Liebherr

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 Type of modification Affected models
(a) Modified actuation of the pressure-relief A 314 Li: 11147
valves for slewing gear
Joint control line Xab replaced by separate A 316 Li: 11152
control lines Xa / Xb for each valve
A 316 Li industrial: 11178
Additional orifice 126 in connection P of valve
125
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 A 316 Li: 11822

(change in design from restricted to blocked
outlet) A 316 Li industrial: 11823
Spool for chassis

(change in design from restricted to open
outlet)
(c) Modified pressure balance 244 for stick A 314 Li: 12814
cylinder
A 316 Li: 12741
Change from pressure balance without shock
absorption to pressure balance with 0.4mm A 316 Li industrial: 11846
shock absorption
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 0.8 mm to 0.6 mm
(d) Modified fan cycle A 312 Li: 13289
Installation of coarse filter 15 in the pressure A 314 Li: 13104

line
to oil motor / radiator fan A 316 Li: 13105
(e) Various modifications to control valve A 312 Li: 16275

block
A 314 Li: 16215
Tuning improved. Pressure balance 224 pilot-
controlled. Shuttle valve 107 integrated into A 316 Li: 16141
control block. Central nozzle 109 screwed in.
New slewing gear module (check valve 123 A 316 Li industrial: 16286
before spool 120).
Modified TC valve 125

Integrated restrictor 126 and bypass line with
restrictor 129
1.02.1
MJFCIFSS
Modification of series Service Manual
Item Type of modification Affected models

(f) Pressure-relief valve in the gear pump / A 312 - A 316 Li: 20241
steering
Gear pump of steering system with integrated
pressure control
(g) Modified electrical system A 312 Li: 20330
A 314 Li: 20334
Modifications:
A 316 Li: 20340
K392 (industrial shut-off) omitted, A 316 Li in.: 20340
S5 with 3 push buttons, S382 modified,
S263 modified, S422 added
(h) New pilot control unit for travel working R 317 Li: 21205
movement:
The two individual pilot control units 2x are
replaced by one pilot control unit 4x
(i) Optimised control of control valve block A 309 Li: 23503
A 311 Li: 23504
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 A 309 Li: 27110
A 311 Li: 27112
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.
See also service information 07-11-37/2005
(l) Speed reduction when working at 1950 A 309 Li: 27110
rpm A 311 Li: 27112
Omission of solenoid valve Y330 for zero
boom switching from P2 during travel
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 309 Li: 26392
A 311 Li: 26396
A hydraulically operated cylinder (via pilot
A 312 Li: 29898
control system) with a locking bolt is installed
A 316 Li: 28061
in the uppercarriage. It is used for the locking
A 316 Li ind.: 28061
of the uppercarriage during parking and
transport of the machine.
(n) Changeover to travel operation A 316 Li: 28061
A 316 Li ind.: 28061
By changing over to the 2 HL 270/290
transmission, the travel motor has also been
upgraded to a DMVA 165 motor.
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 mainte-
nance 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 ma-
chine 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 regula-
tions 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 ) de-
signed 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 ac-
cordance 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 min-
imum 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 per-
son. 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 super-
vision and guidance of an experienced person.
Check and observe any person working or operating the machine at least periodically if they ob-
serve 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, ...
1.10.1
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MJFCIFSS
Safety instructions Service Manual
Crushing and burn prevention
For certain tasks, safety glasses, hard hats, safety boots, work gloves, reflective vests, ear pro-
tection etc. are required.
Consult the supervisor at the job site for special safety instructions and regulations.
Always raise the safety lever before leaving the operators seat.
When entering or leaving the cab, do not use the steering column, the control panel or the joy-
sticks 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 main-
tenance 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 miss-
ing 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 ad-
justment 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 align-
ment 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 con-
tact 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 sup-
ported from below with hardwood beams.
1.10.2
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MJFCIFSS
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, rub-
bing 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 pro-
vided 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 load-
ing 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 A-
equipment), 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.
1.10.3
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MJFCIFSS
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 operators 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 op-
eration.
Follow the regulations effective for the relevant site.
Never start the machine without the drivers 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 drivers 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 drivers 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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MJFCIFSS
Towing the machine safely
9 Towing the machine safely
Always observe the correct procedure: See chapter Towing the machine in this operating man-
ual.
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 regu-
lations 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 operators 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 nec-
essary, 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 operators seat as long as the machine is still moving.
Never leave the machine unattended while the Diesel engine is running.
1.10.5
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MJFCIFSS
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, hoist-
ing 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 work-
ing tool and the operators 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 tim-
ber)
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 condi-
tions.
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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MJFCIFSS
NOTE: The weight of absorbent material, such as wooden logs, depends on the length, the diam-
eter and the specific weight. The existing influencing factors for a natural product, such as mois-
ture, 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 direc-
tion. 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 cent-
er 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 sup-
ported 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 operators cab elevation
To enter and exit the machine, park the machine on ground, which is level in lengthwise and hor-
izontal 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.
1.10.7
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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 operators 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 utili-
zation. 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 recommenda-
tions 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 char-
acteristics 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 suffi-
cient 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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MJFCIFSS
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 LIEB-
HERRs 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 pur-
pose.
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 sup-
ported.
Never lie under the machine, if it is lifted by the work equipment without properly propping the ma-
chine.
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 han-
dling 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 de-
vice.
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.
1.10.9
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MJFCIFSS
Safe maintenance of the machine
12 Safe maintenance of the machine
12.1 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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MJFCIFSS
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.
1.10.11
copyright by
MJFCIFSS
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-to-
metal 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
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 emergency-
stop 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)
1.10.13
copyright by
MJFCIFSS
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 / Dnomination
Blatt/Page/Feuille: 1
bestehend aus 6 Blatt
Mjfcifss! Preloads and tightening torques consisting of Pages
compos Feuille
for screws with metric coarse and fine
threads
according to DIN 13, sheet 12 WN 4037 I
The preload forces and tightening torques compiled in the table
are based on the VDI 2230, July 1986.
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 Metric fine thread

Surface finish: Surface finish:
- black-chrome finished or phosphatised oiled - black-chrome finished or phosphatised oiled
- electro-galvanized - electro-galvanized
- flZn according to LH standard 10021432 dry - flZn according to LH standard 10021432 dry
Tightening Tightening
Thread Class Assembly preload torque Thread Class Assembly preload torque
FM in N MA in Nm FM in N MA in Nm
for mean friction factor G= 0.12 for mean friction factor G= 0.12
8.8 4 050 2.8
M4 10.9 6 000 4.1
12.9 7 000 4.8
8.8 6 600 5.5
M5 10.9 9 700 8.1
12.9 11 400 9.5
8.8 9 400 9.5
M6 10.9 13 700 14.0
12.9 16 100 16.5
8.8 13 700 15.5
M7 10.9 20 100 23.0
12.9 23 500 27
8.8 17 200 23 8.8 18 800 24.5
M8 10.9 25 000 34 M8x1 10.9 27 500 36
12.9 29 500 40 12.9 32 500 43
8.8 24 800 36
M9x1 10.9 36 500 53
12.9 42 500 62
8.8 27 500 46 8.8 31 500 52
M10 10.9 40 000 68 M10x1 10.9 46 500 76
12.9 47 000 79 12.9 54 000 89
8.8 29 500 49
M10x1.25 10.9 43 000 72
12.9 51 000 84
8.8 40 000 79 8.8 45 000 87
M12 10.9 59 000 117 M12x1.25 10.9 66 000 125
12.9 69 000 135 12.9 77 000 150
8.8 42 500 83
M12x1.5 10.9 62 000 122
12.9 73 000 145
8.8 55 000 125 8.8 61 000 135
M14 10.9 80 000 185 M14x1.5 10.9 89 000 200
12.9 94 000 215 12.9 104 000 235
8.8 75 000 195 8.8 82 000 205
M16 10.9 111 000 280 M16x1.5 10.9 121 000 300
12.9 130 000 330 12.9 141 000 360
01/2005 1.20.1
Metric coarse thread Metric fine thread
Surface finish: Surface finish:
- black-chrome finished or phosphatised oiled - black-chrome finished or phosphatised oiled
- electro-galvanized - electro-galvanized
- flZn according to LH standard 10021432 dry - flZn according to LH standard 10021432 dry
Thread Class Assembly preload torque Thread Class Assembly preload torque
FM in N MA in Nm FM in N MA in Nm
for mean friction factor G= 0.12 for mean friction factor G= 0.12
8.8 94 000 280 8.8 110 000 310
M18 10.9 135 000 390 M18x1.5 10.9 157 000 440
12.9 157 000 460 12.9 184 000 520
8.8 102 000 290
M18x2 10.9 146 000 420
12.9 170 000 490
8.8 121 000 390 8.8 139 000 430
M20 10.9 173 000 560 M20x1.5 10.9 199 000 620
12.9 202 000 650 12.9 232 000 720
8.8 152 000 530 8.8 171 000 580
M22 10.9 216 000 750 M22x1.5 10.9 245 000 820
12.9 250 000 880 12.9 285 000 960
8.8 175 000 670 8.8 207 000 760
M24 10.9 249 000 960 M24x1.5 10.9 295 000 1090
12.9 290 000 1120 12.9 346 000 1270
8.8 196 000 730
M24x2 10.9 280 000 1040
12.9 325 000 1220
8.8 230 000 1000 8.8 267 000 1110
M27 10.9 330 000 1400 M27x1.5 10.9 381 000 1580
12.9 385 000 1650 12.9 445 000 1850
8.8 255 000 1070
M27x2 10.9 365 000 1500
12.9 425 000 1800
8.8 280 000 1350 8.8 335 000 1540
M30 10.9 400 000 1900 M30x1.5 10.9 477 000 2190
12.9 465 000 2250 12.9 558 000 2560
8.8 321 000 1490
M30x2 10.9 457 000 2120
12.9 534 000 2480
8.8 350 000 1850 8.8 410 000 2050
M33 10.9 495 000 2600 M33x1.5 10.9 584 000 2920
12.9 580 000 3000 12.9 683 000 3420
8.8 395 000 2000
M33x2 10.9 560 000 2800
12.9 660 000 3300
8.8 410 000 2350 8.8 492 000 2680
M36 10.9 580 000 3300 M36x1.5 10.9 701 000 3820
12.9 680 000 3900 12.9 820 000 4470
8.8 440 000 2500
M36x3 10.9 630 000 3500
12.9 740 000 4100
8.8 490 000 3000 8.8 582 000 3430
M39 10.9 700 000 4300 M39x1.5 10.9 830 000 4890
12.9 820 000 5100 12.9 971 000 5720
8.8 530 000 3200
M39x3 10.9 750 000 4600
12.9 880 000 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 57
01/2005 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 Type with EOLASTIC seal
Thread Thread
Type torques Type torques
M or G M or G
in Nm in Nm
Light-duty series L 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 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 Lr A 3 C G1A 330 GE 28 Lr Ed A 3 C G1A 310
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 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
1.21. 1
MJF C I F S S
Tightening torques Service Manual
of swivelling connections (Ermeto)
Type with sealing edge Type with EOLASTIC seal
Thread Thread
Type torques Type torques
M or G M or G
in Nm in Nm
GE 25 SR A 3 C G1A 340 GE 25 SR ED A 3 C G1A 310
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 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)
Tightening torques Tightening torques

Type Type
Thread Nm Thread Nm
Light-duty series 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 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
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
1.21. 2
MJF C I F S S
Service Manual Tightening torques
Tightening torques Tightening torques

Type Type
Thread 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 SM KDS A 3 C M 48 X 2.0 700
Tab. 2 Tightening torques of swivelling connections
3 of screw-in studs (Ermeto)
Screw-in Screw-in
Type VSTI torques Type VSTI torques
thread M thread G
Nm 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 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 26X1.5 ED A3C M 26 X 1.5 120 VSTI 1 1/2 ED A3C G 1 1/2 A 450
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
1.21. 3
MJF C I F S S
Tightening torques Service Manual
1.21. 4
MJF C I F S S
Bezeichnung
Mj f c i f s s ! Assembly instruction
consisting of Pages
compos Feuille
for pistons and piston nuts
(hydraulic cylinders) WN 4121 B
Contents
1. Scope of application
2. Description
3. Referenced documents (torque table)
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 Piston
B Assembly wrench
C 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
A Marks on the piston nut 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 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)
The date indicates the latest version of this table. Edition: 11.04.2005
This document is not covered by the revision service.
FS Preload Piston Piston nut Thread

4121- Torque Turn.distance Turning angle Turns distance Turning angle M
... Mv [Nm] [mm] ~ [] [mm] ~ [] [mm]
071 100 11 +1 30 21 +1 57 42x1,5
072 100 21 +1 57 21 +1 57 42x1,5
073 100 18 +1 49 19 +1 52 42x1,5
075 100 19 +1 52 21 +1 57 42x1,5
079 100 11 +1 30 21 +1 57 42x1,5
080 100 18 +1 49 - - 42x1,5
091 100 13 +1 30 19 +1 44 50x2
092 100 25 +1 57 19 +1 44 50x2
093 100 24 +1 55 19 +1 44 50x2
095 100 13 +1 30 19 +1 44 50x2
096 100 10 +1 23 9 +1 21 50x2/SW65
097 100 17 +1 39 19 +1 44 50x2
098 100 17 +1 39 - - 50x2
099 100 24 +1 55 19 +1 44 50x2
111 100 16 +1 33 18 +1 37 56x2
112 100 17 +1 35 18 +1 37 56x2
113 100 18 +1 37 18 +1 37 56x2
114 100 19 +1 39 - - 56x2
115 100 18 +1 37 - - 56x2
121 150 15 +1 29 19 +1 36 60x2
123 150 17 +1 32 19 +1 36 60x2
126 150 14 +1 27 - - 60x2
127 150 22 +1 42 - - 60x2
151 150 15 +1 27 19 +1 34 65x2
152 150 20 +1 35 19 +1 34 65x2
153 150 20 +1 35 - - 65x2
171 150 12 +2 20 18 +1 30 68x2
173 150 19 +2 32 18 +1 30 68x2
174 150 25 +2 42 18 +1 30 68x2
175 150 25 +2 42 18 +1 30 68x2
176 150 19 +2 32 18 +1 30 68x2
177 150 19 +2 32 18 +1 30 68x2
179 150 11 +2 19 18 +1 30 68x2
180 150 20 +2 34 18 +1 30 68x2
181 150 20 +2 34 - - 68x2
183 200 - - 40 +2 67 68x2
201 200 17 +2 26 16 +1 24 76x2
202 200 26 +2 39 16 +1 24 76x2
203 200 27 +2 41 16 +1 24 76x2
204 200 27 +2 41 16 +1 24 76x2
205 200 13 +2 20 - - 76x2
206 200 25 +2 38 25 +1 38 76x2
207 200 23 +2 35 - - 76x2
208 200 15 +2 22 - - 76x2
209 200 30 +2 45 - - 76x2
231 200 8 +2 11 16 +1 22 85x3
232 200 17 +2 23 16 +1 22 85x3
09 / 2005 1.22.5
FS Preload Piston Piston nut Thread
4121- Torque Turn.distance Turning angle Turns distance Turning angle M
... Mv [Nm] [mm] ~ [] [mm] ~ [] [mm]
234 200 22 +2 30 - - 85x3
261 250 20 +2 25 10 +1 12 95x3
281 250 20 +2 23 13 +1 15 100x3
282 250 25 +2 29 - - 100x3
301 300 21 +3 22 20 +2 21 110x3
302 300 18 +3 19 20 +2 21 110x3
303 300 20 +3 21 20 +2 21 110x3
304 300 23 +3 24 20 +2 21 110x3
305 300 9 +3 9 - - 110x3
306 300 24 +3 25 - - 110x3
307 300 27 +3 28 - - 110x3
331 400 23 +3 22 20 +2 19 120x3
332 400 11 +3 11 - - 120x3
333 400 27 +3 26 - - 120x3
334 400 20 +3 19 20 +2 19 120x3
335 400 30 +3 29 - - 120x3
501 200 21 +2 30 - - 80x2
531 500 34 +3 28 - - 140x3
1.22.6 09 / 2005
Bezeichnung
Mj f c i f s s ! Assembly instruction
consisting of Pages
compos Feuille
for piston rod bearings with external threads
(hydraulic cylinders) WN 4122 B
Contents
2. Description
3. Referenced documents (torque table)
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 Bearing head
B Assembly wrench
C 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 Marks on the cylinder tube and the auter diameter of the bearing head after application
of the pretightening torque
B Mark on the cylinder tube
C Turning angle
D Turning distance
E Mark on the bearing head after tightening
F Cylinder Tube
G 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. Edition: 24.01.2005
This document is not covered by the revision service.
.
NU Preload Piston rod bearing

Turning
4122- Torque distance Turning angle
... Mv [Nm] [mm] ~ []
001
011 50 7 +1 10
016 100 10 +1 12
017 100 10 +1 12
026 100 9 +1 10
027 100 10 +1 11
031 100 8 +1 8
036 100 8 +1 9
039
041
046
047
051
052
151 400 14 +1 6
1.24.4 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.
1.50. 1
MJF C I F S S
Fuels, lubricants and other consumables Service Manual
1.1 Lubricant table
Description Medium Symbol Classification Viscosity
Diesel engine Engine oil Refer to the instructions of the engine

manufacturer
(see Deutz manual)
Hydraulic tank Engine oil API-CD, API- SAE 10W

CD+SF, SAE 10W-30
CCMC-D4, SAE 10W-40
CCMC-D5, SAE 15W-40
ACEA-E1, SAE 20W-20
ACEA-E3 SAE 30W
Slewing gear mechanism Gear oil API - GL -5 SAE 80W90

(as stop brake) MIL-L 2105 B, or
C or D SAE 90
Slewing gear mechanism Gear oil API - GL -5 SAE 90 LS

(as positioning slewing MIL-L 2105 B
brake)
Steering axle Gear oil API - GL -5 SAE 90 LS

MIL-L 2105 B
ZF TE-ML 05
Rigid axle Gear oil API - GL -5 SAE 90 LS

with multi-disc brake MIL-L 2105 B
ZF TE-ML 05
Rigid axle Gear oil API - GL -5 SAE 90 LS

with drum brake MIL-L 2105 B
ZF TE-ML 05
Wheel hubs in steering and Gear oil API - GL -5 SAE 90 LS

rigid axles with multi-disc MIL-L 2105 B
and drum brakes ZF TE-ML 05
Transmission Gear oil ZF TE-ML 07 SAE 10 W 30

SAE 10 W 20
Travel gear Gear oil API - GL -5 SAE 80W90

MIL-L 2105 B or
ZF TE-ML 05 SAE 90
1.50. 2
MJF C I F S S
Description Medium Symbol Classification Viscosity
Tracks and gearing of the Grease High-pressure Consiste MPG-A

slewing ring, bearing of the grease ncy 2
equipment KP2k or EP2 NLGI
grade
with
lithium
complex
Tab. 8
Hinges, joints, locks Engine oil - - - -
Sealing rubber on doors Silicone - - - -

and covering sections spray or
talcum
powder
Tab. 1 Lubricant table
*BI = 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.
1.1.1 Fuel and consumables
Description Medium Symbol
Fuel tank Conventional diesel fuel with <= 0.5 % sulphur content
Coolant Anticorrosion and antifreeze agent
Windscreen washer Conventional windscreen cleaning agent or denatured -

system alcohol
Coolant of air- R 134 a -

conditioning system
Refrigeration oil in SD PLANETELF PAG SP 20 -

7H15 a/c compressor ID no. 8504414 (0.25 litre) or. 7620633 (1.0 litre)
Tab. 2 Fuel and consumables
1.50. 3
MJF C I F S S
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 CG-4, CF-4, CH-4

Institute)
ACEA (CCMC) classification E2-96 (D4), E3-96 (D5), E4-98

(Association des Constructeurs
Europens de lAutomobile)
Tab. 3 Lubricating oil for the diesel engine
2.1.1 Oil change intervals for turbocharged engines
Oil change interval

depending on oil quality:
Sulphur content CH-4
Operating conditions E3-96 (D5)
of fuel CG-4
E4-98
CF-4
E5-99
E2-96 (D4)
Temperature normally not max. 0.5 % 250 h 500 h
dropping below -10C higher than 0.5 % 125 h 250 h
below -10 C max. 0.5 % 125 h 250 h
higher than 0.5 % - 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
Branded fuels in Germany and elsewhere therefore contain lubricating additives. The lubricity of the
fuel must be < 400 m 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)
1.50. 5
MJF C I F S S
Diesel fuel petrol mixing ratio
Outdoor temperature Addition of

Summer diesel fuel %
C 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 %

Outdoor
temperature C Grade -15 Grade -20 Grade -15 Grade -20
C C C C
0 to -10 100 100 - -
-10 to -15 100 100 - -
-15 to -20 70 100 30 -
-20 to -25 50 70 50* 30
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 Hydraulic oil
2.3.1 Mineral oil

Use only motor oils that conform to the specifications and requirements below:
Single grade engine API - CD / CCMC - D4 / ACEA - E1

oils: Mercedes-Benz specifications, sheet no. 226.0 and
227.0
Multigrade engine API - CD + SF / CCMC - D5 / ACEA - E3

oil: 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
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
1.50. 7
MJF C I F S S
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 m): 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 m): 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-m filter cartridges instead of the standard 20 / 5-m cartridges.
Replace the breather filter on the hydraulic tank with a 2-m fine filter (mesh size of series filters:
7 m).
Replace the 2-m 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-m filter cartridges 2-m breather filters.
All machines produced after approx. September 2005 have been equipped with 2-m 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
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 The grease must conform to specification KP2k,
lube points 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, Gleitmo 800

also used for the mounting of piston ID no. 8300004 (40g tube)
rod bearings and cushioning
sleeves to hydraulic cylinders
Anti-friction varnish and lubricant for Gleitmo 900

LIKUFIX coupling system ID no. 8610227 (400 ml spray can)
Special corrosion inhibitor for Castrol-Tarp

mounting recesses for sealing ID no. 8300005 (40g tube)
elements at hydraulic cylinders
Other grease: LIEBHERR CTK special lubricant

Lubricant used for the mounting of ID no. 861331301 (400g cartridge)
pumps to prevent fretting corrosion
on spline meshes
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 Grease and other process chemicals
2.5 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.
1.50. 9
MJF C I F S S
Content of corrosion
Outdoor temperature to Water content in % 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 0.6 to 3.6 mmol / l (3 to 20 d)
hardness)
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 Max. concentration of water contaminations for use with corrosion inhibitors and
antifreeze agents
1.50. 10
MJF C I F S S
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, Wrzburg D
Antigel DB 486 Sotragal SA, St. Priest F
Aral Khlerfrostschutz A Aral AG, Bochum D
Avia Frostschutz APN (G48-00) Deutsche Avia-Minerall 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 / Chevron Texaco, San Ramon, CA USA
Coolant
DEUTZ Khlschutzmittel 0101 1490 Deutz Service International GmbH, Cologne D
Esso Khlerfrostschutz Esso AG, Hamburg D
Fircofin Fuchs Minerallwerke 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
1.50. 11
MJF C I F S S
Brand Producer Country

Glysantin (G48-00) BASF AG, Ludwigshafen D
Havoline XLC Arteco, Ghent B

Chevron DEX-Cool Extended Life Anti-Freeze / Chevron Texaco, San Ramon, CA USA
Coolant
Igol Antigel Type DB Igol France, Paris F
Labo FP 100 Labo Industrie, Nanteree F
Motul Anti-Freeze Motul SA, Aubervilles F
OMV Khlerfrostschutzmittel OMV AG, Schwechat A

Organifreeze Total Deutschland GmbH, Dsseldorf D
OZO Frostschutz S Total Deutschland GmbH, Dsseldorf D
Total Antigel S-MB 486 Total Deutschland GmbH, Dsseldorf D

Total Frostfrei Total Deutschland GmbH, Dsseldorf D
Castrol Anti-Freeze O Total Deutschland GmbH, Dsseldorf D
Wintershall Khlerschutz Wintershall Minerall GmbH, Dsseldorf 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 Caltex UK Ltd, London GB
(ready-to-use-version)
Chevron DEX-Cool Extended Life Prediluted Chevron Texaco, San Ramon, CA USA
50/50 Anti-Freeze / Coolant
Havoline XLC, 50/50 Arteco, Ghent B
Chevron DEX-Cool Extended Life Prediluted 50/ Chevron Texaco, San Ramon, CA USA
50 Anti-Freeze / Coolant
Organicool 50/50 Total Deutschland GmbH, Dsseldorf D
Tab. 12 Approved corrosion inhibitors / antifreeze agents / 50:50 premix
1.50. 12
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 ZF-Powerfluidx ZF-Powerfluidx
Wheel hubsx 05A / 05B / 05C / 05D / 05C / 05D / 05E / 05F / 05G
Stub shafts 05E / 05F / 05G
2. Axles with hypoid drive
(AP 420R; AV230; MT-C 2025; MT-C2035; 05A / 05B / 05C / 05D 05C / 05D
MT-C2075)
3. MT-D 3105 (only oil circuit brake) --- ZF-Powerfluid
MT-L 3000 (with sintered brake linings) 05E / 05F / 05G
4. MS-T 3025, MS-T 3035, MS-T 3045,
MS-T 3055, MS-T 3060x ZF-Powerfluid ZF-Powerfluid
05A / 05B / 05C / 05D
MT-T 3025, MT-T 3035, MT-T 3045 05E / 05F / 05G 05E / 05F / 05G
MT 2075 (old: AP 2075),

MT 2085 (old: AP 2085)
5. ZF-half-shafts (planetary final drives) for 05A / 05B / 05C / 05D ---
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 ZF Passau GmbH ZF Friedrichshafen AG
previous editions. The current list can be requested from any ZF D-94030 Passau D-88038 Friedrichshafen
after-sales service center or accessed on the Internet under phone: + 49 7541 77 3505
www.zf.com. fax: + 49 7541 77 7319
09 / 2005 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 ZF Powerfluid

05G
Load class Oil change interval
1 1500 h 2000 h
2 1000 h 1500 h
3 500 h 1000 h
Load classes
Load class Examples of applications

- Dumper
1 - Mobile excavator with low driving-mode share (<25%)x
- Wheel loader with hydrostatic drivex
- Other axles without wet brakes
- Mobile excavator with increased driving-mode share (>25%)
2 - Wheel loader, grader, backhoe, telescopic handlerx
- T 7000 half shafts
- Wheel loader operated under extreme braking conditions
3 - Mobile excavator, material-handling areasx
- At ambient temperatures > 40C
1.55.2 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 GETRIEBEL GH 80W-90
ADDINOL LUBE OIL GMBH, LEUNA/D ADDINOL GETRIEBEL GX 80 W 90 ML
AGIP SCHMIERTECHNIK GMBH, WRZBURG/D AUTOL HYPOID-GETRIEBEL SAE 80W-90
ARAL AG, BOCHUM/D ARAL GETRIEBEOL EP PLUS 80W-90
ARAL AG, BOCHUM/D ARAL GETRIEBEOL HYP 85W-90
ARAL AG, BOCHUM/D ARAL GETRIEBEL HYP SAE 85W-140
ARMORINE S.A., LANESTER CEDEX/F PM 90
AVIA MINERALL-AG, MNCHEN/D AVIA HYPOID 90 EP
AVIA MINERALL-AG, MNCHEN/D AVIA SYNTOGEAR FE 80W-90
BAYWA AG, MNCHEN/D BAYWA HYPOID GETRIEBEL 85W-90
BAYWA AG, MNCHEN/D BAYWA SUPER 8090 MC
BEIJING TONGYI PETROLEUM CH. CO. LTD., BEIJING/CN XIECHENG 85W-90 GEAR OIL
BLASER SWISSLUBE AG, HASLE-REGSAU/CH HYPOID-GETRIEBEL 80W90
BLASER SWISSLUBE AG, HASLE-REGSAU/CH HYPOID-GETRIEBEL 90
BP INTERNATIONAL, PANGBOURNE, READING/GB BP ENERGEAR DL 80W-90
BP INTERNATIONAL, PANGBOURNE, READING/GB BP ENERGEAR HT 80W-90
BP INTERNATIONAL, PANGBOURNE, READING/GB BP ENERGEAR HYPO 80W-90
BP INTERNATIONAL, PANGBOURNE, READING/GB BP ENERGEAR HYPO 90
BP INTERNATIONAL, PANGBOURNE, READING/GB ENERGEAR HT 85W140
BP INTERNATIONAL, PANGBOURNE, READING/GB FRONTOL GETRIEBEL FE SAE 80W-90
BP INTERNATIONAL, PANGBOURNE, READING/GB FRONTOL HYPOID GETRIEBEL B SAE 85W-140
BP INTERNATIONAL, PANGBOURNE, READING/GB FRONTOL HYPOID GETRIEBEL B SAE 90
BUCHER AG LANGENTHAL, LANGENTHAL/CH MOTOREX GEAR OIL UNIVERSAL 80W/90
CALPAM MINERALL-GMBH, ASCHAFFENBURG/D CALPAM MULTI GEAR OIL FE 80W90
CALPAM MINERALL-GMBH, ASCHAFFENBURG/D CALPAM SUPER GEAR OIL 85W90 GL 5
CASTROL INTERNATIONAL, PANGBOURNE READING/GB CASTROL AF-STO 85W140
CASTROL INTERNATIONAL, PANGBOURNE READING/GB CASTROL AGRI GEAR GL5 90
CASTROL INTERNATIONAL, PANGBOURNE READING/GB CASTROL AGRI GEAR ULTRA
CASTROL INTERNATIONAL, PANGBOURNE READING/GB CASTROL DYNADRIVE 80W-90
CASTROL INTERNATIONAL, PANGBOURNE READING/GB CASTROL EPX 85W-140
CASTROL INTERNATIONAL, PANGBOURNE READING/GB CASTROL EPX 90
CASTROL INTERNATIONAL, PANGBOURNE READING/GB CASTROL EPX M 90
CASTROL INTERNATIONAL, PANGBOURNE READING/GB CASTROL MULTIDRIVE 80W90
CEPSA LUBRICANTS S.A., MADRID/E CEPSA TRANSMISIONES EP 90
CEPSA LUBRICANTS S.A., MADRID/E CEPSA TRANSMISIONES EP MULTIG. 85W-140
CEPSA LUBRICANTS S.A., MADRID/E CEPSA TRANSMISIONES EP MULTIGRADO 80W-90
CEPSA LUBRICANTS S.A., MADRID/E ERTOIL EP CAMBIOS Y DIFERENCIALES SAE 90
CEPSA LUBRICANTS S.A., MADRID/E ERTOIL EP MULT. CAMBIOS Y DIFERENCIALES 80W-90
CHEVRONTEXACO GLOBAL LUBRICANTS, SAN RAMON/USA CHEVRON RPM UNIVERSAL GEAR LUBRICANT SAE 80W-90
CHEVRONTEXACO, GHENT/B GEARTEX EP-B 85W-90
CHEVRONTEXACO, GHENT/B GEARTEX EP-C 85W-140
CHEVRONTEXACO, GHENT/B MULTIGEAR 80W-90
CHEVRONTEXACO, SYDNEY/AUS CALTEX HYPOID LD SAE 85W-90
CHEVRONTEXACO, SYDNEY/AUS CALTEX HYPOID LD SAE 90
CONDAT LUBRIFIANTS, CHASSE SUR RHONE/F GEAR S 80W90
DE OLIEBRON B.V., ZWIJNDRECHT/NL TOR SUPER GEAR OIL 80W90
ENI S.P.A. REFINING & MARKETING DIVISION, ROME/I AGIP ROTRA MP 85W-140
ENI S.P.A. REFINING & MARKETING DIVISION, ROME/I AGIP ROTRA TRUCK GEAR 85W-140
ENI S.P.A. REFINING & MARKETING DIVISION, ROME/I ROTRA MP 80W-90
ENI S.P.A. REFINING & MARKETING DIVISION, ROME/I ROTRA TRUCK GEAR 80W-90
EXXON MOBIL CORPORATION, FAIRFAX, VIRGINIA/USA ESSO GEAR OIL GX-D 85W-90
EXXON MOBIL CORPORATION, FAIRFAX, VIRGINIA/USA ESSO GEAR OIL TDL 80W-90
EXXON MOBIL CORPORATION, FAIRFAX, VIRGINIA/USA MOBILUBE HD-A 85W-90
EXXON MOBIL CORPORATION, FAIRFAX, VIRGINIA/USA MOBILUBE S 80W-90
FALCON OIL COMPANY LTD., SHARJAH/UAE FALCON SUPER MP GEAR OIL 85W/140 GL-5
FL SELENIA S.P.A., VILLASTELLONE/I AKCELA GEAR 135H EP (SAE 80W90)
FL SELENIA S.P.A., VILLASTELLONE/I AKROS EP 90 SAE 80W90
09 / 2005 1.55.3
FL SELENIA S.P.A., VILLASTELLONE/I AMBRA HYPOIDE 140 SAE 85W140

FL SELENIA S.P.A., VILLASTELLONE/I ARBOR TRW 140 (SAE 85W140)
FL SELENIA S.P.A., VILLASTELLONE/I TUTELA W140/M-DA SAE 85W140
FUCHS PETROLUB AG, MANNHEIM/D TITAN GEAR HYP SAE 90
FUCHS PETROLUB AG, MANNHEIM/D TITAN SUPERGEAR MC 80W-90
GENOL GMBH & CO., WIEN/A GENOL GEAR-SYN 80W-90
GENOL GMBH & CO., WIEN/A GENOL HYPOLUBE 80W-90
GINOUVES GEORGES SA, LA FARLEDE/F YORK 793 SAE 80W90
GREAT WALL LUBE OIL CO., BEIJING/CHINA GREATWALL 85W/90 GL-5
GRUPA LOTOS SA, GDANSK/PL LOTOS TITANIS GL-5 SAE 80W/90
GULF OIL INTERNATIONAL, PITTSBURG/USA GULF GEAR DB 85W 90
HAFA, PARIS/F HYPOID PL SAE 80W-90
HANDEL MIJ NOVIOL B.V., NIJMEGEN/NL KENDALL NS-MP GEAR LUBE SAE 80W-90
HUILES BERLIET S.A., SAINT PRIEST/F RTO HD 80W-90
HUILES BERLIET S.A., SAINT PRIEST/F RTO LONGEVIA P ECO 80W-140
IGOL FRANCE SA, AMIENS/F GEAR M 80W90
IGOL FRANCE SA, AMIENS/F HYPOID B SAE85W90
JOHN DEERE, WATERLOO/USA GL-5 GEAR LUBRICANT (80W90)
KOMPRESSOL-OEL VERKAUFS GMBH, KLN/D KOMPRESSOL-HYPOID EW SAE 80W-90
KRAFFT S.A., ANDOAIN/E HIDROIL EP SAE 80W-90
KUWAIT PETROLEUM R&T B.V., EUROPOORT RT/NL Q8 AUTO 12 SAE 80W-90
KUWAIT PETROLEUM R&T B.V., EUROPOORT RT/NL Q8 AXLE OIL XG SAE 80W-140
KUWAIT PETROLEUM R&T B.V., EUROPOORT RT/NL Q8 GEAR OIL XG SAE 80W-90
KUWAIT PETROLEUM R&T B.V., EUROPOORT RT/NL Q8 T 55 SAE 80W-90
KUWAIT PETROLEUM R&T B.V., EUROPOORT RT/NL Q8 T 55 SAE 90
KUWAIT PETROLEUM R&T B.V., EUROPOORT RT/NL Q8 TRANS XGS SAE 75W-90
LIQUI MOLY GMBH, ULM/D HYPOID GETRIEBEL GL 5 SAE 80W-90
LIQUI MOLY GMBH, ULM/D HYPOID GETRIEBEL GL 5 SAE 90W
LIQUI MOLY GMBH, ULM/D HYPOID GETRIEBEL TDL SAE 80W-90
MAROIL S.R.L. CONC. BARDAHL MANU. CO.,ALTOPASCIO/I BARDAHL T&D OIL 80W 90
MAZIVA ZAGREB D.O.O, ZAGREB/HR INA HIPENOL GTL DB 90
MAZIVA ZAGREB D.O.O, ZAGREB/HR INA HIPENOL GTL HD 80W-90
MAZIVA ZAGREB D.O.O, ZAGREB/HR INA HIPENOL TDL 80W-90
MEGUIN GMBH & CO. KG MINERALOELWERKE, SAARLOUIS/D MEGOL HYPOID-GETRIEBEOEL GL 5 SAE 80W-90
MEGUIN GMBH & CO. KG MINERALOELWERKE, SAARLOUIS/D MEGOL HYPOID-GETRIEBEOEL TDL SAE 80W-90
MILLERS OILS LIMITED, BRIGHOUSE/GB SYNTRAN II/MILLERS TRX 80W/90
MINERALL-RAFFIN. DOLLBERGEN, UETZE-DOLLBERGEN/D PENNASOL HYPOID-GETRIEBEOEL GL 5 SAE 80W90
MINERALL-RAFFIN. DOLLBERGEN, UETZE-DOLLBERGEN/D PENNASOL HYPOID-GETRIEBEOEL GL 5 SAE 90
MINERALL-RAFFIN. DOLLBERGEN, UETZE-DOLLBERGEN/D PENNASOL LONGLIFE GEAR GL 5 SAE 80W90
MINERALL-RAFFIN. DOLLBERGEN, UETZE-DOLLBERGEN/D PENNASOL LONGLIFE GEAR GL 5 SAE 90
MODRICA OIL REFINERY, MODRICA/BIH HIPOIDNO ULJE B SAE 80W90
MODRICA OIL REFINERY, MODRICA/BIH HIPOIDNO ULJE B SAE 90
MOL-LUB LTD., ALMASFUZITO/H MOL HYKOMOL K 85W-90
MOL-LUB LTD., ALMASFUZITO/H MOL HYKOMOL KZ 80W-90
MORRIS LUBRICANTS, SHREWSBURY/GB MORRIS EP 80W/90
MOTUL SA, AUBERVILLIERS CEDEX/F MOTUL TRANS MB 85W-90
NEW PROCESS AG, TBACH/CH HD GEAROIL SAE 90
NOVA STILMOIL SPA, MODENA/I GEARING PLUS 80W90
OEL-BRACK AG, HUNZENSCHWIL/CH MIDLAND SUPER M 5 80W-90
OEL-BRACK AG, HUNZENSCHWIL/CH MIDLAND SUPER M 5 85W90
OEST, GEORG MINERALLWERK, FREUDENSTADT/D OEST MEHRZWECK-GETRIEBEL FE SAE 80W-90
OEST, GEORG MINERALLWERK, FREUDENSTADT/D OEST MEHRZWECK-GETRIEBEL SPEZIAL SAE 85W-140
OMV AG, SCHWECHAT/A OMV GEAR OIL B SAE 85W-90
OMV AG, SCHWECHAT/A OMV GEAR OIL XD-5 SAE 80W-90
OMV AG, SCHWECHAT/A OMV UNIGEAR SAE 80W-90
ORLY INTERNATIONAL G.I.E., VIEUX-THANN/F ORLY AURIGA EP SAE 85W140
1.55.4 09 / 2005
ORLY INTERNATIONAL G.I.E., VIEUX-THANN/F ORLY LYRA EP

PAKELO MOTOR OIL S.R.L, SAN BONIFACIO (VR)/I PAKELO GEAR OIL EP GL-5 SAE 80W/90
PAKELO MOTOR OIL S.R.L, SAN BONIFACIO (VR)/I PAKELO GLOBAL GEAR CBS SAE 75W/90
PAKELO MOTOR OIL S.R.L, SAN BONIFACIO (VR)/I PAKELO GLOBAL GEAR DLS SAE 85W/140
PAKELO MOTOR OIL S.R.L, SAN BONIFACIO (VR)/I PAKELO GLOBAL GEAR SA SAE 80W/90
PAKELO MOTOR OIL S.R.L, SAN BONIFACIO (VR)/I PAKELO GLOBAL MULTIGEAR CBS
PAKELO MOTOR OIL S.R.L, SAN BONIFACIO (VR)/I PAKELO GLOBAL MULTIGEAR CBS DLS
PAKELO MOTOR OIL S.R.L, SAN BONIFACIO (VR)/I PAKELO GLOBAL MULTIGEAR SA SAE 80W/140
PANOLIN AG, MADETSWIL/CH PANOLIN SUPER DUTY 80W/90
PANOLIN AG, MADETSWIL/CH PANOLIN SUPER DUTY 90
PANOLIN AG, MADETSWIL/CH PANOLIN TOPGEAR 80W/90
PETRO-CANADA LUBRICANTS, MISSISSAUGA/CDN TRAXON 80W-90
PETROGAL S.A., LISBOA/P GALP TRANSOIL HP 80W90
PETROGAL S.A., LISBOA/P GALP TRANSVEX TDL 85W140
PETROL OFISI A.S, MASLAK-ISTANBUL-TURKEY/TR PO UNI. KEBAN EP MAN 80W/90
PRISTA OIL AD, ROUSSE/BG PRISTA EP 85W140
PRISTA OIL AD, ROUSSE/BG PRISTA EP 90
PT PERTAMINA (PERSERO), JAKARTA/RI RORED HD-A SAE80W-90
PT PERTAMINA (PERSERO), JAKARTA/RI RORED HD-A SAE90
RAFINERIA NAFTY JEDLICZE SA, JEDLICZE/PL HIPOL EXTRA GL-5 80W-90
RAFINERIA NAFTY JEDLICZE SA, JEDLICZE/PL HIPOL SUPER GL-5 80W-90
RAVENSBERGER SCHMIERSTOFFVERTRIEB GMBH, WERTHER/D RAVENOL HYP. EPX GETR.L 85W-140 GL5
RAVENSBERGER SCHMIERSTOFFVERTRIEB GMBH, WERTHER/D RAVENOL HYPOID EPX GETR.-OEL 80W-90 GL 5
RAVENSBERGER SCHMIERSTOFFVERTRIEB GMBH, WERTHER/D RAVENOL HYPOID EPX GETRIEBE-OEL SAE 90 GL-5
RAVENSBERGER SCHMIERSTOFFVERTRIEB GMBH, WERTHER/D RAVENOL SLG SPEC. LKW GETR.L 80W90
REPSOL LUBRICANTES, MADRID/E CARTAGO EP SAE 90
REPSOL LUBRICANTES, MADRID/E CARTAGO EP SAE 80W90
S.A.E.L., MADRID/E GULF MULTIPURPOSE GEAR LUBRICANT 85W-90
SHARJAH NATIONAL LUBE OIL CO. LTD., SHARJAH/UAE SHARLU MP GEAR LUBE 80W/90 (GL-5)
SHARJAH NATIONAL LUBE OIL CO. LTD., SHARJAH/UAE SHARLU MP GEAR LUBE 85W/140(GL-5)
SHELL ASEOL AG, BERN 5/CH ASEOL TOPRESS 320
SHELL ASEOL AG, BERN 5/CH ASEOL TOPRESS 80W-90
SHELL BRASIL, BARRA DA TIJUCA - RIO DE JANEIRO/BR SHELL SPIRAX A 90
SHELL INTERNATIONAL PETROLEUM COMP LTD, LONDON/GB SHELL SPIRAX AX 80W-90
SHELL INTERNATIONAL PETROLEUM COMP LTD, LONDON/GB SHELL SPIRAX AX 90
SHELL INTERNATIONAL PETROLEUM COMP LTD, LONDON/GB SHELL SPIRAX MB 90
SHELL INTERNATIONAL PETROLEUM COMP LTD, LONDON/GB SHELL SPIRAX MX 80W-90
SHELL INTERNATIONAL PETROLEUM COMP LTD, LONDON/GB SHELL SPIRAX ST 80W-140
SRS SCHMIERSTOFF VERTRIEB GMBH, SALZBERGEN/D WINTERSHALL GETRIEBEFLUID SML 80W-90
SRS SCHMIERSTOFF VERTRIEB GMBH, SALZBERGEN/D WINTERSHALL WIOLIN HYPOID-GETRIEBEL 80W-90
SRS SCHMIERSTOFF VERTRIEB GMBH, SALZBERGEN/D WINTERSHALL WIOLIN HYPOID-GETRIEBEL 90
STATOIL LUBRICANTS, STOCKHOLM/S GEARWAY G5 80W-90
STRUB + CO AG, REIDEN/CH STRUB MULTIGEAR SGO 80W-90
SUOMEN PETROOLI OY, HAMINA/FIN TEBOIL HYPOID SAE 80W-140
SYNECO SPA, SAN GIULIANO MILANESE/I AMPLEX 80W90
TEDEX PRODUCTION SP.Z.O.O., TOMASZOW MAZOWIECKI/PL TEDEX SUPER GEAR OIL (3343ML) SAE 80W90
TEXACO BRASIL S.A., RIO DE JANEIRO/BR MULTIGEAR EP SAE 90
TOTAL LUBRIFIANTS S.A., PARIS/F ANTAR EPR 90
TOTAL LUBRIFIANTS S.A., PARIS/F ANTAR EPR 80W-90
TOTAL LUBRIFIANTS S.A., PARIS/F ANTAR UNIVERSAL FE 80W-140
TOTAL LUBRIFIANTS S.A., PARIS/F FINA PONTONIC A 80W-140
TOTAL LUBRIFIANTS S.A., PARIS/F FINA PONTONIC MDL 80W-90
TOTAL LUBRIFIANTS S.A., PARIS/F FINA PONTONIC MP 80W-90
TOTAL LUBRIFIANTS S.A., PARIS/F TOTAL EP B 80W-90
09 / 2005 1.55.5
TOTAL LUBRIFIANTS S.A., PARIS/F TOTAL EP-B 85W-140

TOTAL LUBRIFIANTS S.A., PARIS/F TOTAL TRANSMISSION MDL 80W-90
TOTAL LUBRIFIANTS S.A., PARIS/F TOTAL TRANSMISSION RS FE 80W-140
TOTAL LUBRIFIANTS S.A., PARIS/F TRANSELF TYPE B 80W-90
TOTAL LUBRIFIANTS S.A., PARIS/F TRANSELF TYPE B 90
TOTAL LUBRIFIANTS S.A., PARIS/F TRANSELF UNIVERSAL FE 80W-140
UNIL S.A., SAUMUR CEDEX/F UNIL OPAL GEAR ZF 80W90
VALVOLINE EUROPE, DORDRECHT/NL HIGH PERFORMANCE GEAR OIL GL-5 90
VALVOLINE EUROPE, DORDRECHT/NL VALVOLINE STX GEAR OIL GL-5 80W-140
VEEDOL INTERNATIONAL, PANGBOURNE READING/GB VEEDOL MULTIGEAR B SAE 90
VEEDOL INTERNATIONAL, PANGBOURNE READING/GB VEEDOL MULTIGEAR C SAE 85W-140
YACCO, ST PIERRE LES ELBEUF/F BVX C 100 80W-90
ZELLER + GMELIN GMBH & CO., EISLINGEN/D DIVINOL GEAR OIL STO SAE 80W-90
ZELLER + GMELIN GMBH & CO., EISLINGEN/D DIVINOL HYPOID-GETRIEBEL SAE 85W-140
ZELLER + GMELIN GMBH & CO., EISLINGEN/D DIVINOL SYNTHOGEAR SAE 75W-90
ZEPPELIN BAUMASCHINEN GMBH, GARCHING/D ZEPPELIN SPEZIALGETRIEBEL GL-4/GL-5 80W-90
ZF FRIEDRICHSHAFEN AG, FRIEDRICHSHAFEN/D ZF-ECOFLUID X
1.55.6 09 / 2005
Lubricant class 05B

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

AGIP SCHMIERTECHNIK GMBH, WRZBURG/D AGIP HLX, SAE 75W-90
AGIP SCHMIERTECHNIK GMBH, WRZBURG/D AGIP ROTRA TRUCK GEAR S, SAE 75W-90
AVIA MINERALL-AG, MNCHEN/D AVIA SYNTOGEAR FE 75W-90 EP
BP INTERNATIONAL, PANGBOURNE, READING/GB BP ENERGEAR SHX 75W90
BP INTERNATIONAL, PANGBOURNE, READING/GB ENERGEAR SHX-M SAE 75W-90
BUCHER AG LANGENTHAL, LANGENTHAL/CH MOTOREX UNISYNT TX
CASTROL INTERNATIONAL, PANGBOURNE READING/GB CASTROL DYNADRIVE PLUS 75W90
CASTROL INTERNATIONAL, PANGBOURNE READING/GB CASTROL SAF-XO SAE 75W-90
CASTROL INTERNATIONAL, PANGBOURNE READING/GB SAF-XT
CEPSA LUBRICANTS S.A., MADRID/E CEPSA TRANSMISIONES EP FE+LD 75W-90
CHEVRONTEXACO, GHENT/B MULTIGEAR S 75W-90
DE OLIEBRON B.V., ZWIJNDRECHT/NL TOR UNIGEAR 75W90 LD
ENI S.P.A. REFINING & MARKETING DIVISION, ROME/I ROTRA LSX 75W-90
EXXON MOBIL CORPORATION, FAIRFAX, VIRGINIA/USA MOBILUBE 1 SHC 75W-90
FUCHS PETROLUB AG, MANNHEIM/D TITAN CYTRAC HSY SAE 75W-90
GINOUVES GEORGES SA, LA FARLEDE/F YORK 896
HAFA, PARIS/F EUROGEAR SAE 75W-90
HUILES BERLIET S.A., SAINT PRIEST/F RTO LONGEVIA PXD ECO 75W-90
IGOL FRANCE SA, AMIENS/F SYNTHEGEAR SAE75W90
MEGUIN GMBH & CO. KG MINERALOELWERKE, SAARLOUIS/D MEGOL GETRIEBEOEL TRUCK-SYNTH SAE 75W-90
MILLERS OILS LIMITED, BRIGHOUSE/GB SYNTRAN FE/MILLERS TRX SYNTH 75W/90
MOTUL SA, AUBERVILLIERS CEDEX/F MOTUL GEAR SYNT TDL 75W-90
NEW PROCESS AG, TBACH/CH GEAROIL SYNTH
OEST, GEORG MINERALLWERK, FREUDENSTADT/D OEST SYNTH GETRIEBEL SAE 75W-90
OMV AG, SCHWECHAT/A OMV UNIGEAR S SAE 75W-90
PAKELO MOTOR OIL S.R.L, SAN BONIFACIO (VR)/I PAKELO GLOBAL MULTIGEAR TS SAE 75W/90
PANOLIN AG, MADETSWIL/CH PANOLIN SUPER DUTY SYNTH 75W/90
S.A.E.L., MADRID/E GULF SYTHETIC GEAR LUBRICANT 75W-90
SHELL INTERNATIONAL PETROLEUM COMP LTD, LONDON/GB SHELL SPIRAX ASX 75W-90
SRS SCHMIERSTOFF VERTRIEB GMBH, SALZBERGEN/D WINTERSHALL GETRIEBEFLUID BOS
STRUB + CO AG, REIDEN/CH VULCOGEAR SYNT SGX 75W-90
TOTAL LUBRIFIANTS S.A., PARIS/F ANTAR EPS 75W-90
TOTAL LUBRIFIANTS S.A., PARIS/F FINA PONTONIC FDL 75W-90
TOTAL LUBRIFIANTS S.A., PARIS/F TOTAL TRANSMISSION SYN FE 75W-90
TOTAL LUBRIFIANTS S.A., PARIS/F TRANSELF SYNTHESE FE 75W-90
VALVOLINE EUROPE, DORDRECHT/NL SYNPOWER GEAR OIL TDL 75W-90
VALVOLINE EUROPE, DORDRECHT/NL VALVOLINE SYNPOWER STX GL-5 75W-140
VEEDOL INTERNATIONAL, PANGBOURNE READING/GB VEEDOL SAF 66
YACCO, ST PIERRE LES ELBEUF/F BVX 1000
09 / 2005 1.55.7
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 GETRIEBEL GH 80W-90 LS
ADDINOL LUBE OIL GMBH, LEUNA/D ADDINOL GETRIEBEL GH 85W-90 LS
ARAL AG, BOCHUM/D ARAL GETRIEBEOL HYP LS 90
AVIA MINERALL-AG, MNCHEN/D AVIA HYPOID 90 LS
AVIA MINERALL-AG, MNCHEN/D AVIA HYPOID 90 LS, 85W-90
BAYWA AG, MNCHEN/D BAYWA GETRIEBEL HYPOID LS 90
BLASER SWISSLUBE AG, HASLE-REGSAU/CH GETRIEBEL LS 85W90
BP INTERNATIONAL, PANGBOURNE, READING/GB BP ENERGEAR LIMSLIP 90
BP INTERNATIONAL, PANGBOURNE, READING/GB FRONTOL GETRIEBEL LS 90
BUCHER AG LANGENTHAL, LANGENTHAL/CH MOTOREX GEAR OIL UNIVERSAL LS 80W/90
CALPAM MINERALL-GMBH, ASCHAFFENBURG/D CALPAM GEAR OIL LS 90
CASTROL INTERNATIONAL, PANGBOURNE READING/GB CASTROL HYPOY LS 90
CASTROL INTERNATIONAL, PANGBOURNE READING/GB CASTROL LSX
CHEVRONTEXACO, GHENT/B GEARTEX LS 80W-90
CHEVRONTEXACO, GHENT/B GEARTEX LS 85W-90
CHEVRONTEXACO, SYDNEY/AUS CALTEX GEAR OIL ZF SAE 80W-90
CHEVRONTEXACO, SYDNEY/AUS CALTEX GEAR OIL ZF SAE 85W-140
CHEVRONTEXACO, SYDNEY/AUS CALTEX GEAR OIL ZF SAE 90
CONDAT LUBRIFIANTS, CHASSE SUR RHONE/F GEAR T ( 90 )
CONDAT LUBRIFIANTS, CHASSE SUR RHONE/F GEAR T (80W90)
DE OLIEBRON B.V., ZWIJNDRECHT/NL TOR SUPER GEAR OIL LS 80W90
ENGEN PETROLEUM LTD., CAPE TOWN/ZA ENGEN GEARLUBE EP 90 LS - SAE 80W-90
ENI S.P.A. REFINING & MARKETING DIVISION, ROME/I AGIP ROTRA MP/S 85W-90
EXXON MOBIL CORPORATION, FAIRFAX, VIRGINIA/USA ESSO GEAR OIL LSA 85W-90
EXXON MOBIL CORPORATION, FAIRFAX, VIRGINIA/USA MOBILUBE LS 85W-90
FL SELENIA S.P.A., VILLASTELLONE/I AKCELA AXLEPOWER (80W90)
FL SELENIA S.P.A., VILLASTELLONE/I AMBRA AXF 80W90
FL SELENIA S.P.A., VILLASTELLONE/I AMBRA STF (80W90)
FUCHS PETROLUB AG, MANNHEIM/D TITAN GEAR LS 90
HAFA, PARIS/F HYPOID PA SAE 80W-90
HUILES BERLIET S.A., SAINT PRIEST/F RTO EP 90 GL
IGOL FRANCE SA, AMIENS/F HYPOID BPA SAE90
JOHN DEERE, WATERLOO/USA GL-5 GEAR LUBRICANT WITH LS ADDITIVE (85W140)
KOMPRESSOL-OEL VERKAUFS GMBH, KLN/D KOMPRESSOL-HYPOID LS SAE 90
LIQUI MOLY GMBH, ULM/D HYPOID GETRIEBEL GL 5 SAE 85W-90 LS
MAZIVA ZAGREB D.O.O, ZAGREB/HR INA HIPENOL GTL LS 90
MEGUIN GMBH & CO. KG MINERALOELWERKE, SAARLOUIS/D MEGOL HYPOID-GETRIEBEOEL GL 5 SAE 85W-90 LS
MINERALL-RAFFIN. DOLLBERGEN, UETZE-DOLLBERGEN/D PENNASOL SPERRDIFFERENTIAL HYPOID GETRIEBEOEL LS90
MOL-LUB LTD., ALMASFUZITO/H MOL HYKOMOL LS 85W-90
NOVA STILMOIL SPA, MODENA/I GEARING WONDER LS SAE 85W90
OEST, GEORG MINERALLWERK, FREUDENSTADT/D OEST GETRIEBEL HYPOID LS 90
OMV AG, SCHWECHAT/A OMV GEAR OIL LS SAE 85W-90
ORLY INTERNATIONAL G.I.E., VIEUX-THANN/F ORLY TUCANA LS
PAKELO MOTOR OIL S.R.L, SAN BONIFACIO (VR)/I PAKELO UNIVERSAL GEAR EP/LS SAE 85W/140
PAKELO MOTOR OIL S.R.L, SAN BONIFACIO (VR)/I PAKELO UNIVERSAL GEAR EP/LS SAE 80W/90
PANOLIN AG, MADETSWIL/CH PANOLIN SUPER DUTY LS 90
PETROGAL S.A., LISBOA/P GALP LS 90
RAVENSBERGER SCHMIERSTOFFVERTRIEB GMBH, WERTHER/D RAVENOL SPERRDIFF.-GETR.-OEL LS 90
REPSOL LUBRICANTES, MADRID/E CS EP AUTOBLOCANTE SAE 85W140
S.A.E.L., MADRID/E GULF LS REAR AXLE OIL 80W-90
SHELL ASEOL AG, BERN 5/CH ASEOL TOPRESS LS 85W-90
SHELL INTERNATIONAL PETROLEUM COMP LTD, LONDON/GB SHELL SPIRAX A LS 85W-140
SHELL INTERNATIONAL PETROLEUM COMP LTD, LONDON/GB SHELL SPIRAX A LS 90
SRS SCHMIERSTOFF VERTRIEB GMBH, SALZBERGEN/D WINTERSHALL WIOLIN RSH
TEXACO BRASIL S.A., RIO DE JANEIRO/BR GEARTEX LS 85W140
TOTAL LUBRIFIANTS S.A., PARIS/F ANTAR BLS 90
TOTAL LUBRIFIANTS S.A., PARIS/F FINA PONTONIC LS 80W-90
TOTAL LUBRIFIANTS S.A., PARIS/F TOTAL TRANSMISSION DA 80W-90
TOTAL LUBRIFIANTS S.A., PARIS/F TRANSELF BLS 90
UNIL S.A., SAUMUR CEDEX/F UNIL OPAL GEAR AB-EP SAE 85W90
VEEDOL INTERNATIONAL, PANGBOURNE READING/GB VEEDOL MULTIGEAR LS SAE 90
YACCO, ST PIERRE LES ELBEUF/F BVX LS 200
ZEPPELIN BAUMASCHINEN GMBH, GARCHING/D ZEPPELIN SPEZIALGETRIEBEL GL-5 LS 90
1.55.8 09 / 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, WRZBURG/D AGIP HLZ, SAE 75W-140
BP INTERNATIONAL, PANGBOURNE, READING/GB BP ENERGEAR SHX S 75W140
BP INTERNATIONAL, PANGBOURNE, READING/GB BP ENERGEAR SHX-ZR 75W-140
CASTROL INTERNATIONAL, PANGBOURNE READING/GB CASTROL SAF-X SAE 75W-140
CASTROL INTERNATIONAL, PANGBOURNE READING/GB CASTROL SAF-XJ SAE 75W-140
CASTROL INTERNATIONAL, PANGBOURNE READING/GB CASTROL SAF-XLS SAE 75W-90
EXXON MOBIL CORPORATION, FAIRFAX, VIRGINIA/USA MOBIL GEARLUBE VS 500
SRS SCHMIERSTOFF VERTRIEB GMBH, SALZBERGEN/D WINTERSHALL GETRIEBEFLUID BMS PLUS
TOTAL LUBRIFIANTS S.A., PARIS/F FINA PONTONIC MLX 75W-140
TOTAL LUBRIFIANTS S.A., PARIS/F TOTAL TRANSMISSION LS 75W-140
09 / 2005 1.55.9
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 KOMATSU WBL 20W40
CNH, BURR RIDGE/USA CASE TRANSAXLE FLUID, SAE 80W-140
EXXON MOBIL CORPORATION, FAIRFAX, VIRGINIA/USA MOBILFLUID 2040
FUCHS PETROLUB AG, MANNHEIM/D TITAN UTTO ZF SAE 20W-40
MAZIVA ZAGREB D.O.O, ZAGREB/HR INA TRANSHIDROL ZF 20W-40
OMV AG, SCHWECHAT/A OMV AUSTROMATIC ZF SAE 20W-40
PAKELO MOTOR OIL S.R.L, SAN BONIFACIO (VR)/I PAKELO UTTO FLUID 4D SAE 20W/40
STRUB + CO AG, REIDEN/CH VULCOTRAC UTTO SAE 20W-40
1.55.10 09 / 2005
Lubricant class 05F

Universal Tractor Transmission Oil (UTTO)
Manufacturer (05F) Trade name (05F)

76 LUBRICANTS (CONOCOPHILLIPS COMP.), HOUSTON/USA 76 HYDRAULIC/TRACTOR FLUID
ARAL AG, BOCHUM/D ARAL FLUID HGS 10W-30
AVIA MINERALL-AG, MNCHEN/D AVIA HYDROFLUID DLZ
BP INTERNATIONAL, PANGBOURNE, READING/GB BP OLEX GO 4926
BP INTERNATIONAL, PANGBOURNE, READING/GB BP TERRAC SUPER TRANSMISSION 10W-30
BP INTERNATIONAL, PANGBOURNE, READING/GB BP TERRAC SUPER TRANSMISSION CVT 10W-30
BP INTERNATIONAL, PANGBOURNE, READING/GB BP TRACTRAN TF 10
BUCHER AG LANGENTHAL, LANGENTHAL/CH MOTOREX POLYFARM 304
CASTROL INTERNATIONAL, PANGBOURNE READING/GB CASTROL AGRI TRANS PLUS 10W-30
CASTROL INTERNATIONAL, PANGBOURNE READING/GB CASTROL AGRI TRANS PLUS CVT 10W-30
CASTROL INTERNATIONAL, PANGBOURNE READING/GB CASTROL KOMATSU UTTO 10W-30
CHEVRONTEXACO, GHENT/B TEXTRAN TDH
CHEVRONTEXACO, GHENT/B TEXTRAN TDH PREMIUM
ENGEN PETROLEUM LTD., CAPE TOWN/ZA ENGEN AGRIFLUID
EXXON MOBIL CORPORATION, FAIRFAX, VIRGINIA/USA ESSO TORQUE FLUID 56
EXXON MOBIL CORPORATION, FAIRFAX, VIRGINIA/USA MOBIL AGRIFLUID 424
FL SELENIA S.P.A., VILLASTELLONE/I AMBRA MULTI G
FUCHS PETROLUB AG, MANNHEIM/D TITAN UTTO J20C
IGOL FRANCE SA, AMIENS/F TICMA FLUID MU SAE80W
KENDALL MOTOR OIL (CONOCOPHILLIPS C.), HOUSTON/USA KENDALL HYKEN 052
KUWAIT PETROLEUM R&T B.V., EUROPOORT RT/NL Q8 T 2000
KUWAIT PETROLEUM R&T B.V., EUROPOORT RT/NL Q8 T 2200
OEL-BRACK AG, HUNZENSCHWIL/CH MIDLAND TOU
OMV AG, SCHWECHAT/A OMV AUSTROMATIC IGB SAE 10W-30
PAKELO MOTOR OIL S.R.L, SAN BONIFACIO (VR)/I PAKELO UTTO FLUID 4D SAE 10W/30
PANOLIN AG, MADETSWIL/CH PANOLIN JD 303
PETROGAL S.A., LISBOA/P GALP TRALUB 807S
RAVENSBERGER SCHMIERSTOFFVERTRIEB GMBH, WERTHER/D RAVENOL UTTO
REPSOL LUBRICANTES, MADRID/E AGRO ORION SAE 10W30
SHELL ASEOL AG, BERN 5/CH ASEOL MULTITRAC 85W
SHELL INTERNATIONAL PETROLEUM COMP LTD, LONDON/GB SHELL DONAX TD 10W-30
SHELL INTERNATIONAL PETROLEUM COMP LTD, LONDON/GB SHELL DONAX TD 5W-30
SRS SCHMIERSTOFF VERTRIEB GMBH, SALZBERGEN/D WINTERSHALL HYDROFLUID N
09 / 2005 1.55.11
Lubricant class 05G

Universal construction-machinery oil
Manufacturer (05G) Trade name (05G)

CATERPILLAR INC., PEORIA/USA CATERPILLAR MULTIPURPOSE TRACTOR OIL (MTO) 10W-30
JOHN DEERE, MANNHEIM/D JOHN DEERE HY-GARD
ZF FRIEDRICHSHAFEN AG, FRIEDRICHSHAFEN/D ZF-POWERFLUID
1.55.12 09 / 2005
Off-Road Driveline Technology
and Axle Systems
Hydrostatic and mechanical drives

and electric drive systems List of lubricants TE-ML 07
Product groups Lubricant classes for Alternative lubricant classes for

service fills (1) service fills (1)
Powershift transmissions
AVG (2) 07B / 07D / 07E ---
HL
Mobile mixer drives
Common oil circuit for transmissionx
and hydrostatic systemx 07C / 07E 07D
P3200
PLM 7, PLM 9
Mobile mixer drives
Separate oil circuits for transmissionx
and hydrostatic systemx 07A / 07C / 07E 07D
P3301, P4300, P5300, P6300,
P7300
PK5300, PK6500, PK7500
Transmissions for lifting equipment 07A / 07E
RME, RMT ---
Swing drives 07D / 07E
DR 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 ZF Passau GmbH ZF Friedrichshafen AG
previous editions. The current list can be requested from any ZF D-94030 Passau D-88038 Friedrichshafenx
after-sales service center or accessed on the Internet under phone: + 49 7541 77 7181
www.zf.com. fax: + 49 7541 77 7319
09 / 2005 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 viscosity grades Powershift transmissions; Mobile mixer drives with separate
classes Mobile mixer drives with common oil circuit;
oil circuit;x Transmissions for lifting
(with pump) equipment; Swing drives;
(without pump)
07A - SAE 75W-90, 75W-140 -40C
---
- SAE 80W-85, 80W-90, -26C
80W-140
- SAE 85W-90, 85W-140, 90 -12C
07C, 07D - SAE 5W-30, 5W-40 -35C -40C
07E - SAE 75W-80, ISO VG 46 -35C -40C
(only 07E)
07B, 07C, 07D - SAE 10W-30, 10W-40 -30C -35C
07B, 07C, 07D - SAE 15W-30, 15W-40 -25C -30C
07D - SAE 20W-20 -20C -25C
07B - SAE 20W-40 -20C ---
07D - SAE 30 -5C -10C
Hydraulic oil - ISO VG 46 --- -10C
- ISO VG 68 --- -5C
(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 -5C, a warm-up phase of at least 10 minutes is
required, irrespective of the viscosity grade used.
1.56.2 09 / 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 GETRIEBEL GX 80 W 90 ML
AGIP SCHMIERTECHNIK GMBH, WRZBURG/D AGIP ROTRA TRUCK GEAR S, SAE 75W-90
AGIP SCHMIERTECHNIK GMBH, WRZBURG/D AUTOL HYPOID-GETRIEBEL SAE 80W-90
ARAL AG, BOCHUM/D ARAL GETRIEBEOL EP PLUS 80W-90
ARAL AG, BOCHUM/D ARAL GETRIEBEOL HYP 85W-90
ARAL AG, BOCHUM/D ARAL GETRIEBEL HYP SAE 85W-140
ARAL AG, BOCHUM/D ARAL GETRIEBEL SNA-C SAE 75W-90
ARMORINE S.A., LANESTER CEDEX/F PM 90
AVIA MINERALL-AG, MNCHEN/D AVIA HYPOID 90 EP
AVIA MINERALL-AG, MNCHEN/D AVIA SYNTOGEAR FE 75W-90 EP
AVIA MINERALL-AG, MNCHEN/D AVIA SYNTOGEAR FE 80W-90
BAYWA AG, MNCHEN/D BAYWA HYPOID GETRIEBEL 85W-90
BAYWA AG, MNCHEN/D BAYWA SUPER 8090 MC
BEIJING TONGYI PETROLEUM CH. CO. LTD., BEIJING/CN XIECHENG 85W-90 GEAR OIL
BLASER SWISSLUBE AG, HASLE-REGSAU/CH HYPOID-GETRIEBEL 90
BP INTERNATIONAL, PANGBOURNE, READING/GB BP ENERGEAR DL 80W-90
BP INTERNATIONAL, PANGBOURNE, READING/GB BP ENERGEAR HT 80W-90
BP INTERNATIONAL, PANGBOURNE, READING/GB BP ENERGEAR HYPO 90
BP INTERNATIONAL, PANGBOURNE, READING/GB ENERGEAR HT 85W140
BP INTERNATIONAL, PANGBOURNE, READING/GB ENERGEAR SHX-M SAE 75W-90
BP INTERNATIONAL, PANGBOURNE, READING/GB FRONTOL GETRIEBEL FE SAE 80W-90
BP INTERNATIONAL, PANGBOURNE, READING/GB FRONTOL HYPOID GETRIEBEL B SAE 85W-140
BP INTERNATIONAL, PANGBOURNE, READING/GB FRONTOL HYPOID GETRIEBEL B SAE 90
BUCHER AG LANGENTHAL, LANGENTHAL/CH MOTOREX PENTA TL
BUCHER AG LANGENTHAL, LANGENTHAL/CH MOTOREX UNISYNT TX
CALPAM MINERALL-GMBH, ASCHAFFENBURG/D CALPAM MULTI GEAR OIL FE 80W90
CALPAM MINERALL-GMBH, ASCHAFFENBURG/D CALPAM SUPER GEAR OIL 85W90 GL 5
CASTROL INTERNATIONAL, PANGBOURNE READING/GB CASTROL AF-STO 85W140
CASTROL INTERNATIONAL, PANGBOURNE READING/GB CASTROL AGRI GEAR GL5 90
CASTROL INTERNATIONAL, PANGBOURNE READING/GB CASTROL AGRI GEAR ULTRA
CASTROL INTERNATIONAL, PANGBOURNE READING/GB CASTROL DYNADRIVE 80W-90
CASTROL INTERNATIONAL, PANGBOURNE READING/GB CASTROL DYNADRIVE PLUS 75W90
CASTROL INTERNATIONAL, PANGBOURNE READING/GB CASTROL EPX 85W-140
CASTROL INTERNATIONAL, PANGBOURNE READING/GB CASTROL EPX 90
CASTROL INTERNATIONAL, PANGBOURNE READING/GB CASTROL EPX M 90
CASTROL INTERNATIONAL, PANGBOURNE READING/GB CASTROL MULTIDRIVE 80W90
CEPSA LUBRICANTS S.A., MADRID/E CEPSA TRANSMISIONES EP 90
CEPSA LUBRICANTS S.A., MADRID/E CEPSA TRANSMISIONES EP FE+LD 75W-90
CEPSA LUBRICANTS S.A., MADRID/E CEPSA TRANSMISIONES EP MULTIG. 85W-140
CEPSA LUBRICANTS S.A., MADRID/E CEPSA TRANSMISIONES EP MULTIGRADO 80W-90
CEPSA LUBRICANTS S.A., MADRID/E ERTOIL EP CAMBIOS Y DIFERENCIALES SAE 90
CHEVRONTEXACO, GHENT/B GEARTEX EP-B 85W-90
09 / 2005 1.56.3
CHEVRONTEXACO, GHENT/B GEARTEX EP-C 85W-140

CHEVRONTEXACO, GHENT/B MULTIGEAR 80W-90
CHEVRONTEXACO, GHENT/B MULTIGEAR S 75W-90
CHEVRONTEXACO, SYDNEY/AUS CALTEX HYPOID LD SAE 85W-90
CHEVRONTEXACO, SYDNEY/AUS CALTEX HYPOID LD SAE 90
COGNIS DEUTSCHLAND GMBH, DSSELDORF/D COGNIS EMGARD UAF 4209, SAE 75W-90
DE OLIEBRON B.V., ZWIJNDRECHT/NL TOR SUPER GEAR OIL 80W90
DE OLIEBRON B.V., ZWIJNDRECHT/NL TOR UNIGEAR 75W90 LD
ENI S.P.A. REFINING & MARKETING DIVISION, ROME/I AGIP ROTRA MP 85W-140
ENI S.P.A. REFINING & MARKETING DIVISION, ROME/I AGIP ROTRA TRUCK GEAR 85W-140
ENI S.P.A. REFINING & MARKETING DIVISION, ROME/I ROTRA LSX 75W-90
ENI S.P.A. REFINING & MARKETING DIVISION, ROME/I ROTRA MP 80W-90
ENI S.P.A. REFINING & MARKETING DIVISION, ROME/I ROTRA TRUCK GEAR 80W-90
EXXON MOBIL CORPORATION, FAIRFAX, VIRGINIA/USA ESSO GEAR OIL GX-D 85W-90
EXXON MOBIL CORPORATION, FAIRFAX, VIRGINIA/USA MOBILUBE 1 SHC 75W-90
EXXON MOBIL CORPORATION, FAIRFAX, VIRGINIA/USA MOBILUBE HD-A 85W-90
EXXON MOBIL CORPORATION, FAIRFAX, VIRGINIA/USA MOBILUBE S 80W-90
FL SELENIA S.P.A., VILLASTELLONE/I AKROS EP 90 SAE 80W90
FUCHS PETROLUB AG, MANNHEIM/D FUCHS TITAN CYTRAC SL SAE 75W-90
FUCHS PETROLUB AG, MANNHEIM/D TITAN CYTRAC HSY SAE 75W-90
FUCHS PETROLUB AG, MANNHEIM/D TITAN GEAR HYP SAE 90
FUCHS PETROLUB AG, MANNHEIM/D TITAN SUPERGEAR MC 80W-90
GENOL GMBH & CO., WIEN/A GENOL GEAR-SYN 80W-90
GENOL GMBH & CO., WIEN/A GENOL HYPOLUBE 80W-90
GINOUVES GEORGES SA, LA FARLEDE/F YORK 896
GREAT WALL LUBE OIL CO., BEIJING/CHINA GREATWALL 85W/90 GL-5
GRUPA LOTOS SA, GDANSK/PL LOTOS TITANIS GL-5 SAE 80W/90
GULF OIL INTERNATIONAL, PITTSBURG/USA GULF GEAR DB 85W 90
HAFA, PARIS/F EUROGEAR SAE 75W-90
HAFA, PARIS/F HYPOID PL SAE 80W-90
HANDEL MIJ NOVIOL B.V., NIJMEGEN/NL KENDALL NS-MP GEAR LUBE SAE 80W-90
HUILES BERLIET S.A., SAINT PRIEST/F RTO HD 80W-90
HUILES BERLIET S.A., SAINT PRIEST/F RTO LONGEVIA PXD ECO 75W-90
IGOL FRANCE SA, AMIENS/F GEAR M 80W90
IGOL FRANCE SA, AMIENS/F HYPOID B SAE85W90
IGOL FRANCE SA, AMIENS/F SYNTHEGEAR SAE75W90
KOMPRESSOL-OEL VERKAUFS GMBH, KLN/D KOMPRESSOL-HYPOID EW SAE 80W-90
KRAFFT S.A., ANDOAIN/E HIDROIL EP SAE 80W-90
KUWAIT PETROLEUM R&T B.V., EUROPOORT RT/NL Q8 AUTO 12 SAE 80W-90
KUWAIT PETROLEUM R&T B.V., EUROPOORT RT/NL Q8 AXLE OIL XG SAE 80W-140
KUWAIT PETROLEUM R&T B.V., EUROPOORT RT/NL Q8 GEAR OIL XG SAE 80W-90
KUWAIT PETROLEUM R&T B.V., EUROPOORT RT/NL Q8 TRANS XGS SAE 75W-90
LIQUI MOLY GMBH, ULM/D HYPOID GETRIEBEL GL 5 SAE 90W
LIQUI MOLY GMBH, ULM/D HYPOID GETRIEBEL TDL SAE 80W-90
MAROIL S.R.L. CONC. BARDAHL MANU. CO.,ALTOPASCIO/I BARDAHL T&D OIL 80W 90
MAZIVA ZAGREB D.O.O, ZAGREB/HR INA HIPENOL GTL DB 90
1.56.4 09 / 2005

MAZIVA ZAGREB D.O.O, ZAGREB/HR INA HIPENOL TDL 80W-90
MEGUIN GMBH & CO. KG MINERALOELWERKE, SAARLOUIS/D MEGOL GETRIEBEOEL TRUCK-SYNTH SAE 75W-90
MEGUIN GMBH & CO. KG MINERALOELWERKE, SAARLOUIS/D MEGOL HYPOID-GETRIEBEOEL TDL SAE 80W-90
MILLERS OILS LIMITED, BRIGHOUSE/GB SYNTRAN FE/MILLERS TRX SYNTH 75W/90
MILLERS OILS LIMITED, BRIGHOUSE/GB SYNTRAN II/MILLERS TRX 80W/90
MINERALL-RAFFIN. DOLLBERGEN, UETZE-DOLLBERGEN/D PENNASOL HYPOID-GETRIEBEOEL GL 5 SAE 90
MINERALL-RAFFIN. DOLLBERGEN, UETZE-DOLLBERGEN/D PENNASOL LONGLIFE GEAR GL 5 SAE 90
MODRICA OIL REFINERY, MODRICA/BIH HIPOIDNO ULJE B SAE 80W90
MODRICA OIL REFINERY, MODRICA/BIH HIPOIDNO ULJE B SAE 90
MOL-LUB LTD., ALMASFUZITO/H MOL HYKOMOL K 85W-90
MOL-LUB LTD., ALMASFUZITO/H MOL HYKOMOL KZ 80W-90
MOTUL SA, AUBERVILLIERS CEDEX/F MOTUL GEAR SYNT TDL 75W-90
MOTUL SA, AUBERVILLIERS CEDEX/F MOTUL TRANS MB 85W-90
NEW PROCESS AG, TBACH/CH GEAROIL SYNTH
NEW PROCESS AG, TBACH/CH HD GEAROIL SAE 90
NOVA STILMOIL SPA, MODENA/I GEARING PLUS 80W90
OEL-BRACK AG, HUNZENSCHWIL/CH MIDLAND SUPER M 5 80W-90
OEL-BRACK AG, HUNZENSCHWIL/CH MIDLAND SUPER M 5 85W90
OEST, GEORG MINERALLWERK, FREUDENSTADT/D OEST MEHRZWECK-GETRIEBEL FE SAE 80W-90
OEST, GEORG MINERALLWERK, FREUDENSTADT/D OEST SYNTH GETRIEBEL SAE 75W-90
OMV AG, SCHWECHAT/A OMV GEAR OIL B SAE 85W-90
OMV AG, SCHWECHAT/A OMV GEAR OIL BSX SAE 75W-90
OMV AG, SCHWECHAT/A OMV GEAR OIL XD-5 SAE 80W-90
OMV AG, SCHWECHAT/A OMV UNIGEAR S SAE 75W-90
OMV AG, SCHWECHAT/A OMV UNIGEAR SAE 80W-90
ORLY INTERNATIONAL G.I.E., VIEUX-THANN/F ORLY AURIGA EP SAE 85W140
ORLY INTERNATIONAL G.I.E., VIEUX-THANN/F ORLY LYRA EP
PAKELO MOTOR OIL S.R.L, SAN BONIFACIO (VR)/I PAKELO GLOBAL GEAR CBS SAE 75W/90
PAKELO MOTOR OIL S.R.L, SAN BONIFACIO (VR)/I PAKELO GLOBAL MULTIGEAR CBS
PAKELO MOTOR OIL S.R.L, SAN BONIFACIO (VR)/I PAKELO GLOBAL MULTIGEAR CBS DLS
PAKELO MOTOR OIL S.R.L, SAN BONIFACIO (VR)/I PAKELO GLOBAL MULTIGEAR SA SAE 80W/140
PAKELO MOTOR OIL S.R.L, SAN BONIFACIO (VR)/I PAKELO GLOBAL MULTIGEAR TS SAE 75W/90
PANOLIN AG, MADETSWIL/CH PANOLIN SUPER DUTY 90
PANOLIN AG, MADETSWIL/CH PANOLIN SUPER DUTY SYNTH 75W/90
PANOLIN AG, MADETSWIL/CH PANOLIN TOPGEAR 80W/90
PETROL OFISI A.S, MASLAK-ISTANBUL-TURKEY/TR PO UNI. KEBAN EP MAN 80W/90
PRISTA OIL AD, ROUSSE/BG PRISTA EP 85W140
PRISTA OIL AD, ROUSSE/BG PRISTA EP 90
PT PERTAMINA (PERSERO), JAKARTA/RI RORED HD-A SAE90
RAFINERIA NAFTY JEDLICZE SA, JEDLICZE/PL HIPOL EXTRA GL-5 80W-90
RAVENSBERGER SCHMIERSTOFFVERTRIEB GMBH, WERTHER/D RAVENOL GETR.OEL 75W-90 VSG VOLLSYNTH.
09 / 2005 1.56.5
RAVENSBERGER SCHMIERSTOFFVERTRIEB GMBH, WERTHER/D RAVENOL HYP. EPX GETR.L 85W-140 GL5
RAVENSBERGER SCHMIERSTOFFVERTRIEB GMBH, WERTHER/D RAVENOL HYPOID EPX GETR.-OEL 80W-90 GL 5
RAVENSBERGER SCHMIERSTOFFVERTRIEB GMBH, WERTHER/D RAVENOL HYPOID EPX GETRIEBE-OEL SAE 90 GL-5
RAVENSBERGER SCHMIERSTOFFVERTRIEB GMBH, WERTHER/D RAVENOL SLG SPEC. LKW GETR.L 80W90
REPSOL LUBRICANTES, MADRID/E CARTAGO EP SAE 90
S.A.E.L., MADRID/E GULF MULTIPURPOSE GEAR LUBRICANT 85W-90
S.A.E.L., MADRID/E GULF SYTHETIC GEAR LUBRICANT 75W-90
SHARJAH NATIONAL LUBE OIL CO. LTD., SHARJAH/UAE SHARLU MP GEAR LUBE 80W/90 (GL-5)
SHARJAH NATIONAL LUBE OIL CO. LTD., SHARJAH/UAE SHARLU MP GEAR LUBE 85W/140(GL-5)
SHELL ASEOL AG, BERN 5/CH ASEOL TOPRESS 320
SHELL BRASIL, BARRA DA TIJUCA - RIO DE JANEIRO/BR SHELL SPIRAX A 90
SHELL INTERNATIONAL PETROLEUM COMP LTD, LONDON/GB SHELL SPIRAX ASX 75W-90
SHELL INTERNATIONAL PETROLEUM COMP LTD, LONDON/GB SHELL SPIRAX AX 90
SHELL INTERNATIONAL PETROLEUM COMP LTD, LONDON/GB SHELL SPIRAX MB 90
SHELL INTERNATIONAL PETROLEUM COMP LTD, LONDON/GB SHELL SPIRAX MX 80W-90
SHELL INTERNATIONAL PETROLEUM COMP LTD, LONDON/GB SHELL SPIRAX ST 80W-140
SRS SCHMIERSTOFF VERTRIEB GMBH, SALZBERGEN/D WINTERSHALL GETRIEBEFLUID AFS
SRS SCHMIERSTOFF VERTRIEB GMBH, SALZBERGEN/D WINTERSHALL GETRIEBEFLUID SML 80W-90
SRS SCHMIERSTOFF VERTRIEB GMBH, SALZBERGEN/D WINTERSHALL WIOLIN HYPOID-GETRIEBEL 90
STRUB + CO AG, REIDEN/CH STRUB MULTIGEAR SGO 80W-90
STRUB + CO AG, REIDEN/CH VULCOGEAR SYNT SGX 75W-90
TEDEX PRODUCTION SP.Z.O.O., TOMASZOW MAZOWIECKI/PL TEDEX SUPER GEAR OIL (3343ML) SAE 80W90
TEXACO BRASIL S.A., RIO DE JANEIRO/BR MULTIGEAR EP SAE 90
TOTAL LUBRIFIANTS S.A., PARIS/F ANTAR EPR 90
TOTAL LUBRIFIANTS S.A., PARIS/F ANTAR EPR 80W-90
TOTAL LUBRIFIANTS S.A., PARIS/F ANTAR EPS 75W-90
TOTAL LUBRIFIANTS S.A., PARIS/F FINA PONTONIC A 80W-140
TOTAL LUBRIFIANTS S.A., PARIS/F FINA PONTONIC FDL 75W-90
TOTAL LUBRIFIANTS S.A., PARIS/F FINA PONTONIC MDL 80W-90
TOTAL LUBRIFIANTS S.A., PARIS/F TOTAL EP-B 85W-140
TOTAL LUBRIFIANTS S.A., PARIS/F TOTAL TRANSMISSION BM 75W-90
TOTAL LUBRIFIANTS S.A., PARIS/F TOTAL TRANSMISSION MDL 80W-90
TOTAL LUBRIFIANTS S.A., PARIS/F TOTAL TRANSMISSION SYN FE 75W-90
TOTAL LUBRIFIANTS S.A., PARIS/F TRANSELF BM 75W-90
TOTAL LUBRIFIANTS S.A., PARIS/F TRANSELF SYNTHESE FE 75W-90
TOTAL LUBRIFIANTS S.A., PARIS/F TRANSELF TYPE B 80W-90
TOTAL LUBRIFIANTS S.A., PARIS/F TRANSELF TYPE B 90
UNIL S.A., SAUMUR CEDEX/F UNIL OPAL GEAR ZF 80W90
VALVOLINE EUROPE, DORDRECHT/NL HIGH PERFORMANCE GEAR OIL GL-5 90
VALVOLINE EUROPE, DORDRECHT/NL SYNPOWER GEAR OIL TDL 75W-90
VEEDOL INTERNATIONAL, PANGBOURNE READING/GB VEEDOL MULTIGEAR B SAE 90
VEEDOL INTERNATIONAL, PANGBOURNE READING/GB VEEDOL MULTIGEAR C SAE 85W-140
YACCO, ST PIERRE LES ELBEUF/F BVX 1000
YACCO, ST PIERRE LES ELBEUF/F BVX C 100 80W-90
1.56.6 09 / 2005
ZELLER + GMELIN GMBH & CO., EISLINGEN/D DIVINOL GEAR OIL STO SAE 80W-90
ZELLER + GMELIN GMBH & CO., EISLINGEN/D DIVINOL HYPOID-GETRIEBEL SAE 85W-140
ZELLER + GMELIN GMBH & CO., EISLINGEN/D DIVINOL SYNTHOGEAR SAE 75W-90
ZEPPELIN BAUMASCHINEN GMBH, GARCHING/D ZEPPELIN SPEZIALGETRIEBEL GL-4/GL-5 80W-90
ZF FRIEDRICHSHAFEN AG, FRIEDRICHSHAFEN/D ZF-ECOFLUID X
09 / 2005 1.56.7
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 ADDINOL SUPER TRAKTOR MU 1045 SAE 10W-40
AGIP SCHMIERTECHNIK GMBH, WRZBURG/D AUTOL AGROTECH SAE 10W-30
ARAL AG, BOCHUM/D ARAL SUPER TRAKTORAL 10W-40
ARAL AG, BOCHUM/D ARAL SUPER TRAKTORAL SAE 10W-30
AVIA MINERALL-AG, MNCHEN/D TRACTAVIA FE 10W-40
AVIA MINERALL-AG, MNCHEN/D TRACTAVIA SPEZIAL 10W-30
BAYWA AG, MNCHEN/D BAYWA SUPER 2000 CD-MC 10W-30
BAYWA AG, MNCHEN/D BAYWA SUPER MULTISYN SL 10W-40
BLASER SWISSLUBE AG, HASLE-REGSAU/CH BLASOL STOU 10W40
BP INTERNATIONAL, PANGBOURNE, READING/GB BP TERRAC SUPER UNIVERSAL 10W-40
BP INTERNATIONAL, PANGBOURNE, READING/GB BP TERRAC UNIVERSAL 15W-30
BP INTERNATIONAL, PANGBOURNE, READING/GB BP TERRAC UNIVERSAL 15W-40
BUCHER AG LANGENTHAL, LANGENTHAL/CH MOTOREX FARMER TRAC
CASTROL INTERNATIONAL, PANGBOURNE READING/GB CASTROL AGRI MP 15W-30
CASTROL INTERNATIONAL, PANGBOURNE READING/GB CASTROL AGRI MP 15W-40
CASTROL INTERNATIONAL, PANGBOURNE READING/GB CASTROL AGRI MP PLUS 10W-30
CASTROL INTERNATIONAL, PANGBOURNE READING/GB CASTROL AGRI MP PLUS 10W-40
CEPSA LUBRICANTS S.A., MADRID/E CEPSA AGRO PLUS 15W-40
CEPSA LUBRICANTS S.A., MADRID/E ERTOIL MULTI AGRO 15W-40
CHEVRONTEXACO, GHENT/B MULTITEX PREMIUM 10W-40
CHEVRONTEXACO, GHENT/B SUPER UNIVERSAL TRACTOR OIL PREMIUM 10W-30
CHEVRONTEXACO, SYDNEY/AUS CALTEX SUPER TRACTOR SAE 15W-40
CHEVRONTEXACO, SYDNEY/AUS CALTEX SUPER TRACTOR SAE 20W-40
CONDAT LUBRIFIANTS, CHASSE SUR RHONE/F MAXITRACT 15W40
CONDAT LUBRIFIANTS, CHASSE SUR RHONE/F VICAM TP 10W40
DE OLIEBRON B.V., ZWIJNDRECHT/NL MULTITRAC 15W30
EXXON MOBIL CORPORATION, FAIRFAX, VIRGINIA/USA ESSO UNIFARM 10W-30
EXXON MOBIL CORPORATION, FAIRFAX, VIRGINIA/USA ESSO UNIFARM 15W-40
EXXON MOBIL CORPORATION, FAIRFAX, VIRGINIA/USA MOBIL AGRI EXTRA 10W-40
EXXON MOBIL CORPORATION, FAIRFAX, VIRGINIA/USA MOBIL AGRI SUPER 10W-30
EXXON MOBIL CORPORATION, FAIRFAX, VIRGINIA/USA MOBIL AGRI SUPER 15W-40
FL SELENIA S.P.A., VILLASTELLONE/I AKCELA MULTI TRACTOR (SAE 10W40)
FL SELENIA S.P.A., VILLASTELLONE/I AKCELA SUPER UNIVERSAL (SAE 10W30)
FL SELENIA S.P.A., VILLASTELLONE/I AKCELA SUPER UNIVERSAL (SAE 15W40)
FL SELENIA S.P.A., VILLASTELLONE/I AKROS MULTI VT SAE 10W30
FL SELENIA S.P.A., VILLASTELLONE/I AKROS UNIVERSAL SAE 10W30
FL SELENIA S.P.A., VILLASTELLONE/I AKROS UNIVERSAL SAE 15W40
FL SELENIA S.P.A., VILLASTELLONE/I AMBRA UNIVERSAL SAE 10W30
FL SELENIA S.P.A., VILLASTELLONE/I AMBRA UNIVERSAL SAE 15W40
FL SELENIA S.P.A., VILLASTELLONE/I AMBRA VT SPECIAL (10W40)
FL SELENIA S.P.A., VILLASTELLONE/I ARBOR UNIVERSAL (SAE 15W40)
FUCHS PETROLUB AG, MANNHEIM/D TITAN HYDRAMOT 10W-40 MC
FUCHS PETROLUB AG, MANNHEIM/D TITAN HYDRAMOT MC 10W-30
GENOL GMBH & CO., WIEN/A GENOL TRAC-SYN 1040
GINOUVES GEORGES SA, LA FARLEDE/F YORK 743 10W40
HAFA, PARIS/F POLYMAT SAE 10W-40
HAFA, PARIS/F SUPER TUT SAE 15W-40
HANDEL MIJ NOVIOL B.V., NIJMEGEN/NL KENDALL MULTIFARM SAE 15W-30
IGOL FRANCE SA, AMIENS/F AGRI MU SUPER 10W40
INA MAZIVA RIJEKA, RIJEKA/HR INA AGRINA 15W-30
KRAFFT S.A., ANDOAIN/E STOU 15W40
KUWAIT PETROLEUM R&T B.V., EUROPOORT RT/NL Q8 T 1000 D SAE 10W-30
KUWAIT PETROLEUM R&T B.V., EUROPOORT RT/NL Q8 T 1000 D SAE 15W-30
MAGNA INDUSTRIAL CO. LIMITED, HONG KONG/HK OMEGA 603 SAE15W40
MEGUIN GMBH & CO. KG MINERALOELWERKE, SAARLOUIS/D MEGOL SUPER TRAKTORENOEL STOU SAE 10W-30
MINERALL-RAFFIN. DOLLBERGEN, UETZE-DOLLBERGEN/D PENNASOL SUPER TRACTOR UNIVERSALOEL STOU 10W30
MINERALL-RAFFIN. DOLLBERGEN, UETZE-DOLLBERGEN/D PENNASOL SUPER TRACTOR UNIVERSALOEL STOU 15W30
MORRIS LUBRICANTS, SHREWSBURY/GB SUPER VERSITRAC
NOVA STILMOIL SPA, MODENA/I MF LUBE+ AGRILUBE UNIVERSAL 10W30
OEL-BRACK AG, HUNZENSCHWIL/CH MIDLAND STOU
OMV AG, SCHWECHAT/A OMV AUSTROTRAC SAE 10W-40
ORLY INTERNATIONAL G.I.E., VIEUX-THANN/F ORLY APOLLO SAE 15W-40
ORLY INTERNATIONAL G.I.E., VIEUX-THANN/F ORLY STOU LUNA
PAKELO MOTOR OIL S.R.L, SAN BONIFACIO (VR)/I PAKELO STOU FLUID SAE 15W/40
1.56.8 09 / 2005
PANOLIN AG, MADETSWIL/CH PANOLIN STOU 10W/30

PANOLIN AG, MADETSWIL/CH PANOLIN STOU 15W/30
PETROGAL S.A., LISBOA/P GALP UNIAGRO
RAVENSBERGER SCHMIERSTOFFVERTRIEB GMBH, WERTHER/D RAVENOL SUTO SAE 15W-30
REPSOL LUBRICANTES, MADRID/E AGRO CERES STOU SAE 15W40
SHELL ASEOL AG, BERN 5/CH ASEOL MULTITRAC SUPER 10W-30
SHELL INTERNATIONAL PETROLEUM COMP LTD, LONDON/GB SHELL HARVELLA T 10W-30
SHELL INTERNATIONAL PETROLEUM COMP LTD, LONDON/GB SHELL HARVELLA T 15W-40
SHELL INTERNATIONAL PETROLEUM COMP LTD, LONDON/GB SHELL HARVELLA TX 10W-40
SRS SCHMIERSTOFF VERTRIEB GMBH, SALZBERGEN/D WINTERSHALL PRIMANOL 10W-30
SRS SCHMIERSTOFF VERTRIEB GMBH, SALZBERGEN/D WINTERSHALL PRIMANOL 10W-40
STRUB + CO AG, REIDEN/CH SUPER TRACTOROEL UNI.10W-30 (STOU)
SYNECO SPA, SAN GIULIANO MILANESE/I MULTITRACTOR STOU 15W40
TAMOIL PETROLI S.P.A., MILANO/I SUPER TRACTOR SAE 15W/40
TOTAL LUBRIFIANTS S.A., PARIS/F ANTAR AGRIA GR4 SAE 10W-40
TOTAL LUBRIFIANTS S.A., PARIS/F ANTAR AGRIA SUPER FM SAE 15W-40
TOTAL LUBRIFIANTS S.A., PARIS/F FINA SUPER UNIVERSAL OIL MF SAE 10W-40
TOTAL LUBRIFIANTS S.A., PARIS/F FINA SUPER UNIVERSAL OIL SAE 15W-30
TOTAL LUBRIFIANTS S.A., PARIS/F FINA SUPER UNIVERSAL OIL SAE 15W-40
TOTAL LUBRIFIANTS S.A., PARIS/F TOTAL MULTAGRI MAX SAE 10W-40
TOTAL LUBRIFIANTS S.A., PARIS/F TOTAL MULTAGRI MS SAE 15W-40
TOTAL LUBRIFIANTS S.A., PARIS/F TOTAL MULTAGRI SUPER 10W-30
TOTAL LUBRIFIANTS S.A., PARIS/F TOTAL MULTAGRI SUPER 15W-40
TOTAL LUBRIFIANTS S.A., PARIS/F TOTAL MULTAGRI SUPER SAE 15W-30
TOTAL LUBRIFIANTS S.A., PARIS/F TRACTORELF ST3 SAE 15W-30
UNIL S.A., SAUMUR CEDEX/F XANTHOS 10W40
VALVOLINE EUROPE, DORDRECHT/NL VALVOLINE STOU 10W-30
09 / 2005 1.56.9
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 ADDINOL SUPER STAR MX 1547 SAE 15W-40
ARAL AG, BOCHUM/D ARAL MULTITURBORAL SAE 15W-40
AVIA MINERALL-AG, MNCHEN/D AVIA MULTI CFE PLUS 10W-40
AVIA MINERALL-AG, MNCHEN/D AVILUB MULTI HDC-B 15W40
BLASER SWISSLUBE AG, HASLE-REGSAU/CH BLASOL MHP 10W40
BLASER SWISSLUBE AG, HASLE-REGSAU/CH BLASOL MHP 15W40
BP INTERNATIONAL, PANGBOURNE, READING/GB BP VANELLUS C6 GLOBAL PLUS SAE 10W-40
BP INTERNATIONAL, PANGBOURNE, READING/GB ECONO VERITAS HDE SAE 10W-40
CEPSA LUBRICANTS S.A., MADRID/E CEPSA DIESEL TURBO SHPD 15W-40
CEPSA LUBRICANTS S.A., MADRID/E CEPSA SUPER MULTIGRADO SHPD 15W-40
CEPSA LUBRICANTS S.A., MADRID/E CEPSA ULTRA SHPD 15W-40
CHEVRONTEXACO GLOBAL LUBRICANTS, SAN RAMON/USA CHEVRON DELO 400 MULTIGRADE SAE 15W-40
KOMPRESSOL-OEL VERKAUFS GMBH, KLN/D KOMPRESSOL-ULTRALUB C SAE 15W-40
KRAFFT S.A., ANDOAIN/E SUPERMULTIGRADO D 15W40
LIQUI MOLY GMBH, ULM/D TOURING HIGH TECH DIESELSPEZIALOIL SAE 15W-40
MEGUIN GMBH & CO. KG MINERALOELWERKE, SAARLOUIS/D MEGOL MOTORENOEL HD-C3 SAE 15W-40
NOVA STILMOIL SPA, MODENA/I ORION SUPER PLUS 15W40
PAKELO MOTOR OIL S.R.L, SAN BONIFACIO (VR)/I PAKELO GOLDEN D/G SAE 15W/40
PAKELO MOTOR OIL S.R.L, SAN BONIFACIO (VR)/I PAKELO PKO HD SUPER 4 SAE 15W/40
RAVENSBERGER SCHMIERSTOFFVERTRIEB GMBH, WERTHER/D RAVENOL FORMEL DIESEL SUPER 15W-40
RAVENSBERGER SCHMIERSTOFFVERTRIEB GMBH, WERTHER/D RAVENOL TURBO-C HD-C 15W-40
REPSOL LUBRICANTES, MADRID/E SUPERTURBO DIESEL SAE 15W40
SHELL ASEOL AG, BERN 5/CH ASEOL PERLA 15W-40
SHELL INTERNATIONAL PETROLEUM COMP LTD, LONDON/GB SHELL RIMULA X 15W-40
SRS SCHMIERSTOFF VERTRIEB GMBH, SALZBERGEN/D WINTERSHALL MULTI REKORD 15W-40
SRS SCHMIERSTOFF VERTRIEB GMBH, SALZBERGEN/D WINTERSHALL MULTI REKORD TOP, SAE 15W-40
STRUB + CO AG, REIDEN/CH SUPER MULTI TURBO 15W-40
SUN OIL COMPANY (BELGIUM) N.V., AARTSELAAR/B FORZA SAE 15W40
VEEDOL INTERNATIONAL, PANGBOURNE READING/GB VEEDOL DIESELSTAR
1.56.10 09 / 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 20W-20 / 30 / 5W-30 / 5W-40 / 10W-30 / 10W-40 /
Swing drives 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
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 20221-

A 311 LI 20222-
A 312 LI 12363-
A 314 LI 2001-
A 316 LI 2001-
A 316 LI-IND 2001-
R 313 LI 27752-
R 317 LI 18161-
Special tools for diesel engines 2.03.1 A 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 313 LI 27752-
R 317 LI 18161-
Special tools for hydraulic systems 2.05.1 A 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 313 LI 27752-
R 317 LI 18161-
Special tools for electric systems 2.06.1 A 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 313 LI 27752-
R 317 LI 18161-
Special tools for gears 2.07.1 A 309 LI 20221-

A 311 LI 20222-
A 312 LI 12363-
A 314 LI 2001-
A 316 LI 2001-
A 316 LI-IND 2001-
2.1
MJFCIFSS
Service Manual
R 313 LI 27752-
R 317 LI 18161-
Special tools for axles 2.08.1 A 309 LI 20221-

A 311 LI 20222-
A 312 LI 12363-
A 314 LI 2001-
A 316 LI 2001-
A 316 LI-IND 2001-
Assembly tools for hydraulic cylinders 2.12.1 A 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 313 LI 27752-
R 317 LI 18161-
Mounting device for piston rod bearings 2.13.1 A 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 313 LI 27752-
R 317 LI 18161-
Slotted nut wrench for slewing gear 2.14.1 A 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 313 LI 27752-
R 317 LI 18161-
Mounting device for slewing gear 2.15.1 A 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 313 LI 27752-
R 317 LI 18161-
Mounting device for travel gear 2.16.1 R 313 LI 27752-

R 317 LI 18161-
2.2
MJFCIFSS
Service Manual Special tools general
Special tools general
for maintenance and repair

Machi
Picture No. Designation Application
Size ID no. ne
1 Measuring neck NW 10 7002404 all

2 NW 12 7008688 types
4 Pressure gauge con- R 1/2" 7002436 all

nection types
5 Pressure gauge direct R 1/2" 7002435 all

connection types
7 High-pressure hose 7002437 all

length types
7002475
8
10 Screw coupling as- M10X1 5005180 all

11 sembly, complete M12X1.5 7402580 types
12 M14X1.5 5004002
13 M16X1.5 7361345
14 R 1/4" 7362579
2.01.1
copyright by
MJFCIFSS
Special tools general Service Manual
Machi
Size ID no. ne
15 Pressure gauge 0-1.6 bar 8042577 all Measuring of operating

types pressures of one or more
16 0-1.6 bar 8042578 hydraulic circuits.
*
17 5002865 * glycerine dampened
18 7361288
19 5002867
20 0-250 7361285
bar *
21 0-400 7500002
bar *
22 0-600 5002866
bar *
30 Differential pressure 10288229 all Measuring of differen-
measuring kit, consis- types ce p between the pump
ting of: and the LS pressure.
30.1 10288155
1 manual measuring
device 3010
30.2 10288152
1 data cable
30.3 10288154
2 measuring cables
30.4 0-600 10288153
2 pressure sensors bar
30.5 10288151
1 power adapter
30.6 7025273
Vehicle connecting ca-
ble see sensors on
30.7 not included in delive- 6140626 01 page 7
30.8 ry! 6140647 01
Pressure sensor
Pressure sensor
33 Fitting 4901372 all
types
34 Measuring neck with 7002404
metal cap
35 Union nut 4774002
36 Cutting ring 4774001
2.01.2
copyright by
MJFCIFSS
Machi
Size ID no. ne
44 Measuring adapter 8504231 all Measuring of current at

types pump regulation
45 Adapter 9956422 all Measuring of the inducti-

types ve pickup B12 from 3-pin
(LH) to 2-pin (Deutz), in
conjunction with tool no.
44
46 Measuring cable 9956436 all Measuring and testing of

types solenoid valves
60 Piezzo speed A 2106 10286429 all Measuring of engine

types speed via pulse frequen-
cy of injection line
62 Ornel speed meter HT 460 7006974 all Measuring of speed with

types reflective strips
63 Shimpo speed meter DT 205 7364284
Strips
64 614063201 with no. 63
2.01.3
copyright by
MJFCIFSS
Machi
Size ID no. ne
65 Multimeter with digital Chauvin 10018500 all Measuring of voltage,

display Arnoux types current and resistance in
electric components and
valves
70 Thermometer 10024185 all Monitoring of temperatu-

non-contact types re of a medium / outside
(infrared) temperature of a unit
GTH
72 Thermometer with pro- 1150 7020372
be and sensor (mag-
netic)
80 Hand pump 8145666 all Sampling of oil for analy-

types sis
82 Sampling valve for oil 7019068

samples, alternative to
hand pump 80
84 Mineral oil analysis kit * no. 1 8145660 all 1 oil sample

types
85 10029626 4 oil samples
*Analyses carried out by WAER

CHECK Germany, lab report in
German
88 Bio oil analysis kit * no. 3 7026817 all 1 oil sample
types

*Analyses carried out by WAER
CHECK Germany, lab report in
German
2.01.4
copyright by
MJFCIFSS
Machi
Size ID no. ne
90 REFCO vacuum pump RD-4 7027552 all Maintenance and repair

types of a/c system
91 ITE filling hose, blue 1,500 7027553 all See item 90

mm types
92 ITE filling hose, yellow 1,500 7027554

mm
93 ITE filling hose, red 1,500 7027555

mm
94 ITE HGV coupling 253a 7027556 all See item 90

types
95 ITE HGV coupling 254 a 7027557
96 4-valve test fittings M4WS5 7027558 all Maintenance and repair

C types of a/c system
100 Dismantling tool M37X1 9583459 all Dismantling of grapple

101 M42X1.5 9583521 types bolts
102 M48X1.5 9583522
2.01.5
copyright by
MJFCIFSS
Machi
Size ID no. ne
105 Universal Passfix pul- M42X1.5 9584738 all Removal of Passfix bolts
ler M48X1.5 types
M58X1.5
120 Diagnostic instrument 5010474 all Diagnostics of D5 WS au-

types xiliary 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 7029179 all Pressurisation of engine
system types cooling system (leakage
test)
140 Torque wrench 4-20 Nm 10045464 all For tightening the hose
types clamps
150 Hand pump with pres- 10454803 all For leakage test of back-
sure gauge types pressure line at particle
filter installation
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 ID no.

2 OEM pressure sensor, measuring range 0 - 1000 bar, output 0 - 20 mA 1001 8329
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
copyright by
MJFCIFSS
Item Sensors ID no.

5 OEM pressure sensor, measuring range 0 - 10 bar, output 0 - 20 mA 1002 7591
6 OEM pressure sensor, measuring range -1 to +6 bar, output 4 - 20 mA (LWE) 5718 886 08
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 ID no.

