Liebherr A900C A904C Litronic Hydraulic Excavator

en
Service Manual
Hydraulic Excavator
A 900 C Litronic - A 924 C Litronic
1 Document identification
Order no.: 10216479

Edition: 09 / 2004
Update no. 1: 01 / 2005
Update no. 2: 05 / 2006
Update no. 3: 09 / 2006
Update no. 4: 04 / 2007
Last update: 07 / 2008
Author: LHB - Technical Documentation Department
2 Product identification
Manufacturer: LIEBHERR Hydraulikbagger GmbH

Type: A 900 C Litronic - A 924 C Litronic
Conformity: CE
3 Address of copyright owner
Liebherr Hydraulikbagger GmbH

Liebherr-Strasse 12
D - 88457 Kirchdorf / IllerGermany
Manual no. ..............................

User: .........................................
Service Handbuch
Introduction
This manual contains technical data, design and functional descriptions, as well as instructions as
regards the operation and the adjustment of machine settings. The document includes a number of
drawings, functional diagrams, as well as detailed views of units and assemblies of LIEBHERR
hydraulic excavators.
The documentation has been designed to support customer support services, but does of course not
replace proper technical training and qualification of the user, and participation in LIEBHERR
operator training courses.
General basic technical information is not included in the manual. For operating instructions and
information on spare parts, please refer to the separate documentation.
During all work on the machine, strictly adhere to the relevant accident prevention and safety
regulations.
Symbols used in this manual
Tasks and procedures that are associated with specific dangers are accompanied by safety
instructions. The safety instructions are graded according to the severity of the risk and are identified
with the terms DANGER, CAUTION and NOTE and the respective danger symbol:
Danger
Warning referring to a danger where there is a high probability of death or serious injury to
operators, unless the prescribed safety measures are taken.
Caution
Warning relating to dangers that might lead to injury or damage to the machine, unless the
prescribed safety measures are taken.
Note
This symbol accompanies instructions and tips regarding the operation, maintenance and repair of
the equipment. If adhered to, the service life of the machine can be prolonged and/or procedures
are made easier.
This symbol precedes entries in a list.

This symbol precedes entries in a sublist.
This symbol identifies requirement that MUST be fulfilled.
This symbol indicates a single procedure in a sequence of procedures.
This symbol indicates a result of an action.
MJFCIFSS
Service Handbuch
This manual has been exclusively compiled for internal use by the registered machine owner.
It may not be replicated or made available to third parties without the explicit written consent of
LIEBHERR, who retains all rights in this documents.
This publication remains the property of LIEBHERR-HYDRAULIKBAGGER GMBH.
All rights reserved printed in Germany.
This manual shall be amended without prior notice to reflect new technical developments and
machine series. LIEBHERR reserves the right to make minor technical amendments to the machines
that might not be reflected in the accompanying documentation.
This document is subject to a revision service. As a registered user of the manual, you will
automatically receive all revised and added sheets.
This manual might be complemented by additional service information sheets issued by LIEBHERR.
Compiled by the Technical Documentation Department.
Published by VS (customer service training)
of LIEBHERR-HYDRAULIKBAGGER GMBH 88457 Kirchdorf / lller, Germany.
We hope that the information in this documentation aimed at improving the service of LIEBHERR
excavators is of use to you.
Document structure
In order to make it easy for users to find a specific sheet or information on a certain group, and to file
amended and additional pages, each page is identified as follows:
A Page number D Engine

B Subgroup E D 924 diesel engine
C Main group F Page
The main groups are listed in the table of contents of the index.
The subgroups are listed on the first page of each group section. The list also includes the machines
and serial number to which the subgroup is relevant.
In the event of minor changes, we will send you the amended page showing the current date.
If an existing subgroup is completely revised and re-edited, the new version will be assigned a new
subgroup number.
MJFCIFSS
General 1
Tools 2
Technical data / maintenance instructions 3
Drive motor 4
Coupling / pump distribution gear 5
Hydraulic system 6
Hydraulic components 7
Electrical system 8
Slewing gear mechanism 9
Slewing ring 10
Transmission 11
Axles 12
Steering 13
Oscillating axle support 14
Brake system 15
Special equipment / accessory kits 16
Operator's cab / heating and air-conditioning 17
Undercarriage / uppercarriage / attachments 18
Tank arrangement 19
Service Manual
SUBGROUP - INDEX
Section Group Type
Changes and amendments to series 1.02.1 A 900 C-LI EDC 24677-

A 904 C-LI EDC 30580-
A 914 C-LI 35112-
A 924 C-LI 34519-
Safety instructions 1.10.1 A 900 C-LI

A 904 C-LI
A 914 C-LI
A 924 C-LI
Tightening torques WN 4037 K 1.20.1 A 900 C-LI

A 900 C-LI EDC
A 904 C-LI
A 904 C-LI EDC
A 914 C-LI
A 924 C-LI
Tightening torques 1.21.1 A 900 C-LI

A 904 C-LI
A 914 C-LI
A 924 C-LI
Assembly instruction for hydraulilc cylinder 1.22.1 A 900 C-LI

WN 4121 C A 900 C-LI EDC
A 904 C-LI
A 904 C-LI EDC
A 914 C-LI
A 924 C-LI
Assembly instruction for hydraulic cylinder 1.24.1 A 900 C-LI

WN 4122 B A 900 C-LI EDC
A 904 C-LI
A 904 C-LI EDC
A 914 C-LI
A 924 C-LI
Lubricants and process chemicals 1.50.1 A 900 C-LI 14675-

A 904 C-LI 16000-
1.1
MJFCIFSS
Service Manual
Lubricants and process chemicals 1.51.1 A 900 C-LI EDC 24677-

A 904 C-LI EDC 30580-
A 914 C-LI 35112-
A 924 C-LI 34519-
TE_ML05 lubricant list 1.55.1 A 900 C-LI

A 904 C-LI
A 914 C-LI
A 924 C-LI
TE_ML07 lubricant list 1.56.1 A 900 C-LI

A 904 C-LI
A 914 C-LI
A 924 C-LI
1.2
MJFCIFSS
Service Manual Changes and amendments to series
2nd addendum
Changes and amendments to series
1 2nd addendum
Change to
Item Type of modification Affected models
group
3.11. Technical data A 900 C from type 1002 24677
4.12. Technical data of mew diesel engine A 900 C from type 1002 24677
A 904 C from type 1003 30580
6.11. Adjustment protocol of A 900 type 1002 A 900 C from type 1002 24677
6.21. New components in hydraulic unit A 900 C from type 1002 24677
A 904 C from type 1003 30580
6.26. Adjustment guidelines with menu interface A 900 C from type 1002 24677
A 904 C from type 1003 30580
a) 6.30. Additional line at control block P" to DRDA. A 900 C from type 987 17700
The LS signal of the stroke limitation has been
increased in order to lower the slewing gear
priority. As a result, the loading movement of
the boom cylinder has been improved.
6.31. Hydraulic system type 1002 A 900 C from type 1002 24677
7.27. New DMVA regulating motor A 900 C from type 1002 24677
A 904 C from type 1003 30580
7.41. New control and regulating unit A 900 C from type 1002 24677
A 904 C from type 1003 30580
8.12. New electrical components A 900 C from type 1002 24677
A 904 C from type 1003 30580
8.34. New electrical system A 900 C from type 1002 24677
A 904 C from type 1003 30580
11.12. New 2HL290 transmission A 900 C from type 1002 24677
A 904 C from type 1003 30580
11.35. New HBGV block A 900 C from type 1002 24677
A 904 C from type 1003 30580
12.40. New MS - E 3060 steering axle A 900 C from type 1002 24677
12.42. New MT - E 3060 rigid axle A 900 C from type 1002 24677
16.46. AHS 11 with Tool Control location of prop. A 900 C 25000
solenoid valve Y 414 changed A 904 C 25000
16.49. AHS 11 with Tool Control location of prop. A 900 C 25000
solenoid valve Y 414 changed A 904 C 25000
16.60. Hydraulic operator's cab elevation A 904 C 26965
Modified hydraulic unit/external emergency
A 904 C 22588
discharge
1.02.1
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MJFCIFSS
Changes and amendments to series Service Manual
3rd addendum
2 3rd addendum
Change to
group
1.51. Lubricants and fuels adjusted to suit new EDC A 900 C from 24677
engines. A 904 C from 30580
3.05. Type overview of new A 904 C series A 904 C from 30580
3.15. Technical data of new A 904 C series A 904 C from 30580
3.25. Inspection and maintenance schedule A 904 C from 30580
3.30. Lubricating schedule of new A 904 C series A 904 C from 30580
amended.
5.20. Pump distribution gear of the DPVP pump A 904 C from 30580
6.15. Adjustment protocol of new A 904 C series A 904 C from 30580
6.34. Hydraulic system of new A 904 C series A 904 C from 30580
7.07. DPVP double variable displacement pump A 904 C from 30580
8.38. Electrical system of industrial model A 904 C from 30580
12.50. New MS - E 3070 steering axle A 904 C from 30580
12.52 New MT - E 3070 rigid axle A 904 C from 30580
12.54. New differential MS/MT 3070 A 904 C from 30580
13:33: New steering cylinder A 904 C from 30580
15.05. Changes of operating pressure of the brake A 900 C from 32355
system A 904 C from 32365
1.02.2
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4th addendum
3 4th addendum
Change to
group
1.00 Factory standards revised
1.51 Lubricants and process chemicals list revised
3.06 Type overview A 914 C 35112
A 924 C 34519
3.16/3.17/ Technical data A 914 C 35112
3.18 A 924 C 34519
3.27 Inspection and maintenance schedule A 914 C 35112
A 924 C 34519
3.30 Lubricating charts A 914 C 35112
A 924 C 34519
4.05 Bleeding of fuel system
4.12/4.13 Technical data of diesel engine A 914 C 35112
A 924 C 34519
6.17 Adjustment protocol A 914 C 35112
6.18 Adjustment protocol A 924 C 34519
6.22 Layout of hydraulic system A 914 C 35112
A 924 C 34519
(b) 6.31 Gripper switching modified A 900 C 35328
6.34 A 904 C 35343
6.28 Setting instructions A 914 C 35112
A 924 C 34519
6.40 Hydraulic system A 914 C 35112
A 924 C 34519
7.31 Extension and retraction times of hydraulic cy-
linders
8.01 Overview of electrical symbols
8.14 Component arrangement A 914 C 35112
A 924 C 34519
8.40 Electrical system (construction model) A 914 C 35112
A 924 C 34519
8.42 Electrical system (industrial model) A 914 C 35112
A 924 C 34519
8.44 Operating symbols on the operator's platform
8.73 Monitoring display from BST version 4.4
8.82 Slip ring rotary connection
8.100 Overview of electric kits from new software version
16.02 Pipe fracture safety valves revised
16.21 Pressure and flow reduction A 914 C 35112
A 924 C 34519
16.32 Generator drive accessory kit
16.34 Generator drive conversion kit
S408 16.60 Changes to hydraulic operator's cab elevation A 904 C 35102
1.02.3
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4th addendum
Change to
group
16.69 LIEBHERR bypass filter
16.70 Reversible fan drive adjustment at display from BST version 4.6
18.53 Semi-automatic central lubrication system
18.54 Automatic central lubrication system
1.02.4
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MJFCIFSS
last update 03/2008
4 last update 03/2008
Change to
group
NEW 3.43 Adjustment protocol V4.7 A 900 C 37762
NEW 3.47 Adjustment protocol V4.7 A 904 C 37774
REVISED 3.50 Adjustment protocol V 4.6 A 914 C 35112
REVISED 3.55 Adjustment protocol V 4.6 A 924 C 34519
REVISED 6.40 Hydraulic system A 914 C/A 924 C 34519
NEW 7.22 Hydraulic fixed-displacement motor A 914 C/A 924 C
NEW 7.32 Hydraulic double plunger cylinder A 900 C - A 924 C
NEW 8.73 Monitoring display V4.6 A 900 C - A 924 C
1.02.5
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MJFCIFSS
last update 05/2008
5 last update 05/2008
Change to
group
REVISED 2.01 Tools A 900 C - A 924 C
REVISED 2.05 Tools A 900 C - A 924 C
REVISED 3.43 Adjustment protocol A 900 C - 37762
NEW 3.51 Adjustment protocol V4.7 A 914 C - 39037
NEW 3.56 Adjustment protocol V4.7 A 924 C - 39037
NEW 6.10 Grab-Control A 904 C (Type 1004/1071)
NEW 6.35 Hydraulic system A 904 C - 39333
NEW 7.55 LSC pilot plate A 914 C - A 924 C
REVISED 8.34 Electrical system A 900 C - A 904 C
NEW 8.99 Self-holding mechanism for quick-change ad- A 900 C - A 924 C
apter locking
REVISED 8.100 Overview of electric kits A 914 C - A 924 C
REVISED 15.10 Hydraulic brake system A 900 C - A 924 C
REVISED 15.20 Compact brake block A 900 C - A 924 C
1.02.6
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MJFCIFSS
Last updated 07/2008
6 Last updated 07/2008
Change to
group
NEW 3.62 Checking and adjusting tasks V4.7 A 900 C - A 904 C
NEW 3.80 Adjustment protocol for kits A 900 C - A 924 C
REVISED 6.34 Hydraulic system A 900 C - A 904 C
REVISED 6.35 Hydraulic system A 900 C - A 904 C
REVISED 7.05 DPVO variable-displacement pump A 900 C
NEW 7.06 DPVO variable-displacement pump A 900 C
REVISED 7.07 DPVP variable-displacement pump A 900 C - A 924 C
REVISED 7.27 Regulating motor DMVA (travel motor) A 900 C - A 924 C
NEW 7.51 LSC control valve block A 900 C - A 904 C
REVISED 8.38 Electrical system A 904 C
REVISED 8.100 Electrical kits, additions made A 900 C - A 924 C
REVISED 10.10 Slewing ring A 900 C - A 924 C
NEW 16.16 Boom cylinder safety system A 900 C - A 924 C
NEW 16.23 Pipe layer A 900 C - A 924 C
REVISED 16.40 Accessory kit AS1 A 900 C - A 904 C
NEW 16.41 Accessory kit AS1 A 914 C - A 924 C
REVISED 16.60 Hydraulic operator's cab elevation A 904 C - A 924 C
NEW 16.65 Dozer blade A 900 C - A 924 C
1.02.7
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MJFCIFSS
Last updated 07/2008
1.02.8
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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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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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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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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.
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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.
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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".
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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.
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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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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.
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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.
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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
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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
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Product code 10409969
Standard Version 001
WN 4037 K
PRELOADS AND TIGHTENING TORQUES FOR SCREWS WITH METRIC

COARSE AND FINE THREADS ACCORDING TO DIN ISO 261
The preloads and torques included in the table are based on the VDI regulations 2230 of July 1986.
(The values of the edition from February 2003 have not been included in the table, as this would not be justified
according to our experience.)
Assembly preloads FM and tightening torques MA at v = 0.9 for headless screws with metric coarse or fine threads
according to DIN ISO 262 (and DIN ISO 965-2);
Head dimensions of hex head screws according to DIN EN ISO 4014 to 4018, screws with hexalobular external
driving heads according to DIN 34800 or Allen head screws according to DIN EN ISO 4762 and "centre" bores
according to DIN EN 20273
Metric coarse thread Metric fine thread
Surface finish: Surface finish:
- black-chrome finish or phosphatised - black-chrome finish or phosphatised
- electro-galvanised oiled - electro-galvanised oiled
- flZn = zinc flake coating - flZn = zinc flake coating
(LH standard 10021432, DAC) (LH standard 10021432, DAC)
Assembly Tightening Assembly Tightening
Thread Class preloads torques Thread Class preloads torques
FM in N MA in Nm FM in N MA in Nm
for mean friction factor µG= 0.12 for mean friction factor µG= 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
.04.08 LHB Wimbauer Alois owatzky Dirk

Date Plant Created Examined Released
This document may not be copied or otherwise reproduced without the prior consent of LIEBHERR.
This document has been created by electronic means and is valid without signature. 1.20.1
Metric coarse thread Metric fine thread
Surface finish: Surface finish:
- black-chrome finish or phosphatised - black-chrome finish or phosphatised
- electro-galvanised oiled - electro-galvanised oiled
- flZn = zinc flake coating - flZn = zinc flake coating
(LH standard 10021432, DAC) (LH standard 10021432, DAC)
Assembly Tightening Assembly Tightening
Thread Class preloads torques Thread Class preloads torques
FM in N MA in Nm FM in N MA in Nm
for mean friction factor µG= 0.12 for mean friction factor µG= 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 important screw connections, we recommend using a torque angle gauge. For such connections, the
required tightening torques (assembly torque, angle of rotation) must be determined individually by the
technical department.
. 1.20.2
– When tightening in aluminum, with or without Helicoil-Inserts, the values for category 8.8 must be used.
However, tightening torques indicated on drawings are binding, to be treated with priority and must be
adhered to.
. 1.20.3
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
Tightening Tightening
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
copyright by
MJFCIFSS
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. 1 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
WH / TH 25 SR KDS A 3 C G1A 320 WH / TH 20 SM KDS A 3 C M 27 X 2.0 320
1.21.2
copyright by
MJFCIFSS
Service Manual Tightening torques
Tightening torques Tightening torques

Type Type
Thread Nm Thread Nm
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. 3 Tightening torques of screw-in studs
VSTI = Hexagon socket plug
1.21.3
copyright by
MJFCIFSS
Tightening torques Service Manual
1.21.4
copyright by
MJFCIFSS
WN 4121 C
Installations for pistons and piston nuts
by hydraulic cylinders
1. Application and purpose

This Liebherr standard applies only to hydraulic cylinders, and in particular to the
mounting of pistons and piston nuts on piston rods from a thread diameter of M42
and greater.
This standard describes the tightening procedure with turning distance and angle.
For threads with diameters smaller than M42, the applicable tightening torque is
indicated in the drawings. The values in the drawings are always binding.
2. Requirements / description of procedure

For the valid torque value number, refer to the drawing. The standard may not be
adopted or transferred to apparently similar geometries.
Use this number to find the applicable turning distance and angle in the torque table
(see item 4).
The torque values have been determined empirically and are subject to changes.
This standard differentiates between two tightening procedures, which are identified
with 3-digit and 4-digit numbers respectively (see chapters 2.1 and 2.2).
1.22.1
1/7
2.1. Tightening with assembly wrench
This tightening procedure applies to 3-digit tightening numbers.
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) to both sides.
Definitions:
Pretightening torque (Mv):

The piston (A) is secured with a torque wrench (B) applied to the square/hexagon
head of the assembly wrench (C). The position of the torque wrench must be
carefully noted (see figure 1).
Turning distance (4):

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 figure 2).
Turning angle (5):

Angle Å°Ã travelled by the piston or piston nut respectively, after application of the
pretightening torque (see figure 2).
Mv B
Figure 1
When applying the pretightening torque (Mv), the torque wrench (B) must point in
the same direction as the assembly wrench (C). Proceed in the same way to
tighten the piston nut, using a suitable assembly wrench.
. 1.22.2
5
4
1 2
5
4
6 2
Figure 2
1: Markings on the piston and the piston rod thread after application of the
pretightening torque
2: Markings on the piston rod thread
3: Markings on the piston after tightening
4: Turning distance
5: Turning angle
6: Markings on the piston nut and the piston rod thread after application of the
pretightening torque
7: Markings on the piston nut after tightening
. 1.22.3
2.2. Tightening with hydraulic assembly device

This tightening procedure applies to 4-digit tightening numbers.
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) to both sides.
Definitions:
Pretightening torque:
Torque applied on the piston or piston nut with the torque wrench (A) via the
hexagon head (B) of the torque converter (C) (see figure 1).
Turning angle:
Angle Å°Ã travelled by the piston or piston nut respectively, after application of the
pretightening torque (see figure 3).
Figure 1
A: Torque wrench
B: Hexagon head
C : Torque converter
. 1.22.4
Operation of the assembly device:

See separate operating manual of the assembly device (H).
For suitable adapters for the piston rod, piston and piston nut, refer to the piston
parts list (see figure 2).
H
B
C
E
Figure 2
A: Piston rod
B: Piston
C : Adapter for piston
D: Adapter for piston rod
E: Piston nut
F: Adapter for piston nut
G: Torque converter
H: Assembly device
. 1.22.5
Figure 3
A: Dial
B: Adjusting screw
C : Angle scale
Before tightening, set the dial (A) with the adjusting screw (B) to position 0° on the
angle scale (C).
The angle scale indicates the turning angle.
If the opening angle of the assembly device is not sufficient to achieve the
prescribed turning angle, mount the device again for a second tightening process.
Note the previously completed angle. Before continuing the tightening process, set
the dial to the last achieved angle value. Repeat this process as often as necessary
to achieve the prescribed turning angle.
. 1.22.6
3. Modifications
4. Other applicable documents

Torque table
Drawing with reference to this Liebherr Standard and the torque number.
. 1.22.7
MJFCIFSS 4. Torque table Status: 16.06.2008
for LH standard 10334184
(Installation instructions for pistons and piston nuts) Page 1 of 2
The date indicates the latest status of the table.

This document is not subject to revision!
Tightening with assembly wrench (see 2.1)
No. Pretightening Piston Piston nut Thread

10334184 torque Turning distance Turning angle Turning distance Turning angle M
- ... [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
078 100 20 +1 55° 14 +1 38° 42x1.5
079 100 11 +1 30° 21 +1 57° 42x1.5
080 100 18 +1 49° - - 42x1.5
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/WS65
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 17 +1 35° 19 +1 39° 56x2
114 100 19 +1 39° - - 56x2
115 100 18 +1 37° - - 56x2
116 100 19 +1 39° - - 56x2
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
234 200 22 +2 30° - - 85x3
236 200 15 +2 20° - - 85x3
237 200 19 +2 26° - - 85x3
1.22.8
MJFCIFSS 4. Torque table Status: 16.06.2008
for LH standard 10334184
(Installation instructions for pistons and piston nuts) Page 2 of 2

10334184 torque Turning distance Turning angle Turning distance Turning angle M
- ... [Nm] [mm] ~ [°] [mm] ~ [°] [mm]
261 250 20 +2 25° 10 +1 12° 95x3
265 250 24 +2 29° 10 +1 12° 95x3
267 250 24 +2 29° - - 95x3
281 250 20 +2 23° 13 +1 15° 100x3
282 250 25 +2 29° - - 100x3
283 250 25 +2 29° 21 +1 24° 100x3
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
336 400 29 +3 28° - - 120x3
501 200 21 +2 30° - - 80x2
531 500 34 +3 28° - - 140x3
Tightening with hydraulic assembly device (see 2.2)

10334184 torque Turning angle Turning angle M
- ... Mv [Nm] [°] [°] [mm]
1000 300 27° +1° 8° +1° 240x4
1001 300 18° +1° 8° +1° 200x4
1002 300 18° +1° 8° +1° 150x4
1003 300 23° +1° 8° +1° 170x4
1004 300 21° +1° 8° +1° 140x4
1005 300 18° +1° 8° +1° 180x4
1006 300 39° +1° 8° +1° 150x3
1007
1008
1.22.9
Bezeichnung
Description / Dénomination
Blatt/Page/Feuille: 1
bestehend aus 4 Blatt
Mjfcifss! Assembly instruction
consisting of Pages
composé Feuille
for piston rod bearings with external threads
(hydraulic cylinders) WN 4122 B
Contents
1. Scope of application
2. Description
3. Referenced documents (torque table)
1. Scope of application
This factory standard applies exclusively to the assembly of hydraulic cylinders. For the
valid factory standard number, refer to the drawing. The standard may not be adopted or
transferred to apparently similar geometries.
The torques have been determined empirically and are subject to changes. The revision
and release dates indicate the latest version of the factory standard.
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
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 Å°Ã 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.
1.24.3
3. List of tightening torques for factory standard 4122
(Assembly instructions for piston and piston nut)
The date indicates the latest version of this table. Edition: 14.09.2007
This document is not covered by the revision service.
NU Preload Piston rod bearing

4122- Torque Turning 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
037 100 10 +1 9
039
041 150 9 +1 7
046 200 12 +1 10
047
051
052
053 200 25 +1 18
061 200 10 +1 7
151 400 14 +1 6
1.24.4
Service Manual Lubricants and process chemicals
General instructions for the changing of lubricants and other process chemicals
Lubricants and process chemicals
1 General instructions for the changing of lubricants and other pro-

cess chemicals
Note!
The filling volumes indicated in the lubricant and process chemical table and in the lubrication sche-
dule in the driver's cab are approximate values only.
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.
Clean all fill screws, lids and drain plugs and the areas around
the 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 ap-
plies 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 inad-
vertent closing.
Before refuelling the machine, switch off the engine. Do not smoke or use naked flames.
1.50.1
copyright by
MJFCIFSS
Lubricants and process chemicals Service Manual
Lubricant table
2 Lubricant table
Description Medium Symbol Classification Viscosity
Diesel engine Engine oil API-CG-4, CF-4 or SAE 5W-40

CH-4, SAE 10W-30
ACEA-E2-96, E3- SAE 10W-40
96 or E4-98 SAE 15W-30
SAE 15W-40
Hydraulic tank Engine oil API-CD, API- SAE 10W

CD+SF, SAE 10W-30
ACEA-E1, SAE 10W-40
ACEA-E3 SAE 15W-40
SAE 20W-20
SAE 30W
Transmission Engine oil API-GL-5 SAE 20 W-20

gear MIL-L 2105 B or
ZF TE-ML 07B/D SAE 10W-40
SAE 15W-40
Slewing gear mecha- Gear oil API-GL-5 SAE 80W-90

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

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

MIL-L 2105 B
ZF TE-ML 05C
Wheel hubs of the Gear oil API-GL-5 SAE 90 LS

Steering axle MIL-L 2105 B or
ZF TE-ML 05C/E SAE 20W-40
Rigid axle Gear oil API-GL-5 SAE 90 LS

MIL-L 2105 B
ZF TE-ML 05C
Wheel hubs of the Gear oil API-GL-5 SAE 90 LS

rigid axle MIL-L 2105 B or
ZF TE-ML 05C/E SAE 20W-40
Pump distribution gear Gear oil API-GL-5 SAE 90 LS

MIL-L 2105 B
Tracks and Grease High-pressure gre- Consistency 2

gearing of the ase NLGI class with
slewing gear, bearing KP2k or EP2 lithium com-
of the attachment plexTab. 8
Hinges, joints, locks Engine oil - - -
1.50.2
copyright by
MJFCIFSS
Lubricant table
Description Medium Symbol Classification Viscosity
Sealing rubber on Silicone - - -

doors and spray or tal-
panelling sections cum pow-
der
Tab. 1 Lubricant table
2.1 Fuels, lubricants and process chemicals
Description Medium Symbol
Fuel tank Conventional diesel fuel with <= 0.5 % sulphur content
Coolant Corrosion inhibitor and antifreeze agent

Filling with DCA 4
BI = SP-C
Windscreen washer Conventional windscreen cleaning agent or denatured al- -

system cohol
Coolant of air-conditio- R 134 a -

ning system
Refrigeration oil in PLANETELF PAG SP 20 -

a/c SD 7 H15 compres- ID no. 8504414 (0.25 litre) or 7620633 (1.0 litre)
sor
Tab. 2 Fuels, lubricants and process chemicals
1.50.3
copyright by
MJFCIFSS
Specifications for fuels, lubricants and process chemicals
3 Specifications for fuels, lubricants and process chemicals
3.1 Lubricating oil for the diesel engine

The instructions regarding the lubricating oil for the diesel engine are based on the following classifi-
cation systems:
Classification Specification
API classification (American Petrol Ins- CG-4, CF-4, CH-4

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

tion des Constructeurs Européens de
l´Automobile)
Tab. 3 Lubricating oil for the diesel engine
Select the oil for the diesel engine according to the following diagram.
Fig. 1 Engine oil for use as a lubricating oil for the diesel engine
3.1.1 Oil change intervals for turbocharged engines
Oil change interval

depending on oil quality:
Sulphur content CH-4
Operating conditions
of fuel CG-4 E3-96 (D5)
CF-4 E4-98
E2-96 (D4)
Temperature normally not max. 0.5 % 250 h 500 h
dropping below -10°C 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.
1.50.4
copyright by
MJFCIFSS
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.
3.2 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.
3.2.1 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 injec-
tion system (especially in distributor fuel injection pumps).
Branded fuels in Germany and elsewhere therefore contain lubricating additives. The lubricity of the
fuel must be < 400 µm in a HFFR test (60°).
The additives should be added by the supplier, who is responsible for the quality of the fuel. We ad-
vise machine operators not to add any secondary lubricity additives to the fuel.
3.2.2 Improvement of fluidity by adding petrol

At outdoor temperatures below approx. 0 °C, the fluidity of summer diesel might not be sufficient,
due to paraffin separation.
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 prevent malfunction at low temperatures, the diesel fuel must be mixed with
standard 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 standard 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).
Applicable fuel specifications

DIN EN 590
ASTM D 975 (89 a) 1 D and 2 D
DIN EN 590 with max. 5 volume % FAME* according to draft standard prEN 14214 (formerly: DIN
51606)
The use of fuels with other specifications is only permitted with the explicit consent of the LIEBHERR
diesel engine
1.50.5
copyright by
MJFCIFSS
development department LIEBHERR MACHINES BULLE SA.
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).
3.2.3 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 manufac-
turers.
3.3 Hydraulic oil
3.3.1 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
copyright by
MJFCIFSS
Fig. 2 Engine oil for use as hydraulic oil
Warm-up instruction
At temperatures to 10 °C below the indicated limit (black bar), the oil must be warmed up as follows:
Warm-up instruction:
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.
3.3.2 Environmentally friendly hydraulic oils
Note!
Do not mix different brands of environmentally friendly hydraulic oils or add such products
with mineral oils (see customer service information)!
At the request of the customer, LIEBHERR will fill the system before delivery. Before using
environmentally friendly hydraulic oils, consult LIEBHERR.
The list of products recommended by LIEBHERR contains only ester-based synthetic oils with a vis-
cosity according to ISO VG 46.
Do not use vegetable oils, as they do not possess the necessary thermal stability.
3.3.3 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 recom-
mends contracting WEAR-CHECK to carry out 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
1.50.7
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3.3.4 Monitoring of hydraulic oil in normal use
Fig. 3 Oil sampling from machines in normal use
h Operating hours 2 Second oil sample

1 First oil sample 3 Subsequent oil samples: every 500 opera-
ting hours
Oil change based on analysis and lab report.

Interval for the change of the hydraulic oil return filter (20/5 µm): first change after 500 operating
hours, then every 1000 operating hours.
3.3.5 Oil sampling from machines used for dust intensive applications:
Fig. 4 Oil sampling from machines used for dust intensive applications
h Operating hours 2 Second oil sample

1 First oil sample 3 Subsequent oil samples: every
250 operating hours
Oil change based on analysis and lab report.

Interval for the change of the hydraulic oil return filter (10 µm): first change after 500 operating hours,
then every 500 operating hours.
3.3.6 Instructions for the reduction of the contamination of the hydraulic oil in ma-
chine used
in dust-intensive application
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 con-
ditions.
In order to prevent premature wear of the hydraulic components, shorten
the intervals between the oil changes (or oil samplings respectively) and observe
the following instructions:
Every 500 operating hours, replace the filter cartridge(s) in the return filter.
Use 10-µm filter cartridges instead of the standard 20 / 5-µm cartridges.
Replace the breather filter on the hydraulic tank with a 2-µm fine filter (mesh size of series filters:
7 µm).
Replace the 2-µm breather at each change of the hydraulic oil (i.e. every 500 operating hours).
1.50.8
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Note!
All machines are equipped with 10-µm filter cartridges and 2-µm breather filters as standard.
From September 2005, all machines will be fitted with 2-µm breather filters.
3.4 Gear oil

Gear oils must conform to the following specifications:
API-GL-5 and MIL-L-2105 B, C or D for viscosity grades SAE 90 or SAE 80W-90
API-GL-5 and MIL-L-2105 B or ZF TE-ML 05C/E for viscosity grades SAE 90LS or SAE 20W-40
Engine oils used in gearboxes must conform to the following specifications:
API-CG-4, CF-4, CF for viscosity grade SAE 20
3.4.1 Grease and other process chemicals
Process chemicals Description / manufacturer
Grease for the slewing ring / The grease must conform to specification KP2k,
general 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 slee- Gleitmo 900
ves to hydraulic cylinders ID no. 8610227 (400 ml spray can)
Special corrosion inhibitor for moun- Castrol-Tarp
ting recesses for sealing elements ID no. 8300005 (40g tube)
at hydraulic cylinders
Other grease:
Lubricant used for the mounting of
pumps to prevent fretting corrosion
on spline meshes
Coolant for air-conditioning system R 134 A

Drain and fill the system according to the instruc-
tions in this manual (air-conditioning assembly).
Refrigeration oil for a/c compressor The SD5H14/SD7H15 a/c compressors are fac-
tory-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
1.50.9
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3.5 Coolant
3.5.1 Corrosion inhibitor and antifreeze agents with DCA (ID no. 8503890, 30 l con-
tainer)
In order to improve the quality of the cooling water, LIEBHERR diesel engines are equipped with wa-
ter filter installations.
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.
A chemical substance (DCA 4) added to the filter protects all parts of the cooling system that are in
direct contact with the coolant, such as the pump, the cylinder bearing sleeves, etc. against cavitati-
on, corrosion, deposits and foam.
As the various engines and models require different cooling water volumes and filter systems, LIEB-
HERR has introduced four different water filter installations.
3.5.2 Coolants with DCA 4 (DIESEL COOLANT ADDITIVES)

The coolant must contain at least 50 volume % of corrosion inhibitor and antifreeze agent during all
seasons. This protects the coolant against freezing to a temperature of -37 °C and ensures adequate
protection against corrosion. In the event of loss of coolant and subsequent refilling, 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 concentrati-
ons tend to result in poor cooling and antifreeze protection.
As part of the regular maintenance, check the mixing ratio and the DCA 4 concentration.
Note!
Change the coolant every 2 years.
The DCA 4 concentration must be between 0.3 and 0.8 units per litre.
To measure this, we recommend using a CC 2602 M test kit from Fleetguard.
Use of DCA 4 without corrosion inhibitor or antifreeze agent

In exceptional cases and where the ambient temperature is at all times above freezing point,
e. g. in tropical zones, and where none of the approved corrosion inhibitors and antifreeze
agents are available, operators may use a coolant consisting of a mixture of water and DCA 4.
In order to protect the cooling system against corrosion, mix approximately double the amount
of DCA 4 with water (see Tab. 9, page 11).
Note!
Change the coolant every year.
The DCA 4 concentration must be between 0.6 and 1.06 units per litre.
To measure this, we recommend using a CC W2602 M test kit from Fleetguard.
3.5.3 Refilling the cooling system

Before refilling the cooling system with new coolant, ensure that it is clean and rinse it, if required.
When filling the system for the first time, and when refilling it after repair work, add liquid DCA 4
to the coolant, to top up the DCA 4 contained in the water filters.
1.50.10
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Cooling system
Required volume of liquid DCA 4 DCA 4 water filter
content
0.5-litre container
litre or litre Product ID no.
ID no. 7363898
24 - 39 3 or 1,4 WF 2071 7367045
40 - 59 4 or 1,9 WF 2072 7381493
60 - 79 5 or 2,4 WF 2073 7367052
80 - 115 8 or 3,8 WF 2073 7367052
Tab. 9 Fill volumes of coolant with DCA 4
3.5.4 Intervals for the change of DCA 4 water filter

The DCA 4 water filter must be changed every 500 operating hours.
Provided there is no coolant loss from the cooling system, the DCA 4 concentration in the system, it
is sufficient to change the coolant every 500 operating hours.
3.5.5 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 earth metals (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 contaminants for use with corrosion inhibitors and antifreeze
agents
Requirements regarding the fresh water quality for coolants with DCA 4
Substance Volume
Total of alkaline earth metals (water 0.6 to 2.7 mmol / l (3 to 15 °d)
hardness)
pH at 20 °C 6.5 to 8.0
Chloride ion content max. 80 mg / l
Total chloride and sulphate max. 80 mg / l
Tab. 11 Max. concentration of water contaminants for use with DCA 4
1.50.11
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Fig. 5 Mixing ratio water : corrosion inhibitor / antifreeze agent
A % of corrosion inhibitor and antifreeze agent

B Antifreeze agent to indicated temperature, according to value A
3.5.6 Approved corrosion inhibitors and antifreeze agents
Concentrates
Brand Producer Country

Agip Antifreeze Plus Agip Petrol S.p.A., Rome I
Agip Langzeit-Frostschutz Autol-Werke GmbH, Würzburg D
Antigel DB 486 Sotragal SA, St. Priest F
Aral Kühlerfrostschutz A Aral AG, Bochum D
Avia Frostschutz APN (G48-00) Deutsche Avia-Mineralöl GmbH, Munich D
BP Antifrost X 2270 A Deutsche BP AG, Hamburg D

BP Napgel C 2270 / 1 BP Chemicals LTD., London GB
Caltex Engine Coolant DB Caltex UK Ltd, London GB

Caltex Extended Life Coolant Caltex UK Ltd, London GB
Castrol Anti-Freeze O Deutsche Castrol Vertriebs GmbH, Hamburg D
Century F.L. Anti-Freeze Century Oils, Hanley, Stoke-on-Tent GB
Chevron DEX-Cool Extended Life Anti-Freeze / Chevron Texaco, San Ramon, CA USA
Coolant
DEUTZ Kühlschutzmittel 0101 1490 Deutz Service International GmbH, Cologne D
Esso Kühlerfrostschutz Esso AG, Hamburg D
Fircofin Fuchs Mineralölwerke GmbH, Mannheim D

Frostschutz Motorex (G48-00) Bucher & Cie, Langenthal CH
Frostschutz 500 Mobil Oil AG, Hamburg D
Glacelf Auto Supra Total Nederland N.V., The Hague NL

Glycoshell AF 405 Shell Deutschland GmbH, Hamburg D
Glycoshell N Shell Deutschland GmbH, Hamburg D
Glysantin (G48-00) BASF AG, Ludwigshafen D
1.50.12
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Brand Producer Country
Havoline XLC Arteco, Ghent B

Havoline 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 Kühlerfrostschutzmittel OMV AG, Schwechat A

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

Total Frostfrei Total Deutschland GmbH, Düsseldorf D
Veedol Anti-Freeze O Deutsche Veedol GmbH, Düsseldorf D
Wintershall Kühlerschutz Wintershall Mineralöl GmbH, Düsseldorf D
Tab. 12 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. 8503890 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
Havoline DEX-Cool Extended Life Prediluted Chevron Texaco, San Ramon, CA USA
50/50 Anti-Freeze / Coolant
Organicool 50/50 Total Deutschland GmbH, Düsseldorf D
Tab. 13 Approved corrosion inhibitors/antifreeze agents / 50:50 premixed products
1.50.13
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1.50.14
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General instructions for the changing of lubricants and other process chemicals
Lubricants and process chemicals
1 General instructions for the changing of lubricants and other pro-

cess chemicals
Note!
The fill volumes specified in the fuel and lubricant table and in the lubrication schedule in the ope-
rator'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.
When handling lubricants and fuels, also observe the following documents:
subgroup "Lubricants and fuels"
"inspection and maintenance schedule" in group 3
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 ap-
plies 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 inad-
vertent closing.
Before refuelling the machine, switch off the engine. Do not smoke or use naked flames.
Turn the battery main switch to position 0 (OFF) and remove the ignition key.
1.51.1
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Lubricant table
2 Lubricant table
Designation Medium Symbol Classification/Name Viscosity
Diesel engine Engine oil Liebherr engine oil 10W-40 SAE 5W-30
Liebherr engine oil 10W-40 low ash SAE 5W-40
Liebherr engine oil 5W-30 SAE 10W-30
SAE 10W-40
SAE 15W-30
SAE 15W-40
Hydraulic system Hydraulic oil Liebherr Hydraulic Basic 68 ISO VG 68

(system capacity / tank Liebherr Hydraulic Basic 100 ISO VG 100
capacity) Liebherr Hydraulic HVI ISO VG 46 (32-68)
Liebherr Hydraulic Plus ISO VG 46 (32-68)
Liebherr Hydraulic Plus Arctic VG 15-46
Engine oil API - CD / ACEA - E1 SAE 10W

(MB 226.0 and 227.0) SAE 10W-30
SAE 10W-40
API - CD, CE, CF / ACEA - E2, E3, SAE 15W-40
E4 SAE 20W-20
(MB 227.5, 228.1, 228.3 and 228.5) SAE 30W
Slewing gear mechanism Gear oil API-GL-5 SAE 80W-90

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

(as positioning slewing brake) MIL-L 2105 B
Transmission Engine oil ZF TE-ML 07 SAE 10W-30

SAE 10W-20
Rigid axle Gear oil API-GL-5 SAE 90 LS

MIL-L 2105 B
ZF TE-ML 05
Wheel hubs of the rigid axle Gear oil API-GL-5 SAE 90 LS

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

MIL-L 2105 B
ZF TE-ML 05
Wheel hubs of the steering Gear oil API-GL-5 SAE 90 LS

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

MIL-L 2105 B, C or D
Tracks and gearing of the Grease Liebherr Universalfett 9900 KP2k consistency 2
slewing ring, bearing of the NLGI grade
equipment
Hinges, joints, locks Engine oil - - -
Sealing rubber on doors and Silicone spray - - -

covering sections or talcum
powder
Tab. 1 Lubricant table
1.51.2
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Fuels, lubricants and process chemicals
3 Fuels, lubricants and process chemicals
Designation Medium Symbol
Fuel tank Conventional diesel fuel with <= 0.5 % sulphur content
Coolant Corrosion inhibitor and antifreeze agent

(see Coolant for the diesel engine on page 5)
Windscreen washer system Conventional windscreen cleaning agent or denatured alcohol -
Coolant of air-conditioning system R 134 a -
Refrigeration oil in a/c compressor PLANETELF PAG SP 20 -
Tab. 2 Fuels, lubricants and process chemicals
4 Diesel fuels
4.1 Specification
The diesel fuels must meet the minimum requirements of the fuel specifications outlined below.
Approved fuel specifications:
- DIN EN 590
- ASTM D 975 (89a) 1D and 2D
The use of fuels with other specifications is only permitted with the explicit consent of the LIEBHERR.
4.2 Sulphur content of diesel fuel

Fuel that meets the DIN EN 590 standard may contain maximum 50 mg/kg (maximum 0.005 weight
percent) of sulphur.
"Low-sulphur" diesel fuels with a sulphur content of less than 0.05 % are only suitable after addition
of a lubrication additive. According to HFRR (60) Test, the lubricity of the diesel fuel may not exceed
460 µm (lubricity-corrected wear scar diameter [1.4] at 60 °C).
When using diesel fuels with a sulphur content of more than 0.5 weight percent, the oil change inter-
vals must be halved.
Do not use fuels with a sulphur content of more than 1 %.
Note!
The ASTM D 975 fuel standard does not specify that the fuels must undergo a fuel lubricity test.
A written confirmation of compliance must be requested from the fuel supplier. 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.
ASTM D 975 fuels must have a cetane number of minimum 45. A cetane number of more than 50
is preferable, especially at temperatures below 0 °C (32 °F).
1.51.3
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Diesel fuels
4.3 Diesel fuels for operation at low temperatures (winter)

At low temperatures, paraffin crystals are formed in the diesel fuel. They increase the flow reduction
in the fuel filter, so that the diesel engine might not be supplied with sufficient fuel.
Note!
For technical reasons, it is forbidden to add petroleum fuel to the diesel.
It it is not possible to achieve adequate flow of the diesel fuel at outdoor temperatures below -
20 °C, we recommend installing a fuel filter heater.
4.4 Lubricating oil for the diesel engine

Modern diesel engines must be lubricated with high-performance oils. They consist of a basic oil with
special additives.
The lubricating oil requirements for LIEBHERR diesel engines are based on the following standards
and regulations:
Designation Specification
ACEA classification (Association des E4, E5, E6, E7
Constructeurs Européens de l'Automo-
bile) Caution: Particle filter only permitted
with E6
API classification (American Petroleum CH-4, CI-4
Institute)
Caution: observe reduced oil change
intervals
Tab. 3 Lubricating oil specifications
4.5 Viscosity
The choice of the lubricating oil viscosity is done according to the SAE classification (Society of Au-
tomotive Engineers).
The relevant factor for the right choice of the SAE class is the ambient temperature.
The SAE classification does not provide any indication as regards the quality of a lubricating oil.
Excessively high viscosity might lead to start-up problems. If the viscosity is too low, the oil's lubrica-
tion might not be sufficiently efficient.
The temperature ranges shown in the diagram are approximate ranges that might temporarily be ex-
ceeded.
Tab. 4 Temperature-based selection of the SAE class
1.51.4
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Coolant for the diesel engine
For ambient temperatures of -20 °C (-4 °F) to +45 °C (+113 °F), we recommend the following diesel
engine oils:
Liebherr Motoroil 10W-40, specification ACEA E4
Liebherr Motoroil 10W-40 low ash, specification ACEA E6
For ambient temperatures of -30 °C (-22 °F) to +30 °C (+86 °F), we recommend the following diesel
engine oils:
Liebherr Motoroil 5W-30, specification ACEA E4
4.6 Lubricating oil change intervals

Oil and filter change: see chapter "Inspection and maintenance schedule"
Subsequent oil changes depend on the climate, sulphur content of the fuel and oil grade. For details,
see the table below.
If the specified operating hours (h) per year are not reached, the diesel engine oil and filter must be
changed at least once every year.
A number of adverse factors (unfavourable operating conditions) affect the length of the change in-
terval.
Such adverse factors include:
Frequent cold starts
Sulphur content in fuel greater than 0.5 %
Ambient temperature below -10 °C
If such factors apply, the oil and filter must be changed according to the table below:
Complication factor Oil quality

CH-4
CI-4
E4 / E5 / E6 / E7
Operating conditions Sulphur content of fuel Interval
Climate normal, to -10 °C to 0.5 % 250 h 500 h
above 0.5 % 125 h 250 h
below -10 °C to 0.5 % 125 h 250 h
above 0.5 % not permissible 125 h
Tab. 5 Oil change intervals required for operation under adverse conditions
h= operating hours
5 Coolant for the diesel engine
The coolant consists of an aqueous solution containing a corrosion inhibitor and an antifreeze agent.
It can be mixed by the operator using the products named below. Alternatively, it can be purchased
as a premixed solution.
5.1 General recommendations

The radiator works only properly when pressurised. It is therefore imperative that it is kept clean and
sealed at all times, that the radiator plug and working valves work properly and that the required
coolant level is maintained.
1.51.5
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Corrosion inhibitors/antifreeze agents approved by LIEBHERR ensure proper protection against

frost, corrosion and cavitation without causing damage to seals and hoses and without foaming.
Coolants that contain unsuitable corrosion inhibitors or antifreeze agents or that have been prepared
incorrectly might cause failure of assemblies and component parts in the coolant circuit due to cavi-
tation or corrosion. Heat-insulating deposits on components that conduct heat might result in overhe-
ating and consequently failure of the engine.
Note!
The use of emulsifiable corrosion inhibitor oils is not permitted.
5.2 Water (fresh water)

Clear and clean water free of particles that meets the following chemical requirements is suitable as
coolant.
Do not use sea water, brackish water, brine or industrial wastewater.
Designation Value / unit

Total of alkaline earth metals (water 0.6 to 3.6 mmol/dm³ (3 to 20 °d)
hardness)
pH at 20 °C 6.5 to 8.5
Chloride ion content max. 80 mg/dm³
Sulphate ion content max. 100 mg/dm³
Tab. 6 Fresh water quality
Designation Value / unit

Total of alkaline earth metals (water 0.6 to 2.7 mmol/dm³ (3 to 15 °d)
hardness)
pH at 20 °C 6.5 to 8.0
Chloride ion content max. 80 mg/dm³
Sulphate ion content max. 80 mg/dm³
Tab. 7 Fresh water quality with use of DCA 4
Water analysis results are available from the local authorities.
5.3 Mixing ratio for coolant

The coolant must contain min 50% corrosion inhibitor and antifreeze agent at all times of the year.
Outdoor temperature to Mixing ratio
°C °F Water % A%
-37 -34 50 50
-50 -58 40 60
A = Corrosion inhibitor and antifreeze agent
Tab. 8 Permissible mixing ratio
1.51.6
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Tab. 9 Temperature-based mixing ratio of water + corrosion inhibitor and antifreeze agent
A Corrosion inhibitor/antifreeze agent content in coolant
5.4 Permitted corrosion inhibitors/antifreeze agent

.
Note!
The mixture of certain corrosion inhibitors and antifreeze agents might negatively affect the proper-
ties of the coolant.
Do not mix different products.
Product Manufacturer Country

Liebherr Antifreeze Concentrate Liebherr D
Addinol Antifreeze Super Addinol Lube Oil GmbH, Leuna D

Agip Antifreeze Plus Aral AG, BochumEni S.p.A., Rome I
Agip Langzeit-Frostschutz Eni S.p.A., Würzburg D
Antigel DB 486 Sotragal SA, St. Priest F
Aral Antifreeze Extra Aral AG, Hamburg D
Avia Antifreeze APN G48 Avia Mineralöl AG, Munich D
BP Isocool BP p.l.c. London GB
Caltex Extended Life Coolant Chevron Texaco *

Castrol Antifreeze NF Castrol, London GB
Chevron Extended Life Coolant Chevron Texaco *
DEUTZ Kühlerschutzmittel 0101 1490 DEUTZ Service International GmbH, Co- D

logne
ESA Frostschutz G48 ESA Burgdorf CH
Fuchs Fricofin Kühlerfrostschutz Fuchs Petrolub AG, Mannheim D
Glacelf Auto Supra (antifreeze) Total, Paris F

GlycoShell Longlife Shell International Petroleum Company, GB
London
GlycoShell N Shell International Petroleum Company, GB
London
Glysantin G48 BASF AG, Ludwigshafen D
Havoline Extended Life Antifreeze / Chevron Texaco *

Coolant
1.51.7
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Havoline XLC Arteco B
Motorex Antifreeze Protect G48 Bucher AG, Langenthal CH

Motul Inugel Optimal Ultra Motul SA, Aubervilliers Cedex F
OMV Kühlerfrostschutz / Coolant Plus OMV Refining & Marketing GmbH, Vien- A
na
* = global
5.5 Permitted premixed coolants
Note!
The combination of different coolants might impair their properties.

Liebherr Antifreeze Mix Liebherr D
Caltex Extended Life Coolant Pre-Mixed Chevron Texaco *

50/50 (ready-to-use-version)
Chevron DEX-COOL Extended Life Pre- Chevron Texaco *
Diluted 50/50 Antifreeze Coolant
Coolelf Auto Supra -37°C Total, Paris F
Havoline XLC, 50/50 Arteco B

Havoline DEX-COOL Extended Life Pre- Chevron Texaco *
Diluted 50/50 Antifreefreeze Coolant
Premix = ready-mixed product (50 % water and 50 % corrosive inhibitor/antifreeze agent)

* = global
5.6 Corrosion inhibitors without antifreeze agent

In exceptional circumstances and at ambient temperatures that are always above freezing
points, e.g. during use in tropical areas where there are no corrosion inhibitors/antifreeze agents
available, the following inhibitors must be added to the coolant:
DCA 4 (Diesel Coolant Additives 4)
Caltex / Chevron / Havoline / Total
In this case, the coolant must be changed annually.
1.51.8
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Hydraulic oil
As part of regular maintenance work, check the concentration and correct it, if necessary.
Note!
The admixture of certain corrosion inhibitors might negatively affect the properties of the coolant.
Drain off a coolant before changing from a corrosion inhibitor with antifreeze agent to a standard
corrosion inhibitor and vice versa.

DCA 4 Diesel Coolant Additives Fleetguard / Cummins Filtration *
Caltex CL Corrosion Inhibitor Concentrate Chevron Texaco *
Chevron Heavy Duty Extended Life Cor- Chevron Texaco *

rosion Inhibitor Nitrite Free (ELC)
Havoline Extended Life Corrosion Inhibi- Chevron Texaco *

tor (XLI)
Total WT Supra Total, Paris F

* = global
6 Hydraulic oil
Hydraulic oils must meet the requirements outlined below.

Non-compliance with these requirements shall void all warranty and liability by LIEBHERR.
Maximum water content of hydraulic oil: < 0,1 %
6.1 Hydraulic oil

LIEBHERR recommends using the following hydraulic oils in its machines (depending on temperatu-
re range):
Tab. 10 Hydraulic oil for use as hydraulic oil (ISO classes)*
1.51.9
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Hydraulic oil
A Ambient temperature
B Cold-start range with warm-up instruction
C Operating range
* temperature-based selection of the ISO class

Liebherr Hydraulic Plus and Liebherr Hydraulic Plus Arctic are suitable for both biological as well as
prolonged operation.
Use only LIEBHERR hydraulic oils. The use of other oils is not permitted. If LIEBHERR oils are not
available locally, use one of the motor oils listed in the following chapter see 6.2 (before choosing an
oil, contact our customer service department).
6.2 Engine oil

If you wish to use other products, it is your responsibility to obtain a warranty declaration from the oil
supplier.
Engine oils that are to be used as hydraulic oils must conform to the following specifications:
Single grade oils (1): API - CD / ACEA - E1

(MB 226.0 and 227.0)
Multigrade oils (2): API - CD, CE, CF / ACEA - E2, E3, E4
(MB 227.5, 228.1, 228.3 and 228.5)
Tab. 11 Engine oils for use as hydraulic oil
Tab. 12 Engine oil for use as hydraulic oil (SAE classes)*
A Ambient temperature 1 Single grade oils

B Cold-start range with warm-up instruction 2 Multigrade oils
C Operating range
* temperature-based selection of the SAE class

** for deviating viscosity grade: consult the LIEBHERR customer service department
6.3 Warm-up instruction

The black bar B indicates that the ambient temperatures are maximum 20 °C below the operating
range C.
1.51.10
copyright by
MJFCIFSS
Hydraulic oil
In the event of a cold start at an ambient temperature below range B, the following warm-up instruc-
tion applies to the hydraulic oil:
1.: Start the diesel engine and run it at approx. 1 / 2 rated speed. Carefully activate the working
hydraulics. Operate the hydraulic cylinder and move them to the stop. After approx. 5 minutes,
start the travel hydraulics. Warm-up time: approx. 10 minutes
After a cold start at even lower ambient temperatures, the following warm-up instruction applies:
2.: Before starting the engine, warm up the hydraulic oil tank. Then proceed according to the
warm-up instructions in 1.
1.51.11
copyright by
MJFCIFSS
Biodegradable hydraulic oil
7 Biodegradable hydraulic oil
Before using biodegradable hydraulic oils, you must consult LIEBHERR.
Caution!
Risk of damage to the hydraulic unit!
When mixing ester-based biodegradable hydraulic oils with mineral oils, there is a risk of aggressive
chemical reactions, which can damage the hydraulic equipment.
Do not mix biodegradable hydraulic oils from different suppliers, and never mix with mineral oils.
The use of bypass filters is mandatory.

Depending on the temperature range, LIEBHERR recommends its poly-alpha olefin (PAO) oils that
are biodegradable according to CEC-L-33-A-93:
Liebherr Hydraulic Plus or Liebherr Hydraulic Plus Arctic
If these oils are not available locally, use one of the following oils (before choosing an oil, contact our
customer service department)
fully saturated synthetic ester-based oils, HEES
Do not use vegetable oils, as they do not possess the necessary thermal stability.
If you wish to use other products, it is your responsibility to obtain a warranty declaration from the oil
supplier.
7.1 Monitoring, filter change and oil change
Note!
Biodegradable hydraulic oils must be checked regularly by means of an oil analysis.
Normal operation: after change of oil* an then at least every 500 operating hours
Dust intensive application: after change of oil* an then at least every 250 operating hours
For mineral oils, an oil analysis is only required if the oil change interval is to be extended.
Normal operation: first time after 1500 operating hours, then every 500 operating hours
Dust intensive application: at least every 250 operating hours
LIEBHERR recommends contracting WEAR-CHECK** with these analyses, and to change the oil
when indicated by the test results in the lab report (see also customer service and product informa-
tion).
* Change of oil = change from mineral oil to biodegradable hydraulic oil

** Yellow kit for machines with biodegradable oil filling (HEPR and HEES)
Green kit for machines with mineral oil filling
Symbol Description
Filter change for hydraulic oil
Oil sampling
Tab. 13 Key to figures
1.51.12
copyright by
MJFCIFSS
Biodegradable hydraulic oil
Hydraulic oil in normal use:
Tab. 14 Oil sampling and filter change in normal use
h Operating hours 1 First oil sample

a Mineral oil 2 Second oil sample
b Biodegradable hydraulic oil 3 Subsequent oil samples: every 500 opera-
ting hours
Oil change after 2000 operating hours, or when indicated by the lab report of the analysis
Interval for the change of the hydraulic oil return filter (20 / 5 µm): first change after 500 and
1000 operating hours, then every 1000 operating hours and after each hydraulic oil change.
Hydraulic oil used in dust intensive applications:
Tab. 15 Oil sampling and filter change in machines used for dust-intensive applications
h Operating hours 1 First oil sample

a Mineral oil 2 Second oil sample
b Biodegradable hydraulic oil 3 Subsequent oil samples: every 250 opera-
ting hours
Oil change after 500 operating hours, or when indicated by the lab report of the analysis
Interval for the change of the hydraulic oil return filter (10 µm): first change after 500 operating hours,
then every 500 operating hours and after each hydraulic oil change.
7.2 Instructions for the reduction of the contamination of the hydraulic oil in ma-
chines 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 con-
ditions.
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:
1.51.13
copyright by
MJFCIFSS
Gear oil / axle oil
Every 500 operating hours, replace the filter cartridge(s) in the return filter.
Use 10-µm filter cartridges instead of the standard 20 / 5-µm cartridges.
The 2-µm breather filter must be replaced every 500 operating hours and after every hydraulic oil
change.
Note!
Machines delivered with hydraulic hammer attachment and retrofitted hydraulic hammer kits are al-
ready fitted with 10-µm filter cartridges in the return filter.
8 Gear oil / axle oil
Gear oils must conform to the following specifications:

API-GL-5 und MIL-L-2105 B, C or D for viscosity grades SAE 90 or SAE 80W-90
API-GL-5 and MIL-L-2105 B or ZF TE-ML 05C/E for viscosity grades SAE 90 LS or SAE 20W-40
Engine oils used in gearboxes must conform to the following specifications:
API-CG-4, CF-4, CF for viscosity grade SAE 20
9 Grease and other process chemicals
Medium Description / manufacturer

Grease for central lubrication sys- Liebherr recommends using the following products for the lu-
tem, general lube points brication of the machine, and in particular for the slewing ring
roller bearings, bolts, crown gears, axles and screws:
- Liebherr Universalfett 9900

- Liebherr Universalfett Arctic (for low-temperature operation)
The grease must conform to specification KP2k, consistency

grade 2, NLGI grade according to DIN 51818 and DIN 51825
or EP 2 according to NF-T-60 132.
The grease must consist of a lithium complex with a VKA va-
lue of minimum 2300 N according to DIN 51350 or ASTM D
2596 respectively.
Contact spray for slip rings Cramolin
Lubricant for pistons, piston nuts, Gleitmo 800
also used for the mounting of piston
rod bearings at hydraulic cylinders
Special corrosion inhibitor for moun- Castrol-Tarp
ting recesses for sealing elements at
hydraulic cylinders
Tab. 16 Grease and other process chemicals
1.51.14
copyright by
MJFCIFSS
1.55.1
1.55.2
1.55.3
1.55.4
1.55.5
1.55.6
1.55.7
1.55.8
1.55.9
1.55.10
1.55.11
1.55.12
1.55.13
1.55.14
1.56.1
1.56.2
1.56.3
1.56.4
1.56.5
1.56.6
1.56.7
1.56.8
1.56.9
1.56.10
Service Manual
SUBGROUP - INDEX
Section Group Type
Special tools general 2.01.1 A 900 C-LI

A 904 C-LI
A 914 C-LI
A 924 C-LI
Special tools for diesel engines 2.02.1 A 900 C-LI

A 904 C-LI
A 914 C-LI
A 924 C-LI
Special tools for hydraulic systems 2.05.1 A 900 C-LI

A 904 C-LI
A 914 C-LI
A 924 C-LI
Special tools for electric 2.06.1 A 900 C-LI

A 904 C-LI
A 914 C-LI
A 924 C-LI
Special tools for gears 2.07.1 A 900 C-LI

A 904 C-LI
A 914 C-LI
A 924 C-LI
Special tools for axles 2.08.1 A 900 C-LI

A 904 C-LI
A 914 C-LI
A 924 C-LI
Assembly tools for hydraulic cylinders 2.12.1 A 900 C-LI 14675-

A 904 C-LI 16000-
A 914 C-LI 35112-
A 924 C-LI 34519-
Mounting device for piston rod bearings 2.13.1 A 900 C-LI

A 904 C-LI
A 914 C-LI
A 924 C-LI
2.1
MJFCIFSS
Service Manual
Slotted nut wrench for slewing gear mechanism 2.14.1 A 900 C-LI
A 904 C-LI
A 914 C-LI
A 924 C-LI
Mounting device for multi-disk brake 2.15.1 A 900 C-LI

A 904 C-LI
A 914 C-LI
A 924 C-LI
2.2
MJFCIFSS
Service Manual Special tools general
Special tools general
maintenance and repair

Mach-
Picture No. Description Application
Size ID no. ine
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 1,000 7002437 all Connection of the pressu-

Length mm types re gauges to all measu-
7002475 ring points (measuring
8 1,500 neck no.1/2 and screw
mm couplings 10-14)
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
Mach-
Size ID no. ine
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 0-10 bar 5002865 * glycerine dampened
*
18 0-40 bar 7361288
*
19 0-60 bar 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 Pressure compensation
types in connection with tool no.
34 Measuring neck with 7002404 30
metal cap
35 Union nut 4774002
36 Cutting ring 4774001
2.01.2
copyright by
MJFCIFSS
Mach-
Size ID no. ine
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 Piezo speed A 2106 10286429 all Measuring of engine

counter 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
Mach-
Size ID no. ine
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 Oil analysis kit * no. 1 7018368 all 6 oil samples

types
85 Oil analysis kit * 8145660 1 oil sample
*Analyses carried out by WAER

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

types
89 Bio oil analysis kit * 7026088 6 oil samples
*Analyses carried out by WAER

CHECK Germany, lab report in
German
2.01.4
copyright by
MJFCIFSS
Mach-
Size ID no. ine
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
Mach-
Size ID no. ine
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 B20 pressure switch 9645488 all Testing of switching pres-

conversion kit types sure (dropping) of B20
consisting of: pressure switch
151 Screw-in stud 7617216
152 T-connection fitting 7405617
153 Measuring piece 7409919
154 Screw nozzle 7368150
150 Hand pump with pres- 10454803 all For leakage test of back-
sure gauge types pressure line at particle
filter installation
2.01.6
copyright by
MJFCIFSS
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
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 revs/min 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 12 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
Maintenance and setting instructions for Liebherr 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 0524044 all Insert at the position of the

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

types
4 High-pressure hand 7009318 all Checking and adjustment

pump with accessories types of start of delivery of the in-
jection pump
10 Measuring device 7022420 all Checking and adjustment

types of start of delivery of the in-
jection pump
2.02.1
copyright by
MJFCIFSS
Special tools for diesel engines Service Manual
Machi
ne
12 Dial gauge 7022418 all Testing and adjustment of
types start of delivery in conjunc-
13 Spacer 7022419 tion with no. 10
18 Removal tool for injec- 0524072 all Removal of injection

tion nozzles types nozzles
19 Adapter for removal 0524029 To be used together with

tool the removal tool
30 Rotating device / at- 052045 all Turning of diesel engine by

tachment to flywheel types means of the flywheel
housing
35 V-belt measuring in- Krikit 8042829 all Measurement V-belt tensi-

strument types on
36 Communication cable 10035410 D 934 Reading of error memory,

for LH-ECU-UP/CR LA 6 / fault analysis, processing
control units D 936 of measurements, calibra-
LA 6 tion
2.02.2
copyright by
MJFCIFSS
Service Manual Special tools for diesel engines
Machi
ne
37 Diagnostic software 10118924 D 934 Used to read error
DC-DESK 2000 for LA 6 / memory, analyse faults,
LH-ECU-UP/CR D 936 edit measurements and
DC4 and DC5 control LA 6 carry out calibrations.
units
Note!
The software is supplied
together each dongle!
38 USB dongle
40 Nozzle gauge 10410078 all Measurement and che-

types cking of nozzle bores and
small drilled holes
2.02.3
copyright by
MJFCIFSS
Special tools for diesel engines Service Manual
2.02.4
copyright by
MJFCIFSS
Service Manual Special tools for hydraulic systems
Special tools for hydraulic systems
2.05.1
copyright by
MJFCIFSS
Special tools for hydraulic systems Service Manual
2.05.2
copyright by
MJFCIFSS
2.05.3
copyright by
MJFCIFSS
2.05.4
copyright by
MJFCIFSS
Intermediate flange/ 1/2 9916093

intermediate block with
con-
nection
R1/4
3/4 9765104
1 9759353
11/4 9309326
Sealing plate 1/2 Installati-

- on,
1 1/2 see Tab. 1
Sealing plates for the sealing of hose connections and SAE flanges
Plate without Plate without puncture, with

Size Plate with puncture O-ring Kantsil ring
puncture thread
1/2 9107878
3/4 9194264
1 9174163 9170178 7264508 7367611
1 1/4 9413318 9420882 7264687 7367612
1 1/2 9465987 7360048 7367613
1/2 9327330
3/4 9327331
1 9327332
1 1/4 9327333
1 1/2 9327334
Tab. 1 Overview of sealing plates
2.05.5
copyright by
MJFCIFSS
2.05.6
copyright by
MJFCIFSS
Service Manual Special tools for electric
Special tools for electric
maintenance and repair of electric connection plugs
Fig. 1 Mate-N-LOK plugs and DT plugs
Fig. 2 Juniortimer and JPT plugs
2.06.1
copyright by
MJFCIFSS
Special tools for electric Service Manual
Machi
Picture no. Description Size ID no. Application
ne
10 Use to crimp the contacts for 1.5 7367025 all
mm2 wires for MATE-N-LOK ad- types
apters
12 Use to crimp the contacts for 2.5 7366314 all

mm2 wires for MATE-N-LOK ad- types
apters
15 Tool used to remove the crimp 7015179 all

contacts from MATE-N-LOK ad- types
apters
20 Socket contact for 1.5 mm2 wires 6202619 all

of the MATE-N-LOCK adapters types
Pin contact for 1.5 mm2 wires of

21 the MATE-N-LOCK adapters 6202620

of the MATE-N-LOCK adapters types

23 the MATE-N-LOCK adapters 6202592
28 Hand crimp tool (according to MIL- 7367086 all

C5015, VG 95234, VG 955342) types
29 Crimping insert for the crimping of 7409779

DEUTSCH adapters with no. 28
pliers
30 Hand crimp tool for the crimping of 8503647 all

contacts for DEUTSCH connec- types
tion plugs
2.06.2
copyright by
MJFCIFSS
Machi
ne
32 Tool for the removal of Size 4 8503633 all
wired crimp contacts at types
the DEUTSCH adap-
ters
33 Size 8 8503632
34 12 8145674
35 16 8145673
36 20 8503630
37 Pin contact for wires of Ø 0.8- 7368251 all
DT adapters 1.0 types
Ø 1.0- 7368406
2.0
Ø 2.0- 6905271
3.0
38 Socket contact for wi- Ø 0.8- 7368252

res of DT adapters 1.0
Ø 1.0- 7368405
2.0
Ø 2.0- 6905272
3.0
Plug
39 7368253
40 Crimping of the punched contacts 7367025 all
of SURE-SEAL adapters types
41 Mounting tool for the insertion of 7367023 all

wired crimp contacts into SURE- types
SEAL CT 31 adapters
42 A: Removal tool for pin contacts 7367020 all

from SURE-SEAL adapters types
B: Removal tool for socket con- 7367022 all

tacts types
43 Installation tubes for CT 31 7022464 all

tool no. 42 types
2.06.3
copyright by
MJFCIFSS
Machi
ne
45 Auxiliary tool used to hold the 7367021 all
SURE-SEAL 2, 3 and 4-pin adap- types
ters during installation and remo-
val of the crimped contacts
46 Similar to tool no. 324, for 5, 6 and 7367085

7-pin contacts
48 Repair kit 7015073 all

containing special tools no. 40, 41, types
42, 45 and 46, including operating
manual and lubricant

of the SURE-SEAL adapters types

51 the SURE-SEAL adapters 6202444
52 Removal tool for contacts of MIC- 7026266 all

ROTIMER adapters types
55 Unlocking tool for 777-310 7022773 all

WAGO plug-type ele- types
ments
60 IC removal tool 8042630 all

types
61 IC insertion tool 8042629
2.06.4
copyright by
MJFCIFSS
Machi
ne
70 Ergocrimp hand tool 6004391 all Used to crimp the contacts
types for JPT (Tyco) adapters
Ergocrimp matrix all Used to crimp the contacts

types for
72 0.5-2.5 10016253
mm2 Junior Power Timer no.
927777-3 / Nr. 927779-3 /
73 927846-2
0.5-2.5 10016255
mm2 Junior power Timer/EDS
74 no. 929938-3/double-
spring contact no. 929940-
0.5-2.5 10016256 3
mm2
flat adapters no. 963745-1
/ 963746-1
80 Removal tool 7415334 all Used to remove the wired
types crimp contacts from the
JPT (Tyco) adapters
90 Crimp tool 10016251 all Used to crimp the Littlefuse

types contacts for JPT (Tyco) ad-
apters, see also no. 92.
92 Ergocrimp matrix 0.5 mm2 10016252 all Used to crimp the contact
-3.32 types in connection with no. 90
mm2
Pin bushing no. 913053 /
913065 / 913066 / 913067
/ 913069 / 913079
Double-spring contact no.

913071 / 913072
2.06.5
copyright by
MJFCIFSS
2.06.6
copyright by
MJFCIFSS
Service Manual Special tools for gears
Special tools for gears
for the maintenance and repair of gear systems

Mach-
ine
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
11 SAT 9199665 drawing, see page 2.14-
250 01)
12 SAT 9202821
275
20 Mounting device SAT 9202825 A 314 Dismantling and assembly

225 A 316 of brake housing/multi-disc
A 900C brake for SAT slewing gear
21 A 904C mechanisms (SAT dra-
wing, see page 2.15-01)
SAT 9199319 A 914C
22 250
SAT 9202826 A 924C

275
30 Mounting device FAT350 9981445 Track Releasing and tightening of
/022 machi- slotted nuts in drive/slew-
FAT350 nes ing gear mechanisms (SAT
/032 drawing, see page 2.16-
01)
31 FAT400 9392820
/063
FAT400
/073
35 Mounting device for FAT350 8503594 Track Installation of slip ring

slide ring seals /022 machi- seals in the travel gears
FAT350 nes (FAT drawing, see page
/032 2.18-01)
36 FAT400 8503179
/063
FAT400
/073
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
types the snap ring into/from the
11 Chuck tip 5 mm 8145768 planetary gear of the axles
12 6 mm 8145769
20 Slotted nut wrench for AP / 7013102 A 900C Used to loosen and tighten
axles APL slotted nuts in planetary
755 gears / axles.
7021789 A 900C
21 AP 755
TR
7014452 A 904C
22 AP 765
APL
765
23 7026768 A 904C
AP 765
TR
30 Centring disc AP / 7013101 A 900C In conjunction with tool no.
APL 20-23
755
AP 755
TR
31 7013920 A 904C
AP /
APL
765 A 904C
APL
35 Centring ring 765 TR 7024975 A 900C
AP /
APL
755
40 Mounting tool AP / 7024127 A 900C Used to insert the cassette
APL seal ring in the hub / axles.
755
42 7024974 A 900C
AP 755
AP 755
TR
44 7024973 A 904C
AP 765 A 914C
APL A 924C
765
45 7027153
AP 765
TR
2.08.1
copyright by
MJFCIFSS
Special tools for axles Service Manual
50 Slip bushing, 2-part AP / 7019632 A 900C Used to mount the brake

APL piston into the hollow
755 wheel.
51 AP / 7024131 A 904C
APL A 914C
765 A 924C
60 Measuring screw for M16 x 7019556 all Used to measure the pad
pad wear 1.5 types wear at the ZP axles.
70 Wrench for hub cap lo- LT71 7024204 A 924 Loosening and tightening
cking nut PL477 HD of hub cap securing nuts at
the axle (steering knuck-
les)
72 Wrench for locking LT71 7026040 A 924 Loosening and tightening

nuts PL477 HD of locking nuts at the plane-
tary carrier
74 Insertion tool for slip LT71 7027696 A 924 Mounting of slip seal ring
seal ring PL477 HD
2.08.2
copyright by
MJFCIFSS
Service Manual Special tools for axles
70 Slotted nut wrench for MS-E 10346444 A 900C Used to loosen and tighten
axles 3060/ A 904C the slotted nuts in the pla-
3070 netary housing / hub carrier
MT-E
3060/
3070
75 Gripping piece MS-E 10354109 A 900C

3060
76 Gripping piece MS-E 10354108 A 904C

3070
78 Removal insert MS-E 7011520 A 900C

3060/ A 904C
3070
80 Removing tool MS-E 7026311 A 900C

3060/ A 904C
3070
2.08.3
copyright by
MJFCIFSS
Special tools for axles Service Manual
81 Magnetic stand MS-E 10454855 A 314/ Use to measure brake pad

3050/ 316 wear, in conjunction with
3060/ dial gauge and extension
3070
MT-E
3050/
3060/
3070
82 Dial gauge 10454856
83 Extension 10454857
85 Removing tool MS-E 10353377 A 900C
3060/ A 904C
3070
90 Counter piece MS-E 7026310 A 900C

3060/ A 904C
3070
95 Mounting tool MS-E 7011527 A 900C Used to insert the outer be-
3060/ A 904C aring race in the joint hou-
3070 sing.
100 Mounting tool MS-E 10353378 A 900C Used to insert shaft seal
3060/ A 904C rings / bushings in the axle
3070 housing and the joint hou-
sing.
103 Handle MS-E 7011518 In conjunction with tool no.
3060/ 103
3070
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. Ø
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
Øa 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 Ø Ø a b c
9600751 80 3/4 170 Ø110 Ø140 Ø160 525 15
9602239 85 3/4 170 Ø115 Ø140 Ø160 525 15
9600418 90 3/4 170 Ø120 Ø150 Ø160 525 15
9597668 100 3/4 170 Ø130 Ø160 Ø180 525 15
9600928 110 3/4 170 Ø160 Ø190 Ø200 525 15
9600769 120 3/4 174 Ø170 Ø200 Ø200 525 15
* width over flats
5 Mounting and expanding sleeves
990 mounting sleeve 991 expanding sleeve

Piston Ø
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 Ø
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 Ø
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 Ø
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 mechanism
Tool used to remove the slotted nut in the slewing gear mechanism
Slotted nut wrench for slewing gear mechanism
1 Tool used to remove the slotted nut in the slewing gear mechanism
Fig. 1 Slotted nut wrench for Sat 225 / 250 / 275 / 300
Slewing gear
ID number
type
SAT 225 9202820
SAT 250 9199665
SAT 275 9202821
SAT 300 9202822
Tab. 1 ID numbers of slotted nut wrenches
2.14.1
copyright by
MJFCIFSS
Slotted nut wrench for slewing gear mechanism 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
250 100 55 46 60 81.5+0.2 86 110 105 3.8 90 35 30 50 67 7.8
275 110 55 46 70 92.2+0.2 95 120 105 3.8 90 35 30 50 70 7.8
300 125 55 46 80 106.5+0.2 110 140 110 3.8 95 35 30 50 73 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 multi-disk brake
Mounting device for multi-disk brake
SAT 225 / 250 / 275 / 300
Fig. 1 Mounting device of slewing gear mechanisms
Size SAT 225 SAT 250 SAT 275 SAT 300

A 268 300 326 364
B 40 40 40 50
C 12 12 12 20
D 10 10 10 15
E 10 10 10 15
F 16 18 18 22
G 100 110 120 130
H 117 131 143 157
ID no. 9202825 9199319 9202826 9202827
Tab. 1 List of mounting device sizes
2.15.1
copyright by
MJFCIFSS
Mounting device for multi-disk brake Service Manual
2.15.2
copyright by
MJFCIFSS
Service Manual
SUBGROUP - INDEX
Section Group Type
Type overview 3.05.1 A 904 C-LI EDC 30580-
Type overview 3.06.1 A 914 C-LI 35112-

A 924 C-LI 34519-
Technical data 3.10.1 A 900 C-LI 14675-
Technical data 3.11.1 A 900 C-LI EDC 24677-
Technical data 3.15.1 A 904 C-LI EDC 30580-
Maintenance and inspection schedule 3.20.1 A 900 C-LI 14675-
Maintenance and inspection schedule 3.21.1 A 900 C-LI EDC 24677-
Maintenance and inspection schedule 3.25.1 A 904 C-LI EDC 30580-

A 924 C-LI 34519-
Lubricating charts 3.30.1 A 900 C-LI 14675-

A 900 C-LI EDC 24677-
A 904 C-LI 16000-
A 904 C-LI EDC 30580-
A 914 C-LI 35112-
A 924 C-LI 34519-
Adjustment protocol V2.10 3.40.1 A 900 C-LI 14675-
Adjustment protocol V4.3 3.41.1 A 900 C-LI EDC 24677-
3.1
MJFCIFSS
Service Manual
Adjustment guideline for hydraulic system 3.60.1 A 900 C-LI 14675-

A 904 C-LI 16000-
Adjustment guidelines for hydraulic system 3.61.1 A 900 C-LI EDC 24677-
A 904 C-LI EDC 30580-
Checking and adjusting tasks V4.7 3.62.1 A 900 C-LI EDC 39762-
A 904 C-LI EDC 37774-
Adjustment guidelines for hydraulic system 3.70.1 A 914 C-LI 35112-

A 924 C-LI 34519-
Adjustment protocol (kits) 3.80.1 A 900 C-LI EDC

A 904 C-LI EDC
A 914 C-LI
A 924 C-LI
3.2
MJFCIFSS
Service Manual Type overview
Type 1003 construction model
Type overview
Note!
In general, there is a wide range of tools and attachments available for each type, which can be ad-
justed to suit the application. The diagrams therefore show only of example of possible attachments.
1 Type 1003 construction model
Fig. 1 Type 1003 construction model
Characteristics:
with blade support
with 2-point support
with blade and 2-point support
Advantages/applications:
Standard machine
High/horizontal adjustment is not useful in connection with 2-point support.
3.05.1
copyright by
MJFCIFSS
Type overview Service Manual
Type 1004 HD (with 4-point support)
2 Type 1004 HD (with 4-point support)
Fig. 2 Type 1004 HD (with 4-point support)
Characteristics:
Extended axles
Undercarriage width 2750 mm, box height centre section 350 mm
Support width 4250 mm
Wheel distance 2800 mm, centre undercarriage
Operator's cab elevation (option 1200, hydraulic operator's cab elevation)
4-point support (optional individual outrigger control)
Allows for better view of the working area
Fast working movements
High load capacity
Great stability thanks to large support base
Sturdy undercarriage
Smooth travel operation with high load capacity
3.05.2
copyright by
MJFCIFSS
Type 1005 construction model (with 4-point support)
3 Type 1005 construction model (with 4-point support)
Fig. 3 Type 1005 construction model (with 4-point support)
Characteristics:
Standard machine
High load capacity
3.05.3
copyright by
MJFCIFSS
Type 1071 industrial model
4 Type 1071 industrial model
Fig. 4 Type 1071 industrial model
Characteristics:
Standard axles
Wheel distance 2750 mm
Operator's cab elevation (option 1200, hydraulic operator's cab elevation).
High load capacity
3.05.4
copyright by
MJFCIFSS
A 914 C type 1044 construction model (2-point support)
Type overview
Note!
In general, there is a wide range of tools and attachments available for each type, which can be ad-
justed to suit the application. The diagrams therefore show only a selection of example of possible
attachments.
1 A 914 C type 1044 construction model (2-point support)
Characteristics:
with blade support
Standard machine
3.06.1
copyright by
MJFCIFSS
Characteristics:
2-point support with blade
4-point support with dozer blade
Standard machine
High load capacity
3.06.2
copyright by
MJFCIFSS
Characteristics:
with blade support
Standard machine
3.06.3
copyright by
MJFCIFSS
Characteristics:
2-point support with blade
Standard machine
High load capacity
3.06.4
copyright by
MJFCIFSS
A 924 C type 1049 industry model (4-point support)
5 A 924 C type 1049 industry model (4-point support)
Fig. 5 Type 1049 industry model (4-point support)
Characteristics:
Box height centre section: 350 mm
Wheel distance 2800 mm, centre undercarriage
Operator's cab elevation (option 800, 1200, 1500, 2000 hydraulic operator's cab elevation)
High load capacity
3.06.5
copyright by
MJFCIFSS
A 924 C type 1050 HD (with log loader blade)
6 A 924 C type 1050 HD (with log loader blade)
Fig. 6 Type 1050 HD (with blade)
Characteristics:
Support blade
Reinforced axles
Reinforced undercarriage
Undercarriage width 3000 mm
Operator's cab elevation (option 800, 1200, 1500, 2000, no hydraulic operator's cab elevation)
High load capacity
3.06.6
copyright by
MJFCIFSS
A 924 C type 1051 HD 4-point support)
7 A 924 C type 1051 HD 4-point support)
Fig. 7 Type 1051 (4-point support)
Characteristics:
Reinforced axles
Reinforced undercarriage
Wheel distance 3000 mm
Operator's cab elevation (option 800, 1200, 1500, 2000 hydraulic operator's cab elevation)
High load capacity
3.06.7
copyright by
MJFCIFSS
A 924 C type 1051 HD 4-point support)
3.06.8
copyright by
MJFCIFSS
Service Manual Technical data
A 900 C Litronic
Technical data
1 A 900 C Litronic
Type 917 / 987 HD
Valid from serial number 14675

General 917 987 HD
Weight of basic machine with 2-point support t 13.3 13.6
Weight of backhoe bucket attachment (2-point support) t 16.0 17.0 16.0 17.3
Overall length (with blade support) mm 4524 4524
Overall width mm 2550 2550
Overall height without attacment mm 3160 3160
Rear reach from centre/slewing radius mm 2200/2275 2200/2275
Ground clearance mm 370 370
Break-out force at tooth KN 101 / 98 101 / 98
Max. drawing pull (in offroad gear and max. operating pressure) KN 86 86
Drive motor 917 987 HD

Type D 924 TI E A2
Power at rated speed according to DIN ISO 9249 kW 88 (120 PS)
Rated speed min-1 1800
Max. torque NM 630 ± 10
at 1000 min-1
Oil volume in engine (filling quantity at oil change with filter) l 23
Oil quality/oil viscosity and oil change intervals see groups 1.50 and 3.30
Fuel tank capacity l 300
Additional information see group 4.11
Hydraulic system 917 987 HD

Hydraulic pump Type LPV 150
Design axial piston swash plate
pump
Drive power of pump with power control (min. power) kW 27
Max. flow l/min 270
Hydraulic oil volume (oil change with filter) l approx. 250
Hydraulic oil and filter change intervals see groups 1.50 and 3.30
Control valve block Type M7/NG 22-16
Rotary connection 7 x Type DDF 720
Rotary connection 6 x Type 815.006
Boom cylinder (adjustable and gooseneck equipment) Ø piston / rod mm 120 / 80
Stick cylinder with adjustable attachment Ø piston / rod mm 120 / 80
A 900 C-LI 14675- 3.10.1

copyright by
MJFCIFSS
Technical data Service Manual
A 900 C Litronic
Hydraulic system 917 987 HD

Bucket cylinder Ø piston / rod mm 100 / 70
Support cylinder with outrigger - blade support Ø piston / rod mm 120 / 70 - 90 / 50
Regulating cylinder with boom attachment Ø piston / rod mm 140 / 80
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 44
Pilot control unit / working attachment / slewing gear Type VG - 7 - 4
Pilot control unit / travel drive Type VG - 7 - 1
Pilot control unit / support Type VG - 7 - 2
Additional information see group 6
Electrical system 917 987 HD

Operating voltage V 24
Battery capacity Ah 2 x 92 (in series)
Alternator voltage / current V/A 28 / 55
Starter V / kW 24 / 5.4
Slewing gear mechanism 917 987 HD

Gearbox Type SAT 225 / 229
Oil motor Type FMF 45
Max. slewing speed min-1 9.0
Oil volume in gearbox l 5.0
Oil quality/oil viscosity and oil change intervals see groups 1.50 and
3.30
Slewing gear brake Type Wet multi-disc brake (ne-
gative)
Transmission 917 987 HD

Gearbox Type 2 HL 100
Oil motor Type LMV 100
Travel speed in creeper / offroad / on-road gear km/h 2.5 / 5.0 / 20.0
Parking brake Type Wet multi-disc brake (ne-
gative)
3.10.2 A 900 C-LI 14675-

copyright by
MJFCIFSS
A 900 C Litronic
Axles 917 987 HD

Steering axle Type APL - B 755
Rigid axle Type AP B 755 TR
Oil volume in steering axle housing l 9.0
Oil volume in steering axle wheel hub l 2 x 2.0
Oil volume in rigid axle housing l 9.0 (10.0 with multi-disk
brake)
Oil volume in rigid axle wheel hub l 2 x 1.0 ( 2.0 l with multi-
disc brake)
Steering axle working brake Type Multi-disc brake
Rigid axle working brake Type Drum brake (multi-disc
brake as kit)
Brake type (positive)
Tyres inch 10.00 - 20
18.00 19.5
Steering 917 987 HD

Hydraulic pump Type Gear pump
Flow l/min 36
Steering / steering valve Type LAGZ 190 / 60
Brake system 917 987 HD

Max. flow l/min 4.6
Central lubrication system 917 987 HD

Volume of grease per operating hour cm3 3.5
Number of cycles / grease processes with automatic greasing (optional) 2
A 900 C-LI 14675- 3.10.3

copyright by
MJFCIFSS
A 900 C Litronic
3.10.4 A 900 C-LI 14675-

copyright by
MJFCIFSS
A 900 C Litronic
Technical data
1 A 900 C Litronic
Type: 1002

Introduction Type 1002
Weight of basic machine with 2-point support t 13.7
Weight of backhoe bucket attachment (2-point support) t 16,3 - 19,2
Overall length (with blade support) mm 4524
Overall width mm 2550
Overall height without attachment mm 3160
Rear reach from centre/slewing radius mm 2260/2330
Ground clearance mm 358
Break-out force at tooth kN 101 / 98
Max. drawing pull (in off-road gear and max. operating pressure) kN 117
Drive motor Type 1002

Type D 934S A6
Rated speed rpm 1800
Max. torque NM 770 ± 10
at 1100 rpm
Hydraulic system Type 1002

Hydraulic pump Type DPVO 165
Design Axial piston swash plate
pump
Max. flow l/min 300
Boom cylinder (adjustable and gooseneck equipment) Ø piston / rod mm 125 / 85
Stick cylinder with adjustable attachment Ø piston / rod mm 130 / 85
A 900 C-LI EDC 24677- 3.11.1

copyright by
MJFCIFSS
A 900 C Litronic
Hydraulic system Type 1002

Bucket cylinder Ø piston / rod mm 105 / 70
Support cylinder with outrigger - blade support Ø piston / rod mm 120 / 70 - 110 / 50
Regulating cylinder with boom attachment Ø piston / rod mm 140 / 80
Pilot control unit / working attachment / slewing gear Type VG 5 4/5 VG 5 4/4
Electrical system Type 1002

Starter V / kW 24 / 5,4
Slewing gear mechanism Type 1002

Max. slewing speed rpm 9,0
Slewing gear brake Type Wet multi-disc brake (ne-
gative)
Transmission Type 1002

Gearbox Type 2 HL 290
Oil motor Type DMVA 165
Travel speed in creeper / off-road / on-road gear km/h 2.5 / 5.0 / 20.0
Parking brake Type Wet multi-disc brake (ne-
gative)
Axles Type 1002

Steering axle Type MS-E 3060
Rigid axle Type MT-E 3060
3.11.2 A 900 C-LI EDC 24677-

copyright by
MJFCIFSS
A 900 C Litronic
Axles Type 1002

Oil volume in steering axle wheel hub l 2 x 2.5
Oil volume in rigid axle housing l 12.5
Oil volume in rigid axle wheel hub l 2.5
Rigid axle working brake Type Multi-disc brake
Tyres inch 10.00 - 20
18.00 19.5
Steering Type 1002

Flow l/min 38
Brake system Type 1002

Max. flow l/min 2.7
Central lubrication system Type 1002

Volume of grease per working hour cm3 3.5
Number of cycles / lubrication with semi-automatic lubrication system 2
A 900 C-LI EDC 24677- 3.11.3

copyright by
MJFCIFSS
A 900 C Litronic
3.11.4 A 900 C-LI EDC 24677-

copyright by
MJFCIFSS
A 904 C Litronic
Technical data
1 A 904 C Litronic
Type 439 / 440 Ind. / 441 Bau

439 / 2- 440 Ind. / 441 Cstr. /
General
point 4-point 4-point
Weight of basic machine t 14.6 16.4 16.0
Weight of backhoe bucket attachment t 18.8 20.6 20.0
Overall length (with blade support) mm 4755 4755 4755
Overall width mm 2550 2550 2550
Overall height without attachment mm 3160 3160 3160
Rear reach from centre/slewing radius mm 2455 / 2485 2455 / 2485 2455 / 2485
Ground clearance mm 350 350 350
Break-out force at tooth KN 120 / 126 120 / 126 120 / 126
Max. drawing pull (in offroad gear and max. operating pres- KN 100 100 100
sure)
439 / 2- 440 Ind. / 441 Cstr. /

Drive motor
Type D 924 TI E A2
Rated speed min-1 2000
Max. torque Nm 730 ± 10
at 1000 min-1
439 / 2- 440 Ind. / 441 Cstr. /

Hydraulic system
Hydraulic pump Type DPVO 165
Design Axial piston swash plate pump
Max. flow l/min 330
A 904 C-LI 16000- 3.14.1

copyright by
MJFCIFSS
A 904 C Litronic
439 / 2- 440 Ind. / 441 Cstr. /

Hydraulic system
Boom cylinder (adjustable and gooseneck equipment) 135 / 85
Ø piston / rod
Stick cylinder with adjustable equipment 130 / 85
Ø piston / rod
Bucket cylinder 120 / 80
Ø piston / rod
Support cylinder with outrigger blade support 120 / 70 - 100 / 50
Ø piston / rod
Regulating cylinder with adjustment 140 / 80
Ø piston / rod
Max. flow / fan drive (cooling) l/min 48.5
,
439 / 2- 440 Ind. / 441 Cstr. /

Electrical system
439 / 2- 440 Ind. / 441 Cstr. /

Slewing gear mechanism
Max. slewing speed min-1 9.0
Slewing gear brake Type Wet multi-disc brake (negative)
439 / 2- 440 Ind. / 441 Cstr. /

Transmission
Gearbox 2 HL 100
Oil motor LMV 100
Travel speed in creeper / offroad / on-road gear 2.5 / 5.0 / 20.0
Oil volume in gearbox 3.3
3.14.2 A 904 C-LI 16000-

copyright by
MJFCIFSS
A 904 C Litronic
439 / 2- 440 Ind. / 441 Cstr. /

Transmission
Parking brake Wet multi-disc brake (negative)
439 / 2- 440 Ind. / 441 Cstr. /

Axles
Steering axle Type APL - B 765 APL-B 765 APL - B 765
Rigid axle Type AP B 765 AP-B 765 AP-B 765
TR
Oil volume in steering axle wheel hub 2 x 2.0
Oil volume in rigid axle housing l 12.0 12.5 12.5
Oil volume in rigid axle wheel hub l 2 x 1.7 2 x 2.0 2 x 2.0
Oil quality/oil viscosity and oil change intervals l see groups 1.50 and 3.30
Rigid axle working brake Type Drum brake Multi-disc Multi-disc
brake brake
Tyres inch 10.00 - 20 10.00-20 10.00-20
18.00 19.5 11.00-20 11.00-20
18.00-19.5 18.00-19.5
439 / 2- 440 Ind. / 441 Cstr. /

Steering
Flow l/min 40
439 / 2- 440 Ind. / 441 Cstr. /

Brake system
Max. flow l/min 5.1
439 / 2- 440 Ind. / 441 Cstr. /

Central lubrication system
Number of cycles / grease processes with automatic greasing (opti- 2
onal)
A 904 C-LI 16000- 3.14.3

copyright by
MJFCIFSS
A 904 C Litronic
3.14.4 A 904 C-LI 16000-

copyright by
MJFCIFSS
A 904 C Litronic
Technical data
1 A 904 C Litronic
Type: 1003 / 1004 / 1005 / 1071

General
Type 1003 1004 1005 1071
version 2-point 4-point 4-point 4-point
from serial number 30580 30802 30581 30713
Weight of basic machine t 14.8 19.6 16.3 17.0
Weight with backhoe bucket/industrial support t 19.2 24.3 20.7 21.5
Overall length (with blade) industrial 4-point support mm 4755 5030 5350 4980
Overall width mm 2550 2750 2550 2550
Overall height without attachment mm 3160 3160 3160 variable
Rear reach from centre/slewing radius mm 2470 / 2470 / 2470 / 2470 /
2515 2515 2515 2515
Ground clearance mm 350 350 350 350
Max. break-out force at tooth kN 95 / 138 120 / 126 95 / 138 120 / 126
Max. drawing pull (in off-road gear and max. opera- kN 117 117 117 117
ting pressure)
Drive motor 1003 1004 1005 1071

2-point 4-point 4-point 4-point
Type D934 S A6
at 1500 rpm
Oil volume in engine (filling quantity at oil change l 29
with filter)
Hydraulic system 1003 1004 1005 1071

Hydraulic pump Type DPVP 108
Max. flow l/min 378
A 904 C-LI EDC 30580- 3.15.1

copyright by
MJFCIFSS
A 904 C Litronic
Hydraulic system 1003 1004 1005 1071

Boom cylinder (adjustable and gooseneck equipment)
Ø piston / rod 135 / 85
Stick cylinder with adjustable attachment Ø piston / rod 135 / 85 115 / 75 135 / 85 135 / 85
Bucket cylinder Ø piston / rod 120 / 80
Support cylinder with outrigger blade support 120 / 70 130 / 80 120 / 70 120 / 70
Ø piston / rod 100 / 60 110 / 60 100 / 60 100 / 60
Regulating cylinder with boom attachment Ø piston / rod 140 / 80
Electrical system 1003 1004 1005 1071

Slewing gear mechanism 1003 1004 1005 1071

Max. slewing speed rpm 9.0
Transmission 1003 1004 1005 1071

Gearbox 2 HL 290
Oil motor DMVA 165
Travel speed in creeper / off-road / on-road gear 2.5 / 5.0 / 20.0
3.15.2 A 904 C-LI EDC 30580-

copyright by
MJFCIFSS
A 904 C Litronic
Transmission 1003 1004 1005 1071

Axles 1003 1004 1005 1071

Oil volume in steering axle housing l 9.6 11.0 9.6 9.6
Oil volume in rigid axle housing l 13.1 14.5 13.1 13.1
Oil volume in rigid axle wheel hub l 2 x 2.0 2 x 2.5 2 x 2.0 2 x 2.0
Tyres inch 10.00 - 20 10.00-20 10.00-20 10.00-20
18.00 19.5 11.00-20 11.00-20 11.00-20
18.00-19.5 18.00-19.5 18.00-19.5
Steering 1003 1004 1005 1071

Flow l/min 38
Brake system 1003 1004 1005 1071

Max. flow l/min 2.7
Central lubrication system 1003 1004 1005 1071

Number of cycles / grease processes with automatic greasing 2
(optional)
A 904 C-LI EDC 30580- 3.15.3

copyright by
MJFCIFSS
A 904 C Litronic
Central lubrication system 1003 1004 1005 1071

3.15.4 A 904 C-LI EDC 30580-

copyright by
MJFCIFSS
A 914 C Litronic
Technical data
1 A 914 C Litronic
Type: 1044 / 1045 Construction

General
Type 1044 1045
Model 2-point 4-point
from serial number 35112 35112
Weight of basic machine with backhoe bucket t approx. 21.1 approx. 22.6
Overall length 2-point / 4-point mm 4350 4980
Overall height without attachment mm 3200 3200
Rear reach from centre/slewing radius mm 2690 /2765 2690 /2765
Max. break-out force at tooth kN 123 / 158 123 / 158
Max. drawing pull (in off-road gear and max. opera- kN 130 130
ting pressure)
Drive motor 1044 1045

2-point 4-point
Type D934 S A6
at 1500 rpm
with filter)
Hydraulic system 1044 1045

2-point 4-point
Max. flow l/min 2X215
Hydraulic oil volume (oil change with filter) l max. 430
Pilot plate Type VT5 25/18
3.16.1
copyright by
MJFCIFSS
A 914 C Litronic

2-point 4-point
Ø piston / rod 135 / 85 150 / 90
Stick cylinder with adjustable attachment Ø piston / rod 125 / 85 135 / 85 140 / 95 150 / 90
Support cylinder with outrigger blade support
Ø piston / rod 120 / 70 100 / 60
Electrical system 1044 1045

2-point 4-point
Slewing gear mechanism 1044 1045

2-point 4-point
Oil motor Type HMF 75-2P
Transmission 1044 1045

2-point 4-point
Gearbox 2 HL 290
Oil motor DMVA 165
3.16.2
copyright by
MJFCIFSS
A 914 C Litronic

2-point 4-point
Axles 1044 1045

2-point 4-point
Oil volume in rigid axle wheel hub l 2 x 2.0 2 x 2.5 2 x 2.0 2 x 2.0
Tyres inch 10.00-20
11.00-20
18.00-19.5
Steering 1044 1045

2-point 4-point
Flow l/min 38
Brake system 1044 1045

2-point 4-point
Max. flow l/min 2.7
central lubrication system 1044 1045

2-point 4-point
(optional)
3.16.3
copyright by
MJFCIFSS
A 914 C Litronic
3.16.4
copyright by
MJFCIFSS
A 924 C Litronic
Technical data
1 A 924 C Litronic
Type: 1047 Construction / 1048 Construction / 1049 Industry

General
Type 1047 1048 1049
Model 2-point 4-point 4-point
from serial number 34519 34519 34519
Weight with backhoe bucket/industrial support t 21.3 - 23.5 23.1 - 25.3
Overall length (with blade) industrial 4-point support mm 5350 4980 4980
Overall width mm 2750 2750 2750
Overall height without attachment mm 3215 3215 3215
Rear reach from centre/slewing radius mm 2730/2810 2730/2810 2730/2810
Ground clearance mm 360 360 360
Max. break-out force at tooth kN 122 / 158 122 / 158 122 / 158
Max. drawing pull (in off-road gear and max. opera- kN 150 150 150
ting pressure)
Drive motor 1047 1048 1049

2-point 4-point 4-point
Type D934 L A6
at 1500 rpm
with filter)
Hydraulic system 1047 1048 1049

Max. flow l/min 2 x 215
Pilot plate Type VT5-VW 25/18
3.17.1
copyright by
MJFCIFSS
A 924 C Litronic
Hydraulic system 1047 1048 1049

Ø piston / rod 140 / 90 140 / 95 150 / 90
Stick cylinder with adjustable attachment Ø piston / rod 125 / 85
Bucket cylinder Ø piston / rod 125 / 70 125 / 80 125 / 85
Ø piston / rod 100 / 60 130 / 80 140 / 85 130 / 80
Electrical system 1047 1048 1049

Slewing gear mechanism 1047 1048 1049

Oil motor Type HMF 75-2P
Transmission 1047 1048 1049

Gearbox 2 HL 290
Oil motor DMVA 165
Travel speed in creeper / off-road / on-road gear 2.5 / 5.0 / 20.,0
3.17.2
copyright by
MJFCIFSS
A 924 C Litronic
Transmission 1047 1048 1049

Axles 1047 1048 1049

Oil volume in rigid axle wheel hub l 2 x 2.5
Tyres inch 10.00-20
11.00-20
18.00-19.5
Steering 1047 1048 1049

Flow l/min 38
Brake system 1047 1048 1049

Max. flow l/min 2.7
central lubrication system 1047 1048 1049

(optional)
3.17.3
copyright by
MJFCIFSS
A 924 C Litronic
3.17.4
copyright by
MJFCIFSS
A 924 C Litronic
Technical data
1 A 924 C Litronic
Type: 1050 HD with blade (wood grapple) / 1051 HD, 4-point

General
Type 1050 1051
Model HD with blade HD with 4-point
Weight with backhoe bucket/industrial support t 24.8 26.6
Overall length (with blade) industrial 4-point support mm 5350 4980
Overall height without attachment mm 3215 3215
Rear reach from centre/slewing radius mm 2730/2810 2730/2810
Max. break-out force at tooth kN 122/158 122/158
Max. drawing pull (in off-road gear and max. opera- kN 150 150
ting pressure)
Drive motor 1050 1051

HD with blade HD with 4-point
Type D934 S A6
at 1500 rpm
with filter)

Max. flow l/min 2 x 215
Pilot plate Type VT5-VW 25/18
3.18.1
copyright by
MJFCIFSS
A 924 C Litronic

Ø piston / rod 135 / 85 150 / 90
Stick cylinder with adjustable attachment Ø piston / rod 125 / 85 135 / 85
Ø piston / rod 120 / 70 100 / 60
Electrical system 1050 1051

Slewing gear mechanism 1050 1051

Oil motor Type HMF75-2P

Gearbox 2 HL 290
Oil motor DMVA 165
3.18.2
copyright by
MJFCIFSS
A 924 C Litronic

Axles 1050 1051

Steering axle Type LT 71PL477 NLB
Rigid axle Type LT 71PL477 NLB
Oil volume in rigid axle wheel hub l 2 x 3.0
Tyres inch 10.00-20
11.00-20
18.00-19.5
Steering 1050 1051

Flow l/min 38
Brake system 1050 1051

Max. flow l/min 2.7
central lubrication system 1050 1051

(optional)
3.18.3
copyright by
MJFCIFSS
A 924 C Litronic
3.18.4
copyright by
MJFCIFSS
Service Manual Maintenance and inspection schedule
A 900 C Litronic from serial no. 14675
Maintenance and inspection schedule
1 A 900 C Litronic from serial no. 14675
Type 917 / 987 HD

Customer: ......................... ID no.: ................... Date: ................
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/
WORK TO BE CARRIED OUT
inspection at
A 900 C 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)
Check and clean cooler, pressure relief valve, coolant hose and fan
Check ribbed V-belts
Replace lubricating oil filter cartridge
A 900 C-LI 14675- 3.20.1

copyright by
MJFCIFSS
Maintenance and inspection schedule Service Manual
Maintenance/
inspection at
A 900 C Litronic
operating hours

(machine operator)
Change engine oil 1)
Check oil, coolant and fuel systems for leakage
Replace water filter cartridge (at least 1 x every 12 months)
Check corrosion inhibitor and antifreeze agent in coolant (change coolant eve-
ry 2 years)
Check intake and exhaust system for leakage (first time after 500 op. hours)
Check and adjust speed adjustment
Check / readjust valve play
Check motor brackets and oil pan for proper mounting
Check flame glow unit (before start of winter season)
Replace cartridge of the fuel fine filter (shorten interval, if necessary) 4)
Replace cartridge of the fuel prefilter (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)
Replace oil separator (every 2 years or 3000 op.hours)
Check / adjust injection nozzle (every 3000 op. hours or upon drop in power)
DIESEL ENGINE - EXHAUST GAS SYSTEM WITH PARTICLE FILTER (optional equipment)
Drain off condensate at the condensate trap.
Condensate trap: check and clean sintered metal filter, check connecting
clamps for proper seat.
Condensate trap: replace sintered metal filter.
Clean particle filter and pre-filter; if required, clean before prescribed interval
has lapsed.
HYDRAULIC SYSTEM
Check oil level in hydraulic tank
Clean magnetic rod in return filter (daily during first 300 op. hours)
Replace return filter cartridge (first time after 500 op. hours) 2)
3.20.2 A 900 C-LI 14675-

copyright by
MJFCIFSS
Maintenance/
inspection at
A 900 C Litronic
operating hours

(machine operator)
Replace filter cartridge in control oil unit
Check components for proper mounting
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
Check / readjust servo, primary and secondary pressures
Change hydraulic oil in tank (optimise interval by carrying out oil analyses) 2), 3)
Replace breather filter on hydraulic tank 2)
Renew filter element in the partial flow filter (option) (every 250 operating hours 2)
for inserts that collect a lot of dust).
ELECTRICAL SYSTEM
Check indicator lights and indicating devices upon startup

Check lighting
Check acid density and level, wire terminals and terminal ports of the batteries
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 op. hours)
SLEWING RING
Check mounting bolts for press fit; slewing gear pining meshing
A 900 C-LI 14675- 3.20.3

copyright by
MJFCIFSS
Maintenance/
inspection at
A 900 C Litronic
operating hours

(machine operator)
TRANSMISSION
Carry out functional test of powershift mechanism and parking brake
Check gearbox, oil motor and joint shafts for proper mounting
AXLES
Check wheel lugs for proper fit
Check axles for proper mounting
Lubricate steering knuckle bearings and oscillating bolt (weekly - monthly ac-
cording to use)
Change oil in axle housing and planetary drives (front and rear) (first time after
500 op. hours)
If travel accounts for more than 30 % of the total operating hours:

Change oil in axle housing (front and rear) (first time after 500 op. hours)
Change oil in planetary drive (front and rear)
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 cylinders for proper mounting
BRAKE SYSTEM
Check system for leakage; check accumulator and brake pressure as well as
check switch
3.20.4 A 900 C-LI 14675-

copyright by
MJFCIFSS
Maintenance/
inspection at
A 900 C Litronic
operating hours

(machine operator)
Carry out functional test
OPERATOR'S CAB + HEATING
Check / add detergent solution in windscreen washer tank
Carry out functional test of heating system (before start of winter season)
Check heating system for leakage

Check door and window hinges as well as locks
Treat rubber seals of the operators cab with silicone or talcum
Treat rubber seals of the covers on the uppercarriage with silicone or talcum
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
Clean recirculated air / fresh air filter; replace, if necessary; shorten interval if
there is excessive generation of dust
Check compressor mounting bolts and drive belts
Check dryer-collector unit (humidity, fill level); replace, if necessary
Check evaporator unit; clean, if necessary
Check electrical lines for chafe marks; check plug connections
Complete functional test of excess pressure switch

Check cooling performance after opening/repair, or if required
Replace dryer-collector unit every 12 months; also check cooling circuit for lea-
kage and change coolant and refrigeration oil
Every 12 months, contract a refrigeration technician to carry out a functional

test of the air flaps and the defrost thermostat
UNDERCARRIAGE + UPPERCARRIAGE + WORKING ATTACHMENTS
Inspect teeth for wear
Lubricate bearing positions through central lubrication point
A 900 C-LI 14675- 3.20.5

copyright by
MJFCIFSS
Maintenance/
inspection at
A 900 C Litronic
operating hours

(machine operator)
Lubricate bearing positions (undercarriage and working attachments)

(depending on use and shift operation, lubricate daily)
Check parts for cracks
Check counter weight and tank for proper mounting
Check lines and screwed connections for proper fit
Check panelling hinges, quick fasteners and gas pressure springs of the caps
Instruct operators in the proper use of the equipment
Have machine lubricated according to lubrication chart and checked for oper-
ating errors by machine operator
HYDRAULIC QUICK CHANGE ADAPTER
Carry out a functional test of the visual and acoustic warning systems
Carry out a visual inspection of the extended locking bolts
Check hydraulic hoses and wire harness

Lubricate locking bolts
Clean mesh filter
MECHANICAL QUICK CHANGE ADAPTER
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
3.20.6 A 900 C-LI 14675-

copyright by
MJFCIFSS
Date: ................................. Mechanic: ................................. Customer: ............................
A 900 C-LI 14675- 3.20.7

copyright by
MJFCIFSS
3.20.8 A 900 C-LI 14675-

copyright by
MJFCIFSS
Type 1002
Note!
Therefore clean the machine thoroughly before starting any maintenance work (see also chapter
"Safe maintenance of machine", subchapters "Cleaning" and "Crack inspection").
Note!
gear brake, working brake, parking brake), the steering, the electrical and the hydraulic systems.
Also to be carried out is a daily visual inspection of the motor, hydraulic system, gearbox and axles
for leakage.
Ins
Maintenance/inspection at WORK TO BE CARRIED OUT

operating hours A 900 C Litronic, type 1002
by maintenance personnel together with authorised specialist

(machine operator) technicians
Initial and single interval
Annually, at the start of the cold season Repeat interval
when required
DIESEL ENGINE
Check the oil level
Visual inspection (leakage, dirt, damage)
Check flap of diesel engine brake

1) Change diesel engine oil
Change oil filter insert (at least once a year)
Check batteries and cable connections

Belt drive: check belt; replace, if necessary / V-ribbed belt: check tension; adjust,
if necessary
Check intake and exhaust systems for general condition, fixture and leakage
Grease the flywheel ring gear
A 900 C-LI EDC 24677- 3.21.1

copyright by
MJFCIFSS


when required
Replace filter insert at the crankcase ventilation
Check oil pan, engine bearings and diesel engine support for proper fixture
Check heating flange

3000 Check vibration dampers for deformation
RADIATOR
Check coolant level
Check cooling and heating systems for general condition and leakage
Check corrosion inhibitor and antifreeze agent concentration in coolant

3000 Change coolant (at least every 2 years)
FUEL SYSTEM
Check water separator at the fuel pre-filter and drain off water, if necessary
Drain water and deposit from fuel tank
4) Check fuel system for leakage and general state
4) Change fuel pre-filter (also in the event of a drop in performance)
Change fuel fine filter
Bleed fuel system
AIR FILTER
Check underpressure indicator of the air filter
Clean dust removal valve of the air filter
Change main element of the dry air filter (according to maintenance indication /
annually)
Change safety element of the dry air filter (at every third main element change /
annually) - do not clean or reuse!
Drain off condensate at the condensate trap
3.21.2 A 900 C-LI EDC 24677-

copyright by
MJFCIFSS


when required
Condensate trap: check and clean sintered metal filter, check connecting clamps
for proper seat
Condensate trap: replace sintered metal filter
Clean particle filter and pre-filter; if required, clean before prescribed interval has
lapsed
ELECTRICAL SYSTEM OF THE DIESEL ENGINE
Check control device bearing for general condition
Check sensor devices and cable connections
HYDRAULIC SYSTEM
Check degree of contamination of the bypass oil filter (special equipment); if re-
quired, change filter element
Clean magnetic rod in return filter (daily during first 300 operating hours)
2) Replace filter insert in return filter
Check the hydraulic oil cooler for dirt; clean it, if necessary
(max. permissible water content for environmentally friendly fluids: 0.1 %; insert
bypass filter, take oil sample)

2), 3) Change hydraulic oil in tank (optimise interval by carrying out oil analyses)
2) Change breather filter on hydraulic tank
ELECTRICAL SYSTEM
Check indicator lights and indicating devices upon start-up
Check lighting
A 900 C-LI EDC 24677- 3.21.3

copyright by
MJFCIFSS


when required
Spray slip rings of the slewing gear connection with Cramolin contact spray

Change gear oil
SLEWING RING
TRANSMISSION
Carry out functional test of power shift mechanism and parking brake
Change gear oil
AXLES
Lubricate steering knuckle bearing and oscillating bolts (weekly or monthly, de-
pending on use)

(In new machines: first time after 50, 100 and then 250 operating hours, and after
each wheel change or loosening of the wheel lugs)
Check fixture of the axles and oscillating axle bearing
pending on use)
Change oil in the axle housing and the planetary drive (front and rear)

Change oil in the axle housing (front and rear)
3.21.4 A 900 C-LI EDC 24677-

copyright by
MJFCIFSS


when required
Check the multi-disc brake for wear (once a year; shorten interval, if necessary)
STEERING
BRAKE SYSTEM
check switch
Check function of heating
Treat rubber seals of the operator's cab with silicone or talcum powder
Treat rubber seals of the access doors in the uppercarriage with silicone or talcum
powder
Check water inlet valve for contamination, and clean, if necessary; carry out func-
tional test of valve
Regularly switch on air-conditioning system (at least 1x every 14 days)
Clean re-circulated air / fresh air filter; replace, if necessary; shorten interval if
A 900 C-LI EDC 24677- 3.21.5

copyright by
MJFCIFSS


when required
Check cooling performance
Replace dryer-collector unit every 12 months; also check cooling circuit for leak-
age and change coolant and refrigeration oil
Every 12 months, employ a refrigeration technician to carry out a functional test of

the air flaps and the defrost thermostat
Lubricate bearing points, using the semi-automatic central lubrication system; ex-
ception: not required in units with fully automatic central lubrication system (op-
tional equipment)
Lubricate daily when required due to type of use and/or shift operation

250 Check parts for cracks
250 Check counter weight and tank for proper mounting

Instruct the operator on how the machine must be lubricated according to the lu-
bricating chart and make him aware of potential operator errors
3.21.6 A 900 C-LI EDC 24677-

copyright by
MJFCIFSS


when required
Clean mesh filter
HYDRAULIC COUPLING / ELECTRIC COUPLING
Clean and check wear parts; replace, if necessary
GENERAL
Check the entire machine to ensure that it is properly maintained and in safe work-
ing order
Explain the machine documentation (in particular the operating manual and safety
instructions) to the operating personnel
Note:
and oil quality.
group 1.50.
Comments / defects
A 900 C-LI EDC 24677- 3.21.7

copyright by
MJFCIFSS
Date: ................................ Mechanic: ................................ Customer: .................................
3.21.8 A 900 C-LI EDC 24677-

copyright by
MJFCIFSS
Type 439 / 440 / 441

Customer: .................... ID no.: .................. Date: ......................
Machine type: .................... Operating hours: .......................
Caution!
1.10 "Save maintenance of machine", subchapters "Cleaning" and "Crack inspection").
Note!
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 904 C Litronic
operating hours

(machine operator)
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)
Check and clean cooler, pressure relief valve, coolant hose and fan
Check ribbed V-belts
Replace lubricating oil filter cartridge
A 904 C-LI 16000- 3.24.1

copyright by
MJFCIFSS
Maintenance/
inspection at
A 904 C Litronic
operating hours

(machine operator)
Change engine oil 1)
Check oil, coolant and fuel systems for leakage
Replace water filter cartridge (at least 1 x every 12 months)
Check corrosion inhibitor and antifreeze agent in coolant (change coolant eve-
ry 2 years)
Check intake and exhaust system for leakage (first time after 500 op. hours)
Check and adjust speed adjustment
Check motor brackets and oil pan for proper mounting
Check flame glow unit (before start of winter season)
Replace cartridge of the fuel fine filter (shorten interval, if necessary) 4)
Replace cartridge of the fuel prefilter (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)
Replace oil separator (every 2 years or 3000 op.hours)
Check / adjust injection nozzle (every 3000 op. hours or upon drop in power)
Drain off condensate at the condensate trap.
Condensate trap: check and clean sintered metal filter, check connecting
clamps for proper seat.
Condensate trap: replace sintered metal filter.
Clean particle filter and pre-filter; if required, clean before prescribed interval
has lapsed.
HYDRAULIC SYSTEM
Clean magnetic rod in return filter (daily during first 300 op. hours)
Replace return filter cartridge (first time after 500 op. hours) 2)
3.24.2 A 904 C-LI 16000-

copyright by
MJFCIFSS
Maintenance/
inspection at
A 904 C Litronic
operating hours

(machine operator)
Clean hydraulic oil cooler (shorten interval, if necessary)

(max. permissible water content for environmentally friendly fluids: 0.1 %; in-
sert bypass filter, take oil sample)
Change hydraulic oil in tank (optimise interval by carrying out oil analyses) 2), 3)
Replace breather filter on hydraulic tank 2)
Renew filter element in the partial flow filter (option) (every 250 operating hours 2)
for inserts that collect a lot of dust).
ELECTRICAL SYSTEM
Check indicator lights and indicating devices upon startup

Check lighting
Spray slip rights of the slewing gear connection with Cramolin contact spray

SLEWING RING
A 904 C-LI 16000- 3.24.3

copyright by
MJFCIFSS
Maintenance/
inspection at
A 904 C Litronic
operating hours

(machine operator)
TRANSMISSION
Carry out functional test of powershift mechanism and parking brake
AXLES
Check axles for proper mounting
Lubricate steering knuckle bearings and oscillating bolt (weekly - monthly ac-
cording to use)
Change oil in axle housing and planetary drives (front and rear) (first time after
500 op. hours)

Change oil in axle housing (front and rear) (first time after 500 op. hours)
STEERING
BRAKE SYSTEM
check switch
3.24.4 A 904 C-LI 16000-

copyright by
MJFCIFSS
Maintenance/
inspection at
A 904 C Litronic
operating hours

(machine operator)
Carry out functional test of heating system (before start of winter season)

Regularly switch on air-conditioning system (at least 1 x every 14 days)
Clean recirculated air / fresh air filter; replace, if necessary; shorten interval if
Check dryer-collector unit (humidity, fill level); replace, if

necessary
Check electrical lines for chafe marks; check plug

connections
Check cooling performance after opening/repair, or if required
Replace dryer-collector unit every 12 months; also check cooling circuit for lea-
kage and change coolant and refrigeration oil
Every 12 months, contract a refrigeration technician to carry out a functional

test of the air flaps and the defrost thermostat
A 904 C-LI 16000- 3.24.5

copyright by
MJFCIFSS
Maintenance/
inspection at
A 904 C Litronic
operating hours

(machine operator)
Lubricate bearing positions through central lubrication point

(depending on use and shift operation, lubricate daily)
Check parts for cracks
Check counter weight and tank for proper mounting
Check panelling hinges, quick fasteners and gas pressure springs of the
caps
Have machine lubricated according to lubrication chart and checked for oper-
ating errors by machine operator
Clean mesh filter
Tab. 1 Inspection and maintenance schedule
Note:
group 1.50.
3.24.6 A 904 C-LI 16000-

copyright by
MJFCIFSS
Comments / defects
Date: ................................. ............................... ................................
A 904 C-LI 16000- 3.24.7

copyright by
MJFCIFSS
3.24.8 A 904 C-LI 16000-

copyright by
MJFCIFSS
Type: 1003 / 1004 / 1005 / 1071

Note!
Note!
for leakage.

operating hours A 904 C Litronic, type 1003 / 1004 / 1005 / 1071

Initial and single interval Initial and single interval
Repeat interval Repeat interval
Annually, at the start of the cold season
when required
DIESEL ENGINE
Check the oil level
Check oil level in pump distributor gear
Replace gear oil in pump distribution gear

if necessary
3.25.1
copyright by
MJFCIFSS


when required

RADIATOR
Check coolant level

FUEL SYSTEM

4) Change fuel pre-filter (also in the event of a drop in performance)
Bleed fuel system
AIR FILTER
annually)
3.25.2
copyright by
MJFCIFSS


when required
for proper seat

lapsed
HYDRAULIC SYSTEM

Check degree of contamination of the bypass oil filter (special equipment); if re-
quired, change filter element


3.25.3
copyright by
MJFCIFSS


when required
ELECTRICAL SYSTEM
Check lighting
Change gear oil
SLEWING RING
TRANSMISSION
Change gear oil
AXLES
pending on use)

3.25.4
copyright by
MJFCIFSS


when required
pending on use)

STEERING
BRAKE SYSTEM
check switch
Treat rubber seals of the operator's cab with silicone or talcum powder
Treat rubber seals of the access doors in the uppercarriage with silicone or talcum
powder
Check water inlet valve for contamination, and clean, if necessary; carry out func-
tional test of valve
3.25.5
copyright by
MJFCIFSS


when required
Replace dryer-collector unit every 12 months; also check cooling circuit for leak-
age and change coolant and refrigeration oil

Lubricate bearing points, using the semi-automatic central lubrication system; ex-
ception: not required in units with fully automatic central lubrication system (op-
tional equipment)


Instruct the operator on how the machine must be lubricated according to the lu-
bricating chart and make him aware of potential operator errors
3.25.6
copyright by
MJFCIFSS


when required

Clean mesh filter
GENERAL
ing order
Note:
and oil quality.
group 1.50.
Comments / defects
3.25.7
copyright by
MJFCIFSS
Date: ............................ Mechanic: ................................. Customer: .................................
3.25.8
copyright by
MJFCIFSS
A 914 C / A 924 C Litronic from serial no. 34519
1 A 914 C / A 924 C Litronic from serial no. 34519
Typ: 1044 / 1045 / 1047 / 1048 / 1049 / 1050 / 1051

Note!
Note!
for leakage.

operating hours A 914 C Litronic, Typ 1044 / 1045
A 924 C Litronic, Typ 1047 / 1048 / 1049 / 1050 / 1051
by maintenance personnel with authorised specialist

(machine operator) technician
when required
DIESEL ENGINE
Check the oil level
Check oil level in pump distributor gear
Replace gear oil in pump distribution gear

3.27.1
copyright by
MJFCIFSS

A 924 C Litronic, Typ 1047 / 1048 / 1049 / 1050 / 1051

when required
if necessary

RADIATOR
Check the coolant level

FUEL SYSTEM

4) Change fuel pre-filter (or in the event of a drop in performance)
Bleed fuel system
AIR FILTER
annually)
3.27.2
copyright by
MJFCIFSS

A 924 C Litronic, Typ 1047 / 1048 / 1049 / 1050 / 1051

when required

for proper seat
lapsed
HYDRAULIC SYSTEM
Check degree of contamination of the bypass oil filter (special equipment); if

required, change filter element


3.27.3
copyright by
MJFCIFSS

A 924 C Litronic, Typ 1047 / 1048 / 1049 / 1050 / 1051

when required
ELECTRICAL SYSTEM
Check lighting
Change gear oil
SLEWING RING
TRANSMISSION
Change gear oil
AXLES
Lubricate steering knuckle bearing and oscillating bolts (weekly or monthly,

depending on use)

3.27.4
copyright by
MJFCIFSS

A 924 C Litronic, Typ 1047 / 1048 / 1049 / 1050 / 1051

when required
Lubricate steering knuckle bearing and oscillating bolts (weekly or monthly,

depending on use)

STEERING
BRAKE SYSTEM
check switch

3.27.5
copyright by
MJFCIFSS

A 924 C Litronic, Typ 1047 / 1048 / 1049 / 1050 / 1051

when required
Replace dryer-collector unit every 12 months; also check cooling circuit for
leakage and change coolant and refrigeration oil

Lubricate bearing points, using the semi-automatic central lubrication system;

exception: not required in units with fully automatic central lubrication system
(optional equipment)
Check grease container of the central lubricating system, refill if necessary


3.27.6
copyright by
MJFCIFSS

A 924 C Litronic, Typ 1047 / 1048 / 1049 / 1050 / 1051

when required
Instruct the operator on how the machine must be lubricated according to the
lubricating chart and make him aware of potential operator errors
Clean mesh filter
GENERAL
ing order
Note:
and oil quality.
group 1.50.
Comments / defects
3.27.7
copyright by
MJFCIFSS
Date: ............................ Mechanic: ................................. Customer: .................................
3.27.8
copyright by
MJFCIFSS
Service Manual Lubricating charts
Lubricating charts
3.30.1
copyright by
MJFCIFSS
Lubricating charts Service Manual
Fig. 1 Lubricating chart for A900 C Litronic from serial no. 14675
3.30.2
copyright by
MJFCIFSS
Volume
Symbol Description
(litre)*
Diesel engine 23.0
Hydraulic tank 210
Slewing gear mechanism 5.0
Transmission 3.3
Rigid axle with multi-disc brake 12.5
Rigid axle with drum brake 12.0
Wheel hub of rigid axle with multi-disc brake 2.0 each
Wheel hub of rigid axle with drum brake 1.7
Steering axle 10.5
Steering axle wheel hub 2.0 each
General lube points
Check oil level
Oil change
First oil change
Lubricate
Operators manual
Tab. 1 Index to lubricating chart
* = approximate values
3.30.3
copyright by
MJFCIFSS
Fig. 2 Lubricating chart for A 900 C Litronic from serial no. 24677
3.30.4
copyright by
MJFCIFSS
Volume
Symbol Description
(litre)*
Diesel engine 28.5
Hydraulic tank 210
Transmission 3.0
Steering axle 9.5
General lube points
Check oil level
Oil change
First oil change
Lubricate
Operators manual
3.30.5
copyright by
MJFCIFSS
3.30.6
copyright by
MJFCIFSS
Volume
Symbol Description
(litre)*
Diesel engine 23.0
Hydraulic tank 210
Transmission 3.3
Rigid axle with drum brake 12.0
Wheel hub of rigid axle with drum brake 1.7
Steering axle 10.5
General lube points
Check oil level
Oil change
First oil change
Lubricate
Operators manual
3.30.7
copyright by
MJFCIFSS
A 904 C Litronic Typ 1003/1005/1071 from serial no. 30580
4 A 904 C Litronic Typ 1003/1005/1071 from serial no. 30580
3.30.8
copyright by
MJFCIFSS
Symbol Description
Diesel engine
Hydraulic tank
Hydraulic oil
Slewing gear mechanism (as stop brake)
Slewing gear mechanism (as positioning slewing brake)
Transmission Gear oil
Rigid axle
Wheel hubs of the rigid axle
Steering axle
Wheel hubs of the steering axle
Pump distributor gear
Tracks and gearing of the slewing ring, bearing of the

equipment
Gearbox or axle, check oil level
Hydraulic tank, check oil level
Carry out first oil change
Change oil
Lubricate machine
Lube point
Medium filling point
Observe operator's manual
3.30.9
copyright by
MJFCIFSS
A 904 C Litronic Typ 1004 from serial no. 30580
5 A 904 C Litronic Typ 1004 from serial no. 30580
3.30.10
copyright by
MJFCIFSS
A 904 C Litronic Typ 1004 from serial no. 30580
Symbol Description
Diesel engine
Hydraulic tank
Hydraulic oil
Rigid axle
Steering axle

equipment
Change oil
Lubricate machine
Lube point
3.30.11
copyright by
MJFCIFSS
A 914 C Litronic Typ 1044/1045 from serial no. 35112
6 A 914 C Litronic Typ 1044/1045 from serial no. 35112
3.30.12
copyright by
MJFCIFSS
Symbol Description
Diesel engine
Hydraulic tank
Hydraulic oil
Rigid axle
Steering axle

equipment
Change oil
Lubricate machine
Lube point
3.30.13
copyright by
MJFCIFSS
7 A 924 C Litronic Typ 1047/1048/1049 from serial no. 34519
3.30.14
copyright by
MJFCIFSS
Symbol Description
Diesel engine
Hydraulic tank
Hydraulic oil
Rigid axle
Steering axle

equipment
Change oil
Lubricate machine
Lube point
3.30.15
copyright by
MJFCIFSS
8 A 924 C Litronic Typ 1050/1051 from serial no. 34519
3.30.16
copyright by
MJFCIFSS
Symbol Description
Diesel engine
Hydraulic tank
Hydraulic oil
Rigid axle
Steering axle

equipment
Change oil
Lubricate machine
Lube point
3.30.17
copyright by
MJFCIFSS
3.30.18
copyright by
MJFCIFSS
Service Manual Adjustment protocol V2.10
A 900 C Litronic from 14675
Adjustment protocol V2.10
1 A 900 C Litronic from 14675
1.1 Excavator control BST software version 2.10 - 2.12, 5.13.1, 5.14, 5.14.1
Date: ............................ Mechanic: ................................. Cust.: .................................
Type: ............................ Serial number: ................................. Operating hours: .................................
Measuring
Actual Possible View
Checks point
value setting Comment
Specified value
1. Basic settings
Data specific to equip-
1.1 ment A900C (A 900-1)
Model
1800 rpm ........... ..............
1.2 Regulating rpm
(2.10/2.12/5.13.1/5.14/1) 1890 +50rpm ........... .............
Max. speed
850 +100rpm ........... .............
Min. speed
147
1.3 Teeth ratio
2. Operating conditions
Warm up equipment
2.1 Oil temperature min. 50 +10°C ........... .............
A 900 C-LI 14675- 3.40.1

copyright by
MJFCIFSS
Adjustment protocol V2.10 Service Manual
Measuring
Checks point
Specified value
3. Pilot pressure Measuring point Mode P

49 ........... .............. Measure settings at valve 51.
32 ±1 bar
via adapter cable at Y50
4. Horsepower control Measuring point
59
4.1 Mode L/F
(2.10/2.12/5.13.1/5.14/1)
Current ........... ..............
Control pressure 400 +10 mA ........... ..............
5 ±1 bar
4.2 Mode E/P
(2.10/2.12/5.13.1/5.14/1)
Current ........... ..............
Control pressure 600 +30 mA ........... ..............
13 +3 bar
Remove plug of Y50.

Set valve to emergency setting.
4.3 Checking regulating (Remove cotter pin and actuate
pressure during emer- Measuring point ........... .............. lever.)
gency operation 59
6.5 ±0.5 bar
5. Check of Measuring point Measure using adapter cable

SF function Y51 57 atY51.
5.1 SF min.(Q. max)

100 to 300 mA Tank pressure
approx. 0.8 bar
5.2 SF min. to SF max.
300 to 760 mA Pressure: see ........... ..............
(Q.reduced) diagram
3.40.2 A 900 C-LI 14675-

copyright by
MJFCIFSS
Measuring
Checks point
Specified value
6. Hydraulic begin Measuring point Pre-select speed step 1. Discon-

of regulation of variable 41 nect plug connection at Y50 / Y51.
displacement pump Adjust setting at screw 23.2.1 of
(basic setting) the pump.
Secondary relief valve 50 +2 bar ........... ..............

262
(extend bucket cylinder)
Reduce to value below
begin of regulation and
turn it in again until the
actuating pressure at 44
begins to drop.
p at 59 = tankpressure
Re-connect Y50.
7. Adjusting the Measuring point Mode P, button SF not active (Y51

differential pressure 41 / 45 disconnected). Take readings bet-
( -p) with function "ex- 19 +1 bar ........... .............. ween MP and LS. Adjust at the
tend bucket cylinder" screw 2 of the pump.
Reduce the pressure set-
ting or set valve 262 to
100 -110 bar at measu-
ring point 41 - MP
p at 57 = tank pressure
Re-connect plug to Y51 . Delete

error codes E 027 / 036.
A 900 C-LI 14675- 3.40.3

copyright by
MJFCIFSS
Measuring
Checks point
Specified value
8. Checking output Insert service plug.

of diesel engine Pre-select speed - mode P.
(power test)
Note: Max. fan speed
This test should only be approx. 1600 rpm
carried out if you suspect Pull out plug (I = 0 mA).
problems (e.g. reduced (Not required from version 5.13.)
output of diesel engine).
Power test menu on the screen
Lower the pressure at the Measuring point (I LR = 100%) - do not change.
secondary pressure relief 41
valves 242 (extend stick
cylinder) and 262 (extend
bucket cylinder) below 140 bar ........... ..............
the test pressure in the
adjustment protocol.
Then increase the pres-
sure again to the test
pressure.
The rpm of the 1800 +10 rpm ........... ..............
diesel engine must never
drop below the rated
speed.
(Read rpm on < 10 bar ........... ..............
screen.) Difference
between measuring
points
41 - 44
8.1 Control pressure Measuring point

during power test 59
> 13 +3 bar ........... ..............
3.40.4 A 900 C-LI 14675-

copyright by
MJFCIFSS
Measuring
Checks point
Specified value
9. Primary pressure Measuring point Pre-select speed mode P valve

(safety valve) 41 105
400 +20 bar ........... .............
Set the secondary relief
valve 262
to a value above the ad-
justment pressure
105 and extend the bu-
cket
cylinder.
Turn out pressure cut-off
valve 104 until
pressure at gauge does
not increase anymore.
(response pressure 105)
10. Secondary pressure Measuring point 45 Mode P

Pressure cut-off valve
104 turned out
(not on block)
Note!
For special equipment (e.g. boom vertically and horizon-
tally adjustable), observe the instructions on the at-
tached information signs, which refer to a reduced
secondary pressure in the relevant control block sec-
tions.
The reduced pressure is generally around 200 bar.
10.1 Operational functions
-Extend boom cylinder 380 +20 bar ........... ..............

-Retract boom cylinder 380 +20 bar ........... .............. Valve 221
-Retract stick cylinder 380 +20 bar ........... .............. Valve 222
-Extend stick cylinder 380 +20 bar ........... .............. Valve 241
-Retract bucket cylinder 380 +20 bar ........... .............. Valve 242
-Extend bucket cylinder 380 +20 bar ........... .............. Valve 261
Valve 262
10.2 Travel functions
-Forward travel 380 +20 bar ........... ..............

-Reverse travel 380 +20 bar ........... .............. Valve 177
Valve 176
A 900 C-LI 14675- 3.40.5

copyright by
MJFCIFSS
Measuring
Checks point
Specified value
11. Operating pressure P Measuring point Mode P

(pressure cut-off) 41 ........... .............. Valve 104
350 +10 bar
3.40.6 A 900 C-LI 14675-

copyright by
MJFCIFSS
Measuring
Checks point
Specified value
12. Slewing gear function Measuring points

Secondary pressure 137/138 Valve125 raised.
12.1 Swivelling back
Turning right 137 Valve 134

260 +10 bar ........... .............. (high-pressure setting)
Lock nut 1
Adjusting screw 2
Turning left 138 Valve 135

Lock nut 1
Adjusting screw 2
12.2 Slowing down

120 ±5 bar ........... .............. (low-pressure setting)
Lock nut 3
Adjusting screw 4

120 ± 5 bar ........... .............. (low-pressure setting)
Lock nut 3
Adjusting screw 4
Note:
In machines with "optimised" slewing gear, differ-
ent pressure settings might apply!
Valves 134 / 135

A 900 C-LI 14675- 3.40.7
copyright by
MJFCIFSS
Measuring
Checks point
Specified value
13. Slewing gear function Adjust settings at valve 125

Primary pressure Measuring point
137 / 138
Turning left or 230 +10 bar ........... ..............

right
14. Travel motor Measuring point Adjusting screw 87.41

45 / M2 on travel motor 170
14.1 Regulation
Begin of regulation 190 bar ........... ..............
End of regulation 270 bar ........... ..............
3.40.8 A 900 C-LI 14675-

copyright by
MJFCIFSS
Measuring
Checks point
Specified value
14.2 Output speed Spool 160

(speed) on drive shaft, measured in on-
road gear
Standard machine 1875 ±25rpm ........... ..............
Speeder machine 2700 ±25rpm ........... ..............
Checking measurement
Y
of stroke limitation
160.1 / 160.2
15.5 mm ........... ..............
Standard machine
11.5 mm ........... .............. Adjust settings at adjusting screw
Speeder machine 1.
16. Hydrostatic fan drive
Checking the fan speed

16.1
Check speed while diesel
engine runs at rated
speed. Disconnect Y347.
When testing fan speed, 1600 ±25rpm ........... ..............

make sure hydraulic oil
temperature is
is > 50° C.
Danger!
Moving fan blades might cause serious injury to fingers and hands.
Before working near the fan, switch off the engine.
A 900 C-LI 14675- 3.40.9

copyright by
MJFCIFSS
3.40.10 A 900 C-LI 14675-

copyright by
MJFCIFSS
A 900 C Litronic type 1002 from 24677
1 A 900 C Litronic type 1002 from 24677
1.1 Excavator control BST - software version V4.3

Date: ................................... Mechanic: ......................................... Cust.: .........................................
Type: ................................... Serial number: ......................................... Operating hours: .........................................

Checks
1.
1.1 Model A900C (A 900-0)
1.2 Regulating rpm 1800 rpm ........... ..............

(V 4.3)
Max. speed ........... ..............
(high idle rpm) 1950 +50rpm
........... ..............
Min. speed
(low idle rpm) 900 +100rpm ........... ...............
Warm up equipment
2.1 Oil temperature min. 50 +10°C ........... ................

49 Measure setting at valve 51.
32 ±1 bar ............ ................
A 900 C-LI EDC 24677- 3.41.1

copyright by
MJFCIFSS

Checks

59
4.1 Y50 test
(LR regulator)
Adjust using menu:

In menu "set data", 6,5 ±1,0 bar ............ ................
select "set control"
Select submenu "test 500 ±10 mA ............ ................
Y50" (ON).
4.2 Checking regulating Measuring point Remove plug from Y50.

pressure during emer- 59 Set valve to emergency position.
gency operation 3.5 ±0.5 bar ............ ............... (Remove cotter pin and actuate
lever.)
4.3 Flow rate reduction (SF Measuring point

function) 57
Y51 test
(LS regulator)
Adjust using menu:

In menu "set data", 8.5 ±1.0 bar ............ ................
Select submenu "test 500 ±10 mA ............ ...............
Y51" (ON).
3.41.2 A 900 C-LI EDC 24677-

copyright by
MJFCIFSS

Checks
5. Check of Measuring point Measure using adapter cable at

SF function Y51 57 Y51.
5.1 SF min.(Q. max) Tank pressure

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

300 to 760 mA diagram ........... ..............
(Q.reduced)
6. Hydraulic begin Measuring point Adjustment at screw 8 of the

of regulation of variab- 41/44 pump.
le-displacement pump
(basic setting)
6.1 Adjust using menu: 50 +2 bar ........... ..............

In menu "set data",
Select "begin of reg."
submenu (ON).
Reduce the secondary

relief valve 262
to below the begin of re-
gulation.
Turn it in again until the
begins to drop.
7. Adjusting the Measuring point Determine the differential pressu-

differential pressure 41 / 45 re between MP and LS, adjust at
screw 2 of the pump.
In menu "set data",
select "set control".
Select submenu "deltaP"
P1/P2 (ON).
( -p) using the "extend

bucket cylinder" function.
ring point 41 MP.
A 900 C-LI EDC 24677- 3.41.3

copyright by
MJFCIFSS

Checks

(power test)
Carry out this test when approx. 1550 rpm
you suspect problems
(e.g. reduced output of Power test menu on the screen
diesel engine). (I LR = 100%) - do not change.
Lower the pressure at the
secondary pressure relief Measuring point
valves 242 (extend stick 41
bucket cylinder) below
the test pressure in the 125 bar ........... ..............
pressure.
The rpm of the diesel en-
gine must never drop be- 1800 +20 rpm
low the rated speed for
this test.
(Read rpm on
screen.) Difference < 10 bar ........... ..............
between measuring
points
41 - 44

> 11+3 bar
........... ..............
3.41.4 A 900 C-LI EDC 24677-

copyright by
MJFCIFSS

Checks

400 +20 bar ........... ..............
valve 262
justment pressure
cket cylinder.
valve 104 until

104 turned out
(not on block)
Note!
tions.

Valve 221
-Retract boom cylinder 380 +20 bar ........... ..............
Valve 222
-Retract stick cylinder 380 +20 bar ........... ..............
Valve 241
-Extend stick cylinder 380 +20 bar ........... ..............
Valve 242
-Retract bucket cylinder 380 +20 bar ........... ..............
Valve 261
-Extend bucket cylinder 380 +20 bar ........... .............
Valve 262
- Forward travel 380 +20 bar ........... ..............
Valve 177
-Reverse travel 380 +20 bar ........... ..............
Valve 176

350 +10 bar
A 900 C-LI EDC 24677- 3.41.5

copyright by
MJFCIFSS

Checks

Secondary pressure 137/138
12.1 Adjust using menu:

In menu "set data",
Select submenu "sle-
wing gear" for high pres-
sure test (ON).
Valve 134
(high-pressure setting)
12.2 Swivelling back Lock nut 1
137 ........... .............. Adjusting screw 2
Turning right 250 +10 bar
Valve 135
Turning left 138 ........... .............. Lock nut 1
250 +10 bar Adjusting screw 2
12.3 Slowing down Valve 135

(low-pressure setting)
Turning right 138 ............ .............. Lock nut 3
90 ±5 bar Adjusting screw 4
Valve 134
Turning left 137 ........... ............... Lock nut 3
90 ± 5 bar Adjusting screw 4
Before making the low-

pressure settings, remo-
ve the pilot control hoses
at the motor.
Valves 134 / 135
3.41.6 A 900 C-LI EDC 24677-

copyright by
MJFCIFSS

Checks
13. Slewing gear function No adjustment necessary!

The parameters are pre-set by the
137 / 138
BST.
Turning left or The sensitivity of the slewing gear
right is adjusted by means of the bar in
Adjust using menu: 200 - 240 -10 bar ........... .............. the menu.
In menu "set SF",
select the submenu for 0 - 100 % ........... ..............
fine control of the sle-
wing gear (page 2)
13.1 Turning speed .......... ............... Settings at the control valve block
9,0 - 9,5 rpm 100
Adjusting screw 120.1
120.1= turning right
120.2= turning left
A 900 C-LI EDC 24677- 3.41.7

copyright by
MJFCIFSS

Checks
14. Travel motor Measuring point Adjusting screw 64

14.1 Regulation

road gear
Drive shaft speed
Drive shaft speed

Check measurement X
at travel motor
Standard machine 21.0 mm ........... .............. Adjust settings at adjusting screw 1

160.1 Reverse travel
Speeder machine 25.0 mm ........... .............. 160.2 Forward travel
3.41.8 A 900 C-LI EDC 24677-

copyright by
MJFCIFSS

Checks

In menu "set data",
Select submenu "delta
fan min/fan max" (ON).
Checking the maximum 450 ±25rpm

fan speed approx. 650 mA
............
Checking the minimum 1550 ±25rpm

............
When testing the fan

speed, ensure that the
hydraulic oil temperature
is > 50° C.
Danger!
A 900 C-LI EDC 24677- 3.41.9

copyright by
MJFCIFSS
3.41.10 A 900 C-LI EDC 24677-

copyright by
MJFCIFSS
1 A 900 C Litronic type 1002 from 29092
1.1 Excavator control BST - software version V4.4


Checks
1.
1.1 Model A900C (A 900-0)
1.2 Regulating rpm 1800 rpm ........... ..............

(V 4.3)
Max. speed ........... ..............
........... ..............
Min. speed
(low idle rpm) 900 +100rpm ........... ...............
Tooth specification 147
Warm up equipment

49 Measure setting at valve 51
32 ±1 bar ............ ................
.
A 900 C-LI EDC 29092- 3.42.1

copyright by
MJFCIFSS

Checks

59
4.1 Y50 test
(LR regulator)
Adjust using menu: 6,5 ±1,0 bar

In menu "set data", ............ ................
select "set control" 500 ±10 mA
Select submenu "test ............ ................
Y50" (ON).
4.2 Checking regulating Measuring point

pressure during emer- 59 Remove plug from Y50.
gency operation 3.5 ±0.5 bar Set valve to emergency position.
............ ............... (Remove cotter pin and actuate
lever.)

function) 57
Y51 test
(LS regulator)
Adjust using menu:

In menu "set data", 8.5 ±1.0 bar
Y51" (ON).
............ ...............
3.42.2 A 900 C-LI EDC 29092-

copyright by
MJFCIFSS

Checks
5. Check of Measuring point Measure using adapter cable at

SF function Y51 57 Y51.


300 to 760 mA diagram ........... ..............
(Q.reduced)
6. Hydraulic begin Measuring point Adjustment at screw 8 of the

of regulation of variab- 41/44 pump.
le-displacement pump
(basic setting)

In menu "set data",
Select "begin of reg."
submenu (ON).
Reduce the secondary

relief valve 262
gulation.
Turn it in again until the
begins to drop.
7. Adjusting the Measuring point Determine the differential pressu-

differential pressure 41 / 45 re between MP and LS, adjust at
screw 2 of the pump.
In menu "set data",
select "set control".
P1/P2 (ON).

ring point 41 MP.
A 900 C-LI EDC 29092- 3.42.3

copyright by
MJFCIFSS

Checks

(power test)
secondary pressure relief
valves 242 (extend stick Measuring point
cylinder) and 262 (extend 41
the test pressure in the ........... ..............
adjustment protocol. 125 bar
pressure.
The rpm of the
speed for this test.
(Read rpm on 1800 +20 rpm
screen.) Difference ........... ..............
between measuring
points
41 - 44 < 10 bar

> 11+3 bar
........... ..............
3.42.4 A 900 C-LI EDC 29092-

copyright by
MJFCIFSS

Checks

400 +20 bar ........... ..............
valve 262
justment pressure
cket cylinder.
valve 104 until

104 turned out
(not on block)
Note!
tions.

Valve 221
-Retract boom cylinder 380 +20 bar ........... ..............
Valve 222
-Retract stick cylinder 380 +20 bar ........... ..............
Valve 241
-Extend stick cylinder 380 +20 bar ........... ..............
Valve 242
-Retract bucket cylinder 380 +20 bar ........... ..............
Valve 261
-Extend bucket cylinder 380 +20 bar ........... .............
Valve 262
-Forward travel 380 +20 bar ........... ..............
Valve 177
-Reverse travel 380 +20 bar ........... ..............
Valve 176

350 +10 bar
A 900 C-LI EDC 29092- 3.42.5

copyright by
MJFCIFSS

Checks

Secondary pressure 137/138

In menu "set data",
sure test (ON).
Valve 134
12.2 Swivelling back (high-pressure setting)
137 Lock nut 1
Turning right 250 +10 bar ........... .............. Adjusting screw 2
Valve 135
Turning left 138 (high-pressure setting)
250 +10 bar ........... .............. Lock nut 1
Adjusting screw 2
12.3 Slowing down
Valve 135
Turning right 138 (low-pressure setting)
90 ±5 bar ............ .............. Lock nut 3
Adjusting screw 4
Valve 134
Turning left 137 (low-pressure setting)
90 ± 5 bar ........... ............... Lock nut 3
Adjusting screw 4
Before making the low-
pressure settings, remo-
ve the pilot control hoses
at the motor.
Valves 134 / 135
3.42.6 A 900 C-LI EDC 29092-

copyright by
MJFCIFSS

Checks

137 / 138
BST.
Adjust using menu: 200 - 240 -10 bar ........... .............. the menu.
In menu "set SF",
select the submenu for 0 - 100 % ........... ..............
wing gear (page 2)
Settings at the control valve block

13.1 Turning speed 6.5 rpm .......... ............... 100
120.2= turning left
A 900 C-LI EDC 29092- 3.42.7

copyright by
MJFCIFSS

Checks

14.1 Regulation

road gear
Drive shaft speed
Drive shaft speed

Check measurement X
at travel motor
Standard machine 21.0 mm ........... .............. Adjust settings at adjusting screw 1

3.42.8 A 900 C-LI EDC 29092-

copyright by
MJFCIFSS

Checks

In menu "set data",

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

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

hydraulic oil temperature
is > 50° C.
Danger!
A 900 C-LI EDC 29092- 3.42.9

copyright by
MJFCIFSS
3.42.10 A 900 C-LI EDC 29092-

copyright by
MJFCIFSS
Type: 1002
1.1 from software version V4.7

Date: Mechanic: Cust.:
Type: Serial number: Operating hours:
Checking/adjustment
Machine-specific data
Machine type
Serial number
Software versions
Operating voltage
Operating hours
Diesel engine
Regulating rpm rpm 1800 .......
Low idle rpm rpm 900 +100 .......
High idle rpm rpm 1950 +50 .......
Number of teeth 147
Oil temperature C° > 50 +10 ....... .......

Warming up equipment
3.43.1
copyright by
MJFCIFSS
Checking/adjustment
Pilot pressure
Preselection of speed mode P.

Set at the valve 51.
Pilot pressure bar 32 ±1 ...... ....... 51 49
Limit load control / flow regulation
Valves Y50 (LR) / Y51 (LS)
Adjust it using the menu:

Call up "set data" menu and select
"set control 2.1" submenu.
Set submenu reg. valve min to

(ON).
Proportional valve min.
Test pressure Y51 (tank pressure) bar approx. ...... ...... ...... 57
0.6
Test pressure Y50 bar 2.0 ±0.5 ...... ...... ...... 59
Test current mA approx.

200
3.43.2
copyright by
MJFCIFSS
Checking/adjustment
Set submenu reg. valve 50% to

(ON).
Proportional valve 50%
Test pressure Y51 bar 9.0 ±1 ...... ...... ...... 57
Test current mA approx. ...... ...... ......

500
Set submenu reg. valve max to

(ON).
Proportional valve max.

800
Set submenu reg. valve emergency

to (ON).
Control pressure in emergency mode
with tilted lever.
Remove the cotter pin and tilt the le-
ver.
Test pressure for emergency operati-

on
Test pressure bar 3.5 ±0.5 ...... ...... ...... 59
Test current mA approx. 0 ...... ...... ......
3.43.3
copyright by
MJFCIFSS
Checking/adjustment
Hydraulic begin of regulation of the variable-displacement pump P1/P2

In menu "set data", submenu "set
control 2.1", set begin of reg. Set
submenu P1/P2 to (ON).
Check LR pressure. bar Tank 59

pressure
Reduce the pressure value of se-

condary pressure-relief valve 262
to a value below the begin of regula-
tion, and then turn it
in again until the control chamber
pressure at the measuring point 44
begins to drop relative to 41.
Begin of regulation bar 50 +2 ....... ....... 8 41

44
3.43.4
copyright by
MJFCIFSS
Checking/adjustment
Differential pressure ( -p)

In the menu "set data", submenu "set
control 2.1", set "deltaP P1/P2" to
(ON).
Check MLS pressure. bar Tank ....... ....... 57

pressure
Extend bucket cylinder with the func-

tion.
Set the pressure-relief valve 262 to
100-120 bar (at the measuring point
41).
Read the differential pressure ( -p)
between 41 (MP) and 45 (LS).
Differential pressure bar 19 +1 ....... ....... 2 41

45
3.43.5
copyright by
MJFCIFSS
Checking/adjustment
Output power of diesel engine (power test)
Note:
Carry out this test when you suspect
problems (e.g. reduced output of die-
sel engine).
Insert the service plug.
Lower the pressure value of the se-

condary pressure-relief valves 242
(extending stick cylinder) and 262
(extending bucket cylinder) to a value
below the test pressure.
Activate power test function at the

display
The fan is automatically set to nemer-

gency.
(I LR = 100%) - do not change.
Slowly increase the pressure value of bar 125 ....... ....... 242 41
the secondary pressure-relief valve 262
242 or 262 until the pressure value is
reached.
At the test pressure, the speed of the rpm 1800 +20 ....... .......
diesel engine may not drop below the
rated speed
(Read rpm on screen) bar < 10 ....... ....... 41

Difference between measuring points 44
41 - 44
3.43.6
copyright by
MJFCIFSS
Checking/adjustment
Pump safety valve
Primary pressure
Preselection of speed mode P
Valve 105
Turn in the pressure cut-off valve 104 104

(to block -90°).
Extend the bucket cylinder and incre-

ase the pressure value of the se-
until the pressure ceases to increase
or the value of 440 bar is reached
(response pressure 105).
Primary pressure bar 400 +20 ....... ....... 105 41
Secondary pressure for working functions
Pressure cut-off valve 104 screwed 45

in
(to block - 90°)
Note!
For special equipment (e.g. vertically
and horizontally adjustable boom),
observe the instructions on the at-
tached information signs, which refer
to a reduced secondary pressure in
the relevant control block sections.
The reduced pressure is generally
around 200 bar.
3.43.7
copyright by
MJFCIFSS
Checking/adjustment
-Retracting boom cylinder bar 380 +20 ....... ....... 222 45
-Extending boom cylinder bar 380 +20 ....... ....... 221 45
-Retracting stick cylinder bar 380 +20 ....... ....... 241 45
-Extending stick cylinder bar 380 +20 ....... ....... 242 45
-Retracting bucket cylinder bar 380 +20 ....... ....... 261 45
-Extending bucket cylinder bar 380 +20 ....... ....... 262 45
-Forward travel bar 380 +20 ....... ....... 177 45
-Reverse travel bar 380 +20 ....... ....... 176 45
Accessory kit AS 1 (optional equipment)
Secondary pressure
Pressurise secondary pressure-relief
valve.
Connection A01 bar 110 +20 ....... ....... 541 45
Connection B01 bar 110 +20 ....... ....... 542 45
Rotating speed
(flow rate)
Checking measurement Y
Connection A01 mm approx. ....... ....... 1 1

15.6
Connection B01 mm approx. ....... ....... 2 2

15.6
3.43.8
copyright by
MJFCIFSS
Checking/adjustment
Operating pressure (pressure cut-off)
Operating pressure bar 350 +10 ....... ....... 104 41

via bucket cylinder function
Slewing gear function
Primary pressure
In menu "set data", submenu "set mA 520 ....... .......

control", set swing 0% to (ON).
Turning left / right
0% bar 200 +10 ....... ....... 11 137

138

100% bar 230 +10 ....... ....... 11 137

138
If required, adjust the pressure with

the adjusting screw 11 at the TC val-
ve Y451.
3.43.9
copyright by
MJFCIFSS
Checking/adjustment
Secondary pressure
Swivelling back

control 2.1", set "swing secondary"
to (ON) (Y451 powered to max. le-
vel).
Turning right bar 250 ±10 ....... ....... 134. 137

2
Turning left bar 250 ±10 ....... ....... 135. 138

2
Slowing down
Before making the low-pressure set-

tings, remove the pilot control hoses
at the motor.
Turning right bar 90 +5 ....... ....... 134. 138

4
Turning left bar 90 +5 ....... ....... 135. 137

4
Turning speed
Adjustment of the control axle of the

slewing gear 120
Turning right rpm 9.0 - 9.5 ....... ....... 120.1

.1
Turning left rpm 9.0 - 9.5 ....... ....... 120.1

.1
3.43.10
copyright by
MJFCIFSS
Checking/adjustment
Travel functions
Travel motor regulation

Adjusting screw 64
on the travel motor 170
Screw in the measuring connection
M2.
Begin of regulation bar 240 ....... ....... 64 45

M2
End of regulation bar 320 ....... ....... 64 45

M2
3.43.11
copyright by
MJFCIFSS
Checking/adjustment
Output speed
(travel speed)
Speed of universal joint shaft

Measures at the universal joint shaft
in on-road gear forward / reverse
Standard machine
Forward rpm 1680 ±25 ....... ....... 160.1

.1
Reverse rpm 1680 ±25 ....... ....... 160.2

.1
Speeder machine
Forward rpm 2520 ±25 ....... ....... 160.1

.1
Reverse rpm 2520 ±25 ....... ....... 160.2

.1
Check measurement Y (standard)
on both sides mm 11.0 ....... ....... 160.1

160.2
on both sides mm 14.0 ....... ....... 160.1

160.2
Check measurement X
at travel motor
Stop screw (Qmin)
Standard machine mm 21.0 ....... ....... 35 35
Speeder machine mm 25.0 ....... ....... 35 35
3.43.12
copyright by
MJFCIFSS
Checking/adjustment
Control of hydraulic fan

Set submenu fan min to (ON).
Fan speed rpm 450 +100 ...... ......
Test current mA approx. ...... ......

650
Set submenu fan max max (ON).
Fan speed rpm 1550+100 ...... ......

250
Set the submenu fan emergency to

(ON).
Fan speed rpm 1600+100 ...... ......
Test current mA approx. 0 ...... ......
3.43.13
copyright by
MJFCIFSS
Checking/adjustment
Steering function
Select mode P.
Turn the vehicle wheels to the outer

steering stop, and then continue tur-
ning the steering wheel.
Note!
The primary pressure-relief valve 5
cannot be adjusted. The valve 5 can
only be replaced, if necessary.
3.43.14
copyright by
MJFCIFSS
Checking/adjustment
Braking function
Brake system
Accumulator charge pressure
Switch-on pressure bar 150 ±5 ....... ....... 74 27
Shut-down pressure bar 185 ±5 ....... ....... 74 27
Switching pressure (B20)
dropping bar 100 ±5 ....... ....... 76 153
increasing bar 125 ±5 ....... ....... 76 27
Working brake
Front brake circuit bar 75 +10 ....... ....... 102 25
Rear brake circuit bar 75 +10 ....... ....... 102 26
Switching pressure (B60) bar 5 ....... ....... 77 25

26
3.43.15
copyright by
MJFCIFSS
3.43.16
copyright by
MJFCIFSS
Type: 1002

Checking/adjustment
Machine type
Serial number
Software versions
Operating voltage
Operating hours
Diesel engine
Low idle rpm rpm 900 +100 .......
Number of teeth 147

3.43.17
copyright by
MJFCIFSS
Checking/adjustment
Pilot pressure

Set at the valve 51.

Set submenu reg. valve min to (ON).
0.6

200
3.43.18
copyright by
MJFCIFSS
Checking/adjustment

(ON).

500

(ON).

800

to (ON).
with tilted lever.
ver.

on
3.43.19
copyright by
MJFCIFSS
Checking/adjustment
Hydraulic begin of regulation of the variable-displacement pump P1/P2


pressure

Begin of regulation bar 50 +2 ....... ....... 8 41

44
3.43.20
copyright by
MJFCIFSS
Checking/adjustment

control 2.1", set deltaP P1/P2 to
(ON).

pressure

tion.
Set the pressure-relief valve 262 to
100-120 bar (at the measuring point
41).

45
3.43.21
copyright by
MJFCIFSS
Checking/adjustment
Note:
sel engine).

Power test function at the display

Activate
gency.
reached.
rated speed

3.43.22
copyright by
MJFCIFSS
Checking/adjustment
Pump safety valve
Primary pressure
Valve 105
Turn in the pressure cut-off valve 104 104

(to block -90°).

ase the pressure value of the se-
Pressure cut-off valve 104 screwed 45

in
(to block - 90°)
Note!
around 200 bar.
3.43.23
copyright by
MJFCIFSS
Checking/adjustment
- Extending boom cylinder bar 380 +20 ....... ....... 221 45
-Extending bucket cylinder bar 380 +20 ....... ....... 262 45
-Forward travel bar 380 +20 ....... ....... 177 45
-Reverse travel bar 380 +20 ....... ....... 176 45
Secondary pressure
valve.
Connection A01 bar 110 +20 ....... ....... 541 45
Connection B01 bar 110 +20 ....... ....... 542 45
Rotating speed
(flow rate)
Connection A01 mm approx. ....... ....... 1 1

15.6
Connection B01 mm approx. ....... ....... 2 2

15.6
3.43.24
copyright by
MJFCIFSS
Checking/adjustment

Primary pressure

0% bar 200 +10 ....... ....... 11 137

138

100% bar 230 +10 ....... ....... 11 137

138

ve Y451.
3.43.25
copyright by
MJFCIFSS
Checking/adjustment
Secondary pressure
Swivelling back

control 2.1", set swing secondary to
(ON) (Y451 powered to max. level).
Turning right bar 250 ±10 ....... ....... 134. 137

2
Turning left bar 250 ±10 ....... ....... 135. 138

2
Slowing down

at the motor.
Turning right bar 90 +5 ....... ....... 134. 138

4
Turning left bar 90 +5 ....... ....... 135. 137

4
Turning speed

slewing gear 120.

.1
Turning left rpm 9.0 - 9.5 ....... ....... 120.1

.1
3.43.26
copyright by
MJFCIFSS
Checking/adjustment
Travel functions

Adjusting screw 64
M2.

M2

M2
3.43.27
copyright by
MJFCIFSS
Checking/adjustment
Output speed
(travel speed)

Measures at the universal joint shaft
Standard machine
Forward rpm 1680 ±25 ....... ....... 160.1

.1
Reverse rpm 1680 ±25 ....... ....... 160.2

.1
Speeder machine
Forward rpm 2520 ±25 ....... ....... 160.1

.1
Reverse rpm 2520 ±25 ....... ....... 160.2

.1
on both sides mm 11.0 ....... ....... 160.1

160.2
on both sides mm 14.0 ....... ....... 160.1

160.2
Check measurement X
at travel motor
Stop screw (Qmin)
3.43.28
copyright by
MJFCIFSS
Checking/adjustment

Fan speed rpm 450 +100 ...... ......

650
Set submenu fan max (ON).
Fan speed rpm 1550+100 ...... ......

250
Set the submenu fan emergency to

(ON).
Fan speed rpm 1600+100 ...... ......
3.43.29
copyright by
MJFCIFSS
Checking/adjustment
Steering function
Select mode P.

Note!
3.43.30
copyright by
MJFCIFSS
Checking/adjustment
Braking function
Brake system
dropping bar 100 ±5 ....... ....... 76 153
increasing bar 125 ±5 ....... ....... 76 27
Working brake

26
3.43.31
copyright by
MJFCIFSS
3.43.32
copyright by
MJFCIFSS
1.1 Excavator control BST software version 2.11 - 2.12, 5.13.1, 5.14, 5.14.1

Checks
1. Basic settings
ment
1.1 Model A904C (A 904-2)
........... ...............
1.2 Regulating rpm 1950 rpm
(2.11/2.12/5.13.1/5.14/1)
........... ...............
Max. speed 2110 +50rpm
........... ..............
Min. speed 850 +100rpm
1.3 Teeth ratio 147
Warm up equipment
2.1 Oil temperature min. 50 +10°C ........... ..............
A 904 C-LI 16000- 3.45.1

copyright by
MJFCIFSS

Checks

49 ........... .............. Measure setting at valve 51.
32 ±1 bar
4. Horsepower control Measuring point using adapter cable at Y50.
59 Remove plug from Y50.
4.1 Mode L/F Set valve to emergency setting.
Current (2.11) ........... ............... (Remove cotter pin and actuate le-
Control pressure 400 mA ........... .............. ver.)
5 ±1 bar
Current (2.12/5.13.1/5.14/ ........... ..............
1) 360 mA ........... ..............
Control pressure 4.0 +1 bar
4 .2 Mode E/P ........... ..............

Current (2.11) 600 mA ........... ..............
Control pressure 7.5 +2 bar
........... ..............
Current (2.12/5.13.1/5.14/ 550 mA ........... ..............
1) 7.0 +2 bar
Control pressure
4.3 Checking regulating Measuring point ........... ...............

pressure during emer- 59
gency operation 2.0 ±0.5 bar
5. Check of 57 Measure using adapter cable

SF function Y51 atY51.


300 to 760 mA diagram ........... ..............
(Q.reduced)
3.45.2 A 904 C-LI 16000-

copyright by
MJFCIFSS

Checks
6. Hydraulic begin of re- Measuring point Pre-select speed step 1. Discon-

gulation (basic setting) 41 nect plug connection at Y50 / Y51.
Secondary relief valve Adjust setting at screw 8 of the
262 50 +2 bar ........... .............. pump.
Reduce to value below
begin of regulation and
turn it in again until the
starts to drop.
Re-connect Y50.
7. Adjusting the Measuring point Mode P, button SF not active (Y51

differential pressure 41 / 45 disconnected). Take readings bet-
( -p) using the "extend 19 +1 bar ........... .............. ween MP and LS. Adjust at screw
bucket cylinder" function. 2 of pump.
ring point 41 - MP
Re-connect plug to Y51. Erase er-

ror codes E 027 / 036.
A 904 C-LI 16000- 3.45.3

copyright by
MJFCIFSS

Checks

(power test)
This test should only be approx. 1750 rpm
carried out if you suspect Pull out plug (I = 0 mA).
problems (e.g. reduced (Not required from version 5.13.)
output of diesel engine).
Power test menu on the screen
Lower the pressure at the Measuring point (I LR = 100%) - do not change.
secondary pressure relief 41
cylinder) and 262 (extend ........... ..............
bucket cylinder) below 130 bar
pressure. ........... ..............
In this process, the speed 2000 +10 rpm
of the diesel engine may
not drop below the rated
speed. ........... ..............
(Read rpm on < 10 bar
screen.) Difference
between measuring
points
41 - 44
........... ..............

> 10 bar
3.45.4 A 904 C-LI 16000-

copyright by
MJFCIFSS

Checks

(safety valve) 41 ........... .............. 105
400 +20 bar
Secondary relief valve
262
above adjustment pres-
sure
105 and extend bucket
cylinder.
valve
104 until

104 turned out
(not on block)
Note!
tions.

-Extend boom cylinder 380 +20 bar .......... .............. Valve 221
-Retract boom cylinder 380 +20 bar ........... .............. Valve 222
80 +20 bar* ........... .............. (*only with 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

-Forward travel 380 +20 bar ........... .............. Valve 177
-Reverse travel 380 +20 bar ........... .............. Valve 176

(pressure cut-off) 41 Valve 104
350 +10 bar ........... ..............
A 904 C-LI 16000- 3.45.5

copyright by
MJFCIFSS

Checks

Secondary pressure 137/138 Valve125 raised.
12.1 Swivelling back

Lock nut 1
Adjusting screw 2
Lock nut 1
12.2 Slowing down Adjusting screw 2

120 ±5 bar ........... .............. (low-pressure setting)
Lock nut 3
Adjusting screw 4

120 ± 5 bar ........... .............. (low-pressure setting)
Lock nut 3
Adjusting screw 4
Note:
In machines with "optimised" slewing gear, differ-
ent pressure settings might apply!
Valves 134 / 135
3.45.6 A 904 C-LI 16000-

copyright by
MJFCIFSS

Checks
13. Slewing gear function Adjust settings at valve 125

137 / 138
Turning left or 240 +10 bar ........... ..............

right
14. Travel motor Measuring point Adjusting screw 87.41

45 / M2 at travel motor 170
14.1 Regulation
Begin of regulation 190 bar ............ ..............
Speeder machine:
A 904 C-LI 16000- 3.45.7

copyright by
MJFCIFSS

Checks

road gear
Checking measure-
ment Y
of stroke limitation
160.1 / 160.2
11.00 mm ........... ..............
Standard machine
14.00 mm ........... ..............
Speeder machine
Adjust settings at adjusting screw1
Checking the fan speed

15.1
Check speed while diesel
engine runs at rated
speed. Disconnect Y347.
When testing fan speed, 1750 ±25rpm ........... ..............

make sure hydraulic oil
temperature is
> 50°C
Danger!
3.45.8 A 904 C-LI 16000-

copyright by
MJFCIFSS
Type: 1003 / 1004 / 1005 / 1071
1.1 BST excavator control software version V4.4

Measuring point Actual Possible View

Checks
Specified value value setting Comment
1. Basic settings
ment
1.1 Model A904C (A 904-0)
........... ..............
1.2 Regulating rpm 1800 rpm
(V 4.3)
Max. speed ........... ..............
Min. speed ........... ...............

(low idle rpm) 900 +100rpm
Tooth specification 147
Warm up equipment

49 ............ ................ Measure setting at valve 51.
32 ±1 bar
A 904 C-LI EDC 30580- 3.46.1

copyright by
MJFCIFSS

Checks

59
4.1 Y50 test
(LR regulator)
Adjust, using the menu:

In menu "set data", 6,5 ±1,0 bar ............ ................
Y50" (ON).
Remove plug from Y50.

Set valve to emergency position.
(Remove cotter pin and actuate
lever.)
4.2 Checking regulating Measuring point

pressure during emer- 59
gency operation 3,5 ±0,5 bar
............ ................

function) 57
Y51 test
(LS regulator)
Adjust, using the menu:

In menu "set data", 8.5 ±1,0 bar
select "set control" ............ ................
Select submenu "test 500 ±10 mA
Y51" (ON). ............ ...............
3.46.2 A 904 C-LI EDC 30580-

copyright by
MJFCIFSS

Checks
5. Check of Measuring point

SF function Y51 57
5.1 SF min. (Q. max)

100 to 300 mA Tank pressure
approx. 0.8 bar
5.2 SF min. to SF max.
300 to 760 mA Pressure: see
(Q. reduced) diagram ........... ..............
6. Hydraulic begin Measuring point Adjustment at the performance re-

of regulation of variable 41 gulators 22.1 (P1) and 24.1 (P2)
displacement pump P1 / 44 / P1 with the adjusting screw 8
P2 43 / P2
(basic setting).
6.1 Adjust, using the menu:

In menu "set data",
Select "begin of reg. P1/
P2" submenu (ON).
6.2 Hydraulic begin of re-

gulation of variable dis-
placement pump P1
valve 262
gulation 50 +2 bar ........... ................
and turn it in again until
the actuating pressure at
44 / P1 begins to drop.

placement pump P2
valve 262
to below the begin of re- 50 +2 bar ............ ................
gulation
A 904 C-LI EDC 30580- 3.46.3

copyright by
MJFCIFSS

Checks
7. Measuring point Read the pressure difference ( -

41 / 45 p) between MP and LS.
Adjustment at the flow regulator
7.1 Adjust, using the menu: 24.5 with the adjusting screw 2.
In menu "set data",
P1/P2 (ON).

Reduce the pressure set- 19 +1 bar
ting or set the valve 262 ........... .............
to 100 -110 bar at measu-
ring point 41 - MP
3.46.4 A 904 C-LI EDC 30580-

copyright by
MJFCIFSS

Checks

of the diesel engine Measuring point Pre-select speed - mode P.
(power test) 41
the test pressure in the 105 bar ........... ................
pressure.
The rpm of the
diesel engine must never 1800 +20 rpm ........... ................
(Read rpm on
screen.) Difference < 10 bar ............ ................
between measuring
points
41 - 44

> 11+3 bar ........... ..............
A 904 C-LI EDC 30580- 3.46.5

copyright by
MJFCIFSS

Checks
9. Primary pressure Measuring point Pre-select speed mode P val-

(safety valve) 41 ve 105
400 +20 bar ........... ..............
valve 262 to a value abo-
ve the adjustment pres-
sure 105 and extend the
bucket cylinder.
Turn up the pressure cut-
off valve 104 until
the pressure at the gauge
does not increase any-
more.
(response pressure105)

104 turned out
(not on block)
Note!
tions.

- Extend boom cylinder 380 +20 bar ........... ..............
Valve 221
- Retract boom cylinder 380 +20 bar ........... ..............
Valve 222
- Retract stick cylinder 380 +20 bar ........... ..............
Valve 241
- Extend stick cylinder 380 +20 bar ........... ..............
Valve 242
- Retract bucket cylinder 380 +20 bar ........... ..............
Valve 261
- Extend bucket cylinder 380 +20 bar ........... .............
Valve 262

Valve 177
- Reverse travel 380 +20 bar ........... ..............
Valve 176
3.46.6 A 904 C-LI EDC 30580-

copyright by
MJFCIFSS

Checks

(pressure cut-off) 41 Valve 104
350 +10 bar ........... ..............
A 904 C-LI EDC 30580- 3.46.7

copyright by
MJFCIFSS

Checks
12. Slewing gear function Measuring points Before making the low-pressure
Secondary pressure 137/138 settings, remove the pilot control
hoses at the motor.
12.1 Adjust, using the menu:
In menu "set data",
sure test (ON). Valve 134
12.2 Swivelling back Lock nut 1
137 Adjusting screw 2
Turning right 260 +10 bar ........... ..............
Valve 135
Turning left 138 Lock nut 1
260 +10 bar ........... .............. Adjusting screw 2
12.3 Slowing down Valve 135

Turning right 138 Lock nut 3
90 ±5 bar ............ .............. Adjusting screw 4
Valve 134
Turning left 137 Lock nut 3
90 ± 5 bar ........... ............... Adjusting screw 4
Note:
In machines with "optimised" slewing gear,
different pressure settings might apply!
Valves 134 / 135
3.46.8 A 904 C-LI EDC 30580-

copyright by
MJFCIFSS

Checks

137 / 138
BST.
Adjust it using the me- 200 - 240 -10 bar ........... .............. the menu.
nu:
In menu "set SF", 0 - 100 % ........... ..............
select the submenu for
wing gear (page 2)
100
13.1 Turning speed 9.0 9.5 rpm Adjusting screw 120.1
.......... ...............
120.2= turning left
A 904 C-LI EDC 30580- 3.46.9

copyright by
MJFCIFSS

Checks

14.1 Regulation

road gear
Drive shaft speed
Drive shaft speed

Check measurement X
at travel motor
Standard machine 21.0 mm ........... .............. 1

3.46.10 A 904 C-LI EDC 30580-

copyright by
MJFCIFSS

Checks

In menu "set data",

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

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

Hydraulic oil temperature
is > 50° C.
Danger!
A 904 C-LI EDC 30580- 3.46.11

copyright by
MJFCIFSS
3.46.12 A 904 C-LI EDC 30580-

copyright by
MJFCIFSS
Type: 1003 / 1004 / 1005 / 1071

Date: ............................ Mechanic: ................................. Cust.: .................................
Type: ............................ Serial number: ................................. Operating hours: .................................
Checking/adjustment
Machine type
Serial number
Software versions
Operating voltage
Operating hours
Diesel engine

Low idle rpm rpm 900 +100 .......
Number of teeth 147

3.47.1
copyright by
MJFCIFSS
Checking/adjustment
Pilot pressure
Pre-select speed - mode P.

Set at valve 51.
Pilot pressure bar 32 ±1 ....... ....... 51 49

3.47.2
copyright by
MJFCIFSS
Checking/adjustment
Set submenu"reg. valve min" to

(ON).

Test pressure Y51 (tank pressure) bar ~ 0.6 ....... ....... ........ 57
Test pressure Y50 bar 2.0 ±0,5 ....... ....... ........ 59
Test current mA ~ 200 ....... ....... ........
Set submenu"reg. valve 50%" to

(ON).

Test pressure Y51 bar 9.0 ±1 ....... ....... ........ 57
Test current mA ~ 500 ....... ....... ........
Set submenu"reg. valve max" to

(ON).

Test current mA ~ 800 ....... ....... ........
Set submenu"reg. valve emergen-

cy" to (ON).
with tilted lever Y50.
ver.

on
Test pressure bar 3.5 ±0,5 ....... ....... ........ 59
Test current mA ~0 ....... ....... ........
3.47.3
copyright by
MJFCIFSS
Checking/adjustment
Hydraulic begin of regulation of the variable displacement pump P1/P2

control 2.1", set "begin of reg. Set

pressure
Double variable-displacement pump
P1
Pressure value of secondary pressu-

re-relief valve 262 (extend bucket cy-
linder)
pressure at measuring point 44 drops
relative to 41.
Begin of regulation P1 bar 50 +2 ....... ....... 22.1 41

8 44
Variable displacement pump P2:
Pressure value of secondary pressu-

re-relief valve 262 (extend bucket cy-
linder)
pressure at measuring point 43 drops
relative to 41.
41
8
3.47.4
copyright by
MJFCIFSS
Checking/adjustment

(ON).
Check MLS pressure. bar Tank

pressure ....... ....... 57

tion.
Secondary pressure-relief valve 262
to 100-120 bar (at the measuring
point41).
bar 19 +1 ....... ....... 2 41

Pressure difference 45
3.47.5
copyright by
MJFCIFSS
Checking/adjustment
Note:
sel engine).


Activate
gency.
Slowly increase the pressure value of

the secondary pressure-relief valve bar 105 ....... ....... 242 41
242 or 262 until the pressure value is 262
reached.
rated speed 41
Difference between measuring points
41 - 44 (P1)
41 - 43 (P2)
3.47.6
copyright by
MJFCIFSS
Checking/adjustment
Pump safety valve
Primary pressure
Pre-select speed mode P
Valve 105
Turn in the pressure cut-off valve 104

(to block -90°).
ase the pressure value of the se- 104
Primary pressure
bar 400 +20 ....... ....... 105 41

104 screwed in
(to block - 90°)
Note!
around 200 bar.
3.47.7
copyright by
MJFCIFSS
Checking/adjustment
- Extend boom cylinder bar 380 +20 ....... ....... 221 45

- Retract boom cylinder bar 380 +20 ....... ....... 222 45
- Retract stick cylinder bar 380 +20 ....... ....... 241 45

- Extend stick cylinder bar 380 +20 ....... ....... 242 45
- Retract bucket cylinder bar 380 +20 ....... ....... 261 45

- Extend bucket cylinder bar 380 +20 ....... ....... 262 45
- Forward travel bar 380 +20 ....... ....... 177 45

- Reverse travel bar 380 +20 ....... ....... 176 45
Secondary pressure
Pre-select speed - mode P
valve.
Connection A01 bar 110 +20 ....... ....... 541 45
Connection B01 bar 110 +20 ....... ....... 542 45
Rotating speed
(flow rate)
Connection A01 mm ~ 15.6 ....... ....... 1 1

Connection B01 mm ~ 15.6 ....... ....... 2 2
3.47.8
copyright by
MJFCIFSS
Checking/adjustment
Operating pressure
via bucket cylinder function bar 350 +10 ....... ....... 104 41
Primary pressure
control", set swing 0% to (ON). mA 520 ....... .......
Turning left / right 0% bar 200 +10 ....... ...... 11 137

138

control", set swing 100% to (ON). mA 600 ....... .......
Turning left / right 100% bar 230 +10 ....... ....... 11 137
138

ve Y451.
3.47.9
copyright by
MJFCIFSS
Checking/adjustment
Secondary pressure
Swivelling back

control 2.1", set "swing secondary"
to (ON) (Y451 powered to max. level)
Turning right bar 250 +10 ....... ....... 134 137

2
Turning left bar 250 +10 ....... ....... 135 138

2
Slowing down

at the motor.
Turning right bar 90 ±5 ....... ....... 134 138

4
Turning left bar 90 ±5 ....... ....... 135 137

4
3.47.10
copyright by
MJFCIFSS
Checking/adjustment
Turning speed

slewing gear 120.

.1
Turning left rpm 9.0 - 9.5 ....... .......

120.2
.1
Travel functions

Adjusting screw 64
M2.

M2

M2
3.47.11
copyright by
MJFCIFSS
Checking/adjustment
Output speed
(travel speed)

Measured at the universal joint shaft
Tyre size 10.00-20: (20 km/h)
Standard machine forward rpm 1680 ±25 ....... ....... 160.1

.1
Standard machine reverse rpm 1680 ±25 ....... .......
160.2
Tyre size 11.00-20: (20 km/h) .1
160.1
Standard machine forward rpm 1550 ±25 ....... ....... .1
Standard machine reverse rpm 1550 ±25 ....... ....... 160.2

.1
Tyre size 10.00-20: (30 km/h)
Speeder machine forward rpm 2520 ±25 ....... ....... 160.1

.1
Speeder machine reverse rpm 2520 ±25 ....... ....... 160.2
.1
Tyre size 11.00-20: (30 km/h)

160.1
Speeder machine forward rpm 2400 ±25 ....... ....... .1
Speeder machine reverse rpm 2400 ±25 ....... ....... 160.2

.1
Check measurement Y (standard) mm 11.0 ....... ....... 160.1

160.2
on both sides
14.0 ....... ....... 160.1
mm 160.2
Check measurement Y (speeder)
on both sides
Check measurement X
at travel motor
Stop screw (Qmin) 21.0 ....... ....... 35 35
Standard machine 25.0 ....... ....... 35 35
Speeder machine
3.47.12
copyright by
MJFCIFSS
Checking/adjustment

Set submenu"fan min" to (ON).
Fan speed rpm 450 +100 ....... .......

Test current mA ~ 650 ....... .......
Set submenu"fan max max" (ON).
Fan speed rpm 1550 +100 ....... .......

Test current mA ~ 250 ....... .......
Set submenu"fan emergency" to

(ON).
Fan speed rpm 1600 +100 ....... .......

Test current mA ~0 ....... .......
3.47.13
copyright by
MJFCIFSS
Checking/adjustment
Steering function
Select mode P.

Note!
cannot be adjusted. The valve5 can
3.47.14
copyright by
MJFCIFSS
Checking/adjustment
Braking function
Brake system

Switching pressure (B20) drop- bar 100 ±5 ....... ....... 76 153

ping
bar 125 ±5 ....... ....... 76 27
increasing
Working brake
Switching pressure (B60) bar 5 ....... ....... 77 25/

26
3.47.15
copyright by
MJFCIFSS
3.47.16
copyright by
MJFCIFSS
1.1 Excavator control BST - software version 4.6

Measuring
Checks point
Specified value
1. Basic settings
1.1 ment A914C (A 914)
Model
1.2 1,800 min-1 ........... ..............
Regulating rpm
(V 4.6)
Max. speed 1950 +50rpm ........... ..............
(high idle rpm)
Min. speed 900 +100rpm ........... ...............

(low idle rpm)
Number of teeth 147
3. Pilot pressure 49 Mode P

32 ±1bar ............ ................ Set at valve 51.
A 914 C-LI 35112- 3.50.1

copyright by
MJFCIFSS
Measuring
Checks point
Specified value
4. Horsepower control 59
4.1 Y50 test

(LR regulator)
Adjust it using the me- 6.5 ±1.0bar ............ ................

nu:
In menu "set data", 500 ±10 mA ............ ................
select "set control2".
Select submenu "test
Y50" (ON).
Remove the plug from Y50.

lever.)
4.2 Checking regulating 59 ............ ................

pressure during emer- 3.5 ±0.5bar
gency operation
4.3 Flow rate reduction (SF 57

function)
Y51 test
(LS regulator)
............ ................
Adjust it using the me- 8.5 ±1.0bar
nu: ............ ...............
In menu "set data", 500 ±10 mA
Y51" (ON).
3.50.2 A 914 C-LI 35112-

copyright by
MJFCIFSS
Measuring
Checks point
Specified value
5. Check of 57 Measure using adapter cable at

SF function Y51 Y51.


300 to 760 mA diagram ........... ..............
(Q.reduced)
A 914 C-LI 35112- 3.50.3

copyright by
MJFCIFSS
Measuring
Checks point
Specified value

of regulation of variable 41 gulators 22.1(P1) and 24.1(P2)
P2 43 / P2
(basic setting)
6.1 Adjust it using the me-

nu:
In menu "set data",
P2" submenu (ON).

placement pump P1
valve 261
to below the begin of re- 70 +2 bar ........... ................
gulation

gulation of the variable
displacement pump P2
valve 261
(extend bucket cylinder) 70 +2 bar ............ ................
gulation
3.50.4 A 914 C-LI 35112-

copyright by
MJFCIFSS
Measuring
Checks point
Specified value
7. Adjusting the Measuring point Read the pressure difference ( -

pressure difference ( - 41 / 45 p) between xP and xLS.
p) Adjustment at the flow regulator
7.1 24.5 with the adjusting screw 2 .
Adjust it using the me-
nu:
In menu "set data",
P1/P2 (ON).
( -p) using the "extend 30 +2 bar

bucket cylinder" function. ........... .............
ting or set the valve 261
ring point 41 - MP
A 914 C-LI 35112- 3.50.5

copyright by
MJFCIFSS
Measuring
Checks point
Specified value
8. Checking of the pump Measuring point

valve 102 41
Pre-select speed mode P 45 - 60 bar ............ ................
Measure check measu-

rement X, if required approx. 27.0 mm ............ ................
(Q min. stop
at variable-displacement pump)
3.50.6 A 914 C-LI 35112-

copyright by
MJFCIFSS
Measuring
Checks point
Specified value
9. Checking output Measuring point Insert service plug.

of the diesel engine 41 Pre-select speed - mode P.
(power test)
Note:
Carry out this test when
you suspect problems Power test menu on the screen
(e.g. reduced output of (I LR = 100%) - do not change.
diesel engine).
cylinder) or 261 (extend
bucket cylinder) below 110 bar ........... ................
pressure.
The rpm of the ........... ................
speed for this test. 1800 +20rpm
(Read rpm on ............ ................
screen.) Difference
between measuring
points
41 - 43/44 <10 bar
........... ..............
A 914 C-LI 35112- 3.50.7

copyright by
MJFCIFSS
Measuring
Checks point
Specified value
10. 45 Mode P
101 raised
(not to block)
Note!
For special equipment (e.g. vertically and horizontally
adjustable boom), observe the instructions on the at-
tached information signs, which refer to a reduced se-
condary pressure in the relevant control block sections.

- 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
- Extend bucket cylinder 380 +20 bar ........... .............. Valve 261
- Retract bucket cylinder 380 +20 bar ........... ............. Valve 262
- Forward travel 380 +20 bar ........... .............. Valve 177

- Reverse travel 380 +20 bar ........... .............. Valve 176
11. Operating pressure P 41 Mode P
(pressure cut-off) 350 +10 bar ........... .............. Valve 101
3.50.8 A 914 C-LI 35112-

copyright by
MJFCIFSS
Measuring
Checks point
Specified value
12. Lowering speed of at- Mode P

tachment
Lowering restrictor of
boom cylinder
Dimension d: ............ ................ Adjusting screw 115
for construction model 19.5 ±1 mm
stick cylinder ............ ................ Adjusting screw 116
Dimension d: 9.0 ±1 mm
for construction model
Lowering restrictor for bu-

cket cylinder ............ ................ Adjusting screw 117
Dimension d: 28.0 ±1 mm
LS pressure check Measuring point

during: 45 ............ ................
Retracting boom cylinder approx. 15 bar ............ ................
Extending stick cylinder approx. 40 bar ............ ................
Retracting bucket cylin- approx. 90 bar

der
Measurement without
attachment!!
A 914 C-LI 35112- 3.50.9

copyright by
MJFCIFSS
Measuring
Checks point
Specified value
13. Slewing gear function Write down check measurement

13.1 Define check measure-
ment
............ ................ TC - DB valve 134 (dimension A)
Check measurement A 22.0 ±1 mm
............ ................ Torque Control valve 137

Check measurement B 20.0 ±1 mm
(dimension B)
Screw in both valves to the stop.
3.50.10 A 914 C-LI 35112-

copyright by
MJFCIFSS
Measuring
Checks point
Specified value
13.2 Secondary pressure Measuring points

145/146/147 Lock and hold (low pressure)
Block uppercarriage (high pressu-
re)
13.3 Swivelling (Pmax)

Counterpressure

260 ±10 bar ........... .............. (high-pressure setting)
Lock nut 2
Adjusting screw 1
Turning left 146
260 ±10 bar ........... .............. Valve 132
Lock nut 2
13.4 Braking (Pbr) Adjusting screw 1
Valve 131
Turning right 145 (low-pressure setting)
85 +10 bar ............ .............. Lock nut 3
Adjusting screw 4
Valve 132
Turning left 146 (low-pressure setting)
85 +10 bar ........... ............... Lock nut 3
Adjusting screw 4
Valves 131 / 132
A 914 C-LI 35112- 3.50.11

copyright by
MJFCIFSS
Measuring
Checks point
Specified value
13.5 Secondary pressure Sec. Measuring points

(at control pressure = 147 Pilot control 14 ±0.1 bar
14bar)
145
Turning right 160 ±5 bar ........... ................ Valve 131
146
Turning left 160 ±5 bar ............ ................ Valve 132
13.6 TC characteristic PTC Measuring points Torque Control valve 137

at control pressure = 16 147
Pilot control 16 ±0.1 bar
bar
145
160 ±5 bar ........... ................
Turning right
146
160 ±5 bar ............ ................
Turning left
TC - DB valve 134
13.7
Primary pressure (high 145
pressure) 245 ±5 bar ............ ................
Turning right 146

245 ±5 bar ............ ................
Turning left
13.8
Stroke limitation of the

spool 41.3 +0.1 mm
Checking measurement
X
* to serial no. 35237
3.50.12 A 914 C-LI 35112-

copyright by
MJFCIFSS
Measuring
Checks point
Specified value
14. Turning speed 9.5 rpm Adjustment of slewing gear motor

........... ................ 130
130.1 = turning right
130.2 = turning left
Adjusting screw 1
Lock nut 2
A 914 C-LI 35112- 3.50.13

copyright by
MJFCIFSS
Measuring
Checks point
Specified value

45 / M2 on the travel motor 170
15.1 Regulation
3.50.14 A 914 C-LI 35112-

copyright by
MJFCIFSS
Measuring
Checks point
Specified value

(travel speed) on drive shaft, measured in on-
Speed of universal joint road gear
shaft
Measured at the universal
joint shaft in on-road gear
forward / reverse
Tyre size 11.00-20:

Standard model (20 km/ 1680 ±25 rpm ........... ..............
h)
2520 ±25 rpm ........... ..............
Speeder model (30 km/h)
Tyre size 11.00-20: 1550 ±25 rpm ............ ................

Standard model (20 km/
h) 2400 ±25 rpm ............ ............... Adjust settings at adjusting screw
1
Speeder model (30 km/h) 160.1 Reverse travel
160.2 Forward travel
Check measurement X 21.0 mm ........... .............
at travel motor
25.0 mm ........... ..............
Standard machine
Speeder machine
A 914 C-LI 35112- 3.50.15

copyright by
MJFCIFSS
Measuring
Checks point
Specified value

17.1 nu:
In menu "set data",
Checking the maximum 500 ±200 rpm 450

±50
fan speed mA
............
Checking the minimum 1450+50 -100rpm

fan speed 170 ±50 mA
............

> 50° C and the bonnet is
open.
Danger!
Before working near the fan, switch off the motor.
3.50.16 A 914 C-LI 35112-

copyright by
MJFCIFSS
Service Manual Adjustment protocol V4.7-
Adjustment protocol V4.7-

3.51A 914 C-LI 39037-
Date: Mechanic Cust.:
Checking/adjustment
Machine type
Serial number
Software versions
Operating voltage
Operating hours
Diesel engine
Low idle rpm rpm 900 +100 .......
Number of teeth 147

3.51.1
copyright by
MJFCIFSS
Adjustment protocol V4.7- Service Manual
Checking/adjustment
Pilot pressure

Set at valve 51.

3.51.2
copyright by
MJFCIFSS
Checking/adjustment
0.6

200

(ON).

500

(ON).

800

to (ON).
with tilted lever.
ver.
3.51.3
copyright by
MJFCIFSS
Checking/adjustment

on
3.51.4
copyright by
MJFCIFSS
Checking/adjustment

Check LR pressure. bar Tank

pressure

P1:


8 44


8 43
3.51.5
copyright by
MJFCIFSS
Checking/adjustment

control 2.1", set deltaP P1/P2 to
(ON).

pressure

tion.
Set secondary pressure-relief valve
261 to 100-120 bar (at the measuring
point 41).

45
3.51.6
copyright by
MJFCIFSS
Checking/adjustment
Note:
sel engine).


Activate
reached.
rated speed

41 - 44 (P1)
41 - 43 (P2)
3.51.7
copyright by
MJFCIFSS
Checking/adjustment
Pump valve
Preselection of mode P
Check pressure bar 45 - 60 ....... ....... 102 41
Measure check measurement X, if re-

quired
(Q min. stop mm approx. ....... ....... 102 X

at variable-displacement pump) 27.0
Turn up the pressure cut-off valve

101 screwed in
(to block - 90°)
Note!
around 200 bar.
3.51.8
copyright by
MJFCIFSS
Checking/adjustment
- Extending boom cylinder bar 380 +20 ....... ....... 221 45
- Extending bucket cylinder bar 380 +20 ....... ....... 262 45
Accessory kit AS1
Secondary pressure
valve.
Secondary relief valve bar 110 +20 ....... ....... 544 45
Rotating speed
(flow rate)
Connection A mm approx. ....... ....... 1 1

10.5
Connection B mm approx. ....... ....... 2 2

10.5
3.51.9
copyright by
MJFCIFSS
Checking/adjustment

3.51.10
copyright by
MJFCIFSS
Checking/adjustment
Lowering speed of attachment
Mode P
Dimension d:
for construction model mm 19.5 ±1 ....... ....... 115
Dimension d:
Lowering restrictor for bucket cy-

linder
Dimension d:
LS pressure check
during
Retracting boom cylinder bar approx. ....... ....... 45

15
Extending stick cylinder bar approx. ....... ....... 45

40
Retracting bucket cylinder bar approx. ....... ....... 45

90
Measurement without
attachment!
3.51.11
copyright by
MJFCIFSS
Checking/adjustment
Define check measurement.

Check measurement A mm 22.0 ±1 ....... ....... 134 A
Check measurement B mm 20.0 ±1 ....... ....... 137 B
Secondary pressure
Swivelling (Pmax)
Counterpressure

2
Turning left bar 260 ±10 ....... ....... 132 1

2
Braking (Pbr)

4
Turning left bar 85 +10 ....... ....... 132 3

4
3.51.12
copyright by
MJFCIFSS
Checking/adjustment
Secondary pressure Psec. bar 14 ±0.1 ....... ....... 147

(at control pressure = 14bar)
Turning right bar 160 ±5 ...... ....... 131 145
Turning left bar 160 ±5 ...... ....... 132 146
TC characteristic PTC bar 16 ±0.1 ...... ....... 137 147

at control pressure = 16 bar
Turning right bar 160 ±5 ...... ....... 145
Turning left bar 160 ±10 ...... ....... 145
Primary pressure (high pressure) 134
Turning left bar 245 ±5 ...... ....... 146
Stroke limitation of the spool
Check measurement X mm 41.3 +0.1 ...... ....... X
3.51.13
copyright by
MJFCIFSS
Checking/adjustment
Turning speed

slewing gear 130.
Turning right rpm 9.5 ....... ....... 130.

1.1
Turning left rpm 9.5 ....... ....... 130.

2.1
3.51.14
copyright by
MJFCIFSS
Checking/adjustment
Travel functions

Adjusting screw 64
M2

M2

M2
3.51.15
copyright by
MJFCIFSS
Checking/adjustment
Output speed
(travel speed)

Tyre size 10.00-20: (20 km/h)
Standard machine forward rpm 1680 ±25 ....... ....... 160.

1.1
Standard machine reverse rpm 1680 ±25 ....... ....... 160.

2.1
Tyre size 11.00-20: (20 km/h)

1.1

2.1
Tyre size 10.00-20: (30 km/h)
Speeder machine forward rpm 2520 ±25 ....... ....... 160.

1.1
Speeder machine reverse rpm 2520 ±25 ....... ....... 160.

2.1
Tyre size 11.00-20: (30 km/h)

1.1

2.1
Check measurement X
at travel motor
Stop screw (Qmin)
3.51.16
copyright by
MJFCIFSS
Checking/adjustment

Call up set data" menu and select
Fan speed rpm 500 +150 ...... ......

-300
Test current mA 500 ±20 ...... ......
Set submenu fan max to (ON).
Fan speed rpm 1450 +50 ...... ......

-100
Test current mA 150 ±20 ...... ......
Set submenu fan emergency to

(ON).
Fan speed rpm 1650 +200 ...... ......

-200
Reversible fan drive (optional equip-

ment)
Normal operation
Fan speed rpm 1450 +50 ...... ......

-100
Test current mA 150 ±20 ...... ......
Reverse operation
Fan speed rpm 1450 +250 ...... ......

-250
Test current mA 150 ±20 ...... ......
3.51.17
copyright by
MJFCIFSS
Checking/adjustment
Steering function
Select mode P.

