydraulic system 3 (low-pressure circuit)
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
A 312 LI 12363-13288 copyright by
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
A 312 LI 12363-13288 copyright by
MJFCIFSS
Service Manual
Hydraulic system Main components and key to diagrams I and II
Fig. 5
Compact control block
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
A 312 LI 12363-13288 copyright by
MJFCIFSS
6.42.3
Hydraulic system
Service Manual
Main components and key to diagrams I and II
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
Restrictor check valve
7
Check valve 3.5 bar
7.59
194
Check valve
8
Preload valve 7.0 bar
7.59
195
Changeover valve
9
Cylinder / speed adjustment
196
Check valves
13
Pressure-relief valve / cooling
220
Spool / boom cylinder
14
Oil motor / radiator fan
221
Secondary pressure-relief valve / extending
20
Variable-displacement pump
222
Secondary pressure-relief valve / retracting
21
Powertrain
224
Pressure balance
21.1
Adjusting unit, complete
227
Restrictor check valve
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
Spool / stick cylinder
7.59
29
Restrictor
241
Secondary pressure-relief valve / retracting
30
Gear pump / cooling
242
Secondary pressure-relief valve / extending
31
Gear pump / steering
244
Pressure balance
32
Gear pump / brake, pilot control
247
Restrictor check valve
41
Measuring point MP
255
Stick cylinder
7.30
44
Measuring point / actuating pressure P
260
Spool / bucket cylinder
7.59
45
Measuring point LS
261
Secondary pressure-relief valve / retracting
49
Measuring point / pilot control
262
Secondary pressure-relief valve / extending
50
Control oil unit
264
Pressure balance
51
Pressure-relief valve
275
Bucket cylinder
52
Pressure filter
277
Shut-off device for grapple operation
53
Check valve
278
Lines to grapple cylinder
54
Accumulator
279
Restrictor check valve only with attachment/quickchange adapter
7.90
57
Measuring point Servo pressure p-lowering
280
Spool / support cylinder
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
A 312 LI 12363-13288 copyright by
MJFCIFSS
Service Manual
Hydraulic system Main components and key to diagrams I and II
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
Spool / grapple rotator
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
Oil motor / grapple rotator
120
Spool / slewing gear
551
Secondary relief valve / turn right
122
Input pressure balance
552
Secondary relief valve / turn left
123
Check valve / load-holding valve
S5
Button / grapple rotator
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
Restrictor check valve
S21
Switch / creeper gear
8.10/8.30
128
Changeover valve
S263
Switch / travelling direction
8.10/8.30
130
Slewing gear motor, complete
S35
Switch / pilot control
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
Measuring point, turning right
Y23
Solenoid valve / turn grapple right
16.44
138
Measuring point, turning left
Y24
Solenoid valve / creeper gear
7.42
155
Slewing gear brake
9.20
Y50
Proportional solenoid valve/LR
7.42
156
Slewing gear mechanism
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
Restrictor check valve
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
Rotary connection 7x
7.78
322
Rotary connection 6x
7.76
400
to brake system
15.10
401
to steering
13.10
16.44
7.42
7.27
A 312 LI 12363-13288 copyright by
MJFCIFSS
6.42.5
Hydraulic system
Service Manual
Main components and key to diagrams I and II
Fig. 6
6.42.6
Hydraulic system 1
copyright by
MJF C I F S S
Service Manual
Hydraulic system Main components and key to diagrams I and II
Fig. 7
Hydraulic system 2
copyright by
MJF C I F S S
6.42.7
Hydraulic system
Service Manual
Main components and key to diagrams I and II
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
A 312 LI 12363-13288 copyright by
MJFCIFSS
Service Manual
Hydraulic system Main components and key to diagrams I and II
Fig. 9
Support option 4-point outriggers
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 320 295 Support cylinder
Rotary connection
Fig. 10
Support option 2-point blade front or rear
A 312 LI 12363-13288 copyright by
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
Double lowering brake valve, see also group valves 7.86
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 left outrigger
100/B1 from control valve block connection B1 S207
Push button / individual control of right outrigger Push button / individual control of blade
295
Support cylinder
S335
297
Double lowering brake valve, see also group valves 7.86
Y56
Solenoid valve / individual control of blade
A 312 LI 12363-13288 copyright by
MJFCIFSS
Service Manual
Hydraulic system Main components and key to diagrams I and II
320
Rotary connection
Y217
325
Slip ring / rotary connection
Y218
A 312 LI 12363-13288 copyright by
MJFCIFSS
Solenoid valve / individual control of left outrigger Solenoid valve / individual control of right outrigger
6.42.11
Hydraulic system
Service Manual
Main components and key to diagrams I and II
6.42.12
A 312 LI 12363-13288 copyright by
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
Bypass valve / return filter (pressure)
87
Valve / positioning brake
6
Oil cooler
88P
Manifold pressure
13
Oil motor radiator fan
88T
Collecting pipe return line
14
Pressure relief valve / fan motor
100
from / to control valve block
7.60
15
Coarse filter (d)
155
to slewing gear brake
9.20
20
Variable-displacement pump
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
to oscillating axle support
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
Switch / creeper gear
8.10/8.30
29
Restrictor
S35
Switch / pilot control
8.10/8.30
30
Gear pump / fan drive
S75
Switch / oscillating axle automatic
8.10/8.30
31
Gear pump / steering
S263 Switch / travel direction
8.10/8.30
32
Gear pump / brake, pilot control
U16
Excavator control BST
8.10/8.30
44
Measuring point actuating pressure
Y3
Solenoid valve servo release
8.10/8.30
45
Measuring point / LS pressure
Y24
Solenoid valve / creeper gear
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
Pressure-relief valve
Y62
Solenoid valve / forward travel
8.10/8.30
52
Pressure filter
Y63
Solenoid valve / reverse travel
8.10/8.30
53
Check valve
Y352 Proportional solenoid valve / fan control
7.05
7.42
A 312 LI 13289-29897 copyright by
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
Y371 Solenoid valve / oscillating axle support
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
Preload valve 7.0 bar
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
Pressure balance / minimum flow
103
Pressure balance / remaining flow
104
Pressure cut-off valve
105
Primary pressure-relief valve
107
Shuttle valve (e)
109
LS central nozzle
120
Spool / slewing gear
122
Input pressure balance
123
Check valve (e)
125
TC valve with additional pressure stage (e)
126
Restrictor Ø 1.5 mm
127
Restrictor check valve
128
Shuttle valve
129
Restrictor (Ø 0.6 mm) (e)
130
Slewing gear motor, complete
132
Powertrain
133
Suction valve
134
Pressure-relief valve with additional pressure stage
135
Pressure-relief valve with additional pressure stage
7.60
7.80
7.24
A 312 LI 13289-29897 copyright by
MJFCIFSS
Service Manual
Hydraulic system Key to diagrams I and II
Items
see group
137
Measuring point 'turn right'
138
Measuring point 'turn left'
155
Slewing gear brake
9.20
156
Slewing gear mechanism
9.10
160
Spool / chassis
7.60
161
Suction valve / reverse travel
162
Suction valve / forward travel
164
Pressure balance, directly controlled
167
Restrictor check valve
170
Travel motor
172
Powertrain
173
Control cylinder / regulating unit
174
Spool / regulating unit
176
Secondary relief valve / forward
177
Secondary relief valve / reverse
7.27
185
Transmission
11.08
190
Travel brake valve, complete
7.27
192
Brake piston
193
Restrictor check valve
194
Check valve
195
Shuttle valve
196
Check valves
220
Spool / boom cylinder
221
Secondary pressure-relief valve / extending
222
Secondary pressure-relief valve / retracting
224
Pressure balance, pilot-controlled (e)
227
Restrictor check valve
233
Distribution block
7.60
235
Boom cylinder
237
Stop cock (devices without item 238)
238
Pipe-fracture safety system (kit)
240
Spool / stick cylinder
241
Secondary pressure-relief valve / retracting
242
Secondary pressure-relief valve / extending
244
Pressure balance, directly controlled
247
Restrictor check valve
7.30
7.60
255
Stick cylinder
7.30
260
Spool / bucket cylinder
7.60
261
Secondary pressure-relief valve / retracting
262
Secondary pressure-relief valve / extending
264
Pressure balance, directly controlled
A 312 LI 13289-29897 copyright by
MJFCIFSS
6.42.15
Hydraulic system
Service Manual
Key to diagrams I and II Items
see group
275
Bucket cylinder
277
Shut-off device for grapple operation
278
Lines leading to grapple
279
Restrictor check valve (QC only)
280
Spool / support cylinder
281
Plug / dummy cartridge
284
Pressure balance, directly controlled
295
Support cylinder
297
Double-load back-pressure valve
320
Rotary connection 7x
7.78
322
Rotary connection 6x
7.76
540
Spool / grapple rotator
16.44
541
Secondary relief valve / turning right
542
Secondary relief valve / turning left
544
Pressure balance, directly controlled
550
Oil motor / grapple rotator
551
Secondary relief valve / turning right
552
Secondary relief valve / turning left
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
Switch / grapple rotator
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
A 312 LI 13289-29897 copyright by
MJFCIFSS
Service Manual
Hydraulic system Key to diagrams I and II
Hydraulic system 3 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.
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
Bypass valve / return filter (pressure)
85
Pilot control unit 2 x, support
7.48
6
Oil cooler
87
Valve / positioning brake
13
Oil motor radiator fan
88P
Manifold pressure
14
Pressure relief valve / fan motor
88T
Collecting pipe return line
15
Coarse filter
100
from / to control valve block
7.60
20
Variable-displacement pump
155
to slewing gear brake
9.20
21
Powertrain
170
from travel engine
21.1 Control cylinder
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
to oscillating axle support
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
Switch / creeper gear
8.10/8.32
30
Gear pump / fan drive
S35
Switch / pilot control
8.10/8.32
31
Gear pump / steering
S75
Switch / oscillating axle automatic
8.10/8.32
32
Gear pump / brake, pilot control
S263 Switch / travel direction
8.10/8.32
44
Measuring point / actuating pressure
U16
Excavator control BST
8.10/8.32
45
Measuring point / LS pressure
Y3
Solenoid valve servo release
8.10/8.32
49
Measuring point / pilot pressure M1
Y24
Solenoid valve / creeper gear
8.10/8.32
50
Control oil unit
Y50
Proportional solenoid valve Power control
8.10/8.32
51
Pressure relief valve
Y51
Proportional solenoid valve LS control
8.10/8.32
52
Pressure filter
Y62
Solenoid valve / forward travel
8.10/8.32
Regulating valve
7.42
A 312 LI 29898copyright by
MJFCIFSS
6.42.21
Hydraulic system
Service Manual
Key to diagrams I and II Item
see group
Item
see group
53
Check valve
Y63
Solenoid valve / reverse travel
54
Accumulator
Y352 Proportional solenoid valve / fan control
8.10/8.32
57
Measuring point / servo pressure -p reduction
Y358 Proportional solenoid valve / motor speed
8.10/8.32
59
Measuring point / servo pressure Power control
Y371 Solenoid valve / oscillating axle support
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
Restrictor check valve
7
Check valve 3.5 bar
7.60
194
Check valve
8
Preload valve 7.0 bar
7.60
195
Shuttle valve
20
from variable-displacement pump
7.05
196
Check valves
23
to regulating valve
220
Spool / boom cylinder
41
Measuring point MP
221
Secondary pressure relief valve / extending
80
Pilot control unit, left 4 way
7.45
222
Secondary pressure relief valve / retracting
81
from pilot control unit, right 4 way
7.45
224
Pressure balance, pilot-controlled
85
from pilot control valve / support
7.48
227
Restrictor check valve
87
from valve / positioning brake
233
Distribution block
88P
from manifold P
235
Boom cylinder
88T
to collecting pipe T
237
Stop cock (in models without item 238)
100
Compact control block 5 x
238
Pipe fracture safety valve (kit)
102
Pressure balance / minimum flow
240
Spool / stick cylinder
103
Pressure balance / remaining flow
241
Secondary pressure relief valve / retracting
104
Pressure cut-off valve
242
Secondary pressure relief valve / extending
105
Primary pressure relief valve
244
Pressure balance, directly controlled
107
Shuttle valve
247
Restrictor check valve
109
LS central nozzle
255
Stick cylinder
7.30
120
Spool / slewing gear
260
Spool / bucket cylinder
7.60
122
Input pressure balance
261
Secondary pressure relief valve / retracting
123
Check valve
262
Secondary pressure relief valve / extending
125
TC valve with additional pressure stage
264
Pressure balance, directly controlled
6.42.22
7.60
7.80
7.60
7.30
7.60
A 312 LI 29898copyright by
MJFCIFSS
Service Manual
Hydraulic system Key to diagrams I and II
Item
see group
Item
see group
126
Restrictor (Ø 1.5 mm)
275
Bucket cylinder
127
Restrictor check valve
277
Shut-off device for grapple operation
128
Shuttle valve
278
Lines leading to grapple
129
Restrictor (Ø 0.6 mm)
279
Restrictor check valve (QC only)
130
Slewing gear motor, complete
280
Spool / support cylinder
132
Powertrain
281
Plug / dummy cartridge
133
Suction valve
284
Pressure balance, directly controlled
134
Pressure relief valve with additional pressure stage
295
Support cylinder
135
Pressure relief valve with additional pressure stage
297
Double load-holding valve
137
Measuring point, turning right
320
Rotary connection 7 way
7.78
138
Measuring point, turning left
322
Rotary connection 6 way
7.76
155
Slewing gear brake
9.20
540
Spool / grapple rotator
16.44
156
Slewing gear mechanism
9.10
541
Secondary relief valve / turn right
160
Travel gear spool
7.60
542
Secondary relief valve / turn left
161
Suction valve / reverse travel
544
Pressure balance, directly controlled
162
Suction valve / forward travel
550
Oil motor / grapple rotator
164
Pressure balance, directly controlled
551
Secondary relief valve / turn right
167
Restrictor check valve
552
Secondary relief valve / turn left
170
Travel motor
S5L
Push button / grapple rotator, left
172
Powertrain
S5R Push button / grapple rotator, right
8.10/8.32
173
Control cylinder / regulating unit
S19
Switch / grapple rotator
8.10/8.32
174
Spool / regulating unit
Y22
Solenoid valve / grapple rotation left
16.44
176
Secondary pressure relief valve / forward travel
Y23
Solenoid valve / grapple rotation right
16.44
177
Secondary pressure relief valve / reverse travel
Y24
from solenoid valve / creeper gear
7.42
185
Transmission
11.20
Y62
from solenoid valve / forward travel
8.10/8.32
190
Travel brake valve, complete
7.27
Y63
from solenoid valve / reverse travel
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
A 312 LI 29898copyright by
MJFCIFSS
6.42.23
Hydraulic system
Service Manual
Key to diagrams I and II
6.42.24
A 312 LI 29898copyright by
MJFCIFSS
Service Manual
Hydraulic system
Hydraulic system Note! For a detailed description of the design and construction of the hydraulic system and the various main components, see group 6.27.
Items
see group
Items
see group
1
Hydraulic tank
19.10
155
Slewing gear brake
9.20
2
Breather filter
19.10
156
Slewing gear mechanism
9.10
3
Stop cock
160
Spool / chassis right
7.60
4
Return filter
19.10
161
Suction valve A1, forward
7.60
5
Bypass valve / return filter (pressure)
19.10
162
Suction valve B1, reverse
7.60
6
Oil cooler
164
Pressure balance, directly controlled
7.60
7
Check valve 3.5 bar
7.60
167
Restrictor check valve
7.60
8
Preload valve 7.0 bar
7.60
180
Spool / chassis left
7.60
10
Cylinder / speed adjustment
181
Suction valve A2, forward
7.60
13
Oil motor radiator fan
182
Suction valve B2, reverse
7.60
14
Pressure relief valve / fan motor
184
Pressure balance, directly controlled
7.60
15
Coarse filter / fan motor
195
Rotary connection 5x
7.77
20
Variable-displacement pump
7.15
196
Rotary connection 1x
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
Performance regulator
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
Gear pump / pilot control
212
Secondary pressure-relief valve chassis, reverse left
7.28
31
Gear pump / fan drive
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
R 313 LI 27752copyright by
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
Spool / boom cylinder
7.60
7.42
221
Secondary pressure-relief valve A3 / extend
7.60
Pressure-relief valve
7.42
222
Secondary pressure-relief valve B3 / retract
7.60
52
Pressure filter
7.42
224
Pressure balance, pilot-controlled
7.60
53
Check valve
7.42
227
Restrictor check valve
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
Pipe-fracture safety system (kit)
81
Pilot control unit, right 4x
7.45
240
Spool / stick cylinder
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
Collecting pipe return line
244
Pressure balance, directly controlled
7.60
100
Compact control block 5x
7.60
247
Restrictor check valve
7.60
102
Pressure balance / minimum flow
7.60
255
Stick cylinder
7.30
103
Pressure balance / remaining flow
7.60
257
Restrictor check valve
104
Pressure cut-off valve
7.60
260
Spool / bucket cylinder
7.60
105
Primary pressure-relief valve
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
Pressure balance, directly controlled
7.60
108
LS main orifice
7.60
275
Bucket cylinder
7.30
109
Shuttle valve
7.60
277
Shut-off device for grapple operation
120
Spool / slewing gear
7.60
278
Lines leading to grapple
122
Input pressure balance
7.60
278
Grapple cylinder
123
Check valve
7.60
279
Restrictor check valve (with QC only)
125
Restrictor Ø 1.8 mm
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
Restrictor check valve
7.60
S21
Switch / creeper gear
8.17/8.38
128
Restrictor Ø 1.2 mm
7.60
U16
Excavator control BST
8.17/8.38
130
Slewing gear motor
7.24
Y3
Solenoid valve servo release
8.17/8.38
6.43.2
7.30
7.90
R 313 LI 27752copyright by
MJFCIFSS
Service Manual
Items
Hydraulic system
see group
Items
see group
132
Powertrain
7.24
Y7
Solenoid valve slewing gear brake
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
Proportional solenoid valve Power control
8.17/8.38
135
Pressure-relief valve with additional pressure level, left A
7.24
Y51
Proportional solenoid valve LS control
8.17/8.38
137
Measuring point / turn right
Y352 Proportional solenoid valve / fan control
8.17/8.38
138
Measuring point / turn left
Y358 Proportional solenoid valve / speed adjustment
8.17/8.38
Y451 Proportional solenoid valve / slewing gear
8.17/8.38
R 313 LI 27752copyright by
MJFCIFSS
6.43.3
Hydraulic system
6.43.4
Service Manual
R 313 LI 27752copyright by
MJFCIFSS
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
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
Main components and key to diagrams I and II
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
Hydraulic system Main components and key to diagrams I and II
Fig. 5
Compact control block
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
Main components and key to diagrams I and II
6.44.4
Item
Designation
1
group
Item
Designation
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
Restrictor check valve
7
Check valve 3.5 bar
7.59
194
check valve
8
Preload valve 7.0 bar
7.59
195
Changeover valve
9
Cylinder / speed adjustment
196
Check valves
13
Pressure-relief valve / cooling
220
Spool / boom cylinder
14
Oil motor / radiator fan
221
Secondary pressure relief valve / extending
20
Variable-displacement pump
222
Secondary pressure relief valve / retracting
21
Powertrain
224
Pressure balance
21.1
Adjusting unit, complete
227
Restrictor check valve
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)
7.14
group
7.59
7.30
23.6
Changeover valve
238
Pipe fracture safety valve (kit)
16.04
28
check valve
240
Spool / stick cylinder
7.59
29
Restrictor
241
Secondary pressure relief valve / retracting
30
Gear pump / cooling
242
Secondary pressure relief valve / extending
31
Gear pump / steering
244
Pressure balance
32
Gear pump / brake, pilot control
247
Restrictor check valve
41
Measuring point MP
255
Stick cylinder
7.30
44
Measuring point / actuating pressure P
260
Spool / bucket cylinder
7.59
45
Measuring point LS
261
Secondary pressure relief valve / retracting
49
Measuring point / pilot control
262
Secondary pressure relief valve / extending
50
Control oil unit
264
Pressure balance
51
Pressure-relief valve
275
Bucket cylinder
52
Pressure filter
277
Shut-off device for grapple operation
53
check valve
278
Lines to grapple cylinder
54
Accumulator
279
Restrictor check valve only with attachment/quickchange adapter
7.90
57
Measuring point Servo pressure p-lowering
280
Spool / support cylinder
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 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
Hydraulic system Main components and key to diagrams I and II
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
Spool / grapple rotator
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
Oil motor / grapple rotator
120
Spool / slewing gear
551
Secondary relief valve / turn right
122
Input pressure balance
552
Secondary relief valve / turn left
123
Check valve / load-holding valve
S5
Button / grapple rotator
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
Restrictor check valve
S21
Switch / creeper gear
8.10/8.30
128
Changeover valve
S263
Switch / travelling direction
8.10/8.30
130
Slewing gear motor, complete
S35
Switch / pilot control
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
Measuring point, turning right
Y23
Solenoid valve / turn grapple right
16.44
138
Measuring point, turning left
Y24
Solenoid valve / creeper gear
7.42
155
Slewing gear brake
9.20
Y50
Proportional solenoid valve/LR
7.42
156
Slewing gear mechanism
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
Restrictor check valve
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
Rotary connection 7x
7.78
322
Rotary connection 6x
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
Main components and key to diagrams I and II
Fig. 6
6.44.6
Hydraulic system 1
copyright by
MJF C I F S S
Service Manual
Hydraulic system Main components and key to diagrams I and II
Fig. 7
Hydraulic system 2
copyright by
MJF C I F S S
6.44.7
Hydraulic system
Service Manual
Main components and key to diagrams I and II
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
6.44.8
Support option 2-point outriggers
Support cylinder
copyright by
MJFCIFSS
Service Manual
Hydraulic system Main components and key to diagrams I and II
Fig. 9
Support option 4-point outriggers
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 320 295 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 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
Double lowering brake valve, see also group valves 7.86
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
6.44.10
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 left outrigger
100/B1 from control valve block connection B1 S207
Push button / individual control of right outrigger Push button / individual control of blade
295
Support cylinder
S335
297
Double lowering brake valve, see also group valves 7.86
Y56
copyright by
MJFCIFSS
Solenoid valve / individual control of blade
Service Manual
Hydraulic system Main components and key to diagrams I and II
320
Rotary connection
Y217
325
Slip ring / rotary connection
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
Main components and key to diagrams I and II
6.44.12
copyright by
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
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
Bypass valve / return filter (pressure)
85
Pilot control valve 2 x / support
7.48
6
Oil cooler
87
Valve / positioning brake
11
from turbo charger / diesel engine
88P
Manifold pressure
12
Check valve 0.2 bar
88T
Collecting pipe return line
13
Oil motor radiator fan
100
from / to control valve block
7.60
14
Pressure relief valve / fan motor
155
to slewing gear brake
9.25
15
Coarse filter (d)
170
from travel motor
20
Variable-displacement pump
322
to rotary connection 6x
7.76
21
Powertrain
400
to brake system
15.10
21.1 Control cylinder
401
to steering system
13.10
23
19.10
7.14
Regulating valve
402
to oscillating axle support
14.10
23.2 Performance regulator
403
to gear shifting
11.10
23.5 LS regulator
S7
Safety switch
8.10/8.30
23.6 Shuttle valve
S21
Switch / creeper gear
8.10/8.30
28
Check valve
S354 Switch / pilot control
8.10/8.30
29
Restrictor
S75
8.10/8.30
30
Gear pump / fan drive
S263 Switch / travel direction
8.10/8.30
31
Gear pump / steering (f)
U16
Excavator control BST
8.10/8.30
32
Gear pump / brake, pilot control
Y3
Solenoid valve servo release
8.10/8.30
44
Measuring point actuating pressure
Y24
Solenoid valve / creeper gear
8.10/8.30
45
Measuring point / LS pressure
Y50
Proportional solenoid valve / LS control
8.10/8.30
49
Measuring point / pilot pressure M1
Y51
Proportional solenoid valve LS control
8.10/8.30
50
Control oil unit
Y62
Solenoid valve / forward travel
8.10/8.30
51
Pressure-relief valve
Y63
Solenoid valve / reverse travel
8.10/8.30
A 314 LI 11147-13103 A 316 LI 11152-13104 A 316 LI-IND 11152-13104
7.42
Switch / oscillating axle automatic
copyright by
MJFCIFSS
6.44.13
Hydraulic system
Service Manual
Key to diagrams I and II Items
see group
Items
see group
52
Pressure filter
Y352 Proportional solenoid valve / fan control
8.10/8.30
53
Check valve
Y358 Proportional solenoid valve / motor speed
8.10/8.30
54
Accumulator
Y371 Solenoid valve / oscillating axle support
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
Preload valve 7.0 bar
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
Pressure balance / minimum flow
103
Pressure balance / remaining flow
104
Pressure cut-off valve
105
Primary pressure-relief valve
107
Shuttle valve (e)
109
LS central nozzle
120
Spool / slewing gear
122
Input pressure balance
123
Check valve (e)
125
TC valve with additional pressure stage (e)
126
Restrictor Ø 1.5 mm
127
Restrictor check valve
128
Shuttle valve
129
Restrictor (Ø 0.6 mm) (e)
130
Slewing gear motor, complete
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
Hydraulic system Key to diagrams I and II
Items
see group
133
Suction valve
134
Pressure-relief valve with additional pressure stage
135
Pressure-relief valve with additional pressure stage
137
Measuring point 'turn right'
138
Measuring point 'turn left'
155
Slewing gear brake
9.20
156
Slewing gear mechanism
9.10 7.60
160
Spool / chassis
161
Suction valve / reverse travel
162
Suction valve / forward travel
164
Pressure balance, directly controlled
167
Restrictor check valve
170
Travel motor
172
Powertrain
173
Control cylinder / regulating unit
174
Spool / regulating unit
176
Secondary relief valve / forward travel
177
Secondary relief valve/ reverse travel
185
Transmission
11.08
190
Travel brake valve, complete
7.27
192
Brake piston
193
Restrictor check valve
194
Check valve
195
Shuttle valve
196
Check valves
220
Spool / boom cylinder
221
Secondary pressure-relief valve / extending
222
Secondary pressure-relief valve / retracting
7.27
7.60
224
Pressure balance, pilot-controlled (e)
227
Restrictor check valve
233
Distribution block
235
Boom cylinder
237
Stop cock (devices without item 238)
238
Pipe-fracture safety system (kit)
240
Spool / stick cylinder
241
Secondary pressure-relief valve / retracting
242
Secondary pressure-relief valve / extending
244
Pressure balance, directly controlled
247
Restrictor check valve
255
Stick cylinder
7.30
260
Spool / bucket cylinder
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
Key to diagrams I and II Items
see group
261
Secondary pressure-relief valve / retracting
262
Secondary pressure-relief valve / extending
264
Pressure balance, directly controlled
275
Bucket cylinder
277
Shut-off device for grapple operation
278
Lines leading to grapple
279
Restrictor check valve (only SW)
280
Spool / support cylinder
281
Plug / dummy cartridge
284
Pressure balance, directly controlled
295
Support cylinder
297
Double-load back-pressure valve
320
Rotary connection 7x
7.78
322
Rotary connection 6x
7.76
540
Spool / grapple rotator
16.44
541
Secondary relief valve / turning right
542
Secondary relief valve / turning left
544
Pressure balance, directly controlled
550
Oil motor / grapple rotator
551
Secondary relief valve / turning right
552
Secondary relief valve / turning left
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
Switch / grapple rotator
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
6.44.16
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.
Index to wiring diagram I Item
see group
1
Hydraulic tank
2 3
Item
see group
59
Measuring point / servo pressure Power control
Breather filter
80
Pilot control unit, left 4 way
7.45
Stop cock
81
Pilot control unit, right 4 way
7.45
4
Return filter
84
Pilot control unit, travel 1 way
7.49
5
Bypass valve / return filter (pressure)
85
Pilot control unit 2 x, support
7.48
6
Oil cooler
87
Valve / positioning brake
11
from turbocharger / engine
88P
Manifold pressure
12
Check valve 0.2 bar
88T
Collecting pipe return line
13
Oil motor radiator fan
100
from / to control valve block
7.60
14
Pressure relief valve / fan motor
155
to slewing gear brake
9.20
15
Coarse filter (d)
170
from travel engine
20
Variable-displacement pump
322
to rotary connection 6 way
7.76
21
Powertrain
19.10
7.14
400
to brake system
15.10
21.1 Control cylinder
401
to steering
13.10
23
402
to oscillating axle support
14.10
23.2 Power regulator
403
to gear switching unit
11.10
23.5 LS regulator
S7
Safety switch
8.10/8.30
23.6 Shuttle valve
S21
Switch / creeper gear
8.10/8.30
28
Check valve
S35
Switch / pilot control
8.10/8.30
29
Restrictor
S75
Switch / oscillating axle automatic
8.10/8.30
30
Gear pump / fan drive
S263 Switch / travel direction
31
Gear pump / steering (f)
U16
Excavator control BST
8.10/8.30
32
Gear pump / brake, pilot control
Y3
Solenoid valve servo release
8.10/8.30
44
Measuring point / actuating pressure
Y24
Solenoid valve / creeper gear
8.10/8.30
45
Measuring point / LS pressure
Y50
Proportional solenoid valve Power control
8.10/8.30
49
Measuring point / pilot pressure M1
Y51
Proportional solenoid valve LS control
8.10/8.30
50
Control oil unit
Y62
Solenoid valve / forward travel
8.10/8.30
51
Pressure relief valve
Y63
Solenoid valve / reverse travel
8.10/8.30
52
Pressure filter
Y352 Proportional solenoid valve / fan control
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
Y358 Proportional solenoid valve / motor speed
8.10/8.30
54
Accumulator
Y371 Solenoid valve / oscillating axle support
8.10/8.30
57
Measuring point / servo pressure -p reduction
Index to wiring diagram II Item
see group
1
to hydraulic tank
6
to hydraulic tank
7
Check valve 3.5 bar
7.60
8
Preload valve 7.0 bar
20
from variable-displacement pump
23 41 80
Pilot control unit, left 4 way
81
Item
see group
192
Brake piston
193
Restrictor check valve
194
Check valve
7.60
195
Shuttle valve
7.14
196
Check valves
to regulating valve
220
Spool / boom cylinder
Measuring point MP
221
Secondary pressure relief valve / extending
7.45
222
Secondary pressure relief valve / retracting
from pilot control unit, right 4 way
7.45
224
Pressure balance, pilot-controlled(e)
85
from pilot control valve / support
7.48
227
Restrictor check valve
87
from valve / positioning brake
233
Distribution block
88P
from manifold P
235
Boom cylinder
88T
to collecting pipe T
237
Stop cock (in models without item 238)
100
Compact control block 5 x
238
Pipe fracture safety valve (kit)
102
Pressure balance / minimum flow
240
Spool / stick cylinder
103
Pressure balance / remaining flow
241
Secondary pressure relief valve / retracting
104
Pressure cut-off valve
242
Secondary pressure relief valve / extending
105
Primary pressure relief valve
244
Pressure balance, directly controlled
107
Shuttle valve (e)
247
Restrictor check valve
109
LS central nozzle
255
Stick cylinder
7.30
120
Spool / slewing gear
260
Spool / bucket cylinder
7.60
122
Input pressure balance
261
Secondary pressure relief valve / retracting
123
Check valve (e)
262
Secondary pressure relief valve / extending
125
TC valve with additional pressure stage (e)
264
Pressure balance, directly controlled
126
Restrictor (Ø 1.5 mm)
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
Restrictor check valve
277
Shut-off device for grapple operation
128
Shuttle valve
278
Lines leading to grapple
129
Restrictor (Ø 0.6 mm) (e)
279
Restrictor check valve (QC only)
130
Slewing gear motor, complete
280
Spool / support cylinder
132
Powertrain
281
Plug / dummy cartridge
133
Suction valve
284
Pressure balance, directly controlled
134
Pressure relief valve with additional pressure stage
295
Support cylinder
135
Pressure relief valve with additional pressure stage
297
Double load-holding valve
137
Measuring point, turning right
320
Rotary connection 7 way
7.78
138
Measuring point, turning left
322
Rotary connection 6 way
7.76
155
Slewing gear brake
9.20
540
Spool / grapple rotator
16.44
156
Slewing gear mechanism
9.10
541
Secondary relief valve / turn right
160
Travel gear spool
7.60
542
Secondary relief valve / turn left
161
Suction valve / reverse travel
544
Pressure balance, directly controlled
162
Suction valve / forward travel
550
Oil motor / grapple rotator
164
Pressure balance, directly controlled
551
Secondary relief valve / turn right
167
Restrictor check valve
552
Secondary relief valve / turn left
170
Travel motor
172 173
7.24
7.60
7.30
S5L Push button / grapple rotator, left
8.10/8.30
Powertrain
S5R Push button / grapple rotator, right
8.10/8.30
Control cylinder / regulating unit
S19
Switch / grapple rotator
8.10/8.30
174
Spool / regulating unit
Y22
Solenoid valve / grapple rotation left
16.44
176
Secondary pressure relief valve / forward travel
Y23
Solenoid valve / grapple rotation right
16.44
177
Secondary pressure relief valve / reverse travel
Y24
from solenoid valve / creeper gear
7.42
185
Transmission
11.10
Y62
from solenoid valve / forward travel
8.10/8.30
190
Travel brake valve, complete
7.26
Y63
from solenoid valve / reverse travel
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
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.
Index to wiring diagram I Item
see group
1
Hydraulic tank
2
Item
see group
59
Measuring point / servo pressure Power control
Breather filter
64
Cylinder / uppercarriage locking mechanism (m)
3
Stop cock
80
Pilot control unit, left 4 way
7.45
4
Return filter
81
Pilot control unit, right 4 way
7.45
5
Bypass valve / return filter (pressure)
84
Pilot control unit, travel 1 way
7.49
6
Oil cooler
85
Pilot control unit 2 x, support
7.48
11
from turbocharger / engine
87
Valve / positioning brake
19.10
12
Check valve 0.2 bar
88P
Manifold pressure
13
Oil motor radiator fan
88T
Collecting pipe return line
14
Pressure relief valve / fan motor
100
from / to control valve block
7.60
15
Coarse filter
155
to slewing gear brake
9.20
20
Variable-displacement pump
170
from travel engine
21
Powertrain
7.05
322
to rotary connection 6 way
7.76
21.1 Control cylinder
400
to brake system
15.10
23
401
to steering
13.10
23.2 Power regulator
402
to oscillating axle support
14.10
23.5 LS regulator
403
to gear switching unit
11.10
23.6 Shuttle valve
S7
Safety switch
8.10/8.32
28
Check valve
S21
Switch / creeper gear
8.10/8.32
29
Restrictor
S35
Switch / pilot control
8.10/8.32
Switch / oscillating axle automatic
Regulating valve
30
Gear pump / fan drive
S75
31
Gear pump / steering
S263 Switch / travel direction
8.10/8.32
32
Gear pump / brake, pilot control
U16
Excavator control BST
8.10/8.32
44
Measuring point / actuating pressure
Y3
Solenoid valve servo release
8.10/8.32
45
Measuring point / LS pressure
Y24
Solenoid valve / creeper gear
8.10/8.32
49
Measuring point / pilot pressure M1
Y50
Proportional solenoid valve Power control
8.10/8.32
50
Control oil unit
Y51
Proportional solenoid valve LS control
8.10/8.32
51
Pressure relief valve
Y62
Solenoid valve / forward travel
8.10/8.32
52
Pressure filter
Y63
Solenoid valve / reverse travel
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
Y352 Proportional solenoid valve / fan control
54
Accumulator
Y358 Proportional solenoid valve / motor speed
57
Measuring point / servo pressure -p reduction
Y371 Solenoid valve / osc. axle support
8.10/8.32
8.10/8.32
Index to wiring diagram II Item
see group
1
to hydraulic tank
6
to hydraulic tank
7
Check valve 3.5 bar
7.60
8
Preload valve 7.0 bar
20
from variable-displacement pump
23 41 80
Pilot control unit, left 4 way
Item
see group
192
Brake piston
193
Restrictor check valve
194
Check valve
7.60
195
Shuttle valve
7.14
196
Check valves
to regulating valve
220
Spool / boom cylinder
Measuring point MP
221
Secondary pressure relief valve / extending
7.45
222
Secondary pressure relief valve / retracting
7.59
81
from pilot control unit, right 4 way
7.45
224
Pressure balance, pilot-controlled
85
from pilot control valve / support
7.48
227
Restrictor check valve
87
from valve / positioning brake
233
Distribution block
88P
from manifold P
235
Boom cylinder
88T
to collecting pipe T
237
Stop cock (in models without item 238)
100
Compact control block 5 x
238
Pipe fracture safety valve (kit)
102
Pressure balance / minimum flow
240
Spool / stick cylinder
103
Pressure balance / remaining flow
241
Secondary pressure relief valve / retracting
104
Pressure cut-off valve
242
Secondary pressure relief valve / extending
105
Primary pressure relief valve
244
Pressure balance, directly controlled
107
Shuttle valve
247
Restrictor check valve
109
LS central nozzle
255
Stick cylinder
7.30
120
Spool / slewing gear
260
Spool / bucket cylinder
7.60
122
Input pressure balance
261
Secondary pressure relief valve / retracting
123
Check valve
262
Secondary pressure relief valve / extending
125
TC valve with additional pressure stage
264
Pressure balance, directly controlled
126
Restrictor (Ø 1.5 mm)
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
Restrictor check valve
277
Shut-off device for grapple operation
128
Shuttle valve
278
Lines leading to grapple
129
Restrictor (Ø 0.6 mm)
279
Restrictor check valve (QC only)
130
Slewing gear motor, complete
280
Spool / support cylinder
132
Powertrain
281
Plug / dummy cartridge
133
Suction valve
284
Pressure balance, directly controlled
134
Pressure relief valve with additional pressure stage
295
Support cylinder
135
Pressure relief valve with additional pressure stage
297
Double load-holding valve
137
Measuring point, turning right
320
Rotary connection 7 way
7.78
138
Measuring point, turning left
322
Rotary connection 6 way
7.76
155
Slewing gear brake
9.20
540
Spool / grapple rotator
16.44
156
Slewing gear mechanism
9.10
541
Secondary relief valve / turn right
160
Travel gear spool
7.60
542
Secondary relief valve / turn left
161
Suction valve / reverse travel
544
Pressure balance, directly controlled
162
Suction valve / forward travel
550
Oil motor / grapple rotator
164
Pressure balance, directly controlled
551
Secondary relief valve / turn right
167
Restrictor check valve
552
Secondary relief valve / turn left
170
Travel motor
S5L
Push button / grapple rotator, left
172
Powertrain
S5R Push button / grapple rotator, right
8.10/8.32
173
Control cylinder / regulating unit
S19
Switch / grapple rotator
8.10/8.32
174
Spool / regulating unit
Y22
Solenoid valve / grapple rotation left
16.44
176
Secondary pressure relief valve / forward travel
Y23
Solenoid valve / grapple rotation right
16.44
177
Secondary pressure relief valve / reverse travel
Y24
from solenoid valve / creeper gear
7.42
185
Transmission
11.20(n)
Y62
from solenoid valve / forward travel
8.10/8.32
190
Travel brake valve, complete
7.27(n)
Y63
from solenoid valve / reverse travel
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
Hydraulic unit Note! For a detailed description of the design and construction of the hydraulic system and the various main components, see group 6.27.