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
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
* number of units for recommended basic equipment
2.01.7
copyright by
MJFCIFSS
2.01.8
copyright by
MJFCIFSS
Service Manual Special tools for diesel engines
Special tools for diesel engines
for the maintenance and adjustment of DEUTZ diesel engines

Machi
Picture no. Designation Size ID no. Application
ne
1a Compression pressure 8008782 all Measurement of compres-
tester types sion pressure
1b Diagram sheets for 100 10012817

item 1a Units
2 Connecting piece for 7019856 all Insert at the position of the

compression pressure types injection valve
tester
3 Nozzle tester 7361236 all Testing of injection nozzles

types
10 V-belt measuring in- Krikit 7019872 all for measurement of V-belt

strument types tension
14 Torx too kit 7014716 all

types
2.03.1
copyright by
MJFCIFSS
Special tools for diesel engines Service Manual
Machi
ne
22 Torx insert key kits for E 14 7019851 all
(long design) types
23 E 18 7021668
24 E 20 7019852
25 Socket for injection WS 15 7019853 all

nozzle (long design) types
(union nut)
30 Torque wrench 7019854 all

types
32 Insert key 7019855 A 312 -

1/4 R 317
35 Turning key 7021680 A 312 -

R 317
2.03.2
copyright by
MJFCIFSS
Machi
ne
40 Mounting device for re- 7021677 all
gulating rod types
50 Mounting tool for 7019861 A 312 -

coolant thermostat R 317
54 Piston ring mounting 7009319 all

pliers types
60 Dismantling tool 7019858 A 312 -

(hooks) for crank shaft R 317
seals (front and rear)
64 Mounting tool for crank 7021676 A 312 -

shaft seals, front (fan R 317
side)
2.03.3
copyright by
MJFCIFSS
Machi
ne
66 Mounting tool for crank 7021675 A 312 -
shaft seal, rear (fly- R 317
wheel side)
68 Mounting tool for crank 7019859 A 309 /

shaft seal (rear) A 311/
R 313
70 Mounting tool for crank 10294728 A 309 /

shaft seal (front) A 311 /
R 313
75 Claw wrench for injec- WS 17 10294729 A 309 /

tion lines A 311 /
R 313
80 Valve seal clamp 10294730 all

types
2.03.4
copyright by
MJFCIFSS
Machi
ne
85 Turning key (multi- 10294731 A 309 /
tooth) for injection A 311/
pump 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 10294734 A 309 /

shafts A 311 /
R 313
105 Removing tool for in- 10294735 A 309 /

jection nozzle, in con- A 311 /
junction with tool no. R 313
115
2.03.5
copyright by
MJFCIFSS
Machi
ne
110 Special key for injec- 10294736 A 309 /
tion line A 311 /
R 313
115 Removal tool for injec- 8008803 all

tion nozzle types
120 Indicator for dial disc 8008789 all

types
2.03.6
copyright by
MJFCIFSS
Service Manual Special tools for hydraulic systems
Special tools for hydraulic systems
Picture No. Desciption Size Order no. Model Application

10 Special wrench for SW 17 9359414 all ty- To adjust primary and se-
pressure -relief valves pes condary pressure-relief
valves in the control valve
11 SW 19 9210371 block
WS 19
20 Safety cap SW 10 7009315 all ty- To secure the adjusting

WS 10 pes screws on the hydraulik ag-
short SW 13 7023492 gregates
long SW 13 l 7615515
SW 17 7380629
short SW 19 7009316
long SW 19 l 7009317
21
22
23
24
25
30 Mounting sleeve See chapter 2.12 all ty- To assemble the O-ring
pes and stepseal ring on hy-
draulic cylinder pistons, va-
riable-displacement pump
pistons and variable dis-
pacement motor regulating
pistons
40 Expanding sleeve See chapter 2.12 all ty- for application, see also
pes tool no. 40
50 Piston wrench See chapter 2.12 all ty-

pes
Details for manufact. see

page 2.12-01
A 309 LI - R 317 LI 2.05.1

copyright by
MJFCIFSS
Special tools for hydraulic systems Service Manual

60 Piston wrench SW 0541333 all ty- To remove and tighten pis-
WS pes ton nuts
61
See chapter 2.12
62
63
64
70 Socket wrench for SW 41 9245656 all ty- To remove and install dam-
threaded bushing pes per pins on hydraulic cylin-
WS 41 ders with damper on
piston/rod side.
80 Mounting tool for pis- M16 9951120 all ty- To dismantle the piston rod
ton rod bearings pes bearing from the hydraulic
M20 9959261 cylinder
M24 9959262
90 Filling device, comple- W24,3 8145359 all ty- To check and refill dia-
te with adapter and fil- 2x1/14 pes phragm and piston type ac-
ling hose 3,0m cumulators
W24.3
2x1/14
3.0m
110 Rod M6 9288234 A 900C Used to remove and install

A 904C piston of pressure balance
on LSC - control valve
block
120 Allen key 9922975 all ty- To remove and install the
pes check valves in connection
K (with radiator bypass val-
ve)
2.05.2 A 309 LI - R 317 LI

copyright by
MJFCIFSS
Service Manual Special tools for hydraulic systems

135 Wrench 10 10114826 A 900C To remove the check valve
mm A 904C 123 (LUDV system)
140 Clamping device for 20 10017281 all ty- To clamp the spool during
spool mm pes disassembly/reassembly
25 10017282
mm
32 10017283
mm
160 Montagehlse 25 9951457 all ty- To assemble the Glyd-ring

mm pes and scraper ring on the
161 22 9951508 plunger piston of the hy-
mm draulic LIKUFIX coupling
162 45 9966421
mm
163 25 951458
mm
180 Vacuum pump com- 00A7. 7405073 all ty- To retain content of hy-
plete, consisting of: 300 pes draulic tank during repair
pump no. 180, vacuum work on the hydraulic sys-
regulation valve no. tem
181 with seal, hose
with filter no. 187
181 Vacuum regulation 10097130

valve complete:
Tank fitting, consisting

of:
184 GE 165 fitting 7002240
185 Cone reducing coup- 7407155
ling 16/85
186 Straight nipple 7024875
A 309 LI - R 317 LI 2.05.3

copyright by
MJFCIFSS
Special tools for hydraulic systems Service Manual
2.05.4 A 309 LI - R 317 LI

copyright by
MJFCIFSS
Service Manual Special tools for electric systems
Special tools for electric systems
2.06.1
copyright by
MJFCIFSS
Special tools for electric systems Service Manual

10 To crimp contacts for MATE-N- 7367025 all ty-
LOK 1.5mm2 leads pes
12 To crimp contacts for MATE-N- 7366314 all ty-

LOK 2.5mm2 connectors pes
15 Extraction tool to remove crimped 7366655 all ty-

contacts from MATE-N-LOK con- pes
nectors
20 Socket contact for 1.5 mm2 wires 6202619 all ty-

for MATE-N-LOCK connectors pes
21 Pin contact for 1.5 mm2 wires for 6202620

MATE-N-LOCK connectors
22 Socket contact for 2.5 mm2 wires 6202591 all ty-

for MATE-N-LOCK connectors pes
23 Pin contact for 2.5 mm2 wires fo 6202592

MATE-N-LOCK connectors
28 Hand-held tool to crimp contacts 7367086 all ty-

(according to MIL-C5015, pes
VG952234, VG 955342)
29 Crimp turret to crimp contacts 7409779

DEUTSCH-type connectors with
special tool no. 28
30 Tool to crimp contacts of 8503647 all ty-

DEUTSCH - type connectors pes
2.06.2
copyright by
MJFCIFSS
Service Manual Special tools for electric systems

32 Extraction tool to re- Size 4 8503633 all ty-
move crimped con- pes
tacts from DEUTSCH-
type connectors
33 Size 8 8503632
34 Size 12 8145674
35 Size 16 8145673
36 Size 20 8503630
37 Pin contact for wires of 0,8- 7368251 all ty-
DT connectors 1,0 pes
1,0- 7368406
2,0
2,0- 6905271
3,0
38 Socket contact for wi- 0,8- 7368252

res of DT connectors 1,0
1,0- 7368405
2,0
2,0- 6905272
3,0
39 Stopfen / Plug / Bou- 7368253

chon
55 Extraction tool for 777-310 7022773 all ty-
WAGO connectors pes
60 IC extraction tool 8042630 all ty-

pes
61 IC mounting tool 8042629
70 Ergocrimp pliers 6004391 all ty- To crimp contacts for wires

pes of JPT (Tyco) connectors
2.06.3
copyright by
MJFCIFSS
Special tools for electric systems Service Manual

Ergocrimp matrix all ty- To crimp contacts for leads
pes
72 0.5-2.5 10016253 Junior Power Timer Nr./no.
mm2 927777-3 / 927779-3 /
927846-2
73 0.5-2.5 10016255 Junior power Timer/EDS

mm2 Nr./no. 929938-3 double
spring contact no.
929940-3
74 0.5-2.5 10016256
mm2 flat adapter no. 963745-1 /
963746-1
80 Extraction tool 7415334 all ty- To remove crimped con-
pes tacts from JPT (Tyco) con-
nectors
90 Crimp plier 10016251 all ty- To crimp littlefuse contacts

pes for leads of JPT (Tyco)
connectors, see also no.
92.
92 Ergocrimp matrix 0.5 mm2 10016252 all ty- In connection with no. 90
-3.32 pes and used to crimp contacts
mm2 for leads
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

Equip
Picture No. Description Size ID no. Application
ment
10 Slotted nut wrench for SAT 9202820 all Releasing and tightening of
slewing gear mecha- 225 types slotted nuts in drive/slew-
nism ing gear mechanisms (SAT
drawing, see page 2.14-
01)
20 Mounting device SAT 9202825 A 309 -

225 R 317
30 Mounting device FAT 9981445 R- Tool used to dismantle and

350/022 machi- mount the multi-disc brake
FAT nes of the FAT slewing gear
350/032 mechanism (drawing, see
page 2.16-01)
35 Mounting device for FAT 8503594 R- For the mounting of slip

slide ring seals 350/022 machi- ring seals in FAT travel
FAT nes gear systems
350/032
2.07.1
copyright by
MJFCIFSS
Special tools for gears Service Manual
2.07.2
copyright by
MJFCIFSS
Service Manual Special tools for axles
Special tools for axles
for the maintenance and repair of axles
10 Collet chuck for axles 7009536 all Used to top in and top out
Chuck tip types the snap ring into/from the
11 5 mm 8145768 planetary gear of the axles
Chuck tip
12 6 mm 8145769
20 Slotted nut wrench for AP/APL 7013102 A 314 / Used to loosen and tighten
axles 745/ A 316 slotted nuts in planetary
755 gears / axles.
21 AP 7021789 A 314 /
745 TR* A 316
AP
755 TR*
22 AP 7014452 A 316
755 HD Indus-
APL try
755 HD
30 Centring disc AP/APL 7013101 A 314 / In conjunction with tool no.
745 A 316 20-22
APL
755
31 AP 7029469 A 314 /
745 TR* A 316
AP
755 TR*
32 AP/APL 7013920 A 316

755 HD Indus-
try
35 Centring ring AP/APL 7024975 A 314 / In conjunction with tool no.
745 TR* A 316 30
APL
755
2.08.1
copyright by
MJFCIFSS
Special tools for axles Service Manual
40 Mounting tool AP/APL 7024127 A 314 Used to insert the cassette

745 seal ring in the hub / axles.
AP A 314
745 TR*
APL
755
42 AP 7024974 A 316
755 TR*
44 APL 7024973 A 316

755 HD Indus-
try
46 AP 7029525 A 316
755 HD Indus-
try
50 Slip bushing, 2-part AP/APL 7019632 A 314 Used to mount the brake
745 piston into the hollow
APL A 316 wheel.
755
51 AP/APL 7024131 A 316

755 HD Indus-
try
60 Measuring screw for M 7019556 A 314 / Used to measure the pad

pad wear 16 x 1.5 A 316 wear at the ZP axles.
65 Measuring tool for pad A 309 / Used to measure the pad

wear A 312 wear at the
multi-disc brake
70 Slotted nut wrench for MS-E 10346444 A 316 Used to loosen and tighten
axles 3060 the slotted nuts in the pla-
MT-E netary housing / hub carrier
3060
2.08.2
copyright by
MJFCIFSS
Service Manual Special tools for axles
75 Gripping piece MS-E 10354109 A 316 Used to remove the inner

3060 bearing race from the joint
housing.
In conjunction with tool no.
78
78 Removal insert MS-E 7011520 A 316

3060
80 Removing tool MS-E 7026311 A 316 Used to remove the outer

3060 bearing race from the joint
housing.
90
85 Removing tool MS-E 10353377 A 316 Used to pull the shaft seal
3060 ring and the bushing from
the axle housing and the
joint housing.
90
90 Counter piece MS-E 7026310 A 316

3060
2.08.3
copyright by
MJFCIFSS
Special tools for axles Service Manual
95 Mounting tool MS-E 7011527 A 316 Used to insert the outer be-
3060 aring race in the joint hou-
sing.
100 Mounting tool MS-E 10353378 A 316 Used to insert shaft seal
3060 rings / bushings in the axle
housing and the joint hou-
sing.
103 Handle MS-E 7011518 In conjunction with tool no.
3060 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)!
2.12.1
copyright by
MJFCIFSS
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 WS Slotted nut

*WS hex. Square ID no.
ID no. paral.
M30X1.5 - 7006469 44 **
M32X1.5 - 7010262 50 **
M33 X1.5 - 9226916 41 1/2 9921132
M36X1.5 - 9875702 50 1/2 9211967
M42X1.5 - 7010163 62 **
M42X1.5 - 9970088 60 1/2 9211967
M42X1.5 - 9113734 55 1/2 9921132
M50X2 - 4129202 70 1/2 9921123
M50X2 - 9166795 65 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
copyright by
MJFCIFSS
Assembly wrenches for WN 4122 piston rod bearings
3 Assembly wrenches for WN 4122 piston rod bearings
Fig. 3 Assembly wrenches for piston rod bearings
0541665 76 62 95 210 9 6 7 15 70 1/2
0541666 87,5 72 110 210 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
2.12.3
copyright by
MJFCIFSS
Assembly wrenches for version 5100 pistons
4 Assembly wrenches for version 5100 pistons
Fig. 4 Assembly wrenches for version 5100 pistons
a WS
Size of piston nut *WS hex. ID no.
for mounting bolts square
M120X3 175 220 3/4 9584641
M140X3 190 240 3/4 9581705
* width over flats
4.1 Assembly wrenches for pistons
Fig. 5 Assembly wrenches for pistons
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
2.12.4
copyright by
MJFCIFSS
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 mm mm mm mm
Piston Piston
ID no.
smallest largest
*SW 6-KT 4-KT l a b c
9600751 80 3/4 170 110 140 160 525 15
9602239 85 3/4 170 115 140 160 525 15
9600418 90 3/4 170 120 150 160 525 15
9597668 100 3/4 170 130 160 180 525 15
9600928 110 3/4 170 160 190 200 525 15
9600769 120 3/4 174 170 200 200 525 15
* width over flats
5 Mounting and expanding sleeves
990 mounting sleeve 991 expanding sleeve

Piston
ID no. 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
2.12.5
copyright by
MJFCIFSS
990 mounting sleeve 991 expanding sleeve

Piston
ID no. 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
Tab. 7 List of mounting and expanding sleeves
2.12.6
copyright by
MJFCIFSS
Mounting sleeves used to insert pistons into cylinders

950 mounting sleeve
Piston
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
Tab. 8 950 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
960 mounting sleeve

Piston rod
ID no.
90 9282761
105 9287177
140 9926806
Tab. 9 960 mounting sleeves
Note!
The 960 mounting sleeve is required in order to prevent damage to sealing and guide elements.
2.12.7
copyright by
MJFCIFSS
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 Thread of Length of

Thread in
bearing head mounting driver mounting driver ID -no.
flange ring
M1 M2 L
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
2.13.1
copyright by
MJFCIFSS
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 Slotted nut wrench for Sat 225
Slewing gear type ID number

SAT 225 9202820
Tab. 1 ID numbers of slottet nut wrenches
2.14.1
copyright by
MJFCIFSS
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 mecha-
nism 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
2.15.1
copyright by
MJFCIFSS
Mounting device for slewing gear Service Manual
2.15.2
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 me-
chanism
Fig. 1 Technical drawing of mounting device
FAT 350
Size
022 / 032
A 238
B 205
C 100
D 108
E 40
F 18
G 16
H 15
ID no. 9981445
Tab. 1 Dimensions of mounting device (in mm)
2.16.1
copyright by
MJFCIFSS
Mounting device for travel gear Service Manual
2.16.2
copyright by
MJFCIFSS
Service Manual
SUBGROUP - INDEX
Section Group Type
Technical data 3.09.1 A 309 LI 20221-
Technical data 3.13.1 R 313 LI 27752-

A 316 LI-IND 2001-
Technical data 3.17.1 R 317 LI 18161-
Inspection and maintenance schedule 3.29.1 A 309 LI 20221-

A 311 LI 20222-
Inspection and maintenance schedule 3.32.1 A 312 LI 12363-

A 314 LI 2001-
A 316 LI 2001-
A 316 LI-IND 2001-
Inspection and maintenance schedule 3.38.1 R 313 LI 27752-

R 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 717 717

Valid from serial number 20221 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 KN 71,1
pressure)
Drive motor 20221 29269

Type BF 4 M 1012 =
Power at rated speed according to DIN ISO 9249 KW 63 (86 PS) =
-1
Rated speed min 2000 =
Max. torque Nm 352 10 =
bei1300-1500 min-1
Oil volume in engine (filling quantity at oil change with filter) l 15,5 =
Oil quality/oil viscosity and oil change intervals see groups 1.50 and =
3.29
Fuel tank capacity l 215 =
Additional information see group 4.02 =
Hydraulic system 20221 29269

Hydraulic pump Typ A 8 VO 55 =
Design axial piston swash =
plate double pump
Drive power of pump with power control (min. power) KW 53 =
Max. flow l/min 212 =
Hydraulic oil volume (oil change with filter) l ca.200 =
Hydraulic oil and filter change intervals see groups 1.50 and =
3.29
Control valve block Typ M8/NG 20 =
Rotary connection 7 x Typ DDF 720 =
A 309 LI 20221- 3.09.1

copyright by
MJFCIFSS
Technical data Service Manual
A 309 Litronic

Rotary connection 6 x Typ 815.006 =
Boom cylinder (adjustable and gooseneck equipment) mm 115 / 70 =
piston / rod
Stick cylinder with adjustable attachment piston / rod mm 90 / 60 =
Bucket cylinder piston / rod mm 80 / 50 =
Swivel cylinder mm 90 / 50 =
Support cylinder with outrigger - blade support piston / rod mm 110 / 50 =
Regulating cylinder with boom attachment 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 l/min 2 51 =
bearing and AS1
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 =
Additional information see group 6. / 7. =
Elektrical system 20221 29269

Operating voltage V 24 =
Battery capacity Ah 2 x 92 (in series) =
Alternator voltage / current V/A 28 / 55 =
Starter V / KW 24 / 4,0 =
Slewing gear mechanism 20221 29269

Gearbox Typ SAT 225 / 220 =
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 3.29
Slewing gear brake Typ wet multi-disc brake =
(negative)
Transmission 20221 29269

Gearbox Typ 2 HL 70 2 HL 270
Oil motor Typ DMVA 108 =
3.09.2 A 309 LI 20221-

copyright by
MJFCIFSS
A 309 Litronic

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
Oil quality/oil viscosity and oil change intervals 1.50 u. 3.29 =
Parking brake Typ wet multi-disc brake =
(negative)
Additional information see group 11.08 group 11.20
Axles 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 l 7,3 =
steering)
Oil volume in wheel hub of steered rigid axle (4-wheel l 2 x 2,0 =
steering)
and 3.29
Steering axle working brake Typ disc brake =
Rigid axle working brake Typ disc brake =
Brake type (positive) =
Additional information see groups =
12.02 / 12.03 / 12.05
Tyres Zoll 9.00 - 20 =
500 / 45 - 20
Steering 20221 29269

Hydraulic pump Typ Gear pump =
Flow l/min 39 =
Steering / steering valve Typ Servostat 2 / LAGS 200
LAGS 200
Additional information see group 13.20/ see group 13.22
13.22
Brake system 20221 29269

Max. flow l/min 2,0 =
A 309 LI 20221- 3.09.3

copyright by
MJFCIFSS
A 309 Litronic
3.09.4 A 309 LI 20221-

copyright by
MJFCIFSS
A 311 Litronic
Technical data
1 A 311 Litronic
Type 718
Typ 718 718

General 20222 29170

Weight of backhoe bucket attachment (2-point support) t 11,99 =
Max. drawing pull (in offroad gear and max. operating KN 71,1
pressure)

Type BF 4 M 1012 =
-1
at 1300-1500 min-1
3.29

Hydraulic pump Typ A 8 VO 55 =
plate double pump
Drive power of pump with power control (min. power) KW 57 =
3.29
A 311 LI 20222- 3.11.1

copyright by
MJFCIFSS
A 311 Litronic

piston / rod
Swivel cylinder mm 90 / 50 =
Support cylinder with outrigger - blade support piston / rod mm 110 / 50 =
Hydraulic pump / pilot control Typ Gear pump =
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 l/min 2 51 =
bearing and AS1


and 3.29
(negative)

3.11.2 A 311 LI 20222-

copyright by
MJFCIFSS
A 311 Litronic

Oil quality/oil viscosity and oil change intervals 1.50 and 3.29 =
(negative)
Axles 20222 29170

Steering axle Typ 262 LD =
Rigid axle Typ 162 LD =
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 l 7,3 =
steering)
Oil volume in wheel hub of steered rigid axle (4-wheel l 2 x 2,0 =
steering)
and 3.29
Rigid axle working brake Typ disc brake =
12.05 / 12.10 / 12.11
Tyres Zoll 9.00 - 20 =
500 / 45 - 20

Flow l/min 39 =
LAGS 200
13.22

A 311 LI 20222- 3.11.3

copyright by
MJFCIFSS
A 311 Litronic
3.11.4 A 311 LI 20222-

copyright by
MJFCIFSS
A 312 Litronic
Technical data
1 A 312 Litronic
Type 719
Typ 719 719

General 12363 29898

Weight of backhoe bucket attachment (2-point support) t 12,5 - 13,5 =
Max. drawing pull (in offroad gear and max. operating KN 87
pressure)

Type BF 4 M 1013 E =
Rated speed min-1 1800 =
at 1400 min-1
3.32

Hydraulic pump Typ LMV 130 =
plate pump
3.32
A 312 LI 12363- 3.12.1

copyright by
MJFCIFSS
A 312 Litronic

piston / rod
Support cylinder with outrigger - blade support piston / rod mm 120 / 70 - 90 / 50 =
Hydraulic pump / Brake system - Servo control Typ Gear pump =
Flow devider K (Brake) / R (Servo control) 2 30


and 3.32
(negative)

3.12.2 A 312 LI 12363-

copyright by
MJFCIFSS
A 312 Litronic

(negative)
Axles 12363 29898

Steering axle Typ 262 / 51 =
Rigid axle Typ 162 / 51 =
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)
and 3.32
Rigid axle working brake Typ drum brake (option =
disc brake)
12.20 / 12.21 / 12.23
Tyres Zoll 10.00 - 20 =
18.00 - 19,5
600 / 40 - 22,5

Flow l/min 44 =
LAGS 200
13.22

A 312 LI 12363- 3.12.3

copyright by
MJFCIFSS
A 312 Litronic
3.12.4 A 312 LI 12363-

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

R 313 Litronic
General
Type 636
Weight of backhoe bucket attachment and 600 mm base pla- t 15.3 (16.4*)
tes
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 pres- kN 151
sure)
Drive motor 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 14,0
Oil quality/oil viscosity and oil change intervals see groups 1.50 and
3.38
Total tank capacity l approx. 230
Additional information see group 4.03
Hydraulic system R 313 Litronic

Type 636
Hydraulic pump Type DPVO 165
Design Axial piston swash pla-
te 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. 350
Hydraulic oil and filter change intervals see groups 1.50 and
3.38
R 313 LI 27752- 3.13.1

copyright by
MJFCIFSS
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) pis- mm 110 / 70
ton / rod
Stick cylinder with adjustable attachment piston / rod mm 115 / 70
Bucket cylinder piston / rod mm 90 / 60
Cylinder with blade support piston / rod mm 130 / 90
Regulating cylinder with boom attachment 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 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 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 5.2
3.38
Slewing gear brake Type Wet multi-disc brake
(negative)
3.13.2 R 313 LI 27752-

copyright by
MJFCIFSS
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 3.0
3.38
Travel brake Type Multi-disc brake
Additional information see group
11.62
or 11.67
Drive R 313 Litronic

Type 636
Drive bar D4 L
Running rollers Type/ D4 L / 2 X 7
num-
ber of
rollers
Support rollers Type/ D4 L / 2 X 2
num-
ber of
rollers
Number of base plates / chains Units 46
Base plate width mm 500/ 600/
750
Specific pressure on ground (max.) N/cm2 4.6(4.9*) / 3.9(4.2*)/
3.2(3.4*)
Additional information see group 12
* in machines with blade
R 313 LI 27752- 3.13.3

copyright by
MJFCIFSS
R 313 Litronic
3.13.4 R 313 LI 27752-

copyright by
MJFCIFSS
A 314 Litronic
Technical data
1 A 314 Litronic
Type 635
Typ 635
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 KN 87
pressure)
Drive motor 2001

Type BF 4 M 1013 EC
Power at rated speed according to DIN ISO 9249 KW 80 (109 PS)
-1
Rated speed min 1800
Max. torque Nm 460 10
at 1400 min-1
Oil volume in engine (filling quantity at oil change with filter) l 15,5
3.32
Fuel tank capacity l 290
Hydraulic system 2001

Hydraulic pump Typ LMV 130
Design axial piston swash
plate pump
Max. flow l/min 234
Hydraulic oil volume (oil change with filter) l ca.250
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 2001- 3.14.1

copyright by
MJFCIFSS
A 314 Litronic
Hydraulic system 2001

Boom cylinder (adjustable and gooseneck equipment) mm 110 / 70
piston / rod
Stick cylinder with adjustable attachment piston / rod mm 115 / 75
Bucket cylinder piston / rod mm 100 / 70
Support cylinder with outrigger - blade support piston / rod mm 120 / 70 - 90 / 50
Regulating cylinder with boom attachment piston / rod mm 140 / 80
Additional cylinder see group 7.35
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 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 wet multi-disc brake
(negative)
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 quality/oil viscosity and oil change intervals 1.50 and 3.32
3.14.2 A 314 LI 2001-

copyright by
MJFCIFSS
A 314 Litronic
Transmission 2001
Parking brake Typ wet multi-disc brake
(negative)
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)
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 10.00 - 20
18.00 - 19,5
600 / 40 - 22,5
Steering 2001
Flow l/min 44
Steering / steering valve Typ Servostat 2 /
LAGS 200
Additional information see group 13.20/
13.22
Brake system 2001

Max. flow l/min 2,0
A 314 LI 2001- 3.14.3

copyright by
MJFCIFSS
A 314 Litronic
3.14.4 A 314 LI 2001-

copyright by
MJFCIFSS
A 316 Litronic
Technical data
1 A 316 Litronic
Type 715 / 716
Typ 715 716 715 716

Valid from serial number 2001 2001 28061 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 - 18,9 - 15,0 - 18,9 -
16,7 21,0 16,7 21,0
Break-out force at tooth KN 66,8 / 90 =
Max. drawing pull (in offroad gear and max. operating KN 90 =
pressure)
Drive motor 2001 2001 28061 28062

Type BF 4 M 1013 EC =
-1
at 1350 min-1
3.32
Hydraulic system 2001 2001 28061 28062

Hydraulic pump Typ LMV 150
Design axial piston swash
plate pump
Max. flow l/min 270
Hydraulic oil volume (oil change with filter) l ca.290
3.32
Control valve block Typ M7/NG 20
Rotary connection 7 x Typ DDF 720
A 316 LI 2001- 3.16.1

A 316 LI-IND 2001- copyright by
MJFCIFSS
A 316 Litronic
Hydraulic system 2001 2001 28061 28062

piston / rod
Stick cylinder with adjustable attachment piston / rod mm 120 / 80 110 / 70 120 / 110 /
80 70
Support cylinder with outrigger - blade support piston / rod mm 120 / 70 - 90 / 50 =
Hydraulic pump / Brake system - Servo control Typ Gear pump =
Flow devider K (Brake) / R (Servo control) 2 30 =
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 = =
Slewing gear mechanism 2001 28061 28062

Gearbox Typ SAT 225 / 218
Oil motor Typ FMF 45
Max. slewing speed min-1 9,0
and 3.32
Slewing gear brake Typ wet multi-disc brake
(negative)
Transmission 2001 2001 28061 28062

Oil motor Typ LMV 100 DMVA 108
3.16.2 A 316 LI 2001-

copyright by A 316 LI-IND 2001-
MJFCIFSS
A 316 Litronic
Transmission 2001 2001 28061 28062

(negative)
Axles 2001 2001 28061 28062

Steering axle Typ APL-B APL-B MS-E 3060
755 755 HD
Rigid axle Typ AP-B AP-B MT-E 3060
755 TR 755 HD
Oil volume in steering axle housing l 9,0 9,5
Oil volume in steering axle wheel hub l 2 x 2,0 2,5
Oil volume in rigid axle housing l 9,0 (10 l 10,0 12,5
at disc
brake)
Oil volume in rigid axle wheel hub l 2 x 1,0 2,0 2,5
(2,0 l at
disc bra-
ke)
and 3.32
Rigid axle working brake Typ drum bra- disc bra- disc brake
ke (option ke
disc bra-
ke)
Additional information see see see groups
groups groups 12.46 / 12.47 /
12.36 / 12.41 / 12.48
12.37 / 12.42 /
12.39 12.44
Tyres Zoll 10.00 - 20 =
18.00 - 19,5 =
600 / 40 - 22,5
=
Steering 2001 2001 28061 28062

Flow l/min 44 =
Steering / steering valve Typ Servostat 2 / LAGZ 190
LAGZ 190
13.24
Brake system 2001 2001 28061 28062

A 316 LI 2001- 3.16.3

MJFCIFSS
A 316 Litronic
Brake system 2001 2001 28061 28062

3.16.4 A 316 LI 2001-

MJFCIFSS
R 317 Litronic
Technical data
1 R 317 Litronic
Type 970/ 362

R 317 Li R 317
General
Type 970 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 =
Rear reach from centre/slewing radius mm 2450 =
Max. drawing pull (in offroad gear and max. operating pressure) KN 151 =
Drive motor R 317 Li R 317

Type 970 Type 362
Type BF 4 M 1013 EC =
Power at rated speed according to DIN ISO 9249 kW 86 (115 HP) =
-1
at 1400 min-1
Oil quality/oil viscosity and oil change intervals see group 1.50 =
and 3.38
Hydraulic system R 317 Li R 317

Type 970 Type 362
Hydraulic pump Type DPVO 165 =
Design 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 =
Hydraulic oil volume (oil change with filter) l approx. 290 =
Hydraulic oil and filter change intervals see group 1.50 =
and 3.38
Control valve block Type M7/NG 20-16 =
R 317 LI 18161- 3.17.1

copyright by
MJFCIFSS
R 317 Litronic
Hydraulic system R 317 Li R 317

Type 970 Type 362
Rotary connection 5-way Type DDF 520 =
Rotary connection 1-way Type 815.001 =
Boom cylinder (adjustable and gooseneck equipment) piston / mm 125 / 70 =
rod
Hydraulic pump / pilot control Type Gear pump =
Hydraulic pump / fan drive (cooling) Type Gear pump =
Pilot control unit / working attachment / slewing gear Type VG - 7 - 4 =
Pilot control unit / travel drive Type 5 TH 6 NR =
Electrical system R 317 Li R 317 Li

Type 970 Type 362
Starter V / kW 24 / 4,8 =
Slewing gear mechanism R 317 Li R 317 Li

Type 970 Type 362
Gearbox Type SAT 225 / 218 =
Oil motor Type FMF 45 =
Max. slewing speed min-1 9.0 =
and 3.38
Slewing gear brake Type Wet multi-disc =
brake (negative)
Travel gear R 317 Li R 317 Li

Type 970 Type 362
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 =
and 3.38
3.17.2 R 317 LI 18161-

copyright by
MJFCIFSS
R 317 Litronic
Travel gear R 317 Li R 317 Li

Type 970 Type 362
Parking brake Type multi-disc brake =
Additional information see group 11.62 /
11.60 / 11.62 11.67
11.65 / 11.67
Translation R 317 Li R 317 Li

Type 970 Type 362
Track bar B 60 L =
Track roller Type/ B 60 L / 2 x 7 D6KL 2 x 9
Qty
Carier roller Type/ B 60 L / 2 x 2 B 60 L / 2 x 3
Qty
Quantity of track pads piece 44 55
Track pad width mm 500 / 600 / 750 / 600/ 900 /
900 / 1000 1000
Ground pressure n/cm2 5,0 / 4,3 / 3,5 / 2,7 3,5 / 2,4 / 2,1
/ 2,4
Additional information see group 12 =
R 317 LI 18161- 3.17.3

copyright by
MJFCIFSS
R 317 Litronic
3.17.4 R 317 LI 18161-

copyright 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.: ................................ Date: .............................
Type: ................................ Operating hours: ................................
Caution!
Careful maintenance can only be carried out when the machine is clean. In particular, visual inspec-
tions, 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 /
WORK TO BE CARRIED OUT
inspection at
A 309 / A 311 Litronic
operating hours
By maintenance personnel By authorized expert personnel Note

(machine operator)
First and only interval
Repeat interval First and only interval
Special interval every 250 hours 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
3.29.1
copyright by
MJFCIFSS
Inspection and maintenance schedule Service Manual
Maintenance /
inspection at
operating hours

(machine operator)
Empty dust collector on air filter (shorten or extend interval as necessary)
Check and clean cooler, pressure relief valve, coolant hose, fan
Replace lube oil filter cartridge
Replace engine oil 1)
Check oil, cooling and fuel system for leaks and condition
Replace water filter cartridge (at least 1 x annually)
Check and adjust throttle control
Check anti-corrosion fluid / antifreeze in coolant (replace coolant every

2 years)
Check condition and tension of the V-belt (using a testing device at operating
temperature). (Replace every 2 years)
Check / adjust valve clearance
Check engine console and oil sump mounts, clamps etc.
Check flexible fuel leak oil line

(change at least every 2 years)
Check intake system and exhaust system for leaks and for condition
Replace fuel fine filter cartridge (or as necessary) 4)
Replace fuel prefilter cartridge (or as necessary) 4)
Replace main element of air filter (according to maintenance indicator / annu-

ally)
Replace safety element of air filter (every third change of main element / annu- Never
ally) 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.) 2)
Replace filter unit on servo oil unit
Check mounting of components
3.29.2
copyright by
MJFCIFSS
Maintenance /
inspection at
operating hours

(machine operator)
Clean hydraulic oil cooler (and as necessary)
Drain off water in hydraulic tank

(when using environmentally friendly fluids, max. 0.1 % part of water permissi-
ble, 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 bat-
teries 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 function of gear shift and parking brake
3.29.3
copyright by
MJFCIFSS
Maintenance /
inspection at
operating hours

(machine operator)
Check mounting of transmission, oil motor and drive shafts
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 applica-
tion)
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
Maintenance /
inspection at
operating hours

(machine operator)
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 op-

erator 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
3.29.5
copyright by
MJFCIFSS
Maintenance /
inspection at
operating hours

(machine operator)
Check condition of hydraulic hoses and of wiring harness
Lubricate locking pins
Clean strainer
MECHANICAL QUICK CHANGE ADAPTER

Tab. 1-1 Inspection and maintenance schedule
1 Engine oil change intervals can be shortened depending on temperature, fuel and oil quality.
2 Observe shortened maintenance intervals in dust intensive application.
3 When using environmentally friendly hydraulic fluids, the maintenance interval is to be determined by regular analy-
sis.
4 Shorten the maintenance interval depending on application (e.g. dust intensive application, barrel refuelling).
Comments / defects
Date: ...................................... Mechanic: ......................................... Customer: .........................................

...
3.29.6
copyright by
MJFCIFSS
A 312 Litronic - A 316 Litronic
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
Machine type: ................................ Operating hours: ................................
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
A 312 - A 316 Litronic
operating hours
by maintenance personnel by authorised specialist technician

(machine operator)
Initial and single interval Note
Repeat interval Initial and single interval
Special interval: every 250 hours Repeat interval
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 neces-
sary)
3.32.1
copyright by
MJFCIFSS
Maintenance/
inspection at
operating hours

(machine operator)
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 eve-
ry 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 4)
on filter type); if necessary, clean or replace at shorter intervals
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
Clean magnetic rod in return filter (daily during first 300 operating hours)
Replace return filter cartridge (first time after 500 operating hours) 2)
Replace filter cartridge in control oil unit
Check components for proper mounting
3.32.2
copyright by
MJFCIFSS
Maintenance/
inspection at
operating hours

(machine operator)
Clean hydraulic oil cooler (shorten interval, if necessary)
Drain water from hydraulic tank

(max. permissible water content for environmentally friendly fluids: 0.1 %; in-
sert 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
3.32.3
copyright by
MJFCIFSS
Maintenance/
inspection at
operating hours

(machine operator)
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 ne-
cessary)
STEERING
Check system for leakage; complete functional test
Check components and steering system parts for proper mounting
OSCILLATING AXLE SUPPORT
Check system for leakage; complete functional test
Check cylinders for proper mounting
BRAKE SYSTEM
Check system for tightness
Carry out functional test
Check pressure of accumulator and brakes; check test switches
OPERATOR'S CAB + HEATING
Check / add detergent solution in windscreen washer tank
Carry out functional test of heating system (before start of winter season)
3.32.4
copyright by
MJFCIFSS
Maintenance/
inspection at
operating hours

(machine operator)
Check heating system for leakage
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 of-
ten
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 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
3.32.5
copyright by
MJFCIFSS
Maintenance/
inspection at
operating hours

(machine operator)
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
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: ......................................... Mechanic: ......................................... Customer: .........................................
3.32.6
copyright by
MJFCIFSS
R 313 Litronic / R 317 Litronic
1 R 313 Litronic / R 317 Litronic
Type: ................................ Operating hours: ................................
Caution!
Careful maintenance can only be carried out when the machine is clean. In particular, visual inspec-
tions, 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

(machine operator)
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)
3.38.1
copyright by
MJFCIFSS
Maintenance /
inspection at
operating hours

(machine operator)
Check and clean cooler, pressure relief valve, coolant hose, fan
Check condition of V-belt
Replace lube oil filter cartridge
Replace engine oil 1)
Check oil, cooling and fuel system for leaks and condition
Replace water filter cartridge (at least 1 x annually)
Check and adjust throttle control
Check engine bracket, oil pan mounting and clamps
Check anti-corrosion fluid / antifreeze in coolant (replace coolant every

2 years)
Check / adjust valve clearance, Renew valve bonnet seal
Check fuel leakage oil line

(replace at least every 2 years)
Check intake system and exhaust system for leaks and for condition
Check glow plugs, change if necessary

Replace fuel fine filter cartridge (or as necessary) 4)
Replace fuel prefilter cartridge (or as necessary) 4)
Replace main element of air filter (according to maintenance indicator / annu-

ally)
Replace safety element of air filter (every third change of main element / annu- Never
ally) clean!
Check clean air line (during filter maintenance)
Replace adjust injection valve (every 3000 operating hours)
HYDRAULIC SYSTEM
Clean magnetic rod in return filter (daily during first 300 hrs.)
Replace filter element in return filter (first time at 500 hrs.) 2)
Replace filter unit on servo oil unit
Check mounting of components
3.38.2
copyright by
MJFCIFSS
Maintenance /
inspection at
operating hours

(machine operator)
Clean hydraulic oil cooler (and as necessary)
Drain off water in hydraulic tank

(when using environmentally friendly fluids, max. 0.1 % part of water permis-
sible, 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 batte-
ries 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 function and action of swing gear brake
SWING RING
Check mounting screws for tight seating and entry of swing gear pinion
TRAVEL GEAR
Check function and effectiveness of travel brake
3.38.3
copyright by
MJFCIFSS
Maintenance /
inspection at
operating hours

(machine operator)
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 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)
3.38.4
copyright by
MJFCIFSS
Maintenance /
inspection at
operating hours

(machine operator)
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.
Check function of visual and acoustic warning devices
Check condition of hydraulic hoses and of wiring harness
Clean strainer
Tab. 1-1 Inspection and maintenance schedule
1 Engine oil change intervals can be shortened depending on temperature, fuel and oil quality.
2 Observe shortened maintenance intervals in dust intensive application.
3 When using environmentally friendly hydraulic fluids, the maintenance interval is to be determined by regular analy-
sis.
4 Shorten the maintenance interval depending on application (e.g. dust intensive application, barrel refuelling).
Comments / defects
3.38.5
copyright by
MJFCIFSS
Date: ...................................... Mechanic: ......................................... Customer: .........................................

...
3.38.6
copyright by
MJFCIFSS
Service Manual
SUBGROUP - INDEX
Section Group Type
Technical data of diesel engines 4.02.1 A 309 LI 20221-

A 311 LI 20222-
Technical data of diesel engines 4.03.1 R 313 LI 27752-

A 316 LI 2001-
A 316 LI-IND 2001-
R 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.: A 309-Li / 20221 A 311-Li / 20222

Power according to DIN / ISO 9249 kW 63 67
PS 86 91
Max. torque (max. engine speed) Nm 352 371
Operating data A 309-Li / 20221 A 311-Li / 20222

Design 4-cylinder - turbo
Operating method 4-stroke direct injection
Bore mm 101
Stroke mm 126
3
Displacement 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

Rated speed min-1 2000 2000
High idle rpm min-1 2100 +40 2100 +50
-1 +100
Low idle rpm min 850 850 +100
Lowest operating speed min-1 1000
-1
Speed at max, engine speed min 1500
Settings A 309-Li / 20221 A 311-Li / 20222

Inlet valve play (cold) mm 0,30
Outlet valve play (cold) mm 0,50
Begin of delivery CA be- see type plate
fore
TDC
4.02.1
copyright by
MJFCIFSS
Technical data of diesel engines Service Manual
Engine type: BF 4 M 2012
Filling volumes (approx. values) A 309-Li / 20221 A 311-Li / 20222

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 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 > 110C), 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 bar 220 +8
at end of service life (3000 operating hours) bar at least 198 +8
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 Main element
1 unit 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 3C
Coolant level sensor 1 unit B3
For order numbers, see respective spare parts list and service packs
Antifreeze agent / Min. temperature for

Water content Antifreeze content
mixing ratio protection
-37C 50% 50%
Note!
Do not exceed an antifreeze concentration of 60%, as this tends to lead to reduced protection and
cooling effect!
4.02.2
copyright by
MJFCIFSS
Engine Type: BF 4 M 2012 C
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 73
PS 99
Speed at max. (engine speed) Nm 422 (1500 rpm)
Operating data R 313-Li / 27752

Design 4-cylinder turbo, intercooled
Type 4-stroke direct injection
Bore mm 101
Boom mm 126
Displacement cm3 4038
Compression ratio 19 : 1
Combustion pressure at starting speed bar 30 - 38
Weight (dry) kg 380
Cooling system Recirculation cooling
Speed range R 313-Li / 27752

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
Begin of delivery CA be- see type plate
fore
TDC
4.03.1
copyright by
MJFCIFSS
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 opera-
ting temperature (coolant
temperature > 110C),
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
New bar 220 +8
after 3000 operating hours bar min. 198 +8
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 Main element
1 Safety element
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 3C
Coolant level sensor 1 B3
Antifreeze agent /
Antifreeze content Water content Antifreeze content
mixing ratio
-37C 50% 50%
4.03.2
copyright by
MJFCIFSS
Note!
cooling effect!
4.03.3
copyright by
MJFCIFSS
4.03.4
copyright by
MJFCIFSS
Engine type: BF 4 M 1013 E
1 Engine type: BF 4 M 1013 E
Installation in machines / from serial no.: A 312-Li / 12363

Power according to DIN / ISO 9249 kW 74
HP 100.7
Max. torque (max. engine speed) Nm 422
Operating data A 312-Li / 12363
Design 4-cylinder - turbo

Bore mm 108
Stroke mm 130
3
Displacement cm 4764
Compression ratio 17.5 : 1
Weight (dry) kg 430 (according to DIN 70020 - A)
Cooling system liquid-cooled
Speed range A 312-Li / 12363

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
Begin of delivery CA be- Preset by manufacturer and specified on type
fore plate
TDC
4.04.1
copyright by
MJFCIFSS
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)

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
new bar 250 +12
after 3000 operating hours bar 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

Oil filter 1
1 Safety element
V-belt 1 10 x 874
1 10x1050
Safety device: oil pressure sensor 1 B 16 response pressure: 0.5 bar
Coolant temperature sensor 1 B2 response temperature 100 3C
Antifreeze agent /
mixing ratio
-37C 50% 50%
Note!
cooling effect!
4.04.2
copyright by
MJFCIFSS
Tightening torques / oversize levels
2 Tightening torques / oversize levels
Installation in models / serial no.: A 312-Li / 12363
Screw tightening torque:

Tightening instructions General notes
Screwed connections
Cylinder head 1. stage Pre-tighten with 50 Nm Apply a little oil to the screw
thread and head surface
2. stage 130 Nm
3. stage 90 degrees According to tightening se-
quence
Screw for V-belt pulley Pre-tighten with 30-40 Nm Apply a little oil to the screw
1. retightening angle 60 degrees
2. retightening angle 60 degrees
Flywheel Pre-tighten with 30 Nm Apply a little oil to the screw

1. stage 60 degrees
2. stage 60 degrees
Oversize levels / limit values Tightening instructions General notes

Cylinder
Normal bore mm 108 + 0.02
Wear limit of bore mm 108.1
Piston
Normal diameter mm 107.785 0.009
Piston height mm Piston class from centre of piston boss
A = 71.10 to piston crown
B = 71.18
C = 71.26
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
Axial play of piston ring

1. Limit of play of compression ring 1. stage - (double-tapered groove)
Limit of play of compression ring mm 0.17
4.04.3
copyright by
MJFCIFSS

Limit of play of grooved piston ring mm 0.10
Piston ring gap

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
4.04.4
copyright by
MJFCIFSS
Engine type: BF 4 M 1013 EC
1 Engine type: BF 4 M 1013 EC
A 316-Li / 2001
Installation in machines / from serial no.: A 314-Li / 2001
R 317 Li / 18161
Power according to DIN / ISO 9249 kW 82 86
PS 109 115
Max. torque (max. engine speed) Nm 458 491
A 316-Li / 2001
R 317 Li / 18161
Design 4-cylinder turbo, intercooled
Bore mm 108
Stroke mm 130
Displacement cm3 4767
Compression ratio 17.5 : 1
Weight (dry) kg 430 (according to DIN 70020 - A)
Cooling system liquid-cooled
A 316-Li / 2001
Speed range A 314-Li / 2001
R 317 Li / 18161
Rated speed min-1 1800
-1
High idle rpm min 1900 +30
Low idle rpm min-1 850 +100
Lowest operating speed min-1 1000
Speed at max. torque min-1 1400
A 316-Li / 2001
Settings A 314-Li / 2001
R 317 Li / 18161
Inlet valve play (cold) mm 0,30
Outlet valve play (cold) mm 0,50
Begin of delivery CA be- Preset by manufacturer and specified on type
fore plate
TDC
4.05.1
copyright by
MJFCIFSS
Engine type: BF 4 M 1013 EC
A 316-Li / 2001
Filling volumes (approx. values) A 314-Li / 2001
R 317 Li / 18161
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)
A 316-Li / 2001
R 317 Li / 18161
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
new bar 250 +12
after 3000 operating hours bar 245 +12
Max. engine inclination towards right or left 30
Max. engine inclination towards fan / flywheel 30
A 316-Li / 2001
Engine wear parts, V-belts and safety devices A 314-Li / 2001
R 317 Li / 18161
Oil filter 1
1 Safety element
V-belt 1 10 x 874
1 10x1050
Safety device: oil pressure sensor 1 B 16 response pressure: 0.5 bar
Coolant temperature sensor 1 B2 response temperature 100 3C
Antifreeze agent /
mixing ratio
-37C 50% 50%
Note!
cooling effect!
4.05.2
copyright by
MJFCIFSS
2 Tightening torques / oversize levels
A 314-Li / 2001
Installation in models / serial no.: A 316-Li / 2001
R 317-Li / 18161
Screw tightening torque:

Tightening instructions General notes
Screwed connections
Cylinder head 1st sta- Pre-tighten with 50 Nm Apply a little oil to the screw
ge thread and head surface
2nd sta- 130 Nm
ge
3rd sta- 90 degrees According to tightening se-
ge quence
Screw for V-belt pulley Pre-tighten with 30-40 Nm Apply a little oil to the screw
1st retightening angle 60 degrees
2nd retightening angle 60 degrees
Flywheel Pre-tighten with 30 Nm Apply a little oil to the screw

1st sta- 60 degrees
ge
2nd sta- 60 degrees
ge

Cylinder
Normal bore mm 108 + 0.02
Wear limit of bore mm 108.1
Piston
Normal diameter mm 107.785 0.009
Piston height mm Piston class from centre of piston boss
A = 71.10 to piston crown
B = 71.18
C = 71.26
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
4.05.3
copyright by
MJFCIFSS
Axial play of piston ring

Limit of play of 1st compression ring 1st sta- - (double-tapered groove)
ge
Limit of play of compression ring mm 0.17
Limit of play of grooved piston ring mm 0.10
Piston ring gap

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
4.05.4
copyright by
MJFCIFSS
Service Manual
SUBGROUP - INDEX
Section Group Type
Coupling 5.05.1 A 309 LI 20221-

A 311 LI 20222-
Clutch 5.10.1 A 312 LI 12363-

A 314 LI 2001-
A 316 LI 2001-
A 316 LI-IND 2001-
R 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 dis-
placement 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
5.05.1
copyright by
MJFCIFSS
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 doub-
le 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 flexi-
bility.
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 mar-
ginally affected.
Fig. 2 Fitting position of the coupling1
1 Coupling, complete (torsion damper) 10 Flywheel

2 Hub 11 Engine intermediate housing
3 Segment 20 Double variable-displacement pump
4 Flexible element 22 Retaining washer
5 Allen head screw 24 Hex head screw
7 Allen head screw
5.05.2
copyright by
MJFCIFSS
Service Manual Coupling
Installation and dismantling of the coupling
3 Installation and dismantling of the coupling
3.1 Dismantling
Secure the variable-displacement pump 20 using a rope.
Remove the Allen head screws 24 and the washers 22.
Remove the flange-mounted double variable displacement pump 20 from the intermediate hou-
sing 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 va-
riable 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 serious-
ly 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 po-
sition, 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).
1 Coupling, complete (torsion damper) 10 Flywheel

2 Hub 11 Engine intermediate housing
3 Segment 20 Double variable-displacement pump
4 Flexible element 22 Retaining washer
7 Allen head and hex head screw
5.05.3
copyright by
MJFCIFSS
Coupling Service Manual
Fig. 3 Sectional drawing showing position and alignment of the coupling
5.05.4
copyright by
MJFCIFSS
Service Manual Clutch
Design and function of coupling
Clutch
1 Design and function of coupling
see Fig. 1 and Fig. 2

The flexible coupling (torsion dampers) 5 is mounted between the diesel engine and the variable-dis-
placement 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.
5.10.1
copyright by
MJFCIFSS
Clutch Service Manual
Fig. 1 Installation position of coupling 5 (a = A 312 - 316, b = R 313 / R 317)
5 Coupling (torsion damper) 80 Holder

7 Allen head / hex head screw 81 Allen head screw
10 Variable-displacement pump
11 Allen head screw C Flywheel
12 Allen head / hex head screw D 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 interme-
diate 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
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 serious-
ly 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 intermedi-
ate 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).
5.10.3
copyright by
MJFCIFSS
Fig. 2 Sectional drawing showing position and alignment of the coupling
5 Coupling (torsion damper) 11 Allen head screw

5.1 Washer 12 Retaining washer
5.2 Hub 81 Allen head screw
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
5.10.4
copyright by
MJFCIFSS
10 Variable-displacement pump C Flywheel / engine

10.10 Pump drive shaft D Intermediate housing / engine
5.10.5
copyright by
MJFCIFSS
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 6.13.1 R 313 LI 27752-

A 316 LI-IND 2001-
Adjustment protocol 6.17.1 R 317 LI 18161-
LSC system 6.20.1 A 312 LI 12363-

A 314 LI 2001-
A 316 LI 2001-
A 316 LI-IND 2001-
R 317 LI 18161-
Design of hydraulic system 6.22.1 A 309 LI 20221-

A 311 LI 20222-
Layout of hydraulic system 6.24.1 A 312 LI 12363-

A 314 LI 2001-
A 316 LI 2001-
A 316 LI-IND 2001-
Layout of hydraulic system 6.27.1 R 313 LI 27752-

R 317 LI 18161-
Adjustment guidelines for hydraulic system 6.30.1 A 309 LI 20221-

A 311 LI 20222-
Adjustment guidelines for hydraulic system 6.34.1 A 312 LI 12363-

A 314 LI 2001-
A 316 LI 2001-
6.1
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

A 311 LI 23507-27111
Hydraulic system 6.40.21 A 309 LI 27110-

A 311 LI 27112-
Hydraulic system 6.42.21 A 312 LI 29898-
Hydraulic system 6.43.1 R 313 LI 27752-

A 316 LI 2001-11151
A 316 LI-IND 2001-11151

A 316 LI 11152-13104
A 316 LI-IND 11152-13104
Hydraulic unit 6.44.21 A 314 LI 13104-

A 316 LI 13105-28060
A 316 LI-IND 13105-28060
Hydraulic unit 6.44.31 A 316 LI 28061-

A 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: .....................................
Measuring
point Actual Possible View
Checks
Specified value Setting. Comment
value
1. Operating conditions - war-

ming up
1.1 Oil temperature min. 50 +10C
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

Set measure at valve 51.
32 1 bar
A 309 LI 20221-27109 6.09.1

copyright by
MJFCIFSS
Adjustment protocol Service Manual
Measuring
Checks
value
3. Horsepower control Measuring using adapter cable at Y50.

point 59
3.1 at speed level 1 (low idle ( X3 )
rpm)
Current 850 +25 mA
Control pressure LR 30 1 bar
3.2 at power test

Remove plug of Y50. Set valve to
Current <50mA emergency setting. (Remove cotter
pin and actuate lever.)
Control pressure LR 1 bar
(tank pressu-
re)
3.3 Checking regulating pres- Measuring

sure for emergency opera- point 59
tion 30 1 bar
6.09.2 A 309 LI 20221-27109

copyright by
MJFCIFSS
Measuring
Checks
value
4. Checking Measuring Take measure using adapter cable

Function Y51 point 57 at Y51.
( X1)
4.1 Current
200 - > 900 mA Pressure: see
via speed steps Diagram
or flow reduction kit
5. Checking
Flow reduction of pump
P1
5.1 Value X
up to pump no. 20194344 9,3 0.2 mm
starting with pump no. 12,4 0.2 mm

20194345
A 309 LI 20221-27109 6.09.3

copyright by
MJFCIFSS
Measuring
Checks
value
6. Begin of hydraulic regu- Measuring Speed - low (about 1,200 min-1)

lation of double variable- point 40/41 Y50 / Y51 not active
displacement Y50 in emergency position (30 bar
Pump at measuring point 59)
(basic setting)
Adjust using screw 1 on pump re-
6.1 Pump P1 50 2 bar gulator
Primary pressure relief val-
ve 120
(extend bucket cylinder)
reduce below begin of re-
gulation, turn in until
actuating pressure at 43 ri- 10 bar
ses to 10 bar
(for auxiliary control block,

AHS ) valve 122 is in char-
ge
6.2 Pump P2 50 2 bar Adjust using screw 2 on pump re-

Primary pressure relief val- gulator
ve 121
(retract support cylinder)
actuating pressure at 44 at 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
Measuring
Checks
value
7. Checking power of the

diesel engine Measuring High idle rpm
(power test) point 41
Note: max. fan speed
Perform this check only 2150 min-1 approx.
when necessary (e.g. Pull out plug (I = 0 mA).
when you detect reduced
engine performance.
Disconnect Y50
and/or launch menu power
test on your laptop
Reduce primary relief val-

ve 120 / 121 (retract stick ( < 50mA)
cylinder) below test pres-
sure. Turn back in until you
reach test pressure again.
Be careful not to lower die- 100 bar
sel engine speed below ra- (each pump)
ted speed. (Check diesel
speed at B12). 2000 +10min-1
Pump at Qmax Measuring

points 41 and
44
Control chamber = tank pressu-
re
A 309 LI 20221-27109 6.09.5

copyright by
MJFCIFSS
Measuring
Checks
value
8. Secondary pressure Measuring

Primary pressure relief val- point 40
ve 120 /
121 screwed in
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
8.2 Travel function Measuring

point 41
- Travel forward 380 +20 bar Valve 214
- Travel reverse 380 +20 bar Valve 215
6.09.6 A 309 LI 20221-27109

copyright by
MJFCIFSS
Measuring
Checks
value
9. Primary pressure / high Measuring High idle rpm

pressure point 40
Primary relief valve 120 350 +10 bar

Retracting bucket cylinder
(with accessory kit AHS11 Measuring

/ AHS 12 point 40
Primary relief valve 122
via hammer starting func- 350 +10 bar
tion; see kit
group 16.)
Measuring
point 41

Retracting support cylinder
10. Primary pressure / low Measuring High idle rpm

pressure point 45
Extending swivel cylinder
A 309 LI 20221-27109 6.09.7

copyright by
MJFCIFSS
Measuring
Checks
value
11. Slewing gear function Measuring

secondary pressure points
197/198
11.1 Turning
Turning right 197 Valve 191

200 +10 bar (high pressure setting)
Lock nut 1
Adjusting screw 2
Turning left 198 Valve 192

Lock nut 1
Adjusting screw 2
11.2 Slowing down

198 Valve 192
Turning right 70 5 bar (low pressure setting)
Lock nut 3
Adjusting screw 4

70 5bar (low pressure setting)
Lock nut 3
Adjusting screw 4
6.09.8 A 309 LI 20221-27109

copyright by
MJFCIFSS
Measuring
Checks
value
12. Travel motor Measuring Adjusting screw 213.1

point on travel motor 210
12.1 Regulation 40 / M
Begin of regulation
240 bar
End of regulation
340 bar
12.2 Output speed on drive shaft, measured during on-

(speed) road gear
Qmin stop screw 212.1
Standard machine 1500 25 min-1
Speeder machine 1930 25 min-1
Checking measurement
Y
Standard machine 23.8 mm
Speeder machine 26.0 mm
A 309 LI 20221-27109 6.09.9

copyright by
MJFCIFSS
Measuring
Checks
value
13. Lowering speed 4 seconds ap-

of equipment prox.
Checking measurement Z 5 mm
of stop screw 162
14. Hydrostatic fan drive
14.1 Checking the fan speed
Check speed while diesel 2150 +50min-1

engine runs at rated
speed. Disconnect Y352.
Hydraulic oil temperature >

should be 50C when che-
cking 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
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)
Type: ......................................... Series no.: ......................................... Operating .........................................

hours:
Measuring point Actual Possible View

Checks Specified value value Setting. Comment
1. Operating conditions -
warming up
1.2 Regulating rpm

1.2.1 during work 1800 rpm
1.2.2 with servo OFF (on-road 1950 rpm
travel)
1.3 Max. speed

1.3.1 during work 1950 +40 rpm
1.3.2 with servo OFF (on-road 2100 +50 rpm
travel) Set measure at valve 51.
1.4 Min. speed 770 +50 rpm
2. Pilot pressure Measuring

point 49
32 1 bar

point 59
rpm)
Current 850 +25 mA
3.2 at power test
Current <50mA
Remove plug of Y50.
Set valve to emergency setting.
(Remove cotter pin and actuate le-
(tank pressu-
ver.)
re)
Diagram, see page 12.

sure for emergency ope- point 59
ration 30 1 bar
A 309 LI 27110- 6.09.11

copyright by
MJFCIFSS


function Y51 point 57 at Y51.
( X1)
4.1 Current
via speed steps diagram
5. Checking
flow reduction of pump
P1
5.1 Value X 12,4 0.2 mm
6.09.12 A 309 LI 27110-

copyright by
MJFCIFSS

6. Begin of hydraulic regu- Measuring Speed - low (about 1,200 rpm)

lation of double variab- point 40/41 Y50 / Y51 not active
le-displacement Y50 in emergency position (30 bar
(basic setting)
Primary pressure relief
valve 120
actuating pressure at 43 10 bar
rises to 10 bar

ge

Primary pressure relief gulator
valve 121

A 309 LI 27110- 6.09.13

copyright by
MJFCIFSS


(power test) point 40/41
Perform this check only 2150 rpm approx.
engine performance.
Disconnect Y50
and/or launch menu po-
wer test on your laptop

sure. Turn back in until
you reach test pressure
again. Be careful not to lo- 100 bar
wer diesel engine speed (each pump)
below rated speed.
(Check diesel speed at
B12). 1800 +10rpm
Pump at Qmax. Measuring

point 43/44
Control chamber = tank
pressure
6.09.14 A 309 LI 27110-

copyright by
MJFCIFSS


Primary pressure relief point 40
valve 120 /
121 screwed in
at upper idle speed
- retract adjusting cylinder 380 +20 bar* Valve 130
Measuring
point 41

* adjustment to 240 bar + 1
revolution of adjusting screw = 380
bar
A 309 LI 27110- 6.09.15

copyright by
MJFCIFSS


point 41

pressure point 40


/ AHS 12 point 40
tion; see kit
group 16.)
Measuring
point 41

Retracting support cylin-
der
6.09.16 A 309 LI 27110-

copyright by
MJFCIFSS


pressure point 45
A 309 LI 27110- 6.09.17

copyright by
MJFCIFSS


197/198
11.1 Turning

Lock nut 1
Adjusting screw 2

Lock nut 1
Adjusting screw 2
11.2 Slowing down

198 Valve 192
Lock nut 3
Adjusting screw 4

Lock nut 3
Adjusting screw 4
6.09.18 A 309 LI 27110-

copyright by
MJFCIFSS


Begin of regulation
240 bar
End of regulation
340 bar

(speed) road gear
Standard machine 1500 25 rpm
Speeder machine 1930 25 rpm
Y

of equipment prox.
of stop screw 162
A 309 LI 27110- 6.09.19

copyright by
MJFCIFSS

Check speed while diesel 2150 +50rpm

Hydraulic oil temperature

> should be 50C when
checking fan speed.
Danger!
Before working near the fan, switch off the engine (observe afterrun).
6.09.20 A 309 LI 27110-

copyright by
MJFCIFSS
Adjustment protocol

hours:
Measuring
Checks
value
1. Operating conditions - war-

ming up
1.3 Max. speed 2100 +50min-1
2. Pilot pressure Measuring Set measure at valve 51.

point 49
32 1 bar
A 311 LI 20222-27111 6.11.1

copyright by
MJFCIFSS
Measuring
Checks
value

point 59
rpm)
Current 850 +25 mA
3.2 at power test
Current <50mA
Remove plug of Y50.
Control pressure LR 12 bar Set valve to emergency setting.
(tank pressu- (Remove cotter pin and actuate le-
re) ver.)

sure for emergency opera- point 59
tion 30 1 bar
6.11.2 A 311 LI 20222-27111

copyright by
MJFCIFSS
Measuring
Checks
value

Function Y51 point 57 atY51.
( X1)
4.1 Current
via speed steps Diagram
5. Checking
Flow reduction of pump
P1
5.1 Value X
up to pump no. 20194344 8,8 0.2 mm
starting with pump no. 11,8 0.2 mm

20194345
A 311 LI 20222-27111 6.11.3

copyright by
MJFCIFSS
Measuring
Checks
value
6. Begin of hydraulic regu- Measuring Speed - low (about 1,200 min-1)

lation of double variable- point 40/41 Y50 / Y51 not active
displacement Y50 in emergency position (30 bar
(basic setting)
ve 120
actuating pressure at 43 ri- 10 bar
ses to 10 bar

ge

gulator
6.2 Pump P2 602 bar
ve 121

6.11.4 A 311 LI 20222-27111

copyright by
MJFCIFSS
Measuring
Checks
value

(power test) point 41
Perform this check only 2150 min-1 approx.
engine performance.
Disconnect Y50
and/or launch menu power
test on your laptop

sure. Turn back in until you
reach test pressure again.
Be careful not to lower die- 110 bar
sel engine speed below ra- (each pump)
ted speed. (Check diesel
speed at B12). 2000 +10min-1
Pump at Qmax Measuring

points 41 and
44
Control chamber = tank pressu-
re
A 311 LI 20222-27111 6.11.5

copyright by
MJFCIFSS
Measuring
Checks
value

Primary pressure relief val- point 40
ve 120 /
121 screwed in
at upper idle speed
- retract adjusting cylinder 380 +20 bar Valve 130
- retract boom cylinder 380 +20 bar Valve 131
- extend boom cylinder 380 +20 bar Valve 132
Measuring
point 41

point 41
Valve 214
- Travel forward 380 +20 bar
Valve 215
- Travel reverse 380 +20 bar
6.11.6 A 311 LI 20222-27111

copyright by
MJFCIFSS
Measuring
Checks
value

pressure point 40


/ AHS 12 point 40
tion; see kit
group 16.)
Measuring
point 41

Retracting support cylinder

pressure point 45
A 311 LI 20222-27111 6.11.7

copyright by
MJFCIFSS
Measuring
Checks
value

197/198
11.1 Turning

Lock nut 1
Adjusting screw 2

Lock nut 1
Adjusting screw 2
11.2 Slowing down

198 Valve 192
Lock nut 3
Adjusting screw 4

Lock nut 3
Adjusting screw 4
6.11.8 A 311 LI 20222-27111

copyright by
MJFCIFSS
Measuring
Checks
value

Begin of regulation 240 bar
End of regulation 340 bar

(speed) road gear
Y

of equipment prox.
of stop screw 162
A 311 LI 20222-27111 6.11.9

copyright by
MJFCIFSS
Measuring
Checks
value
Check speed while diesel 2150 +50min-1

Hydraulic oil temperature >

should be 50C when che-
cking fan speed.
Danger!
6.11.10 A 311 LI 20222-27111

copyright by
MJFCIFSS
Adjustment protocol
2 A 311 Litronic from 27112 (applicable from software version 5.12)

hours:

warming up
1.2 Regulating rpm

1.2.1 during work 1800 rpm
1.2.2 with servo OFF (on-road 1950 rpm
travel)
1.3 Max. speed

1.3.1 during work 1950 +40 rpm
1.3.2 with servo OFF (on-road 2100 +50 rpm
travel) Set measure at valve 51.
1.4 Min. speed 770 +50 rpm

point 49
32 1 bar

point 59
rpm)
Current 850 +25 mA
3.2 at power test
Current <50mA
Remove plug of Y50.
Set valve to emergency setting.
(Remove cotter pin and actuate le-
(tank pressu-
ver.)
re)
Diagram, see page 12.

sure for emergency ope- point 59
ration 30 1 bar
A 311 LI 27112- 6.11.11

copyright by
MJFCIFSS


function Y51 point 57 at Y51.
( X1)
4.1 Current
via speed steps diagram
5. Checking
flow reduction of pump
P1
5.1 Value X 11,8 0.2 mm
6.11.12 A 311 LI 27112-

copyright by
MJFCIFSS

6. Begin of hydraulic regu- Measuring Speed - low (about 1,200 rpm)

lation of double variab- point 40/41 Y50 / Y51 not active
le-displacement Y50 in emergency position (30 bar
(basic setting)
Primary pressure relief
valve 120
actuating pressure at 43 10 bar
rises to 10 bar

ge

Primary pressure relief gulator
valve 121

A 311 LI 27112- 6.11.13

copyright by
MJFCIFSS


(power test) point 40/41
Perform this check only 2150 rpm approx.
engine performance.
Disconnect Y50
and/or launch menu po-
wer test on your laptop

sure. Turn back in until
you reach test pressure
again. Be careful not to lo- 120 bar
wer diesel engine speed (each pump)
below rated speed.
(Check diesel speed at
B12). 1800 +10rpm
Pump at Qmax. Measuring

point 43/44
Control chamber = tank
pressure
6.11.14 A 311 LI 27112-

copyright by
MJFCIFSS


Primary pressure relief point 40
valve 120 /
121 screwed in
at upper idle speed
- retract adjusting cylinder 380 +20 bar* Valve 130
Measuring
point 41

* adjustment to 240 bar + 1
revolution of adjusting screw = 380
bar
A 311 LI 27112- 6.11.15

copyright by
MJFCIFSS


point 41

pressure point 40


/ AHS 12 point 40
tion; see kit
group 16.)
Measuring
point 41

Retracting support cylin-
der
6.11.16 A 311 LI 27112-

copyright by
MJFCIFSS


pressure point 45
A 311 LI 27112- 6.11.17

copyright by
MJFCIFSS


197/198
11.1 Turning

Lock nut 1
Adjusting screw 2

Lock nut 1
Adjusting screw 2
11.2 Slowing down

198 Valve 192
Lock nut 3
Adjusting screw 4

Lock nut 3
Adjusting screw 4
6.11.18 A 311 LI 27112-

copyright by
MJFCIFSS


Begin of regulation
240 bar
End of regulation
340 bar

(speed) road gear
Standard machine 1500 25 rpm
Speeder machine 1930 25 rpm
Y

of equipment prox.
of stop screw 162
A 311 LI 27112- 6.11.19

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MJFCIFSS

Check speed while diesel 2150 +50rpm


> should be 50C when
checking fan speed.
Danger!
Before working near the fan, switch off the engine (observe afterrun).
6.11.20 A 311 LI 27112-

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MJFCIFSS
Adjustment protocol
Typ: ......................................... Serial-No: ......................................... Operating .........................................

hours:
Measuring
Checks
Specified value setting Comment
value
1. Operating conditions
Warm up equipment
1.3 Max. speed 1910 +50min-1
1.4 Min. speed 770 +50min-1 Adjusting at valve 51

point 49
32 1 bar
3. Horsepower control Measuring

point 59
3.1 at rpm step 9 using adapter cable at Y50
(speed max.rpm)
Current 560 +30 mA

(until software 1.5)
11 +2 bar
Control pressure
600 +30 mA
Current
(from software 1.6) 13 +3 bar
Control pressure
Remove plug at Y50.
3.2 Control pressure at 20 +2 bar Set valve to emergency setting.
Power test (Remove cotter pin and actuate le-
ver.)

sure during point 59
emergency operation 3,2 0,5 bar
A 312 LI 12363- 6.12.1

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MJFCIFSS
Measuring
Checks
value
4. Checking Measuring Using adapter cable at Y51

Fine control functionY51 point 57
4.1 Fine control min. 0.8 bar ap-

(Q.max) prox.(Tank
100 < 280 mA pressure)
4.2 Fine control min. to Pressure: see

Fine control max. diagram
280.>.640 mA
(dim. cross-section)
5. Begin of hydraulic Measuring Select low speed (appr.1200 min-1

regulation of variable point 41 Disconnect plug connection at Y50
displacement pump / Y51. Adjust setting at screw
23.2.1 of pump.
5.1 (basic setting)
until software 1.5 65 2 bar
from software 1.6 50 2 bar
Set secondary relief valve

262 (extend bucket cylin-
der) below begin of regula-
tion.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 12363-

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MJFCIFSS
Measuring
Checks
value
6. Adjusting pressure diffe- Measuring max. rpm (step 9), button p not
rence ( p) point 41 / 45 active (Y51 disconnected). Take
with function extend bu- 23 +1 bar readings between MP and LS. Ad-
cket cylinder just at screw 23.5.1 of pump.
Reduce or set pressure at Adjustment

valve 262 at 100-120 bar up to 500 ope-
at Measuring point 41 - rating hours
MP. 24 +1 bar
p at 57 = tank pressure
Re-connect plug at Y51.
7. Checking power of die- high idle rpm

sel engine (power test)
Note: Max. fan speed
Carry out this test only 2230 min-1 approx.
when you suspect the en-
gine runs at reduced po-
wer).
Set secondary pressure
relief valves 242 (extend Measuring
stick cylinder*) and 262 point 41
(extend bucket cylinder*)
below test pressure. Raise
again until you reach test 110 bar
pressure again. The rpm of
the diesel engine must ne-
ver drop below rated
speed. 1800 +10min-1
(Read rpm on screen.)
Difference between
measuring points 41 and < 10 bar
44.
* Both functions are ne-

cessary to get the
max.pump flow.
A 312 LI 12363- 6.12.3

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MJFCIFSS
Measuring
Checks
value
8. Primary pressure Measuring

(safety valve) point 41
8.1 Main relief valve 105 400 +20 bar

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 Measuring high idle rpm

flow cut-off pressure at point 45
104 raised
(not on block).
9.1 Working functions
-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

+20 bar
-Extend bucket cylinder 380 Valve 262
6.12.4 A 312 LI 12363-

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MJFCIFSS
Measuring
Checks
value

point 45
-Travel forward 380 +20 bar Valve 176
-Travel reverse 380 +20 bar Valve 177
10. Operating pressure p Measuring max. rpm (step 9)

point 41 Valve 104
10.1 Pressure cut-off
350 +10 bar
A 312 LI 12363- 6.12.5

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MJFCIFSS
Measuring
Checks
value
11. Slewing gear functions
Secondary pressure Measuring Pressure setting at valve 125, see

point 137/138 fig. on page 7, raised.
11.1 Turning

250 +10 bar (High pressure setting)
Lock nut 1
Adjusting screw 2

Lock nut 1
Adjusting screw 2
11.2 Slowing down, braking

Valve 134
Turning right 138 (Low pressure setting)
90 5 bar Lock nut 3
Adjusting screw 4
Valve 135
Turning left 137 (Low pressure setting)
90 5bar Lock nut 3
Adjusting screw 4
Valves 134 / 135
6.12.6 A 312 LI 12363-

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MJFCIFSS
Measuring
Checks
value

Primary pressure Measuring Carry out settings on valve 125
point 137 / 138
Turning left or 200 5 bar

right

point 45 / M on travel motor
13.1 Regulation
A 312 LI 12363- 6.12.7

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MJFCIFSS
Measuring
Checks
value
13.2 Output speed Measured on drive shaft, during

(speed) on-road gear
Checking measurement Y 16,0 mm Spool 160
14.1 Checking fan speed
Check speed while diesel 2230 50 min-1


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 12363-

copyright by
MJFCIFSS
R 313 Litronic from 27752
Adjustment protocol
1 R 313 Litronic from 27752
Date: ......................................... Mechanic: ......................................... Cust.: .........................................
Type: ......................................... Serial no.: ......................................... Operating .........................................

hours:
Measuring
Checks
value
Warm up equipment
1.2 Regulating rpm 1780 rpm
1.3 Max. speed 1900 +30rpm
1.4 Min. speed 770 +50rpm
2. Pilot pressure Measuring Set at valve 51.

point 49
32 1bar
3. Horsepower control Measuring Measure at Y50 using the adapter

point 59 cable.
3.1 at speed step 9
(high idle rpm)
Current 580 +30 mA

Control pressure 7 +2 bar
3.2 Control pressure during 10+2 bar

power test
Remove the plug from Y50.

Set valve to emergency position
3.3 Check of regulating pres- Measuring (remove cotter pin and tilt lever).
sure during emergency point 59
operation 2.0 0.5bar
6.13.1
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MJFCIFSS
Measuring
Checks
value
4. Check of Measuring Measure using adapter cable at

Y51 function point 57 Y51.
4.1 SF min /(Q.max.) max. 0.8 bar

100 < 300 mA (tank
pressure)
4.2 SF min. to SF.max.
Pressure: see
(300 > 760 mA) diagram
(Q.reduction)
5. Hydraulic begin of regu- Measuring Speed - low ( approx. 1200 rpm)

lation of variable dis- point 41 Y 50 / Y 51 disconnected.
placement Adjust at screw 8 of the pump regu-
pump (basic setting) lator.
Set the secondary relief

valve 262 50 2bar
to a value below begin of
regulation; turn in again
until the actuating pressure
at 44 starts to drop.
Re-connect the plug to Y50.
6.13.2
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MJFCIFSS
Measuring
Checks
value
6. Adjustment of the diffe- Measuring Maximum speed step (step 9).

rential pressure ( -p) point Button -p disabled (Y51 discon-
Extend bucket cylinder 41 / 45 nected). Read value between MP
with function. 19 +1 bar and LS. Adjust at the screw 2 at the
Lower pressure setting or Adjustment pump.
adjust the valve 262 to up to 500
100-120 bar at measuring operating
point 41 -MP. hours
P at 57 = tank pressure 20 +1 bar
Re-connect plug to Y51.
7. Checking diesel engine High idle rpm

power
(power test) Max. fan speed
Note:
This test should only be approx. 1500 rpm
carried out if Pull out plug (I = 0 mA).
you suspect problems (e.g.
reduced output of diesel
engine).
Lower the pressure at the Measuring
secondary pressure relief point 41
valves 242 (extend stick
cylinder) and 262 (extend
bucket cylinder) below the
test pressure in the 110 bar
adjustment protocol. Then
increase the pressure
again to the test pressure. 1800 +10rpm
Ensure that the diesel
engine speed does not
drop below the rated
speed (speed is indicated
at engine speedometer).
<10 bar
Difference between the
measuring points 41 - 44
6.13.3
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MJFCIFSS
Measuring
Checks
value

Safety valve 105 point 41
400 +20 bar
Set the secondary pressu-
re-relief valves 262 to a va-
lue above the adjustment
pressure of 105 and ex-
tend the bucket cylinder.
Turn up the pressure cut-
off 104 until the value
shown at the pressure gau-
ge stops to increase
(response pressure 105).
6.13.4
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MJFCIFSS
Measuring
Checks
value
9. Secondary pressure Measuring High idle speed

Pressure cut-off 104 scre- point 45
wed in (not to block)
- 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
+20
-Retract bucket cylinder 380 bar
Valve 261
Extend bucket cylinder 380 +20 bar
Valve 262
6.13.5
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MJFCIFSS
Measuring
Checks
value
9.2 Travel functions Measuring Disconnect the line 210 to the bra-
point 45 ke.
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
10. Operating pressure p Measuring Maximum speed step (step 9)

point 41 Valve 104
(pressure cut-off) 350 +10 bar
6.13.6
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MJFCIFSS
Measuring
Checks
value
11. Slewing gear function Measuring Valve 125 screwed in

Secondary pressure points
137/138
11.1 Swivelling back
Valve 134
Turning right 137 (high-pressure setting)
250 +10 bar Lock nut 1
Adjusting screw 2
Valve 135
Turning left 138 (high-pressure setting)
250 +10 bar Lock nut 1
Adjusting screw 2
11.2 Slowing down

Valve 135
Turning right 138 (low-pressure setting)
90 5bar Lock nut 3
Adjusting screw 4
Valve 134
Turning left 137 (low-pressure setting)
90 5bar Lock nut 3
Adjusting screw 4
6.13.7
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Measuring
Checks
value
12. Slewing gear function Adjust settings at valve 125.

Primary pressure Measuring
point
137 / 138
Turning left or right 230 +10 bar
at Y451 100% 580 mA
50% 540 mA
0% 500 mA
6.13.8
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MJFCIFSS
Measuring
Checks
value
13. Regulating travel motor Measured at tumbler wheel (output

speed of gearbox) at stroke stop
160.1, 160.2, 180.1, 180.2
13.1 Speed Screw .3
Normal travel 15 1 rpm
Checking measurement Y 15.0 mm
13.2 Fast travel mode (activa- 45 1 rpm Qmin stop screw Vmin
ted with switch S21, hare
symbol)
13.3
Qmin stop Vmin
Straight-ahead travel with 45 rpm
same speed at both sides.
6.13.9
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MJFCIFSS
Measuring
Checks
value
Checking the fan speed

14.1
Check the speed while the
diesel engine runs at rated
speed and Y347 is discon-
nected. 1500+ 50rpm
During the fan speed

check, the hydraulic oil
temperature should be >
50 C.
Danger!
6.13.10
copyright by
MJFCIFSS
Adjustment protocol

hours:
Measuring
Checks
value
Warm up equipment
1.3 Max. speed 1900 +30min-1

point 49 Adjusting at valve 51
32 1 bar

point 59
3.1 at speed level 9 using adapter cable at Y50
(high idle rpm)
Current 560 +30 mA

11 +2 bar
Control pressure
600 +30 mA
Current
Control pressure
Remove plug at Y50.
ver.)

A 314 LI 2001- 6.14.1

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MJFCIFSS
Measuring
Checks
value


(Q.max) prox. (Tank

280.>.640 mA

23.2.1 of pump.
5.1 (basic setting)

starts to go down.
Re-connect Y50.
6.14.2 A 314 LI 2001-

copyright by
MJFCIFSS
Measuring
Checks
value

MP. 24 +1 bar

wer).
Difference between
44.

cessary to get the
max.pump flow.
A 314 LI 2001- 6.14.3

copyright by
MJFCIFSS
Measuring
Checks
value

400 +20 bar
8.1 Main relief valve 105

bucket cylinder.
pressure gauge does
not go up any more.

104 raised
(not on block).

Valve 221
-Extend boom cylinder +20 bar
380
Valve 222
+20
-Retract boom cylinder 380 bar
Valve 241
-Retract stick cylinder 380 +20 bar
Valve 242
-Extend stick cylinder 380 +20 bar
Valve 261
-Retract bucket cylinder 380 +20 bar
Valve 262
+20 bar
-Extend bucket cylinder 380
6.14.4 A 314 LI 2001-

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MJFCIFSS
Measuring
Checks
value

point 45

point 41 Valve 104
10.1 Pressure cut-off
350 +10 bar
A 314 LI 2001- 6.14.5

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MJFCIFSS
Measuring
Checks
value

11.1 Turning 137 Valve 135

Turning right Lock nut 1
Adjusting screw 2

Lock nut 1
Adjusting screw 2
Slowing down, braking

11.2
120 5 bar (Low pressure setting)
Lock nut 3
Adjusting screw 4

120 5bar (Low pressure setting)
Lock nut 3
Adjusting screw 4
from Seri-
al no.
2001
from Seri-
al no.
11147
Valves 134 / 135
6.14.6 A 314 LI 2001-

copyright by
MJFCIFSS
Measuring
Checks
value

point 137 / 138

right

point 45 / M on travel motor
13.1 Regulation
A 314 LI 2001- 6.14.7

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MJFCIFSS
Measuring
Checks
value

Checking measurement Y 16,7 mm Spool 160


check.
Danger!
6.14.8 A 314 LI 2001-

copyright by
MJFCIFSS
Adjustment protocol

hours:
Measuring
Checks
value
Warm up equipment
1.3 Max. speed 1900 +30min-1

point 49 Adjusting at valve 51
32 1 bar

point 59
3.1 at speed level 9 using adapter cable at Y50
(high idle rpm)
Current 560 +30 mA

11 +2 bar
Control pressure
600 +30 mA
Current
Control pressure
Remove plug at Y50.
ver.)

A 316 LI 2001- 6.16.1

MJFCIFSS
Measuring
Checks
value


(Q.max) prox. (Tank

280.>.640 mA

23.2.1 of pump.
5.1 (basic setting)

starts to go down.
Re-connect Y50.
6.16.2 A 316 LI 2001-

MJFCIFSS
Measuring
Checks
value

MP. 24 +1 bar

wer).
Difference between
44.

cessary to get the
max.pump flow.
A 316 LI 2001- 6.16.3

MJFCIFSS
Measuring
Checks
value

400 +20 bar
8.1 Main relief valve 105

bucket cylinder.
pressure gauge does
not go up any more.

104 raised
(not on block).

80 +20 bar* *(only industrial equipment)
-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
6.16.4 A 316 LI 2001-

MJFCIFSS
Measuring
Checks
value

point 45

point 41 Valve 104
10.1 Pressure cut-off 350 +10 bar
A 316 LI 2001- 6.16.5

MJFCIFSS
Measuring
Checks
value

11.1 Turning
137 Valve 135
Turning right 250 +10 bar (High pressure setting)
Lock nut 1
Adjusting screw 2

Lock nut 1
Adjusting screw 2
Slowing down, braking
11.2 Turning right 138 Valve 134

Lock nut 3
Adjusting screw 4

Lock nut 3
Adjusting screw 4
from Seri-
al no.
2001
from Seri-
al no.
11152
Valves 134 / 135
6.16.6 A 316 LI 2001-

MJFCIFSS
Measuring
Checks
value

point 137 / 138

right

point 45 / M2 on travel motor
13.1 Regulation
A 316 LI 2001- 6.16.7

MJFCIFSS
Measuring
Checks
value

Standard machine
until SNo. 28060 1860 25 min-1
from SNo. 28061 1680 25 min-1
Speeder machine
until SNo. 28060 2790 25 min-1
from SNo. 28061 2520 25 min-1 Spool 160
Checking measurement Y 16,7 mm


check.
Danger!
6.16.8 A 316 LI 2001-

MJFCIFSS
Adjustment protocol
1 R 317 Litronic from 18161
......................................... Serial number: ......................................... Operating .........................................

hours:
Actual Possible View

Checks
value setting Comment
warming up
1.3 Max. speed 1900 +30min-1
2. Pilot pressure Measuring point Set measure at valve 51.

49
32 1 bar
3. Horsepower control Measuring point using adapter cable at Y50.

59
3.1 at speed level 1

(low idle rpm)
Current 500+30 mA
Control pressure 6+2 bar
3.2 Control pressure 10 +2 bar

on Power test
Remove plug of Y50.

3.3 Checking regulating pres- Measuring point Set valve to emergency setting.
sure during emergency 59 (Remove cotter pin and actuate
operation 2.0 0.5 bar lever.)
R 317 LI 18161- 6.17.1

copyright by
MJFCIFSS

Checks
4. Checking SF function Measuring point Take measure using adapter ca-

Y51 57 ble at Y51.
4.1 SF min.(Q. max) Tank pressure

100 < 300 mA 0.8 bar approx.
4.2 SF min. to SF max. Pressure: see

300 < 760 mA diagram
5. Begin of hydraulic Measuring point Select low speed (appr.1200 min-

1)
regulation of variable 41
displacement pump Disconnect plug connection at
(basic setting) Y50 / Y51. Adjust setting at screw
23.2.1 of pump.
Set secondary relief valve 50 +2 bar
der) below begin of regu-
lation.Screw in again until
starts to go down.
Re-connect Y50.
6.17.2 R 317 LI 18161-

copyright by
MJFCIFSS

Checks
6. Adjusting pressure dif- Measuring point max. rpm (step 9), button p not
ference ( p) 41 / 45 active (Y51 disconnected). Take
with function extend bu- 19+1 bar readings between MP and LS. Ad-
cket cylinder just at screw 2 of pump.
until 500 hrs.
Reduce or set pressure at 20+1 bar
valve 262 at 100-120 bar
at Measuring point 41 -
MP.
Checking power of die- high idle rpm

sel engine
(power test) max. fan speed
Note: 1600 min-1 approx.
Carry out this check only Pull out plug (I = 0 mA)
when necessary (e.g.
when you suspect the
motor runs at reduced po-
wer.
Set secondary pressure Measuring point
relief valves 242 (extend 41
stick cylinder) and 262
below test pressure. Rai- 110 bar
se again until you reach
test pressure again.The
rpm of the diesel engine
must never drop below 1800 +10min-1
rated speed. (Read rpm
on screen.)
Difference between
44.
R 317 LI 18161- 6.17.3

copyright by
MJFCIFSS

Checks
8. Primary pressure Measuring point

P
Main relief valve 105 41

400+20 bar
bucket cylinder.
Raise pressure at pressu-
re cut-off valve 104 until
pressure gauge does
not go up any more.
9. Secondary pressure Measuring point high idle rpm

Pressure cut-off 104 45
screwed in (not on block).
-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
6.17.4 R 317 LI 18161-

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MJFCIFSS

Checks
9.2 Travel functions Measuring point disconnect brake hose 210

45
-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
10. Operating pressure p Measuring point max RPM ( step 9)

(pressure cut-off) 41 Valve 104
350 +10 bar
R 317 LI 18161- 6.17.5

copyright by
MJFCIFSS

Checks
11. Slewing gear functions Measuring points Valve125 raised.

Secondary pressure 137/138
11.1 Turning

Lock nut 1
Adjusting screw 2

Lock nut 1
Adjusting screw 2
11.2 Slowing down, braking

Lock nut 3
Adjusting screw 4

Lock nut 3
Adjusting screw 4
6.17.6 R 317 LI 18161-

copyright by
MJFCIFSS

Checks
12. Slewing gear functions Carry out settings on valve 125

Primary pressure Measuring point
137 / 138
Turning left or right 230 +10 bar
13. Travel motor measured on turas

Hoist limit screw .3 on
13.1 Slow travel speed 160.1, 160.2, 180.1, 180.2
Normal Travel 151 min-1
Control measurement Y 15 mm
R 317 LI 18161- 6.17.7

copyright by
MJFCIFSS

Checks
13.2 Fast travel speed Q-min screw Vmin

(with switch S21) 45 1 min-1
Check speed while diesel

engine runs at rated 1600 +50 min-1

> should be 50 C during
check.
Danger!
Be sure to switch off motor when working near the fan.
6.17.8 R 317 LI 18161-

copyright by
MJFCIFSS
Service Manual LSC system
Basic principle - general description of functions
LSC system
1 Basic principle - general description of functions
1.1 Introduction
The LIEBHERR hydraulic excavator generation of the A 312 - R 317 Litronic series is equipped with
the LSC hydraulic control system (Liebherr synchronous control).
It allows operators to work much faster and much more precisely, thanks to easier and simpler overall
handling of the machine.
The biggest advantage of the LSC system is, however, that handling and operation can be adapted
much better to prevailing working conditions.
The speed of the working movement is determined by the displacement of the control lever / pilot con-
trol 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 respec-
tive 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
6.20.1
copyright by
MJFCIFSS
LSC system Service Manual
LUDV system
be controlled by actuating the pilot-control lever. It determines the control pressure, which is propor-
tional 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 th-
rough 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 consu-
mer 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 = p2; the flow Qv1 is proportional to cross-section A1, and Qv2 is
proportional to cross-section A2.
The flow generated by the pump at the gauge orifice cross-sections A1 and A2 is proportional to the-
se 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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MJFCIFSS
LUDV system
Fig. 1 Principle of LUDV system
A1 Gauge orifice (spool 1) p1 Pressure in front of pressure balance 1

A2 Gauge orifice (spool 2) p2 Pressure in front of pressure balance 2
Dw 1 Pressure balance of spool 1) Pp Pump pressure
Dw 2 Pressure balance of spool 2) p1 Pressure difference between Pp and p1
F1 External force applied to consumer 1 p2 Pressure difference between Pp and p2
F2 External force applied to consumer 2 p3 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
6.20.3
copyright by
MJFCIFSS
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 con-
trolled on the basis of the requirements and made available by the variable capacity pump. If a se-
cond 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 con-
sumer 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 per-
formance on the other.
The performance of the pump is equal to the flow rate Q of the pump multiplied by the highest consu-
mer pressure (load pressure + p).
Loss in performance might be caused by volumes required by other consumers, multiplied by the cor-
responding 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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MJFCIFSS
Horsepower control by means of proportional solenoid valve Y50
Fig. 2 Horsepower control in LSC system
21 Powertrain (variable-displacement pump) 235 Boom cylinder

23.2 Performance regulator (A 312 - 316) R75 Potentiometer for speed adjustment
25 Performance regulator (R 317) U16 Excavator control (BST)
220 Spool Y50 Proportional valve (LR)
6.20.5
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MJFCIFSS
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 incre-
ased.
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 sup-
plies 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 con-
sumer. 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 increa-
ses.
The balance is established when the pressure difference in the spool reaches the value p pre-set
at the LS regulator (pump pressure - consumer pressure in LS line).
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. ca-
pacity 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 Flow regulation by means of proportional solenoid valve Y51
4.2.1 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 p is smaller, and the pump can maintain the reduced p with
a smaller volume of oil.
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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MJFCIFSS
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
26 Flow regulator (R 317) Y51 Proportional valve LS ( p reduction)
B33 Sensor (kit)
4.2.2 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.
6.20.7
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MJFCIFSS
Hydraulic diagram
5 Hydraulic diagram
Fig. 4 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 224 Pressure balance
23.5 LS regulator 235 Consumer
100 Control valve block 260 Spool
102 Pressure balance / minimum flow 264 Pressure balance
103 Pressure balance / remaining flow 275 to consumer (bucket cylinder)
104 Pressure cut-off valve
6.20.8
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MJFCIFSS
Hydraulic diagram
6.20.9
copyright by
MJFCIFSS
Hydraulic diagram
6.20.10
copyright by
MJFCIFSS
Hydraulic diagram
6.20.11
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MJFCIFSS
Hydraulic diagram
6.20.12
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MJFCIFSS
Service Manual Design of hydraulic system
Tank arrangement
Layout of hydraulic system
1 Tank arrangement
Fig. 1 Hydraulic tank with filters and other components

11
1 Hydraulic tank 11 From turbo charger / diesel engine

2 Breather filter 12 Check valve
3 Stop cock B8 Hydraulic oil temperature transducer
4 Return filter B285 Hydraulic oil temperature transducer(fan control)
5 Integrated bypass valve
1.1 Hydraulic tank
1.1.1 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 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
1.1.2 Filter units:

Return filter 4 with two-stage glass-fibre filter element and bypass valve 5 (integrated in return fil-
ter)
Breather filter 2
Filter elements:
Return filter element for commissioning (factory-installed) 10
Return filter element for cleaning of circuit (after oil change / pump failure) 5
Return filter element for normal operation, two-stage20 / 5 ,
for use in dusty environments single-stage 10
Breather filter 2 complete, for normal operation 7 ,
for use in dusty environments 2
6.22.1
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MJFCIFSS
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 Double variable-displacement pump 20
2.1.1 Powered by:

Diesel engine
Via torsion dampers (flexible coupling)
2.1.2 Design:
Axial piston inclined axle
2.1.3 Classification:
Axial piston drive system with inclined axle
6.22.2
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MJFCIFSS
Hydraulic pumps
Hydromechanic adjusting unit

Regulating unit
Technical data and description of functions:
see double variable-displacement pump in group 7.02
2.2 Gear pumps 30 - 33
2.2.1 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)
2.2.3 Pump 32 for steering:

Powered by diesel engine (direct)
Supply of Servostat / steering valve
2.2.4 Pump 33 for pilot control:

Powered via gear pump 32 (flange-connected)
Supply of control oil unit
6.22.3
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MJFCIFSS
Pilot control
3 Pilot control
Fig. 3 Pilot control units on operator's platform and control oil unit
A Control oil unit from start of series 86 Pilot control unit 2x, for kit
B Control oil unit from serial no. () 87 Positioning brake / slewing gear
1 Hydraulic tank Y3 Solenoid valve of servo safety shut-down
50 Control oil unit Y24 Solenoid valve / creeper gear
80 Pilot control unit 4x, left Y50 Proportional solenoid valve / power control
81 Pilot control unit 4x, right Y51 Proportional solenoid valve / flow reduction P1
84 Pilot control unit 1x, for travel drive 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.
20
6.22.4
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MJFCIFSS
Arrangement of control valve block
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.
3.3 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 (low-
pressure circuit)
100 Compact control block (high pressure) 107 Spool / bucket cylinder
101 Spool / slewing gear 108 Spool / travel motor
102 Spool / stick cylinder 109 Spool / combined boom cylinder /
stick cylinder
103 Spool / support cylinder 110 Auxiliary control valve block (low pres-
sure)
105 Spool / regulating cylinder 112 Spool / slewing gear
106 Spool / boom cylinder 113 Spool / grapple rotator
6.22.5
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MJFCIFSS
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 Oil rotary connections located in the pivot point of the upper/undercarriage
260 Oil rotary connection for high pressure 262 Oil rotary connection for low pressure
7x 6x
5.1 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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MJFCIFSS
Consumers and attachments
6 Consumers and attachments
Fig. 6 Consumers and attachments
64 Hydraulic cylinder for uppercarriage 210 Regulating travel motor DMVA

locking mechanism (*)
160-250 Hydraulic cylinder for attachment 225 Transmission
and support
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 Classification:
6.2.1 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.
6.22.7
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MJFCIFSS
Hydraulic cylinder
7 Hydraulic cylinder
Fig. 7 Arrangement of consumers and working attachments
64 Hydraulic cylinder / uppercarriage locking 230 Support cylinder

mechanism
160 Boom cylinder 240 Swivel cylinder
170 Stick cylinder 250 Regulating cylinder
180 Bucket cylinder
7.1 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

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 cus-
hioning
6.22.8
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MJFCIFSS
Slewing gear motor
8 Slewing gear motor
Fig. 8 Slewing gear motor mounted in slewing gear mechanism
190 Slewing gear motor FMF 195 Slewing gear mechanism SAT 225
8.1 Purpose:
Slewing gear motor 190driving the slewing gear mechanism
Slewing gear mechanism 195 rotating the uppercarriage
9 Travel motor
Fig. 9 Travel motor, flange-mounted to transmission
210 Travel motor DMVA 225 Transmission 2 HL 70 / 2 HL 270
6.22.9
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MJFCIFSS
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 Hydraulic oil cooler
13 Oil motor / radiator fan B2 Hydraulic oil temperature transducer (fan con-
trol)
14 Pressure relief valve / fan motor B285 Hydraulic oil temperature transducer (fan con-
trol)
15 Coarse filter / fan motor Y352 Proportional solenoid valve / fan
30 Gear pump / cooling
10.1 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
copyright by
MJFCIFSS
6.22.11
copyright by
MJFCIFSS
6.22.12
copyright by
MJFCIFSS
Service Manual Layout of hydraulic system
Hydraulic tank
1 Hydraulic tank
Fig. 1 Hydraulic tank
1 Hydraulic tank 4 Return filter

2 Breather filter 5 Safety check valve
3 Stop cock K Oil level sight glass
1.1 Purpose
Supplies purified and cooled oil to the hydraulic pumps.
Provides reservoir for return oil, with return filters.
Preloads oil to prevent cavitation.
6.24.1
copyright by
MJFCIFSS
Layout of hydraulic system Service Manual
Hydraulic tank
1.2 Design
Fig. 2 Section drawing of hydraulic tank
1 Hydraulic tank A Return side

2 Breather filter B Suction side
3 Stop cock C Drain valve (collection area)
4 Return filter D Drain valve (suction side)
5 Safety check valve K Oil level sight glass
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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MJFCIFSS
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
Design:
Axial piston powertrain
Adjustable unit with swash plate
Regulating unit 23 with performance regulator GLR and LS regulator
see variable-displacement pump in group 7.05
6.24.3
copyright by
MJFCIFSS
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
6.24.4
copyright by
MJFCIFSS
Compact control block
3 Compact control block
Fig. 5 Compact control block 100
3.1 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
with suction function) for attachment
Stroke limitation of the spool
For a description of the functions, see group 7.60
6.24.5
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MJFCIFSS
4.1 Purpose
Cooling of return oil
Cooled by motor-driven fan
Fig. 6 design of hydraulic oil cooling system

13
6 Hydraulic oil cooler 14 Pressure-relief valve

13 Blower motor Y352 Proportional solenoid valve
4.2 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.
6.24.6
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MJFCIFSS
5.1 Purpose
Transfer of hydraulic oil from the uppercarriage to the undercarriage and vice versa.
5.2 Design
Travel drive, outrigger and blade support, steering and leak oil
Braking system, gear shifting, creeper gear system, oscillating axle support
For a detailed description, see groups 7.76 and 7.78.
Fig. 7 Oil rotary connection
320 Rotary connection for high pressure 322 Rotary connection for low pressure
6.24.7
copyright by
MJFCIFSS
Consumers / working attachments
6 Consumers / working attachments
130 Slewing gear motor 255 Stick cylinder

170 Travel motor 275 Bucket cylinder
235 Boom cylinder 295 Support cylinder
6.1 Function and classification

Conversion of hydraulic energy into mechanical energy
stroke, see 6.2.
Hydraulic device for the transmission of torque in a rotary motion, see 6.3.
6.2 Cylinder
Design:
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
copyright by
MJFCIFSS
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 foot-
operated 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 85 Pilot control unit / support

80 Pilot control unit for stick and rotary move- 86 Pilot control unit for accessory kits
ment
6.24.9
copyright by
MJFCIFSS
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 attach-
ments, 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
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 con-
trol 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
copyright by
MJFCIFSS
Tank arrangement
1 Tank arrangement
Fig. 1 Hydraulic tank with filters and other components

11
1 Hydraulic tank 50 Control oil unit

2 Breather filter B8 Temperature transducer / hydraulic oil
3 Stop cock B285 Temperature transducer / hydraulic oil (fan con-
trol)
4 Return filter K Sight glasses for hydraulic oil level
5 Integrated bypass valve
1.1 Hydraulic tank
1.1.1 Purpose:
Supplies purified oil to hydraulic pumps.
Reservoir for return oil, with return filters.
Preloads oil to prevent cavitation.
1.1.2 Filter units:

Return filter 4 with two-stage glass-fibre filter element and bypass valve 5 (integrated in return fil-
ter)
6.27.1
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MJFCIFSS
Hydraulic pumps
Breather filter 2
1.1.3 Filter elements:

Return filter element for commissioning (factory-installed) 10
Return filter element for cleaning of circuit (after oil change / pump failure) 5
Return filter element for normal operation, two-stage 20 / 5 ,
for use in dusty environments single-stage 10
Breather filter 2 complete, for normal operation 7 ,
for use in dusty environments 2
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
copyright by
MJFCIFSS
Pilot control
2.1 Variable-displacement pump 20
2.1.1 Powered by:

diesel engine
2.1.2 Design:
Axial piston swash plate
2.1.3 Classification:
Axial piston drive system with swash plate
Hydromechanical adjusting unit
Regulating unit
see variable-displacement pump in group 7.05
2.2 Gear pumps 30 / 31:
2.2.1 Pump 30 for pilot control:

Driven by variable-displacement pump 20 (built in)
Supply of control oil unit
2.2.2 Pump 31 for hydraulic fan drive:

Powered by variable-displacement pump (flange-connected)
Supply of hydraulic fan drive
3 Pilot control
Fig. 3 Control oil unit 50 and view of pilot control units on operator's platform
6.27.3
copyright by
MJFCIFSS
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, Y50 Proportional solenoid valve / power control
left
83 Pilot control unit 1x, for travel drive, Y51 Proportional solenoid valve / flow reduction
right
86 Pilot control unit 2x, for accessory kit
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 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
For description, see maintenance regulations in group 3.
6.27.4
copyright by
MJFCIFSS
Arrangement of control valve block
4 Arrangement of control valve block
Fig. 4 Compact control valve block 100
100 Compact control valve block 220 Spool / boom cylinder

120 Spool / slewing gear 240 Spool / stick cylinder
160 Spool for travel, right 260 Spool / bucket cylinder
180 Spool for travel, left
4.1 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
with suction function)
Bleeder valves of control lids
6.27.5
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MJFCIFSS
Fig. 5 Oil rotary connections located in the pivot point of the upper/undercarriage
195 Oil rotary connection for high pressure 196 Oil rotary connection for low pressure
5x 1x
5.1 Purpose:
feeds hydraulic oil from the uppercarriage to the undercarriage and vice versa
5.2 Design:
Travel drive left forward / reverse
Travel drive right forward / reverse
Leak oil
Fast travel gear shifting
For a description, see groups 7.75 and 7.77.
6.27.6
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MJFCIFSS
Consumers and attachments
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
6.1 Purpose:
Convert hydraulic energy to mechanical energy
6.2 Classification:
6.2.1 Cylinders 235 / 255 / 275

stroke.
6.2.2 Oil motors 130 / 200 / 201

Hydraulic device for the transmission of torque in a rotary motion.
6.27.7
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MJFCIFSS
Hydraulic cylinder
7 Hydraulic cylinder
Fig. 7 Arrangement of consumers and working attachments
235 Boom cylinder 275 Bucket cylinder

255 Stick cylinder
7.1 Design:
without end-of-travel cushioning
with end-of-travel cushioning, one-end / two-end

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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MJFCIFSS
Slewing gear motor
8 Slewing gear motor
Fig. 8 Slewing gear motor mounted in slewing gear mechanism
130 FMF slewing gear motor 156 Slewing gear mechanism SAT 225
8.1 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 216 Travel gear

201 Travel motor, right
6.27.9
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MJFCIFSS
9.1 Purpose
Travel motors 200 / 201 driving the travel gear 216
Travel gear 216 drives the tumbler wheels and chains
10.1 Purpose
Cooling of return oil
Cooled by motor-driven fan
Fig. 10 Design of hydraulic oil cooling system

13
6 Hydraulic oil cooler 14 Pressure-relief valve

13 Blower motor Y352 Proportional solenoid valve
10.2 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.
6.27.10
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MJFCIFSS
6.27.11
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MJFCIFSS
6.27.12
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MJFCIFSS
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 machi-
ne 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 Measuring points at variable-displacement pump LPV 20, control valve block 50 and con-
trol oil unit 100
40 Measuring point for high pressure of pump 1 at the control valve block 100 (connection M1)
41 Measuring point for high pressure of pump 2 at the control valve block 100 (connection M2)
43 Measuring point for the control chamber pressure at the pump P1
44 Measuring point for the control chamber pressure at the pump P2
45 Measuring point for low pressure at the flow distributor connection R of the gear pump 31 for
the offset boom bearing and AS1
49 Measuring point for the pilot pressure at the control oil unit 50 (connection M)
57 Measuring point for the flow reduction control pressure (connection X1) at the pump 20
59 Measuring point for the power control pressure (connection X3) at the pump 20
197 Measuring point for the slewing gear working pressure at the slewing gear motor 190 (con-
nection MA for turning right)
198 Measuring point for the slewing gear working pressure at the slewing gear motor 190 (con-
nection MB, turning left)
Note
If a AHS 1, AHS 11 or AHS 12 attachment kit is installed, the measuring point 40 for the high pres-
sure from the pump 1 is located at the auxiliary control valve block.
6.30.1
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MJFCIFSS
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 equip-
ment:
MS measuring system tool, 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 cable and accessories for the measuring of speed and tempe-
rature
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 val-
ves 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 50C.
The pressure gauges must be glycerine-filled and have an indicating accuracy of below 1% rela-
tive 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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MJFCIFSS
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' com-
mand 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.
6.30.3
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MJFCIFSS
Checking the proportional solenoid valve Y50
4 Checking the proportional solenoid valve Y50
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 Proportional solenoid valve / power control

59 Measuring point LR (power control)
Current OK Pressure OK => Everything OK

Current OK Pressure not => Replace proportional solenoid valve.
OK
Current not Pressure not => Search for fault in the electrical system and the horse-
OK OK power 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.
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.
6.30.4
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MJFCIFSS
Re-set the lever to its initial position.

Insert the cotter pin.
Disconnect the pressure sensor or gauge and seal the measuring point 59.
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.
measuring point 57.
50 Control oil unit Y51 Proportional solenoid valve / flow reduction

57 Measuring point LS (flow reduction)
Current OK Pressure OK => Everything OK

OK
Current not Pressure not => Search for fault in the electrical system.
OK OK
Note!
The characteristic of the solenoid valve Y51 cannot be adjusted.
6.30.5
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MJFCIFSS
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 pivo-
ting 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 val-
ve).
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 pro-
tocol.
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 Adjusting screw for flow reduction of pump P1
72 Screw plug 74 Seal-Lock collar nut

73 Threaded stud 75 Safety cap
6.30.6
copyright by
MJFCIFSS
Checking and adjusting the variable-displacement pumps
7 Checking and adjusting the variable-displacement pumps
Fig. 6 Measuring connections and valves
1 Adjusting screw of begin of regulation P1 50 Control oil unit

2 Adjusting screw of begin of regulation P2
X1 20
3 Lock nut / adjustment Y50 (basic setting / 59 Measuring point for the power control
emergency operation) pressure (connection X3) at the pump 20
20 120 Primary pressure relief valve for pump P1
40 Measuring point for high pressure from 121 Primary pressure relief valve for pump P2
pump 1 at the control valve block 100
(connection M1)
Y50 Proportional solenoid valve / power con-
trol
43 Measuring point for the control chamber Y51 Proportional solenoid valve / flow reduc-
pressure at the pump P1 tion
44 Measuring point for the control chamber
pressure at the pump P2
7.1 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).
6.30.7
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MJFCIFSS
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 regula-
tion (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 pres-
sure.
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.
Lower the pressure at the primary pressure relief valve 121 to a value below the begin of regula-
tion (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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MJFCIFSS
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 pres-
sure.
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.
6.30.9
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MJFCIFSS
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 Pump, control oil unit, control valve block and cooling unit
20 Double variable-displacement pump 120 Primary pressure relief valve for pump P1
A8VO
40 Measuring point for high pressure of 121 Primary pressure relief valve for pump P2
(connection M1)
41 Measuring point for high pressure of Y50 Proportional solenoid valve / power control
(connection M2)
43 Measuring point for the control chamber Y51 Proportional solenoid valve / flow reduction
44 Measuring point for the control chamber Y352 Proportional solenoid valve of radiator fan
50 Control oil unit
6.30.10
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MJFCIFSS
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 pres-
sure (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 => Diesel engine output OK
rpm
Speed < Regulating => Diesel engine output not OK
rpm
* from software version V5.12, only the speed level 8 is reached when the servo steering is switched
on (through S35).
6.30.11
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MJFCIFSS
Checking and adjusting the secondary pressure
9 Checking and adjusting the secondary pressure
Fig. 8 Control valve block with measuring connections and valves

100
40 Measuring point (pump P1) 127 Secondary relief valve / retracting stick
cylinder
41 Measuring point (pump P2) 128 Secondary relief valve / retracting stick
cylinder
100 Compact control block 129 Secondary relief valve / extending stick
cylinder
120 Primary pressure relief valve of pump P1 130 Secondary relief valve / retracting regula-
ting cylinder
121 Primary pressure relief valve of pump P2 131 Secondary relief valve / retracting boom
cylinder
132 Secondary relief valve / extending boom
cylinder
133 Secondary relief valve / retracting bucket
cylinder
134 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 ad-
justing value of the secondary pressure relief valves (see adjustment protocol), (turn in valves).
Extend or retract the respective cylinder.
6.30.12
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MJFCIFSS
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.
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 be-
low.
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 Travel motor with valves
210 Travel motor DMVA 214 Secondary relief valve / forward travel
215 Secondary relief valve / reverse travel

Preselect on-road gear.
Apply the working brake (locking device engaged).
Operate the travel motor 210 and move forward and back.
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.
6.30.13
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MJFCIFSS
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).
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.
Compare the pressure indicated at the measuring point 40 with the prescribed pressure (see ad-
justment protocol).
Turn the primary pressure relief valve 120 until the prescribed pressure is reached.

Fully extend the support cylinder.

Compare the pressure indicated at the measuring point 41 with the prescribed pressure (see ad-
justment protocol).
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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MJFCIFSS
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 Low pressure control block and diesel engine with working and auxiliary pumps
31 Gear pump / brake and attachment kit AS 110 Low pressure control valve block
with flow distributor
45 Measuring point for low pressure 123 Pressure relief valve for low pressure
Start the machine.
Fully extend the swivel cylinder.
To do this, remove the safety cap and loosen the lock nut (WS 19). Using an Allen key (WS 4),turn
the adjusting screw.
6.30.15
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MJFCIFSS
Checking and adjusting secondary pressure for slewing gear
12 Checking and adjusting secondary pressure for slewing gear
Fig. 11 Slewing gear motor with measuring points and 2-stage valves
190 Slewing gear motor 197 Measuring point, turning right

191 Secondary pressure relief valve, turning right 198 Measuring point, turning left
192 Secondary pressure relief valve, turning left
12.1 Start-up pressure settings

Danger!
Uncontrolled rotating movement of the uppercarriage during adjusting work can lead to serious in-
jury 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.

Turn the slewing with full load to the right.
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 the slewing with full load to the left.

6.30.16
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MJFCIFSS
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 Setting brake pressure

Disconnect and dummy both hose connections to XA and XB.
Turn the slewing with full load to the right.
Compare the pressure indicated at the measuring point 198 with the prescribed low pressure (bra-
king right, see adjustment protocol).
If necessary, loosen the lock nut 3 and adjust the pressure relief valve 192 using the adjusting
screw 4.
Turn the slewing with full load to the left.

Compare the pressure indicated at the measuring point 197 with the prescribed low pressure (bra-
king left, see adjustment protocol).
If necessary, loosen the lock nut 3 and adjust the pressure relief valve 191 using the adjusting
screw 4.
Re-connect the hose connections to XA and XB.
6.30.17
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MJFCIFSS
Checking travel motor 210
13 Checking travel motor 210
Fig. 12 Control valve block and travel motor
3.35 Screw plug at measuring point M 40 Measuring point for working pressure of
pump P1
4.14 Qmin stop 100 Control valve block
4.28 Safety cap 210 Travel motor DMVA
13.1 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.
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 con-
nect the pressure sensor (see Fig. 12).
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
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 Q Engine flow consumption
M Measuring point at the travel motor 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 measu-
ring 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.
6.30.19
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MJFCIFSS
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 3.17 Lock nut

3.14 Qmin stop screw 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 clo-
thing 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 bra-
ckets, etc.).
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 (measure-
ment 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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MJFCIFSS
Adjusting of max. output speed / max. travel speed
Operate the travel motor in on-road gear at full speed.

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 ax-
le) 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:
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.

6.30.21
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MJFCIFSS
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.
Fig. 15 Stroke limitation of the boom cylinder spool
100 Compact control block 162 Stop screw of stroke limitation

106 Spool / boom cylinder 163 Lock nut
Start the machine.

Extend the attachment.
Fully extend the boom cylinder.
Fully retract the boom cylinder.
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 = Prolong lowering time
Turn out = Shorten lowering time
Tighten the lock nut 163.
6.30.22
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MJFCIFSS
Checking fan control
16 Checking fan control
Fig. 16 Hydraulic radiator fan located near the diesel engine
13 Fan motor Y352 Proportional solenoid valve
Danger!
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 discon-
nect 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.
6.30.23
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MJFCIFSS
Checking fan control
6.30.24
copyright by
MJFCIFSS
Pressure check
1 Pressure check
1.1 Arrangement of measuring points
Fig. 1 Layout of measuring points, part 1
20 Variable-displacement pump 50 Control oil unit

41 Measuring point for high pressure 57 Measuring point LS pressure
at the control block 100 (MP connection) at the control oil unit 50 (MLS connection)
44 Measuring point for actuating pressure 59 Measuring point LR pressure
at the pump 20 (MA connection) at the control oil unit 50 (MLR connection)
45 Measuring point for LS pressure 100 Control valve block
at the pump 20 (LS connection)
49 Measuring point for pilot pressure
at the control oil unit 50 (M1 connection)
6.34.1
copyright by
MJFCIFSS
Pressure check
Fig. 2 Layout of measuring points, part 2
137 Measuring point for slewing gear working 138 Measuring point for slewing gear working
pressure at the slewing gear motor 130 pressure at the slewing gear motor 130
(MA connection / pivot right) (MB connection / pivot left)
1.2 Measuring instruments / adjusting tools / safety of adjusting screws
1.2.1 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:
For actuating pressure measurement:
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:
For actuating pressure measurement:
plus measuring cables and accessories for the measuring of speed and temperature
6.34.2
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MJFCIFSS
1.2.2 Adjusting tools:

All adjustments to the valves / units can be made with conventional ring spanners, open-end wren-
ches and Allen keys.
1.2.3 Securing of the adjusting screws:

To protect the adjusting screws against tampering and unintentional maladjustment, they must be se-
cured (depending on the model):
with lead seal wire
with safety caps, see "Special tools" in group no 2.05

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 set-
tings of valves and units.
Fig. 3 Checking and adjusting pilot pressure
49 Measuring point 51 Adjusting screw

50 Control oil unit
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 adjust-
ment protocol).
If necessary, adjust the setting of pressure relief valve 51.

Loosen the lock nut (WS 13).
6.34.3
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MJFCIFSS
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 Adjustment of the pump 20
6.34.4
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MJFCIFSS
20 Variable-displacement pump 262 Secondary pressure relief valve

23.2.1 Adjusting screw Y24 Solenoid valve
41 Measuring point Y50 Solenoid valve
The settings of the hydraulic begin of regulation must be adjusted at minimum pump rate. Before ad-
justing the settings, the pressure must be adjusted, so that the performance regulator = tank pressu-
re.
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.

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.
6.34.5
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MJFCIFSS
3.2 Checking and adjusting the differential pressure ( p) between the pump pres-
sure and the LS pressure
Fig. 5 Adjustment of the working pump, part 1
1 Measuring cable 41 Measuring point

2 Pressure sensor 45 Measuring point
3 Measuring neck 23.5.1Adjusting screw
4 Measuring point 262 Pressure-relief valve
5 Differential pressure measuring instru-
ment
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) th-
rough 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 diffe-
rential pressure p between the measuring points 41 and 45, and compare them with the prescri-
bed value (see adjustment protocol).
6.34.6
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MJFCIFSS
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 23.5.1 Adjusting screw

23.5 Load sensing regulator
If necessary, adjust the differential pressure setting pat flow regulator 23.5 of the variable-
displacement pump.
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).
6.34.7
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MJFCIFSS
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 Output check of the diesel engine
41 Measuring point H307 Indicator light

242 Secondary pressure relief valve S382 Fine control switch
262 Secondary pressure relief valve
4.2 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 connec-
tion 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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MJFCIFSS
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.
6.34.9
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MJFCIFSS
Adjusting pressure relief and cut-off valves
5 Adjusting pressure relief and cut-off valves
Fig. 8 Measuring points and valves at the pump and control block
20 Variable-displacement pump 177 Reverse travel

41 Measuring point MP 221 Extending boom cylinder
45 Measuring point MLS 222 Retracting boom cylinder
100 Control valve block 241 Retracting stick cylinder
104 Pressure cut-off valve 242 Extending stick cylinder
105 Primary pressure relief valve 261 Retracting bucket cylinder
170 Travel motor LMV / DMVA 262 Extending bucket cylinder
176 Forward travel
A 316 to 28060
* A 316 from 28061
5.1 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
Run the diesel engine at its upper idle speed (fine regulation disabled tank pressure at measu-
ring point 57, see Fig. 1).
Extend the bucket / grapple cylinder to the stop.
Increase the pressure cut-off value 104 by turning in the valve (up to max. 440 bar, or until se-
condary pressure-relief valve 262 responds, plus 1/2 turn).
Increase the pressure at the secondary pressure-relief valve 262 until the safety valve 105 re-
sponds, 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.

Turn the adjusting screw clockwise, using an Allen key (WS 6).

Turn the adjusting screw anticlockwise, using an Allen key (WS 6).
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).


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).

6.34.11
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MJFCIFSS
Checking and adjusting the secondary pressure for the slewing gear

Fig. 9 TC valve and slewing gear motor with pressure-relief valves, sample diagram
6.34.12
copyright by
MJFCIFSS
Checking and adjusting the secondary pressure for the slewing gear
I 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)
3 Primary setting (operating pressure)
125 TC valve 130 Slewing gear motor

125.1 Valve body 134 Secondary pressure-relief valve
125.2 Lock nut 135 Secondary pressure-relief valve
128 Shuttle valve 137 Measuring point
128.2 Screw fitting 138 Measuring point
6.1 Adjustment of the start-up pressure, Fig. 9

Danger!
Uppercarriage may execute uncontrolled rotary movements,
posing a hazard to mechanics and equipment.
Lock the uppercarriage against the undercarriage, using locking bolts.
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 se-
condary 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.
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.
6.34.13
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MJFCIFSS
Checking the travel motor 170

Press the pilot control unit fort "turning right" to the stop (measuring point 137).
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.
Turn the valve body 125.1 of the TC valve to adjust the pressure to that prescribed in the adjust-
ment protocol.
7 Checking the travel motor 170
7.1 Adjustment of the begin of regulation (end of regulation)
Fig. 10 Checking the travel motor, part 1
20 Variable-displacement pump 45 Measuring point
Condition: The outputs of the diesel engine and the hydraulic pump must correspond to the
prescribed values (see adjusting protocols and hydraulic pump settings in group 7.05).
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 re-
quired) 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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MJFCIFSS
3.14 Threaded stud Qmin. (A 312 and A 170.26 Begin of regulation / adjusting screw
316*) (A 314/316)
4.14 Begin of regulation / adjusting screw M Measuring connection (A 312 and A
(A 312 and A 316*) 316*)
170 Travel motor M2 Measuring connection (A 314/316)
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).
6.34.15
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MJFCIFSS
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 sud-
denly to the high pressure value, so that the pressure values at the measuring points 45 and
M/M2 are the same, Fig. 12.
160.1 Stroke limitation 1 160.2 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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MJFCIFSS
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 factory-
set 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 measu-
ring 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 circum-
stances.
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).
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.
6.34.17
copyright by
MJFCIFSS
Checking the fan control system
8 Checking the fan control system
Fig. 13 Fan motor with proportional solenoid valve
13 Fan motor Y352 Proportional solenoid valve
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.
nect 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).
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.
Note!
6.34.18
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MJFCIFSS
Arrangement of measuring points
1 Arrangement of measuring points
Fig. 1 Measuring points at variable-displacement pump DPVO 20, the control valve block 50,
the control oil unit 100 and the slewing gear motor 130
41 Measuring point for high pressure at control valve block 100 (connection MP)
44 Measuring point for control chamber pressure at pump20 (connection MA)
45 Measuring point for LS pressure at pump 20 (connection X2)
49 Measuring point for pilot pressure at control oil unit 50 (connection M1)
57 Measuring point - LS pressure at control oil unit 50 (connection MLS)
59 Measuring point - LR pressure at control oil unit 50 (connection MLR)
137 Measuring point for slewing-gear working pressure at slewing gear motor130 (connection MA
turn right)
138 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:
6.37.1
copyright by
MJFCIFSS
Measuring instruments / adjusting tools / safety of adjusting screws
Differential pressure gauge / kit 0 - 600 Tool in group 2.01

bar
Speed measurement Speed counter No. 60 or 62
Temperature measurement Thermometer 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 tempe-
rature
Note!
If the differential pressure gauge for measuring p is not available, use one of the following pres-
sure gauges (examples):
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).
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 50C.
The pressure gauges must be glycerine-filled and have an indicating accuracy of below 1% rela-
tive 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' com-
mand 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
copyright by
MJFCIFSS
Fig. 2 Control oil unit with valve and measuring connection
49 Measuring connection - control pressure 51 Pressure relief valve / pilot control

50 Control oil unit
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.
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.
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.
measuring point 59.
6.37.3
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MJFCIFSS
50 Control oil unit Y50 Proportional solenoid valve / power control

59 Measuring point MLR (power control)
Current OK Pressure OK => everything OK

OK
Current not Pressure not => Search for fault in the electrical system and the horse-
OK OK power 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.
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
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.
measuring point 57.
50 Control oil unit Y51 Proportional solenoid valve / flow reduction

57 Measuring point MLS (flow reduction)
Current OK Pressure OK => everything OK

OK
Current not Pressure not => Search for fault in the electrical system.
OK OK
Note!
The characteristic of the solenoid valve cannot be adjusted.
6.37.5
copyright by
MJFCIFSS
Checking and adjusting the variable-displacement pump
6 Checking and adjusting the variable-displacement pump
Fig. 5 Measuring connections and valves
8 Begin of regulation / adjusting screw 57 Measuring point for flow reduction / con-
trol pressure (connection MLS)
20 Variable displacement pump DPVO 59 Measuring point for the power control /
pressure (connection MLR)
41 Measuring point for high pressure at con- 100 Compact control block
trol valve block 100 (connection MP)
44 Measuring point for control chamber pres- Y50 Proportional solenoid valve / power con-
sure at pump20 (connection MA) trol
50 Control oil unit Y51 Proportional solenoid valve / flow reduc-
tion
6.1 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.
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
copyright by
MJFCIFSS
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).
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 seconda-
ry relief valve 262.
Connect the plug to the proportional solenoid valve Y50 / Y51.
6.2 Checking and adjusting the differential pressure ( - p) between the pump
pressure and the LS pressure
Before adjusting the differential pressure -p, check the begin of regulation and the horsepower
control Y50.
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 pres-
sure value, always first test and recalibrate the pressure sensors (for detailed instructions, see ope-
rating 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 re-
place 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
6.37.7
copyright by
MJFCIFSS
C Measuring neck (ID no. 4901372) P1 Measuring connection

D Measuring point 41 P2 Measuring connection
6.2.2 Adjusting differential pressure -p
Fig. 7 Measuring connections and valves at the hydraulic pump 20, the control oil unit 50 and
the control valve block100
2 Adjusting screw -p 57 Measuring point for flow reduction / con-

trol pressure (connection MLS)
20 Variable displacement pump DPVO 59 Measuring point for the power control /
pressure (connection MLR)
41 Measuring point for high pressure at con- 100 Compact control block
trol valve block 100 (connection MP)
44 Measuring point for control chamber pres- Y50 Proportional solenoid valve / power con-
sure at pump20 (connection MA) trol
45 Measuring point for LS pressure at pump Y51 Proportional solenoid valve / flow reduc-
20 tion
50 Control oil unit
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.
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-displace-
ment pump 20.
Turn clockwise (cw) = increase differential pressure -p
Turn counter-clockwise (ccw) = reduce differential pressure -p
6.37.8
copyright by
MJFCIFSS
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 Proportional solenoid valve / cooling and measuring points at the variable-displacement
pump and the control valve block
20 Double variable-displacement pump 242 Secondary pressure relief valve for exten-
A8VO ding stick cylinder
41 Measuring point for high pressure of 262 Secondary pressure relief valve for exten-
pump 2 at control valve block 100 (con- ding bucket cylinder
nection MP)
44 Measuring point for control chamber Y352 Proportional solenoid valve / radiator fan
pressure at pump20 (connection MA)
7.2 Proceed as follows:

Disconnect the plug at the solenoid valve Y 352 (fan) (see Fig. 8).
6.37.9
copyright by
MJFCIFSS
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.
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 prescri-
bed pressure (see adjustment protocol).
Control chamber pressure, pressure difference< 10 bar, pump pressure (10 bar max.)
Read motor speed at speed counter.
Speed > Regulating => Diesel engine output OK
rpm
Speed < Regulating => Diesel engine output not OK
rpm
8 Adjusting pressure relief and cut-off valves
Fig. 9 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 Secondary pressure relief valve / reverse
travel, right
100 Compact control block 221 Extend boom cylinder
6.37.10
copyright by
MJFCIFSS
104 Pressure cut-off valve 222 Retract boom cylinder

105 Safety valve 241 Retract stick cylinder
200 Travel motor, left 242 Extend stick cylinder
201 Travel motor, right 261 Retract bucket cylinder
210 Brake hose 262 Extend bucket cylinder
211 Secondary pressure relief valve / forward
travel, left
Note!
All measurements must be completed at maximum engine speed. Check the secondary pressure
relief valves at the measuring point 45 (p LS). Check the pressure cut-off valve 104 and the safety
valve 105 at the measuring point 41 (p pump).
8.1 Checking and adjusting the secondary pressure relief valves
8.1.1 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.
Check tank pressure at the measuring point 57 (MLS - see Fig. 7).
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!
6.37.11
copyright by
MJFCIFSS
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.
Check the pressure at the valves 211 - 214, compare it with the prescribed pressure (see adjust-
ment 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.
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 2-stage pressure relief valve for turning

left
125.1 Valve body 135.1 Lock nut
125.2 Lock nut 135.2 Adjusting screw for start-up pressure
128 Shuttle valve 135.3 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 Measuring point for turning right
right
134.1 Lock nut
134.2 Adjusting screw for start-up pressure
134.3 Lock nut XA Control pressure connection, turn left
134.4 Adjusting screw for brake pressure XB Control pressure connection, turn right
I : 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 pres-
sure for swivelling
1 : Secondary setting, minimum value (braking)
2 : Secondary setting (starting)
6.37.12
copyright by
MJFCIFSS
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
6.37.13
copyright by
MJFCIFSS
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.
Lock the uppercarriage against the undercarriage, using locking bolts.
Connect the pressure sensor to the measuring points 137 / 138.

Block the uppercarriage (maximum pressure cannot be reached when the uppercarriage is rota-
ted).
Turn in the valve body at the TC valve 125.1 until p primary is higher than the pressure at the se-
condary relief valve (complete 2 turns approx.).
Start the machine.
Press the pilot control unit for 'turn left' to the stop.
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.
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.
screw 4.
Press pilot control unit 'turn right' to the stop (measuring point 137).
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).
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
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 Stroke limitation 180.1 Stroke limitation
160.2 Stroke limitation 180.2 Stroke limitation
160.3 Adjusting screw 180.3 Adjusting screw
160.4 Lock nut 180.4 Lock nut
Note!
The max. speed is factory-set by means of the spool stroke limitation (value Y - see adjustment pro-
tocol) 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, pro-
vided that the maximum speed measured at the tumbler wheel does not correspond to the value in
the adjustment protocol.
Lift one side of the chassis, using the attachment, and run the respective travel drive at normal
speed (S21 not actuated).
Measure the maximum speed of the tumbler wheel and compare with the prescribed value in the
adjustment protocol.
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.
6.37.15
copyright by
MJFCIFSS
Adjustment of the maximum speed (Qmin stop / fast travel)

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.
Compare the actual speed of the tumbler wheel with the nominal speed specified in the adjust-
ment protocol.
If the actual speed is below the nominal speed, adjust the Qmin stop screw of the respective re-
gulating 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

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 Oil motor and proportional solenoid valve / fan control with pressure relief valve
13 Oil motor radiator fan Y352 Proportional solenoid valve / radiator fan
14 Pressure relief valve / fan motor
Danger!
Moving fan blades might cause serious injury to fingers and hands.
The fan speed to be measured depends on the current temperature of the coolant and the hydraulic
oil.
nect 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).
To check the fan speed with the speed counter (tool no. 62 / 63), apply a reflective strip to the fan
blade.
6.37.17
copyright by
MJFCIFSS
Start the motor.