Note!
3.51.18
copyright by
MJFCIFSS
Checking/adjustment
Braking function
Brake system
Switching pressure (B20) dropping bar 100 ±5 ....... ....... 76 153
increasing bar 125 ±5 ....... ....... 76 27
Working brake

26
3.51.19
copyright by
MJFCIFSS
3.51.20
copyright by
MJFCIFSS

Type: 1049 / 1050 / 1051 Industrial
1.1 Excavator control BST - software version 4.6

Measuring
Checks point
Specified value
1. Basic settings
1.1 ment A924C (A 924)
Model
1.2 1,800 min-1 ........... ..............
Regulating rpm
(V 4.6)
Max. speed 1950 +50rpm ........... ..............
(high idle rpm)
900 +100rpm
Min. speed ........... ...............
(low idle rpm)
Number of teeth 147
3. Pilot pressure 49 Mode P

32 ±1bar ............ ................ Set at valve 51.
A 924 C-LI 34519- 3.55.1

copyright by
MJFCIFSS
Measuring
Checks point
Specified value
4. Horsepower control 59
4.1 Y50 test

(LR regulator)

nu: 6.5 ±1.0bar ............ ................
In menu "set data",
select "set control2". 500 ±10 mA ............ ................
Y50" (ON).
Remove the plug from Y50.
lever.)
4.2 Checking regulating 59

pressure during emer- 3.5 ±0.5bar ............ ................
gency operation
4.3 Flow rate reduction (SF 57

function)
Y51 test
(LS regulator) ............ ................
Adjust it using the me- 8.5 ±1.0bar ............ ...............

nu:
In menu "set data", 500 ±10 mA
Y51" (ON).
3.55.2 A 924 C-LI 34519-

copyright by
MJFCIFSS
Measuring
Checks point
Specified value
5. Check of 57 Measure using adapter cable at

SF function Y51 Y51.

100 to 300 mA ~ 0.8 bar

300 to 760 mA diagram ........... ..............
(Q.reduced)
A 924 C-LI 34519- 3.55.3

copyright by
MJFCIFSS
Measuring
Checks point
Specified value

of regulation of variable 41 gulators 22.1(P1) and 24.1(P2)
P2 43 / P2
(basic setting)

nu:
In menu "set data",
P2" submenu (ON).

placement pump P1
valve 261
to below the begin of re- 70 +2 bar ........... ................
gulation

gulation of the variable
displacement pump P2
valve 261
(extend bucket cylinder) 70 +2 bar ............ ................
gulation
3.55.4 A 924 C-LI 34519-

copyright by
MJFCIFSS
Measuring
Checks point
Specified value
7. Adjusting the Measuring point Read the pressure difference ( -

pressure difference ( - 41 / 45 p) between xP and xLS.
p) Adjustment at the flow regulator
24.5 with the adjusting screw 2 .
nu:
In menu "set data",
P1/P2 (ON).
( -p) using the "extend 30 +2 bar

bucket cylinder" function. ........... .............
ting or set the valve 261
ring point 41 - MP
A 924 C-LI 34519- 3.55.5

copyright by
MJFCIFSS
Measuring
Checks point
Specified value
8. Checking of the pump Measuring point

valve 102 41
Pre-select speed mode P 45 - 60 bar ............ ................
Measure check measu-

rement X, if required ~ 27.0 mm ............ ................
(Q min. stop
at variable-displacement pump)
3.55.6 A 924 C-LI 34519-

copyright by
MJFCIFSS
Measuring
Checks point
Specified value
9. Checking output 41 Insert service plug.

of the diesel engine Pre-select speed - mode P.
(power test)
Note:
Carry out this test when
you suspect problems Power test menu on the screen
(e.g. reduced output of (I LR = 100%) - do not change.
diesel engine).
cylinder) or 261 (extend
bucket cylinder) below 135 bar ........... ................
pressure.
The rpm of the ........... ................
(Read rpm on 1800 +20rpm ............ ................
screen.) Difference
between measuring
points
41 - 43/44 <10 bar
........... ..............
A 924 C-LI 34519- 3.55.7

copyright by
MJFCIFSS
Measuring
Checks point
Specified value
10. 45 Mode P
101 raised
(not to block)
Note!
For special equipment (e.g. vertically and horizontally
adjustable boom), observe the instructions on the at-
tached information signs, which refer to a reduced se-
condary pressure in the relevant control block sections.

- Extend boom cylinder 380 +20 bar ........... ..............
Valve 221
- Retract boom cylinder 380 +20 bar ........... ..............
Valve 222
*80 +20 bar ........... ..............
- Retract stick cylinder 380 +20 bar ........... ..............
Valve 241
- Extend stick cylinder 380 +20 bar ........... ..............
Valve 242
- Extend bucket cylinder 380 +20 bar ........... .............
Valve 261
- Retract bucket cylinder 380 +20 bar
Valve 262
* industrial equipment only!
Valve 177
- Reverse travel 380 +20 bar ........... ..............
Valve 176
3.55.8 A 924 C-LI 34519-

copyright by
MJFCIFSS
Measuring
Checks point
Specified value
11. Operating pressure P 41 Mode P

(pressure cut-off) 350 +10 bar ........... .............. Valve 101
12. Lowering speed of at- Mode P

tachment
boom cylinder
Dimension d: 19.5 ±1 mm ............ ................
for construction model 15.0 ±1 mm ............ ................ Adjusting screw 115
for industrial equipment*
stick cylinder 9.0 ±1 mm ............ ................
Dimension d: 23.0 ±1 mm ............ ................ Adjusting screw 116
Lowering restrictor for bu-

cket cylinder 28.0 ±1 mm ............ ................
Dimension d: 28.0 ±1 mm ............ ................ Adjusting screw 117
LS pressure check 45
during ............ ................
Retracting boom cylinder ~ 15/15* bar
............ ................
Extending stick cylinder ~ 40/100* bar
............ ................
Retracting bucket cylin- ~ 90/90* bar
der
Measurement without
attachment!
A 924 C-LI 34519- 3.55.9

copyright by
MJFCIFSS
Measuring
Checks point
Specified value
13. Slewing gear function Write down check measurement
13.1 Define check measure-

ment 22.0 ±1 mm ............ ................ TC - DB valve 134 (dimension A)
Check measurement A
Torque Control valve 137
20.0 ±1 mm ............ ................ (dimension B)
Check measurement B
3.55.10 A 924 C-LI 34519-

copyright by
MJFCIFSS
Measuring
Checks point
Specified value
13.2 Slewing gear function Measuring points

Secondary pressure 145/146/147 Lock and hold (low pressure)
Block uppercarriage (high pressu-
re)
13.3 Swivelling (Pmax)

Counterpressure
145 Valve 131

Turning right 260 ±10bar ........... .............. (high-pressure setting)
Lock nut 2
Adjusting screw 1
146
Turning left 260 ±10bar ........... .............. Valve 132
Lock nut 2
13.4 Braking (Pbr) Adjusting screw 1
145 Valve 131

Turning right 85 +10 bar ............ .............. (low-pressure setting)
Lock nut 3
Adjusting screw 4
146 Valve 132

Turning left 85 +10 bar ........... ............... (low-pressure setting)
Lock nut 3
Adjusting screw 4
Valves 131 / 132
A 924 C-LI 34519- 3.55.11

copyright by
MJFCIFSS
Measuring
Checks point
Specified value
13.5 Secondary pressure Measuring points

Psek. (at control pressu- 147 Pilot control 14 ±0.1 bar
re = 14bar)
145
Turning right 160 ±5 bar ........... ................ Valve 131
146
Turning left 160 ±5 bar ............ ................ Valve 132
3.55.12 A 924 C-LI 34519-

copyright by
MJFCIFSS
Measuring
Checks point
Specified value
13.6 TC characteristic PTC Measuring points Torque Control valve 137

at control pressure = 16 147
Pilot control 16 ±0.1 bar
bar
Turning right 145 ........... ................

160 ±5bar
Turning left 146 ............ ................

160 ±5bar
TC - DB valve 134
13.7 Primary pressure (high
pressure)
............ ................
Turning right 145
245 ±5bar
............ ................
Turning left 146
245 ±5bar
13.8 Stroke limitation of the

spool
............ ...............
Check measurement X
41.3 +0.1 mm
A 924 C-LI 34519- 3.55.13

copyright by
MJFCIFSS
Measuring
Checks point
Specified value
14. Turning speed 8.5 rpm Adjustment of slewing gear motor

........... ................ 130
130.1 = turning right
130.2 = turning left
Adjusting screw 1
Lock nut 2
3.55.14 A 924 C-LI 34519-

copyright by
MJFCIFSS
Measuring
Checks point
Specified value

45 / M2 on the travel motor 170
15.1 Regulation
A 924 C-LI 34519- 3.55.15

copyright by
MJFCIFSS
Measuring
Checks point
Specified value

(travel speed) on drive shaft, measured in on-
Speed of universal joint road gear
shaft
Measured at the universal
joint shaft in on-road gear
forward / reverse
Tyre size 11.00-20: ........... ..............

Standard model (20 km/
h) 1850 ±25 rpm
........... ..............
Speeder model (25 km/h)
2320 ±25 rpm
........... ................
Drive shaft speed
Type 1050/1051 HD 2170 ±25 rpm Adjust settings at adjusting screw
1
Check measurement X 160.1 Reverse travel
at travel motor ........... .............. 160.2 Forward travel
Standard machine 22.5 mm ........... ..............
Type 1050/1051 HD 25.0 mm
3.55.16 A 924 C-LI 34519-

copyright by
MJFCIFSS
Measuring
Checks point
Specified value

nu:
In menu "set data",
Checking the maximum 500 ±200 rpm 450

±50
fan speed mA
............
Checking the minimum 1450+50 -100rpm

fan speed 170 ±50 mA
............

> 50° C and the bonnet is
open.
Danger!
Before working near the fan, switch off the motor.
A 924 C-LI 34519- 3.55.17

copyright by
MJFCIFSS
3.55.18 A 924 C-LI 34519-

copyright by
MJFCIFSS
Type: 1049 / 1050 / 1051 Industrial
Checking/adjustment
Machine type
Serial number
Software versions
Operating voltage
Operating hours
Diesel engine
Low idle rpm rpm 900 +100 .......
Number of teeth 147

3.56.1
copyright by
MJFCIFSS
Checking/adjustment
Pilot pressure

Set at valve 51.

3.56.2
copyright by
MJFCIFSS
Checking/adjustment
0.6

200

(ON).

500

(ON).

800

to (ON).
with tilted lever.
ver.
3.56.3
copyright by
MJFCIFSS
Checking/adjustment

on
3.56.4
copyright by
MJFCIFSS
Checking/adjustment

Check LR pressure. bar Tank

pressure

P1:


8 44


8 43
3.56.5
copyright by
MJFCIFSS
Checking/adjustment

(ON).

pressure

tion.
Set secondary pressure-relief valve
261 to 100-120 bar (at the measuring
point 41).

45
3.56.6
copyright by
MJFCIFSS
Checking/adjustment
Note:
sel engine).


Activate
reached.
rated speed

41 - 44 (P1)
41 - 43 (P2)
3.56.7
copyright by
MJFCIFSS
Checking/adjustment
Pump valve
Preselection of mode P
Check pressure bar 45 - 60 ....... ....... 102 41
Measure check measurement X, if re-

quired
(Q min. stop mm approx. ....... ....... 102 X

at variable-displacement pump) 27.0
Turn up the pressure cut-off valve

101 screwed in
(to block - 90°)
Note!
around 200 bar.
3.56.8
copyright by
MJFCIFSS
Checking/adjustment
- Retract boom cylinder bar 380 +20 ....... ....... 222 45
- Extend boom cylinder bar 380 +20 ....... ....... 221 45
bar *80 +20
- Retracting stick cylinder bar 380 +20 ....... ....... 241 45
- Extend stick cylinder bar 380 +20 ....... ....... 242 45
- Retract bucket cylinder bar 380 +20 ....... ....... 261 45
- Extend bucket cylinder bar 380 +20 ....... ....... 262 45
* industrial equipment only
Accessory kit AS1
Secondary pressure
valve.
Secondary relief valve bar 110 +20 ....... ....... 544 45
Rotating speed
(flow rate)
Connection A mm approx. ....... ....... 1 1

10.5
Connection B mm approx. ....... ....... 2 2

10.5
3.56.9
copyright by
MJFCIFSS
Checking/adjustment

3.56.10
copyright by
MJFCIFSS
Checking/adjustment
Lowering speed of attachment
Mode P
Dimension d:
for industrial equipment* mm 15.0 ±1 ....... ....... 115
Dimension d:
Lowering restrictor for bucket cy-

linder
Dimension d:
LS pressure check
during
Retracting boom cylinder bar approx. ....... ....... 45

15/15*
Extending stick cylinder bar approx. ....... ....... 45

40/100*
Retracting bucket cylinder bar approx. ....... ....... 45

90/90*
Measurement without
attachment!
3.56.11
copyright by
MJFCIFSS
Checking/adjustment
Define check measurement. Screw

in both valves to the stop.
Check measurement A mm 22.0 ±1 ....... ....... 134 A
Check measurement B mm 20.0 ±1 ....... ....... 137 B
Secondary pressure
Swivelling (Pmax)
Counterpressure

2
Turning left bar 260 ±10 ....... ....... 132 1

2
Braking (Pbr)

4
Turning left bar 85 +10 ....... ....... 132 3

4
3.56.12
copyright by
MJFCIFSS
Checking/adjustment
Secondary pressure Psec. bar 14 ±0.1 ....... ....... 147

(at control pressure = 14bar)
Turning right bar 160 ±5 ...... ....... 131 145
Turning left bar 160 ±5 ...... ....... 132 146
TC characteristic PTC bar 16 ±0.1 ...... ....... 137 147

at control pressure = 16 bar
Turning left bar 160 ±10 ...... ....... 145
Primary pressure (high pressure) 134
Turning left bar 245 ±5 ...... ....... 146
Check measurement X mm 41.3 +0.1 ...... ....... X
3.56.13
copyright by
MJFCIFSS
Checking/adjustment
Turning speed

slewing gear 130.
Turning right rpm 9.5 ....... ....... 130.

1.1
Turning left rpm 9.5 ....... ....... 130.

2.1
3.56.14
copyright by
MJFCIFSS
Checking/adjustment
Travel functions

Adjusting screw 64
M2.

M2

M2
3.56.15
copyright by
MJFCIFSS
Checking/adjustment
Output speed
(travel speed)

Tyre size 11.00-20: (20 km/h)

1.1

2.1
Tyre size 11.00-20: (25 km/h)

1.1

2.1
Check measurement X
at travel motor
Stop screw (Qmin)
3.56.16
copyright by
MJFCIFSS
Checking/adjustment

Fan speed rpm 500 +150 ...... ......

-300
Test current mA 500 ±20 ...... ......
Set submenu fan max max to (ON).
Fan speed rpm 1450 +50 ...... ......

-100
Test current mA 150 ±20 ...... ......
Set submenu fan emergency to

(ON).
Fan speed rpm 1650 +200 ...... ......

-200
Reversible fan drive (optional equip-

ment)
Normal operation
Fan speed rpm 1450 +50 ...... ......

-100
Test current mA 150 ±20 ...... ......
Reverse operation
Fan speed rpm 1450 +250 ...... ......

-250
Test current mA 150 ±20 ...... ......
3.56.17
copyright by
MJFCIFSS
Checking/adjustment
Steering function
Select mode P.

Note!
3.56.18
copyright by
MJFCIFSS
Checking/adjustment
Braking function
Brake system
Switching pressure B20 dropping bar 100 ±5 ....... ....... 76 153
increasing bar 125 ±5 ....... ....... 76 27
Working brake
Switching pressure B60 bar 5 ....... ....... 77 25

26
3.56.19
copyright by
MJFCIFSS
3.56.20
copyright by
MJFCIFSS
Service Manual Adjustment guideline for hydraulic system
Arrangement of measuring points
Adjustment guideline for hydraulic system
1 Arrangement of measuring points
Fig. 1 Measuring points at variable displacement pump LPV 20, control valve block 100 and
control oil unit 50
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 control valve block 100 (connection LS)
49 Measuring point for pilot pressure at control oil unit 50 (connection M1)
57 Measuring point - LS pressure at control oil unit 50
59 Measuring point - LS pressure at control oil unit 50
Fig. 2 Measuring points at variable displacement pump DPVO 20, control valve block 100 and
control oil unit 50
44 Measuring point for control chamber pressure at pump20 (connection MA)
57 Measuring point - LS pressure at pump 20 (connection MLS)
59 Measuring point - LS pressure at pump 20 (connection MLR)
A 900 C-LI 14675- 3.60.1

A 904 C-LI 16000- copyright by
MJFCIFSS
Adjustment guideline for hydraulic system Service Manual
Measuring instruments / adjusting tools / safety of adjusting screws
Note!
From 11 / 2003, the measuring points 57 and 59 in the A 904 C Litronic are located at the variable
displacement pump DPVO 20 (see Fig. 2) instead of at the control oil unit (see Fig. 1).
From 09 / 2004, the measuring points 57 and 59 in the A 900 C Litronic are located at the variable
displacement pump LPV 20 (see Fig. 1) instead of at the control oil unit.
Fig. 3 Slewing gear motor 130
2 Measuring instruments / adjusting tools / safety of adjusting

screws
2.1 Measuring instruments

You need the following measuring instruments to check and/or adjust the hydraulic equipment:
Differential pressure gauge / kit 0 - 600 Tools 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 measuring pilot pressure > Pressure sensor 0 - 60 bar
for measuring high pressu- > Pressure sensor 0 -600 bar
res
for measuring actuating > Pressure sensor 0 -600 bar
pressure
plus measuring cable and accessories for measurements 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):
Pressure gauge 0 - 600 bar, tool no. 22
3.60.2 A 900 C-LI 14675-

copyright by A 904 C-LI 16000-
MJFCIFSS
Note!
For adjusting valves and units, use commercially available high-quality tools, for instance:
ring spanners, open end spanners and Allen keys.
Be sure to secure adjusting screws against tampering and unintentional modification:
Use lead seal wire.
Use safety caps (see tools no. 20 thru 25).
2.2 Information for adjustment; pre-conditions
Note!
In the event of hydraulic failures, go through the complete adjustment protocol, in the order as
prescribed.
The min. oil temperature specified can be attained by actuating 'close bucket' at the secondary
reducing pressure relief valve 262 (close bucket / grapple).
2.2.1 Before you start checking / adjusting the hydraulic system, be sure the follo-
wing conditions are fulfilled:
Check device-specific data according to indications on the screen:
Model
Regulating rpm
Serial number
Versions of display, keyboard and BST (excavator control)
Number of teeth on flywheel
Operating voltage
Operating temperature of hydraulic system as measured in tank and displayed (min. 50°C)
Fig. 4 Device-specific indications on the screen
Note!
Remember that during the guaranteed period only representatives of LIEBHERR may modify set-
tings of valves and units.
A 900 C-LI 14675- 3.60.3

MJFCIFSS
Checking and adjusting pilot pressure
3 Checking and adjusting pilot pressure
Fig. 5 Control oil unit connections50
Connect pressure gauge to measuring point 49

Run machine to nominal speed mode P
Compare displayed pressure to specified pressure (see adjustment protocol)
If necessary: correct setting of pressure relief valve 51
Proceed as follows: Remove safety cap. Loosen locknut (SW13). Use Allen key (SW4) to turn ad-
justing screw.
Turning clockwise (cw) = increases pressure
Turning counter-clockwise (ccw) = decreases pressure
When finished: Be sure to secure adjusting screw 51 by a locknut. Replace safety cap.
Remove differential pressure gauge. Close measuring point 49.
4 Checking proportional solenoid valve Y 50
Connect pressure sensor to measuring point 59 Fig. 8

Start machine
Select window ILR in the monitoring display
Fig. 6 Checking proportional solenoid valve Y50
Run machine to mode E / F / L / P
3.60.4 A 900 C-LI 14675-

MJFCIFSS
Checking proportional solenoid valve Y 50
Compare current values (indication in monitoring display ILR) and pressure values to regulation
diagram (see Fig. 9 / Fig. 10)
Current okay Pressure okay => everything in order

Current okay Pressure not => Replace proportional solenoid valve.
okay
Current not Pressure not => Run troubleshooting procedure in electrical system and
okay okay horsepower control
Note!
The characteristic of the solenoid valve cannot be adjusted.
4.1 Setting regulating pressure for emergency operation

Switch off machine
Remove plug from proportional solenoid valve Y 50
Remove cotter pin
Actuate lever
Start machine
Pre-select speed step 10
Compare pressure values with adjustment protocol. Correct, if necessary.
Proceed as follows: Remove locknut. Turn insert by hand
Turn clockwise (cw) to increase pressure
Turn counter-clockwise (ccw) to reduce pressure
Re-set lever to initial position
Replace cotter pin
Remove pressure sensor. Close measuring point 59.
A 900 C-LI 14675- 3.60.5

MJFCIFSS
5 Checking proportional solenoid valve Y 51
Fig. 8
Connect pressure sensor to measuring point 57
Start machine
Select window I-EV1 in the monitoring display
Fig. 7 Checking proportional solenoid valve Y50
Run machine to function SF

Compare current values (indication in monitoring display I-EV1) and pressure values to regulation
diagram (see Fig. 9 Fig. 10)
Current okay Pressure okay => everything in order
Current okay Pressure not => Replace proportional solenoid valve
okay
Current not Pressure not => Run troubleshooting procedure in electrical system
okay okay
Note!
3.60.6 A 900 C-LI 14675-

MJFCIFSS
Fig. 8 Measuring connections 57 / 59 at control oil unit 50 on A 900 C and variable displacement
pump 20 on A 904 C
Fig. 9 Regulation diagram Y50 for A 900 C - Y51 for A 900 C / A904 C
A 900 C-LI 14675- 3.60.7

MJFCIFSS
Fig. 10 Regulation diagram Y50 in connection with variable displacement pump DPVO on exca-
vator A 904 C
3.60.8 A 900 C-LI 14675-

MJFCIFSS
Checking and adjusting variable displacement pumps
6 Checking and adjusting variable displacement pumps
Fig. 11 Measuring connections and valves
For adjusting the begin of hydraulic regulation, adjust the branching regulating the pump from Q
max to Q min.
Disconnect plugs on proportional solenoid valves Y50 and Y51. Measure pressure at measuring
points 57 (MLS) and 59 (MLR). Target = tank pressure.
Connect pressure sensor to measuring point 41 (p pump - control block 100)
Connect pressure sensor to measuring point 44 (p control chamber - variable displacement pump 20)
Run diesel engine to speed step 1
Apply function 'close bucket / grapple' to block
Press pilot control valve all the way to the stop
Screw out secondary pressure relief valve 262 below start of regulation (p pump pressure = p control
chamber)
Carefully replace secondary relief valve 262 until p control chamber is about 5 - 10 bar below p pump
pressure
Compare pressure at measuring point 41 (p pump pressure ) to values given in adjustment protocol
If necessary, make settings using regulating valve
A 900 C-LI 14675- 3.60.9

MJFCIFSS
Proceed as follows:
Start machine
Run diesel engine to speed step 1
To do this, set specified value for begin of regulation (see adjustment protocol) at secondary relief
valve 262 (measuring point 41)
Turn adjusting screw 23.2.1 (A900C) / 8 (A904C) until p pump pressure = p control chamber
Carefully turn adjusting screw back to initial position until p control chamber is about 5 - 10 bar below
p pump pressure
Secure screw by a locknut
Check begin of regulation again: Reduce and increase pressure with secondary relief valve 262
Replace plugs on proportional solenoid valve Y50 / Y51
6.1 Check and adjust difference ( - p) between pump pressure and LS pressure
Before adjusting differential pressure -p, check begin of regulation and horsepower control Y50
Note!
Because the tolerance of differential pressure -p is very low (+1 bar), be sure to have suitable
measuring instruments with sufficient precision. Such measuring instruments do not always deter-
mine a precise value. To make sure, always check and adjust the pressure sensors (see operating
instructions of your measuring device). Connect both pressure sensors to the same source (100 -
110 bar). The difference between values indicated should not be more than 0.5 bar. In the event of
higher differences, adjust sensors using the measuring device (if possible), or replace altogether.
6.1.1 Synchronisation
Fig. 12 Synchronising pressure sensors
A Measuring instrument E Pressure sensor

B Control valve block F Measuring cable
C Measuring neck (ID no. 4901372) P1 Measuring connection
D Measuring point 41 P2 Measuring connection
3.60.10 A 900 C-LI 14675-

MJFCIFSS
6.1.2 How to proceed
Fig. 13 Measuring connections and valves at hydraulic pumps 20 and at control block 100
Disconnect plug connection of proportional solenoid valve Y51 (see Fig. 11). Check pressure at
measuring point 57 (target = tank pressure)
Connect pressure sensor to measuring points 41 (p pump) / 45 (p LS) (see Fig. 13)
Start machine
Run machine to mode P
Connect pilot control valve 'close bucket / grapple' to block
Reduce secondary relief valve 262 to specified value
Check difference
If necessary, correct differential pressures setting -p at flow regulator 23.5.1 / 2 of variable dis-
placement pump 20
Turning clockwise (cw) = increases differential pressure -p
Turning counter-clockwise = decreases differential pressure -p
(ccw)
When finished, secure adjusting screw by a locknut

Replace plug connection at proportional solenoid valve Y 51
A 900 C-LI 14675- 3.60.11

MJFCIFSS
Checking output power of the diesel engine (power test)
Fig. 14 Error message on display
Note!
When you disconnect Y50 / Y51 (see Fig. 11), the display will show error messages E027 (LR) /
E036 (EV1 - LS).
7 Checking output power of the diesel engine (power test)
7.1 Principle
The power input of the pump can be calculated using the following formula:
If the pump is maintained at max. pivoting angle, the power input of the powertrain depends on the
pressure, exclusively (see adjustment protocol). This pressure value has been determined individu-
ally for every type and size of attachment. Secondary consumers are taken into consideration.
Fig. 15 Circuit board A 1001, service plug connection X31, screen display power test
3.60.12 A 900 C-LI 14675-

MJFCIFSS
Adjusting pressure relief and cut-off valves
7.2 Proceed as follows:

Disconnect plug at solenoid valve Y 347 (fan) (see Fig. 21)
Note!
From BST version 5.13.1, the fan is is run at maximum speed when the power test menu is selected.
There is therefore no need to adjust the solenoid valve Y347.
Connect pressure sensor (0-600 bar) to measuring point 41 (p pump) (see Fig. 11)
Connect pressure sensor (0-600 bar) to measuring point 44 (p LS) (see Fig. 11)
Start machine
Run machine to mode P (check max. speed)
SF not in operation
Connect functions 'extend stick cylinder' and 'close bucket' to block
Decrease secondary pressure relief valves 242 (extend stick cylinder - Fig. 16) and 262 (extend
bucket cylinder - Fig. 16) below adjustment-protocol test pressure
Start power test in menu monitoring display
Increase pressure until you reach the value indicated at measuring point 41 (see adjustment pro-
tocol)
Control chamber pressure, pressure difference< 10 bar, pump pressure (10 bar max.)
Read speed at monitoring display
Speed > Regulating => Diesel engine power okay
rpm
Speed < Regulating => Diesel engine power not okay
rpm
8 Adjusting pressure relief and cut-off valves
Fig. 16 Control valve block100 and travel engine 170 with measuring connections and valves
41 Measuring point(pump) 241 Retract stick cylinder

45 Measuring point(LS signal) 242 Extend stick cylinder
104 Pressure cut-off valve 261 Retract bucket cylinder
105 Safety valve 262 Extend bucket cylinder
221 Extend boom cylinder 176 Travel forward
A 900 C-LI 14675- 3.60.13

MJFCIFSS
222 Retract boom cylinder 177 Travel reverse
Note!
Execute all measurements in mode P. Check secondary pressure relief valves at measuring point
45 (p LS). Check pressure cut-off valve 104 and safety valve 105 at measuring point 41 (p pump).
8.1 Method I (plus adjustment of valve 105):

Connect pressure sensor to measuring point 41 (p pump) and measuring point 45 (p LS)
Start machine
SF not in operation. Check tank pressure at measuring point 57 (MLS - see Fig. 11)
Increase the value of pressure cut-off value 104 by turning it in (up to max. 440 bar, or until se-
condary relief valve 262 responds plus 1/2 turn)
Increase pressure at secondary relief valve 262 until safety valve 105 responds, but no more than
max. 440 bar at measuring point 41 (p pump)t
If necessary, set safety valve 105 (measuring point 41 - p pump) to correct value
Set secondary relief valve 262 (measuring point 45 p LS)
Secure secondary relief valve 262 by a locknut
Activate the remaining secondary relief valves by connecting the movements to the block. Correct
settings, if necessary (measuring point 45 p LS)
Set operating pressure at pressure cut-off valve 104 (measuring point 41 p pump)
3.60.14 A 900 C-LI 14675-

MJFCIFSS
Checking and adjusting secondary pressure for slewing gear
9 Checking and adjusting secondary pressure for slewing gear
Fig. 17 Slewing gear motor 130 with pressure relief valves 134 / 135 and TC valve 125 - example
diagram
I : Relations between secondary protection and control pressure 'pivot'

II : Relations between high pressure and control pressure 'pivot'
III : Relations between motor flow consumption (speed) and control pressure 'pivot'
1 : Secondary setting minimum value (braking)
2 : Secondary setting (start-up)
3 : Primary setting (operating pressure)
A 900 C-LI 14675- 3.60.15

MJFCIFSS
Checking and adjusting secondary pressure for slewing gear
9.1 Start-up pressure settings Fig. 17

Danger!
Uppercarriage may execute uncontrolled rotary movements,
posing hazards to mechanics and equipment.
Activate slewing gear brake.
Lock uppercarriage against undercarriage. Use locking bolts.
Anchor equipment to the ground.
Connect pressure sensor to measuring point 137 / 138

Jam uppercarriage. Max. pressure will not be reached when uppercarriage turns.
Turn in valve body at TC valve 125.1 until p primary is above the pressure of the secondary relief
valve (2 turns approx.)
Start machine
Press pilot control valve 'pivot left' all the way to the stop
Compare pressure to adjustment protocol values (measuring point 138)
If necessary: Remove locknut 1 and set relief valve 135 using adjusting screw 2.
Press pilot control valve 'turn right|' all the way to the stop
Compare pressure to adjustment protocol values (measuring point 137)
If necessary: Remove locknut 1 and set relief valve 134 using adjusting screw 2
9.2 Setting brake pressure, Fig. 17

Disconnect and dummy both hose connection with X and Y
Press pilot control valve 'turn left' all the way to the stop
Druck mit dem Einstellprotokoll vergleichen (Messstelle 138)
Press pilot control valve 'turn right|' all the way to the stop (Measuring point 137)
Re-connect hose connections to X and Y
9.3 Set TC valve 125, Fig. 17

Turn back as many turns as turned previously
Turn valve body 125.1 TC valve to adjust the value given in the adjustment protocol
3.60.16 A 900 C-LI 14675-

MJFCIFSS
Checking travel engine 170
10 Checking travel engine 170
Fig. 18 Find measuring point and adjusting screw at control block 100, adjustments at travel en-
gine 170
10.1 Setting begin of regulation (end of regulation), Fig. 18 and Fig. 19
10.1.1 Condition:
Danger!
There may be uncontrolled travel movements (insufficient braking). Hazards exist for mechanics,
operators, vehicle and the environment.
Press equipment into the soil
Extend supports. Immobilise machine.
The power of the diesel engine and the hydraulic pump must be in line with the values prescribed
in the adjustment protocol.
Connect pressure sensor to measuring point 45 (control block 100)
There is a screw plug at the top and to the side on the cover of the adjusting unit of measuring
connection M2. Remove, and insert screw coupling assembly M10X1. You will need special tools
and possibly an extension. Connect pressure sensor.(see Fig. 18)
Start machine
Pre-select a high gear
Run machine against closed brake (on-road gear). Press pedal slowly and carefully to rev up tra-
vel engine. High pressure builds up at measuring point 45
Below begin of regulation for engine A, there should be no pressure build-up at measuring con-
nection M2. That means the oil motor is at minimum pivot angle.
Continue to rev up the engine all the way up to max. value. Keep your eyes on both pressure sen-
sors (at measuring points 45 and M2).
From the moment of begin of regulation A and on, the pressure at measuring connection M2
must continue to go up (about 1/2 high pressure value). That means the oil motor goes towards
max. pivot angle
As soon as the high pressure (at measuring point 45) reaches the value of end of regulation
B, the value taken at measuring point M2 will suddenly surge to the high pressure value as
well, i.e. measuring point 45 and M2 display identical values (see Fig. 19)
A 900 C-LI 14675- 3.60.17

MJFCIFSS
Checking travel engine 170
Fig. 19 Regulating curve of the travel engine
A Begin of regulation B End of regulation
If the pressure value for the end of regulation B is not in line with the value specified, make cor-
rections using adjusting screw 170.26. see Fig. 18
Proceed as follows: Release adjusting screw 170.26. Use Allen (SW3) key to turn screw until end
of regulation B is correct
Turning in = increases end of regulation

Turning out = decreases end of regulation
Note!
Begin of regulation A cannot be adjusted separately.
When finished adjusting end of regulation B, secure adjusting screw 170.26 by a locknut
Remove both pressure sensors and the screw coupling assembly. Close both measuring points
M2 - M10x1 / 45
3.60.18 A 900 C-LI 14675-

MJFCIFSS
Setting max. output speed / max. travel speed
11 Setting max. output speed / max. travel speed
Fig. 20 Spool 160 for chassis
Note!
Manufacturer has fixed the max. speed by means of spool stroke limitation (value Y - see adjust-
ment protocol). Do not not tamper.
If there is a problem with the max. travel speed of the machine, the setting can be modified, if the
max. speed of the universal joint shaft (connection between gearbox and axles) is not in line with the
value stated in the adjustment protocol.
Proceed as follows: Jack up vehicle. Run on-road gear (pilot control valve full throttle)
If necessary, attach pressure measuring connections with travel control circuit. Measure control
pressure at pilot control valve
Measure max. speed of a drive shaft using speed counter HT 460 (tools - page 2.01.10). Compare
to speed indicated in adjustment protocol
If the speed you measure is not in line with the value prescribed, proceed as follows:
Danger!
To measure the speed of the drive shaft, it is necessary to affix a reflective strip to the shaft. During
that work, it is absolutely imperative that the chassis is not set in motion.
It is absolutely imperative that no persons stay under the machine during any and all measurements
with moving wheels and universal joint shafts.

Remove the cap nut of the chassis control shaft of control block 100
Remove locknut 2 of the stroke limitation and turn adjusting screw 1 as required
The speed of the drive shaft measured must be in line with the value prescribed
Turning in = reduces speed
Turning out = increases speed
Repeat the adjustment on the other side of the spool (travelling forward and reverse)
Be sure to secure adjusting screws 160.1 / 160.2 when speed has been adjusted correctly
Replace cap nuts
A 900 C-LI 14675- 3.60.19

MJFCIFSS
Checking fan control
12 Checking fan control
Fig. 21 Fan control with pressure relief valve 14 (cooling)
12.1 Checking fan speed
Danger!
Moving fan blades are a severe hazard to fingers and hands
Be sure to switch off motor when working near the fan
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 proportional solenoid valve Y347 (max. fan speed).
For the purpose of checking, the temperature of the hydraulic oil must be > 50 °C (see adjustment
protocol)
Determine hydraulic oil temperature
If the temperature of the hydraulic oil is too low, it must be raised before checking
Disconnect cable at proportional solenoid valve Y347 at fan motor 13 (Fig. 21)
For checking the fan speed with the speed counter (tool no. 62 / 63), a reflective strip must be
affixed to a blade of the fan
Introduce the pressure measuring connection into the cooling circuit (not within scope of delivery).
Connect pressure sensor
Start motor
Switch motor to mode P
Measure max. fan speed
Compare fan speed measured to value prescribed (see adjustment protocol)
Note!
There is no way of adjusting the fan speed. The pressure has been pre-set by the manufacturer and
must not be changed. The measurement serves only to establish good functioning. If measure-
ments indicate substantial differences between actual and specified values, check hydraulic circuit
for possible disturbances.
3.60.20 A 900 C-LI 14675-

MJFCIFSS
Service Manual Adjustment guidelines for hydraulic system
Menu-based adjustment program from BST version 4.3
Adjustment guidelines for hydraulic system
1 Menu-based adjustment program from BST version 4.3
Caution!
During any and all adjustment and setting procedures, be sure to know and respect general safety
instructions as laid out in group 1.10.
Adjustment and setting by skilled and well trained personnel only.
The adjustment of the hydraulic parameters is facilitated by the menu-based adjustment program at
the display. In this process, the pre-set parameters are transferred to the BBT / BST.
When you change between the various settings and when you close the settings menu or start the
BBT, the values are set to OFF.
Set data:
Setting equipment-specific data.
Set control:
This menu contains various items and options for set-up
tasks.
test Y50:
Testing of proportional solenoid valve of the power cont-
rol (horsepower control)
The current to Y50 is thereby increased to 500 mA.
A 900 C-LI EDC 24677- 3.61.1

A 904 C-LI EDC 30580- copyright by
MJFCIFSS
Adjustment guidelines for hydraulic system Service Manual
test Y51:
Testing of proportional solenoid valve of the flow regula-
tor
begin of reg. P1 / P2:

Adjustment of the begin of regulation P1 / P2.
BBT:speed step 2.
BST:LR current 0 mA.
BST:EV1 / EV2 / EV6 = 100 %.
delta P1 / P2:
Adjustment of delta p P1/P2.
BBT:speed step 10.
BST:LR current = mode P
BST EV1 / EV2 / EV6 = 100 %.
slewing gear:
Adjustment of the secondary cartridge at the slewing ge-
ar.
Actuation of SAT current at EV3 = max current
3.61.2 A 900 C-LI EDC 24677-

copyright by A 904 C-LI EDC 30580-
MJFCIFSS
fan min:
Adjustment of minimum fan speed
Maximum current at fan output (EV5).
BBT: speed step 3
fan max:
Adjustment of maximum fan speed
Minimum current at fan output (EV5).
BBT: speed step 10.
2 Menu-based adjustment program from BST version 4.4
Note!
From BBT version 4.4, there are two distinct submenus of the set data menu, namely set control1
and set control2.
The set control1 service menu is only accessible at inspector level. When changing between the
various setting parameters and when closing the settings menu or starting the BBT, the previous
values remain stored.
The service menu set control2 is accessible at the technician level. When changing between the
various setting parameters and when closing the settings menu or starting the BBT, the values are
set to OFF.
A 900 C-LI EDC 24677- 3.61.3

MJFCIFSS
Service plug connected (technician level)

Set data:
set control2:
tasks.
test Y50:
rol (horsepower control)
test Y51:
tor
3.61.4 A 900 C-LI EDC 24677-

MJFCIFSS

BBT:speed step 2.
BST:EV1 / EV2 / EV6 = 100%.
delta P1 / P2:
BBT:speed step 10.
BST EV1 / EV2 / EV6 = 100%.
slewing gear:
Adjustment of the secondary cartridge at the slewing ge-
ar.
Actuation of SAT current at EV3 = max current
fan min:
BBT: speed step 3
A 900 C-LI EDC 24677- 3.61.5

MJFCIFSS
fan max:
BBT: speed step 10.
Fig. 1 Measuring points A 900 C
44 Measuring point for control chamber pressure at pump 20 (connection MA)
57 Measuring point for LS pressure at pump 20 (connection MLS)
59 Measuring point for LR pressure at pump 20 (connection MLR, horsepower control)
3.61.6 A 900 C-LI EDC 24677-

MJFCIFSS
Fig. 2 Measuring points A 904 C
43 Measuring point for control chamber pressure at pump P2 (connection MA)
137 Measuring point for slewing-gear working pressure at slewing gear motor 130 (connection MA
turn right)
138 Measuring point for slewing-gear working pressure at slewing gear motor 130 (connection MB
turn left)
A 900 C-LI EDC 24677- 3.61.7

MJFCIFSS

screws
4.1 Measuring instruments:

To check and/or adjust the hydraulic unit, you need the following measuring equipment and tools:
Differential pressure gauge / kit 0 - 600 bar Tool in group 2.01
For speed measurement: Speed meter No. 60 or 63
For temperature measurement: Thermometer No. 70
Alternative:
LMS measuring system, tool no. 40
For pilot pressure: > Pressure sensor 0 - 600 bar
For high pressure: > Pressure sensor 0 - 600 bar
For control chamber pressu- > Pressure sensor 0 - 600 bar
re measurement:
plus measuring cables and accessories for the measuring of speed and tempe-
rature
Note!
sure gauges:
pressure gauge 0 - 600 bar, tool no. 22
For tolerance reasons, the p measurement may only be carried out with a pressure gauge.
Note!
For the adjustment of valves and units, use commercially available high-quality tools, for instance:
Always secure the adjusting screws against tampering and unintentional modification:
with lead seal wire
with safety caps
4.2 Instructions for adjustment / pre-conditions
Note!
In the event of a hydraulic failure, follow the instructions in the adjustment guidelines or the ad-
justment protocol in the prescribed sequence.
To achieve the prescribed minimum oil temperature (>50°C), run the machine for some time to
warm it up.
Before you start checking / adjusting the hydraulic system, be sure the following conditions are
fulfilled:
Check the device-specific data according to indications on the screen, see Fig. 4:
Model
Serial number
Operating voltage
3.61.8 A 900 C-LI EDC 24677-

MJFCIFSS
Checking and adjusting the pilot pressure
Note!
5 Checking and adjusting the pilot pressure
Fig. 5 Control oil unit connections 50
Connect the pressure gauge to the measuring point 49.

Run the machine to nominal speed, mode P.
Compare the indicated pressure with the prescribed pressure (see adjustment protocol).
If necessary, adjust the setting of pressure relief valve 51.
To do this, remove the safety cap at the pressure relief valve 51 and 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 at the pressure relief valve 51 with the lock nut and replace the safety
cap.
Remove the pressure gauge and seal the measuring point 49.
A 900 C-LI EDC 24677- 3.61.9

MJFCIFSS
Checking the proportional solenoid valve Y 50 (LR)
6 Checking the proportional solenoid valve Y 50 (LR)
Fig. 6 Menu: test Y50 (horsepower regulation)
Insert service plug.

Select "set data" in service menu.
Press arrow keys to select submenu "set control".
Set submenu "test Y50" to (ON).
The solenoid valve is powered with 500 mA.
Connect a pressure sensor to the measuring point 59.
Fig. 7 Measuring points
Start the machine.

Compare the indicated pressure, (see Regulating diagram Y50 on page 13).
Current OK Pressure OK => OK

Current OK Pressure not OK => Replace proportional solenoid valve.
Current not OK Pressure not OK => Search for fault in the electrical system.
Note!
3.61.10 A 900 C-LI EDC 24677-

MJFCIFSS
6.1 Adjusting the regulating pressure for emergency operation
Fig. 8 Adjusting emergency operation
Connect the pressure sensor (0-60 bar) to the measuring point 59.
Switch off machine.
Remove the plug 1 from the proportional solenoid valve Y 50.
Remove the cotter pin 2.
Actuate the 3 lever.
Start the machine.
Pre-select speed step 10.
Compare the pressure values with those in the adjustment protocol and adjust, if necessary.
To do this, remove the lock nut 4 and turn the insert by hand.
Reset the lever 3 to its initial position.
Insert the cotter pin 2.
Reconnect the plug to the proportional solenoid valve Y 50.
Remove the pressure sensor and seal the measuring point 59.
A 900 C-LI EDC 24677- 3.61.11

MJFCIFSS
Checking the proportional solenoid valve Y 51 (LS)
7 Checking the proportional solenoid valve Y 51 (LS)
Fig. 9 Menu: test Y51

Fig. 10 Measuring points
Start the machine.


Current OK Pressure not OK => Replace proportional solenoid valve.
Current not OK Pressure not OK => Search for fault in the electrical system.
Note!
3.61.12 A 900 C-LI EDC 24677-

MJFCIFSS
Fig. 11 Regulating diagram Y50
A 900 C-LI EDC 24677- 3.61.13

MJFCIFSS
Checking and adjusting the variable-displacement pumps (begin of regulation)
8 Checking and adjusting the variable-displacement pumps (begin

of regulation)
8.1 Adjust P1 / P2 using menu assistance

During the adjustment of the begin of hydraulic regulation, the switch changing the pump from Q max
to Q min is actuated.
3.61.14 A 900 C-LI EDC 24677-

MJFCIFSS
Fig. 14 Menu "begin of reg. P1/P2"

Select submenu "begin of reg. P1/P2 to (ON).
8.2 Checking and adjusting A 900 C

Measure the pressure at the measuring points 57 (MLS) and 59 (MLR) (nominal = tank pressure).
Connect the pressure sensor to the measuring point 41 (p pump pressure - control block 100).
Connect pressure sensor to measuring point 44 (p control chamber - variable displacement pump 20).
Fully close the bucket / grapple.
Press the pilot control unit to the stop.
Adjust the secondary pressure relief valve 262 to a position below the begin of regulation (p
pump pressure = p control chamber).
Slowly screw in the secondary relief valve 262 again, until p control chamber is about 5 - 10 bar below
p pump pressure.
Compare the pressure at the measuring point 41 (p pump pressure ) with the values in the adjustment
protocol.
If necessary, adjust the settings using the regulating valve.
Proceed as follows:
Start the machine.
To do this, set the secondary pressure relief valve 262 (measuring point 41) to the nominal value
for begin of regulation (see adjustment protocol).
Turn in the adjusting screw 8 until p pump pressure = p control chamber.
Carefully turn out the adjusting screw until p control chamber is about 5 - 10 bar below p pump pressure.
Secure the screw with a lock nut.
Check the begin of regulation again: reduce and increase the pressure by means of the secondary
relief valve 262.
A 900 C-LI EDC 24677- 3.61.15

MJFCIFSS
Setting and adjusting P1

Connect the pressure sensor to the measuring point 41 (p pump - control block 100).
Connect pressure sensor to measuring point 44 (p control chamber - variable displacement pump 20).
Unscrew the secondary pressure relief valve 262 to a position below the begin of regulation (p
p pump pressure.
protocol.
Proceed as follows:
Start the machine.
Turn in the adjusting screw 22.1 until p pump pressure = p control chamber.
relief valve 262.

Connect the pressure sensor to the measuring point 41 (p pump - control block 100).
Connect the pressure sensor to the measuring point 43/P2 (p control chamber - variable displace-
ment pump 20).
Adjust the secondary pressure relief valve 262 to a position below the begin of regulation (p
p pump pressure.
protocol.
Proceed as follows:
Start the machine.
3.61.16 A 900 C-LI EDC 24677-

MJFCIFSS
Checking and adjusting the differential pressure (r - p)

Turn in the adjusting screw 24.1 until p pump pressure = p control chamber.
relief valve 262.
9 Checking and adjusting the differential pressure ( - p)
Difference between pump pressure and 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 appropriate accuracy.
As such measuring instruments do not always determine the precise pressure value, always first
test and recalibrate the pressure sensors (for detailed instructions, see operating manual of your
measuring device). Connect both pressure sensors to the same pressure source (100 - 110 bar).
The difference between the indicated values should not exceed 0.5 bar.
In the event of a greater difference, adjust the sensors using a calibration device (if possible), or
replace them.
9.1 Adjusting differential pressure ( - p) using the menu
Fig. 15 Measuring connections and valves at the hydraulic pumps 20 and at the control block 100
A 900 C-LI EDC 24677- 3.61.17

MJFCIFSS
Fig. 16 Menu "delta P1/P2"

Set submenu "delta P1/P2" to (ON).
9.2 Adjustment of A 900 C

Check pressure at the measuring point 57 (nominal = tank pressure).
Connect a pressure sensor to the measuring points 41 (p pump) / 45 (p LS).
Start the machine.
Fully close the bucket / grapple with the pilot control unit.
Reduce the secondary relief valve 262 to the specified value.
Check differential pressure.
If necessary, adjust the differential pressure setting -p at the flow regulator 2 of the variable-dis-
placement pump 20.
Turn clockwise (cw) = increase differential pressure -p
Turn counter-clockwise (ccw) = reduce differential pressure -p
When finished, secure adjusting screw with a lock nut.

Adjust the secondary relief valve 262 to the specified value.
9.3 Adjustment of A 904 C (P1/P2)

Connect a pressure sensor to the measuring points 41 (p pump) / 45 (p LS).
Start the machine.
If necessary, adjust the differential pressure setting -p at the flow regulator 24.5 of the variable-
3.61.18 A 900 C-LI EDC 24677-

MJFCIFSS
displacement pump 20.

When finished, secure adjusting screw with a lock nut.

A 900 C-LI EDC 24677- 3.61.19

MJFCIFSS
Checking output power of the diesel engine (power test)
10 Checking output power of the diesel engine (power test)
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 and speed. This pressure value has been measured individually for each mo-
del and size of attachment, whereby secondary consumers have also been taken into consideration.

Connect the pressure sensor (0-600 bar) to the measuring point 41 (p pump) (see Fig. 15).
Connect the pressure sensor (0-600 bar) to the measuring point 44 (p LS) (see Fig. 15).
Start the machine.
Disconnect Y51 and check the pressure (SF disabled).
Fully extend the stick cylinder and close the bucket.
Press the pilot control units to the stop.
Decrease the secondary pressure relief valves 242 (extend stick cylinder - Fig. 18) and 262 (ex-
tend bucket cylinder - Fig. 18) below the test pressure in the adjustment protocol.
Call up power test in menu monitoring display.
Increase the pressure until the pressure indicated at the measuring point 41 reaches the prescri-
bed pressure (see adjustment protocol).
Check the differential pressure between the control chamber pressure and the pump pressure (<
10 bar).
3.61.20 A 900 C-LI EDC 24677-

MJFCIFSS
Read speed at monitoring display.

Speed > Regulating => Diesel engine output OK
rpm
Speed < Regulating => Diesel engine output not OK
rpm
11 Adjusting pressure relief and cut-off valves
Fig. 18 Control valve block 100 and travel engine 170 with measuring connections and valves
41 Measuring point (pump) 241 Retract stick cylinder

45 Measuring point (LS signal) 242 Extend stick cylinder
104 Pressure cut-off valve 261 Retract bucket cylinder
105 Safety valve 262 Extend bucket cylinder
221 Extend boom cylinder 176 Travel forward
222 Retract boom cylinder 177 Travel reverse
Note!
Execute all measurements in mode P. 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).
11.1 Method I (including adjustment of valve 105):

Connect a pressure sensors to the measuring point 41 (p pump) and the measuring point 45 (p LS).
Start the machine.
Run machine to mode P.
SF not in operation. Check the tank pressure at the measuring point 57 (MLS - see Fig. 13).
Increase the value of pressure cut-off value 104 by turning it in (up to max. 440 bar, or until the
secondary relief valve 262 responds, plus 1/2 turn).
Increase the pressure at the secondary relief valve 262 until the safety valve 105 responds, but
only up to 440 bar at the measuring point 41 (p pump).
If necessary, set the safety valve 105 (measuring point 41 - p pump) to the correct value.
A 900 C-LI EDC 24677- 3.61.21

MJFCIFSS
Checking and adjusting secondary pressure of slewing gear
Adjust the secondary relief valve 262 (measuring point 45 p LS).

Secure the secondary relief valve 262 with a lock nut.
settings, if necessary (measuring point 45 p LS).
Adjust the operating pressure at pressure cut-off valve 104 (measuring point 41 p pump).
12 Checking and adjusting secondary pressure of slewing gear
Fig. 19 Menu "slewing gear"

Set submenu "slewing gear" to (ON).
Activate menu "slewing gear". That way, the electric torque control valve Y451 receives 600 mA
of current, and high pressure is established, see Fig. 21.
Adjust high pressure at secondary pressure relief valves.
Note!
In the
In the menu controlling the slewing-gear sensitivity: set the bar indicator to max. see Fig. 20.
The maximum current required for the adjustment is already entered in the menu "slewing gear".
When the system is adjusted towards "max", the slewing gear responds quicker.
When the system is adjusted towards "min", the slewing gear responds slower.
Fig. 20 Menu for sensitivity of the slewing gear
3.61.22 A 900 C-LI EDC 24677-

MJFCIFSS
Fig. 21 Diagram for setting the slewing gear
A 900 C-LI EDC 24677- 3.61.23

MJFCIFSS
Fig. 22 Slewing gear motor 130 with pressure relief valves 134/135
I : Relationship between the secondary protection and the control pressure for swivelling
II : Relationship between high pressure and the control pressure for swivelling
1 : Secondary setting, minimum value for braking / coasting of revolving deck
2 : Secondary setting for swivelling of the revolving deck
12.1 Adjusting the brake pressure, Fig. 22

Disconnect the pilot control hoses X and Y.
3.61.24 A 900 C-LI EDC 24677-

MJFCIFSS
Checking the travel motor 170
Press the pilot control unit for "turn left" to the stop.
Compare pressure to adjustment protocol.
If necessary, remove the lock nut 3 and adjust the settings of the pressure-relief valve 135 with
the adjusting screw 4
Press the pilot control unit for "turning right" to the stop.
Reconnect the pilot control hoses X and Y.
13 Checking the travel motor 170
Fig. 23 Adjustments to travel motor
13.1 Adjustment of begin of regulation (end of regulation), Fig. 23 and Fig. 24
13.1.1 Condition:
Danger!
Uncontrolled travel movements (poor brake application) results in danger to mechanics, operators,
the vehicle and the environment!
Push the attachment into the soil.
Extend all supports and immobilize the machine.
The output of the diesel engine and the hydraulic pump must correspond to the values prescribed
Connect a pressure sensor to the measuring point 45 (control block 100).
Remove the screw plug from the measuring point M2, connect the screw coupling M10X1 (special
tool and extension, if necessary) and connect the pressure sensor (see Fig. 23).
Start the machine, set it to P mode and pre-select the 2nd gear (on-road gear).
Jack up the machine and run the travel motor in on-road gear at full speed (operate pilot control
unit).
Slowly press down the brake pedal to apply the working brake. High pressure builds up at the
measuring point 45.
Below the begin of regulation for the motor A, there should be no pressure build-up at the
measuring connection M2, i.e. the oil motor is at minimum pivoting angle.
A 900 C-LI EDC 24677- 3.61.25

MJFCIFSS
Continue to accelerate the motor to max. value. Keep your eyes on the two pressure sensors (at
measuring points 45 and M2).
From the moment of the begin of regulation A, the pressure at the measuring connection M2
must continue to increase (to about 1/2 high pressure value). As a result, the oil motor is moved
towards maximum pivot angle.
As soon as the high pressure (at measuring point 45) reaches the value of the end of regulation
B, the value measured at the measuring point M2 increases to the high pressure value, i.e. the
pressures at measuring points 45 and M2 are identical, (see Fig. 24).
If the pressure value for the end of regulation B is not in line with the value specified, make cor-
rections using adjusting screw 64, see Fig. 23.
To do this, loosen the adjusting screw 64. Using an Allen key (WS3), turn the screw until the end
of regulation B is adjusted correctly.
Turn in = increase the end of regulation

Turn out = reduce the end of regulation
Note!
The begin of regulation A cannot be adjusted separately.
When the adjustment of the end of regulation B, is completed, secure the adjusting screw 64 with
a lock nut.
Remove the two pressure sensors and the screw coupling assembly. Seal both measuring points
M2 / 45.
3.61.26 A 900 C-LI EDC 24677-

MJFCIFSS
Adjusting of max. output speed / max. travel speed
14 Adjusting of max. output speed / max. travel speed
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.
Check the checking measurement X at the travel motor.
If the max. travel speed of the vehicle is unsatisfactory, the setting can be modified.
Caution!
To measure the speed, you must attach a reflecting strip to the universal joint shaft. This requires
access to the undercarriage of the machine, This poses a great danger for mechanics.
Access the undercarriage area only when all wheels are standing on firm ground and all brakes
are applied.
During the measuring procedure, when the wheel are turning, ensure that no persons are stan-
ding within the danger zone of the wheels.
Jack up the vehicle and run it in on-road gear (pilot control valve at full throttle).
If necessary, insert a pressure measuring connection into the travel control circuit. Measure the
control pressure at the pilot control valve.
Measure the max. speed of a drive shaft using a HT 460 speed counter (see tools in group 2).
Compare the measured speed with that in the adjustment protocol.
Remove the cap nut of the chassis control axle 160 of the control valve block 100.
Remove the lock nut 2 of the stroke limitation and turn the adjusting screw 1 as required.
Turn in = reduce speed
Turn out = increase speed
A 900 C-LI EDC 24677- 3.61.27

MJFCIFSS
Checking the fan control system
Repeat the adjustment on the other side of the spool (forward and reverse travel).
After completion of the adjustment, secure the adjusting screws 160.1 / 160.2.
Replace the cap nuts.
15 Checking the fan control system
Danger!
Moving fan blades can cause serious injury to fingers and hands.
the air condition.
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.
15.1 Adjustment of minimum fan speed
Fig. 26 Menu "fan min"

Set submenu "fan min" to (ON).
To check the fan speed with the speed counter (tool no. 62 / 63), apply a reflective strip to one of
the fan blades.
Run the machine to mode P.
Measure the minimum fan speed.
Compare the measured fan speed with the prescribed speed (see adjustment protocol).
3.61.28 A 900 C-LI EDC 24677-

MJFCIFSS
15.2 Adjustment of maximum fan speed
Fig. 27 Menu "fan max"

Set submenu "fan max" to (ON).
the fan blades.
Measure the maximum fan speed.
A 900 C-LI EDC 24677- 3.61.29

MJFCIFSS
3.61.30 A 900 C-LI EDC 24677-

MJFCIFSS
Service Manual Checking and adjusting tasks V4.7
Menu-guided adjustment support
Checking and adjusting tasks V4.7
1 Menu-guided adjustment support
Caution!
Ensure that the machine operator in the operator's cab and the maintenance workers can at all ti-
mes see each other.
When you change between the various settings and when you close the settings menu 2.1 or start
the BBT, the values are set to OFF.
Insert the dongle.
Set data:
set control 2.1:

tasks.
reg.valve min:
Testing of proportional Solenoid valves Y50 and Y51.
BST: EV1 / EV2 = 200mA
BBT: speed step 10
3.62.1
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MJFCIFSS
Checking and adjusting tasks V4.7 Service Manual
reg.valve 50%:
BST: EV1 / EV2 = 500 mA
BBT: speed step 10
reg.valve max:
BST: EV1 / EV2 = 800 mA
BBT: speed step 10

reg.valve emergency:
Testing of proportional Solenoid valves Y50 and Y51 in
emergency mode.
BST: EV1 / EV2 = 0 mA
BBT: speed step 10


Testing of the begin of regulation P1 / P2
BBT: speed step 1
BST: EV1 / EV2 / EV6 = 100%
delta P1 / P2:
Testing of delta P1/P2
BBT: speed step 10
BST EV1 / EV2 / EV6 = 100%.
swing 0%:
Testing of minimum primary pressure at slewing gear
BST:520 mA.
BBT: speed step 10
3.62.2
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MJFCIFSS
swing 100%:
Testing of maximum primary pressure at slewing gear
BST:600 mA.
BBT: speed step 10
swing secondary:
Testing of secondary pressure at slewing gear
BST:900mA.
BBT: speed step 10
fan min:
Testing of minimum fan speed
BST: max. fan current 650 mA
BBT: speed step 10
fan max:
Testing of maximum fan speed
BST: min. fan current 250 mA
BBT: speed step 10
fan emergency:
Testing of fan motor emergency system
BST: fan current 0 mA
BBT: speed step 10
3.62.3
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MJFCIFSS
Fig. 1 Measuring points at the variable-displacement pumps 20
43/P2 Measuring point for control chamber pressure at pump 20 (connection MA)
44 Measuring point for control chamber pressure at pump 20 (connection MA)
44/P1 Measuring point for control chamber pressure at pump 20 (connection MA)
Fig. 2 Measuring points at the control block 100 and the control oil unit 50
3.62.4
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MJFCIFSS
Fig. 3 Measuring points on the slewing gear motor 130
137 Measuring point for slewing-gear working pressure at slewing gear motor 130 (connection MA
turn right)
138 Measuring point for slewing-gear working pressure at slewing gear motor 130 (connection MB
turn left)
Fig. 4 Measuring points of the brake system
25 Measuring point / front brake circuit (in undercarriage)

26 Measuring point / rear brake circuit (in undercarriage)
27 Measuring point / brake system at compact brake block
Fig. 5 Measuring point at the steering system
83 Measuring point of the steering system on the gear pump of the steering system
3.62.5
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MJFCIFSS

screws
Note!
The special tools necessary for the adjustments described here are listed with the ID no. in group
2.01.

The pressure gauges must be glycerine-damped with an indication accuracy of less than 1%.
The pressure gauges must have an indication accuracy of o0.3 bar.
Differential pressure gauge / kit 0 - 600 bar
For speed measurement: Piezzo speed No. 60 or 63
Alternative:
LMS measuring system
For pilot pressure: > Pressure gauge 0 - 60 bar
For high pressure: > Pressure gauge 0 - 600 bar
For control chamber pressure measurement: > Pressure gauge 0 - 600 bar
plus measuring cables and accessories for the measuring of speed and temperature
Note!
sure gauges:
Note!
safety caps
3.62.6
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MJFCIFSS
Operating conditions/setting instructions
4 Operating conditions/setting instructions
fulfilled:
4.1 Machine-specific data

Check the machine-specific data according to indications on the screen, (see Fig. 6 on page7):
Location of Measuring
Check / adjustment Unit Setting
adjustment point
Machine type (typ:) - - - -
Serial number (serie:) - - - -
Software versions (ver:) Versions of display, keyboard and BST
Operating voltage (volt:) - - - -
Operating hours (hours:) - - - -
Tab. 1 Machine-specific data
Fig. 6 Machine-specific data.
4.2 Diesel engine

adjustment point
Regulating rpm rpm 1800 - -
Low idle rpm rpm 900 +100 - -
High idle rpm rpm 1950 +50 - -
Number of teeth 147 - -
Tab. 2 Diesel engine
4.3 Operating conditions

adjustment point
Oil temperature C° > 50 +10 - -
3.62.7
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MJFCIFSS
Tab. 3 Operating conditions
In the event of a hydraulic failure, follow the instructions in the adjustment guidelines or the adjus-
tment protocol in the prescribed sequence.
To achieve the prescribed minimum oil temperature (>50°C), run the machine for some time.
adjustment point
Pilot pressure bar 32 ±1 51 49
Tab. 4 Settings
Fig. 7 Control oil unit with adjusting screw / pilot control pressure
Connect pressure gauge (60 bar) to measuring point 49.

Start the machine, move the safety lever to its bottom position and set the unit to mode P.
Compare the pressure shown at the pressure gauge with the prescribed pressure, see Tab. 7.
If necessary, adjust the setting of pressure-relief valve 51.

To do this, remove the protective cap and loosen the lock nut (WS 13).
Increasing pressure
Turn the adjusting screw 51 clockwise, using an Allen key (WS 4).
The pressure is increased.
Reducing 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.
3.62.8
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MJFCIFSS
Checking and adjusting the limit load control system
6 Checking and adjusting the limit load control system
adjustment point
reg.valve min
Test pressure Y51 (tank pressure) bar 0.6 57
Test pressure Y50 bar 2.0.0 ±0.5 59
Test current mA approx. 200
reg.valve 50%
Test pressure Y51 (tank pressure) bar 9.0 ±1 57
Test pressure Y50 bar 6.5 ±1 59
reg.valve max
Test pressure Y51 (tank pressure) bar 21.0 ±1 57
Test pressure Y50 bar 11.0 ±1 59
reg.valve emergency (emergency

operation)
Test pressure Y50 bar 3.5 ±0.5 59
Tab. 5 Settings
Ü
Note!
For guide values, see the regulating diagram, (see Regulating diagrams Y50 and Y51 on
page 12).
3.62.9
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MJFCIFSS
Fig. 8 Checking and adjusting the limit load control system
Connect the pressure gauge (0-60 bar) to the measuring point 57/59, see Fig. 8.
Connect the measuring adapter 1 to Y50/Y51 and the multimeter 2.
Fig. 9 Connection of the multimeter
Start the machine and move the safety lever to its bottom position.
Select set data in the service menu.
Press the arrow keys to select submenu set control 2.1.
6.1 Testing of minimum pressure

Use the arrow keys to select menu option reg.valve min.
Confirm the selection with the menu key.

Set submenu reg.valve min to (ON).
3.62.10
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MJFCIFSS
Fig. 10 reg. valve min
Compare the indicated values with the prescribed values (see adjustment protocol).
6.2 Testing of pressure at 50%

Use the arrow keys to select menu option reg.valve 50%.

Set submenu reg.valve 50% to (ON).
Fig. 11 reg.valve 50%
6.3 Testing of maximum pressure

Use the arrow keys to select menu option reg.valve max.

Set submenu reg.valve max to (ON).
Fig. 12 reg. valve max
3.62.11
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MJFCIFSS
Fig. 13 Regulating diagrams Y50 and Y51
3.62.12
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MJFCIFSS
6.5 Testing of emergency operation

Use the arrow keys to select menu option reg.valve emergency.

Set submenu reg.valve max to (ON).
Fig. 14 reg. valve max
Remove the cotter pin 2 and tilt the lever 3.
Compare the pressure values at the measuring point 57/59 see Fig. 7 with the prescribed values
and adjust them, if necessary.
Turn counter-clockwise (ccw)=reduce pressure
Tilt lever 3 back to its original position and insert cotter pin 2.
Remove the pressure gauge and the multimeter and seal the measuring point 57/59.
3.62.13
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MJFCIFSS
6.6 Checking/adjustment of the hydraulic begin of regulation P1/P2
adjustment point
Pressure at performance regulator bar Tank pressure - 59
Begin of pump regulation bar 50 +2 8 41
44
44 / P1
43 / P2
Tab. 6 Settings
6.7 Adjustment with menu

Connect a pressure gauge (0-600 bar) to the measuring point 41.
Connect the pressure gauge at the measuring point 44 or 44/P1 and 43/P2 (p control chamber - va-
riable-displacement pump 20).

Set the begin of reg. P1/P2 submenu to (ON).
Fig. 16 begin of reg. P1/P2 submenu
Fig. 17 Checking/adjustment of the begin of regulation
3.62.14
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MJFCIFSS
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 25 = tank pres-
sure.
Connect a pressure gauge (060 bar) to the measuring point 59 (pump 20.
Connect pressure gauge (0 - 600 bar) to the measuring point 41 (control block 100).
Connect a pressure gauge (0 - 600 bar) to the measuring point 44 (pump 20.
Compare the pressure measured at the measuring point 59 and compare it with the prescribed
value, see Tab. 6.
Extend bucket cylinder.

Set the secondary pressure-relief valve 262 to a value below the begin of regulation (pressure at
measuring point 44 = pressure at measuring point 41)
Slowly turn in the adjusting screw of the secondary pressure-relief valve 262 while monitoring the
pump pressure at the measuring point 41 and the control chamber pressure at the measuring
point 44.
At the prescribed begin of regulation (see settings), the actuating pressure at the measuring
point 44 must begin to drop relative to the pump pressure at measuring point 41.
If necessary, adjust the regulating valve settings.

Loosen the lock nut (WS 13) of the adjusting screw 8.
Adjusting the begin of regulation to a later point

Turn the adjusting screw 8 (WS 6) clockwise.
Pressure is increased = later begin of regulation
Adjusting the begin of regulation to an earlier point

Turn the adjusting screw 8 (WS 6) counter-clockwise.
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 8.
After checking or adjusting the regulating valves, adjust the secondary pressure-relief valve 262
to the prescribed value, (see 9.2 on page24).
3.62.15
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MJFCIFSS
6.9 Checking and adjusting A 904 C/P1
Fig. 18 Adjustment of the hydraulic begin of regulation P1
justing the settings, the pressure must be adjusted, so that the performance regulator 22.1 = tank
pressure.
Connect a pressure gauge (0 - 60 bar) to the measuring point 59 (pump 20).
Connect a pressure gauge (0 - 600 bar) to the measuring point 44/P1 (pump 20).
Start the machine and check the pressure at the measuring point 59 and compare it with the va-
lues in table 6.

point 44/P1.
At the prescribed begin of regulation (see table), the actuating pressure at the measuring
point 44 must begin to drop relative to the pump pressure at measuring point 41.
If necessary, adjust the settings of the regulating valve 22.1.

To do this, loosen the lock nut (WS 13) of the adjusting screw 8.


Note!
3.62.16
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MJFCIFSS
to the prescribed value, (see 9.2 on page24).
6.10 Checking and adjusting A 904 C/P2
Fig. 19 Adjustment of the hydraulic begin of regulation P2
justing the settings, the pressure must be adjusted, so that the performance regulator 24.1 = tank
pressure.
Connect a pressure gauge (0 - 600 bar) to the measuring point 43/P2 (pump 20).
Start the machine and check the pressure at the measuring point 59 and compare with the values
in table 6.

point 43/P2.
At the prescribed begin of regulation (see table), the actuating pressure at the measuring
point 44/P2 must begin to drop relative to the pump pressure at measuring point 41.
If necessary, adjust the settings of the regulating valve 24.1.

Loosen the lock nut (WS 13) of the adjusting screw 8.


3.62.17
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MJFCIFSS
Checking and adjusting the differential pressure
Note!
to the prescribed value.
7 Checking and adjusting the differential pressure
adjustment point
Pressure at the flow regulator bar Tank pressure - 57
Difference between pump pressure bar 19 +1 52 41
and LS pressure 45
Tab. 7 Settings

control Y50.
Note!
test and recalibrate the pressure gauges (for detailed instructions, see operating manual of your
measuring device). Connect both pressure gauges to the same pressure source (100 - 110 bar).
In the event of a greater difference, adjust the gauges using a calibration device (if possible), or re-
place them.
Insert the dongle.

Press the arrow keys to select submenu set control.
Set submenu delta P1/P2 to (ON).
3.62.18
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MJFCIFSS
7.2 Adjustment of A 900 C
Fig. 21 Adjustment of the differential pressure

Connect the pressure gauge (0 - 600 bar) to the measuring points 41 (p pump) and 45 (p LS) (con-
trol block 100).
Check the differential pressure and compare it with the setting data, see Tab. 7.
If necessary, adjust the differential pressure setting -p at the flow regulator 26 of the variable-
Increasing the differential pressure

Reducing the differential pressure

Turn the adjusting screw 2 (SW 6) counter-clockwise.
Adjust the secondary relief valve 262 to the prescribed value, (see 9.2 on page24).
3.62.19
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MJFCIFSS
7.3 Adjustment of A 904 C (P1/P2)
Fig. 22 Adjustment of the differential pressure

Connect the pressure gauge (0 - 600 bar) to the measuring point 41 (p pump) and 45 (p LS) (control
block 100).
Check the differential pressure and compare it with the setting data, see Tab. 7.
If necessary, adjust the differential pressure setting -p at the flow regulator 24.5 of the variable-
Increasing the differential pressure

Reducing the differential pressure

Turn the adjusting screw 2 (SW 6) counter-clockwise.
Adjust the secondary relief valve 262 to the prescribed value, (see 9.2 on page24).
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 o1.0 bar).
3.62.20
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MJFCIFSS
Checking the output power of the diesel engine (power test)
8 Checking the output power of the diesel engine (power test)
adjustment point
Test pressure A 900 C bar 125 242 / 262 41
A 904 C bar 105 242 / 262 41
Rated speed rpm 1800 - -
Difference between pump pressure bar < 10 - 41/ 44
and adjusting pressure
Tab. 8 Settings
Principle:
Note!
If the pump is maintained at maximum pivot angle, the power input of the powertrain is determined

Connect the pressure gauge (0-600 bar) to the measuring point 41 (p pump).
Connect the pressure gauge (0-600 bar) to the measuring point 44 (p LS).
Connect the dongle X31.
3.62.21
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MJFCIFSS
Checking the output power of the diesel engine (power test)
Run the machine to mode P (check max. speed)
Lower the adjusting pressure of the secondary pressure-relief valves 242 (extending stick cylin-
der) and 262 (extending bucket cylinder) to approx. 100 bar.
Extend the stick and bucket cylinder*.
* 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.
Fig. 24 Checking the diesel engine output
Call up power test in menu monitoring display,see Fig. 22.
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 adjusting screw of the secondary pressure-relief valve 242 or 262 until the prescribed
value is reached (see settings date, observe machine type), while checking the speed.
The power settings of the diesel engine are correct, when the diesel engine is pushed maxi-
mum to the prescribed value, see Tab. 8.
After checking of the engine output, let the diesel engine run at lower idle speed for approx. 1 mi-
nute.
Switch off the engine (ignition off).
The Powertest function is deactivated.
Adjust the secondary pressure-relief valves 242 and 262 to the prescribed value, (see 9.2 on
page24).
3.62.22
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MJFCIFSS
Adjusting pressure-relief and cut-off valves
9 Adjusting pressure-relief and cut-off valves
9.1 Checking/adjusting the pump safety valve 105
adjustment point
Pump safety valve bar 400 +20 105 41
Tab. 9 Settings
Fig. 25 Checking and adjustment of the pressure cut-off valve
Connect the pressure gauge to the measuring point 41 (control block 100).
Increase the pressure cut-off 104 - by turning in the adjusting screw on the block and by turning
it back by a 1/4 rotation (90°).
Extend the bucket/grapple cylinder to the stop and fully actuate the right pilot control unit.
Increase the adjusting pressure at the secondary pressure-relief valve 262 (turning in adjusting
screw ) until the safety valve 105 responds.
This occurs when a further turning in of the adjusting screw of the secondary pressure-relief valve
262 does not result in a pressure increase at the measuring point 41.
Caution!
For reasons of safety, the pressure peaks above the permissible value may not put a strain onto the
unit.
To ensure this, adjust the safety valve 105 to a value of maximum 440 bar (measuring point 41).
Compare the pressure value with the prescribed pressure of the primary pressure-relief valve 105,
see Tab. 9. If necessary, adjust the settings.
To do this, loosen the lock nut (WS 17).
Increasing pressure
Turn the adjusting screw clockwise, using an Allen key (WS 5).
3.62.23
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MJFCIFSS
Reducing pressure
Turn the adjusting screw counter-clockwise, using an Allen key (WS 5).
After completion of the adjustment, secure the adjusting screw with a lock nut.
9.2 Checking/adjusting the secondary pressure-relief valves 176 / 177, 221 - 262
adjustment point
Secondary pressure for extending boom bar 380 +20 221 45
cylinder bar 380 +20 222 45
Secondary pressure for retracting boom
cylinder
Secondary pressure for retracting stick cy- bar 380 +20 241 45
linder bar 380 +20 242 45
Secondary pressure for extending stick cy-
linder
Secondary pressure for retracting bucket bar 380 +20 261 45
cylinder bar 380 +20 262 45
Secondary pressure for extending bucket
cylinder
Secondary pressure for reverse travel bar 380 +20 176 45
Secondary pressure for forward travel bar 380 +20 177 45
Tab. 10 Settings
Fig. 26 Measuring points and valves at the pump, control block and travel motor
Connect a pressure gauge to the measuring point 45.

Check the 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, see Tab. 10 (measuring point 45).
Loosen the lock nut (WS 17).
Increasing pressure
3.62.24
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MJFCIFSS
Reducing pressure
9.3 Checking/adjusting secondary pressure-relief valve for attachment kit AS1
adjustment point
Secondary pressure for turning grapple to bar 110 +20 541 45
the left
Secondary pressure for turning grapple to bar 110 +20 542 45
the right
Turning speed for turning grapple to the bar 15.6 1 1
left
Turning speed for turning grapple to the bar 15.6 2 2
right
Tab. 11 Settings
Fig. 27 Checking/adjusting accessory kit AS1
Remove the protective cap at the measuring point 45.

Connect a pressure gauge (600 bar).
Close the stop cocks or disconnect the pressure connections (seal).
Pressurise the accessory kit, using the keys S5L / S5R located at the left pilot control unit.
Compare the pressure indicated at the pressure gauge with the prescribed pressure, see Tab. 11.
If necessary, re-adjust the pressure by means of the adjusting screw at the corresponding pres-
sure-relief valve 541 / 542.
Proceed as follows: Loosen the lock nut. Use a WS 6 Allen key to turn the adjusting screw.
Turn in the adjusting screw.
3.62.25
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MJFCIFSS
Increasing pressure
Turn out the adjusting screw.
Reduce the pressure.
Open the stop cocks or pressure connections.
9.4 Adjusting the operating pressure (pressure cut-off valve 104)
adjustment point
Operating pressure bar 350 +10 104 41
Tab. 12 Settings
Fig. 28 Adjustment of the operating pressure at the pressure cut-off valve 104
Extend the bucket/grapple cylinder to the stop and fully actuate the right pilot control unit.
Set the operating pressure at the cut-off valve 104 to the prescribed value, see Tab. 12 (measu-
ring point 41).
Loosen the lock nut (WS 17).
Increasing pressure
Reducing pressure
3.62.26
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MJFCIFSS
Checking the slewing gear
10 Checking the slewing gear
adjustment point
Current at Y451 at 0% mA 520 +50
Primary pressure at 0% bar 200 +10 11 137 / 138
Current at Y451 at 100% mA 600 +50
Primary pressure at 100% bar 230 +10 11 137 / 138
Tab. 13 Settings
10.1 Checking and adjusting the secondary pressure for the slewing gear
adjustment point
Start-up
Secondary pressure / turning right bar 250 +10 134.2 137
Secondary pressure / turning left bar 250 +10 134.2 138
Slowing down
Secondary pressure / turning right bar 90 ±5 134.4 137
Secondary pressure / turning left bar 90 ±5 134.4 138
Tab. 14 Settings
Danger!
To check and adjust the slewing gear drive, the system must be pressurised to maximum pressure.
This can lead to inadvertent rotation of the uppercarriage and thus poses a great risk of injury to
mechanics. Objects located within the swivel range of the machine could be damaged. To prevent
this, complete the following steps:
Apply the slewing gear brake.
Anchor the equipment to the ground.
Fig. 29 Adjustment of the slewing gear
3.62.27
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MJFCIFSS
10.2 Checking the primary pressure
Connect a pressure gauge (0-600 bar) to measuring point 137 / 138.

Block the uppercarriage by applying the slewing gear brake and by engaging the uppercarriage
locking mechanism (the max. pressure is not reached when the uppercarriage is swivelled).
10.2.1 Testing of minimum primary pressure at 0%

Set submenu swing 0% to (ON).
Press the pilot control unit for "turning left/right" to the stop.
Compare the pressure value with that in the adjustment protocol (measuring point 137/138).
10.2.2 Testing of maximum primary pressure at 100%

Set submenu swing 100% to (ON).
3.62.28
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MJFCIFSS
Fig. 30 Adjustment of the proportional solenoid valve Y452
If required, loosen the lock nut 12 of the proportional solenoid valve Y451 and adjust the maximum
pressure with the adjusting screw 11.
After completion of the adjustment, secure the adjusting screw 11 with the lock nut 12.
10.3 Checking the current to proportional solenoid valve Y451
Note!
The parameters of the torque control characteristic are preset by the BST excavator control system.
The power to the proportional solenoid valve Y451 can be read on the multimeter and compared with
the prescribed values.
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Fig. 31 Diagram for slewing gear adjustment (Torque Control characteristic)
Connect the measuring adapter to Y451 and to the multimeter.

Compare the displayed values with the prescribed settings, see Tab. 14.
10.4 Checking/adjustment of the secondary pressure
Note!
In order to ensure accurate pressure limitation/pressure settings of the slewing gear function, the
secondary pressure at the secondary pressure-relief valves 134 / 135 must be at least 10 bar above
the measured primary pressure.
10.5 Adjustment of the swivelling pressure (high pressure)

Adjustment of the valve 134/135 (high pressure):
Set submenu swing secondary to (ON).
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Fig. 32 Submenu swing secondary
Compare the pressure with that in the adjustment protocol.
If necessary, loosen the lock nut 1 and adjust the settings of the pressure-relief valve 134 with
the adjusting screw 2.
10.6 Adjustment of the brake pressure (low pressure)

Adjustment of the valve 134/135 (low pressure):
Remove the pilot control hoses (connection XA/XB).
Fig. 33 Remove the pilot control hoses.
Compare the pressure with that in the adjustment protocol.
Reconnect the pilot control hoses (connection XA/XB) to the motor.
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10.6.1 Adjustment of the start-up pressure (high pressure settings)
Fig. 34 Slewing gear motor with pressure-relief valves, with sample diagram
I Relationship between the secondary protection and the control pressure for
swivelling
5 Secondary setting, minimum value (braking)
6 Secondary setting, maximum value (starting)
1 Lock nut 130 Slewing gear motor

2 Adjusting screw / high pressure 134 Secondary pressure-relief valve
3 Lock nut 135 Secondary pressure-relief valve
4 Adjusting screw / low pressure 137 Measuring point
138 Measuring point
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10.7 Adjustment of the maximum turning speed
adjustment point
Turning speed / turning right rpm 9.0 - 9.5 120.1.1 -
Turning speed / turning left rpm 9.0 - 9.5 120.2.1 -
Tab. 15 Settings
Fig. 35 Adjustment of the maximum turning speed
The maximum turning speed of the uppercarriage is determined by the stroke limitation settings of
the spool / slewing gear.
Danger!
To determine the maximum turning speed of the uppercarriage, the uppercarriage must be moved
at full speed for minimum 1 minute. Risk of injury or even death! Ensure that no persons are stan-
ding within the range of operation of the uppercarriage when this measurement is carried out!
All persons must leave the danger area of the machine.
Secure the undercarriage. If necessary, use supports.
Move the pilot control unit for turning slewing gear to the right / left to the stop.
When the maximum turning speed is reached, start the time period for the uppercarriage speed
measurement.
Measure the number of revolutions per minute and compare it with the prescribed settings, see
Tab. 15.
If necessary, remove the cap nut, loosen the lock nut 2 and turn the stop screw 1 of the stroke
limitation 120.1 / 120.2.
To increase speed:
Turn the adjusting screw 1 out.
The speed is increased.
To reduce speed:
Turn the adjusting screw 1 in.
The speed is reduced.
Repeat the adjustment on the other side of the spool 120 (left and right rotation).
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After the adjustment is completed, secure the adjusting screw with the lock nuts 2 and then re-
place the cap nuts.
11.1 Adjustment of the begin of regulation / end of regulation
adjustment point
Begin of regulation bar 240 64 45 / M2
End of regulation bar 320 64 45 / M2
Tab. 16 Settings
Danger!
For inspection and adjustment 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 attachments on the ground. Lift the undercarriage from the ground, if required.
Establish visual or acoustic contact with the operating personnel.
Fig. 36 Checking/adjustment of the travel motor
Note!
The difference between the begin of regulation and the end of regulation of the oil motor is preset
and cannot be adjusted. This means that a change to the end of regulation value automatically re-
sults in a change to the begin of regulation value.
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).
Connect the pressure gauge to the measuring point 45 (pump 20), see Fig. 30.
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Remove the screw plug from the measuring connection M2, see Fig. 35.
Screw in the M10x1 screw coupling assembly (tool no. 10 in group 2.01, with extension, if re-
quired) and connect a pressure gauge.
unit). Take all necessary safety precautions.
Operate the brake pedal to slowly apply the working brake (4-wheel brake). High pressure builds
up at the measuring point 45.
Below the begin of regulation of the motor (see settings values), there should be no pressure
build-up at the measuring connection M2, i.e. the oil motor is at minimum pivot angle.
Continue to accelerate the motor to max. value. Keep your eyes on the two pressure gauges (at
From the moment of begin of regulation, 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 measuring point 45) reaches the value of the end of regulation, see
table 16, the pressure at the measuring point M2 suddenly increases to the high pressure va-
lue, i.e. the pressure at the measuring points 45 and M2 are the same.
If the pressure value for the end of regulation does not correspond to the prescribed value, it can be
adjusted by means of the adjusting screw 64, see Fig. 35.
To do this, release the adjusting screw 64.
Increasing the end of regulation

The end of regulation is increased.
Reducing the end of regulation

Turn adjusting screw 64 out.
The end of regulation is reduced.
Remove the two pressure gauges, remove the screw coupling at M2 and seal both measuring
points.
11.2 Adjustment of the minimum pivot angle

adjustment point
Check dimension X in A 900 C
Standard machine mm approx. 21.0 35 35
Speeder machine mm approx. 25.0 35 35
Check dimension X in A 904 C
Standard machine mm approx. 21.0 35 35
Speeder machine mm approx. 25.0 35 35
Tab. 17 Settings
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Fig. 37 Stop screw (threaded stud) of the swivel yoke for minimum pivot angle
The minimum pivot angle is limited by the threaded stud 35, see Fig. 35. The angle is factory-set by
the manufacturer and may not be changed.
The correct position of the threaded stud 35 can be used as a reference point by measuring the
dimension X, see Fig. 36 and Tab. 17.
11.3 Adjustment of the maximum output speed/maximum travel speed
adjustment point
Universal joint shaft speed in A 900 C
Standard machineForward travel rpm 1680 ±25 160.1.1 -
Reverse travel rpm 1680 ±25 160.2.1 -
Speeder machine Forward travel rpm 2520 ±25 160.1.1 -

Standard machine mm 11 - 160.1
Speeder machine mm 14 - 160.2
Universal joint shaft speed in A 904 C
Tyre size 10.00-20: (20 km/h)

Tyre size 11.00-20: (20 km/h)

Tyre size 10.00-20: (30 km/h)

Speeder machineForward travel
rpm 2520 ±25 160.2.1 -
Tyre size 11.00-20: (30 km/h)
Speeder machineForward travel
rpm 2400 ±25 160.2.1 -
Standard machine mm 11 - 160.1
Speeder machine mm 14 - 160.2
Tab. 18 Settings
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Fig. 38 Checking/adjustment of the travel motor
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
(dimension Y, see above) and may only be adjusted in exceptional circumstances.
If there is a problem with the max. travel speed of the machine, the setting can be modified, if the
max. speed measured at the universal joint shaft (connection between gearbox and axles) is not in
line with the value stated in the settings values.
Adjustment of the maximum output speed:

Jack up the vehicle and run it in on-road gear (travel pedal pressed down to stop).
Measure the maximum speed of one joint shaft, using the HT 460 speed meter (for tool, see
page 2.01) and compare with the prescribed speed (see setting values).
If the measured speed does not correspond to the prescribed speed, proceed as follows:
At the 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.
After completion of the adjustment, retract the support.
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adjustment point
Fan speed (fan min) rpm 450 +100 - -
Test current mA approx. 650 - -
Fan speed (fan max) rpm 1550 +100 - -
Test current mA approx. 250 - -
Fan speed (fan emergency) rpm 1600 +100 - -
Test current (emergency operation) mA approx. 0 - -
Tab. 19 Settings
Danger!
Shut down the engine.
Do not reach into the fan operating range until the fan blades have come to a standstill.
Fig. 39 Checking/adjustment of fan motor with proportional solenoid valve
Note!
changed. If the measurement indicates that there is a substantial difference between the actual and
the prescribed value, check the hydraulic circuit for leakage.
The fan speed to be measured is determined by the actual coolant temperature and the hydraulic
oil temperature as well as the switching state of the a/c system (ON/OFF).
the fan blades.
Connect the measuring adapter to Y347 and to the multimeter.
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Use the arrow keys to select menu option fan min.

Fig. 40 fan min
Start the machine, move the safety lever to its bottom position and measure the minimum fan
speed.
Compare the measured fan speed with the prescribed rated speed, see Tab. 19.
Compare the current values at the multimeter with the prescribed settings.

Use the arrow keys to select menu option fan max.

Set submenu fan max to (ON).
Fig. 41 fan max
Start the machine, move the safety lever to its bottom position and measure the maximum fan
speed.
12.3 Testing of emergency operation

Use the arrow keys to select menu option fan emergency.
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Checking the steering system

Set submenufan emergency to (ON)..
Fig. 42 fan emergency
Start the machine, move the safety lever to its bottom position and measure the minimum fan
speed.
Note!
After correct adjustment of the machine, remove the pressure gauges and seal the measuring
points.
13 Checking the steering system
13.1 Checking the pressure-relief valve in the steering valve 84
adjustment point
Primary pressure bar 180 +8 - 83
Tab. 20 Settings
Fig. 43 Checking the steering system
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Checking the brake system
Remove the cap at the measuring point 83 and connect a pressure gauge (600 bar).
Heat the hydraulic system to operating temperature (>50?).
Move the vehicle wheels to the outer steering positions (right and left).
Slowly turn the steering wheel against the resistance.
Compare the pressure indicated at the pressure gauge with the prescribed pressure, see Tab. 20.
If the pressure is not reached at only one of the steering positions (left/right), it is likely that the
shock valve 6 is faulty.
If the pressure is not reached in both steering positions, it is likely that the primary pressure-
relief valve is faulty.
Caution!
Faults in the steering valves can cause problems with the steering function or failure of the servo
system. The manufacturer therefore explicitly prohibits repairs / replacements of the safety valves
in the steering valve 84.
If measurements reveal that the necessary steering pressure is not reached, it is likely that the pri-
mary pressure-relief valve / shock valve 5/6 is defective. In this case, the complete steering valve
84 must be replaced.
The installation and dismantling of the steering valve 84 is described in group 13.20 / 13.25.
After the installation of the new steering valve 84, check the steering system again for proper func-
tioning and adjust the pressure settings, if necessary.
Remove the pressure gauge at the measuring point 83 and mount the cover cap.
14 Checking the brake system
adjustment point
Switch-on pressure bar 150 ±5 74 27
Shut-down pressure bar 185 ±5
Brake pressure
front bar 75 +10 102 25
rear bar 75 +10 102 26
dropping bar 100 ±5 76 153
increasing bar 125 ±5 76 27
Switching pressure (B60) bar 5 77 25/26
Tab. 21 Settings
3.62.41
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Fig. 44 Checking/adjusting the brake system
14.1 Checking the accumulator charge pressure

Connect the 0-600 bar pressure gauge to measuring point 27 and check the following values:
14.1.1 Switch-on and shut-off pressure of the charging valve 5

Start the machine and recharge the unit.
The pressure at the measuring point 27 rises until the prescribed shut-off pressure is reached
(see adjustment protocol).
The accumulator valve 5 is now switched, so that the system is depressurised, and the pres-
sure at the measuring point 27 drops to zero.
Repeatedly actuate the brake pedal 11 until the pressure in the accumulators drops to the switch-
on pressure level.
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 gauge. If necessary, use the pressure switch conversion
kit B20, see 14.1.3.
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 table).
Turn in = Increasing pressure
Turn out = Reduce pressure
Protect the adjusting screw with a protective cap.
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Fig. 45 Compact brake block with accumulator and brake pedal
14.1.2 Switching pressure of pressure switch B20 (increasing)

If there is a fault indicating that the pressure switch is faulty, the switching pressure of the pressure
switch B20 can be checked through the existing measuring point 27 see Fig. 43within the increasing
range:
Connect a pressure gauge (0-600 bar) to the measuring point 27.
Start the machine and monitor the pressure gauge and the indicator LED H23: when the prescri-
bed switching pressure is reached (see Tab. 21), the indicator LED H23 must be off.
The switching pressure of the pressure switch B20 should only be adjusted after the dropping
switching pressure has been checked, see 14.1.3.
14.1.3 Switching pressure of pressure switch B20 (dropping)

TUEV requires that the switching pressure of the pressure switch B20 is checked in the dropping ran-
ge.
Note!
The switching pressure of the pressure switch B20 in the dropping range can only be checked by
installing an additional measuring point 153 between the connection DS2 and the pressure switch
B20, see Fig. 46.
Switch off the engine. Release the pressure from the system.
Disconnect the pressure switch B20 from the connection DS2 and screw in the "pressure switch
B20 conversion kit"; for details, see tool list 2.01.
Screw the pressure switch B20 into the screw piece of the "pressure switch B20 conversion kit".
Start the machine and charge the brake accumulator to the maximum level.
Shut down the diesel engine, leave the ignition on and reduce the brake pressure by repeatedly
operating the foot pedal.
As soon as the switching pressure (dropping) is reached, the indicator LED H23 at the control
desk is on.
Read the pressure at the additional measuring point 153 at the moment the indicator LED H23 is
3.62.43
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lit, and compare it with the prescribed pressure value, see Tab. 21.
If the pressure switch B20 does not switch at the prescribed value, adjust it with a screwdriver:
Increase switching pressure

Turn the adjusting screw 76 clockwise.
Reduce switching pressure

Turn the adjusting screw 76 counter-clockwise.
Caution!
For safety reasons, the pressure switch conversion kit must be removed after the check has been
completed.
To do this, follow the instructions below and then mount the pressure switch B20 in its original
position (connection DS2).
Screw out the pressure switch B20
Remove the "pressure switch B20 conversion kit".
Screw in the pressure switch B20 to the connection DS2.
Establish the electrical connections and test them.
Fig. 46 Measuring point for accumulator pressure and compact brake block with pressure swit-
ches and conversion kit
14.1.4 Switching pressure of pressure switch B60

Connect a pressure gauge (0-600 bar) to the measuring point 27, see Fig. 43.
Start the machine and recharge the brake accumulator.
Carefully press down the brake pedal 11, see Fig. 47.
The brake lights E19 / E20 must be on when the pedal 11 is pressed down only a little.
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Read the pressure at the additional measuring point at the moment the brake lights are lit, and
compare it with the prescribed settings, see Tab. 21.


Install an additional measuring point.
14.2 Checking the brake pressure of the working brake
Fig. 47 Brake pedal and operating linkage of the brake valve at the compact brake block
Connect a pressure gauge (0-600 bar) to the measuring points 25 and 26.
Fig. 48 Measuring points of the brake system
Start the machine. Press down the foot brake pedal 11 and lock it.
The actual brake pressure, as shown at the pressure gauge, must correspond to the respective
settings value, see Tab. 21.
To adjust the brake pressure, modify the linkage length as follows:
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Press the pedal 11 down to the stop and check whether the pedal 11 engages in the locking lever
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 corresponds to the prescribed pressure.
Subsequently tighten the lock nut 17 and disengage the pedal 11.
Unlock and drive out the pin 18 (Ø 10 mm) inserted between the fork head 16 and the pedal lever,
and insert a Ø 9 mm pin (drill bore, if necessary).
Loosen and adjust the stop screw 29 until there is no play between the fork head 16 and the in-
serted pin.
Secure the stop screw 29 with a lock nut.
Remove the Ø 9 mm adjusting pin and re-insert and lock the original Ø 10 mm pin 18.
The threaded rod is now correctly pre-stressed (1 mm).
After the adjustment is completed, check whether the measuring points 25 and 26 remain without
pressure when the pedal 11 is not pressed.
If required, readjust the position of stop screw 29.
14.2.1 Checking the brake accumulators 14 and 15

Connect a pressure gauge (0-600 bar) to the measuring point 27, (see Fig. 46 on page44).
Connect a pressure gauge (0-600 bar) to the measuring points 25 and 26.
Start the machine. Charge the system all the way up to shut-off pressure.
Shut down the machine and slowly press down the brake pedal 11, (see Fig. 46 on page44) at
least ten times, with short intervals.
Having pressed down the pedal 10 times, the brake pressure at the measuring points 25 and
26 should not have dropped below 50 bar (filling pressure).
If the pressure has dropped below the prescribed value, there is most probably a problem with
accumulators 14 / 15. Release the pressure from the system and install new accumulators.
Remove the pressure gauge and seal the measuring points 25, 26 and 27.
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Adjustment guidelines for hydraulic system
Note!
When you change between the various setting points and when you close the settings menu or start
the BBT, the values are set to OFF.
Note!
From BST version 4.4, there are two distinct submenus of the set data menu, namely set control1
and set control2.
The set control1 service menu is only accessible at inspector level. When changing between the
various setting parameters and when closing the settings menu or start the BBT, the previous va-
lues remain stored.
The service menu set control2 is accessible at the technician level. When changing between the
various setting parameters and when closing the settings menu or start the BBT, the values are set
to OFF.

Set data:
A 914 C-LI 35112- 3.70.1

MJFCIFSS
set control2:
This menu contains various items and options for the ad-
justment of settings.
test Y50:
rol (horsepower control).
test Y51:
tor.

BBT:speed step 2 (fixed).
BST:EV1 / EV6 = 100%.
Y78 OFF
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delta P1 / P2:
BBT:speed step 10 (fixed).
BST EV1 / EV6 = 100%.
fan min:
BBT: speed step 3
fan max:
BBT: speed step 10.
A 914 C-LI 35112- 3.70.3

MJFCIFSS

screws
Note!
The special tools necessary for the adjustments described here are listed with the ID no. in group
2.01.

For speed measurement: Speed meter No. 60 or 63

Alternative:
LMS measuring system
For pilot pressure: > Pressure sensor 0 - 600 bar
For high pressure: > Pressure sensor 0 - 600 bar
For control chamber pressu- > Pressure sensor 0 - 600 bar
re measurement:
plus measuring cables and accessories for the measuring of speed and tempe-
rature
Note!
sure gauges:
Note!
with lead seal wire
with safety caps
1.2 Instructions for adjustment / pre-conditions
Note!
In the event of a hydraulic failure, follow the instructions in the adjustment guidelines or the ad-
justment protocol in the prescribed sequence.
To achieve the prescribed minimum oil temperature (>50°C), run the machine for some time.
fulfilled:
3.70.4 A 914 C-LI 35112-

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Check the device-specific data according to indications on the screen, see Fig. 1:
Model
Serial number
Operating voltage
i
Fig. 2 Arrangement of measuring points
41 Measuring point for pump pressure at the pilot plate 100 (connection xP)
45 Measuring point for LS pressure at pilot plate 100 (connection xLS)
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145 Measuring point for slewing gear working pressure at slewing gear motor 130 (turn right)
146 Measuring point for slewing gear working pressure at slewing gear motor 130 (turn left)
147 Measuring point for slewing gear control pressure at slewing gear motor 130
Fig. 4 Control oil unit connections 50

Run the machine to nominal speed, mode P.
Compare the indicated pressure with the prescribed pressure (see adjustment protocol).
If necessary, adjust the setting of pressure-relief valve 51.
To do this, remove the safety cap at the pressure-relief valve 51 and loosen the lock nut (WS 13).
Use an Allen key (WS 4) to turn the adjusting screw.
Secure the adjusting screw at the pressure-relief valve 51 with the lock nut and replace the safety
cap.
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4 Checking the proportional solenoid valve Y 50 (LR)
Fig. 5 Menu: test Y50 (horsepower regulation)

Select "Set data" in service menu.
Press arrow keys to select submenu "Set control".
Fig. 6 Measuring points 57/59 at the variable-displacement pump 20
Start the machine.


Current OK Pressure not => Replace proportional solenoid valve.
OK
Current not Pressure not => Search for fault in the electrical system.
OK OK
Note!
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Switch off machine.
Remove the plug 1 from the proportional solenoid valve Y 50.
Remove the cotter pin 2.
Actuate the 3 lever.
Start the machine.
Compare the pressure values with those in the adjustment protocol and adjust, if necessary.
Reset the lever 3 to its initial position.
Insert the cotter pin 2.
Reconnect the plug to the proportional solenoid valve Y 50.
5 Checking the proportional solenoid valve Y 51 (LS)
Fig. 8 Menu: test Y51

Press arrow keys to select submenu "set control2".
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Connect pressure sensor to measuring point 57 (LS).
Fig. 9 Measuring points 57/59 at the variable-displacement pump 20
Start the machine.


Current OK Pressure not => Replace proportional solenoid valve.
OK
Pressure not => Search for fault in the electrical system.
OK
Note!
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3.70.10 A 914 C-LI 35112-

MJFCIFSS
6 Checking and adjusting the variable-displacement pumps (begin

of regulation)
6.1 Adjust P1 / P2 using menu assistance

During the adjustment of the begin of hydraulic regulation, the switch changing the pump from Q max
to Q min is actuated.
Fig. 12 Menu "begin of reg. P1/P2"

Select submenu "begin of reg. P1/P2 to (ON).
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6.2 Adjustment and testing

Connect the pressure sensor to the measuring point 41 (p pump - pilot plate 100).
Connect pressure sensor to measuring point 44 (p control chamber - variable-displacement pump 20).
Unscrew the secondary pressure-relief valve 261 to a position below the begin of regulation (p
p pump pressure.
protocol.
Proceed as follows:
Start the machine.
To do this, set the secondary pressure-relief valve 261 (measuring point 41) to the nominal value
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Turn in the adjusting screw 8 at the performance regulator 22.1/P1, until p pump pressure = p control
chamber
Carefully unscrew the adjusting screw 8 until p control chamber is about 5 - 10 bar below p pump pres-
sure.
relief valve 261.
Remove the pressure sensor and seal the measuring point.

Connect the pressure sensor to the measuring point 43/P2 (p control chamber - variable-displace-
ment pump 20).
Unscrew the secondary pressure-relief valve 261 to a position below the begin of regulation (p
p pump pressure.
protocol.
Proceed as follows:
Start the machine.
To do this, set the secondary pressure-relief valve 261 (measuring point 41) to the nominal value
Turn in the adjusting screw 8 at the performance regulator 24.1/P2, until p pump pressure = p control
chamber
Carefully unscrew the adjusting screw 8 until p control chamber is about 5 - 10 bar below p pump pres-
sure.
relief valve 261.
7 Checking and adjusting the differential pressure ( - p)

control Y50.
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Note!
test and recalibrate the pressure sensors (for detailed instructions, see operating manual of your
measuring device). Connect both pressure sensors to the same pressure source (100 - 110 bar).
In the event of a greater difference, adjust the sensors using a calibration device (if possible), or
replace them.

Set submenu "delta P1/P2" to (ON).
7.2 Setting (P1/P2)
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Checking of the pump valve 102

Connect a pressure sensor to the measuring points 41 (xp pump) / 45 (xp LS).
Start the machine.
If necessary, adjust the differential pressure setting -p with the adjusting screw 2 at the flow re-
gulator 24.5 of the variable-displacement pump 20.
When finished, secure the adjusting screw 2 with a lock nut.

8 Checking of the pump valve 102
Compare the pressure at the measuring point 41 with the values in the adjustment protocol.
If the pressure does not correspond to the prescribed set value:
First check the check measurement X (Q-min.stop at the variable-displacement pump).
Check measurement X OK, adjust pump valve 102.
Fig. 16 Checking of the pump valve 102
Loosen the lock nut 1 and adjust the settings with the adjusting screw 2 to the prescribed value.
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Checking output power of the diesel engine
9 Checking output power of the diesel engine
9.1 Power test
Principle:
If the pump is maintained at maximum pivoting angle, the power input of the powertrain is determined
Fig. 17 Power test
Printed circuit board A 1001

Service plug port X31
Power test screen display
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Checking output power of the diesel engine
Fig. 18 Checking of output power
Connect the pressure sensor (0-600 bar) to the measuring point 41 (p pump).
Connect the pressure sensor (0-600 bar) to the measuring point 43P1/44P2 (control chamber).
Start the machine.
Disconnect Y51 and check the pressure (SF disabled).
Fully extend the stick cylinder and close the bucket.
Press the pilot control units to the stop.
Reduce the settings of the secondary pressure-relief valves 242 (extend stick cylinder ) and 261
(extend bucket cylinder ) to a value below the test pressure specified in the adjustment protocol.
Call up power test in menu monitoring display.
Increase the pressure until the pressure indicated at the measuring point 41 reaches the prescri-
bed pressure (see adjustment protocol).
Check the differential pressure between the control chamber pressure and the pump pressure (<
10 bar).
Read speed at monitoring display.
Speed > => Diesel engine output OK
Speed < => Diesel engine output not OK
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Adjusting the pressure limitation settings of the working functions
10 Adjusting the pressure limitation settings of the working functions
Fig. 19 Adjustment of the secondary pressure-relief valve settings:
176 Travel reverse 241 Retract stick cylinder

*retract at top
177 Travel forward 242 Extend stick cylinder
*extend at bottom
221 Extend boom cylinder 261 Extend bucket cylinder
222 Retract boom cylinder 262 Retract bucket cylinder
* industrial model
Note!
Execute all measurements in mode P. Check the secondary pressure-relief valves at the measuring
point 45 (p LS). Check the pressure cut-off valve 101 at the measuring point 41 (p pump).
3.70.18 A 914 C-LI 35112-

MJFCIFSS
Checking and adjusting the pressure cut-off valve 101
Fig. 20 Adjustment of the secondary pressure-relief valve settings:
Connect a pressure sensors to the measuring point 41 (p pump) and the measuring point 45 (p LS).
Start the machine.
SF not in operation. Check the tank pressure at the measuring point 57 (MLS - see Fig. 13).
Increase the value of pressure cut-off value 101 by turning it in (up to max. 440 bar, or until the
secondary relief valve 261 responds, plus 1/2 turn).
Increase the pressure at the secondary relief valve 261 until the safety valve 101 responds, but
only up to 440 bar at the measuring point 41 (p pump).
Adjust the secondary relief valve 261 (measuring point 45 p LS).
Secure the secondary relief valve 261 with a lock nut.
settings, if necessary (measuring point 45 p LS).
Adjust the operating pressure at pressure cut-off valve 101 (measuring point 41 p pump),(see
Checking and adjusting the pressure cut-off valve 101 on page 19).
11 Checking and adjusting the pressure cut-off valve 101
Fig. 21 Pressure cut-off valve 101
A 914 C-LI 35112- 3.70.19

MJFCIFSS
Checking and adjusting the lowering speed of the attachment

Compare the pressure at the measuring point 41 with the values in the adjustment protocol.
If necessary, adjust the setting of pressure cut-off valve 101.
Loosen the lock nut 2 (WS19) and turn the adjusting screw 1 (WS5).
After completion of the settings, lock the adjusting screw 1 with the lock nut 2.
12 Checking and adjusting the lowering speed of the attachment
12.1 Lowering restrictor 115/116/117
Fig. 22 Lowering restrictor 115/116/117
Park the machine on level ground.

Extend the boom cylinder until the attachment is in a horizontal position.
The cylinder should move smoothly without jerking.
Fully retract stick.
Extend the stick or bucket cylinder. The cylinder should move smoothly and without jerking.
If required, adjust the settings of the lowering restrictors 115/116/117.
3.70.20 A 914 C-LI 35112-

MJFCIFSS
Checking and adjusting the slewing gear functions
Guide values for dimension d of the adjusting screw:
Item Model Dimension d Test pres- Measuring
sure point
Lowering restric- Design type 19.5 ±1 mm Retracting 45

tor 115 industrial model 15.0 ±1 mm approx. 50
Boom cylinder bar
Lowering restric- Design type 9.0 ±1 mm Extending 45
tor 116 industrial model 23.0 ±1 mm approx.
Stick cylinder 100 bar
Lowering restric- Design type 28 ±1 mm Extending 45
tor 117 industrial model 28 ±1 mm approx.
Bucket cylinder 130 bar
Loosen the lock nut and turn the adjusting screw until the guide value is reached.
Check the pump pressure at the measuring point 45 while making working movements.
13 Checking and adjusting the slewing gear functions
Danger!
Uppercarriage may execute uncontrolled rotary movements, posing a hazard to mechanics and
equipment.
Apply the slewing gear brake (switch S17).
Uppercarriage is locked in its position.
Lower the attachment to the ground.
13.1 Checking/adjusting high pressure-relief valves 131/132
13.1.1 Adjusting the upper pressure level (counter-pressure)
Fig. 23 Adjustment of accelerating/braking movement
A 914 C-LI 35112- 3.70.21

MJFCIFSS
In order to facilitate the adjustment of the basic position of the TC pressure-relief valve 134 (dimen-
sion A) and the Torque Control valve 137 (dimension B), proceed as follows:
Write down the check measurements at the valves 134 and 137. For guideline values, see adjus-
tment protocol.
Turn both valves 134 and 137 to the stop.
Adjust the secondary pressure.
Fig. 24 Setting values
Note!
Turn clockwise = increase pressure
Turn counter-clockwise = reduce pressure
One full revolution corresponds to a pressure change of approx. 235 bar.
Connect a pressure sensor to the measuring point 145/146.

Block the uppercarriage and actuate the switch S17.
Press the pilot control unit for 'turn right' to the stop.
Compare the pressure with that in the adjustment protocol (measuring point 145).
Press the pilot control unit for 'turn left' to the stop.
3.70.22 A 914 C-LI 35112-

MJFCIFSS
13.1.2 Adjusting the lower pressure level (braking)
Danger!
Rotating movements of the uppercarriage during dynamic measurement pose a hazard to mecha-
nics and equipment.
Ensure that no persons or other objects are located in the swivelling range.

Release the slewing gear brake (switch S17).
After the maximum swivelling speed is reached, release the pilot control unit and read the pres-
sure indicated at the measuring point 145.
If necessary, loosen the lock nut 3 and set the pressure-relief valve 131, using adjusting screw
4 and the special tool no. 18.
13.1.3 Checking and adjusting characteristic (high pressure-relief valves)
Note!
These valves are factory-set, (see Diagram of slewing gear settings on page 26) and it is normally
not necessary to check and readjust them.
If the characteristic has been changed, the brake pressure must be checked and adjusted accordin-
gly, (see Adjusting the lower pressure level (braking) on page 23).

Block the uppercarriage.
Adjust the pilot control pressure for turning left/right with the pilot control unit (select a high initial
pressure and then lower it; for set pressure value, see adjustment protocol).
Read the pilot control pressure indicated at the measuring point 147.
Compare the pressure values with those in the adjustment protocol (measuring point 145/146).
If necessary, loosen the lock nut 5 and adjust the characteristic with the adjusting screw 6.
A 914 C-LI 35112- 3.70.23

MJFCIFSS
13.2 Checking and adjusting the maximum acceleration pressure at the TC pressu-
re-relief valve 134
Fig. 26 Adjusting pressure-relief valve 134
Note!
The TC pressure-relief valve 134 limits the acceleration pressure for turning right/left.
Adjust the setting valve A at the TC pressure-relief valve 134; for guide values, see adjustment
protocol.
Press the pilot control unit for 'turn left/right' to the stop.
13.3 Checking and adjusting Torque Control valve 137 (characteristic)
Fig. 27 Adjusting Torque Control valve 137
3.70.24 A 914 C-LI 35112-

MJFCIFSS
Connect a pressure sensor to the measuring point 145/146/147.

Adjust the setting valve B at the Torque Control valve 137; for guide values, see adjustment pro-
tocol.
Adjust the pilot control pressure for turning left/right with the pilot control unit to 16 bar (select a
high initial pressure and then lower it; for set pressure value, see adjustment protocol).
Read the pilot control pressure indicated at the measuring point 145/146.
If necessary, loosen the lock nut 2 and set the Torque Control valve 137 using the adjusting
screw 1.
If the pressure settings of the Torque Control valve 137 cannot be adjusted, first set the characteristic
of the high pressure limitation, (see Checking and adjusting characteristic (high pressure-relief val-
ves) on page 23).
Note!
The values shown in the diagram below are sample values only. For the actual applicable values,
see the adjustment protocol.
I Relationship between the secondary protection and the control pressure for swivelling
II Relationship between high pressure and the control pressure for swivelling
1 Minimum secondary set value
2 Secondary value Pst dependent
4 Limited by control pressure
5 Torque control
Secondary limitation
Working pressure for lowering
A 914 C-LI 35112- 3.70.25

MJFCIFSS
Fig. 28 Diagram of slewing gear settings
3.70.26 A 914 C-LI 35112-

MJFCIFSS
14.1 Adjustment of the begin of regulation (end of regulation)
14.1.1 Condition:
Danger!
Uncontrolled travel movements (poor brake application) results in danger to mechanics, operators,
the vehicle and the environment!
Push the attachment into the soil.
Extend all supports and immobilize the machine.
Fig. 29 Adjustments to the travel motor
The output of the diesel engine and the hydraulic pump must correspond to the values prescribed
Connect a pressure sensor to the measuring point 45 (control block 100).
Remove the screw plug from the measuring point M2, connect the screw coupling M10X1 (special
tool and extension, if necessary) and connect the pressure sensor.
Start the machine, set it to P mode and pre-select the 2nd gear (on-road gear).
unit).
Slowly press down the brake pedal to apply the working brake. High pressure builds up at the
measuring point 45.
Below the begin of regulation for the motor A, there should be no pressure build-up at the
measuring connection M2, i.e. the oil motor is at minimum pivoting angle.
Continue to accelerate the motor to max. value. Keep your eyes on the two pressure sensors (at
From the moment of the begin of regulation A, the pressure at the measuring connection M2
must continue to increase (to about 1/2 high pressure value). As a result, the oil motor is moved
towards maximum pivot angle.
As soon as the high pressure (at measuring point 45) reaches the value of the end of regulation
B, the value measured at the measuring point M2 increases to the high pressure value, i.e. the
pressures at measuring points 45 and M2 are identical, (see Fig. 30).
A 914 C-LI 35112- 3.70.27

MJFCIFSS
If the pressure value for the end of regulation B does not correspond to the prescribed value, make
corrections using the adjusting screw 64.
To do this, loosen the adjusting screw 64. Using an Allen key (WS3), turn the screw until the end
of regulation B is adjusted correctly.
Turn in = increase the end of regulation

Turn out = reduce the end of regulation
Note!
The begin of regulation A cannot be adjusted separately.
When the adjustment of the end of regulation B, is completed, secure the adjusting screw 64 with
a lock nut.
Remove the two pressure sensors and the screw coupling assembly. Seal both measuring points
M2 / 45.
3.70.28 A 914 C-LI 35112-

MJFCIFSS
Adjusting of max. output speed / max. travel speed
15 Adjusting of max. output speed / max. travel speed
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.
Check the checking measurement X at the travel motor.
If the max. travel speed of the vehicle is unsatisfactory, the setting can be modified.
Caution!
To measure the speed, you must attach a reflecting strip to the universal joint shaft. This requires
access to the undercarriage of the machine, This poses a great danger for mechanics.
Access the undercarriage area only when all wheels are standing on firm ground and all brakes
are applied.
During the measuring procedure, when the wheels are turning, ensure that no persons are stan-
ding within the danger zone of the wheels.
Jack up the vehicle and run it in on-road gear (pilot control valve/pedal to stop, engine run at full
throttle).
If necessary, insert a pressure measuring connection into the travel control circuit. Measure the
control pressure at the pilot control valve.
Measure the max. speed of a drive shaft using a HT 460 speed counter (see tools in group 2).
Compare the measured speed with that in the adjustment protocol.
Remove the protective cap of the chassis control axle 160 of the control valve block 100.
Remove the lock nut 2 of the stroke limitation and turn the adjusting screw 1 as required.
Turn in = reduce speed
A 914 C-LI 35112- 3.70.29

MJFCIFSS
Turn out = increase speed
Repeat the adjustment on the other side of the spool (forward and reverse travel).
After completion of the adjustment, secure the adjusting screws 160.1 / 160.2.
Replace the protective cap.
Danger!
the air condition.
protocol) and the bonnet must be opened.
Note!
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.
Fig. 32 Menu "fan min"

Set submenu "fan min" to (ON).
the fan blades.
Start the engine.
Measure the minimum fan speed.
3.70.30 A 914 C-LI 35112-

MJFCIFSS
Fig. 33 Menu "fan max"

Set submenu "fan max" to (ON).
the fan blades.
Start the engine.
Measure the maximum fan speed.
A 914 C-LI 35112- 3.70.31

MJFCIFSS
3.70.32 A 914 C-LI 35112-

MJFCIFSS
Service Manual Adjustment protocol (kits)
Adjustment protocol (kits)
1 A 900 C Litronic - A 924 C Litronic
Note!
For a detailed description of the respective kit (optional equipment), refer to the service manual in
group 16.
Checking/adjustment
Attachment kit AHS1 (optional equipment)
Secondary pressure

(to block -90°).
Extending regulating cylinder bar 380 +20 ....... ....... 501 45
Retracting regulating cylinder bar 380 +20 ....... ....... 502 45
After adjustment, set the pressure

cut-off valve 104 to the prescribed va-
lue, see adjustment protocol of basic
machine.
3.80.1
copyright by
MJFCIFSS
Adjustment protocol (kits) Service Manual
Checking/adjustment
Accessory kit AHS11 with Tool Control (optional equipment)
Secondary pressure

(to block -90°).
Adjustment with menu

Set opt1 EV6 to 0%.
Low pressure
Press down the left pedal. bar 100+10 ....... ....... 512 45
Low pressure
Press down the right foot pedal. bar 100+10 ....... ....... 511 45
Adjustment with menu

Set opt1 EV6 to 100%.
High pressure
Press down the left pedal. bar 380+20 ....... ....... 20 45
High pressure
Press down the right foot pedal. bar 380+20 ....... ....... 20 45
After adjustment, set the pressure

cut-off valve 104 to the prescribed va-
lue, see adjustment protocol of basic
machine.
Accessory kit AHS12 with Tool Control (optional equipment)
see AHS1 and AHS11
3.80.2
copyright by
MJFCIFSS
Checking/adjustment
Hydraulic cab elevation system (optional equipment)
Maximum operating pressure
Move the operator's cab to its top bar 180 ....... ....... 15 18
stop.
Lifting speed l approx. ....... .......

10-20
sec. approx. ....... .......

13-15
Check measurement X mm approx. ....... ....... X 12

8.5
Dozer blade (optional equipment)
Pressure control
Pressure-relief valve bar 240 ±5 ....... ....... 304 305
Fully extend dozer blade forwards

(lower to firm ground).
3.80.3
copyright by
MJFCIFSS
Checking/adjustment
Reversible fan drive
Pressure-relief valve bar 115+5 ....... ....... 3 9

(reversing)
Press and hold the button S160 for

more than 15 seconds.
Secondary pressure-relief valve bar 200+10 ....... ....... 8 9
Disconnect the plug at the proportio-

nal solenoid valve Y347. The fan is
operated at maximum output level
(emergency operation).
Proportional pressure-relief valve bar 180 ....... ....... 2 9

Y347
For fan speed and test current,

see adjustment protocol of the basic
machine
3.80.4
copyright by
MJFCIFSS
Checking/adjustment
Generator drive (optional equipment)
pump pressure
Pump safety valve bar 280+20 ....... ....... 422 432
Disconnect hydraulic line B and seal

with dummy plug.
Press the switch S46.
Generator speed rpm 3050+50 ....... ....... 421
Flow regulator bar p 12 - ....... ....... 421 431

14 432
3.80.5
copyright by
MJFCIFSS
3.80.6
copyright by
MJFCIFSS
Service Manual
SUBGROUP - INDEX
Section Group Type
Bleeding the fuel system 4.05.1 A 900 C-LI EDC 24677-

A 904 C-LI EDC 30580-
A 914 C-LI 35112-
A 924 C-LI 34519-
Technical data of diesel engines 4.11.1 A 900 C-LI 14675-

A 904 C-LI 16000-
Technical data of diesel engines 4.12.1 A 900 C-LI EDC 24677-

A 904 C-LI EDC 30580-
Technical data of diesel engines 4.13.1 A 914 C-LI 35112-

A 924 C-LI 34519-
Installation and check list for 4.26.1 A 900 C-LI EDC

diesel particle filter A 904 C-LI EDC
A 914 C-LI
A 924 C-LI
Liebherr diesel particle filter accessory kit 4.27.1 A 900 C-LI EDC
A 904 C-LI EDC
A 914 C-LI
A 924 C-LI
4.1
MJFCIFSS
Service Manual
4.2
MJFCIFSS
Service Handbuch Bleeding the fuel system
Bleeding fuel system
Bleeding the fuel system
1 Bleeding fuel system
The fuel filters must be bled after:

Change of fuel filters
The fuel system must be bled after:
Fuel tank run empty
Start up of the diesel engine after work on the fuel system
2 Bleeding of fuel filter
Fig. 1 Bleeding fuel filter
Note!
To bleed the fuel filter, open the bleeder screw on the filter head of the fine filter. It is not necessary
to open the fuel/injection lines and connections.
Loosen the bleeder screw 1 on the filter head of the fine filter and turn out by 2-3 turns.
Operate the hand pump 2 until the fuel leaks out without bubbles.
Tighten the bleeder screw 1 on the filter head of the fine filter.
Operate the hand pump 2 until there is a noticeable resistance.
Start engine.
Note!
If the engine fails to start, repeat the bleeding procedure.
A 900 C-LI EDC 24677- 4.05.1

A 914 C-LI 35112- MJFCIFSS
A 924 C-LI 34519-
Bleeding the fuel system Service Handbuch
Bleeding of fuel system
3 Bleeding of fuel system
3.1 Bleeding fuel pre-filter:
Fig. 2 Bleeder screw on filter head of the fuel pre-filter
Loosen the bleeder screw 1 on the filter head of the fuel pre-filter and turn out by 2-3 turns.
Tighten the bleeder screw 1 on the filter head of the fuel pre-filter.
3.2 Bleeding fuel fine filter:
Fig. 3 Bleeder screw on the filter head of the fuel fine filter
Loosen the bleeder screw 1 on the filter head of the fine filter and turn out by 2-3 turns.
Tighten the bleeder screw 1 on the filter head of the fine filter.
4.05.2 A 900 C-LI EDC 24677-

MJFCIFSS A 914 C-LI 35112-
A 924 C-LI 34519-
Bleeding of injection lines, up to serial number 32997 (software version 4.2):
3.3 Bleeding on the crankcase*:
Fig. 4 Bleeder screw on the crankcase
Loosen bleeder screw 1 on the crankcase and turn out by 2-3 turns.
Tighten the bleeder screw 1 on the crankcase.
* depending on engine serial number
4 Bleeding of injection lines, up to serial number 32997 (software version

4.2):
Note!
The injection lines must be marked each time they are opened,
as they must be replaced after having been opened three times.
Fig. 5 Marks on injection lines
A 900 C-LI EDC 24677- 4.05.3

A 924 C-LI 34519-
Bleeding of injection lines, up to serial number 32997 (software version 4.2):
Fig. 6 Injection lines of cylinders 1 and 4
Loosen the injection line on the nozzle-side connection 1 from cylinder 1 (first cylinder) and on the
pump-side connection 2 from cylinder 4 respectively cylinder 6 (last cylinder) by 1/3 turn.
Operate the hand pump 2 until the fuel leaks out of the injection lines without bubbles.
Tighten the nozzle-side connections 1 with 27 - 33 Nm and the pump-side connection 2 with
25 - 40 Nm.
Start diesel engine.
Note!
If the engine fails to start, repeat the bleeding procedure.
4.05.4 A 900 C-LI EDC 24677-

A 924 C-LI 34519-
Start diesel engine in the bleeding mode (Purge function) starting software version 4.4
5 Start diesel engine in the bleeding mode (Purge function) starting

software version 4.4
Notice!
Starting in the bleeding mode will be necessary, if the fuel tank was run empty completely.
The completely run empty fuel system must be bled by hand as described in the previous chapters.
However air still remains in the high pressure fuel system. This air can escape during the starting pro-
cedure of the engine.
The bleeding function (operators level, PURGE) supports this process. The high pressure fuel sys-
tem will automatically be bled, the engine starts better.
The menu PURGE is available when the engine is not running.

Turn on the ignition.
Select the menu PURGE in the operators level
Fig. 7 Menu Purge
Press the menu button

The bleeding mode is active (purge = ON)
Start diesel engine
The injection system is using the maximum fuel delivery. In this condition there will be increa-
sed formation of smoke.
If the engine starts and reaches a specified speed (> 500 rpm), the bleeding function is turned
off automatically (purge = OFF) and the menu will no longer show in the display.
The injection system is working in a normal operating condition.
Do not operate the starter motor for more than 20 seconds without interruption.
If the engine does not start, repeat the bleeding process and start the engine again in the bleeding
mode.
A 900 C-LI EDC 24677- 4.05.5

A 924 C-LI 34519-
Start diesel engine in the bleeding mode (Purge function) starting software version 4.4
4.05.6 A 900 C-LI EDC 24677-

A 924 C-LI 34519-
Service Manual Technical data of diesel engines
Engine type: D 924 TI - E
Technical data of diesel engines
1 Engine type: D 924 TI - E
Version: A2
Installation in machines / from serial no.: A 900 C-Li / 14675 A 904 C-Li / 16000
Power according to DIN / ISO 9249 kW 88 99
PS 120 135
Max. torque (max. engine speed) Nm 630 730
Operating data A 900 C-Li / 14675 A 904 C-Li / 16000

Design 4-cylinder - turbo
Operating method 4-stroke direct injection
Bore mm 122
Stroke mm 142
Displacement cm3 6636
Firing sequence 1-3-4-2
Compression ratio 17,2 : 1
Combustion pressure at starting speed bar 20 - 28
Firing interval °kW 180
Weight (dry) kg 740
Direction of rotation (seen from flywheel) left
Flywheel housing SAE 2
Cooling system Recirculation cooling
Speed range A 900 C-Li / 14675 A 904 C-Li / 16000

Rated speed min-1 1800 2000
High idle rpm min-1 1890 +50 2110 +50
Low idle rpm min-1 850 +100 850 +100
Lowest operating speed min-1 1000
Speed at max, engine speed min-1 1000
Settings A 900 C-Li / 14675 A 904 C-Li / 16000

Inlet valve play (cold) mm 0,25
Outlet valve play (cold) mm 0,30
Begin of delivery °CA be- see type plate
fore
TDC
Tooth backlash in oil pump gear mm 0.15 0.25 (engine in mounting position: cy-
linder head down
A 900 C-LI 14675- 4.11.1

MJFCIFSS
Technical data of diesel engines Service Manual
Filling volumes (approx. values) A 900 C-Li / 14675 A 904 C-Li / 16000
Lubricating oil in standard oil pan l max. 20.5 / min. 13.5
Lubricating oil system (filter / cooler / channels) l 5
Filling volumes (for oil change with filter replacement) l 23
Cooling liquid including coolant l 26,5

Coolant temperature °C 79 to max. 100
Thermostat opening temperature °C 79
Pressure in cooling system bar min. 1.1 in engine at operating temperature
(coolant temperature > 80°C), measured at
coolant pump outlet (connection to heating)
at nominal engine speed
Lubricating oil temperature °C max. 115
Min. lubricating oil pressure °C
Injection nozzles DLLA 142P632

Injection pressure of injection nozzles:
new bar 225 +8
at end of service life bar 217 +8
Max. engine inclination towards right or left 45 °
Max. engine inclination towards front or rear 45 °
Engine wear parts A 900 C-Li / 14675 A 904 C-Li / 16000

Fuel double filter 1 unit 50-60X10-6 prefilter
1 unit 7X10-6 fine filter
Oil filter 2 units
Air filter 1 unit Main element
1 unit Safety element
V-belt 1 unit 8PK 1850 NDIN 7867
Safety device: oil pressure sensor 1 unit Response pressure: 0.5 bar
Coolant temperature sensor 1 unit Response temp. 100 ±3°C
Coolant level sensor 1 unit
For order numbers, see respective spare parts list and service packs
Antifreeze agent / Min. temperature for

Water content Antifreeze content
mixing ratio protection
-37°C 50% 50%
Note!
Do not exceed an antifreeze concentration of 60%, as this tends to lead to reduced protection and
cooling effect!
4.11.2 A 900 C-LI 14675-

MJFCIFSS
1.0.1 Tightening torques for diesel engine
Tightening torques for screws: Initial load Tightening angle Retightenin

Screwed connections g
Bearing cover (1) 30 Nm
Main bearing cap 1st stage 30°
2nd stage 30°
Main bearing screws 3rdstage 30°
Total 90°
Connecting-rod (1) 30 Nm
1st stage 45°
Connecting-rod screws 2nd stage 30°
3rd stage 30°
Total 105°
Flywheel housing (1) 30 Nm 30 or 80 Nm (see
Fig. 1)
Cylinder head with metal-elastomer seal (1) 30Nm (see Fig. 2)
1st stage 90 Nm
2nd stage 70°
3rd stage 70°
4th stage 70°
5th stage 70°
Total 280°
Drive shaft at front crankshaft end (1) 30 Nm
1st stage 45° or 100 Nm
2nd stage 45° or 160 Nm
Total 90° or 160 Nm
Flywheel (1) 30 Nm
1st stage 30° or 180 Nm
2nd stage 35° or 330 Nm
Total 65° or 330 Nm
Intermediate gear (2) 60 Nm 70° or 280 Nm
Camshaft gear (M20x1.5) (2) 130 Nm 105° or 650 Nm
1.0.2 General notes:

(1) Lubricate screw thread and head surface with oil
(2) Treat screw thread with Loctite 242 / 243
A 900 C-LI 14675- 4.11.3

MJFCIFSS
1.0.3 Tightening of flywheel housing screws
Caution!
Strictly observe sequence 1 - 2 - 3 - 4 - 5 - 6 - 7 - 8 - 9 - 10 11!
Fig. 1 Flywheel housing at diesel engine
1.0.4 Tightening of cylinder head screws
Caution!
Strictly observe sequence 1 - 2 - 3 - 4 - 5 6!
Fig. 2 Cylinder head cover at diesel engine
4.11.4 A 900 C-LI 14675-

MJFCIFSS
Engine type: D 934 SA6

Note!
For instructions regarding maintenance and repair work, please refer to the separate workshop ma-
nual of the diesel engine.
1 Engine type: D 934 SA6
Version: A2
at rated speed PS 129 143
Max. torque (max. engine speed) Nm 630 730

Design 4-cylinder - turbo
Type Electronic injection PLD
Bore mm 122
Stroke mm 136
Displacement cm3 6400
Compression ratio 17 : 1
Weight (dry) kg 840
Direction of rotation (seen from flywheel) left
Cooling system Recirculation cooling

Rated speed rpm 1800 1800
High idle rpm rpm 1950 +50 1950 +50
Low idle rpm rpm 900 +100 900 +100
Coolant pump and water circuit A 900 C-Li / 24677 A 904 C-Li / 30580
Volume of coolant (without radiator system) l 15
Max. coolant temperature °C 100
Minimum pressure in cooling system bar 0.6
Temperature difference between radiator input and °C min. 3°, tolerance 3°-7°
output at 90°
Flow rate of coolant pump at 1900 l/min l 285
Water pressure at engine output at 90° bar 1.0 1.5
A 900 C-LI EDC 24677- 4.12.1

MJFCIFSS
Water pressure at engine input at 90° bar 0.3 0.6
Thermostat opening temperature °C 79°
Thermostat fully opened °C 92°
Oil pump and oil circuit A 900 C-Li / 24677 A 904 C-Li / 30580
Lubricating oil pressure 800 1/min at water temp. bar 1.5
90°C
90°C
Lubricating oil pressure 1800 1/min at water temp. bar 4.6 6.2
90°C
Max. oil temperature max. in oil pan °C 115°
Flow rate of oil pump at 1900 l/min l 186
Oil volume in oil pan with filter l approx. 29
Gear width of oil pump mm 43
Injection unit A 900 C-Li / 24677 A 904 C-Li / 30580

Opening pressure of injection nozzles (new) bar 330 -15
Opening pressure of injection nozzles (during opera- bar 300 +8 - 3
tion)
Max. fuel temperature after radiator °C <60°
Max. fuel temperature at pump input °C <60°
Fuel pressure in low-pressure circuit bar 2.5 ±0.4
Bushing distance mm 0.07 +0.03 0.02
Piston protrusion (measured from the edge of the bu- mm 0.15
shing
Cylinder head A 900 C-Li / 24677 A 904 C-Li / 30580

Outlet valve play (cold) mm 0.4
Valve offset at inlet mm 0.8 +0.38
Valve offset outlet mm 0.9 +0.38
Air system A 900 C-Li / 24677 A 904 C-Li / 30580

Max. intercooling air temperature after radiator °C 45-55
Max. pressure loss through radiator mbar 100
Axial/radial play at turbo charger mm 0.16 / 0.43

For order numbers of engine wear parts, refer to the latest issue of the spare parts catalogue (LIDOS), or the spare
parts list of the unit or the service pack.
4.12.2 A 900 C-LI EDC 24677-

MJFCIFSS
Filling volumes (for oil change with filter replacement) l approx. 29
Cooling liquid including coolant l 30
Antifreeze agent /
Antifreeze content Water content Antifreeze content
mixing ratio
-37°C 50% 50%
Note!
cooling effect!
1.1 Tightening torques for diesel engine
Tightening torques for screws: Pre-tighten with torque Final tightening angle
Screwed connections
Cheese head bolts Step 1 = 20 Nm Step 3 = 90°+90°+90°=
Step 2 = 75 Nm 270°
Screws for toggle lever block 65 Nm
Connecting-rod screw 60 Nm + 120 Nm + 200 Nm Pre-tighten with 20 Nm + 55
Nm
Main bearing screws 100 Nm + 250 Nm + 400 Nm Pre-tighten with 30 Nm + 120
Nm
Flywheel screws 80 Nm + 160 Nm + 240 Nm Pre-tighten with 30 Nm + 90
Nm
Angle 40° + 40° = 80°
Flywheel housing screws Pre-tighten with45 Nm
Tighten with 125 Nm
Screws for crankshaft end at fan side 80 Nm + 180 Nm + 260 Nm Pre-tighten with 20 Nm + 80
Nm
Angle 30° + 30 ° = 60°
Screws for cam shaft gear 50 Nm + 125 Nm + 200 Nm Pre-tighten with 20 Nm + 50
front Nm
Angle 35° = 35°
rear Nm
Angle 40° = 40°
Pressure tube nozzle 50 Nm
Injection valve holder 50 Nm
Injection lines
Pump side 25 - 40 Nm
Nozzle side 20 - 25 Nm
Piston cooling nozzle 30 Nm
A 900 C-LI EDC 24677- 4.12.3

MJFCIFSS
Screwed connections
Mounting bolts 60 Nm
4.12.4 A 900 C-LI EDC 24677-

MJFCIFSS
Engine type: D 934 S/L A6

Note!
For instructions regarding maintenance and repair work, please refer to the separate workshop ma-
nual of the diesel engine.
1 Engine type: D 934 S/L A6
Version: A2
at rated speed PS 163 183
Max. torque (max. engine speed 1500 min-1) Nm 753 860

Design 4 Zylinder - Turbo
Type elektronische Einspritzung PLD
Bore mm 122
Stroke mm 136 (S) 150 (L)
Displacement cm3 6400 7000
Compression ratio 17 : 1
Weight (dry) kg 840
Direction of rotation (seen from flywheel) links
Cooling system Kühlmittel-Umlauf

Rated speed rpm 1800 1800
High idle rpm rpm 1950 +50 1950 +50
Low idle rpm rpm 900 +100 900 +100
Volume of coolant (without radiator system) l 15
Max. coolant temperature °C 100
Minimum pressure in cooling system bar 0.6
Temperature difference between radiator input and °C min. 3°, tolerance 3°-7°
output at 90°
Flow rate of coolant pump at 1900 l/min l 285
Water pressure at engine output at 90° bar 1.0 1.5
4.13.1
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MJFCIFSS
Water pressure at engine input at 90° bar 0.3 0.6
Thermostat opening temperature °C 79°
Thermostat fully opened °C 92°
Oil pump and oil circuit A 914 C-Li / 35112 A 924 C-Li / 34519
90°C
90°C
Lubricating oil pressure 1800 1/min at water temp. bar 4.6 6.2
90°C
Max. oil temperature max. in oil pan °C 115°
Flow rate of oil pump at 1900 l/min l 186
Oil volume in oil pan with filter l approx. 29
Gear width of oil pump mm 43
Injection unit A 914 C-Li / 35112 A 924 C-Li / 34519

Opening pressure of injection nozzles (new) bar 330 -15
Opening pressure of injection nozzles (during opera- bar 300 +8 - 3
tion)
Max. fuel temperature after radiator °C <60°
Max. fuel temperature at pump input °C <60°
Fuel pressure in low-pressure circuit bar 2.5 ±0.4
Bushing distance mm 0.07 +0.03 0.02
Piston protrusion (measured from the edge of the bu- mm 0.15
shing
Cylinder head A 914 C-Li / 35112 A 924 C-Li / 34519

Outlet valve play (cold) mm 0.4
Valve offset at inlet mm 0.8 +0.38
Valve offset outlet mm 0.9 +0.38
Air system A 914 C-Li / 35112 A 924 C-Li / 34519

Max. intercooling air temperature after radiator °C 45-55
Max. pressure loss through radiator mbar 100
Axial/radial play at turbo charger mm 0.16 / 0.43

For order numbers of engine wear parts, refer to the latest issue of the spare parts catalogue (LIDOS), or the spare
parts list of the unit or the service pack.
4.13.2
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MJFCIFSS
Filling volumes (for oil change with filter replacement) l approx. 29
Cooling liquid including coolant l 30
Antifreeze agent /
Antifreeze content Water content Antifreeze content
mixing ratio
-37°C 50% 50%
Note!
cooling effect!
1.1 Tightening torques for diesel engine
Screwed connections
Cheese head bolts Step 1 = 20 Nm Step 3 = 90°+90°+90°=
Step 2 = 75 Nm 270°
Screws for toggle lever block 65 Nm
Connecting-rod screw 60 Nm + 120 Nm + 200 Nm Pre-tighten with 20 Nm + 55
Nm
Main bearing screws 100 Nm + 250 Nm + 400 Nm Pre-tighten with 30 Nm + 120
Nm
Flywheel screws 80 Nm + 160 Nm + 240 Nm Pre-tighten with 30 Nm + 90
Nm
Angle 40° + 40° = 80°
Flywheel housing screws Pre-tighten with45 Nm
Tighten with 125 Nm
Screws for crankshaft end at fan side 80 Nm + 180 Nm + 260 Nm Pre-tighten with 20 Nm + 80
Nm
Angle 30° + 30 ° = 60°
front Nm
Angle 35° = 35°
rear Nm
Angle 40° = 40°
Pressure tube nozzle 50 Nm
Injection valve holder 50 Nm
Injection lines
Pump side 25 - 40 Nm
Nozzle side 20 - 25 Nm
Piston cooling nozzle 30 Nm
4.13.3
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MJFCIFSS
Screwed connections
Mounting bolts 60 Nm
4.13.4
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MJFCIFSS
Service Manual Installation and check list for diesel particle filter
Installation and check list for diesel particle filter
for the installation of the particle filter

A 900 C - A 924 C Litronic
Note!
The manufacturer will only confirm the warranty terms, if the completed and signed installation and
check list is returned.
In addition, the prescribed maintenance intervals of the assembly / particle filter must be adhered
to. Always refer to the maintenance instructions in group 4.30 in the service manual.
Installation certificate
Vehicle / diesel engine
Machine:
(type)
Vehicle identification number:
PIN e.g. WLHZ 10400 ZK 325051 (17 digits)
Diesel engine model:
(MODEL, see below)
Serial no. of diesel engine:
(ENGINE NUMBER, see below)
Diesel engine operating hours:
(on display)
Particle filter
ID no. Serial no.
Kit no. ________________
Input element
Centre element / filter
Data logger
Diesel engine Input element 10 Centre element / filter 30
4.26.1
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MJFCIFSS
Installation and check list for diesel particle filter Service Manual
Checks
Measuring point Actual View

Checks
Specified value value Comment
1. Checking of engine yes / no

(prior to filter installation)
1.1 Air filter clean

...............
1.2 Exhaust gas turbocharger tight

...............
1.3 Oil feed line to the diesel engine Liebherr Motoroil

10 W 40 low ash ...............
1.4 Diesel engine injection

no blue fumes ...............
and combustion OK
Warm up machine.
2.1 Oil temperature min. 50 +10°C ...............
2.2 Speed step PP
without load 1950 +30rpm ...............
with load 1800 ± 10 rpm ...............
4.26.2
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MJFCIFSS
Service Manual Installation and check list for diesel particle filter

Checks
3. Tightness of the backpressure Check LED A Check the line between the input
line, with simultaneous Display D module and the data logger for lea-
testing of the warning system. kage, using a hand pump (tool list
Disconnect the backpressure line group 2.01).
at point T of the input element,
Separating point T for the testing
close the swivel elbow W.
of the backpressure line
Install adapter for a hand pump to
the connection L and produce
test pressure with the hand
pump.
The test pressure must remain
constant (max. 0.5 bar) for mini-
mum 1 minute.
Lead pressure
Red LED is on A
3.1 at A175 (Druck/pressure)
Backpressure Indicating and control unit A175
> 160 mbar ...............
Main pressure / limit load
Red LED on A at A175 and buz-
3.2 zer signal
Backpressure
Testing of temperature sen- > 180 mbar ...............
sors
3 minutes after the start, the sen-
3.3 sor in front of the filter must show
a higher value than that behind Minimum tempe-
the filter (on display: temperature rature
1 > temperature 2). > 80 °C ...............
Testing of speed indicator

H1 monitoring display (in right
The speed value indicated on the
control console)
display of A175 must correspond
3.4 to that shown on the display H1.
Tolerance limit
Testing of the recording func- < ± 100 rpm ...............
tion
After the engine is started, the
display of A175 must switch from
the "Ready for operation" menu
to the "Measurement (pressure,
3.5 speed or temperature)" menu.
4.26.3
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MJFCIFSS
Installation and check list for diesel particle filter Service Manual

Checks
4. Normal backpressure value Read the value from the data log-
(apply load on the diesel engine ger through the indicating and con-
by fully pressurising the hydraulic trol unit A175 and enter the value
<135 mbar ...............
system) here.
1800 rpm
at full-load speed
5. Tightness of the exhaust gas Visual inspection yes / no If there are clear signs of leakage,
system check the system for loose connec-
Soot in the exhaust gas system tions.
...............
with connections and Suspected filter break
soot in the end pipe ............... Replace filter.
Danger!
There is a risk of injury from burns when working on the hot and/or running engine.
When checking the engine, wear protective gloves and suitable protective clothing.
Inform operating personnel of the potential risks and the danger area associated with the inspec-
tion work.
Take provisions to ensure that the engine cannot be inadvertently started.
Type: ....................................... Serial no.: ....................................... Operating hours: .........................................
Date: ....................................... Mechanic: ....................................... Cust.: .........................................
Date: ....................................... Checked for completeness by the Service Center: .........................................

..
4.26.4
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MJFCIFSS
Service Manual Liebherr diesel particle filter accessory kit
Function
Liebherr diesel particle filter accessory kit
1 Function
The diesel particle filter can be installed in Liebherr hydraulic excavators as an exhaust gas cleaning
system for the diesel engine.
The particle filter accessory kit consists of the following main components:
Particle filter 10
Condensate trap with sintered metal filter 100
Data logger A133
Indicating and control unit A175
Fig. 1 Main components of the particle filter accessory kit
10 Particle filter A133 Data logger

100 Condensate trap/filter A175 Indicating / control unit
4.27.1
copyright by
MJFCIFSS
Liebherr diesel particle filter accessory kit Service Manual
Design of the accessory kit
2 Design of the accessory kit
2.1 Particle filter

The particle filter is installed between the exhaust pipes of the diesel engine at the location of the si-
lencer.
The particle filter is made in stainless steel and is fully insulated and noise optimised. It consists of
the following main components:
Input module 15 adjusted to suit the model, with radial / axial* input.
Output module 20 adjusted to suit the model, with radial / axial* output.
Filter module 30 with integrated particle filter
Centring rings 50 / 60 with seal rings 65
Connecting clamps 70
Fig. 2 Design of the particle filter
15 Input module 50 Centring ring, output

20 Output module 60 Centring ring, input
30 Filter module 65 Seal rings
31 Silencer / muffler 70 Connecting clamp
* depending on model
4.27.2
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MJFCIFSS
Design of the accessory kit
2.2 Backpressure monitoring system

The backpressure monitoring system includes a backpressure line from the particle filter to the data
logger. As this line is exposed to great temperature differences during operation (especially during
the cold season), condensate that might contain soot particles collects in the line.
These particles are held back by the filter 100 and must be removed at prescribed intervals.
Regularly drain off condensate, (see Maintenance of filter (condensate trap) 100 on page 8).
Fig. 3 Condensate trap for exhaust backpressure to the monitoring element
100 Filter, complete 201 Tank with seal ring

103 Sintered metal filter with holder
2.3 Monitoring elements, see Fig. 4
All control and monitoring signals from the particle filter are recorded and stored by the data logger
A133.
The particle filter is monitored and controlled by means of the indicating and control unit A175 in the
operator's cab.
Depending on the state and operating hours of the engine, the particle filter might be contaminated
with particles formed in the channels and burnt-off particles from the oil ash.
To check the contamination of the particle filter, the system measures the backpressure in front of
the filter. The greater the contamination, the higher the backpressure. From a certain limit value (de-
termined by machine model), the red warning LED A (Druck/pressure) at the indicating and control
unit A175 is on. It indicates to the machine operator that the filter's absorption capacity has been re-
ached.
The particle filter is regenerated by increasing the exhaust gas temperature. This can be done by the
machine operator. At a temperature of 250°C or higher in the filter, the collected soot particles are
incinerated. Subsequently, the machine can be operated in normal mode until the red warning LED
is on or until the next scheduled maintenance, (see Regeneration of the built-in particle filter on
page 6).
4.27.3
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MJFCIFSS
Function of diesel particle filter
If the above measure does not result in a reduced exhaust backpressure, check the system and clean
the filter module , if required, see 5.1.4.
When the red warning LED A is on and the buzzer sounds (indicating a system error or a limit load
of the filter module ), check the system and clean the filter module, if required, (see Maintenance
on page 7).
Fig. 4 Monitoring elements
A133 Data logger A175 Indicating and control unit
3 Function of diesel particle filter
3.1 Particle filtering

The exhaust gas cleaning system reduces the diesel particle load (PM) and the concentration of ga-
seous pollutants (CO and HC). The particles are held back in the monolith where they accumulate.
The particles are removed from the exhaust gas when it is fed through the porous channel walls of
the monolith. The inlet channels are sealed at the other end. This means that the exhaust gas must
escape through the coated channel walls. The large number of channels results in an extremely large
filter surface and thus a high retention capacity for soot particles.
Fig. 5 Principle of the particle filter
4.27.4
copyright by
MJFCIFSS
Monitoring and operation
1 Raw gas in front of the filter 3 Channel seal

2 Channel wall 4 Cleaned exhaust gas behind the filter
4 Monitoring and operation
Fig. 6 Indicating and control unit
A175 Indicating / control unit

A Warning LED (Druck/pressure) E Confirmation key
B Error ED (System error) F Menu key
C Operating mode LED (Power) G no function assigned
D Display
4.1 Automatic indication at the display and indicator lights
Display/indicator message LED Cause Remedy
Thermocouple 1 (or 2) defective yellow (B) Temperature sensor defective or Press key E: deactivation of warning buzzer
This signal is accompanied by a war- malfunctioning sound.
ning buzzer sound. Check temperature sensor, reconnect or re-
place.
ERROR idle run / temp. yellow (B Device operated for too long at low Press key E: deactivation of warning buzzer
This signal is accompanied by a war- exhaust gas temperature (low engine sound.
ning buzzer sound. load) Increase machine / motor load (full-load ope-
ration)
Idle operation period too long. Operate machine at a higher speed.
Defect at terminal W - Interruption of speed monitoring Press key E: deactivation of warning buzzer
This signal is accompanied by a war- sound.
ning buzzer sound. Check line of the speed meter and replace, if
necessary.
Lead pressure reached. Red LED (A) High load of soot and ash particles in Operate the machine at full load until the
on particle filter back pressure drops.
If the back pressure does not drop: Clean the
filter (call LIEBHERR service department).
4.27.5
copyright by
MJFCIFSS
Monitoring and operation
Display/indicator message LED Cause Remedy
Main load pressure reached. Red LED (A) Excessive load of particle filter from Press key E: deactivation of warning buzzer
This signal is accompanied by a war- flashes soot and ash particles sound.
ning buzzer sound. Clean the filter.
Filter defective of pressure line all LEDs Particle filter (or bypass) defective, or Press key E: deactivation of warning buzzer
blocked. flash pressure line blocked, or sound.
This signal is accompanied by an in- leakage in pressure line Check particle filter and pressure line.
terrupted warning buzzer sound. Replace the filter module, remove the blocka-
ge in the pressure line or fix the leakage.
Call LIEBHERR service depart- - Preset operating time to next service/ Press key E:
ment. filter module cleaning task has Complete service/clean filter according to the
lapsed. instructions.
After service, reset the device (reset opera-
ting hour counter):
press and hold keys G and F for minimum 5
seconds.
4.2 Query and operation with key F

After the ignition is switched on, the message "data logger ready" is displayed. After the diesel engine
has been started, the display shows the last used menu.
To navigate through the display menu, press the F key.
To change display, press and hold the F key for two seconds.
The following information can be called up:
Temperature 1 (°C) / temperature 2 (°C)
Indicates the two exhaust gas temperatures in front of the filter (engine side) and behind the filter
(exhaust pipe side)
Pressure (mbar) displayed after engine start
Indicates the exhaust air back pressure
Temperature 1 (°C) / pressure (mbar)
Indicates the pressure as well as the exhaust air temperature in front of the filter (engine side).
Temperature 2 (°C) / pressure (mbar)
Indicates the pressure as well as the exhaust air temperature behind the filter (exhaust pipe side).
Speed (rpm) / pressure (mbar)
Indicates the exhaust air pressure and diesel engine speed.
4.3 Regeneration of the built-in particle filter

The particle filter works best if the exhaust gas temperature is above 250 °C for at least 50 % of the
operating time. Under these conditions, it regenerates itself.
If the minimum exhaust gas temperature cannot be reached during the machine operating time, the
permissible exhaust gas backpressure / lead pressure will be reached at some point (warning LED A
at the control unit A175 is on). If this is the case, the filter 30 must be regenerated. During the rege-
neration process, the deposits in the particle filter are pyro-cleaned at a high exhaust gas tempera-
ture. Operate the attachment (possibly with load) so that the hydraulic unit is fully pressurised and
the diesel engine is operating at maximum load.
If the exhaust gas backpressure fails to drop, switch off the diesel engine, wait for approx. 30 minutes
and repeat the above regeneration procedure. If this does not lead to the desired result, dismantle
the filter 30 and return it for cleaning to an authorised workshop (customer service / supplier), see
5.1.4
4.27.6
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MJFCIFSS
Maintenance
5 Maintenance
Note!
The particle filter may only be used in conjunction with diesel engines filled with Liebherr Motoroil
10 W 40 low ash engine oil.
If other oil products are used, the particle filter might quickly become clogged up with oil ash (making
shorter cleaning intervals / every 1000 operating hours necessary).
5.1 Maintenance of the particle filter

As a rule, the filter element 30 must be cleaned at least every 2000 operating hours. In this case,
the preliminary filter in the input module 15 must also be cleaned.
Caution!
Do not touch the particle filter when it is hot, as this can cause serious injury from burns.
Do not inhale the ash residue in the filter as it can cause damage to the respiratory system.
Fine particles can cause damage to eyes.
Let the filter cool down.
Always wear protective gloves.
When cleaning the filter, wear face mask and protective goggles.
5.1.1 Checking of connecting clamps

The connecting clamps 70 hold together the 3 main elements of the particle filter. If the clamps 70
are released, the exhaust gas system is not air-tight any more, so that the filter cannot work properly
and the indicated values and statuses are inaccurate.
To ensure tightness, the screws of the clamps 70 must be retightened every 500 operating hours.
with the correct tightening torque (12 Nm).
5.1.2 Dismantling of filter and input module for cleaning
After the filter 10 has cooled down, release the clamps 70.
Slide the clamps 70 onto the filter module 30.
Lift the filter module 30 with the clamps 70 from the machine.
Remove the centring rings 50 and 60 from the filter module 30.
Release the clamp (exhaust gas hose) and disconnect the line.
Disconnect the backpressure line at the input module 15.
Release the fastening clamp 19.
Lift the input module 15 from the uppercarriage.
Clean the filter module, see 5.1.3 and
5.1.3 Cleaning of the preliminary filter after the maintenance interval has lapsed
When the prescribed maintenance interval (2000 operating hours) is reached, the preliminary filter at
the input element 15 must be cleaned as follows:
Position the input module in front of a funnel with adjusted diameter and a vacuum cleaner hose
or similar piece of equipment.
Switch on the vacuum cleaner and blow out the preliminary filter with oil-free compressed air.
4.27.7
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MJFCIFSS
Maintenance
Turn the filter in axial direction and blow it out from the other side.
After proper cleaning, re-insert the input module 15, see 5.1.5.
5.1.4 Cleaning of the particle filter after the maintenance interval has lapsed or in
the event of a malfunction
Caution!
When the prescribed maintenance interval (2000 operating hours) or the limit load is reached (war-
ning LED A on the control unit A175 is on and the buzzer sounds), clean the filter 30.
If the machine is operated when the particle filter load limit is reached, the engine could be damaged
and the guarantee of the manufacturer is voided.
Immediately ship the filter to an authorised workshop (customer service / dealer). At the work-
shop, the filter module 30 is autoclaved for 6 hours at approx. 600°C.
For the handling of replacement modules for the change/cleaning of the filter module 30, observe
the local conditions and the applicable instructions, e.g. VERT specifications for particle filter sys-
tems in BAFU / SUVA filter list.
When using a replacement module 30.1, secure it with the centring rings 50 / 60 , seal rings and
the clamps 70 to the input and output module 15/20, (see Installation of the input module and the
filter module after cleaning on page 8)
5.1.5 Installation of the input module and the filter module after cleaning
Place the input module 15 in the uppercarriage.
Secure the input module 15 with the fastening clamp 19 after having aligned it in its position.
Connect the backpressure line to the input module 15.
Connect the exhaust gas hose to the input module 15 and tighten the clamp.
Note!
The different lengths of the centring rings 50 / 60 in the input and output modules 15 / 20 ensure
that the filter 30 / replacement module 30.1 is installed correctly (in the correct flow direction).
For air-tight installation, mount new sealing rings 65 to the centring rings 50 / 60.
Remove the old sealing rings 65 from the centring rings 50 / 60 and clean the centring rings 50 /
60 to remove all sealant and adhesive residue.
65 50 / 60
Insert the centring rings 50 / 60 at the correct side of the filter module 30 / replacement module
30.1.
Insert the filter module 30 or the replacement module 30.1 with the clamps 70 and the inserted
centring rings 50 / 60 between the input and the output module 15 / 20 and align in axial and radial
direction.
Slide the clamps 70 over the gap between the input / filter / output modules.
Tighten the clamps 70 with a torque of 12 Nm.
5.2 Maintenance of filter (condensate trap) 100
Draining condensate:
The condensate must be regularly drained into a container 201.
4.27.8
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MJFCIFSS
Maintenance
Turn the drain screw 203 by 90° counter-clockwise (direction A), Fig. 7 to drain off the condensate
into a suitable container.
Caution!
The backpressure monitoring system works only correctly, if the system is completely tight and the
filter 100 is sealed.
The drain valve must therefore be closed properly.
To close the drain valve, turn the drain screw 203 by 90° clockwise (direction Z), Fig. 7.
Checking / replacing filter 100:

The sintered metal filter 103 must be checked every 500 operating hours and cleaned, if necessa-
ry.
Replace the sintered metal filter 103 every 1000 operating hours.
Turn the drain screw 203 by 90° counter-clockwise (direction A) to drain off the condensate into
a suitable container.
Remove the container 201.
Remove the cap nut 105.
Pull off the filter parts 104 - 101 and clean or replace the sintered metal filter cartridge 103.
Reassemble the filter parts 101 - 104 in the correct sequence, see Fig. 7, and position and tighten
the cap nut 105.
Mount the container 201 with the seal ring 202
To close the drain valve, turn the drain screw 203 by 90° clockwise (direction Z), .
Fig. 7 Design of the condensate trap
100 Filter, complete 201 Container

101 Centrifuge 202 Seal ring
102 Shield 203 Release valve
103 Sintered metal filter element
104 Shielding plate A Drain valve open
105 Cap nut Z Drain valve closed
4.27.9
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MJFCIFSS
Retrofitting of particle filter accessory kit
6 Retrofitting of particle filter accessory kit
6.1 Important instructions
Note!
Please note that all work on the exhaust gas system must be carried out by technicians authorised
by LIEBHERR.
6.2 Preconditions
The diesel engine must be filled with Liebherr Motoroil 10 W 40 low ash engine oil.
6.3 Design of the particle filter, see Fig. 1 and Fig. 9
Note!
The particle filter replaces the standard silencer and is installed in its place.
The backpressure monitoring system can only work properly, if the backpressure line from the par-
ticle filter 10 and the filter 100 to the data logger A133 is completely air-tight.
After the filter has been installed, the system must be tested for leakage.
Check the system for leakage by applying a test pressure.
Remove the installed silencer.

Install the particle filter 10 with the provided fastening elements in the uppercarriage. For detailed
instructions, see enclosed installation drawing and assembly parts list.
Secure the exhaust gas lines and the end pipe at the input / output module.
Mount the data logger A133 in the proper location.
Mount the indicating and control unit A175 in the proper location.
Install the condensate trap 100 in the proper location.
Mount the backpressure line from the particle filter 10 and the filter 100 to the data logger A133,
maintaining an angle of inclination of 2° (rising).
Test the backpressure line with a suitable tool (hand pump with pressure indicator, see tool no.
2.01) for tightness, see 6.4.
Install all electrical connections according to the supplied installation drawings.
Start the diesel engine and slowly increase the load (allow the engine to warm up).
Check the values at the control unit A175.
With the new filter module, the backpressure in front of the filter (pressure 1) must be max.
120 mbar.
All values/responses are listed in the enclosed installation and test list. Complete the list and re-
turn it to Liebherr Hydraulikbagger GmbH , Service Center, Liebherrstr. D - 88457 Kirchdorf / Iller,
Germany.
4.27.10
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MJFCIFSS
6.4 Leakage testing of the backpressure line between the filter and the data logger
Caution!
Excessive test pressure might cause damage to the filter and monitoring system.
Never pressurise the exhaust gas system with a compressed air gun or a similar device.
Apply only pressures of max. 0.5 bar generated with a hand pump.
Disconnect the backpressure line L at the point T on the input element 15.
Connect the hand pump adapter (see tool list 2.01) to the backpressure line L. Ensure that the
connection is air-tight.
Seal the swivel elbow W with a plug.
Pressurise the exhaust gas system with the hand pump (max. 0.5 bar) and check the pressure
loss.
There may be no pressure loss within a period of 1 minute.
If a pressure loss is detected, check the connection of the backpressure line L to the data logger.
If the system is properly sealed, remove the plug and connect the backpressure line L to the input
element 15, ensuring an air-tight connection.
Fig. 8 Separating point for tightness test
15 Input module L Backpressure line

100 to filter / condensate trap T Separating point
A133 to data logger W swivel elbow
4.27.11
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MJFCIFSS
6.5 Layout of the components according to spare parts catalogue
Fig. 9 Particle filter with holder and backpressure line with filter
10 Particle filter 150 Precondition:

engine filled with Liebherr Motoroil 10W40
low ash engine oil
(available in different lot sizes)
100 Condensate trap/filter A133 Data logger
4.27.12
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MJFCIFSS
Fig. 10 Electrical system, part 1
A133 Data logger X1313 Interface to Data logger

A175 Indicating / control unit X1315 Plug connection, 5-pin
X1316 Plug connection, 5-pin
4.27.13
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MJFCIFSS
Fig. 11 Electrical system, part 2, for various machine models
A127 Printed circuit board / power F351 Fuse

E50 Electric box K288 Relay terminal 15
F340 Fuse X1312 Plug connection / CS revolving deck
data logger, 1-pin
For electric diagram, see group 8.102
4.27.14
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MJFCIFSS
Service Manual
SUBGROUP - INDEX
Section Group Type
Coupling 5.10.1 A 900 C-LI 14675-

A 904 C-LI 16000-
A 914 C-LI 35112-
A 924 C-LI 34519-
Pump distributor gear 5.20.1 A 904 C-LI 30580-

A 914 C-LI 35112-
A 924 C-LI 34519-
5.1
MJFCIFSS
Service Manual
5.2
MJFCIFSS
Service Manual Coupling
Function
Coupling
1 Function
The flexible coupling (torsion damper) installed between the diesel engine and the variable-
displacement pump compensates displacements of the shafts (crank shaft pump drive shaft)
resulting from manufacturing tolerances and dimensional inaccuracies. It also dampens torque
impacts and load fluctuations.
It is a permanent coupling and thus transmits the motor torque directly and continuously to the pump.
Decoupling is not possible.
Fig. 1 Built-in coupling in motor
A 900 C Litronic 5.10. 1

A 904 C Litronic MJFCIFSS
Coupling Service Manual
Design and function of coupling
2 Design and function of coupling
see Fig. 3
The disk 5.1 is connected with screws to the flywheel C of the diesel engine. The hub 5.2 is guided
axially by the circular disk 5.3 riveted onto the hub 5.2.
The hub 5.2 can be moved in radial direction on the 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 (non-positive connection).
The power flow 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 disks 5.3 and the drive shaft 10.10 of
the pump 10.
Torque impacts upon startup 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 nearly fully
released.
The rotational vibration from the engine is also significantly dampened so that the pump 10 is only
marginally affected.
Fig. 2 Position and alignment of coupling 5 (a = A 900 C, b = A 904 C)
5 Coupling (torsion damper) 10 Variable-displacement pump

7 Allen head and hex head screw 12 Allen head and hex head screw
5.10. 2 A 900 C Litronic

MJFCIFSS A 904 C Litronic
Service Manual Coupling
Installation and dismantling of the coupling
3 Installation and dismantling of the coupling
see Fig. 3
3.1 Dismantling
Secure variable-displacement pump 10 using a rope
Loosen screws 12
Disconnect flange connection between the variable-displacement pump 10 and the intermediate
housing B of the diesel engine, and pull pump from the coupling
Remove mounting bolts 7
Observe position and alignment of coupling 5
Remove coupling 5 from the flywheel of the diesel engine C
3.2 Installation
Mount coupling 5 on the flywheel C
Note!
Observe correct position and alignment, see Fig. 3. Check position and alignment by measuring A
and comparing it to the value in the table.
Machine A 900C Li A 904 C Li

Measurement A (in mm) approx. 14.00 approx. 15.55
Tab. 3 Check measurement A for correct installation position and alignment
If the values in the table are not reached, turn coupling by 180° (axial).
Tighten Allen screws 7 (tightening torque 68 Nm)
Slightly lubricate the gearing of the pump 10 and the hub 5.2 (use LIEBHERR CTK special grease,
see also page 1.50.9)
Insert the pump drive shaft into the hub 5.2 and secure the pump 10 to the intermediate housing
of the diesel engine, using Allen screws 12 (tightening torque: 68 Nm)

Coupling Service Manual
Installation and dismantling of the coupling
Fig. 3 Sectional drawing showing position and alignment of the coupling
5 Coupling (torsion damper) 10 Variable-displacement pump

5.1 Disc 10.10 Drive shaft
5.2 Hub 12 Allen screw/hex head screw
5.3 Disc B Intermediate housing / engine
5.4 Pressure spring C Flywheel / engine
7 Allen screw/hex head screw

Service Manual Pump distributor gear
Function
1 Function
The pump distribution gear is a spur gear system mounted between the drive engine and hydraulic
pump.
It is driven by the flywheel of the diesel engine through a flexible coupling, transmitting the power to
the hydraulic pumps.
Fig. 1 Pump distributor gear
5.20.1
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MJFCIFSS
Pump distributor gear Service Manual
Technical data
2 Technical data
Machine A 904 C Litronic A 914 C / A 924 C Litronic

Type 1003/1004/1005/1071 1044/1045/1047/1048/1049/1050/1051
Pump distributor gear PVG 352 C 359
Transmission ratio to double variable- 0,903
displacement pump
Transmission ratio to variable-displace- 0,738
ment pump
Weight 255 kg
Oil volume in gearbox 1,9 l
Oil grade API-GL-5 / MIL-L 2105 B
Oil viscosity SAE 90 LS
Tab. 1 Technical data
5.20.2
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MJFCIFSS
Design
3 Design
The pump distribution gear consists of the following main components:

Pump distribution gear 1
Variable-displacement pump 20
Hex head screws for attachment to the drive engine 4
Oil filler neck/level gauge 5
Oil drain valve 7 with seal ring 8
The pump distribution gear 1 is flange-mounted to the diesel engine.
The pump distribution gear 1 contains the double variable-displacement pump 20 used for the
working movements (driving, rotation and operation of the attachment).
Regularly (at least every 50 operating hours) check the oil level in the pump distribution gear 1 by
means of the oil filler neck/level gauge 5. The gear oil is filled through the oil filler neck 5.
The oil drain valve 7 is located at the bottom (centre) of the pump distribution gear 1. For an oil
change, attach an oil discharge hose to the oil drain valve through which the oil is then drained from
the gear, (see "Oil change in the pump distributor gear", page 6).
Fig. 2 Components of the pump distribution gear
1 Pump distributor gear 7 Oil drain valve

4 Mounting screws (hex head) 8 Sealing ring
5 Oil filler neck/level gauge 20 Double variable-displacement pump
5.20.3
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MJFCIFSS
Functional description
4 Functional description
The force of the drive engine is transmitted through the drive shaft 10 onto the pump distribution gear,
where it is distributed through the spur gears 11 and 12 to the individual pumps.
The transmission ratios to the double variable-displacement pump and the variable displacement
pumps are adjustable so that the flow rate can be accurately adjusted.
10 Drive shaft 33 Deep groove ball bearing

11 Spur gear 40 Cylinder pin
12 Spur gear 41 Allen head screw
18 Cover 42 Allen head screw
30 Cylindrical roller bearing 60 Radial shaft seal ring
31 Cylindrical roller bearing 61 Shim ring
32 Cylindrical roller bearing
5.20.4
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MJFCIFSS
Fig. 3 Sectional drawing of the pump distribution gear
5.20.5
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MJFCIFSS
Maintenance
5 Maintenance
5.1 Oil change in the pump distributor gear
Note!
The oil must be changed while the machine is warm.
Dismantling of the pump box.

Remove the oil level gauge 5.
Remove the screw plug of the oil drain valve 7 and attach the oil drain house 14.
Place a suitable container for the collection of the oil under the valve and screw in the oil hose 14
tot the stop.
Remove the oil discharge hose 14 and mount the screw plug.
5 and fill oil through the oil filler neck 5
Check the oil level, using the oil level gauge 5.
Run the diesel engine for a short period of time and check again the oil level.
Mount the pump box.
Fig. 4 Oil change in the pump distributor gear
1 Pump distributor gear 7 Oil drain valve

5 Oil filler neck/dipstick 14 Oil discharge hose
5.20.6
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MJFCIFSS
Installation and dismantling of the pump distribution gear
6 Installation and dismantling of the pump distribution gear
6.1 Dismantling of the pump distribution gear
Note!
To ensure that all parts are kept clean and free of oil, use a vacuum pump (tool no. 180 - 187 in
group 2.05) when dismantling and installing the pump distribution gear.
Ensure that all pressure, leak oil and control lines are depressurised.
Dismantling of the pump box.
Close the stop cock 15 at the hydraulic oil tank, (position A).
Disconnect the suction, pressure, control and leak oil lines from the hydraulic pumps. Collect the
hydraulic oil in a suitable oil pan.
Disconnect the electrical plugs and adapters.
Drain the oil from the pump distribution gear, (see "Maintenance", page 6).
Using suitable lifting tackle and lifting gear, secure the pump distribution gear 1 together with the
pump 20.
Loosen the mounting screws 4 at the pump distribution gear 1.
Remove the mounting screws 4 and pull the pump distribution gear 1 from the gearing of the drive
engine.
Fig. 5 Installation and dismantling of the pump distribution gear
1 Pump distributor gear 15 Stop cock

4 Mounting screws (hex head) 20 Double variable-displacement pump
5 Oil filler neck/level gauge A Stop cock position "CLOSED"
5.20.7
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MJFCIFSS
Installation and dismantling of the pump distribution gear
6.2 Installation of the pump distribution gear

Ensure that the sealing surface at the pump distribution gear is clean, free of oil and grease and
not in any way damaged. If necessary, clean it with a suitable detergent.
Apply some grease onto the sealing surfaces at the pump distribution gear and the drive shaft,
see group 1.51.
Insert the drive shaft into the gearing of the drive engine.
Insert the mounting screws 4 and tighten them with the prescribed torque.
Connect the suction, pressure, control and leak oil lines from the hydraulic pumps.
Connect the electrical plugs and adapters.
Fill in the new oil through the oil filler neck 5 of the pump distribution gear 1 until the mark on the
oil level gauge 5 is reached.
Open the stop cock 15 on hydraulic tank.
Bleed the hydraulic pumps, see group 7.01.
Run the diesel engine for a short period of time and check again the oil level in the oil distribution
gear.
Check the pumps for leakage.
Mount the pump box.
5.20.8
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MJFCIFSS
Service Manual
SUBGROUP - INDEX
Section Group Type
LSC system 6.01.1 A 900 C-LI 14675-

A 900 C-LI EDC 24677-
A 904 C-LI 16000-
A 904 C-LI EDC 30580-
Grab control 6.10.1 A 904 C-LI-IND EDC 39333-
Design of hydraulic system 6.20.1 A 900 C-LI 14675-

A 904 C-LI 16000-
Layout of hydraulic system 6.21.1 A 900 C-LI EDC 24677-

A 904 C-LI EDC 30580-
Layout of hydraulic system 6.22.1 A 914 C-LI 35112-

A 924 C-LI 34519-
Hydraulic system A 900 C 6.30.1 A 900 C-LI 14675-
Hydraulic system A 900 C 6.31.1 A 900 C-LI EDC 24677-
Hydraulic system A 904 C 6.32.1 A 904 C-LI 16000-
Hydraulic system A 914/A924 C 6.40.1 A 914 C-LI 35112-

A 924 C-LI 34519-
6.1
MJFCIFSS
Service Manual
6.2
MJFCIFSS
Service Manual LSC system
Basic principle - general description of functions
LSC system
1 Basic principle - general description of functions
1.1 General
The latest generation of Liebherr hydraulic excavators A 900C - A 904C Litronic comes with our new
"LSC system" (Liebherr Synchron Comfort system).
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
Horse-power control
Note!
For detailed information on the design of components mentioned above, please turn to respective
subgroups of service manual.
6.01.1
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MJFCIFSS
LSC system Service Manual
Functional description of LSC system
2 Functional description of LSC system
LSC is a servo pilot-controlled and 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 flows supplied by the pump and going through the spool and on to the consu-
mers can be controlled by the operator actuating the pilot-control lever. This will determine the control
pressure which is proportional to the displacement of the lever.
That means:
Short displacement of lever / pedal at the pilot control valve = low control pressure at the spool =
small flow cross-section = low speed of consumer.
Long displacement 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:
That means:
High p setting = high flow rate
Low p setting = low flow rate
Values for p are pre-set at the pump, i.e. volumes depend on cross-sections.
The on-board electronics make it possible to use a proportional solenoid valve (Y51) to lower that p
continuously and so adapt speeds of working movements to prevailing work conditions and consumer
requirements.
6.01.2
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MJFCIFSS
2.1 LUDV system

Within the load-sensing system, the LUDV system is connected, in each case, to a spool (gauge ori-
fice) belonging to the respective consumer, and a subsequent pressure balance. The load pressure
of each individual consumer (LS signal) is detected at the pressure channel leading to the consumer.
The highest load pressure in each case is reported back by the pressure balance of the working
pump.
The p generated by the pressure spring of the LS regulator (sitting on the working pump) is used
as a reference p for the system.
p1 = p2´ corresponds to Ap1 = Ap2 - that means flow Qv1 is proportional to cross-section A1; and
Qv2 is proportional to A2.
The flow generated by the pump at gauge-orifice cross-sections A1 and A2 is proportional. The p's
at the gauge orifices ( p1 and p2) are equal due to pressures 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. Because of the status signal p2 having the highest
load pressure and acting on all pressure balances, flow distribution continues to depend on the ope-
ration of controls, independent of other individual load pressures.
2.1.1 Proportional split of flow volumes

Example: Consumer 1 requires e.g. Q = 200 l/min. The amount of oil is provided on demand by the
variable capacity pump, just as required. However, if a second consumer 2 requiring Q = 150 l/min.
enters the picture, the max. flow rate of the pump, i.e. Q = 300 l/min is split among both consumers
in a ratio of 300 to 350 = 0.85. That means consumer 1 receives only Q = 171.5 l/min while
consumer 2 receives Q = 128.5 l/min.
2.1.2 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 equals flow rate Q of the pump multiplied with the highest consumer
pressure (load pressure + p).
Lost performance can be derived from the volumes required by other consumers, multiplied with the
corresponding differential pressures ( p at the highest load pressure).
A higher loss of performance arises when a consumer is operated with a pressure cut-off valve.
6.01.3
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MJFCIFSS
Fig. 1 Principle of LUDV system
2.2 Smart 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
6.01.4
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MJFCIFSS
Horsepower control with proportional solenoid valve Y 50
3 Horsepower control with proportional solenoid valve Y 50
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 valveY50.
3.2 Performance selection with mode switches S86 (BBT):

Switch S86 on the control panel selects four different modes:
L: Mode LIFT (speed step 5 - extremely sensitive lifting of loads)
F: Mode FINE (speed step 10 - grading works)
E: Mode ECO (speed step 8 - economic operation)
P: Mode POWER (speed step 10)
Mode L / F: If ILR current is somewhere between 300 and 500 mA =>. That means control pressure
pLR is between 4 and 10 bar.
Mode E / P: If ILR current is somewhere between 500 and 1000 mA =>. That means control pressure
pLR is between 10 and 20 bar.
Detailed data: see adjustment protocols
Fig. 2 Horsepower control in LSC system
21 Powertrain (variable displacement pump) 235 Boom cylinder

23.2 Performance regulator (A 900 C) S86 Mode switch
25 Performance regulator (A 904 C) U16 Excavator control (BST)
220 Spool Y50 Proportional valve (LR)
6.01.5
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MJFCIFSS
On-demand flow control
If current is smaller than 300 mA = pLR 0 bar (tank pressure). That means begin of regulation is
equal to begin of basic regulation, and performance drop of the pump is minimum.
If current increases above 300 mA, the control pressure goes up. That means the begin of regulation
is later than begin of basic regulation, and the performance drop of the pump increases.
4 On-demand flow control
Machines with a load-sensing hydraulic circuit have on-demand flow control to control pump flows.
That means the powertrain of the working pump supplies only the amount of oil needed by the con-
sumers. This will avoid any unnecessary circulation and throttle losses.
4.1 Functional description of on-demand flow control

(see Fig. 4 on page 8)
When all the spools (220, 260) are in their neutral positions (no control oil for spools 220 / 260), the
pump will supply only the oil required for standby operation. The flow regulator pivots the pump back
all the way to stop Q min. (standby operation = Qremain at circulation pressure).
Actuation of a spool (gauge orifice opens) will reduce the normal ( p) between pump and consumer.
This difference in pressure effects a shifting of the flow regulator 23.5 / 26 due to the pre-set pressure
spring (pump pressure is smaller).
The flow via the bores in spool 220 / 260 is comparable to the flow that goes through a gauge orifice.
With increasing flow rates towards the consumer, the pressure difference at the gauge orifice incre-
ases, too.
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 has been calculated so that the pressure difference is equal to
the value p(LS) pre-set at the regulator when the desired nominal flow rate has been reached with
the spool completely open.
If spool 220 / 260 is shifted back to an interim position, the aperture of the gauge orifice shrinks, and
the pressure difference p(LS) is attained with a smaller amount of oil. 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) goes down. But because it stays the same for all the consu-
mers, all flows are reduced by the same factor.
6.01.6
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MJFCIFSS
Flow regulation with proportional solenoid valve Y 51
5 Flow regulation with proportional solenoid valve Y 51
5.1 Working speed and fine control

Proportional valve Y51 is set under pilot pressure (pst) and counteracts the spring force of the flow
regulator (LS) 23.5 / 26 on the basis of the pre-selected % setting in the BST via pMLS , thus lowering
the p .
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 outlet is reached.
Fig. 3 Flow regulation in the LSC system
5.2 Adapting flow reduction to working conditions
Flow reduction registered under: Switch Adjustment

SF: Travel adjustment SF = M8 S354 (SF) Set SF
I1 - I4 (Opt.1-4) B33-2/I... Set pump
M1 - M7 B33-1 /M... Set data / set pump
Reducing pumping capacity:

I Ls < 300 mA = pMLS = 0 bar (tank pressure) p = basic setting
Note!
Working speeds can be opened at SF screen and tested immediately, using the joysticks.
21 Powertrain (variable displacement pump) H1 Display

23.5 Flow regulator S354 Switch (SF)
26 Flow regulator Y51 Proportional valve ( p reduction)
B33 Sensor (kit)
6.01.7
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MJFCIFSS
Hydraulic schematic
6 Hydraulic schematic
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 Adjustment 224 Pressure balance
23.5 LS regulator 235 Consumer
100 Control valve block 260 Spool
102 Minimum-flow pressure balance 264 Pressure balance
103 Remaining-flow pressure balance 275 to consumer (bucket cylinder)
104 Pressure cut-off valve
6.01.8
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MJFCIFSS
Service Manual Grab control
Function/design
Grab control
1 Function/design
The Grab Control function is installed in model A 904 C EDC (type 1004/1071 industrial) from version
V4.7.
The function is activated in the grab-control (ON) menu and by the subsequent actuation of the switch
S85 and the keyboard (BBT). The pressure setting at the grapple is reduced in proportion to the con-
trol pressure for extending the stick or lifting the boom. As a consequence, the pressure cut-off func-
tion of the system is not triggered and there is sufficient oil for the boom and stick movement.
The pressure setting of the grapple can only be adjusted by the technician, in consultation with the
machine operator. The adjustment is made in the excavator menu.
The proportional solenoid valve Y514 with the pressure sensor B359 and the shuttle valve 200 is
mounted together with the proportional solenoid valve Y451 of the slewing gear fine control on the
side of the tank 1.
The restrictor valve 300 is screwed into the control block 100, connection LS1.
Fig. 1 Design of hydraulic system
1 Hydraulic tank 300 Restrictor check valve

5 Pilot control pressure / extending stick B359 Pressure sensor / closing grapple -
cylinder proportional
16 Pilot pressure / lifting boom Y451 Proportional solenoid valve / slewing gear
fine control
6.10.1
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MJFCIFSS
Grab control Service Manual
Functional description, see Fig. 2
20 Hydraulic pump with flow regulator Y514 Proportional solenoid valve Closing
grapple - proportional
100 Control valve block S85 Switch / grapple operation
200 Shuttle valve
2 Functional description, see Fig. 2
Note!
The electrical connections are shown in the circuit diagram of group 8.100.
The Grab Control function enables the machine operator to move the boom 220 and the stick cylinder
240 faster while operating the grapple (pressure cut-off valve 104.
If the function is activated in the grab-control (ON) menu and by actuating the switch S85, the pres-
sure at the grapple 260 is reduced in proportion to the control pressure for extending the stick 240 or
lifting the boom 220 respectively. It ensures that the pressure cut-off function 104 of the system is not
triggered and that sufficient oil is available for the boom and stick movement.
The extent by which the pressure is reduced can be set in the grab-values menu.
100% = low pressure at grapple (high movement velocity for stick/boom)
0% = high pressure at grapple (low movement velocity for stick/boom)
If the grab control is not activated (S85 off), the proportional solenoid valve Y514 is kept by the control
system (BST) at the maximum current value (approx. 800 mA). The proportional solenoid valve Y514
is a negatively acting valve: when supplied with maximum current, the valve opens when the pressure
is high. When supplied with minimum current, the valve opens when the pressure is low.
The pressure sensor B359 measures the pilot pressure at the connections 5 and 16. Depending on
the pilot control pressure, the shuttle valve 200 determines the pressure applied to the pressure sen-
sor B359. This pressure generates a current that is controlled by a characteristic at the output EV4.
If the pressure balance 264 is not pressurised through the connection P4, the balance remains
closed in all three positions. This means that the LS signal is not affected.
2.1 Grab Control set to 0%

If 0% is selected in the grab-value submenu, the proportional solenoid valve Y514 (EV4) is powered
with the maximum current (approx. 650 mA). This means that the setting is higher than that of the
pressure cut-off valve 104. The grapple closing function can be operated at maximum pressure (high
clamping force).
The maximum pressure is limited by the pressure cut-off valve 104 so that the variable-displacement
pump 20 is reset to the residual volume. The velocity of the working movements for the boom and
stick cylinder is lowered.
2.2 Grab Control set to 100%

If 100% is selected in the grab-value submenu, the proportional solenoid valve Y514 (EV4) is powe-
red with the minimum current (approx. 300 mA). This ensures that the pressure is kept to a low level.
Grapple closing function can now not be operated at maximum pressure (low clamping force).
The pressure cut-off valve 104 is not actuated. This means that the variable-displacement pump 20
supplies the boom and stick with sufficient oil.
6.10.2
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MJFCIFSS
Fig. 2 Hydraulic diagram
6.10.3
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MJFCIFSS
1 to hydraulic tank 240 Spool / stick cylinder

5 Pilot control pressure / extending stick 260 Spool / grapple cylinder
cylinder
16 Pilot pressure / lifting boom 264 Pressure balance, directly controlled
20 from hydraulic pump A1/A2 300 Restrictor check valve
100 Control valve block B359 Pressure sensor / closing grapple
200 Shuttle valve Y451 Proportional solenoid valve / slewing
gear fine control
220 Spool / boom cylinder Y514 Proportional solenoid valve Closing
2.3 Activating Grab Control
Connect the dongle.

Select the set config submenu via the set data menu.
In the grab-control submenu, use the arrow keys UP/DOWN to select ON and confirm with the
Menu key.
Grab Control is activated.
Fig. 3 Activating Grab Control
Note!
The Grab Control function is activated in the grab-control submenu and then started with the switch
S85.
2.4 Adjusting Grab Control settings
Caution!
Risk of injury due to low clamping force when the grapple is closed (S85 activated).
To lift heavy loads, or if maximum clamping force is required, switch off S85.
In the set values submenu, the grapple pressure settings can be set to any value between 0 and
100%, based on the wishes of the machine operator. The factory settings (default value) is 50%.
Connect dongle and actuate switch S85.
Select the set values submenu via the set data menu.
6.10.4
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MJFCIFSS
Error codes
The grab-value submenu is displayed.