Item
see group
Item
see group
1
Hydraulic tank
19.10
137
Measuring point, turning right
2
Breather filter
19.10
138
Measuring point, turning left
3
Stop cock
155
Slewing gear brake
9.20
4
Return filter
19.10
156
Slewing gear mechanism
9.10
5
Bypass valve / return filter (pressure)
19.10
160
Spool / chassis right
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
Preload valve 7.0 bar
7.60
164
Pressure balance, directly controlled
7.60
10
Cylinder / speed adjustment
167
Restrictor check valve
7.60
11
from turbocharger / engine
180
Spool / chassis left
7.60
12
Check valve 0.2 bar
181
Suction valve A2 / forward
7.60
13
Oil motor radiator fan
182
Suction valve B2 / reverse
7.60
14
Pressure relief valve / fan motor
184
Pressure balance, directly controlled
7.60
15
Coarse filter / fan motor
195
Rotary connection 5 x
7.77
20
Variable-displacement pump
7.16
196
Rotary connection 1 x
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
Shifting piston, oil motor adjustment
7.28
25
Performance regulator
7.16
205
Brake valve
7.28
26
Flow regulator
7.16
206
Shuttle valve
7.28
27
Shuttle valve
7.16
207
2-way valve / brake control pressure
7.28
28
Check valve
7.16
208
Pressure reduction valve / brake pressure
7.28
29
Restrictor
7.16
211
Secondary pressure relief valve chassis, forward left
7.28
30
Gear pump / pilot control
212
Secondary pressure relief valve chassis, reverse left
7.28
31
Gear pump / fan drive
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
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
Measuring point LS (variable-displacement pump)
216
Travel gear
11.60
49
Measuring point / control pressure M1
220
Spool / boom cylinder
7.60
50
Control oil unit
7.43
221
Secondary relief valve A3 / extending
7.60
51
Pressure relief valve
7.43
222
Secondary relief valve / retracting
7.60
52
Pressure filter
7.43
224
Pressure balance, pilot-controlled
7.60
53
Check valve
7.43
227
Restrictor check valve
7.60
7.43
54
Accumulator
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 (in models without item 238)
80
Pilot control unit, left 4 x
7.45
238
Pipe fracture safety valve (kit)
81
Pilot control unit, right 4 x
7.45
240
Spool / stick cylinder
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
Pressure balance, directly controlled
7.60
85
Pilot control unit 2 x, support
247
Restrictor check valve
7.60
88P
Manifold pressure
255
Stick cylinder
7.30
88T
Collecting pipe return line
257
Restrictor check valve
100
Compact control valve block 5 x
7.60
260
Spool / bucket cylinder
7.60
102
Pressure balance / minimum flow
7.60
261
Secondary relief valve A4 / retracting
7.60
103
Pressure balance / remaining flow
7.60
262
Secondary relief valve B4 / extending
7.60
104
Pressure cut-off valve
7.60
264
Pressure balance, directly controlled
7.60
105
Primary pressure relief valve
7.60
275
Bucket cylinder
7.30
106
Shift valve Qmax. variable displacement motor
7.60
277
Shut-off device for grapple operation
107
Shuttle valve
7.60
278
Lines leading to grapple
108
LS mainmain orifice
7.60
278
Grapple cylinder
109
Shuttle valve
7.60
279
Restrictor check valve (QC only)
120
Spool / slewing gear
7.60
122
Input pressure balance
7.60
6.47.2
7.30
7.90
R 317 LI 18161-21204 copyright by
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
TC valve with additional pressure level
7.80
S21
Switch / creeper gear
8.17/8.40
126
Restrictor (Ø 1.5 mm)
7.80
U16
Excavator control BST
8.17/8.40
127
Restrictor check valve
7.60
Y3
Solenoid valve servo release
8.17/8.40
128
Shuttle valve
7.60
Y7
Solenoid valve slewing gear brake
8.17/8.40
129
Restrictor (Ø 0.6 mm)
7.80
Y24
Solenoid valve / fast travel
8.17/8.40
130
Slewing gear motor
7.24
Y50
Proportional solenoid valve Power control
8.17/8.40
132
Powertrain
7.24
Y51
Proportional solenoid valve LS control
8.17/8.40
133
Suction valve
7.24
Y352 Proportional solenoid valve / fan control
8.17/8.40
134
Pressure relief valve with additional pressure level, r B
7.24
Y358 Proportional solenoid valve / speed adjustment
8.17/8.40
135
Pressure relief valve with additional pressure level, l A
7.24
R 317 LI 18161-21204 copyright by
MJFCIFSS
6.47.3
Hydraulic unit
6.47.4
Service Manual
R 317 LI 18161-21204 copyright by
MJFCIFSS
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 6.27.
Item
see group
Item
see group
1
Hydraulic tank
19.10
137
Measuring point, turning right
2
Breather filter
19.10
138
Measuring point, turning left
3
Stop cock
155
Slewing gear brake
9.20
4
Return filter
19.10
156
Slewing gear mechanism
9.10
5
Bypass valve / return filter (pressure)
19.10
160
Spool / chassis right
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
Preload valve 7.0 bar
7.60
164
Pressure balance, directly controlled
7.60
10
Cylinder / speed adjustment
167
Restrictor check valve
7.60
11
from turbocharger / engine
180
Spool / chassis left
7.60
12
Check valve 0.2 bar
181
Suction valve A2 / forward
7.60
13
Oil motor radiator fan
182
Suction valve B2 / reverse
7.60
14
Pressure relief valve / fan motor
184
Pressure balance, directly controlled
7.60
15
Coarse filter / fan motor
195
Rotary connection 5 x
7.77
20
Variable-displacement pump
7.16
196
Rotary connection 1 x
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
Shifting piston, oil motor adjustment
7.28
25
Performance regulator
7.16
205
Brake valve
7.28
26
Flow regulator
7.16
206
Shuttle valve
7.28
27
Shuttle valve
7.16
207
2-way valve / brake control pressure
7.28
28
Check valve
7.16
208
Pressure reduction valve / brake pressure
7.28
29
Restrictor
7.16
211
Secondary pressure relief valve chassis, forward left
7.28
30
Gear pump / pilot control
212
Secondary pressure relief valve chassis, reverse left
7.28
31
Gear pump / fan drive
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
R 317 LI 21205copyright by
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
Measuring point LS (variable-displacement pump)
216
Travel gear
11.60
49
Measuring point / control pressure M1
220
Spool / boom cylinder
7.60
50
Control oil unit
7.43
221
Secondary relief valve A3 / extending
7.60
51
Pressure relief valve
7.43
222
Secondary relief valve / retracting
7.60
52
Pressure filter
7.43
224
Pressure balance, pilot-controlled
7.60
53
Check valve
7.43
227
Restrictor check valve
7.60
7.43
54
Accumulator
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 (in models without item 238)
80
Pilot control unit, left 4 x
7.45
238
Pipe fracture safety valve (kit)
81
Pilot control unit, right 4 x
7.45
240
Spool / stick cylinder
7.60
82
Pilot control unit, travel, left 4 x
7.46:11
241
Secondary relief valve A5 / retracting
7.60
84
Pilot control unit, travel 1 x
242
Secondary relief valve B5 / extending
7.60
85
Pilot control unit 2 x, support
244
Pressure balance, directly controlled
7.60
88P
Manifold pressure
247
Restrictor check valve
7.60
88T
Collecting pipe return line
255
Stick cylinder
7.30
100
Compact control valve block 5 x
7.60
257
Restrictor check valve
102
Pressure balance / minimum flow
7.60
260
Spool / bucket cylinder
7.60
103
Pressure balance / remaining flow
7.60
261
Secondary relief valve A4 / retracting
7.60
104
Pressure cut-off valve
7.60
262
Secondary relief valve B4 / extending
7.60
105
Primary pressure relief valve
7.60
264
Pressure balance, directly controlled
7.60
106
Shift valve Qmax. variable displacement motor
7.60
275
Bucket cylinder
7.30
107
Shuttle valve
7.60
277
Shut-off device for grapple operation
108
LS mainmain orifice
7.60
278
Lines leading to grapple
109
Shuttle valve
7.60
278
Grapple cylinder
120
Spool / slewing gear
7.60
279
Restrictor check valve (QC only)
122
Input pressure balance
7.60
6.47.12
7.30
7.90
R 317 LI 21205copyright by
MJFCIFSS
Service Manual
Hydraulic unit
see group
Item
see group
Item
123
Check valve
7.60
125
TC valve with additional pressure level
7.80
S17
Switch slewing gear brake
8.17/8.40
126
Restrictor (Ø 1.5 mm)
7.80
S21
Switch / creeper gear
8.17/8.40
127
Restrictor check valve
7.60
U16
Excavator control BST
8.17/8.40
128
Shuttle valve
7.60
Y3
Solenoid valve servo release
8.17/8.40
129
Restrictor (Ø 0.6 mm)
7.80
Y7
Solenoid valve slewing gear brake
8.17/8.40
130
Slewing gear motor
7.24
Y24
Solenoid valve / fast travel
8.17/8.40
132
Powertrain
7.24
Y50
Proportional solenoid valve Power control
8.17/8.40
133
Suction valve
7.24
Y51
Proportional solenoid valve LS control
8.17/8.40
134
Pressure relief valve with additional pressure level, r B
7.24
Y352 Proportional solenoid valve / fan control
8.17/8.40
135
Pressure relief valve with additional pressure level, l A
7.24
Y358 Proportional solenoid valve / speed adjustment
8.17/8.40
R 317 LI 21205copyright by
MJFCIFSS
6.47.13
Hydraulic unit
6.47.14
Service Manual
R 317 LI 21205copyright by
MJFCIFSS
Service Manual
SUBGROUP - INDEX Section
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
A 312 LI 12363A 314 LI 2001A 316 LI 2001A 316 LI-IND 2001-
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
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-
FMF hydraulic fixed displacement motor
7.24.1
A 314 LI 2001-11146 A 316 LI 2001-11151 A 316 LI-IND 2001-11151
FMF hydraulic fixed displacement motor
7.24.11
A 309 LI 20221A 311 LI 20222A 312 LI 12363A 314 LI 11147A 316 LI 11152A 316 LI-IND 11152R 313 LI 27752R 317 LI 18161-
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
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-
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-
Control oil and regulation unit
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
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-
Pilot control unit 2 way for travel gear drive
7.46.1
R 317 LI 18161-
7.2 MJFCIFSS
Service Manual
SUBGROUP - INDEX Section
Group
Type
Pilot control unit 4x
7.46.11
R 313 LI 27752R 317 LI 21205-
Pilot control valve 2 x
7.47.1
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-
Pilot control valve 2 x
7.48.1
A 309 LI 20221A 311 LI 20222A 312 LI 12363A 314 LI 2001A 316 LI 2001A 316 LI-IND 2001-
Pilot control valve 1 x
7.49.1
A 309 LI 20221A 311 LI 20222A 312 LI 12363A 314 LI 2001A 316 LI 2001A 316 LI-IND 2001-
Compact control block
7.50.1
A 309 LI 20221A 311 LI 20222-
LSC control block
7.60.1
A 312 LI 12363A 314 LI 2001A 316 LI 2001A 316 LI-IND 2001R 313 LI 27752R 317 LI 18161-
Rotary connection 1 x
7.75.1
R 313 LI 27752R 317 LI 18161-
7.3 MJFCIFSS
Service Manual Rotary connection 6 x
7.76.1
A 309 LI 20221A 311 LI 20222A 312 LI 12363A 314 LI 2001A 316 LI 2001A 316 LI-IND 2001-
Rotary connection 5 x
7.77.1
R 313 LI 27752R 317 LI 18161-
Rotary connection 7 x
7.78.1
A 309 LI 20221A 311 LI 20222A 312 LI 12363A 314 LI 2001A 316 LI 2001A 316 LI-IND 2001-
TC valve
7.80.1
A 312 LI 12363A 314 LI 2001A 316 LI 2001A 316 LI-IND 2001R 317 LI 18161-
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
Gear pump / fan drive
copyright by
MJFCIFSS
7.02.1
Double variable-displacement pump A8VO
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
A 311 Litronic 20222
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
Double variable-displacement pump A8VO
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
Double variable-displacement pump A8VO
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
Tapered roller bearing
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
Double variable-displacement pump A8VO
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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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.
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7.02.9
Double variable-displacement pump A8VO
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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MJFCIFSS
7.02.11
Double variable-displacement pump A8VO
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
Seal-Lock collar nut Safety cap
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
Screw plug Threaded stud
31 32
Centre peg Disc spring
74 75
Seal-Lock collar nut Safety cap
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
Cylindrical roller bearing
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
Double variable-displacement pump A8VO
Service Manual
Regulating characteristic for A 309 Fig. 7
Double variable-displacement pump A8VO
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
Double variable-displacement pump A8VO
Service Manual
Regulating characteristic for A 311
7.02.16
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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
LPV variable displacement pump
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7.05.1
LPV variable displacement pump
Service Manual
General information
2 General information Machine from serial number
A 312 Litronic 12363
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
LPV variable displacement pump
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
Gear pump / pilot control
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
LPV variable displacement pump
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
23.2 Performance regulator
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
LPV variable displacement pump
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
LPV variable displacement pump Pump regulation
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
Performance regulator
23.9
Piston
23.5 23.6
Load-sensing regulator Shuttle valve
23.13 2.314
Regulating spring Regulating spring
23.7
Spool
44
Measuring point / actuating pressure
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7.05.9
LPV variable displacement pump
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
LPV variable displacement pump Pump regulation
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
Spool / stick cylinder
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
Spool / support cylinder
170
Travel motor
295
Support cylinder
220
Spool / boom cylinder
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7.05.11
LPV variable displacement pump
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
LPV variable displacement pump
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
Adjusting screw Lock nut
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
LPV variable displacement pump
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
* items in hydraulic diagram
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
LPV variable displacement pump
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
Performance diagram of the LPV 130 variable-displacement pump in A 314 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
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7.05.19
LPV variable displacement pump
Service Manual
LPV 150 pump performance diagrams
10
LPV 150 pump performance diagrams
Fig. 15
H P
Performance diagram of the LPV 150 variable-displacement pump in A 316 Litronic machines
S -1.5
Hyperbola for rated power Power
to software version 1.5
(*)Qn is the rated flow rate (=volume at PO(LS)) of the respective spool
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
DPVO variable displacement pump
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7.10.1
DPVO variable displacement pump
Service Manual
Purpose
7.10.2
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Service Manual
DPVO variable displacement pump General information
2 General information Equipment from serial number
R 317 Litronic 18161
Type of pump
DPVO 165
Input speed
1800 min-1
Drive power of diesel engine (nominal power) = Pmax
86 kW
Volumetric delivery max. min.
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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MJFCIFSS
7.10.3
DPVO variable displacement pump
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
DPVO variable displacement pump
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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MJFCIFSS
7.10.7
DPVO variable displacement pump
Service Manual
Pump regulation
5 Pump regulation 5.1
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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MJFCIFSS
7.10.9
DPVO variable displacement pump
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
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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
Control chamber pressure
p)
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MJFCIFSS
7.10.11
DPVO variable displacement pump
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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MJFCIFSS
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
DPVO variable displacement pump
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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MJFCIFSS
7.15.1
DPVO variable-displacement pump
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
Measuring point / LS pressure
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
R 313 Litronic 27752
Pump type
DPVO 165
Input speed
1800 rpm
Drive power of diesel engine (nominal power) = Pmax
73 kW
Volumetric delivery max. min.
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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MJFCIFSS
7.15.3
DPVO variable-displacement pump
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
Measuring point / LS pressure
22 23
Control piston Measuring cylinder
50 100
from/to control oil unit to control valve block
24
Lever (rocker)
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Performance regulator
Service Manual
DPVO variable-displacement pump Functional description
3 Functional description 3.1
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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MJFCIFSS
7.15.5
DPVO variable-displacement pump
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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MJFCIFSS
Service Manual
DPVO variable-displacement pump Pump regulation
4 Pump regulation 4.1
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
Control chamber pressure
17
Spool
T
Tank pressure
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MJFCIFSS
7.15.7
DPVO variable-displacement pump
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
Screw plug Threaded stud
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
DPVO variable-displacement pump
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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MJFCIFSS
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
Pressure spring Pressure spring
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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MJFCIFSS
7.15.11
DPVO variable-displacement pump
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
DPVO variable-displacement pump
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
Pressure-relief valve
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
Y352 Proportional solenoid valve / fan control
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MJFCIFSS
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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MJFCIFSS
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
Pressure-relief valve
U16
Excavator control BST
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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MJFCIFSS
7.20.5
Cooling unit
Service Manual
Function of the fan control
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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MJFCIFSS
Service Manual
Cooling unit Function of the fan control
2.2.2
Diagram of model A 312
Fig. 5
Temperatures current and current speed and pressure
Y352
Proportional solenoid valve
T
Temperature of medium (oil, coolant)
p
Pressure in cooling circuit
n
Speed of annular fan
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MJFCIFSS
7.20.7
Cooling unit
Service Manual
Function of the fan control
2.2.3
Diagram of model R 313
Fig. 6
7.20.8
Temperatures current and current speed and pressure
Y352
Proportional solenoid valve
T
Temperature of medium (oil, coolant)
p
Pressure in cooling circuit
n
Speed of annular fan
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MJFCIFSS
Service Manual
Cooling unit Function of the fan control
2.2.4
Diagram of model A 314 - R 317
Fig. 7
Temperatures current and current speed and pressure
Y352
Proportional solenoid valve
T
Temperature of medium (oil, coolant)
p
Pressure in cooling circuit
n
Speed of annular fan
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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MJFCIFSS
7.20.9
Cooling unit
Service Manual
Function of the fan control
7.20.10
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MJFCIFSS
Service Manual
FMF hydraulic fixed displacement motor Function
FMF hydraulic fixed displacement motor 1 Function The FMF hydraulic fixed displacement motor is of the built-in type. Its purpose is to drive the slewing gear mechanism of the machine. The axial piston motor is of the swash plate design and sits on the slewing gear mechanism of the machine.
Fig. 1
FMF hydraulic fixed displacement motor
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MJFCIFSS
7.24.1
FMF hydraulic fixed displacement motor
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
copyright by
MJFCIFSS
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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MJFCIFSS
Pressure-relief valve with additional pressure stage Pressure-relief valve with additional pressure stage
7.24.3
FMF hydraulic fixed displacement motor
Service Manual
Functional description
4 Functional description 4.1
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
copyright by
MJFCIFSS
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
Radial shaft seal ring 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
Locking pin
29
Shim
12
Housing
30
Shim (supplied only with repair set / locking ring
13
Mounting plate
134
Pressure relief valve B with additional pressure stage
13.21
Screw plug
135
Pressure relief valve B with additional pressure stage
14
Allen head screw
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MJFCIFSS
7.24.5
FMF hydraulic fixed displacement motor
Service Manual
Functional description
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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MJFCIFSS
Service Manual
FMF hydraulic fixed displacement motor Functional description
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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MJFCIFSS
7.24.7
FMF hydraulic fixed displacement motor
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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MJFCIFSS
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
FMF hydraulic fixed displacement motor
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MJFCIFSS
7.24.11
FMF hydraulic fixed displacement motor
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
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.
7.24.12
copyright by
MJFCIFSS
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
Pressure-relief valve with additional pressure stage
13
Mounting plate
135
Pressure-relief valve with additional pressure stage
130
Oil motor, complete
137
Measuring connection MA
132 133
Powertrain, complete Suction valve
138
Measuring connection MB
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MJFCIFSS
7.24.13
FMF hydraulic fixed displacement motor
Service Manual
Functional description
9 Functional description 9.1
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
copyright by
MJFCIFSS
Service Manual
FMF hydraulic fixed displacement motor Functional description
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
Pressure relief valve B with additional pressure stage
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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MJFCIFSS
7.24.15
FMF hydraulic fixed displacement motor
Service Manual
Functional description
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
copyright by
MJFCIFSS
Service Manual
FMF hydraulic fixed displacement motor Functional description
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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MJFCIFSS
7.24.17
FMF hydraulic fixed displacement motor
Service Manual
Maintenance and repairs
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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MJFCIFSS
7.26.1
LMV regulating motor
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
LMV regulating motor
Service Manual
Functional description
4 Functional description 4.1
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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MJFCIFSS
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
Allen head screw Retaining washer
79 84
Pilot plate Swivel yoke
25
Allen head screw
85
Sliding disc
29
Allen head screw
87
Actuation device (174*)
32
Cylindrical roller bearing
95
Drive shaft
33
Cylindrical roller bearing
97
Locking ring Mounting flange
Cylinder (172*)
34
Cylindrical roller bearing
98
35 36
Radial shaft seal ring O-ring
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
LMV regulating motor
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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MJFCIFSS
Service Manual
LMV regulating motor Functional description
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
LMV regulating motor
Service Manual
Functional description 19
Guide ring
20
Restrictor
173* Regulating unit / control cylinder
* items in hydraulic diagram
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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Service Manual
LMV regulating motor Functional description
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
LMV regulating motor
Service Manual
Functional description
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
* items in hydraulic diagram
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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MJFCIFSS
7.26.11
LMV regulating motor
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
Adjusting screw Lock nut
.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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7.26.13
LMV regulating motor
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
* items in hydraulic diagram
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7.26.15
LMV regulating motor
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)
* items in hydraulic diagram
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
DMVA regulating motor
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
Max. oil flow consumption
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
Adjustable settings of oil motor A
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
Max. oil flow consumption
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
Adjustable settings of oil motor A
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
Secondary pressure-relief valves
380+20 bar
Technical data of the travel motor for model A 316 Litronic
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7.27.3
DMVA regulating motor
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
Secondary pressure-relief valve
80
Housing
177
Secondary pressure-relief valve
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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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MJFCIFSS
7.27.5
DMVA regulating motor
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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Service Manual
DMVA regulating motor Functional description of the travel motor
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
DMVA regulating motor
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
DMVA regulating motor Functional description of the travel motor
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
DMVA regulating motor
Service Manual
Maintenance and repairs
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
DMVA regulating motor
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
Travel brake valve, complete
52 67
Check valve Push rod
192 193
Brake piston Restrictor bolt
68
Pressure spring (adjusting spring)
194
Check valve
69
Pressure spring (regulating spring)
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
DMVA regulating motor
Service Manual
DMVA regulating motor
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
Secondary pressure-relief valve
12
Bolt
177
Secondary pressure-relief valve
13
Pressure spring
192
Piston
14
Cylindrical roller bearing
193
Restrictor bolt
15
Cylindrical roller bearing
194
Check valve
16
Cylindrical roller bearing
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
Pressure spring (regulating spring)
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
Regulating motor A6VE
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7.28.1
Regulating motor A6VE
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
Max. oil flow consumption
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
Regulating motor A6VE
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
Travel motor, left Travel motor, right
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
from control oil unit
208
Pressure reduction valve / brake pressure
100
Compact control block
209
Double stop valve
106
Shift valve / Qmax Regulating motors
211
Secondary pressure relief valve, powertrain, forward left
195
Rotary connection 5 x
212
196
Rotary connection 1 x
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
Regulating motor A6VE
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
Regulating motor A6VE
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
Radial shaft seal ring
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
Regulating motor A6VE
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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7.28.11
Regulating motor A6VE
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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7.28.13
Regulating motor A6VE
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
Regulating motor A6VE
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
Pressure spring O-ring
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7.28.17
Regulating motor A6VE
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
adjustable attachment
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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MJFCIFSS
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 29 443 1040
adjustable attachment
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
Stick cylinder at 29 761 1000
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
Regulating cylinder at 29 447 1049
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
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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7.35.1
Hydraulic cylinder
7.35.2
Service Manual
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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 29 680 1048
adjustable attachment
2
120
70
895
1420
091
29 615 1040
Industrial gooseneck boom
2
120
70
895
1420
091
Stick cylinder at 29 497 1040
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
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
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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7.36.1
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
Control oil and regulation unit
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
Y371 Solenoid valve / oscillating axle support
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.
copyright by
MJFCIFSS
7.40.3
Control oil and regulation unit
Service Manual
Functional description
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
copyright by
MJFCIFSS
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
Proportional solenoid valve / flow reduction P1
copyright by
MJFCIFSS
7.40.5
Control oil and regulation unit
Service Manual
Emergency position of the proportional solenoid valve Y50
7.40.6
copyright by
MJFCIFSS
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
Control oil and regulation unit
copyright by
MJFCIFSS
7.42.1
Control oil and regulation unit
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
copyright by
MJFCIFSS
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
Proportional solenoid valve / power control
55 56
Dummy plate Dummy plate
Y51 Proportional solenoid valve / LS control Y371 Solenoid valve / oscillating axle support (wheel machines only)
copyright by
MJFCIFSS
7.42.3
Control oil and regulation unit
Service Manual
Functional description
3 Functional description (see Fig. 2, page 3)
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
copyright by
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).
copyright by
MJFCIFSS
7.42.5
Control oil and regulation unit
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
Proportional solenoid valve / power control
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
copyright by
MJFCIFSS
7.45.1
Pilot control unit 4 x
Service Manual
Functional description
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
copyright by
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
Pilot control unit 4 x
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
copyright by
MJFCIFSS
7.45.5
Pilot control unit 4 x
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
X1046* Plug connection, 12-pin
191
Allen head screw
X1047* Plug connection, 3-pin
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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MJFCIFSS
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
Pilot control unit 4 x
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
copyright by
MJFCIFSS
7.46.1
Pilot control unit 2 way for travel gear drive
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
copyright by
MJFCIFSS
7.46.3
Pilot control unit 2 way for travel gear drive
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)
copyright by
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
Pilot control unit 2 way for travel gear drive
Service Manual
Exploded view and sectional drawing
7.46.6
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 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
Pressure spring (return spring)
998.3
PDF seal (item 37)
29
Retaining plate
998.4
O-ring (item 38)
30
Cap
998.5
Protective cover (cap)
copyright by
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
Pilot control unit 2 way for travel gear drive
Service Manual
Exploded view and sectional drawing
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
Functional description
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
copyright by
MJFCIFSS
7.46.13
for travel gear drive
Service Manual
Exploded view and sectional drawing
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
Pilot control unit, complete
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
for travel gear drive
Service Manual
Exploded view and sectional drawing
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
copyright by
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
Pilot control valve 2 x
Service Manual
Functional description
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
Pilot control valve 2 x
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
Pressure spring (return spring)
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
Pilot control valve 2 x
Service Manual
Sectional drawing
7.47.6
copyright by
MJFCIFSS
Service Manual
Pilot control valve 2 x Description
Pilot control valve 2 x 1 Description The operator controls outrigger and/or blade support operations by means of the pilot control valve and lever (on the control console, to the right). There are two regulating pistons 12 (pressure control valves), sitting in an axial position in housing 70, complete with pressure, return and control connections. There is a sort of tipping switch on top, (with lever 64) to actuate regulating piston 12. The tipping switch 3, which can move to and fro, presses with each movement against a screwed-in threaded thud which, again, presses against a spring-loaded pushrod. This actuates regulating piston 12 underneath (with regulating spring and return spring) and, thus, opens it towards pressure channel P, outlet 1 / 2. There is a cover to protect pushrod, guide bushing etc. against dirt.
Fig. 1
Pilot control valve 2 x with hydraulic diagram
copyright by
MJFCIFSS
7.48.1
Pilot control valve 2 x
Service Manual
Functional description
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
Pilot control valve 2 x
Service Manual
Exploded view
4 Exploded view
Fig. 3
7.48.4
Exploded drawing: pilot control valve
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
Pressure spring (regulating spring)
98
Repair kit
28
Pressure spring (return spring)
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
Pilot control valve 2 x
Service Manual
Sectional drawing
7.48.6
copyright by
MJFCIFSS
Service Manual
Pilot control valve 1 x Description
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
Pilot control valve 1 x
Service Manual
Functional description
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
Pilot control valve 1 x
Service Manual
Repair
3.3
Exploded view
Fig. 3
Exploded drawing: pilot control valve
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
Pressure spring (return spring)
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
Pressure spring (regulating spring)
98.4 O-ring
26
Pressure spring (return spring)
98.5 Protective cap
copyright by
MJFCIFSS
Washer
7.49.5
Pilot control valve 1 x
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
Compact control block
copyright by
MJFCIFSS
7.50.1
Compact control block
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
Leak oil max. at load pressure at oil temperature
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
Compact control block
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
Compact control block
131
Secondary pressure-relief valve, regulating cylinder B5 Secondary pressure-relief valve, boom cylinder A6
101
Slewing gear spool
132
Secondary pressure-relief valve, boom cylinder B6
102
Stick cylinder spool
133
Secondary pressure-relief valve, bucket cylinder A7
103
Support cylinder spool
134
Secondary pressure-relief valve, bucket cylinder B7
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
Compact control block Description
Fig. 2
Control valve block - front and rear view
copyright by
MJFCIFSS
7.50.5
Compact control block
Service Manual
Description 1
to tank
127
Secondary pressure-relief valve, stick cylinder A2
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
Secondary pressure-relief valve, boom cylinder A6
41
Measuring point P2
132
Secondary pressure-relief valve, boom cylinder B6
100
Compact control block
133
Secondary pressure-relief valve, bucket cylinder A7
101
Slewing gear spool
134
102
Stick cylinder spool
135
Secondary pressure-relief valve, bucket cylinder B7 Suction valve travel motor A8
103
Support cylinder spool
136
Suction valve travel motor B8
105 106
Regulating cylinder spool Boom cylinder spool
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
Preload valve 5.5 bar
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
Compact control block Description
Fig. 3
Diagram of control valve block
copyright by
MJFCIFSS
7.50.7
Compact control block
Service Manual
Description
7.50.8
10 12
Plate Control lid, bottom
105 106
Regulating cylinder spool Boom cylinder spool
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
Secondary pressure-relief valve, stick cylinder B2
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
Secondary pressure-relief valve, boom cylinder A6
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
Secondary pressure-relief valve, bucket cylinder B7
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
Check valve Load-holding valve
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
Stick cylinder spool
162
Adjusting screw
103
Support cylinder spool
copyright by
MJFCIFSS
Service Manual
Compact control block Description
Fig. 4
Design of the control valve block 100
copyright by
MJFCIFSS
7.50.9
Compact control block
Service Manual
Description of functions
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.
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MJFCIFSS
7.50.11
Compact control block
Service Manual
Description of functions
7.50.12
12
Control lid, bottom
13 14
Control lid, top 108 Control lid with stroke limitation 109
107
23
Spring pack
127
Secondary pressure-relief valve, stick cylinder A2
24
Spring pack
128
Secondary pressure-relief valve, stick cylinder B2
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
Secondary pressure-relief valve, bucket cylinder B7
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
Check valve Load-holding valve
111 102
Auxiliary block Stick cylinder spool
152 157
Check valve O-ring
103
Support cylinder spool
158
Cone / load-holding valve
105 106
Regulating cylinder spool Boom cylinder spool
159
Pressure spring / load-holding valve
Bucket cylinder spool Travel motor spool Combined boom / stick cylinder spool
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MJFCIFSS
Service Manual
Compact control block Description of functions
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
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MJFCIFSS
Return channel, tank side
7.50.13
Compact control block
Service Manual
Description of functions
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
Compact control block
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
Spring pack, complete
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
Compact control block Description of functions
Fig. 6
Control axle 4 with auxiliary block and integrated cooler and tank preload valves
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MJFCIFSS
7.50.15
Compact control block
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
Compact control block
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
copyright by
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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MJFCIFSS
7.50.19
Compact control block
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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MJFCIFSS
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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MJFCIFSS
7.50.21
Compact control block
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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MJFCIFSS
Service Manual
Compact control block Description
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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MJFCIFSS
7.50.23
Compact control block
Service Manual
Description of functions
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
Secondary pressure-relief valve
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
copyright by
MJFCIFSS
Service Manual
Compact control block Description of functions
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
Spring pack, complete
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
Cone / load-holding valve
33
O-ring
159
Pressure spring / load-holding valve
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MJFCIFSS
7.50.25
Compact control block
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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MJFCIFSS
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
Compact control block
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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MJFCIFSS
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
from sn. 2001 M7-1340-20 from sn.11822 M7-1340-22 from sn.12741 M7-1340-23 from sn.16141 M7-1340-31
Industry
from sn. 2001 M7-1341-20 from sn.11823 M7-1341-22 from sn.12845 M7-1341-23 from sn.16286 M7-1341-31
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
240 Stick cylinder Ext.
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
-
Leak oil max. at load pressure at oil temperature
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
240 Stick cylinder Ext.
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
copyright by
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
copyright by
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.
copyright by
MJFCIFSS
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
Pressure balance / remaining flow
224
Pressure balance (pilot-controlled)
104
Pressure cut-off valve
227
Restrictor check valve
105
Primary pressure-relief valve
240
Spool / stick cylinder
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
Restrictor check valve
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
copyright by
MJFCIFSS
Service Manual
LSC control block Design of A 312 - A 316 control block
Fig. 2
Control valve block for A 312 - A 316 - front and rear view
copyright by
MJFCIFSS
7.60.7
LSC control block
Service Manual
Design of A 312 - A 316 control block
7.60.8
7
Check valve (3.5 bar)
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
Secondary pressure-relief valve / extend
100
Compact control valve block 5 x
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
Pressure cut-off valve
240
Spool / stick cylinder
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
Pressure balance (directly controlled)
108 109
Restrictor (LS central nozzle) Restrictor check valve
247 260
Restrictor check valve Spool / bucket cylinder
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
Pressure balance (directly controlled)
127 160
Restrictor check valve Spool / travel drive
280 281
Spool / chassis left Suction valve
161 162
Suction valve Suction valve
284
Pressure balance (directly controlled)
*
from index 31, see Tab. 2, pilot-controlled (directly controlled pressure balance: see items 244 / 264)
copyright by
MJFCIFSS
Restrictor check valve
Service Manual
LSC control block Design of A 312 - A 316 control block
Fig. 3
Hydraulic diagram of LSC control block for A 312 - A 316
copyright by
MJFCIFSS
7.60.9
LSC control block
Service Manual
Design of A 312 - A 316 control block
Fig. 4
7.60.10
Exploded view of control block for A 312 - 316
100
Compact control block
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
Secondary pressure-relief valve
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
copyright by
MJFCIFSS
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
Restrictor check valve
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.
copyright by
MJFCIFSS
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
Spool / chassis left Suction valve
100 102
Compact control valve block 5 x Pressure balance / minimum flow
182 184
Suction valve Pressure balance
103
Pressure balance / remaining flow
187
Restrictor check valve
104
Pressure cut-off valve
220
Spool / boom cylinder
105
Primary pressure-relief valve
221
Secondary pressure-relief valve A3
106
Shift valve / Qmax Regulating motor
222
Secondary pressure-relief valve B3
107
Shuttle valve
224
Pressure balance (pilot-controlled)
108
Restrictor (LS central nozzle)
227
Restrictor check valve
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
Restrictor check valve Spool / bucket cylinder
127
Restrictor check valve
261
Secondary pressure-relief valve A4
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
Suction valve Suction valve
373 810
Screw plug Mounting plate
164
Pressure balance
811
Allen head screw
167
Restrictor check valve
copyright by
MJFCIFSS
Service Manual
LSC control block Design of R 317 control block
Fig. 5
Control valve block for R 317 - front and rear view
copyright by
MJFCIFSS
7.60.13
LSC control block
Service Manual
Design of R 317 control block
7.60.14
7
Check valve (3.5 bar)
167
Restrictor check valve
8 41
Preload valve (7.0 bar) Measuring point MP
180 181
Spool / chassis left Suction valve
45
Measuring point LS
182
Suction valve
100
Compact control valve block 5 x
184
Pressure balance (directly controlled)
102
Pressure balance / minimum flow (flow controller)
187
Restrictor check valve
103
Pressure balance (remaining flow control- 220 ler)
Spool / boom cylinder
104
Pressure cut-off valve
221
Secondary pressure-relief valve / extend
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
Restrictor check valve
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
Restrictor check valve
127 160
Restrictor check valve Spool / chassis right
260 261
Spool / bucket cylinder Secondary pressure-relief valve / retract
161 162
Suction valve Suction valve
262 264
Secondary pressure-relief valve / extend Pressure balance (directly controlled)
164
Pressure balance (directly controlled)
copyright by
MJFCIFSS
Service Manual
LSC control block Design of R 317 control block
Fig. 6
Hydraulic diagram of LSC control valve block for R 317
copyright by
MJFCIFSS
7.60.15
LSC control block
Service Manual
Design of R 317 control block
Fig. 7
7.60.16
Exploded view of control valve block for R 317
100
Compact control block
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
Pressure cut-off valve
180
Spool / chassis left
105 110
Primary pressure-relief valve End plate
182 184
Suction valve Piston / pressure balance (directly controlled)
111
Allen head screw
187
Restrictor check valve
120 130
Spool / slewing gear O-ring
220 221
Spool / boom Spring plate
131
Spring plate
222
Secondary pressure-relief valve
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
Restrictor check valve
160
Spool / chassis right
240
Spool / stick
162
Suction valve
242
Secondary pressure-relief valve
164
Piston / pressure balance (directly controlled)
244
Piston / pressure balance (directly controlled)
165
Spring / pressure balance
247
Restrictor check valve
166
O-ring
260
Spool / bucket
copyright by
MJFCIFSS
Service Manual
LSC control block Functional description (short description)
167
Restrictor check valve
262
Secondary pressure-relief valve
168
Screw plug
264
Piston / pressure balance (directly controlled)
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
Compact control block
222
Secondary pressure-relief valve / boom
104
Pressure cut-off valve
224
Pressure balance (pilot-controlled)
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
Secondary pressure-relief valve
181
Suction valve
262
Pressure-relief valve / bucket
182
Suction valve
264
Pressure balance, directly controlled
184
Pressure balance, directly controlled
280
Spool / support (A only)
220
Spool / boom
284
Pressure balance, directly controlled
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
Primary pressure-relief valve
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
Restrictor check valve
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
Pressure cut-off valve
copyright by
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
LSC control block Input section / input element
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
Pressure-relief valve
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
Input section / input element
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
LSC control block Input section / input element
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
Pressure cut-off valve
322
Pressure spring
105
Primary pressure-relief valve
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
copyright by
MJFCIFSS
Service Manual
LSC control block Input section / input element
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
Input section / input element
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
Pressure cut-off valve
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MJFCIFSS
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
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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
Pressure balance, directly controlled
241/242
Secondary pressure-relief valves
167
Restrictor check valve
244**
Pressure balance, directly controlled
170
Cone / load-holding valve
247
Restrictor check valve
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**
Pressure balance, directly controlled
184*
Pressure balance, directly controlled
280
Spool / support
187*
Restrictor check valve
281
Screw plugs only with section support
220
Spool / boom
284**
Pressure balance, directly controlled
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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
Restrictor check valve
6
Orifice
240
Spool / stick
100
Control valve block
247
Restrictor check valve
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
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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.
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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
Pressure spring O-ring
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.
copyright by
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.
copyright by
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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MJFCIFSS
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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MJFCIFSS
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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MJFCIFSS
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
Allen head screw 335
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
Auxiliary control axles
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
copyright by
MJFCIFSS
Service Manual
LSC control block Auxiliary control axles
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.
copyright by
MJFCIFSS
7.60.49
LSC control block
Service Manual
Auxiliary control axles
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
LSC control block Auxiliary control axles
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
copyright by
MJFCIFSS
7.60.51
LSC control block
Service Manual
Auxiliary control axles
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
copyright by
MJFCIFSS
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
Allen head screw 135
10 Nm
Allen head screws 811
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
copyright by
MJFCIFSS
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
Secondary pressure-relief valve
811
Allen head screw
542
Secondary pressure-relief valve
Y22
Solenoid valve / grapple rotation left
544
Pressure balance
Y23
Solenoid valve / grapple rotation right
copyright by
MJFCIFSS
7.60.55
LSC control block
Service Manual
LSC auxiliary control axles
Fig. 35
7.60.56
Auxiliary control axle AS1
540
Spool / AS 1
544
Pressure balance
541 542
Secondary pressure-relief valve Secondary pressure-relief valve
Y22 Y23
Solenoid valve / grapple rotation left Solenoid valve / grapple rotation right
copyright by
MJFCIFSS
Service Manual
LSC control block LSC auxiliary control axles
Fig. 36 27
Sectional drawing of auxiliary control axle AS1 541
Cone / load-holding valve
Secondary pressure-relief valve
28
Pressure spring / L
542
Secondary pressure-relief valve
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
Solenoid valve / grapple rotation right
540
Spool / auxiliary control block AS1
copyright by
MJFCIFSS
7.60.57
LSC control block
Service Manual
LSC auxiliary control axles
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
copyright by
MJFCIFSS
Service Manual
LSC control block LSC auxiliary control axles
100
Compact control block
510
Spool / hydraulic hammer, etc.
500
Spool / regulating cylinder
511
Secondary pressure-relief valve /extend cylinder, 2-step
501
Secondary pressure-relief valve
512
Secondary pressure-relief valve / retract cylinder
502
Secondary pressure-relief valve
514
Pressure balance
504
Pressure balance
517
Restrictor check valve
507
Restrictor check valve
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
LSC auxiliary control axles
Fig. 37
7.60.60
Auxiliary control axles for AHS 1, AHS 11 and AHS 12
copyright by
MJFCIFSS
Service Manual
LSC control block LSC auxiliary control axles
Fig. 38
Auxiliary axles AHS 1, AHS 11 and AHS 12
copyright by
MJFCIFSS
7.60.61
LSC control block
Service Manual
LSC auxiliary control axles
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)
copyright by
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
copyright by
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
copyright by
MJFCIFSS
7.75.1
Rotary connection 1 x
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
Rotary connection 1 x
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
copyright by
MJFCIFSS
7.75.5
Rotary connection 1 x
Service Manual
Sectional drawing
7.75.6
copyright by
MJFCIFSS
Service Manual
Rotary connection 6 x Design
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
copyright by
MJFCIFSS
7.76.1
Rotary connection 6 x
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
Rotary connection 6 x
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
Sectional drawing of the rotary connection
copyright by
MJFCIFSS
7.76.5
Rotary connection 6 x
Service Manual
Exploded view of new design
6 Exploded view of new design
Fig. 5
7.76.6
Exploded view of rotary connection
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
Sectional drawing of the rotary connection
copyright by
MJFCIFSS
7.76.7
Rotary connection 6 x
Service Manual
Sectional drawing of modified design
7.76.8
copyright by
MJFCIFSS
Service Manual
Rotary connection 5 x Design
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
copyright by
MJFCIFSS
7.77.1
Rotary connection 5 x
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)
3 Removal and installation 3.1
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
Rotary connection 5 x Removal and installation
Fig. 2
Installation position of rotary connection
1
Rotary connection 5x, complete
32
Hex head screw
17 18
Hex head screw Retaining washer
33 34
Retaining washer Hex nut
19
Driver
41
Allen head screw
20
Rotary connection 1x, complete
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
Rotary connection 5 x
Service Manual
Exploded view
4 Exploded view
Fig. 3
7.77.4
Exploded view of rotary connection
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
Sectional drawing of the rotary connection
copyright by
MJFCIFSS
7.77.5
Rotary connection 5 x
Service Manual
Sectional drawing
7.77.6
copyright by
MJFCIFSS
Service Manual
Rotary connection 7 x Design
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
Rotary connection 7 x
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
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MJFCIFSS
Service Manual
Rotary connection 7 x Removal and installation
3 Removal and installation 3.1
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.