Note!
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 Items see

group 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 7.90
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 197 Measuring point 'turn left' 7.24
Pressure-relief l valve
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 pres- 212 Control piston 7.27
sure for regulation P1
A 309 LI 20221-23502 6.40.1

A 311 LI 20222-23506 copyright by
MJFCIFSS
Hydraulic system Service Manual
A 309 from 20221 / A 311 from 20222
Items see Items see

group group
44 Measuring point / actuating pres- 213 Spool 7.27
49 Measuring point / pilot pressure 214 Secondary pressure-relief l valve / 7.27
chassis forward A
50 Control oil unit 7.40 215 Secondary pressure-relief l valve / 7.27
chassis reverse B
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 220 Restrictor check valve 7.27
(LS)
Flow reduction P1
59 Measuring point servo pressure 225 Transmission 11.08
(LR)
Power control
75 Check valve P2 - reset 230 Support cylinder 7.30
76 Shuttle valve / compound circuit 231 Double load-holding valve / blade 7.86
support
80 Pilot control valve left 4 x 7.45 241 to Double load-holding valve / 7.82
swivel cylinder, see 6.40.9
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 7.47 262 Rotary connection 6 x 7.76
boom
87 Positioning brake / slewing gear 9.25 300 Line leading to oscillating axles 14.10
support
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 15.10
Brake system
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 8.09/8.20
Bucket swivel bearing
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 / 7.50 Y3 Solenoid valve / pilot control 8.09/8.20
stick cylinder
110 to control valve block, low pressure 7.62 Y24 Solenoid valve / creeper gear 8.09/8.20
120 Primary pressure relief valve pump 7.50 Y50 Proportional solenoid valve 8.09/8.20
P1 Power control
6.40.2 A 309 LI 20221-23502

copyright by A 311 LI 20222-23506
MJFCIFSS
A 309 from 20221 / A 311 from 20222
Items see Items see

group group
121 Primary pressure relief valve pump 7.50 Y51 Proportional solenoid valve / flow 8.09/8.20
P2 reduction P1
127 Secondary pressure relief valve, 7.50 Y62 Solenoid valve / travel direction 8.09/8.20
stick cylinder A2
stick cylinder B2
129 Secondary pressure relief valve, 7.50 Y262 Solenoid valve: bucket cylinder / 8.09/8.20
control cylinder A5 swivel bearing
130 Secondary pressure relief valve, 7.50 Y330 Solenoid valve / flow reduction P2 8.09/8.20
control cylinder B5
131 Secondary pressure relief valve / 7.50 Y352 Proportional solenoid valve / fan 8.09/8.20
boom cylinder A6
132 Secondary pressure relief valve / 7.50 Y358 Proportional solenoid valve / speed 8.09/8.20
boom cylinder B6 adjustment
133 Secondary pressure relief valve / 7.50 Y371 Solenoid valve / oscillating axle 8.09/8.20
bucket cylinder A7 support
A 309 LI 20221-23502 6.40.3

MJFCIFSS
A 309 from 20221 / A 311 from 20222
6.40.4 A 309 LI 20221-23502

MJFCIFSS
Hydraulic system 3 (low-pressure circuit)
21 Hydraulic system 3 (low-pressure circuit)
Fig. 1 Hydraulic system 3 (low-pressure circuit)
Items see Items see

group group
1 to hydraulic tank 159 Restrictor 7.56
31 from gear pump / low-pressure cir- 240 Swivel cylinder 7.30
cuit: brake
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, low- 7.56 261 Pressure relief valve
pressure circuit
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 6.40.9

MJF C I F S S
Items see Items see

group group
157 Adjustment restrictor / oil quantity, 7.62 Y262 fromSolenoid valve bucket swivel 8.09/8.20
rotator bearing
6.40.10 A 309 LI 20221-23502

MJF C I F S S
Key to diagrams I and II (high pressure circuit)
Hydraulic system
3 Key to diagrams I and II (high pressure circuit)
Note!
main components see group 6.20.
Items see Items see

group 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 cylin-
der (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 7.90
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 197 Measuring point 'turn left' 7.24
Pressure-relief l valve
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 pres- 212 Control piston 7.27
A 309 LI 23503-27109 6.40.11

MJFCIFSS
Items see Items see

group group
44 Measuring point / actuating pres- 213 Spool 7.27
49 Measuring point / pilot pressure 214 Secondary pressure-relief l valve / 7.27
chassis forward A
50 Control oil unit 7.40 215 Secondary pressure-relief l valve / 7.27
chassis reverse B
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 220 Restrictor check valve 7.27
(LS)
Flow reduction P1
59 Measuring point servo pressure 225 Transmission 11.08
(LR)
Power control
75 Check valve P2 - reset 230 Support cylinder 7.30
76 Shuttle valve / compound circuit 231 Double load-holding valve / blade 7.86
support
80 Pilot control valve left 4 x 7.45 241 to Double load-holding valve / 7.82
swivel cylinder, see 6.40.9
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 7.47 262 Rotary connection 6 x 7.76
boom
87 Positioning brake / slewing gear 9.25 300 Line leading to oscillating axles 14.10
support
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 15.10
Brake system
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 8.09/8.20
Bucket swivel bearing
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 / 7.50 U16 Excavator control BST 8.09/8.20
stick cylinder
110 to control valve block, low pressure 7.62 Y3 Solenoid valve / pilot control 8.09/8.20
120 Primary pressure relief valve pump 7.50 Y24 Solenoid valve / creeper gear 8.09/8.20
P1
6.40.12 A 309 LI 23503-27109

MJFCIFSS
Items see Items see

group group
121 Primary pressure relief valve pump 7.50 Y50 Proportional solenoid valve 8.09/8.20
P2 Power control
127 Secondary pressure relief valve, 7.50 Y51 Proportional solenoid valve / flow 8.09/8.20
stick cylinder A2 reduction P1
stick cylinder B2
control cylinder A5
130 Secondary pressure relief valve, 7.50 Y262 Solenoid valve: bucket cylinder / 8.09/8.20
control cylinder B5 swivel bearing
131 Secondary pressure relief valve / 7.50 Y330 Solenoid valve / flow reduction P2 8.09/8.20
boom cylinder A6
132 Secondary pressure relief valve / 7.50 Y352 Proportional solenoid valve / fan 8.09/8.20
boom cylinder B6
133 Secondary pressure relief valve / 7.50 Y358 Proportional solenoid valve / speed 8.09/8.20
bucket cylinder A7 adjustment
134 Secondary pressure relief valve / 7.50 Y371 Solenoid valve / oscillating axle 8.09/8.20
bucket cylinder B7 support
135 Suction valve travel motor A8
(i) Brand, see group 1.02
A 309 LI 23503-27109 6.40.13

MJFCIFSS
6.40.14 A 309 LI 23503-27109

MJFCIFSS
Items see Items see

group group
cuit: brake
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, low- 7.56 261 Pressure relief valve
pressure circuit
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
123 Primary pressure relief valve 7.56 S19 Button / grapple rotator 8.09/8.20
157 Adjustment restrictor / oil quantity, 7.62 Y262 fromSolenoid valve bucket swivel 8.09/8.20
rotator bearing
A 309 LI 23503-27109 6.40.19

MJFCIFSS
6.40.20 A 309 LI 23503-27109

MJFCIFSS
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 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)
A 309 LI 27110- 6.40.21

A 311 LI 27112- copyright by
MJFCIFSS
Items 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 7.50
136 Suction valve travel motor B8
6.40.22 A 309 LI 27110-

copyright by A 311 LI 27112-
MJFCIFSS
Items 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 0.8 mm
157 Shuttle valve turning right 0.8 mm
158 Shuttle valve retracting stick cylinder 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 0.6 mm (k)
168 Shuttle valve extending boom cylinder 0.8 mm (k)
169 Shuttle valve retracting boom cylinder 0.8 mm (k)
170 Stick cylinder 7.30
171 Restrictor check valve (k) 7.90
180 Bucket cylinder 7.30
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
A 309 LI 27110- 6.40.23

MJFCIFSS
Items 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
6.40.24 A 309 LI 27110-

MJFCIFSS
Item see Item see

group group
cuit - brake
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 7.56 261 Pressure-relief valve
circuit
111 Input section 7.56 262 Pressure-relief valve
112 Spool / slewing gear 7.56 S5L Push button: 'turn grapple left' 8.09/8.20
123 Prim. pressure relief valve 7.56 S19 Button / grapple rotator 8.09/8.20
157 Adjustment restrictor / oil volume Y262 from solenoid valve changeover 8.09/8.20
rotator bucket cylinder - swivel bearing
A 309 LI 27110- 6.40.29

MJFCIFSS
6.40.30 A 309 LI 27110-

MJFCIFSS
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 Hydraulic variable- displacement pump 32 Brake and control oil pump
30 Cooling fan pump 50 Control oil unit
Fig. 2 Pilot control units
80 Pilot control unit for stick and rotary 85 Pilot control unit for outrigger and blade
movement support
81 Pilot control unit for boom and bucket 86 Pilot control unit for working movement of
movement 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 6.42.1

copyright by
MJFCIFSS
Fig. 3 Consumer

Fig. 4 Rotary connections
320 Rotary connection 7x for high-pressure oil 322 Rotary connection 6x for low-pressure oil
6.42.2 A 312 LI 12363-13288

copyright by
MJFCIFSS
Fig. 5 Compact control block
100 Control valve block 280 Spool for support cylinder

160 Spool for travel 120 Slewing gear control axle
220 Spool for boom cylinder 540 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 6.42.3

copyright by
MJFCIFSS
Item Designation Group Item Designation Group
1 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 7.59
14 Oil motor / radiator fan 221 Secondary pressure-relief valve /
extending
20 Variable-displacement pump 7.14 222 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 7.30
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 pres- 260 Spool / bucket cylinder 7.59
sure P
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 7.42 264 Pressure balance
51 Pressure-relief valve 275 Bucket cylinder 7.30
52 Pressure filter 277 Shut-off device for grapple operati-
on
53 Check valve 278 Lines to grapple cylinder
54 Accumulator 279 Restrictor check valve 7.90
only with attachment/quick-
change adapter
57 Measuring point Servo pressure 280 Spool / support cylinder 7.59
p-lowering
59 Measuring point Servo pressure 281 Plug / dummy cartridge
powercontrol
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 7.86
page 6.42-09 and 6.42-10
6.42.4 A 312 LI 12363-13288

copyright by
MJFCIFSS
Item Designation Group Item Designation Group

85 Pilot control unit 2x,- support 7.48 320 Rotary connection 7x 7.78
87 Valve / positioning brake 322 Rotary connection 6x 7.76
88 Collecting pipe P/T 400 to brake system 15.10
100 Compact control block 5x- 7.59 401 to steering 13.10
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 16.44
120 Spool / slewing gear 7.59 551 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 S7 Switch / safety switch 8.10/8.30
level
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 7.24 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 additio- Y3 Solenoid valve / servo release 7.42
nal pressure stage
136 pressure-relief valve with additio- Y22 Solenoid valve / turn grapple left 16.44
nal pressure stage
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 7.42
support
170 Travel motor, complete 7.27
172 Powertrain
173 Control cylinder / regulating unit
174 Spool / regulating unit
A 312 LI 12363-13288 6.42.5

copyright by
MJFCIFSS
Fig. 6 Hydraulic system 1
6.42.6
copyright by
MJF C I F S S
6.42.7
copyright by
MJF C I F S S
Fig. 8 Support option 2-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 Rotary connection
295 Support cylinder
6.42.8 A 312 LI 12363-13288

copyright by
MJFCIFSS
group valves 7.86
Fig. 10 Support option 2-point blade front or rear
A 312 LI 12363-13288 6.42.9

copyright by
MJFCIFSS
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 Y56 Solenoid valve / individual control of
group valves 7.86 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 Support option 4-point front blade / rear outriggers with individual control
outrigger
outrigger
6.42.10 A 312 LI 12363-13288

copyright by
MJFCIFSS

outrigger
right outrigger
A 312 LI 12363-13288 6.42.11

copyright by
MJFCIFSS
6.42.12 A 312 LI 12363-13288

copyright by
MJFCIFSS
Key to diagrams I and II
Hydraulic system
Note!
main components, see group 6.24.
Key to diagram I
Items see Items see
group group
1 Hydraulic tank 19.10 80 Pilot control unit, left 4x 7.45
2 Breather filter 81 Pilot control unit, right 4x 7.45
3 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 (pres- 87 Valve / positioning brake
sure)
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 7.05 170 Travel motor
21 Powertrain 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 7.42 Y51 Proportional solenoid valve LS con- 8.10/8.30
trol
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 8.10/8.30
control
A 312 LI 13289-29897 6.42.13

copyright by
MJFCIFSS
Items see Items see

group group
54 Accumulator Y358 Proportional solenoid valve / motor 8.10/8.30
speed
57 Measuring point servo pressure Y371 Solenoid valve / oscillating axle 8.10/8.30
-p reduction support
59 Measuring point servo pressure LR
Index to wiring diagram II

Items see
group
1 to hydraulic tank
6 to oil cooler
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 7.60
102 Pressure balance / minimum flow
103 Pressure balance / remaining flow
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) 7.80
126 Restrictor 1.5 mm
127 Restrictor check valve
128 Shuttle valve
129 Restrictor ( 0.6 mm) (e)
130 Slewing gear motor, complete 7.24
132 Powertrain
133 Suction valve
134 Pressure-relief valve with additional pressure stage
6.42.14 A 312 LI 13289-29897

copyright by
MJFCIFSS
Items see
group
137 Measuring point 'turn right'
138 Measuring point 'turn left'
160 Spool / chassis 7.60
161 Suction valve / reverse travel
162 Suction valve / forward travel
164 Pressure balance, directly controlled
170 Travel motor 7.27
172 Powertrain
176 Secondary relief valve / forward
177 Secondary relief valve / reverse
185 Transmission 11.08
190 Travel brake valve, complete 7.27
192 Brake piston
194 Check valve
195 Shuttle valve
196 Check valves
220 Spool / boom cylinder 7.60
221 Secondary pressure-relief valve / extending
222 Secondary pressure-relief valve / retracting
224 Pressure balance, pilot-controlled (e)
233 Distribution block
237 Stop cock (devices without item 238)
238 Pipe-fracture safety system (kit)
A 312 LI 13289-29897 6.42.15

copyright by
MJFCIFSS
Items see
group
277 Shut-off device for
grapple operation
278 Lines leading to grapple
(QC only)
280 Spool / support cylinder 7.60
281 Plug / dummy cartridge
297 Double-load back-pressure valve
320 Rotary connection 7x 7.78
540 Spool / grapple rotator 16.44
541 Secondary relief valve / turning right
542 Secondary relief valve / turning left
550 Oil motor / grapple rotator
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
Hydraulic system
Note!
Index to wiring diagram I

Item see Item see
group group
1 Hydraulic tank 19.10 64 Cylinder / uppercarriage locking
mechanism (m)
2 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 (pres- 85 Pilot control unit 2 x, support 7.48
sure)
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 7.05 155 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 Regulating valve 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 pres- U16 Excavator control BST 8.10/8.32
sure
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 7.42 Y50 Proportional solenoid valve 8.10/8.32
Power control
51 Pressure relief valve Y51 Proportional solenoid valve LS con- 8.10/8.32
trol
52 Pressure filter Y62 Solenoid valve / forward travel 8.10/8.32
A 312 LI 29898- 6.42.21

copyright by
MJFCIFSS
Item see Item see

group group
53 Check valve Y63 Solenoid valve / reverse travel 8.10/8.32
54 Accumulator Y352 Proportional solenoid valve / fan 8.10/8.32
control
57 Measuring point / servo pressure Y358 Proportional solenoid valve / motor 8.10/8.32
-p reduction speed
59 Measuring point / servo pressure Y371 Solenoid valve / oscillating axle 8.10/8.32
Power control support

Item see Item see
group group
1 to hydraulic tank 192 Brake piston
6 to hydraulic tank 193 Restrictor 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 7.60
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 7.30
88T to collecting pipe T 237 Stop cock (in models without item
238)
100 Compact control block 5 x 7.60 238 Pipe fracture safety valve (kit)
102 Pressure balance / minimum flow 240 Spool / stick cylinder 7.60
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 control-
led
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 7.80 264 Pressure balance, directly control-
stage led
6.42.22 A 312 LI 29898-

copyright by
MJFCIFSS
Item see Item see

group group
126 Restrictor ( 1.5 mm) 275 Bucket cylinder 7.30
127 Restrictor check valve 277 Shut-off device for
grapple operation
128 Shuttle valve 278 Lines leading to grapple
129 Restrictor ( 0.6 mm) 279 Restrictor check valve
(QC only)
130 Slewing gear motor, complete 7.24 280 Spool / support cylinder 7.60
132 Powertrain 281 Plug / dummy cartridge
133 Suction valve 284 Pressure balance, directly control-
led
134 Pressure relief valve with additional 295 Support cylinder 7.30
pressure stage
135 Pressure relief valve with additional 297 Double load-holding valve
pressure stage
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 control-
led
162 Suction valve / forward travel 550 Oil motor / grapple rotator
164 Pressure balance, directly control- 551 Secondary relief valve / turn right
led
167 Restrictor check valve 552 Secondary relief valve / turn left
170 Travel motor 7.27 S5L Push button / grapple rotator, left 8.10/8.32
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 / Y23 Solenoid valve / grapple rotation 16.44
forward travel right
177 Secondary pressure relief valve / Y24 from solenoid valve / creeper gear 7.42
reverse travel
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
(m), see changes in group 1.02
A 312 LI 29898- 6.42.23

copyright by
MJFCIFSS
6.42.24 A 312 LI 29898-

copyright by
MJFCIFSS
Hydraulic system
Note!
see see
Items Items
group 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 (pres- 19.10 162 Suction valve B1, reverse 7.60
sure)
6 Oil cooler 164 Pressure balance, directly control- 7.60
led
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 control- 7.60
led
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 pres- 7.28
sure
28 Check valve 7.15 208 Pressure reduction valve / brake 7.28
pressure
29 Restrictor 7.15 211 Secondary pressure-relief valve 7.28
chassis, forward left
30 Gear pump / pilot control 212 Secondary pressure-relief valve 7.28
chassis, reverse left
31 Gear pump / fan drive 213 Secondary pressure-relief valve 7.28
chassis, forward right
41 Measuring point MP 214 Secondary pressure-relief valve 7.28
(control valve block) chassis, reverse right
44 Measuring point actuating pressure 215 Travel brake 11.67
(variable-displacement pump)
45 Measuring point LS 216 Travel gear 11.62
R 313 LI 27752- 6.43.1

copyright by
MJFCIFSS
see see
Items Items
group group
49 Measuring point control pressure 220 Spool / boom cylinder 7.60
M1
50 Control oil unit 7.42 221 Secondary pressure-relief valve A3 7.60
/ extend
51 Pressure-relief valve 7.42 222 Secondary pressure-relief valve B3 7.60
/ retract
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 235 Boom cylinder 7.30
(MLS)
-p reduction
59 Measuring point servo pressure 237 Stop cock (machines without item
(MLR) 238)
Power control
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 7.60
/ retract
88P Manifold pressure 242 Secondary pressure-relief valve / 7.60
extend
88T Collecting pipe return line 244 Pressure balance, directly control- 7.60
led
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 7.60
/ retract
106 Shift valve regulating motor Qmin 7.60 262 Secondary pressure-relief valve B4 7.60
/ extend
107 Shuttle valve 7.60 264 Pressure balance, directly control- 7.60
led
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
(with QC only)
125 Restrictor 1.8 mm 7.80 B335 Pressure switch / slewing gear 8.17/8.38
126 Shuttle valve 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 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 R 313 LI 27752-

copyright by
MJFCIFSS
see see
Items Items
group 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 additio- 7.24 Y50 Proportional solenoid valve 8.17/8.38
nal pressure level, right B Power control
135 Pressure-relief valve with additio- 7.24 Y51 Proportional solenoid valve LS con- 8.17/8.38
nal pressure level, left A trol
137 Measuring point / turn right Y352 Proportional solenoid valve / fan 8.17/8.38
control
138 Measuring point / turn left Y358 Proportional solenoid valve / speed 8.17/8.38
adjustment
Y451 Proportional solenoid valve / sle- 8.17/8.38
wing gear
R 313 LI 27752- 6.43.3

copyright by
MJFCIFSS
6.43.4 R 313 LI 27752-

copyright by
MJFCIFSS
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 Hydraulic variable displacement pump 32 Brake and control oil pump
30 Cooling fan pump 50 Control oil unit
Fig. 2 Pilot control units
80 Pilot control unit for stick and rotary 85 Pilot control unit for outrigger and blade
movement support
81 Pilot control unit for boom and bucket 86 Pilot control unit for working movement of
movement auxiliary attachments (hydraulic boom
adjustment, hydraulic hammer, etc.)
84 Pilot control unit for travel movement 87 Pedal for positioning brake
6.44.1
copyright by
MJFCIFSS
Fig. 3 Consumer

Fig. 4 Rotary connections
320 Rotary connection 7x for high-pressure oil 322 Rotary connection 6x for low-pressure oil
6.44.2
copyright by
MJFCIFSS
100 Control valve block with 280 Spool for support cylinder
160 Spool for travel 120 Slewing gear control axle
220 Spool for boom cylinder 540 Control axle for grapple rotation
240 Spool for stick cylinder 41-284 Valves, etc. see next page
260 Spool for bucket cylinder
6.44.3
copyright by
MJFCIFSS
Item Designation group Item Designation group
1 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 7.59
14 Oil motor / radiator fan 221 Secondary pressure relief valve /
extending
20 Variable-displacement pump 7.14 222 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 7.30
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 pres- 260 Spool / bucket cylinder 7.59
sure P
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 7.42 264 Pressure balance
51 Pressure-relief valve 275 Bucket cylinder 7.30
52 Pressure filter 277 Shut-off device for grapple operati-
on
53 check valve 278 Lines to grapple cylinder
54 Accumulator 279 Restrictor check valve 7.90
only with attachment/quick-
change adapter
57 Measuring point Servo pressure 280 Spool / support cylinder 7.59
p-lowering
59 Measuring point Servo pressure 281 Plug / dummy cartridge
powercontrol
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 7.86
page 6.42-09 and 6.42-10
6.44.4
copyright by
MJFCIFSS
Item Designation group Item Designation group

85 Pilot control unit 2x,- support 7.48 320 Rotary connection 7x 7.78
87 Valve / positioning brake 322 Rotary connection 6x 7.76
88 Collecting pipe P/T 400 to brake system 15.10
100 Compact control block 5x- 7.59 401 to steering 13.10
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 16.44
120 Spool / slewing gear 7.59 551 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 S7 Switch / safety switch 8.10/8.30
level
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 7.24 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 additio- Y3 Solenoid valve / servo release 7.42
nal pressure stage
136 Pressure relief valve with additio- Y22 Solenoid valve / turn grapple left 16.44
nal pressure stage
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 7.42
support
170 Travel motor, complete 7.27
172 Powertrain
6.44.5
copyright by
MJFCIFSS
6.44.6
copyright by
MJF C I F S S
6.44.7
copyright by
MJF C I F S S
group valves 7.86
6.44.8
copyright by
MJFCIFSS
group valves 7.86
Fig. 10 Support option 2-point blade front or rear
6.44.9
copyright by
MJFCIFSS
outrigger
outrigger
outrigger
right outrigger
Fig. 11 Support option 4-point front blade / rear outriggers with individual control
outrigger
outrigger
6.44.10
copyright by
MJFCIFSS

outrigger
right outrigger
6.44.11
copyright by
MJFCIFSS
6.44.12
copyright by
MJFCIFSS
Hydraulic system
Note!
Key to diagram I
Items see Items see

group group
1 Hydraulic tank 19.10 59 Measuring point servo pressure LR
2 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 (pres- 85 Pilot control valve 2 x / support 7.48
sure)
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 7.14 322 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 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 Switch / oscillating axle automatic 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 8.10/8.30
control
49 Measuring point / pilot pressure M1 Y51 Proportional solenoid valve LS con- 8.10/8.30
trol
50 Control oil unit 7.42 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 6.44.13

A 316 LI-IND 11152-13104 MJFCIFSS
Items see Items see

group group
52 Pressure filter Y352 Proportional solenoid valve / fan 8.10/8.30
control
53 Check valve Y358 Proportional solenoid valve / motor 8.10/8.30
speed
54 Accumulator Y371 Solenoid valve / oscillating axle 8.10/8.30
support
57 Measuring point servo pressure
-p reduction
Key to diagram II
Items see
group
1 to hydraulic tank
6 to oil cooler
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 7.60
102 Pressure balance / minimum flow
103 Pressure balance / remaining flow
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) 7.80
126 Restrictor 1.5 mm
128 Shuttle valve
129 Restrictor ( 0.6 mm) (e)
130 Slewing gear motor, complete 7.24
132 Powertrain
6.44.14 A 314 LI 11147-13103

MJFCIFSS A 316 LI-IND 11152-13104
Items see
group
133 Suction valve
137 Measuring point 'turn right'
138 Measuring point 'turn left'
160 Spool / chassis 7.60
161 Suction valve / reverse travel
162 Suction valve / forward travel
170 Travel motor 7.27
172 Powertrain
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
194 Check valve
195 Shuttle valve
196 Check valves
220 Spool / boom cylinder 7.60
224 Pressure balance, pilot-controlled (e)
237 Stop cock (devices without item 238)
238 Pipe-fracture safety system (kit)
A 314 LI 11147-13103 6.44.15

Items see
group
277 Shut-off device for grapple operation
278 Lines leading to grapple
279 Restrictor check valve (only SW)
280 Spool / support cylinder 7.60
281 Plug / dummy cartridge
297 Double-load back-pressure valve
540 Spool / grapple rotator 16.44
550 Oil motor / grapple rotator
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 A 314 LI 11147-13103

Service Manual Hydraulic unit
Hydraulic unit
Note!

Item see Item see
group group
1 Hydraulic tank 19.10 59 Measuring point / servo pressure
Power control
2 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 (pres- 85 Pilot control unit 2 x, support 7.48
sure)
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 7.14 322 to rotary connection 6 way 7.76
21 Powertrain 400 to brake system 15.10
21.1 Control cylinder 401 to steering 13.10
23 Regulating valve 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 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 pres- Y24 Solenoid valve / creeper gear 8.10/8.30
sure
45 Measuring point / LS pressure Y50 Proportional solenoid valve 8.10/8.30
Power control
49 Measuring point / pilot pressure M1 Y51 Proportional solenoid valve LS con- 8.10/8.30
trol
50 Control oil unit 7.42 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 8.10/8.30
control
A 314 LI 13104- 6.44.21

Hydraulic unit Service Manual
Item see Item see

group group
53 Check valve Y358 Proportional solenoid valve / motor 8.10/8.30
speed
54 Accumulator Y371 Solenoid valve / oscillating axle 8.10/8.30
support
57 Measuring point / servo pressure
-p reduction

Item see Item see
group group
extending
retracting
81 from pilot control unit, right 4 way 7.45 224 Pressure balance, pilot-control-
led(e)
238)
retracting
extending
led
107 Shuttle valve (e) 247 Restrictor check valve
retracting
123 Check valve (e) 262 Secondary pressure relief valve /
extending
stage (e) led
6.44.22 A 314 LI 13104-

Item see Item see

group group
grapple operation
129 Restrictor ( 0.6 mm) (e) 279 Restrictor check valve
(QC only)
led
pressure stage
pressure stage
led
led
170 Travel motor 7.26 S5L Push button / grapple rotator, left 8.10/8.30
reverse travel
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
(d)/(e)/(f), see changes in group 1.02
A 314 LI 13104- 6.44.23

6.44.24 A 314 LI 13104-

Hydraulic unit
Note!

Item see Item see
group group
1 Hydraulic tank 19.10 59 Measuring point / servo pressure
Power control
2 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 (pres- 84 Pilot control unit, travel 1 way 7.49
sure)
6 Oil cooler 85 Pilot control unit 2 x, support 7.48
11 from turbocharger / engine 87 Valve / positioning brake
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 7.05 170 from travel engine
21 Powertrain 322 to rotary connection 6 way 7.76
21.1 Control cylinder 400 to brake system 15.10
23 Regulating valve 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
30 Gear pump / fan drive S75 Switch / oscillating axle automatic 8.10/8.32
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 pres- Y3 Solenoid valve servo release 8.10/8.32
sure
45 Measuring point / LS pressure Y24 Solenoid valve / creeper gear 8.10/8.32
49 Measuring point / pilot pressure M1 Y50 Proportional solenoid valve 8.10/8.32
Power control
50 Control oil unit 7.42 Y51 Proportional solenoid valve LS con- 8.10/8.32
trol
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 28061- 6.44.31

MJFCIFSS
Item see Item see

group group
53 Check valve Y352 Proportional solenoid valve / fan 8.10/8.32
control
54 Accumulator Y358 Proportional solenoid valve / motor
speed
57 Measuring point / servo pressure Y371 Solenoid valve / osc. axle support 8.10/8.32
-p reduction

Item see Item see
group group
extending
retracting
81 from pilot control unit, right 4 way 7.45 224 Pressure balance, pilot-controlled
238)
retracting
extending
led
retracting
123 Check valve 262 Secondary pressure relief valve /
extending
stage led
6.44.32 A 316 LI 28061-

MJFCIFSS
Item see Item see

group group
grapple operation
129 Restrictor ( 0.6 mm) 279 Restrictor check valve
(QC only)
led
pressure stage
pressure stage
led
led
170 Travel motor 7.27(n) S5L Push button / grapple rotator, left 8.10/8.32
reverse travel
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
(m)/(n), see changes in group 1.02
A 316 LI 28061- 6.44.33

MJFCIFSS
6.44.34 A 316 LI 28061-

MJFCIFSS
Hydraulic unit
Note!
see see
Item Item
group 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 (pres- 19.10 160 Spool / chassis right 7.60
sure)
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 control- 7.60
led
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
led
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
23 Measuring cylinder 7.16 202 Adjustment 7.28
24 Elbow lever 7.16 203 Shifting piston, oil motor adjustment 7.28
sure
pressure
29 Restrictor 7.16 211 Secondary pressure relief valve 7.28
30 Gear pump / pilot control 212 Secondary pressure relief valve 7.28
31 Gear pump / fan drive 213 Secondary pressure relief valve 7.28
41 Measuring point MP 214 Secondary pressure relief valve 7.28
R 317 LI 18161-21204 6.47.1

copyright by
MJFCIFSS
see see
Item Item
group group
44 Measuring point / actuating pres- 215 Travel brake 11.65
sure
49 Measuring point / control pressure 220 Spool / boom cylinder 7.60
M1
50 Control oil unit 7.43 221 Secondary relief valve A3 / exten- 7.60
ding
51 Pressure relief valve 7.43 222 Secondary relief valve / retracting 7.60
(MLS)
-p reduction
59 Measuring point servo pressure 237 Stop cock (in models without item
(MLR) 238)
Power control
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 / retrac- 7.60
ting
83 Pilot control unit, travel, right 2 x 7.46 242 Secondary relief valve B5 / exten- 7.60
ding
84 Pilot control unit, travel 1 x 244 Pressure balance, directly control- 7.60
led
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 / retrac- 7.60
ting
103 Pressure balance / remaining flow 7.60 262 Secondary relief valve B4 / exten- 7.60
ding
104 Pressure cut-off valve 7.60 264 Pressure balance, directly control- 7.60
led
105 Primary pressure relief valve 7.60 275 Bucket cylinder 7.30
106 Shift valve Qmax. variable displace- 7.60 277 Shut-off device for
ment motor 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 7.90
(QC only)
120 Spool / slewing gear 7.60
122 Input pressure balance 7.60
6.47.2 R 317 LI 18161-21204

copyright by
MJFCIFSS
see see
Item Item
group group
123 Check valve 7.60 S17 Switch slewing gear brake 8.17/8.40
125 TC valve with additional pressure 7.80 S21 Switch / creeper gear 8.17/8.40
level
126 Restrictor ( 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 ( 0.6 mm) 7.80 Y24 Solenoid valve / fast travel 8.17/8.40
130 Slewing gear motor 7.24 Y50 Proportional solenoid valve 8.17/8.40
Power control
132 Powertrain 7.24 Y51 Proportional solenoid valve LS con- 8.17/8.40
trol
133 Suction valve 7.24 Y352 Proportional solenoid valve / fan 8.17/8.40
control
134 Pressure relief valve with additional 7.24 Y358 Proportional solenoid valve / speed 8.17/8.40
pressure level, r B adjustment
135 Pressure relief valve with additional 7.24
pressure level, l A
R 317 LI 18161-21204 6.47.3

copyright by
MJFCIFSS
6.47.4 R 317 LI 18161-21204

copyright by
MJFCIFSS
Hydraulic unit
Note!
see see
Item Item
group 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 (pres- 19.10 160 Spool / chassis right 7.60
sure)
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 control- 7.60
led
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
led
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
23 Measuring cylinder 7.16 202 Adjustment 7.28
24 Elbow lever 7.16 203 Shifting piston, oil motor adjustment 7.28
sure
pressure
29 Restrictor 7.16 211 Secondary pressure relief valve 7.28
30 Gear pump / pilot control 212 Secondary pressure relief valve 7.28
31 Gear pump / fan drive 213 Secondary pressure relief valve 7.28
41 Measuring point MP 214 Secondary pressure relief valve 7.28
R 317 LI 21205- 6.47.11

copyright by
MJFCIFSS
see see
Item Item
group group
44 Measuring point / actuating pres- 215 Travel brake 11.65
sure
49 Measuring point / control pressure 220 Spool / boom cylinder 7.60
M1
50 Control oil unit 7.43 221 Secondary relief valve A3 / exten- 7.60
ding
51 Pressure relief valve 7.43 222 Secondary relief valve / retracting 7.60
(MLS)
-p reduction
59 Measuring point servo pressure 237 Stop cock (in models without item
(MLR) 238)
Power control
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 / retrac- 7.60
ting
84 Pilot control unit, travel 1 x 242 Secondary relief valve B5 / exten- 7.60
ding
85 Pilot control unit 2 x, support 244 Pressure balance, directly control- 7.60
led
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 / retrac- 7.60
ting
104 Pressure cut-off valve 7.60 262 Secondary relief valve B4 / exten- 7.60
ding
105 Primary pressure relief valve 7.60 264 Pressure balance, directly control- 7.60
led
106 Shift valve Qmax. variable displace- 7.60 275 Bucket cylinder 7.30
ment motor
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 7.90
(QC only)
122 Input pressure balance 7.60
6.47.12 R 317 LI 21205-

copyright by
MJFCIFSS
see see
Item Item
group group
125 TC valve with additional pressure 7.80 S17 Switch slewing gear brake 8.17/8.40
level
126 Restrictor ( 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 ( 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 8.17/8.40
Power control
133 Suction valve 7.24 Y51 Proportional solenoid valve LS con- 8.17/8.40
trol
134 Pressure relief valve with additional 7.24 Y352 Proportional solenoid valve / fan 8.17/8.40
pressure level, r B control
135 Pressure relief valve with additional 7.24 Y358 Proportional solenoid valve / speed 8.17/8.40
pressure level, l A adjustment
R 317 LI 21205- 6.47.13

copyright by
MJFCIFSS
6.47.14 R 317 LI 21205-

copyright by
MJFCIFSS
Service Manual
SUBGROUP - INDEX
Section Group Type
Hydraulic pumps - dismantling, 7.01.1 A 309 LI 20221-

installation and initial operation 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-
Double variable-displacement pump A8VO 7.02.1 A 309 LI 20221-

A 311 LI 20222-
LPV variable displacement pump 7.05.1 A 312 LI 12363-

A 314 LI 2001-
A 316 LI 2001-
A 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 20221-

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

A 311 LI 20222-
A 312 LI 12363-
A 314 LI 11147-
A 316 LI 11152-
A 316 LI-IND 11152-
R 313 LI 27752-
R 317 LI 18161-
7.1
MJFCIFSS
Service Manual
LMV regulating motor 7.26.1 A 314 LI 2001-

A 316 LI 2001-28060
A 316 LI-IND 2001-28060
DMVA regulating motor 7.27.1 A 309 LI 20221-

A 311 LI 20222-
A 312 LI 12363-
A 316 LI 28061-
A 316 LI-IND 28061-
Regulating motor A6VE 7.28.1 R 313 LI 27752-

R 317 LI 18161-
Hydraulic cylinder 7.30.1 A 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 313 LI 27752-
R 317 LI 18161-

A 316 LI-IND 2001-
Control oil and regulation unit 7.40.1 A 309 LI 20221-

A 311 LI 20222-
Control oil and regulation unit 7.42.1 A 312 LI 12363-

A 314 LI 2001-
A 316 LI 2001-
A 316 LI-IND 2001-
R 313 LI 27752-
R 317 LI 18161-
Pilot control unit 4 x 7.45.1 A 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 313 LI 27752-
R 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 27752-

R 317 LI 21205-
Pilot control valve 2 x 7.47.1 A 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 313 LI 27752-
R 317 LI 18161-

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

A 311 LI 20222-
A 312 LI 12363-
A 314 LI 2001-
A 316 LI 2001-
A 316 LI-IND 2001-
Compact control block 7.50.1 A 309 LI 20221-

A 311 LI 20222-
LSC control block 7.60.1 A 312 LI 12363-

A 314 LI 2001-
A 316 LI 2001-
A 316 LI-IND 2001-
R 313 LI 27752-
R 317 LI 18161-
Rotary connection 1 x 7.75.1 R 313 LI 27752-

R 317 LI 18161-
7.3
MJFCIFSS
Service Manual
Rotary connection 6 x 7.76.1 A 309 LI 20221-

A 311 LI 20222-
A 312 LI 12363-
A 314 LI 2001-
A 316 LI 2001-
A 316 LI-IND 2001-
Rotary connection 5 x 7.77.1 R 313 LI 27752-

R 317 LI 18161-
Rotary connection 7 x 7.78.1 A 309 LI 20221-

A 311 LI 20222-
A 312 LI 12363-
A 314 LI 2001-
A 316 LI 2001-
A 316 LI-IND 2001-
TC valve 7.80.1 A 312 LI 12363-

A 314 LI 2001-
A 316 LI 2001-
A 316 LI-IND 2001-
R 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.)
7.01.1
copyright by
MJFCIFSS
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 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
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 33 Gear pump
2.1 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.
7.01.3
copyright by
MJFCIFSS
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 50C.
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 adjust-
ment 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 con-
trol 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 22 Pump P2

pump, complete
21 Pump P1 30 Gear pump / fan drive
7.02.1
copyright by
MJFCIFSS
Double variable-displacement pump A8VO Service Manual
Function
7.02.2
copyright by
MJFCIFSS
General information
2 General information
Equipment A 309 Litronic A 311 Litronic

from serial number 20221 20222
Type of pump A8VO 55 A8VO 55
Input speed 2000 min-1 2000 min-1
Drive power of diesel engine
63 kW 67kW
(nominal power) = Pmax
Max. input power of the pumps 59 kW 63 kW
Volumetric delivery per pump
max. 106 l/min 106 l/min
min. 20 l/min 20 l/min
Hydraulic output per pump
13.5 kW 15.7 kW
(basic operation)
Begin of regulation (basic operation) 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,
12.4 mm 11.8 mm
flow reduction)
Check measurement Y (threaded stud 56 /
Qmax stop)
Settings and comparative values Flow from solenoid Flow from solenoid
valve Y50 valve Y50
I max 850 + 25 mA 850 + 25 mA

I emergency operation 0 mA 0 mA
Settings and comparative values Control pressure from Control pressure from
solenoid valve Y50 solenoid valve Y50
P max. 0 +1 bar 0 +1 bar

P emergency operation 30+2 bar 30+2 bar
Tab. 1 Technical data
7.02.3
copyright by
MJFCIFSS
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 adju-
stable 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 actu-
ation 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 Elements of the pump A8VO
7.02.4
copyright by
MJFCIFSS
Description
1 Pump housing 70 Actuation device

40 Regulator housing 78 Stroke limitation / flow limitation
60 Actuation housing 98 Flange for gear pump
65 Begin of regulation / adjusting screw
Fig. 3 Hydraulic diagram of A8VO
1 from / to hydraulic tank 28 Spool / flow limitation

13 to oil motor / fan drive 29 Actuation device, complete
20 Double variable-displacement pump, 30 Gear pump / cooling
complete
21 Powertrain P1 43 Measuring point / actuating pressure
pump 1
22 Powertrain P2 44 Measuring point / actuating pressure
pump 2
23 Pump regulator / actuation housing, com- 57 Measuring point MR / flow reduction con-
plete trol pressure
24 Pump adjustment 59 Measuring point LR / power control pres-
sure
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
7.02.5
copyright by
MJFCIFSS
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 oppo-
site 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 con-
trol neck 49. By placing the cylinder 30 into an incline position to the pinion axis (by means of regu-
lating 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 lub-
ricating 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 re-
spective 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 hou-
sing 1.
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 Radial shaft seal ring 90 Stub shaft
8 Tapered roller bearing 91 Gear
9 Tapered roller bearing 92 Cylindrical roller bearing
10 Tapered roller bearing 94 Cover
11 Slotted nut 95 Gear
30 Cylinder 96 Deep groove ball bearing
31 Centre peg 97 Deep groove ball bearing
32 Disc springs 98 Flange
33 Conical piston A1 Pressure connection of pump P1
34 Piston ring A2 Pressure connection of pump P2
35 Return plate S joint suction connection P1/P2
36 Oval head screw V Profile of inclined axle
7.02.6
copyright by
MJFCIFSS
Fig. 4 Powertrain of the pump A8VO
7.02.7
copyright by
MJFCIFSS
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 re-
gulator housing 40 and cannot be modified.
Fig. 5 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 Hex head screw 58 Safety cap
54 Cover
7.02.8
copyright by
MJFCIFSS
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 cha-
racteristic.
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 ope-
rating 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 ma-
ximum 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 out-
put (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 deli-
very is adjusted in line with the control pressure. If the set flow volume or the operating pressure ex-
ceeds 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.
7.02.9
copyright by
MJFCIFSS
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 63 Spring bushing
40 Regulator housing 64 Pressure spring ( 16.2 mm)
41 Control piston 65 Threaded stud (begin of regulation)
42 Spring plate 66 Seal-Lock collar nut
43 Spring plate 67 Safety cap
44 Pressure spring ( 30.4 mm, regulating 70 Actuation device
spring)
45 Pressure spring ( 21.8 mm, regulating 71 Actuation housing
spring)
46 Pressure spring ( 22.5 mm, regulating 72 Screw plug
spring)
47 Spring plate 73 Threaded stud
49 Control neck 74 Seal-Lock collar nut
50 Threaded stud 75 Safety cap
51 Piston 76 Spring plate
52 Hex head screw 77 Pressure spring
54 Cover 78 Control piston
55 Allen head screw 79 Control bushing
56 Threaded stud / Qmax stop 80 Spool
57 Seal-Lock collar nut 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
copyright by
MJFCIFSS
Pump regulation
Fig. 6 Sectional drawing of power regulator LA
7.02.11
copyright by
MJFCIFSS
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 Housing 55 Allen head screw

2 Input pinion / drive shaft 56 Threaded stud / Qmax stop
3 Input pinion 57 Seal-Lock collar nut
4 Locking ring 58 Safety cap
5 Radial shaft seal ring 59 Screw plug (M12x1.5)
6 O-ring 60 Actuation housing
7 Snap ring 61 Measuring connection / begin of regula-
tion ( M10x1)
8 Tapered roller bearing 63 Spring bushing
9 Tapered roller bearing 64 Pressure spring ( 16.2 mm)
10 Tapered roller bearing 65 Threaded stud / begin of regulation
11 Slotted nut 70 Actuation device
25 Spool 71 Actuation housing
26 Restrictor 72 Screw plug
30 Cylinder 73 Threaded stud
31 Centre peg 74 Seal-Lock collar nut
32 Disc spring 75 Safety cap
33 Conical piston 76 Spring plate
35 Return plate 77 Pressure spring
38 Control lens 78 Control piston
40 Regulator housing 79 Control bushing
41 Control piston 80 Spool
42 Spring plate 81 Pin
43 Spring plate 82 Screw plug (M12x1.5)
44 Pressure spring ( 30.4 mm, regulating 84 Threaded stud
spring)
45 Pressure spring ( 21.8 mm, regulating 85 Seal-Lock collar nut
spring)
46 Pressure spring ( 22.5 mm, regulating 86 Safety cap
spring)
47 Spring plate 100 Stub shaft
49 Control neck 101 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
7.02.12
copyright by
MJFCIFSS
Sectional drawing of the double variable-displacement pump A8VO
7 Sectional drawing of the double variable-displacement pump

A8VO
7.02.13
copyright by
MJFCIFSS
Regulating characteristic for A 309
Fig. 7 Double variable-displacement pump A8VO
8 Regulating characteristic for A 309
Fig. 8 Performance characteristics of the pumps P1 / P2
7.02.14
copyright by
MJFCIFSS
9 Regulating characteristic for A 311
Fig. 9 Performance characteristics of the pumps P1 / P2
7.02.15
copyright by
MJFCIFSS
7.02.16
copyright by
MJFCIFSS
Service Manual LPV variable displacement pump
Purpose
LPV variable displacement pump
1 Purpose
The LPV variable displacement pump is of the axial piston swash-plate type. Powertrain and gear
pump are powered by the diesel engine via the flexible coupling (torsion damper).
The variable displacement pump regulates its output according to actual requirements and, thus, pro-
vides 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
7.05.1
copyright by
MJFCIFSS
LPV variable displacement pump Service Manual
General information
A 312 A 314 A 316

Machine
Litronic Litronic Litronic
from serial number
12363 2001 2001
Pump type LPV 130 LPV 130 LPV 150
Input speed 1800 rpm 1800 rpm 1800 rpm
Drive power of diesel engine 74 kW 80 kW 86 kW
(rated power)
Volumetric delivery max. 234 l/min 234 l/min 270 l/min
min. 30 l/min 30 l/min 30 l/min
Hydraulic performance (basic performance) 30 kW 30 kW 27 kW
23 kW (*) 23 kW (*) 35 kW (*)
Begin of regulation (with basic settings) 65 2 bar 65 2 bar 65 2 bar
50 2 bar(*) 50 2 bar(*) 50 2 bar(*)
Begin of regulation (at rated output of the diesel 155 bar 165 bar 155 bar
engine)
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.
(*) from software version 1.6
7.05.2
copyright by
MJFCIFSS
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 re-
gulator (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 LPV components
1 Powertrain (21*) 13 Connecting flange

5 Pump regulation 23* Regulating valve
8 Gear pump(30*) 23.2* Performance regulator
11 Mounting plate 23.5* Load sensing regulator
* items in hydraulic diagram
7.05.3
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Description
Fig. 3 LPV hydraulic diagram
1 to hydraulic tank 23.6 Shuttle valve

3 from stop cock / tank 28 from check valve
20 LPV pump unit 29 Restrictor
21 Powertrain 30 Gear pump / pilot control
21.1 Control piston 44 Measuring point / actuating pressure
23 Regulating valve 45 Measuring point / LS pressure
23.2 Performance regulator 50 from control oil unit
23.5 LS regulator 100 from / to control valve block
7.05.4
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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 bea-
rings 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 bet-
ween 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 ar-
ranged 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 con-
trol 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 pres-
sure 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.
7.05.5
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Pump regulation
5 Pump regulation
5.1 Performance regulator 23.2 with regulating piston 23.2.7, see Fig. 4
5.1.1 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 po-
sition 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 slo-
pe 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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Pump regulation
Fig. 4 Sectional drawing of performance regulator 23.2
23 Regulating valve 2.19 Spring plate

23.2 Performance regulator 2.33 Rod
2.4 Pressure rod 2.35 Lid
2.5 Return piston 23.5 Load-sensing regulator
2.6 Lever 23.6 Shuttle valve
2.7 Regulating piston 5.10 Control piston
2.11 Regulating spring 5.13 Adjusting screw
2.12 Regulating spring 5.24 Hex nut
2.13 Pressure spring / begin of regulation 44 Measuring point actuating pressure
7.05.7
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Pump regulation
5.1.2 Stage for performance change
Fig. 5 Pump regulation
21 Powertrain GLR Connection from LR control oil unit

21.1 Control cylinder LS 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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Pump regulation
5.2 Load-sensing regulator 23.5
5.2.1 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 con-
trol 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 pres-
sure 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 Load-sensing regulator 23.13 Regulating spring
23.6 Shuttle valve 2.314 Regulating spring
23.7 Spool 44 Measuring point / actuating pressure
7.05.9
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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 regu-
lating 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 P is smaller, and the pump can maintain the reduced P with
a smaller amount of oil.
The pump pivots only to the point where the pre-set flow rate at the pump inlet is reached.
Fig. 7 Diagram: variable displacement pump
21 Powertrain 23.5 LS regulator

21.1 Adjustment 23.6 Shuttle valve
23 Regulating valve 30 Gear pump / pilot control
23.2 Performance regulator 44 Measuring point / actuating pressure
7.05.10
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Pump regulation
5.3 Fine control and/or flow reduction via p reduction
Fig. 8 Hydraulic diagram: flow reduction
21 Powertrain 235 Boom cylinder

21.1 Control cylinder 240 Spool / stick cylinder
23.5 LS regulator 255 Stick cylinder
120 Spool / slewing gear 260 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
7.05.11
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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 Pressure spring 5.32 Sleeve
5.24 Hex nut
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 ad-
justed by means of adjusting screw 5.13 (with lock nut 5.24). It has been pre-set at the factory to gu-
arantee sufficient cooling and lubrication of the powertrain.
The min. pivot angle should not be changed under normal circumstances (adjusting screw 5.13 is se-
cured against tampering by lock nut 5.24 and safety cap 5.29).
7.05.12
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Adjustment of LPV variable displacement pump (LR - LS)
6.2 Adjustment of differential pressure p (LS) and begin of hydraulic regulation

of the working pump
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 p(LS) by means of adjusting
screw 23.2.1 and 23.5.1
23.2.1 Adjusting screw of performance regula- 23.5.1 Adjusting screw of load-sensing regula-
tor tor
23.2.2 Lock nut 23.5.2 Lock nut
7.05.13
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Sectional drawing: pump regulation 23
7 Sectional drawing: pump regulation 23
Key re. sectional drawing, see Fig. 11

2.1 Adjusting screw 23.2 Performance regulator
2.2 Lock nut 23.5 Load-sensing regulator
2.4 Pressure rod 23.6 Shuttle check valve
2.5 Return piston 44 Measuring point MA
2.6 Lever 5.1 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 Regulating spring 5.8 Piston
2.12 Regulating spring 5.9 Piston
2.13 Pressure spring / begin of regulation 5.10 Spring plate
2.14 Spacer 2.11 Spring plate
2.15 O-ring 5.13 Pressure spring
2.18 Guide sleeve 5.15 O-ring
2.19 Spring plate 5.16 O-ring
2.20 Lid 5.17 Guide sleeve
2.21 Allen head screw 5.22 O-ring
2.33 Rod 6.1 Valve insert
2.34 O-ring 6.2 Sleeve
2.35 Lid 6.3 Ball
2.36 Allen head screw 6.4 O-ring
23 Regulating valve 6.5 O-ring
7.05.14
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Sectional drawing: pump regulation 23
Fig. 11 Sectional drawing: Pump regulation
7.05.15
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Sectional drawing of the complete LPV pump
8 Sectional drawing of the complete LPV pump
1.0 Powertrain 5.14 Pressure spring

1.1 Pump casing 5.24 Hex nut
1.2 Swivel yoke 5.25 Allen head screw
1.9 Piston slipper 5.30 Sliding block
1.10 Drive shaft 11 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 Pressure spring 13.3 Cylindrical needle bearing
5. Adjustment (21.1*) 13.4 Radial shaft seal ring
5.10 Control piston 23* Regulating valve
5.11 Lid 23.2* Performance regulator
5.12 Lid 23.5* LS regulator
5.13 Stop screw / Qmin 44* Measuring point / actuating pressure
7.05.16
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Sectional drawing of the complete LPV pump
Fig. 12 Sectional drawing of LPV variable displacement pump
7.05.17
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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 ma-
chines
H Hyperbola for rated power S -1.5 to software version 1.5

P Power
(*)Qn is the rated flow rate (=volume at PO(LS)) of the respective spool
7.05.18
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LPV 130 pump performance diagram
chines

P Power
7.05.19
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MJFCIFSS
LPV 150 pump performance diagrams
10 LPV 150 pump performance diagrams
chines

P Power
7.05.20
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MJFCIFSS
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 inte-
grated 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 sen-
sing 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
7.10.1
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MJFCIFSS
DPVO variable displacement pump Service Manual
Purpose
7.10.2
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MJFCIFSS
General information
Equipment R 317 Litronic

from serial number 18161
Type of pump DPVO 165
Input speed 1800 min-1
Drive power of diesel engine 86 kW
Volumetric delivery
max. 297 l/min
min. 40 l/min
Hydraulic performance (basic performance) 29 kW
Begin of regulation (with basic settings) 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

Flow from solenoid valve Y50
P min. 1,5 +1 bar
P max 6 +3 bar
7.10.3
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MJFCIFSS
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 pi-
vot 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 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 Regulator housing AX Pressure connection locked up
25 Performance regulator (LR) T 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
7.10.4
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Description
29 Restrictor X4 Connection p -subsidence

30 Gear pump
Fig. 3 Hydraulic schematic: DPVO
1 to hydraulic tank 25 Performance regulator

3 from stop cock / tank 26 Flow regulator
4 Pressure spring / p 27 Shuttle valve
10 Pressure spring / begin of regulation 28 Check valve
15 Connecting pin (swivel yoke) 29 Restrictor
16 Return piston 30 Gear pump / pilot control
20 DPVO pump unit 44 Measuring point / actuating pressure
21 Powertrain 45 Measuring point / LS pressure
22 Control piston 50 from / to control oil unit
23 Measuring cylinder 100 to control valve block
24 Lever (rocker)
7.10.5
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MJFCIFSS
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 ro-
tating 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 pres-
sure side.
Fig. 4 Section: powertrain
16 Cylinder 33 Return ball

17 Pilot plate 34 Return plate
18 Pin 35 Spring
7.10.6
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Functional description of variable displacement pump
19 Piston 35 Spring
4.1.1 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 perfor-
mance 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 con-
trol 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 Adjusting the swivel yoke
3 stop screw Q-min 22 Control piston

7 Swivel yoke 37 Connecting link
11 roll pin 38 Locknut
12 Pin 39 Collar
7.10.7
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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, re-
gulation of the pump performance is effected along a hyperbolic line. The pump delivers larger volu-
mes 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.

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 re-
turn 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 View: control edges S1 and S2
10 Spring pP Pump pressure

11 Spring SK Control chamber pressure
7.10.8
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Pump regulation
17 Control piston T Tank pressure
Fig. 7 Sectional drawing: performance regulator 25
1 Plug 12 Bushing
2 Threaded stud 13 Spring plate
3 Pressure spring 14 Ball
4 O-ring 15 Connecting pin (swivel yoke)
5 O-ring 16 Return piston
6 Regulator housing 17 Spool
7 Sealing nut 23 Piston with slipper (measuring cylinder)
8 Adjusting screw 24 Lever
9 Plug pP Pump pressure
10 Pressure spring (begin of regulation) SK Control chamber pressure
11 Pressure spring T Tank pressure
Note!
Tightening torques: Screw plug 1 / 9 = 35 Nm; sealing nut 7 = 18 Nm.
7.10.9
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MJFCIFSS
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 ad-
justed 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
Fig. 8 Flow regulator 26 on mounting plate 1 , connection X4 for p-reduction
1 Mounting plate 15 Control piston

2 Regulating screw 26 Flow regulator
3 Nut
4 Spring (Adjusting p) pP Pump pressure
9 Sealnut X4 Control pressure p -subsidence
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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Pump regulation
5.3 Regulation of pressure difference P LS
5.3.1 Standby
As soon as all the consumers are closed, the flow from the pump will build up a backpressure in chan-
nel 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 ac-
ting on the spring side of piston 15, and piston 15 will switch right. Control edge S1 opens, pump pres-
sure 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 mo-
re, 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 Plug 12 Backing ring

2 Adjusting screw 13 O-ring
3 Nut 14 Pressure spring
4 Pressure spring(adjustment p) 15 Spool
5 Piston pP Pump pressure
6 Bushing pLS LS-Druck
7 Bushing pMLS p-Reduction
8 Piston S1 Control edge pump pressure
9 Sealing nut S2 Control edge tank pressure
10 Backing ring SK Control chamber pressure
7.10.11
copyright by
MJFCIFSS
Adjustment of DPVO variable displacement pump
11 O-ring T 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".
1 Mounting plate 17 Pilot plate

2 Connecting flange 18 Locking pin (against tampering)
3 Stop screw 19 Piston with slipper
4 Locking ring 22 Control piston
5 Drive shaft 30 Gear pump
6 Regulator housing 31 Sliding disc
7 Swivel yoke 32 Set of discs
8 Cylindrical roller bearing 33 Return ball
9 O-ring 34 Return plate
10 Sliding bearing 35 Pressure spring
11 Roll pin 36 Pressure spring
12 Pin 37 Connecting link
13 O-ring 38 Hex nut
14 Cylindrical roller bearing 39 Stop sleeve
15 Pin 40 Pump casing
16 Cylinder with bushing
7.10.12
copyright by
MJFCIFSS
Fig. 10 Sectional drawing: DPVO
7.10.13
copyright by
MJFCIFSS
Regulating characteristics
7 Regulating characteristics
Fig. 11 Performance curve: DPVO 165
7.10.14
copyright by
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 po-
wered by the diesel engine via the flexible coupling (torsion damper).
The variable-displacement pump regulates its flow rate according to current requirements (load sen-
sing 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 re-
gulating and adjusting the pump performance) is screw-mounted in the regulator housing 49. It ob-
tains feedback concerning the current pivot angle by means of a pin.
The flow regulator 26 used to adjust the flow and the differential pressure p is also screw-mounted
to the regulator housing 49.
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.
7.15.1
copyright by
MJFCIFSS
DPVO variable-displacement pump Service Manual
Design
Fig. 1 Components of the DPVO
25 Performance regulator (LR) 48 Qmin stop screw

26 Flow regulator (LS) 49 Regulator housing
27 Shuttle valve
28 Check valve A1 Pressure connection
29 Restrictor AX Pressure connection sealed
30 Gear pump / pilot control FE Pressure connection of control oil pump
31 Gear pump / fan control S Suction connection
40 Pump casing 7 Leak oil connection
44 Measuring point pSK (control chamber X2 Measuring point / LS pressure
pressure)
46 Mounting plate X3 Connection of control oil unit LR
47 Connecting flange X4 Connection -p reduction
7.15.2
copyright by
MJFCIFSS
Technical data
2 Technical data
Machine R 313 Litronic

Pump type DPVO 165
Input speed 1800 rpm
Drive power of diesel engine 73 kW
Volumetric delivery
max. 297 l/min
min. 40 l/min
Hydraulic performance (basic performance) 29 kW
Begin of regulation (with basic settings) 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

Control pressure from sole-
noid valve Y50
P min. 1.5 +1 bar
P max. 7 +2 bar
7.15.3
copyright by
MJFCIFSS
Technical data
Fig. 2 Hydraulic diagram of DPVO
1 to hydraulic tank 25 Performance regulator

3 from stop cock / tank 26 Flow regulator
4 Pressure spring / p 27 Shuttle valve
10 Pressure spring / begin of regulation 28 Check valve
13 to oil motor / fan drive 29 Restrictor
15 Connecting pin (swivel yoke) 30 Gear pump / pilot control
16 Return piston 31 Gear pump / fan control
20 DPVO pump unit 44 Measuring point / actuating pressure
21 Powertrain 45 Measuring point / LS pressure
22 Control piston 50 from/to control oil unit
23 Measuring cylinder 100 to control valve block
24 Lever (rocker)
7.15.4
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MJFCIFSS
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 bet-
ween 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 bet-
ween 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 di-
ameter 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
7.15.5
copyright by
MJFCIFSS
19 Piston 36 Pressure spring
3.1.1 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 regu-
lator 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 fac-
tory-set. It is recommended not to tamper with these angle settings.
Fig. 4 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
7.15.6
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MJFCIFSS
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 cor-
responds 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.

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 pres-
sure 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 con-
stant 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 th-
rough 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 re-
established, 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
7.15.7
copyright by
MJFCIFSS
Pump regulation
Fig. 6 Sectional drawing of performance regulator 25
26 Flow regulator, complete 91 Pressure spring

49 Regulator housing 92 Bushing
81 Screw plug 93 Spring plate
82 Threaded stud 94 Ball
83 Pressure spring 95 Connecting pin (swivel yoke)
84 O-ring 96 Return piston
85 O-ring 97 Spool
86 Regulator housing 98 Piston with slipper (measuring cylinder)
87 Sealing nut 99 Lever
88 Adjusting screw pP Working pressure
89 Screw plug SK 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
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 consu-
mers.
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 con-
nected 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 Flow regulator, complete 62 Spool

49 Regulator housing 63 Piston
51 Screw plug 64 Control sleeve
52 Adjusting screw 65 Piston
56 Sealing nut 73 O-ring with backing ring
58 Lock nut Pp Pump pressure
59 Pressure spring (adjustment p) pLS LS pressure
60 Pressure spring T Return channel
61 Seal X2 Connection control block-LS
X4 Connection T to tank
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.
7.15.9
copyright by
MJFCIFSS
Pump regulation
4.3 Regulation of pressure difference P LS
4.3.1 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 Control edges S1 and S2 at the flow regulator
51 Screw plug 68 Backing ring

52 Adjusting screw 72 Backing ring
56 Sealing nut 73 O-ring
58 Nut
7.15.10
copyright by
MJFCIFSS
59 Pressure spring (adjustment p) pP Working pressure

60 Pressure spring pLS LS pressure
62 Spool S1 Pump pressure control edge
63 Piston S2 Tank pressure control edge
64 Bushing SK Control chamber pressure
65 Piston T 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 p LS and begin of the hydraulic regu-
lation
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".

5 Drive shaft 30 Gear pump
6 Regulator housing 31 Sliding disc
7 Swivel yoke 32 Set of discs
8 Cylindrical roller bearing 33 Return ball
10 Sliding bearing 35 Pressure spring
11 Roll pin 36 Pressure spring
12 Pin 37 Connecting link
13 O-ring 38 Hex nut
14 Cylindrical roller bearing 39 Stop sleeve
15 Pin 40 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
7.15.11
copyright by
MJFCIFSS
Fig. 9 Sectional drawing of DPVO
7.15.12
copyright by
MJFCIFSS
6 Regulating characteristics
Fig. 10 Performance curve of DPVO 165
7.15.13
copyright by
MJFCIFSS
7.15.14
copyright by
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 require-
ments (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 ther-
mostat-controlled.
Fig. 1 Cooling unit, e.g. in three parts
6 Hydraulic oil cooler FS Finger guard

13 Blower motor H Air scoop
14 Pressure-relief valve LLK Intercooling air cooler / engine
MWK Water cooler (coolant) / engine
RL Annular fan
Y352 Proportional solenoid valve
7.20.1
copyright by
MJFCIFSS
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 positio-
ned 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 ne-
cessary 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 tempe-
rature B2. The fan speed is controlled electronically, relative to the temperature, through the propor-
tional 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 Valve position

Temperature Fan speed
BST Y352
60 C oil temperature and Imax Largest opening nmin
90 C coolant temperature
60 - 80 C oil temperature and Imax - Imin Medium opening nmin - nmax
90 - 100 C coolant temperature
80 C oil temperature and Imin Smallest opening nmax
100 C coolant temperature
7.20.2
copyright by
MJFCIFSS
Function and design
Fig. 2 Components of the fan control system
1 Hydraulic tank 30 Gear pump / fan drive

(A 309-316)
13 Oil motor / fan drive 31 Gear pump / fan drive (R 313 / R 317)
14 Proportional pressure-relief valve B2 Temperature transducer / coolant
15 Coarse filter fan motor B285 Temperature transducer / hydraulic oil
20 Variable-displacement pump / double Y352 Proportional solenoid valve / fan control
variable-displacement pump
7.20.3
copyright by
MJFCIFSS
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 285 (min.) or T 2 (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 285 (max.) or T 2 (max.) re-
spectively, 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 val-
ve Y352 is nearly linear, i.e. each temperature between these two limit points corresponds to a spe-
cific 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, re-
sulting in maximum speed of the fan n fan (max.).
Fig. 3 Cooling unit and fan circuit
A Layout from start of series B Layout from change in series

1 Hydraulic tank 31 Gear pump (in R 313 / R 317)
6 Hydraulic oil cooler 100 from compact control block connection K
7.20.4
copyright by
MJFCIFSS
7 Cooler for motor coolant B2 Temperature transducer / coolant

9 Annular fan B285 Temperature transducer / hydraulic oil
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)
2.1 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.
7.20.5
copyright by
MJFCIFSS
2.2 Diagrams
2.2.1 Diagram of model A 309/ A 311
Fig. 4 Temperature current and current speed and pressure
Y352 to proportional solenoid valve T Temperature of medium (oil, coolant)

p Pressure in cooling circuit n Speed of annular fan
7.20.6
copyright by
MJFCIFSS
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)

7.20.7
copyright by
MJFCIFSS
2.2.3 Diagram of model R 313

7.20.8
copyright by
MJFCIFSS
2.2.4 Diagram of model A 314 - R 317

Note!
Speed during emergency operation (failure of Y352):
Inot = 0 mA = nmax
p not a the pressure-relief valve 14 = pmax
7.20.9
copyright by
MJFCIFSS
7.20.10
copyright by
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
7.24.1
copyright by
MJFCIFSS
FMF hydraulic fixed displacement motor Service Manual
General information and tightening torques
2 General information and tightening torques

Machines from serial number
Type of oil motor FMF 45
Oil flow consumption 45 cm3/rev
Max. leak oil at max. working pressure 6 l/min
Allen head screws 14 118 Nm

Screw plug / leak-oil connection S 68 Nm
Pressure relief valve 134 / 135 100-120 Nm
Screw plug / suction valve 133.1 250 Nm
Measuring connection 137 / 138 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
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 Pressure-relief valve with additional pres-

sure stage
13 Mounting plate 135 Pressure-relief valve with additional pres-
sure stage
130 Oil motor, complete 137 Measuring connection MA
132 Powertrain, complete 138 Measuring connection MB
133 Suction valve
7.24.3
copyright by
MJFCIFSS
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 balan-
ced 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 pres-
surised 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 pis-
tons 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
Fig. 3 Sectional drawing of fixed displacement motor
2 Roller bearing 15 Locking ring

3 Output shaft 16 Radial shaft seal ring
4 Cylinder 17 O-ring
5 Piston 18 O-ring
5.1 Slipper 19 O-ring
6 Eccentric disc 22 Snap ring
7 Return plate 23 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
7.24.5
copyright by
MJFCIFSS
4.2 Functioning of valves on the mounting plate, see Fig. 4
4.2.1 Suction valves 133

The suction valves (acting as check valves) ensure that the oil motor is always properly filled (no ca-
vitation 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 clo-
sing 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 diffe-
rential 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 ap-
plied 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
copyright by
MJFCIFSS
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 134.21 Ball
133.10 Cone 134.22 O-ring
133.11 Screw plug 134.23 Pressure spring
133.14 Pressure spring 134.24 Pressure spring
133.17 O-ring 134.25 O-ring
134 Pressure relief valve / turn right A with 134.26 Backing ring
additional pressure stage
134.10 Adjusting screw 134.27 O-ring
134.12 Piston 134.29 O-ring
134.13 Nut 134.30 O-ring
134.14 Bushing* 134.31 Pressure spring
134.15 Bushing 134.98 Seal kit
134.16 Nut 135 Pressure relief valve / turn left B with
additional
pressure level items .10 - 0.98, see 134
134.17 Bushing* 137 Measuring point MA / turn right
134.18 Valve seat 138 Measuring point MB / turn left
* one piece (roller bearing)
7.24.7
copyright by
MJFCIFSS
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 reas-
semble 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 re-
adjusted. See adjustment guideline and protocol in group 6.
7.24.8
copyright by
MJFCIFSS
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
7.24.11
copyright by
MJFCIFSS
General information and tightening torques
7 General information and tightening torques

Machines from serial number
Type of oil motor FMF 45
Oil flow consumption 45 cm3/rev
Max. leak oil at max. working pressure 6 l/min
Allen head screws 14 118 Nm

Screw plug / leak-oil connection S 68 Nm
Pressure relief valve 134 / 135 100-120 Nm
Screw plug / suction valve 133.1 250 Nm
Measuring connection 137 / 138 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
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 pres-

sure stage
13 Mounting plate 135 Pressure-relief valve with additional pres-
sure stage
130 Oil motor, complete 137 Measuring connection MA
132 Powertrain, complete 138 Measuring connection MB
133 Suction valve
7.24.13
copyright by
MJFCIFSS
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 balan-
If pressure oil is supplied to the operating connections A or B, the respective four pistons 5 are pres-
surised 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 pis-
tons corresponds to the inclination of the eccentric disc 6 and determines the volume of oil consumed.
As the oil flow consumption remains constant at all times, it is the travel / output speed of the oil motor
that is changed accordingly via the spool when the oil supply changes.
7.24.14
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MJFCIFSS
Fig. 7 Sectional drawing of fixed displacement motor
2 Roller bearing 15 Locking ring

3 Output shaft 16 Radial shaft seal ring
5 Piston 18 O-ring
5.1 Slipper 19 O-ring
6 Eccentric disc 22 Snap ring
7 Return plate 23 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 137 Measuring point MA / pivot right
138 Measuring point MA / turn left
7.24.15
copyright by
MJFCIFSS
9.2 Functioning of valves on the mounting plate, see Fig. 8
9.2.1 Suction valves 133

The suction valves (acting as check valves) ensure that the oil motor is always properly filled (no ca-
vitation 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 clo-
sing 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 diffe-
rential 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 ap-
plied the piston .12 through the connection XA or XB respectively, the internal boreholes in the moun-
ting 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
Fig. 8 Sectional drawing of mounting plate
13 Mounting plate 134.19 Piston

14 Allen head screw 134.20 Cone
133 Check valve / suction valve 134.21 Ball
133.10 Cone 134.22 O-ring
133.11 Screw plug 134.23 Pressure spring
133.14 Pressure spring 134.24 Pressure spring
133.17 O-ring 134.25 O-ring
134 Pressure relief valve / turn right A with 134.26 Backing ring
additional
pressure stage
134.12 Piston 134.29 O-ring
134.13 Nut 134.30 O-ring
134.14 Bushing* 134.31 Pressure spring
134.15 Bushing 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
* one piece (roller bearing)
7.24.17
copyright by
MJFCIFSS
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 reas-
semble 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 re-
adjusted. See adjustment guideline and protocol in group 6.
7.24.18
copyright by
MJFCIFSS
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 (de-
pending 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
7.26.1
copyright by
MJFCIFSS
LMV regulating motor Service Manual
General information
Machine A 314-Li A 314-Li A 316-Li A 316-Li

from serial number Unit 2001 2001 2001 2001
Design N Speeder N Speeder
Oil motor 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
Begin of regulation (1) bar 240 240 240 240
End of regulation bar 320 320 320 320
Max. admissible amount of l/min 8,0 8,0 8,0 8,0
leak oil
Adjustable settings of oil motor

A Regulation end of oil motor
Min. pivot angle
Measure X (standard value), mm 11.0 11.0 11.8 14.0
see Fig. 4
B Drive shaft speed rpm 178025 267025 186025 279025
(jacked up)
Travel pressure (2) 86 115 82 105
C Secondary pressure-relief val- bar 380+20 380+20 380+20 380+20
ves
(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
copyright by
MJFCIFSS
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 Travel motor, complete 177 Secondary pressure-relief valve
173 Control cylinder 190 Brake valve, complete
174 Spool
7.26.3
copyright by
MJFCIFSS
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 bet-
ween 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 pres-
sure 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 pis-
tons 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 (connec-
tion 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 moun-
ting 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 hou-
sing 2 to the outside.
7.26.4
copyright by
MJFCIFSS
Fig. 3 Sectional drawing: travel motor / powertrain 170
2 Housing 75 Cylinder (172*)

5 Adjusting device 77.1 Piston (172*)
12 Flange 77.2 Slipper
15 Seal 78.1 Return ball with pressure spring
18 O-ring 78.2 Return plate
20 Allen head screw 79 Pilot plate
21 Retaining washer 84 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
34 Cylindrical roller bearing 98 Mounting flange
35 Radial shaft seal ring 100 Mounting plate
36 O-ring 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
7.26.5
copyright by
MJFCIFSS
Fig. 4 Sectional drawing of the regulating unit of the regulating motor, actuating device and con-
trol cylinder
4.2 Functioning of the regulating unit (control cylinder), see Fig. 5
4.2.1 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 con-
trol 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
copyright by
MJFCIFSS
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 Lid 22 O-ring
12 Lid 23 Backing ring
13 Stop screw 25 Seal ring
14 Pressure spring 26 O-ring
15 Lock nut 27 Guide bushing
16 Protective cap 28 Circlip
17 O-ring 30 Sliding block
18 Backing ring 84 Swivel yoke
7.26.7
copyright by
MJFCIFSS
19 Guide ring 173* Regulating unit / control cylinder

20 Restrictor
4.3 Functioning of the regulating unit (actuation device 87), see Fig. 5 / Fig. 6
4.3.1 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 mo-
ved 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 re-
gulating spring .24 is higher again than the hydraulic force at the spool .11. That means, the po-
wertrain 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 re-
gulation 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 pro-
tection for the oil motor against reaction forces from the outside and, thus, excess pressure.
7.26.8
copyright by
MJFCIFSS
Fig. 6 Sectional drawing of regulating unit / actuation device 87
.01 Screw .24 Regulation spring

.10 Regulating valve (housing) .25 Lever
.11 Spool .26 Lock nut
.12 Spring plate .27 Plug
.13 Guide rod .28 Screw plug
.14 Lid .29 Guide
.15 Control sleeve .34 Snap ring
.16 Guide .35 Axle
.17 Lid .39 Allen head screw
.18 Guide sleeve .41 Adjusting screw
.19 Pressure spring (begin of regulation) .42 Ball
.20 Seal .43 Measuring cylinder
.21 Shim .45 Snap ring
.22 Spring plate .46 Pin
.23 Seal ring
7.26.9
copyright by
MJFCIFSS
Fig. 7 Sectional drawing of mounting plate 100
.1 Secondary relief valve (176* travel for- .13 O-ring

ward)
.1 Secondary relief valve (177* travel for- .14 O-ring
ward)
.3 Check valve (175*) 15 Allen head screw
.4 Screw plug 172* Powertrain
.10 Mounting plate A/B Bores (high pressure from control
valve block)
7.26.10
copyright by
MJFCIFSS
Maintenance and inspection
0.12 Screw plug G Bores (high pressure from shuttle

valve 195 in brake valve
5 Maintenance and inspection
5.1 Maintenance and repair works on oil motor

Liebherr oil motors do not require any maintenance whatsoever.
For sealing and repair work, please refer to the separate
repair instructions "LMV regulating motor".
This hydraulic regulating motor has been pre-set by the manufacturer and must not be changed.
In the event of malfunction of the motor, check the control function.
To do this, proceed as described in the adjustment guidelines and the adjustment protocol, see
group 6.
Danger!
For inspection, adjustment and repair work, it is necessary to access the undercarriage.
This can be dangerous for technicians. There is a risk of serious injury or even death from rotating
wheels and shafts, or if the machine begins to move.
Always apply the parking brake.
Place the attachment on the ground.
Establish visual or acoustic contact with the operating personnel.
5.2 Checking oil motor for leakage

Disconnect the hose L leading from the connection T1 of the oil motor to the lower rotary connec-
tion 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.
7.26.11
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MJFCIFSS
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 moun-
ting plate of the regulating motor. They put a limit on the pressure between the oil motor and the con-
trol 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 pres-
sure 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 pi-
lot 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, th-
rough 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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MJFCIFSS
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 Housing - front part .26 O-ring
.1.2 Housing - back part .27 O-ring
.2 Main piston .28 Backing ring
.3 Pressure spring .7 Adjusting screw
.4 Valve insert .8 Lock nut
.5 Pilot control cone .10 Protective cover
.6 Pressure spring 999 O-ring (seal kit)
A Bore / main cone T1 Outlet pilot control cone
B Bore / valve insert T2 Outlet main cone
P High pressure
7.26.13
copyright by
MJFCIFSS
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 Functioning of brake valve
8.2.1 Function of brake valve 190* during travel

High-pressure oil flows through the connection A / B, the check valve 210 - 230 (196*) and the con-
nection 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 bra-
ke 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 rest-
ricted, 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
copyright by
MJFCIFSS
Brake valve
Fig. 10 Sectional drawing of brake valve 190*
10 Housing 230 Valve cone

20 Brake piston 250 Screw plug
30 Pin 300 Shuttle check valve
40 Valve seat 310 Screw plug
50 Valve seat 999 O-ring (seal kit)
70 Spring plate
100 Screw plug 190* Brake valve
110 Screw plug 192* Brake piston
140 Restrictor bolt 193* Shuttle valve
170 Pressure spring 194* Check valve
200 Cone 195* Shuttle valve
210 Guide 196* Check valve
220 Pressure spring
7.26.15
copyright by
MJFCIFSS
Brake valve
Fig. 11 Exploded view of brake valve
10 Housing 210 Guide

20 Brake piston 220 Pressure spring
30 Pin 230 Valve cone
40 Valve seat 250 Screw plug
50 Valve seat 300 Shuttle check valve
70 Spring plate 310 Screw plug
100 Screw plug 420 Screw plug
110 Screw plug 480 Hex nut
140 Restrictor bolt 490 Mounting bolt
170 Pressure spring 999 O-ring (seal kit)
200 Cone
7.26.16
copyright by
MJFCIFSS
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 regula-
ting 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 con-
sumption 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.
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 conse-
quent cavitation.
Fig. 1 DMVA travel motor
7.27.1
copyright by
MJFCIFSS
DMVA regulating motor Service Manual
Technical data
2 Technical data
Machine A 309 Litronic / A 312 Litronic /

A 311 Litronic
Oil motor DMVA 108 DMVA 108
Max. oil flow consumption 106.5 cm3/rev 106.5 cm3/rev
Oil flow consumption min.
Standard machine 52.3 cm3/rev 48.8 cm3/rev
Speeder 38.5 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
A Begin of regulation of the oil motor 240 bar 240 bar
at the adjusting screw
B Qmin. pivot angle
Dimension X of the stop screw 35
(guide value)
Standard machine 23.8 mm 14.8 mm
Speeder 26 mm -
C Drive shaft speed
Standard machine 1500 rpm (25 rpm) 1850 rpm (25 rpm)
Speeder 1930 rpm (25 rpm) 2780 rpm (25 rpm)
High pressure 115 bar 115 bar

D Secondary pressure-relief valves 380+20 bar 380+20 bar
Tab. 1 Technical data of the travel motor for machines A 309 Litronic to A 312 Litronic
7.27.2
copyright by
MJFCIFSS
Technical data
Machine A 316 Litronic

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
A Begin of regulation of the oil motor 190 bar
at the adjusting screw
B Qmin. pivot angle
Dimension X of the stop screw 35
(guide value)
Standard machine 21 mm
Speeder -
C Drive shaft speed 1680 rpm (25 rpm)
Adjusting screw 92 for stroke limita- 16.7 mm

tion of the control axle 160 (dimensi- 12.9 mm*
on Y) 115 bar
High pressure
D Secondary pressure-relief valves 380+20 bar
Tab. 2 Technical data of the travel motor for model A 316 Litronic
7.27.3
copyright by
MJFCIFSS
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 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
7.27.4
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MJFCIFSS
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 arran-
gement in the cylinder 3, which is in gear with drive shaft 4. The bottom ends of the pistons are desi-
gned 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 balan-
If pressure oil is supplied to the operating connections A or B, the respective four pistons are pres-
surised through the kidney-shaped slots in the pilot plate 5. Another four pistons press the non-ener-
gised 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 pres-
sure 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 corres-
ponds 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 sur-
face 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 pres-
sure 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.
7.27.5
copyright by
MJFCIFSS
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 pres-
sure 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 po-
sition, 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 diffe-
rence = 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 D - 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 adjus-
ting 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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MJFCIFSS
Fig. 4 Sectional drawing of the regulator
61 Bushing 69 Pressure spring (regulating spring)

62 Bushing 72 Ball
63 Spring plate 174 Spool
64 Adjusting screw A High pressure through valve 52
65 Spring plate B Pressure to control piston 173
66 Spring plate C High pressure through valve 195
67 Push rod T to tank
68 Pressure spring (adjusting spring)
Fig. 5 Magnified view of the surface difference (detail Z)
7.27.7
copyright by
MJFCIFSS
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 Arrangement of the valves for pressure protection
52 Check valve 176/177 Secondary pressure-relief valves

173 Control piston 194 Check valve
4.6 Creeper gear mode

The travel motor is kept at a maximum swivel angle (creeper gear mode) with the switch S21 (stan-
dard 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 (inde-
pendent 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
copyright by
MJFCIFSS
4.7 Functioning of brake valve

When a travel motion of the machine is initiated, the working pressure that is being built up acts th-
rough 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 dis-
placed 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
7.27.9
copyright by
MJFCIFSS
Note!
Liebherr oil motors do not require any maintenance whatsoever.
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.
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 determi-
ne 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
copyright by
MJFCIFSS
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 Setting value of Qmin stop screw

35 Stop screw 51 Protective cap
6.4 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
7.27.11
copyright by
MJFCIFSS
Hydraulic diagram of the travel motor
7 Hydraulic diagram of the travel motor
34 Connecting link 177 Secondary pressure-relief valve, reverse

35 Stop screw 190 Travel brake valve, complete
52 Check valve 192 Brake piston
67 Push rod 193 Restrictor bolt
68 Pressure spring (adjusting spring) 194 Check valve
69 Pressure spring (regulating spring) 195 Shuttle valve
170 Travel motor, complete 196 Check valve
172 Complete powertrain X Connection for control pressure from sole-
noid 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
7.27.12
copyright by
MJFCIFSS
Hydraulic diagram of the travel motor
Fig. 10 Hydraulic diagram of the travel motor
7.27.13
copyright by
MJFCIFSS
DMVA regulating motor
8 DMVA regulating motor
Item 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
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)
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
7.27.14
copyright by
MJFCIFSS
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 exca-
vator (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 (de-
pending on the operating pressure).
The variable flow consumption of the oil motor determines the torque and speed of the drive shaft.
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 adjus-
tment) (fast travel).
.
Fig. 1 Regulating motor A6VE
7.28.1
copyright by
MJFCIFSS
Regulating motor A6VE Service Manual
Function
7.28.2
copyright by
MJFCIFSS
Function
1.1 Technical data
Equipment R 313 / R 317

Unit
from serial number 27752 / 18161
Regulating motor Type A6VE
Max. oil flow consumption cm3 54.8
Max. torque Nm 349
Operating pressure bar 350
Max. leak oil l/min 8

Check measurement X.
Qmin Stop 8 mm approx.15.5
Qmax Stop 11 mm approx.15.5
Brake release pressure bar approx. 30
Secondary pressure relief valves 211-214 bar 380 +20
Tab. 1 Technical data and settings
7.28.3
copyright by
MJFCIFSS
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 Design of regulating motor
2 Motor housing 211 Secondary pressure relief valve, power-

train, forward left
8 Stop screw (Qmin) 212 Secondary pressure relief valve, power-
train,reverse left
11 Stop screw (Qmax) 213 Secondary pressure relief valve, power-
train, forward right
20 End plate 214 Secondary pressure relief valve, power-
train, reverse right
200 Travel motor, left A Pressure/return line connection
201 Travel motor, right B Pressure/return line connection
209 Double stop valve T1 Leak oil connection
7.28.4
copyright by
MJFCIFSS
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, power-
train, forward left
195 Rotary connection 5 x 212 Secondary pressure relief valve, power-
train,reverse left
196 Rotary connection 1 x 213 Secondary pressure relief valve, power-
train, forward right
200 Travel motor, left 214 Secondary pressure relief valve, power-
train, reverse right
201 Travel motor, right 215 Travel brake
7.28.5
copyright by
MJFCIFSS
Description
202 Powertrain adjusting device 216 Travel gear

203 Shifting piston / powertrain adjusting S21 Switch (fast travel)
device
205 Brake valve Y24 Solenoid valve (fast travel)
206 Shuttle valve
7.28.6
copyright by
MJFCIFSS
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 balan-
ced 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 po-
sition = 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.
7.28.7
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Sectional drawings of the regulating motor
4 Sectional drawings of the regulating motor
Fig. 4 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 Back-up washer 16 Tuning disc (S = 3.50 4.00 mm)
6 O-ring 17 Pressure spring
8 Stop screw (Qmin) 19 Oval head screw
9 Seal-Lock collar nut 20 End plate
10 O-ring 39 Tapered roller bearing
11 Stop screw (Qmax)
7.28.8
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20 End plate 36 Screw plug

21 Control piston 37 Double pull-off plug
22 Control neck 202 Adjusting device
23 Control bushing 203 Shifting piston (powertrain adjustment)
24 Spool 205 Brake valve
25 Pressure spring 206 Shuttle valve
26 Screw plug 208 Pressure reduction valve
27 Restriction screw 209 Double stop valve
28 Restriction screw 211 Secondary pressure relief valve, chassis,
forward left
30 Restriction pin 212 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
7.28.9
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MJFCIFSS
Fig. 5 Sectional drawing of adjusting device
7.28.10
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MJFCIFSS
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.
repair instructions "A6VE regulating motor".
Danger!
Danger areas: undercarriage - crushing hazard for mechanics, if machine unintentionally starts rol-
ling 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.
7.28.11
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MJFCIFSS
Inspection, maintenance and adjustment
Fig. 6 Leak oil check at the regulating motor
210 Brake hose from the oil motor to the multi- L Leak oil line
disc brake
T1 Leak oil connection at oil motor
7.28.12
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MJFCIFSS
Double stop valve 209
6 Double stop valve 209
Fig. 7 Double stop valve 209
1 Valve cone 20 Housing / mounting plate

2 Pressure spring 209 Double stop valve, complete
3 Valve seat
4 Valve cone A Pressure/return line connection
5 Pressure spring B Pressure/return line connection
6 Screw plug R return line from brake valve
11 O-ring U from/to powertrain and pressure control
6.1 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 con-
nection 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 con-
trol 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).
7.28.13
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Brake valve 205
7 Brake valve 205
Fig. 8 Sectional drawing of brake valve 205
1 Brake piston 6 Restriction screw

2 Screw plug 10 Restriction pin
4 Washer 205 Brake valve, complete
5 Restriction screw 209 Double stop valve
7.1 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 pres-
sure 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 con-
nection from A or B to S.
7.28.14
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MJFCIFSS
Pressure reduction valve (brake pressure) 208
8 Pressure reduction valve (brake pressure) 208
Fig. 9 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
8.1 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 bu-
shing 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 re-
lease of the multi-disc brake when the machine is standing still or is travelling.
7.28.15
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MJFCIFSS
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 hy-
draulic 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.

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 po-
sitions (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 pres-
sure 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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MJFCIFSS
Fig. 10 Sectional drawing of the pressure relief valve 211 - 214
1 Main cone 6 Adjusting screw

2 Pilot control cone 7 Lock nut
3 Pressure spring 8 Housing (front section)
4 Housing (rear section) 9 Pressure spring
5 Protective cap 10 O-ring
7.28.17
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MJFCIFSS
7.28.18
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MJFCIFSS
Service Manual Hydraulic cylinder
Function
Hydraulic cylinder
1 Function
The LIEBHERR hydraulic cylinders are primarily used as working cylinders for the movement of at-
tachments. 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 Piston surface

Retracting 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 ex-
tension), 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
7.30.1
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MJFCIFSS
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 Exploded view of a hydraulic cylinder with various piston, cushioning and stroke shorte-
ning options.
1 Bushing 20 Hex head screw

2 Sleeve (stroke reduction as optional 25 Circlip
extra)
3 Piston (stroke reduction as optional extra) 31 Screw
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
7.30.2
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MJFCIFSS
Description
15 Radial seal ring
Fig. 3 Sealing elements at the piston 12 and the piston rod bearing 13
9 Cushioning sleeve 125 Backing ring

12 Piston 126 Piston guide ring
13 Piston rod bearing 131 Guide ring
25 Ring 132 Backing ring
91 O-ring 133 O-ring
92 Seal ring 134 Scraper ring
121 Piston guide ring 135 O-ring
122 Turcon-Glyd ring 136 Rimseal ring (secondary protection)
124 O-ring 138 Turcon Stepseal (primary protection)
2.1 Cylinder variants, see Fig. 17 / Fig. 18

The uncushioned hydraulic cylinder (type I) is used mainly with supports and with certain (less fre-
quently 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-
7.30.3
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MJFCIFSS
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.
3.1 One-side end-of-travel cushioning
3.1.1 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 be-
aring 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 bo-
res 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 Sectional drawing of the hydraulic cylinder
7.30.4
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MJFCIFSS
3.2 Two-side end-of-travel cushioning, see Fig. 5
3.2.1 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 cushio-
ning 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
7.30.5
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MJFCIFSS
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 per-
sonnel.
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 ne-
cessary.
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 hy-
draulic connections.
7.30.6
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MJFCIFSS
Removal and installation of hydraulic cylinders
4.3 Bleeding cylinder after repair
4.3.1 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 re-
maining 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
7.30.7
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MJFCIFSS
Replacing seals
5 Replacing seals
Fig. 7 Partial section of the hydraulic cylinder
4 Piston nut 33 Disc

8 Piston rod 121 Piston guide ring
9 Cushioning sleeve 122 Turcon-Glyd ring
12 Piston 123 O-ring
13 Piston rod bearing 124 O-ring
20 Hex head screw 125 Backing ring
25 Snap ring 126 Piston guide ring
5.1 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, com-
plete 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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MJFCIFSS
Replacing seals
5.2 Assembly of sealing and guide elements on the piston
5.2.1 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 Piston rod bearing 137 O-ring

135 O-ring 138 Turcon Stepseal (primary protection)
136 Rimseal Ring (secondary 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.
7.30.9
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MJFCIFSS
Replacing seals
Fig. 9 Mount the piston rod bearing using the mounting sleeve for special piston rod shapes
c Mounting sleeve, see tools in group 2.01 / 8 Piston rod

2.12
13 Piston rod bearing
Slide the cushioning sleeve 9 (not required for hydraulic cylinders without end-of-travel cushio-
ning) onto the piston rod 8.
7.30.10
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MJFCIFSS
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 Distinguishing features of seal rings
136 Rimseal ring s Flange - inclined

138 Stepseal ring g Flange - straight
Colour Rimseal 136 => dark grey - polished or turquoise (new)

Stepseal 138 => light grey - matt
Elasticity Rimseal 136 => flexible
Stepseal 138 => rigid
Shape Rimseal 136 => flange inclined
Stepseal 138 => flange straight
5.2.3 Mounting to piston
Note!
The Turcon-Glyd ring 122 must be expanded before mounting and then returned to its normal sha-
pe, 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. 60C).
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.
7.30.11
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MJFCIFSS
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 Mounting sleeve 121 Piston guide ring

b Expanding sleeve 122 Turcon-Glyd ring
9 Cushioning sleeve 123 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 prescri-
bed 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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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 engra-
ved 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 in-
stallation 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 Screw 126 Piston guide ring
32 Cushioning sleeve
7.30.13
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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 Cylinder tube 33 Disc

13 Piston rod bearing 132 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 con-
nections.
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
copyright by
MJFCIFSS
Piston rod bearing types
Fig. 14 Assembly wrenches for screw-type piston rod bearings
8 Piston rod 13 Piston rod bearing

10 Cylinder tube
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
7.30.15
copyright by
MJFCIFSS
Piston types on hydraulic cylinders
8 Piston types on hydraulic cylinders
Fig. 16 Piston types 12
A Piston 12 secured with piston nut

B Piston 12 with integrated piston nut
7.30.16
copyright by
MJFCIFSS
End-of-travel cushioning
9 End-of-travel cushioning
Fig. 17 Options for end-of-travel cushioning and stroke reduction
Option I without end-of-travel cushioning

Option II 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
7.30.17
copyright by
MJFCIFSS
Stroke reduction
32 Cushioning sleeve
10 Stroke reduction
Fig. 18 Cylinder with stroke reduction
Option G Stroke reduction with sleeve 2

Option H Stroke reduction with piston 3
7.30.18
copyright by
MJFCIFSS
Hydraulic cylinder
Stroke Fitting
Installed as D d WN 4121
Drawing no. eff. length
(in equipment) (mm) (mm) (mm) (mm) 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 Gooseneck boom 1 110 75 1050 1590 091
29 524 4049 Bucket cylinder 1 90 60 900 1340 073
Regulating cylinder at
29 447 1040 hydraulic boom adjustment 1 140 80 700 1140 171
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 adjus-
29 513 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
7.34.1
copyright by
MJFCIFSS
7.34.2
copyright by
MJFCIFSS
Hydraulic cylinder
Stroke Fitting

Boom cylinder at

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
Grapple cylinder at
29 128 1000 clamshell grab 2 70 50 350 710 (*)
Support cylinder at
29 530 1049 Blade support 2 90 50 205 515 075

29 530 2049 Blade support 2 90 50 205 515 075
7.35.1
copyright by
MJFCIFSS
7.35.2
copyright by
MJFCIFSS
Hydraulic cylinder
Stroke Fitting

Boom cylinder at
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
Grapple cylinder at
29 128 1000 clamshell grab 2 70 50 350 710 (*)
Support cylinder at

29 530 1049 Blade support 2 90 50 205 515 075
29 530 2049 Blade support 2 90 50 205 515 075
7.36.1
copyright by
MJFCIFSS
7.36.2
copyright by
MJFCIFSS
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 multi-
disc brake of the slewing gear.
Fig. 1 Control oil unit
7.40.1
copyright by
MJFCIFSS
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 accumu-
lator 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 Control oil unit with control and regulating valves, pressure-reduction valve, pressure ac-
cumulator and measuring point
49 Measuring point for control pres- Y3 Solenoid valve / servo release

sure
50 Control oil and regulation unit Y24 Solenoid valve / creeper gear switching
51 Pressure-relief valve Y50 Proportional solenoid valve / power control
52 Pressure filter Y51 Proportional solenoid valve / LS control
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
7.40.2
copyright by
MJFCIFSS
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 re-
gulating 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 con-
trol 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 limita-
tion 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.
7.40.3
copyright by
MJFCIFSS
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
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 Normal position a and emergency position b of the regulating solenoid valve Y50
5
1 Adapter 5 Lock nut

2 Cotter pin 50 Control oil unit
3 Lever Y50 Proportional solenoid valve / performance control
4 Adjusting nut Y51 Proportional solenoid valve / flow reduction P1
7.40.5
copyright by
MJFCIFSS
Emergency position of the proportional solenoid valve Y50
7.40.6
copyright by
MJFCIFSS
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
7.42.1
copyright by
MJFCIFSS
Description
2 Description
The control oil unit 50 consists primarily of an aluminium block. At its front, it is equipped with a pres-
sure 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
Description
Fig. 2 Control oil unit with control and regulating valves, pressure-reduction valve, pressure ac-
cumulator and measuring points
49 Measuring point for control pressure 57 Measuring point ( p reduction)

50 Control oil and regulation unit 59 Measuring point (power control)
51 Pressure-relief valve Y3 Solenoid valve / servo release
52 Pressure filter Y7 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 con-
trol
55 Dummy plate Y51 Proportional solenoid valve / LS control
56 Dummy plate Y371 Solenoid valve / oscillating axle support
(wheel machines only)
7.42.3
copyright by
MJFCIFSS
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 pres-
sure 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 sup-
port 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 con-
trol 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 pres-
sure connection for the power control of the working pumps.
The proportional solenoid valve Y51 regulates the control pressure p(LS), which determines the limi-
tation 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
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 so-
lenoid 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 num-
ber 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).
7.42.5
copyright by
MJFCIFSS
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 Emergency position of the regulating solenoid valves Y50 and Y51
1 Adapter 57 Measuring point (rp reduction)

2 Cotter pin 59 Measuring point (power control)
3 Lever
4 Adjusting nut Y50 Proportional solenoid valve / power control
5 Lock nut Y51 Proportional solenoid valve / LS control
7.42.6
copyright by
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 wor-
king functions of lifting, stick movements, bucket cylinder movements and turning of the uppercarri-
age.
There are four regulating pistons 12 (pressure control valves) inserted in an axial position in the hou-
sing 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
7.45.1
copyright by
MJFCIFSS
Pilot control unit 4 x Service Manual
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 regula-
ting spring 25 shifts the regulating piston 12. The control oil flows through the radial and axial bore-
holes 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 pre-
defined 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
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
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 Point a Point b

A 309 - R 317 5.8 -0.3 bar 24.3 bar
7.45.3
copyright by
MJFCIFSS
Exploded view
4 Exploded view
Fig. 3 Pilot control valve model I until May 2004, model II from June 2004
10 Housing 98.2 Bushing

12 Regulating piston 98.3 PDF seal
13 Bushing (press-fitted) 98.4 O-ring
15 Spring plate 98.5 Protective cap
16 Universal joint 140 Plate
17 Hex nut 150 Bellows
18 Switching disc 160 Sleeve
23 Disc 166 Nut
25 Pressure spring (regulating spring) 171 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 Switch / travel direction
98.1 Pushrod S382
7.45.4
copyright by
MJFCIFSS
Sectional drawing
5 Sectional drawing
Fig. 4 Sectional drawing of the pilot control unit
7.45.5
copyright by
MJFCIFSS
Sectional drawing
140 Plate B19R* Sensor transducer / right

142 Retaining washer B19L* Sensor transducer / left
144 Spacer sleeve S5R* Push button / turn grapple right
146 Allen head screw S5L* Push button / turn grapple left
150 Bellows
160 Sleeve S263* Switch / travel direction
166 Hex head screw S382* Switch / fine adjustment (A 312 - R 317)
170 Handle X15-2* Plug connection, 2-pin
171 Handle section X80* Plug connection, 3-pin
172 Handle section X81* Plug connection, 3-pin
173 Sensor surface X342* Plug connection / 3-pin
177 Dummy cap X909* Plug connection, 2-pin
190 Sheet metal screw X1046* Plug connection, 12-pin
191 Allen head screw X1047* Plug connection, 3-pin
192 Wire harness X1048* Plug connection, 12-pin
193 Adapter X1049 Plug connection, 3-pin
200 Sheet metal screw
201 Small parts kit
202 Pressure spring * Installation according to machine type
and serial number, see electrical system
of basic machine, group 8.
7.45.6
copyright by
MJFCIFSS
Sectional drawing
Fig. 5 Pilot control valve, right, with electrical components
Fig. 6 Pilot control valve, left, with electrical components
7.45.7
copyright by
MJFCIFSS
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 hou-
sing 10, complete with pressure, return and control connections. The regulating pistons 12 are ope-
rated 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
7.46.1
copyright by
MJFCIFSS
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.
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 pres-
sure is established, which shifts the spool 12 proportionally to the pressure increase. At a set pres-
sure (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 connec-
tion 7 for other control functions (connection 7 is temporarily closed).
3 Repairs

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

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
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 ergo-
nomic 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
7.46.3
copyright by
MJFCIFSS
Exploded view and sectional drawing
4 Exploded view and sectional drawing
1 Pilot control unit, complete 33 Screw plug

2 Pedal, complete 36 Seal plug
2.1 Pedal 37 PDF seal
2.2 Cover 38 O-ring
2.3 Threaded stud 40 Sealing ring
2.4 Hex nut 41 Washer
2.5 Bushing 42 Washer
10R Housing right 45 Ball
10L Housing left 46 Hex nut
10.2 Pressed-in bushing 47 Disc
12 Regulating piston 50 Screw plug
13 Pushrod 51 Sealing ring
14 Bushing
15 Spring plate
20 Valve insert 998 Repair kit, consisting of
23 Disc 998.1 Pushrod (item 13)
25 Pressure spring (regulating spring) 998.2 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)
7.46.4
copyright by
MJFCIFSS
Fig. 3 Exploded view of the pilot control units for the right and left travel gear drives
7.46.5
copyright by
MJFCIFSS
1 Pilot control unit, complete 33 Screw plug

2 Pedal, complete 36 Seal plug
2.1 Pedal 37 PDF seal
2.2 Cover 38 O-ring
2.3 Threaded stud 40 Sealing ring
2.4 Hex nut 41 Washer
10R Housing right 45 Ball
10L Housing left 46 Hex nut
10.2 Pressed-in bushing 47 Disc
13 Pushrod 51 Sealing ring
14 Bushing
15 Spring plate
20 Valve insert 998 Repair kit, consisting of
23 Disc 998.1 Pushrod (item 13)
25 Pressure spring (regulating spring) 998.2 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)
7.46.6
copyright by
MJFCIFSS
Fig. 4 Sectional drawing of a pilot control unit for the travel gear
7.46.7
copyright by
MJFCIFSS
7.46.8
copyright by
MJFCIFSS
Service Manual Pilot control unit 4x
Design
Pilot control unit 4x

for travel gear drive
5 Design

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 hou-
sing 3, complete with pressure, return and control connections. The regulating pistons 16 are opera-
ted 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 - con-
trol 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
7.46.11
copyright by
MJFCIFSS
for travel gear drive Service Manual
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 re-
gulating 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.
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. Simulta-
neously, 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 con-
trol 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 th-
rough 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

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 ne-
cessary 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

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.
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
7.46.13
copyright by
MJFCIFSS
8 Exploded view and sectional drawing
Fig. 7 Exploded view of pilot control unit operation
2 Pilot control unit, complete 30 Pin

20 Left pedal 31 Washer
25 Right pedal 32 Cotter pin
26 Allen head screw 41 Allen head screw
27 Base 42 Retaining washer
28 Base
7.46.14
copyright by
MJFCIFSS
Service Manual for travel gear drive
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 Plate, complete 15 Nozzle set
7.1 Bearing block 16 Regulating piston
7.2 Allen head screw 17 Shuttle valve
7.3 Pin 18 Threaded stud
7.4 Threaded stud
8 Pushrod
9 Hollow rod
10 Regulating unit
11 Spring set
7.46.15
copyright by
MJFCIFSS
Fig. 9 Sectional drawing of the pilot control unit
6 Switch disc
7 Plate, complete 11.1 Regulation spring
7.1 Bearing block 11.2 Return spring
7.2 Allen head screw 12 Pushrod
7.3 Pin 13 Return spring
7.4 Threaded stud 15 Nozzle set
8 Pushrod 16 Regulating piston
9 Hollow rod 17 Shuttle valve
10 Regulating unit 18 Threaded stud
11 Spring set 19 Control connection
7.46.16
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
7.47.1
copyright by
MJFCIFSS
Pilot control valve 2 x Service Manual
see Fig. 3 / Fig. 4

When pedals 2 and/or 3 are actuated, threaded stud 47 presses pushrod 98.1 down and shifts regu-
lating 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 corres-
ponds 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
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 rea-
ched 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 connec-
tion 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.
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
Point a Point b
A 309 - R 317 Litronic 5.8 -0.3 bar 24.3 bar
7.47.3
copyright by
MJFCIFSS
Exploded view
4 Exploded view
Fig. 3 Exploded drawing: pilot control valve
1 Housing 40 Seal ring

2 Pedal to the left 41 Washer
3 Pedal to the right 45 Ball
3.1 Bushing 46 Hex nut
10 Bearing pillow block 47 Threaded stud
11 Pin 48 Hex nut
13 Bushing (pressed in) 51 Seal ring
15 Spring plate 52 Snap ring
16 Bushing 98 Repair kit
20 Valve insert 98.1 Pushrod
23 Washer 98.2 Bushing
25 Pressure spring (regulating spring) 98.3 PDF seal
26 Pressure spring (return spring) 98.4 O-ring
33 Screw plug 98.5 Protective cover
7.47.4
copyright by
MJFCIFSS
Sectional drawing
5 Sectional drawing
Fig. 4 Sectional drawing
7.47.5
copyright by
MJFCIFSS
Sectional drawing
7.47.6
copyright by
MJFCIFSS
Description
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.
Fig. 1 Pilot control valve 2 x with hydraulic diagram
7.48.1
copyright by
MJFCIFSS
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

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.

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.
Place plate 29. Screw in screws 21.
Place protective covers 98.5.
7.48.2
copyright by
MJFCIFSS
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
Point a Point b
A 309 - A 316 Litronic und A 309 - R 317 Litronic TCD 5.8 -0.3 bar 24.3 bar
7.48.3
copyright by
MJFCIFSS
Exploded view
4 Exploded view
3 Tipping switch 52 Shim

12 Regulating piston 54 Shim
15 Spring plate 64 Lever
17 Hex nut 65 Handle
18 Threaded stud 66 Bellows
20 Allen head screw 68 Hex nut
21 Allen head screw 70 Housing
23 Split disc 71 Bushing (pressed in)
24 Axle 90 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 Washer 98.3 PDF seal
50 Washer 98.4 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 machi-
nes from start of series
7.48.4
copyright by
MJFCIFSS
Sectional drawing
5 Sectional drawing
Fig. 4 Sectional drawing: pilot control valve
7.48.5
copyright by
MJFCIFSS
Sectional drawing
7.48.6
copyright by
MJFCIFSS
Description
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, com-
plete with pressure, return and control connections. There is a second pedal 2 on top to actuate re-
gulating 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).
Fig. 1 Pilot control valve 1x with hydraulic diagram
7.49.1
copyright by
MJFCIFSS
Fig. 3 / Fig. 4
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 'tra-
vel 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 pre-
defined 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

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. Re-
move 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.

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.
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
Repair
Fig. 2 Diagram: c = control pressure in bar, d = lever displacement in angular degree
Point a Point b
A 309 - A 316 6.5 bar 25 bar
7.49.3
copyright by
MJFCIFSS
Repair
3.3 Exploded view
1 Plate 26 Pressure spring (return spring)

2 Pedal 37 Washer
6 Housing 38 Washer
7 Pin 39* Shim ring
9 Washer 85 Retaining washer
11 Cotter pin 86 Hex head screw
12 Regulating piston 98 Repair kit
15 Spring plate 98.1 Pushrod
17 Bushing (pressed in) 98.2 Bushing
23 Washer 98.3 PDF seal
25 Pressure spring (regulating spring) 98.4 O-ring
26 Pressure spring (return spring) 98.5 Protective cover
* Omitted in A 309 - 312 machines from
start of series
in A 314 - 316 machines from serial no.
11500.
7.49.4
copyright by
MJFCIFSS
Repair
3.4 Sectional drawing
Fig. 4 Sectional drawing: pilot control valve
6 Housing 37 Washer
12 Regulating piston 38 Washer
15 Spring plate 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
7.49.5
copyright by
MJFCIFSS
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 pres-
sure-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.
7.50.1
copyright by
MJFCIFSS
Compact control block Service Manual
Technical data
2 Technical data
Contained in: A 309 Litronic A 311 Litronic

Type 717 718
Series M8-1384-00 8M8-16
Spool Unit 101 102 103 105 106 107

Slewing Stick Support Regula- Boom cy- Bucket cy-
gear cylinder cylinder ting linder linder
cylinder
Ext. Retr. Ext. Retr. Ext. Retr. Ext. Retr. Ext. Retr. Ext. Retr.
Nominal block mm 20 20 20 20 20 20
width
Consumer connec- inch 3/4 3/4 3/4 3/4 3/4 1/2
tion
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
3
Leak oil max. cm /min 60 60 60 60 60 60
at load pressure bar 150 150 150 150 150 150
C
at oil temperature 50 50 50 50 50 50
Spool Unit 108 109

Travel mo- Total
tor Boom /
stick
cylinder
Ext. Retr. Ext. Retr.
Nominal block mm 20 20
width
Consumer connec- inch 3/4 3/4
tion
piston rod mm 20 20
Piston stroke mm 9.0 9.0 8.0 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. cm3/min 60 60
at load pressure bar 150 150
C
at oil temperature 50 50
* p1 = Control pressure at begin of regulation (fine-control phase)

p2 = Control pressure in final position of spool
7.50.2
copyright by
MJFCIFSS
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 attach-
ment) 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 scre-
wed 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.
7.50.3
copyright by
MJFCIFSS
Description
10 Plate 127 Secondary pressure-relief valve, stick

cylinder A2
30 Allen head screw 128 Secondary pressure-relief valve, stick
cylinder B2
40 Measuring point P1 129 Secondary pressure-relief valve, regula-
ting cylinder A5
41 Measuring point P2 130 Secondary pressure-relief valve, regula-
ting cylinder B5
100 Compact control block 131 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 Regulating cylinder spool 135 Suction valve, travel motor A8
106 Boom cylinder spool 136 Suction valve, travel motor B8
107 Bucket cylinder spool 150 Check valve
108 Travel motor spool 151 Load-holding valve
109 Combined boom cylinder / 152 Check valve
stick cylinder spool
111 Auxiliary block 153 Check valve 0.5 bar
120 Prim. pressure-relief valve pump P1 154 Check valve 5.5 bar
121 Prim. pressure-relief valve pump P2 162 Stroke limitation adjusting screw
7.50.4
copyright by
MJFCIFSS
Description
Fig. 2 Control valve block - front and rear view
7.50.5
copyright by
MJFCIFSS
Description
1 to tank 127 Secondary pressure-relief valve, stick

cylinder A2
6 to oil cooler 128 Secondary pressure-relief valve, stick
cylinder B2
10 Plate 129 Secondary pressure-relief valve, regula-
ting cylinder A5
20 from pump 130 Secondary pressure-relief valve, regula-
ting 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 Secondary pressure-relief valve, bucket
cylinder B7
102 Stick cylinder spool 135 Suction valve travel motor A8
103 Support cylinder spool 136 Suction valve travel motor B8
105 Regulating cylinder spool 150 Check valve
106 Boom cylinder spool 151 Load-holding valve
107 Bucket cylinder spool 152 Check valve
108 Travel motor spool 153 Check valve 0.5 bar
109 Combined boom cylinder / 154 Preload valve 5.5 bar
stick cylinder spool
111 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
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MJFCIFSS
Description
Fig. 3 Diagram of control valve block
7.50.7
copyright by
MJFCIFSS
Description
10 Plate 105 Regulating cylinder spool

12 Control lid, bottom 106 Boom cylinder spool
13 Control lid, top 107 Bucket cylinder spool
14 Control lid with stroke limitation (for 108 Travel motor spool
lowering of boom)
23 Spring pack, complete 109 Combined boom / stick cylinder spool
24 Spring pack, complete 111 Auxiliary block
25 Spring pack, complete 120 Prim. pressure-relief valve pump P1
26 Spring pack, complete 121 Prim. pressure-relief valve pump P2
27 Regulating spring (various characteristics) 127 Secondary pressure-relief valve, stick
cylinder A2
28 Spring plate 128 Secondary pressure-relief valve, stick
cylinder B2
29 Lock washer 129 Secondary pressure-relief valve, regula-
ting cylinder A5
30 Allen head screw 130 Secondary pressure-relief valve, regula-
ting cylinder B5
31 Allen head screw 131 Secondary pressure-relief valve, boom
cylinder A6
32 Washer 132 Secondary pressure-relief valve, boom
cylinder B6
33 O-ring 133 Secondary pressure-relief valve, bucket
cylinder A7
34 O-ring 134 Secondary pressure-relief valve, bucket
cylinder B7
40 Measuring point for pump P1 135 Suction valve, travel A8
41 Measuring point for pump P2 135 Suction valve, travel B8
49 Bushing 150 Check valve
50 Threaded stud 151 Load-holding valve
51 Hex nut 152 Check valve
52 Washer 153 Check valve 0.5 bar
100 Compact control block 154 Preload valve 5.5 bar
101 Slewing gear spool 155 Restrictor valve
102 Stick cylinder spool 162 Adjusting screw
103 Support cylinder spool
7.50.8
copyright by
MJFCIFSS
Description
Fig. 4 Design of the control valve block 100
7.50.9
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MJFCIFSS
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 pressure-
free 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 pressure-
free 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, bypas-
sing 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 consu-
mer, 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 chan-
nel 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 connec-
tions 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
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MJFCIFSS
The internal leakage of a consumer connection under pressure is influenced by the length of the over-
lap 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 Combined shifting and priorities
4.4.1 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 com-
bined 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 sup-
plied 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 pri-
ority 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 con-
sumers are actuated.
7.50.11
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MJFCIFSS
12 Control lid, bottom 107 Bucket cylinder spool

13 Control lid, top 108 Travel motor spool
14 Control lid with stroke limitation 109 Combined boom / stick cylinder spool
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 Regulating spring (various cha- 130 Secondary pressure-relief valve, regulating cylinder
racteristics) B5
28 Spring plate 131 Secondary pressure-relief valve, boom cylinder A6
29 Lock washer 132 Secondary pressure-relief valve, boom cylinder B6
30 Allen head screw 133 Secondary pressure-relief valve, bucket cylinder A7
31 Allen head screw 134 Secondary pressure-relief valve, bucket cylinder B7
32 Washer 135 Suction valve / forward travel
33 O-ring 136 Suction valve / reverse travel
100 Compact control block 150 Check valve
101 Slewing gear spool 151 Load-holding valve
111 Auxiliary block 152 Check valve
102 Stick cylinder spool 157 O-ring
103 Support cylinder spool 158 Cone / load-holding valve
105 Regulating cylinder spool 159 Pressure spring / load-holding valve
106 Boom cylinder spool
7.50.12
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MJFCIFSS
Fig. 5 Sectional drawings of working axles 1,2,3,5,6,7 and 8
F Free passage T Return channel, tank side

P Pressure channel, pump side VA/VB channel, consumer side
7.50.13
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MJFCIFSS
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 con-
sumer.
The priority of the return flow of the oil through the cooler is implemented by means of different pre-
loads 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.
5 Valve seat 32 Washer

6 Valve cone 33 O-ring
7 Pressure spring (0.5 bar) 55 Reducer
8 Shim 56 O-ring
9 Pressure spring (5.5 bar) 57 Pressure spring
11 Valve seat 58 Pressure spring
12 Control lid, bottom 59 Spring plate
13 Control lid, top 60 Valve cone
17 Connecting piece 61 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 Backing ring 152 Check valve
22 O-ring 153 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
7.50.14
copyright by
MJFCIFSS
Fig. 6 Control axle 4 with auxiliary block and integrated cooler and tank preload valves
7.50.15
copyright by
MJFCIFSS
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 bet-
ween 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-cont-
rolled) 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 val-
ves is identical with that of the primary pressure-relief valves.
The pressure settings are however significantly higher than those of the primary pressure-relief val-
ves.
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 Description of functions
5.3.1 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
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 Main cone 11 Piston seal
4 Pilot control cone 12 O-ring
7 Lock nut 15 O-ring
7.50.17
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MJFCIFSS
6 Suction valves 135/136
The suction valves (i.e. feeder valves / check valves) are mainly used in conjunction with rotating con-
sumers.
The risk of insufficient oil, i.e. cavitation, in oil motors is greatest when there are delays in the opera-
tion 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.
6.1.1 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 th-
rough the bore T to the respective side of the consumer A / B.
7.50.18
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MJFCIFSS
Fig. 8 Suction valves 135/136
1 Valve insert 33 O-ring

3 Main cone 34 Backing ring
6 Screw 35 O-ring
31 Piston seal
7.50.19
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MJFCIFSS
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-pres-
surisation).
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 re-
installed 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
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 m tolerance. This means that spools supplied for replacement usually have
a tolerance of 8-10 m, 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 in-
formation 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.
7.50.21
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MJFCIFSS
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 al-
lows 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 Accessory kit AHS 12
7.50.22
copyright by
MJFCIFSS
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.
7.50.23
copyright by
MJFCIFSS
Fig. 11 Hydraulic diagram of the auxiliary axle AHS 12
100 Compact control block 120 Primary pressure-relief valve

115 Auxiliary control valve block 143 Secondary pressure-relief valve with addi-
tional pressure stage
116 Spool / kit AHS 12 144 Secondary pressure-relief valve
The design and function of the auxiliary axle AHS corresponds to that of the working axles, (see "De-
sign of the control valve block", page 3) and see page 3.
7.50.24
copyright by
MJFCIFSS
Fig. 12 Sectional drawing of auxiliary axle AHS 12
12 Control lid, bottom 115 Auxiliary control valve block (low pressure)
13 Control lid, top 116 Spool AHS12
24 Spring pack, complete 143 Secondary pressure-relief valve with additional pres-
sure stage, hydraulic hammer A9
27 Regulation spring 144 Secondary pressure-relief valve, kit AHS B9
28 Spring plate 151 Load-holding valve
29 Lock washer 152 Check valve
31 Allen head screw 157 O-ring
32 Washer 158 Cone / load-holding valve
33 O-ring 159 Pressure spring / load-holding valve
7.50.25
copyright by
MJFCIFSS
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 - se-
condary 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 pres-
sure 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 con-
nections to a pre-set value.
As the pressure valves in the hydraulic system must be able to cater for great flows of oil, our machi-
nes 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 Pressure and feeder valve 143
7.50.26
copyright by
MJFCIFSS

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
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
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
7.50.27
copyright by
MJFCIFSS
7.50.28
copyright by
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 con-
tains 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
7.60.1
copyright by
MJFCIFSS
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: A 312 Litronic A 314 Litronic A 316 Litronic

Type 719 635 715 / 716
Construction from sn.12363 M7-1442-20 from sn. 2001 M7-1340-20 from sn. 2001 M7-1340-20
from sn.16275 M7-1442-31 from sn.11820 M7-1340-22 from sn.11822 M7-1340-22
from sn.11814 M7-1340-23 from sn.12741 M7-1340-23
from sn.16215 M7-1340-31 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. 2001 M7-1433-20 from sn. 2001 M7-1433-20
from sn.15864 M7-1443-31 from sn.12734 M7-1433-21 from sn.12734 M7-1433-21
from sn.15964 M7-1433-31 from sn.15964 M7-1433-31
Spool Unit 220 240 260 160 280 120

Boom Stick Bucket Travel Support Slew-
cylinder cylinder cylinder motor cylinder ing gear
Ext. Retr. Ext. Retr. Ext. Retr. Ext. Retr.
width
Consumer connec- () 3/4 3/4 3/4 3/4 3/4 1/2
tion A/B
piston rod mm 25 25 25 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 mm 17.4 17.2 17.3 17.5 15.9 16.0 16.7 15.8 15.5 16.3
A 312 - A 316 14.0 13.6 14.5 14.3 13.2 13.0 12.9 13.0 13.0 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 l/min 220 90 220 150 180 100 120 75 65 120
A 312 Speeder l/min 220 90 220 150 180 100 200 75 65 120
A 314 l/min 220 90 220 150 180 100 120 75 65 120
A 316 l/min 220 90 220 150 180 100 120 75 65 120
314/316 Speeder l/min 220 90 220 150 180 100 200 75 65 120
A 316 Industry l/min 300 70 300 110 225 175 150 220 190 120
Restr. check valve
at connection a / b mm 0.8# 0.8 - - 0.8 - 0.8
Leak oil max. cm3/min 60 60 60 60 60 60
C
at oil temperature 50 50 50 50 50 50
# from index 23 = diameter 0.6 mm sn. = Serial number
7.60.2
copyright by
MJFCIFSS
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: R 313 Litronic R 317 Litronic

Type 790 790
standard model from sn. 27752 M7-1748-30 from sn. 18161 M7-1466-31
Spool Unit 220 240 260 160 180 120

Boom Stick Bucket Drive Drive Slew-
cylinder cylinder cylinder motor motor ing gear
Ext. Retr. Ext. Retr. Ext. Retr.
width
Consumer connec- () 3/4 3/4 3/4 3/4 3/4 1/2
tion A/B
piston rod mm 25 25 25 25 25 25
Piston stroke mm 9.0 9.0 9.0 9.0 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 13.2 13.0 14.5 14.5 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
p2bar 0.5 mm*** bar 20.6 20.6 20.6 20.6 20.6 20.6 20.6 20.6 20.6
Qn (A)/Qn(B)
R 313 l/min 195 85 250 150 210 90 125 125 140
R 317 220 90 220 150 180 100 125 125 120
Restrictor check
valve at connection
a/b mm 0.6 0.6 0.8 0.8 - - 0.8 0.8 0.8
Leak oil max. cm3/min 60 60 60 60 60 60
at oil temperature C 50 50 50 50 50 50
* 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 p = nominal value
7.60.3
copyright by
MJFCIFSS
General data of R 313 / R 317 Litronic control block
7.60.4
copyright by
MJFCIFSS
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 sys-
tem
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 com-
pact block.
7.60.5
copyright by
MJFCIFSS
4.2 Control block for A 312 - 316 and components
7 Check valve (3.5 bar) 167 Restrictor check valve

8 Preload valve (7.0 bar) 220 Spool / boom cylinder
100 Compact control valve block 5 x 221 Secondary pressure-relief valve A3
102 Pressure balance / minimum flow 222 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 Restrictor check valve 247 Restrictor check valve
110 Mounting plate 260 Spool / bucket cylinder
111 Allen head screw 261 Secondary pressure-relief valve A4
120 Spool / slewing gear 262 Secondary pressure-relief valve B4
122 Inlet pressure balance 264 Pressure balance
123 Check valve 280 Spool / support
127 Restrictor check valve 281 Screw plug / dummy cartridge
134 Control lid 284 Pressure balance
135 Allen head screw 334 Control lid
140 Screw plug 369 Screw plug
160 Spool / chassis right 373 Screw plug
161 Suction valve 810 Mounting plate
162 Suction valve 811 Allen head screw
164 Pressure balance
7.60.6
copyright by
MJFCIFSS
Fig. 2 Control valve block for A 312 - A 316 - front and rear view
7.60.7
copyright by
MJFCIFSS
7 Check valve (3.5 bar) 164 Pressure balance (directly controlled)

8 Preload valve (7.0 bar) 167 Restrictor check valve
41 Measuring point MP 220 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 224 Pressure balance (direct / pilot-control-
controller) led*)
103 Pressure balance (remaining flow control- 227 Restrictor check valve
ler)
104 Pressure cut-off valve 240 Spool / stick cylinder
105 Primary pressure-relief valve 241 Secondary pressure-relief valve / retract
106 Shift valve / Qmax Regulating motor 242 Secondary pressure-relief valve / extend
107 Shuttle valve 244 Pressure balance (directly controlled)
108 Restrictor (LS central nozzle) 247 Restrictor check valve
109 Restrictor check valve 260 Spool / bucket cylinder
120 Spool / slewing gear 261 Secondary pressure-relief valve / retract
122 Inlet pressure balance (supply pressure 262 Secondary pressure-relief valve / extend
balance)
123 Check valve 264 Pressure balance (directly controlled)
127 Restrictor check valve 280 Spool / chassis left
160 Spool / travel drive 281 Suction valve
161 Suction valve 284 Pressure balance (directly controlled)
162 Suction valve
* from index 31, see Tab. 2, pilot-controlled
(directly controlled pressure balance: see
items 244 / 264)
7.60.8
copyright by
MJFCIFSS
Fig. 3 Hydraulic diagram of LSC control block for A 312 - A 316
7.60.9
copyright by
MJFCIFSS
Fig. 4 Exploded view of control block for A 312 - 316
100 Compact control block 169 Screw plug

102 Pressure balance / minimum flow (LS outlet) 170 Cone / load-holding valve
103 Residual flow pressure balance (unloading 171 Pressure spring / load-holding valve
valve)
104 Pressure cut-off valve 172 Screw plug
105 Primary pressure-relief valve 220 Spool / boom
110 End plate 221 Spring plate
111 Allen head screw 222 Secondary pressure-relief valve
120 Control axle / slewing gear 223 Pressure spring
130 O-ring 224 Piston / pressure balance (pilot-con-
trolled)
132 Regulation spring 227 Restrictor check valve
134 Control lid 240 Spool / stick
135 Allen head screw 242 Secondary pressure-relief valve
140 Screw plug 244 Piston / pressure balance (directly
controlled)
160 Spool / travel drive 247 Restrictor check valve
162 Suction valve 260 Spool / bucket
164 Piston / pressure balance (directly controlled) 262 Secondary pressure-relief valve
165 Spring / pressure balance 264 Piston / pressure balance (directly
controlled)
7.60.10
copyright by
MJFCIFSS
Design of R 317 control block
166 O-ring 280 Spool / support

167 Restrictor check valve 281 Screw plug
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 sys-
tem
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 com-
pact block.
7.60.11
copyright by
MJFCIFSS
5.2 Control block R 317 and components
7 Check valve (3.5 bar) 180 Spool / chassis left

8 Preload valve (7.0 bar) 181 Suction valve
100 Compact control valve block 5 x 182 Suction valve
102 Pressure balance / minimum flow 184 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 Restrictor check valve 240 Spool / stick cylinder
110 Mounting plate 241 Secondary pressure-relief valve A5
111 Allen head screw 242 Secondary pressure-relief valve B5
120 Spool / slewing gear 244 Pressure balance
122 Inlet pressure balance 247 Restrictor check valve
123 Check valve 260 Spool / bucket cylinder
127 Restrictor check valve 261 Secondary pressure-relief valve A4
134 Control lid 262 Secondary pressure-relief valve B4
135 Allen head screw 264 Pressure balance
140 Screw plug 334 Control lid
160 Spool / chassis right 369 Screw plug
161 Suction valve 373 Screw plug
162 Suction valve 810 Mounting plate
164 Pressure balance 811 Allen head screw
7.60.12
copyright by
MJFCIFSS
Fig. 5 Control valve block for R 317 - front and rear view
7.60.13
copyright by
MJFCIFSS
7 Check valve (3.5 bar) 167 Restrictor check valve

8 Preload valve (7.0 bar) 180 Spool / chassis left
41 Measuring point MP 181 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 187 Restrictor check valve
controller)
103 Pressure balance (remaining flow control- 220 Spool / boom cylinder
ler)
104 Pressure cut-off valve 221 Secondary pressure-relief valve / extend
105 Primary pressure-relief valve 222 Secondary pressure-relief valve / retract
106 Shift valve / Qmax Regulating motor 224 Pressure balance (pilot-controlled)
108 Restrictor (LS central nozzle) 240 Spool / stick cylinder
109 Restrictor check valve 241 Secondary pressure-relief valve / retract
120 Spool / slewing gear 242 Secondary pressure-relief valve / extend
122 Inlet pressure balance (supply pressure 244 Pressure balance (directly controlled)
balance)
123 Check valve 247 Restrictor check valve
127 Restrictor check valve 260 Spool / bucket cylinder
160 Spool / chassis right 261 Secondary pressure-relief valve / retract
161 Suction valve 262 Secondary pressure-relief valve / extend
162 Suction valve 264 Pressure balance (directly controlled)
164 Pressure balance (directly controlled)
7.60.14
copyright by
MJFCIFSS
Fig. 6 Hydraulic diagram of LSC control valve block for R 317
7.60.15
copyright by
MJFCIFSS
Fig. 7 Exploded view of control valve block for R 317
100 Compact control block 170 Cone / load-holding valve

102 Pressure balance / minimum flow (LS outlet) 171 Pressure spring / load-holding valve
103 Residual flow pressure balance (unloading valve) 172 Screw plug
104 Pressure cut-off valve 180 Spool / chassis left
105 Primary pressure-relief valve 182 Suction valve
110 End plate 184 Piston / pressure balance (directly
controlled)
111 Allen head screw 187 Restrictor check valve
120 Spool / slewing gear 220 Spool / boom
131 Spring plate 222 Secondary pressure-relief valve
132 Regulation spring 223 Pressure spring
134 Control lid 224 Piston / pressure balance (pilot-con-
trolled)
135 Allen head screw 225 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
7.60.16
copyright by
MJFCIFSS
Functional description (short description)
167 Restrictor check valve 262 Secondary pressure-relief valve

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 regu-
lating 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 va-
riable displacement pump through 103 to the tank.
6.2 Working position, (see Fig. 16, page 29)
6.2.1 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 pro-
portion to the LS pressure), i.e. the consumer with the highest load pressure determines the LS pres-
sure. 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 170-
172 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 con-
sumer.
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.
7.60.17
copyright by
MJFCIFSS
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 Spool / chassis right / travel drive 241 Secondary pressure-relief valve
161 Suction valve 242 Pressure-relief valve / stick
162 Suction valve 244 Pressure balance, directly controlled
164 Pressure balance, directly controlled 260 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
* only in A machines/R machines
7.60.18
copyright by
MJFCIFSS
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 O-ring 107 Shuttle valve
4 Screw plug 108 LS central nozzle ( 1.6 mm)
5 Shim 109 Restrictor check valve
6 Pressure spring 210 Valve seat
7 Check valve (cooler) 211 Restrictor bolt
8 Check valve (tank) 219 Valve seat
100 Compact block 275 Screw plug
102 Pressure balance / minimum flow (flow control- 221 Spring plate
ler)
103 Residual flow pressure balance (unloading 222 Pressure spring
valve)
7.60.19
copyright by
MJFCIFSS
Fig. 10 Hydraulic diagram: input section - control valve block
6 to oil cooler 100 Compact block

7 Check valve (3.5 bar) 102 Pressure balance / minimum flow (flow
controller)
8 Check valve (7 bar) 103 Residual flow pressure balance (unloa-
ding valve)
20 from variable-displacement pump 104 Pressure cut-off valve
26 to LS regulator 105 Primary pressure-relief valve
41 Measuring point MP 107 Shuttle valve
45 Measuring point LS 108 LS central nozzle
7.1 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 preloa-
ded 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 con-
sumer.
The priority of the return flow of the oil through the cooler is implemented by means of different pre-
loads 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 addi-
tional 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 (con-
tamination, 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
Fig. 11 Sectional drawing of inlet elements in the oil return section
1 Cone 8 Preload valve, complete (7.0 bar)

2 Pressure spring 25 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 Pressure spring P connection / pump pressure
7 Check valve, complete (3.5 bar) MP Measuring connection / pump pressure
T Tank channel
7.60.21
copyright by
MJFCIFSS
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 (ap-
prox. 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 replace-
ment. 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 pres-
sure 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 redu-
cing 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 volu-
mes 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
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 275 Screw plug
controller)
For details, see Fig. 13
103 Piston/pressure balance (unloading valve) 321 Spring plate
104 Pressure cut-off valve 322 Pressure spring
105 Primary pressure-relief valve LS LS signal from the consumer with the
highest load
107 Shuttle valve P Pump pressure
108 LS central nozzle T Tank channel
7.60.23
copyright by
MJFCIFSS
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 Sectional drawing of the inlet element "residual pressure balance and external shuttle val-
ve"
100 Compact block 16 Backing ring/pressure balance

102 Minimum flow pressure balance, com- 103 Residual flow pressure balance (unloading
plete valve)
1 Valve insert/pressure balance 104 Pressure cut-off valve
2 Piston/pressure balance 107 Shuttle valve
3 Pressure spring/pressure balance 108 LS central nozzle
4 Screw plug/pressure balance 211 Restrictor bolt
14 O-ring/pressure balance 321 Spring plate
7.60.24
copyright by
MJFCIFSS
15 O-ring/pressure balance 322 Pressure spring
7.4 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 propaga-
tion 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 beha-
viour.
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 par-
ticularly important where several consumers are run to their limit and the fully opened pressure ba-
lances feed oil into the LS line.
7.60.25
copyright by
MJFCIFSS
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, load-
sensing and/or power regulation are disabled.
Once a consumer reaches its max. permissible operating pressure, the cut-off valve is actuated, re-
lieving 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 maxi-
mum 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 Pressure cut-off valve 104
1 Valve insert 11 Backing ring

5 Spring plate 13 Backing ring
7 Washer 15 O-ring
10 Circlip 104 Pressure cut-off valve
7.60.26
copyright by
MJFCIFSS
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 seconda-
ry 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 inde-
pendent 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 ori-
ginal 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 m tolerance. This means that the spools supplied for replacement usually
have a tolerance range of 8-10 m, 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 spe-
cified 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.
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The tolerance is indicated on the front face /control lid of the control block (e.g. 10 = 10 m). 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 in-
formation 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 Control axles with regulating springs and control lid at the control valve block
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Fig. 16 Control axles of the compact control valve block (left) and travel gear (right)
100 Compact control block 221/222 Secondary pressure-relief valves

134 Control lid 224 Pressure balance, pilot-controlled
160 Spool / chassis right 227 Restrictor check valve
161/162 Suction valves chassis right 240 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 Pressure spring / load-holding valve 260 Spool / bucket
180 Spool / chassis left 261/262 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
Control lid 134
* in R machines only
** Sectional drawing, (see Fig. 19, page 32)
9 Control lid 134
Fig. 17 Control lid 134
1 Cap nut 167 Restrictor check valve / travel drive (A)

2 O-ring 167 Restrictor check valve / travel right (R)
3 Lock nut 187 Restrictor check valve / travel left (L)
4 Adjusting screw / stroke limitation 227 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 dis-
placed 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 dam-
pened.
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 adjus-
ting 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
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MJFCIFSS
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 Cap nut 167 Restrictor check valve

2 O-ring 180 Spool / chassis left*
3 Lock nut 187 Restrictor check valve*
4 Adjusting screw / stroke limitation 220 Spool / boom
5 Shuttle 227 Restrictor check valve
6 Orifice 240 Spool / stick
100 Control valve block 247 Restrictor check valve
130 O-ring 260 Spool / bucket
131 Spring plate 280 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
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MJFCIFSS
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 regu-
lator. 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 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
7.60.32
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MJFCIFSS
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 ba-
lance and also acts through the internal channels in the pressure balance on the rear of the load-
holding 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 con-
sumer 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 con-
nection 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 regu-
lator (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 re-
main 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
10.3 Low pressure
10.3.1 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-sec-
tion 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 ori-
fices. 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 diffe-
rence 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 re-
quested 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 re-
spective open cross-sections.
7.60.34
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MJFCIFSS
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 (pul-
ling) loads. In such a case, the consumer is controlled in relation to the actual load, via the outlet ori-
fices.
Fig. 22 Pressure balance in position "spool closed"
a no LS signal 160 Spool / travel

b LS signal 164 Piston
100 Control valve block
7.60.35
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MJFCIFSS
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 pressu-
re balance in the LUDV system. Its function therefore corresponds to the basic functions of the direct-
ly 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 Pilot-controlled pressure balance (front view and sectional drawing)
1 Pilot control piston 165 Pressure spring

4 Spring plate 224 Pressure balance (pilot-controlled)
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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 consu-
mer 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 Pressure spring R Regulating orifice
100 Control valve block pch High pressure (LS)
220 Spool pcl Low pressure
224 Pressure balance
7.60.37
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MJFCIFSS
11.1.2 High pressure section:

The pilot control piston 1 is shifted against pressure spring 2, thus relieving the spring side of the pres-
sure balance main piston. At the same time, the consumer with the highest load pressure is connec-
ted to the LS pressure, which in turn acts on the LS controller of the working pump.
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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MJFCIFSS
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 at-
tachments 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 re-
spective 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 ex-
tended 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.

