Liebherr A309li - 307li - SERVICE MANUAL

Service Manual
SUBGROUP - INDEX
Section
Group
Type
Modification of series
1.02.1
A 309 LI - R 317 LI
Safety instructions
1.10.1
A 309 LI - R 317 LI
Tightening torques WN 4037
1.20.1
A 309 LI - R 317 LI
Tightening torques for screw connections
1.21.1
A 309 LI - R 317 LI
Assembly instruction for cylinder (WN 4121B)
1.22.1
A 309 LI - R 317 LI
Assembly instruction for cylinder (WN 4122B)
1.24.1
A 309 LI - R 317 LI
Fuels, lubricants and other consumables
1.50.1
A 309 LI -R 317 LI
Lubricant list TE-ML 05
1.55.1
A 309 LI -R 317 LI
Lubricant list TE-ML 07
1.56.1
A 309 LI -R 317 LI
1.1
MJFCIFSS
Service Manual
1.2
MJFCIFSS
Service Manual
Item
(a)
Type of modification
Modified actuation of the pressure-relief
valves for slewing gear
Joint control line Xab replaced by separate
control lines Xa / Xb for each valve
Additional orifice 126 in connection P of valve
125
Affected models
A 314 Li: 11147
A 316 Li: 11152
A 316 Li industrial: 11178
Modified measuring connections

Measuring connections 137 / 138 are moved
from the side to the top
(b)
Modified spool
A 314 Li: 11820
Spool for slewing gear

(change in design from restricted to blocked
outlet)
A 316 Li: 11822

Spool for chassis

(change in design from restricted to open
outlet)
(c)
Modified pressure balance 244 for stick

cylinder
Change from pressure balance without shock
absorption to pressure balance with 0.4mm
shock absorption
A 314 Li: 12814

A 316 Li: 12741
Additional control line from control valve block

connection MLS to pressure balance 244 at
spring side connection LSE
Modified shuttle valves 227
(a3 /b3) for boom cylinder spool
Change from 0.8 mm to 0.6 mm
(d)
(e)
Modified fan cycle
A 312 Li: 13289
Installation of coarse filter 15 in the pressure

line
to oil motor / radiator fan
A 314 Li: 13104
Various modifications to control valve

block
A 312 Li: 16275
Tuning improved. Pressure balance 224 pilotcontrolled. Shuttle valve 107 integrated into
control block. Central nozzle 109 screwed in.
New slewing gear module (check valve 123
before spool 120).
A 316 Li: 13105
A 314 Li: 16215

A 316 Li: 16141
Modified TC valve 125

Integrated restrictor 126 and bypass line with
restrictor 129
1.02.1
MJFCIFSS
Item
(f)
Service Manual
Type of modification
Pressure-relief valve in the gear pump /
steering
Affected models
A 312 - A 316 Li: 20241
Gear pump of steering system with integrated

pressure control
(g)
Modified electrical system

Modifications:
K392 (industrial shut-off) omitted,
S5 with 3 push buttons, S382 modified,
S263 modified, S422 added
(h)
New pilot control unit for travel working

movement:
A 312 Li: 20330

A 314 Li: 20334
A 316 Li: 20340
A 316 Li in.: 20340
R 317 Li: 21205
The two individual pilot control units 2x are

replaced by one pilot control unit 4x
(i)
Optimised control of control valve block

Regulating cylinder spool modified; control of
spool of combined boom / slewing gear with
shuttle valves
Restrictor check valve 171 for stick cylinder is
omitted
(k)
Optimisation of fine control

Spool of the boom and regulating cylinder and
the summary pistons modified. Installation of
priority circuit "Total of boom before total of
stick" with decoupling.
Actuation of boom and stick spools with
additional shuttle valves.
A 309 Li: 23503

A 311 Li: 23504
A 309 Li: 27110

A 311 Li: 27112
See also service information 07-11-37/2005

(l)
Speed reduction when working at 1950

rpm
Omission of solenoid valve Y330 for zero
boom switching from P2 during travel
A 309 Li: 27110

A 311 Li: 27112
The solenoid valve Y330 at the control oil unit

is omitted.
See service information 07-11-37/2005
(m)
Hydraulic slewing ring locking mechanism

A hydraulically operated cylinder (via pilot
control system) with a locking bolt is installed
in the uppercarriage. It is used for the locking
of the uppercarriage during parking and
transport of the machine.
(n)
Changeover to travel operation

By changing over to the 2 HL 270/290
transmission, the travel motor has also been
upgraded to a DMVA 165 motor.
A 309 Li: 26392

A 311 Li: 26396
A 312 Li: 29898
A 316 Li: 28061
A 316 Li ind.: 28061
A 316 Li: 28061
A 316 Li ind.: 28061
1.02A 309 LI 20221-A 311 LI 20222-A 312 LI 12363-A 314 LI 2001-A 316 LI 2001-A 316 LI-IND 2001-R 317 LI 18161-
1.02.2
MJFCIFSS
Service Manual
Safety instructions
Proper use
Safety instructions
Working with the machine holds dangers to which you as the owner, machine operator or maintenance expert could be exposed. If you regularly read and observe the safety information, you can
guard against dangers and accidents. This applies especially to persons, who are working on the machine only occasionally, such as for maintenance work. The following information comprises safety
regulations which, if followed conscientiously, will guarantee your safety and that of other persons,
as well as avoid damage to the machine.
Following these regulations does not release you from the responsibility to follow all safety regulations and guidelines valid for the jobsite, as required by law or issued by trade associations.
For EU countries, guideline 89/655/EEC contains the minimum safety information applicable to the
operator.
1 Proper use
The hydraulic excavator is a machine with attachments (such as backhoe, grapple, bucket ) designed to loosen, take on, transport and dump soil, rocks and other materials, where the load is
predominantly transported without moving the machine. Moving the machine when it is carrying a
load must be carried out by observing the appropriate safety measures (see section "Notes for
machine operating safety").
Machines used for load-lifting work are subject to specific conditions and must be equipped with
the stipulated safety devices (see section Load-lifting work).
Other or additional usage, such as for demolition or material handling work, requires special
equipment and may also require special safety devices. These attachments (e.g. log grapple,
demolition hammer, concrete cutter etc.) may only be attached and used with approval and in accordance with the basic machine manufacturer.
Transporting persons is not deemed to be intended use. The manufacturer is not liable for damage
resulting from this action. The risk must be assumed solely by the user.
Observing the operating instructions and the inspection / maintenance instructions is also deemed
to be appropriate and destined use in accordance with regulations.
2 General Safety instructions

Please familiarize yourself with the operating instructions before starting the machine.
Please verify that you have supplemental instructions and have read and understood these (this
may concern special options for the machine).
Only explicitly authorized personnel may operate, maintain or repair the machine. The legal minimum age must be observed.
Use only trained or instructed personnel. Clearly define who is responsible for the operation or
set up, maintenance and repair. Allow personnel to refuse unsafe instructions given by a third person. This also applies to traffic regulations. Reject unsafe instructions by third parties and/or allow
your personnel to reject these. This also applies in regards to traffic regulations.
Any person still in training should only operate or work on the machine under the constant supervision and guidance of an experienced person.
Check and observe any person working or operating the machine at least periodically if they observe safety instructions and guidelines given in the Operating manual.
Wear proper work clothing when operating or working on the machine. Avoid wearing rings,
watches, ties, scarves, open jackets or loose clothing. There is a danger of injury, as these items
could get caught or be pulled in.The following are mandatory for certain tasks: Safety glasses,
safety shoes, safety helmet, work gloves, reflecting vest, hearing protection, ...
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1.10.1
Safety instructions
Service Manual
Crushing and burn prevention

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

Never work underneath the attachment as long as it is not safely resting on the ground or properly
supported.
Do not use any damaged or insufficiently supporting load carrying devices, such as ropes or
chains.
Always wear work gloves when handling wire ropes.
When working on the attachment, never align bores with your fingers, always use a suitable alignment tool.
Please verify that no objects enter the fan while the Diesel engine is running. Rotating fans will
swirl and throw out objects, which can damage the fan.
At or near operating temperature, the engine cooling system is hot and under pressure. Avoid contact with any components containing coolant. Danger of severe burns.
Check the coolant level only after the radiator cap on the expansion tank is cool enough to touch.
Turn the cap carefully to relieve the pressure.
At or near operating temperature, the engine and the hydraulic oil are hot. Do not allow your skin
to come into contact with hot oil or components containing hot oil.
Always wear safety glasses and protective gloves when handling batteries. Avoid sparks and
open flames.
Never permit anyone to guide the grapple by hand.
When working on the engine area, make sure that the side doors are properly secured with the
appropriate supports to prevent them from closing inadvertently.
Never work underneath the machine if it is raised with the attachment, without being properly supported from below with hardwood beams.
1.10.2
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Service Manual
Safety instructions
Fire and explosion prevention
4 Fire and explosion prevention

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

Due to the space restrictions during transport, use only suitable transporting and lifting devices
with sufficient capacity
Park the machine on a level surface and chock the chains and/or wheels.
If necessary, remove parts of the attachment during transport.
The ramp to drive onto the transporting vehicle should not exceed an inclination of 30 and be provided with a wood covering to prevent sliding.
Clean the undercarriage. The undercarriage must be swept clean, meaning, the chains / wheels
must be free of snow, ice and sludge prior to driving onto the ramp.
Align the machine precisely with the loading ramp.
Attach the manual lever for sensitive driving (crawler excavator) to the driving pedals.
Note that a guide gives the necessary signals to the machine driver.
Drop the equipment in and drive it onto the loading ramp. Keep the equipment tight over the loading surface and drive it carefully onto the ramp and further into the transporting vehicle.
The superstructure must be secured with the undercarriage by using locking bolts (only for Aequipment), after loading the machine onto the low loader.
Secure the machine and the remaining equipment parts with chains and chocks against shifting
according to national regulations for loading and transporting.
Release all pressure lines (as described in these operating instructions), pull the ignition key and
pull the safety lever up prior to leaving the machine.
Close all cab and panel doors.
Verify that no one is located on the machine during the transport.
Investigate the travel route, specifically in reference to limits for width, height and weight prior to
the transport.
Pay special attention when driving under electrical lines and bridges and when passing through
tunnels.
Use the same care for unloading as for loading.
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1.10.3
Safety instructions
Service Manual
Bringing the machine safely into service
6 Bringing the machine safely into service