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MJFCIFSS
7.78.3
Rotary connection 7 x
Service Manual
Removal and installation
Fig. 2
7.78.4
Installation position of rotary connection
3
Lid
115
Rotary connection 6x, complete
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
Exploded view of rotary connection
3
Lid
11
Rotor
4 5
Screw plug Screw plug
12 13
Hex head screw Stator
6 7
Retaining washer Hex head screw
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
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MJFCIFSS
7.78.5
Rotary connection 7 x
Service Manual
Sectional drawing
5 Sectional drawing
Fig. 4
7.78.6
Sectional drawing of the rotary connection
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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.
2 Functional description 2.1
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.
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MJFCIFSS
7.80.1
TC valve
Service Manual
Functional description
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
Pilot control piston
13 Restrictor
10 Lock nut
7.80.2
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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
Pilot control piston
22
Screw plug
10
Hex nut
29
O-ring
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MJFCIFSS
7.80.3
TC valve
Service Manual
Sectional drawing
7.80.4
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MJFCIFSS
Service Manual
SUBGROUP - INDEX Section
Group
Type
Component arrangement
8.09.1
A 309 LI 20221A 311 LI 20222-
Component arrangement
8.10.1
A 312 LI 12363A 314 LI 2001A 316 LI 2001A 316 LI-IND 2001-
Component arrangement
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
A 312 LI 12363A 314 LI 2001A 316 LI 2001A 316 LI-IND 2001-
Electrical system
8.32.1
A 312 LI 20330A 314 LI 20334A 316 LI 20340A 316 LI-IND 20340-
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
A 309 LI 20221A 311 LI 20222A 312 LI 12363A 314 LI 2001A 316 LI 2001A 316 LI-IND 2001R 317 LI 18161-
BST excavator control system
8.70.1
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-
Slip ring rotary connection
8.80.1
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-
Directory of electric kits
8.100.1
A 312 LI 12363A 314 LI 2001A 316 LI 2001A 316 LI-IND 2001-
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
S16-S398 Switches, see Fig. 18
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
Component arrangement
Service Manual
A125 printed circuit board R75
Potentiometer speed see Fig. 17
S*
Switches for various kits
S1
Pre-heating and start switch
U16
Excavator control BST
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
Plug connection / 6-pin
P2
Potentiometer flow limitation (P2)
X838-1 Plug connection / 9-pin (service)
P3
Potentiometer flow limitation (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
Plug connection / 2-pin
X973
Power socket (12V)
X836 Plug connection / 4-pin
8.09.2
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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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8.09.3
Component arrangement
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
Solenoid valve / parking brake
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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8.09.5
Component arrangement
Service Manual
Sensors / transducers
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)
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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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8.09.7
Component arrangement
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
Component arrangement
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
Component arrangement Overview of control console
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
Component arrangement
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
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8.09.13
Component arrangement
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
Housing recess* 21-pin Housing recess* 21-pin
X12
Housing recess* 2-pin
X960
Housing recess* 21-pin
X27 X28
Housing recess* 2-pin Housing recess* 2-pin
X961 X962
Housing recess* 21-pin Housing recess* 21-pin
X29
Housing recess* 2-pin
X963
Housing recess* 21-pin
X952
Housing recess* 21-pin
X964
Housing recess* 21-pin
X953
Housing recess* 21-pin
X965
Housing recess* 21-pin
X954 X955
Housing recess* 21-pin Housing recess* 15-pin
X966 X967
Housing recess* 21-pin Housing recess* 21-pin
X956 X957
Housing recess* 21-pin Housing recess* 21-pin
X1106 Housing recess* 4-pin
*Recesses for plugs
8.09.14
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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
Solenoid valve / fast travel
Y50
Proportional solenoid valve / power control
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
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MJFCIFSS
8.09.15
Component arrangement
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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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
Component arrangement
Service Manual
Solenoid valves
8.09.18
copyright by
MJFCIFSS
A 309 LI 20221A 311 LI 20222-
Service Manual
Component arrangement Control elements
Component arrangement 1 Control elements 1.1
Overview of operator's platform
Fig. 1
Operator's platform seen from the operator
A126
Printed circuit board (autocheck)
S1
Pre-heating and start switch
B19L
Sensor transducer / left pilot control unit
S5
Push button / turn grapple
B19R
Sensor transducer / right pilot control S8-S218 Switches, see Fig. 25 unit
B40
Sensor transducer / travel
S18-S422 Switches, see Fig. 21
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
Switch / travel direction
P6-P50
Displays / clock see Fig. 21
S382
Switch fine adjustment ON / OFF
A 312 LI 12363A 314 LI 2001A 316 LI 2001A 316 LI-IND 2001-
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MJF C I F S S
8.10.1
Component arrangement
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
2 A125 printed circuit board
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
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A 312 LI 12363A 314 LI 2001A 316 LI 2001A 316 LI-IND 2001-
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
Plug connection / 8-pin
P1
Potentiometer flow limitation (P1)
X838
Plug connection / 6-pin
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
Plug connection / 4-pin
A 312 LI 12363A 314 LI 2001A 316 LI 2001A 316 LI-IND 2001-
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MJF C I F S S
Screw terminal / 3-pin
8.10.3
Component arrangement
Service Manual
E50 safety and power switch cabinet
3 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
Solenoid valve / travel forward
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
Solenoid valve / reverse travel
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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A 312 LI 12363A 314 LI 2001A 316 LI 2001A 316 LI-IND 2001-
Service Manual
Component arrangement Sensors / transducers
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
4 Sensors / transducers
Fig. 8
Fuel level sensor B1 (mounted on the fuel tank)
Fig. 9
Diesel engine, output side
B2
A 312 LI 12363A 314 LI 2001A 316 LI 2001A 316 LI-IND 2001-
Temperature sensor / engine coolant
M1
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Starter
8.10.5
Component arrangement
Service Manual
Sensors / transducers
Fig. 10
Coolant level sensor B3 (mounted on coolant / expansion tank)
Fig. 11
Diesel engine, output side
B7
Fig. 12 B8
8.10.6
Y12 Y29
Vacuum switch / air filter
Solenoid valve / excess fuel for starting Solenoid valve / engine shut-down
Hydraulic tank, bottom
Switch / hydraulic oil temperature (indica- B285 Transducer / hydraulic oil temperature tor light) (fan control)
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A 312 LI 12363A 314 LI 2001A 316 LI 2001A 316 LI-IND 2001-
Service Manual
Component arrangement Sensors / transducers
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
Solenoid valve / parking brake
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
Switch / engine oil pressure
Engine, seen from rear
B12 Transducer / engine speed
A 312 LI 12363A 314 LI 2001A 316 LI 2001A 316 LI-IND 2001-
Y55
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8.10.7
Component arrangement
Service Manual
Sensors / transducers
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
Boom cylinder with pressure switch, overload warning system B21 (kit)
Fig. 18
Water sensor B289 (located near fuel prefilter)
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A 312 LI 12363A 314 LI 2001A 316 LI 2001A 316 LI-IND 2001-
Service Manual
Component arrangement Fuses
5 Fuses
Fig. 19
Component arrangement on control console, front right
F304-F339 Fuses, (see Fig. 20 on page9)
Fig. 20
P5
Operating hour meter
Fuses in the control console, front right
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
Heating / air-conditioning system (kit - terminal 30) Heating / air-conditioning system (kit - terminal 15)
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
A 312 LI 12363A 314 LI 2001A 316 LI 2001A 316 LI-IND 2001-
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MJF C I F S S
8.10.9
Component arrangement
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)
6 Overview of control console
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
A 312 LI 12363A 314 LI 2001A 316 LI 2001A 316 LI-IND 2001-
Service Manual
Component arrangement Overview of control console
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
Quick change adapter*
A 312 LI 12363A 314 LI 2001A 316 LI 2001A 316 LI-IND 2001-
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MJF C I F S S
8.10.11
Component arrangement
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
Quick change adapter*
* 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.
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MJF C I F S S
A 312 LI 12363A 314 LI 2001A 316 LI 2001A 316 LI-IND 2001-
Service Manual
Component arrangement Overview of control console
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
A 312 LI 12363A 314 LI 2001A 316 LI 2001A 316 LI-IND 2001-
Beacon
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MJF C I F S S
8.10.13
Component arrangement
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
7 Battery and battery main switch
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
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A 312 LI 12363A 314 LI 2001A 316 LI 2001A 316 LI-IND 2001-
Service Manual
Component arrangement Generator / starter
8 Generator / starter
Fig. 28 G1
Diesel engine, radiator side Alternator
M1
Starter
9 Distribution board
Fig. 29
Distribution board with relays and buzzer, located at the control console, rear right
H27
Warning buzzer
K375
Relay / kit*
K63
Relay / indicator
K386
Relay / safety switch
A 312 LI 12363A 314 LI 2001A 316 LI 2001A 316 LI-IND 2001-
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MJF C I F S S
8.10.15
Component arrangement
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
Relay / terminal 15 servo
* Kit
Fig. 30
Plus after ignition / permanent plus Ground
# only in models A 312 to serial no. 27113
Distribution board with plug connection located at the control console, rear right
X10
Housing recess* 2-pin
X958
Housing recess* 21-pin
X11 X12
Housing recess* 2-pin Housing recess* 2-pin
X959 X960
Housing recess* 21-pin Housing recess* 21-pin
X27
Housing recess* 2-pin
X961
Housing recess* 21-pin
X28 X29
Housing recess* 2-pin Housing recess* 2-pin
X962 X963
Housing recess* 21-pin Housing recess* 21-pin
X952 X953
Housing recess* 21-pin Housing recess* 21-pin
X964 X965
Housing recess* 21-pin Housing recess* 21-pin
X954
Housing recess* 21-pin
X966
Housing recess* 21-pin
X955
Housing recess* 15-pin
X967
Housing recess* 21-pin
X956
Housing recess* 21-pin
X1106 Housing recess* 4-pin
X957
Housing recess* 21-pin
*Recesses for plugs
8.10.16
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MJF C I F S S
A 312 LI 12363A 314 LI 2001A 316 LI 2001A 316 LI-IND 2001-
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
A 312 LI 12363A 314 LI 2001A 316 LI 2001A 316 LI-IND 2001-
S389
Switch air cushioning
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MJF C I F S S
Switch / seat heating
8.10.17
Component arrangement
Service Manual
Solenoid valves
11
Solenoid valves
Fig. 33 Y3
Solenoid valve / pilot control pressure
Y24
Solenoid valve / creeper gear
Y50
Proportional solenoid valve / power control
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
A 312 LI 12363A 314 LI 2001A 316 LI 2001A 316 LI-IND 2001-
Service Manual
Component arrangement Solenoid valves
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.
A 312 LI 12363A 314 LI 2001A 316 LI 2001A 316 LI-IND 2001-
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MJF C I F S S
8.10.19
Component arrangement
Service Manual
Solenoid valves
8.10.20
Fig. 37
Proportional solenoid valve / fan control Y352 (located on the oil motor / fan)
Fig. 38
Proportional solenoid valve / motor speed adjustment Y358 (located on the hydraulic tank)
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A 312 LI 12363A 314 LI 2001A 316 LI 2001A 316 LI-IND 2001-
Service Manual
Component arrangement Control elements
Component arrangement 1 Control elements 1.1
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
Pre-heating and start switch
B40R
Sensor transducer / pilot control unit Travel right
S5
Push button / turn grapple
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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Switch fine adjustment ON / OFF Switches for various kits
8.17.1
Component arrangement
Service Manual
A125 printed circuit board H10
U16
Buzzer
Excavator control BST
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 K370-K386 Relay on distribution boardsiehe Fig. 20
Fig. 3
8.17.2
S7 C
Safety switch Heating
A125 printed circuit board potentiometer
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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
Plug connection / 2-pin
X839
Screw terminal / 3-pin
X835 X836
Plug connection / 2-pin Plug connection / 4-pin
X973
Power socket (12V)
Plug connection / 8-pin
3 E50 safety and power switch cabinet
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
Component arrangement
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
4 Sensors / transducers
Fig. 6
Fuel level sensor B1 (mounted on the fuel tank)
Fig. 7
Engine output side
B2
8.17.4
Temperature sensor / engine coolant
M1
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MJFCIFSS
Starter
R 313 LI 27752R 317 LI 18161-
Service Manual
Component arrangement Sensors / transducers
Fig. 8
Coolant level sensor B3 (mounted on coolant / expansion tank)
Fig. 9
Diesel engine, output side
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
Component arrangement
Service Manual
Sensors / transducers
Fig. 10 B8
Hydraulic tank, bottom
Switch / hydraulic oil temperature (indica- B285 Transducer / hydraulic oil temperature tor light) (fan control)
Fig. 11
Engine, seen from rear
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
Component arrangement Fuses
Fig. 12
Boom cylinder with pressure switch, overload warning system B21 (kit)
5 Fuses
Fig. 13
Fuses in the control console, front right
F304-F339Fuses siehe Fig. 14
Fig. 14
P5
Operating hour meter
Fuses in the control console, front right
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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8.17.7
Component arrangement
Service Manual
Fuses
8.17.8
F318
20 A
Heating / air-conditioning system (kit - terminal 30) Heating / air-conditioning system (kit - terminal 15)
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
Component arrangement Overview of control console
6 Overview of control console
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
Component arrangement
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
Quick change adapter*
* 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
Component arrangement Overview of control console
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
Component arrangement
Service Manual
Battery and battery main switch
7 Battery and battery main switch
Fig. 19 G2
Battery compartment in uppercarriage, front right S9
Batteries
Battery main switch
8 Distribution board
Fig. 20
Distribution board with relays and buzzer, located at the control console, rear right
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
Distribution board with plug connection located at the control console, rear right
X10
Housing recess* 2-pin
X957 Housing recess* 21-pin
X11
Housing recess* 2-pin
X958 Housing recess* 21-pin
X12 X27
Housing recess* 2-pin Housing recess* 2-pin
X959 Housing recess* 21-pin X960 Housing recess* 21-pin
X28 X29
Housing recess* 2-pin Housing recess* 2-pin
X961 Housing recess* 21-pin X962 Housing recess* 21-pin
X962 Housing recess* 21-pin X952 Housing recess* 21-pin
X963 Housing recess* 21-pin X964 Housing recess* 21-pin
X953 Housing recess* 21-pin
X965 Housing recess* 21-pin
X954 Housing recess* 21-pin X955 Housing recess* 15-pin
X966 Housing recess* 21-pin X967 Housing recess* 21-pin
X956 Housing recess* 21-pin *Recesses for plugs
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MJFCIFSS
8.17.13
Component arrangement
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
Solenoid valve / fast travel
copyright by
MJFCIFSS
Proportional solenoid valve / power control Proportional solenoid valve / flow limitation
R 313 LI 27752R 317 LI 18161-
Service Manual
Component arrangement Solenoid valves
Fig. 24 Y22
Additional control valve block AS1
Solenoid valve / grapple rotator
Y23
Solenoid valve / grapple rotator
Fig. 25
Proportional solenoid valve / fan control Y352 (located on the oil motor / fan)
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-
copyright by
MJFCIFSS
8.17.15
Component arrangement
Service Manual
Solenoid valves
8.17.16
copyright by
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
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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
A127, hydraulic tank
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
copyright by
MJFCIFSS
Cab roof, rear
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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
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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
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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
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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
Excavator control BST
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
Plug connection: fuse - distribution board / 21-pin
X964
Plug connection: fuse - distribution board / 21-pin
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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MJFCIFSS
8.20.9
Electrical system
Service Manual
1a Power supply, board A127
8.20.10
copyright by
MJFCIFSS
A 309 LI 20221A 311 LI 20222-
Service Manual
Electrical system
1b Power supply, board A127 / fuses
A 309 LI 20221A 311 LI 20222-
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MJFCIFSS
8.20.11
Electrical system
Service Manual
1c Power supply, board A 127 / relay
8.20.12
copyright by
MJFCIFSS
A 309 LI 20221A 311 LI 20222-
Service Manual
Electrical system
2 Pre-heating
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MJFCIFSS
8.20.13
Electrical system
Service Manual
3 Motor shut-down
8.20.14
copyright by
MJFCIFSS
A 309 LI 20221A 311 LI 20222-
Service Manual
Electrical system
4 Direction indicator system / horn
A 309 LI 20221A 311 LI 20222-
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MJFCIFSS
8.20.15
Electrical system
Service Manual
5 Work headlight
8.20.16
copyright by
MJFCIFSS
A 309 LI 20221A 311 LI 20222-
Service Manual
Electrical system
6 Lighting installation
A 309 LI 20221A 311 LI 20222-
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MJFCIFSS
8.20.17
Electrical system
Service Manual
7 Windscreen wiper / washer systems
8.20.18
copyright by
MJFCIFSS
A 309 LI 20221A 311 LI 20222-
Service Manual
Electrical system
8 Interior lights, radio
A 309 LI 20221A 311 LI 20222-
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MJFCIFSS
8.20.19
Electrical system
Service Manual
9 Brake light
8.20.20
copyright by
MJFCIFSS
A 309 LI 20221A 311 LI 20222-
Service Manual
Electrical system
10 Travel direction switch
A 309 LI 20221A 311 LI 20222-
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MJFCIFSS
8.20.21
Electrical system
Service Manual
11 Creeper gear first gear
8.20.22
copyright by
MJFCIFSS
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Service Manual
Electrical system
12 Optional 4-wheel steering
A 309 LI 20221A 311 LI 20222-
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MJFCIFSS
8.20.23
Electrical system
Service Manual
13 Parking brake
8.20.24
copyright by
MJFCIFSS
A 309 LI 20221A 311 LI 20222-
Service Manual
Electrical system
14 Safety switch
A 309 LI 20221A 311 LI 20222-
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MJFCIFSS
8.20.25
Electrical system
Service Manual
15 Servo
8.20.26
copyright by
MJFCIFSS
A 309 LI 20221A 311 LI 20222-
Service Manual
Electrical system
16 Power supply / socket
A 309 LI 20221A 311 LI 20222-
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MJFCIFSS
8.20.27
Electrical system
17 Fuel gauge
8.20.28
Service Manual
18 Clock
copyright by
MJFCIFSS
19 Hour meter
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Service Manual
Electrical system
20 Motor temperature
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MJFCIFSS
8.20.29
Electrical system
Service Manual
21a Indicator lights
8.20.30
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MJFCIFSS
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Service Manual
Electrical system
21b Autocheck / main warning buzzer / charge indicator
A 309 LI 20221A 311 LI 20222-
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MJFCIFSS
8.20.31
Electrical system
Service Manual
22 Speed adjustment
8.20.32
copyright by
MJFCIFSS
A 309 LI 20221A 311 LI 20222-
Service Manual
Electrical system
23 BST excavator-control power supply
A 309 LI 20221A 311 LI 20222-
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MJFCIFSS
8.20.33
Electrical system
Service Manual
25 Optional: AS I
8.20.34
copyright by
MJFCIFSS
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Service Manual
Electrical system
26 Regulating valves
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MJFCIFSS
8.20.35
Electrical system
Service Manual
27 Speed sensor
8.20.36
copyright by
MJFCIFSS
A 309 LI 20221A 311 LI 20222-
Service Manual
Electrical system
28 Sensor control
A 309 LI 20221A 311 LI 20222-
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MJFCIFSS
8.20.37
Electrical system
Service Manual
29 Fan control
8.20.38
copyright by
MJFCIFSS
A 309 LI 20221A 311 LI 20222-
Service Manual
Electrical system
30a Heating
A 309 LI 20221A 311 LI 20222-
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MJFCIFSS
8.20.39
Electrical system
Service Manual
30b Heating
8.20.40
copyright by
MJFCIFSS
A 309 LI 20221A 311 LI 20222-
Service Manual
Electrical system
30c Heating
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copyright by
MJFCIFSS
8.20.41
Electrical system
Service Manual
31 Electrical set adjustment - seat made by Isringhausen
8.20.42
copyright by
MJFCIFSS
A 309 LI 20221A 311 LI 20222-
Service Manual
Electrical system
32 Seat heating - seat made by Isringhausen
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copyright by
MJFCIFSS
8.20.43
Electrical system
Service Manual
33 Automatic oscillating axle locking device
8.20.44
copyright by
MJFCIFSS
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Service Manual
Electrical system
34 Optional AHS11 / AHS12
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copyright by
MJFCIFSS
8.20.45
Electrical system
Service Manual
35 Optional blade / individual control outrigger
8.20.46
copyright by
MJFCIFSS
A 309 LI 20221A 311 LI 20222-
Service Manual
Electrical system
36 Optional overload warning system
A 309 LI 20221A 311 LI 20222-
copyright by
MJFCIFSS
8.20.47
Electrical system
Service Manual
37 Optional beacon
8.20.48
copyright by
MJFCIFSS
A 309 LI 20221A 311 LI 20222-
Service Manual
Electrical system
38 Optional bucket quick-change adapter
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copyright by
MJFCIFSS
8.20.49
Electrical system
Service Manual
40 Swivel bearing
8.20.50
copyright by
MJFCIFSS
A 309 LI 20221A 311 LI 20222-
Service Manual
Electrical system
42 Ground
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copyright by
MJFCIFSS
8.20.51
Electrical system
Service Manual
43 Ground
8.20.52
copyright by
MJFCIFSS
A 309 LI 20221A 311 LI 20222-
Service Manual
Electrical system
44 Ground
A 309 LI 20221A 311 LI 20222-
copyright by
MJFCIFSS
8.20.53
Electrical system
Service Manual
45 Class 30 / class 15
8.20.54
copyright by
MJFCIFSS
A 309 LI 20221A 311 LI 20222-
Service Manual
Electrical system
Electrical system Item
Description
Step
Location / arrangement
A3 A125 A126
Radio (optional) Potentiometer board Printed circuit board (autocheck)
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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copyright by
MJFCIFSS
Electric cabinet at hydraulic tank Below operator's platform Distribution board
8.22.1
Electrical system
Service Manual
Item
Description
Step
Location / arrangement
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
_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 console A127, hydraulic tank
Fuse A127 K302, R60
50A
2
A127, hydraulic tank
Fuse A127 terminal 15, terminal 30, S44
7.5A
1b
A127, hydraulic tank
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
copyright by
MJFCIFSS
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
Location / arrangement
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
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15A 7.5A 15A 15A 7.5A 15A 15A 15A 5A 7.5A 15A 25A 20A 15A 10A 20A 7.5A 10A 2A 3A
copyright by
MJFCIFSS
8.22.3
Electrical system
Service Manual
Item
Description
Step
Location / arrangement
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
copyright by
MJFCIFSS
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Service Manual
Electrical system
Item
Description
Step
Location / arrangement
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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copyright by
MJFCIFSS
8.22.5
Electrical system
Service Manual
Item
Description
Step
Location / arrangement
T1
Voltage transformer / radio
8
Left console
U16
BST excavator control system
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
copyright by
MJFCIFSS
A 309 LI 29269A 311 LI 29270-
Service Manual
Electrical system
Item
Description
Step
Location / arrangement
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
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 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
Plug connection revolving deck BST excavator control / 21pin
X955
Plug connection revolving deck distribution board / 15-pin
X956
Plug connection BST excavator control distribution board / 21-pin
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
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
A 309 LI 29269A 311 LI 29270-
copyright by
MJFCIFSS
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
Location / arrangement
X962
Plug connection display distribution board / 21-pin
Right console
X963
Plug connection fuse distribution board / 21-pin
X964
Plug connection fuse distribution board / 21-pin
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
copyright by
MJFCIFSS
A 309 LI 29269A 311 LI 29270-
Service Manual
Electrical system
Item
Description
Step
Location / arrangement
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
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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
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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
4 Direction indicator system / horn
A 309 LI 29269A 311 LI 29270-
copyright by
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
6 Lighting installation
A 309 LI 29269A 311 LI 29270-
copyright by
MJFCIFSS
8.22.17
Electrical system
Service Manual
7 Windscreen wiper / washer systems
8.22.18
copyright by
MJFCIFSS
A 309 LI 29269A 311 LI 29270-
Service Manual
Electrical system
8 Interior lights, radio
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copyright by
MJFCIFSS
8.22.19
Electrical system
Service Manual
9 Brake light
8.22.20
copyright by
MJFCIFSS
A 309 LI 29269A 311 LI 29270-
Service Manual
Electrical system
10 Travel direction switch
A 309 LI 29269A 311 LI 29270-
copyright by
MJFCIFSS
8.22.21
Electrical system
Service Manual
11 Creeper gear first gear
8.22.22
copyright by
MJFCIFSS
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Service Manual
Electrical system
12 Optional 4-wheel steering
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copyright by
MJFCIFSS
8.22.23
Electrical system
Service Manual
13 Parking brake
8.22.24
copyright by
MJFCIFSS
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Service Manual
Electrical system
14 Safety switch
A 309 LI 29269A 311 LI 29270-
copyright by
MJFCIFSS
8.22.25
Electrical system
Service Manual
15 Servo
8.22.26
copyright by
MJFCIFSS
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Service Manual
Electrical system
16 Power supply / socket
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MJFCIFSS
8.22.27
Electrical system
17 Fuel gauge
8.22.28
Service Manual
18 Clock
copyright by
MJFCIFSS
19 Hour meter
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Service Manual
Electrical system
20 Motor temperature
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MJFCIFSS
8.22.29
Electrical system
Service Manual
21a Indicator lights
8.22.30
copyright by
MJFCIFSS
A 309 LI 29269A 311 LI 29270-
Service Manual
Electrical system
21b Autocheck / main warning buzzer / charge indicator
A 309 LI 29269A 311 LI 29270-
copyright by
MJFCIFSS
8.22.31
Electrical system
Service Manual
22 Speed adjustment
8.22.32
copyright by
MJFCIFSS
A 309 LI 29269A 311 LI 29270-
Service Manual
Electrical system
23 BST excavator-control power supply
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copyright by
MJFCIFSS
8.22.33
Electrical system
Service Manual
25 Optional AS I
8.22.34
copyright by
MJFCIFSS
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Service Manual
Electrical system
26 Regulating valves
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MJFCIFSS
8.22.35
Electrical system
Service Manual
27 Speed sensor
8.22.36
copyright by
MJFCIFSS
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Service Manual
Electrical system
28 Sensor control
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MJFCIFSS
8.22.37
Electrical system
Service Manual
29 Fan control
8.22.38
copyright by
MJFCIFSS
A 309 LI 29269A 311 LI 29270-
Service Manual
Electrical system
30a Heating
A 309 LI 29269A 311 LI 29270-
copyright by
MJFCIFSS
8.22.39
Electrical system
Service Manual
30b Heating
8.22.40
copyright by
MJFCIFSS
A 309 LI 29269A 311 LI 29270-
Service Manual
Electrical system
30c Heating
A 309 LI 29269A 311 LI 29270-
copyright by
MJFCIFSS
8.22.41
Electrical system
Service Manual
31 Electrical set adjustment / seat made by Isringhausen
8.22.42
copyright by
MJFCIFSS
A 309 LI 29269A 311 LI 29270-
Service Manual
Electrical system
32 Seat heating / seat made by Isringhausen
A 309 LI 29269A 311 LI 29270-
copyright by
MJFCIFSS
8.22.43
Electrical system
Service Manual
33 Automatic oscillating axle locking device
8.22.44
copyright by
MJFCIFSS
A 309 LI 29269A 311 LI 29270-
Service Manual
Electrical system
34 Optional AHS11 / AHS12
A 309 LI 29269A 311 LI 29270-
copyright by
MJFCIFSS
8.22.45
Electrical system
Service Manual
35 Optional blade / individual control outrigger
8.22.46
copyright by
MJFCIFSS
A 309 LI 29269A 311 LI 29270-
Service Manual
Electrical system
36 Optional overload warning system
A 309 LI 29269A 311 LI 29270-
copyright by
MJFCIFSS
8.22.47
Electrical system
Service Manual
37 Optional beacon
8.22.48
copyright by
MJFCIFSS
A 309 LI 29269A 311 LI 29270-
Service Manual
Electrical system
38 Optional bucket quick-change adapter
A 309 LI 29269A 311 LI 29270-
copyright by
MJFCIFSS
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
A 309 LI 29269A 311 LI 29270-
copyright by
MJFCIFSS
8.22.51
Electrical system
Service Manual
43 Ground
8.22.52
copyright by
MJFCIFSS
A 309 LI 29269A 311 LI 29270-
Service Manual
Electrical system
44 Ground
A 309 LI 29269A 311 LI 29270-
copyright by
MJFCIFSS
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
Electrical system Item
Description
Step
Location/arrangement
A3 A125 A126
Radio (optional) Potentiometer board Printed circuit board (autocheck)
Operator's cab, rear Left bracket Right bracket
A127
Printed circuit board / power
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
Pressure switch / overload
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
A 312 LI 12363A 314 LI 2001A 316 LI 2001A 316 LI-IND 2001-
copyright by
MJFCIFSS
Electric cabinet at hydraulic tank Distribution board
8.30.1
Electrical system
Service Manual
Item
Description
Step
Location/arrangement
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
_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
50A
2
A127, hydraulic tank
Fuse A127 terminal 15, terminal 30, S44
7.5A
1b
A127, hydraulic tank
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
A 312 LI 12363A 314 LI 2001A 316 LI 2001A 316 LI-IND 2001-
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
Location/arrangement
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
Alternator Batteries
1a 1a
Diesel engine Battery box
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
A 312 LI 12363A 314 LI 2001A 316 LI 2001A 316 LI-IND 2001-
15A 7.5A 15A 15A 7.5A 15A 15A 15A 5A 7.5A 15A 25A 20A 15A 10A 20A 7.5A
copyright by
MJFCIFSS
8.30.3
Electrical system
Service Manual
Item
Description
Step
Location/arrangement
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
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 7b 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
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
A 312 LI 12363A 314 LI 2001A 316 LI 2001A 316 LI-IND 2001-
Service Manual
Electrical system
Item
Description
Step
Location/arrangement
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
A 312 LI 12363A 314 LI 2001A 316 LI 2001A 316 LI-IND 2001-
copyright by
MJFCIFSS
8.30.5
Electrical system
Service Manual
Item
Description
Step
Location/arrangement
T1
Voltage transformer / radio
8
Left bracket
U16
BST excavator control system
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
A 312 LI 12363A 314 LI 2001A 316 LI 2001A 316 LI-IND 2001-
Service Manual
Electrical system
Item
Description
Step
Location/arrangement
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
Plug connection to BST excavator control / 24-pin
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
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 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
Plug connection BST excavator control distribution board / 21-pin
X957
Plug connection switch distribution board / 21-pin
X958
Plug connection switch distribution board / 21-pin
X959
Plug connection fuse distribution board / 21-pin
A 312 LI 12363A 314 LI 2001A 316 LI 2001A 316 LI-IND 2001-
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
Location/arrangement
X960
Plug connection operator's platform distribution board / 21pin
Right bracket
X961
Plug connection display distribution board / 21-pin
X962
Plug connection display distribution board / 21-pin
X963
Plug connection fuse distribution board / 21-pin
X964
Plug connection fuse distribution board / 21-pin
X965 X966
Plug connection BST excavator control distribution board / 21-pin Plug connection A 125 distribution board / 21-pin
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
A 312 LI 12363A 314 LI 2001A 316 LI 2001A 316 LI-IND 2001-
Service Manual
Electrical system
Item
Description
Step
Location/arrangement
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
A 312 LI 12363A 314 LI 2001A 316 LI 2001A 316 LI-IND 2001-
copyright by
MJFCIFSS
8.30.9
Electrical system
Service Manual
1a power supply, board A127
8.30.10
copyright by
MJFCIFSS
A 312 LI 12363A 314 LI 2001A 316 LI 2001A 316 LI-IND 2001-
Service Manual
Electrical system
1b power supply, board A127 / fuses
A 312 LI 12363A 314 LI 2001A 316 LI 2001A 316 LI-IND 2001-
copyright by
MJFCIFSS
8.30.11
Electrical system
Service Manual
1c power supply, board A 127 / relay
8.30.12
copyright by
MJFCIFSS
A 312 LI 12363A 314 LI 2001A 316 LI 2001A 316 LI-IND 2001-
Service Manual
Electrical system
2 Pre-heating
A 312 LI 12363A 314 LI 2001A 316 LI 2001A 316 LI-IND 2001-
copyright by
MJFCIFSS
8.30.13
Electrical system
Service Manual
3 Motor shut-down
8.30.14
copyright by
MJFCIFSS
A 312 LI 12363A 314 LI 2001A 316 LI 2001A 316 LI-IND 2001-
Service Manual
Electrical system
4 Direction indicator system / horn
A 312 LI 12363A 314 LI 2001A 316 LI 2001A 316 LI-IND 2001-
copyright by
MJFCIFSS
8.30.15
Electrical system
Service Manual
5 Work headlight
8.30.16
copyright by
MJFCIFSS
A 312 LI 12363A 314 LI 2001A 316 LI 2001A 316 LI-IND 2001-
Service Manual
Electrical system
6 Lighting installation
A 312 LI 12363A 314 LI 2001A 316 LI 2001A 316 LI-IND 2001-
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
A 312 LI 12363A 314 LI 2001A 316 LI 2001A 316 LI-IND 2001-
Service Manual
Electrical system
7b Windscreen wiper/washer systems A 312 from 12363/A 314/316 from 12736
A 312 LI 12363A 314 LI 2001A 316 LI 2001A 316 LI-IND 2001-
copyright by
MJFCIFSS
8.30.19
Electrical system
Service Manual
8 Interior lights, radio
8.30.20
copyright by
MJFCIFSS
A 312 LI 12363A 314 LI 2001A 316 LI 2001A 316 LI-IND 2001-
Service Manual
Electrical system
9 Brake light
A 312 LI 12363A 314 LI 2001A 316 LI 2001A 316 LI-IND 2001-
copyright by
MJFCIFSS
8.30.21
Electrical system
Service Manual
10 Travel direction switch
8.30.22
copyright by
MJFCIFSS
A 312 LI 12363A 314 LI 2001A 316 LI 2001A 316 LI-IND 2001-
Service Manual
Electrical system
11 Creeper speed
A 312 LI 12363A 314 LI 2001A 316 LI 2001A 316 LI-IND 2001-
copyright by
MJFCIFSS
8.30.23
Electrical system
12
8.30.24
Service Manual
1st gear
copyright by
MJFCIFSS
A 312 LI 12363A 314 LI 2001A 316 LI 2001A 316 LI-IND 2001-
Service Manual
Electrical system
13 Parking brake
A 312 LI 12363A 314 LI 2001A 316 LI 2001A 316 LI-IND 2001-
copyright by
MJFCIFSS
8.30.25
Electrical system
Service Manual
14 Safety switch
8.30.26
copyright by
MJFCIFSS
A 312 LI 12363A 314 LI 2001A 316 LI 2001A 316 LI-IND 2001-
Service Manual
Electrical system
15 Servo
A 312 LI 12363A 314 LI 2001A 316 LI 2001A 316 LI-IND 2001-
copyright by
MJFCIFSS
8.30.27
Electrical system
Service Manual
16 Power supply / socket
8.30.28
copyright by
MJFCIFSS
A 312 LI 12363A 314 LI 2001A 316 LI 2001A 316 LI-IND 2001-
Service Manual
Fuel gauge
A 312 LI 12363A 314 LI 2001A 316 LI 2001A 316 LI-IND 2001-
Electrical system
18 Clock
copyright by
MJFCIFSS
19 Hour meter
8.30.29
Electrical system
Service Manual
20 Motor temperature
8.30.30
copyright by
MJFCIFSS
A 312 LI 12363A 314 LI 2001A 316 LI 2001A 316 LI-IND 2001-
Service Manual
Electrical system
21a Indicator lights
A 312 LI 12363A 314 LI 2001A 316 LI 2001A 316 LI-IND 2001-
copyright by
MJFCIFSS
8.30.31
Electrical system
Service Manual
21b Autocheck / main warning buzzer / charge indicator
8.30.32
copyright by
MJFCIFSS
A 312 LI 12363A 314 LI 2001A 316 LI 2001A 316 LI-IND 2001-
Service Manual
Electrical system
22 Speed adjustment
A 312 LI 12363A 314 LI 2001A 316 LI 2001A 316 LI-IND 2001-
copyright by
MJFCIFSS
8.30.33
Electrical system
Service Manual
23 BST excavator-control power supply
8.30.34
copyright by
MJFCIFSS
A 312 LI 12363A 314 LI 2001A 316 LI 2001A 316 LI-IND 2001-
Service Manual
Electrical system
24 Fine control
A 312 LI 12363A 314 LI 2001A 316 LI 2001A 316 LI-IND 2001-
copyright by
MJFCIFSS
8.30.35
Electrical system
Service Manual
25 Optional AS I
8.30.36
copyright by
MJFCIFSS
A 312 LI 12363A 314 LI 2001A 316 LI 2001A 316 LI-IND 2001-
Service Manual
Electrical system
26 Regulating valves
A 312 LI 12363A 314 LI 2001A 316 LI 2001A 316 LI-IND 2001-
copyright by
MJFCIFSS
8.30.37
Electrical system
Service Manual
27 Speed sensor
8.30.38
copyright by
MJFCIFSS
A 312 LI 12363A 314 LI 2001A 316 LI 2001A 316 LI-IND 2001-
Service Manual
Electrical system
28 Sensor control
A 312 LI 12363A 314 LI 2001A 316 LI 2001A 316 LI-IND 2001-
copyright by
MJFCIFSS
8.30.39
Electrical system
Service Manual
29 Fan control
8.30.40
copyright by
MJFCIFSS
A 312 LI 12363A 314 LI 2001A 316 LI 2001A 316 LI-IND 2001-
Service Manual
Electrical system
30a Heating
A 312 LI 12363A 314 LI 2001A 316 LI 2001A 316 LI-IND 2001-
copyright by
MJFCIFSS
8.30.41
Electrical system
Service Manual
30b Heating
8.30.42
copyright by
MJFCIFSS
A 312 LI 12363A 314 LI 2001A 316 LI 2001A 316 LI-IND 2001-
Service Manual
Electrical system
30c Heating
A 312 LI 12363A 314 LI 2001A 316 LI 2001A 316 LI-IND 2001-
copyright by
MJFCIFSS
8.30.43
Electrical system
Service Manual
31 Electrical set adjustment / seat made by Isringhausen
8.30.44
copyright by
MJFCIFSS
A 312 LI 12363A 314 LI 2001A 316 LI 2001A 316 LI-IND 2001-
Service Manual
Electrical system
32 Seat heating / seat made by Isringhausen
A 312 LI 12363A 314 LI 2001A 316 LI 2001A 316 LI-IND 2001-
copyright by
MJFCIFSS
8.30.45
Electrical system
Service Manual
33 Automatic oscillating axle locking device
8.30.46
copyright by
MJFCIFSS
A 312 LI 12363A 314 LI 2001A 316 LI 2001A 316 LI-IND 2001-
Service Manual
Electrical system
34 Optional AHS11 / AHS12
A 312 LI 12363A 314 LI 2001A 316 LI 2001A 316 LI-IND 2001-
copyright by
MJFCIFSS
8.30.47
Electrical system
Service Manual
35 Optional blade / individual control outrigger
8.30.48
copyright by
MJFCIFSS
A 312 LI 12363A 314 LI 2001A 316 LI 2001A 316 LI-IND 2001-
Service Manual
Electrical system
36 Optional overload warning system
A 312 LI 12363A 314 LI 2001A 316 LI 2001A 316 LI-IND 2001-
copyright by
MJFCIFSS
8.30.49
Electrical system
Service Manual
37 Optional beacon
8.30.50
copyright by
MJFCIFSS
A 312 LI 12363A 314 LI 2001A 316 LI 2001A 316 LI-IND 2001-
Service Manual
Electrical system
38 Optional bucket quick-change adapter
A 312 LI 12363A 314 LI 2001A 316 LI 2001A 316 LI-IND 2001-
copyright by
MJFCIFSS
8.30.51
Electrical system
Service Manual
39 Optional industrial shut-down
8.30.52
copyright by
MJFCIFSS
A 312 LI 12363A 314 LI 2001A 316 LI 2001A 316 LI-IND 2001-
Service Manual
Electrical system
40 Reserve
A 312 LI 12363A 314 LI 2001A 316 LI 2001A 316 LI-IND 2001-
copyright by
MJFCIFSS
8.30.53
Electrical system
Service Manual
41 Optional magnet system
8.30.54
copyright by
MJFCIFSS
A 312 LI 12363A 314 LI 2001A 316 LI 2001A 316 LI-IND 2001-
Service Manual
Electrical system
42 Ground
A 312 LI 12363A 314 LI 2001A 316 LI 2001A 316 LI-IND 2001-
copyright by
MJFCIFSS
8.30.55
Electrical system
Service Manual
43 Ground
8.30.56
copyright by
MJFCIFSS
A 312 LI 12363A 314 LI 2001A 316 LI 2001A 316 LI-IND 2001-
Service Manual
Electrical system
44 Ground
A 312 LI 12363A 314 LI 2001A 316 LI 2001A 316 LI-IND 2001-
copyright by
MJFCIFSS
8.30.57
Electrical system
Service Manual
45 Terminal 30 / terminal 15
8.30.58
copyright by
MJFCIFSS
A 312 LI 12363A 314 LI 2001A 316 LI 2001A 316 LI-IND 2001-
Service Manual
Electrical system
Electrical system Item
Description
Step
Location/arrangement
A3 A125 A126
Radio (optional) Potentiometer board Printed circuit board (autocheck)
Operator's cab, rear Left bracket Right bracket
A127
Printed circuit board / power
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
Pressure switch / overload
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
A 312 LI 20330A 314 LI 20334A 316 LI 20340A 316 LI-IND 20340-
copyright by
MJFCIFSS
Electric cabinet at hydraulic tank Distribution board
8.32.1
Electrical system
Service Manual
Item
Description
Step
Location/arrangement
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
Rear roof light, rear, with plug
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
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
_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
50A
2
A127, hydraulic tank
Fuse A127 terminal 15, terminal 30, S44
7.5A
1b
A127, hydraulic tank
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
copyright by
MJFCIFSS
Rear cab roof
A 312 LI 20330A 314 LI 20334A 316 LI 20340A 316 LI-IND 20340-
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
Location/arrangement
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
Alternator Batteries
1a 1a
Diesel engine Battery box
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
A 312 LI 20330A 314 LI 20334A 316 LI 20340A 316 LI-IND 20340-
15A 15A 15A 7.5A 15A 15A 7.5A 15A 15A 15A 5A 7.5A 15A 25A 20A 15A 10A 20A 7.5A
copyright by
MJFCIFSS
8.32.3
Electrical system
Service Manual
Item
Description
Step
Location/arrangement
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
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
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
copyright by
MJFCIFSS
A 312 LI 20330A 314 LI 20334A 316 LI 20340A 316 LI-IND 20340-
Service Manual
Electrical system
Item
Description
Step
Location/arrangement
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
A 312 LI 20330A 314 LI 20334A 316 LI 20340A 316 LI-IND 20340-
copyright by
MJFCIFSS
8.32.5
Electrical system
Service Manual
Item
Description
Step
Location/arrangement
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
Voltage transformer / radio
8
Left bracket
U16
BST excavator control system
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
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 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
A 312 LI 20330A 314 LI 20334A 316 LI 20340A 316 LI-IND 20340-
Service Manual
Electrical system
Item
Description
Step
Location/arrangement
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
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 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
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
Plug connection BST excavator control distribution board / 21-pin
X957
Plug connection switch distribution board / 21-pin
X958
Plug connection switch distribution board / 21-pin
X959
Plug connection fuse distribution board / 21-pin
A 312 LI 20330A 314 LI 20334A 316 LI 20340A 316 LI-IND 20340-
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 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
Location/arrangement
X960
Plug connection operator's platform distribution board / 21pin
Right bracket
X961
Plug connection display distribution board / 21-pin
X962
Plug connection display distribution board / 21-pin
X963
Plug connection fuse distribution board / 21-pin
X964
Plug connection fuse distribution board / 21-pin
X965 X966
Plug connection BST excavator control distribution board / 21-pin Plug connection A 125 distribution board / 21-pin
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
Plug connection display distribution board / 21-pin
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
Right bracket Right bracket
A 312 LI 20330A 314 LI 20334A 316 LI 20340A 316 LI-IND 20340-
Service Manual
Electrical system
Item
Description
Step
Location/arrangement
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
A 312 LI 20330A 314 LI 20334A 316 LI 20340A 316 LI-IND 20340-
copyright by
MJFCIFSS
8.32.9
Electrical system
Service Manual
1a power supply, board A127
8.32.10
copyright by
MJFCIFSS
A 312 LI 20330A 314 LI 20334A 316 LI 20340A 316 LI-IND 20340-
Service Manual
Electrical system
1b power supply, board A127 / fuses
A 312 LI 20330A 314 LI 20334A 316 LI 20340A 316 LI-IND 20340-
copyright by
MJFCIFSS
8.32.11
Electrical system
Service Manual
1c power supply, board A 127 / relay
8.32.12
copyright by
MJFCIFSS
A 312 LI 20330A 314 LI 20334A 316 LI 20340A 316 LI-IND 20340-
Service Manual
Electrical system
2 Pre-heating
A 312 LI 20330A 314 LI 20334A 316 LI 20340A 316 LI-IND 20340-
copyright by
MJFCIFSS
8.32.13
Electrical system
Service Manual
3 Motor shut-down