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 pres-
sure 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
pressure springs 8 / 9 so that the required amount of oil can flow through the bore T and the connec-
tion P to the respective side of the consumer.
7.60.39
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MJFCIFSS
Pressure-relief and feeder valves
Fig. 27 Pressure and feeder valve 105 / 221 - 262
1 Housing 9 Pressure spring

2 Valve insert 10 Safety cap
3 Main cone 11 Piston seal
4 Pilot control cone 12 O-ring
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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 consu-
mers.
The risk of insufficient oil, i.e. cavitation, in oil motors is greatest when there are delays in the opera-
tion 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.
13.1.1 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 th-
rough the bore T to the respective side of the consumer A / B.
7.60.41
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MJFCIFSS
Feeder valves 161 / 162 / 181 / 182
Fig. 28 Feeder valves 161 / 162 / 181 / 182

3 Main cone 34 Backing ring
6 Screw 35 O-ring
31 Piston seal
7.60.42
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MJFCIFSS
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 (so-
lenoid 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).
7.60.43
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MJFCIFSS
Shift valve for Qmin shifting (fast run) of the regulating motor 106 (in R models only)
Fig. 29 Sectional drawing of shifting valve (Qmin shifting)
1 Connecting piece 11 O-ring

2 Bushing 17 Backing ring
3 Piston guide 18 O-ring
4 Pressure spring 50 from the control oil unit
5 Spring plate 100 Compact control block
6 Shifting piston 106 Shift valve, complete
7 Piston 200 from/to travel motor left
8 Threaded stud 201 from/to travel motor right
14.2 Repairs
In the event of malfunction, the valve 106 can be screwed out and inspection for damage and conta-
mination.
7.60.44
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MJFCIFSS
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.
Proceed as follows: Unscrew the breather filter on the hydraulic tank with 1 turn (slow de-pres-
surisation).
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 flan-
ges, 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 re-
installed 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.
7.60.45
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MJFCIFSS
Maintenance
15.4 Tightening torques for the valves and screw plugs of control valve block 100
Pressure balance 102 120 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 10 Nm Screw plug 278 10 Nm
Allen head screw 111 70 Nm Allen head screw 320 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 20 Nm Screw plug 369 90 Nm
Screw plug 168/169 200 Nm Screw plug 373 120 Nm
Load-holding valve 172 100 Nm Screw plug 475 30 Nm
Suction valves 161/162/181/182 100 Nm Screw plug 476 60 Nm
Valve seat 210/219 120 Nm Screw plug 490 3.5 Nm
Pressure-relief valves 221 - 262 100 Nm Screw plug 811 55 Nm
Check valve 233/234 10 Nm
15.5 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 instruc-
tions). To test the secondary pressure-relief valves, increase the set value of the pressure cut-off val-
ve 104 to a value above the expected peak (see adjustment protocol and guidelines for the hydraulic
system, group 6).
7.60.46
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MJFCIFSS
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 con-
sumers 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 Hydraulic diagram of slewing gear element 120 with TC valve 125
17.2 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 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.
7.60.47
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MJFCIFSS
Fig. 31 Slewing gear segment
100 Compact control block 332 Pressure spring

120 Spool / slewing gear segment 333 Washer
122 Inlet/supply pressure balance 334 Control lid
123 Check valve 335 Allen head screw
125 TC valve 365 Pressure spring
126 Restrictor ( 1.5 mm) 369 Screw plug
127 Restrictor check valve 371 Pressure spring
128 Shuttle valve 372 O-ring
129 Restrictor ( 1.5 mm) 373 Screw plug
130 Nozzle ( 0.9 mm) 475 Screw plug
131 Nozzle ( 1.5 mm) 810 End plate
132 Cone 811 Allen head screw
330 O-ring 999 Seal kit
331 Spring plate
7.60.48
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MJFCIFSS
17.3 Functional description of slewing gear spool
17.3.1 Priority of slewing gear

In a single-circuit LUDV system, all consumers are arranged in parallel and supplied by a single wor-
king pump. In the LUDV system, the slewing gear is always given priority. It can be controlled inde-
pendently 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 ac-
tual 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 (correspon-
ding 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 cho-
sen 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 ta-
ken 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 ad-
missible pslewing gear with respect to pcontrol pressure and, thus, the available torque. The correspon-
ding 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 ro-
tary motion.
7.60.49
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MJFCIFSS
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 pslew-
ing 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 los-
ses. 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 sup-
plied to the slewing gear motor increase when pslewing gear drops until the required pressure accor-
ding 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 con-
sumer connections A and B.
The valve 125 is factory-set and cannot be adjusted. Should modifications become necessary, pro-
ceed 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 inspec-
tion (contamination, spring break) or replacement.
7.60.50
copyright by
MJFCIFSS
Fig. 32 Sectional drawing of slewing-gear element
120 Spool / slewing-gear segment 372 O-ring

122 Inlet/supply pressure balance 373 Screw plug
127 Restrictor check valve 475 Screw plug
130 Nozzle ( 0.9 mm) D1 Supply gauge orifice p-A01 or p-B01
131 Nozzle ( 1.5 mm) D2 Outlet orifice A01 - T or B01 - T
132 Cone (load-holding function) pV 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
7.60.51
copyright by
MJFCIFSS
7.60.52
copyright by
MJFCIFSS
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
7.60.53
copyright by
MJFCIFSS
LSC auxiliary control axles
19 LSC auxiliary control axles
M7 - 205 M7 - 205
M7 - 205
Secondary valve Secondary valve
Product SX/14-1X 2 axles
without additional with additional
Unit (AHS 1 + AHS 11)
pressure stage pressure stage
Contained in: AS1 AHS 1 AHS11 AHS 12

Spool 540 500 510 500 and 510
for Grapple rotator Boom Hydraulic ham- All auxiliary at-
adjusting device mer tachments
left right Extend Retract Extend Retract
Nom. block width () 14 20 20 20
Consumer connec- (G3/4) (SAE /4) (SAE 3/4) (SAE 3/4)
tion
piston rod mm 18 25 25 25
Piston stroke mm 8 8 11 11 11 11 11
Setting value Y see AHS 1 / AHS
A 312 - R 317 mm 15.6 15.6 17.4 17.4 17.4 17.4 11
14.7(^) 14.7(^ 14.7(^) 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 mm - 1.0 1.0
at connection b mm - 1.0 1.0
Max. leak oil cm3/min 60 60 see AHS 1 / AHS
at load pressure bar 150 150 11
at oil temperature C 50 50
Tab. 3 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 / 514 160 Nm
Allen head screws 111 70 Nm Restrictor check valve 507/517 20 Nm
Allen head screws 122 110 Nm Pressure-relief valve 541 542 90 Nm
Allen head screw 135 10 Nm Allen head screws 811 55 Nm at AS1
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 p = nominal value
7.60.54
copyright by
MJFCIFSS
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-moun-
ted to the control valve block adjacent to the slewing gear element. The above devices for move-
ments are supplied with oil by the main working pump.
The individual segment is equipped with an electromagnetic-hydraulic control of the spool. The pro-
portional 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 ba-
lance 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
7.60.55
copyright by
MJFCIFSS
Fig. 35 Auxiliary control axle AS1
540 Spool / AS 1 544 Pressure balance

541 Secondary pressure-relief valve Y22 Solenoid valve / grapple rotation left
542 Secondary pressure-relief valve Y23 Solenoid valve / grapple rotation right
7.60.56
copyright by
MJFCIFSS
Fig. 36 Sectional drawing of auxiliary control axle AS1
27 Cone / load-holding valve 541 Secondary pressure-relief valve

28 Pressure spring / L 542 Secondary pressure-relief valve
29 Screw plug 544 Pressure balance
30 O-ring 810 End plate
31 Seal-Lock collar nut 811 Allen head screw
32 Adjusting screw / stroke limitation Y22 Solenoid valve / grapple rotation left
33 Pressure spring Y23 Solenoid valve / grapple rotation right
540 Spool / auxiliary control block AS1
7.60.57
copyright by
MJFCIFSS
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 connec-
tions 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 mo-
difying 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 bet-
ween 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.

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.

The design of the individual segment for the working movement 'hydraulic adjustment of boom hy-
draulic 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.
7.60.58
copyright by
MJFCIFSS
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
7.60.59
copyright by
MJFCIFSS
Fig. 37 Auxiliary control axles for AHS 1, AHS 11 and AHS 12
7.60.60
copyright by
MJFCIFSS
Fig. 38 Auxiliary axles AHS 1, AHS 11 and AHS 12
7.60.61
copyright by
MJFCIFSS
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 Cone 501 Pressure and feeder valve, 1-step
28 Pressure spring 502 Pressure and feeder valve, 1-step
29 Screw plug 504 Pressure balance
34 O-ring 507 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 Pressure spring 517 Restrictor check valve
100 Compact block 520 AHS 12
110 End plate 999 Seal kit
* various lengths (depend on the number of auxiliary elements)
7.60.62
copyright by
MJFCIFSS
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 - se-
condary 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, lar-
ger 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.
Fig. 40 Pressure and feeder valve 511 (2-step)
7.60.63
copyright by
MJFCIFSS

The pressure P built up in the consumer circuit acts on the front face of the main cone 5 and, through
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
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
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 Sectional drawing of pressure and feeder valve 511
7.60.64
copyright by
MJFCIFSS
Fig. 42 Pressure and feeder valve with additional pressure stage (2-step)
1 Housing 27 O-ring
4 Screw 31 Piston seal
5 Main cone 32 O-ring
6 Bushing 33 O-ring
7 Pressure spring 34 Backing ring
8 Piston 35 O-ring
9 Shifting piston 37 O-ring
10 Lock nut 511 Pressure-relief valve, 2-step, complete
11 Lock nut 999 Seal kit
15 Pilot control cone D1 Bore
18 Pressure spring D2 Ring face
21 Shim X Connection for control pressure
7.60.65
copyright by
MJFCIFSS
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 con-
nects 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 undercar-
riage.
The rotor 1 is mounted above the rotor of the 5x rotary connection (high pressure) to the uppercarri-
age.
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
7.75.1
copyright by
MJFCIFSS
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 con-
nection 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
Sealing of the 1x rotary connection, see Fig. 3 and Fig. 4
Fig. 2 Installation and dismantling of the rotary connection
1 Rotor 20 Rotary connection 5x, complete

2 Stator 25 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
7.75.3
copyright by
MJFCIFSS
Exploded view
4 Exploded view
Fig. 3 Exploded view of the rotary connection
1 Rotor 11 Quad ring

2 Stator 12 V seal
3 Thrust washer 999 Seal kit
4 Nut
7.75.4
copyright by
MJFCIFSS
Sectional drawing
5 Sectional drawing
Fig. 4 Sectional drawing of the rotary connection
7.75.5
copyright by
MJFCIFSS
Sectional drawing
7.75.6
copyright by
MJFCIFSS
Design
1 Design
The stator 2, the pipe coupling 4 and the flange 5 with the connections 1-6 are connected to the un-
dercarriage via the stator of the 7 x rotary connection (high pressure). The rotor 1 with the connec-
tions 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 coup-
ling 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.
7.76.1
copyright by
MJFCIFSS
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 con-
nection. 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
Removal and installation
Fig. 2 Installation and dismantling of the rotary connection
4 Pipe coupling 28 Retaining washer

5 Flange 29 Hex nut
6 Hollow screw 30 Driver
7 Seal washer 32 Allen head screw
9 Tooth lock washer 33 Retaining washer
25 Rotary connection 6x, complete 40 Rotary connection 7x, complete
27 Allen head screw 44 Lid
7.76.3
copyright by
MJFCIFSS
Exploded view of previous design
4 Exploded view of previous design
Fig. 3 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 Flange 21 V seal
6 Hollow screw 22 Rotor seal
7 Seal washer 25 Rotary connection
7.76.4
copyright by
MJFCIFSS
Sectional drawing of previous design
5 Sectional drawing of previous design
7.76.5
copyright by
MJFCIFSS
Exploded view of new design
6 Exploded view of new design
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 Flange 21 V seal
6 Hollow screw 22 Rotor seal
7 Seal washer 25 Rotary connection
A modified design from 08 / 2002
7.76.6
copyright by
MJFCIFSS
Sectional drawing of modified design
7 Sectional drawing of modified design
7.76.7
copyright by
MJFCIFSS
Sectional drawing of modified design
7.76.8
copyright by
MJFCIFSS
Design
1 Design
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. Spe-
cial 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.
7.77.1
copyright by
MJFCIFSS
Connection 0 Leak oil

Return of the leak oil from the travel motor to the transmission
Connection 1 Travel motor, right
Supply from the control block connection B1 to the travel motor (right, reverse
motion)
Connection 2 Travel motor, left
Supply from the control block connection B2 to the travel motor (left, reverse
motion)
Connection 3 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)

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 con-
nection 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
Fig. 2 Installation position of rotary connection
1 Rotary connection 5x, complete 32 Hex head screw

17 Hex head screw 33 Retaining washer
18 Retaining washer 34 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 Pressure line 50 Undercarriage
25 Fitting
7.77.3
copyright by
MJFCIFSS
Exploded view
4 Exploded view
3 Cover 11 Rotor
4 Screw plug 15 Felt washer
5 Retaining washer 16* 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.
7.77.4
copyright by
MJFCIFSS
Sectional drawing
5 Sectional drawing
7.77.5
copyright by
MJFCIFSS
Sectional drawing
7.77.6
copyright by
MJFCIFSS
Design
1 Design
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. Spe-
cial 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.
2.1 Model A 309 - A 311 Litronic

Recycling of leak oil from travel motor and auxiliary gearbox
7.78.1
copyright by
MJFCIFSS
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)
Supply from control block connection B8 to travel motor (forward)
Supply from control block connection B3 to support cylinders (extend)
Connection 5 Steering
Supply from Servostat to steering cylinder (travel, right)
Supply from Servostat to steering cylinder (travel, left)
2.2 Model A 312 - A 316 Litronic

Recycling of leak oil from travel motor and auxiliary gearbox
Supply from control block connection A2 to travel motor (reverse)
Supply from control block connection B1 to support cylinders (retract)
Supply from control block connection B2 to travel motor (forward)
Supply from control block connection A1 to support cylinders (extend)
Supply from Servostat to steering cylinder (travel, right)
Supply from Servostat to steering cylinder (travel, left)
7.78.2
copyright by
MJFCIFSS

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 con-
nection 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 atten-
tion to marks you made earlier.
Re-install all other lines and parts you may have removed before.
7.78.3
copyright by
MJFCIFSS
Fig. 2 Installation position of rotary connection
3 Lid 115 Rotary connection 6x, complete

10 Rotary connection 5x, complete 116 Flange
12 Hex head screw 117 Seal
17 Hex head screw 118 Tooth lock washer
18 Retaining washer 119 Hollow screw
19 Driver 120 Allen head screw
26 Retaining washer 121 Retaining washer
27 Allen head screw 122 Hex nut
125 Undercarriage
7.78.4
copyright by
MJFCIFSS
Exploded view
4 Exploded view
3 Lid 11 Rotor
4 Screw plug 12 Hex head screw
5 Screw plug 13 Stator
6 Retaining washer 15* Felt washer
7 Hex head screw 16# 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 * In models A 309 - A 312 from start of
of series production series production
in machine model A 314 from serial no. in machine model A 314 from serial no.
9972 9972
in machine model A 316 from serial no. in machine model A 316 from serial no.
9701 9701
B Version in models A 309 - A 311 from start # In models A 309 - A 311 from start of
of series production series production
in machine model A 312 - 316 from serial in machine model A 312 - 316 from serial
no. 17250 no. 17250
7.78.5
copyright by
MJFCIFSS
Sectional drawing
5 Sectional drawing
7.78.6
copyright by
MJFCIFSS
Service Manual TC valve
Purpose
TC valve
1 Purpose
The directly controlled 2-stage torque control valve allows the operator to continuously control the ad-
missible 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 ma-
nufacturer. In order to prevent actuation of the secondary valves - and the resulting losses - the high-
est 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.
2.1 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 pres-
sure 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 chan-
nel leading to tank connection T, respectively, also improve the fine-control and regulating behaviour
of the valve.
7.80.1
copyright by
MJFCIFSS
TC valve Service Manual
2.3 Setting the valve

The valve has a pre-determined fixed setting. Should modifications become necessary, proceed ac-
cording 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
copyright by
MJFCIFSS
Service Manual TC valve
Sectional drawing
3 Sectional drawing
Fig. 2 Sectional drawing and hydraulic schematic of TC valve
1 Housing 11 Shuttle valve 1.2 / 0.3 mm

2 Valve body 12 Restrictor 1.5 mm
3 Valve insert 13 Restrictor 0.9 mm
4 Piston guide 14 Stroke stop
5 Piston 16 O-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
7.80.3
copyright by
MJFCIFSS
TC valve Service Manual
Sectional drawing
7.80.4
copyright by
MJFCIFSS
Service Manual
SUBGROUP - INDEX
Section Group Type
Component arrangement 8.09.1 A 309 LI 20221-

A 311 LI 20222-
Component arrangement 8.10.1 A 312 LI 12363-

A 314 LI 2001-
A 316 LI 2001-
A 316 LI-IND 2001-
Component arrangement 8.17.1 R 313 LI 27752-

R 317 LI 18161-
Electrical system 8.20.9 A 309 LI 20221-

A 311 LI 20222-

A 311 LI 29270-

A 314 LI 2001-
A 316 LI 2001-
A 316 LI-IND 2001-

A 314 LI 20334-
A 316 LI 20340-
A 316 LI-IND 20340-

A 316 LI 28061-

A 316 LI 31134-
R 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 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-
BST excavator control system 8.70.1 A 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 313 LI 27752-
R 317 LI 18161-
Slip ring rotary connection 8.80.1 A 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 313 LI 27752-
R 317 LI 18161-
Directory of electric kits 8.100.1 A 312 LI 12363-

A 314 LI 2001-
A 316 LI 2001-
A 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 Push button / turn grapple

B19L Sensor transducer / left pilot control S8-S218 Switches, see Fig. 19
unit
B19R Sensor transducer / right pilot control S18-S422 Switches, see Fig. 17
unit
B40 Sensor transducer / travel S16-S398 Switches, see Fig. 18
B290 Sensor transducer left (kit) S32 Indicator switch, horn
B291 Sensor transducer right (kit) S44 Hazard light switch
E8 Cigarette lighter S63 Switch / offset boom bearing
H7-H336 Indicator lights see Fig. 17 S75 Switch / oscillating axle locking
device
H9 Horn S263 Switch / travel direction
H10 Buzzer S439L Switch button / split blade left
P6-P50 Displays / clock see Fig. 17 S439R Switch button / split blade right
A 309 LI 20221- 8.09.1

MJFCIFSS
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 S7 Safety switch

K63-K386 Relays on the distribution board (fig. 1-23) C Heating
Fig. 3 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)
S1 Code switch X838-3 Plug connection CAN bus / 2-pin
X834 Plug connection / 2-pin X839 Screw terminal / 3-pin
X835 Plug connection / 2-pin X973 Power socket (12V)
X836 Plug connection / 4-pin
8.09.2 A 309 LI 20221-

MJFCIFSS
E50 safety and power switch cabinet
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 - power (fig. 1-5)
Fig. 5 A127 printed circuit board - power
Termina1 5Plus after ignition F302 Fuses terminal 15, terminal 30, B3, S44
(7.5 A)
terminal 19Pre-heating F303 Fuse Y29 (7.5 A)
Terminal 30EPermanent plus (input) F332 Fuse M1, Y12 (25 A)
Terminal 30APermanent plus (output) 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 Fuse terminal 15, terminal 30 (50 A) K-A to K-ERelay / option
F301 Fuse K302, R60 (70 A)
A 309 LI 20221- 8.09.3

MJFCIFSS
Sensors / transducers
4 Sensors / transducers
Fig. 6 Fuel level sensor B1 (mounted on the fuel tank)
Fig. 7 Diesel engine, output side
B2 Temperature sensor / engine coolant Y12 Solenoid valve / excess fuel for starting
B7 Vacuum switch / air filter Y29 Solenoid valve / engine shut-down
B232 Temperature switch / excess fuel for star-
ting
8.09.4 A 309 LI 20221-

MJFCIFSS
Fig. 8 Coolant level sensor B3 (mounted on coolant / expansion tank)
Fig. 9 Hydraulic tank, bottom
B8 Switch / hydraulic oil temperature (indi- B285 Transducer / hydraulic oil temperature
cator light) (fan control)
HBGV block mounted on hydraulic tank (engine side)
Fig. 10 HBGV block mounted on hydraulic tank (engine side)
A HBGV block at unit B HBGV block at unit

A 309 to serial no. 29268, A 309 from serial no. 29269,
A 311 to serial no. 29169 A 311 from serial no. 29170
B10 Pressure switch / Parking brake Y55 Solenoid valve / first gear
Y6 Solenoid valve / parking brake Y60 Solenoid valve / parking brake
Y55 Solenoid valve / first gear
A 309 LI 20221- 8.09.5

MJFCIFSS
Fig. 11 Engine, seen from rear
B12 Transducer / engine speed B16 Switch / engine oil pressure
Fig. 12 Compact brake block located under the operator's cab
B20 Pressure switch / accumulator pres- B266 Proximity switch / oscillating axle automatic
sure
B60 Pressure switch / brake light S4 Switch / horn
Fig. 13 Boom cylinder with pressure switch, overload warning system B21 (kit)
8.09.6 A 309 LI 20221-

MJFCIFSS
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) P5 Operating hour meter
Fig. 16 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
A 309 LI 20221- 8.09.7

MJFCIFSS
Fuses
F313 5A Brake light

F314 3A Safety lever
F315 15 A Excavator control
F316 7.5 A Sensor control / console
F318 20 A Heating / air-conditioning system (kit - terminal 30)
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 15 A Reserve
F329 5A Servo control
F330 7.5 A AHS / AS1
F331 15 A Reserve
F336 15 A External fuse for lighting
F337 15 A Support / solenoid
F338 15 A Horn
F339 20 A A/c condenser (kit)
8.09.8 A 309 LI 20221-

MJFCIFSS
Overview of control console
6 Overview of control console
Fig. 17 Control console A (front right)
Indicating elements:
P6 Dial indicator / coolant temperature P50 Clock

P7 Dial indicator / fuel reserve
Indicator lights:
H7 Engine oil pressure H167 Forward travel
H11 Pre-heating H168 Reverse travel
H12 Battery charging H175 Engine overheating
H13 Air filter contamination H176 Oscillating axle automatic
H15 Hydraulic oil temperature H186 Offset boom bearing
A 309 LI 20221- 8.09.9

MJFCIFSS
H16 Overload warning system* H26 Quick change adapter*

H18 Coolant level H196 Scrap shear / sorting grapple*
H19 Indicator H311 Oscillating axle locking mechanism
H20 Parking brake H336 Water in fuel filter
H23 Accumulator pressure
* kit
Switches, potentiometers
R75 Speed adjustment S241 Hydraulic hammer

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. 18 Control console B (front centre)
S1 Pre-heating and start switch S92 Rotary potentiometer / air distribution

S16 Parking brake S93 Rotary potentiometer for heating-a/c
system
S20 Idle automatic S284 Heating-a/c system blower (4 speeds)
S35 Switch / servo control S318 A/c system*
S74 Immobiliser* S398 Reversing switch
* kit
() This switch has been removed without replacement, see service information 08-08-06/2006
8.09.10 A 309 LI 20221-

MJFCIFSS
Fig. 19 Control console C (rear right)
E8 Cigarette lighter S22 Work headlights, front, front

roof light*
F307-F343Fuses, see Fig. 20 S22-1 Rear roof light*
S8 Beacon* S61 Travel light
S11 Windscreen washer system S218 Roof window wiper*
S14 Windscreen wiper
* kit
Fig. 20 Fuses and relays, control console, rear right
F307 7.5A Parking light / tail light

F308 7.5A Right parking light / tail light
F309 7.5A Travel light, left
F310 7.5A Travel light, right
F311 15 A Windscreen wiper / washing system
F317 7.5A Beacon*
F323 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 20221- 8.09.11

MJFCIFSS
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* H192 Indicator light / dog walk steering
S309 Rotary switch / 4-wheel steering
7 Battery and battery main switch
Fig. 22 Battery compartment in uppercarriage, front right

e
F359 Fuse permanent ground clock (3 A) S9 Battery main switch

G2 Batteries
8.09.12 A 309 LI 20221-

MJFCIFSS
Generator / starter
8 Generator / starter
Fig. 23 Diesel engine, radiator side
G1 Alternator M1 Starter
9 Distribution board
Fig. 24 Distribution board with relays and buzzer, located at the control console, rear right
A 309 LI 20221- 8.09.13

MJFCIFSS
Distribution board
H27 Warning buzzer K375 Relay / kit*

K63 Relay / indicator K386 Relay / safety switch
K250 Relay / oscillating axle support K445 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 Ground
K370 Relay / terminal 15 servo
* kit
Fig. 25 Distribution board with plug connection located at the control console, rear right
X10 Housing recess* 2-pin X958 Housing recess* 21-pin

X957 Housing recess* 21-pin
*Recesses for plugs
8.09.14 A 309 LI 20221-

MJFCIFSS
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 Proportional solenoid valve / flow limitation
Y24 Solenoid valve / fast travel Y330 Solenoid valve / pump regulation
removed on machine A 309 from Sno 26291
and A 311 from Sno 27086
Y50 Proportional solenoid valve / power Y371 Solenoid valve / oscillating axle support
control
A 309 LI 20221- 8.09.15

MJFCIFSS
Solenoid valves
Fig. 28 Low-pressure control valve block AS1 and valve block for travel / offset boom bearing (lo-
cated at fuel tank)
Y22 Solenoid valve / grapple rotator Y63 Solenoid valve / grapple rotator
Y23 Solenoid valve / grapple rotator Y262 Solenoid valve / switchover bucket offset
boom bearing
Y62 Solenoid valve / travel forward
Fig. 29 Outrigger bearing at rear of undercarriage

et
Y217 Solenoid valve / left outrigger Y218 Solenoid valve / right outrigger
8.09.16 A 309 LI 20221-

MJFCIFSS
Solenoid valves
Fig. 30 Auxiliary solenoid valve below the control valve block
Y268 Solenoid valve / changeover Y299 Solenoid valve / AHS* additional pres-
AHS pilot control sure 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 20221- 8.09.17

MJFCIFSS
Solenoid valves
8.09.18 A 309 LI 20221-

MJFCIFSS
Control elements
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 S5 Push button / turn grapple
unit
B19R Sensor transducer / right pilot control S8-S218 Switches, see Fig. 25
unit
B40 Sensor transducer / travel S18-S422 Switches, see Fig. 21
B290 Sensor transducer left (kit) S16-S398 Switches, see Fig. 23
B291 Sensor transducer right (kit) S32 Indicator switch, horn
E8 Cigarette lighter S44 Hazard light switch
H7-H336 Indicator lights see Fig. 21 S63 Switch / offset boom bearing
H9 Horn S75 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 12363- 8.10.1

A 316 LI 2001- MJF C I F S S
A 316 LI-IND 2001-
R75 Potentiometer speed see Fig. 21 S* Switches for various kits

R76 Potentiometer / fine adjustment U16 Excavator control BST
Fig. 2 Installation of the printed circuit board A125 in the housing behind the left control console
in machine model A 312 from serial no. 20432, A 314 units to serial no. 20333 and A 316
units to serial no. 20339.
A 125 Printed circuit board potentiometer S7 Safety switch

K63-K386 Relays on the distribution board (fig. 1-23) C Heating
Fig. 3 Installation of the printed circuit board A125 without housing behind the left control con-
sole (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 C Heating

K63-K386 Relays on the distribution board (fig. 1-23) F Function box
S7 Safety switch
8.10.2 A 312 LI 12363-

MJF C I F S S A 316 LI 2001-
A 316 LI-IND 2001-
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.

V156-4 Blocking diode kit X839 Screw terminal / 3-pin
X835 Plug connection / 2-pin X974-4 Diode plug, 2-pin (kit)
A 312 LI 12363- 8.10.3

A 316 LI 2001- MJF C I F S S
A 316 LI-IND 2001-
Fig. 6 Installation of the fuse box and solenoid valves at the hydraulic tank
A127 Printed circuit board / power, see Fig. 7 Y63 Solenoid valve / reverse travel
E50 Safety and power switch cabinet Y268 Solenoid valve changeover adjusting
equipment / hammer (kit)
Y62 Solenoid valve / travel forward Y299 Solenoid valve pressure reduction (kit)
Fig. 7 Printed circuit board / powerA127
KL15 Plus after ignition F302 Fuses terminal 15, terminal 30, B3, S44
(7.5 A)
KL19 Pre-heating F303 Fuse Y29 (7.5 A)
KL30E Permanent plus (input) F332 Fuse M1, Y12 (25 A)
KL30A Permanent plus (output) F-A to F-HFuse / option
KL31 Ground K16-1 Relay / terminal 50
8.10.4 A 312 LI 12363-

MJF C I F S S A 316 LI 2001-
A 316 LI-IND 2001-
KL50 Engine start K288 Relay / terminal 15

F300 Fuse terminal 15, terminal 30 K-A to K-ERelay / option
(50 A)
F301 Fuse K302, R60 (70 A)
B2 Temperature sensor / engine coolant M1 Starter
A 312 LI 12363- 8.10.5

A 316 LI 2001- MJF C I F S S
A 316 LI-IND 2001-
B7 Vacuum switch / air filter Y12 Solenoid valve / excess fuel for starting
Y29 Solenoid valve / engine shut-down
B8 Switch / hydraulic oil temperature (indica- B285 Transducer / hydraulic oil temperature
tor light) (fan control)
8.10.6 A 312 LI 12363-

MJF C I F S S A 316 LI 2001-
A 316 LI-IND 2001-
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 Y55 Solenoid valve / 1st gear
Y6 Solenoid valve / parking brake
Fig. 14 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
Y55 Solenoid valve / 1st gear Y60 Solenoid valve / 2nd gear
B12 Transducer / engine speed B16 Switch / engine oil pressure
A 312 LI 12363- 8.10.7

A 316 LI 2001- MJF C I F S S
A 316 LI-IND 2001-
Fig. 16 Compact brake block located under the operator's cab
B20 Pressure switch / accumulator pres- B266 Proximity switch / oscillating axle automatic
sure
B60 Pressure switch / brake light S4 Switch / horn
Fig. 18 Water sensor B289 (located near fuel prefilter)
8.10.8 A 312 LI 12363-

MJF C I F S S A 316 LI 2001-
A 316 LI-IND 2001-
Fuses
5 Fuses
Fig. 19 Component arrangement on control console, front right
F304-F339 Fuses, P5 Operating hour meter


F306 15 A Reserve
F312 7.5 A Indicators
F313 5A Brake light
F314 3A Safety lever
F316 7.5 A Sensor control / console
F320 15 A Reserve
F321 15 A Reserve
F322 7.5 A Voltage transformer
F325 7.5 A Parking brake / travel
F327 15 A Reserve
F328 15 A Reserve
A 312 LI 12363- 8.10.9

A 316 LI 2001- MJF C I F S S
A 316 LI-IND 2001-
F329 5A Servo control

F330 7.5 A AHS / AS1
F331 15 A Reserve
F337 15 A Support / solenoid
F338 15 A Horn
Fig. 21 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.
8.10.10 A 312 LI 12363-

MJF C I F S S A 316 LI 2001-
A 316 LI-IND 2001-
Fig. 22 Control console A (front right) in model A 312 from serial no. 20433, A 314 units from se-
rial no. 20334 and A 316 units from serial no. 20340.

P7 Fuel level indicator
Indicator lights:
H7 Engine oil pressure H167 Forward travel
H11 Pre-heating H168 Reverse travel
H13 Air filter contamination H176 Oscillating axle automatic
H15 Hydraulic oil temperature H186 Offset boom bearing
H16 Overload warning system* H26 Quick change adapter*
A 312 LI 12363- 8.10.11

A 316 LI 2001- MJF C I F S S
A 316 LI-IND 2001-
H18 Coolant level H196 Scrap shear / sorting grapple*

H19 Indicator H311 Oscillating axle locking mechanism
H20 Parking brake H307 Fine adjustment (delta P)
H23 Accumulator pressure H336 Water in fuel filter
* kit
Switches, potentiometers
R75 Speed adjustment S241 Hydraulic hammer

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 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.
8.10.12 A 312 LI 12363-

MJF C I F S S A 316 LI 2001-
A 316 LI-IND 2001-
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 Rotary potentiometer for heating-a/c

system
S35 Switch / servo control S318 A/c system*
S74 Immobiliser* S398 Reversing switch
S92 Rotary potentiometer / air distribution
* kit
E8 Cigarette lighter S22* Work headlights, front, front

roof light
F307-F343 Fuses, see Fig. 26 S22-1 Rear roof light
S8* Beacon S61 Travel light
A 312 LI 12363- 8.10.13

A 316 LI 2001- MJF C I F S S
A 316 LI-IND 2001-
S11 Windscreen washer system S90 # Interval switch / windscreen wiper

S14 Windscreen wiper S218* Roof window wiper
* Kit # 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 7.5A Right parking light / tail light
F309 7.5A Travel light, left
F310 7.5A Travel light, right
F317* 7.5A Beacon
F323* 15 A Work light / attachment
F324* 15 A Work headlight, roof
F343* 7.5A Roof window wiper
K414 Relay interval control device*
* kit

e
E4 Travel light, right G2 Batteries

E15 Parking light, right S9 Battery main switch
E23 Indicator light, front right
8.10.14 A 312 LI 12363-

MJF C I F S S A 316 LI 2001-
A 316 LI-IND 2001-
Generator / starter
8 Generator / starter
Fig. 28 Diesel engine, radiator side
G1 Alternator M1 Starter
H27 Warning buzzer K375 Relay / kit*

K63 Relay / indicator K386 Relay / safety switch
A 312 LI 12363- 8.10.15

A 316 LI 2001- MJF C I F S S
A 316 LI-IND 2001-
Distribution board
K250 Relay / oscillating axle support K392# Relay / industrial shut-off*

K251 Relay / hand brake (light) KL15 Plus after ignition / permanent plus
K252 Relay / servo hand brake (buzzer) KL30 Plus after ignition / permanent plus
K315 Relay / brake light A Ground
K370 Relay / terminal 15 servo
* Kit # only in models A 312 to serial no. 27113

*Recesses for plugs
8.10.16 A 312 LI 12363-

MJF C I F S S A 316 LI 2001-
A 316 LI-IND 2001-
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 Switch air cushioning S389 Switch / seat heating
A 312 LI 12363- 8.10.17

A 316 LI 2001- MJF C I F S S
A 316 LI-IND 2001-
Solenoid valves
11 Solenoid valves
Fig. 33 Control oil unit with solenoid valves (located on the engine side of the hydraulic tank)
Y3 Solenoid valve / pilot control pressure Y51 Proportional solenoid valve / flow limita-
tion
Y24 Solenoid valve / creeper gear Y371 Solenoid valve / oscillating axle support
Y50 Proportional solenoid valve / power con-
trol
Fig. 34 Compact control block with auxiliary control axle for AS1 kit
Y22 Solenoid valve / grapple rotator left Y23 Solenoid valve / grapple rotator right
8.10.18 A 312 LI 12363-

MJF C I F S S A 316 LI 2001-
A 316 LI-IND 2001-
Solenoid valves
Fig. 35 Outrigger bearing at rear of undercarriage
Y217 Solenoid valve / left outrigger * Y218 Solenoid valve / right outrigger *
Fig. 36 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 12363- 8.10.19

A 316 LI 2001- MJF C I F S S
A 316 LI-IND 2001-
Solenoid valves
Fig. 38 Proportional solenoid valve / motor speed adjustment Y358 (located on the hydraulic
tank)
8.10.20 A 312 LI 12363-

MJF C I F S S A 316 LI 2001-
A 316 LI-IND 2001-
Control elements
1 Control elements
1.1 Overview of operator's cab
Fig. 1 Operator's cab seen from the operator
A126 Printed circuit board (autocheck) P6-P50 Displays / clock siehe Fig. 15
B19L Sensor transducer / left pilot control unit R75 Potentiometer / speed siehe Fig. 15
B19R Sensor transducer / right pilot control R76 Potentiometer / fine adjustment
unit
B40L Sensor transducer / pilot control unit S1 Pre-heating and start switch
Travel left
B40R Sensor transducer / pilot control unit S5 Push button / turn grapple
Travel right
B290 Sensor transducer / pilot control unit S8-S218Switch siehe Fig. 17
Kit left
B291 Sensor transducer / pilot control unit S17-S382 Switchsiehe Fig. 15
Kit right
E8 Cigarette lighter S20-S398 Switch siehe Fig. 16
H7-H307Indicator lamps siehe Fig. 15 S382 Switch fine adjustment ON / OFF
H9 Horn S* Switches for various kits
R 313 LI 27752- 8.17.1

R 317 LI 18161- copyright by
MJFCIFSS
H10 Buzzer U16 Excavator control BST
Fig. 2 A125 printed circuit board installed at the left control console behind the function box
A 125 printed circuit board potentiometer S7 Safety switch

K370-K386 Relay on distribution boardsiehe Fig. 20 C Heating
Fig. 3 A125 printed circuit board potentiometer
8.17.2 R 313 LI 27752-

copyright by R 317 LI 18161-
MJFCIFSS

X834 Plug connection / 2-pin X839 Screw terminal / 3-pin
Fig. 4 Component arrangement in E50 safety cabinet on the hydraulic tank
E50 safety and power switch cabinet Y299 Solenoid valve / AHS 11 kit
A127 printed circuit board / powersiehe Fig. 5
Fig. 5 A127 printed circuit board / power
R 313 LI 27752- 8.17.3

MJFCIFSS
KL15 Plus after ignition F302 Fuses KL 15, KL 30, B3, S44 (7.5 A)
KL19 Pre-heating F303 Fuse Y29 (7.5 A)
KL30E Permanent plus (input) F332 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 Relay / terminal 15
F300 Fuse KL15, KL 30 K_A - K_E Relay / optional
F301 Fuse K302, R60
Fig. 7 Engine output side
B2 Temperature sensor / engine coolant M1 Starter
8.17.4 R 313 LI 27752-

MJFCIFSS
B7 Vacuum switch / air filter (located at the Y12 Solenoid valve / excess fuel for starting
suction pipe between the air filter and the (located on the housing / speed adjusting
engine) device)
R 313 LI 27752- 8.17.5

MJFCIFSS
B8 Switch / hydraulic oil temperature (indica- B285 Transducer / hydraulic oil temperature
tor light) (fan control)
B12 Transducer / engine speed G1 Three-phase regulator

B16 Switch / engine oil pressure R60 Pin-type glow plugs (located at the
engine)
8.17.6 R 313 LI 27752-

MJFCIFSS
Fuses
5 Fuses
F304-F339Fuses siehe Fig. 14 P5 Operating hour meter

F306 15 A Reserve
F314 3 A Safety lever
F316 7,5 A Sensor control / console
R 313 LI 27752- 8.17.7

MJFCIFSS
Fuses
F318 20 A Heating / air-conditioning system (kit - terminal

30)
F319 15 A Heating / air-conditioning system (kit - terminal
15)
F320 15 A Reserve
F321 15 A Reserve
F322 7,5 A Voltage transformer
F327 15 A Reserve
F328 15 A Reserve
F329 5 A Servo control
F330 7,5 A AHS / AS
F331 15 A Reserve
F338 15 A Horn
8.17.8 R 313 LI 27752-

MJFCIFSS
Fig. 15 Control console A (front right)
P7 Dial indicator fuel reserve
Indicator lights:
H7 Engine oil pressure H18 Coolant level
R 313 LI 27752- 8.17.9

MJFCIFSS
H11 Pre-heating H26 Quick change adapter*

H13 Air filter contamination H196 Scrap shear / sorting grapple*
H15 Hydraulic oil temperature H307 Fine adjustment ( p)
H16 Overload warning system*
* kit
Operation / switches, potentiometers
R75 Speed adjustment S47 Quick change adapter*
S17 Slewing gear brake S241 Hydraulic hammer
S18 Overload warning system* S360 Acknowledgement of quick change adapter
buzzer*
S19 Grapple rotator* S382 Activation fine control adjustment
S21 Fast travel
* kit
Fig. 16 Control console B (front centre)

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 R 313 LI 27752-

MJFCIFSS
E8 Cigarette lighter S22 Work headlights, front, front

roof light*
F307-F343Fuses siehe Fig. 18 S22-1 Rear roof light*
S8 Beacon* S61 Travel light
S11 Windscreen washer system S218 Roof window wiper*
S14 Windscreen wiper
* kit
Fig. 18 Fuses and relays, control console, rear
F307 7.5 A Parking light / tail light

F308 7.5 A Right parking light / tail light
F309 7.5 A Travel light, left
F310 7.5 A Travel light, right
F317 7.5 A Beacon*
F323 15 A 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 27752- 8.17.11

MJFCIFSS
G2 Batteries S9 Battery main switch
H27 Warning buzzer K386 Relay / safety switch

K370 Relay / KL 15 servo KL15 / KL 30Plus after ignition / permanent plus
K375 Relay / kit* C Ground
* kit
8.17.12 R 313 LI 27752-

MJFCIFSS
Distribution board

*Recesses for plugs
R 313 LI 27752- 8.17.13

MJFCIFSS
Seat heating
9 Seat heating
Fig. 22 Seat heating switch S389 at the front of the operator seat
10 Solenoid valves
Fig. 23 Control oil unit (located at the rear of the hydraulic tank)
Y3 Solenoid valve / pilot control pressure Y50 Proportional solenoid valve / power con-
trol
Y7 Solenoid valve / slewing gear brake Y51 Proportional solenoid valve / flow limita-
tion
Y24 Solenoid valve / fast travel
8.17.14 R 313 LI 27752-

MJFCIFSS
Solenoid valves
Fig. 24 Additional control valve block AS1
Y22 Solenoid valve / grapple rotator Y23 Solenoid valve / grapple rotator
Fig. 26 Proportional solenoid valve / motor speed Y358 (located at the separating panel of the
control valve block console)
R 313 LI 27752- 8.17.15

MJFCIFSS
Solenoid valves
8.17.16 R 313 LI 27752-

MJFCIFSS
Service Manual Electrical system
Electrical system
Item Description Step Place / layout
A3 Radio (optional) 8 Operator's cab, back
A125 Potentiometer board 26/34 Left bracket
A126 Printed circuit board (autocheck) 4/10/13/ Right bracket
21a/21b/
24/33/34/
36/38/40/
A127 Printed circuit board: power 1a/1b/1c/ Electric cabinet at hydrau-
2/3 lic tank
A134 Control: 4-wheel steering 12 below operator's platform
A1017 Printed circuit board: quick-change adapter 38 Distribution board
B1 Transducer/fuel level - with plug 17 Fuel tank

B2 Temperature sensor for motor coolant 20 Motor, top fan side
B3 Transducer/motor coolant - with plug 21a Engine compartment
B7 Vacuum switch / air filter 21a Suction pipe - air filter
B8 Switch / hydraulic oil temperature 21a Hydraulic tank, bottom
B10 Pressure switch / parking brake 13 HBGV block
B12 Transducer / motor speed 27 Flywheel housing / motor
B16 Switch / motor oil pressure 21a Motor housing
B19L Sensor transducer - pilot control valve, left 28 Joystick, left
B19R Sensor transducer - pilot control valve, right 28 Joystick, right
B20 Pressure switch / accumulator pressure 21a Brake block beneath ope-
rator's platform
B21 Pressure switch UL 36 Boom cylinder section -
piston side
B26 Proximity switch / quick-change adapter 38 Quick-change adapter
B40 Proximity switch / pilot pressure valve: travel 28 Travelling pedal
B50L Loudspeaker, left 8 Cab, rear left
B50R Loudspeaker, right 8 Cab, rear right
B60 Pressure switch / brake light 9 Brake block beneath ope-
rator's platform
B232 Temperature switch / excess fuel for starting 1a Motor
B248H Sensor for rear axle alignment 12 Rear axle housing
B248V Sensor for front axle alignment 12 Front axle housing
B266 Proximity switch / oscillating axle automatic 33 Lower brake pedal
B285 Transducer hydraulic oil temperature / fan control 29 Tank
B289 Water sensor in fuel tank 21a Preliminary fuel filter
B290 Proximity switch / kit pedal 34 Operators platform
E1 work headlight for attachments 5 Attachment

E2 Front roof light 5 Front cab roof
E3 Travel light, left 6 Revolving deck, front
E4 Travel light, right 6 Revolving deck, front
E7 Roof-mounted light 8 Cab
E8 Cigarette lighter 8 Bracket, rear right
E9 Beacon 37 Cab, top
E15 Parking light, right 6 Revolving deck, front right
A 309 LI 20221- 8.20.1

MJFCIFSS
Electrical system Service Manual

E16 Parking light, left 6 Revolving deck, front left
E17 Tail light, right 6 Revolving deck, rear right
E18 Tail light, left 6 Revolving deck, rear left
E19 Brake light, right 6 Revolving deck, rear right
E20 Brake light, left 6 Revolving deck, rear left
E21 Direction indicator, front left 4 Revolving deck, front left
E22 Direction indicator, rear left 4 Revolving deck, rear left
E23 Direction indicator, front right 4 Revolving deck, front right
E24 Direction indicator, rear right 4 Revolving deck, backside,
to the right
E50 Electric cabinet 1a/1b/1c/ Hydraulic tank
2/3/40
E150 Rear roof light, with plug 5 Cab roof, rear
F_A Fuse optional _A 1b A127, hydraulic tank

F_B Fuse optional _A 1b A127, hydraulic tank
F_C Fuse optional _A 1b A127, hydraulic tank
F_D Fuse optional _A 1b A127, hydraulic tank
F_E Fuse optional _A 1b A127, hydraulic tank
F_F Fuse optional _A 1b A127, hydraulic tank
F_G Fuse optional _A 1b A127, hydraulic tank
F_H Fuse optional _A 1b A127, hydraulic tank
F_I Fuse optional _A 1b A127, hydraulic tank
F_K Fuse optional _A 1b A127, hydraulic tank
F_L Fuse optional _A 1b A127, hydraulic tank
F_M Fuse optional _A 1b A127, hydraulic tank
F_N Fuse optional 70 A 1a A127, hydraulic tank
FRes Fuse, reserve _A 14 Right bracket
F20/ Fuse A127 class 30 to class 15 50A 1a A127, hydraulic tank
F300
F19/ Fuse A127 K302, R60 70A 2 A127, hydraulic tank
F301
F22/ Fuse A127 class 15, class 30, S44 7.5A 1b A127, hydraulic tank
F302
F303 Fuse A127, Y29 7.5A 3 A127, hydraulic tank
F304 Fuse S1 15A 1a Right bracket
F305 Fuse E7, E8, P50 15A 8 Right bracket
F306 Fuse X10 15A 16 Right bracket
F307 Fuse E16, E17, P6, P7, P50 7.5A 6 Bracket, backside, to the
right
F308 Fuse E15, E18 7.5A 6 Bracket, backside, to the
right
F309 Fuse E3 7.5A 6 Bracket, backside, to the
right
F310 Fuse E4 7.5A 6 Bracket, backside, to the
right
F311 Fuse M3, M4 15A 7 Bracket, backside, to the
right
F312 Fuse S44, E21, E22, E23, E24 7.5A 4 Right bracket
F313 Fuse E19, E20 5A 9 Right bracket
8.20.2 A 309 LI 20221-

MJFCIFSS

F314 Fuse S7 3A 14 Right bracket
F315 Fuse BST (excavator control) 15A 23 Right bracket
F316 Fuse: servo control 7.5A 28 Right bracket
F317 Fuse: beacon 7.5A 37 Bracket, backside, to the
right
F318 Fuse: heating / air condition, class 30 20A 30c Right bracket
F319 Fuse: heating / air condition, class 15 15A 30c Right bracket
F322 Fuse T1 7.5A 8 Right bracket
F323 Fuse E1 15A 5 Bracket, backside, to the
right
F324 Fuse S22 - E2, S22-1 - E150 15A 5 Bracket, backside, to the
right
F325 Fuse S16, K251 7.5A 13 Right bracket
F326 Fuse S21 - Y24, S42 - Y55 15A 11 Right bracket
F330 Fuse: kits 7.5A 16 Right bracket
F332 Fuse A127, M1, Y12 25A 1a A127, hydraulic tank
F337 Fuse: support 15A 35 Right bracket
F338 Fuse H9, seat heating 10A 4 Right bracket
F339 Fuse: a/c condenser 20A 30c Right bracket
F343 Fuse: roof window wiper 7.5A 7 Right bracket
F356 Fuse: 4-wheel steering, class 15 10A 1b A127, hydraulic tank
F359 Fuse: permanent ground - clock 3A 42 Battery box
G1 alternator 1a diesel engine

G2 batteries 1a Battery box
H7 Indicator light: motor oil pressure 21a Right bracket

H9 horn 4 below operator's platform
H10 Warning buzzer 21b Right bracket
H11 Indicator light: pre-heat 2 Right bracket
H12 Indicator light: charge 21b Right bracket
H13 Indicator light: air filter dirty 21a Right bracket
H15 Indicator light: hydraulic oil temperature 21a Right bracket
H16 Indicator light: overload warning (kit) 36 Right bracket
H18 Indicator light: coolant level 21a Right bracket
H19 Indicator light: direction indicator 4 Right bracket
H20 Indicator light: parking brake 13 Right bracket
H23 Indicator light: accumulator pressure 21a Right bracket
H26 Indicator light: quick-change adapter 38 Right bracket
H27 warning buzzer 13 Right bracket
H167 Indicator light: travel forward 10 Right bracket
A 309 LI 20221- 8.20.3

MJFCIFSS

H168 Indicator light: travel reverse 10 Right bracket
H175 Indicator light: motor overheating 21a Right bracket
H176 Indicator light: oscillating-axle locking device 33 Right bracket
H186 Indicator light: swivel bearing 40 Right bracket
H191 Indicator light: 4-wheel steering 12 Left bracket
H192 Indicator light: dog-walk steering mode 12 Left bracket
H196 Indicator light: sorting grapple 34 Right bracket
H301 Indicator light: error BST 26 A125, left bracket
H311 Indicator light: oscillating axle locked 33 Right bracket
H336 Indicator light: water in fuel filter 21a Right bracket
HRes Indicator light: reserve 40 Right bracket
K_A Relay optional 1c A127, hydraulic tank

K_B Relay optional 1c A127, hydraulic tank
K_C Relay optional 1c A127, hydraulic tank
K_D Relay optional 1c A127, hydraulic tank
K_E Relay optional 1c A127, hydraulic tank
K16-1 Relay terminal 50 1a A127, hydraulic tank
K16-2 Relay, disconnected 1a A127, hydraulic tank
K63 Relay: direction indicator 4 Right bracket
K250 Relay: oscillating axle automatic 33 Right bracket
K251 Relay: hand brake (indicator light H20) 13 Right bracket
K252 Relay servo - hand brake (buzzer) 13 Right bracket
K288 Relay, terminal 15 3 A127, hydraulic tank
K302 Relay: pre-heat 2 A127, hydraulic tank
K315 Relay: brake light 9 Right bracket
K364 Relay to A1017 38 Quick-change adapter
board
K370 Relay KL15, servo 15 Right bracket
K375 Relay kit - quantity 34 Operator's platform, back
K386 Relay, safety switch S7 14 Right bracket
K393 Relay, air-spring seat 31 Operators platform
K403 Relay: heating 30a Operator's platform, back
K405 Relay: heating 30b Operator's platform, back
K414 Relay: intermittent windscreen wiper 7 Operator's platform, back
K445 Relay: travel shut-off 4-wheel steering 10 Right bracket
M1 Starter 1a Diesel engine

M3 Motor: windscreen washer system 7 Cab, back
M4 Motor: windscreen wiper with plug 7 Windscreen
M60 Windscreen washer system: roof (optional) 7 Cab, top
M65 blower motor 30b Operator's platform, back
M68 Windscreen washer system: roof (optional) 7 Cab, top
M70 Motor: air-spring seat 31 Operators platform
M71 Servo motor water valve 30a Operator's platform, back
M72 Servo motor: air diffusion 30a Operator's platform, back
8.20.4 A 309 LI 20221-

MJFCIFSS

M73 Servo motor: air diffusion 30a Operator's platform, back
P1 Potentiometer flow limitation 1 26 Left bracket

P5 Display: operating hour meter 19 Right bracket, bottom
P6 Display: motor temperature 20 Right bracket
P7 Display: fuel level 17 Right bracket
P50 Display: clock 18 Right bracket
R60 Pin-type glow plug, with plug 2 diesel engine

R75 Potentiometer: speed 22 Right bracket
R78-1 seat heating 32 Operators platform
R78-2 seat heating 32 Operators platform
RS232 Laptop interface 26 Left bracket
S1 Pre-heating and start switch 1a Right bracket

S1 Code switch A125 26 Left bracket
S4 Switch: horn H9 4 Cab floor plate
S5L Push button 'turn grapple left' Y22 25 Pilot control valve, left
S5M Push button, centre (no function) 25 Pilot control valve, left
S5R Push button 'turn grapple right' Y23 25 Pilot control valve, left
S7 safety switch 14 Left bracket
S8 Switch: beacon 37 Bracket, backside, to the
right
S9 battery main switch 42 Battery compartment
S11 Switch: windscreen washer system M3 7 Bracket, backside, to the
right
S14 Switch: windscreen wiper M4 7 Bracket, backside, to the
right
S16 Switch: parking brake Y6 13 Right bracket
S18 Switch: overload warning system (optional) 36 Right bracket
S19 Switch: grapple rotator Y22, Y23 25 Right bracket
S20 Switch: sensor control 28 Right bracket
S21 Switch: creeper gear Y24 11 Right bracket
S22 Switch: work headlight E1 / roof light E2 5 Bracket, backside, to the
right
S22-1 Switch: auxiliary headlight / roof light 5 Bracket, backside, to the
right
S32 Switch: direction indicator / horn 4 steering column
S35 Switch: servo 15 Right bracket
S42 Switch. first gear Y55 11 Right bracket
S44 Switch: hazard light 4 Right bracket
S47 Switch: Bucket quick-change adapter (optional) 38 Right bracket
S61 Switch: lighting installation 6 Bracket, backside, to the
right
S63 Switch: swivel bearing 40 Pilot control valve right
S75 Switch: oscillating axle locking device Y371 33 Right bracket
S92 Potentiometer: air diffusion 30a Right bracket
A 309 LI 20221- 8.20.5

MJFCIFSS

S93 Potentiometer: heating / air condition 30a Right bracket
S218 Switch: roof window wiper (optional) 7 Bracket, backside
S241 Switch: accessory kit AHS 11 / AHS 12 (optional) 34 Right bracket
S263 Switch: travel direction 10 Pilot control valve, left
S272 Junction box undercarriage 12/35 Undercarriage
S283 Switch: windscreen wiper release 7 windscreen
S284 Switch: four-step blower 30b Right bracket
S309 Rotary switch: 4-wheel steering 12 Left bracket
S343 Switch: individual control, back 35 Right bracket
S360 Switch: Mute switch for buzzer UL 38 Right bracket
S388 Switch: air-spring seat 31 operator seat
S389 Switch: seat heating 32 operator seat
S398 Reversing switch / air diffusion 30a Right bracket
S422 Switch: mute switch for radio 8 Right bracket
S439L Push button: split blade, left 35 Pilot control valve: support
S439R Push button: split blade, right 35 Pilot control valve: support
T1 Voltage transformer / radio 8 Left bracket
U16 Excavator control BST 2/15(I)/ Right bracket

20-23/26-
29/34
V155 Blocking diode: oscillating axle 33 Right bracket
V156-2 Blocking diode H311 - S75 33 Right bracket
V156-4 Diode input quantity 34 Right bracket
V171 Blocking diode: buzzer 13 Right bracket
X10 Plug connection distribution board / 2-pin 16 Right bracket

X65 Plug connection to voltage transformer / 2-pin 8 Right bracket
X66 Plug connection to voltage transformer / 2-pin 8 Right bracket
X67-1 Plug connection A3 power supply / 8-pin 8 Operator's platform, left
X90 Plug connection: heating fan motor 30b Operators platform
X196 B40 plug connection / 3-pin 28 Travelling pedal
X197 Plug connection / 3-pin 33 Brake pedal
X230 Plug connection distribution board / 3-pin 10/13 Right bracket
X262-1 Plug connection: wire harness quick-change adapter, 8-pin 38 Bearing block
X262-3 Plug connection: wire harness quick-change adapter, 8-pin 38 stick
X262-4 Plug connection: wire harness quick-change adapter, 2-pin 38 Quick-change adapter
X301 Plug connection: wire harness, 12-pin 35 Revolving deck
X304 Plug connection: wire harness, console, 6-pin 35 Right bracket
8.20.6 A 309 LI 20221-

MJFCIFSS

X404 Plug connection: work headlight / 4-pin 5 Revolving deck
X406 Plug connection: transducer fuel reserve / 3-pin 17 Revolving deck
X407 Plug connection: revolving deck UL 2-pin 36 Revolving deck
X410 Plug-type connection distribution board / 2-pin 38 Right bracket
X550 Plug connection: switch S32 / 6-pin 4 steering column
X834 Plug connection to A 125 / 2-pin 26 Left bracket
X837 Plug connection to A 125 / 8-pin 26/34 Left bracket
X838-1 Plug connection to A 125 / 9-pin 26 Left bracket
X838-3 Plug connection CAN - bus connection, 2-pin 26 Left bracket
X839 Screw terminal on A125 / 3-pin 34 Left bracket
X842-1 Climate plug connection / 15-pin 30c Right bracket
X842-2 Plug connection: console, ignition switch / 2-pin 30c Right bracket
X842-3 Plug connection: blocking diode / 2-pin 33 Right bracket
X856 Plug connection to BST excavator control / 40-pin 2/15(I)/ Right bracket
20-23/26-
29/34
X857 Plug connection to BST excavator control / 24-pin 21a/22- Right bracket
23/26/28/
34
X859 Plug connection / 21-pin 30a/30b Operator's platform, back
X860 Plug connection / 6-pin 30a Operator's platform, back
X863 Plug connection / 15-pin 30a/30b Operator's platform, back
X924-1 B290 plug connection / 3-pin 34 below operator's platform
X924-2 B291 plug connection / 3-pin 34 below operator's platform
X950 Plug connection: console display autocheck / 21-pin 4/10/13/ Right bracket
21a/33/
36/38/40
X951 Plug connection: console display autocheck / 21-pin 4/10/13/ Right bracket
21b/34/
38/40
X952 Plug connection: revolving deck - BST excavator control / 21- 10-15/25/ Right bracket
pin 30c/33/
34/40
X953 Plug connection: revolving deck - distribution board / 21-pin 1/4-6/12/ Right bracket
13/17/
21a/36/42
X954 Plug connection: revolving deck - BST excavator control / 21- 2/12/20/ Right bracket
pin 22/26/27/
29
X955 Plug connection: revolving deck - distribution board / 15-pin 1a/3/4/35/ Right bracket
38
A 309 LI 20221- 8.20.7

MJFCIFSS

X956 Plug connection: BST excavator control - distribution board / 2/15(I)/ Right bracket
21-pin 20-23/26/
28/34/43
X957 Plug connection: switch - distribution board / 21-pin 8/11/20/ Right bracket
22/25/34/
35/
X958 Plug connection: switch - distribution board / 21-pin 18/28/34/ Right bracket
35/36/38/
43
X959 Plug connection: fuse - distribution board / 21-pin 15/30c/ Right bracket
35/40
X960 Plug connection: operator's platform - distribution board / 21- 4/6/9/21a/ Right bracket
pin 28/33/34
X961 Plug connection: display - distribution board / 21-pin 2/6/13/17/ Right bracket
20/21a/
21b/33
X962 Plug connection: display - distribution board / 21-pin 4/10/13/ Right bracket
14/21b/
28/34/38/
40
X963 Plug connection: fuse - distribution board / 21-pin 6/8/9/11/ Right bracket
13-16/23/
24/28/35
X964 Plug connection: fuse - distribution board / 21-pin 1a/3/4/13/ Right bracket
14/16/28/
33/43
X965 Plug connection: BST excavator control - distribution board / 26/34 Right bracket
21-pin
X966 Plug connection A 125 - distribution board / 21-pin 8/10/12/ Right bracket
14/25/28/
32/34/43
X967 Plug connection: display - distribution board / 21-pin 5/6/8/37 Right bracket
X967-1 Plug connection: wire harness - connection / 1-pin 45 Operator's platform, back
X967-2 Plug connection: wire harness - connection / 1-pin 43 Operator's platform, back
X968-1 Plug connection: quantity 2 / 1-pin 34 Right bracket
X968-2 Plug connection: quantity 3 / 1-pin 34 Right bracket
X971 Plug connection: seat adjustment / 2-pin 31 Operators platform
X972 Plug connection: seat heating / 2-pin 32 Operators platform
X973 Power socket, 12V 8 Left bracket
X974-2 Plug connection: blocking diode / 2-pin 33 Right bracket
X974-4 Plug connection: blocking diode / 2-pin 34 Cab, right
X1046 Plug connection / 12-pin 10/25 Left bracket
X1047 Plug connection B19L / 3-pin 28 Pilot control valve, left
X1048 Plug connection / 12-pin 40 Pilot control valve right
X1049 Plug connection: B19R / 3-pin 28 Pilot control valve right
X1090 Plug connection / 6-pin 12 below operator's platform
X1104 Plug connection / -pin 35 Right bracket
X1106 Plug connection / 4-pin 14/15 Right bracket
X1117 Plug connection: 4-wheel steering, 6-pin 12/14/43 Right bracket
X1118 Plug connection: blocking diode, 2-pin 13 Right bracket
8.20.8 A 309 LI 20221-

MJFCIFSS

Y3 Solenoid valve: pilot pressure 15 control oil unit
Y6 Solenoid valve: parking brake 13 HBGV block
Y12 Solenoid valve: excess fuel for starting 1a Regulator: motor
Y20 magnetic clutch / a/c compressor 30c diesel engine
Y22 Solenoid valve / grapple rotator 25 control valve block
Y23 Solenoid valve / grapple rotator 25 control valve block
Y24 Solenoid valve: creeper gear 11 control oil unit
Y28-1 Solenoid valve: quick-change adapter 38 Quick-change adapter
Y28-2 Solenoid valve: quick-change adapter 38 Quick-change adapter
Y29 Solenoid valve: motor shut-down 3 Regulating rod: motor
Y50 Proportional solenoid valve: power control 26 control oil unit
Y51 Proportional solenoid valve: flow limitation 26 control oil unit
Y55 Solenoid valve: first gear 11 HBGV block
Y56 Solenoid valve: blade 35 Undercarriage
Y62 Solenoid valve: travel forward 10 Hydraulic tank
Y63 Solenoid valve: travel reverse 10 Hydraulic tank
Y217 Solenoid valve: outrigger, rear left 35 Undercarriage
Y218 Solenoid valve: outrigger, rear right 35 Undercarriage
Y229-1 Solenoid valve: dog-walk steering mode 12 Undercarriage
Y229-2 Solenoid valve: 4-wheel steering 12 Undercarriage
Y262 Solenoid valve: bucket swivel bearing 40 Fuel tank
Y268 Solenoid valve: flow reduction, AHS 34 Hydraulic tank
Y294-1 Solenoid valve: 4-wheel steering 12 below operator's platform
Y294-2 Solenoid valve: 4-wheel steering 12 below operator's platform
Y299 Solenoid valve: flow reduction, AHS 34 Hydraulic tank
Y330 Solenoid valve: pump regulation 15 control oil unit
Y352 Proportional solenoid valve: fan control 29 Fan / radiator
Y358 Proportional solenoid valve: motor speed with plug 22 Bulkhead
Y371 Solenoid valve: oscillating axle support 33 control oil unit
A 309 LI 20221- 8.20.9

MJFCIFSS
1a Power supply, board A127
8.20.10 A 309 LI 20221-

MJFCIFSS
1b Power supply, board A127 / fuses
A 309 LI 20221- 8.20.11

MJFCIFSS
1c Power supply, board A 127 / relay
8.20.12 A 309 LI 20221-

MJFCIFSS
2 Pre-heating
A 309 LI 20221- 8.20.13

MJFCIFSS
3 Motor shut-down
8.20.14 A 309 LI 20221-

MJFCIFSS
4 Direction indicator system / horn
A 309 LI 20221- 8.20.15

MJFCIFSS
5 Work headlight
8.20.16 A 309 LI 20221-

MJFCIFSS
6 Lighting installation
A 309 LI 20221- 8.20.17

MJFCIFSS
7 Windscreen wiper / washer systems
8.20.18 A 309 LI 20221-

MJFCIFSS
8 Interior lights, radio
A 309 LI 20221- 8.20.19

MJFCIFSS
9 Brake light
8.20.20 A 309 LI 20221-

MJFCIFSS
10 Travel direction switch
A 309 LI 20221- 8.20.21

MJFCIFSS
11 Creeper gear first gear
8.20.22 A 309 LI 20221-

MJFCIFSS
12 Optional 4-wheel steering
A 309 LI 20221- 8.20.23

MJFCIFSS
13 Parking brake
8.20.24 A 309 LI 20221-

MJFCIFSS
14 Safety switch
A 309 LI 20221- 8.20.25

MJFCIFSS
15 Servo
8.20.26 A 309 LI 20221-

MJFCIFSS
16 Power supply / socket
A 309 LI 20221- 8.20.27

MJFCIFSS
17 Fuel gauge 18 Clock 19 Hour meter
8.20.28 A 309 LI 20221-

MJFCIFSS
20 Motor temperature
A 309 LI 20221- 8.20.29

MJFCIFSS
21a Indicator lights
8.20.30 A 309 LI 20221-

MJFCIFSS
21b Autocheck / main warning buzzer / charge indicator
A 309 LI 20221- 8.20.31

MJFCIFSS
22 Speed adjustment
8.20.32 A 309 LI 20221-

MJFCIFSS
23 BST excavator-control power supply
A 309 LI 20221- 8.20.33

MJFCIFSS
25 Optional: AS I
8.20.34 A 309 LI 20221-

MJFCIFSS
26 Regulating valves
A 309 LI 20221- 8.20.35

MJFCIFSS
27 Speed sensor
8.20.36 A 309 LI 20221-

MJFCIFSS
28 Sensor control
A 309 LI 20221- 8.20.37

MJFCIFSS
29 Fan control
8.20.38 A 309 LI 20221-

MJFCIFSS
30a Heating
A 309 LI 20221- 8.20.39

MJFCIFSS
30b Heating
8.20.40 A 309 LI 20221-

MJFCIFSS
30c Heating
A 309 LI 20221- 8.20.41

MJFCIFSS
31 Electrical set adjustment - seat made by Isringhausen
8.20.42 A 309 LI 20221-

MJFCIFSS
32 Seat heating - seat made by Isringhausen
A 309 LI 20221- 8.20.43

MJFCIFSS
33 Automatic oscillating axle locking device
8.20.44 A 309 LI 20221-

MJFCIFSS
34 Optional AHS11 / AHS12
A 309 LI 20221- 8.20.45

MJFCIFSS
35 Optional blade / individual control outrigger
8.20.46 A 309 LI 20221-

MJFCIFSS
36 Optional overload warning system
A 309 LI 20221- 8.20.47

MJFCIFSS
37 Optional beacon
8.20.48 A 309 LI 20221-

MJFCIFSS
38 Optional bucket quick-change adapter
A 309 LI 20221- 8.20.49

MJFCIFSS
40 Swivel bearing
8.20.50 A 309 LI 20221-

MJFCIFSS
42 Ground
A 309 LI 20221- 8.20.51

MJFCIFSS
43 Ground
8.20.52 A 309 LI 20221-

MJFCIFSS
44 Ground
A 309 LI 20221- 8.20.53

MJFCIFSS
45 Class 30 / class 15
8.20.54 A 309 LI 20221-

MJFCIFSS
Electrical system
Item Description Step Location / arrangement
A3 Radio (optional) 8 Operator's cab, rear
A125 Potentiometer board 26/34 Left console
A126 Printed circuit board (autocheck) 4/10/13/ Right console
21a/21b/
24/33/36/
38/40/
A127 Printed circuit board / power 1a/1b/1c/ Electric cabinet at hydrau-
2/3 lic tank
A134 Control: 4-wheel steering 12 Below operator's platform
A1017 Printed circuit board / quick-change adapter 38 Distribution board
B1 Transducer / fuel level, with plug 17 Fuel tank

B2 Temperature sensor / motor coolant 20 Motor, top fan side
B3 Transducer / motor coolant, with plug 21a Engine compartment
B7 Vacuum switch / air filter 21a Suction pipe / air filter
B19L Sensor transducer / left pilot control unit 28 Left joystick
B19R Sensor transducer / right pilot control unit 28 Right joystick
rator's platform
B21 Pressure switch / overload 36 Boom cylinder section -
piston side
B26 Proximity switch / quick-change adapter 38 Quick-change adapter
B33 Pressure switch / accessory kit 34 Near control valve block
B40 Proximity switch / pilot pressure valve, travel 28 Travelling pedal
rator's platform
B232 Temperature switch / excess fuel for starting 1a Engine
B248H Sensor for rear axle alignment 12 Rear axle housing
B248V Sensor for front axle alignment 12 Front axle housing
B285 Transducer hydraulic oil temperature / fan control 29 Tank
B289 Water sensor in fuel tank 21a Preliminary fuel filter
E1 Work light / attachment 5 Attachment

E8 Cigarette lighter 8 Right console, rear
A 309 LI 29269- 8.22.1

MJFCIFSS

E21 Indicator light, front left 4 Revolving deck, front left
E22 Indicator light, rear left 4 Revolving deck, rear left
E23 Indicator light, front right 4 Revolving deck, front right
E24 Indicator light, rear right 4 Revolving deck, rear right
2/3/40
E150 Rear roof light, rear, with plug 5 Rear cab roof

FRes Fuse, reserve _A 14 Right console
F20/ Fuse A127 terminal 30 to terminal 15 50A 1a A127, hydraulic tank
F300
F301
F22/ Fuse A127 terminal 15, terminal 30, S44 7.5A 1b A127, hydraulic tank
F302
F304 Fuse S1 15A 1a Right console
F305 Fuse E7, E8, P50 15A 8 Right console
F306 Fuse X10 15A 16 Right console
F307 Fuse E16, E17, P6, P7, P50 7.5A 6 Right console, rear
F308 Fuse E15, E18 7.5A 6 Right console, rear
F309 Fuse E3 7.5A 6 Right console, rear
F310 Fuse E4 7.5A 6 Right console, rear
F311 Fuse M3, M4 15A 7 Right console, rear
F312 Fuse S44, E21, E22, E23, E24 7.5A 4 Right console
F313 Fuse E19, E20 5A 9 Right console
F314 Fuse S7 3A 14 Right console
F315 Fuse BST 15A 23 Right console
F316 Fuse servo control 7.5A 28 Right console
F317 Fuse beacon 7.5A 37 Right console, rear
F318 Fuse heating / air conditioning, terminal 30 20A 30c Right console
F319 Fuse heating / air conditioning, terminal 15 15A 30c Right console
8.22.2 A 309 LI 29269-

MJFCIFSS

F322 Fuse T1 7.5A 8 Right console
F323 Fuse E1 15A 5 Right console, rear
F324 Fuse S22 - E2, S22-1 - E150 15A 5 Right console, rear
F325 Fuse S16, K251 7.5A 13 Right console
F326 Fuse S21 - Y24, S42 - Y55 15A 11 Right console
F330 Fuse kits 7.5A 16 Right console
F337 Fuse support 15A 35 Right console
F338 Fuse H9, seat heating 10A 4 Right console
F339 Fuse a/c condenser 20A 30c Right console
F343 Fuse roof window wiper 7.5A 7 Right console
F359 Fuse: permanent ground - clock 3A 42 Battery box
G1 Alternator 1a Diesel engine

G2 Batteries 1a Battery box
H7 Indicator light / motor oil pressure 21a Right console

H9 Horn 4 Below operator's platform
H10 Warning buzzer 21b Right console
H11 Indicator light / pre-heating 2 Right console
H12 Indicator light / charging 21b Right console
H13 Indicator light / air filter contamination 21a Right console
H15 Indicator light / hydraulic oil temperature 21a Right console
H16 Indicator light / overload warning (kit) 36 Right console
H18 Indicator light / coolant level 21a Right console
H19 Indicator light / indicator 4 Right console
H20 Indicator light / parking brake 13 Right console
H23 Indicator light / accumulator pressure 21a Right console
H26 Indicator light / quick-change adapter 38 Right console
H27 Warning buzzer 13 Right console
H167 Indicator light / forward travel 10 Right console
H168 Indicator light / reverse travel 10 Right console
H175 Indicator light / motor overheating 21a Right console
H176 Indicator light / oscillating-axle locking device 33 Right console
H186 Indicator light / swivel bearing 40 Right console
H191 Indicator light: 4-wheel steering 12 Left console
H192 Indicator light: dog-walk steering mode 12 Left console
H196 Indicator light / sorting grapple 34 Right console
H301 Indicator light / error BST 26 A125, left console
H311 Indicator light / oscillating axle locked 33 Right console
A 309 LI 29269- 8.22.3

MJFCIFSS

H336 Indicator light: water in fuel filter 21a Right console
HRes Indicator light: reserve 40 Right console
K_A Relay, optional 1c A127, hydraulic tank

K_B Relay, optional 1c A127, hydraulic tank
K_C Relay, optional 1c A127, hydraulic tank
K_D Relay, optional 1c A127, hydraulic tank
K_E Relay, optional 1c A127, hydraulic tank
K16-1 Relay terminal 50 1a A127, hydraulic tank
K63 Relay / direction indicator 4 Right console
K250 Relay / oscillating axle automatic 33 Right console
K251 Relay / hand brake (indicator light H20) 13 Right console
K288 Relay terminal 15 3 A127, hydraulic tank
K302 Relay / pre-heating 2 A127, hydraulic tank
K315 Relay brake light 9 Right console
board
K370 Relay terminal 15, servo 15 Right console
K375 Relay / kit, quantity 34 Operator's platform, rear
K386 Relay / safety switch S7 14 Right console
K393 Relay / air-spring seat 31 Operator's platform
K403 Relay / heating 30a Operator's platform, rear
K405 Relay / heating 30b Operator's platform, rear
K414 Relay / windscreen wiper interval 7 Operator's platform, rear
K445 Relay: travel shut-off 4-wheel steering 10 Right console
K466 Relay horn H9 4 Right console

M3 Motor / windscreen washer system 7 Operator's cab, rear
M4 Motor / windscreen wiper with plug 7 Windscreen
M60 Windscreen washer system / roof (optional) 7 Cab, top
M65 Blower motor 30b Operator's platform, rear
M70 Motor / air-spring seat 31 Operator's platform
M71 Servo motor / water valve 30a Operator's platform, rear
M72 Servo motor / air distribution 30a Operator's platform, rear
P1 Potentiometer / flow limitation 1 26 Left console

P5 Display / operating hour meter 19 Right console, bottom
P6 Display / motor temperature 20 Right console
P7 Indicator / fuel level 17 Right console
P50 Display / clock 18 Right console
R60 Pin-type glow plug, with plug 2 Diesel engine
8.22.4 A 309 LI 29269-

MJFCIFSS

R75 Potentiometer / speed 22 Right console
R78-1 Seat heating 32 Operator's platform
RS232 Laptop interface 26 Left console
S1 Pre-heating and start switch 1a Right console

S1 Code switch A125 26 Left console
S4 Switch / horn H9 4 Cab floor plate
S5L Push button / turning grapple to the left, Y22 25 Left pilot control unit
S5M Push button, centre (no function) 4,25 Left pilot control unit
S5R Push button / turning grapple to the right, Y23 25 Left pilot control unit
S7 Safety switch 14 Left console
S8 Switch / beacon 37 Right console, rear
S9 Battery main switch 42 Battery compartment
S11 Switch / windscreen washer system M3 7 Right console, rear
S14 Switch / windscreen wipers M4 7 Right console, rear
S16 Switch / parking brake Y6 13 Right console
S18 Switch / overload warning system (optional) 36 Right console
S19 Switch / grapple rotator Y22, Y23 25 Right console
S20 Switch / sensor control 28 Right console
S21 Switch / creeper gear Y24 11 Right console
S22 Switch / work light E1 / roof light E2 5 Right console, rear
S22-1 Switch / auxiliary headlight / roof light 5 Right console, rear
S32 Switch / direction indicator / horn 4 Steering column
S35 Switch servo 15 Right console
S42 Switch / first gear Y55 11 Right console
S44 Switch / hazard light 4 Right console
S47 Switch / bucket quick-change adapter (optional) 38 Right console
S61 Switch / lighting installation 6 Right console, rear
S63 Switch / swivel bearing 40 Right pilot control unit
S75 Switch / oscillating axle locking device Y371 33 Right console
S92 Potentiometer / air distribution 30a Right console
S93 Potentiometer / heating / air condition 30a Right console
S218 Switch / roof window wiper (optional) 7 Right console, rear
S241 Switch / accessory kit AHS 11 / AHS 12 (optional) 34 Right console
S263 Switch / travelling direction 10 Left pilot control unit
S272 Junction box, undercarriage 12/35 Undercarriage
S283 Switch / windscreen wiper release 7 Windscreen
S284 Switch / four-step blower 30b Right console
S309 Rotary switch: 4-wheel steering 12 Left console
S360 Switch / mute switch for overload buzzer 38 Right console
S388 Switch / air-spring seat 31 Operator seat
S389 Switch / seat heating 32 Operator seat
S398 Reversing switch / air distribution 30a Right console
S422 Switch / mute switch for radio 8 Right console
S439L Push button: split blade, left 35 Pilot control valve: support
S439R Push button: split blade, right 35 Pilot control valve: support
A 309 LI 29269- 8.22.5

MJFCIFSS

T1 Voltage transformer / radio 8 Left console
U16 BST excavator control system 2/15/20- Right console

23/26-29/
34
V155 Blocking diode / oscillating axle 33 Right console
V156-2 Blocking diode H311 - S75 33 Right console
V156-4 Diode / input quantity 34 Right console
V171 Blocking diode: buzzer 13 Right console
V181 Amplifier magnet Y22 25 Right console, rear
V182 Amplifier magnet Y23 25 Right console, rear
X10 Plug connection distribution board / 2-pin 16 Right console

X65 Plug connection on voltage transformer / 2-pin 8 Right console
X66 Plug connection on voltage transformer / 2-pin 8 Right console
X90 Plug connection / heating fan motor 30b Operator's platform
X196 Plug connection B40 / 3-pin 28 Travelling pedal
X197 Plug connection, 3-pin 33 Brake pedal
X230 Plug connection distribution board / 3-pin 10/13 Right console
X262-1 Plug connection wire harness quick-change adapter / 8-pin 38 Bearing block
X262-3 Plug connection wire harness quick-change adapter / 8-pin 38 Stick
X262-4 Plug connection wire harness quick-change adapter / 2-pin 38 Quick-change adapter
X301 Plug connection: wire harness, 12-pin 35 Revolving deck
X304 Plug connection wire harness, console / 6-pin 35 Right console
X404 Plug connection work headlight / 4-pin 5 Revolving deck
X406 Plug connection transducer fuel reserve / 3-pin 17 Revolving deck
X407 Plug connection revolving deck overload / 2-pin 36 Revolving deck
X550 Plug connection switch S32 / 6-pin 4 Steering column
X834 Plug connection to A 125 / 2-pin 26 Left console
X837 Plug connection to A 125 / 8-pin 26/34 Left console
X838-1 Plug connection to A 125 / 9-pin 26 Left console
X838-2 Plug connection to A 125 / 9-pin 26 Left console
8.22.6 A 309 LI 29269-

MJFCIFSS

X838-3 Plug connection CAN - bus / 2-pin 26 Left console
X839 Screw terminal on A125 / 3-pin 34 Left console
X842-1 Plug connection air-conditioning / 15-pin 30c Right console
X842-2 Plug connection console, ignition switch / 2-pin 30c Right console
X842-3 Plug connection blocking diode / 2-pin 33 Right console
X856 Plug connection to BST excavator control / 40-pin 2/15/20- Right console
23/26-29/
34
X857 Plug connection to BST excavator control / 24-pin 21a/22- Right console
23/26/28/
34
X859 Plug connection, 21-pin 30a/30b Operator's platform, rear
X860 Plug connection, 6-pin 30a Operator's platform, rear
X863 Plug connection, 15-pin 30a/30b Operator's platform, rear
X924-1 Plug connection B290 / 3-pin 34 Below operator's platform
X950 Plug connection console display autocheck / 21-pin 4/10/13/ Right console
21a/33/
36/38/40
X951 Plug connection console display autocheck / 21-pin 4/10/13/ Right console
21b/34/
38/40
X952 Plug connection revolving deck BST excavator control / 21- 10-15/25/ Right console
pin 30c/33/
34/40
X953 Plug connection revolving deck distribution board / 21-pin 1/4-6/12/ Right console
13/17/
21a/36/42
X954 Plug connection revolving deck BST excavator control / 21- 2/12/20/ Right console
pin 22/26/27/
29
X955 Plug connection revolving deck distribution board / 15-pin 1a/3/4/35/ Right console
38
X956 Plug connection BST excavator control distribution board / 2/15 /20- Right console
21-pin 23/26/28/
34/43
X957 Plug connection switch distribution board / 21-pin 8/11/20/ Right console
22/25/34/
35/
X958 Plug connection switch distribution board / 21-pin 18/28/34/ Right console
35/36/38/
43
X959 Plug connection fuse distribution board / 21-pin 15/30c/ Right console
35/40
X960 Plug connection operator's platform distribution board / 21- 4/6/9/21a/ Right console
pin 28/33/34
X961 Plug connection display distribution board / 21-pin 2/6/13/17/ Right console
20/21a/
21b/33
A 309 LI 29269- 8.22.7

MJFCIFSS

X962 Plug connection display distribution board / 21-pin 4/10/13/ Right console
14/21b/
28/34/38/
40
X963 Plug connection fuse distribution board / 21-pin 6/8/9/11/ Right console
13-16/23/
24/28/35
X964 Plug connection fuse distribution board / 21-pin 1a/3/4/13/ Right console
14/16/28/
33/43
X965 Plug connection BST excavator control distribution board / 26/34 Right console
21-pin
X966 Plug connection A 125 distribution board / 21-pin 8/10/12/ Right console
14/25/28/
32/34/43
X967 Plug connection display distribution board / 21-pin 5/6/8/37 Right console
X967-1 Plug connection wire harness connection / 1-pin 45 Operator's platform, rear
X968-1 Plug connection quantity 2 / 1-pin 34 Right console
X968-2 Plug connection quantity 3 / 1-pin 34 Right console
X971 Plug connection seat adjustment / 2-pin 31 Operator's platform
X972 Plug connection seat heating / 2-pin 32 Operator's platform
X973 Power socket, 12V 8 Left console
X974-4 Plug connection blocking diode / 2-pin 34 Cab, right
X1046 Plug connection, 12-pin 10/25 Left console
X1047 Plug connection B19L / 3-pin 28 Left pilot control unit
X1048 Plug connection, 12-pin 4/40 Right pilot control unit
X1049 Plug connection B19R / 3-pin 28 Right pilot control unit
X1090 Plug connection, 6-pin 12 Below operator's platform
X1104 Plug connection / -pin 35 Right console
X1106 Plug connection / 4-pin 14/15 Right console
X1117 Plug connection: 4-wheel steering, 6-pin 12/14/43 Right console
X1118 Plug connection: blocking diode, 2-pin 13 Right console
Y3 Solenoid valve / pilot pressure 15 Control oil unit

Y12 Solenoid valve / excess fuel for starting 1a Regulator / motor
Y20 Magnetic clutch / a/c compressor 30c Diesel engine
Y22 Solenoid valve / grapple rotator 25 Control valve block
Y24 Solenoid valve / creeper gear 11 Control oil unit
Y28-1 Solenoid valve / quick change adapter 38 Quick-change adapter
Y28-2 Solenoid valve / quick change adapter 38 Quick-change adapter
Y29 Solenoid valve / engine shut-down 3 Regulating rod / motor
Y50 Proportional solenoid valve / power control 26 Control oil unit
Y51 Proportional solenoid valve / flow limitation 26 Control oil unit
Y55 Solenoid valve / first gear 11 HBGV block
Y60 Solenoid valve / parking brake 11 HBGV block
Y56 Solenoid valve / blade 35 Undercarriage
Y62 Solenoid valve / forward travel 10 Hydraulic tank
8.22.8 A 309 LI 29269-

MJFCIFSS

Y63 Solenoid valve / reverse travel 10 Hydraulic tank
Y217 Solenoid valve / outrigger, rear left 35 Undercarriage
Y218 Solenoid valve / outrigger, rear right 35 Undercarriage
Y229-1 Solenoid valve: dog-walk steering mode 12 Undercarriage
Y229-2 Solenoid valve: 4-wheel steering 12 Undercarriage
Y262 Solenoid valve: bucket swivel bearing 40 Fuel tank
Y268 Solenoid valve / flow reduction, AHS 34 Near control oil unit
Y294-1 Solenoid valve: 4-wheel steering 12 Below operator's platform
Y294-2 Solenoid valve: 4-wheel steering 12 Below operator's platform
Y299 Solenoid valve / flow reduction, AHS 34 Near control oil unit
Y352 Proportional solenoid valve / fan control 29 Fan / radiator
Y358 Proportional solenoid valve / motor speed with plug 22 Bulkhead
Y371 Solenoid valve/oscillating axle support 33 Near control oil unit
Y451 Solenoid valve / combined lifting of boom 34 Near control oil unit
A 309 LI 29269- 8.22.9

MJFCIFSS
1a power supply, board A127
8.22.10 A 309 LI 29269-

MJFCIFSS
1b power supply, board A127 / fuses
A 309 LI 29269- 8.22.11

MJFCIFSS
1c power supply, board A 127 / relay
8.22.12 A 309 LI 29269-

MJFCIFSS
2 Pre-heating
A 309 LI 29269- 8.22.13

MJFCIFSS
3 Motor shut-down
8.22.14 A 309 LI 29269-

MJFCIFSS
A 309 LI 29269- 8.22.15

MJFCIFSS
5 Work headlight
8.22.16 A 309 LI 29269-

MJFCIFSS
A 309 LI 29269- 8.22.17

MJFCIFSS
8.22.18 A 309 LI 29269-

MJFCIFSS
A 309 LI 29269- 8.22.19

MJFCIFSS
9 Brake light
8.22.20 A 309 LI 29269-

MJFCIFSS
A 309 LI 29269- 8.22.21

MJFCIFSS
11 Creeper gear first gear
8.22.22 A 309 LI 29269-

MJFCIFSS
12 Optional 4-wheel steering
A 309 LI 29269- 8.22.23

MJFCIFSS
13 Parking brake
8.22.24 A 309 LI 29269-

MJFCIFSS
14 Safety switch
A 309 LI 29269- 8.22.25

MJFCIFSS
15 Servo
8.22.26 A 309 LI 29269-

MJFCIFSS
A 309 LI 29269- 8.22.27

MJFCIFSS
8.22.28 A 309 LI 29269-

MJFCIFSS
A 309 LI 29269- 8.22.29

MJFCIFSS
8.22.30 A 309 LI 29269-

MJFCIFSS
A 309 LI 29269- 8.22.31

MJFCIFSS
22 Speed adjustment
8.22.32 A 309 LI 29269-

MJFCIFSS
A 309 LI 29269- 8.22.33

MJFCIFSS
25 Optional AS I
8.22.34 A 309 LI 29269-

MJFCIFSS
A 309 LI 29269- 8.22.35

MJFCIFSS
27 Speed sensor
8.22.36 A 309 LI 29269-

MJFCIFSS
28 Sensor control
A 309 LI 29269- 8.22.37

MJFCIFSS
29 Fan control
8.22.38 A 309 LI 29269-

MJFCIFSS
30a Heating
A 309 LI 29269- 8.22.39

MJFCIFSS
30b Heating
8.22.40 A 309 LI 29269-

MJFCIFSS
30c Heating
A 309 LI 29269- 8.22.41

MJFCIFSS
31 Electrical set adjustment / seat made by Isringhausen
8.22.42 A 309 LI 29269-

MJFCIFSS
32 Seat heating / seat made by Isringhausen
A 309 LI 29269- 8.22.43

MJFCIFSS
8.22.44 A 309 LI 29269-

MJFCIFSS
A 309 LI 29269- 8.22.45

MJFCIFSS
8.22.46 A 309 LI 29269-

MJFCIFSS
A 309 LI 29269- 8.22.47

MJFCIFSS
37 Optional beacon
8.22.48 A 309 LI 29269-

MJFCIFSS
A 309 LI 29269- 8.22.49

MJFCIFSS
40 Swivel bearing
8.22.50 A 309 LI 29269-

MJFCIFSS
42 Ground
A 309 LI 29269- 8.22.51

MJFCIFSS
43 Ground
8.22.52 A 309 LI 29269-

MJFCIFSS
44 Ground
A 309 LI 29269- 8.22.53

MJFCIFSS
45 Terminal 30 / terminal 15
8.22.54 A 309 LI 29269-

MJFCIFSS
Electrical system
Item Description Step Location/arrangement

21a/21b/
24/33/34/
36/38/40/
41
2/3 lic tank
A1017 Printed circuit board / quick change adapter 38 Distribution board

B3 Transducer / motor coolant, with plug 21a Engine compartment
rator's platform
piston side
B26 Proximity switch / quick-change adapter 38 Quick change adapter
rator's platform
B204 Proximity switch / industrial shut-down 39 Attachment
B285 Transducer hydraulic oil temperature / fan control 29 Hydraulic tank
B290 Proximity switch / kit pedal 34 Operator's platform

E8 Cigarette lighter 8 Right bracket, rear
A 312 LI 12363- 8.30.1

A 316 LI 2001- MJFCIFSS
A 316 LI-IND 2001-

2/3/40

F300
F301
F302
F307 Fuse E16, E17, P6, P7, P50 7.5A 6 Right bracket, rear
F308 Fuse E15, E18 7.5A 6 Right bracket, rear
F309 Fuse E3 7.5A 6 Right bracket, rear
F311 Fuse M3, M4 15A 7 Right bracket, rear
F315 Fuse BST 15A 23 Right bracket
F316 Fuse servo control 7.5A 28 Right bracket
F317 Fuse beacon 7.5A 37 Right bracket, rear
F318 Fuse heating / air conditioning, terminal 30 20A 30c Right bracket
8.30.2 A 312 LI 12363-

MJFCIFSS A 316 LI 2001-
A 316 LI-IND 2001-

F323 Fuse E1 15A 5 Right bracket, rear
F324 Fuse S22 - E2, S22-1 - E150 15A 5 Right bracket, rear
F330 Fuse kits 7.5A 24 Right bracket
F337 Fuse support 15A 35 Right bracket
F339 Fuse a/c condenser 20A 30c Right bracket
F343 Fuse roof window wiper 7.5A 7b Right bracket

H7 Indicator light / motor oil pressure 21a Right bracket

H11 Indicator light / pre-heating 2 Right bracket
H12 Indicator light / charging 21b Right bracket
H13 Indicator light / air filter contamination 21a Right bracket
H15 Indicator light / hydraulic oil temperature 21a Right bracket
H16 Indicator light / overload warning (kit) 36 Right bracket
H18 Indicator light / coolant level 21a Right bracket
H19 Indicator light / indicator 4 Right bracket
H20 Indicator light / parking brake 13 Right bracket
H23 Indicator light / accumulator pressure 21a Right bracket
H26 Indicator light / quick-change adapter 38 Right bracket
H27 Warning buzzer 13 Right bracket
H167 Indicator light / forward travel 10 Right bracket
H168 Indicator light / reverse travel 10 Right bracket
H175 Indicator light / motor overheating 21a Right bracket
H176 Indicator light / oscillating-axle locking device 33 Right bracket
H186 Indicator light / swivel bearing 40 Right bracket
H196 Indicator light / sorting grapple 34 Right bracket
H301 Indicator light / error BST 26 A125, left bracket
H307 Indicator lamp / delta P 24 Right bracket
H311 Indicator light / oscillating axle locked 33 Right bracket

A 312 LI 12363- 8.30.3

A 316 LI-IND 2001-

K16-1 Relay, terminal 50 1a A127, hydraulic tank
K63 Relay / direction indicator 4 Right bracket
K250 Relay / oscillating axle automatic 33 Right bracket
K251 Relay / hand brake (indicator light H20) 13 Right bracket
K252 Relay servo / hand brake (buzzer) 13 Right bracket
K315 Relay brake light 9 Right bracket
board
K370 Relay terminal 15, servo 15 Right bracket
K386 Relay / safety switch S7 14 Right bracket
K392 Relay / optional industry shutt off 39 Right bracket

M60 Windscreen washer system / roof (optional) 7b Cab, top
P1 Potentiometer / flow limitation 1 26 A125, left bracket

P5 Display / operating hour meter 19 Right bracket, bottom
P6 Display / motor temperature 20 Right bracket
P7 Indicator / fuel level 17 Right bracket
P50 Display / clock 18 Right bracket

R75 Potentiometer / speed 22 Right bracket
R76 Potentiometer / fine adjustment 24 Right bracket
R78 -2 Seat heating 32 Operator's platform
8.30.4 A 312 LI 12363-

A 316 LI-IND 2001-

S1 Code switch A125 26 A125, left bracket
S7 Safety switch 14 Left bracket
S8 Switch / beacon 37 Right bracket, rear
S11 Switch / windscreen washer system M3 7 Right bracket, rear
S14 Switch / windscreen wipers M4 7 Right bracket, rear
S16 Switch / parking brake Y6 13 Right bracket
S18 Switch / overload warning system (optional) 36 Right bracket
S19 Switch / grapple rotator Y22, Y23 25 Right bracket
S20 Switch / sensor control 28 Right bracket
S21 Switch / creeper gear Y24 11 Right bracket
S22 Switch / work light E1 / roof light E2 5 Right bracket, rear
S22-1 Switch / auxiliary headlight / roof light 5 Right bracket, rear
S35 Switch servo 15 Right bracket
S42 Switch / first gear Y55 12 Right bracket
S44 Switch / hazard light 4 Right bracket
S45 Switch / priotity (optional) 34 Right bracket
S46 Switch / magnet system (optional) 41 Right bracket
S47 Switch / bucket quick-change adapter (optional) 38 Right bracket
S61 Switch / lighting installation 6 Right bracket, rear
S75 Switch / oscillating axle locking device Y371 33 Right bracket
S90 Intervall switch / windshield wiper 7a Cab right
S92 Potentiometer / air distribution 30a Right bracket
S93 Potentiometer / heating / air condition 30a Right bracket
S204 Switch / outrigger, front left 35 Right bracket
S205 Switch / outrigger, front right 35 Right bracket
S206 Switch / outrigger, rear left 35 Right bracket
S207 Switch / outrigger, rear right 35 Right bracket
S216 Push button / bypass 39 Right bracket
S218 Switch / roof window wiper (optional) 7b Right bracket, rear
S241 Switch / accessory kit AHS 11 / AHS 12 (optional) 34 Right bracket
S272 Junction box, undercarriage 35 Undercarriage
S284 Switch / four-step blower 30b Right bracket
S335 Switch / blade (optional) 35 Right bracket
S360 Switch / mute switch for overload buzzer 38 Right bracket
S382 Switch / fine adjustment ON / OFF 24 Right bracket
S398 Reversing switch / air distribution 30a Right bracket
A 312 LI 12363- 8.30.5

A 316 LI-IND 2001-

U16 BST excavator control system 2/20-24/ Right bracket

26-29/34/
41
V155 Blocking diode / oscillating axle 33 Right bracket
V156-1 Blocking diode H307 - BST 24 Right bracket
V156-3 Blocking diode S14-S90 7a Right bracket
V156-4 Diode / input quantity 34 Right bracket

X15-2 Plug connection / 2-pin 25 Left bracket
X65 Plug connection on voltage transformer / 2-pin 8 Right bracket
X80 Plug connection B19L / 3-pin 28 Pilot control valve, left
X81 Plug connection B19R / 3-pin 28 Pilot control valve, right
X262-4 Plug connection wire harness quick-change adapter / 2-pin 38 Quick change adapter
X301 Plug connection wire harness, 12-pin 35 Revolving deck
X304 Plug connection wire harness, console / 6-pin 35 Right bracket
X327 Plug connection wire harness / revolving deck 39 Basic boom bearing block
X342 Plug connection / 3-pin 10 Left bracket
X406 Plug connection transducer fuel reserve / 3-pin 17 Revolving deck X
8.30.6 A 312 LI 12363-

A 316 LI-IND 2001-

X838-3 Plug connection CAN - bus / 2-pin 26 Left bracket
X842-1 Plug connection air-conditioning / 15-pin 30c Right bracket
X842-2 Plug connection console, ignition switch / 2-pin 30c Right bracket
X842-3 Plug connection blocking diode / 2-pin 33 Right bracket
X856 Plug connection to BST excavator control / 40-pin 2/20-24/ Right bracket
26-29/34
24/26/28/
34
X859 Plug connection / 21-pin 30a/30b Operator's platform, rear
X860 Plug connection / 6-pin 30a Operator's platform, rear
X909 Plug connection fine control / 2-pin 30a/30b Operator's platform, rear
X950 Plug connection console display autocheck / 21-pin 4/10/13/ Right bracket
21a/33/
36/38/40/
41
21b/34/
38/40/41
X952 Plug connection revolving deck BST excavator control / 21- 10-13/15/ Right bracket
pin 25/30c/
33/34
X953 Plug connection revolving deck distribution board / 21-pin 1/4-6/9/ Right bracket
13/17/
21a/36/42
X954 Plug connection revolving deck BST excavator control / 21- 2/20/22/ Right bracket
pin 26/27/29
X955 Plug connection revolving deck distribution board / 15-pin 1a/3/4/38/ Right bracket
39
X956 Plug connection BST excavator control distribution board / 2/20-24/ Right bracket
21-pin 28/34/41/
43
X957 Plug connection switch distribution board / 21-pin 8/11/12/ Right bracket
20/22/25/
34/35
35/36/38/
39/41/43
X959 Plug connection fuse distribution board / 21-pin 10/24/30c Right bracket
A 312 LI 12363- 8.30.7

A 316 LI-IND 2001-

X960 Plug connection operator's platform distribution board / 21- 4/6/9/21a/ Right bracket
pin 28/33/34/
40
X961 Plug connection display distribution board / 21-pin 2/6/13/17/ Right bracket
20/21a/
21b/24/33
X962 Plug connection display distribution board / 21-pin 4/10/13/ Right bracket
14/21b/
28/34/38/
40/41
X963 Plug connection fuse distribution board / 21-pin 6/8/9/11/ Right bracket
13/14/16/
23/24/28/
35
X964 Plug connection fuse distribution board / 21-pin 1a/3/4/13/ Right bracket
14/28/33/
43
X965 Plug connection BST excavator control distribution board / 26/34 Right bracket
21-pin
X966 Plug connection A 125 distribution board / 21-pin 8/14/24/ Right bracket
25/28/32/
34/43
X967 Plug connection display distribution board / 21-pin 5/6/8/37 Right bracket
X968-1 Plug connection quantity 2 / 1-pin 34 Right bracket
X974-3 Plug connection blocking diode / 2-pin 7a Right bracket

Y20 magnetic clutch / a/c compressor 30c Diesel engine
Y28-1 Solenoid valve / quick change adapter 38 Quick change adapter
8.30.8 A 312 LI 12363-

A 316 LI-IND 2001-

Y212 Solenoid valve / industrial shut-down 39 Uppercarriage
Y215 Solenoid valve / outrigger, front left 35 Undercarriage
Y216 Solenoid valve / outrigger, front right 35 Undercarriage
Y268 Solenoid valve / flow reduction, AHS 34 Hydraulic tank
Y358 Proportional solenoid valve / motor speed with plug 22 Control valve block panel
Y371 Solenoid valve/oscillating axle support 33 Control oil unit
A 312 LI 12363- 8.30.9

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

A 316 LI-IND 2001-
A 312 LI 12363- 8.30.11

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

A 316 LI-IND 2001-
2 Pre-heating
A 312 LI 12363- 8.30.13

A 316 LI-IND 2001-
3 Motor shut-down
8.30.14 A 312 LI 12363-

A 316 LI-IND 2001-
A 312 LI 12363- 8.30.15

A 316 LI-IND 2001-
5 Work headlight
8.30.16 A 312 LI 12363-

A 316 LI-IND 2001-
A 312 LI 12363- 8.30.17

A 316 LI-IND 2001-
7a Windscreen wiper / washer systems only A 314 / 316 from 2001
8.30.18 A 312 LI 12363-

A 316 LI-IND 2001-
7b Windscreen wiper/washer systems A 312 from 12363/A 314/316 from 12736
A 312 LI 12363- 8.30.19

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

A 316 LI-IND 2001-
9 Brake light
A 312 LI 12363- 8.30.21

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

A 316 LI-IND 2001-
11 Creeper speed
A 312 LI 12363- 8.30.23

A 316 LI-IND 2001-
12 1st gear
8.30.24 A 312 LI 12363-

A 316 LI-IND 2001-
13 Parking brake
A 312 LI 12363- 8.30.25

A 316 LI-IND 2001-
14 Safety switch
8.30.26 A 312 LI 12363-

A 316 LI-IND 2001-
15 Servo
A 312 LI 12363- 8.30.27

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

A 316 LI-IND 2001-
Fuel gauge 18 Clock 19 Hour meter
A 312 LI 12363- 8.30.29

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

A 316 LI-IND 2001-
A 312 LI 12363- 8.30.31

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

A 316 LI-IND 2001-
22 Speed adjustment
A 312 LI 12363- 8.30.33

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

A 316 LI-IND 2001-
24 Fine control
A 312 LI 12363- 8.30.35

A 316 LI-IND 2001-
25 Optional AS I
8.30.36 A 312 LI 12363-

A 316 LI-IND 2001-
A 312 LI 12363- 8.30.37

A 316 LI-IND 2001-
27 Speed sensor
8.30.38 A 312 LI 12363-

A 316 LI-IND 2001-
28 Sensor control
A 312 LI 12363- 8.30.39

A 316 LI-IND 2001-
29 Fan control
8.30.40 A 312 LI 12363-

A 316 LI-IND 2001-
30a Heating
A 312 LI 12363- 8.30.41

A 316 LI-IND 2001-
30b Heating
8.30.42 A 312 LI 12363-

A 316 LI-IND 2001-
30c Heating
A 312 LI 12363- 8.30.43

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

A 316 LI-IND 2001-
A 312 LI 12363- 8.30.45

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

A 316 LI-IND 2001-
A 312 LI 12363- 8.30.47

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

A 316 LI-IND 2001-
A 312 LI 12363- 8.30.49

A 316 LI-IND 2001-
37 Optional beacon
8.30.50 A 312 LI 12363-

A 316 LI-IND 2001-
A 312 LI 12363- 8.30.51

A 316 LI-IND 2001-
39 Optional industrial shut-down
8.30.52 A 312 LI 12363-

A 316 LI-IND 2001-
40 Reserve
A 312 LI 12363- 8.30.53

A 316 LI-IND 2001-
41 Optional magnet system
8.30.54 A 312 LI 12363-

A 316 LI-IND 2001-
42 Ground
A 312 LI 12363- 8.30.55

A 316 LI-IND 2001-
43 Ground
8.30.56 A 312 LI 12363-

A 316 LI-IND 2001-
44 Ground
A 312 LI 12363- 8.30.57

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

A 316 LI-IND 2001-
Electrical system

21a/21b/
24/33/34/
36/38/40/
41/47
2/3 lic tank
A1017 Printed circuit board / quick change adapter 38 Distribution board

B3 Transducer / motor coolant, with plug 21a/47 Engine compartment
B7 Vacuum switch / air filter 21a/47 Suction pipe / air filter
B8 Switch / hydraulic oil temperature 21a/47 Hydraulic tank, bottom
B20 Pressure switch / accumulator pressure 21a/47 Brake block beneath ope-
rator's platform
piston side
rator's platform
B204 Proximity switch / industrial shut-down 39 Attachment
E1 Work light / attachment 5,46 Attachment

E2L Front roof light left 46 Front cab roof
E2R Front roof light right 46 Front cab roof
E8 Cigarette lighter 8 Right bracket, rear
A 312 LI 20330- 8.32.1

A 316 LI-IND 20340-

2/3/40

F300
F301
F302
F307 Fuse E16, E17, P6, P7, P50 7.5A 6 Right bracket, rear
F308 Fuse E15, E18 7.5A 6 Right bracket, rear
F311 Fuse M3, M4 15A 7 Right bracket, rear
F315 Fuse BST 15A 23 Right bracket
F316 Fuse servo control 7.5A 28 Right bracket
F317 Fuse beacon 7.5A 37 Right bracket, rear
8.32.2 A 312 LI 20330-

A 316 LI-IND 20340-

F323 Fuse E1 15A 5, 46 Right bracket, rear
F324 Fuse S22 - E2, S22-1 - E150 15A 5, 46 Right bracket, rear
F330 Fuse kits 7.5A 24 Right bracket
F337 Fuse support 15A 35 Right bracket
F339 Fuse a/c condenser 20A 30c Right bracket
F343 Fuse roof window wiper 7.5A 7 Right bracket


H13 Indicator light / air filter contamination 21a/47 Right bracket
H15 Indicator light / hydraulic oil temperature 21a/47 Right bracket
H18 Indicator light / coolant level 21a/47 Right bracket
H19 Indicator light / indicator 4 Right bracket
H20 Indicator light / parking brake 13 Right bracket
H23 Indicator light / accumulator pressure 21a/47 Right bracket
H167 Indicator light / forward travel 10 Right bracket
H168 Indicator light / reverse travel 10 Right bracket
H175 Indicator light / motor overheating 21a/47 Right bracket
H176 Indicator light / oscillating-axle locking device 33 Right bracket
H186 Indicator light / swivel bearing 40 Right bracket
H311 Indicator light / oscillating axle locked 33 Right bracket
H336 Warning lamp / water in fuel filter 33 Right bracket
A 312 LI 20330- 8.32.3