Press the arrow keys UP/DOWN to adjust the % value in the change value field to the desired
value.
Press the Back key to exit the submenu.
The % value is stored.
Fig. 4 Grab Control settings
3 Error codes
Error code Effect Cause What you can do

E 030 Proportional solenoid valve Cable break at proportional Check plug connections and
Y514 is not monitored. Pro- solenoid valve Y514 solenoid valve Y514; replace,
portional pressure control is if necessary.
not possible.
E 150 Pilot pressure is not measu- Wire break Check plug connections and
red. Current at pressure sensor pressure sensor B359; re-
B359 < 3mA place, if necessary.
E 151 Pilot pressure is not measu- Short circuit Check plug connections and
red. Current at pressure sensor pressure sensor B359; re-
B359 > 21mA place, if necessary.
6.10.5
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MJFCIFSS
Error codes
6.10.6
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MJFCIFSS
Service Manual Design of hydraulic system
Tank arrangement
Design of hydraulic system
1 Tank arrangement
Fig. 1 Hydraulic and fuel tank 1
1 Hydraulic and fuel tank 9 Tank lid and strainer

2 Breather filter B8 Oil temperature sensor
3 Stop cock B14 Electrical oil-level sensor
4 Return filter B39 Fuel level sensor
5 Integrated check valve
Two-component construction:
Fuel tank, see group 19
Hydraulic tank, see group 19
1.1 Hydraulic tank

Purpose:
Take up all hydraulic oils from the entire equipment
Separate inlet and return sections. Baffle oil with baffle plates on the inside.
Supply purified oil to hydraulic pumps.
Reservoir for return oil, with return filters.
Preload oil to prevent cavitation.
6.20.1
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MJFCIFSS
Design of hydraulic system Service Manual
Tank arrangement
Fig. 2 Sectional drawing of hydraulic tank 1
Classification:
Return section A
Filter chamber B with return filter 4 and magnetic rod
Breather filter 2
Intake section C with stop cock 3
Filter units:
Return filter 4 with two-stage glass-fibre filter element and safety check valve 5 (integrated in re-
turn filter)
Filter elements:
for intake (initial outfit) 10 µ
for normal application: two-stage 20 / 5 µ; for dust-intensive application: one-stage 10 µ
Breather filter: for normal application: 7 µ; for dust-intensive application: 2 µ
Maintenance:
Changing hydraulic oil
Replacing return filter element and breather filter
Draining tank
see maintenance regulation in group 3
6.20.2
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MJFCIFSS
Hydraulic pumps
2 Hydraulic pumps
Fig. 3 Variable displacement pumps 20 for a: A 900 C Litronic, b: A 904 C Litronic
20 Variable displacement pump 26 Flow regulator

23 Regulating unit 30 Gear pump
25 Performance regulator
2.1 Variable displacement pump 20

Powered by:
diesel engine
via torsion dampers (flexible coupling)
Design:
Axial piston swash plate
Classification:
Axial piston powertrain
Adjustable unit with swash plate
Regulating unit with performance regulator (GLR) and flow regulator (LS regulator)
Technical data and description of functions:
see variable displacement pump in group 7
6.20.3
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MJFCIFSS
Hydraulic pumps
Fig. 4 Gear pumps 31 / 32 / 33
2.2 Gear pumps:

Pump 30 for pilot control, see Fig. 3:
Driven by variable displacement pump 20
Supply to control oil unit: see group 7.42
Flow rate: see "Technical data" in group 3
Pump 31 for steering see Fig. 4:
Powered by diesel engine
Supply to servostat / steering valve: see group 13.10
Pump 32 for braking system, see Fig. 4:
Supply to braking system see group 15.10
Pump 33 for hydrostatic fan drive:
Powered by diesel engine (flange-mounted)
Supply to hydrostatic fan drive
Flow rate see "Technical data" in group 3
6.20.4
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MJFCIFSS
Arrangement of control valve block
3 Arrangement of control valve block
Fig. 5 Control valve block 100 with slewing-gear and kit axle
Design:
Compact control block 100
Integrated LUDV control
Input section
5 spools
one pressure balance for each spool, used for LUDV control
Possibility to flange-mount more sections, e.g. another kit axle
Pressure control by means of screwed-in pressure relief valves (primary and secondary valves
with suction function)
Suction valves for chassis
Stroke limitation of spools
Bleeder valves of control lids
Description of functions: see group 7.50
6.20.5
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MJFCIFSS
Hydraulic oil cooler
4 Hydraulic oil cooler
Fig. 6 Oil cooler
6 Oil cooler B8 Oil temperature sensor

13 Blower motor Y347 Proportional solenoid valve
14 Pressure relief valve
Design:
Four-component cooling unit consisting of oil cooler 6 for hydraulic oil cooling (bottom), engine
cooling for diesel engine (centre), charge cooling for diesel engine (top) and condenser for air con-
dition (front).
Hydrostatic fan drive depends on hydraulic and coolant temperature and air condition with high
air flow rate
Fan speed is controlled electronically, with respect to temperature, via proportional solenoid
valve Y347
6.20.6
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MJFCIFSS
Fig. 7 Diagrams - hydraulic oil cooler

(
2 (°C) Coolant temperature

Â8 (°C) Hydraulic oil temperature
I Y347 mA Current to solenoid valve Y347
p (bar) Pressure in hydrostatic fan drive
(min-1) Fan speed
6.20.7
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MJFCIFSS
4.1 Functional description

If the temperature of hydraulic oil and/or coolant is below or equal to the limit value specified
Â8 (min.) and Â2 (min.), resp., the output current to solenoid valve Y347 of BST (U16) is
I Y347 (max.).
In such a case, the pressure at prop. valve Y347 is reduced to a low value. This has the effect that
the speed of the fan is reduced to min. working speed fan (min.). Surplus from pump 33 is recycled
back to tank via relief valve 14.
If temperatures exceed limit values specified Â8 (max.) and Â2 (max.), resp., the current at solenoid
valve Y347 drops (A 900 C => 220 mA, A 904 C => 180 mA).
The setting of relief valve 14 now corresponds to min. value. Flow volumes from pump 33 go nearly
exclusively to fan motor 13, now. The speed of the fan fan (max.) and the oil pressure of the hydraulic
drive p(max.) hit max. values.
Between the min. and max. values mentioned, the current of the BST (U16) will be linear with respect
to solenoid valve Y347. That means, every interim temperature will correspond to a certain
current I and pressure p between min. and max. which will lead to a certain fan speed in each case
(see diagrams).
Fig. 8 Hydraulic diagram: fan control
Note!
Speed during emergency operation: (failure at Y347)
A 900 C: Inot = mA = approx. 1600 min-1
Pnot at pressure relief valve 14 = 160 bar
A 904 C: Inot = mA = approx. 1750 min-1
Pnot at pressure relief valve 14 = 180 bar
Air condition switched on:

400 mA* = approx. 850 min-1 of fan blade
* The current going to solenoid Y347 depends on the version of the BST. See group 8.71.
6.20.8
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MJFCIFSS
Oil rotary connection
5 Oil rotary connection
Fig. 9 Oil rotary connection 320 / 322
Purpose:
Lead through hydraulic oil from uppercarriage to undercarriage and vice versa
Design:
Oil rotary connection 320 for high pressures
Travel drive, outrigger and blade support, steering, and leak oil
Oil rotary connection 322 for low pressures
Braking system, gear shifting, creeper gear system, oscillating axle support
Description: see groups 7.70 and 7.75.
6.20.9
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MJFCIFSS
Consumers / working attachments
6 Consumers / working attachments
Fig. 10 Consumers and attachments
Purpose:
Convert hydraulic energy to mechanical energy
Classification:
Hydraulic device for the transmission of pushing and/or pulling forces in a linear motion with a li-
mited stroke.
Hydraulic device for the transmission of torque forces in a rotary motion.
6.20.10
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MJFCIFSS
6.1 Cylinder
Fig. 11 Arrangement of consumers and working attachments
Design:
Differential cylinder
no end-of-travel cushioner
with end-of-travel cushioner - one end / two-end
Description of functions: see group 7.30
Classification:
Boom cylinder 235 actuates basic boom, with end-of-travel cushioner on the piston side.
Stick cylinder 255 actuates stick, with cushioning at both ends.
Bucket cylinder 275 actuates bucket, with end-of-travel cushioner on piston side.
Support cylinder 295 actuates supporting outrigger and/or blade, no end-of-travel cushioning.
Adjustable boom cylinder 525 (kit AHS 1)
6.2 Oil motor

Design:
constant (with constant oil flow consumption)
regulated (with variable oil flow consumption)
Description of functions: see groups 7.20 and 7.25.
Classification:
Slewing-gear fixed displacement motor 130 with integrated control actuates uppercarriage via sle-
wing gear mechanism
Regulating travel motor 170 actuates vehicle wheels via transmission with travel brake valve 190
6.20.11
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MJFCIFSS
Pilot control
7 Pilot control
Fig. 12 Control oil unit 50 and view of pilot control valves on operator's platform
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.)
Design and function:
Pressure generated by separate gear pump 30
Control oil unit 50 regulates, monitors, filters, stores and distributes control oil and pressure.
Proportional solenoid valves Y50 / Y51 control variable displacement pump 20. Solenoid valve Y3
shuts off pilot pressure Y7. Control of slewing gear brake Y66 and oscillating axle support.
Pilot control valves 80 - 86 with regulating characteristics for comfortable operation:
Pilot control valves 80 and 81 with joystick to operate slewing gear and attachments.
Pilot control valve 84 with foot pedal for the operation of the chassis.
Pilot control valve 85 with lever to operate support.
Pilot control valve 86 with foot pedal to operate supplementary attachments (kit).
Control lines leading from pilot control valves to the control lids of the various spools.
Maintenance:
Replacing filter elements (control oil filter in control oil unit)
Description: see maintenance regulation in group 3.
6.20.12
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MJFCIFSS
Service Manual Layout of hydraulic system
Tank arrangement
Layout of hydraulic system
1 Tank arrangement
Fig. 1 Hydraulic tank 1
1 Hydraulic tank 5 Integrated check valve

3 Stop cock B14 Electrical oil-level sensor
4 Return filter
1.1 Hydraulic tank

Purpose:
Holds the entire volume of hydraulic oil for the entire equipment.
Separates inlet and return sections. Baffle oil with baffle plates on the inside.
Supplies purified oil to hydraulic pumps.
Preloads oil to prevent cavitation.
Filter units:
Return filter 4 with two-stage glass-fibre filter element and safety check valve 5 (integrated in re-
turn filter)
Filter elements:
Breather filter for normal and dust-intensive application 2 µ.
Maintenance:
Changing hydraulic oil.
Draining tank.
see maintenance regulations in group 3
A 900 C-LI EDC 24677- 6.21.1

MJFCIFSS
Layout of hydraulic system Service Manual
Hydraulic pumps
2 Hydraulic pumps
Fig. 2 Variable-displacement pumps 20 for a: A 900 C Litronic, b: A 904 C Litronic
20 Variable-displacement pump 26 Flow regulator

23 Regulating unit 30 Gear pump
25 Power regulator
2.1 Variable-displacement pump 20

Powered by:
Diesel engine
Via torsion dampers (flexible coupling)
Design:
Classification:
see variable-displacement pump in group 7
6.21.2 A 900 C-LI EDC 24677-

MJFCIFSS
Hydraulic pumps
2.2 Gear pumps:

Pump 30 for pilot controlsee Fig. 2:
Driven by variable-displacement pump 20
Supply to control oil unit, see group 7.42
For flow rate, see "Technical data" in group 3
Pump 31 for steering, see Fig. 3:
Supply to servostat / steering valve, see group 13.10
Pump 32 for brake system, see Fig. 3:
Supply to braking system, see group 15.10
Pump 33 for hydraulic fan drive:
Supply of hydraulic fan drive
A 900 C-LI EDC 24677- 6.21.3

MJFCIFSS
Fig. 4 Control valve block 100 with slewing-gear and kit axle
Design:
Compact control block 100
Input section
5 spools
For description of functions, see group 7.50
6.21.4 A 900 C-LI EDC 24677-

MJFCIFSS
Fig. 5 Oil cooler
6 Oil cooler 33 Gear pump (fan control)

13 Blower motor B8 Oil temperature sensor
14 Pressure relief valve Y347 Proportional solenoid valve
Design:
Four-component cooling unit consisting of oil cooler 6 for hydraulic oil cooling (bottom), engine
cooling for diesel engine (centre), charge cooling for diesel engine (top) and condenser for air con-
dition (front).
Hydrostatic fan drive depends on hydraulic and coolant temperature and air condition with high
air flow rate
Fan speed is controlled electronically, with respect to temperature, via proportional solenoid valve
Y347
A 900 C-LI EDC 24677- 6.21.5

MJFCIFSS
Fig. 6 Diagrams - hydraulic oil cooler

(
2 (°C) Coolant temperature

Â8 (°C) Hydraulic oil temperature
I Y347 mA Current to solenoid valve Y347
p (bar) Pressure in hydrostatic fan drive
n (rpm) Fan speed
6.21.6 A 900 C-LI EDC 24677-

MJFCIFSS

If the temperature of the hydraulic oil and/or the coolant is below or equal to the set limit value Â8
(min.) or Â2 (min.), the output current to the solenoid valve Y347 of the BST (U16) is I Y347 (max.).
In such a case, the pressure at the prop. valve Y347 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 from pump
33 is recycled back to tank through the pressure relief valve 14.
If temperatures exceed the set limit values Â8 (max.) or Â2 (max.), the current at solenoid valve Y347
drops (A 900 C => 220 mA, A 904 C => 180 mA).
The setting of pressure relief valve 14 now corresponds to min. value. Nearly the entire flow volume
of the pump 33 flows to the fan motor 13. The speed of the fan n fan (max.) and the oil pressure of the
hydraulic drive p(max.) reach the max. values.
Between the minimum and maximum values, the current of the BST (U16) is linear with respect to
solenoid valve Y347. This means that every interim temperature corresponds to a specific current I
and pressure p between min. and max., which results in a specific fan speed (see diagrams).
Fig. 7 Hydraulic diagram: fan control
Note!
Speed during emergency operation: (failure of Y347)
A 900 C: Iemer = mA = approx. 1825 rpm
Pemer at relief valve 14 = 200 bar
A 904 C Iemer = mA = approx. 1750 rpm
Pemer at relief valve 14 = 180 bar
Air conditioning switched on:
400 mA* = approx. 850 rpm of fan blade
* The current to the solenoid Y347 depends on the version of the BST. See group 8.71.
A 900 C-LI EDC 24677- 6.21.7

MJFCIFSS
Purpose:
feeds hydraulic oil from the uppercarriage to the undercarriage and vice versa
Design:
Oil rotary connection 320 for high pressure
Oil rotary connection 322 for low pressure
For a description, see groups 7.70 and 7.75.
6.21.8 A 900 C-LI EDC 24677-

MJFCIFSS
130 Slewing gear motor 255 Stick cylinder

170 Travel motor 275 Bucket cylinder
190 Travel brake valve 295 Support cylinder
235 Boom cylinder 455 Uppercarriage locking cylinder
Purpose:
Conversion of hydraulic energy to mechanical energy
Classification:
Hydraulic device for the transmission of pushing and/or pulling forces in a linear motion with li-
mited stroke.
Hydraulic device for the transfer of torque in a rotary motion.
A 900 C-LI EDC 24677- 6.21.9

MJFCIFSS
6.1 Cylinder
Design:
Single-side cylinder
Mechanical return
without end-of-travel cushioning
with end-of-travel cushioning, one-end / two-end
Classification:
Single-side cylinders as:
hydraulic cylinder 455 for the locking of the uppercarriage during on-road travel and transport (on-
ly required for machines with adjustable attachment).
Differential cylinder as:
Boom cylinder 235 actuating basic boom, with end-of-travel cushioning on the piston side.
Stick cylinder 255 moving the bucket stick, with cushioning at both ends.
Bucket cylinder 275 moving the bucket, with end-of-travel cushioning on piston side.
Support cylinder 295 moving outrigger and/or blade support, no end-of-travel cushioning
6.2 Oil motor

Design:
Classification:
The slewing-gear fixed displacement motor 130 with integrated control actuates the uppercarriage
via the slewing gear mechanism.
The regulating travel motor 170 drives the vehicle wheels through the transmission with the travel
brake valve 190.
6.21.10 A 900 C-LI EDC 24677-

MJFCIFSS
Pilot control
7 Pilot control
Fig. 11 Control oil unit 50 and view of pilot control valves on operator's platform
Purpose:
foot-operated controls (pilot control valves / joystick, etc.)
Pressure generation by separate gear pump 30
Control oil unit 50 for the regulation, monitoring, filtering, storage and distribution of the control oil
and pressure.
Proportional solenoid valves Y50 / Y51 for the control of the variable-displacement pump 20. Sole-
noid valve Y3 to cut off the pilot pressure Y7; control of the slewing gear brake Y66, the oscillating
axle support and Y24 for creeper gear.
Pilot control units 80 and 81 with joystick for the operation of the slewing gear and the attach-
ments.
Pilot control unit 84 with foot pedal for the operation of the chassis.
Pilot control unit 85 with lever for the operation of the support system.
Pilot control unit 86 with foot pedal for the operation of the auxiliary equipment (kit)
Control lines leading from the pilot control units to the control caps of the respective spools.
Maintenance:
Replacement of filter elements (control oil filter in control oil unit).
For description, see maintenance regulations in group 3.
A 900 C-LI EDC 24677- 6.21.11

MJFCIFSS
Pilot control
6.21.12 A 900 C-LI EDC 24677-

MJFCIFSS
Layout of hydraulic system
Fig. 1 Layout of hydraulic system
1 Hydraulic tank 50 Control oil unit

6 Oil cooler 100 Pilot plate
20 Double variable-displacement pump 130 Slewing gear motor
30 Gear pump (pilot control) 200 Operator's platform
31 Gear pump (steering) 320 Rotary connection (high pressure)
32 Gear pump (brake system) 322 Rotary connection (low pressure)
33 Gear pump (fan drive)
6.22.1
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MJFCIFSS
Tank arrangement
1 Tank arrangement
Fig. 2 Hydraulic tank 1
1 Hydraulic tank 5 Integrated bypass valve

3 Stop cock B14 Oil level sensor
4 Return filter
1.1 Hydraulic tank

Purpose:
Holds the entire volume of hydraulic oil for the entire equipment.
Separates inlet and return sections. Baffle oil with baffle plates on the inside.
Supplies purified oil to hydraulic pumps.
Preloads oil to prevent cavitation.
Filter units:
Return filter 4 with two-stage glass-fibre filter element and safety bypass valve 5 (integrated in re-
turn filter)
Filter elements:
Breather filter for normal and dust-intensive application 2 µ.
Maintenance
Changing hydraulic oil.
Draining tank.
see maintenance regulations in group 3
6.22.2
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MJFCIFSS
Hydraulic pumps
2 Hydraulic pumps
Fig. 3 Variable-displacement pumps 20
20 Variable-displacement pump 24 Regulating unit P2

22 Regulating unit P1 30 Gear pump
2.1 Variable-displacement pump 20

Powered by:
diesel engine
Via torsion dampers (flexible coupling)
Design:
Classification:
see variable-displacement pump in group 7
6.22.3
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MJFCIFSS
Hydraulic pumps
2.2 Gear pumps:

Pump 30 for pilot controlsee Fig. 3:
Driven by variable-displacement pump 20
Supply to control oil unit, see group 7.42
Pump 31 for steering, see Fig. 4:
Supply to Servostat / steering valve, see group 13.10
Pump 32 for brake system, see Fig. 4:
Supply to braking system, see group 15.10
Pump 33 for hydraulic fan drive:
Supply of hydraulic fan drive
6.22.4
copyright by
MJFCIFSS
Fig. 5 Pilot plate 100
Design:
Pilot plate 100
5 way valves (spools), two pressure balances with switch for each spool.
6.22.5
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MJFCIFSS
Fig. 6 Oil cooler
6 Oil cooler B8 Oil temperature sensor

13 Blower motor B14 Oil level sensor
14 Pressure relief valve Y347 Proportional solenoid valve
33 Gear pump (fan control)

(
6.22.6
copyright by
MJFCIFSS
Purpose:
feeds hydraulic oil from the uppercarriage to the undercarriage and vice versa
Design:
Oil rotary connection 320 for high pressure
Oil rotary connection 322 for low pressure
For a description, see groups 7.70 and 7.75.
6.22.7
copyright by
MJFCIFSS

190 Travel brake valve 295 Support cylinder
235 Boom cylinder 455 Uppercarriage locking cylinder
Purpose:
Conversion of hydraulic energy to mechanical energy
Classification:
Hydraulic device for the transmission of pushing and/or pulling forces in a linear motion with li-
mited stroke.
Hydraulic device for the transfer of torque in a rotary motion.
6.22.8
copyright by
MJFCIFSS
6.1 Cylinder
Design:
Single-side cylinder
Mechanical return
without end-of-travel cushioning
with end-of-travel cushioning, one-end / two-end
Classification:
Single-side cylinders as:
hydraulic cylinder 455 for the locking of the uppercarriage during on-road travel and transport (on-
ly required for machines with adjustable attachment).
Differential cylinder as:
Boom cylinder 235 actuating basic boom, with end-of-travel cushioning on the piston side.
Stick cylinder 255 moving the bucket stick, with cushioning at both ends.
Bucket cylinder 275 moving the bucket, with end-of-travel cushioning on piston side.
Support cylinder 295 moving outrigger and/or blade support, no end-of-travel cushioning
6.2 Oil motor

Design:
Classification:
The slewing-gear fixed displacement motor 130 with integrated control actuates the uppercarriage
via the slewing gear mechanism.
The regulating travel motor 170 drives the vehicle wheels through the transmission with the travel
brake valve 190.
6.22.9
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MJFCIFSS
Pilot control
7 Pilot control
Fig. 10 Control oil unit 50 and view of pilot control valves on operator's platform 200
Purpose:
foot-operated controls (pilot control valves / joystick, etc.)
Pressure generation by separate gear pump 30
Control oil unit 50 for the regulation, monitoring, filtering, storage and distribution of the control oil
and pressure.
Proportional solenoid valves Y50 /Y51 for the control of the variable-displacement pump 20. Solenoid
valve Y3 to cut off the pilot pressure Y7; control of the slewing gear brake Y66, the oscillating axle
support and Y24 for creeper gear.
Pilot control units 80 and 81 with joystick for the operation of the slewing gear and the attach-
ments.
Pilot control unit 84 with foot pedal for the operation of the chassis.
Pilot control unit 85 with lever for the operation of the support system.
Pilot control unit 86 with foot pedal for the operation of the auxiliary equipment (kit)
Control lines leading from the pilot control units to the control caps of the respective spools.
Maintenance
Replacement of filter elements (control oil filter in control oil unit).
For description, see maintenance regulations in group 3.
6.22.10
copyright by
MJFCIFSS
Service Manual Hydraulic system A 900 C, starting with 14675
Hydraulic system A 900 C, starting with 14675
Type: 917 / 987

Note!
For a detailed description of the design and construction of the hydraulic system and the various
main components, see group 6.20.
Index to wiring diagram I

Item see Item see
group group
1 Hydraulic tank 81 Pilot control unit, right 4 x 7.48
2 Breather filter 84 Pilot control unit, travel 1 x 7.42
3 Stop cock 85 Pilot control unit 2 x, support 7.46
4 Return filter 88P Manifold pressure
5 Bypass valve / return filter (pres- 88T Collecting pipe return line
sure)
6 Oil cooler 100 from / to control valve block
13 Oil motor radiator fan 125 TC valve 7.80
14 Pressure relief valve / fan motor 155 to slewing gear brake
20 Variable-displacement pump 7.02/7.05 320 from rotary connection 7 x 7.75
21 Powertrain 322 to rotary connection 6 x 7.70
21.1 Control cylinder 400 to oscillating axle support 14.10
23 Regulating valve 401 to gear switching unit 11.10
23.2 Power regulator S7 Safety switch 8.10
23.5 Flow regulator S17 Switch slewing gear brake 8.10
23.6 Shuttle valve S21 Switch / creeper gear 8.10
28 Check valve S30 Switch / travel direction 8.10
29 Restrictor S354 Switch / pilot control 8.10
30 Gear pump / pilot control S75 Switch / oscillating axle automatic 8.10
33 Gear pump / fan U16 Excavator control BST 8.10
44 Measuring point / actuating pres- Y3 Solenoid valve servo release 8.10
sure
49 Measuring point / control pressure Y7 Solenoid valve slewing gear brake 8.10
M1
50 Control oil unit 7.40 Y24 Solenoid valve / creeper gear 8.10
51 Pressure relief valve Y50 Proportional solenoid valve 8.10
power control
52 Pressure filter Y51 Proportional solenoid valve LS con- 8.10
trol
53 Check valve Y62 Solenoid valve / forward travel 8.10
54 Accumulator Y63 Solenoid valve / reverse travel 8.10
57 Measuring point / servo pressure Y66 Solenoid valve / oscillating axle 8.10
-p reduction support
A 900 C-LI 14675- 6.30.1

copyright by
MJFCIFSS
Hydraulic system A 900 C, starting with 14675 Service Manual
Item see Item see

group group
59 Measuring point / servo pressure Y50 Proportional solenoid valve - fan 8.10
power control
80 Pilot control unit, left 4 x 7.48
Index to wiring diagram II

Item see Item see
group group
1 to hydraulic tank 192 Brake piston
6 to hydraulic tank 193 Restrictor check valve
7 Check valve 3.5 bar 7.50 194 Check valve
8 Preload valve 7.0 bar 7.50 195 Shuttle valve
20 from variable-displacement pump 7.02/7.05 196 Check valves
26 to flow regulator 220 Spool / boom cylinder 7.50
41 Measuring point MP 221 Secondary pressure relief valve /
extending
45 Measuring point LS 222 Secondary pressure relief valve /
retracting
50 from the control oil unit 7.40 224 Pressure balance, pilot-controlled
80 Pilot control unit, left 4 x 7.48 227 Restrictor check valve
81 from pilot control unit, right 4 x 7.48 233 Distribution block
85 from pilot control valve / support 7.46 235 Boom cylinder 7.30
88 from manifold P 237 Stop cock (in models without item
238)
88 to collecting pipe T 238 Pipe fracture safety valve (kit)
100 Compact control block 5 x 7.50 240 Spool / stick cylinder 7.50
102 Pressure balance / minimum flow 241 Secondary pressure relief valve /
retracting
103 Pressure balance / remaining flow 242 Secondary pressure relief valve /
extending
104 Turn out pressure cut-off valve 244 Pressure balance, pilot-controlled
105 Primary pressure relief valve 247 Restrictor check valve
107 Shuttle valve 255 Stick cylinder 7.30
108 LS main orifice 260 Spool / bucket cylinder 7.50
109 Shuttle valve Only in A 900 C Litronic HD type 987
120 Spool / slewing gear 261 Secondary pressure relief valve /
retracting
122 Input pressure balance 262 Secondary pressure relief valve /
extending
123 Check valve 264 Pressure balance, pilot-controlled
125 TC valve with additional pressure 7.80 275 Bucket cylinder 7.30
level
126 Restrictor (Ø 1.5 mm) 277 Shut-off device for
grapple operation
127 Restrictor check valve 278 Lines leading to grapple
6.30.2 A 900 C-LI 14675-

copyright by
MJFCIFSS
Item see Item see

group group
128 Shuttle valve 279 Restrictor check valve
(QC only)
129 Restrictor (Ø 0.6 mm) 280 Spool / support cylinder 7.50
130 Slewing gear motor 7.20 281 Plug / dummy cartridge
132 Powertrain 284 Pressure balance, directly control-
led
133 Suction valve 295 Support cylinder 7.30
134 Pressure relief valve with additional 297 Double load-holding valve
pressure stage
135 Pressure relief valve with additional 320 Rotary connection 7 x
pressure stage
137 Measuring point, swivelling right 322 Rotary connection 6 x
138 Measuring point, swivelling left 540 Spool / grapple rotator 16.40
155 Slewing gear brake 9.20 541 Secondary relief valve / turn right
156 Slewing gear mechanism 9.10 542 Secondary relief valve / turn left
160 Travel gear spool 7.50 544 Pressure balance, directly control-
led
161 Suction valve 550 Oil motor / grapple rotator
162 Suction valve 551 Secondary relief valve / turn right
164 Pressure balance, directly control- 552 Secondary relief valve / turn left
led
167 Restrictor check valve S5L Push button / grapple rotator, left 8.10
170 Travel motor 7.25 S5R Push button / grapple rotator, right 8.10
172 Powertrain S19 Switch / grapple rotator 8.10
173 Control cylinder / regulating unit Y22 Solenoid valve / grapple rotation left 16.40
174 Spool / regulating unit Y23 Solenoid valve / grapple rotation 16.40
right
176 Secondary pressure relief valve / Y24 from solenoid valve / creeper gear 7.40
reverse travel
177 Secondary pressure relief valve / Y62 from solenoid valve / forward travel 8.10
forward travel
185 Transmission 11.10 Y63 from solenoid valve / reverse travel 8.10
190 Travel brake valve
A 900 C-LI 14675- 6.30.3

copyright by
MJFCIFSS
Support alternatives: 2-support / 4-support outrigger
1 Support alternatives: 2-support / 4-support outrigger
Fig. 1 Hydraulic diagram: 2-support / 4-support outriggers
100 A1 Connection of control valve block 297 Double lowering brake valve
100 B1 Connection of control valve block 320 Rotary connection
295 Outrigger support cylinder
6.30.4 A 900 C-LI 14675-

copyright by
MJFCIFSS
Support alternative: 2-support blade front or back; 4-support blade front - outrigger back, or the other way round.
2 Support alternative: 2-support blade front or back; 4-support blade

front - outrigger back, or the other way round.
100 A1 Connection of control valve block 325 Slip ring - electrical system Rotary con-
nection
100 B1 Connection of control valve block S206 Push button / individual control outrigger,
left
294 Blade support cylinder S207 Push button / individual control outrigger,
right
295 Outrigger support cylinder S335 Push button / individual control of blade
297 Double lowering brake valve Y56 Solenoid valve / individual control of blade
A 900 C-LI 14675- 6.30.5

copyright by
MJFCIFSS
298 Double lowering brake valve Y217 Solenoid valve / individual control of out-
rigger, left
320 Rotary connection Y218 Solenoid valve / individual control of out-
rigger, right
6.30.6 A 900 C-LI 14675-

copyright by
MJFCIFSS
Service Manual Hydraulic system A 900 C, from 24677
Hydraulic system A 900 C, from 24677
Type: 1002
Note!

Item see Item see
group group
1 Hydraulic tank 81 Pilot control unit, right 4 x 7.48
2 Breather filter 84 Pilot control unit, travel 1 x 7.42
3 Stop cock 85 Pilot control unit 2 x, support 7.46
4 Return filter 88P Manifold pressure
5 Bypass valve / return filter (pres- 88T Collecting pipe return line
sure)
6 Oil cooler 100 from / to control valve block
13 Oil motor radiator fan 130 to slewing gear motor 7.20
14 Pressure relief valve / fan motor 155 to slewing gear brake
20 Variable-displacement pump 7.05 320 from rotary connection 7 x 7.75
22 Control cylinder 400 to oscillating axle support 14.10
25 Power regulator 455 Uppercarriage locking
26 Flow regulator B335 Pressure sensor of slewing gear
fine control
27 Shuttle valve S7 Safety switch 8.10
28 Check valve S17 Switch slewing gear brake 8.10
29 Restrictor S21 Switch / creeper gear 8.10
30 Gear pump / pilot control S30 Switch / travel direction 8.10
31 Gear pump / steering S354 Switch / pilot control 8.10
32 Brake gear pump S75 Switch / oscillating axle automatic 8.10
33 Gear pump / fan U16 Excavator control BST 8.10
44 Measuring point / actuating pres- Y3 Solenoid valve servo release 8.10
sure
49 Measuring point / control pressure Y7 Solenoid valve slewing gear brake 8.10
M1
50 Control oil unit 7.41 Y24 Solenoid valve / creeper gear 8.10
51 Pressure relief valve Y50 Proportional solenoid valve 8.10
Power control
52 Pressure filter Y51 Proportional solenoid valve 8.10
Flow regulator
53 Check valve Y62 Solenoid valve / forward travel 8.10
54 Accumulator Y63 Solenoid valve / reverse travel 8.10
A 900 C-LI EDC 24677- 6.31.1

copyright by
MJFCIFSS
Hydraulic system A 900 C, from 24677 Service Manual
Item see Item see

group group
57 Measuring point / servo pressure Y66 Solenoid valve / oscillating axle 8.10
-p reduction support
59 Measuring point / servo pressure Y50 Proportional solenoid valve - fan 8.10
Power control
80 Pilot control unit, left 4 x 7.48 Y451 to proportional solenoid valve / sle-
wing gear
fine control

Item see Item see
group group
1 to hydraulic tank 194 Check valve
6 to oil cooler 195 Shuttle valve
7 Check valve 3.5 bar 7.50 196 Check valves
8 Preload valve 7.0 bar 7.50 220 Spool / boom cylinder 7.50
20 from variable-displacement pump 7.02/7.05 221 Secondary pressure relief valve /
extending
26 to flow regulator (20X2) 222 Secondary pressure relief valve /
retracting
41 Measuring point MP 224 Pressure balance, pilot-controlled
45 Measuring point LS 227 Restrictor check valve
50 from control oil unit 7.40 233 Distribution block
80 Pilot control unit, left 4 x 7.48 235 Boom cylinder 7.30
81 from pilot control unit, right 4 x 7.48 237 Stop cock (in models without item
238)
85 from pilot control valve / support 7.46 238 Pipe fracture safety valve (kit)
88 Distributor P 240 Spool / stick cylinder 7.50
88 Collecting pipe T 241 Secondary pressure relief valve /
retracting
100 Compact control block 5 x 7.50 242 Secondary pressure relief valve /
extending
102 Pressure balance / minimum flow 244 Pressure balance, pilot-controlled
103 Pressure balance / remaining flow 247 Restrictor check valve
104 Pressure cut-off valve 255 Stick cylinder 7.30
105 Primary pressure relief valve 260 Spool / bucket cylinder 7.50
107 Shuttle valve
108 LS main orifice 261 Secondary pressure relief valve /
retracting
109 Shuttle valve 262 Secondary pressure relief valve /
extending
120 Spool / slewing gear 264 Pressure balance, pilot-controlled
122 Input pressure balance 275 Bucket cylinder 7.30
127 Restrictor check valve 7.80 277 Shut-off device for
grapple operation
6.31.2 A 900 C-LI EDC 24677-

copyright by
MJFCIFSS
Item see Item see

group group
130 Slewing gear motor 7.20 278 Lines leading to grapple
132 Powertrain 279 Restrictor check valve
(QC only)
133 Suction valve 280 Spool / support cylinder 7.50
134 Pressure relief valve with additional
pressure stage
135 Pressure relief valve with additional 284 Pressure balance, directly control-
pressure stage led
137 Measuring point, swivelling left 295 Support cylinder 7.30
138 Measuring point, swivelling right 297 Double load-holding valve
155 Slewing gear brake 9.20 320 Rotary connection 7 x
156 Slewing gear mechanism 9.10 322 Rotary connection 6 x
160 Travel gear spool 7.50 540 Spool / grapple rotator 16.40
162 Suction valve 542 Secondary relief valve / turn left
164 Pressure balance, directly control- 544 Pressure balance, directly control-
led led
167 Restrictor check valve 550 Oil motor / grapple rotator
170 Travel motor 7.25 551 Secondary relief valve / turn right
172 Powertrain 552 Secondary relief valve / turn left
173 Control cylinder / regulating unit S5L Push button / grapple rotator, left 8.10
174 Spool / regulating unit S5R Push button / grapple rotator, right 8.10
176 Secondary pressure relief valve / S19 Switch / grapple rotator 8.10
forward travel
177 Secondary pressure relief valve / Y22 Solenoid valve / grapple rotation left 16.40
reverse travel
185 Transmission 11.10 Y23 Solenoid valve / grapple rotation 16.40
right
190 Travel brake valve Y24 from solenoid valve / creeper gear 7.40
192 Brake piston Y62 from solenoid valve / forward travel 8.10
193 Restrictor check valve Y63 from solenoid valve / reverse travel 8.10
Y451 Proportional solenoid valve / sle-
wing gear fine control
A 900 C-LI EDC 24677- 6.31.3

copyright by
MJFCIFSS
100 A1 Connection of control valve block 297 Double stop valve

6.31.4 A 900 C-LI EDC 24677-

copyright by
MJFCIFSS

100 A1 Connection of control valve block 325 Slip ring rotary connection
100 B1 Connection of control valve block S206 Push button / individual control outrigger,
left
294 Blade support cylinder S207 Push button / individual control outrigger,
right
295 Outrigger cylinder S335 Push button / individual control of blade
297 Double stop valve Y56 Solenoid valve / individual control of blade
A 900 C-LI EDC 24677- 6.31.5

copyright by
MJFCIFSS
rigger, left
rigger, right
6.31.6 A 900 C-LI EDC 24677-

copyright by
MJFCIFSS
Hydraulic system A 904 C, starting with 16000

Note!

Items see Items see
group group
1 Hydraulic tank 59 Measuring point servo pressure
Power control
2 Breather filter 80 Pilot control valve, left 4 x 7.48
3 Stop cock 81 Pilot control valve, right 4 x 7.48
4 Return filter 84 Pilot control valve 1 x - travelling 7.42
85 Pilot control valve 2 x - support 7.46
6 Oil cooler 88P Manifold pressure
9 Pressure-reducing valve - tank pre- 88T Collecting pipe return line
load
10 Check valve 100 from / to control valve block
13 Oil motor radiator fan 125 from TC valve 7.80
14 Pressure relief valve fan motor 155 to slewing gear brake
20 Variable displacement pump 7.02/7.05 320 from rotary connection 7 x 7.75
22 Control cylinder 400 to oscillating axle support 14.10
23 Measuring cylinder 401 to gear shifting 11.10
24 Angular lever S7 Safety switch 8.10
25 Performance regulator S17 Switch / slewing gear brake 8.10
26 Flow regulator S21 Switch / creeper gear 8.10
27 Shuttle valve S30 Switch / travel direction 8.10
28 Check valve S354 Switch / pilot control 8.10
29 Restrictor S75 Switch / oscillating axle automatic 8.10
30 Gear pump / pilot control U16 Excavator control BST 8.10
33 Gear pump / fan Y3 Solenoid valve / servo release 8.10
44 Measuring point actuating pressure Y7 Solenoid valve / slewing gear brake 8.10
Y24 Solenoid valve / creeper gear 8.10
50 Control oil unit 7.40 Y50 Proportional solenoid valve / 8.10
power control
51 Pressure-relief valve 8.10
52 Pressure filter Y62 Solenoid valve / travel forward 8.10
53 Check valve Y63 Solenoid valve / travel reverse 8.10
54 Accumulator Y66 Solenoid valve / oscillating axle 8.10
support
57 Measuring point servo pressure Y347 Proportional solenoid valve / fan 8.10
-p reduction
A 904 C-LI 16000- 6.32.1

copyright by
MJFCIFSS

Items see Items see
group group
1 to hydraulic tank 192 Brake piston
6 to oil cooler 193 Restrictor check valve
7 Check valve 3.5 bar 7.50 194 Check valve
8 Preload valve 7.0 bar 7.50 195 Shuttle valve
20 from variable-displacement pump 7.02/7.05 196 Check valves
26 to flow regulator 220 Spool / boom cylinder 7.50
41 Measuring point MP 221 Extend secondary relief valve
45 Measuring point LS 224 Pressure balance, pilot-controlled
50 from control oil unit 7.40 227 Restrictor check valve
80 from pilot control valve, left 4 x 7.48 233 Distribution block
81 from pilot control valve, right 4 x 7.48 235 Boom cylinder 7.30
85 from pilot control valve - support 7.46
88 from manifold P 238 Pipe-fracture safety system (kit)
88 to collecting pipe T 240 Spool / stick cylinder 7.50
100 Compact control block 5 x 7.50 241 Retract secondary relief valve
102 Pressure balance, minimum flow 242 Extend secondary relief valve
103 Pressure balance, remaining flow 244 Pressure balance, pilot-controlled
104 Pressure cut-off valve 247 Restrictor check valve
105 Primary pressure-relief valve 253 Manifold stick cylinder
(industrial equipment)
108 LS mainmain orifice 260 Spool / bucket cylinder 7.50
120 Spool / slewing gear 261 Retract secondary relief valve
122 Input measure balance 262 Extend secondary relief valve
123 Check valve 264 Pressure balance, pilot-controlled
7.80 275 Bucket cylinder 7.30
126 Restrictor Ø 1.5 mm 277 Shut-off device for
grapple operation
127 Restrictor check valve 278 Lines leading to grapple
128 Shuttle valve 278 Grapple cylinder (industrial equip-
ment)
129 Restrictor Ø 0.6 mm 279 Restrictor check valve (only SW)
130 Slewing gear motor 7.20 280 Spool / support cylinder 7.50
132 Powertrain 281 Plug / dummy cartridge
133 Suction valve
134 Relief valve with additional pres- 295 Support cylinder 7.30
sure level
135 Relief valve with additional pres- 297 Double stop valve
sure level
137 Measuring point 'pivot right' 320 Rotary connection 7 x
138 Measuring point 'pivot left' 322 Rotary connection 6 x
155 Slewing gear brake 9.20 540 Spool / grapple rotator 16.40
6.32.2 A 904 C-LI 16000-

copyright by
MJFCIFSS
Items see Items see

group group
156 Slewing gear mechanism 9.10 541 Secondary relief valve / turn right
160 Spool / chassis 7.50 542 Secondary relief valve / turn left
161 Suction valve
551 Secondary relief valve / turn right
167 Restrictor check valve 552 Secondary relief valve / turn left
170 Travel engine 7.25 S5L Push button / grapple rotator, left 8.10
172 Powertrain S5R Push button / grapple rotator, right 8.10
173 Control cylinder / regulating unit S19 Button / grapple rotator 8.10
174 Spool / regulating unit Y22 Solenoid valve / grapple, turn left 8.10
176 Y23 Solenoid valve / grapple, turn right 8.10
177 Y24 from solenoid valve / creeper gear 8.10
185 Transmission 11.10 Y62 from solenoid valve - travel forward 8.10
190 Travel brake valve Y63 from solenoid valve - travel reverse 8.10
222 Retract secondary relief valve
A 904 C-LI 16000- 6.32.3

copyright by
MJFCIFSS
Fig. 1 Hydraulic schematic: 2-support / 4-support outriggers

295 Outriggers - support cylinder
6.32.4 A 904 C-LI 16000-

copyright by
MJFCIFSS

Fig. 2 Hydraulic schematic: 2-support / 4-support outriggers
100 A1 Connection of control valve block 325 Slip ring - rotary connection
100 B1 Connection of control valve block S206
294 Blade support cylinder S207
295 Cylinder - support S335 Push button / individual control blade
297 Double stop valve Y56 Solenoid valve / individual control blade
298 Y217
320 Rotary connection Y218
A 904 C-LI 16000- 6.32.5

copyright by
MJFCIFSS
6.32.6 A 904 C-LI 16000-

copyright by
MJFCIFSS
Type: 1003/1004/1005/1071
Note!

Items see Items see
group group
1 Hydraulic tank 6.21 54 Accumulator
2 Breather filter
-p reduction
3 Stop cock
Power control
4 Return filter 80 Pilot control valve, left 4 x 7.48
5 Bypass valve / return filter (pres- 81 Pilot control valve, right 4 x 7.48
sure)
6 Oil cooler 6.21 84 Pilot control valve 1 x - travelling 7.42
13 Oil motor radiator fan 85 Pilot control valve 2 x - support 7.46
14 Pressure relief valve fan motor 88P Manifold pressure
20 Double variable-displacement 7.07 88T Collecting pipe return line
pump
21 Powertrain P1 100 from / to control valve block
21.1 Control piston 130 Slewing gear motor 7.20
22 Regulating unit P1 155 to slewing gear brake
22.1 Performance regulator P1 320 from rotary connection 7 x 7.75
22.3 Restrictor (Ø 1.5 mm) 322 to rotary connection 6 x 7.70
22.6 Shuttle valve 400 to oscillating axle support 14.10
23 Powertrain P2 455 Uppercarriage locking device
23.1 Control piston B335 Pressure sensor of slewing gear
fine control
24 Regulating unit P2 S7 Safety switch 8.10
24.1 Performance regulator P2 S17 Switch slewing gear brake 8.10
24.3 Restrictor (Ø 1.5 mm) S21 Switch / creeper gear 8.10
24.5 Flow regulator P1 / P2 S30 Switch / travel direction 8.10
24.6 Shuttle valve S354 Switch / pilot control 8.10
28 Check valve S75 Switch / oscillating axle automatic 8.10
31 Gear pump - steering Y3 Solenoid valve servo release 8.10
32 Brake gear pump Y7 Solenoid valve slewing gear brake 8.10
33 Gear pump / fan Y24 Solenoid valve / creeper gear 8.10
30 Gear pump / pilot control Y50 Proportional solenoid valve 8.10
Power control
A 904 C-LI EDC 30580- 6.34.1

copyright by
MJFCIFSS
Items see Items see

group group
43 Measuring point of control chamber 6.21 Y51 Proportional solenoid valve 8.10
pressure P2 Flow regulator
44 Measuring point of control chamber 6.21 Y62 Solenoid valve / forward travel 8.10
pressure P1
6.21 Y63 Solenoid valve / reverse travel 8.10
50 Control oil unit 6.21 Y66 Solenoid valve / oscillating axle
support
51 Pressure-relief valve Y50 Proportional solenoid valve - fan
52 Pressure filter Y451 from proportional solenoid valve /
slewing gear fine control
53 Check valve 7.41

Items see Items see
group group
1 tohydraulic tank 194 Check valve
20 from the variable-displacement 7.07 221 Secondary pressure-relief valve /
pump extending
24.5 to flow regulator (X2) 222 Secondary pressure-relief valve /
retracting
41 Measuring point MP (pump pres- 224 Pressure balance, pilot-controlled
sure)
45 Measuring point LS (LS pressure) 227 Restrictor check valve
80 from pilot control valve, left 4 x 7.48 235 Boom cylinder 7.30
81 from pilot control valve, right 4 x 7.48 237 Stop cock (devices without item
238)
85 from pilot control valve - support 7.46 238 Pipe-fracture safety system (kit)
88P Manifold P 240 Spool / stick cylinder 7.50
88T Collecting pipe T 241 Secondary pressure-relief valve /
retracting
100 Compact control block 5 x 7.50 242 Secondary pressure-relief valve /
extending
102 Pressure balance: minimum flow 244 Pressure balance, pilot-controlled
103 Pressure balance: remaining flow 247 Restrictor check valve
104 Pressure cut-off valve 253 Distributor stick cylinder (industrial
model)
105 Primary pressure relief valve 254 Pipe fracture safety valve stick
cylinder (industrial model)
108 LS mainmain orifice 260 Spool / bucket cylinder 7.50
6.34.2 A 904 C-LI EDC 30580-

copyright by
MJFCIFSS
Items see Items see

group group
109 Shuttle valve 261 Secondary pressure-relief valve /
retracting
120 Spool / slewing gear 262 Secondary pressure-relief valve /
extending
122 Input pressure balance 264 Pressure balance, directly control-
led
127 Restrictor check valve 7.80 275 Bucket cylinder 7.30
130 Slewing gear motor 7.20 277 Shut-off device for
Grapple operation
132 Powertrain 278 Lines leading to grapple
133 Suction valve 279 Restrictor check valve
(QC only)
134 Pressure-relief valve with additio- 280 Spool / support cylinder 7.50
nal pressure stage
135 Pressure-relief valve with additio- 284 Pressure balance, directly control-
nal pressure stage led
137 Measuring point 'pivot left' 295 Support cylinder 7.30
138 Measuring point 'pivot right' 297 Double-load back-pressure valve
160 Spool / chassis 7.50 540 Spool / grapple rotator 16.40
led led
176 Secondary relief valve - forward S19 Switch / grapple rotator 8.10
177 Secondary relief valve - travel Y22 Solenoid valve / grapple rotation left 16.40
reverse
185 Transmission 11.10 Y23 Solenoid valve / grapple rotation 16.40
right
A 904 C-LI EDC 30580- 6.34.3

copyright by
MJFCIFSS
Alternative supports: 2-support / 4-support outrigger
1 Alternative supports: 2-support / 4-support outrigger

295 Outriggers - support cylinder
6.34.4 A 904 C-LI EDC 30580-

copyright by
MJFCIFSS
Alternative supports: 2-support blade front or back; 4-support blade front - outrigger back, or the other way round
2 Alternative supports: 2-support blade front or back; 4-support bla-

de front - outrigger back, or the other way round
100 A1 Connection of control valve block 325 Slip ring - rotary connection
295 Cylinder - support S335 Push button / individual control of blade
298 Counter-torque-lowering double brake Y217 Solenoid valve / individual control of out-
valve rigger, left
rigger, right
A 904 C-LI EDC 30580- 6.34.5

copyright by
MJFCIFSS
Alternative supports: 2-support blade front or back; 4-support blade front - outrigger back, or the other way round
6.34.6 A 904 C-LI EDC 30580-

copyright by
MJFCIFSS
Type: 1003/1004/1005/1071
Note!

Items see Items see
group group
2 Breather filter
-p reduction
3 Stop cock
Power control
4 Return filter 80 Pilot control unit, left 4 x 7.48
5 Bypass valve / return filter (pres- 81 Pilot control unit, right 4 x 7.48
sure)
6 Oil cooler 6.21 84 Pilot control unit, travel 1 x 7.42
13 Oil motor radiator fan 85 Pilot control unit 2 x, support 7.46
14 Pressure relief valve / fan motor 88P Manifold pressure
pump
22 Control unit P1 155 to slewing gear brake
22.3 Restrictor (Ø 1.5 mm) 322 to rotary connection 6 x 7.70
23 Powertrain P2 455 Uppercarriage locking
23.1 Control piston B335 Pressure sensor of slewing gear
fine control
24.1 Performance regulator P2 S17 Switch slewing gear brake 8.10
24.5 Flow regulator P1 / P2 S30 Switch / travel direction 8.10
31 Gear pump / steering Y3 Solenoid valve servo release 8.10
Power control
A 904 C-LI EDC 35343- 6.34.11

copyright by
MJFCIFSS
Items see Items see

group group
pressure P1
6.21 Y63 Solenoid valve / reverse travel 8.10
support
53 Check valve 7.41

Items see Items see
group group
1 to hydraulic tank 194 Check valve
20 from variable-displacement pump 7.07 221 Secondary pressure relief valve /
extending
24.5 to flow regulator (X2) 222 Secondary pressure relief valve /
retracting
41 Measuring point MP (pump pres- 224 Pressure balance, pilot-controlled
sure)
45 Measuring point LS (LS pressure) 227 Restrictor check valve
80 Pilot control unit, left 4 x 7.48 235 Boom cylinder 7.30
81 from pilot control unit, right 4 x 7.48
85 from pilot control valve / support 7.46 238 Pipe fracture safety valve (kit)
88P Manifold P 240 Spool / stick cylinder 7.50
88T Collecting pipe T 241 Secondary pressure relief valve /
retracting
100 Compact control block 5 x 7.50 242 Secondary pressure relief valve /
extending
102 Pressure balance / minimum flow 244 Pressure balance, pilot-controlled
104 Pressure cut-off valve 253 Distributor stick cylinder (industrial
model)
105 Primary pressure relief valve 254 Pipe fracture safety valve stick
108 LS main orifice 260 Spool / bucket cylinder 7.50
6.34.12 A 904 C-LI EDC 35343-

copyright by
MJFCIFSS
Items see Items see

group group
109 Shuttle valve 261 Secondary pressure relief valve /
retracting
120 Spool / slewing gear 262 Secondary pressure relief valve /
extending
122 Input pressure balance 264 Pressure balance, pilot-controlled
127 Restrictor check valve 7.80 275 Bucket cylinder 7.30
Grapple operation
132 Powertrain 278 Lines leading to grapple
(QC only)
134 Pressure relief valve with additional 280 Spool / support cylinder 7.50
pressure stage
135 Pressure relief valve with additional 284 Pressure balance, directly control-
pressure stage led
137 Measuring point, swivelling left 295 Support cylinder 7.30
138 Measuring point, swivelling right 297 Double load-holding valve
160 Travel gear spool 7.50 540 Spool / grapple rotator 16.40
led led
176 Secondary pressure relief valve / S19 Switch / grapple rotator 8.10
forward travel
177 Secondary pressure relief valve / Y22 Solenoid valve / grapple rotation left 16.40
reverse travel
185 Transmission 11.10 16.40
A 904 C-LI EDC 35343- 6.34.13

copyright by
MJFCIFSS

6.34.14 A 904 C-LI EDC 35343-

copyright by
MJFCIFSS

100 A1 Connection of control valve block 325 Slip ring rotary connection
295 Outrigger cylinder S335 Push button / individual control of blade

A 904 C-LI EDC 35343- 6.34.15

copyright by
MJFCIFSS
rigger, left
rigger, right
6.34.16 A 904 C-LI EDC 35343-

copyright by
MJFCIFSS
Type: 1004/1071
Note!

Items see Items see
group group
1 to hydraulic tank 195 Shuttle valve
6 to oil cooler 196 Check valves
7 Check valve 3.5 bar 7.50 220 Spool / boom cylinder 7.50
8 Preload valve 7.0 bar 7.50 221 Secondary pressure-relief valve /
extending
pump retracting
24.5 to flow regulator (X2) 224 Pressure balance, pilot-controlled
41 Measuring point MP (pump pres- 227 Restrictor check valve
sure)
45 Measuring point LS (LS pressure) 233 Distribution block
50 from control oil unit 7.40 235 Boom cylinder 7.30
80 from pilot control unit 4x / left 7.48 237 Stop cock (machines without item
238)
81 from pilot control unit 4x / right 7.48 238 Pipe-fracture safety system (kit)
85 from pilot control valve / support 7.46 240 Spool / stick cylinder 7.50
88P Manifold P 241 Secondary pressure-relief valve /
retracting
88T Collecting pipe T 242 Secondary pressure-relief valve /
extending
100 Compact control block 5x 7.50 244 Pressure balance, pilot-controlled
102 Pressure balance / minimum flow 247 Restrictor check valve
103 Pressure balance / remaining flow 253 Distributor stick cylinder (industrial
model)
104 Pressure cut-off valve 254 Pipe fracture safety valve stick
105 Primary pressure-relief valve 255 Stick cylinder 7.30
108 LS main orifice 260 Spool / grapple cylinder 7.50
109 Shuttle valve 261 Secondary pressure-relief valve /
retracting
120 Spool / slewing gear 262 Secondary pressure-relief valve /
extending
122 Input pressure balance 264 Pressure balance, directly control-
led
127 Restrictor check valve 7.80 275 Grapple cylinder 7.30
A 904 C-LI EDC 39333- 6.35.1

copyright by
MJFCIFSS
Items see Items see

group group
grapple operation
132 Powertrain 280 Spool / support cylinder 7.50
133 Suction valve 284 Pressure balance, directly control-
led
134 Pressure-relief valve with additio- 295 Support cylinder 7.30
nal pressure stage
135 Pressure-relief valve with additio- 298 Double-load back-pressure valve
nal pressure stage
137 Measuring point / pivoting left 320 Rotary connection 7x
138 Measuring point / pivoting right 322 Rotary connection 6x
155 Slewing gear brake 9.20 540 Spool / grapple rotator 16.40
156 Slewing gear mechanism 9.10 541 Secondary relief valve / turning right
160 Spool / chassis 7.50 542 Secondary relief valve / turning left
161 Suction valve 544 Pressure balance, directly control-
led
164 Pressure balance, pilot-controlled 551 Secondary relief valve / turning right
167 Restrictor check valve 552 Secondary relief valve / turning left
170 Travel motor 7.25 B359 Pressure sensor / closing grapple -
proportional
172 Powertrain S5L Push button / grapple rotator, left 8.12
173 Control cylinder / regulating unit S5R Push button / grapple rotator, right 8.12
174 Spool / regulating unit S19 Switch / grapple rotator 8.12
176 Secondary relief valve / forward Y22 Solenoid valve / grapple rotation left 16.40
177 Secondary relief valve / reverse Y23 Solenoid valve / grapple rotation 16.40
right
185 Transmission 11.12 Y24 from solenoid valve / creeper gear 7.40
190 Travel brake valve Y62 from solenoid valve / forward travel 8.12
192 Brake piston Y63 from solenoid valve / reverse travel 8.12
193 Restrictor check valve Y451 Proportional solenoid valve / sle-
194 Check valve Y514 Proportional solenoid valve/closing

Items see Items see
group group
2 Breather filter 57 Measuring point servo pressure
(LS)
-p reduction
3 Stop valve 59 Measuring point servo pressure
(LR)
Power control
6.35.2 A 904 C-LI EDC 39333-

copyright by
MJFCIFSS
Items see Items see

group group
4 Return filter 80 Pilot control unit 4x / left 7.48
5 Bypass valve / return filter (pres- 81 Pilot control unit 4x / right 7.48
sure)
6 Oil cooler 6.21 84 Pilot control unit 1x / travelling 7.42
13 Oil motor radiator fan 85 Pilot control unit 2x / support 7.46
14 Pressure relief valve / fan motor 88P Manifold pressure
pump
22 Regulating unit P1 155 to slewing gear brake
22.3 Restrictor (Ø 1.5 mm) 322 to rotary connection 6x 7.70
23 Powertrain P2 455 Uppercarriage locking device
23.1 Control piston B335 Pressure sensor - slewing gear
fine control
24.1 Performance regulator P2 S17 Switch / slewing gear brake 8.12
24.5 Flow regulator P1 / P2 S30 Switch - travel direction 8.12
31 Gear pump - steering Y3 Solenoid valve servo release 8.12
Power control
pressure P1
49 Measuring point control pressure 6.21 Y63 Solenoid valve / reverse travel 8.12
M1
support
53 Check valve 7.41
A 904 C-LI EDC 39333- 6.35.3

copyright by
MJFCIFSS
6.35.4 A 904 C-LI EDC 39333-

copyright by
MJFCIFSS
Service Manual Hydraulic system A 914/A924 C, from 34519
Hydraulic system A 914/A924 C, from 34519
Type: 1044/1045/1047/1048 models

Type: 1049 Industry/1050 HD (log loader)/ 1051 HD with 4-point support
Note!
Key to circuit diagram I

Items see Items see
group group
1 Hydraulic tank 6.22 80 Pilot control unit 4x / left
2 Breather filter 81 Pilot control unit 4x / right 7.48
3 Stop valve 84 Pilot control unit 1x / travelling 7.42
4 Return filter 85 Pilot control unit 2x / support 7.46
5 Bypass valve / return filter (pres- 88P Manifold pressure
sure)
6 Oil cooler 6.22 88T Collecting pipe return line
13 Oil motor radiator fan 100 from / to pilot plate
20 Double variable-displacement 7.07 130 Slewing gear motor 7.22
pump to slewing gear way valve
21 Powertrain P1 155 to slewing gear brake
21.1 Control piston (measuring piston) 160 to travel motor way valve
22 Regulating unit P1 (control cylinder) 220 to boom cylinder way valve
22.1 Performance regulator P1 240 to stick cylinder way valve
22.3 Restrictor (Ø 1.5 mm) 260 to bucket grapple way valve
22.6 Shuttle valve 280 to support way valve
23 Powertrain P2 320 from rotary connection 7 x 7.75
23.1 Control piston (measuring piston) 322 to rotary connection 6x 7.70
24 Regulating unit P2 (control cylinder) 400 to oscillating axle support 14.10
24.1 Performance regulator P2 455 Uppercarriage locking device 6.22
(in construction models only)
24.3 Restrictor (Ø 1.5 mm) S7 Safety switch 8.14
24.5 Flow regulator P1 / P2 S17 Switch / slewing gear brake 8.14
24.6 Shuttle valve S21 Switch / creeper gear 8.14
28 Check valve S30 Switch - travel direction 8.14
30 Gear pump / pilot control 6.22 S35 Switch / pilot control 8.14
31 Gear pump - steering 6.22 S75 Switch / oscillating axle automatic 8.14
S85 Switch / grapple
32 Brake gear pump 6.22 U16 Excavator control BST 8.14
33 Gear pump / fan 6.22 Y3 Solenoid valve servo release 8.14
43 Measuring point of control chamber 6.22 Y7 Solenoid valve slewing gear brake 8.14
pressure P2
A 914 C-LI 35112- 6.40.1

MJFCIFSS
Hydraulic system A 914/A924 C, from 34519 Service Manual
Items see Items see

group group
44 Measuring point of control chamber 6.22 Y24 Solenoid valve / creeper gear 8.14
pressure P1
Y50 Proportional solenoid valve 8.14
Power control
50 Control oil unit 7.41 Y51 Proportional solenoid valve 8.14
Flow regulator
51 Pressure-relief valve Y62 Solenoid valve / forward travel 8.14
52 Pressure filter Y63 Solenoid valve / reverse travel 8.14
53 Check valve Y66 Solenoid valve / oscillating axle 8.14
support
54 Accumulator Y50 Proportional solenoid valve - fan 8.14
Y502 Solenoid valve / grapple 8.14
-p reduction
Power control

Items see Items see
group group
1 to hydraulic tank 196 Check valves
6 to oil cooler 220 Way valve / boom cylinder 7.52
pump extending
24.5 to flow regulator (X2) 7.52 222 Secondary pressure-relief valve /
retracting
7.07 223 Spool / boom cylinder
45 Measuring point xLS (LS pressure) 224 Pressure-relief bleeder valve
50 from control oil unit 7.41 225 Pressure-relief bleeder valve
80 from pilot control unit 4x / left 7.46 226 Restrictor valve / control pressure
81 from pilot control unit 4x / right 7.46 227 Stroke limiter / spool
85 from pilot control valve / support 233 Distribution block
88P from manifold P 235 Boom cylinder 7.30
100 Pilot plate 7.52 237 Stop cock (in machines without
item 238)
101 Pressure cut-off valve (LS_Druck) 238 Pipe-fracture safety system (kit)
102 Pump valve 240 Way valve / stick cylinder 7.52
103 Restrictor 241 Secondary pressure-relief valve /
extending
106 Valve / LS shutdown of grapple 242 Secondary pressure-relief valve /
retracting
107 Pressurisation valve / return T 243 Spool / stick cylinder
108 Pressurisation valve / return K 244 Pressure-relief bleeder valve
109 Shift valve / pressure build-up 245 Pressure-relief bleeder valve
6.40.2 A 914 C-LI 35112-

MJFCIFSS
Service Manual Hydraulic system A 914/A924 C, from 34519
Items see Items see

group group
110 Regeneration plate 246 Restrictor check valve / control
pressure
111 Shift valve 247 Stroke limiter / spool
(construction model)
112 Shuttle valve 248 Pressure-relief valve / bypass valve
113 Piston 254 Pipe fracture safety valve / stick
114 Piston 255 Stick cylinder 7.30
115 Lowering restrictor / boom cylinder 260 Way valve / bucket cylinder
116 Lowering restrictor / stick cylinder 260 Way valve / grapple cylinder
(industrial model)
117 Lowering restrictor / bucket grapple 261 Secondary pressure-relief valve /
cylinder extending
130 Slewing gear motor with way valve 7.80 262 Secondary pressure-relief valve /
retracting
131 Secondary pressure-relief valve / 7.22 263 Spool / bucket grapple cylinder
turning right
132 Secondary pressure-relief valve / 264 Pressure-relief bleeder valve
turning left
133 Spool / turning 265 Pressure-relief bleeder valve
134 TC pressure-relief valve 267 Stroke limiter / spool
135 Restrictor check valve / control 275 Bucket cylinder
pressure (construction model)
136 Stroke limiter / spool 278 Grapple cylinder
(industrial model)
137 Torque control valve 280 Way valve / support 7.30
138 Priority switching swivelling/pres- 281 Suction valve / support
sure balance
139 Anti-reaction valve 282 Suction valve / support
141 Check valve / LS pressure 283 Spool / support
142 Return check valve 284 Pressure-relief bleeder valve
143 Feeder valve 285 Pressure-relief bleeder valve
145 Measuring point / turning right 286 Restrictor check valve
Control pressure
146 Measuring point / turning left 287 Stroke limiter / spool
147 Measuring point / control pressure 295 Support cylinder
148 Shuttle valve 298 Double-load back-pressure valve
155 Slewing gear brake 9.20 320 Rotary connection 7x
156 Slewing gear mechanism 9.10 322 Rotary connection 6x
160 Way valve / travel motor 7.52 540 Way valve / grapple rotator 16.40
161 Suction valve 543 Spool / grapple rotator
162 Suction valve 544 Secondary pressure-relief valve
163 Spool / travel 547 Stroke limiter / spool
A 914 C-LI 35112- 6.40.3

MJFCIFSS
Hydraulic system A 914/A924 C, from 34519 Service Manual
Items see Items see

group group
164 Pressure-relief bleeder valve 549 Input pressure balance
165 Pressure-relief bleeder valve 550 Oil motor / grapple rotator
166 Restrictor check valve 551 Primary pressure-relief valve / turn
Control pressure right
167 Stroke limiter / spool 552 Primary pressure-relief valve / turn
left
170 Travel motor 7.25 S5L Push button / grapple rotator, left 8.14
172 Powertrain S5R Push button / grapple rotator, right 8.14
173 Control cylinder / regulating unit S19 Switch / grapple rotator 8.14
174 Spool / regulating unit Y22 Solenoid valve / grapple rotation 16.40
right
176 Secondary relief valve / forward Y23 Solenoid valve / grapple rotation left 16.40
177 Secondary relief valve / reverse Y24 from solenoid valve / creeper gear 7.41
185 Transmission 11.10 Y53 Radiator shift valve
190 Travel brake valve Y62 from solenoid valve / forward travel 8.14
192 Brake piston Y63 from solenoid valve / reverse travel 8.14
193 Restrictor check valve Y502 Solenoid valve / grapple
194 Check valve
195 Shuttle valve
6.40.4 A 914 C-LI 35112-

MJFCIFSS
Service Manual
SUBGROUP - INDEX
Section Group Type
Hydraulic pumps - dismantling, installation 7.01.1 A 900 C-LI 14675-

and initial operation A 904 C-LI 16000-
A 914 C-LI 35112-
A 924 C-LI 34519-
LPV variable displacement pump 7.02.1 A 900 C-LI 14675-
Variable-displacement pump DPVO 165 7.05.1 A 900 C-LI EDC 24677-

A 904 C-LI 16000-
Variable-displacement pump DPVO 165 7.06.1 A 900 C-LI EDC 39762-
Double variable-displacement pump 7.07.1 A 904 C-LI EDC 30580-

DPVP 108 A 914 C-LI 35112-
A 924 C-LI 34519-
FMF hydraulic fixed displacement motor 7.20.1 A 900 C-LI 14675-

A 904 C-LI 16000-
HMF 75-02P hydraulic 7.22.1 A 914 C-LI 35112-

fixed-displacement motor A 924 C-LI 34519-
LMV regulating motor 7.25.1 A 900 C-LI 14675-

A 904 C-LI 16000-
Regulating motor DMVA (travel motor) 7.27.1 A 900 C-LI EDC 24677-
A 904 C-LI EDC 30580-
A 914 C-LI 35112-
A 924 C-LI 34519-
Hydraulic cylinder 7.30.1 A 900 C-LI 14675-

A 900 C-LI EDC 24677-
A 904 C-LI 16000-
A 904 C-LI EDC 30580-
A 914 C-LI 35112-
A 924 C-LI 34519-
Extension and retraction times of 7.31.1 A 900 C-LI EDC

hydraulic cylinders A 904 C-LI
A 914 C-LI
A 924 C-LI
7.1
MJFCIFSS
Service Manual
Hydraulic double plunger cylinder 7.32.1 A 900 C-LI EDC

A 904 C-LI EDC
A 914 C-LI
A 924 C-LI
Control oil and regulation unit 7.40.1 A 900 C-LI 14675-

A 904 C-LI 16000-
Control oil and regulation unit 7.41.1 A 900 C-LI EDC 24677-
A 904 C-LI EDC 30580-
A 914 C-LI 35112-
A 924 C-LI 34519-
Pilot control valve 1 x 7.42.1 A 900 C-LI 14675-

A 904 C-LI 16000-
A 914 C-LI 35112-
A 924 C-LI 34519-

A 904 C-LI 16000-
A 914 C-LI 35112-
A 924 C-LI 34519-

A 904 C-LI 16000-
A 914 C-LI 35112-
A 924 C-LI 34519-

A 904 C-LI 16000-
A 914 C-LI 35112-
A 924 C-LI 34519-
LSC control valve block 7.50.1 A 900 C-LI 14675-

A 904 C-LI 16000-
Control block LSC 7.51.1 A 900 C-LI EDC 24677-

A 904 C-LI EDC 30580-
LSC pilot plate 7.55.1 A 914 C-LI 35112-

A 924 C-LI 34519-
Leak oil check at control valve blocks 7.68.1 A 900 C-LI 14675-
A 904 C-LI 16000-
A 914 C-LI 35112-
A 924 C-LI 34519-
7.2
MJFCIFSS
Service Manual
SUBGROUP - INDEX
Section Group Type
Rotary connection 6 x 7.70.1 A 900 C-LI 14675-

A 904 C-LI 16000-
A 914 C-LI 35112-
A 924 C-LI 34519-
Rotary connection 7 x 7.75.1 A 900 C-LI 14675-

A 904 C-LI 16000-
A 914 C-LI 35112-
A 924 C-LI 34519-
TC valve 7.80.1 A 900 C-LI 14675-

A 904 C-LI 16000-
Double stop valve for outrigger support 7.85.1 A 900 C-LI 14675-
A 904 C-LI 16000-
7.3
MJFCIFSS
Service Manual
7.4
MJFCIFSS
Service Manual Hydraulic pumps - dismantling, installation and initial
Variable displacement pump 20 / working hydraulics
Hydraulic pumps - dismantling, installation and

initial operation
1 Variable displacement pump 20 / working hydraulics
Caution!
Unsecured hydraulic pumps can cause serious injury from crushing!
Always secure hydraulic pumps with suitable lifting tackle and hoisting gear.
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
Fig. 1 Hydraulic pumps
a = A 900 C from serial no. 14675 - 24676

b = A 900 C from serial no. 24677
A 904 C from serial no. 16000 - 30579
c = A 904 C from serial no. 30580
1.1 Dismantling
Close the stop cock 3 at the hydraulic tank, (position b), see Fig. 2.
Collect the hydraulic oil. Use a suitable oil pan.
Always secure hydraulic pump 20 with suitable lifting tackle and hoisting gear.
7.01.1
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MJFCIFSS
Hydraulic pumps - dismantling, installation and initial Service Manual
Variable displacement pump 20 / working hydraulics
Disconnect hoses / lines at pump 20. Collect the hydraulic oil.

Loosen and remove the Allen head and hex head screws 12.
Remove the hydraulic pump 20.
Fig. 2 Stop cock 3
a = open
b = closed
1.2 Installation
Flange-mount the hydraulic pump 20 at the diesel engine.
Insert the Allen head and hex head screws 12 and tighten them with the prescribed torque, see
Fig. 1.
Connect all hoses / lines to the hydraulic pump 20.
Remove the oil pan.
1.3 Start-up
Before starting the system, fill the hydraulic tank all the way to full mark at the top. Open the stop
cock 3 at the hydraulic tank, (position a).
Unscrew the leak oil lines T1 at the pump 20 until hydraulic oil escapes (no foam).
Screw the leak oil lines T1 tight again.
Check the screw fittings and lines for tightness.
Make the suction hose air-tight. (Re-tighten the connection and/or the pipe clamps.)
1.4 Bleeding of hydraulic pumps
Note!
After work on the hydraulic pump, oil change in the hydraulic unit or after the use of a vacuum pump,
the hydraulic pump must be bled.
Before the initial start-up of the pump, and after a repair or a pump change, the oil housing must be
filled with hydraulic oil. This is done through the leak oil connection T1.
Initial start-up after a pump replacement or use of a vacuum pump.

Run the diesel engine for about 10 seconds using starter, but do not start the engine yet.
7.01.2
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Service Manual Hydraulic pumps - dismantling, installation and initial
Gear pumps
Start the diesel engine. Let it run for about 7 minutes at low idle speed.
Check the oil level the in hydraulic tank. Fill up, if necessary.
Loosen the leak oil line T1 at the variable-displacement pump 20, but do not disconnect it.
Bleed the pump with the diesel engine at low idle speed
until oil escapes from the leak connection (liquid, no foam).
Re-tighten the leak oil line (not necessary with gear pumps).
Run the hydraulic system at full power and with hydraulic oil that is at a working temperature of at
least 50°C.
Check the settings of the system's pressure-relief valves.
In the event of a pressure increase, reduce the engine speed.
Also check the electrical signals and settings, if necessary. See adjustment protocol and ad-
justment guideline, group 6.
Check the system for tightness.
2 Gear pumps
Fig. 3 Gear pumps 31 / 32 and 33
a = A 900 C from serial no. 14675 - 24676

A 904 C from serial no. 16000 - 30579
b = A 900 C from serial no. 24677
A 904 C from serial no. 30580
Gear pump 30 for pilot control, (see Hydraulic pumps on page 1)

Gear pump 31 steering
Gear pump 32 for brake system
7.01.3
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MJFCIFSS
Hydraulic pumps - dismantling, installation and initial Service Manual
Gear pumps
Gear pump 33 hydraulic fan drive
2.1 Dismantling
Close the stop cock 3 at the hydraulic tank, (position b)..
Place suitable oil pan under hydraulic pumps.
Disconnect the hoses / lines at the pumps. Collect the hydraulic oil.
Loosen and remove the Allen head and hex head screws.
Remove the hydraulic pumps.
2.2 Installation
Install the hydraulic pumps.
Insert the Allen head and hex head screws and tighten them with the prescribed torque, see Fig. 3.
Connect all hoses / lines at the pumps.
2.3 Start-up
Before starting the system, fill the hydraulic tank all the way to full mark at the top. Open the stop
cock 3 at the hydraulic tank, (position a).see Fig. 2
Note!
The 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 (P).
Bleed the pump with the diesel engine at low idle speed
until the oil runs out of the pressure connection (liquid, not oil foam).
Tighten the screw connections with the prescribed torque, see Fig. 3.
Check the connection for tightness.
7.01.4
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MJFCIFSS
Service Manual LPV variable displacement pump
Purpose
LPV variable displacement pump
1 Purpose
The LPV variable displacement pump is of the axial piston swash-plate type. Powertrain and gear
pump are powered by the diesel engine via the flexible coupling (torsion damper).
The variable displacement pump regulates its output according to actual requirements and, thus, 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
A 900 C-LI 14675- 7.02.1

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MJFCIFSS
LPV variable displacement pump Service Manual
General information
2 General information
Equipment A 900 C Litronic

from serial number 14675
Type of pump LPV 150
Input speed 1800 min-1
Drive power of diesel engine 88 kW
(nominal power)
Volumetric delivery max. 270 l/min
min. 30 l/min
Hydraulic performance (basic performance) 27 kW
Begin of regulation (with basic settings) 50 ± 2 bar
Control oil pump / pilot control 36 l/min
Checking measurement X (Q min. stop) 16.3 mm
For current from solenoid valve Y50, see adjustment protocol in group 6
For settings and comparative values, see adjustment protocol in group 6
7.02.2 A 900 C-LI 14675-

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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 consists of drive shaft, cylinder and piston. It can be adjusted / regulated by means of
the swivel yoke.
Pump regulation 23 consists of flow regulator (LS regulator) and performance regulator. It is mounted
on the powertrain and connected to the swivel yoke via a lever and pump regulation 5.
The load-sensing regulator serves to adjust 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 11 Mounting plate

5 Pump regulation 13 Connecting flange
8 Gear pump(30*) 23* Regulating valve
* items in hydraulic schematic
A 900 C-LI 14675- 7.02.3

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MJFCIFSS
Description
Fig. 3 LPV hydraulic schematic
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
7.02.4 A 900 C-LI 14675-

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MJFCIFSS
4.1 Powertrain, see Fig. 12

Bearing of drive shaft 1.10 is arranged by means of mounting plate 11 and mounting flange 13, with
needle bearings 11.3 / 13.3. It drives cylinder 1.11 and the nine pistons 1.9 via the gearing. Clutch
sleeve 11.31 conveys some of the driving power to flange-mounted gear pump 8 (pilot control).
Bearing of pistons 1.9 is arranged with slippers. 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 cylinder 1.11, pistons 1.9 execute a double stroke. The length of the stroke
depends on the inclination of swivel yoke 1.2. Rotary bearing of the swivel yoke is arranged via flan-
ges 12 and roller bearing 12.34. The rotary motion of swivel yoke 1.2 is brought about by control pis-
ton 5.10 engaging into the swivel yoke at every axial motion.
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. 12

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 standby 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 siehe Fig. 13 applies from the beginning of basic regulati-
on)
Pivoting back of the pump is effected by the regulating unit of the pump (pump regulation).
A 900 C-LI 14675- 7.02.5

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MJFCIFSS
Pump regulation
5 Pump regulation
5.1 Performance regulator 23.2 with regulating piston
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 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.
7.02.6 A 900 C-LI 14675-

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MJFCIFSS
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 Spool
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
A 900 C-LI 14675- 7.02.7

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MJFCIFSS
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.
Load-sensing regulator 23.5 sits on performance regulator 23.2.
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. 5 Sectional drawing: load-sensing regulator 23.5
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
23.8 Piston
7.02.8 A 900 C-LI 14675-

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Level of performance change
6 Level of performance change
Fig. 6 Pump regulation
This level allows to hydraulically adjust the pump regulation characteristics during operation.
As soon as a pressure is connected to chamber B (siehe Fig. 4) via regulator connection GLR,
a force is generated at spool 2.7 which is proportional to pressure GLR and which shifts the spool
towards "pump at Qmax". A new balance at the spool can come about only if the pressure from the
pump goes up. The higher the GLR pressure, the higher the pump pressure at begin of regulation.
Pump regulation continues as described in 5.1 auf Seite 6. However, the regulation characteristics in
the P-Q diagram have been shifted towards higher pressure (i.e. higher performance) in order to at-
tain a value that is proportional to the GLR pressure.
Connection GLR receives the output pressure of performance-regulating solenoid valve Y50 (LR
valve).
A 900 C-LI 14675- 7.02.9

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MJFCIFSS
6.1 Limitation of max. pump flow rate ( P decrease), .

As soon as chamber PST of LS regulator 23.5 is connected to pressure from regulating solenoid valve
Y51, an additional pressure force will be generated at the piston that acts against the preload force
of the regulating springs.
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 Schematic: variable displacement pump
21 Shuttle valve 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
7.02.10 A 900 C-LI 14675-

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6.2 Fine control and/or flow reduction via p reduction
Fig. 8 Hydraulic schematic: flow reduction
120 Spool / slewing gear 240 Spool / stick cylinder

160 Spool / chassis 260 Spool / bucket cylinder
220 Spool / boom cylinder 280 Spool / support cylinder
235 Boom cylinder 295 Support cylinder
A 900 C-LI 14675- 7.02.11

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Adjustment of LPV variable displacement pump (LR - LS)
7 Adjustment of LPV variable displacement pump (LR - LS)
7.1 Min. and max. pivot angle of the pump
Fig. 9 Min. and max. pivot angle of the variable displacement pump
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 locknut 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 locknut 5.24 and safety cap 5.29).
7.02.12 A 900 C-LI 14675-

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MJFCIFSS
Adjustment of LPV variable displacement pump (LR - LS)
7.2 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
A 900 C-LI 14675- 7.02.13

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MJFCIFSS
Sectional drawing: pump regulation
8 Sectional drawing: pump regulation
Fig. 11 Sectional drawing: regulation
7.02.14 A 900 C-LI 14675-

copyright by
MJFCIFSS
2.1 Adjusting screw 23.2 Performance regulator

2.2 Locknut 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 Locknut
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
2.16 O-ring 5.14 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
A 900 C-LI 14675- 7.02.15

copyright by
MJFCIFSS
Fig. 12 Sectional drawing: LPV variable displacement pump
7.02.16 A 900 C-LI 14675-

copyright by
MJFCIFSS
Sectional drawing: LPV

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
A 900 C-LI 14675- 7.02.17

copyright by
MJFCIFSS
Regulating characteristic
9 Regulating characteristic
Fig. 13 Performance chart: LPV variable adjustment pump
7.02.18 A 900 C-LI 14675-

copyright by
MJFCIFSS
Service Manual Variable-displacement pump DPVO 165
Function/design
Variable-displacement pump DPVO 165
1 Function/design
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 variable-displacement pump consists of the following main components:
Powertrain 21
Pump casing 40
Mounting plate 46
Regulator housing 49
The DPVO variable-displacement pump is flanged to the diesel engine with connection 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 on the pivot angle by means of a pin.
Flow regulator 26 sits right on mounting plate 46. It controls the volumetric flow and the adjustment
of the differential pressure p.
The gear pump 30 (pilot control) is mounted to the mounting plate 46. It is driven by means of an in-
ternal drive shaft. There is an opening in the mounting plate for the installation of an additional gear
pump, if required.
7.05.1
copyright by
MJFCIFSS
Variable-displacement pump DPVO 165 Service Manual
Function/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 A1 Pressure connection
28 Check valve AX Pressure connection sealed
29 Restrictor FE Pressure connection of control oil pump
30 Gear pump / pilot 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
Note!
In order to prevent damage to the pump, observe the torque (87 Nm) for the Allen head screws 41
when installing the gear pump 30, see Fig. 1.
7.05.2
copyright by
MJFCIFSS
Function/design
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
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)
7.05.3
copyright by
MJFCIFSS
Technical data
2 Technical data
Machine A 900 C Litronic A 904 C Litronic

Pump type DPVO 165 DPVO 165
Input speed 1800 rpm 2000 rpm
Drive power of diesel engine 95 kW 99 kW
(nominal power) = Pmax
Volumetric delivery
max. 300 l/min 330 l/min
min. 40 l/min 40 l/min
Hydraulic performance (basic performance) 27 kW 27 kW
Begin of regulation (with basic settings) 50 ± 2 bar 50 ± 2 bar
Control oil pump / pilot control 40 l/min 40 l/min
Check measurement X (Q min. stop) 15.6 mm 15.6 mm
Current from solenoid valve Y50, see setting protocols in group 3

For parameters and reference values, see adjustment protocol in group 3.
3 Functional description of variable-displacement pump
3.1 Powertrain 21, (see Sectional drawing of DPVO on page 11)

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 flange-mounted gear pump 30 (pilot con-
trol).
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 rotary roller bea-
ring 14. The rotary motion of the swivel yoke 7 is effected by means of a connection between the con-
trol 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.
7.05.4
copyright by
MJFCIFSS
Functional description of variable-displacement pump
The pilot plate 17 separates the pressure side from the suction side of the powertrain. The pilot plate
17 has kidney-shaped openings 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
19 Piston 36 Pressure spring
3.1.1 Adjusting the pivot angle of the pump

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 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
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 standby mode (i.e. all pilot control valves in neutral position), the pump delivers only min. flow vo-
lumes (about 40 l/min - pre-set in the factory by means of the stop screw 48).
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.
7.05.5
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MJFCIFSS
Pump regulation
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
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.
4.1.1 Begin of pump regulation

When the working pressure pP in the system rises to the value of the begin of regulation, the force
from the measuring cylinder 23 to the lever 24 is increased. The spool 97 is shifted against the 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).
7.05.6
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MJFCIFSS
Pump regulation
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
90 Pressure spring Pp Pump pressure

91 Pressure spring SK Control chamber pressure
97 Spool T Tank pressure
Fig. 6 Sectional drawing of performance regulator 25
25 Flow regulator, complete 93 Spring plate

49 Regulator housing 94 Ball
81 Screw plug 95 Connecting pin (swivel yoke)
83 Pressure spring 96 Return piston
84 O-ring 97 Spool
7.05.7
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MJFCIFSS
Pump regulation
85 O-ring 98 Piston with slipper (measuring cylinder)

88 Adjusting screw 99 Lever
89 Screw plug pP Working pressure
90 Pressure spring (begin of regulation) SK Control chamber pressure
91 Pressure spring T Tank pressure
92 Bushing
Note!
Tightening torques: Screw plug 81 / 89 = 35 Nm; sealing nut 87 = 18 Nm.
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 connected with the tank, or the pump pres-
sure 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 26
7.05.8
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MJFCIFSS
Pump regulation
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 9 = 8 Nm; nut 3 = 120 Nm.
4.3 Regulation of pressure difference P LS
4.3.1 Standby
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.
7.05.9
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MJFCIFSS
Adjustment of DPVO variable-displacement pump
The pump pivots back.
Fig. 8 Sectional drawing of load-sensing regulator
51 Screw plug 68 Backing ring

52 Adjusting screw 72 Backing ring
56 Sealing nut 73 O-ring
58 Nut pP Working pressure
59 Pressure spring(adjustment p) pLS LS pressure
60 Pressure spring S1 Pump pressure control edge
62 Spool S2 Tank pressure control edge
63 Piston SK Control chamber pressure
64 Bushing T Tank pressure
65 Piston X2 Connection at regulator housing
66 Bushing X4 Connection at regulator housing
67 O-ring
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 3 "Adjustment protocol" and "Adjustment guideline".
7.05.10
copyright by
MJFCIFSS
Fig. 9 Sectional drawing of DPVO
7.05.11
copyright by
MJFCIFSS
Regulating characteristics
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
6 Regulating characteristics
Fig. 10 Performance curve of DPVO 165
7.05.12
copyright by
MJFCIFSS
Design
Variable-displacement pump DPVO 165
1 Design
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).
Powertrain 21
Pump casing 40
Mounting plate 46
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.
pump, if required.
7.06.1
copyright by
MJFCIFSS
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 A1 Pressure connection
28 Check valve AX Pressure connection sealed
29 Restrictor FE Pressure connection of control oil pump
30 Gear pump / pilot control S Suction connection
31 Gear pump / fan control 7 Leak oil connection
40 Pump casing X2 Measuring point / LS pressure
44 Measuring point pSK (control chamber X3 Connection of control oil unit LR
pressure)
46 Mounting plate X4 Connection -p reduction
47 Connecting flange
7.06.2
copyright by
MJFCIFSS
Design
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)
7.06.3
copyright by
MJFCIFSS
Technical data
2 Technical data
Machine A 900 C Litronic

Pump type DPVO 165
Input speed 1800 rpm
Drive power of diesel engine 95 kW
Volumetric delivery
max. 300 l/min
min. 40 l/min
Hydraulic performance (basic performance) 27 kW
Begin of regulation (with basic settings) 50 ± 2 bar
Control oil pump / pilot control 40 l/min
Check measurement X (Q min. stop) 15.6 mm
Current from solenoid valve Y50, see setting protocols in group 3

For parameters and reference values, see adjustment protocol in group 3.
3.1 Powertrain 21, see Fig. 9

19 via the gearing. The toothing on the drive shaft drives the integrated and flange-mounted gear
pump 30/31.
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.
7.06.4
copyright by
MJFCIFSS

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.
16 Cylinder 33 Return ball

17 Pilot plate 34 Return plate
18 Pin 35 Pressure spring
19 Piston 36 Pressure spring
3.1.1 Adjusting the pivot angle of the pump, see Fig. 9

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.
In standby mode (i.e. all pilot control valves in neutral position), the pump supplies only minimum
flows, (see Tab. 1 on page4).

The min. pivot angle of the powertrain is determined by the stop screw 48 (with lock nut 38). It is fac-
7.06.5
copyright by
MJFCIFSS
Pump regulation
7 Swivel yoke 37 Connecting link

11 Roll pin 38 Lock nut
12 Pin 39 Sleeve
22 Control piston 48 Qmin stop screw
4 Pump regulation
4.1 Performance regulator 25 (LR) hyperbolic regulator

pin 15.

7.06.6
copyright by
MJFCIFSS
Pump regulation

Fig. 6 Sectional drawing of performance regulator 25
26 Flow regulator, complete 92 Bushing

49 Regulator housing 93 Spring plate
81 Screw plug 94 Ball
82 Threaded stud 95 Connecting pin (swivel yoke)
7.06.7
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MJFCIFSS
Pump regulation
84 O-ring 97 Spool
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
91 Pressure spring
Note!
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.
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 63 Piston

49 Regulator housing 64 Control sleeve
51 Screw plug 65 Piston
52 Adjusting screw 73 O-ring with backing ring
56 Sealing nut Pp Pump pressure
7.06.8
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MJFCIFSS
Pump regulation
58 Lock nut pLS LS pressure

59 Pressure spring (adjustment p) T Return channel
60 Pressure spring X2 Connection control block-LS
61 Seal X4 Connection T to tank
62 Spool
Note!
Screw down the flow regulator 26 all the way to stop. Tighten it with 5 Nm max.
4.3.1 Standby
4.3.2 Pivoting out

4.3.3 Pivoting back

7.06.9
copyright by
MJFCIFSS
Fig. 8 Control edges S1 and S2 at the flow regulator

58 Nut
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
67 O-ring X4 Connection at regulator housing
5 Adjustment of DPVO variable-displacement pump
lation
Note!
7.06.10
copyright by
MJFCIFSS
Fig. 9 Sectional drawing of DPVO
7.06.11
copyright by
MJFCIFSS
Regulating characteristics
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 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
6 Regulating characteristics
Fig. 10 Performance curve of DPVO 165
7.06.12
copyright by
MJFCIFSS
Service Manual Double variable-displacement pump DPVP 108
Function
Double variable-displacement pump DPVP 108
1 Function
The DPVP double variable-displacement pump is of the axial piston swash-plate type. Powertrain
and integrated pilot-control gear pump are powered by the diesel engine via the flexible coupling (tor-
sion damper).
Powertrain 21/23
Regulating unit 22/24
Mounting plate 25
Pump distribution gear 27, see group 5.20.
The DPVP variable-displacement pump is flanged to the diesel engine with connection flange 26.
Powertrains 21/23 consist of a drive shaft, cylinder and piston. They can be adjusted / regulated by
means of the swivel yoke.
The regulating units 22 and 24 are mounted to the powertrains 21 and 23. The performance regula-
tors 22.1/24.1 for the regulation and adjustment of the pump performance) are mounted in the regu-
lator unit 22/24. They obtain feedback concerning the pivot angle by means of a pin.
The flow regulator 24.5 used to adjust the flow and the differential pressure p is also screw-moun-
ted to the regulator unit 24.
pump, if required.
7.07.1
copyright by
MJFCIFSS
Double variable-displacement pump DPVP 108 Service Manual
Function
Fig. 1 Components of the DPVP
20 Pump unit DPVP 108, complete 25 Mounting plate

21 Powertrain P1 26 Connecting flange
22 Regulating unit P1 27 Pump distribution gear PVG 352 C 359
22.1 Performance regulator P1 28 Q min. - stop P1
22.6 Shuttle valve (Fa1) 29 Q min. - stop P2
23 Powertrain P2 30 Gear pump / pilot control
24 Regulating unit P2 41 Allen head screw
24.1 Performance regulator P2 43 Measuring point M2 / control chamber pres-
sure P2
24.5 Flow regulator P1 / P2 44 Measuring point M1 / control chamber pres-
sure P1
24.6 Shuttle valve (Fa2)
A1/P1 Pressure line S Suction line

A2/P2 Pressure line T to tank
Fa1 from the control oil unit connection P1 X2 to the control block connection LS
Fa2 from the control oil unit connection P1 X3 to the control oil unit connection LR
FE to control oil unit P X4 to the control oil unit connection LS
Note!
In order to prevent damage to the pump, observe the torque (87 Nm) for the Allen head screws 41
when installing the gear pump 30.
7.07.2
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MJFCIFSS
Function
Fig. 2 Hydraulic schematic: DPVP
20 Pump unit DPVP 108, complete 24 Regulating unit P2

21 Powertrain P1 24.1 Performance regulator P2
21.1 Control piston 24.3 Restrictor (Ø 1.5 mm)
22 Regulating unit P1 24.5 Flow regulator P1 / P2
22.1 Performance regulator P1 24.6 Shuttle valve (Fa2)
22.3 Restrictor (Ø 1.5 mm) 30 Gear pump - control oil unit
22.6 Shuttle valve (Fa1) 43 Measuring point M2 / control chamber
pressure P2
23 Powertrain P2 44 Measuring point M1 / control chamber
pressure P1
23.1 Control piston
7.07.3
copyright by
MJFCIFSS
Technical data
2 Technical data
Machine A 904 C - Litronic A 914 C - Litronic A 924 C - Litronic

Type 1003/1004/1005/1071 1044/1045 1047/1048/1050/1051
Pump type DPVP 108 DPVP 108 DPVP 108
Input speed 1800 rpm 1800 rpm 1800 rpm
Drive power of diesel engine 105 kW 120 kW 135 kW
Volumetric delivery
max. 2 x 189 l/min 2 x 215 l/min 2 x 215 l/min
min. 2 x 40 l/min 2 x 40 l/min 2 x 40 l/min
Hydraulic performance (basic per- 105 kW 120 kW 135 kW
formance)
Begin of regulation (with basic set- 50 ± 2 bar 70 + 2 bar 70 + 2 bar
tings)
Control oil pump / pilot control 40 l/min 40 l/min 40 l/min
Check measurement X (Q min. approx. 27.0 mm approx. 27.0 mm approx. 27.0 mm
stop)
Settings and comparative values Power from

solenoid valve
Y50/Y51
For parameters and reference values, see adjustment proto-
col in group 6.
3 Functional description of variable-displacement pump
(see Fig., page 12) and Fig. 10
3.1 Powertrains 21/23, (see Fig. 10, page 12)

19 via the gearing. The toothing on the drive shaft drives the flange-mounted gear pump 30 (pilot con-
trol).
7.07.4
copyright by
MJFCIFSS
Functional description of variable-displacement pump
stroke depends on the inclination of swivel yoke 7. The swivel yoke is borne on the rotary roller bea-
ring 14. The rotary motion of the swivel yoke 7 is effected by means of a connection between the con-
trol piston 32 and the connecting link 37 at every axial motion of the piston.
The pilot plate 17 separates the pressure side from the suction side of the powertrain. The pilot plate
17 has kidney-shaped openings on the suction side, and three smaller kidney-shaped openings on
the pressure side.
3.1.1 Adjusting the pivot angle of the pump

of the pin 12 and the roll pin 11. The axial motion of the control piston 32 (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.
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 28/29).

The min. pivot angle of the powertrain is determined by stop screw 28/29 (with lock nut 38). It is fac-
7.07.5
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MJFCIFSS
Pump regulation
4 Pump regulation
4.1 Performance regulator 22.1 / 24.1 (LR) hyperbolic regulator

pin 15.

7.07.6
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MJFCIFSS
Pump regulation

Fig. 6 Sectional drawing of performance regulator 22.1 / 24.1
26 Flow regulator, complete 92 Bushing

49 Regulator housing 93 Spring plate
81 Screw plug 94 Ball
82 Threaded stud 95 Connecting pin (swivel yoke)
7.07.7
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MJFCIFSS
Pump regulation
84 O-ring 97 Spool
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
91 Pressure spring
Note!
4.2 Flow regulator 24.5 (LS regulator)

The flow regulators 24.5 are used to adapt the flow rates of the pump to the requirements of the con-
sumers.
The flow regulators 24.5 are screw-mounted to the regulator housing 49. It consists of the following
main components: 3-piece piston 63/64/65 and pressure spring 59 with adjusting screw 52.
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
24.5 Flow regulator, complete 63 Piston

49 Regulator housing 64 Control sleeve
51 Screw plug 65 Piston
52 Adjusting screw 73 O-ring with backing ring
56 Sealing nut Pp Pump pressure
7.07.8
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Pump regulation
58 Lock nut pLS LS pressure

59 Pressure spring (adjustment p) T Return channel
60 Pressure spring X2 Connection control block-LS
61 Seal X4 Connection T to tank
62 Spool
s
Note!
Screw down the flow regulator 24.5 all the way to stop. Tighten it with 5 Nm max.
4.3.1 Standby
4.3.2 Pivoting out

4.3.3 Pivoting back

7.07.9
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Adjustment of DPVP variable-displacement pump
Fig. 8 Control edges S1 and S2 at the flow regulator

58 Nut
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
67 O-ring X4 Connection at regulator housing
5 Adjustment of DPVP variable-displacement pump
lation
Note!
7.07.10
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MJFCIFSS
5 Drive shaft 24.1 Performance regulator (P2)

7 Swivel yoke 25 Mounting plate
8 Roller bearing 26 Connecting flange
10 Sliding bearing 27 Pump distribution gear
11 Roll pin 28 Q min. - stop P1
12 Pin 29 Q min. - stop P2
14 Roller bearing 30 Gear pump
15 Connecting pin 31 Sliding disc
16 Cylinder 32 Regulating cylinder
17 Pilot plate 33 Return ball
18 Cylinder pin 34 Return plate
19 Piston with slipper 35 Pressure spring
20 Pump unit 36 Pressure spring
21 Powertrain (P1) 37 Connecting link
22 Regulating unit (P1) 38 Lock nut
22.1 Performance regulator (P1) 39 Sleeve
23 Powertrain (P2) 41 Allen head screw
24 Regulating unit (P2)
7.07.11
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Fig. 9 Sectional drawing 1
7.07.12
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MJFCIFSS
Fig. 10 Sectional drawing 2
7.07.13
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MJFCIFSS
Performance curve - DPVP
6 Performance curve - DPVP
Fig. 11 Performance curve - DPVP 90
7.07.14
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MJFCIFSS
Service Manual FMF hydraulic fixed displacement motor
Purpose
FMF hydraulic fixed displacement motor
1 Purpose
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 of the machine.
Fig. 1 FMF hydraulic fixed displacement motor
A 900 C-LI 14675- 7.20.1

MJFCIFSS
FMF hydraulic fixed displacement motor Service Manual
General information and tightening torques
2 General information and tightening torques
Machine series A 900 C Litronic A 904 C Litronic

Type of oil motor FMF 45 FMF 45
Oil flow consumption 45 cm3 per round 45 cm3 per round
Leak oil max. at (350 bar) 6 l/min 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!
Adjustment of valves 134 / 135: see adjustment protocol and adjustment guideline in group 6.
7.20.2 A 900 C-LI 14675-

MJFCIFSS
Description
3 Description
Axial-piston oil motors are energy transformers best characterised by the axial orientation of their pis-
tons in a cylinder.
Oil motor 130 consists mainly of two 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 on top of mounting plate 13.
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 Relief valve with additional pressure level

13 Mounting plate 135 Relief valve with additional pressure level
130 Oil motor 137 Measuring connection MA
132 Powertrain 138 Measuring connection MB
133 Suction valve
4.1 Functioning of the oil motor, see Fig. 3 and see Fig. 4
Nine pistons 5 are arranged in housing 12, in a circle, parallel to output shaft 3. They run in
A 900 C-LI 14675- 7.20.3

MJFCIFSS
cylinder 4, which is in gear with output shaft 3.

The bottom ends of the pistons are designed as ball joints and sit in slippers 5.1. They are held on
fixed eccentric disc 6 by return ball 8 and return plate 7.
The hydrostatic bearing arrangement of slippers 5.1 on thrust washer 6 (by means of bores in piston
5 and slippers 5.1) reduces the otherwise high friction between slippers and eccentric disc to a mini-
mum.
When there is no pressure, cylinder 4 is pressed against disc cam 8 by pressure springs 8.1 which
are installed in return ball 8. As soon as the pressure goes up, cylinder 4 and disc cam 9 are balanced
by hydraulic forces in such a way that the oil film at the control surface is maintained at all times, even
under high loads, and the amount of leak oil is reduced to a minimum. Some of the leak oil is used to
lubricate the moving parts of the powertrain and guided externally back to the tank.
If pressure oil is supplied to operating connections A or B, it will act on four pistons 5 in each case,
via kidney-shaped slots in pilot plate 9. Another four pistons 5 displace the oil not carrying energy via
kidney-shaped openings in pilot plate 9 and connection B and/or A back 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. That force acts on eccentric disc 6 via piston 5 and slipper 5.1.
The radial component of that force (together with the limb of the cylinder acting as a lever arm) ge-
nerate a torque which is transmitted on to cylinder 4 and output shaft 3 .
That torque can be influenced only by the oil pressure applied, i.e. high pressure = high torque. The
two-way action acting on the oil motor (connection A or B) effects a change of direction of the torque
at drive shaft 3 (left or right-hand rotation).
For every rotary motion of cylinder 4, pistons 5 execute a double stroke. That stroke of the piston cor-
responds to the inclination of eccentric disc 6 and determines the amount 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.
7.20.4 A 900 C-LI 14675-

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Fig. 3 Sectional drawing: 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 /lok-
king ring
13 Mounting plate 134 Pressure relief valve B with additional
pressure level
13.21 Screw plug 135 Pressure relief valve B with additional
pressure level
14 Allen head screw 137 Measuring point MA / pivot right
A 900 C-LI 14675- 7.20.5

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) make sure the oil motor is always properly filled (no ca-
vitation e.g. when relief valves blow off or in the event of leaks). If there is a lack of pressure at con-
nection A or B, the pressure difference lifts cone 133.10 (against the force of spring 133.14) from its
seat, and the oil can flow from connection S to 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 XA / XB.
Pressure control
If the pressure increases in the slewing gear circuit in undesirable ways, destruction would hit the
weakest point, e.g. screwed connections or hydraulic hoses.
In order to prevent that, we provide a sort of pre-determined breaking point. So, in our case, the in-
creasing operating pressure in the slewing gear circuit acts on a pressure relief valve. It limits the
max. pressure in the slewing gear and its connection to the pre-set value.
For the ease of functioning and manufacture, we use indirect (pilot-controlled) pressure relief valves.
With these valves, we use a relief valve that works directly as a pilot control valve to actuate a second,
larger valve.
The resulting pressure (in A or B) acts on the front face of piston (main cone) .19, as well as on its
backside (via a small bore) and closes it. At the same time, the pressure acts on pilot control
cone .20. Pressure spring .23 pushes pilot control cone .20 into its closing position (static condition).
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.
The differing cross-sections of the bores in piston .19 and valve insert .18 generate a pressure diffe-
rence between the front and back sides of piston .19. The effect of the pressure difference is that pis-
ton .19 is shifted against pressure spring .23, and a high amount of oil can flow off to return side 5
and/or the other side.
Additional pressure level

If the pilot control valve for the actuation of the slewing gear is not actuated, connection XA / XB is
relieved.
Level 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 relief valve 134 / 135 is set to the low value (level 1).
If the pilot control valve is switched to slewing gear control, the pilot pressure acts on piston .12 via
connection XA or XB and internal bores in mounting plate 13 plus more bores and annular passages
in 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 relief valve 134 / 135 is set to the high value (level 2).
Adjustment of relief valves 134 / 135 with additional pressure level: see adjustment protocol and ad-
justment guideline in group 6.
7.20.6 A 900 C-LI 14675-

MJFCIFSS
Fig. 4 Sectional drawing: 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 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 level
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 - 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)
A 900 C-LI 14675- 7.20.7

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 fixed displacement oil motors FMF".
5.1 Sealing jobs on valves on mounting valve
Replacement of O-ring 133.17 or spring 133.14 on suction valves 133:

Remove screw plug 133.11 complete with measuring connections 137 / 138. Remove cone 133.10,
spring 133.14 and O-ring 133.17.
Check cones 133.10 for free movement. Place new spring or O-ring in valve, and put together again.
When re-mounting the valve, be sure to properly re-tighten screw plug 133.11 complete with measu-
ring connections 137 / 138 (250 Nm).
Sealing jobs on pressure relief valves 134 and 135

Use seal kit .93.
Remove and/or dismount valve 134 / 135 completely, as needed.
Check parts for good functioning, and whether fit for re-use.
Note!
When you are finished replacing the defective sealing element, be sure to correctly assemble. Install
complete valve (torques between 100 and 120 Nm).
After the replacement of O-rings .22, .27, .29, it is imperative to re-adjust the response pressures of
the valve. See adjustment guideline and protocol in group 6.
7.20.8 A 900 C-LI 14675-

MJFCIFSS
Service Manual HMF 75-02P hydraulic fixed-displacement motor
Function and design
HMF 75-02P hydraulic fixed-displacement motor
1 Function and design
The hydraulic fixed-displacement motor is a axial piston motor of the swash plate type designed for
an open circuit. The high-pressure hydraulic motor has a constant pivot angle. It is used to drive the
slewing gear mechanism of the machine and features all functions that are required for optimised sle-
wing gear operation.
Way valve function for rotation
Priority valve for slewing gear
Torque control
Secondary and suction valve 131/132 with controllable characteristic
Feeder valve
Anti-reaction function
Outlet function
The hydraulic fixed-displacement motor 130 consists of three main components:
The motor housing 1 encases the drive shaft and the complete powertrain.
The valves are combined in a compact unit in the control base receptacle 2.
Anti-reaction plate 139 with internal A-B connection.
Fig. 1 Hydraulic fixed-displacement motor 130
7.22.1
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MJFCIFSS
HMF 75-02P hydraulic fixed-displacement motor Service Manual
Function and design
Fig. 2 Basic design of powertrain
1 Motor housing 7 Cylinder block

2 Control base receptacle 131 Secondary pressure-relief valve / swivel-
ling right
3 Radial shaft seal ring 132 Secondary pressure-relief valve / swivel-
ling left
4 Shaft 141 Check valve / LS pressure
5 Working piston 142 Check valve / tank return line
6 Control base
7.22.2
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MJFCIFSS
Function and design
Fig. 3 Exploded view of control base receptacle 2
131 143 Feeder valve

132 145 Measuring point / turning right
133 Spool / turning 146 Measuring point / turning left
134 TC pressure-relief valve 147 Measuring point / control pressure
135 Restrictor check valve / control pressure 148 Shuttle valve
136 Stroke limiter / spool d1 Nozzle in restrictor check valves
137 Torque control valve d2 Nozzle in actuating circuit of pressure-
relief valves
131/132
138 Input pressure balance d3 Pilot control pressure nozzle (for torque
Priority switching / swivelling control)
139 Anti reaction valve d4 Nozzle / LS pressure at input pressure
balance
140 Check valve d5 Nozzle for torque control valve 137
141 Check valve / LS pressure d6 Housing flushing nozzle
142 Preload valve d7 Nozzle for A-B connection
Return check valve
7.22.3
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MJFCIFSS
Technical data
2 Technical data
Machine series A 914 C Litronic A 924 C Litronic

Type of oil motor HMF 75-O2P
Flow consumption cm3 75.9
Leak oil max. at (200 bar) l/min 9.0
Start of movement bar 8.5 ±0.5
Spool 133
Nozzle dimensions
Nozzle d1 Ø mm 0.4
Nozzle d2 Ø mm 0.6
Nozzle d3 Ø mm 0.8
Nozzle d4 Ø mm 0.6
Nozzle d5 Ø mm 1.3
Nozzle d6 Ø mm 1.6
Nozzle d7 Ø mm 1.0 construction / 1.2 industry
Tightening torques
Sealing flange nut 16 Nm 60
Lock nut 125 Nm 50
Lock nut 127 Nm 5
Secondary pressure-relief val- Nm 80 +10
ves 131/132
Lock nut 117 at secondary pres- Nm 70
sure-relief valves 131/132
Restrictor check valve 135 Nm 9
Sealing flange nut at Nm 60
TC pressure-relief valve 134
Torque control valve 137 Nm 100
7.22.4
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MJFCIFSS
3.1 Way valve 133, Fig. 4 and Fig. 5

The spool 133 of the way valve is used to actuate the motor. It is centred in its neutral position by the
two springs 15. The pump pressure acts on the motor through the connection P.
Using the pilot control unit, the operator can build up the control pressure in the spring chamber X/Y
necessary to perform the desired swivelling motion.
The spool 133 is shifted according to the preselected control pressure and the oil flows from P to A
(B) and to B (A) and T.
The open channel acts as a gauge orifice after which the LS pressure is measured and transmitted
to the pump controller. The oil flow (slewing gear speed) is adjusted according to the control pressure.
The piston stroke can be restricted with a stop screw 17 so that the maximum flow rate is limited. The
restrictor check valves 135 attenuate the spool movement in both directions.
7.22.5
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MJFCIFSS
Fig. 5 Sectional drawing of the control base receptacle 2
15 Pressure spring 139 Anti reaction valve

16 Sealing flange nut 140 High pressure check valve
17 Stop screw 141 Check valve / LS pressure
18 Shims 142 Preload valve
Return check valve
19 Control cap 143 Feeder valves
7.22.6
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MJFCIFSS
22 Pressure spring 145 Measuring point / turning right

23 Pressure spring 146 Measuring point / turning left
130 Slewing gear motor with way valve 147 Measuring point / control pressure
131 Secondary pressure-relief valve / turning 148 Shuttle valve
right
132 Secondary pressure-relief valve / turning d1 Nozzle in restrictor check valves 135/136
left
133 Spool / turning d2 Nozzle in actuating circuit of pressure-
relief valves
131/132
134 TC pressure-relief valve d3 Pilot control pressure nozzle (for torque
control)
135 Restrictor check valve / control pressure d4 Nozzle / LS pressure at input pressure
balance
136 Stroke limiter / spool d5 Nozzle for torque control valve 137
137 Torque control valve d6 Housing flushing nozzle
138 Priority switching swivelling / d7 Nozzle for A-B connection
input pressure balance
3.2 Priority valve 138 (input pressure balance), see Fig. 7

The priority valve 138 is installed in the channel P in front of the spool 133, see Fig. 5.
The system LS pressure that is applied onto the hydraulic motor through the connection LS does not
affect the control system of the input pressure balance 138, and the check valve 141 in the control
base receptacle 2 prioritises the slewing gear.
Fig. 6 Control base receptacle 2, see Fig. 2
3.3 Torque control, see Fig. 6

The TC valve 137 determines the acceleration pressure. The machine operator selects the desired
oil flow rate as well as the variable acceleration pressure at the pilot control unit. This prevents the
pressure-relief valves 131/132 (secondary valves) from being opened. The maximum acceleration
pressure is set at the TC pressure-relief valve 134.
7.22.7
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MJFCIFSS
Fig. 7 Sectional drawing, see Fig. 5
18 Piston 134 TC pressure-relief valve

20 Regulating piston 137 Torque control valve
22 Spring 138 Priority switching swivelling /
input pressure balance
23 Adjusting spring
3.4 Secondary pressure relief valves with suction function

The secondary pressure-relief valves 131/132 are adjustable. They are factory-set to a basic value.
When a control pressure of > 5 bar is applied at the connections X/Y, (see Hydraulic diagram on
page 5) the set valve pressure is changed from the basic value to the maximum value. The control
pressure of the way valve is used as the actuating pressure.
During the acceleration phase, the associated secondary pressure-relief valve is adjusted to the ma-
ximum set value, depending on the control pressure and along a characteristic. If the machine ope-
rator wishes to make smooth movements, the pilot control unit must be held in 0 position, and the
uppercarriage is moved against the basic settings of the secondary pressure-relief valves 131/132
(minimum setting 50 bar).
If the operator desires hard braking of the uppercarriage, he must change the setting of the respective
secondary pressure-relief valve 131/132 to the maximum value. The uppercarriage is now slowed
down against maximum pressure. Depending on the control pressure set by the machine operator,
the controllable secondary pressure-relief valves 131/132 can be used to adjust the brake pressure
along a defined characteristic with minimum and maximum value.
The minimum and maximum value are mechanically adjustable from the outside. The control pres-
sure can be adjusted along the TC characteristic from the outside.
The outlet side of the pressure-relief valves 131/132 is exposed to the preload tank return pressure,
facilitating reloading through the suction valves.
7.22.8
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MJFCIFSS
Fig. 8 Secondary pressure relief valves 131 / 132
70 Piston 119 Adjusting screw

71 Needle piston 120 Stop screw
72 Spring 121 Spring
73 Spring 124 Adjusting screw
76 Valve cone 125 Lock nut
77 Spring 126 Adjusting screw
115 Spring 127 Lock nut
116 Piston T/T1 to hydraulic tank
117 Lock nut x/y Control pressure connections
3.5 Feeder valves 143

To prevent cavitation, it is possible to supply the slewing gear system directly through the feeder val-
ves 143 that are connected to the preloaded tank return line in the control block.
Fig. 9 Feeder valve 143
7.22.9
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MJFCIFSS
3.6 Anti reaction valve 139

During the stop phase, the anti-reaction valve 139 connects the two main connections A and B so
that all pressure is effectively released. The uppercarriage comes to a smooth halt.
Fig. 10 Anti-reaction valve
96 Valve plunger 103 O-ring

97 Nozzle 139 Anti-reaction valve
98 Nozzle 145 Measuring point / turning right
99 Nozzle 146 Measuring point / turning left
100 Screw plug d7 Nozzle for A-B connection
3.7 Outlet function, (see Hydraulic diagram on page 5)

The tank return line (channel T) is always preloaded. A metered amount of oil is fed through the nozz-
le D3, acting as flushing oil to cool the housing of the hydraulic motor. It then leaves the housing to-
gether with any leak oil to the connection L/U.
7.22.10
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MJFCIFSS
4 Checking and adjusting the slewing gear functions
Check measurement A mm 22.0 ±1 134

Check measurement B mm 20.0 ±1 137
Secondary pressure / swivelling in
Test pressure / turning right bar 260 ±10 131
Test pressure / turning left bar 260 ±10 132
Secondary pressure / slowing down
Turning right bar 85 +10 131
Turning left bar 85 +10 132
Secondary pressure Psec.
(at control pressure = 14bar) bar 14 ±0.1 147
Turning right bar 160 ±5 145
Turning left bar 160 ±5 146
TC characteristic P TC
(at control pressure = 16bar) 16 ±0.1 147

Primary pressure

Stroke limitation of the spool mm 41.3 +0.1 X
Turning speed rpm 9.5
Tab. 2 Parameters
Danger!
Uppercarriage may execute uncontrolled rotary movements, pose a hazard to mechanics and
equipment.
Apply the slewing gear brake (switch S17).
Upper carriage is locked in its position.
Lower the attachment to the ground.
4.1 Checking and adjusting the spool stroke limitation
Fig. 11 Stroke limitation of the spool
7.22.11
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MJFCIFSS
Remove control lid and measure check dimension X.

Compare check dimension X with the settings in the adjustment protocol and adjust it, if necessa-
ry.
Remount the control lid.
4.2 Checking and adjusting high pressure-relief valves 131/132
4.2.1 Adjusting the upper pressure level (counter-pressure)

In order to facilitate the adjustment of the basic position of the TC pressure-relief valve 134 (dimen-
sion A) and the torque control valve 137 (dimension B), proceed as follows:
Write down the check measurements at the valves 134 and 137. For guideline values, see adjus-
tment protocol.
Turn both valves 134 and 137 to a value above the secondary pressure
Adjust the secondary pressure.
Note!
7.22.12
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MJFCIFSS
Block the uppercarriage and actuate the switch S17.

4.2.2 Adjusting the lower pressure level (braking)
Danger!
Rotating movements of the uppercarriage during dynamic measurement pose a hazard to mecha-
nics and equipment.
Ensure that no persons or other objects are located in the swivelling range.

Release the slewing gear brake (switch S17).
7.22.13
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MJFCIFSS
4.2.3 Checking and adjusting characteristic (high pressure-relief valves)
Note!
These valves are factory-set, (see Diagram of slewing gear settings on page 16) and it is normally
not necessary to check and readjust them.
If the characteristic has been changed, the brake pressure must be checked and adjusted accordin-
gly, (see Adjusting the lower pressure level (braking) on page 13).

Adjust the pilot control pressure for turning left/right with the pilot control unit (select a high initial
pressure and then lower it; for set pressure value, see adjustment protocol).
Read the pilot control pressure indicated at the measuring point 147.
Compare the pressure values with those in the adjustment protocol (measuring point 145/146).
If necessary, loosen the lock nut 5 and adjust the characteristic with the adjusting screw 6.
4.3 Checking and adjusting the maximum acceleration pressure at the TC pressu-
re-relief valve 134
Fig. 15 Adjusting pressure-relief valve 134
Note!
The TC pressure-relief valve 134 limits the acceleration pressure for turning right/left.
Adjust the setting valve A at the TC pressure-relief valve 134; for guide values, see adjustment
protocol.
7.22.14
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MJFCIFSS
Press the pilot control unit for 'turn left/right' to the stop.
4.4 Checking and adjusting torque control valve 137 (characteristic)
Fig. 16 Adjusting torque control valve 137
Connect a pressure sensor to the measuring point 145/146/147.

Adjust the setting valve B at the torque control valve 137; for guide values, see adjustment proto-
col.
Adjust the pilot control pressure for turning left/right with the pilot control unit to 16 bar (select a
high initial pressure and then lower it; for set pressure value, see adjustment protocol).
Read the pilot control pressure indicated at the measuring point 145/146.
If necessary, loosen the lock nut 2 and set the torque control valve 137 using the adjusting
screw 1.
If the pressure settings of the torque control valve 137 cannot be adjusted, first set the characteristic
of the high pressure limitation, (see Checking and adjusting characteristic (high pressure-relief val-
ves) on page 14).
Note!
The values shown in the diagram below are sample values only. For the actual applicable values,
see the adjustment protocol.
I Relationship between the secondary protection and the control pressure for swivelling
II Relationship between high pressure and the control pressure for swivelling
2 Secondary value Pst dependent
4 Limited by control pressure
5 Torque control
7.22.15
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MJFCIFSS
Secondary limitation
Working pressure for lowering
Fig. 17 Diagram of slewing gear settings
7.22.16
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MJFCIFSS
7.22.17
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MJFCIFSS
7.22.18
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MJFCIFSS
Service Manual LMV regulating motor
Purpose
LMV regulating motor
1 Purpose
The axial-piston oil motor is of the swash-plate type. It is flanged to the transmission of the machine.
Flows from the variable displacement pump go through brake valve "Connection A or B" to the oil
motor and act on the pistons of the powertrain. The pistons (moving in the axial direction inside the
cylinder of the powertrain) act on cylinder and drive shaft and generate a certain torque.
The regulating and adjusting unit adjusts the pivot angle = flow consumption of the oil motor (depen-
ding on the operating pressure).
The variable flow consumption of the oil motor determines 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
A 900 C-LI 14675- 7.25.1

MJFCIFSS
LMV regulating motor Service Manual
General information
Equipment A 900 C-Li A 900 C-Li A 904 C-Li A 904 C-Li

from serial number Unit 14675 14675 16000 16000
Design N Speeder N Speeder
Oil motor Type LMV 100 LMV 100 LMV 100 LMV 140
Oil flow consumption max. cm3 per 100 100 100 140
round
Oil flow consumption min. cm3 per 46.8 46.8 67.1 91.8
round
Begin of regulation (1) bar 190 190 190 190
End of regulation bar 270 270 270 250
Max. admissible amount of leak oil l/min 8.0 8.0 8.0 10.0
Adjustable settings of oil motor

A Regulation end of oil motor
Min. pivot angle
Measure X (standard value), see Fig. 4 mm 11.0 11.0 11.8 14.0
B Drive shaft speed (jacked up) min-1 1875±25 2700±25 2175±25 2075±25
Travel pressure (2) 90 100 90 105
C Secondary pressure relief valves bar 380+20 380+20 380+20 380+20
Note!
(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 6.25.
(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 6.25.
7.25.2 A 900 C-LI 14675-

MJFCIFSS
Description
3 Description
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. Mounting plate 100 carries secondary pressure relief valves 176 / 177.
Control cylinder 173 and spool 174 sit directly on travel motor 170.
Right at mounting plate 100 is brake valve 190, acting in both travel directions.
Fig. 2 Design of LMV regulating motor
A 900 C-LI 14675- 7.25.3

MJFCIFSS
4.1 Functioning of powertrain, see Fig. 3

Nine pistons 77.1 are arranged in housing 2, in a circle, parallel to drive shaft 95. They run in axial
arrangement in cylinder 75, which is in gear with drive shaft 95. The bottom ends of the pistons are
designed as ball joints and sit in slippers 77.2. They are held on swivel yoke 84 (swash plate) by re-
turn ball 78.1 and return plate 78.2.
The hydrostatic bearing arrangement of slippers 77.2 on sliding disc 85 in swivel yoke 84 (by means
of bores in piston 77.1 and slippers 77.2) reduces the friction between slippers and sliding disc to a
minimum.
When there is no pressure, cylinder 75 is pressed against pilot plate 79 by pressure springs and re-
turn plate 78.2 which are installed in return ball 78.2. When the pressure goes up, cylinder 75 and
disc cam 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 operating connections A or B, it will act on four pistons in each case,
via kidney-shaped slots in pilot plate 79. Another four pistons transport oil that does not carry any
energy via kidney-shaped slots in pilot plate 79, connection A or B, and brake valve 190 (see Fig.
2) back 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. That force acts on swivel yoke 84 via pistons 77.1 and slipper 77.2. The radial
component of that force (together with the limb of the cylinder acting as a lever arm) generates a
torque which is transmitted to cylinder 75 and drive shaft 95 and, thus, represents the input torque of
the oil motor.
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).
Bearing of drive shaft 95 is arranged by means of roller bearings 32 and 33 in mounting plate 100
and mounting flange 98.
Sealing between housing 2 and drive shaft 95 by means of shaft seal 35 and O-ring 36 in locking
ring 97. Seal 15 seals off the contact faces of mounting flange 98 and housing 2 to the outside.
7.25.4 A 900 C-LI 14675-

MJFCIFSS
Fig. 3 Sectional drawing: travel motor / powertrain 170
2 Housing 75 Cylinder (172*)

5 Adjustment 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
44 Shim ring 174* Regulating unit / spool (see Fig. 6)
70 Spacer ring
A 900 C-LI 14675- 7.25.5

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, pressure spring 14 holds control piston 10 in control cylinder
173 in the direction of Qmin. The pressure oil of the relevant high-pressure side (A or B) acts on the
small face of the piston (spring side) of control 10, via internal bores and check valves 3 in mounting
plate 100 (Fig. 7) . Swivel yoke 84 is switched to small pivot angle (Qmin.) = large output speed; low
oil flow consumption - low torque. This happens via the control neck with sliding block 30 that enga-
ges with control piston 10. The motion of control 10 in the direction of min. pivot angle is limited by
stop screw 13.
4.2.2 High-pressure value above begin of regulation

High-pressure oil gets to the large face of control piston 10 via spool and restrictor 20. Due to the
larger effective piston face, control piston 10 pushes in the direction of large pivot angle = smaller
input speed; large oil flow consumption, high rpm. This happens via control neck with sliding block 30
of swivel yoke 84. The max. pivot angle is limited by guide ring 19 (dead stop). The hydraulical con-
nection between spool and control piston is locked after a relative movement of control piston 10, the
adjustment procedure comes to an end. This happens thanks to the mechanical connection between
control piston 10 and regulating spring .24, via lever .25 (see Fig. 6).
As soon as the high pressure goes down, the large face of control piston 10 is relieved, the powertrain
goes down.
7.25.6 A 900 C-LI 14675-

MJFCIFSS
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 Sealing ring
14 Pressure spring 26 O-ring
15 Locknut 27 Guide bushing
16 Protective cap 28 Circlip
17 O-ring 30 Sliding block
18 Backing ring 84 Swivel yoke
19 Guide ring 173* Regulating unit / control cylinder
20 Restrictor
A 900 C-LI 14675- 7.25.7

MJFCIFSS
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 spool .11 (measuring cylinder .43)
of actuation device 87, via connection G of the flanged on brake valve and via internal bores in moun-
ting plate 100.
If the high-pressure value is lower than begin of regulation as adjusted at adjusting screw .41, spring
.19 pushes spool .11 with the help of guide rod .13 against the right-hand stop, in the direction of
shim .21. The large face of the control piston is relieved, and the powertrain is switched to Qmin via
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, spool .11 is moved
against guide .13 and adjusting spring.19. As soon as the control edge of spool .11 opens, high pres-
sure gets to the large face of the control piston via restrictor 20. Control piston 10 pushes swivel yoke
84 towards larger pivot angles.
The mechanical connection between the control piston and regulating spring .24 via lever .25 has the
effect that regulating spring .24 is preloaded to a higher degree during adjustment. That means, 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 re-
gulating motor is at max. pivot angle.
As soon as the high pressure goes down again, below begin of regulation, the spring force of regu-
lating spring .24 is higher again than the hydraulic force at spool .11. That means, the powertrain is
switched to a smaller pivot angle.
4.3.3 Creeper gear mode

Thanks to push button S21 on the display (stand equipment) and solenoid valveY24 (see 'hydraulic
system' , group 6) in the hydraulic system, it is possible to maintain the oil motor constantly at max.
pivot angle (creeper gear mode).
When button S21 is pushed, pilot pressure is guided to spool .11 via control connection X, which
is then shifted against pressure springs .19 and .24. That means, the high pressure applied now and
immediately acts on the large face of the control piston (independent of regulation settings) so that
the oil motor is switched to a large pivot angle.
That means, the machine has a great tractive power.
4.3.4 Securing the oil motor, see Fig. 7

The two pilot-controlled pressure relief valves 1 on mounting plate100 provide secondary protection
to the oil motor, against reaction forces from the outside and, thus, excess pressure.
7.25.8 A 900 C-LI 14675-

MJFCIFSS
Fig. 6 Sectional drawing of regulating unit / actuation device 87
.01 Screw .24 Regulating spring

.10 Regulating valve (housing) .25 Lever
.11 Spool .26 Locknut
.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 Sealing ring
A 900 C-LI 14675- 7.25.9

MJFCIFSS
Fig. 7 Sectional drawing of mounting plate 100
176* .13 O-ring

177* .14 O-ring
.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)
.12 Screw plug G Bores (high pressure from shuttle
valve 195 in brake valve
7.25.10 A 900 C-LI 14675-

MJFCIFSS
Maintenance and inspection
5 Maintenance and inspection
5.1 Maintenance and repair works on oil motor
Note!
Liebherr oil motors do not require any maintenance whatsoever.
When you detect disturbances in connection with the motor, it will be indispensable to check the
regulation system. Proceed according to adjustment guideline and protocol, see group 6.
For sealing and repair jobs, please refer to separate
repair instructions "LMV regulating motor".
This hydraulic regulating motor has been pre-set by the manufacturer and must not be changed.
Danger!
Hazardous areas: undercarriage - crushing hazard for mechanics if machine unintentionally starts
rolling
Be sure to apply parking brake.
Place attachments on the ground.
Contact operating personnel.
5.2 Check oil motor for leaks.

Find hose L leading from connection T1 of the oil motor to the lower rotary connection. Disconnect
from rotary connection. Close open connection.
Apply machine brakes, put full power on oil motor (max. high pressure).
Collect leak oil from oil motor. Use hose L and suitable and sufficiently large container.
Determine how much leak oil you actually collected and compare to max. admissible value. (see
Technical data on page 2)
Oil motors producing too much leak oil should be exchanged.
Re-connect hose L when finished with measurements.
Fig. 8 Leak oil connection at oil motor
A 900 C-LI 14675- 7.25.11

MJFCIFSS
Secondary pressure relief valves 1(176* / 177*)
6 Secondary pressure relief valves 1(176* / 177*)
6.1 Design, see Fig. 9

Secondary pressure relief valves 1 are of the cartridge type and screwed directly into the mounting
plate of the regulating motor. They put a limit on the pressure between oil motor and control valve
block with the spools 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
that we use a sort of pre-determined breaking point. In our scenario, the pressure rising in the hy-
draulic system acts on a certain type of integrated hydraulic device. We call this a pressure relief val-
ve. It limits the max. pressure in the consumer and its connection with the pre-set value. Because the
pressure valves in this hydraulic system must handle great flows of oil, we use indirect (pilot-cont-
rolled) pressure relief valves for reasons of manufacture and better functioning. With these valves,
we use a relief valve 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 .2 and, at
the same time, on its backside as well, via bore A. At the same time, there is also pressure at pilot
control cone .5.
Pressure springs .3 and .6 push main piston .2 and pilot control cone .5 into their closing positions
(static condition).
As soon as the pressure in the oil motor attains a value above the adjusting value for pressure and
adjusting spring .6 (due to external forces acting on the powertrain), pilot control cone .5 is lifted from
its seat and admits some oil to return channel (T1).
The differing cross-sections of the bores A in main piston .2 and B in valve insert .4 generate a pres-
sure difference between front and back side of main piston .2. The pressure difference leads to main
piston .2 being shifted against pressure springs .3 so that a great amount of oil can flow off to the non-
pressurised return side (T2).
The excessive pressure in the system goes down, and main piston .2 is, again, pushed against the
sealing edge at the lower part of housing .1. Furthermore, adjusting spring .6 pushes pilot control
cone .5 against valve insert .4, i.e. the connection between pressurised side and return side (T1/T2)
is closed.
7.25.12 A 900 C-LI 14675-

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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 Locknut
.5 Pilot control cone .10 Protective cap
.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
A 900 C-LI 14675- 7.25.13

MJFCIFSS
Functioning of brake valve
8 Functioning of brake valve
8.0.1 Purpose of brake valve 190*, see Fig. 10

The travel brake valve is flanged to the mounting plate of regulating travel motor 170*. During down-
hill travel or deceleration of the machine, it prevents insufficient filling and over-speeding of the regu-
lating 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.
This prevents over-speeding of the oil motor.
8.0.2 Travel function of brake valve 190*

High-pressure oil flows through connection A / B, check valve 210 - 230 (196*) and connection A / B
to mounting plate 100 where it acts on the powertrain of oil motor 170*.
The return oil from the oil motor flows via connection A / B back to the brake valve. Check
valve 210 - 230 (196*) closes so that brake piston 20 (192*) (in closing position) is throttled via the
ring gap (reduced diameter) at the end of the pistons and shuttle valve 50 / 140 (193*) and is, thus,
slowly shifted against pressure spring 170. The brake pistons 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.
8.0.3 Braking function

During downhill travel or deceleration, the operating pressure (high pressure) goes down. That
means, the pressure at brake piston 20 (192*) goes down as well. Pressure spring 170 pushes brake
piston 20 (192*) into braking position.
The connection of the return oil from the oil motor from connection B / A to connection B / A is
throttled, i.e. the oil flow (and, thus, the speed of the oil motor) is reduced.
The small bores in 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.
10 Housing 250 Screw plug

20 Brake piston 260 O-ring
30 Pin 300 Shuttle check valve
40 Valve seat 310 Screw plug
50 Valve seat 420 Screw plug
70 Spring plate 480 Hex nut
100 Screw plug 490 Mounting bolt
110 Screw plug 999 O-ring (seal kit)
140 Restrictor bolt 190* Brake valve
170 Pressure spring 192* Brake piston
200 Cone 193* Shuttle valve
210 Guide 194* Check valve
220 Pressure spring 195* Shuttle valve
230 Valve cone 196* Check valve
7.25.14 A 900 C-LI 14675-

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Fig. 10 Sectional drawing of brake valve 190*
A 900 C-LI 14675- 7.25.15

MJFCIFSS
Fig. 11 Exploded view of brake valve
7.25.16 A 900 C-LI 14675-

MJFCIFSS
Service Manual Regulating motor DMVA (travel motor)
Design of hydraulic travel motor
Regulating motor DMVA (travel 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.
Both values are in inverse ratio, i.e.:
High flow consumption Qmax = high torque = low speed of travel motor
Low flow consumption Qmax = low torque = high speed of travel motor
The brake valve integrated into the mounting plate restricts the return flow to the control valve block
or the tank respectively, thus slowing down the drive. This approach prevents overspeeding of the
travel motor when travelling down a slope and consequent cavitation.
Fig. 1 DMVA travel motor
7.27.1
copyright by
MJFCIFSS
Regulating motor DMVA (travel motor) Service Manual
Technical data
2 Technical data
Machine A 900 C Litronic A 904 C Litronic A 914 C / A 924 C

Type 1002 1003/1004/1005/ 1044/1045/1047/
1071 1048/1049/1050/
1051
Oil motor DMVA 165 DMVA 165 DMVA 165
Max. oil flow consumption 165 cm3/rev 165 cm3/rev 165 cm3/rev
Oil flow consumption min. 94 cm3/rev 94 cm3/rev 94 cm3/rev
Begin of regulation (high pressure) 240 bar 240 bar 240 bar
End of regulation (high pressure) 320 bar 320 bar 320 bar
Max. pivot angle 22° 22° 22°
Min. pivot angle 10.8° 10.8° 10.8°
Max. permissible leak oil volume 7 l/min 7 l/min 7 l/min
at 350 bar and an oil temperature of 50° C
Adjustable settings of oil motor
A Begin of regulation of the oil motor 240 bar 240 bar 240 bar
at the adjusting screw 64
B Min. pivot angle
Dimension X of the stop screw 35
(guide value)
Standard machine 21.0 mm 21.0 mm 21.0 mm
Speeder 25.0 mm 25.0 mm 25.0 mm
Standard machine model A 924 C 22.5 mm
Type 1050/1051 HD 25.0 mm
C Drive shaft speed When adjusting the universal joint shaft speed,
Standard machine take into account the tyre size.
Speeder For adjustment values, refer to the adjustment protocols of the re-
spective machine in group 3.
Adjusting screw 92 for stroke limita-
tion of the control axle 160 (dimensi- 15.5 mm 15.5 mm 15.5 mm
on Y)
115 bar 115 bar 115 bar
High pressure
D Secondary pressure-relief valves 380 +20 bar 380 +20 bar 380 +20 bar
7.27.2
copyright by
MJFCIFSS
Design
3 Design
The travel motor consists of the following main components:

Powertrain 172
Mounting plate 30
Regulator 60
The housing 80 encloses the entire powertrain 172 with swivel yoke, piston, pilot plate and sliding
disc.
The housing 80 is screwed to the mounting plate 30. The mounting plate contains the secondary
pressure-relief valves 176/177, the control and regulating unit and the brake valve acting in both di-
rections 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
7.27.3
copyright by
MJFCIFSS
Functional description of the travel motor
4 Functional description of the travel motor
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 friction to a minimum, despite the high surface pressure
between the slipper and the swivel yoke 9.
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-
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 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 generates a certain force determined by the
pressure and the 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. That stroke corres-
ponds to the inclination of swivel yoke 9 and determines the amount of oil consumed.
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 piston face of the control piston 173 (minimum pressure valve at the end of regulation),
see Tab. 1.
The regulating piston 174 is in regulating position, i.e. the flow from the high pressure side through
the check valve 175 to the large piston surface of the spool 173 and the flow from the large piston
surface of the spool 173 to the tank side are blocked. The maximum swivel angle is determined by
the stop of the spool 173 at the guide bushing 33. The motor remains in this position, until the high
pressure drops below the pressure value at the end of regulation.
Within the regulated range, the travel motor can reach any position that corresponds to a working
pressure of between Qmax and Qmin. If the working pressure drops below the value at the begin of
regulation, the spool 173 touches the stop screw 35, i.e. the travel motor's flow consumption capacity
is lowest at high drive shaft speed, high speed and low drawing pull.
7.27.4
copyright by
MJFCIFSS
Fig. 3 Sectional drawing at the begin of regulation (spool)
32 Mounting plate 38 Lock nut

33 Guide bushing 42 Pin
34 Connecting link 50 Measuring connection of the actuating pres-
sure M
35 Stop screw
4.3 Function prior to the begin of regulation

see Fig. 3 and Fig. 4
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 175 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.
The working pressure acts on the spool 174 through the check valves 175. The spool 174 is held by
the preloaded adjusting spring 68 in its basic position so that the flow from the high pressure side
through the check valve 175 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 exceeds the pressure value of the begin of regulation, see Tab. 1.
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 Ø D - Ø d, (see Fig. 5 on page6) of the spool 174, pushing it against the adjusting spring
68. The control edge of the 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 po-
wertrain in direction Qmax. As a result, the powertrain is swivelled to a large swivel angle. The push
rod 67 acts as a sensing device and relieves the return spring 69, so that the force ratio between the
adjusting spring 68 + return spring 69 differs from the working pressure. As a result, the spool 174
returns to its regulating position (= closed position) and the actuating procedure is completed.
At the respective working pressure (end of regulation) the powertrain is set again to the maximum
swivel angle.
7.27.5
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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 77 Lead seal
64 Adjusting screw 174 Spool
65 Spring plate A High pressure through valve 52
66 Spring plate SK Pressure to control piston 173
67 Pressure rod C High pressure through valve 195
68 Compression spring (adjusting spring) T to tank
Fig. 5 Magnified view of the surface difference (detail Z)
7.27.6
copyright by
MJFCIFSS
4.5 Fuse
The two pilot-controlled pressure-relief valves 176 / 177 protect the travel motor against overpressure
(secondary protection).
The suction valves (check valves) 196 prevent cavitation when the secondary pressure-relief valves
176 / 177 respond.
Fig. 6 Arrangement of the valves for pressure protection
173 Control piston 194 Check valve

176/177 Secondary pressure-relief valves 196 Check valve
4.6 Creeper gear mode

The travel motor is kept at a maximum swivel angle (creeper gear mode) when the switch S21 (stan-
dard equipment) is actuated on the control console and the solenoid valve Y24 located on the control
oil unit is powered as a result.
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
machine is thus easier to steer, while the drawing pull is not increased.
7.27.7
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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 pilot control pressure at the brake piston 192 and the
pressure spring 48 determines the automatic brake function. The brake effect results from the rest-
riction of the oil from the motor. Irregular braking of the travel motor is prevented by the check valves
196 with bypass bores, see Fig. 6.
Fig. 7 Arrangement of the valves for the brake function
45 Valve seat 192 Piston

46 Spring plate 193 Restrictor bolt
47 Lid 194 Check valve
48 Pressure spring
7.27.8
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MJFCIFSS
Maintenance and repairs
5 Maintenance and repairs
Note!
Liebherr oil motors do not require any maintenance whatsoever.
This travel motor has been pre-set by the manufacturer and its settings should not be changed.
For sealing and repair work, please refer to the separate
repair instructions for DMVA regulating motors.
6 Checking and adjusting the travel motor
Danger!
For inspection, adjustment and repair work, it is necessary to access the undercarriage.
This can be dangerous for technicians. There is a risk of serious injury or event death, if the machine
begins to move.
Extend the supports.
Place attachments on the ground. Lift the undercarriage from the ground, if required.
Apply the parking brake.
Establish visual or acoustic contact with the operating personnel.
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 3 "Adjustment protocol" and "Testing and adjusting tasks".
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 flow volume of the spool for travelling (stroke limitation 160.1/160.2).
The maximum speed is factory-set by the manufacturer and may not be changed.
The minimum flow consumption of the oil motor is limited by the Qmin stop screw 35.
If the maximum travel speed of the vehicle is unsatisfactory, the setting can be adjusted. To determi-
ne the actual value, check the dimension Y of the stroke limitation adjusting screw 160.1 / 160.2.
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). For
settings see Tab. 1.
7.27.9
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MJFCIFSS
Checking and adjusting the travel motor
Fig. 8 Control axle / travel at control block
100 Compact control block 160.1 Stroke limitation, reverse travel

160 Control axle / travel 160.2 Stroke limitation / forward travel
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 may 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 Tab. 1.
Fig. 9 Setting value of Qmin stop screw
32 Mounting plate 38 Lock nut

35 Stop screw 51 Protective cover
Note!
The location of installation of the oil motor depends on the machine model.
7.27.10
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Hydraulic diagram of the travel motor
6.4 Checking travel motor for leakage

Oil temperature in machine: 50°C
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.
2. Put the machine in gear, 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. 1.
If there is excessive leakage, replace the oil motor.
Remove the hose section and reconnect the leak oil hose to connection T1.
Fig. 10 Connection T1 for the leakage check of the travel motor
7 Hydraulic diagram of the travel motor
34 Connecting link 190 Travel brake valve, complete

35 Stop screw 192 Brake piston
67 Pressure rod 193 Restrictor bolt
68 Compression spring (adjusting spring) 194 Check valve
69 Pressure spring (regulating spring) 195 Shuttle valve
170 Travel motor, complete 196 Check valve
172 Complete powertrain
173 Control piston X Connection for control pressure from sole-
noid valve Y24
174 Spool T1 Leak oil connection
175 Check valve R Pressure/return line connection, reverse
176 Secondary pressure-relief valve V Pressure/return line connection, forward
forward
177 Secondary pressure-relief valve M Measuring connection / control chamber
reverse pressure
7.27.11
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MJFCIFSS
Fig. 11 Hydraulic diagram of the travel motor
7.27.12
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MJFCIFSS
Items Items
2 Piston with slipper 34 Connecting link
3 Cylinder with bushing 35 Stop screw
4 Drive shaft 36 Backing ring
5 Pilot plate 37 O-ring
6 Return ball 38 Lock nut
7 Return plate 39 Allen head screw
8 Sliding disc 41 Jacket ring
9 Swivel yoke 42 Pin
10 Locking ring 43 Roll pin
11 Pin 45 Valve seat
12 Pin 46 Spring plate
13 Pressure spring 47 Lid
14 Cylindrical roller bearing 48 Pressure spring
15 Cylindrical roller bearing 50 Screw cap (measuring point M)
16 Cylindrical roller bearing 51 Protective cap
17 Radial shaft seal ring 80 Housing
18 O-ring 82 O-ring
19 Snap ring 83 Cylinder pin
20 Snap ring 172 Complete powertrain
21 Allen head screw 173 Control piston
22 Roll pin 192 Piston
31 Screw plug 193 Restrictor bolt
32 Mounting plate 194 Check valve
33 Guide bushing
Note!
Observe set value B, see Tab. 1.
7.27.13
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MJFCIFSS
Sectional drawings
8 Sectional drawings
Fig. 12 Sectional drawing of transmission and brake valve
7.27.14
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MJFCIFSS
Sectional drawings
Item Item
9 Swivel yoke 71 Circlip
30 Connecting plate, complete 72 Ball
31 Screw plug 73 O-ring
32 Mounting plate 74 O-ring
39 Allen head screw 75 Allen head screw
40 Allen head screw 76 Protective cover
44 Pin 77 Lead seal
45 Valve seat 78 Washer
48 Pressure spring 79 Allen head screw
49 O-ring 80 Housing
60 Regulator, complete 81 Cylinder pin
61 Bushing 173 Control piston
62 Bushing 174 Spool
63 Spring plate 175 Check valve
64 Adjusting screw 176 Secondary pressure-relief valve
65 Spring plate 177 Secondary pressure-relief valve
66 Spring plate 192 Piston
67 Pressure rod 193 Restrictor bolt
68 Compression spring (adjusting spring) 194 Check valve
69 Pressure spring (regulating spring) 195 Shuttle valve
70 Lock nut
Note!
Observe set values A and D, see Tab. 1.
7.27.15
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MJFCIFSS
Sectional drawings
Fig. 13 Sectional drawing of pilot plate and brake valve
7.27.16
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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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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. 60°C).
Apply a little oil to the O-ring 125 and the Turcon-Glyd ring 122 and place them onto the piston 12,
using the mounting sleeve b and the expanding sleeve b (for special tools, see group 2.05).
After installation, return the Turcon-Glyd ring 122 to its original shape, using the piston tightening
strap.
Insert the first backing ring 125, the O-ring 124 and the second backing ring into the piston 12.
Apply Castrol Tarp to the internal piston chamber.
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
12 Piston 124 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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MJFCIFSS
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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MJFCIFSS
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
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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
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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
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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
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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
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MJFCIFSS
Service Manual Extension and retraction times of hydraulic cylinders
Function and design
Extension and retraction times of hydraulic

cylinders
The actual extension and retraction times of a cylinder can deviate from the theoretical (calculated)
times, due to malfunction of components.
In order to identify a cause of a malfunction or fault, the theoretical time must be calculated and com-
pared with the actually measured time.
1.1 Calculation of the theoretical extension and retraction time

The times calculated here are based on the maximum volumetric flow of the spool and the maximum
intake capacity of the cylinder.
Differential cylinders feature different volumes for extension and retraction.
Fig. 1 Data required for the calculation of the extension and retraction times
Ad Piston rod area lH Cylinder stoke length

AD Effective area for extension Va Extension rate = < retraction
Adifference Effective area for retraction Ve Retraction rate = > extension
The following data must be determined for calculation purposes:

Dimensions of the cylinder; measure the dimensions on site, e.g. for model A 914: stick cylinder
piston rod 95 mm. Alternatively, refer to the specifications in the spare parts catalogue (piston di-
ameter: 140 mm).
Measure the actual stroke length:
fully retract the cylinder, mark the position of the scraper ring on the piston rod, using a felt-tip pen;
fully extend the cylinder and measure the distance between the scraper ring and the above mark.
The actual volumetric flow rate of the spool in the way valve (e.g. for stick cylinder) is specified in
the technical data of the control block, group 7.53: 360 l/min for extension and 220 l/min for retrac-
tion.
1.1.1 Formula
tExtension in seconds = piston area x stroke: Flow rate
7.31.1
copyright by
MJFCIFSS
Extension and retraction times of hydraulic cylinders Service Manual
Function and design
tRetraction in seconds = piston ring area x stroke: Flow rate
1.1.2 Sample calculations

To be determined: extension time for stick cylinder of model A 914 B
t = 3.46 3,5 seconds
To be determined: retraction time for stick cylinder of model A 914 B
t = 3.05 3 seconds
Note!
The above example refers to a situation where one spool supplies one working cylinder with oil.
Where one spool supplies two working cylinders with oil, the intake volume must be doubled (e.g.
for stick cylinder with industrial stick).
In the above formula, multiply the respective figure by 2.
To be determined: extension time for stick cylinder of model A 914 B industrial
t = 3.96 4 seconds
1.2 Measuring the extension and retraction times of a cylinder

Position the machine in such a way that the cylinder to be measured can be fully extended and
retracted without posing any danger to persons, machines and adjacent buildings or objects.
Warm up the machine to its normal operating temperature.
Actuate the respective pilot control unit to the stop.
Measure the time of the maximum piston stroke (distance travelled by piston rod) from fully retrac-
ted to fully extended and vice versa (use a stop watch to obtain accurate times).
Compare the average time with the theoretical time, see 1.1.
7.31.2
copyright by
MJFCIFSS
Service Manual Hydraulic double plunger cylinder
Design
Hydraulic double plunger cylinder
1 Design
The LIEBHERR double plunger cylinder is used as a working cylinder to move the ditch cleaning /
swivel bucket.
The hydraulic cylinder consists of the following main components:
The cylinders 20 inserted in the ditch cleaning / swivel bucket 10.
The piston rod 8 connected through the swivel bearing 70 to the bearing block 60.
Fig. 1 Hydraulic double plunger cylinder in a ditch cleaning bucket
8 Piston rod 70 Swivel bearing

10 Ditch cleaning / swivel bucket 72 Double check valve
20 Cylinder 74 Hydr. connections from AS1 control block
60 Bearing block 76 Hydr. connections to bearing block
The pressure chambers are sealed with Zurcon seal rings in the cylinders 20. The scraper ring in the
cylinder 20 protects the piston rod 8 against dirt. The guide rings 50 guide the piston rod 8 during
movement. For more details regarding the sealing elements, see Fig. 4.
Hydraulic oil is fed to the right side of the piston rod 8, pushing the cylinder to the right and swivelling
the bucket to the right. Hydraulic oil is fed to the left side of the piston rod 8, pushing the cylinder to
the left and swivelling the bucket to the left.
The velocity and the force of the extending cylinder (at constant oil flow and pressure) are the same
7.32.1
copyright by
MJFCIFSS
Hydraulic double plunger cylinder Service Manual
for both movements.

To ensure that there is no leak oil escaping from the extended cylinder, the return oil is fed through
the hydraulically operated double check valve 72. The oil fed through the bearing block 60 opens the
double check valve 72, so that the return oil from the cylinder 20 can flow back to the control block.
The pressure-relief valves in the double check valve 72 act as secondary safety devices.
When the button S5L or S5R for swivelling the bucket is actuated, the oil flows from the additional
control block AS1 connection A02 / B02 through lines to the bucket.
The oil in the hydraulic circuit AS1 pressurises the double check valve 72 connection V1-C1 or V2-
C2, through the boreholes A1/A2 in the screw-mounted bearing block 60 and the boreholes in the
piston rod of the cylinder 20.
The pressure in the cylinder 20 pushes the bucket connected to the cylinder 20 outwards and swivels
the bucket around its fulcrum.
The return oil from the other cylinder side (retracting cylinder) is fed through the bearing block 60, the
open double check valve 72 and the lines to the additional control block AS1.
7.32.2
copyright by
MJFCIFSS
Exploded view of hydraulic double plunger cylinder
3 Exploded view of hydraulic double plunger cylinder
Fig. 3 Exploded view of double plunger cylinder
1 Hydraulic cylinder, complete 50 Guide ring

8 Piston rod 60 Bearing block
20 Cylinder 70 Swivel bearing
30 Scraper ring 801 Corrosion inhibitor
40 Zurcon-L ring 999 Seal kit
7.32.3
copyright by
MJFCIFSS
Sectional drawing of hydraulic double plunger cylinder
4 Sectional drawing of hydraulic double plunger cylinder
8 Piston rod A1 Oil supply to cylinder / right

10 Bearing pipe / bucket A2 Oil supply to cylinder / left
20 Cylinder C Section through oil supply line
30 Scraper ring D Section through oil supply line
40 Zurcon-L ring E Section through bearing block fixture
50 Guide ring F Section through bearing block fixture
60 Bearing block V1 Retracted cylinder
V2 Extended cylinder
7.32.4
copyright by
MJFCIFSS
Sectional drawing of hydraulic double plunger cylinder
Fig. 4 Sectional drawing of hydraulic double plunger cylinder
7.32.5
copyright by
MJFCIFSS
Removing / installing double plunger cylinder
5 Removing / installing double plunger cylinder
Caution!
When the cylinder is removed from or installed 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 bucket on the ground. Ensure that the
cylinder is stopped in a suitable position for removal and installation.
Switch off the diesel engine. Release the hydraulic pressure from the 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.
Release the preload pressure of the hydraulic tank by loosening the breather filter at the tank.
Secure the swivel bearing by attaching it to lifting tackle. If necessary, secure the bucket.
5.1 Dismantling, see Fig. 5

Remove the hydraulic hoses from the double check valve 62 and collect the escaping oil in a sui-
table container with the necessary capacity (as piston rod 8 will be moved).
Move the piston rod 8 to the stop.
Remove the snap rings 93 and the shims 92.
Remove the plug 67 of the inlet bore 10a at the bearing pipe / bucket.
By moving the swivel bearing 70 , move the bearing block 60 with the piston rod 8 in the cylinders
20 in axial direction until the 1st Allen head screw 62 is aligned with the access bore 10a.
1. Remove the Allen head screw 62, and move the piston rod 8 further in axial direction to the next
Allen head screw 62 to be removed, etc.
Pull out the pin 90 between the two tabs 90 and the bearing block 60. If necessary, use a special
removal tool to pull out the pin 90.
Remove the flanges with hoses from the bearing block 60.
Remove the bearing block 60 and the seal 66 (roll pins 61 remain in the piston rod 8).
Note!
The locking mechanism of the cylinders 20 in the bearing pipe / bucket comes in two versions:
With small buckets, one cylinder 20 is locked with a spacer 110 at the pipe end, and the other
cylinder 20 is locked with a locking bolt 82.
With large (wide) buckets, the two cylinders 20 are locked with a locking bolt 82.
Release the locking bolt 82 and remove it from the bearing pipe/bucket.
Remove the seal cover 80.
Through the access borehole 10b on the bearing pipe /bucket, push the following parts from the
bearing pipe / bucket: cylinder 20, piston rod 8, cylinder 20 and spacer 110 (if installed).
Carefully place the piston rod 8 on a clean surface and reseal the cylinder 20, if necessary, see 6.
7.32.6
copyright by
MJFCIFSS
5.2 Installation, see Fig. 5

Clean the inside of the bearing pipe / bucket.
Insert the spacer 110 (for small buckets) or a bearing bolt 82 (for wide buckets) in the bearing pipe
/ bucket.
Mount the complete hydraulic cylinder and push it into the bearing pipe / bucket to the stop at the
spacer of bolt.
Place the seal kit 66 on the bearing pipe / bucket.
Insert the seal rings 64 in the piston rod 8.
Ensure that the roll pins 67 are correctly inserted in the bearing block 60.
Place the bearing block 60 in the correct position on the piston rod 8 (observe correct position of
the seal rings 64).
Move the piston rod in axial and radial direction until the 1st through-hole for the Allen head screws
62 is in line with the access borehole 10a.
1. Insert and tighten the 1st Allen head screw 62, and move the piston rod 8 further in axial direc-
tion to the next Allen head screw 62 to be tightened, etc.
Tighten all screws according to the factory standard, see group 1.20.
Seal the access borehole 10a with the plug 65.
When the piston rod 8 is in one of its maximum positions, apply a little grease to the pin 91 and
drive it in between the two tabs 90 and the bearing block 60.
Insert the shims 91 and the snap rings 93.
Reconnect the flanges with hoses to the bearing block 60.
Connect the hydraulic hoses from the double check valve 72 to the bearing block 60 according to
the relevant instructions, see 5.3.
Bleed the hydraulic cylinders, see 5.3.
Apply maximum pressure to both cylinders 20 (max. working pressure) to test them for leakage.
Preload the seal 66 with the pressure spring 67:
If the spring preload settings are adjusted correctly with the clamping bolt 68 , the seal is pu-
shed in all positions against the bearing pipe / bucket.
Note!
When working in water or mud, there is a risk that dirt collects in the bearing pipe / bucket, even if
the seal 66 is in its correct position. During winter time, the sliding face between the seal and the
bearing pipe might freeze tight.
If this occurs, clean / flush the bearing pipe ,see 5.4.
To prevent seizing, apply Gleitmo 900 onto the sliding face of the seal and the bearing pipe, see
group 1.50.
7.32.7
copyright by
MJFCIFSS
1 Hydraulic cylinder, complete 67 Plug

10 Ditch cleaning bucket 70 Swivel bearing
10a Access borehole / screws 72 Double check valve
10b Access borehole / spacer / cylinder 80 Lid
60 Bearing block 82 Locking bolt
61 Roll pin 90 Tabs
62 Allen head screw 91 Pin
63 Seal ring 92 Shim
64 Pressure spring 93 Snap ring
65 Clamping screw 110 Spacer
66 Seal
7.32.8
copyright by
MJFCIFSS
Fig. 5 Assembly and dismantling of the double plunger cylinder
5.3 Bleeding cylinder after repair
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. To prevent this, 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
7.32.9
copyright by
MJFCIFSS
air-tight.
Connect the hose and completely extend one cylinder slowly and carefully, at low idle rpm, so that
the air at the other cylinder can escape completely. Collect escaping oil in a suitable container.
When the cylinder is fully extended, connect the other line.
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.
Now fully pressurise the two cylinder (maximum pressure).
5.4 Maintenance
The bucket maintenance is limited to regular lubrication of the bearing of the bucket and the swivel
bucket. The cylinder does not require any maintenance.
In connection with certain applications, dirt might enter the bearing pipe / bucket near the cylinder,
despite proper preloading and position of the seal 66. In this case, we recommend flushing / cleaning
the system as follows:
Remove the plug 67.
Screw off the plug 68 (G1/2) from the seal 68 and connect the adapter for the water hose and
then connect the water hose.
Flush the inside of the pipe with water.
Swivel the bucket several times to remove the dirt from the inside of the pipe.
After cleaning is completed, disconnect the water line and replace the plug 67 / 68.
Fig. 6 Sealing of bearing pipe
66 Seal 68 Plug
67 Plug
7.32.10
copyright by
MJFCIFSS
Replacing seals
6 Replacing seals
Note!
When dismantling and installing the piston rod 8 , handle the part with special caution as the chro-
mium surface could easily be damaged. Such damage could lead to leakage.
Avoid damaging the surface of the piston rod.
6.1 Dismantling
Remove the cylinder 20 with the piston rod 8 from the swivel bucket, see 5.
Pull the cylinders 20 on both sides from the piston rod 8.
Remove the scraper ring 30 from the cylinder 20.
Caution!
As it is somewhat difficult to remove the Zurcon seal ring 40 , there is a risk of damage to the groove
faces in the cylinder, which in turn can lead to leakage after installation of the new seal ring 60.
Do not attempt to remove the seal ring 60 from the groove with a sharp-edged tool.
Carefully insert a pin-type tool (e.g. tack) into the seal ring 60 and lift it from the cylinder 20.
If necessary, remove the guide rings 50 from the cylinder 20.
6.2 Assembly
Carefully remove all dirt, dust, chips and other extraneous material from the parts.
Check all parts for suitability for reuse.
Parts that show damage to the piston rod such as dents and grooves near the seal must be re-
placed.
Treat the seal housings with LIEBHERR corrosion inhibitor (Tarp 40g tube - ID no. 830005).
Apply a little grease to the guide rings 50 and insert them into the cylinder 20.
Note!
Incorrectly installed seal rings can cause leakage at the cylinder seal.
Observe correct position for installation (direction of pressure!) of the seal ring 40!
Apply a little oil to the seal ring 40 and squeeze it together, see Fig. 8, avoiding kinking.
Insert the seal ring 40 into the cylinder 20.
Squeeze and place the scraper ring 30 in the same way, see Fig. 8, and insert it in its correct po-
sition, see Fig. 7.
7.32.11
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MJFCIFSS
Replacing seals
Fig. 7 Detailed drawing
8 Piston rod 40 Zurcon-L ring

10 Bearing pipe / ditch cleaning bucket 50 Guide ring
20 Cylinder A1 Oil supply to cylinder / right
30 Scraper ring A2 Oil supply to cylinder / left
Fig. 8 Installation of sealing rings
20 Cylinder 40 Zurcon Z ring (secondary protection)

30 Scraper ring
7.32.12
copyright by
MJFCIFSS
Service Manual Control oil and regulation unit
Purpose
Control oil and regulation unit
1 Purpose
The control oil and regulation unit generates the servo pressure for the pilot control and the regulating
pressures for the working pumps.
It also generates the pressure signals of the control of the oscillating axle support and the multi-disc
brake of the slewing gear.
Fig. 1 Control oil and regulation unit
A 900 C-LI 14675- 7.40.1

MJFCIFSS
Control oil and regulation unit Service Manual
Description
2 Description
The control oil unit 50 consists primarily of an aluminium block. At its front, it is equipped with a 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
At this point, the control pressure for the power control, which is generated by solenoid valve Y50, is
measured. See performance change in groups 7.02 and 7.05.
Note!
As of November 2003, the measuring points 57 and 59 in the A 904 C Litronic models have been
moved from the control oil unit to the DPVO variable displacement pump 20.
As of November 2003, the measuring points 57 and 59 in the A 900 C Litronic models have been
moved from the control oil unit to the LPV variable displacement pump 20.
7.40.2 A 900 C-LI 14675-

MJFCIFSS
Description
Fig. 2 Control oil and regulating unit 50
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
53 Check valve Y50 Proportional solenoid valve / power con-
trol
54 Accumulator Y51 Proportional solenoid valve / LS control
55 Dummy plate Y66 Solenoid valve / oscillating axle support
56 Dummy plate
A 900 C-LI 14675- 7.40.3

MJFCIFSS
(see Fig. 2 on page 3)
3.1 Generation of servo pressure

The control oil unit is fed via connection P with the flow from the gear pump. The unit contains a 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 switching solenoid valves Y3, Y66 and Y7 provide control pressure to outlets A1,
A2 and/or A3. In neutral position, the outlets are connected to the tank.
Through connection A1, the solenoid valve Y3 releases control pressure to the pilot control devices.
Through connection A2, the solenoid valve Y66 acts on the circuit for the control of the oscillating
axle support.
Through connection A3, the solenoid valve Y7 controls the multi-disc brake in the slewing gear me-
chanism.
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).
7.40.4 A 900 C-LI 14675-

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).
A 900 C-LI 14675- 7.40.5

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 locknut 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
7.40.6 A 900 C-LI 14675-

MJFCIFSS
Function
Control oil and regulation unit
1 Function
The control oil and regulation unit limits the servo pressure for the pilot control and the regulating
pressures for the working pumps.
The servo pressure is distributed through the control oil and regulating unit to the various solenoid
valves for oscillating axle support, the creeper gear shifting or application of the multi-disc brake of
the slewing gear.
The pressure necessary for emergency operation is maintained in the accumulator.
Fig. 1 Control oil and regulation unit
7.41.1
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 control
oil unit 50 also features a solenoid valve Y24 for creeper gear shifting, which is located at the side of
the unit. The measuring point 49 and the accumulator are screw-mounted to the top of the unit.
The measuring points 57 ( p - lowering Y51) and 59 (power control Y50) are located at the respec-
tive variable-displacement pump, see Fig. 2.
The pressure filter 52 is screwed into the base of the unit beside the proportional solenoid valves Y50
and Y51. The control oil block also features an integrated check valve 53.
2.1 Arrangement of measuring points

Stationary measuring points 49, 57 and 59 are provided for the measurement of 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 how to check pressures in main group 6.
Measuring point 57 at variable-displacement pump 20

At this point, the control pressure for p reduction generated by the solenoid valve Y51 is measured.
See also flow reduction in group 16.20.
Measuring point 59 at variable-displacement pump 20

At this point, the control pressure for the power control, generated by the solenoid valve Y50 is
measured. See also power change in groups 7.02 and 7.05.
Fig. 2 Measuring points at the variable-displacement pumps
a A 900 C Litronic b A 904 C Litronic
7.41.2
copyright by
MJFCIFSS
Description
Fig. 3 Control oil and regulating unit 50
49 Measuring point for control pressure 56 Dummy plate

50 Control oil and regulation unit Y3 Solenoid valve / servo release
51 Pressure-relief valve Y7 Solenoid valve / slewing gear brake
52 Pressure filter Y24 Solenoid valve / creeper gear
53 Check valve Y50 Proportional solenoid valve / power con-
trol
54 Accumulator Y51 Proportional solenoid valve / LS control
55 Dummy plate Y66 Solenoid valve / oscillating axle support
7.41.3
copyright by
MJFCIFSS
(see Fig. 3, page 3)
3.1 Generation of servo pressure

The control oil unit is supplied with oil via the connection P from the gear pump. The unit contains a
pressure relief valve 51 of the cartridge type that is screwed into the unit. It limits the control pressure
to a certain value (see adjustment protocol).
The oil flows through the filter 52 and the check valve 53 to the accumulator 54. The accumulator 54
allows for a small 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 behind the filter 52 . It provides control pressure to the foot pedal.
3.2 Function of switching solenoid valves

Through the pressure channels in the control oil unit, the pressure oil acts on the switching solenoid
valves Y3, Y7, Y24 and Y66 and on the regulating solenoid valves Y50 and Y51.
When switched, the switching solenoid valves Y3, Y66 and Y7 connect the outlets A1, A2 and/or A3
to the control pressure, while Y 24 connects the outlet A. 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 the connection A3, the solenoid valve Y7 controls the multi-disc brake in the slewing gear
mechanism.
Through the connection A, the solenoid valve Y24 switches between creeper and on-road gear.
Through the connection A2, the solenoid valve Y66 applies pressure to the circuit for the control of
the oscillating axle support.
3.3 Proportional solenoid valves Y50 / Y51

The proportional solenoid valves for the power control Y50 or flow limitation Y51 of the working
pumps of the control oil unit are used to build up a pressure at their outputs, 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 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 also acts on connection X4 of the pump
regulator. Via the LS regulator, it reduces the pre-set ( P reduction) and, thus, limits the maximum
pump flow. This pressure is thus referred to as p ( pred) in other groups in this manual.
7.41.4
copyright by
MJFCIFSS
Characteristics of the proportional solenoid valves Y50 and Y51
4 Characteristics of the proportional solenoid valves Y50 and Y51
Fig. 4 Regulation diagrams
a = Y51
b = Y50
The regulation characteristics illustrate the inter-relation between input current ( I ) of the regulating
solenoids and the regulating pressure (p) at the outlets LR or LS.
The effect of the pressures p (GLR) at outlet LR or p ( Pred) 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
ILR of Y50 (or Iev of Y51).
The measurement and subsequent adjustment of currents IY50 and IY51/EV1 to fixed values can be
executed with sufficient accuracy by means of the display menus (see group 8.71).
7.41.5
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 connecting plug 1 at the proportional solenoid valve must
be unplugged in order to prevent interference from 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 57 or 59 respectively,(see "Measuring points
at the variable-displacement pumps", page 2).
While the engine is running and the lever 3 is in a horizontal position, remove the lock nut 4 and
turn the adjusting screw 5 until the desired pressure is obtained.
Re-tighten the lock nut 4, holding the adjusting screw 5 in its position and re-check the pressure.
Fig. 5 Emergency position of the proportional solenoid valves Y50 and Y51
1 Plug connection 5 Adjusting screw

2 Cotter pin Y50 Proportional solenoid valve / power con-
trol
3 Lever Y51 Proportional solenoid valve / LS control
4 Lock nut
7.41.6
copyright by
MJFCIFSS
Service Manual Pilot control valve 1 x
Description
Pilot control valve 1 x
1 Description
The operator controls the operations of the chassis by means of a foot pedal, to the right, in front of
his seat, in the running plate of the base of the operator's platform. It actuates the pilot control valve.
There is a regulating piston 12 (pressure control valve), sitting in an axial position in housing 6, 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).
There is a cover to protect pushrod, guide bushing etc. against dirt.
Fig. 1 Pilot control valve 1x with hydraulic diagram
A 900 C-LI 14675- 7.42.1

A 924 C-LI 34519-
Pilot control valve 1 x Service Manual
Fig. 3 / Fig. 4
The pilot control valve is of the pressure regulating type. That means, regulating piston 12 of the pilot
control valve builds up pressure on the discharge side, between pilot control valve and control valve
block, and is, thus, shifted, against the pressure from pressure spring 25.
Actuation of pedal 2 will push pushrod 98.1 down. At the same time, it will shift regulating piston 12
by means of regulating spring 25. The radial and axial bores in regulating piston 12 let control oil from
pressure channel P penetrate into connection 1 and the control line, to flow on to solenoid valve '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
3.1 Dismantling the regulating unit

Remove hex head screws 86.
Remove protective cover 98.5. Remove plate 1 complete with pedal 2.
Pull pushrod 98.1 with bushing 98.2 from housing 6. Press pushrod 98.1 out of bushing 98.2. 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.
3.2 Installing the regulating unit

Before installation, be sure to clean all parts and check whether they are fit for re-use.
Place washers 37 / 38, pressure spring 25 and spring plate 15 on regulating piston 12. Place split
disc 23.
Push spring plate 15 into housing 6 and bushing 17, complete with pre-installed regulating piston
12 and pressure spring 25 and pressure spring 26.
Install new O-ring 98.4 and PDF seal 98.3 in bushing 98.2.
Insert pushrod 98.1. Install bushing 98.2 complete with pushrod 98.1 in housing 6.
Place plate 1 in one piece. Screw in screws 86 complete with washers 85.
Screw in pin 7 with retaining washer 9. Secure with cotter pin 11 (see Fig. 3).
Place protective cover 98.5. Check pilot control valve for correct operation.
7.42.2 A 900 C-LI 14675-

A 924 C-LI 34519-
Repair
Fig. 2 Diagram: c = control pressure in bar, d = lever displacement in angular degree
Point a Point b
A 900 C Litronic from 14675 6.5 bar 25 bar
A 904 C Litronic from 16000 6.5 bar 25 bar
A 900 C-LI 14675- 7.42.3

A 924 C-LI 34519-
Repair
3.3 Exploded view
Fig. 3 Exploded drawing: pilot control valve
1 Plate 26 Pressure spring (return spring)

2 Pedal 37 Washer
6 Housing 38 Washer
7 Pin 85 Retaining washer
9 Washer 86 Hex head screw
11 Cotter pin 98 Repair kit
12 Regulating piston 98.1 Pushrod
15 Spring plate 98.2 Bushing
17 Bushing (pressed in) 98.3 PDF seal
23 Washer 98.4 O-ring
25 Pressure spring (regulating spring) 98.5 Protective cover
7.42.4 A 900 C-LI 14675-

A 924 C-LI 34519-
Repair
3.4 Sectional drawing
Fig. 4 Sectional drawing: pilot control valve
A 900 C-LI 14675- 7.42.5

A 924 C-LI 34519-
Repair
7.42.6 A 900 C-LI 14675-

A 924 C-LI 34519-
Description
1 Description
The two pilot control valves with foot pedals, in front of the operator's seat to the left, in the rnning
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.
Fig. 1 Pilot control valve 2 x with hydraulic diagram
A 900 C-LI 14675- 7.44.1

A 924 C-LI 34519-
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 psiton 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 presssure 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

Lift pedal 2 / 3
Remove protective covers 98.5. Remove screws 46. Remove plate 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 plate 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.

7.44.2 A 900 C-LI 14675-

A 924 C-LI 34519-
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 10 and bushing 16, complete with pre-installed regulating piston
12 and pressure spring 25 / 26.
Place plate 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 locknut 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.
Check valve for dirt and damage.
Install ball 45. Install seal 40. Apply Loctite 572 to valve insert 20 and screw in completely
(torque: 10 Nm).
.
Point a Point b
A 900 C Litronic from 14675 5.8 -0.3 bar 24.3 bar
A 900 C-LI 14675- 7.44.3

A 924 C-LI 34519-
Exploded view
4 Exploded view
1 Housing 40 Seal ring

2 Pedal to the left 41 Washer
2.1 Bushing 42 Washer
3 Pedal to the right 45 Ball
3.1 Bushing 46 Hex head Screw
10 Plate 47 Threaded stud
11 Pin 48 Hex nut
12 Regulating piston 50 Screw plug
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
35 Plug
7.44.4 A 900 C-LI 14675-

A 924 C-LI 34519-
Sectional drawing
5 Sectional drawing
Fig. 4 Sectional drawing
A 900 C-LI 14675- 7.44.5

A 924 C-LI 34519-
Sectional drawing
7.44.6 A 900 C-LI 14675-

A 924 C-LI 34519-
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
A 900 C-LI 14675- 7.46.1

A 924 C-LI 34519-
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.
the pre-defined displacement of the lever (see Fig. 2). The pressure acts on the face of regulating
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 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 .

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.
7.46.2 A 900 C-LI 14675-

A 924 C-LI 34519-
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 locknut 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.
.
Point a Point b
A 900 C-LI 14675- 7.46.3

A 924 C-LI 34519-
Exploded view
4 Exploded view
3 Tipping switch 54 Shim

12 Regulating piston 64 Lever
15 Spring plate 65 Handle
17 Hex nut 66 Bellows
18 Threaded stud 68 Hex nut
20 Allen head screw 70 Housing
21 Allen head screw 71 Bushing (pressed in)
23 Split disc 90 Connecting link
24 Axle 98 Repair kit
25 Pressure spring (regulating spring) 98.1 Pushrod
28 Pressure spring (return spring) 98.2 Bushing
29 Cover plate 98.3 PDF seal
49 Washer 98.4 O-ring
50 Washer 98.5 Protective cover
52 Shim
7.46.4 A 900 C-LI 14675-

A 924 C-LI 34519-
Sectional drawing
5 Sectional drawing
A 900 C-LI 14675- 7.46.5

A 924 C-LI 34519-
Sectional drawing
7.46.6 A 900 C-LI 14675-

A 924 C-LI 34519-
Description
1 Description
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), sitting in an axial position in housing
10, complete with pressure, return and control connections. Joystick 1 (sitting on top) with universal
joint 16 and switch disc 18 serves to actuate regulating piston 12.
Joystick 1 can be moved freely in any direction. With each movement, it presses against one or se-
veral spring-loaded pushrods, thanks to switch disc 18 which is attached to the joystick. This actuates
regulating piston 12 underneath (with regulating spring see Fig. 5 and return spring see Fig. 5) and,
thus, opens it towards pressure channel P, outlet 1 / 2 / 3 / 4.
Bellows 31 protects universal joint, pushrods, guide bushing etc. against dirt.
Fig. 1 Joystick with hydraulic schematic
A 900 C-LI 14675- 7.48.1

A 924 C-LI 34519-
see Fig. 6
Upon actuation of joystick 1, switch disc 18 pushes 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 connections 1, 2, 3, 4) and the control line to one of the control
connections of the control valve block.
the pre-defined displacement of the lever (see Fig. 2). The pressure acts on the face of regulating
Depending on how joystick 1 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 di-
rectly. At this point, the spool will receive the max. control pressure.
3 Repair

Pull up bellows 31.
Loosen locknut 21. Remove sleeve 20 with joystick components 1 / 2.
Remove nut 17 and switch disc 18. Remove universal joint 16 from housing 10.
Remove protective covers 98.5 and lid 32. Pull pushrod 98.1 complete with bushing 98.2 from
housing 10.
Press regulating piston 12 out of housing 10 (from below), complete with pressure springs 25 and
28 and spring plate 15 with disc 23.
Remove disc 23* from spring plate 15.

Place washers 49 / 50, pressure spring 25 and spring plate 15 on regulating piston 12.
Place disc 23*.
Push spring plate 15 into housing 10 and bushing 13, complete with pre-installed regulating
piston 12 and pressure spring 25 and pressure spring 28.
Replace lid 32 and protective cover 98.5. Screw in universal joint 16 (torque: 20 Nm).
Screw in switch disc 18 complete with nut 17. Adjust pilot control valve to zero position.
7.48.2 A 900 C-LI 14675-

A 924 C-LI 34519-
Repair
Screw sleeve 20 complete with joystick 1 into nut 17. Tighten nut 21 - take care that joystick 1 is
in the correct position.
Pull bellows 31 down over disc 30.
* New variant II does not contain disc 23, see Fig. 5.
3.3 Pilot control valve adjustment in zero position, see Fig. 6

Switch disc 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.
To adjust: loosen nut 17. Turn 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, be sure to re-tighten
nut 17.
A 900 C-LI 14675- 7.48.3

A 924 C-LI 34519-
Exploded views
4 Exploded views
Fig. 3 Pilot control valve, right, with electrical components
Fig. 4 Pilot control valve, left, with electrical components
7.48.4 A 900 C-LI 14675-

A 924 C-LI 34519-
Exploded views
Fig. 5 Pilot control valvevariant I until May 2004, variant II out in June 2004
A 900 C-LI 14675- 7.48.5

A 924 C-LI 34519-
Sectional drawing
5 Sectional drawing
7.48.6 A 900 C-LI 14675-

A 924 C-LI 34519-
Sectional drawing
1 Handle section 31 Bellows

2 Handle section 32 Lid
3 Sensor face 49 Washer
7 Dummy cap 50 Washer
10 Housing 80 Wire grommet
11 Pilot control valve, complete 81 Bushing
12 Regulating piston 98 Repair kit
13 Bushing (pressed in) 98.1 Pushrod
15 Spring plate 98.2 Bushing
16 Universal joint 98.3 PDF seal
17 Hex nut 98.4 O-ring
18 Switch disc 98.5 Protective cover
20 Sleeve B19L/R Sensor transducer
21 Nut S5R Switch
22 Wire harness S5L Switch
23 Washer S30 Switch / travel direction
24 Wire harness X7 Plug-type connection at A1001 3-pin
25 Pressure spring (regulating spring) X8 Plug-type connection at A1001 3-pin
28 Pressure spring (return spring) X15-1 Plug-type connection at A1100 4-pin
30 Plate X342 Plug-type connection for S30 3-pin
A 900 C-LI 14675- 7.48.7

A 924 C-LI 34519-
Sectional drawing
7.48.8 A 900 C-LI 14675-

A 924 C-LI 34519-
Service Manual LSC control valve block
Purpose
LSC control valve block
1 Purpose
All machines of the Litronic series are equipped with the LSC control system.
The control unit of the hydraulic LSC control was designed as a compact control block with LUDV
system. The control block contains five spools (working and travel functions) with the corresponding
valves.
There is an additional control block segment for the slewing gear drive and 'turn grapple (AS1).
Fig. 1 LSC control valve block
7.50.1
copyright by
MJFCIFSS
LSC control valve block Service Manual
Purpose
7.50.2
copyright by
MJFCIFSS
General information
Contained in: A 900 C Litronic A 900 C Litronic A 904 C Litronic A 904 C Litronic
Type 917 987 439 / 441 (Cstr) 440(Ind.)
Standard model M7-1169-31/7 M7-22 M7-1532-31/7 M7-22 M7-1170-30/6 M7-22
Industrie M7-1197-30/7 M7-22

Speeder M7-1169-30/7 M7-22 M7-1546-30/7 M7-22 M7-1547-30/7 M7-22 M7-1548-30/7 M7-22
spool Unit 220 240 260 280 160 120

Boom Stick Bucket Support Travel Slewing
cylinder cylinder cylinder cylinder motor gear
Ex- Re- Ex- Re- Ex- Re- Ex- Re- Ex- Re- Ex- Re-
tend tract tend tract tend tract tend tract tend tract tend tract
Nominal width: mm 22 22 22 22 22 20
block
Consumer connec- () 3/4 3/4 3/4 3/4 3/4 3/4
tion
Ø piston rod mm 25 25 25 25 25 25
Piston stroke mm 11.0 11.0 11.0 11.0 11.0 11.0 11.0 11.0 11.0 11.0 9.0 9.0
Setting value Y mm
A 900 C 17.0 15.5 15.8 15.8 16.0 15.7 16.0 16.0 15.5 15.5 16.0 16.0
A 904 C 17.0 15.7 15.8 15.8 17.0 16.5 16.3 16.0 15.5 15.5 15.8 15.8
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 20.6 20.6 20.6 20.6 20.6 20.6 20.6 20.6 20.6 20.6 20.6 20.6
Qn (A)/Qn(B) l/min
A 900 C (917)° 260 120 270 260 180 140 220 190 185 185 135 135
A 900 C (917)* 275 275
A 900 C (987)° 260 120 200 240 180 140 220 190 185 185 135 135
A 900 C (987)* 260 120 200 240 180 140 220 190 275 275 135 135
A 904 C (building)° 300 70 300 260 225 175 220 190 150 150 120 120
A 904 C (industry)* 300 70 290 230 225 175 220 190 275 275 135 135
A 904 C (industry)° 300 70 300 110 225 175 220 190 150 150 120 120
Restrictor check mm
valve
at connection a 0.8 0.8 0.8 0.8
(mm) 0.8 0.8 0.8 0.8
at connection b
(mm)
Leak oil max. 60 60 60 60 60 60
at load pressure 150 150 150 150 150 150
at oil temperature 50 50 50 50 50 50
* Standard
° Speeder
7.50.3
copyright by
MJFCIFSS
General information
Fig. 2 Hydraulic schematic: LSC control valve block
7.50.4
copyright by
MJFCIFSS
General information
7 Check valve (3.5 bar) 222 Retract secondary relief valve

8 Preload valve (7.0 bar) 224 Pressure balance (pilot-controlled)
41 Measuring point MP 227 Restrictor check valve
45 Measuring point LS 240 Spool / stick cylinder
100 Compact control block 5 x 241 Retract secondary relief valve
102 Pressure balance: minimum flow 242 Extend secondary relief valve
103 Pressure balance: remaining flow 244 Pressure balance (pilot-controlled)
104 Pressure cut-off valve 247 Restrictor check valve
105 Primary pressure-relief valve 260 Spool / bucket cylinder
107 Shuttle valve 261 Retract secondary relief valve
108 Restrictor (central nozzle of load-sensing 262 Extend secondary relief valve
regulation system)
120 Spool / slewing gear 264 Pressure balance (pilot-controlled)
122 Input pressure balance 280 Spool / support
123 Check valve 281 Screw plug
127 Restrictor check valve 284 Pressure balance (directly controlled)
160 Spool / chassis 540 Spool / accessory kit AS1
161 Suction valve, forward 541 Secondary relief valve / AS1
162 Suction valve - reverse 542 Secondary relief valve / AS1
164 Pressure balance (directly controlled) 544 Pressure balance
167 Restrictor check valve Y22 Solenoid valve: actuation 540
220 Spool / boom cylinder Y23 Solenoid valve: actuation 540
221 Extend secondary relief valve
7.50.5
copyright by
MJFCIFSS
Compact control block
3 Compact control block
3.1 Classification of control valve block, see Fig. 2

Input section:
Connection P for oil pump flow
Connection K for return flow to hydraulic cooler
Connection MP for pump pressure
Connections MLS and LS1 for extreme load signal from 'travel direction right', control-block side
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
Pressure balance / remaining flow 103 for a fast and direct response in the system
Pressure cut-off valve 104 as a limiting valve for the working pressure
Primary pressure relief valve 105 to protect the system
Control and distribution area:
Operating connections A1 - A5 and B1 - B5 for supply and return flows of consumers
Connection H for pilot control oil of control oil unit 50
Connection S for direct suction of slewing gear motor 130
Connection T for return oil to hydraulic tank1
Preload valve 8 (7 bar) in block for return as radiator bypass valve
Minimum-flow pressure balance102 to stabilise load pressure
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 chassis, lifting, stick, bucket
and support
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 compensation of the va-
rious axles
Restrictor check valves 127 / 167 / 227 and 247 for the fine control of spools 120 / 160 / 220
and 240
Secondary pressure relief valve 221 / 222 / 241 / 242 / 261 and 262 to protect the consumer circuit
in closed condition
Note!
For slewing gear and supplementary attachments, you can flange installation kits and other indivi-
dual components with a spool to the compact block.
7.50.6
copyright by
MJFCIFSS
Compact control block
Fig. 3 Positions of control valve block100
100 Compact control valve block 170 Cone / load-holding valve

102 Pressure balance: minimum flow 171 Pressure spring / load-holding valve
103 Remaining-flow pressure balance 172 Screw plug
110 End plate 220 Spool / lifting
111 Allen head screw 221 Spring plate
120 Control axle / slewing gear 222 Secondary pressure-relief valve
130 O-ring 223 Pressure spring
131 Spring plate 224 Pressure balance, pilot-controlled
132 Regulation spring 225 Screw plug
134 Control lid 227 Restrictor check valve
135 Allen head screw 240 Spool / stick
140 Screw plug 242 Secondary pressure-relief valve
160 Spool / chassis 244 Pressure balance, pilot-controlled
164 Piston / pressure balance, directly control- 260 Spool / bucket
led
165 Spring / pressure balance 262 Secondary pressure-relief valve
166 O-ring 264 Pressure balance, pilot-controlled
167 Restrictor check valve 280 Spool / support
168 Screw plug 284 Piston / pressure balance, directly control-
led
169 Screw plug 999 Seal kit
7.50.7
copyright by
MJFCIFSS
Functional description (condensed)
4 Functional description (condensed)
4.1 Neutral position

All spools 160 / 220 / 240 / 260 and 280 are maintained in a neutral position by means of regulating
and return springs 132. The connection between pump connection and consumer is closed. The con-
nection between consumer and tank is closed.
Pressure balances 164 / 224 / 244 / 264 and 284 are in a neutral position (connections are closed).
Pressure balance / remaining flow 103 is open. The pre-set flushing volumes go from variable dis-
placement pump via 103 on to the tank.
4.2 Working position
4.2.1 Working position of a spool

Connection between sections P and P opens, oil flows.
Pressure balances 224 thru 284 are pressurised and opened completely.
When the spool is in its working position, oil flows via the pressure balances on to the flow regulator.
The pressure in the pump is increased and exceeds the load-holding function. The consumer recei-
ves oil.
Pressure balance 103 closes. That means, the flow from the pump is now available to the consumer.
4.2.2 Working positions of several spools, siehe Fig. 4

Connection between sections P and P opens, oil flows.
Pressure balances 224 thru 284 are pressurised and shifted in the direction of the spring side (with
respect to the LS pressure). That means, the consumer with the highest load pressure determines
the LS pressure. That means, pressure balances 224 thru 284 of each spool always switch to the
same pressure difference ( - p) at different load pressures.
Pivoting of the pump is effected according to the oil requirements of the various consumers.
Oil flows via the control edge of the respective pressure balance and load-holding valves 170 - 172
to section PA or PB, to consumer connection A 1- 5 or B 1- 5, and to the consumer.
Remaining flow pressure balance 103 closes. The flow from the pump is now available to the consu-
mer.
The decisive advantage 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.
7.50.8
copyright by
MJFCIFSS
Fig. 4 Sectional drawing: control axles
100 Compact control block 241 Secondary pressure-relief valve

134 Control lid 242 Pressure relief valve / stick
140 Screw plug (only bucket shaft) 244 Pressure balance, pilot-controlled
160 Spool / travel / support 247 Restrictor check valve
161 Suction valve, forward 260 Spool / bucket
162 Suction valve - reverse 261 Secondary pressure-relief valve
164 Pressure balance, directly controlled 262 Pressure relief valve / bucket
167 Restrictor check valve 264 Pressure balance, pilot-controlled
170 Cone 280 Spool / support
171 Pressure spring 281 Dummy cartridge (only support)
172 Cone 284 Pressure balance, directly controlled
220 Spool / lifting a1-a5 Control pressure connection, bottom
221 Secondary pressure-relief valve b1-b5 Control pressure connections, top
222 Secondary pressure-relief valve / lifting A1-A5 Control pressure connection, bottom
224 Pressure balance, pilot-controlled B1-B5 Control pressure connections, top
227 Restrictor check valve
240 Spool / stick Y control axle chassis / support
7.50.9
copyright by
MJFCIFSS
Input section / input element
5 Input section / input element
5.1 Description
The input element comprises the central functions of the system, like e.g. primary pressure control
(valve 105), pressure limitation for load-sensing regulation system (LS) (pressure cut-off valve 104),
remaining flow pressure balance 103, minimum flow pressure balance 102, LS central nozzle 108
and check valve 7 (radiator valve), check valve 8 (tank valve).
Fig. 5 Exploded drawing: input element
1 Cone 104 Pressure cut-off valve

2 Pressure spring 105 Primary pressure relief valve
3 Shim 107 Shuttle valve
4 O-ring 108 LS main orifice Ø 1.6 mm
5 Cone 110 End plate
7 Check valve (radiator) 210 Valve seat
8 Check valve (tank) 211 Restrictor bolt
9 Pushrod 219 Valve seat
10 O-ring 221 Spring plate
41 Screw coupling, measuring point MP 222 Pressure spring
45 Screw coupling, measuring point LS 225 Screw plug
100 Compact block 275 Screw plug
102 Pressure balance: minimum flow 276 Screw plug
103 Pressure balance: remaining flow 999 Seal kit
7.50.10
copyright by
MJFCIFSS
Fig. 6 Hydraulic schematic: Input section - control valve block
6 to oil cooler 102 Pressure balance: minimum flow

7 Check valve (3.5 bar) 103 Pressure balance: remaining flow
20 from the variable-displacement pump 104 Pressure cut-off valve
23/26 to load-sensing regulator 105 Primary pressure-relief valve
41 Measuring point MP 107 Shuttle valve
45 Measuring point LS 108 central nozzle of load-sensing regula-
tion system
100 Compact block 110 End plate
5.2 Minimum flow pressure balance / input pressure balance 102, Fig. 7
Valve 102 (which is screwed into block 100 from above) continuously allows a small amount of oil
(about 0.7 l/min.) to flow from the LS line to the tank. This allows to eliminate pressure increases in
the LS line due to impacts. Furthermore, with consumers not actuated (neutral positions of spools),
the LS line is relieved to tank via valve 102.
The 2-way flow limitation valve consists of an orifice and pressure balance with regulating piston 11.
The pressure balance keeps pressure decrease p constant - and, thus, the amount of outflowing
oil independent of the LS pressure. The value p is derived from the selected cross-section of the
orifice (spool).
The valve cannot be adjusted and needs no maintenance. 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 com-
pletely. In the event of leaks on the outside, use new set of seals (item 15 - 18).
7.50.11
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MJFCIFSS
Fig. 7 Sectional drawing: travel control axle 160
1 Cone 17 Backing ring

2 Pressure spring (7.0 bar) 18 Backing ring
3 Shim 100 Compact block
4 O-ring 102 Pressure balance: minimum flow
8 Check valve 160 Spool: travel
10 Valve insert 164 Pressure balance
11 Piston 169 Screw plug
12 Bushing (pressed in) 272 Nozzle Ø 0.6 mm
13 Stop sleeve 273 Nozzle Ø 1.2 mm
14 Pressure spring 274 Line to check valve 274
15 O-ring 278 Screw plug
16 O-ring
7.50.12
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MJFCIFSS
5.3 Remaining flow pressure balance 103, see Fig. 5 and see Fig. 9
The standby pressure will shift piston 103 via the integrated channels against the force of spring 222.
At the same time, the LS channel will be relieved to tank via valve 102. Thus will be established a
connection between pressure side P and tank side T, and the pre-set quantity of oil will flow off. The
valve (in connection with the LS pump regulator) will make sure there will be a volumetric flow rate of
Qmin at standby pressure in idle mode. That means, the resulting loss of power in this mode is rather
low.
As soon as a consumer is actuated, the load pressure of the consumer gets to the spool.
Pressure and spring force push piston 103 in a proportional ratio to the amount required and decre-
ase the outlet cross-section of the orifice in the direction of the tank.
If the min. amount of the consumer is smaller, the quantity allotted via the gauge orifice of the spool
will have priority going to the consumer, due to the lower p spool. The remaining differential quan-
tity will continue to flow off to the tank side via the controlled control edge.
As soon as the amounts called up by one or more spool(s) exceed Qmin, valve 103 will close com-
pletely and shut off the connection with the tank side.
to check the valve for dirt and/or damage. Unscrew screw plug 225. Take components 221 and 222
out of housing. Check for re-usability and good function. Replace, if necessary.
7.50.13
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MJFCIFSS
5.4 Pressure cut-off valve 104

LS-pressure cut-off valve 104 works as a pressure controller. As soon as the pre-set pressure value
is reached, it decreases the volumetric delivery of the pump to Qmin. This function has priority over
the pump's power and flow regulation systems. That means, as soon as the pressure cut-off has been
actuated, load-sensing and/or power regulation are no longer possible.
Once a consumer reaches its max. admissible operating pressure, the cut-off valve will be actuated,
and relieves the LS signal towards the LS main nozzle in the control valve block to the tank. The LS
signal, which is reported to the pump, cannot increase any further, and the pump regulates the flow
in such a way that a max. pump pressure of LS + p is built up in the pump channel.
The pressure cut-off valve is nothing else but the pressure relief valve of the LS line.
Make sure the valve is periodically checked and adjusted. Use a maintenance schedule.
Fig. 8 Pressure cut-off valve 104
1 Valve insert 11 Backing ring

5 Spring plate 13 Backing ring
7 Washer 15 O-ring
8 Lock nut 16 O-ring
10 Circlip 104 Pressure cut-off valve
7.50.14
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MJFCIFSS
5.5 LS shuttle valve 107

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, thus, power peaks of the pump are prevented in
the LS line, thanks to the interrelations of the various orifices and capacities (capacities of various
cross-sections). Peaks will be compensated thanks to the pulsating of the hose and/or the compres-
sibility of the oil volume. That way, the pump will not react aggressively and in unwanted ways to short
peaks and, thus, maintains a stable operating behaviour.
In the event of disturbances, it is possible to check valve 107 for dirt. Screw out valve insert. Pull out
double-sided cone. Check for correct function and re-usability. Replace, if necessary. Be sure to re-
install double-sided cone in the correct manner.
5.6 Primary pressure-relief valve 105 (pump safety valve)

The purpose of the primary pressure relief valve is to protect the pump against excessive pressure
in case of failure of the secondary pressure relief valve and cut-off valve. It is supposed to react only
in emergencies. Therefore, its pressure setting is significantly higher than that of the cut-off valve and
system pressure.
Functioning and design of this valve are identical with the secondary pressure relief valves of the con-
trol axles for lifting, stick and bucket.
5.7 Radiator and tank preload valves 7 / 8

The compact control block has central radiator and tank connections. The return lines are preloaded,
thanks to pressure springs 2 / 6 of the check valves. The resulting back pressure at the outlet gua-
rantees a sufficient inflow in the event of negative loads on the outside (boom down, uphill travel etc.)
and, thus, prevents cavitation.
The amounts required for backfeeding are usually available in the volumes displaced by the consu-
mer.
The priority that returning the oil has over the radiator is implemented by means of differing preloads
for the different valves, thanks to different pressure springs 2 (3.5 bar for tank preload) and 6 (7 bar
for radiator protection). With increasing volumetric flow, the resistance in the radiator line increases,
too, and the additional amount is led directly to the tank.
The valves do not require maintenance. In the event of disturbances, it is possible to check the valve
for dirt and/or damage. Remove screw plug from housing 100, complete with pressure spring 2 / 6
and cone 1 / 5. Check for good function and re-usability. Replace, if necessary. Leaks on the outside:
install new O-ring 4 / 10.
5.8 LS central nozzle 108

The LS central nozzle is meant to be a restrictor and dampener at the LS oil inlet at the input element.
When the pressure cut-off valve is actuated, this restrictor will lower p, and the cut-off valve can
lower the pump volume thanks to the regulator for the remaining flow.
7.50.15
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MJFCIFSS
Fig. 9 Sectional drawing: input element
1 Cone 211 Shuttle valve

2 Pressure spring 219 Valve seat
3 Shim 221 Spring plate
7 Check valve 225 Screw plug
100 Compact block 275 Screw plug
103 Piston / pressure balance K Connection to oil cooler
104 Pressure cut-off valve LS LS signal from the consumer with the
highest load
107 Shuttle valve P Pump pressure
108 LS central nozzle T Tank channel
210 Valve seat
7.50.16
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MJFCIFSS
Control and distribution area
6 Control and distribution area
6.1 Control axles, see Fig. 10

Each control axle has the necessary spool complete with actuation (control lid, regulating springs),
required for its respective function, a pressure balance and the corresponding connections with se-
condary protection.
6.2 Spools 160, 240, 260 and 280

The geometry of the spools and their orifices have been designed and adapted especially 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. With that in mind, the
max. volumetric flow rate to the consumer can be derived from the max. cross-section available.
In the event of disturbances, it is possible to check spools 160 thru 280 for damage and dirt etc. Re-
move upper control lid 134. Pull out corresponding spool. Check for condition, good functioning and
re-usability.
6.3 Removal of spools 160 thru 280
Caution!
Before dismantling control lines: relieve pressure from hydraulic circuit.
Lid 134 is spring-loaded.
Risk of injury
Pull spool 160 thru 280 from control valve block 100.
Dismantle control line in question.