8.32.14
copyright by
MJFCIFSS
A 312 LI 20330A 314 LI 20334A 316 LI 20340A 316 LI-IND 20340-
Service Manual
Electrical system
4 Direction indicator system / horn
A 312 LI 20330A 314 LI 20334A 316 LI 20340A 316 LI-IND 20340-
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
A 312 LI 20330A 314 LI 20334A 316 LI 20340A 316 LI-IND 20340-
Service Manual
Electrical system
6 Lighting installation
A 312 LI 20330A 314 LI 20334A 316 LI 20340A 316 LI-IND 20340-
copyright by
MJFCIFSS
8.32.17
Electrical system
Service Manual
7 Windscreen wiper / washer systems
8.32.18
copyright by
MJFCIFSS
A 312 LI 20330A 314 LI 20334A 316 LI 20340A 316 LI-IND 20340-
Service Manual
Electrical system
8 Interior lights, radio
A 312 LI 20330A 314 LI 20334A 316 LI 20340A 316 LI-IND 20340-
copyright by
MJFCIFSS
8.32.19
Electrical system
Service Manual
9 Brake light
8.32.20
copyright by
MJFCIFSS
A 312 LI 20330A 314 LI 20334A 316 LI 20340A 316 LI-IND 20340-
Service Manual
Electrical system
10 Travel direction switch
A 312 LI 20330A 314 LI 20334A 316 LI 20340A 316 LI-IND 20340-
copyright by
MJFCIFSS
8.32.21
Electrical system
Service Manual
11 Creeper speed
8.32.22
copyright by
MJFCIFSS
A 312 LI 20330A 314 LI 20334A 316 LI 20340A 316 LI-IND 20340-
Service Manual
12
A 312 LI 20330A 314 LI 20334A 316 LI 20340A 316 LI-IND 20340-
Electrical system
1st gear
copyright by
MJFCIFSS
8.32.23
Electrical system
Service Manual
13 Parking brake
8.32.24
copyright by
MJFCIFSS
A 312 LI 20330A 314 LI 20334A 316 LI 20340A 316 LI-IND 20340-
Service Manual
Electrical system
14 Safety switch
A 312 LI 20330A 314 LI 20334A 316 LI 20340A 316 LI-IND 20340-
copyright by
MJFCIFSS
8.32.25
Electrical system
Service Manual
15 Servo
8.32.26
copyright by
MJFCIFSS
A 312 LI 20330A 314 LI 20334A 316 LI 20340A 316 LI-IND 20340-
Service Manual
Electrical system
16 Power supply / socket
A 312 LI 20330A 314 LI 20334A 316 LI 20340A 316 LI-IND 20340-
copyright by
MJFCIFSS
8.32.27
Electrical system
17 Fuel gauge
8.32.28
Service Manual
18 Clock
copyright by
MJFCIFSS
19 Hour meter
A 312 LI 20330A 314 LI 20334A 316 LI 20340A 316 LI-IND 20340-
Service Manual
Electrical system
20 Motor temperature
A 312 LI 20330A 314 LI 20334A 316 LI 20340A 316 LI-IND 20340-
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
A 312 LI 20330A 314 LI 20334A 316 LI 20340A 316 LI-IND 20340-
Service Manual
Electrical system
21b Autocheck / main warning buzzer / charge indicator
A 312 LI 20330A 314 LI 20334A 316 LI 20340A 316 LI-IND 20340-
copyright by
MJFCIFSS
8.32.31
Electrical system
Service Manual
22 Speed adjustment
8.32.32
copyright by
MJFCIFSS
A 312 LI 20330A 314 LI 20334A 316 LI 20340A 316 LI-IND 20340-
Service Manual
Electrical system
23 BST excavator-control power supply
A 312 LI 20330A 314 LI 20334A 316 LI 20340A 316 LI-IND 20340-
copyright by
MJFCIFSS
8.32.33
Electrical system
Service Manual
24 Fine control
8.32.34
copyright by
MJFCIFSS
A 312 LI 20330A 314 LI 20334A 316 LI 20340A 316 LI-IND 20340-
Service Manual
Electrical system
25 Optional AS I
A 312 LI 20330A 314 LI 20334A 316 LI 20340A 316 LI-IND 20340-
copyright by
MJFCIFSS
8.32.35
Electrical system
Service Manual
26 Regulating valves
8.32.36
copyright by
MJFCIFSS
A 312 LI 20330A 314 LI 20334A 316 LI 20340A 316 LI-IND 20340-
Service Manual
Electrical system
27 Speed sensor
A 312 LI 20330A 314 LI 20334A 316 LI 20340A 316 LI-IND 20340-
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
A 312 LI 20330A 314 LI 20334A 316 LI 20340A 316 LI-IND 20340-
Service Manual
Electrical system
29 Fan control
A 312 LI 20330A 314 LI 20334A 316 LI 20340A 316 LI-IND 20340-
copyright by
MJFCIFSS
8.32.39
Electrical system
Service Manual
30a Heating
8.32.40
copyright by
MJFCIFSS
A 312 LI 20330A 314 LI 20334A 316 LI 20340A 316 LI-IND 20340-
Service Manual
Electrical system
30b Heating
A 312 LI 20330A 314 LI 20334A 316 LI 20340A 316 LI-IND 20340-
copyright by
MJFCIFSS
8.32.41
Electrical system
Service Manual
30c Heating
8.32.42
copyright by
MJFCIFSS
A 312 LI 20330A 314 LI 20334A 316 LI 20340A 316 LI-IND 20340-
Service Manual
Electrical system
31 Electrical set adjustment / seat made by Isringhausen
A 312 LI 20330A 314 LI 20334A 316 LI 20340A 316 LI-IND 20340-
copyright by
MJFCIFSS
8.32.43
Electrical system
Service Manual
32 Seat heating / seat made by Isringhausen
8.32.44
copyright by
MJFCIFSS
A 312 LI 20330A 314 LI 20334A 316 LI 20340A 316 LI-IND 20340-
Service Manual
Electrical system
33 Automatic oscillating axle locking device
A 312 LI 20330A 314 LI 20334A 316 LI 20340A 316 LI-IND 20340-
copyright by
MJFCIFSS
8.32.45
Electrical system
Service Manual
34 Optional AHS11 / AHS12
8.32.46
copyright by
MJFCIFSS
A 312 LI 20330A 314 LI 20334A 316 LI 20340A 316 LI-IND 20340-
Service Manual
Electrical system
35 Optional blade / individual control outrigger
A 312 LI 20330A 314 LI 20334A 316 LI 20340A 316 LI-IND 20340-
copyright by
MJFCIFSS
8.32.47
Electrical system
Service Manual
36 Optional overload warning system
8.32.48
copyright by
MJFCIFSS
A 312 LI 20330A 314 LI 20334A 316 LI 20340A 316 LI-IND 20340-
Service Manual
Electrical system
37 Optional beacon
A 312 LI 20330A 314 LI 20334A 316 LI 20340A 316 LI-IND 20340-
copyright by
MJFCIFSS
8.32.49
Electrical system
Service Manual
38 Optional bucket quick-change adapter
8.32.50
copyright by
MJFCIFSS
A 312 LI 20330A 314 LI 20334A 316 LI 20340A 316 LI-IND 20340-
Service Manual
Electrical system
39 Optional industrial shut-down
A 312 LI 20330A 314 LI 20334A 316 LI 20340A 316 LI-IND 20340-
copyright by
MJFCIFSS
8.32.51
Electrical system
Service Manual
40 Reserve
8.32.52
copyright by
MJFCIFSS
A 312 LI 20330A 314 LI 20334A 316 LI 20340A 316 LI-IND 20340-
Service Manual
Electrical system
41 Optional magnet system
A 312 LI 20330A 314 LI 20334A 316 LI 20340A 316 LI-IND 20340-
copyright by
MJFCIFSS
8.32.53
Electrical system
Service Manual
42 Ground
8.32.54
copyright by
MJFCIFSS
A 312 LI 20330A 314 LI 20334A 316 LI 20340A 316 LI-IND 20340-
Service Manual
Electrical system
43 Ground
A 312 LI 20330A 314 LI 20334A 316 LI 20340A 316 LI-IND 20340-
copyright by
MJFCIFSS
8.32.55
Electrical system
Service Manual
44 Ground
8.32.56
copyright by
MJFCIFSS
A 312 LI 20330A 314 LI 20334A 316 LI 20340A 316 LI-IND 20340-
Service Manual
Electrical system
45 Terminal 30 / terminal 15
A 312 LI 20330A 314 LI 20334A 316 LI 20340A 316 LI-IND 20340-
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
A 312 LI 20330A 314 LI 20334A 316 LI 20340A 316 LI-IND 20340-
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)
A 312 LI 20330A 314 LI 20334A 316 LI 20340A 316 LI-IND 20340-
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
A 312 LI 20330A 314 LI 20334A 316 LI 20340A 316 LI-IND 20340-
Service Manual
Electrical system
Electrical system Item
Description
Step
Location/arrangement
A3 A 125 A 126
Radio (optional) Potentiometer board Printed circuit board (autocheck)
Operator's cab, back Left bracket Right bracket
A 127
Printed circuit board / power
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
Rear roof light, rear, with plug
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
R 317 LI 18161copyright by
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
Location/arrangement
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
A127, hydraulic tank
Fuse A127 terminal 15, terminal 30, B3, S44
7.5A
1b
A127, hydraulic tank
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
R 317 LI 18161copyright by
MJFCIFSS
Service Manual
Electrical system
Item
Description
Step
Location/arrangement
G1 G2
Alternator Batteries
1a 1a
Diesel engine Battery box
H7 H9 H10 H11 H12 H13 H15 H16 H18 H26 H27 H175 H196 H301 H307
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
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 Operators platform Operator's platform, rear Operator's platform, rear Operator's platform, rear
R 317 LI 18161copyright by
MJFCIFSS
8.40.3
Electrical system
Service Manual
Item
Description
Step
Location/arrangement
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 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
R 317 LI 18161copyright by
MJFCIFSS
Service Manual
Electrical system
Item
Description
Step
Location/arrangement
S422
Switch / mute switch for radio
8
Right bracket
T1
Voltage transformer / radio
8
Right bracket
U16
BST excavator control system
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
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 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
R 317 LI 18161copyright by
MJFCIFSS
8.40.5
Electrical system
Service Manual
Item
Description
Step
Location/arrangement
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
Plug connection to BST excavator control / 24-pin
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
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 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
Plug connection BST excavator control distribution board / 21-pin
X957
Plug connection switch distribution board / 21-pin
X958
Plug connection switch distribution board / 21-pin
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
R 317 LI 18161copyright by
MJFCIFSS
Service Manual
Electrical system
Item
Description
Step
Location/arrangement
X962
Plug connection display distribution board / 21-pin
Right bracket
X963
Plug connection fuse distribution board / 21-pin
X964
Plug connection fuse distribution board / 21-pin
X965 X966
Plug connection BST excavator control distribution board / 21-pin Plug connection A 125 distribution board / 21-pin
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
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 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
R 317 LI 18161copyright by
MJFCIFSS
Right bracket
8.40.7
Electrical system
Service Manual
Item
Description
Step
Location/arrangement
Y358
Proportional solenoid valve / motor speed with plug
22
Control valve block panel
8.40.8
R 317 LI 18161copyright by
MJFCIFSS
Service Manual
Electrical system
1a power supply, board A127
R 317 LI 18161copyright by
MJFCIFSS
8.40.9
Electrical system
Service Manual
1b power supply, board A127 / fuses
8.40.10
R 317 LI 18161copyright by
MJFCIFSS
Service Manual
Electrical system
1c power supply, board A 127 / relay
R 317 LI 18161copyright by
MJFCIFSS
8.40.11
Electrical system
Service Manual
2 Pre-heating
8.40.12
R 317 LI 18161copyright by
MJFCIFSS
Service Manual
Electrical system
3 Motor shut-down
R 317 LI 18161copyright by
MJFCIFSS
8.40.13
Electrical system
Service Manual
4 Direction indicator system / horn
8.40.14
R 317 LI 18161copyright by
MJFCIFSS
Service Manual
Electrical system
5 Work headlight
R 317 LI 18161copyright by
MJFCIFSS
8.40.15
Electrical system
Service Manual
6 Lighting installation
8.40.16
R 317 LI 18161copyright by
MJFCIFSS
Service Manual
Electrical system
7 Windscreen wiper / washer systems
R 317 LI 18161copyright by
MJFCIFSS
8.40.17
Electrical system
Service Manual
8 Interior lights, radio
8.40.18
R 317 LI 18161copyright by
MJFCIFSS
Service Manual
Electrical system
9 Brake light
R 317 LI 18161copyright by
MJFCIFSS
8.40.19
Electrical system
Service Manual
10 Travel direction switch
8.40.20
R 317 LI 18161copyright by
MJFCIFSS
Service Manual
Electrical system
11 Rapid gear
R 317 LI 18161copyright by
MJFCIFSS
8.40.21
Electrical system
Service Manual
12 1st gear
8.40.22
R 317 LI 18161copyright by
MJFCIFSS
Service Manual
Electrical system
13 Parking brake
R 317 LI 18161copyright by
MJFCIFSS
8.40.23
Electrical system
Service Manual
14 Safety switch
8.40.24
R 317 LI 18161copyright by
MJFCIFSS
Service Manual
Electrical system
15 Servo swing gear brake
R 317 LI 18161copyright by
MJFCIFSS
8.40.25
Electrical system
Service Manual
16 Power supply / socket
8.40.26
R 317 LI 18161copyright by
MJFCIFSS
Service Manual
17 Fuel gauge
Electrical system
18 Clock
R 317 LI 18161copyright by
MJFCIFSS
19 Hour meter
8.40.27
Electrical system
Service Manual
20 Motor temperature
8.40.28
R 317 LI 18161copyright by
MJFCIFSS
Service Manual
Electrical system
21a Indicator lights
R 317 LI 18161copyright by
MJFCIFSS
8.40.29
Electrical system
Service Manual
21b Autocheck / main warning buzzer / charge indicator
8.40.30
R 317 LI 18161copyright by
MJFCIFSS
Service Manual
Electrical system
22 Speed adjustment
R 317 LI 18161copyright by
MJFCIFSS
8.40.31
Electrical system
Service Manual
23 Excavator-control power supply
8.40.32
R 317 LI 18161copyright by
MJFCIFSS
Service Manual
Electrical system
24 Excavator-control power supply
R 317 LI 18161copyright by
MJFCIFSS
8.40.33
Electrical system
Service Manual
25 Optional AS I
8.40.34
R 317 LI 18161copyright by
MJFCIFSS
Service Manual
Electrical system
26 Regulating valves
R 317 LI 18161copyright by
MJFCIFSS
8.40.35
Electrical system
Service Manual
27 Speed sensor
8.40.36
R 317 LI 18161copyright by
MJFCIFSS
Service Manual
Electrical system
28 Sensor control up to serial number 21204
R 317 LI 18161copyright by
MJFCIFSS
8.40.37
Electrical system
Service Manual
28 Sensor control from serial number 21205
8.40.38
R 317 LI 18161copyright by
MJFCIFSS
Service Manual
Electrical system
29 Fan control
R 317 LI 18161copyright by
MJFCIFSS
8.40.39
Electrical system
Service Manual
30a Heating
8.40.40
R 317 LI 18161copyright by
MJFCIFSS
Service Manual
Electrical system
30b Heating
R 317 LI 18161copyright by
MJFCIFSS
8.40.41
Electrical system
Service Manual
30c Heating
8.40.42
R 317 LI 18161copyright by
MJFCIFSS
Service Manual
Electrical system
31 Electrical set adjustment / seat made by Isringhausen
R 317 LI 18161copyright by
MJFCIFSS
8.40.43
Electrical system
Service Manual
32 Seat heating / seat made by Isringhausen
8.40.44
R 317 LI 18161copyright by
MJFCIFSS
Service Manual
Electrical system
33 Automatic oscillating axle locking device
R 317 LI 18161copyright by
MJFCIFSS
8.40.45
Electrical system
Service Manual
34 Optional AHS11 / AHS12
8.40.46
R 317 LI 18161copyright by
MJFCIFSS
Service Manual
Electrical system
35 Optional blade / individual control outrigger
R 317 LI 18161copyright by
MJFCIFSS
8.40.47
Electrical system
Service Manual
36 Optional overload warning system
8.40.48
R 317 LI 18161copyright by
MJFCIFSS
Service Manual
Electrical system
37 Optional beacon
R 317 LI 18161copyright by
MJFCIFSS
8.40.49
Electrical system
Service Manual
38 Optional bucket quick-change adapter
8.40.50
R 317 LI 18161copyright by
MJFCIFSS
Service Manual
Electrical system
39 Optional industrial shut-down
R 317 LI 18161copyright by
MJFCIFSS
8.40.51
Electrical system
Service Manual
40 Reserve
8.40.52
R 317 LI 18161copyright by
MJFCIFSS
Service Manual
Electrical system
41 Optional magnet system
R 317 LI 18161copyright by
MJFCIFSS
8.40.53
Electrical system
Service Manual
42 Ground
8.40.54
R 317 LI 18161copyright by
MJFCIFSS
Service Manual
Electrical system
43 Ground
R 317 LI 18161copyright by
MJFCIFSS
8.40.55
Electrical system
Service Manual
44 Ground
8.40.56
R 317 LI 18161copyright by
MJFCIFSS
Service Manual
Electrical system
45 Terminal 30 / terminal 15
R 317 LI 18161copyright by
MJFCIFSS
8.40.57
Electrical system
8.40.58
Service Manual
R 317 LI 18161copyright by
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
A 309 LI - R 317 LI copyright by
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
A 309 LI - R 317 LI copyright by
MJF C I F S S
Service Manual
Electric kits Key to accessory kit diagrams
2 Key to accessory kit diagrams Item
Description
Step
Location/arrangement
A3 A123 A125
Radio Printed circuit board PCB potentiometers
Left console Left console Left console
A126
PCB / autocheck
A127
Printed circuit board / power
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
A 309 LI - R 317 LI copyright by
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
Location/arrangement
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
Electric kits Key to accessory kit diagrams
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
H33 H90 H158 H159 H167 H168 H176 H183 H196 H249 H293 H293 H298 H299 H311
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
Location/arrangement
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
A 309 LI - R 317 LI copyright by
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
Electric kits Key to accessory kit diagrams
Item
Description
Step
Location/arrangement
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
A 309 LI - R 317 LI copyright by
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
Key to accessory kit diagrams Item
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
A 309 LI - R 317 LI copyright by
MJF C I F S S
Service Manual
Electric kits Key to accessory kit diagrams
Item S382 S384 S398 S405 S406 S419 S423 S424 S439L S439R S442 S443L S443R S451 S452 S457 S464
Description
Step
Switch / fine regulation OFF
Location/arrangement
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
A 309 LI - R 317 LI copyright by
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
Key to accessory kit diagrams Item
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
Right console Right console Right console
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
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Service Manual
Electric kits Key to accessory kit diagrams
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
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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
Location/arrangement
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
Plug connection distribution board / 21-pin
X954 X955
Plug connection distribution board / 21-pin Plug connection distribution board / 15-pin
X956
Plug connection distribution board / 21-pin
X957
Plug connection distribution board / 21-pin
X958
Plug connection distribution board / 21-pin
X959
Plug connection distribution board / 21-pin
X960
Plug connection distribution board / 21-pin
X961
Plug connection distribution board / 21-pin
X962
Plug connection distribution board / 21-pin
X963
Plug connection distribution board / 21-pin
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
Right console, rear Right console, rear Right console, rear Right console, rear Right console, rear
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Service Manual
Electric kits Key to accessory kit diagrams
Item
Description
Step
Location/arrangement
X964
Plug connection distribution board / 21-pin
Right console, rear
X965 X966
Plug connection BST- CS A125 / 21-pin Plug connection A125 wire harness / 21-pin
X967
Plug connection distribution board / 21-pin
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
A 309 LI - R 317 LI copyright by
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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
Key to accessory kit diagrams Item
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
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Service Manual
Electric kits Key to accessory kit diagrams
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
Location/arrangement
Solenoid valve / grapple rotator
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
A 309 LI - R 317 LI copyright by
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
Key to accessory kit diagrams Item
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
Near control valve block
84,110 115 106
Near control valve block Near control valve block Near control valve block
106
Near control valve block
106 118
Near control valve block Near control valve block
Cable colours
Item
Tab. 2
Location/arrangement 90 91 92
Terminal designation
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Service Manual
Electric kits Key to accessory kit diagrams
A 309 LI - R 317 LI copyright by
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8.45.17
Electric kits
Service Manual
Key to accessory kit diagrams Step 50 Item
Designation
Location / arrangement
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
A 309 LI - R 317 LI copyright by
MJF C I F S S
Service Manual
Electric kits Key to accessory kit diagrams
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
A 309 LI - R 317 LI copyright by
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
A 309 LI - R 317 LI copyright by
MJF C I F S S
Service Manual
Electric kits Key to accessory kit diagrams
51
A 312 Litronic / 314 Litronic / A 316 Litronic AHS11 AHS11 AHS11
A 309 LI - R 317 LI copyright by
MJF C I F S S
8.45.21
Electric kits
Service Manual
Key to accessory kit diagrams Step 51 Location / arrangement
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
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
15.0 A 15.0 A
** in basic machine
8.45.22
A 309 LI - R 317 LI copyright by
MJF C I F S S
Service Manual
Electric kits Key to accessory kit diagrams
51
A 312 Litronic / 314 Litronic / A 316 Litronic AHS12 AHS12 AHS12
A 309 LI - R 317 LI copyright by
MJF C I F S S
8.45.23
Electric kits
Service Manual
Key to accessory kit diagrams Step 51 Location / arrangement
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
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
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
A 309 LI - R 317 LI copyright by
MJF C I F S S
Service Manual
Electric kits Key to accessory kit diagrams
51
A 312 Litronic / 314 Litronic / A 316 Litronic AHS12 & PRIO AHS12 & PRIO AHS12 & PRIO
A 309 LI - R 317 LI copyright by
MJF C I F S S
8.45.25
Electric kits
Service Manual
Key to accessory kit diagrams Step 52/1 Item
Designation
Location / arrangement
A 127**
Printed circuit board / power
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
A 309 LI - R 317 LI copyright by
MJF C I F S S
Service Manual
Electric kits Key to accessory kit diagrams
52/1
A 309 Litronic - R 317 Litronic BETANKUNGSPUMPE REFUELLING PUMP PUMPE DE REMPL.
A 309 LI - R 317 LI copyright by
MJF C I F S S
8.45.27
Electric kits
Service Manual
Key to accessory kit diagrams Step 52/2 Item
Designation
Location / arrangement
A 127**
Printed circuit board / power
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
A 309 LI - R 317 LI copyright by
MJF C I F S S
Service Manual
Electric kits Key to accessory kit diagrams
52/2
A 309 Litronic - R 317 Litronic BETANKUNGSPUMPE REFUELLING PUMP PUMPE DE REMPL.
A 309 LI - R 317 LI copyright by
MJF C I F S S
8.45.29
Electric kits
Service Manual
Key to accessory kit diagrams Step 53 Location / arrangement
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
A 309 LI - R 317 LI copyright by
MJF C I F S S
Service Manual
Electric kits Key to accessory kit diagrams
53
A 316 Litronic (IND) HYDRAULISCHE FAHRERHAUSERHÖHUNG HYDRAULIC CAB ELEVATION HYDR.P.CONTRE POIDS DEMONTABLE
A 309 LI - R 317 LI copyright by
MJF C I F S S
8.45.31
Electric kits
Service Manual
Key to accessory kit diagrams Step 54 Location / arrangement
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
A 309 LI - R 317 LI copyright by
MJF C I F S S
Service Manual
Electric kits Key to accessory kit diagrams
54
A 312 Litronic / A 314 Litronic / A 316 Litronic / A 316 (IND) ÜBERLASTWARNEINRICHTUNG OVERLOAD WARNING SYSTEM AVERITISSEUR DE SUCHARGE
A 309 LI - R 317 LI copyright by
MJF C I F S S
8.45.33
Electric kits
Service Manual
Key to accessory kit diagrams Step 55/1 Item
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**
Location / arrangement
15.0 A
Fuse box in control console, front right
** in basic diagram
8.45.34
A 309 LI - R 317 LI copyright by
MJF C I F S S
Service Manual
Electric kits Key to accessory kit diagrams
55/1
A 316 Litronic (IND) STEUERUNG MAGNETANLAGE MAGNET SYSTEM CONTROL CONTROLE DE MONTAGE PLATEAU MAGNETIQUE
A 309 LI - R 317 LI copyright by
MJF C I F S S
8.45.35
Electric kits
Service Manual
Key to accessory kit diagrams Step 55/2 Item
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**
Location / arrangement
15.0 A
Fuse box in control console, front right
** in basic diagram
8.45.36
A 309 LI - R 317 LI copyright by
MJF C I F S S
Service Manual
Electric kits Key to accessory kit diagrams
55/2
A 316 Litronic (IND) STEUERUNG MAGNETANLAGE MAGNET SYSTEM CONTROL CONTROLE DE MONTAGE PLATEAU MAGNETIQUE
A 309 LI - R 317 LI copyright by
MJF C I F S S
8.45.37
Electric kits
Service Manual
Key to accessory kit diagrams Step 55/3 Item
Designation
A 126**
Autocheck PCB
F337**
Fuse
S6L S46
Button / magnet system Switch / magnet system
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
Solenoid valve / magnet unit
X74-1 X217 X370 X856** X950** X951** X956** X958** X962**
Location / arrangement
15.0 A
Fuse box in control console, front right
** in basic diagram
8.45.38
A 309 LI - R 317 LI copyright by
MJF C I F S S
Service Manual
Electric kits Key to accessory kit diagrams
55/3
A 316 Litronic (IND) STEUERUNG MAGNETANLAGE MAGNET SYSTEM CONTROL CONTROLE DE MONTAGE PLATEAU MAGNETIQUE
A 309 LI - R 317 LI copyright by
MJF C I F S S
8.45.39
Electric kits
Service Manual
Key to accessory kit diagrams Step 56 Item
Designation
Location / arrangement
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
Fuse box in control console, front right
** in basic diagram
8.45.40
A 309 LI - R 317 LI copyright by
MJF C I F S S
Service Manual
Electric kits Key to accessory kit diagrams
56
A 316 Litronic (IND) INDUSTRIEABSCHALTUNG IND. SHUTDOWN INTERRUPTION IND.ELEVABLE
A 309 LI - R 317 LI copyright by
MJF C I F S S
8.45.41
Electric kits
Service Manual
Key to accessory kit diagrams Step 57 Item
Designation
Location / arrangement
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
A 309 LI - R 317 LI copyright by
MJF C I F S S
Service Manual
Electric kits Key to accessory kit diagrams
57
A 312 Litronic / A 314 Litronic / A 316 Litronic / A 316 (IND) RADIO RADIO RADIO
A 309 LI - R 317 LI copyright by
MJF C I F S S
8.45.43
Electric kits
Service Manual
Key to accessory kit diagrams Step 58 Item
Designation
E9
Beacon
Location / arrangement
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
A 309 LI - R 317 LI copyright by
MJF C I F S S
Service Manual
Electric kits Key to accessory kit diagrams
58
A 312 Litronic / A 314 Litronic / A 316 Litronic / A 316 (IND) RUNDUMKENNLEUCHTE BEACON GIROPHARE
A 309 LI - R 317 LI copyright by
MJF C I F S S
8.45.45
Electric kits
Service Manual
Key to accessory kit diagrams Step 59 Item
Designation
Location / arrangement
A 127**
Printed circuit board / power
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
A 309 LI - R 317 LI copyright by
MJF C I F S S
Service Manual
Electric kits Key to accessory kit diagrams
59
A 312 Litronic / A 314 Litronic / A 316 Litronic / A 316 (IND) MOTORSTOP ENGINE STOP ARRET MOTEUR
A 309 LI - R 317 LI copyright by
MJF C I F S S
8.45.47
Electric kits
Service Manual
Key to accessory kit diagrams Step 60 Item
Designation
Location / arrangement
A127**
Printed circuit board / power
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
A 309 LI - R 317 LI copyright by
MJF C I F S S
Service Manual
Electric kits Key to accessory kit diagrams
60
A 312 Litronic / A 314 Litronic / A 316 Litronic / A 316 (IND) WEGFAHRSPERRE IMMOBILISER ANTIVOL DE DEMARRAGE
A 309 LI - R 317 LI copyright by
MJF C I F S S
8.45.49
Electric kits
Service Manual
Key to accessory kit diagrams Step 61 Item
Designation
Location / arrangement
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
A 309 LI - R 317 LI copyright by
MJF C I F S S
Service Manual
Electric kits Key to accessory kit diagrams
61
A 312 Litronic / A 314 Litronic / A 316 Litronic / A 316 (IND) FAHRWARNEINRICHTUNG TRAVEL ALARM AVERTISSEUR DE MARCHE
A 309 LI - R 317 LI copyright by
MJF C I F S S
8.45.51
Electric kits
Service Manual
Key to accessory kit diagrams Step 62 Item
Designation
Location / arrangement
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
A 309 LI - R 317 LI copyright by
MJF C I F S S
Service Manual
Electric kits Key to accessory kit diagrams
62
A 312 Litronic / A 314 Litronic / A 316 Litronic SCHNELLWECHSLER QUICK-CHANGE ADAPTER ADAPTEUR A CHANGEMENT RAPIDE
A 309 LI - R 317 LI copyright by
MJF C I F S S
8.45.53
Electric kits
Service Manual
Key to accessory kit diagrams Step 63 Item
Designation
Location / arrangement
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
A 309 LI - R 317 LI copyright by
MJF C I F S S
Service Manual
Electric kits Key to accessory kit diagrams
63
A 316 Litronic (IND) INDUSTRIESCHNELLWECHSLER IND. QUICK-CHANGE ADAPTER ADAPT. RAPIDE INDUSTRIE
A 309 LI - R 317 LI copyright by
MJF C I F S S
8.45.55
Electric kits
Service Manual
Key to accessory kit diagrams Step 64 Item
Designation
Location / arrangement
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
A 309 LI - R 317 LI copyright by
MJF C I F S S
Service Manual
Electric kits Key to accessory kit diagrams
64a Air-conditioning system
A 309 LI - R 317 LI copyright by
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
A 309 LI - R 317 LI copyright by
MJF C I F S S
Service Manual
Electric kits Key to accessory kit diagrams
64c Air-conditioning system
A 309 LI - R 317 LI copyright by
MJF C I F S S
8.45.59
Electric kits
Service Manual
Key to accessory kit diagrams Step 65 Item
Designation
Location / arrangement
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**
Plug connection, 4-pin Plug connection, 21-pin
15.0 A 15.0 A
** in basic diagram
8.45.60
A 309 LI - R 317 LI copyright by
MJF C I F S S
Service Manual
Electric kits Key to accessory kit diagrams
65
A 312 Litronic / A 314 Litronic / A 316 Litronic / A 316 (IND) ZUSATZSCHEINWERFER AUXILIARY HEADLIGHT PROJECTEURS SUPPLEMENTAIRES
A 309 LI - R 317 LI copyright by
MJF C I F S S
8.45.61
Electric kits
Service Manual
Key to accessory kit diagrams Step 66/1 Item
Designation
Location / arrangement
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
A 309 LI - R 317 LI copyright by
MJF C I F S S
Service Manual
Electric kits Key to accessory kit diagrams
66/1
A 312 Litronic / A 314 Litronic / A 316 Litronic / A 316 (IND) ANBAUSATZ UMSCHALTSCHIEBER CHANGEOVER VALVE ACCESSORY KIT ENSEMBLE DE MONTAGE
A 309 LI - R 317 LI copyright by
MJF C I F S S
8.45.63
Electric kits
Service Manual
Key to accessory kit diagrams Step 66/2 Item
Designation
Location / arrangement
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
A 309 LI - R 317 LI copyright by
MJF C I F S S
Service Manual
Electric kits Key to accessory kit diagrams
66/2
A 312 Litronic / A 314 Litronic / A 316 Litronic / A 316 (IND) ANBAUSATZ UMSCHALTSCHIEBER CHANGEOVER VALVE ACCESSORY KIT ENSEMBLE DE MONTAGE
A 309 LI - R 317 LI copyright by
MJF C I F S S
8.45.65
Electric kits
Service Manual
Key to accessory kit diagrams Step 67 Item
Designation
Location / arrangement
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
A 309 LI - R 317 LI copyright by
MJF C I F S S
Service Manual
Electric kits Key to accessory kit diagrams
67
A 312 Litronic / A 314 Litronic / A 316 Litronic / A 316 (IND) BETRIEBSSTUNDENZÄHLER HOUR COUNTER COMPTEUR HORAIRE
A 309 LI - R 317 LI copyright by
MJF C I F S S
8.45.67
Electric kits
Service Manual
Key to accessory kit diagrams Step 68 Item
Designation
Location / arrangement
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
A 309 LI - R 317 LI copyright by
MJF C I F S S
Service Manual
Electric kits Key to accessory kit diagrams
68
A 312 Litronic / A 314 Litronic / A 316 Litronic / A 316 (IND) RÜCKFAHRWARNEINRICHTUNG BACK-UP WARNING DEVICE AVERTISSEUR DE MARCHE ARRIERE
A 309 LI - R 317 LI copyright by
MJF C I F S S
8.45.69
Electric kits
Service Manual
Key to accessory kit diagrams Step 69 Item
Designation
Location / arrangement
A 127**
Printed circuit board / power
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
A 309 LI - R 317 LI copyright by
MJF C I F S S
Service Manual
Electric kits Key to accessory kit diagrams
69
A 312 Litronic / A 314 Litronic / A 316 Litronic / A 316 (IND) KRAFTSTOFFVORWÄRMUNG FUEL PREHEATER PRECHAUFFE DE CARBURANT
A 309 LI - R 317 LI copyright by
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
Location / arrangement
A127
Printed circuit board / power
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
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Service Manual
Electric kits Key to accessory kit diagrams
70
A 312 Litronic / A 314 Litronic / A 316 Litronic / A 316 (IND) STANDHEIZUNG D5WS AUXILIARY HEATER CHAUFFAGE SUPPLEMENT SUPPLEMENTAIRE A L'ARRET
A 309 LI - R 317 LI copyright by
MJF C I F S S
8.45.73
Electric kits
Service Manual
Key to accessory kit diagrams Step 71
8.45.74
Item
Designation
Location / arrangement
A127
Printed circuit board / power
F342
Fuse terminal 15
T4
Voltage transformer
X989
Power socket 12V / 20 A / 2-pin
15.0 A
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Service Manual
Electric kits Key to accessory kit diagrams
71
A 312 Litronic / A 314 Litronic / A 316 Litronic / A 316 (IND) STECKDOSE 12V 20A SOCKET 12V 20A PRISE 12V 20A
A 309 LI - R 317 LI copyright by
MJF C I F S S
8.45.75
Electric kits
Service Manual
Key to accessory kit diagrams Step 72
8.45.76
Item
Designation
Location / arrangement
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
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MJF C I F S S
Service Manual
Electric kits Key to accessory kit diagrams
72
A 312 Litronic / A 314 Litronic / A 316 Litronic / A 316 (IND) HUBBEGRENZUNG STROKE LIMITER LIMITEUR DE COURSE DE LEVAGE
A 309 LI - R 317 LI copyright by
MJF C I F S S
8.45.77
Electric kits
Service Manual
Key to accessory kit diagrams Step 73
8.45.78
Item
Designation
Location / arrangement
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
Fuse box in control console, front right
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Service Manual
Electric kits Key to accessory kit diagrams
73
A 312 Litronic / A 314 Litronic / A 316 Litronic / A 316 (IND) EINZELSTEUERUNG SCHILD / SCHILD BLADE / BLADE INDIVIDUAL CONTROL COMMANDE UNIQUE LAME / LAME
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8.45.79
Electric kits
Service Manual
Key to accessory kit diagrams Step 74
8.45.80
Item
Designation
Location / arrangement
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
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Electric kits Key to accessory kit diagrams
74
A 312 Litronic / A 314 Litronic / A 316 Litronic / A 316 (IND) KENNZEICHENLEUCHTE LAMP ECLAIREAGE DE LA PLAQUE D'IMMATRICULATION
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MJF C I F S S
8.45.81
Electric kits
Service Manual
Key to accessory kit diagrams Step 75
8.45.82
Item
Designation
Location / arrangement
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
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Service Manual
Electric kits Key to accessory kit diagrams
75
A 312 Litronic / A 314 Litronic / A 316 Litronic / A 316 (IND) ZENTRALSCHMIERANLAGE CENTRAL LUBRICATION SYSTEM DISP. DE GRAISSAGE CENTRALISE
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8.45.83
Electric kits
Service Manual
Key to accessory kit diagrams Step 76
8.45.84
Item
Designation
Location / arrangement
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
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Electric kits Key to accessory kit diagrams
76
A 316 Litronic (IND) NOTABLASS EMERCENCY LOWERING DESCENTE SECOURS
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8.45.85
Electric kits
Service Manual
Key to accessory kit diagrams Step 77
8.45.86
Item
Designation
Location / arrangement
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
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Electric kits Key to accessory kit diagrams
77
A 316 Litronic (IND) HUBBEGRENZUNG SCHWENKARM STROKE LIMITER BASIC BOOM LIMITEUR DE COURSE FLECHE DE BASE
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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
Location / arrangement
F331
Fuse X29
H323
Indicator light / lateral adjustment
K370
Relay servo
S356
Switch / changeover valve
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
Solenoid valve / changeover valve
15.0 A
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Electric kits Key to accessory kit diagrams
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
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8.45.89
Electric kits
Service Manual
Key to accessory kit diagrams Step 78/2
8.45.90
Item
Designation
Location / arrangement
F330
Fuse kits
H307
Indicator light / delta P
R76
Potentiometer / fine adjustment
S382
Switch / fine adjustment ON / OFF
U16
BST excavator control system
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
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Electric kits Key to accessory kit diagrams
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
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8.45.91
Electric kits
Service Manual
Key to accessory kit diagrams Step 79
8.45.92
Item
Designation
Location / arrangement
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
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Electric kits Key to accessory kit diagrams
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
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8.45.93
Electric kits
Service Manual
Key to accessory kit diagrams Step 80
8.45.94
Item
Designation
Location / arrangement
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
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Electric kits Key to accessory kit diagrams
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
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8.45.95
Electric kits
Service Manual
Key to accessory kit diagrams Step 81 Item
Designation
Location / arrangement
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**
Relay / changeover hammer / pile driver
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
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Service Manual
Electric kits Key to accessory kit diagrams
81
A 312 Litronic / A 314 Litronic / A 316 Litronic / A 316 (IND) BAUSATZMENGE UMSCHALTBAR SWITCHABLE FLOW REDUCTION REDUCTION DE DEBIT
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MJF C I F S S
8.45.97
Electric kits
Service Manual
Key to accessory kit diagrams Step 82 Item
Designation
Location / arrangement
F307** F336**
Fuse E16, E17 Fuse S61
H324
Inclinometer illumination
Right control console, front
P6**
Display / motor temperature
Right controle
S61**
Switch / lighting installation
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
** item from basic diagram
8.45.98
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Service Manual
Electric kits Key to accessory kit diagrams
82
A 312 Litronic / A 314 Litronic / A 316 Litronic (IND) BELEUCHTUNG NEIGUNGSMESSER ILLUMINATION INCLINOMETER ECLAIRAGE NIVEAU ELECTRONIQUEB
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MJF C I F S S
8.45.99
Electric kits
Service Manual
Key to accessory kit diagrams Step 83/1 Item
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
** item from basic diagram
8.45.100
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Service Manual
Electric kits Key to accessory kit diagrams
83/1 A 312 Litronic / A 314 Litronic / A 316 Litronic (IND) HUBBEGRENZUNG KRÜGER KRUEGER STROKE LIMITER LIMITEUR DE COURSE ELECTRIQUE
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MJF C I F S S
8.45.101
Electric kits
Service Manual
Key to accessory kit diagrams Step 83/2
8.45.102
Item
Designation
Location / arrangement
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
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Electric kits Key to accessory kit diagrams
83/2
A 312 Litronic / A 314 Litronic / A 316 Litronic (IND) HUBBEGRENZUNG KRÜGER KRUEGER STROKE LIMITIER LIMITEUR DE COURSE ELECTRIQUE
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MJF C I F S S
8.45.103
Electric kits
Service Manual
Key to accessory kit diagrams Step 84/1 Item
Designation
Location / arrangement
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
Right console, front Right console, front
** item from basic diagram
8.45.104
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Service Manual
Electric kits Key to accessory kit diagrams
84/1 A 312 Litronic / A 314 Litronic / A 316 Litronic (IND) UMSCHALTUNG LÖFFELKIPPKREIS / AHS SWITCHING SYSTEM BUCKET / AHS COMMUTATEUR GODET CURAGE / AHS
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8.45.105
Electric kits
Service Manual
Key to accessory kit diagrams Step 84/2 Item
Designation
Location / arrangement
A125**
PCB potentiometers
Left console
B33
Pressure switch pst for AHS section
Near control valve block
F320** F321** F330** F331**
Fuse X11 / X12 Fuse X12 Fuse kits Fuse X29
H322
Warning light / changeover
Right control console
K375**
Relay / signal flow reduction AHS
Right console, rear
S241** S405
Switch AHS 11 / AHS 12 Switch / changeover
Right controle Right console
U16**
BST excavator control system
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
** item from basic diagram
8.45.106
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Service Manual
Electric kits Key to accessory kit diagrams
84/2
A 309 Litronic / A 311 Litronic UMSCHALTUNG LÖFFELKIPPKREIS / AHS SWITCHING SYSTEM BUCKET / AHS COMMUTATEUR GODET CURAGE / AHS
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MJF C I F S S
8.45.107
Electric kits
Service Manual
Key to accessory kit diagrams Step 84/3
8.45.108
Item
Designation
Location / arrangement
A125** A133
PCB potentiometers Printed circuit board
Left console Left console
B33
Pressure switch pst for AHS section
Near control valve block
F321** F330**
Fuse X12 to kits fuse
H196** H322
Indicator light / sorting grapple Warning light / changeover
Right control desk Right control console
K375**
Relay / signal flow reduction AHS
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**
BST excavator control system
Right console, rear
V156-4 V169
Blocking diode A125 Blocking diode
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
Right console, front Right console, front
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Electric kits Key to accessory kit diagrams
84/3 A 309 Litronic / A 311 Litronic UMSCHALTUNG LÖFFELKIPPKREIS / AHS SWITCHING SYSTEM BUCKET / AHS COMMUTATEUR GODET CURAGE / AHS
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8.45.109
Electric kits
Service Manual
Key to accessory kit diagrams Step 85 Item
Designation
Location / arrangement
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
** item from basic diagram
8.45.110
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Service Manual
Electric kits Key to accessory kit diagrams
85
A 309 - A 316 Litronic PARTICLE FILTER PURITECH FILTRE DE PARTICULES PURITECH PARTICLE FILTER PURITECH
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8.45.111
Electric kits
Service Manual
Key to accessory kit diagrams Step 86/1 Item
Designation
Location / arrangement
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
Right console, front
** item from basic diagram
8.45.112
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Service Manual
Electric kits Key to accessory kit diagrams
86/1 A 312 Litronic / A 314 Litronic / A 316 Litronic (IND) ANBAUSATZ MAHKORB MOWER RAKE GODET FAUCARDEUR
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MJF C I F S S
8.45.113
Electric kits
Service Manual
Key to accessory kit diagrams Step 86/2 Item
Designation
Location / arrangement
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
Right console, front
** item from basic diagram
8.45.114
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Service Manual
Electric kits Key to accessory kit diagrams
86/2 A 312 Litronic / A 314 Litronic / A 316 Litronic (IND) ANBAUSATZ MAHKORB MOWER RAKE GODET FAUCARDEUR
A 309 LI - R 317 LI copyright by
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8.45.115
Electric kits
Service Manual
Key to accessory kit diagrams Step 87 Item
Designation
Location / arrangement
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
Right console, front
** item from basic diagram
8.45.116
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Service Manual
Electric kits Key to accessory kit diagrams
87
A 316 Litronic (IND) ANHANGEKUPPLUNG TRAILER COUPLING D'ATTELAGE
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MJF C I F S S
8.45.117
Electric kits
Service Manual
Key to accessory kit diagrams Step 88 Item
Designation
Location / arrangement
A123
Printed circuit board
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
Right console, front
** item from basic diagram
8.45.118
A 309 LI - R 317 LI copyright by
MJF C I F S S
Service Manual
Electric kits Key to accessory kit diagrams
88
A 316 Litronic (IND) JOY-STICK LENKUNG JOYSTICK CONTROL COMMAND DU VOLANT DE DIRECTION
A 309 LI - R 317 LI copyright by
MJF C I F S S
8.45.119
Electric kits
Service Manual
Key to accessory kit diagrams Step 89 Item
Designation
Location / arrangement
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
Right console, front
** item from basic diagram
8.45.120
A 309 LI - R 317 LI copyright by
MJF C I F S S
Service Manual
Electric kits Key to accessory kit diagrams
89
A 312 Litronic / A 314 Litronic / A 316 Litronic (IND) RÜCKFAHRWARNEINRICHTUNG OPTISCH UND AKUSTISCH BACK-UP WARNING DEVICE AVERTISSEUR DE MARCHE ARRIERE
A 309 LI - R 317 LI copyright by
MJF C I F S S
8.45.121
Electric kits
Service Manual
Key to accessory kit diagrams Step 90 Item
Designation
Location / arrangement
B233
Proximity switch / bucket cylinder movement
At stick
F331**
Fuse X29
H328
Indicator light / shut-down active
Right control console
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
Right console, front
** item from basic diagram
8.45.122
A 309 LI - R 317 LI copyright by
MJF C I F S S
Service Manual
Electric kits Key to accessory kit diagrams
90 A 312 Li / A 314 Li / A 316 Li (IND) / R 317 Li ABSCHALTUNG LÖFFELKIPPZYLINDER
A 309 LI - R 317 LI copyright by
MJF C I F S S
8.45.123
Electric kits
Service Manual
Key to accessory kit diagrams Step 91 Item
Designation
Location / arrangement
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
Right console, front Right console, front
** item from basic diagram
8.45.124
A 309 LI - R 317 LI copyright by
MJF C I F S S
Service Manual
Electric kits Key to accessory kit diagrams
91
A 312 Litronic / A 314 Litronic / A 316 Litronic (IND) ANBAUSATZ BOHRLAFETTE DRILLING SLIDE ACCESSORY KIT EQUIPEMENT COMPLEMENTAIRE AFFUT
A 309 LI - R 317 LI copyright by
MJF C I F S S
8.45.125
Electric kits
Service Manual
Key to accessory kit diagrams Step 92 Item
Designation
Location / arrangement
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
** item from basic diagram
8.45.126
A 309 LI - R 317 LI copyright by
MJF C I F S S
Service Manual
Electric kits Key to accessory kit diagrams
92
A 309 Litronic / A 311 Litronic SCHILD EINZELSTEUERUNG OPTION LAME DE NIVELAGE/BRAS STABILISATEUR OPTION DOZER BLADE/OUTRIGGER INDIVIDUAL CONTROL
A 309 LI - R 317 LI copyright by
MJF C I F S S
8.45.127
Electric kits
Service Manual
Key to accessory kit diagrams Step 93 Item
Designation
Location / arrangement
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
Right console Right console
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
Right console, front
** item from basic diagram
8.45.128
A 309 LI - R 317 LI copyright by
MJF C I F S S
Service Manual
Electric kits Key to accessory kit diagrams
93
A 312 Litronic / A 314 Litronic / A 316 Litronic (IND) TELESCOPIC SUPPORT BLADE
A 309 LI - R 317 LI copyright by
MJF C I F S S
8.45.129
Electric kits
Service Manual
Key to accessory kit diagrams Step 94 Item
Designation
Location / arrangement
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
Hydraulic tank Hydraulic tank
15.0 A
Right console, front
** item from basic diagram
8.45.130
A 309 LI - R 317 LI copyright by
MJF C I F S S
Service Manual
Electric kits Key to accessory kit diagrams
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
A 309 LI - R 317 LI copyright by
MJF C I F S S
8.45.131
Electric kits
Service Manual
Key to accessory kit diagrams Step 95 Item
Designation
Location / arrangement
A127**
Printed circuit board / power
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
** item from basic diagram
8.45.132
A 309 LI - R 317 LI copyright by
MJF C I F S S
Service Manual
Electric kits Key to accessory kit diagrams
95
A 312 Li / A 314 Li / A 316 Li (IND) / R 317 Li MOTORSTOP ZEITGESTEUERT ENGINE STOP WITH TIMER ARRET MOTEUR AUTOMATIQUE
A 309 LI - R 317 LI copyright by
MJF C I F S S
8.45.133
Electric kits
Service Manual
Key to accessory kit diagrams Step 96 Item
Designation
Location / arrangement
A1017**
to quick-change adapter board
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**
Solenoid valve / grapple rotator Solenoid valve / grapple rotator
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.