A 316 LI-IND 20340-

K63 Relay / direction indicator 4 Right bracket
K250 Relay / oscillating axle automatic 33 Right bracket
K251 Relay / hand brake (indicator light H20) 13 Right bracket
K252 Relay servo / hand brake (buzzer) 13 Right bracket
K315 Relay brake light 9 Right bracket
board
K370 Relay terminal 15, servo 15 Right bracket
K447 Relay / Front roof light 46 Operator's platform, rear
K448 Relay / Rear roof light 46 Operator's platform, rear
K449 Relay / Front work light 46 Operator's platform, rear


P5 Display / operating hour meter 19 Right bracket, bottom

8.32.4 A 312 LI 20330-

A 316 LI-IND 20340-

R78 -2 Seat heating 32 Operator's platform

S1 Code switch A125 26 A125, left bracket
S5M Push button, centre (no function) 25 Left pilot control unit
S16 Switch / parking brake Y6 13 Right bracket
S21 Switch / creeper gear Y24 11 Right bracket
S22 Switch / work light E1 / roof light E2 5, 46 Right bracket, rear
S22-1 Switch / auxiliary headlight / roof light 5, 46 Right bracket, rear
S35 Switch servo 15 Right bracket
S42 Switch / first gear Y55 12 Right bracket
S44 Switch / hazard light 4 Right bracket
S75 Switch / oscillating axle locking device Y371 33 Right bracket
S204 Switch / outrigger, front left 35 Right bracket
S205 Switch / outrigger, front right 35 Right bracket
S206 Switch / outrigger, rear left 35 Right bracket
S207 Switch / outrigger, rear right 35 Right bracket
S216 Push button / bypass 39 Right bracket
S218 Switch / roof window wiper (optional) 7 Right bracket, rear
S241 Switch / accessory kit AHS 11 / AHS 12 (optional) 34 Right bracket
S272 Junction box, undercarriage 35 Undercarriage
S335 Switch / blade (optional) 35 Right bracket
S360 Switch / mute switch for overload buzzer 38 Right bracket
S382 Switch / fine adjustment ON / OFF 24 Right bracket
A 312 LI 20330- 8.32.5

A 316 LI-IND 20340-

S422 Switch / mute switch for radio 8 Right bracket
U16 BST excavator control system 2/20-24/ Right bracket

26-29/34/
41

X301 Plug connection wire harness, 12-pin 35 Revolving deck
X327 Plug connection wire harness / revolving deck 39 Basic boom bearing block
X406 Plug connection transducer fuel reserve / 3-pin 17 Revolving deck X
8.32.6 A 312 LI 20330-

A 316 LI-IND 20340-

X838-3 Plug connection CAN - bus / 2-pin 26 Left bracket
X856 Plug connection to BST excavator control / 40-pin 2/20-24/ Right bracket
26-29/34
24/26/28/
34/47
21a/33/
36/38/40/
41/47
21b/34/
38/40/41
X952 Plug connection revolving deck BST excavator control / 21- 10-13/15/ Right bracket
pin 25/30c/
33/34
X953 Plug connection revolving deck distribution board / 21-pin 1/4-6/9/ Right bracket
13/17/
21a/36/
42/47
X954 Plug connection revolving deck BST excavator control / 21- 2/20/22/ Right bracket
pin 26/27/29
X955 Plug connection revolving deck distribution board / 15-pin 1a/3/4/38/ Right bracket
39
21-pin 28/34/41/
43
20/22/25/
34/35
35/36/38/
39/41/43
A 312 LI 20330- 8.32.7

A 316 LI-IND 20340-

pin 28/33/34/
47
20/21a/
21b/24/
33/47
14/21b/
28/34/38/
40/41
13/14/16/
23/24/28/
35
14/28/33/
43
21-pin
25/28/32/
34/43
46
X1046 Plug connection / 12-pin 24/25 Left bracket
X1048 Plug connection / 12-pin 10 Right pilot control unit
X1116 Plug connection / 2-pin 15 Right bracket

Y20 magnetic clutch / a/c compressor 30c Diesel engine
8.32.8 A 312 LI 20330-

A 316 LI-IND 20340-

Y212 Solenoid valve / industrial shut-down 39 Uppercarriage
Y215 Solenoid valve / outrigger, front left 35 Undercarriage
Y216 Solenoid valve / outrigger, front right 35 Undercarriage
Y371 Solenoid valve/oscillating axle support 33 Control oil unit
A 312 LI 20330- 8.32.9

A 316 LI-IND 20340-
8.32.10 A 312 LI 20330-

A 316 LI-IND 20340-
A 312 LI 20330- 8.32.11

A 316 LI-IND 20340-
8.32.12 A 312 LI 20330-

A 316 LI-IND 20340-
2 Pre-heating
A 312 LI 20330- 8.32.13

A 316 LI-IND 20340-
3 Motor shut-down
8.32.14 A 312 LI 20330-

A 316 LI-IND 20340-
A 312 LI 20330- 8.32.15

A 316 LI-IND 20340-
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 A 312 LI 20330-

A 316 LI-IND 20340-
A 312 LI 20330- 8.32.17

A 316 LI-IND 20340-
8.32.18 A 312 LI 20330-

A 316 LI-IND 20340-
A 312 LI 20330- 8.32.19

A 316 LI-IND 20340-
9 Brake light
8.32.20 A 312 LI 20330-

A 316 LI-IND 20340-
A 312 LI 20330- 8.32.21

A 316 LI-IND 20340-
11 Creeper speed
8.32.22 A 312 LI 20330-

A 316 LI-IND 20340-
12 1st gear
A 312 LI 20330- 8.32.23

A 316 LI-IND 20340-
13 Parking brake
8.32.24 A 312 LI 20330-

A 316 LI-IND 20340-
14 Safety switch
A 312 LI 20330- 8.32.25

A 316 LI-IND 20340-
15 Servo
8.32.26 A 312 LI 20330-

A 316 LI-IND 20340-
A 312 LI 20330- 8.32.27

A 316 LI-IND 20340-
8.32.28 A 312 LI 20330-

A 316 LI-IND 20340-
A 312 LI 20330- 8.32.29

A 316 LI-IND 20340-

(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 A 312 LI 20330-

A 316 LI-IND 20340-
A 312 LI 20330- 8.32.31

A 316 LI-IND 20340-
22 Speed adjustment
8.32.32 A 312 LI 20330-

A 316 LI-IND 20340-
A 312 LI 20330- 8.32.33

A 316 LI-IND 20340-
24 Fine control
8.32.34 A 312 LI 20330-

A 316 LI-IND 20340-
25 Optional AS I
A 312 LI 20330- 8.32.35

A 316 LI-IND 20340-
8.32.36 A 312 LI 20330-

A 316 LI-IND 20340-
27 Speed sensor
A 312 LI 20330- 8.32.37

A 316 LI-IND 20340-
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 A 312 LI 20330-

A 316 LI-IND 20340-
29 Fan control
A 312 LI 20330- 8.32.39

A 316 LI-IND 20340-
30a Heating
8.32.40 A 312 LI 20330-

A 316 LI-IND 20340-
30b Heating
A 312 LI 20330- 8.32.41

A 316 LI-IND 20340-
30c Heating
8.32.42 A 312 LI 20330-

A 316 LI-IND 20340-
A 312 LI 20330- 8.32.43

A 316 LI-IND 20340-
8.32.44 A 312 LI 20330-

A 316 LI-IND 20340-
A 312 LI 20330- 8.32.45

A 316 LI-IND 20340-
8.32.46 A 312 LI 20330-

A 316 LI-IND 20340-
A 312 LI 20330- 8.32.47

A 316 LI-IND 20340-
8.32.48 A 312 LI 20330-

A 316 LI-IND 20340-
37 Optional beacon
A 312 LI 20330- 8.32.49

A 316 LI-IND 20340-
8.32.50 A 312 LI 20330-

A 316 LI-IND 20340-
A 312 LI 20330- 8.32.51

A 316 LI-IND 20340-
40 Reserve
8.32.52 A 312 LI 20330-

A 316 LI-IND 20340-
A 312 LI 20330- 8.32.53

A 316 LI-IND 20340-
42 Ground
8.32.54 A 312 LI 20330-

A 316 LI-IND 20340-
43 Ground
A 312 LI 20330- 8.32.55

A 316 LI-IND 20340-
44 Ground
8.32.56 A 312 LI 20330-

A 316 LI-IND 20340-
A 312 LI 20330- 8.32.57

A 316 LI-IND 20340-
46 (5) Work headlight

(on machine A 316 from 25766)
8.32.58 A 312 LI 20330-

A 316 LI-IND 20340-
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 20330- 8.32.59

A 316 LI-IND 20340-
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 A 312 LI 20330-

A 316 LI-IND 20340-
Electrical system
A3 Radio (optional) 8 Operator's cab, back
A 125 Potentiometer board 26/34 Left bracket
A 126 Printed circuit board (autocheck) 4/10/13/ Right bracket
21a/21b/
24/33/34/
36/38/40/
41
A 127 Printed circuit board / power 1a/1b/1c/ Hydraulic tank
2/3
A 1017 Printed circuit board/quick change adapter 38 Distribution board
B1 Transducer/fuel level - with plug 17 Fuel tank

B2 Temperature sensor / motor coolant 20 Motor
B3 Transducer / motor coolant - with plug 21a Expansion tank
B12 Transducer / motor speed 27 Flywheel housing
B21 Pressure switch / overload 36 Boom cylinder / piston
side
B40L Proximity switch / pilot control unit, left, travel 28 Travelling pedal, left
B40R Proximity switch / pilot control unit, right, travel 28 Travelling pedal, right

E8 Cigarette lighter 8 Bracket, rear, right
2/3

R 317 LI 18161- 8.40.1

copyright by
MJFCIFSS

F300
F301
F22/ Fuse A127 terminal 15, terminal 30, B3, S44 7.5A 1b A127, hydraulic tank
F302
F304 Fuse S1 15A 1a Right bracket, front
F305 Fuse E7, E8, P50 15A 8 Right bracket, front
F306 Fuse X10 15A 16 Right bracket, front
F307 Fuse E16, E17, P6, P7, P50 7.5A 6 Bracket, rear, right
F308 Fuse E15, E18 7.5A 6 Bracket, rear, right
F309 Fuse E3 7.5A 6 Bracket, rear, right
F310 Fuse E4 7.5A 6 Bracket, rear, right
F311 Fuse M4 15A 7 Bracket, rear, right
F314 Fuse S7 3A 14 Right bracket, front
F315 Fuse BST 15A 23 Right bracket, front
F316 Fuse servo control 7.5A 28 Right bracket, front
F317 Fuse servo control 7.5A 37 Bracket, rear, right
F318 Fuse heating / air conditioning, terminal 30 20A 30c Right bracket, front
F319 Fuse heating / air conditioning, terminal 15 15A 30c Right bracket, front
F322 Fuse T1 7.5A 8 Right bracket, front
F323 Fuse E1 15A 5 Bracket, rear, right
F324 Fuse S22 - E2, S22-1 - E150 15A 5 Bracket, rear, right
F326 Fuse S21 - Y24 15A 11 Right bracket, front
F329 Fuse servo 5A 15 Right bracket, front
F330 Fuse kits 15A 24 Right bracket, front
F332 Fuse A127, M1, Y12 25A 1a Hydraulic tank
F336 Fuse S61 20A 6 Right bracket, front
F337 Fuse support 15A 35 Right bracket, front
F338 Fuse H9, seat heating 15A 4 Right bracket, front
F339 Fuse a/c condenser 20A 30c Right bracket, front
F343 Fuse roof window wiper 7.5A 7 Bracket, rear, right
8.40.2 R 317 LI 18161-

copyright by
MJFCIFSS


H13 Indicator light / air filter contamination 21a Right bracket
H15 Indicator light / hydraulic oil temperature 21a Right bracket
H18 Indicator light / coolant level 21a Right bracket
H175 Indicator light / motor overheating 21a Right bracket

board
K370 Relay / fine control, grapple rotation 15 Right bracket
K375 Relay / kit - quantity 34 Operator's platform, back
K393 Relay / air-spring seat 31 Operators platform

M70 Motor / air-spring seat 31 Operators platform
R 317 LI 18161- 8.40.3

copyright by
MJFCIFSS
P1 Potentiometer / flow limitation 1 26 Left bracket

P5 Display / operating hour meter 19 Left bracket, bottom

R78-1 Seat heating 32 Operators platform
R78-2 Seat heating 32 Operators platform
S1 Ignition switch 1a Right bracket

S1 Code switch A125 26 Left bracket
S5L Push button/turning grapple to the left, Y22 25 Left pilot control unit
S5M Push button, centre (no function) 25 Left pilot control unit
S17 Switch / slewing gear brake Y7 15 Right bracket
S21 Switch / rapid gear Y24 11 Right bracket
S22 Switch / work light E1 / roof light E2 5 Right bracket, rear
S22-1 Switch / auxiliary headlight / roof light 5 Right bracket, rear
S218 Switch / roof window wiper (optional) 7 Right bracket, rear
S241 Switch / accessory kit AHS 11 / AHS 12 (optional) 34 Right bracket, rear
S283 Switch / windscreen wiper release 7 Windscreen, bottom
S360 Push button / muting overload buzzer (optional) 38 Right bracket
S382 Switch / fine adjustment ON / OFF 24 Right pilot control unit
8.40.4 R 317 LI 18161-

copyright by
MJFCIFSS

S422 Switch / mute switch for radio 8 Right bracket
T1 Voltage transformer / radio 8 Right bracket
U16 BST excavator control system 2/20/26- Right bracket

29/34/41

X90 Plug connection / heating fan motor 30b Operators platform
X197 Plug connection / 3-pin 33 Travelling pedal
X262-1 Plug connection / wire harness quick-change adapter / 8-pin 38 Bearing block
X406 Plug connection transducer fuel reserve / 3-pin 17 Revolving deck
X407 Plug connection wire harness revolving deck / 2-pin 36 Revolving deck
R 317 LI 18161- 8.40.5

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MJFCIFSS

X838-3 Plug connection to A 125 / CAN bus / 2-pin 26 Left bracket
X856 Plug connection to BST excavator control / 40-pin 2/20/24/ Right bracket
26-29/38/
41
24/26/28/
34
X902 Plug connection / 9-pin 4/6/42 Basic boom bearing block
21a/24/
33/36/38/
40/41
21b/34/
38/40/41
X952 Plug connection revolving deck - BST excavator control / 21- 10-13/15/ Right bracket
pin 25/30c/
33/34
X953 Plug connection revolving deck - distribution board / 21-pin 4-6/9/13/ Right bracket
17/21a/
36/42
X954 Plug connection revolving deck - BST excavator control / 21- 2/20/22/ Right bracket
pin 26/27/29
X955 Plug connection revolving deck - distribution board / 15-pin 1a/3/4/38/ Right bracket
39
21-pin 28/34/41/
43
15/20/22/
25/34/35
35/36/38/
39/41/43
pin 28/33/34
X961 Plug connection / display distribution board / 21-pin 2/6/13/17/ Right bracket
20/21a/
21b/24/33
8.40.6 R 317 LI 18161-

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MJFCIFSS

14/21b/
34/38/40/
41
13/14/16/
23/24/28/
35
15/28/33/
43
21-pin
25/28/32/
34/43
X967 Plug connection display distribution board / 21-pin 5/6/8/37 Right bracket
X971 Plug connection seat adjustment / 2-pin 31 Operators platform
X972 Plug connection seat heating / 2-pin 32 Operators platform
X1046 Plug connection / 12-pin 24,25 Left bracket
X1048 Plug connection / 12-pin 10 Right pilot control unit
X1115 Plug connection slewing gear brake / 2-pin 15 Below operator's platform
X1116 Plug connection slewing gear brake / 2-pin 15 Right bracket

Y7 Solenoid valve / slewing gear brake 15 Control oil unit
Y20 Magnetic valve / a/c compressor 30c Diesel engine
Y24 Solenoid valve / fast travel 11 Control oil unit
R 317 LI 18161- 8.40.7

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MJFCIFSS

8.40.8 R 317 LI 18161-

copyright by
MJFCIFSS
R 317 LI 18161- 8.40.9

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MJFCIFSS
8.40.10 R 317 LI 18161-

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MJFCIFSS
R 317 LI 18161- 8.40.11

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MJFCIFSS
2 Pre-heating
8.40.12 R 317 LI 18161-

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MJFCIFSS
3 Motor shut-down
R 317 LI 18161- 8.40.13

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MJFCIFSS
8.40.14 R 317 LI 18161-

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MJFCIFSS
5 Work headlight
R 317 LI 18161- 8.40.15

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MJFCIFSS
8.40.16 R 317 LI 18161-

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MJFCIFSS
R 317 LI 18161- 8.40.17

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MJFCIFSS
8.40.18 R 317 LI 18161-

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MJFCIFSS
9 Brake light
R 317 LI 18161- 8.40.19

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MJFCIFSS
8.40.20 R 317 LI 18161-

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MJFCIFSS
11 Rapid gear
R 317 LI 18161- 8.40.21

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12 1st gear
8.40.22 R 317 LI 18161-

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13 Parking brake
R 317 LI 18161- 8.40.23

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MJFCIFSS
14 Safety switch
8.40.24 R 317 LI 18161-

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15 Servo swing gear brake
R 317 LI 18161- 8.40.25

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MJFCIFSS
8.40.26 R 317 LI 18161-

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MJFCIFSS
R 317 LI 18161- 8.40.27

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MJFCIFSS
8.40.28 R 317 LI 18161-

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MJFCIFSS
R 317 LI 18161- 8.40.29

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MJFCIFSS
8.40.30 R 317 LI 18161-

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MJFCIFSS
22 Speed adjustment
R 317 LI 18161- 8.40.31

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23 Excavator-control power supply
8.40.32 R 317 LI 18161-

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24 Excavator-control power supply
R 317 LI 18161- 8.40.33

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25 Optional AS I
8.40.34 R 317 LI 18161-

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MJFCIFSS
R 317 LI 18161- 8.40.35

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MJFCIFSS
27 Speed sensor
8.40.36 R 317 LI 18161-

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28 Sensor control up to serial number 21204
R 317 LI 18161- 8.40.37

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MJFCIFSS
28 Sensor control from serial number 21205
8.40.38 R 317 LI 18161-

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MJFCIFSS
29 Fan control
R 317 LI 18161- 8.40.39

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30a Heating
8.40.40 R 317 LI 18161-

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30b Heating
R 317 LI 18161- 8.40.41

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30c Heating
8.40.42 R 317 LI 18161-

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MJFCIFSS
R 317 LI 18161- 8.40.43

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MJFCIFSS
8.40.44 R 317 LI 18161-

copyright by
MJFCIFSS
R 317 LI 18161- 8.40.45

copyright by
MJFCIFSS
8.40.46 R 317 LI 18161-

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MJFCIFSS
R 317 LI 18161- 8.40.47

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MJFCIFSS
8.40.48 R 317 LI 18161-

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MJFCIFSS
37 Optional beacon
R 317 LI 18161- 8.40.49

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MJFCIFSS
8.40.50 R 317 LI 18161-

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MJFCIFSS
R 317 LI 18161- 8.40.51

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MJFCIFSS
40 Reserve
8.40.52 R 317 LI 18161-

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MJFCIFSS
R 317 LI 18161- 8.40.53

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MJFCIFSS
42 Ground
8.40.54 R 317 LI 18161-

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MJFCIFSS
43 Ground
R 317 LI 18161- 8.40.55

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MJFCIFSS
44 Ground
8.40.56 R 317 LI 18161-

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MJFCIFSS
R 317 LI 18161- 8.40.57

copyright by
MJFCIFSS
8.40.58 R 317 LI 18161-

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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

List of electric units 8.45.3
50 Changeover blade - outrigger/individual control 8.45.19
51 AHS 11 8.45.21
51 AHS 12 8.45.23
51 AHS 12 & PRIO 8.45.25
52-1 Refuelling pump 8.45.27
52-2 Refuelling pump 8.45.29
53 Hydraulic operator's cab elevation (lift frame) 8.45.31
54 Overload warning system 8.45.33
55-1 Magnet system control 8.45.35
56 Industrial shut-off 8.45.41
57 Radio system 8.45.43
58 Beacon 8.45.45
59 Motor stop (emergency-stop) 8.45.47
60 Immobiliser 8.45.49
61 Travel alarm 8.45.51
62 Quick change adapter 8.45.53
63 Industrial quick change adapter 8.45.55
64 a - c Air-conditioning system 8.45.57 - 8.45.59
65 Auxiliary headlight equipment 8.65.61
66-1 Accessory kit changeover valve 8.45.63
67 Operating hour meter 8.45.67
68 Back-up alarm 8.45.69
69 Fuel pre-heating 8.45.71
70 Auxiliary heater 8.45.73
71 Power socket 8.45.75
72 Stroke limitation at hydraulic boom adjusting device 8.56.77
73 Individual control (blade) 8.45.79
74 License plate light 8.45.81
75 Central lubrication system 8.45.83
76 Emergency drain 8.45.85
77 Stroke limitation (basic boom) 8.45.87
78-2 Accessory kit changeover valve fine regulation switch 8.45.91
79 Stroke limitation (boom and stick) 8.45.93
80 AS1 actuating device in handle, left and right 8.45.95
81 Kit quantity switchable 8.45.97
82 Inclinometer illumination 8.45.99
83/1 Krger stroke limitation part 1 8.45.101
A 309 LI - R 317 LI 8.45.1

copyright by
MJF C I F S S
Electric kits Service Manual
List of kits
Step Kit Page

83/2 Krger stroke limitation part 2 8.45.103
84/1 Changeover bucket tilt circuit / AHS 8.45.105
85 Puritech particle filter 8.45.111
86/1 Mower rake accessory kit 8.45.113
86/2 Mower rake accessory kit 8.45.115
87 Trailer coupling 8.45.117
88 Joystick control 8.45.119
89 Visual and acoustic back-up warning 8.45.121
90 Bucket cylinder shut-off 8.45.123
91 Special installation kit bore gun carriage 8.45.125
92 Individual blade control 8.45.127
93 Telescopic support blade 8.45.129
94 Actua tion valve spool with pushbutton 8.45.131
95 Timed motor stop 8.45.133
96 Turn grapple with right rocker button 8.45.135
97/1 Auxiliary indicators 8.45.137
97/2 Auxiliary lamps 8.45.139
97/3 Auxiliary lamps 8.45.141
98 Travel direction switch in left handle 8.45.143
99 Horn operation through push buttons 8.45.145
100 Changeover Fuchs control 8.45.147
101 Outrigger monitoring system 8.45.149
102 Reversible fan 8.45.151
103 Automatic oscillating axle locking device 8.45.153
104 Travel alarm new 8.45.155
105 Accessory kit changeover valve, new 8.45.157
108 Stroke limitation boom and stick 8.45.163
109 AS1 actuator in left and right handle A 312 - R 317 8.45.165
110 Changeover bucket tilt circuit A 309 / 311 8.45.167
111 Kit for reduction of engine speed during work 8.45.169
power reduction
112 Slider section operation through push buttons 8.45.171
113 Turn grapple with right rocker button 8.45.173
114 Individual blade / outrigger control 8.45.175
115 Flow distributor 8.45.177
116 emi-automatic central lubrication system 8.45.179
117 Stick cylinder shut-down 8.45.181
118 Automatic shut-down mechanism at the gooseneck boom 8.45.183
119 Puritech particle filter 8.45.185
120 AS1 accessory kit with 3 buttons - handle 8.45.187
121 Xenon light 8.45.189
8.45.2 A 309 LI - R 317 LI

copyright by
MJF C I F S S
Key to accessory kit diagrams
2 Key to accessory kit diagrams

A3 Radio 8*, 57 Left console
A123 Printed circuit board 88 Left console
A125 PCB potentiometers 26*,51,81,84, Left console
110,115
A126 PCB / autocheck 21*,54,55,68,81, Right console
89,97,103
A127 Printed circuit board / power 1*,51,52,59,60,69,70, Hydraulic tank
71,95,100
A133 Printed circuit board 85,119 Left console
A1017 Printed circuit board / quick-change adapter 38*,54,62 Right console, rear
A1202 Printed circuit board / frequency conversion 67 Near fuel tank
B10 Pressure switch / parking brake 13*,68 HBGV block

B19 Handle sensor / sensor control 25*, 120 Left pilot control unit
B21 Pressure switch / overload warning system 36*,54,118 Boom cylinder
B26 Proximity switch quick-change adapter 38*,62 Quick change adapt. head
B33 Pressure switch pst for AHS section 84,110 Near control valve block
B36 Pressure switch/travel alarm 61,104 Operator's platform / front
B40 Proximity switch / travel pedal 28*,51,81 Operator's platform / front
B50 Loudspeaker 8*,57 Cab
B51-1 Piston detector 75 Revolving deck, front right
B204 Proximity switch / industrial stick 39*,56,117 Industrial stick
B213 Proximity switch / boom shut-down 79,108 Stick
B214 Proximity switch / boom shut-down 72,77,79,108 Basic boom bearing block
B233 Proximity switch / bucket cylinder movement 90 At stick
B290 Proximity switch / adjusting pedal left 34*,51,81,100,101 Operator's platform / front
B291 Proximity switch / adjusting pedal, right 34*,51,81 Operator's platform / front
B294 Pressure switch a/c compressor 64b A/c compressor
B295 Heating thermostat 64b Operator's platform, base
B306 Particle filter temperature sensor 85,119 Particle filter
E1 Work light / attachment 5*,16*,65 Attachment

E2 Auxiliary headlight / front of roof 5*,65 Front cab roof
E2L Work light, front left 121 Uppercarriage, front
E2R Work light, front right with plug 121 Uppercarriage, front
E3 Headlight uppercarriage left 6*,65,74,97 Front cab roof
E4 Headlight uppercarriage, right 6*,74,97 Cab roof
E9 Beacon 37*,58 Cab roof
E15 Parking light, right 6,*74,97 Revolving deck, front right
E16 Parking light, left 6*,74,97 Revolving deck, front left
E17 Rear light, right 6*,74,97 Revolving deck, rear right
E18 Tail light, left 6*,74,97 Revolving deck, rear left
E19 Brake light, right 6*,74,97 Weight, right
E20 Brake light, left 6*,74,97 Weight, left
E21 Indicator light, front left 4*,97 Revolving deck, front left
E22 Indicator light, rear left 4*,97 Weight, left
A 309 LI - R 317 LI 8.45.3

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MJF C I F S S

E23 Indicator light, front right 4*,97 Revolving deck, front right
E24 Indicator light, rear right 4*,97 Weight, left
E30 D5W5 auxiliary heater 70 Hydraulic tank
E50 Power and safety switch cabinet 1to3*,70,85,119 Hydraulic tank
E150 Roof light 5*,65 Rear cab roof
E150L Working light, rear left 121 Uppercarriage, rear
E150R Work light, front right with plug 121 Uppercarriage, rear
E163 License plate light 74 Cap, rear
E164 Illumination 80 Right console, front
E167 Beacon for back-up warning 89 Cap, top right
E169 Position light, front right in indicator 97 Revolving deck, right
E170 Position light, front left in indicator 97 Revolving deck, left
E171 Outline light, right 97 Uppercarriage, right
E172 Outline light, left 97 Uppercarriage, left
E172 License plate light 74, Uppercarriage, rear
E173 Auxiliary indicator, right 97 Uppercarriage, front right
E174 Auxiliary indicator, left 97 Uppercarriage, front left
F20/F300 A127 50.0 A 1a*,95 Left console

F20 E15, E18 2.0 A 95 Left console
F34 Fuse A 127 auxiliary heating 25.0 A 70 Near hydraulic tank
F35 Fuse A 127 auxiliary heating 15.0 A 70 Near hydraulic tank
F36 Fuse A 127 timer, water vent. 7.5 A 70 Near hydraulic tank
F216 Fuse A127 refuelling pump 20.0 A 52 Near hydraulic tank
F300 Fuse A127 terminal 30 to termin. 15 70.0 A 1*,59,60 Near hydraulic tank
F301 Fuse 15.0 A 110 Right control desk, rear
F303 Fuse A127, Y29 7.5 A 3*,59,60,95 Near hydraulic tank
F304 Fuse A127 S1 15.0 A 1*,57,60 Right console, front
F306 Fuse X10 15.0 A 16*,60 Right console, front
F307 Fuse E16, E17 7.5 A 6*,74,82,97 Right console, rear
F308 Fuse E15, E18 7.5 A 6*,74,97 Right console, rear
F309 Fuse E3 7.5 A 6*,74,97 Right console, rear
F310 Fuse E4 7.5 A 6*,74,97 Right console, rear
F312 Fuse S44,E21 - E24 7.5 A 4*,97 Right console
F314 Fuse S7 15.0 A 14*,60,111 Right console, front
F316 Fuse sensor control 7.5 A 28*,51,54,62,81 Right console, front
F317 Fuse E9 7.5 A 37*,58 Cab
F318 Fuse heating / air conditioning ter- 20.0 A 30c*,64c Right console, front
minal 30
F319 Fuse heating /air cond. terminal 15 3.0 A 30c*,64c Right console, front
F320 Fuse X11 / X12 15.0 A 16*,55,61,67,69,75, Right console, front
83,84,87,91,101,102,
104,116
F321 Fuse X12 15.0 A 16*,84, Right console, front
F322 Fuse T1 15.0 A 8*,57 Right console, front
F323 Fuse E1 10.0 A 5*,65 Right console, rear
F324 Fuse E2, E150 10.0 A 5*,65 Right console, rear
F325 Fuse S16, S263 7.5 A 13*,68,89,95 Right console, front
F326 Fuse Y24, Y55, Y371, QC adapter 15.0 A 11*,62,103 Right console, front
8.45.4 A 309 LI - R 317 LI

copyright by
MJF C I F S S

F327 Fuse industrial stick 15.0 A 16*,63 Right console, front
F329 Fuse industrial stick 15.0 A 15*,53,111 Right console, front
F330 Fuse kits 15.0 A 24*,51,81,84,98 Right console, front
F331 Fuse X29 15.0 A 16*,66,72,77,78, Right console, front
79,84,86,88,90,91,
94,100,105,106,
108,112,117,118
F332 Fuse A127 M1, Y12 25.0 A 1*,60 Hydraulic tank
F336 Fuse S61 20.0 A 6*,74,97 Right console, front
F337 Fuse kits 15.0 A 35*,50,55,56,73, Right console, front
92,93,114
F338 Fuse capacitor motors 20.0 A 4*,82,97,99 Right console, front
F339 Fuse capacitor motors 20.0 A 30c*,64c Right console, front
F340 Fuse A 127 Thermoline 15.0 A 69 Near hydraulic tank
F342 Fuse terminal 15 A 127 15.0 A 71 Near hydraulic tank
F344 Fuse terminal 15 A 127 7.5 A 76 Near hydraulic tank
F345 Fuse Xenon roof light 15.0 A 121 Right control desk, rear
F346 Fuse Xenon headlight, left 15.0 A 121 Right control desk, rear
F347 Fuse Xenon headlight, front right 15.0 A 121 Right control desk, rear
F348 Fuse Xenon headlight, rear left 15.0 A 121 Right control desk, rear
F349 Fuse Xenon headlight, rear right 15.0 A 121 Right control desk, rear
F351 Fuse (F_H) 3A 85,119 Near hydraulic tank
F364 Fuse control (F_G) 15.0 A 100 Printed circuit board A127
G1 Alternator 1a*, 67 Diesel engine

G2 battery 1a*, 70 Battery box
H9 Horn 4*,97,99 Right console

H10 Warning buzzer overload warning system 21b*,54 Right console
H16 Indicator light / overload warning system 36*,54,118 Right control desk
H19 Indicator light / indicator 4*,97 Right control desk
H26 Indicator light / quick-change adapter 38*,62,63 Right control desk
H27 Warning buzzer 13*,62,63,72,77, Right console
79,108,111
H33 Back-up alarm travel warning 61,104 Hydraulic tank, top
H90 Indicator light / change of direction of fan 102 Right control desk
H158 Indicator light / Fuchs control ON 100 Right control console
H159 Indicator light / stroke limitation ON 83 Right control console
H167 Indicator light / forward travel 10*,68,89 Right control desk
H168 Indicator light / reverse travel 10*,68,89 Right control desk
H176 Indicator lamp / oscillating axle automatic 33*,92,103 Right console
H183 Buzzer / back-up alarm 68,89 Cap, top left
H196 Indicator light / sorting grapple 34*,51,84,107,110 Right control desk
H249 Indicator light / bypass ON 79,108 Right control desk, centre
H293 Indicator light / operator's cab 53 Right control desk
H293 Indicator light / operator's cab 53 Right control desk
H298 Warning light/exhaust backpressure 85,119 Right control console
H299 Warning buzzer/exhaust backpressure 85,119 Right control console
H311 Indicator lamp / oscillating axle locked 103 Right console
A 309 LI - R 317 LI 8.45.5

copyright by
MJF C I F S S

H315 Warning light shut-down bridged 113,118 Right console
H322 Warning light/changeover 84,110 Right control console
H323 Indicator light / lateral adjustment 78,105,107 Right console
H324 Inclinometer illumination 82 Right control console
H328 Indicator light / shut-down active 90 Right control console
H329 Indicator light / mower rake operation 78,86 Right console
H343 Warning light / outriggers not retracted 101 Right control console
H344 Indicator light / flow distributor 115 Right control console
K1 Relay / preliminary shut-off Krger electronics 83 in control box / Krger

K2 Relay / shut-off Krger electronics 83 in control box / Krger
K30 Relay/refuelling pump control circuit 52 Near fuel tank
K33 Relay / Thermoline A127 69 Near hydraulic tank
K63 Relay / direction indicator 4*,97 Near hydraulic tank
K229 Relay / changeover (K_B) 79,95,100 A127
K250 Relay / oscillating axle automatic 33*,103 Right console, rear
K251 Relay / parking brake 13*,68,89,95 Right console, rear
K261 Relay / solen. valve actuation in case of bypass 13*,68,83,95 Right console, rear
K288 Relay / terminal 15 at A127 3*,59,95 Near hydraulic tank
K333-1 Relay / boom shut-off 72,77 Distribution board
K333-2 Relay / boom shut-off 72,77 Distribution board
K334 Relay / boom shut-off 72,77 Distribution board
K358 Relay / heating ON A127 70,87 Near hydraulic tank
K359 Relay / water circuit ON A127 70,87 Near hydraulic tank
K360 Relay / heater fan ON A127 70,87 Near hydraulic tank
K362 Relay fan control 89 Left console
K364 Relay / quick change valves A1017 38*,62 Right console, rear
K368 Relay / terminal 15 A127 1*,60 Near hydraulic tank
K369 Relay / terminal 15 A127 1*,60 Near hydraulic tank
K370 Relay / fine regulation, grapple 15*,66,78,105,111 Right console, rear
K375 Relay / changeover hammer / pile driver 34*,51,81,84,107,110 Right console, rear
K375 Relay / signal flow reduction AHS 84,91,115 Right console, rear
K386 Relay / safety switch 14*,60,111 Right console, rear
K392 Relay for industrial shut-off 56 Right console, rear
K403 Relay / heating 30a*,64a Operator's platform, rear
K404 Relay / capacitor motors 64b Operator's platform, rear
K405 Relay / blower switch 30b*,64b Operator's platform, rear
K407-1 Relay / travel warning mute 61,104 Right console, rear
K407-2 Time relay / traction-delayed travel warning 10s. 61,104 Right console, rear
K414 Relay / boom shut-off 7*,79,108 Distribution board
K436 Step relay (autom. reset) 91 Distribution board
K437 Relay / signal flow reduction drilling slide 91 Distribution board
K438 Step relay / mower rake operation 78,86 Distribution board
K439 Relay / drop-out delayed 95 Distribution board
K455 Relay/changeover switch 106 Distribution board
K464 Relay / oscillating axle release 103 Distribution board
K467 Step relay / flow distributor operation 115 Distribution board
8.45.6 A 309 LI - R 317 LI

copyright by
MJF C I F S S

K471 Relay inversion signal servo OFF 111 Distribution board
K473 Relay shutdown attachment 118 Distribution board
KT20 Time relay / fan afterrun 102 Near weight
KT21 Time relay / direction of rotation switching 102 Near weight
M1 Starter 1a*/60 Engine

M6 Refuelling pump 52 Near fuel tank
M52 Coolant pump 70 Near heating
M53 Fuel metering pump 87 Near heating
M71 Servo motor / water valve 30a*, 64a Operator's platform, rear
M72 Servo motor / air distribution 30a*, 64a Operator's platform, rear
M73 Servo motor / air distribution 30a*, 64a Operator's platform, rear
M74-1 Fan motor / condenser 64b Condenser blower
P1 Potentiometer / flow reduction A125 26*, 51,84 Left console, bottom

P5-1 Operating hour meter / idle run 67 Near fuel tank
P5-2 Operating hour meter / partial load 67 Near fuel tank
P5-3 Operating hour meter / full load 67 Near fuel tank
P6 Display / motor temperature 82 Right control desk
R8 Thermoline 69 Near fuel tank

R70 rotary potentiometer 83 At basic boom
R71 rotary potentiometer 83 At boom
S1 Ignition switch 1a*, 57,60 Right control desk

S4 Horn switch 4*,97,99 Cab floor plate
S5L Push button / turning grapple to the left, Y22 25*,62,80,96,109,120 Left pilot control unit
S5R Push button / turning grapple to the right, Y23 25*,62,80,96,109,120 Left pilot control unit
S5M Push button, centre, optional 120 Left pilot control unit
S6L Push button / magnet unit, grapple operation, 55,61,80,88,94,99, Right pilot control unit
joystick 103,104,109,112,113
control, horn activation, oscillating axle release , 115
S6R Push button / magnet unit, grapple operation, 55,61,80,88,94,99, Right pilot control unit
joystick 103,104,109,112,
control, horn activation 113,115
S6R Push button / bridging of horn shut-off 79 Right pilot control unit
S7 Safety switch 14*,60,111 Left console, bottom
S8 Switch / beacon 37*,58 Keyboard of right console
S9 Battery main switch 42*,70 Battery compartment
S16 Parking brake switch 13*,62 Right control desk
S18 Switch/overload warning system 36*,54,62,118 Keyboard of right console
S19 Switch / grapple rotator Y22, Y23 25*,80,96,109,113, Keyboard of right console
120
S22 Auxiliary headlight switch 5*,65 Keyboard of right console
S22-1 Auxiliary roof headlight switch 5*,65 Keyboard of right console
S25 Switch/refuelling pump ON 52 Near fuel tank
S32 Steering column switch 97,99 Steering column
A 309 LI - R 317 LI 8.45.7

copyright by
MJF C I F S S

S35 Switch servo 15*,53,111 Keyboard of right console
S44 Hazard warning lights switch 4*,97 Right console
S45 Switch/priority 51,81 Right control desk
S46 Switch/control magnet system 41*,55 Right control desk
S47 Key switch/activate quick change adapter 38*,62 Right control desk
S47-1 Key switch/activate quick change adapter 63 Right control desk
S47-2 Key/activate quick change adapter 63 Right control desk
S59 Switch/refuelling pump OFF 52 Near fuel tank
S61 Switch / lighting installation 6*,74,82,97 Right console, rear
S74 Code key for immobiliser 60 Right console
S75 Switch/oscillating axle locking device 33*,103 Right console
S78 Push button / emergency drain 76 Right console
S84-1 Push button / central lubrication with plug 75,116 Right control desk
S92 Potentiometer / air distribution 30a*,64a Right control desk
S93 Rotary switch / air-conditioning, heating 30a*,64a Right control desk
S124 Switch / activation of mower rack operation 78,86,113 Right control desk
S160 Switch / change of direction of rotation 102 Right control desk
S204 Switch/front left outrigger support 35*,50 Right control desk
S205 Switch/front right outrigger support 35*,50 Right control desk
S206 Switch/rear left outrigger support 35*,50 Right control desk
S207 Switch/rear right outrigger support 35*,50 Right control desk
S213 Switch/fuel pre-heating 69 Right control desk
S216 Switch/industrial shut-down 39*,56,117 Right control desk
S232 Digital timer/auxiliary heating 70 left control desk
S241 Switch AHS 11 / AHS 12 51,81,84,107,110 Right control desk
S247 Key switch / Fuchs control 100 Right control desk
S249 Key switch / boom shut-off with plug 72,79,83,108,118 Right control desk, rear
S263 Switch / travelling direction 10*,68,89,98 Right pilot control unit
S269 Switch in slip ring 68,89 rotary connection
S270 Switch in slip ring 68,89 rotary connection
S272 Slip-ring case 35*,50,73,92,93, Undercarriage
101,114
S284 Switch / blower (4 speeds) 30b*,64b Right control desk
S291 Push button / bridging boom shut-off with plug 72,77,108 Right control desk
S291 Push button / bridging boom shut-off with plug 79,83 Right control console
S313 Switch / emergency-stop 77 Right control desk, rear
S318 Switch a/c system 30b*,64b Right control desk
S321 Switch / activate joystick steering 88 Right control desk
S335 Switch / changeover blade - outrigger 35*,73,92,114 Right control desk
S335-1 Switch / front blade 73 Right control desk
S335-2 Switch / rear blade 73 Right control desk
S341 Float switch / refuelling pump 52 Near fuel tank
S343 Switch / individual control, back 92,114 Right control desk
S356 Switch / changeover valve with plug 66,78,105,106,107 Right console, rear
S360 Switch / acknowledgement QC buzzer 38*,62 Right control desk
S361 Switch / hydr. operator's cab elevation 53 Right console, rear
S379 Switch/releasing key kits 94,101,112 Right console
S380 Switch / mower rake activation 78,86 Right control desk
8.45.8 A 309 LI - R 317 LI

copyright by
MJF C I F S S

S382 Switch / fine regulation OFF 24*,78,79,96,98 Left pilot control unit
or right control desk
S384 Switch / operating hour meter 82 Near fuel tank
S398 Reversing switch / heating 30a*,64a Right control desk
S405 Switch / changeover 84,110 Right console
S406 Switch / kit quantity changeover 81 Right console
S419 Switch / trailer coupling 87 Right console
S423 Key switch / bridging shut-off 90 Right console
S424 Push button / continuous operation AHS 91 Right console
S439L Push button / support pilot control unit 92 Pilot control valve: support
S439R Push button / support pilot control unit 92,114 Pilot control valve: support
S442 Switch / changeover blade UP/DOWN - ON/ 93 Right console
OFF
S443L Push button / telescope blade, left rear 93 Pilot control valve: support
S443R Push button / telescope blade, right rear 93 Pilot control valve: support
S451 Bypass switch stick cylinder 96,113 In handle, right
S452 Switch / rotating grapple with rocker button 96 Right console
S457 Rocker button / magnet unit ON/OFF 55 Right console
S464 Switch activation / flow distributor 115 Right console
T1 Voltage transformer / radio 8*,57 Left console

T4 Voltage transformer / 12V / 20 A 71 Near fuel tank
U4-1 Central lubrication system 75,116 Near fuel tank

U7 Switching system / magnet unit 55 Operator's cab, front
U13 Electronic box / auto-scan 60 Right console, front
U16 BST excavator control system 2*,20to29*,51,55,81, Right console, rear
84,110,111,115
V11 LED on A1017 62 Right console, rear

V35 Diode on A126 55 Right console
V154 Blocking diode / QC warning 63 Right console, front
V155 blocking diode 33*,103 Left console
V156-2 blocking diode 33*,103 Left console
V156-3 blocking diode 62 Right console, rear
V156-4 Blocking diode A125 34*,51,81,84, A125 printed circuit board
110,115
V163-1 Blocking diode / QC signal 72,77 Right console
V163-2 Boom shut-off signal 72,77 Right console
V172-1 Blocking diode / signal Y428 - Y217 93 Right console
V172-2 Blocking diode / signal Y428 - Y218 93 Right console
V166 blocking diode 81 Right console
V168 decay diode 59,95 A 127
V169 blocking diode 84 A 125
V173 Blocking diode BTKP 52 Near fuel tank
V177 Blocking diode signal flow distributor 115 Right console
V178-1 Blocking diode signal Servo-S7 111 Right console
V178-2 Blocking diode signal Servo-S7 111 Right console
V179 Blocking diode signal actuation Y465 118 Right console
A 309 LI - R 317 LI 8.45.9

copyright by
MJF C I F S S

V180 Blocking diode signal actuation H16 118 Right console
V181 Amplifier actuation grapple turning left 120 Right console
V182 Amplifier actuation grapple turning right 120 Right console
X10 Plug connection distribution board / 2-pin 16*,60 Right console

X11 Plug connection on distribution board / 2-pin 16*,55,61,67,69,75, Right console
83,87,91,101,104,
116
X12 Plug connection on distribution board / 2-pin 16*,84 Right console
X15 Plug connection, 3-pin 88 Right joystick
X15-2 Plug connection, 3-pin 62,80,96,109,113 Left console
X20 Terminal for kit / 2-pin 1b*,85,119 Printed circuit board A127
X27 Plug connection, 2-pin 16*,63 Right console, rear
X29 Plug connection distribution board / 2-pin 16*,66,72,77,78,79, Right console, rear
84,86,88,90,91,94,
100,105,106,108,
110, 112,117,118
X65 Plug connection T1 / 2-pin 8*,57 Left console
X66 Plug connection T1 / 2-pin 8*,57 Left console
X67-1 Plug connection A3 power supply / 8-pin 8*,57 Cab
X67-2 Plug connection loudspeaker / 8-pin 8*,57 Cab
X74 Plug connection S6 / 3-pin 55,61,79,80,96,99, Right console
103,108,109,112,
113,115
X74-1 Plug connection magnet unit CS / 1-pin 55 Right console
X95 Plug connection to S232, 4-pin 70 Left console
X98 Plug connection to M53, 2-pin 70 Auxiliary heating
X99 Plug connection to M52 / 2-pin 70 Auxiliary heating
X133-1 Plug connection to B51-1 / 2-pin 75 Revolving deck, front
X143-1 Plug connection to U4-1 / 4-pin 75,116 Near fuel tank
X204 Plug connection to buzzer / 2-pin 61,104 Left console
X206 Plug connection to B36, 2-pin 61,104 Right console
X207 Plug connection to B36, 2-pin 61,104 Right console
X217 Plug connection magnet unit CS / 2-pin 55 Operator's cab, front
X230 Plug connection on A1100, 3-pin 10*,13*,98 Left console
X262 Plug connection to quick change adapter, 8-pin 38*,63 Attachment
X262-1 Plug connection on bearing block, 8-pin 38*,62,63 Bearing block
X296 Plug connection left handle / 1-pin 80,109 Left pilot control unit
X297 Plug connection left handle / 1-pin 80,109 Right pilot control unit
X301 Plug connection on slip ring, 12-pin 35*,50,73,87,92,93, Rotary connection
101,114
X304 Plug con. to S204, S205, S206, S207, 6-pin 35*,50,73,92,93,114 Right console, rear
X312 Plug connection on slip ring, 12-pin 68,89 Rotary connection
X313 Plug connection on slip ring, 12-pin 68,89 Rotary connection
X314 Plug connection to electr. buzzer / 2-pin 68,89 Revolving deck
X324-1 Plug connection, 2-pin 61,68,89,104 Revolving deck
X324-2 Plug connection, 2-pin 61,104 Revolving deck
8.45.10 A 309 LI - R 317 LI

copyright by
MJF C I F S S

X327 Plug connection, 3-pin 39*,56,117 Industrial stick
X342 Plug connection to travel selection switch, 3-pin 68,89 Right console
X358 Plug connection, 2-pin 66 Revolving deck
X358-1 Plug connection under operator's platform / 2- 78,105,106 Operator's platform
pin
X358-2 Plug connection, 2-pin 78,105,106 Fuel tank
X370 Plug connection magnet unit CS / 2-pin 55 Near attachment
X374 Plug connection, 5-pin 83 Right control console, rear
X378 Plug connection to Y354 and Y355 / 2-pin 83 Right control console, rear
X379 Plug connection, 5-pin 83 Right control console, rear
X381 Plug connection to R70, 4-pin 83 At basic boom
X358-1 Plug connection to R70, 4-pin 83 Near attachment
X382 Plug connection to R71, 4-pin 83 At basic boom
X404 Plug connection, 4-pin 5*,65 Attachment
X407 Plug connection to revolving deck CS / 2-pin 36*,54,94,112,118 Right control console
X408 Plug connection to revolving deck CS / 2-pin 94,112 Right control console
X410 Plug connection power supply A1017 / 2-pin 38*,62,94 Right console, rear
X411 Plug connection A1017 / 4-pin 38*,62 Right console, rear
X412 Plug connection A1017 / 2-pin 38*,62 Right console, rear
X412 Plug connection to Y307 / 3-pin 88 Right console, rear
X413 Plug connection, 4-pin 38*,62,63, Right console, rear
X413 Plug connection to S321 / 3-pin 88 Right console, rear
X414 Plug connection to A123 / 5-pin 88 Right console, rear
X446 Plug connection to S47 / 5-pin 63 Right console
X447 Plug connection / warning system blocking dio- 63 Right console
de
X550 Plug connection 4*,97,99 Right console
X689 Plug connection blocking diodes / 6-pin 70,83 Right console
X738 Plug connection Thermoline 69 Near fuel tank
X771 Plug connection, 5-pin 35*,50,73,93, 101 Left console
X798 Plug connection blocking diode / 3-pin 62 Right console, rear
X821 Plug connection distribution board / 21-pin 53 Right console, front
X822 Plug connection distribution board / 21-pin 53 Right console, front
X829 Plug connection distribution board / 21-pin 53 Right console, rear
X837 Plug connection A125 / 8-pin 26*,51,81,84, Left console, bottom
110,115
X839 Plug connection / screw terminal on A125 / 3-pin 34*,51,81,84, Left console, bottom
110,115
X842-1 Plug connection, 15-pin 30c*,64c Right console
X842-2 Plug connection, 2-pin 64c,70 Right console
X856 Plug connection BST wire harness / 40-pin 2*,20to29*,55,84,110 Right console
,115
X857 Plug connection: BST excavator control / 24-pin 21to29*,51,81,84, Right console
110,115
X859 Plug connection, 21-pin 30*,64a/b Operator's platform, rear
X860 Plug connection, 6-pin 30a*,64a Operator's platform, rear
A 309 LI - R 317 LI 8.45.11

copyright by
MJF C I F S S

X863 Plug connection, 15-pin 30*,64a/b Operator's platform, rear
X864 Plug connection, 4-pin 64c Operator's platform, rear
X891-1 Plug connection at valve Y360 / 2-pin 63 Attachment
X891-2 Plug connection to stick, 2-pin 63 Attachment
X902 Plug connection, 6-pin 74 Lighting, front right
X909 Plug connection to H300 warning light / 3-pin 100 Left console
X914 Plug connection to wire harness P5 / 6-pin 67 Near fuel tank
X915 Plug connection on A1202 / 16-pin 67 Near fuel tank
X924-2 Plug connection to B291, 3-pin 34*,51,81 Auxiliary pedal, right
X950 Plug connection autocheck / 21-pin 4*,10*,13*,21a*,54,6 Right console
2,68,89,97,103
X951 Plug connection autocheck / 21-pin 4*,10*,13*,21b*,51,5 Right console
4, 55,62,68,81,89,98
X952 Plug connection distribution board / 21-pin 10 to Right console, rear
13*,51,64c,68,80,84,
89,95,96,103,107,10
9,110, 111,113, 120
X953 Plug connection distribution board / 21-pin 1until 6*,54,74,82,97, Right console, rear
110,118
X954 Plug connection distribution board / 21-pin 110 Right console, rear
X955 Plug connection distribution board / 15-pin 1*to4*,56,60,62,63, Right console, rear
64c,67,74,92,97,114
X956 Plug connection distribution board / 21-pin 2*,20until24*,55,56,8 Right console, rear
1, 98, 111
X957 Plug connection distribution board / 21-pin 8*,11*,50,51,62,73, Right console, rear
80,81,84,92,93,96,
107,109,110,113,
114, 115,120
X958 Plug connection distribution board / 21-pin 18*,28*,50, Right console, rear
51,54,55,56,62,73,81
,84,92,93,107,
110,114, 118
X959 Plug connection distribution board / 21-pin 10*;24*,30*,64c,68,8 Right console, rear
9,92,98,103,111, 114
X960 Plug connection distribution board / 21-pin 4*,6*,9*,51, Right console, rear
74,81,97,99
X961 Plug connection distribution board / 21-pin 2*,6*,13*,62,74,82,97 Right console, rear
,103
X962 Plug connection distribution board / 21-pin 4*,10*,13*,51,55,68, Right console, rear
81,89,95,97,98,111
X963 Plug connection distribution board / 21-pin 6*,8*,9*, Right console, rear
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
8.45.12 A 309 LI - R 317 LI

copyright by
MJF C I F S S

X964 Plug connection distribution board / 21-pin 1*,3*,4*,60,64c,97,99 Right console, rear
103,111
X965 Plug connection BST- CS A125 / 21-pin 26*,34*,84,110, 115 Right console, rear
X966 Plug connection A125 wire harness / 21-pin 8*,14*,51,57,60,62, Right console, rear
80,81,84,96,98,109,
111,113,115,120
X967 Plug connection distribution board / 21-pin 5*,6*,57,58, Right console, rear
65,74,82,97
X968-1 Plug connection A125 CS / 1-pin 34*,81,84,110,115 Left console, bottom
X968-2 Plug connection A125 CS / 1-pin 34*,81,84,110,115 Left console, bottom
X968-3 Plug connection A125 CS / 1-pin 81 Left console, bottom
X973 Power socket, 12V 8*,57 Left console
X974-2 Plug connection blocking diode / 2-pin 103 Left console, bottom
X974-4 Plug connection A125 CS / 2-pin 34*,81,84,110, 115 Left console, bottom
X974-5 Plug connection adapter CS / 1-pin 84 A125
X979 Plug connection switch CS / 2-pin 69 Revolving deck
X982 Plug connection switch CS / 3-pin 69 Revolving deck
X983 Plug connection distribution board / 3-pin 78,105,106 Right console, rear
X987 Plug connection auxiliary heating CS / 8-pin 70 Near operator's cab
X988-1 Plug connection blocking diodes / 8-pin 72, 77,79,108 Right console
X988-4 Plug connection blocking diodes / 6-pin 79,108 Right console
X989 Socket 12V / 20 A / 12-pin 71 Left console
X993 Plug connection beacon / 2-pin 89 Uppercarriage, rear
X998 Plug connection, 2-pin 76 Left console
X999-1 Plug connection, 1-pin 76 Left console
X999-2 Plug connection, 2-pin 76 Left console
X999-3 Plug connection, A 127 /1-pin 76 Near hydraulic tank
X998 Plug connection, 3-pin 116 Below operator's platform
X1006 Plug terminal / 1-pin 59,95 Near A127
X1011 Plug connection decay diode / 3-pin 59,95 Near A127
X1017 Plug connection to Y237/Y238 / 4-pin 83 Near hydraulic tank
X1028 Plug connection to S405 and H322 / 4-pin 84,110 Right control console, rear
X1029 Plug connection solenoid valves / 4-pin 84,110 Right control console, rear
X1040 Plug connection to display unit / 3-pin 85,119 Electric box E50
X1041 Plug connection for temperature sensor / 2-pin 85,119 Electric box E50
X1046 Plug connection, 12-pin 24*,25*,55,78,80, Left console
98,107,109,120
X1046-1 Plug handle extension / 6-pin 80,98,109 Right handle
X1048 Plug connection, 12-pin 10*,55,61,80,98,98, Right handle
103,104,112,115
X1046-1 Plug to handle switch / 3-pin 55,98 Right handle
X1050 Plug connection adapter switch CS / 3-pin 78,86 Right handle
X1051 Plug connection switch CS / 3-pin 78,86 Right handle
A 309 LI - R 317 LI 8.45.13

copyright by
MJF C I F S S

X1052 Plug connection mower rake drive CS / 4-pin 78,86 Right handle
X1053 Plug connection slip ring CS / 1-pin 87 Distribution board
X1060 Plug connection switch / 3-pin 90 Right control console
X1061 Plug connection, 8-pin 90 Near upper carriage Y409
X1062 Plug connection, 3-pin 90 Bearing block
X1070-1 Plug connection solenoid valve / 2-pin 91 Near hydraulic tank
X1070-2 Plug connection solenoid valve / 2-pin 91 Near hydraulic tank
X1104 Plug connection, 1-pin 92,93,114 Right control desk
X1106 Plug connection power supply / 4-pin 111 Right control desk
X1117 Plug connection 4-wheel steering / 6-pin 111 Right control desk
X1132 Plug connection extension bridging / 3-pin 79,108 Left control desk
X1138 Plug connection A127 - refuelling pump / 2-pin 52 Near hydraulic tank
X1179 Plug connection to display unit / 3-pin 96,113 Right control console
X1186 Plug connection, 3-pin 74,97 Engine compar., left rear
X1190 Plug connection float switch / 2-pin 52 Near fuel tank
X1198 Plug connection for temperature sensor / 2-pin 97 Uppercarriage, right
X1210 Plug connection delta p / 3-pin 78 Right control desk
X1213 Plug connection decay diode / 2-pin 100 Right control console
X1215 Plug connection warning light / 2-pin 101 Right control console
X1218 Plug connection warning light / 2-pin 101 Right control console
X1224 Plug connection pressure switch / 3-pin 84 Distribution board
X1226 Plug connection solenoid valves / 2-pin 106 Solenoid valves
X1234 Plug connection adapter switch CS / 6-pin 102 Distribution board
X1235 Plug connection magnet unit CS / 4-pin 102 Distribution board
X1240 Plug connection adapter switch CS / 4-pin 115 Right control desk
X1241 Plug connection switch CS flow distributor / 2- 115 Right control desk
pin
X1242 Plug connection CS solenoid valve / 2-pin 115 Right control desk
X1243 Plug connection switch CS flow distributor / 1- 115 Right control desk
pin
X1244 Plug connection CS diode / 2-pin 115 Right control desk
X1251 Plug connection switch CS / 2-pin 116 Right control desk
X1253 Plug connection blocking diode / 2-pin 117 Right control desk
X1254 Plug connection solenoid valve / 2-pin 117 Right control desk
X1255 Plug connection switch CS / 3-pin 117 Right control desk
X1260 Plug connection switch / 3-pin 118 Right control desk
X1261 Plug connection solenoid valves / 4-pin 118 Right control desk
X1262 Plug connection solenoid valves / 4-pin 118 Right control desk
X1263 Plug connection blocking diode / 2-pin 118 Right control desk
X1265 Plug connection, 21-pin 120 Right control desk

Y6 Solenoid valve / parking brake 13*,60 HBGV block
Y12 Solenoid valve / excess fuel for starting 1a*,60 Diesel engine regulator
Y20 Coupling/air-conditioning system 30c*,64c Engine compartment
Y22 Solenoid valve / grapple rotator 25*,80,96,109, Control valve block
113,120
8.45.14 A 309 LI - R 317 LI

copyright by
MJF C I F S S

Y23 Solenoid valve / grapple rotator 25*,80,96,109, Control valve block
113,120
Y28-1 Solenoid valve / quick change adapter 38*,62 Quick-change adapter
Y28-2 Solenoid valve / quick change adapter 38*,62 Quick-change adapter
Y29 Solenoid valve / engine shut-down 3*,59,60,95 Engine regulating rod
Y56 Solenoid valve / changeover outrigger - blade 35*,50,73,92,114 Undercarriage
Y62 Solenoid valve / forward travel 10*,68,89 Hydraulic tank
Y63 Solenoid valve / reverse travel 10*,68,89 Hydraulic tank
Y204 Solenoid valve / emergency discharge 76 Lift frame base
Y212 Solenoid valve/industrial shut-down 39*,56,117 Industrial stick
Y212-1 Solenoid valve blocking stick lowering 118 Industrial stick
Y215 Solenoid valve / front left outrigger support 35*,50 Undercarriage
Y216 Solenoid valve / front right outrigger support 35*,50 Undercarriage
Y217 Solenoid valve / rear left outrigger support 35*,50,73,92,93,114 Undercarriage
Y218 Solenoid valve / rear right outrigger support 35*,50,73,92,93,114 Undercarriage
Y236-1 Solenoid valve/changeover 100 Near control valve block
Y237 Solenoid valve / boom shut-off 72,77,79,83,108,118 Near hydraulic tank
Y238 Solenoid valve/stroke limitation 72,79,108 Near hydraulic tank
Y238 Solenoid valve/stick shut-down 83 Near hydraulic tank
Y268 Solenoid valve / grapple hammer 34*,51,84,107,110 Near hydraulic tank
Y295 Solenoid valve / magnet unit 55,115 Basic boom bearing block
Y299 Solenoid valve / changeover pressure limitation 34*,51,84,107,110 Near hydraulic tank
Y307 Proportional solenoid valve/steering 88 Below operator's platform
Y330 Solenoid valve / pump regulation 111 Control oil unit
Y332 Solenoid valve / changeover valve 66,78,105,106 Attachment
Y341 Solenoid valve / lift frame 53 Behind cab
Y354 Solenoid valve / pressure limitation pst / boom 83 Near hydraulic tank
cylinder extension bridged
Y355 Solenoid valve / pressure limitation pst / boom 83 Near hydraulic tank
cylinder extension
Y356 Solenoid valve / fan stop 102 Near weight
Y357 Solenoid valve/priority circuit 51 Near hydraulic tank
Y357 Solenoid valve / change of direction of rotation 102 Near weight
Y360 Solenoid valve / industrial quick change adapter 63 Industrial stick
Y363 Solenoid valve/retracting 101 Behind cab
Y365 Solenoid valve / cylinder retraction 94,101,112 Hydraulic tank
Y366 Solenoid valve / cylinder extension / hammer 94,101,112 Hydraulic tank
Y371 Solenoid valve / oscillating axle 33*,103 Control oil unit
Y385-1 Solenoid valve/changeover bucket cylinder - 84,110 Behind cab
AHS
Y385-2 Solenoid valve/changeover bucket cylinder - 84,110 Behind cab
AHS
Y405 Solenoid valve / mower rack forward 78,86 Control valve block
Y406 Solenoid valve / mower rack, reverse 86 Control valve block
Y406 Solenoid valve / trailer coupling OPEN/ 87 Uppercarriage, rear
CLOSED
A 309 LI - R 317 LI 8.45.15

copyright by
MJF C I F S S

Y409 Solenoid valve / tilt cylinder shut-off 90 Near hydraulic tank
Y410 Solenoid valve / continuous operation AHS 91 Near hydraulic tank
Y428 Solenoid valve / changeover UP/DOWN - tele- 92 Undercarriage
scope OUT/IN
Y443 Pipe fracture safety stop valve / regulating cylin- 106 Near control valve block
der extending
Y444 Pipe fracture safety stop valve / regulating cylin- 106 Near control valve block
der retracting
Y451 Solenoid valve / combined lifting of boom 84,110 Near control valve block
Y452 Solenoid valve AHS actuation 115 Near control valve block
Y453 Sol. valve control press. changeover / piston 106 Near control valve block
side
Y454 Sol. valve control press. changeover / piston 106 Near control valve block
side
Y456 Solenoid valve changeover control lines 106 Near control valve block
Y465 Block solenoid valve / boom lowering 118 Near control valve block
Item Designation
be beige
bl blue
br brown
ge yellow
gn green
gr grey
rt red
sw black
vi purple
ws white
Tab. 1 Cable colours
Item 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
Tab. 2 Terminal designation
8.45.16 A 309 LI - R 317 LI

copyright by
MJF C I F S S
A 309 LI - R 317 LI 8.45.17

copyright by
MJF C I F S S
Step 50
Item Designation Location / arrangement
F337 Fuse 15 A Fuse box in control console,
front right
S204 Switch / front left outrigger support

S205 Switch / front right outrigger support
S206 Switch / rear left outrigger support
S207 Switch / rear right outrigger support
S272** Slip-ring case
S335 Blade support switch
X301 Plug connection, 8-pin

X957** Plug connection, 21-pin
Y 56 Solenoid valve blade support

Y215 Solenoid valve / front left outrigger support
Y216 Solenoid valve / front right outrigger support
Y217 Solenoid valve / rear left outrigger support
Y218 Solenoid valve / rear right outrigger support
** in basic machine
8.45.18 A 309 LI - R 317 LI

copyright by
MJF C I F S S
50 A 312 Litronic / 314 Litronic / A 316 Litronic

UMSCHALTUNG SCHILD / PRATZE EINZELSTEUERUNG 4PKT EINZELSTEUERUNG 2PKT
DOZER BLADE / OUTRIGGER CHAN- 4PT. OUTRIGGER INDIVIDUAL 2PT. OUTRIGGER INDIVIDUAL
GEOVER CONTROL CONTROL
COMMUTATION DE LAME DE NIVE- COMMANDE UNIQUE 4POINTS COMMANDE UNIQUE 2POINTS
LAGE / BRAS STABILISATEUR
A 309 LI - R 317 LI 8.45.19

copyright by
MJF C I F S S
Step 51
Location /
Item Designation
arrangement
A125** Compact potentiometer PCB
A126** Autocheck PCB
B40** Proximity switch / travel pedal right

B290** Proximity switch / adjusting pedal left
B291** Proximity switch / adjusting pedal right
F316** Fuse / indicator instruments / overload warning system / 15A

sensor control
F330** ASH/AS1 fuse / fine adjustment 15 A
H196 Indicator light / sorting grapple
K375 Relay / changeover hammer / pile driver
P1** Flow reduction potentiometer
S45 Prio switch (not installed)

S241 Switch AHS 12
U16 Electronic box BST
V156-4 Blocking diode

X837** Plug connection, 8-pin / / A125 left console
X839** Screw terminal, 3-pin / / kit PCB
X857** Plug connection, 24-pin / / BST
X924-2** Plug connection, 3-pin / / accessory kit pedal
X951** Plug connection, 21-pin / / autocheck
X952** Plug connection, 21-pin / / revolving deck CS distribution board
X956** Plug connection, 21-pin / / CS BST distribution board
X957** Plug connection, 21-pin / / console switch distribution board
X960** Plug connection, 21-pin / / platform CS distribution board
X963** Plug connection, 21-pin / / console ignition key distribution board
X966** Plug connection, 21-pin / / CS AI 25 distribution board
X974-4 Plug connection, 2-pin / / / CS AI 25 diode plug
Y299 Solenoid valve pressure control
** in basic machine
8.45.20 A 309 LI - R 317 LI

copyright by
MJF C I F S S

AHS11
AHS11
AHS11
A 309 LI - R 317 LI 8.45.21

copyright by
MJF C I F S S
Step 51
Location /
Item Designation
arrangement
A125** Compact potentiometer board
B40** Proximity switch right travel pedal

F316** Fuse / indicator instruments / overload warning sys- 15.0 A

tem / sensor control
F330** ASH/ AS1 fuse / fine adjustment 15.0 A

S241 Switch AHS 12

X837** Plug connection, 8-pin / A125 left console
X839** Screw terminal, 3-pin / kit PCB
X857** Plug connection, 24-pin / BST
X924-2** Plug connection, 3-pin / accessory kit pedal
X951** Plug connection, 21-pin / autocheck
X952** Plug connection, 21-pin / revolving deck CS distribution board
X956** Plug connection, 21-pin / CS BST distribution board
X957** Plug connection, 21-pin / console switch distribution board
X960** Plug connection, 21-pin / platform CS distribution board
X963** Plug connection, 21-pin / console ignition key distribution board
X966** Plug connection, 21-pin / CS AI 25 distribution board
X974-4 Plug connection, 2-pin / CS AI 25 diode plug
Y299 Solenoid valve pressure control
** in basic machine
8.45.22 A 309 LI - R 317 LI

copyright by
MJF C I F S S

AHS12
AHS12
AHS12
A 309 LI - R 317 LI 8.45.23

copyright by
MJF C I F S S
Step 51
Location /
Item Designation
arrangement
A125** Compact potentiometer board
B40** Proximity switch / travel pedal right

F316** Fuse / indicator instruments / overload warning system 15.0 A

/ sensor control
F330** ASH/AS1 fuse / fine adjustment 15.0 A

S241 Switch AHS 12
X837** Plug connection, 8-pin / A125 left console

X839** Screw terminal, 3-pin / kit PCB
X857** Plug connection, 24-pin / BST
X924-2** Plug connection, 3-pin / accessory kit pedal
X960** Plug connection, 21-pin / platform CS distribution board
X963** Plug connection, 21-pin / console ignition key distribution board
X966** Plug connection, 21-pin / CS A125 distribution board
X974-4 Plug connection, 2-pin / CS A125 diode plug
Y268 Solenoid valve / grapple / hammer

Y299 Solenoid valve / pressure control
Y357 Solenoid valve / priority circuit
** in basic machine
8.45.24 A 309 LI - R 317 LI

copyright by
MJF C I F S S

AHS12 & PRIO
AHS12 & PRIO
AHS12 & PRIO
A 309 LI - R 317 LI 8.45.25

copyright by
MJF C I F S S
Step 52/1
A 127** Printed circuit board / power
F216 Fuse / refuelling pump 20.0 A
K30 Relay / refuelling pump
M6 Refuelling pump
S25 Switch / refuelling pump ON

S59 Switch / refuelling pump OFF
S341 Float switch / refuelling pump
** in basic diagram
8.45.26 A 309 LI - R 317 LI

copyright by
MJF C I F S S
52/1 A 309 Litronic - R 317 Litronic

BETANKUNGSPUMPE
REFUELLING PUMP
PUMPE DE REMPL.
A 309 LI - R 317 LI 8.45.27

copyright by
MJF C I F S S
Step 52/2
F216 Fuse / refuelling pump 15.0 A
K30 Relay / refuelling pump
M6 Refuelling pump
S25 Switch / refuelling pump ON

S59 Switch / refuelling pump OFF
S341 Float switch / refuelling pump
V173 Blocking diode BTKP
X7 Plug connection on A127 (F_L)

X1138 Plug connection, 2-pin / A127 refuelling pump
X1190 Plug connection, 2-pin / float switch
** in basic diagram
8.45.28 A 309 LI - R 317 LI

copyright by
MJF C I F S S
52/2 A 309 Litronic - R 317 Litronic

BETANKUNGSPUMPE
REFUELLING PUMP
PUMPE DE REMPL.
A 309 LI - R 317 LI 8.45.29

copyright by
MJF C I F S S
Step 53
Location /
Item Designation
arrangement
F329** Servo switch fuse 15.0 A
H293 Indicator light / operator's cab
S35** Switch / front left outrigger support

S361 Switch / hydraulic cab elevation
X821** Plug connection, 21-pin / console (switch) distribution board

Y341 Solenoid valve / cab lift frame UP and DOWN
** in basic diagram
8.45.30 A 309 LI - R 317 LI

copyright by
MJF C I F S S
53 A 316 Litronic (IND)

HYDRAULISCHE FAHRERHAUSERHHUNG
HYDRAULIC CAB ELEVATION
HYDR.P.CONTRE POIDS DEMONTABLE
A 309 LI - R 317 LI 8.45.31

copyright by
MJF C I F S S
Step 54
Location /
Item Designation
arrangement
A 126** Autocheck PCB
B21 Pressure switch / overload warning system
H10 Buzzer / overload warning system

H16 Indicator light / overload warning system
S18 Switch / overload warning system

S20** Switch / sensor control
X407** Plug connection, 2-pin / revolving deck CS overload warning sys-

tem
X950** Plug connection, 21-pin / A 126
X951** Plug connection, 21-pin / A 126
** in basic diagram
8.45.32 A 309 LI - R 317 LI

copyright by
MJF C I F S S
54 A 312 Litronic / A 314 Litronic / A 316 Litronic / A 316 (IND)

BERLASTWARNEINRICHTUNG
OVERLOAD WARNING SYSTEM
AVERITISSEUR DE SUCHARGE
A 309 LI - R 317 LI 8.45.33

copyright by
MJF C I F S S
Step 55/1
F337 Fuse 15.0 A Fuse box in control conso-

le, front right
S6L Button / magnet system

S46 Switch / magnet system
U7 Switching system / magnet system

U16** Electronic box BST
X11** Plug connection, 2-pin / magnet system CS distribution

board
X74 Plug connection, 2-pin / magnet system CS, handle / but-
ton
X74-1 Plug connection, 1-pin / magnet system CS, handle / but-
ton
X217 Plug connection, 2-pin / magnet system CS
X370 Plug connection, 2-pin / magnet system CS, solenoid val-
ve CS
X856** Plug connection, 40-pin / CS BST
X958** Plug connection, 21-pin / console switch distribution
board
X962** Plug connection, 21-pin / console indicator distribution
board
X963** Plug connection, 21-pin / fuse distribution board
Y295** Solenoid valve / magnet unit
** in basic diagram
8.45.34 A 309 LI - R 317 LI

copyright by
MJF C I F S S
55/1 A 316 Litronic (IND)

STEUERUNG MAGNETANLAGE
MAGNET SYSTEM CONTROL
CONTROLE DE MONTAGE PLATEAU MAGNETIQUE
A 309 LI - R 317 LI 8.45.35

copyright by
MJF C I F S S
Step 55/2

le, front right

U7 Switching system / magnet system

X11** Plug connection, 2-pin / magnet system CS distribution

board
ton
ton
ve CS
board
board
Y295** Solenoid valve / magnet unit
** in basic diagram
8.45.36 A 309 LI - R 317 LI

copyright by
MJF C I F S S

A 309 LI - R 317 LI 8.45.37

copyright by
MJF C I F S S
Step 55/3
F337** Fuse 15.0 A Fuse box in control conso-

le, front right

U7 Switching system / magnet unit


ton
ton
ve CS
board
board
Y295 Solenoid valve / magnet unit
** in basic diagram
8.45.38 A 309 LI - R 317 LI

copyright by
MJF C I F S S

A 309 LI - R 317 LI 8.45.39

copyright by
MJF C I F S S
Step 56
B204 Proximity switch

le, front right
K392 Relay for industrial shut-shut-down
S216 Switch/industrial shut-down

Y212 Solenoid valve / industrial shut-down
** in basic diagram
8.45.40 A 309 LI - R 317 LI

copyright by
MJF C I F S S

INDUSTRIEABSCHALTUNG
IND. SHUTDOWN
INTERRUPTION IND.ELEVABLE
A 309 LI - R 317 LI 8.45.41

copyright by
MJF C I F S S
Step 57
A3** Radio
B50** Loudspeaker
F304** Fuse S1 15.0 A

F322** Fuse T1 15.0 A
S1** Start and pre-heating switch
T1** Voltage transformer
X65** Plug connection, 2-pin / T1 / 24 V

X66** Plug connection, 2-pin / T1 / 12 V
X67-1** Plug connection, 8-pin / A3 power supply
X67-2** Plug connection, 8-pin, A3 loudspeaker
X963** Plug connection, 21-pin / distribution board
X973** Power socket
** in basic diagram
8.45.42 A 309 LI - R 317 LI

copyright by
MJF C I F S S

RADIO
RADIO
RADIO
A 309 LI - R 317 LI 8.45.43

copyright by
MJF C I F S S
Step 58
Location /
Item Designation
arrangement
E9 Beacon
F317** Fuse 7.5 A

Working light / beacon
S8 Switch / beacon
X967** Plug connection, 21-pin / console indicator distribution board

X993 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

RUNDUMKENNLEUCHTE
BEACON
GIROPHARE
A 309 LI - R 317 LI 8.45.45

copyright by
MJF C I F S S
Step 59
F300** Fuse A127 / terminal 30 to terminal 15 50.0 A

F303** Fuse A127, Y29 7.5 A
K288** Relay 15 A127
S313 Switch / engine shut-down
V168 Decay diode
X1006 Plug terminal, 1-pin

X1011 Plug connection decay diode, 3-pin
Y29** Solenoid valve / engine stop
** see basic diagram of electrical system
8.45.46 A 309 LI - R 317 LI

copyright by
MJF C I F S S

MOTORSTOP
ENGINE STOP
ARRET MOTEUR
A 309 LI - R 317 LI 8.45.47

copyright by
MJF C I F S S
Step 60
A127** Printed circuit board / power
F300** Fuse terminal 30 to terminal 15 50.0 A

F303** Fuse Y29 B3 7.5 A
F304** External fuse S1 15.0 A
F306** Fuse X10 15.0 A
F314** Fuse S7 15.0 A
F332** Fuse M1, Y12 25.0 A
K368** Relay of terminal 50

K369** Relay of terminal 15
K386** Relay / safety switch
M1** Starter
S1** Start switch / right console

S7** Safety switch / left console
S74 Code key for immobiliser
U13 Electronic box / auto-scan

X955** Plug connection, 15-pin / revolving deck CS distribution
board
X963** Plug connection, 21-pin, fuse distribution board
X964** Plug connection, 21-pin, fuse distribution board
X966** Plug connection, 21-pin, A 125 distribution board
Y6** Solenoid valve / parking brake

Y12** Solenoid valve / cold-start aid
Y29** Solenoid valve / engine stop
** in basic diagram
8.45.48 A 309 LI - R 317 LI

copyright by
MJF C I F S S

WEGFAHRSPERRE
IMMOBILISER
ANTIVOL DE DEMARRAGE
A 309 LI - R 317 LI 8.45.49

copyright by
MJF C I F S S
Step 61
B36 Pressure switch
F320** Fuse X11 / X12 15.0 A
H33 Back-up alarm
K407-1 Relay / travel warning mute

K407-2 Time relay, delayed travel warning 10 sec.
S6L Push button / grapple pilot control right

S6R Push button / grapple pilot control right

X74 Plug connection, 3-pin / cable with button
X204 Plug connection, 2-pin / to buzzer H33
X206 Plug connection, 2-pin / to pressure switch B36
X207 Plug connection, 2-pin / to pressure switch B36
X324-1 Plug connection, 2-pin / to buzzer H33
X324-2 Plug connection, 2-pin / to buzzer H33
** in basic diagram
8.45.50 A 309 LI - R 317 LI

copyright by
MJF C I F S S

FAHRWARNEINRICHTUNG
TRAVEL ALARM
AVERTISSEUR DE MARCHE
A 309 LI - R 317 LI 8.45.51

copyright by
MJF C I F S S
Step 62
A1017 Printed circuit board / quick-change adapter
B26 Proximity switch / bucket quick-change adapter
F316** Fuse sensor / sensor control / console

F326** Fuse creeper gear / 1st gear / oscillating axle /S
H26 Indicator light / quick-change adapter

H27** Buzzer
K364 Relay / quick-change adapter valves

S47 Key switch
S360 Buzzer acknowledgement
V156-3 Quick-change adapter blocking diode
X15-2** Plug connection, 3-pin / to S5

X262 Plug connection, 8-pin / to quick-change adapter
X262-1 Plug connection, 8-pin / on bearing block
X262-3 Plug connection, 8-pin / on stick
X262-4 Plug connection, 2-pin / on valve Y28-1
X262-5 Plug connection, 2-pin / on valve Y28-1
X262-6 Plug connection, 2-pin / on B26
X410 Plug connection A 1017 power supply
X411 Plug connection key switch
X412 Plug connection A 1017 - AS1 button
X413 Plug connection, 4-pin, quick-change warning
X798 Plug connection, 3 pin / blocking diode
Y28-1 Solenoid valve / quick-change adapter

Y28-2 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
62 A 312 Litronic / A 314 Litronic / A 316 Litronic

SCHNELLWECHSLER
QUICK-CHANGE ADAPTER
ADAPTEUR A CHANGEMENT RAPIDE
A 309 LI - R 317 LI 8.45.53

copyright by
MJF C I F S S
Step 63
F327** Fuse / industrial stick quick-change adapter 15.0 A
H26 Quick-change indicator light

H27** Quick-change warning buzzer
S47-1 Key switch / activate quick-change adapter

S47-2 Key switch / activate quick-change adapter
V154 Blocking diode / quick-change warning system
X262 Plug connection, 8-pin / distribution board

X262-1 Plug connection, 8-pin / bearing block
X446 Plug connection, 5-pin / S47-1/2
X447 Plug connection to blocking diode / quick-change war-
ning system
X8911 Plug connection, 2-pin / on valve Y360
X891-2 Plug connection, 2-pin / on stick
Y360 Solenoid valve / quick-change adapter
** in basic diagram
8.45.54 A 309 LI - R 317 LI

copyright by
MJF C I F S S

INDUSTRIESCHNELLWECHSLER
IND. QUICK-CHANGE ADAPTER
ADAPT. RAPIDE INDUSTRIE
A 309 LI - R 317 LI 8.45.55

copyright by
MJF C I F S S
Step 64
B294 Pressure switch / a/c compressor
B295 Heating thermostat
F318** Fuse heating/air-conditioning system Kl30 20.0 A

F319** Fuse heating/air-conditioning system terminal 3.0 A
15
F339** Fuse capacitor motors 20.0 A
K402 Relay / heating

K403** Relay / heating
K404 Relay / capacitor motors
K405 Relay / blower switch
M65** Blower motor

M71** Servo motor / water valve
M72** Servo motor / air distribution
M73** Servo motor / eversing - air distribution
M74-1 Fan motor / condenser
S92** Potentiometer / air distribution

S93** Potentiometer / heating / air conditioning system
S284** Switch / four-step blower
S318 Switch a/c system
S398** Reversing switch / heating
X842-1** Plug connection, 15-pin

Y20 Solenoid valve / a/c coupling
** in basic diagram
8.45.56 A 309 LI - R 317 LI

copyright by
MJF C I F S S
64a Air-conditioning system
A 309 LI - R 317 LI 8.45.57

copyright by
MJF C I F S S
64b Air-conditioning system
8.45.58 A 309 LI - R 317 LI

copyright by
MJF C I F S S
64c Air-conditioning system
A 309 LI - R 317 LI 8.45.59

copyright by
MJF C I F S S
Step 65
E1** Working light / attachment
E2** Auxiliary headlight (roof) / front
E 150** Auxiliary headlight (roof) / rear
F323** Fuse 15.0 A

F324** Fuse 15.0 A
S22** Switch / auxiliary headlight

S22-1** Switch / auxiliary headlight

** in basic diagram
8.45.60 A 309 LI - R 317 LI

copyright by
MJF C I F S S

ZUSATZSCHEINWERFER
AUXILIARY HEADLIGHT
PROJECTEURS SUPPLEMENTAIRES
A 309 LI - R 317 LI 8.45.61

copyright by
MJF C I F S S
Step 66/1
F331** Fuse 15.0 A
K370 Relay servo

S356 Switch / changeover valve

Y332 Solenoid valve / changeover valve
** in basic diagram
8.45.62 A 309 LI - R 317 LI

copyright by
MJF C I F S S
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 8.45.63

copyright by
MJF C I F S S
Step 66/2
F331** Fuse 15.0 A
K455 Relay / changeover valve UP, horizontal

X358-1 Plug connection, 2-pin / under operator's platform
X358-2 Plug connection, 2-pin / fuel tank
X1226 Plug connection, 2-pin / magnet system

Y443 Check valve / boon cylinder pipe fracture safety valve
Y444 Check valve / boon cylinder pipe fracture safety valve
** in basic diagram
8.45.64 A 309 LI - R 317 LI

copyright by
MJF C I F S S

ENSEMBLE DE MONTAGE
A 309 LI - R 317 LI 8.45.65

copyright by
MJF C I F S S
Step 67
A1202 Frequency switching board
F320** Fuse X11 / X12 15.0 A
G1** Alternator
P5-1 Operating hour meter / idle run

P5-2 Operating hour meter / partial load
P5-3 Operating hour meter / full load
S384 Switch / operating hour meter

X914 Plug connection, 6-pin, operating our meter CS
X915 Plug connection, 16-pin / on A 1202
** in basic diagram
8.45.66 A 309 LI - R 317 LI

copyright by
MJF C I F S S

BETRIEBSSTUNDENZHLER
HOUR COUNTER
COMPTEUR HORAIRE
A 309 LI - R 317 LI 8.45.67

copyright by
MJF C I F S S
Step 68
F325** Fuse S16, S263 (7.5 A)
H167** Indicator light / forward travel

H168** Indicator light / forward travel
H183 Electronic buzzer
K251** Relay / hand brake (light)
S263 Pilot control unit switch, right

S269 Switch in slip ring
S270 Switch in slip ring
X312 Plug connection, 12-pin / slip ring

X313 Plug connection, 12-pin / slip ring
X314 Plug connection, 2-pin / electronic buzzer
X324-1 Plug connection, 2-pin / electronic buzzer
X342** Plug connection, 3-pin / travel switch
X950** Plug connection, 21-pin / on A 126
X951** Plug connection, 21-pin / on A 126
X952** Plug connection, 21-pin / revolving deck CS BST
board
Y62** Solenoid valve, forward travel

Y63** Solenoid valve, reverse travel
** in basic diagram
8.45.68 A 309 LI - R 317 LI

copyright by
MJF C I F S S

RCKFAHRWARNEINRICHTUNG
BACK-UP WARNING DEVICE
AVERTISSEUR DE MARCHE ARRIERE
A 309 LI - R 317 LI 8.45.69

copyright by
MJF C I F S S
Step 69
F320** Fuse X11 15.0 A

F340 Fuse Thermoline 15.0 A
K33 Relay Thermoline
R8 Thermoline
S237 Switch / fuel pre-heating

X738 Plug connection, 2-pin / Thermoline
X963** Plug connection / distribution board
X979 Plug connection, 2-pin / switch CS
X982 Plug connection, 3-pin / switch CS
** in basic diagram
8.45.70 A 309 LI - R 317 LI

copyright by
MJF C I F S S

KRAFTSTOFFVORWRMUNG
FUEL PREHEATER
PRECHAUFFE DE CARBURANT
A 309 LI - R 317 LI 8.45.71

copyright by
MJF C I F S S
Step 70
A127 Printed circuit board / power
E30 D5WS auxiliary heating

E50 Power cabinet and fuse cabinet
F34 Fuse / auxiliary heater to ground 25.0 A

F35 Fuse / auxiliary heater control unit 15.0 A
F36 Fuse / auxiliary heater timer, water valve, hea- 15.0 A
ting
G2 Battery
K358 Relay heating ON

K359 Relay water circuit ON
K360 Relay / heater fan ON
M52 Water pump

M53 Fuel metering pump
S9 Battery main switch

S232 Digital timer
X95 Plug connection, 4-pin / to S232

X98 Plug connection, 2-pin / to fuel metering pump
X99 Plug connection, 2-pin / to water recirculation pump
X100 Plug connection, 2-pin / to water recirculation pump
X101 Plug connection, 8-pin / to auxiliary heater control device
X689 Plug connection, 6-pin / blocking diodes
X842-2 Plug connection, 2-pin / heater - auxiliary heater
X987 Plug connection, 8-pin / auxiliary heater
8.45.72 A 309 LI - R 317 LI

copyright by
MJF C I F S S

STANDHEIZUNG D5WS
AUXILIARY HEATER
CHAUFFAGE SUPPLEMENT SUPPLEMENTAIRE A L'ARRET
A 309 LI - R 317 LI 8.45.73

copyright by
MJF C I F S S
Step 71
A127 Printed circuit board / power
F342 Fuse terminal 15 15.0 A
T4 Voltage transformer
X989 Power socket 12V / 20 A / 2-pin
8.45.74 A 309 LI - R 317 LI

copyright by
MJF C I F S S

STECKDOSE 12V 20A
SOCKET 12V 20A
PRISE 12V 20A
A 309 LI - R 317 LI 8.45.75

copyright by
MJF C I F S S
Step 72
B214 Proximity switch / boom shut-down
F331 Fuse X29 15.0 A
H27 Buzzer / quick-change adapter / boom shut-down
K333-1 Relay / boom shut-down

K334 Relay / boom shut-down
S249 Key switch with plug / boom shut-down

S291 Push button with plug / override boom shut-down
V163-1 Blocking diode / QC signal

V163-2 Blocking diode / signal boom shut-down

X988-1 Plug connection, 8-pin / boom shut-down CS
X988-3 Plug connection, 3-pin / blocking diodes
Y237 Solenoid valve / boom shut-down

8.45.76 A 309 LI - R 317 LI

copyright by
MJF C I F S S

HUBBEGRENZUNG
STROKE LIMITER
LIMITEUR DE COURSE DE LEVAGE
A 309 LI - R 317 LI 8.45.77

copyright by
MJF C I F S S
Step 73
le, front right
S272 Slip-ring case

S335 Blade support switch
S335-1 Switch front blade
S335-2 Switch / rear blade
X301 Plug connection, 12-pin / slip rig distribution board

X304 Plug connection, 6-pin / console right
Y56 Solenoid valve / blade support, front

Y217 Solenoid valve / outrigger support, rear left
Y218 Solenoid valve / outrigger support, rear right
8.45.78 A 309 LI - R 317 LI

copyright by
MJF C I F S S

EINZELSTEUERUNG SCHILD / SCHILD
BLADE / BLADE INDIVIDUAL CONTROL
COMMANDE UNIQUE LAME / LAME
A 309 LI - R 317 LI 8.45.79

copyright by
MJF C I F S S
Step 74
F307 Fuse E16, E17 7.5 A
F308 Fuse E15, E18 7.5 A
F309 Fuse E3 7.5 A
F310 Fuse E4 7.5 A
F336 Fuse S61 20.0 A
E4 Headlight uppercarriage, right

E15 Parking light, right
E18 Tail light, left
E163 License plate light
S61 Switch / lighting installation
X902 Plug connection, 6-pin / lighting system

8.45.80 A 309 LI - R 317 LI

copyright by
MJF C I F S S

KENNZEICHENLEUCHTE
LAMP
ECLAIREAGE DE LA PLAQUE D'IMMATRICULATION
A 309 LI - R 317 LI 8.45.81

copyright by
MJF C I F S S
Step 75
B51-1 Piston detector
F320 Fuse X11 15.0 A
S84-1 Push button with plug / central lubrication
U4-1 Central lubrication system

X133-1 Plug connection, 2-pin / piston detector
X143-1 Plug connection, 4-pin / central lubrication system
X998 Plug connection, 3-pin / under operator's platform
8.45.82 A 309 LI - R 317 LI

copyright by
MJF C I F S S

ZENTRALSCHMIERANLAGE
CENTRAL LUBRICATION SYSTEM
DISP. DE GRAISSAGE CENTRALISE
A 309 LI - R 317 LI 8.45.83

copyright by
MJF C I F S S
Step 76
F344 Fuse / emergency lowering 7.5 A
S78 Push button / emergency lowering
X999-1 Plug connection, 2-pin / fuse - switch

X999-2 Plug connection, 2-pin / fuse - switch
X999-3 Plug connection, 1-pin / switch - solenoid valve
Y204 Solenoid valve / emergency lowering
8.45.84 A 309 LI - R 317 LI

copyright by
MJF C I F S S

NOTABLASS
EMERCENCY LOWERING
DESCENTE SECOURS
A 309 LI - R 317 LI 8.45.85

copyright by
MJF C I F S S
Step 77
B214 Proximity switch / boom shut-down
F331 Fuse X29 15.0 A
H27 Quick-change adapter buzzer / boom shut-down

S249 Key switch / boom shut-down

S291 Push button with plug / override boom shut-down
V163-1 Blocking diode / QC signal

V163-2 Blocking diode / signal boom shut-down

8.45.86 A 309 LI - R 317 LI

copyright by
MJF C I F S S

HUBBEGRENZUNG SCHWENKARM
STROKE LIMITER BASIC BOOM
LIMITEUR DE COURSE FLECHE DE BASE
A 309 LI - R 317 LI 8.45.87

copyright by
MJF C I F S S
Step 78/1
F331 Fuse X29 15.0 A
H323 Indicator light / lateral adjustment
K370 Relay servo

X358-1 Plug connection, 2-pin / under operator's platform
X358-2 Plug connection, 2-pin / fuel tank
8.45.88 A 309 LI - R 317 LI

copyright by
MJF C I F S S

ENSEMBLE DE MONTAGE TIROIR D'INVERSION
A 309 LI - R 317 LI 8.45.89

copyright by
MJF C I F S S
Step 78/2
F330 Fuse kits 15.0 A
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 Plug connection, 40-pin / BST wire harness

X857 Plug connection, 24-pin / BST
X909 Plug connection, 2-pin / to S382
X966 Plug connection, 21-pin / A125 wire harness
X974-1 Plug connection, 2-pin / blocking diode
8.45.90 A 309 LI - R 317 LI

copyright by
MJF C I F S S

ANBAUSATZ UMSCHALTSCHIEBER / FEINREGELUNG
CHANGEOVER VALVE / FINE ADJUSTMENT
ENSEMBLE DE MONTAGE TIROIR D'INVERSION / REGLAGE
A 309 LI - R 317 LI 8.45.91

copyright by
MJF C I F S S
Step 79
B213 Proximity switch boom shut-down at stick
B214 Proximity switch boom shut-down at bearing block
F331 Fuse X29 15.0 A
H27 Buzzer / quick-change adapter / boom shut-down

H249 Indicator light / override ON
S6R Push button override boom shut-down in right pilot cont-

rol unit
S249 Key switch with plug / boom shut-down ON

X74 Plug connection, 3-pin handle right
X988-6 Plug connection, 4-pin / to B214
Y237 Solenoid valve boom shut-down / stick

Y238 Solenoid valve boom shut-down / boom
8.45.92 A 309 LI - R 317 LI

copyright by
MJF C I F S S

HUBBEGRENZUNG HUB UND STIEL
STROKE LIMITER AND STICK
LIMITEUR DE COURSE LEVAGE ET BALANCIER
A 309 LI - R 317 LI 8.45.93

copyright by
MJF C I F S S
Step 80
S5L Push button / left grapple rotator, left pilot control unit
S5R Push button / right grapple rotator, left pilot control unit
S6L Push button / left grapple rotator, right pilot control unit
S6R Push button / right grapple rotator, right pilot control unit
S19 Switch / grapple rotator, right console
X15-2 Plug connection, 3-pin / left handle

X296 Plug connection, 1-pin / left handle
X297 Plug connection, 3-pin / handle right
Y22 Solenoid valve / left grapple rotator

Y23 Solenoid valve / right grapple rotator
8.45.94 A 309 LI - R 317 LI

copyright by
MJF C I F S S

BETTIGUNG AS1 IM GRIFF LINKS UND RECHTS
GRAPPLE CONTROL IN LEFT AND RIGHT JOYSTICK
CDE. AS DANS LE MANIPULATEUR GAUCHE ET DROITE
A 309 LI - R 317 LI 8.45.95

copyright by
MJF C I F S S
Step 81
A125** PCB potentiometers Left console
A126** PCB / autocheck Right console
B40** Proximity switch / travel pedal Base plate

B290** Proximity switch / kit pedal Base plate
B291** Proximity switch / kit pedal Base plate
F316** Fuse / indicator instruments / overload warning 15.0 A Right console, front
F330** Fuse kits 15.0 A Right console, front
K375** Relay / changeover hammer / pile driver Right control console, rear
S45 Prio switch (not installed) Right controle

S241** Switch AHS 11 / AHS 12 Right controle
S406 Switch / kit quantity changeover Right console
U16** Electronic box BST Right console
V156-4** Blocking diode A125 A125

V166 Diode with plug A 125
X837** Plug connection, 8-pin / distribution board Left console

X839** Plug connection, 3-pin / screw terminal on A125 Left console, bottom
X857** Plug connection, 24-pin / distribution board Right console, rear
X924-2** Plug connection, 3-pin / B291 below operator's platform
X968-1** Plug connection, 1-pin / distribution board A125
X968-2** Plug connection, 1-pin / distribution board A125
X974-4** Plug connection, 2-pin / A125 CS Left console, bottom
** item from basic diagram
8.45.96 A 309 LI - R 317 LI

copyright by
MJF C I F S S

BAUSATZMENGE UMSCHALTBAR
SWITCHABLE FLOW REDUCTION
REDUCTION DE DEBIT
A 309 LI - R 317 LI 8.45.97

copyright by
MJF C I F S S
Step 82
F307** Fuse E16, E17 7.5 A Right console, rear
F336** Fuse S61 20.0 A Right console, front
H324 Inclinometer illumination Right control console,

front
P6** Display / motor temperature Right controle
S61** Switch / lighting installation Right console, rear

8.45.98 A 309 LI - R 317 LI

copyright by
MJF C I F S S
82 A 312 Litronic / A 314 Litronic / A 316 Litronic (IND)

BELEUCHTUNG NEIGUNGSMESSER
ILLUMINATION INCLINOMETER
ECLAIRAGE NIVEAU ELECTRONIQUEB
A 309 LI - R 317 LI 8.45.99

copyright by
MJF C I F S S
Step 83/1
F320** Fuse X11 / X12 15.0 A Right console, front
H159 Indicator light / stroke limitation ON Right control console
K261 Relay / solenoid valve actuation in case of override Right console, rear
S249 Key switch / boom shut-down with plug Right controle, rear
S291 Push button with plug / override boom shut-down Right control console
X11** Plug connection, 2-pin / on distribution board Right console

X374 Plug connection, 5-pin Right control console, rear
X378 Plug connection, 2-pin / to Y354 and Y355 Right control console, rear
X689 Plug connection, 6-pin / blocking diodes Right console
X963 Plug connection, 2-pin / distribution board Right console, rear
X1017 Plug connection, 4-pin / to Y237 - Y238 Near hydraulic tank
Y237 Solenoid valve / boom shut-down Near hydraulic tank

Y238 Solenoid valve / stick shut-down Near hydraulic tank
Y354 Solenoid valve / pressure limitation pst / boom cylinder Near hydraulic tank
extension override
Y355 Solenoid valve / pressure limitation pst / boom cylinder Near hydraulic tank
extension
8.45.100 A 309 LI - R 317 LI

copyright by
MJF C I F S S
83/1 A 312 Litronic / A 314 Litronic / A 316 Litronic (IND)

HUBBEGRENZUNG KRGER
KRUEGER STROKE LIMITER
LIMITEUR DE COURSE ELECTRIQUE
A 309 LI - R 317 LI 8.45.101

copyright by
MJF C I F S S
Step 83/2
A Krueger indicating instrument
B Krueger control box
K1 Relay / preliminary shut-down Krger electronics in control box / Krger

K2 Relay / shut-down Krger electronics in control box / Krger
R70 Rotary potentiometer At basic boom

R71 Rotary potentiometer At boom

X381 Plug connection, 4-pin / to R70 At basic boom
X358-1 Plug connection, 4-pin / to R70 At basic boom
X382 Plug connection, 4-pin / to R71 At boom
X382-1 Plug connection, 4-pin / to R71 At boom
X382-2 Plug connection, 4-pin / to R71 At boom
8.45.102 A 309 LI - R 317 LI

copyright by
MJF C I F S S

HUBBEGRENZUNG KRGER
KRUEGER STROKE LIMITIER
LIMITEUR DE COURSE ELECTRIQUE
A 309 LI - R 317 LI 8.45.103

copyright by
MJF C I F S S
Step 84/1

F331** Fuse X29 15.0 A Right console, front
H322 Warning light / changeover Right control console

DOWN
P1** Potentiometer / flow reduction A125 Left console, bottom

S405 Switch / changeover Right console
V156-4** Blocking diode A125 A125

V169 Blocking diode A 125

X837** Plug connection, 8-pin / A125 Left console, bottom
X1028 Plug connection, 4-pin / to S405 and H322 Right control console, rear
X1029 Plug connection, 4-pin / solenoid valves Right control console, rear
Y385-1 Solenoid valve / changeover bucket cylinder - AHS Behind cab

8.45.104 A 309 LI - R 317 LI

copyright by
MJF C I F S S

UMSCHALTUNG LFFELKIPPKREIS / AHS
SWITCHING SYSTEM BUCKET / AHS
COMMUTATEUR GODET CURAGE / AHS
A 309 LI - R 317 LI 8.45.105

copyright by
MJF C I F S S
Step 84/2
B33 Pressure switch pst for AHS section Near control valve block

K375** Relay / signal flow reduction AHS Right console, rear

U16** BST excavator control system Right console, rear
V156-4 Blocking diode A125 A125

X856** Plug connection, 40-pin / BST wire harness Right console
X857** Plug connection, 24-pin / BST Right console
X965** Plug connection, 21-pin / BST- CS A125 Right console, rear
X966** Plug connection, 21-pin / A125 wire harness Right console, rear
X1224 Plug connection, 3-pin / pressure switch Distribution board
Y268** Solenoid valve / grapple hammer Near hydraulic tank

Y299** Solenoid valve / changeover pressure limitation Near hydraulic tank
8.45.106 A 309 LI - R 317 LI

copyright by
MJF C I F S S
84/2 A 309 Litronic / A 311 Litronic

A 309 LI - R 317 LI 8.45.107

copyright by
MJF C I F S S
Step 84/3
A133 Printed circuit board Left console

F330** to kits fuse 15.0 A Right console, front
H196** Indicator light / sorting grapple Right control desk

S19** to switch / grapple rotator Y22, Y23 Keyboard of right console

S241** Switch AHS 11 / AHS 12 Right control desk

V169 Blocking diode A 125

X968-1 Plug connection, 1-pin / A125 CS Left console, bottom
X1224 Plug connection, 3-pin / pressure switch Distribution board
Y268 Solenoid valve / grapple hammer Near hydraulic tank
Y299 Solenoid valve / changeover pressure limitation Near hydraulic tank
Y451 Solenoid valve / combined lifting of boom Near hydraulic tank
8.45.108 A 309 LI - R 317 LI

copyright by
MJF C I F S S

A 309 LI - R 317 LI 8.45.109

copyright by
MJF C I F S S
Step 85
B306 Particle filter temperature sensor Particle filter
E50 Power and safety switch cabinet Hydraulic tank
F351 Fuse (F_H) 3A Near hydraulic tank
H298 Warning light / exhaust backpressure Right control console

H299 Warning buzzer / exhaust backpressure Right control console
X20 Terminal for kit, 2-pin Printed circuit board A127

X1040 Plug connection, 3-pin / to display unit Electric box E50
X1041 Plug connection, 2-pin / for temperature sensor Electric box E50
8.45.110 A 309 LI - R 317 LI

copyright by
MJF C I F S S
85 A 309 - A 316 Litronic

PARTICLE FILTER PURITECH
FILTRE DE PARTICULES PURITECH
PARTICLE FILTER PURITECH
A 309 LI - R 317 LI 8.45.111

copyright by
MJF C I F S S
Step 86/1
S124 Switch / activation of mower rack operation Right controle

S380 Switch / mower rake activation Right controle

X1050 Plug connection, 3-pin / adapter switch CS Right handle
X1051 Plug connection, 3-pin / switch CS Right handle
X1052 Plug connection, 4-pin / mower rake drive CS Right handle
Y405 Solenoid valve with plug / mower rack forward

Y406 Solenoid valve with plug / mower rack reverse
8.45.112 A 309 LI - R 317 LI

copyright by
MJF C I F S S

ANBAUSATZ MAHKORB
MOWER RAKE
GODET FAUCARDEUR
A 309 LI - R 317 LI 8.45.113

copyright by
MJF C I F S S
Step 86/2
A1017 to quick-change adapter board Right console, rear
H329 Indicator light / mower rake operation Right console
K438 Step relay / mower rake operation Distribution board
S5L** Push button / turning grapple to the left, Y22 Left pilot control unit
S5R** Push button / turning grapple to the right, Y23 Left pilot control unit
S19** Switch / grapple rotator Y22, Y23 Keyboard of right console
S124 Switch / activation of mower rack operation Right controle
S241** to switch AHS 11 / AHS 12 Right controle
S380 Override switch stick cylinder In handle, right

X412** to plug connection distribution board / 2-pin Right console, rear
X1046** Plug connection, 12-pin Left console
X1050 Plug connection, 3-pin / adapter switch CS Right handle
X1052 Plug connection, 4-pin / mower rake drive CS Right handle
Y22** Solenoid valve / grapple rotator Control valve block

Y405 Solenoid valve with plug / mower rack forward Mower rake
8.45.114 A 309 LI - R 317 LI

copyright by
MJF C I F S S

ANBAUSATZ MAHKORB
MOWER RAKE
GODET FAUCARDEUR
A 309 LI - R 317 LI 8.45.115

copyright by
MJF C I F S S
Step 87
F320 Fuse X11 / X12 15.0 A Right console, front
S272 Slip-ring case Undercarriages

S419 Switch / trailer coupling Right console
X11 Plug connection, 2-pin / on distribution board Right console

X301 Plug connection, 12-pin / on slip ring Rotary connection
X963 Plug connection, 2-pin / distribution board Right console, rear
X1053 Plug connection, 1-pin / slip ring CS Distribution board
Y406 Solenoid valve / trailer coupling OPEN/CLOSED Uppercarriage, rear
8.45.116 A 309 LI - R 317 LI

copyright by
MJF C I F S S

ANHANGEKUPPLUNG
TRAILER COUPLING
D'ATTELAGE
A 309 LI - R 317 LI 8.45.117

copyright by
MJF C I F S S
Step 88
S6L Push button / joystick control Right pilot control unit

S6R Push button / joystick control Right pilot control unit
S321 Switch / activate joystick steering Right controle
X15 Plug connection, 3-pin Right joystick

X412 Plug connection, 3-pin / to Y307 Right console, rear
X413 Plug connection, 3-pin / to S321 Right console, rear
X414 Plug connection, 5-pin / to A123 Right console, rear
Y307 Proportional solenoid valve / steering below operator's platform
8.45.118 A 309 LI - R 317 LI

copyright by
MJF C I F S S

JOY-STICK LENKUNG
JOYSTICK CONTROL
COMMAND DU VOLANT DE DIRECTION
A 309 LI - R 317 LI 8.45.119

copyright by
MJF C I F S S
Step 89
B10** to pressure switch / parking brake HBGV block
E167 Beacon for back-up warning Cap, top right
F325** Fuse S16, S263 7.5 A Right console, front
H167** Indicator light / forward travel Right controle

H168** Indicator light / reverse travel Right controle
H183 Buzzer / back-up alarm Cap, top left
K251** Relay / parking brake Right console, rear
S263** Switch / travelling direction Right pilot control unit

S269 Switch in slip ring Rotary connection
S270 Switch in slip ring Rotary connection

X314 Plug connection, 2-pin / to electr. buzzer Revolving deck
X324-1 Plug connection, 2-pin Revolving deck
X342 Plug connection, 3-pin / to travel selection switch Right console
X950** Plug connection, 21-pin / autocheck Right console
X993 Plug connection, 2-pin / beacon Uppercarriage, rear
Y62** Solenoid valve / forward travel Hydraulic tank

Y63** Solenoid valve / reverse travel Hydraulic tank
8.45.120 A 309 LI - R 317 LI

copyright by
MJF C I F S S

RCKFAHRWARNEINRICHTUNG OPTISCH UND AKUSTISCH
BACK-UP WARNING DEVICE
AVERTISSEUR DE MARCHE ARRIERE
A 309 LI - R 317 LI 8.45.121

copyright by
MJF C I F S S
Step 90
B233 Proximity switch / bucket cylinder movement At stick
H328 Indicator light / shut-down active Right control console
S423 Key switch / shut-down override Right console

X1060 Plug connection, 3-pin / switch Right control console

X1061 Plug connection, 8-pin Uppercarriage
X1062 Plug connection, 3-pin Bearing block
Y409 Solenoid valve / tilt cylinder shut-down Near hydraulic tank
8.45.122 A 309 LI - R 317 LI

copyright by
MJF C I F S S
90 A 312 Li / A 314 Li / A 316 Li (IND) / R 317 Li

ABSCHALTUNG LFFELKIPPZYLINDER
A 309 LI - R 317 LI 8.45.123

copyright by
MJF C I F S S
Step 91

K436 Step relay (atom. reset) Distribution board
K437 Relay / signal flow reduction drilling slide Distribution board
S424 Push button / continuous operation AHS Right console

X1070-1 Plug connection, 2-pin / solenoid valve Near hydraulic tank
X1070-2 Plug connection, 2-pin / solenoid valve Near hydraulic tank
Y410 Solenoid valve / continuous operation AHS Near hydraulic tank
8.45.124 A 309 LI - R 317 LI

copyright by
MJF C I F S S

ANBAUSATZ BOHRLAFETTE
DRILLING SLIDE ACCESSORY KIT
EQUIPEMENT COMPLEMENTAIRE AFFUT
A 309 LI - R 317 LI 8.45.125

copyright by
MJF C I F S S
Step 92
S272** Slip-ring case Undercarriages

S335** Switch / preselection changeover blade - outrigger Right controle
S343 Switch / individual control, back Right controle
S439R Push button / support pilot control unit Pilot control valve / sup-
port
S439R Push button / support pilot control unit Pilot control valve / sup-
port
X301** Plug connection, 12-pin / on slip ring Rotary connection

X304** Plug connection, 6-pin / to S04, S205, S206, S207 Right console, rear
X1104 Plug connection, 1-pin Right controle
Y56** Solenoid valve / changeover outrigger - blade Undercarriages

Y217** Solenoid valve / rear left outrigger support Undercarriages
Y218** Solenoid valve / rear right outrigger support Undercarriages
8.45.126 A 309 LI - R 317 LI

copyright by
MJF C I F S S

SCHILD EINZELSTEUERUNG
OPTION LAME DE NIVELAGE/BRAS STABILISATEUR
OPTION DOZER BLADE/OUTRIGGER INDIVIDUAL CONTROL
A 309 LI - R 317 LI 8.45.127

copyright by
MJF C I F S S
Step 93
S7** to safety switch Left console

S443L Push button / telescope blade, left rear Pilot control valve: support
S443R Push button / telescope blade, right rear Pilot control valve / sup-
port
V172-1 Blocking diode / signal Y428 - Y217 Right console

V172-2 Blocking diode / signal Y428 - Y218 Right console

X304** Plug connection, 6-pin / to S04, S205, S206, S207 Right console, rear
X1104 Plug connection, 1-pin Right controle
Y217** Solenoid valve / rear left outrigger support Undercarriages

Y218** Solenoid valve / rear right outrigger support Undercarriages
Y428 Solenoid valve / changeover UP/DOWN - telescope Undercarriages
OUT/IN
8.45.128 A 309 LI - R 317 LI

copyright by
MJF C I F S S

TELESCOPIC SUPPORT BLADE
A 309 LI - R 317 LI 8.45.129

copyright by
MJF C I F S S
Step 94
S6L Push button / activation horizontal adjustment Right pilot control unit
S6R Push button / activation horizontal adjustment Right pilot control unit
S379 Switch / release of push button for horizontal adjustment Right console
(right handle)

X407** Plug connection: 2-pin, / reolving deck CS Right control console
X408 Plug connection, 2-pin / to revolving deck CS Right control console
X410** Plug connection, 2-pin / power supply A1017 Right console, rear
Y365 Solenoid valve / cylinder retraction Hydraulic tank

Y366 Solenoid valve / cylinder extension / hammer Hydraulic tank
8.45.130 A 309 LI - R 317 LI

copyright by
MJF C I F S S
94 A 312 Litronic / A 314 Litronic / A 316 Litronic / R 317 Litronic

BETTIGUNG SCHIEBERSEKTION BER TASTER
ACTUATION VALVE SPOOL WITH PUSH BUTTON
COMMANDE TIROIR DE DISTRIDUTION AVEC BOUTON POUSSOIR
A 309 LI - R 317 LI 8.45.131

copyright by
MJF C I F S S
Step 95
A127** Printed circuit board / power Hydraulic tank
F20/ Fuse terminal 30 to terminal 15 50.0 A A127 hydraulic tank

F300**
F303** Fuse A127, Y29 7.5 A Near hydraulic tank
F325** Fuse S16, S263 7.5 A Right console, front
K251** Relay / parking brake Right console, rear

K288** Relay / terminal 15 at A127 Near hydraulic tank
K439 Relay / drop-out delayed Distribution board
V168 Decay diode A 127

X1006 Plug terminal, 1-pin Near A127
X1011 Plug connection, 3-pin / decay diode Near A127
Y29** Solenoid valve / engine shut-down Engine block regulating

rod
8.45.132 A 309 LI - R 317 LI

copyright by
MJF C I F S S

MOTORSTOP ZEITGESTEUERT
ENGINE STOP WITH TIMER
ARRET MOTEUR AUTOMATIQUE
A 309 LI - R 317 LI 8.45.133

copyright by
MJF C I F S S
Step 96
A1017** to quick-change adapter board Right console, rear
S45 to priority switch Right controle
S241** to switch AHS 11 / AHS 12 Right controle
S382** Switch / fine regulation OFF Right controle
S451 Rocker button / rotating grapple Left pilot control unit
S452 Switch / rotating grapple with rocker button Right console
X15-2** Plug connection, 3-pin Left console

X74** Plug connection, 3-pin / S6 Right console
X1179 Plug connection, 3-pin / to display unit Right control console

Z= 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.
8.45.134 A 309 LI - R 317 LI

copyright by
MJF C I F S S

GREIFER DREHEN BER RECHTEN WIPPTASTER
GRAPPLE ROTATOR
MECHANISME DE ROTATION
A 309 LI - R 317 LI 8.45.135

copyright by
MJF C I F S S
Step 97/1
E21** Indicator light, front left Revolving deck, front left

E22** Indicator light, rear left Weight, left
E23 Indicator light, front right Revolving deck, front right
E24 Indicator light, rear right Weight, left
E173 Auxiliary indicator, right Uppercarriage, front right
E174 Auxiliary indicator, left Uppercarriage, front left
F302** to fuse S44 7.5 A A127

F312** Fuse S44,E21 - E24 7.5 A Right console
F338** Fuse capacitor motors 20.0 A Right console, front
H9** Horn Right console

H19** Indicator light / indicator Right controle
K63** Relay / direction indicator Near hydraulic tank
M70** to motor / air-spring seat Operator's platform
S4** Horn switch Cab floor plate

S32 Steering column switch Steering column
S44** Hazard warning lights switch Right console
S389** to switch seat heating Operator seat
X550** Plug connection Right console

8.45.136 A 309 LI - R 317 LI

copyright by
MJF C I F S S
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 8.45.137

copyright by
MJF C I F S S
Step 97/2
E3** Headlight uppercarriage, left Front cab roof
E4** Headlight uppercarriage, right Cab roof
E15** Parking light, right Revolving deck, front right
E16** Parking light, left Revolving deck, front left
E17** Rear light, right Revolving deck, rear right
E18** Tail light, left Revolving deck, rear left
E19** Brake light, right Weight, right
E20** Brake light, left Weight, left
E23** to indicator light, front right Revolving deck, front right
E171 Outline light, right Uppercarriage, right
E172 Outline light, left Uppercarriage, left

F309** Fuse E3 7.5 A Right console, rear
K315** to relay / brake light Right console, rear
P6** to indicator / engine temperature Right controle

X1186** Plug connection, 3-pin Engine compartment, left
rear
X1198** Plug connection, 2-pin / for temperature sensor Uppercarriage, right
8.45.138 A 309 LI - R 317 LI

copyright by
MJF C I F S S

ZUSATZ - LEUCHTEN / LICHTANLAGE
LIGHTING SYSTEM
ECLAIRAGE
A 309 LI - R 317 LI 8.45.139

copyright by
MJF C I F S S
Step 97/3
E3** Headlight uppercarriage left Front cab roof
E4** Headlight uppercarriage, right Cab roof
E15** Parking light, right Revolving deck, front right
E16** Parking light, left Revolving deck, front left
E17** Rear light, right Revolving deck, rear right
E18** Tail light, left Revolving deck, rear left
E169 Position light, front right in indicator Revolving deck, right
E170 Position light, front left in indicator Revolving deck, left
E171 Outline light, right Uppercarriage, right
E172 Outline light, left Uppercarriage, left
F20** to fuse terminal 30 7.5 A A127

P6** to indicator / engine temperature Right controle

8.45.140 A 309 LI - R 317 LI

copyright by
MJF C I F S S

ZUSATZ - LEUCHTEN / LICHTANLAGE
LIGHTING SYSTEM
ECLAIRAGE
A 309 LI - R 317 LI 8.45.141

copyright by
MJF C I F S S
Step 98
S16** to parking brake switch Right control console

S263** Switch / travelling direction Right pilot control unit
S382** Switch / fine regulation OFF Right controle
U16** BST excavator control system Right controle
X230** Plug connection, 3-pin / on A1100 Left console

X1046-1 Plug handle extension, 6-pin Right handle
X1048** Plug connection, 12-pin Right handle
X1046-1 Plug to handle switch, 3-pin Right handle
8.45.142 A 309 LI - R 317 LI

copyright by
MJF C I F S S

SCHALTER FAHRTRICHTUNG IM LINKEN GRIFF
TRAVEL DIRECTION SELECTION IN LEFT JOYSTICK
INTTERRUPTEUR SENS DE MARCHE AU MANIPULATEUR GAUCHE
A 309 LI - R 317 LI 8.45.143

copyright by
MJF C I F S S
Step 99
F338** Fuse S4, seat heating 10.0 A Right console, front
at 309-311
F338** Fuse S4, seat heating 15.0 A Right console, front
at 312-316
H9** Horn Right console
S4** Horn switch Cab floor plate

S6L Push button / horn activation Right pilot control unit
S6R Push button / horn activation Right pilot control unit
S32 Steering column switch Steering column
X74 Plug connection, 3-pin / S6 Right console

X550** Plug connection Right console
8.45.144 A 309 LI - R 317 LI

copyright by
MJF C I F S S
99 A 309 Li / A 311 Li / A 312 Li / A 314 Li / A 316 Li

BETTIGUNG HUPE BER TASTER
HORN ACTUATION WITH PUSH BUTTON
COMMANDE AVERTISSEUR AVEC BOUTON POUSSOIR
A 309 LI - R 317 LI 8.45.145

copyright by
MJF C I F S S
Step 100
A127** Printed circuit board / power Hydraulic tank

F364 Fuse 15.0 A Printed circuit board A127
H158 Indicator light / Fuchs control ON Right control console
K229 Relay / changeover (K_B) A127
S247 Key switch / Fuchs control Right controle

X1213 Plug connection, 2-pin / decay diode Right control console
Y236-1 Solenoid valve / changeover Near control valve block

8.45.146 A 309 LI - R 317 LI

copyright by
MJF C I F S S

UMSCHALTUNG FUCHS-STEUERUNG
SWITCHING FUCHS SERVO CONTROLS
COMMUTATION COMMANDE FUCHS
A 309 LI - R 317 LI 8.45.147

copyright by
MJF C I F S S
Step 101
B290** Proximity switch / adjusting pedal left Operator's platform / front
H343 Warning light / outriggers not retracted Right control console

X1215 Plug connection, 2-pin / warning light Right control console
X1218 Plug connection, 3-pin / warning light Right control console
8.45.148 A 309 LI - R 317 LI

copyright by
MJF C I F S S
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 8.45.149

copyright by
MJF C I F S S
Step 102
H90 Indicator light / change of direction of fan Right console
KT20 Time relay / fan afterrun Distribution board

KT21 Time relay / direction of rotation switching Distribution board
S160 Switch / change of direction of rotation Right console

X1234 Plug connection, 6-pin / adapter switch CS Right console
X1235 Plug connection, 4-pin / magnet unit CS Behind cab
Y356 Solenoid valve / fan stop Counter weight

Y357 Solenoid valve / change of direction of rotation Counter weight
8.45.150 A 309 LI - R 317 LI

copyright by
MJF C I F S S
102 A 309 Li / A 311 Li / A 312 Li / A 314 Li / A 316 Li IND / R 317 Li

LFTERANTRIEB REVERSIERBAR
REVERSIBLE FAN DRIVE
ENTRAINEMENT DU VENTILATEUR REVERSIBLE
A 309 LI - R 317 LI 8.45.151

copyright by
MJF C I F S S
Step 103
F326** Fuse Y24, Y55, Y371, QC adapter 15.0 A Right console, front
H176** Indicator lamp / oscillating axle automatic Right console

H311** Indicator lamp / oscillating axle locked Right console
K250** Relay / oscillating axle automatic