Remove screws 135.
Remove lid 134 with O-ring 130.
Remove pressure spring 132 and spring plate 131.
6.4 Installation of spools

Important information for installation / replacement of pistons:
The various spools installed are matched to the specific requirements of their respective operati-
onal functions (lifting, stick etc.) and cannot be exchanged among each other for that reason.
If you want to remove several spools at a time, make sure they will be re-installed in their original
bores.
Usually, the bores in the control valve blocks are made for perfect fit. If this applies to all the bores
in the block, the ID tag of the block will have the end number "000". 'Perfect fit' and the zeroes are
meant to indicate that the bores have ± 0 µm tolerance. That means, spools supplied for replace-
ment usually have a tolerance range of 8 - 10 µm, and the amount of leak oil falls into normal stan-
dards.
Zero-tolerance bores are marked with steel stamping numeral 0. Replacement with spools accor-
ding to the ET spare parts catalogue is possible.
If one or several bores of the control block do not fall within zero tolerance standards, this will be
indicated on the ID tag. To find out which bore is meant, remove the top lid of the spool in question.
7.50.17
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MJFCIFSS
Find the tolerance of the bore on the front face of the control block, e.g. 10 = 10. That means, re-
placement of the spool according to the ET spare parts block will not be possible. A special spool
for that particular tolerance will have to be made.
When ordering spare spools, please be sure to give all indications from the ID tag. See also ser-
vice information no. 1-14-52 / 2000.
Be sure to install spool in the correct position.
Choose matching spool and grease lightly.
Insert into control valve block 100 with great care.
Place spring plate131 and pressure spring132 on spool.
Place lid 134 complete with O-ring 130 on spool 100. Screw down screws 135.
Fig. 10 Control axles on control valve block 100
100 Compact control valve block 167 Restrictor check valve

130 O-ring 220 Spool / lifting
131 Spring plate 227 Restrictor check valve
132 Regulation spring 240 Spool / stick
135 Allen head screw 260 Spool / bucket
140 Screw plug 280 Spool / support
160 Spool / chassis 999 O-ring
7.50.18
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MJFCIFSS
Control lid 134
7 Control lid 134
Fig. 11 Control lid 134
1 Cap nut 140 Screw plug

2 O-ring 167 Restrictor check valve (travel)
3 Lock nut 227 Restrictor check valve (lifting)
4 Adjusting screw / stroke limitation 247 Restrictor check valve (stick)
134 Control lid Y Setting value of stroke limitation
Control lid 134 sits on both sides of spools 120 thru 280, and is fixed to compact block 100. The con-
trol oil required for actuating the spool comes through control connection a / b of control lid 134.
Some of the control axles have a shuttle dampening function (restrictor check valve 167 / 227 / 247)
in the inlet area of the control connection. This effects a certain degree of throttling of the oil displaced
by the spool in the opposite control lid and, thus, a reduction of the shifting speed of the spool. This
effects a smooth start of the motion of the consumer and, thus, a good handling and fine-control.
The dampening of the respective consumer movement (A) is effected by means of restrictor check
valve 167 / 227 / 247 in the opposite control lid (B). Oil enters into the control lid (e.g. at connection
a) through the valve seat, which is opening. The oil displaced by the spool (e.g. via connection b)
closes the valve seat so that the control oil displaced must go through the orifice of the valve. The
cross section of the orifice (and thus the shifting speed) has been matched to the characteristics of
each individual consumer. Thanks to the throttling in the outlet towards T, the dampening effect works
with abrupt actuation as well as for abrupt relief.
In addition, the control lid is equipped with a stroke limitation 4 for the spool. Like that, the max. speed
of the consumer can be limited.
The setting has been pre-set by the supplier / manufacturer. Do not tamper. Adjusting screws 4 are
secured by means of locknut 3. Cap nut 1 protects them against damage.
Checking setting value Y works for rough adjustment only. A precise setting of absolute max. quan-
tities going to consumers is possible only using a flow meter on the outlet of the control block.
7.50.19
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MJFCIFSS
Control lid 134
Flushing grooves a of spools 160 thru 280 make a connection between the tank and control lid 134.
Together with the tank preload of the control valve block, this means a continuous flow of oil as long
as the pilot control valve is not actuated. That means, the flushing volume is available for preheating
the control oil circuit.
Fig. 12 Sectional drawing: control lid134
1 Cap nut 167 Restrictor check valve

2 O-ring 220 Spool / lifting
3 Lock nut 227 Restrictor check valve
4 Adjusting screw / stroke limitation 240 Spool / stick
5 Shuttle 247 Restrictor check valve
6 Orifice 260 Spool / bucket
100 Control valve block 280 Spool / support
131 Spring plate a Flushing grooves
132 Regulation spring a1-a5 Control pressure connection, bottom
134 Control lid b1-b5 Control pressure connections, top
160 Spool / chassis
7.50.20
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MJFCIFSS
Directly controlled pressure balance 164 / 284
8 Directly controlled pressure balance 164 / 284
see Fig. 4
On-demand flows are controlled by means of the cross-section of the opening of the respective spool
shaft and the LS pressure at the pump regulator.
Responsible for that are the pressure balances connected to each spool shaft and sitting in the con-
trol block.
LUDV pressure balance 164 / 284 with pressure spring 165 of each section is situated downstream
of the gauge orifice of the spool.
This pressure balance reports to the pump regulator the pressure of the consumer with the highest
load. For all consumers with lower loads, the pressure balance compensates for the LS pressure with
the prevailing load pressure of the consumer in point.
In the neutral position of the spool, the connection between pump and channel p is blocked by the
spool (siehe Fig. 14). In this position, the pressure in channel p and behind the load-holding valves
is dissipated nearly to tank level, thanks to the movement of the piston. The consumer connections
are blocked by the spool in the housing. That means, the consumer sits between two oil columns and
is fixed.
Fig. 13 Pressure balance 164 / 284
164 Pressure balance 167 Screw plug

165 Pressure spring 284 Pressure balance
166 O-ring
7.50.21
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MJFCIFSS
8.1 High pressure

As soon as the spool is shifted, the supply orifice of the spool opens the connection between pump
connection p and the channel p. The resulting pressure in this space will shift the pressure balance.
Via the internal channels in the pressure balance, it also acts on the back side of the load-holding
valves.
Consumer pressure pc of connection A acts via the channels in the spool and is available at the front
side of the left-hand load-holding valve. With pump pressure p rising above consumer pressure pc,
the load-holding valve will open. The connection between pump and consumer has been established,
now, and initiates the movement. The displaced oil will flow back to the tank via the outlet orifice. The
secondary pressure relief valves remain closed as long as the pressure in the consumer connection
remains below the pre-set pressure value.
Fig. 14 Pressure balance in high-pressure position
pc high = LS signal to pump regulator
8.2 Consumer with highest load is actuated

For individual movements, or when the load pressure of the consumer pc is the highest in the system,
the LS pressure will be generated from the spring space of the corresponding pressure balance. Tap-
ping pressure at this point guarantees that only the highest load pressure will be reported. The pres-
sure balances of the other sections will block off effects generated by other consumers.
This LS signal will be reported to the flow regulator (LS regulator) of the variable displacement pump,
and also to the spring chambers of the other LUDV pressure balances. The pressure balance is fully
open. Channel p is connected to consumer connection pc, without pressure drop.
Feeding the LS signal of the load-holding valves guarantees that the consumer connection is blocked
until the necessary operating pressure is reached, and prevents sudden drops in the event of nega-
tive (pulling) loads.
7.50.22
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MJFCIFSS
8.3 Low pressure
8.3.1 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 opening
cross-section of the gauge orifice (spool).
When several movements overlap, the load pressure of the consumer with the highest pressure acts
via the central LS line in the spring chambers of the other LUDV pressure balances. The resulting
pressure in channel p of this section is derived from the highest reported LS pressure (p = LS +
spring force). The LUDV pressure balances automatically regulate pressure p of the various shafts
by limiting the flow cross-section to the consumer channel to the same value. The p at the gauge
orifice is identical. That means, the speed of the consumer is independent of the difference of the load
pressures. As the pressure balance is under the influence of the load signal with the highest load on
the spring side, it cannot open completely. By mediation of the pressure balance, which is only partly
open at this time, there will be yet another pressure difference which depends on the individual load.
Fig. 15 Pressure balance in low-pressure position
d = LS = pc high
e = pc low
F = spring chamber
R = regulating orifice
8.3.2 LUDV function

The LUDV system works even in case of a saturation deficit. In such a case, the oil volume called up
via the sum of the open gauge-orifice cross-sections at the existing p will exceed the max. 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 pivoting the variable displacement pump even
further. The p set at the regulator will collapse.
In this condition, the LUDV system will maintain the p at the same level across all the open gauge
orifices. That means, the consumer(s) with the highest pressure will not just shut down in the event
of a saturation deficit. Instead, the speeds of all the consumers actuated will go down in a proportional
relation to the open cross-sections.
7.50.23
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MJFCIFSS
When all the pressure balances are in balance -

- the LS system pressure in all the spring chambers of the pressure balances will be the same
- the p in front of the gauge orifices of the section with the lower load will correspond to the LS
pressure of the consumer with the highest load
p inlet orifice = ppump - p
The p at the inlet orifices of all consumers is always equal. In the event of a saturation deficit, the
p will go down, but, again, all consumers to the same degree.
The pressure differences p inlet orifices between p and each individual consumer pressure pc will
be regulated and levelled automatically by adapting the opening cross-section, so that the volumetric
flows are split proportionally.
8.3.3 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. 16 Pressure balance closed in slide position
a no LS signal 164 Piston

b LS signal 280 Spool / support
100 Control valve block 284 Piston
160 Spool / travel
7.50.24
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MJFCIFSS
Pilot-controlled pressure balances 224 / 244 and 264
9 Pilot-controlled pressure balances 224 / 244 and 264
Pilot-controlled pressure balances 224 / 244 and 264 do the same job in the LUDV system as the
directly controlled pressure balances 164 and 284. For that reason, the functioning of the pilot-cont-
rolled ones is just like the basic function of the directly controlled pressure balances.
Additional features of pressure balances 224 / 244 and 264:

Finer and more precise regulation behaviour thanks to the pilot control pistons 1 with pressure
spring 2 in the pressure balance.
Those pilot control pistons with their very fast reaction times take over the blocking and opening func-
tions with respect to the pressure signal between the consumers with the highest and the lower pres-
sures.
Fig. 17 Pressure balance, pilot-controlled
1 Pilot control piston 166 O-ring

2 Pressure spring 168 Screw plug
3 Spring plate 224 Pressure balance (pilot-controlled)
4 Spring plate 244 Pressure balance (pilot-controlled)
165 Pressure spring 264 Pressure balance (pilot-controlled)
7.50.25
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MJFCIFSS
9.0.1 Low pressure section:

Pilot control piston 1 is in its starting position, i.e. it connects the current LS pressure of the consumer
with the highest pressure to the spring side of the pressure balance. Like that, the pressure balance
regulates the pump pressure of the consumers with the lower pressure and brings them to the LS
pressure of the consumer.
Fig. 18 Pressure balance low-pressure position (LS signal from consumer with highest pressure)
1 Pilot control piston 264 Pressure balance

2 Pressure spring F Spring chamber
100 Control valve block R Regulating orifice
224 Pressure balance pch High pressure (LS)
240 Spool pcl Low pressure
244 Pressure balance
7.50.26
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MJFCIFSS
9.0.2 High pressure section:

Pilot control piston 1 is shifted against pressure spring 2. That means, the spring side of the main
piston is relieved. At the same time, the consumer with the highest load is connected to the LS pres-
sure. This, again, acts on the LS regulator of the working pump.
Fig. 19 Pressure balance in high-pressure position (pc high = LS signal to pump regulator)
Fig. 20 Pressure balance closed in slide position
7.50.27
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MJFCIFSS
Pressure and feeder valves
10 Pressure and feeder valves
Pilot-controlled pressure relief valves 105 / 221 - 262 of the various consumer connections are all of
the cartridge type and screwed directly into control valve block 100. They limit the pressure between
pump, control block and working attachments and/or between working attachments and control block
when the spools are closed (secondary function).
If the pressure increases in the circuit of an attachment in undesirable ways, destruction would hit the
weakest point, e.g. screwed connections or hydraulic hoses. In order to prevent that, we provide a
sort of pre-determined breaking point. In our scenario, the pressure rising in the hydraulic system acts
on a certain type of integrated hydraulic device. We call this a pressure relief valve. It limits the max.
pressure in the consumer and its connection with the pre-set value.
Because the pressure valves in this hydraulic system must handle great flows of oil, we use indirect
(pilot-controlled) pressure relief valves for reasons of manufacture and better functioning. With these
valves, we use a relief valve that works directly as a pilot control valve to actuate a second, larger
valve.
At the same time, the pressure relief valves act as feeder valves. Different flow rates of oil coming in
and going out of the operating cylinders will lead to a vacuum. This happens, for instance, when you
deal with pulling loads on the outside, e.g. 'extend stick cylinder' with particularly long sticks. In such
a case, the speed of the consumer will not be controlled by means of quantities determined by the
gauge orifice, but (independently of loads) via the outlet edge of the spool.
In order to prevent that, the valves connect the return side with the corresponding low-pressure side
so that additional oil can be sucked in.
10.1.1 Pressure control

The pressure (P) applied in the circuit of the consumer acts on the front face of main cone 3 and, at
the same time, on its back side as well, via bore D1. The pressure also acts on pilot control cone 4.
Springs 8 / 9 and 5 press main cone 3 and pilot control cone 4 into their closing positions (static con-
dition).
and adjusting spring 5, pilot control cone 4 is lifted from its seat, and some oil can penetrate into the
return channel.
Due to the different cross-sections of bores D1 in main cone 3 and D2 in valve insert 2, there will be
a pressure difference between the front and back sides of main cone 3.
10.1.2 Feed
As soon as there is a vacuum in one of the working circuits, the higher pressure in the hydraulic tank
will act via bore T in housing 1 against the ring face of main cone 3. Thanks to that pressure diffe-
rence, main cone 3 will be lifted from its seat (due to its active face) against the force of pressure
springs 8 / 9 so that the missing amount of oil can flow via bore T to the side of the consumer as re-
quired.
7.50.28
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MJFCIFSS
Fig. 21 Pressure and feeder valves 105 / 221 - 262
1 Housing 9 Pressure spring

2 Valve insert 10 Protective cover
3 Main cone 11 Piston seal
4 Pilot control cone 12 O-ring
7.50.29
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MJFCIFSS
Feeder valves 161 / 162
11 Feeder valves 161 / 162
see Fig. 22
Feeder valves (i.e. suction valves / check valves) are used with rotating consumers.
The danger of insufficient filling, i.e. cavitation in oil motors is greatest when there are delays in the
operation of the machine (downhill travel). When decelerating, the oil motor of the chassis runs idle.
that means, the pressure peaks due to the high moment of inertia during downhill travel make the
brake valves react while the spools are blocked.
What is more, at 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
downhill force.
The feeder valve makes the required amount of oil available to the operating connection to avoid ca-
vitation.
11.1.1 Closing position:

The current high pressure arrives from channel P via bore D at the spring side of main cone 3 and
shifts it against the sealing lip at valve insert 1, i.e. valve 161 / 162 is closed off towards the consumer
side.
11.1.2 Suction:
If there is a vacuum in this working circuit, the higher pressure in the hydraulic tank will act via bore
T of valve insert 1 on the ring face of main cone 3.
Due to the pressure difference, main cone 3 will be lifted from its seat (due to its active face) against
the force of pressure springs 8 so that the missing amount of oil can flow via bore T to the side of the
consumer A2 / B2 as required
7.50.30
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MJFCIFSS
Feeder valves 161 / 162
Fig. 22 Feeder valve 161 / 162
1 Valve insert 33 O-ring

3 Main cone 34 Backing ring
6 Screw 35 O-ring
31 Piston seal
7.50.31
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MJFCIFSS
Repair works on control valve block
12 Repair works on control valve block
Caution!
Before you begin any repair works on the control valve block, be sure to relieve tank and servo pre-
loads.
Switch off diesel engine.
Proceed as follows: Unscrew breather filter on hydraulic tank about 1 turn (slow de-pressurisa-
tion).
Remove backpressures
Turn ignition key on position.
Actuate all pilot control valves in all possible directions.
12.1 Leaks on the outside

Leaks on control valve block: Replace seals on screwed connections, SAE flanges, caps and valves.
12.1.1 Spools
Unscrew control line in question.
Remove Allen head screws 135. Remove control lid 134.
Remove pressure spring 132 with spring plate 131. Pull spool in question out of housing.
Note!
If you want to remove several spools at a time, be sure you put them back into the correct bores
afterwards (markings, etc.).
Spare spools have the spool's axis marking A1 - A5 engraved on the front side vis-à-vis the spring
and on the shaft of the spring plate package.
Before you install the spool: check for good condition of housing O-rings (spool lid seals). Check
for correct condition of spools (no scores on surface).
Install in reverse sequence. Insert spools precisely and with care. Avoid jamming. Do not use
force.
12.1.2 Pressure balances and valves

To repair pressure balances and valves, take out of housing completely.
To access load-holding valves 170 - 172, remove suction valves 161 / 162 and secondary pressure
relief valves 221 - 262.
When installing valves: check outside seal rings for good condition.
Avoid damage, twisting and warping. Fit seals tightly.
Use correct torques for tightening additional shafts, valves and screwed connections.
7.50.32
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MJFCIFSS
Maintenance
12.1.3 Torque values for control valve block 100

Pressure balance 102 120 Nm Check valve 233/234 10 Nm
Pressure cut-off valve 104 25 Nm Nozzle 271 6.5 Nm
Pressure relief valve 105 120 Nm Check valve 274 3.5 Nm
Nozzle 108 8 Nm Plug 275 30 Nm
Allen head screw 111 70 Nm Plug 276 60 Nm
Allen head screw 135 10.5 Nm Plug 278 10 Nm
Plug 140 20 Nm Allen head screw 320 70 Nm
Restrictor check valve 167/227/247/267 20 Nm Allen head screw 335 10.5 Nm
Plug 168/169 200 Nm Valve 341 20 Nm
Load-holding valve 172 150 Nm Plug 369 90 Nm
Suction valves 161/162 120 Nm Plug 373 120 Nm
Pressure relief valves 182 120 Nm Plug 475 30 Nm
Valve seat 210/219 15 Nm Plug 476 60 Nm
Pressure relief valves 221 - 262 120 Nm Plug 490 3.5 Nm
Plug 225 60 Nm Plug 811 55 Nm
Information for installation:

The contact surface must be absolutely even.
Mounting bolts must be tightened evenly, in a cross-wise pattern.
Contact faces of SAE connections must be clean.
Pipes and hose lines must be properly laid, without any twists, warps, tensions etc.
group 1.20
13 Maintenance
Periodically check control valve block for leaks. Periodically check pressure cut-off valve 104 and se-
condary pressure relief valves 221 - 262. Use pertinent maintenance regulations. Check for correct
adjustment. For checking secondary pressure relief valves 182. Increase set value of pressure cut-
off valve 104 above the value of expected peak. (See adjustment protocol and guideline for hydraulic
system, group 6).
7.50.33
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MJFCIFSS
Additional control axles
14 Additional control axles
14.1 Slewing gear element, see Fig. 24

Classification 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
ConnectionDRDA for pressure line leading to TC valve 125, see group 7.80
Spool 120 for working movements of uppercarriage, turn left and right
Input pressure balance 122 for priority circuit
Check valve 123 prevents any effects on the slewing gear from any consumers actuated at the
same time that might be under higher pressure.
Control lid 334 of the axle with stroke limitation of spool 120, control pressure connections a01
and b01 and regulating and return spring 335
Restrictor check valves 127 for fine-control of spool 120
14.2 Repair works on control valve block
Leaks on the outside

Replace seal rings of flanges, lids and valves. Replace screw plugs, when no longer tight.
Spools
Remove Allen head screws 335.
Remove control lid 334. (Careful: lid 334 is spring-loaded.)
Remove pressure spring 332. Pull spool 120 from the housing.
Install in reverse sequence.
Valves
To repair valves: Take out of housing completely. If necessary, exchange against spares as listed in
ET spare parts catalogue.
Fig. 23 Hydraulic schematic: Slewing-gear element 120 with TC valve 125
7.50.34
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MJFCIFSS
Fig. 24 Slewing-gear segment
100 Compact control block 332 Pressure spring

120 Spool / slewing-gear segment 333 Washer
122 Input measure balance 334 Control lid
123 Check valve 335 Allen head screw
125 TC valve 365 Pressure spring
126 Restrictor Ø 1.5 mm 369 Screw plug
127 Restrictor check valve 371 Pressure spring
128 Shuttle valve 372 O-ring
130 Nozzle Ø 0.9 mm 475 Screw plug
131 Nozzle Ø 1.5 mm 810 End plate
132 Cone 811 Allen head screw
330 O-ring 999 Seal kit
331 Spring plate
7.50.35
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MJFCIFSS
14.3 Functional description of slewing gear spool
14.3.1 Priority of slewing gear

In the one-circuit LUDV system, all consumers are arranged in parallel and supplied by one and the
same working pump. In the LUDV system, it is the slewing gear that has always priority. It can be
controlled independently of all the other consumers.
The question of priorities arises whenever the system must work with a deficit in saturation and the
LUDV system automatically influences the speed of movements with respect to the degree of the ac-
tual saturation deficit.
Putting a priority on the slewing gear turned out to be necessary because most operators do not like
the speed being automatically influenced by other movements. What is more, any automatic accele-
ration due to the LUDV principle is considered as unacceptable.
With those requirements in mind, we put the priority on the slewing gear whenever several move-
ments must be carried out simultaneously. It works like this:
The module is the only consumer in the system that works with a 2-way pressure balance in the sup-
ply flow leading to the gauge orifice. The pressure balance for the section, in front of the gauge orifice,
compares load pressure LS slewing gear and the setting o the spring of the pressure balance to pres-
sure p that it obtains from the gauge orifice. The p gauge orifice is maintained at a constant level
(corresponding to the type of spring used) and, thus, allows a speed control that is independent of
the load pressure The only way to modify quantity or speed is a change at the gauge orifice.
14.3.2 Attachment section is consumer with highest load pressure

Thanks to the check valve in the LS line between module and system, it is not possible that the control
of the slewing gear is influenced by consumers with higher loads that happen to run at the same time.
The difference between pump pressure psystem and operating pressure p of the slewing gear ele-
ment 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 case of high differences between psystem and p and increases /
pens with decreasing pressure differences.
The quantities supplied by the pump and not called up by the slewing gear within the performance
regulation will be distributed proportionally to the other active consumers according to the LUDV prin-
ciple.
14.3.3 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. It acts on the back side of the LUDV pressure balances and the
p regulator of the variable displacement pump. The quantities supplied by the pump and not called
up by the slewing gear within the performance regulation will be distributed to the other active con-
sumers according to the LUDV principle.
14.3.4 Slewing gear torque control

For a sensitive acceleration of the slewing gear, we need a torque control (pressure control) in order
to influence the value of the acceleration.
During acceleration from zero, the slewing gear will call up only a small amount of oil. Nevertheless,
in a pure LS control, it will generate the max. load pressure in the slewing gear and, thus, the max.
rotary acceleration. For that reason, the one speed that is independent of the load pressure (via 2-
way supply pressure balance 360) will be overridden by a torque control.
125
7.50.36
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MJFCIFSS
14.3.5 Loss-free acceleration

Torque control valve 125 sits separately on the hydraulic tank. It is integrated into the LS line of the
module of the pressure balance. That way, the slewing gear obtains the quantity necessary to build
up the required operating pressure. This is because the preceding pressure balance (with the pre-
selected pslewing gear attained) steps down regulation and supplies only the amount necessary to
maintain the pressure. Thanks to that combination, the acceleration of the slewing gear works without
any losses. Furthermore, the max. admissible acceleration pressure at torque control valve 125 is
about 30 bar below the topmost setting of the 2-step slewing-gear valves in the oil motor. That
means, the secondary valves will not respond, and the corresponding losses will be avoided. Thanks
to the torque control, the quantities supplied to the slewing gear motor will go up when pslewing gear
drops until the required pressure according to the pre-set p pressure spring has been attained via the
gauge orifice.
14.3.6 Deceleration of the slewing gear

Deceleration of the slewing gear is effected via the outlet orifices of the spool leading to the tank, and
the pressure relief valves leading to the motor. Min. deceleration is derived from 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 a smooth deceleration. Again, the rule applies: More pcontrol pressure increases the addi-
tional pressure level of the secondary cartridge continuously all the way up to the max. admissible
value.
Both values can be adjusted independently by controlling the admissible acceleration pressure via
the torque control valve and the deceleration via the brake valves on the motor.
In the neutral position of the spool, the slewing gear is hydraulically fixed by means of the locked con-
sumer connections A and B.
Valve 125 has a fixed setting. Should modifications become necessary, proceed according to adjus-
tment 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.
7.50.37
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MJFCIFSS
Fig. 25 Sectional drawing: slewing-gear element
120 Spool / slewing-gear segment 372 O-ring

122 Input measure balance 373 Screw plug
127 Restrictor check valve 475 Screw plug
130 Nozzle Ø 0.9 mm D1
131 Nozzle Ø 1.5 mm D2 Outlet orifice A01 - T and/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
7.50.38
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MJFCIFSS
LSC additional control axles
15 LSC additional control axles
M7 - 205 M7 - 205
M7 - 205
Secondary valve Secondary valve
Description SX/14-1X 2 axles
without additional with additional
Unit (AHS 1 + AHS 11)
pressure level pressure level
Contained in: AS1 AHS 1 AHS11 AHS 12

Spool 540 500 510 520
for grapple rotator Kit AHS 1 Kit AHS 11 Kit AHS 12
left right Exten- Retrac- Exten- Retrac- Exten- Retrac-
ding ting ding ting ding ting
Nominal width: () 14 20 20 20
block (G3/4) (SAE §/4) (SAE 3/4) (SAE 3/4)
Consumer connec-
tion
Ø piston rod mm 18 25 25 25
Piston stroke mm 8 8 11 11 11 11 11 11
Setting value Y
A 900 C mm 15.6 15.6 14.2 14.2 14.2 14.2 14.2 14.2#
A 904 C mm 15.6 15.6 14.2 14.2 14.2 14.2 14.2 14.2#
p1 ± 0.5 bar 2.0 2.0 7.0 7.0 7.0 7.0 7.0 7.0
p2 ± 0.5 bar 23.4 23.4 20.6 20.6 20.6 20.6 20.6 20.6
Qn (A)/Qn(B)
A 900 C l/min 30 30 200 140 200 200* 200 200*
A 904 C l/min 30 30 200 140 200 200* 200 200*
Restrictor check
valves mm 1.0 1.0 1.0
At connection a mm 1.0 1.0 1.0
At connection b
Leak oil max. cm3/min 60 60 60
at load pressure bar 150 150 150
at oil temperature °C 50 50 50
Tab. 2 List: LSC additional control axles
* = when connected to lateral boom adjustment, be sure to reduce flow on both sides. Proceed as follows: To adjust, turn
stop screw to Y = 15 mm (top) and Y = 12 mm (bottom).
# = when connecting to regulating cylinder / hydraulic boom adjustment, reduce flow to piston rod side to 140 l/min. Pro-
ceed as follows: Turn stop screw 270 degrees = 0.7 mm. Measure Y will be reduced to 13.5 mm.
Magnet Y22 / Y23 12 Nm Allen head screws 122 110 Nm at AHS 12

Pressure relief valve 541 / 542 90 Nm Allen head screws 811 55 Nm at AS1
Seal Lock collar nut 1.70 38 Nm Pressure balance 544 160 Nm
Allen head screw 20 10 Nm Pressure relief valve 502 120 Nm
screw plug 29 100 Nm Pressure relief valve 501 120 Nm
Allen head screws 122 70 Nm Restrictor check 112 20 Nm
valve
Qn (A) / Qn (B) = nominal flow rate at outlet A / B at p = nominal value

p1 = control pressure at begin of regulation
p2 = control pressure in final position
7.50.39
copyright by
MJFCIFSS
Kit elements for additional control axles
16 Kit elements for additional control axles
16.1 grapple turn element (kit AS1)

Flange additional element AS1 as a kit to the control valve block next to the slewing gear element.
That way, working movements 'turn grapple' and 'tilt bucket' receive oil from the main working pump,
too.
16.2 Kit elements (kits AHS 1, AHS 11 and AHS 12)

For additional functions, e.g. accessory kits AHS1, AHS11 and AHS 12, more additional axles can
be flanged to the left-hand side of the compact control block.
16.3 Additional control block for accessory kits AS1, AHS 11 and AHS 12
To control yet another working movement, you can mount an additional 1x additional element to com-
pact block 100.
Each control axle (additional control block) has the necessary spool complete with actuation (control
lid, regulating springs), required for its respective function, a pressure balance and the corresponding
connections with secondary protection. It has an hydraulic connection to series block 100 via the
pressure, return and LS channels. O-rings seal off the flange faces of the channels.
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 generated by modifying
the cross-section of the gauge orifice and via the stroke of the spool. With that in mind, the max. vo-
lumetric flow rate to the consumer can be derived from the max. cross-section available.
To retrofit one or several additional axles, proceed as follows: Remove end plate 110 / 810. Mount
new axle between block 100 and plate 110 / 810.
7.50.40
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MJFCIFSS
Fig. 26 Additional control axles AS1, AHS 1, AHS 11 and AHS 12
7.50.41
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MJFCIFSS
Fig. 27 Additional control axle AS1
41 Measuring point MP 512 Secondary relief valve retract cylinder

45 Measuring point LS 514 Pressure balance
100 Compact control block 517 Restrictor check valve
104 Pressure cut-off valve 520 Accessory kit AHS 12 consists of
Auxiliary axles AHS 1 and AHS 11
500 Spool / regulating cylinder 540 Spool / AS 1
501 Secondary relief valve 541 Secondary pressure-relief valve
502 Secondary relief valve - extend cylinder 542 Secondary pressure-relief valve
504 Pressure balance 544 Pressure balance
507 Restrictor check valve Y22 Solenoid valve / grapple rotation left
510 Spool / hydraulic hammer etc. Y23 Solenoid valve / grapple rotation right
511 Secondary relief valve - extend cylinder,
2-step
7.50.42
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MJFCIFSS
Fig. 28 Additional control axles for AHS 1, AHS 11 and AHS 12
7.50.43
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MJFCIFSS
16.4 Additional control valve block for accessory kit AS 1

The individual segment for the working movement 'grapple turn drive' is equipped with a magnetic-
hydraulic actuation for the spool. That means, the proportional actuation of the piston has been de-
signed not in the same way as with the other two auxiliary axles, but as a so-called "on-off control".
The control pressure at connection a / b will be lead to the spring space of spool 540 only after actu-
ation of the pre-designated solenoid Y22 / Y23. That way, the spool completely cuts through. Pres-
sure balance 544 fulfils the same purpose as the other pressure balances in compact block 100.
Adjust stroke limitation of the spool according to indications in group 16.40.
Functionality and adjustment of the secondary protection correspond to group 16.40.
Fig. 29 Auxiliary axle at 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 Mounting 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 / additional control block AS1
7.50.44
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MJFCIFSS
Sectional drawing
17 Sectional drawing
7.50.45
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MJFCIFSS
Sectional drawing
17.1 Additional control valve block for accessory kit AHS 1

The individual segment for the working movement 'hydraulic adjustment of boom' etc. corresponds
to the design and construction of the lifting, stick and bucket axles of the compact block.
Description of functioning and adjustment: see group 16.43.

The individual segment for the working movement 'hydraulic hammer' corresponds to the design and
construction of the lifting, stick and bucket axles of the compact block. Only the function 'actuate hy-
draulic hammer' has a 2-step secondary pressure relief valve.
Additional control valve block for accessory kit AHS 23 siehe Fig. 31 andFig. 32.

The individual segment for the working movement 'hydraulic adjustment of boom hydraulic hammer
/ hydraulic adjustment of boom telescopic demolition stick / scrap shear / concrete crusher / sorting
grapple' etc. corresponds to the design and construction of the lifting, stick and bucket axles of the
compact block.
Only the function 'actuate hydraulic hammer' has a 2-step secondary pressure relief valve.
15 Control lid 122 Allen head screw*

20 Allen head screw 500 Spool / segment AS 1
27 Cone 501 Pressure and feeder valve, 1-step
28 Pressure spring 502 Pressure and feeder valve, 1-step
34 O-ring 507 Restrictor check valve
70 O-ring 510 Spool / segment AS 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 999 Seal kit
110 End plate
* various lengths (depend on the number of additional elements)
7.50.46
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MJFCIFSS
Sectional drawing
Fig. 31 Auxiliary axles AHS 1, AHS 11 and AHS 12
7.50.47
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MJFCIFSS
Sectional drawing
Fig. 32 Additional control shafts, left = AHS 1 / 11, right = AHS 12
7.50.48
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MJFCIFSS
Pressure and feeder valves 511 (2-step at AHS 11)
18 Pressure and feeder valves 511 (2-step at AHS 11)
Pilot-controlled pressure relief valve 511 of the consumer connection is of the cartridge type and in-
serted directly into control valve block 100. The valve has an additional hydraulic pressure level and
can be, therefore, used for two different pressure ranges. It limits the pressure between pump, control
valve block and working attachment (level 1 - primary function - hammer operation) and/or between
working attachments and control block when the spool is closed (level 2 - secondary function - regu-
lating cylinder protection).
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. We call this
a pressure relief valve. It limits the max. pressure in the consumer and its connections with the pre-
set value.
Because the pressure valves in this hydraulic system must handle great flows of oil, we use indirect
(pilot-controlled) pressure relief valves for reasons of manufacture and better functioning. With these
valves, we use a relief valve that works directly as a pilot control valve to actuate a second, larger
valve.
At the same time, pressure relief valve 501 serves as a feeder valve. Different flow rates of oil coming
in and going out of the operating cylinders will lead to a vacuum. This can happen, in particular, when
pulling loads appear on the outside, e.g. extending regulating cylinder. In such a case, the speed of
the consumer will not be controlled by means of quantities determined by the gauge orifice, but (in-
dependently of loads) via the outlet edge of the spool.
Fig. 33 Pressure and feeder valve 511 (2-step)
7.50.49
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MJFCIFSS
18.1.1 Pressure control

The pressure (P) applied in the circuit of the consumer acts on the front face of main cone 5 and, at
the same time, on its back side as well, via bore D1. The pressure also acts on pilot control cone 15.
Springs 7 and 18 push main cone 5 and pilot control cone 15 into their closing positions (static con-
dition).
and adjusting spring 18, pilot control cone 15 is lifted from its seat, and some oil can penetrate into
the return channel. Due to the different cross-sections of bores D1 in bushing 6 and ring face D2 in
valve insert 2, there will be a pressure difference between the front and back sides of main cone 5.
The effect of that pressure difference is that main cone 5 will be shifted against pressure spring 7,
and a substantial amount of oil can flow off to the non-pressurised return side T.
18.1.2 Additional pressure level

Level 1 (low pressure - protection of hydraulic hammer) connection X is connected to
the tank. Pre-loading of pressure spring 18 is lower.
Level 2 (higher pressure - protection of regulating cylinder) connection X receives pilot
pressure. That way, pre-loading of pressure spring 18 via shifting piston 9 and
piston 8 will be stronger, which results in a higher blow-off pressure.
18.1.3 Feed
As soon as there is a vacuum in one of the attachment circuits, the higher pressure in the hydraulic
tank will act via bore T in housing 1 against the ring face of main cone 5. Thanks to that pressure
difference, main cone 5 will be lifted from its seat (due to its active face) against the force of pressure
spring 7 so that the missing amount of oil can flow via bore T to the side of the consumer as required.
Fig. 34 Sectional drawing: pressure and feeder valve 511
7.50.50
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MJFCIFSS
Fig. 35 Pressure and feeder valve 503
1 Housing 21 Shim
3 Adjusting screw 28 O-ring
4 Screw 30 Backing ring
6 Bushing 32 O-ring
8 Piston 34 Backing ring
9 Shifting piston 35 O-ring
11 Lock nut 999 Seal kit
15 Pilot control cone D1 Bore
18 Pressure spring D2 Ring face
7.50.51
copyright by
MJFCIFSS
Design of the control valve block
19 Design of the control valve block
7 Check valve (3.5 bar) 220 Spool / boom cylinder

8 Preload valve (7.0 bar) 221 Extend secondary relief valve
100 Compact control block 5 x 222 Retract secondary relief valve
102 Pressure balance: minimum flow 224 Pressure balance (pilot-controlled)
103 Pressure balance: remaining flow 227 Restrictor check valve
104 Pressure cut-off valve 240 Spool / stick cylinder
105 Primary pressure-relief valve 241 Retract secondary relief valve
107 Shuttle valve 242 Extend secondary relief valve
108 Restrictor (LS central nozzle) 244 Pressure balance (pilot-controlled)
110 Mounting plate 247 Restrictor check valve
111 Allen head screw 260 Spool / bucket cylinder
120 Spool / slewing gear 261 Retract secondary relief valve
122 Input pressure balance 262 Extend secondary relief valve
123 Check valve 264 Pressure balance (pilot-controlled)
127 Restrictor check valve 280 Spool / support
134 Control lid 281 Screw plug
135 Allen head screw 284 Pressure balance
140 Screw plug 334 Control lid
160 Spool / chassis 540 Additional control valve AS1
162 Suction valve - reverse 810 Mounting plate
164 Pressure balance 811 Allen head screw
7.50.52
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MJFCIFSS
7.50.53
copyright by
MJFCIFSS
7.50.54
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MJFCIFSS
Service Manual Control block LSC
Function/design
Control block LSC
1 Function/design
The control unit of the hydraulic LSC control was designed as a compact control block with LUDV
system. The control block contains five spools (working and travel functions) with the corresponding
valves.
There is an additional control block segment for the slewing gear drive and 'turn grapple' (AS1).
1.1 Classification of control valve block, see Fig. 1

Input section
Connection P for oil pump flow
Connection K for return flow to hydraulic cooler
Connection MP for pump pressure
Connections MLS and LS1 for extreme load signal from 'travel direction right', control-block side
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
Pressure balance / remaining flow 103 for a fast and direct response in the system
Pressure cut-off valve 104 as a limiting valve for the working pressure
Primary pressure-relief valve 105 to protect the system
Operating connections A1 - A5 and B1 - B5 for supply and return flows of consumers
Connection H for pilot control oil of control oil unit
Connection S for direct suction of slewing gear motor
Connection T for return oil to hydraulic tank
Preload valve 8 (7 bar) in block for return as radiator bypass valve
Minimum-flow pressure balance 102 to stabilise load pressure
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.
Spool 160 / 220 / 240 / 260 and 280 for the working movements of the chassis, boom, stick, bucket
and support
Suction valves 161 and 162 to prevent cavitation in the travel drive system
Pressure balance 164 / 224 / 224 / 264 and 284 for LS signal message re. compensation of the
individual axles
Restrictor check valves 127 / 167 / 227 and 247 for the fine control of the spools 120 / 160 / 220
and 240
Secondary pressure-relief valve 221 / 222 / 241 / 242 / 261 and 262 to protect the consumer circuit
in closed condition
Note!
For slewing gear and supplementary attachments, you can flange installation kits and other indivi-
dual components with a spool to the compact block.
7.51.1
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MJFCIFSS
Control block LSC Service Manual
Function/design
Fig. 1 Design of the control valve block
7.51.2
copyright by
MJFCIFSS
Function/design
7 Check valve (3.5 bar) 220 Spool / boom cylinder

8 Preload valve (7.0 bar) 221 Secondary pressure-relief valve / exten-
ding
100 Compact control block 5 x 222 Secondary pressure-relief valve / retrac-
ting
102 Pressure balance / minimum flow 224 Pressure balance (pilot-controlled)
104 Pressure cut-off valve 240 Spool / stick cylinder
105 Primary pressure-relief valve 241 Secondary pressure-relief valve / retrac-
ting
107 Shuttle valve 242 Secondary pressure-relief valve / exten-
ding
108 Restrictor (LS central nozzle) 244 Pressure balance (pilot-controlled)
110 Mounting plate 247 Restrictor check valve
111 Allen head screw 260 Spool / bucket cylinder
120 Spool / slewing gear 261 Secondary pressure-relief valve / retrac-
ting
122 Input pressure balance 262 Secondary pressure-relief valve / exten-
ding
123 Check valve 264* Pressure balance (directly controlled)
127 Restrictor check valve 264 Pressure balance (pilot-controlled)
134 Control lid 280 Spool / support
135 Allen head screw 281 Screw plug
140 Screw plug (bucket only) 284 Pressure balance (directly controlled)
160 Spool / chassis 334 Control lid
161 Suction valve, forward 540 Additional control valve AS1
162 Suction valve - reverse 810 Mounting plate
164 Pressure balance 811 Allen head screw
*only in model A 904 C Industrial
7.51.3
copyright by
MJFCIFSS
Function/design
Fig. 2 Hydraulic diagram of construction model
7.51.4
copyright by
MJFCIFSS
Function/design
Fig. 3 Hydraulic diagram of industrial model
7.51.5
copyright by
MJFCIFSS
Technical data
2 Technical data
A 904 C Litronic
Contained in: A 900 C Litronic A 904 C Litronic A 904 C Litronic
1003/1005
Type 1002 (construction) 1004 (HD) 1071 (industrial)
(construction)
Standard model M7-1676-30/7 M7-22 M7-1643-30/7 M7-22
Industry M7-1544-31/7 M7-22 M7-1544-31/7 M7-22
Spool Unit 220 240 260 280 160 120

Boom Stick Bucket Support Travel Slewing
cylinder cylinder cylinder cylinder motor gear
Nominal width of mm 22 22 22 22 22 20
block
Consumer connec- () 1 1 1 1 1 3/4
tion
Ø piston rod mm 25 25 25 25 25 25
Piston stroke mm 11.0 11.0 11.0 11.0 11.0 11.0 11.0 11.0 11.0 11.0 9.0 9.0
Setting value Y mm .9
A 900 C 17.0 15.5 15.8 15.8 16.0 15.7 16.0 16.0 15.5 15.5 16.0 16.0
A 904 C 17.0 15.7 15.8 15.8 17.0 16.5 16.3 16.0 15.5 15.5 15.8 15.8
p1 bar ± 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
p2 bar ± 0.5 mm bar 20.6 20.6 20.6 20.6 20.6 20.6 20.6 20.6 20.6 20.6 20.6 20.6
Qn (A)/Qn (B) l/min
A 900 C (1002) 270 120 260 210 250 150 220 140 200 200 130 130
A 904 C (1003) 300 120 260 210 250 150 130 70 200 200 130 130
A 904 C (1005) 300 120 260 210 250 150 130 70 200 200 130 130
A 904 C HD (1004) 270 90 350 250 250 150 220 140 200 200 135 135
A 904 C (1071) 270 90 350 250 250 150 220 140 200 200 135 135
Restrictor check mm
valve
at connection a 0.8 0.8 0.8 0.8
(mm) 0.8 0.8 0.8 0.8
at connection b
(mm)
Leak oil max cm3/min 60 60 60 60 60 60
at load pressure bar 150 150 150 150 150 150
at oil temperature °C 50 50 50 50 50 50
7.51.6
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MJFCIFSS
3 Input section / input element
3.1 Design
The input element contains the central system functions such as the primary pressure control (valve
105), LS pressure-relief (cut-off valve 104), residual flow pressure balance 103, minimum-flow pres-
sure balance 102 and LS central nozzle 108, as well as check valve 7 (cooler valve) and check valve
8 (tank valve).
Fig. 4 Exploded drawing: input element
7.51.7
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MJFCIFSS
100 Compact block 210 Valve seat

102 Pressure balance / minimum flow 211 Restrictor bolt
103 Pressure balance / remaining flow 219 Valve seat
104 Pressure cut-off valve 221 Spring plate
105 Primary pressure-relief valve 222 Pressure spring
107 Shuttle valve 225 Screw plug
108 LS main orifice Ø 1.6 mm 275 Screw plug
3.2 Minimum flow pressure balance / input pressure balance 102

The valve 102 (which is screwed into the block 100 from the top) allows a small amount of oil (approx.
0.7 l/min.) to flow continuously from the LS line to the tank. This allows to eliminate pressure incre-
ases in the LS line due to impacts. 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 pressure balance with regulating piston 11.
The pressure balance keeps pressure decrease p constant - and, thus, the amount of outflowing
oil independent of the LS pressure. The value p is derived from the selected cross-section of the
orifice (spool).
to check the valve for dirt and/or a broken spring: remove and dismantle; if necessary, replace com-
pletely. In the event of leaks on the outside, use new set of seals (items 15 - 18).
Fig. 5 Sectional drawing of input pressure balance
1 Cone 17 Backing ring

2 Pressure spring (7.0 bar) 18 Backing ring
3 Shim 100 Compact block
7.51.8
copyright by
MJFCIFSS
4 O-ring 102 Pressure balance / minimum flow

8 Check valve 160 Spool / travel
10 Valve insert 164 Pressure balance
12 Bushing (pressed in) 272 Nozzle Ø 0.6 mm
13 Stop sleeve 273 Nozzle Ø 1.2 mm
14 Pressure spring 274 Line to check valve 274
16 O-ring
3.3 Remaining flow pressure balance 103, see Fig. 6

During standby operation , there is a continuous flow volume Qmin amounting to about 30 - 40 l/min.
When consumers are not in operation, this generates (due to the p of the valve, and due to the
additional tank preload) a standby pressure at pump connection MP. Therefore, the system pressure
levels out at about 35 bar in this operating condition.
The standby pressure pushes the piston 103 through the integrated channels against the spring 222.
Simultaneously, the LS channel is relieved through the valve 102 to the tank. Thus is established a
connection between pressure side P and tank side T, and the pre-set quantity of oil flows off. The
valve ensures that, in the event of idle run, there is still a minimum volume flow Qmin at standby pres-
sure to the tank. That means, the resulting loss of power in this mode is rather low.
When a consumer is operated, the load pressure of the consumer acts on the piston. The pressure
and spring force shift the piston 103 in proportion to the required volume and reduces the outlet cross-
section of the orifice to the tank.
If the min. amount of the consumer is smaller, the quantity allotted via the gauge orifice of the spool
is fed with priority to the consumer, due to the lower p spool. The remaining differential quantity
continues to flow to the tank side via the controlled control edge.
As soon as the amounts requested by one or more spool(s) exceed Qmin, the valve 103 closes com-
pletely and shut off the connection to the tank side.
to check the valve for dirt and/or damage. Unscrew screw plug 225. Take components 221 and 222
out of housing. Check for re-usability and good function. Replace, if necessary.
3.4 Pressure cut-off valve 104, see Fig. 6

The LS pressure cut-off valve 104 works as a pressure controller. As soon as the pre-set pressure
value is reached, it decreases the volumetric delivery of the pump to Qmin. This function has priority
over the pump's power and flow regulation systems. That means, as soon as the pressure cut-off has
been actuated, load-sensing and/or power regulation are no longer possible.
Once a consumer reaches its max. admissible operating pressure, the cut-off valve will be actuated,
and relieves the LS signal towards the LS main nozzle in the control valve block to the tank. The LS
signal, which is reported to the pump, cannot increase any further, and the pump regulates the flow
in such a way that a max. pump pressure of LS + p is built up in the pump channel.
The pressure cut-off valve is nothing else but the pressure-relief valve of the LS line.
Make sure the valve is periodically checked and adjusted. Use a maintenance schedule.
7.51.9
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Fig. 6 Sectional drawing: input element
1 Valve insert 100 Compact block

4 Adjusting screw 103 Pressure balance / remaining flow
5 Spring plate 104 Pressure cut-off valve
6 Pressure spring 107 Shuttle valve
7 Washer 108 Restrictor (LS central nozzle)
8 Lock nut 210 Valve seat
10 Circlip 211 Restrictor bolt
11 Backing ring 219 Valve seat
12 Backing ring 221 Spring plate
13 Backing ring 222 Pressure spring
16 O-ring
7.51.10
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MJFCIFSS
3.5 Primary pressure-relief valve 105 (pump safety valve)

The purpose of the primary pressure-relief valve is to protect the pump against excessive pressure
in case of failure of the secondary pressure-relief valve and cut-off valve. It is supposed to react only
in emergencies. Therefore, its pressure setting is significantly higher than that of the cut-off valve and
system pressure and the installed secondary pressure-relief valves.
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 Pressure and feeder valves on page 29).
3.6 LS shuttle valve 107

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. Peaks are com-
pensated thanks to the pulsating of the hose and/or the compressibility of the oil volume. This pre-
vents aggressive or unwanted responses of the pump to sudden peaks, ensuring stable operating
behaviour.
In the event of disturbances, it is possible to check valve 107 for dirt. Screw out valve insert. Pull out
double-sided cone. Check for correct function and re-usability. Replace, if necessary.
3.7 Radiator and tank preload valves 7 / 8

The compact control block has central radiator and tank connections. The return lines are preloaded,
thanks to pressure springs 2 / 6 of the check valves. The resulting back pressure at the outlet gua-
rantees a sufficient inflow in the event of negative loads on the outside (boom down, uphill travel etc.)
and, thus, prevents cavitation.
The amounts required for backfeeding are usually available in the volumes displaced by the consu-
mer.
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 radiator line increases, too, and the
additional amount is fed directly to the tank.
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 / 5 from the housing 100 for inspection (con-
tamination, defect), testing and replacement. If there are leaks on the outside, replace the O-ring 4 /
10.
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Fig. 7 Radiator and tank preload valves 7 / 8
1 Cone 7 Check valve (radiator)

2 Pressure spring 8 Check valve (tank)
3 Shim 9 Shim
4 O-ring 10 O-ring
5 Cone 100 Control valve block
6 Pressure spring
4 Functional description (condensed)

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 the pump and consumer is closed. The con-
nection between consumer and tank is closed.
The pressure balances 164 / 224 / 244 / 264 and 284 are in a neutral position (connections are
closed).
Pressure balance / remaining flow 103 is open, i.e. the pre-set flushing volume is pumped from the
variable-displacement pump through 103 to the tank.
4.2 Working position of a spool, Fig. 9

The connection between sections P and P opens, oil flows.
Pressure balances 224 through 284 are pressurised and opened completely.
When the spool is in its working position, oil flows via the pressure balances on to the flow regulator.
The pressure in the pump is increased and exceeds the load-holding function. The consumer recei-
ves oil.
Pressure balance 103 closes. That means, the flow from the pump is now available to the consumer.
7.51.12
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4.2.1 Working positions of several spools, see Fig. 9

The connection between sections P andP opens, oil flows.
Pressure balances 224 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 224 to 284 of each spool always switch to the same pressure difference
( -p), even at different load pressures.
Pivoting of the pump is effected according to the oil requirements of the various consumers.
The oil is fed via the control edge of the respective pressure balance and load-holding valves 170172
to section PA or PB, to the consumer connection A1 - A5 or B1 - B5 and to the consumer.
Remaining flow pressure balance 103 closes. The flow from the pump is now available to the consu-
mer.
The decisive advantage 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.
Fig. 8 Spool 160-280
100 Control valve block 240 Spool / stick

160 Spool / travel 260 Spool / bucket
220 Spool / boom 280 Spool / support
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Fig. 9 Boom, stick and bucket cylinder sections
7.51.14
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100 Compact control block 241 Secondary pressure-relief valve

134 Control lid 242 Pressure-relief valve / stick
140 Screw plug (only bucket shaft) 244 Pressure balance, pilot-controlled
170 Cone 247 Restrictor check valve
171 Pressure spring 260 Spool / bucket
172 Cone 261 Secondary pressure-relief valve
220 Spool / boom 262 Pressure-relief valve / bucket
221 Secondary pressure-relief valve 264 Pressure balance, pilot-controlled/
direct
222 Secondary pressure-relief valve / boom a3-a5 Control pressure connections, bottom
224 Pressure balance, pilot-controlled b3-b5 Control pressure connections, top
227 Restrictor check valve A3-A5 Control pressure connections, bottom
240 Spool / stick B3-B5 Control pressure connections, top
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Fig. 10 Sectional drawing of travel/support section
7.51.16
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100 Compact control block 170 Cone

134 Control lid 171 Pressure spring
140 Screw plug (only bucket shaft) 172 Cone
160 Spool / travel / support 280 Spool / support
161 Suction valve, forward 281 Dummy cartridge (only support)
162 Suction valve - reverse 284 Pressure balance, directly controlled
164 Pressure balance, pilot-controlled a2/b2 Control pressure connections, bottom/
top
167 Restrictor check valve A2/B2 High pressure connection, bottom/top
169 Screw plug
7.51.17
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Control and distribution section
5 Control and distribution section
5.1 Control axles

Each control axle has the necessary spool complete with actuation (control lid, regulating springs),
required for its respective function, the pressure balance and the corresponding connections with se-
condary protection.
5.1.1 Spools 160, 240, 260 and 280

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.
5.1.2 Removal of spools 160 - 280
Caution!
Before dismantling the control lines, relieve pressure from hydraulic circuit.
Lid 134 is spring-loaded.
Risk of injury!
Pull the spool 160 to 280 from the control valve block 100.
Dismantle the control line in question.

Remove the screws 135.
Remove the lid 134 with the O-ring 130.
Remove the pressure spring 132 and the spring plate 131.
5.1.3 Installation of spools

Important information for installation / replacement of pistons:
The various spools installed are matched to the specific requirements of their respective operati-
onal functions (lifting, stick etc.) and cannot be exchanged among each other for that reason.
If you want to remove several spools at a time, make sure they are re-installed in their original
bores.
Usually, the bores in the control valve blocks are made for perfect fit. If this applies to all the bores
in the block, the type plate of the block contains the end number "000". 'Perfect fit' and the zeroes
are meant to indicate that the bores have ± 0 µm tolerance. That means, spools supplied for re-
placement usually have a tolerance range of 8-10 µm, and the amount of leak oil falls into normal
standards.
Zero-tolerance bores are marked with steel stamping numeral 0. Replacement with spools accor-
ding to the spare parts catalogue is possible.
If one or several bores of the control block do not fall within zero tolerance standards, this is indi-
cated on the type plate. To find out which bore is meant, remove the top lid of the spool in question.
Find the tolerance of the bore on the front face of the control block, e.g. 10 = 10. That means, re-
placement of the spool according to the spare parts catalogue is not possible. A special spool for
that particular tolerance must be made.
When ordering spare spools, please be sure to give all indications from the type plate. See also ser-
vice information no. 1-14-52 / 2000.
7.51.18
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Control and distribution section
Be sure to install spool in the correct position.

Choose matching spool and grease them lightly.
Insert it into the control valve block 100 with great care.
Place the spring plate 131 and the pressure spring 132 onto the spool.
Place the lid 134 together with the O-ring 130 onto the control block 100 and secure it with the
screws 135.
Fig. 11 Control and distribution section
100 Compact control valve block 167 Restrictor check valve

130 O-ring 220 Spool / boom
131 Spring plate 227 Restrictor check valve
132 Regulation spring 240 Spool / stick
135 Allen head screw 260 Spool / bucket
140 Screw plug 280 Spool / support
160 Spool / chassis
7.51.19
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Control lid 134
6 Control lid 134
Fig. 12 Control lid 134
1 Cap nut 140 Screw plug (bucket)

2 O-ring 167 Restrictor check valve (travel)
3 Lock nut 227 Restrictor check valve (lifting)
4 Adjusting screw / stroke limitation 247 Restrictor check valve (stick)
134 Control lid Y Setting value of stroke limitation
135 Allen head screw
The control lid 134 is located on both sides of the spools 120 to 280 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 / 227 / 247)
in the inlet area of the control connection. This effects a certain degree of throttling of the oil displaced
by the spool in the opposite control lid and, thus, a reduction of the shifting speed of the spool. This
effects a smooth start of the motion of the consumer and good handling and fine-control.
The dampening of the respective consumer movement (A) is effected by means of the restrictor
check valve 167 / 227 / 247 in the opposite control lid (B). Oil enters the control lid (e.g. at connection
a) through the valve seat, which is opening. The oil displaced by the spool (e.g. via connection b)
closes the valve seat so that the control oil displaced must go through the orifice of the valve. The
cross section of the orifice (and thus the shifting speed) has been matched to the characteristics of
each individual consumer. Thanks to the throttling in the outlet towards T, the dampening effect works
with swift actuation as well as for immediate relief.
In addition, the control lid is equipped with a stroke limitation 4 for the spool. Like that, the max. speed
of the consumer can be limited.
The setting has been pre-set by the supplier / manufacturer. Do not tamper. The adjusting screws 4
are secured with the lock nuts 3 and protected against damage by the cap nut 1.
Checking setting value Y works for rough adjustment only. Precise setting of absolute max. quantities
going to consumers is possible only using a flow meter on the outlet of the control block.
The flushing grooves a of the spools 160 to 280 form a connection between the tank and control lid
134. Together with the tank preload of the control valve block, this means a continuous flow of oil as
long as the pilot control valve is not actuated. That means that the flushing volume is available for
preheating the control oil circuit.
7.51.20
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Control lid 134
Fig. 13 Sectional drawing: control lid 134
1 Cap nut 167 Restrictor check valve

2 O-ring 220 Spool / boom
3 Lock nut 227 Restrictor check valve
4 Adjusting screw / stroke limitation 240 Spool / stick
5 Shuttle 247 Restrictor check valve
6 Orifice 260 Spool / bucket
100 Control valve block 280 Spool / closing cylinder
131 Spring plate a Flushing grooves
132 Regulation spring a1-a5 Control pressure connection, bottom
134 Control lid b1-b5 Control pressure connections, top
160 Spool / chassis
7.51.21
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MJFCIFSS
Pressure balances in the control block
7 Pressure balances in the control block
Fig. 14 Pressure balances in the control block
164 Pressure balance (pilot-controlled) 224 Pressure balance (pilot-controlled)

167 Screw plug 264 Pressure balance (pilot-controlled)
168 Screw plug 264* Pressure balance (directly controlled)
169 Screw plug 284 Pressure balance (directly controlled)
*A904 C (industrial)
7.51.22
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7.1 Directly controlled pressure balance 264* / 284

On-demand flows are controlled by means of the cross-section of the opening of the respective spool
shaft and the LS pressure at the pump regulator.
Responsible for that are the pressure balances connected to each spool shaft and sitting in the con-
trol block.
The LUDV pressure balance 264 / 284 with the pressure spring 165 of each section is situated
downstream of the gauge orifice of the spool.
This pressure balance reports to the pump regulator the pressure of the consumer with the highest
load. For all consumers with lower loads, the pressure balance compensates for the LS pressure with
the prevailing load pressure of the consumer in question.
In the neutral position of the spool, the connection between pump and channel p is blocked by the
spool (see Fig. 16). In this position, the pressure in channel p and behind the load-holding valves is
dissipated nearly to tank level, thanks to the movement of the piston. The consumer connections are
blocked by the spool in the housing. That means, the consumer sits between two oil columns and is
fixed.
Fig. 15 Directly controlled pressure balances 264 / 284

165 Pressure spring 284 Pressure balance, directly controlled
166 O-ring
7.51.23
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7.2 High pressure

As soon as the spool is shifted, the supply orifice of the spool opens the connection between pump
connection p and the channel p. The resulting pressure in this space shifts the pressure balance.
Via the internal channels in the pressure balance, it also acts on the rear side of the load-holding val-
ves.
Consumer pressure pc of connection A acts via the channels in the spool and is available at the front
side of the left-hand load-holding valve. With pump pressure p rising above consumer pressure pc,
the load-holding valve opens. The connection between pump and consumer has been established,
now, and initiates the movement. The displaced oil flows back to the tank via the outlet orifice. The
secondary pressure-relief valves remain closed as long as the pressure in the consumer connection
remains below the pre-set pressure value.
Fig. 16 Pressure balance in high-pressure position
pc high = LS signal to pump regulator
7.3 Consumer with highest load is actuated

For individual movements, or when the load pressure of the consumer pc is the highest in the system,
the LS pressure is generated from the spring space of the corresponding pressure balance. Tapping
pressure at this point guarantees that only the highest load pressure is signalled. The pressure ba-
lances of the other sections blocks off effects generated by other consumers.
This LS signal is sent to the flow regulator (LS regulator) of the variable-displacement pump, and also
to the spring chambers of the other LUDV pressure balances. The pressure balance is fully open.
Channel p is connected to consumer connection pc, without pressure drop.
Feeding the LS signal of the load-holding valves guarantees that the consumer connection is blocked
until the necessary operating pressure is reached, and prevents sudden drops in the event of nega-
tive (pulling) loads.
7.4 Low pressure
7.4.1 Load-sensing function

In the saturated area, the LUDV system operates as a load-sensing regulation system only. The
speed of the consumer is controlled independently of the load pressure, by means of the opening
cross-section of the gauge orifice (spool).
When several movements overlap, the load pressure of the consumer with the highest pressure acts
7.51.24
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via the central LS line in the spring chambers of the other LUDV pressure balances. The resulting
pressure in channel p of this section is derived from the highest reported LS pressure (p = LS +
spring force). The LUDV pressure balances automatically regulate pressure p of the various shafts
by limiting the flow cross-section to the consumer channel to the same value. The p at the gauge
orifice is identical. That means, the speed of the consumer is independent of the difference of the load
pressures. As the pressure balance is under the influence of the load signal with the highest load on
the spring side, it cannot open completely. The pressure balance, which is only partly open, genera-
tes another pressure difference which depends on the individual load.
Fig. 17 Pressure balance in low-pressure position
d = LS = pc high
e = pc low
F = spring chamber
R = regulating orifice
7.4.2 LUDV function

The LUDV system works even in case of a saturation deficit. In such a case, the oil volume requested
on the basis of the sum of the open gauge-orifice cross-sections at the existing p exceeds the max.
flow rate of the pump within the limits 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 pivoting the variable-displacement pump even further
+. p set at the regulator collapses.
Under this condition, the LUDV system maintains p at the same level across all the open gauge
orifices. This means that, in the event of a saturation deficit, the system does not simply shut off the
consumer(s) with the highest pressure. Instead, the speeds of all the actuated consumers drops pro-
portionally to the open cross-sections.
7.51.25
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When all the pressure balances are in balance:

the LS system pressure in all the spring chambers of the pressure balances is the same
p in front of the gauge orifices of the section with the lower load corresponds to the LS pressure
of the consumer with the highest load
p inlet orifice = ppump - p
p at the inlet orifices of all consumers is always equal. In the event of a saturation deficit, p drops
down, but, again, at all consumers to the same degree.
The pressure differences p inlet orifices between p and each individual consumer pressure pc is re-
gulated and levelled automatically by adapting the opening cross-section, so that the volumetric flows
are split proportionally.
7.4.3 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. 18 Pressure balance in position "spool closed"
a no LS signal 164 Piston / pressure balance

b LS signal 280 Spool
100 Control valve block 284 Piston / pressure balance
160 Spool / travel
7.5 Pilot-controlled pressure balances 164 / 284 / 224 / 244 and 264
Pilot-controlled pressure balances 164 / 284 / 224 / 244 and 264 take over the same tasks in the
LUDV system as directly controlled pressure balances 164 and 184. For that reason, the function of
this pilot-controlled pressure balance corresponds to the basic function of the directly controlled pres-
sure balances.
Additional features of pressure balances 164 / 284 / 224 / 244 and 264:
Finer and more precise regulation behaviour thanks to the pilot control pistons 1 with the pressure
spring 2 in the pressure balance.
These pilot control pistons with their very fast reaction times take over the blocking and opening func-
tions with respect to the pressure signal between the consumers with the highest and the lower pres-
sures.
7.51.26
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Fig. 19 Pressure balances, pilot-controlled
163 Screw plug 193 Spring plate

164 Pressure balance (pilot-controlled) 194 Spring plate
166 O-ring 225 Restrictor 2x Ø 0.8 mm
168 Screw plug 244 Pressure balance (pilot-controlled)
169 Screw plug 245 Restrictor 2x Ø 0.8 mm
191 Pilot control piston 264 Pressure balance (pilot-controlled)
7.6 Low pressure section:

Pilot control piston 1 is in its starting position, i.e. it connects the current LS pressure of the consumer
with the highest pressure to the spring side of the pressure balance. Like that, the pressure balance
regulates the pump pressure of the consumers with the lower pressure and brings them to the LS
pressure of the consumer.
7.51.27
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Fig. 20 Pressure balance low-pressure position (LS signal from consumer with highest pressure)
7.7 High pressure section:

Pilot control piston 1 is shifted against pressure spring 2. That means, the spring side of the main
piston is relieved. At the same time, the consumer with the highest load is connected to the LS pres-
sure. This, again, acts on the LS regulator of the working pump.
Fig. 21 Pressure balance in high-pressure position (pc high = LS signal to pump regulator)
Fig. 22 Pressure balance in position "spool closed"
1 Pilot control piston 264 Pressure balance
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2 Pressure spring F Spring chamber

100 Control valve block R Regulating orifice
224 Pressure balance pch High pressure (LS)
240 Spool pcl Low pressure
244 Pressure balance
8 Pressure and feeder valves
Fig. 23 Pressure and feeder valves in the control block
100 Compact control valve block 171 Pressure spring / load-holding valve
102 Pressure balance / minimum flow 172 Screw plug
105 Primary pressure-relief valve 222 Secondary pressure-relief valve
162 Suction valve 242 Secondary pressure-relief valve

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 pump, control block and working attachments and/or between working attachments and
control block when the spools are closed (secondary function).
weakest point, e.g. screwed connections or hydraulic hoses. In order to prevent that, we provide a
sort of pre-determined breaking point. In our scenario, the pressure rising in the hydraulic system acts
on a certain type of integrated hydraulic device. We call this a pressure-relief valve. It limits the ma-
ximum pressure in the consumer and its connection to the pre-set value.
7.51.29
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As the pressure valves in the hydraulic system must be able to cater for large 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 pressure-relief valve is installed that works directly as a pilot con-
trol valve to actuate a second, larger valve.
At the same time, the pressure-relief valves act as feeder valves. Different flow rates of oil coming in
and going out of the operating cylinders leads to a vacuum. This happens, for instance, when you
deal with pulling loads on the outside, e.g. 'extend stick cylinder' with particularly long sticks. In such
a case, the speed of the consumer is not controlled by means of quantities determined by the gauge
orifice, but (independently of loads) via the outlet edge of the spool.
8.1.1 Pressure limitation, see Fig. 23

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 also acts 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).
and adjusting spring 5, pilot control cone 4 is lifted from its seat, and some oil can penetrate 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 volume of oil flows to the non-pressurised return side T.
8.1.2 Feed
If there is a vacuum in a working circuit, the higher pressure in the hydraulic tank is applied through
the bore T of the housing 1 onto the ring face of the main cone 3. As a result of the pressure difference
across the effective surface of the main cone 3, the main cone is pressed against the force of the
pressure springs 8 / 9 so that the required amount of oil can flow through the bore T to the respective
side of the consumer.
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Fig. 24 Pressure and feeder valve
1 Housing 9 Pressure spring

2 Valve insert 10 Protective cover
4 Pilot control cone 12 O-ring
8.2 Feeder valves 161 / 162

Feeder valves (i.e. suction valves / check valves) are used with rotating consumers.
The danger of insufficient filling, i.e. cavitation in oil motors is greatest when there are delays in the
operation of the machine (downhill travel). When decelerating, the oil motor of the chassis runs idle.
The pressure peaks due to the high moment of inertia during downhill travel make the brake valves
react while the spools are blocked.
What is more, at 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
downhill force.
The feeder valve makes the required amount of oil available to the operating connection to avoid ca-
vitation.
7.51.31
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8.3 Closing position:

The high pressure in channel P 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 is closed
towards the consumer side.
8.4 Suction:
If there is a vacuum in this working circuit, the higher pressure in the hydraulic tank acts via the bore
T of the valve insert 1 on the ring face of 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 A2 / B2.
Fig. 25 Feeder valves

3 Main cone 34 Backing ring
6 Screw 35 O-ring
31 Piston seal
7.51.32
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MJFCIFSS
Repair works on control valve block
9 Repair works on control valve block
Caution!
Before you begin any repair works on the control valve block, be sure to relieve tank and servo pre-
loads.
Switch off the diesel engine.
Proceed as follows: Unscrew breather filter on hydraulic tank about 1 turn (slow de-pressurisa-
tion).
Releasing backpressures
Turn ignition key to ignition position.
Actuate all pilot control valves in all possible directions.
9.1 Leaks on the outside

Leaks on control valve block: Replace seals on screwed connections, SAE flanges, caps and valves.
9.1.1 Spool
Description for the installation and removal of the spool
Note!
If you want to remove several spools at a time, be sure you put them back into the correct bores
afterwards (markings, etc.).
Spare spools have the spool's axis marking A1 - A5 engraved on the front side opposite the spring
and on the shaft of the spring plate package.
Before you install the spool: check for good condition of housing O-rings (spool lid seals). Check
for correct condition of spools (no scores on surface).
Install in reverse sequence. Insert spools precisely and with care. Avoid jamming. Do not use
force.
9.1.2 Pressure balances and valves

To repair pressure balances and valves, take out of housing completely.
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 valves: check outside seal rings for good condition.
Avoid damage, twisting and warping. Fit seals tightly.
Use correct torques for tightening additional shafts, valves and screwed connections.
7.51.33
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Maintenance
9.1.3 Torque values for control valve block 100

check valve 7/8 10 Nm Valve seat 210/219 15 Nm
Pressure balance 102 25 Nm Pressure-relief valves 221 - 262 120 Nm
Pressure cut-off valve 104 25 Nm Screw plug 229 60 Nm
Pressure-relief valve 105 120 Nm Screw plug 275 10 Nm
shift valve 106 80 Nm Screw plug 277 10 Nm
Nozzle 108 6.5 Nm Screw plug 278 10 Nm
Nozzle 109 8 Nm Allen head screw 320 70 Nm
Allen head screw 111 110 Nm Allen head screw 335 10.5 Nm
Allen head screw 135 10,4 Nm Screw plug 369 90 Nm
Screw plug 140 20 Nm Screw plug 373 120 Nm
Restrictor check valve 127/167/187/227/247 20 Nm Screw plug 475 30 Nm
Plug 163/168/169 300 Nm Screw plug 491 3.5 Nm
Load-holding valve 172 150 Nm Allen head screw 811 .555 Nm
Suction valves 161/162 120 Nm
Information for installation:

The contact surface must be absolutely even.
Mounting bolts must be tightened evenly, in a cross-wise pattern.
Contact faces of SAE connections must be clean.
Pipes and hose lines must be properly laid, without any twists, warps, tensions etc.
Be sure to respect correct torques with screws and bolts, screwed connections etc. (See group
1.20 "torques of screws, bolts, screw-in studs").
10 Maintenance
Periodically check control valve block for leaks. Regularly check the pressure cut-off valve 104 and
the secondary pressure-relief valves 221 - 262 for correct settings (see maintenance instructions).
To check the secondary pressure-relief valves 182, increase the set value of the pressure cut-off val-
ve 104 above the expected peak value (see adjustment protocol and guideline for hydraulic system,
group 6).
Note!
For maintenance and adjusting work
7.51.34
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MJFCIFSS
11 Additional control axles
11.1 Slewing gear element, Fig. 27

Classification 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 of the proportional pressure-relief valve Y451.
Spool 120 for working movements of uppercarriage, turn left and right
Input pressure balance 122 for priority circuit
Check valve 123 prevents any effects on the slewing gear from any consumers actuated at the
same time that might be under higher 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 335
Restrictor check valves 127 for fine-control of spool 120
11.2 Repair works on control valve block
Leaks on the outside

Replace seal rings of flanges, lids and valves. Replace screw plugs, when no longer tight.
Spool
Remove the Allen head screws 335.
Remove control lid 334. (Careful: lid 334 is spring-loaded.)
Remove pressure spring 332. Pull spool 120 from the housing.
Install in reverse sequence.
Valves
To repair valves: Take out of housing completely. If necessary, exchange against spares as listed in
the spare parts catalogue.
Fig. 26 Hydraulic diagram of slewing gear element 120
7.51.35
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MJFCIFSS
Fig. 27 Slewing gear segment
120 Spool / slewing-gear segment 334 Control lid

122 Input pressure balance 335 Allen head screw
123 Check valve 365 Pressure spring
127 Restrictor check valve 371 Pressure spring
130 Nozzle Ø 0.9 mm 372 O-ring
131 Nozzle Ø 1.5 mm 373 Screw plug
132 Cone 475 Screw plug
330 O-ring 810 End plate
331 Spring plate 811 Allen head screw
332 Pressure spring Y451 Prop. solenoid valve
333 Washer
7.51.36
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MJFCIFSS
11.3 Functional description of slewing gear spool
11.3.1 Priority of slewing gear

In the one-circuit LUDV system, all consumers are arranged in parallel and supplied by one and the
same working pump. In the LUDV system, it is the slewing gear that has always priority. It can be
controlled independently of all the other consumers.
The question of priorities arises whenever the system must work with a deficit in saturation and the
LUDV system automatically influences the speed of movements with respect to the degree of the ac-
tual saturation deficit.
Putting a priority on the slewing gear turned out to be necessary because most operators do not like
the speed being automatically influenced by other movements. What is more, any automatic accele-
ration due to the LUDV principle is considered as unacceptable.
With those requirements in mind, we put the priority on the slewing gear whenever several move-
ments must be carried out simultaneously. It works like this:
The module is the only consumer in the system that works with a 2-way pressure balance in the sup-
ply flow leading to the gauge orifice. The pressure balance for the section, in front of the gauge orifice,
compares load pressure LS slewing gear and the setting of the spring of the pressure balance to pres-
sure p that it obtains from the gauge orifice. The p gauge orifice is maintained at a constant level
(corresponding to the type of spring used) and, thus, allows a speed control that is independent of
the load pressure. The only way to modify quantity or speed is a change at the gauge orifice.
11.3.2 Attachment section is consumer with highest load pressure

Thanks to the check valve in the LS line between module and system, it is not possible that the control
of the slewing gear is influenced by consumers with higher loads that happen to run at the same time.
The difference between pump pressure psystem and operating pressure p of the slewing gear ele-
ment 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 case of great differences between psystem and p and increases /
pens with decreasing pressure differences.
The quantities supplied by the pump and not requested by the slewing gear within the performance
regulation are distributed proportionally to the other active consumers according to the LUDV princip-
le.
11.3.3 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. It acts on the rear side of the LUDV pressure balances and the
p regulator of the variable-displacement pump. The quantities supplied by the pump and not re-
quested by the slewing gear within the performance regulation are distributed to the other active con-
sumers according to the LUDV principle.
11.3.4 Slewing gear torque control

For a sensitive acceleration of the slewing gear, we need a torque control (pressure control) in order
to influence the value of the acceleration.
During acceleration from zero, the slewing gear will call up only a small amount of oil. With LS control,
it generates the max. load pressure in the slewing gear and, thus, the max. rotary acceleration. For
that reason, the one speed that is independent of the load pressure (via 2-way supply pressure ba-
lance 360) is overridden by a torque control.
The control pressure chosen by the operator is converted by the pressure gauge B335 (see hydraulic
unit) into a signal that is then sent to the UEC control unit. The UEC control sends a current that cor-
responds to the chosen control pressure to the proportional solenoid valve Y451. Depending on the
current, proportional solenoid valve Y451 closes or opens the primary pressure connection in the sle-
wing gear circuit to the tank. This results in the control of the available torque. The corresponding
7.51.37
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MJFCIFSS
operating pressure is generated proportionally to the control pressure, i.e. the angle of the pilot con-
trol valve. By changing the current parameters in %, the operator can adjust the rotational speed to
achieve a more sensitive rotary movement.
11.3.5 Loss-free acceleration

The proportional solenoid valve Y451 is located near the control block in the LS line of the module of
the pressure balance. This design ensures that the slewing gear is supplied only with the quantity of
oil required to build up the necessary working pressure. As soon as the pre-set pslewing gear is rea-
ched, the preceding pressure balance reduces the flow, and only supplies the amount necessary to
maintain the pressure. Thanks to this combination, the acceleration of the slewing gear works without
any losses.
The maximum permissible acceleration pressure is at approx. 10 - 20 bar below the topmost setting
of the 2-step slewing gear valves in the oil motor. This means that the secondary valves does not
respond, and the corresponding losses are avoided. Thanks to the torque control, the quantities sup-
plied to the slewing gear motor goes up when pslewing gear drops until the required pressure accor-
ding to the pre-set p pressure spring has been attained via the gauge orifice.
11.3.6 Deceleration of the slewing gear

Deceleration of the slewing gear is effected via the outlet orifices of the spool leading to the tank, and
the pressure-relief valves leading to the motor. Min. deceleration is derived from 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 a smooth deceleration. Again, the rule applies: More pcontrol pressure increases the addi-
tional pressure level of the secondary cartridge continuously all the way up to the max. admissible
value.
Both values can be adjusted independently by controlling the admissible acceleration pressure with
the proportional solenoid valve Y451 and the deceleration via the brake valves on the motor.
In the neutral position of the spool, the slewing gear is hydraulically fixed by means of the locked con-
sumer connections A and B.
Should adjustments become necessary, proceed according to the adjustment protocol and the in-
spection and adjustment instructions; see group 3.
and dismantle; if necessary, replace completely.
7.51.38
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MJFCIFSS
Fig. 28 Sectional drawing of slewing gear element
120 Spool / slewing-gear segment 372 O-ring

122 Input pressure balance 373 Screw plug
127 Restrictor check valve 475 Screw plug
130 Nozzle Ø 0.9 mm D1 Supply gauge orifice p-A01 and/or p-
B01
131 Nozzle Ø 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
7.51.39
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MJFCIFSS
12 LSC additional control axles
M7 - 205 M7 - 205
M7 - 205
Secondary valve Secondary valve
Product SX/14-1X 2 axles
without additional with additional
Unit (AHS1 + AHS11)
pressure level pressure level
Contained in: AS1 AHS1 AHS11 AHS12

Spool 540 500 510 520
for grapple rotator Kit AHS1 Kit AHS11 Kit AHS12
Left right Exten- Retrac- Exten- Retrac- Exten- Retrac-
ding ting ding ting ding ting
Nominal width of () 14 20 20 20
block (G3/4) (SAE 3/4) (SAE 3/4) (SAE 3/4)
Consumer connec-
tion
Ø piston rod mm 18 25 25 25
Piston stroke mm 8 8 11 11 11 11 11 11
Setting value Y
A 900 C mm 15.6 15.6 14.2 14.2 14.2 14.2 14.2 14.2#
A 904 C mm 15.6 15.6 14.2 14.2 14.2 14.2 14.2 14.2#
p1 ± 0.5 bar 2.0 2.0 7.0 7.0 7.0 7.0 7.0 7.0
p2 ± 0.5 bar 23,4 23,4 20.6 20.6 20.6 20.6 20.6 20.6
Qn (A)/Qn (B)
A 900 C l/min 30 30 220 150 200 200* 200 200*
A 904 C l/min 30 30 220 150 200 200* 200 200*
Restrictor check
valves mm 1.0 1.0 1.0
At connection a mm 1.0 1.0 1.0
At connection b
Max. leak oil cm3/min 60 60 60
at load pressure bar 150 150 150
at oil temperature °C 50 50 50
Tab. 2 List: LSC additional control axles
* = when connected to lateral boom adjustment, be sure to reduce flow on both sides. Proceed as follows: To adjust, turn
the stop screw to Y = 15mm (top) and Y = 12 mm (bottom).
# = when connecting to regulating cylinder / hydraulic boom adjustment, reduce flow to piston rod side to 140 l/min. Pro-
ceed as follows: Turn stop screw 270 degrees = 0.7 mm. Measure Y is reduced to 13.5 mm.
Magnet Y22 / Y23 12 Nm Allen head screws 122 110 Nm at AHS12

Pressure-relief valve 541 / 542 90 Nm Allen head screws 811 55 Nm at AS1
Seal Lock collar nut 1.70 38 Nm Pressure balance 544 160 Nm
Allen head screw 20 10 Nm Pressure-relief valve 502 120 Nm
Screw plug 29 100 Nm Pressure-relief valve 501 120 Nm
Allen head screws 122 70 Nm Restrictor check 112 20 Nm
valve
Qn (A) / Qn (B) = nominal flow rate at outlet A / Bat r = nominal value

p1 = control pressure at begin of regulation
7.51.40
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MJFCIFSS
12.1 Grapple rotator element (kit AS1/540)

Flange additional element AS1(540) as a kit to the control valve block next to the slewing gear ele-
ment. That way, the working movements 'turn grapple' and 'tilt bucket' receive oil from the main wor-
king pump, too.
12.2 Kit elements (kits AHS1, AHS11 and AHS12)

For additional functions, e.g. accessory kits AHS1(500), AHS11(510) and AHS12(520), more additi-
onal axles can be flange-mounted to the left-hand side of the compact control block.
12.3 Additional control block for accessory kits AS1, AHS11 and AHS12
To control yet another working movement, you can mount an additional 1 x additional element to
compact block 100.
Each control axle (additional control block) has the necessary spool complete with actuation (control
lid, regulating springs), required for its respective function, a pressure balance and the corresponding
connections with secondary protection. It has an hydraulic connection to series block 100 via the
pressure, return and LS channels. O-rings seal off the flange faces of the channels.
To retrofit one or more additional axles, remove the end plate 110 or 810 and mount the new axle
between the block 100 and the plate 110 / 810.
Fig. 29 Additional control axles
7.51.41
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MJFCIFSS
12.4 Additional control valve block for accessory kit AS 1, see Fig. 30
The individual segment for the working movement 'grapple turn drive' is equipped with a magnetic-
hydraulic actuation for the spool. That means, the proportional actuation of the piston has been de-
signed not in the same way as with the other two additional axles, but as a so-called "on-off control".
The control pressure at connection a / b is led to the spring chamber of the spool 540 only after ac-
tuation of the respective solenoid Y22 / Y23. That way, the spool completely cuts through. The pres-
sure balance 544 fulfils the same purpose as the other pressure balances in the compact block 100.
For function and settings, see group 16.
Fig. 30 Additional axle at AS1
540 Additional control valve AS1 810 Mounting 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
7.51.42
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MJFCIFSS

28 Pressure spring / L 542 Secondary pressure-relief valve
30 O-ring 810 Mounting 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 / additional control block AS1
7.51.43
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MJFCIFSS
12.5 Additional control valve block for accessory kit AHS1

The individual segment for the working movement 'hydraulic adjustment of boom' etc. corresponds
to the design and construction of the lifting, stick and bucket axles of the compact block.
Fig. 32 Additional control block AHS1
500 Additional control axle AHS1 504 Pressure balance

501 Secondary pressure-relief valve 507 Restrictor check valve
502 Secondary pressure-relief valve
12.6 Additional control block for accessory kit AHS11 with Tool Control
The individual segment for the working movement 'hydraulic hammer' corresponds to the design and
construction of the lifting, stick and bucket axles of the compact block. Only the function 'actuate hy-
draulic hammer' has a 2-step secondary pressure-relief valve.
Fig. 33 Accessory kit AHS11 with Tool Control
510 Additional control axle AHS11 514 Pressure balance

511 Pressure-relief valve, process pressure- 517 Restrictor check valve
controlled
512 Pressure-relief valve, process pressure- Y414 Proportional solenoid valve
controlled
7.51.44
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MJFCIFSS
12.7 Additional control block for accessory kit AHS12 with Tool Control
The individual segment for the working movement 'hydraulic adjustment of boom hydraulic hammer
/ hydraulic adjustment of boom telescopic demolition stick / scrap shear / concrete crusher / sorting
grapple' etc. corresponds to the design and construction of the lifting, stick and bucket axles of the
compact block.
Only the function 'actuate hydraulic hammer' has a 2-step secondary pressure-relief valve.
For a description of the functions and adjustment, see group 16.
Fig. 34 Additional control block AHS12 with Tool Control
500 Additional control axle AHS1 511 Pressure-relief valve, process pressure-
controlled
501 Secondary pressure-relief valve 512 Pressure-relief valve, process pressure-
controlled
502 Secondary pressure-relief valve 514 Pressure balance
504 Pressure balance 517 Restrictor check valve
507 Restrictor check valve 520 Additional control axle AHS12
510 Additional control axle AHS11 Y414 Proportional solenoid valve
7.51.45
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MJFCIFSS
Fig. 35 Additional axles AHS1, AHS11 and AHS 2 with Tool Control
7.51.46
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MJFCIFSS
Fig. 36 Additional control axles AHS1
7.51.47
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MJFCIFSS
Fig. 37 Additional control axles AHS11
7.51.48
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MJFCIFSS
15 Control lid 110 End plate

20 Allen head screw 122 Allen head screw*
27 Cone 500 Spool / segment AHS1
28 Pressure spring 501 Secondary pressure-relief valve
29 Screw plug 502 Secondary pressure-relief valve
34 O-ring 504 Pressure balance
70 O-ring 507 Restrictor check valve
71 Screw plug 510 Spool / segment AHS11
72 Pressure spring 511 Pressure-relief valve, process pressure-
controlled
90 Spring plate 512 Pressure-relief valve, process pressure-
controlled
91 Pressure spring 514 Pressure balance
100 Compact block 517 Restrictor check valve
* various lengths (depending on the number of additional elements)
12.8 Pressure-relief valves 511 / 512

If the pressure in the circuit of a working attachment rises, it begins to act on the built-in hydraulic
device. We call this a pressure-relief valve. It limits the max. pressure in the consumer and its con-
nections with the pre-set value.
As high flows result in pressure on the pressure valves of the hydraulic unit, the machine is equipped
with indirectly responding (pilot-controlled) pressure-relief valves. In these valves, a pressure-relief
valve is installed that works directly as a pilot control valve to actuate a second, larger valve.
The pressure-relief valves 511 / 512 are process pressure-controlled. The oil flowing to the tank when
the valve is opened is fed externally via the proportional solenoid valve Y414 that is opened or closed.
The current to the proportional solenoid valve Y414 thus determines the settings of the secondary
protection: Minimum current = low pressure and maximum current = high pressure.
7.51.49
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MJFCIFSS
Fig. 38 Proportional pressure control
12.9 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 is kept in its closed position as the area B3 is greater than the area B4 exposed
to the same pressure P.
The pressure spring 3 pushes the pilot control cone 4 into its closed position.
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 via connection (T) to the tank, see 12.10.
Due to the different cross-sections of the bore B1 in the bushing 12 and the ring face B2 in the screw
plug 6, a pressure difference is built up between the front and rear sides of the main cone 5. The main
cone 5 is lifted and the connection T to the tank is opened. Any excess pressure is thus released to
the tank (secondary relief).
12.10 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 BST).
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-relpressure-relief valve is re-
duced in proportion to the actual current through the valve. The main cone 5 is thus lifted from its seat
7.51.50
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MJFCIFSS
and the oil flow channel P - T is opened. The pressure set in the menu is established.
The settings for the proportional valve Y414 can be manually adjusted and saved for each attachment
in the respective menu, see group 16.
Fig. 39 Sectional drawing of pressure-relief valve 511 / 512 (process pressure-controlled)
1 Adjusting screw 511 Secondary pressure-relief valve for pres-

sure reduction
2 Lock nut 512 Secondary pressure-relief valve for pres-
sure reduction
3 Pressure and adjusting spring
4 Pilot control cone B1 Bore for pressure behind cone 5
5 Main cone B2 Ring face between screw plug 6 and cone
4
6 Screw plug B3 Effective surface behind cone 5
7 Housing B4 Effective surface in front of cone 5
11 Pressure spring P Pressure connection
12 Bushing T Tank connection
14 Magnetic coil Y Process pressure connection
15 Valve seat
7.51.51
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MJFCIFSS
7.51.52
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MJFCIFSS
Service Manual LSC pilot plate
Function
LSC pilot plate
1 Function
The control unit of the hydraulic LSC control has been designed as a modular pilot plate.
The way valves for the travel function and the functions of the boom, stick and bucket cylinders, the
supports and the grapple rotation are flange-mounted to the pilot plate.
For additional functions, e.g. AHS 11 and (AHS 12+AHS 11 = AHS 12) attachment kits, additional
way valves can be flange-mounted to the left side of the pilot plate.
Note!
For detailed instructions regarding the settings of the individual components of the LSC pilot plate,
see group 3 in the service manual.
Fig. 1 LSC pilot plate
7.55.1
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MJFCIFSS
LSC pilot plate Service Manual
Technical data
2 Technical data
Spool Unit 220 240 260 280 160 540

Boom Stick Bucket Support Travel Grapple
cylinder cylinder cylinder cylinder motor Rotate
Nominal width of mm 25 25 18 18 18 14
block
Consumer connec- () 1 1 3/4 3/4 3/4 3/4
tion
Ø piston rod mm 32 32 25 25 25 20
Piston stroke mm 12.1 12.1 12.5 12.5 10.1 10.1 10.0 10.0 10.0 10.0 5.0 5.0
Setting value X mm
A 914 C 48.1 48.1 48.3 48.3 41.5 41.2 38.4 38.6 40.5 40.5 36.0 36.0
(construction)
A 924 C 48.1 48.1 48.3 48.3 41.5 41.2 38.4 38.6 40.5 40.5 36.0 36.0
(construction)
A 924 C (industrial) 48.1 48.1 48.5 48.5 41.5 41.2 41.0 41.0 40.5 40.5 36.0 36.0
D (shims) mm 1.6 1.6 1.3 2.0 2.3 2.3 2.3 2.3 2.0 2.0 3.0 3.0
p1bar ± 0.5 mm bar 8.5 8.5 9.0 8.5 8.5 8.5 8.5 8.5 8.0 8.0 - -
p2bar ± 0.5 mm bar 25.5 25.5 26.8 26.2 24.5 24.5 23.8 23.8 23.2 23.2 - -
Qn (A)/Qn(B) l/min
A 914 C 380 120 425 320 280 170 130 95 200 200 30 30
(construction)
A 924 C 380 120 425 320 280 170 130 95 200 200 30 30
(construction)
A 924 C (industrial) 330 115 410 160 280 170 250 250 200 200 30 30
Restrictor check mm
valve
At connection x 1.15 1.15 0.8
At connection y 0.8 0.8
Leak oil max. cm3/min 75 75 70 70 70
at load pressure bar 150 150 150 150 150
at oil temperature °C 50 50 50 50 50
Note!
Shim thickness: "D": 0.3mm; 0.5mm; 1.0mm
Qn (A)/ Qn (B) = nominal flow rate at outlet A / B at 30 bar -p = nominal value
p1 = control pressure at begin of control
7.55.2
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MJFCIFSS
Technical data
7.55.3
copyright by
MJFCIFSS
Design
3 Design
Fig. 3 Front view of pilot plate (construction model)
Note!
The pressure-relief valve 248 is only installed in machines with LSC pilot plate (construction model).
7.55.4
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MJFCIFSS
Design
Fig. 4 Hydraulic diagram of construction model
7.55.5
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MJFCIFSS
Design
41 Measuring point xP (pump pressure) 246 Restrictor check valve / control pressure
45 Measuring point xLS (LS pressure) 247 Stroke limiter / spool
100 Pilot plate 248 Pressure-relief valve / bypass valve
101 Pressure cut-off valve (LS pressure) 260 Way valve / bucket cylinder
102 Pump valve 261 Secondary pressure-relief valve / exten-
ding
103 Restrictor (LS relief) 262 Secondary pressure-relief valve / retrac-
ting
106 Valve / LS shutdown of grapple 263 Spool / boom cylinder
107 Pressurisation valve / return T 264 Pressure-relief bleeder valve
109 Pressure build-up 267 Stroke limiter / spool
110 Regeneration plate 280 Way valve / support
111 Shift valve 281 Suction valve / support
112 Shuttle valve 282 Suction valve / support
113 Piston 283 Spool / support
114 Piston 284 Pressure-relief bleeder valve
115 Lowering restrictor / boom cylinder 285 Pressure-relief bleeder valve
116 Lowering restrictor / stick cylinder 286 Restrictor check valve
Control pressure
117 287 Stroke limiter / spool
160 Way valve / travel motor 287 Stroke limiter / spool
161 Suction valve 540 Way valve / grapple rotator
163 Spool / travel 544 Secondary pressure-relief valve
164 Pressure-relief bleeder valve 547 Stroke limiter / spool
166 Restrictor check valve Y22 Solenoid valve / grapple rotation right
Control pressure
167 Stroke limiter / spool Y23 Solenoid valve / grapple rotation left
220 Way valve / boom cylinder Y53 Radiator shift valve
221 Secondary pressure-relief valve / exten- A-A5 High-pressure connections
ding
222 Secondary pressure-relief valve / retrac- B-B5 High-pressure connections
ting
223 Spool / boom cylinder K Radiator connection
224 Pressure-relief bleeder valve LS/LSS LS pressure signal
225 Pressure-relief bleeder valve P1 Pump 1 connection
226 Restrictor valve / control pressure P2 Pump 2 connection
227 Stroke limiter / spool P3 Control pressure connection
240 Way valve / stick cylinder T/T1 Tank connection
241 Secondary pressure-relief valve / exten- T2 Leak oil connection
ding
242 Secondary pressure-relief valve / retrac- X1-X5 Control pressure connections, A side
ting
243 Spool / stick cylinder Y1-Y5 Control pressure connections, B side
244 Pressure-relief bleeder valve Z/Z1 Control pressure connection
245 Pressure-relief bleeder valve DHS Pressure build-up
7.55.6
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MJFCIFSS
Design
Note!
For a detailed description of the individual way valves, (see Design and function of the way valves
on page 21).
Fig. 5 Front view of pilot plate (industrial model)
Note!
In contrast to the construction model, the section 240 for the stick cylinders is installed at a 180°
angle.
7.55.7
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MJFCIFSS
Design
Fig. 6 Hydraulic diagram of industrial model
7.55.8
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MJFCIFSS
Design
41 Measuring point xP (pump pressure)

45 Measuring point xLS (LS pressure) 246 Restrictor check valve / control pressure
100 Pilot plate 247 Stroke limiter / spool
ding
103 Restrictor (LS central nozzle) 262 Secondary pressure-relief valve / retrac-
ting
106 Valve / LS shutdown of grapple 263 Spool / boom cylinder
Control pressure
117 Lowering restrictor / bucket grapple cylin- 287 Stroke limiter / spool
der
Control pressure
ding
B-B5 High-pressure connections
ding
ting
7.55.9
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MJFCIFSS
Design
Note!
For a detailed description of the individual way valves, (see Design and function of the way valves
on page 21).
Fig. 7 Rear view of pilot plate 100
A-A5 High-pressure connections X1-X5 Control pressure connections

B-B5 High-pressure connections Y1-Y5 Control pressure connections
K Radiator connection Y53 Radiator shift valve
LS LS pressure signal 102 Pump valve
P1 Pump 1 connection 110 Regeneration plate
7.55.10
copyright by
MJFCIFSS
Design
P2 Pump 2 connection 115 Lowering restrictor / boom cylinder

P3 Control pressure connection 116 Lowering restrictor / stick cylinder
T Tank connection 117 Lowering restrictor / bucket grapple cylin-
der
T2 Leak oil connection
3.1 Installation of the way valves

The way valves 160-540 are designed as disc valves. They are flange-mounted to the pilot plate 100.
The way valves 220, 240 and 260 are flange-mounted to the front side, while the way valves 160 and
280 are flange-mounted to the side of the plate.
In machines with optional equipment, there might be additional flange-mounted way valves required,
(see Auxiliary way valves for AHS 1 and AHS 11 on page 34).
The connections T,P and LS, (see Fig. 7 on page10) between the way valves and the pilot plate are
established through internal channels and flange bores in the connecting faces.
All consumer connections A and B are located at the front side (seen in direction of travel). With way
valves that are used for the control of hydraulic cylinders, the connection A is always connected to
the piston face, while the connection B is connected to the rod side.
Fig. 8 Installation of the way valves
7.55.11
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MJFCIFSS
Design
100 Pilot plate 248 Pressure-relief valve / bypass valve

(in construction models only)
123 End plate 260 Way valve / bucket cylinder
160 Way valve / travel 280 Way valve / support cylinder
220 Way valve / boom cylinder 540 Way valve / rotating grapple
240 Way valve / stick cylinder
7.55.12
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MJFCIFSS
Design
3.2 Pilot plate 100
Fig. 9 Design of pilot plate
7.55.13
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MJFCIFSS
Design
Fig. 10 Design of the regeneration plate
100 Pilot plate 112 Shuttle valve (2x in construction model)

101 Pressure cut-off valve (LS pressure) 113 Piston
102 Pump valve 114 Piston
103 Restrictor 115 Lowering restrictor / boom cylinder
106 Valve / LS grapple shutdown 116 Lowering restrictor / stick cylinder
7.55.14
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MJFCIFSS
Functions of the valves in the pilot plate 100
107 Pressurisation valve / return T 117 Lowering restrictor / bucket grapple cylin-
der
108 Pressurisation valve / return K Y53 Radiator shift valve
109 Pressure build-up 112 Shuttle valve
110 Regeneration plate A Construction model
111 Shift valve B Industrial model

All way valves for the control of working and travel movements are flange-mounted to the pilot plate
100.
The pilot plate is supplied with oil through the connections P1 and P2 by the two working pumps. It
combines the two flows in a single pressure channel and then distributes the hydraulic oil to all way
valves.
At the return side, the pilot plate collects the oil flowing from the T channel of the way valves and feeds
it through the pressurisation valves 107 and 108 and then through the connection "T" (directly to
tank) and "K" (first to radiator) and then back to the hydraulic tank. The automatic control of the oil
cooling system is based on the hydraulic fan control and the proportional solenoid valve Y53 attached
to the valve 110.
In addition, the pilot plate 100 generates the highest LS pressure based on the pressures in the va-
rious LS channels of the way valves. This high pressure flow is then communicated through the con-
nection "LS" to the pump controller.
4 Functions of the valves in the pilot plate 100
4.1 Pressure cut-off valve 101
4.1.1 Function of pressure cut-off valve

This valve limits the maximum LS pressure in the pilot plate 100 to the preset value.
This ensures that the maximum pump high pressure is limited by the pump regulator to a pressure
that is maximum -p (LS) higher.
If the consumer is for example moved to the stop, the working pump of the LS regulator is swivelled
to the Qmin stop and the maximum pressure is maintained. The higher set secondary pressure-relief
valves fail to respond.
7.55.15
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MJFCIFSS
Fig. 11 Section drawing of pressure cut-off valve
1 Valve cartridge 6 Valve cone

2 Sealing flange nut 7 Backing ring
3 Threaded stud 8 O-ring
4 Spring plate 9 O-ring
5 Valve insert 10 Spring
4.2 Pump valve 102

The valve 102 limits the pressure difference between the pump high pressure and the LS pressure
to a value above the value -p (LS) set at the pump.
The valve prevents pressure peaks that might occur in the dynamic behaviour of the pump and that
cannot be reduced by the -p regulator, for example during the sudden closing of a spool, when the
drive motor is started, etc.).
7.55.16
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MJFCIFSS
Fig. 12 Sectional drawing of pump valve
11 Valve cartridge 15 Spring plate

12 Adjusting screw 16 Valve insert
13 Sealing flange nut 17 Backing ring
14 Spring 18 O-ring
4.3 Valve / LS grapple shutdown 106 grapple operation, see Fig. 13

If grapple operation is preselected (push button S85 actuated) and if the movements "extending stick"
is started, the connection "Z1" of the pilot plate 100 is pressurised with servo pressure and the shifting
piston of the valve 106 is switched to its closed position.
The pressure in the "close grapple" circuit is thus not built up in the main LS channel.
This prevents that the high pressure in the "close grapple" circuit resulting in a reduction in the stick
extending speed. The option to propel a load using the grapple remains therefore still possible, even
if the operator keeps the grapple tongs closed against the stop.
4.4 Pressurisation valves 107 and 108, see Fig. 13

These valves are used to maintain a slight counterpressure in the return circuit of the way valves (pre-
vention of cavitation).
At normal operating temperatures, the oil flows through the pressurisation valve 108 (3bar) back to
the hydraulic oil cooler. If the hydraulic oil is cold, the counterpressure in the return circuit is increa-
sed. The valve 107 (5bar) set to a slightly higher value is opened and allows the oil to flow back to
the tank. The hydraulic oil cooler is thus protected against pressure peaks.
The pistons 113 and 114 in the valve 110, (see Fig. 9 on page13), can increase the response pressure
of the valves 107 and 108 for certain work procedures.
4.5 Valve 110 for the oil return from boom and stick, see Fig. 13
The servo pressures at the connection y1 of the way valve 220 (retracting boom cylinder) and at
7.55.17
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MJFCIFSS
the connection x2 of the way valve 240 (extending stick cylinder) are connected by internal bores
in the valves and in the pilot plate 100 with the valve 110.
If one of the above movements is started, the shift valve 111 is switched via the shuttle valve 112 (in
industrial models: one valve only). The pilot control pressure at the connection P3 of the pilot plate
100 is built up at the external working surfaces of the pistons 113 and 114.
These pistons apply a force to the cones in the valves 107 and 108. This force is in the same direction
as the effect of the preload spring of the valves.
This results in an increase in the counterpressure in the tank channel of the pilot plate and thus faci-
litates the taking up of oil at the piston side of the boom cylinders (or at the piston side of the stick
cylinder). Caviation is thus prevented.
4.6 Temperature-dependent hydraulic oil cooling
4.6.1 No oil cooling (for oil temperatures up to 40 °C), see Fig. 10

The valve Y53 is powered (740 mA). The channel for the control oil from connection P3 to the piston
113 is open through the valves Y53 and 112.
The cone of the pressurisation valve 108 is pressurised at the spring side and thus blocks the return
oil flow to the oil cooler.
4.7 Oil cooling (for oil temperatures above 40°C), see Fig. 10
The valve Y53 blocks the channel of the control oil to the piston 113 proportionally to the current to
Y53 (740 mA-100 mA). The valve 108 is released.
The oil flow (return oil flow) increases proportionally to the opening movement of the valve Y53 (3 bar
opening pressure) through the valve 108, the connection K and the oil cooler.
7.55.18
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MJFCIFSS
Fig. 13 Sectional drawing of pilot plate
100 Pilot plate 110 Regeneration plate

101 Pressure cut-off valve (LS pressure) 111 Shift valve
102 Pump valve 112 Shuttle valve (2x in construction model)
106 Valve / LS grapple shutdown 113 Piston
107 Pressurisation valve / return T 114 Piston
108 Pressurisation valve / return K Y53 Radiator shift valve
7.55.19
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MJFCIFSS
4.8 Lowering restrictors 115-117
Fig. 14 Lowering restrictor at pilot plate
4.8.1 Lowering restrictor for boom cylinder 115

This restrictor is used in the return channel from the piston side of the boom cylinder. It thus limits the
retracting speed of the boom cylinder.
4.8.2 Lowering restrictor for stick cylinder 116

This restrictor is used in the return channel from the piston side of the stick cylinder. It thus limits the
retracting speed of the stick cylinder.
4.8.3 Lowering restrictor for bucket cylinder 117

This restrictor is used in the return channel from the piston side of the bucket cylinder. It thus limits
the retracting speed of the bucket cylinder.
4.9 Pressure-relief valve 248 (bypass valve)
Note!
The pressure-relief valve 248 is only installed in construction models.
The valve is factory-set and its settings may not be changed.
The pressure-relief and suction valve 248 consists of a housing with a main and a pilot control sec-
tion. The main control section consists of the piston 46 with the needle piston 53 and is pressed by
the springs 47 and 48 into the valve seat (sealed seat).
The pilot control section consists of a valve cone 50 that is pressed by the spring 51 into the valve
seat (sealed seat). The maximum response pressure is adjusted by means of shims 60.
By increasing the control pressure at the piston 58, the maximum pressure value can be lowered. By
turning the adjusting screw 52, the travel of the piston 58 can be limited, so that the lowered response
pressure (caution: factory settings!) of the response pressure can be set to the desired value.
If required, the piston 58 can be blocked with the adjusting screw 52. This disables the control pres-
sure relief and the standard maximum pressure settings are applied.
7.55.20
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MJFCIFSS
Design and function of the way valves
Fig. 15 Pressure-relief valve 248
46 Piston 58 Piston
47 Spring 59 Spring
48 Spring 60 Shims
50 Valve cone 61 Shims
51 Spring 62 Nozzle
52 Adjusting screw 63 O-ring
53 Needle piston A2 Consumer channel
54 Piston face C Chamber C
55 O-ring D Chamber D
56 Transverse slot T1 Tank channel
57 Control pressure channel
5 Design and function of the way valves
This chapter describes the way valve 220 for boom cylinder. The following way valves operate in the
same way:
240 for stick cylinder
260 for bucket cylinder
280 for support cylinder
500 for AHS11 (hydraulic hammer)
520 for AHS11 (auxiliary cylinder)
The way valve 220 is designed as a disc valve. It is mounted on the base plate (pilot plate 100) and
consists of a way valve housing 24 with the connections P, LS, T and the consumer flange connec-
tions A and B located above them. The valve contains the spool 223 and the two pressure balances
225 and 226 containing the switches 227 and 228.
7.55.21
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MJFCIFSS
At the secondary side, the unit is equipped with a pressure-relief and suction valves 221 and 222.
The control connections in the lids 19 contain restrictor check valves 25. The bleeder valves 23 for
the lid 19 are mounted in the way valve housing 24.
The stop screws 21 limit the piston stroke and thus determine the flow volume when the nominal va-
lue -p (LS) is reached in the piston rod.
The shims 18 can be used to adjust the preload of the regulation springs 20 and thus the control pres-
sure at the start of the opening movement.
Depending on the consumer and the fed consumer side, the pilot control connections "x" and "y"
(threaded bores) might be equipped with restrictor check valves 25, see Fig. 17. The bucket cylinder
section 260 does not contain any restrictor check valves 25.
The valves 23 are used to limit the pressure and bleed the control oil in the two lids 19.
The secondary pressure-relief valves 221 and 222 are designed as cartridge valves and are screwed
in below/above the consumer connections in the way valve housing. They limit the secondary pres-
sures between the spool and the consumer to the set maximum values and feature an integrated suc-
tion function. This means that they allow for oil flow from the return to the consumer connection side,
as soon as the pressure in "A" or "B" drops below the pressure in "T".
The suction valves 281 and 282, (see Way valve for the support section 280 on page 26) are of the
cartridge type and screwed in above/below the consumer connection in the way valve housing 280.
They allow for the flow of oil from "T" to the respective consumer connection "A4" or "B4" and thus
prevent cavitation.
Fig. 16 Hydraulic diagram of the boom cylinder way valve 220
18 Shim 220 Way valve / boom cylinder

19 Lid 221 Secondary pressure-relief valve
20 Regulation spring 222 Secondary pressure-relief valve
21 Stop screw 223 Spool
22 Sealing flange nut 225 Load compensator P-A
23 Pressure-relief valve/bleeder valve 226 Load compensator P-B
24 Way valve housing 227 Switch
25 Restrictor check valve 228 Switch
7.55.22
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MJFCIFSS
5.1 Way valve for the boom cylinder section 220
Fig. 17 Way valve for the boom cylinder section 220
7.55.23
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MJFCIFSS
5.2 Way valve for the stick cylinder section 240
Fig. 18 Way valve for the stick cylinder section 240
7.55.24
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MJFCIFSS
5.3 Way valve for the bucket cylinder section 260
Fig. 19 Way valve for the bucket cylinder section 260
7.55.25
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MJFCIFSS
5.4 Way valve for the support section 280
Fig. 20 Way valve for the support section 280
7.55.26
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MJFCIFSS
5.5 Way valve for the travel section 160

The spool 163 contains two pressure balances (load compensators) 165 and 166, which in turn con-
tain the switches 167 and 168.
The spool determines the oil volume fed to the connected consumer, depending on the control pres-
sure applied to the connection "x5" or "y5", the pressure in the LS channels and the total flow volume
of the working pumps.
The stop screws 21 limit the piston stroke and thus determine the flow volume when the nominal va-
lue -p (LS) is reached at the spool.
The shims 26 can be used to adjust the preload of the regulation springs 20 and thus the control pres-
sure at the start of the opening movement.
Depending on the consumer and the fed consumer side, the pilot control connections "x5" and "y5"
might be equipped with restrictor check valves 23.
The valves 25 are used to limit the pressure and bleed the control oil system in the two lids 19.
The suction valves 161 and 162 are of the cartridge type and screwed in above/below the consumer
connection in the way valve housing. They allow oil to flow from the return side to the consumer con-
nection as soon as the pressure in "A5" or "B5" drops below the pressure in "T".
Fig. 21 Hydraulic diagram of the travel way valve 160
18 Shim 160 Way valve / travel motor

19 Lid 161 Suction valve
20 Regulation spring 162 Suction valve
21 Stop screw 163 Spool
22 Sealing flange nut 165 Load compensator P-A
23 Pressure-relief valve/bleeder valve 166 Load compensator P-B
24 Way valve housing 167 Switch
25 Restrictor check valve 168 Switch
7.55.27
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MJFCIFSS
Fig. 22 Way valve for the travel section 160
7.55.28
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MJFCIFSS
5.6 Way valve for the grapple rotation section 540
Fig. 23 Way valve for the grapple rotation section 540
7.55.29
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MJFCIFSS
Fig. 24 Hydraulic diagram for the grapple rotation section 540
41 Measuring point xP (pump pressure)

45 Measuring point xLS (LS pressure) 246 Restrictor check valve / control pressure
100 Pilot plate 247 Stroke limiter / spool
ding
103 Restrictor (LS central nozzle) 262 Secondary pressure-relief valve / retrac-
ting
106 Valve / LS grapple shutdown 263 Spool / boom cylinder
Control pressure
117 Lowering restrictor / bucket grapple cylin- 287 Stroke limiter / spool
der
Control pressure
7.55.30
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MJFCIFSS
Design and function of the valves 161-282

ding
222 Secondary pressure-relief valve / retrac- B-B5 High-pressure connections
ting
ding
ting
6 Design and function of the valves 161-282
6.1 Secondary pressure-relief valves for the boom, bucket and stick sections 220,
240 and 260 respectively
The pressure-relief and suction valves screwed into the way valves consists of a housing with a main
and a pilot control section. The main control section consists of the piston 26 with the needle piston
33 and is pressed by the springs 27 and 28 into the valve seat (sealed seat).
The pilot control section consists of a valve cone 29 that is pressed by the spring 30 into the valve
seat. The force of the spring 31 acting on the valve cone 29 can be adjusted with the adjusting screw
31, in order to set the response pressure of the pressure-relief valve to the desired value.
7.55.31
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MJFCIFSS
Fig. 25 Sectional drawing
23 Bleeder valve 34 O-ring

26 Piston 35 Transverse slot
27 Spring 36 Piston face
28 Spring B Chamber B (consumer channel)
29 Valve cone C Chamber C
30 Spring D Chamber D
31 Adjusting screw T Tank channel
32 Lock nut T1 Tank channel
33 Needle piston
Note!
when unscrewing the secondary pressure-relief valves, the O-ring 34 might remain in the valve hou-
sing.
To prevent this, carefully loosen the secondary pressure-relief valves and unscrew them from
the housing.
Always remove the O-rings from the housing, inspect them for damage and replace them, if ne-
cessary.
6.2 Pressure-relief valve function

If the pressure in the chamber B through the channel in the needle piston 33 in chamber C reaches
the setting value of the valve cone 29, the cone is opened. The oil held back behind the valve cone
29 in the chamber D can now flow through the channel T1 to the chamber T.
This results in a pressure drop in the chamber C, and the piston 26 with the needle piston 33 is lifted
by the pressure acting on the effective piston surface 36. The needle piston 33 reaches the valve
7.55.32
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MJFCIFSS
cone and positions itself at its front face.

The connection from the chamber B to the chamber T is established and the backpressure is relie-
ved. To ensure a more effective control of the pressure-relief valve, the upper front surface of the
needle piston 33 is equipped with a transverse slot 35. If the needle piston 33 is positioned on the
valve cone 29, the transverse slot 35 acts as a restrictor.
The oil flows through the channel in the needle piston 33 and via the transverse slot 35 in the upper
front face to the chamber C. If the pressure is lower than the force of the spring 30, the pressure dif-
ference between the chambers B and C is equalised. As a consequence, the force of the springs 27
and 28 acts on the piston 26, pushing it into its valve seat.
6.3 Suction valve function

The channel T is always pressurised (preload valve in the pilot plate). If pressure is built up in the
chamber B, and this pressure is lower than the pressure in the channel T, a pressure difference oc-
curs and the oil in the chamber T acts on the effective piston surface 36. The piston 26 is pushed
against the force of the springs 27 and 28 so that it is shifted, opening the connection between the
chamber T and the chamber B. The resulting pressure equalisation prevents cavitation.
6.4 Suction valves for travel and support sections 160 and 280 respectively
The suction valves 161, 162, 281, 282 screwed into the way valves 160 and 280 (with bypass) consist
of a housing with the valve seat 43 containing the piston 39 with the spring 40. The valves are factory-
set and cannot be adjusted.
The channel T is always pressurised. If pressure is built up in the chamber B, and this pressure is
lower than the pressure in the channel T, a pressure difference occurs and the oil in the chamber T
acts on the effective piston surface 38. The piston 39 is pushed against the force of the spring 40 so
that it is shifted, opening the connection between the channel T and the chamber B. The resulting
pressure equalisation prevents cavitation.
Fig. 26 Suction valves for travel and support sections
7.55.33
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MJFCIFSS
Auxiliary way valves for AHS 1 and AHS 11
7 Auxiliary way valves for AHS 1 and AHS 11
23 Bleeder valve 160 Way valve / travel

37 Housing 161 Suction valve
38 Effective piston face 162 Suction valve
39 Piston 280 Way valve / support
40 Spring 281 Suction valve with bypass
42 Spring chamber 282 Suction valve with bypass
43 O-ring B Consumer connection
44 Connecting channel T Tank channel
For additional functions, e.g. accessory kits AHS1, AHS11 (AHS1+AHS11=AHS12) more additional
axles can be flange-mounted to the left-hand side of the pilot plate (seen in the direction of travel).
The basic design of the way valves 500 and 520 is identical with that of the valves used for the wor-
king movements 220 etc. (see Design and function of the way valves on page 21).
If one or more additional axles are retrofitted, the end plate 123 must be removed and the desired
additional axle must be flange-mounted to the pilot plate 100.
Note!
For a description of the function and settings of the AHS 11/AHS 12 accessory kit, see group 16.50.
7.55.34
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MJFCIFSS
Technical data
Fig. 27 Way valves for AHS 11 and AHS 12
8 Technical data
Spool Unit 500 520

Hammer/ Additional
cylinder cylinder
Ex- Re- Ex- Re-
tend tract tend tract
Nominal width of mm 18 14
block
Consumer connec- () 3/4 3/4
tion
Ø piston rod mm 25 25
7.55.35
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MJFCIFSS
Technical data
Spool Unit 500 520

Hammer/ Additional
cylinder cylinder
Ex- Re- Ex- Re-
tend tract tend tract
Piston stroke mm 9.0 9.0 9.0 9.0
Setting value X mm 40.0 40.0 40.0 40.0
D (shims) mm 2.0 2.0 1.0 1.0
p1bar ± 0.5 mm bar 8.5 8.5 8.5 8.5
p2bar ± 0.5 mm bar 21.5 21.5 21.5 21.5
Qn (A)/Qn(B) l/min
A 914 C 250 250 250 250
A 924 C 250 250 250 250
Restrictor check val- mm

ve
At connection x
At connection y
Leak oil max. cm3/min 90 90
at load pressure bar 150 150
at oil temperature °C 50 50
Note!
Shim thickness: "D": 0.3mm; 0.5mm; 1.0mm
Qn (A)/ Qn (B) = nominal flow rate at outlet A / B at 30 bar -p = nominal value
p1 = control pressure at begin of control
8.1 AHS 11 way valve

The design of the individual segment for the working movement "hydraulic hammer" corresponds to
that of the boom, stick and support way valves. For the "hydraulic hammer" function, a secondary
pressure-relief valve that can be adjusted by means of the control pressure is installed.
7.55.36
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MJFCIFSS
Technical data
Fig. 29 Hydraulic diagram of AHS 11
Fig. 30 AHS 11
501 Secondary pressure-relief valve with addi- 505 Stroke limiter / spool
tional pressure stage
7.55.37
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MJFCIFSS
Technical data
502 Secondary pressure-relief valve with addi- 506 Pressure-relief and bleeder valve
tional pressure stage
503 Spool 507 Pressure-relief and bleeder valve
504 Stroke limiter / spool
8.2 Function of the secondary pressure-relief valves 501 / 502

The pilot-controlled pressure-relief and suction valve ensures the pressure and sucks up oil. The pilot
control cone 73 is pre-loaded with the pressure spring 74 and the main cone 71 is hydraulically inser-
ted. The pilot control cone 73 and the main cone 71 are opened as soon as the pressure value is
reached. The preload of the pressure spring 74 and thus the pressure settings are determined based
on the force applied to the piston 76:
8.2.1 without application of control pressure (low pressure)

The force applied to the piston 75 is determined by the adjusting screw 80. The further the piston 75
is pushed inwards through the adjusting screw 80, the greater the preload force of the pressure spring
74 and thus the adjusting pressure of the valve 501 / 502.
8.2.2 with application of control pressure (high pressure)

If the port Z is pressurised through the proportional solenoid valve Y414 with a preset control pres-
sure, the same pressure is applied through the bore Z1 to the piston 76. The piston 76 applies an
additional force to the piston 75. As a result, the total preload force applied to the pressure spring 74
is increased, and thus also the pressure of the valve. The maximum value for the pressure increase
can be adjusted with the limiter screw 80.
7.55.38
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MJFCIFSS
Technical data
Fig. 31 Pressure-relief valve with external additional control pressure stage
70 Valve cartridge 79 Lock nut

71 Main cone 80 Adjusting screw / low pressure
72 Pressure spring 81 Lock nut
73 Pilot control cone 82 Adjusting screw characteristic
75 Piston 501 Secondary pressure-relief valve
77 Pressure spring Z Control pressure connection of Y414
78 Adjusting screw / high pressure Z1 Bore / oil channel
8.3 AHS 12 (AHS 1 + AHS 11) way valve

The basic design of the individual segment of the working movement "hydraulic hammer", the hydrau-
lic boom adjustment, the telescopic demolition stick, the scrap shears, the concrete crusher, the sor-
ting grapple, etc. correspond to that of the boom, stick and support valve.
7.55.39
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MJFCIFSS
Technical data
Fig. 33 AHS 12
521 Secondary pressure-relief valve 525 Stroke limiter / spool

522 Secondary pressure-relief valve 526 Pressure-relief and bleeder valve
523 Spool 527 Pressure-relief and bleeder valve
524 Stroke limiter / spool
7.55.40
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MJFCIFSS
Technical data
8.4 Function of the secondary pressure-relief valves 521 / 522
Note!
For a detailed description of the secondary pressure-relief valves, (see Secondary pressure-relief
valves for the boom, bucket and stick sections 220, 240 and 260 respectively on page 31).
7.55.41
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MJFCIFSS
Technical data
7.55.42
copyright by
MJFCIFSS
Service Manual Leak oil check at control valve blocks
Function and design
Leak oil check at control valve blocks
The leak oil of a spool is measured by means of the extending or retracting speed of the pressurised
hydraulic cylinder, which is connected to the spool in neutral position.
The volume of leak oil in the control valve block should be measured at a load pressure of 150 bar
and a temperature of 50°C (in hydraulic tank).
Before checking the control valve block for leak oil, first check the secondary valves (visual inspec-
tion, with valve exchange, if this is required) and the operating cylinder (dummy), as the respective
values refer only to leakage from the spool in the control valve block.
To check the block for leak oil from the spool, connect a pressure sensor at the respective pressure
line between the operating cylinder and the control valve block (use measuring equipment, if re-
quired).
Warm up the machine to its normal operating temperature.
Extend attachment
until the pressure sensor indicates a value of 150 bar (apply load, if necessary).
Apply a mark (with marker) on the cylinder piston rod in order to measure the distance the piston
rod travels in one minute.
The maximum permissible extending and retracting speed of the piston rod (or the permissible leak
oil volume from the spool respectively) are shown in the diagram, (see Leak oil diagram on page 2).
The maximum permissible leak oil volume is specified in the technical data of the respective control
valve block documentation.
Note!
The values in the diagram refer to a system where a single operating cylinder is supplied with oil by
a single spool.
For systems with two operating cylinders supplied by one spool, the maximum permissible speed is
half that for single operating cylinder systems.
A 900 C-LI 14675- 7.68.1

A 924 C-LI 34519-
Leak oil check at control valve blocks Service Manual
Function and design
Fig. 1 Leak oil diagram
Va: extending speed of piston rod

Ve: retracting speed of piston rod
Example:
In a A 904 C machine the single bucket cylinder with a piston diameter D = 120mm and a rod diameter
d = 80mm is fed by a single spool 260 with NW 22.
In this control valve block (NW 22), the maximum leak oil rate per spool is Q= 60 cm3 /min.
According to the diagram, this corresponds to a maximum permissible retracting speed of the cylinder
of 5.2 mm/min. The maximum permissible extending speed of the cylinder is 9.5 mm/min
7.68.2 A 900 C-LI 14675-

A 924 C-LI 34519-
Service Manual Rotary connection 6 x
Description
Rotary connection 6 x
1 Description
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.
Stator 2, pipe coupling 4 and flange 5 with connections 1 - 6 are connected to the undercarriage via
the stator of the 7x rotary connection (high pressure) . Rotor 1 with connections 1 - 6 is fixed to the
uppercarriage via the rotor of the 7x rotary connection (high pressure).
There are bores leading from line connections 1 - 6 of the uppercarriage to the annular chambers.
Rotor seal 22 in rotor 1 seals them off against each other.
Every annular chamber is connected to pipe coupling 4 and the connections of flange 5 via a radial
and axial bore in stator 2.
The two V-seals 21 prevent the penetration of dirt.
Fig. 1 Rotary connection
7.70.1
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MJFCIFSS
Rotary connection 6 x Service Manual
Connections and hydraulic connections
2 Connections and hydraulic connections
Connection 1 Brake system / working brake

Supply from the foot brake valve (compact brake block), connection B1, to the
multi-disc brakes / front axle
Connection 2 Transmission
Supply from brake and HBGV switch block (connection A) to shift lo
ck / gearbox connection P1
Connection 3 Transmission
Supply from brake and HBGV switch block (connection B) to shift lo
ck / gearbox connection P2
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 (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 Removal of 6 x rotary connection for sealing works, see Fig. 2

Mark hydraulic lines leading to the rotary connection (bottom). Disconnect.
Remove hollow screw 6 completely. Pull off flange 5. Be careful with seal washer 7.
Mark hydraulic lines leading to rotary connection (top). Disconnect.
Remove Allen head screws 32. Remove driver 30.
Remove nut 29. Remove washers 28. Pull rotary connection 25 from rotary connection 40.
3.2 Installation of 6 x rotary connection after sealing works, see Fig. 2

Insert complete rotary connection 25 into rotary connection 40. Install lid 44. Install nuts 29 com-
plete with washers 28 on screws 27.
Install driver 30 on rotary connection 40. Screw down with Allen head screws 32 and washer.
Place seal washer 7 in flange 5. Put flange 5 on pipe coupling 4 of the rotary connection. Pay at-
tention to the locking pin in coupling 4, bore in seal washer 7 and flange 5.
Install hollow screw 6 complete with tooth lock washer 9. Tighten with torque: 50 Nm.
Connect all the hydraulic lines to the completed rotary connection. Pay attention to markings you
made before.
7.70.2
copyright by
MJFCIFSS
Removal and installation
Fig. 2 Installation and removal of rotary connection
7.70.3
copyright by
MJFCIFSS
Exploded view
4 Exploded view
Fig. 3 Exploded view: 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
8 Thrust washer 999 Seal kit
7.70.4
copyright by
MJFCIFSS
Sectional drawing
5 Sectional drawing
Fig. 4 Sectional drawing: rotary connection
7.70.5
copyright by
MJFCIFSS
Sectional drawing
7.70.6
copyright by
MJFCIFSS
Description
Rotary connection 7 x
1 Description
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 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.
Fig. 1 Rotary connection
2 Connections and hydraulic connections
2.1 A 900 C Litronic

Connection 0 Leak oil
Recycling of leak oil from travel motor and auxiliary gearbox
7.75.1
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MJFCIFSS
Connections and hydraulic connections
Connection 1 Travel motor

Supply from control block connection A2 to travel motor (forward)
Connection 2 Support cylinder
Supply from control block connection B1 to support cylinders (retract)
Supply from control block connection B2 to travel motor (reverse)
Supply from control block connection A1 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 A 904 C Litronic

Connection 0 Leak oil
Recycling of leak oil from travel motor and auxiliary gearbox
Supply from control block connection A2 to travel motor (forward)
Supply from control block connection A1 to support cylinders (extend)
Supply from control block connection B2 to travel motor (reverse)
Supply from control block connection B1 to support cylinders (retract)
Supply from servostat to steering cylinder (travel, right)
Supply from servostat to steering cylinder (travel, left)
7.75.2
copyright by
MJFCIFSS
Removal and installation
3 Removal and installation
3.1 Removal of 7 x rotary connection for sealing works, see Fig. 2

Mark hydraulic lines leading to rotary connections 10 and 125. Disconnect.
Remove Allen head screws 27. Remove driver 25.
Remove nuts 21. Remove washer 20.
Pull rotary connection 125 from rotary connection 11.
Unscrew hex head screw 12. Lift rotary connection 10 out of undercarriage.
3.2 Installation of 7 x rotary connection after sealing works, see Fig. 2

Replace rotary connection 10 into undercarriage. Let the driving pin snap into driver 19. Replace
screws 12 and 17 complete with retaining washers 18.
Install rotary connection 125 in rotary connection 10. Place lid 3. Be careful with the seal.
Install nuts 121 complete with washers 120 on screws 116.
Install driver 25 on rotary connection 10. Screw down with Allen head screws 27 and washers 26.
Fasten flange 115 to rotary connection 125, using hollow screw 116 (tooth lock washer 119). Pay
attention to correct position of seal 117.
Re-connect hydraulic lines to rotary connections 10 and 15 (top and bottom). Pay attention to mar-
kings you made before.
Re-install all other lines and parts you may have removed before.
Fig. 2 Installation position of rotary connection
7.75.3
copyright by
MJFCIFSS
Exploded view
4 Exploded view
Fig. 3 Exploded view of rotary connection
3 Lid 19 Driver
4 Screw plug 25 Driver
5 Screw plug 26 Washer
6 Retaining washer 27 Allen head screw
7 Hex head screw 98 Seal kit - consists of 9 seals:
1 felt washer, 2 outer seals top / bottom, 7
inside seals
10 Rotary connection 115 Flange
11 Rotor 116 Hollow screw
12 Hex head screw 117 Seal
13 Stator 119 Tooth lock washer
15 Felt washer 120 Washer
16 Plug 121 Hex nut
17 Hex head screw 125 Rotary connection
18 Washer 126 Allen head screw
7.75.4
copyright by
MJFCIFSS
Sectional drawing
5 Sectional drawing
Fig. 4 Sectional drawing: rotary connection
7.75.5
copyright by
MJFCIFSS
Sectional drawing
7.75.6
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.
A 900 C-LI 14675- 7.80.1

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.
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
7.80.2 A 900 C-LI 14675-

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 Ø 1.2 / 0.3 mm

2 Valve body 12 Restrictor Ø 1.5 mm
3 Valve insert 13 Restrictor Ø 0.9 mm
4 Piston guide 14 Stroke stop
5 Piston 16 O-ring
6 Pressure spring 17 Backing ring
7 Spring sleeve 19 Backing ring
8 Valve cone 20 O-ring
9 Pilot control piston 22 Screw plug
10 Hex nut 29 O-ring
A 900 C-LI 14675- 7.80.3

MJFCIFSS
TC valve Service Manual
Sectional drawing
7.80.4 A 900 C-LI 14675-

MJFCIFSS
Service Manual Double stop valve for outrigger support
Function
Double stop valve for outrigger support
1 Function
The hydraulically releasable double stop valve is attached to the piston side of the support cylinders.
The valve seals the support cylinder at the piston and the piston rod side, shielding it against the high
pressure from the control valve block (flow direction ASt - A or BSt - BZ respectively).
Fig. 1 Double stop valve
A 900 C-LI 14675- 7.85.1

MJFCIFSS
Double stop valve for outrigger support Service Manual
2.1 Extending the support cylinder

The hydraulic oil is fed from connection A1 of the control valve block through connection AST and
acts on the valve cone 6a. It also flows through the bypass line and puts pressure onto the piston side
of the support cylinder 295.
As the piston rod side of the cylinder is closed by the 10, pressure is built up at the valve lifter 11. The
lifter is moved and oil flows from the piston rod side to the connection BST and back to the control
valve block.
2.2 Retracting the support cylinder

The hydraulic oil is fed from connection B1 of the control valve block through connection BST and
acts on the valve cone 6b. It also flows through the bypass line and puts pressure onto the piston rod
side of the support cylinder 295.
As the valve lifter 10 is in idle position, pressure is built up at the piston side of the cylinder.
As this pressure corresponds to that at the piston rod side, oil is pressed through the nozzle 7a to the
valve lifter 10, which is moved into operating position.
The return oil at the piston side flows through connection AST to the control valve block and then to
the tank.
Note!
Note
In the event of malfunctions (internal valve leakage, etc.) disconnect the pressure line and check
the valve, (see Inspection and repair on page 3).
The opening pressure at the connections AST and BST is approx. 40-45 bar.
Fig. 2 Hydraulic diagram of the double stop valve
7.85.2 A 900 C-LI 14675-

MJFCIFSS
Inspection and repair
3 Inspection and repair
(see Cutting plane - double stop valve on page 4)
3.1 Internal leakage in valve

Support is not stable
Check the sealing edge of the valve cone 6a or 6b and the pistons 10/11 for free movement and
correct seat respectively.
Remove the screw plug 19 / 22 or 21 respectively.
Pull the valve cone 6a or 6b from the valve block and inspect the sealing edges for scorings and
dirt.
Clean the valve block, insert the valve cone 6a or 6b and the pressure spring 14. Tighten the
screw plugs 21 or 22/19.
Remove the screw plug 18 and seal ring 16. Remove the stop 3 with the pressure spring 12 and
the spring plate 2 from the valve block 1.
Pull the valve lifter 11 from the housing.
Inspect the O-ring 25 and the Turcon-Glyd ring 24 for damage. Reuse only undamaged parts.
Inspect the valve lifter 11 for ridges. Check the housing for dirt.
Reinstall the parts in the correct sequence.
Remove the screw plug 20 with the O-ring 30.
Remove the spring plate 5 with the pressure spring 13 and the disc 29 from the valve block 1.
Pull the valve lifter 10 from the housing.
Inspect the O-ring 25 and the Turcon-Glyd ring 24 for damage. Reuse only undamaged parts.
Inspect the valve lifter 10 for ridges. Check the housing for dirt.
Reinstall the parts in the correct sequence.
If required, check whether there is any backpressure at the connection M1 / M2 when the support
cylinder is fully extended (use pressure sensor).
A 900 C-LI 14675- 7.85.3

MJFCIFSS
Fig. 3 Cutting plane - double stop valve
Fig. 4 Cutting planes A - B and C - D
Fig. 5 Cutting planes E - F and G - H
7.85.4 A 900 C-LI 14675-

MJFCIFSS
Fig. 6 Cutting planes K - L and M - N
1 Valve block 15 Sealing ring

2 Spring plate 16 Sealing ring
3 Stop 17 Screw plug
5 Spring plate 18 Screw plug
6a Valve cone / check valve 19 Screw plug
6b Valve cone / check valve 20 Screw plug
7a Nozzle Ø 1.0 mm 21 Screw plug
7b Nozzle Ø 1.0 mm 22 Screw plug
8 Screw plug 23 Sealing ring
9 Screw plug 24 Turcon-Glyd ring
10 Valve lifter (stop valve / piston side) 25 O-ring
11 Valve lifter (stop valve / piston side) 26 O-ring
12 Pressure spring 29 Disc
13 Pressure spring 30 Sealing ring
14 Pressure spring
A 900 C-LI 14675- 7.85.5

MJFCIFSS
7.85.6 A 900 C-LI 14675-

MJFCIFSS
Service Manual
SUBGROUP - INDEX
Section Group Type
Overview of electrical symbols 8.01.1 A 900 C-LI 14675-

A 904 C-LI 16000-
A 914 C-LI 35112-
A 924 C-LI 34519-
Component arrangement 8.10.1 A 900 C-LI 14675-

A 904 C-LI 16000-
Component arrangement 8.12.1 A 900 C-LI EDC 24677-

A 904 C-LI EDC 30580-
Component arrangement 8.14.1 A 914 C-LI 35112-

A 924 C-LI 34519-
Electrical system 8.32.10 A 900 C-LI 14675-

A 904 C-LI 16000-
Electrical system (construction model) 8.34/E3.1 A 900 C-LI 24677-

A 904 C-LI 30580-
Electrical system (industrial model) 8.38/E3.1 A 904 C-LI 30713-
Electrical system (construction model) 8.40/E3.1 A 914 C-LI 35112-

A 924 C-LI 34520-
Electrical system (industrial model) 8.42/E3.1 A 924 C-LI 34520-
Operating symbols on the operator's platform 8.44.1 A 900 C-LI 14675-

A 904 C-LI 16000-
A 914 C-LI 35112-
A 924 C-LI 34519-
List of electric kits 8.45.1 A 900 C-LI 14675-

A 904 C-LI 16000-
Excavator control BST (version 2.. or V5..) 8.70.1 A 900 C-LI 14675-
A 904 C-LI 16000-
Monitoring display 8.71.1 A 900 C-LI 14675-

A 904 C-LI 16000-
8.1
MJFCIFSS
Service Manual
Monitoring display 8.72.1 A 900 C-LI 21794-

A 904 C-LI 16000-
Monitoring display from version 4.4/4.5/4.6 8.73.1 A 900 C-LI EDC 24677-
A 904 C-LI EDC 30580-
A 914 C-LI 35112-
A 924 C-LI 34519-
Control panel 8.79.1 A 900 C-LI 14675-

A 904 C-LI 16000-
A 914 C-LI 35112-
A 924 C-LI 34519-
Error code list 8.80.1 A 900 C-LI 14675-

A 904 C-LI 16000-
A 914 C-LI 35112-
A 924 C-LI 34519-
Slip ring rotary connection 8.82.1 A 900 C-LI 14675-

A 904 C-LI 16000-
A 914 C-LI 35112-
A 924 C-LI 34519-
Self-holding mechanism for quick-change 8.99.1 A 900 C-LI EDC

adapter locking A 904 C-LI
A 914 C-LI
A 924 C-LI
Directory of electric kits 8.100.1 A 900 C-LI EDC

A 904 C-LI EDC
A 914 C-LI
A 924 C-LI
8.2
MJFCIFSS
Service Manual Overview of electrical symbols
Overview of symbols
Overview of electrical symbols

Note!
A new software package is being used for the drawing of the electrical diagrams of machines from
models A 900 C 24677 and A 904 C 30580 .
The symbols and their meaning are shown in the table below for a better understanding of the dia-
grams.
1 Overview of symbols
Symbol Designation Symbol Designation
Input (assembly) Output (assembly)
NC contact, touch-sensitive NO contact, touch-sensitive
Speed sensor, 2-pin Angular speed encoder

Electrical accelerator pedal
Speed sensor, 2-pin Pressure switch, NC contact,

2-pin
Pressure switch changer Pressure switch with 4-20 mA

current output
Pressure switch with 0-5 V Pressure switch with swit-

voltage output ching output NC/NO contact
PNP
8.01.1
copyright by
MJFCIFSS
Overview of electrical symbols Service Manual
Overview of symbols
Level switch, 2-pin with swit- Level switch, 3-pin with swit-
ching output ching output (+)
Light switch with changing Inductive proximity switch NC

light, switching to dark contact PNP
Capacitive proximity switch Inclination sensor 4-20mA

NO contact NPN current output
Level switch, tank sensor Level switch, tank sensor

+ mechanical NC contact
Thermal NC contact Thermal NO contact with mo-

nitoring
Detector with switching out- Angle sensor including S/A

put converter
Loudspeaker Main light with position light
Roof-mounted light Beacon
8.01.2
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MJFCIFSS
Overview of symbols
Rear light with brake/tail light Heating element

and indicator
Heating element with thermal Heating flange

switch (NC contact)
Cigarette lighter Semiconductor fuse

(poly-switch)
General fuse Automatic cut-out

Automatic protective power
switch
Battery Alternator
Generator
lamp / general Horn
Buzzer Relay contact

Double NO contact
Relay contact Relay contact

NC contact NO contact
8.01.3
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MJFCIFSS
Overview of symbols
Relay contact Contact mirror relay

Changer
Electronic indicator relay Relay with 1 changeover con-

tact
Coil reset with diode
Coil (without reset) Coil with shut-down delay (wi-

thout reset)
Coil with switch-on delay Time relay

(without reset) (with drop-out delay)
Time relay
(with pick-up delay)
Coil with reset Coil with progress relay

Resistor (VDR) (surge relay)
Coil with suppressor diode Coil / inductivity

(reset with diode)
Starter DC motor with

blower
8.01.4
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MJFCIFSS
Overview of symbols
DC motor with blower, speed DC motor

adjustable
DC motor / pump DC motor / pump

Windscreen washer system
Windscreen wiper Servo motor
Slip ring contact Operating hour meter
Operating hour meter Speedometer
Backlit fuel indicator Backlit temperature indicator
Backlit clock Resistor
Glow plug Resistor, negative temperatu-

re coefficient hot conductor
8.01.5
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MJFCIFSS
Overview of symbols
Potentiometer Resistor, positive temperatu-

re coefficient cold conductor
Resistor, varistor Variable resistor

(voltage-dependent resistor) General
Multi-position switch Battery main switch, 1-pin,

4 positions actuator removable in positi-
on "0"
Battery main switch, 1-pin, Rotary switch with 3 positions

actuator removable in positi- (NC-off-NO)
on "1"
Hot start switch
NC auxiliary contact NO auxiliary contact
Interval relay Steering column switch with

horn, indicator
Mechanical NC limit switch Mechanical NC/NO limit

switch
8.01.6
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MJFCIFSS
Overview of symbols
Mechanical NO limit switch Mechanical changeover con-

tact limit switch for slip ring
Mechanical limit switch Button 1 NC contact, 1 NO

2 NO contact contact
Indicator light
Button NO contact / general Button NC contact / general
Hazard light switch with Ignition switch

search and function lighting (without pre-heating)
SWF switch with 2 changeo- SWF switch with 1 changeo-

ver contact, lighting and actu- ver contact, lighting
ation lock
DC/DC converter Diode

(direct current converter)
LED LED
flashing
Z diode Amplifier
8.01.7
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MJFCIFSS
Overview of symbols
Amplifier with LED for input/ NPN transistor

output, fault
PNP transistor Aerial
Terminal (disconnectable) Potential bolts (screwed con-

nections)
Potential point Cable kit view for

(plug connections) "stripped"
M10 ground bolt (slave)

M10 ground bolt (master symbol)
Cable kit view for Socket contact

"wire end ferrule"
Socket connection Metering pump

with terminals
Valve Valve with reset (diode)
8.01.8
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MJFCIFSS
Overview of symbols
Valve with reset Valve with reset

(interconnected Z-diodes) (varistor)
Twisting of wires Revision note
Revision note Cable kit - note
Tightness symbol Cable kit - note
Cable kit - note Cable kit - note
Cable kit - note Cable kit - note
Standard plug connection Device plug

(plug-plug) (device/valve plug)
8.01.9
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MJFCIFSS
Overview of symbols
Forced wiring Field, housing, assembly
Potential arrow target directly Potential arrow source

from fuse
Potential arrow target Potential arrow source
Potential arrow target Cross references

directly to earth Source documents
Cross references
Target documents
8.01.10
copyright by
MJFCIFSS
Overview of symbols
1.1 General equipment
Fig. 1 General equipment
1 Unit code 7 Connecting pin 2 (-) supply

2 Location sign 9 Connecting pin 3 (output)
3 Equipment code (EC) 10 Colour or exposed wire
4 Engine oil pressure 11 Output: switching contact can be PNP or
NPN
(power output, voltage output)
5 Function text 12 Output: NO contact
6 Type of converter p=pressure>electric 13 Technical data
unit
7 Connecting pin 1 (+) supply
8.01.11
copyright by
MJFCIFSS
Overview of symbols
1.2 Example of master - slave relationship in relay
Fig. 2 Master - slave relationship in relay
14 Relay coil (slave) 18 Cross reference to slave (coil)

15 Cross reference to master 19 Cross reference to master
16 Cross reference to slave 20 NO contact (slave)
17 Master symbol
8.01.12
copyright by
MJFCIFSS
Overview of symbols
1.3 Overview for the connection of the display (example)
Fig. 3 Overview for the connection of the display (example)
21 Equipment code (EC) 27 Module name

22 Physical address 28 Input/output address
23 Reference to slave (input/output) 29 Module number
24 Commend re. (input/output) 30 Pin name
25 Example 31 Plug name
26 Cross reference to master 32 Input/output address (for programmers /
software)
8.01.13
copyright by
MJFCIFSS
Overview of symbols
8.01.14
copyright by
MJFCIFSS
Service Manual Component arrangement
Control elements
Component arrangement
1 Control elements
Fig. 1 View of the operator's platform
A3 Radio S4 Direction indicator switch / horn

A154 Emergency control S7 Safety switch
A1001 Printed circuit board ESP01 S30 Travel selector switch
A1009 Additional circuit board (for kits) S71 Switch / emergency start / emergency
operation
A1001 Printed circuit board ESP02 S72 Switch / speed High/Low
H10-1 Signalling buzzer / warning S73 Switch / emergency operation
H10-2 Signalling buzzer / parking brake T1 Voltage transformer
P5 Operating hour meter U16 Electronics / BST excavator control
S1 Ignition switch
A 900 C-LI 14675- 8.10.1

MJFCIFSS
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Monitoring display
2 Monitoring display
Fig. 3 Monitoring display
A Analogue indicator H24 Indicator light / flow indicator

B Check display P2 LED indicator / coolant temperature
C Main screen P2.1 Warning range / coolant temperature
(red LED)
D Screen menu control P2 LED indicator / fuel level
H2 Indicator light / motor oil pressure P3.1 Reserve indicator / fuel level (red LED)
H12 Indicator light / battery S349 Screen button / BACK
H19 Indicator light / travel direction indicator S350 Screen button / DOWN
H20 Indicator light / parking brake S351 Screen button / UP
H23 Indicator light / accumulator pressure S352
(working brake)
8.10.3
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MJFCIFSS
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Printed circuit board A 1001 (ESP-01)
Fuses and relays

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K1 Relay / windscreen wiper K4 Relay / reserve

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K3 Relay / reserve
Amplifiers with indicator light diodes (LEDs)

Amplifier LED LED LED
V2 Additional pressure level H1 LED green H2 LED red H3 LED yellow
Input signal Fault Output signal
V3 Travel brake H4 LED green H5 LED red H6 LED yellow
V4 Slewing gear brake H7 LED green H8 LED red H9 LED yellow
V5 Solenoid valve - pilot cont- H10 LED green H11 LED yellow H12 LED red
rol Input signal Output signal Fault
V6 Fast travel H13 LED green H14 LED yellow H15 LED red
Input signal Output signal Fault
V7 Windscreen washer sys- H16 LED green H17 LED yellow H18 LED red
tem Input signal Output signal Fault
V8 Heater fan, level 1 H19 LED green H20 LED yellow H21 LED red
V21 Headlight - uppercarriage H25 LED green H26 LED yellow H27 LED red
V24 Roof light H28 LED green H29 LED yellow H30 LED red
V26 Beacon H31 LED green H32 LED yellow H33 LED red
V32 Glow plug H34 LED green H35 LED yellow H36 LED red
V37 Rotating device, right H40 LED green H41 LED yellow H43 LED red
Input signal Output signal Fault (R+L)
V44 Pressure cut-off valve H37 LED green H38 LED red H39 LED yellow
V57 Transistor / windscreen wi- H42 LED green
per Input signal
V83 Rotating device, left H44 LED green H45 LED yellow
Input signal Output signal
V92 Sensors H46 LED green
Input signal
A 900 C-LI 14675- 8.10.7

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Ý±³°±²»²¬ ¿®®¿²¹»³»²¬ Í»®ª·½» Ó¿²«¿´
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Control elements
1 Control elements
Fig. 1 Operator's platform

A 154 Emergency control S7 Safety switch
operation
A1100 Printed circuit board ESP02 S72 Switch / High/Low speed
H10-1 Signalling buzzer / warning S73 Switch / emergency actuation
P5 Operating hour meter T1 Voltage transformer
S1 Ignition switch U16 Electronics / BST excavator control
8.12.1
copyright by
MJFCIFSS
Component arrangement Service Manual
Control elements
Fig. 2 Operator's view: electrical control elements
E8 Cigarette lighter S6M Push button / magnet system ON/OFF /

option
H1 Monitoring display S32 Steering column switch / direction indica-
tor - horn
S2 Keyboard S44 Switch / hazard light
S5L Push button / turn grapple left S47 Switch / quick-change adapter (optional
equipment)
S5R Push button / turn grapple right S75 Push button / oscillating axle automatic
S5M Push button / (special function) S218 Switch / cab roof wiper (optional equip-
ment)
S6L Push button / (special function) Sx Additional switches for kits - see group
8.45
S6R Push button / (special function) U38 Air-condition control panel
8.12.2
copyright by
MJFCIFSS
Monitoring display

C Main screen P2.1 Warning range / coolant temperature (red
LED)
H23 Indicator light / accumulator pressure S352 Screen button / MENU and confirmation
(working brake) (OK)
8.12.3
copyright by
MJFCIFSS
Control console
3 Control console
Fig. 4 Control console
P4 Display / motor speed S38 Switch / special function 3 (changeover

kit)
S10 Switch / work headlight S39 Switch / special function 4
S11 Switch / windscreen washer system S41 Switch / beacon
S14 Switch / windscreen wiper S42 Switch / off-road gear
S16 Switch / parking brake S56 Switch / no function
S17 Switch / slewing gear brake S85 Switch / grapple operation
S18 Switch / overload warning system S86 Switch with LED / mode selection
S19 Switch / additional function (e.g. rotating S228 Push button / step up speed step
device)
S20 Switch / sensor-controlled low idle auto- S228 Push button / step down speed step
matic
S21 Switch / creeper gear S354 Switch / performance step: super finish
S22 Switch / parking light - travel light X2 Plug connection / control console - printed
circuit board A 1001
8.12.4
copyright by
MJFCIFSS
Control console
S35 Switch / servo shutdown X40 Plug connection / control console - screen
S36 Switch / special function 1 (speeder) X42 Code plug / control console
S37 Switch / special function 2 (changeover X50 Plug connection / control console - printed
from blade to outrigger) circuit board A1100
Note!
(M) This is where switched functions are being stored when the machine is shut down. When the
electronics are launched again, the original state will be restored (as before shutdown).
For information on keyboard repair, please refer to group 8.74.
Fig. 5 Rear of control console
8.12.5
copyright by
MJFCIFSS
4 Printed circuit board A 1001 (ESP-01)
Fig. 6 Printed circuit board A 1001 (ESP-01)
8.12.6
copyright by
MJFCIFSS
Fuses and relays


K3 Relay / reserve

per Input signal
Input signal
8.12.7
copyright by
MJFCIFSS
Plug connections
X1 Plug connection to U16 / 5-pin X14 Plug connection to power supply S2 /
3-pin
X2 Plug connection to S2 / 37-pin X16 Plug connection / 2-pin
X3 Plug connection to A1100 / 10-pin X17 Plug connection / 3-pin
X4 Plug connection to E1 / 4-pin X18 Plug connection / 6-pin
X5.1 Plug connection / 8-pin X19 Plug connection / 6-pin
X5.2 Plug connection / 3-pin X20 Plug connection to M3, M4, E2, E7, E9 /
10-pin
X6.1 Plug connection / 6-pin X21 Plug connection to kit: grapple S5 / 3-pin
X6.2 Plug connection / 8-pin X22 Plug connection to E52 / 2-pin
X7 Plug connection to sensor B19L / 3-pin X23 Plug connection / 2-pin
X8 Plug connection to sensor B19R / X30 Plug connection (diagnosis) / 9-pin
3-pin
X9 Plug connection to sensor B40 / 2-pin X31 Plug connection (service - plug) /
9-pin
X10 Plug connection to sensor B41 / 2-pin X32 Plug connection (keyboard) / 9-pin
X11 Plug connection to safety lever / X33 Plug connection (diagnosis) / 9-pin
4-pin
X12 Plug connection to S1 / 4-pin X43 Plug connection
X13 Plug connection to S57 / 2-pin
8.12.8
copyright by
MJFCIFSS
Fig. 7 a = plug-in plate, b = printed circuit board A1100 (ESP-02)
8.12.9
copyright by
MJFCIFSS
Fuses
F1 Parking light, tail light / left (2A) F14 E52 (15A)
F2 Parking light, tail light / right (2A) F15 B60, X220/1 (7.5A)
F3 V160, K330, K331 (7.5A) F16 E21, E22, E23, E24 (7.5A)
F4 V156, V158, X202/4 (15A) F17 X214-1/1 (15A
F5 V151, V152, V154 (15A) F18 X214-2/1 (15A)
F6 V150, brake light / right and left (15A) F19 E8 (7.5A)
F7 Work headlight, roof light (15A) F20 X215/1 (15A)
F8 Solenoid valve pilot control slewing-gear F21 S1 - class 30 (15A)
brake (7.5A)
F9 M4 (7.5A) F22 E7, X12/1 (7.5A)
F10 M3, X16/1, Y22, Y23 (15A) F23 E4 (7.5A)
F11 X214-3 (15A) F24 E3 (7.5A)
F12 Amplifiers A 1001 (15A) F250 Keyboard S2 - class 15 (2A)
F13 U16 (15A) F251 Keyboard S2 - class 30 (2A)
Indicator light diodes (LEDs)

H28 LED signal: ground travelling valves H55 LED: power supply X214-3/1
H29 LED: ground travelling valves H56 LED: power supply Amplifiers A1001
H37 LED: actuation of relay travel light K332 H57 LED: power supply U16
H38 LED: actuation of relay K334 H58 LED: power supply E52
H39 LED: actuation of relay K331 H59 LED: power supply X214-2/1
H41 LED: actuation of relay K333 H61 LED: power supply / LED: power supply
160, K330, K331
H44 LED: power supply class 15 H62 LED: fuse F250
H45 LED: power supply B60 H63 LED: power supply sensor 24V
H46 LED: power supply V156, V158, Y62, Y63 H64 LED E18, E16
H47 LED: power supply SF2, SF3, SF4 H65 LED E15, E17
H48 LED: power supply E19, E20, SF1, Y55, H66 LED E3
Y66
H49 LED: power supply E21, E22, E23, E24 H67 LED E4
H50 LED: power supply X214-1/1 H68 LED: power supply indicator unit
H51 LED: power supply Y22, Y23, M3, E9, H69 LED: power supply electronics
K302, X16/1
H52 LED: power supply M4 H70 LED: power supply class 30, X215/1
H53 LED: power supply Y6, Y7, Y3, Y24 H71 LED: power supply class 30 S1
H54 LED: power supply E2, E1 H72 LED: power supply class 30, E7, H9
Relay
K330 Relay socket / kit K333 Relay / kit
K332 Relay / travel light K335 Relay / overload warning device -
switchable
8.12.10
copyright by
MJFCIFSS
Amplifiers
V150 Amplifiers, kit SF1 V157 Amplifier, kit
V151 Amplifier, kit SF2 V158 Amplifier: kit safety lever
V152 Amplifier: kit SF3 V159 Amplifier: travelling valves
V153 Amplifier: kit SF4 V160 Amplifier: kit
V154 Amplifier: first gear V161 Amplifier: parking light
V155 Amplifier: oscillating axle V162 Amplifier: indicator unit
V156 Amplifier: servo kit V163 Amplifier: brake light
Plug connections
X14-2 Plug connection on A1100 / 4-pin X217 Plug connection to BS K334 / 6-pin
X50 Plug connection between S2 and A1100 / X218 Plug connection to KS excavator control /
25-pin 4-pin
X154 Plug connection to KS motor / 15-pin X219 Plug connection to BS overload warning
device, switchable / 2-pin
X155 Plug connection KS revolving deck / 15- X220 Plug connection to BS optional equipment
pin / 3-pin
X159 Plug connection to KS motor / 9-pin X221 Terminal for flow limitation / 3-pin
X200 Plug connection to KS revolving deck / X222 Plug connection magnet system / 2-pin
15-pin
X201 Plug connection to KS operator's platform X223 Plug connection input signal / 2-pin
/ 6-pin
X202 Plug connection to KS operator's platform X224 Plug connection oscillating axle automatic
/ 12-pin / 6-pin
X203 Plug connection to E8 / 2-pin X225 Plug connection analogue signal 1 / 3-pin
X204 Plug connection to KS excavator control / X226 Plug connection analogue signal 2 / 3-pin
3-pin
X205 Plug connection to kit SF1 / 2-pin X227 Plug connection frequency signal 1 / 3-pin
X206 Plug connection to BS SF2 / 2-pin X228 Plug connection frequency signal 2 / 3-pin
X207 Plug connection to BS SF3 / 2-pin X229 Plug connection hazard light / 2-pin
X208 Plug connection to BS SF4 / 2-pin X230 Plug connection / 3-pin
X209 Plug connection to servo kit / 2-pin X231 Plug connection: sub-D with CAN 2 bus
X210 Plug connection to BS safety lever / X232 Plug connection to KS console, right / 10-
2-pin pin
X211 Plug connection to BS servo / 2-pin X233 Plug connection to B33 / 3-pin
X212 Plug connection to BS servo / 2-pin X234 Plug connection to kit / 2-pin
X213 Plug connection to BS servo / 2-pin X235 Plug connection to fuses F250/251 / 4-pin
X214-1Plug connection to BS class 15 / 2-pin X246 Plug connection to KS revolving deck /
12-pin
X214-2Plug connection to BS class 15 / 2-pin X247 Plug connection to KS motor / 2-pin
X214-3Plug connection to BS class 15 / 2-pin X248 Plug connection to KS revolving deck / 2-
pin
X215 Plug connection to BS class 30 / 2-pin X249 Plug connection to KS revolving deck / 3-
pin
X216 Plug connection to BS K333 / 6-pin
8.12.11
copyright by
MJFCIFSS
D 934S A6 diesel engine
6 D 934S A6 diesel engine
Fig. 8 D 934S A6 diesel engine
A700 Engine control M1 Starter

B3 Transducer / coolant level R51 Heater flange
B12 Speed transducer (sensor) Y20 Magnetic coupling / a/c compressor
G1 Alternator
8.12.12
copyright by
MJFCIFSS
Tank and control oil unit
7 Tank and control oil unit
Fig. 9 Hydraulic tank, fuel tank - with control oil unit
B8 Transducer / hydraulic oil temperature Y7 Solenoid valve / slewing gear brake

B14 Transducer / hydraulic oil level Y24 Solenoid valve / creeper gear
B39 Transducer / fuel level Y50 Proportional solenoid valve / power con-
trol
H9 Horn Y51 Proportional solenoid valve / -p reduc-
tion
Y3 Solenoid valve / pilot control pressure Y66 Solenoid valve / oscillating axle support
8.12.13
copyright by
MJFCIFSS
Other components
8 Other components
Fig. 10 HBGV block and solenoid valve on basic boom's bearing block
Y6 Solenoid valve / 2nd gear resp. On-road travel

Y55 Solenoid valve: first gear
Fig. 11 Operator's platform from below
B20 Pressure switch / accumulator pressure

B40 Proximity switch / pilot pressure valve, travel
Grapple Brake light switch
cylin-
der
B60
Y62 Solenoid valve: travel forward
Y63 Solenoid valve: travel reverse
B266 Proximity switch / oscillating axle automatic
8.12.14
copyright by
MJFCIFSS
Other components
Fig. 12 Proportional solenoid valve: fan control Y347 (situated at blower motor of cooling unit)
Fig. 13 Radiator area
E50 Power and safety switch cabinet, see Fig. 17

G2 Batteries
S9 Battery main switch
8.12.15
copyright by
MJFCIFSS
Other components
Fig. 14 Control valve block with auxiliary axles 540
Y22 Solenoid valve / turn grapple

Fig. 15 Slewing gear fine control
B335 Pressure sensor / slewing gear fine control

Y451 Solenoid valve / slewing gear fine control
8.12.16
copyright by
MJFCIFSS
Other components
Fig. 16 Air condition components
B43 Thermostat / a/c system M77 Motor / control console air flap
B44 Pressure switch / a/c system M78 Motor / air flap, legroom and window
B255 Temperature sensor / cabin U37 Control unit / heating and air-conditioning
system
B257 Temperature sensor / blow-out air U38 Control panel
M13 Motor / evaporator blower Y20 Solenoid valve / a/c clutch
M75 Motor / ambient air flap Y46 Solenoid valve / heating system
M76 Motor / rear panel air flap
8.12.17
copyright by
MJFCIFSS
Safety and power switch cabinet
9 Safety and power switch cabinet
Fig. 17 E50 Safety and power switch cabinet
8.12.18
copyright by
MJFCIFSS
F19 Fuse / pre-heat system (100A) F110 Engine control terminal 30 (50A)
F20 Fuse / main circuit (50A) F115 Emergency operation terminal 15 (7.5A)
F22 Warning light system (7.5A) F116 Engine control terminal 30 (7.5A)
F31 Heating and a/c system terminal 15 F117 Engine control terminal 15 (7.5A)
(7.5A)
F33 Refuelling pump (7.5A) F122 Engine control, monitoring, pre-heating
(7.5A)
F34 Reserve F133 Elevating operator's cab* (7.5A)
F35 Reserve F253 Attachment headlight ( if 4 headlights
are installed)* (25A)
F36 Refuelling pump (20A) K127 Relay of emergency operation speed
control
F36-2 Stroke limitation/stick cylinder switch- K128 Relay emergency motor start
off* (15A)
F37 Heating and a/c system terminal 20 K288 Main relay terminal 15
(20A)
K66-1 Plug base K302 Relay pre-heating terminal 19
K66-2 Plug base K415 Attachment headlight
F109 Special equipment with additional head-
light* (50A)
* optional equipment
8.12.19
copyright by
MJFCIFSS
8.12.20
copyright by
MJFCIFSS
Control elements
1 Control elements
Fig. 1 Operator's platform

A 154 Emergency control S7 Safety switch
operation
A1100 Printed circuit board ESP02 S72 Switch / High/Low speed
H10-1 Signalling buzzer / warning S73 Switch / emergency actuation
P5 Operating hour meter T1 Voltage transformer
S1 Ignition switch U16 Electronics / BST excavator control
8.14.1
copyright by
MJFCIFSS
Control elements
Fig. 2 Operator's view: electrical control elements
E8 Cigarette lighter S6M Push button / magnet system ON/OFF /

option
H1 Monitoring display S32 Steering column switch / direction indica-
tor - horn
S2 Keyboard S44 Switch / hazard light
S5L Push button / turn grapple left S47 Switch / quick-change adapter (optional
equipment)
S5R Push button / turn grapple right S75 Push button / oscillating axle automatic
S5M Push button / (special function) S218 Switch / cab roof wiper (optional equip-
ment)
S6L Push button / (special function) Sx Additional switches for kits - see group
8.45/8.100
S6R Push button / (special function) U38 Air-condition control panel
8.14.2
copyright by
MJFCIFSS
Monitoring display

C Main screen P2.1 Warning range / coolant temperature (red
LED)
H23 Indicator light / accumulator pressure S352 Screen button / MENU and confirmation
(working brake) (OK)
8.14.3
copyright by
MJFCIFSS
Control console
3 Control console
Fig. 4 Control console
P4 Display / motor speed S38 Switch / special function 3 (changeover

kit)
S10 Switch / work headlight S39 Switch / special function 4
S11 Switch / windscreen washer system S41 Switch / beacon
S14 Switch / windscreen wiper S42 Switch / off-road gear
S16 Switch / parking brake S56 Switch / no function
S17 Switch / slewing gear brake S85 Switch / grapple operation
S18 Switch / overload warning system S86 Switch with LED / mode selection
S19 Switch / additional function (e.g. rotating S228 Push button / step up speed step
device)
S20 Switch / sensor-controlled low idle auto- S228 Push button / step down speed step
matic
S21 Switch / creeper gear S354 Switch / performance step: super finish
S22 Switch / parking light - travel light X2 Plug connection / control console - printed
circuit board A 1001
8.14.4
copyright by
MJFCIFSS
Control console
S35 Switch / servo shutdown X40 Plug connection / control console - screen
S36 Switch / special function 1 (speeder) X42 Code plug / control console
S37 Switch / special function 2 (changeover X50 Plug connection / control console - printed
from blade to outrigger) circuit board A1100
Note!
(M) This is where switched functions are being stored when the machine is shut down. When the
electronics are launched again, the original state will be restored (as before shutdown).
For information on keyboard repair, please refer to group 8.74.
Fig. 5 Rear of control console
8.14.5
copyright by
MJFCIFSS
Fig. 6 Printed circuit board A 1001 (ESP-01)
8.14.6
copyright by
MJFCIFSS
Fuses and relays


K3 Relay / reserve

per Input signal
Input signal
8.14.7
copyright by
MJFCIFSS
Plug connections
X1 Plug connection to U16 / 5-pin X14 Plug connection to power supply S2 /
3-pin
X2 Plug connection to S2 / 37-pin X16 Plug connection / 2-pin
X3 Plug connection to A1100 / 10-pin X17 Plug connection / 3-pin
X4 Plug connection to E1 / 4-pin X18 Plug connection / 6-pin
X5.1 Plug connection / 8-pin X19 Plug connection / 6-pin
X5.2 Plug connection / 3-pin X20 Plug connection to M3, M4, E2, E7, E9 /
10-pin
X6.1 Plug connection / 6-pin X21 Plug connection to kit: grapple S5 / 3-pin
X6.2 Plug connection / 8-pin X22 Plug connection to E52 / 2-pin
X7 Plug connection to sensor B19L / 3-pin X23 Plug connection / 2-pin
X8 Plug connection to sensor B19R / X30 Plug connection (diagnosis) / 9-pin
3-pin
X9 Plug connection to sensor B40 / 2-pin X31 Plug connection (service - plug) /
9-pin
X10 Plug connection to sensor B41 / 2-pin X32 Plug connection (keyboard) / 9-pin
X11 Plug connection to safety lever / X33 Plug connection (diagnosis) / 9-pin
4-pin
X12 Plug connection to S1 / 4-pin X43 Plug connection
X13 Plug connection to S57 / 2-pin
8.14.8
copyright by
MJFCIFSS
Fig. 7 a = plug-in plate, b = printed circuit board A1100 (ESP-02)
8.14.9
copyright by
MJFCIFSS
Fuses
F1 Parking light, tail light / left (2A) F14 E52 (15A)
F2 Parking light, tail light / right (2A) F15 B60, X220/1 (7.5A)
F3 V160, K330, K331 (7.5A) F16 E21, E22, E23, E24 (7.5A)
F4 V156, V158, X202/4 (15A) F17 X214-1/1 (15A
F5 V151, V152, V154 (15A) F18 X214-2/1 (15A)
F6 V150, brake light / right and left (15A) F19 E8 (7.5A)
F7 Work headlight, roof light (15A) F20 X215/1 (15A)
F8 Solenoid valve pilot control slewing-gear F21 S1 - class 30 (15A)
brake (7.5A)
F9 M4 (7.5A) F22 E7, X12/1 (7.5A)
F10 M3, X16/1, Y22, Y23 (15A) F23 E4 (7.5A)
F11 X214-3 (15A) F24 E3 (7.5A)
F12 Amplifiers A 1001 (15A) F250 Keyboard S2 - class 15 (2A)
F13 U16 (15A) F251 Keyboard S2 - class 30 (2A)
Indicator light diodes (LEDs)

H28 LED signal: ground travelling valves H55 LED: power supply X214-3/1
H29 LED: ground travelling valves H56 LED: power supply Amplifiers A1001
H37 LED: actuation of relay travel light K332 H57 LED: power supply U16
H39 LED: actuation of relay K331 H59 LED: power supply X214-2/1
H41 LED: actuation of relay K333 H61 LED: power supply / LED: power supply
160, K330, K331
H44 LED: power supply class 15 H62 LED: fuse F250
H45 LED: power supply B60 H63 LED: power supply sensor 24V
H46 LED: power supply V156, V158, Y62, Y63 H64 LED E18, E16
H47 LED: power supply SF2, SF3, SF4 H65 LED E15, E17
H48 LED: power supply E19, E20, SF1, Y55, H66 LED E3
Y66
H49 LED: power supply E21, E22, E23, E24 H67 LED E4
H50 LED: power supply X214-1/1 H68 LED: power supply indicator unit
H51 LED: power supply Y22, Y23, M3, E9, H69 LED: power supply electronics
K302, X16/1
H52 LED: power supply M4 H70 LED: power supply class 30, X215/1
H53 LED: power supply Y6, Y7, Y3, Y24 H71 LED: power supply class 30 S1
H54 LED: power supply E2, E1 H72 LED: power supply class 30, E7, H9
Relay
K332 Relay / travel light K335 Relay / overload warning device -
switchable
8.14.10
copyright by
MJFCIFSS
Amplifiers
V150 Amplifiers, kit SF1 V157 Amplifier, kit
V151 Amplifier, kit SF2 V158 Amplifier: kit safety lever
V152 Amplifier: kit SF3 V159 Amplifier: travelling valves
V153 Amplifier: kit SF4 V160 Amplifier: kit
V154 Amplifier: first gear V161 Amplifier: parking light
V155 Amplifier: oscillating axle V162 Amplifier: indicator unit
V156 Amplifier: servo kit V163 Amplifier: brake light
Plug connections
X14-2 Plug connection on A1100 / 4-pin X217 Plug connection to BS K334 / 6-pin
X50 Plug connection between S2 and A1100 / X218 Plug connection to KS excavator control /
25-pin 4-pin
X154 Plug connection to KS motor / 15-pin X219 Plug connection to BS overload warning
device, switchable / 2-pin
X155 Plug connection KS revolving deck / 15- X220 Plug connection to BS optional equipment
pin / 3-pin
X159 Plug connection to KS motor / 9-pin X221 Terminal for flow limitation / 3-pin
X200 Plug connection to KS revolving deck / X222 Plug connection magnet system / 2-pin
15-pin
X201 Plug connection to KS operator's platform X223 Plug connection input signal / 2-pin
/ 6-pin
X202 Plug connection to KS operator's platform X224 Plug connection oscillating axle automatic
/ 12-pin / 6-pin
X203 Plug connection to E8 / 2-pin X225 Plug connection analogue signal 1 / 3-pin
X204 Plug connection to KS excavator control / X226 Plug connection analogue signal 2 / 3-pin
3-pin
X205 Plug connection to kit SF1 / 2-pin X227 Plug connection frequency signal 1 / 3-pin
X206 Plug connection to BS SF2 / 2-pin X228 Plug connection frequency signal 2 / 3-pin
X207 Plug connection to BS SF3 / 2-pin X229 Plug connection hazard light / 2-pin
X208 Plug connection to BS SF4 / 2-pin X230 Plug connection / 3-pin
X209 Plug connection to servo kit / 2-pin X231 Plug connection: sub-D with CAN 2 bus
X210 Plug connection to BS safety lever / X232 Plug connection to KS console, right / 10-
2-pin pin
X211 Plug connection to BS servo / 2-pin X233 Plug connection to B33 / 3-pin
X212 Plug connection to BS servo / 2-pin X234 Plug connection to kit / 2-pin
X213 Plug connection to BS servo / 2-pin X235 Plug connection to fuses F250/251 / 4-pin
X214-1Plug connection to BS class 15 / 2-pin X246 Plug connection to KS revolving deck /
12-pin
X214-2Plug connection to BS class 15 / 2-pin X247 Plug connection to KS motor / 2-pin
X214-3Plug connection to BS class 15 / 2-pin X248 Plug connection to KS revolving deck / 2-
pin
X215 Plug connection to BS class 30 / 2-pin X249 Plug connection to KS revolving deck / 3-
pin
X216 Plug connection to BS K333 / 6-pin
8.14.11
copyright by
MJFCIFSS
D 934S A6 diesel engine
6 D 934S A6 diesel engine
Fig. 8 D 934S A6 diesel engine
A700 Engine control M1 Starter

B3 Transducer / coolant level R51 Heater flange
B12 Speed transducer (sensor) Y20 Magnetic coupling / a/c compressor
G1 Alternator
8.14.12
copyright by
MJFCIFSS
Tank and control oil unit
7 Tank and control oil unit
Fig. 9 Hydraulic tank, fuel tank - with control oil unit
B8 Transducer / hydraulic oil temperature Y7 Solenoid valve / slewing gear brake

B14 Transducer / hydraulic oil level Y24 Solenoid valve / creeper gear
B39 Transducer / fuel level Y50 Proportional solenoid valve / power con-
trol
H9 Horn Y51 Proportional solenoid valve / -p reduc-
tion
Y3 Solenoid valve / pilot control pressure Y66 Solenoid valve / oscillating axle support
8.14.13
copyright by
MJFCIFSS
Other components
8 Other components
Fig. 10 HBGV block and solenoid valve on basic boom's bearing block
Y6 Solenoid valve / 2nd gear resp. On-road travel

Y55 Solenoid valve: first gear
Fig. 11 Operator's platform from below
B20 Pressure switch / accumulator pressure

B40 Proximity switch / pilot pressure valve, travel
B60 Brake light switch
Y62 Solenoid valve: travel forward
Y63 Solenoid valve: travel reverse
B266 Proximity switch / oscillating axle automatic
8.14.14
copyright by
MJFCIFSS
Other components
Fig. 12 Proportional solenoid valve: fan control Y347 (situated at blower motor of cooling unit)
Fig. 13 Radiator area
E50 Power and safety switch cabinet, see Fig. 17

G2 Batteries
S9 Battery main switch
8.14.15
copyright by
MJFCIFSS
Other components
Fig. 14 Control valve block with auxiliary axles 540

Fig. 15 Ansicht Magnetventil Umschaltung Greifer
Y502 Magnetventil Umschaltung Greifer
8.14.16
copyright by
MJFCIFSS
Other components
Fig. 16 Air condition components
B43 Thermostat / a/c system M77 Motor / control console air flap
B44 Pressure switch / a/c system M78 Motor / air flap, legroom and window
B255 Temperature sensor / cabin U37 Control unit / heating and air-conditioning
system
B257 Temperature sensor / blow-out air U38 Control panel
M13 Motor / evaporator blower Y20 Solenoid valve / a/c clutch
M75 Motor / ambient air flap Y46 Solenoid valve / heating system
M76 Motor / rear panel air flap
8.14.17
copyright by
MJFCIFSS
9 Safety and power switch cabinet
Fig. 17 E50 Safety and power switch cabinet
8.14.18
copyright by
MJFCIFSS
F19 Fuse / pre-heat system (100A) F110 Engine control terminal 30 (50A)
F20 Fuse / main circuit (50A) F115 Emergency operation terminal 15 (7.5A)
F22 Warning light system (7.5A) F116 Engine control terminal 30 (7.5A)
F31 Heating and a/c system terminal 15 F117 Engine control terminal 15 (7.5A)
(7.5A)
F33 Refuelling pump (7.5A) F122 Engine control, monitoring, pre-heating
(7.5A)
F34 Reserve F133 Elevating operator's cab* (7.5A)
F35 Reserve F253 Attachment headlight ( if 4 headlights
are installed)* (25A)
F36 Refuelling pump (20A) K127 Relay of emergency operation speed
control
F36-2 Stroke limitation/stick cylinder switch- K128 Relay emergency motor start
off* (15A)
F37 Heating and a/c system terminal 20 K288 Main relay terminal 15
(20A)
K66-1 Plug base K302 Relay pre-heating terminal 19
K66-2 Plug base K415 Attachment headlight
F109 Special equipment with additional head-
light* (50A)
* optional equipment
8.14.19
copyright by
MJFCIFSS
8.14.20
copyright by
MJFCIFSS
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Èîïï Ð´«¹ ½±²²»½¬·±² ±² ßïïðð ®»»®ª» ó µ·¬ ñ îó°·² íì Ô»º¬ ¾®¿½µ»¬
Èîïî Ð´«¹ ½±²²»½¬·±² ±² ßïïðð ®»»®ª» ó µ·¬ ñ íó°·² íë Ô»º¬ ¾®¿½µ»¬
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Èîïìóï Ð´«¹ ½±²²»½¬·±² ¬± ßïïðð ½´¿ ïë µ·¬ ñ îó°·² íé Ô»º¬ ¾®¿½µ»¬
Èîïìóî Ð´«¹ ½±²²»½¬·±² ¬± ßïïðð ½´¿ ïë µ·¬ ñ îó°·² íé Ô»º¬ ¾®¿½µ»¬
Èîïìóí Ð´«¹ ½±²²»½¬·±² ¬± ßïïðð ½´¿ ïë µ·¬ ñ îó°·² ìð Ô»º¬ ¾®¿½µ»¬
Èîïë Ð´«¹ ½±²²»½¬·±² ¬± ßïïðð ½´¿ íð µ·¬ ñ îó°·² íé Ô»º¬ ¾®¿½µ»¬
Èîïê Ð´«¹ ½±²²»½¬·±² ±² ßïïðð Õííí ó µ·¬ ñ êó°·² íè Ô»º¬ ¾®¿½µ»¬
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Èîïç íç Ô»º¬ ¾®¿½µ»¬
Èîîð Ð´«¹ ½±²²»½¬·±² ±² ßïïðð º±® µ·¬ °»½·¿´ ñ íó°·² îè Ô»º¬ ¾®¿½µ»¬
Èîîï Ì»®³·²¿´ ±² ßïïðð º±® º´±© ´·³·¬¿¬·±² ñ í ¨ îè Ô»º¬ ¾®¿½µ»¬
Èîîî Ð´«¹ ½±²²»½¬·±² ±² ßïïðð º±® ±´»²±·¼ ñ îó°·² íï Ô»º¬ ¾®¿½µ»¬
Èîîí Ð´«¹ ½±²²»½¬·±² ±² ßïïðð º±® ·²°«¬ ñ îó°·² íï Ô»º¬ ¾®¿½µ»¬
Èîîì Ð´«¹ ½±²²»½¬·±² ±² ßïïðð º±® ±½·´´¿¬·²¹ ¿¨´» ñ êó°·² íî Ô»º¬ ¾®¿½µ»¬
Èîîë Ð´«¹ ½±²²»½¬·±² ±² ßïïðð º±® ¿²¿´±¹«» ·¹²¿´ ï ñ íó°·² íì Ô»º¬ ¾®¿½µ»¬
Èîîê Ð´«¹ ½±²²»½¬·±² ±² ßïïðð º±® ¿²¿´±¹«» ·¹²¿´ î ñ íó°·² íë Ô»º¬ ¾®¿½µ»¬
Èîîé Ð´«¹ ½±²²»½¬·±² ±² ßïïðð º±® Ò¿³«® º®»¯«»²½§ ï ñ íó°·² íë Ô»º¬ ¾®¿½µ»¬
Èîîè Ð´«¹ ½±²²»½¬·±² ±² ßïïðð º±® Ò¿³«® º®»¯«»²½§ î ñ íó°·² íê Ô»º¬ ¾®¿½µ»¬
Èîîç Ð´«¹ ½±²²»½¬·±² ±² ßïïðð °±©»® «°°´§ ¸¿¦¿®¼ ´·¹¸¬ ñ îó°·² îè Ô»º¬ ¾®¿½µ»¬
Èîíð Ð´«¹ ½±²²»½¬·±² ¬± ßïïðð ñ íó°·² íí Ô»º¬ ¾®¿½µ»¬
Èîíï Ð´«¹ ½±²²»½¬·±²æ «¾ ó Ü ±² ßïïðð ©·¬¸ ÝßÒ î ó ¾« îç Ô»º¬ ¾®¿½µ»¬
Èîíî íçóìï Ô»º¬ ¾®¿½µ»¬
Èîíí Ð´«¹ ½±²²»½¬·±² ±² ßïïðð ¬± Þíí ñ íó°·² íê Ô»º¬ ¾®¿½µ»¬
Èîíì Ð´«¹ ½±²²»½¬·±² ±² ßïïðð º±® µ·¬ ñ îó°·² ìï Ô»º¬ ¾®¿½µ»¬
Èîíë Ð´«¹ ½±²²»½¬·±² ±² ßïïðð ¬± º«» Úîëð ñ Úîëï ñ ìó°·² îè Ô»º¬ ¾®¿½µ»¬
Èîìê ïëóîð Ô»º¬ ¾®¿½µ»¬
Èîìé Ð´«¹ ½±²²»½¬·±² ¬± °´«¹ó·² °´¿¬» ¬± ÕÍ ³±¬±® ñ îó°·² í Ô»º¬ ¾®¿½µ»¬
Èîìè Ð´«¹ ½±²²»½¬·±² ±² °´«¹ó·² °´¿¬» ¬± ÕÍ ®»ª±´ª·²¹ ¼»½µ ñ îó°·² îè Ô»º¬ ¾®¿½µ»¬
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Èîëï Ð´«¹ ½±²²»½¬·±² ¿¬ ·¹²·¬·±² ©·¬½¸ ñ îó°·² í Ô»º¬ ¾®¿½µ»¬
Èîëî Ð´«¹ ½±²²»½¬·±² ¬± ±½·´´¿¬·²¹ ¿¨´» ©·¬½¸ íî Ô»º¬ ¾®¿½µ»¬
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Èíïç Ð´«¹ ½±²²»½¬·±² º±® ÞÌÕÐ ñ ïó°·² ì ¾»´±© Ûëð
Èíîð Ð´«¹ ½±²²»½¬·±² º±® ÞÌÕÐ ñ îó°·² ì ¾»´±© Ûëð
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'
14:31
4
Service Manual Operating symbols on the operator's platform
Overview of symbols
Operating symbols on the operator's platform
1 Overview of symbols
Symbol Designation Use/designation of assembly Location
S124 Mower rake kit in operation Right console

H329
S124 Mower rake kit ON Right console

H329
S395 Heating element Left console
S387 Separ water filter with monitoring sys- Right console

tem
S47 Quick change adapter Right console
S47 Industrial quick-change adapter Right console
S47 Quick-change equipment Right console
8.44.1
copyright by
MJFCIFSS
Operating symbols on the operator's platform Service Manual
Overview of symbols
H341 Quick-change adapter powered Right console
S209 Topas quick-change adapter Right console

Retract telescopic grapple
S208 Topas quick-change adapter Right console

Extend telescopic grapple
S403 Stick cylinder shut-down Right console
H315 Automatic shut-off mechanism OFF Right console

S396
S291 Overriding of stroke limitation of basic Right console

boom
S466 Stick cylinder shut-down Right console

Height limitation for stick
S393 24 V stick plug on stick Right console
8.44.2
copyright by
MJFCIFSS
Overview of symbols
S364 Lowering without pressure Right console

Attachment lowering lock
S216 Industrial shut-down Right console
S291 Hydraulic boom adjustment Right console

Stroke limitation
S291 Stroke limitation Right console

H159
H320 Changeover ZETKO control Right console

Extending ZETKO
H320 Changeover ZETKO control Right console

Bending ZETKO
H322 Changeover bucket / attachment kit Right console

S405
S400 Additional pressure level Left console
8.44.3
copyright by
MJFCIFSS
Overview of symbols
S35 Servo control Right console
S419 Clutch Right console
S424 Drilling slide Right console

Push button / continuous operation
AHS
S422 Radio mute mode Right console
S452 Grapple rotation with rocker switch Right console
S447 Burning particle filter Right console

Full load simulation for particle filter
S462 Pulling unit UP Right console
S461 Pulling unit DOWN Right console
8.44.4
copyright by
MJFCIFSS
Overview of symbols
S453 Continuous operation of attachments Right console
S458 Continuous operation of closing cylin- Right console

der
S338 Compressor of wagon brake system Right console

Pneumatic load hook
H297 Friction wheel operation Left console

Conversion of rail chassis
S401 Rail guide Right console
S484 Continuous operation attachments - re- Right console

lease
H345 Fault in traverse potentiometer Right console
S200 Hydraulic operator's cab elevation Left console

Cab UP
8.44.5
copyright by
MJFCIFSS
Overview of symbols

Cab DOWN
S202 Cab FORWARD Left console
S203 Cab BACK Left console

Cab/ lift frame
S216 Engine shut-down Left console

Engine stop switching reversed
S218 Windscreen wiper Right console
S275 Work headlight Right console
S238 4-wheel steering Left console
8.44.6
copyright by
MJFCIFSS
Overview of symbols
S238 4-wheel steering Left console

Rear axle switched off
S239 4-wheel steering with dog-walk steering Left console

mode
H325 Steering changeover check Right console
S413 Steering changeover ON Left console
S321 Joystick control Right console
S247 LIEBHERR control Right console

H292 Changeover Euro - LIEBHERR
H158 Fuchs steering Right console
S45 Priority circuit Left console
8.44.7
copyright by
MJFCIFSS
Overview of symbols
H292 Special control changeover Right console
S204 Individual control right outrigger Left console

S205
S206 Individual control right outrigger Left console

S207
S435 Changeover travel / support Right console

H310 Outrigger symbol (blade at rear)
S356 Changeover valve in undercarriage Right console
S409 Support automatic Right console
H343 Outrigger monitoring system Right console
S335 Blade mirrored Right console
8.44.8
copyright by
MJFCIFSS
Overview of symbols
S335 Blade mirrored Left console
S469 swivel rotator Right console

S80 Tilt ditch cleaning bucket
S46 Magnet systems Right console
S356 Trailer coupling Left console
S210 Cold-start system Right console

Cold-start aid
S84 Central lubrication Right console
S84 Central lubrication system Right console
S359 Sorting grapple Right console

H347
8.44.9
copyright by
MJFCIFSS
Overview of symbols
S357 Lifting boom when closing grapple Right console
S356 Function of regulating cylinder Right console

ASU changeover valve
H295 Data transmission Right console
S374 Slewing ladder Left console
S26 Fuel pre-heating Right console

S213
S237
H298 Exhaust backpressure Right console
H300 Fill level of additive Right console
S379 Release button Right console
8.44.10
copyright by
MJFCIFSS
Overview of symbols
S445 Turning stick with changeover valve Right console

Flow reduction with button
8.44.11
copyright by
MJFCIFSS
Overview of symbols
8.44.12
copyright by
MJFCIFSS
Service Manual
List of electric kits
Step Kit Table / figure
50 AHS 11 / AHS 12 (see Tab. 1 on page7)

51-1 Lift frame (see Tab. 2 on page9)
51-2 Lift frame actuated with rocker switch with lever (see Tab. 3 on page11)
52-1 Individual control 2/4-point support (see Tab. 6 on page17)
53-1 Changeover from blade to outrigger (see Tab. 9 on page23)
53-2 Changeover from blade to outrigger (see Tab. 10 on page25)
53-3 Individual control 2-point support rear / blade front (see Tab. 11 on page27)
53-4 Individual control 2-point support front / blade rear (see Tab. 12 on page29)
53-5 Individual control blade / blade (see Tab. 13 on page31)
54-1 Switchable overload warning system (see Tab. 14 on page 32)
54-2 Overload warning system (see Tab. 15 on page 34)
55-1/2 Outrigger control / outrigger control with travel shut-down (see Tab. 16 on page 36)
56 Overload warning system (see Tab. 17 on page 38)
57 Back-up alarm (see Tab. 18 on page 40)
58-1 Changeover blade to outrigger / individual control 2-point support (see Tab. 19 on page 42)
58-2 Changeover blade to outrigger / individual control 2-point support (see Tab. 20 on page 44)
58-3 Individual control outrigger and blade (see Tab. 21 on page 46)
58-4 Individual control outrigger and blade (see Tab. 22 on page 48)
59 Automatic oscillating axle locking device (industrial) (see Tab. 23 on page 50)
60-1 Travel alarm (see Tab. 24 on page 52)
60-2 Travel alarm US model (see Tab. 25 on page 54)
61-1 4-wheel steering with dog-walk steering mode (see Tab. 26 on page 56)
61-2 4-wheel steering (see Tab. 27 on page 58)
62 Roof light, facing back (see Tab. 28 on page 60)
63-1 Individual control 2-point support (see Tab. 29 on page 62)
8.45.1
copyright by
MJFCIFSS
Service Manual
65-1 KBI cold-starting aid (see Tab. 35 on page 74)

65-2 KBI cold-starting aid (see Tab. 36 on page 76)
66-1/2/3 Mozelt / Woko magnet system, US model (see Tab. 37 on page 78)
66-4 Mozelt magnet system with magnetic clutch (see Tab. 38 on page 80)
67-1 Industrial shut-down (see Tab. 39 on page 82)
67-2 Industrial shut-down (see Tab. 40 on page 84)
68 Travel shut-down at lift frame extension (see Tab. 41 on page 86)
69-1/2 Industrial quick-change adapter / bucket quick-change adapter (see Tab. 42 on page 88)
69-3/4 Bucket quick-change adapter / quick-change adapter (see Tab. 43 on page 92)
69-5 Industrial quick-change adapter (see Tab. 44 on page 96)
69-6 Bucket quick-change adapter (see Tab. 45 on page 100)
70-1 Topas quick-change adapter (see Tab. 46 on page 104)
70-2 Topas quick-change adapter with 2-step operation (see Tab. 47 on page 108)
71 Changeover grapple - bucket (see Tab. 48 on page 112)
72-1 Separate windscreen wiper system / wiper system (see Tab. 49 on page 114)
72-2 Wiper system for rear window (see Tab. 50 on page 116)
73 Auxiliary headlight equipment (see Tab. 51 on page 118)
74 Air-conditioning system (see Tab. 52 on page 120)
75 2 counter weight lights, rear (see Tab. 53 on page 124)
76-1 Auxiliary beacon at counter weight (see Tab. 54 on page 126)
76-2 License plate light (see Tab. 55 on page 128)
77-1 Changeover valve (see Tab. 56 on page 130)

78-1/2 Slewing ladder (see Tab. 59 on page 136)
79 Changeover EURO - LIEBHERR control (see Tab. 60 on page 138)
80 Inclinometer (see Tab. 61 on page 140)
81 Stroke limitation / hydraulic boom adjustment (see Tab. 62 on page 142)

82 24V - 12V voltage converter (see Tab. 63 on page 144)
83-1 Magnet system with hydraulic LAM drive (see Tab. 64 on page 146)
83-2 Magnet system with hydraulic MOZELT drive (see Tab. 65 on page 148)
83-3 Magnet system with hydraulic WOKO drive (see Tab. 66 on page 150)
8.45.2
copyright by
MJFCIFSS
Service Manual
83-4 LIEBHERR hydro magnet HYMAC (see Tab. 67 on page 152)
83-5 Magnet system with hydraulic drive (see Tab. 68 on page 155)
83-6 Magnet system with hydraulic MOZELT drive (see Tab. 69 on page 157)
84 UNIKAT exhaust gas filter (see Tab. 70 on page 159)

85 Hose drum (see Tab. 71 on page 161)
86 Turning grapple / ditch cleaning bucket (see Tab. 72 on page 163)
87 D5WS auxiliary heating (see Tab. 73 on page 166)
88 E50 field test (see Tab. 74 on page 169)
89 LINNIG fan (see Tab. 75 on page 171)
90 Power socket for mobile phone (see Tab. 76 on page 173)
91 M20 radio modem (see Tab. 77 on page 175)
92 Krüger stroke limitation (see Tab. 78 on page 177)
93-1 Priority circuit (see Tab. 79 on page 180)
93-2 Flow and pressure settings / priority circuit with Tool Control (see Tab. 80 on page 183)
94 Radiator bypass valve (see Tab. 81 on page 185)
95 Changeover EURO LIEBHERR special control (see Tab. 82 on page 187)
96 Float position (see Tab. 83 on page 189)
97 Particle filter for exhaust system (see Tab. 84 on page 191)
98 Learning circuit (see Tab. 85 on page 193)

99-1 Limitation for boom/stick extension with bypass (see Tab. 86 on page 195)
99-2 Permanent limitation for boom cylinder extension (see Tab. 87 on page 197)
99-3 Limitation for boom cylinder extension with bypass (see Tab. 88 on page 199)
99-4 Limitation for stick cylinder extension with bypass (see Tab. 89 on page 201)
100 Metering device with particle filter (see Tab. 90 on page 203)
101 AHS 11 actuation via push button (see Tab. 91 on page 206)
103-1/2 Joystick steering (see Tab. 92 on page 209)
103-3/4 Joystick steering (see Tab. 93 on page 211)

104 Power supply for sensors (see Tab. 94 on page 213)
105 Earth contact ESP01 windscreen wiper (see Tab. 95 on page 215)
106-1 Lifting boom when closing grapple (see Tab. 96 on page 217)
106-2 Lifting boom when closing grapple (see Tab. 97 on page 219)
108 Separ water filter with monitoring system (see Tab. 98 on page 221)
109-1 Auxiliary water pump (see Tab. 99 on page 223)
109-2 Auxiliary water pump (see Tab. 100 on page 225)
110 Grammer seat heating (see Tab. 101 on page 227)
8.45.3
copyright by
MJFCIFSS
Service Manual
111-1/2/3 2x Xenon roof light to front (see Tab. 102 on page 229)
112-1 Mower rake accessory kit (see Tab. 103 on page 231)
112-2 Mower rake kit via step relay (see Tab. 104 on page 233)
113 Automatic shut-off mechanism (see Tab. 105 on page 236)

114 Oil bypass filter monitor (see Tab. 106 on page 239)
115-1 Quick-change adapter (see Tab. 107 on page 241)
115-2 Quick-change adapter (see Tab. 108 on page 243)
116 Turn grapple in left joystick lever (see Tab. 109 on page 245)
117-1 Stick cylinder shut-down (see Tab. 110 on page 248)
117-2 Stick cylinder shut-down (see Tab. 111 on page 252)
120 Changeover bucket tilt circuit / AHS (see Tab. 112 on page 255)
123 Two-hand operation (see Tab. 113 on page 257)
125 Oscillating-axle locking device in left joystick (see Tab. 114 on page 259)
126-1 Turning stick with changeover valve (see Tab. 115 on page 262)
126-2 Turning stick without changeover valve (see Tab. 116 on page 266)
129 HYDAC refuelling pump (see Tab. 119 on page 273)
130 PURITECH particle filter (see Tab. 120 on page 275)

131 Fuel pre-heating (see Tab. 121 on page 277)
132 Stroke limitation / hydraulic boom adjustment (see Tab. 122 on page 279)
133 Changeover ZETKO control via AHS12 (see Tab. 123 on page 281)
134 ZETKO priority circuit / tunnelling stick (see Tab. 124 on page 283)
135-1/2 Operation of lorry tilting device (optional (see Tab. 125 on page 287)
135-3 Industrial LIKUFIX (see Tab. 126 on page 289)
135-4 LIKUFIX quick-change adapter (see Tab. 127 on page 291)
136-1 Flow and pressure settings (see Tab. 128 on page 293)
137 Radio mute mode (see Tab. 131 on page 299)
8.45.4
copyright by
MJFCIFSS
Service Manual Electric kits
Electric kits
8.45A 900 C-LI 14675-A 904 C-LI 16000-
Key to cable colours

rt = redge = yellowws = whitegn = greenbe = beige
bl = bluesw = blackvi = purplegr = greybr = brown
8.45.5
copyright by
MJFCIFSS
Electric kits Service Manual
AHS 11 / AHS 12
1 AHS 11 / AHS 12
8.45.6
copyright by
MJFCIFSS
AHS 11 / AHS 12
Step 50
Item Description Step Location/arrangement
A1009 Decay diode board 50 Right console

A1100 ESP 02 printed circuit board 50 Left console
B33 Pressure switch/flow limitation 50 AHS11 pedal valve

AHS12 behind toolbox
F5 A1100 amplifier V151, V152, V153, V157 28 Left console

(1.5A)
F11 A1100 spare plug X214-3 (1.5A) 40 Left console
H44 LED terminal 15 power supply 28 Left console

H47 LED power supply SF2, SF3, SF4 28 Left console
H55 LED power supply X214-3 28 Left console
S88 Key switch for hammer / pile driver 50 Right console
V152 Amplifier (A1100) SF3 kit 39 Left console
X14-2 Plug on A1100, 5-pin 28 Left console

X51 Plug on A1009, 3-pin 50 Right console
X 139 Plug to wire harness B33 / 3-pin 50 Left console
X140 Plug to wire harness revolving deck, 2-pin 50 Left console
X207 Plug on A1100 for SF3 (AHS12) kit, 2-pin 30 Left console
X214-3 Plug on A1100 terminal 15 kit, 2-pin 40 Left console
X232 Plug on A1100 to wire harness control console, 40 Left console
right, 10-pin
X233 Plug on A1100 to B33, 3-pin 36 Left console
Y61 AHS12 solenoid valve 50 Behind toolbox

Tab. 1 AHS11/AHS12
8.45.7
copyright by
MJFCIFSS
Lift frame
2 Lift frame
8.45.8
copyright by
MJFCIFSS
Lift frame
Step 51
*A1100 ESP02 printed circuit board 27 - 41 Left console
*F4 Fuse of amplifier V156, V158, X202/4 (15A) 28 A1100

*F20 Fuse X215/1 (15A) 28 A1100
*H44 LED terminal 15 power supply 28 A1100

*H46 LED power supply V156, V158, Y62, Y63 28 A1100
H70 LED terminal 30 power supply 28 A1100
MP86 Ground connection behind operator's platform 51 Behind operator's platform
S78 Emergency discharge button 51 Left console

S79 Emergency discharge button 51 Radiator / battery com-
partment
S200 Operator' cab up button 51 Left console
S201 Operator's cab down button 51 Left console
*V156 Amplifier servo kit 32 A1100
*X209 Plug for servo kit / 2-pin 32 A1100

*X215 Plug for terminal 30 kit / 2-pin 37 A1100
X311 Plug for lift frame, 4-pin 51 Left console
Y200 Solenoid valve/lift frame UP 51 Lift frame base

Y201 Solenoid valve/lift frame DOWN 51 Lift frame base
Y204 Solenoid valve/lift frame emergency discharge 51 Lift frame base
* = basic diagram
Tab. 2 Lift frame
8.45.9
copyright by
MJFCIFSS
Lift frame actuated with rocker switch with lever
3 Lift frame actuated with rocker switch with lever
8.45.10
copyright by
MJFCIFSS
Lift frame actuated with rocker switch with lever
Step 51

*F20 Fuse X215/1 (15A) 28 A1100


partment
S408 T-handle switch for lift frame control 51 - 2 Left console

X311 Plug for lift frame / 4-pin 51 Left console

* = basic diagram
Tab. 3 Lift frame actuated with rocker switch with lever
8.45.11
copyright by
MJFCIFSS
Lift frame
4 Lift frame
Lift frame
8.45.12
copyright by
MJFCIFSS
Lift frame
Step 51

*F20 Fuse X215/1 (15A) 28 A1100


partment

X689 Plug of diode / 6-pin 51-3 Left console

* = basic diagram
Tab. 4 Lift frame
8.45.13
copyright by
MJFCIFSS
Lift frame
5 Lift frame
8.45.14
copyright by
MJFCIFSS
Lift frame
Step 51

*F20 Fuse X215/1 (15A) 28 A1100


partment

X689 Plug of diode / 6-pin 51-3 Left console

* = basic diagram
Tab. 5 Lift frame
8.45.15
copyright by
MJFCIFSS
Individual control 2/4-point support, rear (A), front (B)
6 Individual control 2/4-point support, rear (A), front (B)
8.45.16
copyright by
MJFCIFSS
Step 52
*A1100 ESP02 printed circuit board 52 Left console
E162 Slip-ring case 52 Undercarriage
*F4 Fuse (15A) 28 Left console
*MP86 Ground connection 52 Behind cab
S204 Switch / front left outrigger support 52 Right console

S205 Switch / front right outrigger support 52 Right console
S206 Switch / rear left outrigger support 52 Right console
S207 Switch / rear right outrigger support 52 Right console
*V156 Amplifier 32 Left console
*X209 Plug connection / 2-pin 32 A1100

X300 Terminal strip 52 E162
X301 Plug connection on slip ring, 12-pin 52 At rotary connection
X303 Plug connection, 4-pin 52 Left console
X304 Plug connection to switch S204, S205, S206, 52 Right console
S207, 6-pin
X305 Plug reserve 52 Left console
Y215 Solenoid valve / front left outrigger support 52 Undercarriage

Y216 Solenoid valve / front right outrigger support 52 Undercarriage
Y217 Solenoid valve / rear left outrigger support 52 Undercarriage
Y218 Solenoid valve / rear right outrigger support 52 Undercarriage
* = basic diagram
Tab. 6 Individual control 2/4-point support
8.45.17
copyright by
MJFCIFSS
with decay diode in plug
8.45.18
copyright by
MJFCIFSS
Step 52
*F_ Fuse (15A) 28 Left console


S207, 6-pin

* = basic diagram
Tab. 7 Individual control 2/4-point support with decay diode in plug
8.45.19
copyright by
MJFCIFSS
with decay diode in plug with power supply from X214
8.45.20
copyright by
MJFCIFSS
Step 52

*X209 Plug connection / 2-pin 32 A1100

*X214_ Plug connection, 2-pin 37, 40 A1100
S207, 6-pin

* = basic diagram
Tab. 8 Individual control 2/4-point support with decay diode in plug power supply from X214
8.45.21
copyright by
MJFCIFSS
Changeover from blade to outrigger
9 Changeover from blade to outrigger
8.45.22
copyright by
MJFCIFSS
Step 53
A Symbol at front blade
B Symbol at front outrigger
*A1100 ESP02 printed circuit board Left console
V156 Amplifier 32 Left console
*X209 Plug connection, 2-pin 53-1 A1100 printed circuit

board
X300 Terminal strip 53 Terminal box
X301 Plug connection at slip ring 53 At rotary connection
X308 Plug connection to switch S335 53 Right console
Y56 Solenoid valve/changeover 53 Undercarriage

* = basic diagram
Tab. 9 Changeover from blade to outrigger
8.45.23
copyright by
MJFCIFSS
10 Changeover from blade to outrigger
Power supply from X214
8.45.24
copyright by
MJFCIFSS
Step 53

S204 Switch / front left outrigger support 53 Left console

S205 Switch / front right outrigger support 53 Left console
S206 Switch / rear left outrigger support 53 Left console
S207 Switch / rear right outrigger support 53 Left console
S335 Switch/changeover blade - outrigger 53 Right console
S335-1 Switch front blade 53 Right console
S335-2 Rear blade 53 Right console
V156 Amplifier 32 Left console
*X209 Plug connection, 2-pin 53-1 A1100 printed circuit

board
*X214_ Plug connection, 2-pin 53 A1100 printed circuit
board

Y56-1 Solenoid valve, front blade 53-5 Undercarriage
Y56-2 Solenoid valve, rear blade 53-5 Undercarriage
Y215 Solenoid valve / front left outrigger support 53-4 Undercarriage
Y216 Solenoid valve / front right outrigger support 53-4 Undercarriage
Y217 Solenoid valve / rear left outrigger support 53-3 Undercarriage
Y218 Solenoid valve / rear right outrigger support 53-3 Undercarriage
* = basic diagram
Tab. 10 Changeover blade / outrigger power supply from X214
8.45.25
copyright by
MJFCIFSS
Individual control 2-point support rear / blade front
11 Individual control 2-point support rear / blade front
8.45.26
copyright by
MJFCIFSS
Individual control 2-point support rear / blade front
Step 53

board

* = basic diagram
Tab. 11 Individual control 2-point support rear / blade front
8.45.27
copyright by
MJFCIFSS
Individual control 2-point support rear / blade rear
12 Individual control 2-point support rear / blade rear
8.45.28
copyright by
MJFCIFSS
Individual control 2-point support rear / blade rear
Step 53

S335 Switch/changeover blade - outrigger 53 Right console

board

Y215 Solenoid valve / front left outrigger support 53-4 Undercarriage
Y216 Solenoid valve / front right outrigger support 53-4 Undercarriage
* = basic diagram
Tab. 12 Individual control 2-point support front / blade rear
8.45.29
copyright by
MJFCIFSS
Individual control blade / blade
13 Individual control blade / blade
8.45.30
copyright by
MJFCIFSS
Individual control blade / blade
Step 53

S335-1 Switch / front blade 53 Right console
S335-2 Rear blade 53 Right console

board

Y56-1 Solenoid valve, front blade 53-5 Undercarriage
Y56-2 Solenoid valve, rear blade 53-5 Undercarriage
* = basic diagram
Tab. 13 Individual control blade / blade
8.45.31
copyright by
MJFCIFSS
Switchable overload warning system
14 Switchable overload warning system
Cam disc, not supported
8.45.32
copyright by
MJFCIFSS
Step 54
A1001* ESP01 printed circuit board 54 Right console
A1100* ESP02 printed circuit board 54 Left console
B21 Pressure switch/fixed pressure range 54 Near bearing block

B201 Pressure switch, cam disc 54 Near bearing block
B202VL Pressure switch / front left support 54 Undercarriage
B202VR Pressure switch / front right support 54 Undercarriage
B202HL Pressure switch / rear left support 54 Undercarriage
B202HR Pressure switch / rear right support 54 Undercarriage
H1* Display 25 Right console

H10-1 Warning buzzer 24 Right console
K335 Relay overload warning system 39 A1100
MP85* Ground connection 54 Bearing block

MP86* Ground connection 54 Behind cab
S2* Keypad 24 Right console

S18 Switch/overload warning system 24 Right console
X2* Plug connection, 37-pin 23 A1001 to S2

X6.2 Plug connection, 8-pin A1001
X40 Plug connection, 9-pin 24 H1 to S2
X49 Plug connection, 3-pin 25 S2
X200 Plug connection, 15-pin 39 A1100
X273 Plug connection, 4-pin 54 At bearing block
X301 Plug connection, 12-pin 54 At slip ring
X305 Plug reserve , 9-pin 54 Left console
X309 Plug connection, 15-pin 24 Right console
X316 Plug, 2-pin 25 Right console
* = basic diagram
Tab. 14 Overload warning, switchable cam disc, not supported
8.45.33
copyright by
MJFCIFSS
Overload warning system
15 Overload warning system
Cam disc, supported / overload activation
8.45.34
copyright by
MJFCIFSS
Step 54
A1001* ESP01 printed circuit board 54 Right console

B201 Pressure switch, cam disc 54 Near bearing block
B202VL Pressure switch/front left support 54 Undercarriage
B202VR Pressure switch/front right support 54 Undercarriage
B202HL Pressure switch/rear left support 54 Undercarriage
B202HR Pressure switch/rear right support 54 Undercarriage

K335 Relay overload warning system 39 A1100
MP85* Ground connection 54 Bearing block

MP86* Ground connection 54 Behind cab

X2* Plug connection, 37-pin 23 A1001 to S2

X6.2 Plug connection, 8-pin A1001
X273 Plug connection, 4-pin 54 at bearing block
X301 Plug connection, 12-pin 54 at slip ring
X305 Plug reserve / 9-pin 54 Left console
* = basic diagram
Tab. 15 Overload warning system cam disc, supported / overload activation
8.45.35
copyright by
MJFCIFSS
Outrigger control / outrigger control with travel shut-down
16 Outrigger control / outrigger control with travel shut-down
8.45.36
copyright by
MJFCIFSS
Outrigger control / outrigger control with travel shut-down
Step 55
B208VL Proximity switch / front left support 55 Undercarriage

B208VR Proximity switch / front right support 55 Undercarriage
B208HL Proximity switch / rear left support 55 Undercarriage
B208HR Proximity switch / rear right support 55 Undercarriage
MP86 Ground connection below cab 55 Behind cab
X50* Plug connection, 25-pin 25 A1100

X214-1 Plug connection, 2-pin 37 A1100
X301 Plug connection, 12-pin 55 At rotary connection
* = basic diagram
Tab. 16 Outrigger control / outrigger control with travel shut-down
8.45.37
copyright by
MJFCIFSS
8.45.38
copyright by
MJFCIFSS
Step 56
*A1001 ESP01 printed circuit board 56 Right console
*A1100 ESP 02 printed circuit board 56 Left console
B21 Pressure switch 56 Undercarriage
*H1 Display 24 Right console

*H10-1 Buzzer 25 Right console
K335 Relay (A1100) 39 Left console
*MP 85 Ground connection 56 Behind cab
*S2 Keypad 24 Right console

*S18 Switch/overload warning system 24 Right console
*X6.2 Plug on A 1100 connection to A1100 Right console

*X200 Plug connection on A1100, 15-pin 39 Left console
*X219 Plug connection on A1100, 2-pin 39 Left console
*X232 Plug connection 39 Left console
X273 Plug connection on A1100, 4-pin 56 Left console
*X309 Plug connection 26 Right console
*X316 Plug connection, 2-pin 24 H10-1
* = basic diagram
Tab. 17 Overload warning system
8.45.39
copyright by
MJFCIFSS
back-up alarm
18 back-up alarm
8.45.40
copyright by
MJFCIFSS
back-up alarm
Step 57
F4 Fuse (15A) 57 Left console
H183 Indicator back-up alarm 57 Cab
S30* Joystick switch 57 Right console
S269 Switch in slip ring 57 Slip ring

S270 Switch in slip ring 57 Slip ring
S272 Slip-ring case 57 Undercarriage
V159 Transistor 33 Left console

Y62 Solenoid valve, forward travel 57 Below operator's platform

Y63 Solenoid valve, reverse travel 57 Below operator's platform
* = basic diagram
Tab. 18 Back-up alarm
8.45.41
copyright by
MJFCIFSS
Changeover blade to outrigger / individual control 2-point support
19 Changeover blade to outrigger / individual control 2-point support
8.45.42
copyright by
MJFCIFSS
Step 58
*A1100 ESP02 printed circuit board 27-41 Left console
*MP65 Ground connection M5 screw 1 Left console

S335 Blade support switch 58 Right console

Y56 Solenoid valve blade support 58 Undercarriage

* = basic diagram
Tab. 19 Changeover blade to outrigger / individual control 2-point support
8.45.43
copyright by
MJFCIFSS
20 Changeover blade to outrigger / individual control 2-point support
Power supply X214
8.45.44
copyright by
MJFCIFSS
Step 58



* = basic diagram
Tab. 20 Changeover blade to outrigger / individual control 2-point support power supply X214
8.45.45
copyright by
MJFCIFSS
Individual control outrigger and blade
21 Individual control outrigger and blade
8.45.46
copyright by
MJFCIFSS
Step 58

*X209 Plug connection, 2-pin 32 Left console

X301 Plug connection at slip ring, 2-pin 58-2 At rotary connection
X303 Plug connection, 4-pin 58-2 Left console

* = basic diagram
Tab. 21 Individual control outrigger and blade
8.45.47
copyright by
MJFCIFSS
22 Individual control outrigger and blade
Power supply from X214
8.45.48
copyright by
MJFCIFSS
Step 58
*A1100 ESPO02 printed circuit board 27-41 Left console

*X214 Plug connection, 2-pin 37,40 Left console

X301 Plug connection at slip ring, 2-pin 58-2 At rotary connection

* = basic diagram
Tab. 22 Individual control outrigger and blade power supply from X214
8.45.49
copyright by
MJFCIFSS
Automatic oscillating axle locking device (industrial)
23 Automatic oscillating axle locking device (industrial)
8.45.50
copyright by
MJFCIFSS
Automatic oscillating axle locking device (industrial)
Step 59
*F6 Fuse A1100 amplifier E19, E20, V150, V153, 28 A1100

V157 (15A)

*H48 LED power supply E19, E20, SF1, Y55, Y66 28 A1100
*S75 Switch oscillating axle locking device Y66 32 Right console