Before starting the machine, perform a thorough walk around inspection.
Visually check the machine for loose bolts, cracks, wear, leaks and damage.
Never start or operate a damaged machine.
Make sure to correct any problems immediately.
Verify that all hoods, covers and doors are closed, however, the locks should remain unlocked.
Verify that all safety tags are available.
Make sure that all windows, as well as the inside and outside mirrors are clean. Secure all doors
and windows to prevent unintentional movement.
Be certain that no one works on or under the machine and warn any personnel in the surrounding
area with the horn before starting the machine.
Before operating the machine, adjust the 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 operation.
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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Service Manual
Safety instructions
Towing the machine safely
9 Towing the machine safely

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

Before starting to work, familiarize yourself with the peculiarities of the job site, the special regulations and warning signals. Part of the surrounding area includes, for example, the obstacles in
the working or movement area, the load carrying capacity of the ground and required safeguards
for the job site to shield it from public highway traffic.
Always keep an adequate safety distance to overhangs, edges, embankments and an unsecured
substrate.
Be particularly cautious in conditions of reduced visibility and changing ground conditions.
Familiarize yourself with the location of power lines on the job site and work particularly careful in
their vicinity. If necessary, inform the responsible authorities.
Maintain a safe distance from electrical overhead lines. Do not approach the line with the
equipment when working near electrical overhead lines. Danger of fatal injury! Inform yourself
about required safety distances.
In case of a flashover, proceed as follows:
do not move the machine or its attachment,
do not leave the 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 necessary, first bring the machine into proper condition to meet federal and local highway standards.
Always turn on the lights in conditions of poor visibility or darkness.
Do not permit any passengers on the machine (except on two way excavators).
Operate the machine only when seated and with the seat belt fastened.
Report any problems or needed repairs and make sure that all required repairs are carried out
immediately.
Personally make sure that no one is endangered by moving the machine.
Before starting to work, always check the brake system as outlined in the operating manual.
Never leave the operators seat as long as the machine is still moving.
Never leave the machine unattended while the Diesel engine is running.
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1.10.5
Safety instructions
Service Manual
Working with the machine safely

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

Particularly when working with a grapple it can be necessary to move the machine with a raised
attachment and picked up load, for example when handling wood or timber.
This will shift the center of gravity of the machine upward in vertical direction. The travel behaviour
of the machine will be strongly influenced, for example reduction of dynamic stability.
For that reason, the following rules must be strictly observed:
Match your travel behaviour to the changed machine characteristics and surrounding conditions.
Reduce the travel speed to avoid sudden braking or steering manoeuvres.
Avoid sudden speed changes, such as braking, acceleration, changes in travel direction.
Turn the uppercarriage only if the undercarriage is stationary.
Turn the uppercarriage only after taking on the load.
Move the machine only after you have taken on the load, lifted it and turned the uppercarriage
in travel position.
If the attachment is raised, there is a danger due to possible oscillating movements and falling
of the picked up load.
A protective screen (FOPS) according to ISO 10262 must be attached on the front on the cab.
The protective screen (FOPS) according to ISO 10262 must be installed if there is a danger of
falling objects from overhead.
Only the maximum permissible load may be picked up with the grapple.
1.10.6
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Service Manual
Safety instructions
NOTE: The weight of absorbent material, such as wooden logs, depends on the length, the diameter and the specific weight. The existing influencing factors for a natural product, such as moisture, must be considered.
The working sequences when working with machines with grapples require special instruction and
training of the machine operator.
The work application is only permitted after the machine operator has received sufficient training
and practical experience.
10.2
Safe application of machines with tower elevation

Due to the tower elevation, the center of gravity of the machine will shift upward in vertical direction. The travel and work behaviour of the machine will thereby be strongly influenced, for example
reduction of dynamic stability.
Due to the elevated center of gravity, the machine must be aligned in horizontal direction before
starting to work. In horizontal direction, the center of gravity of the uppercarriage is above the center of the undercarriage, which reduces the danger of tipping over.
The machine can rock despite leveling and tip over!
For that reason, the following rules must be strictly observed:
When driving the machine:
Swing the uppercarriage parallel to the undercarriage (transport position).
Pull the attachment as close as possible to the machine.
Only then may the outriggers be retracted and the machine be driven.
Driving with loads is not permitted.
Check the roadway to ensure the ground is solid and even! Pot holes and uneven road surfaces
endanger the stability of the machine.
Match your travel behaviour to the changed machine characteristics (higher center of gravity)
and surrounding conditions.
Reduce the travel speed to avoid sudden braking or steering manoeuvres.
Avoid sudden speed changes, such as braking, acceleration, changes in travel direction.
Drive uphill and over obstacles only in lengthwise direction, to avoid impermissible transverse
slopes of the machine.
Special care must be taken when driving through narrow passages drive slowly!
In material handling operation:
Before moving (turning) the uppercarriage from transport position, the machine must be supported and horizontally aligned.
Make sure to check the placement surface of the outriggers (load carrying capacity of ground).
Sinking of an outrigger below ground level would result in devastating consequences!
Carry out all movements with increased caution.
To turn a load, move the attachment as close as possible to the machine (Caution! Oscillating
grapple), while holding the load as close as possible to the undercarriage and above the
ground.
Avoid abrupt slow down or acceleration of the attachment or uppercarriage.
Never lift a heavier load than stated in the load chart.
10.3
Additional notes for machines with fixed operators cab elevation

To enter and exit the machine, park the machine on ground, which is level in lengthwise and horizontal direction. Position the uppercarriage to the undercarriage in such a way that the steps and
ladders are aligned.
Keep steps, ladders and handholds (handles) in proper condition. Make especially sure that they
are free of dirt, oil, ice and snow.
NOTE: To ensure that the doors open in all weather conditions, lubricate the weather strips at
least every two month, or more often, if necessary, with talcum powder or silicon. Lubricate the
door hinges and locks regularly.
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1.10.7
Safety instructions
Service Manual

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 utilization. Especially the following parameters have a significant influence:
Terrain conditions: Unevenness and potholes;
Operating techniques: Speed, steering, braking, control of operating elements of the machine
during travel as well as working.
The machine operator determines the vibration impact to a great part, since he himself selects the
speed, the gear ratio, the working manner and the travel route.
This results in a wide range of various vibration impacts for the same machine type.
The full body vibration impact for the machine operator can be reduced if the following recommendations are observed:
Select the appropriate machine, equipment parts and auxiliary devices for the corresponding
tasks.
Use a machine equipped with the appropriate seat (i.e. for earth moving machines, for example
hydraulic excavators, a seat which meets EN ISO 7096).
Keep the seat in good order and adjust it as follows:
The seat adjustment and the suspension should be made according to the weight and the size
of the operator.
Check the suspension and the adjustment mechanism regularly and make sure that the characteristics of the seat remain as specified by the seat manufacturer.
Check the maintenance condition of the machine, especially regarding: Tire pressure, brakes,
steering, mechanical connections, etc.
Do not steer, brake, accelerate and shift or move and load the attachment of the machine in a jerky
manner.
Match the machine speed to the travel route to avoid vibration impacts.
Decrease the speed when driving on pathless terrain;
Drive around obstacles and avoid very impassable terrain.
Keep the quality of the terrain where the machine is working and travelling in good order:
Remove large rocks and obstacles;
Fill furrows and holes;
To establish and retain suitable terrain conditions, keep machines available and allow for sufficient time.
Travel longer distances (i.e. on public roads) with suitable (medium) speed.
For machines, which are frequently used for travel, utilize special auxiliary systems for travel (if
installed), which reduce the vibration for this application.
If such auxiliary systems are not available, regulate the speed to keep the machine from "rocking".
1.10.8
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Service Manual
Safety instructions
Safe installation and removal of attachment parts
11 Safe installation and removal of attachment parts

Equipment and attachment parts made by other manufacturers or those which do not have LIEBHERRs general approval for installation may not be installed on the machine without prior written
approval by LIEBHERR.
LIEBHERR must be provided with the required technical documentation necessary for this purpose.
When installing attachment parts, which are supplied via the machine's hydraulics system, such
as an attachment with cylinder movement, it must be ensured that different types of oil are not
mixed together.
Mixing environmentally friendly hydraulic oils made by different manufacturers as well as mixing
them with mineral oils must be avoided.
Set the machine on a level and stable ground prior to any attachment and removal of equipment
parts.
Lock the uppercarriage with the locking pin to the undercarriage.
Do not work under the equipment as long as it does not contact the ground or prior to being supported.
Never lie under the machine, if it is lifted by the work equipment without properly propping the machine.
Before releasing a line or bolt, you must reduce the pressure in the hydraulic system as described
in these operating instructions.
Do not attempt to lift heavy parts. Use suitable lifting devices with sufficient load carrying capacity.
Do not use damaged or insufficiently sized ropes or cables. Always wear work gloves when handling wire cables.
When working on the equipment: Switch off the Diesel engine and turn the safety lever upward.
Never align the holes with your fingers; use a suitable mandrel.
During repairs: Make sure that the hydraulic lines are properly attached and that all fittings and
connections are properly tightened.
As soon as an attachment part is removed and supported, close off the openings in the hydraulic
circuit to prevent dirt infiltration. Permit only authorized persons near the machine or the lifting device.
11.1
Safe removal and installation of attachment pins

If possible, always use a hydraulic pin pulling device to push out the pins on the attachment.
If pins must be removed with a sledge hammer, use a punch and a guide tube held by another
person.
To drive out a pin, install the impact screw from the tool box in the threaded bore of the pin and
hit the screw only.
For the installation of a pin retained with castle nut and cotter pin, drive the pin in first to the stop,
then install the castle nut by hand until contact and tighten it only to the point where the cotter pin
can be installed.
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1.10.9
Safety instructions
Service Manual
Safe maintenance of the machine
12
12.1