K464 Relay / oscillating axle release Distribution board
S6L Push buttons magnet unit, grapple activation, joystick Right pilot control unit
steering, horn actuation, oscillating axle release
S6R Push buttons magnet unit, grapple activation, joystick Right pilot control unit
steering, horn actuation
S7** to safety switch Left console, bottom
S35** to servo switch Keyboard of right console
S75** Switch / oscillating axle locking device Right console
V155** Blocking diode Left console

V156-2** Blocking diode Left console
X74** Plug connection, 3-pin / S6 Right console

X842-3** Plug connection, 2 pin / blocking diode Right console
X974-2** Plug connection, 2 pin / blocking diode Left console, bottom
Y371** Solenoid valve / oscillating axle Control oil unit
8.45.152 A 309 LI - R 317 LI

copyright by
MJF C I F S S
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 8.45.153

copyright by
MJF C I F S S
Step 104
B36 Pressure switch Right pilot control unit
H33 Back-up alarm Right console
K407-1 Relay / travel warning mute Distribution board

K407-2 Time relay / delayed travel warning Distribution board
S6L Push button / right pilot control device travel warning Right pilot control unit
X11** Plug connection, 2-pin / distribution board Right console

X204 Plug connection, 2-pin / to buzzer H33 Right console, rear
X206 Plug connection, 2-pin / to pressure switch B36 Right console
X207 Plug connection, 2-pin / to pressure switch B36 Right console, rear
X324-1 Plug connection, 2-pin / to buzzer H33 Hood
X324-2 Plug connection, 2-pin / to buzzer H33 Revolving deck
X1048** Plug connection, 12-pin, CS console, ignition switch Right console
** in basic machine
8.45.154 A 309 LI - R 317 LI

copyright by
MJF C I F S S
104 A 309 - A 316 Li

FAHRWARNEINRICHTUNG
TRAVEL ALARM
AVERTISSEUR DE MARCHE
A 309 LI - R 317 LI 8.45.155

copyright by
MJF C I F S S
Step 105
F331** Fuse 15.0 A Right console, front
H323 Indicator light / lateral adjustment Right console
K370** Relay servo Right console, rear
S356 Switch / changeover valve Right console

X358-1 Plug connection, 2-pin below operator's platform
X358-2 Plug connection, 2-pin Fuel tank
X1046 Plug connection, 12-pin Right console, rear
Y332** Solenoid valve / changeover valve Attachments
8.45.156 A 309 LI - R 317 LI

copyright by
MJF C I F S S
105 A 309 - A 316 Li

TIROIR DIVERSION
A 309 LI - R 317 LI 8.45.157

copyright by
MJF C I F S S
Step 106
K455 Relay / changeover valve UP, horizontal Right console, rear

X358-1 Plug connection, 2-pin below operator's platform
X358-2 Plug connection, 2-pin Fuel tank
X1226 Plug connection, 2-pin / solenoid valves Hydraulic tank
X1245 Plug connection, 4-pin / solenoid valves below operator's platform
X1246 Plug connection, 2-pin / solenoid valves Hydraulic tank
Y332 Solenoid valve / changeover valve Slewing boom

Y443 Pipe fracture safety stop valve / regulating cylinder exten- Hydraulic tank
ding
Y444 Pipe fracture safety stop valve / regulating cylinder exten- Hydraulic tank
ding
Y453 Solenoid valve control pressure changeover / piston side below operator's platform
Y454 Solenoid valve control pressure changeover / rod side below operator's platform
Y456 Solenoid valve changeover control line at regulating cy- Hydraulic tank
linder
8.45.158 A 309 LI - R 317 LI

copyright by
MJF C I F S S
106 A 312 - R 317 Li

TIROIR DIVERSION
A 309 LI - R 317 LI 8.45.159

copyright by
MJF C I F S S
Step 107
H196 Indicator light / sorting grapple Right console

H323 Indicator light / lateral adjustment Right console
K375** Relay / changeover hammer / pile driver Right console, rear
S241 Switch AHS 12 Right console


X1046 Plug connection, 12-pin Left pilot control unit
Y268** Solenoid valve changeover Hydraulic tank

Y299** Solenoid valve / additional pressure stage Hydraulic tank
8.45.160 A 309 LI - R 317 LI

copyright by
MJF C I F S S
107 A 312 - R 317 Li

TIROIR DIVERSION
A 309 LI - R 317 LI 8.45.161

copyright by
MJF C I F S S
Step 108
B213 Proximity switch boom shut-down at stick Attachments
B214 Proximity switch boom shut-down at bearing block Attachments
H27 Quick-change adapter buzzer / boom shut-down Right controle, rear

H249 Indicator light / override ON Right controle, rear
K414 Relay / boom shut-down Right console, rear
S249 Key switch boom shut-down ON Right console

S291 Button boom shut-down override / left pilot control unit Right console

X74 Plug connection, 3-pin / to S6 below operator's platform
X988-1 Plug connection, 8-pin / boom shut-down Revolving deck
X988-2 Plug connection, 4-pin / boom shut-down Attachments
X988-3 Plug connection, 3-pin / blocking diodes Right console, rear
X988-6 Plug connection, 3-pin / to B214 Attachments
X1132 Plug connection, 3-pin / extension Left console, rear
Y237 Solenoid valve / stick shut-down Hydraulic tank

Y238 Solenoid valve / boom shut-down Hydraulic tank
8.45.162 A 309 LI - R 317 LI

copyright by
MJF C I F S S
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 8.45.163

copyright by
MJF C I F S S
Step 109
S6L Push button / turning grapple to the left, Y22 Right pilot control unit
S6R Push button / turning grapple to the right, Y23 Right pilot control unit
X15-2** Plug connection, 3-pin Left console

X74 Plug connection, 3-pin / S6 Right console
X1046 Plug connection, 12-pin / left handle Left control console
X1046-1 Plug connection, 6-pin / handle extension Left control console
X1048 Plug connection, 12-pin Right control console

8.45.164 A 309 LI - R 317 LI

copyright by
MJF C I F S S
109 A 312 - R 317 Li

BETTIGUNG AS1 IM GRIFF LINKS UND RECHTS
GRAPPLE CONTROL IN LEFT AND RIGHT JOYSTICK
CDE. AS 1 DANS MANIPULATEUR GUAUGE ET DROITE
A 309 LI - R 317 LI 8.45.165

copyright by
MJF C I F S S
Step 110
F330** to fuse 15.0 A Right console, front

S19** to switch AS 1 Right controle


Y268** Solenoid valve / grapple hammer Near hydraulic tank

Y299** Solenoid valve / changeover pressure limitation Near hydraulic tank
Y451 Solenoid valve / combined lifting of boom Behind cab
8.45.166 A 309 LI - R 317 LI

copyright by
MJF C I F S S

A 309 LI - R 317 LI 8.45.167

copyright by
MJF C I F S S
Step 111
FRes** Fuse, reserve Right console, front
H27** Warning buzzer Right control console
K370** Relay terminal 15 servo Right console, rear

K386** Relay / safety switch Right console, rear
K471 Relay inversion signal servo OFF Right console, rear
S7** Safety switch Left console

S35** Switch servo shut-down Right controle
V178-1 Blocking diode signal Servo-S7 Right console, rear

V178-2 Blocking diode signal Servo-S7 Right console, rear

X1106 Plug connection, 4-pin / power supply Right control console, rear
X1117 Plug connection, 6-pin / 4-wheel steering Right control console, rear
Y3** Solenoid valve / pilot pressure Control oil unit

Y330** Solenoid valve / pump regulation Control oil unit
(not required during series)
8.45.168 A 309 LI - R 317 LI

copyright by
MJF C I F S S

BAUSATZ ABSENKUNG MOTORDREHZAHL BEIM ARBEITEN / LEISTUNGSREDZIERUNG
KIT LOWERING ENGINE RPM DURING WORK / POWER REDUCTION
KIT REDUCTION DE PUISSNANCE
A 309 LI - R 317 LI 8.45.169

copyright by
MJF C I F S S
Step 112
S6L Push button / activation horizontal adjustment Right pilot control unit
S6R Push button / activation horizontal adjustment Right pilot control unit
S379 Switch / release of push button for horizontal adjustment Right console
(right handle)

X74** Plug connection, 3-pin / button Right console, rear
X407** Plug connection, 4-pin / switch Right control console
X408 Plug connection, 4-pin / solenoid valves Right control console
Y365 Solenoid valve / cylinder retraction Hydraulic tank

Y366 Solenoid valve / cylinder extension / hammer Hydraulic tank
8.45.170 A 309 LI - R 317 LI

copyright by
MJF C I F S S
112 A 312 Litronic / A 314 Litronic / A 316 Litronic / R 317 Litronic

BETTIGUNG SCHIEBERSEKTION BER TASTER
VALVE SPOOL ACTUATION WITH PUSH BUTTON
COMMANDE TIROIR DE DISTRIDUTION AVEC BOUTON POUSSOIR
A 309 LI - R 317 LI 8.45.171

copyright by
MJF C I F S S
Step 113
S6L** Push button / turning grapple to the left, Y22 Right pilot control unit
S6R** Push button / turning grapple to the right, Y23 Right pilot control unit
S124 Switch / rotating grapple with rocker button Right console
S241** to switch accessory kit AHS Right console
S451 Rocker button / rotating grapple Right pilot control unit

X1179 Plug connection, 3-pin / to display unit Right control console

8.45.172 A 309 LI - R 317 LI

copyright by
MJF C I F S S

GREIFER DREHEN BER RECHTEN WIPPTASTER
GRAPPLE ROTATOR
MECHANISME DE ROTATION
A 309 LI - R 317 LI 8.45.173

copyright by
MJF C I F S S
Step 114
F337** Fuse 15.0 A Fuse box in control conso-
le, front right

S124 Blade support switch Right control console
S343 Switch individual control, back, optional Right control console
S439L Push button / support pilot control unit Right control console
S439R Push button / support pilot control unit Right control console
X301 Plug connection, 12-pin / slip rig distribution board Right control console, rear
X304 Plug connection, 4-pin / console right Right control console, rear
X955 Plug connection, 21-pin / distribution board Right control console, rear
X1104 Plug connection, 3-pin / handle right Right control console, rear
Y56 Solenoid valve / blade support, front Undercarriages

Y217 Solenoid valve / outrigger support, rear left Support cylinders
Y218 Solenoid valve / outrigger support, rear right Support cylinders
8.45.174 A 309 LI - R 317 LI

copyright by
MJF C I F S S
114 A 309 / A 311 Litronic

SCHILDEINZELSTEUERUNG PRATZE
INDIVIDUAL BLADE CONTROL OUTRIGGER
COMMANDE UNIQUE LAME / STABILISATEUR
A 309 LI - R 317 LI 8.45.175

copyright by
MJF C I F S S
Step 115
A125** PCB potentiometers Near hydraulic tank
H344 Indicator light / flow distributor Right control console

K467 Step relay / flow distributor operation Right console, rear
S6L Left button Right pilot control unit

S6R Right button Right pilot control unit
S464 Switch activation / flow distributor operation Right console
V156-4 Diode / input quantity Right console, rear

V177 Blocking diode signal flow reduction / flow distributor Right console, rear
X74 Plug connection, 3-pin / handle right Right console, rear

X968-1** Plug connection, 1-pin / A125 CS Near hydraulic tank
X1240 Plug connection, 4-pin / adapter switch CS Near hydraulic tank
X1241 Plug connection, 2-pin / CS flow distributor Near hydraulic tank
X1242 Plug connection, 2-pin / CS solenoid valve Near hydraulic tank
X1243 Plug connection, 1-pin / CS flow distributor Right control console, rear
X1244 Plug connection, 2-pin / CS diode Counter weight
Y295 Solenoid valve flow distributor Counter weight

Y452 Solenoid valve changeover AHS actuation Fuel tank
8.45.176 A 309 LI - R 317 LI

copyright by
MJF C I F S S
115 A 309 / A 311 Litronic

MENGENTEILER
FLOW DISTRIBUTOR
DIVISEUR DE DEBIT
A 309 LI - R 317 LI 8.45.177

copyright by
MJF C I F S S
Step 116
F320** Fuse X11 15.0 A
S84-1 Push button with plug / central lubrication
U4-1 Central lubrication system

X143-1 Plug connection, 4-pin / central lubrication system
X998 Plug connection, 3-pin / under operator's platform
X1251 Plug connection, 4-pin / CS switch
8.45.178 A 309 LI - R 317 LI

copyright by
MJF C I F S S
116 A 309 - R 317 Litronic

ZENTRALSCHMIERANLAGE SEMIAUTOMATISCH
SEMIAUTOMATIC CENTRAL LUBRICATION SYSTEM
DISP. DE GRAISSAGE CENRALISE SEMIAUTOMATIQUE
A 309 LI - R 317 LI 8.45.179

copyright by
MJF C I F S S
Step 117
B204 Proximity switch stick cylinder shut-down At stick
S216 Button stick cylinder shut-down override Right console

X327 Plug connection, 2-pin Attachments
X1254 Plug connection, 2-pin / solenoid valve Right control console
X1255 Plug connection, 3-pin / button Right control console
Y212 Solenoid valve shut-down stick cylinder Near hydraulic tank
8.45.180 A 309 LI - R 317 LI

copyright by
MJF C I F S S
117 A 309 - A 311 Litronic

STIELZYLINDERABSCHALTUNG
STICK CYLINDER SHUT-DOWN
ARRET PILOTAGE VERIN BALANCIER
A 309 LI - R 317 LI 8.45.181

copyright by
MJF C I F S S
Step 118
B21** Pressure switch / overload Boom cylinder bearing
H16** Warning light overload warning system Right console

H20** to indicator light parking brake Right console
H315 Warning light shut-down override Right console
K473 Relay shutdown attachment Distribution board
S18 Switch / overload warning system Right console

S396 Key switch shut-down override Right console
V179 Blocking dialog signal / flow distributor control to override Left console
V180 Blocking diode signal / H16 actuation to ground Left console

X407 Plug connection, 2-pin / pressure switch Right console
X1253 Plug connection, 2 pin / blocking diode Right console, rear
X1260 Plug connection, 3-pin / switch Right console, rear
X1261 Plug connection, 4-pin / solenoid valves Right console, rear
X1262 Plug connection, 4-pin / solenoid valves Right console, rear
X1263 Plug connection, 2 pin / blocking diode Right console, rear
Y212-1 Solenoid valve blocking stick lowering Hydraulic tank

Y237 Solenoid valve blocking stick lifting Hydraulic tank
Y465 Solenoid valve blocking lower boom Hydraulic tank
8.45.182 A 309 LI - R 317 LI

copyright by
MJF C I F S S
118 A 312 - R 317 Litronic

AUTOMATISCHE ABSCHALTEINRICHTUNG BEI MONOAUSLEGER
AUTOMATIC SHUT-DOWN
INTERRUPTION AUTOMATIQUE
A 309 LI - R 317 LI 8.45.183

copyright by
MJF C I F S S
Step 119
B306 Particle filter temperature sensor Particle filter
E50 Power and safety switch cabinet Hydraulic tank
F351 Fuse (F_H) 3A Electric box E50
H298 Warning light / exhaust backpressure Right control console

H299 Warning buzzer / exhaust backpressure Right control console
X20 Terminal for kit Printed circuit board A127

X1040 Plug connection, 3-pin / to display unit Electric box E50
X1041 Plug connection, 2-pin / for temperature sensor Electric box E50
8.45.184 A 309 LI - R 317 LI

copyright by
MJF C I F S S
119 A 309 - A 316 Litronic

ARTICLEFILTER PURITECH
FILTRE DE PARTICULES PURITECH
PURITECH PARTICLE FILTER
A 309 LI - R 317 LI 8.45.185

copyright by
MJF C I F S S
Step 120
A1017 to quick-change adapter board Right control desk
B19L Sensor transducer Left pilot control unit
S5L Push button / grapple rotator left Left pilot control unit
S5M Push button / central option Left pilot control unit
S5R Push button / grapple rotator right Left pilot control unit
S19 Switch / grapple rotator Right control desk
V181 Amplifier actuation grapple rotation left Right control desk, rear
V182 Amplifier actuation grapple rotation right Right control desk, rear
X952 Plug connection, 21-pin / distribution board Right control desk, rear
X1046 Plug connection, 12-pin / left handle Left control desk
X1047 Plug connection, 3-pin Left pilot control unit
X1265 Plug connection, 12-pin Right control desk, rear
Y22 Solenoid valve grapple rotator left Hydraulic tank

Y23 Solenoid valve grapple rotator right Hydraulic tank
8.45.186 A 309 LI - R 317 LI

copyright by
MJF C I F S S
120 A 309 - A 316 Litronic

AS1 / GRIFF MIT 3 TASTEN
AS1 / JOYSTICK WITH 3 SWITCHES
AS1 / MANIPULATEUR AVEC 3 INTERRUPTEURS
A 309 LI - R 317 LI 8.45.187

copyright by
MJF C I F S S
Step 121
E2L Work light, left Attachments
E2R Work light, right Attachments
E2R2 Plug connection Attachments
E150L Work light, rear left Roof
E150R Work light, rear right Roof
E150R2 Plug connection Roof
F345 Fuse Xenon roof light Right control desk, rear

F346 Fuse Xenon headlight front left Right control desk, rear
F347 Fuse Xenon headlight front right Right control desk, rear
F348 Fuse Xenon headlight rear left Right control desk, rear
F349 Fuse Xenon headlight rear right Right control desk, rear
K420 Relay for Xenon headlight front left Right control desk, rear
K421 Relay for Xenon headlight front right Right control desk, rear
K422 Relay for Xenon headlight rear left Right control desk, rear
K423 Relay for Xenon headlight rear right 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 Plug connection cab revolving deck / 4-pin Revolving deck

X1013/1 Terminal 4-pin / power supply terminal 30 Revolving deck
X1013/2 Terminal 4-pin / power supply terminal 30 Revolving deck
X1013/3 Terminal 4-pin / actuation for E2 Revolving deck
X1013/4 Terminal 4-pin / actuation for E150 Revolving deck
X1013/5 Terminal 4-pin / power supply E2 L Revolving deck
X1013/6 Terminal 4-pin / power supply E2 R Revolving deck
X1013/7 Terminal 4-pin / power supply E150 L Revolving deck
X1013/8 Terminal 4-pin / power supply E150 R Revolving deck
X1013/9 Terminal 4-pin / ground E2 Revolving deck
X1013/10 Terminal 4-pin / ground E150 Revolving deck
X1013/11 Terminal 4-pin / ground supply Revolving deck
X1013/12 Terminal 4-pin / ground supply Revolving deck
8.45.188 A 309 LI - R 317 LI

copyright by
MJF C I F S S
121 A 309 - A 316 Litronic

XENON - SCHEINWERFER
XENON HEADLIGHTS
PHARES - XENON
A 309 LI - R 317 LI 8.45.189

copyright by
MJF C I F S S
8.45.190 A 309 LI - R 317 LI

copyright by
MJF C I F S S
Service Manual BST excavator control system
Function
BST excavator control system
1 Function
The LIEBHERR hydraulic excavator generation of the Litronic series is equipped with an electrical
BST excavator control system and the associated units and elements.
The BST (U16) excavator control system controls the diesel engine, the hydraulic pump, the monito-
ring 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 BST excavator control system
20 Eprom (program version (V1.2 - V5......) U16 Excavator control system
8.70.1
copyright by
MJFCIFSS
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.
A127 printed circuit board / power R76 Potentiometer / fine adjustment

(A 312 - R 317 only)
B2 Temperature sensor / engine coolant U16 Excavator control BST
B3 Transducer / coolant level X10-X967 Plug connections between U16
and the individual components
B8 Switch / hydraulic oil temperature Y50 Proportional solenoid valve / power
control
B12 Transducer / engine speed Y51 Proportional solenoid valve / flow

limitation
B16 Switch / engine oil pressure Y352 Proportional solenoid valve / fan
control
B285 Transducer / hydraulic oil tempera- Y358 Proportional solenoid valve / engine
ture (fan control) speed
R75 Potentiometer for speed adjustment
8.70.2
copyright by
MJFCIFSS
Description
Fig. 2 Connections of BST
8.70.3
copyright by
MJFCIFSS
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 tempe-
rature 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 > 0C = 6 sec.
Coolant temperature tK < 0C = 6 sec. + 0.3 x tK
Example:
Coolant temperature tK = - 20C
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 < 0C = 18 sec.
Coolant temperature > 0C = 16 sec. + 0.3 x tK
Example:
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 < 0C = 99 sec. + 4 x tK
Example:
99 sec. + 20 x 4 99 sec. + 80 sec. = 179 sec.
Coolant temperature tK > 0C = 99 sec.- 1.6 x tK
99 sec. + 20 x 1.6 99 sec. + 32 sec. = 67 sec. 1 min
3.2 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 < 20C, 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> 0C or
when the set maximum phase time (3 minutes) has lapsed.
8.70.4
copyright by
MJFCIFSS
Fig. 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
3.3 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 Speed Frequency Current from

step (without load) 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
8.70.5
copyright by
MJFCIFSS
Speed Speed Frequency Current from

step (without load) BST version 5.11
8 1950 rpm 4226 - 4246 Hz 685 mA
9 2120rpm 4558 Hz 820 mA
3.3.2 Speed steps of models A 312 - R 317:
Speed Speed Frequency Current to Current from

step (without load) BST version 1.2 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
3.4 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 re-
gulating 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 elec-
trohydraulic 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
Fig. 4 Speed adjustment
10 Regulating cylinder / engine speed B12 Transducer / engine speed

35 Speed adjusting lever S46 Magnet system switch (only in A 316
industrial model)
50 Bowden cable R75 Potentiometer / speed adjustment
Y358 Proportional solenoid valve / engine
speed
3.6 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 tempe-
rature, through the proportional solenoid valve Y352.
Design and function of the fan control system, see group 7.20
8.70.7
copyright by
MJFCIFSS
Fig. 5 Components of the fan control system
B2 Temperature sensor / engine coolant Y352 Proportional solenoid valve / fan

control
B285 Transducer / hydraulic oil tempera-
ture/ fan control
3.7 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
copyright by
MJFCIFSS
Fig. 6 Components of the sensor control
A in A models B290 Inductive proximity switch in left foot

pedal (kit)
B19R Capacitive right handle sensor B291 Inductive proximity switch in right foot
pedal (kit)
B19L Capacitive left handle sensor S20 Sensor control switch
B40 Inductive proximity switch in foot pedal R75 Potentiometer / speed
(travel)
B40R Inductive proximity switch in foot pedal R in R machines only
(travel)
B40L Inductive proximity switch in foot pedal
(travel)
3.8 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.
8.70.9
copyright by
MJFCIFSS
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 Regulating speeds in model A 309 / 311
Speed Speed
Regulating rpm Reduction
step (without load)
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
3.8.2 Speed steps of models A 312 - R 317:
Speed Speed
Regulating rpm Reduction
step (without load)
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
3.9 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 nor-
mal 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
copyright by
MJF C I F S S
Low flow rate small p reduction normal p in system maximum pump flow rate
High flow rate large p reduction low p in system minimum pump flow rate
3.9.1 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.
8.70.11
copyright by
MJF C I F S S
Fig. 7 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 S241 Switch AHS 11 / AHS 12 accessory kit
pedal (kit)
H307 Indicator light p - reduction S382 Fine adjustment switch
(A 312 - R 317 only) (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
8.70.12
copyright by
MJFCIFSS
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 para-
meters 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
8.70.13
copyright by
MJFCIFSS
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 (clo-
ckwise).
Error LED
Error code Sensor / actuator Cause / switching status
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)
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 Speed adjustment potentiometer Wire fault continuous
067 Fine adjustment potentiometer Wire fault flashing
422 Left handle sensor Short to plus flashing

423 Left handle sensor Wire fault flashing
445 Right handle sensor Short to plus flashing

446 Right handle sensor Wire fault flashing
501 Engine oil pressure switch Switch actuated continuous
502 Coolant level switch Switch actuated flashing
503 Coolant temperature switch Switch actuated flashing
8.70.14
copyright by
MJFCIFSS
Error LED
Error code Sensor / actuator Cause / switching status
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 flashing
511 Supply voltage + UB Overvoltage >30V
513 Fan switch Switch actuated flashing
8.70.15
copyright by
MJFCIFSS
8.70.16
copyright by
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/con-
tact brackets and microswitches are installed.
Fig. 1 Slip ring rotary connection
8.80.1
copyright by
MJFCIFSS
Slip ring rotary connection Service Manual
Design
2 Design

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 Slip ring rotary connection in uppercarriage
8.80.2
copyright by
MJFCIFSS
Design
Fig. 3 Exploded view of slip ring rotary connection
1 Adapter ring 23 Forcing screw

2 Bearing washer (base plate) 24 O-ring
3 Base flange 25 Deep groove ball bearing
4 Hood, glued to hood pipe 7 26 Lock washer
5 Ring 27 Snap ring
6 Slip ring 28 Snap ring
7 Hood pipe 29 Lock washer
8 Threaded cable gland 30 Hex nut
9 Insulating ferrule 31 Holding plate of potentiometer
10 Slip ring 32 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 Contact bracket holder 39 Angle gauge (optional)
15 Cover plate 42 Pipe
17 Threaded rod 43 Threaded cable gland
18 Threaded rod 45 Threaded rod
19 Threaded rod 50 Hex nut
22 Microswitch attachment 55 Hex nut
8.80.3
copyright by
MJFCIFSS

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, irrespec-
tive 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
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 under-
carriage 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 Electrical connections
4 Hood X301 Plug connection slip ring / 12-pin

30 Hex nut
35 Hex nut
4.1 Adjustment of the angle sensor 39 (optional)
Note!
For a detailed description of the angle sensor 39 settings, see the respective kit.
8.80.5
copyright by
MJFCIFSS
Maintenance
1 Adapter ring 23 Forcing screw

2 Bearing washer (base plate) 24 O-ring
3 Base flange 25 Deep groove ball bearing
4 Hood with hood pipe 26 Lock washer
5 Ring 27 Snap ring
6 Slip ring 28 Snap ring
8 Threaded cable gland 29 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 Contact bracket holder 37 Washer
15 Cover plate 39 Angle sensor (optional)
16 Back-up washer 42 Brass pipe
17 Threaded rod 44 Brass pipe
18 Threaded rod 45 Threaded rod
20 FGR pipe 46 Washer
21 Countersunk screw 55 Hex nut
22 Microswitch attachment
8.80.6
copyright by
MJFCIFSS
Maintenance
Fig. 5 Sectional drawing of slip ring
8.80.7
copyright by
MJFCIFSS
Maintenance
Fig. 6 Section A-A Slip ring rotary connection
8 Threaded cable gland 40 Contact pin

11 Contact bracket, gold-plated 41 Plug
12 Contact bracket, nickel-plated 43 Threaded cable gland
34 Flat adapter
Fig. 7 Section B-B Slip ring rotary connection
8.80.8
copyright by
MJFCIFSS
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 8.110 A 312 - A 316

Bridging button in left handle
Mower rake 8.111 A 312 - A 316
Auxiliary heating 8.112 A 312 - A 316
8.100.1
copyright by
MJF C I F S S
Service Manual
8.100.2
copyright by
MJF C I F S S
PROJEKT:
103281525_2_bs_hoch_seitl_im_linken_griff
LIEBHERR HYDRAULIKBAGGER GMBH LIEBHERR HYDRAULIKBAGGER GMBH
PROJEKT:
-F330.A -F330.E
/4.A6
/5.A3
-F331.A -F331.E
/5.F4
-F337.E
/3.C8
PROJEKT:
-MP/VP.X3
PROJEKT:
/2.E6
A126
PROJEKT:
/2.E6
/2.E6
PROJEKT:
PROJEKT:
Service Manual
SUBGROUP - INDEX
Section Group Type
Slewing gear mechanism 9.10.1 A 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 313 LI 27752-
R 317 LI 18161-
Slewing gear brake 9.20.1 A 309 LI 20221-

A 311 LI 20222-
A 312 LI 12363-
A 314 LI 2001-
A 316 LI 2001-
A 316 LI-IND 2001-
Slewing gear brake 9.24.1 R 313 LI 27752-

R 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
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
9.10.1
copyright by
MJF C I F S S
Slewing gear mechanism Service Manual
Technical data
2 Technical data
R 313
Litronic
A 309 - A 311 A 312 A 314 - A 27752
Machine
Litronic Litronic 316 Litronic
from serial number
20221 12363 2001 R 317
Litronic
18161
Gearbox type Sat 225 / 240 SAT 225 / SAT 225 / 218
228
Max. drive speed 21720 min-1
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 SAE 80 W 90 / SAE 90 W
(with positioning brake
actuated with foot pedal) (SAE 90 LS)
Brake Hydraulically released multi-disc brake
Min. release pressure 20 bar
Max. release pressure 33 bar
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 Settings and tightening torques
9.10.2
copyright by
MJF C I F S S
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 plane-
tary 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 Grease cap 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 distribu-
tion 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.
9.10.3
copyright by
MJF C I F S S
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 Gear oil tank with oil drain valve

Fit bore of the slewing gear in the upper carriage
1 Hydraulic tank 119 Slewing gear

13 Oil tank 135 Valve
110 Slewing gear 136 Protective cover
115 Allen head screw 138 Oil drain hose (included in the machine
toolbox)
9.10.4
copyright by
MJF C I F S S
Repair of the gear system
118 Uppercarriage
5.1 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.
9.10.5
copyright by
MJF C I F S S
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 Oil motor with seals and fixture attaching it to the slewing gear mechanism
62 Hex head screw 98 O-ring

97 Oil motor 115 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
copyright by
MJF C I F S S
Exploded view of the gearbox
8 Exploded view 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 Planetary gear 63 Allen head screw
11 Planetary gear 64 Retaining washer
15 Planetary carrier 65 Retaining washer
17 Output shaft 70 Snap ring
20 Sun wheel 71 Snap ring
25 Brake housing 73 Snap ring
26 Grease cap 82 O-ring
30 Annular piston 83 O-ring
31 Locking ring 84 O-ring
35 Thrust plate 86 Fitting
36 Inner disc 88 Lip seal
37 Outer disc 89 Lip seal
40 Disc carrier 90 Radial shaft seal ring
43 Pressure spring 91 Nilos ring
44 Pressure spring 92 Screw-in stud
45 Stop washer 93 Fitting
46 Stop washer 94 Plug
47 Slotted nut 98 Screw-in stud
49 Washer 900 Repair kit / brake
57 Tapered roller bearing 910 Seal kit / swing drive
58 Tapered roller bearing 960 Brake disc set
9.10.7
copyright by
MJF C I F S S
Exploded view of the gearbox
Fig. 5 Exploded view of the gearbox
9.10.8
copyright by
MJF C I F S S
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 Planetary gear 63 Allen head screw
11 Planetary gear 64 Retaining washer
17 Output shaft 70 Snap ring
20 Sun wheel 71 Snap ring
25 Brake housing 73 Snap ring
26 Grease cap 82 O-ring
30 Annular piston 83 O-ring
35 Thrust plate 86 Fitting
36 Inner disc 88 Lip seal
40 Disc carrier 90 Radial shaft seal ring
43 Pressure spring 91 Nilos ring
44 Pressure spring 92 Screw-in stud
45 Stop washer 93 Fitting
46 Stop washer 94 Plug
47 Slotted nut 98 Screw-in stud
49 Washer 900 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).
9.10.9
copyright by
MJF C I F S S
Sectional drawing
10 Sectional drawing
Fig. 6 Sectional drawing of slewing gear mechanism
9.10.10
copyright by
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

The brake valve 87 with the pedal is located to the left of the steering column in the operator's cab.
87 K 25
50 88P
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 Inner disc 87 Brake valve with pedal and retainer
37 Outer disc K Pressure chamber / opening pressure
9.20.1
copyright by
MJF C I F S S
Slewing gear brake Service Manual
Design of the slewing gear brake
Fig. 2 Components of the slewing gear brake system
50 Control oil unit 88T Collecting pipe / return oil

87 Brake valve 195 Slewing gear brake
88P Distributor / pilot control oil 196 Slewing gear mechanism
9.20.2
copyright by
MJF C I F S S
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 (cor-
responding 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 pe-
dal 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 uppercar-
riage (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* Hydraulic tank 50* Control oil unit

20* Variable displacement pump 87 Brake valve
25 Brake housing/Slewing gear brake 88P Distributor / pilot control oil
30 Annular piston 88T Collecting pipe / return oil
30* Gear pump / servo control 195 Multi-disc brake
36 Inner disc 196 Slewing gear mechanism
37 Outer disc 197 Pedal with return spring and retainer
43 Pressure spring S7 Current from safety switch
44 Pressure spring Y3 Solenoid valve / pilot pressure
49 Measuring point pilot / opening pressure
* item of the hydraulic system
9.20.3
copyright by
MJF C I F S S
Hydraulic diagram
3 Hydraulic diagram
9.20.4
copyright by
MJF C I F S S
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

Remove the mounting bolts of the oil motor and pull the oil motor with the flange-connected hy-
draulic lines from the gearbox.
Disconnect the brake line from the brake connection at the gear.
Remove the entire brake housing 25 from the sun wheel 20
9.20.5
copyright by
MJF C I F S S
Repair of brake
Fig. 3 Sectional drawing of the brake housing
20 Sun wheel / gear 66 Retaining washer

25 Brake housing/Slewing gear brake 83 O-ring
61 Allen head screw
4.1.2 Dismantling of the brake housing 25

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
Mount the lower thrust plate 35 in the sun wheel 20.
9.20.6
copyright by
MJF C I F S S
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, ap-
plying 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

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 Allen head screw

25 Brake housing/slewing gear brake 66 Retaining washer
30 Annular piston 73 Snap ring
35 Thrust plate 83 O-ring
36 Inner disc 86 Screw plug
40 Disc carrier 89 Lip seal
43 Pressure spring 92 Plug
44 Pressure spring 200 Mounting device (special tool)
9.20.7
copyright by
MJF C I F S S
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
9.20.8
copyright by
MJF C I F S S
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 exces-
sive 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 Outer disc Y7 Solenoid valve slewing gear brake
43 Pressure spring
9.24.1
copyright by
MJF C I F S S
Design
1.3 Switch S17

The switch S17 is used to control the slewing gear function (apply-release) through the solenoid val-
ve 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 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 Switch slewing gear brake
Y7 Solenoid valve slewing gear brake
9.24.2
copyright by
MJF C I F S S
Design
9.24.3
copyright by
MJF C I F S S
Design
1.4 Function of slewing gear brake system
1.4.1 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 con-
nection 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 op-
tion. In this case, the brake described in section 1.4.1 (with S17 and Y7) is blocked,, i.e. the connec-
tion 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.
1 Hydraulic tank 195 Slewing gear brake

25 Brake housing 196 Slewing gear mechanism
29 Gear pump / pilot control
30 Annular piston F337 Fuse slewing gear brake 15 A
36 Inner disc S17 Switch slewing gear brake
37 Outer disc X958
43 Pressure spring X963
44 Pressure spring X1115
49 Measuring point pilot control / opening X1116
pressure
50 Control oil unit Y7 Solenoid valve slewing gear brake
9.24.4
copyright by
MJF C I F S S
Hydraulic diagram
2 Hydraulic diagram
9.24.5
copyright by
MJF C I F S S
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).
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

Remove the mounting bolts of the oil motor and pull the oil motor with the flange-connected hy-
draulic lines from the gearbox.
Disconnect the brake line from the brake connection at the gear.
Remove the entire brake housing 25 from the sun wheel 20
9.24.6
copyright by
MJF C I F S S
Repair of brake
Fig. 3 Sectional drawing of the brake housing
20 Sun wheel / gear 66 Retaining washer

25 Brake housing/slewing gear brake 83 O-ring
61 Allen head screw
3.1.2 Dismantling of the brake housing 25

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
9.24.7
copyright by
MJF C I F S S
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

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)
20 Sun wheel / gear 61 Allen head screw

25 Brake housing/slewing gear brake 66 Retaining washer
30 Annular piston 73 Snap ring
35 Thrust plate 83 O-ring
36 Inner disc 86 Screw plug
40 Disc carrier 89 Lip seal
43 Pressure spring 92 Plug
44 Pressure spring 200 Mounting device
9.24.8
copyright by
MJF C I F S S
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
9.24.9
copyright by
MJF C I F S S
Repair of brake
9.24.10
copyright by
MJF C I F S S
Service Manual
SUBGROUP - INDEX
Section Group Type
Slewing ring 10.10.1 A 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 313 LI 27752-
R 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 be-
aring against dirt.
To turn the uppercarriage, the slewing gear mechanism engages with the involute teething of the in-
ner race of the slewing ring.
Fig. 1 Location of the slewing ring in the undercarriage
10.10.1
copyright by
MJF C I F S S
Slewing ring Service Manual
Technical data
2 Technical data
Machine A 309-Li A 311-Li A 312-Li

from serial number 20221 20222 12363
Tilting play
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
Weight of uppercarriage
with offset boom bearing kg 5540 6030 6300
With attachment kg 6600 - 6800 7400 - 7600 8560 - 8620
Tightening torques
Mounting bolts M 16 M 16 M 16
Quality 10.9 280 Nm 280 Nm 280 Nm
Machine R 313-Li A 314-Li A 316-Li

from serial number 27752 2001 2001
Tilting play
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
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 R 317-Li
Tilting play
Factory play 0.5 mm
Max. play 1.5 mm
Tooth backlash 1.4 mm
with offset boom bearing kg 7800
With attachment kg 10370 - 12070
Tightening torques
Mounting bolts M 20
Quality 10.9 560 Nm
* in A 316 Industry
10.10.2
copyright by
MJF C I F S S
Fig. 2 Sectional drawing of the slewing ring
1 Outer race 4 Upper sealing lip

2 Inner race 5 Lower sealing lip
3 Ball 6 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 sle-
wing 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.
10.10.3
copyright by
MJF C I F S S
Measuring of clearance
4 Measuring of clearance
Fig. 3 Measuring of tilting play a and tooth backlash b (tooth impression in lead sheet)
4.1 Tilting play measurement
4.1.1 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 stiff-
ness, 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 machi-
ne 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.
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
copyright by
MJF C I F S S
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 Measuring of tooth backlash
4.2.1 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 sle-
wing 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 1.00 mm
Tooth face B + 0.40 mm
Tooth backlash 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.
10.10.5
copyright by
MJF C I F S S
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 uppercar-
riage.
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 re-
placed.
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 ali-
gned 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 po-
sition (see Fig. 4).
10.10.6
copyright by
MJF C I F S S
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 upper-
carriage 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 sle-
wing ring tooth and the plug A at the outer race must be at an angle of 90 to the main working di-
rection.
10.10.7
copyright by
MJF C I F S S
Installation
Fig. 5 Correct attachment of lifting tackle for the lifting of the uppercarriage
10.10.8
copyright by
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 2001-

A 316 LI 2001-28060
A 316 LI-IND 2001-28060
2 HL 270 / 290 transmission 11.20.1 A 309 LI 29269-

A 311 LI 29170-
A 312 LI 29898-
A 316 LI 28061-
A 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 2001-
A 316 LI 2001-28060
A 316 LI-IND 2001-28060
HBGV block for 2 HL 270 / 290 11.32.1 A 309 LI 29269-

A 311 LI 29170-
A 312 LI 29898-
A 316 LI 28061-
A 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 27752-

R 317 LI 23450-
Travel brake 11.65.1 R 317 LI 18161-23449
Travel brake 11.67.1 R 313 LI 27752-

R 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 flan-
ge-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
11.08.1
copyright by
MJF C I F S S
2 HL 70 transmission Service Manual
Technical data
2 Technical data
Machine A 309Li / A 311 Li A 312 Li

from serial number 20221 / 20222 12363
A 309 / 311 Li A 312 Li
Speeder Speeder
Gearbox type 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
Gear ratio
1st gear 5.00 5.00
2nd gear 1.29 1.29
Weight 110 kg 110 kg
Oil volume in gearbox 2.3 l 2.3 l
Oil viscosity SAE 20 W-20 or SAE 20 W-20 or
SAE 10 W-30 SAE 10 W-30
Operating temperature 80 - 110 80 - 110
Short-time max. 120 120
Hydraulic control
Max. control oil level of gear pump 32 32 l/min 32 l/min
Residual flow R from flow distributor approx. 30 l/min approx. 30 l/min
Pilot pressure of hydraulic unit and release pressure of multi-disc brake / coupling
Pressure-relief valve 51 32 1 bar 32 1 bar
Measuring points 49, 65, 103, 104 approx. 32 bar approx. 32 bar
Brake backpressure
Pressure-relief valve 63 7 - 15 bar 7 - 15 bar
(Measuring point 65)
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 6 - 7 bar 6 - 7 bar
at shift speed 2.0 - 2.6 bar 2.0 - 2.6 bar
Shift lock on-road gear/off-road gear
Switching speed 800 100 rpm(+) 800 100 rpm(+)
(drive shaft / oil motor)
Switching speed 620 80 rpm (+) 620 80 rpm (+)
(drive shaft / universal joint)
((*)maximum permissible value

( ) withmodified push button
(+) at oil temperature 80C
The switching range results from the tolerance orifice 77 min / max from pump 71.
11.08.2
copyright by
MJF C I F S S
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 multi-
disc 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 pres-
sure).
When in on-road gear, the multi-disc brake is hydraulically released, and the multi-disc clutch is me-
chanically engaged. In off-road gear, control pressure is applied to the clutch, which is thus disen-
gaged, 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 trans-
mission 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 bra-
ke, 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 cen-
trifugal lubrication). The moving clutch parts are supplied with lubricating oil fed through lubrication
channel.
11.08.3
copyright by
MJF C I F S S
Design
3.1 Design of transmission
1 Connecting flange / regulating motor 7 Shift lock

2 Disc springs 8 Rotary-type pump for shift lock and lubri-
cation
3 Release mechanism 9 Spur drive
4 Multi-disc clutch
5 Multi-disc brake a Input
6 Planetary drive b Output
11.08.4
copyright by
MJF C I F S S
Fig. 3 and Fig. 4
4.1 Summary
4.1.1 Parking
Power circuit interrupted (ignition off) Multi-disc brake 87 and multi-disc clutch 93
applied by disc springs 90 / 91
4.1.2 Braking
Switch S16 operated Multi-disc brake 87 and multi-disc clutch 93
4.1.3 On-road gear

Switch S42 not operated Brake 87 (outside) released by control pressure,
clutch 93 engaged by disc springs 91
4.1.4 Off-road gear

Switch S42 operated Brake 87 (outside) applied by disc springs 90,
clutch 93 (inside) opened by control
pressure
4.2 Function of parking brake
4.2.1 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:

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.
Pressure switch B10 closed, indicator light H20 on
The machine cannot be started.
4.2.3 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, connec-
tion 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, rest-
rictor effect of the valve 100 and preload of the valve 63.
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MJF C I F S S
Preload is gradually reduced to zero.

The multi-disc clutch 93 is released via the shift lock 70 connection P2 and the HBGV block con-
nection B T to the accumulator.
4.3 Gear function and power flow
4.3.1 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 flan-
ge-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 second speed reduction of the planetary drive / spur drive results in a high reducing gear ratio,
(see Technical data on page 2).
4.4 Function of shift lock
4.4.1 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 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.
4.4.2 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 back-
pressure at the orifice 77 and the resulting piston force are smaller than the spring force.
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MJF C I F S S
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 pres-
sure 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 pres-
sure 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 ope-
rate 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 shifting piston in neutral position machine can be
shifted from on-road gear to off-road gear.
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
4.5 Diagram of gearbox / hydraulic circuit
Fig. 3 Diagram of transmission and shift lock
a Output 72 Leakage check valve

b Shut-off mechanism 73 Shuttle check valve
e Oil supply transmission 74 Pressure-relief valve
B to multi-disc brake 75 Shifting piston
C Release mechanism 76 Check valve
EB Bleeder / multi-disc brake 77 Orifice
EK Bleeder / multi-disc clutch 80 Transmission
EL Bleeder / release mechanism 87 Multi-disc brake
J Measuring point on-road gear 90 Disc springs
K to multi-disc clutch 91 Disc springs
L Measuring point pump pressure 93 Multi-disc clutch
M Measuring point off-road gear 95 Piston / release mechanism
P1 from HBGV block 100 Restrictor check valve
P2 from HBGV block 101 Restrictor check valve
60 from HBGV block 102 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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MJF C I F S S
Positions of the shift lock 70
5 Positions of the shift lock 70
5.1 Machine in on-road gear (2nd gear)

Control oil
Function /
Input speed to Function / shift lock
transmission
connection
Shift speed travel Gear pump 71 delivers a specific

motor oil volume
(> 700 - 900 rpm)
Drive shaft Pump pressure Pp max. 7.0 bar
(> 540 - 700 rpm) Shifting piston 75 in working po-
sition
P1 Shifting pressure Sp over shuttle

check valve 73
B Via external line to

multi-disc brake. Brake
released
Valves 72 and 73 block the con-

nection to point K.
Point K is connected via the Multi-disc clutch
check valve 76 and connection closed. Gear ratio pla-
P2 to the tank. netary 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 Shift lock 79 Oil supply / transmission

71 Lubricating oil pump B Connection to multi-disc brake
71.2 Suction filter (maintenance-free) K Connection to multi-disc clutch
72 Leakage check valve P1 from HBGV block
73 Shuttle check valve P2 from HBGV block
74 Pressure-relief valve Pp Pump pressure
75 Shifting piston S Suction chamber / pump
76 Check valve Sp Shifting pressure
77 Orifice T Return / tank
78 Connection of lubricating oil supply
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MJF C I F S S
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
5.2 Travel in on-road gear

On-road gear (1st gear) preselected with switch S42
Control oil
Function /
transmission
connection
Shift speed Gear pump 71 delivers a spe-

Travel motor cific oil volume
(> 700 - 900 rpm)
Universal joint shaft Pump pressure Pp max. 7.0
(> 540 - 700 rpm) 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.

released
Point K is connected via the Multi-disc clutch

check valve 72 and connec- closed. Gear ratio pla-
tion P1 to the tank. netary drive = 1: 1
(2nd gear)
Shifting-down to 1st
gear not possible;
shifting down only pos-
sible 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
74 Pressure-relief valve P2 from HBGV block
75 Shifting piston Pp Pump pressure
76 Check valve S Suction chamber / pump
77 Orifice Sp Shifting pressure
11.08.11
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MJF C I F S S
off-road gear preselected
11.08.12
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MJF C I F S S
5.3 Off-road gear (1st gear) preselected with switch S42

Control oil
Function /
transmission
connection
Shift speed Gear pump 71 delivers a spe-

Travel motor cific oil volume
(< 700 - 900 rpm)
Universal joint shaft Pump pressure Pp low
(< 540 - 700 rpm) 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 ge-
ar)
Valve 72 blocks the connec-
tion to point B.
Point B is connected via the
shifting piston 75 (open cont- Multi-disc brake de-
rol edge) and connection P1 pressurised, brake ap-
to the tank. plied

71 Lubricating oil pump B to multi-disc brake
71.2 Suction filter (maintenance-free) K to multi-disc clutch
78 to lubricating oil supply
11.08.13
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MJF C I F S S
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
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 in-
tegrated 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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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).
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 par-
king 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 Switch and indicator light of the models A 312 to serial no. 20329
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MJF C I F S S
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 Foot pedal / working brake H168 Indicator light / reverse travel

23 Foot pedal retainer S16 Switch / parking brake
84* Travel pilot control unit S42 Switch 1st gear
H20 Indicator light of parking brake S263 Switch / travel direction
H167 Indicator light / forward travel
* Items of hydraulic unit
11.08.17
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MJF C I F S S
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 par-
king 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 me-
chanism as follows:
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MJF C I F S S
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 HBGV block S T-handle screw / emergency activation

80 Gearbox (bottom view) Y6 Brake valve
95 Piston / release mechanism
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.
Association (Tiefbau-Berufsgenossenschaft) for powertrains and earth-moving equipment.
The service life and operating time of the gearbox depend primarily on regular and careful mainte-
nance and servicing of the unit. It is therefore important that the following instructions are strictly fol-
lowed.
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MJF C I F S S
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 - 40C), 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 Maintenance tasks to be carried out on the gearbox 80
1 Oil drain screw 2 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 main-
tenance 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.
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MJF C I F S S
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 = Increase pressure
Turn out = Reduce pressure
After the pressure has been adjusted, tighten the sealing nut and replace the protective cap.
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 HBGV block 103 Measuring point
63 Backpressure valve 104 Measuring point
11.08.21
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MJF C I F S S
Dismantling, repair and installation of the gearbox
9 Dismantling, repair and installation of the gearbox
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.
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).
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MJF C I F S S
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 was-
hers 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 cham-
bers (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 EL Bleeder / release mechanism

EK Bleeder / multi-disc clutch
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MJF C I F S S
Fig. 13 Undercarriage with transmission
3 Universal joint shaft 52 Retaining washer

7 Hex nut 54 Hex head screw
9 Undercarriage 60 Retaining washer
22 Hex head screw 62 Hex head screw
40 Angle bracket 80 Transmission, complete
44 Hex head screw 210 Oil motor with brake valve
11.08.24
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MJF C I F S S
Components and layout
10 Components and layout
Fig. 14 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 Control pressure connection
64 Accumulator R Residual flow from flow distributor / gear
pump
65 Backpressure measuring point Y6 Brake valve
70 Shift lock Y55 Shift valve
11.08.25
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MJF C I F S S
Hydraulic release mechanism and hydraulic accumulator
11 Hydraulic release mechanism and hydraulic accumulator
Fig. 15 Sectional drawing and diagram of hydraulic release mechanism
11.08.26
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MJF C I F S S
70 from/to shift lock 103 Measuring point / brake B

87 from/to multi-disc brake 104 Measuring point / clutch K
93 from/to multi-disc clutch 105 Safety valve
95 Piston / hydraulic release mechanism 106 Shift valve
100 Restrictor check valve 107 Bleeder (EB) / multi-disc brake
101 Restrictor check valve 107 Bleeder (EL) / release mechanism
102 Accumulator 210 Regulating motor
11.08.27
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MJF C I F S S
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 Housing (80/102*) 13 Spur drive (97*)
5 Housing (80/102*) 14 Shift lock (70*)
6 Oil lines 15 Shift lock (70*)
7 Clutch (91/92/93/94*) 16 Output (98/99*)
8 Clutch (91/92/93/94*) 17 Output (98/99*)
9 Multi-disc brake (87/89/90*)
* Items in sectional drawing on page
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MJF C I F S S
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
12.2 Clutch 7/8 and multi-disc brake 9/10
Fig. 17 Exploded view of the clutch and the multi-disc brake based on spare parts list
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MJF C I F S S
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
12.4 Oil lines 6 and shift lock 14/15
Fig. 19 Exploded views of oil lines and shift lock based on spare parts list
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MJF C I F S S
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
1 Hydraulic tank (*) 86 Hollow gear

2 Breather filter (*) 87 Multi-disc brake (6 inner discs)
3 Stop cock (*) 89 Piston
4 Return filter (*) 90 Disc springs
5 Bypass valve / return line (*) 91 Disc springs
20 Variable displacement pump (*) 92 Piston
21 Powertrain 93 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 Pressure-relief valve (*) 99 Output flange
52 Pressure filter (*) 103 Measuring point / brake B
53 Check valve (*) 104 Measuring point / clutch K
54 Accumulator (*) 210 Regulating motor (*)
60 HBGV block 322 Rotary connection 6x (*)
63 Backpressure-limiting valve 400 to compact brake block
64 Accumulator
65 Measuring point / backpressure and A126 from/to autocheck printed circuit board
release pressure (X)
66 Check valve B10 Pressure switch / parking brake (X)
70 Shift lock, complete H20 Indicator light of parking brake (X)
71 Gear pump K251 Relay / parking brake (X)
71.2 Suction filter S16 Push button / parking brake (X)
72 Leakage check valve S42 Push button / off-road gear (X)
73 Shuttle check valve Y3 Solenoid valve / pilot control (*)
74 Pressure-relief valve (6-8 bar) Y6 Solenoid valve / parking brake (X)
75 Shifting piston Y24 Solenoid valve / creeper gear (*)
76 Check valve Y50 Solenoid valve / power control (X)
77 Orifice Y50 Solenoid valve / power control (X)
80 Transmission Y55 Solenoid valve / 1st gear (X)
81 Connecting flange Y62 Solenoid valve / forward travel (X)
82 Drive shaft Y63 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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MJF C I F S S
Function
2 HL 100 transmission
1 Function
The 2 HL 100 transmission is attached to the undercarriage. It distributes the drive force from the flan-
ge-connected engine through the drive shafts to the input axles.
11.10.1
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MJF C I F S S
Technical data
2 Technical data
Machine A 314 Li A 316 Li

A 314 Li A 314 Li
Speeder 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
Gear ratio
1st gear 5.35 5.35
2nd gear 1.39 1.39
Weight 125 kg 125 kg
Oil volume in gearbox 3.3 l 3.3 l
Oil viscosity SAE 20 W-20 or SAE 20 W-20 or
SAE 10 W-30 SAE 10 W-30
Operating temperature 80 - 110 80 - 110
Short-time max. 120 120
Hydraulic control
Max. control oil level of gear pump 32 32 l/min 32 l/min
Residual flow R from flow distributor approx. 30 l/min approx. 30 l/min
Pressure-relief valve 51 32 1 bar 32 1 bar
Measuring points 49, 65, 103, 104 approx. 32 bar approx. 32 bar
Brake backpressure
Pressure-relief valve 63 12.5 bar 12.5 bar
(Measuring point 65)
Shifting pressure of pressure switch B10 26.5 bar 26.5 bar
25 2.5 bar () 25 2.5 bar ()
Shift lock pump pressure (pressure-relief valve 74)
at max. input speed
at shift speed 6 - 8 bar 6 - 8 bar
2.0 - 2.6 bar 2.0 - 2.6 bar
Switching speed 580 - 950 rpm (+) 580 - 950 rpm (+)
Switching speed 415 - 680 rpm (+) 415 - 680 rpm (+)
(*) maximum permissible value

( ) withmodified pressure switch
(+) at oil temperature 80C
The switching range results from the tolerance orifice 77 min / max from pump 71.
11.10.2
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MJF C I F S S
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 multi-
disc 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 pres-
sure).
chanically engaged. In off-road gear, control pressure is applied to the clutch, which is thus disen-
gaged, and the brake is applied by means of the spring force.
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 mecha-
nism. In OFF position, it interrupts the power transmission between input and output. When disen-
gaged, the parking brake is disabled.
The shut-off mechanism thus acts as the auxiliary release device required by law for the parking bra-
ke, 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.
trifugal lubrication). The moving clutch parts are supplied with lubricating oil fed through the lubrica-
tion channel.
11.10.3
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MJF C I F S S
Design
1 Connecting flange / regulating motor 8 Control pressure rotary-type pump

2 Shifting pressure accumulator 9 Spur gear drive
3 Multi-disc clutch 10 Disc springs
4 Multi-disc brake 11 Restrictor valve
5 Planetary drive a Input
6 Shut-off mechanism b Output
7 Shift lock
11.10.4
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MJF C I F S S
Fig. 3 and Fig. 4
4.1 Summary description
4.1.1 Parking
Power circuit interrupted (ignition off) Multi-disc brake 87 and multi-disc clutch 93
4.1.2 Braking
4.1.3 On-road gear

Switch S42 not operated Brake 87 (outside) released by control pressure,
4.1.4 Off-road gear

Switch S42 operated Brake 87 (outside) applied by disc springs 90,
clutch 93 (inside) opened by control
pressure
4.2.1 Diesel engine off:

4.2.2 Diesel engine on:

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.
Pressure switch B10 closed, indicator light H20 on.
4.2.3 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, connec-
tion 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.
11.10.5
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MJF C I F S S
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.
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 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 second speed reduction of the planetary drive / spur drive results in a high reducing gear ratio,
(see Technical data on page 2).
4.4.1 General
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 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.
4.4.2 Normal position of shift lock

side.
11.10.6
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MJF C I F S S
When the piston is in this position (neutral position), oil flow from P1 B or from P2 K is possible so
sure P2 and the spring force are higher than the pump pressure.

sure side P2) is fed through the leakage check valve 72 through connection P1 to the tank. The valve
or off-road gear.

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.

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 ope-
rate the shifting piston 75 is determined by the backpressure at the orifice 77 for the lubricating oil
supply.

piston 75.

The check valve 76 feeds the oil that is replaced when the shifting piston 75 is moved through P2 to
the tank.
11.10.7
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MJF C I F S S
4.5 Diagram of gear system / hydraulic circuit
Fig. 3 Diagram of transmission and shift lock
a Output 60 from HBGV block

b Shut-off mechanism 70 Shift lock
d Oil supply transmission control 71 Lubricating oil pump
e Oil supply transmission 71.2 Suction filter (maintenance-free)
B to multi-disc brake 72 Leakage check valve
E Leak oil control circuit 73 Shuttle check valve
J Measuring point on-road gear 74 Pressure-relief valve
K to multi-disc clutch 75 Shifting piston
L Measuring point pump pressure 76 Check valve
M Measuring point off-road gear 77 Orifice
P1 from HBGV block 80 Transmission
P2 from HBGV block 87 Multi-disc brake
S Suction chamber / pump 93 Multi-disc clutch
102 Accumulator
210 Regulating travel motor
11.10.8
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MJF C I F S S

Control oil
Function /
transmission
connection
800 rpm to Gear pump 71 delivers a specific

max. rpm oil volume
Pump pressure Pp max. 8.0 bar
Shifting piston 75 in working po-

sition
P1 Shifting pressure Sp over shuttle

check valve 73

released

nection to point K
Point K is connected via the Multi-disc clutch enga-
check valve 76 and connection ged. Gear ratio plane-
P2 to the tank tary drive = 1: 1 (2nd
gear)
pump pressure is applied to the shifting piston 75. The piston is pressed against the pressure spring
and moved into working position.
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.

71 Lubricating oil pump B Connection to multi-disc brake
71.2 Suction filter (maintenance-free) K Connection to multi-disc clutch
11.10.9
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MJF C I F S S
at high speed
11.10.10
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MJF C I F S S

Control oil
Function /
transmission
connection
800 rpm to Gear pump 71 delivers a spe-

max. rpm cific oil volume
Pump pressure Pp max. 8.0

bar
P2 Shifting pressure Sp over the

P1

released

check valve 72 and connec- ged. Gear ratio plane-
tion P1 to the tank tary drive = 1:
1 (2nd gear)
Shifting-down to 1st
gear not possible;
Shifting down only pos-
speed is below 800
rpm

71.2 Suction filter (maintenance-free) B Connection to multi-disc brake
72 Leakage check valve K Connection to multi-disc clutch
74 Pressure-relief valve P2 from HBGV block
11.10.11
copyright by
MJF C I F S S
11.10.12
copyright by
MJF C I F S S

Control oil
Function /
transmission
connection
0-800 rpm Gear pump 71 delivers a spe-

cific oil volume
Pump pressure Pp low
Shifting piston 75 in neutral

position
P2 Shifting pressure Sp over

of control spool)
multi-disc brake.
Clutch released

drive = 1 : 3.87 (1st ge-
ar)
tion to point B
shifting piston 75 (open cont- Multi-disc brake de-
rol edge) and connection P1 pressurised, brake ap-
to the tank plied

71 Lubricating oil pump B to multi-disc brake
71.2 Suction filter (maintenance-free) K to multi-disc clutch
11.10.13
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MJF C I F S S
11.10.14
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MJF C I F S S
Fig. 7 or Fig. 8


the operator's seat, see Fig. 7 or Fig. 8.
operated.

Preselect the travel direction at the preselection switch S263 located in the right pilot control unit, see
Fig. 7 or Fig. 8.
tegrated into the right control desk, see Fig. 7 or Fig. 8.
the indicator light H167 (forward) is on.
If the pilot control unit 84, Fig. 7 or Fig. 8, is actuated, the machine travels forward.
the indicator light H168 (reverse) is on.
If the pilot control unit 84, Fig. 7 or Fig. 8, is actuated, the machine travels backward.
6.4 Brakes
Caution!

Engage the locking device 23 of the working brake (pedal 22 to the right of the steering column),
see Fig. 7 or Fig. 8.
11.10.15
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MJF C I F S S
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).
The pressure switch B10 is released.
Note!
still.
king brake.

The clutch 87 (brake) and 93 (1st gear) is automatically engaged.
Fig. 7 Switch and indicator light of the models A 314 to serial no. 20333 and A 316 to serial no.
20339
11.10.16
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MJF C I F S S
Fig. 8 Switch and indicator light of the models A 314 from serial no. 20334 and A 316 machines
from serial no. 20340

H167 Indicator light / forward travel
* Items of hydraulic unit
11.10.17
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MJF C I F S S
Caution!

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.
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.
Disconnect the gear drive and brake from the output.
Danger!
Park the machine on a level surface and secure it with chucks against rolling away.
in its position.
Association (Tiefbau-Berufsgenossenschaft) for the powertrains and earth-moving equipment.
Remove the hex head screws 109, Fig. 9.

Turn the lever 108 of the gear-shift fork to position OFF (in direction of arrow).
Secure the lever 108 with the hex head screw 109 in its turned position.
11.10.18
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MJF C I F S S
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 Brake valve
vation
8 Maintenance
Danger!
secured.
Always adhere to the safety instructions in group 1.10 "Safe maintenance of machine".
lowed.
8.1 Oil level check

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.
11.10.19
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MJF C I F S S
Maintenance
8.2 Oil change

the oil:
Remove the oil discharge screw 1.
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.
Screw in the screw 2 of the gearbox 80 (ensure that the seal ring is positioned properly).
Fig. 10 Maintenance tasks to be carried out on the transmission 80
1 Oil drain screw 2 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 main-
tenance work.
In the event of malfunctions or failures, check the pressures in the gear system as described below.
Note!
8.3.1 Checking the release pressure of the clutch, see Fig. 11

Connect the pressure sensor (0-60 bar) to the measuring point 103 (multi-disc brake / connection
B) or the measuring point 104 (multi-disc clutch / connection K).
Preselect on-road or off-road gear and check release pressure, (see Technical data on page 2).
A release pressure below the nominal pressure is possibly caused by a defect in the shift lock 70.
If the pressure is too low, check and adjust the pressure of the pilot system.
After adjustment of the pressure, remove the pressure sensor and seal the measuring point(s).
11.10.20
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MJF C I F S S
Maintenance
8.3.2 Checking the backpressure of the brake, see Fig. 11

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.
After the pressure has been adjusted, tighten the sealing nut and replace the protective cap.
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
11.10.21
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MJF C I F S S
9 Dismantling, repair and installation of the gearbox
9.1 Dismantling of the gearbox for repair work
Danger!
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.
Remove the gearbox 80 with the plate 5 from the undercarriage 9.
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.
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

Tighten the nuts 17 with the washers 18 (tightening torque 79 Nm).
Place the plate 5 on the gearbox 80.
Apply Omnifit 100 to the thread of the hex head screws 12, insert them with the washers 13 into
the gearbox 80 and tighten them (tightening torque 430 Nm).
Place the gearbox 80 with the plate 5 in the undercarriage 9, using suitable lifting gear.
11.10.22
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MJF C I F S S
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 re-
peatedly 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 Undercarriage 80 Transmission, complete
11 Hex head screw 210 Oil motor with brake valve
12 Hex head screw
11.10.23
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MJF C I F S S
Components and layout
10 Components and layout
Fig. 13 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 Connection for control pressure to HBGV
block
64 Accumulator R Residual flow from flow distributor / gear
pump
65 Backpressure measuring point Y6 Brake valve
70 Shift lock Y55 Shift valve
0 Check valve, complete

consisting of assemblies 1- 11
1 Drive housing (81/102*) 7 Planetary drive (83/84/85/86*)
2 Drive (82/101*) 8 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
11.10.24
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MJF C I F S S
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
11.10.25
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MJF C I F S S
11.2 Gear housing 3 and oil lines 4
Fig. 15 Exploded view of gear housing based on spare parts list
11.10.26
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MJF C I F S S
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
11.10.27
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MJF C I F S S
11.4 Planetary drive 7, gear shut-down mechanism 8 and spur drive 9
Fig. 17 Exploded views of the planetary drive, shut-down mechanism and spur drive based on
spare parts list
11.10.28
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MJF C I F S S
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
11.10.29
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MJF C I F S S
1 Hydraulic tank (*) 85 Planetary carrier

2 Breather filter (*) 86 Hollow gear
3 Stop cock (*) 87 Multi-disc brake (5 inner discs)
4 Return filter (*) 89 Piston
5 Bypass valve / return line (*) 90 Disc springs
20 Variable displacement pump (*) 91 Disc springs
21 Powertrain 92 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 Pressure-relief valve (*) 98 Helical gear
52 Pressure filter (*) 99 Output flange
53 Check valve (*) 100 Restrictor check valve (orifice 1.2
mm) O
54 Accumulator (*) 101 Restrictor check valve (orifice 0.8
mm) O
57 Measuring point 102 Accumulator
59 Measuring point 103 Measuring point / brake B
63 Backpressure-limiting valve 104 Measuring point / clutch K
64 Accumulator 210 Regulating motor (*)
65 Measuring point / backpressure and 322 Rotary connection 6x (*)
release pressure
66 Check valve 400 to compact brake block
70 Shift lock, complete A126 from/to autocheck printed circuit board
(X)
71 Gear pump B10 Pressure switch / parking brake (X)
71.2 Suction filter H20 Indicator light of parking brake (X)
72 Leakage check valve K251 Relay / parking brake (X)
73 Shuttle check valve S16 Push button / parking brake (X)
74 Pressure-relief valve (6-8 bar) S42 Push button / off-road gear (X)
75 Shifting piston Y3 Solenoid valve / pilot control (*)
76 Check valve Y6 Solenoid valve / parking brake (X)
77 Orifice Y24 Solenoid valve / creeper gear (*)
80 Transmission Y50 Solenoid valve / power control (X)
81 Connecting flange Y51 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 (*)

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.
Fig. 1 2 HL 270 / 290 transmission
11.20.1
copyright by
MJF C I F S S
2 HL 270 / 290 transmission Service Manual
Technical data
2 Technical data
Machine A 309 Li / A 311 Li A 312 Li A 316 Li

from serial number 29269 / 29170 29898 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
Gear ratio
1. gear 4,87 4,87 4,87
2. gear 1,20 1,20 1,20
Weight 135 kg 135 kg 135 kg
Oil volume in gearbox 3.0 l 3.0 l 3.0 l
Oil viscosity SAE 20 W -20 SAE 20 W-20 or SAE 20 W-20 or
or SAE 10 W-30 SAE 10 W-30 SAE 10 W-30
Hydraulic control
Max. control oil level of gear pump / 33 32 32
flow distributor 22 l/min 30 l/min 30 l/min
pressure-relief valve 51 32 1 bar 32 1 bar 32 1 bar
Measuring points 49, 63, MB, MK approx. 32 bar approx. 32 bar approx. 32 bar
Shift lock pump pressure (pressure-
relief valve 74)
at max. input speed 6 - 8 bar 6 - 8 bar 6 - 8 bar
at shift speed 2.0 - 2.6 bar 2.0 - 2.6 bar 2.0 - 2.6 bar
Switching speed 800 100 rpm 800 100 rpm 800 100 rpm
Switching speed 667 70 rpm 667 70 rpm 667 70 rpm
(*) maximum permissible value
11.20.2
copyright by
MJF C I F S S
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).
chanically 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 pres-
sure.
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. Depen-
ding on the machine speed, the spool is set to neutral or working position respectively, i.e. the pre-
selected 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 pre-
vented by the shift lock, but by the brake valve that is flange-mounted to the oil motor.
trifugal lubrication). The moving clutch parts are supplied with lubricating oil fed through the lubrica-
tion 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 emer-
gency 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.
11.20.3
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MJF C I F S S
Design
Fig. 2 Transmission 2 HL 270/290
1 Disc springs 8 Output flange

2 Drive shaft 9 Output flange
3 Multi-disc brake 10 Connecting flange / regulating motor
4 Multi-disc clutch 11 Shift lock
5 Planetary drive a Input
6 Lubricating oil pump b Output
7 Spur gear drive
11.20.4
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MJF C I F S S
See also diagram on page 11.20.31.
4.1 Parking
Power circuit interrupted (ignition off) Multi-disc brake 87 (outer) and multi-disc clutch
93 (inner)
4.2 Braking
4.3 On-road gear

Switch S42 not operated Brake 87 released by control pressure,
closed
4.4 Off-road gear

Switch S42 operated Brake 87 applied by disc springs 90,
clutch 93 opened by control
pressure

Diesel engine off:
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 .
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.
11.20.5
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MJF C I F S S
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.
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 re-
duction) and drives the axles, and thus the drive wheel of the machine, via the drive flange 100
and the flange-connected universal joint shafts.

The planetary gears 84 are propelled through the drive shaft 82 by the oil motor 210. The plane-
tary 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.

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.

sure side K) is fed through the leakage check valve 72 through connection B to the tank. The valve
or off-road gear.

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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MJF C I F S S

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.

piston 75.

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

side.
When the piston is in this position (neutral position), oil flow from B B or from K K is possible so
sure K and the spring force are higher than the pump pressure.
11.20.7
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MJF C I F S S
4.9 Diagram of gearbox / hydraulic circuit
Items in transmission diagram, (see Fig. 3 on page9)

a Output 3 Lubrication nipple / emergency activa-
tion
b Planetary drive 4 Bleeder / emergency activation
c Spur gear drive 5 Pressure relief valve / emergency acti-
vation
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 70 Shift lock
K/K/K to multi-disc clutch 71 Lubricating oil pump
L Measuring point pump pressure 71.2 Suction filter (maintenance-free)
M Measuring point off-road gear 72 Leakage check valve
MB Measuring point multi-disc brake 73 Shuttle check valve
MK Measuring point multi-disk clutch 74 Pressure-relief valve
+P from control oil unit 75 Shifting piston
S Suction chamber / pump 76 Check valve
T to tank 77 Orifice
80 Transmission, complete
Y55 Solenoid / 1st gear 87 Multi-disc brake
Y60 Solenoid / 2nd gear 93 Multi-disc clutch
101 Accumulator
210 Regulating travel motor
11.20.8
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MJF C I F S S
Fig. 3 Diagram of transmission and shift lock (shifting position = 2nd gear)
11.20.9
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MJF C I F S S
Control oil
Function /
transmission
connection
800 rpm to Gear pump 71 delivers a specific

max. speed oil volume
Pump pressure Pp max. 7.0 bar
Shifting piston 75 in working po-

sition
B Shifting pressure Sp over shuttle

check valve 73

released

nection to point K.

check valve 76 and connection K ged. Gear ratio plane-
to the tank. tary drive = 1: 1 (2nd
gear)

71 Lubricating oil pump B from HBGV block
71.2 Suction filter (maintenance-free) B to multi-disc brake
72 Leakage check valve K to HBGV block
73 Shuttle check valve K from multi-disc clutch
pump pressure is applied to the shifting piston 75. The shifting piston is thus pressed against the pres-
sure spring into working position.
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.
11.20.10
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MJF C I F S S
at high speed
11.20.11
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MJF C I F S S
Control oil
Function /
transmission
connection
800 rpm to Gear pump 71 delivers a spe-

max. speed cific oil volume
Pump pressure Pp max. 7.0

bar
K Shifting pressure Sp over the

B.

released

check valve 72 and connec- ged. Gear ratio plane-
tion B to the tank. tary drive = 1: 1 (2nd
gear)
Shifting down to 1st

gear not possible.
shifting down only pos-
speed is below 800
rpm

71.2 Suction filter (maintenance-free) B to HBGV block
72 Leakage check valve B to multi-disc brake
73 Shuttle check valve K from HBGV block
74 Pressure-relief valve K from multi-disc clutch
11.20.12
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MJF C I F S S
11.20.13
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MJF C I F S S
Control oil
Function /
transmission
connection
0-800 min-1 Gear pump 71 delivers a spe-

cific oil volume
Pump pressure Pp low
Shifting piston 75 in neutral

position
K Shifting pressure Sp over

of control spool)
multi-disc brake.
Clutch released

drive = 1 : 3.87 (1st ge-
ar)

tion to point B.
shifting piston 75 (open cont- Multi-disc brake not
rol edge) and connection B to pressurised
the tank. Brake applied

71 Lubricating oil pump B to HBGV block
71.2 Suction filter (maintenance-free) B from multi-disc brake
72 Leakage check valve K from HBGV block
73 Shuttle check valve K to multi-disc clutch
11.20.14
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MJF C I F S S
11.20.15
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MJF C I F S S
Fig. 7


the operator's seat, Fig. 7.
operated.

Preselect the travel direction at the preselection switch S263 located in the right pilot control unit, Fig.
7.
tegrated into the right control desk, Fig. 7.
The indicator light H167 (forward) is on.
When the pilot control unit 84, Fig. 7, is actuated the machine travels forward.
The indicator light H168 (reverse) is on.
When the pilot control unit 84, Fig. 7, is actuated, the machine travels backward.
6.4 Brakes
Caution!

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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MJF C I F S S
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.
The indicator light in the switch S16 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 ap-
plied (see also electrical system).
Note!
still.
king brake.

The multi-disc packs 87 and 93 are closed automatically.
Fig. 7 Switches and indicator lights

H167 Indicator light / forward travel * Items of hydraulic unit
11.20.17
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MJF C I F S S
Caution!
To tow the machine, use a suitably dimensioned rod.
Never use a cable or rope.

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 Valve block
60 Valve block, complete Y55 Solenoid valve / 1st gear

67 T-handle screw / emergency activation Y60 Solenoid valve / 2nd gear parking brake
11.20.18
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MJF C I F S S

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.
Before accessing the danger area and the area of the undercarriage, secure the wheels with
chucks.
in its position.
Disconnect the solenoid valves Y6 / Y55 to disable gear switching when the emergency activa-
tion is on.
Fig. 9 Transmission with emergency activation of the gearbox
3 Lubrication nipple / emergency activation 5 Pressure relief valve / emergency activation

4 Bleeder / emergency activation
7.2.1 Switch on emergency activation

Using the grease gun (included in machine toolbox), press normal grease into the lubrication nipp-
le 1 until it escapes at the pressure relief valve 3.
The machine can now be towed away, see 7.2.
11.20.19
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MJF C I F S S
Maintenance
Caution!
Vor
When the diesel engine is shut down, the working brake can still perform a few braking manoeuvres,
even if the brake accumulator is filled.
Before setting the gearbox back to normal mode (after towing) deactivate the emergency activa-
tion!
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!
secured.
lowed.
8.1 Oil level check

3.
Carefully clean and remove the screw plug at the check and filling opening 10 at the gearbox 80
and check the oil level.
11.20.20
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MJF C I F S S
Maintenance
8.2 Oil change

the oil:
Carefully clean and remove the screw plug from the oil discharge bore 9 and the control and refill
bore 10 at the gearbox 80.
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.
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 Oil discharge bore, oil check and filling opening
9 Oil discharge bore 80 Transmission, complete

10 Oil check and filling opening
11.20.21
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MJF C I F S S
Maintenance
Fig. 11 Measuring points at the gearbox and valve block
60 Valve block, complete 70 Shift lock

62 Pressure valve 80 Transmission, complete
63 Measuring point / opening pressure MB Measuring connection for multi-disc brake
MK Measuring connection for multi-disc clutch
Note!
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, com-
paring 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
Installation, dismantling and repair
9 Installation, dismantling and repair
Danger!
9.1 In models A 309 - A 312
Fig. 12 Dismantling and installation of the gearbox in models A 309 - A 312
12 Universal joint shaft 60 Hex head screw

13 Hex nut 62 Washer
40 Angle bracket 80 Gearbox, complete
44 Hex head screw 210 Oil motor / travel drive
52 Washer EB Bleeder connection B
54 Hex head screw EK Bleeder connection K
9.1.1 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.
11.20.23
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MJF C I F S S
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 con-
nection 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 gearbox 80 and the angle console 40 from the gearbox 80.
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

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.
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
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 Dismantling and installation of the gearbox in models A 314 - A 316
12 Universal joint shaft 19 Hex head screw

14 Plate 26 Nut
15 Washer 80 Gearbox, complete
16 Hex head screw 210 Oil motor / travel drive
17 Rubber pads EB Bleeder connection B
18 Washer EK Bleeder connection K
9.2.1 Dismantling of the gearbox

Lift undercarriage using the outrigger support system
11.20.25
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MJF C I F S S
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.
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

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.
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.
11.20.26
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MJF C I F S S
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.
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 Gearbox bleeder
4 Bleeder / emergency activation EB Bleeder for multi-disc brake

EK Bleeder for multi-disc clutch

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-
11.20.27
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MJF C I F S S
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 pressuri-
sed).
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 hy-
draulic 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, re-
move the high pressure hose) and replace the protective caps.
11.20.28
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MJF C I F S S
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 Measuring point / control pressure
tributor (residual flow for pilot control)
33 Gear pump / pilot control 50 Control oil unit
Fig. 16 Valve block in the uppercarriage with solenoid valves and measuring point
60 Valve block Y6 Solenoid valve / parking brake

62 Pressure valve Y55 Solenoid / 1st gear
63 Measuring point / opening pressure
11.20.29
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MJF C I F S S
1 Hydraulic tank 90 Disc springs / multi-disc clutch

3 Lubrication nipple / emergency activa- 91 Piston / multi-disc clutch fixed
tion
4 Bleeder / emergency activation 92 Piston / multi-disc clutch rotating
5 Pressure relief valve / emergency acti- 93 Multi-disc clutch
vation
20 Double variable-displacement pump (*) 94 Inner disc carrier
A 309 - A 311
20 Variable-displacement pump (*) A 312 - 95 Pressure spring
A 316
32 Gear pump / pilot control and 96 Piston / emergency activation
brake (*)
33 Gear pump / pilot control (*) 97 Counterpart / emergency activation
49 Measuring point / pilot pressure (*) 98 Bolt / emergency activation
50 Control oil unit / pilot control (*) 99 Spur gear
51 Pressure relief valve / pilot control 100 Output flange
60 Valve block, complete 101 Accumulator
61 Shifting piston 102 Restrictor check valve
62 Pressure valve 210 Regulating motor (*)
63 Measuring point / opening pressure 322 Rotary connection 6x (*)
67 Emergency activation / shifting to 1st
gear
70 Shift lock, complete EB Bleeder / brake B
71 Gear pump EK Bleeder / clutch K
71.2 Suction filter MB Measuring point / brake B
72 Leakage check valve MK Measuring point / clutch K
73 Shuttle check valve H20 Indicator light of parking brake (X)
74 Pressure-relief valve (6-8 bar) S16 Push button / parking brake (X)
75 Shifting piston S42 Push button / off-road gear (X)
76 Check valve Y55 Solenoid / 1st gear (X)
77 Orifice Y60 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 Planetary gear K/K/K Pressure oil supply to multi-disc clutch
85 Planetary carrier J, M Measuring connections
86 Hollow gear P, Pp Pressure from control oil pump
87 Multi-disc brake S, Sp Suction connection (lubricating pres-
sure)
88 Piston / multi-disc brake T Return connection
89 Disc springs / multi-disc brake

11.20.30
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MJF C I F S S
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 sys-
tem 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 di-
rection 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 hy-
draulic 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 clut-
ches in the event of an emergency braking manoeuvre.
Fig. 1 Hydraulic diagram and HBGV block 60
60 HBGV block 66 Check valve

63 Backpressure-limiting valve B10* Pressure switch
64 Hydraulic accumulator Y55* Solenoid valve / 1st gear
65 Measuring point Y6* Solenoid valve / parking brake
* items in electrical / hydraulic diagram
11.30.1
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MJF C I F S S
HBGV block for 2 HL 70 / 100 Service Manual
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.

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 connec-
tions 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 re-
turns 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 pres-
sure. 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 en-
gine 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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MJF C I F S S
Fig. 2 Sectional drawing of the HBGV block
10 Housing 110 Magnetic tube

20 Piston 120 Magnetic coil
30 Piston 130 Protective cover
40 Spring plate 160 Collar nut
50 Screw plug 170 Ball
60 Adjusting screw 180 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
11.30.3
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MJF C I F S S
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 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 back-
pressure (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 corres-
ponds 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 ope-
ning 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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MJF C I F S S
Function and design
HBGV block for 2 HL 270 / 290
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 T-handle for emergency operation P Connection to pilot control pressure
Y55 Solenoid valve / 1st gear T Tank connection
11.32.1
copyright by
MJF C I F S S

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-hol-
ding transmission. The oil from the piston chambers of the gearbox is fed through connection T to the
hydraulic tank.

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 so-
lenoid 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 pres-
sure. 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
copyright by
MJF C I F S S
Fig. 2 Functional diagram
1 to hydraulic tank 322 Rotary connection 6 x

50 from control oil unit S16 Switch / parking brake
60 HBGV block S42 Switch / off-road gear
61 Piston Y55 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 Pressure spring P Connection to pilot control pressure
67 T-handle for emergency operation T Tank connection
185 Transmission
11.32.3
copyright by
MJF C I F S S
Fig. 3 Sectional drawing of the HBGV block
60 HBGV block 67 T-handle for emergency operation

61 Piston / shift valve 68 Spring plate
62 Pressure-relief valve Y55 Solenoid valve / 1st gear
64 Piston / pressure-relief valve Y60 Solenoid valve / 2nd gear
66 Pressure spring
11.32.4
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MJF C I F S S
Pressure-relief valve 62
3 Pressure-relief valve 62
Fig. 4 Pressure relief valve in HBGV block
3.1 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 reduc-
tion 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 con-
trol pressure through the connection B.
The machine can now be removed from the danger area.
11.32.5
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MJF C I F S S
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
11.60.1
copyright by
MJF C I F S S
Travel gear F40 Service Manual
General information
Equipment R 317-Li
Gearbox type F40 - 110
Input speed max. (fast travel) 5479 min-1
min. (normal travel) 1713 min-1
Output speed 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
Oil viscosity SAE 90 W
SAE 80 W 90
SAE 90 LS
Brake Hydraulically released multi-disc bra-
ke
Min. brake release pressure 18 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 34 Nm
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 new 3.2 mm
Wear limit 5.0 mm
resulting in a maximum permissible wear of
the entire disc pack of 1.8 mm
Items A - D (see Fig. 2) Items E - H (see Fig. 6) Items I (see Fig. 8)
Tab. 1 Technical data, settings and tightening torques
11.60.2
copyright by
MJF C I F S S
(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 sta-
ge 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.
4 Maintenance

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 ge-
arbox, 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.
11.60.3
copyright by
MJF C I F S S
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 Travel gear 8 Hex head screw
3 Oil motor 9 Cover
4 Tumbler wheel 11 Hex head screw
5 Hex head screw 12 Washer
6 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
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
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 Oil drain position A and oil filling and checking position B
5.2 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.
11.60.5
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MJF C I F S S
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).
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 Seal between the oil motor and the gearbox

3 Oil motor 15 O-ring
Note!
11.60.6
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MJF C I F S S
Sealing of gearbox
Please note:
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).
Insert both screw plugs 900; for tightening torque, (see Tab. 1, page 2).
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.
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 dis-
mantled. 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".
11.60.7
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MJF C I F S S
Exploded view of the travel gear system
7 Exploded view of the travel gear system
Fig. 5 Exploded view of the travel gear system
3 Oil motor 220 Tapered roller bearing

7 Hex head screw 260 Nut
10 Planetary carrier (planetary stage I) 290 Slide ring seal
15 O-ring 310 Shim
20 Planetary carrier (planetary stage II) 320 Adjusting ring
30 Planetary carrier (planetary stage III) 550 Circlip
40 Hollow gear 600 O-ring
50 Cover 800 Allen head screw
80 Pinion 810 O-ring
11.60.8
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MJF C I F S S
Sectional drawing of the travel gear system
90 Pinion 840 Allen head screw

100 Pinion 850 O-ring
200 Suspension tube 900 Screw plug
210 Hub 990 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.
11.60.9
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MJF C I F S S
Exploded view of the travel brake
9 Exploded view of the travel brake
Fig. 7 Exploded view of the travel brake
10 Carrier 90 Outer disc (steel)

20 Hub 100 Inner disc (sinter)
30 Piston 110 Snap ring
40 Cover 140 Backing ring
70 Seal 170 O-ring
80 Seal 180 Backing ring
11.60.10
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MJF C I F S S
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.
11.60.11
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MJF C I F S S
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
11.62.1
copyright by
MJF C I F S S
FAT 350 travel gear system Service Manual
Technical data
2 Technical data
Machine R 313-Li / R 317-Li

from serial number 27752 / 23450
Gearbox type FAT 350 P062
Input speed max. (fast travel) 5479 rpm
min. (normal travel) 1713 rpm
Output speed 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
Oil viscosity SAE 90 W
SAE 80 W 90
SAE 90 LS
Brake Hydraulically released multi-disc bra-
ke
Settings and tightening torques, to be observed for installation:

A) Check dimension for the installation of the oil motor 93.5+1 Nm
102
B) Check dimension for the axial play at the wheel end 3.5 + 1 mm
(from end of drive shaft 35 to flange face of the
lid 40
C) Friction torque of ball bearing 11 100 Nm
D) Tightening torque for threaded stud 1.4 69 Nm*
E) Tightening torque for Allen head screws 46 46 Nm**
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)
* secured with Loctite 242

** secured with Loctite 272
11.62.2
copyright by
MJF C I F S S
(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 car-
rier 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 pla-
netary 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.
4 Maintenance

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 ge-
arbox, 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.
11.62.3
copyright by
MJF C I F S S
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 Longitudinal member 106 Hex head screw

102 Oil motor 108 Lid
103 Tumbler wheel 109 Hex head screw
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:
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.
11.62.4
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MJF C I F S S
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.
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 gear-
box 101 .
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 under-
carriage.
Fig. 3 Gear positions for oil discharge, refilling and inspection
48 Screw plug E Oil filling bore

A Oil discharge bore K Inspection bore
5.2 Installation
see Fig. 2, see Fig. 4
Caution!
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.
11.62.5
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MJF C I F S S
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.
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

102 Oil motor 112 O-ring
Note!
11.62.6
copyright by
MJF C I F S S
Sealing gearbox
Before you start assembly, please note:

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.
Insert both screw plugs 48; for tightening torque, (see Tab. 1 on page2).
Disconnect the pressure, leak oil, lubricating and brake lines from the oil motor 103 (seal ope-
nings).
Remove the screws 106 and pull the oil motor 102 from the gearbox 101 .
Replace the O-ring 112 of the oil motor 102.
Insert and tighten the screws 106; for tightening torque, see Table 1, page 2.
Mount the cover 108 and tighten the hex head screws 109 with washers 110; for tightening tor-
ques, Table 1, page 2.

Note!
mantled. 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'.
11.62.7
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MJF C I F S S
Sealing gearbox
1 Connected carrier (planetary stage III) 41 Stop washer

1.2 Seal plug 42 L-ring
1.3 Taper pin 45 O-ring
1.4 Threaded stud 46 Allen head screw
2 Snap ring 48 Screw plug
3 Stop washer 50 Thrust plate
5 Planetary gear 51 Inner disc
6 Snap ring 52 Outer disc
7 Seal plug 55 Disc carrier
10 Sun wheel 56 Lip seal
11 Ball 57 Lip seal
15 Sun gear 60 Annular piston
20 Planetary carrier (planetary stage II) 61 Pressure spring (large)
21 Stop washer 62 Pressure spring (small)
22 Planetary gear 63 Locking ring
23 Snap ring 64 Snap ring
25 Sun gear 70 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 Snap ring 76 Circlip
35 Drive shaft 95 Planetary carrier
36 Circlip 102 Oil motor
38 Ball cage 106 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
7 Sectional drawing of the travel gear system
Fig. 5 Travel gear system
11.62.9
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MJF C I F S S
11.62.10
copyright by
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 ma-
chine.
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 dri-
ve.
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 Pilot control unit, travel left 200 Travel motor, left

83 Pilot control unit, travel right 201 Travel motor, right
100 Compact control block 205 Brake valve
160 Spool / chassis right 215 Travel brake
180 Spool / chassis left 216 Travel gear
11.65.1
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MJF C I F S S
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 re-
quired 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 pis-
ton 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, com-
bined 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 posi-
tively 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 con-
nected 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
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 re-
leased.
Fig. 2 Sectional view of the travel brake
10 Carrier 110 Snap ring

20 Hub 140 Backing ring
40 Cover 160 Backing ring
70 Seal A Suspension tube
80 Seal B Planetary carrier stage III
90 Outer disc C Drive shaft / oil motor
100 Inner disc D Input pinion / gearbox
11.65.3
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MJF C I F S S
1 to hydraulic tank 212 Secondary pressure-relief valve

160 from / to spool travel right 213 Secondary pressure-relief valve
180 from / to spool travel left 214 Secondary pressure-relief valve
195 Rotary connection 5 x 215 Travel brake
196 Rotary connection 1 x 216 Travel gear
200 Travel motor, left Y24 from solenoid valve / fast travel
202 Adjusting device
203 Shifting piston, oil motor adjust- Bre Connection for brake control pressure/release
ment pressure
205 Brake valve MA Measuring point for travel high pressure
206 Shuttle valve MB Measuring point for travel high pressure
207 2-way shift valve R Connection for high pressure, reverse travel
208 Pressure reduction valve / brake 7 Leak oil connection
pressure
210 Brake line V Connection for high pressure, forward travel
211 Secondary pressure-relief valve X Connection for control pressure/fast travel
11.65.4
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MJF C I F S S
Fig. 3 Travel motors with brake valve and travel brake in travel gearbox
11.65.5
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MJF C I F S S
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 pres-
sure, 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).

mantled 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
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 ma-
chine.
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 dri-
ve.
For a description of the travel brake valves 205, see group 7.28 hydraulic components).
Fig. 1 Components of the hydraulic system and brake
82 Travel pilot control unit 200 Travel motor, left

100 Compact control block 201 Travel motor, right
160 Spool / chassis right 205 Travel brake valve
180 Spool / chassis left 215 Travel brake
216 Travel gear
11.67.1
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MJF C I F S S
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 re-
quired 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 ge-
ar.
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
pressure reducing valve 208 converts the existing high pressure into the release pressure for the mul-
ti-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 Connected carrier (planetary stage III) 55 Disc carrier

2 Snap ring 56 Lip seal
7 Seal plug 57 Lip seal
15 Sun gear (planetary stage III) 60 Annular piston
35 Drive shaft 61 Pressure spring (large)
36 Circlip 62 Pressure spring (small)
50 Thrust plate 63 Locking ring
51 Inner disc 64 Snap ring
52 Outer disc pBre Brake connection
11.67.3
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MJF C I F S S
1 to hydraulic tank 212 Secondary pressure-relief valve

160 from / to spool travel right 213 Secondary pressure-relief valve
180 from / to spool travel left 214 Secondary pressure-relief valve
195 Rotary connection 5 x 215 Travel brake
196 Rotary connection 1 x 216 Travel gear
200 Travel motor, left Y24 from solenoid valve / fast travel
202 Adjusting device
203 Shifting piston, oil motor adjust- Bre Connection for brake control pressure/release
ment pressure
205 Brake valve MA Measuring point for travel high pressure
206 Shuttle valve MB Measuring point for travel high pressure
207 2-way shift valve R Connection for high pressure, reverse travel
208 Pressure reduction valve / brake 7 Leak oil connection
pressure
210 Brake line V Connection for high pressure, forward travel
211 Secondary pressure-relief valve X Connection for control pressure/fast travel
11.67.4
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MJF C I F S S
Fig. 3 Travel motors with brake valve and travel brake in travel gearbox
11.67.5
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MJF C I F S S
Repair of the travel brake
Note!
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 pres-
sure, 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!

mantled 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 20221-
A 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 12.41.1 A 316 LI-IND 2001-28060

with multi-disc brake
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 28061-

A 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 28061-

A 316 LI-IND 28061-
MS/MT - E 3060 drive unit and differential 12.48.1 A 316 LI 28061-

A 316 LI-IND 28061-
Tyres and spacer rings 12.54.1 A 309 LI 20221-

A 311 LI 20222-
A 312 LI 12363-
A 314 LI 2001-
A 316 LI 2001-
A 316 LI-IND 2001-
Chassis / drive 12.60.1 R 313 LI 27752-

R 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 27752-

R 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 27752-

R 317 LI 18161-
Tensioning unit 12.75.1 R 313 LI 27752-

R 317 LI 18161-
Idler 12.78.1 R 313 LI 27752-

R 317 LI 18161-
Running roller 12.81.1 R 313 LI 27752-

R 317 LI 18161-
Support roller 12.84.1 R 313 LI 27752-

R 317 LI 18161-
Slide ring seal 12.86.1 R 313 LI 27752-

R 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 hou-
sings 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 com-
pensates 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
12.02.1
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MJF C I F S S
Steering axle 212 with multi-disc brake Service Manual
General information
Equipment A 309-Li A 309-Li

Unit model 717 717
Serial number 20221 21648
Axle type 212 / 440 212 / 567
Design Planetary steering axle
Total gear ratio
Standard 13.71
Speeder 13.71
Brake Wet multi-disc brake
Oil volume in axle
Differential and axle shaft 7.3 l
Planetary drive 0.8 l per side
(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 housing bearing 322 / 327 30 -60 Nm
B Friction torque of the wheel bearing 329 10 -30 Nm
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 120 Nm
2nd stage 255 -285 Nm
K Distance B of the adjusting screw 345 to the lock nut 38 1 mm
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: 50 bar
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, 116 - 128 Nm
see also group "Steering".
Q Torque of the spherical end sections of the piston rod / 240 - 270 Nm
cylinder 4 , see also group "Steering"
R Torque for the joint tie rod 5 at the cylinder, 298 - 328 Nm
S Torque for the slotted nut 6 at the joint tie rods, 260 - 290 Nm
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)
12.02.2
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MJF C I F S S
General information
secured with Loctite 242

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.
12.02.3
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MJF C I F S S
(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 diffe-
rential 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 pini-
on 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
Maintenance of the axle
Fig. 2 Inspection of brake discs for wear
12.02.5
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MJF C I F S S
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 pre-
vention regulations issued by the German Ground Construction Trade Association (Tiefbau-Berufs-
genossenschaft).
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 ax-
les.
5.3 Installation of the steering axle after repair, (see Fig. 3 on page 7)
Place the steering axle 621 in the undercarriage 620, using suitable lifting gear.
Check the oscillating axle bearing for proper functioning (i.e. reusability of thrust bushings 602).
Place the old or new thrust bushings 602 and brackets 603 on the steering axle 621 and secure
the steering axle 621 to the undercarriage, using the hex head screws 608.
Lubricate the oscillating axle bearing at the lubrication nipple 604.
Attach the universal joint shaft 610 with the nuts 611 to the differential of the steering axle 621.
Connect the brake lines to the multi-disc brake and bleed the brake (see group 15.10).
Connect the hydraulic lines to the steering cylinder and bleed the steering system (see group
13.20).
Mount the vehicle wheels 622 .
Lower the undercarriage and remove the chocks.
Tighten the wheel lugs 338 with the prescribed torque, see table 1.
12.02.6
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MJF C I F S S
Fig. 3 Dismantling and installation of the steering axle
338 Wheel lug 608 Hex head screw

601 Intermediate bushing 610 Universal joint shaft
602 Thrust bushing 611 Hex nut
603 Bracket 620 Undercarriage
604 Conical lubrication nipple 621 Steering axle
605 Plug 622 Vehicle wheels
623 Rigid axle
5.4 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-
12.02.7
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MJF C I F S S
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 Dismantling and assembly of parts for the replacement of the brake discs
12.02.8
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MJF C I F S S
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 Screw 28 Sealing ring
3 Axle shaft 29 Tapered roller bearing
4 Hex head screw 30 Wheel stud
5 Washer 31 Wheel hub
6 Intermediate bushing 32 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 Thrust bushing 38 Wheel lug
13 Bushing 40 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 Lower steering knuckle bolt 49 Locking plate
20 Sealing ring 50 Snap ring
21 Joint 57 Shim (S = 0.15 / 0.20 / 0.50)
22 Left joint housing 59 Repair kit for planetary housing
12.02.9
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MJF C I F S S
23 Sealing ring 66 Repair kit for left joint housing

25 Magnetic plug 67 Repair kit for right joint housing
26 Plug 75 Washer
76 Washer
301 Hex nut 328 Sealing ring

302 Screw 329 Tapered roller bearing
303 Axle shaft 330 Wheel stud
306 Intermediate bushing 331 Wheel hub
307 Sealing ring 332 O-ring
308 Deep groove ball bearing 333 Crown gear
309 Snap ring 334 Hollow gear carrier
310 O-ring 335 Snap ring
311 Joint 336 Planetary gear
312 Thrust bushing 337 Bearing
313 Bushing 338 Wheel lug
314 Screw 340 Countersunk screw
315 Cover 341 Planetary housing
316 Plug 342 Stud
317 Conical lubrication nipple 343 Nut
318 Upper steering knuckle bolt 344 Snap ring
319 Lower steering knuckle bolt 345 Adjusting screw
320 Sealing ring 349 Locking plate
321 Joint 350 Snap ring
322 Left joint housing 357 Shim (S = 0.15 / 0.20 / 0.50)
323 Sealing ring 375 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
Fig. 6 Output end of the steering axle
12.02.11
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MJF C I F S S
Steering axle brake
7 Steering axle brake
Fig. 7 Working brake (assembly 40)
1 Brake disc 8 Anti-extrusion ring

3 Spring 10 Counter disc
4 Piston 11 Bleeder screw
5 Spring 12 Plug
6 Anti-extrusion ring 13 Pin
7 O-ring 14 Piston repair kit
101 O-ring 402 Adjusting screw

102 Intermediate cover 403 Spring
103 Housing / differential 404 Piston
204 Tapered roller bearing 405 Spring
205 Shaft nut 406 Anti-extrusion ring
207 Allen head screw 407 O-ring
303 Axle shaft 408 Anti-extrusion ring
305 Washer 410 Counter disc
311 Joint 411 Bleeder screw
325 Screw plug 412 Plug
326 Screw plug 413 Pin
401 Brake disc
12.02.12
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MJF C I F S S
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.
12.02.13
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MJF C I F S S
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 7 Cotter pin
cylinder
5 Joint tie rod, complete 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 planetary drives.
The axle shafts contain the hydraulically operated wet multi-disc brake, which is located near the con-
nection 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
12.03.1
copyright by
MJF C I F S S
Rigid axle 112 with multi-disc brake Service Manual
Function
12.03.2
copyright by
MJF C I F S S
General information
Equipment A 309-Li
Unit model 717
Serial number 20221
Axle type 112 / 209
Design Planetary rigid axle
Total gear ratio
Standard 13.71
Speeder 13.71
Planetary drive 6.0
Oil volume in axle
A Friction torque of the wheel bearing 311 10 -30 Nm
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 1st stage 120 Nm
2nd stage 255 - 285 Nm
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 50 bar
Items A / C / D / E (see Fig. 6), item F (see Fig. 2), items B and G (see Fig. 8)

2.1 Tyre pressure

12.03.3
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MJF C I F S S
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 flan-
ge 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.
on 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 sta-
tionary crown gear 313. This results in a great speed reduction and thus increased power transmis-
sion 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).
Inspect the brake once every 12 months for damage and wear. During the annual inspection, or if
following problems occur:
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 measu-
re 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
copyright by
MJF C I F S S
Fig. 2 Inspection of brake discs for wear
12.03.5
copyright by
MJF C I F S S
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 ma-
chinery. Always comply with the safety instructions in the operating manual and the accident pre-
vention regulations issued by the German Ground Construction Trade Association (Tiefbau-
Berufsgenossenschaft).
Block the wheels of the steering axle 604 with chocks.

the rigid axle 604.
Disconnect and seal the brake line to the multi-disc brakes (collect any escaping oil).
Lift the undercarriage 600 and secure the rigid axle 604 with suitable lifting tackle.
625
600
Note!
For detailed repair instructions for the axle, refer to the separate Repair manual for Dana plane-
tary 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.
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
copyright by
MJF C I F S S
Fig. 3 Dismantling and installation of the rigid axle
319 Wheel lug 611 Universal joint shaft

332 Washer 615 Hex nut
600 Undercarriage 620 Hex head screw
602 Steering axle 622 Washer
603 Vehicle wheels 625 Hex nut / lock nut
604 Rigid axle 630 Plate
5.4 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 O-
ring 101.
Remove the brake and counter discs 401 / 410 from the gearing of the axle shaft 327.
12.03.7
copyright by
MJF C I F S S
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!
that the connection to the oil filling and check bore is not blocked when the counter disc 410 is moun-
ted.
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 Dismantling and assembly of parts for the replacement of the brake discs
101 O-ring 303 Hex head screw

103 Differential housing 304 Screw plug
107 Screw plug 327 Axle shaft
108 Screw plug 401 Brake disc
301 Axle shaft 410 Counter disc
302 Washer
12.03.8
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MJF C I F S S
Output end of the rigid axle
6 Output end of the rigid axle
Fig. 5 Output end of rigid axle (assembly 30)
1 Axle shaft 16 Snap ring

2 Washer 17 Planetary gear
3 Hex head screw 18 Roller bearing
4 Screw plug 19 Wheel lug
5 Screw plug 20 Sealing ring
6 Sealing ring 22 Countersunk screw
8 Wheel stud 23 Planetary housing
9 Wheel hub 24 Nut
10 O-ring 25 Stud
11 Tapered roller bearing 26 Thrust washer
12 Snap ring 27 Axle shaft
13 Crown gear 30 Repair kit for planetary housing
14 Hollow gear carrier 31 Washer (centring ring)
15 Locking plate 32 Washer (lock washer)
12.03.9
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MJF C I F S S
301 Axle shaft 317 Planetary gear

304 Screw plug 318 Roller bearing
306 Sealing ring 319 Wheel lug
308 Wheel stud 320 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
copyright by
MJF C I F S S
Fig. 6 Output end of the rigid axle
12.03.11
copyright by
MJF C I F S S
Brake of the rigid axle
7 Brake of the rigid axle
1 Brake disc 8 Anti-extrusion ring

3 Spring 10 Counter disc
4 Piston 11 Bleeder screw
5 Spring 12 Plug
6 Anti-extrusion ring 13 Pin
7 O-ring 14 Piston repair kit
101 O-ring 401 Brake disc

102 Intermediate cover 402 Adjusting screw
103 Housing / differential 403 Spring
201 Tapered roller bearing 404 Piston
225 Shaft nut 405 Spring
226 Allen head screw 406 Anti-extrusion ring
301 Axle shaft 407 O-ring
302 Washer 408 Anti-extrusion ring
304 Screw plug 410 Counter disc
305 Screw plug 411 Bleeder screw
327 Axle shaft 412 Plug
413 Pin
12.03.12
copyright by
MJF C I F S S
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.
12.03.13
copyright by
MJF C I F S S
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 pla-
netary outputs and thus the vehicle wheels.
Fig. 1 Differential of he steering and rigid axle
12.05.1
copyright by
MJF C I F S S
Differential for the axles 112 / 212 / 162 / 262 Service Manual
Function
12.05.2
copyright by
MJF C I F S S
General information
Equipment A 309 /311 Li

Unit model 718 / 719
Serial number 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 Dimension on the shaft circumfe-
rence 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)
B Tooth backlash of the crown wheel kit 203 / 212 0.18 - 0.23 mm
C Bearing preload of the differential bearing 201 / 204 1 - 4 Nm
213 120 - 170 Ncm
E Torque for the hex heads screws 206 / 207 or 211 / 226 24 - 26 Nm
respectively
F Torque for the hex head screws 208 / 210 128 - 142 Nm
G Torque for the hex head screws 217 145 Nm
H Torque for the nut 218 / 223 280 - 310 Nm
I Torque for the shaft nut 219 500 Nm
Items A - I (see Fig. 3 on page 7) und (see Fig. 5 on page 11)
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
12.05.3
copyright by
MJF C I F S S
General information
Assembly 10 Assembly 20
1 O-ring 1 O-ring
2 Intermediate cover 2 Shim 0.15 / 0.20 / 0.40 / 0.50
3 Housing 3 Bevel gear with crown wheel kit
4 Cover 4 Tapered roller bearing
5 Bleeder 5 Shaft nut
6 O-ring 6 Allen head screw
7 Plug 7 Allen head screw
8 Magnetic plug 8 Hex head screw
9 Thrust washer
10 Differential gear shaft wheel
Assembly 60 11 Pin
1 Intermediate bushing 12 Snap ring
2 Stop bushing 13 Thrust washer
3 Bracket 14 Balancing shaft gears
4 Conical lubrication nipple 15 Differential housing
5 Plug 16 Tapered roller bearing
6 Bracket, complete 17 Shim 0.10 / 0.15 / 0.20 / 0.30
18 Spacer ring
19 Shaft nut
20 Sealing ring
21 Protective plate
22 Flange
23 Nut
24 Snap ring
25 Repair kit for differential
12.05.4
copyright by
MJF C I F S S
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)
12.05.5
copyright by
MJF C I F S S
101 O-ring 211 Pin

102 Intermediate cover 212 Snap ring
103 Housing 213 Thrust washer
104 Cover 214 Balancing shaft gears
105 Bleeder 215 Differential housing
106 Sealing ring 216 Tapered roller bearing
107 Plug 217 Shim 0.10 / 0.15 / 0.20 / 0.30
108 Magnetic plug 218 Spacer ring
201 O-ring 219 Shaft nut
202 Shim 0.15 / 0.20 / 0.40 / 0.50 220 Sealing ring
203 Bevel gear with crown wheel kit 221 Protective plate
204 Tapered roller bearing 222 Flange
205 Shaft nut 223 Nut
206 Allen head screw 224 Snap ring
207 Allen head screw 314 Axle shaft
208 Hex head screw 334 Axle shaft
209 Thrust washer 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
4 Differential of the steering axle
Fig. 3 Sectional drawing of the differential of the steering axle
12.05.7
copyright by
MJF C I F S S
2 Intermediate cover 2 Differential housing
3 Housing 3 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 Allen head screw
12 Bevel gear with crown wheel kit
13 Tapered roller bearing
14 Shim 0.10 / 0.15 / 0.20
15 Shim 0.20 / 0.40 / 0.50
16 O-ring
17 Hex head screw
18 Nut
19 Shaft nut
20 Sealing ring
21 Protective plate
22 Cover
23 Spacer ring
24 O-ring
25 Shaft nut
26 Allen head screw
27 Flange
12.05.8
copyright by
MJF C I F S S
Differential of the rigid axle
5 Differential of the rigid axle
Fig. 4 Differential (assemblies 10 and 20)
12.05.9
copyright by
MJF C I F S S
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
104 Cover 215 Shim 0.20 / 0.40 / 0.50
105 Bleeder 216 O-ring
107 Plug 217 Hex head screw
108 Magnetic plug 218 Nut
109 Snap ring 219 Shaft nut
201 Tapered roller bearing 220 Sealing ring
202 Differential housing 221 Protective plate
203 Axle shaft wheel 222 Cover
204 Pin 223 Spacer ring
205 Snap ring 224 O-ring
208 Balancing shaft gears 227 Flange
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
Fig. 5 Sectional drawing
12.05.11
copyright by
MJF C I F S S
12.05.12
copyright by
MJF C I F S S
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 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 pres-
surised 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
pensates uneven surfaces so that all wheels of the vehicle are always in contact with the ground.
Fig. 1 Steering axle 262 LD
12.10.1
copyright by
MJF C I F S S
Steering axle 262 LD with multi-disc brake Service Manual
General information and settings
2 General information and settings
Equipment A 311-Li
Unit model 718
Serial number 20222
Axle type 262 / 056
Total gear ratio
Standard 13.71
Speeder 13.71
Oil volume in axle
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 20 Nm
D Torque for the hex nuts 303 60 - 70 Nm
E Torque for the hex head screws 304 283 Nm
G Torque for the nuts 331 148 Nm
H Setting value B for the stop screw 332 at the joint housing 36.2 1 mm
327/ 328see also group 'Steering'.
I Torque for the wheel lugs 345 460 Nm
K Torque for the nuts 347 1st stage 120 Nm
L Torque for the countersunk screws 349 40 - 50 Nm
M Torque for the nuts 356 200 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 419 128 Nm
Q Dimension X of the disc pack 415 / 416 (new) 21.0 mm
(see Fig. 3 on page 6) Wear limit 19.2 mm
R Testing of multi-disc brakes
Items A - P (see Fig. 8 on page 13), item Q (see Fig. 3 on page 6)
12.10.2
copyright by
MJF C I F S S
General information and settings
Equipment A 311-Li
Unit model 718
Serial number 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, 116 - 128 Nm
see also group 'Steering'.
U Torque of the spherical end sections of the piston rod / 240 - 270 Nm
cylinder 4 , see also group 'Steering'
V Torque for the nut at the joint tie rod 5, 298 - 328 Nm
W Torque for the slotted nut 6 / joint tie rods5, 260 - 290 Nm
Items T - W (see Fig. 7 on page 11)

2.1 Tyre pressure

12.10.3
copyright by
MJF C I F S S
3.1 Power flow in the steering axle, (see Tab. 1 on page 3)

ge 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.
on and crown wheel) to the joint 315 meshing with the axle shaft gear.
315
and the 344
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
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 re-
ferring to the repair manual for Dana planetary steering axles 262 LD.
12.10.4
copyright by
MJF C I F S S
Fig. 2 Dismantling of the wheel hub for inspection and/or replacement of the brake discs
301 Axle shaft 347 Nut

307 Screw plug 348 Planetary housing
327 Right joint housing 349 Countersunk screw
328 Left joint housing 353 Centring ring
336 Locking plate 354 Lock washer
337-339Hollow wheel, complete 404 O-ring
340 O-ring 415 Counter disc
341 Wheel hub 416 Brake disc
342 Sealing ring 417 Cover
343 Tapered roller bearing 419 Screw
345 Wheel lug
12.10.5
copyright by
MJF C I F S S
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!
that the connection to the oil filling and check bore (outer missing tooth) is not blocked when the
counter disc 415 is mounted.
5.1 Dismantling of the steering axle for repair work
Danger!
Block the wheels of the rigid axle 623 with chocks.

the steering axle.
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
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.
13.20).
Tighten the wheel lugs 345 with the prescribed torque, see Tab. 1.
Fig. 4 Installation of the steering wheel in the undercarriage
12.10.7
copyright by
MJF C I F S S
345 Wheel lug 608 Hex head screw

354 Centring ring 610 Universal joint shaft
601 Intermediate bushing 611 Hex nut
602 Thrust bushing 620 Undercarriage
603 Bracket 621 Steering axle
604 Conical lubrication nipple 622 Vehicle wheels
605 Plug 623 Rigid axle
6 Output end of the steering axle
Fig. 5 Output end of the steering axle (assembly 30)
1 Axle shaft 30 Lower steering knuckle bolt

2 Screw 31 Nut
3 Hex nut 32 Adjusting screw
4 Hex head screw 33 Bearing
5 Washer 34 Planetary gear
7 Plug 35 Snap ring
8 Magnetic plug 36 Locking plate
9 Snap ring 37 Hollow gear carrier
10 Snap ring 38 Crown gear
12.10.8
copyright by
MJF C I F S S
11 Deep groove ball bearing 39 Snap ring

12 Sealing ring 40 O-ring
13 Intermediate bushing 41 Wheel hub
14 O-ring 42 Sealing ring
15 Joint 43 Tapered roller bearing
16 Sealing ring 44 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 Sealing ring 51 Magnetic plug
26 Bushing 56 Nut
27 Right joint housing 57 Stud
28 Left joint housing 60 Repair kit for left joint housing
29 Joint 61 Repair kit for right joint housing
12.10.9
copyright by
MJF C I F S S
Steering axle brake
7 Steering axle brake
1 Plug 12 Adjusting screw

2 Bleeder screw 13 Spring
3 Pin 14 Adjusting screw
4 O-ring 15 Counter disc
6 Outer anti-extrusion ring 17 Cover
7 Piston 19 Screw
8 Inner O-ring 20 Screw plug
9 Inner anti-extrusion ring 21 Sealing ring
10 Counter disc 22 Screw
11 Spring
12.10.10
copyright by
MJF C I F S S
8 Steering cylinder of the steering axle
Fig. 7 Steering cylinder in differential (assembly 50)
1 Allen head screw 6 Slotted nut

4 Steering cylinder, complete, see group 13.33 Stee- 7 Cotter pin
ring cylinder
5 Joint tie rod, complete 10 Differential, complete
Note!
Observe torques T - W for repairs of the axle, Tab. 1 page 3.
12.10.11
copyright by
MJF C I F S S
301 Axle shaft 339 Snap ring

302 Screw 340 O-ring
303 Hex nut 341 Wheel hub
307 Plug 342 Sealing ring
309 Snap ring 343 Tapered roller bearing
310 Snap ring 40 344 Wheel stud
311 Deep groove ball bearing 345 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 Thrust bushing 402 Bleeder screw
318 Screw 403 Pin
320 Plug 404 O-ring
321 Conical lubrication nipple 405 O-ring
322 Upper steering knuckle bolt 406 Outer anti-extrusion ring
323 Shim (S = 0.15 / 0.20 / 0.50) 407 Piston
324 Sealing ring 408 Inner O-ring
326 Bushing 409 Inner anti-extrusion ring
327 Right joint housing 410 Counter disc
328 Left joint housing 411 Spring
329 Joint 412 Adjusting screw
330 Lower steering knuckle bolt 413 Spring
331 Nut 414 Adjusting screw
332 Adjusting screw 415 Counter disc
333 Bearing 416 Brake disc
334 Planetary gear 417 Cover
335 Snap ring 419 Screw
336 Locking plate 420 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
Fig. 8 Output system and working brake of the steering axle
12.10.13
copyright by
MJF C I F S S
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
12.11.1
copyright by
MJF C I F S S
Rigid axle 162LD with multi-disc brake Service Manual
Function
12.11.2
copyright by
MJF C I F S S
General information
Equipment A 311-Li
Unit model 718
Serial number 20222
Axle type 162 / 056
Total gear ratio
Standard 13.71
Speeder 13.71
Oil volume in axle
A Friction torque of the wheel bearing 324 10 - 30 Nm
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 40 - 50 Nm
E Torque for the nuts 322 1st stage 120 Nm
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 425 219 - 242 Nm
L Dimension X of the disc pack 421 / 422 (new) 21 mm
(see Fig. 3 page 6) Wear limit 19.2 mm
M Checking of the multi-disc brakes:
Items A - K (see Fig. 7 page 13), item L (see Fig. 3 page 6)

2.1 Tyre pressure

12.11.3
copyright by
MJF C I F S S
3.1 Power flow in the rigid axle, (see Fig. 7 page 13)
ge 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.
on 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 sta-
tionary 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).
Also carry out a wear check of the brake discs 422, if any of the
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 re-
ferring to the repair manual for Dana planetary rigid axles 162 LD.
12.11.4
copyright by
MJF C I F S S
Fig. 2 Dismantling of the wheel hub for inspection and/or replacement of the brake discs
301 Axle shaft 324 Tapered roller bearing

306 Sealing ring 325 Wheel hub
308 Wheel lug 331 Centring ring
309 O-ring 332 Lock washer
310-312Hollow wheel, complete 406 Cover
313 Locking plate 408 O-ring
319 Countersunk screw 422 Brake disc
320 Planetary housing 423 Cover
321 Thrust washer 425 Screw
322 Nut
12.11.5
copyright by
MJF C I F S S
4.1 Checking of discs for wear (see Fig. 2 page 5)

422 406/423
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 Dimension X for brake disc wear check
Note!
that the connection to the oil filling and check bore is not blocked when the counter disc 421 is moun-
ted.
12.11.6
copyright by
MJF C I F S S
5.1 Dismantling of the rigid axle for repair work, see Fig. 4
Danger!
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.
Loosen the hex head screws 615 and remove the universal joint shaft 611.
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.
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

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.
Lower the undercarriage 600 and remove the chocks.
Tighten the wheel lugs 308 with the prescribed torque, see Tab. 1.
12.11.7
copyright by
MJF C I F S S
Fig. 4 Dismantling and installation of the rigid axle
308 Wheel lug 611 Universal joint shaft

332 Lock washer 615 Hex nut
602 Steering axle 622 Washer
603 Vehicle wheels 625 Hex nut
604 Rigid axle 630 Plate
12.11.8
copyright by
MJF C I F S S
Sectional drawing of the rigid axle
6 Sectional drawing of the rigid axle
Fig. 5 Output end of rigid axle (assembly 30)
1 Axle shaft 18 Plug

2 Hex head screw 19 Countersunk screw
3 Washer 20 Planetary housing
4 Screw plug 21 Thrust washer
5 Screw plug 22 Wheel lug
6 Sealing ring 23 Stud
7 Wheel stud 24 Tapered roller bearing
8 Wheel lug 25 Wheel hub
9 O-ring 26 Axle shaft
10 Snap ring 27 Repair kit for planetary housing
11 Crown gear 28 Stud
12 Hollow gear carrier 29 Hex nut
13 Locking plate 30 Sealing ring
14 Snap ring 31 Centring ring
15 Planetary gear 32 Lock washer
16 Bearing
12.11.9
copyright by
MJF C I F S S
7 Brake of the rigid axle
1 O-ring 14 Spring washer

2 Sealing ring 15 Hex head screw
4 Plug 17 Spring
5 Bleeder screw 19 Spring
6 Cover 20 Adjusting screw
7 Pin 21 Counter disc
9 O-ring 23 Cover
10 Outer anti-extrusion ring 25 Screw
11 Piston 26 Screw
12 Inner O-ring 27 Magnetic plug
13 Inner anti-extrusion ring
12.11.10
copyright by
MJF C I F S S
12.11.11
copyright by
MJF C I F S S
102 Intermediate cover 329 Hex nut

103 Differential housing 330 Sealing ring
301 Axle shaft 331 Centring ring
302 Hex head screw 332 Lock washer
303 Washer 401 O-ring
306 Sealing ring 404 Plug
307 Wheel stud 405 Bleeder screw
308 Wheel lug 406 Cover
309 O-ring 407 Pin
311 Crown gear 409 O-ring
312 Hollow gear carrier 410 Outer anti-extrusion ring
313 Locking plate 411 Piston
314 Snap ring 412 Inner O-ring
315 Planetary gear 413 Inner anti-extrusion ring
316 Bearing 414 Spring washer
319 Countersunk screw 416 Counter disc
320 Planetary housing 417 Spring
321 Thrust washer 418 Adjusting screw
322 Nut 419 Spring
323 Stud 420 Adjusting screw
324 Tapered roller bearing 421 Counter disc
325 Wheel hub 422 Brake disc
326 Axle shaft 423 Cover
328 Stud 425 Hex head screw
Note!
A-K
12.11.12
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MJF C I F S S
Fig. 7 Output system and working brake of the rigid axle
12.11.13
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MJF C I F S S
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 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 multi-
disc brake. It is applied when the brake pedal (working brake) is operated and the brake is pressuri-
sed with brake oil.
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 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
12.20.1
copyright by
MJF C I F S S
Steering axle Service Manual
Function
12.20.2
copyright by
MJF C I F S S
Technical data
2 Technical data
Series Litronic Litronic

Machine A 312 A 312
Machine model 719 719
Axle type 262/51 262/53
Ratio wheel hub input : total input 17.5
Oil volume in axle 8,2 l
Wheel hub 3,0 l
Oil quality/viscosity API-GL-5/SAE 90 LS
A Friction torque of the joint bearing 3.26 and 3.27 30 - 60 Nm
B Friction torque of the wheel bearing hub 3.47 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 Tightening torque of the nuts 3.18 initial 120 Nm
final 285 Nm
F 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 Tightening torque of the nuts 3.28 148 Nm
K Tightening torque of the slotted nuts/tie rod 5.1 260 - 290 Nm
L Tightening torque of 5.3 116 - 128 Nm
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 53 Nm
P Check of multi-disc brakes:
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
2.1 Tyre pressure

12.20.3
copyright by
MJF C I F S S
3.1 Power flow in the steering axle

The input torque of the transmission is transmitted through the universal joint shaft to the output flan-
the differential spider with balancing and axle shaft gears, which is borne in the cage, see Fig. 7.
on 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).
Danger!
For maintenance work on the axles, the undercarriage of the machine must be accessed. This po-
ses a great danger for mechanics.
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 gre-
ase 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 tes-
ting 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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MJF C I F S S
Fig. 2 Maintenance of the axle
8.1 Plug 3.47 Wheel hub

3.2 Seal ring 4.9 Brake discs
3.32 Gear 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 replace-
ment!).
Check the dimension X of the complete disc pack using a calliper gauge:
nominal dimension X at the new brake discs = 44.850.75 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.
12.20.5
copyright by
MJF C I F S S
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 ma-
chine. There is a risk of death to the technician, as limbs could become crushed.
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.