S223 Switch automatic oscillating axle locking device 59 Slip ring
*V155 Amplifier A1100 oscillating axle 59 A1100
*X50 Plug between S2-A1100, 25-pin 25, 27 Left and right console
*200 Plug on A1100 to wire harness revolving deck 31 Left console
*X224 Plug for oscillating axle and kits 32 Left console
*X252 Plug oscillating axle selection switch S75, 3-pin 32 Right console
X312 Plug slip ring switch, 12-pin 59 Swivel block bearing
X313 Plug slip ring switch, 15-pin 59 Swivel block bearing
*Y66 Solenoid valve / oscillating axle 32 Control oil unit
* = basic diagram
Tab. 23 Automatic oscillating axle locking device (industrial)
8.45.51
copyright by
MJFCIFSS
Travel alarm
24 Travel alarm
8.45.52
copyright by
MJFCIFSS
Travel alarm
Step 60
A100 Printed circuit board/travel alarm 60 Left console
B200 Pressure switch/travel alarm 60 Below travelling pedal
H33 Travel alarm horn 60 Revolving deck

S55 Rocker switch 60 Left joystick
*V158 Amplifier safety lever kit 33 A1100
X15-2 Plug, 2-pin 33 Left armrest

X205 Plug, 2-pin 33 Left armrest
*X210 Plug for safety lever kit, 2-pin 33 A1100
* = basic diagram
Tab. 24 Travel alarm
8.45.53
copyright by
MJFCIFSS
Travel alarm US model
25 Travel alarm US model
8.45.54
copyright by
MJFCIFSS
Travel alarm US model
Step 60
A100 Printed circuit board/travel alarm 60 Left console
B200 Pressure switch/travel alarm 60 Below travelling pedal
H33 Travel alarm horn 60 Revolving deck

S5L Left push button 60 Left joystick

S5R Right push button 60 Left joystick
*V158 Amplifier safety lever kit 33 A1100
*X15-2 Plug, 2-pin 33 Left armrest

*X210 Plug for safety lever kit, 2-pin 33 A1100
* = basic diagram
Tab. 25 Travel alarm US model
8.45.55
copyright by
MJFCIFSS
4-wheel steering with dog-walk steering mode
26 4-wheel steering with dog-walk steering mode
8.45.56
copyright by
MJFCIFSS
4-wheel steering with dog-walk steering mode
Step 61
B212 Proximity switch 61 Undercarriage
*H154 indication 61 Left console
S238 Switch/4-wheel steering 61 Left console

S239 Switch/dog walk 61 Left console
X214 Plug connection, 2-pin 61 A1100 printed circuit

board
X300 Terminal strip 61 E162 terminal box
Y229 Solenoid valve/4-wheel steering 61 Undercarriage

Y295 Solenoid valve/dog walk 61 Undercarriage
* = basic diagram
Tab. 26 4-wheel steering with dog-walk steering mode
8.45.57
copyright by
MJFCIFSS
4-wheel steering
27 4-wheel steering
8.45.58
copyright by
MJFCIFSS
4-wheel steering
Step 61
S238 Switch/4-wheel steering 61 Left console

board
X300 Terminal strip 61 E162 terminal box
Y229 Solenoid valve/4-wheel steering 61 Undercarriage
* = basic diagram
Tab. 27 4-wheel steering
8.45.59
copyright by
MJFCIFSS
Roof light, to back
28 Roof light, to back
8.45.60
copyright by
MJFCIFSS
Roof light, to back
Step 62
K280 Relay roof light 62 Left console
*MP65 Ground connection 62 Left console
S275 Roof light, facing back 62 Right console
S275 Plug connection at plug S275, 3-pin 62 Right console

X214-2 Plug connection, 2-pin 62 Left console
X334 Plug connection, 2-pin reserve 62 Right console
X335 Plug connection, 2-pin 62 Cab roof
E150 Roof light 62 Rear cab roof
* = basic diagram
Tab. 28 Roof light, facing back
8.45.61
copyright by
MJFCIFSS
Individual control 2-point support
29 Individual control 2-point support
8.45.62
copyright by
MJFCIFSS
Step 63



* = basic diagram
Tab. 29 Individual control 2-point support
8.45.63
copyright by
MJFCIFSS
8.45.64
copyright by
MJFCIFSS
Step 63


X301 Plug connection on slip ring, 12-pin 63-2 At rotary connection

* = basic diagram
Tab. 30 Individual control 2-point support with decay diode in plug
8.45.65
copyright by
MJFCIFSS
with decay diode in plug power supply from X214
8.45.66
copyright by
MJFCIFSS
Step 63

*X214 Plug connection on A1100, 2-pin 37,40 Left console

X301 Plug connection on slip ring, 12-pin 63-2 At rotary connection

* = basic diagram
Tab. 31 Individual control 2-point support with decay diode in plug power supply from X214
8.45.67
copyright by
MJFCIFSS
8.45.68
copyright by
MJFCIFSS
Step 64

S206 Switch rear left outrigger support 64 Right console
S207 Switch rear right outrigger support 64 Right console
S272 Slip ring case 64 Undercarriage

X771 Plug connection / 5-pin 64 At rotary connection
Y215 Solenoid valve front left outrigger support 64 Undercarriage

Y216 Solenoid valve front right outrigger support 64 Undercarriage
Y217 Solenoid valve rear left outrigger support 64 Undercarriage
Y218 Solenoid valve rear right outrigger support 64 Undercarriage
* = basic diagram
Tab. 32 Individual control 4-point support
8.45.69
copyright by
MJFCIFSS
8.45.70
copyright by
MJFCIFSS
Step 64
*MP86 Ground connection 1 Behind operator's plat-

form


X771 Plug connection / 5-pin 64 At rotary connection

* = basic diagram
Tab. 33 Individual control 4-point support with decay diode in plug
8.45.71
copyright by
MJFCIFSS
with decay diode in plug power supply from X214
8.45.72
copyright by
MJFCIFSS
Step 64

form

*X214-_ Plug connection, 2-pin 37,40 Left console

X301 Plug connection at slip ring 64-2 At rotary connection

* = basic diagram
Tab. 34 Individual control 4-point support with decay diode in plug power supply from X214
8.45.73
copyright by
MJFCIFSS
KBI cold-starting aid
35 KBI cold-starting aid
8.45.74
copyright by
MJFCIFSS
Step 65
B220 Temperature sensor 65 Engine compartment
*E50 Power and safety switch cabinet 1-3 Battery compartment
F103 Fuse (7.5A) 65 E50
*K16 Starter relay 1-3 E50

*K288 Relay terminal 15 1-3 E50
*K93 Control relay 65 E50
*K94 Main relay 65 E50
*MP65 Ground connection MR screw 1 Left console

MP90 Ground connection main fuses E50 3 Electric box E50
*S1 Ignition switch 3 Right console

S210 Cold start ON switch 65 Right console
V139 Diode 1N 4003/1A 65 E50

V141 Diode 1N 4003/1A 65 E50
S210 Plug connection, 3-pin 65 Right console

X69 Plug connection, 12-pin 1-3 at E50
X219 Plug connection, 2-pin Engine compartment
X251 Plug connection, 2-pin at S1 3 Left console
X321 Plug connection, 3-pin 65 E50
Y334 Valve/start pilot 65 Engine compartment
* = basic diagram
Tab. 35 KBI cold-starting aid
8.45.75
copyright by
MJFCIFSS
36 KBI cold-starting aid
8.45.76
copyright by
MJFCIFSS
Step 65
*B220 Temperature sensor 65 Engine compartment
*F20 E50 fuse main circuit (50A) 3 E50

F103 Fuse (7.5A) 65 E50
*K16 Starter relay 1-3 E50

*K288 Relay terminal 15 1-3 E50
*K93 Control relay 65 E50
*K94 Main relay 65 E50
*MP65 Ground connection MR screw 1 Left console

*MP90 Ground connection main fuses E50 3 Electric box E50

S210 Cold start ON switch 65 Right console
V139 Diode 1N 4003/1A 65 E50

V141 Diode 1N 4003/1A 65 E50
S210 Plug connection, 3-pin 65 Right console

X69 Plug connection, 12-pin 1-3 At E50
X156 Plug A1010, 15-pin wire harness power 2-4 Left console
X219 Plug connection, 2-pin Engine compartment
X251 Plug connection, 2-pin at S1 3 Left console
Y334 Valve/start pilot 65 Engine compartment
* = basic diagram
Tab. 36 KBI cold-starting aid
8.45.77
copyright by
MJFCIFSS
Mozelt / Woko magnet system, US model
37 Mozelt / Woko magnet system, US model
8.45.78
copyright by
MJFCIFSS
Mozelt / Woko magnet system, US model
Step 66
*F18 Fuse (15A)
S6L Magnet ON switch 66 Right joystick

S6R Switch reserve 66 Right joystick
S46 Magnet system ON switch 55 Right console
S55 Switch LAM generator 66 Left joystick
V140 Blocking diode/magnet system 66 Left console

*X214-2 Plug on A1100 terminal 15 kit, 2-pin 37 Left console
X324-1 Plug connection, 1-pin to S46 66 Right console
X324-3 Plug connection, 1-pin to S6L 66 Right console
* = basic diagram
Tab. 37 Mozelt / Woko magnet system, US model
8.45.79
copyright by
MJFCIFSS
Mozelt magnet system with magnetic clutch
38 Mozelt magnet system with magnetic clutch
8.45.80
copyright by
MJFCIFSS
Mozelt magnet system with magnetic clutch
Step 66
*F18 Fuse (15A) for X
K355 Relay for magnetic clutch 66-5 Left console
S6L Magnet ON switch 66 Right joystick

S46 Magnet system ON switch 55 Right console

Y296 Flow distributor generator 66-5 Revolving deck
* = basic diagram
Tab. 38 Mozelt magnet system with magnetic clutch
8.45.81
copyright by
MJFCIFSS
Industrial shut-down
39 Industrial shut-down
8.45.82
copyright by
MJFCIFSS
Step 67
*A1009 Printed circuit board 67 Right console
B204 Proximity switch 67-1/ Industrial stick

67-2
S216 Switch/industrial shut-down 67 Right console

X214-1 Plug connection, 2-pin 67 A1100 printed circuit
board
X327 Plug connection, 3-pin 67 Bearing block interface
X328 Plug connection, 3-pin 67 Bearing block
X329 Plug connection, 2-pin 67 Proximity switch stick
Y212 Solenoid valve/industrial shut-down 67 Behind operator's plat-

form
* = basic diagram
Tab. 39 Industrial shut-down
8.45.83
copyright by
MJFCIFSS
40 Industrial shut-down
Bypass in left joystick
8.45.84
copyright by
MJFCIFSS
Step 67
B204 Proximity switch 67-1/ Industrial stick

67-2
S55 Bypass switch 67 Left pilot control unit

S216 Switch/industrial shut-down 67 Right console
V162 decay diode 67 Left console

X214-2 Plug connection, 2-pin 67 A1100 printed circuit
board
X327 Plug connection, 3-pin 67 Bearing block interface
X329 Plug connection, 2-pin 67 Proximity switch stick
X430 Plug connection, 6-pin 67-3 Below left bracket
X454 Plug connection, 2-pin 67-4 Right console
Y212 Solenoid valve/industrial shut-down 67 Control oil unit
* = basic diagram
Tab. 40 Industrial shut-down bypass in left joystick
8.45.85
copyright by
MJFCIFSS
Travel shut-down at lift frame extension
41 Travel shut-down at lift frame extension
8.45.86
copyright by
MJFCIFSS
Travel shut-down at lift frame extension
Step 68
B274 Proximity switch 68 Behind cab
F4 Fuse (15A) 28 A1100 ESP02
H28 LED control travel amplifier V159 33 A1100

H29 LED travel amplifier V159 33 A1100
H44 LED terminal 15 28 A1100
H46 LED F4 28 A1100
*S30 Travel switch / R = reverse / V = forward 33 Right joystick
*V159 Travel amplifier 33 A1100

board
*Y62 Solenoid valve, forward travel 33 Below operator's platform

*Y63 Solenoid valve, reverse travel 33 Below operator's platform
* = basic diagram
Tab. 41 Travel shut-down at lift frame extension
8.45.87
copyright by
MJFCIFSS
Industrial quick-change adapter / bucket quick-change adapter
42 Industrial quick-change adapter / bucket quick-change adapter
8.45.88
copyright by
MJFCIFSS
Step 69
*A1009 Decay diode board 69 Right console
B26 Proximity switch/bucket quick-change adapter 69 At quick-change adapter

head
*E 25 Keypad lighting 69 Keypad
F11 A1100 spare plug X214-3 (15A) 40 Left console
*H10 Buzzer 69 Right console

*H44 LED terminal 15 power supply 28 Left console
*H55 LED power supply X214-3 28 Left console
K3 Relay 69 A1001
K4 Relay 69 A1001
*S2 Keypad 69 Left console

*S47 Key switch / pressure switch 69 Right console
*X2 Plug connection keypad 69 Right console

*X14-1 Plug connection keypad 69 Right console
X17 Plug on A1001 22 Right console
X40 Plug connection keypad - display 69 Right console
X49 Plug connection keypad - buzzer 69 Right console
X262 Plug connection to quick-change adapter, 8-pin 69 A1017 right bracket
X262-1 Plug connection on bearing block, 8-pin 69 Bearing block
X262-2 Plug connection on boom, 8-pin 69 Boom
X262-3 Plug connection to stick, 8-pin 69 Stick
X262-4 Plug connection at valve Y28-1, 2-pin 69 Quick-change adapter
head
head
X262-6 Plug connection on B26, 3-pin 69 Quick-change adapter
head
Y28-1 Solenoid valve quick-change adapter 69 Quick-change adapter

8.45.89
copyright by
MJFCIFSS
Step 69
1 Actuated by quick-change adapter release
(normally-closed contact)
3 Released
4 Locked
(normally-open contact)
6 Continuous at water level / water temperature /
hydraulic oil level
* = basic diagram
Tab. 42 Industrial quick-change adapter, bucket quick-change adapter
8.45.90
copyright by
MJFCIFSS
8.45.91
copyright by
MJFCIFSS
Bucket quick-change adapter quick-change adapter
43 Bucket quick-change adapter quick-change adapter
with hold function and two-hand operation with normally-open contact
8.45.92
copyright by
MJFCIFSS
Step 69
*A1001 Printed circuit board relay 69 Right console
B26 Proximity switch/bucket quick-change adapter 69 at quick-change adapter

head

K3 Relay 69 A1001
K4 Relay 69 A1001
S47-1 Actuate quick-change adapter key switch 69 Right console

S47-2 Actuate quick-change adapter pressure switch 69 Right console

head
head
head
X410 Plug connection, power supply A1017 69-5 A1017
X411 Plug connection, key switch, 2-pin 69-5 A1017
X412 Plug connection A1017 AS1 key, 2-pin 69-5 A1017
X413 Plug connection quick-change adapter alarm, 69-5 A1017
4-pin
X446 Plug connection to S47 1/2, 5-pin 69-7 A1017
X447 Plug connection blocking diode warning quick- 69-7 Right console
change adapter

8.45.93
copyright by
MJFCIFSS
Step 69
3 Released
4 Locked
hydraulic oil level
* = basic diagram
Tab. 43 Bucket quick-change adapter with hold function and two-hand operation / normally-open
contact
8.45.94
copyright by
MJFCIFSS
8.45.95
copyright by
MJFCIFSS
Industrial quick-change adapter
44 Industrial quick-change adapter
with key switch and pressure switch
8.45.96
copyright by
MJFCIFSS
Step 69
*A1017 Printed circuit board / quick-change adapter 69 Right console

head

K3 Relay 69 A1001
K4 Relay 69 A1001
K364 Relay quick-change adapter intervals 69-5 A1017
S5L Left joystick key 20 Left joystick

S5R Right joystick key 20 Right joystick
S47 Key switch / pressure switch 69 Right console
V11 LED solenoid valve quick-change adapter 69-5 A1017

V12 LED monitoring system quick-change adapter 69-5 A1017
X2 Plug connection keypad 69 Right console

X15-1 Plug connection on S5, 3-pin 20 Left console
head
head
head
4-pin
8.45.97
copyright by
MJFCIFSS
Step 69

3 Released
4 Locked
hydraulic oil level
* = basic diagram
Tab. 44 Industrial quick-change adapter with key switch and pressure switch
8.45.98
copyright by
MJFCIFSS
8.45.99
copyright by
MJFCIFSS
Bucket quick-change adapter
45 Bucket quick-change adapter
with hold function, two-hand operation and pressure switch
8.45.100
copyright by
MJFCIFSS
Step 69
A1017 Printed circuit board / quick-change adapter 69 Right console

head
*E25 Keypad lighting 69 Keypad
*H1 Display 69 Left console

*H10 Buzzer 69 Right console
H47 LED power supply SF2, SF3, SF4 28 Left console
K3 Relay 69 A1001
K4 Relay 69 A1001
K364 Relay quick-change adapter intervals 69-5 A1017
S5L Left joystick key 20 Left joystick

S5R Right joystick key 20 Right joystick
S47 Key switch / pressure switch 69 Right console
V11 LED solenoid valve quick-change adapter 69-5 A1017

V12 LED monitoring system quick-change adapter 69-5 A1017
X2 Plug connection keypad 69 Right console

X15-1 Plug connection on S5, 3-pin 20 Left console
head
head
head
8.45.101
copyright by
MJFCIFSS
Step 69
4-pin


3 Released
4 Locked
hydraulic oil level
* = basic diagram
Tab. 45 Bucket quick-change adapter with hold function, two-hand operation and pressure switch
8.45.102
copyright by
MJFCIFSS
8.45.103
copyright by
MJFCIFSS
Topas quick-change adapter
46 Topas quick-change adapter
8.45.104
copyright by
MJFCIFSS
Step 70
*A1001 ESP01 printed circuit board Right console

*K3 Relay quick-change adapter warning buzzer 22 A1001

and symbol
S6L Magnet ON switch 70 Right travel lever

S6R Switch reserve 70 Right travel lever
S46 Switch magnet system OFF 70 Right console
S47 Actuate quick-change adapter key switch 70 Right console
S208 Push button extend lorry telescope Y338 70 Right console
S209 Push button retract lorry telescope Y337 70 Right console
S224 Switch clamp lorry Y340 70 Left joystick

X15-3 Plug connection to S224, 3-pin 70 Left pilot control unit

*X17 Plug connection quick-change adapter alarm, 22 A1001
3-pin
Y55 Plug connection on A1009, 3-pin 69 Right console
X342 Plug connection, 8-pin 70 Boom
X343 Plug connection, 7-pin 70 Stick
8.45.105
copyright by
MJFCIFSS
Step 70
Y28 Solenoid valve quick-change adapter industrial 70 Industrial quick-change
stick adapter
Y214 Solenoid valve/pressure relief 70 Control valve block
Y337 Solenoid valve/retracting lorry telescopic me- 70 TOPAS quick-change ad-
chanism apter
Y338 Solenoid valve/extending lorry telescopic me- 70 TOPAS quick-change ad-
chanism apter
Y339 Solenoid valve/locking coupling 70 TOPAS quick-change ad-
apter
Y340 Solenoid valve/clamping lorry 70 TOPAS quick-change ad-
apter
* = basic diagram
Tab. 46 Topas quick-change adapter
8.45.106
copyright by
MJFCIFSS
8.45.107
copyright by
MJFCIFSS
Topas quick-change adapter with 2-step operation
47 Topas quick-change adapter with 2-step operation
8.45.108
copyright by
MJFCIFSS
Step 70


and symbol
S6L Magnet ON switch 70 Right travel lever

S6R Switch reserve 70 Right travel lever
S46 Switch magnet system OFF 70 Right console
S47-1 Actuate quick-change adapter key switch 70 Right console
S47-2 Actuate quick-change adapter pressure switch 70 Right console

V154 Blocking diode quick-change adapter 70 Right console
X15-3 Plug connection to S224, 3-pin 70 Left pilot control unit

*X17 Plug connection quick-change adapter alarm, 22 A1001
3-pin
X342 Plug connection, 8-pin 70 Boom
8.45.109
copyright by
MJFCIFSS
Step 70
X343 Plug connection, 7-pin 70 Stick
X446 Plug connection to S47-1/2, 5-pin 70 Right console
X447 Plug connection quick-change adapter blo- 70 Right console
cking diode, 2-pin
Y28 Solenoid valve quick-change adapter industrial 70 Industrial quick-change
stick adapter
chanism apter
chanism apter
Y339 Solenoid valve/locking coupling 70 TOPAS quick-change ad-
apter
apter
* = basic diagram
Tab. 47 Topas quick-change adapter with 2-step operation
8.45.110
copyright by
MJFCIFSS
8.45.111
copyright by
MJFCIFSS
Changeover grapple - bucket
48 Changeover grapple - bucket
8.45.112
copyright by
MJFCIFSS
Changeover grapple - bucket
Step 71
F4 Reserve 28 Left console
S359 Switch bucket - grapple 71 Right console
*X210 Plug on A1100, 2-pin 33 Left console

X345 Plug connection in control console , 2-pin 71 Left console
X346 Plug connection on bearing block, 4-pin 71 Bearing block
X347 Plug connection on boom, 4-pin 71 Boom
Y335 Solenoid valve changeover grapple bucket, 71 Attachment

2-pin
Y335 Solenoid valve changeover grapple bucket, 71 Attachment
2-pin
* = basic diagram
Tab. 48 Changeover grapple - bucket
8.45.113
copyright by
MJFCIFSS
Separate windscreen wiper system / wiper system
49 Separate windscreen wiper system / wiper system
for bullet-proof glass in roof
8.45.114
copyright by
MJFCIFSS
Separate windscreen wiper system / wiper system
Step 72
*A1100 Amplifier PCB 28-41 Left armrest
F18 Fuse (15A) 37 Left armrest
M60 Separate windscreen wiper motor 72 Cab roof/rear window

M68 Separate splash motor 72 Behind cab
S218 Switch separate windscreen wiper 72 Right armrest

S362 Button separate splash motor 72 Right armrest
*X214 Kit plug, 2-pin 37 Left armrest

X348-1 Plug connection, 4-pin 72 Right armrest
X348-2 Plug connection, 4-pin 72 Cab roof
X349 Plug connection, 4-pin 72 Right armrest
* = basic diagram
Tab. 49 Separate windscreen wiper system / wiper system for bullet-proof glass in roof
8.45.115
copyright by
MJFCIFSS
Wiper system for rear window
50 Wiper system for rear window
8.45.116
copyright by
MJFCIFSS
Wiper system for rear window
Step 72
*A1100 Amplifier PCB 28-41 Left armrest
*F18 Fuse (15A) 37 Left armrest
M60 Separate windscreen wiper motor 72 Cab roof/rear window
S218 Switch separate windscreen wiper 72 Right armrest
*X214 Kit plug, 2-pin 37 Left armrest

X348-1 Plug connection, 4-pin 72 Right armrest
X348-2 Plug connection, 4-pin 72 Cab roof
* = basic diagram
Tab. 50 Wiper system for rear window
8.45.117
copyright by
MJFCIFSS
Auxiliary headlight equipment
51 Auxiliary headlight equipment
8.45.118
copyright by
MJFCIFSS
Auxiliary headlight equipment
Step 73
*E1 Attachment light 73 Boom, stick

F204 Fuse (15A) 73 E50
K308 Relay auxiliary headlight 73 E50
S10 Switch headlight 25 Left console
X5.1 Plug, 8-pin 16 A1001

X177 Plug connection, 2-pin 73 Engine compartment
X353-1 Plug connection, 4-pin 73 Stick
* = basic diagram
Tab. 51 Auxiliary headlight equipment
8.45.119
copyright by
MJFCIFSS
Air-conditioning system
52 Air-conditioning system
8.45.120
copyright by
MJFCIFSS
Step 74
B43 Sensor / air condition 26 Operator's platform
B44 Sensor / air condition 26 Operator's platform
B45 Temperature sensor a/c system 26 Operator's platform
*F20 E50 fuse main circuit (50A) 3 E50

*F31 E50 fuse a/c system (7.5A) 3 E50
*F32 E50 fuse fan motor M2 (15A) 3 E50
F252 E50 fuse fan motor M64 (15A) 74 E50
K286 Relay a/c system evaporator 74 E50

*K288 Relay terminal 15 3 E50
Terminal 1 : minus
Terminal 2 : output heating
Terminal 3 : output cooling
Terminal 4 : temperature sensor
Terminal 5 : +24V
Terminal 6 : temperature sensor (switching
point = 3.8/3.9V)
Terminal 7 : temperature regulator (switching
point = 3.8/3.9V)
Terminal 8 : temperature regulator (switching
point = 7.0/7.2V)
*M12 Engine fresh air flap a/c system 26 Operator's platform

*M13 Fan / a/c system 26 Operator's platform
*MP65 Chassis ground M5 screw 1 Left console
*S92 Rotary switch air-conditioning flap 26 Air-conditioning system

*S93 Rotary switch/air-conditioning heating 26 Air-conditioning system
*S94 Rotary switch air-conditioning fan output, step- 26 Air-conditioning system
less
*S95 Rotary switch/air-conditioning cooling 26 Air-conditioning system
*U28 Thermotronic a/c system 26 Operator's platform

*U29 Electronic box a/c system 26 Operator's platform
*U31 Control module condenser a/c system 26 Operator's platform
*V1 Control diode cooling fan 26 Control module a/c sys-

tem
*V2 Control diode heating fan 26 Control module a/c sys-
tem
*V3 Control diode water timing valve 26 Control module a/c sys-
tem
8.45.121
copyright by
MJFCIFSS
Step 74
*X69 Plug at E50, 12-pin 2-3 Battery compartment
*X79 Plug coupling a/c condenser 74 Left console
*X84_2 Plug a/c system, 2-pin 26 Left console
*X84_3 Plug a/c fan motor, 2-pin 26 Left console
*X86 Plug, 9-pin 26 Left console
X87 Plug, 3-pin 26 Left console
*353 Plug actuation signal fan, 1-pin 74 Left console
X353-1 Plug actuation signal fan, 1-pin 74 E50
X354 Plug actuation signal fan, 1-pin 74 Left console
Y20 A/c compressor coupling 26 Injection pump

Y46 Timing valve a/c system 26 Below operator's platform
* = basic diagram
Tab. 52 Air-conditioning system
8.45.122
copyright by
MJFCIFSS
8.45.123
copyright by
MJFCIFSS
2 counter weight lights to rear
53 2 counter weight lights to rear
8.45.124
copyright by
MJFCIFSS
2 counter weight lights to rear
Step 75
E151 Counter weight light 75 Weight, rear
K280 Relay roof light (counter weight light) 75 Left console
*MP65 Ground connections 75 Left console
S275 Switch with plug connection / 3-pin roof light to 75 Right console
rear

X334 Plug connection, 2-pin counter weight light 75 Right console
X356 Plug connection, 2-pin 75 Engine bonnet
* = basic diagram
Tab. 53 2 counter weight lights, rear
8.45.125
copyright by
MJFCIFSS
Auxiliary beacon at counter weight
54 Auxiliary beacon at counter weight
8.45.126
copyright by
MJFCIFSS
Auxiliary beacon at counter weight
Step 76
E9 Beacon 14 Cab roof

E9.1 Beacon 76 At counter weight
F10 Fuse (15A) 76 A1100
S41 Switch / beacon 76 Right console
V26 Amplifier 14 Right console
X20.8 Plug, 10-pin 76 Right console

X357 Plug connection, 2-pin 76 At counter weight
X3_2 Plug connection, 6-pin 76 Right console
* = basic diagram
Tab. 54 Auxiliary beacon at counter weight
8.45.127
copyright by
MJFCIFSS
License plate light
55 License plate light
8.45.128
copyright by
MJFCIFSS
License plate light
Step 76
E17 Right tail light 36 To the right behind the

counter weight
E163 License plate light 76 At counter weight
*F2 Fuse (2A) 76 A1100
S41 Switch / beacon 76 Right console
*V161 Amplifier 36 A1100
X200 Plug 76 Right console
* = basic diagram
Tab. 55 License plate light
8.45.129
copyright by
MJFCIFSS
Changeover valve
56 Changeover valve
8.45.130
copyright by
MJFCIFSS
Changeover valve
Step 77
A without rocker switch S390 77 Right console
*F11 Fuse (15A) 77 A1100
S356 Switch/changeover valve 77 Right console

S390 Switch/changeover valve 77 Left joystick
X51 Plug, 3-pin 77 A1009

X52 Plug, 3-pin 77 A1009
X53 Plug, 3-pin 77 A1009
X54 Plug, 3-pin 77 A1009
X55 Plug, 2-pin 77 A1009
X214-3 Plug, 2-pin 77 A1100
Y332 Changeover valve 77 Attachment

Y356 Solenoid valve/pressure limitation for lateral 77 Behind operator's plat-
adjustment form
Y443 Solenoid valve pilot control pipe-fracture safety 77 Behind operator's plat-
piston side form
piston side form
* = basic diagram
Tab. 56 Changeover valve
8.45.131
copyright by
MJFCIFSS
Changeover valve
57 Changeover valve
with pressure limitation for lateral adjustment
8.45.132
copyright by
MJFCIFSS
Changeover valve
Step 77
*F11 Fuse (15A) 77 A1100

S390 Changeover valve switch 77 Left joystick
X51 Plug, 3-pin 77 A1009

X52 Plug, 3-pin 77 A1009
X53 Plug, 3-pin 77 A1009
X54 Plug, 3-pin 77 A1009
X55 Plug, 2-pin 77 A1009
X214-3 Plug, 2-pin 77 A1100
X402 Plug, 2-pin 77 Behind operator's plat-
form

Y356 Solenoid valve/pressure limitation for lateral 77 Behind operator's plat-
adjustment form
* = basic diagram
Tab. 57 Changeover valve with pressure limitation for lateral adjustment
8.45.133
copyright by
MJFCIFSS
Changeover valve
58 Changeover valve
Changeover kit at regulation cylinder - lateral adjustment
8.45.134
copyright by
MJFCIFSS
Changeover valve
Step 77
*F11 Fuse (15A) 77 A1100
K455 Relay 77 Left console

S390 Switch/changeover valve 77 Left joystick
X51 Plug, 3-pin 77 A1009

X52 Plug, 3-pin 77 A1009
X53 Plug, 3-pin 77 A1009
X54 Plug, 3-pin 77 A1009
X55 Plug, 2-pin 77 A1009
X56 Plug, 3-pin 77 A1009
X57 Plug, 2-pin 77 A1009
X214-3 Plug, 2-pin 77 A1100

piston side form
* = basic diagram
Tab. 58 Changeover valve (changeover kit at regulation cylinder - lateral adjustment)
8.45.135
copyright by
MJFCIFSS
Slewing ladder
59 Slewing ladder
8.45.136
copyright by
MJFCIFSS
Slewing ladder
Step 78
B301 Proximity switch 78-1 Below operator's platform
*F8 Fuse (7.5A) 78 A1100

*F11 Fuse terminal 15 kit (15A) 37 A1100
*H44 LED fuse terminal 15 28 A1100

*H53 LED fuse F8 40 A1100
*H55 LED kit 37 A1100
K211 Slewing ladder relay 78-2 A1100
MP60 Ground connection 78 Below operator's plat-

form, centre
MP12 Ground connection 78 Right console
*S7 Safety switch 78 Left console

S374 Slewing ladder key 78-2 Left console
*X3 Plug, 10-pin 19 A1001

*X11 Plug, 4-pin 78 Right console
*X214-3 Kit plug, 2-pin 37 A1100
*X216 Plug, 6-pin to kin relay base 38 A1100
*X232 Plug, 10-pin 40 A1100
Y205 Solenoid valve/slewing ladder 78 Below operator's platform
* = basic diagram
Tab. 59 Slewing ladder
8.45.137
copyright by
MJFCIFSS
Changeover EURO - LIEBHERR control
60 Changeover EURO - LIEBHERR control
8.45.138
copyright by
MJFCIFSS
Changeover EURO - LIEBHERR control
Step 79
H292 Lamp with plug connection, 2-pin 79 Right console
K229 Relay changeover Euro - LIEBHERR 79 Right console
S247 Changeover switch with plug connection, 2-pin 79 Right console
*X51 Plug connection, 2-pin A1009 79 Right console

*X57 Plug connection, 2-pin A 1009 79 Right console
*X59 Plug connection, 2-pin A 1009 79 Right console
X236-1 Plug connection, 2-pin Y236/1 79 Behind cab
Y236-1 Solenoid valve changeover LIEBHERR / 79 Behind cab

EURO
EURO
EURO
EURO
* = basic diagram
Tab. 60 Changeover EURO - LIEBHERR control
8.45.139
copyright by
MJFCIFSS
Inclinometer
61 Inclinometer
8.45.140
copyright by
MJFCIFSS
Inclinometer
SA1009PCB37right console
Step 80
*E164 Illumination 80 Right front console
*F10 Fuse (7.5A) 80 A1100
*X3 Plug 19 Right console

X16.1 Plug connection, 2-pin 80 Right console
X232 Plug 40 Left console
* = basic diagram
Tab. 61 Inclinometer
8.45.141
copyright by
MJFCIFSS
Stroke limitation hydraulic boom adjustment
62 Stroke limitation hydraulic boom adjustment
8.45.142
copyright by
MJFCIFSS
Stroke limitation hydraulic boom adjustment
Step 81
B214 Stroke limitation proximity switch 81 at bearing block
*H10-2 Warning buzzer 25 Left console

*H44 LED terminal 15 28 A1100
*H59 LED F18 37 A1100
K333 Relay buzzer control 38 A1100

K334 Relay valve actuation stroke limitation 38 A1100
S249 Key switch stroke limitation ON 81 Right console

S291 Key + lamp bypass stroke limitation 81 Right console
*X214-2 Plug connection, 2-pin 37 Left console

*X216 Plug, 6-pin to relay K333 38 Left console
*X217 Plug, 6-pin to relay K334 38 Left console
X361 Plug connection to shut-down valves, 4-pin 81 Right console
X362 Plug connection to proximity switch B214, 4-pin 81 Right console
X363 Plug connection to proximity switch B214, 4-pin 81 Boom
X365 Plug connection decay diode / 2-pin 81 Right console
X366 Plug connection decay diode / 2-pin 81 Right console
Y237 Solenoid valve/stroke limitation 81 Valve block

Y238 Solenoid valve stroke limitation on-road travel 81 Valve block
* = basic diagram
Tab. 62 Stroke limitation / hydraulic boom adjustment
8.45.143
copyright by
MJFCIFSS
24V - 12V voltage converter
63 24V - 12V voltage converter
8.45.144
copyright by
MJFCIFSS
24V - 12V voltage converter
Step 82
*F206 Fuse (15A) 82 E50
S364 Power socket, 12V 82 Engine compartment
T2 Voltage transformer 82 Behind cab
X364 Plug connection, 3-pin 82 Behind cab
* = basic diagram
Tab. 63 24V - 12V voltage converter
8.45.145
copyright by
MJFCIFSS
Magnet system with hydraulic LAM drive
64 Magnet system with hydraulic LAM drive
8.45.146
copyright by
MJFCIFSS
Magnet system with hydraulic LAM drive
Step 83
K355 Relay 83
M Magnet generator
S46 Switch/control magnet system 83 Right console

*X74 Plug connection, 3-pin 83 Right console


X324-1 Plug connection, 1-pin 83 Right console
X324-A Plug connection, 1-pin 83 Right console
Y296 Flow distributor 83 Behind operator's plat-

form
* = basic diagram
Tab. 64 Magnet system with hydraulic LAM drive
8.45.147
copyright by
MJFCIFSS
Magnet system with hydraulic MOZELT drive
65 Magnet system with hydraulic MOZELT drive
8.45.148
copyright by
MJFCIFSS
Step 83
K355 Relay 83
S6L Magnet ON switch / Europe 83 Right joystick




form
* = basic diagram
Tab. 65 Magnet system with hydraulic MOZELT drive
8.45.149
copyright by
MJFCIFSS
Magnet system with hydraulic WOKO drive
66 Magnet system with hydraulic WOKO drive
8.45.150
copyright by
MJFCIFSS
Magnet system with hydraulic WOKO drive
Step 83
K355 Relay 83




form
* = basic diagram
Tab. 66 Magnet system with hydraulic WOKO drive
8.45.151
copyright by
MJFCIFSS
LIEBHERR hydro magnet HYMAC
67 LIEBHERR hydro magnet HYMAC
8.45.152
copyright by
MJFCIFSS
Magnet system with hydraulic drive
Step 83
K355 Relay 83



Y450 Neutral recirculation valve at auxiliary pump for 83-4 Fuel tank
HYMAC
* = basic diagram
Tab. 67 LIEBHERR hydro magnet HYMAC
68 Magnet system with hydraulic drive
and switch-on protection
8.45.153
copyright by
MJFCIFSS
8.45.154
copyright by
MJFCIFSS
Step 83
K355 Relay 83


*X217 Plug on A1100, 6-pin 39 A1100

X1205 Plug to pilot contacts quick-change adapter, 2- 83-5 Left console
pin
X1231 Plug to quick-change adapter kit, 2-pin 83-5 Right console
X1232 Plug to solenoid valve, 4-pin 83-5 Left console

form
* = basic diagram
Tab. 68 Magnet system with hydraulic drive and switch-on protection
8.45.155
copyright by
MJFCIFSS
69 Magnet system with hydraulic MOZELT drive
8.45.156
copyright by
MJFCIFSS
Step 83
K355 Relay 83

S457 Magnet ON / OFF key 83 Left joystick



form
* = basic diagram
Tab. 69 Magnet system with hydraulic MOZELT drive
8.45.157
copyright by
MJFCIFSS
UNIKAT exhaust gas filter
70 UNIKAT exhaust gas filter
8.45.158
copyright by
MJFCIFSS
UNIKAT exhaust gas filter
Step 84
B258 Pressure switch 84 Exhaust gas filter
H189 Signalling light/exhaust gas filter 84 Right console

* = basic diagram
Tab. 70 UNIKAT exhaust gas filter
8.45.159
copyright by
MJFCIFSS
Hose drum
71 Hose drum
8.45.160
copyright by
MJFCIFSS
Hose drum
Step 85
B262 Pressure switch 85 Left console
*H44 Control LED terminal 15 to A1100 28 Left console

*H46 Control LED F4 from A1100 28 Left console
K327 Relay 85 Left console
*S35 Servo switch on keypad 25 Right console
*X209 Kit plug on A1100, 2-pin 32 Left console

Y306 solenoid valve 85 Bearing block
* = basic diagram
Tab. 71 Hose drum
8.45.161
copyright by
MJFCIFSS
Turning grapple / ditch cleaning bucket
72 Turning grapple / ditch cleaning bucket
8.45.162
copyright by
MJFCIFSS
Turning grapple / ditch cleaning bucket
Step 86
*A1001 ESP01 printed circuit board Right armrest
*A1100 ESP02 printed circuit board Left armrest
*F5 Fuse terminal 15 (7.5A) 40 Left armrest
*S2 Keypad (right console) 25 Right armrest

*S5L Push button / turn grapple left 20 Left joystick
*S5R Push button / turn grapple right 20 Left joystick
*S55 Switch reserve 20 Left joystick
S80 Selector switch / ditch cleaning bucket swit- 86 Right armrest
ching (right console)
*X2 Plug 52-A1001, 37-pin 22-23 Right armrest

*X6-1 Plug A1001, 6-pin 14 Right armrest
*X6-2 Plug A1001, 8-pin 20 Right armrest
*X15-1 Plug S5L/R, 3-pin 20 Left armrest
*X15-3 Plug S55, 3-pin 20 Left armrest
*X16 Plug A1001, 2-pin 19 Right armrest
*X21 Plug A1001, 3-pin 20 Right armrest
X232 Plug on A1100 to wire harness control console, 39-41 Left armrest
right, 10-pin
X234 Plug from A 1100 for kit, 2-pin 41 Left armrest
X246 Plug on plug-in board to wire harness slewing 15-18 Left armrest
gear, 10-pin
*Y22 Solenoid valve / grapple rotator 20 Bearing block

*Y23 Solenoid valve / grapple rotator 20 Bearing block
Y78 Solenoid valve / shut-down grapple control 41 Control oil unit
* = basic diagram
Tab. 72 Turn grapple / ditch cleaning bucket
8.45.163
copyright by
MJFCIFSS
D5WS auxiliary heating
73 D5WS auxiliary heating
8.45.164
copyright by
MJFCIFSS
Step 87
A Burner motor E30
B Glow plug E30
C Overheating sensor E30
D Temperature sensor E30
E Flame sensor E30
*B43 A/c sensor 26 Air-conditioning system

*B44 A/c sensor 26 Dryer
*B45 Temperature sensor a/c system 26 U28
E30 D5WS auxiliary heating 87 Revolving deck

*E50 Power cabinet and fuse cabinet 87 Battery compartment
*F20 Automatic cut-out main circuit (50A) 3 E50

*F22 Fuse terminal 20 (7.5A) hazard light 3 E50
*F31 Fuse terminal 15 (7.5A) a/c system 3 E50
*F32 Fuse terminal 15 (15A) a/c system without au- 3 E50
xiliary heating
*F33 Fuse (15A) kit 3 E50
F34 Fuse terminal 30 (25A) auxiliary heating to 87 E50
ground
F35 Fuse terminal 30 (15A) auxiliary heating control 87 E50
device
F36 Fuse terminal 30 (15A) timer, water valve with 87 E50
heating
*F37 Fuse terminal 30 (15A) heating fan 3 E50
*G2 battery 2 Battery compartment
*K288 Relay main circuit E50 terminal 15 3 E50

K358 Relay heating ON 87 E50
K359 Relay water circuit ON 87 E50
K360 Relay heater fan ON 87 E50
*M12 A/c system recirculation flap 26 Cab

*M13 A/c system heating fan 26 Cab
M52 Coolant pump 87 Auxiliary heating
M53 Fuel metering pump 87 Fuel tank
*S9 Battery switch-off 2 Battery compartment

*S92 Switch a/c system 26 Left console
S232 Digital timer/auxiliary heating 87 Left console
S232 Digital weekly timer auxiliary heating 87 Right console
8.45.165
copyright by
MJFCIFSS
Step 87
*U28 Thermotronic a/c system 26 Evaporator unit

*U29 Control module 26 Evaporator unit
*U31 Condenser control module 26 Evaporator unit
*X45 Plug E50, 9-pin 3 E50
*X69 Plug E50, 12-pin 3 E50
*X79 Plug a/c system, 2-pin 26 Left console
*X84-2 Plug a/c system, 2-pin 26 Left console
*X84-3 Plug a/c system, 2-pin 26 Left console
*X86 Plug control module a/c system, 9-pin 26 Left console
X87 Plug control module a/c system, 3-pin 26 Left console
*X88 Plug U29-Y46 a/c system, 2-pin 26 Below operator's platform
*X94 Plug M12, 2-pin 26 Evaporator unit
X95 Plug to S232, 4-pin 87 Right console
X96 Plug E50 to wire harness heating a/c console 87 E50
left, 6-pin
X98 Plug to fuel metering pump, 2-pin 87 Auxiliary heating
X99 Plug to recirculation pump, 2-pin 87 Auxiliary heating
X101 Plug to auxiliary heating control device, 8-pin 87 Auxiliary heating
X102 Plug E50 to wire harness heating unit, 8-pin 87 E50
*Y20 A/c clutch 26 Motor

*Y46 Solenoid valve cooling water valve 26 Below operator's platform
* = basic diagram
Tab. 73 D5WS auxiliary heating
8.45.166
copyright by
MJFCIFSS
8.45.167
copyright by
MJFCIFSS
E50 field test
74 E50 field test
With Siemens relay and flat fuses
8.45.168
copyright by
MJFCIFSS
E50 field test
Step 88
D1 Diode cube 88 E50
D2 Diode cube 88 E50
*E50 Electric cabinet 3 Battery compartment
*F19 Fuse (70A) for pre-heating / refuelling pump 3 E50

*F20 Main fuse (50A) 3 E50
*F22 Fuse (7.5A) hazard light 3 E50
*F31 Fuse (7.5A) a/c system 3 E50
*F32 Fuse (15A) heating fan 3 E50
*F37 Fuse kit terminal 30 3 E50
*K16 Relay terminal 50 starter 3 E50

*K288 Main relay terminal 15 3 E50
*K302 Relay pre-heating 3 E50
MP90 Ground connection in electric cabinet 3 E50
*X45 Plug E50, 9-pin 3 E50

*X69 Plug on E50, 12-pin 3 E50
*X170 Plug, 1-pin 2 Battery compartment
* = basic diagram
Tab. 74 Field test E50 with Siemens relay and flat fuses
8.45.169
copyright by
MJFCIFSS
LINNIG fan
75 LINNIG fan
8.45.170
copyright by
MJFCIFSS
LINNIG fan
Step 89
*B2 Water temperature transducer 89 Motor, top fan side

*B8 Hydraulic oil temperature sensor 89 Hydraulic oil tank
*E50 Power and safety switch cabinet 89
*F18 Fuse (15A) 89-1 A1100
K362 Relay fan control 89 Left console
*S95 Switch a/c system ON 26 Right console
*U16 BST (excavator control) 89 Right armrest

*U28 Thermotronic 89 Air-conditioning system
*V1 Decay diode a/c system 89 Left console
*X134 Plug B8-B14, 4-pin 89 Hydraulic tank

*X135 Plug BST (excavator control), 40-pin 89 BST (excavator control)
*X186 Plug B2, 2-pin 89 B2
*X214-2 Plug on A1100 for terminal 15 kit, 2-pin 89-1 A1100
X366-1 Plug fan coupling, 1-pin 89 Left console
S366-2 Plug fan coupling, 1-pin 89 E50
X367-1 Plug fan coupling, 1-pin 89 Left console
X367-2 Plug fan coupling, 1-pin 89 E50
X368 Plug fan coupling control signal a/c system, 1- 89 Left console
pin
X689 Plug diode plug, 6-pin 89 Left console
Y347 Fan clutch 89 Fan
* = basic diagram
Tab. 75 LINNIG fan
8.45.171
copyright by
MJFCIFSS
Power socket for mobile phone
76 Power socket for mobile phone
8.45.172
copyright by
MJFCIFSS
Power socket for mobile phone
Step 90
*A1100 Printed circuit board 27-41 Left console
*F18 Fuse (15A) X214-2 37 A1100
H59 LED power supply X214-2 37 A1100
T2 Voltage transformer 90-1 Right console
X677 Power socket for mobile phone 12V/7.5A 90-1 Right console
* = basic diagram
Tab. 76 Power socket for mobile phone
8.45.173
copyright by
MJFCIFSS
M20 radio modem
77 M20 radio modem
8.45.174
copyright by
MJFCIFSS
M20 radio modem
Step 91
*A1001 A1001 printed circuit board 10-22 Right console
*A1100 Printed circuit board 27-41 Left console
A1102 Amplifier on separate PCB for radio modem 91 Right console
*E50 Power switch cabinet 3 Battery compartment

*F20 Fuse (15A) 37 A1100
H295 Indicator light data transfer 91 Right console
U59 M20 radio modem 91 Right console
*X32 Serial interface 10 A1001

*X45 Plug E50, 9-pin 3 E50
*X69 Plug on E50, 12-pin 3 E50
*X159 Plug on plug-in board to cable harness motor, 3 Left console
9-pin
*X215 Plug on 1100, 2-pin 37 Left console
X369 Plug on 1102, 5-pin 91 A1102
X371 Serial interface on U59 91 U59
X372 Power supply U59, 6-pin 91 A1102
X372-1 Power supply U59, 6-pin 91 U59
* = basic diagram
Tab. 77 M20 radio modem
8.45.175
copyright by
MJFCIFSS
Krüger stroke limitation
78 Krüger stroke limitation
8.45.176
copyright by
MJFCIFSS
Krüger stroke limitation
Step 92
B247 Proximity switch/changeover grapple - bucket 92 Stick
*F11 Fuse (15A) 92-1 Â1100
*H55 LED for F11 92 Right console

H159 Indicator light stroke limitation ON 92 Right console
K1 Relay preliminary shut-off Krüger electronics 92 Krüger control

K2 Relay switch-on Krüger electronics 92 Krüger control
K261 Relay SDS changeover contact 92 A1100 / A107
R70 Rotary potentiometer, basic boom 92 Basic boom

R71 Rotary potentiometer, boom 92 Boom
S249 Key switch stroke limitation ON 92 Right console

S291 Suppression button stroke limitation 92 Right console
*X214-3 Kit plug terminal 15, 2-pin 40 A1100

X216 Plug, 6-pin 92 A1100
X376 Plug to Y237, 2-pin 92 Revolving deck
X377 Plug to Y238, 2-pin 92 Revolving deck
X378 Plug to Y354 and Y355, 2-pin 92 Revolving deck
X380-1 Plug to B247, 3-pin 92 Basic boom bearing block
X380-2 Plug to B247, 3-pin 92 Stick
X381 Plug to R70, 3-pin 92
X382 Plug to R71, 3-pin 92
X689 Diode plug 3x, 6-pin 92 Left console
Y237 Solenoid valve / boom shut-off 92 Revolving deck

Y238 Solenoid valve shut-down on-road travel 92 Revolving deck
Y354 Solenoid valve bypass pilot control pressure 92 Revolving deck
control, lift boom
Y355 Solenoid valve pilot control pressure control, lift 92 Revolving deck
boom
* = basic diagram
Tab. 78 Krüger stroke limitation
8.45.177
copyright by
MJFCIFSS
Priority circuit
79 Priority circuit
8.45.178
copyright by
MJFCIFSS
Priority circuit
Step 93
*A1009 Decay diode board Right console

*A1100 ESO02 printed circuit board Left console
*F4 Fuse (15A) 3 A1100

*F5 A1100 amplifier V151, V152, V153, V157 (15A) 28 Left console
*F11 A1100 reserve plug X214_3 (15A) 40 Left console

*H46 LED power supply 28 Left console
*H47 LED power supply SF2, SF3, SF4 28 Left console
*H55 LED power supply X214_3 40 Left console

form
S45 Switch/priority 93 Left console

S88 Key switch AHS11 / AHS12 93 Right console
*V152 Amplifier (A1100) SF3 kit 30 Left console
*X14_2 Plug on A1100, 5-pin 28 Left console

X139 Plug to cable harness B33, 3-pin 93 Left console
X140 Plug to cable harness revolving deck, 2-pin 93 Left console
X209 Plug, 2-pin
X214_3 Plug on A1100 for terminal 15, 2-pin 40 Left console
right, 10-pin
X393 Plug to solenoid valve Y357, 2-pin 93 Left console
X394 Plug reset Y357, 2-pin 93 Left console

Y91 Solenoid valve AHS 11 93 Behind toolbox
Y357 Solenoid valve / priority circuit 93 Control valve block
* = basic diagram
8.45.179
copyright by
MJFCIFSS
Priority circuit
Tab. 79 Priority circuit
8.45.180
copyright by
MJFCIFSS
Priority circuit
8.45.181
copyright by
MJFCIFSS
Flow and pressure settings / priority circuit with Tool Control
80 Flow and pressure settings / priority circuit with Tool Control
8.45.182
copyright by
MJFCIFSS
Flow and pressure settings / priority circuit with Tool Control
Step 93
*F4 Fuse (15A) 3 A1100


S45 Switch/priority 93 Left console

S88 Key switch AHS11 / AHS12 93 Right console

*U16 BST excavator control system Right console

*X135 Plug on U16 Right console
X209 Plug on A1100, 2-pin 30 Left console
right, 10-pin
X393 Plug to solenoid valve Y357, 2-pin 93 Left console
X394 Plug reset Y357, 2-pin 93 Left console
*X698 Plug Y414, 2-pin Left console

Y357 Solenoid valve/priority circuit 93 Control valve block
Y414 Solenoid valve pressure adjustment 93- Below control valve
3.99-4
* = basic diagram
Tab. 80 Flow and pressure settings / priority circuit with Tool Control
8.45.183
copyright by
MJFCIFSS
Radiator bypass valve
81 Radiator bypass valve
8.45.184
copyright by
MJFCIFSS
Radiator bypass valve
Step 94
*B8 Hydraulic oil temperature sensor 8 Hydraulic oil tank

*B14 Switch hydraulic oil level 8 Hydraulic oil tank
*MP1 Electronic ground Left console
*U16 Excavator control 6-9 Right armrest
*X134 Plug B8-B14, 4-pin 8 Hydraulic oil tank

*X135 Plug BST (excavator control), 40-pin 6-9 Excavator control
*X155 Plug, 15-pin Left console
X396 Plug radiator bypass valve 8 Control valve block
Y53 Radiator bypass valve 8 Control valve block
* = basic diagram
Tab. 81 Radiator bypass valve
8.45.185
copyright by
MJFCIFSS
Changeover EURO LIEBHERR special control
82 Changeover EURO LIEBHERR special control
8.45.186
copyright by
MJFCIFSS
Changeover EURO LIEBHERR special control
Step 95
A1009 PCB decay diodes 95-1 Right console

*H59 LED fuse F18 37 A1100
H292 Indicator light 95-1 Right console
K229 Relay changeover EURO - LIEBHERR 95-1 Right console
*MP86 Ground connection 95-1 Behind cab
S247 Key switch control switch-over 95-1 Right console
X51 Plug connection, 2-pin A1009 95-1 Right console

*X214-2 Plug connection, 2-pin 95-1 A1100
X236-1 Plug connection, 2-pin Y236/1 95-1 Behind cab
Y236-1 Valve special control 95-1 Behind cab

Y236-2 Valve special control 95-1 Behind cab
* = basic diagram
Tab. 82 Changeover EURO LIEBHERR special control
8.45.187
copyright by
MJFCIFSS
Float position
83 Float position
8.45.188
copyright by
MJFCIFSS
Float position
Step 96
*A1009 PCB decay diodes 96 Right console
B33 Pressure switch 96 Pedal valve
*F11 Fuse (15A) X214-3 40 Left console
*H55 LED fuse F11 40 A1100
K333 Relay 38 A1100

K334 Relay 38 A1100
*MP 86 Ground connection 30 Behind cab
S35 Switch servo 25 Keypad

S55 Joystick switch 96 Right console
S88 Switch 96 Right console
S359 Switch changeover bucket - grapple 96 Right console
V156 Amplifier servo kit 32 Right console
*X14-2 Plug connection on A1100, 5-pin 28 Left console

X51 Plug connection on A1009, 3-pin 96 Right console
X139 Plug connection to B33 96 Right console
X140 Plug connection to Y91 96 Right console
X209 Plug connection on A1100 for servo kit, 2-pin 32 Left console
X214-3 Plug connection on A1100 for terminal 15 kit, 2- 40 Left console
pin
X216 Plug connection on A1100 for K333 kit, 6-pin 38 Left console
X217 Plug connection on A1100 for K334 kit, 6-pin 38 Left console
X232 Plug on A1100 to wire harness control console, 39-41 Left console
right, 10-pin
X233 Plug connection on A1100 to B33, 3-pin 36 Left console
Y91 Valve pressure increase 96 Behind toolbox
* = basic diagram
Tab. 83 Float position
8.45.189
copyright by
MJFCIFSS
Particle filter for exhaust system
84 Particle filter for exhaust system
8.45.190
copyright by
MJFCIFSS
Particle filter for exhaust system
Step 97
A1200 Particle filter control 97-1 Right console
B280 Pressure sensor 0-1 bar 97-1 Cabin beam, front left
*F18 A1100 fuse plug X214-2 (15A) 37 A1100
*G1 alternator 97-1 Motor
H298 Warning light/exhaust backpressure 97-1 Cabin beam, front left

H299 Warning buzzer/exhaust backpressure 97-1 Cabin beam, front left
*M50 Ground connection engine block 2 Engine block
*MP65 Ground connection left armrest 3 Left armrest
*P5 Operating hour meter 3 Left console
*X154 Plug to wire harness motor, 15-pin 3 Left console

*X214-2 Plug on A1100 terminal 15 kit, 2-pin 37 A1100
X251 Plug at ignition switch, 2-pin 3 Right console
X397 Plug control particle filter control A1200, 16-pin 97-1 Right console
X398 Plug signal, 2-pin 97-1 Left console
X399 Plug indicator unit particle filter, 6-pin 97-1 Left console
*Y29 Engine shut-off magnet 4 Motor
* = basic diagram
Tab. 84 Particle filter for exhaust system
8.45.191
copyright by
MJFCIFSS
Learning circuit
85 Learning circuit
8.45.192
copyright by
MJFCIFSS
Learning circuit
Step 98
*A1100 Amplifier PCB ESP02 98 Left console
S377 Key switch learning circuit 98 Right console
X221 Terminal flow reduction 98 A1100
* = basic diagram
Tab. 85 Learning circuit
8.45.193
copyright by
MJFCIFSS
Limitation for boom/stick extension with bypass
86 Limitation for boom/stick extension with bypass
8.45.194
copyright by
MJFCIFSS
Limitation for boom/stick extension with bypass
Step 99
A1009 PCB decay diodes 99 Right console
A1100 ESP02 printed circuit board 27-41 Left console
B213 Proximity switch/stick shut-down 99 Stick bearing block

B214 Stroke limitation proximity switch 99 Basic boom bearing block
F11 Fuse (15A) terminal 15 for X214-3 40 Left console
S249 Key switch stick and stroke limitation 99 Right console

S291 Key switch bypass stroke stick limitation 99 Right console
S417 Rocker button 20 Left joystick
*X15-1 Plug S5L, 3-pin 20 Left console

X214-3 Plug connection on A1100, 2-pin 40 Left console
X403 Plug connection to solenoid valve Y233, 2-pin 99 Behind cab
X404-1 Plug connection, 4-pin, to B213 stick shut-off 99 Behind cab
X404-2 Plug connection, 4-pin, to B213 stick shut-off 99 Basic boom bearing block
X405 Plug connection, 3-pin diode plug for stick stro- 99 Cabin exit
ke limitation
X436 Plug connection, 4-pin to S249 key switch stick 99 Right console
stroke limitation
X437 Plug connection to S249, 4-pin 99 Right console
X438 Plug connection to S291 bypass switch, 3-pin 99 Right console
X439 Plug connection to B214 and Y238, 6-pin 99 Cabin exit
X440-1 Plug connection to B214, 4-pin 99 Behind cab
X440-2 Plug connection to B214, 4-pin 99 Basic boom bearing block
X441 Plug connection to Y238, 2-pin 99 Behind cab
X443 Plug connection, 4-pin diode plug for stick stro- 99 Right console
ke limitation
Y233 Solenoid valve for stick shut-down 99 Behind toolbox

Y238 Solenoid valve for stroke limitation 99 Behind toolbox
* = basic diagram
Tab. 86 Limitation for boom/stick extension with bypass
8.45.195
copyright by
MJFCIFSS
Permanent limitation for boom cylinder extension
87 Permanent limitation for boom cylinder extension
8.45.196
copyright by
MJFCIFSS
Permanent limitation for boom cylinder extension
Step 99
*F11 Fuse (15A) terminal 15 for X214-3 40 Left console
*X51 Plug connection on A1009, 3-pin 99 Right console

* = basic diagram
Tab. 87 Permanent limitation of boom cylinder extension
8.45.197
copyright by
MJFCIFSS
Limitation for boom cylinder extension with bypass
88 Limitation for boom cylinder extension with bypass
8.45.198
copyright by
MJFCIFSS
Limitation for boom cylinder extension with bypass
Step 99

*F11 Fuse (15A) terminal 15 for X214-3 40 Left console


stroke limitation
X437 Plug connection S249, 4-pin 99 Right console
ke limitation
* = basic diagram
Tab. 88 Limitation of boom cylinder extension with bypass
8.45.199
copyright by
MJFCIFSS
Limitation for stick cylinder extension with bypass
89 Limitation for stick cylinder extension with bypass
8.45.200
copyright by
MJFCIFSS
Limitation for stick cylinder extension with bypass
Step 99
A1100 ESP02 printed circuit board 27-41 Left console
F11 Fuse (15A) terminal 15 for X214-3 40 Left console


X403 Plug connection solenoid valve Y233, 2-pin 99 Behind cab
X404-1 Plug connection, 4-pin, to B213 stick shut-off 99 Behind cab
X404-2 Plug connection, 4-pin, to B213 stick shut-off 99 Basic boom bearing block
X405 Plug connection, 3-pin diode plug for stick stro- 99 Cabin exit
ke limitation
stroke limitation
X437 Plug connection S249, 4-pin 99 Right console
ke limitation
Y233 Solenoid valve for stick shut-down 99 Behind toolbox
* = basic diagram
Tab. 89 Limitation of stick cylinder extension with bypass
8.45.201
copyright by
MJFCIFSS
Metering device for particle filter
90 Metering device for particle filter
8.45.202
copyright by
MJFCIFSS
Metering device for particle filter
Step 100
A129 Additive control 100 Left console
*A1001 Amplifier PCB ESP01 Right console
*A1100 Amplifier PCB ESP02 Left console
*B39 Fuel tank sensor 18 Fuel tank

B281 Filling level sensor 100 Additive tank
*F17 Fuse 37 A1100
H300 Warning light additive filling level 100 Counterpressure indica-

tor
M69 Additive metering pump 100 Fuel tank
*MP83 Ground connection to fuel tank, front 19 Fuel tank

*MP85 Ground connection at bearing block 19 Bearing block
*X6.2 Plug on A1001, 8-pin 18-20 A1001

*X122 Plug B39, 4-pin 19 Fuel tank
*X141 Plug refuelling pump, 3-pin 19 Refuelling pump
*X214-1 Plug for kits, 2-pin 37 A1100
*X246 Plug on plug-in plate, 10-pin Left console
X435 Plug to B39, 1-pin 100 Left console
X904-1 Plug, 2-pin 100 Left console
X904-2 Plug to metering pump M69, 2-pin 100 Left console
X904-3 Plug to filling level switch B281, 2-pin 100 Left console
X904-4 Plug to warning light filling level, 3-pin 100 Left console
X904-8 Plug to filling level switch B281, 2-pin 100 Additive tank
* = basic diagram
Tab. 90 Metering device for particle filter
8.45.203
copyright by
MJFCIFSS
AHS 11 actuation via push button
91 AHS 11 actuation via push button
8.45.204
copyright by
MJFCIFSS
Step 101

AHS12 behind toolbox
*F11 A1100 spare plug X214-3 (15A) 40 Left console

*S5L Left push button 20 Left joystick

*S5R Right push button 20 Left joystick
S6L Left push button 33 Right joystick
S6R Right push button 33 Right joystick
S379 Switch releasing key kits (AHS11) 101 Right console
*V152 Amplifier (A1100) SF3 kits 30 Left console

X54 Plug on 1009, 3-pin 101 Right console
X55 Plug on A 1009, 3-pin 101 Right console
X139 Plug to wire harness B33, 3-pin 101 Left console
*X207 Plug on A1100 for SF3 (AHS12) kit, 2-pin 30 Left console
*X232 Plug on A1100 to wire harness control console, 40 Left console
right, 10-pin
*X233 Plug on A1100 to B33, 3-pin 36 Left console
X408 Plug to Y365, 2-pin 101 At toolbox
X409 Plug to Y366, 2-pin 101 At toolbox
X410 Plug, 3-pin to key 101 Right /left pilot control unit

Y365 Solenoid valve/retracting 101 Behind toolbox
8.45.205
copyright by
MJFCIFSS
Step 101
Y366 Solenoid valve/extending hammer 101 Behind toolbox
* = basic diagram
Tab. 91 AHS 11 actuation via push button
8.45.206
copyright by
MJFCIFSS
8.45.207
copyright by
MJFCIFSS
Joystick steering
92 Joystick steering
via key in right pilot control unit via electrical pilot control unit
8.45.208
copyright by
MJFCIFSS
Joystick steering
Step 103
*A1100 Printed circuit board Left console
A123 Potentiometer PCB joystick steering 103 Right console
*F11 Fuse terminal 15 (15A) 40 A1100
*H55 LED after fuse F11 40 A1100
*S6L Left push button 33 Right joystick

*S6R Right push button 33 Right joystick
S321 Joystick steering switch 103 Right console
U58 Electronic pilot control unit for steering 103 Right console
*X15 Plug at right joystick 33 Below right joystick

X412 Plug to solenoid valve 307, 3-pin 103 Left console
Y307 Proportional valve steering 103 Below operator's platform
* = basic diagram
Tab. 92 Joystick steering via key in right pilot control unit via electrical pilot control unit
8.45.209
copyright by
MJFCIFSS
Joystick steering
93 Joystick steering
via key in left pilot control unit
8.45.210
copyright by
MJFCIFSS
Joystick steering
Step 103
A123 Potentiometer PCB joystick steering 103 Right console
*F11 Fuse terminal 15 (15A) 40 A1100
*H55 LED after fuse F11 40 A1100

S321 Joystick steering switch 103 Right console
*X15 Plug at right joystick 33 Below right joystick

X412 Plug to solenoid valve 307, 3-pin 103 Left console
Y307 Proportional valve steering 103 Below operator's platform
* = basic diagram
Tab. 93 Joystick steering via button in left pilot control unit
8.45.211
copyright by
MJFCIFSS
Power supply for sensors
94 Power supply for sensors
8.45.212
copyright by
MJFCIFSS
Power supply for sensors
Step 104
*A1100 Amplifier PCB ESP02 Left console
*B19L Handle sensor 16 Left joystick

*B19R Handle sensor 16 Right joystick
*B40 Proximity switch left travel pedal 17 Left travel pedal
*B41 Proximity switch right travel pedal 17 Right travel pedal
*B266 Proximity switch/brake pedal 17 Brake pedal
*F12 Fuse terminal 15 41 A1100
*MP1 Electronic ground Left console
*X2 Plug, 37-pin A1001

*X7 Plug B19L, 3-pin 16 A1001
*X8 Plug B19R, 3-pin 15 A1001
*X9 Plug B40, 2-pin 17 A1001
*X10 Plug B41, B266, 2-pin 17 A1001
*X196 Plug B40, 3-pin 17 B40
*X197 Plug B41, B266 17 B41, B266
*X232 Plug, 10-pin 41 A1100
* = basic diagram
Tab. 94 Power supply for sensors
8.45.213
copyright by
MJFCIFSS
Earth contact ESP01 windscreen wiper
95 Earth contact ESP01 windscreen wiper
8.45.214
copyright by
MJFCIFSS
Earth contact ESP01 windscreen wiper
Step 105
*A1001 Amplifier PCB ASP01 Right console
*K1 Windscreen wiper relay A1001
*MP60 Ground connection Below operator's platform
*X3 Plug connection, 10-pin A1001

* = basic diagram
Tab. 95 Earth contact ESP01 windscreen wiper
8.45.215
copyright by
MJFCIFSS
Lifting boom when closing grapple
96 Lifting boom when closing grapple
Pressure switch on revolving deck
8.45.216
copyright by
MJFCIFSS
Step 106
B273 Pressure switch/closing grapple 106 Behind operator's plat-

form
*F17 Fuse (15A) 37 A1100
*H50 LED 37 A1100
K354 Relay lift boom when grapple closes 38 A1100
S357 Switch/lifting boom when grapple closes 106 A1100
*X214-2 Plug connection kit, 2-pin 37 A1100

*X216 Plug connection relay K354, 6-pin 38 A1100
X423 Plug connection to switch S357, 4-pin 106 Right console
X424 Plug connection to B273 / Y333, 3-pin 106 Left console
X425 Plug connection to B273, 3-pin 106 B273
X428 Plug connection reset Y333, 2-pin 106 Left console
Y333 Solenoid valve/Lifting boom when grapple clo- 106 In front of control valve
ses
* = basic diagram
Tab. 96 Lift boom when grapple closes, pressure switch on revolving deck
8.45.217
copyright by
MJFCIFSS
97 Lifting boom when closing grapple
Pressure switch in right console
8.45.218
copyright by
MJFCIFSS
Step 106
B273 Pressure switch/closing grapple 106 Right console
*F17 Fuse (15A) 37 A1100
*H50 LED 37 A1100
K354 Relay lift boom when grapple closes 38 A1100
S357 Switch/lifting boom when grapple closes 106 A1100
*X214-2 Plug connection kit, 2-pin 37 A1100

*X216 Plug connection relay K354, 6-pin 38 A1100
X423 Plug connection to switch S357, 4-pin 106 Right console
X424 Plug connection to B273 / Y333, 3-pin 106 Left console
X425 Plug connection to B273, 3-pin 106 B273
X428 Plug connection reset Y333, 2-pin 106 Left console
Y333 Solenoid valve/Lifting boom when grapple clo- 106 In front of control valve
ses
* = basic diagram
Tab. 97 Lift boom when grapple closes, pressure switch in right console
8.45.219
copyright by
MJFCIFSS
Separ water filter with monitoring system
98 Separ water filter with monitoring system
8.45.220
copyright by
MJFCIFSS
Separ water filter with monitoring system
Step 108
A130 Printed circuit board/water separator Right console
B289 Water sensor Separ water filter
H308 Warning buzzer/water filter Right console
S387 Key for testing of PCB function Right console
X214 Kit plug, 2-pin Left console

X432 Plug to S335, 4-pin Right console
X433 Plug to A130, 6-pin Right console
X434 Plug to B289, 2-pin Right console
* = basic diagram
Tab. 98 Separ water filter with monitoring system
8.45.221
copyright by
MJFCIFSS
Auxiliary coolant pump
99 Auxiliary coolant pump
8.45.222
copyright by
MJFCIFSS
Step 109

device
F36 Fuse terminal 30 (15A) timer, water valve and 109 E50
heating fan
F37 Fuse terminal 30 (15A) heating fan 109 E50

M52 Coolant pump 109 Auxiliary heating

M52-2 Auxiliary coolant pump 109 Auxiliary heating
MP90 Ground connection in E50 2 E50
*U29 Control module water timing valve 26 A/c heating device

*X45 Plug E50, 9-pin 3 E50
*X86 Plug control module a/c system, 9-pin 26 Left console
left, 6-pin
* = basic diagram
Tab. 99 Auxiliary coolant pump
8.45.223
copyright by
MJFCIFSS
100 Auxiliary coolant pump
8.45.224
copyright by
MJFCIFSS
Step 109

F34 Fuse terminal 30 (25A) auxiliary heating to 56 E50
ground
device
F350 Fuse 30 (20A) a/c system 3 E50
F361 Fuse terminal 30 (7.5A) coolant pump 109 E50

M52-2 Auxiliary water pump 109 Auxiliary heating

MP90 Ground connection in E50 2 E50
*S9 Battery switch 2 Battery compartment
S232 Digital timer auxiliary heating (left armrest) 56 Right console
*X45 Plug E50, 9-pin 3 E50

left, 6-pin
*X170 Plug wire harness battery starter, 1-pin 2 Battery compartment
X1131 Plug diode plug E50, 2-pin 56 E50
* = basic diagram
Tab. 100 Auxiliary water pump
8.45.225
copyright by
MJFCIFSS
Grammer seat heating
101 Grammer seat heating
8.45.226
copyright by
MJFCIFSS
Grammer seat heating
Step 110
B1 Active lumbar support
B2 Active lumbar support
H1 Backrest heating
H2 Seat heating
LF1 Air spring
V1 Residual spring travel control and height adjus-

tment in spring mechanism
V2 Roller with cam disc
V3 Active lumbar support valve
V5 Seat heating (optional)
*X214-3 Plug connection, 2-pin A1100
* = basic diagram
Tab. 101 Grammer seat heating
8.45.227
copyright by
MJFCIFSS
2x Xenon roof light to front
102 2x Xenon roof light to front
8.45.228
copyright by
MJFCIFSS
2x Xenon roof light to front
Step 111
*A1001 Amplifier PCB ESP01 10-22 Right console
*E1 Work headlight 16 Boom

E160-1 Xenon roof light, front 111 Cab roof
E160-2 Xenon roof light, front 111 Cab roof
*F4 Fuse roof light (15A) 111-1 Support plate

*F12 Headlight fuse (15A) 111-2 A1 PCB
*F14 Fuse work headlight (15A) 111-1 Support plate
*F20 Main fuse (50A) 111-1 Fuse box
F239 Fuse 2x Xenon roof light, front 111 Left console
*K20 Relay roof light 111-1 Support plate

*K20 Headlight relay 111-2 A1 PCB
K395 Relay 2x Xenon roof light, front 111 Left console
*S22 Switch work headlight 111-1 Console
*V21 Amplifier roof light 111 A1001 PCB
*X2-2 Plug, 12-pin 111-2 A1 PCB

*X2-2 Plug wire harness revolving deck console, 12- 111-1 Plug-in plate
pin
*X3 Plug, 10-pin 19 A1001 PCB
*X3 Plug, 12-pin 111-2 A1 PCB
*X3-1 Plug adapter cable cab, 9-pin 111/11/ Right bottom console
15
*X3-5 Plug wire harness right console plug-in plate, 9- 111-1 Plug-in plate
pin
*X4 Plug between display and A1, 37-pin 111-2 Left console
*X5.1 Plug, 8-pin 19 A1001 PCB
*X20 Plug, 10-pin 19 A1001 PCB
*X30-1 Plug console support plate, 15-pin 111-1 Support plate
*X30-2 Plug plug-in plate support plate, 15-pin 111-1 Plug-in plate
*X404 Plug wire harness revolving deck work head- 111-1
light, 2-pin
*X418 Terminal strip, 3x 111-1 Support plate
X445 Plug Xenon roof headlight, 1-pin 111-1 Right bottom console
* = basic diagram
Tab. 102 2x Xenon roof light to front
8.45.229
copyright by
MJFCIFSS
Mower rake accessory kit
103 Mower rake accessory kit
8.45.230
copyright by
MJFCIFSS
Mower rake accessory kit
Step 112
*A1001 ESP01 PCB (right armrest) Right console
A1009-2 Decay relay PCB (left armrest) Right console
*A1100 ESP02 PCB (left armrest) Left console
F18 Fuse (15A) Left console
*S5L Switch turn grapple left Left joystick

*S5R Switch turn grapple right Left joystick
*S19 Push button rotator Keypad
S55 Push button mower rake Left joystick
S124 Switch rotator / mover rake Right console
*X2 Plug S2-A1001, 37-pin A1001

*X6-2 Plug, 8-pin A1001
*X15-1 Socket, 3-pin Below left pilot control
unit
*X15-3 Plug, 3-pin Below left pilot control
unit
X55 Plug, 2-pin A1009

*214-2 Plug, 2-pin A1009
*X248 Plug connection on plug-in board to wire har- Left console
ness revolving deck
X418 Plug Y414, 2-pin Revolving deck
X420 Plug, 1-pin Right console
Y22 Solenoid valve grapple rotator Control valve block

Y44 Solenoid valve mower rake Revolving deck
* = basic diagram
Tab. 103 Mower rake accessory kit
8.45.231
copyright by
MJFCIFSS
Mower rake kit via step relay
104 Mower rake kit via step relay
8.45.232
copyright by
MJFCIFSS
Mower rake kit via step relay
Step 112
*A1001 ESP01 PCB (right armrest) Right console
A1009-2 Decay relay PCB (left armrest) Right console
*A1100 ESP02 PCB (left armrest) Left console
H329 Indicator light mower rake ON Right console
K438 Step relay mower rake A1001
*S5L Push button turn grapple left Left joystick

*S5R Switch turn grapple right Left joystick
*S19 Push button rotator Keypad
*S35 Button servo ON Keypad
S55 Push button mower rake Left joystick
S124 Switch rotator / mover rake Right console
*V156 Amplifier servo A1100
*X2 Plug S2-A1001, 37-pin A1001

*X6-2 Plug, 8-pin A1001
*X15-1 Socket, 3-pin Below left pilot control
unit
*X15-3 Plug, 3-pin Below left pilot control
unit

*X209 Plug servo kit, 2-pin A1100
*214-2 Plug, 2-pin A1009
*X248 Plug connection on plug-in board to wire har- Left console
ness revolving deck
X418 Plug Y414, 2-pin Revolving deck
X420 Plug, 1-pin Right console

Y44 Solenoid valve mower rake Revolving deck
* = basic diagram
Tab. 104 Mower rake kit via step relay
8.45.233
copyright by
MJFCIFSS
Automatic shut-off mechanism
105 Automatic shut-off mechanism
8.45.234
copyright by
MJFCIFSS
Step 113
*A1001 ESP01 printed circuit board 10-22 Right console

B201 Pressure switch/cam disc 113 Near bearing block
B202VL Pressure switch/front left support 113 Undercarriage
B202VR Pressure switch/front right support 113 Undercarriage
B202HL Pressure switch/rear left support 113 Undercarriage
B202HR Pressure switch/rear right support 113 Undercarriage

H315 Warning light shut-down bridged 113 Right console
K333 Relay automatic shut-down 38 A1100

K335 Relay overload warning 39 A1100
*MP86 Ground connection 113 Bearing block
*S2 Keypad 24 Right console

S396 Key switch / bridging shut-off 113 Right console
V158 Blocking diode warning light H315 113 Left console

V159 Decay diode solenoid valve Y212, Y233, Y237, 113 Left console
Y238
*X2 Plug connection, 37-pin 23 A1001 to S2

*X6.2 Plug connection, 8-pin A1001
X273 Plug connection, 4-pin 113 at bearing block
X301 Plug connection, 12-pin 113 at slip ring
X305 Plug reserve / 9-pin 113 Left console
X450 Plug connection for blocking diode, 2-pin 113 Left console
8.45.235
copyright by
MJFCIFSS
Step 113
X451 Plug connection for decay diode, 2-pin 113 Left console
Y212 Block solenoid valve stick ON 113

Y233 Block solenoid valve stick OFF 113
Y237 Block solenoid valve lower boom 113
Y238 Block solenoid valve regulating cylinder ON 113
* = basic diagram
Tab. 105 Automatic shut-off mechanism
8.45.236
copyright by
MJFCIFSS
8.45.237
copyright by
MJFCIFSS
Oil bypass filter monitor
106 Oil bypass filter monitor
8.45.238
copyright by
MJFCIFSS
Oil bypass filter monitor
Step 114
A Switch alarm 100% Hydraulic oil tank
B Switch warning 75% Hydraulic oil tank
B293 Pressure switch/oil bypass filter 114 Hydraulic oil tank
C Terminal on PCB
*F32 Fan motor fuse 3 E50

F241 Fuse oil bypass filter display 114 E50
*G2 Batteries 2 Battery compartment
*S9 Isolating switch, battery switch 2 E50
*X45 Plug connection on E50, 9-pin 3 E50
* = basic diagram
Tab. 106 Oil bypass filter monitor
8.45.239
copyright by
MJFCIFSS
Quick-change adapter
107 Quick-change adapter
with automatic LIKUFIX hydraulic clutch
8.45.240
copyright by
MJFCIFSS
Step 115
head
X262-1 Plug connection, 8 or 3-pin 115 Basic boom bearing block

X262-3 Plug connection, 8 or 3-pin 115 Stick
head
head
head
X263-1 Plug connection, 2-pin 115 Basic boom bearing block
X263-2 Plug connection, 2-pin 115 Boom
X263-3 Plug connection, 2-pin 115 Quick-change adapter /
stick
X452-1 Plug connection to solenoid valve Y376-1 115 Stick

Y376-1 Check valve grapple rotator cycle 115 Stick
Y387-1 Solenoid valve/LIKUFIX pressure relief 115 Basic boom bearing block

3 Released
4 Locked
* = basic diagram
Tab. 107 Quick-change adapter with automatic LIKUFIX hydraulic clutch system
8.45.241
copyright by
MJFCIFSS
108 Quick-change adapter
with automatic LIKUFIX hydraulic clutch
8.45.242
copyright by
MJFCIFSS
Step 115
head

X262-3 Plug connection, 8 or 3-pin 115 Stick
head
head
head
X263-1 Plug connection, 2-pin 115 Basic boom bearing block
X263-2 Plug connection, 2-pin 115 Boom
X263-3 Plug connection, 2-pin 115 Quick-change adapter /
stick


3 Released
4 Locked
* = basic diagram
Tab. 108 Quick-change adapter with automatic LIKUFIX hydraulic clutch system
8.45.243
copyright by
MJFCIFSS
Turn grapple in right joystick lever
109 Turn grapple in right joystick lever
8.45.244
copyright by
MJFCIFSS
Turn grapple in right joystick lever
Step 116
*A1001 ESP01 printed circuit board 10-22 Right console

*S19 Switch rotating grapple 25 Keypad
*X6.2 Plug connection, 8-pin A1001 18-20 Right console

*X15-1 Plug connection, 3-pin 20 Left console
*X21 Plug connection, 3-pin A1001 20 Left console
* = basic diagram
Tab. 109 Turn grapple in left joystick lever
8.45.245
copyright by
MJFCIFSS
Stick cylinder shut-down
110 Stick cylinder shut-down
Optional bypass in left pilot control unit
8.45.246
copyright by
MJFCIFSS
Step 117

*A1100 Amplifier PCB Left console
*MP1 Ground connection on A1100 27 Left console

*MP64 Ground connection screen on A1001 22/25 Right console
R70 Stick cylinder potentiometer 117 Stick
*S2 Keypad 23-25 Right console

S55 Rocker switch in left joystick Left pilot control unit
*S75 Oscillating axle switch 32 Right console
S403 Bypass switch stick cylinder 117 Right console
*U16 Excavator control Right console
*V8 Amplifier on A1001 18 Right console

*X1 Plug connection between A1001 and excavator 9-10 Right console
control, 24-pin
*X2 Plug connection, 37-pin 22-23 Right console
*X44 Plug connection code plug excavator control, 9 Right console
3-pin
*X50 Plug connection between A1100 and S2, 25- 25/27 Right/left control console
pin
*X224 Plug connection on wire harness control conso- 32 Left console
le right, 6-pin
*X252 Plug connection to oscillating axle switch, 3-pin 32 Right console
X453 Plug connection to rocker switch S55, 2-pin Left pilot control unit
X458-1 Plug connection to stick cylinder potentiometer, 117-1 Right console
4-pin
X458-2 Plug connection to stick cylinder potentiometer, 117 Bearing block
4-pin
X458-3 Plug connection to stick cylinder potentiometer, 117 Stick
4-pin
X460 Plug connection, 2-pin Left console
Y212 Solenoid valve retract stick cylinder 117 Behind operator's plat-
form
Y233 Solenoid valve extend stick cylinder 117 Behind operator's plat-
form
8.45.247
copyright by
MJFCIFSS
Step 117
* = basic diagram
Tab. 110 Stick cylinder shut-down, optional bypass in left pilot control unit
8.45.248
copyright by
MJFCIFSS
8.45.249
copyright by
MJFCIFSS
111 Stick cylinder shut-down
Optional bypass in left pilot control unit
8.45.250
copyright by
MJFCIFSS
Step 117
*A1100 Amplifier PCB Left console
*F17 Fuse on A1100 X214-1/1 (15A) 37 Left console

*H50 LED on A1100 power supply X214-1/1 37 Left console
*MP1 Ground connection on A1100 27 Left console
R70 Stick cylinder potentiometer 117 Stick
*S2 Keypad 23-25 Right console

S55 Rocker switch in left joystick Left pilot control unit
*S75 Oscillating axle switch 32 Right console
S403 Bypass switch stick cylinder 117 Right console
*U16 Excavator control Right console

*X1 Plug connection between A1001 and excavator 9-10 Right console
control, 25-pin
*X2 Plug connection, 37-pin 22-23 Right console
*X44 Plug connection code plug excavator control, 9 Right console
3-pin
*X50 Plug connection between A1100 and S2, 25- 25/27 Right/left control console
pin
*X214-1 Plug connection terminal 15, 2-pin (kit) 37 Left console
*X224 Plug connection on wire harness control conso- 32 Left console
le right, 6-pin
*X252 Plug connection to oscillating axle switch, 3-pin 32 Right console
X453 Plug connection to rocker switch S55, 2-pin Left pilot control unit
X458-1 Plug connection to stick cylinder potentiometer, 117-2 Left console
4-pin
X458-2 Plug connection to stick cylinder potentiometer, 117 Bearing block
4-pin
X458-3 Plug connection to stick cylinder potentiometer, 117 Stick
4-pin
Y212 Solenoid valve retract stick cylinder 117 Behind operator's plat-
form
8.45.251
copyright by
MJFCIFSS
Step 117
Y233 Solenoid valve extend stick cylinder 117 Behind operator's plat-
form
* = basic diagram
Tab. 111 Stick cylinder shut-down, optional bypass in left pilot control unit
8.45.252
copyright by
MJFCIFSS
8.45.253
copyright by
MJFCIFSS
Changeover bucket tilt circuit / AHS
112 Changeover bucket tilt circuit / AHS
8.45.254
copyright by
MJFCIFSS
Changeover bucket tilt circuit / AHS
Step 120

*H59 LED fuse F18 37 A1100
H322 Lamp 120 Right console
K419 Relay changeover bucket tilting circuit OFF 120 Right console
S405 Switch 120 Right console
X51 Plug connection, 2-pin A1009 120 Right console

X214-2 Plug connection A904 A924, 2-pin 120 A1100
X236-1 Plug connection Y236/1 / Y385-1, 2-pin 120 Behind cab
X236-2 Plug connection Y236/2 / Y385/2, 2-pin 120 Behind cab
Y385-1 Solenoid valve changeover bucket tilt circuit / 120 Behind cab
AHS
Y385-2 Solenoid valve changeover bucket tilt circuit / 120 Behind cab
AHS
* = basic diagram
Tab. 112 Changeover bucket tilt circuit / AHS
8.45.255
copyright by
MJFCIFSS
Two-hand operation
113 Two-hand operation
for safety-relevant functions
8.45.256
copyright by
MJFCIFSS
Two-hand operation
Step 123
*F11 Fuse (15A) kits A1100
K378 Relay two-hand operation 123 Right console


X74 Plug connection, 3-pin (connection to magnet Right console

system)
X214-3 Kit plug, 2-pin 123 A1100
* = basic diagram
Tab. 113 Two-hand operation for safety-relevant functions
8.45.257
copyright by
MJFCIFSS
Oscillating-axle locking device in left joystick
114 Oscillating-axle locking device in left joystick
8.45.258
copyright by
MJFCIFSS
Oscillating-axle locking device in left joystick
Step 125
*F6 Fuse A1100 amplifier E19, E20, V150, V153, 28 A1100

V157 (15A)

*H48 LED power supply E19, E20, Y55, Y66 28 A1100
*S75 Switch oscillating axle locking device Y66 32 Right console

S411 Rocker switch oscillating axle locking 125 Left joystick
*V155 Amplifier A1100 oscillating axle 125 A1100
*X50 Plug between S2-A1100, 25-pin 25/27 Left and right console
*X200 Plug to A1100 to wire harness revolving deck 31 Left console
*X224 Plug for oscillating axle and kits 32 Left console
*X252 Plug oscillating axle selection switch S75, 3-pin 32 Right console
X1020 Plug to rocker switch, 3-pin 125 Left console
*Y66 Solenoid valve / oscillating axle 32 Control oil unit
* = basic diagram
Tab. 114 Oscillating-axle locking device in left joystick
8.45.259
copyright by
MJFCIFSS
Turning stick with changeover valve
115 Turning stick with changeover valve
8.45.260
copyright by
MJFCIFSS
Step 126
B33 Pressure switch/flow limitation 126 AHS pedal valve

K428 Relay pressure flow limitation 126 Left console

K457 Relay locking push button S6L/S6R 126 Left console
S6L Push button left / turning stick, pile driver, ham- 126 Right joystick
mer
S6R Right push button / pile driver 126 Right joystick
S412 Rocker switch turning stick / hammer, pile dri- 126 Left joystick
ver
S445 Push button flow reduction turning stick / pile 126 Right console
driver, hammer

X15_1 Plug to wire harness joystick lever extension, 3- 126 Left console
pin
X74 Plug to cable with push button, 3-pin 126 Right console
right, 10-pin
8.45.261
copyright by
MJFCIFSS
Step 126
X689 Plug wire harness diode, 6-pin 126 Left console
X1025 Plug to cable with switch, 3-pin 126 Left console
X1026 Plug to Y390, 2-pin 126 Left console
X1142 Plug wire harness left - wire harness cab - wire 126 Left console
harness bridge, 3-pin

Y390 Solenoid valve / changeover valve 126 Basic boom
Y426 Solenoid valve flow reduction turning stick / pile 126 Behind cab
driver, hammer
driver, hammer
* = basic diagram
Tab. 115 Turning stick with changeover valve
8.45.262
copyright by
MJFCIFSS
8.45.263
copyright by
MJFCIFSS
Turning stick without changeover valve
116 Turning stick without changeover valve
8.45.264
copyright by
MJFCIFSS
Step 126

K457 Relay locking push button S6L/S6R 126 Left console
S6L Push button left / turning stick, pile driver, ham- 126 Right joystick
mer
S6R Right push button / pile driver 126 Right joystick
S412 Rocker switch turning stick / hammer, pile dri- 126 Left joystick
ver
S445 Push button flow reduction turning stick / pile 126 Right console
driver, hammer

X15_1 Plug to wire harness joystick lever extension, 3- 126 Left console
pin
X74 Plug to cable with push button, 3-pin 126 Right console
right, 10-pin
X1025 Plug to cable with switch, 3-pin 126 Left console
8.45.265
copyright by
MJFCIFSS
Step 126
X1142 Plug wire harness left wire harness cab wire 126 Left console
harness bridge, 3-pin

driver, hammer
driver, hammer
* = basic diagram
Tab. 116 Turning stick without changeover valve
8.45.266
copyright by
MJFCIFSS
8.45.267
copyright by
MJFCIFSS
License plate light behind cab
117 License plate light behind cab
8.45.268
copyright by
MJFCIFSS
Step 127
E16 Parking light, front left Below operator's platform

E18 Left tail light Counter weight
E163 License plate light Behind cab
*F1 Fuse left parking light (3A) A1100
*H64 LED parking light left A1100

*H248 LED actuation signal V161 A1100
*H249 LED fault indicator V161 A1100
*MP 60 Ground connection Below operator's platform

*MP61 Ground connection A1100
*V161 Amplifier parking lights A1100
X200 Plug, 15-pin Left console

X202 Plug, 12-pin A1100
* = basic diagram
Tab. 117 License plate light behind cab
8.45.269
copyright by
MJFCIFSS
118 License plate light behind cab
8.45.270
copyright by
MJFCIFSS
Step 127
A1100 ESP02 printed circuit board Left console
E16 Parking light, front left Below operator's platform

E18 Left tail light Counter weight
E163 License plate light Behind cab
F1 Fuse left parking light (3A) A1100
H64 LED parking light left A1100

H248 LED actuation signal V161 A1100
H249 LED fault indicator V161 A1100
MP 60 Ground connection Below operator's platform

MP61 Ground connection A1100
S22 Switch license light ON A1100
V161 Amplifier parking light A1100

X202 Plug, 12-pin A1100
X1136 Plug, 2-pin Cab
* = basic diagram
Tab. 118 License plate light behind cab
8.45.271
copyright by
MJFCIFSS
HYDAC refuelling pump
119 HYDAC refuelling pump
8.45.272
copyright by
MJFCIFSS
HYDAC refuelling pump
Step 129
*B39 Level shut-down fuel tank 19 Fuel tank
E13 Operating box refuelling pump 129 Front fuel tank

E42 Control box refuelling box 129 Front fuel tank
*E50 Power and safety switch cabinet 2,3 Battery compartment
*F19 Fuse pre-heating, refuelling pump (70A) 2 E50

F216 Fuse control circuit refuelling pump (7.5A) 129 E50
K18 Actuating relay refuelling pump 129 E42

K30 Relay refuelling pump 129 E42
*K302 Pre-heat relay 3 E50
M6 Refuelling pump 129 Front fuel tank
*R51 Flame glow plug 3 Motor
*S9 Battery main switch 2 Battery compartment

S25 Push button ON for refuelling pump 129 E13
S59 Push button OFF for refuelling pump 129 E13
*X45 Plug connection, 9-pin 3 E50

*X69 Plug connection, 12-pin 2,3 E50
*X122 Plug connection, 4-pin 3 on fuel tank
X141 Plug connection, 3-pin 129 Front fuel tank
*X170 Plug connection, 1-pin 2 Battery compartment
*X320 Plug connection, 2-pin 4 E50
Y1 Solenoid valve for glow plug 3 Engine
* = basic diagram
Tab. 119 HYDAC refuelling pump
8.45.273
copyright by
MJFCIFSS
PURITECH particle filter
120 PURITECH particle filter
8.45.274
copyright by
MJFCIFSS
PURITECH particle filter
Step 130
A Exhaust backpressure
A133 Puritech data logger Engine compartment
B306 Particle filter temperature sensor Particle filter
*E50 power switch cabinet Battery compartment
F351 Fuse (3A) E50
H299 Warning buzzer/exhaust backpressure Operator's platform
*X1040 Plug connection, 3-pin E50

*X1041 Plug connection, 2-pin E50
* = basic diagram
Tab. 120 PURITECH particle filter
8.45.275
copyright by
MJFCIFSS
Fuel pre-heating
121 Fuel pre-heating
8.45.276
copyright by
MJFCIFSS
Fuel pre-heating
Step 131
*E50 power switch cabinet 1-3 Battery compartment
*F18 Kit drawing (15A) 37 A1100
H59 LED for fuse F18 37 A1100
K56 Relay fuel pre-heating 131 E50
R8 Fuel pre-heating 131 Engine
S26 Switch/fuel pre-heating 131 Right console
X69 Plug, 12-pin 3 E50

X142 Plug to reserve line, 1-pin Left console
X144 Plug, 2-pin 131 Engine
X145 Plug, 1-pin 131 E50
X146 Plug, 1-pin 131 E50
X165_4 Kit plug terminal 15, 2-pin 131 Left console
X214_2 Kit plug terminal 15, 2-pin 37 A1100
* = basic diagram
Tab. 121 Fuel pre-heating
8.45.277
copyright by
MJFCIFSS
Stroke limitation / hydraulic boom adjustment
122 Stroke limitation / hydraulic boom adjustment
8.45.278
copyright by
MJFCIFSS
Stroke limitation / hydraulic boom adjustment
Step 132
B214 Stroke limitation proximity switch Boom
*F18 Fuse proximity switch / solenoid valves stroke Left console

(15A)
K334 Relay to A1100 stroke limitation Left console
*X214-3 Plug connection A1100 terminal 15, 2-pin Left console

*X217 Plug connection A1100 proximity switch / sole- Left console
noid valve / power supply, 6-pin
X363 Plug connection proximity switch, 3-pin Bearing block
X363 Plug connection bypass, 3-pin, shut-down Bearing block
bridged
Y99-1 Solenoid valve boom shut-down lift boom (Zet- Behind cab
ko)
Y99-2 Solenoid valve boom shut-down bending (Zet- Behind cab
ko)
* = basic diagram
Tab. 122 Stroke limitation / hydraulic boom adjustment
8.45.279
copyright by
MJFCIFSS
Changeover ZETKO control via AHS12
123 Changeover ZETKO control via AHS12
8.45.280
copyright by
MJFCIFSS
Changeover ZETKO control via AHS12
Step 133
*F15 Fuse solenoid valve AHS12 (7.5A) A1100
H320 Indicator light ZETKO changeover bending / Right console

turning
K409 Step relay ZETKO changeover bending / tur- Left console

ning
S6L Push button ZETKO changeover bending / tur- Right joystick

ning
S6R Push button right ZETKO changeover bending Right joystick
/ turning
X74 Plug to cable with push button, 3-pin Right console

*X207 Plug connection to A1100 for solenoid valve Left console
AHS 12 cable harness revolving desk
X220 Plug connection on A1100 for terminal 15 step Left console
relay K409, 3-pin
Y61 AHS12 solenoid valve Behind cab
* = basic diagram
Tab. 123 Changeover ZETKO control via AHS12
8.45.281
copyright by
MJFCIFSS
ZETKO priority circuit / tunnelling stick
124 ZETKO priority circuit / tunnelling stick
8.45.282
copyright by
MJFCIFSS
ZETKO priority circuit / tunnelling stick
Step 134
*F4 Fuse solenoid valve A1100
S432 Rocker switch pressure control pilot control unit Left joystick
*X210 Plug connection on terminal 15, 2-pin Left console

X1085 Plug connection solenoid valves / 2-pin Left console
X1086 Plug connection rocker switch with cable, 3-pin Left console
Y415 Solenoid valve control pilot control pressure Behind cab

ZETKO
ZETKO
tunnelling stick
tunnelling stick
* = basic diagram
Tab. 124 ZETKO priority circuit / tunnelling stick
8.45.283
copyright by
MJFCIFSS
Operation of lorry tilting device (optional)
125 Operation of lorry tilting device (optional)
Industrial LIKUFIX with MOZELT system belt drive
8.45.284
copyright by
MJFCIFSS
Step 135
A MOZELT indicator ON/OFF

B Connecting terminal bridge obsolete

B26-1 Proximity switch quick-change adapter 135 Industrial LIKUFIX
B26-2 Proximity switch quick-change adapter 135 Industrial LIKUFIX

*F11 Fuse (15A) 135-3 A1100
A1100
H44 LED terminal 15 28 A1100
H46 LED F4 28 A1100
H59 LED F18 37 A1100
K3 Relay quick-change adapter warning buzzer 22 A1001

K4 Relay quick-change adapter warning buzzer 22 A1001
and symbol
K364 Relay quick-change adapter 69 A1017
N1 Slip ring 2+6x 135 Industrial LIKUFIX upper

section
S5L Push button left turn grapple 20 Left joystick

S5R Push button right turn grapple 20 Left joystick
S6L Push button left magnet ON 70 Right joystick
S6R Push button right reserve 70 Right joystick
S46 Switch magnet system ON/OFF 70 Right console
S47 Push button quick-change adapter 69 Right console
T4002 Designation MOZELT generator 135-3 Revolving deck

*V156 Amplifier 32 A1100
X15-1 Plug to S5, 3-pin 20 Left console

X15-3 Plug to S224, 3-pin 135 Left console
8.45.285
copyright by
MJFCIFSS
Step 135
X17 Plug connection quick-change adapter war- 22 A1001
ning, 3-pin
X21 Plug, 3-pin 20 A1001
*X50 Plug, 25-pin Keypad

X262 Plug connection to quick-change adapter, 8-pin 135 Right console
X262-1 Plug connection to quick-change adapter, 8-pin 135 Bearing block
X262-3 Plug connection to quick-change adapter, 8-pin 135 Stick
X446 Plug connection to S47-1/2, 5-pin 70 Right console
X447 Plug connection quick-change adapter blo- 70 Right console
cking diode, 2-pin
X1096-1 Plug connection lorry tilting operation, 6-pin 135 Left console
X1096-2 Plug connection lorry tilting operation, 6-pin 135 Bearing block
X1096-3 Plug connection lorry tilting operation, 6-pin 135 Stick
X1096-4 Plug connection lorry tilting operation, 6-pin 135 Industrial LIKUFIX
X1097 Plug connection industrial LIKUFIX, 8-pin 135 Industrial LIKUFIX upper
section
X1140 Automatic plug for LIKUFIX, 3+6-pin 135 Industrial LIKUFIX
Y28-1 Solenoid valve quick-change adapter grapple 1135 Industrial LIKUFIX

turning circuit
Y28-2 Solenoid valve quick-change adapter grapple 1135 Industrial LIKUFIX
turning circuit
chanism apter
chanism apter
apter
Y376-1 Solenoid valve check valve grapple turning cir- 135 Bearing block
cuit
Y376-2 Solenoid valve check valve grapple turning cir- 135 Bearing block
cuit
8.45.286
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Step 135
Y387-1 Solenoid valve pressure relief grapple turning 135 Bearing block
circuit
Y387-2 Solenoid valve pressure relief grapple turning 135 Bearing block
circuit
* = basic diagram
Tab. 125 Operation of lorry tilting device (optional) / industrial LIKUFIX with MOZELT unit belt drive
8.45.287
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Industrial LIKUFIX
126 Industrial LIKUFIX
with MOZELT system hydraulic drive
8.45.288
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Service Manual
Industrial LIKUFIX
Step 135

A1100
*H59 LED F18 37 A1100

*S47 Push button quick-change adapter 69 Right console
*X50 Plug, 25-pin Keypad


Y296 Solenoid valve hydraulic generator drive 135 Revolving deck
* = basic diagram
Tab. 126 Industrial LIKUFIX with MOZELT system hydraulic drive
8.45A 900 C-LI 14675-A 904 C-LI 16000-
8.45.289
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Service Manual
LIKUFIX quick-change adapter with magnet system and magnet switch
127 LIKUFIX quick-change adapter with magnet system and magnet

switch
8.45.290
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Service Manual
LIKUFIX quick-change adapter with magnet system and magnet switch
Step 135
A1100 ESP02 printed circuit board 70 Left console

A1100
H59 LED F18 37 A1100
K335 Relay Right console
S5L Push button left turn grapple 20 Left joystick

S5R Push button right turn grapple 20 Left joystick
S6R Push button right reserve 70 Right joystick
S47 Push button quick-change adapter 69 Right console
T4002 Designation MOZELT generator 135-3 Revolving deck

V156 Amplifier 32 A1100
X50 Plug, 25-pin Keypad

X370 Plug connection, 2-pin 135 Revolving deck
Y296 Solenoid valve hydraulic generator drive 135 Revolving deck
* = basic diagram
Tab. 127 LIKUFIX quick-change adapter with magnet system and magnet switch
8.45.291
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Service Manual
Flow and pressure settings (changeover kit)
128 Flow and pressure settings (changeover kit)
8.45.292
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Service Manual
Flow and pressure settings (changeover kit)
Step 136
*B33 Pressure switch/flow limitation 50 Behind toolbox

*S88 Plug, 4-pin 50 Right console
*U16 Excavator control 6-9 Right console
*X14_2 Plug on 1100, 5-pin 28 Left console

*X51 Plug on A1009, 3-pin 50 Right console
*X139 Plug to wire harness B33, 3-pin 50 Left console
*X135 Plug BST (excavator control), 40-pin 8 Right console
*X140 Plug to wire harness revolving deck, 2-pin 50 Left console
*X155 Plug on plug-in board to cable harness excava- 8 Left console
tor control to cable harness slewing gear, 15-
pin
*X214-3 Plug connection on A1100 for terminal 15, 2-pin 40 Left console
right, 10-pin

Y414 Solenoid valve pressure control 136 Control oil unit (A914B-
A924B)
Y414 Solenoid valve pressure control 136 Below control valve
(A900-A904)
* = basic diagram
Tab. 128 Flow and pressure settings (changeover kit)
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Service Manual
Flow and pressure settings
129 Flow and pressure settings
(retrofit kit) Kit activation display error codes
8.45.294
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Service Manual
Step 136


right, 10-pin

A924B)
(A900-A904)
* = basic diagram
Tab. 129 Flow and pressure settings (retrofit kit) / kit activation display
130 Flow and pressure settings
Kit activation display
8.45.295
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Service Manual
8.45.296
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Service Manual
Step 136

right, 10-pin

A924B)
(A900-A904)
* = basic diagram
Tab. 130 Flow and pressure settings / kit activation display / error codes
8.45.297
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Service Manual
Radio mute mode
131 Radio mute mode
8.45.298
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Service Manual
Radio mute mode
Step 137
*A3 Radio 4 Left console
B50 Loudspeaker 4 Operators cab
*S1 Hot start switch 3 Right console

S422 Radio mute switch 137 Right console
T1 24/12V voltage converter 4 Right console
X3_2 Plug, 6-pin 4 Right console

X65 Plug, 24V voltage converter, 2-pin 4 Right console
X66 Plug, 12V voltage converter, 2-pin 4 Right console
X67-1 Plug radio, 8-pin 4 Left console
X67-2 Plug radio, 8-pin 4 Left console
* = basic diagram
Tab. 131 Radio mute mode
8.45.299
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Service Manual
Radio mute mode
8.45.300
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Service Manual Excavator control BST (version 2.. or V5..)
Function
Excavator control BST (version 2.. or V5..)

8.70A 900 C-LI 14675-A 904 C-LI 16000-
1 Function
The LIEBHERR hydraulic excavator generation of the C series is equipped with an electrical BST ex-
cavator control system and the associated units and elements.
The BST (U16) excavator control system controls the diesel engine, the hydraulic pump, the hydrau-
lic fan and a number of monitoring functions.
The BST control performs the following functions for the control of the machine:
Recording of diesel engine speed
Adjustment of diesel engine speed
Controlling of warm-up phase for hydraulic oil
Recording of sensor values
Controlling of warm-up phase of diesel engine
Horsepower control
Limitation of pressure and pump delivery volume
Monitoring of system sensors and actuators
Fig. 1 BST (U16) excavator control system
8.70.1
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Excavator control BST (version 2.. or V5..) Service Manual
Description
2 Description
The BST is installed in the right console on the operator's platform.

The BST is connected via the CAN-BUS (CAN1) to the BBT. This connection is used for the ex-
change of information between the two control systems. The BST features the following inputs and
outputs:
Inputs:
B2 Transducer / coolant temperature
B3 Switch / coolant level
B5 Transducer / engine oil pressure
B8 Transducer / hydraulic oil temperature
B12 Transducer / engine speed
B14 Pick-up / hydraulic oil level
Outputs:
M5 Engine / speed adjustment
Y50 Proportional solenoid valve / power control
Y51 Prop. valve / volume control
Y347 Prop. valve / fan control
Y414 Prop. valve / pressure settings (optional)
The emergency control device E52 is installed at the speed adjustment output between the BST and
the speed-adjustment servo motor. It enables the operator to adjust the engine speed in the event of
a control system failure. The various sensor values and output currents of the proportional valves are
shown at the display (DISP02).
The listed items are installed in the diesel engine, the radiator, the right console, the hydraulic and
fuel tank as well as the control oil unit, see Fig. 2.
8.70.2
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Description
Fig. 2 Connections of BST
8.70.3
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The BST controls or monitors the following functions, (see "Connections of BST", page 3).
3.1 Recording of diesel engine speed
Fig. 3 Speed adjustment and mode functions
The speed sensor B12 at the diesel engine transmits the actual diesel engine speed as a frequency
value to the BST.
The value recorded by the B12 is required for the diesel engine speed adjustment and power control.
3.2 Adjustment of diesel engine speed

The following parameters values are required for correct speed adjustment:
Number of teeth (to determine the speed in rpm)
High idle rpm of steps 1 to 10 (values are preset in BST)
The speed of the diesel engine can be adjusted by means of keys S228/S229 at the control panel
(BBT). The machine operator can choose between 10 different speed steps. These steps are shown
at the display P4.
The system also features four modes with permanently assigned speed steps. These modes
(L,F,E,P) can be preselected with the switch S86.
The selected speed step is communicated by the BBT via CAN1 to the BST. The speed is adjusted
by means of a speed-adjustment servo motor.
Depending on the polarity of the control voltage, the diesel engine speed is increased or reduced.
When selecting a speed step, the speed-adjustment servo motor is operated until the machine-de-
pendent high idle speed is reached. When this speed is reached, the speed-adjustment servo motor
(steps 2 to 9) is stopped.
Note!
Depending on the software version, the high idle speeds of the speed steps might differ slightly.
3.3 Warm-up phase of diesel engine

The warm-up phase of the diesel engine is controlled on the basis of the measured diesel engine
coolant temperature G2. If, after the start of the diesel engine, the coolant temperature is< 20°C, a
8.70.4
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MJFCIFSS
minimum speed (step 3) is set by the BBT .

The speed step is shown at the BBT. During the active warm-up phase of maximum 3 minutes, the
operator can increase or reduce the speed. The warm-up phase of the diesel engine is terminated as
soon as the coolant temperature is> 20 °C or when the set maximum phase time has lapsed. This
function can be deactivated in menu (set data - set config - water warm up) (from version V 2.4 (BBT/
DISP02)).
3.4 Warm-up phase for hydraulic oil temperature

The warm-up phase of the hydraulic oil is controlled on the basis of the measured hydraulic oil tem-
perature B8. If, after the start of the diesel engine, the actual hydraulic oil temperature is < 8°C, the
current to the solenoid valve Y50 is set to the value of mode L.
The warm-up phase of the hydraulic oil is terminated as soon as the oil temperature is > 8 °C or when
the set maximum phase time has lapsed. This function can be deactivated in menu (set data - set
config - oil warm up).
3.5 Control of hydraulic fan

The hydrostatic fan drive is controlled by the hydraulic oil temperature B8, the coolant temperature
B2 and the a/c system. The fan speed is controlled electronically, relative to the temperature, through
the proportional solenoid valve Y347.
The following parameters values are required for the correct control of the fan:
Valve current and temperature for the determination of the maximum fan speed at a given hydrau-
lic oil temperature
Valve current and temperature for the determination of the minimum fan speed at a given hydrau-
lic oil temperature
Valve current and temperature for the determination of the maximum fan speed at a given coolant
temperature
Valve current and temperature for the determination of the minimum fan speed at a given coolant
temperature
Basic current for the determination of the fan speed at low diesel engine speed, without a/c system
Basic current for the determination of the fan speed at high diesel engine speed, without a/c sys-
tem
Basic current for the determination of the fan speed at low diesel engine speed, with a/c system
Basic current for the determination of the fan speed at high diesel engine speed, with a/c system
Between the above minimum and maximum values, the current of the BST to the solenoid valve Y347
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!
When Y347 is disconnected, the fan is operated at maximum speed.
For diagrams of the hydraulic fan control, see group 6.20.
8.70.5
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MJFCIFSS
Fig. 4 Components of the hydraulic fan control
3.6 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 power is selected by means of the mode key S86. A current defined by the BST for each model
is fed to the solenoid valve Y50.
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 10
Regulator limit value in mode P (max. LR current in mode P)
Regulator limit value in mode E (max. LR current in mode E)
Regulator limit value in mode F (max. LR current in mode F)
Regulator limit value in mode L (max. LR current in mode L)
Fig. 5 Components of horsepower control
8.70.6
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MJFCIFSS
The solenoid valve Y50 located at the control oil unit controls the oil flow and thus the control pressure
to the regulating valve (LR regulator) of the variable-displacement pump.
Depending on the speed step and the actual load of the diesel engine, the horsepower control adjusts
the preset regulating rpm.
Note!
Depending on the software version, the regulating rpm of the speed steps might differ slightly.
3.7 Pressure and volume reduction

Certain attachments such as hammers, pile drivers, etc. require specific pressure and flow values
that are lower than those generated under normal operating conditions of the machine. Otherwise,
these attachments might not work properly.
The relevant settings
are made at the display (Disp.02).
stored in the BBT.
output and controlled by the BST
Fig. 6 Selecting external inputs EV1/EV6
Note!
Depending on the software, the screen display might vary from that shown here.
8.70.7
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MJFCIFSS
3.8 The following options are available:
3.8.1 Internal flow reduction (fine adjustment)
Fig. 7 Flow limitation menu in mode SF (S354)
Actuate the switch S354 on the control panel to activate or deactivate the fine adjustment function
preset in the operator's menu. The flow reduction is controlled by means of the solenoid valve Y51.
The current generated by the BST is fed to the proportional solenoid valve Y51. As a result of the
control pressure at the flow regulator (LS regulator) of the variable-displacement pump the value P
is reduced.
3.8.2 External flow reduction with Tool Control

The flow volume is reduced at the main screen, see Fig. 6. The flow reduction is activated by means
of the pressure switch B33.
If the input is active (I1), the BBT signals the value preset for the selected option through the CAN1
to the BST.
The menu is displayed after activation at the main screen. The current generated by the BST is fed
to the proportional solenoid valve Y51. As a result of the control pressure at the flow regulator (LS
regulator) of the variable-displacement pump, the value P is reduced.
3.8.3 Pressure reduction via Tool Control

The pressure reduction is controlled through output EV6 of the BST to the proportional solenoid valve
Y414. To adjust the system pressure (high pressure), enter the required nominal value at the display.
Fig. 8 Proportional solenoid valve Y414 on the uppercarriage
Y414 Proportional solenoid valve B33 Pressure switch / flow limitation
8.70.8
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MJFCIFSS
Note!
From version 5.13.1, the pressure can also be reduced by 10 selection options and 10 flow settings.
For detailed instructions regarding the adjustment of the pressure and flow reduction settings, see
group 16.20.
For a description of the AHS11/12 with Tool Control, see groups 16.46/16.48.
3.9 Monitoring of system sensors and actuators

The BST excavator control system monitors the sensors and actuators required for its proper func-
tioning. In the event of a failure, the respective fault messages are recognised, saved in the BBT and
indicated on the display (Disp.02) (error code display).
For a list of fault messages, see group 8.80.
8.70.9
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8.70.10
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MJFCIFSS
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Service Manual Monitoring display
Monitoring display
8.72A 900 C-LI 21794-A 904 C-LI 16000-
A Analogue indicator C Main screen

B Check display D Screen menu control
Note!
All switches, sensors etc. mentioned in this group are described in detail in group 8.10.
In this group, explanations concerning the screen menu control (starting with version 5.7.1) come
as a summarised description in a table. For more detailed instructions of the menu control used up
to version 2.12, please see group 8.71.
A 900 C-LI 21794- 8.72.1

MJFCIFSS
Monitoring display Service Manual
Ranges of analogue indicator and check display
1 Ranges of analogue indicator and check display
1.1 Display P2 for diesel-engine coolant temperature

Display must be in green range during operation.
In the event of overheating (beyond 98°C), the red LEDs P2-1 at the end of the display will flash.
At the same time, the buzzer will sound overheat alarm. Furthermore, a warning symbol will appear
on the LCD screen. The system will store error code E503 .
Stop all works immediately.
Let engine continue in high idle (no load) for about 3 to 5 minutes.
The alarm message will persist for more than 60 seconds.
Get engine into low idle gear.
Shut down engine.
Find and remove cause.
1.2 Indication of fuel level P3

The LEDs lighting up on the analogue indicator display show how much fuel is in the tank.
When red LEDs P3.1 light up, fuel remaining in the tank amounts to 10 - 20 % (depending on type of
machine).
1.3 Engine oil pressure - check display H2

Indicator lamp H2 lights up, if the oil pressure in the engine falls below a certain pre-set value during
operation (depends on current rpm).
Low oil pressure will set off an acoustic alarm in the operator's cab (buzzer), and the system will store
the incident under error code E501.
Get engine into low idle gear, immediately.
Shut down engine immediately.
1.4 Indicator light H12: battery charging

Indicator lamp H12 lights up as soon as the starter key is turned on position.
The indicator light goes out as soon as the engine is started.
During operation, the indicator lamp lights up, if the V-belt of the alternator or the electrical charging
system are defect.
Let engine run in low idle for about 20 seconds.
Shut down engine.
Find and remove cause.
8.72.2 A 900 C-LI 21794-

MJFCIFSS
1.5 Lamp H19: direction indicator

Lamp H19 starts to flash whenever the direction indicator switch or hazard light have been actuated.
1.6 Indicator light H20: parking brake

Indicator light H20 lights up when the parking brake has been engaged (switch - parking brake) or
the upper safety lever has been actuated or when the pressure falls below the release pressure.
1.7 Indicator light H23: accumulator charge pressure (working brake)

Indicator lamp H23 lights up, if the accumulator pressure is too low. The brake may not be functional
any more.
Whenever this lamp lights up, the occurrence is stored under error code E 510. The buzzer gives two
short signals.
Get engine into low idle gear.
Move safety lever to the top.
Check brake system.
Danger!
The brake will be operational only to some extend. Be sure to move machine out of harm's way and
shut down.
1.8 Indicator light H24: flow indicator / steering

Indicator lamp H24 lights up, if the oil flow going to the steering servostat is insufficient.
Whenever this lamp lights up, the occurrence is stored under error code E 509. The buzzer gives two
short signals.
Shut down engine.
Check steering pump and system.
Danger!
In such a state, the machine can be steered only with much physical strength. Be sure to move ma-
chine out of harm's way and shut down.
A 900 C-LI 21794- 8.72.3

MJFCIFSS
menu control for screen
2 menu control for screen
2.1 LCD screen: buttons
Fig. 2 LCD screen
The display has four buttons for operation:
Fig. 3 menu control for screen
S349: ButtonBACK
S350: ButtonDOWN
S351: ButtonUP
S352: ButtonMENU*
* Switch-over between main and sub-menus
Use these buttons to move from operator's menu to sub-menus (and back) or browse among pages.
8.72.4 A 900 C-LI 21794-

MJFCIFSS
Main screen
2.2 Setting contrast of LCD screen

Simultaneously press buttons MENU and UP (more contrast) or DOWN (less contrast).
The value set at this point will be stored in the system.
Setting brightness of main screen
Simultaneously press buttons BACK and UP (brighter) or DOWN (darker).
The value set at this point will be stored in the system.
Note!
There is a light sensor at the top left of the monitoring display. It controls the brightness of the main
screen with respect to the ambient brightness. Automatic brightness control will then be based on
the basic setting entered with the buttons. The display will be dimmed when the environment gets
darker.
Resetting brightness and contrast to default settings:

Switch off ignition.
Simultaneously press and hold buttons UPandDOWN.
Switch on ignition again.
Do not release buttons before end of autocheck.
3 Main screen
The main screen appears after the machine has been switched on and will remain visible until you
press MENU and change to the menu selection screen.
Fig. 4 Main screen
EC Wire error TI Total operating counter, daily counter

INF Information 1 Selected option (attachment)
SY Symbols / time 2 Symbol R will be displayed when a flow
control is active.
A 900 C-LI 21794- 8.72.5

MJFCIFSS
Layout of main screen
4 Layout of main screen
4.1 Field SY
The time is displayed in the upper part of the screen. To the left, you see error and warning symbols,
up to 2 symbols at a time. If there is reason to show more than 2 symbols, they will wander and dis-
appear to the left, one symbol every 10 seconds.
List (see "Warning symbols in field SY:", page 7) contains all the symbols that can appear in this field.
4.2 Field EC
Display window EC shows the error codes of current electrical faults in the electronics of the excava-
tor (faults in the lines, sensors etc.). Up to seven error codes can be shown at any time. If there are
more than seven faults, an arrow will appear besides the error code window, showing where else in
the list error codes occurred. The total will be shown at the bottom of the EC field.
Press buttons UP and/or DOWN
to scroll up or down through the error code window.
4.3 Field INF

The field INF (bottom right in the main screen) is for the display of temporary information, also in gra-
phic form. If there is reason to show more than three symbols, they will wander and disappear to the
left, one symbol every 10 seconds.
Displayed information comes in the form of graphics or text, indicating e.g. a function launched (pre-
heating etc.), important pointers and reminders (scheduled service check) and/or dangers (overload
etc.)(see "Information symbols in field INF", page 9).
4.4 Field TI
This field, to the bottom right, displays machine operating hours, the daily operating hours counter
and the attachment selected.
Symbol indicates that there is a flow limitation for the pumps (see "menu" for status of hydraulic
pumps and electrical inputs and outputs, page 11).
The open-end spanner may appear when the ignition is engaged. It means to indicate the next sche-
duled service check is due.
The display usually showing the daily operating hours now shows the hours of the current service
interval, see Fig. 4. The service check symbol disappears after about 8 seconds.
4.5 Screen control in the event of error displays

As soon as a fault condition displayed in field SY is confirmed as NEW, the display returns to the main
screen window. The corresponding error output is active.
Depending on the actual occurrence (importance), there may be an acoustic signal at the same time
(buzzer), either continuously or in recurring intervals.
The symbol indicates a possibility to reset the buzzer.
8.72.6 A 900 C-LI 21794-

MJFCIFSS
Warning symbols in field SY:
Pressing button S349 "Back" will confirm errors with continuous signal, i.e. the
buzzer is switched off.
5 Warning symbols in field SY:
E 502 Low coolant level:

This symbols means to indicate the level of coolant has dropped below mi-
nimum.
The buzzer will sound, in addition.
Run motor down to low idle, go on about 5 secs. and switch off.
Find leak and repair.
E 503 Coolant overheat:
This symbol goes on together with the red LEDs on display P2.
(see Fig. 1, page 1).
E 504 Low hydraulic oil level:

This symbols means to indicate the level of hydraulic oil has dropped below
minimum.
The buzzer will sound, in addition.
Switch off motor. Find leak and repair.
Remember: hydraulic oil may be filled up only using return filter.
E 505 Hydraulic oil overheat:
This symbol appears when the temperature of the hydraulic oil in the tank
rises above 98°C. The buzzer will give two short signals.
Switch off motor.
Find and repair the defect (e.g. clean cooler, repair blower and/or thermostat
etc.).
E 511 Excess voltage:
This symbol appears in the event of operating voltage surges beyond 30
volts for 0.5 seconds or longer. The buzzer will give two short signals.
Quick-change adapter:
This symbol appears when the motion sensor of the quick-change adapter
has been activated, i.e. the locking bolt has been retracted (danger). Error
codes are not displayed. The buzzer sounds.
A 900 C-LI 21794- 8.72.7

MJFCIFSS
Delay Duration of
Operating errors displayed Display of
error code between start signal until
and/or stored in field SY symbol
and display storage
Low motor oil pressure E 501 15 sec. 1.5 sec. 5 sec.

Low coolant level E 502 none at once 5 sec.
Coolant overheat E 503 none at once 60 sec.
Low hydraulic oil level E 504 none at once 5 sec.
Hydraulic oil overheat E 505 none at once 60 sec.
high voltage E 511 none at once 0 sec.
Tab. 1 Operating errors in field SY
Operating errors displayed Delay Duration of

Display of
and stored by means of error code between start signal until
symbol
indicator lights and display storage
Low oil quantity (flow indicati- E 509 15 sec. at once 1 sec.

on / steering)
Low accumulator charge pres- E 510 60 sec. at once 1 sec.

sure (working brake)
Tab. 2 Operating errors stored
8.72.8 A 900 C-LI 21794-

MJFCIFSS
Information symbols in field INF
6 Information symbols in field INF
Pre-heat:
This symbol appears as long as a pre-heat procedure is in progress.
End of pre-heating:
The pre-heating process is stopped after about 20 seconds. The symbol
"End of pre-heating" is displayed on the LCD screen.
Buzzer mute:
This symbol appears when an error message has appeared and the buzzer
goes on.
Press button S349 to confirm and switch off acoustic signals (continuous
and recurrent).
Scheduled service check:
This symbol may appear after ignition and self-check and stay for about 10
secs. It indicates the next service check is due.
Manual diesel-engine rpm adjustment:

This symbol appears when the switch for manual rpm adjustment (E 52 -
right-hand control console, back) is on "Manu".
Travel forward
This symbol appears when the travel switch is on "Travel forward".
Travel reverse
This symbol appears when the travel switch is on "Travel reverse".
Oscillating axle lock active:

This symbol appears when the locking switch of the oscillating axle has been
switched to position "1". For a detailed description of oscillating axle func-
tions, see group 14.10.
Automatic oscillating axle lock active:
switched to position "A". For a detailed description of oscillating axle func-
Outrigger support:
This symbol appears when the sensors / proximity switches have been acti-
vated due to the extension of one or several outriggers (danger). (Applicable
only if kit "outrigger monitoring system" is operational.)
This symbol appears when the overload warning system is activated to warn
the operator that the max. bearing capacity of the machine has been rea-
ched. The buzzer sounds.
No overload warning available:
This symbol appears when overload warning has been triggered, but the
machine does not dispose of an overload warning system.
A 900 C-LI 21794- 8.72.9

MJFCIFSS
Stick cylinder shut-down at stick retraction (only with industrial equip-

ment):
This symbol appears when the stick has been retracted all the way to the
max. admissible angle, and stick cylinder shut-down prevents any further re-
traction of the stick.
Suppression of stick cylinder shut-down for stick retraction (only with in-
dustrial equipment):
This symbol appears when (for retraction) stick cylinder shut-down has been
suppressed (using suppression button). The buzzer sounds.
Stick cylinder shut-down at stick extension (only with industrial equip-
ment):
This symbol appears when the stick has been extended all the way to the
max. admissible angle, and stick cylinder shut-down prevents any further ex-
tension of the stick.
Suppression of stick cylinder shut-down for stick extension (only with in-
This symbol appears when (for extension) stick cylinder shut-down has been
suppressed (using suppression button ). The buzzer sounds.
Reserve functions 2, 3 and 4:
This symbol appears when additional functions for add-ons have been in-
stalled.
Checking code plug data:

Code plug data is okay (only for keyboard replacement).
Changing operation of parking brake and slewing gear brake:

This symbol appears when switch S73 is on emergency position.
Pointer "Attention!" Control modes have changed:

Servo controls have changed:

8.72.10 A 900 C-LI 21794-

MJFCIFSS
wire fault messages
7 wire fault messages
Designation / sensor Type of errors Error codes

Motor oil pressure / B5 Ground connection E 001
+ 24 V short circuit E 002
wire break E 003
Coolant level / B3 Ground connection E 004
Error + 24 V short circuit E 005
in wire break E 006
circuit
of Coolant temperature / B2 Ground connection E 007
sensor + 24 V short circuit E 008
for wire break E 009
monitoring Hydraulic oil level / B14 Ground connection E 010
of: + 24 V short circuit E 011
wire break E 012
Hydraulic oil temperature / B8 Ground connection E 013
wire break E 015
Diesel engine - rpm / B12 Ground connection E 022
wire break E 024
Amplifier LR1 / Y50 wire fault E 027
Amplifier EV 5 / Y347 (fan control wire fault E 033
Amplifier EV 1 / Y51 wire fault E 036
Error Amplifier EV 3 / Y53 (thermostat) wire fault E 042
in regula- Fan regulation (Linning) wire fault E 045
ting circuit Proportional valve Y414
of:
Connection SWF motor Disturbance in SWF E 046
motor
Potentiometer electronic stick shut- Ground connection E 049
down / R70 wire break E 050
short to plus
A 900 C-LI 21794- 8.72.11

MJFCIFSS
wire fault messages
Designation / sensor Type of errors Error codes

No code plug E 302
No CAN bus connection between keyboard and BST printed cir- E 303
cuit board
(Message can appear even if BST excavator control is not ope-
rational, e.g. no power supply etc.)
Other: No CAN bus connection between keyboard and ESP01 printed E 305
Errors: circuit board. (Message can appear even if ESP01 is not opera-
tional.)
No CAN bus connection between keyboard and ESP02 printed E 306
circuit board. (Message can appear even if ESP02 is not opera-
tional.)
No CAN bus connection between keyboard and display; E 308
or: keyboard not operational.
Keyboard and display softwares not compatible. E 309
Hardware coding and software co- Coding error E 319
ding not compatible.
Did not receive any known machine Coding error E 321
type from BBT.
Hardware coding unknown. Coding error E 322
Sensor handle 1 B19L Short to plus E 442
Ground connection E 443
wire break
Sensor handle 2 B19R Short to plus E 445
wire break
Fuel tank sensor B39 Short to plus E 456
wire break
Status of amplifiers at ESP01 connection fault E 601
Status of amplifiers at ESP02 connection fault E 602
8.72.12 A 900 C-LI 21794-

MJFCIFSS
Output of information via menus in LCD screen
8 Output of information via menus in LCD screen
The following description applies to machines with:

display DISP 02
Keyboard BBT-02
Excavator control BST-EHR
8.1 menu selection
Fig. 5 Menu selection "Reset hours" - operator's menu
Select operator's menu.

Push button MENU on main screen.
The list of available menus will be displayed. see Fig. 5
To select menu, press buttons UP and/or DOWN.
The preceding and/or subsequent operator's menu will now appear black on the screen.
The selected menu appears in inverse graphics. (The example shows the menu Daily operating
hours.)
Press Menu again.
The sub-menu of the selected function appears.
Press Back.
to exit the function.
9 Authorisations for the various menus
Execution of the various functions requires authorisations (service level), which are organised in va-
rious levels. This sort of organisation allows to limit access to certain functions that require a certain
degree of knowledge to those persons who know the machine and components.
9.1 There are three levels.

The first level can be accessed by everybody. For levels 2 and 3, personnel will need a plug at "X30"
or "X31" for amplifier board A1001 containing the appropriate coding.
A 900 C-LI 21794- 8.72.13

MJFCIFSS
Level 1 for operators (no plug required for access)
10 Level 1 for operators (no plug required for access)
Symbol Description
Resetting the clock counting daily operating hours
Working speed in mode SF
Confirming scheduled service check
Tool Control. Selection of flow control depending on attach-

ment used (e.g. hammer).
Operating hours
Hydraulic pumps and electrical inputs
Errors (operating errors and electrical system errors)
Setting time
Electronic stick cylinder shut-down

(requires activation by LIEBHERR customer service)
immobiliser
8.72.14 A 900 C-LI 21794-

MJFCIFSS
Levels 2 and 3 for mechanics and inspectors
11 Levels 2 and 3 for mechanics and inspectors
All the functionalities pertaining to level 1 plus

information concerning diesel engine.
Menu for stored data (hours, errors,
setting parameters and errors via the serial in-
terface of the BBT.
Setting external flow limitations of consumers
(hammer, grapple etc.)
Pre-setting values for performance test
Defining error code suppression and individu-
al excavator functions
Erasing test error memories
Level 2 for mechanics (service plug required for access)
All the functions of level 2.

Setting additional device-specific parameters
Erasing additional error memories
Releasing additional device-specific menu
items (e.g. immobiliser)
Level 3 for inspectors (service plug required for access)
A 900 C-LI 21794- 8.72.15

MJFCIFSS
8.72.16 A 900 C-LI 21794-

MJFCIFSS
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Service Manual Monitoring display from version 4.4/4.5/4.6
Monitoring display from version 4.4/4.5/4.6
A Analogue indicator C Main screen

B Check display D Screen menu control
Note!
All switches, sensors etc. mentioned in this group are described in detail in group 8.12.
The menu control system from version 4.4. is introduced in this group in the form of a concise table.
For a detailed description of the control menus up to version 4.4., see group 8.73.
8.73.1
copyright by
MJFCIFSS
Monitoring display from version 4.4/4.5/4.6 Service Manual
1 Ranges of analogue indicator and check display
1.1 Display P2 for diesel engine coolant temperature

Display must be in green range during operation.
In the event of overheating (beyond 98°C), the red LEDs P2-1 at the bottom of the display flash.
At the same time, the buzzer sounds an overheat alarm. A warning symbol appears on the LCD
screen. The system stores the error code E503.
Stop all works immediately.
Let engine continue in high idle (no load) for about 3 to 5 minutes.
The alarm message remains displayed for more than 60 seconds.
Set engine into low idle gear.
Switch off the engine.
Find and eliminate cause.
1.2 Indication of fuel level P3

The LEDs lighting up on the analogue indicator display show how much fuel is in the tank.
When the red LEDs P3.1 light up, fuel remaining in the tank amounts to 10 - 20 % (depending on type
of machine).
1.3 Engine oil pressure - check display H2

The indicator light H2 lights up, if the oil pressure in the engine falls below a certain pre-set value
during operation (depends on current rpm).
Low oil pressure sets off an acoustic alarm in the operator's cab (buzzer), and the system stores the
incident under error code E501.
Immediately switch the engine to low idle gear.
Shut down engine immediately.
1.4 Indicator light H12: battery charging

Indicator light H12 lights up as soon as the starter button is in contact position.
The indicator light goes out as soon as the engine is started.
During operation, the indicator light lights up, if the V-belt of the alternator or the electrical charging
system are defective.
Let engine run in low idle for about 20 seconds.
Find and eliminate cause.
8.73.2
copyright by
MJFCIFSS
1.5 Direction indicator light H19

Light H19 starts to flash whenever the direction indicator switch or hazard light have been actuated.
1.6 Parking brake indicator light H20

The indicator light H20 lights up when the parking brake has been engaged (switch - parking brake)
or the upper safety lever has been actuated or when the pressure falls below the release pressure.
1.7 Accumulator charge pressure (working brake) indicator light H23

The indicator light H23 lights up, if the accumulator pressure is too low. The brake may not be func-
tional any more.
Whenever this light is on, the occurrence is stored under error code E 510. The buzzer gives two short
signals.
Set engine into low idle gear.
Move the safety lever to the top.
Check the brake system.
Danger!
Risk of injury due to brake malfunction.
In the event of a malfunction, move the machine from the danger area and halt it there.
1.8 Flow indicator / steering indicator light H24

The indicator light H24 lights up, if the oil flow going to the steering Servostat is insufficient.
Whenever this light is on, the occurrence is stored under error code E 509. The buzzer gives two short
signals.
Check the steering pump and system.
Danger!
Risk of injury due to stiff steering.
In the event of a malfunction, move the machine from the danger area and halt it there.
8.73.3
copyright by
MJFCIFSS
Menu control for screen
2 Menu control for screen
2.1 LCD screen buttons
Fig. 2 LCD screen
The display 200 is operated with four buttons:
Fig. 3 Menu control for screen
S349: Button BACK

S350: Button DOWN
S351: Button UP
S352: Button MENU*
* Switching between main and submenus
Use these buttons to move from operator's menu to submenus (and back) or browse through pages.
8.73.4
copyright by
MJFCIFSS
Main screen of operator's menu
2.2 Setting contrast of LCD screen

Simultaneously press buttons MENU and UP (more contrast) or DOWN (less contrast).
The value set at this point is stored in the system.
Setting brightness of main screen
Simultaneously press buttons BACK and UP (brighter) or DOWN (darker).
The value set at this point is stored in the system.
Note!
There is a light sensor at the top left of the monitoring display. It controls the brightness of the main
screen with respect to the ambient brightness. Automatic brightness control is based on the basic
setting entered with the buttons. The display is dimmed when the environment gets darker.
Resetting brightness and contrast to default settings:

Simultaneously press and hold buttons UP and DOWN.
Switch on the ignition again.
Do not release the buttons before end of autocheck.
3 Main screen of operator's menu
The main screen appears after the machine has been switched on and will remain visible until you
press MENU and change to the menu selection screen.
Fig. 4 Main screen

INF Information 1 Selected option (e.g. "Hammer")
SY Symbols / time 2 Symbol "R" is displayed, if the flow limita-
tion is activated.
8.73.5
copyright by
MJFCIFSS
Layout of main screen
4 Layout of main screen
4.1 Field SY
The time is displayed in the upper part of the screen. To the left, you see error messages and warning
symbols. If the system needs to display more than 2 symbols, the clock is hidden. If more than 4 sym-
bols are to be displayed, they are moved across the screen from left to right by one symbol every 10
seconds.
The list (see Warning symbols in field SY: on page 7) contains all the symbols that can appear in
this field.
4.2 Field EC
Display window EC shows the error codes of current electrical faults in the electronics of the excava-
tor (faults in the lines, sensors etc.). Up to seven error codes can be shown at any one time. If there
are more than seven faults, an arrow appears besides the error code window, showing where else in
the list error codes occurred. The total is shown at the bottom of the EC field.
Press buttons UP and/or DOWN
to scroll up or down through the error code window.
4.3 Field INF

The field INF on the main screen is used to display temporary information, also in graphic form. If
there is reason to show more than three symbols, they move across the screen and disappear to the
left, one symbol every 10 seconds.
Displayed information comes in the form of graphics or text, indicating e.g. a function launched (pre-
heating etc.), important pointers and reminders (scheduled service check) and/or dangers (overload
etc.)(see Information symbols in field INF on page 8).
4.4 Field TI
This field, to the bottom right, displays machine operating hours, the daily operating hours counter
and the attachment selected.
The symbol indicates that the flow limitation for the pumps is activated (see status menu of the
hydraulic pumps and the electrical inputs and outputs on page 11).
The open-end spanner may appear when the ignition is engaged. It indicates that the next scheduled
service check is due.
The display usually showing the daily operating hours now shows the hours of the current service
interval, see Fig. 4. The service check symbol disappears after about 8 seconds.
4.5 Screen control in the event of error displays

As soon as a fault displayed in field SY is confirmed as NEW, the display returns to the main screen
window. The corresponding error output is active.
Depending on the actual occurrence (importance), there may be an acoustic signal at the same time
(buzzer), either continuously or in recurring intervals.
The symbol indicates a possibility to reset the buzzer.
8.73.6
copyright by
MJFCIFSS
Pressing button S349 "Back" will confirm errors with continuous signal, i.e. the
buzzer is switched off.
5 Warning symbols in field SY:
E 502 Low coolant level:

This symbols indicates that the level of coolant has dropped below mini-
mum.
The buzzer sounds.
Run engine down to low idle, let it run for about 5 seconds and switch off.
Find leak and repair.
E 503 Coolant overheat:
This symbol goes on together with the red LEDs on display P2.
(see Fig. 1 on page1).
E 504 Low hydraulic oil level:

This symbol indicates that the level of hydraulic oil has dropped below the
minimum mark.
The buzzer sounds.
Switch off engine. Find leak and repair.
Remember: hydraulic oil may be filled up only using return filter.
E 505 Hydraulic oil overheat:
This symbol appears when the temperature of the hydraulic oil in the tank
rises above 98°C. The buzzer gives two short signals.
Find and repair the defect (e.g. clean cooler, repair blower and/or thermostat
etc.).
E 511 Excess voltage:
This symbol appears in the event of operating voltage surges beyond 30 V
for 0.5 seconds or longer. The buzzer gives two short signals.
Quick-change adapter:
This symbol appears when the motion sensor of the quick-change adapter
has been activated, i.e. the locking bolt has been retracted (danger). Error
codes are not displayed. The buzzer sounds.
8.73.7
copyright by
MJFCIFSS
6 Information symbols in field INF
Pre-heat:
This symbol appears as long as a pre-heat procedure is in progress.
End of pre-heating:
The pre-heating process is stopped after about 20 seconds. The symbol
"End of pre-heating" is displayed on the LCD screen.
Buzzer mute:
This symbol appears when an error message has appeared and the buzzer
goes on.
Press the button S349 to acknowledge the error and to switch off the acous-
tic signal (continuous).
Scheduled service check:
This symbol may appear after ignition and self-check and stay for about 10
seconds It indicates the next service check is due.
Manual diesel-engine rpm adjustment:

This symbol is displayed when the diesel engine is started in emergency
mode by means of the switch S71. It indicates that the speed can be adjus-
ted manually with the switch S72.
Travel forward
This symbol appears when the travel switch is on "Travel forward".
Travel reverse
This symbol appears when the travel switch is on "Travel reverse".
Oscillating axle lock active:

actuated. For a detailed description of oscillating axle functions, see group
14.10.
Automatic oscillating axle lock active:
switched to position "A". For a detailed description of oscillating axle func-
Outrigger support:
This symbol appears when the sensors / proximity switches have been acti-
vated due to the extension of one or several outriggers (danger). (Applicable
only if kit "outrigger monitoring system" is operational.)
This symbol appears when the overload warning system is activated to warn
the operator that the max. bearing capacity of the machine has been rea-
ched. The buzzer sounds.
No overload warning available:
This symbol appears when an overload warning has been triggered, but the
machine is not equipped with an overload warning system.
8.73.8
copyright by
MJFCIFSS
Stick cylinder shut-down at stick retraction (only with industrial equip-

ment):
This symbol appears when the stick has been retracted to the max. admis-
sible angle, and stick cylinder shut-down prevents any further retraction of
the stick.
Suppression of stick cylinder shut-down for stick retraction (only with in-
This symbol appears when (for retraction) stick cylinder shut-down has been
suppressed (using suppression button). The buzzer sounds.
Stick cylinder shut-down at stick extension (only with industrial equip-
ment):
This symbol appears when the stick has been extended to the max. admis-
sible angle, and stick cylinder shut-down prevents any further extension of
the stick.
Suppression of stick cylinder shut-down for stick extension (only with in-
This symbol appears when (for extension) stick cylinder shut-down has been
suppressed (using suppression button ). The buzzer sounds.
Reserve functions 2, 3 and 4:
This symbol appears when additional functions for add-ons have been in-
stalled.
Checking code plug data:

Code plug data is okay (only for keyboard replacement).
Changing operation of parking brake and slewing gear brake:

This symbol appears when the switch S73 is in emergency position.
Pointer "Attention!" Control modes have changed:

Servo controls have changed:

8.73.9
copyright by
MJFCIFSS
Output of information via menus in LCD screen
7 Output of information via menus in LCD screen
The following description applies to machines with:

Display DISP 02
Keypad BBT-02
Excavator control BST-EHR
7.1 Menu selection
Fig. 5 Menu selection "Reset hours" - operator's menu
Selecting operator's menu.

Press the button MENU on the main screen.
The list of available menus is be displayed, see Fig. 5.
To select a menu, press the buttons UP and/or DOWN.
The preceding and/or subsequent operator's menu is highlighted in black on the screen.
The selected menu appears in inverse graphics. (The example shows the menu Daily operating
hours.)
Press the Menu button again.
The submenu of the selected function appears.
Press the Back key
to exit the function.
7.2 Authorisations for the various menus

Execution of the various functions requires authorisations (service level), which are organised on va-
rious levels. This sort of organisation allows to limit access to certain functions that require a certain
degree of knowledge to those persons who know the machine and components.
7.3 There are three access levels.

The first level can be accessed by everybody. For levels 2 and 3, personnel need a dongle for "X30"
or "X31" of the amplifier board A1001 containing the appropriate coding.
8.73.10
copyright by
MJFCIFSS
Level 1 for operators (no dongle required for access)
8 Level 1 for operators (no dongle required for access)
Symbol Description
Resetting the clock counting daily operating hours
Super Finish menu / sensitivity of the slewing gear
Confirming scheduled service check
Tool Control Selection of working tool settings (e.g. hydraulic

hammer)
Operating hours, machine data
Status of hydraulic pumps and electrical inputs/outputs
Errors (operating errors and electrical system errors)
Setting of current time
Electronic stick cylinder shut-down

Automatic central lubrication system mode (optional equip-

ment)
Purge mode
Starting diesel engine in PURGE mode
8.73.11
copyright by
MJFCIFSS
9 Levels 2 and 3 for mechanics and inspectors
All the functionalities pertaining to level 1 plus

information concerning diesel engine
Menu for stored data (hours, errors)
Setting parameters and errors via the serial
interface of the BBT
Setting external flow limitations of consumers
(hammer, grapple etc.)
Pre-setting values for performance test
Defining error code suppression and individu-
al excavator functions
Erasing test error memories
Level 2 for mechanics (dongle required for access)
All the functions of level 2.

Setting additional device-specific parameters
Erasing additional error memories
Releasing additional device-specific menu
items (e.g. immobiliser)
Level 3 for inspectors (dongle required for access)
8.73.12
copyright by
MJFCIFSS
Service Manual
8.73.13
MJFCIFSS
Service Manual
Menu control V.4.4/4.4
8.73.14
MJFCIFSS
Service Manual
BBT/DISP V4.4/4.4
Inspector
Mechanic
Operator
8.73.15
MJFCIFSS
Service Manual
8.73.16
MJFCIFSS
Service Manual
BBT/DISP V4.4/4.4
Inspector
Mechanic
Operator
8.73.17
MJFCIFSS
Service Manual
8.73.18
MJFCIFSS
Service Manual
BBT/DISP V4.4/4.4
Inspector
Mechanic
Operator
8.73.19
MJFCIFSS
Service Manual
8.73.20
MJFCIFSS
Service Manual
BBT/DISP V4.4/4.4
Inspector
Mechanic
Operator
8.73.21
MJFCIFSS
Service Manual
8.73.22
MJFCIFSS
Service Manual
8.73.23
MJFCIFSS
Service Manual
8.73.24
MJFCIFSS
Service Manual
BBT/DISP V4.4/4.4
Inspector
Mechanic
Operator
8.73.25
MJFCIFSS
Service Manual
8.73.26
MJFCIFSS
Service Manual
BBT/DISP V4.4/4.4
Inspector
Mechanic
Operator
8.73.27
MJFCIFSS
Service Manual
8.73.28
MJFCIFSS
Service Manual
BBT/DISP V4.4/4.4
Inspector
Mechanic
Operator
8.73.29
MJFCIFSS
Service Manual
8.73.30
MJFCIFSS
Service Manual
BBT/DISP V4.4/4.4
Inspector
Mechanic
Operator
8.73.31
MJFCIFSS
Service Manual
8.73.32
MJFCIFSS
Service Manual
BBT/DISP V4.4/4.4
Inspector
Mechanic
Operator
8.73.33
MJFCIFSS
Service Manual
8.73.34
MJFCIFSS
Service Manual
BBT/DISP V4.4/4.4
Inspector
Mechanic
Operator
8.73.35
MJFCIFSS
Service Manual
8.73.36
MJFCIFSS
Service Manual
BBT/DISP V4.4/4.4
Inspector
Mechanic
Operator
8.73.37
MJFCIFSS
Service Manual
8.73.38
MJFCIFSS
Service Manual
BBT/DISP V4.4/4.4
Inspector
Mechanic
Operator
8.73.39
MJFCIFSS
Service Manual
8.73.40
MJFCIFSS
Service Manual
BBT/DISP V4.4/4.4
Inspector
Mechanic
Operator
8.73.41
MJFCIFSS
Service Manual
8.73.42
MJFCIFSS
Service Manual
BBT/DISP V4.4/4.4
Inspector
Mechanic
Operator
8.73.43
MJFCIFSS
Service Manual
8.73.44
MJFCIFSS
Service Manual
BBT/DISP V4.4/4.4
Inspector
Mechanic
Operator
8.73.45
MJFCIFSS
Service Manual
8.73.46
MJFCIFSS
Service Manual
BBT/DISP V4.4/4.4
Inspector
Mechanic
Operator
8.73.47
MJFCIFSS
Service Manual
8.73.48
MJFCIFSS
Service Manual
BBT/DISP V4.4/4.4
Inspector
Mechanic
Operator
8.73.49
MJFCIFSS
Service Manual
Menu control V4.5/V4.6
8.73.50
MJFCIFSS
MJFCIFSS
8.73.51
Operator
Mechanic
Inspector
BBT/DISP2
V4.5/V4.5
BBT/DISP2
V4.6/V4.6
Service Manual
Service Manual
8.73.52
MJFCIFSS
MJFCIFSS
8.73.53
Operator
Mechanic
Inspector
BBT/DISP2
V4.5/V4.5
BBT/DISP2
V4.6/V4.6
Service Manual
Service Manual
8.73.54
MJFCIFSS
MJFCIFSS
8.73.55
Operator
Mechanic
Inspector
BBT/DISP2
V4.5/V4.5
BBT/DISP2
V4.6/V4.6
Service Manual
Service Manual
8.73.56
MJFCIFSS
MJFCIFSS
8.73.57
Operator
Mechanic
Inspector
BBT/DISP2
V4.5/V4.5
BBT/DISP2
V4.6/V4.6
Service Manual
Service Manual
8.73.58
MJFCIFSS
Service Manual
8.73.59
MJFCIFSS
Service Manual
8.73.60
MJFCIFSS
MJFCIFSS
8.73.61
Operator
Mechanic
Inspector
BBT/DISP2
V4.5/V4.5
BBT/DISP2
V4.6/V4.6
Service Manual
Service Manual
8.73.62
MJFCIFSS
MJFCIFSS
8.73.63
Operator
Mechanic
Inspector
BBT/DISP2
V4.5/V4.5
BBT/DISP2
V4.6/V4.6
Service Manual
Service Manual
8.73.64
MJFCIFSS
MJFCIFSS
8.73.65
Operator
Mechanic
Inspector
BBT/DISP2
V4.5/V4.5
BBT/DISP2
V4.6/V4.6
Service Manual
Service Manual
8.73.66
MJFCIFSS
MJFCIFSS
8.73.67
Operator
Mechanic
Inspector
BBT/DISP2
V4.5/V4.5
BBT/DISP2
V4.6/V4.6
Service Manual
Service Manual
8.73.68
MJFCIFSS
MJFCIFSS
8.73.69
Operator
Mechanic
Inspector
BBT/DISP2
V4.5/V4.5
BBT/DISP2
V4.6/V4.6
Service Manual
Service Manual
8.73.70
MJFCIFSS
MJFCIFSS
8.73.71
Operator
Mechanic
Inspector
BBT/DISP2
V4.5/V4.5
BBT/DISP2
V4.6/V4.6
Service Manual
Service Manual
8.73.72
MJFCIFSS
MJFCIFSS
8.73.73
Operator
Mechanic
Inspector
BBT/DISP2
V4.5/V4.5
BBT/DISP2
V4.6/V4.6
Service Manual
Service Manual
8.73.74
MJFCIFSS
MJFCIFSS
8.73.75
Operator
Mechanic
Inspector
BBT/DISP2
V4.5/V4.5
BBT/DISP2
V4.6/V4.6
Service Manual
Service Manual
8.73.76
MJFCIFSS
MJFCIFSS
8.73.77
Operator
Mechanic
Inspector
BBT/DISP2
V4.5/V4.5
BBT/DISP2
V4.6/V4.6
Service Manual
Service Manual
8.73.78
MJFCIFSS
MJFCIFSS
8.73.79
Operator
Mechanic
Inspector
BBT/DISP2
V4.5/V4.5
BBT/DISP2
V4.6/V4.6
Service Manual
Service Manual
8.73.80
MJFCIFSS
MJFCIFSS
8.73.81
Operator
Mechanic
Inspector
BBT/DISP2
V4.5/V4.5
BBT/DISP2
V4.6/V4.6
Service Manual
Service Manual
8.73.82
MJFCIFSS
MJFCIFSS
8.73.83
Operator
Mechanic
Inspector
BBT/DISP2
V4.5/V4.5
BBT/DISP2
V4.6/V4.6
Service Manual
Service Manual
8.73.84
MJFCIFSS
MJFCIFSS
8.73.85
Operator
Mechanic
Inspector
BBT/DISP2
V4.5/V4.5
BBT/DISP2
V4.6/V4.6
Service Manual
Service Manual
8.73.86
MJFCIFSS
Service Manual Control panel
Coding plug
Control panel
1 Coding plug
Fig. 1 Connections between coding plug and keyboard
1 Control panel S2 6 Coding plug X42

2 Microprocessor 7 EEPROM memory for operational data
3 Connection plug X42 8 Coding of machine type
4 Indication display H1
Note!
The control panel of the machine (called BBT from now on) has a coding plug on connection plug
X42. Its purpose is as follows:
1.1 Coding function

15-pin plug X42 detects the type of machine, thanks to the hardware coding. In the absence of a valid
coding plug, the keyboard is not operational.
8.79.1
copyright by
MJFCIFSS
Control panel Service Manual
Coding plug
1.2 Memory function

The coding plug stores current machine data in a data memory (serial EEPROM), as listed below.
Thanks to this method, it is possible to exchange keyboards and re-enter data from the plug into the
new keyboard.
Data stored:
Type of equipment, serial number and settings in menu Set config
Current operating hour
Current operating times (screen i-hours)
Current settings of flow limitation (internal and external values)
Currently selected flow limitation options
Error memory for water level (E502)
Error memory for water temperature (E503)
Error memory for hydraulic oil (E504)
Error memory for hydraulic oil temperature (E505)
Error memory for motor oil pressure (E501)
Confirmed service intervals / service checks
Transfer of data from the keyboard to the coding plug for storage is carried out
automatically, every 30 minutes approx.
It is possible, in addition, to force a copy of the data stored pressing buttons Modeand SF
(see following paragraph) in order to save data to the plug, e.g. before you exchange the BBT .
8.79.2
copyright by
MJFCIFSS
Replacing control panel
2 Replacing control panel
Fig. 2 Printed circuit board A1001, service plug X31 and parameters in display
Note!
Before you replace the panel, you should read the most important parameters of the keyboard in
the display and write them down (i.e. serial no., operating hours, flow limitations, number of opera-
ting errors E5xx in error memory etc. See menus i-hours, i-errors and Set option).
Before you replace the BBT, check the data in the coding plug.
Switch off ignition. Insert green service plug into X31 of board A1001 (ESP01) (see Fig. 2).
8.79.3
copyright by
MJFCIFSS
Secure data in coding plug.
3 Secure data in coding plug.
Fig. 3 Checking keyboard data
Proceed as follows:
Switch off ignition. Insert service plug. Press and hold buttons MODE and SF . Hold buttons
and, simultaneously, turn key on position.
The keyboard will now check its data against the data stored in the plug.
If the data is okay, the display will show the message X42 - OK .
If the keyboard and plug data do not match, the keyboard data will be automatically copied to
the plug. (LEDs of speed adjustment flash running signal).
Finally, a message X42 -OK will appear.
8.79.4
copyright by
MJFCIFSS
Replacing keyboard S2
4 Replacing keyboard S2
Fig. 4 BBT rear view
Be sure to switch off main power switch before you disconnect the connection plug.
Remove connection plugs from keyboard you want to remove. Plug into new keyboard. Plug in
correctly. Secure. (see Fig. 4)
Automatic transfer of data from coding plug to new keyboard
As soon as the control is launched (self-check), the data in the EEPROM are automatically che-
cked. The data stored will then be automatically transferred from the plug to the new keyboard.
Data transfer is indicated by running light signal of the speed adjustment LEDs on the keyboard.
When finished, all the important data listed and essential for operation are available in the new
keyboard.
Checking transferred data in the new BBT:
Call up display menu and compare data indicated with data you wrote down before replacement.
8.79.5
copyright by
MJFCIFSS
Replacing glow bulbs of backlit keyboard
5 Replacing glow bulbs of backlit keyboard
Fig. 5 Layout of glow bulbs in operator keyboard
The backlit keyboard has six glow bulbs (L) underneath upper part of keyboard.
New keyboards are always supplied with two spares.
5.1 For replacement of bulbs, proceed as follows:

Remove keyboard from right-hand control desk.
Remove four M3 Philips screws in the sides of the keyboard housing. Lift off upper part of key-
board.
For safety reasons: Do not disconnect plug connection (S) see Fig. 5 between top and bottom
parts of keyboard.
Pull out old bulb (L) from socket.
Pull spare (E), see Fig. 5, from socket. Or insert spare bulb ID no. 6004408 (see ET spare parts
catalogue) into socket.
Replace upper part of keyboard. Replace four lateral M3 Philips screws.
Replace keyboard into control desk.
8.79.6
copyright by
MJFCIFSS
Service Manual Error code list
Error code list

Engine oil pressure not moni- + 24 V short circuit Check engine oil level, con-
E 002 tored. tact LIEBHERR customer
E 003 Pressure switch B5 Short to ground or wire break service.
E 004 Cooling water level not moni- Short to ground Check coolant level, contact
E 005 tored. + 24 V short circuit LIEBHERR customer service.
Water level sensor B3
E 006 Wire break
E 007 Cooling water temperature Short to ground Check cable.
E 009 not monitored. Signal from PLD Contact LIEBHERR customer
Water temperature sensor B2 + 24V short circuit or wire service.
break
E 010 Hydraulic oil level not monito- Short to ground Check hydraulic oil level, con-
E 011 red. + 24 V short circuit tact LIEBHERR
Hydraulic oil level sensor B14 customer service.
E 012 Wire break
E 013 Hydraulic oil temperature not Short to ground Check cable.
E 014 monitored. +24V short circuit Contact LIEBHERR customer
Hydraulic oil temperature service.
E 015 transducer B8 Wire break
E 016 Gear oil temperature not mo- Short to ground Check radiator for dirt, con-
E 017 nitored. (from A934) + 24 V short circuit tact LIEBHERR customer
Transmission temperature service.
E 018 sensor B15 Wire break
E 022 Diesel engine speed not mo- Short to ground Switch to emergency speed
E 023 nitored; diesel engine speed + 24 V short circuit adjustment S71 and S72 and
cannot be changed through emergency operation of wor-
E 024 keyboard; reduced hydraulic Wire break king pumps Y50,
power contact LIEBHERR customer
Diesel engine speed sensor service.
B12 Emergency operation of wor-
king pumps Y50 (only in PLD
machines).

E 027 Insufficient hydraulic power LR cable fault for perfor- Emergency operation of wor-
Power regulating solenoid mance regulation of the hy- king pumps Y50; contact
Y50 draulic pump LIEBHERR customer service.
E 030 not assigned
E 033 Maximum fan speed EV 5 cable fault of the electric Contact LIEBHERR customer
Fan control Y347 valve for the hydraulic fan service.
control
E 036 Quantity reduction for hy- EVA 1 cable fault for the flow Attachments with flow limitati-
draulic attachments not wor- limitation of the hydraulic on may not be operated. Con-
king. pump tact LIEBHERR customer
Flow limitation Y51 service.
8.80.1
copyright by
MJFCIFSS
Error code list Service Manual

E 039 Quantity reduction for hy- EVA 2 cable fault at the amp- Attachments with flow limitati-
draulic attachments not wor- lifier for the flow limitation of on may not be operated. Con-
king. (A 934 - A 954 only, the second hydraulic pump tact LIEBHERR customer
optional equipment) service.
Flow limitation Y52
E 042 Slewing gear fine control wit- EVA 3 cable fault at valve Contact LIEBHERR customer
hout function Y451 (A 900 C - A 904 C) service.
Monitoring of hydraulic oil Y53 (A 914C-A 924C)
cooling system without fric-
tion
No power reduction at slew- Y103 (A 934C-A 954C)
ing gear
E 045 Insufficient pressure for at- EVA 6 cable fault at electrical Contact LIEBHERR customer
tachment pressure control valve service.
Tool Control Y414
E 046 Diesel engine speed cannot Speed-adjustment servo mo- Switch to emergency speed
be adjusted through key- tor for diesel engine speed adjustment S71 and S72 and
board. faulty. emergency operation of wor-
Speed-adjustment servo mo- king pumps Y50. Contact
tor M5 LIEBHERR customer service.
E 053 Stick cannot be moved Short circuit to ground or wire Connect potentiometer, con-
E 054 Potentiometer R70 break; potentiometer not contact LIEBHERR customer
nected service.
+24V short circuit Switch on emergency actuati-
on.
E 056 Fine adjustment of slewing Short to ground Check pressure switch in left
E 057 gear not responding Wire break pilot control unit.
Pressure sensor B335 Contact LIEBHERR customer
E 058 service.
E 063 Engine power reduced Short to ground Check cabling.
E 065 Intercooling air temperature Wire break Contact LIEBHERR customer
sensor service.
E 070 not assigned
E 072 Error is displayed +24V short circuit Check cabling.
E 073 Intercooling air pressure sen- Wire break Contact LIEBHERR customer
sor service.
E 074 Diesel engine cannot be star- Wire break Check cabling.
E 075 ted. Short to ground Contact LIEBHERR customer
Starter terminal 50 service.
E 078 Error is displayed PLD hardware failure Contact LIEBHERR customer
E 079 PLD software failure service.
E 081 In the event of failure of both Speed sensor Speed1 Contact LIEBHERR customer
E 082 sensors, the engine cannot Speed sensor Speed2 service.
be started.
E 084 Failure of pre-heating and af- Cold start unit Check engine control unit,
ter-heating function +24V short circuit heating flange and wire har-
E 085 Malfunction ness.
Contact LIEBHERR customer
E 086 Wire break service.
E 087 Error is displayed Speed difference between Contact LIEBHERR customer
Speed1 and Speed2 service.
8.80.2
copyright by
MJFCIFSS

E 088 Engine power reduced Fault in ambient air pressure Check wiring and sensor.
sensor
E 089 Machine cannot be started Wire fault Check cabling between engi-
Ware in fuel filter ne control unit and sensor.
E 090 Engine power reduced Short to ground Check cabling between engi-
E 091 Fuel temperature sensor Wire break ne control unit and sensor.
Short to plus
E 098 Error is displayed Fault in cable connection D+ Check alternator and cabling
to PLD electronics to alternator.
E 099 Alternator defective Contact LIEBHERR customer
service.
E 100 Error is displayed Speed signal Speed1 Check speed sensor
E 101 Speed signal Speed2 Check cabling to engine con-
trol unit.
service.
E 102 Engine cannot be started Crank shaft synchronisation Switch ignition off and on.
failed Check speed sensor.
service.
E 103 Error is displayed Speed sensor of cam shaft Check cabling to speed trans-
defective ducer, speed sensor.
E 104 No speed signal at cam shaft Contact LIEBHERR customer
service.
E 105 Engine cannot be started Cam shaft synchronisation Check speed sensor.
failed Contact LIEBHERR customer
service.
E 109 Error is displayed CAN1 hardware failure Check cabling, plugs and
E 110 No Can1 data (timeout) CAN assemblies.
service.
E 111 Error is displayed Injector A1 defective Check cabling, plug and engi-
E 112 Error is displayed Injector A1 BIP fault ne control unit.
E 113 Error is displayed Injector A2 defective service.
E 114 Error is displayed Injector A2 BIP error
E 115 Error is displayed Injector A3 BIP defective
E 117 Error is displayed Injector A4 BIP defective
E 119 Error is displayed Injector B1 BIP defective
E 120 Error is displayed Injector B1 BIP error
8.80.3
copyright by
MJFCIFSS

E 127 Error is displayed Bank1 parameters missing Contact LIEBHERR customer
E 128 Error is displayed Bank2 parameters missing service.
E 135 Error is displayed 5V reference 1 defective

E 137 Error is displayed 5V reference 3 defective service.

E 302 Input through keyboard not No code plug Contact LIEBHERR customer
possible X42 service.
E 303 Diesel engine speed cannot No CAN bus connection bet- Switch to emergency speed
be adjusted through key- ween keyboard and BST prin- adjustment S71 and S72 and
board; reduced hydraulic po- ted circuit board (message is emergency operation of wor-
wer. also displayed, if BST is not king pumps Y50,
ready for operation, e.g. if not emergency operation of wor-
Reduced hydraulic power in powered) king pumps Y50 (only in PLD
PLD machines machines).
service.
E 305 Malfunction, e.g. in travel bra- No CAN bus connection bet- Switch to emergency operati-
ke, slewing gear brake, servo ween keyboard and ESP01 on of servo pressure circuits
steering printed circuit board (mes- S73. Contact LIEBHERR
sage is also displayed, if customer service.
ESP01 is not ready for opera-
tion)
E 306 Malfunction, e.g. in travel di- No CAN bus connection bet- Contact LIEBHERR customer
rection switch, gear shifting ween keyboard and ESP02 service.
system, oscillating axle lo- printed circuit board (mes-
cking mechanism, accessory sage is also displayed, if
kits ESP02 is not ready for opera-
tion)
E 307 Speed adjustment not pos- No CAN bus connection bet- Contact LIEBHERR customer
sible ween keyboard and PLD die- service.
PLD electronics A 700 sel engine regulating unit
(message is also displayed, if
PLD regulator is not ready for
operation)

E 308 No or incorrect display No connection of keyboard to Contact LIEBHERR customer
display; keyboard defective service.
E 309 Software incompatibility bet-
ween keyboard and display
E 314 Diesel engine switches to Time-out of PLD Contact LIEBHERR customer
emergency mode service.
E 315 Error is displayed (A 900 C No CAN bus connection bet- Contact LIEBHERR customer
ZW) ween UEC-HBG and UEC service.
undercarriage
8.80.4
copyright by
MJFCIFSS
Error symbols and indicator lights in combination with error codes

E 319 Diesel engine speed cannot Hardware coding does not Switch to emergency speed
be adjusted through key- match software coding adjustment S71 and S72 and
E 321 board; reduced hydraulic po- No known machine type re- emergency operation of wor-
wer ceived from keyboard king pumps Y50. Contact
Code plug X42 LIEBHERR customer service.
E 322 Hardware coding X44 Unknown hardware coding

E 442 Failure of idle automatic at + 24 V short circuit Deactivate idle automatic
E 443 left joystick, engine remains Short to ground or wire break S20. Call LIEBHERR custo-
at lower speed mer service.
Handle sensor B19L
E 445 Failure of idle automatic at + 24 V short circuit Deactivate idle automatic
E 446 right joystick, engine remains Short to ground or wire break S20. Call LIEBHERR custo-
at lower speed mer service.
Handle sensor B19R
E 450 Engine load at lowering of at- Lowering without pressure Contact LIEBHERR customer
tachment + 24 V short circuit service.
Pressure sensor B145 Short to ground or wire break
E 454 Failure of speed sensor for + 24 V short circuit Contact LIEBHERR customer
E 455 slewing gear drive; Risk of Short to ground or wire break service.
damage to slewing gear bra-
ke (A 934-A 954)
Slewing gear sensor B53
E 456 Fuel level indicator defective Short to ground Check fuel level in tank,
E 458 Tank sensor B39 + 24 V short circuit or wire contact LIEBHERR customer
break service.
1 Error symbols and indicator lights in combination with

error codes
The faults and errors listed below are indicated by symbols on the screen or by indicator lights. The
respective error codes are not displayed in field EC of the operator menu. The only way to read them
is in the list-S-Exxx menu.
Error code Symbol Effect Cause What you can do

E 501 Indicator light H2 on, Diesel engine oil pressure When this light is on, immedi-
buzzer on. too low ately switch the engine to its
lower idle speed and shut it
down.
E 502 Symbol is displayed, Low coolant level Set the engine to low idle
buzzer is on. speed and switch it off after
30 seconds. Find leak and re-
pair.
8.80.5
copyright by
MJFCIFSS

E 503 Symbol and P2 display Overheating of coolant Set the engine to low idle
are on, buzzer is on. speed and switch it off after
30 seconds. Check radiator
for dirt, check coolant level.
service.
E 504 Symbol is displayed, Low hydraulic oil level Set the engine to low idle
buzzer is on. speed and switch it off after
30 seconds. Find leak and re-
pair. Add hydraulic oil.
E 505 Symbol is displayed, Overheating of hydraulic oil Set the engine to low idle
buzzer is on speed and switch it off after
30 seconds. Check radiator
for dirt. Contact LIEBHERR
customer service.
E 506 Symbol is displayed, Oil temperature in pump Set the engine to low idle
buzzer is on distributor gear too high speed and switch it off after
30 seconds. Check hydraulic
oil cooler for dirt.
service.
E 510 Indicator light H23 on, Brake pump flow rate too Set engine into low idle gear.
buzzer on. low or accumulator char- Check brake system.
ging valve defective Contact LIEBHERR customer
Accumulated brake pressu- service.
re
<100 bar
E 511 Symbol is displayed. Overvoltage at BBT Contact LIEBHERR customer
service.
E 512 Problems at start-up of Battery charge too low Contact LIEBHERR customer
hydraulic excavator; Undervoltage at PLD service.
symbol is displayed
E 513 Control system shuts Battery voltage too high Contact LIEBHERR customer
down hydraulic exca- Overvoltage at PLD service.
vator; battery gasses,
symbol is displayed
E 514 Central lubrication sys- Signal to frequency valve Carry out intermediate lubri-
E 515 tem B51 continuous after the set cation.
Lubrication control wit- monitoring time has lapsed Contact LIEBHERR customer
hout function service.
(frequency valve B51)
E 516 Diesel engine cannot Emergency-stop EDC error, Contact LIEBHERR customer
be started, or engine engine control has detected service.
shut-down an internal error
E 517 Diesel engine shuts Injector fault Contact LIEBHERR customer

down; symbol is dis- service.
played
8.80.6
copyright by
MJFCIFSS

E 518 Diesel engine shuts Start synchronisation error Contact LIEBHERR customer
down; symbol is dis- service.
played
E 519 Symbol is displayed, Engine speed warning Contact LIEBHERR customer
buzzer is on threshold exceeded service.
E 520 Diesel engine shuts Engine speed safety thres- Contact LIEBHERR customer
down; symbol is dis- hold exceeded service.
played; buzzer is on
E 521 Diesel engine shuts Both speed sensors Contact LIEBHERR customer
down; symbol is dis- defective service.
played
E 522 Diesel engine shuts Low lubrication oil pressure Contact LIEBHERR customer
down; symbol is dis- - safety threshold exceeded service.
played; buzzer is on engine shutdown
E 523 Symbol is displayed, Engine coolant overheating Let machine cool down, e.g.
buzzer is on (>7 seconds) - safety thres- in F mode; check radiator for
hold exceeded dirt; check coolant level; con-
tact LIEBHERR customer
service.
E 524 Symbol is displayed, Intercooling air overheating Check radiator for dirt.
buzzer is on (>7 seconds) - safety thres- Contact LIEBHERR customer
hold exceeded service.
E 525 Symbol is displayed, Engine fault in emergency Immediately shut down the
buzzer is on mode machine.
service.
E 526 Symbol is displayed, Fuel temperature warning Check radiator for dirt.
buzzer is on threshold exceeded Contact LIEBHERR customer
service.
E 527 Symbol is displayed, Fuel temperature safety Immediately shut down the
buzzer is on threshold exceeded machine. Contact LIEBHERR
customer service
E 528 Symbol is displayed. Water in fuel filter Drain water from water trap.
E 530 Symbol is displayed, Internal error in engine con- Contact LIEBHERR customer
buzzer is on trol unit service.
E 532 Symbol is displayed. Fuel pressure below war- Fuel filter, check tank. Con-
ning threshold tact LIEBHERR customer
service.
E 533 Symbol is displayed. Fuel pressure below safety Shut down machine. Contact
threshold LIEBHERR customer service.
E 534 Symbol is displayed. Fuel pressure warning Contact LIEBHERR customer

threshold exceeded service.
8.80.7
copyright by
MJFCIFSS
Troubleshooting

E 535 Symbol is displayed Fuel pressure safety thres- Contact LIEBHERR customer
hold exceeded service.
E 597 Engine power is redu- Intercooling air temperature Let machine cool down, e.g.
ced; symbol is display- warning threshold excee- in F mode; check radiator for
ed; buzzer is on ded dirt. Contact LIEBHERR cus-
tomer service.
2 Troubleshooting
2.1 Diesel engine and fuel system
Error / fault Cause Remedy

Starter fails to turn Main fuse defective Replace fuse
Battery connections loose or corro- Clean and tighten loose connec-
ded tions
Battery voltage too low Charge or replace battery
Starter circuit open, or contacts cor- Consult LIEBHERR customer ser-
roded vice
Starter defective Consult LIEBHERR customer ser-
vice
Starter turns slowly Battery voltage too low Charge or replace battery
Battery connections loose or corro- Clean and tighten loose connec-
ded tions
Ambient temperature too low Take measurements required for
winter operation
Diesel engine fails to start Fuel tank nearly/completely empty Add fuel and bleed fuel system
Underpressure in the tank Remove tank lid
Fuel filter dirty Clean or change filter and bleed the
fuel system; drain off fuel / clean
tank
Ambient temperature below 0°C For operation and control under ex-
treme conditions, see operating ma-
nual
Heating flange defective (at low Check heating flange; replace, if ne-
temperatures) cessary
Starter failure Check line connections, service
starter
Batteries flat Recharge / replace batteries
8.80.8
copyright by
MJFCIFSS
Troubleshooting

Engine starts, but stops immediately Fuel tank empty (underpressure in Add fuel and bleed fuel system
or runs irregularly tank)
Fuel filter dirty Clean or change filter and bleed fuel
system (tank)
In winter: engine oil viscosity too Use an engine oil that is suitable for
high the actual ambient temperature
Dry air filter dirty Clean or replace main filter element
Air in fuel system Bleed fuel system
Bleeding valve in fuel tank blocked Clean
Fuel line, pre-filter or strainer in fuel Clean and bleed fuel system
tank blocked
Fuel line kinked Check line and repair, if required
Diesel engine emits grey or black fu- Dry air filter dirty Clean or replace filter
mes Injection nozzles jammed or no in- Contact LIEBHERR customer ser-
jection vice
Turbo charger defective Contact LIEBHERR customer ser-
vice
White steam emitted by diesel engi- Water in combustion room Contact LIEBHERR customer ser-
ne vice
Injection too late Contact LIEBHERR customer ser-
vice
Heating flange defective (at low Check heating flange; replace, if ne-
temperatures) cessary
Blue exhaust fumes Oil level too high Correct oil level
Lubricating oil in combustion cham- Contact LIEBHERR customer ser-
ber vice
Crankcase ventilation defective Contact LIEBHERR customer ser-
vice
Diesel engine knocking Combustion problems Contact LIEBHERR customer ser-
vice
Diesel engine knocking Excessive valve play Contact LIEBHERR customer ser-
vice
Injection nozzles damaged or car- Contact LIEBHERR customer ser-
bonised vice
Damaged bearing Contact LIEBHERR customer ser-
vice
Piston ring worn or broken Contact LIEBHERR customer ser-
vice
Diesel engine does not reach full Speed not set to maximum value Set speed to maximum value
speed Injection unit settings incorrect Contact LIEBHERR customer ser-
vice
Dry air filter dirty Clean or replace filter
Insufficient fuel supply Clean or replace fuel filter; check li-
nes, drain water from tank
8.80.9
copyright by
MJFCIFSS
Troubleshooting

Poor diesel engine performance Fuel system defective (blockage, Inspect for leakage, change filter;
leakage) contact LIEBHERR customer ser-
vice
Intercooling pressure too low Visual inspection for loose clamps,
defective seals and damaged ho-
ses; clean air filter
Intercooling air temperature too high Clean intercooling air cooler; con-
(power reduced by engine control tact LIEBHERR customer service
unit)
Coolant temperature too high (po- Check coolant level; check radiator
wer reduced by engine control unit) for dirt, clean if necessary; check fan
and thermostat; consult LIEBHERR
customer service
Fuel temperature too high (power Contact LIEBHERR customer ser-
reduced by engine control unit) vice
Injection nozzles jammed or no in- Contact LIEBHERR customer ser-
jection vice
Diesel engine compression too low Contact LIEBHERR customer ser-
vice
Fault in electronic components Contact LIEBHERR customer ser-
vice
Diesel engine too hot Insufficient amount of coolant Add coolant, check for tightness
Water pump defective Repair
Thermostats fail to work Replace thermostats
Radiator dirty Cleaning radiator
Coolant temperature sensor defecti- Consult LIEBHERR customer ser-
ve vice
Insufficient oil pressure in diesel en- Oil level too low Adjust oil level
gine Oil pressure indicator defective Change oil pressure switch
Note!
Immediately switch off the diesel en-
gine
Diesel engine uses too much oil Leak in diesel engine Retighten screws; replace seals, if
required
Oil in coolant or coolant in oil Consult LIEBHERR customer ser-
vice
Unusual noises / noise at exhaust Leakage in exhaust gas system Check / repair exhaust gas system
side
2.2 Hydraulic system

Unusual noises / noise from Stop valve at the hydraulic tank Open stop cock
hydraulic pumps closed
Note! Hydraulic pumps take in air Check oil level in the hydraulic tank,
Immediately switch off the diesel en- check suction lines for leakage
gine
8.80.10
copyright by
MJFCIFSS
Troubleshooting

Modes E and P show poor perfor- No performance adjustment by Disconnect cable at connection
mance means of proportional solenoid val- Y50, remove cotter pin, set toggle
ve Y50 switch to emergency position
Hydraulic oil temperature too high Radiator dirty Cleaning radiator
Fan or fan control defective Eliminate fault / contact LIEBHERR
customer service.
Hydraulic oil level too low Oil loss Repair leak, replace hoses, add oil
through the return filter
Travel function not available Safety lever moved up Move safety lever down
No direction of travel selected Select the direction of travel using
the travel selection switch in the
right joystick
Pressure switch of parking brake Contact LIEBHERR customer ser-
defective vice
Parking brake not released Release parking brake using the
switch
Parking brake cannot be released Servo pressure OK:
with the switch Actuate emergency function Y6
No servo pressure:
Contact LIEBHERR customer ser-
vice
Working brake applied Release working brake
Slewing gear failure Servo control not working Move safety lever down
Switch on servo control
Slewing gear brake activated Move safety lever down
Release slewing gear brake
No working movement Servo control not working Move safety lever down
Switch on servo control
No servo pressure Contact LIEBHERR customer ser-
vice
No pump high pressure Contact LIEBHERR customer ser-
vice
2.3 Travelling

Machine fails to travel forward or Safety lever moved up Move safety lever down. Release
back Parking brake applied with switch parking brake with switch S16
S16 Preselect direction of travel with
No direction of travel selected switch S30.
Working brake applied with brake Release working brake with the re-
pedal and retainer tainer. Consult LIEBHERR custo-
mer service.
8.80.11
copyright by
MJFCIFSS
Troubleshooting

Machine moves too slowly Incorrect gear ratio reduction with Select different gear ratio reduction,
switch S42. using switch S42.
Creeper speed activated with Deactivate creeper speed with
switch S21. Travel pedal cannot be switch S21.
fully pushed down. Clean cab floor.
Super-Finish activated with switch Deactivate Super-Finish with switch
S354 (if installed). S354 (if installed). Switch off emer-
Emergency control activated gency control and switch machine to
standard operating mode. Contact
LIEBHERR customer service.
2.4 Brake

Warning re. accumulator charge Fault in steering pump Contact LIEBHERR customer ser-
pressure Brake accumulator defective vice
2.5 Electrical system

Battery charging indicator light does V-belt of alternator loose or broken Tighten or replace V-belt
not go off Alternator defective Replace alternator
Batteries not sufficiently charged Batteries defective Replace batteries
Battery connections dirty / oxidised Clean battery connections
Cable loose or defective Connect or replace cable
Failure of indicator light or indicating Incandescent lamp burnt out; indi- Replace defective part
instrument cating instrument defective
Failure of one or more instrument Adapters disconnected or defective; Plug in or change adapter; eliminate
panel functions earth connector disconnected; short cause of short circuit; replace fuse
circuit - fuse blown or reset automatic cut-out
Diesel speed cannot be adjusted th- Idle automatic switch S20 actuated Hold joystick or release switch of
rough keyboard (mode and arrow idle automatic S20
keys) Excavator electronics for speed ad- Changeover to emergency control
justment not working for speed adjustment S71 and S72.
No signal from speed sensor B12 Contact LIEBHERR customer ser-
vice.
Idle automatic without function; Permanent sensor signal Consult LIEBHERR customer ser-
speed fails to drop vice
Switch S20 deactivated Activate switch S20
Servo control cannot be activated Fault in electrical system of excava- Activate emergency operation with
with switch tor switch S73 in the right joystick.
Parking brake cannot be released Caution: The servo and brake circuit
with switch can now only be switched off with
the safety lever. The keyboard is
Slewing gear brake cannot be re- disabled. Contact LIEBHERR custo-
leased with switch mer service.
8.80.12
copyright by
MJFCIFSS
Troubleshooting
2.6 Heating and air-conditioning system

No warm air escaping from heating Stop valves of coolant line on the Open stop valve
system diesel engine closed
Engine not at operating temperature Heat engine to operating temperatu-
re
Heating blower not working No power Check fuse and cable; replace if re-
quired
Blower motor defective Replace blower motor
Low air circulation rate in operator's Ambient air filter / recirculation air fil- Clean air intake openings; replace
cab ter contaminated ambient air filter
Air outlets closed Open air outlets
2.7 Working attachment

Cylinder responds to load Piston seal on cylinder defective Service cylinder
Excessive bearing play in attach- Bearing points worn Replace bearing components
ment
Attachment cannot be rotated, swi- Auxiliary function not activated Release auxiliary function with
velled or operated switch S19
Lines not connected Connect lines
8.80.13
copyright by
MJFCIFSS
Troubleshooting
8.80.14
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
8.82.1
copyright by
MJFCIFSS
Slip ring rotary connection Service Manual
Design
2 Design
(see Fig. 3 on page3)

The base flange 3, adapter ring 1 and the associated slip rings 6/9/10 are fixed to the stator of the oil
rotary connection and thus permanently fixed to the undercarriage.
The bearing disk 2 with the contact bracket holders 14, the shims 143 and the contact brackets 11/
12 is fixed to the rotor of the oil rotary connection, and thus permanently secured 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
8.82.2
copyright by
MJFCIFSS
Design
Fig. 3 Exploded view Slip ring rotary connection
1 Adapter ring 23 Forcing screw

2 Bearing disk (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
8.82.3
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.
3.1 Diagram of slip ring assignment

1 Terminal A1100 printed circuit board
2 Y215 front left individual control
3 Y216 front right individual control
4 Y217 rear left individual control
5 Y218 rear right individual control
6 Y56 changeover blade/outrigger
8 B208 outrigger control
9 Ground
11 Ground
12 Ground
8.82.4
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 1.50/1.51.
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.
8.82.5
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
8.82.6
copyright by
MJFCIFSS
Maintenance
Fig. 5 Sectional drawing of slip ring
8.82.7
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
8.82.8
copyright by
MJFCIFSS
Service Manual Self-holding mechanism for quick-change adapter lok-
Function
Self-holding mechanism for quick-change adapter

locking
1 Function
This kit does not affect the normal operation of the hydraulic quick-change adapter but reduces wear
at the seals of the LIKUFIX coupling system in the event of incorrect operation. This is done with the
self-holding function for locking.
Note!
The self-holding function may only be used for locking. Whether it is activated for locking or relea-
sing depends however on the grapple rotation function. This might vary from machine to machine
and you must therefore check the settings before installing the kit, see Fig. 1.
If the self-holding function is set to be activated during releasing, the pins at the plug connection
X412-1B must be exchanged, (see Exchanging the plug connections on page 5).
2 Normal operation of the hydraulic quick-change adapter
Danger!
Risk of injury!
After the working tool is released, it is fully disconnected from the machine. There is a risk that the
working tool becomes inadvertently dislodged.
Position the working tool as little above the ground as is necessary before starting the release
procedure, in order to avoid dangerous movements.
2.1 Switch S19

The auxiliary hydraulic unit for the grapple rotator and the quick-change adapter is activated with the
switch S19.
Press the switch.
The auxiliary equipment is activated.
The LED in the switch is on.
Press the switch again.
The auxiliary equipment is deactivated.
The LED indicator in the switch is off.
2.1.1 Press the button S47.

The quick-change adapter is activated. The lock pin can now be operated.
Push buttons S5L and S5R

Actuate the push button S5L = lock pin is moved out (locking)
Actuate the push button S5R = lock pin is moved in (releasing)
The push buttons are located at the right and/or left pilot control unit (depending on machine equip-
ment).
8.99.1
copyright by
MJFCIFSS
Self-holding mechanism for quick-change adapter lok- Service Manual
Fig. 1 Push button at pilot control unit
E Actuation button at left pilot control unit C Actuation button at left and right pilot control
(standard model) unit (optional equipment)
G Actuation button at right pilot control unit
(optional equipment)
Quick-change adapter icon

The symbol is displayed
during the release process or
when the lock bolt is retracted.
2.2 Two-hand control / holding function

For safety reasons, the locking/release process is only started when the two control elements are ac-
tuated simultaneously.
With one hand, press the button S47 and, with the other hand, press the button S5L or S5L (two-
hand control).
You can then release the button S47, and continue to operate the locking pin with the buttons S5L or
S5R (holding function).
To change the direction of movement of the lock pin, press the button S47 and then press the button
S5L or S5R respectively.
Note!
For a detailed description of the hydraulic quick-change adapter, refer to group 16 in the service
manual.
The electrical connections are shown in the circuit diagram of group 8.100 ff.
The relay K500 picks up when the valves Y28-1 and Y28-2 are activated. The NO contacts 4 and 5
of the relay K500 are parallel to the NO contacts 13 and 14 of the switch S47. The self-holding func-
tion is actuated with the NO contacts 2 and 3 (K500). The self-holding function is activated as long
as the button S5L is pressed and while the pin 2 of the quick-change adapter board A1017 is powered
through output X413.
As long as the pins 3 is released, it generates a plus signal (+24V) through the proximity switch B26.
This ensures that the switch S47 (contact 13/14) remains only locked during the locking process and
until the pins are fully locked (B26) and the button S5L is released.
8.99.2
copyright by
MJFCIFSS
Installation instructions
Fig. 2 Functional description
4 Installation instructions
Fig. 3 Installation instruction for right console
8.99.3
copyright by
MJFCIFSS
Remove the top cover 1 of the right console, see Fig. 3.

Mount the pinboard A107 (with fixed relay) on the console 2 and plug in the plug connection K500.
Connect the plug connections of the wire harness one by one on the quick-change board A1017.
Connect the other plug connections to the cable harness of the machine, see Fig. 4.
Test the self-holding function, (see Testing of self-holding function on page 5).
Fig. 4 Installation instruction for cable harness
A107 Pinboard (relay) X262 Plug connection / quick-change adapter

A1017 Printed circuit board / quick-change X411 Plug connection on quick-change adap-
adapter ter board
K500 Relay (ST2) of quick-change adapter for X412 Plug connection on quick-change adap-
self-holding function ter board
K500 Plug connection to relay X412-1B Plug connection
V197 Blocking diode X412-1S Plug connection
V198 Blocking diode X413 Plug connection on quick-change adap-
ter board
8.99.4
copyright by
MJFCIFSS
4.1 Testing of self-holding function
Caution!
To prevent damage to the machine and the LIKUFIX coupling system, you must test the operation
of the two-hand control.
The bolt may only be released 3 when the button S47 is pressed. This ensures pressure release of
the hydraulic system during the coupling process.
Retract the pins 3 of the hydraulic quick-change adapter half-way, by pressing the button S5R (re-
leasing).
The buzzer sounds.
Press only the button S5R again (releasing).
If the pins 3 continue to be released while the button S47 is NOT pressed, there is a malfunc-
tion.
If the pins 3 remain locked while the button S47 is NOT pressed, the system is working pro-
perly.
Fig. 5 Testing of self-holding function
If the above malfunction occurs, exchange pin 1 and pin 2, (see Exchanging the plug connec-
tions on page 5).
Fault detection:
.

The pins 3 continue to be released The self-holding function is applied Exchange pin 1 and pin 2 at the plug
while the button S47 is NOT to the release function. connection X412-1B and test the
pressed. This results in a malfunction. system again.
The pins 3 are not being released The self-holding function is applied Actuate S47 and fully release the
while the button S47 is NOT to the locking function. pin 3.
pressed. The system works properly. As soon as the buzzer is activated,
locking is always possible without
actuating the button S47.
4.2 Exchanging the plug connections

If test reveals that the self-holding function is applied during the release process, proceed as follows:
Disconnect the pins 1 and 2 from the plug connection X412-1B, using a suitable tool (see tools in
group 2.06).
Exchange the pins 1 and 2 and reconnect them.
The self-holding function applies now to the locking process.
8.99.5
copyright by
MJFCIFSS
Test self-holding function again.
Fig. 6 Exchange of pins
8.99.6
copyright by
MJFCIFSS
Service Manual Directory of electric kits
Directory of electric kits
Chapter Group Type
Magnet systems 8.101 A 904 C Litronic 30580

Generator drive hydraulic LIKUFIX 8.102 A 904 C Litronic 30580
Hydraulic cab elevation 8.103 A 904 C Litronic 30580
Automatic central lubrication system 8.104 A 900 C Litronic 24677
A 904 C Litronic 30580
Lifting boom when grapple closes 8.105 A 900 C Litronic 24677
Travel alarm systems 8.106 A 900 C Litronic 24677
Overload warning system 8.107 A 900 C Litronic 24677
Stick cylinder shut-down 8.108 A 900 C Litronic 24677
Industrial shut-down proximity switch 8.109 A 900 C Litronic 24677
Quick-change adapter 8.110 A 900 C Litronic 24677
Back-up alarm system 8.111 A 904 C Litronic 30580
Joystick steering 8.112 A 900 C Litronic 24677
Individual control 4-point support 8.113 A 904 C Litronic 30580
Individual control 4-point support 8.114 A 900 C Litronic 24677
Outrigger control 8.115 A 900 C Litronic 24677
4-wheel steering 8.116 A 900 C Litronic 24677
8.100.1
copyright by
MJFCIFSS
Directory of electric kits Service Manual
Travel forward/reverse in left handle 8.117 A 900 C Litronic 24677

Auxiliary heating 8.118 A 900 C Litronic 24677
Stroke limitation 8.119 A 900 C Litronic 24677
Changeover valve 8.120 A 900 C Litronic 24677
Mower rake 8.121 A 900 C Litronic 24677
Rotating stick with changeover valve 8.122 A 900 C Litronic 24677
AHS12 changeover 8.123 A 900 C Litronic 24677
Puritech particle filter 8.124 A 900 C Litronic 24677
Grab control 8.125 A 904 C Litronic 39333
Individual control with dozer blade 8.126 A 904 C Litronic 30580
Boom cylinder protection 8.127 A 900 C Litronic 24677
Pipe layer 8.128 A 900 C Litronic 24677
8.100.2
copyright by
MJFCIFSS
Service Manual
SUBGROUP - INDEX
Section Group Type
Slewing gear mechanism 9.10.1 A 900 C-LI 14675-

A 904 C-LI 16000-
Slewing gear brake 9.20.1 A 900 C-LI 14675-

A 904 C-LI 16000-
9.1
MJFCIFSS
Service Manual
9.2
MJFCIFSS
Service Manual Slewing gear mechanism
Function
Slewing gear mechanism
1 Function
The two-stage planetary gear is driven by the FMF hydraulic oil motor to which it is connected with a
flange.
Through the attached output shaft and the internally toothed slewing ring, it turns the uppercarriage
on the undercarriage of the machine.
The wet multi-disc brake integrated into the gearbox acts directly on 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

Slewing gear mechanism Service Manual
General information
Machine A 900 C-Li A 904 C-Li

Slewing gear type Sat 225 / 229
Max. drive speed 2550 min-1
Max. output torque 5600 Nm
Gear ratio 1: 31,7
Weight (approx.) 130 kg
Oil volume in gearbox 5.0 l
Oil quality API - GL - 5
Oil viscosity SAE 90 W
(with pedal-operated positioning brake) SAE 80 W 90
SAE 90 LS
Brake Hydraulically released multi-disc brake
Min. release pressure 20 bar
Max. release pressure 33 bar

see Fig. 7
The input torque is transferred from the hydraulic oil motor 97 to the sun gear 5. Through the
planetary gears 10 and the planetary carrier 15, the sun gear 5 drives the sun gear 6 at the oil motor
speed geared down by planetary stage I.
Through the planetary gears 11 and the planetary carrier 16, the sun gear 6 drives the output
shaft 17 at the 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 at the same rate.
3.1 Function of lubricating system
Fig. 2 Lubricating system at slewing gear
2 Housing 115 Screw

13 Oil tank 135 Drain valve
26 Lubricant cap 140 Distribution block
100 Lubrication nipple
The lubricant cap 26 on the housing 2 covers the pinion of the drive shaft to the connection of the
slewing ring. The cap 26 is connected through the distribution block 140 of the central lubrication
system from where it is filled with grease. Every time the uppercarriage is rotated, grease is applied
onto the gearing of the pinion and slewing ring.

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.

Installation and dismantling of the slewing gear mechanism
5 Installation and dismantling of the slewing gear mechanism
see Fig. 2
Fig. 3 Slewing gear mechanism in the slewing ring
5.1 Dismantling
Prior to dismantling the mechanism, release all pressure from the pressure, leak oil and brake
lines.
Place assembly onto the floor.
Remove the protective cap of the drain valve 135 .
Mount the oil discharge hose (included in delivery) and drain the gear oil into a suitable container.
Remove the oil discharge house and mount the protective cap of the drain valve 135.
Remove parts and hydraulic lines that impede the dismantling of the gearbox.
Disconnect the pressure, leak oil, lubricating and brake lines at the oil motor and the gear box.
Remove the screws 115 and lift the gearbox from the uppercarriage, using suitable lifting tackle.
5.2 Installation
Apply anti-corrosion grease (Optimol Paste White Id-Nr. 8500307) to the area near 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 upper carriage.
Insert the screws 115 and tighten with the prescribed torque.
Connect the brake, leak oil, lubrication and pressure lines to the gearbox and the 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.
Inspect the gear and pinion mesh in the slewing ring for leakage and complete a function test.
Add grease through the separate lubrication nipple and bleed the central lubrication system.
Replenish or replace grease packing of the slewing ring lubrication through the lubrication
nipple 100 and the distribution block 140.

Sealing of gearbox
Check lubrication of the gearing.
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/Allen 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. 3 Tightening torques
6 Sealing of gearbox
Fig. 4 Seals at slewing gear mechanism
5 Sun gear 25 Brake housing

20 Sun wheel 61 Allen head screw
Note!
The work described below can be completed while the gearbox is mounted.
6.0.1 Please note:

Prior to the installation, clean all parts to be reused and inspect them carefully for damage.
Prior to installation, apply a little oil or grease to all sealing elements.

Sealing of drive motor section
7 Sealing of drive motor section
Remove all lines that impede access to the gearbox.