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
copyright by
MJFCIFSS
Service Manual
Safety instructions
Remove all temporary covers.
Check all fuel, engine oil and hydraulic lines for leakage, loose connections, chaffing and
damage.
Repair all detected defects.
Lubricate slewing ring as well as all bearings and pin connections to eliminate water or detergent
that might have penetrated these assemblies.
12.3
Crack detection
The machines are subject to various loads and stresses, depending on the actual application,
location of operation, operating hours and the ambient conditions. The various load scenarios
result in service lives of the machine components that might differ from each other. This might lead
to cracks or loose connections, especially on load-bearing parts. This applies in particular to
machines used for loading or industrial purposes, or to machines equipped with optional
equipment, such as demolition excavators. To maintain the operational safety of the machine, it
must be regularly inspected for cracks, loose connections and other visible damage.
To be able to inspect the machine for cracks, it must be kept clean.
The inspections must be carried out as described in the inspection and maintenance schedule:
every 250 operating hours, by the maintenance personnel of the machine operator
every 500 operating hours by authorised specialist technicians.
We strongly recommend to carry out these inspections after the machine has been placed on a
firm and level surface, and by applying various different loads in longitudinal and transverse
direction by moving the attachment. Always comply with the applicable workplace safety and
accident prevention regulations.
Particular care is required for the inspection of load-bearing components, in particular:
The steel structure of the undercarriage with axle and gearbox bearings, the support system,
the lower slewing ring support, the tower and the slewing ring.
The steel structure of the uppercarriage with bearing block for booms and boom cylinders, the
upper slewing ring support, the cab bearing, and the securing devices of the slewing gear and
ballasts.
The steel components of the attachments, e.g. booms, members, quick change adapters,
digging buckets and grapples.
Hydraulic cylinders, axles, steering components, bolts and pin connections, ladders, steps and
securing devices.
The crack inspection is a visual inspection. To improve the reliability of the inspection, check areas
where you suspect cracks or areas that are not easily accessible (e.g. at the slewing ring support)
with a dye penetration test.
Immediately eliminate any detected damage. Welding work on load-bearing parts of earth moving
machines, handling and transport equipment must be carried out by specialist welding technicians
and according to best welding practice. If in doubt, contact the LIEBHERR customer service
department to discuss the envisaged measures.
12.4
Welding work
Welding, torch-cutting and grinding work on the machine is only permitted with the explicit consent
of the manufacturer. Before carrying out such work, clean the machine and remove any dust and
flammable material around the equipment.
Ensure that the working areas is properly ventilated. Risk of fire and/or explosion!
Before carrying out arc welding work, or work on the electric components of the machine,
disconnect the battery.
First disconnect the negative pole, then disconnect the positive pole. To reconnect the battery,
first connect the positive pole, then the negative pole.
For arc welding work, position the earth contact point at the machine as close as possible to the
welding area.
copyright by
MJFCIFSS
1.10.11
Safety instructions
Service Manual
12.5
Fuels and lubricants

When handling oil, grease or other chemical products, always comply with the respective safety
instructions provided by the supplier.
All fuels, lubricants and replaced parts must be disposed of in a safe and environmentally friendly
manner.
Handle hot fuels and lubricants with particular care to prevent
injury.
12.6
Repairs
Do not attempt to lift heavy parts by hand but use suitable lifting gear with appropriate load-bearing
capacity. To replace component parts and assemblies, attach and secure them carefully to
suitable lifting tackle and ensure that they cannot cause damage or injury while being transported.
Use only lifting tackle that is in proper working order and has the necessary load-bearing capacity.
Do not stand under suspended loads.
Never use chaffed or damaged lifting tackle or gear that does not have the necessary load-bearing
capacity.
When working with wire cables, always wear protective gloves.
Only experienced personnel may attach loads and guide crane operators. The signaller must be
positioned within the sight of the machine operator. Alternatively, the signaller and the operator
might be in contact through walkie-talkies or similar devices.
When working above head height, use safe ladders and platforms.
Never use machine parts as climbing aids, unless they are designed for this purpose.
When working at great height, wear suitable safety gear.
Keep all handles, steps, railings, platforms and ladders free of dirt, snow and ice.
When working at the attachment (e.g. replacement of teeth), ensure that it is properly supported.
Avoid metal supports (metal-to-metal contact).
Never stand below a machine propped up by means of the attachment, unless the machine has
been properly secured with supports.
Jack up the machine in such a way that shifting weights cannot impair its stability. Avoid metal-tometal contact.
All work on the chassis, brake and steering systems must be carried out by suitably trained
specialists technicians.
If the machine is to be repaired while standing on a slope, the chains must be secured with sprags
and the uppercarriage must be locked onto the undercarriage with the locking bolt.
All work on the hydraulic equipment must be carried out by specialist technicians who are trained
and experienced in the field of hydraulics.
When searching for leaks, always wear protective gloves, as high-pressure liquid might penetrate
the skin and cause damage.
Before loosening or disconnecting any lines of screwed connections, lower the attachment to the
ground, shut down the diesel engine and release the pressure from the hydraulic system. After
the diesel engine has been shut down, insert the ignition key and turn it to its ON position, then
move all control devices (joystick and pedals) of the pilot control units in all directions in order to
release the control pressure and backpressures in the circuits. Continue with releasing the tank
pressure as described in this manual.
12.7
Electrical system
Regularly inspect the electrical system.
Ensure that any detected faults such as loose connections, blown fuses and light bulbs, scorched
or chafed cables are eliminated without delay by specialist technicians.
Use only original fuses of the prescribed amperage.
1.10.12
copyright by
MJFCIFSS
Service Manual
Safety instructions
For machines equipped with electrical medium-voltage and high-voltage lines:

In the event of a disruption in the power supply, immediately shut down the machine.
All work on the electrical equipment of the machine must be carried out by a trained electrician or
specialist technician under the supervision of an electrician and in accordance with the relevant
electro-technical regulations and guidelines.
When working on powered parts, always employ a second person with access to the emergencystop or main switch to shut down the system in the event of an emergency. Cordon off the work
area, using red and white chain and a suitable warning sign. Always use insulated tools.
When working on medium-voltage and high-voltage assemblies, first disconnect them from the
power supply, and then short-circuit the supply line and the assemblies (e.g. condensers) using
an earthing rod.
Check all parts for voltage, then earth them and short-circuit them. Insulate adjacent parts that
remain powered.
Before carrying out arc welding work, or work on the electric components of the machine,
disconnect the battery.
First disconnect the negative pole, then disconnect the positive pole. To reconnect the battery,
first connect the positive pole, then the negative pole.
12.8
Hydraulic accumulators
All work on hydraulic accumulators must be carried out by specialist technicians.
Improper installation and handling of hydraulic accumulators can lead to serious injury.
Never use hydraulic accumulators that are damaged.
Before carrying out any work on a hydraulic accumulator, release the pressure from the hydraulic
system as described in this operating manual.
Do not carry out any welding or soldering work on the hydraulic accumulator and protect it from
mechanical impact.
The hydraulic accumulator might become damaged or ruptured if exposed to heat arising from
mechanical impact. RISK OF EXPLOSION!
Fill the hydraulic accumulator only with nitrogen. Do not use oxygen or air! RISK OF EXPLOSION!
During operation, the storage body might become hot, so that there is a risk of injury.
New hydraulic accumulators must be pressurised to the level required for the actual purpose
before they are commissioned.
The operating data (minimum and maximum pressure) are permanently attached to the hydraulic
accumulators. Ensure that this identification is legible at all times.
12.9
Hydraulic and other hoses

The repair of hydraulic and other hoses is prohibited!
All hoses and fittings must be inspected every 2 weeks for damage. If any damage is suspected,
immediately check the respective line for leakage and visible damage!
Always replace damaged parts without delay! Escaping oil can lead to serious injury or fire!
Even if stored and used properly, hoses tend to age, so that their service life is limited.
Improper storage, mechanical damage and inadmissible loads are however the most common
causes of failure.
As regards the permissible period of use, observe the applicable standards, regulations and
rules for hoses and hose lines.
Use of the hose with near limit loads and stresses (e.g. at high temperature, frequent movement,
extremely high pulse frequencies, multiple shift operation) may shorten its service life.
Replace hoses, if the inspection reveals any of the following:
Damage at the outer jacket exposing the ply (e.g. caused by chafing, wear, cuts or cracks)
Embrittlement of the outer jacket (formation of cracks in the hose material)
copyright by
MJFCIFSS
1.10.13
Safety instructions
Service Manual

Deformation of the hose when pressurised, depressurised, or at bends, resulting in separation
of the layers, bubbles, etc.
Leakage
Non-compliance with installation requirements
Damage or deformation of the hose fittings, which might impair the fitting strength of the
connection between fitting and hose
Disconnection of the hose from the fittings
Corrosion at the fittings, impairing its function and strength
Always replace hoses and hose connections with original spare parts.
Ensure that all hoses and lines are installed and connected properly. Do not confuse connections.
When replacing hoses and hose lines:
Ensure that the hoses are installed without torsion. For high-pressure hoses first insert the
screws at the pipe clips or full flanges at both ends, and then tighten them.
For high-pressure hoses and lines with angled fittings, first tighten the flange at the angled fitting
and then the one at the straight fitting.
Pipe clamps at other point of the hose may not be attached and tightened, when the hose ends
are properly secured.
Daily inspect all hose clips, covers and protective devices to ensure that they are properly
secured and tightened. Avoid vibration and damage during operation.
To prevent chafing, install hoses and lines in such a way that they are not in contact with other
hoses, lines or machine parts.
We recommend keeping a minimum distance of 1/2 the outer hose diameter between the hose
and any other parts. The distance should in any case not be less than 10 to 15 mm.
When replacing hoses and hose lines connected to moving parts (e.g. from the boom to the
stick), first check that they are not rubbing on any other parts when the machine is operated.
12.10
Cab protection (FOPS)