A 309 LI - R 317 LI copyright by
MJF C I F S S
Service Manual
Electric kits Key to accessory kit diagrams
96
A 312 Litronic / A 314 Litronic / A 316 Litronic (IND) GREIFER DREHEN ÜBER RECHTEN WIPPTASTER GRAPPLE ROTATOR MECHANISME DE ROTATION
A 309 LI - R 317 LI copyright by
MJF C I F S S
8.45.135
Electric kits
Service Manual
Key to accessory kit diagrams Step 97/1 Item
Designation
Location / arrangement
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
** item from basic diagram
8.45.136
A 309 LI - R 317 LI copyright by
MJF C I F S S
Service Manual
Electric kits Key to accessory kit diagrams
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
A 309 LI - R 317 LI copyright by
MJF C I F S S
8.45.137
Electric kits
Service Manual
Key to accessory kit diagrams Step 97/2 Item
Designation
Location / arrangement
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**
Switch / lighting installation
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
** item from basic diagram
8.45.138
A 309 LI - R 317 LI copyright by
MJF C I F S S
Service Manual
Electric kits Key to accessory kit diagrams
97/2
A 309 Litronic / A 311 Litronic ZUSATZ - LEUCHTEN / LICHTANLAGE LIGHTING SYSTEM ECLAIRAGE
A 309 LI - R 317 LI copyright by
MJF C I F S S
8.45.139
Electric kits
Service Manual
Key to accessory kit diagrams Step 97/3 Item
Designation
Location / arrangement
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**
Switch / lighting installation
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
Right console, rear Right console, rear Right console, rear Right console, rear Right console, rear
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
** item from basic diagram
8.45.140
A 309 LI - R 317 LI copyright by
MJF C I F S S
Service Manual
Electric kits Key to accessory kit diagrams
97/3
A 312 Litronic / A 314 Litronic / A 316 Litronic (IND) ZUSATZ - LEUCHTEN / LICHTANLAGE LIGHTING SYSTEM ECLAIRAGE
A 309 LI - R 317 LI copyright by
MJF C I F S S
8.45.141
Electric kits
Service Manual
Key to accessory kit diagrams Step 98 Item
Designation
Location / arrangement
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**
BST excavator control system
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
Right console, front
** item from basic diagram
8.45.142
A 309 LI - R 317 LI copyright by
MJF C I F S S
Service Manual
Electric kits Key to accessory kit diagrams
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
A 309 LI - R 317 LI copyright by
MJF C I F S S
8.45.143
Electric kits
Service Manual
Key to accessory kit diagrams Step 99 Item
Designation
Location / arrangement
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
Right console, front Right console, front
** item from basic diagram
8.45.144
A 309 LI - R 317 LI copyright by
MJF C I F S S
Service Manual
Electric kits Key to accessory kit diagrams
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
A 309 LI - R 317 LI copyright by
MJF C I F S S
8.45.145
Electric kits
Service Manual
Key to accessory kit diagrams Step 100 Item
Designation
Location / arrangement
A127**
Printed circuit board / power
Hydraulic tank
F331** F364
Fuse X29 Fuse
H158
Indicator light / Fuchs control ON
Right control console
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
Right console, rear Right console, rear
X1213
Plug connection, 2-pin / decay diode
Right control console
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
** item from basic diagram
8.45.146
A 309 LI - R 317 LI copyright by
MJF C I F S S
Service Manual
Electric kits Key to accessory kit diagrams
100 A 312 Li / A 314 Li / A 316 Li (IND) / R 317 Li UMSCHALTUNG FUCHS-STEUERUNG SWITCHING FUCHS SERVO CONTROLS COMMUTATION COMMANDE FUCHS
A 309 LI - R 317 LI copyright by
MJF C I F S S
8.45.147
Electric kits
Service Manual
Key to accessory kit diagrams Step 101 Item
Designation
Location / arrangement
B290**
Proximity switch / adjusting pedal left
Operator's platform / front
F320**
Fuse X11 / X12
H343
Warning light / outriggers not retracted
Right control console
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
Right console, front
** item from basic diagram
8.45.148
A 309 LI - R 317 LI copyright by
MJF C I F S S
Service Manual
Electric kits Key to accessory kit diagrams
101 A 312 Li / A 314 Li / A 316 Li (IND) PRATZENKONTROLLE OUTRIGGER CONTROL BRAS STABO OSATEIRS DE CONTROL
A 309 LI - R 317 LI copyright by
MJF C I F S S
8.45.149
Electric kits
Service Manual
Key to accessory kit diagrams Step 102 Item
Designation
Location / arrangement
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
Right console, front
** item from basic diagram
8.45.150
A 309 LI - R 317 LI copyright by
MJF C I F S S
Service Manual
Electric kits Key to accessory kit diagrams
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
A 309 LI - R 317 LI copyright by
MJF C I F S S
8.45.151
Electric kits
Service Manual
Key to accessory kit diagrams Step 103 Item
Designation
Location / arrangement
A126**
PCB / autocheck
Right console
F326**
Fuse Y24, Y55, Y371, QC adapter
H176** H311**
Indicator lamp / oscillating axle automatic Indicator lamp / oscillating axle locked
Right console Right console
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
Left console Left console
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 console, front
Right pilot control unit Right pilot control unit
** item from basic diagram
8.45.152
A 309 LI - R 317 LI copyright by
MJF C I F S S
Service Manual
Electric kits Key to accessory kit diagrams
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
A 309 LI - R 317 LI copyright by
MJF C I F S S
8.45.153
Electric kits
Service Manual
Key to accessory kit diagrams Step 104 Item
Designation
Location / arrangement
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
A 309 LI - R 317 LI copyright by
MJF C I F S S
Service Manual
Electric kits Key to accessory kit diagrams
104 A 309 - A 316 Li FAHRWARNEINRICHTUNG TRAVEL ALARM AVERTISSEUR DE MARCHE
A 309 LI - R 317 LI copyright by
MJF C I F S S
8.45.155
Electric kits
Service Manual
Key to accessory kit diagrams Step 105 Item
Designation
Location / arrangement
F331**
Fuse
H323
Indicator light / lateral adjustment
Right console
K370**
Relay servo
Right console, rear
S356
Switch / changeover valve
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**
Solenoid valve / changeover valve
Attachments
15.0 A
Right console, front
** item from basic diagram
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Service Manual
Electric kits Key to accessory kit diagrams
105 A 309 - A 316 Li ANBAUSATZ UMSCHALTSCHIEBER CHANGEOVER VALVE ACCESSORY KIT TIROIR DIVERSION
A 309 LI - R 317 LI copyright by
MJF C I F S S
8.45.157
Electric kits
Service Manual
Key to accessory kit diagrams
Step 106 Item
Designation
F331**
Fuse Y24, Y55, Y371, QC adapter
K455
Relay / changeover valve UP, horizontal
Right console, rear
S356
Switch / changeover valve
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
Right console, front
Hydraulic tank below operator's platform below operator's platform Hydraulic tank
** item from basic diagram
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Service Manual
Electric kits Key to accessory kit diagrams
106 A 312 - R 317 Li ANBAUSATZ UMSCHALTSCHIEBER CHANGEOVER VALVE ACCESSORY KIT TIROIR DIVERSION
A 309 LI - R 317 LI copyright by
MJF C I F S S
8.45.159
Electric kits
Service Manual
Key to accessory kit diagrams
Step 107 Item
Designation
Location / arrangement
F330**
Fuse
H196 H323
Indicator light / sorting grapple Indicator light / lateral adjustment
Right console Right console
K375**
Relay / changeover hammer / pile driver
Right console, rear
S241 S356
Switch AHS 12 Switch / changeover valve
Right console Right console
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
Hydraulic tank Hydraulic tank
15.0 A
Right console, front
** item from basic diagram
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Service Manual
Electric kits Key to accessory kit diagrams
107 A 312 - R 317 Li ANBAUSATZ UMSCHALTSCHIEBER CHANGEOVER VALVE ACCESSORY KIT TIROIR DIVERSION
A 309 LI - R 317 LI copyright by
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8.45.161
Electric kits
Service Manual
Key to accessory kit diagrams
Step 108 Item
Designation
Location / arrangement
B213 B214
Proximity switch boom shut-down at stick Proximity switch boom shut-down at bearing block
Attachments Attachments
F331**
Fuse Y24, Y55, Y371, QC adapter
Right console, front
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
Right console Right console
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
Hydraulic tank Hydraulic tank
15.0 A
** item from basic diagram
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Service Manual
Electric kits Key to accessory kit diagrams
108 A 312 - R 317 Li HUBBEGRENZUNG HUB UND STIEL STROKE LIMITER AND STICK LIMITEUR DE COURSE LEVAGE ET BALNCIER
A 309 LI - R 317 LI copyright by
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8.45.163
Electric kits
Service Manual
Key to accessory kit diagrams
Step 109 Item
Designation
Location / arrangement
A1017**
to quick-change adapter board
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**
Solenoid valve / grapple rotator Solenoid valve / grapple rotator
Control valve block Control valve block
** item from basic diagram
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Service Manual
Electric kits Key to accessory kit diagrams
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
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8.45.165
Electric kits
Service Manual
Key to accessory kit diagrams
Step 110 Item
Designation
Location / arrangement
A125**
PCB potentiometers
Left console
B33
Pressure switch pst for AHS section
Near control valve block
F330** F331**
to fuse Fuse X29
H322
Warning light / changeover
Right control console
K375**
Relay / signal flow reduction AHS
Right console, rear
S19** S241** S405
to switch AS 1 Switch AHS 11 / AHS 12 Switch / changeover
Right controle Right controle Right console
U16**
BST excavator control system
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
Right console, front Right console, front
** item from basic diagram
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Electric kits Key to accessory kit diagrams
110
A 309 Litronic / A 311 Litronic UMSCHALTUNG LÖFFELKIPPKREIS / AHS SWITCHING SYSTEM BUCKET / AHS COMMUTATEUR GODET CURAGE / AHS
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Electric kits
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Key to accessory kit diagrams
Step 111 Item
Designation
Location / arrangement
F314** F329** FRes**
Fuse S7 Fuse S35 Fuse, reserve
H27**
Warning buzzer
Right control console
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**
BST excavator control system
Right console, rear
V178-1 V178-2
Blocking diode signal Servo-S7 Blocking diode signal Servo-S7
Right console, rear Right console, rear
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
** item from basic diagram
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Electric kits Key to accessory kit diagrams
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
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8.45.169
Electric kits
Service Manual
Key to accessory kit diagrams
Step 112 Item
Designation
Location / arrangement
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** 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
Hydraulic tank Hydraulic tank
15.0 A
Right console, front
** item from basic diagram
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Service Manual
Electric kits Key to accessory kit diagrams
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
A 309 LI - R 317 LI copyright by
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8.45.171
Electric kits
Service Manual
Key to accessory kit diagrams
Step 113 Item
Designation
Location / arrangement
A1017**
to quick-change adapter board
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**
Solenoid valve / grapple rotator Solenoid valve / grapple rotator
Control valve block Control valve block
** item from basic diagram
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Service Manual
Electric kits Key to accessory kit diagrams
113 A 312 Litronic / A 314 Litronic / A 316 Litronic (IND) GREIFER DREHEN ÜBER RECHTEN WIPPTASTER GRAPPLE ROTATOR MECHANISME DE ROTATION
A 309 LI - R 317 LI copyright by
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8.45.173
Electric kits
Service Manual
Key to accessory kit diagrams
Step 114 Item
Designation
Location / arrangement
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
Fuse box in control console, front right
** item from basic diagram
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Electric kits Key to accessory kit diagrams
114 A 309 / A 311 Litronic SCHILDEINZELSTEUERUNG PRATZE INDIVIDUAL BLADE CONTROL OUTRIGGER COMMANDE UNIQUE LAME / STABILISATEUR
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8.45.175
Electric kits
Service Manual
Key to accessory kit diagrams
Step 115 Item
Designation
Location / arrangement
A125**
PCB potentiometers
Near hydraulic tank
H344
Indicator light / flow distributor
Right control console
K375** K467
Relay / signal flow reduction AHS Step relay / flow distributor operation
Right console, rear Right console, rear
S6L S6R S464
Left button Right button Switch activation / flow distributor operation
Right pilot control unit Right pilot control unit Right console
U16**
BST excavator control system
Right console, rear
V156-4 V177
Diode / input quantity Blocking diode signal flow reduction / flow distributor
Right console, rear Right console, rear
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
** item from basic diagram
8.45.176
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Service Manual
Electric kits Key to accessory kit diagrams
115 A 309 / A 311 Litronic MENGENTEILER FLOW DISTRIBUTOR DIVISEUR DE DEBIT
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MJF C I F S S
8.45.177
Electric kits
Service Manual
Key to accessory kit diagrams
Step 116 Item
Designation
Location / arrangement
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
** item from basic diagram
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Service Manual
Electric kits Key to accessory kit diagrams
116 A 309 - R 317 Litronic ZENTRALSCHMIERANLAGE SEMIAUTOMATISCH SEMIAUTOMATIC CENTRAL LUBRICATION SYSTEM DISP. DE GRAISSAGE CENRALISE SEMIAUTOMATIQUE
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8.45.179
Electric kits
Service Manual
Key to accessory kit diagrams
Step 117 Item
Designation
Location / arrangement
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
Right console, front
** item from basic diagram
8.45.180
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Electric kits Key to accessory kit diagrams
117 A 309 - A 311 Litronic STIELZYLINDERABSCHALTUNG STICK CYLINDER SHUT-DOWN ARRET PILOTAGE VERIN BALANCIER
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8.45.181
Electric kits
Service Manual
Key to accessory kit diagrams
Step 118 Item
Designation
Location / arrangement
B21**
Pressure switch / overload
Boom cylinder bearing
F331**
Fuse
H16** H20** H315
Warning light overload warning system to indicator light parking brake Warning light shut-down override
Right console Right console Right console
K473
Relay shutdown attachment
Distribution board
S18 S396
Switch / overload warning system Key switch shut-down override
Right console Right console
V179 V180
Blocking dialog signal / flow distributor control to override Blocking diode signal / H16 actuation to ground
Left console Left console
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
Right console, front
** item from basic diagram
8.45.182
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Electric kits Key to accessory kit diagrams
118 A 312 - R 317 Litronic AUTOMATISCHE ABSCHALTEINRICHTUNG BEI MONOAUSLEGER AUTOMATIC SHUT-DOWN INTERRUPTION AUTOMATIQUE
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8.45.183
Electric kits
Service Manual
Key to accessory kit diagrams
Step 119 Item
Designation
Location / arrangement
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 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
** item from basic diagram
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Electric kits Key to accessory kit diagrams
119 A 309 - A 316 Litronic ARTICLEFILTER PURITECH FILTRE DE PARTICULES PURITECH PURITECH PARTICLE FILTER
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8.45.185
Electric kits
Service Manual
Key to accessory kit diagrams
Step 120 Item
Designation
Location / arrangement
A1017
to quick-change adapter board
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
Hydraulic tank Hydraulic tank
** item from basic diagram
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120 A 309 - A 316 Litronic AS1 / GRIFF MIT 3 TASTEN AS1 / JOYSTICK WITH 3 SWITCHES AS1 / MANIPULATEUR AVEC 3 INTERRUPTEURS
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Key to accessory kit diagrams
Step 121
8.45.188
Item
Designation
Location / arrangement
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
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121 A 309 - A 316 Litronic XENON - SCHEINWERFER XENON HEADLIGHTS PHARES - XENON
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Key to accessory kit diagrams
8.45.190
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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
BST excavator control system
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
Proportional solenoid valve / flow limitation
B16
Switch / engine oil pressure
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
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MJFCIFSS
Service Manual
BST excavator control system Description
Fig. 2
Connections of BST
copyright by
MJFCIFSS
8.70.3
BST excavator control system
Service Manual
Functional description
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
printed circuit board / power
H11
Pre-heating indicator light
B2
Temperature sensor / engine coolant
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
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MJFCIFSS
8.70.5
BST excavator control system
Service Manual
Functional description
3.3.2
3.4
Speed step
Speed (without load)
Frequency
Current from BST version 5.11
8
1950 rpm
4226 - 4246 Hz
685 mA
9
2120rpm
4558 Hz
820 mA
Speed steps of models A 312 - R 317: Speed step
Speed (without load)
Frequency
Current to BST version 1.2
Current from BST version 1.3
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
copyright by
MJFCIFSS
Service Manual
BST excavator control system Functional description
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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MJFCIFSS
8.70.7
BST excavator control system
Service Manual
Functional description
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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MJFCIFSS
Service Manual
BST excavator control system Functional description
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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MJFCIFSS
8.70.9
BST excavator control system
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
Speed (without load)
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
Speed (without load)
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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MJF C I F S S
Service Manual
BST excavator control system Functional description
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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MJF C I F S S
8.70.11
BST excavator control system
Service Manual
Functional description
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
Proportional solenoid valve / power control
P2
Flow limitation potentiometer
Y51
Proportional solenoid valve / flow limitation
P3
Flow limitation potentiometer
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Service Manual
BST excavator control system Functional description
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
BST excavator control system
Service Manual
Functional description
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
Cooling water temperature sensor
Short to plus
continuous
009
Cooling water temperature sensor
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
Hydraulic oil temperature sensor
Short to plus
continuous
009
Hydraulic oil temperature sensor
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
Diesel engine speed sensor
Short to plus
continuous
024
Diesel engine speed sensor
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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Service Manual
BST excavator control system Functional description
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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MJFCIFSS
flashing
flashing
8.70.15
BST excavator control system
Service Manual
Functional description
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
Slip ring rotary connection
copyright by
MJFCIFSS
8.80.1
Slip ring rotary connection
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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MJFCIFSS
8.80.3
Slip ring rotary connection
Service Manual
Functional description
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
copyright by
MJFCIFSS
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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MJFCIFSS
8.80.5
Slip ring rotary connection
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
copyright by
MJFCIFSS
8.80.7
Slip ring rotary connection
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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MJF C I F S S
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
© LIEBHERR HYDRAULIKBAGGER GMBH
/4.A6 /5.A3
PROJEKT: 103281525_2_bs_hoch_seitl_im_linken_griff © LIEBHERR HYDRAULIKBAGGER GMBH
-F330.A
-F331.A
-F330.E
-F331.E
/5.F4 -F337.E /3.C8
© LIEBHERR HYDRAULIKBAGGER GMBH
PROJEKT: 103281525_2_bs_hoch_seitl_im_linken_griff © LIEBHERR HYDRAULIKBAGGER GMBH
-MP/VP.X3
© LIEBHERR HYDRAULIKBAGGER GMBH
PROJEKT: 103281525_2_bs_hoch_seitl_im_linken_griff © LIEBHERR HYDRAULIKBAGGER GMBH
/2.E6
A126
© LIEBHERR HYDRAULIKBAGGER GMBH
PROJEKT: 103281525_2_bs_hoch_seitl_im_linken_griff © LIEBHERR HYDRAULIKBAGGER GMBH
/2.E6
/2.E6
© LIEBHERR HYDRAULIKBAGGER GMBH
PROJEKT: 103281525_2_bs_hoch_seitl_im_linken_griff © LIEBHERR HYDRAULIKBAGGER GMBH
© LIEBHERR HYDRAULIKBAGGER GMBH
PROJEKT: 103281525_2_bs_hoch_seitl_im_linken_griff © LIEBHERR HYDRAULIKBAGGER GMBH
Service Manual
SUBGROUP - INDEX Section
Group
Type
Slewing gear mechanism
9.10.1
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-
Slewing gear brake
9.20.1
A 309 LI 20221A 311 LI 20222A 312 LI 12363A 314 LI 2001A 316 LI 2001A 316 LI-IND 2001-
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
Slewing gear mechanism
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
Slewing gear mechanism
Service Manual
Technical data
2 Technical data
Machine from serial number
A 309 - A 311 Litronic 20221
Gearbox type
Sat 225 / 240
A 312 Litronic 12363
SAT 225 / 228
R 317 Litronic 18161
SAT 225 / 218
21720 min-1
Max. drive speed Max. output torque
5600 Nm
Gear ratio
1: 31.7
Weight (approx.)
130 kg
Oil volume in gearbox
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
R 313 Litronic 27752
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)
Tightening torque of Allen head screws 61
190 Nm
E)
Tightening torque of hex head screws 62
195 Nm
F)
Tightening torque of Allen head screws 63
117 Nm
G)
Tightening torque of Allen head screws 115
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
Slewing gear mechanism
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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MJF C I F S S
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
Slewing gear mechanism
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
Allen head screw Allen head screw
6
Sun gear
62
Hex head screw
10 11
Planetary gear Planetary gear
63 64
Allen head screw Retaining washer
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
Radial shaft seal ring
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
Tapered roller bearing
910
Seal kit / swing drive
58
Tapered roller bearing
960
Brake disc set
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MJF C I F S S
9.10.7
Slewing gear mechanism
Service Manual
Exploded view of the gearbox
Fig. 5
9.10.8
Exploded view of the gearbox
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MJF C I F S S
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
Allen head screw Retaining washer
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
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
Radial shaft seal ring
43 44
Pressure spring Pressure spring
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
Tapered roller bearing
910
Seal kit / swing drive
58
Tapered roller bearing
960
Brake disc set
Observe the settings and tightening torques A - F for the installation, (see Tab. 2 on page2).
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MJF C I F S S
9.10.9
Slewing gear mechanism
Service Manual
Sectional drawing
10
Sectional drawing
Fig. 6
9.10.10
Sectional drawing of slewing gear mechanism
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MJF C I F S S
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
Inner disc Outer disc
87 K
Brake valve with pedal and retainer Pressure chamber / opening pressure
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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
Pressure spring Pressure spring
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
Brake housing/slewing gear brake
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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MJF C I F S S
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
Brake housing/slewing gear brake
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
Solenoid valve slewing gear brake
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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
Slewing gear mechanism
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
Gear pump / pilot control
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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Solenoid valve slewing gear brake
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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MJF C I F S S
Service Manual
Slewing gear brake Repair of brake
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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MJF C I F S S
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
Allen head screw Retaining washer
30
Annular piston
73
Snap ring
31 35
Locking ring Thrust plate
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
Pressure spring Pressure spring
92 200
Plug Mounting device
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Service Manual
Slewing gear brake Repair of brake
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
SUBGROUP - INDEX Section
Group
Type
Slewing ring
10.10.1
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-
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
2 Technical data Machine from serial number
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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MJF C I F S S
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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MJF C I F S S
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.
copyright by
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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MJF C I F S S
Service Manual
SUBGROUP - INDEX Section
Group
Type
2 HL 70 transmission
11.08.1
A 309 LI 20221-29268 A 311 LI 20222-29169 A 312 LI 12363-29897
2 HL 100 transmission
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
A 309 LI 29269A 311 LI 29170A 312 LI 29898A 316 LI 28061A 316 LI-IND 28061-
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
HBGV block for 2 HL 270 / 290
11.32.1
A 309 LI 29269A 311 LI 29170A 312 LI 29898A 316 LI 28061A 316 LI-IND 28061-
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
2 HL 70 transmission
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MJF C I F S S
11.08.1
2 HL 70 transmission
Service Manual
Technical data
2 Technical data Machine from serial number
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
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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MJF C I F S S
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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MJF C I F S S
11.08.3
2 HL 70 transmission
Service Manual
Design
3.1
Design of transmission
Fig. 2
11.08.4
2 HL 70 transmission
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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MJF C I F S S
11.08.5
2 HL 70 transmission
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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MJF C I F S S
Service Manual
2 HL 70 transmission Functional description
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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MJF C I F S S
11.08.7
2 HL 70 transmission
Service Manual
Functional description
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
Regulating travel motor
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
Pressure-relief valve Shifting piston
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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MJF C I F S S
11.08.9
2 HL 70 transmission
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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MJF C I F S S
Service Manual
2 HL 70 transmission Positions of the shift lock 70
5.2
Travel in on-road gear On-road gear (1st gear) preselected with switch S42 (see Fig. 5 on page12)
Input speed
Control oil to connection
Shift speed Travel motor (> 700 - 900 rpm) Universal joint shaft (> 540 - 700 rpm)
Function / shift lock
Function / transmission
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
71 Lubricating oil pump 71.2 Suction filter (maintenance-free)
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
Pressure-relief valve
P2
from HBGV block
75 76
Shifting piston Check valve
Pp S
Pump pressure Suction chamber / pump
77
Orifice
Sp
Shifting pressure
Shift lock
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MJF C I F S S
11.08.11
2 HL 70 transmission
Service Manual
Positions of the shift lock 70
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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MJF C I F S S
Service Manual
2 HL 70 transmission Positions of the shift lock 70
5.3
Off-road gear (1st gear) preselected with switch S42 (see Fig. 6 on page14)
Input speed
Control oil to connection
Shift speed Travel motor (< 700 - 900 rpm) Universal joint shaft (< 540 - 700 rpm)
Function / shift lock
Function / transmission
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
Oil supply / transmission
71
Lubricating oil pump
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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MJF C I F S S
11.08.13
2 HL 70 transmission
Service Manual
Positions of the shift lock 70
Fig. 6
11.08.14
Hydraulic diagram and sectional drawing of the transmission during travel in off-road gear
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MJF C I F S S
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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MJF C I F S S
11.08.15
2 HL 70 transmission
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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Service Manual
2 HL 70 transmission Operation of the machine
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
Switch / travel direction
*
Items of hydraulic unit
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11.08.17
2 HL 70 transmission
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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MJF C I F S S
11.08.19
2 HL 70 transmission
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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MJF C I F S S
11.08.21
2 HL 70 transmission
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
Bleeder / multi-disc brake
EK
Bleeder / multi-disc clutch
EL
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Bleeder / release mechanism
11.08.23
2 HL 70 transmission
Service Manual
Dismantling, repair and installation of the gearbox
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
Retaining washer Hex head screw
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
2 HL 70 transmission
Service Manual
Hydraulic release mechanism and hydraulic accumulator
11
Hydraulic release mechanism and hydraulic accumulator
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
Restrictor check valve
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
2 HL 70 transmission
Service Manual
Hydraulic release mechanism and hydraulic accumulator
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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MJF C I F S S
11.08.29
2 HL 70 transmission
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
2 HL 70 transmission Exploded view of gearbox components
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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MJF C I F S S
11.08.31
2 HL 70 transmission
Service Manual
Exploded view of gearbox components
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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Service Manual
2 HL 70 transmission Exploded view of gearbox components
12.5
Gear drive 16/17
Fig. 20
Exploded views of output end based on spare parts list
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MJF C I F S S
11.08.33
2 HL 70 transmission
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
2 HL 100 transmission
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11.10.1
2 HL 100 transmission
Service Manual
Technical data
2 Technical data Machine from serial number
A 314 Li 2001 A 314 Li Speeder
A 316 Li 2001 A 314 Li Speeder
Gearbox type
2 HL 100
2 HL 100
Max. drive power (*)
110 kW
110 kW
Max. input torque (*)
770 Nm
770 Nm
Max. input speed (*)
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°
32 l/min approx. 30 l/min
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
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
Switching speed (drive shaft / oil motor)
580 - 950 rpm (+)
580 - 950 rpm (+)
Switching speed (drive shaft / universal joint)
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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MJF C I F S S
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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MJF C I F S S
11.10.3
2 HL 100 transmission
Service Manual
Design
3.1
Design of transmission
Fig. 2
11.10.4
2 HL 100 transmission
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
2 HL 100 transmission Functional description
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
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 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
2 HL 100 transmission
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
2 HL 100 transmission Functional description
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
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.
copyright by
MJF C I F S S
11.10.7
2 HL 100 transmission
Service Manual
Functional description
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
Pressure-relief valve Shifting piston
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
Restrictor check valve
101
Restrictor check valve
102 210
Accumulator Regulating travel motor
copyright by
MJF C I F S S
Service Manual
2 HL 100 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
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
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 73
Leakage check valve Shuttle check valve
P1 P2
from HBGV block from HBGV block
74
Pressure-relief valve
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
copyright by
MJF C I F S S
11.10.9
2 HL 100 transmission
Service Manual
Positions of the shift lock 70
Fig. 4
11.10.10
Hydraulic diagram and sectional drawing of the transmission during travel in on-road gear at high speed
copyright by
MJF C I F S S
Service Manual
2 HL 100 transmission Positions of the shift lock 70
5.2
Travel in on-road gear On-road gear (1st gear) preselected with switch S42 (see Fig. 5 on page12)
Input speed
Control oil to connection
Function / shift lock
Function / transmission
Gear pump 71 delivers a specific oil volume
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
Connection of lubricating oil supply
71
Lubricating oil pump
79
Oil supply / transmission
71.2 Suction filter (maintenance-free)
B
Connection to multi-disc brake
72
Leakage check valve
K
Connection to multi-disc clutch
73 74
Shuttle check valve Pressure-relief valve
P1 P2
from HBGV block from HBGV block
75 76
Shifting piston Check valve
Pp S
Pump pressure Suction chamber / pump
77
Orifice
Sp
Shifting pressure
copyright by
MJF C I F S S
11.10.11
2 HL 100 transmission
Service Manual
Positions of the shift lock 70
Fig. 5
11.10.12
Hydraulic diagram and sectional drawing of the transmission during travel in on-road gear – off-road gear preselected
copyright by
MJF C I F S S
Service Manual
2 HL 100 transmission Positions of the shift lock 70
5.3
Off-road gear (1st gear) preselected with switch S42 (see Fig. 6 on page14)
Input speed
Control oil to connection
Function / shift lock
Function / transmission
Gear pump 71 delivers a specific oil volume
0-800 rpm
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
Oil supply / transmission
71
Lubricating oil pump
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 76
Shifting piston Check valve
S Sp
Suction chamber / pump Shifting pressure
77
Orifice
T
Return / tank
78
to lubricating oil supply
copyright by
MJF C I F S S
11.10.13
2 HL 100 transmission
Service Manual
Positions of the shift lock 70
Fig. 6
11.10.14
Hydraulic diagram and sectional drawing of the transmission during travel in off-road gear
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MJF C I F S S
Service Manual
2 HL 100 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. 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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MJF C I F S S
11.10.15
2 HL 100 transmission
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
2 HL 100 transmission Operation of the machine
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
Switch / travel direction
*
Items of hydraulic unit
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MJF C I F S S
11.10.17
2 HL 100 transmission
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. 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
copyright by
MJF C I F S S
Service Manual
2 HL 100 transmission Maintenance
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.
copyright by
MJF C I F S S
11.10.19
2 HL 100 transmission
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
copyright by
MJF C I F S S
Service Manual
2 HL 100 transmission Maintenance
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
copyright by
MJF C I F S S
11.10.21
2 HL 100 transmission
Service Manual
Dismantling, repair and installation of the gearbox
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
copyright by
MJF C I F S S
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
Universal joint shaft
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
copyright by
MJF C I F S S
11.10.23
2 HL 100 transmission
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
Measuring point / pilot pressure
210
Regulating travel motor
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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MJF C I F S S
Service Manual
2 HL 100 transmission Exploded view of gearbox components
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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MJF C I F S S
11.10.25
2 HL 100 transmission
Service Manual
Exploded view of gearbox components
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
2 HL 100 transmission Exploded view of gearbox components
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
copyright by
MJF C I F S S
11.10.27
2 HL 100 transmission
Service Manual
Exploded view of gearbox components
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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MJF C I F S S
Service Manual
2 HL 100 transmission Exploded view of gearbox components
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
copyright by
MJF C I F S S
11.10.29
2 HL 100 transmission
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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MJF C I F S S
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
2 HL 270 / 290 transmission
copyright by
MJF C I F S S
11.20.1
2 HL 270 / 290 transmission
Service Manual
Technical data
2 Technical data Machine from serial number
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
Max. drive power (*)
110 kW
110 kW
110 kW
Input torque at P max.