Leak oil and control lines at the oil motor may remain connected.
Remove the screws 62 and lift the oil motor from the gearbox.
Replace the O-ring of the oil motor.
Place oil motor in the gearbox.
Insert the screws 62 and tighten with the prescribed tightening torque, see Tab. 3.
Note!
For detailed instructions regarding the above sealing work, refer to chapter "Repair of brake" in
subgroup "Slewing gear brake". See group 9.20 "Repair of brake".
Fig. 5 Installation position of slewing gear and lubricating system
10 Slewing gear 25 Extension

11 Grease filter 31 Hose
13 Oil tank 35 Valve
20 Sealing ring 40 Hex head screw
21 Allen head screw 45 Retaining washer

Exploded view
8 Exploded view
Fig. 6 Exploded view
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 Disc 900 Repair kit / brake
57 Tapered roller bearing 910 Seal kit / swing drive
58 Tapered roller bearing 960 Brake disc set

Sectional drawing
9 Sectional drawing
Fig. 7 Sectional drawing of slewing gear mechanism

Sectional drawing
2 Output shaft 58 Tapered roller bearing

10 Planetary gear 62 Hex head screw
11 Planetary gear 63 Allen head screw
15 Planetary carrier 64 Disc
17 Output shaft 66 Retaining washer
20 Sun wheel 70 Snap ring
25 Brake housing 71 Snap ring
26 Grease cap 73 Snap ring
30 Annular piston 82 O-ring
31 Locking ring 83 O-ring
35 Thrust plate 84 O-ring
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 97 FMF oil motor
46 Stop washer 98 O-ring
47 Slotted nut 115 Allen head screw
49 Disc 135 Valve
57 Tapered roller bearing

Service Manual Slewing gear brake
Description
Slewing gear brake
1 Description
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 pressed
together by the preload force of the pressure springs 43 / 44 (force closure) and are released when
pilot pressure is applied to the annular piston 30 located opposite the pressure springs.
1.2 Solenoid valve Y7

The solenoid valve Y7 is integrated into the control oil unit 50.
In neutral position, the solenoid valve connects the chamber K through port A3 to the tank (brake
applied).
In working position, the solenoid valve connects the chamber K through port A3 to the pilot pressure
(brake released).
Fig. 1 Slewing gear mechanism with control oil unit

Slewing gear brake Service Manual
Description
1.3 A 1001 printed circuit board

This printed circuit board controls the solenoid valve Y7 (Fig. 1) via the performance amplifier V4.
When the printed circuit board receives signal "Brake released" via CAN-BUS 2 from the control
panel, the amplifier is switched so that the output to the solenoid valve Y7 (Fig. 1) is powered.
For details of the components and layout of the A 1001 printed circuit board see "Components of the
electric system").
Fig. 2 Mounting position of A1001 printed circuit board
1.4 Function and control of slewing gear brake system
Fig. 3 Push button S17 at the control console

Description
1.5 Operation of the brake

In models A 900 C and A 904 C, the brake is controlled directly by means of button S17.
Fig. 4 Direct control
Position A = brake applied = LED on = Y7 in neutral position = brake applied

Position B = brake released = LED off = Y7 powered = brake released

Hydraulic diagram
2 Hydraulic diagram
30 Hydraulic pump / pilot control A1001-X3 Plug connection / 10-pin

50 Control oil unit A1001-X6.1 Plug connection / 6-pin
190 Slewing gear motor A1001-V4 Amplifier / slewing gear brake
195 Slewing gear brake A1100
196 Slewing gear mechanism A1100-F8 7.5 A fuse
A1001 A1100-H53 Yellow LED / power supply
A1001-H7 Green LED / input signal A1100-X232/2 Plug connection to control
console CS right
A1001-H8 Red LED / fault A1100-X246/3
A1001-H9 Yellow LED / output signal Y7 Solenoid valve / slewing gear

Repair of brake
3 Repair of brake
3.0.1 Sealing of brake and replacement of brake discs

Noisy operation and/or poor braking action
indicate that the lining surfaces are worn.
Replace lining discs without delay.
Note!
We recommend replacing the entire disc pack. The brake can be repaired without dismantling the
gear.
Caution!
Before carrying out a repair of the brake, take all necessary safety measures to protect persons and
equipment, such as ensuring that the machine is standing on a level surface, or, if positioned on a
slope, is properly secured. Release the pressure in the brake oil system.
Fig. 6 Section of the slewing gear mechanism of the "SAT slewing gear mechanism" subgroup
3.0.2 Dismantling of oil motor and the brake housing 25

Remove all lines that impede access to the gearbox.
Remove the mounting bolts of the oil motor and pull the oil motor with the flange-connected
hydraulic lines from the gearbox.
Remove the brake line from the gearbox.
Remove the Allen head screws 61.
Remove the entire brake housing 25 from the sun wheel20

Repair of brake
3.0.3 Dismantling of the brake housing 25
Caution!
The locking ring 31 and the annular piston 30 are spring-loaded.
Risk of injury
Hold locking ring when topping out the snap ring 73.
Top out the snap ring 73, release the device and remove it.
Remove the entire brake piston 30 and the pressure springs 43 / 44. Pull O-ring 82 and lip
seal 88 with backing rings from the brake housing 25.
Push the locking ring 31 from the annular piston 30 and remove the lip seal 89 with backing ring.
Remove the front thrust plate 35, the brake discs 36 / 37 and rear thrust plate 35 from the sun
wheel 20.
Fig. 7 Sectional drawing of the brake housing 25 , rotated by 90°

Repair of brake
3.0.4 Installation of the brake housing 25, see Fig. 7

Prior to the installation, clean all parts to be reused and inspect them carefully for damage.
Mount the rear thrust plate 35 in the sun wheel 20.
Mount the outer and inner discs 37 / 36 in the following sequence:
Outer disc - inner disc - outer disc, etc.
Mount the front thrust plate 35 on the last outer disc.
Insert the lip seal 89 with backing rings into the locking ring 31.
Insert the lip seal 88 with backing rings into the brake housing 25.
Note!
Mount backing rings to non-pressurised side.
Before mounting, apply a little grease onto the lip seal.
Before mounting, apply a little grease onto the O-ring 82 .

Mount the O-ring 82 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.
Top in the snap ring 73 (ensure proper seat).
Remove the mounting device.
3.0.5 Mounting of brake housing 25 and slewing gear motor, see Fig. 6 / Fig. 7
Replace the O-ring at the oil motor and the O-ring 84 at the brake housing. Before mounting the
rings, apply a little oil to them.
Insert the complete brake housing 25 into the sun wheel 20 and secure it with the screws 61 with
washer 66.
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 brake line to the gearbox.
Test brake function, (see Function and control of slewing gear brake system on page 2)

Repair of brake

Service Manual
SUBGROUP - INDEX
Section Group Type
Slewing ring 10.10.1 A 900 C-LI 14675-

A 904 C-LI 16000-
1.1
MJFCIFSS
Service Manual
1.2
MJFCIFSS
Service Manual Slewing ring
Design and function
Slewing ring
1 Design and function
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.
To turn the uppercarriage, the slewing gear mechanism engages with the involute internal teething
of the slewing ring.
Fig. 1 Slewing ring mounted in undercarriage with sectional drawing
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
10.10.1
copyright by
MJFCIFSS
Slewing ring Service Manual
Technical data
lubrication system at regular intervals, see also inspection and maintenance schedule for group 3.
2 Technical data
Machine A 900 C - ZW Litronic A 900 C - ZW Litronic

Tilting play
Factory play 0.6 mm
Max. play 1.5 mm
Maximum tooth backlash 1.4 mm
Weight of uppercarriage
Without attachment kg 8500 - 9000
With attachment kg 11250 - 13500
Tightening torques
Mounting bolts M 20
Quality 10.9 560 Nm

Tilting play
Factory play 0.6 mm 0.6 mm
Max. play 1.5 mm 1.5 mm
Maximum tooth backlash 1.4 mm 1.4 mm
Without attachment kg 8550 9360
With attachment kg 12100 - 13000 13800 - 14600
Tightening torques
Mounting bolts M 20 M 20
Quality 10.9 560 Nm 560 Nm

Type 1002 1003/1004/1005/1071
Tilting play
Without attachment kg approx. 9000 approx. 9000 - 11000
With attachment kg approx. 16300 - 19200 approx. 14800 - 24300
Tightening torques
10.10.2
copyright by
MJFCIFSS
Measuring of clearance

Type 1002 1003/1004/1005/1071

Type 1044/1045 1047/1048/1049/1050/1051
Tilting play
Without attachment kg approx. 10000 approx. 10000 - 12000
With attachment kg approx. 21000 - approx. 21500 - 25500
23000
Tightening torques
3 Measuring of clearance
Fig. 2 Measuring of tilting play a and tooth backlash b (tooth impression in lead sheet)
3.1 Tilting play measurement
3.1.1 Factory tilting play

Maximum play of a new installed bearingsee Tab. 1).
10.10.3
copyright by
MJFCIFSS
Measuring of clearance
3.1.2 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.
3.1.3 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.
Apply the slewing gear brake.
Place the attachment on the ground.
Move the magnetic base holder at the uppercarriage to a suitable position.
Note!
In order to prevent faulty measurements, ensure that the magnetic-base holder is properly secured
in its position.
Before mounting the holder, carefully clean the respective area.
Mount the dial gauge in a position that is in line with the attachment on the slewing gear (see Fig.
2).
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.
3.2 Measuring of tooth backlash
3.2.1 Tooth backlash

corresponds to the tooth backlash occurring for various reasons when a new bearing is combined
with a new pinion.
10.10.4
copyright by
MJFCIFSS
Dismantling
3.2.2 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
4 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.
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. 4.
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.
10.10.5
copyright by
MJFCIFSS
Installation
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.
5 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.
Observe the prescribed tightening torque.
5.1 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. 3.
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. 3).
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. 2).
10.10.6
copyright by
MJFCIFSS
Installation
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. 3 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.
Fig. 4 Correct attachment of lifting tackle for the lifting of the uppercarriage
10.10.7
copyright by
MJFCIFSS
Installation
10.10.8
copyright by
MJFCIFSS
Service Manual
SUBGROUP - INDEX
Section Group Type
2 HL 100 transmission 11.10.1 A 900 C-LI 14675-

A 904 C-LI 16000-
2 HL 290 transmission 11.12.1 A 900 C-LI EDC 24677-

A 904 C-LI EDC 30580-
A 914 C-LI 35112-
A 924 C-LI 34519-
HBGV block for 2 HL 100 transmission 11.30.1 A 900 C-LI 14675-

A 904 C-LI 16000-
HBGV block for transmission 2 HL 290 11.35.1 A 900 C-LI EDC 24677-
A 904 C-LI EDC 30580-
A 914 C-LI 35112-
A 924 C-LI 34519-
11.1
MJFCIFSS
Service Manual
11.2
MJFCIFSS
Service Manual 2 HL 100 transmission
Function
2 HL 100 transmission
1 Function
The 2 HL 100 transmission is attached to the undercarriage. It distributes the drive force from the 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 offroad gear must be manually selected.
The input system, shift lock and the output elements are attached to the gearbox.
Fig. 1 2 HL 100 transmission
A 900 C-LI 14675- 11.10.1

MJFCIFSS
2 HL 100 transmission Service Manual
General information
Machine A 900 C Li A 904 C Li

A 900 C Li A 904 C Li
Speeder Speeder
Transmission type 2 HL 100 2 HL 100
Max. drive power (*) 110 kW 110 kW
Input torque at P max. 650 Nm 650 Nm
5 brake discs 5 brake discs
Max. input torque (*) 770 Nm 770 Nm
Max. input speed (*) 4500 min-1 4500 min-1
Gear ratio
1st gear 5.35 5.35
2nd gear 1.39 1.39
Weight 140 kg 140 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 in gear pump 36 l/min 36 l/min
30
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, approx. 32 bar approx. 32 bar
104
Brake backpressure
Pressure-relief valve 63 12.5 bar 12.5 bar
(Measuring point 65)
Shifting pressure of pressure
switch B10 25 ± 2.5 bar 25 ± 2.5 bar
Shift lock pump pressure (pres-
sure-relief valve 74)
at max. input speed 6 - 8 bar 6 - 8 bar
at shift speed 2.0 - 2.6 bar 2.0 - 2.6 bar
Shift lock on-road gear/offroad gear
Switching speed 800 ± 100 min-1 800 ± 100 min-1
(drive shaft / oil motor)
Switching speed 575 ± 70 575 ± 70
(drive shaft / universal joint) min-1 min-1
(*) maximum permissible value
11.10.2 A 900 C-LI 14675-

MJFCIFSS
Description
3 Description
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 by spring force (disc springs) and hydraulically released (control pressure).
When in on-road gear, the multi-disc brake is hydraulically released, and the multi-disc clutch is me-
chanically engaged. In offroad 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.
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 vent 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. For this purpose, the machine is equipped with a spool
pressurised 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 offroad 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.
A 900 C-LI 14675- 11.10.3

MJFCIFSS
Description
3.1 Design of transmission
1 Connecting flange / regulating motor 8 Control pressure rotary-type pump

2 Shifting pressure accumulator 9 Spur gear
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 A 900 C-LI 14675-

MJFCIFSS
Operation of the machine
4 Operation of the machine
4.1 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.
Fig. 3 Control console and right pilot control unit
4.2 Gear preselection, see Fig. 3

The on-road gear is automatically selected.
The 1st gear / offroad gear is preselected at the switch S42 located on the right console beside the
operator's seat.
When the switch S42 is activated, the LED in the switch is on (offroad gear preselected). The gear
shift initiated by the switch S42 is activated by solenoid valve Y55 located on the HBGV block.
The gear is automatically shifted from on-road to offroad, 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.
4.3 Preselection of travel direction, see Fig. 3

Preselect the travel direction at the preselection switch S30 located in the right pilot control unit.
The selected travel direction is indicated on the main display screen with F for forward and R for re-
verse).
Reversing (i.e. switching from forward to reverse motion and back) is possible in both gears.
A 900 C-LI 14675- 11.10.5

MJFCIFSS
Braking
5 Braking
Fig. 4 Switch S16 and indicator light H20
Caution!
The parking brake may not be applied during work. During work, apply the working brake (pedal 2
to the right of the steering column) and lock it with the locking device 1.
By applying the parking brake (multi-disc brake 87 - see hydraulic diagram) with switch S16, the ma-
chine is secured against inadvertent rolling-off when parked. When the parking brake is applied, the
LED in the switch S16 is on (see Fig. 4).
By applying the parking brake, the opened pressure switch B10 (see hydraulic diagram) automatical-
ly disconnects the electric mass and connection to the solenoid valves for the travel direction prese-
lection, so that the machine cannot be moved when the brake is applied (see also electrical system).
Note!
The brake is designed as a parking brake and may only be applied when the machine is standing
still.
When parking on slopes, we recommend securing the vehicle with wedges, in addition to the par-
king brake.
5.1 Parking of the machine

Turn the ignition key of the machine to position 0 and remove it.
This automatically closes the couplings 87 (brake see hydraulic diagram) and 93 (1st gear
see hydraulic diagram).
11.10.6 A 900 C-LI 14675-

MJFCIFSS
Towing of the machine
6 Towing of the machine
Note!
The machine may only be towed if absolutely necessary. When towing the machine, please note:
max. towing speed = 5 km/h
max. towing distance = 10 km
6.1 Towing with running diesel engine
Fig. 5 Bottom view of HBGV block and gear system
Before towing the machine, ensure that the gear is supplied with pilot control oil.
Release the parking brake with switch S16 (Fig. 4) (indicator light H20 is off - Fig. 4)
If there is no battery voltage, and in the event of an electric failure, turn in the t-handle screw at the
HBGV block 60 to set the brake valve 61 to its working position.
6.2 Towing with switched-off diesel engine, see Fig. 5

Disconnect the gear drive and brake from the output.
Release the lever 108 of the gear-shift fork with the hex head screw 109.
Set to OFF position (arrow).
Secure the lever 108 with the hex head screw 109 in its turned position.
Caution!
The parking brake is disabled while the machine is being towed. When diesel engine is shut down,
the working brake can 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 stiff).
The machine may only be towed away from the danger zone but not any further!
A 900 C-LI 14675- 11.10.7

MJFCIFSS
Maintenance
7 Maintenance
All maintenance work must be carried out according to the inspection and maintenance schedule and
the instructions in this operating manual.
Caution!
For all inspection and maintenance work on the gear system, adhere to the relevant safety and ac-
cident prevention regulations for powertrains and earth moving machinery. For detailed instruction,
see the safety instructions.
8.1 Parking
Power circuit interrupted (ignition off) Multi-disc brake 87 and multi-disc clutch 93
closed by disc springs 90 / 91
8.2 Braking
Switch S16 operated Multi-disc brake 87 and multi-disc clutch 93
closed by disc springs 90 / 91
8.3 On-road gear

Switch S42 not operated Brake 87 (outside) released by control pressure,
clutch 93 (inside) closed by disc springs 91
8.4 Offroad gear

Switch S42 operated Brake 87 (outside) closed by disc springs 90,
clutch 93 (inside) opened by control
pressure
8.5 Function of parking brake

Diesel engine off:
No control pressure from the control oil unit 50
Multi-disc brake 87 and multi-disc clutch 93 (1st gear) closed by disc springs 90 / 91
Diesel engine on:
Switch S16 in brake position (LED on)
Brake valve 61 in neutral position, thus no pressure at connection A P1 B and brake 87
Multi-disc brake 87 and multi-disc clutch 93 (1st gear) closed by disc springs 90 / 91
Pressure switch B10 closed, indicator light H20 on
Machine cannot be moved
Braking machine when in motion:
11.10.8 A 900 C-LI 14675-

MJFCIFSS
Switch S16 in brake position (integrated lamp on)

Brake valve in neutral position
Pressure in the piston chamber of the multi-disc brake 87 via shift lock 70 connection B, shifting
piston 75 connection P1, rotary connection 322, HBGV block 60 connection A shift valve 62 and
brake valve 61 to backpressure valve 63 reduced to zero
Slow closing of brake by piston with preloaded pressure spring of accumulator 102, restrictor ef-
fect of valve 100 and preload of valve 63
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
8.6 Gear function and power flow

On-road gear / 2nd gear (no preselection with switch S42):
Multi-disc brake 87 is released
Multi-disc clutch 93 is closed
The sun gear 83 and hollow gear 86 are driven via the closed clutch 93 together by the oil motor
210 through the drive shaft 82.
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 lower speed (speed reduction) and
drives the axles, and thus the drive wheel of the machine, via the drive flange 99 and the flange-
connected universal joint shafts.
Offroad gear / 1st gear (preselection with switch S42):
Multi-disc brake 87 is closed
Multi-disc clutch 93 is released
The sun gear 83 is driven by the oil motor 210 via the drive shaft 82. The planetary carriers 84 roll
on the stationary hollow gear 86 through the closed multi-disc brake 87.
The planetary carrier 85 drives the sliding sleeve 95 via the jaw clutch 96 and the helical gear 97.
The larger helical gear 98 meshing with the gear 97 rotates at lower speed (speed reduction) and
drives the axles, and thus the drive wheel of the machine, via the drive flange 99 and the flange-
connected universal joint shafts.
The second speed reduction of the planetary drive / spur drive results in a high reducing gear ratio,
(see Technical data on page 2).
8.7 Function of shift lock

The shift lock 70 protects the gear system and the hydraulic motor against excessive speed, which
might occur when the drive change from on-road to offroad gear while travelling at relatively high
speed. 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 offroad speed is not possible. The preselected offroad 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 offroad gear. The on-road gear can be chosen at any
speed.
8.8 Leakage check valve 72

If the offroad gear is preselected, the leak oil from the shifting piston 75 and the check valve 73 (of
pressure side P2) is fed through the leakage check valve 72 to tank P1. The valve 72 also blocks off
the control pressure to the multi-disc brake 87 when the machine is driven in on-road or offroad gear.
A 900 C-LI 14675- 11.10.9

MJFCIFSS
8.9 Shuttle check valve 73

If the offroad gear is preselected, the shuttle check valve 73 blocks the flow from P2 to P1. If the ma-
chine is in on-road gear and moves at a speed above the shifting-down point, it blocks the flow from
P1 to P2.
8.10 Pressure-relief valve 74

The pressure-relief valve 74 protects the lubricating pump 71 against pressure above 6 to 8 bar. It
opens only, if the machine is moving above the shifting-down point, i.e. the pressure required to ope-
rate the shifting piston 75 and thus the shifting-down point, are determined by the backpressure at
the orifice 77 for the lubricating oil supply.
8.11 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 determine 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 offroad gear
High speed high flow high backpressure shifting piston in working position machine can only
be shifted to on-road gear shifting to offroad gear locked
8.12 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.
8.13 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.
If the piston is in neutral position, there is oil flow from P1 B or P2 K so that the machine can be
shifted between on-road and offroad gear.
If the offroad gear is chosen, the shifting piston 75 remains in neutral position, as the shifting pressure
P2 and the spring force are higher than the pump pressure.
It is thus possible to shift the machine up to on-road gear.
11.10.10 A 900 C-LI 14675-

MJFCIFSS
8.14 Diagram of gear - hydraulic system
Fig. 6 Diagram of transmission and shift lock
B to multi-disc brake 60 from HBGV block

E Leal oil control circuit 70 Shift lock
J Measuring point on-road gear 71 Lubricating oil pump
K to multi-disc clutch 71.2 Suction filter (maintenance-free)
L Measuring point pump pressure 72 Leakage check valve
M Measuring point offroad gear 73 Shuttle check valve
P1 from HBGV block 74 Pressure-relief valve
P2 from HBGV block 75 Shifting piston
S Suction chamber / pump 76 Check valve
a Output 77 Orifice
b Shut-off mechanism 87 Multi-disc brake
c Hydraulic motor 93 Multi-disc clutch
d Oil supply transmission control 100 Restrictor check valve
e Oil supply transmission 101 Restrictor check valve
f Transmission 102 Accumulator
g Shift lock
A 900 C-LI 14675- 11.10.11

MJFCIFSS
8.15 Machine in on-road gear (2nd gear)
Control oil
Function /
Input speed to Function / shift lock
transmission
connection
800 min-1 to Gear pump 71 delivers a specific

max. min-1 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
B via external line to mul-

ti-disc brake. Brake re-
leased
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 offroad 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 con-
nection B, i.e. 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 into offroad 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
11.10.12 A 900 C-LI 14675-

MJFCIFSS
Fig. 7 Hydraulic diagram and sectional drawing of the transmission during travel in on-road gear
at high speed
A 900 C-LI 14675- 11.10.13

MJFCIFSS
8.16 On-rod gear (1st gear) preselected with switch S42
Function /
Input speed Function / shift lock
transmission
800 min-1 to Gear pump 71 delivers a spe-

max. min-1 cific oil volume
Pump pressure Pp max. 8.0

bar
Spool 75 in working position
P2 Shifting pressure Sp over

shifting piston 75 and shuttle
check valve 73; valve 73 also
blocks connection to P1
via external line to mul-

B ti-disc brake. Brake re-
leased
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
min-1
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
11.10.14 A 900 C-LI 14675-

MJFCIFSS
offroad gear preselected
A 900 C-LI 14675- 11.10.15

MJFCIFSS
8.17 Offroad gear (1st gear) preselected with switch S42
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
P2 Shifting pressure Sp over
shifting piston 75 (open edge
of control spool)
K via external line to mul-
ti-disc brake. Clutch re-
leased
Gear ratio of planetary

drive = 1:3.87
(1st gear)
Valve 72 blocks the connec-

tion to point B.
Point B is connected via the
shifting piston 75 (open edge Multi-disc brake de-
of control spool) and connec- pressurised, brake ap-
tion P1 to the tank. plied

71 Lubricating oil pump B to multi-disc brake
71.2 Suction filter (maintenance-free) K to multi-disc clutch
72 Leakage check valve P1 from HBGV block
74 Pressure-relief valve Pp Pump pressure
78 to lubricating oil supply
11.10.16 A 900 C-LI 14675-

MJFCIFSS
Fig. 9 Hydraulic diagram and sectional drawing of the transmission during travel in offroad gear
A 900 C-LI 14675- 11.10.17

MJFCIFSS
8.18 Inspection of transmission
Fig. 10 Measuring points at the transmission and HBGV block
Note!
The inspection must be carried out while the machine is at operating temperature and the diesel
engine running at high idle speed.
8.18.1 Checking the release pressure of the clutch, see Fig. 10
Preselect on-road or offroad 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).
8.18.2 Checking the backpressure of the brake, see Fig. 10

Apply the brake with switch S16 and measure the pressure at the measuring point 65, (see Tech-
nical 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.
Screw in = Increase pressure
Screw out = Reduce pressure
After the pressure has been adjusted, tighten the lock nut and replace the protective cap.
11.10.18 A 900 C-LI 14675-

MJFCIFSS
8.19 Arrangement of the units
Fig. 11 Working pumps 20 and control oil unit50
20 Axial piston variable-displacement pump 51 Pressure-relief valve

30 Gear pump 52 Pressure filter
49 Measuring point 54 Accumulator
50 Control oil unit
Fig. 12 HBGV block 60
60 HBGV block 66 Check valve

63 Backpressure valve B10 Pressure switch
64 Accumulator Y6 Brake valve
65 Measuring point Y55 Shift valve
A 900 C-LI 14675- 11.10.19

MJFCIFSS
1 Hydraulic tank (*) 85 Planetary carrier

2 Breather filter (*) 86 Hollow gear
3 Stop cock (*) 87 Multi-disc brake (with 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
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
54 Accumulator (*) 101
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 6 x (*)
release pressure
66 Check valve 400 to compact brake block
70 Shift lock, complete A1100 ESP 02 printed circuit board (X)
71 Gear pump B10 Pressure switch / parking brake (X)
71.2 Suction filter H20 indicator light of parking brake
72 Leakage check valve S16 Push button / parking brake (X)
73 Shuttle check valve S42 Push button / offroad gear (X)
74 Pressure-relief valve (6-8 bar) Y3 Solenoid valve / pilot control (*)
75 Shifting piston Y6 Solenoid valve / parking brake (X)
76 Check valve Y7 Solenoid valve / slewing gear (*)
77 Orifice Y50 Solenoid valve / power control
80 Distributor gear Y51 Solenoid valve / X-P lowering
81 Connecting flange Y55 Solenoid valve / 1st gear (X)
82 Drive shaft Y62 Solenoid valve / forward travel (X)
83 Sun gear Y63 Solenoid valve / reverse travel (X)
84 Planetary gear Y66 Solenoid valve / oscillating axle (*)
* = Items in hydraulic diagram of group 6

X = Items in electrical diagram of group 8
O = built into housing connection
11.10.20 A 900 C-LI 14675-

MJFCIFSS
Fig. 13 2 HL 100 transmisson
A 900 C-LI 14675- 11.10.21

MJFCIFSS
11.10.22 A 900 C-LI 14675-

MJFCIFSS
Function
2 HL 290 transmission
1 Function
The 2 HL 290 transmission is attached to the undercarriage. It distributes the drive force from the
flange-connected regulating travel motor 210 through the drive shafts to the input axles.
The transmission 80 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 70 and the output elements are attached to the gearbox.
Fig. 1 2 HL 290 transmission with DMVA 165 travel motor
70 Shift lock 210 Regulating travel motor

80 Transmission, complete
11.12.1
copyright by
MJFCIFSS
Technical data
2 Technical data
Gearbox type 2 HL 290

Max. drive power (*) 110 KW
Input torque at P max. 650 Nm
Max. input torque (*) 950 Nm
Max. input speed (*) 3500 rpm
Gear ratio
1st gear 4,87
2nd gear 1,20
Weight 135 kg
Oil volume in gearbox 3,0 l
Oil viscosity SAE 20 W-20 or SAE 10 W-30
Hydraulic control
Max. control oil level of gear pump 36 l/min
30
Pilot pressure of hydraulic unit and release pressure of multi-disc brake / coupling
Pressure-relief valve 51 32 ±1 bar
Measuring points 49, 63, MB, MK approx. 32 bar
Shift lock pump pressure (pressure-
relief valve 74)
at max. input speed 6 - 8 bar
at shift speed 2,0 - 2,6 bar
Shift lock on-road gear/off-road gear
Switching speed 800 ± 100 rpm
(drive shaft / oil motor)
Switching speed 667 ± 70 rpm
(drive shaft / universal joint)
(*) maximum permissible value
11.12.2
copyright by
MJFCIFSS
Description
3 Description
see Fig. 2
The 2 HL 290 transmission is designed as a powershift transmission with a planetary and a spur gear.
The powershift transmission of the planetary drive consists of a rotating multi-disc clutch and a multi-
disc brake mounted in a housing attached at the top of the planetary drive. Both the clutch and the
brake are applied by spring force (disc springs) and hydraulically released (control pressure).
When in on-road gear, the multi-disc brake is hydraulically released, and the multi-disc clutch is me-
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 transmission is driven by an axial piston regulating motor with brake valve. For a description of
the complete hydraulic system, the regulating motor and the brake valve, see groups 6 and 7.
The hydraulic shift lock mounted on the gearbox prevents shifting down at high speeds. It is operated
by the flow produced to pressurize a spool through a gear pump driven by the transmission. 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.
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 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.
11.12.3
copyright by
MJFCIFSS
Description
3.1 Design of transmission
1 Disc springs 8 Output flange at rigid axle

2 Drive shaft 9 Output shaft at steering axle
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
11.12.4
copyright by
MJFCIFSS
See also diagram on page 11.12.31.
4.1 Parking
Power circuit interrupted (ignition off) Multi-disc brake 87 (outside) and multi-disc clutch 93
(inside) engaged with disk springs 89 / 90
4.2 Braking
Switch S16 operated Multi-disc brake 87 and multi-disc clutch 93
applied by disc springs 89 / 90
4.3 On-road gear

Switch S42 not operated Brake 87 released by control pressure,
clutch 93 engaged with disc springs 90
4.4 Off-road gear

Switch S42 operated Brake 87 applied with disc springs 90
clutch 93 disengaged by control pressure
4.5 Function of parking brake

Diesel engine off:
No control pressure from the control oil unit 50.
Multi-disc brake 87 and multi-disc clutch 93 (1st gear) applied by disc springs 89 / 90.
Diesel engine on:
Switch S16 in brake position (LED on).
Brake valve Y6 in neutral position, and thus no pressure at connection P - B.
Multi-disc brake 87 and multi-disc clutch 93 (1st gear) engaged by disc springs 89 / 90.
Indicator light H20 is on.
Machine cannot be started.
4.5.1 Braking 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.
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.
11.12.5
copyright by
MJFCIFSS
4.6 Gear function and power flow
4.6.1 On-road gear / 2nd gear (no preselection with switch S42):
Multi-disc brake 87 is released.
Multi-disc clutch 93 is engaged.
The planetary carrier 85 and the hollow gear 86 are driven simultaneously through the engaged
clutch 93 and the drive shaft 82 by the oil motor 210.
There is therefore no speed reduction by the planetary drive. The planetary carrier 85 propels the
spur gear 99.
The larger helical gear 99 meshing with the planetary carrier 85 rotates at a lower speed (speed
reduction) and drives the axles, and thus the drive wheel of the machine, via the drive flange 100
and the flange-connected universal joint shafts.
4.6.2 Off-road gear / 1st gear (preselection with switch S42):

Multi-disc brake 87 is applied.
Multi-disc clutch 93 is disengaged.
The planetary gears 84 are propelled through the drive shaft 82 by the oil motor 210. The 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 wheel of the machine, via the drive flange 100
and the flange-connected universal joint shafts.
The second speed reduction of the planetary drive / spur drive results in a high reducing gear ratio.
4.7 Function of shift lock

The shift lock 70 protects the gear system and the hydraulic motor against excessive speed, which
might occur when the drive changes from on-road to off-road gear while travelling at relatively high
speeds.
If the input speed and thus the drive speed are above the set shifting-down point, gear switching from
on-road to off-road speed is not possible. The preselected off-road gear is only released by the shift
lock 70 when the shifting-down point is reached. If the input speed is below the shifting-down point,
the machine is automatically shifted to the selected off-road gear. The on-road gear can be chosen
at any speed.
4.7.1 Leakage check valve 72

If off-road gear is preselected, the leak oil from the shifting piston 75 and the check valve 73 (at pres-
sure side P2) is fed through the leakage check valve 72 through connection B to the tank. The valve
72 also blocks the control pressure to the multi-disc brake 87 when the machine is driven in on-road
or off-road gear.
4.7.2 Shuttle check valve 73

If the off-road gear is preselected, the shuttle check valve 73 blocks the flow from connection K to B.
If the machine is in on-road gear and moves at a speed above the shifting-down point, it blocks the
flow from connection B to K.
4.7.3 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.
11.12.6
copyright by
MJFCIFSS
4.7.4 Shifting piston 75

The shifting piston 75 acts as the actual shift lock. The flow, which is given by the input speed of the
gear system, and the resulting backpressure at the orifice 77 determines the position of the shifting
piston 75.
Low speed low flow low backpressure 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.
4.7.5 Check valve 76

The check valve 76 feeds the oil that is replaced when the shifting piston 75 is moved through K to
the tank.
4.8 Normal position of shift lock

The rotary-type pump / gear pump 71 driven by the gear input shaft sucks oil from the gear sump
through the internal bores and the suction filter 71.2. It produces an oil pressure, which is determined
by the input speed (output speed of the oil motor) and corresponds to the pressure at the orifice 77
for the lubricating oil supply of the gear system. A part of the oil is used to lubricate the gear system,
while the rest moves the shifting piston 75, or is returned by the pressure-relief valve 74 to the suction
side.
The pump flow, the lubricating oil orifice 77 and the characteristic of the pressure spring in the shifting
piston 75 are adjusted in such away that, at input speeds below the shifting-down point, the back-
pressure at the orifice 77 and the resulting piston force are smaller than the spring force.
When the piston is in this position (neutral position), oil flow from B B or from K K is possible so
that the machine can be switched to on-road or off-road speed.
If the off-road gear is chosen, the shifting piston 75 remains in neutral position, as the shifting 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.
11.12.7
copyright by
MJFCIFSS
11.12.8
copyright by
MJFCIFSS
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
J Measuring point on-road gear 67 Emergency activation / shifting to 1st
gear
K/K/K to multi-disc clutch 70 Shift lock
L Measuring point pump pressure 71 Lubricating oil pump
M Measuring point off-road gear 71.2 Suction filter (maintenance-free)
MB Measuring point multi-disc brake 72 Leakage check valve
MK Measuring point multi-disk clutch 73 Shuttle check valve
P from control oil unit 74 Pressure relief valve
S Suction chamber / pump 75 Shifting piston
T to tank 76 Check valve
Y6 Solenoid / on-road gear brake 77 Orifice
Y55 Solenoid / 1st gear 80 Transmission, complete
87 Multi-disc brake
93 Multi-disc clutch
102 Accumulator
210 Regulating travel motor
11.12.9
copyright by
MJFCIFSS
4.9 Diagram of gear - hydraulic system
Fig. 3 Diagram of transmission and shift lock (shifting position = 2nd gear)
11.12.10
copyright by
MJFCIFSS
Positions of shift lock 70
5 Positions of shift lock 70
5.1 Machine in on-road gear (2nd gear)
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
B 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 enga-

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
74 Pressure relief valve Pp Pump pressure
78 Connection of lubricating oil supply
11.12.11
copyright by
MJFCIFSS
at high speed
11.12.12
copyright by
MJFCIFSS
If the machine is in on-road gear and the speeds are above the shifting-down point, an increased
pump pressure is applied to the shifting piston 75. The shifting piston is thus pressed against the pres-
sure spring into working position.
If the operator now preselects the off-road gear, the pressure applied to the shift lock 70 changes
from connection B to connection K. The shuttle check valve 73 continues to release the pressure to
connection B so that shifting down is not possible. The machine remains in on-road gear.
Only when the speed is reduced to below the shifting-down point (reduction of travel speed), the
spring presses the piston 75 into its neutral position, i.e. the machine can now be set to off-road gear.
5.2 Travel in on-road gear
On-road gear (1st gear) preselected with switch S42
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
Spool 75 in working position
K Shifting pressure Sp over the

shifting piston 75 and the
shuttle check valve 73; valve
73 also blocks connection to
B.
B Via external line to

multi-disc brake.
Brake released
Point K is connected via the Multi-disc clutch enga-

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-
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 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
75 Shifting piston Pp Pump pressure
76 Check valve S Suction chamber / pump
11.12.13
copyright by
MJFCIFSS
77 Orifice Sp Shifting pressure
off-road gear preselected
11.12.14
copyright by
MJFCIFSS
5.3 Off-road gear (1st gear) preselected with switch S42
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
K Shifting pressure Sp over
shifting piston 75 (open edge
of control spool)
K Via external line to

multi-disc brake.
Clutch released
Gear ratio of planetary

drive = 1:3.87 (1st 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 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
74 Pressure relief valve Pp Pump pressure
78 to lubricating oil supply
11.12.15
copyright by
MJFCIFSS
Fig. 6 Hydraulic diagram and sectional drawing of the transmission during travel in off-road gear
11.12.16
copyright by
MJFCIFSS
11.12.17
copyright by
MJFCIFSS
Operation of the machine
6 Operation of the machine
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.
Fig. 7 Control console, right pilot control unit and travel pilot control unit
84 Travel pilot control unit S30 Travel forward/reverse switch

S42 Gear shifting 1st gear switch
6.2 Gear preselection, see Fig. 7

The on-road gear is automatically selected.
The 1st gear/ off-road gear is preselected with switch S42.
When the switch S42 is activated, the LED in the switch is on (off-road gear preselected). The gear
shift initiated by the switch S42 is activated by the solenoid valve Y55 located on the valve block 60,
Fig. 9.
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, see Fig. 7

The direction of travel is preselected with switch S30.
The selected travel direction is indicated on the main display screen with F for forward and R for re-
verse).
Reversing (i.e. switching from forward to reverse motion and back) is possible in both gears.
11.12.18
copyright by
MJFCIFSS
Brakes
7 Brakes
Caution!
The parking brake is designed in such a way that it cannot be operated during work.
Otherwise, the machine would be damaged.
During work, use only the working brake.

Actuate the pedal 2 of the working brake (to the right of the steering column) until the brake is
fully applied (foot pedal 2 engages in the locking device 1, see Fig. 8).
Fig. 8 Working brake pedal and parking brake switch with indicator light
1 Locking device H20 Indicator light of parking brake

2 Foot pedal / working brake S16 Switch / parking brake
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, see Fig. 8.
Actuate the switch S16:
The brake is applied.
The LED in the switch S16 is on.
The indicator light H20 is on.
By applying the parking brake, the electric mass, and connection to the solenoid valves for the travel
direction preselection are disconnected, so that the machine cannot be moved when the brake is ap-
plied (see also electrical system).
Note!
The brake is designed as a parking brake and may only be applied when the machine is standing
still.
When parking on slopes, we recommend securing the vehicle with wedges, in addition to the par-
king brake.
11.12.19
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MJFCIFSS
Towing the machine
7.1 Parking the machine

Turn the ignition key of the machine to position 0 and remove it.
The multi-disc packs 87 and 93 are closed automatically.
8 Towing the machine
Caution!
The towing of the machine is a dangerous manoeuvre with a risk of injury to the driver and damage
to the machine. The machine may only be towed if absolutely necessary, e.g. to carry out repairs at
a suitable location or workshop.
To tow the machine, use a suitably dimensioned rod.
Never use a cable or rope.
When towing the machine, please note:
max. towing speed = 10 km/h
max. towing distance = 5 km
8.1 Towing with running diesel engine
Fig. 9 Valve block
60 HBGV block Y6 Solenoid valve / on-road gear

67 T-handle screw / emergency activation Y55 Solenoid valve / 1st gear
Before towing the machine, ensure that the gear is supplied with pilot control oil.
Release the parking brake with switch S16 (Fig. 8) (indicator light H20 is off - Fig. 8)
If there is no battery power or in the event of an electric failure, activate the emergency mode at the
double solenoid valve Y6/Y55:
Turn in the T-handle screw 67 at the double solenoid valve Y6/Y55. The valve plunger is pressed
into its open position.
11.12.20
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MJFCIFSS
Towing the machine
8.2 Towing with switched-off diesel engine, see Fig. 9

In this case, there is no pilot control oil at the valve block 60 required to release the parking brake.
Danger!
With the subsequent emergency activation for towing, the parking brake is temporarily disabled.
Emergency activation requires access to the undercarriage of the machine. There is a risk of serious
injury or even death to the technician, if the machine begins to move.
Before accessing the danger area and the area of the undercarriage, secure the wheels with
chucks.
Access the area of the undercarriage only when the machine is shut down and properly secured
in its position.
Adhere to the accident prevention regulations issued by the German Ground Construction Trade
Association (Tiefbau-Berufsgenossenschaft) for the powertrains and earth-moving equipment.
Disconnect the solenoid valves Y6 / Y55 to disable gear switching when the emergency activa-
tion is on.
Fig. 10 Transmission with emergency activation of the gearbox
1 Lubrication nipple of emergency activation 2 Bleeder of emergency activation

1B Line 3 Pressure relief valve of emergency activa-
tion
8.2.1 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 8, page 20), top.
11.12.21
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MJFCIFSS
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.
When the diesel engine is off, the machine can only be steered with the emergency steering system
(steering wheel is stiff).
The machine may only be towed away from the danger zone but not any further!
Before setting the gearbox back to normal mode (after towing) deactivate the emergency activa-
tion!
Do not lubricate the lubrication nipple 1, Fig. 10, of the emergency activation.
8.2.2 Deactivating emergency activation

Open the bleeder 2 of the emergency activation.
If the gear can be shifted, switch it to on-road gear (S16 not actuated - S42 not actuated).
The LED in the switch S16 / S42 and the indicator light H20 are off.
If the gearbox is dismantled, apply pilot control pressure to connection B at the gearbox.
Close the bleeder 2.
Release the pressure supply at connection B or actuate S16.
The multi-disc brake and the multi-disc clutch are now again operational.
9 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.
Secure it against rolling away.
Only carry out maintenance work on the gearbox, if the machine is fully shut down and properly
secured.
Always adhere to the safety instructions in group 1.10 "Safe maintenance of machine".
Note!
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
followed.
9.1 Oil level check

Check the oil level at the intervals laid down in the inspection and maintenance schedule, see group
3.
Switch off the diesel engine.
Carefully clean and remove the screw plug at the check and filling opening 10 at the gearbox 80
and check the oil level.
11.12.22
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MJFCIFSS
Maintenance
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.
Fig. 11 Oil discharge bore, oil check and filling opening
9 Oil discharge bore 80 Transmission, complete

10 Oil check and filling opening
9.2 Oil change

Ensure that the gearbox is at operating temperature and shut down the diesel engine.
Carefully clean the oil discharge and check screw 9 / 10 and then open it.
Remove the oil discharge and check screw 9 / 10.
Drain off the oil at the discharge screw 9.
Carefully clean the oil discharge screw 9 and its sealing face.
Insert the oil discharge screw 9 with the seal ring and tighten it.
Add the prescribed gear oil through the oil check screw opening 10 until it reaches the lower edge
of the opening.
Carefully clean the oil check screw 10 and its sealing face.
Insert the oil filling screw 10 with the seal ring and tighten it.
11.12.23
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MJFCIFSS
Maintenance
9.3 Inspection of transmission
Fig. 12 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!
The inspection must be carried out while the machine is at operating temperature and the diesel
engine running at high idle speed.
9.3.1 Checking the release pressure of the discs, see Fig. 12.
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", page 2).
After adjustment, remove the pressure sensors and seal the measuring points.
9.3.2 Checking the opening pressure in the piston chamber / multi-disc brake and
multi-disc clutch, see Fig. 12
Connect the pressure sensor (0-60 bar) to the measuring points MB and MK.
Release the parking brake with switch S16 and measure the pressure at the measuring point MB,
comparing it with the prescribed value, (see "Technical data", page 2).
1. Select the gear with switch S42 and measure the pressure at the measuring point MK, compa-
ring it with the prescribed value (see "Technical data", 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.
11.12.24
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MJFCIFSS
Installation, dismantling and repair
10 Installation, dismantling and repair
Danger!
The dismantling and installation of the gearbox requires access to the undercarriage of the machine.
There is a risk of death to the technician, as limbs could become crushed.
Secure it against rolling away.
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.
Fig. 13 Transmission and universal joint shafts in the undercarriage
12 Universal joint shaft 19 Hex head screw

13 Hex nut 24 Disc
14 Plate 26 Nut
15 Disc 80 Gearbox, complete
16 Hex head screw 210 Oil motor / travel drive
17 Rubber pads EB Bleeder connection B
18 Disc EK Bleeder connection K
11.12.25
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MJFCIFSS
Installation, dismantling and repair
10.1 Dismantling of the gearbox
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 8.2.1
Remove the hex nuts 13 and remove the universal joint shafts 12 from the output flanges.
By cranking the wheels of the machine, screw connections at the universal joint shaft flange con-
nection that are normally not accessible become accessible.
Apply the parking brake with switch S16 (indicator light H20 and LED in switch are on).
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.
10.2 Repairs
Note!
For detailed repair instructions for the axle, refer to the separate "Repair manual for 2 HL 250 / 270
/ 290 transmission".
10.3 Installation of the gearbox

Apply sealant to the flange surface of the gearbox 80 and the oil motor 210.
Insert the oil motor 210 into the gearbox 80.
Tighten the nuts 26 with the washers 24.
Apply a tightening torque of 280 Nm.
Place the plate 14 to 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.
11.12.26
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MJFCIFSS
Bleeding of gearbox

Connect all hydraulic lines of the gearbox 80 and the oil motor 210.
Start the diesel engine.
Release the parking brake with switch S16 (indicator light H20 and indicator light in the switch S16
are off).
Mount the universal joint shafts 12 to the output flanges of the gearbox 80 and tighten the hex nuts
13.
By cranking the wheels of the machine, screw connections at the universal joint shaft flange con-
nection that are normally not accessible become accessible.
If the emergency activation is on, deactivate it, see section 8.2.2.
Check all screw connections at the gearbox and the oil motor for leakage.
Carefully bleed the gearbox.
11 Bleeding of gearbox
Fig. 14 Gearbox bleeder
EB Bleeder for multi-disc brake 2 Bleeder of emergency activation

EK Bleeder for multi-disc clutch

Remove the protective cap of the bleeder EB.
Attach a house to the bleeder nozzle EB and collect the escaping hydraulic oil in a suitable con-
tainer.
Release the parking brake with switch S16, (see Fig. 8, page 19), (brake connection pressurised).
If a new gearbox has been installed, also open bleeder 4 (no oil escaping here).
This approach ensures that the emergency activation is in its initial position.
11.12.27
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MJFCIFSS
Bleeding of gearbox
Open the bleeder EB and bleed the multi-disc brake for approx. 20 seconds.
Close the two bleeders 2 and EB, (see Fig. 10, page 21).
Remove the protective cap of the bleeder EK.
Attach a house to the bleeder nozzle EK and collect the escaping hydraulic oil in a suitable con-
tainer.
Switch the machine into off-road gear S42, (see Fig. 8, page 19), (clutch connection pressurised).
Open the bleeder EK and bleed the multi-disc clutch for approx. 20 seconds.
Close the bleeder EK.
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 and replace the pro-
tective caps.
11.12.28
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MJFCIFSS
Bleeding of gearbox
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 Variable-displacement pump / double 94 Inner disc carrier
variable-displacement pump (*)
30 Gear pump / pilot control (*) 95 Pressure spring
49 Measuring point / pilot pressure (*) 96 Piston / emergency activation
50 Control oil unit / pilot control (*) 97 Counterpart / emergency activation
51 Pressure relief valve / pilot control 98 Bolt / emergency activation
60 Valve block, complete 99 Spur gear
61 Shifting piston 100 Output flange
62 Pressure valve 101 Piston
63 Measuring point / opening pressure 102 Restrictor check valve
67 Emergency activation / shifting to 1st 210 Regulating motor (*)
gear
70 Shift lock, complete 322 Rotary connection 6 x (*)
71 Gear pump
71.2 Suction filter EB Bleeder / brake B
72 Leakage check valve EK Bleeder / clutch K
73 Shuttle and check valve MB Measuring point / brake B
74 Pressure-relief valve (6-8 bar) MK Measuring point / clutch K
75 Shifting piston H20 Indicator light of parking brake (X)
76 Check valve S16 Push button / parking brake (X)
77 Orifice S42 Push button / off-road gear (X)
80 Transmission, complete Y6 Solenoid / on-road gear (X)
81 Connecting flange Y55 Solenoid / 1st gear (X)
82 Drive shaft Connection:
84 Planetary gear B/B/B Pressure oil supply of multi-disc brake
85 Planetary carrier K/K/K Pressure oil supply to multi-disc clutch
86 Hollow gear J, M Measuring connections
87 Multi-disc brake P, Pp Pressure from control oil pump
88 Piston / multi-disc brake S, Sp Suction connection (lubricating pres-
sure)
89 Disc springs / multi-disc brake T Return connection
* = Items in hydraulic diagram of group 6

X = Items in electrical diagram of group 8
11.12.29
copyright by
MJFCIFSS
Bleeding of gearbox
11.12.30
copyright by
MJFCIFSS
Service Manual HBGV block for 2 HL 100 transmission
Function
HBGV block for 2 HL 100 transmission
1 Function
Machines with 2 HL 100 powershift transmissions are equipped with a transmission control system
as standard.
(HBGV block = hand brake and gear shift valve block)
The HBGV block has the following functions:
The solenoid valve Y6 (shifting piston 20 with solenoid part 120 -see 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.
63 60
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 hydraulic diagram
A 900 C-LI 14675- 11.30.1

MJFCIFSS
HBGV block for 2 HL 100 transmission Service Manual
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 gear is fed through connection T to the hydraulic tank.

If the switches S16 and S42 are not actuated, both solenoid valves 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 gear 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 opened, while the multi-disc clutch remains closed. The machine is thus 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 thus 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 opened as the brake piston is pressurised with control pressu-
re. 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 thus 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 A 900 C-LI 14675-

MJFCIFSS
Service Manual HBGV block for 2 HL 100 transmission
Fig. 2 Sectional drawing of the HBGV block
10 Housing 120 Magnetic coil

20 Piston 130 Protective cap
30 Piston 160 Collar nut
40 Spring plate 170 Ball
50 Screw plug 180 Nozzle
60 Adjusting screw 190 Protective cap
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
110 Magnetic tube
A 900 C-LI 14675- 11.30.3

MJFCIFSS
HBGV block for 2 HL 100 transmission Service Manual
2.5 Testing and adjustment of the backpressure-limiting valve 63
Fig. 3 HBGV block
Remove the cover cap at the measuring point 65 and connect the pressure sensor.
Start the diesel motor and observe the pressure sensor.
Release and re-apply 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 backpressure (see chapter "General information" for group 11.10)
2.6 Correction of pressure

Remove the cover cap 190.
Loosen the collar nut 160.
Turn the adjusting screw 60 at the backpressure-limiting valve 63 until the actual pressure corre-
sponds to the nominal pressure.
60 = to increase pressure.
60 = to reduce pressure.
After the pressure has been adjusted, tighten the collar nut 160 and replace the cover cap 190.
2.7 Inspection of the hydraulic tank 64

Release and re-apply 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 backpressure (see chapter "General information" for group 11.10)
If the hydraulic tank 64 works properly, the opening pressure gradually drops to the backpres-
sure as regulated by valve 63. The pressure then remains at this level for a period of time. If
the opening pressure suddenly drops to a value near 0 bar when the brake is applied, the hy-
draulic tank 64 is defective and must be replaced.
11.30.4 A 900 C-LI 14675-

MJFCIFSS
Service Manual HBGV block for transmission 2 HL 290
Function and design
HBGV block for transmission 2 HL 290
Machines with 2 HL 290 powershift transmissions are equipped with a transmission control system
as standard.
(HBGV block = hand brake and gear shift valve block)
The HBGV block mounted to the basic boom bearing block has the following functions:
Control of the parking brake (solenoid valves Y6 and Y55 idle).
Control of the on-road gear (solenoid valve Y6 active -Y55 idle).
Control of the 1st gear (solenoid valve Y6 idle -Y55 active).
Emergency operation in the event of failure of the electric solenoid valves Y6 and Y55, turn in the
T-handle 63 at the HBGV block 60. The 1st gear is selected.
Securing the gear against insufficient or excessive control pressure by means of pressure valve
62.
Fig. 1 HBGV block 60
60 HBGV block Y55 Solenoid valve / 1st gear

62 Pressure 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
Y6 Solenoid valve / on-road gear T Tank connection
11.35.1
copyright by
MJFCIFSS
HBGV block for transmission 2 HL 290 Service Manual
see and Fig. 3

The HBGV block is supplied with pressure oil by the pilot control oil pump 30 through connection Fe
and connection P. The control pressure of the HBGV block can be measured at measuring point 63
(M).
The block is linked through the connections K / B and hydraulic lines to the shift lock of the powershift
transmission. The oil from the piston chambers of the gear is fed through connection T to the hydrau-
lic tank.
2.1 Neutral position (parking brake applied)

If the parking brake is applied with switch S16 (LED on), the solenoid valves Y6 and Y55 are not po-
wered. The shifting piston 61 is moved to its centre position, so that the connections B and K to the
tank are released and the parking brake is activated while the machine remains in gear.
2.2 Control of the multi-disc brake (2nd gear / on-road gear)

If the solenoid valve Y6 is powered, the piston 61 is moved to position a, see . As a result, the con-
nections between P and B and between K and T are opened. The machine is shifted to 2nd gear (on-
road gear).
2.3 Control of the multi-disc clutch (1st gear / off-road gear)

If the switch S42 is actuated, the solenoid valve Y55 is powered, shifting the piston 61 to position b,
see . As a result, the connections between P and K and between B and T are opened. The machine
is shifted to 1st gear (off-road gear).
2.4 Emergency operation of the multi-disc brake (with pilot control pressure)
If there is a fault in the electrical system so that gear switching is not possible, even when the diesel
engine is running and the correct pilot control pressure is available, (Y6 and Y55 not powered), turn
in the T-handle 67 for emergency operation.
By turning in the T-handle 67, the shifting piston 61 is moved so that the connections between P and
K and between B and T are opened. The machine can now be set to 1st gear so that it can be moved.
Note!
For a detailed description of the shifting positions and the 2HL290 transmission, see group 11.12.
in the service manual.
11.35.2
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MJFCIFSS
Fig. 2 Functional diagram
1 to hydraulic tank 322 Rotary connection 6 x

30 from pilot control pump S16 Switch / on-road gear - parking brake
60 HBGV block S42 Switch / off-road gear
61 Shifting piston Y6 Solenoid valve / on-road gear
62 Pressure valve Y55 Solenoid valve / 1st 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
11.35.3
copyright by
MJFCIFSS
Fig. 3 Sectional drawing of the HBGV block
60 HBGV block 67 T-handle for emergency operation

61 Shifting piston 68 Spring plate
62 Pressure valve Y6 Solenoid valve / on-road gear
64 Piston / pressure-relief valve Y55 Solenoid valve / 1st gear
66 Pressure spring
11.35.4
copyright by
MJFCIFSS
Pressure valve 62
3 Pressure valve 62
Fig. 4 Pressure relief valve in HBGV block
3.1 Function
The pressure valve 62 inserted in the HBGV block 60 protects the transmission from damage caused
by insufficient or excessive control pressure. It ensures that no pressure < 26 bar is applied to the
gear shifting valve, which activates the parking brake.
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 (60 bar).
Pressure at measuring point 63 = pilot pressure.
Note!
The pressure relief valve 62 is fixed by the spring pressure force 66 and cannot be adjusted.
11.35.5
copyright by
MJFCIFSS
Pressure valve 62
11.35.6
copyright by
MJFCIFSS
Service Manual
SUBGROUP - INDEX
Section Group Type
Tyres 12.01.1 A 900 C-LI 14675-

A 900 C-LI EDC 24677-
A 904 C-LI 16000-
A 904 C-LI EDC 30580-
A 914 C-LI 35112-
A 924 C-LI 34519-
APL - B 755 steering axle with multi-disc brake 12.10.1 A 900 C-LI 14675-
AP - B 755 rigid axle with drum brake 12.12.1 A 900 C-LI 14675-
Differential for AP / APL - B 755 axles 12.16.1 A 900 C-LI 14675-
APL - B 765 steering axle with multi-disc brake 12.20.1 A 904 C-LI 16000-
AP - B 765 rigid axle with drum brake 12.22.1 A 904 C-LI 16000-
AP - B 765 rigid axle with multi-disc brake 12.24.1 A 904 C-LI 16000-
Differential for AP / APL - B 765 axles 12.26.1 A 904 C-LI 16000-
MS - E 3060 steering axle 12.40.1 A 900 C-LI EDC 24677-
MT - E 3060 rigid axle 12.42.1 A 900 C-LI EDC 24677-
MS/MT - E 3060 drive unit and differential 12.44.1 A 900 C-LI EDC 24677-
MS - E 3070 steering axle 12.50.1 A 904 C-LI EDC 30580-

A 914 C-LI 35112-
A 924 C-LI 34519-
MT - E 3070 rigid axle 12.52.1 A 904 C-LI EDC 30580-

A 914 C-LI 35112-
A 924 C-LI 34519-
MS/MT - E 3070 drive unit and differential 12.54.1 A 904 C-LI EDC 30580-
A 914 C-LI 35112-
A 924 C-LI 34519-
12.1
MJFCIFSS
Service Manual
12.2
MJFCIFSS
Service Manual Tyres
General
Tyres
1 General
Repairs to the wheel, including the removal of the tyres from the rims, must be carried out by qualified
specialists with suitable tools.
2 Checking tyre pressure
Fig. 1 Checking tyre pressure, safety distance
Danger!
Risk of injury from exploding tyres!
If the tyre inflation device is used incorrectly or without the necessary care, there is a risk of serious
injury or even death due to:
Bursting tyres caused by excessive inflation.
Blasting out of the lip seal.
Flat tyres may not be inflated, but must be repaired in a specialist workshop.
When inflating the tyres, use a suitably long inflation hose with self-adhesive pinch valve.
Ensure that no persons are standing in the danger zone when the tyre is inflated.
Do not mount tyres of different size.
The tyre pressure affects the operating behaviour of the machine. The pressure must therefore be
regularly checked and adjusted, if necessary.
Ensure that the machine is standing in a safe position and is secured against rolling away
(chocks).
The correct nominal values for tyre pressure for the chosen mounted tyres and the machine kit
are available.
For nominal values, refer to the table below.
Attach measuring device and adjust the tyre pressure, if necessary.
12.01.1
copyright by
MJFCIFSS
Tyres Service Manual
Checking tyre pressure
2.1 Checking wheel lugs for proper fit

Tightening torque for wheel lugs:
A 900 C = 460 Nm
A 904 C = 460 Nm
A 914 C = 460 Nm
A 924 C = 460 Nm
Danger!
Loose or incorrectly tightened wheel lugs might cause wheels to become loose and even fall off,
causing serious injury.
After each wheel change or loosening of the wheel lugs:
Tighten the wheel lugs with the correct torque and re-check the torque subsequently three times
after 50, 100 and 250 operating hours.
Ensure that the machine is standing in a safe position and is secured against rolling away
(chocks).
Ensure that a torque spanner of the required range is available.
Fig. 2 Tightening wheel lug
Check the wheel lugs on each wheel and retighten them, if necessary.
12.01.2
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MJFCIFSS
Tyres and spacer rings
3 Tyres and spacer rings
3.1 A 900 C Litronic from 14675
Type: 917 / 987

Press
Tyre Spacer
EW Size Manufacturer PR ure
type rings
[bar]
10.00-20 Amor Gard Nokia 16 ?? MH 2
10.00-20 8 NB 38 Mitas 16 7.50 MH 3
10.00-20 EM-22 Mitas 16 7.50 MH 3
10.00-20 EM-23 Mitas 16 7.50 MH 3
10.00-20 8 solid tyres Gumasol MH 4
10.00-20 8NB38ML, Extra Mitas 14 7.50 MH 3
18 R 19.5 4 XF Michelin 16 7.50 -
10.00-20 8TBXTL504 Taifa 16 7.50 MH 3
X 10.00-20 8 Titan Continental 16 7.50 MH 4
X 10.00-20 8 E 91-2 Dunlop 16 7.50 MH 4
X 10.00 R 20 8 XL Michelin 16 7.50 -
X 10.00-20 8 NB 38 Mitas 16 7.50 MH 4
X 10.00-20 8NB38ML, Extra Mitas 14 6.50 MH 4
X 10.00-20 EM - 22 Mitas 16 7.50 MH 4
10.00-20 EM - 23 Mitas 16 7.50 MH 4
Tab. 1 Tyres and spacer rings
Types: 439 / 440 / 441

Press
Tyre Spacer
type rings
[bar]
10.00-20 8 solid tyres Gumasol 16 7.75 MH 4
10.00-20 EM - 22 Mitas 16 7.50 MH 4
10.00-20 EM - 23 Mitas 16 7.5 MH 4
11.00-20 8 Titan Continental 16 7.5 MH 3
11.00-20 8 Fast-Grip Bridgestone 16 7.5 MH 3
11.00-20 8 Amor Gard Nokia 16 7.50 MH 2
11.00-20 8 solid tyres Gumasol - - MH
11.00-20 8 NB 38 Mitas 16 7.50 MH 3
18R19.5 4 XF Michelin 7.50 MH 2
12.01.3
copyright by
MJFCIFSS
Types: 665 / 439

Press
Tyre Spacer
type rings
[bar]
600/40-22.5 4 HDI-331 Alliance 16 6.00 -
10.00-20 8NB38ML, Extra Mitas 14 6.50 MH 4
X 315/80 R22.5 8 Grader Bandenmarkt 18 8.50
Type: 1002
Press
Tyre Spacer
type rings
[bar]
10.00-20 8 E 91 - 2 Dunlop 16 7.5 MH§3
10.00-20 8 NB 38 Mitas 16 7.5 MH 3
10.00-20 8 NB38 ML Extra Mitas 14 7.5 MH 3
10.00-20 8 NB 59 Mitas 16 7.5
10.00-20 EM-22 Mitas 16 7.5 MH 3
10.00-20 EM-23 Mitas 16 7.5 MH 3
10.00-20 Amor Gard Nokia 16 9.0 MH 2
18R - 19.5 4 XF Michelin 7.5

315/80R22.5 8 Grader Bandenmarkt 18 8.5
600/40-22.5 4 HDI - 331 Alliance 16 6.0
600/40-22.5 Mitas TR - 12 Mitas 6.0
X 10.00-20 8 E 91-2 Dunlop 16 7.5 MH 4
X 10.00-20 8 NB 38 Mitas 16 7.5 MH 8
X 10.00-20 8 NB38 ML Extra Mitas 14 6.5 MH 4
X 10.00-20 8 NB 59 Mitas 16 7.5 MH 8
X 10.00-20 EM - 22 Mitas 16 7.5 MH 4
X 10.00-20 EM - 23 Mitas 16 7.5 MH 4
12.01.4
copyright by
MJFCIFSS
Types: 1003 / 1004 / 1005 / 1071

Press
Tyre Spacer
type rings
[bar]
10.00-20 8 E 91- 2 Dunlop 16 7.5 MH 4
10.00-20 8 NB 38 Mitas 16 7.5 MH 8
10.00-20 8 NB 59 Mitas 16 7.5 MH 8
10.00-20 EM - 22 Mitas 16 7.5 MH 4
10.00-20 EM - 23 Mitas 16 7.5 MH4
10.00-20 Amor Gard Nokia 16 7.5 MH 8

11.00-20 8 solid tyres Gumasol
11.00-20 8 NB 38 Mitas 16 7.5 MH 3
11.00-20 8 NB 59 Mitas 16 7.5 MH 3
MH 3
18R 19.5 4 XF Michelin 7.5
* 600/40-22.5 4 HDI-331 Alliance 16 6.0

* 10.00 20 8 NB38 ML Extra Mitas 14 6.5 MH 4
* use only type 1003
12.01.5
copyright by
MJFCIFSS
Types: 1044 / 1045

Press
Tyre Spacer
type rings
[bar]
10.00-20 8 E 91- 2 Dunlop 16 7.5 MH 4
10.00-20 8 NB 38 Mitas 16 7.5 MH 8
10.00-20 8 NB 59 Mitas 16 7.5 MH 8
10.00-20 EM - 22 Mitas 16 7.5 MH 4
10.00-20 EM - 23 Mitas 16 7.5 MH4

11.00-20 8 solid tyres Gumasol
11.00-20 8 NB 38 Mitas 16 7.5 MH 3
11.00-20 8 NB 59 Mitas 16 7.5 MH 3
12.00 - 20 8 solid tyres Watts MH 5
18R 19.5 4 Breit XF Michelin 16 7.5
12.01.6
copyright by
MJFCIFSS
Types: 1047 / 1048 / 1049

Press
Tyre Spacer
type rings
[bar]
10.00-20 8 E 91- 2 Dunlop 16 7.5 MH 4
10.00-20 8 NB 59 Mitas 16 7.5 MH 8

11.00-20 8 XZM-TL Michelin 8.0
11.00-20 8 NB 38 Mitas 16 7.5 MH 3
11.00-20 8 NB 59 Mitas 16 7.5 MH 3
18R 22.5 4 Breit XF Michelin 16 7.5
12.01.7
copyright by
MJFCIFSS
Types: 1050 / 1051

Press
Tyre Spacer
type rings
[bar]
11.00 R 20 8 XZM-TL Michelin 8.0
11.00 R 20 8 NB 59 Mitas 16 7.5 MH 3
12.00 - 20 8 solid tyres SP30 Gumasol

12.00 R 20 8 XZM-TL Michelin 7.5
12.00 - 20 8 NB 59 Mitas 18 7.5 MH 3
12.00 - 20 8 Amor Gard Nokia 18 9.0 MH 2
12.00 - 20 8 Amor Gard Nokia 20 9.0 MH 2
12.01.8
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MJFCIFSS
Service Manual APL - B 755 steering axle with multi-disc brake
Function
APL - B 755 steering axle with multi-disc brake
1 Function
The axle housing of the steering axle, which transfers the axle load of the machine to the drive
wheels, is equipped with a built-in differential.
The differential transmits 50% of the output power of the transmission via the universal joint shafts to
the planetary drives of the wheel hubs.
Due to the technical design combining a high planetary gear ratio in the wheel hub with a small bevel
gear ratio in the differential, the differential is very compact, providing for great ground clearance.
The wheel hub contains the planetary drive as well as the hydraulically operated wet multi-disc brake.
It is pressurised and applied when the brake pedal (working brake) is operated. For a more detailed
description of the brake system, see group 15.10.
The steering cylinder (synchronised speed cylinder) built into the differential of the steering axle
moves the wheels through the joint housings (steering knuckles) between the two stop positions. For
a detailed description of the steering cylinder, see group 13.30.
The steering cylinder is mounted directly on the undercarriage (oscillating bearing). This design com-
pensates uneven surfaces so that all wheels of the vehicle are always in contact with the ground.
During digging operation, the oscillating movement of the steering axles can be blocked by means of
the two swing axle support cylinders attached to the undercarriage, see group 14.10.
Fig. 1 APL - B 755 steering axle
A 900 C-LI 14675- 12.10.1

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MJFCIFSS
APL - B 755 steering axle with multi-disc brake Service Manual
Function
12.10.2 A 900 C-LI 14675-

copyright by
MJFCIFSS
General information
Machine A 900 C-Li

Unit model 917 / 987
Serial number 14675
Axle type APL - B 755
Design Planetary steering axle
Gear ratio
Standard 17.52
Speeder 17.52
Brake Wet multi-disc brake
Oil volume in axle
Axle housing 9.0 l
Planetary drive 2.0 l per side
(filling level at the check screws is binding)
Oil quality/viscosity API - GL 5 / SAE 90 LS
Settings, to be observed for installation:
A End play of the double joint drive shaft 20 0.3 - 0.6 mm
B Clearance of the disc pack83 / 84 (piston stroke)
new 3.1 - 3.5 mm
at max. wear 5.0 mm
C Rolling resistance of the joint housing bearing 35 / 36 40 - 50 Nm
D Rolling resistance of the wheel bearing 61/64 (new) 8 - 12 Nm
E Torque for the slotted nut 32 1400 + 500 Nm
F Torque for the hex head screws 41 280 Nm
G Torque for the hex head screws 82 11 Nm
H Torque for the Allen head screws 103 55 Nm
I Torque for the wheel lugs 107 420 Nm
Torque of the slotted nut / tie rods, 300 Nm
see steering
K Multi-disc brakes:
High pressure test, max. value 150 bar
Max. pressure drop after 5 min. 3 bar
Low pressure test 1 - 5 bar
Visible pressure drop after 15 seconds is not permissible
Items A - K (see Fig. 7)
2.0.1 Tyre pressure

The tyre pressure depends on the tyre size, tyre ply rating and brand. For details, see overview of
tyres in group 12.35.
3.1 Power flow in the steering axle, see Fig. 7

The input torque of the transmission is transmitted through the drive shaft to the output flange of the
A 900 C-LI 14675- 12.10.3

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MJFCIFSS
Maintenance of the axle
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 double joint drive shaft 20 meshing with the axle shaft gear.
The sun gear shaft 91, which is connected through the disc carrier 92 to the double joint drive shaft
20, drives the planetary gears 95. These roll off on the stationary hollow gear 68. This leads to a high
speed reduction and thus a high torque transmission to the planetary carrier 94. The planetary
carrier 94, via the wheel studs 104, drives the vehicle wheels with the resulting torque and speed (re-
sulting from the overall gear ratio).
4 Maintenance of the axle
The axle must be regularly serviced according to the intervals laid down in the service or operating
manual.
The manufacturer also prescribes an annual inspection of the disc lining for wear, see Fig. 2.
Replace the brake lining (see instructions below), if the annual inspection reveals wear, or if any of
the following problems occurs:
Reduced braking force
Reduced brake pressure
Changes in the oil level in the wheel hub
Unusual braking noises
Measuring of brake lining wear

Turn wheel hub until the small screw plug M16 is at the top, see Fig. 2.
Apply working brake to the stop.
Remove the screw plug and screw in the measuring plug M16 (tool ID no. 7019556) to the stop;
tighten it with 10 Nm.
Measure and write down distance X from the screw head to the plane recess at the planetary
carrier, see Fig. 2.
Release the brake, screw measuring screw in further and tighten it again with 10 Nm.
Measure and write down distance Y from the screw head to the plane recess of the planetary
carrier.
Calculate the difference between the two measurements "X" - "Y" . This value corresponds to
the piston stroke.
Note!
Limit value for piston stroke with wear = 5.2 mm
If the actual value exceeds the permissible limit value, replace the entire brake disc pack.
12.10.4 A 900 C-LI 14675-

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Dismantling, repair and installation of the steering axle
Fig. 2 A = screw plug M 16; B = measuring screw M 16
5 Dismantling, repair and installation of the steering axle
5.1 Dismantling of the steering axle for repair work
Danger!
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).
Lift the undercarriage 5 at the front and secure the wheels of the steering axle 4 using chocks.
If required, remove the wheels 1 from the steering axle.
Disconnect the hydraulic lines to the steering cylinder and the brake line to the multi-disc brakes
and seal the line openings (collect escaping oil).
Loosen the hex head screw 2 and remove the universal joint shaft 3.
Lift the undercarriage 5 and secure the steering axle 4 with suitable lifting tackle.
Remove the hex head screws 6 and the plate 7, drive out the pin 8 (do not damage spacers 9)
and lower the steering axle 4.
A 900 C-LI 14675- 12.10.5

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MJFCIFSS
5.2 Repairs on the steering axle
Note!
For detailed repair instructions for the axle, refer to the separate "Repair manual for APL-B 755
ZP axles".
5.3 Installation of the steering axle

Insert the steering axle 4 in the undercarriage, using suitable lifting tackle. Insert spacer 9 and dri-
ve in pin 8.
Secure pin 8 with the plate 7 and the screws 6.
Lubricate the steering axle bearing at the lubrication nipple 10.
Secure the universal joint shaft 3 with the screws 2 to the differential of the steering axle 4.
Connect the brake lines to the multi-disc brake and bleed the brake (see group 15.10).
Connect the hydraulic lines to the steering cylinder and bleed the steering system (see group
13.20).
Mount the vehicle wheels 1 .
Lower the undercarriage and remove the chocks.
Tighten the wheel lugs with the prescribed torque, see Tab. 1.
Fig. 3 Undercarriage with axles
1 Vehicle wheels 7 Plate

2 Hex head screw 8 Pin
3 Joint shaft 9 Spacer
4 Steering axle 10 Lubrication nipple
5 Undercarriage 11 Locknut
6 Hex head screw
12.10.6 A 900 C-LI 14675-

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MJFCIFSS
Exploded view of the steering axle
6 Exploded view of the steering axle
Fig. 4 Steering axle (assembly 17)
.10 Axle housing .260 O-ring

.30 Axle housing .290 Stub shaft
.40 Bearing bushing .330 Snap ring
.50 Washer .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
.240 Screw plug .630 Slotted nut
.250 Screw plug .640 Cotter pin
A 900 C-LI 14675- 12.10.7

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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 .390 Bleeder valve
.114 Bearing pin .500 Stop screw
.120 Hex head screw
12.10.8 A 900 C-LI 14675-

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Fig. 6 Output (assembly 19)
.10 Radial shaft seal ring .280 Inner disc

.30 Roller bearing .290 End washer
.40 Ring .300 Snap ring
.50 Roller bearing .320 Thrust washer
.80 Hub .340 Sun gear shaft
.90 O-ring .350 Disc carrier
.120 Plug .360 Snap ring
.130 O-ring .370 Snap ring
.140 Junk ring .390 Planetary carrier
.150 Snap ring .400 Planetary gear
.160 Hollow gear .410 Roller bearing
.200 Piston .420 Junk ring
.210 Lip seal .430 Snap ring
.214 Backing ring .480 Thrust washer
.220 Lip seal .490 O-ring
.230 Backing ring .500 Screw plug
.232 Back-up washer .510 Allen head screw
.238 Pressure spring .540 Wheel stud
.248 Locknut .550 Lock washer
.256 Hex head screw .560 Centring ring
.258 Spring sleeve .570 Wheel lug
.270 Outer disc
A 900 C-LI 14675- 12.10.9

copyright by
MJFCIFSS
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 19240 Hex head screw
20 18170 Double joint drive 81 19254 Hex head screw
shaft
31 18010 Right joint housing 82 19248 Locknut
32 18010 Slotted nut 83 19270 Outer disc
35 18050 Roller bearing 84 19280 Inner disc
36 18050 Roller bearing 85 19290 End washer
37 18080 Sealing cap 86 19150 Snap ring
38 18090 O-ring 87 19320 Thrust washer
39 18100 Washer 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 Tabelle 1 auf Seite 3.
12.10.10 A 900 C-LI 14675-

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MJFCIFSS
Fig. 7 Sectional drawing of steering axle
A 900 C-LI 14675- 12.10.11

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MJFCIFSS
12.10.12 A 900 C-LI 14675-

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Service Manual AP - B 755 rigid axle with drum brake
Function
AP - B 755 rigid axle with drum brake
1 Function
The axle housing of the rigid axle, which transfers the axle load of the machine to the drive wheels,
is equipped with a built-in differential.
The 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 brake is pressurised with brake oil.
Fig. 1 AP - B 755 rigid axle with drum brake
Machine A 900 C Li.

Unit model 917/ 987
Serial number 14675
Axle type AP-B 755
A 900 C-LI 14675- 12.12.1

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MJFCIFSS
AP - B 755 rigid axle with drum brake Service Manual
General information
Machine A 900 C Li.

Unit model 917/ 987
Serial number 14675
Design Planetary rigid axle
Gear ratio
Standard 17.52
Speeder 17.52
Brake Drum brake
Oil volume in axle
Axle housing 9.0 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 19
D Torque for the Allen screws 27 / 28 280 Nm
E Torque for the slotted nut 31 1400 + 200 Nm
F Torque for the self locking screw 87
G Torque for the Allen head screws 103 55 Nm
H Torque for the wheel lugs 107 420 Nm
I Drum brakes 20: 2mm
Residual lining thickness of the brake system (glued) min.
Items A - I (see Fig. 6)
2.0.1 Tyre pressure

12.12.2 A 900 C-LI 14675-

copyright by
MJFCIFSS
3.1 Power flow in the rigid axle, see Fig. 6

The input torque of the transmission is transmitted through the universal joint shaft to the output flan-
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 stub shaft 7 meshing with the axle shaft gear.
The sun gear shaft 91, which is connected through the planetary carrier 94 to the stub shaft 7, drives
the planetary gears 95. These roll off on the stationary hollow gear 68. This leads to a significant
speed reduction and thus a high torque transmission to the rotating planetary carrier 94. The plane-
tary carrier 94, via the wheel studs 104, drives the vehicle wheels with the resulting torque and speed
(resulting from the overall gear ratio).
manual.
The regular maintenance tasks include a test of the drum brake, see group 15.
5 Dismantling, repair and installation of the rigid axle
5.1 Dismantling of the rigid axle for repair work
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).
Lift the undercarriage at the rear and secure the wheels of the steering axle 6 using chocks.
If required, remove the wheels 1 from the rigid axle 2.
Disconnect the brake lines of the drum brake and seal the line openings.
Loosen the hex head screws 4 and remove the universal joint shaft 5 from the differential of the
rigid axle.
Secure the rigid axle 2 with suitable lifting tackle.
Remove the hex head nuts 7 and the screws 8 and then remove the rigid axle 2 from the under-
carriage 9.
5.2 Repairs on the rigid axle
Note!
For detailed repair instructions for the axle, refer to the separate "Repair manual for AP-B 755 ax-
les".
A 900 C-LI 14675- 12.12.3

copyright by
MJFCIFSS
Dismantling, repair and installation of the rigid axle
5.3 Installation of the rigid axle

Place the rigid axle 2 in the undercarriage 9, using suitable lifting tackle. Secure with the hex head
screws 8 and the nuts 7 to the undercarriage. Lock the nuts 7.
Attach the universal joint shaft 5 to the differential of the rigid axle 2, using the hex nuts 3 and the
hex head screws 4.
Connect the brake line of the drum brake and bleed the brake.
Mount the vehicle wheels 1.
1 Vehicle wheels 6 Steering axle

2 Rigid axle 7 Hex nut
3 Hex nut 8 Hex head screw
4 Hex head screw 9 Undercarriage
5 Drive shaft
12.12.4 A 900 C-LI 14675-

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Exploded view of the rigid axle
6 Exploded view of the rigid axle
Fig. 3 Axle housing 17
17010 Axle housing part I 17150 Fit bolt

17030 Axle housing part II 17240 Screw plug
17050 Washer (0.50 2.0 mm) 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 Washer
A 900 C-LI 14675- 12.12.5

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MJFCIFSS
Fig. 4 Drum brake 2
2 Brake 2340 Pin

2010 Brake drum 2350 Locking plate
2040 Brake disc 2370 Tension spring
2050 Pin 19160 Hollow gear
2080 Disc spring 22010 Hub carrier
2090 Washer 22010 Slotted nut
2100 Hex nut 22070 Allen head screw
2170 Wheel cylinder 22080 Allen head screw
2180 Lock washer 22090 O-ring
2190 Hex head screw 22110 Retainer plate
2270 Brake pad
12.12.6 A 900 C-LI 14675-

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Fig. 5 Hub carrier and output of the wheel bearings or the planetary gear 19
19010 Radial shaft seal ring 19410 Roller bearing

19030 Roller bearing 19420 Junk ring
19040 Ring (S = 4.0 5.0 mm) 19430 Snap ring
19050 Roller bearing 19480 Thrust washer (S = 3.0 5.0 mm)
19080 Hub 19490 O-ring
19160 Hollow gear 19510 Allen head screw
19184 Locking plate 19540 Wheel stud
19190 Self locking screw 19550 Lock washer
19340 Sun gear shaft 19560 Centring ring
19390 Planetary carrier 19570 Wheel lug
19400 Planetary gear
A 900 C-LI 14675- 12.12.7

copyright by
MJFCIFSS
ZP figure ZP figure
Item Description Item Description
no. no.
1 17010 Axle housing part I 61 19030 Roller bearing
17030 Axle housing part II 62 19080 Hub
7 17290 Stub shaft 63 19090 O-ring
8 17690 Sleeve 64 19050 Roller bearing
9 17700 Snap ring 68 19160 Hollow gear
10 2000 Brake 71 19040 Ring
11 2010 Brake drum 86 19184 Locking plate
12 2040 Brake disc 87 19190 Self locking screw
17 2170 Wheel cylinder 91 19340 Sun gear shaft
18 2180 Lock washer 94 19390 Planetary carrier
19 2190 Hex head screw 95 19400 Planetary gear
20 2270 Brake pad 96 19410 Roller bearing
21 2340 Pin 97 19420 Junk ring
22 2350 Locking plate 98 19430 Snap ring
23 2370 Tension spring 99 19480 Thrust washer
27 22070 Allen head screw 101 19490 O-ring
28 22080 Allen head screw 102 19500 Screw
plug
30 22010 Hub carrier 103 19510 Allen head screw
31 22010 Slotted nut 104 19540 Wheel stud
33 22110 Retainer plate 105 19550 Lock washer
37 22090 O-ring 106 19560 Centring ring
60 19010 Radial shaft seal ring 107 19570 Wheel lug
Note!
Observe settings and torques A, B, C, D, E, F, G, H, I, see Fig. 6 and see Tab. 1.
12.12.8 A 900 C-LI 14675-

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Fig. 6 Sectional drawing of rigid sleeve
A 900 C-LI 14675- 12.12.9

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MJFCIFSS
12.12.10 A 900 C-LI 14675-

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MJFCIFSS
Service Manual Differential for AP / APL - B 755 axles
Function
Differential for AP / APL - B 755 axles
1 Function
The differential is built into the axle housing of the steering and rigid axle. It transmits 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 a 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
A 900 C-LI 14675- 12.16.1

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Differential for AP / APL - B 755 axles Service Manual
General information
Machine A 900 C-Li

Unit model 917/ 987
Serial number 14675
Axle type BK
Gear ratio 3.18
This differential is not available as a complete unit. The component parts of the differentials for the
steering and the rear axle are identical.
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 - 0.2 mm
C Bearing preload of the differential bearing 3 / 4 1 - 4 Nm
D Rolling resistance of the driving pinion bearing 16/19 1 - 2 Nm
E Torque for the hex nut 11 550 Nm
F Torque for the hex head screws 6 and the fit bolt 7 390 Nm
G Torque for the Allen head screws 22 145 Nm
Items A - G (see Fig. 4)
Note!
The differential can only be dismantled, installed and repaired together with the respective axle.
Please also refer to the separate repair manual
"AP / APL - B 755 ZP axles".
12.16.2 A 900 C-LI 14675-

copyright by
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General information
2.1 Exploded view of the differential
Fig. 2 Input (assembly 17)
10 Bevel gear kit (crown wheel and bevel 210 Input flange
pinion)
50 Washer 220 Valance
80 Roller bearing 270 Washer
110 Ring 290 Hex head screw
160 Roller bearing 310 Locking plate
190 Radial shaft seal ring
A 900 C-LI 14675- 12.16.3

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General information
Fig. 3 Differential (assembly 73)
10 Crown wheel 720 Differential spider

570 Differential cage 800 Allen head screw
640 Axle shaft gears 850 Washer
650 Thrust washer 860 Connex heavy-duty spring pin
670 Balancing shaft gears 870 Roll pin S
680 Thrust washer
12.16.4 A 900 C-LI 14675-

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Sectional drawing of the differential
3 Sectional drawing of the differential
ZP figure ZP figure
no. no.
1.1 17010 Axle housing I 16 16170 Tapered roller bea-
ring
1.2 17030 Axle housing II 17 16110 Bushing
2.1 17050 Washer 18 16050 Adjusting disc
2.2 17050 Washer 19 16070 Tapered roller 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 Balancing axle
12 16270 Washer 27 73680 Thrust washer
13 16210 Input flange 28 73670 Balancing gear
14 16220 Valance 29 73870 Roll pin "S"
15 16190 Radial shaft seal ring 30 73860 Heavy-duty roll pin
"Connex"
For additional drawings, see group 12.10 and 12.12 respectively
Note!
Observe settings and torques A, B, C, D, E, F, G, see Fig. 4 and Tabelle 1 auf Seite 2.
A 900 C-LI 14675- 12.16.5

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MJFCIFSS
Fig. 4 Sectional drawing of the differential
12.16.6 A 900 C-LI 14675-

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MJFCIFSS
Function
APL - B 765 steering axle with multi-disc brake
1 Function
wheels, is equipped with a built-in differential.
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.
moves the wheels through the joint housings (steering knuckles) between the two stop positions. For
a detailed description of the steering cylinder, see group 13.32.
Fig. 1 APL - B 765 steering axle
A 904 C-LI 16000- 12.20.1

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Function
12.20.2 A 904 C-LI 16000-

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MJFCIFSS
General information
Machine A 904 C Li.

Unit model 439 / 440 / 441
Serial number 16000
Axle type APL - B 765
Gear ratio
Standard 20.36
Speeder 13.55
Oil volume in axle
Axle housing 10.5 l
A End play of the double joint drive shaft 20 0.4 - 0.6 mm
B Clearance of the disc pack83 / 84 (piston stroke)
new 2.4 - 2.8 mm
at max. wear 4.5 mm
C Rolling resistance of the joint housing bearing 35 / 36 40 - 50 Nm
D Rolling resistance of the wheel bearing 61 (new) 10 - 15 Nm
E Torque for the slotted nut 32 1200 Nm
G Torque for the hex nuts 82 15 Nm
H Torque for the Allen head screws 88 120 Nm
I Torque for the Allen head screws 103 86 Nm
K Torque for the wheel lugs 107 570 Nm
Torque of the slotted nut / tie rods, 340 - 360 Nm
see steering
L Multi-disc brakes:
Items A - L (see Fig. 7)
2.0.1 Tyre pressure

A 904 C-LI 16000- 12.20.3

copyright by
MJFCIFSS

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 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 leads to
a high speed reduction and thus a high torque transmission to the planetary carrier 94. The planetary
carrier 94, via the wheel studs 104, drives the vehicle wheels with the resulting torque and speed (re-
sulting from the overall gear ratio).
manual.
The manufacturer also prescribes regular inspections of the disc lining for wear, see Fig. 2.
Replace the brake lining (see instructions below), if the annual inspection reveals wear, or if any of
the following problems occurs:

carrier.
Calculate the difference between the two measurements "X" - "Y". This value corresponds to
the piston stroke.
Note!
Limit value for piston stroke with wear
APL - B 765 with 2 inner discs = 3.0 mm
APL - B 765 with 3 inner discs = 4.5 mm
12.20.4 A 904 C-LI 16000-

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Fig. 2 A = screw plug M 16, B = measuring screw M 16
Danger!
genossenschaft).
Lift the undercarriage at the front and secure the wheels of the steering axle 12 using chocks.
Loosen the hex nuts 2 and remove the universal joint shaft 3.
Secure the steering axle 4 with suitable lifting tackle.
A 904 C-LI 16000- 12.20.5

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MJFCIFSS
5.2 Repairs on the steering axle
Note!
For detailed repair instructions for the axle, refer to the separate "Repair manual for APL-B 765
ZP axles".

Insert the steering axle 4 in the undercarriage, using suitable lifting tackle. Insert spacer 9 and dri-
ve in pin 8.
Secure the universal joint shaft 3 with the screws 2 to the differential of the steering axle 4.
Connect the hydraulic lines to the steering cylinder and bleed the steering system
(see group 13.20).

2 Hex head screw 8 Pin
5 Undercarriage 11 Locknut
6 Hex head screw 12 Rigid axle
12.20.6 A 904 C-LI 16000-

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6 Exploded view of the steering axle
Fig. 4 Axle housing (assembly 17)
10 Axle housing 360 Bushing

40 Bushing 460 Self locking screw
240 Screw plug 470 Self locking screw
250 Screw plug 480 Stud
260 O-ring 490 Locknut
340 Bushing 540 Double joint drive shaft
350 Radial shaft seal ring 620 Screw plug
A 904 C-LI 16000- 12.20.7

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Fig. 5 Joint housing (assembly 18)
10 Left joint housing 111 O-ring

10 Right joint housing 120 Hex head screw
10 Slotted nut 130 Lubrication nipple
30 Plug 140 Lubrication nipple
40 Lid 150 Bushing
50 Roller bearing 160 Radial shaft seal ring
80 Sealing cap 390 Bleeder valve
90 O-ring 410 Screw neck
94 Bearing pin 420 O-ring
100 Washer 480 Stop washer
110 Bearing pin 500 Stop screw
12.20.8 A 904 C-LI 16000-

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Fig. 6 Output (assembly 19)
19010 Radial shaft seal ring 19310 Locking plate

19030 Roller bearing 19320 Thrust washer
19080 Hub 19326 Allen head screw
19090 O-ring 19330 Shim
19100 Hollow gear 19336 Snap ring
19130 O-ring 19340 Sun gear shaft
19144 Backing ring 19350 Disc carrier
19154 Backing ring 19380 Snap ring
19180 Bushing 19390 Planetary carrier
19210 Lip seal 19400 Planetary gear
19214 Backing ring 19410 Roller bearing
19220 Lip seal 19412 Washer
19230 Backing ring 19420 Junk ring
19232 Back-up washer 19430 O-ring
19236 Spring sleeve 19480 Thrust washer
19238 Pressure spring 19484 Circlip
19244 Circlip 19490 Screw plug
19246 Hex head screw 19510 Allen head screw
19248 Locknut 19540 Wheel stud
19270 Outer disc 19550 Lock washer
19280 Inner disc 19560 Centring ring
19290 End washer 19570 Wheel lug
A 904 C-LI 16000- 12.20.9

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MJFCIFSS
ZP figure ZP figure
no. no.
1 17010 Axle housing 75 19220 Lip seal
8 17340 Bushing 76 19230 Backing ring
9 17350 Radial shaft seal ring 77 19323 Back-up washer
20 17540 Double joint drive 78 19236 Spring sleeve
shaft
31 18010 Right joint housing 79 19238 Pressure spring
32 18010 Slotted nut 80 19244 Circlip
34 18040 Lid 81 19246 Hex head screw
35 18050 Outer bearing race 82 19248 Locknut
36 18060 Inner bearing race 83 19270 Outer disc
37 18080 Sealing cap 84 19280 Inner disc
38 18090 O-ring 85 19290 End washer
39 18100 Washer 86 19310 Locking plate
40 18110 Bearing pin 87 19320 Thrust washer
41 18120 Hex head screw 88 19326 Allen head screw
42 18130 Lubrication nipple 89 19330 Shim
43 18150 Bushing 90 19336 Snap ring
45 18390 Bleeder valve 91 19340 Sun gear shaft
46 18410 Screw neck 92 19350 Disc carrier
53 18420 O-ring 93 19380 Snap ring
60 19010 Radial shaft seal ring 94 19390 Planetary carrier
61 19030 Roller bearing 95 19400 Planetary gear
62 19080 Hub 96 19410 Roller bearing
63 19090 O-ring 97 19420 Junk ring
64 19100 Hollow gear 98 19430 Snap ring
65 19130 O-ring 99 19480 Thrust washer
66 19144 Backing ring 101 19490 Screw plug
67 19154 Backing ring 103 19510 Allen head screw
71 19180 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
Note!
Observe settings and torques A, B, C, D, E, F, G, H, I, K, L, see Fig. 7 and Tabelle 1 auf Seite 3.
12.20.10 A 904 C-LI 16000-

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A 904 C-LI 16000- 12.20.11

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12.20.12 A 904 C-LI 16000-

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Function
AP - B 765 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,
see group 15.10.
Fig. 1 AP - B 765 rigid axle with drum brake
A 904 C-LI 16000- 12.22.1

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MJFCIFSS
General information
Machine A 904 C-Li

Machine model 439 / 440 / 441
Serial number 16000
Axle type AP-B 765
Gear ratio
Standard 20,36
Speeder 13,55
Brake Drum brake
Oil volume in axle
Axle housing 12.0 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 (new) 10 - 15 Nm
(without sealing element)
C Torque for the hex nut 31 1400 + 200 Nm
D Torque for the hex head screw 19 84 Nm
E Torque for the Allen head screws 27/28 280 Nm
F Torque for the Allen head screws 32 390 Nm
G Tightening torque for the Allen head screws 103 55 Nm
H Torque for the wheel lugs 107 420 Nm
I Drum brakes: Residual lining thickness of the brake system 2 mm
(glued) min.
Items A - I (see Fig. 6)
2.0.1 Tyre pressure

12.22.2 A 904 C-LI 16000-

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MJFCIFSS

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.
The sun gear shaft 91, which is connected through the sleeve 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).
manual.
The regular maintenance tasks include a test of the drum brake, see group 15.
Danger!
genossenschaft).
Disconnect the brake lines of the drum brakes and seal the line openings.
Remove the hex head nuts 3 or the hex head screw 4 respectively and remove the universal joint
shaft 5 from the differential of the rigid axle.
Remove the hex head nuts 7 and the screw 8, and lower the rigid axle 2.
5.2 Repair of the rigid axle
Note!
For detailed repair instructions for the axle, refer to the separate "Repair manual for AP-B 765 ZP
axles".
A 904 C-LI 16000- 12.22.3

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MJFCIFSS

Install the rigid axle 2 in the undercarriage 9, using lifting gear and secure with the hex head screw
8 and the nuts 7 to the undercarriage 9; lock the nuts 7.
Attach the universal joint shaft 5 to the differential of the rigid axle 2, using the hex nut 3 or the hex
head screw 4.
Connect the brake lines to the multi-disc brake and bleed the brake, see group 15.10.

5 Drive shaft
12.22.4 A 904 C-LI 16000-

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6 Exploded view of the rigid axle
Fig. 3 Axle housing (assembly 17)
.10 Axle housing part I .460 Self locking screw

.240 Screw plug .620 Screw plug
.250 Screw plug .690 Sleeve
.260 O-ring .700 Snap ring
.290 Stub shaft
A 904 C-LI 16000- 12.22.5

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Fig. 4 Drum brake 2
8 Slotted nut 203 Cylinder

9 Valance 210 Wheel cylinder
10 Hub carrier 220 Lock washer
40 Brake drum 230 Hex head screw
100 Allen head screw 240 Brake pad
101 Allen head screw 250 Pin
130 Disc 260 Locking plate
201 Brake disc 270 Tension spring
202 Adapter
12.22.6 A 904 C-LI 16000-

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MJFCIFSS
19010 Radial shaft seal ring 19412 Disc

19030 Roller bearing 19420 Circlip
19040 Ring (S = 26.0 - 27.2 mm) 19430 Snap ring
19080 Hub 19480 Thrust washer (S = 1.5 - 3.0 mm)
19160 Hollow gear 19500 Screw plug
19184 Locking plate 19510 Allen head screw
19190 Self locking screw 19540 Wheel stud
19340 Sun gear shaft 19550 Lock washer
19390 Planetary carrier 19560 Centring ring
19400 Planetary gear 19570 Wheel lug
19410 Roller bearing
A 904 C-LI 16000- 12.22.7

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MJFCIFSS
ZP figure ZP figure
no. no.
1 17010 Axle housing 61 19030 Roller bearing
7 17290 Stub shaft 62 19080 Hub
8 17690 Sleeve 63 19090 O-ring
9 17700 Snap ring 68 19160 Hollow gear
11 2040 Brake drum 71 19040 Ring
12 201 Brake disc 86 19184 Locking plate
13 202 Adapter 87 19190 Self locking screw
17 210 Wheel cylinder 91 19340 Sun gear shaft
18 220 Lock washer 94 19390 Planetary carrier
19 230 Hex head screw 95 19400 Planetary gear
20 240 Brake pad 96 19410 Roller bearing
21 250 Pin 97 19420 Junk ring
22 260 Locking plate 98 19430 Snap ring
23 270 Tension spring 99 19480 Thrust washer
27 100 Allen head screw 101 19490 O-ring
28 101 Allen head screw 102 19500 Screw
plug
30 10 Hub carrier 103 19510 Allen head screw
31 8 Slotted nut
32 80 Allen head screw 104 19540 Wheel stud
33 9 Valance 105 19550 Lock washer
37 22090 O-ring 106 19560 Centring ring
60 19010 Radial shaft seal ring 107 19570 Wheel lug
Note!
Observe settings and torques A, B, C, D, E, F, G, H, I, see Fig. 6 and Table 1, page 2.
12.22.8 A 904 C-LI 16000-

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MJFCIFSS
A 904 C-LI 16000- 12.22.9

copyright by
MJFCIFSS
12.22.10 A 904 C-LI 16000-

copyright by
MJFCIFSS
Service Manual AP - B 765 rigid axle with multi-disc brake
Function
AP - B 765 rigid axle with multi-disc brake
1 Function
It is applied when the brake pedal (working brake) is operated and brake is pressurised with brake oil.
For a detailed description of the brake system, see group 15.10.
Fig. 1 AP - B 765 rigid axle with multi-disc brake
A 904 C-LI 16000- 12.24.1

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MJFCIFSS
AP - B 765 rigid axle with multi-disc brake Service Manual
Function
12.24.2 A 904 C-LI 16000-

copyright by
MJFCIFSS
General information

Unit model 440 441
Serial number 16000 16000
Axle type AP-B 765
Gear ratio Standard 20.36
Speeder 13.55
Oil volume in axle (filling level at the check Axle housing 12.5 l
screws is binding) Planetary drive 2.0 l per side
Oil quality API - GL 5 / SAE 90 LS
A* End play of the stub shaft 7 0.4 - 0.6 mm
B* Clearance of the disc pack 83/84 (pis- new 2.4 - 2.8 mm
ton stroke) at max. wear 4.5 mm
C* Rolling resistance of the wheel bearing 61 (new) 10 - 15 Nm
D* Torque for the slotted nut 32 1200 - 1400 Nm
E* Torque for the hex head screws 33 390 Nm
F* Torque for the hex head screws 82 15 Nm
G* Torque for the Allen head screws 103 86 Nm
H* Torque for the wheel lugs 107 570 Nm
I* Multi-disc brakes:
* Items A - I (see Fig. 7)
2.0.1 Tyre pressure

A 904 C-LI 16000- 12.24.3

copyright by
MJFCIFSS

ge of the differential. The bevel pinion and crown wheel transfer the torque to the differential spider
with balancing and axle shaft gears, which is borne in the differential cage.
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 leads to a high speed reduc-
tion and thus a high torque transmission to the rotating planetary carrier 94. The planetary carrier 94,
via the wheel studs 104, drives the vehicle wheels with the resulting torque and speed (resulting from
the overall gear ratio).
manual.
The manufacturer also prescribes an annual inspection of the disc lining for wear, see Fig. 2.
If the annual inspection reveals wear, or if any of the following problems occurs, proceed as described
in 4.1:
4.1 Measuring of brake lining wear

carrier.
Calculate the difference between the two measurements "X" - "Y". This value corresponds to
the piston stroke.
Note!
Limit value for piston stroke with wear
AP - B 765 with 2 inner discs = 3.0 mm
AP - B 765 with 3 inner discs = 4.5 mm
12.24.4 A 904 C-LI 16000-

copyright by
MJFCIFSS
Fig. 2 A = screw plug M 16, B = measuring screw M 16
Danger!
genossenschaft).
Disconnect the brake lines of the multi-disc brakes and seal the line openings.
Loosen the hex head screw 4 and remove the universal joint shaft 5 from the differential of the
rigid axle.
Remove the hex nuts 7 and the screw 8 and then remove the rigid axle 2 from the undercarriage 9.
5.2 Repairs on the rigid axle
Note!
"Repair manual for AP-B 765 ZP axles"

Place the rigid axle 2 in the undercarriage 9, using suitable lifting tackle. Secure with the hex head
screw 8 and the nuts 7 to the undercarriage 9. Lock the nuts 7.
Attach the universal joint shaft 5 to the differential of the rigid axle 2, using the hex head screw 4.
A 904 C-LI 16000- 12.24.5

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Connect the brake lines to the brake and bleed it, see group 15.10.

5 Drive shaft
12.24.6 A 904 C-LI 16000-

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5.4 Exploded view of the rigid axle
Fig. 4 Axle housing 17
17010 Axle housing 17290 Stub shaft

17240 Screw plug 17460 Self locking screw
17250 Screw plug 17620 Screw plug
17260 O-ring
A 904 C-LI 16000- 12.24.7

copyright by
MJFCIFSS
Fig. 5 Drum brake 22
22010 Hub carrier 22280 Screw neck

22010 Slotted nut 22300 O-ring
22050 Valance 22320 Bleeder valve
22070 Hex head screw
12.24.8 A 904 C-LI 16000-

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19010 Radial shaft seal ring 19280 Inner disc

19030 Roller bearing 19290 End washer
19080 Hub 19310 Locking plate
19090 O-ring 19320 Thrust washer
19100 Internal gear carrier (old) 19340 Sun gear shaft
19144 Backing ring 19350 Disc carrier
19154 Backing ring 19380 Snap ring
19160 Hollow gear (old) 19390 Planetary carrier
19170 Circlip (old) 19400 Planetary gear
19174 Circlip (old) 19410 Roller bearing
19180 Bushing (26.0 - 27.2) 19420 Junk ring
19200 Piston (old) 19430 Snap ring
19210 Lip seal 19480 Thrust washer (1.5 mm - 3.0 mm)
19214 Backing ring 19484 Circlip
19220 Lip seal 19490 O-ring
19230 Backing ring 19500 Screw plug
19232 Back-up washer 19510 Allen head screw
19236 Spring sleeve 19540 Wheel stud
A 904 C-LI 16000- 12.24.9

copyright by
MJFCIFSS
19238 Pressure spring 19550 Lock washer

19244 Circlip 19560 Centring ring
19246 Hex head screw 19570 Wheel lug
19248 Locknut 191000 Hollow wheel (new one-piece)
19260 Radial shaft seal ring 192000 Piston (new)
19270 Outer disc (2.0 mm - 3.0 mm)
ZP figure ZP figure
no. no.
1 17010 Axle housing part 81 19246 Hex head screw
7 17290 Stub shaft 82 19248 Locknut
30 22050 Valance 83 19270 Outer disc
31 22010 Hub carrier 84 19280 Inner disc
32 22010 Slotted nut 85 19290 End washer
33 22070 Hex head screw 86 19310 Locking plate
45 22280 Screw neck 87 19320 Thrust washer
46 22300 O-ring 91 19340 Sun gear shaft
47 22320 Bleeder valve 92 19350 Disc carrier
60 19010 Radial shaft seal ring 93 19380 Snap ring
61 19030 Roller bearing 94 19390 Planetary carrier
62 19080 Hub 95 19400 Planetary gear
63 19090 O-ring 96 19410 Roller bearing
65 19130 O-ring 97 19420 Junk ring
66 19144 Backing ring 98 19430 Snap ring
67 19154 Backing ring 99 19480 Thrust washer
68 19160 Hollow gear 100 19484 Circlip
71 19180 Bushing 101 19490 O-ring
73 19210 Lip seal 102 19500 Screw plug
74 19214 Backing ring 103 19510 Allen head screw
75 19220 Lip seal 104 19540 Wheel stud
76 19230 Backing ring 105 19550 Lock washer
77 19232 Back-up washer 106 19560 Centring ring
78 19236 Spring sleeve 107 19570 Wheel lug
79 19238 Pressure spring 108 19260 Radial shaft seal ring
80 19244 Circlip 109 19494 O-ring
Note!
Observe settings and torques A, B, C, D, E, F, G, H, I, see Fig. 7 and Tabelle 1 auf Seite 3.
12.24.10 A 904 C-LI 16000-

copyright by
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A 904 C-LI 16000- 12.24.11

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12.24.12 A 904 C-LI 16000-

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Function
Differential for AP / APL - B 765 axles
1 Function
The differential is built into the axle housing of the steering and rigid axle. It transmits 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 a equalising device when the vehicle is negotiating a corner. If the me-
axle shaft gears.
The balancing movement has however a negative effect on the traction of the excavator when driving
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
A 904 C-LI 16000- 12.26.1

copyright by
MJFCIFSS
General information
Machine A 904 C-Li

Unit model 439 / 440 / 441
Serial number 16000
Axle type BK
Gear ratio 3.18
D Rolling resistance of the driving pinion bearing 3/4 2 -3 Nm
B Rolling resistance of the differential bearing 8/10 1 - 4 Nm
C Setting value of the bevel gear kit 25 etched onto the end face of
the pinion
D Tooth backlash of the bevel gear kit 25 0.15 - 0.20 mm

E Max. wobble of the crown wheel 25 0.08 mm
F Width of the bearing bracket 2.2 on the axle drive housing 258 ± 0.1 mm
G Torque for the hex head screws 2.3 190 Nm
H Torque for the adjusting nut 11 550 Nm
I Torque for the hex nut 16 600 Nm
Secure with Loctite 262
K Torque for the
hex head screws 34 (M12x1.5/10.9) 125 Nm
hex head screws 35 (M16x1.5/10.9) 315 Nm
L Torque for the
hex head screws and nuts 41/42/44
(M14x1.5/12.9) 250 Nm
Torque for the 300 Nm
hex head screws / guide M16
(only in steering axle, see steering system)
Items A - L (see Fig. 4)
12.26.2 A 904 C-LI 16000-

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Dismantling, repair and installation of the differential of the steering axle
3 Dismantling, repair and installation of the differential of the stee-

ring axle
Danger!
Prior to dismantling the differential, take all necessary safety measures to protect persons and ma-
3.1 Dismantling of the differential for repair work

Secure the wheels of the rigid axle with wheel chocks.
Lift the machine at the front and support the undercarriage.
Remove the wheels of the steering axle and disconnect the brake and steering cylinder lines.
Remove the screw plug of the axle housing (oil discharge) and drain the gear oil into a suitable
container.
Close the screw plug.
Release the slotted nut of the tie rods and remove it. Remove the tie rod from the right and left
joint housings.
Remove the hex head screws of the axle drive housing bearings and dismantle the bearing pins
at the top and bottom. Remove the entire drive system with the double joint drive shaft from the
axle housing, holding the spacers at the upper bearing pins.
Disconnect the universal joint shaft from the differential. Remove the self locking screws and lock-
nuts. To release the upper locknuts you might have to first remove the piston rod guide of the stee-
ring cylinder. Screw in the two adjusting screws, secure the differential to lifting tackle and remove
it from the axle housing.
3.2 Repair of differential
Note!
For detailed repair instructions for the differential, refer to the separate "Repair manual for AP /
APL-B 765 ZP axles".
A 904 C-LI 16000- 12.26.3

copyright by
MJFCIFSS
Dismantling, repair and installation of the differential of the rigid axle
3.3 Installation of the differential

Apply Loctite 262 onto the flange face between the axle housing and the differential. Screw in the
two adjusting screws and insert the differential into the axle housing.
Screw in the self locking screws and the locknuts, connect the universal joint shafts to the diffe-
rential and secure them (observe torques), see Tabelle 1 auf Seite 2
Mount the complete planetary drive on the axle housing and insert the double joint drive shaft into
the differential.
Insert the spacers at the upper bearing bores, and insert the upper and lower bearing pins.
Screw in the hex head screws of the bearing pins.
Insert the tie rods into the joint housing.
Mount and secure the slotted nut.
Remove the screw plug of the axle housing (oil check) and add gear oil (see recommended pro-
ducts). Close the screw plug.
Connect the lines to the brakes and the steering cylinder. Bleed the brake and the steering.
Mount the vehicle wheels with centring and lock washers and insert the wheel lugs. Tighten them
with the prescribed torque, see group 12.20.
.
Caution!
All self locking screws and nuts of the differential and the universal joint shaft may only be used on-
ce.
4 Dismantling, repair and installation of the differential of the rigid

axle
The procedures differs slightly for machines with multi-disc brakes and those with drum bra-
kes respectively:
Danger!
Prior to dismantling the differential, take all necessary safety measures to protect persons and ma-
4.1 Dismantling of the differential of the rigid axle with multi-disc or drum brake
Secure the wheels of the steering axle with wheel chocks.
Lift the machine at the rear and support the undercarriage.
Remove the wheels from the rigid axle and disconnect the brake lines.
Remove the screw plugs from the axle housing and the planetary drives (oil discharge) and drain
the gear oil into a suitable container (multi-disc brake only).
Insert the screw plug of the axle housing (multi-disc brake only).
Remove the Allen screws of the planetary drives and pull the planetary carriers 94 on both sides
from the hubs 62. Remove the complete sun gear shafts with the disc carriers from the stub shafts
and the disc packs (multi-disc brake only).
Remove the brake drum 40 (drum brake only).
Remove the Allen screws of the planetary drives and pull the planetary carriers 94 on both sides
12.26.4 A 904 C-LI 16000-

copyright by
MJFCIFSS
from the hubs 62. Remove the complete sun gear shafts from the stub shafts and the disc packs
(multi-disc brake only).
Pull the stub shafts from the differential.
Top the snap ring out of the hollow gear and remove the disc packs with the end washers (required
for subsequent installation of the disc carriers, multi-disc brake only).
Disconnect the universal joint shaft from the differential. Mark the differential at the axle housing
side. Remove the self locking screws and pull the entire differential from the axle housing.
Note!
For detailed repair instructions for the differential, refer to the separate "Repair manual for AP /
APL-B 765 ZP axles".
4.3 Installation of the differential of the rigid axle with multi-disc or drum brake
Apply Loctite 262 onto the flange face between the axle housing and the differential. Screw in the
two adjusting screws and insert the differential into the axle housing (observe marks).
Insert the self locking screws 41/42 , attach the universal joint shaft to the differential and secure
it (for torques, see Tabelle 1 auf Seite 2
Insert the stub shafts into the differential to the stop.
Move the disc carrier with the sun gears on both sides across the stub shaft gearing and position
against the thrust washers (multi-disc brake only).
Alternately mount the outer and inner discs, starting with an outer disc, observing the disc se-
quence (multi-disc brake only).
Mount the end washer and top the snap rings into the hollow wheels.
Mount the planetary carriers with the sun gear shaft, tighten the Allen screws and mount the brake
drum.
Note!
All self locking screws and nuts of the differential and the universal joint shaft may only be used on-
ce.
A 904 C-LI 16000- 12.26.5

copyright by
MJFCIFSS
4.4 Exploded view of the differential
Fig. 2 Differential 55
55001 Differential 55230 Roll pin

55020 Axle drive housing 55280 Radial shaft seal ring
55060 Inner bearing race 55300 Washer
55070 Outer bearing race 55320 Hex nut
55090 Bushing 55330 Ring
55130 Adjusting disc 55420 Input flange
55140 Roller bearing 55430 Protective plate
55170 Roller bearing 55440 Hex head screw
55210 Roller bearing 55500 Bevel gear kit
55220 Adjusting nut
12.26.6 A 904 C-LI 16000-

copyright by
MJFCIFSS
Fig. 3 Differential 53
53570 Differential cage 53700 Differential spider

53640 Axle shaft gear 53800 Hex head screw
53650 Thrust washer 53850 Hex head screw
53670 Balancing bevel gear 53860 Roll pin
53680 Thrust washer 53870 Roll pin
A 904 C-LI 16000- 12.26.7

copyright by
MJFCIFSS
5 Sectional drawing of the differential
Item ZP figure Description Item ZP figure Description

no. no.
1 Axle housing I 25 55500 Bevel gear kit
2.1 55020 Axle drive housing 26 53570 Differential cage
2.2 55020 Bearing bracket
2.3 Hex head screw 27 53640 Axle shaft gear
3 55060 Inner bearing race 28 53650 Thrust washer
4 55070 Outer bearing race 29 53670 Balancing shaft gear
5 55330 Ring 30 53680 Thrust washer
7 55130 Adjusting disc 31 53700 Differential spider
8 55140 Roller bearing 34 53800 Hex head screw
9 55170 Roller bearing 35 53850 Hex head screw
10 55210 Roller bearing 36 53860 Roll pin
11 55220 Adjusting nut 37 53870 Roll pin
12 55230 Roll pin 40 17360 Bushing*
14 55280 Radial shaft seal ring 41 17460 Self locking screw
15 55300 Washer 42 17470 Self locking screw*
16 55320 Hex nut 17480 Stud*
18 55420 Output flange 17490 Locknut*
19 55430 Protective plate
*These components are not part of rigid axle differentials
Note!
Observe settings and torques A, B, C, D, E, F, G, H, I, K, L (see Fig. 4 and Tabelle 1 auf Seite 2).
The design of the rigid axle differential differs slightly from that of the steering axle.
12.26.8 A 904 C-LI 16000-

copyright by
MJFCIFSS
A 904 C-LI 16000- 12.26.9

copyright by
MJFCIFSS
12.26.10 A 904 C-LI 16000-

copyright by
MJFCIFSS
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 13.31.
Fig. 1 MS - E 3060 steering axle
12.40.1
copyright by
MJFCIFSS
MS - E 3060 steering axle Service Manual
Function
12.40.2
copyright by
MJFCIFSS
Technical data
2 Technical data
Machine A 900 C-Li

Machine model 1002
Serial number 24677
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
Low pressure test 5 bar
Visible pressure drop after 5 minutes is not permissible
Tightening torque of the slotted nut / tie rods, 100 Nm
see steering
* Items A - K, see Fig. 10
Tyre pressure
12.40.3
copyright by
MJFCIFSS
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
12.40.4
copyright by
MJFCIFSS
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!
For a detailed description of the differential, see group 12.44.
12.40.5
copyright by
MJFCIFSS
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
12.40.6
copyright by
MJFCIFSS
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
12.40.7
copyright by
MJFCIFSS
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
71 Screw plug 90 Pressure spring
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
80 Snap ring 97 Outer 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
12.40.8
copyright by
MJFCIFSS

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).
12.40.9
copyright by
MJFCIFSS
Danger!
For maintenance work on the axles, the undercarriage of the machine must be accessed, which po-
ses a great danger for mechanics.
manual. Regularly check the wheel lugs 108 for the correct tightening torque, (see Tab. 1, page 3).
The oscillating axle bearing of the steering knuckle bearing must be lubricated and lubricating oil must
be changed at fixed intervals laid down in the inspection and maintenance schedule.
The testing of the multi-disc brake is an integral part of the maintenance; for detailed instructions, see
also chapter "Brakes" in group 15.10.
The manufacturer also prescribes an annual inspection of the disc lining for wear, (see Fig. 8, page
11).
The above check must be carried out annually, or if one of the following problems arise:
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).
12.40.10
copyright by
MJFCIFSS
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 (Ø 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
12.40.11
copyright by
MJFCIFSS
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.
Lift the undercarriage 5 at the front and secure the wheels of the rigid axle 4 using chocks.
Loosen the hex head screws 2 and remove the universal joint shaft 3.
Remove the hex head screws 6 and remove the plate 7. Drive out the bolt 8 and lower the steering
axle 4.
6.2 Repairs to the steering axle
Note!
For detailed repair instructions for the axle, refer to the separate Repair manual for ZF axles MS-
E 3050/3060/3070.

Install the steering axle 4 in the undercarriage, using lifting gear, and drive in the pin 8.
Secure the universal joint shaft 3 with the screws 2 to the output flange / output of the steering
axle 4.
13.20).
12.40.12
copyright by
MJFCIFSS
1 Vehicle wheels 6 Hex head screw

2 Hex head screw 7 Plate
3 Joint shaft 8 Pin
5 Undercarriage 11 Lock nut
12.40.13
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MJFCIFSS
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
57 O-ring 93 Hex head screw
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!
Observe settings and torques A, B, C, D, E, F, G, H, I, K, see Fig. 10 and Table 1, page 3.
12.40.14
copyright by
MJFCIFSS
12.40.15
copyright by
MJFCIFSS
12.40.16
copyright by
MJFCIFSS
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
12.42.1
copyright by
MJFCIFSS
MT - E 3060 rigid axle Service Manual
Function
12.42.2
copyright by
MJFCIFSS
Technical data
2 Technical data
Machine A 900 C-Li

Machine model 1002
Serial number 24677
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
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
I* Check of multi-disc brakes:
* Items A - H (see Fig. 10)
Tyre pressure
12.42.3
copyright by
MJFCIFSS
Description
3 Description
The rigid axle screw-mounted to the undercarriage consists of the following main components:
Axle housing 3
Hub carrier 4
Drive unit 5
Fig. 2 Design of rigid axle
1 Input 5 Output
drive
4 Hub carrier 8 Oil discharge / axle housing
12.42.4
copyright by
MJFCIFSS
Description
Fig. 3 Design of the drive unit

11 Pinion 21 Washer
15 Ring (S=10.94-12.38mm) 25 Balancing shaft gear
Note!
12.42.5
copyright by
MJFCIFSS
Description
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
12.42.6
copyright by
MJFCIFSS
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
12.42.7
copyright by
MJFCIFSS
Description

77 Washer 95 O-ring
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
12.42.8
copyright by
MJFCIFSS

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.
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).
12.42.9
copyright by
MJFCIFSS
Danger!
For maintenance work on the axles, the undercarriage of the machine must be accessed. This po-
The lubricating oil must be changed at fixed intervals laid down in the inspection and maintenance
schedule.
11).

Caution!
12.42.10
copyright by
MJFCIFSS

the piston 89.
measured value.
.
Note!
Limit value for piston travel with wear at 6 discs = 6.0 mm.
2 Measuring bore (Ø 10 mm) 83 Hollow gear

Oil filling/ oil discharge bore
12.42.11
copyright by
MJFCIFSS
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.
Lift the undercarriage 5 at the rear and secure the wheels of the steering axle using chocks.
If required, remove the vehicle wheels 1 from the rigid axle .
Disconnect and seal the brake line to the multi-disc brakes (collect any escaping oil).
Loosen the hex head screws 2 and remove the universal joint shaft 3.
Lift the undercarriage 5 and secure the rigid axle 8 with suitable lifting tackle.
Loosen the hex nuts 9 and remove the hex head screws 7. Lift the rigid axle 8 from the 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

Place the rigid axle 8 in the undercarriage 5, using suitable lifting gear.
Screw in the hex head screw 7 and tighten it with the prescribed torque.
Secure the universal joint shaft 3 with the screws 2 to the output flange / drive of the rigid axle 8.
12.42.12
copyright by
MJFCIFSS
1 Vehicle wheels 5 Undercarriage

2 Hex head screw 6 Washer
3 Joint shaft 7 Hex head screw
4 Lock nut 8 Rigid axle
12.42.13
copyright by
MJFCIFSS
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
57 Hex head screw 95 O-ring
70 Planetary carrier 96 Inner disc
74 Allen head screw 97 Outer disc
75 Circlip 99 Roller bearing
76 Planetary gear 100 Spacer bushing
77 Washer 101 Hub
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!
12.42.14
copyright by
MJFCIFSS
12.42.15
copyright by
MJFCIFSS
12.42.16
copyright by
MJFCIFSS
Service Manual MS/MT - E 3060 drive unit and differential
Function
MS/MT - E 3060 drive unit and differential
1 Function
The drive unit and differential are integrated into the axle housing of the steering and rigid axle. They
transmit the output power of the transmission to the planetary drives of the wheel hubs, adjusting the
speed and torque by means of bevel pinions and the crown wheel.
The differential also acts as an equalising device when the vehicle is negotiating a corner. If the me-
axle shaft gears.
Fig. 1 Differential
12.44.1
copyright by
MJFCIFSS
MS/MT - E 3060 drive unit and differential Service Manual
Function
12.44.2
copyright by
MJFCIFSS
Technical data
2 Technical data
Machine A 900 C-Li

Machine model 1002
Serial number 24677
Axle type MT-MS
Gear ratio 3,18
This differential is not available as a complete unit. The component parts of the differentials for the
steering and the rear axle are identical.
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
G Tightening torque for the Allen head screws 20 145 Nm
Items A - G
12.44.3
copyright by
MJFCIFSS
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
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
20 Allen head screw 49 Hex head screw
12.44.4
copyright by
MJFCIFSS
Description
3.1 Design of differential
Fig. 2 Design of differential
12.44.5
copyright by
MJFCIFSS
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 12.40 for the steering axle and group 12.42 for the rigid axle.
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.
12.44.6
copyright by
MJFCIFSS
12.44.7
copyright by
MJFCIFSS
12.44.8
copyright by
MJFCIFSS
Function
MS - E 3070 steering axle
1 Function
wheels, is equipped with a built-in drive / differential.
gear ratio in the drive, the differential 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.
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.
Fig. 1 MS - E 3070 steering axle
12.50.1
copyright by
MJFCIFSS
Function
12.50.2
copyright by
MJFCIFSS
Technical data
2 Technical data
Axle type MS-E 3070

Gear ratio 16,00
Oil volume in axle
Axle housing 9.6 l
Axle housing (in type 1004: extended axles) 11.0 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 6.5 mm
C* Rolling resistance of joint housing bearing 68 40 - 50 Nm
D* Rolling resistance of wheel bearing 99 8 - 12 Nm
E* Torque for the slotted nut 54 1400 + 200 Nm
G* Torque for the hex head screws 93 11 Nm
H* Torque for the Allen head screws 74 55 Nm
I* Torque for the wheel lugs 108 460 Nm
K* Check of multi-disc brakes:
Tightening torque of the slotted nut / tie rods, 100 Nm
see steering
* Items A - K, see Fig. 10
Tyre pressure
12.50.3
copyright by
MJFCIFSS
Design
3 Design
The steering axle screw-mounted to the undercarriage consists of the following main components:
Axle housing 3
Joint housing 4 with axle drive housing
Drive unit 5
Steering 6
Fig. 2 Design of steering axle
1 Input 6 Steering
drive
4 Joint housing 9 Oil discharge / axle housing
5 Output
12.50.4
copyright by
MJFCIFSS
Design
Fig. 3 Design of drive unit/differential

11 Pinion 21 Allen head screw
15 Ring (S=10.94-12.38mm) 25 Balancing shaft gears
Note!
12.50.5
copyright by
MJFCIFSS
Design
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 with washer
38 Double yoke 110 O-ring
39 Joint yoke (sun gear shaft) 111 Washers
40 Tie rod (left) 112 Roller bearing
41 Ball joint
12.50.6
copyright by
MJFCIFSS
Design
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
12.50.7
copyright by
MJFCIFSS
Design

77 Disc 95 O-ring
81 Thrust washer (S = 1.50-3.00mm) 98 O-ring
83 Hollow gear 101 Hub
84 Cylinder pin 103 Radial shaft seal ring
85 Backing ring 104 Allen head screw
87 Lip seal
12.50.8
copyright by
MJFCIFSS

The input torque of the transmission is transmitted through the drive shaft to the input flange of the
drive system. A bevel pinion and crown wheel transfer the torque via the differential case/differential
to the differential spider with balancing and axle shaft gears, which is borne in the cage.
results in a great speed reduction and associated power transmission to the rotating planetary carrier
70. The planetary carrier 70 drives the vehicle wheels through the wheel studs 105 with the respec-
tive force and speed (based on the overall gear ratio).
12.50.9
copyright by
MJFCIFSS
Danger!
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.
11).

Caution!
12.50.10
copyright by
MJFCIFSS

the piston 89.
measured value.
Note!
Limit value for piston stroke with wear = 6.5 mm.
Remove the dial gauge 3 with the magnetic stand.

2 Internal measuring bore (Ø = 10 mm) 83 Hollow gear

12.50.11
copyright by
MJFCIFSS
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.
Lift the undercarriage 5 at the front and secure the wheels of the rigid axle using chocks.
Remove the hex head screws 2 and the lock nuts 11 and remove the universal joint shaft 3.
Remove the hex head screws 6 and the plate 7, drive out the pin 8 and lower the steering axle 4,
(observe position of the spacers 9).
6.2 Repairs to the steering axle
Note!
E 3050/3060/3070".

Insert the steering axle 4 in the undercarriage 5, using suitable lifting tackle. Insert and drive in the
pin 8 (observe position of spacers 9).
Secure the pin 8 with the plate 7 and the screws 6.
Secure the universal joint shaft 3 with the screws 2 and lock nuts 11 to the input flange / input of
the steering axle 4.
13.25).
12.50.12
copyright by
MJFCIFSS

2 Hex head screw 8 Bolt
5 Undercarriage 11 Lock nut
6 Hex head screw with washer
12.50.13
copyright by
MJFCIFSS
30 Axle housing 76 Planetary gear

36 Yoke 78 Roller bearing
37 Joint yoke 82 O-ring
38 Double yoke 83 Hollow gear
39 Joint shaft (sun gear shaft) 85 Backing ring
50 Joint housing 86 Lip seal
51 Snap ring 87 Lip seal
52 Thrust washer 88 Backing ring
53 Thrust washer 89 Piston
54 Slotted nut 90 Pressure spring
56 Sealing cap 91 Pressure spring
57 O-ring 92 Spring sleeve
59 Lubrication nipple 94 Disc carrier
61 Washer (S=0.60-2.00mm) 96 Inner disc
62 Bearing pin 97 Outer disc
63 Lubrication nipple 99 Roller bearing
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
Note!
Observe settings and torques A, B, C, D, E, F, G, H, I, K, see Fig. 10 and Table 1, page 3.
12.50.14
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MJFCIFSS
12.50.15
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MJFCIFSS
12.50.16
copyright by
MJFCIFSS
Function
MT - E 3070 rigid axle
1 Function
is equipped with a built-in drive / differential.
gear ratio in the drive, the differential 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 3070 rigid axle
12.52.1
copyright by
MJFCIFSS
Function
12.52.2
copyright by
MJFCIFSS
Technical data
2 Technical data
Axle type MT-E 3070

Gear ratio Standard 16,00
Oil volume in axle
Axle housing 13.1 l
Axle housing (in type 1004: extended axles) 14.5 l
Planetary drive (in type 1004: extended axles) 2.5 l per side
Planetary drive
B* Clearance of the disc pack 96/97 (pis- new 0.7 - 1.3 mm
ton 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
I Check of multi-disc brakes:
* Items A - H (see Fig. 10)
Tyre pressure
12.52.3
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MJFCIFSS
Design
3 Design
The rigid axle screw-mounted to the undercarriage consists of the following main components:
Axle housing 3
Hub carrier 4
Drive unit 5
Fig. 2 Design of rigid axle
1 Input 5 Output
drive
4 Hub carrier 8 Oil discharge / axle housing
12.52.4
copyright by
MJFCIFSS
Design
Fig. 3 Design of the drive unit

11 Pinion 21 Allen head screw
15 Ring (S=10.94-12.38mm) 25 Balancing shaft gears
Note!
12.52.5
copyright by
MJFCIFSS
Design
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 Disc
12.52.6
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MJFCIFSS
Design
3.3 Design of the 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 Disc
52 Bleeder 57 Hex head screw
53 Plug
12.52.7
copyright by
MJFCIFSS
Design

77 Disc 95 O-ring
81 Thrust washer (S = 1.50-3.00mm) 98 O-ring
83 Hollow gear 101 Hub
84 Cylinder pin 103 Radial shaft seal ring
85 Backing ring 104 Allen head screw
87 Backing ring
12.52.8
copyright by
MJFCIFSS

The input torque of the transmission is transmitted through the drive shaft to the input flange of the
drive. 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.
results in a great speed reduction and associated power transmission to the rotating planetary carrier
70. The planetary carrier 70 drives the vehicle wheels through the wheel studs 105 with the respec-
tive force and speed (based on the overall gear ratio).
12.52.9
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MJFCIFSS
Danger!
The lubricating oil must be changed at fixed intervals laid down in the inspection and maintenance
schedule.
11).

Caution!
12.52.10
copyright by
MJFCIFSS

the piston 89.
measured value.
.
Note!
2 Internal measuring bore (Ø = 10 mm) 83 Hollow gear

12.52.11
copyright by
MJFCIFSS
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.
Lift the undercarriage 5 at the rear and secure the wheels of the steering axle using chocks.
If required, remove the vehicle wheels 1 from the rigid axle.
Disconnect and seal the brake line to the multi-disc brakes (collect any escaping oil).
Remove the hex head screws 2 and the lock nuts 11 and remove the universal joint shaft 3.
Lift the undercarriage 5 and secure the rigid axle 8 with suitable lifting tackle.
Loosen the hex nuts 4 and remove the hex head screws 7. Lift the rigid axle 8 from the undercar-
riage 5.
Note!
E 3050/3060/3070".

Place the rigid axle 8 in the undercarriage 5, using suitable lifting gear.
Screw in the hex head screw 7, mount the lock nuts 4 and tighten them with the prescribed torque.
Secure the universal joint shaft 3 with the screws 2 and lock nuts 11 to the input flange / input of
the rigid axle 8.
12.52.12
copyright by
MJFCIFSS
1 Vehicle wheels 6 Disc

2 Hex head screw 7 Hex head screw
3 Joint shaft 8 Rigid axle
4 Lock nut 11 Lock nut
5 Undercarriage
12.52.13
copyright by
MJFCIFSS
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
57 Hex head screw 94 Disc carrier
70 Planetary carrier 95 O-ring
74 Allen head screw 96 Inner disc
75 Circlip 97 Outer disc
76 Planetary gear 99 Roller bearing
77 Disc 101 Hub
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!
12.52.14
copyright by
MJFCIFSS
12.52.15
copyright by
MJFCIFSS
12.52.16
copyright by
MJFCIFSS
Function
MS/MT - E 3070 drive unit and differential
1 Function
The drive unit and differential are integrated into the axle housing of the steering and rigid axle. They
transmit the output power of the transmission to the planetary drives of the wheel hubs, adjusting the
speed and torque by means of bevel pinions and the crown wheel.
The differential also acts as an equalising device when the vehicle is negotiating a corner. If the me-
axle shaft gears.
Fig. 1 Differential
12.54.1
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MJFCIFSS
Function
12.54.2
copyright by
MJFCIFSS
Technical data
2 Technical data
Axle type MT-MS

Gear ratio 3,18
This differential is not available as a complete unit. The component parts of the differentials for the steering and
the rear axle are identical.
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
G Torque for the hex head screws 20 300 Nm
H Torque for the hex head screws 21 122 Nm
Items A - H (see Fig. 3, page 7)
12.54.3
copyright by
MJFCIFSS
Design
3 Design
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 Drive unit (complete) 22 Differential cage

2 Differential (complete) 23 Thrust washer
3 Axle housing (complete) 24 Axle shaft gear
10 Crown wheel 25 Balancing shaft gears
11 Pinion 26 Thrust washer
12 Roller bearing 27 Balancing axle
13 Disc (S=0.70-1.50mm) 28 Heavy-duty roll pin
14 Roller bearing 29 Roll pin
15 Ring (S=10.94-12.38mm) 31 Axle drive housing
16 Radial shaft seal ring 32 Clamping bush
17 Protective plate 33 Roller bearing
18 Input flange 34 Washer
19 Hex nut with washer 35 O-ring
20 Hex head screw 49 Hex head screw
21 Hex head screw
12.54.4
copyright by
MJFCIFSS
Design
3.1 Design of differential
Fig. 2 Design of differential
12.54.5
copyright by
MJFCIFSS
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 12.50 for the steering axle and group 12.52 for the rigid axle.
Note!
"ZF axles MT/MS-E 3050/3060/3070".
10 Crown wheel 24 Axle shaft gear

11 Pinion 25 Balancing shaft gears
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 30 Axle housing
17 Protective plate 31 Axle drive housing
18 Output flange 32 O-ring
19 Hex nut with washer 33 Roller bearing
20 Hex head screw 34 Washer
22 Differential cage 36 Stub shaft
23 Thrust washer 49 Hex head screw
Note!
Observe settings and torques A, B, C, D, E, F, G, and H, and well as Table 1, page 3.
12.54.6
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MJFCIFSS
12.54.7
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MJFCIFSS
12.54.8
copyright by
MJFCIFSS
Service Manual
SUBGROUP - INDEX
Section Group Type
Hydraulic steering system 13.10.1 A 900 C-LI 14675-

A 904 C-LI 16000-
A 914 C-LI 35112-
A 924 C-LI 34519-
Servostat 13.20.1 A 900 C-LI 14675-

A 904 C-LI 16000-
Steering valve 13.25.1 A 900 C-LI 14675-18087

A 904 C-LI 16000-
A 914 C-LI 35112-
A 924 C-LI 34519-
Steering cylinder 13.30.1 A 900 C-LI 14675-
Steering cylinder 13.31.1 A 900 C-LI EDC 24677-
Steering cylinder 13.32.1 A 904 C-LI 16000-
Steering cylinder 13.33.1 A 904 C-LI-IND 30580-

A 914 C-LI 35112-
A 924 C-LI 34519-
13.1
MJFCIFSS
Service Manual
13.2
MJFCIFSS
Service Manual Hydraulic steering system
Function
Hydraulic steering system
1 Function
The hydrostatic steering is designed as a hydraulic power assisted steering with hydrostatic
transmission of the steering effort to the wheels. There is no mechanical connection to the steering
axle.
Fig. 1 Hydraulic steering system
2 Description
2.1 Steering pump 31

The hydraulic pump consists of a gear pump that is directly connected with a flange to the diesel
engine.
The pump takes up hydraulic oil from the tank 1 and transfers it to the steering valve / Servostat 84.
2.2 Steering valve / Servostat 84, see Fig. 6

The Servostat 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.
13.10 1
MJFCIFSS
Hydraulic steering system Service Manual
Description
The oil is pumped from the pump 31 through the pressure port P to the Servostat/steering valve.
When the steering wheel is turned, the operating connection L or R of the steering cylinder 86 is
pressurised. The return oil is fed through the tank port T to the tank 1.
Fig. 2 Steering column a, gear pump 82 and steering valve/Servostat 84
2.3 Rotary connection 85, see Fig. 3

The seven-fold oil rotary connection is a special connection for hydraulic oil between the
uppercarriage and the undercarriage and is located at the centre of the slewing ring.
The pressure oil from the steering valve/Servostat 84 is fed through the slewing ring 85 to the steering
cylinder 86, while the return oil flows from the steering cylinder via the steering valve/Servostat 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 steering valve/Servostat 84 so that
the connected steering knuckles are moved ever time the piston rod is moved in axial direction,
adjusting the steering angle of the wheels.
13.10 2
MJFCIFSS
Function of the steering system
Fig. 3 Rotary connection 85 and steering cylinder 86
3 Function of the steering system
see Fig. 6
The gear pump 31 takes up oil from the tank 1 and transfers it to the steering valve/Servostat 84
port P. When the valve actuator in the steering valve/Servostat 84 is in neutral position (neutral
position of the steering wheel), oil flows through port T back to the tank 1.
By turning the steering wheel to the left or right, the pressure oil flows from the steering valve/
Servostat 84, connection L or connection R, and the rotary connection 85 to the respective side of
the steering cylinder 86. The return oil flows from the steering cylinder through the non-pressurised
side back to the tank 1.
By pressurising the steering cylinder 86, the piston with the piston rod is moved in the corresponding
direction, thus rotating the steering housing (steering knuckles) so that the axle is steered.
The built-in hand pump of the steering valve/Servostat 84 can be used to pressurise the steering
cylinder 86 in the event of a failure of the gear pump 31.
The integrated primary and secondary pressure relief valves of the steering valve/Servostat 84
protect the entire steering system against excess pressure.
3.1 Pressure check and adjustment of the steering system
Note!
The pressure adjustments must be made at operating temperature of the hydraulic oil and at full
throttle. To adjust the pressure settings, use suitable pressure sensors.
13.10 3
MJFCIFSS
3.2 Inspection of the primary pressure relief valve 5/29 in the steering valve/
Servostat 84
Fig. 4 A: Steering valve 84 (A 900 C 14675 - 18087); (A 904 C)
Turn the vehicle wheels to the outer steering stop, and then continue turning the steering wheel.
Measure the pressure at the pressure sensor and compare it with the nominal pressure (see group
13.20 or 13.25). If necessary, replace the primary cartridge (not adjustable).
13.10 4
MJFCIFSS
3.3 Shock valves 6 and secondary pressure relief valves 44 in the steering valve/
Servostat 84
Fig. 5 Shock valve 6 in the steering valve 84 and secondary pressure relief valve 44
Note!
The secondary pressure relief valves 44 (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 steering
valve/Servostat 84 (see groups 13.20 and 13.22).
13.10 5
MJFCIFSS
Fig. 6 Hydraulic diagram of the steering system, a = direction of travel
1 Hydraulic tank 84 Servostat / steering valve

31 Steering pump 85 Rotary connection (320*)
83 Measuring point for steering 86 Steering cylinder
L/P operating connection R/T operating connection
* items in hydraulic diagram
13.10 6
MJFCIFSS
Service Manual Servostat
Function
Servostat
1 Function
The Servostat 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.
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
MJFCIFSS
Servostat Service Manual
General information
Machine A 900 C-Li

Manufacturer model Servostat 2
Type no. 8474955194
Valve settings:
Pressure-relief valve 29 (primary pressure) 180 bar
Safety valves 44 (secondary pressure) 240 bar
Pump rate of the hydraulic pump 82 40 l/min
Settings and torques for the installation of the Servostat
Setting value for spool(19.2) 2.3 ± 0.01mm
End play of the joint shaft (10) 0.03 mm
Turning torque of the steering shafts (56) max. 8 Nm
Torque for the hex head screws (1) 32 ± 3 Nm
Torque for the pressure relief valve (29) 30 ± 3 Nm
Torque for the filter cartridge (43) 12 ± 3 Nm
13.20. 2
MJFCIFSS
Description
3 Description
The Servostat consists of:
Component Description
Metering pump 8 consisting of stators 8.1 and 8.2 it pumps when rotating clockwise
as well as anticlockwise
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 be used to take oil from the return line, if the
machine is steered without hydraulic assistance
Suction valve 36 helps prevent cavitation in the steering system
TÜV check located in the pressure port, prevents air from
valve 31 penetrating the system in the event of a break of the pressure line
Pressure-relief valve 29 limits the delivery pressure of the motor-driven pump to the
required maximum value (primary pressure)
Stop valve 22 prevents the wheels from being automatically reset
when the spool is fully deflected, and reduces excessive
pressure peaks in the piston interior
Tab. 1 Components of the Servostat
3.2 Metering pump

The rotor 8.2 of the metering pump 8 is driven by the joint shaft 10 and is connected through the
steering shaft 56 with the steering wheel. It has one tooth less than the stator, so that a "gap" occurs
in the toothing when it is rotated.
At the position opposite the missing tooth (also known as chamber), the tooth of the rotor fits into the
internal tooth of the stator. When the rotor rotates, the other teeth and tooth chambers thus form
extended suction zones and compressed pressure zones. The rotor centre thereby completes a
planetary motion.
This movement is in the opposite direction of the rotation of the steering shaft, and its angular speed
is six times higher. The suction and pressure zones rotate at the speed of the planetary movement
of the rotor.
This requires a synchronised distribution control, which is achieved by the rotating motion of the
spool.
3.3 Control valve

The control valve consists of the control sleeve 19.1 and the spool, which is located inside the sleeve
and can be rotated and moved in axial direction 19.2. Its barrel surface is equipped with control
groves aligned in radial and axial direction. These grooves match channels in the valve bore of the
housing.
When the steering wheel is turned, the rotary movement is transferred by the steering shaft via the
centring spring and from there transmitted via the joint shaft to the metering pump 8. The spool is
connected through the joint shaft to the pump rotor. This connection is torsionally rigid. The relative
rotation between the steering shaft and the spool, which is made possible by the centring spring
allows for the axial shifting of the spool by means of a steep-pitch thread.
The axial movement of the spool controls the operating pressure and the direction of the oil flow. The
13.20. 3
MJFCIFSS
radial movement controls the synchronised distribution control of the metering pump.
see Fig. 3
4.1 Neutral position of the control valve

When the steering wheel is not turned, the spool 19.2 is in neutral position. As a result, the oil flow
generated by the hydraulic oil pump flows through the pressure channel P to the return channels
T1 and T2 located to the right and the left, and from there to the oil tank. The oil in the other channel
and in the hand pump is thereby not moved. In the closed version, the control channels for the
operating cylinders L and R are not connected to the distributing grooves HP1 and HP2. The built-in
safety valve 44 prevents pressure peaks in the steering system, which can occur in the event of
sudden loads during the travel.
4.2 Valve in working position

By turning the steering wheel, the joint shaft 10 is moved via the steering shaft 56 and the centring
spring 52. Its gear thereby engages with the internal rotor of the hand pump so that it rotates. The oil
pressure in the cylinder required for the steering acts against the rotation of the rotor 8.2. As a result,
the angle of rotation of the steering shaft becomes greater than that of the rotor 8.2 and the spool
19.2. A driving pin and the steep-spindle thread coupling between the spool and the stop bushing
ensures that the spool is rotated relative to the steering shaft only if there is simultaneous axial
movement.
When the spool is moved in the housing in axial direction to the left (steering wheel is turned
anticlockwise), the distributing grooves HP1 of the spool are opened. The oil flows from connection
P through the pressurised chamber to the distributing grooves HP1. As the distribution control
rotates, there are at any time 3 distributing grooves of the spool connected to 3 distributing channels
of the housing, which lead to the suction zone of the hand pump. The oil flows from the pressure zone
of the hand pump though another set of 3 distributing channels to the 3 aligned distributing grooves
HP2 and the annular groove L to the operating cylinder. The left side of the operating cylinder is
connected through the opened channel T1 to the return line T.
To negotiate a right turn, i.e. when the steering wheel is turned clockwise, the valve plunger is shifted
to the right. As a result, the following channels are connected to each other:
P the pressure oil from the power steering pump can reach the suction zone of the hand
pump
HP1 to R the oil leaving the hand pump flows to the operating cylinder
L to T2 from the operating cylinder, the oil flows into the return channel
When steering the vehicle without assistance from the motor-driven pump, for example when the
vehicle is towed, the operator must generate the oil pressure required to change the direction of travel
by operating the hand pump. This means that there is considerably more effort required to turn the
steering wheel than is normally the case when the pump 82 is in operation.
When the machine is standing still, there is normally more effort required than can be generated by
a single person, so that steering is nearly impossible.
13.20. 4
MJFCIFSS
Check
5 Check
Note!
When inspecting the system, always check all screwed connections and lines of the hydrostatic
steering system for leakage. The piston rod of the operating cylinder might be covered in a thin film
of oil. Ensure however that no oil drops are formed. Always check the steering units for proper
mounting.
5.1 Bleeding of the steering system

Start the diesel engine and operate the steering several times by turning the wheels from one end
position to the other.
Test drive the vehicle on a cordoned-off offroad 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.
5.2 Installation and dismantling of the Servostat
Note!
Before dismantling the Servostat, take all measures necessary to secure and block the machine
(see group 1).
Label the hydraulic lines of the Servostat, disconnect them and seal the openings (collect
escaping oil).
Remove the M8 mounting bolts from the Servostat and the steering column and lift the Servostat
from the base plate (if necessary, secure the loose steering column).
Note!
In order to ensure proper functioning of the Servostat and the entire steering system, keep all
components of the system and all lines clean. 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. 5
MJFCIFSS
Check
5.3 Commissioning of the steering system

In order to prevent dirt particles in the lines entering the pressure relief valve when the system is
operated for the first time, we recommend to let the steering system run for a few minutes at various
engine speeds, without actually turning the steering wheel, allowing the oil to flush the system.
Then turn the steering wheel several times to the right and to the left without reaching the steering
lock, while the engine is run at a medium speed (until the operating temperature is reached). We
recommend subsequently removing and cleaning the filter cartridge 43 of the steering system (torque
12 Nm). Bleed the steering system.
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 to the system.
13.20. 6
MJFCIFSS
Exploded view
6 Exploded view
Fig. 2 Exploded view of the Servostat
13.20. 7
MJFCIFSS
Sectional drawing of the Servostat
7 Sectional drawing of the Servostat
Fig. 3 Sectional drawing and hydraulic diagram of the Servostat
13.20. 8
MJFCIFSS
Sectional drawing of the Servostat
1 Hex head screw 36.1 Seal washer

2 Cover 36.2 Cover plate
3 Spacer 37.1 Plug
3.1 Washer 38 Pressure spring
5 O-ring 43 Filter
8 Rotor kit (metering pump) 44 Safety valve
8.1 Stator 44.4 Valve seat
8.2 Rotor 44.5 Valve seat
9 Cover plate 44.7 Tapered plug
10 Joint shaft 50.1 Stop bushing
19 Housing/valve plunger 51 Flat spring
19.1 Steering housing 51.1 Spacer plate
19.2 Spool 52 Spring bracket with centring spring
21 O-ring 55 Coupler
22 Plug 56 Steering column
22.1 Pressure spring 57 Driving pin
22.4 Stop/pressure relief valve 59 Axial needle bearing
23.1 Valve cone 60 Washer
23.2 Seal washer 61 Backing ring
23.3 Cover plate 61.1 O-ring
23.4 Pressure spring 62 Spacer ring
23.5 Valve guide 69 ID tag
29 Pressure-relief valve 70 Round head grooved pin
30 O-ring 76 O-ring
31 TÜV check valve 79 Flange
34 Plug 81 Hydraulic tank
35 O-ring 82 Pump (31*)
35.1 O-ring 85 Oil rotary connection (320*)
36 Suction valve 86 Steering cylinder
13.20. 9
MJFCIFSS
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
11 Hex nut 31 Washer
15 Top plate 40 Pedal
13.20. 10
MJFCIFSS
Service Manual Steering valve
Function
Steering valve
1 Function
The steering valve serves as a hydraulic power assisted steering with hydrostatic transmission to the
steered wheels. It does away with a mechanical connection from the steering wheel to the steering
linkage and the steering knuckles of the steering axle.
In servo operation, the steering valve works with two rotor kits. In emergency mode, one rotor kit is
switched off.
In the event of failure of the steering pump, the machine can be steered manually to some extent, i.e.
to be towed away.
The size for servo operation is based on the total size of the rotor kits and is chosen in such a way
that the wheels can be moved from one stop to the other with 3 to 5 full turns of the steering wheel.
Fig. 1 Steering valve
13.25. 1
MJFCIFSS
Steering valve Service Manual
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
13.25. 2
MJFCIFSS
Description
3 Description
The steering valve consists of:
Component Description
Spool 1 adjusted in axial direction
Control sleeve 2 with control grooves
Shock valves 6 limits the oil pressure that might occur in the lines L and
R to the operating cylinder (secondary pressure)
Rotor kits 3/10 In normal mode, the rotor kits 3/10 pump the hydraulic oil to
the steering cylinders; Rotor kit 3 for emergency operation
Suction valve 7/8 helps prevent cavitation in the steering system
Pressure-relief valve 5 limits the delivery pressure of the motor-driven pump to the
required maximum value (primary pressure)
Check valve 9 prevents impacts to the steering wheel in the event of
excessive external forces
Tab. 1 Component parts of the steering valve
3.2 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 groves
aligned in radial and axial direction. These grooves match channels in the valve bore of the housing.
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
7 Suction valve 24 Valve housing
13.25. 3
MJFCIFSS
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
sleeve 2. As a consequence, a number of channels are opened between the spool 1 and the sleeve
2. The hydraulic oil then acts on the rotor kits 3 and 10, putting them into motion. From the rotor kits,
the hydraulic oil flows to the steering cylinder. The rotation of the two rotors acts on the sleeve, which
rotates together with the piston 1.
The size of the opened channels depends on the turning speed of the steering wheel. If the steering
movement is halted, the spool 1 comes to a standstill, while the oil still flowing through the open
channels to the rotor let the rotor and thus the sleeve 2 rotate further.

By turning the steering wheel, the channels are closed. The rotor and thus the steering cylinder
remain in the desired position. The centring spring 4 thereby moves and then secures the spool 1 and
the sleeve 2 in their neutral position. While the steering wheel is not operated, the line between port
(P) and the tank connection (T) is open and the pump flow is fed at very low pressure to the tank. In
neutral position, the connections L and R are closed.
The system pressure in the steering cycle is limited by the pressure relief valve 5.
The two shock valves 6 shut off the connections L and R to the steering cylinder. If one of the shock
valves is opened, the escaping oil is fed through the suction valve 7/8 to the opposite side or the
leaked oil is sucked from the tank respectively.
4.3 Emergency operation

In the event of a failure of the hydraulic pump, the steering valve acts as a hand pump. In such a case,
the supply pressure (control pressure for the changing pistons) drops to zero. The spring 13 moves
the changing piston 12 into its initial position so that the chambers of the rotor kit 10 are connected
to the chamber. Simultaneously, the connection between the rotor kits is blocked. The volumetric
displacement of the steering unit is thus reduced by the volume of the rotor kit 10. The rotor kit 3
determines the volumetric displacement during normal operation.
If necessary, hydraulic oil is sucked through the suction valve 8 from the tank line, whereby the check
valve 9 prevents that air is being sucked in through the pump connection (P). In normal operation,
the valve 9 prevents impacts to the steering wheel by excessive external steering forces.
13.25. 4
MJFCIFSS
Sectional drawing of the steering valve
5 Sectional drawing of the steering valve
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
13.25. 5
MJFCIFSS
Installation and dismantling of the steering valve
6 Installation and dismantling of the steering valve
Note!
For safety reasons, replace the valve if you experience any problems in relation to the steering
valve. Leakage can be sealed with a seal kit 999 available from LIEBHERR.
6.1 Dismantling of the steering valve
Note!
Before dismantling the steering valve, take all measures necessary to secure and block the machine
(see group 1).
Label the hydraulic lines of the steering valve, disconnect them and seal the openings (collect
escaping oil).
Remove the M10 mounting bolts from the steering valve and the steering column and lift the
steering valve from the base plate (if necessary, secure the loose steering column).
6.2 Installation of the steering valve, see Fig. 5
Note!
In order to ensure proper functioning of the steering valve and the entire steering system, ensure
that all components of the system and all lines are kept clean. To prevent foreign bodies and dirt
from entering the steering oil circuit, do not remove the plugs sealing the lines to the steering valve,
oil pump, operating cylinder, valves, etc. until they are finally reconnected. Carefully deburr and
clean all line ends and screw connections.
Apply grease (with lithium or calcium complex) to the missing tooth area and mount the steering
valve on the shaft 2 of the steering column.
Secure the steering valve and the steering column 1 to the base plate, using the four M10 hex
head screws (with washers) (torque: 46 Nm).
Connect the hydraulic lines to the steering valve (observe marks).
L = Pressure side of the operating cylinder when steering wheel is turned anticlockwise
P = Pressure line (pump)
R = Pressure side of the operating cylinder when steering wheel is turned clockwise
T = Return line (to tank)
13.25. 6
MJFCIFSS
Installation and dismantling of the steering valve
6.3 Commissioning of the steering system

In order to prevent dirt particles in the lines entering the pressure relief valve when the system is
operated for the first time, we recommend to let the steering system run for a few minutes at various
engine speeds, without actually turning the steering wheel, allowing the oil to flush the system.
Then turn the steering wheel several times to the right and to the left without reaching the steering
lock, while the engine is run at a medium speed (until the operating temperature is reached). Bleed
the steering system.
6.4 Bleeding of the steering system

Start the diesel engine and operate the steering several times by turning the wheels from one end
position to the other.
Test drive the vehicle on a cordoned-off offroad 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.
13.25. 7
MJFCIFSS
Exploded view of the steering valve
7 Exploded view of the steering valve
Fig. 4 Exploded drawing of the steering valve
1 Spool 14 Spacer bolt

2 Control sleeve 15 Hex head screw
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
13.25. 8
MJFCIFSS
7.1 Exploded view of the steering column
Fig. 5 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
11 Hex nut 31 Washer
15 Top plate 40 Pedal
13.25. 9
MJFCIFSS
13.25. 10
MJFCIFSS
Service Manual Steering cylinder
Design and function
Steering cylinder
see Fig. 5
The steering cylinder is integrated into the differential of the steering axle.
The cylinder 1 and the two piston rod guides 4 and 20 are mounted in the cast housing of the axle
housing.
The steering cylinder is of the synchronous cylinder design (i.e. cylinder with piston rods on both
sides).
The two rod ends are connected by the tie rods 24 and the ball joints to the joint housings 30 (steering
knuckles). The piston rod 8 with the attached piston 9 moves in axial direction, thereby moving the
steering knuckles from one steering stop to the other.
The connections L and R of the Servostat of the steering system are linked via hydraulic hoses and
the oil rotary connection to the left or right connection of the steering cylinder respectively .
Fig. 1 Steering cylinder on the steering axle
13.30. 1
MJFCIFSS
Steering cylinder Service Manual
Replacement of the steering cylinder sealing elements
2 Replacement of the steering cylinder sealing elements
Note!
The sealing elements can be replaced without removing the steering axle or the differential. The
figures below are sections from the sectional drawing (see Fig. 5).
Please also refer to the separate repair manual "APL-B 755 / APL-B 765 ZP planetary axles".
Caution!
Before dismantling or installing the steering cylinder, take all necessary safety measures
(see group 1). Before opening the steering cylinder, depressurise the hydraulic circuit.
2.1 Dismantling
Unlock and remove the slotted nuts 28.

Disconnect the tie rods 24 with the ball joints from the joint housings.
Move stop ring 26 along the piston rod 8.
Heat the connection of the right tie rod 24 and the piston rod (secured with Loctite) and remove
the axial joints 23 from the piston rod 8.
Remove the stop ring 26, the hex head screws 21 and the guide 20 from the axle housing 31 and
the piston rod 8 (observe washer 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 necessary, pull the cylinder 1 and the guide 4 from the axle housing and check the O-rings
2, 3 and 5 for damage (see Fig. 5). Do not reuse, if damaged.
13.30. 2
MJFCIFSS
Fig. 3 Section of the sectional drawing of the steering cylinder
Installation instructions:
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, 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 755 ZP planetary axles").
Mount the guide 20 and secure with the screws 21 (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 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 into the joint housing 30 and secure with the slotted nuts
28 (torque 300 Nm). Lock the slotted nuts 28 with cotter pins 29.
13.30. 3
MJFCIFSS
Exploded view
3 Exploded view
Fig. 4 Exploded drawing of the steering valve
10 Cylinder 400 Stop ring

30 O-ring 550 Left tie rod
70 Guide 560 Right tie rod
80 O-ring 600 Axial joint
150 Scraper ring 605 Bellows
160 Lip seal 610 Right ball joint
170 Piston rod 611 Left ball joint
240 Sealing ring 620 Clamp
250 Scraper 630 Slotted nut
280 Washer 640 Cotter pin
320 Guide 700 Axle housing
350 Hex head screw
13.30. 4
MJFCIFSS
Sectional drawing
4 Sectional drawing
Fig. 5 Sectional drawing of the steering cylinder and the axial joint
Item ET item Description Item ET item Description

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 30 Right /left joint housing
17 280 Washer, of various 31 700 Axle housing
thickness
20 320 Guide
13.30. 5
MJFCIFSS
Sectional drawing
13.30. 6
MJFCIFSS
Design and function
Steering cylinder
13.31A 900 C-LI EDC 24677-
(see "Sectional drawing of the steering cylinder", page 5)

The steering cylinder 1 and the piston rod guide 2 are inserted into the axle drive housing 31.
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 17 and the piston rod 18 with the joint housings (stee-
ring knuckles). The piston rod 3 with the attached piston moves in axial direction, thereby moving the
The connections L and R of the steering valve of the steering system are linked via hydraulic hoses
and the oil rotary connection to the left or right connection of the steering cylinder respectively.
13.31.1
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MJFCIFSS
Note!
The sealing elements can be replaced without removing the steering axle or the differential.
"ZF planetary axles MS-E 3050/3060/3070".
Danger!
The dismantling and installation of the steering cylinder requires access to the undercarriage of the
machine. There is a risk of death to the technician, as limbs could become crushed.
2.1 Dismantling, (see "Sectional drawing of the steering cylinder", page 5)

Loosen the slotted nuts 19 at the two tie rods 19.
Carefully drive the tie rods 17 with the ball joint 18 from the cone seat.
If necessary, heat the connecting area between the tie rod 17 and the ball joint 18 (secured with
Loctite, see arrow a).
Separate the two tie rods 17 from the ball joint 18.
Disconnect the hydraulic connections and remove the screws from the steering cylinder.
Remove the hex head screws 14 at the flange 12.
Fig. 2 Assembly and dismantling of the steering cylinder
12 Flange 18 Ball joint

14 Hex head screw 19 Slotted nut
15 Axial joint 31 Axle drive housing
17 Tie rod
13.31.2
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MJFCIFSS
Note!
Steering cylinders that are secured with a locking agent are more difficult to dismantle.
If necessary, heat the axle drive housing in the marked area (arrow c), see Fig. 4.
Drive the steering cylinder from the axle drive housing 31, using a plastic mallet.
Remove the external circlip 13 and remove the flange 12, see Fig. 4.
Remove the snap ring 10.
Drive the guide 2 from the cylinder tube until the snap ring 9 can be removed.
Drive the piston rod 3 with the guide 2 from the cylinder tube, using a plastic mallet.
Check all sealing elements, and replace them if necessary.
2.2 Installation, (see "Sectional drawing of the steering cylinder", page 5)
Mount the sealing elements in the correct sequence.
Mount the lip seal 6 and the scraper 7 in the steering cylinder 1.
Mount the slip bushing on the piston rod 3.
Insert the O-ring 4b and push it with the slip bushing into the ring groove of the piston.
Insert the seat seal ring 4a and push it with the slip bushing into the ring groove of the piston.
Calibrate the seat seal ring 4a using the calibration bushing.
Insert the two guide rings 5 into the ring groove of the piston.
Insert the piston rod 3 into the steering cylinder 1; check the installation position.
Mount the groove ring 6, the scraper 7 and the dual ring 8 in/on the piston rod guide 2.
Mount the piston rod guide 2 onto the piston rod 3.
Slide the piston rod guide 2 into the steering cylinder until the circlip 9 can be mounted.
Insert the O-ring 20 into the recess.
Secure the piston rod guide with the snap ring 10.
Mount the flange 12 and secure it with the snap ring 13.
Apply Loctite 574 to the contact surfaces (arrow c) to secure the steering cylinder 1 to the axle
drive housing 31, see Fig. 4.
Insert the steering cylinder and secure it with the hex head screws 14; observe correct tightening
torque.
Apply Loctite 243 to approx. 3 revolutions of the thread of the axial joint 15 (arrow b), see Fig. 2.
Mount the tie rod 17; observe the correct installation position and tightening torque, see Fig. 4.
Mount the new slotted nut 19, observe the tightening torque, see Fig. 2.
13.31.3
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MJFCIFSS
Note!
For safety reasons, use the slotted nuts 19 only once.
Tighten the screws of the clamp 16 only after the steering has been aligned.
If steering alignment is required, please refer to the instructions in the repair manual
Fig. 3 Design of the steering cylinder
1 Steering cylinder (complete) 11 Wrench cap (piston rod)

2 Piston rod guide 12 Flange
3 Piston rod with piston 13 Circlip
4a O-ring 14 Hex head screw
4b Seat seal ring 15 Axial joint
5 Guide ring 16 Clamp
6 Lip seal 17 Tie rod
7 Scraper 18 Ball joint
8 Dual ring 19 Slotted nut
9 Circlip 20 O-ring
10 Snap ring
13.31.4
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MJFCIFSS
Fig. 4 Sectional drawing of the steering cylinder
13.31.5
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MJFCIFSS
13.31.6
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MJFCIFSS
Design and function
Steering cylinder
see Fig. 6
The steering cylinder is integrated into the differential of the steering axle.
The cylinder 12 and the two piston rod guides 14 and 27 are mounted in the cast housing of the axle
housing.
The steering cylinder is of the synchronous cylinder design (i.e. cylinder with piston rods on both
sides).
The two rod ends are connected by the tie rods 8 to the joint housings 3 (steering knuckles). The
piston rod 18 with the attached piston 19 (see Fig. 2) moves in axial direction, thereby moving the
The connections L and R of the Servostat of the steering system are linked via hydraulic hoses and
the oil rotary connection to the left or right connection of the steering cylinder respectively .
13.32. 1
MJFCIFSS
Note!
The sealing elements can be replaced without removing the steering axle or the differential. The
figures below are sections from the sectional drawing (see Fig. 6). Please also refer to the separate
repair manual "APL-B 765 ZP axles".
Caution!
Before dismantling or installing the steering cylinder, take all necessary safety measures
(see group 1).
2.1 Dismantling
Fig. 2 Steering cylinder on the axle
Unlock and remove the slotted nuts 9.

Disconnect the tie rods 8 from the joint housings 3.
Release and slide back the stop ring 4 (see Fig. 6).
Release the tie rod 8 on the piston rod, heat it (secured with Loctite) and remove it from the piston
rod 18.
Remove the hex head screws 29 and pull the guides 14 and 27 from the differential 1. Pull the
piston rod 18 from the cylinder (observe guide ring 28).
Remove the O-ring 13 and pull the cylinder 12 from the differential 1.
Pull the Turcon-Glyd ring and the O-ring 24 from the piston 19.
Remove the guide rings 15, the scraper 16 and the lip seal 17 from the guides 14/27.
13.32. 2
MJFCIFSS
Fig. 3 Sectional drawing of the mounting sleeve
a Mounting sleeve 19 Piston

b Expanding sleeve 24 Seals (Turcon-Glyd and O-ring)
2.2.1 Installation instructions:

Mount the O-ring 24 on the piston 19.
Heat the Turcon-Glyd ring 24 in an oil both to approx. 60°C and mount it, using a mounting and
expanding sleeve, see Fig. 3 as well as the special tools described in group 2.05 (let Turcon-Glyd
ring rebound after installation, using a tightening strap).
Insert the guide rings 15, the scraper 16 and the lip seals 17 into the guides 14 and 27
(see Fig. 6).
13.32.3
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MJFCIFSS
Fig. 4 Tie rod, mounted to piston rod
Note!
Ensure that sealing lip of the lip seal 17 faces the pressure side, while the dust lip of the scraper 16
is at the outside (see Fig. 6).
Insert the cylinder 12 into the bore of the differential 1 and mount the O-ring 13.
Slide the two guides 14 and 17 onto the piston rod 18 and the cylinder 12 (observe correct position
to enable oil supply, and correct position of washer 25; if necessary, use grease as an adhesive).
Tighten the hex head screws 29 (torque 300 Nm).
Mount the stop ring 4 onto the piston rod 18.
Treat the threads of the tie rods 8 with Loctite (no. 242) and screw the complete tie rods into the
piston rod (torque 400 Nm).
.
Note!
The tie rods must be screwed in to the stop in the piston rods 18 to prevent misalignment.
Secure the tie rods/axial joints 8 to the piston rod by beading the collar.
Push the stop ring 4 (steering stop) onto the tie rod 8 until it touches the axial joint and secure it
with the two threaded studs 5 (torque 18 Nm).
Insert the tie rods into the joint housing 3.
Tighten the slotted nut 9 (torque 350 Nm) and secure with the cotter pin 10.
Note!
The thickness of the stop ring 4 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 765 ZP axles".
13.32.4
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MJFCIFSS
2.3 Exploded view
Fig. 5 Exploded drawing of the steering cylinder
13.32. 5
MJFCIFSS
Item ET item Description Item ET item Description

1 700 Differential / axle drive housing 13 20 O-ring
3 Right /left joint housing 14 70 Guide
4 400 Stop ring 15 80 Guide ring
5 410 Threaded stud 16 150 Scraper
8 640 Right tie rod 17 160 Lip seal
641 Left tie rod 18 170 Piston rod with piston
650 Axial joint 19 Piston
660 Right ball joint 24 244 Seal (consisting of a
Turcon-Glyd ring and
an O-ring)
661 Left ball joint 25 280 Washer
670 Clamp 27 320 Guide
9 680 Slotted nut 28 330 Guide ring
10 690 Cotter pin 29 350 Hex head screw
12 10 Cylinder
13.32. 6
MJFCIFSS
Sectional drawing
3 Sectional drawing
Fig. 6 Sectional drawing of the steering cylinder and the axial joint
13.32. 7
MJFCIFSS
Sectional drawing
13.32. 8
MJFCIFSS
Design and function
Steering cylinder
(see "Sectional drawing of the steering cylinder", page 5)

The steering cylinder 1 and the piston rod guide 2 are inserted into the axle drive housing 31.
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 17 to the joint housings 3 (steering knuckles). The
piston rod 3 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 steering valve of the steering system are linked via hydraulic hoses
and the oil rotary connection to the left or right connection of the steering cylinder respectively.
13.33.1
copyright by
MJFCIFSS
Note!
The sealing elements can be replaced without removing the steering axle or the differential.
Danger!
The dismantling and installation of the steering cylinder requires access to the undercarriage of the
machine. There is a risk of death to the technician, as limbs could become crushed.
2.1 Dismantling, (see "Sectional drawing of the steering cylinder", page 5)

Loosen the slotted nuts 17 at the two tie rods 19.
Carefully drive the tie rods 17 with the ball joint 18 from the cone seat.
If necessary, heat the connecting area between the tie rod 17 and the ball joint 18 (secured with
Loctite, see arrow a).
If necessary, separate the two tie rods 17 from the ball joint 18.
Disconnect the hydraulic connections and remove the screws from the steering cylinder.
Remove the hex head screws 14 at the flange 12.
Fig. 2 Assembly and dismantling of the steering cylinder
12 Flange 18 Ball joint

14 Hex head screw 19 Slotted nut
15 Axial joint 31 Axle drive housing
17 Tie rod
13.33.2
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MJFCIFSS
Note!
Steering cylinders that are secured with a locking agent are more difficult to dismantle.
If necessary, heat the axle drive housing in the marked area (arrow c), see Fig. 4.
Drive the steering cylinder from the axle drive housing 31, using a plastic mallet.
Remove the external circlip 13 and remove the flange 12, see Fig. 4.
Remove the snap ring 10.
Drive the guide 2 from the cylinder tube until the snap ring 9 can be removed.
Drive the piston rod 3 with the guide 2 from the cylinder tube, using a plastic mallet.
Check all sealing elements, and replace them if necessary.
2.2 Installation, (see "Sectional drawing of the steering cylinder", page 5)
Mount the sealing elements in the correct sequence.
Mount the lip seal 6 and the scraper 7 in the steering cylinder 1.
Mount the slip bushing on the piston rod 3, see repair instructions.
Insert the O-ring 4b and push it with the slip bushing into the ring groove of the piston.
Insert the seat seal ring 4a and push it with the slip bushing into the ring groove of the piston.
Calibrate the seat seal ring 4a using the calibration bushing.
Insert the two guide rings 5 into the ring groove of the piston.
Insert the piston rod 3 into the steering cylinder 1; check the installation position.
Mount the groove ring 6, the scraper 7 and the dual ring 8 in/on the piston rod guide 2.
Mount the piston rod guide 2 onto the piston rod 3.
Slide the piston rod guide 2 into the steering cylinder until the circlip 9 can be mounted.
Insert the O-ring 20 into the recess.
Secure the piston rod guide with the snap ring 10.
Mount the flange 12 and secure it with the snap ring 13.
Apply Loctite 574 to the contact surfaces (arrow c) to secure the steering cylinder 1 to the axle
drive housing 31, see Fig. 4.
Insert the steering cylinder and secure it with the hex head screws 14; observe correct tightening
torque.
Apply Loctite 243 to approx. 3 revolutions of the thread of the axial joint 15 (arrow b), see Fig. 2.
Mount the tie rod 17; observe the correct installation position and tightening torque, see Fig. 4.
Mount the new slotted nut 19, observe the tightening torque, see Fig. 2.
13.33.3
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MJFCIFSS
Note!
For safety reasons, use the slotted nuts 19 only once.
Tighten the screws of the clamp 16 only after the steering has been aligned.
If steering alignment is required, please refer to the instructions in the repair manual
Fig. 3 Design of the steering cylinder
1 Steering cylinder (complete) 11 Wrench cap (piston rod)

2 Piston rod guide 12 Flange
3 Piston rod with piston 13 Circlip
4a Seat seal ring 14 Hex head screw
4b O-ring 15 Axial joint
5 Guide ring 16 Lock nut
6 Lip seal 17 Tie rod
7 Scraper 18 Ball joint
8 Dual ring 19 Slotted nut
9 Circlip 20 O-ring
10 Snap ring 31 Axle drive housing
13.33.4
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MJFCIFSS
Fig. 4 Sectional drawing of the steering cylinder
13.33.5
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MJFCIFSS
13.33.6
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MJFCIFSS
Service Manual
SUBGROUP - INDEX
Section Group Type
Oscillating axle support with automatic control 14.10.1 A 900 C-LI 14675-
A 904 C-LI 16000-
A 914 C-LI 35112-
A 924 C-LI 34519-
Support cylinder 14.20.1 A 900 C-LI 14675-

A 904 C-LI 16000-
A 914 C-LI 35112-
A 924 C-LI 34519-
14.1
MJFCIFSS
Service Manual
14.2
MJFCIFSS
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
14.10. 1
MJFCIFSS
Oscillating axle support with automatic control Service Manual
Description
2 Description
2.1 Support cylinder 1, see Fig. 2 / Fig. 8

The support cylinders 1 with screwed-in stop valve 5 are located to the right and left above the
steering axle on the undercarriage.
The plunger pistons in the cylinders 2 block and release the oscillating motion of the steering axle.
When in blocking position (solenoid valve Y66 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 Y66 powered), the cylinder chambers are
connected to each other, i.e. the pistons follow the oscillating motion of the steering axle.
The cylinders are continuously fed with oil (1 to 2 l/min) by the pilot system through the restrictor
(0.5 mm) in the unlocking piston of the stop valve 5.
To prevent the steering axle from oscillating when the supports are engaged (compression by air
content in oil), the connecting line between the two cylinders 1 is equipped with restrictors 20, the
check valve, 11 and the accumulator 24.
The check valve 11 ensures that the return line to the tank and the accumulator 24 are pressurised
with «minimum 6 bar.
This means that the unloaded piston is continuously pressed against the axle as long as the
oscillating axle is locked.
The cylinder 1 and the associated lines must be inspected for proper connection and leakage at the
prescribed intervals, see maintenance instructions in group 3.
Fig. 2 Support cylinder 1
14.10. 2
MJFCIFSS
Description
2.2 Oil rotary connections, see Fig. 3

The six-fold oil rotary connection 322 is mounted on the seven-fold rotary connection 320 (high-
pressure connection). Control oil is fed from the solenoid valve Y66 through the oil rotary
connection 322 to the stop valve 5 of the support cylinders.
Fig. 3 Control oil unit 50 and oil rotary connection 320 / 322
2.3 Solenoid valve Y66, see Fig. 3

The solenoid valve Y66 is integrated into the control oil unit 50 of the pilot system. It consists of a
hydraulic 3/2 way valve with electric actuator.
When in working position, the solenoid valve Y66 is open allowing control oil flow to the stop
valves 5. In neutral position, it blocks the control oil flow and thereby relieves the stop valve 5 to the
tank.
Fig. 4 A 1100 printed circuit board in the left control console
This printed circuit board controls the solenoid valve Y66 through the amplifier V155.
When the printed circuit board receives signal "block oscillating axle" from the switch S75 via the CAN
BUS 2, and provided that the switch S75 is in position A or I, the amplifier V155 is switched, shutting
down the power output to the solenoid valve Y66. The same happens if the signal is received from
the proximity switch B266. see Fig. 5
14.10. 3
MJFCIFSS
Description
Fig. 5 Rotary switchS75 and pressure switch B266
Position I = Symbol for oscillating axle support locked

Position A = Symbol for oscillating axle support blocked in automatic
mode
When the rotary switch S75 is in position 0, the solenoid valve Y66 is powered and set to its
working position, which in turn unlocks the oscillating axle.
The safety lever S7 is turned down.
When the rotary switch S75 is in position I (symbol for oscillating axle blocked is shown on the main
screen), the solenoid valve Y66 is set to neutral position so that the oscillating axle is locked.
When the rotary switch S75 is in position A (symbol for oscillating axle automatically blocked is shown
on the main screen) the automatic oscillating axle locking mechanism is selected. The axle remains
however initially unlocked.
If the working brake (wheel brake) is applied, the solenoid valve Y66 is not powered (due to signal
from proximity switch B266 and amplifier V155, Fig. 4) so that it returns to its neutral position, thus
locking the oscillating axle.
Danger!
If the automatic oscillating axle locking mechanism is preselected (switch S75 in position A), the
oscillating axle is automatically unlocked as soon as the working brake is released.
This might lead to reduced stability of the machine so that it might tilt over, if the uppercarriage is
swivelled out with a heavy load.
For safety reasons, the oscillating axle cannot be released, if there is a system overload.
When the machine is to be moved while it carries a load (e.g. filled digging tool, load suspended
on safety hook), switch off the automatic oscillating axle locking mechanism before taking up the
load, and ensure that the oscillating axle remains permanently locked (switch S75 in position I).
14.10. 4
MJFCIFSS
3.1 Support function, Fig. 8

The rotary switch S75 is in position I or A, and the working brake is applied (symbol for oscillating
axle locked is shown on the main screen). The solenoid valve Y66 is in neutral position.
The control line from the solenoid valve Y66 to the support cylinders is not pressurised. The valve
cone of the stop valve 5 is in closing position - the oscillating axle is locked.
3.2 Oscillating function

The rotary switch S75 is in position 0, and the working brake is released (no symbol on the main
screen).
The solenoid valve Y66 is powered and set to its operating position. The control line St is pressurised
with pilot pressure through the solenoid valve Y66 and the rotary connection 322.
The valve cone of the stop valve is lifted from its seat so that the two support cylinders are connected
to each other - the oscillating axle is released.
3.3 Bleeding of the system

As the cylinders are permanently flushed with control oil, the system is automatically bled. Separate
bleeding is thus not necessary.
After repairs, fill the cylinder with oil, insert the stop valve 5 and connect the lines. Set the switch S75
(see Fig. 5) to position O (oscillating axle released) and flush the system for at least 5 minutes while
the diesel engine is on.
Subsequently complete a functional test.
Fig. 6 Hydraulic system of the oscillating axle support mechanism
14.10. 5
MJFCIFSS
Functional test
4 Functional test
Fig. 7 Functional test of the locked oscillating axle
Ensure that the front axle is unlocked (switch S75 in position 0 - Fig. 5), 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 (repeat bleeding, if necessary).
The piston 2 of the support cylinder (piston with load) may not move inwards.
If required, check the valve cone in the stop valve.
Complete the above functional test on both support cylinders 1.
14.10. 6
MJFCIFSS
Hydraulic diagram
5 Hydraulic diagram
Fig. 8 Diagram of the hydraulic and electrical systems
14.10. 7
MJFCIFSS
Hydraulic diagram
1 Cylinder B266 Proximity switch / brake pedal

2 Piston F6 Fuse A1100 / 15 A
5 Stop valve MP1 Ground connection of the PCB of the left
console
11 Check valve MP82 Ground connection of the revolving deck /
6 bar preload tank to the rear
20 Restrictor (Ø 1.5 mm) S75 Rotary switch of the automatic oscillating
axle support mechanism
24 Diaphragm accumulator V155 amplifier of oscillating axle Y66
30 Gear pump / pilot control X2 Plug connection S2-A1001 / 37-pin
49 Measuring point for pilot pressure X10 Plug connection A1001 - B266 / 2-pin
50 Control oil unit X50 Plug connection S2 - A1100 / 25-pin
51 Pressure-relief valve X197 Plug connection B266 / 3-pin
52 Pressure filter X200 Plug connection A1100 to revolving deck CS
15-pin
53 Check valve X224 Plug connection A1100 - automatic
oscillating axle locking
mechanism, 6-pin
54 Accumulator X252 Plug connection S75 / 3-pin
170 Leak oil line from travel motor Y3 Solenoid valve / pilot control
320 Rotary connection 7 x Y7 Solenoid valve / slewing gear brake
322 Rotary connection 6 x Y50 Proportional solenoid / LR control
A1001 ESP01 printed circuit board / Y51 Proportional solenoid / LS control
right control desk
A1100 ESP02 printed circuit board / Y66 Solenoid valve / oscillating axle support
left control desk
14.10. 8
MJFCIFSS
Service Manual Support cylinder
Description
Support cylinder
1 Description
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. When the machine
is in working position, it is supported by the pistons, which are resting on oil columns in the cylinder
chambers of the support cylinders.
To release the axle so that it can oscillate, the stop valves (hydraulically operated check valves)
screwed into the cylinder base are opened, so that the pistons can follow the oscillating motion of the
axle.
Fig. 1 Support cylinder on the undercarriage
14.20. 1
MJFCIFSS
Support cylinder Service Manual
Function of the support cylinder
2 Function of the support cylinder
see Fig. 5
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 hydraulic line in the cylinder and
depressurised to the tank.
In locking position, the valve cone 5.3 is closed, so that the piston 2 is blocked in its position by the
oil in the cylinder room.
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
cylinder on the other side of the undercarriage.
Fig. 2 Exploded view of the support cylinder 1
1 Cylinder 13 O-ring
2 Piston 15 Guide ring
5 Stop valve 20 Plug
10 Special scraper ring 801 LH corrosion inhibitor
12 Turcon-Stepseal ring 999 Seal kit
14.20. 2
MJFCIFSS
Function of the stop valve
3 Function of the stop valve
see Fig. 3
3.1 Blocking position

The control oil connection ST is not under pressure. The unlocking bolt 5.7 is pressed upwards by
the pressure spring 5.8. The hydraulic pressure produced in the cylinder chamber as the oscillating
axle presses against the plunger of the support cylinder presses the valve cone 5.3 upwards. The
cone thereby fully closes the connection P to the other support cylinder. The ball 5.17 closes the
connection P - ST.
3.2 Release position

The release piston 5.7 is pressurised through the solenoid valve Y66 and the connection ST with pilot
pressure and thus pushed downwards against the valve cone 5.3.
When the cylinder is fully or nearly load-free, the valve cone 5.3 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 5.3 is only lifted from its seat, if the load pressure on the
respective support cylinder is below 420 bar.
When there is some oscillating motion by the axle, the oil can then escape from the cylinder chamber
through connection P and/or flow into the cylinder at the other side of the undercarriage.
A little pilot control oil flows through the restrictor 5.16, the check valve 5.17 / 5.18 and bore C into
the connecting line and thus continuously refills the pressure accumulator of the system.
14.20. 3
MJFCIFSS
Sectional drawing
4 Sectional drawing
Fig. 3 Sectional drawing of the stop valve
5.1 Valve housing 5.9 Backing ring

5.2 Connector screw 5.10 O-ring
5.3 Valve cone 5.11 O-ring
5.4 Pressure spring 5.13 O-ring
5.6 Snap ring 5.16 Restrictor
5.7 Unlocking bolt 5.17 Ball
5 Maintenance
The regular maintenance of the support cylinder includes a visual inspection of the cylinder for
leakage and proper mounting at predefined intervals, see maintenance instructions in group 3.
14.20. 4
MJFCIFSS
Installation and dismantling of the support cylinder
6 Installation and dismantling of the support cylinder
6.1 Dismantling
Position the equipment on the ground.
Release tank preload.
Disconnect and seal the hydraulic lines in front of the support cylinder 1.
Loosen the mounting bolts 22 and remove the support cylinder from the undercarriage.
6.2 Installation
Place the support cylinder 1 against the undercarriage and secure with the hex head screw 22 to
the undercarriage.
Align properly (tightening torque for the screws 22 = 1060 Nm)
Connect the hydraulic lines to the cylinders.
Flush the oscillating axle support mechanism so that it is automatically bled, and complete a
functional test, see group 14.10.
Fig. 4 Installation of the support cylinders 1 onto the undercarriage
7 Replace the sealing elements of the support cylinder.
To replace the entire seal kit, you need a "Support cylinder seal kit" and a "Stop valve seal kit".
14.20. 5
MJFCIFSS
Replace the sealing elements of the support cylinder.
7.1 Dismantling of support cylinder, see Fig. 5

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 5.9 and the O-rings 5.10 and 5.11.
Push the piston 2 from the cylinder and inspect it for damage and ridges.
Remove the scraper ring 10, the Turcon-Stepseal ring 12 and the O-ring 13 from the cylinder 1.
7.2 Installation of support cylinder, see Fig. 5

Carefully clean all parts.
7.2.1 Installation instructions

Inspect all components and sealing elements for damage. Reuse only undamaged parts.
Do not use pointed or sharp-edged tools to mount the sealing elements.
Remove chips and other foreign particles.
Before mounting them, treat all parts with hydraulic oil. Apply corrosion inhibitor 801 (tube
8300005) into the gaps between the guide ring 15 and the scraper ring 10.
Insert new Turcon-Stepseal ring 12 with O-ring 13 into the cylinder 1.
Note!
When squeezing the Turcon-Stepseal ring 12, avoid kinking.
Observe correct installation position.

Insert the new scraper ring 10 with O-ring.
Carefully push the piston 2 into the cylinder 1.
Place the O-rings 5.10 / 5.11 and the backing ring 5.9 onto the stop valve 5.
If required, replace the O-rings 5.13 and 5.14 after removing the connecting screw 5.2
(torque 160 Nm).
Screw the compete stop valve 5 into the cylinder 1 (torque 300 Nm)
Check stop valve at the cylinder for tightness, see group 14.10.
Mount the support cylinder 1 onto the undercarriage, complete a functional test and connect the
lines to the stop valve and the support cylinder, see 6.2.
14.20. 6
MJFCIFSS
Sectional drawing
8 Sectional drawing
Fig. 5 Sectional drawing of the support cylinder and the stop valve
1 Cylinder 5.10 O-ring

2 Piston 5.11 O-ring
5 Stop valve 5.13 O-ring
5.1 Valve housing 5.14 O-ring
5.2 Connector screw 5.16 Restrictor
5.3 Valve cone 5.17 Ball
5.5 Spring plate 10 Special scraper ring
5.6 Snap ring 12 Turcon-Stepseal ring
5.7 Unlocking bolt 13 O-ring
5.8 Pressure spring 15 Guide ring
5.9 Backing ring
14.20. 7
MJFCIFSS
Sectional drawing
14.20. 8
MJFCIFSS
Service Manual
SUBGROUP - INDEX
Section Group Type
Operating pressures of the brake system 15.05.1 A 900 C-LI 14675-

A 904 C-LI 16000-
A 914 C-LI 35112-
A 924 C-LI 34519-
Hydraulic brake system 15.10.1 A 900 C-LI 14675-

A 904 C-LI 16000-
A 914 C-LI 35112-
A 924 C-LI 34519-
Compact brake block 15.20.1 A 900 C-LI 14675-

A 904 C-LI 16000-
A 914 C-LI 35112-
A 924 C-LI 34519-
15.1
MJFCIFSS
Service Manual
15.2
MJFCIFSS
Service Manual Operating pressures of the brake system
Technical data
Operating pressures of the brake system
1 Technical data
Machine A 900 C A 904 C

Series Unit Litronic Litronic
Serial number 14675-32354 16000-32364
Gear pump 32
Brake oil max. l/min 2,5
Accumulator charging valve 5
in compact brake block 4
Switch-on pressure bar 125 ±5
Shut-off pressure bar 150 ±5
Switching range bar 15 +20
Shifting pressure of pressure switch B20 bar 100 ±5
Brake system
Brake pressure in front and
rear brake circuits (measuring point 25 / 26) bar 75 +10
Shifting pressure of pressure switch B60 bar 3
Accumulators 14 and 15
Rated flow cm3 700
Filling pressure (nitrogen) bar 50
Max. permissible operating pressure bar 180
15.05.1
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MJFCIFSS
Operating pressures of the brake system Service Manual
Technical data
2 Technical data
Machine Unit A 900 C A 904 C

Series Litronic Litronic
Serial number from 32355 32365
Gear pump 32
B20 bar 100 ±5
Brake system
Rated flow cm3 1000
15.05.2
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MJFCIFSS
Service Manual Operating pressures of the brake system
Technical data
3 Technical data
Machine Unit A 914 C A 924 C

Series Litronic Litronic
Serial number from 35112 34519
Gear pump 32
B20 bar 100 ±5
Brake system
Rated flow cm3 1000
15.05.3
copyright by
MJFCIFSS
Operating pressures of the brake system Service Manual
Technical data
15.05.4
copyright by
MJFCIFSS
Service Manual Hydraulic brake system
Design of brake system
Hydraulic brake system
1 Design of brake system
The LIEBHERR hydraulic excavators are equipped with hydraulic dual-circuit brake systems. This
working brake is charged by the gear pump 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 brakes 21).
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 32 Gear pump / brake system

11 Foot pedal / working brake 322 Rotary connection (low pressure)
20 Multi-disc brake, front S16 Pressure switch/parking brake
21 Multi-disc brake, rear H23 Indicator LED: accumulator pressure
15.10.1
copyright by
MJFCIFSS
Hydraulic brake system Service Manual
1.1 Gear pump 32

The gear pump 32 is driven directly by the diesel engine. It takes up hydraulic oil from the tank and
feeds it to the compact brake block 4, see Fig. 3.
Fig. 2 Gear pump 32
1.2 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 adjustment protocol, group 3) is reached, the
valve 5 with the pressure balance 6 and the pressure regulator 7, see Fig. 12, automatically feed the
flow from the gear pump 33 back to the tank 1 or controls the oil flow to the connected brake accu-
mulators 14 and 15 after the charging pressure has dropped to the level of the additional pressure.
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
are applied.
If the accumulator pressure is sufficiently high, the pressure switch B20 opens the electrical contact,
see adjusting protocol of group 3. As a result, the indicator LED 24 at the control console is 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 and adjusting
protocol in group 3), 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).
15.10.2
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MJFCIFSS
1.3 Accumulator
The accumulators 14 and 15 - located below the operator's cab near the compact brake block 4 - fulfil
an important safety function. In the event of a failure of the pump 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 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 of oscillating axle auto-
matic
1.4 Multi-disc brakes 20 and 21, see 3

The axles of the machine are equipped with multi-disc brakes.
When the brake is applied with the brake pedal 11, the brake pistons of the brakes 20 / 21 in the axles
are pressurised with oil through the brake valve 10.
The breaking effect is generated due to the friction when the discs of the pack 20 / 21 are pressed
together.
15.10.3
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MJFCIFSS
Function of the brake system
Fig. 4 Multi-disc brake 20/21 integrated in the axles
2 Function of the brake system
see Fig. 5 and Fig. 12.
2.1 System not pressurised, or switch-on pressure reached

The gear pump 32 feeds hydraulic oil to the compact brake block 4 through connection P. The hy-
draulic oil flows via the internal channels, the check valve 8 and the connections S1/S2 into the con-
nected 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 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.
2.2 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.
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.
15.10.4
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MJFCIFSS
2.3 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 of the axle. As a consequence, the brakes are
applied.
If the force applied to 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 to the pedal is reduced, the control edges of brake pistons 63 / 64 open the con-
nection to the tank, so that the brake pressure is reduced until an equilibrium of forces is established
above and below the pistons 63 / 64.
When the brake pedal 11 and the brake pistons 63 / 64 return to their initial position, the brakes 20 /
21 are released to the tank.
1 Hydraulic tank 50 Pressure spring / pilot control piston

4 Compact brake block 51 Pressure spring / accumulator pressure
6 Pressure balance 52 Pressure spring / brake piston return
7 Pressure regulator 53 Pressure spring / brake piston return
8 Check valve 56 Pressure spring / pressure balance
9 Double check valve 57 Pressure spring / brake pressure
10 Foot brake valve 58 Pressure spring / brake pressure
11 Foot brake pedal with housing 63 Brake piston
14 Brake accumulator / front brake circuit 64 Brake piston
15 Brake accumulator / rear brake circuit 72 Spool
20 Multi-disc brake / steering axle 81 Pin
21 Multi-disc brake / rigid axle 88T Collecting pipe
25 Measuring point / front brake pressure 102 Threaded bolt
26 Measuring point / rear brake pressure 131 Sleeve
27 Measuring point / accumulator pressure 132 Bushing
32 Gear pump / brake system 135 Pilot control piston
38 Piston / pressure balance 322 Rotary connection
15.10.5
copyright by
MJFCIFSS
Fig. 5 Sectional drawing of the compact brake block with hydraulic lines
15.10.6
copyright by
MJFCIFSS
Bleeding of the brake system
Note!
The brake system is filled with oil from the hydraulic unit, see group 1.50/1.51.
When the oil in the hydraulic tank is replaced with a different product (e.g. environmentally friendly
hydraulic fluid), the oil in the brake system must also be replaced. This means that the oil in the brake
system must be drained through the bleeder screws at the wheels. Minimum drain volume: 0.5 l per
axle. The accumulators might have to be charged several times by repeated starting of the diesel en-
gine.
Note!
Do not drain the oil while the engine is on, as the accumulators are otherwise not emptied.
3 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 positions of the bleeder valve
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 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.
15.10.7
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MJFCIFSS
Inspection and adjustment of the brake system settings
4 Inspection and adjustment of the brake system settings
4.1 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.
For adjusting the pressure, use glycerine damped pressure sensors, exclusively. Accuracy must
be at least 1 % of the full scale value.
Caution!
Prior to any inspection or adjustment work on the machine, take any and all safety and accident pre-
vention measures required to protect personnel. See pertinent accident prevention regulations (in
Germany: UVVs of "Tiefbau BG").
4.2 Layout of measuring points 25, 26 and 27
4.2.1 Measuring point 25

Used to check the brake pressure in the front brake circuit.
4.2.2 Measuring point 26

Used to check the brake pressure in the rear brake circuit.
4.2.3 Measuring point 27 on the compact brake block 4

Used to check the switch-on and the shut-off pressure, the accumulator pressure and the switching
pressure of the pressure switch B20.
Fig. 7 Measuring points for the brake pressure in the undercarriage and measuring point of the
accumulator pressure.
4 Compact brake block 27 Measuring point / accumulator pressure
15.10.8
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MJFCIFSS
25 Measuring point / front brake pressure 32 Gear pump / brake system

26 Measuring point / rear brake pressure
4.3 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 and
B60.
4.3.1 Switch-on and shut-off pressure of the charging valve 5

Connect a pressure sensor (0-600 bar) to the measuring point 27, see Fig. 7.
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 and adjustment protocol of group 3.
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 until the system is recharged or the switch-on pres-
sure 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. Use B20 pressure switch conversion kit, if neces-
sary, see 4.3.3.
If required, loosen the lock nut 75 and adjust and the switch-on and switch-off pressures to the
prescribed value by turning the adjusting screw 74 (see operating pressures, group 15.05 and ad-
justment protocol of group 3).
Turn in = Increasing pressure
Turn out = Reduce pressure
Fig. 8 Compact brake block 4 below the operator's cab
4 Compact brake block 74 Adjusting screw

5 Integrated accumulator charging valve 75 Lock nut
11 Brake pedal 102 Threaded bolt
16 Fork head B20 Pressure switch / accumulator pressure
17 Lock nut B60 Pressure switch / brake light
18 Pin
Connect the 0-600 bar pressure sensor to measuring point 27 and check the following values:
15.10.9
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MJFCIFSS
4.3.2 Switching pressure of pressure switch B20 (increasing)

If there is a fault indicating that the pressure switch is faulty, the switching pressure of the pressure
switch B20 can be checked through the existing measuring point 27 within the increasing range:
Connect a pressure sensor (0-600 bar) to the measuring point 27.
Start the diesel engine and monitor the pressure sensor and the indicator LED H23: when the
prescribed switching pressure is reached (see brake operating pressures in group 15.05), the in-
dicator LED H23 must be off.
The switching pressure of the pressure switch B20 should only be adjusted after the dropping
switching pressure has been checked, see 4.3.3.
Fig. 9 Measuring point for accumulator pressure and indicator LED in indicating and control unit
27 Measuring point / accumulator pressure H23 Indicator LED for accumulator pressure
4.3.3 Switching pressure of pressure switch B20 (dropping)

TUEV requires that the switching pressure of the pressure switch B20 is checked in the dropping ran-
ge.
Note!
The switching pressure of the pressure switch B20 in the dropping range can only be checked by
installing an additional measuring point 153 between the connection DS2 and the pressure switch
B20, see Fig. 10.
Disconnect the pressure switch B20 from the connection DS2 and screw in the "pressure switch
B20 conversion kit"; for details, see tool list 2.01 and Fig. 10.
Screw the pressure switch B20 into the screw piece of the "pressure switch B20 conversion kit".
Start the diesel engine and charge the brake accumulator to the maximum level.
Shut down the diesel engine, leave the ignition on and reduce the brake pressure by repeatedly
operating the foot pedal.
As soon as the switching pressure (dropping) is reached, the indicator LED H23 at the control
desk is on.
Read the pressure at the additional measuring point 153 at the moment the indicator LED H23 is
lit, and compare it with the prescribed pressure value.
15.10.10
copyright by
MJFCIFSS


Caution!
For safety reasons, the pressure switch conversion kit must be removed after the check has been
completed.
To do this, follow the instructions below and then mount the pressure switch B20 in its original
position (connection DS2).
Screw out the pressure switch B20
Remove the "pressure switch B20 conversion kit".
Screw in the pressure switch B20 to the connection DS2.
Establish the electrical connections and test them.
Fig. 10 Measuring point for accumulator pressure and compact brake block with pressure swit-
4 Compact brake block 152 T-connection fitting
27 Measuring point / accumulator pressure 153 Measuring piece
74 Adjusting screw / accumulator charge 154 Screw piece
pressure
76 Adjusting screw / response pressure B20 Pressure switch / accumulator pressure
B20
77 Adjusting screw / response pressure B60 Pressure switch / brake light
B60
151 Screw-in stud
ches and conversion kit
15.10.11
copyright by
MJFCIFSS
4.3.4 Switching pressure of pressure switch B60

Connect a pressure sensor (0-600 bar) to the measuring point 25, see Fig. 7.
Start the diesel engine and recharge the brake accumulator.
Carefully operate the foot pedal 11, see Fig. 8.
The brake lights E19 / E20 must be on when the pedal 11 is pressed down only a little.
Read the pressure at the additional measuring point at the moment the brake lights are lit, and
compare it with the prescribed pressure value.