For certain machine applications LIEBHERR offers optional cab protection systems of various
designs. These systems consist of a full length FOPS (falling objects protective structure) or a top
guard and front guard to protect the operator's cab and windscreen area from falling objects (for
example rocks or debris).
The full length FOPS wraps around the operator's cab, is mounted to the uppercarriage and is a
stand-alone system.
The top and front guards are either bolted individually or in combination to the cab structure. In that
case the operator's cab is also part of the cab protection system and is subject to the following
instructions.
Never operate a machine if one of these protections is damaged in any way.
Damages may occur due to:
structural modifications or repairs (for example welding, cutting or drilling)
deformation after an accident
falling objects
Structural modifications or repairs of any kind are prohibited without the expressed, written
approval of LIEBHERR.
1.10.14
copyright by
MJFCIFSS
Bezeichnung
Description / Dnomination
Mjfcifss!
Blatt/Page/Feuille:
Preloads and tightening torques

for screws with metric coarse and fine
threads
according to DIN 13, sheet 12
bestehend aus
consisting of
compos
The preload forces and tightening torques compiled in the table

are based on the VDI 2230, July 1986.
Blatt
Pages
Feuille
WN 4037 I
Assembly preloads FM and tightening torques MA for headless screws with metric coarse or
fine threads according to DIN ISO 262 and DIN ISO 965 T2 (replaces DIN 13, part 13)
and head dimensions of hexagon head bolts according to DIN EN 24014 (replaces DIN 931, part 1)
or hexagon socket head cap screws according to DIN EN ISO 4762 (replaces DIN 912)
Metric coarse thread
Surface finish:
black-chrome finished or phosphatised
oiled
electro-galvanized
flZn according to LH standard 10021432 dry
Tightening
torque
Thread
Class
Assembly preload
FM in N
MA in Nm
for mean friction factor
M4
M5
M6
M7
M8
8.8
10.9
12.9
8.8
10.9
12.9
8.8
10.9
12.9
8.8
10.9
12.9
8.8
10.9
12.9
4 050
6 000
7 000
6 600
9 700
11 400
9 400
13 700
16 100
13 700
20 100
23 500
17 200
25 000
29 500
G= 0.12
2.8
4.1
4.8
5.5
8.1
9.5
9.5
14.0
16.5
15.5
23.0
27
23
34
40
Metric fine thread

Surface finish:
oiled
electro-galvanized
Tightening
torque
Thread
Class
Assembly preload
FM in N
MA in Nm
M8x1
M9x1
M10
8.8
10.9
12.9
27 500
40 000
47 000
46
68
79
M10x1
M10x1.25
M12
8.8
10.9
12.9
40 000
59 000
69 000
79
117
135
M12x1.25
M12x1.5
M14
M16
01/2005
8.8
10.9
12.9
8.8
10.9
12.9
55 000
80 000
94 000
75 000
111 000
130 000
125
185
215
195
280
330
M14x1.5
M16x1.5
8.8
10.9
12.9
8.8
10.9
12.9
8.8
10.9
12.9
8.8
10.9
12.9
8.8
10.9
12.9
8.8
10.9
12.9
8.8
10.9
12.9
8.8
10.9
12.9
18 800
27 500
32 500
24 800
36 500
42 500
31 500
46 500
54 000
29 500
43 000
51 000
45 000
66 000
77 000
42 500
62 000
73 000
61 000
89 000
104 000
82 000
121 000
141 000
G= 0.12
24.5
36
43
36
53
62
52
76
89
49
72
84
87
125
150
83
122
145
135
200
235
205
300
360
1.20.1
Metric coarse thread

Surface finish:
oiled
electro-galvanized
Tightening
Thread
Class
Assembly preload
torque
MA in Nm
FM in N
M18
8.8
10.9
12.9
94 000
135 000
157 000
G= 0.12
280
390
460
Metric fine thread

Surface finish:
oiled
electro-galvanized
Tightening
Thread
Class
Assembly preload
torque
FM in N
MA in Nm
M18x1.5
M18x2
M20
M22
M24
8.8
10.9
12.9
8.8
10.9
12.9
8.8
10.9
12.9
121 000
173 000
202 000
152 000
216 000
250 000
175 000
249 000
290 000
390
560
650
530
750
880
670
960
1120
M20x1.5
M22x1.5
M24x1.5
M24x2
M27
8.8
10.9
12.9
230 000
330 000
385 000
1000
1400
1650
M27x1.5
M27x2
M30
8.8
10.9
12.9
280 000
400 000
465 000
1350
1900
2250
M30x1.5
M30x2
M33
8.8
10.9
12.9
350 000
495 000
580 000
1850
2600
3000
M33x1.5
M33x2
M36
8.8
10.9
12.9
410 000
580 000
680 000
2350
3300
3900
M36x1.5
M36x3
M39
8.8
10.9
12.9
490 000
700 000
820 000
3000
4300
5100
M39x1.5
M39x3
8.8
10.9
12.9
8.8
10.9
12.9
8.8
10.9
12.9
8.8
10.9
12.9
8.8
10.9
12.9
8.8
10.9
12.9
8.8
10.9
12.9
8.8
10.9
12.9
8.8
10.9
12.9
8.8
10.9
12.9
8.8
10.9
12.9
8.8
10.9
12.9
8.8
10.9
12.9
8.8
10.9
12.9
8.8
10.9
12.9
8.8
10.9
12.9
110 000
157 000
184 000
102 000
146 000
170 000
139 000
199 000
232 000
171 000
245 000
285 000
207 000
295 000
346 000
196 000
280 000
325 000
267 000
381 000
445 000
255 000
365 000
425 000
335 000
477 000
558 000
321 000
457 000
534 000
410 000
584 000
683 000
395 000
560 000
660 000
492 000
701 000
820 000
440 000
630 000
740 000
582 000
830 000
971 000
530 000
750 000
880 000
G= 0.12
310
440
520
290
420
490
430
620
720
580
820
960
760
1090
1270
730
1040
1220
1110
1580
1850
1070
1500
1800
1540
2190
2560
1490
2120
2480
2050
2920
3420
2000
2800
3300
2680
3820
4470
2500
3500
4100
3430
4890
5720
3200
4600
5300
Notes:
Torques indicated in drawings have precedence over those specified in the factory standards
and must at all times be adhered to.
For very important screw connections, we recommend applying the angle tightening method.
Alternatively determine the total friction factor by carrying out a series of tests and refer to VDI
2230 or consult the technical department for the relevant tightening torques.
1.20.2
01/2005
Appendix:
Angle tightening method
With the angle tightening method, the bolt is turned by a defined angle , which is based on the
flexible elongation of the bolt and compression of the screwed plates. Depending on the bolt
size, it is preloaded by a given torque before it is inserted into the parts to be secured, so that
the zero point of the angle measurement can be determined. From this zero angle o = 0, the
bolt can be preloaded - irrespective of the friction factor of the thread and the contact surface by turning it by the retightening angle .
Example 1:
Bolt: M14 10.9, grip length Lk=80mm;
According to table (strength class 10.9):
Pretightening torque MA = 50Nm; retightening angle
45
Example 2:
Bolt: M24 12.9, grip length Lk=100mm;
According to table (strength class 12.9):
Pretightening torque MA = 160Nm; retightening angle
01/2005
57
1.20.3
1.20.4
01/2005
01/2005
1.20.5
1.20.6
01/2005
Service Manual
Tightening torques
of screw-in studs (Ermeto)
Tightening torques
1 of screw-in studs (Ermeto)
1.1
mating material: steel (Grease well before inserting!)

Type with sealing edge
Thread
M or G
Type
Type with EOLASTIC seal

Tightening
torques
in Nm
Type
Light-duty series L
Thread
M or G
Tightening
torques
in Nm
Light-duty series L
GE 06 LM A 3 C
M 10x1
18
GE 06 LM ED A 3 C
M 10x1
18
GE 06 LR A 3 C
G 1/8 A
18
GE 06 LR ED A 3 C
G 1/8 A
18
GE 08 LM A 3 C
M 12x1.5
30
GE 08 LM ED A 3 C
M 12x1.5
25
GE 08 LR A 3 C
G 1/4 A
35
GE 08 LR ED A 3 C
G 1/4 A
35
GE 10 LM A 3 C
M 14x1.5
45
GE 10 LM ED A 3 C
M 14x1.5
45
GE 10 LR A 3 C
G 1/4 A
35
GE 10 LR ED A 3 C
G 1/4 A
35
GE 12 LM A 3 C
M 16x1.5
65
GE 12 LM ED A 3 C
M 16x1.5
55
GE 12 LR A 3 C
G 3/8 A
70
GE 12 LR ED A 3 C
G 3/8 A
70
GE 15 LM A 3 C
M 18x1.5
80
GE 15 LM ED A 3 C
M 18x1.5
70
GE 15 LR A 3 C
G 1/2 A
140
GE 15 LR ED A 3 C
G 1/2 A
90
GE 18 LM A 3 C
M 22x1.5
140
GE 18 LM ED A 3 C
M 22x1.5
125
GE 18 LR A 3 C
G 1/2 A
100
GE 18 LR ED A 3 C
G 1/2 A
90
GE 22 Lm A 3 C
M 22x1.5
140
GE 22 Lm Ed A 3 C
M 26x1.5
180
GE 22 Lr A 3 C
G 3/4
180
GE 22 Lr Ed A 3 C
G 3/4 A
180
GE 28 Lm A 3 C
M 33x2.0
340
GE 28 Lm Ed A 3 C
M 33x2.0
310
GE 28 Lr A 3 C
G1A
330
GE 28 Lr Ed A 3 C
G1A
310
GE 35 Lm A 3 C
M 42x2.0
500
GE 35 Lm Ed A 3 C
M 42x2.0
450
GE 35 Lr A 3 C
G 1 1/4 A
540
GE 35 Lr Ed A 3 C
G 1 1/4 A
450
GE 42 Lm A 3 C
M 48x2.0
630
GE 42 Lm Ed A 3 C
M 48x2.0
540
GE 42 Lr A 3 C
G 1 1/2 A
630
GE 42 Lr Ed A 3 C
G 1 1/2 A
540
Heavy-duty series S
Heavy-duty series S
GE 06 SM A 3 C
M 12x1.5
35
GE 06 SM ED A 3 C
M 12x1.5
35
GE 06 SR A 3 C
G 1/4 A
55
GE 06 SR ED A 3 C
G 1/4 A
55
GE 08 SM A 3 C
M 14x1.5
55
GE 08 SM ED A 3 C
M 14x1.5
55
GE 08 SR A 3 C
G 1/4 A
55
GE 08 SR ED A 3 C
G 1/4 A
55
GE 10 SM A 3 C
M 16x1.5
70
GE 10 SM ED A 3 C
M 16x1.5
70
GE 10 SR A 3 C
G 3/8 A
90
GE 10 SR ED A 3 C
G 3/8 A
80
GE 12 SM A 3 C
M 18x1.5
110
GE 12 SM ED A 3 C
M 18x1.5
90
GE 12 SR A 3 C
G 3/8 A
90
GE 12 SR ED A 3 C
G 3/8 A
80
GE 14 SM A 3 C
M 20x1.5
150
GE 14 SM ED A 3 C
M 20x1.5
125
GE 14 SR A 3 C
G 1/2 A
150
GE 14 SR ED A 3 C
G 1/2 A
115
MJF C I F S S
1.21. 1
Tightening torques
Service Manual
of swivelling connections (Ermeto)