Block the wheels of the rigid axle 111 with chocks. Lift the undercarriage 130 and secure the
12.20.6
copyright by
MJF C I F S S
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 stee-
ring axle 110.
Connect the hydraulic lines to the steering cylinder and bleed the steering system. For detailed
instructions, see group 13.10/13.20/13.32.
12.20.7
copyright by
MJF C I F S S
Exploded view of the steering axle
8 Exploded view of the steering axle
Fig. 4 Output
1 Differential, see group 12.23 3.26 Joint housing

3 Output, complete 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 Hex head screw 3.31 Planetary gear
3.5 Nut 3.32 Gear
3.6 Screw 3.33 Hollow gear carrier
3.7 Outer race 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 3.38 Nut
3.12 Intermediate bushing 3.39 Locking plate
3.13 O-ring 3.40 Stud
12.20.8
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MJF C I F S S
3.14 Joint 3.41 Snap ring

3.15 Seal ring 3.42 Bearing
3.16 Bearing 3.43 O-ring
3.17 Steering knuckle bolt 3.44 Nut
3.18 Screw 3.45 Wheel stud
3.19 Cover 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 3.53 Lock washer
3.24 Spacer ring 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 4.12 Brake disc
3.32 Gear 4.13 Spring
3.33 Hollow gear carrier, see Fig. 4 4.14 Adjusting screw
4 Brake, complete 4.16 Pin
4.1 Bleeder screw 4.17 O-ring
4.2 Plug 4.18 Seal ring
12.20.9
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MJF C I F S S
4.8 Ring 4.19 Screw plug

4.9 Brake disc 4.20 Piston repair kit
4.10 Counter disc
Fig. 6 Steering cylinder
1 Differential, complete, see page 12.23-05 5.2 Cylinder

5 Steering cylinder, complete 5.3 Allen head screw
5.1 Joint tie rod
12.20.10
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MJF C I F S S
Sectional drawing of steering axle
9 Sectional drawing of steering axle
Fig. 7 Steering axle with disc brake
12.20.11
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MJF C I F S S
1 Differential, see group 12.23 3.31 Planetary gear

3 Output, complete 3.32 Gear
3.1 Plug 3.33 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 Nut 3.37 Countersunk screw
3.6 Screw 3.38 Nut
3.7 Outer race 3.39 Locking plate
3.8 Snap ring 3.40 Stud
3.9 Snap ring 3.41 Snap ring
3.10 Deep groove ball bearing 3.42 Bearing
3.11 Seal ring 3.43 O-ring
3.12 Intermediate bushing 3.44 Nut
3.13 O-ring 3.45 Wheel stud
3.14 Joint 3.47 Wheel hub
3.15 Seal ring 3.48 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 Cover 4.1 Bleeder screw
3.20 Plug 4.2 Plug
3.21 Conical lubrication nipple 4.8 Ring
3.22 Shim ring 4.9 Brake disc
3.23 Dust sealing ring 4.10 Counter disc
3.24 Spacer ring 4.11 Allen head screw
3.25 Steering knuckle bolt 4.12 Brake disc
3.26 Joint housing 4.14 Adjusting screw
3.27 Joint housing 4.17 O-ring
3.28 Nut 4.20 Piston repair kit
3.29 Stop screw
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
copyright by
MJF C I F S S
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 bra-
ke. 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
12.21.1
copyright by
MJF C I F S S
Rigid axle Service Manual
Technical data
2 Technical data
Series Litronic
Machine A 312
Machine model 719
Serial number 12363
Axle type 162/55
Ratio wheel hug input : total input 17.5/6.0
Brake West multi-disc brake
Oil volume in axle Axle support/ total 10.5. l
differential/wheel hub
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:
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
2.1 Tyre pressure

12.21.2
copyright by
MJF C I F S S
3.1 Power flow in the rigid axle

See also sectional drawing Fig. 6 and drawing on page 12.23-11.
ge 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.
on 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).
Danger!
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).
schedule.
12.21.3
copyright by
MJF C I F S S
Dismantling of the rigid axle for repair work
8.2 Wheel hub 3.28 Hex head screw

3.4 Magnetic plug 4.1 Brake discs
3.9 Spring washer 4.2 Counter discs
3.10 Cover X Nominal dimension/limit dimension
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 = 44.850.75 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 machi-
ne. There is a risk of death to the technician, as limbs could become crushed.
12.21.4
copyright by
MJF C I F S S
Repair of the rigid axle
Fig. 3 Dismantling and installing the rigid axle
110 Steering axle 117 Hex nut

111 Rigid axle 127 Hex head screw
112 Vehicle wheels 128 Nut
115 Universal joint shaft 129 Washer
If required, remove the vehicle wheels 112 from the rigid axle.
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.
12.21.5
copyright by
MJF C I F S S
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 (tigh-
tening 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.
12.21.6
copyright by
MJF C I F S S
Exploded view of the rigid axle
8 Exploded view of the rigid axle
Fig. 4 Output
1 Differential, see group 12.23 3.16 Bearing

3 Output, complete 3.17 Snap ring
3.1 Planetary housing 3.18 Gear
3.2 Wheel hub 3.19 Axle shaft
3.3 Bearing 3.20 Axle shaft
3.4 Magnetic plug 3.21 Hex head screw
3.5 Plug 3.22 Washer
3.6 Intermediate bushing 3.23 Pin
3.7 O-ring 3.24 Seal ring
3.8 Allen head screw 3.25 Plug washer
3.9 Spring washer 3.26 Plug
3.10 Cover 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
12.21.7
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MJF C I F S S
3.15 Washer
Fig. 5 Brake
3.10 Cover, see Fig. 4 4.6 Piston

4 Brake, complete 4.7 O-ring
4.1 Brake disc 4.8 Ring
4.2 Counter disc 4.9 Spring
4.3 Ring 4.10 Adjusting screw
4.5 Spring
12.21.8
copyright by
MJF C I F S S
Fig. 6 Rigid axle with multi-disc brake
12.21.9
copyright by
MJF C I F S S
3 Output, complete 3.22 Washer

3.1 Planetary housing 3.23 Pin
3.2 Wheel hub 3.24 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 Intermediate bushing 3.28 Hex head screw
3.7 O-ring 3.29 Thrust washer
3.8 Allen head screw 3.33 Centring ring
3.9 Spring washer 3.34 Lock ring
3.10 Cover 4 Brake, complete
3.11 Seal ring 4.1 Brake disc
3.12 Wheel stud 4.2 Counter disc
3.13 Nut 4.3 Ring
3.14 Planetary gear 4.4 Adjusting screw
3.15 Washer 4.5 Spring
3.16 Bearing 4.6 Piston
3.17 Snap ring 4.7 O-ring
3.18 Gear 4.8 Ring
3.19 Axle shaft 4.9 Spring
3.20 Axle shaft 4.10 Adjusting screw
3.21 Hex head screw 4.11 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 pla-
netary outputs and thus the vehicle wheels.
Fig. 1 Differential of the steering and rigid axle
12.23.1
copyright by
MJF C I F S S
Differential for 162 / 262 axles Service Manual
Function
12.23.2
copyright by
MJF C I F S S
Technical data
2 Technical data
Machine A 312 Li
Machine model 719
Serial number 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 Dimension on the shaft circumfe-
rence 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)
B Tooth backlash of the crown wheel kit 203 / 212 0.13 - 0.18 mm
(through nut 205 / 225 )
D Rolling resistance of the input pinion bearing 213 / 120 - 170 Ncm
216
(increase or reduce shim thickness (+ / -) 60 Ncm
by 0.01 mm)
E Torque for the hex heads screws 206 / 207 or 211 / 226 24 - 26 Nm
respectively
F Torque for the hex head screws 208 / 210 128 - 142 Nm
G Torque for the hex head screws 217 90 - 100 Nm
H Torque for the nut 218 / 223 280 - 310 Nm
I Torque for the shaft nut 219 500 - 570 Nm
Items A - I (see Fig. 3 on page7) and (see Fig. 5 on page11)
Note!
"162 / 262 Dana axles"
Position on steering axle

Position on rigid axle
12.23.3
copyright by
MJF C I F S S
Exploded view of the differential of the steering axle
3 Exploded view of the differential of the steering axle
1 O-ring 1 O-ring
2 Intermediate cover 2 Shim 0.15 / 0.20 / 0.40 / 0.50 mm
3 Housing 3 Bevel gear with crown wheel kit
4 Lid 4 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 11 Pin
1 Intermediate bushing 12 Snap ring
2 Thrust bushing 13 Thrust washer
3 Support bracket 14 Balancing shaft gear
4 Conical lubrication nipple 15 Differential housing
5 Plug 16 Tapered roller bearing
6 Bracket, complete 17 Shim 0.10 / 0.15 / 0.20 / 0.30 mm
18 Spacer ring
19 Shaft nut
20 Seal ring
21 Protective plate
22 Flange
23 Nut
24 Snap ring
12.23.4
copyright by
MJF C I F S S
Fig. 2 Exploded view of the differential (assemblies 10 and 20)

and the oscillating axle bearing (assembly 60)
12.23.5
copyright by
MJF C I F S S
4 Exploded view of the differential of the steering axle
101 O-ring 211 Pin

102 Intermediate cover 212 Snap ring
103 Housing 213 Thrust washer
104 Lid 214 Balancing shaft gear
105 Bleeder 215 Differential housing
106 Seal ring 216 Tapered roller bearing
107 Plug 217 Shim 0.10 / 0.15 / 0.20 / 0.30 mm
108 Magnetic plug 218 Spacer ring
201 O-ring 219 Shaft nut
202 Shim 0.15 / 0.20 / 0.40 / 0.50 mm 220 Seal ring
203 Bevel gear with crown wheel kit 221 Protective plate
204 Tapered roller bearing 222 Flange
205 Shaft nut 223 Nut
206 Allen head screw 224 Snap ring
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
Fig. 3 Sectional drawing of the differential of the steering axle
12.23.7
copyright by
MJF C I F S S
Exploded view of the differential of the rigid axle
5 Exploded view of the differential of the rigid axle
2 Intermediate cover 2 Differential housing
3 Housing 3 Axle shaft wheel
4 Lid 4 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 Hex head screw
11 Allen head screw
12 Bevel gear with crown wheel kit
13 Tapered roller bearing
14 Shim 0.10 / 0.15 / 0.20 mm
15 Shim 0.20 / 0.40 / 0.50 mm
16 O-ring
17 Hex head screw
18 Nut
19 Shaft nut
20 Seal ring
21 Protective plate
22 Lid
23 Spacer ring
24 O-ring
25 Shaft nut
26 Allen head screw
27 Flange
12.23.8
copyright by
MJF C I F S S
Exploded view of the differential of the rigid axle
Fig. 4 Differential (assemblies 10 and 20)
12.23.9
copyright by
MJF C I F S S
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 Bleeder 216 O-ring
108 Magnetic plug 218 Nut
201 Tapered roller bearing 220 Seal ring
202 Differential housing 221 Protective plate
203 Axle shaft wheel 222 Lid
204 Pin 223 Spacer ring
208 Balancing shaft gear 227 Flange
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
Fig. 5 Sectional drawing of the differential of the rigid axle
12.23.11
copyright by
MJF C I F S S
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
wheels, is equipped with a built-in differential.
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.
Fig. 1 APL - B 745 steering axle
12.28.1
copyright by
MJF C I F S S
APL - B 745 steering axle with multi-disc brake Service Manual
Function
12.28.2
copyright by
MJF C I F S S
Technical data
2 Technical data
Machine A 314 Litronic A 314 Litronic

Axle type APL - B 745
Gear ratio
Standard 17,52 16,62
Speeder 17,52 16,62
Oil volume in axle
Axle housing 7.5 l
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 2.5 - 2.9 mm
at max. wear 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 1550 + 500 Nm
H Torque for the Allen head screws 103 32 Nm
Tightening torque of the slotted nut / tie rods, 300 Nm
see steering cylinder
K Multi-disc brakes:
Max. pressure drop after 5 min. 3 bar
Low pressure test 5 bar
Visible pressure drop after 15 seconds is not permissible
Items A - K, (see Fig. 7, page 11)
2.1 Tyre pressure

12.28.3
copyright by
MJF C I F S S
3.1 Power flow in the steering axle, (see Fig. 7, page 11)
The sun gear shaft 91, which is connected through the disc carrier 92 to the double joint drive shaft
20, drives the planetary gears 95. These roll off on the stationary hollow gear 68. This results in a
great speed reduction and associated power transmission to the rotating planetary carrier 94. The
planetary carrier 94 drives the vehicle wheels through the wheel studs 104 with the respective force
and speed (based on the overall gear ratio).
Danger!
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.
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:
Changes in the oil level in the wheel hub
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 car-
rier.
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
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
Danger!
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.
12.28.5
copyright by
MJF C I F S S
Note!
For detailed repair instructions for the axle, refer to the separate "Repair manual for APL-B 745
ZP axles".

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.
13.20).
Tighten the wheel lugs with the prescribed torque, see Tab. 1.
Fig. 3 Undercarriage with axles
1 Vehicle wheels 8 Bolt

2 Hex head screw 9 Spacer
3 Joint shaft 10 Lubrication nipple
4 Steering axle 11 Lock nut
5 Undercarriage 12 Rigid axle
12.28.6
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MJF C I F S S
6 Hex head screw 13 Disc

7 Plate 14 Retaining washer
Fig. 4 Steering axle (assembly 17)
.10 Axle housing .290 Stub shaft

.30 Axle housing .330 Snap ring
.40 Bearing bushing .340 Bushing
.50 Washer (S = 0.5 - 2.0mm) .350 Radial shaft seal ring
.90 Roller bearing .550 Left tie rod
.100 Roller bearing .560 Right tie rod
.120 O-ring .600 Axial joint
.130 Hex head screw .605 Bellows
.140 Disc .610 Right ball joint, complete
.150 Fit bolt .611 Left ball joint, complete
.240 Screw plug .620 Clamp
.250 Screw plug .630 Slotted nut
.260 O-ring .640 Cotter pin
12.28.7
copyright by
MJF C I F S S
Fig. 5 Joint housing (assembly 18)
.10 Left joint housing .130 Lubrication nipple

.10 Right joint housing .150 Bushing
.10 Slotted nut .160 Radial shaft seal ring
.50 Roller bearing .170 Universal joint
.80 Sealing cap .200 Snap ring
.90 O-ring .270 Plug
.100 Washer (S = 1.2 - 2.0mm) .390 Bleeder valve
.114 Bearing pin .480 Stop washer (S = 2.0 - 6.0 mm)
.120 Hex head screw .500 Stop screw
12.28.8
copyright by
MJF C I F S S
Fig. 6 Output (assembly 19)
.10 Radial shaft seal ring .290 End washer

.30 Roller bearing .300 Snap ring
.40 Ring (S = 14.0 - 15.0 mm) .320 Thrust washer
.50 Roller bearing .340 Sun gear shaft
.80 Hub .350 Disc carrier
.90 O-ring .360 Snap ring
.120 Plug .370 Snap ring
.130 O-ring .390 Planetary carrier
.140 Junk ring .400 Planetary gear
.150 Snap ring .410 Roller bearing
.160 Hollow gear .420 Junk ring
.200 Piston .430 Snap ring
.210 Lip seal .480 Thrust washer (S = 2.0 3.0 mm)
.214 Backing ring .490 O-ring
.220 Lip seal .500 Screw plug (oil drainage)
.230 Backing ring .510 Allen head screw
.232 Backing washer .540 Wheel stud
.238 Pressure spring .550 Lock washer
.248 Lock nut .560 Centring ring
.256 Hex head screw .570 Wheel lug
.258 Spring sleeve .620 Screw plug (measuring bore)
.270 Outer disc (S = 2.0 3.0 mm) .630 O-ring
.280 Inner disc
12.28.9
copyright by
MJF C I F S S
Item ZP figure Description Item ZP figure Description

no. no.
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 81 19256 Hex head screw
shaft
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
Fig. 7 Sectional drawing of steering axle(see Fig. 7, page 11)
12.28.11
copyright by
MJF C I F S S
12.28.12
copyright by
MJF C I F S S
Service Manual AP - B 745 rigid axle with drum brake
Function
AP - B 745 rigid axle with drum brake
1 Function
is equipped with a built-in differential.
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
12.29.1
copyright by
MJF C I F S S
AP - B 745 rigid axle with drum brake Service Manual
Technical data
2 Technical data
Machine A 314 Li A 314 Li

Axle type AP-B 745
Gear ratio
Standard 17,52 16,62
Speeder 17,52 16,62
Brake Drum brake
Oil volume in axle
Axle housing and planetary drive 10.4 l
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) 8 - 12 Nm
(without sealing element)
C Torque for the hex head screw 3 560 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
K Check of drum brakes 20: 2 mm
Residual lining thickness of the brake system (glued) min.
Items A, B, D- K (see Fig. 6, page 9) and item C (see Fig. 2, page 4)
2.0.1 Tyre pressure

12.29.2
copyright by
MJF C I F S S
3.1 Power flow in the rigid axle, see Fig. 6

on 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 plane-
tary 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).
Danger!
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.
5.1 Dismantling of the rigid axle for repair work
Danger!
Lift the undercarriage at the rear and secure the wheels of the steering axle 6 using chocks.
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
12.29.3
copyright by
MJF C I F S S
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 under-
carriage 9.
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).
1 Vehicle wheels 6 Steering axle

2 Rigid axle 7 Hex nut
12.29.4
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MJF C I F S S
5 Drive shaft
Fig. 3 Axle housing, group 17
17010 Axle housing part I 17150 Fit bolt

17030 Axle housing part II 17240 Screw plug
17050 Washer (S = 0.10 - 2.0mm) 17250 Screw plug
17090 Roller bearing 17260 O-ring
17100 Roller bearing 17290 Stub shaft
17120 O-ring 17690 Sleeve
17130 Hex head screw 17700 Snap ring
17140 Disc
12.29.5
copyright by
MJF C I F S S
Fig. 4 Hub carrier, group 22 and drum brake, group 2 (1 = old) and (400 = new)
1 Brake (old) 350 Locking plate

10 Brake drum 370 Tension spring
50 Adapter 400 Brake (new)
60 Brake disc 410 Adapter
70 Bolt 420 Wheel cylinder
80 Disc spring 430 Allen head screw
90 Disc 440 Disc
100 Hex nut 510 Hub carrier
120 Countersunk screw 510 Slotted nut
170 Wheel cylinder 570 Allen head screw
180 Lock washer 580 Allen head screw
270 Brake pad 610 Retainer plate
340 Bolt
12.29.6
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MJF C I F S S
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 Roller bearing 420 Junk ring
40 Ring (S = 14.0 - 15.2 mm) 430 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 Hollow gear 510 Allen head screw
184 Locking plate 540 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
12.29.7
copyright by
MJF C I F S S
ZP figure ZP figure
Item Description Item Description
no. no.
Group 17 Group 19
1 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
Group 2 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
Group 22 101 490 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
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
copyright by
MJF C I F S S
Fig. 6 Sectional drawing of rigid sleeve
12.29.9
copyright by
MJF C I F S S
12.29.10
copyright by
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.
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
12.30.1
copyright by
MJF C I F S S
AP - B 745 rigid axle Service Manual
Technical data
2 Technical data
Series Litronic Litronic

Machine A 314 A 314
Axle type AP-B 745
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
new 2.5 - 2.9 mm
at max. wear 5.0 mm
C Rolling resistance of the wheel bearing 61 (new) 8 - 12 Nm
D Torque for the slotted nut 31 1550+500 Nm
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 Tightening torque for the nuts 3.18 560 Nm
K Check of multi-disc brakes:
For items A - H, seesee Fig. 7
Item I, see Fig. 3
2.1 Tyre pressure

12.30.2
copyright by
MJF C I F S S
3.1 Power flow in the rigid axle

See also sectional drawing Fig. 7 and drawing on page 12.31-09.
The sun gear 91, which is connected through the disc carrier 92 to the stub shaft 7, drives the pla-
netary gears 95. These roll off on the stationary hollow gear 68. This results in a great speed reduc-
tion 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).
Danger!
inspection and maintenance schedule in group 3. Regularly check the wheel lugs 107 for the correct
tightening torque, (see Tab. 1 on page 2).
schedule.
The manufacturer also prescribes regular inspections of the disc lining for wear.
12.30.3
copyright by
MJF C I F S S
Dismantling of the rigid axle for repair work
1 M16 screw plug 2 M16 measuring screw
This check should be carried out annually or if any of the following occur:
or unusual brake noises

Turn the wheel hub until the small M16 screw plug is at the top, see Fig. 2.
Remove the screw plug and screw in the M16 measuring plug (tool ID no. 7019556) to the stop;
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
Calculate the difference between the two measurements X and Y. This value corresponds to the pis-
ton stroke.
If the permissible limit value is exceeded, replace all brake discs.
5 Dismantling of the rigid axle for repair work
Danger!
issued by the German Ground Construction Trade Association (Tiefbau-Berufsgenossenschaft).
12.30.4
copyright by
MJF C I F S S
Repair of the rigid axle
Fig. 3 Dismantling and installing the rigid axle
110 Steering axle 127 Hex head screw

111 Rigid axle 128 Nut
112 Vehicle wheels 129 Washer
115 Universal joint shaft 130 Undercarriage
117 Hex head screw
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
axles with multi-disc brakes" .
12.30.5
copyright by
MJF C I F S S
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).
12.30.6
copyright by
MJF C I F S S
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) 17 240 Screw plug
17 090 Roller bearing 17 250 Screw plug
17 100 Roller bearing 17 260 O-ring
17 120 O-ring 17 290 Stub shaft
17 130 Hex head screw
12.30.7
copyright by
MJF C I F S S
Hub carrier
9 Hub carrier
Fig. 5 Hub carrier
22 010 Hub carrier complete with 22 090 O-ring

22 010 Slotted nut 22 110 Retainer plate
22 050 Washer 22 160 Bleeder valve
22 070 Allen head screw
12.30.8
copyright by
MJF C I F S S
Output
10 Output
Fig. 6 Output
19 010 Radial shaft seal ring 22 290 End washer

19 040 Ring (14.0 - 15.0 mm) 22 320 Thrust washer
19 050 Roller bearing 22 340 Sun gear shaft
19 080 Hub 22 350 Disc carrier
19 090 O-ring 22 370 Snap ring
19 120 Plug 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 22 430 Snap ring
19 200 Piston 22 480 Thrust washer (s=2.0 - 3.0 mm)
19 210 Lip seal 22 490 O-ring
19 214 Ring 22 500 Screw plug (oil drainage)
19 230 Backing ring 22 510 Allen head screw
19 232 Back-up washer 22 540 Wheel stud
12.30.9
copyright by
MJF C I F S S
Output
19 238 Pressure spring 22 550 Lock washer

19 248 Lock nut 22 560 Centring ring
19 256 Allen head screw 22 570 Wheel lug
19 258 Spring sleeve 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 Rigid axle with multi-disc brake
12.30.10
copyright by
MJF C I F S S
Output
Item ZP figure Designation Item ZP figure Designation

no. no.
1 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).
12.30.11
copyright by
MJF C I F S S
Output
12.30.12
copyright by
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 me-
chanical 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 re-
sult 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
12.31.1
copyright by
MJF C I F S S
Differential for AP / APL - B 745 axles Service Manual
Technical data
2 Technical data

Machine model 635
Serial number 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.
A Setting value of the crown wheel kit 20 (etched onto the end side of
the pinion 20.1)
B Tooth backlash of the crown wheel kit 20 0.15 - 0.25 mm
0.18 - 0.23 mm (Speeder)
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
Items A - G (see Fig. 5)
Note!
"AP / APL - B 745 ZP axles".
12.31.2
copyright by
MJF C I F S S
Exploded view of the differential
3 Exploded view of the differential
Fig. 2 Input (assembly 16)
10 Bevel gear kit (crown wheel and bevel 210 Input flange
pinion)
50 Washer (S = 1.0 - 1.5 mm) 220 Valance
80 Tapered roller bearing 270 Washer
110 Ring (S = 11.6 - 12.38 mm) 290 Hex nut
160 Tapered roller bearing 310 Locking plate
190 Radial shaft seal ring
12.31.3
copyright by
MJF C I F S S
Fig. 3 Differential (assembly 73)
10 Crown wheel 720 Differential spider

570 Differential cage 800 Allen head screw
640 Axle shaft gear 850 Washer
650 Thrust washer 860 Connex heavy-duty spring pin
670 Balancing shaft gear 870 Roll pin S
680 Thrust washer
12.31.4
copyright by
MJF C I F S S
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 Bearing bushing .260 Seal
.50 Washer (S = 0.1 - 2.0 mm) .290 Stub shaft
.90 Roller bearing .330 O-ring
.100 Roller bearing .340 Bearing bushing
.120 O-ring .350 Seal ring
.130 Hex head screw .690 Bearing bushing
.140 Washer .700 Seal ring
.150 Fit bolt
12.31.5
copyright by
MJF C I F S S
Sectional drawing of the differential
5 Sectional drawing of the differential
ZP figure ZP figure
Item Designation Item Designation
no. no.
1.1 17010 Axle housing I 16 16160 Tapered roller bea-
ring
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 bea-
ring
3 17090 Tapered roller bea- 20.1 16010 Bevel pinion
ring
4 17100 Tapered roller bea- 20.2 16010 Crown wheel
ring
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
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.
12.31.6
copyright by
MJF C I F S S
Fig. 5 Sectional drawing of the differential
12.31.7
copyright by
MJF C I F S S
12.31.8
copyright by
MJF C I F S S
Function
APL - B 755 steering axle with multi-disc brake
1 Function
12.36.1
copyright by
MJF C I F S S
Function
12.36.2
copyright by
MJF C I F S S
Technical data
2 Technical data

Machine model 715
Serial number 2001
Axle type APL - B 755
Gear ratio
Standard 17.52
Speeder 17.52
Oil volume in axle
Axle housing 9.0 l
A End play of the double joint drive shaft 20 0.3 - 0.6 mm
new 3.1 - 3.5 mm
at max. wear 5.0 mm
D Rolling resistance of the wheel bearing 61/64 (new) 8 - 12 Nm
E Torque for the slotted nut 32 1400 + 500 Nm
see steering
K Multi-disc brakes:
Low pressure test 1 - 5 bar
Items A - K ((see Fig. 7 on page11))
2.0.1 Tyre pressure

12.36.3
copyright by
MJF C I F S S
3.1 Power flow in the steering axle, (see Fig. 7 on page11)

Danger!
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).
be changed at fixed intervals laid down in the maintenance instructions.

Turn wheel hub until the small screw plug M16 is at the top, see Fig. 2.
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
to the piston stroke.
Note!
Danger!
Remove the hex head screws 6 and the plate 7 (new bearing).
12.36.5
copyright by
MJF C I F S S
Note!
ZP axles".

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).
13.20).
1 Vehicle wheels 8 Pin

12.36.6
copyright by
MJF C I F S S

.10 Axle housing .260 O-ring

.30 Axle housing .290 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 Roller bearing .600 Axial joint
.120 O-ring .605 Bellows
.130 Hex head screw .610 Right ball joint, complete
.140 Washer .611 Left ball joint, complete
.150 Fit bolt .620 Clamp
.250 Screw plug .640 Cotter pin
12.36.7
copyright by
MJF C I F S S
.10 Left joint housing .130 Lubrication nipple

.10 Right joint housing .150 Bushing
.10 Slotted nut .160 Radial shaft seal ring
.80 Sealing cap .200 Snap ring
.90 O-ring .270 Plug
.100 Washer (S = 0.6 - 2.0 mm) .390 Bleeder valve
.114 Bearing pin .500 Stop screw
.120 Hex head screw
12.36.8
copyright by
MJF C I F S S

.50 Roller bearing .340 Sun gear shaft
.80 Hub .350 Disc carrier
.90 O-ring .360 Snap ring
.130 O-ring 0.390 Planetary carrier
.140 Junk ring .400 Planetary gear
.150 Snap ring .410 Roller bearing
.160 Hollow gear .420 Junk ring
.200 Piston .430 Snap ring
.210 Lip seal .480 Thrust washer (S = 1.5 - 3.0 mm)
.214 Backing ring .490 O-ring
.220 Lip seal .500 Screw plug (oil drainage)
.230 Backing ring .510 Allen head screw
.232 Back-up washer .540 Wheel stud
.238 Pressure spring .550 Lock washer
.248 Lock nut .560 Centring ring
.256 Hex head screw .570 Wheel lug
.258 Spring sleeve .620 Screw plug (measuring bore)
.270 Outer disc (S = 2.0 - 3.0 mm) .630 O-ring
.280 Inner disc
12.36.9
copyright by
MJF C I F S S

no. no.
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 81 19254 Hex head screw
shaft
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
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!
12.36.10
copyright by
MJF C I F S S
Fig. 7 Sectional drawing of steering axle
12.36.11
copyright by
MJF C I F S S
12.36.12
copyright by
MJF C I F S S
Function
AP - B 755 rigid axle with drum brake
1 Function
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 A 316 Li:

Machine model 715
Serial number 2001
Axle type AP-B 755 TR
12.37.1
copyright by
MJF C I F S S
Technical data
Machine A 316 Li:

Machine model 715
Serial number 2001
Gear ratio
Standard 17,52
Speeder 17,52
Brake Drum brake
Oil volume in axle
Axle housing 9.0 l
B Rolling resistance of the wheel bearing 61 / 64 (new) 8 - 12 Nm
C Torque for the hex head screw 3 560 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
K Check of drum brakes 20: 2 mm
Residual lining thickness of the brake system (glued) min.
Items A, B, D- K (see Fig. 6 on page9) and item C (see Fig. 2 on page4)
2.1 Tyre pressure

12.37.2
copyright by
MJF C I F S S
3.1 Power transfer in the rigid axle, see Fig. 6

The sun gear shaft 91, which is connected through the sleeve 8 to the stub shaft 7, drives the plane-
tary 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).
Danger!
group 3. Regularly check the wheel lugs 107 for the correct tightening torque, (see Tab. 1 on page2).
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.
Danger!
rigid axle.
12.37.3
copyright by
MJF C I F S S
carriage 9.
Note!
axles with drum brakes".

Install the rigid axle 2 in the undercarriage 9, using lifting gear and secure it with the hex head

5 Universal joint shaft
12.37.4
copyright by
MJF C I F S S

17050 Washer (S = 0.10 - 2.0 mm) 17250 Screw plug
17140 Washer
12.37.5
copyright by
MJF C I F S S
Fig. 4 Hub carrier, group 22 and drum brake, group 2 (1 = old) and (400 = new)
1 Brake (old) 350 Locking plate

10 Brake drum 370 Tension spring
50 Adapter 400 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 Countersunk screw 510 Slotted nut
170 Wheel cylinder 570 Allen head screw
180 Lock washer 580 Allen head screw
270 Brake pad 610 Retainer plate
340 Pin
12.37.6
copyright by
MJF C I F S S
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 Roller bearing 420 Junk ring
40 Ring (S = 3.4 - 5.0 mm) 430 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 Hollow gear 510 Allen head screw
184 Locking plate 540 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
12.37.7
copyright by
MJF C I F S S
ZP figure ZP figure
no. no.
Group 17 Group 19
1 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
Group 2 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
Group 22 101 490 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
Note!
Observe the setting values and tightening torques A, B, D, E, F, G, H, I, K , see Fig. 6 and (see Tab.
1 on page 2).
12.37.8
copyright by
MJF C I F S S
12.37.9
copyright by
MJF C I F S S
12.37.10
copyright by
MJF C I F S S
Function
Differential for AP / APL - B 755 axles
1 Function
axle shaft gears.
Fig. 1 Differential of steering and rigid axle
12.39.1
copyright by
MJF C I F S S
Technical data
2 Technical data

Machine model 715 / 716
Serial number 2001
Axle type BK
Gear ratio 3,18
the pinion 20.1)
0.18 - 0.23 mm (speeder)
Note!
"AP / APL - B 755 ZP axles".
12.39.2
copyright by
MJF C I F S S
pinion)
80 Tapered roller bearing 270 Washer (S = 10.94 - 12.38 mm)
110 Ring (S = 10.97 - 11.36 mm) 290 Hex nut
160 Tapered roller bearing 310 Locking plate
12.39.3
copyright by
MJF C I F S S

680 Thrust washer
12.39.4
copyright by
MJF C I F S S

.150 Fit bolt
12.39.5
copyright by
MJF C I F S S
ZP figure ZP figure
no. no.
ring
1.2 17030 Axle housing II 17 16110 Bushing
ring
ring
ring
5 17120 O-ring 21 73850 Washer
11 16290 Hex nut 26 73720 Balancing axle
"Connex"
Note!
12.39.6
copyright by
MJF C I F S S
12.39.7
copyright by
MJF C I F S S
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
12.41.1
copyright by
MJF C I F S S
APL - B 755 HD steering axle with multi-disc brake Service Manual
Function
12.41.2
copyright by
MJF C I F S S
Technical data
2 Technical data
Machine A 316 Litronic Industry

Machine model 716
Serial number 2001
Axle type APL-B 755 HD
Gear ratio
Standard 17.72
Speeder -
Oil volume in axle
Axle housing 9.0 l
A End play of the double joint shaft 20 with sun gear shaft 0.4 - 0.6 mm
91
new 2.4 - 2.8 mm
at max. wear 4.5 mm
D Rolling resistance of the wheel bearing 61 (new) 10 - 15 Nm
(without sealing elements)
E Torque for the slotted nut 32 1200 - 1400 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, 340 - 360 Nm
see steering cylinder, group 16.34
L Multi-disc brakes:
Low pressure test 1 - 5 bar
Items A - L ((see Fig. 7 on page12))
2.0.1 Tyre pressure

12.41.3
copyright by
MJF C I F S S
3.1 Power flow in the steering axle, (see Fig. 7 on page12)

Danger!

carrier.
12.41.4
copyright by
MJF C I F S S
Note!
Danger!
Remove the hex head screws 6 and the plate 7 (new bearing).
12.41.5
copyright by
MJF C I F S S
Note!
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).
13.20).
1 Vehicle wheels 8 Pin

12.41.6
copyright by
MJF C I F S S

.10 Axle housing part I .260 O-ring

.30 Axle housing part II .290 Stub shaft
.40 Bearing bushing .330 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 O-ring .605 Bellows
.130 Hex head screw .610 Right tie rod, complete
.140 Washer .611 Left tie rod, complete
.150 Fit bolt .620 Clamp
.250 Screw plug .640 Cotter pin
12.41.7
copyright by
MJF C I F S S

.30
.10 Left joint housing, with slotted nut .130 Lubrication nipple
.20 Right joint housing, with slotted nut .150 Bushing
.30 Plug .160 Radial shaft seal ring
.80 Sealing cap .390 Bleeder valve
.90 O-ring .480 Washer (S = 1.9 - 3.0 mm)
.100 Washer (S = 0.6 - 2.0 mm) .490 Pipe
.114 Bearing pin .500 Stop screw
.120 Hex head screw .510 Separate slotted nut
12.41.8
copyright by
MJF C I F S S

.40 Ring (S = 26.0 - 27.0 mm) .310 Locking plate
.80 Hub .320 Thrust washer
.90 O-ring .326 Allen head screw
.100 Hollow gear carrier .340 Sun gear shaft
.120 Plug .344 O-ring
.130 O-ring .350 Disc carrier
.144 Backing ring .380 Snap ring
.154 Backing ring .390 Planetary carrier
.200 Piston .392 Screw plug (measuring bore)
.210 Lip seal .400 Planetary gear
.214 Backing ring .410 Roller bearing
.230 Backing ring .412 Washer
.232 Back-up washer .420 Junk ring
.236 Spring sleeve .430 Snap ring
.238 Pressure spring .480 Thrust washer (1.5 - 3.0 mm)
.244 Circlip .500 Screw plug (oil drainage)
12.41.9
copyright by
MJF C I F S S
.246 Hex head screw .510 Allen head screw

.248 Lock nut .540 Wheel stud
.256 Hex head screw .550 Lock washer
.270 Outer disc (S = 2.0 - 3.0 mm) .560 Centring ring
.280 Inner disc .570 Wheel lug

no. no.
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 83 19270 Outer disc
shaft
31 18010 Right joint housing 84 19280 Inner disc
18020 Left joint housing 85 19290 End washer
32 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
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
12.41.10
copyright by
MJF C I F S S
Note!
12.41.11
copyright by
MJF C I F S S
12.41.12
copyright by
MJF C I F S S
Service Manual AP - B 755 rigid axle with multi-disc brake
Function
AP - B 755 rigid axle with multi-disc brake
1 Function
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
12.42.1
copyright by
MJF C I F S S
AP - B 755 rigid axle with multi-disc brake Service Manual
Technical data
2 Technical data
Machine A 316 Li:

Machine model 716
Serial number 2001
Axle type AP-B 755 HD
Gear ratio
Standard 17.72
Speeder -
Brake Multi-disc brake
Oil volume in axle
Axle housing 10.0 l
new 2.4 - 2.8 mm
at max. wear 4.5 mm
C Rolling resistance of the wheel bearing 61 (new) 10 - 15 Nm
(without sealing elements)
D Tightening torque for the nuts 3 560 Nm
E Tightening torque for the slotted nut 32 1200 - 1400 Nm
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:
Items A, B, C, E, K (see Fig. 7 on page11) and item D (see Fig. 3 on page5)
2.1 Tyre pressure

12.42.2
copyright by
MJF C I F S S
3.1 Power transfer in the rigid axle, see Fig. 7

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 re-
duction 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).
Danger!

carrier.
12.42.3
copyright by
MJF C I F S S
Note!
Danger!
issued by the German Ground Construction Trade Association (Tiefbau-Berufsgenossenschaft).
rigid axle.
carriage 9.
12.42.4
copyright by
MJF C I F S S
Note!
axles with multi-disc brakes".

Install the rigid axle 2 in the undercarriage 9, using lifting gear and secure with the hex head

5 Universal joint shaft
12.42.5
copyright by
MJF C I F S S

17050 Washer (S = 0.15 - 2.0 mm) 17250 Screw plug
17140 Washer
12.42.6
copyright by
MJF C I F S S
Fig. 5 Hub carrier
10 Hub carrier complete with slotted nut 110 Retainer plate

70 Allen head screw 160 Bleeder valve
90 O-ring 330 Separate slotted nut
12.42.7
copyright by
MJF C I F S S
Fig. 6 Output of planetary gear group 19
.10 Radial shaft seal ring .300 Snap ring

.30 Roller bearing .310 Locking plate
.80 Hub .340 Sun gear shaft
.90 O-ring .344 O-ring
.100 Hollow gear carrier .350 Disc carrier
.130 O-ring .390 Planetary carrier
.144 Backing ring .392 Screw plug (measuring bore)
.154 Backing ring .400 Planetary gear
.200 Piston .410 Roller bearing
.210 Lip seal .412 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
12.42.8
copyright by
MJF C I F S S
.248 Lock nut .540 Wheel stud

.256 Hex head screw .550 Lock washer
.270 Outer disc (S = 2.0 - 3.0 mm) .560 Centring ring
.280 Inner disc .570 Wheel lug
.290 End washer
12.42.9
copyright by
MJF C I F S S

no. no.
1 17010 Axle housing part I 80 19244 Circlip
17030 Axle housing part II 81 19246 Hex head screw
7 17290 Stub shaft 82 19248 Lock nut
3 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
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
12.42.11
copyright by
MJF C I F S S
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
axle shaft gears.
Fig. 1 Differential
12.44.1
copyright by
MJF C I F S S
Differential for AP / APL - B 755 HD axles Service Manual
Technical data
2 Technical data

Machine model 716
Serial number 2001
Axle type BK
Gear ratio 3.18
the pinion 20.1)
0.18 - 0.23 mm (Speeder)
Note!
"AP / APL - B 755 HD ZP axles".
12.44.2
copyright by
MJF C I F S S
pinion)
80 Roller bearing 270 Washer
110 Ring (S = 10.94 - 12.38 mm) 290 Hex head screw
160 Roller bearing 310 Locking plate
12.44.3
copyright by
MJF C I F S S

680 Thrust washer
12.44.4
copyright by
MJF C I F S S

.150 Fit bolt
12.44.5
copyright by
MJF C I F S S
ZP figure ZP figure
no. no.
ring
1.2 17030 Axle housing II 17 16110 Bushing
ring
ring
ring
5 17120 O-ring 21 73850 Washer
11 16290 Hex nut 26 73720 Balancing axle
"Connex"
Note!
12.44.6
copyright by
MJF C I F S S
12.44.7
copyright by
MJF C I F S S
12.44.8
copyright by
MJF C I F S S
Service Manual MS - E 3060 steering axle
Function
MS - E 3060 steering axle
1 Function
wheels, is equipped with a built-in drive / differential.
gear ratio in the differential, the drive unit is very compact, providing for great ground clearance.
The brake is applied when the brake pedal (working brake) is operated and the brake is pressurised
with brake oil.
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.
Fig. 1 MS - E 3060 steering axle
12.46.1
copyright by
MJF C I F S S
MS - E 3060 steering axle Service Manual
Function
12.46.2
copyright by
MJF C I F S S
Technical data
2 Technical data
Machine A 316 Li
Serial number 28061 / 28062
Axle type MS-E 3060
Gear ratio 16,00
Oil volume in axle
Axle housing 9.5 l
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 1.2 - 1.8 mm
at max. wear 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 1400 + 200 Nm
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:
Max. pressure drop after 5 minutes 3 bar
Visible pressure drop after 5 minutes is not permissible
see steering
* Items A - K, see Fig. 10
Tyre pressure
12.46.3
copyright by
MJF C I F S S
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 Design of steering axle
1 Input 6 Steering
2 Differential 7 Oil discharge / oil filling opening / planetary
drive
3 Axle housing with axle drive housing 8 Oil filling control bore / axle housing
4 Joint housing 9 Oil discharge / axle housing
5 Output
12.46.4
copyright by
MJF C I F S S
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 Roller bearing 24 Axle shaft gear
15 Ring (S=10.94-12.38mm) 25 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!
12.46.5
copyright by
MJF C I F S S
Description
3.2 Layout of the axle housing 3
Fig. 4 Design of axle housing
30 Axle housing 42 Hex nut

31 Axle drive housing 43 Axial joint
32 Clamping bush 44 Slotted nut
33 Bushing 45 Tie rod (right)
34 Radial shaft seal ring 46 Ball joint
35 Double joint drive shaft (complete) 47 Hex nut
36 Yoke 48 Axial joint
37 Joint yoke 49 Hex head screw
38 Double yoke 110 O-ring
39 Joint yoke (sun gear shaft) 111 Washers
40 Tie rod (left) 112 Roller bearing
41 Ball joint
12.46.6
copyright by
MJF C I F S S
Description
3.3 Design of the joint housing 4
Fig. 5 Design of joint housing
30 Axle housing 59 Lubrication nipple

39 Joint yoke (sun gear shaft) 60 Hex head screw
50 Joint housing (complete) 61 Washer (S=0.60-2.00mm)
51 Snap ring 62 Bearing pin
52 Thrust washer 63 Lubrication nipple
53 Thrust washer 64 Plug
54 Slotted nut 65 Bleeder
55 O-ring 66 Bushing
56 Sealing cap 67 Radial shaft seal ring
57 O-ring 68 Roller bearing
58 Bearing pin 69 Hex head screw
12.46.7
copyright by
MJF C I F S S
Description
3.4 Design of output unit 5
Fig. 6 Design of the output unit
50 Joint housing 88 Backing ring

70 Planetary carrier 89 Piston
74 Allen head screw 92 Spring sleeve
75 Circlip 93 Hex head screw
76 Planetary gear 94 Disc carrier
77 Washer 95 O-ring
78 Roller bearing 96 Inner disc
81 Thrust washer (S = -1.50-3.00mm) 98 O-ring
83 Hollow gear 100 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
12.46.8
copyright by
MJF C I F S S
4.1 Power flow in the steering axle, see Fig. 10

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 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).
12.46.9
copyright by
MJF C I F S S
Danger!
For maintenance work on the axles, the undercarriage of the machine must be accessed, which po-
manual. Regularly check the wheel lugs 108 for the correct tightening torque, (see Tab. 1, page 3).
The manufacturer also prescribes an annual inspection of the disc lining for wear, (see Fig. 8, page
11).
Fig. 7 Wear assessment

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
copyright by
MJF C I F S S
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.
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 Measuring bore ( 10 mm) 83 Hollow gear

3 Dial gauge with magnetic stand 89 Piston
70 Planetary carrier 96/97 Disc pack
71 Screw plug X Piston travel
Oil filling / oil discharge bore
12.46.11
copyright by
MJF C I F S S
Danger!
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.
Note!
For detailed repair instructions for the axle, refer to the separate Repair manual for ZF axles MS-
E 3050/3060/3070.

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.
Secure the universal joint shaft 3 with the screws 2 to the output flange / output of the steering
axle 4.
13.20).
12.46.12
copyright by
MJF C I F S S
1 Vehicle wheels 6 Hex head screw

2 Hex head screw 7 Plate
3 Joint shaft 8 Pin
4 Steering axle 10 Lubrication nipple
5 Undercarriage 11 Lock nut
12.46.13
copyright by
MJF C I F S S
30 Axle housing 78 Roller bearing

36 Yoke 82 O-ring
37 Joint yoke 83 Hollow gear
38 Double yoke 85 Backing ring
39 Joint shaft (sun gear shaft) 86 Lip seal
50 Joint housing 87 Lip seal
51 Snap ring 88 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
58 Bearing pin 94 Disc carrier
59 Lubrication nipple 95 O-ring
60 Hex head screw 96 Inner disc
61 Washer (S=0.60-2.00mm) 97 Outer disc
62 Bearing pin 99 Roller bearing
63 Lubrication nipple 100 Spacer bushing
65 Bleeder 101 Hub
66 Bushing 103 Radial shaft seal ring
67 Radial shaft seal ring 104 Allen head screw
68 Roller bearing 105 Wheel stud
70 Planetary carrier 106 Lock washer
74 Allen head screw 107 Centring ring
75 Circlip 108 Wheel lug
76 Planetary gear
Note!
12.46.14
copyright by
MJF C I F S S
12.46.15
copyright by
MJF C I F S S
12.46.16
copyright by
MJF C I F S S
Service Manual MT - E 3060 rigid axle
Function
MT - E 3060 rigid axle
1 Function
is equipped with a built-in drive / differential.
gear ratio in the differential, the drive unit is very compact, providing for great ground clearance.
It is applied when the brake pedal (working brake) is operated and the brake is pressurised with brake
oil.
I
Fig. 1 MT - E 3060 rigid axle
12.47.1
copyright by
MJF C I F S S
MT - E 3060 rigid axle Service Manual
Function
12.47.2
copyright by
MJF C I F S S
Technical data
2 Technical data
Machine A 316 Li
Axle type MT-E 3060
Gear ratio Standard 16,00
Oil volume in axle (filling level at the check Axle housing 12.5 l
screws is binding) Planetary drive 2.5 l per side
Oil quality API - GL 5 / SAE 90 LS
A* End play of the stub shaft 36 0.4 - 0.6 mm
B* Clearance of the disc pack 96/97(piston new 0.7 - 1.3 mm
stroke) at max. wear 6.0 mm at 6 discs
6.5 mm at 7 discs
C* Rolling resistance of the wheel hub 99 8 - 12 Nm
D* Torque for the slotted nut 54 1400 +600 Nm
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:
Max. pressure drop after 5 minutes 3 bar
Visible pressure drop after 5 minutes is not permissible
* Items A - H (see Fig. 10)
Tyre pressure
12.47.3
copyright by
MJF C I F S S
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 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
12.47.4
copyright by
MJF C I F S S
Description
3.1 Design of drive unit 1 and differential 2
Fig. 3 Design of the drive unit
10 Crown wheel 20 Allen head screw

11 Pinion 21 Washer
12 Roller bearing 22 Differential cage
14 Roller bearing 24 Axle shaft gear
15 Ring (S=10.94-12.38mm) 25 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!
12.47.5
copyright by
MJF C I F S S
Description
3.2 Layout of the axle housing 3
Fig. 4 Design of axle housing
30 Axle housing 34 Washer (S = 0.10 - 2.0mm)

31 Axle drive housing 35 O-ring
32 Hex head screw 36 Stub shaft
33 Roller bearing 37 Washer
12.47.6
copyright by
MJF C I F S S
Description
3.3 Design of hub carrier 4
Fig. 5 Design of hub carrier
30 Axle housing 54 Slotted nut

50 Hub carrier 55 O-ring
51 Sun gear shaft 56 Washer
52 Bleeder 57 Hex head screw
53 Plug
12.47.7
copyright by
MJF C I F S S
Description
3.4 Design of output unit 5
Fig. 6 Design of the output unit
50 Joint housing 88 Backing ring

70 Planetary carrier 89 Piston
74 Allen head screw 92 Spring sleeve
75 Circlip 93 Hex head screw
76 Planetary gear 94 Disc carrier
77 Washer 95 O-ring
78 Roller bearing 96 Inner disc
81 Thrust washer (S = -1.50-3.00mm) 98 O-ring
83 Hollow gear 100 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
12.47.8
copyright by
MJF C I F S S
4.1 Power flow in the rigid axle, see Fig. 10

drive system. A bevel pinion and crown wheel transfer the torque via the differential case to the dif-
ferential spider with balancing and axle shaft gears, which is borne in the cage.
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).
12.47.9
copyright by
MJF C I F S S
Danger!
manual. Regularly check the wheel lugs 108 for the correct tightening torque, (see Tab. 1, page 3).
schedule.
The manufacturer also prescribes an annual inspection of the disc lining for wear, (see Fig. 8, page
11).
Fig. 7 Wear assessment

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
copyright by
MJF C I F S S
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.
Fig. 8 Wear measurement at the disc pack
2 Measuring bore ( 10 mm) 83 Hollow gear

3 Dial gauge with magnetic stand 89 Piston
70 Planetary carrier 96/97 Disc pack
71 Screw plug X Piston travel
Oil filling/ oil discharge bore
12.47.11
copyright by
MJF C I F S S
Danger!
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 .
Loosen the hex nuts 9 and remove the hex head screws 7. Lift the rigid axle 8 from the undercar-
riage 5.
Note!
For detailed repair instructions for the axle, refer to the separate "Repair manual for ZF axles MT-
E 3050/3060/3070".
6.3 Installation of the rigid axle after repair work

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.
12.47.12
copyright by
MJF C I F S S
1 Vehicle wheels 5 Undercarriage

3 Joint shaft 7 Hex head screw
4 Lock nut 8 Rigid axle
12.47.13
copyright by
MJF C I F S S
6 Screw plug 87 Lip seal

30 Axle housing 88 Backing ring
36 Stub shaft 89 Piston
50 Hub carrier 90 Pressure spring
51 Sun gear shaft 91 Pressure spring
54 Slotted nut 92 Spring sleeve
56 Sealing cap 94 Disc carrier
70 Planetary carrier 96 Inner disc
74 Allen head screw 97 Outer disc
75 Circlip 99 Roller bearing
76 Planetary gear 100 Spacer bushing
77 Washer 101 Hub
78 Roller bearing 103 Radial shaft seal ring
80 Snap ring 104 Allen head screw
82 O-ring 105 Wheel stud
83 Hollow gear 106 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
copyright by
MJF C I F S S
12.47.15
copyright by
MJF C I F S S
12.47.16
copyright by
MJF C I F S S
Service Manual MS/MT - E 3060 drive unit and differential
Function
MS/MT - E 3060 drive unit and differential
1 Function
The drive unit and differential are integrated into the axle housing of the steering and rigid axle. They
transmit the output power of the transmission to the planetary drives of the wheel hubs, adjusting the
speed and torque by means of bevel pinions and the crown wheel.
axle shaft gears.
Fig. 1 Differential
12.48.1
copyright by
MJF C I F S S
MS/MT - E 3060 drive unit and differential Service Manual
Function
12.48.2
copyright by
MJF C I F S S
Technical data
2 Technical data
Machine A 316 Li
Axle type MT-MS
Gear ratio 3,18
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
F Tightening torque for the hex head screws 49 390 Nm
Items A - G
12.48.3
copyright by
MJF C I F S S
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.
1 Input 21 Washer
2 Differential 22 Differential cage
3 Axle housing 23 Thrust washer
10 Crown wheel 24 Axle shaft gear
11 Pinion 25 Balancing shaft gear
12 Roller bearing 26 Thrust washer
13 Disc (S=0.70-1.50mm) 27 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 Protective plate 32 O-ring
18 Input flange 33 Washer
19 Hexagon nut with washer 34 Roller bearing
12.48.4
copyright by
MJF C I F S S
Description
3.1 Design of differential
Fig. 2 Design of differential
12.48.5
copyright by
MJF C I F S S
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 ma-
chine. 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.
4.1 Repair of differential
Note!
"ZF axles MT/MS-E 3050/3060/3070".
10 Crown wheel 23 Thrust washer

11 Pinion 24 Axle shaft gear
12 Roller bearing 25 Balancing shaft gear
14 Roller bearing 27 Balancing axle
15 Ring (S=10.94-12.38mm) 28 Heavy-duty roll pin
16 Radial shaft seal ring 29 Roll pin
17 Protective plate 30 Axle housing
18 Output flange 31 Axle drive housing
19 Hexagon nut with washer 32 O-ring
20 Allen head screw 33 Washer
21 Washer 34 Roller bearing
22 Differential cage 49 Hex head screws
Note!
Observe settings and torques A, B, C, D, E, F, G, and Table 1, page 3.
12.48.6
copyright by
MJF C I F S S
12.48.7
copyright by
MJF C I F S S
12.48.8
copyright by
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
Tyre Pressure Spacer

Size Producer PR
type [bar] 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 -
Tab. 1 Tyres and spacer rings 309
Type: 718
Size Producer PR
type [bar] 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 - 6,00 -
12.54.1
copyright by
MJF C I F S S
Tyres and spacer rings Service Manual
A 312 and A 314 Litronic
2 A 312 and A 314 Litronic
Types: 719

Size Producer PR
type [bar] 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 -
Type 635

Size Producer PR
type [bar] rings
10.00-20 8 E 91-2 Dunlop 16 7,50 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 -
12.54.2
copyright by
MJF C I F S S
Service Manual Tyres and spacer rings
A 316 Litronic
3 A 316 Litronic
Type: 715
Size Producer PR
type [bar] 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 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 -
Type: 716

Size Producer PR
type [bar] rings
10.00-20 8 NB 38 Mitas 16 7,50 MH 3
10.00-20 8 Gumasol Euromaster - - MH 4
Type: 715 / 716 EW

Size Producer PR
type [bar] 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
Tab. 5 Tyres and spacer rings 316Broad tire
12.54.3
copyright by
MJF C I F S S
Tyres and spacer rings Service Manual
A 316 Litronic
12.54.4
copyright by
MJF C I F S S
Service Manual Chassis / drive
Design
Chassis / drive
1 Design
The chassis / drive consist of three main components:

The chain 40 with chain link 41 and base plate 45
Tensioning unit 66 with grease tensioner 3, pressure spring 67 and idler 2
Running roller 38
Support roller 39
Chassis drive with travel gear 65 and tumbler wheel 63
Fig. 1 Design
2 Idler 45 Base plate

3 Grease tensioner 62 Longitudinal member
38 Running roller 63 Tumbler wheel
39 Support roller 65 Travel gear
40 Chain 66 Tensioning unit, complete
41 Chain link 67 Spring
12.60.1
copyright by
MJF C I F S S
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!
the screws, can cause serious damage of components such as longitudinal members, running rol-
lers 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
copyright by
MJF C I F S S
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 longitu-
dinal 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 inter-
vals, 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.
12.60.3
copyright by
MJF C I F S S
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.

2 Idler 56 Hex head screw
3 Grease tensioner 59 Lubrication nipple
4 Lid 60 Extension
5 Lid 61 USIT ring
6 Locking mechanism 62 Longitudinal member
7 Hex head screw 63 Tumbler wheel
8 Hex head screw 65 Travel drive
30 Regulating motor 66 Tensioning unit
31 Hex head screw 67 Spring
38 Running roller 70 Lid
39 Support roller 71 Hex head screw
40 Chain 72 Hose
41 Chain link 73 Hose
42 End bolt 74 Hose
43 End bushing 75 Allen head screw
45 Base plate 76 Flange halves
49 Spacer ring 77 Hose
50 Allen head screw 78 Hose
51 Square nut 79 Rectangular ring
12.60.4
copyright by
MJF C I F S S
Fig. 2 Chassis parts
12.60.5
copyright by
MJF C I F S S
12.60.6
copyright by
MJF C I F S S
Service Manual Technical data / tightening torques
Technical data / tightening torques
Machine R 313
Type 636
valid from serial no. 27752
Chain
Type D4 L
Number of segments 46
Base plate
Type Three-step
Model D4 L
Width / spec. weight on ground (15 t / 16 t * usable weight) 500 mm / 4.6 N / cm
4.9 N / cm *
600 mm / 3.9 N / cm
4.2 N / cm *
750 mm / 3.2 N / cm
3.4 N / cm *
Base plate screws
Thread 5/8-18 UNF X16
Tightening torques 180 20 Nm + 120
Travel gear
Type FAT 350
Number per chain 1
Tightening torque for mounting screws 560 Nm
Tumbler wheel
Number per chain 1
Running roller
Type D4 L
Number per chain 7
Support roller
Type D4 L
Number per chain 2
Tightening torques of mounting screws and bolts 280 Nm
Lubrication nipple (extension)
Number per chain 1

Torque 170 Nm
12.62.1
copyright by
MJF C I F S S
Technical data / tightening torques Service Manual
12.62.2
copyright by
MJF C I F S S
Service Manual Technical data / tightening torques
Technical data / tightening torques

Machine R 317 R 317
Type 970 362
valid from serial no. 18161 18161
Chain
Type B 60 L B 60 L
Number of segments 44 55
Base plate
type Three-step Three-step
Type B 60 L B 60 L
Width / specific base plate load (with hydr. boom 500 mm / 5.0 N / cm 600 mm / 3.5 N / cm
adjusting device, 17t usable weight) 600 mm / 4.3 N / cm 900 mm / 2.4 N / cm
750 mm / 3.5 N / cm 1000 mm / 2.1 N / cm
900 mm / 2.7 N / cm
1000 mm / 2.4 N / cm
Base plate screws
Thread M 20 x 1.5 M 20 x 1.5
Tightening torques 740 - 840 Nm 740 - 840 Nm
Travel gear
Type FAT 350 FAT 350
Number per chain 1 1
Tightening torque for mounting screws 560 Nm 560 Nm
Tumbler wheel
Running roller
Type B 60 D6 KL
Support roller
Type B 60 L B 60 L
Tightening torques of mounting screws and bolts 280 Nm 280 Nm
Lubrication nipple (extension)

Tightening torques of mounting screws and bolts 170 Nm 170 Nm
Tab. 1 Technical Data
12.64.1
copyright by
MJF C I F S S
Technical data / tightening torques Service Manual
12.64.2
copyright by
MJF C I F S S
Service Manual Wear of chassis parts
Introduction
Wear of chassis parts
1 Introduction
Chassis parts are subject to wear from movement, loads and contact between parts.
Improper driving and manoeuvring (e.g. sudden turning, uneven loads, incorrect crossing of obstac-
les) 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 ele-
vated 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 measure-
ments 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 com-
paring the measured dimension (actual value) with the corresponding dimension of the new part
(nominal value), see wear limits, group 12.67, 12.69..
12.66.1
copyright by
MJF C I F S S
Wear of chassis parts Service Manual
Chain links
Example:
Hn = height of new part = 126 mm

Hv = wear limit of part = 116 mm
H = actual height (measured = 120 mm
height)
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 Measurement of inner wear of bolts and bushings using a ruler. The measurement is car-
ried out on the tight chain and across 4 chain links.
12.66.2
copyright by
MJF C I F S S
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.
12.66.3
copyright by
MJF C I F S S
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 Measurement with calliper gauge or outside calliper of wearing surface wear of support
roller.
12.66.4
copyright by
MJF C I F S S
Service Manual D4L wear limits
D4L wear limits
New Wear limit
Tumbler wheel Zv
to
tip of gear
Chain link Hn Hv
96.0 90.0
Chain bolt Ln Lv
686.8 698.8
Chain bushing
Dn Dv
normal impact
46.3
54.2
high impact
48.9
New Wear limit
12.67.1
copyright by
MJF C I F S S
D4L wear limits Service Manual
Base plate Hn Hv
25 12.5
Idler Hn Hv
17 23.5
Running roller Dn Dv
138 126
Support roller Dn Dv
120 110
12.67.2
copyright by
MJF C I F S S
Service Manual Wear limits - B60
Wear limits - B60
New Wear limit
Tumbler wheel Zv
to
Tip of gear
Chain link Hn Hv
105 98
Chain bolt Ln Lv
761 774
Chain bushing Dn Dv
59 54
Tab. 1 Wear limits
12.69.1
copyright by
MJF C I F S S
Wear limits - B60 Service Manual
New Wear limit
Base plate Hn Hv
28 12.5
Idler Hn Hv
20 25
Running roller Dn Dv
154 141
Support roller Dn Dv
120 107
12.69.2
copyright by
MJF C I F S S
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. Per-
sons working near the chain are thus exposed to a serious risk of injury when the member is drop-
ped 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 lo-
cated 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 be-
velled front edges, (see Fig. 4 on page3).
Fig. 1 Lifting longitudinal member using the attachment
1.1 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 com-
plete with the extension 60 (tightening torque 170 Nm).
12.72.1
copyright by
MJF C I F S S
Chain Service Manual
Dismantling complete chain
Fig. 2 Screw plug with release groove and lubrication nipple
4 Lid (access to lubrication nipple) 60 Lubrication nipple extension (WS 27)

8 Hex head screw
59 Lubrication nipple (WS 22) N Release groove
1.2 Opening and removing chain
Note!
Press the thumb screw from the inside of the chain outwards. Push out the grooved end bolts (in-
wards 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
copyright by
MJF C I F S S
Mounting chain
Fig. 3 Direction of travel for chain dismantling
A Roll-off direction 4 Lid

F Direction of travel 42 End bolt
Fig. 4 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 out-
side, (see 3 on page6).
Screw in the lubrication nipple 59 with the extension 60 and the UNIT seal ring at the grease ten-
sioner and tighten the chain with the grease gun.
12.72.3
copyright by
MJF C I F S S
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 Lid 80 Manual grease gun

59 Lubrication nipple 82 Nozzle pipe
60 Extension
2.1 Checking chain tension

Release the chain by moving fore and back.
Place the measuring rod 90 onto the section between the support rollers.
12.72.4
copyright by
MJF C I F S S
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 Chain dip of correction tensioned chain
A Insufficiently tensioned chain X Chain dip

B Correctly tensioned chain Y1-Y2 Chain dip
90 Measuring rod
2.2 Tensioning chain

As the chassis is exposed to normal wear, the chain tension must be regularly checked and redesi-
gned, 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.
12.72.5
copyright by
MJF C I F S S
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 availab-
le, 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
copyright by
MJF C I F S S
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).
12.72.7
copyright by
MJF C I F S S
Repair of damaged chain
Fig. 9 Replacement of damaged base plates
1-4 Tightening of base plate screws 51 Base plate nut

50 Hex head screw for base plate
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 C Fraction point at chain link

48 Complete side chain link D Torch cuts at chain link
12.72.8
copyright by
MJF C I F S S
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 Burn in hole, using a blow torch

43 Bushing G Backing with hammer
48 Complete side chain link H Direction of bolt drive-out
E Grinding chain link to a plane surface K Bolt stub
12.72.9
copyright by
MJF C I F S S
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 47 Drive-in direction of thumb end bolt

43 End bushing 48 Complete side chain link
44 Complete side chain link 49 Spacer ring
46 New chain link
12.72.10
copyright by
MJF C I F S S
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 lo-
cking 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 ten-
sioner 3.
Press in grease (over-tensioning chain) until the spring plate 68 is lifted from the locking mecha-
nisms 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 longitu-
dinal member 62.
12.75.1
copyright by
MJF C I F S S
Tensioning unit Service Manual
Dismantling grease tensioner
Fig. 1 Assembling tensioning unit and idler
2 Idler, complete 14 Backing ring

3 Grease tensioner 59 Lubrication nipple
10 Piston 60 Extension
11 Housing 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
copyright by
MJF C I F S S
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 sur-
face 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).
12.75.3
copyright by
MJF C I F S S
Fig. 2 Tensioning unit with idler
2 Idler 7 Hex head screw

3 Grease tensioner 59 Lubrication nipple (with extension)
4 Lid 62 Longitudinal member
5 Lid 67 Spring
6 Locking mechanism 68 Spring plate
12.75.4
copyright by
MJF C I F S S
Fig. 3 Sectional drawing of tensioning unit
4 Lid 13 Scraper
5 Lid 59 Lubrication nipple
6 Locking mechanism 60 USIT ring
7 Hex head screw 62 Longitudinal member
10 Piston 67 Spring
11 Housing 68 Spring plate
12 Compact seal
Machine Piston 10 Free length Preloaded Preload force Spring tra- S

Type (mm) Lo length kN vel (mm)
Serial number (mm) L1 (mm) L
(mm)
R 313
80 423 354 85 45 38
636
27752
R 317
362 / 790 100 442 372 140 56 49
18161
Tab. 1 Technical data of tensioning unit
12.75.5
copyright by
MJF C I F S S
12.75.6
copyright by
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:
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
12.78.1
copyright by
MJF C I F S S
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 Sectional drawing of the idler
1 Axle 8 Roll pin

2 Bearing bushing 9 Trapezoid ring
3 Screw plug 10 Slide ring
4 O-ring 11 Idler
5 Slide ring seal 12 Hex head screw
6 O-ring 13 Washer
7 Sliding piece 14 Housing
12.78.2
copyright by
MJF C I F S S
Service Manual Idler
Fig. 2 Exploded view of the idler
Fig. 3 Filling position of the idler
15 Oil level
12.78.3
copyright by
MJF C I F S S
Idler Service Manual
12.78.4
copyright by
MJF C I F S S
Service Manual Running roller
Dismantling
Running roller
1 Dismantling
Remove the screw cap 5 and drain off the oil.

Drive out the roll pin 8 on both sides of the running roller axle 10 and remove the end piece 7 from
the axle. Remove the slide ring seal halves 9 from the running roller body 1 and the end piece 7.
Remove the O-ring 11 from the running roller axle. Pull the running roller axle 10 from the running
roller body and drive out the roll pin 8. Push the running roller bushings 4 from the running roller
body.
2 Assembly
Push the running roller bushings 4 into the running roller body.
Insert the running roller axle 10 into the running roller body and place the seals 11 into the grooves
of the running roller axle.
Place the slide seal ring halves 9 into the running roller body and insert the end piece 7, (see group
12.71).
Mount the end piece 7 on the running roller axle 10 and secure it with the roll pin 8.
Check axial play (movability). Drive in the running roller with compressed air at approx. 6 bar and
check for leakage.
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
12.81.1
copyright by
MJF C I F S S
Running roller Service Manual
Fig. 2 Exploded view of running roller
Fig. 3 Sectional drawing of running roller
1 Running roller body 9 Slide ring seal

4 Running roller bushing 10 Running roller axle
5 Screw plug 11 O-ring
6 Sealing ring 12 Trapezoid ring
7 End piece 13 Slide ring
8 Roll pin
12.81.2
copyright by
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 lea-
kage.
Fill oil into the support roller, observing the filling instructions below.
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 perpen-
dicular. 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
12.84.1
copyright by
MJF C I F S S
Support roller Service Manual
Fig. 1 Filling position of support roller
15 Oil level
For the items in fig. 2 and 3, page 3.

1 Screw 7 Axles
2 O-ring 8 Bushing
3 Allen head screw 9 Seal
4 Stop washer 10 End cap
5 Bearing bushing 11 Cover
6 Screw plug 12 Support roller body
12.84.2
copyright by
MJF C I F S S
Service Manual Support roller
Fig. 2 Exploded view of the support roller
Fig. 3 Sectional drawing of support roller
12.84.3
copyright by
MJF C I F S S
Support roller Service Manual
12.84.4
copyright by
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 trape-
zoid 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.
12.86.1
copyright by
MJF C I F S S
Slide ring seal Service Manual
Installation instructions for slide ring seals
Fig. 1 Slide ring seal
3 Trapezoid ring 4 Slide ring
Fig. 2 Sectional drawing of slide ring seal Correctly installed slide ring seal
1 Sliding face 5 Chamber radius

2 Slide face cone 6 Installation bevel
3 Trapezoid ring 7 Borehole diameter
4 Slide ring 8 Housing face
12.86.2
copyright by
MJF C I F S S
Service Manual
SUBGROUP - INDEX
Section Group Type
Operating pressures of the steering system 13.05.1 A 309 LI 20221-

A 311 LI 20222-
A 312 LI 12363-
A 314 LI 2001-
A 316 LI 2001-
A 316 LI-IND 2001-
Hydraulic steering system 13.10.1 A 309 LI 20221-

A 311 LI 20222-
A 312 LI 12363-
A 314 LI 2001-
A 316 LI 2001-
A 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 21649-

A 311 LI 21649-
A 312 LI 19112-
A 314 LI 19112-
Steering valve 13.24.1 A 316 LI 24955-

A 316 LI-IND 24955-
Steering cylinders 13.32.1 A 309 LI 20221-

A 311 LI 20222-
A 312 LI 12363-
Steering cylinders 13.34.1 A 314 LI 2001-

A 316 LI 2001-
A 316 LI-IND 2001-
4-wheel steering 13.50.1 A 309 LI 20221-

A 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
Machine A 309/311 A 312/314 A 316

Series Litronic Litronic Litronic
Unit
Gear pump 31 / 32:
Max. oil flow to steering pump 31/32 l/min 39 44 44
Adjustment pressures
Adjustment pressure at pressure-reli- bar 230 +15 230+15 230+15
ef valve 88
at flow rate 15 - 20 l/min
Adjustment pressure at primary pres- bar 180 +10 180 +10 180 10
sure-relief valve 29
in Servostat
Adjustment pressure at primary pres- bar 180 +10 180 +10 195 10
sure-relief valve 5
in steering valve
Secondary pressure relief valve 44 bar 240 10 240 10 240 10
in Servostat
Secondary pressure relief valve 6 bar 240 10 240 10 250 10
in steering valve
Tab. 1 Technical data of machine series
Machine A 309/A 311

4-wheel steering kit
Unit
Gear pump 32
Max. oil flow to steering pump 32 l/min 39
Adjustment pressures
Adjustment pressure at pressure-reli- bar 230 +15
ef valve 88
at flow rate 15 - 20 l/min
Adjustment pressure at primary pres- bar 210 +10
sure-relief valve 29 in Servostat
Adjustment pressure at primary pres- bar 210 +10
sure-relief valve 5
in steering valve
Secondary pressure relief valve 44 bar 260 10
in Servostat
Secondary pressure relief valve 6 bar 260 10
in steering valve
Tab. 2 Technical data of 4-wheel steering system
13.05.1
copyright by
MJF C I F S S
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.
13.10.1
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MJF C I F S S
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 Steering column
2.3 Rotary connection 85, see Fig. 3

The seven-fold oil rotary connection 85 is a special connection for hydraulic oil between the upper-
carriage 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 stee-
ring 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 axi-
al direction, adjusting the steering angle of the wheels.
13.10.2
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MJF C I F S S
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

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 po-
sition 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 pro-
tect 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).
13.10.3
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MJF C I F S S
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 / stee-
ring 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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MJF C I F S S
Fig. 4 Servostat / steering valve with primary pressure relief valve
5 Primary pressure relief valve in the steering 83 Measuring point for steering pressure
valve 84
29 84 Servostat A / steering valve B
88 Pressure relief valve / pump
13.10.5
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MJF C I F S S
3.4 Check of the secondary pressure relief valves 44 / shock valve 6 in the Servo-
stat / 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 Secondary pressure relief valves in the Servostat and shock valves in the steering valve
6 Shock valve in the steering valve 84 84 Servostat A / steering valve B

44 Secondary pressure relief valve in the Ser-
vostat 84
1 Hydraulic tank (*) 85 Rotary connection (320*)

5 Primary pressure relief valve in the 86 Steering cylinder
steering valve 84
6 Shock valve in the steering valve 84 87 Preload valve 3 bar (only in A 316)
29 Primary pressure relief valve in the Ser- 88 Pressure relief valve
vostat 84 A 309 / 311 from start of series
A 312 - 316 from serial no. 20241
31 Steering pump A 312 - 316 (*)
32 Steering pump A 309 / 311 (*) L Operating connection, turning left
44 Secondary pressure relief valve in the R Operating connection, turning right
Servostat 84
83 Measuring point for steering P Pressure connection
84 A Servostat T Return channel
84 B1 LAGS steering valve F Direction of travel
(A 309 from 20221
A 311 from 20222
A 312 and A 314 from 19112),
see group 13.22
84 B2 LAGZ steering valve
(A 316 from 17171),see group 13.24
* items in the hydraulic diagram of group 6.
13.10.6
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MJF C I F S S
Fig. 6 Diagram of the steering system with Servostat 84 A
13.10.7
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MJF C I F S S
Fig. 7 Diagram of the steering system with steering valves 84/B1, 84/B2 and pressure relief val-
ve 88
13.10.8
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MJF C I F S S
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
13.20.1
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Servostat Service Manual
General information
Equipment A 309 Li A 311 Li A 312 Li A 314 Li A 316-Li

from serial number 20221 20222 18161 2001 2001
Manufacturer model Servostat 2
Type no. 8474955194
Valve settings:
Pressure relief valve 29 (primary pressure) 18010 bar 18010 bar 18010 bar 18010 bar 18010 bar
Safety valves 44 (secondary pressure) 24010 bar 24010 bar 24010 bar 24010 bar 24010 bar
Pump rate of the hydraulic pump 82 39 l/min 39 l/min 44 l/min 44 l/min 44 l/min
Settings and torques for the installation of the Servostat
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 30 3 Nm
pressure relief valve (29)
Torque for the filter insert (43) 12 3 Nm
13.20.2
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MJF C I F S S
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 clockwi-
se or anticlockwise direction.
Spool 19.2 adjusted in axial direction
Hose safety limits the oil pressure that might occur in the lines L and
valve 44 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
TV check located in the pressure connection, preventing the taking in
valve 31 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 Component parts of the Servostat
3.1 Metering pump

The rotor 8.2 of the metering pump 8 is driven by the joint shaft 10 and is connected through the stee-
ring 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 zo-
nes 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 pla-
netary 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 con-
trol 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
13.20.3
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MJF C I F S S
metering pump.
4.1 Neutral position of the steering valve

If the steering wheel is not turned, the spool 19.2 is in neutral position. This allows for the flow gene-
rated by the pressure oil pump to exit the pressure channel P through the left and right return chan-
nels 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 mo-
vement 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 dis-
tribution 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 pres-
sure zone of the hand pump, the oil flows also through 3 assigned distributing channels to 3 distribu-
ting 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 opera-
ting 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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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.
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 esca-
ping 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).
13.20.5
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MJF C I F S S
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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MJF C I F S S
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 ope-
rated for the first time, we recommend to let the steering system run for a few minutes at various en-
gine 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 re-
commend 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.
13.20.7
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Inspection
1 Hex head screw 35.1 O-ring

2 Cover 36 Suction valve
3 Spacer 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 Stator 43 Filter
8.2 Rotor 44 Safety valve
9 Cover plate 44.4 Valve seat
10 Joint shaft 44.5 Valve seat
19 Housing / valve plunger 44.7 Tapered plug
19.1 Steering housing 50.1 Stop bushing
19.2 Spool 51 Flat spring
21 O-ring 51.1 Spacer plate
22 Plug 52 Spring carrier with centring spring
22.1 Pressure spring 55 Coupler
22.4 Stop / pressure relief valve 56 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 61 Backing ring
23.5 Valve guide 61.1 O-ring
29 Pressure relief valve 62 Spacer ring
30 O-ring 69 ID tag
31 TV check valve 70 Grooved drive stud
34 Plug 76 O-ring
35 O-ring 79 Flange
13.20.8
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Exploded view
6 Exploded view
Fig. 2 Exploded drawing of the Servostat
13.20.9
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Exploded view
8 Rotor kit (metering pump) 29 Pressure relief valve

8.1 Stator 31 TV check valve
8.2 Rotor 36 Suction valve
10 Joint shaft 44 Safety valve
19 Housing / valve plunger 52 Spring carrier with centring spring
19.1 Steering housing 56 Steering column
19.2 Spool 81 Hydraulic tank (1*)
22 Plug 82 Pump (32*)
22.1 Pressure spring 85 Oil rotary connection (320*)
22.4 Stop / pressure relief valve 86 Steering cylinder
23 Stop valve
13.20.10
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Sectional drawing of the Servostat
7 Sectional drawing of the Servostat
Fig. 3 Sectional drawing and hydraulic diagram of the Servostat
13.20.11
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MJF C I F S S
Exploded view of the steering column
8 Exploded view of the steering column
Fig. 4 Exploded view of the adjustable steering column for Servostat
1 Steering column 16 Hex nut

2 Shaft 17 Lock washer
3 Universal joint 18 Hex head screw
5 Hex nut 21 Roll pin
6 Pin 22 Washer
7 Hex nut 23 Hex nut
8 Absorber 24 Oval head screw
9 Rotating pin 25 Base plate
10 Washer 30 Pedal (old version)
15 Top plate 40 Pedal (new version)
13.20.12
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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 mode, the steering valve works with a rotor kit.
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
13.22.1
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Steering valve Service Manual
General information
Machine A 309 Li / A 311Li A 312 / A 314

from serial number 20221 / 20222 19112
Steering mode 2-wheel stee- 4-wheel stee- 2-wheel stee-
ring ring ring
Steering mode Steering valve Steering valve Steering valve

Manufacturer model LAGS 200/20 LAGS 200/20 LAGS 200/20
Max. flow rate 50 l/min 50 l/min
Valve settings:
Pressure-relief valve 5 (primary pressure) 180+10 bar 210+10 bar 180+10 bar
Shock valve 6 (secondary pressure) 240 10 bar 260 10 bar 240 10 bar
Pump rate of the hydraulic pump 31 / 32 39 l/min 39 l/min 44 l/min
Flow rate in servo operation 200 cm3/rev 200 cm3/rev 200 cm3/rev
Flow rate in emergency operation 20 cm3/rev 20 cm3/rev 20 cm3/rev
Pressure fluid temperature range -20 to +80 C -20 to +80 C -20 to +80 C
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 pressu-
re).
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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MJF C I F S S
Design
Fig. 2 Design of steering valve, diagram
1 Spool 7 Suction valve

2 Control sleeve 8 Suction valve
3 Rotor kit 9 Check valve
5 Pressure-relief valve 24 Valve housing
6 Shock valve
13.22.3
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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 slee-
ve 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.

By turning the steering wheel, the channel is closed. The rotor and the steering cylinder are now in
the desired position. The centring spring 4 aligns the spool 1 and the sleeve 2 and keeps them in
neutral position. If the steering wheel is not turned, the line between the pump connection P and the
tank connection T is opened and the pump volume flow is fed to the tank at virtually no pressure. In
neutral position, the connections L and R are closed.
The system pressure in the steering cycle is limited by the pressure-relief valve 5.
The two shock valves 6 shut off the connections L and R to the steering cylinder. If one of the shock
valves 6 is opened, the escaping oil is fed through the suction valve 7/8 to the opposite side, or the
leaked oil is sucked from the tank.
4.3 Emergency operation

In the event of a failure of the gear pump (steering pump), the steering valve acts as a hand pump.
If necessary, hydraulic oil can sucked through the suction valve 8 from the tank line, whereby the
check valve 9 prevents that air is being sucked in through the pump connection P.
13.22.4
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MJF C I F S S
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 Control sleeve 15 Hex head screw
3 Rotor kit 16 Cover
4 Centring spring 19 Thrust washer
5 pressure-relief valve 20 Drive shaft
6 Shock valve 21 Rotor gear
7 Suction valve 23 Needle roller
8 Suction valve 24 Valve housing
9 Check valve
13.22.5
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MJF C I F S S
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

Label the hydraulic lines of the steering valve, disconnect them and seal the openings (collect es-
caping oil).
Remove the mounting bolts M10 from the steering valve and the steering column and lift the stee-
ring 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).
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 re-
placed 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 "Dismant-
ling 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.
lock, while the engine is run at a medium speed (until operating temperature is reached).
Bleed the steering system.
13.22.6
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MJF C I F S S
Troubleshooting
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 ma-
chine.
To prevent this, bleed the system as described below:

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 partic-
les.
Therefore add hydraulic oil through the return filter.
10 Exploded view of the steering valve
Fig. 4 Exploded view of steering valve
13.22.7
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MJF C I F S S

3 Rotor kit 16 Cover
4 Centring spring 19 Thrust washer
5 Pressure-relief valve 20 Drive shaft
6 Shock valve 21 Rotor gear
7 Suction valve 23 Needle roller
9 Check valve 999 Seal kit
11 Exploded view of the steering column
Fig. 5 Exploded view of steering column

6 Bolt 22 Washer
13.22.8
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MJF C I F S S

10 Washer 30 Pedal
15 Top plate 40 Pedal
13.22.9
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MJF C I F S S
13.22.10
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MJF C I F S S
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.
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
13.24.1
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MJF C I F S S
General information
Machine A 900 C-Li A 904 C

from serial number 14675-18087 16000
Manufacturer model LAGZ 190 / 60 steering valve
Max. flow rate 50 l/min
Valve settings:
Pressure-relief valve 5 (primary pressure) 180 + 8 bar
Shock valve 6 (secondary pressure) 240 + 10 bar
Pump rate of the hydraulic pump 31 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
13.24.2
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MJF C I F S S
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 pressu-
re).
Shock valves 6 The shock valves limit the oil pressure that might occur in the
lines L and R to the operating cylinder (secondary pressu-
re).
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 emer-
gency
Housing 24 All parts of the steering valve are encased in the housing.
Tab. 2 Component parts of the steering valve
3.1 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.
13.24.3
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MJF C I F S S
Fig. 2 Design of the steering valve
1 Spool 9 Check valve

2 Control sleeve 10 Rotor kit 2
3 Rotor kit 1 11 Changeover housing
5 Pressure-relief valve 12 Changing piston
6 Shock valve 13 Pressure spring
8 Suction valve
see Fig. 3
4.1 Servo operation

Through the steering column, the spool 1 of the steering valve is rotated relatively to the steering slee-
ve 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 chan-
nels to the rotor let the rotor and thus the sleeve 2 rotate further.

By turning the steering wheel, the channels are closed. The rotor and thus the steering cylinder re-
main 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
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 lea-
ked oil is sucked from the tank respectively.

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 dis-
placement of the steering unit is thus reduced by the volume of the rotor kit 10. The rotor kit 3 deter-
mines 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
13.24.5
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MJF C I F S S
Fig. 3 Sectional drawing of the steering valve
1 Spool 13 Pressure spring

2 Control sleeve 14 Spacer bolt
3 Rotor kit 1 15 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 Check valve 21 Rotor gear 1
10 Rotor kit 2 22 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 val-
ve. 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 es-
caping oil).
Remove the M10 mounting bolts from the steering valve and the steering column and lift the stee-
ring 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
Connect the hydraulic lines to the steering valve (observe marks).

13.24.7
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MJF C I F S S
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 ope-
rated for the first time, we recommend to let the steering system run for a few minutes at various en-
gine speeds, without actually turning the steering wheel, allowing the oil to flush the system.
lock, while the engine is run at a medium speed (until the operating temperature is reached). Bleed
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
Exploded view of the steering valve
7 Exploded view of the steering valve
Fig. 4 Exploded drawing of the steering valve

3 Rotor kit 1 16 Cover
4 Centring spring 17 Rotor gear 2
5 Pressure-relief valve 18 Washer
6 Shock valve 19 Thrust washer
7 Suction valve 20 Drive shaft
8 Suction valve 21 Rotor gear 1
9 Check valve 22 Splined shaft
10 Rotor kit 2 23 Needle roller
11 Changeover housing 24 Valve housing
12 Changing piston 999 Seal kit
13 Pressure spring
13.24.9
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MJF C I F S S
Exploded view of the steering valve
7.1 Exploded view of the steering column
Fig. 5 Exploded view of the adjustable steering column for Servostat

6 Pin 22 Washer
10 Washer 30 Pedal
15 Top plate 40 Pedal
13.24.10
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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 si-
des).
The two rod ends are connected by joint tie rods and ball joints to the joint housings (steering knuck-
les). 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
13.32.1
copyright by
MJF C I F S S
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 fi-
gures 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.
Lift the undercarriage and secure the lifted undercarriage with suitable props.
Association (Tiefbau-Berufsgenossenschaft).
2.1 Dismantling of steering system and removing steering cylinder from the diffe-
rential
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 mo-
ving 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
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 Piston rod 5.24 Guard ring
5.20 Joint tie rod
Fig. 3 Section of the sectional drawing of the steering cylinder
5.1 Snap ring 5.8 Scraper ring

5.2 Cylinder head 5.9 Seal ring
5.3 Cylinder 5.10 Guide ring
5.4 Circlip 5.11 Guide ring
5.5 Piston rod with piston 5.12 O-ring
13.32.3
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MJF C I F S S

5.7 Backing ring
2.3 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".
K Piston seal Z Cylinder head seal

5.1 Snap ring 5.8 Scraper ring
5.2 Cylinder head 5.9 Seal ring
5.3 Cylinder 5.10 Guide ring
13.32.4
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MJF C I F S S
Sectional drawing of the steering cylinder
5.4 Circlip 5.11 Guide ring

5.5 Piston rod with piston 5.12 O-ring
5.7 Backing ring
3 Sectional drawing of the steering cylinder
Fig. 4 Sectional drawing of the steering cylinder
13.32.5
copyright by
MJF C I F S S
Sectional drawing of the steering cylinder
13.32.6
copyright by
MJF C I F S S
Design and function
Steering cylinders
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 si-
des).
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 hy-
draulic hoses and the oil rotary connection to the left or right connection of the steering cylinder re-
spectively, see also steering system, group 13.
13.34.1
copyright by
MJF C I F S S
2 Replacement of the steering cylinder sealing elements
Note!
The sealing elements can be replaced without removing the steering axle or the differential. The fi-
gures 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.
Lift the undercarriage and secure the lifted undercarriage with suitable props.
Association (Tiefbau-Berufsgenossenschaft).
2.1 Dismantling
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
Disconnect the axial joints 23 from the piston rod 8.

Remove the stop ring 26.
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 9 Piston rod with piston

4 Guide
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").
13.34.3
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MJF C I F S S
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 "APL-
B 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 Exploded drawing of the steering valve
13.34.4
copyright by
MJF C I F S S
Sectional drawing
10 Cylinder 400 Stop ring

70 Guide 550 Tie rod (left)
80 O-ring 560 Tie rod (right)
150 Scraper ring 600 Axial joint
160 Lip seal 605 Bellows
170 Piston rod with piston 610 Right ball joint
240 Seal ring 611 Left ball joint
250 Scraper 620 Clamp
280 Washer 630 Slotted nut
320 Guide 640 Cotter pin
350 Hex head screw 700 Axle housing
4 Sectional drawing
Fig. 5 Sectional drawing of the steering cylinder and the axial joint
13.34.5
copyright by
MJF C I F S S
Sectional drawing
Item ET item Designation Item ET item Designation

1 10 Cylinder 21 350 Hex head screw
2 30 O-ring 23 600 Axial joint
4 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 25 620 Clamp
9 180 Piston 26 400 Stop ring
15 240 Sealing ring 27 460 O-ring
16 150 Scraper 28 Right /left joint housing
17 280 Washer, of various thick- 29 700 Axle housing
ness
20 320 Guide
13.34.6
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MJF C I F S S
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
13.50.1
copyright by
MJF C I F S S
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 stee-
ring 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 Gear pump, steering column and steering valve
a Steering column 84 Steering valve

32 Gear pump / steering 88 Pressure-relief valve
2.3 Steering valve 92 for centring

The steering valve 92 located below the operator's cab base plate ensure that the wheels are auto-
matically 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
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 Y229-
1 and Y229-2 and mounted in the undercarriage.
The steering control A134 powers the respective solenoids Y229-1 and Y229-2. The steering cylin-
ders 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 ex-
ternal forces interfere with the system. The vehicle meets the TUEV requirements for travel on public
roads.
Fig. 3 6/3-way shift valve in upper carriage and 4/3-way shift valve and load-holding valve in un-
dercarriage
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
2.6 Rotary connection 260

The seven-fold oil rotary connection is a special connection for hydraulic oil between the uppercarri-
age 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 mo-
ved 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.
13.50.3
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MJF C I F S S
Description
Fig. 4 Rotary connection, slip ring rotary connection and steering cylinders
86-1 Front axle steering cylinder 260 Rotary connection 7 x

86-2 Rear axle steering cylinder 265 Slip ring rotary connection 9x
2.8 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 Electronic steering system A134, mounted to the revolving desk below the operator's cab
2.9 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
Operation of the 4-wheel steering
Fig. 6 Rotary switch and indicator lights
H191 Indicator light / 4-wheel steering S309 Selection switch for 2-wheel/4-wheel/
crab steer mode
H192 Crab steer indicator light
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.
= Rear 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.
= Rear axle left
= Rear axle right
The machine can now move sideward.
Tab. 3-1 Characteristics and advantages of the available steering modes
13.50.5
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MJF C I F S S
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 opera-
tor.
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 subse-
quently 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

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

13.50.6
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MJF C I F S S

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 stee-
ring 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 Switch / servo control

H192 Indicator light / crab steer mode S263 Switch / travel direction
S7 Safety switch with lever S309 Selection switch for 4-wheel/crab steer
mode
13.50.7
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MJF C I F S S
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.

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.
1 from/to tank A134 4-wheel steering control

31 Gear pump / low-pressure circuit + B248-H Proximity switch rear axle
brake
32 Gear pump / steering with pressure- B248-V Proximity switch front axle
relief valve
33 Gear pump / pilot control MP2 Ground connection
50 from the control oil unit S309 Selection switch / 4-wheel steering
83 Measuring point for steering pressure U16 Excavator control BST
84 Steering valve 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 Rear axle steering cylinder Y294-1 Solenoid shift valve for wheel centring
88P Distributor Y294-2 Solenoid shift valve for wheel centring
88T Collecting pipe
92 6/3-way shift valve
98 Load-holding valve
260 Rotary connection 7 x
265 Slip ring rotary connection 9x
13.50.8
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MJF C I F S S
Fig. 8 4-wheel steering in neutral position
13.50.9
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MJF C I F S S
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 con-
nection 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.

brake
relief valve
88T Collecting pipe
13.50.10
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MJF C I F S S
Fig. 9 2-wheel steering
13.50.11
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MJF C I F S S
4.3 4-wheel steering

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.
nection 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 stee-
ring cylinder 86-1.
The wheels of the front axle are moved to the right, and the vehicle travels to the right.

brake
relief valve
88T Collecting pipe
13.50.12
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MJF C I F S S
Fig. 10 4-wheel steering
13.50.13
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MJF C I F S S
4.4 Crab steering

The steering valve 92 is in neutral position and the shift valve 94 is in working position II.
The indicator lamp H192 is on.
nection 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 displaced oil from the right side of the steering cylinder 86-2 is fed through the valve 98 connec-
tion C1- V1, and the valve 94 connection B-P, pressurising the right connection of the steering cylin-
der 86-1. The wheels of the front axle are moved to the right, and the vehicle travels to the right.

brake
relief valve
88T Collecting pipe
13.50.14
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MJF C I F S S
Fig. 11 Crab steering
13.50.15
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MJF C I F S S
4.5 Reset (centring) of wheels prior to switching to a different steering mode
4.5.1 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 po-
sition).
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.

brake
relief valve
88T Collecting pipe
13.50.16
copyright by
MJF C I F S S
Fig. 12 Centring from 2-wheel steering mode
13.50.17
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MJF C I F S S
4.5.2 Centring from 4-wheel steering mode after steering to the right
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.
tion P-A, and the valve 98 connection V2 - C2, pressurising the left connection of the steering cylinder
86-2.
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.
P-T, the rotary connection 260 connection 5 and the valve 92 connection A - T1 back to the tank 1.

brake
relief valve
88T Collecting pipe
13.50.18
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MJF C I F S S
Fig. 13 Centring from 4-wheel steering mode after steering to the right
13.50.19
copyright by
MJF C I F S S
4.5.3 Centring from crab steering mode after steering to the right
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.
tion P-B, and the valve 98 connection V1 - C1, pressurising the right connection of the steering cy-
linder 86-2.
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.
P-T, the rotary connection 260 connection 5 and the valve 92 connection A - T1 back to the tank 1.

brake
relief valve
88T Collecting pipe
13.50.20
copyright by
MJF C I F S S
Fig. 14 Centring of wheels from crab steer mode
13.50.21
copyright by
MJF C I F S S
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 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 pres- 260 Rotary connection
sure
84 Steering valve Y294-1 Solenoid
88P Distributor Y294-2 Magnet
13.50.22
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MJF C I F S S
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 changeo- Y294-1 Solenoid
ver)
98 Load-holding valve Y294-2 Solenoid
13.50.23
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MJF C I F S S
Electrical system
6 Electrical system
Fig. 17 Electrical components in uppercarriage
A127 printed circuit board / power KS Wire harness of potentiometer board

A125
A134 4-wheel steering control S309 Selection switch / 4-wheel steering
F356 Fuse / 4-wheel steering, terminal 15 X1117 Plug connection / 4-wheel steering, 6-
pin
F357 Fuse / 4-wheel steering, terminal 30 Y294-1 Solenoid shift valve for wheel centring
H191 Indicator light / 4-wheel steering Y294-2 Solenoid shift valve for wheel centring
H192 Crab steer indicator light
13.50.24
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MJF C I F S S
Electrical system
Fig. 18 Electrical components in undercarriage
265 Slip ring rotary connection X1090 Plug connection / 6-pin

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
13.50.25
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MJF C I F S S
Block diagram of 4-wheel steering
7 Block diagram of 4-wheel steering
Fig. 19 Block diagram
A134 4-wheel steering control K370 Relay / terminal 15 servo

A125 Potentiometer board K445 Relay / travel shut-off /4-wheel steering
A126 Printed circuit board (auto check) MP V Ground connection / distribution board
A127 Printed circuit board / power S35 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 Fuse / 4-wheel steering, terminal 15 RS232 Laptop interface
F357 Fuse / 4-wheel steering, terminal 30 Y229-1 Solenoid shift valve for crab steering
H27 Warning buzzer Y229-2 Solenoid shift valve for 4-wheel steering
H191 Indicator light / 4-wheel steering Y294-1 Solenoid shift valve for wheel centring
H191 Crab steer indicator light Y294-2 Solenoid shift valve for wheel centring
K252 Relay / servo
13.50.26
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MJF C I F S S
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 sig-
nal 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 con-
ditions, (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 ac-
tivated; 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
13.50.27
copyright by
MJF C I F S S
Fault messages
13.50.28
copyright by
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 20221-

A 311 LI 20222-
A 312 LI 12363-
A 314 LI 2001-
A 316 LI 2001-
A 316 LI-IND 2001-
Support cylinders 14.20.1 A 309 LI 20221-

A 311 LI 20222-
A 312 LI 12363-
A 314 LI 2001-
A 316 LI 2001-
A 316 LI-IND 2001-
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
14.10.1
copyright by
MJF C I F S S
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 stee-
ring 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 con-
nected 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 restric-
tor (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 con-
tent 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 oscilla-
ting 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 Undercarriage with support cylinders and main components
1 Support cylinder, complete 5 Stop valve

2 Piston 10 Undercarriage
14.10.2
copyright by
MJF C I F S S
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-pres-
sure 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 val-
ves 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 A Control oil unit for model A 309 / 311 from
start of series
320 Rotary connection 7 x for high pressure 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
14.10.3
copyright by
MJF C I F S S
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 Switch safety lever

tic
H176 Indicator light of automatic support S75 Rotary switch of oscillating axle sup-
port
H311 Indicator light / oscillating axle locked
3 Operation of oscillating axle support
3.1 Releasing oscillating axle locking system

The safety lever S7 is turned down.
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 direc-
tion or otherwise change the kinematics of the equipment.
Operating status:
14.10.4
copyright by
MJF C I F S S
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

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 oscil-
lating 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).

Turn the switch S75 to position A.
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 wit-
hout load, or load swivelled in travel direction)
14.10.5
copyright by
MJF C I F S S
Function of the oscillating axle support mechanism
4 Function of the oscillating axle support mechanism
4.1 Oscillating function
4.1.1 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 con-
nected to each other through the connection P at the cylinder 1 and the connected lines. The oscil-
lating 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
The valve cone of the stop valve 5 is lifted from its seat so that the two support cylinders are connec-
ted 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 Support function
4.2.1 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
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
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 posi-
tion, 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
copyright by
MJF C I F S S
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 Stop valve 320 Rotary connection 7 x
11 Check valve 322 Rotary connection 6 x
20 Restrictor
14.10.7
copyright by
MJF C I F S S
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 Functional test of the locked oscillating axle
14.10.8
copyright by
MJF C I F S S
Functional test
14.10.9
copyright by
MJF C I F S S
Hydraulic diagram
7 Hydraulic diagram
1 Cylinder H176 Indicator light of oscillating axle automatic

2 Piston H311 Indicator light / oscillating axle locked
5 Stop valve K250 Relay / oscillating axle automatic
11 Check valve S35 Switch / servo control
6 bar preload
20 Restrictor ( 1.5 mm) S75 Rotary switch of the automatic oscillating
axle Oscillating axle support
24 Diaphragm accumulator V155 Blocking diode S75-K250
32 Gear pump / brake and pilot control V156-2 Blocking diode S75-H311
unit (312 316)
33 Gear pump/pilot control unit (309- X197 Plug connection B266 / 3-pin
311)
49 Measuring point for pilot pressure X842-3 Plug connection A1001 - B266 / 2-pin
50 Control oil unit X856 Plug connection to BST / 40-pin
170 Leak oil line from travel motor X857 Plug connection to BST / 24-pin
302 Line to steering system (309-311) X950 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 Printed circuit board (autocheck) X958 Plug connection switch distributor / 21-pin
B266 Proximity switch / brake pedal X960 Plug connection operator's platform distribu-
tor / 21-pin
C Version in models A 309 / A 311 X961 Plug connection indicator distributor / 21-pin
D Version in models A 312 to serial X963 Plug connection fuse distributor / 21-pin
no. 20329 / A 314 to serial no.
20333 /
A 314 to serial no. 20339
F316 Fuse servo steering / 15 A X964 Plug connection fuse distributor / 21-pin
F326 Fuse S75 / 15 A X974-2 Plug connection blocking diode / 2-pin
F329 Fuse S35 / 5 A Y371 Solenoid valve / oscillating axle support
C in models A 309 and A 311 D in models A 312 to serial no. 20329

A 314 to serial no. 20333 and
14.10.10
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MJF C I F S S
Hydraulic diagram
Fig. 7 Diagram of electric and hydraulic system for automatic oscillating axle support
14.10.11
copyright by
MJF C I F S S
Hydraulic diagram
14.10.12
copyright by
MJF C I F S S
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 machi-
ne is in working position, it is supported by the pistons 2, which are resting on oil columns in the cy-
linder 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 5 Stop valve

2 Piston
14.20.1
copyright by
MJF C I F S S
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 Exploded view of the support cylinder 1
2 Piston 15 Guide ring
5 Stop valve 801 Corrosion inhibitor Tarp
10 Special scraper ring 999 Seal kit
12 Turcon-Stepseal ring
14.20.2
copyright by
MJF C I F S S
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 con-
nection 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 cham-
ber 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
14.20.3
copyright by
MJF C I F S S
Maintenance
5 Stop valve, complete 24 Backing ring

11 Release piston 26 O-ring
14 Restrictor 27 O-ring
16 Pressure spring 31 Valve cone
17 Pressure spring 32 Spring plate
18 Ball 33 Pressure spring
21 Connector screw 34 Snap ring
22 O-ring 35 Valve housing
23 O-ring
4 Maintenance
The regular maintenance of the support cylinder includes a visual inspection of the cylinder for lea-
kage 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
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.
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 func-
tional test, see group 14.10.
Fig. 4 Installation of the support cylinders to the undercarriage
1 Support cylinder 29 Washer

14.20.5
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MJF C I F S S
Sealing the support cylinders
6 Sealing the support cylinders
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
Sealing the support cylinders
Fig. 5 Correct installation of the Turcon-Stepseal ring
1 Cylinder 12 Turcon-Stepseal ring

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.
14.20.7
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MJF C I F S S
Sectional drawing
7 Sectional drawing
1 Cylinder 21 Connector screw

2 Piston 22 O-ring
5 Stop valve 23 O-ring
10 Special scraper ring 24 Backing ring
11 Release piston 26 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 Pressure spring 35 Valve housing
18 Ball
14.20.8
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MJF C I F S S
Sectional drawing
Fig. 6 Sectional drawing of the support cylinder and the stop valve
14.20.9
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MJF C I F S S
Sectional drawing
14.20.10
copyright by
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 20221-

A 311 LI 20222-
A 312 LI 12363-
A 314 LI 2001-
A 316 LI 2001-
A 316 LI-IND 2001-
Hydraulic brake system 15.10.1 A 309 LI 20221-

A 311 LI 20222-
A 312 LI 12363-
A 314 LI 2001-
A 316 LI 2001-
A 316 LI-IND 2001-
Compact brake block 15.20.1 A 309 LI 20221-

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

Machine Litronic Litronic Litronic
Einheit
Series from from from
20221 20222 2001
Gear pump 31 / 32
Brake oil max. l/min 2 2
Accumulator charging valve 5
in compact brake block 4
Switch-on pressure bar 125 5 125 5
5
Shut-off pressure bar 150 150 5
Switching range bar 20 +15 20 +15
Shifting pressure of pressure switch B20 bar
abate 100 5 100 5
rise 125 5 125 5
Brake system
Brake pressure in front and
rear brake circuits (measuring point 25 / bar 50+5 55 +5 75 +10
26)
Shifting pressure of pressure switch B60 bar 5 5
Accumulators 14 and 15
Rated flow cm3 700 700
Filling pressure (nitrogen) bar 40 40
Max. permissible pressure bar 180 180
A 316
Machine
Einheit Litronic
Series
from 28061
Gear pump 31 / 32
Brake oil max. l/min 2
Accumulator charging valve 5
in compact brake block 4
Switch-on pressure bar 150 5
Shut-off pressure bar 185 5
Switching range bar 35 +15
15.05.1
copyright by
MJF C I F S S
Operating pressures of the brake system Service Manual
General information
A 316
Machine
Einheit Litronic
Series
from 28061
Shifting pressure of pressure switch B20 bar
abate 100 5
rise 125 5
Brake system
Brake pressure in front and
rear brake circuits (measuring point 25 / bar 75 +10
26)
Shifting pressure of pressure switch B60 bar 5
Accumulators 14 and 15
Rated flow cm3 1000
Filling pressure (nitrogen) bar 45
Max. permissible pressure bar 200
15.05.2
copyright by
MJF C I F S S
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
15.10.1
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MJF C I F S S
Hydraulic brake system Service Manual
Design of brake system
21 Multi-disc brake, rear H23 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 hy-
draulic 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 Gear pumps flange-mounted to the diesel engine
4 to compact brake block 31 Gear pump with flow distributor for low-pres-
sure circuit and brake system (A309/311)
27 Measuring point / accumulator pressure 32 Gear pump with flow distributor for pilot con-
trol and brake system (A312-316)
K Connection for constant flow of the flow dis-
tributor
2.2 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 bra-
ke 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
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 elec-
trical 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 automa-
tic
15.10.3
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MJF C I F S S
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
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 spring-
facing surface of the pressure balance 6 and also relieves this surface to the connection T. The pres-
sure 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
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 in-
wards, 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 estab-
lished 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.
15.10.5
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MJF C I F S S
4 Compact brake block 38 Piston/pressure balance

6 Pressure balance 50 Pressure spring / pilot control piston
7 Pressure regulator 51 Pressure spring / accumulator pressure
8 Check valve 52 Pressure spring / brake piston return
9 Double check valve 53 Pressure spring / brake piston return
10 Foot brake valve 56 Pressure spring / pressure balance
11 Foot brake pedal with housing 57 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 Measuring point / front brake pressure 102 Threaded bolt
26 Measuring point / rear brake pressure 131 Sleeve
27 Measuring point / accumulator pressure 132 Bushing
31 Gear pump / low pressure relay and 135 Pilot control piston
brake system (A 309/311)
32 Gear pump / pilot control and brake 322 Rotary connection
system (A 312- 316)
15.10.6
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MJF C I F S S
Fig. 5 Sectional drawing of the compact brake block with hydraulic lines
15.10.7
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MJF C I F S S
Bleeding of the brake system
Note!
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 en-
gine.
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 Bleeder valve B Dust cap
Start diesel engine and let it run for approx. 2 minutes.

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
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!
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 mo-
del A 312.
Fig. 7 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 27 Measuring point / accumulator pressure

26 Measuring point / rear brake pressure
5.2.1 Measuring point 25

Used to check the brake pressure in the front brake circuit.
15.10.9
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MJF C I F S S
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 char-
ging 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 Fork head 75 Lock nut
17 Lock nut 102 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 as-
sembly 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 prescri-
bed value by turning the adjusting screw 74 (see operating pressures, group 15.05).
15.10.10
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MJF C I F S S
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 Foot brake pedal 18 Bolt
12 Locking lever 29 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 respec-
tive 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 pres-
sure.
Re-tighten the lock nut 17.
15.10.11
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MJF C I F S S
Disengage the pedal 11.

Unlock and drive out the pin 18 ( 10 mm) inserted between the fork head 16 and the pedal lever,
and insert a 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 in-
serted pin.
Secure the stop screw 29 with a lock nut.
Remove the 9 mm adjusting pin and re-insert and lock the original 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.
1 Hydraulic tank 28 Diesel engine

4 Compact brake block 31 Gear pump / low pressure circuit and
brake (A309-311)
5 Accumulator charging valve 32 Gear pump / pilot control and brake
system (A312-316)
6 Pressure balance 38 Piston
7 Pressure regulator 51 Pressure spring / accumulator pressure
8 Check valve 57 Pressure spring / brake pressure
9 Shuttle check valve / double check 58 Pressure spring / brake pressure
valve
10 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 Multi-disc brake / steering axle 322 Rotary connection 6 x
21 Multi-disc brake / rigid axle B20 Pressure switch / accumulator charge
pressure
22 Drum brake / rigid axle B60 Pressure switch / brake light
25 Measuring point / front brake circuit E19 Right brake light
26 Measuring point / rear brake circuit E20 Left brake light
27 Measuring point / accumulator charge H23 Indicator light / accumulator charging
pressure pressure
15.10.12
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MJF C I F S S
Hydraulic diagram
6 Hydraulic diagram
Fig. 10 Hydraulic brake system
15.10.13
copyright by
MJF C I F S S
Hydraulic diagram
15.10.14
copyright by
MJF C I F S S
Service Manual Compact brake block
Design
Compact brake block
1 Design

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 dif-
ferent brake circuit containing oil, which is taken from the respective accumulator circuits.
Fig. 1 Compact brake block 4
15.20.1
copyright by
MJF C I F S S
Compact brake block Service Manual
Functional description of the accumulator charging valve 5
2 Functional description of the accumulator charging valve 5

The accumulator charging valve 5 or the pressure shut-off valve ensures that the pressure in the bra-
ke 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 switch-
on 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 pres-
sure 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 ope-
ned).
If the pressure in the accumulator circuit drops below the lower switching point (switch-on point) the
spool 72 is pushed by the pressure spring 51 into its basic position. As a result, pressure is applied
to the spring side face of the pressure balance 6. The piston 38 blocks the connection P-N and the
gear pump 33 pumps the oil again into the accumulator circuit.
15.20.2
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MJF C I F S S
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 to multi-disc brake or drum brake / rigid axle
Connection DS1 Pressure switch / brake light (B60*)
Connection DS2 Pressure switch / accumulator pressure (B20*)
* item in electrical diagram
15.20.3
copyright by
MJF C I F S S
Connections at the compact brake block
Fig. 3 Hydraulic diagram of compact brake block
1 to hydraulic tank 31 from gear pump with flow distributor (A 309-

311)
4 Compact brake block 32 from gear pump with flow distributor (A 312-
316
5 Accumulator charging valve 38 Piston / pressure balance
6 Pressure balance, complete 51 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 Brake valve, complete 64 Brake piston
11 Brake pedal 72 Spool
14 to brake accumulator / steering axle 88 to collecting pipe
circuit
15 to brake accumulator / rigid axle cir- 135 Pilot control piston
cuit
20 to brake cylinders / steering axle with 999 Seal kit, complete, consisting of
multi-disc brake bellows, radial shaft seal ring and various
backing and O-rings
21 to brake cylinders / rigid axle with
multi-disc brake
15.20.4
copyright by
MJF C I F S S
Sectional drawing
22 to brake cylinders / rigid axle with B20 Pressure switch / accumulator pressure
drum brake
27 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
15.20.5
copyright by
MJF C I F S S
Sectional drawing
Fig. 5 Exploded view of compact brake block from start of series production
4 Compact brake block 64 Brake piston

5 Accumulator charging valve 66 Screw plug
6 Pressure balance, complete 72 Spool
7 Pressure control element, com- 77 Screw plug
plete
8 Check valve 78 Snap ring
9 Double check valve 81 Pin
10 Foot brake valve, complete 102 Threaded bolt
15 Washer 130 Valve insert, complete
22 Washer 131 Sleeve
24 Pipe 132 Bushing
31 Spring plate 133 Sleeve
38 Piston 134 Check valve
39 Spring plate 135 Pilot control piston
49 Pressure spring 141 Pressure switch
50 Pressure spring 142 Seal ring
51 Pressure spring 144 Pressure switch
52 Pressure spring 163 Reducer
53 Pressure spring 165 Screw plug
56 Pressure spring 166 Reducer
15.20.6
copyright by
MJF C I F S S
Sectional drawing
57 Pressure spring 999 Seal kit, complete

58 Pressure spring B20 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
15.20.7
copyright by
MJF C I F S S
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 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-
Pipe fracture safety valve for stick cylinder 16.06.1 A 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-
Pipe fracture safety valve 16.10.1 A 312 LI 12363-

for regulating cylinder A 314 LI 2001-
A 316 LI 2001-
A 316 LI-IND 2001-
R 317 LI 18161-
Overload warning system 16.12.1 A 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-
Hydraulic quick change adapter 16.16.1 A 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-
Flow reduction 16.19.1 A 309 LI 20221-

A 311 LI 20222-
16.1
MJF C I F S S
Service Manual
Flow reduction 16.20.1 A 312 LI 12363-

A 314 LI 2001-
A 316 LI 2001-
A 316 LI-IND 2001-
LIKUFIX Hydraulic Coupling System 16.24.1 A 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-
Hydraulic hammers 16.30.1 A 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-
Accessory kit AS1 16.44.1 A 312 LI 12363-

A 314 LI 2001-
A 316 LI 2001-
A 316 LI-IND 2001-
R 317 LI 18161-
Accessory kit AHS 1 16.48.1 A 312 LI 12363-

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

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

A 311 LI 20222-

A 314 LI 2001-
A 316 LI 2001-
A 316 LI-IND 2001-
R 317 LI 18161-
16.2
MJF C I F S S
Service Manual
SUBGROUP - INDEX
Section Group Type
Accessory kit AHS 11 / AHS 12 16.57.1 A 312 LI 12363-

with Tool Control A 314 LI 2001-
A 316 LI 2001-
A 316 LI-IND 2001-
R 317 LI 18161-
Accessory kit AHS 12 with changeover valve 16.58.1 A 312 LI 12363-

A 314 LI 2001-
A 316 LI 2001-
A 316 LI-IND 2001-
R 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 23702-

A 311 LI 23254-
Kit for control switch-over 16.64.1 A 312 LI 12363-

A 314 LI 2001-
A 316 LI 2001-
A 316 LI-IND 2001-
Dozer blade 16.66.1 A 312 LI 12363-

A 314 LI 2001-
A 316 LI 2001-
A 316 LI-IND 2001-
Hydraulic cab elevation system 16.70.1 A 312 LI 12363-

A 314 LI 2001-
A 316 LI 2001-
A 316 LI-IND 2001-
R 317 LI 18161-
Speeder kit 16.74.1 A 312 LI 12363-

A 314 LI 2001-
A 316 LI 2001-
A 316 LI-IND 2001-
16.3
MJF C I F S S
Service Manual
Generator drive accessory kit 16.86.1 A 316 LI-IND 2001-
16.4
MJF C I F S S
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 re-
quired 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)
16.04.1
copyright by
MJF C I F S S
Pipe fracture safety valve for boom cylinders Service Manual
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 pres-
sure spring 29.6, which results in a relief of the piston side. The oil escapes partly through the rest-
rictor 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 rest-
rictor 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 th-
rough the respective connection in the control block to the rod side of the cylinder 160/235.
Key of sectional drawing, see Fig. 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 Screw plug with O-ring 19 Screw plug with O-ring
7 Pilot control piston, complete 23 Restrictor check valve
7.1 Valve guide 27 Protective cap
7.2 Adjusting screw 29 Pressure-relief valve, complete
7.3 Protective cap 29.1 Valve guide
16.04.2
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MJF C I F S S
Sectional drawing
7.4 Seal ring 29.2 Adjusting screw

7.5 Pressure spring 29.3 Lock nut
7.6 Valve cone 29.4 Spring guide
7.7 Valve plunger 29.5 Seal ring
8 Check valve, complete 29.7 Valve cone
8.1 Valve guide 30 Filter cartridge
8.2 Cone 31 Screw plug with seal ring
9 O-ring 40 Slide ring
11 O-ring 42 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
16.04.3
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MJF C I F S S
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 obser-
ved.
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 val-
ve/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 depres-
surised)

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
control system on).
16.04.4
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MJF C I F S S
Remove the measuring hose and screw coupling.