Install additional measuring point.
4.4 Checking of the brake pressure of the working brake
Fig. 11 Brake pedal and operating linkage of the brake valve at the compact brake block
11 Brake pedal 17 Lock nut

12 Locking lever 18 Pin
13 Stop screw / front 29 Stop screw / rear
16 Fork head 102 Threaded bolt
Connect a pressure sensor (0-600 bar) to the 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:
15.10.12
copyright by
MJFCIFSS
Press the pedal 11 down to the stop and check whether the pedal 11 engages in the locking lever
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 26Fig. 7 corresponds to the prescribed pres-
sure.
Re-tighten the lock nut 17 .
Release the pedal 11.
Unlock and drive out the pin 18 (Ø 10 mm) inserted between the fork head 16 and the pedal lever,
and insert a Ø 9 mm pin (drill bore, if necessary).
Loosen and adjust the stop screw 29 until there is no play between the fork head 16 and the in-
serted pin.
Secure the stop screw 29 with a lock nut.
Remove the Ø 9 mm adjusting pin and re-insert and lock the original Ø 10 mm pin 18.
The threaded rod is now correctly pre-stressed (1 mm).
After the adjustment is completed, check whether the measuring points 25 and 26 remain without
pressure when the pedal 11 is not pressed.
If required, readjust the position of stop screw 29.
4.4.1 Checking of the brake accumulators 14 and 15, (see Fig. 3 on page3)
Connect a pressure sensor (0-600 bar) to the measuring point 27, (see Fig. 7 on page8).
Connect a 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, see Fig. 10 - 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 the pressure has dropped below the prescribed value, 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 33 Gear pump / brake system
5 Accumulator charging valve 38 Piston
6 Pressure balance 51 Pressure spring / accumulator pressure
7 Pressure regulator 57 Pressure spring / brake pressure
8 Check valve 58 Pressure spring / brake pressure
9 Shuttle check valve / double check 63 Brake piston / front brake circuit
valve
10 Foot brake valve 64 Brake piston / front brake circuit
11 Brake pedal 72 Spool
14 Brake accumulator / front brake circuit 135 Pilot control piston
15 Brake accumulator / rear brake circuit 322 Rotary connection 6x
20 Multi-disc brake / steering axle B20 Pressure switch / accumulator charge
pressure
21 Multi-disc brake / rigid axle B60 Pressure switch / brake light
15.10.13
copyright by
MJFCIFSS
24 Indicator LED for accumulator pressure E19 Right brake light

25 Measuring point / front brake circuit E20 Left brake light
26 Measuring point / rear brake circuit H23 Indicator LED for accumulator pressure
27 Measuring point / accumulator charge
pressure
15.10.14
copyright by
MJFCIFSS
Hydraulic diagram
5 Hydraulic diagram
Fig. 12 Hydraulic brake system
15.10.15
copyright by
MJFCIFSS
Electrical components of brake system
6 Electrical components of brake system
Note!
For details regarding the electrical components and connections of the brake system, see circuit di-
agram for group 8.
15.10.16
copyright by
MJFCIFSS
Service Manual Compact brake block
Design
Compact brake block
1 Design
4 5 10
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 brakes of the axles through two different
brake circuits containing oil, which is taken from the respective accumulator circuits.
Fig. 1 Compact brake block 4
4 Compact brake block B20 Pressure switch / accumulator pressure

5 Accumulator charging valve B60 Pressure switch / brake light
10 Brake valve, complete
15.20.1
copyright by
MJFCIFSS
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 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 different 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 32 pumps the oil again into the accumulator circuit.
15.20.2
copyright by
MJFCIFSS
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 gear pump

Connection N and T to tank
Connection BR1 to multi-disc brake / steering axle
Connection BR2 to multi-disc 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
MJFCIFSS
Hydraulic diagram
4 Hydraulic diagram
Fig. 3 Hydraulic diagram of compact brake block
1 to hydraulic tank 51 Pressure spring / accumulator pressure

4 Compact brake block 57 Pressure spring / brake pressure
5 Accumulator charging valve 58 Pressure spring / brake pressure
6 Pressure balance, complete 63 Brake piston
7 Pressure regulator 64 Brake piston
8 Check valve 72 Spool
9 Double check valve 88 to collecting pipe
10 Brake valve, complete 135 Pilot control piston
11 Brake pedal 322 Rotary connection 6x
14 to brake accumulator / steering axle cir- 999 Seal kit, complete
cuit
15 to brake accumulator / rigid axle circuit B20 Pressure switch / accumulator pressure
20 to multi-disc brake / steering axle B60 Pressure switch / brake light
21 to multi-disc brake / rigid axle E19 Right brake light
27 Measuring point / accumulator pres- E20 Left brake light
sure
32 from brake system gear pump H23 Indicator LED for accumulator pressure
15.20.4
copyright by
MJFCIFSS
Exploded view
38 Piston / pressure balance
5 Exploded view
Fig. 4 Exploded view of compact brake block
Key to exploded view, see Fig. 4 and sectional drawing, see Fig. 5
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
14 Spring plate 112 Screw plug
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
15.20.5
copyright by
MJFCIFSS
Exploded view
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
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
5.1 Sectional drawing
Fig. 5 Sectional drawing of the compact brake block
15.20.6
copyright by
MJFCIFSS
Service Manual
SUBGROUP - INDEX
Section Group Type
Pipe fracture safety device for boom cylinders 16.01.1 A 900 C-LI 14675-
A 904 C-LI 16000-
Pipe fracture safety valve for stick cylinder 16.02.1 A 900 C-LI EDC 24677-
A 904 C-LI EDC 30580-
Pipe fracture safety valve for boom cylinders 16.03.1 A 900 C-LI EDC 24677-
A 904 C-LI EDC 30580-
Pipe fracture safety valve for boom cylinders 16.04.1 A 914 C-LI 35112-
A 924 C-LI 34519-
Overload warning system 16.06.1 A 900 C-LI 14675-

A 904 C-LI 16000-
Switchable overload warning system 16.08.1 A 900 C-LI 14675-18087

A 904 C-LI 16000-
A 914 C-LI 35112-
A 924 C-LI 34519-
Hydraulic quick change adapter 16.15.1 A 900 C-LI 14675-

A 904 C-LI 16000-
Boom cylinder protection system 16.16.1 A 900 C-LI EDC 24677-

A 904 C-LI EDC 30580-
A 914 C-LI 35112-
A 924 C-LI 34519-
LIKUFIX Hydraulic Coupling System 16.18.1 A 900 C-LI 14675-

A 904 C-LI 16000-
Pressure and flow reduction 16.20.1 A 900 C-LI 14675-

A 904 C-LI 16000-
Pressure and flow reduction 16.21.1 A 914 C-LI 35112-

A 924 C-LI 34519-
Hydraulic hammer 16.22.1 A 900 C-LI 14675-

A 904 C-LI 16000-
16.1
MJFCIFSS
Service Manual
Pipe layer 16.23.1 A 900 C-LI 14675-

A 904 C-LI 16000-
A 914 C-LI 35112-
A 924 C-LI 34519-
Speeder kit 16.30.1 A 900 C-LI 14675-

A 904 C-LI 16000-
Generator drive accessory kit 16.32.1 A 904 C-LI EDC 30580-
Generator conversion kit for LIKUFIX 16.34.1 A 904 C-LI EDC 30580-
Accessory kit AS1 16.40.1 A 900 C-LI 14675-

A 904 C-LI 16000-
A 914 C-LI 35112-
A 924 C-LI 34519-
Accessory kit AS1 16.41.1 A 914 C-LI 35112-

A 924 C-LI 34519-
Accessory kit AHS 1 16.43.1 A 900 C-LI 14675-

A 904 C-LI 16000-

A 904 C-LI 16000-
Accessory kit AHS 11 with Tool Control 16.46.1 A 900 C-LI 14675-
A 904 C-LI 16000-

A 904 C-LI 16000-
Accessory kit AHS 12 with Tool Control 16.49.1 A 900 C-LI 14675-
A 904 C-LI 16000-
Accessory kit AHS 11 / AHS 12 16.50.1 A 914 C-LI 35112-

with Tool Control A 924 C-LI 34519-
Hydraulic operator's cab elevation 16.60.1 A 904 C-LI 16000-

A 924 C-LI 34514-
Individual control 16.62.1 A 900 C-LI 14675-

A 904 C-LI 16000-
Dozer blade 16.64.1 A 900 C-LI 14675-

A 904 C-LI 16000-
Dozer blade 16.65.1 A 904 C-LI EDC 30580-

A 914 C-LI 35112-
A 924 C-LI 34519-
16.2
MJFCIFSS
Service Manual
SUBGROUP - INDEX
Section Group Type
Refuelling pump 16.66.1 A 900 C-LI 14675-

A 904 C-LI 16000-
A 914 C-LI 35112-
A 924 C-LI 34519-
Bypass filter 16.68.1 A 900 C-LI 14675-

A 900 C-LI EDC
A 904 C-LI 16000-
A 904 C-LI EDC
Liebherr bypass filter 16.69.1 A 900 C-LI EDC 24677-

A 904 C-LI EDC 30580-
A 914 C-LI 35112-
A 924 C-LI 34519-
Reversible fan drive 16.70.1 A 900 C-LI 14675-

A 904 C-LI 16000-
A 914 C-LI 35112-
A 924 C-LI 34519-
16.3
MJFCIFSS
Service Manual
16.4
MJFCIFSS
Service Manual Pipe fracture safety device for boom cylinders
Function
Pipe fracture safety device for boom cylinders
1 Function
The pipe fracture safety valve is connected directly to the pressure connection of the boom cylinder
(piston side).
The pipe fracture safety valve described here is also independent of the adjustment pressure. It is
used to secure the boom cylinder.
The pipe fracture safety valve consists of a brake cylinder with check valve and a control piston. The
pressure relief valve installed in the housing acts as a secondary safety device.
The valve prevents uncontrolled lowering of the attachment or the load in the event of a pipe fracture
If there is no pressure at the control pressure port, the pipe fracture safety valve seals the respective
cylinder connection.
Fig. 1 Pipe fracture safety valve at the hydraulic cylinder
16.01.1
copyright by
MJFCIFSS
Pipe fracture safety device for boom cylinders Service Manual
see Fig. 8
2.1 Operating cylinders 235 in stroke direction

The hydraulic oil flows from the control valve block 100 connection A5 to valve 238, connection V2.
The sleeves 12 and 42 are moved, and the oil pressurises the cylinder from the piston side via con-
nection C2. The cylinders 235 are extended. After completion of the working movement, the check
valve 8 closes. The return is blocked, i.e. the load is held leak oil free.
2.2 Pressure protection

The secondary pressure protection is provided by the pressurisation of the cone 29.7 via the filter
cartridge 30. In the even of pressure peaks, the cone 29.7 is moved against the prestressed pressure
spring 29.6, thus relieving the piston side. The oil escapes via the restrictor check valve 23, (see Fig.
8 on page 11) pressuring the piston 3, which moves plunger 7.7. Additional oil from the piston side
flows now through V2 to the control valve block 100 and the secondary pressure relief valve 221 (ex-
tending boom cylinder 235). The valve 221 is opened and oil can flow off to the tank.
2.3 Operating cylinders 235 in lowering direction

The pilot pressure at the control valve block 100, connection B5 used to operate the spool 220 for
the working movement "lower attachment" pressurises the control piston 3 via connection PiL and the
restrictor check valve 23.
The control piston 3 presses against the valve plunger 7.7, moving it towards the pressure spring 7.5.
After a short stroke, the sleeve 42 reaches the valve guide 7.1 opening the leak oil free blockage. The
cylinders 235 are retracted.
The oil flows from the cylinder room via connections C2 and V2 to the control valve block and returns
from there to the hydraulic tank. At the same time, oil flows from the pump P2 via the respective con-
nection of the control valve block to the rod side of the cylinder 235.
16.01.2
copyright by
MJFCIFSS
Sectional drawing
3 Sectional drawing
Fig. 2 Sectional drawing of the pipe fracture safety valve

2 Slide ring 14 Spring guide
3 Pilot piston 15 O-ring
4 Housing 16 Backing ring
6 O-ring 18 O-ring
7 Control piston, complete 19 Screw plug with O-ring
7.1 Valve guide 27 Protective cap
7.2 Adjusting screw 29.1 Valve guide
7.3 Protective cap 29.2 Adjusting screw
7.4 Sealing ring 29.4 Spring guide
7.5 Pressure spring 29.5 Sealing ring
7.6 Valve cone 29.6 Pressure spring
7.7 Valve plunger 29.7 Valve cone
7.8 O-ring 30 Filter cartridge
8 Check valve, complete 31 Screw plug with sealing ring
8.1 Valve guide 40 Slide ring
8.2 Cone 41 O-ring
9 O-ring 42 Valve seat (sleeve)
10 Slide ring 43 Pressure spring
11 O-ring 44 Spring guide
12 Valve seat (sleeve)
16.01.3
copyright by
MJFCIFSS
Dismantling and installation of the valve 238
4 Dismantling and installation of the valve 238
see Fig. 2
4.1 Sealing and repair work

.
Note!
The sealing work can be carried out while the valve remains installed.
Note!
Before installing the valve, carefully clean all parts and inspect them for reusability. Replace all
sealing rings and treat them with a little oil.
Lower the attachment without load onto the subgrade.

Release tank preload and lift RBS valve(s) by repeatedly operating the pilot control valve for lifting.
Release the hydraulic pressure from the lowering valve while the diesel engine is switched off (ig-
nition and pilot control on) .
4.2 Dismantling and installation of the control piston 3

Remove the screw plug 19 and press the piston 3 from the housing 4 (if necessary, pressurise
connection T with compressed air).
Mount the O-ring 1 and the slide ring 2 onto the control piston 3 and check the radial and axial
bore in the piston for dirt.
Insert the control piston 3 into the bore.
Mount the screw plug 19 with O-ring.
4.3 Dismantling and installation of the valve plunger 7.7

Remove the valve guide 7 complete with pressure spring 7.5 and the valve cone 7.6 (caution:
«spring preload!)
Pull the plunger 7.7 from the housing 4 and remove the sleeve 42 with the pressure spring 43 and
the spring guide, using a magnet, if necessary.
If required, remove the screw plugs and sealing rings.
Mount the sealing rings 40 / 41 on the sleeve 42. Insert the spring guide 44, the pressure spring
43 and the complete sleeves 42 into the housing bore.
Mount the O-ring 7.8 onto the valve guide 7.1. Insert the valve guide 7.1 complete with the valve
plunger 7.7, the valve cone 7.6 and the pressure spring 7.5 into the bore and screw it in.
16.01.4
copyright by
MJFCIFSS
Adjustment guidelines
4.4 Dismantling and installation of the pressure relief valve 29

Remove the protective cap 27 at the valve 29.
Remove the complete valve guide 29.1. Remove the filter cartridge 30 if necessary, using a ma-
gnet.
Reinsert the filter cartridge 30 and screw in the valve 29.
Adjust the pressure at the valves 7 and 29 to the prescribed secondary pressure and start of mo-
vement, see adjustment guidelines.
5 Adjustment guidelines

Note!
The valves 238 are factory-set and cannot be adjusted (lead-sealed). If the lead seal is broken, it
must be suspected that the factory settings have been tampered with.
To check the current settings, remove the protective caps 7.3 and 27. Measure distance X from the
upper edge of the adjusting screw 7.2 / 29.2 to the valve guide 7.1 or lock nut 29.3 respectively.
Adjusting screw 7.2 :

Adjusting screw 29.2 :
If, after a repair, etc., the valve settings deviate from the factory settings, correct the settings by tur-
ning the adjusting screw until the above distance is reached (rough adjustment).
Heat the hydraulic oil to operating temperature.
Set the speed of the diesel engine to the rated speed.
To adjust the pressure, use suitable pressure sensors.
Note!
Please note that, during the warranty period, all work on the valves must be carried out by LIEB-
HERR technicians.
Fig. 3 Adjusting points and additional measuring points at the pipe fracture safety valve
16.01.5
copyright by
MJFCIFSS
5.2 Adjustment of the secondary pressure, see Fig. 3
Fig. 4 Measuring points at the pipe fracture safety valve and control valve block

Switch off the engine and release the pressure from the valve.
Remove the plug 5 at connection E or the measuring connection 52 (in units equipped with over-
load warning system). Collect escaping oil.
Insert the measuring connection 50 (1/4", tool ID no. 7362579) into the connection E of the two
valves 238 (or valve 238 of the left boom cylinder in units equipped with overload warning system).
Instead of mounting the measuring connection 50, you may connect a measuring hose with a T-piece
to the measuring connection 52, see group 2.01. Items 33, 34, 35, 36.
Remove the cover cap from the measuring point 41 (at control valve block 100) and connect the
mini measuring hose between the measuring point 50 (in connection E).
Connect a pressure sensor (600 bar) with measuring connection (1.5 2.5 m) to the other measu-
ring connection 50 of the valve 238 (connection E) (in units with overload warning system, connect
it to the measuring connection 52).
Extend the boom cylinder 235 to the stop.
Turn the secondary pressure relief valve 221 (spool 220) for "extend boom cylinder" by at least 2
full revolutions.
The lowering of the pressure is required to allow oil to flow out through the connection V2 of
the valve 238, see Fig. 8
16.01.6
copyright by
MJFCIFSS
Fig. 5 Pressure relief valve 29 at the pipe fracture safety valve
First measure distance X from screw 29.2 to the lock nut 29.3, (see Adjustment guidelines on
page 5).
Remove the protective cap 27 from the valve 29.
Loosen the lock nut 29.3 (WS 10) and remove the adjusting screw 29.2 using an Allen key (WS
3) by turning it by 360 degrees.
Extend the bucket cylinder fully to the stop.
Pressure is built up via the measuring hose at the connections E of the valve 238 and at the
measuring point 50 with pressure sensor.
Screw in the adjusting screw 29.2
until a pressure of 240 bar is built up at the measuring point 50, then screw in the adjusting
screw 29.2 by exactly 180 degrees (180° = 170 bar).
The prescribed adjustment pressure of the valve 29 is calculated as follows:
240 bar Measured pressure

+ 170 bar Pressure increase achieved by
screwing in
= 410 ±10 bar
Note!
Both valves 238 must be set to the same pressure.
Adjust the valve 29 at the second pipe fracture safety valve 238.
After completion of the adjustment:

Tighten the lock nut 29.3 .
Insert the seal wire through the adjusting screw 29.2 and the protective cap 27.
Lead-seal the pressure relief valve 29.
Switch off the engine and release the pressure from the system.
Disconnect the pressure sensor, the measuring hoses and the measuring connection 50.
16.01.7
copyright by
MJFCIFSS
Insert the plug 5 into connection E.

Adjust the secondary pressure relief valve 222, see Fig. 8 to the prescribed pressure (see group
6).
5.3 Adjustment of the start of movement, valve 7, see Fig. 3

Release the pressure from the pilot control system.
Mount the T-piece with the measuring connection in the control line to the connection Pil of the
valve 238.
Connect the pressure sensor (0-60 bar) .
Carefully activate the function "lower attachment" at the right control unit. Read the control pres-
sure indicated on the pressure sensor at the start of movement of the attachment.
The control pressure at the start of movement should be = 7.5 ± 0.5 bar.
If required, adjust the pressure by turning the adjusting screw 7.2 of the valve 7 as follows:
1 full revolution (360°) = change of pressure by 5 bar
Screw in 7.2 = Increase pressure
Screw out 7.2 = Reduce pressure
After adjustment, measure the distance X from the screw 7.2 to the valve guide 7.1. Mount the pro-
tective cap 7.3 with the sealing ring 7.4 on the adjusting screw 7.2.
Adjust dimension X at the second pipe fracture safety valve 238 and check the start of the opening
motion of the two valves, which must be simultaneous.
If the response pressure is too high, measure the distance X at the left or at the right valve (control
piston) and then turn by 360 degrees.
At the opposite valve 238 adjust the start of movement, measure distance X, set the same distance
at the other valve and check again the opening motion of the two valves.
Apply a lead seal to the valve.
Release the pressure from the system and remove the pressure gauge and the T-piece.
Fig. 6 Valve 7 with adjusting screw 7.2 and connections PiL / T
16.01.8
copyright by
MJFCIFSS
Hydraulic connections and lines
6 Hydraulic connections and lines
Fig. 7 Hydraulic connections and lines
16.01.9
copyright by
MJFCIFSS
22
1 Hydraulic tank 100 Control valve block

5 Hex head screw 220 Spool / boom cylinder
6 to hydraulic oil cooler 221 Secondary pressure relief valve for
"extend boom cylinder"
14 Rectangular ring 222 Secondary pressure relief valve for
"retract boom cylinder"
16 Allen head screw 224 Pressure balance
20 from pump 235 Boom cylinder
23 to pump regulator 238 Pipe fracture safety valve
37 Hex head screw 238.7 Control piston
41 Measuring point MP 238.8 Check valve
43 Screw coupling 238.23 Restrictor check valve
45 Measuring point LS 238.29 Pressure-relief valve
50 Screw coupling (to be installed for measu- 238.30 Filter
rement)
52 Measuring connection (only for units with
overload warning system)
81/1 from pilot control unit (right) / connection 1
(lowering)
81/3 from pilot control unit (right) / connection 3
(lifting)
16.01.10
copyright by
MJFCIFSS
Fig. 8 Hydraulic diagram of the pipe fracture safety valve
16.01.11
copyright by
MJFCIFSS
16.01.12
copyright by
MJFCIFSS
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 pipe fracture safety valve at hydraulic cylinder
see Fig. 7
16.02.1
copyright by
MJFCIFSS
Pipe fracture safety valve for stick cylinder Service Manual
2.1 Extending cylinder 255

The pilot pressure at the control block 100 connection b3 used to actuate the spool 240 for working
movement "Extend stick cylinder" applies pressure to the pilot piston 3 of the piston-side valve 258.
This pressure is applied through the connection Pil and the restrictor check valve 23.
The pilot 3 presses against valve plunger 7.7 and, thus, shifts it against the pressure spring 7.5. After
a short stroke, the sleeve 42 finds purchase on valve guide 7.1, and the leak oil free shut-off device
is opened.
The hydraulic oil flows from the control block 100 connection B3 to the piston-side connection of the
cylinder 255. The return oil from the piston side flows through the connections C2 and V2 of the open
valve 258 and the connection A3 of the control block 100 to the tank. 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.
2.2 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 rod side. The oil escapes partly through the
restrictor check valve 23 and pressurises, at the same time, the piston 3, which then shifts the piston
7(see Fig. 3 on page3). More oil flows from the piston rod side through the open valve 7 and the con-
nections C2 and V2 to the control block 100 and the secondary pressure-relief valve 241 (stick cylin-
der 255 retracting). The valve 241 opens to allow the oil to flow back to the tank.
2.3 Retracting cylinder 255

The pilot control pressure at the control pressure 100 connection a3 acts on the spool 240 for the
working movement "Retract stick cylinder".
The hydraulic oil now flows from the control block 100 connection A3 to the rod-side valve 258 con-
nection 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 B3 of the control block 100 to the
tank. The cylinder 255 is retracted. When the working movement is completed, the check valve 8 clo-
ses again. The return line is blocked, i.e. the load is held without any leak oil.
Fig. 2 Section 240 at the control block 100
16.02.2
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MJFCIFSS
Sectional drawing
3 Sectional drawing
Fig. 3 Sectional drawing of pipe fracture safety system

2 Slide ring 14 Spring guide
3 Pilot piston 15 O-ring
4 Housing 16 Backing ring
6 O-ring 18 O-ring
7 Control piston, complete 19 Screw plug with O ring
7.1 Valve guide 27 Protective cover
7.2 Adjusting screw 29 Pressure-relief valve, complete
7.3 Protective cover 29.1 Valve guide
7.4 Seal ring 29.2 Adjusting screw
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
16.02.3
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MJFCIFSS
Repair and sealing of valve 258
4 Repair and sealing of valve 258

.
Danger!
Defective valves 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
Note!
In the event of external leakage of the valves, the valves may only be resealed, if this work does not
require the dismantling of the valve.
To reseal the valve, use only the seal kit provided by the manufacturer.
4.2 Assembly and dismantling of the pipe fracture safety valves
Danger!
The dismantling, installation or sealing of the valves requires workers to access the danger area of
the machine. This bears risks for the mechanic, as equipment might move uncontrolled when a val-
ve/hydraulic circuit is opened.
Never open the hydraulic circuit of the pipe fracture safety valves while the circuit is pressurised.
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).
Release the tank pressure.
After the hydraulic circuit of the valves 258 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 258, see Fig. 4

Remove the protective cap from the measuring neck 52 at the connections Pil and T.
If the measuring neck 52 is not available: Remove the screw plug from the connections Pil and T.
Screw the M12x1.5 screw coupling (tool no. 11 from group 2.01) into the bores.
Install the Minimess high pressure hose between the connection Pil and connection T.
Actuate the boom cylinder to retract it (keep pilot control unit pushed forward).
The control circuit is bled.
Put down unloaded attachments on flat and firm ground.
Release the tank pressure and the load-holding valve(s) by actuating the pilot control device for
control system on).
16.02.4
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MJFCIFSS
Remove the measuring hose and screw coupling.

Screw in the screw plug at the connections Pil and T.
Fig. 4 Screw coupling for the bleeding of the hydraulic circuit and the pipe fracture safety valve
52 Screw coupling 258 Pipe fracture safety valve

255 Stick cylinder
16.02.5
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MJFCIFSS
Inspection and testing of pipe fracture valves
5 Inspection and testing of pipe fracture valves
Danger!
The inspection and testing of the pipe fracture safety valves require access to the danger area of
the machine. There is a risk to life and limb for mechanics from uncontrolled machine movements.
Park the machine on a level surface.
Secure it against uncontrolled movement.
Only carry out inspections, if the machine is fully shut down and properly secured.
Before opening the hydraulic circuit release all pressure from the hydraulic system.
The valves 258 have been pre-set by the manufacturer. The setting cannot be changed and is se-
cured 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 valve preset by the manufacturer.
5.1 Pressure check, see Fig. 5

Switch off the engine. Release the pressure from the valve.
Remove the screw plug 5 at the connection E and drain the pressure oil through the bleeding con-
nection 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 258. In machines that are equipped with an overload warning system, insert the connection
only in the valve 258 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 41 (at the control block 100) and connect a Minimess
hose between the measuring points 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 241 (spool 240) to extend the stick cylinder to minimum
150 bar.
Reduce the pressure, so that the oil can flow through connection V2 of valve 258.
Fully pressurise the bucket and grapple cylinder to reach high pressure.
Turn in the secondary pressure valve 262 (spool 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 and listen for pressure sounds.
When the secondary pressure-relief valve 29, (see Fig. 3 on page3), opens, a hissing sound
is audible.
The pressure indicated at the measuring point 52 must correspond to the prescribed adjusting
pressure of the valve.
16.02.6
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MJFCIFSS
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 valves and pressure cut-off valve, see adjustment protocol
in group 6, and remove the pressure gauge.
Fig. 5 Measuring points at the pipe fracture safety valves and at the respective pressure-relief
valves at the control blocks
5 Plug 240 Spool / stick cylinder

41 Measuring point MP 241 Secondary pressure-relief valve / retrac-
ting stick cylinder
52 Measuring neck 258 Pipe fracture safety valve
100 Control valve block 260 Spool / bucket cylinder
104 Pressure cut-off valve 262 Secondary pressure-relief valve / exten-
ding bucket cylinder
16.02.7
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MJFCIFSS
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.
At operating temperature (approx. 50°C), fully lift the attachment and hold it in this position.
The load may not drop by more than 100 mm within the first 10 seconds (according to ISO 8643).
If the drop is greater, there is a problem with the hydraulic unit or the valve. Inspect the valve to locate
and identify the problem.
Danger!
The inspection of the valves requires access to the danger area of the machine. This bears risks for
the mechanic, as equipment might move uncontrolled when a valve/hydraulic circuit is opened.
Extend the attachment so that the valve can be accessed.

Lift the attachment slightly (by approx. 20 cm).
Switch off the diesel engine and release the tank pressure.
Place an oil pan under the valve to collect the leak oil.
Remove the line to the high pressure connection V2, (see Fig. 5 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).
16.02.8
copyright by
MJFCIFSS
Hydraulic connections and links
6 Hydraulic connections and links
Fig. 6 Hydraulic connections and links
22
1 Hydraulic tank 244 Pressure balance

52 Measuring connection 255 Stick cylinder
81/1 from pilot control valve, right / connection 258 Pipe fracture safety valve
1 (retracting stick cylinder)
81/3 from pilot control valve, right / connection 258.7 Control piston
3 (extending stick cylinder)
100 Control valve block 258.8 Check valve
240 Spool / stick cylinder 258.23 Restrictor check valve
241 Secondary pressure-relief valve / retrac- 258.29 Pressure-relief valve
ting stick cylinder
242 Extend secondary relief valve 258.30 Filter
16.02.9
copyright by
MJFCIFSS
Fig. 7 Hydraulic diagram: pipe fracture safety system
16.02.10
copyright by
MJFCIFSS
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 described here is independent of the adjustment pressure. It is used
for securing the boom cylinder.
The pipe fracture safety valve consists of a brake piston with check valve and the control piston ne-
cessary for control. The pressure-relief valve in the housing is responsible for secondary protection.
Fig. 1 pipe fracture safety valve at hydraulic cylinder
16.03.1
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MJFCIFSS
Pipe fracture safety valve for boom cylinders Service Manual
Design
2 Design

The pipe fracture safety valve 238 consists of a housing 26, a control piston 15, a regulating unit 22
(piston and sleeve) and a secondary pressure-relief valve 6.
The secondary pressure-relief valve 6 with filter insert 16 is screwed directly into the housing 26.
The check valve 30 is integrated into the housing 26.
Fig. 2 Design of the pipe fracture safety valve
16.03.2
copyright by
MJFCIFSS
Sectional drawing
3 Sectional drawing
Fig. 3 Sectional drawing of pipe fracture safety system
16.03.3
copyright by
MJFCIFSS
Sectional drawing
1 Washer 23 Slide ring (Teflon)

2 Spring recess 24 Valve plunger
3 Screw plug 25 Plug
4 Spring housing 26 Housing
5 Pilot piston 27 Screw plug
6 Secondary pressure-relief valve 28 Spring
7 Pre-opening piston 30 Check valve
8 Screw plug 31 O-ring
9 Screw plug 32 Spring
10 Pilot lever rod 33 Spring
11 Nozzle 34 Backing ring
14 Plug 35 O-ring
15 Control piston, complete 36 O-ring
16 Filter cartridge 37 O-ring
17 Plug 38 Backing ring
18 Seal cap 39 Spring
22 Piston with sleeve 40 O-ring
Fig. 4 Functional description of pipe fracture safety valve
16.03.4
copyright by
MJFCIFSS

The pilot pressure at the control block 100 connection a5 for the actuation of the spool 220 for working
movement "Lift attachment" is applied.
Hydraulic oil now flows from the control block 100 connection A5 to the valve 238 connection A. The
control piston 15 is shifted, and pressure oil pressurises the piston side of the cylinder through con-
nection A1. The cylinders 235 are extended.
The return oil from the rod side flows through the connection B5 of the control block 100 to the tank.
When the working movement is completed, the check valve 30 closes again. The return line is blo-
cked, i.e. the load is held without any leak oil.

The secondary pressure control is based on the application of pressure onto the pressure-relief valve
6 through the filter insert 16. In the event of pressure peaks, the piston side is relieved to the tank.
The pressure oil shifts the control piston 15 and opens the connection A1 to A to the connection T.
In a next step, more oil from the piston side flows via the connection A to the control valve block 100
and the secondary pressure-relief valve 221 (stick cylinder 235 extending). This oil flow is restricted.
The valve 221 opens to allow the oil to flow back to the tank.

The pilot pressure at the control block 100 connection b5 for the actuation of the spool 220 for working
movement "Lower attachment" pressurises the entire control piston 15 via connection X. The piston
is thus shifted and the connection A1 to A is opened. The cylinders are retracted.
The oil from the cylinder chamber (piston side) flows via connection A to the control block 100 con-
nection A5 and from there to the hydraulic tank. This flow is restricted. At the same time, oil from the
pump P1 flows via the corresponding connection B5 of the control valve block to the rod side of the
cylinder 235.
Fig. 5 Section 220 at the control block 100
Fig. 6 g
16.03.5
copyright by
MJFCIFSS

.
Danger!
ved.
5.1 Sealing work
Note!
5.2 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-
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
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).
5.3 Bleeding of pipe fracture safety valve 238
Note!
The pipe fracture safety valves 238 are self-bleeding and do not need to be bled.
To bleed the pipe fracture safety valves, move the attachment.
16.03.6
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MJFCIFSS
Danger!
ved.
6.1 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.
At operating temperature (approx. 50°C), fully lift the attachment and hold it in this position.
The load may not drop by more than 100 mm within the first 10 seconds (according to ISO 8643).
If the drop is greater, there is a problem with the hydraulic unit or the valve. Inspect the valve to locate
and identify the problem.
Danger!
The inspection of the valves requires access to the danger area of the machine. This bears risks for
the mechanic, as equipment might move uncontrolled when a valve/hydraulic circuit is opened.
Extend the attachment so that the valve can be accessed.

Lift the attachment slightly (by approx. 20 cm).
Switch off the diesel engine and release the tank pressure.
Place an oil pan under the valve to collect the leak oil.
Remove the line to the high pressure connection A.
16.03.7
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MJFCIFSS
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.
Fig. 7 Connections of pipe fracture safety system
1 to hydraulic tank 81/1 from pilot control valve, right / connection

1 (lower)
6 Secondary pressure-relief valve 81/3 from pilot control valve, right / connection
3 (lift)
15 Control piston 100 Control valve block
16 Filter cartridge 220 Spool / boom cylinder
20 from pump 221 Secondary pressure-relief valve - extend
boom cylinder
24.5 to pump regulator 222 Secondary pressure-relief valve - retract
boom cylinder
30 Check valve 224 Pressure balance
41 Measuring point MP 235 Boom cylinder
45 Measuring point LS 238 Pipe fracture safety valve
52 Measuring connection
16.03.8
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MJFCIFSS
Fig. 8 Hydraulic diagram: pipe fracture safety system
16.03.9
copyright by
MJFCIFSS
16.03.10
copyright by
MJFCIFSS
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).
As the opening ratio is extremely high, the pipe fracture safety valve operates independently of the
load pressure, return pressure and set pressure. It protects the entire equipment against damage
from pipe fracture.
Fig. 1 Pipe fracture safety valves at the boom cylinder
16.04.1
copyright by
MJFCIFSS
Design
2 Design
The pipe fracture safety valve consists of the housing 1, the control unit 2, the regulating unit 3 and
the secondary pressure unit 5.
The blocking function (check valve function of connection A1 - B) during the extension of the boom
cylinder is assumed by the regulating piston 34 with pressure spring 36.
For the easy bleeding of the control chamber at the control piston 22, the system is equipped with a
bleeder screw 60 located between the connection X and the leak oil connection L.
In the event of an emergency, the attachment can be lowered slowly with the emergency release
screw 70. The emergency release screw 70 is located between the connection B (cylinder connec-
tion) and the leak oil connection L.
Fig. 2 Main components of pipe fracture safety valve
1 Housing 60 Threaded stud / bleeder screw

2 Control unit 70 Threaded stud / emergency release
3 Regulating unit 238 Pipe fracture safety valve
5 Secondary valve unit
12 Allen head screw A1 High-pressure connection, inlet side
15 Rectangular ring B High-pressure connection, cylinder side
22 Control piston E High-pressure connection, compensating
line
34 Regulating piston L Return connection
36 Pressure spring X Control oil connection
16.04.2
copyright by
MJFCIFSS
Sectional drawing, see Fig. 3 and hydraulic diagram, see Fig. 7

Hydraulic oil flows from the control axle 220 connection A1 and through the distribution block 233 to
the valves 238 connection A1. The regulating piston 34 in the valve is shifted against the pressure
spring 36. Through the connection A1 - B of the valve 238, the pressure oil pressurises the piston
side of the cylinder 235. The two cylinders 235 are extended simultaneously.
The return oil from the rod side flows through the distribution block 233 and the connection B1 of the
control axle 220 to the tank. When the working movement is completed, the regulating piston 34 in
the valve closes. The return line is blocked, i.e. the load is held without any leak oil.

The secondary pressure control is based on the application of the load pressure onto the cone 53. In
the event of pressure peaks, the cone 53 is shifted against the preloaded pressure spring 54 and 55,
which results in a relief on the piston side. The oil escapes over the edge between the cone 53 and
the adjusting screw 51 and connection A1 to the control axle 220 and the secondary pressure-relief
valve 221 (extending boom cylinder 235). The valve 221 opens to allow the oil to flow back to the tank.

The pilot control pressure at the control axle 220 connection x1 used for the operation of the spool
223 for the working movement "Lowering attachment" also pressurises the control piston 22 through
connection X.
The control piston 22 with form-mounted thrust pillar pushes the pilot control piston 35 from its seat
in the control piston 33. Part of the load pressure is released to the return system through the cut
control grooves located at the circumference of the pilot control piston 35. If the control pressure is
increased further, more oil flows out through the borehole C of the pilot control piston 35 than can
flow in via the ring surface D of the control piston 34. The counterpressure is thus reduced. The re-
gulating piston 34 opens and allows the oil to flow to the return system until an equilibrium is estab-
lished. This process is repeated each time the control pressure changes. From a load pressure of
approx. 100 bar, the volume flowing from the system is constant (flow control valve function / principle
of after-run of the manufacturer).
The hydraulic oil flows from the control axle 220 connection B1 to the distributor 233 to the piston-
side connection. The cylinders 235 are retracted.
The oil from the piston chamber flows through the connection B and A1 to the control axle 220 and
from there to the hydraulic tank.
In the event of a fast change of movement from lowering to lifting, the oil behind the pilot control piston
35 must be moved out quickly. To facilitate this, the response check valve 39 between the screw plug
31 and the guide 32 opens.
16.04.3
copyright by
MJFCIFSS
Sectional drawing
4 Sectional drawing
Key of sectional drawing, see Fig. 3
1 Housing 51 Adjusting screw

21 Lid 52 Lock nut
22 Control piston 53 Valve cone
23 Pressure spring 54 Pressure spring
25 Shim 56 Spring plate
26 Washer 57 Screw plug
31 Sealing element 58 Protective cover
32 Guide element 60 Threaded stud / bleeder screw for control
block
33 Valve seat 61 Sealing nut
34 Regulating piston 70 Threaded stud / emergency release
35 Pilot control piston 71 Sealing nut
36 Pressure spring 238 Pipe fracture safety valve
39 Ball (check valve)
16.04.4
copyright by
MJFCIFSS
Sectional drawing
Fig. 3 Sectional drawing of pipe fracture safety valve
16.04.5
copyright by
MJFCIFSS
Caution!
ved.
5.1 Sealing work

5.2 Dismantling and installation of pipe fracture safety valve, see Fig. 2 and Fig. 4
.
Danger!
The dismantling, installation or sealing of the valve requires workers to access the danger area of
the machine. This poses a risk to the mechanic, as equipment might move uncontrolled when a val-
Place the unloaded attachment on the ground (piston side of the cylinder must be fully depres-
surised) If required, release the pressure by loosening the emergency release screw 70, see 5.4.
Depressurise the pipe fracture safety valve(s) by actuating the pilot control unit for lowering to
the stop and holding it in this position while the diesel engine is off (ignition and pilot control sys-
tem on).
After the connections at the valve 238 are opened, air in the control circuit might cause problems.
The system must therefore be bleed, see 5.3.
Disconnect all hydraulic lines to the valve 238 (collect escaping oil).
Screw out the cylinder screws 12 and remove the complete valve.
Carefully clean the threaded and sealing surfaces of the valve and screw connections.
Place a new valve 238 with a new seal ring 15 on the cylinder 235.
Screw in the Allen head screws 12 and tighten them (torque 68 Nm).
Reconnect all hydraulic connections (check for leakage).
Bleed the valves, see 5.3.
16.04.6
copyright by
MJFCIFSS
5.3 Bleeding of pipe fracture safety valve 238, see Fig. 4

(control pressure release)
Loosen the sealing nut 61.
Loosen the bleeder screw 60 (do not screw out fully, see note below).
Actuate and hold the pilot control unit for the lowering of the boom.
The control circuit is bled.
.
Caution!
The bleeder screw 60 is designed as a threaded stud with cone used to control the oil flow from the
control circuit to the return side.
The screw 60 must be loosened with great care. If it is screwed out too far, it might be propelled
from its seat, ripping out the last thread turns. This could lead to serious injury from the screw or the
pressurised oil jet.
Turn out the screw 60 by maximum 3 revolutions.
If the screw is loosened, or if there are leaks at the sealing edge, the valve control pressure might
change.
After the system is bled, fully tighten the screw 60.
Check the sealing nut 61 for damage and tighten it with 20 Nm.
5.4 Emergency release of the attachment, see Fig. 4

In the event of an emergency (no control pressure), the attachment can be depressurised by means
of the emergency release valve 70 at the valve 238.
Danger!
The emergency procedure requires access to the undercarriage of the machine. There is a risk of
serious injury or even death to mechanics from crushing, if the attachment is moved.
Secure the machine against rolling away.
Access the danger area only when the machine is shut down and properly secured in its position.
As there is a connecting line between the connections E, it is sufficient to open the emergency release
valve 70 at the left pipe fracture safety valve only (for safety reasons).
Loosen the sealing nut 71.
Carefully loosen the emergency release screw 70 (loosen the screw by 1 revolution only).
Slowly lower the attachment to the ground.
Caution!
The emergency release screw 70 is designed as a cone, blocking the oil flow from the consumer to
the leak oil connection L. If the screw is loosened, or if there are leaks at the sealing edge, the valve
control might be changed.
After the system is bled, fully tighten the screw 70.
Check the sealing nut 71 for damage and tighten it with 20 Nm.
16.04.7
copyright by
MJFCIFSS
Fig. 4 Bleeder valve, emergency release and secondary valve at the pipe fracture safety valve
12 Allen head screw 70 Emergency release valve

51 Adjusting screw of secondary pressure- 71 Sealing and lock nut
relief valve
60 Bleeder screw 235 Boom cylinder
61 Sealing and lock nut 238 Pipe fracture safety valve
16.04.8
copyright by
MJFCIFSS
Danger!
ved.
6.1 Pressure check, see Fig. 5

Switch off the engine. Release the pressure from the valves.
Carefully loosen the union nut at the connecting line of the connections E and release the pressure
oil (collect escaping oil).
Remove the union nut and the sealing cone and mount the T-piece with 2 Minimess necks 52.
Remove the cap from the measuring point 41 (-xP at the pilot plate 100) and connect a Minimess
hose between the measuring point 41 and one of the measuring necks 52.
Connect a pressure sensor (600 bar) with a measuring line (1.5 - 2.5 m) to the other installed
measuring neck 52.
Screw out the secondary pressure-relief valve 221 (way valve 220) used to extend the boom cy-
linder to a position that corresponds 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 high pressure.
Screw in the secondary pressure valve 262 (way valve 260) used to extend 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 101 and listen for pressure sounds.
When the secondary pressure-relief valve 5, (see Fig. 2 on page2), opens, a hissing sound is
audible.
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.
16.04.9
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MJFCIFSS
Remove the hose, T-piece and measuring necks. Mount the sealing cone and the union nut.
Readjust the secondary pressure-relief valves and the pressure cut-off valve, see adjustment pro-
tocol in group 6, and remove the pressure gauge.
Fig. 5 Measuring points at the pipe fracture safety valves and at the respective pressure-relief
valves at the control blocks
41 Measuring point MP 221 Secondary pressure-relief valve -

extend boom cylinder
52 Measuring neck 238 Pipe fracture safety valve
100 Pilot plate 260 Way valve / bucket cylinder
104 Pressure cut-off valve 262 Secondary pressure-relief valve / exten-
ding bucket cylinder
220 Way valve / boom cylinder
16.04.10
copyright by
MJFCIFSS
7 Hydraulic connections and links
Fig. 6 Hydraulic connections and links
1 Hydraulic tank 235 Boom cylinder

233 Distribution block 238 Pipe fracture safety valve
16.04.11
copyright by
MJFCIFSS
Hydraulic diagram
8 Hydraulic diagram
Components of hydraulic diagram, see Fig. 7
2 Control unit 220.1 Stroke limitation / spool

3 Regulating unit 220.2 Stroke limitation / spool
5 Secondary valve unit 220.3 Restrictor check valve
20 from pump P1 220.7 Pressure-relief bleeder valve
21 from pump P2 220.8 Pressure-relief bleeder valve
41 Measuring point pump -xP 221 Secondary pressure-relief valve -
extend boom cylinder
45 Measuring point -xLS 222 Secondary pressure-relief valve - retract
boom cylinder
60 Bleeder screw 223 Spool / boom cylinder
70 Emergency release valve 225 Pressure balance
81/1 from pilot control unit, right / connection 226 Pressure balance
1 (lowering attachment)
81/3 from pilot control unit, right / connection 227 Switch
3 (lifting attachment)
100 Pilot plate 228 Switch
101 Pressure cut-off valve 233 Distribution block
115 Lowering restrictor / boom cylinder 235 Boom cylinder
220 Control axle / boom cylinder 238 Pipe fracture safety valve
16.04.12
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MJFCIFSS
Hydraulic diagram
Fig. 7 Hydraulic diagram of the boom cylinder pipe fracture safety system
16.04.13
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MJFCIFSS
Hydraulic diagram
16.04.14
copyright by
MJFCIFSS
Service Manual Overload warning system
Function
1 Function
Machines used to lift, transport and lower loads attached by ropes, cables, chains, etc. where the at-
tachment and release of loads requires manual handling by personnel, are subject to a number of
safety instructions laid down in the European standard EN 474-5. Such lifting operations also include
the lifting and lowering of pipes, manhole rings and vessels.
Caution!
Machines may only be used for load lifting, if they are equipped with the prescribed safety devices.
A copy of the load lift chart must be kept in the operator's cab for reference.
1.1 Load lifting operation

Lifting tackle:
Used to securely attach the load
Load hooks mounted instead of digging buckets, or safety hooks welded onto digging buckets are
deemed safe lifting tackle.
Overload warning system:
The overload warning system must warn the machine operator with a visual and an acoustic signal
when the permitted load according to the load chart is reached or exceeded respectively.
Line break monitoring system:
(pipe fracture safety valve) on the boom cylinders. The pipe fracture safety valve must conform to
ISO 8643.
Fig. 1 A = Overload warning system without pipe fracture safety valve, B = Overload warning
system with pipe fracture safety valve
A 900 C-LI 14675- 16.06.1

MJFCIFSS
Overload warning system Service Manual
Function
Danger!
The overload warning system does not disable or halt the machine when the limit load is exceeded.
The operator is only informed of the situation. When carrying out load lifting work, always adhere to
the applicable accident prevention regulations. Never use defective machinery for load lifting work.
After repair, the machine must first be inspected by a specialist technician in accordance with the
testing and adjustment guidelines before it may be used for load lifting operation.
General:
The overload warning system warns the operator with a visual symbol on the screen (see Fig. 2)
and an acoustic buzzer signal when the maximum permissible load is reached.
Lift only loads of which the weight is known, and refer to the load lift chart to check whether the
actual load is within the permitted load range of the respective machine model.
The maximum load values in the chart correspond to max. 75% of the tip load or 87% of the hy-
draulic lifting power according to ISO 10567.
For machines with attached backhoe bucket (with bucket cylinder, change lever and connecting
link), the values at the tip of the stick are relevant here. The machine must thereby stand on a firm
and level surface, with closed swing axle and swivelable by 360° .
For machines with attached bucket cylinder, change lever and connecting link, the values are in-
creased by the values applicable to the attachment components.
When using a quick change adapter (SWA), the values for SWA 33 are reduced by110 kg, while
those for 48 are reduced by 190 kg.
For industrial equipment, the values at the load hook are relevant here. The machine must thereby
stand on a firm and level surface, with closed swing axle and swivelable by 360° .
The load values might also change depending on the type of attachment connected to the machi-
ne (grapple, etc.).
Startup:
The overload warning system may only be used in connection with load lifting work. To switch on
the system, press the S18 button (see Fig. 2).
Before starting the overload warning system for the first time, adjust it according to the instruc-
tions.
Prior to a shift, complete a functional test of the system by fully extending the boom cylinder so
that the maximum operating pressure is built up. The system must now issue a visual and acoustic
warning signal.
All moving parts of the overload warning system must be regularly inspected for appropriate clea-
rance and must be lubricated.
The machine used for load lifting work must undergo an annual load test.
This can be done with adequate accuracy as described below:
Multiply the load capacity value for "swivelling" (i.e. not supported) or "transverse" with 1.33 and
add 150 kg. Attach the test load at the prescribed reach (see table) to the machine. Take into ac-
count any attachments such as buckets or grapples.
Carefully swivel the uppercarriage with the load (lifted to a position just above the ground) by 360°.
The machine may not topple over during this manoeuvre. One wheel or a section of a crawler
might be lifted from the ground, which is permissible.
The warning system must trigger a signal.
In addition, the overload warning system must be tested every 12 months by a specialist techni-
cian and adjusted according to the prescribed load values, if necessary.
16.06.2 A 900 C-LI 14675-

MJFCIFSS
Description
Note!
Disable the overload warning system when working with a digging bucket, as the increased load on
the machine in connection with such work would otherwise result in a continuous warning signal.
Press switch S18.
The overload warning system is deactivated.
The LED in the switch is off.
2 Description
Fig. 2 Switch S18 and display in the check field of the screen H1
Switch S18 to switch the overload warning system on/off

Symbol in the check field of the screen : visual signal indicating that the overload warning system
has been triggered
The visual signal is accompanied by an audible signal from the buzzer H10-1.
Constant pressure switch B21, with measuring point 66, located at the right boom cylinder 235
B21 makes contact with the check display on the screen and the buzzer H10-1, as soon as the
max. permissible load is reached = switching pressure e.g. 153 bar punched into the sheet me-
tal plate
Constant pressure switch B21, with measuring point 66, located at the pipe fracture safety
valve 238 of the right boom cylinder 235
B21 makes contact with the check display on the screen and the buzzer H10-1, as soon as the
max. permissible load is reached = switching pressure e.g. 153 bar punched into the plate
A 900 C-LI 14675- 16.06.3

MJFCIFSS
Fig. 5
The warning signal is triggered by the electro-hydraulic pressure switch B31 (constant pressure
switch). The pressure switch B21 is connected to the pressure connection at the piston side of the
boom cylinder 235.
When the load pressure in the boom cylinder reaches the switching pressure, the pressure switch
B21 makes electrical contact with the buzzer H10-1 and the check display on the screen, so that the
operator is informed of the status of the machine. The switching pressure preset at the pressure
switch B21, varies from model to model.
4 Installation instructions
4.1 Overload warning system in machines without pipe fracture safety valve
Install the flange 2 complete with measuring neck and pressure switch 8 (B21) between the piston
side of the right boom cylinder 235 / A and the pressure line 12.
4.2 Overload warning system in machines with pipe fracture safety valve
Mount holder 2 to the pipe fracture safety valve 238. Mount the pressure switch 3 (B21) to the
holder 2.
Install the connections between the pressure switch, the connection E of the pipe fracture safety
valve 238 and the right boom cylinder 235 with measuring connection 66 (measuring neck 13).
Install the electrical connections between the pressure switch B21 and the printed circuit board
A1010 or A1100 respectively (see diagram).
16.06.4 A 900 C-LI 14675-

MJFCIFSS
Overload warning system with hydraulic connections
5 Overload warning system with hydraulic connections
Fig. 3 Installation of the overload warning system in the boom cylinders 235
Boom cylinder 235 without pipe fracture safety valve A

2 Flange 12 Pressure line
3 Rectangular ring 15 Measuring connection
4 Allen head screw 37 Wire harness
7 Protective cap 40 Sheet metal plate
8 Pressure switch (B21*) 41 Allen head screw
9 Screw-in stud 42 Hex nut
10 Screw-in stud 235 Boom cylinder
Boom cylinder 235 with pipe fracture safety valve B

2 Holder 10 Fitting
3 Pressure switch (B21*) 11 Screw connection
5 Allen head screw 12 Screw connection
6 Hex nut 13 Measuring connection
7 Washer 14 Screw-in stud
8 Hex head screw 37 Wire harness
9 Washer 40 Sheet metal plate
* item in electrical diagram
A 900 C-LI 14675- 16.06.5

MJFCIFSS
Remove the cover cap from the measuring connection 66 and connect the pressure sensor in
such a way that the indicator is visible from the operator's cab.
Switch on the overload warning system with switch S18 and open the stop cock (if installed) bet-
ween the overload warning system and the boom cylinder connection.
Move the boom cylinder 235 to its upper stop position and check whether the overload warning
system has been triggered (symbol on screen and buzzer signal).
Gradually build up the prescribed switching pressure indicated (punched into the sheet metal plate
40 of the switch B21, see Fig. 4) by operating the right pilot control extending the boom cylinder.
6.1 Example:

with hydraulic boom adjustment
(the value punched in at the pressure switch is binding) 153 bar 173 bar
Note!
In machines where the overload warning system is retrofitted, the pressure value is included in the
enclosed installation drawing and must be punched into the sheet metal plate 40, arrow see Fig. 4.
If the overload warning system is not triggered at the prescribed pressure, adjust the switching pres-
sure at the pressure switch B21.
To do this, remove the cap 7, if required, and loosen the self locking screw S of the pressure switch
B21.
Using a screwdriver, turn the adjusting screw E. The switching pressure is adjusted as follows:
Turn screw clockwise
switching pressure is increased
Turn screw anticlockwise
switching pressure is reduced
Lock the adjusting screw E with the self locking screw S.
If the overload warning system is only triggered at a pressure that is above the prescribed pressure,
readjust the switching point (pressure) again. A switching pressure below the prescribed limit pres-
sure is however permissible.
Fig. 4 Cylinder 235 with and without pipe fracture safety valve
16.06.6 A 900 C-LI 14675-

MJFCIFSS
Hydraulic / electrical diagram
7 Hydraulic / electrical diagram
Fig. 5 Hydraulic / electrical diagram of the overload warning system
66 Measuring connection MP85 Ground connection

100 A5 control valve block / connection S2 Keypad
100 B5 control valve block / connection S18 Overload warning system switch
233 Distribution block / boom cylinder X2 Plug connection
235 Boom cylinder X6.2 Plug connection
238 Pipe fracture safety valve X200 Plug connection
A1001 ESP 01 printed circuit board X219 Plug connection
A1100 ESP 02 printed circuit board X232 Plug connection
B21 Constant pressure switch X273 Plug connection
H1 Monitoring display X309 Plug connection
H10-1 Buzzer A Electrical system / basic machine
K335 Relay / overload warning system B Electric system / kit
KL15 Terminal 15
A 900 C-LI 14675- 16.06.7

MJFCIFSS
16.06.8 A 900 C-LI 14675-

MJFCIFSS
Service Manual Switchable overload warning system
Function
1 Function
Machines used to lift, transport and lower loads attached by ropes, cables, chains, etc. where the at-
tachment and release of loads requires manual handling by personnel, are subject to a number of
safety instructions laid down in the European standard EN 474-5. Such lifting operations also include
the lifting and lowering of pipes, manhole rings and vessels.
Caution!
Hydraulic excavators may only be used for load lifting, if they are equipped with the prescribed safe-
ty devices.
1.1 Load lifting operation

Machines used to lift loads must be equipped with the following safety devices:
Lifting tackle:
Used to securely attach the load
Load hooks mounted instead of digging buckets, or safety hooks welded onto digging buckets are
deemed safe lifting tackle.
Overload warning system:
The overload warning system must warn the machine operator with a visual and an acoustic signal
when the permitted load according to the load chart is reached or exceeded respectively.
Line break monitoring system:
(pipe fracture safety valve) on the boom cylinders. The pipe fracture safety valve must conform to
ISO 8643.
Fig. 1 Switchable overload warning system A = roller level down, B = roller level up
A 900 C-LI 14675-18087 16.08.1

A 924 C-LI 34519-
Switchable overload warning system Service Manual
Function
Danger!
The overload warning system does not disable or halt the machine when the limit load is exceeded.
The operator is only informed of the situation.
When carrying out load lifting work with a hydraulic excavator, always adhere to the applicable ac-
cident prevention regulations.
Never use defective machinery for load lifting work. After repair, the machine must first be inspected
by a specialist technician in accordance with the testing and adjustment guidelines before it may be
used for load lifting operation.
General:
The overload warning system warns the operator with a visual symbol on the screen (see Fig. 2)
and an acoustic buzzer signal when the maximum permissible load is reached.
Only lift loads of which the weight is known, and refer to the load lift chart to check whether the
actual load is within the permitted load range of the respective machine model.
The prescribed maximum load values correspond to max. 75% of the tip load or 87% of the hy-
draulic lifting power according to ISO 10567.
For machines with attached backhoe bucket (with bucket cylinder, change lever and connecting
link), the values at the tip of the stick are relevant here. The machine must thereby stand on a firm
and level surface, with closed swing axle and swivelable by 360° .
For machines with attached bucket cylinder, change lever and connecting link, the values are in-
creased by the values applicable to the attachment components.
When using a quick change adapter (SWA) the values are reduced by 110 kg for SWA 33 and
190 kg for SWA 48.
For industrial equipment, the values at the load hook are relevant here. The machine must thereby
stand on a firm and level surface, with closed swing axle and swivelable by 360° .
The load values might also change depending on the type of attachment connected to the machi-
ne (grapple, etc.).
Startup:
The overload warning system may only be used in connection with load lifting work. To switch on
the overload warning system, press the S18 button at the control desk in the operator's cab, see
Fig. 2.
Before starting the overload warning system for the first time, adjust it according to the instruc-
tions.
Prior to a shift, complete a functional test of the system by fully extending the boom cylinder so
that the maximum operating pressure is built up. The system must now issue a visual and acoustic
warning signal.
All moving parts of the overload warning system must be regularly inspected for appropriate clea-
rance and must be lubricated.
The machine used for load lifting work must undergo an annual load test.
This can be done with adequate accuracy as described below:
Multiply the load capacity value for "swivelling" (i.e. not supported) or "transverse" with 1.33 and
add 150 kg. Attach the test load at the prescribed reach (see table) to the machine. Take into ac-
count any attachments such as buckets or grapples.
Carefully swivel the uppercarriage with the load (lifted to a position just above the ground) by 360°.
The machine may not topple over during this manoeuvre. One wheel or a section of a crawler
might be lifted from the ground, which is permissible.
The warning system must trigger a signal.
In addition, the overload warning system must be tested every 12 months by a specialist techni-
cian and adjusted according to the prescribed load values, if necessary.
16.08.2 A 900 C-LI 14675-18087

A 924 C-LI 34519-
Description
Note!
Disable the overload warning system when working with a digging bucket, as the increased load on
the machine in connection with such work would otherwise result in a constant warning signal.
Press switch S18.
The overload warning system is deactivated.
2 Description
Fig. 2 Switch S18 and display in the check field of the screen H1
Switch S18 to switch the overload warning system on/off

Symbol in the check field of the screen H1: visual signal indicating that the overload warning sys-
tem has been triggered
The visual signal is accompanied by an audible signal from the buzzer H10-1.
The piston pressure switch B21 and the pipe spring pressure switch B201 with cam disc, which
are mounted on basic boom bearing, makes electrical contact with the indicator screen and the
buzzer H10-1 as soon as the switching pressure (i.e. maximum load weight) is reached. This pres-
sure might vary depending on the status of the machine (supported, not supported).
The cam disc 2 for the pipe spring pressure switch B201 is labelled with ID code C according to
the kit parts list, and also carries line marks and the respective switching pressure for the switching
points A and B.
Fig. 3 Cam disc 2 with switching points and respective switching pressures
A 900 C-LI 14675-18087 16.08.3

A 924 C-LI 34519-
Description
Fig. 4 Oil pressure switch B202, slip-ring case E162 and slip-ring body 90
When the machine is supported, the oil pressure switches B202 located at the support cylinders
295 establish an electric contact via relay K335 from the piston pressure switch B21 to the pipe
spring pressure switch B201. The 4 oil pressure switches B202 are electrically connected to each
other through the junction box B162 (earth).
The slip ring rotary connection 90 secured to the six-fold and seven-fold oil rotary connection con-
nects the vehicle mass to the oil pressure switches B202. When all switches B202 are closed, the
earth contact is connected to the vehicle mass via relay K335.
16.08.4 A 900 C-LI 14675-18087

A 924 C-LI 34519-
see Fig. 8
The overload warning system warns the machine operator with a visual and an acoustic signal that
the permitted limit value for load weights according to DIN 15019, sheets 2 is reached. The machine
is however not shut down.
The switchable overload warning system takes into account that the load moments of the support and
the unsupported machine differ from each other.
3.1 Low load range low load moment (machine not supported)
The visual and acoustic warning signal (check display at the H1 monitoring screen and buzzer H10-1)
are triggered via relay K335 by the electro-hydraulic constant switch B21 (piston pressure switch),
which is connected to the piston sides of the boom cylinders 335.
3.2 High load range high load moment (machine supported)

In order to take full advantage of the load range of the machine, the overload warning system is au-
tomatically switched to the high load range when the four support cylinders 295 (4-point support) are
extended. For this purpose, the electrical circuit is opened by the constant pressures switch B21
when a pressure of approx. 60 bar is reached at the oil pressure switches B202 connected to each
support cylinder 295, while relay K335 establishes a contact with the adjustable pressure switch
B201 with cam disc 2.
The warning signal is thus triggered by the pressure switch B201 (pipe spring pressure switch). The
lifting capacity varies in line with the reach. In order to calibrate the overload warning system with the
actual limit values for load weights, the switching point of the pressure switch B201 is gradually ad-
justed by means of the cam disc 2 and the roller lever, depending on the boom position. The cam disc
is designed in such a way that the switching pressure of the pressure switch is adjusted in line with
the respective permissible load weight at the actual boom position.
The load weight values include a safety margin of 25% for tipping on firm and level ground.
The pressure switch B201 is also connected to the pressure connection at the piston side of the two
boom cylinders 235.
When the load pressure in the boom cylinders reaches the switching pressure, the pressure switch
B201 makes electrical contact via the relay K335 to the buzzer H10-1 and the check display H1 on
the screen (symbol), so that the operator is informed of the danger status of the machine.
A 900 C-LI 14675-18087 16.08.5

A 924 C-LI 34519-
Installation
4 Installation
The bearing pin (revolving deck basic boom) is equipped with a bore for the installation of the over-
load warning system.
Mount the pin 14.
Mount the tab 11 with the attached pressure switch onto the neck of the pin 14.
Tighten the screw 10 with nut 9 and washer 8.
Mount a suitable cam disc 2, using the roll pin 23 and the Allen head screws 25 (with washers 24)
onto the revolving piece 20.
Note!
Coordination of the overload warning system with the actual load moment and the applicable limit
weights can only be achieved by selecting the correct cam disc.
Each cam disc assigned to a machine carries a punched ID number (specified in the kit or order do-
cumentation, or the spare parts catalogue / machine card).
Mount the revolving piece 20 onto the greased neck of the tab 11, secure it with the washer 26
and the screw 27 and check all movable parts of the warning system for free movement.
Lift the basic boom to its upper limit point and turn the eccentric adjusting screw 29 so that the line
of mark A on the cam disc matches the contact point of the switch roller.
Secure the pressure switch B21 with plate 40 to the bearing block of the uppercarriage or the tab
11, using screws 51. Connect the leak oil line to the collecting pipe of the hydraulic system (only
with pressure switch type 1).
Establish the hydraulic connection between the boom cylinder contact at the piston side (via dis-
tributor 233) and the pressure switch B21 / B201.
Mount the oil pressure switches B202 on the support cylinders 295 and secure the slip-ring rotary
connection 90 to the six-fold rotary connection 322.
Establish the electrical connections as shown in diagram, see Fig. 8.
Adjust the warning system for both load ranges and test it, see 6.
16.08.6 A 900 C-LI 14675-18087

A 924 C-LI 34519-
Switchable overload warning system with hydraulic connections
5 Switchable overload warning system with hydraulic connections
Fig. 5 Exploded view of the overload warning system
2 Cam disc 30 Pipe spring pressure switch (B201*)

6 Electrical components of overload 31 Allen head screw
warning system
8 Retaining washer 32 Hex nut
9 Hex nut 33 Retaining washer
10 Hex head screw 40 Plate
11 Tab 41 Allen head screw
14 Flange bolt 42 Hex nut
20 Revolving piece 43 Washer
21 Bushing 50 Pressure switch (B21*)
22 Lubrication nipple 51 Allen head screw
23 Roll pin 52 Hex nut
24 Retaining washer 53 Washer
25 Allen head screw 66 Measuring connection
26 Washer 90 Slip-ring rotary connection
27 Hex head screw 91 Pipe fracture safety valve
28 Hex nut B202 Oil pressure switch / support
29 Eccentric adjusting screw * Items in electrical diagram
A 900 C-LI 14675-18087 16.08.7

A 924 C-LI 34519-
Remove the cover cap from the measuring connection 66 and connect the pressure sensor (pres-
sure range 0-400 bar) in such a way that the indicator is visible from the operator's cab.
Switch on the overload warning system with switch S18 and open the stop cock 67 between the
overload warning system and the boom cylinder connection.
Move the boom cylinder to its upper stop position and check whether the overload warning system
has been triggered (symbol on screen and buzzer signal).
6.1 Adjustment within the low load range (machine not supported)
Move the basic boom to its upper limit position and establish the required switching pressure (pun-
ched into the sheet metal plate 84 of the switch B21) by operating the pilot control device to the
right.
.
Note!
In machines where the overload warning system is retrofitted, the switching pressure is specified in
the enclosed installation drawing and must be punched into sheet metal plate 75 of the switch B21,
or into the sheet metal plate 84.
If the overload warning system is not triggered at the prescribed pressure, adjust the switching pres-
sure at the pressure switch B21.
To do this, loosen the self locking screw S of the pressure switch B21.
Using a screwdriver, turn the adjusting screw E. The switching pressure is adjusted as follows:
Turn screw clockwise
Turn screw anticlockwise
Lock the adjusting screw E with the self locking screw S.
If the overload warning system is only triggered at a pressure that is above the prescribed pressure,
readjust the switching point (pressure) again. A switching pressure below the prescribed limit pres-
sure is however permissible.
Fig. 6 Pressure switch B21 with plate showing the switching pressure 84
16.08.8 A 900 C-LI 14675-18087

A 924 C-LI 34519-
6.2 Adjusting within the high load range (machine supported)
6.2.1 Upper limit position (switching point A)

Extend the support cylinders 295 so that all wheels of the vehicle are load-free (load pressure min.
60 bar). Move the basic boom to its upper limit position and adjust the cam disc 2 with the adjusting
screw 29 so that the switch roller is aligned with the line mark A, see 6.2.2. By operating the pilot
control device to the right (extend boom cylinder), increase the pressure to the value indicated at line
mark A.
This pressure is shown at the connected pressure sensor.
If the warning system is not triggered when the above pressure is reached, correct the settings of the
pressure switch B201 to the required pressure (at the front side, accessible when the cover cap F is
removed).
Turn adjusting screw SA clockwise
Turn adjusting screw SA anticlockwise
6.2.2 Lower limit position (switching point B)

Lower the basic boom until the line at mark B is aligned with the roller switch.
By operating the pilot control device to the right (retract boom cylinder), increase the pressure to
the value indicated at line mark B. This pressure is then shown at the pressure sensor.
When the respective pressure is reached, the warning signal must be triggered.
If the warning system is not triggered when the above pressure is reached, correct the settings of the
pressure switch B201 to the required pressure (at the top side, accessible when the cover cap G is
removed).
Turn adjusting screw SB clockwise
Turn adjusting screw SB anticlockwise
A switching pressure below the prescribed limit pressure is however permissible.
Mount the cover caps F and G and disconnect the pressure sensor.
Fig. 7 Adjustment of the overload warning system
A 900 C-LI 14675-18087 16.08.9

A 924 C-LI 34519-
2 Cam disc K335 Relay / overload warning system

66 Measuring connection MP85 Ground connection
67 Stop cock MP89 Ground connection
90 Slip-ring rotary connection S2 Keypad
100 A5 control valve block / connection S18 Overload warning system switch
100 B5 control valve block / connection X2 Plug connection, 37-pin
220 A1 way valve / connection (A914/924) X6.2 Plug connection, 8-pin
220 B1 way valve / connection (A914/924) X40 Plug connection, 9-pin
233 Distribution block / boom cylinder X49 Plug connection, 3-pin
235 Boom cylinder X200 Plug connection, 15-pin
238 Pipe fracture safety valve (kit) X219 Plug connection, 2-pin
295 Support cylinder X232 Plug connection, 10-pin
A1001 ESP 01 printed circuit board X273 Plug connection, 4-pin
A1100 ESP 02 printed circuit board X300 Terminal strip
B21 Piston pressure switch X301 Plug connection, 12-pin
B201 Pipe spring pressure switch X305 Plug connection, 9-pin
B202 Oil pressure switch X306 Plug connection, 2-pin
E162 Slip-ring case X309 Plug connection, 15-pin
H1 Monitoring display
H10-1 Buzzer A Electrical system / basic machine
KL15 Terminal 15 B Electric system / kit
16.08.10 A 900 C-LI 14675-18087

A 924 C-LI 34519-
7 Hydraulic / electrical diagram
Fig. 8 Functional diagram of the overload warning system
A 900 C-LI 14675-18087 16.08.11

A 924 C-LI 34519-
16.08.12 A 900 C-LI 14675-18087

A 924 C-LI 34519-
Service Manual Hydraulic quick change adapter
Function
Hydraulic quick change adapter
1 Function
Where the work requires frequent changing attachments, LIEBHERR offers a special system consi-
derably reducing the retooling times.
The system is based on a hydraulic quick change adapter. Its parts are combined in a complete kit
containing all mechanical, hydraulic and electrical parts.
The quick change adapter is opened and closed through the hydraulic circuit of the grapple rotator
(AS1).
Note!
To ensure safe and reliable operation of the attached tools, always adhere to the instructions in the
separate "Operating and maintenance manual for hydraulic / mechanical quick change adap-
ters".
Fig. 1 Hydraulic quick change adapter
16.15.1
copyright by
MJFCIFSS
Hydraulic quick change adapter Service Manual
Description
2 Description
the hydraulic quick change adapter consists of the following main parts:
Quick change unit 10
Locking unit 20
Cylinder 30
Covering parts 50
Safety latches 60
Auxiliary axle 540
Solenoid valves Y28-1,Y28-2
Control elements S5L/S5R, S19, S47, see Fig. 4 and associated wire harnesses
To secure the adapter when closed, it is equipped with two single-blocking solenoid valves Y28-1 and
Y28.2 built into the piston and rod side connections of the locking cylinder.
The quick change adapter is operated via AS1 (grapple rotor). The auxiliary axle 540 is flange-moun-
ted to the slewing gear spool 120 at the control valve block 100.
The locking unit 20 is equipped with covering parts 50 protecting it against dirt.
Note!
For detailed instructions regarding the use and operation of the quick change adapter, please refer
to the separate operating and maintenance manual for quick change adapters.
The system is protected by means of the pressure relief valves 541/542 in the auxiliary control valve
block 540 that are screwed in and set to 120 bar. For detailed instructions regarding testing and ad-
justment of the accessory kit, see the description of the "AS1" grapple rotator / tilting bucket, group
16.40.
Fig. 2 Main component parts of the hydraulic quick change adapter
16.15.2
copyright by
MJFCIFSS
Description
Fig. 3 Design of the hydraulic quick change adapter
10 Quick change unit 100 Heavy-duty roll pin

20 Locking unit B26 Proximity switch with plug
30 Cylinder Y28-1 2/2 way valve
50 Covering parts Y28-2 2/2 way valve
60 Safety latches
16.15.3
copyright by
MJFCIFSS
see Fig. 11
3.1 Working position - "closed"

Engage the attachment to be used (bucket, etc.) in the mounting hooks.
Press the switch S19 (LED is on).
Press and turn/press the key switch/push button S47.
By pressing the left button S5L located on the left joystick 80, the solenoid valve Y22, and switch/
push button S47 as well as the valves Y28-1/Y28-2 (via A 1017) are powered. As long as the button
S5L is pressed, S47 can be released (hold function). The oil flows from the working pump via the
auxiliary control axle 540, connection B02 via the sieve 6 to the way valve Y28-2, which is shifted in
flow direction. Via connection B-B´, the oil pressurises the locking cylinder 11 from the piston side.
The return oil at the rod side flows via the way valve Y28-1, connection A´-A and the connection A02
of the block 540 to the tank.
The cylinder 30 is extended and presses the two locking pins 11 outwards through levers. The at-
tachment is now properly locked and bolted to the quick change unit 10. When the left button S5L is
released, the way valves Y28-1/Y28-2 are reset to their blocking position. The locking mechanism is
thus protected by the blocked valves Y28-1/Y28-2 against inadvertent operation of the button S5R.
Press the switch S19 (LED is off).
If the locking pins 12/13 are inadvertently retracted, for whatever reason, the proximity switch B26 is
activated, triggering an electrical signal to the buzzer and the indicator light H26 (locking pins retrac-
ted). The operator is thus informed by a visual and an acoustic signal of the danger. Immediately shut
down the machine, establish the cause of the problem and eliminate it.
3.2 Change position - "open"

Place the attachment to be mounted (bucket, etc.) onto the ground.
Press the switch S19 (LED is on).
Press and turn/press the key switch/push button S47.
By pressing the right button S5R located on the left joystick 80, the solenoid valve Y23, and switch
S47 as well as the valves Y28-1/Y28-2 (via A1017) are powered. As long as the button S5R is
pressed, S47 can be released (hold function). The oil flows from the working pump via the auxiliary
control axle 540, connection A02 via the sieve 6 to the way valve Y28-1, which is shifted in flow di-
rection. Via connection A-A´, the oil pressurises the locking cylinder 11 from the rod side. The return
oil at the piston side flows via the way valve Y28-2, connection B´-B and the connection B02 of the
block 540 to the tank.
The cylinder 30 is retracted and pulls the pins 12/13 inwards, so that the mounted attachment is re-
leased.
When the pin 11 is retracted, the proximity switch B26 is activated. The buzzer H27 and the indicator
light H26 indicate that the quick change adapter is open, which is a dangerous operation state.
Release the right button S5R. Mount the new attachment, or deactivate the switch S19 (LED is off).
Note!
For load lifting work without digging bucket, retract the pins of the quick change adapter. To avoid
a buzzer signal, set the buzzer to mute.
16.15.4
copyright by
MJFCIFSS
Operation of the quick change adapter
4 Operation of the quick change adapter
Fig. 4 Operating elements
4.1 Switch S19

The switch S19 is used to activate the hydraulic auxiliary equipment for the grapple rotator and the
quick change adapter.
Press the switch.
The auxiliary equipment is activated.
The auxiliary equipment is deactivated.
4.1.1 Push button S47

The key switch S47 (up to serial no. 19157)
Key switch S47 can be set to two positions:
Position 0: The locking pins cannot be operated.
Position 1: The key switch can be pressed down. This activates the quick change adapter, and
the locking pins can now be operated.
Push button S47 (from serial no. 19158:)
Press this push button to activate the quick change adapter. The locking pins can now be operated.
Note!
The warning signal of the buzzer can be temporarily muted by pressing the key S349 (back) at
the display (only required for machines with overload monitoring system).
The warning symbol H26 indicator light "quick change adapter released" (locking pins retracted)
indicates the danger status of the machine. This symbol is displayed on the check field SY of the
screen.
16.15.5
copyright by
MJFCIFSS
Maintenance instructions
5 Maintenance instructions
Fig. 5 Clean mesh filter
Note!
The filter disc 12 must be cleaned at least every 2000 operating hours, or at shorter intervals, de-
pending on the actual frequency of use of the quick change adapter.
Remove the cover 50 by removing the screws 21 from the quick change adapter.
Remove the screw connections and the hydraulic hoses from the hydraulic cylinder 10.
Screw out the outer support body 13, using a tool (e.g. thumbnail).
Remove the filter disc 12, inspect it and clean or replace it, if necessary.
Place the filter disc 12 onto the inner support body 11 and mount the outer support body 13.
Reconnect the screw connections and the hydraulic hoses to the hydraulic cylinder 30.
Replace the cover 50 and secure it with the screws 21 to the quick change adapter.
6 Adjustment of the proximity switch B26
Fig. 6 Locking unit with proximity switch B26
16.15.6
copyright by
MJFCIFSS
Sealing elements at the bearing head / piston
Retract the locking pins 11.

Loosen the lock nut 10.2 .
Screw in the proximity switch B26 to the stop at the pin 11.
Rotate the switch B26 by 360 degrees anticlockwise = clearance of 1 mm
(permissible tolerance: ±1/3 mm).
Carry out a functional test of the switch B26 by repeatedly extending and retracting the locking
pins 11.
7 Sealing elements at the bearing head / piston
Fig. 7 Seal kit of the bearing head / piston
5 Double scraper ring 13 Bearing head

6 O-ring 14 Piston guide ring
7 O-ring 15 O-ring
16.15.7
copyright by
MJFCIFSS
Exploded view of the quick change adapter
8 Backing ring 16 Turcon AQ seal

9 Sealing (Zurcon-L-Cup) 998 Seal kit / piston
12 Piston rod bearing 999 Seal kit / bearing head / piston
8 Exploded view of the quick change adapter
Fig. 8 Exploded drawing of the quick change adapter
4 Hex nut 28 Screw plug

5 Retaining washer 30 Cylinder
16.15.8
copyright by
MJFCIFSS
Exploded view of the electrical system
6 Filter disc 31 Left lever

8 Piston rod 40 Right lever
11 Pin 50 Pin
13 Bearing head 100 Heavy-duty roll pin
20 Locking unit 110 Heavy-duty roll pin
9 Exploded view of the electrical system
Fig. 9 Exploded view of the electrical system
A1001 ESP 01 printed circuit board X21 Plug connection on A 1001, 3-pin
A1017 printed circuit board X167 Plug connection on
A 1010, 2-pin
A1100 ESP 02 printed circuit board X214-3 Plug connection on A 100, 2-pin
B26 Proximity switch X262 Plug connection to quick change adap-
ter, 8-pin
F4 Fuse spare plug X 167 / A X262-1 Plug connection at bearing block, 8-pin
1010 with 4x extension, 2-pin
F11 Fuse spare plug X 214 / A X262-3 Plug connection at stick, 8-pin
1100
K3 Relay / A 1001 X262-3 Plug connection adapter cable, 3-pin
K43 Relay / A 1001 262-4 Plug connection on valve Y28, 2-pin
K364 Quick change relay / A 1017 262-5 Plug connection on valve Y28, 2-pin
16.15.9
copyright by
MJFCIFSS
S5L Push button / closing quick change X262-6 Plug connection at B26, 3-pin
adapter
S5R Push button / opening quick change X410 Plug connection on A 1017, 2-pin
adapter
S47 Key switch X411 Plug connection on A 1017, 4-pin
V11 LED quick change adapter solenoid X412 Plug connection on A 1017, 2-pin
valve
V12 LED quick change adapter solenoid X413 Plug connection on A 1017, 4-pin
valve
X2 Plug connection on A1001, 37-pin Y28-1 Solenoid / seat valve
X15-1 Plug connection on S5, 3-pin Y28-2 Solenoid / seat valve
X17 Plug connection on A1001, 3-pin
16.15.10
copyright by
MJFCIFSS
Electrical diagram of the hydraulic quick change adapter
10 Electrical diagram of the hydraulic quick change adapter
Fig. 10 Electrical diagram of the hydraulic quick change adapter
16.15.11
copyright by
MJFCIFSS
Hydraulic diagram with electrical components
11 Hydraulic diagram with electrical components
Fig. 11 Hydraulic diagram with electrical components
10 Quick change unit A1017 printed circuit board

11 Pin A1100 ESP02 printed circuit board
20 Locking unit B26 Proximity switch
30 Cylinder K364 Quick change relay
80 Left pilot control unit S5L Push button / left auxiliary device
88P from pressure distributor S5R Push button / right auxiliary device
88T to collecting pipe of return S19 Switch / auxiliary device
120 Control axle of slewing gear S47 Key switch/push button
540 Control piston of hydraulic drive Y22 Solenoid / locking adapter
541 Secondary pressure relief valve / Y23 Solenoid / releasing adapter
retracting cylinder
542 Secondary pressure relief valve / Y28-1 Solenoid / seat valve rod side
extending cylinder
544 Pressure balance Y28-2 Solenoid / seat valve piston side
A1001 ESP01 printed circuit board
16.15.12
copyright by
MJFCIFSS
Service Manual Boom cylinder protection system
Function/design
Boom cylinder protection system
1 Function/design
The boom cylinder protection system prevents the machine (construction model) from being lifted
with the attachment function "lowering boom". The boom cylinders give way before the pressure
against the ground becomes too high. The machine operator is thus in a position to protect the at-
tachment as well as the ground he is working on.
If a plate vibrator is attached, the attachment is in the "floating position".
The pressure inlet valve 222 with pressure shut-off stage is integrated into the control block 100, re-
placing the standard screwed-in secondary pressure-relief valve.
The solenoid valve Y82 for the switching over to the boom cylinder protection system is mounted to
the uppercarriage behind the operator's cab.
The function is actuated by means of the rocker switch S55, the switch S98 and the pilot control units
80 and 81 located in the operator's cab, (see Fig. 3 on page4).
88 Distributor X55 Plug connection, 3-pin

100 Control valve block/pilot plate X56 Plug connection, 3-pin
222 Pressure inlet valve X57 Plug connection, 3-pin
A1009 Plug-in board X166 Plug connection, 2-pin
S55 Rocker switch X214-3 Plug connection, 2-pin
S98 Switch X1046 Plug connection
X15-3 Plug connection, 3-pin Y82 Solenoid valve
16.16.1
copyright by
MJFCIFSS
Boom cylinder protection system Service Manual
Function/design
Fig. 1 Hydraulic and electrical system A 900 C - A 904 C
16.16.2
copyright by
MJFCIFSS
Function/design
Fig. 2 Hydraulic and electrical system A 914 C - A 924 C
16.16.3
copyright by
MJFCIFSS
Note!
Fig. 3 Operation
The operation is in two steps. The boom cylinder protection system is preselected with the switch S98
and then activated with the rocker switch S55 located at the left pilot control unit 80.
The indicator light in the switch is on.
The boom cylinder protection system is switched on (preselected).
Press and hold the rocker switch S55.
The boom cylinder protection system is activated.
Carry out the work with the attachment.
Release the rocker switch S55.
The boom cylinder protection system is deactivated.
Press the switch S98 again.
The indicator light in the switch is off.
The boom protection system is deactivated.
2.1 Low pressure stage (boom cylinder protection system)

If the switch S98 is actuated and the rocker switch S55 is pressed, the solenoid valve Y82 is powered
and opens the connection from P to A. The pilot control oil pressurises the pressure inlet valve 222.
The pilot control oil reduces the spring force of the preset spring of the pressure inlet valve.
This in turn reduces the response pressure of the pressure inlet valve 222 so that the connection to
the tank is opened quicker when the "lowering boom" function is actuated. This prevents the machine
from being lifted when the "lowering boom" function is on.
16.16.4
copyright by
MJFCIFSS
Fig. 4 Hydraulic diagram A 900 C - A 904 C
16.16.5
copyright by
MJFCIFSS
Fig. 5 Hydraulic diagram A 914 C - A 924 C
16.16.6
copyright by
MJFCIFSS
Adjustment
3 Adjustment
adjustment point
Pressure-relief valve bar 380 +20 222 45
A 900 C - A 904 C bar 70
Pressure-relief valve bar 380 +20 222 45
A 914 C - A 924 C bar 80
Pressure cut-off valve bar 350 +10 104 41
A 900 C - A 904 C
Pressure cut-off valve bar 350 +10 101 41
A 914 C - A 924 C
Tab. 1 Parameters
Fig. 6 Adjustment for A 900 C - A 904 C
Fig. 7 Adjustment for A 914 C - A 924 C
Connect the pressure gauge to the measuring points 41 and 45.
16.16.7
copyright by
MJFCIFSS
Adjustment
Increase the setting of the pressure cut-off valve 101/104 by turning it in (to max. 440 bar), see
adjustment protocol in group 3.
3.1 Adjustment of high pressure stage

Operate the "lowering boom" function to the block.
Press the pilot control unit 81 to the stop.
value, see Tab. 1.
If the prescribed pressure is not reached:

Loosen the lock nut 3 at the pressure inlet valve 222.
Adjust the high pressure value with the adjusting screw 4.
Tighten the lock nut 3 again.
3.2 Adjustment of low pressure stage

Press and hold the switch S98 together with the rocker switch S55.
The boom cylinder protection system is activated.
Operate the "lowering boom" function to the block.
Press the pilot control unit 81 to the stop.
value, see Tab. 1.

Loosen the lock nut 2 at the pressure inlet valve 222.
Adjust the low pressure value with the adjusting screw 1.
Tighten the lock nut 2 again.
After correct adjustment, set the pressure cut-off valve 101/104 to the prescribed value.
Remove the pressure gauges and seal the measuring points.
16.16.8
copyright by
MJFCIFSS
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
A 900 C-LI 14675- 16.18.1

MJFCIFSS
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
16.18.2 A 900 C-LI 14675-

MJFCIFSS
2.1 Design of the LIKUFIX coupling system mounted to quick change adapter 48
Fig. 3 LIKUFIX 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.
A 900 C-LI 14675- 16.18.3

MJFCIFSS
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
30 Protective cover 90 Tie-down device
50 Guide bushing 100 Tie-down device
60 Coupling sleeve 110 Locking plate
70 Coupling sleeve
16.18.4 A 900 C-LI 14675-

MJFCIFSS
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.
A 900 C-LI 14675- 16.18.5

MJFCIFSS
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
42 Allen head screw 100 Tie-down device
50 Plunger
16.18.6 A 900 C-LI 14675-

MJFCIFSS
2.5 Assembly drawing of LIKUFIX
Fig. 7 The attachment-specific LIKUFIX 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
A 900 C-LI 14675- 16.18.7

MJFCIFSS
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 16.15.
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 Betätigen des Schnellwechslers über Druck-
taste S5R/S5L werden die Magnetventile Y376-1 und Y376-2 bestromt und sperren den Öldurchfluss
zu den Anschlüssen E und D am LIKUFIX. Der Ölkreislauf beim Koppeln bzw.Entkoppeln ist somit
drucklos.Nicht Bestromt sind sie geöffnet, so dass das Öl zu den Anschlüssen E und D gelangen
kann.
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
16.18.8 A 900 C-LI 14675-

MJFCIFSS
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.
A 900 C-LI 14675- 16.18.9

MJFCIFSS
Fig. 10 In models manufactured after 08/2003, the relief valves Y387-1/Y387-2 are mounted at
the control valve block 100.
16.18.10 A 900 C-LI 14675-

MJFCIFSS
3.2 Function of the plunger cylinders 50
Fig. 11 Hydraulic connections of the plunger cylinders at the attachment and changeover
valve 60
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.
A 900 C-LI 14675- 16.18.11

MJFCIFSS
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
16.18.12 A 900 C-LI 14675-

MJFCIFSS
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
A 900 C-LI 14675- 16.18.13

MJFCIFSS
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 10/20 = coupling plug; 60/70 = coupling sleeve
16.18.14 A 900 C-LI 14675-

MJFCIFSS
4.2 Sectional drawing of coupling sleeves / plugs
Fig. 15 A = coupling open; B = coupling closed
A 900 C-LI 14675- 16.18.15

MJFCIFSS
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
16.18.16 A 900 C-LI 14675-

MJFCIFSS
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.
A 900 C-LI 14675- 16.18.17

MJFCIFSS
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
16.18.18 A 900 C-LI 14675-

MJFCIFSS
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.
A 900 C-LI 14675- 16.18.19

MJFCIFSS
Hydraulic and electric units
7 Hydraulic and electric units
Key to hydraulic diagram

3 LIKUFIX part at quick change adapter 544 Pressure balance
4 LIKUFIX part at attachment 550 Oil motor / grapple rotator
10/20 Coupling plug S5L Push button / grapple rotator left
40 Restrictor S5R Push button / grapple rotator right
60/70 Coupling sleeve S19 Button / grapple rotator
80 Pilot control valve left Y22 Solenoid valve / grapple rotation left
88P Manifold P Y23 Solenoid valve / grapple rotation left
88T Collecting pipe T Y28-1 Solenoid / seat valve rod side
120 Spool / slewing gear Y28-2 Solenoid / seat valve piston side
515 Hydraulic hammer Y376-1 Check valve on base side
517 Additional consumer Y376-2 Check valve on boom side
540 Spool / grapple rotator Y387-1 Relief valve
541 Secondary relief valve / rotation right Y387-2 Relief valve
542 Secondary relief valve / rotation left
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 as normally closed switch

B B26 as normally open switch
C Option with Sure Seal plug B26 as NO switch
16.18.20 A 900 C-LI 14675-

MJFCIFSS
Fig. 20 Hydraulic diagram of LIKUFIX
A 900 C-LI 14675- 16.18.21

MJFCIFSS
Fig. 21 Electric diagram of LIKUFIX
16.18.22 A 900 C-LI 14675-

MJFCIFSS
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
A 900 C-LI 14675- 16.18.23

MJFCIFSS
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.
16.18.24 A 900 C-LI 14675-

MJFCIFSS
Fig. 23 Hydraulic diagrams for the various attachments
A 900 C-LI 14675- 16.18.25

MJFCIFSS
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 hydrau-
lic 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.
16.18.26 A 900 C-LI 14675-

MJFCIFSS
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.
A 900 C-LI 14675- 16.18.27

MJFCIFSS
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
16.18.28 A 900 C-LI 14675-

MJFCIFSS
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.
A 900 C-LI 14675- 16.18.29

MJFCIFSS
Instructions for the replacement of the coupling plug seal
16.18.30 A 900 C-LI 14675-

MJFCIFSS
Service Manual Pressure and flow reduction
Function and design
Pressure and flow reduction
that are lower than those generated under normal operating conditions. Otherwise, these attach-
ments might not work properly.
Operating personnel should be in a position to easily and efficiently adjust the pressure and flow to
the level required for the attachment.
The accessory kits AHS 11 / AHS 12 with Tool Control, see groups 16.46 and 16.49 allow for the
automated adjustment of the pressure and flow values in the machine to 10 different preset levels.
D
Fig. 1 Accessory kits
A 900 C-LI 14675- 16.20.1

MJFCIFSS
Pressure and flow reduction Service Manual
Adjustment of pressure and flow reduction settings
2 Adjustment of pressure and flow reduction settings
2.1 Entry at LCD screen in the operator's cab (entry of nominal value)
Note!
The pressure and flow reduction settings can only be changed at service level 2 or 3.
Remove the rear cover at the right control desk.

Insert service plug to plug connectionX31 of the A 1001 printed circuit board.
Fig. 2 Connection point X31 for service plug
2.2 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 maximum cross-section at the steering rod corresponds to EV1=100%.
Based on the diagram, enter the desired or required oil volume in % as shown on the screen, see Fig.
20 and see Fig. 21.
The flow reduction is achieved by reducing the differential pressure ( -p) at the pump regulator. The
required control pressure is built up by means of the proportional solenoid valve Y51 that is part of
the control oil unit 50.
The entry of the desired % value at the LCD screen and a switch signal, issued for example by pres-
sure switches (B33/2 I1) the excavator control system BST (U16) generates a specific solenoid cur-
rent (in mA). The control pressure is built up proportionally.
16.20.2 A 900 C-LI 14675-

MJFCIFSS
2.3 Pressure reduction

The pressure reduction is controlled via output EV6 of the BST and the proportional solenoid valve
Y414. The proportional solenoid valve Y414 continuously adjusts the system pressure at the pressu-
re relief valve 511 / 512.
To adjust the system pressure (high pressure), enter the required nominal value at the display.
Note!
In order to achieve correct values, check the basic settings of the machine (for settings and va-
lues, see adjustment protocol).
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.
A 900 C-LI 14675- 16.20.3

MJFCIFSS
Adjustment of flow reduction
3 Adjustment of flow reduction
Fig. 3 Selecting "set pumps" menu
Press the menu button in the main screen.

A list of the available menus is displayed.
Select "set pumps" menu.
Fig. 4 Menu for external flow and pressure limitation
In this menu, you can enter the flow and pressure reductions for the respective attachments.
Fig. 5 Options 1-10
Select menu I1 for external inputs for flow and pressure limitation.
Inputs I2 - I4 are not assigned.
16.20.4 A 900 C-LI 14675-

MJFCIFSS
Fig. 6 Selecting external input EV1.
Select desired option 1-10 (e.g. opt1).

The pressure and flow settings menu is displayed.
Select EV1 (external input for flow reduction to Y51).

The set values are displayed (in %).
Note!
Only the inputs EV1 for flow reduction and EV6 for pressure reduction are used to adjust the set-
tings.
All other inputs (EV2, EV3) and the quota are used in other machine types only.
The factory setting is 55%.
Fig. 7 Menu for the adjustment of the % values
Adjustment of the factory settings to the desired flow reduction value

Using the arrow button, select the desired flow rate in %, see Fig. 20 or see Fig. 21
Press the "Back" button.
The submenu is closed.
The adjusted flow reduction value is saved.
Note!
If the value is changed while an attachment is being operated, there might be a slight temporary
pressure loss or malfunction, as the current drops to 0 mA upon changing options and subsequently
increases again.
A 900 C-LI 14675- 16.20.5

MJFCIFSS
Adjustment of pressure reduction
4 Adjustment of pressure reduction
Fig. 8 Selecting "set pumps" menu

Fig. 10 Options 1-10

16.20.6 A 900 C-LI 14675-

MJFCIFSS
Select EV6 (external input for pressure reduction).

The set values are displayed in %.
Note!
tings.
All other inputs (EV2, EV3) and the quota are used in other machine types only.
Adjustment of the factory settings to the desired pressure reduction value

Using the arrow button, select the desired pressure reduction in %, see Fig. 22.
The adjusted pressure reduction value is saved.
A 900 C-LI 14675- 16.20.7

MJFCIFSS
Attachment name settings
5 Attachment name settings

In the
Fig. 13 "set pumps" menu
the main screen field TI, you have the option to enter the names of 10 attachments (e.g. "hammer"),
(see Main screen on page 10).
Select menu I1.
16.20.8 A 900 C-LI 14675-

MJFCIFSS
Select desired option 1-10 (e.g. option 1).

Fig. 16 "Info" menu
Select the "Info" menu.

The input field of the "Info" menu is displayed.
Fig. 17 Input field in "Info" menu.
Using the arrow button, enter the desired name of the attachment.
The selected symbol is displayed in the window with the black background.
Note!
All characters (in upper and lower casing respectively), special characters and numbers are assig-
ned in this sequence to the arrow button.
Please note that the last character of the name must be entered first. To change field to enter indi-
vidual letters, press the book button.
Fig. 18 Example of entry for hammer
Press the "Back" key to save the entry and exit the menu.
A 900 C-LI 14675- 16.20.9

MJFCIFSS

The name of the attachment is now saved.
5.1 Display in main screen

After the settings menu has been closed, the name of the attachment is shown in field TI.
Fig. 19 Main screen

SY Symbols / time 2 Symbol R is displayed only, if the
attachment is operated with flow reduc-
tion.
16.20.10 A 900 C-LI 14675-

MJFCIFSS
Diagram for flow reduction in A 900 C (Y51)
6 Diagram for flow reduction in A 900 C (Y51)
Fig. 20 Diagram for flow reduction for hammer operation with A 900 C
A 900 C-LI 14675- 16.20.11

MJFCIFSS
Diagram for flow reduction in A 904 C (Y51)
7 Diagram for flow reduction in A 904 C (Y51)
Fig. 21 Diagram for flow reduction for hammer operation with A 904 C
16.20.12 A 900 C-LI 14675-

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Diagram of pressure reduction
8 Diagram of pressure reduction
Fig. 22 Diagram of pressure reduction
A 900 C-LI 14675- 16.20.13

MJFCIFSS
Diagram of pressure reduction
8.1 Characteristics of outputs EV1 and EV6
Fig. 23 BST current to Y51 (EV1)
Fig. 24 BST currents to Y414 (EV6)
16.20.14 A 900 C-LI 14675-

MJFCIFSS
Function and design
Pressure and flow reduction
that are lower than those generated under normal operating conditions. Otherwise, these attach-
ments might not work properly.
Operating personnel should be in a position to easily and efficiently adjust the pressure and flow to
the level required for the attachment.
The accessory kits AHS 11 / AHS 12 with Tool Control, see groups 16.50 allow for the automated
adjustment of the pressure and flow values in the machine to 10 different preset levels.
D
Fig. 1 Accessory kits
16.21.1
copyright by
MJFCIFSS
2 Adjustment of pressure and flow reduction settings
2.1 Entry at LCD screen in the operator's cab (entry of nominal value)
Note!
The pressure and flow reduction settings can be changed only in service levels 2 and 3.
Remove the rear cover of the right control desk.

Insert service plug in plug connection X31 of the A 1001 printed circuit board.
Fig. 2 Connection point X31 for service plug
2.2 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.
This max. cross-section of the spool of the auxiliary way valve corresponds to specification
EV1=100%.
The flow reduction is achieved by reducing the differential pressure ( -p) at the pump regulator. The
required control pressure is built up by means of the proportional solenoid valve Y51 that is part of
the control oil unit 50.
The entry of the desired % value at the LCD screen and a switch signal, issued for example by pres-
sure switches (B33/2 I1) the excavator control system BST (U16) generates a specific solenoid cur-
rent (in mA). The control pressure is built up proportionally.
16.21.2
copyright by
MJFCIFSS
2.3 Pressure reduction

The pressure reduction is controlled via output EV6 of the BST and the proportional solenoid valve
Y414. The proportional solenoid valve Y414 limits the system pressure at any chosen point through
the respective pressure-relief valve of the auxiliary way valve AHS 11 / AHS 12.
To adjust the system pressure (high pressure), enter the required nominal value at the display.
3 Adjustment of flow reduction
Note!
In order to be able to select the correct pressure and flow reduction settings against the backdrop
of a multitude of different attachment systems offered, you must install a suitable measuring turbine
or pressure sensor in the pressure lines of the equipment.
Observe the flow and pressure values of the various attachments, as specified by OEMs.
Fig. 3 Menu "Set pumps"

In this menu, you can enter the flow and pressure reductions for the respective attachments.
16.21.3
copyright by
MJFCIFSS
Fig. 5 Options 1-10

Select EV1 (external input for flow reduction to Y51).

The set values are displayed (in %).
Note!
tings.
All other inputs EV2, EV3 and the quota are used in other machine types only.
16.21.4
copyright by
MJFCIFSS
Adjustment of the factory settings to the desired flow reduction value

Using the arrow button, select the desired flow rate in %.
The adjusted flow reduction value is saved.
Note!
If the value is changed while an attachment is being operated, there might be a slight temporary loss
in performance (speed/pressure) or malfunction, as the current drops to 0 mA upon changing opti-
ons and subsequently increases again.
4 Adjustment of pressure reduction
Note!
In order to be able to select the correct pressure and flow reduction settings against the backdrop
of a multitude of different attachment systems offered, you must install a suitable measuring turbine
or pressure sensor in the pressure lines of the equipment.
Observe the flow and pressure values of the various attachments, as specified by OEMs.
Fig. 8 Menu "set pumps"

16.21.5
copyright by
MJFCIFSS

Select EV6 (external input for pressure reduction).

The set values are displayed in %.
Note!
tings.
All other inputs EV2, EV3 and the quota are used in other machine types only.
16.21.6
copyright by
MJFCIFSS
Adjustment of the factory settings to the desired pressure reduction value

Using the arrow button, select the desired pressure reduction in %.
The adjusted pressure reduction value is saved.
5 Attachment name settings
Fig. 13 "set pumps" menu
In the main screen field TI, you have the option to enter the names of 10 attachments (e.g. "hammer"),
(see Main screen on page 10).
16.21.7
copyright by
MJFCIFSS
Select menu I1.

Fig. 16 "Info" menu
Select the "Info" menu.

The input field of the "Info" menu is displayed.
16.21.8
copyright by
MJFCIFSS
Fig. 17 Input field in "Info" menu.
Using the arrow button, enter the desired name of the attachment.
The selected symbol is displayed in the window with the black background.
Note!
All characters (in upper and lower casing respectively), special characters and numbers are assig-
ned in this sequence to the arrow button.
Please note that the last character of the name must be entered first. To change field to enter indi-
vidual letters, press the book button.
Fig. 18 Example of entry for hammer
Press the "Back" key to save the entry and exit the menu.
The name of the attachment is now saved.
5.1 Display in main screen

After the settings menu has been closed, the name of the attachment is shown in field TI.
16.21.9
copyright by
MJFCIFSS
Fig. 19 Main screen

SY Symbols / time 2 Symbol "R" is displayed only, if the
attachment is operated with flow reduc-
tion.
16.21.10
copyright by
MJFCIFSS
Service Manual Hydraulic hammer
Function
Hydraulic hammer
1 Function
The hydraulic hammer is a powerful tool used in road construction, demolition and other specialised
work, as well as in quarries. They help compact, open, break up, crush and shatter material such as
stone, concrete, etc. Any LIEBHERR hydraulic excavator can be used to carry and power a hammer.
Please ensure that hydraulic output (pressure and oil volume) required for the operation of the hy-
draulic hammer does not exceed the capacity of the excavator. For details, see the relevant data
sheets 16.22-03 to 16.22-14.
Fig. 1 Hydraulic hammer
A 900 C-LI 14675- 16.22.1

MJFCIFSS
Hydraulic hammer Service Manual
Operating and maintenance instructions
2 Operating and maintenance instructions
Note!
When using a hammer, there is an increased risk of contamination of the hydraulic oil in the exca-
vator, due to the extremely dusty ambient air in the working environment. This can lead to the pre-
mature wear of the hydraulic components (especially the pump parts).
LIEBHERR has therefore issued the following additional instructions for operators of excavators that
are used to drive hydraulic hammers:
Change the hydraulic oil every 500 operating hours.
Replace the standard cartridge of the return filter / hydraulic tank (20 / 5 µm) with a 10-µm cart-
ridge.
Replace this fine filter cartridge (10 µm) every 500 operating hours.
Replace the breather filter / hydraulic tank (7 µm) with a 2-µm fine filter.
This filter (2 µm) must be replaced at every hydraulic oil change (i.e. every 500 operating hours).
When changing the hydraulic oil, also clean the hydraulic tank and release the oil from all hydraulic
cylinders.
After the system has been refilled, install a 5-µm cleaning cartridge in the return filter, and replace
it after 50 operating hours with a 10-µm fine filter cartridge.
Regularly have the hydraulic oil tested for contamination by a laboratory (oil analysis).
3 Parts supplied by the hammer manufacturer
Note!
The following parts and assemblies are offered by manufacturers: The respective manufacturer is
responsible for service, warranty, etc.
Supplied by the hammer manufacturer:

Hydraulic hammer
Working tools (e.g. chisel)
Attachment holder, e.g. connecting unit to excavator
Supplied by LIEBHERR:
Accessory kit for hydraulic hammers integrated in basic machine (e.g. AHS 11 / AHS 12)
Lines for the hydraulic hammer, mounted on the basic boom and boom, or on the gooseneck
boom respectively
Lines for the hydraulic hammer installed on the stick
Functional description with diagram and pressure adjustment guidelines for the accessory kits AHS
11 and AHS 12 respectively.
The following tables show hammer units and types recommended by LIEBHERR for use with the spe-
cified excavator models.
16.22.2 A 900 C-LI 14675-

MJFCIFSS
ATLAS COPCO hydraulic hammers
4 ATLAS COPCO hydraulic hammers
Type Tex Tex Tex Tex Tex Tex

Unit
Product 700 H 900 H 900 HS 1400 HS 1800 HS 2000 HS
Operating weight (1) kg 715 860 925 1460 2125 2460
Oil requirements l/min 55-120 55-120 55-120 80-180 110-120 110-120

Operating pressure / hammer bar 140 100-140 100-140 100-160 100-160 100-160
Adjustment pressure of machi- bar 160 160 160 180 180 180
ne
see AHS 11, AHS 12
Return (2) left left left left left left
Mountable to machine model:
A 900 C Litronic X
A 904 C Litronic X X X
1) including standard chisel and suspension

2) seen from the operator seat
3) only with 2.20 m and 2.70 m stick
A 900 C-LI 14675- 16.22.3

MJFCIFSS
EURORAM hydraulic hammers
5 EURORAM hydraulic hammers
Type Unit RM RM RM RM RM RM
Product 115 120 130 140 145 160
Operating pressure / hammer bar 120-130 120-130 120-130 120-130 140-195 140-150
ne
see AHS 11, AHS 12
A 900 C Litronic X
A 904 C Litronic X X (3)

16.22.4 A 900 C-LI 14675-

MJFCIFSS
FRD hydraulic hammers
6 FRD hydraulic hammers
Type Unit HB HB HB HB
Product 10G 15G 20G 30G
Operating weight (1) kg 815 1115 1625 2220
Oil requirements l/min 70-105 90-120 125-190 150-190
Operating pressure / hammer bar 140-160 150-170 160-180 160-180

Adjustment pressure of machi- bar 180 190 200 200
ne
see AHS 11, AHS 12
Return (2) left left left left
A 900 C Litronic X X

A 900 C-LI 14675- 16.22.5

MJFCIFSS
INDECO hydraulic hammers
7 INDECO hydraulic hammers
Type Unit MES MEST MES MES MES MES

Product 1750 2000 2500 3000 3500 5000
Operating pressure / hammer bar 120-130 120-130 120-130 120-130 140-150 140-150
ne
see AHS 11, AHS 12
A 900 C Litronic X
A 904 C Litronic X X (3)

16.22.6 A 900 C-LI 14675-

MJFCIFSS
KRUPP hydraulic hammers
8 KRUPP hydraulic hammers
Type Unit HM HM HM HM HM HM
Product 560 720 780 960 1000 1500
Oil requirements l/min 70-120 90-120/ 100-140 110-140 130-160 140-180

140-170 130-170
(8) (8)
Operating pressure / hammer bar 170 140-170 160-180 160-180 160-180 160-180
90-120 120-140
(8) (8)
Adjustment pressure bar 190 190 200 200 200 200

of the machine
see AHS 11, AHS 12
Return (2) right right right right right right
A 900 C Litronic X
A 904 C Litronic X (3) X (3)

8) only in low-pressure version
A 900 C-LI 14675- 16.22.7

MJFCIFSS
MONTABERT hydraulic hammers
9 MONTABERT hydraulic hammers
Type Unit BRV BRH 570/ BRV BRV BRV BRV BRV
Product 700 BRM 900 32 1200 1600 45 55
Operating weight (1) kg 955 1100 1380 1505 2150 2440 3170
Oil requirements l/min 100-140 110-145/ 125-155 140-170 200-230 180-265 240-320
100-150
Operating pressure / bar 140 85/125 135 155 165 165 165
hammer
Adjustment pressu- bar 160 110/150 160 180 190 190 190
re of
the machine, see
AHS 11, AHS 12
Return (2) left left left left left left left
A 900 C Litronic X
A 904 C Litronic X X X (3)

16.22.8 A 900 C-LI 14675-

MJFCIFSS
NPK hydraulic hammers
10 NPK hydraulic hammers
Type Unit H7 H8 H10 E12 H12 E15 H16

Product X XA XE X X X X
Operating weight kg 1060 1250 1600 1850 2100 2500 2700

(1)
Oil requirements l/min 90-140 100-150 100-150 165-210 125-155 180-265 140-180
170-210(8) 175-225
Operating pressu- bar 120-140 130-150 130-150 160-180 160-180 170-190 160-180
re / 120-140(8) 130-150
hammer
Adjustment pres- bar 160 170 170 200 200 200 200
sure of the machi- 160 (8) 170
ne, see AHS 11,
AHS 12
A 900 C Litronic X
A 904 C Litronic X

A 900 C-LI 14675- 16.22.9

MJFCIFSS
RAMMER hydraulic hammers
11 RAMMER hydraulic hammers
Type Unit S29N/ E64/ E66N G80NC/

E68/C S83 S84
Product S29N/ E64C E66C PRO
Operating weight kg 540/820 1040 1330 1710 2260 2350 2900

(1)
Oil requirements l/min 60-135/ 70-130 100-170 120-200 160-230 160-230 210-310
60-120
Operating pressu- bar 175/ 190/ 135-145 135-145 130-140 140-150/ 135-145
re/hammer 200 135-145 120-160
Adjustment pressu- bar 200/ 210/ 170 170 160 170/ 170
re of the machine, 220 170 180
see AHS 11, AHS
12

16.22.10 A 900 C-LI 14675-

MJFCIFSS
STANLEY hydraulic hammers
12 STANLEY hydraulic hammers
Type MB MB MB MB MB MB
Unit
Product 875 1950 1975 2950 2975 3950
Operating pressure/hammer bar 125 130 130 140 140 145
Adjustment pressure bar 150 150 150 160 160 170

of the machine
see AHS 11, AHS 12
A 900 C Litronic X
A 904 C Litronic X X X

A 900 C-LI 14675- 16.22.11

MJFCIFSS
TABE hydraulic hammers
13 TABE hydraulic hammers
Type AGB AGB AGB ABGB

Unit
Product 1000 1300 1600 2000
Operating weight (1) kg 1000 1200 1600 2000
Oil requirements l/min 115-150 140-150 165-175 170-180
Operating pressure/hammer bar 80-90 100-120 130-140 130-140
Adjustment pressure bar 110 140 160 160

of the machine
see AHS 11, AHS 12
Return (2) no data no data no data no data
availab- availab- availab- availab-
le le le le
A 900 C Litronic X
A 904 C Litronic X

16.22.12 A 900 C-LI 14675-

MJFCIFSS
VIBRA RAM hydraulic hammers
14 VIBRA RAM hydraulic hammers
Type VRH VRH VRH

Unit
Product 115S 135S 150S
Operating weight (1) kg 1280 1510 2250
Oil requirements l/min 90-120 100-135 100-165

130-170(8) 130-170(8)
Operating pressure/hammer bar 140-170 150-180 160-180

100-120(8) 120-180(8)
Adjustment pressure bar 190 200 200

of the machine 140 (8) 200 (8)
see AHS 11, AHS 12
Return (2) left left left
A 900 C Litronic
A 904 C Litronic X (3)

A 900 C-LI 14675- 16.22.13

MJFCIFSS
WIMMER hydraulic hammers
15 WIMMER hydraulic hammers
Type W- W- W-
Unit
Product 550 660 770
Operating weight (1) kg 1050 1700 2250
l/min l/min 70-120 120-160 160-230
Operating pressure/hammer bar 120-165 120-165 120-165
Adjustment pressure bar 180 180 180

of the machine
see AHS 11, AHS 12
Return (2) left/right right right
A 900 C Litronic X
A 904 C Litronic X

16.22.14 A 900 C-LI 14675-

MJFCIFSS
Service Manual Pipe layer
Function/design
Pipe layer
1 Function/design
The pipe layer is used to install and connect pipes of various diameters and materials. It is operated
from the operator's cab.
To operate the attachment, the machine must be equipped with the AHS 11 attachment kit with Tool
Control.
Equipment:
Rotator, for continuous rotation in two directions
Prism-shaped grippers catering for various pipe diameters
Large gripper surfaces
Insertion cylinder for the connection of pipes (adjustable)
Suspension device for attachment with quick-change system (e.g. LIKUFIX)
Changing of operating mode: mechanical or electrical (optional extra)
Fig. 1 Design of pipe layer
2 LIKUFIX mounting plate 14 Rear support, adjustable

4 Rotator 15 Pipe gripper
5 Hydraulic rotary connection 16 Universal joint
7 Pressure-relief valve 17 Front support
9 Gripper cylinder 18 Holder
10 Insertion cylinder (insertion device)
16.23.1
copyright by
MJFCIFSS
Pipe layer Service Manual
Function/design
Fig. 2 Hydraulic unit with mechanical changeover
16.23.2
copyright by
MJFCIFSS
Function/design
Fig. 3 Hydraulic unit with electrical changeover
16.23.3
copyright by
MJFCIFSS
Function/design
4 Rotator 11 Measuring point

5 Hydraulic rotary connection 12 Electrical rotary connection
7 Pressure-relief valve Y434-1 Solenoid valve / opening gripper
cylinder
8 Check valve Y434-2 Solenoid valve / closing gripper cylin-
der
9 Gripper cylinder Y435-1 Insertion cylinder solenoid valve /
inserting pipe
10 Insertion cylinder (insertion device) Y435-2 Insertion cylinder solenoid valve / pul-
ling pipe
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Technical data
2 Technical data
Pipe layer
Max. pipe length 3.0 m
Pipe diameter 450 to 800 mm (optional to 300 mm)
Dead weight 1300 kg
Load capacity max. 1500 kg
Pressure-relief valve 7 (factory settings) 250 bar
Note!
Actuating pipe layer:
Fig. 5 Overview of control elements
k Foot pedal for "Open pipe gripper / pull out pipe section"
m Foot pedal for "Close pipe gripper / insert pipe section"
L Push button "Turn left"
R Push button "Turn right"
Press the push buttons L and R to turn the machine. The pipe layer is operated by means of the pe-
dals m and k.
Press the foot pedal k down.
The pipe gripper is opened / the insertion device pulls out the pipe section
16.23.5
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Press the foot pedal m down.

The pipe gripper is closed / the insertion device pushes in the pipe section
Note!
The descriptions below refer to the standard control devices at the LIEBHERR operator's platform.
The devices might vary in other machines.
3.1 Pipe layer turning left/right, see Fig. 6

When the push button for turning left or right is pressed, the spool in the section 540 (turning gripper)
of the control block 100 is shifted.
The high pressure oil in the system flows through the connections B02 or A02 and the LIKUFIX
mounting plate 2 to the swing drive 4 of the pipe layer. This allows the operator to move the entire
pipe layer in the indicated directions of rotation L or R, (see Overview of control elements on
page 5).
3.2 Closing and opening pipe gripper (mechanical), see Fig. 6

Select operating mode A "Pipe gripper", (see on page 18).
Closing pipe gripper:

When the foot pedal m (closing) is actuated, the spool in the section 510 (additional axle AHS 11) of
the control block 100 is shifted.
The high pressure oil flows through the connection B and the LIKUFIX mounting plate 2, the rotary
connection 5, the changeover valve 6 and then through the connection P1 to Z1 and the check valve
8 to the piston side of the gripper cylinder 9. The gripper cylinder 9 is extended and closes.
The return oil flows through the opposite side back to the tank.
Opening pipe gripper:

When the foot pedal k (opening) is actuated, the spool in the section 510 (additional axle AHS 11) of
The high pressure oil flows through the connection A and the LIKUFIX mounting plate 2, the rotary
connection 5, the changeover valve 6 and then through the connection P2 to Z2 to the rod side of the
gripper cylinder 9. The check valve 8 is opened and the gripper cylinder 9 is opened. The return oil
flows through the opposite side back to the tank.
3.3 Pulling and inserting the pipe section (mechanical)

Select operating mode B "Insertion device", (see on page 18).
Inserting pipe section:

When the foot pedal m (inserting) is actuated, the spool in the section 510 (additional axle AHS 11)
of the control block 100 is shifted.
connection 5, the changeover valve 6 and then through the connection P1 to G1, the check valve 7
and the connection G1 to the rod side of the insertion cylinder 10. The insertion cylinder 10 is retrac-
ted. The pipe section can now be pushed into the socket of the second pipe, (see Working with the
pipe layer on page 17).
At the same time, the oil at the pressure-relief valve 7 and at the measuring point 11 where the inser-
16.23.6
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MJFCIFSS
tion pressure of the insertion cylinder 10 is limited, (see Adjusting hydraulic pressure on page 13).
The return oil flows through the opposite side back to the tank.
Note!
While the pipe section is being inserted, high pressure must be applied to the piston side of the grip-
per cylinder 9. This is ensured by the check valve in the changeover block 6.
This prevents the pipe section from slipping while being inserted.
Pulling out pipe section:

When the foot pedal k (pulling) is actuated, the spool in the section 510 (additional axle AHS 11) of
connection 5, the changeover valve 6 and then through the connection P2 to G2 to the piston side of
the gripper cylinder 10. The insertion cylinder 10 is extended. The return oil flows through the oppo-
site side back to the tank.
1 to tank 8 Check valve

2 LIKUFIX mounting plate 9 Gripper cylinder
3 Shuttle valve 10 Insertion cylinder (insertion device)
4 Rotator 11 Measuring point
5 Hydraulic rotary connection 510 AHS additional axle
6 Changeover block 540 Additional axle / rotating gripper
7 Pressure-relief valve
16.23.7
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MJFCIFSS
Fig. 6 Hydraulic diagram with mechanical changeover (shown here: operating mode B)
16.23.8
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MJFCIFSS
3.4 Closing and opening pipe gripper (electrical), see Fig. 8

Select operating mode A "Pipe gripper", (see Electrical switching of the operating mode (optional
equipment): on page 16).
The switching device is now activated and can be used.
Press and hold the button S6M and press and hold the button S498.
Operating mode A "Pipe gripper" is activated.
Fig. 7 Switching between modes
Closing pipe gripper:

The solenoid valves Y434-1/Y434-2 are powered and the connection to the piston side or the rod side
of the gripper cylinder 9 is opened.
Simultaneously, the solenoid valves Y435-1/Y435-2 are powered.
When the foot pedal m (closing) is actuated, the spool in the section 510 (additional axle AHS 11) of
connection 5 and the solenoid valve Y434-2 and then through the connection B to A and the check
valve 8 to the piston side of the gripper cylinder 9. The gripper cylinder 9 is extended and closes. The
return oil flows through the opposite side back to the tank.
Opening pipe gripper:

The solenoid valves Y434-1/Y434-2 are powered and the connections to the piston side or the rod
side of the gripper cylinder 9 are opened.
When the foot pedal k (opening) is actuated, the spool in the section 510 (additional axle AHS 11) of
connection 5, the changeover valve Y434-1 and then through the connection A to B to the rod side
of the gripper cylinder 9. The check valve 8 is opened and the gripper cylinder 9 is retracted and
opens. The return oil flows through the opposite side back to the tank.
3.5 Pulling and inserting the pipe section (electrical)

Select operating mode B "Insertion device", (see Electrical switching of the operating mode (op-
tional equipment): on page 16).
Release all buttons.
Operating mode B "Insertion device" is activated.
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Inserting pipe section:

The solenoid valves Y435-1/Y435-2 are not powered and the connections to the piston side of the
insertion cylinder 10 or to the rod side to the connection A to the section 510 are opened.
When the foot pedal m (inserting) is actuated, the spool in the section 510 (additional axle AHS) of
connection 5, the changeover valves Y435-1 and then through the connection B to A to the rod side
of the insertion cylinder 10. The insertion cylinder 10 is retracted. The pipe section can now be pu-
shed into the socket of the second pipe, (see Working with the pipe layer on page 17). The return
oil flows through the opposite side back to the tank.
At the same time, the oil acts on the pressure-relief valve 7 and on the measuring point 11 where the
insertion pressure of the insertion cylinder 10 is limited, (see Adjusting hydraulic pressure on
page 13).
Pulling out pipe section:
When the foot pedal k (pulling) is actuated, the spool in the section 510 (additional axle AHS 11) of
connection 5, the changeover valves Y435-2 to the piston side of the insertion cylinder 10. The inser-
tion cylinder 10 is extended. The return oil flows through the opposite side back to the tank.
1 to tank 10 Insertion cylinder (insertion device)

2 LIKUFIX mounting plate 11 Measuring point
3 Shuttle valve 510 Additional axle AHS 11
4 Rotator 540 Additional axle / rotating gripper AS1
5 Hydraulic rotary connection Y434-1 Solenoid valve / opening gripper cylin-
der
7 Pressure-relief valve Y434-2 Solenoid valve / closing gripper cylinder
8 Check valve Y435-1 Insertion cylinder solenoid valve / inser-
ting pipe
9 Gripper cylinder Y435-2 Insertion cylinder solenoid valve / pul-
ling pipe
16.23.10
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MJFCIFSS
Fig. 8 Hydraulic diagram with electrical changeover (shown here: operating mode B)
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MJFCIFSS
Adjustment of pipe layer
4 Adjustment of pipe layer
4.1 Adjusting gripper to pipe diameter

The pipe layer can be adjusted to suit different pipe diameters by means of the prism-shaped adapter
plates. This is done by adjusting the distance of the pipe section to the support frame of the pipe grip-
per.
Adjust the settings so that the gripper can take up the pipe section at the centre.
Standard adapter (Ø 450 mm to 600 mm):
Fig. 9 Attaching standard adapter
Screw together the required number of adapter plates.

Add and remove adapter plates as necessary.
Adapter for small pipe diameters (Ø 300 mm to 450 mm)
Fig. 10 Attaching adapters for small pipe diameters
Hook the adapter plates to both jaws of the pipe gripper 15.
Attach the adapter plates to the holder 18, front support 17 and rear support 14.
16.23.12
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Fig. 11 Adjusting rear support 14
Remove the screws 19.

Turn the spindle 20 with an open-end spanner to move the support until it matches the pipe dia-
meter.
Tighten the screws 19 again.
Fig. 12 Example of different pipe diameters
Check handling by moving the pipe section; if necessary, adjust the settings.
4.2 Adjusting hydraulic pressure

The hydraulic pressure determines the force applied by the pipe gripper and the insertion device. The
pressure settings must be suitable for the strength of the pipe section and the respective connecting
elements.
The pipe layer works at two different pressure levels:
Pressure of pipe layer (adjustment in Tool Control menu)
Pressure of insertion device (adjustment at pressure-relief valve 7)
Adjusting pressure of pipe gripper:

Note!
For detailed pressure adjustment instructions for the Tool Control menu, see group 16 "Pressure
and flow reduction".
To prevent damage to the attachment and the machine, you must check the basic settings (manda-
tory requirement).
16.23.13
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Guide values recommended by LIEBHERR:
Material Pressure [bar]
Pipes made in concrete, metal or heavy-duty plastic (weight > 300 320 to 350
kg)
Light-duty plastic pipes (weight < 300 kg) 150 to 350
Select the settings for the attachment accordingly.
Adjusting the pressure of the insertion device:

The maximum pressure of the insertion cylinder 10 is adjusted directly at the pipe layer. For this pur-
pose, the insertion cylinder 10 is equipped with the pressure-relief valve 7 and the measuring point
11 for the connection of a pressure gauge, see Fig. 13.
The (machine-generated) pressure must be set to a relatively high value in order to facilitate the pipe
gripper operation. This however results in a relatively great force for the insertion device.
If the insertion force for pipe sections does not exceed a specific value, the pressure of the insertion
cylinder must be limited (see manufacturer specifications, see Tab. 1).
Fig. 13 Pressure-relief valve at the insertion cylinder
Danger!
Risk of accidents caused by unexpected machine movements during adjustment of the settings.
All settings must be adjusted by qualified technical personnel.
Select pressure, see Tab. 2 (observe manufacturer specifications).

Retract the insertion cylinder to the stop.
Place the pipe layer safely on the ground.
Connect a pressure gauge to the measuring point 11.
Remove the cap at the valve 7.
Using a spanner, loosen the lock nut.
Press the foot pedal m down.
16.23.14
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Adjust the pressure to the desired value, using an Allen key.

Release the foot pedal.
Tighten the lock nut.
Replace the cap at the valve 7, remove the pressure gauge and seal the measuring point.
Pressure [bar] Insertion force [kN]
100 20
110 22
120 24
130 26
140 28
150 30
160 32
170 34
180 36
190 38
200 40
210 42
220 44
230 46
240 48
250 50
260 52
270 54
280 56
290 58
300 60
310 62
320 64
330 66
340 68
350 70
Tab. 2 Insertion device; ratio between pressure and insertion force
16.23.15
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MJFCIFSS
Selection of operating mode
5 Selection of operating mode
According to the selected operating mode, the pipe gripper (A) or the insertion device (B) is operated.
Before and after the laying of pipes, the machine must be switched to insertion device mode with the
hand lever on the pipe layer.
5.1 Mechanical changeover of the operating mode (standard):
Fig. 14 Operating mode switching lever
A "Pipe gripper" operating mode B "Insertion device" operating mode
Danger!
Do not stand close to the pipe layer, as this could lead to serious injury or even death!
Before operating the machine, communicate with the other workers on the site (machine opera-
tor and auxiliary worker).
Ensure that the auxiliary worker does not come near the pipe layer unless for the purpose of swit-
ching operating mode.
Before switching operating mode, lower the pipe layer fully.
Tilt the safety lever upwards.
Turn the hand lever to the respective position.

Ensure that the hand lever is turned to the stop (fully horizontal or vertical).
5.2 Electrical switching of the operating mode (optional equipment):

According to the selected operating mode, the pipe gripper or the insertion device is operated. Before
and after laying pipes, select the correct operating mode by actuating the relevant switch.
Switching mode: see operating manual
Operating mode A "Pipe gripper"
The machine is equipped with control elements for operating mode switching. The machine can be
switched over without the assistance. The procedure can be carried out easily and efficiently from the
operator's cab.
Activating switching device:

The switching device is now activated and can be used.
16.23.16
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MJFCIFSS
Working with the pipe layer
To switch from pipe layer to excavator: Press the switch S498 again.
The switching device is deactivated.
Switching between modes:

According to the selected operating mode, the pipe gripper or the insertion device is used. For safety
reasons, the system only switches over when the following two control elements are actuated simul-
taneously: buttons S6M and S55.
Operating mode A "Pipe gripper" (switched mode)
Operating mode B "Insertion device" (default mode)
6 Working with the pipe layer
Working method:
If necessary attach adapters that suit the pipe diameter.
Ensure that the hydraulic pressure and the insertion force are properly set.
Before taking up a pipe section, complete all necessary preparations for the pipeline system, fol-
lowing the instructions of the manufacturer (e.g. greasing of connecting elements).
Note!
Improper movement of the working attachment might lead to an overload at the insertion device.
Risk of damage to the cylinder!
Only connect the channel pipe section with the insertion device and do not attempt to achieve
connections by moving the attachment.
Never place the weight of the machine onto the pipe layer.
Note!
Operating mode B "Insertion device" prevents inadvertent opening of the pipe gripper.
Lift the pipe section only after operating mode "Insertion device" has been selected.
Fig. 15 Taking up and positioning pipe section
If necessary, open the insertion device.

Select operating mode A "Pipe gripper".
Move safety lever down.
Place pipe layer on the pipe.
Close the pipe gripper without lifting the pipe.
16.23.17
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Check whether the pipe is properly engaged in the pipe gripper and cannot become jammed. If
this is not the case, open and then close the gripper again.
Select operating mode B "Insertion device".
Lift the pipe section.
Place the pipe section in the correct position.
Lower the pipe section beside a previously laid pipe section.
Ensure that the pipe sections do not touch each other.
Place the holder at the sleeve of the previously laid pipe section.
Fig. 16 Align the pipe section and insert it, while the pipe gripper is opened
Lower the attachment until the two pipe sections are parallel to each other.
Using the insertion device, push the pipe section into the sleeve of the previously laid pipe section.
Select operating mode A "Pipe gripper".
Open the pipe gripper and lift the pipe layer.
Fig. 17 Switching between modes
Press and hold the button S6M and press and hold the button S55.
Operating mode A "Pipe gripper" is activated.
Operate the pipe gripper with the pedals m / k.
Release all buttons.
Operating mode B "Insertion device" is activated.
Operate the insertion device with the pedals m / k.
16.23.18
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In both modes, press the push buttons L and R respectively to turn the machine. We recommend
however not to use the turning function together with the pipe gripper.
16.23.19
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MJFCIFSS
16.23.20
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MJFCIFSS
Service Manual Speeder kit
Function and design
Speeder kit
The LIEBHERR models A 900 C Litronic to A 904 C Litronic are available as speeder models.
Speeder models can travel at a considerably higher maximum speed than standard models.
Note!
Note
In model A 900 C, the higher maximum travel speed is achieved by a higher flow rate in the control
axle for travel, while the travel engine is the same as in the standard serial model.
In model A 904 C, the higher maximum travel speed is achieved by a higher flow rate in the control
axle for travel combined with a larger travel engine and smaller gear ratio in the axles.
Fig. 1 Travel motor 170
Note!
If the maximum travel speed of the machine is not suitable for the actual operating environment, it
can be adjusted, provided that the measured maximum speed of the universal joint shaft (connec-
tion between gearbox and axle) does not correspond to the value specified in the adjustment pro-
tocol, see group 6.
A 900 C-LI 14675- 16.30.1

MJFCIFSS
Speeder kit Service Manual
Settings
2 Settings
2.1 Adjustment of the maximum output speed / maximum travel speed
Note!
The adjustment must be completed in accordance with the adjustment notes (safety instructions
and operating conditions) described in group 6. The maximum flow volume is defined by the stroke
limitation of the spool 160 (dimension Y, see also adjustment notes in group 6) and may not be
changed.
Fig. 2 Control valve block 100 with control axle160 chassis
Speeder machines are equipped with a control axle 160 that has been specially developed for higher
speeds and is connected to the machine-specific control valve block 100 (for control valve block no.,
see ID tag).
If the settings must be corrected, proceed as follows:
Jack up the vehicle and put it into on-road gear (pilot control unit operated).
Measure the maximum speed of a joint shaft, using a HT 460 revolution counter and compare the
measured value with the nominal speed (see adjustment protocol).
If the measured speed does not correspond to the nominal speed, proceed as follows:
Set the pilot control unit to advanced control.
Remove the cap nut from the chassis control axle 160 of the control valve block 100.
Remove the lock nut .2 of the stroke limiter 160.1 / 160.2 and turn the adjusting screw .1 until the
measured universal joint shaft speed corresponds to the nominal speed.
Screw in the stroke limiter.
speed is reduced
Screw out the stroke limiter
speed is increased
Complete the above adjustments on the other side of the spool 160 (forward / reverse travel).
After the speed has been adjusted, secure the adjusting screws 160.1 / 160.2 with the lock nut .2
(hold adjusting screw .1 while mounting the lock nut), and tighten the cap nuts.
16.30.2 A 900 C-LI 14675-

MJFCIFSS
Service Manual Speeder kit
Adjustment of the minimum intake volume at the travel engine
3 Adjustment of the minimum intake volume at the travel engine
Note!
The minimum pivoting angle is determined by a threaded stud.
Do not modify the factory settings.
The correct position of the threaded stud in the housing can be checked by measuring dimension
X, see group 7.26, which might serve as a recommended value.
A 900 C-LI 14675- 16.30.3

MJFCIFSS
Speeder kit Service Manual
Adjustment of the minimum intake volume at the travel engine
16.30.4 A 900 C-LI 14675-

MJFCIFSS
Service Manual Generator drive accessory kit
Function
Generator drive accessory kit
1 Function
The generator drive accessory kit includes all components required for the operation of a magnet sys-
tem.
Magnet systems with the standard load lifting magnet tool are used to take up, load and sort ferro-
magnetic parts, i.e. all iron parts up to a certain alloy content.
The A 904 type 1004/1071 mobile excavator serves thereby as a support and energy supply unit. The
generator is driven hydraulically. The hydraulic energy of a variable-displacement 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.
Fig. 1 Machine with load lifting magnet
16.32.1
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MJFCIFSS
Generator drive accessory kit Service Manual
Function
16.32.2
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MJFCIFSS
Technical data
2 Technical data
Designation Unit Generator

13 kW
Generator 400 DPE0715/DGT060 230 V 56.5 A
(13kW)
Variable-displacement pump 420: A10VO45
Input speed rpm 2250
Volumetric delivery cm3 45
Flow
Speed step 10 l/min. max. 101
Speed step 8 max. 81
Axial piston - fixed-displacement motor 420:
Output speed rpm 3050 +50
Oil flow consumption cm3 23
l/min. approx. 70
Pressure-relief and restrictor valves:
Flow regulator 421 (difference: measuring points 431/ bar p 12 -14
432)
p is determined by the set output speed
Pump safety valve 422 (measuring point 432) bar 280 +20
16.32.3
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MJFCIFSS
Design, see Fig. 2and Fig. 3
3 Design, see Fig. 2and Fig. 3
The variable-displacement pump 420 with the flow regulator 421 and the pump safety valve 422 is
flange-mounted to the auxiliary drive 425 of the diesel engine.
The intermediate block 430 with the integrated restrictors 433/434, (see Fig. 9 on page13) and the
measuring points 431 and 432 is flange-mounted to the variable-displacement pump 420.
The solenoid valve Y462 is mounted with a bracket to a point above the control oil unit on the hydrau-
lic tank 1.
The generator 400 and the fixed-displacement motor 410 are mounted on a bearing block located
behind the operator's cab or the lift frame respectively (in models with elevated operator's cab) in the
uppercarriage.
The check valve 402 is connected with screws to the fixed-displacement motor 410.
1 Hydraulic tank 430 Intermediate block

400 Generator 431 Measuring point LS
401 Measuring point 432 Measuring point P
402 Check valve Y462 Solenoid valve / generator
403 Guard A High-pressure connection (oil motor)
410 Fixed-displacement motor B/410 High-pressure connection (pump)
420 Variable displacement pump B/420 High-pressure connection (oil motor)
421 Flow regulator S Tank connection (pump)
422 Pump safety valve LS Control line
425 Auxiliary drive S Tank connection (oil motor)
16.32.4
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MJFCIFSS
Fig. 2 Design
16.32.5
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MJFCIFSS
Fig. 3 Hydraulic connections
16.32.6
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MJFCIFSS
Description of functions, (see Hydraulic diagram on page 13)
4 Description of functions, (see Hydraulic diagram on page 13)
Note!
For details regarding the electrical components and connections of the kit, see circuit diagram from
group 8.101.
If the magnet system is switched off, the variable-displacement pump 420 driven by the diesel engine
pumps a minimum quantity of oil via the intermediate block 430 and the integrated restrictors 433/
434 to the fixed-displacement motor 410 (stand-by operation). This oil is required as a lubricant and
a coolant of the system components when the generator is off.
If the switch S46 is actuated, the solenoid valve Y462 is powered and opens. The excavator control
system (BST) switches the engine speed to speed level 8.
The speed is regulated by means of a restrictor 433 (Ø5.5) in the intermediate block 430, based on
the regulating delta p at the flow regulator 421. The pressure difference in the LS line switches the
flow regulator 421 to position "open". The oil flows into the control chamber of the pivot angle adjus-
ting unit 423.
The variable-displacement pump 420 is swivelled to the set flow rate, so that a regulator volume of
oil is fed to the fixed-displacement motor 410. The fixed-displacement motor drives the generator 400
to which it is connected via a flexible coupling.
4.1 Pump safety valve 422

In order to prevent damage to the variable-displacement pump, the pressure of the unit is limited by
the pump safety valve 422 (pressure restriction). If the pressure exceeds the set spring force of the
valve, the valve is opened and the control chamber of the pivot angle adjusting unit 423 is depressu-
rised. As a result, the variable-displacement pump 420 is swivelled back to quantity zero (Q=0).
4.2 Check valve 402 (suction system)

The check valve 402 acts as a suction device for the oil motor 410.
16.32.7
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MJFCIFSS
Operation of the magnet system
5 Operation of the magnet system
Caution!
Incorrect operation could result in serious injury to persons and damage to the machine.
Before activating quick-change mode (exchange of tools), switch off the magnet system.
Only switch on the magnet system when the attachment is mounted and connected.
5.1 Switch S46 for magnet system

The generator drive and the magnet system are switched on and off with the switch S46 located in
the right control console.
After the magnet system is activated, the device is automatically switched as follows:
The motor speed P4, see Fig. 5, is increased to minimum level 8.
The idle automatic switched on with switch S20 is disabled.
Fig. 4 Switch of magnet system
Danger!
In the event of a drop in the current, the magnet might lose its load!
Ensure that no persons are standing under suspended loads.
Prevent inadvertent actuation of the push button S6L and the switch S55.
5.2 S 6 L push button, see Fig. 5

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.
5.3 Switch S55 (US version), see Fig. 5

The load lifting magnet is activated and deactivated with the switch S55 in the left joystick.
16.32.8
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MJFCIFSS
Operation of the magnet system
Press the switch S55 up.

The magnet is activated.
Press the switch S55 down.
The magnet is deactivated.
Fig. 5 Switch or rocker switch/lifting magnet and motor speed indicator
P4 Display / motor speed S6L Magnet system switch

S20 Switch / idle automatic S55 Magnet system rocker switch (US ver-
sion)
16.32.9
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MJFCIFSS
Magnet system settings
6 Magnet system settings
6.1 Adjustment of pump pressure, see Fig. 7

Warm up machine to operating temperature, (min. 50 °C).
Connect a pressure sensor to the measuring point 432 (P).
Unscrew the line B (arrow) between the variable-displacement pump 420 and the generator 400,
and seal with a dummy plug.
Fig. 6 Adjustment of pump pressure
Switch on generator using the switch S46.

Read the pump pressure measured at the measuring point 432 and compare it with the technical
data, see Tab. 1.
If adjustment is necessary, proceed as follows:

Loosen the lock nut 3 (WS13) at the pump pressure regulator 422.
Adjust the pump pressure to the prescribed set value by turning the adjusting screw 4 (WS4), (see
Technical data on page 3).
After completion of the adjustment, tighten the lock nut 3 at the pump regulator 422.
Reconnect the line B.
16.32.10
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MJFCIFSS
Fig. 7 Adjustment of pump pressure and generator speed
6.2 Adjustment of generator speed, see Fig. 7

Adjustment by means of induction speedometer:
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. 8.
Fig. 8 Application of reflective strips
Activate the generator drive with the switch S46.

Measure the output speed of the generator 400, using a suitable speedometer, and compare it
with the prescribed output speed, (see Technical data on page 3).
16.32.11
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If adjustment is necessary, proceed as follows:

Loosen the lock nut 1 (WS14) at the flow regulator 421.
Screw in the adjusting screw 2 (WS4) = reduce output speed or screw out the adjusting screw =
increase output speed.
After completion of the adjustment, tighten the lock nut 1 at the flow regulator 421.
Deactivate the generator drive by actuating the switch S46.
Remove the reflective strops and mount the guard 403.
1 Hydraulic tank 423 Pivot angle adjustment

20 Double variable-displacement pump 430 Intermediate block
400 Generator 431 Measuring point LS
401 Measuring point 432 Measuring point P
402 Check valve 433 Restrictor
410 Fixed-displacement motor 434 Restrictor
420 Variable displacement pump S46 Magnet system switch
421 Flow regulator Y462 Solenoid valve / generator
422 Pump safety valve
16.32.12
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MJFCIFSS
16.32.13
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MJFCIFSS
100 Generator control device X324 Plug connection of control device

Magnet system
A1100 Printed circuit board X370 Plug connection of generator drive
K355 Relay / magnet system X411 Plug connection of quick-change adap-
ter (optional)
S6L Push button (activation of magnet X1048 Quick-change adapter / right handle
system)
S46 Magnet system switch X1063 Quick-change adapter / interface motor
- operator's platform
S47 Push button / quick change adapter X1205 Quick-change adapter
(optional)
X214-2 Plug connection to A1100 X1231 Quick-change adapter
X217 Plug connection to A1100 X1232 Quick-change adapter
X222 Plug connection to A1100 Y462 Solenoid valve / generator drive
16.32.14
copyright by
MJFCIFSS
Service Manual Generator conversion kit for LIKUFIX
Function
Generator conversion kit for LIKUFIX
1 Function
Danger!
Generators can be used to generate electricity.
Contact with electrically powered couplings can lead to serious injury or even death.
Do not operate the switch S46.
With LIKUFIX, the generator conversion kit must be used.
If the generator kit is operated with LIKUFIX, the use of the conversion kit for generator drive is man-
datory for safety reasons. This ensures that the generator is halted when the switch S46 is off.
Some electric power might be generated by the power source (generator 400) when the small resi-
dual amount of oil required for cooling and lubrication of the system is moved through the system.
Upon coupling with LIKUFIX, the coupling contacts might become powered. The solenoid valve Y488
and an integrated restrictor prevent the generator from generating power when residual oil is pumped
by the variable-displacement pump, (see Description of functions (see Hydraulic diagram on
page 4) on page 2).
Fig. 1 Generator conversion kit for LIKUFIX
16.34.1
copyright by
MJFCIFSS
Generator conversion kit for LIKUFIX Service Manual
Design, see Fig. 2
2 Design, see Fig. 2
The solenoid valve Y488 with the mounting plate 407 is screwed to the console 408 on the bearing
block of the generator 400. The restrictor 406 is integrated into a screw fitting, which in turn is screwed
into the mounting plate 407.
3 Description of functions (see Hydraulic diagram on page 4)
Note!
For details regarding the electrical components and connections of the kit, see circuit diagram for
group 8.102.
Do not operate the switch S46 (generator drive not ON).

The variable-displacement pump 420 pumps a small amount of oil through the intermediate block 430
to the solenoid valve Y488. The solenoid valve Y488 is opened so that the oil can flow through the
restrictor 406 to the tank 1.
The restrictor 406 causes a backpressure and the variable-displacement pump 420 is swivelled by
the minimum pivot angle. The solenoid valve Y488 closes the connection between the variable-dis-
placement pump 420 and the fixed-displacement motor 410. The pumped oil is fed to the tank 1. The
generator 400 thus remains in standstill and no electricity is generated.
3.1 Adjustment and operation
Note!
For detailed instructions on the operation and adjustment of the generator attachment kit, refer to
group 16.32.
1 Hydraulic tank 410 Fixed-displacement motor

400 Generator 420 Variable-displacement pump
401 Measuring point 430 Intermediate block
402 Check valve 431 Measuring point LS
406 Restrictor Ø 2.0mm 432 Measuring point P
407 Mounting plate Y462 Solenoid valve (generator)
408 Console Y419 Solenoid valve (changeover)
16.34.2
copyright by
MJFCIFSS
Service Manual Generator conversion kit for LIKUFIX
Description of functions (see Hydraulic diagram on page 4)
Fig. 2 Hydraulic and electrical connections
16.34.3
copyright by
MJFCIFSS
Generator conversion kit for LIKUFIX Service Manual
Description of functions (see Hydraulic diagram on page 4)
16.34.4
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MJFCIFSS
Service Manual Accessory kit AS1
Function/design
Accessory kit AS1
1 Function/design
Auxiliary attachments that can be connected to the hydraulic excavator often require special compo-
nents, hydraulic lines and hoses for control and drive purposes.
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 Hydraulic quick-change adapter
C Ditch cleaning bucket, with swivel hydraulics
The pressure required for these additional functions is built up through the additional control axle 540
flange-mounted to the compact control block / slewing gear element 120. The solenoid valves Y22 /
Y23 on the spool are operated with the push buttons S5L/S5R in the left pilot control unit.
Fig. 1 Attachments for AS1
16.40.1
copyright by
MJFCIFSS
Accessory kit AS1 Service Manual
Technical data
2 Technical data
Pressure limit (in

Attachments and associated pressure-relief valves bar)
primary secondary
Secondary pressure-relief valve 541 / 542
(This valve limits the operating pressure and, thus, the operating 110 +20 bar
pressure at measuring point 45) at the additional control axle 540
Primary pressure-relief valves 551 / 552 100 +10 bar
(primary protection for oil motor 550 / grapple rotator)
Secondary pressure-relief valves 562/563 500 ±20bar
(secondary protection for cylinder 560 / tilting bucket)
Tightening torques of mounting screws and bolts 55 Nm
(Allen head screws) of additional 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 15.6 mm
16.40.2
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MJFCIFSS
Operation
3 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.
Fig. 2 Control devices of AS1
80 Left pilot control unit S19 Switch / preselection / kit AS1

S5L Button for actuation of grapple / bucket / S47 Push button / quick-change adapter
quick-change adapter
S5R Button for actuation of grapple / bucket /
3.1 Preselecting kit AS1:

Switch S16 is operated.
The buttons S5L / S5R are activated.
3.2 Turning grapple to the left, swivelling bucket to the left, locking quick-change
adapter:
Press and hold the button S5L.
When the button S5L is pressed, the attached grapple turns to the left.
When the button S5L is pressed, the attached bucket swivels to the left.
Press the buttons S5L and S47.
The quick-change adapter locks in the attached working tool.
3.3 Turning grapple to the right, swivelling bucket to the right, releasing quick-
change adapter:
Press and hold the button S5R.
16.40.3
copyright by
MJFCIFSS
Functioning of the accessory kit
When the button S5R is pressed, the attached grapple turns to the right.
When the button S5R is pressed, the attached bucket swivels to the right.
Press the buttons S5R and S47.
The quick-change adapter of the attached working tool is released, see also group 16.16.
3.4 Switching off kit AS1:

The AS1 is deactivated.
The indicator lamp in the switch is off.
4 Functioning of the accessory kit
Note!
The electrical connections are shown in the circuit diagram of group 8.
The hydraulic connections are shown in the hydraulic diagram, see Fig. 6.
4.1 Neutral position, see Fig. 6

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 po-
sition 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 left pilot control unit 80 to power the solenoid
Y22 or Y23 of the additional control axle and to shift the spool 540 with maximum control pressure to
its 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 additional control axle 540 connection "A02" or "B02" to the connected
consumer.
4.3 Oil circuit with grapple

Oil from the connection "A02" or "B02" of the additional 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 additional
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 additional control axle 540 are switched to their neutral position during a rotary motion, the oil mo-
tor acts as a pump. The resulting excess pressure in the line L or R is released through the pressure-
relief valve 551/552.
16.40.4
copyright by
MJFCIFSS
Pressure check and adjustment
4.4 Oil circuit with ditch cleaning / tilting bucket

Oil from the connection "A02" for swivelling to the right or "B02" for swivelling to the left of the addi-
tional control axle 540 flows through the double check valve 561 connection "V1-C1" or "V2 - C2" to
the cylinder 560.
Pressure is built up, opening the hydraulic double check valve 561 towards the return side. The cy-
linder 560 is extended or retracted and turns the bucket into the horizontal position, by means of a 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 additional control axle 540 to the control
block 100.
The pressure-relief valves 541 / 542 integrated into the additional 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 565.
4.5 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 additional 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 additional control axle 540 to the control block 100.
The pressure-relief valves 541 / 542 integrated into the additional control axle 540 limit the pressure
at the quick-change adapter.
5 Pressure check and adjustment

Pressure adjustment at operating temperature and in mode P.
Use suitable pressure gauges 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.
5.2 Checking of the pressure-relief valves 541 / 542

Compare the pressure at the pressure gauge with the prescribed pressure, see Tab. 1. If necessary,
re-adjust the pressure by means of the adjusting screw at the corresponding pressure-relief valve 541
/ 542.
Turn screw in
Increasing pressure
16.40.5
copyright by
MJFCIFSS
Turn screw out

Reduce pressure
When the adjustment is completed, re-tighten lock nut.
Fig. 3 AS1 adjustment
5.3 Checking the double-acting primary pressure-relief valve 551 / 552

(not applicable for ditch cleaning / tilting bucket and quick-change adapter)
Lock grapple rotator. Actuate the solenoid Y22 / Y23 on both sides.
Compare the pressure at the pressure gauge 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.
16.40.6
copyright by
MJFCIFSS
Fig. 4 Oil motor with shock valves and tilting bucket with double check valve
A Shock valve 552 Pressure-relief valve / turning right

B New tilting bucket models 565 Double check valve
550 Oil motor / grapple rotator 566 Pressure-relief valve, swivelling to left
551 Pressure-relief l valve / turning left 567 Pressure-relief valve, swivelling to right
16.40.7
copyright by
MJFCIFSS
5.4 Inspecting secondary pressure-relief valves 566 / 567

(only in AS1 kit for ditch cleaning / tilting bucket)
Note!
The secondary pressure-relief valves 566 / 567, see Fig. 5 are factory-set and the pressure settings
can only be adjusted at considerable expense.
Inspection must be limited to the condition of the pressure springs of relief valve 566 / 567 (setting
and breakage).
Caution!
Risk of injury to eyes and hands from preload of the spring in the valves 566 / 567.
Carefully remove the screw plug on the housing of the valve 566 / 567.
Check the valve for damage.

Reassemble the valve 565. If required, replace the entire valve.
5.5 Adjusting the flow of the spool 540
(rotating speed of grapple)
Fig. 5 Adjustment of the stroke limitation
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 grab.
Turn stop in or out, respectively.
Turn out stroke limitation
To increase speed:
Turn in stroke limitation
to reduce speed. (Possible only to a certain degree because pump's Q.min volume play a cer-
tain role as well.)
When finished setting the speed, secure stop screws 540.1 / 540.2 with a lock nut.
16.40.8
copyright by
MJFCIFSS
Hydraulic system AS1
20 from the variable-displacement pump 540 Spool / AS1

24.5 to pump regulator (A 900 C) 541 Secondary pressure-relief valve
26 to pump regulator (A 904 C) 542 Secondary pressure-relief valve
41 Measuring point MP 544 Pressure balance
45 Measuring point MS S5L Press push button
88 P from distribution block S5R Press push button
88 to collecting pipe T S19 Switch / kit AS1
100 Control valve block Y22 Solenoid valve
120 Spool / slewing gear Y23 Solenoid valve
Hydraulic system - turn grab
550 Oil motor 552 Primary pressure-relief valve - turn left

551 Primary pressure-relief valve - turn right
Hydraulic system - tilting bucket
560 Cylinder - swivel bucket 564 Restrictor

562 Secondary pressure-relief valve - piston 565 Double check valve
side
563 Secondary pressure-relief valve - rod side
Hydraulic system - quick-change adapter
570 Locking cylinder Y28-1 Solenoid / seat valve

571 Seat valve Y28-2 Solenoid / seat valve
572 Filter disc
16.40.9
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MJFCIFSS
Fig. 6 Hydraulic diagram of kit AS1
16.40.10
copyright by
MJFCIFSS
Function/design
Accessory kit AS1
1 Function/design
Auxiliary attachments that can be connected to the hydraulic excavator often require special compo-
nents, hydraulic lines and hoses for control and drive purposes.
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 Hydraulic quick-change adapter
C Ditch cleaning bucket, with swivel hydraulics
These additional tools are pressurised through the auxiliary way valve 540 flange-mounted to the pilot
plate / way valve 280 for the support. The solenoid valves Y22 / Y23 on the spool are operated with
the push buttons S5L/S5R in the left pilot control unit.
Fig. 1 Attachments for AS1
16.41.1
copyright by
MJFCIFSS
Technical data
2 Technical data
Pressure limit (in

Attachments and associated pressure-relief valves bar)
primary secondary
Secondary pressure-relief valve 541 / 542
(This valve limits the operating pressure and, thus, the operating 110 +20 bar
pressure at measuring point 45) at the additional control axle 540
Primary pressure-relief valves 551 / 552 100 +10 bar
(primary protection for oil motor 550 / grapple rotator)
Secondary pressure-relief valves 562/563 500 ±20bar
(secondary protection for cylinder 560 / tilting bucket)
Tightening torques of mounting screws and bolts 49 Nm
(Allen head screws) of the auxiliary way valve 540
Max. flow rate at spool 540 30 l/min
via limitation of stroke of spool
Stroke limitation of spool 540
16.41.2
copyright by
MJFCIFSS
Operation
3 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.
Fig. 2 Control devices of AS1
80 Left pilot control unit S19 Switch / preselection / kit AS1

S5L Button for actuation of grapple / bucket / S47 Push button / quick-change adapter
S5R Button for actuation of grapple / bucket /
3.1 Preselecting kit AS1:

Switch S16 is operated.
The buttons S5L / S5R are activated.
3.2 Turning grapple to the left, swivelling bucket to the left, locking quick-change
adapter:
Press and hold the button S5L.
When the button S5L is pressed, the attached grapple turns to the left.
When the button S5L is pressed, the attached bucket swivels to the left.
Press the buttons S5L and S47.
The quick-change adapter locks in the attached working tool.
3.3 Turning grapple to the right, swivelling bucket to the right, releasing quick-
change adapter:
Press and hold the button S5R.
16.41.3
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MJFCIFSS
Functioning of the accessory kit
When the button S5R is pressed, the attached grapple turns to the right.
When the button S5R is pressed, the attached bucket swivels to the right.
Press the buttons S5R and S47.
The quick-change adapter of the attached working tool is released, see also group 16.16.
3.4 Switching off kit AS1:

The AS1 is deactivated.
4 Functioning of the accessory kit
Note!
The electrical connections are shown in the circuit diagram of group 8.
The hydraulic connections are shown in the hydraulic diagram, see .
4.1 Neutral position, see

The solenoids Y22 / Y23 are not powered. There is no pressure applied to the spool 543, and the
control lines leading to the tank are relieved. The variable-displacement pump 20 is in stand-by po-
sition 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 left pilot control unit 80 to power the solenoid
Y22 or Y23 of the auxiliary way valve and to shift the spool 540 with maximum control pressure to its
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 pilot plate 100 through the way
valve 280 and the auxiliary way valve 540 connection "A" or "B" to the connected consumer.
4.3 Oil circuit with grapple

Oil from the connection "A" or "B" of the auxiliary way valve 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 sle-
wing 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 "B" or "A" or the auxiliary way
valve 540 to the pilot plate 100.
The double-acting pressure-relief valve 551 secures the oil motor 550. If the solenoids Y22 / Y23 of
the auxiliary way valve 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.
16.41.4
copyright by
MJFCIFSS
4.4 Oil circuit with ditch cleaning / tilting bucket

Oil from the connection "A" for swivelling to the right or "B" for swivelling to the left of the auxiliary
way valve 540 flows through the double check valve 561 connection "V1-C1" or "V2 - C2" to the cy-
linder 560.
Pressure is built up, opening the hydraulic double check valve 561 towards the return side. The cy-
linder 560 is extended or retracted and turns the bucket into the horizontal position, by means of a 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 "B" or "A" of the auxiliary way valve 540 to the pilot plate 100.
The pressure-relief valve 544 is integrated into the auxiliary way valve 540 and limits 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 565.
4.5 Oil circuit with quick-change adapter

Oil from the connection "A" for the retracting (releasing) of the locking cylinder 570 or "B" for the
extending (locking) of the locking cylinder 570 in the auxiliary way valve 540 flows through the sole-
noid 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 "B" or "A" to the auxiliary way valve 540 to the control block 100.
The pressure-relief valve 544 is integrated into the auxiliary way valve 540 and protects the quick-
change adapter.

Pressure adjustment at operating temperature and in mode P.
Use suitable pressure gauges 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.
5.2 Testing of pressure-relief valve 544

Compare the pressure at the pressure gauge with the prescribed pressure, see Tab. 1. If necessary,
re-adjust the pressure by means of the adjusting screw at the pressure-relief valve 544.
Turn screw in
Increasing pressure
Turn screw out
16.41.5
copyright by
MJFCIFSS
Reduce pressure
When the adjustment is completed, re-tighten lock nut.
Fig. 3 AS1 adjustment
5.3 Checking the double-acting primary pressure-relief valve 551 / 552

(not applicable for ditch cleaning / tilting bucket and quick-change adapter)
Lock grapple rotator. Actuate the solenoid Y22 / Y23 on both sides.
Compare the pressure at the pressure gauge 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.
16.41.6
copyright by
MJFCIFSS
Fig. 4 Oil motor with shock valves and tilting bucket with double check valve
A Shock valve 552 Pressure-relief valve / turning right

B New tilting bucket models 565 Double check valve
550 Oil motor / grapple rotator 566 Pressure-relief valve, swivelling to left
551 Pressure-relief l valve / turning left 567 Pressure-relief valve, swivelling to right
5.4 Inspecting secondary pressure-relief valves 566 / 567

(only in AS1 kit for ditch cleaning / tilting bucket)
Note!
The secondary pressure-relief valves 566 / 567, see Fig. 5 are factory-set and the pressure settings
can only be adjusted at considerable expense.
Inspection must be limited to the condition of the pressure springs of relief valve 566 / 567 (setting
and breakage).
Caution!
Risk of injury to eyes and hands from preload of the spring in the valves 566 / 567.
Carefully remove the screw plug on the housing of the valve 566 / 567.
Check the valve for damage.

Reassemble the valve 565. If required, replace the entire valve.
16.41.7
copyright by
MJFCIFSS
5.5 Adjusting the flow of the spool 540
(rotating speed of grapple)
Fig. 5 Adjustment of the stroke limitation
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 grab.
Turn stop in or out, respectively.
Turn out stroke limitation
To increase speed:
Turn in stroke limitation
to reduce speed. (Possible only to a certain degree because pump's Q.min volume play a cer-
tain role as well.)
When finished setting the speed, secure stop screws 540.1 / 540.2 with a lock nut.
16.41.8
copyright by
MJFCIFSS
Hydraulic system AS1

20 from the variable-displacement pump 542 Secondary pressure-relief valve
24.5 to pump regulator 543 Spool / AS1
45 Measuring point MS 544 Pressure balance
88 P from distribution block S5L Press push button
100 Pilot plate S5R Press push button
280 Way valve / support S19 Switch / kit AS1
540 Auxiliary way valve / AS1 Y22 Solenoid valve
541 Secondary pressure-relief valve Y23 Solenoid valve
Hydraulic system - turn grab

550 Oil motor 552 Primary pressure-relief valve - turn left
551 Primary pressure-relief valve - turn right
Hydraulic system - tilting bucket

560 Cylinder - swivel bucket 564 Restrictor
562 Secondary pressure-relief valve - piston 565 Double check valve
side
563 Secondary pressure-relief valve - rod side
Hydraulic system - quick-change adapter

570 Locking cylinder Y28-1 Solenoid / seat valve
571 Seat valve Y28-2 Solenoid / seat valve
572 Filter disc
16.41.9
copyright by
MJFCIFSS
Fig. 6 Hydraulic diagram for kit AS1
16.41.10
copyright by
MJFCIFSS
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.
These parts have been combined in accessory kits. As there is a wide range of different auxiliary at-
tachments for machines, we offer a number of different accessory kits to suit the equipment.
The accessory kit AHS 1 described below is required for the installation of the following auxiliary at-
tachments to a machine:
Hydraulic boom adjustment
vertically and horizontally adjustable gooseneck boom
Fig. 1 Machine with hydraulic boom adjustment
A 900 C-LI 14675- 16.43.1

MJFCIFSS
Accessory kit AHS 1 Service Manual
General information
Attachments and associated pressure relief Pressure limit (in bar)

valve primary secondary
Pressure cut-off valve 104
(valve limiting the power control pressure and 350 +10 bar
thus the operating pressure at the measuring
point 41) in the control valve block 100
Secondary pressure-relief valve 501 / 502 380 +20 bar

(for cylinder 535 in the auxiliary block 500)
Piston 500 Dimension Y of stop screw 500.1 14.2 mm
Dimension Y of stop screw 500.2 14.2 mm
Flow rate at the outlet A / B
extending: 200 I/min
retracting: 140 l/min
16.43.2 A 900 C-LI 14675-

MJFCIFSS
Function and operation
3 Function and operation
see Fig. 6
The accessory kit AHS 1 allows the machine operator to operate the attachment (consumer) for the
hydraulic boom adjustment or for a vertically and horizontally adjustable gooseneck boom:
Caution!
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 Pilot control unit 89 with pedal
Operation of the boom regulating cylinder

Press foot pedal k down.
The boom regulating cylinder is extended, i.e. the attachment is moved upwards.
Vertically and horizontally adjustable gooseneck boom
The boom is swivelled to the right.
By pressing down the pedal k of the kit pilot control unit 86, the spool 500 in the auxiliary control axle
is pressurised proportionally, and oil flows from the variable-displacement pump 20 to the piston side
of the regulating cylinder 535, so that the cylinder is extended.
Operation of the boom regulating cylinder
Press foot pedal m down.
The boom regulating cylinder is retracted, i.e. the attachment is moved downwards.
Vertically and horizontally adjustable gooseneck boom
The boom is swivelled to the left.
By pressing down the pedal m of the kit pilot control unit 86, the spool 500 in the auxiliary control axle
is pressurised proportionally, and oil flows from the variable-displacement pump 20 to the rod side of
the regulating cylinder 535, so that the cylinder is retracted.
4.1 Important adjustment notes:

A 900 C-LI 14675- 16.43.3

MJFCIFSS
Increase the diesel engine speed to mode P.

Note!
HERR technicians.
The pressure relief valves must be protected against unauthorised manipulation with lead seal wire
or safety caps.
4.2 Checking and adjustment of the secondary pressure relief valve 501 / 502
Fig. 3 Piston 500 in the auxiliary control axle AHS 1
Connect pressure sensor to measuring point 45.

Extend/retract the cylinder 535 to its stop.
Screw in the pressure cut-off valve 104.
The pressure must be above the adjustment pressure of the secondary pressure relief
valves 501 / 502.
Turn the adjusting screw at the secondary pressure relief valve 501 / 502 until the pressure sensor
indicates the nominal pressure, see Tab. 1.
Adjust the settings of the pressure cut-off valve 104.
4.2.1 Adjustment of the pressure cut-off valve 104, mode P see Fig. 3
Move the stick cylinder to the stop and set the pressure cut-off valve 104 to the required pressure
by turning the adjusting screw, see Tab. 1.
16.43.4 A 900 C-LI 14675-

MJFCIFSS
4.3 Adjustment of the stoke limitation of the spool 500
Fig. 4 Stroke limitation of the spool 500
The stroke of the spool 500 for maximum oil flow is factory-set by means of the stroke limiter 500.1 /
500.2 and should not be modified.
The dimension Y, see Tab. 1 serves as a reference value for the prescribed settings. If dimension Y
does not correspond to the prescribed value, adjust the stroke limiter as follows:
Remove the safety cap 1.3, loosen the lock nut 1.2 and turn the stop screw 1.1 until dimension Y
matches the prescribed value.
Tighten the lock nut 1.2 and mount the safety cap 1.3.
A 900 C-LI 14675- 16.43.5

MJFCIFSS
Exploded view
5 Exploded view
Fig. 5 Hydraulic connections AHS 1
1 Tank 100 Compact control block 5 x

20 from variable-displacement pump 104 Pressure cut-off valve
21 Powertrain 500 Auxiliary spool AHS 1
30 Gear pump / pilot control 501 Retracting secondary pressure relief
valve / cylinder 525
41 Measuring point MP 502 Secondary pressure relief valve / exten-
ding cylinder 525
45 Measuring point LS 504 Pressure balance
50 from the control oil unit 507 Restrictor check valve
86 Pilot control unit two-fold, with pedal 525 Regulating cylinder
88P Distributor 526 Load holding valve (piston side)
88T Collecting pipe 527 Load holding valve (rod side)
16.43.6 A 900 C-LI 14675-

MJFCIFSS
Hydraulic diagram
6 Hydraulic diagram
Fig. 6 Hydraulic diagram AHS 1
A 900 C-LI 14675- 16.43.7

MJFCIFSS
Hydraulic diagram
16.43.8 A 900 C-LI 14675-

MJFCIFSS
Function
Accessory kit AHS 11
1 Function
The accessory kit AHS 11 described below is required for the installation of the following auxiliary
attachments to a machine:
Hydraulic hammer
Telescopic demolition stick
Scrap shear
Concrete crusher
Sorting grapple
Fig. 1 Machine and hydraulic hammer attachment
A 900 C-LI 14675- 16.45.1

MJFCIFSS
General information

Secondary pressure-relief valve with additional
pressure level 511 200 +10 bar (*)
Level 1 (hydraulic hammer 535) 380 +20 bar
Level 2 (oil motor 516 / cylinder 537)
(in auxiliary block 510)
secondary pressure relief valves 512 380 +20 bar
for oil motor 516 or cylinder 537 respectively 200 bar (#)
retracting: 200 I/min
(#) In machines with the auxiliary attachments "45° offset boom bearing" or "lateral boom adjustment", the secondary val-
ve 512 controlling the flow at the piston side of the cylinder 517 is set to 200 bar and acts as a primary pressure relief
valve.
16.45.2 A 900 C-LI 14675-

MJFCIFSS
The accessory kit AHS 11 allows the operator to work with two completely different attachments (con-
sumers) using a single kit type:
Operation of the cylinder, e.g. for hydraulic boom adjustment, demolition stick, scrap shear, con-
crete crusher or sorting grapple
Operation of the hydraulic hammer
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 Pilot control unit 86 and key switch S88
By operating the switch S88 at the right control desk, the pilot control system is switched over by
means of the solenoid valve Y91 (Fig. 9) to the respective functional position.
When the key switch S88 is in "hammer" position, the pressure relief valve 511 (with additional pres-
sure level) is set to the reduced pressure value.
Attachment with reduced pressure
Example: Hydraulic hammer
Turn the key switch S88 to position "hammer" in order to activate the flow limitation and pressure
reduction.
If required, select flow reduction in the operator's menu, see Fig. 3.
The hydraulic hammer is operated.
By changing from position "hammer" to position "cylinder", the pressure relief valve 511 (Fig. 6)
with additional pressure level (via solenoid valve Y91) is set to the maximum pressure value:
Attachment with high pressure (cylinder movement):
Example: Scrap shear
Turn the key switch S88 to position "cylinder".
The cylinder is extended, i.e. the scrap shear is closed.
The cylinder is retracted, i.e. the scrap shear is opened.
A 900 C-LI 14675- 16.45.3

MJFCIFSS
3.1 Flow reduction in "hammer" position
Fig. 3 Main screen and proportional solenoid valve Y51 for flow reduction in the control oil
unit 50
The "flow reduction" function is implemented by means of the proportional solenoid valve Y51 in con-
junction with the excavator control system U16, see group 16.20.
Note!
With the flow limitation options I1 of the main screen, preset (maximum or reduced) pump flow vo-
lumes can be assigned to the attachment.
The flow limitation settings are accessible at authorisation level 2 by technicians who have a ser-
vice plug, which allows them to access the "set pumps" menu (see group 8.71).
16.45.4 A 900 C-LI 14675-

MJFCIFSS

Note!
HERR technicians. The pressure relief valves must be protected against unauthorised manipulation
with lead seal wire or safety caps.
4.2 Checking and adjustment of the secondary pressure relief valve 511
511
Disconnect the control line from the additional pressure level 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 to the hammer and seal it.
Only required, if a hydraulic hammer is to be attached.
Fig. 4 Auxiliary control block 510 in the auxiliary control axle AHS 11
A 900 C-LI 14675- 16.45.5

MJFCIFSS
4.2.1 Adjustment of pressure level 2 (higher pressure level)

Loosen the lock nut 14.2 and block the shifting piston 12 by screwing in the adjusting screw 11.
Pressurise the hydraulic hammer 535 to the limit, or move the cylinder 537 to the stop (Fig. 11).
Loosen the lock nut 14.1 and turn the adjusting screw 10 at the pressure relief valve 511 until the
pressure sensor indicates the nominal pressure, (see Tab. 1 on page 2).
Reset the system to pressure level 1.
4.2.2 Adjustment of pressure level 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 indicates the
nominal pressure, (see Tab. 1 on page 2).
Reconnect the control line to the connection X .
Set the pressure cut-off valve 104 (Fig. 6) to the prescribed value.
Fig. 5 Sectional drawing of the secondary pressure relief valve 511
16.45.6 A 900 C-LI 14675-

MJFCIFSS
Fig. 6 Auxiliary control block 500

Extend/retract the cylinder 537 to its stop.
The pressure must be above the adjustment pressure of the secondary pressure relief valve
512.
Turn the adjusting screw at the secondary pressure relief valve 512 until the pressure sensor in-
dicates the nominal pressure, (see Tab. 1 on page 2).
4.3.1 Adjustment of the pressure cut-off valve 104

Select mode P.
Move the stick cylinder to the stop and set the pressure cut-off valve 104 to the required pressure,
(see Tab. 1 on page 2) by turning the adjusting screw.
A 900 C-LI 14675- 16.45.7

MJFCIFSS
The stroke of the spool 510 for maximum oil flow is factory-set by means of the stroke limiter
510.1 / 510.2 and should not be modified.
The dimension Y, (see Tab. 1 on page 2) serves as a reference value for the prescribed settings. If
dimension Y does not correspond to the prescribed value, adjust the stroke limiter as follows:
16.45.8 A 900 C-LI 14675-

MJFCIFSS
Exploded view
5 Exploded view
Fig. 8 Exploded view of the hydraulic connections AHS 11
Fig. 9 Exploded view of the electrical system AHS 11
A 900 C-LI 14675- 16.45.9

MJFCIFSS
Exploded view
1 to tank F5 Fuse / amplifier V151 (15A)

20 from variable-displacement pump F11 Fuse / spare plug X214-3
41 Measuring point MP H44 LED terminal 15 power supply
45 Measuring point LS H47 LED power supply SF2, SF3,
SF4
50 from the control oil unit H55 LED power supply X214-3
86 Pilot control unit two-fold, with pedal MP86 Ground connection behind the opera-
tor's cab
88P Distributor S88 Key switch / hammer pile driver
88T Collecting pipe V152 Amplifier / kit (AHS 12)
100 Compact control block 5 x X14-2 Plug connection on A1100, 5-pin
104 Pressure cut-off valve X51 Plug connection on A1009, 3-pin
510 Auxiliary spool AHS 11 X52 Plug connection on A1009, 3-pin
511 Secondary pressure relief valve with X53 Plug connection on A1009, 3-pin
additional pressure level /
cylinder 537 retracted, or hammer
512 Secondary pressure relief valve / exten- X54 Plug connection on A1009, 3-pin
ding cylinder 537
514 Pressure balance X55 B33 plug connection, 3-pin
517 Restrictor check valve X139 Plug connection revolving deck CS, 3-
pin
535 Hydraulic hammer X140 Plug connection terminal 15 kit, 2-pin
536 Pile driver X207 Plug connection on A1100, 2-pin
537 Shear X214-3 Plug connection on A1100, 2-pin
538 Stop cock X232 Plug connection on A1100, 10-pin
A1009 Printed circuit board / kit X233 Plug connection on A1100, 3-pin
A1100 ESP 02 printed circuit board Y91 Solenoid valve / secondary pressure
hammer
B33 Pressure switch / flow limitation
16.45.10 A 900 C-LI 14675-

MJFCIFSS
Electrical diagram
6 Electrical diagram
Fig. 10 Electrical diagram AHS 11
A 900 C-LI 14675- 16.45.11

MJFCIFSS
Hydraulic diagram
7 Hydraulic diagram
16.45.12 A 900 C-LI 14675-

MJFCIFSS
Service Manual Accessory kit AHS 11 with Tool Control
Function
Accessory kit AHS 11 with Tool Control
1 Function
attachments to a machine:
Hydraulic hammer
Scrap shear
Concrete crusher
Sorting grapple
Fig. 1 Machine and hydraulic hammer attachment
16.46.1
copyright by
MJFCIFSS
Accessory kit AHS 11 with Tool Control Service Manual
Function
16.46.2
copyright by
MJFCIFSS
Technical data
2 Technical data

(this valve limits the LS pressure and thus the 350 +10 bar
operating pressure at measuring point 41 in the
control block 100)
Secondary pressure relief valves 511/512
Low-pressure (basic settings) 100 +10 bar
Proportional valve Y414 (with max. current)
High pressure 380 +20 bar
Extending: 200 l/min
Retracting: 200 l/min
Measure Y of stop screw 510.2 14.2 mm
16.46.3
copyright by
MJFCIFSS
Description
3 Description
The accessory kit includes the following components:

Auxiliary control axle 510 with pressure relief valves 511 (bottom) and 512 (top)
Proportional valve Y414
Pilot control unit 86
The auxiliary control axle 510 is flange-connected to the control valve block 100. The proportional
valve Y414 is screwed to the bracket of the control valve block 100.
The pressure switch B33 used to limit the flow is secured with screws to the side of the uppercarriage.
The pilot control unit 86 is equipped with pedals for the control of the attachment and is integrated
into the pedal plate to the left. The hydraulic connections are equipped with a shuttle valve 90 in-
stalled at the rear of the control valve block 100.
Fig. 2 Hydraulic unit AHS 11 with Tool Control
86 Pilot control unit two-fold, with pedal 510 Auxiliary control axle
88P Distributor 511 Pressure-relief valve
88T Collecting pipe 512 Pressure-relief valve
90 Shuttle valve B33 Pressure switch / flow limitation
100 Control valve block Y414 Prop. valve
16.46.4
copyright by
MJFCIFSS
Description
Fig. 3 Hydraulic system from serial no. 25000
86 Pilot control unit two-fold, with pedal 510 Auxiliary control axle
88P Distributor 511 Pressure-relief valve
90 Shuttle valve B33 Pressure switch / flow limitation
91 Retaining plate Y414 Prop. valve
100 Control valve block
16.46.5
copyright by
MJFCIFSS
The accessory kit AHS 11 allows the operator to work with ten completely different attachments (con-
One consumer not requiring pressure and/or flow reduction
One consumer requiring pressure and/or flow reduction
Note!
Incorrect pressure or flow reduction settings may result in damage to the attachment (e.g. hydraulic
hammer or reduced tool performance (e.g. mill).
Fig. 4 Pilot control unit 86 and menu display on the screen
Display field TI symbol 1 shows the selected attachment.

The symbol 2 is displayed only, if the attachment is operated with flow reduction.
Note!
The pressure and flow reduction settings must be made at service level 2/3.
For detailed instructions for the adjustment of the pressure and flow reduction settings, see group
16.20.
16.46.6
copyright by
MJFCIFSS
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 BST. The so-
lenoid 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. 5 Sectional drawing of proportional pressure relief valve Y414
16.46.7
copyright by
MJFCIFSS
4.2 Functional description of secondary pressure relief valve 511 / 512

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.
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

by valve Y414 via the connection Y in the pressure relief valve 511 / 512.
rent (which in turn is controlled by the BST), (see "Functional description of proportional pressure re-
lief valve Y414", page 7).
The later valve Y414 is opened via T1, the higher the operating pressure. When the valve Y414 opens
the connection to T1, the pressure of the column in the pressure relief valve is reduced in proportion
to the actual current through the valve. The main cone 5 is thus lifted from its seat and the oil flow
channel P - T is opened. The pressure set in the menu is established.
in the respective menu, see group 16.20.
1 Adjusting screw 12 Bushing

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
16.46.8
copyright by
MJFCIFSS
Fig. 6 Function of pressure control system
16.46.9
copyright by
MJFCIFSS
Caution!
Adjustment and setting may only be undertaken by skilled and well trained personnel.

Note!
5.2 Adjustment of the pressure reduction system (low pressure)

Select mode P.
In menu "opt.1", set EV6 to 0%.
Operate the left pedal m and then the right pedal k.
For nominal pressure at the measuring point 45 (basic settings), (see "Technical data",
page 3).
Adjust the secondary pressure relief valve 512.
Operate the left pedal m and check the pressure at the measuring point 45.
Operate the right pedal k and check the pressure at the measuring point 45.
The two measured pressures must be identical.
16.46.10
copyright by
MJFCIFSS
Fig. 7 Adjusting points and operation
16.46.11
copyright by
MJFCIFSS
5.3 Adjustment of pressure reduction system (high pressure)

Set pressure cut-off valve 104 to a higher value range (400 bar at measuring point 45).
Connect the pressure sensor to the measuring point 45, see Fig. 7.
Select mode P.
Operate left or right pedal.
High pressure at the measuring point 45 (basic settings), (see "Technical data", page 3)
Adjust the screw 20 at the proportional valve Y414 until the prescribed high pressure is reached.
Compare pressure at the left and right foot pedal.
Fig. 8 Pedal 86 in operator's cab and Y 414
a = up to serial no 24999: located below the control valve block

b = from serial no. 25000: mounted to the uppercarriage
5.3.1 Adjustment of the pressure cut-off valve 104, see Fig. 7

Select mode P.
Move the stick cylinder to the stop and adjust the pressure cut-off valve 104 to the required pres-
sure (see Tab. 1, page 3) by turning the adjusting screw.
16.46.12
copyright by
MJFCIFSS
The stroke of the spool 510 for maximum oil flow is factory set by means of the stroke limitation 510.1
/ 510.2 and should not be modified.
The dimension Y, (see Tab. 1, page 3) 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 adjusted.
16.46.13
copyright by
MJFCIFSS
Hydraulic diagram
6 Hydraulic diagram
16.46.14
copyright by
MJFCIFSS
Electrical system
7 Electrical system
Fig. 11 Electric diagram of Tool Control
16.46.15
copyright by
MJFCIFSS
Electrical system
1 to tank 18/C data to BBT (flow reduction)

20 from variable-displacement pump A1009 Decay diode board
41 Measuring point MP A1001 Printed circuit board ESP02
45 Measuring point LS B33 Pressure switch / flow limitation
50 from the control oil unit F5 A1100 fuse (15A)
86 Pilot control unit two-fold, with pedal F11 A1100 fuse X214-3
88P Distributor H44 LED: power supply class 15

88T Collecting pipe H47 LED: power supply
SF2,SF3,SF4
90 Shuttle valve H55 LED power supply X214-3
100 Compact control block 5 x S88 Plug/4-pin to switch
104 Pressure cut-off valve U16 Excavator control system BST
510 Auxiliary spool AHS 11 V152 Amplifier (A1100) SF3 kit
511 Secondary pressure relief valve with X14-2 Plug connection on A1100 / 5-pin
512 Secondary pressure relief valve / exten- X51 Plug connection on A1009 / 3-pin
ding cylinder 537
514 Pressure balance X52 Plug connection on A1009 / 3-pin
517 Restrictor check valve X53 Plug connection on A1009 / 3-pin
535 Hydraulic hammer X54 Plug connection on A1009 / 3-pin
536 Pile driver X55 Plug connection on A1009 / 3-pin
537 Shear X135 BST plug / 40-pin
538 Stop cock X139 Plug connection to CS B33 / 3-pin
X140 Plug connection to CS revolving deck /
2-pin
X207 Plug connection on A1100 for SF3 / 2-
pin
X214-3 Plug connection on A1100 / 2-pin
X232 Plug connection on A1100 / 10-pin
X233 Plug connection on A1100 to B33 / 3-pin
Y61 Solenoid valve (only AHS12)
Y414* Prop.solenoid valve / pressure limitation
X1144 Plug connection / 2-pin
16.46.16
copyright by
MJFCIFSS
Function
Accessory kit AHS 12
1 Function
attachments with two hydraulic cylinders to a machine:
Hydraulic boom adjustment, vertical and horizontal or with offset boom bearing
Boom, laterally adjustable with scrap shear or concrete crusher
Hydraulic boom adjustment with telescopic demolition stick and hydraulic hammer
Fig. 1 Hydraulic boom adjustment A, hydraulic hammer B, telescopic demolition stick C
A 900 C-LI 14675- 16.48.1

MJFCIFSS
General information

Secondary pressure-relief valves 501 and 502 380 +20 bar
for cylinder 525
Secondary pressure-relief valve with additional
pressure level 511 200 +10 bar (*)
Level 1 (hydraulic hammer 535) 380 +10 bar
Level 2 (oil motor 536 / cylinder 537)
Secondary pressure relief valves 512 380 +20 bar
for oil motor 536 or cylinder 537 respectively (200 bar #)
retracting: 200 I/min
Stroke limitation of the spool 500-520

(*) Always observe the instructions and specifications of the hammer manufacturer, see also group 16.22.
(#) In machines with the auxiliary attachments "45° offset boom bearing" or "lateral boom adjustment",
the secondary valve 502 controlling the flow at the piston side of the cylinder 517 is set to 200 bar and acts as a primary
pressure relief valve.
16.48.2 A 900 C-LI 14675-

MJFCIFSS
The accessory kit AHS 12 allows the operator to work with a range of completely different attach-
ments (consumers) using a single kit type:
Operation of the cylinder, e.g. for hydraulic boom adjustment, demolition stick, scrap shear, con-
crete crusher or sorting grapple
Operation of the hydraulic hammer
Note!
Caution!
Fig. 2 Pilot control unit 86 and key switch S88
Operate the switch S38 (SF3) at the right control desk to switch over the pilot control via the solenoid
valve Y61 from spool 500 to spool 510.
Operation of the boom regulating cylinder:

Switch S38 is deactivated.
Key switch S88 is disabled.
The boom regulating cylinder is extended, i.e. the attachment is moved upwards.
The boom regulating cylinder is retracted, i.e. the attachment is moved downwards.
When the key switch S88 is in "hammer" position, the pressure relief valve 511 (with additional pres-
sure level) is set to the reduced pressure value.
By operating the switch S88 at the right control desk, the pilot control system is switched over by
means of the solenoid valve Y91 (see Fig. 10) to the respective functional position.
A 900 C-LI 14675- 16.48.3

MJFCIFSS
Attachment with reduced pressure

Example: Hydraulic hammer
Press switch S38.
Turn the key switch S88 to position "hammer" in order to activate the flow limitation and pressure
reduction.
If required, select flow reduction in the operator's menu.
The hydraulic hammer is operated.
By changing from position "hammer" to position "cylinder", the pressure relief valve 511 (Fig. 6)
with additional pressure level (via solenoid valve Y91) is set to the maximum pressure value:
Attachment with high pressure (cylinder movement):
Example: Scrap shear
Turn the key switch S88 to position "cylinder".
The cylinder is extended, i.e. the scrap shear is closed.
The cylinder is retracted, i.e. the scrap shear is opened.
3.1 Flow reduction in "hammer" position
Fig. 3 Main screen and proportional solenoid valve Y51 for flow reduction in the control oil unit
50
The "flow reduction" function is implemented by means of the proportional solenoid valve Y51 in con-
junction with the excavator control system U16, see group 16.20.
Note!
With the flow limitation options I1 of the main screen, preset (maximum or reduced) pump flow vo-
lumes can be assigned to the attachment.
The flow limitation settings are accessible at authorisation level 2 by technicians who have a ser-
vice plug, which allows them to access the "set pumps" menu (see group 8.71).
16.48.4 A 900 C-LI 14675-

MJFCIFSS

Note!
511
Disconnect the control line from the additional pressure level 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 to the hammer and seal it.
Only required, if a hydraulic hammer is to be attached.
Fig. 4 Secondary pressure-relief valve 511 with additional pressure level
A 900 C-LI 14675- 16.48.5

MJFCIFSS
4.2.1 Adjustment of pressure level 2 (higher pressure level)

Loosen the lock nut 14.2 and block the shifting piston 12 by screwing in the adjusting screw 11.
Pressurise the hydraulic hammer 535 to the limit, or move the cylinder 537 to the stop.
Loosen the lock nut 14.1 and turn the adjusting screw 10 at the pressure relief valve 511 until the
pressure sensor indicates the nominal pressure, see Tab. 1.
Reset the system to pressure level 1.
4.2.2 Adjustment of pressure level 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 indicates the
nominal pressure, see Tab. 1.
Reconnect the control line to the connection X .
Set the pressure cut-off valve 104 (Fig. 6) to the prescribed value.
Fig. 5 Sectional drawing of the secondary pressure relief valve 501
16.48.6 A 900 C-LI 14675-

MJFCIFSS
4.3 Checking and adjustment of the secondary pressure relief valve 501 / 502 / 512

Extend/retract the cylinder 525 / 537 to its stop.
Screw in the pressure cut-off valve 104 (the pressure must be above the adjustment pressure of
the secondary pressure relief valve 501, 502, 512).
Turn the adjusting screw at the secondary pressure relief valve 501, 502, 512 until the pressure
sensor indicates the nominal pressure, see Tab. 1.
4.4 Adjustment of the pressure cut-off valve 104, see Fig. 6

Move the stick cylinder to the stop and set the pressure cut-off valve 104 to the required pressure
by turning the adjusting screw, see Tab. 1.
A 900 C-LI 14675- 16.48.7

MJFCIFSS
4.5 Adjustment of the stoke limitation of the spool 500 / 510
Fig. 7 Adjustment of the stoke limitation of the spool 500 / 510
The stroke of the spool 500 /510 for maximum oil flow is factory-set by means of the stroke limiter
500.1 / 500.2, 510.1 / 510.2 and should not be modified.
The dimension Y, see Tab. 1 serves as a reference value for the prescribed settings. If dimension Y
does not correspond to the prescribed value, adjust the stroke limiter as follows:
16.48.8 A 900 C-LI 14675-

MJFCIFSS
Exploded view
5 Exploded view
Fig. 8 Hydraulic connections AHS 12
Fig. 9 Electrical diagram AHS 12
A 900 C-LI 14675- 16.48.9

MJFCIFSS
Exploded view
1 to tank 537 Shear

20 from variable-displacement pump 538 Stop cock
41 Measuring point MP A1009Printed circuit board / kit
45 Measuring point LS A1100ESP 02 printed circuit board
50 from the control oil unit B33 Pressure switch flow reduction
86 Pilot control unit two-fold, with pedal F5 Fuse / amplifier V151 (15A)
88P Distributor F11 Fuse / spare plug X214-3
88T Collecting pipe H44 LED termina15 power supply
100 Compact control block H47 LED power supply SF2, SF3, SF4
104 Pressure cut-off valve H55 LED power supply X214-3
500 Auxiliary spool AHS 1 S38 Switch
501 Secondary pressure relief valve / retrac- S88 Key switch
ting cylinder 525
502 Secondary pressure relief valve / exten- MP86 Ground connection behind the operator's
ding cylinder 525 cab
504 Pressure balance V152 Amplifier / kit AHS 12
507 Restrictor check valve X51 Plug connection on A1009, 3-pin
510 Auxiliary spool AHS 11 X53 Plug connection on A1009, 3-pin
511 Secondary pressure relief valve / retrac- X54 Plug connection on A1009, 3-pin
ting cylinder 517 or hammer
512 Secondary pressure relief valve / exten- X55 B33 plug connection, 3-pin
ding cylinder 517
514 Pressure balance X139 Plug connection revolving deck CS, 3-pin
517 Restrictor check valve X140 Plug connection terminal 15 kit, 2-pin
525 Regulating cylinder X207 Plug connection on A1100, 2-pin
526 Load holding valve X214 Plug connection on A1100, 2-pin
527 Load holding valve X233 Plug connection on A1100, 3-pin
535 Hydraulic hammer Y61 Solenoid valve / changeover hammer
536 Pile driver Y91 Solenoid valve / secondary pressure ham-
mer
16.48.10 A 900 C-LI 14675-

MJFCIFSS
Electrical diagram
Fig. 10 Electrical system AHS 12
A 900 C-LI 14675- 16.48.11

MJFCIFSS
Hydraulic diagram
7 Hydraulic diagram
16.48.12 A 900 C-LI 14675-

MJFCIFSS
Function
Accessory kit AHS 12 with Tool Control
1 Function
attachments with two hydraulic cylinders to a machine:
Hydraulic boom adjustment, vertical and horizontal or with offset boom bearing
Boom, laterally adjustable with scrap shear or concrete crusher
Hydraulic boom adjustment with telescopic demolition stick and hydraulic hammer
Fig. 1 Hydraulic boom adjustment A, hydraulic hammer B, telescopic demolition stick C
16.49.1
copyright by
MJFCIFSS
Function
16.49.2
copyright by
MJFCIFSS
Technical data
2 Technical data

operating pressure at measuring point 41 in the
control block 100)
Secondary pressure relief valves 501 and 502 380 +20 bar
for cylinder 525
Secondary pressure relief valves 511/512
Low-pressure (basic settings) 100 +10 bar
Proportional valve Y414 (with max. current)
High pressure 380 +20 bar
Stroke limitation of the spools 500-520

16.49.3
copyright by
MJFCIFSS
Description
3 Description
The accessory kit includes the following components:

Auxiliary control axle 500, 510 with pressure relief valves 501, 502, 511 and 512
Proportional valve Y414
Pilot control unit 86
The auxiliary control axles 500 / 510 are flange-connected to the control valve block 100. The pro-
portional valve Y414 is screwed to the bracket of the control valve block 100.
The pressure switch B33 used to limit the flow is secured with screws to the side of the uppercarriage.
The pilot control unit 86 is equipped with pedals for the control of the attachment and is integrated
into the pedal plate to the left. The hydraulic connections are equipped with a shuttle valve 90 in-
stalled at the rear of the control valve block 100.
The solenoid valve Y61 used to switch between the auxiliary axles 500 and 510 is located behind the
operator's cab and screwed to the uppercarriage.
Fig. 2 Hydraulic system AHS 12 with Tool Control up to serial no. 24999
86 Pilot control unit two-fold, with pedal 502 Pressure-relief valve

88P Distributor 510 Auxiliary control axle AHS 11
90 Shuttle valve 512 Pressure-relief valve
16.49.4
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MJFCIFSS
Description
100 Control valve block B33 Pressure switch / flow limitation

500 Auxiliary control axle AHS 12 Y61 Solenoid valve / changeover hammer
501 Pressure-relief valve Y414 Prop. valve
Fig. 3 Hydraulic system from serial no. 25000
86 Pilot control unit two-fold, with pedal 502 Pressure-relief valve

88P Distributor 510 Auxiliary control axle AHS 11
90 Shuttle valve 512 Pressure-relief valve
91 Retaining plate B33 Pressure switch / flow limitation
100 Control valve block Y61 Solenoid valve / changeover hammer
500 Auxiliary control axle AHS 12 Y414 Prop. valve
16.49.5
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MJFCIFSS
The accessory kit AHS 12 allows the operator to work with ten completely different attachments (con-
Caution!
Beim
Note!
Fig. 4 Pilot control unit 86 and menu display on the screen
Display field TI symbol 1 shows the selected attachment.

The symbol 2 is displayed when the pressure switch B33 (flow limitation) is switched.
By actuating the switch S38 (SF3) located on the right control desk, the pilot control can be swit-
ched from spool 500 to spool 510 by means of the solenoid valve Y61.
Note!
For detailed instructions for the adjustment of the pressure and flow reduction settings, see group
16.20.
16.49.6
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MJFCIFSS
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 BST. The so-
lenoid 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. 5 Sectional drawing of proportional pressure relief valve Y414
4.2 Functional description of secondary pressure relief valve 511 / 512

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.
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).
16.49.7
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MJFCIFSS
4.3 Proportional pressure control

by valve Y414 via the connection Y in the pressure relief valve 511 / 512.
rent (which in turn is controlled by the BST).
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.
in the respective menu, see group 16.20.
1 Adjusting screw 7 Housing

2 Lock nut 8 Cone
4 Pilot control cone 10 Screw plug
5 Main cone 11 Pressure spring
6 Screw plug 12 Bushing
16.49.8
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MJFCIFSS
Fig. 6 Secondary pressure relief valve 511 / 512
16.49.9
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MJFCIFSS
Caution!
Adjustment and setting may only be undertaken by skilled and well trained personnel.

Note!
5.2 Adjustment of the pressure reduction system (low pressure)

Select mode P.
Operate the left pedal m and then the right pedal k.
For nominal pressure at the measuring point 45 (basic settings), (see "Technical data",
page 3).
Operate the left pedal m and check the pressure at the measuring point 45.
Operate the right pedal k and check the pressure at the measuring point 45.
16.49.10
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MJFCIFSS
Fig. 7 Adjusting points and operation
16.49.11
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MJFCIFSS
5.3 Adjustment of pressure reduction system (high pressure)

Set pressure cut-off valve 104 to a higher value range (400 bar at the measuring point 45)
Connect the pressure sensor to the measuring point 45, see Fig. 7.
Select mode P.
Operate left or right pedal.
For nominal high pressure at the measuring point 45 (basic settings), (see "Technical data",
page 3).
Adjust the screw 20 at the proportional valve Y414 until the prescribed high pressure is reached.
Compare pressure at left and right foot pedal.
Fig. 8 Pedal 86 in operator's cab and Y 414 installed below the control valve block
a = up to serial no 24999: located below the control valve block

b = from serial no. 25000: mounted to the uppercarriage
16.49.12
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MJFCIFSS
5.4 Checking and adjustment of the secondary pressure relief valve 501 / 502
Fig. 9 Auxiliary control valve blocks AHS 12 with secondary pressure relief valves 501, 502

Extend/retract the cylinder 525 / 537 to its stop.
Turn in the pressure cut-off valve 104 (pressure must be above the prescribed pressure for the
secondary pressure relief valve 501, 502 ).
Turn the adjusting screw at the secondary pressure relief valve 501, 502 until the pressure sensor
indicates the prescribed pressure, (see "Technical data", page 3).
5.5 Adjustment of the pressure cut-off valve 104

Select mode P.
sure (see "Technical data", page 3) by turning the adjusting screw.
16.49.13
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MJFCIFSS
5.6 Adjustment of the stroke limitation of the spools 500 /510
Fig. 10 Stroke limitation of the spools 500 / 510
The stroke of the spool 500 / 510 for maximum oil flow is factory-set by means of the stroke limiters
500.1 / 500.2 and 510.1 / 510.2 and should not be modified.
The dimension Y, (see "Technical data", page 3) serves as a reference value for the prescribed set-
tings. If dimension Y does not correspond to the prescribed value, adjust the stroke limiter as follows:
Remove the protective cap 1.3, loosen the lock nut 1.2 and turn the stop screw 1.1 until dimension
Y is adjusted.
16.49.14
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MJFCIFSS
Hydraulic diagram
6 Hydraulic diagram
16.49.15
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MJFCIFSS
Electrical system
7 Electrical system
16.49.16
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MJFCIFSS
Electrical system
1 to tank 18/C data to BBT (flow reduction)

20 from variable-displacement pump A1009 Decay diode board
41 Measuring point MP A1001 Printed circuit board ESP02
45 Measuring point LS B33 Pressure switch / flow limitation
50 from the control oil unit F5 A1100 fuse (15A)
86 Pilot control unit two-fold, with pedal F11 A1100 fuse X214-3
88P Distributor H44 LED: power supply class 15

88T Collecting pipe H47 LED: power supply
SF2,SF3,SF4
90 Shuttle valve H55 LED power supply X214-3
100 Compact control block 5 x S88 Plug/4-pin to switch
104 Pressure cut-off valve U16 Excavator control system BST
510 Auxiliary spool AHS 11 V152 Amplifier (A1100) SF3 kit
511 Secondary pressure relief valve with X14-2 Plug connection on A1100 / 5-pin
512 Secondary pressure relief valve / exten- X51 Plug connection on A1009 / 3-pin
ding cylinder 537
514 Pressure balance X52 Plug connection on A1009 / 3-pin
517 Restrictor check valve X53 Plug connection on A1009 / 3-pin
535 Hydraulic hammer X54 Plug connection on A1009 / 3-pin
536 Pile driver X55 Plug connection on A1009 / 3-pin
537 Shear X135 BST plug / 40-pin
538 Stop cock X139 Plug connection to CS B33 / 3-pin
X140 Plug connection to CS revolving deck /
2-pin
X207 Plug connection on A1100 for SF3 / 2-
pin
X214-3 Plug connection on A1100 / 2-pin
X233 Plug connection on A1100 to B33 / 3-pin
Y61 Solenoid valve AHS12
Y414 Prop.solenoid valve / pressure limitation
Note!
* From serial no. 25000, connection T is located at the solenoid valve Y414 and directly at the tank 1.
16.49.17
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MJFCIFSS
Electrical system
16.49.18
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MJFCIFSS
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
Pile driver
Scrap shear
Concrete crusher
Sorting grapple
and with AHS 12 in combination with hydraulic boom adjustment
Fig. 1 Machine with monoblock or adjustable attachment and hydraulic hammer attachment
16.50.1
copyright by
MJFCIFSS
Accessory kit AHS 11 / AHS 12 with Tool Control Service Manual
Function
16.50.2
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MJFCIFSS
Technical data
2 Technical data

operating pressure at the measuring point 41)
in the valve plate 100
Secondary pressure-relief valves 501 / 502 in au-
xiliary way valve 500
(these valves limit the working pressure at the
consumer to the preset variable value)
Measuring point 45
Secondary pressure-relief valves 501
Low pressure (EV6 set to 0%) 120 +10 bar
High pressure (EV6 set to 100%) 380 +20 bar

Secondary pressure-relief valves 502
Low pressure (EV6 set to 0%) 120 +10 bar
High pressure (EV6 set to 100%) 380 +20 bar

Pressure during hammer operation (*) or boom 200 bar
adjustment / 45° offset boom bearing (#)
Secondary pressure-relief valves 521 / 522 in au-
xiliary way valve 520 380 +20 bar
(these valves limit the working pressure at the
consumer to the preset value)
Measuring point 45
Flow rate at output A6 / B6 / A7 / B7
Stroke limiter of the spool 500 / 520
Dimension Y of stop screw 500.1 / 520.1 18.5 mm
Dimension Y of stop screw 500.2 / 520.2 18.5 mm
(*) always observe the instructions and specifications of the hammer manufacturer (see also group 16.22)
(#) In machines with the auxiliary attachments "45° offset boom bearing" or "lateral boom adjustment", the secondary val-
ve 502 controlling the flow at the piston side of the cylinder 502 is set to 200 bar.
16.50.3
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MJFCIFSS
Design
3 Design
The accessory kit AHS 11 includes the following components:

Auxiliary way valve 500, pressure-relief valves 501 and 502 with control pressure build-up.
Proportional solenoid valve Y414.
Pilot control unit 86 with shuttle valve 566 and pressure switch B33.
The proportional solenoid valve Y414 is screwed to the control oil unit 50.
The pressure switch B33 with the shuttle valve 566 used to limit the flow is screw-mounted to the rear
of the operator's cab on the machine uppercarriage.
The pilot control unit 86 is equipped with pedals for the control of the attachments and is integrated
into the pedal plate to the left.
1 Hydraulic tank 502 Pressure-relief valve with additional pres-

sure stage
50 Control oil unit 565 Measuring point - control pressure
86 Pilot control unit two-fold, with pedals 566 Shuttle valve
88P Distributor B33 Pressure switch / flow limitation
88T Collecting pipe Y51 Prop. solenoid valve / flow control
500 Auxiliary way valve Y414 Prop. solenoid valve / pressure reduction
16.50.4
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MJFCIFSS
Design
501 Pressure-relief valve with additional pres-

sure stage
The accessory kit AHS 12 includes the following components:

Auxiliary way valves 500 / 520.
Proportional solenoid valve Y414.
Pilot control device 86 with shuttle valve 566 and pressure switch B33.
Solenoid valve Y61 for changeover between AHS11 and AHS12.
50 Control oil unit 520 Auxiliary way valve / regulating cylinder

86 Pilot control unit two-fold, with pedal 565 Measuring point / control pressure
88P Distributor 566 Shuttle valve
88T Collecting pipe B33 Pressure switch / flow limitation
500 Y61 Solenoid valve / changeover
501 Pressure-relief valve with additional pres- Y414 Prop. solenoid valve / pressure reduction
sure stage
502 Pressure-relief valve with additional pres-
sure stage
16.50.5
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MJFCIFSS
The auxiliary axle 500/520 of the accessory kit AHS 11 / AHS 12 allows the operator to work with
ten completely different attachments (consumers) using a single kit type:
Note!
To ensure proper use and functioning of the accessory kit, the connected units must be operated
according to the instructions in this manual:
Before starting the mounted attachment, the necessary pressure and flow reduction must be se-
lected in the "set options" (EV1 for flow rate in% and EV6 for pressure in %).
The selected tool (e.g. "Hammer") is shown in the display field 1.
Control the attachment using the pedals m and / or k of the pilot control unit 86.
Symbol "R" in field 2 is displayed only, if the attachment is operated with flow reduction.
Fig. 4 Pilot control unit and menu display on the screen
1 Attachment display 86 Pilot control unit for accessory kit

2 Symbol for flow reduction
16.50.6
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MJFCIFSS
Note!
For detailed instructions regarding the adjustment of the pressure and flow reduction settings, see
group 16.21.
4.1 Function AHS 11 with Tool Control, see Fig. 10 and Fig. 11
When the pilot control unit 86
is actuated, 1.
the ppressure switch B33 is pressurised through the shuttle valve 566.
The pressure switch B33 issues a signal through the printed circuit board A1100 and the BBT
(display/switching unit) to the BST U16.
U16 energises the proportional solenoid valve Y51 according to the stored value for flow re-
duction (selected in the "set option" menu).
Y51 feeds the resulting control pressure to the flow regulator at the pump and thus reduces
the regular -p value.
The pump flow rate is reduced.
U16 energises the proportional solenoid valve Y414 based on the saved pressure reduction
value (selected in "set option" menu) with a specific current.
Y414 feeds the resulting control pressure to the port Z of the two pressure-relief valves 501 /
502.
The setting pressure of the valves 501 / 502 is adjusted to the corresponding value.
2.
the auxiliary way valve 500 is pressurised with the preset control pressure through the port X / Y.
The spool 503 of the way valve 500 is shifted.
The reduced flow of the pump 20 reaches the consumer through port A / B.
The reduced high pressure pressurises the consumer 515 / 516 / 517 of the auxiliary attach-
ment.
4.2 Function of the proportional solenoid valve Y414, see Fig. 10 and Fig. 11
In order to achieve proportional pressure control, the pressure in the consumer circuit is controlled
by the valve Y414 via the connection Z at the pressure-relief valve 501 / 502.
This valve allows you to steplessly adjust the working pressure to be restricted, in proportion to an
electric nominal value.
To adjust the working pressure (high pressure), select the respective option in the BBT. The BBT
forwards this data to the BST, which then energises the magnetic coil of the valve Y414 , according
to the selected option.
At nominal value 0 or in the event of a power failure, the minimum pressure is established.
Control oil enters the the system through a pressure channel in the control oil unit 50, reaching the
flange-mounted housing of the valve Y414.
The proportional solenoid valve Y414 converts the electrical current into mechanical force, which
then acts on the integrated piston. The piston opens the control edge to the pressure connection and
regulates the pressure at the two secondary pressure-relief valves 501 / 502. The greater the current
to the proportional solenoid valve Y414, the greater the control pressure to the port Z of the pressure-
relief valves 501 / 502. The pressure increase in the pressure-relief valve is proportional to the ap-
plied current.
16.50.7
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MJFCIFSS
The pilot-controlled pressure-relief and suction valve ensures the pressure and sucks up oil. The pilot
control cone 4 is pre-loaded with the pressure spring 5 and the main cone 2 is hydraulically inserted.
The pilot control cone 4 and the main cone 2 are opened as soon as the pressure value is reached.
The preload of the pressure spring 5 and thus the pressure settings are determined based on the
force applied to the piston 7:
4.3.1 without application of control pressure (low pressure)

The force applied to the piston 6 is determined by the adjusting screw 11. The further the piston 6 is
pushed inwards through the adjusting screw 11, the greater the preload force of the pressure spring
5 and thus the adjusting pressure of the valve 501 / 502.
4.3.2 with application of control pressure (high pressure)

If the port Z is pressurised through the proportional solenoid valve Y414 with a preset control pres-
sure, the same pressure is applied through the bore Z1 to the piston 7 an. The piston 7 applies an
additional force to the piston 6. As a result, the total preload force applied to the pressure spring 5 is
increased, and thus also the pressure of the valve. The maximum value for the pressure increase can
be adjusted with the limiter screw 11.
Fig. 5 Pressure-relief valve with external additional control pressure stage
16.50.8
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MJFCIFSS
Pressure test and settings of the valves 501 / 502
1 Valve cartridge 10 Lock nut

2 Main cone 11 Adjusting screw / low pressure
4 Pilot control cone 13 Adjusting screw characteristic
8 Pressure spring Z Control pressure connection of Y414
9 Adjusting screw / high pressure Z1 Bore / oil channel
5 Pressure test and settings of the valves 501 / 502
(see Pressure testing and adjustment for AHS11 / AHS12 on page 12)
Caution!
HERR technicians.
Adjustment and setting work may only be carried out by skilled and suitable trained maintenance
personnel.