Type with sealing edge
Thread
M or G
Type
GE 16 SM A 3 C
M 22x1.5
Type with EOLASTIC seal

Tightening
torques
in Nm
Type
170
GE 16 SM ED A 3 C
Thread
M or G
Tightening
torques
in Nm
M 22x1.5
135
GE 16 SR A 3 C
G 1/2 A
130
GE 16 SR ED A 3 C
G 1/2 A
115
GE 20 SM A 3 C
M 27x2.0
270
GE 20 SM ED A 3 C
M 27x2.0
180
GE 20 SR A 3 C
G 3/4 A
270
GE 20 SR ED A 3 C
G 3/4 A
180
GE 25 SM A 3 C
M 33x2.0
410
GE 25 SM ED A 3 C
M 33x2.0
310
GE 25 SR A 3 C
G1A
340
GE 25 SR ED A 3 C
G1A
310
GE 30 SM A 3 C
M 42x2.0
540
GE 30 SM ED A 3 C
M 42x2.0
450
GE 30 SR A 3 C
G 1 1/4 A
540
GE 30 SR ED A 3 C
G 1 1/4 A
450
GE 38 SM A 3 C
M 48x2.0
700
GE 38 SM ED A 3 C
M 48x2.0
540
GE 38 SR A 3 C
G 1 1/2 A
700
GE 28 SR ED A 3 C
M 1 1/2 A
540
Tab. 2
Tightening torques of screw-in studs
GE = Straight screw-in connection (with metric thread M or pipe thread G)
2 of swivelling connections (Ermeto)

2.1

Tightening torques
Type
Thread
Tightening torques
Type
Nm
Light-duty series
Thread
Nm
Light-duty series
WH / TH 06 LR KDS A 3 C
G 1/8 A
18
WH / TH 06 LM KDS A 3 C
M 10 X 1
18
G 1/4 A
45
M 12 X 1.5
45
G 3/8 A
45
M 14 X 1.5
55
G 1/2 A
70
M 16 X 1.5
80
G 3/4 A
120
M 18 X 1.5
100
G1A
120
M 22 X 1.5
140
G 1 1/4 A
230
M 27 X 2.0
320
G 1 1/4 A
320
M 33 X 2.0
360
G 1 1/4 A
540
M 42 X 2.0
540
G 1 1/2 A
700
M 48 X 2.0
700
Heavy-duty series
Heavy-duty series
WH / TH 06 SR KDS A 3 C
G 1/4 A
45
WH / TH 06 SM KDS A 3 C
M 12 X 1.5
45
G 1/4 A
45
M 14 X 1.5
55
G 3/8 A
70
M 16 X 1.5
80
G 3/8 A
70
M 18 X 1.5
100
G 1/2 A
120
M 20 X 1.5
125
G 3/4 A
230
M 22 X 1.5
135
1.21. 2
MJF C I F S S
Service Manual
Tightening torques
Tightening torques
Type
Thread
Tightening torques
Type
Nm
Thread
Nm
G1A
320
M 27 X 2.0
320
G 1 1/4 A
540
M 33 X 2.0
360
G 1/4 A
700
M 42 X 2.0
540
M 48 X 2.0
700
Tab. 2
Tightening torques of swivelling connections
3 of screw-in studs (Ermeto)

3.1
Type VSTI
Screw-in
thread M
Tightening
torques
Nm
Type VSTI
Screw-in
thread G
Tightening
torques
Nm
VSTI 10X1 ED A3C
M 10 X 1
12
VSTI 1/8 ED A3C
G 1/8 A
13
VSTI 12X1.5 ED A3C
M 12 X 1.5
25
VSTI 1/4 ED A3C
G 1/4 A
30
VSTI 14X1.5 ED A3C
M 14 X 1.5
35
VSTI 3/8 ED A3C
G 3/8 A
60
VSTI 16X1.5 ED A3C
M 16 X 1.5
55
VSTI 1/2 ED A3C
G 1/2 A
80
VSTI 18X1.5 ED A3C
M 18 X 1.5
65
VSTI 3/4 ED A3C
G 3/4 A
140
VSTI 20X1.5 ED A3C
M 20 X 1.5
80
VSTI 1 ED A3C
G1A
200
VSTI 22X1.5 ED A3C
M 22 X 1.5
90
VSTI 1 1/4 ED A3C
G 1 1/4 A
450
VSTI 1 1/2 ED A3C
G 1 1/2 A
450
VSTI 26X1.5 ED A3C
M 26 X 1.5
120
VSTI 27X2 ED A3C
M 27 X 2.0
135
VSTI 33X2 ED A3C
M 33 X 2.0
225
VSTI 42X2 ED A3C
M 42 X 2.0
360
VSTI 48X2 ED A3C
M 48 X 2.0
360
Tab. 2
Tightening torques of screw-in studs
VSTI = Hexagon socket plug
MJF C I F S S
1.21. 3
Tightening torques
Service Manual
1.21. 4
MJF C I F S S
Bezeichnung
Mj f c i f s s !
Assembly instruction
for pistons and piston nuts
(hydraulic cylinders)
Blatt/Page/Feuille:
bestehend aus
consisting of
compos
Blatt
Pages
Feuille
WN 4121 B
Contents
1.
Scope of application
2.
Description
3.
Referenced documents (torque table)
1.
This factory standard applies exclusively to the assembly of hydraulic cylinders with a
thread diameter of M42 and greater. For the valid factory standard number, refer to the
drawing. The standard may not be adopted or transferred to apparently similar
geometries.
The torques have been determined empirically and are subject to changes. The revision
and release dates indicate the latest version of the factory standard.
For threads with diameters smaller than M42, the applicable tightening torques are
indicated in the drawings.
The values in the drawings are always binding.
09 / 2005
1.22.1
2.
Description
Preparation:
Clean the contact surfaces (threads contact faces between piston rod, piston and piston
nut) and apply a thin layer of Gleitmo high-performance lubricating grease (ID no. 8300
004, 40 g tube) on both sides.
Definitions:
Pretightening torque
The piston is secured with a torque wrench applied to the square/hexagon head of the
assembly wrench. The position of the torque wrench must be carefully noted (see figure
1).
Figure 1
A
B
C
Piston
Assembly wrench
Torque wrench
When applying the pretightening torque, the torque wrench must point in the same
direction as the assembly wrench.
Proceed in the same way to tighten the piston nut, using a suitable assembly wrench.
1.22.2
09 / 2005
Turning distance:
Radian measure [mm] travelled as a result of the tightening of the piston, or piston nut
along the outer thread diameter, after application of the pretightening torque (see figures
2 and 3).
Turning angle:
Angle \^ travelled by the piston or piston nut respectively, after application of the
pretightening torque (see figures 2 and 3).
Figure 2
A
Marks on the piston and piston rod thread after application of the
pretightening torque
B
Mark on the piston rod thread
C
Turning angle
D
Turning distance
E
Mark on the piston after tightening
Figure 3
Marks on the piston nut and piston rod thread after application of the
A
pretightening torque
B
Mark on the piston rod thread
C
Turning angle
D
Turning distance
E
Mark on the piston nut after tightening
09 / 2005
1.22.3
1.22.4
09 / 2005
3.
List of tightening torques for factory standard 4121

(Assembly instructions for piston and piston nur)
Edition: 11.04.2005
The date indicates the latest version of this table.