650 Nm
650 Nm
650 Nm
Max. input torque (*)
770 Nm
770 Nm
950 Nm
Max. input speed (*)
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
Switching speed (drive shaft / oil motor)
800 ± 100 rpm
800 ± 100 rpm
800 ± 100 rpm
Switching speed (drive shaft / universal joint)
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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MJF C I F S S
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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MJF C I F S S
11.20.3
2 HL 270 / 290 transmission
Service Manual
Design
3.1
Design of transmission
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
Lubricating oil pump
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
Off-road gear Switch S42 operated
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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MJF C I F S S
11.20.5
2 HL 270 / 290 transmission
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
2 HL 270 / 290 transmission Functional description
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
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.
4.7.5
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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MJF C I F S S
11.20.7
2 HL 270 / 290 transmission
Service Manual
Functional description
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
Bleeder / multi-disc brake
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
Shift lock Lubricating oil pump
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
Shuttle check valve Pressure-relief valve
+P
from control oil unit
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
Restrictor check valve
210
Regulating travel motor
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Service Manual
2 HL 270 / 290 transmission Functional description
Fig. 3
Diagram of transmission and shift lock (shifting position = 2nd gear)
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MJF C I F S S
11.20.9
2 HL 270 / 290 transmission
Service Manual
Positions of the shift lock 70
5 Positions of the shift lock 70 5.1
Machine in on-road gear (2nd gear)
Input speed
Control oil to connection
Function / shift lock
Function / transmission
Gear pump 71 delivers a specific oil volume
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
Leakage check valve Shuttle check valve
K K’
to HBGV block from multi-disc clutch
74 75
Pressure-relief valve Shifting piston
Pp S
Pump pressure Suction chamber / pump
76 77
Check valve Orifice
Sp T
Shifting pressure Return / tank
78
Connection of lubricating oil supply
Shift lock Lubricating oil pump
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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MJF C I F S S
Service Manual
2 HL 270 / 290 transmission Positions of the shift lock 70
Fig. 4
Hydraulic diagram and sectional drawing of the transmission during travel in on-road gear at high speed
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MJF C I F S S
11.20.11
2 HL 270 / 290 transmission
Service Manual
Positions of the shift lock 70
5.2
Travel in on-road gear On-road gear (1st gear) preselected with switch S42 Input speed
Control oil to connection
Function / shift lock
Function / transmission
Gear pump 71 delivers a specific oil volume
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
71.2 Suction filter (maintenance-free) 72 Leakage check valve
B B’
to HBGV block to multi-disc brake
73 74
Shuttle check valve Pressure-relief valve
K K’
from HBGV block from multi-disc clutch
75
Shifting piston
Pp
Pump pressure
76 77
Check valve Orifice
S Sp
Suction chamber / pump Shifting pressure
Shift lock Lubricating oil pump
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Service Manual
2 HL 270 / 290 transmission Positions of the shift lock 70
Fig. 5
Hydraulic diagram and sectional drawing of the transmission during travel in on-road gear – off-road gear preselected
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MJF C I F S S
11.20.13
2 HL 270 / 290 transmission
Service Manual
Positions of the shift lock 70
5.3
Off-road gear (1st gear) preselected with switch S42
Input speed
Control oil to connection
0-800 min-1
Function / shift lock
Function / transmission
Gear pump 71 delivers a specific oil volume Pump pressure Pp low Shifting piston 75 in neutral position K
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 B to the tank.
70
11.20.14
Multi-disc brake not pressurised Brake applied
79
Oil supply / transmission
71 Lubricating oil pump 71.2 Suction filter (maintenance-free)
B B’
to HBGV block from multi-disc brake
72
Leakage check valve
K
from HBGV block
73 74
Shuttle check valve Pressure-relief valve
K’ Pp
to multi-disc clutch Pump pressure
75 76
Shifting piston Check valve
S Sp
Suction chamber / pump Shifting pressure
77
Orifice
T
Return / tank
78
to lubricating oil supply
Shift lock
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Service Manual
2 HL 270 / 290 transmission Positions of the shift lock 70
Fig. 6
Hydraulic diagram and sectional drawing of the transmission during travel in off-road gear
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MJF C I F S S
11.20.15
2 HL 270 / 290 transmission
Service Manual
Operation of the machine
6 Operation of the machine Fig. 7
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, 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
Switch / travel direction
H167
Indicator light / forward travel
*
Items of hydraulic unit
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MJF C I F S S
11.20.17
2 HL 270 / 290 transmission
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. 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
Lubrication nipple / emergency activation
4
Bleeder / emergency activation
5
Pressure relief valve / emergency activation
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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MJF C I F S S
11.20.19
2 HL 270 / 290 transmission
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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MJF C I F S S
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
2 HL 270 / 290 transmission
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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MJF C I F S S
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
Universal joint shaft
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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MJF C I F S S
11.20.23
2 HL 270 / 290 transmission
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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MJF C I F S S
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
Universal joint shaft
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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MJF C I F S S
11.20.25
2 HL 270 / 290 transmission
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
Bleeder / emergency activation
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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MJF C I F S S
11.20.27
2 HL 270 / 290 transmission
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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MJF C I F S S
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
Gear pump / pilot control
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
Solenoid valve / parking brake
62 63
Pressure valve Measuring point / opening pressure
Y55
Solenoid / 1st gear
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MJF C I F S S
11.20.29
2 HL 270 / 290 transmission
Service Manual
Component arrangement 1
Hydraulic tank
90
Disc springs / multi-disc clutch
3
Lubrication nipple / emergency activation
91
Piston / multi-disc clutch fixed
4
Bleeder / emergency activation
92
Piston / multi-disc clutch rotating
5
Pressure relief valve / emergency activation
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
Leakage check valve Shuttle check valve
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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MJF C I F S S
11.30.1
HBGV block for 2 HL 70 / 100
Service Manual
Functional description
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
Solenoid valve / parking brake
100
Pressure spring
Y55
Solenoid valve / 1st gear
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MJF C I F S S
11.30.3
HBGV block for 2 HL 70 / 100
Service Manual
Functional description
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
Solenoid valve / 2nd gear
62
Pressure-relief valve
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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MJF C I F S S
11.32.1
HBGV block for 2 HL 270 / 290
Service Manual
Functional description
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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MJF C I F S S
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
Pressure-relief valve
Y60
Solenoid valve / 2nd gear
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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MJF C I F S S
11.32.3
HBGV block for 2 HL 270 / 290
Service Manual
Functional description
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
Pressure-relief valve
Y55
Solenoid valve / 1st gear
64 66
Piston / pressure-relief valve Pressure spring
Y60
Solenoid valve / 2nd gear
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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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MJF C I F S S
11.32.5
HBGV block for 2 HL 270 / 290
Service Manual
Pressure-relief valve 62
11.32.6
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MJF C I F S S
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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MJF C I F S S
11.60.1
Travel gear F40
Service Manual
General information
2 General information Equipment from serial number
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
min. (normal travel)
15.5 min-1
Max. output torque
40,000 Nm
Max. brake torque
420 Nm
Gear ratio
1: 110.38
Weight (approx.)
228 kg
Oil volume in gearbox
4.5 l
Oil quality
API - GL - 5
Oil viscosity
SAE 90 W SAE 80 W 90 SAE 90 LS
Brake
Hydraulically released multi-disc brake
Min. brake release pressure
18 bar
Min. brake release pressure
33 bar
Settings and tightening torques, to be observed for installation: A)
Tightening torque for hex head screws 5
195 Nm
B)
Tightening torque for hex head screws 7
620 Nm
C)
Tightening torque for hex head screws 8
300 Nm
D)
Tightening torque for hex head screws 11
300 Nm
E)
Tightening torque for nut 260
9000 Nm
F)
Tightening torque of Allen head screws 800
G)
Tightening torque of Allen head screws 840
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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MJF C I F S S
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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MJF C I F S S
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
Hex head screw Cover
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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MJF C I F S S
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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MJF C I F S S
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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MJF C I F S S
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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MJF C I F S S
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
Tapered roller bearing
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
O-ring Allen head screw
80
Pinion
810
O-ring
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MJF C I F S S
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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MJF C I F S S
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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MJF C I F S S
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.
copyright by
MJF C I F S S
11.60.11
Travel gear F40
Service Manual
Sectional view of the travel brake
11.60.12
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MJF C I F S S
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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MJF C I F S S
11.62.1
FAT 350 travel gear system
Service Manual
Technical data
2 Technical data Machine from serial number
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
min. (normal travel)
15.5 rpm
Max. output torque
35,000 Nm
Max. brake torque
420 Nm
Gear ratio
1: 113
Weight (approx.)
180 kg
Oil volume in gearbox
4.1 l
Oil quality
API - GL - 5
Oil viscosity
SAE 90 W SAE 80 W 90 SAE 90 LS
Brake
Hydraulically released multi-disc brake
Min. brake release pressure
18 bar
Min. brake release pressure
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)
Tightening torque for hex head screws 104
560 Nm
H)
Tightening torque for hex head screws 106
280 Nm
I)
Tightening torque for hex head screws 107
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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MJF C I F S S
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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MJF C I F S S
11.62.3
FAT 350 travel gear system
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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MJF C I F S S
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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MJF C I F S S
11.62.5
FAT 350 travel gear system
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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MJF C I F S S
11.62.7
FAT 350 travel gear system
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
Inner disc Outer disc
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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MJF C I F S S
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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MJF C I F S S
11.62.9
FAT 350 travel gear system
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
Travel motor, left Travel motor, right
100 160
Compact control block Spool / chassis right
205 215
Brake valve Travel brake
180
Spool / chassis left
216
Travel gear
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MJF C I F S S
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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MJF C I F S S
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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MJF C I F S S
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
Secondary pressure-relief valve Secondary pressure-relief valve
180 195
from / to spool travel left Rotary connection 5 x
214 215
Secondary pressure-relief valve Travel brake
196
Rotary connection 1 x
216
Travel gear
200 201
Travel motor, left Travel motor, right
Y24
from solenoid valve / fast travel
202
Adjusting device
203
Shifting piston, oil motor adjustment
Bre
Connection for brake control pressure/release pressure
205 206
Brake valve Shuttle valve
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
Secondary pressure-relief valve
X
Connection for control pressure/fast travel
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MJF C I F S S
Service Manual
Travel brake Function of the brake system
Fig. 3
Travel motors with brake valve and travel brake in travel gearbox
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MJF C I F S S
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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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 7.28 hydraulic components).
Fig. 1 82 100
Components of the hydraulic system and brake 200 201
Travel pilot control unit Compact control block
Travel motor, left Travel motor, right
160
Spool / chassis right
205
Travel brake valve
180
Spool / chassis left
215
Travel brake
216
Travel gear
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MJF C I F S S
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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MJF C I F S S
Service Manual
Travel brake Function of the brake system
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
Function of the brake system
11.67.4
1 160
to hydraulic tank from / to spool travel right
212 213
Secondary pressure-relief valve Secondary pressure-relief valve
180 195
from / to spool travel left Rotary connection 5 x
214 215
Secondary pressure-relief valve Travel brake
196
Rotary connection 1 x
216
Travel gear
200 201
Travel motor, left Travel motor, right
Y24
from solenoid valve / fast travel
202
Adjusting device
203
Shifting piston, oil motor adjustment
Bre
Connection for brake control pressure/release pressure
205 206
Brake valve Shuttle valve
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
Secondary pressure-relief valve
X
Connection for control pressure/fast travel
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MJF C I F S S
Service Manual
Travel brake Function of the brake system
Fig. 3
Travel motors with brake valve and travel brake in travel gearbox
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MJF C I F S S
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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MJF C I F S S
Service Manual
SUBGROUP - INDEX Section
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
AP - B 755 rigid axle with drum brake
12.37.1
A 316 LI 2001-28060
Differential for AP / APL - B 755 axles
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
A 309 LI 20221A 311 LI 20222A 312 LI 12363A 314 LI 2001A 316 LI 2001A 316 LI-IND 2001-
Chassis / drive
12.60.1
R 313 LI 27752R 317 LI 18161-
Technical data / tightening torques
12.62.1
R 313 LI 27752-
Technical data / tightening torques
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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MJF C I F S S
12.02.1
Steering axle 212 with multi-disc brake
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
Torque for the hex head screws 302
15 Nm
E
Torque for the hex head screw 304
283 Nm
F
Torque for the hex head screws 314
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
Technical data, settings and tightening torques
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MJF C I F S S
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.
copyright by
MJF C I F S S
12.02.3
Steering axle 212 with multi-disc brake
Service Manual
Description of functions
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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MJF C I F S S
Service Manual
Steering axle 212 with multi-disc brake Maintenance of the axle
Fig. 2
Inspection of brake discs for wear
copyright by
MJF C I F S S
12.02.5
Steering axle 212 with multi-disc brake
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
copyright by
MJF C I F S S
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
Universal joint shaft
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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MJF C I F S S
12.02.7
Steering axle 212 with multi-disc brake
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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MJF C I F S S
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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MJF C I F S S
12.02.9
Steering axle 212 with multi-disc brake
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
Intermediate bushing
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
Conical lubrication nipple
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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MJF C I F S S
12.02.11
Steering axle 212 with multi-disc brake
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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MJF C I F S S
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.
copyright by
MJF C I F S S
12.02.13
Steering axle 212 with multi-disc brake
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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MJF C I F S S
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
copyright by
MJF C I F S S
12.03.1
Rigid axle 112 with multi-disc brake
Service Manual
Function
12.03.2
copyright by
MJF C I F S S
Service Manual
Rigid axle 112 with multi-disc brake General information
2 General information Equipment Unit model Serial number
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
Wet multi-disc brake
Oil volume in axle Differential and axle shaft Planetary drive (filling level at the check screws is binding)
8.0 l 2.1 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 wheel bearing 311
B
Torque for the hex head screw 303
283 Nm
C
Torque for the wheel lugs 319
460 Nm
D
Torque for the countersunk screws 322
50 Nm
E
Torque for the nuts 324
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
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.
copyright by
MJF C I F S S
12.03.3
Rigid axle 112 with multi-disc brake
Service Manual
Functional description
3 Functional description 3.1
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
copyright by
MJF C I F S S
12.03.5
Rigid axle 112 with multi-disc brake
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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MJF C I F S S
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
Universal joint shaft
332
Washer
615
Hex nut
600 602
Undercarriage Steering axle
620 622
Hex head screw Washer
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.
copyright by
MJF C I F S S
12.03.7
Rigid axle 112 with multi-disc brake
Service Manual
Dismantling, repair and installation of the rigid axle
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
Screw plug Sealing ring
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
Crown gear Hollow gear carrier
30 31
Repair kit for planetary housing Washer (centring ring)
15
Locking plate
32
Washer (lock washer)
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MJF C I F S S
12.03.9
Rigid axle 112 with multi-disc brake
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
Tapered roller bearing
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
Washer (lock washer)
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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MJF C I F S S
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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MJF C I F S S
12.03.11
Rigid axle 112 with multi-disc brake
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
Anti-extrusion ring O-ring
3
Spring
10
Counter disc
4 5
Piston Spring
11 12
Bleeder screw Plug
6 7
Anti-extrusion ring O-ring
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
Anti-extrusion ring O-ring
304
Screw plug
410
Counter disc
305
Screw plug
411
Bleeder screw
327
Axle shaft
412 413
Plug Pin
copyright by
MJF C I F S S
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.
copyright by
MJF C I F S S
12.03.13
Rigid axle 112 with multi-disc brake
Service Manual
Brake of the rigid axle
12.03.14
copyright by
MJF C I F S S
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
copyright by
MJF C I F S S
12.05.1
Differential for the axles 112 / 212 / 162 / 262 Function
12.05.2
copyright by
MJF C I F S S
Service Manual
Service Manual
Differential for the axles 112 / 212 / 162 / 262 General information
2 General information Equipment Unit model Serial number
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
Torque for the hex head screws 208
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
Technical data, settings and tightening torques
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
copyright by
MJF C I F S S
12.05.3
Differential for the axles 112 / 212 / 162 / 262
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
Tapered roller bearing Shaft nut
6 7
O-ring Plug
6 7
Allen head screw Allen head screw
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
Conical lubrication nipple
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
copyright by
MJF C I F S S
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)
copyright by
MJF C I F S S
12.05.5
Differential for the axles 112 / 212 / 162 / 262
Service Manual
Differential of the steering axle
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
Sealing ring Protective plate
204 205
Tapered roller bearing Shaft nut
222 223
Flange Nut
206 207
Allen head screw Allen head screw
224 314
Snap ring Axle shaft
208
Hex head screw
334
Axle shaft
209 210
Thrust washer Differential gear shaft wheel
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
copyright by
MJF C I F S S
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
copyright by
MJF C I F S S
12.05.7
Differential for the axles 112 / 212 / 162 / 262
Service Manual
Differential of the steering axle
12.05.8
Assembly 10 1 O-ring
Assembly 20 1 Tapered roller bearing
2 3
Intermediate cover Housing
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
Tapered roller bearing
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
Sealing ring Protective plate
22 23
Cover Spacer ring
24
O-ring
25 26
Shaft nut Allen head screw
27 28
Flange Repair kit for differential
copyright by
MJF C I F S S
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)
copyright by
MJF C I F S S
12.05.9
Differential for the axles 112 / 212 / 162 / 262
Service Manual
Differential of the rigid axle
101
O-ring
212
Bevel gear with crown wheel kit
102 103
Intermediate cover Housing
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
Sealing ring Protective plate
203
Axle shaft wheel
222
Cover
204 205
Pin Snap ring
223 224
Spacer ring O-ring
206 207
Snap ring Thrust washer
225 226
Shaft nut Allen head screw
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
copyright by
MJF C I F S S
Service Manual
Differential for the axles 112 / 212 / 162 / 262 Differential of the rigid axle
Fig. 5
Sectional drawing
copyright by
MJF C I F S S
12.05.11
Differential for the axles 112 / 212 / 162 / 262 Differential of the rigid axle
12.05.12
copyright by
MJF C I F S S
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
copyright by
MJF C I F S S
12.10.1
Steering axle 262 LD with multi-disc brake
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
Planetary steering axle
Total gear ratio Standard Speeder
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 2.0 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 327 / 328
30 - 60 Nm
B
Friction torque of the wheel bearing 343
10 - 30 Nm
C
Torque for the hex head screws 302
D
Torque for the hex nuts 303
E
Torque for the hex head screws 304
283 Nm
F
Torque for the hex head screws 318
140 Nm
20 Nm 60 - 70 Nm
G
Torque for the nuts 331
H
Setting value B for the stop screw 332 at the joint housing 327/ 328see also group 'Steering'.
I
Torque for the wheel lugs 345
K
Torque for the nuts 347
L
Torque for the countersunk screws 349
M
Torque for the nuts 356
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
Torque for the hex head screws 419
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
Technical data, settings and tightening torques 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.
copyright by
MJF C I F S S
12.10.3
Steering axle 262 LD with multi-disc brake
Service Manual
Functional description
3 Functional description 3.1
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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MJF C I F S S
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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MJF C I F S S
12.10.5
Steering axle 262 LD with multi-disc brake
Service Manual
Dismantling, repair and installation of the steering axle
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.
5 Dismantling, repair and installation of the steering axle 5.1
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
copyright by
MJF C I F S S
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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MJF C I F S S
12.10.7
Steering axle 262 LD with multi-disc brake
Service Manual
Output end of the steering axle 345
Wheel lug
608
Hex head screw
354
Centring ring
610
Universal joint shaft
601
Intermediate bushing
611
Hex nut
602 603
Thrust bushing Bracket
620 621
Undercarriage Steering axle
604
Conical lubrication nipple
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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MJF C I F S S
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
Conical lubrication nipple
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
copyright by
MJF C I F S S
12.10.9
Steering axle 262 LD with multi-disc brake
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
Working brake (assembly 40)
Spring
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MJF C I F S S
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.
copyright by
MJF C I F S S
12.10.11
Steering axle 262 LD with multi-disc brake
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
Tapered roller bearing
310 311
Snap ring 40 Deep groove ball bearing
344 345
Wheel stud Wheel lug
312
Sealing ring
346
Stud
313
Intermediate bushing
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
Spring Adjusting screw
330 331
Lower steering knuckle bolt Nut
413 414
Spring Adjusting screw
332
Adjusting screw
415
Counter disc
333 334
Bearing Planetary gear
416 417
Brake disc Cover
335 336
Snap ring Locking plate
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
copyright by
MJF C I F S S
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
copyright by
MJF C I F S S
12.10.13
Steering axle 262 LD with multi-disc brake
Service Manual
Steering cylinder of the steering axle
12.10.14
copyright by
MJF C I F S S
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
copyright by
MJF C I F S S
12.11.1
Rigid axle 162LD with multi-disc brake
Service Manual
Function
12.11.2
copyright by
MJF C I F S S
Service Manual
Rigid axle 162LD with multi-disc brake General information
2 General information Equipment Unit model Serial number
A 311-Li 718 20222
Axle type
162 / 056
Design
Planetary rigid axle
Total gear ratio Standard Speeder
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)
8.0 l 2.1 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 wheel bearing 324
B
Torque for the hex head screws 302
283 Nm
C
Torque for the wheel lugs 308
460 Nm
D
Torque for the countersunk screws 319
E
Torque for the nuts 322
F
Torque for the nuts 329
200 Nm
G
Torque for the hex head screws 415
9 - 10 Nm
H
Torque for the readjusting screws 418
5 - 7 Nm
I
Torque for the readjusting screws 420
10 - 15 Nm
K
Torque for the hex head screws 425
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
Technical data, settings and tightening torques 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.
copyright by
MJF C I F S S
12.11.3
Rigid axle 162LD with multi-disc brake
Service Manual
Functional description
3 Functional description 3.1
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
copyright by
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
Tapered roller bearing
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
copyright by
MJF C I F S S
12.11.5
Rigid axle 162LD with multi-disc brake
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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MJF C I F S S
Service Manual
Rigid axle 162LD with multi-disc brake 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. 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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MJF C I F S S
12.11.7
Rigid axle 162LD with multi-disc brake
Service Manual
Dismantling, repair and installation of the rigid axle
Fig. 4
12.11.8
Dismantling and installation of the rigid axle
308
Wheel lug
611
Universal joint shaft
332
Lock washer
615
Hex nut
600 602
Undercarriage Steering axle
620 622
Hex head screw Washer
603 604
Vehicle wheels Rigid axle
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
Axle shaft Hex head screw
18 19
Plug Countersunk screw
3 4
Washer Screw plug
20 21
Planetary housing Thrust washer
5
Screw plug
22
Wheel lug
6
Sealing ring
23
Stud
7
Wheel stud
24
Tapered roller bearing
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
Rigid axle 162LD with multi-disc brake
Service Manual
Brake of the rigid axle
7 Brake of the rigid axle
Fig. 6
12.11.10
Working brake (assembly 40)
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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MJF C I F S S
Service Manual
Rigid axle 162LD with multi-disc brake Brake of the rigid axle
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MJF C I F S S
12.11.11
Rigid axle 162LD with multi-disc brake
Service Manual
Brake of the rigid axle
102 103
Intermediate cover Differential housing
329 330
Hex nut Sealing ring
301 302
Axle shaft Hex head screw
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
Crown gear Hollow gear carrier
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
Planetary housing Thrust washer
417 418
Spring Adjusting screw
322 323
Nut Stud
419 420
Spring Adjusting screw
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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MJF C I F S S
12.11.13
Rigid axle 162LD with multi-disc brake
Service Manual
Brake of the rigid axle
12.11.14
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MJF C I F S S
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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MJF C I F S S
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
Planetary steering axle
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
Settings and tightening torques to be observed for installation: A
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
Tyre pressure The tyre pressure depends on the tyre size, tyre ply rating and brand. For details, see overview of tyres in group 12.54.
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12.20.3
Steering axle
Service Manual
Functional description
3 Functional description 3.1
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
Universal joint shaft
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
Intermediate bushing O-ring
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
2 Technical data Series Machine Machine model Serial number
Litronic A 312 719 12363
Axle type
162/55
Design
Planetary rigid axle
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
Tyre pressure The tyre pressure depends on the tyre size, tyre ply rating and brand. For details, see overview of tyres in group 12.54.
12.21.2
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MJF C I F S S
Service Manual
Rigid axle Functional description
3 Functional description 3.1
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
Maintenance of the axle
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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
copyright by
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
Hex nut Hex head screw
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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MJF C I F S S
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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MJF C I F S S
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
Intermediate bushing O-ring
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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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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Service Manual
Rigid axle Sectional drawing of the rigid axle
9 Sectional drawing of the rigid axle
Fig. 6
Rigid axle with multi-disc brake
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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
Intermediate bushing O-ring
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
Axle shaft Hex head screw
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
Differential for 162 / 262 axles
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
Torque for the hex head screws 208
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
Technical data, settings and tightening torques
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
Differential for 162 / 262 axles
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
Snap ring Thrust washer
3 4
Support bracket Conical lubrication nipple
14 15
Balancing shaft gear Differential housing
5
Plug
16
Tapered roller bearing
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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MJF C I F S S
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
Differential for 162 / 262 axles
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
Intermediate cover Housing
212 213
Snap ring Thrust washer
104
Lid
214
Balancing shaft gear
105
Bleeder
215
Differential housing
106
Seal ring
216
Tapered roller bearing
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
Tapered roller bearing Shaft nut
222 223
Flange Nut
206 207
Allen head screw Allen head screw
224 314
Snap ring Axle shaft
208
Hex head screw
334
Axle shaft
209 210
Thrust washer Differential gear shaft wheel
349
Screw plug
Note! Observe settings and torques A, B, C, D, E, F, H, I and Table 1, page 3.
12.23.6
copyright by
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
Differential for 162 / 262 axles
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
Differential housing
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
Balancing shaft gear
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
copyright by
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)
copyright by
MJF C I F S S
12.23.9
Differential for 162 / 262 axles
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
Bevel gear with crown wheel kit
102
Intermediate cover
213
Tapered roller bearing
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
Tapered roller bearing
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
Snap ring Thrust washer
225 226
Shaft nut Allen head screw
208
Balancing shaft gear
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
Sectional drawing of the differential of the rigid axle
copyright by
MJF C I F S S
12.23.11
Differential for 162 / 262 axles
Service Manual
Sectional drawing of the differential of the rigid axle
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
APL - B 745 steering axle with multi-disc brake Function
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
2 Technical data Machine Machine model Serial number
A 314 Litronic 635 2001
Axle type
A 314 Litronic 635 11308
APL - B 745
Design
Planetary steering axle
Gear ratio Standard Speeder
17,52 17,52
Brake
16,62 16,62
Wet multi-disc brake
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
Torque for the hex head screws 41
280 Nm
G
Torque for the hex head screws 82
11 Nm
H
Torque for the Allen head screws 103
32 Nm
I
Torque for the wheel lugs 107
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
Tyre pressure The tyre pressure depends on the tyre size, tyre ply rating and brand. For details, see overview of tyres in group 12.54.
copyright by
MJF C I F S S
12.28.3
APL - B 745 steering axle with multi-disc brake
Service Manual
Functional description
3 Functional description 3.1
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
5 Dismantling, repair and installation of the steering axle 5.1
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 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.
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MJF C I F S S
12.28.5
APL - B 745 steering axle with multi-disc brake
Service Manual
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 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
6 Exploded view of the steering axle
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
Screw plug Screw plug
.620 .630
Clamp Slotted nut
.260
O-ring
.640
Cotter pin
copyright by
MJF C I F S S
12.28.7
APL - B 745 steering axle with multi-disc brake
Service Manual
Exploded view of the steering axle
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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Service Manual
APL - B 745 steering axle with multi-disc brake Exploded view of the steering axle
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
Lip seal Backing ring
.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
copyright by
MJF C I F S S
12.28.9
APL - B 745 steering axle with multi-disc brake
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
Radial shaft seal ring
78
19258
Spring sleeve
10
18160
Radial shaft seal ring
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
Radial shaft seal ring
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
7 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
APL - B 745 steering axle with multi-disc brake Sectional drawing of steering axle
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
AP - B 755 rigid axle with drum brake
copyright by
MJF C I F S S
12.29.1
AP - B 745 rigid axle with drum brake
Service Manual
Technical data
2 Technical data Machine Machine model Serial number
A 314 Li 635 2001
Axle type
A 314 Li 635 11308
AP-B 745
Design
Planetary rigid axle
Gear ratio Standard Speeder
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
Torque for the hex head screw 3
560 Nm
D
Torque for the hex head screws 19
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
Torque for the Allen head screws 103
33 Nm
I
Torque for the wheel lugs 107
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
Tyre pressure The tyre pressure depends on the tyre size, tyre ply rating and brand. For details, see overview of tyres in group 12.54.
12.29.2
copyright by
MJF C I F S S
Service Manual
AP - B 745 rigid axle with drum brake Functional description
3 Functional description 3.1
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.
5 Dismantling, repair and installation of the rigid axle 5.1
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
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MJF C I F S S
12.29.3
AP - B 745 rigid axle with drum brake
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
Undercarriage with axles
1
Vehicle wheels
6
Steering axle
2 3
Rigid axle Hex nut
7 8
Hex nut Hex head screw
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
6 Exploded view of the rigid axle
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
AP - B 745 rigid axle with drum brake
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
AP - B 745 rigid axle with drum brake Exploded view of the rigid axle
Fig. 5
Hub carrier and output of the wheel bearings or the planetary gear, group 19
10
Radial shaft seal ring
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
AP - B 745 rigid axle with drum brake
Service Manual
Exploded view of the rigid axle
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
Radial shaft seal ring
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
7 Sectional drawing of the rigid axle
Fig. 6
Sectional drawing of rigid sleeve
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12.29.9
AP - B 745 rigid axle with drum brake
Service Manual
Sectional drawing of the rigid axle
12.29.10
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MJF C I F S S
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
AP - B 745 rigid axle
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MJF C I F S S
12.30.1
AP - B 745 rigid axle
Service Manual
Technical data
2 Technical data Series Machine Machine model Serial number
Litronic A 314 635 2001
Axle type
Litronic A 314 635 11308
AP-B 745
Design
Planetary rigid axle
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
Oil quality/viscosity
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
Tyre pressure The tyre pressure depends on the tyre size, tyre ply rating and brand. For details, see overview of tyres in group 12.54.
12.30.2
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Service Manual
AP - B 745 rigid axle Functional description
3 Functional description 3.1
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
Maintenance of the axle
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12.30.3
AP - B 745 rigid axle
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
Universal joint shaft
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
AP - B 745 rigid axle
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
AP - B 745 rigid axle
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
AP - B 745 rigid axle
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
Rigid axle with multi-disc brake
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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
Radial shaft seal ring
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
AP - B 745 rigid axle
Service Manual
Output
12.30.12
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MJF C I F S S
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
Differential for AP / APL - B 745 axles
Service Manual
Technical data
2 Technical data Machine Machine model Serial number
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
Torque for the hex nut 11
430 Nm
F
Torque for the hex head screws 6 and the fit bolt 7
410 Nm
G Tightening torque for the Allen head screws 22
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
Tapered roller bearing
310
Locking plate
190
Radial shaft seal ring
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12.31.3
Differential for AP / APL - B 745 axles
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
Differential for AP / APL - B 745 axles
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
Tapered roller bearing
1.2
17030
Axle housing II
17
16110
Ring
2.1
17050
Washer
18
16050
Adjusting disc
2.2
17050
Washer
19
16080
Tapered roller bearing
3
17090
Tapered roller bearing
20.1
16010
Bevel pinion
4
17100
Tapered roller bearing
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
Radial shaft seal ring
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
Sectional drawing of the differential
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12.31.7
Differential for AP / APL - B 745 axles
Service Manual
Sectional drawing of the differential
12.31.8
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MJF C I F S S
Service Manual
APL - B 755 steering axle with multi-disc brake Function
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
APL - B 755 steering axle
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12.36.1
APL - B 755 steering axle with multi-disc brake Function
12.36.2
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Service Manual
Service Manual
APL - B 755 steering axle with multi-disc brake Technical data
2 Technical data Machine Machine model Serial number
A 316 Litronic 715 2001
Axle type
APL - B 755
Design
Planetary steering axle
Gear ratio Standard Speeder
17.52 17.52
Brake
Wet multi-disc brake
Oil volume in axle Axle housing Planetary drive (filling level at the check screws is binding) Oil quality/viscosity
9.0 l 2.0 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
3.1 - 3.5 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
Torque for the hex head screws 41
280 Nm
G
Torque for the hex head screws 82
11 Nm
H
Torque for the Allen head screws 103
55 Nm
I
Torque for the wheel lugs 107
420 Nm
Tightening torque of the slotted nut / tie rods, see steering
300 Nm
K
1400 + 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
150 bar 3 bar 1 - 5 bar
Items A - K ((see Fig. 7 on page11)) Tab. 1
2.0.1
Technical data
Tyre pressure The tyre pressure depends on the tyre size, tyre ply rating and brand. For details, see overview of tyres in group 12.54.
copyright by
MJF C I F S S
12.36.3
APL - B 755 steering axle with multi-disc brake
Service Manual
Functional description
3 Functional description 3.1
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).
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 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
copyright by
MJF C I F S S
Service Manual
APL - B 755 steering axle with multi-disc brake Dismantling, repair and installation of the steering axle to the piston stroke.
Note! Limit value for piston stroke with wear = 5.2 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
5 Dismantling, repair and installation of the steering axle 5.1
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 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
12.36.5
APL - B 755 steering axle with multi-disc brake
Service Manual
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 APL-B 755 ZP axles".
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
Undercarriage with axles
1
Vehicle wheels
8
Pin
2 3
Hex head screw Joint shaft
9 10
Spacer Lubrication nipple
4 5
Steering axle Undercarriage
11 12
Lock nut Rigid axle
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MJF C I F S S
Service Manual
APL - B 755 steering axle with multi-disc brake Exploded view of the steering axle
6 7
13 14
Hex head screw Plate
Washer Retaining washer
6 Exploded view of the steering axle
Fig. 4
Steering axle (assembly 17)
.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
Radial shaft seal ring
.100 .120
Roller bearing O-ring
.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
Screw plug Screw plug
.630 .640
Slotted nut Cotter pin
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MJF C I F S S
12.36.7
APL - B 755 steering axle with multi-disc brake
Service Manual
Exploded view of the steering axle
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
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Service Manual
APL - B 755 steering axle with multi-disc brake Exploded view of the steering axle
Fig. 6
Output (assembly 19)
.10
Radial shaft seal ring
.290
End washer
.30 .40
Roller bearing Ring (S = 14.0 - 15.2 mm)
.300 .320
Snap ring Thrust washer
.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
Allen head screw Wheel stud
.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
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MJF C I F S S
12.36.9
APL - B 755 steering axle with multi-disc brake
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
Radial shaft seal ring
78
19258
Spring sleeve
10
18160
Radial shaft seal ring
79
19240
Hex head screw
20
18170
Double joint drive shaft
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
Radial shaft seal ring
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
Note! Observe settings and torques A, B, C, D, E, F, G, H, I, K, see Fig. 7 and Table 1, page 3.
12.36.10
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MJF C I F S S
Service Manual
APL - B 755 steering axle with multi-disc brake Sectional drawing of steering axle
7 Sectional drawing of steering axle
Fig. 7
Sectional drawing of steering axle
copyright by
MJF C I F S S
12.36.11
APL - B 755 steering axle with multi-disc brake Sectional drawing of steering axle
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
AP - B 755 rigid axle with drum brake
2 Technical data Machine Machine model Serial number
A 316 Li: 715 2001
Axle type
AP-B 755 TR
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12.37.1
AP - B 755 rigid axle with drum brake
Service Manual
Technical data Machine Machine model Serial number
A 316 Li: 715 2001
Design
Planetary rigid axle
Gear ratio Standard Speeder
17,52 17,52
Brake
Drum brake
Oil volume in axle Axle housing Planetary drive (filling level at the check screws is binding)
9.0 l 1.0 l per side
Oil quality/viscosity
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
B
Rolling resistance of the wheel bearing 61 / 64 (new) (without sealing element)
C
Torque for the hex head screw 3
560 Nm
D
Torque for the hex head screws 19
79 Nm
E
Torque for the Allen head screws 27/28
F
Torque for the hex nut 31
G
Torque for the self locking screw 87
69 Nm
H
Torque for the Allen head screws 103
33 Nm
I
Torque for the wheel lugs 107
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
Tyre pressure The tyre pressure depends on the tyre size, tyre ply rating and brand. For details, see overview of tyres in group 12.54.
12.37.2
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MJF C I F S S
Service Manual
AP - B 755 rigid axle with drum brake Functional description
3 Functional description 3.1
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.
5 Dismantling, repair and installation of the rigid axle 5.1
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.
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MJF C I F S S
12.37.3
AP - B 755 rigid axle with drum brake
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
Undercarriage with axles
1 2
Vehicle wheels Rigid axle
6 7
Steering axle Hex nut
3 4
Hex nut Hex head screw
8 9
Hex head screw Undercarriage
5
Universal joint shaft
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Service Manual
AP - B 755 rigid axle with drum brake Exploded view of the rigid axle
6 Exploded view of the rigid axle Fig. 3
Axle housing, group 17
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
AP - B 755 rigid axle with drum brake
Service Manual
Exploded view of the rigid axle
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
AP - B 755 rigid axle with drum brake Exploded view of the rigid axle
Fig. 5
Hub carrier and output of the wheel bearings or the planetary gear, group 19
10 30
Radial shaft seal ring Roller bearing
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
Wheel stud Lock washer
340
Sun gear shaft
560
Centring ring
390 400
Planetary carrier Planetary gear
570
Wheel lug
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MJF C I F S S
12.37.7
AP - B 755 rigid axle with drum brake
Service Manual
Exploded view of the rigid axle
Item
ZP figure no.
Designation
Item
Group 17 1
ZP figure no.
Designation
Group 19
17010
Axle housing part I
60
10
Radial shaft seal ring
17030
Axle housing part II
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
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MJF C I F S S
Service Manual
AP - B 755 rigid axle with drum brake Sectional drawing of the rigid axle
7 Sectional drawing of the rigid axle
Fig. 6
Sectional drawing of rigid sleeve
copyright by
MJF C I F S S
12.37.9
AP - B 755 rigid axle with drum brake
Service Manual
Sectional drawing of the rigid axle
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
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12.39.1
Differential for AP / APL - B 755 axles
Service Manual
Technical data
2 Technical data Machine Machine model Serial number
A 316 Litronic 715 / 716 2001
Axle type
BK
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 20 B Tooth backlash of the crown wheel kit 20
(etched onto the end side of the pinion 20.1) 0.15 - 0.2 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
Torque for the hex nut 11
550 Nm
F
Torque for the hex head screws 6 and the fit bolt 7
390 Nm
G Tightening torque for the Allen head screws 22
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 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
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 = 0.7 - 1.5 mm)
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
Tapered roller bearing
310
Locking plate
190
Radial shaft seal ring
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MJF C I F S S
12.39.3
Differential for AP / APL - B 755 axles
Service Manual
Exploded view of the differential
Fig. 3
12.39.4
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 755 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
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
O-ring Hex head screw
.350 .690
Seal ring Bearing bushing
.140
Washer
.700
Seal ring
.150
Fit bolt
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MJF C I F S S
12.39.5
Differential for AP / APL - B 755 axles
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
16170
Tapered roller bearing
1.2
17030
Axle housing II
17
16110
Bushing
2.1
17050
Washer
18
16050
Adjusting disc
2.2
17050
Washer
19
16070
Tapered roller bearing
3
17090
Tapered roller bearing
20.1
16010
Bevel pinion
4
17100
Tapered roller bearing
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
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
Radial shaft seal ring
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.