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 238 Pipe fracture safety valve
16.04.5
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MJF C I F S S
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.
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.
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 val-
ves and replace them with new valves preset by the manufacturer.
ved.
5.1 Pressure check, see Fig. 4

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 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 Mini-
mess 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 measu-
ring connection 52 of the valve 258 (connection E).
Turn the secondary pressure-relief valve 131/221 (spool 106/220) to extend the boom cylinder to
minimum 150 bar.
Reduce the pressure, so that the oil can flow through connection V2 of valve 238.
Fully pressurise the bucket and grapple cylinder to reach maximum pressure.
Turn in the secondary pressure valve 133/262 (spool 107/260) for extending the bucket cylinder,
(increase the pressure above the prescribed adjusting pressure of the valve = 410 + 10 bar).
Slowly turn in the pressure cut-off valve 104 (A 312- R 317) or the primary pressure-relief valve
120/122 (A 309 - A 311) and listen for pressure sounds.
When the secondary pressure-relief valve 29, (see Fig. 2 on page3), opens, a hissing sound
is audible.
16.04.6
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MJF C I F S S
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 frac-
ture 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 Secondary pressure-relief valve / exten-
ding boom cylinder
52 Measuring neck 133 Secondary pressure-relief valve / exten-
ding bucket cylinder
100 Compact control block 220 Boom cylinder spool ( 312 - 317)
104 Pressure cut-off valve (A 312 - R 317) 221 Secondary pressure-relief valve / exten-
ding boom cylinder
16.04.7
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MJF C I F S S
106 Spool / boom cylinder 238 Pipe fracture safety valve

107 Spool / bucket cylinder 260 Bucket cylinder spool ( 312 - 317)
120 Primary pressure-relief valve (A 309/ 311) 262 Secondary pressure-relief valve / exten-
5.2 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. 50C), 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 dama-
ged.
In this case, replace the valve, (see 4.2 on page4).
50 to control oil unit 160 Boom cylinder

52 Bleeding and measuring connection 235 Boom cylinder
88T Collecting pipe 238 Pipe fracture safety valve
16.04.8
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MJF C I F S S
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
16.04.9
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MJF C I F S S
6.2 Models A 312 - R 317
Fig. 6 Hydraulic connections and lines in models A 312 R 317
16.04.10
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MJF C I F S S
16.04.11
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MJF C I F S S
Components of hydraulic diagram, see Fig. 7
1 to hydraulic tank 130 to slewing gear motor

6 to hydraulic oil cooler 131 Secondary pressure-relief valve / exten-
ding 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 1 238.7 Control piston
(lowering attachment)
81/3 from right pilot control unit / connection 3 238.8 Check valve
(lifting attachment)
100 Control valve block 238.23 Restrictor check valve
106 Spool / boom cylinder 238.29 Pressure-relief valve
238.30 Filter
16.04.12
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MJF C I F S S
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
16.04.13
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MJF C I F S S
Components of hydraulic diagram, see Fig. 8
1 to hydraulic tank 221 Secondary pressure-relief valve / exten-

ding 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 Measuring point MP 235 Boom cylinder
50 to control oil unit 238 Pipe fracture safety valve
52 Bleeding and measuring connection 238.7 Control piston
81/1 from right pilot control unit / connection 1 238.8 Check valve
(lowering attachment)
81/3 from right pilot control unit / connection 3 238.23 Restrictor check valve
(lifting attachment)
100 Control valve block 238.29 Pressure-relief valve
220 Spool / boom cylinder 238.30 Filter
16.04.14
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MJF C I F S S
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
16.04.15
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MJF C I F S S
16.04.16
copyright by
MJF C I F S S
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 (pis-
ton 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 re-
quired 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)
16.06.1
copyright by
MJF C I F S S
Pipe fracture safety valve for stick cylinder Service Manual
Sectional drawing, see Fig. 2, hydraulic diagrams see Fig. 7 and Fig. 8 and Fig. 9.
2.1 Single-side pipe fracture safety valve (A 309 - R 317)
2.1.1 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 val-
ve 258. This pressure is applied through the connection Pil and the restrictor check valve 23.
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

sure 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 Double-side pipe fracture safety valve (A 312 - R 317 only)
2.2.1 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.
16.06.2
copyright by
MJF C I F S S
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 comple-
ted, 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

rictor 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.
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 comple-
ted, 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

rictor 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.
16.06.3
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MJF C I F S S
Key of sectional drawing, see Fig. 2
1 O-ring 14 Spring guide

3 Pilot piston 16 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 Valve guide 29 Pressure-relief valve, complete
7.2 Adjusting screw 29.1 Valve guide
7.3 Protective cap 29.2 Adjusting screw
7.4 Seal ring 29.3 Lock nut
7.5 Pressure spring 29.4 Spring guide
7.6 Valve cone 29.5 Seal ring
7.7 Valve plunger 29.6 Pressure spring
7.8 O-ring 29.7 Valve cone
8 Check valve, complete 30 Filter cartridge
8.1 Valve guide 31 Screw plug with seal ring
8.2 Cone 40 Slide ring
9 O-ring 41 O-ring
10 Slide ring 42 Valve seat (sleeve)
12 Valve seat (sleeve) 44 Spring guide
13 Pressure spring
16.06.4
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MJF C I F S S
Sectional drawing
3 Sectional drawing
Fig. 2 Sectional drawing of pipe fracture safety valve
16.06.5
copyright by
MJF C I F S S
4 Repair and sealing of valve 258

.
Danger!
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.
ved.
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.
4.2 Assembly and dismantling of the pipe fracture safety valves
Danger!
Never open the hydraulic circuit of the pipe fracture safety valves while the circuit is pressurised.
surised)

Depressurise the pipe fracture safety valve(s) by actuating the pilot control device for lifting and
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

Release the tank pressure and the load-holding valves by actuating the pilot control device for lo-
wering to the stop and holding it in this position while the diesel engine is off (ignition and pilot
control system on).
16.06.6
copyright by
MJF C I F S S
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
16.06.7
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MJF C I F S S
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.
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.
ves and replace them with new valve preset by the manufacturer.
ved.
5.1 Pressure check, see Fig. 4

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 Mini-
mess 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 measu-
ring 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 cy-
linder 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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MJF C I F S S
If the prescribed adjusting pressure is not reached in the above test, replace the entire pipe frac-
ture 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
A Pipe fracture safety valve, single side (A 127 Secondary pressure-relief valve / exten-
309 - R 317) ding stick cylinder
A Pipe fracture safety valve, double side 128 Secondary pressure-relief valve / exten-
(A 312 - R 317) ding stick cylinder
5 Screw plug 133 Secondary pressure-relief valve / exten-
40 Measuring point P1 (A 309 - A 311) 170 Stick cylinder
41 Measuring point MP (A 312 - R 317) 240 Spool of stick cylinder (312 - 317)
52 Measuring neck 241 Secondary pressure-relief valve / retrac-
ting stick cylinder
100 Compact control block 242 Secondary pressure-relief valve / exten-
ding stick cylinder
104 Pressure cut-off valve (A 312 - R 317) 255 Stick cylinder
102 Spool of stick cylinder (A 309 - 311) 258 Pipe fracture safety valve
107 Bucket cylinder spool (A 309 - 311) 260 Bucket cylinder spool (312 - 317)
120 Primary pressure-relief valve (A 309 A 262 Secondary pressure-relief valve / exten-
311) ding bucket cylinder
122 Primary pressure-relief valve (A 309/
311 with AHS)
16.06.9
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MJF C I F S S
6.1 Single-side pipe fracture safety valve, models A 309 - A 311
Fig. 5 Hydraulic connections and lines in models A 309 - 311
52 Bleeding connection / Minimess 170 Stick cylinder

88T Collecting pipe 258 Pipe fracture safety valve
16.06.10
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MJF C I F S S
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
16.06.11
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MJF C I F S S
Components in hydraulic diagram, see Fig. 7 and Fig. 8 and Fig. 9
1 Hydraulic tank 170 Stick cylinder

6 to hydraulic oil cooler 171 Restrictor check valve / stick cylinder
20 from variable-displacement pump 240 Spool / stick cylinder
23 to pump regulator 241 Secondary pressure-relief valve / retrac-
ting stick cylinder
41 Measuring point P2 (A 309 - A 311) 242 Secondary pressure-relief valve / exten-
ding stick cylinder
41 Measuring point MP (A 312 - R 317) 244 Pressure balance
50 Screw coupling (install for measure- 247 Restrictor check valve
ment)
52 Measuring and bleeding connection 255 Stick cylinder
80/1 from left pilot control unit / connection 1 258 Pipe fracture safety valve
(retracting stick cylinder)
80/3 from left pilot control unit / connection 3 258.7 Control piston
(extending stick cylinder)
100 Control valve block 258.8 Check valve
102 Spool / stick cylinder 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
16.06.12
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MJF C I F S S
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
16.06.13
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MJF C I F S S
7.2 Single-side pipe fracture safety valve, models A 312 - R 317
16.06.14
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MJF C I F S S
7.3 Double-side pipe fracture safety valve, models A 312 - R 317
16.06.15
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MJF C I F S S
16.06.16
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MJF C I F S S
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
16.10.1
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MJF C I F S S
Pipe fracture safety valve for regulating cylinder Service Manual
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 con-
nection V2. The sleeves 57 is shifted, and pressure oil pressurises the piston side of the cylinder th-
rough 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 con-
nection V2. The sleeves 57 is shifted, and pressure oil pressurises the piston side of the cylinder th-
rough 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 pres-
sure-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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MJF C I F S S
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 O-ring 42 O-ring
6 Screw plug 50 Pilot piston
8 Screw plug 51 Valve plunger
9 O-ring 52 Valve guide
10 Backing ring 53 Valve cone
12 O-ring 55 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 O-ring 61 Nozzle ( 0.6 mm)
34 O-ring
16.10.3
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MJF C I F S S
Repair and sealing of valve 516 / 517
3 Repair and sealing of valve 516 / 517

.
Danger!
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 sup-
plied and preset by the manufacturer.
ved.
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.
3.2 Mounting and dismantling of the pipe fracture safety valves
Danger!
Never open the hydraulic circuit of the load-holding valves while the circuit is pressurised.
surised).

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

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).
16.10.4
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MJF C I F S S
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
16.10.5
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MJF C I F S S
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 ma-
chine. There is a risk to life and limb for mechanics from uncontrolled machine movements.
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 set-
tings have been tampered with.
ves and replace them with new valve preset by the manufacturer.
ved.
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
Fig. 4 Exploded view from ET list
1 Hydraulic tank 500 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 Load-holding valve, piston side
517 Load-holding side, piston rod side
16.10.7
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MJF C I F S S
Components in hydraulic diagram, see Fig. 5

1 to hydraulic tank 86 from auxiliary pilot control unit
6 to oil cooler 100 Control valve block
20 from variable-displacement pump 104 Pressure cut-off valve
23 to pump regulator 500 Auxiliary control axle with spool for regu-
lating cylinder
41 Measuring point MP for pump pressure 501 Secondary pressure-relief valve / retrac-
ting regulating cylinder
48 Bleeding opening for connection Pil and T 502 Secondary pressure-relief valve / exten-
ding regulating cylinder
49 Retrofitted measuring point for load pres- 504 Pressure balance
sure at connection E
50 Pilot piston 515 Regulating cylinder
51 Valve plunger / main valve
54 Pressure spring
57 Sleeve / check valve 516 Load-holding valve, piston side
60 Filter 517 Load-holding side, piston rod side
61 Nozzle
16.10.8
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MJF C I F S S
Hydraulic diagram
6 Hydraulic diagram
Fig. 5 Hydraulic diagram of pipe fracture safety valve, regulating cylinder
16.10.9
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MJF C I F S S
Hydraulic diagram
16.10.10
copyright by
MJF C I F S S
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 re-
quired to attach and release the loads, are subject to certain safety regulations laid down in the Eu-
ropean 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-frac- D Overload warning system with pipe-frac-
ture safety, e.g. in model A 309 / 311 ture safety, e.g. in model A 312 - R 317
B Overload warning system with pipe-frac-
ture safety, e.g. in model A 312 - R 317
16.12.1
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MJF C I F S S
Overload warning system Service Manual
Function
Danger!
The machine may only be used for lifting operations, if it is equipped with the necessary safety de-
vices 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 ad-
justment 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 dig-
ging bucket are deemed safe.
Overload warning system:
If the actual load reaches or exceeds the permissible load according to the load lift chart, the over-
load 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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MJF C I F S S
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 ad-
justment 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 swi-
velled 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.
16.12.3
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MJF C I F S S
Design and function
Fig. 2 Switch and indicator light in the front right control console
H16Indicator light S360 Switch / buzzer acknowledgement

The switch S18 is located in the control console.

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
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 Pipe fracture safety valve

160 Boom cylinder B21 Pressure switch
235 Boom cylinder
(*) 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.
16.12.5
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MJF C I F S S
Setting instructions
4.1 Example:
Machine A 309 A 311 A 312 R 313 A 314 A 316 317

Attachment* and
A 316
Pressures in bar Ind.
with hydraulic - - 169-5 - - 178-5
boom adjustment
with hydraulic 132-5 141-5 161-5 - 141-5 145-5 -
boom adjustment (with 2-point
or blade support)
with hydraulic boom adjustment - - 175-5 - - -
(vertical and horizontal)
with hydraulic boom adjustment 138-5 146-5 - - - 150-5 -
(with 4-point or
blade and outrigger support)
with gooseneck boom - - - 167-5 - - 177-5
with gooseneck boom - 159-5 - 147-5 145-5 -
(with 2-point or blade support)
with gooseneck boom - - - - 147-5 150-5 -
(with 2-point/4-point or blade
support)
with gooseneck boom - - - 170-5 - -
(horizontally adjustable)
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 em-
bossed 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 swit-
ching 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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MJF C I F S S
Fig. 4 Pressure switch with adjusting device and pressure indication
B21 Pressure switch B Plate (with switching pressure*)

K Protective cap
ES Adjusting screw / switching point
SS Self-locking screw
(*) Switching pressure (machine-specific)
16.12.7
copyright by
MJF C I F S S
66 Measuring connection H16 Indicator light

100 A5 control block / connection S18 Switch / overload warning system
100 B5 control block / connection S20 to sensor control switch
160 Boom cylinder (A 309/A 311) X407 Plug connection, 2-pin
161 Pipe fracture safety valve (A 309/A 311) X950 Plug connection, 21-pin
233 Distribution block / boom cylinder X951 Plug connection, 21-pin
235 Boom cylinder (A 312 - R 317) X953 Plug connection, 21-pin
238 Pipe fracture safety valve (A 312 - R X958 Plug connection, 21-pin
317)
A126 Printed circuit board (autocheck)
B21 Constant pressure switch A Electrical system / basic machine
H10 Buzzer B Electrical system / kit
16.12.8
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MJF C I F S S
Hydraulic and electric diagram
5 Hydraulic and electric diagram
Fig. 5 Hydraulic and electric diagram of the overload warning system
16.12.9
copyright by
MJF C I F S S
Hydraulic and electric diagram
16.12.10
copyright by
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 elec-
trical components for the operation of the equipment.
The locking and release function of the quick change adapter are operated through the hydraulic cir-
cuit for the grapple rotator (AS1).
Note!
For the safe operation of the attached working tools, always adhere to the instructions in the sepa-
rate operating and maintenance manual for hydraulic/mechanical quick change adapters.
Fig. 1 Hydraulic quick change adapter
16.16.1
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MJF C I F S S
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 Y28-
1 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" ac-
cessory 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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MJF C I F S S
Fig. 2 Main components and drive system of the hydraulic quick change adapter
10 Quick change adapter 123 Primary pressure relief valve

20 Locking unit 540 Spool of hydraulic drive
50 Covering parts 541 Secondary relief valve / retracting cylin-
der
100 Compact control block 542 Secondary relief valve / extending cylin-
der
110 Low pressure block Y22 Solenoid valve / locking adapter
113 Spool of hydraulic drive Y23 Solenoid valve / releasing adapter
16.16.3
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MJF C I F S S
Fig. 3 Design of hydraulic quick change adapter
10 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 Covering parts Y28-2 2/2-way valve
60 Securing flap
16.16.4
copyright by
MJF C I F S S
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 re-
leased (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 flow-
through position. The oil applies pressure to the piston side of the locking cylinder 24 via the connec-
tion 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 ope-
ration 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 pro-
blem 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 flow-
through position. The oil applies pressure to the piston rod side of the locking cylinder 21 via the con-
nection 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 indi-
cator 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.
16.16.5
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MJF C I F S S
Operation of the quick change adapter
4 Operation of the quick change adapter
Fig. 4 Control elements
80 Left pilot control unit S19 Switch / quick change adapter

H26 Indicator light / quick change adapter S47 Switch / quick change adapter
S5L Push button / locking quick change S360 Switch / buzzer acknowledgement
adapter
S5R Push button / releasing quick change
adapter
4.1 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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MJF C I F S S
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 buzzer H10 emits a warning sound.
The quick change adapter is locked / the lock pins are fully extended.
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.
The buzzer H10 is off.
The buzzer H10 only emits a warning signal after the lock pins have been extended again.
16.16.7
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MJF C I F S S
Maintenance instructions
5 Maintenance instructions
The filter disc 35 must be regularly inspected for dirt and cleaned, if necessary. The inspection inter-
val 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 Cleaning mesh filter
30 Cylinder 36 External support body

34 Internal support body 50 Lid / covering parts
35 Filter disc 51 Hex head screw
16.16.8
copyright by
MJF C I F S S
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.
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 per-
missible).
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 Locking unit with proximity switch
21 Lock pin B26 Proximity switch

90 Lock nut
16.16.9
copyright by
MJF C I F S S
Sealing elements bearing head / piston
7 Sealing elements bearing head / piston
Fig. 7 Sealing kit bearing head / piston
36 Bearing head 75 Piston rod bearing

70 Double scraper ring 76 Piston guide ring
71 O-ring 77 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
16.16.10
copyright by
MJF C I F S S
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 Right lever 39 Retaining washer
24 Pin 40 Piston rod
25 Heavy-duty roll pin 41 Piston
26 Heavy-duty roll pin 42 Screw plug
30 Cylinder L Parts are secured with Loctite 243
16.16.11
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MJF C I F S S
Hydraulic diagrams with electrical components
9 Hydraulic diagrams with electrical components
9.1 Quick change adapter in models A 309 - A 311
1 to hydraulic tank A1017 Printed circuit board / quick change

adapter
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 S5L Push button/auxiliary activation left, or
Residual flow distributor locking quick change adapter
33 Filter disc S5R Push button/auxiliary activation right, or
releasing quick change adapter
45 Low pressure measuring point S19 Switch / auxiliary activation
80 Left pilot control unit S47 Push button
110 Low pressure control block S360 Switch / buzzer acknowledgement
111 Input section X262 Plug connections,
see electric diagrams
112 Spool / slewing gear X411 Plug connection,
113 Spool grapple rotator / quick change X412 Plug connection,
adapter see electric diagrams
123 Primary pressure relief valve X413 Plug connection,
156 Check valve Y22 Solenoid / locking adapter
157 Adjustment restrictor / oil volume Y23 Solenoid / releasing adapter
158 Shuttle valve Y28-1 Solenoid / seat valve rod side
Y28-2 Solenoid / seat valve piston side
16.16.12
copyright by
MJF C I F S S
Fig. 9 Hydraulic diagram with electric components, models A 309 - A 311
16.16.13
copyright by
MJF C I F S S
9.2 Quick change adapter in models A 312 - R 317
10 Quick change unit A1017 Printed circuit board / quick change

adapter
20 Locking unit B26 Proximity switch
21 Lock pin H10 Warning buzzer
30 Cylinder H26 Indicator light
33 Filter disc K364 Quick change relay
80 Left pilot control unit S5L Push button/auxiliary activation left, or
locking quick change adapter
88P from pressure manifold S5R Push button/auxiliary activation right, or
releasing quick change adapter
88T to collecting pipe return line S19 Switch / auxiliary activation
120 Spool / slewing gear S47 Push button
540 Spool of hydraulic drive grapple rotator / S360 Switch / buzzer acknowledgement
quick change adapter
541 Secondary pressure-relief valve / retrac- X262 Plug connections,
ting cylinder see electric diagrams
542 Secondary pressure-relief valve, exten- X411 Plug connection,

ding cylinder see electric diagrams
544 Pressure balance X412 Plug connection,

X413 Plug connection,
Y22 Solenoid / locking adapter
Y23 Solenoid / releasing adapter
Y28-1 Solenoid / seat valve rod side
Y28-2 Solenoid / seat valve piston side
16.16.14
copyright by
MJF C I F S S
Fig. 10 Hydraulic diagram with electric components, models A 312 - R 317
16.16.15
copyright by
MJF C I F S S
Electrical system
10 Electrical system
Fig. 11 Exploded view of electrical system
A1017 Printed circuit board / quick change X262-4

adapter
B26 Proximity switch of quick change adap- X262-5
ter
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 Y28-1 Solenoid / seat valve
X262-1 Plug connection / 8-pin Y28-2 Solenoid / seat valve
X262-3 Plug connection / 8-pin 100 Cable harness of revolving deck
101 Cable harness of quick change adapter
11 Electric diagram of hydraulic quick change adapter
For the electrical diagrams of the hydraulic quick change adapter, please refer to the electrical docu-
mentation of the attachments and basic machine of the respective model in group 8.
16.16.16
copyright by
MJF C I F S S
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 proper-
ly.
The flow reduction can be easily adjusted by the operating personnel to suit any connected attach-
ment.
With the AHS 12 accessory kit, preset flow reductions can be activated.
Fig. 1 Attachments such as hydraulic hammers, sorting grapples, and various auxiliary cylin-
ders
Note!
The flow reduction must conform to the maximum permissible oil volume as specified by the manuf-
acturer 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.
16.19.1
copyright by
MJF C I F S S
Flow reduction Service Manual
Function
2 Function
Fig. 2 Operator's cab with printed circuit board, pilot control device, switch kit, proportional so-
lenoid valve and pump regulator
21 Pump P1 A125 Potentiometer board

50 Control oil unit B290 Proximity switch / flow reduction
70 Actuation device / pump regulator S241 Switch / AHS 12 kit
78 integrated spool/stroke limitation Y51 Proportional solenoid valve / flow reduc-
tion P1
86 Pilot control device / kit
The desired or required oil flow volume is determined by the current fed to the proportional solenoid
valve Y51 and the proportional actuation pressure to the spool 78 of the actuation device 70 of the
variable-displacement pump P1. It determines the flow reduction (stroke limitation of pump P1), re-
sulting 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 at-
tachment is reduced.
16.19.2
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MJF C I F S S
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
16.19.3
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MJF C I F S S
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 pres-
sure 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 gui-
de 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 va-
lues, 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 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

Y51 Proportional solenoid valve K Console
S Clamping mechanism
16.19.4
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MJF C I F S S
The printed circuit board A125 is located behind the left control console and can be accessed as fol-
lows:
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 20 Double variable-displacement pump

P1 Potentiometer / flow volume 1 21 Pump P1
P2 Potentiometer / flow volume 2 57 Measuring point / servo pressure flow reduction
P3 Potentiometer / flow volume 3
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 ob-
served at the turbine.
Prior to adjusting the flow reduction with a measuring turbine, ensure that the basic machine set-
tings are OK.
16.19.5
copyright by
MJF C I F S S
16.19.6
copyright by
MJF C I F S S
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 re-
quired 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
16.20.1
copyright by
MJF C I F S S
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:
Flow rate Q in l/min = cross-section A of the restrictor (spool opening) x -p.
Regular -p (= 23+1 bar) maximum flow rate.
The -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 volu-
me of the pump
In machines that are equipped with the AHS 11 or AHS 12 accessory kit, a pressure and flow reduc-
tion 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 re-
spective potentiometer P1 / P2 / P3.
The settings of the potentiometer P1 / P2 / P3 (located on the printed circuit board A125) can be ad-
justed 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
copyright by
MJF C I F S S
Adjustment of flow reduction settings
3.1 Position of the printed circuit board A 125 with potentiometers P1/P2/P3
3.1.1 in models A 312 to 20432, A 314 to 20333 and A 316 to 20339

57 Measuring point MLS (flow reduction) 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 reduc-
tion
The printed circuit board A125 is located in the electric cabinet behind the left control console and
can be accessed as follows:
Remove the screws and lift the cover D from the electric cabinet EK.
16.20.3
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MJF C I F S S
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

57 Measuring point MLS (flow reduction) B291 Proximity switch / sensor control
86 Pilot control device / kit K Console / function box
S Clamping mechanism
S241 Switch AHS 11 / AHS 12 accessory kit
Y51 Proportional solenoid valve / flow reduc-
tion
lows:
3.2 Adjustment procedure, see Fig. 2, see Fig. 3 and Fig. 4

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
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 ob-
served at the turbine.
Prior to adjusting the flow reduction with a measuring turbine, ensure that the basic machine set-
tings are OK.
16.20.5
copyright by
MJF C I F S S
Diagram for flow reduction in A 312 R 317 (Y51)
4 Diagram for flow reduction in A 312 R 317 (Y51)
Fig. 5 Diagram for flow reduction for hammer operation with A 312 R 317
4.1 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 dia-
gram.
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
copyright by
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 hydrau-
lic 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 grapp-
le, 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
16.24.1
copyright by
MJF C I F S S
LIKUFIX Hydraulic Coupling System Service Manual
Design of LIKUFIX hydraulic coupling system
2 Design of LIKUFIX hydraulic coupling system
Fig. 2 LIKUFIX coupling system with attachments
1 Protective cover at the quick change adapter 4 LIKUFIX hydraulic coupling at the working
tool
2 Protective cover at the working tool 5 Alternative hydraulic coupling at the working
tool
3 LIKUFIX hydraulic coupling at quick change
adapter
2.1 Design of the LIKUFIX coupling system mounted to quick change adapter 33 /
48
16.24.2
copyright by
MJF C I F S S
Fig. 3 LIKUFIX 33 / 48 accessory kit
2.1.1 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 hy-
draulic 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.
16.24.3
copyright by
MJF C I F S S
2.2 Exploded drawing of LIKUFIX mounted to quick change adapter
Fig. 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 Coupling sleeve 110 Locking plate
70 Coupling sleeve
16.24.4
copyright by
MJF C I F S S
2.3 Design of LIKUFIX coupling system mounted to the attachments
Fig. 5 LIKUFIX mounted to attachment
2.3.1 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 cou-
pling, 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.
16.24.5
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MJF C I F S S
2.4 Exploded drawing of LIKUFIX mounted to an attachment
Fig. 6 LIKUFIX for attachments
10 Coupling housing 80 Retaining plate

20 Guide bolt 81 Allen head screw
30 Protective cover 90 Tie-down device
40 Pressure spring 91 Allen head screw
41 Allen head screw 92 Retaining washer
42 Allen head screw 100 Tie-down device
50 Plunger
16.24.6
copyright by
MJF C I F S S
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 41 Hex head screw

11 Hex head screw 42 Retaining washer
12 Retaining washer 43 Washer
20 LIKUFIX (accessory kit) 80 Stop
30 Protective cover 81 Allen head screw
40 Cover 90 Plug
16.24.7
copyright by
MJF C I F S S
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
T
oil flow channels when the attachment is removed. Beim Bettigen des Schnellwechslers ber Druck-
taste S5R/S5L werden die Magnetventile Y376-1 und Y376-2 bestromt und sperren den ldurchfluss
zu den Anschlssen E und D am LIKUFIX. Der lkreislauf beim Koppeln bzw.Entkoppeln ist somit
drucklos.Nicht Bestromt sind sie geffnet, so dass das l zu den Anschlssen E und D gelangen
kann.
Fig. 8 Check valves mounted on boom
A Working line (high pressure) Y376-1 solenoid valve rotating grab right
B Working line (high pressure) Y376-2 solenoid valve rotating grab left
E Hydraulic line rotating grab left
E Hydraulic line rotating grab right
16.24.8
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MJF C I F S S
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 adap-
ter 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 Y376-1 Check valves

X262-3 Plug connection Y376-2 Check valves
16.24.9
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MJF C I F S S
Fig. 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
16.24.10
copyright by
MJF C I F S S
3.2 Function of the plunger cylinders 50
Fig. 11 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
3.2.1 Control of the plunger cylinders 50

The plunger cylinders 50 are controlled and operated through the working line A (in other attach-
ments: 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 attach-
ments, 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 pro-
perly 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.
16.24.11
copyright by
MJF C I F S S
3.3 Exploded drawing of plunger
Fig. 12 Plunger (X = observe correct alignment and position of disc springs).
10 Plunger cylinder 31 Circlip

11 O-ring 50 Disc spring
12 Scraper ring 990 Mounting sleeve for Glyd ring
20 Piston 991 Expanding sleeve for Glyd ring
21 Turcon-Glyd ring 992 Mounting sleeve (insertion aid for piston
into cylinder)
22 O-ring 993 Mounting sleeve for scraper ring
30 Thrust plate 999 Cylinder seal kit
16.24.12
copyright by
MJF C I F S S
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 3 Plunger cylinder

2 Disc spring pack
16.24.13
copyright by
MJF C I F S S
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 in-
ward 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 cou-
pling 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 Coupling plug and coupling sleeve
10 Coupling plug M24X1,5 60 Coupling sleeve M24X1,5

20 Coupling plug M36X2 70 Coupling sleeve M36X2
16.24.14
copyright by
MJF C I F S S
4.2 Sectional drawing of coupling sleeves / plugs
Fig. 15 A = coupling open; B = coupling closed
10 Coupling plug M24X1,5 60 Coupling sleeve M24X1,5

.4 Valve .2 Valve
.6 Spring .4 Spring
20 Coupling plug M36X2 .6 Valve cover
.7 Dust cover
.8 Spring
70 Coupling sleeve M36X2
16.24.15
copyright by
MJF C I F S S
Fig. 16 Sectional drawing of coupling sleeve
60 Coupling sleeve M24X1.5 .7 Dust cover

70 Coupling sleeve M36X2 .8 Spring
.1 Housing .9 Adapter
.2 Valve .10 Retainer
.3 Valve seat .11 O-ring
.4 Spring .12 O-ring
.5 Guide .13 O-ring
.6 Valve cover
16.24.16
copyright by
MJF C I F S S
Fig. 17 Sectional drawing of coupling plug
10 Coupling plug M24X1.5 .4 Valve

20 Coupling sleeve M36X2 .5 Valve seat
.1 Plug housing .6 Spring
.2 Adapter .7 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.
16.24.17
copyright by
MJF C I F S S
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 neces-
sary, 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 connec-
ted 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 LIKUFIX during coupling
3 Coupling housing upper section at the 4 Coupling housing lower part at the attach-
quick change adapter ment e.g. grapple
16.24.18
copyright by
MJF C I F S S
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.
16.24.19
copyright by
MJF C I F S S
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 Coupling plug 542 Secondary relief valve / rotation left
40 Restrictor 544 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 Collecting pipe T S19 Button / grapple rotator
110 Low pressure-control valve block Y22 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
156 Check valve Y28-2 Solenoid / seat valve piston side
157 Adjusting restrictor Y376-1 Check valve on base side
158 Two way check valve Y376-2 Check valve on boom side
515 Hydraulic hammer Y387-1 Relief valve
517 Additional consumer Y387-2 Relief valve
10* Hydraulic quick change device (kit)

see group 16.15
Key to electric diagram

B26 Proximity switch of quick change adap- X263-3 Plug-type connection / 2-pin
ter
X262-1 Plug-type connection, 8-pin or 3-pin X452-1 Plug-type connection to SV Y376-1
X262-2 Plug-type connection, 8-pin or 3-pin X452-2 Plug-type connection to SV Y376-2
X262-3 Plug-type connection, 8-pin or 3-pin Y28-1 Solenoid valve of quick change device
X262-4 Plug-type connection at valve 28-1/2- Y28-2 Solenoid valve of quick change device
pin
X262-5 Plug-type connection at valve Y28-2/2- Y376-1 Check valve grapple rotator cycle
pin
X262-6 Plug-type connection at B26 / 3-pin Y376-2 Check valve grapple rotator cycle
X263-1 Plug-type connection / 2-pin Y387-1 Solenoid valve for LIKUFIX relief
X263-2 Plug-type connection / 2-pin Y387-2 Solenoid valve for LIKUFIX relief
A B26 als ffner

B B26 als Schlieer
C Option mit Sure Seal-Stecker B26 als Schlieer
16.24.20
copyright by
MJF C I F S S
Fig. 20 Hydraulic diagram of LIKUFIX
16.24.21
copyright by
MJF C I F S S
Fig. 21 Electric diagram of LIKUFIX
16.24.22
copyright by
MJF C I F S S
Connection options for LIKUFIX system
8 Connection options for LIKUFIX system
Fig. 22 Universal interface for member / attachment
A Actuation of P1(G1) a View: in driving direction, right side

Optional switching of control
A Actuation of P2(G2) b Operator's cab
C Hammer return line c In wheel models
D Actuation of D1 d In track models
E Actuation of D2 x View: against driving direction, from front
y View: in driving direction, from rear
Left Right
Coupling Actuation Function Coupling Actuation Function

Rotate grab to left Rotate grab to right
E D2 Lock quick change adap- D D1 Release quick change ad-
ter apter
G2 Extend bucket cylinder G1 Retract bucket cylinder
B P2 Close pressure (AHS) cir- A P1 Open pressure (AHS) cir-
cuit of grab/shear cuit of hammer advance
line
grab/shear
16.24.23
copyright by
MJF C I F S S
Left Right

C Hammer return line/ leak oil
The following principle applies: Movement to the right = pressure in right line, and vice versa
Left Right
With optional "switching of AHS control with bucket function" kit.
B G2 Close pressure (AHS) cir- A G1 Open pressure (AHS) cir-
cuit cuit of hammer advance
of grab/shear line grab/shear
P2 Extend bucket cylinder P1 Retract bucket cylinder
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
copyright by
MJF C I F S S
Fig. 23 Hydraulic diagrams for the various attachments
16.24.25
copyright by
MJF C I F S S
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 e Hydraulic hammer without swivel bearing
grapple (mill 1 direction of rotation)
c Vibrator plate with rotator, f Ditch cleaning bucket, tilting bucket, com-
Hydraulic hammer with swivel bearing pactor, 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
copyright by
MJF C I F S S
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 cou-
pling is likely to be leaking.
Check the seal ring in valve .2 for damage. Also check whether a foreign object has been jam-
med in the coupling.
Complete a visual inspection of the inside of the coupling:
Push in the dust cover .7, using a screwdriver.
16.24.27
copyright by
MJF C I F S S
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 lea-
king coupling plug into the spring space, so that drops form at the decoupled sleeve.
Fig. 25 Oil-filled section of the coupling sleeve
10.5 Identification of the leaking coupling plug:

Remove all oil and grease from the coupling plates (use brake cleaner).
Connect attachment.
Pressurise all lines.
Immediately decouple the device.
Check coupling plates.
Oil film around the coupling sleeve of the leaking plug
Replace seal ring at defective coupling plug
16.24.28
copyright by
MJF C I F S S
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 scre-
wdriver.
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.
16.24.29
copyright by
MJF C I F S S
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 (pres-
sure 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
16.30.1
copyright by
MJF C I F S S
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 m) with a 10 m cartridge.
This fine filter cartridge (10 m) must be replaced every 500 operating hours.
the breather filter / hydraulic tank (7 m*) must be replaced with a 2 m fine filter.
This fine filter cartridge (2 m) 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 m) in the return filter, which must
be replaced after 50 operating hours by a fine filter cartridge (10 m).
Regularly check the hydraulic oil for contamination (laboratory oil analysis).
Note!
Hineri
* From approx. Sept. 2005 all machines have been equipped with the 2 m 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 sup-
plier 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
copyright by
MJF C I F S S
ATLAS - COPCO hydraulic hammers
4 ATLAS - COPCO hydraulic hammers
4.1 SB and TEX
Type SB Tex Tex Tex

Product 450 400 H 600 H 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 machi- bar 170 170 170 170

ne
see AHS 11 / AHS 12
Return (2) right NB NB left

Attachable to machine types:
A 309 Litronic X X
A 311 Litronic X X
A 312 X X
A 314 X
A 316 X
R 317 X
1) including standard chisel and suspension kit

2) seen from operator seat
NB no details in brochure
16.30.3
copyright by
MJF C I F S S
ATLAS - COPCO hydraulic hammers
4.2 MB (former Krupp HM)
Previous
type HM HM HM
Product 190 350 580
New
type MB MB
Product 500 800
Unit
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 bar 150 180 190

of machine
see AHS 11 / AHS 12
Return (2) right right right

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

16.30.4
copyright by
MJF C I F S S
EURORAM hydraulic hammers
5 EURORAM hydraulic hammers
Type RM RM
Product 90 115
Unit
Effective weight (1) kg 625 875
Oil flow l/min 60-95 85 - 115
Operating pressure / hammer bar 145 160
Adjustment pressure of machi- bar 170 180

ne
see AHS 11 / AHS 12
Return (2) NB NB
A 309 Litronic X
A 311 Litronic X
A 312 Litronic X
A 314 Litronic X
A 316 Litronic X
R 317 Litronic X

16.30.5
copyright by
MJF C I F S S
FRD hydraulic hammers
6 FRD hydraulic hammers
Type HB HB
Product 10G 15G
Unit
Oil flow l/min 70-90 90-120
Adjustment pressure of machi- bar 180 190

ne
see AHS 11 / AHS 12
Return (2) right right
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

16.30.6
copyright by
MJF C I F S S
INDECO hydraulic hammers
7 INDECO hydraulic hammers
Type MES MEST MES

Product 1200 1500 1750
Unit
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 machi- bar 140 150 150

ne
see AHS 11 / AHS 12
Return (2) right right right
A 309 Litronic X
A 311 Litronic X
A 312 Litronic X
A 314 Litronic X X
A 316 Litronic X X
R 317 Litronic X X

16.30.7
copyright by
MJF C I F S S
NPK hydraulic hammers
8 NPK hydraulic hammers
Type H4
Product XE
Unit
Effective weight (1) kg 565
Oil flow l/min 50-80
Operating pressu- bar 110

re /
hammer
Adjustment pres- bar 130

sure of machine,
see AHS 11 / AHS
12
Return (2) right
A 309 Litronic X
A 311 Litronic X
A 312 Litronic X
A 314 Litronic
A 316 Litronic
R 317 Litronic

16.30.8
copyright by
MJF C I F S S
RAMMER hydraulic hammers
9 RAMMER hydraulic hammers
Type
S25 S26 N S29C/ E64/
Product
Unit
Effective weight (1) kg 425 540 820 1000
Oil flow l/min 50-150 60-135 60-120 70-130
Operating pressure bar 180 175 200 190

/ hammer
Adjustment pressu- bar 200 205 220 220

re of machine, see
AHS 11 / AHS 12
Return (2) 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

16.30.9
copyright by
MJF C I F S S
Ingersoll hydraulic hammers
10 Ingersoll hydraulic hammers
Type 130 270 C

Product
Unit
Oil flow l/min 70-110 90-130
Adjustment pressure bar 190 130

of machine
see AHS 11 / AHS 12
Return (2) left left
A 309 Litronic X
A 311 Litronic X
A 312 Litronic X
A 314 Litronic X
A 316 Litronic X
R 317 Litronic X

16.30.10
copyright by
MJF C I F S S
TABE and Stanley hydraulic hammers
11 TABE and Stanley hydraulic hammers
Producer Tabe Stanley

Type AGB MB
Product 370 875
Unit
Oil flow l/min 65-80 80-115

of machine
see AHS 11 / AHS 12
Return (2) NB right
A 309 Litronic X
A 311 Litronic X
A 312 Litronic X
A 314 Litronic X
A 316 Litronic X
R 317 Litronic X

16.30.11
copyright by
MJF C I F S S
WIMMER hydraulic hammers
12 WIMMER hydraulic hammers
Type W 440 W 550

Product
Unit
Oil flowl/min l/min 60-100 70-130

of machine
see AHS 11 / AHS 12
Return (2) 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 X

16.30.12
copyright by
MJF C I F S S
Service Manual Accessory kit AS1
Function
Accessory kit AS1
1 Function
Auxiliary attachments that can be connected to the hydraulic excavator often require special compo-
nents, 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 at-
tachments 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
16.44.1
copyright by
MJF C I F S S
Accessory kit AS1 Service Manual
General information
Attachments and associated pressure relief valve Pressure limit (in bar)
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 / 552 100 +10 bar
(primary protection for oil motor 550 / grapple rotator)
Secondary pressure relief valves 562/563 500 20 bar
(secondary protection for cylinder 560 / tilting bucket, old model)
Secondary pressure relief valves 566/567 350 20 bar
(secondary protection for cylinder 560 / tilting bucket, new model)
Tightening torques of mounting screws and bolts 55 Nm
(Allen head screws) of auxiliary axle 540
Max. flow rate at spool 540 30 l/min
via limitation of stroke of spool
Stroke limitation of spool 540
Measure Y of the stop screw 540.1 17.0 mm
16.44.2
copyright by
MJF C I F S S
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 con-
nected consumer.
Fig. 2 Control devices of AS1
80 Left pilot control unit S5L Button for actuation of grapple / bucket /
quick-change adapter
S5R Button for actuation of grapple / bucket /
quick-change adapter
S19 Switch / preselection / kit AS1
16.44.3
copyright by
MJF C I F S S
Functioning of the accessory kit
Fig. 3 Auxiliary control axle AS1 flange-mounted to the slewing gear axle of the compact block
100 Control valve block 542 Pressure-relief valve connection B02

540 Spool / AS1 Y22 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 posi-
tion 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 sle-
wing 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
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 pressure-
relief 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 auxi-
liary 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 cy-
linder 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 "C2-
V2" 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 pres-
sure-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 con-
nection "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.
16.44.5
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MJF C I F S S
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.
Fig. 4 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 Measuring point LS 541 Pressure-relief valve
100 Control valve block 542 Pressure-relief valve
16.44.6
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MJF C I F S S
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 pres-
sure 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.
Fig. 5 Oil motor with shock valves and tilting bucket with twin/double check valve
A Shock valve 561 Double check valve

B Shock valve 562 Pressure-relief valve, swivelling to left
C for old tilting bucket models 563 Pressure-relief valve, swivelling to right
D for new tilting bucket models 565 Double check valve
550 Oil motor / grapple rotator 566 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
16.44.7
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MJF C I F S S
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 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 Stroke limitation spool, bottom
.1 Stop screw
.2 Stop screw
16.44.8
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MJF C I F S S
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 tam-
pered 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.
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.
16.44.9
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MJF C I F S S
5.6 Hydraulic unit AS1 (basic diagram)

1 to hydraulic tank 120 Spool / slewing gear
6 to hydraulic oil cooler 540 Spool / AS1
20 Variable-displacement pump 541 Pressure-relief valve connection A02
23 Pump regulator (A 312-316) 542 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
5.6.1 Hydraulic system - turning grapple attachment

550 Oil motor 552 Pressure-relief valve / turning left
551 Pressure-relief valve / turning right
5.6.2 Hydraulic system tilting bucket attachment

560 Cylinder / swivelling bucket 563 Pressure-relief valve, rod side
561 Double check valve 564 Restrictor
562 Pressure-relief valve, piston side
5.6.3 Hydraulic system quick-change adapter

570 Locking cylinder Y28-1 Solenoid / seat valve
571 Seat valve Y28-2 Solenoid / seat valve
572 Filter disc
16.44.10
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MJF C I F S S
Fig. 7 Hydraulic diagram of the AS1 kit
16.44.11
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MJF C I F S S
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, hy-
draulic lines and hoses for control and drive purposes.
tachments 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 attach-
ment 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
16.48.1
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MJF C I F S S
Accessory kit AHS 1 Service Manual
General information
Attachments and associated pressure-relief Pressure limit (in bar)

valves primary secondary
Pressure cut-off valve 104
(this valve limits the LS pressure and thus the 350 +10 bar
operating pressure at the control block 100)
Secondary pressure relief valves 501/502
(for cylinder 515) 380 +20 bar
(in the auxiliary control axle 500)
Piston 500
Dimension Y of stop screw 500.1 16.3 mm (from serial no. 14517 = 14.7 mm)
for the retraction of the cylinder
for the extension of the cylinder
For more information on the auxiliary axle AHS1,

see 7.60.55.
16.48.2
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MJF C I F S S
Operation
3 Operation
The accessory kit AHS 1 enables the operator to operate the working attachment (consumer) for hy-
draulic boom adjustment.
Note!
To ensure proper use and functioning of the accessory kit AHS 1, the connected units must be ope-
rated 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.
16.48.3
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MJF C I F S S
4.1 Important adjustment notes:

Heat the hydraulic oil to operating temperature.
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 LIEB-
HERR technicians. The pressure-relief valves must be protected against unauthorised manipulation
with safety caps.
Fig. 3 Variable displacement pumps with measuring point LS and compact control valve block
with measuring point MP and auxiliary axle AHS1.
120
20 Variable displacement pump (LPV or 104 Pressure cut-off valve

DPVO)
41 Measuring point MP for pump pressure 500 Auxiliary control axle with spool for auxi-
liary cylinder (regulating cylinder)
45 Measuring point LS for LS pressure 501 Secondary pressure-relief valve / retract
regulating cylinder
100 Control valve block 502 Secondary pressure-relief valve / extend
regulating cylinder
16.48.4
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MJF C I F S S
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 sen-
sor/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 pres-
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.
4.4 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
500.1 Stroke limitation / retract regulating cylinder 1.3 Safety cap
500.2 Stroke limitation / extend regulating cylinder
16.48.5
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MJF C I F S S
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:

Turn the stop screw 1.1 until dimension Y is reached.
Re-tighten the lock nut 1.2.
16.48.6
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MJF C I F S S
Fig. 5 Hydraulic connections of AHS 1 kit
1 Hydraulic tank 500 Spool of auxiliary cylinder(e.g. regulating

cylinder)
50 from the control oil unit 501 Secondary pressure relief valve / cylinder
515 retracting
86 Pilot control unit 2x, with pedal 502 Secondary pressure relief valve / extend
cylinder 515
88P Distributor
88T Collecting pipe B290 Proximity switch / sensor control (kit)
100 Compact control block B291 Proximity switch / sensor control (kit)
16.48.7
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MJF C I F S S
Hydraulic system
6 Hydraulic system
1 from / to hydraulic tank 100 Compact control block

6 to oil cooler 104 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 Measuring point MP 504 Pressure balance
45 Measuring point LS 507 Restrictor check valve
50 from the control oil unit 515 Regulating cylinder / hydr. boom adjusting
device
86 Pilot control unit 2x, with pedal 516 Load-holding valve, piston side
88P Distributor 517 Load-holding side, piston rod side
88T Collecting pipe
16.48.8
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MJF C I F S S
Hydraulic system
16.48.9
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MJF C I F S S
Hydraulic system
16.48.10
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MJF C I F S S
Function
Accessory kit AHS 11
1 Function
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 mo-
vable boom or an offset boom bearing
Fig. 1 Auxiliary attachments available for basic machine (examples)
A Hydraulic hammer B Sorting grapple
16.52.1
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MJF C I F S S
General information

(This valve limits the LS pressure) in control valve 350 +10 bar
block 100
Secondary pressure-relief valve with additional
pressure stage 511 200 +10 bar (*)
Stage 1 (hydraulic hammer 535) 380 +20 bar (**)
Stage 2 (extend cylinder 537)
(in the auxiliary axle 510)
Secondary pressure-relief valves 522 380 +20 bar
for the retraction of the cylinder537
Piston 510 dimension Y of stop screw 510.1 17.4 mm (15 mm***)
from serial no. 14517 = 14.7 (11.5 mm***)
Dimension Y of stop screw 510.2 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 17+1 bar (*)
via proportional solenoid valve Y51
(*) 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 cy-
linder 512 is set to 200 bar and acts as a primary pressure relief valve.
(***) In machines with the auxiliary attachments "45 offset boom bearing" or "horizontal boom
movement", the flow volume of the auxiliary control axle 510 for the cylinder 537 is reduced by
means of the stroke limitation 510.1 / 510.2.
16.52.2
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MJF C I F S S
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 Operator's cab with pilot control device, switch and indicator lamp for the accessory kit
86 Pilot control device of kit H196 Sorting grapple indicator lamp

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.
Unreduced flow rate and maximum permissible pressure (stage 2) on the sorting grapple cy-
linder (via spool 510).
Sorting grapple cylinder is extended, and the sorting gripper is closed.
Sorting grapple cylinder is retracted, and the sorting gripper is opened.
16.52.3
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MJF C I F S S
Operation of the hydraulic hammer:

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 ham-
mer; for sorting grapple, etc.: no pressure or flow reduction at connection A6).
Hydraulic hammer is pressurised.
16.52.4
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MJF C I F S S

Note!
with safety caps.
with measuring point MP and auxiliary axle AHS11
120
20 Variable displacement pump (LPV 104 Pressure cut-off valve

or DPVO)
41 Measuring point MP for pump pres- 510 Auxiliary control axle AHS 11 with spool
sure
45 Measuring point LS for LS pressure 511 Secondary pressure-relief valve with additional
pressure stage / extending cylinder 537 or ham-
mer
100 Compact control block 512 Secondary pressure relief valve / retracting
cylinder 537 or pile driver
16.52.5
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MJF C I F S S
Fig. 4 Secondary pressure-relief valve with additional pressure stage
10 Adjusting screw 15 Lock nut

11 Adjusting screw 30 Bushing
12 Shifting piston 33 Valve seat
13 Piston 511 Secondary pressure-relief valve, com-
plete
14 Lock nut X Control pressure connection
4.2 Checking and adjustment of the secondary pressure relief valve 511
Connect the pressure sensor/gauge to measuring points 41 and 45.
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 build-
up by leak oil at the control pressure connection X -).
Disconnect the pressure line from the hammer and seal it.
Only required, if a hydraulic hammer is to be attached.
4.2.1 Adjustment of pressure stage 2 (higher pressure level)

Loosen the lock nut 15 and block the shifting piston 12 by screwing in the adjusting screw 11.
Press down the right pedal to pressurise the hydraulic hammer 535 with maximum permissible
pressure or to extend the cylinder537 to its stop.
Loosen the lock nut 14 and turn the adjusting screw 10 at the pressure-relief valve 511 until the
pressure sensor indicates the nominal pressure for stage 2, see Table 1, page 2, is indicated at
the pressure sensor/gauge at the measuring point 45.
Re-tighten lock nut 14.
Reset the system to pressure stage 1.
4.2.2 Adjustment of pressure stage 1 (lower pressure level)

Pressurise the hydraulic hammer 535 to the limit value.
Turn the adjusting screw 11 at the pressure-relief valve 511 until the pressure sensor/gauge
16.52.6
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MJF C I F S S
(measuring point 45) indicates the nominal pressure, see Tab. 1.

Reconnect the control line to the connection X.
Fig. 5 Auxiliary control axle AHS 11 with secondary pressure-relief valves 511 and 512
20 Variable displacement pump (LPV 104 Pressure cut-off valve

or DPVO)
41 Measuring point MP for pump pres- 510 Auxiliary control axle AHS 11 with spool
sure
45 Measuring point LS for LS pressure 511 Secondary pressure-relief valve with additional
pressure stage / extend cylinder 537 or hammer
100 Control valve block 512 Secondary pressure relief valve / retracting
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/gau-
ge at the measuring point 45 indicates the nominal pressure, Table 1, page 2.
4.4 Adjustment of the pressure cut-off valve 104

16.52.7
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MJF C I F S S


510 Hydraulic hammer/cylinder spool 1.2 Lock nut
510.1 Stroke limitation / cylinder retraction 1.3 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

16.52.8
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MJF C I F S S
Fig. 7 Hydraulic connections AHS 11
16.52.9
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MJF C I F S S
Hydraulic system
6 Hydraulic system
1 from / to hydraulic tank 510 Spool / hydraulic hammer / cylinder / pile

driver
6 to oil cooler 511 Secondary pressure-relief valve / retract
hydraulic hammer 535 cylinder 537
20 Variable-displacement pump 512 Secondary pressure relief valve / extend
cylinder 537
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 Pilot control unit 2x, with pedal 538 Stop cock
88P Distributor B290 Proximity switch / sensor control (kit)
88T Collecting pipe B291 Proximity switch / sensor control (kit)
100 Compact control block Y62 Solenoid valve / travel
104 Pressure cut-off valve Y63 Solenoid valve / travel
Y299 Solenoid valve / secondary pressure ham-
mer
16.52.10
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MJF C I F S S
Hydraulic system
16.52.11
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MJF C I F S S
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
Function
1 Function
The AHS 12 accessory kit described below enables operators to use two different auxiliary attach-
ments 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 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
one auxiliary control axle at the main control valve block with pressure and flow reduction of a
high-pressure connection:
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.
A Hydraulic boom adjusting device C Sorting grapple

B Hydraulic hammer
16.54.1
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MJF C I F S S
General information

Primary pressure-relief valve 122
(valve limiting the working pressure of the pump 350 +10 bar
P1 at the measuring point 40) in the control valve
block 100
Stage 1 (hydraulic hammer 535) 380 +20 bar
for the retracting of cylinder537 (200 bar **)
Current at proportional solenoid valve Y51 640 mA
Control pressure at the pump P1 23+1 bar
(*) 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 adjus-
tment", the secondary valve 515 controlling the flow at the piston side of the cylinder 537is set to 200
bar and acts as a primary pressure-relief valve.
16.54.2
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MJF C I F S S
3 Function and operation
The accessory kit AHS 12 allows the machine operator to control the connected auxiliary attach-
ments (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!
Danger!

S241 Switch AHS12
and flow reduction by means of the solenoid valve Y268 and Y299.

Set switch S241 to position 0 (not actuated)
The LED in the switch is off.
Unreduced flow rate and maximum permissible pressure on the boom regulating cylinder (via
spool 106).
16.54.3
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MJF C I F S S
Press right pedal to the stop.

Press left pedal to the stop.

The LED in the switch is off.
Unreduced flow rate and maximum permissible pressure on the sorting grapple cylinder (via
spool 510).
Press left pedal to the stop.

The LED in the switch is 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).
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.

Note!
with lead seal wire or safety caps.
16.54.4
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MJF C I F S S
Fig. 3 Compact control block with auxiliary axle AHS12

120
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

13 Piston 511 Secondary pressure-relief valve, com-
plete
16.54.5
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MJF C I F S S
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.
4.2.1 Adjustment of pressure stage 2 (higher pressure level)

Press down the right pedal to pressurise the hydraulic hammer 535 or the cylinder 537 with the
maximum permissible pressure.
pressure sensor indicates the nominal pressure for stage 2, Table 1, page 2.
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.
Fig. 5 Auxiliary axle AHS 12 with primary and secondary pressure-relief valves
16.54.6
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MJF C I F S S
Flow reduction of pump P1
40 Measuring point for AHS 12 working pres- 510 Hydraulic hammer/cylinder spool
sure
100 Control valve 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
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 in-
dicates 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 re-
quired pressure (measured at measuring point 40) by turning the adjusting screw, see Tab. 1.
5 Flow reduction of pump P1
The flow reduction function is implemented in conjunction with the potentiometers P1 - P3 on the prin-
ted 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

16.54.7
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MJF C I F S S
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 Proportional solenoid valve / flow
reduction
57 Measuring point for flow reduction K Console
86 Pilot control device of kit S Clamping mechanism
6 Adjustment of flow reduction
lows:
For detailed instructions on how to adjust the various flow reductions, refer to group16.19, flow re-
duction.
16.54.8
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MJF C I F S S
16.54.9
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MJF C I F S S
Hydraulic system
8 Hydraulic system
1 to tank 109 Combined boom / stick cylinder spool

20 Double variable-displacement pump 120 Dummy cartridge / screw plug
40 Measuring point P1 121 Primary pressure-relief valve pump P2
41 Measuring point P2 122 Primary pressure-relief valve pump P1
50 from the control oil unit 150 Check valve
76 Shuttle valve of combined shifting of stick 151 Load-holding valve
78 Shuttle valve of combined shifting of 152 Check valve
boom
86 Pilot control unit two-fold, with pedal 250 Regulating cylinder / hydr. boom adjusting
device
88P Distributor 251 Double load-holding valve
88T Collecting pipe 510 Auxiliary spool AHS 12
100 Compact control block 511 Secondary pressure-relief valve / extend
cylinder 517 or hammer
101 Slewing gear spool 512 Secondary pressure relief valve / retract
cylinder 537
102 Stick cylinder spool 535 Hydraulic hammer
103 Support cylinder spool 537 Sorting grapple cylinder
105 Regulating cylinder spool
106 Boom cylinder spool S241 AHS 12 switch
107 Bucket cylinder spool 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
Hydraulic system
16.54.11
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MJF C I F S S
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
Function
1 Function
The AHS 12 accessory kit described below enables operators to use two different auxiliary attach-
ments 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 reduc-
tion for the high-pressure connections:
(vertical), a horizontally adjustable boom or an offset boom bearing
second auxiliary control axle without pressure/flow reduction for a high-pressure connection:
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.

B Hydraulic hammer
16.56.1
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MJF C I F S S
General information

block 100
Secondary pressure relief valves 501/502 380 +20 bar
for regulating cylinder 525 extension and retrac-
tion
Stage 1 (hydraulic hammer 535) 380 +20 bar
for the retraction of the cylinder537 200 bar (**)
from serial no. 14517 =14.7 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 17+1 bar (*)
(*) 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
Operation
3 Operation
The accessory kit AHS 12 allows the machine operator to control the connected auxiliary attach-
ments (consumers) by means of the auxiliary pilot control unit 86.
of switch S241.
Note!
Danger!
Fig. 2 Operator's cab with pilot control unit, switch and indicator lamp for the accessory kit
86 Pilot control unit of kit H196 Sorting grapple indicator lamp

S241 Switch AHS12
and flow reduction by means of the solenoid valves Y268 and Y299.
16.56.3
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MJF C I F S S
Operation

Set the switch S241 to position 0 (not actuated).
spool 500).
Unreduced flow rate and maximum permissible pressure (stage 2) on the sorting grapple cy-
linder (via spool 510).

The indicator lam in the switch is 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 ham-
mer; for sorting grapple, etc.: no pressure or flow reduction at connection B7).
16.56.4
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MJF C I F S S

Note!
with safety caps.
with measuring point MP and auxiliary axles AHS12
120
20 Variable displacement pump (LPV 500 Auxiliary control axle AHS 1 with spool
or DPVO)
41 Measuring point MP for pump pres- 501 Secondary pressure relief valve / extend cylin-
sure der 525
45 Measuring point LS for LS pressure 502 Secondary pressure relief valve / retract cylinder
525
100 Compact control block 510 Auxiliary control axle AHS 11 with spool
104 Pressure cut-off valve 511 Secondary pressure-relief valve with additional
512 Secondary pressure relief valve / retracting
16.56.5
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MJF C I F S S
Fig. 4 Secondary pressure-relief valve with additional pressure stage

13 Piston 511 Secondary pressure-relief valve,complete
Connect the pressure sensor/gauge to measuring points 41 and 45.
The pressure must be above the adjustment pressure of the secondary pressure relief valve
511.
4.2.1 Adjustment of pressure stage 2 (higher pressure stage)

Press down the right pedal to pressurise the cylinder 537.
pressure sensor/gauge indicates the nominal pressure for stage 2, see Table 1, page 2.
4.2.2 Adjustment of pressure stage 1 (lower pressure stage)

Pressurise the hydraulic hammer 535 to the limit value.
pressure sensor/gauge indicates the nominal pressure for stage 1, see Table 1, page 2.
Re-tighten lock nut 15.
16.56.6
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MJF C I F S S
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 se-
condary pressure-relief valves
20 Variable displacement pump (LPV 500 Auxiliary control axle AHS 1 with spool
or DPVO)
41 Measuring point MP for pump pres- 501 Secondary pressure relief valve / extend cylin-
sure der 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
512 Secondary pressure relief valve / retracting
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.
16.56.7
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MJF C I F S S
4.4 Adjustment of the pressure cut-off valve 104 (see Fig. 5, page 7)
4.5 Adjustment of the stroke limiter of the spools 500 and 510
Fig. 6 Stroke limiter of the spool 500 and 510

500.1 Stroke limitation / retract regulating cylinder 1.3 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.

16.56.8
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MJF C I F S S
1 Hydraulic tank B290 Proximity switch / sensor control

50 Control oil unit B291 Proximity switch / sensor control
86 Pilot control unit 2x, with pedals X924-1 Plug connection, 3x
88P Distributor X924-2 Plug connection, 3x
88T Collecting pipe Y62 Solenoid valve / travel
100 Compact control block Y63 Solenoid valve / travel
500 Spool / regulating cylinder Y268 Solenoid valve / changeover regulating
cylinder - hammer
510 Spool / hydraulic hammer / cylinder / Y299 Solenoid valve / secondary pressure
pile driver hammer
511 Secondary pressure relief valve with
additional pressure stage / hydr. ham-
mer - cyl.
16.56.9
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MJF C I F S S
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 addi-
tional pressure stage / retract hydraulic
hammer 535 cylinder 537
20 from variable-displacement pump 512 Secondary pressure relief valve / extend
cylinder 537
23 Regulating valve 514 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 Distributor 536 Pile driver
88T Collecting pipe 537 Cylinder (auxiliary device)
100 Compact control block 538 Stop cock
104 Pressure cut-off valve B290 Proximity switch / sensor control (kit)
500 Spool / regulating cylinder B291 Proximity switch / sensor control (kit)
501 Secondary pressure-relief valve / retract S241 AHS 12 switch
regulating cylinder 525
502 Secondary pressure-relief valve / extend Y62 Solenoid valve / travel
504 Pressure balance Y63 Solenoid valve / travel
507 Restrictor check valve Y268 Solenoid valve / changeover regulating
cylinder - hammer
Y299 Solenoid valve / secondary pressure ham-
mer
16.56.10
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MJF C I F S S
Hydraulic system
16.56.11
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MJF C I F S S
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
The accessory kits AHS 11 and AHS 12 described below are required for the installation of the fol-
lowing 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

B Hydraulic hammer
16.57.1
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MJF C I F S S
Accessory kit AHS 11 / AHS 12 with Tool Control Service Manual
General information
Attachments and associated pressure relief Pressure limit (in bar)

valve primary secondary
(this valve limits the LS pressure and thus the 350 +10 bar
operating pressure at the measuring point 41 in
the control block 100)
Secondary pressure relief valves 511/512
Low-pressure (basic settings) 100 +10 bar
High pressure (proportional valve Y414 with max. 380 +20 bar
current)
Flow rate at the outlet A / B
Extending: 200 l/min
Retracting: 200 l/min
Piston 510 dimension Y of stop screw 510.1 14.2 mm
16.57.2
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MJF C I F S S
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 propor-
tional solenoid valve Y414 is screw-mounted to the hydraulic tank 1 below the solenoid valve for for-
ward/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 lo-
cated 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
16.57.3
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MJF C I F S S
100 Control valve block Y268 Solenoid valve / changeover regulating

cylinder / hammer
500 Auxiliary control axle regulating cylinder Y414 Prop. valve pressure reduction
510 Auxiliary control axle / hydraulic hammer Y463 Prop. valve / flow reduction
511 Pressure relief valve with additional pres- Y464 Prop. valve / flow reduction
sure stage
512 Pressure relief valve with additional pres-
sure stage
The accessory kits AHS 11 / AHS 12 allow the operator to work with two completely different attach-
ments (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
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 16 Valve cone

15 Valve seat
16.57.5
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MJF C I F S S
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 pres-
sure 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 cur-
rent (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 pro-
portion 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.

2 Lock nut 14 Magnetic coil
3 Pressure spring 15 Valve seat
4 Pilot control cone 16 Valve cone
5 Main cone 511 Secondary pressure relief valve
6 Screw plug 512 Secondary pressure relief valve
7 Housing Y414 Prop. solenoid valve
11 Pressure spring
16.57.6
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MJF C I F S S
Fig. 4 Function of pressure control system
16.57.7
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MJF C I F S S
Fig. 5 Pilot control unit and menu display on the screen

A155 Tool Control keyboard S241 Switch AHS12
16.57.8
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MJF C I F S S
Operation
5 Operation
5.1 Operating working tool

spool 500).
Tool Control is disabled (pressure and flow reduction are not possible).
Operating the sorting grapple or hydraulic hammer:
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.
The sorting grapple cylinder is extended at the set speed and pressure, i.e. the sorting grapple
closes.
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 cur-
rently 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.
16.57.9
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MJF C I F S S
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 Keyboard unit A155 with "Tool Control" screen
EV1 Oil volume 1 F2 DOWN arrow button

EV1 Oil volume 2 F3 UP arrow button
EV2 Pressure F4 "Menu" button
16.57.10
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MJF C I F S S

To adjust the pressure, use suitable pressure sensors.
Note!
HERR 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:
Turn the adjusting screw anticlockwise, using an Allen key:
Operate the right pedal 86 and check the pressure at the measuring point 45.
Compare the pressures:
they must correspond.
16.57.11
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MJF C I F S S
Fig. 7 Adjusting points and operation
20 Variable-displacement pump LPV / 104 Pressure cut-off valve

DPVO
41 Measuring point MP 500 Spool / regulating cylinder
45 Measuring point LS 510 Hydraulic hammer/cylinder spool
86 Pilot control device of kit 511 Secondary pressure relief valve with
additional pressure level /
hammer / additional consumer
100 Compact control block 512 Secondary pressure relief valve with
additional pressure level
6.3 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.
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:
16.57.12
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MJF C I F S S
Turn the adjusting screw 20 anticlockwise, using an Allen key:

Compare the high pressure values of the right and the left foot pedal.
the two measured pressures must be identical.
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 Foot pedal in the operator's cab and proportional solenoid valve attached to the hydraulic
tank
1 Hydraulic tank 86 Secondary pressure relief valve

20 Adjusting screw Y414 Prop. solenoid valve
16.57.13
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MJF C I F S S
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 pres-
sure (see Tab. 1, page 2) by turning the adjusting screw.

500.1 Stroke limitation / retracting regulating cylinder 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
The dimension Y, (see Tab. 1, page 2) serves as a reference value for the prescribed settings. If di-
mension 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
16.57.15
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MJF C I F S S
Hydraulic diagram
7 Hydraulic diagram
Items in hydraulic diagram, (see Fig. 10, page 17)

1 to tank 514 Pressure balance
6 to oil cooler 517 Restrictor check valve
20 from variable-displacement pump 525 Regulating cylinder
23 Pump regulator 526 Load holding valve
41 Measuring point MP 527 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 Collecting pipe 535 Hydraulic hammer
90 Shuttle valve 536 Pile driver
100 Compact control block 5 x 537 Shear
104 Pressure cut-off valve 538 Stop cock
500 Auxiliary spool / regulating cylinder
501 Secondary pressure relief valve / retrac- A155 Keyboard unit
ting cylinder 525
502 Secondary pressure relief valve / exten- A156 ESX control
ding cylinder 537
504 Pressure balance S241 AHS 11 / AHS 12 switch
507 Restrictor check valve Y268 Solenoid valve changeover auxiliary
axle 500/ 501
510 Auxiliary spool / hammer or additional Y414 Prop.solenoid valve / pressure limitation
consumer
511 Secondary pressure relief valve with Y463 Prop.solenoid valve flow reduction ham-
additional pressure level / mer control axle
512 Secondary pressure relief valve with Y464 Prop.solenoid valve flow reduction ham-
additional pressure level / additional mer control axle
consumer
16.57.16
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MJF C I F S S
Hydraulic diagram
Fig. 10 Hydraulic diagram of AHS 11 with Tool Control
16.57.17
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MJF C I F S S
Electrical system
8 Electrical system
Fig. 11 Electrical system of AHS 12 accessory kit with Tool Control
A155 Keyboard unit / display with plug X974-4 Plug

X1 and X3
A156 ESX control unit with plug X1 X1252 CanBus interface
S241 Switch AHS12 Y268 Solenoid valve / changeover auxiliary
axle 500/ 501
X11 Plug Y299 Plug connection to solenoid valve
X414 Plug Y414 Prop.solenoid valve / pressure limitation
X463 Plug Y463 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
tachments 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:
(vertical) and a horizontally adjustable boom.
second auxiliary control axle without pressure/flow reduction for a high-pressure connection:
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 con-
trol axle from vertically to horizontally adjustable boom
As all functions are controlled with the same pilot control device (pedal), they cannot be operated si-
multaneously.
16.58.1
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MJF C I F S S
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)

block 100
Secondary pressure relief valves 501/502 380 +20 bar
for regulating cylinder 525 / 545 extension and re-
traction
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
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 connec-
ted auxiliary attachments, by means of the auxiliary pilot control unit 86.
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 con-
nected units must be operated according to the instructions in this manual:

S241 Switch AHS12
S356 Switch/changeover valve
Actuate switches S241 and S356 to preselect the desired attachment and activate it through the so-
lenoid valve Y332.
Operation of the boom regulating cylinder 252 (vertical):
16.58.3
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MJF C I F S S
Operation

spool 500).
Operation of the boom regulating cylinder 545 (horizontal):

The indicator in the switch is off.
Switch S356 is actuated.
spool 500).
The regulating cylinder (vertical) 545 is retracted, i.e. the boom is swivelled to the right.
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
Function
4 Function
4.1 Operation of the boom regulating cylinder 525 (horizontal):

Set switch S241 to position 0 (not actuated).
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 so-
lenoid 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 con-
nection 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 so-
lenoid 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 con-
nection 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 S356 to ON (active).
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 so-
lenoid 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 val-
ve Y332, connection B6 of the control valve block 100 and the spool 500 to the tank. The cylinder is
16.58.5
copyright by
MJF C I F S S
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 so-
lenoid 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 re-
tracted, 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
copyright by
MJF C I F S S
Note!
For a detailed description of testing procedures and pressure adjustments, see AHS 12, group
16.56.
16.58.7
copyright by
MJF C I F S S
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
1 Hydraulic tank 545 Regulating cylinder (horizontal move-

ment)
255 Stick cylinder 7 546 Double load-holding valve
500 Regulating cylinder spool
525 Regulating cylinder (vertical movement) Y332 Solenoid valve / changeover valve
526 Load-holding valve (piston side) Y443 Stop valve for cylinder retracting
527 Load-holding valve (rod side) Y444 Stop valve for cylinder extending
16.58.8
copyright by
MJF C I F S S
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
16.58.9
copyright by
MJF C I F S S
Hydraulic system
7 Hydraulic system
1 from / to hydraulic tank 514 Pressure balance

20 Variable-displacement pump 517 Restrictor check valve
23 Regulating valve 525 Regulating cylinder
41 Measuring point MP 526 Load-holding valve (piston side)
45 Measuring point LS 527 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 move-
ment)
104 Pressure cut-off valve 546 Double load-holding valve
500 Spool / regulating cylinder
501 Secondary pressure-relief valve / retrac- S241 Switch / changeover regulating cylinder -
ting reg. cyl. 525 / extending reg. cyl. 545 hydraulic hammer
502 Secondary pressure-relief valve / exten- S356 Switch / changeover of boom adjustment
ding reg. cyl. 525 / retracting reg. cyl. 545 horizontal - vertical
504 Pressure balance Y268 Solenoid valve / changeover regulating
cylinder - hammer
507 Restrictor check valve Y299 Solenoid valve / secondary pressure ham-
mer
510 Spool / hydraulic hammer / cylinder / pile Y332 Solenoid valve / changeover valve
driver
511 Secondary pressure-relief valve / extend Y443 Stop valve for cylinder retracing
hydraulic hammer cylinder 535 cylinder
537
512 Secondary pressure relief valve / cylinder Y444 Stop valve for cylinder extending
537 retracting
The valve is not built into all machines

(subsequently added to machine equip-
ment).
16.58.10
copyright by
MJF C I F S S
Hydraulic system
Fig. 5 Hydraulic diagram of the changeover valve kit
16.58.11
copyright by
MJF C I F S S
Electrical system
8 Electrical system
Step 66 / 78#
Item Description Location/arrangement
K455 Relay/changeover switch Right control console
S356 Switch/changeover valve Right control desk
X29** Plug connection distribution board / 2-pin Right console, rear
X358-1 Plug connection / 2-pin Below operator's platform
X358-2 Plug connection / 2-pin Fuel tank
X983 Plug connection solenoid valves / 3-pin Right console, rear
X1226 Plug connection A125 CS / 2-pin Left console, bottom
Y332 Solenoid valve / changeover valve Basic boom
Y443 Stop valve/ regulating cylinder extending Hydraulic tank
Y444 Stop valve/ regulating cylinder retracting Hydraulic tank
16.58.12
copyright by
MJF C I F S S
Electrical system
** in basic diagram The item is not built into all machines

# For other options of kit layout changeover (subsequently added to machine equip-
valve, see group 8.45. ment).
16.58.13
copyright by
MJF C I F S S
Electrical kit step 66 / 78
9 Electrical kit step 66 / 78
Fig. 6 Electrical kit for changeover valve, see also step 66 / 78 in group 8.45, electrical kits.
16.58.14
copyright by
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 out-
rigger 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 cy-
linders is thereby controlled by means of the "outrigger support" function.
Fig. 1 Hydraulic excavator with 4-point outrigger support
16.60.1
copyright by
MJF C I F S S
Individual control Service Manual
Design
2 Design
The kit for individual control consists of a number of operating elements, solenoid valves and hydrau-
lic 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 th-
rough 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 sys-
tem 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 Pilot control unit and switch for individual outrigger control
85 Pilot control unit S204 Individual control system switch

S205 Individual control system switch
16.60.2
copyright by
MJF C I F S S
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
Y218 Solenoid valve
Individual control of rear right outrigger
16.60.3
copyright by
MJF C I F S S
see Fig. 4 and see Fig. 5

When in neutral position, the solenoid valves Y215 - Y218 close the pressure connection B; as a re-
sult, 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 ro-
tary 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 con-
nection 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 A1 from control valve block connection S206 Switch / individual outrigger control, left
A1
100 B1 from control valve block B1 S207 Switch / individual outrigger control,
right
295 Support cylinder Y217 Solenoid valve
297 Double lowering brake valve Y218 Solenoid valve
320 Rotary connection (high pressure)
325 Slip ring rotary connection
16.60.4
copyright by
MJF C I F S S
Fig. 4 Hydraulic diagram of support option with 2-point support and individual control
16.60.5
copyright by
MJF C I F S S
100 A1 from control valve block connection S205 Switch / individual control of front right
A1 outrigger
100 B1 from control valve block B1 S206 Switch / individual control of rear left
outrigger
295 Support cylinder S207 Switch / individual control of rear right
outrigger
297 Double lowering brake valve Y215 Solenoid valve
320 Rotary connection (high pressure) Y216 Solenoid valve
Individual control of front right outrigger
325 Slip ring rotary connection Y217 Solenoid valve
S204 Switch / individual control of front left Y218 Solenoid valve
outrigger Individual control of rear right outrigger
16.60.6
copyright by
MJF C I F S S
Fig. 5 Hydraulic diagram of support option with 4-point support and individual control
16.60.7
copyright by
MJF C I F S S
Fig. 6 Electrical system of individual control
F337 Fuse (15 A) (front control console) X771 Plug connection, 5-pin
S204 Individual control system switch X957 Plug connection, 21-pin
S207 Individual control system switch Y61 Solenoid valve / changeover
(without function with individual control)
S272 Junction box Y215 Solenoid valve
S335 Changeover switch Y216 Solenoid valve
(without function with individual control) Individual control of front right outrigger
X301 Plug connection, 1-pin Y217 Solenoid valve
X304 Plug connection, 6-pin Y218 Solenoid valve
16.60.8
copyright by
MJF C I F S S
Electric diagram of individual control system
4 Electric diagram of individual control system
16.60.9
copyright by
MJF C I F S S
Electric diagram of individual control system
16.60.10
copyright by
MJF C I F S S
Service Manual Kit for control switch-over
Function
Kit for control switch-over
A 309 up to serial no. 23701

A 311 up to serial no. 23253
1 Function
This kit allows the operator to control the auxiliary attachment with the foot pedal or with the joystick.
To install the kit, a number of units, hydraulic lines and hoses required for the switch-over of the con-
trol 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 m Operate hydraulic hammer / close sorting
grapple
f Tilt bucket outwards n Open sorting grapple
after switch-over: after switch-over:

e Operate hydraulic hammer / close sorting m Tilt bucket inwards
grapple
f Open sorting grapple n Tilt bucket outwards
16.62.1
copyright by
MJF C I F S S
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 lo-
cation at the machine.
Fig. 2 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 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 the key switch S405 to position A or B (switch-over not possible)
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
copyright by
MJF C I F S S
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
2.2 Operation of bucket cylinder 180 and shears / sorting grapple 537 (standard):
Set the key switch S405 to position A.
spool 510).
The cylinder of the sorting grapple / shears is extended (sorting grapple / shears closed)
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):
The indicator light at the switch is not on (as shown in section 2.2)
Set the key switch S405 to position B
spool 510).
16.62.3
copyright by
MJF C I F S S
Operation
2.4 Operation of bucket cylinder 180 and hydraulic hammer 535 (standard):
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 hydraulic hammer is pressurised.
no function assigned
2.5 Operation of bucket cylinder 180 and hydraulic hammer 535 (after switch-
over):
16.62.4
copyright by
MJF C I F S S
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)
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 connec-
tion 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 connec-
tion 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.
tion 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.
16.62.5
copyright by
MJF C I F S S
device 81 (joystick)
Operation of bucket cylinder with pilot control unit 86 (pedals)
Set the key switch S405 to position B.
The solenoid valves Y385-1 / Y385-2 are in working position.

The hydraulic hammer 535 / the cylinder 537 is extended, moving the attachment.
the working pump 20 through eh connection A7 to the piston side of the bucket cylinder 180.
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 connec-
tion 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 solenoid valve Y385-2 connection 3-1 to the control valve block 100 connection b7. The spool
the bucket cylinder 180.
3.3 Pressure reduction at auxiliary control valve block, and combined shifting
when boom is lowered
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
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.
Note!
For a description of the valve and stroke limiter settings in auxiliary axle AHS 12, refer to group
16.54.
16.62.7
copyright by
MJF C I F S S
Components and hydraulic lines A 309 up to serial no. 23701 and A 311 up to serial no. 23253

A 309 up to serial no. 23701 and A 311 up to serial no. 23253
Fig. 3 Hydraulic connections of control switch-over kit
1 Hydraulic tank B33 Pressure switch flow reduction

50 Control oil unit Y22 Solenoid valve / grapple rotator left
78 Shuttle valve / combined shifting Y23 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 off-
set boom bearing
100 Compact control block Y268 Solenoid valve / changeover regulating
cylinder - hammer
16.62.8
copyright by
MJF C I F S S
Components and hydraulic lines A 309 up to serial no. 23701 and A 311 up to serial no. 23253
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 Y385-2 Solenoid valve changeover bucket cyl. -
AHS
109 Combined boom / stick cylinder spool
additional pressure stage / retract hydr.
hammer cyl.
16.62.9
copyright by
MJF C I F S S
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 511 Secondary pressure-relief valve /
pump extend hydraulic hammer 535 cylinder
537
40 Measuring point P1 512 Secondary pressure relief valve / retract
cylinder 537
78 Shuttle valve / combined shifting 537 Cylinder (auxiliary activation, e.g. sor-
ting
grapple)
79 Shuttle valve / pressure switch B33
81 Pilot control unit 4x, with joystick B33 Pressure switch flow reduction
86 Pilot control unit 2x, with pedals S63 Switch / offset boom bearing
88P Distributor S241 Switch / changeover regulating cylinder
- hydraulic hammer
88T Collecting pipe S263 Switch / travel direction
100 Compact control block S405 Key switch / control switch-over
105 Regulating cylinder spool Y62 Solenoid valve / travel forward
106 Boom cylinder spool Y63 Solenoid valve / travel reverse
107 Bucket cylinder spool Y262 Solenoid valve / switch-over bucket off-
set boom bearing
109 Combined boom / stick cylinder spool Y268 Solenoid valve / changeover regulating
cylinder - hammer
122 Primary pressure-relief valve pump P1 Y299 Solenoid valve / secondary pressure
hammer
180 Bucket cylinder Y385-1 Solenoid valve / changeover bucket cyl.
- AHS
250 Regulating cylinder Y385-2 Solenoid valve / changeover bucket cyl.
- AHS
251 Double load-holding valve
16.62.10
copyright by
MJF C I F S S
Hydraulic diagram of the kit
16.62.11
copyright by
MJF C I F S S
Electrical system
7 Electrical system
H322 Warning light / switch-over Right control console
X12** Plug connection distribution board / 2-pin Right console

X1029 Plug connection solenoid valves / 4-pin Right control console, rear
X1224 Plug connection to B33 / 3-pin Distribution board
Y385-1 Solenoid valve / changeover bucket cylinder- AHS Near fuel tank
Y385-2 Solenoid valve / changeover bucket cylinder - AHS Near fuel tank
** position from basic diagram
16.62.12
copyright by
MJF C I F S S
Electrical system
Fig. 5 Electrical system of switch-over control kit
16.62.13
copyright by
MJF C I F S S
Electrical system
Step 84/2#


X12** Plug connection on distribution board / 2-pin Right console

X837** Plug connection A125 / 8-pin Left console, bottom
X839** Plug connection / screw terminal on A125 / 3-pin Left console, bottom
X856** Plug connection BST wire harness / 40-pin Right console
X857** Plug connection BST excavator control / 24-pin Right console
X965** Plug connection BST- CS A125 / 21-pin Right console, rear
X966** Plug connection A125 wire harness / 21-pin Right console, rear
X968-1** Plug connection A125 CS / 1-pin Left console, bottom
X1028 Plug connection to S405 and H322 / 4-pin Right control console, rear
X1224 Plug connection pressure switch / 3-pin Distribution board
Y268** to solenoid valve / grapple hammer Near hydraulic tank

Y299** to solenoid valve secondary pressure hammer Near hydraulic tank

# see also electric kits in group 8.45
16.62.14
copyright by
MJF C I F S S
Electrical system
16.62.15
copyright by
MJF C I F S S
Electrical system
16.62.16
copyright by
MJF C I F S S
Function
A 309 from serial no. 23702

A 311 from serial no. 23254
8 Function
trol are required.
ment with joystick
grapple

grapple
16.62.21
copyright by
MJF C I F S S
Operation
9 Operation
Caution!
kit
S241 Switch AHS12
spool 105).
16.62.22
copyright by
MJF C I F S S
Operation

spool 510).
switch-over):
The indicator light in the switch is not on (as shown in section 9.2)
spool 510).
16.62.23
copyright by
MJF C I F S S
Operation
The indicator light H196 is not on (as shown in section 9.5)
over):
16.62.24
copyright by
MJF C I F S S
Note!
For the regularly functions of the accessory kit AHS 12 that can be activated with switch S241, ple-
ase refer to group 16.54.
unit 86 (pedals)

10.1.2 Retracting
the solenoid valve Y385-2 connection 3-4 to the auxiliary control axle 510 connection b9. The spool
the cylinder 537.
tion 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.
16.62.25
copyright by
MJF C I F S S
Set the switch S241 to position 1 or 2.
10.2.1 Extending / pressurising hammer

the working pump 20 through the connection A7 to the piston side of the bucket cylinder 180.
10.2.2 Retracting
2 through the solenoid valve Y262 connection P1-A1 and through the solenoid valve Y385-2 connec-
the working pump 20 through the connection B9 to the rod side of the cylinder 537.
the bucket cylinder 180.
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
Note!
16.54.
16.62.27
copyright by
MJF C I F S S
Components and hydraulic lines A 309 from serial no. 23702 and A 311 from serial no. 23254

A 309 from serial no. 23702 and A 311 from serial no. 23254
16.62.28
copyright by
MJF C I F S S
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 Control oil unit Y22 Solenoid valve / grapple rotator left
78 Shuttle valve / combined shifting Y23 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 off-
set 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
AHS
109 Combined boom / stick cylinder spool Y451 Solenoid valve switch-over buzzer /
boom
additional pressure stage / retract hydr.
hammer cyl.
16.62.29
copyright by
MJF C I F S S
Hydraulic system
13 Hydraulic system
546
1 to hydraulic tank 510 Spool / hydraulic hammer /

cylinder
20 from double variable-displacement 511 Secondary pressure-relief valve /
pump extend hydraulic hammer 535 cylinder
537
40 Measuring point P1 512 Secondary pressure relief valve / retract
cylinder 537

78 Shuttle valve / combined shifting 537 Cylinder (auxiliary activation, e.g. sor-
ting
grapple)
79 Shuttle valve / pressure switch B33
81 Pilot control unit 4x, with joystick B33 Pressure switch flow reduction
86 Pilot control unit 2x, with pedals S63 Switch / offset boom bearing
88P Distributor S241 Switch / changeover regulating cylinder
- hydraulic hammer
88T Collecting pipe S263 Switch / travel direction
100 Compact control block S405 Key switch / control switch-over
105 Regulating cylinder spool Y62 Solenoid valve / travel forward
106 Boom cylinder spool Y63 Solenoid valve / travel reverse
107 Bucket cylinder spool Y262 Solenoid valve / switch-over bucket off-
set boom bearing
109 Combined boom / stick cylinder spool Y268 Solenoid valve / changeover regulating
cylinder - hammer
122 Primary pressure-relief valve pump P1 Y299 Solenoid valve / secondary pressure
hammer
180 Bucket cylinder Y385-1 Solenoid valve / changeover bucket cyl.
- AHS
250 Regulating cylinder Y385-2 Solenoid valve / changeover bucket cyl.
- AHS
251 Double load-holding valve Y451 Solenoid valve switch-over buzzer /
boom
16.62.30
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MJF C I F S S
Hydraulic system
16.62.31
copyright by
MJF C I F S S
Electrical system
K375** Relay / signal flow reduction kit AHS Right console, rear

X952** Plug connection revolving deck BST excavator control / Right console, rear
21-pin
Y268 Solenoid valve / changeover adjustable boom - hammer Near control valve block
Y299 Solenoid valve / additional pressure stage Near control valve block
Y451 Solenoid valve switch-over buzzer / lower boom Near control valve block
16.62.32
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MJF C I F S S
Electrical system
16.62.33
copyright by
MJF C I F S S
Electrical system
Step 84/2#

H196** Indicator light / sorting grapple Right control console

S19/5** to switch AS1 Right control desk


X12** Plug connection on distribution board / 2-pin Right console

X856** Plug connection BST wire harness / 40-pin Right console
X857** Plug connection BST excavator control / 24-pin Right console
X965** Plug connection BST- CS A125 / 21-pin Right console, rear
X966** Plug connection A125 wire harness / 21-pin Right console, rear
X1224 Plug connection pressure switch / 3-pin Distribution board
Y268** to solenoid valve / grapple hammer Near control valve block

Y299** to solenoid valve / pressure reduction Near control valve block
Y385-1 Solenoid valve / changeover bucket cylinder - AHS at fuel tank
Y385-2 Solenoid valve / changeover bucket cylinder - AHS at fuel tank
Y451 Solenoid valve switch-over buzzer / boom Near control valve block

16.62.34
copyright by
MJF C I F S S
Electrical system
16.62.35
copyright by
MJF C I F S S
Electrical system
16.62.36
copyright by
MJF C I F S S
Function
1 Function
trol are required.
ment with joystick
grapple

grapple
A 312 LI 12363- 16.64.1

A 316 LI 2001- MJF C I F S S
A 316 LI-IND 2001-
Operation
2 Operation
Caution!
kit
S241 Switch AHS12
spool 500).
16.64.2 A 312 LI 12363-

MJF C I F S S A 316 LI 2001-
A 316 LI-IND 2001-
Operation

spool 510).
switch-over):
The indicator light in the switch is not on (as shown in section 2.2)
spool 510).
A 312 LI 12363- 16.64.3

A 316 LI 2001- MJF C I F S S
A 316 LI-IND 2001-
Operation
The indicator light H196 is not on (as shown in section 2.5)
over):
16.64.4 A 312 LI 12363-

MJF C I F S S A 316 LI 2001-
A 316 LI-IND 2001-
Note!
For the regular functions of the accessory kit AHS 12 that can be activated with switch S241, please
refer to group 16.56.
unit 86 (pedals)

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.
3.1.2 Retracting
When the left pedal of the pilot control unit 86 is pressed down, control oil is fed from connection 2
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.
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.
A 312 LI 12363- 16.64.5

A 316 LI 2001- MJF C I F S S
A 316 LI-IND 2001-

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 hy-
draulic hammer 535 or the piston side of the cylinder 537 respectively.
3.2.2 Retraction of attachment/pressurisation of pile driver

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.
the bucket cylinder 275. The cylinder is retracted; the bucket is tilted outwards.
pressure boost cartridge of the valve 511 and through the solenoid valve Y299 connection P-A is blo-
cked, 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.
Note!
16.56.
16.64.6 A 312 LI 12363-

MJF C I F S S A 316 LI 2001-
A 316 LI-IND 2001-
1 Hydraulic tank Y62 Solenoid valve / travel forward

50 Control oil unit Y63 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 ham-
mer
100 Compact control block Y385-1 Solenoid valve changeover bucket cyl. -
AHS
AHS
additional pressure stage / extend
hydr. hammer cyl.
A 312 LI 12363- 16.64.7

A 316 LI 2001- MJF C I F S S
A 316 LI-IND 2001-
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 Measuring point MP 517 Restrictor check valve
45 Measuring point LS 525 Regulating cylinder
50 from the control oil unit 526 Load-holding valve
81 Pilot control unit 4x, with joystick 527 Load-holding valve
86 Pilot control unit 2x, with pedals 535 Hydraulic hammer
88P Distributor 537 Cylinder (auxiliary activation, e.g. sor-
ting
grapple)
88T Collecting pipe B33 Pressure switch flow reduction
100 Compact control block S63 Switch / offset boom bearing
104 Pressure cut-off valve S241 Switch / changeover regulating cylinder
- hydraulic hammer
260 Bucket cylinder spool S263 Switch / travel direction
275 Bucket cylinder S405 Key switch / control switch-over
500 Spool / regulating cylinder / Y62 Solenoid valve / travel forward
cylinder
501 Secondary pressure-relief valve / retract Y63 Solenoid valve / travel reverse
502 Secondary pressure-relief valve / Y262 Solenoid valve / switch-over bucket off-
extend regulating cylinder 525 set boom bearing
504 Pressure balance Y268 Solenoid valve / changeover regulating
cylinder - hammer
507 Restrictor check valve Y299 Solenoid valve / secondary pressure
hammer
510 Spool / hydraulic hammer / Y385-1 Solenoid valve / changeover bucket cyl.
cylinder - AHS
511 Secondary pressure-relief valve / Y385-2 Solenoid valve / changeover bucket cyl.
extend hydraulic hammer 535 cylinder - AHS
537
16.64.8 A 312 LI 12363-

MJF C I F S S A 316 LI 2001-
A 316 LI-IND 2001-
Hydraulic system
A 312 LI 12363- 16.64.9

A 316 LI 2001- MJF C I F S S
A 316 LI-IND 2001-
Electrical system
7 Electrical system
S405 Switch / switch-over Right console

Y451 Solenoid valve switch-over buzzer / boom Near fuel tank
16.64.10 A 312 LI 12363-

MJF C I F S S A 316 LI 2001-
A 316 LI-IND 2001-
Electrical system
A 312 LI 12363- 16.64.11

A 316 LI 2001- MJF C I F S S
A 316 LI-IND 2001-
Electrical system
Step 84/1#

P1** Flow reduction potentiometer Right control console


V169 Blocking diode A125



16.64.12 A 312 LI 12363-

MJF C I F S S A 316 LI 2001-
A 316 LI-IND 2001-
Electrical system
A 312 LI 12363- 16.64.13

A 316 LI 2001- MJF C I F S S
A 316 LI-IND 2001-
Electrical system
16.64.14 A 312 LI 12363-

MJF C I F S S A 316 LI 2001-
A 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 in-
crease its load capacity.
Fig. 1 4-point outrigger support with dozer blade at the undercarriage
16.66.1
copyright by
MJF C I F S S
Dozer blade Service Manual
Technical data
2 Technical data
Machine A 312 - A 316 Li
Adjusting pressure at the

pressure-relief valve 304 240 5 bar
Tab. 1 Adjusting pressure for the dozer blade cylinder
3 Design

The dozer blade equipped with these devices (cylinder, beam, etc.) is designed exclusively for gra-
ding 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 sup-
port 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 se-
cures 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 connec-
tion A1 through the rotary connection 320 to the solenoid valve Y56 connection A1 - C1. From con-
nection 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
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 ro-
tary 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.

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 Pilot control unit / support

b Lifting dozer blade S335 Switch / dozer blade
16.66.3
copyright by
MJF C I F S S
Operation of dozer blade
Fig. 3 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
16.66.4
copyright by
MJF C I F S S
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 Way valve 6x 10 Lock washer

2 Pressure reducing valve (switching pressure 11 Lock washer
reduction)
3 Way valve / magnet 12 O-ring
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
16.66.5
copyright by
MJF C I F S S
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. The-
re is a risk of death to the technician, as he could be crushed under the machine.
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 304 Pressure-relief valve

100 A1/B1 from control valve block
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.
16.66.6
copyright by
MJF C I F S S
Sectional drawing of hydraulically releasable check valve 302
Fig. 7 Sectional drawing of pressure-relief valve
19 Adjusting screw 304 Pressure-relief valve, complete

21 Protective cover
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 Pushrod 999 Seal kit
6 Valve cone
16.66.7
copyright by
MJF C I F S S
Hydraulic diagram
9 Hydraulic diagram
9.1 at 2-point undercarriage, model A 316
Fig. 9 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 Solenoid valve 6x
16.66.8
copyright by
MJF C I F S S
Hydraulic diagram
9.2 at 4-point undercarriage, model A 316
Fig. 10 Hydraulic diagram of dozer blade with 4-point support
100 from compact control block 320 Rotary connection 7x

295 Support cylinder / outriggers 325 Slip ring / rotary connection
297 Double stop valve 395 Dozer blade cylinder
302 Hydraulically releasable check valve S335 Switch / changeover blade - outrigger
304 Pressure-relief valve Y56 Solenoid valve 6x
16.66.9
copyright by
MJF C I F S S
Electrical system
Fig. 11 Electrical system in upper and undercarriage
F337 Fuse (15 A) X771 Plug connection, 5-pin

S272 Junction box X957 Plug connection, 21-pin
S335 Switch / dozer blade - outrigger X958 Plug connection, 21-pin
X301 Plug connection, 12-pin X963 Plug connection, 21-pin
X304 Plug connection, 6-pin Y56 Solenoid valve 6x
16.66.10
copyright by
MJF C I F S S
Electrical diagram
11 Electrical diagram
Fig. 12 Electrical diagram of switchover system blade - outrigger, see basic diagram step 35
16.66.11
copyright by
MJF C I F S S
Electrical diagram
16.66.12
copyright by
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
16.70.1
copyright by
MJF C I F S S
Hydraulic cab elevation system Service Manual
Technical data
2 Technical data
Machine: A 316 Litronic Industry

Type: 716
Serial number: 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 14 l/min

Flow volume / spool connection B 32 l/min
Setting value Y (bottom) 16 mm
Setting value Y (top) 17 mm
Setting values of the valves
Secondary pressure-relief valve 601
for working pressure of cab elevation system 100+10 bar
These valves act as primary valves (measuring point 41).
Secondary pressure-relief valve 602

for working pressure of cab elevation system 150+10 bar
These valves act as primary valves (measuring point 41).
Caution!
An incorrectly set proximity switch of the stick shut-down can lead to injury to the operator and da-
mage 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
copyright by
MJF C I F S S
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 ad-
ditional control block 600.
Other valves (pressure-relief valves 601 and 602, load holding / lowering brake valve 623) are desi-
gned 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 76 Left strut

72 Beam 78 Carrier
74 Right strut
16.70.3
copyright by
MJF C I F S S
Design
Fig. 3 Pilot control of hydraulic cab elevation system
1 Hydraulic tank 100 Compact control block

80 Pilot control valve left / stick 600 Additional control block / operator's cab
adjustment
90 Pilot control unit of cab elevation system 623 Load holding / lowering brake valve
16.70.4
copyright by
MJF C I F S S
Design
Fig. 4 Components of the hydraulic operator's cab elevation
20 Variable-displacement pump 619 Restrictor check valve / pipe fracture

safety valve
100 Compact control block 620 Hydraulic accumulator
600 Additional control block 623 Load holding / lowering brake valve
615 Cylinder
16.70.5
copyright by
MJF C I F S S
Design
Fig. 5 Installation position of the additional control block and the load holding / lowering brake
valve
100 Compact control block 623 Load holding / lowering brake valve
600 Additional control block
3.1 Control devices in operator's cab
Fig. 6 Control devices in the left control console for the hydraulic cab elevation system
90 Pilot control unit of cab elevation system S78 Button for emergency lowering (from
serial no. 12390, see Fig. 9)
16.70.6
copyright by
MJF C I F S S
Design
Fig. 7 Installation position of the accumulator, restrictor check valves and cylinders in the sup-
port
615 Cylinder for cab elevation system 620 Hydraulic accumulator

619 Restrictor check valve / pipe fracture
safety valve
16.70.7
copyright by
MJF C I F S S

The pilot control unit 90 is not actuated, and the spool 600 is in its neutral position. The variable-dis-
placement 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 con-
trol 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.

In the event of a failure of the diesel engine or the control system of the adjustable operator's cab, it
can be lowered manually.
There are three methods of emergency lowering:
16.70.8
copyright by
MJF C I F S S
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 lo-
wering 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 lowe-
red.
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 pre-
vent this, complete the following steps:
After lowering the cab, always return the lever of the block ball valve 621 / 622 to its initial posi-
tion.
16.70.9
copyright by
MJF C I F S S
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 lo-
wered 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 lo-
wered, see Fig. 9.
Fig. 9 Emergency lowering system from serial no. 12390
1 Hydraulic tank S78 Button / emergency lowering system

90 Pilot control unit of cab elevation system Y204 Solenoid valve / 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 pre-
vent this, complete the following steps:
After lowering the cab, return the handle A of the solenoid valve Y204 to its initial position.
16.70.10
copyright by
MJF C I F S S
Fig. 10 Installation position of the emergency valve at the support
Y204 Solenoid valve / emergency lowering E Connection from the cylinders 615
system
A Handle of mechanical emergency T to hydraulic tank
lowering system
16.70.11
copyright by
MJF C I F S S
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.
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 sup-
ports.
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
600 Additional control block 602 Pressure-relief valve / lifting cab
600.1 Lock nut (WS 22)
16.70.12
copyright by
MJF C I F S S
5.2 Settings of additional control block 600
5.2.1 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.
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
16.70.13
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MJF C I F S S
Hydraulic unit of the operator's cab elevation
6 Hydraulic unit of the operator's cab elevation
1 Hydraulic tank 600 Additional control block

6 to oil cooler 601 Pressure-relief valve / lowering cab
20 Variable-displacement pump 602 Pressure-relief valve / lifting cab
23 Regulating valve / pump 604 Pressure balance
30 Gear pump / cooling 615 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 from control oil unit 620 Hydraulic accumulator
80 Pilot control valve, left slewing gear / stick 621 Block ball valve of emergency lowering
system (in operator's cab from serial no.
2001)
88P Distributor of control block 622 Block ball valve of emergency lowering
system (at the rear of support, from serial
no. 2001)
88T Collecting pipe / tank 623 Load holding / lowering brake valve
90 Pilot control unit of cab elevation system T16 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)
16.70.14
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MJF C I F S S
Hydraulic unit of the operator's cab elevation
Fig. 13 Hydraulic diagram of cab elevation system
16.70.15
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MJF C I F S S
Electrical system of hydraulic operator's cab elevation system
7 Electrical system of hydraulic operator's cab elevation system
Fig. 14 Electrical system of the hydraulic operator's cab elevation system from serial no. 12390
A127 Printed circuit board / power X909-1 Plug connection, 2-pin

F344 Fuse emergency lowering system X909-2 Plug connection, 2-pin
KL 31 Earth connection terminal X909-3 Plug connection, 2-pin
S78 Emergency cab lowering system sym- Y78 Button / emergency lowering system
bol
X9 Plug connection on board A127
16.70.16
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MJF C I F S S
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 Button / emergency lowering system X909-2 Plug connection, 2-pin
Y204 Solenoid valve / emergency lowering X909-3 Plug connection, 2-pin
system
16.70.17
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MJF C I F S S
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) 170 Travel motor

17 Threaded stud (A 312)
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).
16.74.1
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MJF C I F S S
Speeder kit Service Manual
Design
2.2 Control block 100 with control axle 160 chassis
Fig. 2 Control block with control axle
100 Control valve block 160.1.1 Adjusting screw

160.2 Stroke limitation 160.1.2 Lock nut
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.
Extend the supports.
Place the attachment on the ground and lift the undercarriage from the ground, if necessary.
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.
At fully actuated pilot control unit, remove the cap nut of the chassis control axle 160 of the control
valve block 100.
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 actua-
ted.
Check the prescribed pilot control pressure at the control caps of the control axle 160 and elimi-
nate 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
16.74.3
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MJF C I F S S
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 mag-
net 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 ge-
nerator 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 A 316 machine with generator and load lifting magnet
400 Generator with hydraulic drive unit 402 Load lifting magnet
16.86.1
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MJF C I F S S
Generator drive accessory kit Service Manual
Technical data
2 Technical data
Description Generator Generator

10 kW 10 kW
from serial no. from serial no.
2001 18429
Gear pump 36:

Drive speed rpm 1841 2008
3
Volumetric delivery cm 28 28
Flow rate l/min. 51,5 56,2
Axial piston - fixed-displacement motor 430:
Output speed min-1 3000 + 50 3150 + 50
3
Flow consumption cm 16 16
Pressure balance 413:
-p 7 - 15 7 - 15
Solenoid pressure relief valve Y295:
Minimum pressure bar 15 15
Maximum pressure bar 190 190+5
Restrictor check valve 417:
Back pressure bar 35 -
Tab. 1 Data of the components
3 Design and function of the generator drive system
3.1 Arrangement of the units to serial no. 18428 (old model)
3.1.1 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
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 , (see Tab. 1, page 2)
Fig. 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 Bearing block 419 Measuring point / return pressure
413 Pressure balance 430 Axial piston - oil motor
416 Check valve Y295 Solenoid pressure relief valve
16.86.3
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MJF C I F S S
3.2 Arrangement of the units from serial no. 18429 (new model)
3.2.1 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 ba-
lance 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 Pump, control block and oil motor of the generator drive system
36 Gear pump 418 Measuring point / working pressure

400 Generator 420 Control valve block
408 Bearing block 430 Oil motor
413 Pressure balance Y294 Solenoid pressure relief valve
16.86.4
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MJF C I F S S
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 Switches and push buttons of the magnet system
S6L Push button of magnet S46 Switch to activate magnet system
3.5 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.
16.86.5
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MJF C I F S S
The magnet is deactivated.
Fig. 5 Switches, rocker switch/load lifting magnet and switch/fine control in special version
S46 Magnet system switch S457 Magnet system rocker switch

S382 Fine control 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 50C.
For operating pressures, flow rates and speed, see section "2. Technical data".
4.1 Adjustment of solenoid pressure relief vale Y295, see Fig. 6

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
= 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 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 Adjusting screw 418 Measuring point / working pressure
7 Lock nut 430 Oil motor
400 Generator Y295 Solenoid pressure relief valve
4.2 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 ba-
lance (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.
16.86.7
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MJF C I F S S
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.
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:
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 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
4.3 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:
Write down the current position of the adjusting restrictor (sleeve) of the restrictor check valve 417.
16.86.8
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MJF C I F S S
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

410 Housing body / pressure balance 419 Measuring point / return pressure
411 Housing body / pressure-relief valve 430 Axial piston - oil motor
415 Restrictor
16.86.9
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MJF C I F S S
Hydraulic diagram of the generator drive system (old version)
6 Hydraulic diagram of the generator drive system (old version)
Item see Item see

group group
1 Hydraulic tank 414 Restrictor ( 4.5 mm)
31 Gear pump / steering 13.10 415 Restrictor ( 7.5 mm)
32 Gear pump / brake and pilot control 15.12 416 Check valve
unit 6.24/6.27
410 Housing body / pressure balance 419 Measuring point / return pressure
411 Housing body / pressure-relief 430 Axial piston - oil motor
valve
16.86.10
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MJF C I F S S
Hydraulic diagram of the generator drive system (old version)
Fig. 9 Hydraulic diagram of the generator drive system (old version)
16.86.11
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MJF C I F S S
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 Control block with pressure balance, solenoid pressure relief valve and restrictors
2 Adjusting screw (internal hex head 5 423 Check valve

mm)
3 Lock nut (WS 17) 424 Restrictor ( 4.5 mm)
5 Cap nut 425 Restrictor ( 7.5 mm)
413 Pressure balance, complete Y295 Solenoid pressure-relief valve
420 Pilot control unit, complete
16.86.12
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MJF C I F S S
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 Hydraulic tank 420 Control valve block

36 Gear pump 425 Minimess damping line (length 600 mm,
function-relevant)
400 Generator 430 Oil motor
433 Spacer*
413 Pressure balance 434 Pipe seal*
418 Measuring point Y295 Solenoid pressure relief valve
* (only for installations without generator)
16.86.13
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MJF C I F S S
Hydraulic diagram of the generator drive system (new version)
9 Hydraulic diagram of the generator drive system (new version)
Item see Item see

group group
1 Hydraulic tank 423 Check valve
31 Gear pump / steering 13.10 424 Restrictor ( 4.5 mm)
32 Gear pump / brake and pilot control 15.12 425 Restrictor ( 7.5 mm)
unit
36 Gear pump 430 Axial piston - oil motor
400 Generator 433 Spacer*
413 Pressure balance 434 Pipe seal*
420 Pilot control unit, complete
* only for installations without gene-
rator
16.86.14
copyright by
MJF C I F S S
Hydraulic diagram of the generator drive system (new version)
Fig. 12 Hydraulic diagram of the generator drive system (new version)
16.86.15
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MJF C I F S S
Electrical system of the generator drive
10 Electrical system of the generator drive
Fig. 13 Different versions of the electrical system / generator drive
16.86.16
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MJF C I F S S
Fig. 14 Versions "load lifting magnet actuation in the left joystick"
S6R Push button, not assigned X90 Plug connection (heating), 2-pin
S6L Push button magnet system ON / OFF X217 Plug connection, 2-pin
S46 Switch to activate magnet system X370 Plug connection, 2-pin
S382 Fine control switch X958 Plug connection, 21-pin
S457 Rocker switch magnet unit ON/OFF X1046 Plug connection, 12-pin
U7 Magnet unit switching unit 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 Solenoid valve
X80 Plug connection (B19L), 3-pin
Note!
For the electrical diagrams of the accessory kit, see group 8.45, sectional drawing 55.
16.86.17
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MJF C I F S S
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 20221-

A 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.
18.15.1
copyright by
MJF C I F S S
Passfix bolts Service Manual
Design
2 Design
Fig. 2 Parts of the Passfix bolt
1 Bolt 4 Nordlock retaining washer

2 Clamping bush 5 Clamping screw
3 Clamping washer
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 pro-
perly 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 attach-
ment. 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 Removal tool and dismantling procedure A and B
6 Adapter 8 Removal screw

7 Removing tool
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 clam-
ping 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 ham-
mer.
Repeat the procedure at the other side.
18.15.3
copyright by
MJF C I F S S
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 Bolt 4 Nordlock retaining washer

2 Clamping bush 5 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 can-
tered.
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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MJF C I F S S
Service Manual
SUBGROUP - INDEX
Section Group Type
Tank arrangement 19.10.1 A 312 LI 12363-

A 314 LI 2001-
A 316 LI 2001-
A 316 LI-IND 2001-
R 313 LI 27752-
R 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.
Fig. 1 Tank arrangement
1 Fuel tank 2 Hydraulic tank
19.10.1
copyright by
MJFCIFSS
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 prescri-
bed intervals in the maintenance instructions. Dispose of the drained condensate (contaminated with
oil) and the spent oil according to the statutory requirements.
The large opening with lid D allows for proper access to the inside of the tank for cleaning purposes.
When adding or changing oil, always pour it through the return filter 4, which is accessible after the
lid has been opened 4.1, see Fig. 6.
The hydraulic tank is preloaded by the turbo charger of the diesel engine through the preload valve
45 ( 0.2 bar).
For repair work on the hydraulic pumps, the stop cock 3 mounted on the suction connection of the
tank can be closed, so that no oil from the tank can flow to the pumps.
The hydraulic tank is equipped with two screwed-in oil temperature sensors.
The hydraulic oil temperature sensor B8 is triggered when the oil temperature reaches 95 -
100 C and issues a negative signal to the indicator light H15, warning the driver.
Switch off the engine, identify the problem (radiator dirty?) and eliminate it.
High or low oil temperatures change the resistance value of the hydraulic oil temperature
sensor B285, which the issues a signal to the excavator control system U16 that controls the fan
of the engine and oil cooling system, see also assembly 8.70.
19.10.2
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MJFCIFSS
2.2 Breather filter 2
Fig. 2 Hydraulic tank with filter
1 Hydraulic tank, complete 4 Return filter, complete

2 Breather filter
The breather filter 2 mounted on the top of the hydraulic tank 1 protects the tank against overpres-
sure 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.
19.10.3
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MJFCIFSS
Fig. 3 Hydraulic tank, connections part 1
2 Breather filter E Suction pipe for generator drive

3 Stop cock T4 Return line from control valve block
4 Return filter, complete T8 Radiator return line
5 Check valve T11 Return line / leak oil variable-displace-
ment pump
A Suction chamber T15 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
19.10.4
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MJFCIFSS
Fig. 4 Hydraulic tank, connections part 2
1 Hydraulic tank, complete T7 Return line / collecting pipe operator's

platform
C Drainage and oil discharge piece T9 Return line / attachment kit AS1
T1 Return line / pipe fracture safety valves of T10 Return line / solenoid valve - travel
boom cylinder
T1' Return line / pipe fracture safety valves of T13 Return line / hydraulic hammer
stick cylinder
T1'' Return line / pipe fracture safety valves of T16 Reserve
reg. cylinder
T2 Return line / leak oil variable-displace- T17 Return line / speed adjustment
ment pump
T3 Return line / leak oil rotary connection T18 Return line / TC valve
T5 Return line / brake system T20 Return line / HBGV block
T6 Return line / steering system T21 Reserve
19.10.5
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MJFCIFSS
Fig. 5 Hydraulic tank, complete
19.10.6
copyright by
MJFCIFSS
1 Hydraulic tank, complete 85 Lid

1/45 Check valve (tank lead pressure) 86 Seal
1/46 Reducing piece 87 Washer
1/50 Hose from turbo charger 88 Hex head screw
2 Breather filter, complete 97 Reduction fitting
2/36 Seal ring 98 Drain valve
2/37 Adapter 99 Seal ring
2/38 Breather filter 100 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 Hex head screw B285 Oil temperature sensor / fan control
3/103 Retaining washer E50 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 Proportional solenoid valve / power con-
trol LR
4/43 Hex head screw Y51 Proportional solenoid valve / flow limita-
tion LS
4/45 Fibreglass cartridge Y62 Solenoid valve / forward travel
4/46 Protective cylinder Y63 Solenoid valve / reverse travel
10 Mounting bolt / tank Y358 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)
2.3 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 cart-
ridges 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 partic-
les), there is a risk of backpressure in the filter chamber. If this pressure exceeds the opening pres-
sure 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 suc-
tion section.
19.10.7
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MJFCIFSS
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 mainte-
nance 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 sys-
tem, 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 ex-
cavators, 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 ac-
cording to the statutory regulations.
When inserting the new filter cartridge, ensure that the seal rings 4.21 and 4.22 are properly in-
stalled. 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
Maintenance
Fig. 6 Return filter
1 Hydraulic tank, complete 4.7 Roll pin

1.1 Tank connection 4.8 Magnetic rod
1.2 Protective cylinder 4.20 Fibreglass filter cartridge
4 Return filter, complete 4.21 O-ring
4.1 Lid with handle 4.22 O-ring
4.2 Flat gasket 4.42 Retaining washer
4.3 Roll pin 4.43 Hex head screw
4.4 Spacer tube 5 Check/bypass valve, complete
4.5 Rod 5.1 Pressure spring
4.6 Receptacle 5.2 Valve sleeve
19.10.9
copyright by
MJFCIFSS
Design of fuel tank
4 Design of fuel tank
Fig. 7 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 Internal lines 48 Hex head screw
11 Mounting bolts 49 Retaining washer
21 Tank lid 60 TC valve / slewing gear
22 Strainer
19.10.10
copyright by
MJFCIFSS
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 th-
rough 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 si-
gnal (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 in-
structions 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 dis-
play field.
19.10.11
copyright by
MJFCIFSS
Design of fuel tank
4.2.1 Tubular-type sensor for model A 309 / 311 to serial no. 31389,
Fig. 8 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 1st switching point (full; 19 Ohm) 9 6th switching point (1/4 full; 54 Ohm)
5 2nd switching point (3/4 full; 25 Ohm) 10 7th switching point (reserve; 70 Ohm)
19.10.12
copyright by
MJFCIFSS
Design of fuel tank
4.2.2 Tubular-type sensor for model A 309 / 311 from serial no. 31390, model A 312
from 31399

4 1st switching point (full; 11 Ohm) 10 6th switching point (reserve; 54 Ohm)
6 2nd switching point (5/8 full; 25 Ohm)
19.10.13
copyright by
MJFCIFSS
Design of fuel tank
4.2.3 Tubular-type sensor for models A 314, A 316 and R 317 to serial no. 31402

4 1st switching point (full; 19 Ohm) 9 6th switching point (1/4 full; 54 Ohm)
19.10.14
copyright by
MJFCIFSS
Design of fuel tank
4.2.4 Tubular-type sensor for models A 314, A 316 and R 317 from serial no. 31403
1 O-ring 7 4th switching point (1/2 full; 29 Ohm)

4 1st switching point (full; 11 Ohm) 10 7th switching point (reserve; 54 Ohm)
6 3rd switching point (5/8 full; 25 Ohm)
19.10.15
copyright by
MJFCIFSS
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 20221-

A 311 LI 20222-
A 312 LI 12363-
A 314 LI 2001-
A 316 LI 2001-
A 316 LI-IND 2001-
R 313 LI 27752-
R 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
17.30.1
copyright by
MJF C I F S S
Heating / air-conditioning system Service Manual
Notes
1 Notes
17.30.2
copyright by
MJF C I F S S
Technical data
2 Technical data
Device A 309 - R 317

Series Litronic
Complete air-conditioning system

Manufacturer Wlfle 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.
17.30.3
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MJF C I F S S
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 conditi-
ons.
4 Mode of operation
Fig. 1 Air-conditioning system, part 1

M74-1
1 Refrigeration compressor M74-1 Fan motor

3 Fluid tank M74-2 Fan motor
4 Dryer insert M74-3 Fan motor
6 Sight glass Y20 Electromagnetic clutch
B294 Pressure switch
The compressor 1 compresses the gaseous R134a refrigerant. In this process, the refrigerant is he-
ated while being liquefied before it flows through the condenser 2 (heat exchanger). The heat is ex-
tracted 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 ad-
justment of the heating performance at 4 levels.
17.30.4
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MJF C I F S S
Design and function
Fig. 2 Air-conditioning system, part 2

M74-1
7 Expansion valve M65 Evaporator blower

8 Evaporator M72 Servo motor
14 Heat exchanger for heating M74 Condenser blower
See also Fig. 3.

The air-conditioning system consists of 3 main components that are connected to each other with ho-
ses:
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-
17.30.5
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MJF C I F S S
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 0C, 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 out-
let 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 re-
frigerant 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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MJF C I F S S
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 pres-
sure 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.
17.30.7
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MJF C I F S S
Design and function
Fig. 3 Diagram of the cooling circuit of the air-conditioning system
1 A/c compressor 9 Temperature sensor

2 Condenser B294 Pressure switch
3 Liquid tank B295 Electr. thermostat
4 Dryer insert M65 Blower motor
6 Sight glass M74 Fan motor
7 Expansion valve Y20 Magnetic clutch
8 Evaporator
17.30.8
copyright by
MJF C I F S S
Design and function
Fig. 4 Heating/air-conditioning circuit
13 Heating/ air-conditioning unit, complete M65 Blower motor

14 Heat exchanger for heating M71 Servo motor / water valve
19 Water valve
17.30.9
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MJF C I F S S
Design and function
Fig. 5 A/c system circuit
1 A/c compressor 14 Heat exchanger for heating

2 Condenser B294 Pressure switch
3 Liquid tank B295 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
17.30.10
copyright by
MJF C I F S S
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 S318 Air-conditioning switch

control
S93 Rotary potentiometer for heating/air- S398 Switch for the assignment of the blower
conditioning control motor (change of direction of air flow
from rear to front)
S284 Switch for blower level 1 4/
warm cold
17.30.11
copyright by
MJF C I F S S
Fig. 8 Control and actuating elements of the air-conditioning system
B295 Electr. thermostat with temperature sen- K405 Relay for blower switch S284
sor
K402 Relay for heating M71 Servo motor / water valve
K403 Relay for heating M73 Servo motor for the reversal of the air
distribution system
K404 Relay of condenser motors M74-1 to
M74-3
6.1 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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MJF C I F S S
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 he-
ating 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 hand-
ling 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 refri-
gerant in suitable containers (see page 16).
Fig. 9 Air-conditioning system service device
Note!
For operating instructions, see the manual issued by the manufacturer.
17.30.13
copyright by
MJF C I F S S
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 re-
leased by combustion are toxic and must not be inhaled!
Do not smoke when handling refrigerants!
17.30.14
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MJF C I F S S
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 concen-
trations 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 sub-
stance. Before carrying out any repair work on refrigeration systems, collect the refrigerant in the re-
cycling 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 ruptu-
re), 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 concen-
trations 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 refrige-
rant 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 cor-
rosive, 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. Un-
der certain circumstances, highly toxic phosgene might be produced! When halogenated fluorocar-
bons are burnt, hydrogen fluoride might be produced.
17.30.15
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MJF C I F S S
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 respi-
ratory 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 sensi-
tise 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.
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-condi-
tioning 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.
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Filling of unit with refrigerant
Disconnect the pump and connect the refrigerant bottle. Open the bottle valve and the red pres-
sure 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 Filling hoses and dryer container
1 Low-pressure line (blue) 2 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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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 compres-
sor is running.
The refrigerant must thereby be added in gaseous form through the open low-pressure gauge val-
ve (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 lubri-
cate 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 Sight glass
1 Floating ball (white) 2 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 pre-
vent 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.
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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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Air condition components
14 Air condition components
Fig. 12 A/c compressor 1 with bracket and V-belt tensioning device

13
1 A/c compressor B294 Pressure switch

2 Condenser B295 Electr. thermostat
3 Liquid tank K402 Relay for heating
4 Dryer insert K403 Relay for heating
6 Sight glass K404 Relay for motors M74
8 Evaporator K405 Relay for blower
13 Heating/ air-conditioning unit M65 Blower motor
14 Heat exchanger for heating M72 Air distribution servo motor
B294 Pressure switch M73 Reversing servo motor
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Fig. 13 Condenser with dryer, sight glass and pressure switch

13
2 Condenser 6 Sight glass

3/4 Dryer B294 Pressure switch
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Fig. 14 Units of the air-conditioning system

13
8 Evaporator K404 Relay for motors M74

14 Heat exchanger K405 Relay for blower
B295 Thermostat M65 Blower motor
K402 Relay for heating M72 Air distribution servo motor
K403 Relay for heating M73 Reversing servo motor
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Electrical diagrams
15 Electrical diagrams
B294 Pressure switch of a/c compressor

B295 Thermostat of heating
F318** Fuse (20 A) of heating/air-conditioning system terminal 30

F319** 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** Blower motor

M71** Water valve servo motor
M72** Air distribution servo motor
M703** Reversing servo motor
M74-1 Condenser fan motor
S92** Air distribution potentiometer

S93** Heating/air-conditioning potentiometer
S284** Blower switch (4 speeds)
S318 Air-conditioning switch
S398** Air distribution reversing switch

Y20 Solenoid valve / a/c clutch
** in basic diagram
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Electrical diagrams
Fig. 15 Air-conditioning system
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Electrical diagrams
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MJF C I F S S
Electrical diagrams
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MJF C I F S S
Troubleshooting
16 Troubleshooting
Fault Cause Remedy
A/c system Faulty electrical connec- Check the connections of the magnetic clutch, swit-
fails to cool tions ches, relays, temperature sensors and control unit.
Air temperature sensor Replace.

defective*
Icing protection tempera- Replace B295 (electrical thermostat only).

ture transducer defective*
Rotary potentiometer de- Replace S93 (electrical thermostat only).

fective
Relay defective Replace K404.
Fuse defective Replace F318/F319.
Compressor shut down af- Clean compressor. Carry out function test of con-
ter exceeding of max. ope- denser blower F339.
rating pressure
Filter dryer blocked* Exchange filter dryer.
Excessive refrigerant in Extract refrigerant.

the system*
Compressor shut down af- Check system for leaks; add refrigerant, if necessa-
ter pressure dropped be- ry.
low min. operating
pressure
Compressor magnetic Replace coil Y20.

clutch defective
V-belt broken Replace V-belt.
System cools Evaporator iced, check Adjust icing protection limit temperature settings of
only for a electrical control unit* the thermostat (only with mechanical thermostat).
short time
Tab. 1 Troubleshooting
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Troubleshooting
Fault Cause Remedy
Cooling ef- Insufficient air flow rate Clean fins in front of the evaporator and condenser.
fect insuffi-
cient Insufficient refrigerant in Add refrigerant until it is visible without bubbles in the
system* sight glass.
Expansion valve blocked* Clean or replace expansion valve.
Expansion valve iced Filter dryer moisture indicator red. Replace filter dry-
over, excessive moisture er.
in system*
Filter dryer partly blocked Exchange filter dryer.
(indicated by ice on the
dryer)*
Air in refrigerant circuit at Evacuate and refill system.

increased pressure va-
lues, bubbles visible in
sight glass*
Loud noise Ball bearing of compres- Replace ball bearing.

from sor worn*
compressor
Magnetic clutch defective* Replace magnetic clutch Y20.
Insufficient oil in Refill oil.

compressor*
Whistling V-belt worn Replace V-belt.

noise from V-
belt V-belt loose Tighten V-belt.
Tab. 1 Troubleshooting
* The tasks marked with an asterisk must be carried out by a specialist refrigeration technician!
17.30.28
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Service Manual

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

Modified measuring connections

Spool for slewing gear A 316 Li: 11822

Spool for chassis

Additional control line from control valve block

Modified shuttle valves 227

Installation of coarse filter 15 in the pressure A 314 Li: 13104

(e) Various modifications to control valve A 312 Li: 16275

Modified TC valve 125

Item Type of modification Affected models

2 General Safety instructions

3 Crushing and burn prevention

4 Fire and explosion prevention

Switch off the Diesel engine prior to filling the tank.

5 Transporting the machine safely

6 Bringing the machine safely into service

Before starting the machine, perform a thorough walk around inspection.

7 Starting the machine safely

8 Shutting down the machine safely

9 Towing the machine safely

10 Working with the machine safely

10.2 Safe application of machines with tower elevation

10.4 Protection from vibrations

11 Safe installation and removal of attachment parts

11.1 Safe removal and installation of attachment pins

12 Safe maintenance of the machine

12.1 General safety instructions

Remove all temporary covers.

12.3 Crack detection

12.4 Welding work

12.5 Fuels and lubricants

12.7 Electrical system

For machines equipped with electrical medium-voltage and high-voltage lines:

12.8 Hydraulic accumulators

12.9 Hydraulic and other hoses

Deformation of the hose when pressurised, depressurised, or at bends, resulting in separation

12.10 Cab protection (FOPS)

Metric coarse thread Metric fine thread

Angle tightening method

According to table (strength class 10.9):

According to table (strength class 12.9):

1 of screw-in studs (Ermeto)

1.1 mating material: steel (Grease well before inserting!)

Type with sealing edge Type with EOLASTIC seal

Type with sealing edge Type with EOLASTIC seal

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 Tightening torques

Tightening torques Tightening torques

Tab. 2 Tightening torques of swivelling connections

3 of screw-in studs (Ermeto)

3.1 mating material: steel (Grease well before inserting!)