This document is not covered by the revision service.
FS
Preload
4121...
071
072
073
075
079
080
091
092
093
095
096
097
098
099
111
112
113
114
115
121
123
126
127
151
152
153
171
173
174
175
176
177
179
180
181
183
201
202
203
204
205
206
207
208
209
231
232
Torque
Mv [Nm]
100
100
100
100
100
100
100
100
100
100
100
100
100
100
100
100
100
100
100
150
150
150
150
150
150
150
150
150
150
150
150
150
150
150
150
200
200
200
200
200
200
200
200
200
200
200
200
09 / 2005
Piston
Piston nut
Turn.distance
Turning angle
Turns distance
Turning angle
[mm]
11 +1
21 +1
18 +1
19 +1
11 +1
18 +1
13 +1
25 +1
24 +1
13 +1
10 +1
17 +1
17 +1
24 +1
16 +1
17 +1
18 +1
19 +1
18 +1
15 +1
17 +1
14 +1
22 +1
15 +1
20 +1
20 +1
12 +2
19 +2
25 +2
25 +2
19 +2
19 +2
11 +2
20 +2
20 +2
17 +2
26 +2
27 +2
27 +2
13 +2
25 +2
23 +2
15 +2
30 +2
8 +2
17 +2
~ []
30
57
49
52
30
49
30
57
55
30
23
39
39
55
33
35
37
39
37
29
32
27
42
27
35
35
20
32
42
42
32
32
19
34
34
26
39
41
41
20
38
35
22
45
11
23
[mm]
21 +1
21 +1
19 +1
21 +1
21 +1
19 +1
19 +1
19 +1
19 +1
9 +1
19 +1
19 +1
18 +1
18 +1
18 +1
19 +1
19 +1
19 +1
19 +1
18 +1
18 +1
18 +1
18 +1
18 +1
18 +1
18 +1
18 +1
40 +2
16 +1
16 +1
16 +1
16 +1
25 +1
16 +1
16 +1
~ []
57
57
52
57
57
44
44
44
44
21
44
44
37
37
37
36
36
34
34
30
30
30
30
30
30
30
30
67
24
24
24
24
38
22
22
Thread
M
[mm]
42x1,5
42x1,5
42x1,5
42x1,5
42x1,5
42x1,5
50x2
50x2
50x2
50x2
50x2/SW65
50x2
50x2
50x2
56x2
56x2
56x2
56x2
56x2
60x2
60x2
60x2
60x2
65x2
65x2
65x2
68x2
68x2
68x2
68x2
68x2
68x2
68x2
68x2
68x2
68x2
76x2
76x2
76x2
76x2
76x2
76x2
76x2
76x2
76x2
85x3
85x3
1.22.5
FS
Preload
4121...
234
261
281
282
301
302
303
304
305
306
307
331
332
333
334
335
501
531
Torque
Mv [Nm]
200
250
250
250
300
300
300
300
300
300
300
400
400
400
400
400
200
500
1.22.6
Piston
Piston nut
Turn.distance
Turning angle
Turns distance
Turning angle
[mm]
22 +2
20 +2
20 +2
25 +2
21 +3
18 +3
20 +3
23 +3
9 +3
24 +3
27 +3
23 +3
11 +3
27 +3
20 +3
30 +3
21 +2
34 +3
~ []
30
25
23
29
22
19
21
24
9
25
28
22
11
26
19
29
30
28
[mm]
10 +1
13 +1
20 +2
20 +2
20 +2
20 +2
20 +2
20 +2
-
~ []
12
15
21
21
21
21
19
19
-
Thread
M
[mm]
85x3
95x3
100x3
100x3
110x3
110x3
110x3
110x3
110x3
110x3
110x3
120x3
120x3
120x3
120x3
120x3
80x2
140x3
09 / 2005
Bezeichnung
Mj f c i f s s !
Assembly instruction
for piston rod bearings with external threads
(hydraulic cylinders)
Blatt/Page/Feuille:
bestehend aus
consisting of
compos
Blatt
Pages
Feuille
WN 4122 B
Contents
1.
2.
Description
3.
Referenced documents (torque table)
1.
This factory standard applies exclusively to the assembly of hydraulic cylinders. For the
valid factory standard number, refer to the drawing. The standard may not be adopted or
transferred to apparently similar geometries.
The torques have been determined empirically and are subject to changes. The revision
and release dates indicate the latest version of the factory standard.
09 / 2005
1.24.1
2.
Description
Preparation:
Clean the threads and apply a thin layer of Gleitmo high-performance lubricating grease
(ID no. 8300 004, 40 g tube) on both sides.
Definitions:
Pretightening torque:
The piston rod bearing is secured with a torque wrench applied to the square of the
assembly wrench. The position of the torque wrench must be carefully noted (see figure 1).
Figure 1
A
B
C
Bearing head
Assembly wrench
Torque wrench
When applying the pretightening torque, the torque wrench must point in the same
direction as the assembly wrench.
1.24.2
09 / 2005
Turning distance:
Radian measure [mm] between the bearing head outer diameter and the cylinder tube,
travelled after application of the pretightening torque (see figure 2).
Turning angle:
Angle \^ travelled by the bearing head after application of the pretightening torque (see
figure 2).
Figure 2
A
B
C
D
E
F
G
Marks on the cylinder tube and the auter diameter of the bearing head after application
of the pretightening torque
Mark on the cylinder tube
Turning angle
Turning distance
Mark on the bearing head after tightening
Cylinder Tube
Bearing head
After the bearing head and the cylinder tube have been tightened, apply a notch mark at the
rod side oil connection level, using a flat chisel.
09 / 2005
1.24.3
3.
List of tightening torques for factory standard 4122
(Assembly instructions for piston and piston nur)
The date indicates the latest version of this table.

This document is not covered by the revision service.
.
1.24.4
NU
Preload
4122...
001
011
016
017
026
027
031
036
039
041
046
047
051
052
151
Torque
Mv [Nm]
Edition: 24.01.2005
Piston rod bearing
Turning
distance
Turning angle
50
100
100
100
100
100
100
7 +1
10 +1
10 +1
9 +1
10 +1
8 +1
8 +1
10
12
12
10
11
8
9
400
14 +1
[mm]
~ []
09 / 2005
Service Manual

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

1 General instructions regarding the change of fuel, hydraulic oils,
lubricants, etc.
Note!
The fill volumes specified in the fuel and lubricant table in the operator manual, and in the
documentation of the assemblies, as well as in the lubrication schedule in the operator's cab are
only approximate values.
After each oil change or refilling, check the fill level in the respective tank or unit.
Note!
Compliance with the instructions regarding lubrication, fill level checks and oil changes improve the
reliability and prolong the service life of the machine. It is very important that the prescribed intervals
for oil change are adhered to and that only products of the prescribed quality and grade are used.
Note!
Cleanliness during the oil change is of crucial importance.
Always clean all fill screws, lids and drain plugs and the area around fill openings.
When draining oil, ensure that the oil is at operating temperature.
Carefully collect the old oil and dispose of it in an environmentally friendly manner. This also
applies to the oil filter cartridges.
Danger!
When checking and/or changing lubricants and fuels:
If not instructed otherwise, ensure that the machine is standing on level and firm ground and that
the engine is shut down.
When working inside the engine compartment, always secure the cover and doors against
inadvertent closing.
Before refuelling the machine, switch off the engine. Do not smoke or use naked flames.
MJF C I F S S
1.50. 1
Service Manual
1.1
1.50. 2
Lubricant table
Description
Medium
Symbol
Diesel engine
Engine oil
Refer to the instructions of the engine

manufacturer
(see Deutz manual)
Hydraulic tank
Engine oil
API-CD, APICD+SF,
CCMC-D4,
CCMC-D5,
ACEA-E1,
ACEA-E3
SAE 10W
SAE 10W-30
SAE 10W-40
SAE 15W-40
SAE 20W-20
SAE 30W
Slewing gear mechanism

(as stop brake)
Gear oil
API - GL -5
MIL-L 2105 B,
C or D
SAE 80W90
or
SAE 90

(as positioning slewing
brake)
Gear oil
API - GL -5
MIL-L 2105 B
SAE 90 LS
Steering axle
Gear oil
API - GL -5
MIL-L 2105 B
ZF TE-ML 05
SAE 90 LS
Rigid axle
with multi-disc brake
Gear oil
API - GL -5
MIL-L 2105 B
ZF TE-ML 05
SAE 90 LS
Rigid axle
with drum brake
Gear oil
API - GL -5
MIL-L 2105 B
ZF TE-ML 05
SAE 90 LS
Wheel hubs in steering and

rigid axles with multi-disc
and drum brakes
Gear oil
API - GL -5
MIL-L 2105 B
ZF TE-ML 05
SAE 90 LS
Transmission
Gear oil
ZF TE-ML 07
SAE 10 W 30
SAE 10 W 20
Travel gear
Gear oil
API - GL -5
MIL-L 2105 B
ZF TE-ML 05
SAE 80W90
or
SAE 90
MJF C I F S S
Classification
Viscosity
Service Manual

Description
Medium
Tracks and gearing of the

slewing ring, bearing of the
equipment
Grease
Hinges, joints, locks
Engine oil
Sealing rubber on doors

and covering sections
Silicone
spray or
talcum
powder
Tab. 1
*BI
1.1.1
Symbol
Classification
Viscosity
High-pressure
grease
KP2k or EP2
Consiste
ncy 2
NLGI
grade
with
lithium
complex
Tab. 8
MPG-A
Lubricant table
=
Lubricant for building machinery and vehicles recommended by the Federation of the German
Construction Industry (Hauptverband der Deutschen Bauindustrie e. V.), see brochure published by
Bauverlag GmbH, Wiesbaden and Berlin regarding the use of lubricant and fuel tables.
Fuel and consumables

Description
Medium
Fuel tank
Conventional diesel fuel with <= 0.5 % sulphur content
Coolant
Anticorrosion and antifreeze agent
Windscreen washer
system
Conventional windscreen cleaning agent or denatured

alcohol
Coolant of airconditioning system
R 134 a
Refrigeration oil in SD
7H15 a/c compressor
PLANETELF PAG SP 20
ID no. 8504414 (0.25 litre) or. 7620633 (1.0 litre)
Tab. 2
Symbol
Fuel and consumables
MJF C I F S S
1.50. 3
Service Manual
Specifications for fuels, lubricants and consumables
2 Specifications for fuels, lubricants and consumables

2.1
Lubricating oil for the diesel engine

Refer to the instructions of the engine manufacturer (see Deutz manual):
Classification
Specification
API classification (American Petrol

Institute)
CG-4, CF-4, CH-4
ACEA (CCMC) classification

(Association des Constructeurs
Europens de lAutomobile)
E2-96 (D4), E3-96 (D5), E4-98
Tab. 3
2.1.1
Lubricating oil for the diesel engine
Oil change intervals for turbocharged engines

Oil change interval
depending on oil quality:
Operating conditions
Sulphur content
of fuel
CH-4
CG-4
CF-4
E2-96 (D4)
E3-96 (D5)
E4-98
E5-99
Temperature normally not

dropping below -10C
max. 0.5 %
higher than 0.5 %
250 h
125 h
500 h
250 h
below -10 C
max. 0.5 %
higher than 0.5 %
125 h
-
250 h
125 h
Tab. 4
Oil change intervals
The oil change intervals of the diesel engine are based on the following criteria:
First oil and filter change after 500 operating hours, if the oil of the first filling was an oil of E3-96
grade
Subsequent filter changes after 500 operating hours
Subsequent oil changes depending on the climate, sulphur content of the fuel and oil grade, Tab.
4.
If the above number of operating hours is not reached within 12 months, change the engine oil
and the oil filter at least once every year.
2.2
Fuel
Diesel fuels should meet the minimum requirements of the fuel specifications named below.
The sulphur content should not exceed 0.5 mass %. A higher sulphur content affects the oil change
intervals and the service life of the engine.
2.2.1
Lubricity
By reducing the sulphur content in diesel, the issue of lubricity has come to the fore. It has been
shown that diesel fuels with the sulphur levels of maximum 0.05 %, which corresponds to the limit in
the European Union, can lead to wear in the injection system (especially in distributor fuel injection
pumps).
1.50. 4
MJF C I F S S
Service Manual