12.39.6
copyright by
MJF C I F S S
Service Manual
Differential for AP / APL - B 755 axles Sectional drawing of the differential
Fig. 5
Sectional drawing of the differential
copyright by
MJF C I F S S
12.39.7
Differential for AP / APL - B 755 axles
Service Manual
Sectional drawing of the differential
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
APL - B 755 steering axle
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
2 Technical data Machine Machine model Serial number
A 316 Litronic Industry 716 2001
Axle type
APL-B 755 HD
Design
Planetary steering axle
Gear ratio Standard Speeder
17.72 -
Brake
Wet multi-disc brake
Oil volume in axle Axle housing Planetary drive (filling level at the check screws is binding) Oil quality/viscosity
9.0 l 2.0 l per side API - GL 5 / SAE 90 LS
Settings to be observed for installation: A
End play of the double joint shaft 20 with sun gear shaft 91
B
Clearance of the disc pack 83 / 84 (piston stroke) new at max. wear
2.4 - 2.8 mm 4.5 mm
C
Rolling resistance of the joint housing bearing 35
40 - 50 Nm
D
Rolling resistance of the wheel bearing 61 (new) (without sealing elements)
10 - 15 Nm
E
Torque for the slotted nut 32
F
Torque for the hex head screws 41
410 Nm
G
Torque for the hex head screws 82
11 Nm
0.4 - 0.6 mm
1200 - 1400 Nm
H
Torque for the Allen head screws 88
120 Nm
I
Torque for the Allen head screws 103
86 Nm
K
Torque for the wheel lugs 107
570 Nm
Tightening torque of the slotted nut / tie rods, see steering cylinder, group 16.34 L
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
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
Tyre pressure The tyre pressure depends on the tyre size, tyre ply rating and brand. For details, see overview of tyres in group 12.54.
copyright by
MJF C I F S S
12.41.3
APL - B 755 HD steering axle with multi-disc brake
Service Manual
Functional description
3 Functional description 3.1
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).
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 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
copyright by
MJF C I F S S
Service Manual
APL - B 755 HD steering axle with multi-disc brake Dismantling, repair and installation of the steering axle to the piston stroke.
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
A = screw plug M 16; B = measuring screw M 16
5 Dismantling, repair and installation of the steering axle 5.1
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 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.
copyright by
MJF C I F S S
12.41.5
APL - B 755 HD steering axle with multi-disc brake
Service Manual
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 APL-B 755 ZP axles".
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
Undercarriage with axles
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
copyright by
MJF C I F S S
Service Manual
APL - B 755 HD steering axle with multi-disc brake Exploded view of the rigid axle
6 7
13 14
Hex head screw Plate
Washer Retaining washer
6 Exploded view of the rigid axle
Fig. 4
Steering axle (assembly 17)
.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
Radial shaft seal ring
.100
Roller bearing
.600
Axial joint
.120 .130
O-ring Hex head screw
.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
APL - B 755 HD steering axle with multi-disc brake
Service Manual
Exploded view of the rigid axle
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
APL - B 755 HD steering axle with multi-disc brake Exploded view of the rigid axle
Fig. 6
Output (assembly 19)
.10
Radial shaft seal ring
.290
End washer
.30 .40
Roller bearing Ring (S = 26.0 - 27.0 mm)
.300 .310
Snap ring Locking plate
.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)
copyright by
MJF C I F S S
12.41.9
APL - B 755 HD steering axle with multi-disc brake
Service Manual
Exploded view of the rigid axle .246 .248
Hex head screw Lock nut
.510 .540
Allen head screw Wheel stud
.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
Radial shaft seal ring
80
19244
Circlip
10
18160
Radial shaft seal ring
81
19246
Hex head screw
11
18150
Bushing
82
19248
Lock nut
20
18170
Double joint drive shaft
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
Separate slotted nut
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
Radial shaft seal ring
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
copyright by
MJF C I F S S
Service Manual
APL - B 755 HD steering axle with multi-disc brake Exploded view of the rigid axle
Note! Observe settings and torques A, B, C, D, E, F, G, H, I, K, see Fig. 7 and Table 1, page 3.
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
7 Sectional drawing of steering axle
Fig. 7
12.41.12
Sectional drawing of steering axle
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
AP - B 755 rigid axle with multi-disc brake
copyright by
MJF C I F S S
12.42.1
AP - B 755 rigid axle with multi-disc brake
Service Manual
Technical data
2 Technical data Machine Machine model Serial number
A 316 Li: 716 2001
Axle type
AP-B 755 HD
Design
Planetary rigid axle
Gear ratio Standard Speeder
17.72 -
Brake
Multi-disc brake
Oil volume in axle Axle housing Planetary drive (filling level at the check screws is binding) Oil quality/viscosity
10.0 l 2.0 l per side API - GL 5 / SAE 90 LS
Settings to be observed for installation: A
End play of the stub shaft 7 with sun gear shaft 90
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 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
Tightening torque for the Allen head screws 33
280 Nm
G
Tightening torque for the lock nuts 82
11 Nm
H
Tightening torque for the Allen head screws 103
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
Tyre pressure The tyre pressure depends on the tyre size, tyre ply rating and brand. For details, see overview of tyres in group 12.54.
12.42.2
copyright by
MJF C I F S S
Service Manual
AP - B 755 rigid axle with multi-disc brake Functional description
3 Functional description 3.1
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.
copyright by
MJF C I F S S
12.42.3
AP - B 755 rigid axle with multi-disc brake
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
A = screw plug M 16; B = measuring screw M 16
5 Dismantling, repair and installation of the rigid axle 5.1
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
copyright by
MJF C I F S S
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
Undercarriage with axles
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
copyright by
MJF C I F S S
12.42.5
AP - B 755 rigid axle with multi-disc brake
Service Manual
Exploded view of the rigid axle
6 Exploded view of the rigid axle
Fig. 4
12.42.6
Axle housing, group 17
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
copyright by
MJF C I F S S
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
copyright by
MJF C I F S S
12.42.7
AP - B 755 rigid axle with multi-disc brake
Service Manual
Exploded view of the rigid axle
Fig. 6
12.42.8
Output of planetary gear group 19
.10
Radial shaft seal ring
.300
Snap ring
.30 .40
Roller bearing Ring (S = 26.0 - 27.0 mm)
.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
copyright by
MJF C I F S S
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
Wheel stud Lock washer
.270 .280
Outer disc (S = 2.0 - 3.0 mm) Inner disc
.560 .570
Centring ring Wheel lug
.290
End washer
copyright by
MJF C I F S S
12.42.9
AP - B 755 rigid axle with multi-disc brake
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
Axle housing part II
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
Radial shaft seal ring
85
19290
End washer
30
22010
Hub carrier
86
19150
Snap ring
22330
Separate slotted nut
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
Radial shaft seal ring
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
MJF C I F S S
Service Manual
AP - B 755 rigid axle with multi-disc brake Sectional drawing of the rigid axle
7 Sectional drawing of the rigid axle
Fig. 7
Sectional drawing of rigid sleeve
copyright by
MJF C I F S S
12.42.11
AP - B 755 rigid axle with multi-disc brake
Service Manual
Sectional drawing of the rigid axle
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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MJF C I F S S
12.44.1
Differential for AP / APL - B 755 HD axles
Service Manual
Technical data
2 Technical data Machine Machine model Serial number
A 316 Litronic 716 2001
Axle type
BK
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 20 B Tooth backlash of the crown wheel kit 20
(etched onto the end side of the pinion 20.1) 0.15 - 0.2 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
Torque for the hex nut 11
550 Nm
F
Torque for the hex head screws 6 and the fit bolt 7
390 Nm
G Tightening torque for the Allen head screws 22
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 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
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 = 0.7 - 1.5 mm)
220
Valance
80 110
Roller bearing Ring (S = 10.94 - 12.38 mm)
270 290
Washer Hex head screw
160
Roller bearing
310
Locking plate
190
Radial shaft seal ring
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12.44.3
Differential for AP / APL - B 755 HD axles
Service Manual
Exploded view of the differential
Fig. 3
12.44.4
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 755 HD 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
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
Hex head screw Washer
.690 .700
Bearing bushing Seal ring
.150
Fit bolt
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12.44.5
Differential for AP / APL - B 755 HD axles
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
16170
Tapered roller bearing
1.2
17030
Axle housing II
17
16110
Bushing
2.1
17050
Washer
18
16050
Adjusting disc
2.2
17050
Washer
19
16070
Tapered roller bearing
3
17090
Tapered roller bearing
20.1
16010
Bevel pinion
4
17100
Tapered roller bearing
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
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
Radial shaft seal ring
30
73860
Heavy-duty roll pin "Connex"
Note! Observe settings and torques A, B, C, D, E, F, G, , see Fig. 5 and Table 1, page 2.
12.44.6
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Service Manual
Differential for AP / APL - B 755 HD axles Sectional drawing of the differential
Fig. 5
Sectional drawing of the differential
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MJF C I F S S
12.44.7
Differential for AP / APL - B 755 HD axles
Service Manual
Sectional drawing of the differential
12.44.8
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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
MS - E 3060 steering axle
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MJF C I F S S
12.46.1
MS - E 3060 steering axle
Service Manual
Function
12.46.2
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MJF C I F S S
Service Manual
MS - E 3060 steering axle Technical data
2 Technical data Machine Machine model Serial number
A 316 Li 715 / 716 28061 / 28062
Axle type
MS-E 3060
Design
Planetary steering axle
Gear ratio
16,00
Brake
Wet multi-disc brake
Oil volume in axle Axle housing Planetary drive (filling level at the check screws is binding) Oil quality/viscosity
9.5 l 2.5 l per side API - GL 5 / SAE 90 LS
Settings, to be observed for installation: A*
Axial play of double joint drive shaft 35
0.3 - 0.6 mm
B*
Clearance of the disc pack 96 / 97 (piston stroke) new at max. wear
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*
Tightening torque of hex head screws 60
280 Nm
G*
Tightening torque of hex head screws 93
11 Nm
H*
Tightening torque of Allen head screws 74
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
Tyre pressure The tyre pressure depends on the tyre size, tyre ply rating and brand. For details, see overview of tyres in group 12.54.
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12.46.3
MS - E 3060 steering axle
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
Radial shaft seal ring
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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MJF C I F S S
12.46.5
MS - E 3060 steering axle
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
Bushing Radial shaft seal ring
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
Radial shaft seal ring Roller bearing
58
Bearing pin
69
Hex head screw
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12.46.7
MS - E 3060 steering axle
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
Piston Pressure spring
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
Inner disc Outer disc
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
Radial shaft seal ring
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
4 Functional description 4.1
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
MS - E 3060 steering axle
Service Manual
Maintenance of the axle
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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Hollow gear Piston
12.46.11
MS - E 3060 steering axle
Service Manual
Dismantling, repair and installation of the steering axle
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
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Service Manual
MS - E 3060 steering axle Dismantling, repair and installation of the steering axle
Fig. 9
Undercarriage with axles
1 2
Vehicle wheels Hex head screw
6 7
Hex head screw Plate
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
MS - E 3060 steering axle
Service Manual
Dismantling, repair and installation of the steering axle 30 36
Axle housing Yoke
78 82
Roller bearing O-ring
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
Lip seal Backing ring
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
Inner disc Outer disc
62 63
Bearing pin Lubrication nipple
99 100
Roller bearing Spacer bushing
65
Bleeder
101
Hub
66 67
Bushing Radial shaft seal ring
103 104
Radial shaft seal ring Allen head screw
68 70
Roller bearing Planetary carrier
105 106
Wheel stud Lock washer
74 75
Allen head screw Circlip
107 108
Centring ring Wheel lug
76
Planetary gear
Note! Observe settings and torques A, B, C, D, E, F, G, H, I, K, see Fig. 10 and Table 1, page 3.
12.46.14
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Service Manual
MS - E 3060 steering axle Dismantling, repair and installation of the steering axle
Fig. 10
Sectional drawing of steering axle
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MJF C I F S S
12.46.15
MS - E 3060 steering axle
Service Manual
Dismantling, repair and installation of the steering axle
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
MT - E 3060 rigid axle
Service Manual
Function
12.47.2
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MJF C I F S S
Service Manual
MT - E 3060 rigid axle Technical data
2 Technical data Machine Machine model Serial number
A 316 Li 715 / 716 28061 / 28062
Axle type
MT-E 3060
Design
Planetary rigid axle
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
12.5 l 2.5 l per side API - GL 5 / SAE 90 LS
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*
Torque for the slotted nut 54
E*
Torque for the hex head screws 57
280 Nm
F*
Torque for the hex head screws 93
8 Nm
G*
Torque for the Allen head screws 74
55 Nm
H*
Torque for the wheel lugs 108
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
Tyre pressure The tyre pressure depends on the tyre size, tyre ply rating and brand. For details, see overview of tyres in group 12.54.
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12.47.3
MT - E 3060 rigid axle
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
Allen head screw Washer
12 13
Roller bearing Disc (S=0.70-1.50mm)
22 23
Differential cage Thrust washer
14 15
Roller bearing Ring (S=10.94-12.38mm)
24 25
Axle shaft gear Balancing shaft gear
16
Radial shaft seal ring
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
MT - E 3060 rigid axle
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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12.47.7
MT - E 3060 rigid axle
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
Piston Pressure spring
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
Inner disc Outer disc
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
Radial shaft seal ring
86
Lip seal
104
Allen head screw
87
Backing ring
105
Wheel stud
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MJF C I F S S
Service Manual
MT - E 3060 rigid axle Functional description
4 Functional description 4.1
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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MJF C I F S S
12.47.9
MT - E 3060 rigid axle
Service Manual
Maintenance of the axle
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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MJF C I F S S
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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MJF C I F S S
Hollow gear
Piston travel
12.47.11
MT - E 3060 rigid axle
Service Manual
Dismantling, repair and installation of the rigid axle
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
Undercarriage with axles
1
Vehicle wheels
5
Undercarriage
2 3
Hex head screw Joint shaft
6 7
Washer Hex head screw
4
Lock nut
8
Rigid axle
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MJF C I F S S
12.47.13
MT - E 3060 rigid axle
Service Manual
Dismantling, repair and installation of the rigid axle 6 30
Screw plug Axle housing
87 88
Lip seal Backing ring
36 50
Stub shaft Hub carrier
89 90
Piston Pressure spring
51
Sun gear shaft
91
Pressure spring
54 55
Slotted nut O-ring
92 93
Spring sleeve Hex head screw
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
Roller bearing Snap ring
103 104
Radial shaft seal ring Allen head screw
82 83
O-ring Hollow gear
105 106
Wheel stud Lock washer
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
Sectional drawing of rigid sleeve
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MJF C I F S S
12.47.15
MT - E 3060 rigid axle
Service Manual
Dismantling, repair and installation of the rigid axle
12.47.16
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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
MS/MT - E 3060 drive unit and differential
Service Manual
Function
12.48.2
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MJF C I F S S
Service Manual
MS/MT - E 3060 drive unit and differential Technical data
2 Technical data Machine Machine model Serial number
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
D Rolling resistance of the driving pinion bearing 12/14
1 - 2 Nm
E
Torque for the hex nut 19
600 Nm
F
Tightening torque for the hex head screws 49
390 Nm
G Tightening torque for the Allen head screws 20
145 Nm
Items A - G Tab. 1
Technical data
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MJF C I F S S
12.48.3
MS/MT - E 3060 drive unit and differential
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
Axle shaft gear Balancing shaft gear
12 13
Roller bearing Disc (S=0.70-1.50mm)
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
Radial shaft seal ring
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
MS/MT - E 3060 drive unit and differential
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
Roller bearing Disc (S=0.70-1.50mm)
25 26
Balancing shaft gear Thrust washer
14 15
Roller bearing Ring (S=10.94-12.38mm)
27 28
Balancing axle Heavy-duty roll pin
16
Radial shaft seal ring
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
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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
Sectional drawing of the differential
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MJF C I F S S
12.48.7
MS/MT - E 3060 drive unit and differential
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
A 311 Litronic from 20222 Type: 718 Size
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
Tyres and spacer rings 311
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12.54.1
Tyres and spacer rings
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
Tyres and spacer rings 312
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
Tyres and spacer rings 314
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Service Manual
Tyres and spacer rings A 316 Litronic
3 A 316 Litronic 3.1
A 316 Litronic from 2001 Type: 715 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
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
Tyres and spacer rings
Service Manual
A 316 Litronic
12.54.4
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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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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
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MJF C I F S S
Service Manual
Technical data / tightening torques
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
Technical data / tightening torques
12.62.2
Service Manual
copyright by
MJF C I F S S
Service Manual
Technical data / tightening torques
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
Technical data / tightening torques
12.64.2
Service Manual
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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
Wear of chassis parts
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
Wear of chassis parts
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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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
copyright by
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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MJF C I F S S
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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MJF C I F S S
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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MJF C I F S S
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
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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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MJF C I F S S
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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MJF C I F S S
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
48 Complete side chain link
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
48 Complete side chain link
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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MJF C I F S S
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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MJF C I F S S
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
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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
Filling instructions
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
Screw plug Sealing ring
11 O-ring 12 Trapezoid ring
7
End piece
13 Slide ring
8
Roll pin
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MJF C I F S S
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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MJF C I F S S
12.84.1
Support roller
Service Manual
Filling instructions
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
O-ring Allen head screw
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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MJF C I F S S
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
Filling instructions
12.84.4
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MJF C I F S S
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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MJF C I F S S
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
SUBGROUP - INDEX Section
Group
Type
Operating pressures of the steering system
13.05.1
A 309 LI 20221A 311 LI 20222A 312 LI 12363A 314 LI 2001A 316 LI 2001A 316 LI-IND 2001-
Hydraulic steering system
13.10.1
A 309 LI 20221A 311 LI 20222A 312 LI 12363A 314 LI 2001A 316 LI 2001A 316 LI-IND 2001-
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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MJF C I F S S
13.05.1
Operating pressures of the steering system
Service Manual
General information
13.05.2
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MJF C I F S S
Service Manual
Hydraulic steering system Function
Hydraulic steering system 1 Function
Fig. 1
Hydraulic steering system
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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MJF C I F S S
13.10.1
Hydraulic steering system
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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MJF C I F S S
13.10.3
Hydraulic steering system
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
Hydraulic steering system Function of the steering system
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
Hydraulic steering system
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
Hydraulic steering system Function of the steering system
Fig. 6
Diagram of the steering system with Servostat 84 A
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13.10.7
Hydraulic steering system
Service Manual
Function of the steering system
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
2 General information Equipment from serial number
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
Technical data, settings and tightening torques
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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
Pressure-relief valve 29
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 Functional description (see Fig. 3, page 11)
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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MJF C I F S S
13.20.9
Servostat
Service Manual
Exploded view
13.20.10
8
Rotor kit (metering pump)
29
Pressure relief valve
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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MJF C I F S S
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
Hex head screw Washer
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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MJF C I F S S
13.22.1
Steering valve
Service Manual
General information
2 General information Machine from serial number
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
Steering valve LAGS 200/20
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.
Pressure-relief valve 5
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
Suction valve Suction valve
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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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
Hex head screw Cover
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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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
Exploded view of the steering column
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
Suction valve Suction valve
23 24
Needle roller Valve housing
9
Check valve
999
Seal kit
Exploded view of the steering column
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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13.22.9
Steering valve
Service Manual
Exploded view of the steering column
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
2 General information Machine from serial number
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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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.
Pressure-relief valve 5
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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MJF C I F S S
13.24.3
Steering valve
Service Manual
Functional description
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
Suction valve Suction valve
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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MJF C I F S S
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
Pressure-relief valve
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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MJF C I F S S
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
Hex head screw Cover
4
Centring spring
17
Rotor gear 2
5
Pressure-relief valve
18
Washer
6
Shock valve
19
Thrust washer
7 8
Suction valve Suction valve
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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MJF C I F S S
13.24.9
Steering valve
Service Manual
Exploded view of the steering valve
7.1
Exploded view of the steering column
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
Hex head screw Washer
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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MJF C I F S S
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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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
Steering cylinder on the steering axle
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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
Steering cylinder on the steering axle
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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MJF C I F S S
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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MJF C I F S S
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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MJF C I F S S
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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MJF C I F S S
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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MJF C I F S S
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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MJF C I F S S
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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MJF C I F S S
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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MJF C I F S S
Switch / servo control
13.50.7
4-wheel steering
Service Manual
Function of the steering system
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
Y294-2 Solenoid shift valve for wheel centring
92 94
6/3-way shift valve 4/3-way shift valve
98
Load-holding valve
260
Rotary connection 7 x
265
Slip ring rotary connection 9x
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MJF C I F S S
Service Manual
4-wheel steering Function of the steering system
Fig. 8
4-wheel steering in neutral position
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MJF C I F S S
13.50.9
4-wheel steering
Service Manual
Function of the steering system
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
B248-H Proximity switch rear axle
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
4-wheel steering control
B248-V Proximity switch front axle
83
Measuring point for steering pressure
U16
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
86-2 88P
Rear axle steering cylinder Distributor
Y294-1 Solenoid shift valve for wheel centring Y294-2 Solenoid shift valve for wheel centring
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
Slip ring rotary connection 9x
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MJF C I F S S
Service Manual
4-wheel steering Function of the steering system
Fig. 9
2-wheel steering
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MJF C I F S S
13.50.11
4-wheel steering
Service Manual
Function of the steering system
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
Measuring point for steering pressure
U16
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
86-2 88P
Rear axle steering cylinder Distributor
Y294-1 Solenoid shift valve for wheel centring Y294-2 Solenoid shift valve for wheel centring
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
Slip ring rotary connection 9x
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MJF C I F S S
Service Manual
4-wheel steering Function of the steering system
Fig. 10
4-wheel steering
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MJF C I F S S
13.50.13
4-wheel steering
Service Manual
Function of the steering system
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
Rear axle steering cylinder Distributor
Y294-1 Solenoid shift valve for wheel centring Y294-2 Solenoid shift valve for wheel centring
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
Slip ring rotary connection 9x
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Ground connection Selection switch / 4-wheel steering
Service Manual
4-wheel steering Function of the steering system
Fig. 11
Crab steering
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MJF C I F S S
13.50.15
4-wheel steering
Service Manual
Function of the steering system
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
Gear pump / low-pressure circuit + brake Gear pump / steering with pressurerelief valve
B248-H Proximity switch rear axle
32
13.50.16
4-wheel steering control
B248-V Proximity switch front axle
33
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
86-2
Rear axle steering cylinder
Y294-1 Solenoid shift valve for wheel centring
88P 88T
Distributor Collecting pipe
Y294-2 Solenoid shift valve for wheel centring
92 94
6/3-way shift valve 4/3-way shift valve
98 260
Load-holding valve Rotary connection 7 x
265
Slip ring rotary connection 9x
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MJF C I F S S
Service Manual
4-wheel steering Function of the steering system
Fig. 12
Centring from 2-wheel steering mode
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MJF C I F S S
13.50.17
4-wheel steering
Service Manual
Function of the steering system
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
Gear pump / low-pressure circuit + brake Gear pump / steering with pressurerelief valve
B248-H Proximity switch rear axle
32
13.50.18
4-wheel steering control
B248-V Proximity switch front axle
33
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
86-2
Rear axle steering cylinder
Y294-1 Solenoid shift valve for wheel centring Y294-2 Solenoid shift valve for wheel centring
88P
Distributor
88T
Collecting pipe
92 94
6/3-way shift valve 4/3-way shift valve
98
Load-holding valve
260
Rotary connection 7 x
265
Slip ring rotary connection 9x
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MJF C I F S S
Service Manual
4-wheel steering Function of the steering system
Fig. 13
Centring from 4-wheel steering mode after steering to the right
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MJF C I F S S
13.50.19
4-wheel steering
Service Manual
Function of the steering system
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
Gear pump / low-pressure circuit + brake Gear pump / steering with pressurerelief valve
B248-H Proximity switch rear axle
32
13.50.20
4-wheel steering control
B248-V Proximity switch front axle
33
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
86-2
Rear axle steering cylinder
Y294-1 Solenoid shift valve for wheel centring Y294-2 Solenoid shift valve for wheel centring
88P
Distributor
88T
Collecting pipe
92 94
6/3-way shift valve 4/3-way shift valve
98
Load-holding valve
260
Rotary connection 7 x
265
Slip ring rotary connection 9x
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MJF C I F S S
Service Manual
4-wheel steering Function of the steering system
Fig. 14
Centring of wheels from crab steer mode
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MJF C I F S S
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
Measuring point for steering pressure
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
Slip ring rotary connection
94
4/3-way shift valve (steering changeover)
Y294-1 Solenoid
98
Load-holding valve
Y294-2 Solenoid
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MJF C I F S S
13.50.23
4-wheel steering
Service Manual
Electrical system
6 Electrical system
Fig. 17
13.50.24
Electrical components in uppercarriage
A127
printed circuit board / power
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
Y294-1 Solenoid shift valve for wheel centring
H191 H192
Indicator light / 4-wheel steering Crab steer indicator light
Y294-2 Solenoid shift valve for wheel centring
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Service Manual
4-wheel steering Electrical system
Fig. 18
265
Electrical components in undercarriage
X1090 Plug connection / 6-pin
Slip ring rotary connection
B248-H Proximity switch rear axle
Y294-1 Solenoid / crab steer mode
B248-V Proximity switch front axle
Y229-2 Solenoid / 4-wheel steering
S272
Junction box / undercarriage
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MJF C I F S S
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
4-wheel steering control
K370
Relay / terminal 15 servo
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
B248-H Proximity switch rear axle
S263
Switch / travel direction
B248-V Proximity switch front axle
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
Y294-2 Solenoid shift valve for wheel centring
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MJF C I F S S
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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MJF C I F S S
13.50.27
4-wheel steering
Service Manual
Fault messages
13.50.28
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MJF C I F S S
Service Manual
SUBGROUP - INDEX Section
Group
Type
Oscillating axle support with automatic control 14.10.1
A 309 LI 20221A 311 LI 20222A 312 LI 12363A 314 LI 2001A 316 LI 2001A 316 LI-IND 2001-
Support cylinders
A 309 LI 20221A 311 LI 20222A 312 LI 12363A 314 LI 2001A 316 LI 2001A 316 LI-IND 2001-
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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MJF C I F S S
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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14.10.3
Oscillating axle support with automatic control
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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MJF C I F S S
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
Oscillating axle support with automatic control
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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MJF C I F S S
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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MJF C I F S S
14.10.7
Oscillating axle support with automatic control
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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MJF C I F S S
Service Manual
Oscillating axle support with automatic control Functional test
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MJF C I F S S
14.10.9
Oscillating axle support with automatic control
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
Restrictor (Ø 1.5 mm)
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
Rotary connection 7 x
X952
Plug connection revolving deck BST / 21-pin
322
Rotary connection 6 x
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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MJF C I F S S
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
copyright by
MJF C I F S S
14.10.11
Oscillating axle support with automatic control Hydraulic diagram
14.10.12
copyright by
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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MJF C I F S S
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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MJF C I F S S
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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MJF C I F S S
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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MJF C I F S S
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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MJF C I F S S
Washer Hex head screw
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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MJF C I F S S
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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MJF C I F S S
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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MJF C I F S S
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
SUBGROUP - INDEX Section
Group
Type
Operating pressures of the brake system
15.05.1
A 309 LI 20221A 311 LI 20222A 312 LI 12363A 314 LI 2001A 316 LI 2001A 316 LI-IND 2001-
Hydraulic brake system
15.10.1
A 309 LI 20221A 311 LI 20222A 312 LI 12363A 314 LI 2001A 316 LI 2001A 316 LI-IND 2001-
Compact brake block
15.20.1
A 309 LI 20221A 311 LI 20222A 312 LI 12363A 314 LI 2001A 316 LI 2001A 316 LI-IND 2001-
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 309 Litronic from 20221
A 311 Litronic from 20222
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
Shifting pressure of pressure switch B60
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
A 316 Litronic from 28061
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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MJF C I F S S
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
Shifting pressure of pressure switch B60
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
Hydraulic brake system
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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MJF C I F S S
15.10.1
Hydraulic brake system
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)
to compact brake block
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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MJF C I F S S
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
to compact brake block
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
Hydraulic brake system
Service Manual
Function of the brake system
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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MJF C I F S S
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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MJF C I F S S
15.10.5
Hydraulic brake system
Service Manual
Function of the brake system
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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MJF C I F S S
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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MJF C I F S S
15.10.7
Hydraulic brake system
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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MJF C I F S S
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
Hydraulic brake system
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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MJF C I F S S
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.
copyright by
MJF C I F S S
15.10.11
Hydraulic brake system
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
Pressure spring / brake pressure
9
58
Pressure spring / brake pressure
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
Pilot control piston
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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MJF C I F S S
Service Manual
Hydraulic brake system Hydraulic diagram
6 Hydraulic diagram
Fig. 10
Hydraulic brake system
copyright by
MJF C I F S S
15.10.13
Hydraulic brake system
Service Manual
Hydraulic diagram
15.10.14
copyright by
MJF C I F S S
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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MJF C I F S S
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
copyright by
MJF C I F S S
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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MJF C I F S S
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
Pressure spring / brake pressure
8
Check valve
58
Pressure spring / brake pressure
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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MJF C I F S S
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
Pressure spring Pressure spring
142 144
Seal ring Pressure switch
52 53
Pressure spring Pressure spring
163 165
Reducer Screw plug
56
Pressure spring
166
Reducer
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MJF C I F S S
Service Manual
Compact brake block Sectional drawing
57 58
Pressure spring Pressure spring
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
copyright by
MJF C I F S S
15.20.7
Compact brake block
Service Manual
Sectional drawing
15.20.8
copyright by
MJF C I F S S
Service Manual
SUBGROUP - INDEX Section
Group
Type
Pipe fracture safety valve for boom cylinders
16.04.1
A 309 LI 20221A 311 LI 20222A 312 LI 12363A 314 LI 2001A 316 LI 2001A 316 LI-IND 2001R 317 LI 18161-
Pipe fracture safety valve for stick cylinder
16.06.1
A 309 LI 20221A 311 LI 20222A 312 LI 12363A 314 LI 2001A 316 LI 2001A 316 LI-IND 2001R 317 LI 18161-
Pipe fracture safety valve for regulating cylinder
16.10.1
A 312 LI 12363A 314 LI 2001A 316 LI 2001A 316 LI-IND 2001R 317 LI 18161-
Overload warning system
16.12.1
A 309 LI 20221A 311 LI 20222A 312 LI 12363A 314 LI 2001A 316 LI 2001A 316 LI-IND 2001R 317 LI 18161-
Hydraulic quick change adapter
16.16.1
A 309 LI 20221A 311 LI 20222A 312 LI 12363A 314 LI 2001A 316 LI 2001A 316 LI-IND 2001R 317 LI 18161-
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
A 312 LI 12363A 314 LI 2001A 316 LI 2001A 316 LI-IND 2001-
LIKUFIX Hydraulic Coupling System
16.24.1
A 309 LI 20221A 311 LI 20222A 312 LI 12363A 314 LI 2001A 316 LI 2001A 316 LI-IND 2001R 317 LI 18161-
Hydraulic hammers
16.30.1
A 309 LI 20221A 311 LI 20222A 312 LI 12363A 314 LI 2001A 316 LI 2001A 316 LI-IND 2001R 317 LI 18161-
Accessory kit AS1
16.44.1
A 312 LI 12363A 314 LI 2001A 316 LI 2001A 316 LI-IND 2001R 317 LI 18161-
Accessory kit AHS 1
16.48.1
A 312 LI 12363A 314 LI 2001A 316 LI 2001A 316 LI-IND 2001R 317 LI 18161-
Accessory kit AHS 11
16.52.1
A 312 LI 12363A 314 LI 2001A 316 LI 2001A 316 LI-IND 2001R 317 LI 18161-
Accessory kit AHS 12
16.54.1
A 309 LI 20221A 311 LI 20222-
Accessory kit AHS 12
16.56.1
A 312 LI 12363A 314 LI 2001A 316 LI 2001A 316 LI-IND 2001R 317 LI 18161-
16.2 MJF C I F S S
Service Manual
SUBGROUP - INDEX Section
Group
Type
Accessory kit AHS 11 / AHS 12 with Tool Control
16.57.1
A 312 LI 12363A 314 LI 2001A 316 LI 2001A 316 LI-IND 2001R 317 LI 18161-
Accessory kit AHS 12 with changeover valve
16.58.1
A 312 LI 12363A 314 LI 2001A 316 LI 2001A 316 LI-IND 2001R 317 LI 18161-
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
Kit for control switch-over
16.62.21
A 309 LI 23702A 311 LI 23254-
Kit for control switch-over
16.64.1
A 312 LI 12363A 314 LI 2001A 316 LI 2001A 316 LI-IND 2001-
Dozer blade
16.66.1
A 312 LI 12363A 314 LI 2001A 316 LI 2001A 316 LI-IND 2001-
Hydraulic cab elevation system
16.70.1
A 312 LI 12363A 314 LI 2001A 316 LI 2001A 316 LI-IND 2001R 317 LI 18161-
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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MJF C I F S S
16.04.1
Pipe fracture safety valve for boom cylinders
Service Manual
Functional description
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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MJF C I F S S
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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MJF C I F S S
16.04.3
Pipe fracture safety valve for boom cylinders
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
copyright by
MJF C I F S S
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
Pipe fracture safety valve
16.04.5
Pipe fracture safety valve for boom cylinders
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
copyright by
MJF C I F S S
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
Compact control block
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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MJF C I F S S
Secondary pressure-relief valve / extending boom cylinder
16.04.7
Pipe fracture safety valve for boom cylinders
Service Manual
Inspection and testing of pipe fracture valves
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
Pipe fracture safety valve for boom cylinders Hydraulic connections and links
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
Pipe fracture safety valve for boom cylinders Hydraulic connections and links
copyright by
MJF C I F S S
16.04.11
Pipe fracture safety valve for boom cylinders
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
Secondary pressure-relief valve / extending boom cylinder
20
from variable-displacement pump
132
Secondary pressure-relief valve / retract cylinder
40
Measuring point P1
160
Boom cylinder
50
to control oil unit
162
Stroke limitation / boom cylinder
52
Bleeding and measuring connection
238
Pipe fracture safety valve
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
Spool / boom cylinder
238.23 Restrictor check valve
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MJF C I F S S
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
copyright by
MJF C I F S S
16.04.13
Pipe fracture safety valve for boom cylinders
Service Manual
Hydraulic diagram of pipe fracture safety system
Components of hydraulic diagram, see Fig. 8 1
to hydraulic tank
221
Secondary pressure-relief valve / extending boom cylinder
6
to hydraulic oil cooler
222
Secondary pressure-relief valve / retract cylinder
20
from variable-displacement pump
224
Pressure balance
23
to pump regulator
227
Restrictor check valve
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
Spool / boom cylinder
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MJF C I F S S
Service Manual
Pipe fracture safety valve for boom cylinders Hydraulic diagram of pipe fracture safety system
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
Pipe fracture safety valve for boom cylinders Hydraulic diagram of pipe fracture safety system
16.04.16
copyright by
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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MJF C I F S S
16.06.1
Pipe fracture safety valve for stick cylinder
Service Manual
Functional description
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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MJF C I F S S
16.06.3
Pipe fracture safety valve for stick cylinder
Service Manual
Functional description
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
Screw plug with O-ring
5
Screw plug with O-ring
19
Screw plug with O-ring
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
O-ring Valve seat (sleeve)
11 12
O-ring Valve seat (sleeve)
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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MJF C I F S S
16.06.5
Pipe fracture safety valve for stick cylinder
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
Pipe fracture safety valve
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MJF C I F S S
16.06.7
Pipe fracture safety valve for stick cylinder
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 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
Compact control block
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
Pipe fracture safety valve for stick cylinder
Service Manual
Hydraulic connections and links
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
Pipe fracture safety valve
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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
Pipe fracture safety valve for stick cylinder
Service Manual
Hydraulic connections and links
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
Restrictor check valve
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
Pipe fracture safety valve for stick cylinder
Service Manual
Hydraulic diagram of pipe fracture safety system
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
Pipe fracture safety valve for stick cylinder
Service Manual
Hydraulic diagram of pipe fracture safety system
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
Pipe fracture safety valve for regulating cylinder
Service Manual
Functional description
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
Pipe fracture safety valve for regulating cylinder
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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MJF C I F S S
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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MJF C I F S S
16.10.5
Pipe fracture safety valve for regulating cylinder
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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MJF C I F S S
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
Pipe fracture safety valve for regulating cylinder
Service Manual
Hydraulic connections and links
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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MJF C I F S S
16.10.9
Pipe fracture safety valve for regulating cylinder Hydraulic diagram
16.10.10
copyright by
MJF C I F S S
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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MJF C I F S S
Overload warning system with pipe-fracture safety, e.g. in model A 312 - R 317
16.12.1
Overload warning system
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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MJF C I F S S
16.12.3
Overload warning system
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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MJF C I F S S
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 (*)
Pipe fracture safety valve
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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MJF C I F S S
16.12.5
Overload warning system
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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MJF C I F S S
16.12.7
Overload warning system
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
Plug connection, 2-pin Plug connection, 21-pin
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
Plug connection, 21-pin Plug connection, 21-pin
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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MJF C I F S S
16.12.9
Overload warning system
Service Manual
Hydraulic and electric diagram
16.12.10
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MJF C I F S S
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
Hydraulic quick change adapter
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16.16.1
Hydraulic quick change adapter
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
Primary pressure relief valve
20 50
Locking unit Covering parts
540 541
Spool of hydraulic drive Secondary relief valve / retracting cylinder
100
Compact control block
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
Hydraulic quick change adapter
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
Hydraulic quick change adapter
Service Manual
Operation of the quick change adapter
4 Operation of the quick change adapter
Fig. 4 80
Left pilot control unit
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
Hydraulic quick change adapter
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
Hydraulic quick change adapter
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
Hydraulic quick change adapter
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
Spool / slewing gear
X411
113
Spool grapple rotator / quick change adapter
X412
Plug connection, see electric diagrams Plug connection, see electric diagrams
123
Primary pressure relief valve
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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MJF C I F S S
16.16.13
Hydraulic quick change adapter
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
Left pilot control unit
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
Plug connection, see electric diagrams
544
Pressure balance
X412
Plug connection, see electric diagrams
X413 Y22
Plug connection, see electric diagrams Solenoid / locking adapter
Y23
Solenoid / releasing adapter
Y28-1 Y28-2
Solenoid / seat valve rod side Solenoid / seat valve piston side
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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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MJF C I F S S
16.16.15
Hydraulic quick change adapter
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
Proportional solenoid valve / flow reduction P1
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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MJF C I F S S
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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MJF C I F S S
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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MJF C I F S S
16.19.5
Flow reduction
Service Manual
Adjustment of pump flow volume
16.19.6
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MJF C I F S S
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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MJF C I F S S
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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MJF C I F S S
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
Pilot control device / kit
D
Cover/electric cabinet
EK Electric cabinet S241 Switch AHS 11 / AHS 12 accessory kit Y51
Proportional solenoid valve / flow reduction
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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MJF C I F S S
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
Pilot control device / kit
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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MJF C I F S S
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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MJF C I F S S
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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MJF C I F S S
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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MJF C I F S S
16.24.1
LIKUFIX Hydraulic Coupling System
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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MJF C I F S S
16.24.3
LIKUFIX Hydraulic Coupling System
Service Manual
Design of LIKUFIX hydraulic coupling system
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
LIKUFIX Hydraulic Coupling System Design of LIKUFIX hydraulic coupling system
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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MJF C I F S S
16.24.5
LIKUFIX Hydraulic Coupling System
Service Manual
Design of LIKUFIX hydraulic coupling system
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
Allen head screw Washer
30 40
Protective cover Pressure spring
90 91
Tie-down device Allen head screw
41 42
Allen head screw Allen head screw
92 100
Retaining washer Tie-down device
50
Plunger
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Service Manual
LIKUFIX Hydraulic Coupling System Design of LIKUFIX hydraulic coupling system
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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MJF C I F S S
16.24.7
LIKUFIX Hydraulic Coupling System
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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MJF C I F S S
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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MJF C I F S S
16.24.9
LIKUFIX Hydraulic Coupling System
Service Manual
Function of LIKUFIX hydraulic coupling system
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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MJF C I F S S
Service Manual
LIKUFIX Hydraulic Coupling System Function of LIKUFIX hydraulic coupling system
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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MJF C I F S S
16.24.11
LIKUFIX Hydraulic Coupling System
Service Manual
Function of LIKUFIX hydraulic coupling system
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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MJF C I F S S
Service Manual
LIKUFIX Hydraulic Coupling System Function of LIKUFIX hydraulic coupling system
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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MJF C I F S S
Plunger cylinder
16.24.13
LIKUFIX Hydraulic Coupling System
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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MJF C I F S S
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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MJF C I F S S
16.24.15
LIKUFIX Hydraulic Coupling System
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.
copyright by
MJF C I F S S
16.24.17
LIKUFIX Hydraulic Coupling System
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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MJF C I F S S
16.24.19
LIKUFIX Hydraulic Coupling System
Service Manual
Hydraulic and electric units
7 Hydraulic and electric units Key to hydraulic diagram 3
LIKUFIX part at quick change adapter
540
Spool / grapple rotator
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
Oil motor / grapple rotator
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
Spool / slewing gear
Y28-1
Solenoid / seat valve rod side Solenoid / seat valve piston side
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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MJF C I F S S
Service Manual
LIKUFIX Hydraulic Coupling System Hydraulic and electric units
.
Fig. 20
Hydraulic diagram of LIKUFIX
copyright by
MJF C I F S S
16.24.21
LIKUFIX Hydraulic Coupling System
Service Manual
Hydraulic and electric units
Fig. 21
16.24.22
Electric diagram of LIKUFIX
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MJF C I F S S
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
Extend bucket cylinder
P2
Close pressure (AHS) circuit of grab/shear
Coupling
Actuation
D
D1
A
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MJF C I F S S
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
LIKUFIX Hydraulic Coupling System
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
Extend bucket cylinder
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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MJF C I F S S
Service Manual
LIKUFIX Hydraulic Coupling System Connection options for LIKUFIX system
Fig. 23
Hydraulic diagrams for the various attachments
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MJF C I F S S
16.24.25
LIKUFIX Hydraulic Coupling System
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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MJF C I F S S
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.