Note!
If the attachment is not actuated, no pressure may be measured at measuring point 565.
If required, bleed the control circuit through the measuring point 565.
5.2 Testing and adjustment of the pressure-relief valves (high pressure)

Set pressure cut-off valve 101 to a higher value range (400 bar at the measuring point 45)
Select mode P.
Press down the left pedal m and retract the cylinder 517 to the stop.
Press down the right pedal k and extend the cylinder 517 to the stop or pressurise the hammer
515 to the maximum pressure value.
Check the high pressure at the measuring point 45, (see Technical data on page 3).
The pressures measured at the two valves 501 / 502 must be identical.
If the prescribed pressure value is not reached:
16.50.9
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MJFCIFSS
Check whether there is any pressure at the measuring point 565.

If the pressure corresponds to the prescribed value (see diagram in group 16.21), correct the
set value of the secondary pressure-relief valve 501 / 502. see 5.4.
If there is no pressure, correct the set value of the proportional solenoid valve Y414, see 5.6.
5.3 Testing and adjustment of the pressure-relief valves (low pressure)

Select mode P.
Press down the left pedal m and extend the cylinder 517 to the stop.
Press down the right pedal k and extend the cylinder 517 to the stop or pressurise the hammer to
the maximum pressure value.
Check the low pressure at the measuring point 45, (see Technical data on page 3).
The pressures measured at the two valves 501 / 502 must be identical.
If the prescribed pressure value is not reached:
Check whether there is any pressure at the measuring point 565.
If there is no pressure at the measuring point, correct the set value of the secondary pressure-
relief valve 501 / 502, see 5.4.
If the pressure does not correspond to the prescribed value, correct the set value of the pro-
portional solenoid valve Y414, see 5.6, or locate the fault and eliminate it.
5.4 Correcting the set value of the secondary pressure-relief valve 501 / 502:
Remove the screw connection to port Z and seal the line.
Press down the left pedal m (for valve 501) or the right pedal k (for valve 502) respectively.
Adjust the high pressure value and then the low pressure value:
5.4.1 Adjustment of pressure stage I (high pressure)

Remove the lock nut 12 and turn the adjusting screw 11 as required (to the block).
Loosen the lock nut 10.
Turn the adjusting screw 9 until the prescribed pressure is measured at the measuring point 45.
Tighten the lock nut 10 with a torque of 70 Nm.
Adjust pressure stage II (low pressure) value.
5.4.2 Adjustment of pressure stage II (low pressure)

Turn the adjusting screw 11 until the prescribed pressure is measured at the measuring point 45.
Tighten the lock nut 12 with a torque of 50 Nm.
16.50.10
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MJFCIFSS
Fig. 6 Pressure-relief valve with additional pressure stage
9 Adjusting screw / high pressure 501 Pressure-relief valve

10 Lock nut 502 Pressure-relief valve
11 Adjusting screw / low pressure Z Control pressure connection of Y414
12 Lock nut
5.5 Adjustment of the pressure cut-off valve 101, see Fig. 7

Select mode P.
sure (see Tab. 1 on page3) by turning the adjusting screw.
16.50.11
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MJFCIFSS
Fig. 7 Pressure testing and adjustment for AHS11 / AHS12
41 Measuring point -xP 502 Pressure-relief valve with additional pressure

stage
45 Measuring point -xLS 520 AHS12 way valve
86 Accessory kit pilot control unit 521 Secondary pressure-relief valve
101 Pressure cut-off valve 522 Secondary pressure-relief valve
500 AHS11 way valve 565 Measuring point for control pressure to the
pressure-relief valves
16.50.12
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MJFCIFSS
501 Pressure-relief valve with additional S38 Switch for pilot control changeover of way
pressure stage valve 500 to way valve 520 and vice versa
5.6 Testing of proportional solenoid valve Y414, see Fig. 8

Connect a current meter to the power connection of the solenoid valve Y414.
Loosen the lock nut 5 at the valve Y414 and turn the adjusting screw 4 until a pressure is measu-
red at the measuring point 565.
Turn back the adjusting screw, until no pressure is measured at the measuring point 565.
Fig. 8 Measuring points, pressure cut-off valve, control oil unit with proportional solenoid valve
3 Plug connection / wire harness 50 Control oil unit

4 Control pressure adjusting screw 101 Pressure cut-off valve
5 Lock nut 565 Measuring point / additional control
pressure stage
41 Measuring point / pump pressure Y414 Proportional solenoid valve
5.7 Adjustment of the stroke limiter of the spool 500 /520

The stroke of the spool 503 / 523 for maximum oil flow is factory-set with the stroke limiter 500.1 /
500.2 and 520.1 / 520.2 and should not be modified.
Remove the safety cap 1.3.
Dimension Y, (see Tab. 1 on page3) serves as a reference value for the prescribed settings. If dimen-
16.50.13
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MJFCIFSS
Hydraulic diagram of AHS 11
sion Y does not correspond to the prescribed value, adjust the stroke limiter as follows:
Loosen the lock nut 1.2 and turn the stop screw 1.1 until dimension Y is reached.
Fig. 9 Stroke limiter of the spool 500 / 520
1.1 Stroke limiter adjusting screw 500 AHS11 way valve

1.2 Lock nut 500.1 Stroke limiter / spool
1.3 Protective cap 500.2 Stroke limiter / spool
100 Valve plate
6 Hydraulic diagram of AHS 11
1 to tank 501 Secondary pressure-relief valve with

additional pressure stage
Retracting cylinder 517
20 from pump 502 Secondary pressure-relief valve /
extending cylinder 517 or hammer
30 from gear pump 503 Spool
49 Measuring point / control pressure 515 Hydraulic hammer
50 Control oil unit 516 Pile driver
86 Pilot control valve, 2 x 517 Auxiliary cylinder
88P Distributor 518 Stop cock
88T Collecting pipe 565 Measuring point / additional control
pressure stage
100 Valve plate 566 Shuttle valve
160 Way valve / travel A1100 Printed circuit board
500 AHS11 way valve B33 Pressure switch / flow limitation
500.1 Stroke limiter / spool U16 from BST
500.2 Stroke limiter / spool Y51 Proportional solenoid valve / flow
500.7 Pressure-relief and bleed valve Y414 Proportional solenoid valve / pressure
500.8 Pressure-relief and bleed valve
16.50.14
copyright by
MJFCIFSS
16.50.15
copyright by
MJFCIFSS
16.50.16
copyright by
MJFCIFSS
7 Hydraulic diagram of AHS 12
1 to tank 518 Stop cock

20 from pump 520 AHS12 way valve
30 from gear pump 520.1 Stroke limiter / spool
49 Measuring point / control pressure 520.2 Stroke limiter / spool
50 Control oil unit 520.7 Pressure-relief and bleed valve
86 Pilot control valve, 2 x 520.8 Pressure-relief and bleed valve
88P Distributor 521 Secondary pressure-relief valve with
88T Collecting pipe 522 Secondary pressure-relief valve /
extending cylinder 535
100 Valve plate 523 Spool
160 Way valve / travel 535 Regulating cylinder
500 AHS11 way valve 536 Load-holding valve
500.1 Stroke limiter / spool 537 Load-holding valve
500.2 Stroke limiter / spool 565 Measuring point / additional control
pressure stage
500.7 Pressure-relief and bleed valve 566 Shuttle valve
500.8 Pressure-relief and bleed valve A1100 Printed circuit board
501 Secondary pressure-relief valve with B33 Pressure switch / flow limitation
502 Secondary pressure-relief valve / exten- S38 Switch / pilot control changeover
ding cylinder 517 or hammer
503 Spool U16 from BST
515 Hydraulic hammer Y51 Proportional solenoid valve / flow
516 Pile driver Y61 Solenoid valve / changeover
517 Auxiliary cylinder Y414 Proportional solenoid valve / pressure
16.50.17
copyright by
MJFCIFSS
Electrical system
8 Electrical system
A1009 Decay diode board X53 Plug connection on A1009 / 3-pin

A1100 Printed circuit board ESP02 X54 Plug connection on A1009 / 3-pin
B33 Pressure switch / flow limitation X55 Plug connection on A1009 / 3-pin
F5 A1100 fuse (15A) X135 BST plug / 40-pin
F11 A1100 fuse X214-3 X139 Plug connection to CS B33 / 3-pin
H44 LED: power supply class 15 X140 Plug connection to CS revolving deck /
2-pin
H47 LED: power supply X207 Plug connection on A1100 for SF3 / 2-
SF2,SF3,SF4 pin
H55 LED power supply X214-3 X214-3 Plug connection on A1100 / 2-pin
S88 Plug / 4-pin to switch X232 Plug connection on A1100 / 10-pin
U16 Excavator control system BST X233 Plug connection on A1100 to B33 / 3-pin
V152 Amplifier (A1100) SF3 kit Y61 Solenoid valve (only AHS12)
X14-2 Plug connection on A1100 / 5-pin Y414 Prop.solenoid valve / pressure limitation
X51 Plug connection on A1009 / 3-pin X1144 Plug connection / 2-pin
16.50.18
copyright by
MJFCIFSS
Service Manual Hydraulic operator's cab elevation
Function/design
Hydraulic operator's cab elevation
1 Function/design
Danger!
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.
Adjust the cab height only when the machine in standing still.
During the adjusting procedure, ensure that no persons are standing in the danger area of the
machine.
Prior to starting the machine, put on the seat belt.
Adjust the stick cylinder shut-down so that the stick with grapple cannot damage the cab when
the latter is at its maximum height and the boom is fully extended.
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 5 m above ground).
The hydraulic operator's cab elevation consists of the following main components:
Cab lift frame
Valve block 20
Lifting cylinder 25
Gear pump 35
Electrical push button S200 / S201 / S78 / S79
To lift / lower the operator's cab, the hydraulic cylinders 25 are pressurised, so that the cab is lifted
on the lift frame.
The oil flow required for this is produced by the gear pump 35 driven directly by the diesel engine .
The oil flow to the cylinders 25 is adjusted by means of the electrically controlled solenoid valve Y200
/ Y201.
Other valves in the valve block ensure the safety and comfort of the operator.
The restrictor check valves 22 built into the cylinders 25 prevent sudden lowering of the cab in the
event of a pipe break.
The operating pressure can be checked at the measuring point 18 at the valve block.
1.1 Control elements of the hydraulic cab elevation system
Fig. 1 Buttons of left bracket
16.60.1
copyright by
MJFCIFSS
Hydraulic operator's cab elevation Service Manual
Function/design
Button S200 Lift operator's cab

Button S201 Lower operator's cab
Button S78 Emergency operation in operator's cab
Button S79 Emergency operation in battery compartment (see Fig. 7 on page8)
1.2 Control elements of operator's cab from serial number 35102
Fig. 2 Changed control elements in left console
Lever switch S408 Lowering/lifting operator's cab

Button S78 Emergency lowering of the operator's cab
Fig. 3 Valve block of the hydraulic operator's cab elevation
16.60.2
copyright by
MJFCIFSS
Function/design
9 Knurled screw for emergency lowering 57 Tank hose

12 Adjusting screw for lifting pressure 58 Pressure line to lifting cylinder 25 rod
side
17 Adjusting screw for pressure-relief valve 60 Pressure line to accumulator 21
18 Measuring connection 61 Pressure line to block ball valve 23,
emergency lowering
20 Valve block (cab elevation system) 62 Pressure line to lifting cylinder 25 piston
side
21 Accumulator 63 Control line "T"
22 Pipe fracture safety valve 64 Control line "P"
23 Block ball valve Y200 Plug-type connection operator's cab
"UP"
25 Cylinder Y201 Plug-type connection operator's cab
"DOWN"
35 Gear pump (operator's cab elevation) Y204 Plug-type connection operator's cab
"emergency lowering"
52 Pressure line of gear pump "P"
16.60.3
copyright by
MJFCIFSS
Function/design
Fig. 4 Hydraulic connections a = to serial no. 26964; b = from serial no. 26965
16.60.4
copyright by
MJFCIFSS
Function/design
Fig. 5 Hydraulic connections from serial number 30580
16.60.5
copyright by
MJFCIFSS
Technical data
2 Technical data
Machine: A 904 C Litronic A 924 C Litronic

Serial number: 16000 34519
Volumetric flow rates
at rated speed (2000 rpm) of diesel engine
Gear pump 35 (operator's cab elevation) 48.5 l/min
from serial no. 26965 35.7 l/min
Settings of valves and units
Solenoid valve 1 Mode P

Adjusting range approx. 10-20 l
Guide value for lifting rate approx. 13-15 seconds
for jerk-free movement of the operator's cab and max. lifting rate by approx. 8.5 mm
adjustment of check measurement X, (see Fig. 10 on page10).
Pressure-relief valve 15
Maximum operating pressure of operator's cab elevation 180 bar
Accumulator 21
for the cushioning of the working movement through measuring point
19 (M2) 40-45 bar
Preload pressure of accumulator 21
Note!
Prior to commissioning the operator's cab elevation system, read the instruction manual.
During commissioning, bleed the control valve block 20 by carefully opening the respective plug.
Before carrying out any repair work on the kit (steel structure, hydraulic or electric system), the cab
must be fully lowered and suitably secured.
16.60.6
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MJFCIFSS
Description of functions, see Fig. 13
3 Description of functions, see Fig. 13
Note!
For details regarding the electrical components and connections of the kit, see circuit diagram from
group 8.103 ff.
3.1 Neutral position of the solenoid valves (Y200 / Y201 and Y204).
The gear pump 35 feeds hydraulic oil to the distribution block 20 through connection P.
When the solenoid valve Y200 / Y201 is in neutral position, the oil flows through the pressure balance
2 and connection T of the valve block 20 to the tank.
When the solenoid valve Y204 is in neutral position, the piston side of the hydraulic cylinder 25 is
sealed from the return line by the stop valve 10, so that the lift frame and the cab remain in the se-
lected position.
The hydraulic system is protected against overpressure by means of the pressure-relief valve 15 that
is installed in the valve block 20.
3.2 Extending cylinder 25 (lifting operator's cab)

Press the button S200 (lever switch S408 in position 1) to switch the solenoid valve Y200. The con-
trol oil switches the spool 13 and opens the connection from P to A.
The oil fed by the pump 35 flows through the connection, internal restrictors and the check valve 8 to
the piston side of the cylinder 25. The return oil flows through the restrictor check valve 11 and the
connection T to the tank.
The operator's cab is lifted as long as the button S200 (S408) is pressed.
3.3 Retracting cylinder 25 (lowering operator's cab)

Press the button S201 (lever switch S408 in position 2) to switch the solenoid valve Y201. The control
oil switches the spool 13 and opens the connection from P to B.
The oil fed by the pump 35 flows through the connection, internal restrictors and the pipe fracture
safety valve 22 to the piston rod side of the cylinder 25. The 2-way valve 10 is in flow-through position.
The return oil is fed through the valve 10 where its flow is restricted, and then through the connection
T to the tank.
The operator's cab is lowered as long as the button S201 (S408) is pressed.
To ensure jerk-free and smooth movement of the cab, the valve block 20 is equipped with the rest-
rictors 4 - 7 and the valve 3.
16.60.7
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MJFCIFSS
Changes to machine operation from serial number 35102:
Fig. 6 Modification of series
Lever switch S408 to position 1 (lifting operator's cab).

Lever switch S408 to position 2 (lowering operator's cab).
3.4 Emergency operation

In the event of a failure of the diesel engine or the control system of the adjustable operator's cab, it
can be lowered manually.
Danger!
Risk of injury from crushing when operator's cab is lowered!
During emergency lowering, keep clear of the danger area to prevent that extremities are caught
by moving parts.
3.5 There are several ways of emergency operation:
Emergency lowering of the operator's cab:

In the event of failure of the hydraulic pump, the operator's cab can be lowered by pressing the button
S78, provided that there is sufficient battery power.
The cab is lowered until the button S78 is released.
Emergency lowering of the cab actuated from outside the cab:
Fig. 7 Emergency lowering button S79 a = to serial no. 22587; = from serial no. 22588
The operator's cab can be manually lowered by pressing the emergency lowering button S79.
Press and hold the emergency lowering button S79 until the cab is fully lowered.
16.60.8
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MJFCIFSS
Emergency lowering in the event of failure of the electrical system:

Danger!
Risk of injury from crushing when operator's cab is lowered!
During emergency lowering, keep clear of the danger area to ensure that no extremities are inad-
vertently caught by moving parts on the control valve block 20.
Slowly open the knurled screw 9.
Monitor the movement of the cab.
In the event of failure of the electrical and hydraulic system, it is possible to lower the operator's cab
by turning out the knurled screw 9 at the emergency discharge valve Y204, which is located in the
cab control / control valve block 20.
For this purpose, the solenoid valve Y204 is operated mechanically, so that the oil at the piston side
of the hydraulic cylinder 25 flows through the pipe fracture safety valve 22 and the solenoid valve
Y204 to the tank. The operator's cab is lowered.
After the operator's cab has been lowered to the stop, turn in the knurled screw 9 to the stop.
Fig. 8 Emergency activation on the solenoid valve Y204
Emergency lowering from outside from serial number 30580:
Fig. 9 Ball valve, emergency lowering of the operator's cab
16.60.9
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MJFCIFSS
Checking and adjustment of the pressure-relief valve 15
The operator's cab can be lowered to the ground by means of the ball valve 23. This valve is located
at rear of the lift frame.
Swivel the ball valve 23 to position 2.
The operator's cab is gradually lowered as long as the ball valve is in position 2.
Note!
If the ball valve is in position 2, the operator's cab cannot be lifted.
After the operator's cab has been fully lowered, turn the ball valve back to position 1.
4 Checking and adjustment of the pressure-relief valve 15
Important adjustment notes:

The pressure adjustments must be made at operating temperature of the hydraulic oil and at the
rated speed.
To adjust the pressure, use suitable pressure gauges.
Note!
Please note that, during the warranty period, work on the valves may only be carried out by LIEB-
HERR technicians.
Fig. 10 Valve block of the hydraulic operator's cab elevation
9 Knurled screw for emergency lowering 17 Adjusting screw

12 Adjusting screw for lifting pressure Y200 Solenoid valve operator's cab "UP"
15 Pressure-relief valve Y201 Solenoid valve operator's cab "DOWN"
16 Lock nut Y204 Solenoid valve operator's cab "emer-
gency lowering"
Connect the pressure gauge to the measuring point 18, (see Fig. 4 on page4).
Move the operator's cab to its top stop.
16.60.10
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MJFCIFSS
Check the pressure at the sensor.

If the prescribed pressure is not reached: adjust the pressure-relief valve 15 accordingly, (see
Technical data on page 6).
Remove lock nut 16 and turn the adjusting screw 17 as required.
Turn in = increase pressure
Turn out = reduce pressure
Re-tighten the lock nut 16.

Remove the pressure gauge.
Note!
If there is a delay in the upward movement of the operator's cab, adjust the flow rate at the spool 13
with the adjusting screw 12. Recommended values, (see Tab. 1 on page6).
4.1 Check of damping accumulator 21
Fig. 11 Damping accumulator 21 and filling device 80
21 Damping accumulator 81 Hexagon insert with knurled screw

72 Plastic cap 82 Union nut
73 Hexagon socket screw 83 Knurled screw for filling
80 Filling device (see group 2.05) 84 Pressure gauge
The damping accumulator 21 is filled to a certain level and pre-loaded at the factory.
If the damping effect of the damping accumulator 21 is not sufficient, check the fill level by completing
the steps below.
Lower the operator's cab to its stop and shut down the engine.
16.60.11
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MJFCIFSS
Note!
In certain cab lift frames, the beam touches the support when the cab is fully lowered. As a result,
there is little space for the operation of the filling device 80.
Support the operator's cab with suitable support gear and secure it properly.
Remove the plastic cap 72 and slightly loosen the hexagon socket screw 73 (WS6).
Mount the filling device 80 to the damping accumulator 21.
Tighten the knurled screw 83 to the stop.
Turn out the hexagon insert with the knurled screw 81.
The filling pressure of the damping accumulator 21 is indicated at the pressure gauge 84.
If the accumulator pressure is within the tolerance range, proceed as described below.
If the accumulator pressure is not within the tolerance range, proceed as described in (see Filling
of damping accumulator 21 when mounted on page 12).
Turn in the hexagon insert with the knurled screw 81.
Open the knurled screw 83 until all pressure is released.
Remove the filling device 80.
Tighten the hexagon socket screw 72 (WS6).
Mount the plastic cap 73.
4.2 Filling of damping accumulator 21 when mounted

The damping accumulator 21 is attached to the cab lift frame, and the filling device 80 is mounted
on the damping accumulator 21.
Loosen the knurled screw 83 slightly until the prescribed pressure is indicated at the pressure gau-
ge, (see Tab. 1 on page6).
Tighten the knurled screw 83.
4.3 Filling of damping accumulator 21 when detached

Carefully disconnect the damping accumulator 21.
Remove the damping accumulator 21 and seal the pressure line.
Place the damping accumulator 21 in a vice or another suitable clamping device.
Remove the plastic cap 72 and slightly loosen the hexagon socket screw 73 (WS6).
Mount the filling device 80 to the damping accumulator 21.
Tighten the knurled screw 83 to the stop.
Turn out the hexagon insert with the knurled screw 81.
Loosen the knurled screw 83 slightly until the prescribed pressure is indicated at the pressure gau-
ge, (see Tab. 1 on page6).
16.60.12
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MJFCIFSS
fault diagnosis
Tighten the knurled screw 83.

Mount the damping accumulator 21 to the cab lift frame.
Connect the pressure line to damping accumulator 21.
5 fault diagnosis
Danger!
Risk to life and limb from dropping operator's cab.
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.
To carry out repair and maintenance work that requires the operator's cab to be elevated:
5.1 Fault
The operator's cab cannot be lowered, despite of the hydraulic and electrical system are working pro-
perly.
5.2 Cause
The pipe fracture safety valve 22 integrated into the cylinder 25 is dirty.
5.3 Remedy
Depressurise the hydraulic system.
Collect escaping oil in a suitable vessel.
Remove the hose lines a screwed to the cylinder 25.
Carefully turn the pipe fracture safety valve 22 from the cylinder bore hole, using pointed pliers.
Clean the pipe fracture safety valve 22 with a suitable detergent.
Re-insert the clean pipe fracture safety valve 22 in the bore hole and tighten it to the stop.
Reconnect the hoses a with the screw connections.
16.60.13
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MJFCIFSS
fault diagnosis
Fig. 12 Faults in the hydraulic operator's cab elevation system
1 to tank 20 Valve block

2 Pressure balance 21 Accumulator
3 Delay valve 22 Pipe fracture safety valve
4 Restrictor Ø 0.6 mm 23 Block ball valve
5 Restrictor Ø 0.6 mm 25 Cylinder
6 Restrictor Ø 0.6 mm 35 Gear pump (operator's cab elevation)
7 Restrictor Ø 0.8 mm 50 from control oil unit
8 Check valve 0.8 bar S78 Button / emergency lowering front
9 Knurled screw S79 Button / emergency lowering rear
10 2-way stop valve S200 Button / lifting operator's cab
11 Restrictor check valve (Ø 1.5 mm) S201 Button / lowering operator's cab
12 Adjusting screw for lifting rate Y200 Button / lifting operator's cab
13 Spool Y201 Solenoid valve / lowering operator's cab
14 Restrictor Ø 0.6 mm Y204 Solenoid valve / emergency lowering
15 Pressure-relief valve S408 Lever switch
16.60.14
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MJFCIFSS
fault diagnosis
Fig. 13 Hydraulic diagram of operator's cab elevation to serial no. 26964
16.60.15
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MJFCIFSS
fault diagnosis
Fig. 14 Hydraulic diagram of operator's cab elevation from serial no. 26965
16.60.16
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MJFCIFSS
fault diagnosis
16.60.17
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MJFCIFSS
fault diagnosis
16.60.18
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MJFCIFSS
Electrical system of operator's cab elevation system
6 Electrical system of operator's cab elevation system
Fig. 17 Electrical unit to serial no. 22587
A1100 ESP 02 printed circuit board S201 Button / lowering operator's cab
F4 Fuse of amplifier V151 (15A) V156 Amplifier servo kit
F20 Fuse of amplifier V215 (15A) X209 Plug connection to servo kit / 2-pin
H44 LED terminal 15 power supply X215 Plug connection to terminal 30 kit / 2-pin
H46 LED power supply V156 X311 Plug connection lift frame / 4-pin
H70 LED terminal 30 power supply X689 Decay diode plug / 6-pin
MP86 Ground connection behind the opera- Y200 Button / lifting operator's cab
tor's platform
S78 Button / emergency lowering front Y201 Solenoid valve / lowering operator's cab
S79 Button / emergency lowering rear Y204 Solenoid valve / emergency lowering
S200 Button / lifting operator's cab
16.60.19
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MJFCIFSS
Fig. 18 Electrical unit from serial no. 22588
A1100 ESP 02 printed circuit board S201 Button / lowering operator's cab
F4 Fuse of amplifier V151 (15A) V156 Amplifier servo kit
F20 Fuse of amplifier V215 (15A) X209 Plug connection to servo kit / 2-pin
H44 LED terminal 15 power supply X215 Plug connection to terminal 30 kit / 2-pin
H46 LED power supply V156 X311 Plug connection lift frame / 4-pin
H70 LED terminal 30 power supply X689 Decay diode plug / 6-pin
MP86 Ground connection behind the opera- Y200 Button / lifting operator's cab
tor's platform
S78 Button / emergency lowering front Y201 Solenoid valve / lowering operator's cab
S78 Button / emergency lowering rear Y204 Solenoid valve / emergency lowering
S200 Button / lifting operator's cab
16.60.20
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MJFCIFSS
Fig. 19 Electrical unit from serial no. 35102
A1100 ESP 02 printed circuit board S408/A3 Plug connection

S78 Button / emergency lowering front V156 Amplifier servo kit
S79 Button / emergency lowering rear X209 Plug connection to servo kit / 2-pin
S200 Plug connection X215 Plug connection to terminal 30 kit / 2-pin
S201 Plug connection X311 Plug connection lift frame / 4-pin
S408 Lever switch Y200 Button / lifting operator's cab
S408/A1 Plug connection Y201 Solenoid valve / lowering operator's cab
S408/A2 Plug connection Y204 Solenoid valve / emergency lowering
16.60.21
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MJFCIFSS
Fig. 20 Electric diagram of operator's cab elevation
16.60.22
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MJFCIFSS
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
A 900 C-LI 14675- 16.62.1

MJFCIFSS
Individual control Service Manual
Description
2 Description
The kit for individual control consists of a number of operating elements, solenoid valves and hydrau-
lic and electrical connections.
The operator can select an individual control system by means of switch S 204- 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 that 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 slip-ring case E162 is mounted in the undercarriage. From this point, all electrical lines of the
system in the undercarriage are fed.
The support cylinder 295 with attached double lowering brake valves 297 are secured with bolts to
the steel structure of the undercarriage.
Fig. 2 Design of the individual control system
16.62.2 A 900 C-LI 14675-

MJFCIFSS
Description
Fig. 3 Hydraulic connections in the undercarriage
A 900 C-LI 14675- 16.62.3

MJFCIFSS
see Fig. 5
The solenoid valves Y215 - Y218 are controlled by means of the switches S204 - S207.
When a switch is pressed, the respective indicator light is on. To extend or retract the respective sup-
port cylinder 295, operate the pilot control unit 85 in the right control console.
When the idle position, the solenoid valves Y215 - Y218 seal the connection B, so that no oil is fed
from the pump to through the spool 280 and the rotary connection 320 to the support cylinder 295.
When the switch Y 204 - Y207 is pressed, the respective solenoid valve Y215 - Y218 is powered th-
rough the slip ring rotary connection 325. The valve is opened and oil can flow through the connection
B - A to the support cylinder 295, where pressure is built up.
Through the lines 2 and 4 of the 7x rotary connection 320, oil is fed from the pump and the spool 280
to the support cylinders 295 located in the undercarriage.
The solenoid valves Y215- Y218 are powered through switch S204 - S207 via the slip ring rotary con-
nection 325.
3.1 Extending an individual support cylinder

Press the switch S204 - S207 to set the respective solenoid valve into operating position.
Push the pilot control unit 85 forward so that hydraulic oil flows from the pump 20 through the spool
280, the rotary connection 320, the solenoid valve Y215, Y216, Y217 or Y218, the connection B - A
and valve 297 to the piston side of the support cylinder 295. The cylinder is now pressurised.
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 valve 297. The cylinder is extended. Oil returns from
the piston rod side of the cylinder through the valve 297 to the tank.
The valve 297 seals the extending support cylinder against the spool 280.
3.2 Retracting an individual support cylinder

Press the switch S204 - S207 to set the respective solenoid valve Y215 - Y218 into operating position.
Pull the pilot control unit 85 back so that the hydraulic oil flows from the pump 20 through the spool
280, the rotary connection 320 and the valve 297 to the piston rod side of the support cylinder 295,
where pressure is now built up.
The pressure generated in this process opens valve 297. Oil returns from the piston side of the cy-
linder through the valve 297, the solenoid valve Y215, Y216, Y217 or Y218 and
connection A- B to the tank.
The idle solenoid valves seal the other cylinders so that no oil flows from there to the tank. The valve
297seals the retracting support cylinder against the spool 280.
16.62.4 A 900 C-LI 14675-

MJFCIFSS
A 900 C-LI 14675- 16.62.5

MJFCIFSS
100 A1 from control valve block connection S207 Individual control system switch
A1
100 B1 from control valve block connection X214 Plug connection / 2-pin
B1
280 Control axle, support
295 Support cylinder Y215 Solenoid valve
Individual control of left front outrigger
297 Double lowering brake valve Y216 Solenoid valve
Individual control of right front outrigger
320 Rotary connection (high pressure) Y217 Solenoid valve
Individual control of right rear outrigger
325 Slip ring rotary connection Y218 Solenoid valve
Individual control of left rear outrigger
A1100 printed circuit board X300 Terminal strip
E162 Slip-ring case X301 Plug connection / 6-pin
F- fuse / kit (15A) X303 Plug connection / 4-pin
S204 Individual control system switch X304 Plug connection / 6-pin
S205 Individual control system switch X305 Plug connection / 9-pin
S206 Individual control system switch
16.62.6 A 900 C-LI 14675-

MJFCIFSS
Electric diagram of individual control system in A 900 C
4 Electric diagram of individual control system in A 900 C
Fig. 6 Electric diagram of individual control system in A 900 C
A 900 C-LI 14675- 16.62.7

MJFCIFSS
Electric diagram of individual control system in A 904 C
5 Electric diagram of individual control system in A 904 C
Fig. 7 Electric diagram of individual control system
16.62.8 A 900 C-LI 14675-

MJFCIFSS
Service Manual Dozer blade
Function
Dozer blade
1 Function
Machines with 2-point and 4-point support can be equipped with a dozer blade.
This blade is designed exclusively for grading work and may not be used to support the machine. It
can only be attached at the front, provided that there is an outrigger support or no support at that end
of the machine.
Lowering the dozer blade does not result in improved stability of the machine, and its load-bearing
capacity is also not increased.
Fig. 1 4-point outrigger support with dozer blade attached to the undercarriage
A 900 C-LI 14675- 16.64.1

MJFCIFSS
Dozer blade Service Manual
Description
2 Description
The dozer blade and its operating devices (cylinders, beam, control axle, etc.) are designed exclusi-
vely for grading work. The pressure at the piston side of the cylinder is controlled by the additional
pressure relief valve 304.
To operate the dozer blade, the hydraulic cylinder 395 is pressurised from the "support cylinder" oil
circuit.
The 6-way solenoid valve Y56 at the undercarriage controls the changeover from the support cylin-
ders to the dozer blade.
The hydraulically releasable check valve 302 is installed in the rod side of the hydraulic circuit. It se-
cures the dozer blade against inadvertent lowering due to leakage.
Fig. 2 Design of the dozer blade and outrigger support
16.64.2 A 900 C-LI 14675-

MJFCIFSS
Description of functions, Fig. 9
3 Description of functions, Fig. 9
3.1 Outrigger support

85
3.2 Operation of the dozer blade

Actuate the switch S335 located in the right control desk to shift the solenoid valve Y56, thus chan-
ging over from the support cylinder function (295) to the dozer blade function (395).
3.2.1 Extending the cylinder 395

When the pilot control device 85 (Fig. 7) is pushed forward, oil flows from the control valve block 100
connection A1 or way valve 280, connection A4 respectively through the rotary connection 320 to the
solenoid valve Y56, connection A2 - C2. From connection C2, the oil flows through the hydraulically
releasable check valve 302, connection V1 - C1 to the piston side of the dozer blade cylinder 385.
A high pressure is built up, and the hydraulically releasable check valve 302 is opened.
The cylinder 395 is extended and presses the dozer blade downward. The return oil from the rod side
of the cylinder flows through the open check valve 302, the solenoid valve Y56, connection C1 - A1,
the rotary connection 320 and the control valve block 100, connection B1 or way valve 280, connec-
tion B4 to the tank.
3.2.2 Retracting the cylinder 395

When the pilot control device 85 (Fig. 7) is pushed backward, oil flows from the control valve block
100 connection B1 or way valve 280. connection B4 respectively through the rotary connection 320
to the solenoid valve Y56, connection A1 - C1. From connection C1, the oil flows through the hydrau-
lically releasable check valve 302, connection V2 - C2 to the rod side of the dozer blade cylinder 385.
The cylinder 395 is retracted and moves the dozer blade upwards. The return oil from the piston side
of the cylinder flows through the open check valve 302, the solenoid valve Y56, connection C2 A2,
the rotary connection 320 and the control valve block 100, connection A1 or way valve 280, connec-
tion A4 to the tank.
A 900 C-LI 14675- 16.64.3

MJFCIFSS
Exploded view / sectional drawing
4 Exploded view / sectional drawing
Fig. 3 Exploded view of the solenoid valve Y56
Fig. 4 Sectional drawing of the solenoid valve Y56
1 Way valve 6 x 10 Lock washer

2 11 Lock washer
3 Way valve / solenoid 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
16.64.4 A 900 C-LI 14675-

MJFCIFSS
Testing of the pressure relief valve 304
5 Testing of the pressure relief valve 304
Fig. 5 Pressure relief valve 304 and measuring point 41 at the control valve block 100
Remove the cover cap from the measuring point 41 at the control valve block 100 and connect a
pressure sensor.
Fully extend the dozer blade (lower to firm ground).
The pressure indicated on the pressure sensor must be within the range of 240 ± 5 bar.
Remove the cover cap 21.

Loosen the lock nut and adjust the pressure by turning the adjusting screw 19.
Screw out the adjusting screw 19
reduce pressure
Screw in the adjusting screw 19
increase pressure
Secure the adjusting screw with the lock nut.
Note!
The pressure at the piston side of the cylinder 395 is limited by the pressure relief valve 304 to
240 ± 5 bar. This ensures that the undercarriage cannot be lifted by means of the dozer blade.
Fig. 6 Sectional drawing of the pressure relief valve 304
A 900 C-LI 14675- 16.64.5

MJFCIFSS
Operation of the outrigger support / dozer blade
6 Operation of the outrigger support / dozer blade
Fig. 7 Switch S335 for support on the right control console
To select the dozer blade, press switch S335. Depending on the front/rear outrigger support type, the
actual switch position might vary.
Press switch S335.
Using the pilot control device 85, lower a or lift b the dozer blade.
Fig. 8 Pilot control device 85
The support is controlled by means of the pilot control device 85.

To extend the supports, press the lever of the pilot control device 85 forward a.
To retract the outrigger support, pull the lever of the pilot control device 85 back b.
16.64.6 A 900 C-LI 14675-

MJFCIFSS
Hydraulic diagram
7 Hydraulic diagram
Fig. 9 Hydraulic diagram of the dozer blade with 4-point support
100 A1/B1 from control valve block (A 900 / A 320 Rotary connection 7 x
904)
280 from way valve (A 914/ A 924) 325 Slip-ring rotary connection
295 Support cylinders / outriggers 395 Dozer blade cylinder
298 Double stop valve S335 Switch / changeover between blade - out-
rigger
302 Hydraulically releasable check valve Y56 Solenoid valve, 6 x
A 900 C-LI 14675- 16.64.7

MJFCIFSS
8 Exploded view of the electrical system
Fig. 10 Electrical system in the uppercarriage and undercarriage

S335 Switch for changeover outrigger/dozer X302 Plug connection / 1-pin
blade
X209 Plug connection / 2-pin X303 Plug connection / 4-pin
16.64.8 A 900 C-LI 14675-

MJFCIFSS
Electrical diagram
X214 Plug connection / 2-pin X305 Plug connection / 9-pin

X214-1 Plug connection / 2-pin X308 Plug connection / 3-pin
X219 Plug connection / 2-pin Y56 Solenoid valve, 6 x
Fig. 11 Electrical diagram

F4 Fuse 15 A X302 Plug connection / 1-pin
S272 Slip-ring case X305 Plug connection / 9-pin
S335 Switch for changeover outrigger/dozer X308 Plug connection / 3-pin
blade
V156 Amplifier servo kit Y56 Solenoid valve, 6 x
A 900 C-LI 14675- 16.64.9

MJFCIFSS
Electrical diagram
16.64.10 A 900 C-LI 14675-

MJFCIFSS
Function/design
Dozer blade
1 Function/design
Danger!
The dozer blade may not be used to support the machine. Lowering the dozer blade does not en-
hance the static torque or load-bearing capacity of the machine.
Use the dozer blade only for grading work and never to support or prop up the machine.
If you wish to increase the stability of the machine, use the supmport system.
Machines with 2-point or 4-point support can be equipped with an optional dozer blade 300 attached
to the undercarriage. The dozer blade is attached with one hydraulic cylinder 395 only and is desig-
ned exclusively for grading work and not as a support device.
The control elements for changeover and operation of the dozer blade are located in the operator's
cab. By activating the solenoid valve Y56, the support cylinder action is switched over to the dozer
blades.
The check valve 306, the pressure-relief valve 304 and the solenoid valve Y56 are integrated into the
valve block 301 in the undercarriage.
To operate the dozer blade, the hydraulic cylinder 395 is pressurised through the oil circuit of the sup-
port cylinder.
Fig. 1 Location of the dozer blade in the undercarriage
300 Dozer blade 395 Hydraulic cylinder for dozer blade

301 Valve block
16.65.1
copyright by
MJFCIFSS
Function/design
Fig. 2 Hydraulic and electrical connections
16.65.2
copyright by
MJFCIFSS
301 Valve block X302 Plug connection, 1-pin

304 Pressure-relief valve X303 Plug connection, 4-pin
305 Measuring point X304 Plug connection, 2-pin
306 Check valve X304.S1Plug connection
325 Slip ring X304.B1Plug connection
395 Hydraulic cylinder (dozer blade) X308 Plug connection
E162 Junction box X1199 Plug connection
S335 Switch / changeover blade - outrigger X1298 Plug connection, 1-pin
S335X Plug connection to switch S335 Y56.X Plug connection
X214 Plug connection, 2-pin Y56 Solenoid valve / dozer blade
(see Hydraulic diagram on page 5)
Note!
2.1 Operation of outrigger support / dozer blade
Fig. 3 Operating dozer blade
The dozer blade can only be operated when the supports are lifted off the ground.
Select the dozer blade by means of switch S335 in the right control console.
The dozer blade is activated, and the outrigger support is temporarily disabled.
Using the control lever 85, lower the dozer blade a or lift the dozer blade b.
The solenoid valve Y56 is switched to dozer blade cylinder 395 function.
The solenoid valves Y215-Y218 are in idle position.
2.1.1 Extending cylinder 395

When the pilot control unit 85 is pushed forward (a), oil flows from the control block 100 through the
16.65.3
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MJFCIFSS
connection A1 or the way valve 280 and the connection A4 via the rotary connection 320 to the so-
lenoid valve Y56, connection A1. From the connection A2, the oil flows to piston side of the dozer
blade cylinder 395.
At the same time, the oil acts on the pressure-relief valve 304 limiting the system pressure. This ensu-
res that the undercarriage cannot be lifted by the dozer blade.
The check valve 306 is depressurised.
The cylinder 395 is extended and pushes the dozer blade down. The return oil flows from the rod side
through the depressurised check valve 306, the rotary connection 320 and the control block 100 con-
nection B1 or the way valve 280 connection B4 to the tank.
2.1.2 Retracting cylinder 395

When the pilot control unit is pulled back (b), oil flows from the control block 100 connection B1 or
the way valve 280 connection B4 through the rotary connection 320 to the valve block 301 connection
B1. The oil then flows through the check valve 306 and the connection B2 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 valve block 301 connection A2 and the solenoid valve Y56 connection A1, the rotary con-
nection 320 and the control block 100 connection A1 or the way valve 280 connection A4 to the tank.
100 A1/B1 from control valve block S204 Individual control system switch
(A900 C - A 904 C)
280 A4/B4 of way valve 280 S205 Individual control system switch
(A914 C - A 924 C)
295 Support cylinder S206 Individual control system switch
298 Double stop valve S207 Individual control system switch
301 Valve block S335 Switch / changeover blade - outrigger
304 Pressure-relief valve Y56 Solenoid valve / dozer blade
305 Measuring point Y215 Solenoid valve / individual outrigger
control
306 Check valve Y216 Solenoid valve / individual outrigger
control
320 Large rotary connection Y217 Solenoid valve / individual outrigger
control
325 Electrical rotary connection Y218 Solenoid valve / individual outrigger
control
395 Hydraulic cylinder (dozer blade)
16.65.4
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MJFCIFSS
16.65.5
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MJFCIFSS
Checking/adjustment of the pressure-relief valve 304
3 Checking/adjustment of the pressure-relief valve 304
Fig. 5 Checking/adjustment of the pressure-relief valve 304
Remove the cap from the measuring point 305 and connect a pressure gauge.
Fully extend the dozer blade (lower it to firm ground).
The indicated pressure may not exceed the prescribed limit pressure of 240 ± 5 bar.
If the pressure is too high or too low, adjust the pressure-relief valve 304 as follows:
Loosen the lock nut 2 and adjust the settings by turning the adjusting screw 1.
Turn adjusting screw 1 out.
After adjustment, secure the adjusting screw with the lock nut.
Note!
The pressure at the piston side in the cylinder 395 is limited by the pressure-relief valve 304 to
240 ± 5 bar. This ensures that the undercarriage cannot be lifted by the dozer blade.
16.65.6
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MJFCIFSS
Service Manual Refuelling pump
Function
Refuelling pump
1 Function
The electrically driven refuelling pump is used to pump the diesel fuel from a fuel tank (drum, etc.)
into the fuel tank of the machine.
The refuelling pump is mounted near the hydraulic and fuel tanks under the lockable cover.
The pressure side of the refuelling pump is permanently connected to a hose leading to the fuel tank.
The suction side of the refuelling pump is equipped with strainer and a hose for immersion into the
fuel container.
Fig. 1 Refuelling pump
16.66.1
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MJFCIFSS
Refuelling pump Service Manual
General information
Equipment A 900 C Litronic A 904 C Litronic

Flow 50 l/min
Protection class IP 65
Motor output 0.12 kW
(operating mode S2 = 15 min)
Motor voltage 24V DC
Current consumption ~10 A
Delivery head 5m (~0.5 bar)
16.66.2
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MJFCIFSS
General information
16.66.3
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MJFCIFSS
Description
3 Description
The refuelling pump kit consists of the following main components:

Refuelling pump 1
Stop cock 2
Suction hose 3
Strainer 4
Protective cap 5
Pressure hose 6
Screw fitting 7
Terminal box 8
Control device 9
Bracket 10
The refuelling pump 1 is mounted near the hydraulic and fuel tanks under the lockable cover.
The suction side of the refuelling pump 1 is equipped with a stock cock 2, a 2.5-metre suction hose
3 and a strainer 4 with a protective cap 5. At the pressure side of the pump, the fuel is fed through a
pressure hose 6, the screw fitting 7 and the riser pipe located in the fuel tank.
The terminal box 8 contains the connections between the power supply of the machine, the control
device 9 and the feed lines to the refuelling pump.
The control device 9 is mounted in a bracket 10 on the refuelling pump 1 and can be removed from
the bracket, if required.
Fig. 2 Components of the refuelling pump
16.66.4
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MJFCIFSS
Description
Fig. 3 Assembly of the pressure hose (A) and suction hose (B)
2 Stop cock 18 Hose

4 Strainer 19 Fitting
5 Protective cap 20 Hose
15 Bracket 21 Hose nipple
16 Hose screw connection 22 Angled neck
17 Clip 23 Glue with Loctite 572
16.66.5
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MJFCIFSS
Danger!
Risk of explosion!
Do not refuel machine near naked flames!
Do not smoke while refuelling the machine!
4.1 Refuelling of the machine, see Fig. 5

Turn ignition key to position 1 (ignition on).
Open the cover 11 of the hydraulic tank 13.
Unlock the step cover 35 and tilt it upwards. Open the cap 36 at the fuel tank (for better tank ven-
tilation).
Remove the suction hose 3 from its storage.
Remove the protective cap 5 from the strainer 4 and place the end of the suction hose 3 into the
fuel container 12.
Open the stop cock 2 (position B).
At the control device 9, actuate the green switch (S25).
Fuel is now pumped into the fuel tank of the machine.
Caution!
Prevent the pump from running dry!
Ensure that there is sufficient fuel in the container so that the fuel level does not drop below the suc-
tion height of the refuelling pump.
Note!
The pump is automatically switched off when the maximum fill level is reached.
The pump can also be switched off manually by actuating the red switch (S59) at the control device.
Close the stop cock 2 (position A).

Pull the suction hose 3 from the fuel container 12 until the strainer 4 is above the fuel level.
Drain all fuel from the suction hose 3.
Place the protective cap 5 on the strainer 4.
Place the suction hose 3 and the control device 9 in the storage tray provided at the hydraulic tank
13.
Close the cap 36 of the fuel tank, fold down the step cover 35 and lock it.
Lock the cover 11 of the hydraulic tank 13.
16.66.6
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MJFCIFSS
Fig. 4 Step cover and tank cap at the fuel tank
35 Step cover 36 Tank cap
16.66.7
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MJFCIFSS
Fig. 5 Functional description of the refuelling pump
1 Refuelling pump 9 Control device

2 Stop cock 10 Bracket
3 Suction hose 11 Cover
4 Strainer 12 Fuel container
5 Protective cap 13 Hydraulic and fuel tank
6 Pressure hose S25 "ON" switch
7 Screw fitting S59 "OFF" switch
8 Terminal box
16.66.8
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MJFCIFSS
Maintenance
5 Maintenance
Regularly clean the strainer 4 attached to the suction hose

To do this, remove the hose 16 from the fitting 19.
Remove the protective cap 5 from the strainer 4.
Clean the strainer 4, using a suitable detergent and carefully blow it out with compressed air.
Connect the hose 16 to the fitting 19.
Place the protective cap 5 on the strainer 4.
Fig. 6 Cleaning of the strainer
4 Strainer 16 Hose screw connection

5 Protective cap 19 Fitting
16.66.9
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MJFCIFSS
Electrical system
6 Electrical system
Fig. 7 Electrical system of the refuelling pump
9 Control device 30 Ground connection MP 83

27 Wire 3006 31 Wire 3007
28 Wire harness of revolving deck (serial) S25 "ON" switch
29 Plug connection X 141 S59 "OFF" switch
Note!
The electrical components and connections are shown in the circuit diagram of group 8.
6.1 Electrical connections

Insert the terminal box E50, and the fuse F33 (7.5A) in slot C of the fuse bar.
In the terminal box E50, connect the wire 31 (3007)to the fuse bar in slot C.
In the terminal box E42, connect the wire 27 (3006) to the threaded stud and secure it with a nut
(M8).
16.66.10
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MJFCIFSS
Service Manual Bypass filter
Function
Bypass filter
1 Function
The bypass filter is designed to remove small particles and water from the hydraulic system.
By installing a bypass filter, the oil change intervals can be prolonged, as the oil remains clean for
longer, and components are well protected.
Note!
Bypass filters must be installed in units operated with bio oils (LIEBHERR requirement)!
Fig. 1 Bypass filter
16.68.1
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MJFCIFSS
Bypass filter Service Manual
Technical data
2 Technical data
2.1 Filter housing
Machine A 900 C Litronic A 904 C Litronic

Serial number 14675 16000
Type SDU-H350-BM2
Capacity
without filter cartridge 3.64 l
with SDFC filter cartridge 2.46 l
Input pressure 5-350 bar

Output pressure 0-1 bar
Max. oil volume in system 400 l
Max. flow rate 120 l/h

Dimensions
Height 325 mm
Diameter 238 mm
Weight 7.5 kg
Connecting threads
Inlet M12x1.5
Outlet M18x1.5
Filter cartridge SDFC
Tab. 1 Technical data of filter housing
16.68.2
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MJFCIFSS
Technical data
2.2 Filter cartridges
Type SDFC
Purity class* 11/9/6
Maximum dirt pick-up capacity (solids) 2500 g

Water 780 ml
Water content* <0.05%

Max. temperature 90 °C
Dimensions
110 mm
Height
195 mm
Diameter
Weight 1000 g ±5%
Oil capacity 1.18 l

paper
Filter medium +
polypropylene
Filter size 1 µm nom.
Volume of filter cartridge 3154 cm3
Filter surface 88 m2
Tab. 2 Technical data of filter cartridge
* = according to ISO 4406 (1987); levels continuously reached, provided that the system is correctly
dimensioned and the filter cartridge is regularly replaced.
16.68.3
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MJFCIFSS
Design
3 Design
The bypass filter 1 is installed at the front of the hydraulic tank.

The bypass filter kit consists of the following main components:
Bypass filter 1
Pressure gauge 2*
Pressure balance 3
Hose 4
Orifice 5
Hose 9
Check valve 10
Fig. 2 Design of the bypass filter
*= the pressure gauge 2 is only mounted on machines supplied before the end of October 2005. Ma-
chines delivered after October 2005 are not equipped with a pressure gauge 2.
The bypass filter 1 is connected to port "S" of the slewing gear oil motor 130. The filter is mounted
with a T- piece 7, a restrictor 6 and an orifice 5. The hydraulic oil flows through the hose 4 to port "P"
at the pressure balance 3, and from there through the filter cartridge 17. The hydraulic oil is fed from
port "T1" of the bypass filter 1 through the hose 9 and the check valve 10 to the hydraulic tank 25.
The check valve 10 prevents oil from escaping the filter housing when the filter cartridge is changed.
The orifice 5 reduces the cross section of the line, thus reducing the volume flow from the slewing
gear oil motor 130 to the bypass filter 1.
The pressure balance 3 controls the volume flow and the pressure during normal operation.
In the event of a severely contaminated filter cartridge 17, backpressure is built up. This pressure,
combined with the spring force, switch over the pressure balance 3. As a result, the hydraulic oil is
returned unfiltered and at an unrestricted flow rate through the check valve 13 to the hydraulic tank
25.
The pressure gauge 2 (if installed) also indicates whether the filter cartridge is contaminated, (see
Maintenance on page 6).
16.68.4
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MJFCIFSS
Fig. 3 Functional diagram of the bypass filter
Fig. 4 Hydraulic connections of the bypass filter
1 Bypass filter 12 Bracket

2 Pressure gauge (only in units delivered 13 Check valve (opening pressure 3.5 bar)
before October 2005)
3 Pressure balance 14 Pressure line
4 Hose 17 Filter cartridge
5 Orifice 25 Hydraulic tank
6 Restrictor 26 Hex head screw with washer
7 T-piece 27 Hex nut
16.68.5
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MJFCIFSS
Maintenance
9 Hose 100 Control valve block

10 Check valve 130 Slewing gear motor
11 Elbow
5 Maintenance
As the cartridge has an extremely great take-up capacity for dirt and water, the exchange intervals
for the filter cartridge can vary considerably, depending on the actual oil contamination and oil flow
rate.
Application Operating hours
Normal operation 500 operating hours
Operation under adverse conditions 250 operating hours
Maximum service life of the filter cartridge: 6 months
If the filter change is carried out on the basis of the value shown on the pressure gauge 2 (backpres-
sure), proceed as follows:
Install a new filter cartridge 17, ensure that the device is at operating temperature and read the
value indicated on the pressure at the gauge 2. We recommend marking the indicator position on
the pressure gauge 2.
When the pressure is increased by 0.5 bar, replace the filter.
Note!
Prior to commissioning the bypass filter, add approx. 3 l of oil into the filter housing 15.
The maximum weight of the old filter cartridge 16 is approx. 4400 g (of which approx. 2500 g dirt).
Replace the filter cartridge.
The normal weight of the old filter cartridge 16 is approx. 3000 g (of which approx. 1000 g dirt).
Filter cartridges of this weight are fully effective.
If a higher weight is determined, shorten the filter change interval.
5.1 Changing of the filter cartridge

Remove the lid screw 21.
Remove the filter lid 19.
Remove the spent filter cartridge 16 by turning it at the carrying straps in clockwise direction while
lifting it slightly.
Allow the oil to collect at the bottom of the cartridge 16 and remove it from the filter housing 15.
Collect the escaping oil in a suitable container.
Check the inlet and outlet of the filter 15 for dirt deposits and clean it.
Note!
Use only filter cartridges 17 whose packaging is undamaged, as exposure to moisture reduces
the service life of the filter cartridge 17!
Do not remove the cardboard jacket of the filter cartridge 17.
16.68.6
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MJFCIFSS
Maintenance
Take the new filter cartridge 17 from the packaging.

Insert the filter cartridge 17 into the housing 15.
Fill the filter housing 15 with the same hydraulic oil as is used in the machine.
Insert the seal ring 18 supplied with the new cartridge in the filter lid 18.
Place the filter lid 19 onto the housing 15.
Check the disc 20 for damage and replace it, if necessary.
Insert the lid screw 21 and tighten it with 50 Nm.
Start the machine and check the bypass filter for leakage.
Fig. 5 Changing the filter cartridge
2 Pressure gauge 19 Filter lid

15 Filter housing 20 Disc
16 Spent filter cartridge 21 Lid screw
17 New filter cartridge 23 Oil collecting pan
18 Seal ring
16.68.7
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MJFCIFSS
Maintenance
16.68.8
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MJFCIFSS
Service Manual Liebherr bypass filter
Function
Liebherr bypass filter
1 Function
The bypass filter is designed to remove small particles and water from the hydraulic system.
By installing a bypass filter, the oil change intervals can be prolonged, as the oil remains clean for
longer, and components are well protected.
Note!
Bypass filters must be installed in units operated with bio oils (LIEBHERR requirement)!
Fig. 1 LIEBHERR bypass filter
16.69.1
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MJFCIFSS
Liebherr bypass filter Service Manual
Technical data
2 Technical data
Machine A 900 C Litronic A 904 C Litronic A 914 C A 924 C Li

Serial number 24677 30580 34519
Type NLF 5-L bypass filter
Feed pressure 10 - 50 bar

Operating pressure 3.5 bar
Max. flow rate 5.0 l/min

Dimensions
Height 345 mm
Diameter 109 mm
Weight 3.0 kg
Connecting threads
Inlet G 1/2"
Outlet G 1/2"
Dirt retention capacity 200 g at 2.5 bar
Filter size 2 µm
Filter surface 4200 cm2
16.69.2
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MJFCIFSS
Technical data
16.69.3
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MJFCIFSS
Design
3 Design
The bypass filter 1 is mounted with a bracket 13 and holder 16 to the inside of the ballast weight.
The bypass filter kit consists of the following main components:
Bypass filter 1
Pressure gauge 2
Pressure-relief valve 3
Filter housing 4
Filter cartridge 7
Filter pot 8
Fig. 2 Hydraulic connections at bypass filter
16.69.4
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MJFCIFSS
Design
Fig. 3 Design of the bypass filter
1 Bypass filter 11 Check valve

2 Pressure gauge 13 Console
3 Pressure-relief valve 14 Hex head screw with washer
(opening pressure 3.5 bar)
4 Filter housing 15 Hex nut
5 Tightening clamp 16 Holder
6 Locknut 17 O-ring
7 Filter cartridge 20 Hydraulic pump (suction pipe)
8 Filter pot 100 Control valve block
9 Drain screw
16.69.5
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MJFCIFSS
The bypass filter 1 is connected to port "S" of the control block 100. The hydraulic oil flows through
a restrictor 10 and port "P" to the bypass filter 1 and from there through the filter cartridge 7. The oil
then flows through port "T" and the check valve 11 to the suction pipe 12 on the hydraulic pump 20.
The check valve 11 prevents oil from escaping the suction pipe of the hydraulic pump 20 when the
filter cartridge is changed.
The restrictor 10 reduces the cross-section of the line, thus reducing the volume flow from the control
block 100 to the bypass filter 1.
The pressure-relief valve 3 (opening pressure 3.5 bar) protects the bypass valve 1 against damage
from excessive pressure in the event of malfunction or when the filter capacity is reached.
If the filter cartridge 7 is very dirty, the backpressure in the bypass filter is increased. As a result, the
pressure-relief valve (opening pressure 3.5 bar) 3 to the outlet T is opened. The hydraulic oil is retur-
ned unfiltered and at an unrestricted flow rate through the check valve 11 to the suction pipe 12 of
the hydraulic tank.
The pressure gauge 2 indicates whether the filter cartridge is contaminated, (see Maintenance on
page 7).
Fig. 4 Functional diagram of the bypass filter
1 Bypass filter 11 Check valve

2 Pressure gauge 12 Suction pipe
3 Pressure-relief valve 20 Hydraulic pump (suction pipe)
7 Filter cartridge 100 Control valve block
10 Restrictor
16.69.6
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MJFCIFSS
Maintenance
5 Maintenance
As the cartridge has an extremely great take-up capacity for dirt and water, the exchange intervals
for the filter cartridge can vary considerably, depending on the actual oil contamination and oil flow
rate.
If the filter is very dirty, the hydraulic oil is not cleaned properly.
The filter must be changed regularly, based on the pressure gauge 2 readings (backpressure). The
more the filter is contaminated, the higher the pressure in the filter housing. If the pressure gauge 2
indicates a pressure of more than 2.5 bar during operation, the filter cartridge must be replaced.
Fig. 5 Backpressure at pressure gauge 2
5.1 Changing of the filter cartridge, see Fig. 6
Caution!
The housing is under pressure.
Escaping oil can cause serious injury to face and hands.
The hydraulic oil temperature must be minimum 50°C (operating temperature).

Drain the oil through the drain screw 9 (WS6), collect escaping oil (approx. 2 litres) in a suitable
container 23.
Remove the clamp 5 by loosening the hexagon nut 6 (WS10).
Remove the filter housing 4 from the filter pot 8.
Turn the old filter cartridge 7 clockwise while lifting it slightly.
Allow the oil to collect at the bottom of the cartridge 7 and remove it from the filter pot 8. Collect
the escaping oil in a suitable container 23.
Check the inlet and outlet of the filter 4 for dirt deposits and clean it.
Check the O-ring 17 in the filter pot 8 for damage or dirt and replace it, if necessary.
16.69.7
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MJFCIFSS
Maintenance
Note!
Use only filter cartridges 7 whose packaging is undamaged, as exposure to moisture reduces
the service life of the filter cartridge!
Take the new filter cartridge 7 from the packaging.

Insert the filter cartridge 7 into the filter pot 8.
Wet the upper side of the filter cartridge 7 and the O-ring 17 with the hydraulic oil used in the ma-
chine.
If required, insert a new O-ring 17 in the filter pot 8.
Carefully place the filter housing 4 on the filter pot 8.
Ensure that the filter housing is properly fitted and secure it with the clamp 5.
Tighten the hexagon screw 6 with a torque of 5 to 10 Nm.
Replace the drain screw 9 (WS6).
Start the machine and check the bypass filter for leakage.
16.69.8
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MJFCIFSS
Maintenance
Fig. 6 Changing the filter cartridge
1 Bypass filter 7 Filter element

2 Pressure gauge 8 Filter pot
3 Pressure-relief valve 9 Drain screw
4 Filter housing 17 O-ring
5 Tightening clamp 23 Oil collecting pan
6 Locknut
16.69.9
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MJFCIFSS
Adjustment of pressure-relief valve 3
6 Adjustment of pressure-relief valve 3
Note!
The pressure-relief valve 3 is factory-set by the manufacturer and may not be changed.
7 Faults
Error Cause Remedy

No oil flow Bypass filter connected incor- Check whether the bypass filter
rectly is connected correctly. Check
flow directions IN and OUT;
change connections, if necessa-
ry
Medium viscosity too high Warm oil to operating temperatu-
re
Filter dirty Medium very dirty Replace filter cartridge
Filter cartridge blocked
Leakage at filter pot 8 Tighten drain screw at filter pot 8
and clamp 6
(5 - 10 Nm)
16.69.10
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MJFCIFSS
Service Manual Reversible fan drive
Function
Reversible fan drive
1 Function
The machine can be equipped with an optional reversible fan drive. This kit enables the machine ope-
rator to reverse the air flow so that the intake area of the radiator is cleaned by the air.
This helps prevent overheating of the diesel engine and the hydraulic unit. If the intake area (ventila-
tion slots, guard, radiator) is often very dirty, we recommend installing the reverse fan drive.
Caution!
The diesel engine and the hydraulic unit can be damaged by overheating, if the cooling performance
is reduced.
Do not run the fan in reverse motion for more than 1 minute.
The reverse fan operation might not be sufficient to fully clean the intake area of the cooling sys-
tem.
The intake area must therefore be regularly inspected and cleaned.
Fig. 1 Direction of air flow with reversed fan operation
16.70.1
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MJFCIFSS
Reversible fan drive Service Manual
Function
16.70.2
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MJFCIFSS
Technical data
2 Technical data
A 900 C A 904 C A 914 C A 924 C

Machine:
Litronic Litronic Litronic Litronic
Serial number:
14675 16000 35112 34519
Min./max. fan speed see adjustment protocols in group 6
Gear pump 33 (max. flow volume) l 48,5
Secondary pressure-relief valve 8 bar 200 +10
Proportional pressure-relief valve Y347 bar 180
min./current
Pressure-relief valve 3 for bar 115 +5
reversing
16.70.3
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MJFCIFSS
Design
3 Design
The reversible fan drive consists of the following main components:

Hydraulic oil cooler 6
Valve block 10
Fan motor 13
Fan pump 33
The fan motor driving the fan propeller is secured with the hex head screws 15 to the hydraulic oil
cooler 6. The fan pump 33 is flange-mounted to the diesel engine.
The valve block 10 is secured with the Allen head screws 14 to the uppercarriage and is located bet-
ween the hydraulic oil cooler and the diesel engine.
The valve block 10 holds the pressure-relief valves 3 and 8. The proportional solenoid valve Y347 as
well as the solenoid valves Y356 / Y357 and the piston 4/5 are also integrated into the valve block.
To check the settings at the valve block 10, it is equipped with the measuring point 9. The assembly
is controlled by means of the button S160 with the indicator light H90 in the right control console.
Fig. 2 Right console
1 Hydraulic tank 17 Washer

3 Pressure-relief valve (reversing) 18 Spring
4 Spool (fan outlet) 19 O-ring
5 Spool (reversion of motion) 20 Plug
6 Hydraulic oil cooler 21 O-ring
7 Check valve 22 Guide screw
8 Secondary pressure-relief valve 33 Fan pump
9 Measuring point 88P Manifold P
10 Valve block 88T Collecting pipe T
11 Spring H90 Indicator light
12 Support bracket S160 Button
13 Fan motor Y347 Proportional pressure-relief valve
14 Allen head screw Y356 Solenoid valve (fan outlet)
15 Hex head screw Y357 Solenoid valve (reversion of motion)
16 Plug
16.70.4
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MJFCIFSS
Design
Fig. 3 Design up to serial no. A 900 C 24676, A 904 C 30579
16.70.5
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MJFCIFSS
Design
16.70.6
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MJFCIFSS
See hydraulic and electric diagram
4.1 Normal operation

If the button S160 is not pressed, the relays KT20/KT21 are in idle position. The indicator light H90
is not on and the solenoid valves Y356 and Y357 are not powered. The hydraulic oil fed by the gear
pump 33 flows through the spools 4 and 5 to the input a at the fan motor 13. This means that, with
normal operation, the hydraulic oil and the coolant are cooled.
The proportional pressure-relief valve Y347 limits the maximum pressure. Depending on the tempe-
rature of the hydraulic oil or the coolant, the proportional pressure-relief valve Y347 is controlled by
the BST and the fan speed is increased or reduced accordingly.
4.2 Slowing down the fan for reversing

Press and hold the button S160 (max. 15 seconds).
U16 (BST) increases the speed through the proportional pressure-relief valve Y347 of the fan,
and the current is increased.
Relay KT20 is activated. The solenoid valve Y356 (remains activated during the entire process) is
powered and switched. The pilot control oil (connection PX) shifts the spool 4 to its changeover po-
sition. The connections P- b and a - T are switched. This results in a short circuit in the hydraulic sys-
tem, and the fan speed is reduced.
The pressure-relief valves protect the system during slowing down against overpressure.
4.3 Reversing direction of fan rotation

Press and hold the button S160 for more than 15 seconds.
U16 (BST) reduces the current to the proportional pressure-relief valve Y347 along a ramp (ap-
prox. 3 sec.).
The relay KT20 is activated, and KT21 is shifted. The solenoid valve Y356 is activated, and the so-
lenoid valve Y357 is powered. The spool 5 is shifted, similar to the spool 4. As a result, the connection
to the outlet b of the fan motor 13 is opened, so that the fan propeller rotates in the opposite direction.
The full oil volume is available at the connections P-b and a-T and the fan motor 13 blows with ma-
ximum speed to remove the dirt from the intake area.
The pressure-relief valve 3 limits the pressure and thus the fan speed.
4.4 Slowing down the fan after reversing

If the button S160 is released (15 seconds), the relay KT20 is activated and the solenoid valve Y356
is powered.
U16 (BST) increases the speed through the proportional pressure-relief valve Y347 of the fan, and
the current is increased.
KT21 drops off and the proportional valve Y357 is not powered. The piston 5 is shifted back to its
initial position. The hydraulic oil flows through the connections P-a and b-T, thus slowing down the
fan motor 13.
16.70.7
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MJFCIFSS
Inspection and adjustment
4.5 Normal operation after reversion

If the button S160 is released (for more than 15 seconds), the relay KT20 (time relay) returns to its
idle position. The solenoid valve Y356 s not powered.
U16 (BST) increases the speed through the proportional pressure-relief valve Y347, and the current
drops off.
The piston 4 returns to its initial position. The fan speed can thus be increased again based on the
measured temperature (normal operation).
5 Inspection and adjustment
Caution!
Fig. 5 Settings at the valve block 10
5.1 Settings at pressure-relief valve 3 (reversion)

16.70.8
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MJFCIFSS
Inspection and adjustment
Press and hold the button S160 for more than 15 seconds.
Fan operation is reversed.
Compare the indicated pressure with the technical data, (see Tab. 1 on page3).
If the measured pressure does not conform to that indicated in the technical data:
Loosen the lock nut 43 (WS 17).
Adjust the pressure at the adjusting screw 44 (WS 5).
Tighten the lock nut 43 and remove the pressure sensor.
5.2 Settings at pressure-relief valve 8 (secondary pressure-relief valve)

Disconnect the plug at the proportional solenoid valve Y347.
The fan is operated at maximum output level (emergency operation).
Compare the indicated pressure with the technical data. (see Tab. 1 on page3)
5.3 Settings at the proportional solenoid valve Y347

The proportional solenoid valve Y347 is controlled depending on the hydraulic and coolant tempera-
ture and the a/c system by the BST.
If the fan speed does not conform to the value in the adjustment protocol (see group 6) for normal
operation of the respective machine model:
Compare the indicated pressure with the technical data, (see Tab. 1 on page3).
16.70.9
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MJFCIFSS
Adjustment of the reversible fan drive from V4.6
6 Adjustment of the reversible fan drive from V4.6
From BST version V4.6, the reversible fan drive can be activated by means of the configuration menu
set dat - set config - fan revers. The settings must be adjusted to the actual use of the machine.
Submenu Function Basic setting
fan rev. time In this menu, the fan reverse run time is indi- 140 seconds
cated in seconds.
Adjustment range: 50 - 600 seconds
fan rev. per In this menu, the pause time to the next auto- *300 hours
matic fan reverse run in hours is indicated.
Adjustment range: 0.5 - 300 hours
* If the value is set to the maximum time of 300 hours, the automatic fan reversing is deactivated.
This function can thus be switched off.
Tab. 2 Basic setting
Fig. 6 Submenu set config
Select the set config submenu via the set dat menu.
Fig. 7 Submenu fan revers
In the submenu set config, se the fan reverse mode fan revers to ON.
The fan reverse mode fan revers is activated.
The set values submenu is displayed.
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Fig. 8 Submenu fan rev.time
Select the fan rev.time submenu.

Using the arrow keys UP/DOWN, select the desired fan reversing time, (see Basic setting on
page 10).
Press the BACK button to exit the menu.
Fig. 9 Submenu fan rev. per
Select the fan rev.per submenu.

Using the arrow keys UP/DOWN, select the desired pause time, (see Basic setting on page 10).
Press the BACK button to exit the menu.
6.1 Termination of the fan reverse run in automatic mode
Note!
While reverse operation is on, the function can be terminated by pressing the button S160.
In the excavator control, the reverse run is set to the set fan flow.
Press the button S160.

The fan reverse operation is started.
16.70.11
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MJFCIFSS
16.70.12
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MJFCIFSS
16.70.13
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MJFCIFSS
Fig. 13 Design of electrical system
16.70.14
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MJFCIFSS
1 Hydraulic tank 33 Fan pump

3 Pressure-relief valve 50/A1 to control oil unit
4 Spool (fan outlet) 88P Manifold P
5 Spool (reversion of motion) 88T Collecting pipe T
6 Hydraulic oil cooler a Input ( fan motor)
7 Check valve b Output (fan motor)
8 Secondary pressure-relief valve Y347 Prop. pressure-relief valve
9 Measuring point Y356 Solenoid valve (fan outlet)
10 Valve block Y357 Solenoid valve (reversion of motion)
13 Fan motor
A1100 Printed circuit board X1 Plug connection to BST

F17 Fuse (15A) X2 Plug connection to button S160
H90 Indicator light reversion of motion X214-1 Plug connection A1100 / 2-pin
KT20 Time relay for Y356 (drop-delayed) X214-2 Plug connection A1100 / 2-pin (optio-
nal)
KT21 Time relay for Y357 (power-delayed) X214-3 Plug connection A1100 / 2-pin (optio-
nal)
S160 Reversion of motion button X356 Plug connection to
solenoid valve fan outlet
U16 Excavator control (BST) X357 Plug connection to
solenoid valve reversion of motion
V7 Diode combination X616 Plug connection / 2-pin
X1 Plug connection to button S160 X681 Plug /2-pin
X1 Plug connection to H90 X834 Plug /1-pin
16.70.15
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MJFCIFSS
16.70.16
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MJFCIFSS
Service Manual
SUBGROUP - INDEX
Section Group Type
Auxiliary heater 17.30.1 A 900 C-LI 14675-

A 904 C-LI 16000-
A 914 C-LI 35112-
A 924 C-LI 34519-
Heating and air-conditioning system 17.50.1 A 900 C-LI 14675-

A 904 C-LI 16000-
A 914 C-LI 35112-
A 924 C-LI 34519-
17.1
MJFCIFSS
Service Manual
17.2
MJFCIFSS
Service Manual Auxiliary heater
Function
Auxiliary heater
1 Function
The auxiliary heating system is operated independently from the diesel engine and is designed as a
warm water heating system connected to the cooling/heating circuit of the diesel engine.
The auxiliary heating system is used to heat the operator's cab through separate air ducts. It also he-
ats the cooling water of the engine.
This ensures that the engine
is easy to start
is fuel-efficient
and operated with minimum wear, especially at low temperatures.
Fig. 1 Heating unit
17.30.1
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MJFCIFSS
Auxiliary heater Service Manual
Function
17.30.2
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MJFCIFSS
General information
Type D5WS
Heating medium Water / coolant
Fuel Conventional diesel (DIN EN 590)
PME (DIN V 51606)
Rated voltage 24 V
Operating range
Upper voltage limit 32 V
Lower voltage limit 20.4 V
Control of heat flow High Low
Heat flow 5000 W 2400 W
Fuel consumption 0.62 l/h 0.27 l/h
during machine operation 37 W 10 W
upon start 110 W
during afterrun 8W
Minimum water throughput rate of heating unit 250 l/h
Minimum throughput rate of water pump against
0.1 bar 950 l/h
Permissible ambient temperature
Operation of heating unit -40°C to +80°C
Operation of metering pump -40°C to +80°C
Storage -40°C to +105°C
Permissible operating pressure max. 2.5 bar
Pre-heating time approx. 20 - 50 seconds
Afterrun time approx. 130 seconds
Weight
without coolant and attachments approx. 2.3 kg
with water pump and metering pump approx. 2.9 kg
Tab. 1 Technical data (all data ± 10%)
17.30.3
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MJFCIFSS
Description
3 Description
The auxiliary heating system consists of the following main components:

Mini timer 6
Water pump 8
Metering pump 14
Silencer 15 with waste gas hose
Combustion air hose 18
Heating unit 20 with bracket 21
Console 22
Auxiliary water pump 23
The heating process is started with the mini timer 6 installed in the left console of the operator's cab.
The water pump 8 mounted below the radiator on the console 22, the auxiliary water pump 23 and
the heating unit 20 are activated with the mini timer. Air is sucked up through the combustion air hose
18. The fuel is supplied directly by the metering pump 14 mounted to the fuel tank. This pump is also
started by the clock. The waste gas escapes through the hose of the silencer 15.
Fig. 2 Main components of the auxiliary heating system
17.30.4
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MJFCIFSS
Description
3.1 Component parts of the heating unit
Fig. 3 Component parts of the heating unit
2 Control unit 50 Jacket

3 Plug connection / 8-pin 51 Pressure spring
7 Combustion air fan 52 Cover for jacket
9 Temperature sensor 53 Cover for combustion air fan
10 Combustion chamber 54 Grommet
11 Overheating sensor 55 Bracket
12 Heat exchanger 56 Gasket and seal kit
16 Glow pencil 57 O-ring
17 Flame sensor 58 Cover
17.30.5
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MJFCIFSS
Operation and function of the auxiliary heating system
4 Operation and function of the auxiliary heating system
Fig. 4 Sectional drawing of the heating unit
1 Electric motor 9 Temperature sensor 17 Flame sensor

2 Control unit 10 Combustion chamber 18 Waste gas hose
3 Plug connection / 8-pin 11 Overheating sensor
4 Vehicle fan relay 12 Heat exchanger A Waste gas
5 Main fuses 13 Cup sieve B Fuel
6 Mini timer 14 Metering pump V Combustion air
7 Combustion air fan 15 Silencer WA Water outlet
8 Water pump 16 Glow pencil WE Water inlet
17.30.6
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MJFCIFSS
4.1 Commissioning of the heating unit

Prior to commissioning, after installation or repair, observe the following:
Bleed the coolant circuit and the fuel supply system.
Prior to completing a test run, open the coolant circuit (set temperature controller to "Warm").
During the test run of the heating unit, check all water and fuel connections for leakage and proper
fit.
Check cooling water level in the expansion tank.
4.2 Safety instructions for heater operation

When operating the auxiliary heating system, adhere to the following instructions:
Before refuelling, switch off the heating unit.
The heating unit may not be operated under conditions where flammable fumes or dust could occur.
The mounting recess for the heating unit may not be used for the storage of other items.
Do not store
fuel canisters
oil or spray cans
gas cartridges
fire extinguishers
cleaning cloths
items of clothing
paper
or similar material on top of or beside the heating unit.
4.3 Switching on of the heating unit

Switch on the auxiliary heating.
If the A/C system is on: text SH (for auxiliary heating) is displayed for some seconds (see Fig.
5, page 8).
The A/C system is switched off and cannot be switched on while the auxiliary heating is in ope-
ration.
The A/C system is again ready for operation when the auxiliary heating is switched off and its
afterrun time has lapsed.
Upon switching on, the indicator lam in the mini click 6 is switched on. The water pumps 6 and 23 are
started and and the combustion air fan 7, glow pencil 16 and the combustion metering pump 14 are
switched on, depending on the actual programme. As soon as a stable flame is established, the glow
pencil 16 is switched off by the timer.
17.30.7
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MJFCIFSS
Fig. 5 Display on the control device of the heating and a/c system
4.4 Control functions

If there is no ignition within 90 seconds from the start of the fuel supply, the heating unit start is re-
peated. If there is no ignition after another 90 seconds of fuel supply, the unit is shut down (fault shut-
down*).
If the flame goes out during operation, the system is restarted. If the heating unit fails to ignite within
90 seconds after the start of the fuel supply, or if the flame goes out within 15 minutes after ignition,
the unit is shut down (fault shut-down). To reset the unit to normal mode, switch it off and immediately
on again.
In the event of overheating (e.g. insufficient water in system, poorly ventilated cooling circuit), the
overheating sensor is triggered. The fuel supply is interrupted and the unit is shut down (fault shut-
down). After the cause of the shut-down has been eliminated and the cooling water temperature has
dropped to below 70°C, restart the heating unit by briefly switching it off and on again.
If the upper or lower voltage limit is reached (see table 1, page 3), the system is automatically shut
down (fault shut-down).
The unit cannot be started if the glow pencil is defective or if the electrical connection to the metering
pump is interrupted.
The speed of the fan motor is constantly monitored. If the motor fails to start or is blocked, and if the
speed drops below 40% of the rated speed, the unit is shut down after 60 seconds (fault shut-down).
*= After a set number of unsuccessful start-up attempts, the control device is locked.
The lock can only released with the diagnostic instrument, (see "Fault diagnosis", page 15), which
can also be used to determine the cause of the fault (for units with mini timers). In systems equipped
with a built-in modular clock (optional) the fault data can be read and the system lock can be released
without the need for a diagnostic instrument.
4.5 Functions during heating operation

When the heating unit 20 is switched on, the generated heat is fed to the heat exchanger 42 of the
vehicle and the diesel engine 40.
After the cooling water has reached a temperature of approx. 30°C, the vehicle fan is switched on
and hot air is fed to the operator's cab.
Depending on the temperatures, the heating unit adjusts the heat output to the following levels: High
- Low - OFF (control break).
17.30.8
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The respective temperature thresholds are preset in the electronic control unit.
At a cooling water temperature of < 70°C, the heating unit operates at level "High".
At a cooling water temperature of approx. 80°C, the heating unit switches to level "Low".
If the heat requirements at level "Low" are low (cooling water temperature 85°C), the heating unit is
shut down after a delay of approx. 130 seconds.
During the control break, the indicator lamp and the water pump remain on.
Fig. 6 Connection to the cooling water circuit
8 W pump 42 Heat exchanger in operator's cab

20 Heating unit 44 Connecting piece
40 Diesel engine
4.6 Switching off of the heating unit
Note!
When the unit is switched off, its fuel supply is interrupted. The combustion air fan and the water
pump are automatically shut down after a delay of approx. 180 seconds.
The unit can be shut down in two different ways:

During continuous operation, by pressing button 33, (see Fig. 7, page 10).
After lapse of preset heating time.
17.30.9
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MJFCIFSS
4.7 mini timer settings
Fig. 7 Mini timer
30 Button to activate setup mode 34 Display for actual time, preset time and hea-
ting time
31 Button to set time forward 35 Symbol for activated preset time
32 Button to set time back 36 Symbol for heating operation
33 ON / OFF button to activate/deactivate pre- 37 Symbol for preset time (1, 2 or 3)
set time
Note!
If no button is pressed within 15 seconds, the display returns to its initial status (= standard time
display).
When adjusting the time with the buttons 31 and 32, press and hold the buttons for faster time
adjustment.
Commissioning of mini timer

After the unit has been connected to the power supply line, all display symbols 34 flash. The heating
unit cannot be started at this point, as the current time is not set.
Setting of current time

Press and hold button 30 for more than 3 seconds
The time display flashes.
Press the buttons 31 and 32 until the current time is displayed.
Press the button 30 for less than 5 seconds
The current time is displayed, and the colon flashes.
Note!
If the button 30 is not pressed within 5 seconds after the adjustment of the current time, the timer
switches to "Heating time settings" mode.
Setting of heating time

Press and hold button 30 for more than 3 seconds
The current time display flashes.
The mini time changes to "Heating time settings" mode.
17.30.10
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The heating symbol and the heating time flash.

Press the buttons 31 and 32 to adjust the heating time (10 to 120 minutes).
Press the button 31 to set the time forward.
Press the button 32 to set the time back.
Press the button 30.
The current time is displayed, and the colon flashes.
Setting of preset time

Press the button 30 1x, 2x or 3x.
The preset time 1, 2 or 3 is called up and shown on the display (35 and 37).
Adjust the preset time, using the buttons 31 and 32.
Press the button 31 to set the time forward.
Press the button 32 to set the time back.
Switching on of the heating unit

Press the button33.
The display shows the remaining heating time and the respective symbol 36.
Switching off of the heating unit

Press the button33.
The heating unit is shut down with a delay of approx. 3 minutes, and the current time is shown
at the display.
Continuous operation
Press and hold the button 32.
The heating unit is switched on.
Press the button 33 again.
The heating unit is switched off.
Activating/deactivating the preset time

Note!
The mini timer caters for up to 3 preset times. Each preset time is automatically deactivated after
the respective heating process is completed, and must thus be reactivated for the next heating pro-
cess.
Press the button 30 1x, 2x or 3x until the desired preset time is shown on the display.
Press the button 33 to activate the selected preset time.
When the time is activated, the ON symbol 35 is displayed.
When the preset time is activated, the respective symbol (37) 1, 2 or 3 is displayed.
Press the button 33 to deactivate the selected preset time.
17.30.11
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MJFCIFSS
Retrofitting of the auxiliary heating system
5 Retrofitting of the auxiliary heating system
Caution!
Risk of short circuit and injury from burns!
Prior to any installation work, shut down the battery main switch, or disconnect the vehicle bat-
tery.
Before carrying out any work at the heating unit, shut it down and allow all hot parts to cool down.
Fig. 8 Installation of the auxiliary heating system
8 Water pump 28 Fuel hose

15 Silencer 42 Heat exchanger in operator's cab
18 Waste gas hose 70 Stock cock in water feed line from the engine
20 Heating unit 71 Stop cock in the water return line to the
engine
22 Console A Water feed line from the engine
23 Auxiliary water pump B Water feed line to the heat exchanger in the
operator's cab
24 Water feed hose C Water return line from the heat exchanger
25 Interface heating unit - water feed line D Water return line to the engine
26 Interface heating unit - heat exchanger E Air intake
27 Water return hose F Waste gas outlet
17.30.12
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MJFCIFSS
Retrofitting of the auxiliary heating system
5.1 Installation of the auxiliary heating system

Mount the heating system 20 on the console22, (see Fig. 8, page 12).
Install the console 22 with all attached devices below the radiator.
Close the taps 70 and 71 at the diesel engine, (see Fig. 8, page 12).
Disconnect the water hose 24 (feed line to bottom of engine) in such a way that the hose reaches
the connection point 25 at the diesel engine.
Ensure that the water hose is not kinked and does not touch any rotating components (e.g. fan
wheel).
Secure the water hose 24 at the connection point 25, using a hose clip.
Cut the water hose 24 connected to the heat exchanger in the operator's cab 42 to size and secure
it to the connection point 26, using a hose clip.
Mount the metering pump 14 to the tank and connect it, (see Fig. 9, page 13).
Lay the fuel hose 28 from the tank to the heating unit and connect it, (see Fig. 10, page 14).
Attach the combustion air hose 18 to the revolving deck.
Secure the silencer 15 and the waste gas hose to the revolving deck, using a clip.
Open the taps 70 and 71 at the diesel engine.
5.2 Installation of the metering pump
Fig. 9 Installation of the metering pump
14 Metering pump 62 Fuel strainer

61 Plug connection X98 63 Connection to fuel tank
17.30.13
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MJFCIFSS
Maintenance
Fig. 10 Lines to and from the metering pump
A Correct laying of lines B Incorrect laying of lines
When installing the metering pump and laying the fuel lines, observe the following:
Cut fuel hoses and pipes with a sharp-edged knife. Ensure that the cutting edges are not squee-
zed or burred.
Do not lay fuel lines near the waste gas line from the heating unit or near the diesel engine.
All fuel lines must be installed with butt joints to prevent bubbles, (see Fig. 10, page 14).
Install the metering pump in such a way that the pressure side is located at the top. Ensure that
the angle of installation is between 15° and 35°, (see Fig. 10, page 14).
6 Maintenance
Check the fuel strainer 62 at the metering pump 14 for contamination, (see Fig. 9, page 13).
17.30.14
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MJFCIFSS
Fault diagnosis
7 Fault diagnosis
Preconditions:
Ensure that
there is sufficient fuel in the tank.
during winter, there is no summer diesel in the fuel lines.
the combustion air and waste gas lines are OK.
all fuses are OK.
Check the battery voltage U Batt (terminal 30).
Disconnect the 8-pin plug X101 (S1 / B1) and measure the voltage between pin 1 (wire 2.52 red)
and pin 2 (2.52 brown) of plug B1. If the measured voltage does not correspond to the battery
voltage, check the fuses, the supply lines, the earth conductor and the positive pole of the bat-
tery for voltage drop (corrosion, loose contact).
Check switch-on signal (S+).
Disconnect the 8-pin plug X101 S1 / B1 and press the button 33 at the mini timer. Measure the
voltage between pin 7 (wire 0.52 yellow) and pin 2 (2.52 brown) of plug B1. If no voltage is
measured, check the supply line (wire 0.52 yellow), the 5A fuse at the main fuses 5 and the mini
timer 6.
Check the mini timer.
Disconnect the plug X95 from the mini timer and bridge the wires 0.52 red and 0.52 yellow. If a
voltage is measured in plug X101 (B1) between pin 7 (wire 0.52 yellow) and pin 2 (wire 0.52
brown), replace the mini timer.
7.1 Fault diagnostics with the diagnostic instrument

For more detailed fault detection, evaluation of the fault memory and release of the control device,
use the diagnostic instrument with adapter cable (optional equipment, for ID no. see group 2.01).
The electronic control device can store up to 5 different fault codes, which can be read with the dia-
gnostic instrument.
Fig. 11 Diagnostic instrument
65 Deletion of the stored fault codes 68 Page through faults F5 - F1

66 Deletion of the stored fault codes 69 Page through faults F1 - F5
67 Call up diagnostic fault code 70 Display
17.30.15
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MJFCIFSS
Fault diagnosis
Fig. 12 Connection of the diagnostic instrument with adapter cable
6 Mini timer 68 Diagnostic instrument

20 Heating unit 69 Adapter cable kit
The current fault is indicated as fault "AF" and is always stored in memory position F1.
Previously recorded faults are stored in the memory positions F2 - F5, and the content of memory
position F5 is overwritten by the fault code of the next fault.
The system detects not only defective component parts but also defective current circuits.
Viewing fault codes

The display shows code "AF" (= current fault) and a 3-digit numerical code (= fault code).
Release of the control system lock and deletion of a fault code

After the cause of the fault has been eliminated:
Press and hold the buttons 65 + 66 simultaneously for at least 2 seconds.
The control device is released and the stored faults F1 - F5 are deleted.
Switch the auxiliary heating system off and on again.
Note!
When connecting the diagnostic instrument, you need an additional adapter cable (see tools in
group 2.01), as the plug connections are difficult to access.
Open the cover of the right console.
Disconnect the mini timer from the cable harness.
Connect the adapter cable of the diagnostic instrument.
17.30.16
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MJFCIFSS
Fault diagnosis
7.2 Fault codes, fault descriptions and remedies
Fault
Description of fault Remedies
code
010 Overvoltage: Overvoltage lasting for minimum 20 seconds without inter-
switch-off ruption at the control device heating unit not in operation
Disconnect plug connection X101 (B1/S1).
Start vehicle engine.
Measure the voltage in plug X101 (B1 between pin 1 and
pin 2).
Voltage > 28 V:
Check generator controller and battery.
011 Undervoltage: Undervoltage lasting for minimum 20 seconds without inter-
switch-off ruption at the control device heating unit not in operation
Disconnect plug connection X101 (B1/S1).
Start vehicle engine.
Measure the voltage in plug X101 (B1 between pin 1 and
pin 2).
Voltage < 20 V:
Check the fuses, the supply lines, the earth connections
and the positive pole of the battery for voltage drop (cor-
rosion).
012 Overheating Temperature at the overheating sensor > 125°C.
(software-controlled Check water circuit.
threshold)
Check all hose connections for leakage.
Check direction of flow at the thermostat and the check
valves.
Bleed the water circuit.
Check the water pump.
Check the temperature and overheating sensors.
014 Possible incident of Temperature difference threshold between overheating sen-
overheating detected sor and temperature sensor > 25K.
(difference evaluati- These fault codes are only displayed, if the heating system
on): is in operation and the water temperature at the overheating
The settings for the sensor is at least 80°C.
heating system with
date of manufacture
up to 12.97 are as fol- Check direction of flow at the thermostat and the check
lows: valves.
Temperature diffe-
rence threshold for
overheating sensor > Check the water pump.
15K.
Minimum water tem-
perature at overhea-
ting sensor 70°C.
17.30.17
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MJFCIFSS
Fault diagnosis
Fault
code
015 Control lock: The control device is automatically locked.
Permissible maxi-
Release the control device by means of the diagnostic in-
mum overheating
strument
events (10) is excee-
ded. Check the water circuit.
valves.
017 Overheating Temperature at the overheating sensor > 130°C.
EMERGENCY-
Check the water circuit.
STOP:
(hardware threshold) Check all hose connections for leakage.
valves.
020 Glow pencil interrupti- Complete function test of built-in glow pencil:
on:
Disconnect pin 9 (1.52 white) and pin 12 (1.52 brown) of
the 14-pin plug.
021 short circuit, overload
or earth contact in Apply 18 V ± 0.1 V at the glow pencil, and measure the
glow pencil output current after 25 seconds.
line. Current = 4.5 A ± 1.5 A
Complete function Glow pencil OK.
test with max. 18 V.
If the glow pencil is OK:
When this value is ex-
ceeded, the glow Check the connecting lines of the glow pencil for dama-
pencil is destroyed ge.
(observe short-circuit
In the event of fault code 021:
strength of the mains
adapter)! Check the installation of the adapter and the corrugated
disk.
Check the lines for damage (short circuit).
17.30.18
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MJFCIFSS
Fault diagnosis
Fault
code
030 Speed of combustion Fan wheel or combustion air fan motor blocked
air fan outside the (frozen, contaminated, stiff, lines touching shaft end, etc.).
permissible range:
Remove blockage.
Check voltage (max.
15 V + 0.2 V). Measure the speed of the combustion air fan motor:
Check the lines for
Disconnect pin 14 (0.752 brown) and pin 13 (0.752 black)
correct connection!
of the 14-pin plug.
brown = +
black = - Apply reflective strips to the shaft.
Apply 15 V to the combustion air fan motor.
adapter)! Measure the speed using a contact-free speed meter.
Speed < 1000 rpm:
replace the combustion air fan
Speed > 1000 rpm:
Replace control device.
031 Combustion air fan Check lines of the combustion air fan motor for correct in-
motor: stallation and damage.
interruption
Measure the speed of the combustion air fan motor:
Check voltage (max.
15 V + 0.2 V). Disconnect pin 14 (0.752 brown) and pin 13 (0.752 black)
Check the lines for of the 14-pin plug.
correct connection!
Apply reflective strips to the shaft.
brown = +
black = - Apply 15 V to the combustion air fan motor.
Measure the speed using a contact-free speed meter.
adapter)! Speed < 1000 rpm:
Speed > 1000 rpm:
replace the control device
17.30.19
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MJFCIFSS
Fault diagnosis
Fault
code
032 Combustion air fan The fan wheel or the combustion air fan motor is blocked
motor: (contaminated, stiff, lines touching shaft end, etc.)
short circuit
Remove blockage.
Check voltage (max.
15 V + 0.2 V). Measure resistance.
Check the lines for
Resistance < 2 k = earth contact:
correct connection!
brown = + replace the combustion air fan
black = -
Resistance > 2 k = no earth contact:
strength of the mains Measure the speed of the combustion air fan motor.
adapter)!
Measure the speed of the combustion air fan motor:
Disconnect pin 14 (0.752 brown) and pin 13 (0.752 black)
of the 14-pin plug.
Apply reflective strips to the shaft.
Apply 15 V to the combustion air fan motor.
Measure the speed using a contact-free speed meter.
Speed < 1000 rpm:
Speed > 1000 rpm:
Replace control device.
038 Relay-controlled ac- Check electrical line to relay.
tuation of the vehicle
fan:
interruption Replace relay.
039 Relay-controlled ac- Remove relay.
tuation of the vehicle Fault code 038 is displayed.
fan:
short circuit, overload
or earth contact. Replace relay.
041 Water pump: Check supply line to water pump:
interruption
Disconnect pin 10 (0.52 brown) and pin 11 (0.52 purple)
of the 14-pin plug.
Eliminate the cause of the fault; replace the water pump,

if necessary.
042 Water pump: Disconnect plug connection in water pump cable har-
short circuit, over- ness:
load, earth contact
If fault code 041 is indicated:
Water pump defective.
Replace water pump.
047 Metering pump: Disconnect plug connection in metering pump cable har-
short circuit, over- ness:
load,
earth contact
Replace metering pump.
17.30.20
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MJFCIFSS
Fault diagnosis
Fault
code
048 Metering pump: Check metering pump cable harness.
interruption
Eliminate cause of fault;
replace metering pump, if necessary.
050 Control lock: Control device is automatically locked.
too many start
Delete fault memory of the control device, using the dia-
attempts
gnostic instrument.
(10 start attempts,
plus one repeat Release control device.
attempt for each
Check fuel level.
failed start)
051 Timeout: Upon start-up, the flame sensor measures a temperature >
cold-blowing 70°C for more than 240 seconds.
Check waste gas and combustion air guide system.
Check flame sensor.
052 Safety delay: Check waste gas and combustion air guide system.
exceeded
Check fuel level.
053 Flame interruption at Warning!
control level "High" In the event of a flame interruption at control levels "High" or
056 "Low", the heating attempts to restart the flame until the
number of start attempts exceeds the above limit and the
control device is locked!
Restart or start attempt = successful fault code display
is cleared.
Fault, as no more start attempts are possible:

Check waste gas and combustion air guide system.
Check fuel level.
Check flame sensor, see fault codes 064 and 065.
060 Temperature sensor: Disconnect control device and inspect the connecting ca-
interruption ble of the temperature sensor for damage.
Lines are OK.
Short-circuit temperature sensor.
Short-circuit temperature sensor:
At the 14-pin plug, connect pin 3 to pin 4.
Switch on heating.
Dismantle and check the temperature sensor.
Check control device; replace it, if necessary.
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Fault diagnosis
Fault
code
061 Temperature sensor: Disconnect control device and inspect the connecting ca-
short circuit, overload ble of the temperature sensor for damage.
or earth contact
Lines are OK.
The test can only be Disconnect 14-pin plug from the control device.
performed on a test
Disconnect pin 3 (0.52 blue) and pin 4 (0.52 blue).
bench, or if the hea-
ting is installed in the Reconnect 14-pin plug to the control device.
machine.
Switch on heating.
064 Flame sensor: Disconnect control device and inspect the connecting ca-
interruption ble of the flame sensor for damage.
Lines are OK.
The test that requires
a bridge in the 14-pin At the 14-pin plug, exchange pin 1 and pin 2.
plug can only be per-
Switch on heating.
formed on a test
bench, or if the hea- If fault code 065 is indicated:
ting is installed in the
Dismantle and check the flame sensor.
machine.
065 Flame sensor: Disconnect control device and inspect the connecting ca-
short circuit, over- ble of the flame sensor for damage.
load, earth contact
Lines are OK.
The test can only be Disconnect 14-pin plug from the control device.
performed on a test
Disconnect pin 1 (0.52 blue) and pin 2 (0.52 brown).
bench, or if the hea-
ting is installed in the Reconnect 14-pin plug to the control device.
machine.
Switch on heating.
Dismantle and check the flame sensor.
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Fault diagnosis
Fault
code
071 Overheating sensor: Disconnect control device and inspect the connecting ca-
interruption ble of the overheating sensor for damage.
Lines are OK.
The test that requires
a bridge in the 14-pin At the 14-pin plug, exchange pin 5 and pin 6.
plug can only be per-
Switch on heating.
formed on a test
bench, or if the hea- If fault code 072 is indicated:
Dismantle and check the overheating sensor.
machine.
072 Overheating sensor: Disconnect control device and inspect the connecting ca-
short circuit, over- ble of the overheating sensor for damage.
load, earth contact
Lines are OK.
Disconnect 14-pin plug from the control device.
The test can only be
Disconnect pin 5 (0.52 red) and pin 6 (0.52 red).
performed on a test
bench, or if the hea- Reconnect 14-pin plug to the control device.
Switch on heating.
machine.
Dismantle and check the overheating sensor.
090 Control device defec- Replace control device.
092 - 103 tive
091 External interference Fault of control device due to interference voltage from the
voltage on-board network caused by poor batteries, chargers and
other sources of interference.
Eliminate sources of interference.
Possible faults that are not indicated on the diagnostic instrument
Description Remedies
Heating fails to start. After the heating is switched on, the water pump and the ve-
hicle fan are started without delay.
7.3 Checking of flame sensor

Check the flame sensor, using a digital multimeter. If the resistance of the flame sensor is outside the
value range shown in the table, replace the flame sensor.
7.3.1 Value table of flame sensor
Temp (°C) -50 0 10 20 30 50 80 90

R( 803 1000 1022 1062 1097 1194 1309 1347
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Electrical system
U (V) 1.407 1.639 1.661 1.719 1.738 1.840 1.948 1.983
Temp (°C) 100 130 150 200 250 300 350 400
R( 1385 1498 1573 1758 1941 2120 2297 2470
U (V) 2.016 2.111 2.171 2.308 2.432 2.542 2.642 2.732
7.4 Checking of overheating and temperature sensors

Check the overheating and temperature sensors, using a digital multimeter. If the resistance value is
outside the value range shown in the table, replace the overheating or temperature sensor.
7.4.1 Value table of overheating and temperature sensors

Temp (°C) 0 10 20 30 40 50 60 70
R (k 32.54 19.87 12.48 8.06 5.33 3.60 2.48 1.75
U (V) 4.275 3.960 3.561 3.100 2.611 2.135 1.705 1.339
Temp (°C) 80 90 100 110 120

R (k 1.25 0.91 0.67 0.50 0.38
U (V) 1.041 0.805 0.622 0.483 0.376
8 Electrical system
Note!
The electrical components and connections are shown in the circuit diagram of group 8.
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Service Manual Heating and air-conditioning system
Function
Heating and air-conditioning system
1 Function
All operator's cabs are equipped with a heating and air-conditioning system, which also allows for the
ventilation of the cab.
Operators have the option to
adjust the temperature in the cab
dehumidify (reheat) the cab during the wet seasons
adjust the ventilation by controlling the flaps and blowers
1.1 General information regarding the air-conditioning system

The air-conditioning system can only be operated when the vehicle engine is switched on.
In cooling mode, the air humidity inside the vehicle is also lowered. This prevents fogging of the
windscreens.
The air-conditioning system is most effective when the windows and doors are closed. If the inte-
rior of the cab is however greatly heated up by the sun, it is advisable to briefly open the doors/
windows to let the heat escape, as this accelerates cooling.
At high temperatures and high humidity, condensation might drip from the evaporator, producing
a puddle under the machine. This is normal and does not indicate leakage.
The filter in the recirculated air grid traps contaminants and thus cleans the air. If the ambient air
is polluted, we recommend operating the system with recirculated air. In order to ensure proper
operation of the air-conditioning system, the elements of the recirculated air grid must be regularly
cleaned and/or replaced.
Caution!
For safety reasons, we recommend that all maintenance work and repairs on the air-conditioning
system are carried out by specialist refrigeration technicians. When working on the cooling cir-
cuit, always adhere to the safety and accident prevention instructions, and especially the environ-
mental protection instructions regarding the refrigerant.
17.50.1
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Heating and air-conditioning system Service Manual
Function
17.50.2
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Technical data
2 Technical data
Heating and air-conditioning unit Type Terminal 2/4

Operating voltage V DC 24
Refrigerant Type R134a
Refrigerant capacity kg approx. 1.4 (without operator's cab elevati-
on)
approx. 1.6 (without operator's cab elevati-
on)
Refrigeration oil in circuit cm3 200
Refrigeration oil grade PAG SP 10
Evaporator cooling capacity kW max. 7.5
Evaporator heating capacity kW max. 9.5
Evaporator air flow m3/h 1165
Evaporator current consumption A 13.4
Compressor Type SD 7 H 15
Compressor weight kg 5,3
Magnetic clutch diameter mm 119
voltage V DC 24
Pressure switch
Low pressure switch off bar 1.5 ± 0.5
switch on bar 3.4 max.
High pressure switch off bar 25.5 ± 0.5
switch on bar 18.0 ± 0.5
Defrost thermostat switch off °C 1.0 ± 1.0
switch on °C 5.5 ± 1.0
Pressure relief valve 9 bar 32.0 ± 4
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Design
3 Design
The air-conditioning system consists of 4 main components that are connected to each other by ho-
ses:
The a/c compressor 1 with electromagnetic clutch Y20 is powered by the diesel engine through
V-belts and is thus located near the diesel engine, at the fan side
The condenser 2 is mounted at the front of the combined radiator (for engine coolant, hydraulic
oil, etc.).
The heating and air-conditioning unit 20 is installed in the operator's cab behind the seat and
forms the low-pressure side of the system. It contains the heating and evaporator battery (heat
exchanger) 8 and the expansion valve 6. The heat exchanger 8 combines the evaporator of the
a/c cooling circuit and the heat exchanger of the warm water heating in a single battery unit. The
defrost thermostat B43 is mounted on the evaporator battery 8. It prevents ice build-up on the eva-
porator battery and 8 switches off the compressor.
The dryer-collector unit 3 is located in the high pressure range of the unit behind the operator's
cab and consists of the internal filter dryer 4 and the sight glass 5. The reservoir 3, the filter dryer
4 and the sight glass 5 form a unit and cannot be separately replaced.
The cooling water of the diesel engine is fed through hoses to the heat exchanger and thus forms
a separate circuit.
1 A/c compressor B255 Temperature sensor / intake air

2 Condenser unit B257 Temperature sensor / blow-out air
3 Reservoir M13 Motor / evaporator blower
4 Filter dryer (internal) M75 Motor / ambient air flap
5 Sight glass M76 Motor / rear panel air flap
6 Expansion valve M77 Motor / control console air flap
8 Heat exchanger M78 Motor / legroom and windscreen air flap
9 Safety valve U37 Control unit / heating and air-condi-
tioning system
10 Dryer-collector unit U38 Control panel
20 Housing of heating and air-conditioning Y20 Magnetic clutch / a/c system
unit
B43 Defrost thermostat / a/c system Y46 Solenoid valve / heating system
B44 Pressure switch / a/c system
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Exploded view of the heating and air-conditioning system
4 Exploded view of the heating and air-conditioning system
Fig. 1 Heating and air-conditioning system
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see Fig. 1 / see Fig. 3
5.1 Principle of the air-conditioning system

The compressor 1 compresses the gaseous refrigerant R134a and feeds it through the heat ex-
changer 2 (condenser), which is cooled by ambient air blown through the unit by the fan propeller of
the combined cooler. The pressurised refrigeration is heated up as a result of the compression in the
compressor. When it is processed through the heat exchanger 2, it is cooled down and condensates.
That is why the heat exchanger is also referred to as the condenser.
The liquid refrigerant is collected in the reservoir 3 and then fed through the dryer 4 and the sight
glass 5 to the expansion valve 6 at the evaporator inlet, where it is depressurised and eventually eva-
porates.
The heat required for evaporation of the refrigerant is taken from the air flow over the evaporator pro-
duced by the blower. As a result, the air in the system is cooled down and then returned to the ope-
rator's cab, lowering the air temperature in the cab.
The gaseous refrigerant flows to the compressor 1 where it is compressed, and the cycle described
above recommences.
5.1.1 A/c compressor 1

The compressor 1 feeds the R134a coolant through the circuit and compresses it.
5.1.2 Condenser 2
In the air-filled fin condenser 2 the heat in the circuit is dissipated into the ambient air and the gaseous
R134a refrigerant becomes liquid.
5.1.3 Dryer-collector unit 10

The liquid refrigerant is collected in the dryer-collector unit 10, which is located downstream from the
condenser 2. It ensures that only liquid refrigerant without bubbles reaches the expansion valve 6.
Due to its chemical properties, the R134a refrigerant contains very little water. At evaporation tem-
peratures below 0°C, any unsolved 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 water from entering the circuit, a number of sieves or filters are installed at the outlet end
of the dryer 10. They remove contaminants such as acidic substances and dirt particles.
The main drying system consists of a hollow part made of sintered silicate beads. It extracts any re-
sidual moisture from the refrigerant and also binds acidic substances. Through the sight glass 5, the
operator can inspect the refrigerant and the humidity content of the system.
During a/c operation, the liquid refrigerant must flow through the sight glass 5 and may not contain
bubbles. The white floating ball 5a must be visible at the top of the sight glass. If this is not the case,
there is insufficient refrigerant in the circuit. Add refrigerant R134a to the system.
The colour of the indicator bead 5b visible through the sight glass changes with the humidity content
of the refrigerant, see Fig. 2.
A grey bead indicates that the humidity content is within the permitted range.
A pink bead indicates that the dryer-collector unit is saturated with water and must be immediately
replaced.
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Note!
From 01/2005 (see ID tag), the dryer-collector units are supplied with modified indicator beads.
NEW:
An orange bead indicates that the humidity content is within the permitted range.
A transparent bead indicates that the dryer-collector unit is saturated with water and must be
immediately replaced.
5.1.4 Expansion valve 6

The R134a refrigerant enters the evaporator through the expansion valve 6, which also acts as a re-
gulating element. It is controlled by means of a temperature sensor located at the outlet of the eva-
porator 8.
If the outlet temperature at the evaporator is below the lower limit value, there is a risk that liquid re-
frigerant might flow into the compressor, damaging it.
To prevent this, the temperature sensor activates the expansion valve 6, which then restricts the inlet
flow to the evaporator 8.
5.1.5 Evaporator 8
The evaporator 8 consists of a heat exchanger that is heated by means of a fan. The heat required
to evaporate the refrigerant flowing through the unit is taken from the air in the cab, which flows along
the fins and pipe walls of the evaporator.
5.1.6 Safety devices

When the maximum pressure is reached on the high pressure side, the pressure switch B44 at the
dryer 10 switches off the a/c compressor 1, preventing damage to the machine.
The pressure relief valve 9 (with diaphragm) built into the dryer-collector unit opens when the pres-
sure reaches 32 bar. The pressure relief valve 9 thus acts as an additional safety device, preventing
damage in the event of failure of the pressure switch B44.
Fig. 2 Dryer 3
5.1.7 Defrost thermostat B43
The defrost thermostat protects the evaporation block against damage from ice:
At temperatures below +1 degree Celsius, measured by the temperature sensor B43, the magnetic
clutch automatically shuts down the compressor to prevent ice formation on the evaporation block.
The blowers (fan and radial blower) are not affected by this.
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Fig. 3 Functional diagram of the heating and air-conditioning system
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Air circuit
A Cabin air 1 Blown out at the control console
B Ambient air 2 Blown out in the legroom and at the winds-
creen
C Air is heated or cooled respectively in the 3 Blown out at the rear panel
heating or evaporation block
D Ambient air is heated in the condenser bat-
tery
Refrigerant circuit
E High pressure (liquid state) G Low pressure (liquid state)
F High pressure (gaseous state) H Low pressure (gaseous state)
Component parts:
1 A/c compressor B255 Temperature sensor / cabin
2 Condenser unit B257 Temperature sensor / blow-out air
3 Reservoir M13 Motor / evaporator blower
4 Filter dryer M75 Motor / ambient air flap
5 Sight glass M76 Motor / rear panel air flap
6 Expansion valve M77 Motor / control console air flap
8 Heat exchanger M78 Motor / legroom and windscreen air flap
9 Safety valve U37 Control unit / heating and air-conditioning
system
10 Dryer-collector unit U38 Control panel
20 Heating and air-conditioning unit Y20 Magnetic clutch / a/c system
B43 Defrost thermostat Y46 Solenoid valve / heating system
B44 Pressure switch / a/c system
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Operation of the heating and air-conditioning system
6 Operation of the heating and air-conditioning system
Fig. 4 Control element
Control keys
1 A/c system ON / OFF (cooling mode) 7 Heating operation manual / automatic
2 Increase cabin temperature 8 Fresh air mode / recirculated air mode
3 Lower cabin temperature 9 Rear panel ventilation flap OPEN / CLOSED
4 Control ON / OFF 10 Right console ventilation flap OPEN / CLO-
SED
5 Fan speed manual / automatic 11 Ventilation flap windscreen legroom
OPEN / CLOSE
6 REHEAT mode 12 Ventilation flap windscreen legroom
OPEN / CLOSE
Main screen display

13 Recirculated air mode 20 Automatic mode
14 REHEAT mode 21 Fan speed indicator bar, manual mode
15 A/c mode (cooling mode) 22 Fan speed symbol, manual mode
16 Rear panel ventilation flap OPEN 23 Heating operation symbol, manual mode
17 Ventilation flap right control console OPEN 24 Heating operation indictor bar, manual mode
18 Ventilation flap windscreen OPEN 25 Nominal value / error code
19 Ventilation panel legroom OPEN 26 Temperature unit (°)
17.50.10
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Note!
In order to achieve optimised a/c settings, select automatic mode 20. The indicator bars 21 and
24 for manual mode are not displayed.
The manual - automatic temperature adjustment cannot be influenced. Only the heating can be
adjusted manually. The automatic a/c system cannot be controlled manually.
In the event of problems such as drafts, etc. the fan speed can be adjusted manually in automatic
mode.
When the control unit detects an error, the error code F1-F5 is shown at the display (flashing
code).
6.1 Switching on of the control unit
Fig. 5 Switching on of the control unit
Switch on the system by pressing key 4.

The control unit performs an auto test. During this period (approx. 12 seconds) the software
version details are displayed on the screen.
The heating and ventilation of the cabin are in operation. If the AUTO (20) symbol is activated, the
heating output and the fan speed are controlled automatically.
6.2 Setting of desired cabin temperature
Fig. 6 Adjustment of the cabin temperature
The 4-digit segment display 25 indicates the desired cabin temperature.

Press key 2 to increase the temperature.
Press key 3 to reduce the temperature.
The set temperature remains stored until it is changed again.
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To cool the cabin, switch to a/c (see 6.4).

To manually adjust the temperature press key 7.
The heating symbol flashes for 5 seconds.
While the heating symbol flashes, press key 2 or 3 to manually increase or reduce the heating
output.
Press key 7 to reset the system to automatic mode.
6.3 Switching temperature display to Fahrenheit
Fig. 7 Switching temperature display to Fahrenheit
Press and hold the fresh air mode key 8.

The symbol 13 is displayed.
Press the key 3.
The temperature is displayed in ° Fahrenheit.
Press the two keys 8 and 3 again to change the temperature display back to ° Celsius.
6.4 A/c operation
Fig. 8 A/c operation and REHEAT function
Activate the a/c operation by pressing the key 1.

The compressor is only switched on automatically by the control unit, if this is necessary.
In order to dehumidify the cabin, switch on the a/c operation while the system is in heating mode.
Press the REHEAT key 6.
REHEAT means that the heating and the air-conditioning unit are running at the same time, in order
17.50.12
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to quickly dehumidify the cab. The air discharge to the windscreen cannot be switched off in REHEAT
mode, and the fan runs at high speed. After approx. 10 minutes, the REHEAT mode is automatically
switched off, and the unit operates according to the preset parameters.
6.5 Recirculated air and fresh air
Fig. 9 Recirculated air and fresh air
The heating and air-conditioning system can be operated with recirculated air or fresh air respec-
tively.
To open / close the fresh air flap, press the key 8.
The symbol 13 indicates that the fresh air flap is closed.
To manually adjust the fan speed, press key 5.
The fan symbol flashes for 5 seconds.
While the fan symbol flashes, press key 2 or 3, see Fig. 6 to manually increase or reduce the fan
output.
To reset the system to automatic mode, press key 5 twice in fast sequence.
6.6 Air ducts and outlets
Fig. 10 Location of the air outlets
The air outlets are located at the seat bracket 8a, at the right control console 8b, at the windscreen
8c and the rear panel of the cab 8d. Open ventilation flaps are indicated with an arrow on the display.
In order to achieve optimum comfort:
In heating mode, open the heating outlets in the legroom 8a, the control console 8b and the wind-
screen 8c.
In a/c mode, open the outlets at the rear panel 8d and the control console 8b.
17.50.13
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Test menu
The best heating and cooling effect can be achieved in recirculated air mode.
Note!
Hi
If the machine is operated for a prolonged period without a/c system, start the compressor every
2 weeks by pressing the REHEAT key 6.
6.7 Operation of the auxiliary heater (special equipment)
Fig. 11 Operation of the auxiliary heater

The auxiliary heating control unit releases the auxiliary heating operation.
During the autotest of the control unit, the software version is displayed for approx. 12 sec. Subse-
quently, the auxiliary heating operation is displayed, see Fig. 11.
The auxiliary heating is switched off at the Klimatronic display and normal operation is activa-
ted. The last saved settings are applied. (If the timer of the auxiliary heating is activated, it re-
mains active, depending on the timer settings, so that the machine is warmed up quicker).
Note!
While the auxiliary heating is on, it is not possible to make manual adjustments. The heating valve
setting is always 100%. The evaporator fan speed is 50%.
For a detailed description of the auxiliary heating, see group 17.30.
7 Test menu
7.1 Starting the vehicle engine
Fig. 12 Ignition switch S1
Start the vehicle engine with the ignition switch S1.
17.50.14
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Test menu
7.2 Switching on the system
Fig. 13 Switching on the control system
Press the ON/OFF key 4.

The control unit performs an auto test. During this period (approx. 12 seconds) the software
version details are displayed on the screen.
7.3 Accessing the test menu
Fig. 14 Accessing the test menu
Press and release key 1.

Simultaneously press and release the keys 7, 6 and 5.
The control unit is now in test mode. The total value of the parameters set in the regulator menu
is now displayed (520 corresponds to basic settings). If the settings deviate from the basic set-
tings, the total flashes. Symbol 13 indicates that D+ (vehicle engine running) has been detec-
ted. All air flaps are closed.
7.4 1st test step: cabin temperature is displayed
Fig. 15 Display of cabin temperature
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Test menu
The current cabin temperature is displayed.
7.5 2nd test step: blow-out temperature is displayed
Fig. 16 Display of blow-out temperature

The current blow-out temperature is displayed.
7.6 3rd test step: not yet assigned
Fig. 17 Display without function

The display is not yet assigned a function.
7.7 4th test step: solenoid valve in the heating supply line is switched on
Fig. 18 Solenoid valve in heating supply line is switched on

The solenoid valve in the heating supply line of the air-conditioning system is switched on.
The functional test (flow rate, current consumption) can now be completed.
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Test menu
Test step 4 is only completed, if D+ (vehicle engine on) is detected.
7.8 5th test step: magnetic clutch of the compressor is switched on
Fig. 19 Magnetic clutch of compressor is switched on

The magnetic clutch of the air-conditioning system is switched on.
The functional test (current consumption, visual inspection) can now be completed.
Test step 5 should be carried out within maximum 5 minutes, as there is otherwise a risk of excessive
ice formation on the evaporator.
7.9 6th test step: fan is started at low speed
Fig. 20 Low fan speed

The evaporator fan is started at minimum speed.
The functional test (current consumption) can now be completed.
All air flaps are closed.
Test step 6 is only carried out, if there is no pressure disturbance or electric short circuit in the mag-
netic clutch circuit.
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Test menu
7.10 7th test step: fan is started at medium speed
Fig. 21 Medium fan speed

The evaporator fan is started at medium speed.
7.11 8th test step: fan is started in high speed
Fig. 22 High fan speed

The evaporator fan is started at high speed.
7.12 9th test step: the recirculated air / fresh air flap is closed
Fig. 23 Recirculated air / fresh air flap closed

The recirculated air / fresh air flap is closed.
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Test menu
After approx. 10 seconds, the flap is set to its end position, so that the functional test (current
consumption, visual inspection) can be completed.
7.13 10th test step: the recirculated air / fresh air flap is opened
Fig. 24 Recirculated air / fresh air flap open

The recirculated air / fresh air flap opens and the fan is running at high speed.
consumption, flow rate, visual inspection) can be completed.
7.14 11th test step: the rear panel flap is opened
Fig. 25 Rear panel flap open

The rear panel flap opens and the fan is running at high speed.
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Test menu
7.15 12th test step: the rear panel flap is closed
Fig. 26 Rear panel flap closed

The rear panel flap is closed and the fan is switched off.
7.16 13th test step: the armrest flap is opened
Fig. 27 Armrest flap open

The armrest flap opens and the fan is running at high speed.
7.17 14th test step: the armrest flap is closed
Fig. 28 Armrest flap closed

The armrest flap is closed and the fan is switched off.
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Test menu
7.18 15th test step: the windscreen / legroom flap is opened
Fig. 29 Windscreen / legroom flap open

The windscreen / legroom flap opens and the fan is running at high speed.
7.19 16th test step: the windscreen / legroom flap is closed
Fig. 30 Windscreen / legroom flap closed

The windscreen / legroom flap is closed and the fan is switched off.
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Test menu
7.20 17th test step: LCD screen test
Fig. 31 LCD screen test

All segments and symbols of the LCD screen are switched on.
Functional check (visual inspection)
7.21 18th test step: exit of test menu and system RESET
Fig. 32 Exiting test menu

The control unit is RESET, while the display shows the details of the software version (durati-
on: approx. 10 seconds).
7.22 Go back one test step
Fig. 33 Back to previous test step

By pressing key 6 (REHEAT key), the operator can return to the previous test step.
17.50.22
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Maintenance of heating and air-conditioning system
8 Maintenance of heating and air-conditioning system
Fig. 34 Filter elements in the operator's cab
8.1 Filter cartridges

Dirty filter elements reduce the air flow through the heating and air-conditioning unit 20, resulting in
frequent ice formation and automatic shutdown of the air-conditioning system.
Remove and clean the recirculated and ambient air filters 1 and 3 of the system every 500 opera-
ting hours. When working in a dusty environment, the filters might have to be cleaned at shorter
intervals.
Do not operate the machine without filters, as this would lead to serious contamination of the heat
exchanger 8 (see Fig. 35).
Note!
To clean the filter elements, blow them out with compressed air or wash them in cold or luke-
warm water.
Do not clean the elements with hot water or steam. Replace damaged or spent filter elements.
To clean or replace recirculated and ambient air filters:

To remove the recirculated air filter 1, tilt the backrest of the operator seat forward.
Open the quick fasteners 2 by turning them by 90 degrees.
Remove the recirculated air filter 1.
Cleaning of the ambient air filter

Remove the deflector 4 at the rear of the operator's cab.
Remove the ambient air filter 3.
To clean the filter elements 1 / 3, blow them out with compressed air or wash them in cold or lu-
17.50.23
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kewarm water.
8.2 Heating system

Every year at the start of the heating period, complete the following maintenance work.
Check the entire coolant circuit for leakage.
Retighten the connections in the coolant circuit, the hose connections at the heat exchanger, the
seals of the stop valves and the hose clamps.
The system may only be operated with coolant containing a suitable corrosion inhibitor and anti-
freeze agent.
Fig. 35 Heating unit and solenoid valve
Bleeding the heating system

To bleed the system, remove the red cap of the bleeder valve at opening A (arrow).
Press in the valve to let the air escape.
Cleaning of the solenoid valve Y46

Every year, at the start of the heating period, dismantle and clean the solenoid valve Y46.
Also clean the solenoid valve, if the heating output is poor.
Rinse the solenoid valve diaphragm with water.
Ensure that the compensation hole of the diaphragm is not blocked.
Inspection of the heat exchanger

Every 12 months, inspect the fins of the heat exchanger 8 for damage.
If they are contaminated, clean them with compressed air.
If necessary, realign the fins.
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8.3 Air-conditioning system
Note!
In order to prevent damage to the compressor, the air-conditioning system must be started and run
every 2 to 3 weeks for about 10 minutes in REHEAT mode (to distribute the oil in the circuit).
During the operating period, the following maintenance work must be completed every 500 opera-
ting hours :
Inspection of the condenser:

Inspect the condenser 8 for dirt.
If necessary, fold the condenser 8 down and clean it from the inside (blower side), using com-
pressed air.
Ensure that the condenser fins are clean.
Dirt on the condenser might lead to excessive pressure in the coolant circuit, so that the air-conditio-
ning system is automatically switched off.
Inspection of the a/c compressor:

Remove the mounting bolts 7 from the a/c compressor and the bracket at the motor.
Check the V-belt of the compressor for wear.
Fig. 36 A/c compressor 1 and condenser 2
Inspection of the dryer-collector unit:

While the diesel engine is on, switch on the air-conditioning system and inspect the level of refri-
gerant in the sight glass 5 of the dryer-collector unit 3.
Fig. 37 Dryer-collector unit
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Note!
If there is insufficient refrigerant in the system, the white floating ball 5a is visible at the bottom of
the sight glass.
In the event of insufficient cooling output, have the system refilled by a refrigeration technician.
Determine the humidity content of the desiccant in the dryer-collector unit 3.

Observe the colour of the indicator bead 5b in the sight glass.
If the bead is blue, the moisture content in the circuit is within the permitted range. A pink bead indi-
cates that the dryer-collector unit is saturated with water.
Note!
NEW from 01/2005:
If the bead is orange, the humidity content in the circuit is within the permitted range.
A transparent bead indicates that the dryer-collector unit is saturated with water.
Immediately replace the dryer-collector unit 3.

Visually inspect the dryer-collector unit 3.
If the dryer-collector unit 3 shows signs of corrosion or damage (e.g. at the console fixtures, hose
connection), replace the dryer-collector unit 3 (pressure vessel).
The dryer-collector unit 3 may only be removed and replaced by a technician trained in the field of
refrigeration.
For this purpose, drain the cooling circuit, inspect it for leakage and refill it. Inspect the hose lines for
chafe marks and replace any damaged hoses. Retighten the hose connections
Fig. 38 Blower motor of the heating and air-conditioning unit
Additional maintenance tasks:

The following maintenance tasks must be carried out at least once every 12 months by a technician
who is trained in refrigeration technology:
Functional test of the blower motor 13 (M13)
Functional test of the air flaps in the heating and air-conditioning system
Inspection of the electrical connections for proper contact
Inspection of the electrical lines for chafe marks
Inspection of the defrost thermostat 7 (B43) in the evaporator (functional test, proper fit and da-
mage)
Functional test of the pressure switch B44 at the dryer-collector unit 3, see Fig. 37
17.50.26
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Safety instructions for all work on the cooling circuit
9 Safety instructions for all work on the cooling circuit
Avoid contact with the refrigerant. Always wear gloves. Protect your eyes with goggles. In the
event of eye contact with the refrigerant, do not rub the eye, but rinse it with plenty of water and
consult a physician.
When draining the system, the refrigerant may not at any time by in contact with the ambient air.
It must be extracted with special equipment for reuse or proper treatment and disposal.
Do not expose the components of the cooling system to high temperature, e.g. by steam cleaning,
welding or varnishing in a dryer. If required, extract the refrigerant.
Before carrying out any repairs, drain the cooling system. Please note that there might still be
some residual pressure in the empty system. Carefully release this pressure before opening any
of the connections.
After completion of the work on the cooling circuit, close all openings with plugs in order to prevent
humid air from penetrating the system.
Only use adapters and sealing elements that are in proper working order. We recommend always
replacing the seals.
Before mounting the seals, treat the sealing faces with special refrigerant.
Seal all connections with Loctite AVX 786 (dry after approx. 1 to 2 hours).
Store spare parts in a dry room and keep them properly sealed. Prior to installing a spare part,
store it at the place of installation until it is cooled down/heated up to the temperature of the am-
bient air (prevention of condensation).
Before connecting the refrigerant hoses, the pipelines, the condenser and the evaporator, blow
them out with nitrogen.
Remove the plugs only immediately before the respective part is mounted. This is particularly im-
portant when installing the reservoir.
Use only R134a.
Do not operate the system, if there is any sign of damage.
If you suspect that the cooling circuit has been exposed to the ambient air for a prolonged period
of time, e.g. after complete loss of the refrigerant, etc., replace the reservoir. This is also recom-
mend after each interference with the system and subsequent refilling.
The following work on the air-conditioning system requires special tools. In the event of malfunc-
tions that require extensive repairs, we recommend contracting a specialist service workshop for
air-conditioning systems.
9.1 Drying and evacuation of the system

By evacuating a cooling system, it is prepared for subsequent filling with refrigerant, and its long-term
tightness can be tested. The system is also dried in the process.
Residual water in the refrigerant circuit reacts with the refrigerant, leading to damage to the system.
Do not use the compressor to evacuate the system, but connect a vacuum pump that is able to ge-
nerate a final vacuum of below 1 torr.
9.2 Leak test

Before evacuating the system, fill the nitrogen through the pressure relief valve (approx. 22 bar) and
test all connections of the cooling system for leakage, using a leak detection spray. With this spray,
leaks are easily detected as foam bubbles appear.
A pressure drop also indicates a leak. After the system has been filled with refrigerant, repeat the leak
test.
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9.3 Filling and draining of the system, see Fig. 39
Filling
The system must be filled with refrigerant in vapour phase and while the machine is running. Do not
exceed the prescribed filling volume. When filling from a large tank, monitor the weight.
If filled correctly, the reservoir should be filled to approximately 1/3, while the evaporator must be filled
to the maximum level at the calculated evaporation temperature. This means that the suction line
temperature should only be a few degrees above the evaporation temperature indicated on the ther-
mometer.
Filling process:
Connect the pressure hose with pressure gauge at the compressor pressure side 10 (high pres-
sure, red).
Connect the suction hose with pressure gauge to the compressor intake side 11 (low pressure,
blue).
Connect the vacuum pump 18 as shown in the diagram.
Turn the pressure valve 10 and the suction valve 11 at the compressor 1 anticlockwise to the stop
(not required in the case of a Schrader valve).
Complete 2 to 3 full clockwise revolutions with the valve ratchet.
Open the valve at the suction and the pressure side.
Switch on the vacuum pump 18 and evacuate the system for approx. 30 minutes or until the suc-
tion pressure gauge 11 indicates that a complete vacuum has been established.
If there are leaks, a complete vacuum cannot be produced. In this case, complete a leak test.
Eliminate the leaks, depressurise the system and restart the evacuation process.
Close the valve at the suction side 11 and the pressure side 10.
Switch off the vacuum pump 18 observe the suction engine to ensure that the vacuum is not de-
stroyed.
Remove the pressure gauge hose from the vacuum pump 18 and connect it to the refrigerant cy-
linder 14.
Open the refrigerant cylinder 14, and disconnect the centre connection from the pressure gauge.
Air can now escape.
Close the connection.
Open the valve 12 at the pressure side 10 and add refrigerant (gaseous) from the cylinder 14.
Add refrigerant until the pressure in the system corresponds to that in the cylinder.
Close the valve 12 at the pressure side 10.
Check the system for leakage.
Start the engine and switch on the cooling system.
Disconnect the valve 12 at the suction side 11 and add refrigerant.
Ensure that no bubbles are visible in the sight glass.
Let the cooling system run for approx. 15 minutes, until the pressure in the system rises (not ap-
plicable with Schrader valve).
Check the system again for leakage.
Close the windows and doors of the operator's cab and set the blower to maximum output level.
Insert a thermometer into the outlet nozzle and start the engine.
Let the engine briefly run at full throttle, then let it run at lower idle rpm for about 3 minutes. Sub-
17.50.28
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sequently, run the engine at upper idle rpm.

If the temperature at the outlet nozzle drops to approx. + 6°C at an ambient temperature of ap-
prox. 20°C, the system is working properly. (Please note that these values apply only to cabs
that are not excessively heated up by the sun).
Open the two connections (at the suction and pressure side of the compressor) by turning them
anticlockwise to the stop, using the valve ratchet.
Remove the suction and pressure lines, mount the dust caps and tighten them.
17.50.29
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Fig. 39 Diagram showing the filling/draining process of the air-conditioning unit
1 A/c compressor 11 Suction side

2 Condenser unit 12 Stop valve
3 Reservoir 13 Stop valve
4 Filter dryer 14 Refrigerant cylinder
5 Sight glass 15 Scales
6 Expansion valve 16 Nitrogen cylinder
7 Pressure side 17 Pressure-reducing valve
8 Heat exchanger 18 Vacuum pump
9 Safety valve 19 Stop cock
10 Dryer-collector unit 20 Dryer-collector unit
17.50.30
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Note!
Compressor with Schrader valve (replacing screw-in valve). When using such test connections at
the compressor, ensure that the filling hoses of the pressure gauge bar are equipped with depres-
sors.
Draining:
For most repairs, it is necessary to first remove the refrigerant from the a/c system. Refrigerant can
only be reused after it has been specially treated.
The refrigerant is normally extracted in the form of vapour. The vapour then condensates in a cooled
tank. It is recommended to slightly heat the machine parts to accelerate this process.
Never use the supply cylinders to collect refrigerant. Use only suitable pressure cylinders that are la-
belled accordingly and that conform to the requirements of the applicable compressed gas regulati-
ons.
When filling the refrigerant from one cylinder to another, ensure that the cylinders are not filled with
more refrigerant than is permitted per litre of volume, to ensure that there is sufficient room for ex-
pansion of the gas.
If the required repairs are of a purely mechanical nature (e.g. replacement of screwed parts), it might
be sufficient to reduce the refrigerant pressure to a level of 0.2 to 0.5 bar above the atmospheric pres-
sure before the respective connection is opened. During the subsequent repair work, a small amount
of refrigerant escapes through the opening, preventing air and humidity from entering the system.
In many cases, it is then possible to rinse the part to be mounted (e.g. condenser, evaporator) with
the escaping refrigerant, so that it is not necessary to evacuate the entire system before refilling it.
Soldering and welding work may only be carried out when the system is filled with nitrogen. The ni-
trogen should thereby leave the system along the shortest possible route in order to quickly remove
breakdown products.
Air-conditioning system service device
Fig. 40 Air-conditioning system service device
Note!
This device has been designed for the evacuation, recycling (cleaning, drying) and filling of the re-
frigerant. For operating instructions, see the manual issued by the manufacturer.
17.50.31
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Fault indication and troubleshooting
10 Fault indication and troubleshooting
Fault Cause Elimination

System cannot be started Loose electrical connections Check electrical connections
Fuse blown Replace fuse
Excess pressure Clean condenser fins
System is running, and sud- Excess pressure caused by Run system until the pressure is
denly shuts down high ambient temperature stabilised
Kinked hose, pressure switch
B44 defective
System cannot be started Insufficient pressure, dryer Replace dryer, must be done by
blocked, saturated refrigeration technician
Insufficient pressure, expan- Clean or replace the expansion
sion valve blocked valve, must be done by refrige-
ration technician
Leakage Check the system for leakage
Insufficient refrigerant Add refrigerant, must be done
by refrigeration technician
Replace the reservoir, filter dryer
and sight glass assembly
The unit is on, but does not Solenoid valve defective Replace solenoid valve
cool Heating is on Switch off heating
Unit is not set to automatic mode
Loud noise from the com- Compressor ball bearing de- Replace compressor, must be
pressor fective done by refrigeration technici-
an
Magnetic clutch defective Replace magnetic clutch
Whistling noise from the V- V-belt worn Replace V-belt
belt V-belt loose Tighten V-belt
10.1 Error code "FO": fault at the room temperature sensor
Fig. 41 Flashing error code for room temperature sensor fault
The control system has detected a fault at the room temperature sensor, and the regulator is disab-
led. Determine the cause of the sensor fault: short circuit, sensor cable break, loose connection at
sensor or control unit, sensor defective.
Eliminate the fault. The sensor is again ready for operation, and the error code disappears. After a
fault, the regulator is operated with the settings as entered before the fault.
17.50.32
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10.2 Error code "F1": fault at the blow-out temperature sensor
Fig. 42 Flashing error code for blow-out temperature sensor fault
The control system has detected a fault at the blow-out temperature sensor, and the regulator is
disabled. Determine the cause of the sensor fault: short circuit, sensor cable break, loose connection
at sensor or control unit, sensor defective.
Eliminate the fault. The sensor is again ready for operation, and the error code disappears. After a
fault, the regulator is operated with the settings as entered before the fault.
10.3 Error code "F3": fault at the legroom/windscreen ventilation flap
Fig. 43 Flashing error code for legroom/windscreen ventilation flap fault
The control system has detected a fault at the legroom/windscreen ventilation flap. The regulator re-
mains operational. Determine the cause of the fault: short circuit, cable break, loose connection at
the ventilation flap motor or control unit, flap motor defective.
Eliminate the fault. The error message disappears. The regulator operation is not affected by a flap
error.
10.4 Error code "F4": pressure fault / fault at magnetic clutch
Fig. 44 Flashing error code for pressure fault / magnetic clutch fault
17.50.33
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The control system has detected a fault at the pressure switch or the magnetic clutch. Determine the
cause of the fault: short circuit, cable break in the supply line to the magnetic clutch, loose connection
at the clutch or control unit.
Excessive or insufficient pressure (insufficient refrigerant) in the cooling system of the air-conditioning
unit. Eliminate the fault. The error message disappears. The regulator is not affected by a pressure
fault / magnetic clutch fault, and only the magnetic clutch output is interrupted.
10.5 Error code "F5": data transmission fault between control panel and control
unit
Fig. 45 Flashing error code for data transmission fault
The data transfer from the control panel to the control unit interrupted. Determine the cause of the
error: short circuit or cable break in the data line to the control unit, loose connection at the control
panel or control unit.
The control panel repeatedly attempts to establish a data connection to the control unit. Eliminate the
error. The error message "F5" disappears.
If the data transfer cannot be re-established, switch off the ignition and switch it on again, to reset the
system.
17.50.34
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Electrical diagram of the air-conditioning system
11 Electrical diagram of the air-conditioning system
Fig. 46 Electrical diagram of the air-conditioning system
17.50.35
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MJFCIFSS
Electrical diagram of the air-conditioning system
B43 Thermostat / a/c system X7 Plug connection a/c electronics, 4-pin

B44 Pressure switch / a/c system X8 Plug connection blower motor, 6-pin
B255 Temperature sensor / cabin X9 Plug connection rear servo motor,
2-pin
B257 Temperature sensor / blow-out air X11 Plug connection servo motor fresh air, 4
pin
M13 Motor / evaporator blower X12 Plug connection rear servo motor,
6-pin
M75 Motor / ambient air flap X13 Plug connection servo motor armrest, 6
pin
M76 Motor / rear panel air flap X14 Plug connection servo motor winds-
creen, 6 pin
M77 Motor / control console air flap X79 Plug connection a/c system, 2-pin
M78 Motor / legroom and windscreen air flap X84-2 Plug connection a/c system, 2-pin
U38 Control panel X84-3 Plug connection a/c system, 2-pin
V1 A/c control blocking diode X87 Plug connection, 3-pin
X1 Plug connection, 24-pin X88 Plug connection, 2-pin
X2 Plug connection, 37-pin X435 Plug connection a/c clutch, 1-pin
X3 Plug connection, 10-pin X1027 Plug connection a/c control panel illumi-
nation
X4 Plug connection, 4-pin Y20 Magnetic clutch / a/c system
X5 Plug connection a/c electronics terminal Y46 Solenoid valve / a/c system
30
X6 Plug connection a/c electronics, 6-pin
17.50.36
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Test schedule for air-conditioning system
12 Test schedule for air-conditioning system
Machine : _____________ Maintenance : _____________

status
Type : _____________ Customer : _____________
Type no. : _____________ Supplier : _____________
Date of delivery : _____________ Mechanic : _____________
Operating hours : _____________
12.1 Maintenance work
Maintenance work completed yes no

1. Fill level of a/c system checked (sight glass) at approx. 18-20° C
2. Evaporator 8 checked for contamination, cleaned if necessary
3. Condenser 2 checked for contamination, cleaned if necessary
4. Filter / dryer 4 checked, replaced, if necessary (corrosion)
5. Functional test of excess pressure switch B44 completed
6. Safety valve 9 checked
7. Defrost sensor at expansion valve 6 checked for proper fit
8. Ambient air filter cleaned or replaced
9. Recirculated air filter cleaned or replaced
10. Compressor fixture and drive belt checked
11. Refrigerant extracted from system, recycled; system refilled with refrige-
rant, cooling performance checked (temperature difference of intake and
blow-out air)
12. Function of defrost thermostat B43 (OFF + 1° C, ON + 5.5° C) checked
13. Automatic mode tested (if available, heating, cooling performance. fan
speed), (see "Maintenance of heating and air-conditioning system",
page 23)
14. Electrical lines checked for chafe marks, plugs checked for proper connec-
tion
15. Evaporator fins aligned with fin aligning tool
16. Humidity content of refrigerant checked (sight glass)
Caution!
For safety reasons, we recommend that all maintenance work and repairs on the air-conditioning
system are carried out by specialist refrigeration technicians (see group 17.50 "Safety instruc-
tions").
17.50.37
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Test schedule for air-conditioning system
17.50.38
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MJFCIFSS
Service Manual
SUBGROUP - INDEX
Section Group Type
Repair instructions for lubrication hoses 18.50.1 A 900 C-LI

A 900 C-ZW 21034-
A 904 C-LI
A 914 C-LI 35112-
A 924 C-LI 34519-
Central lubrication system 18.51.1 A 900 C-LI 14675-

A 904 C-LI 16000-
A 914 C-LI 35112-
A 924 C-LI 34519-
Semi-automatic central lubrication system 18.53.1 A 900 C-LI 25563-

A 904 C-LI 25567-
A 914 C-LI 35112-
A 924 C-LI 34519-
Fully automatic central lubricating system 18.54.1 A 900 C-LI EDC

A 904 C-LI
A 914 C-LI
A 924 C-LI
Central lubrication pump 18.56.1 A 900 C-LI 14675-

A 904 C-LI 16000-
A 914 C-LI 35112-
A 924 C-LI 34519-
SX-E progressive distributor 18.58.1 A 900 C-LI 14675-

A 904 C-LI 16000-
A 914 C-LI 35112-
A 924 C-LI 34519-
MX-F progressive distributor 18.59.1 A 900 C-LI 14675-

A 904 C-LI 16000-
A 914 C-LI 35112-
A 924 C-LI 34519-
18.1
MJFCIFSS
Service Manual
18.2
MJFCIFSS
Service Manual Repair instructions for lubrication hoses
Mounting of collet
Repair instructions for lubrication hoses

In the event of damage to lubrication houses (breakage, tearing, kinking, etc.) LIEBHERR provides
a special repair kit that allows you to repair the hose, so that it does not have to be replaced (espe-
cially efficient for very long hoses that are part of an attachment).
The repair kit enables you to repair damaged and torn hoses and an efficient and safe way.
Short lines showing damage are best replaced, which is also possible with the repair kit (spare con-
necting elements). The procedure for installation is the same as for repair (no need for straight screw
connection 5).
Product ID no.: Hose size (ND)
Hose repair kit 10114979 4 / 6,3
Repair kit for connecting pieces, complete 10014611 4 / 6.3
1 Mounting of collet
Hold the lubrication hose 1 using gripper tongues 2.

Grease or oil the hose end.
Turn the collet3 (WS17) anticlockwise to open it.
Open it until dimension X is reached, see Fig. 1.
Remove the gripper tongues 2.
Fig. 1 Mounting of collet
18.50.1
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MJFCIFSS
Repair instructions for lubrication hoses Service Manual
Mounting of pipe nozzle
2 Mounting of pipe nozzle
Oil the thread and the conical end of the pipe nozzle 4.
Turn the pipe nozzle 4 (WS12) into the mounted collet 3 (WS17) to the stop.
Fig. 2 Mounting of pipe nozzle
2.1 Mounting instructions
Note!
The diameters of hoses might vary slightly, due to manufacturing processes. If the hose diameter is
smaller, it might it might be possible to mount the collet 3 onto the hose without the need or force or
tools, so that the hose is not properly held in place in the collet.
Remedy:
Press the last 1 to 2 mm of the collet 3 at the hose insertion side to an oval shape.
This prevents that the house is pushed off the collet when the pipe nozzle 4 is screwed in.
2.2 Connecting lubrication hoses

Use straight screw connectors 5 to connect high-pressure hoses 1.
Tighten the screw connection 5 with the prescribed torque.
The hose repair is now completed.
Fig. 3 Completed hose repair

1
1 High-pressure hose 4 Pipe nozzle

3 Collet 5 Straight screw connection
18.50.2
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MJFCIFSS
Service Manual Central lubrication system
Function and design
Central lubrication system
The LIEBHERR central lubrication system is a progressive system, i.e. all connected lube points are
supplied with the required quantity of grease according to a predefined sequence.
With the central lubrication system, operators can thus lubricate all lube point at the machine by
adding grease to a single lubrication nipple.
This lubrication nipple 1 is located on top of the tank.
The grease added through the lubrication nipple 1 is distributed to the individual lube points through
the main distributor 2 and then to the secondary distributors 3, 4, 5, 6, etc. located at the front of the
uppercarriage and on the attachments.
The following assemblies and points are connected to the central lubrication system:
Ball races of the slewing ring
Slewing ring toothing
Certain bearings of the working attachment
Lube points of the undercarriage are not supplied by the central lubrication system.
Note!
On request, the central lubrication system can be equipped with an optional electric pump, which
ensures that all bearing positions connected to the lubrication system are lubricated at regular
intervals while the machine is in operation. Such a pump thus does away with manual lubrication.
For a description of the design and function of the electric pump, see group 18.56.
18.51. 1
MJFCIFSS
Central lubrication system Service Manual
Function and design
Fig. 1 Central lubrication system
1 Central lubrication nipple 32 Pressure relief valve (with lubricating

pump only)
2 Main distributor (type SXE-2) B51-1 Limit switch (optional)
3-7 Secondary distributor (type MX-F) U4 Lubricating pump (optional)
13 Grease filter
18.51. 2
MJFCIFSS
Positions of the distributors and lube points
2 Positions of the distributors and lube points
The diagram below shows the lube points and distributors of a standard machine (with hydraulic
boom adjustment and backhoe bucket), including the number and rated capacities of the distributor
elements and the distributed grease volumes per lubrication cycle with default settings (= factory
settings).
The equipment of the progressive system in other machine types (e.g. with gooseneck boom,
industrial equipment, demolition attachments, tunnelling machines, etc.) might differ from the
example shown here.
In wheel models, secondary distributor 6 is not included in the standard version but available as an
extension kit, i.e. the bearing points of connecting links and buckets are not connected to the central
lubrication system. These parts must be lubricated individually.
Fig. 2 Diagram of the central lubrication system
1 Central lubrication nipple 13 Main line

1* Central lubrication pump (kit) 14 Main line
2 Main distributor 16 Main line
3 Secondary distributor / slewing ring and 17 Main line
boom cylinder
4 Secondary distributor / boom 18 Boom bearing / adjustable boom
5 Secondary distributor / stick 19 Boom bearing / adjustable boom
6 Secondary distributor / connecting link 20 Stick connecting link
8 Secondary distributor / adjustable A Main distributor without extension kit
attachment
vertical - horizontal
9 Secondary distributor / boom adjustment B Main distributor with extension kit
vertical - horizontal
12 Main line
18.51. 3
MJFCIFSS
Positions of the distributors and lube points
Fig. 3 Position of the lube points of the machine
1 Central lubrication nipple 6 Secondary distributor (kit)

Connecting link / bucket kit
2 Main distributor 8 Secondary distributor
adjustable boom / vertical - horizontal
3 Secondary distributor 9 Secondary distributor
Slewing ring with boom cylinder Boom bearing / vertical - horizontal
4 Secondary distributor
Basic boom / vertical - horizontal
18.51. 4
MJFCIFSS
Central lubrication system for the uppercarriage and attachments
3 Central lubrication system for the uppercarriage and attachments
The machine is equipped with a central lubrication system, saving operators considerable time every
day. All lube points at the uppercarriage (slewing ring, slewing gear pinion) as well as all bearings of
the attachment including the base tipping cylinder are permanently connected to the lubrication
system. On request, the steering axle of the undercarriage can also be lubricated through a central
lube point.
The central lubrication requires approx. 3.5cm³ of grease per working hour. For an average
8-hour day, the system thus distributes approx. 28 to 30 cm³ of grease in total.
A conventional hand grease gun applies at least 1.5 cm³ of grease per stroke. Lubrication with 30 cm³
requires about 30 hand gun strokes.
The required grease should be ideally added to the system every half day, or at least once per shift
(i.e. every 8 to 10 hours):
per shift, add about 20 hand gun strokes of grease through the central lubrication nipple 1 .
or
per half day, add about 10 hand gun strokes of grease through the central lubrication nipple 1 .
For the grease specifications, please refer to the lubricant table in group 1.50.
During lubrication, check whether the check pin 27 at the main distributor 2 is moving back and forth,
indicating that the grease is being distributed through the system. The main distributor 2 is located at
the front of the revolving deck.
If the check pin does not move, inspect the system for the following possible defects:
Blockage or kinking of the supply line
High grease viscosity due to cold temperature
Grease filter at the central lubrication nipple 1 blocked
Identify and eliminate the cause.
Fig. 4 Manual lubrication
18.51. 5
MJFCIFSS
Clean grease filter
4 Clean grease filter
Fig. 5 Grease filter
1 Lubrication nipple 4 Sealing ring

2 Filter element 5 Sealing ring
3 Screw connection 6 Filter housing
Note!
The filter element 2 located behind the lubrication nipple 1 must be inspected every 1000 operating
hours for contamination and cleaned, if necessary.
Disconnect the lubrication line from the filter outlet.

Remove the filter housing 6 and take out the filter element 2.
When reinstalling the filter, ensure that the sealing ring 4 is properly aligned and close and tighten
the filter housing 6 with 80 Nm.
Reconnect the lubrication line.
18.51. 6
MJFCIFSS
Service Manual Semi-automatic central lubrication system
Function
Semi-automatic central lubrication system
1 Function
The machine is equipped with a semi-automatic central lubrication system. This means that the lube
points at the uppercarriage and the working attachment do not need to be lubricated manually. The
bearing points connected to the lubrication system can be lubricated during machine operation by
starting the lubrication process from the operator's platform.
This saves time as it does away with the daily manual lubrication of the machine.
The undercarriage, on the other hand, is not connected to the central lubrication system and must be
greased manually.
Note!
As there is a versatile and large range of attachments, it is not possible to document all connection
options. The description in this document therefore refers only to the semi-automatic lubrication sys-
tem and the main distributor.
Fig. 1 Semi-automatic lubrication system in the uppercarriage
18.53.1
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MJFCIFSS
Semi-automatic central lubrication system Service Manual
Technical data
2 Technical data
Note!
The technical data of the lubricating pump is included in the documentation of group 18.56.
For the order number of the filling pump and grease cartridges, refer to the spare parts catalogue
(Lidos). For details regarding the grease grade, refer to the lubricant table for group 1.50/1.51.
3 Design
The lubricating pump 1 is mounted on a holder 20 and screwed to the hydraulic tank. To protect the
system against overpressure, the pressure-relief valve 9 is installed on the lubricating pump 1.
In the event of failure of the lubricating pump, it is possible to grease the machine through the emer-
gency lubrication nipple 25.
The main distributor 2 with the check pin 27 is mounted with screws to the front side of the undercar-
riage. The distributor is connected to the lubricating pump 1.
The semi-automatic lubrication system is activated by mean of the switch S84 in the right console of
the operator's platform.
Note!
For a description of the lubricating pump 1, see group 18.56.
1 Lubricating pump 22 Lubrication nipple (for standard grease

gun)
2 Main distributor 25 Emergency lubrication nipple
3 Filling pump 27 Check pin
9 pressure-relief valve S84* Switch
15 Washer X143 Plug connection
16 Allen head screw X164-2 Plug connection
18 Hex nut X182-1 Plug connection
20 Holder X182-2 Plug connection
21 Adapter (filling of grease tank with filling
pump 3)
*new symbol from 12/2006
18.53.2
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MJFCIFSS
Design
Fig. 2 Design of the semi-automatic lubrication system
18.53.3
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MJFCIFSS
Operation of lubrication system
4 Operation of lubrication system
4.1 Starting lubrication cycle:

To start a lubrication cycle, press the switch S84. As long as the switch is pressed, the electric pump
continues to deliver grease to the connected lube and bearing points.
Carry out at least one lubricating cycle during every shift.
The indicator light in the switch flashes.
The grease is supplied to the connected bearing points.
Let the indicator light flash until grease escapes at the base of the boom cylinders.
Note!
The time required for lubrication depends on the grease temperature and the type and number of
components connected to the central lubrication system. At extremely low ambient temperatures,
lubrication might take up to 30 minutes.
4.2 Terminating lubrication cycle:

The lubrication procedure is completed.
4.3 Functional check
Fig. 3 Functional check
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During the lubrication process, it is possible to check whether grease flows properly observing the
check pin at the distributor 27: if grease flows properly, the check pin 27 is constantly moved back
and forth.
If the check pin does not move, inspect the system for the following possible defects:
Blockage or kinking of the feed line (grease escapes at the safety valve 9).
High grease viscosity due to low ambient temperature.
Insufficient product in grease tank.
Fault in motor power circuit.
Identify and eliminate the cause of the fault.
If the lubricating pump is defective, the lube points connected to the lubrication system can be grea-
sed centrally with a lubricating pump/grease gun through the lubrication nipple 22.
4.4 Adding grease to the grease tank
Note!
In order to prevent contamination and damage to the product, keep the grease tank closed.
It is not necessary to remove the lid to refill the grease tank.
To add product to the grease tank, use the adapter 21.

Insert the grease cartridge into the supplied filling pump 3, connect it on the adapter 21 and press
the cartridge content into the tank.
If the filling pump 3 or the grease cartridge are not available, use a grease gun or a lubricating pump
to fill the tank, connecting them to the lubrication nipple 22.
After the grease tank 1 has been refilled, complete an intermediate lubrication procedure.
Completing intermediate lubrication

Automatic: Start lubrication process with the switch S84.
- alternatively -
Manual: Apply grease to the lubrication nipple 25.
Continue the manual intermediate lubrication until grease escapes at bearings at the base of the
boom cylinders.
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Service Handbuch Fully automatic central lubricating system
Task/System description
Fully automatic central lubricating system
1 Task/System description
Upon customers request (optional installation) a fully automatic central lubricating system can be in-
stalled on machines with EDC diesel engine.
With this system, manual lubrication of the bearing points on the uppercarriage and attachment is no
longer necessary. All the bearing points connected to the lubricating system will be lubricated regu-
larily during work. This system is controlled by the keypad. Changes in regard to the intensity of lub-
rication can be done over the display of the machine.
Fig. 1 Design of the lubricating system
1 Grease pump B51X Connector (proximity switch)

2 Progressive distributor S84-1 Button (manual intermediate lubrication)
B51 Proximity switch central lubrication X143 Connector
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Fully automatic central lubricating system Service Handbuch
Notice!
The electrical components and connections of this installation kit are documented in the electrical
schematic in group 8.104.
The fully automatic lubricating system is a progressive system. It lubricates the grease points con-
nected to it progressively and therefor one after the other.
A proximity switch B51 is mounted on the main distributor 2, indicating the lubricating cycles to the
keypad.
2.1 Complete system

The electrically operated central lubricating pump 1 delivers grease to the main progressive distribu-
tor and distributes from there to the connected sub-distributors. They in turn deliver the grease to the
allocated grease points. The excavator keypad controls the lubricating cycle and the break time of
the lubricating pump. Refer to group 18 for a detailed description of pumps and distributors.
2.2 Safety function

The pressure relief valve on the central lubricating pump monitors the grease system. If a grease
point does not consume any grease from the distributor, the progressive distributor jams. The pres-
sure in the lubricating system increases. If the permissible limit value is exceeded, grease will be re-
leased by the relief valve. At the same time the signals from the proximity switch B51 for cycle control
are missing.
If the lubricating cycles are not carried out within a predefined time, the lubricating system is shut
down by the keypad. This circumstance is indicated to the operator by a symbol and will be registered
in the errorcode memory with error codes E 514 / 515.
Fig. 2 Error symbol in display (top left).
3 Activating the lubricating system
To enable the control of the lubricating pump via the keypad, the relating parameter in the keypad
must be activated.
Connect green service plug on circuit board ESP01, connector X30/X31, see Fig. 8.
Select menü set data, set config and set grease auto to ON.
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Activating the lubricating system
Fig. 3 Activating the lubricating system
This makes the following, additional menue available for the operator / mechanic:
Fig. 4 Operator / Mechanic Menue
3.1 Lubricating modes

Three lubricating modes H, N and L are factory defined and are available for selection.
I
Mode Application Lubrication Setting
H heavy duty (Heavy duty) large amount of TON: 20min

grease TCYC: 30min
CNT: 2
N normal (Normal duty) medium amount of TON: 20min

grease TCYC: 50min
CNT: 2
L light (Light duty) small amount of TON: 20min
grease TCYC: 60min
CNT: 2
Tab. 1 Adjustment values for modes H/N/L
Selection is done via the display, depending upon the access level (operator / mechanic), see Fig. 4.
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Activating the lubricating system
Fig. 5 Selection of the lubricating modes
T-ON-Zeit Monitoring time of the proximity switch B51

TCYC-Zeit Duration of the entire lubricating cycle
CNT-Wert Number of cycles until the lubricating pump is switched off
If the operator selects one of the 3 indicated modes, the lubricating pump will be activated under con-
sideration of the already elapsed control time TCYC. The delivery of grease will start moving the pis-
tons in the main distributor / sub distributors.
A stroke surveillance via proximity switch B51 is given on one piston of the main distributor. This
switch sends two impulses into the keypad per cycle CNT.
If the impulses (1 cycle) of the proximity switch B51 are interrupted longer than the defined TON time
once the lubricating cycle has started, a symbol, refer to Fig. 2 on the display will inform the operator.
At the same time errorcodes E514/515 are stored in the error memory.
3.2 Significance of the parameters
3.2.1 Piston stroke control starting BBT Version 4.5

T-ON-time Monitoring time of the proximity switch B51, in relationship to the CNT value the
proximity switch produces twice the amount of impulses into the control
system. If these impulses (1 cycle) are interrupted beyond the specified time,
an error sybol will appear on the display and error codes are stored in the error
memory.
Value range: 0 - 20 min.
TCYC-time Duration of the entire lubricating cycle (time window until the lubricating pump
is turned on again)
Value range: 0 - 60 min
CNT-value Amount of cycles (1 cycle = 2 impulses), until the lubricating pump is turned off.
Value range: 2 - 50 cycles
Time control up to BBT Version 4.4 selectable.

If the CNT-value is set to 0, the T-ON time determines the on-time of the lubricating pump. With the
TCYC time the entire lubricating window, which is the time until the lubricating pump is turned on
again, is defined.
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Adjustment of the lubricating parameters
4 Adjustment of the lubricating parameters
In case the predetermined grease quantities H / N / L do not match the corresponding machine ap-
plication, they can be adapted in the service menue.
Connect green service plug to circuit board ESP01, connector X30/X31.
Select menue set data, set grease auto.
Select the desired lubricating mode and confirm with the book button.
Select the corresponding parameter.
The currently stored value is displayed.
Press up/down button to change value.
Press back button to store value.
Fig. 6 Adjustment of the lubricating parameter
5 Error messages
If the impulses of the proximity switch B51 are interrupted beyond the specified time T ON, the error
symbol on the left will appear on the display. Therefor the lubricating pump 1 is no longer active.
The error codes E514 and E515 (starting BBT-Software V 4.5) will be stored in the error memory list
S-Exx.
I
Fig. 7 Error codes in the service menue
By activating an intermediate lubrication (button S84-1) this condition will be bypassed, which means
the lubricating pump 1 will be activated again. If the problem (blocked distribution system) still exists,
the error message will reappear after the T ON time has elapsed and the lubricating pump will be
turned off again.
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Procedure to transfer stored data
5.1 Intermediate lubrication

Recognition of an intermediate lubrication is done exclusively when the lubricating pump is turned off,
since the signal detection for the proximity switch B51 and the intermediate lubrication uses the same
input on the electronic.
Proceed as follows if an intermediate lubrication is necessary:
Press button S84-1 (right console) for manual intermediate lubrication.
New lubrication cycle starts and the lubrication break is interrupted.
In case of an error (see error messages on page 5) button S84-1 also serves the function of a reset
button. The error symbol on the display will be deleted by activating an intermediate lubrication.
6 Procedure to transfer stored data
6.1 Preparation
Connect PC to the keypad via connector X32 on circuit board A1001 (Data transfer cable Id.No.
9684327)
Connect green service plug to connector X30 or X31.
Fig. 8 Connectors on circuit board A1001
Start PC and activate terminal program LikomWinE by double clicking the smbol.
Fig. 9 Desktop LIKOM
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If necessary, select port and confirm changes by clicking OK.
Fig. 10 Selection of port
Select file in the menu bar.

Select open recording file and determine file name.
Fig. 11 Open recording file
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Select folder in which the recording file shall be saved.

Enter file name, under which the record shall be stored.
Example:
A 900 C - machine.
1002 - model type.
36580 - serial number.
a - Identififcation of the number of data transfers on the corresponding machine.
txt - File ending for text files
Confirm entry by clicking to Open.
Fig. 12 Open LOG -file
6.2 Transfer of stored data

Go to i-data in the display menu and select corresponding menu.
Fig. 13 Transfer of stored data.
print hours Among other readout of operating hours, confirmed service intervals,
changes of the individual lubricating parameters (H/N/L) and the amount
of lubricating cycles (incl. intermediate lubrications).
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print param Readout of preset flow reductions, parameters and adjusted lubricating
parameters.
Select desired menu with the arrow buttons.

Start readout by pressing the book button.
The corresponding information is immedeately stored in the recording file previously opened (f.e.
A900C_1002_36580a.txt). Storage of one or more menu points is possible by confirming correspon-
dingly .
Close the recording file once the download of data is completed.
Fig. 14 Closing the recording file
6.3 Edit / print downloaded files

To be able to edit or print the data stored on the PC the corresponding file (f.e.
A900_1002_36580a.txt) must be opened with an editor or word processing program.
Klick to edit file in the menu file.
Fig. 15 Edit file
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1 Select the folder in which the file was stored.

2 Select the file including the data which shall be edited or printed.
Fig. 16 Select folder.
Example:
Fig. 17 Left - current lubricating parameters / right - changes of the lubricating parameters
(1) With info grease parameter the current settings for the 3 lubricating modes are displayed.
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Checking the impulses of proximity switch B51
The term (changed at:xx hours) indicates at which operating hour they were changed the last
time.
(2) Under grease option indication is made to the mode the operator selected.
(3) With info grease auto changes the changes of the settings in relationship to a certain ope-
rating hour a recorded. The values under old indicate the previous, the values under new the
new settings.
(4) In the area counter greasing Clock the amount of lubricating cycles carried out are coun-
ted. The term counter intermediate greasing visualizes the amount of intermediate lubricati-
ons.
7 Checking the impulses of proximity switch B51
The function of the proximity switch B51 can be checked using the LED integrated in the proximity
switch. Each cycle will let the LED light up.
Note!
Whether or not this signal reaches the control system can only be determined using the terminal
program LIKOM.
Fig. 18 Checking the proximity switch B51
Select the command V24 functions BBT in the menu excavator in LIKOM to do so.
Afterwards take up communication with the control system by selecting the command connect
BBT and thereafter inputs BBT.
Fig. 19 Functions BBT.
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Checking the impulses of proximity switch B51
Monitor the digital inputs (X50) on port 20 for signal. A minus (-) means the input is not active, the
circle or zero (o) means a signal is being applied to the control system
Fig. 20 Terminal program to check the signal
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Service Manual Central lubrication pump
Function
Central lubrication pump
1 Function
On request, the central lubrication system of the machine can be equipped with an electric pump.
This pump does away with the manual lubrication of the uppercarriage and the attachment. While the
machine is operated, the bearings connected to the lubrication system are regularly lubricated. The
lube points at the undercarriage cannot be connected to the automatic lubrication system.
Fig. 1 Central lubrication pump
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Central lubrication pump Service Manual
General information

Unit
motor
Operating voltage V 24 V DC
Speed rpm 15
Current consumption: A
Idle run at + 20° C 0.4
Full load at + 20° C 1.1
Fuse A 3
Pump
Max. operating pressure bar 280
(set at pressure relief valve 9)
Permissible operating temperature °C -35 to +80
Tank capacity:
Transparent tank kg 4
Direction of rotation of the agitator blade clockwise
Pump rate of the pump elements: mm 3
PE-120 120
PE-120 V (adjustable) 40 - 120
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Description
3 Description
The complete lubrication system U4 consists of a transparent grease tank 13 with the agitator blade
12, the electric motor 10 of the lubricating pump 15 and the integrated control unit 16 located in the
bottom section of the assembly, initiating the lubrication cycles.
The proximity switch B51-1 at the distributor monitors the actual cycle rate against the set rate.
The lubrication system can be equipped with up to three separate pump elements that work
independently of each other.
For the monitoring and initiating of an additional lubrication cycle, the operator can press the push
button S84 at the right control console or key 19 at the pump.
Fig. 2 Central lubrication pump
Fig. 3 Connection of control unit
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Description
Fig. 4 Exploded view of the central lubricating pump
3 Pump housing 13 Tank

4 Screen plate 15 Pump element
5 Eccentric 16 Control unit
6 Thrust plate with guide ring 21 Filling adapter
7 Delivery plunger 22 Emergency filling nipple
9 Pressure relief valve 23 Tank lid
10 DC motor 25 Emergency lubrication nipple
12 Agitator blade
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During one revolution of the eccentric 5 the delivery plunger 7 is lifted, and a predefined volume of
grease (determined by the plunger diameter and stroke travel) enters the plunger chamber, see Tab.
1, which is then pumped through the main line.
Fig. 5 Sectional drawing of the central lubricating pump
3 Pump housing 10 DC motor

4 Screen plate 12 Agitator blade
5 Eccentric 13 Tank
6 Thrust plate 15 Lubricating pump
7 Delivery plunger 16 Control unit
8 Check valve 19 ON/OFF button
9 Pressure relief valve
Note!
Sectional drawing a: pump element takes up grease; sectional drawing b: pump element expels
grease
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Dismantling and installation of the pump element in the electric pump:
Caution!
Rotating agitator blade!
Risk of injury to fingers and hands!
Prior to dismantling or mounting the pump element, switch off the pump.
Fig. 6 Installation and dismantling of the pump element 15
5.1 Dismantling:
Pull the pump element 15 with partly pulled-out plunger 7 upwards at an angle from the bore in
the housing.
When removing the pump element 15, ensure that the plunger 7 does not remain in the pump
housing.
5.2 Installation:
Insert the pump element with partly pulled-out plunger 7 diagonally upwards into the bore in the
housing (see drawing a).
When the plunger head touches the sealing ring, rotate the element into a horizontal position
(see drawing b).
The plunger head must run in the groove of the guide ring 6.
Insert and tighten the pump element 15.
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Integrated control system (EP-tronic)
6 Integrated control system (EP-tronic)
Fig. 7 Greasing processes
2 Main distributor B51-1 Proximity switch

2.3 Metering element CD Cycle time
a 1st greasing process NS Number of cycles (lubrication time)
b 2nd greasing process
6.1 Monitoring of the lubrication system by means of the proximity switch

During the greasing process, the various lube points are lubricated in a preset sequence (progressive
system). Each movement of the plunger in the metering element 2.3 of the main distributor 2
generates a pulse in the built-in proximity switch B51-1.
The control unit 16 (see Fig. 5) stops the pump as soon as one greasing process is completed, i.e.
as soon as the number of generated pulses has reached the preset number of pulses (number of
cycles).
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Functions of the control system and operating devices
7 Functions of the control system and operating devices
When the machine is switched on, the indicator light of key S84 at the right control console and the
green LED 17 on the lubricating pump are on for approx. 1.5 seconds, indicating that the electric
pump is ready for operation.
Each time the control system is connected, a greasing process is started.
While a greasing process is being completed, the integrated indicator light of key S84 and the green
LED 17 are continuously on.
The greasing process is automatically stopped after the set number of cycles NS has been registered
by the proximity switch B51-1 (see Fig. 7).
The next greasing process is started after the preset cycle time CD has lapsed.
In the event of a fault in the lubricating circuit (no cycle signal at the proximity switch B51-1 for approx.
20 minutes from the start of a greasing process), both LEDs 17 and 18 as well as the indicator light
of key S84 flash.
Possible causes of the fault:
Blockage or kinking of the supply line (grease flows out at the safety valve 9)
Defective proximity switch B51-1 or defective electrical connection
High grease viscosity due to cold temperature
Insufficient grease in the tank
Fault in the 24 V power supply circuit of the motor 10
Identify and eliminate the cause.
The integrated electronic control unit is equipped with a data memory, holding all relevant parameter
data (i.e. times, number of cycles, etc.).
If the ignition is switched off during a greasing process or break in the greasing process, the number
of completed stroke cycles and the total completed cycle times are recorded. When the ignition is
switched on again, the relevant data is read from the memory and the required number of yet to
perform cycles and cycle breaks are completed.
If the internal battery of the control unit is defective, the red LED 18 flashes at intervals of 0.5 seconds.
If the lubrication system is working properly, the operator can start an additional greasing process by
pressing the push button 19 or key S84 at the rear control console. An additional greasing process
might also be started for test purposes. The pump immediately starts the next cycle, and the
previously recorded greasing process and cycle times are reset.
Fig. 8 Operation of the lubrication system
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Settings at the control unit
8 Settings at the control unit
8.1 Adjustment of the cycle time (CD) settings

The cycle time can be adjusted to a value of between 0.5 and 8 hours at the CD (cycle duration)
selection switch (accessible after the transparent cover is removed).
Factory cycle time settings:
Model A 900C-Li A 904 C-Li

Cycle time CD in hours 1 1
8.2 Adjustment of the number of cycles (NS) settings

The number of cycles per greasing process at the main distributor can be adjusted at the NS (number
of strokes) selector switch (accessible after the transparent cover is removed).
Factory number of cycle settings:
Model A 900 C-Li A 904 C Li

Number of cycles 2 2
1 Operational readiness NS=

1.5 seconds after start
2 Greasing process NS=

during lubrication
3 Cycle error at the proximity

switch
4 Battery fault
Fig. 9 CD / NS settings
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Emergency lubrication and grease consumption
9 Emergency lubrication and grease consumption
Emergency lubrication
If the lubricating pump is defective, the lube points connected to the lubrication system can be
greased manually with a grease gun at lubrication nipple 25 .
Per working day or shift, apply approx. 30-60 cm3 of grease onto the lubrication nipple 25.
Alternatively, press in grease until clear lubricant escapes at the boom cylinder / uppercarriage
bearing.
Grease consumption
The grease consumption depends on the factory-set cycle times and number of cycles. At a cycle
time of 1 hour and number of cycles = 2 (factory settings of machines A 900 C to A904 C), the average
grease consumption is 3.5 to 5.5 cm3 per hour of operation, i.e. around 0.33 to 0.50 kg of grease per
100 operating hours.
Refilling of the grease tank

Check the filling level in the grease tank 13 once a week, and add grease, if necessary.
For lubricant specifications, see the operating and maintenance manual of the machine, or group
1.50 "Lubricants".
The grease tank is normally refilled through the special adapter 21. For this purpose, insert a grease
cartridge in the enclosed hand pump 31, connect the pump to the adapter 21 and empty the entire
cartridge content into the tank 13.
Do not fill the tank through the lid 23, as this might lead to an air pocket in the grease, which in turn
can cause the pump to run idle and become damaged. If there is no special filling pump 31 or grease
cartridge available, fill the tank 13 through the lubrication nipple 22.
Fig. 10 Refilling of the grease tank
9 Pressure relief valve 22 Emergency filling nipple

13 Tank 23 Tank lid
19 Push button 25 Emergency lubrication nipple
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Diagnostic software
21 Filling adapter 31 Hand pump
10 Diagnostic software
10.1 Communication with the control unit from a PC

The BEKA-DiSys diagnostic program has been designed for the configuration of newly installed units,
the adjustment of the parameter settings, and the testing of faulty central lubrication systems.
PC hardware requirements:
IBM-compatible PC, 486 and higher
8 Mb RAM
Windows 95, 98, ME, NT or 2000
Double-speed CD-ROM drive
The BEKA-DiSys communication and diagnostic software is available from the spare parts
department (ID no. 1000 84 27).
Its user-friendly interface allows operators to:
choose the interface language
read out data
adjust settings
complete hardware tests
monitor greasing processes
view error logs with date and time of the error
compile operating data statistics, user intervention logs and lists of settings
The complete software package consists of:
CD-ROM with diagnostic software
Data cable for the connection of the control unit to the serial interface of the PC
Software manual
License registration form
Each data cable is individually encoded, so that it is identified by the control unit each time data is
transferred. This method of identification of the cable allows the control unit to compile a history log
showing all data transfers and the respective user details.
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Diagnostic software
Fig. 11 Screenshot of a diagnostic software window
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MJFCIFSS
Service Manual SX-E progressive distributor
Function
SX-E progressive distributor
1 Function
The SXE-2 progressive distributor is a distribution device equipped with a hydraulic sequence control.
Its plunger is controlled by the lubricant fed to the distributor, ensuring that lubricant exits in the
desired sequence at the individual outlets. In the event of disrupted lubricant flow, e.g. if a supply line
or a lube point is blocked, the distributor is also automatically stopped.
Such stops are monitored. In the event of a blockage, the counterpressure caused by the blockage
is so great that it cannot be overcome. In automatic pumps such as the EP-1 electric pump, lubricant
escapes through the pressure relief valve. The progressive distributors are designed as variable
modular kits, so that each distributor can be modified to suit a changing number of lube points or an
increased volume.
The SXE-2 progressive distributor consists mainly of a number of distributor discs. Each disc contains
a basic element and a metering element, or a dummy element. The basic elements are classified into
start, centre and end elements.
Thanks to their modular design, both the flow rate at the individual outlets and the number of outlets
can be adjusted.
To achieve different flow volumes per plunger stroke, install metering elements with different plunger
diameters. These elements can be exchanged at any stage. to reduce the number of lube points on
a built-in distributor, install a dummy element, or remove a basic element with metering element. To
extend the distributor, add a basic element with metering element.
Fig. 1 SXE-2 progressive distributor with four distributor discs and six outlets
AE Start element GE Basic element

BE Dummy element ME Centre element
DE Metering element x Inlet screw connection
EE End element y Outlet screw connections
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SX-E progressive distributor Service Manual
Description
2 Description
2.1 SXE-2 basic elements

The progressive distributor consists of the following component parts:
:
1 Start element AE (without plunger)

1 Metering element DE
1 End element EE
Note!
To ensure proper operation of the SXE-2 progressive distributor, all three flow elements must be
installed, i.e. each distributor must consist of at least three metering elements.
Dummy elements do not contain a plunger and therefore do not count here.
Fig. 2 Start element, a = distributor outlet, b = distributor inlet
The basic elements are classified into start, centre and end elements. Each metering or dummy
element can be mounted onto any basic element, see Fig. 2 to see Fig. 5.
Each distributor must include a start element, one to eight centre elements and an end element.
The connections between the elements are sealed with O-rings, which are installed in the centre and
end elements, see Fig. 4 and see Fig. 5.
The distributor inlet of the start element is compatible with all inlet screw connections. The outlet
screw connections are screwed into the distributor outlets.
Fig. 3 Screw connections
1 Straight screw connection 3 Swivelling elbow

2 Elbow
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Description
Fig. 4 Centre element with O-ring kit 998 and distributor outlet a (at both sides)
Fig. 5 End element with O-ring kit 998 and distributor outlet a (at both sides)
2.2 Metering elements of the SXE-2 progressive distributor

The metering elements for the SXE-2 progressive distributors are responsible for the proper dosing
and distribution of the supplied grease. They are equipped with plungers of various diameter, which
determine the actual feed volume.
The metering elements must be screwed onto the basic elements. The connections between the
metering elements and the basic elements are sealed with O-rings.
Mount the metering elements onto the basic elements and tighten the two M5X35 Allen head screws
with a torque of 5 Nm.
Fig. 6 Metering element dummy element, O-ring kit 998
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MJFCIFSS
Description
2.3 Dummy elements of the SXE-2 progressive distributor

If a lube point in the system is removed, or if the distributor is to be equipped with additional outlets
for future extensions of the machine, install dummy elements.
These elements do not contain a plunger, and distributors containing dummy elements must consist
of at least four distributor discs, namely a start element, at least two centre elements, an end element
and three metering elements. Connections to dummy elements are also sealed with O-rings.
Mount the dummy elements onto the basic elements and tighten the two M5X35 Allen head screws
with a torque of 5 Nm.
2.4 Combining two outlets of the SXE-2 progressive distributor

For lube points requiring large quantities of grease, you have the option to combine two or more
outlets at the progressive distributor. Per basic element, two outlets can be combined by means of
screw plugs with sealing rings.
Operators can combine the two outlets of one basic element, or two outlets of different yet adjacent
basic elements.
In order to combine the two outlets of one basic element, connect the two outlets by removing the
sealing screw 1 between the two outlets and then closing one outlet with the screw plug 2. The flow
volume of the sealed outlet is now fed through the open side, i.e. the flow volume at this outlet is
doubled.
To separate combined outlets in progressive distributors, insert the sealing screw 1 with sealing ring.
Fig. 7 2 outlets per standard element, sealing screw 1
Fig. 8 2 outlets of element combined:

sealing screw 1 removed, and screw plug2 mounted
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Description
2.5 Combining three or four outlets of the SXE-2 progressive distributor using a
distributor bridge
The flow volumes of two outlets of two different distributor discs can be combined with a distributor
bridge featuring one outlet. To do this, remove the outlet screw connections for the outlets to be
combined and mount the distributor bridge 3. The sealing screws 1 between the outlets of the same
element remain in place. The flow volumes at the outlets of the two distributor discs are now
combined at the distributor bridge outlet.
Fig. 9 Distributor bridge 3 with hollow screw 4 (with outlet) and hollow screw 5 (without outlet)
Fig. 10 3 outlets combined through one distributor bridge with outlet, sealing screw removed
1
1 Sealing screw 3 Distributor bridge with hollows screw 4 with outlet

2 Screw plug
To combine three outlets with a distributor bridge, remove the sealing screw in one of the respective
basic elements.
The outlet screw connections of the adjacent distributor discs that are to be combined are connected
on one side with a distributor bridge. Seal the outlet opposite the bridge of the basic element from
which the sealing screw 1 has been removed with a screw plug 2. The flow volumes of the three
outlets are now combined at the outlet of the distributor bridge 3.
To combine four outlets, remove the sealing screw 1 in both connected basic elements, and seal the
opposite outlets with screw plugs 2. The flow volumes of the four outlets are now combined at the
outlet of the distributor bridge 3.
18.58. 5
MJFCIFSS
Description
Fig. 11 4 outlets combined through one distributor bridge with outlet, sealing screw removed
1 Sealing screw 3 Distributor bridge with hollows screw 4 (with outlet)

2 Screw plug
18.58. 6
MJFCIFSS
Description
2.6 Combining three or four outlets of the SXE-2 progressive distributor using a
distributor bridge without outlet
Distributor bridges 3 without outlets can be used to combine three or four outlets of adjacent basic
elements.
To combine three outlets with a distributor bridge, remove the sealing screw 1 in one of the respective
basic elements. The outlet screw connections of the adjacent distributor discs that are to be
combined are connected on one side with a distributor bridge 3.
The outlet opposite the distributor bridge 3 at the basic elements whose sealing screw 1 has been
removed acts now as the outlet for the combined flow volume of all joined outlets.
Fig. 12 Distributor bridge 3 with hollows screw 5 (without outlet)
Fig. 13 3 outlets combined through one distributor bridge 3 (without outlet 5), sealing screw
removed
To combine four outlets with a distributor bridge, remove the sealing screws 1 in both basic elements.
Replace the outlet screw connections on one side of the two distributor discs with a distributor bridge
3 without outlet. Seal one of the outlets opposite the distributor bridge 3 with a screw plug 2. The other
outlet serves as the combined outlet of the joined elements.
In order to combine five or more outlets, you must join distributor bridges as described above.
18.58. 7
MJFCIFSS
Description
Fig. 14 4 outlets combined with one distributor bridge 3 (without outlet 5) and sealing ring 1,
screw plug removed
2.7 SXE-2 progressive distributor elements with stroke indicator

Metering elements of the models 400 SXE-2 to 760 SXE-2 can be equipped with a stroke indicator.
This indicator cannot be retrofitted.
Fig. 15 SXE-2 progressive distributor with stroke indicator
2.7.1 Function of the stroke indicator, see Fig. 15

A pin 8 is attached to the plunger of the metering element 7. This pin is visible at each plunger stroke
through the transparent cap 9.
Fig. 16 Sectional drawing of the stroke indicator mechanism
18.58. 8
MJFCIFSS
Description
2.8 SXE-2 progressive distributor elements with proximity switch

6
Remove the transparent cap of the progressive distributor and screw in the proximity switch 6.
Distributors with proximity switches are used to monitor the unit or to count the number of plunger
strokes in cycle-controlled systems.
Fig. 17 SXE-2 progressive distributor with attached proximity switch 6
2.8.1 Function of the proximity switch, see Fig. 18

A pin 8 is attached to the plunger of the metering element 7. At each plunger stroke, it approaches
the proximity switch 6, triggering a signal. This signal can be processed in various ways, depending
on the control system type and/or the settings.
Fig. 18 Proximity switch 6 attached to metering element 7
18.58. 9
MJFCIFSS
The progressive distributor consists of a number of distributor discs that are combined with each
other by means of tie rods with washers and nuts to distributors. The metering elements are secured
with Allen head screws to the basic elements. The elements are sealed with O-rings.
The following four diagrams show the sequence of movements of the plungers and the distribution of
the lubricant.
3.1 Figure A:
The lubricant flows through the inlet of the distributor and through all distributor discs to plunger (II)
Fig. 19 Sectional drawing A Progressive distributor with pressure chamber a
3.2 Figure B:
The plunger (II) is moved to the left and lubricant is pressed from the left pressure chamber of the
delivery plunger to the outlet 1.
The metering plungers (III) are then moved so that lubricant is fed through the outlets 3.
18.58. 10
MJFCIFSS
Fig. 20 Sectional drawing B Progressive distributor
3.3 Figure C:
As the plunger (III) is moved, lubricant is fed to the left end of the delivery plunger (I) and thus pressed
from the right pressure chamber of the plunger to outlet 4.
Subsequently, the delivery plungers (II) and (III) are moved and lubricant is pressed to outlets 5 and 6.
Fig. 21 Sectional drawing C Progressive distributor
As the delivery plunger (III) is moved, lubricant is fed to the right end of the delivery plunger (see
figure A) and the next progressive distributor cycle is started. The above cycle is repeated as long as
lubricant is fed to the progressive distributor.
18.58. 11
MJFCIFSS
3.4 Figure D:
The
above cycle is repeated as long as lubricant is fed to the progressive distributor.
Fig. 22 Sectional drawing D Progressive distributor
18.58. 12
MJFCIFSS
Fig. 23
1 Start element 17 Distributor bridge without outlet

2 Centre element 18 Distributor bridge with outlet
3 End element 19 Cap
6 Tie rod 20 Proximity switch
7 Washer 21 Connecting line
8 Hex nut 30 Connecting element
9 Elbow 101 Metering element 500
10 Extension 102 Metering element 100
11 Sealing ring 103 Metering element 300
12 Screw-in connection 104 Metering element 000
13 Allen head screw 105 Metering element 100
14 Outlet 998 O-ring kit
15 Screw plug 999 O-ring kit
16 Sealing ring
18.58. 13
MJFCIFSS
18.58. 14
MJFCIFSS
Service Manual MX-F progressive distributor
Function
MX-F progressive distributor
1 Function
The MX-F progressive distributor is a distribution device equipped with a hydraulic sequence control.
Its plunger is controlled by the lubricant fed to the distributor, ensuring that lubricant exits in the
desired sequence at the individual outlets. In the event of disrupted lubricant flow, e.g. if a supply line
or a lube point is blocked, the distributor is also automatically stopped. Such stops are monitored. In
the event of a blockage, the counterpressure caused by the blockage is so great that it cannot be
overcome. In automatic pumps such as the EP-1 electric pump, lubricant escapes through the
pressure relief valve. The progressive distributors are designed as variable modular kits, so that each
distributor can be modified to suit a changing number of lube points or an increased volume. The
modular design with discs also allows for the combination of different distributor discs with various
flow capacities per plunger stroke in a single progressive distributor. The different flow volumes per
plunger stroke are the result of different plunger diameters. To work properly, a progressive
distributor must feature at least three plungers, i.e. three distributing elements.
Fig. 1 Progressive distributor with distributing elements and eight outlets
AE Start element x Inlet screw connection

ME Centre element y Outlet screw connection
EE End element
18.59. 1
MJFCIFSS
MX-F progressive distributor Service Manual
Description
2 Description
2.1 MX-F elements

The progressive distributor consists of the following component parts:
I
1 Start element AE (without plunger)

2-11 Centre elements ME
1 End element EE
These elements are held together with tie rods (Allen head screws and tooth lock washers to form
distribution blocks. The elements are sealed with O-rings.
All screw connections with M10x1 threads can be connected to a start element AE. The outlet screw
connections are screwed into the centre and end elements ME / EE.
Fig. 2 Progressive distributor elements AE, ME and EE
2.2 MX-F outlet screw connections

The polyamide or steel pipe is normally secured to the distributor with a sleeve nut B and a double
cone ring C. The pipe nozzle used for the connection of the high pressure hose can also be secured
to the distributor with a sleeve nut B.
Fig. 3 Sleeve nut B and double cone ring C
18.59. 2
MJFCIFSS
Description
2.3 MX-F check valves

The check valves are used in connection with a high pressure hose, e.g. for lube points with
increased counter pressure or for main distributors. The polyamide pipe and the high pressure hose
are connected to the check valve with a sleeve nut B and a double cone ring C. Do not connect the
check valve to the pipe and tube using a sleeve nut and cutting ring.
Fig. 4 Check valve for main distributor D and auxiliary distributor E
2.4 MX-F Combining two outlets

For large lube points, it might be necessary to combine two outputs of the progressive distributor.
Each disc of the distributor is equipped with two outlets. Where two outlets are to be combined,
choose the two outlets of one disc. By inserting the threaded stud E, the two sides of the disc are
separated. Seal the side to be closed off by inserting a screw plug F. The flow volume of the sealed
outlet is now fed through the open side, i.e. the flow volume at this outlet is doubled.
Fig. 5 Distributor element with one outlet
Fig. 6 Distributor element with two outlets
18.59. 3
MJFCIFSS
Description
2.5 MX-F Combining three and more outlets

If the combined flow volume of the two outlets of one disc is not sufficient to adequately lubricate for
instance very large bearings or to fill main distributors, operators have the option to combine the
outlets of two or more discs. For this purpose, two (or more) distributor discs are connected as
described below with a pipe section or a distributor bridge H. Depending on the element from which
the threaded stud F, which separates the two sides of a disc, is removed, three outlets are combined.
The flow volume of the sealed outlets is added to that of the single open outlet. The total metered
volume corresponds thus to the combined volume of the combined element sides.
Fig. 7 Distributor element with three outlets
Fig. 8 Distributor element with four outlets
18.59. 4
MJFCIFSS
Description
2.6 MX-F Combining outlets with screw connections

To combine outlets, it is normally necessary to insert additional screw plugs G.
Fig. 9 Screw plug G
To separate combined outlets in a progressive distributor, reinsert the threaded stud F.
Fig. 10 Threaded stud F
Distributor elements can be combined by means of pipe bridges or distributor bridges. A pipe bridge
H is only required, where three or more outlets are combined, as the flow volume must always be fed
through one of the discs in the progressive distributor. Always remove the threaded stud F in one of
the two distributor discs that are to be combined by means of a pipe bridge. It is also possible to
combine four outlets using a pipe bridge H. In this case, remove the threaded stud F in both distributor
discs to be combined, and seal one of the two outlets opposite the pipe bridge H with a
screw plug G. Pipe bridges H can be ordered as separate parts.
Fig. 11 Pipe bridge H with double restrictor 7, sleeve nut B and double cone ring C
18.59. 5
MJFCIFSS
Description
2.7 Distributor bridges are available in two designs:

Type 1 - Distributor bridges without outlet I
These distributor bridges serve the same purpose as the pipe bridges H.
Fig. 12 Distributor bridge without outlet I
Type 2 Distributor bridges with outlet J

Distributor bridges with outlet J can be used to combine two, three or four outlets of adjacent
distributor discs. To combine four outlets, remove the threaded stud F in both distributor discs, and
seal the opposite outlets with screw plugs G. The flow volumes of the four outlets are now combined
at the outlet of the distributor bridge. To combine three outlets with a distributor bridge, remove the
threaded stud F in one of the respective distributor discs. The flow volumes of the three outlets are
now combined at the outlet of the distributor bridge. If only two outlets at two adjacent distributor discs
are to be connected, do not remove the threaded stud F in the two distributor discs. The flow volumes
of the two outlets are now combined at the outlet of the distributor bridge.
Fig. 13 Distributor bridge with outlet J
18.59. 6
MJFCIFSS
3.1 Lubricant flow 1:

The lubricant flows through the inlet of the distributor and through all distributor discs to plunger I
Fig. 14 Lubricant flow in the plunger

The plunger I is moved to the left and lubricant is pressed from the left pressure chamber of the
delivery plunger to the outlet 1. The metering plungers II and III are then moved so that lubricant is
fed through the outlets 2 and 3.
18.59. 7
MJFCIFSS

As the plunger III is moved, lubricant is fed to the left end of the delivery plunger I and thus pressed
from the right pressure chamber of the plunger I to outlet 4. Subsequently, the delivery plungers II
and III are moved and lubricant is pressed to outlets 5 and 6. As the delivery plunger III is moved,
lubricant is fed to the right end of the delivery plunger (see Fig. 14) and the next progressive
distributor cycle is started. The above cycle is repeated as long as lubricant is fed to the progressive
distributor.
I Delivery plunger 3 Outlet

II Metering plunger 4 Outlet
III Metering plunger 5 Outlet
1 Outlet 6 Outlet
2 Outlet A Pressure chamber
18.59. 8
MJFCIFSS
Exploded view
4 Exploded view
The MX-F components of the progressive plunger distributor are available from LIEBHERR service
agent as spare parts for maintenance and repair work.
Note!
The lubricating cycle and its components may not be modified in any way without the prior written
consent of LIEBHERR. Non-compliance shall void the warranty.
Fig. 17 Exploded view of the spare parts
1 Start element 17 Distributor bridge without outlet

2 Centre element 18 Distributor bridge with outlet
3 End element 19 Cap
6 Tie rod 20 Proximity switch
7 Washer 21 Connecting line
8 Hex nut 30 Connecting element
9 Elbow 101 Metering element 500
10 Extension 102 Metering element 100
11 Sealing ring 103 Metering element 300
12 Screw-in connection 104 Metering element 000
13 Allen head screw 105 Metering element 100
14 Outlet 998 O-ring kit
15 Screw plug 999 O-ring kit
16 Sealing ring
18.59. 9
MJFCIFSS
Exploded view
18.59. 10
MJFCIFSS

Liebherr A900C A904C Litronic Hydraulic Excavator

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Order no.: 10216479

Manufacturer: LIEBHERR Hydraulikbagger GmbH

3 Address of copyright owner

Liebherr Hydraulikbagger GmbH

Manual no. ..............................

Symbols used in this manual

 This symbol precedes entries in a list.

A Page number D Engine

Technical data / maintenance instructions 3

Coupling / pump distribution gear 5

Slewing gear mechanism 9

Oscillating axle support 14

Special equipment / accessory kits 16

Operator's cab / heating and air-conditioning 17

Undercarriage / uppercarriage / attachments 18

Section Group Type

Changes and amendments to series 1.02.1 A 900 C-LI EDC 24677-

Safety instructions 1.10.1 A 900 C-LI

Tightening torques WN 4037 K 1.20.1 A 900 C-LI

Tightening torques 1.21.1 A 900 C-LI

Assembly instruction for hydraulilc cylinder 1.22.1 A 900 C-LI

Assembly instruction for hydraulic cylinder 1.24.1 A 900 C-LI

Lubricants and process chemicals 1.50.1 A 900 C-LI 14675-

Lubricants and process chemicals 1.51.1 A 900 C-LI EDC 24677-

TE_ML05 lubricant list 1.55.1 A 900 C-LI

TE_ML07 lubricant list 1.56.1 A 900 C-LI

Changes and amendments to series

4 last update 03/2008

5 last update 05/2008

6 Last updated 07/2008

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)

PRELOADS AND TIGHTENING TORQUES FOR SCREWS WITH METRIC

.04.08 LHB Wimbauer Alois owatzky Dirk

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

This symbol precedes entries in a list.

Switch off the Diesel engine prior to filling the tank.

Before starting the machine, perform a thorough walk around inspection.

Remove all temporary covers.

For machines equipped with electrical medium-voltage and high-voltage lines:

Deformation of the hose when pressurised, depressurised, or at bends, resulting in separation

Diesel fuel petrol mixing ratio

Tab. 5 Summer diesel fuel petrol mixing ratio