Branded fuels in Germany and elsewhere therefore contain lubricating additives. The lubricity of the
fuel must be < 400 m in a HFFR test (60).
The additives should be added by the supplier, who is responsible for the quality of the fuel. We
advise machine operators not to add any secondary lubricity additives to the fuel.
2.2.2
Improvement of fluidity by adding petrol

At outdoor temperatures below approx. 0 C, the fluidity of summer diesel might not be sufficient, due
to the separation of paraffin.
This also applies to winter diesel at temperatures below approx. -15 C. There is however diesel fuel
on the market, containing additives that make it suitable for use at temperatures to -20 C.
In order to avoid malfunction at low temperatures, diesel must be mixed with normal petrol or
petroleum.
This approach must be considered an emergency measure and the petrol content may never exceed
30 % (volume).
Do not use premium petrol for this mixture. Please note that the engine output might be reduced due
to the addition of petrol. The addition of petrol should therefore be based on the actual outdoor
temperature and kept as low as possible.
Danger!
For safety reasons, the diesel-petrol mix must be produced in the fuel tank.
Note!
When filling tank, first fill in the lighter additional fuel (petrol) and than add the diesel. Run the motor
until the entire fuel system is filled with the fuel mix (see Tab. 6, page 6).
Approved fuel specifications

DIN EN 590
ASTM D 975 (89 a) 1D and 2D
DIN EN 590 with max. 5 volume % FAME* according to draft standard prEN 14214 (formerly: DIN
51606)
MJF C I F S S
1.50. 5
Service Manual
Diesel fuel petrol mixing ratio

Outdoor temperature
C
Summer diesel fuel %
Addition of
petrol %
0 to -10
70
30
-10 to -15
50
50*
-15 to -20
-20 to -25
Tab. 5
Summer diesel fuel petrol mixing ratio

Winter diesel fuel %
Addition of petrol %
Grade -15
C
Grade -20
C
Grade -15
C
Grade -20
C
0 to -10
100
100
-10 to -15
100
100
-15 to -20
70
100
30
-20 to -25
50
70
50*
30
Outdoor
temperature C
Tab. 6
Winter diesel fuel petrol mixing ratio
* If an additive content of 50 % is required, use only petroleum (not standard petrol).
2.2.3
Diesel fuel additives (fluidity improvers)

Fluidity improvers are widely available and help improve the fluidity of diesel at low temperatures.
When using such additives, always adhere to the dosing and handling instructions of the
manufacturers.
2.3
2.3.1
Hydraulic oil
Mineral oil
Use only motor oils that conform to the specifications and requirements below:
Single grade engine
oils:
API - CD / CCMC - D4 / ACEA - E1

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

Mercedes-Benz specifications, sheet no. 227.5 and
228.3
Tab. 7
Engine oils to be used as hydraulic oils
Select the engine oil for use as hydraulic oil according to the following diagram.
1.50. 6
MJF C I F S S
Service Manual

Fig. 1
Engine oil for use as hydraulic oil
Warm-up instruction
At temperatures to 10 C below the indicted limit (black bar), the oil must be warmed up as follows:
Start diesel engine and run it at approx. 1 / 2 the rated speed. Operate the hydraulic cylinders and
motors, but do not move the cylinders to their stops. Warm-up time: approx. 10 minutes
At lower temperatures: Before starting the engine, warm up the oil tank.
2.3.2
Environmentally friendly hydraulic oils

Note!
Do not mix different brands of environmentally friendly hydraulic oils or such oils with mineral oils
(see customer service information)!
LIEBHERR will fill the system before delivery, based on a list of approved oils. Before using
environmentally friendly oils, you must consult LIEBHERR.
The list of products recommended by LIEBHERR contains only ester-based synthetic oils with a
viscosity according to ISO VG 46.
Do not use vegetable oils, as they do not possess the necessary thermal stability.
2.3.3
Monitoring of hydraulic oil

Note!
Environmentally friendly hydraulic oils must be regularly tested by means of an oil analysis. For
mineral oils, we recommend carrying out oil analyses at regular intervals. LIEBHERR
recommends contracting WEAR-CHECK with these analyses, and to change the oil when indicated
by the test results (see also customer service and product information).
Machines in normal use: at least every 500 operating hours
Machines used for dust intensive applications: at least every 250 operating hours
2.3.4
Monitoring of hydraulic oil in normal use
Fig. 2
Oil sampling from machines in normal use
MJF C I F S S
1.50. 7
Service Manual

h
Operating hours
Second oil sample
First oil sample
Subsequent oil samples: every 500

operating hours
Oil change based on analysis and lab report.

Interval for the change of the hydraulic oil return filter (20/5 m): first change after 500 operating
hours, then every 1000 operating hours.
2.3.5
Oil sampling from machines used for dust intensive applications:
Fig. 3
Oil sampling from machines used for dust intensive applications
Operating hours
Second oil sample
First oil sample
Subsequent oil samples: every

250 operating hours
Oil change based on analysis and lab report.

Interval for the change of the hydraulic oil return filter (10 m): first change after 500 operating hours,
then every 500 operating hours.
2.3.6
Instructions for the reduction of the contamination of the hydraulic oil in

machine used for dust intensive applications
If the machine is normally operated with a hydraulic hammer or under similar conditions (considerable
dust generation), the hydraulic oil might become more contaminated than under normal working
conditions.
In order to prevent premature wear of the hydraulic components, shorten the intervals between the
oil changes (or oil samples respectively) and observe the following instructions:
Every 500 operating hours, replace the filter cartridge(s) in the return filter.
Use 10-m filter cartridges instead of the standard 20 / 5-m cartridges.
Replace the breather filter on the hydraulic tank with a 2-m fine filter (mesh size of series filters:
7 m).
Replace the 2-m breather at each change of the hydraulic oil (i.e. every 500 operating hours).
Note!
Machines that are delivered with a fully installed AHS 11 or AHS12 accessory kit, and machines
with retrofitted kits are already equipped with 10-m filter cartridges 2-m breather filters.
All machines produced after approx. September 2005 have been equipped with 2-m breather
filters.
2.4
Gear oil
Gear oils must conform to the following specifications:
API-GL-5 and MIL-L-2105 B, C or D respectively for viscosity grade SAE 90
Engine oils used in gearboxes must conform to the following specifications:
API-CG-4, CF-4, CF for viscosity grade SAE 20
1.50. 8
MJF C I F S S
Service Manual

For viscosity grades SAE 80 and SAE 90 according to MIL-L-2105 D, you may use an oil of viscosity
grade SAE 80W90.
2.4.1
Grease and other process chemicals

Process chemicals
Description / manufacturer
Grease for slewing ring / general

lube points
The grease must conform to specification KP2k,

consistency grade 2, NLGI grade according to
DIN 51818 and DIN 51825 or EP 2 according to
NF-T-60 132.
The grease must consist of a lithium complex
with a VKA value of minimum 2300 N according
to DIN 51350 or ASTM D 2596 respectively.
Contact spray for slip rings
Cramolin
ID no. 7024145
Lubricant for pistons, piston nuts,

also used for the mounting of piston
rod bearings and cushioning
sleeves to hydraulic cylinders
Gleitmo 800
ID no. 8300004 (40g tube)
Anti-friction varnish and lubricant for

LIKUFIX coupling system
Gleitmo 900
ID no. 8610227 (400 ml spray can)
Special corrosion inhibitor for

mounting recesses for sealing
elements at hydraulic cylinders
Castrol-Tarp
ID no. 8300005 (40g tube)
Other grease:
Lubricant used for the mounting of
pumps to prevent fretting corrosion
on spline meshes
LIEBHERR CTK special lubricant

ID no. 861331301 (400g cartridge)
Coolant for air-conditioning system
R 134 A
Drain and fill the system according to the
instructions in this manual (air-conditioning
assembly).
Refrigeration oil for a/c compressor
The SD5H14 / SD7H15 a/c compressors are

factory-filled with Planetelf PAG SP 20.
ID no. 8504414 (0.25 litre can)
ID no. 7620633 (1.0 litre can)
The compressor supplier does not permit the use
of any other refrigeration oil.
Tab. 8
2.5
Grease and other process chemicals
Coolant
In order to improve the quality of the cooling water, LIEBHERR diesel engines are equipped with
water filter installations for Deutz engines.
This ensures that the coolant is also filtered in the bypass flow where dirt and rust particles that might
lead to leakage in the cooling pump are removed.
MJF C I F S S
1.50. 9
Service Manual
Outdoor temperature to
Water content in %
Content of corrosion
inhibitors/antifreeze
agents in %
-37 C / -34 F
50
50
-50 C / -58 F
40
60
Tab. 9
Mixing ratio water : corrosion inhibitor / antifreeze agent
The coolant must contain at least 50 volume % of corrosion inhibitor and antifreeze agent during all
seasons. This protected the coolant against freezing to a temperature of -37 C and ensures
adequate protection against corrosion. In the event of loss of coolant, ensure that the additive
concentration does not drop below 50 volume %.
Note!
Do not exceed a corrosion inhibitor and antifreeze agent concentration of 60 %! Higher
concentrations tend to result in poor cooling and antifreeze protection.
As part of the regular maintenance, check the mixing ratio.
Note!
Change the coolant every 2 years.
Before refilling the cooling system with new coolant, ensure that it is clean and rinse it, if required.
2.5.1
Requirements regarding the fresh water quality

To prepare the coolant, use clean water with as little limestone content as possible. In most cases,
the local drinking water meets these requirements. Do not use sea water, brackish water, brine or
industrial wastewater.
Requirements regarding the fresh water quality for coolants with corrosion inhibitors
and antifreeze agents
Substance
Volume
Total of alkaline earths (water

hardness)
0.6 to 3.6 mmol / l (3 to 20 d)
pH at 20 C
6.5 to 8.5
Chloride ion content
max. 80 mg / l
Total chloride and sulphate
max. 100 mg / l
Tab. 10
1.50. 10
Max. concentration of water contaminations for use with corrosion inhibitors and
antifreeze agents
MJF C I F S S
Service Manual