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MJF C I F S S
16.24.27
LIKUFIX Hydraulic Coupling System
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
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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.
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MJF C I F S S
16.24.29
LIKUFIX Hydraulic Coupling System
Service Manual
Instructions for the replacement of the coupling plug seal
16.24.30
copyright by
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
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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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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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MJF C I F S S
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
Operating pressure / hammer
bar
130
160
170
Adjustment pressure of machine see AHS 11 / AHS 12
bar
150
180
190
right
right
right
A 309 Litronic
X
X
A 311 Litronic
X
X
A 312 Litronic
X
X
Return (2) Attachable to machine types:
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
Effective weight (1)
kg
625
875
Oil flow
l/min
60-95
85 - 115
Operating pressure / hammer
bar
145
160
Adjustment pressure of machine see AHS 11 / AHS 12
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)
including standard chisel and suspension kit
2) NB
seen from operator seat no details in brochure
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MJF C I F S S
16.30.5
Hydraulic hammers
Service Manual
FRD hydraulic hammers
6
FRD hydraulic hammers Type Product
Unit
HB 10G
HB 15G
Effective weight (1)
kg
785
1100
Oil flow
l/min
70-90
90-120
Operating pressure / hammer
bar
160
170
Adjustment pressure of machine see AHS 11 / AHS 12
bar
180
190
right
right
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
X
R 317 Litronic
X
X
Tab. 4
16.30.6
Technical data 1)
including standard chisel and suspension kit
2)
seen from operator seat
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Service Manual
Hydraulic hammers INDECO hydraulic hammers
7
INDECO hydraulic hammers Type Product
Unit
MES 1200
MEST 1500
MES 1750
Effective weight (1)
kg
600
780
950
Oil flow
l/min
60-90
80-125
85-115
Operating pressure / hammer
bar
120
130
130
Adjustment pressure of machine see AHS 11 / AHS 12
bar
140
150
150
right
right
right
A 314 Litronic
X
X
A 316 Litronic
X
X
R 317 Litronic
X
X
Return (2) Attachable to machine types: A 309 Litronic
X
A 311 Litronic
X
A 312 Litronic
X
Tab. 5
Technical data 1)
including standard chisel and suspension kit
2)
seen from operator seat
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MJF C I F S S
16.30.7
Hydraulic hammers
Service Manual
NPK hydraulic hammers
8 NPK hydraulic hammers Type Product
Unit
H4 XE
Effective weight (1)
kg
565
Oil flow
l/min
50-80
Operating pressure / hammer
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)
including standard chisel and suspension kit
2)
seen from operator seat
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Service Manual
Hydraulic hammers RAMMER hydraulic hammers
9 RAMMER hydraulic hammers Type Product
S25
S26 N
S29C/
E64/
Unit
Effective weight (1)
kg
425
540
820
1000
Oil flow
l/min
50-150
60-135
60-120
70-130
Operating pressure / hammer
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
Return (2) Attachable to machine types:
Tab. 7
Technical data 1) 2)
including standard chisel and suspension kit seen from operator seat
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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
Unit Effective weight (1)
kg
370
695
Oil flow
l/min
70-110
90-130
Operating pressure / hammer
bar
170
110
Adjustment pressure of machine see AHS 11 / AHS 12
bar
190
130
left
left
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. 8
Technical data 1) 2)
16.30.10
including standard chisel and suspension kit seen from operator seat
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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
Unit Effective weight (1)
kg
390
875
Oil flow
l/min
65-80
80-115
Operating pressure / hammer
bar
130
125
Adjustment pressure of machine see AHS 11 / AHS 12
bar
150
160
NB
right
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. 9
Technical data 1) 2)
including standard chisel and suspension kit seen from operator seat
NB
no details in brochure
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MJF C I F S S
16.30.11
Hydraulic hammers
Service Manual
WIMMER hydraulic hammers
12 WIMMER hydraulic hammers Type Product
W 440
W 550
Unit Effective weight (1)
kg
600
1150
Oil flowl/min
l/min
60-100
70-130
Operating pressure / hammer
bar
130
135
Adjustment pressure of machine see AHS 11 / AHS 12
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
Return (2) Attachable to machine types:
Tab. 10
Technical data 1) 2)
16.30.12
X
including standard chisel and suspension kit seen from operator seat
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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
copyright by
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
Left pilot control unit
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
Solenoid valve / grapple rotation right
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
copyright by
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.
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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
Variable-displacement pump
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
Accessory kit AS1 Pressure check and adjustment
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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16.44.7
Accessory kit AS1
Service Manual
Pressure check and adjustment
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
Accessory kit AS1 Pressure check and adjustment
– 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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MJF C I F S S
16.44.9
Accessory kit AS1
Service Manual
Pressure check and adjustment
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
from control oil unit
S19
Switch / kit AS1
88
P from distribution block
Y22
Solenoid valve
88
to collecting pipe T
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
Accessory kit AS1 Pressure check and adjustment
Fig. 7
Hydraulic diagram of the AS1 kit
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MJF C I F S S
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
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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
Pressure limit (in bar)
Technical data
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MJF C I F S S
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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MJF C I F S S
16.48.3
Accessory kit AHS 1
Service Manual
Pressure check and adjustment
4 Pressure check and adjustment 4.1
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
Pressure cut-off valve
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
Compact control block
1.1
Stop screw
500
Spool / regulating cylinder
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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MJF C I F S S
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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MJF C I F S S
Service Manual
Accessory kit AHS 1 Components and hydraulic lines
5 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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MJF C I F S S
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
Compact control block Pressure cut-off valve
20
Variable-displacement pump
500
Regulating cylinder spool
23
Regulating valve
501
Secondary pressure relief valve / cylinder 515 retracting
30
Gear pump / fan drive
502
Secondary pressure relief valve / extend cylinder 515
41 45
Measuring point MP Measuring point LS
504 507
Pressure balance Restrictor check valve
50
from the control oil unit
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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MJF C I F S S
Service Manual
Accessory kit AHS 1 Hydraulic system
copyright by
MJF C I F S S
16.48.9
Accessory kit AHS 1
Service Manual
Hydraulic system
16.48.10
copyright by
MJF C I F S S
Service Manual
Accessory kit AHS 11 Function
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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MJF C I F S S
16.52.1
Accessory kit AHS 11
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
copyright by
MJF C I F S S
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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MJF C I F S S
16.52.3
Accessory kit AHS 11
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
copyright by
MJF C I F S S
Service Manual
Accessory kit AHS 11 Pressure check and adjustment
4 Pressure check and adjustment 4.1
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
Variable displacement pumps with measuring point LS and compact control valve block with measuring point MP and auxiliary axle AHS11
20
Variable displacement pump (LPV or DPVO)
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
Compact control block
512
Pressure cut-off valve
Secondary pressure relief valve / retracting cylinder 537 or pile driver
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MJF C I F S S
16.52.5
Accessory kit AHS 11
Service Manual
Pressure check and adjustment
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
copyright by
MJF C I F S S
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
Measuring point LS for LS pressure 511
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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MJF C I F S S
16.52.7
Accessory kit AHS 11
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
Adjustment of the stoke limitation of the spool 510
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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MJF C I F S S
Service Manual
Accessory kit AHS 11 Components and hydraulic lines
5 Components and hydraulic lines
Fig. 7
Hydraulic connections AHS 11
copyright by
MJF C I F S S
16.52.9
Accessory kit AHS 11
Service Manual
Hydraulic system
6 Hydraulic system
16.52.10
1
from / to hydraulic tank
510
6
to oil cooler
511
20
Variable-displacement pump
512
23
Regulating valve
514
Pressure balance
30
Gear pump / cooling
517
Restrictor check valve
41
Measuring point MP
535
Hydraulic hammer
45
Measuring point LS
536
Pile driver
50
from the control oil unit
537
Cylinder (auxiliary device)
86 88P
Pilot control unit 2x, with pedal Distributor
538 Stop cock B290 Proximity switch / sensor control (kit)
88T 100
Collecting pipe Compact control block
B291 Proximity switch / sensor control (kit) Y62 Solenoid valve / travel
104
Pressure cut-off valve
Y63 Solenoid valve / travel Y299 Solenoid valve / secondary pressure hammer
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MJF C I F S S
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
Accessory kit AHS 11 Hydraulic system
copyright by
MJF C I F S S
16.52.11
Accessory kit AHS 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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MJF C I F S S
Service Manual
Accessory kit AHS 12 Function
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
Auxiliary attachments available for basic machine (examples)
A Hydraulic boom adjusting device B Hydraulic hammer
C Sorting grapple
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MJF C I F S S
16.54.1
Accessory kit AHS 12
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)
Pressure limit (in bar) primary
secondary
350 +10 bar
150 +10 bar (*) 380 +20 bar 380 +20 bar (200 bar **)
Current at proportional solenoid valve Y51
640 mA
Control pressure at the pump P1 via proportional solenoid valve Y51
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
copyright by
MJF C I F S S
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:
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 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 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).
copyright by
MJF C I F S S
16.54.3
Accessory kit AHS 12
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.
4 Pressure check and adjustment 4.1
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
copyright by
MJF C I F S S
Service Manual
Accessory kit AHS 12 Pressure check and adjustment
Fig. 3 120
Compact control block with auxiliary axle AHS12
40
Measuring point for pump pressure
510
Hydraulic hammer/cylinder spool
100
Compact control block
511
Activate the secondary pressure-relief valve of the hydraulic hammer / extend cylinder
122
Primary pressure-relief valve P1
512
Secondary pressure-relief valve / retract cylinder
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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MJF C I F S S
16.54.5
Accessory kit AHS 12
Service Manual
Pressure check and adjustment
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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MJF C I F S S
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
A125 Potentiometer board
P1
Potentiometer / flow volume 1
P2 P3
Potentiometer / flow volume 2 Potentiometer / flow volume 3
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MJF C I F S S
16.54.7
Accessory kit AHS 12
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
Double variable-displacement pump
A125 Potentiometer board
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
Pilot control device of kit
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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MJF C I F S S
Service Manual
Accessory kit AHS 12 Components and hydraulic lines
7 Components and hydraulic lines
Fig. 8
Hydraulic connections AHS 12
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MJF C I F S S
16.54.9
Accessory kit AHS 12
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
Distributor Collecting pipe
251 510
Double load-holding valve Auxiliary spool AHS 12
100
Compact control block
511
101
Slewing gear spool
512
Secondary pressure-relief valve / extend cylinder 517 or hammer Secondary pressure relief valve / retract cylinder 537
102
Stick cylinder spool
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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MJF C I F S S
Load-holding valve
Service Manual
Accessory kit AHS 12 Hydraulic system
copyright by
MJF C I F S S
16.54.11
Accessory kit AHS 12
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
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MJF C I F S S
Service Manual
Accessory kit AHS 12 Function
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
Auxiliary attachments available for basic machine (examples)
A Hydraulic boom adjusting device
C Sorting grapple
B Hydraulic hammer
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MJF C I F S S
16.56.1
Accessory kit AHS 12
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 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 (*)
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 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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MJF C I F S S
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:
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 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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MJF C I F S S
16.56.3
Accessory kit AHS 12
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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MJF C I F S S
Service Manual
Accessory kit AHS 12 Pressure check and adjustment
4 Pressure check and adjustment 4.1
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
Variable displacement pumps with measuring point LS and compact control valve block with measuring point MP and auxiliary axles AHS12
20
Variable displacement pump (LPV or DPVO)
500
41
Measuring point MP for pump pres- 501 sure
Secondary pressure relief valve / extend cylinder 525
45
Measuring point LS for LS pressure 502
100
Compact control block
510
Secondary pressure relief valve / retract cylinder 525 Auxiliary control axle AHS 11 with spool
104
Pressure cut-off valve
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
Auxiliary control axle AHS 1 with spool
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MJF C I F S S
16.56.5
Accessory kit AHS 12
Service Manual
Pressure check and adjustment
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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MJF C I F S S
Service Manual
Accessory kit AHS 12 Pressure check and adjustment
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
Variable displacement pump (LPV or DPVO)
500
41
Measuring point MP for pump pres- 501 sure
Secondary pressure relief valve / extend cylinder 525
45
Measuring point LS for LS pressure 502
Secondary pressure relief valve / retract cylinder 525
100
Control valve block
510
Auxiliary control axle AHS 11 with spool
104
Pressure cut-off valve
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
Auxiliary control axle AHS 1 with spool
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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MJF C I F S S
16.56.7
Accessory kit AHS 12
Service Manual
Pressure check and adjustment
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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MJF C I F S S
Service Manual
Accessory kit AHS 12 Components and hydraulic lines
5 Components and hydraulic lines
Fig. 7
Hydraulic connections AHS 12
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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MJF C I F S S
Proximity switch / sensor control
16.56.9
Accessory kit AHS 12
Service Manual
Hydraulic system
6 Hydraulic system 1
Hydraulic tank
510
Spool / hydraulic hammer / cylinder / pile driver
6
to oil cooler
511
Secondary pressure-relief valve with additional pressure stage / retract hydraulic hammer 535 cylinder 537
20
from variable-displacement pump
512
23
Regulating valve
514
Secondary pressure relief valve / extend cylinder 537 Pressure balance
30
Gear pump / cooling
517
Restrictor check valve
41
Measuring point MP
525
Regulating cylinder
45
Measuring point LS
526
Load-holding valve (piston side)
50
from the control oil unit
527
Load-holding valve (rod side)
86
Pilot control unit 2x, with pedals
535
Hydraulic hammer
88P 88T
Distributor Collecting pipe
536 537
Pile driver Cylinder (auxiliary device)
100 104
Compact control block Pressure cut-off valve
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
Pressure balance Restrictor check valve
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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MJF C I F S S
Service Manual
Accessory kit AHS 12 Hydraulic system
copyright by
MJF C I F S S
16.56.11
Accessory kit AHS 12
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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MJF C I F S S
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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MJF C I F S S
16.57.1
Accessory kit AHS 11 / AHS 12 with Tool Control
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
Pressure limit (in bar)
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
Solenoid valve / forward travel
86
Pilot control unit two-fold, with pedal
Y62
Solenoid valve / reverse travel
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MJF C I F S S
16.57.3
Accessory kit AHS 11 / AHS 12 with Tool Control
Service Manual
Functional description 100
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
Pressure relief valve with additional pressure stage
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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MJF C I F S S
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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MJF C I F S S
Valve cone
16.57.5
Accessory kit AHS 11 / AHS 12 with Tool Control
Service Manual
Functional description
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
Secondary pressure relief valve
7
Housing
Y414 Prop. solenoid valve
11
Pressure spring
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MJF C I F S S
Service Manual
Accessory kit AHS 11 / AHS 12 with Tool Control Functional description
Fig. 4
Function of pressure control system
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MJF C I F S S
16.57.7
Accessory kit AHS 11 / AHS 12 with Tool Control
Service Manual
Functional description
Fig. 5 86
Pilot control unit and menu display on the screen H196 Sorting grapple indicator lamp
Pilot control device of kit
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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MJF C I F S S
16.57.9
Accessory kit AHS 11 / AHS 12 with Tool Control
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
6 Pressure check and adjustment 6.1
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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MJF C I F S S
16.57.11
Accessory kit AHS 11 / AHS 12 with Tool Control
Service Manual
Pressure check and adjustment
Fig. 7
6.3
Adjusting points and operation
20
Variable-displacement pump LPV / DPVO
104
Pressure cut-off valve
41 45
Measuring point MP Measuring point LS
500 510
Spool / regulating cylinder Hydraulic hammer/cylinder spool
86
Pilot control device of kit
511
100
Compact control block
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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MJF C I F S S
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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MJF C I F S S
16.57.13
Accessory kit AHS 11 / AHS 12 with Tool Control
Service Manual
Pressure check and adjustment
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
Adjustment of the stoke limitation of the spool 510
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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MJF C I F S S
Service Manual
Accessory kit AHS 11 / AHS 12 with Tool Control Pressure check and adjustment
copyright by
MJF C I F S S
16.57.15
Accessory kit AHS 11 / AHS 12 with Tool Control
Service Manual
Hydraulic diagram
7 Hydraulic diagram Items in hydraulic diagram, (see Fig. 10, page 17) 1 6
514 517
Pressure balance Restrictor check valve
20
from variable-displacement pump
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
from control oil unit
536
Pile driver
86
Pilot control unit two-fold, with pedal
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
Pressure balance Restrictor check valve
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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MJF C I F S S
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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MJF C I F S S
16.57.17
Accessory kit AHS 11 / AHS 12 with Tool Control
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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MJF C I F S S
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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MJF C I F S S
16.58.1
Accessory kit AHS 12 with changeover valve
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
Pressure limit (in bar) primary
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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MJF C I F S S
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
Pilot control device of kit
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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MJF C I F S S
16.58.3
Accessory kit AHS 12 with changeover valve
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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MJF C I F S S
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
Accessory kit AHS 12 with changeover valve
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
Accessory kit AHS 12 with changeover valve
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
Regulating cylinder spool
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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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
Accessory kit AHS 12 with changeover valve
Service Manual
Hydraulic system
7 Hydraulic system 1 20
from / to hydraulic tank Variable-displacement pump
514 517
Pressure balance Restrictor check valve
23
Regulating valve
525
Regulating cylinder
41 45
Measuring point MP Measuring point LS
526 527
Load-holding valve (piston side) Load-holding valve (rod side)
50
from the control oil unit
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
Compact control block
545
Regulating cylinder (horizontal movement)
104 500
Pressure cut-off valve Spool / regulating cylinder
546
Double load-holding valve
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
Restrictor check valve
510
Spool / hydraulic hammer / cylinder / pile driver
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
Accessory kit AHS 12 with changeover valve
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
Location/arrangement
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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MJF C I F S S
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.
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MJF C I F S S
°
The item is not built into all machines (subsequently added to machine equipment).
16.58.13
Accessory kit AHS 12 with changeover valve
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
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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
Individual control system switch
S206
Individual control system switch
S207
Individual control system switch
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MJF C I F S S
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
Slip ring / rotary connection
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
Functional description
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
Rotary connection (high pressure)
325
Slip ring rotary connection
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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
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MJF C I F S S
16.60.5
Individual control
Service Manual
Functional description
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
Double lowering brake valve
Y215
Solenoid valve Individual control of front left outrigger
320
Rotary connection (high pressure)
Y216
Solenoid valve Individual control of front right outrigger
325
Slip ring rotary connection
Y217
Solenoid valve Individual control of rear left outrigger
S204
Switch / individual control of front left outrigger
Y218
Solenoid valve Individual control of rear right outrigger
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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
Functional description
Fig. 6
16.60.8
Electrical system of individual control
F337 S204
Fuse (15 A) (front control console) Individual control system switch
X771 X957
Plug connection, 5-pin Plug connection, 21-pin
S205 S206
Individual control system switch Individual control system switch
X958 X963
Plug connection, 21-pin Plug connection, 21-pin
S207
Individual control system switch
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
Plug connection, 1-pin
Y217
Solenoid valve Individual control of rear left outrigger
X304
Plug connection, 6-pin
Y218
Solenoid valve Individual control of rear right outrigger
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MJF C I F S S
Solenoid valve Individual control of front right outrigger
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
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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
Tilt bucket outwards
16.62.1
Kit for control switch-over
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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16.62.3
Kit for control switch-over
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
copyright by
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.
copyright by
MJF C I F S S
16.62.5
Kit for control switch-over
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
copyright by
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.
copyright by
MJF C I F S S
16.62.7
Kit for control switch-over
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
Solenoid valve / travel forward
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
Compact control block
Y268
Solenoid valve / changeover regulating cylinder - hammer
copyright by
MJF C I F S S
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
Regulating cylinder spool
106
Boom cylinder spool
107
Bucket cylinder spool
109
Combined boom / stick cylinder spool
510
Hydraulic hammer/cylinder spool
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
Hydraulic connections of control switch-over kit
copyright by
MJF C I F S S
16.62.9
Kit for control switch-over
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
Secondary pressure relief valve / retract cylinder 537
50
from the control oil unit
535
Hydraulic hammer
78
Shuttle valve / combined shifting
537
Cylinder (auxiliary activation, e.g. sorting grapple)
79
Shuttle valve / pressure switch B33
81
Pilot control unit 4x, with joystick
B33
Pressure switch flow reduction
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
Switch / travel direction
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
Combined boom / stick cylinder spool
Y268
Solenoid valve / changeover regulating cylinder - hammer
122
Primary pressure-relief valve pump P1
Y299
180
Bucket cylinder
250
Regulating cylinder
251
Double load-holding valve
*
16.62.10
Solenoid valve / secondary pressure hammer Y385-1 Solenoid valve / changeover bucket cyl. - AHS Y385-2 Solenoid valve / changeover bucket cyl. - AHS
marked with P2 at the control valve block
copyright by
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
Kit for control switch-over
Service Manual
Electrical system
7 Electrical system B33
Pressure switch pst for AHS section
Near control valve block
H322
Warning light / switch-over
Right control console
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
copyright by
MJF C I F S S
Service Manual
Kit for control switch-over Electrical system
Fig. 5
Electrical system of switch-over control kit
copyright by
MJF C I F S S
16.62.13
Kit for control switch-over
Service Manual
Electrical system Step 84/2# Item
Description
Location/arrangement
A125**
PCB potentiometers
Left console
B33
Pressure switch pst for AHS section
Near control valve block
F321** F330** F331**
Fuse X12 Fuse kits Fuse X29
H322
Warning light / switch-over
Right control console
K375**
Relay / signal flow reduction AHS
Right console, rear
S241** S405
Switch AHS 11 / AHS 12 Switch / changeover
Right control desk Right console
U16**
BST excavator control system
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 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
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
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
Right console, front Right console, front Right console, front
Service Manual
Kit for control switch-over Electrical system
copyright by
MJF C I F S S
16.62.15
Kit for control switch-over
Service Manual
Electrical system
16.62.16
copyright by
MJF C I F S S
Service Manual
Kit for control switch-over Function
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
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
copyright by
MJF C I F S S
Tilt bucket outwards
16.62.21
Kit for control switch-over
Service Manual
Operation
9 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. 7
Operator's cab with pilot control devices, switches and indicator lamps for the switch-over kit
81
Pilot control unit with joystick
H196
Sorting grapple indicator lamp
86
Pilot control unit with pedals
H322
Indicator light / control switch-over
S241 S405
Switch AHS12 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.
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
copyright by
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
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)
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
copyright by
MJF C I F S S
16.62.23
Kit for control switch-over
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
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
16.62.24
copyright by
MJF C I F S S
Service Manual
Kit for control switch-over Function of switch-over / control
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.
copyright by
MJF C I F S S
16.62.25
Kit for control switch-over
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.
16.62.26
copyright by
MJF C I F S S
Service Manual
Kit for control switch-over Pressure check and adjustment
11 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.
copyright by
MJF C I F S S
16.62.27
Kit for control switch-over
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
16.62.28
Hydraulic connections of control switch-over kit
copyright by
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
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
Solenoid valve / travel forward
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
Compact control block
Y268
Solenoid valve / changeover regulating cylinder - hammer
105
Regulating cylinder spool
Y299
Solenoid valve / secondary pressure hammer
106
Boom cylinder spool
Y385-1 Solenoid valve changeover bucket cyl. AHS
107
Bucket cylinder spool
109
Combined boom / stick cylinder spool
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.
copyright by
MJF C I F S S
16.62.29
Kit for control switch-over
Service Manual
Hydraulic system Fig. 9
13
Hydraulic connections of control switch-over kit
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
Secondary pressure relief valve / retract cylinder 537
50
from the control oil unit
535
Hydraulic hammer
78
Shuttle valve / combined shifting
537
Cylinder (auxiliary activation, e.g. sorting grapple)
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
Collecting pipe Compact control block
S263 S405
Switch / travel direction Key switch / control switch-over
105 106
Regulating cylinder spool Boom cylinder spool
Y62 Y63
Solenoid valve / travel forward Solenoid valve / travel reverse
107
Bucket cylinder spool
Y262
Solenoid valve / switch-over bucket offset boom bearing
109
Combined boom / stick cylinder spool
Y268
122
Primary pressure-relief valve pump P1
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
Double load-holding valve
Y385-2 Solenoid valve / changeover bucket cyl. - AHS Y451 Solenoid valve switch-over buzzer / boom
*
16.62.30
marked with P2 at the control valve block
copyright by
MJF C I F S S
Service Manual
Kit for control switch-over Hydraulic system
copyright by
MJF C I F S S
16.62.31
Kit for control switch-over
Service Manual
Electrical system
14
Electrical system B33
Pressure switch pst for AHS section
Near control valve block
H322
Warning light / switch-over
Right control console
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
** position from basic diagram
16.62.32
copyright by
MJF C I F S S
Service Manual
Kit for control switch-over Electrical system
Fig. 10
Electrical system of switch-over control kit
copyright by
MJF C I F S S
16.62.33
Kit for control switch-over
Service Manual
Electrical system Step 84/2# Item
Description
Location/arrangement
A125**
PCB potentiometers
Left console
B33
Pressure switch pst for AHS section
Near control valve block
F321** F330** F331**
Fuse X12 Fuse kits Fuse X29
H196** H322
Indicator light / sorting grapple Warning light / switch-over
Right control console Right control console
K375**
Relay / signal flow reduction AHS
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
X12** X29** X837** X839** X856** X857** X957** X958** X963** X965** X966** X968-1** X968-2** X974-4** X1028 X1029 X1224
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
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 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
** position from basic diagram # see also electric kits in group 8.45
16.62.34
copyright by
MJF C I F S S
Right console, front Right console, front Right console, front
Service Manual
Kit for control switch-over Electrical system
copyright by
MJF C I F S S
16.62.35
Kit for control switch-over
Service Manual
Electrical system
16.62.36
copyright by
MJF C I F S S
Service Manual
Kit for control switch-over Function
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
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: e Operate hydraulic hammer / close sorting grapple
after switch-over: m Tilt bucket inwards
f
n
A 312 LI 12363A 314 LI 2001A 316 LI 2001A 316 LI-IND 2001-
Open sorting grapple
copyright by
MJF C I F S S
Tilt bucket outwards
16.64.1
Kit for control switch-over
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 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
copyright by
MJF C I F S S
A 312 LI 12363A 314 LI 2001A 316 LI 2001A 316 LI-IND 2001-
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 275 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 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
A 312 LI 12363A 314 LI 2001A 316 LI 2001A 316 LI-IND 2001-
copyright by
MJF C I F S S
16.64.3
Kit for control switch-over
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
Operation of bucket cylinder 275 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
16.64.4
copyright by
MJF C I F S S
A 312 LI 12363A 314 LI 2001A 316 LI 2001A 316 LI-IND 2001-
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 16.56.
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.
A 312 LI 12363A 314 LI 2001A 316 LI 2001A 316 LI-IND 2001-
copyright by
MJF C I F S S
16.64.5
Kit for control switch-over
Service Manual
Pressure check and adjustment
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.
4 Pressure check and adjustment Note! For a description of the valve and stroke limiter settings in auxiliary axle AHS 12, refer to group 16.56.
16.64.6
copyright by
MJF C I F S S
A 312 LI 12363A 314 LI 2001A 316 LI 2001A 316 LI-IND 2001-
Service Manual
Kit for control switch-over Components and hydraulic lines
5 Components and hydraulic lines
Fig. 3
Hydraulic connections of control switch-over kit
1 50
Hydraulic tank Control oil unit
Y62 Y63
Solenoid valve / travel forward Solenoid valve / travel reverse
81
Pilot control unit with joystick
Y268
Solenoid valve / changeover regulating cylinder - hammer
86
Pilot control unit with pedals
Y299
Solenoid valve / secondary pressure hammer
100
Compact control block
Y385-1 Solenoid valve changeover bucket cyl. AHS
260
Bucket cylinder spool
Y385-2 Solenoid valve changeover bucket cyl. AHS
510
Hydraulic hammer/cylinder spool
511
Secondary pressure relief valve with additional pressure stage / extend hydr. hammer cyl.
A 312 LI 12363A 314 LI 2001A 316 LI 2001A 316 LI-IND 2001-
copyright by
MJF C I F S S
16.64.7
Kit for control switch-over
Service Manual
Hydraulic system
6 Hydraulic system 1
to hydraulic tank
512
Retracting secondary pressure relief valve / cylinder 537
20
from variable-displacement pump
514
Pressure balance
41 45
Measuring point MP Measuring point LS
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
Cylinder (auxiliary activation, e.g. sorting grapple)
88T 100
Collecting pipe Compact control block
B33 S63
Pressure switch flow reduction Switch / offset boom bearing
104
Pressure cut-off valve
S241
260
Bucket cylinder spool
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
Solenoid valve / travel reverse
504
Secondary pressure-relief valve / extend regulating cylinder 525 Pressure balance
Y268
507
Restrictor check valve
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
copyright by
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
A 312 LI 12363A 314 LI 2001A 316 LI 2001A 316 LI-IND 2001-
Service Manual
Kit for control switch-over Hydraulic system
A 312 LI 12363A 314 LI 2001A 316 LI 2001A 316 LI-IND 2001-
copyright by
MJF C I F S S
16.64.9
Kit for control switch-over
Service Manual
Electrical system
7 Electrical system B33
Pressure switch pst for AHS section
Near control valve block
H322
Warning light / switch-over
Right control console
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
** position from basic diagram
16.64.10
copyright by
MJF C I F S S
A 312 LI 12363A 314 LI 2001A 316 LI 2001A 316 LI-IND 2001-
Service Manual
Kit for control switch-over Electrical system
Fig. 4
A 312 LI 12363A 314 LI 2001A 316 LI 2001A 316 LI-IND 2001-
Electrical system of switch-over control kit
copyright by
MJF C I F S S
16.64.11
Kit for control switch-over
Service Manual
Electrical system Step 84/1# Item
Description
Location/arrangement
A125**
PCB potentiometers
Left console
F330** F331**
Fuse kits Fuse X29
H322
Warning light / switch-over
Right control console
P1**
Flow reduction potentiometer
Right control console
S241** S405
Switch AHS 11 / AHS 12 Switch / changeover
Right control desk Right console
U16**
BST excavator control system
Right console, rear
V156-4 V169
Blocking diode A125 Blocking diode
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
Right console, front Right console, front
** position from basic diagram # see also electric kits in group 8.45
16.64.12
copyright by
MJF C I F S S
A 312 LI 12363A 314 LI 2001A 316 LI 2001A 316 LI-IND 2001-
Service Manual
Kit for control switch-over Electrical system
A 312 LI 12363A 314 LI 2001A 316 LI 2001A 316 LI-IND 2001-
copyright by
MJF C I F S S
16.64.13
Kit for control switch-over
Service Manual
Electrical system
16.64.14
copyright by
MJF C I F S S
A 312 LI 12363A 314 LI 2001A 316 LI 2001A 316 LI-IND 2001-
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
copyright by
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
copyright by
MJF C I F S S
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
copyright by
MJF C I F S S
Pilot control unit / support
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
Slip ring / rotary connection
304
Pressure-relief valve
395
Dozer blade cylinder
320
Rotary connection 7x
Y56
Solenoid valve 6x
copyright by
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
copyright by
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
Pressure-relief valve
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
copyright by
MJF C I F S S
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
copyright by
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
Rotary connection 7x
295
Support cylinder / outriggers
325
Slip ring / rotary connection
297
Double lowering brake valve
395
Dozer blade cylinder
302
Hydraulically releasable check valve
S335 Switch / changeover blade - outrigger
304
Pressure-relief valve
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
Pressure-relief valve
Y56
copyright by
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
Plug connection, 21-pin
S335
Switch / dozer blade - outrigger
X958
Plug connection, 21-pin
Plug connection, 5-pin
X301
Plug connection, 12-pin
X963
Plug connection, 21-pin
X304
Plug connection, 6-pin
Y56
Solenoid valve 6x
copyright by
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
Hydraulic cab elevation system
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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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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16.70.3
Hydraulic cab elevation system
Service Manual
Design
Fig. 3
16.70.4
Pilot control of hydraulic cab elevation system
1
Hydraulic tank
100
Compact control block
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
Hydraulic cab elevation system Design
Fig. 4
Components of the hydraulic operator's cab elevation
20
Variable-displacement pump
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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16.70.5
Hydraulic cab elevation system
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
Hydraulic cab elevation system Design
Fig. 7
Installation position of the accumulator, restrictor check valves and cylinders in the support
615
Cylinder for cab elevation system
619
Restrictor check valve / pipe fracture safety valve
620
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MJF C I F S S
Hydraulic accumulator
16.70.7
Hydraulic cab elevation system
Service Manual
Functional description
4 Functional description 4.1
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
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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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16.70.9
Hydraulic cab elevation system
Service Manual
Functional description
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
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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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16.70.11
Hydraulic cab elevation system
Service Manual
Pressure check and adjustment
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
Compact control block
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
Pressure-relief valve / lifting cab
600.2
Adjusting screw (size 6 Allen key)
604
Pressure balance
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16.70.13
Hydraulic cab elevation system
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
Variable-displacement pump
602
Pressure-relief valve / lifting cab
23 30
Regulating valve / pump Gear pump / cooling
604 615
Pressure balance Cylinder for cab elevation system
41
Measuring point / pump pressure
618
Hydraulically releasable check valve
45
Measuring point / LS pressure
619
Restrictor check valve / pipe fracture safety valve
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
Compact control block
S78
Button for emergency lowering system (from serial no. 12390)
104
Pressure cut-off valve
Y204 Solenoid valve of emergency lowering system (from serial no. 12390)
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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
Hydraulic cab elevation system
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
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MJF C I F S S
16.70.17
Hydraulic cab elevation system
Service Manual
Electrical system of hydraulic operator's cab elevation system
16.70.18
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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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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
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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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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
Restrictor check valve
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
Generator drive accessory kit
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
Measuring point / working pressure
400 408
Generator Bearing block
420 430
Control valve block Oil motor
413
Pressure balance
Y294
Solenoid pressure relief valve
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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
Generator drive accessory kit
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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MJF C I F S S
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
Restrictor check valve
6 7
Adjusting screw Lock nut
418 430
Measuring point / working pressure Oil motor
400
Generator
Y295
Solenoid pressure relief valve
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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MJF C I F S S
16.86.7
Generator drive accessory kit
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
copyright by
MJF C I F S S
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
Solenoid pressure relief valve
415
Restrictor
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MJF C I F S S
16.86.9
Generator drive accessory kit
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
Gear pump / steering
32
Gear pump / brake and pilot control unit
36 400
Item
see group
414
Restrictor (Ø 4.5 mm)
13.10
415
Restrictor (Ø 7.5 mm)
15.12 6.24/6.27
416
Check valve
Gear pump
417
Restrictor check valve
Generator
418
Measuring point / working pressure
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
copyright by
MJF C I F S S
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)
copyright by
MJF C I F S S
16.86.11
Generator drive accessory kit
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
Restrictor (Ø 4.5 mm)
5
Cap nut
425
Restrictor (Ø 7.5 mm)
413
Pressure balance, complete
Y295 Solenoid pressure-relief valve
420
Pilot control unit, complete
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MJF C I F S S
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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MJF C I F S S
16.86.13
Generator drive accessory kit
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
Gear pump / steering
32
Gear pump / brake and pilot control unit
36 400
Item
see group
423
Check valve
13.10
424
Restrictor (Ø 4.5 mm)
15.12
425
Restrictor (Ø 7.5 mm)
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
copyright by
MJF C I F S S
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)
copyright by
MJF C I F S S
16.86.15
Generator drive accessory kit
Service Manual
Electrical system of the generator drive
10
Electrical system of the generator drive
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
Plug connection, 2-pin Plug connection, 2-pin
S382
Fine control switch
X958
Plug connection, 21-pin
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
Plug connection, 3-pin
X1048 Plug connection, 12-pin
X74
Plug connection, 2-pin
X1048-1Plug connection, 6-pin
X74-1
Plug connection, 1-pin
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.
copyright by
MJF C I F S S
16.86.17
Generator drive accessory kit
Service Manual
Electrical system of the generator drive
16.86.18
copyright by
MJF C I F S S
Service Manual
SUBGROUP - INDEX Section
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.
copyright by
MJF C I F S S
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
copyright by
MJF C I F S S
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.
copyright by
MJF C I F S S
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
SUBGROUP - INDEX Section
Group
Type
Tank arrangement
19.10.1
A 312 LI 12363A 314 LI 2001A 316 LI 2001A 316 LI-IND 2001R 313 LI 27752R 317 LI 18161-
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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MJFCIFSS
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
copyright by
MJFCIFSS
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.
copyright by
MJFCIFSS
19.10.3
Tank arrangement
Service Manual
Design and function of the hydraulic tank
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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MJFCIFSS
Service Manual
Tank arrangement Design and function of the hydraulic tank
Fig. 4
Hydraulic tank, connections part 2
1
Hydraulic tank, complete
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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MJFCIFSS
19.10.5
Tank arrangement
Service Manual
Design and function of the hydraulic tank
Fig. 5
19.10.6
Hydraulic tank, complete
copyright by
MJFCIFSS
Service Manual
Tank arrangement Design and function of the hydraulic tank
2.3
1
Hydraulic tank, complete
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
Hex head screw Retaining washer
B285 E50
Oil temperature sensor / fan control Power and fuse cabinet
4
Return filter, complete
Y3
Solenoid valve / pilot control
4/41
Return filter, see Fig. 6
Y24
Solenoid valve / creeper gear
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
Solenoid valve / oscillating axle support
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.
copyright by
MJFCIFSS
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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MJFCIFSS
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
Hex head screw Retaining washer
21
Tank lid
60
TC valve / slewing gear
22
Strainer
copyright by
MJFCIFSS
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.
copyright by
MJFCIFSS
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
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)
copyright by
MJFCIFSS
Service Manual
Tank arrangement Design of fuel tank
4.2.2
Tubular-type sensor for model A 309 / 311 from serial no. 31390, model A 312 from 31399
Fig. 9
Switching points of tubular-type sensor
1 2
O-ring Magnet
7 8
3rd switching point (1/2 full; 29 Ohm) 4th switching point (3/8 full; 35 Ohm)
3
Adjusting ring, secured with screw
9
5th switching point (1/4 full; 43 Ohm)
4
1st switching point (full; 11 Ohm)
10
6th switching point (reserve; 54 Ohm)
5
2nd switching point (3/4 full; 19 Ohm)
11
7th switching point (reserve; 70 Ohm)
6
2nd switching point (5/8 full; 25 Ohm)
copyright by
MJFCIFSS
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
Switching points of tubular-type sensor
1
O-ring
6
3rd switching point (5/8 full; 29 Ohm)
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)
copyright by
MJFCIFSS
Service Manual
Tank arrangement Design of fuel tank
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
4th switching point (1/2 full; 29 Ohm)
2
Magnet
8
5th switching point (3/8 full; 35 Ohm)
3
Adjusting ring, secured with screw
9
6th switching point (1/4 full; 43 Ohm)
4
1st switching point (full; 11 Ohm)
10
7th switching point (reserve; 54 Ohm)
5
2nd switching point (3/4 full; 19 Ohm)
11
8th switching point (reserve; 70 Ohm)
6
3rd switching point (5/8 full; 25 Ohm)
copyright by
MJFCIFSS
19.10.15
Tank arrangement
Service Manual
Design of fuel tank
19.10.16
copyright by
MJFCIFSS
Service Manual
SUBGROUP - INDEX Section
Group
Type
Heating / air-conditioning system
17.30.1
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-
17.1 MJF C I F S S
Service Manual
1.2 MJF C I F S S
Service Manual
Heating / air-conditioning system
Heating / air-conditioning system
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
Installation instructions
Page 17.30.14
Maintenance
Page 17.30.18
Fault diagnosis
17.30Page 17.30.27
copyright by
MJF C I F S S
17.30.1
Heating / air-conditioning system
Service Manual
Notes
1 Notes
17.30.2
copyright by
MJF C I F S S
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
Heating / air-conditioning system
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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Heating / air-conditioning system
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
Heating / air-conditioning system Design and function
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
Heating / air-conditioning system
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
Dryer insert Sight glass
M65 Blower motor M74 Fan motor
7 8
Expansion valve Evaporator
Y20
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Magnetic clutch
Service Manual
Heating / air-conditioning system Design and function
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
Heating / air-conditioning system
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
Heating / air-conditioning system
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
Heating / air-conditioning system
Service Manual
Installation instructions
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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17.30.15
Heating / air-conditioning system
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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17.30.17
Heating / air-conditioning system
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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17.30.19
Heating / air-conditioning system
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
Dryer insert Sight glass
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
Heating / air-conditioning system
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**
Plug connection, 21-pin
X860**
Plug connection, 6-pin
X861**
Plug connection, 6-pin
X862** X863**
Plug connection, 6-pin Plug connection, 15-pin
X864
Plug connection, 4-pin
X952**
Plug connection, 21-pin
X955**
Plug connection, 15-pin
X959**
Plug connection, 21-pin
X964**
Plug connection, 21-pin
Y20
Solenoid valve / a/c clutch
** in basic diagram
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17.30.23
Heating / air-conditioning system
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
Air-conditioning system
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17.30.25
Heating / air-conditioning system
Service Manual
Electrical diagrams
Fig. 17
17.30.26
Air-conditioning system
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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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17.30.27
Heating / air-conditioning system
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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