Fig. 4
Mixing ratio water : corrosion inhibitor / antifreeze agent
A % of corrosion inhibitor and antifreeze agent

B Antifreeze agent to indicated temperature, according to value A
2.5.2
Approved corrosion inhibitors and antifreeze agents

Concentrates
Brand
Producer
Country
Agip Antifreeze Plus
Agip Petrol S.p.A., Rome
Agip Langzeit-Frostschutz
Autol-Werke GmbH, Wrzburg
Antigel DB 486
Sotragal SA, St. Priest
Aral Khlerfrostschutz A
Aral AG, Bochum
Avia Frostschutz APN (G48-00)
Deutsche Avia-Minerall GmbH, Munich
BP Antifrost X 2270 A
Deutsche BP AG, Hamburg
BP Napgel C 2270 / 1
BP Chemicals LTD., London
GB
Caltex Engine Coolant DB
Caltex UK Ltd, London
GB
Caltex Extended Life Coolant
GB
Castrol Anti-Freeze O
Deutsche Castrol Vertriebs GmbH, Hamburg
Century F.L. Anti-Freeze
Century Oils, Hanley, Stoke-on-Tent
GB
Chevron DEX-Cool Extended Life Anti-Freeze /

Coolant
Chevron Texaco, San Ramon, CA
USA
DEUTZ Khlschutzmittel 0101 1490
Deutz Service International GmbH, Cologne
Esso Khlerfrostschutz
Esso AG, Hamburg
Fircofin
Fuchs Minerallwerke GmbH, Mannheim
Frostschutz Motorex (G48-00)
Bucher & Cie, Langenthal
CH
Frostschutz 500
Mobil Oil AG, Hamburg
Glacelf Auto Supra
Total Nederland N.V., The Hague
NL
Glycoshell AF 405
Shell Deutschland GmbH, Hamburg
Glycoshell N
Shell Deutschland GmbH, Hamburg
MJF C I F S S
1.50. 11
Service Manual

Brand
Producer
Country
Glysantin (G48-00)
BASF AG, Ludwigshafen
Havoline XLC
Arteco, Ghent
Chevron DEX-Cool Extended Life Anti-Freeze /

Coolant
USA
Igol Antigel Type DB
Igol France, Paris
Labo FP 100
Labo Industrie, Nanteree
Motul Anti-Freeze
Motul SA, Aubervilles
OMV Khlerfrostschutzmittel
OMV AG, Schwechat
Organifreeze
Total Deutschland GmbH, Dsseldorf
OZO Frostschutz S
Total Antigel S-MB 486
Total Frostfrei
Castrol Anti-Freeze O
Wintershall Khlerschutz
Wintershall Minerall GmbH, Dsseldorf
Tab. 11
Approved corrosion inhibitors and antifreeze agents
50:50 premixed products (water: corrosion inhibitor / antifreeze agent)

Product
Producer
Country
Liebherr Anti-Freeze APN Mix ID no. 8611045
Liebherr
Caltex Extended Life Coolant Pre-Mixed 50/50

(ready-to-use-version)
GB
Chevron DEX-Cool Extended Life Prediluted

50/50 Anti-Freeze / Coolant
USA
Havoline XLC, 50/50
Arteco, Ghent
Chevron DEX-Cool Extended Life Prediluted 50/

50 Anti-Freeze / Coolant
USA
Organicool 50/50
Tab. 12
1.50. 12
Approved corrosion inhibitors / antifreeze agents / 50:50 premix
MJF C I F S S
Off-Road Driveline Technology

and Axle Systems
Axles for off-road vehicles
List of lubricants TE-ML 05

Lubricant classes for service fills (1)
Product groups
without
with
wet multi-disc brakes and / or

multi-disk limited-slip differentials
1. Axles (exception see section 2-5)
Differentialsx
Wheel hubsx
Stub shafts
2. Axles with hypoid drive
(AP 420R; AV230; MT-C 2025; MT-C2035;
MT-C2075)
ZF-Powerfluidx
05A / 05B / 05C / 05D /
05E / 05F / 05G
ZF-Powerfluidx
05C / 05D / 05E / 05F / 05G
05A / 05B / 05C / 05D
05C / 05D
---
ZF-Powerfluid
05E / 05F / 05G
ZF-Powerfluid
05A / 05B / 05C / 05D
05E / 05F / 05G
ZF-Powerfluid
05E / 05F / 05G
05A / 05B / 05C / 05D
---
3. MT-D 3105 (only oil circuit brake)

MT-L 3000 (with sintered brake linings)
4. MS-T 3025, MS-T 3035, MS-T 3045,
MS-T 3055, MS-T 3060x
MT-T 3025, MT-T 3035, MT-T 3045
MT 2075 (old: AP 2075),
MT 2085 (old: AP 2085)
5. ZF-half-shafts (planetary final drives) for
tractor transmissions T-7000
(1) Refer to the following pages for approved commercial products.

A lithium saponified multipurpose grease of NLGI class 2 which is mixable with mineral oil is to be used at greasing points
(grease code KP2K-30 in acc. with DIN 51825 or ISO-L-XCCHB2 in accordance with ISO 6743-9).
Additives of any kind added later to the oil change the oil in a manner that is unpredictable, and they are therefore not
permitted. No liability of any kind will be accepted by ZF for any damage resulting from the use of such additives.
The list of lubricants TE-ML 05, Edition 01.04.2005 replaces all

previous editions. The current list can be requested from any ZF
after-sales service center or accessed on the Internet under
www.zf.com.
09 / 2005
ZF Passau GmbH
ZF Friedrichshafen AG
D-94030 Passau
D-88038 Friedrichshafen
phone: + 49 7541 77 3505
fax:
+ 49 7541 77 7319
1.55.1
Continued
ZF Friedrichshafen AG / List of lubricants TE-ML 05, edition 01.04.2005
Oil change intervals

Lubricant class
05A, 05B, 05C, 05D, 05E, 05F
Load class
ZF Powerfluid
05G
Oil change interval
1500 h
2000 h
1000 h
1500 h
500 h
1000 h
Load classes
Load class
1
1.55.2
Examples of applications
- Dumper
- Mobile excavator with low driving-mode share (<25%)x
- Wheel loader with hydrostatic drivex
- Other axles without wet brakes
- Mobile excavator with increased driving-mode share (>25%)

- Wheel loader, grader, backhoe, telescopic handlerx
- T 7000 half shafts
- Wheel loader operated under extreme braking conditions

- Mobile excavator, material-handling areasx
- At ambient temperatures > 40C
09 / 2005
Continue
Lubricant class 05A

Gear oilx
Viscosity grades: SAE 75W-90 / 75W-140 / 80W-90 / 80W-140 / 85W-90 / 85W-140 / 90
Manufacturer (05A)
Trade name (05A)
ADDINOL LUBE OIL GMBH, LEUNA/D

AGIP SCHMIERTECHNIK GMBH, WRZBURG/D
ARAL AG, BOCHUM/D
ARAL AG, BOCHUM/D
ARAL AG, BOCHUM/D
ARMORINE S.A., LANESTER CEDEX/F
AVIA MINERALL-AG, MNCHEN/D
BAYWA AG, MNCHEN/D
BAYWA AG, MNCHEN/D
BEIJING TONGYI PETROLEUM CH. CO. LTD., BEIJING/CN
BLASER SWISSLUBE AG, HASLE-REGSAU/CH
BP INTERNATIONAL, PANGBOURNE, READING/GB
BUCHER AG LANGENTHAL, LANGENTHAL/CH
CALPAM MINERALL-GMBH, ASCHAFFENBURG/D
CASTROL INTERNATIONAL, PANGBOURNE READING/GB
CEPSA LUBRICANTS S.A., MADRID/E
CHEVRONTEXACO GLOBAL LUBRICANTS, SAN RAMON/USA
CHEVRONTEXACO, GHENT/B
CHEVRONTEXACO, SYDNEY/AUS
CONDAT LUBRIFIANTS, CHASSE SUR RHONE/F
DE OLIEBRON B.V., ZWIJNDRECHT/NL
ENI S.P.A. REFINING & MARKETING DIVISION, ROME/I
EXXON MOBIL CORPORATION, FAIRFAX, VIRGINIA/USA
FALCON OIL COMPANY LTD., SHARJAH/UAE
FL SELENIA S.P.A., VILLASTELLONE/I
ADDINOL GETRIEBEL GH 80W-90

ADDINOL GETRIEBEL GX 80 W 90 ML
AUTOL HYPOID-GETRIEBEL SAE 80W-90
ARAL GETRIEBEOL EP PLUS 80W-90
ARAL GETRIEBEOL HYP 85W-90
ARAL GETRIEBEL HYP SAE 85W-140
PM 90
AVIA HYPOID 90 EP
AVIA SYNTOGEAR FE 80W-90
BAYWA HYPOID GETRIEBEL 85W-90
BAYWA SUPER 8090 MC
XIECHENG 85W-90 GEAR OIL
HYPOID-GETRIEBEL 80W90
HYPOID-GETRIEBEL 90
BP ENERGEAR DL 80W-90
BP ENERGEAR HT 80W-90
BP ENERGEAR HYPO 80W-90
BP ENERGEAR HYPO 90
ENERGEAR HT 85W140
FRONTOL GETRIEBEL FE SAE 80W-90
FRONTOL HYPOID GETRIEBEL B SAE 85W-140
FRONTOL HYPOID GETRIEBEL B SAE 90
MOTOREX GEAR OIL UNIVERSAL 80W/90
CALPAM MULTI GEAR OIL FE 80W90
CALPAM SUPER GEAR OIL 85W90 GL 5
CASTROL AF-STO 85W140
CASTROL AGRI GEAR GL5 90
CASTROL AGRI GEAR ULTRA
CASTROL DYNADRIVE 80W-90
CASTROL EPX 85W-140
CASTROL EPX 90
CASTROL EPX M 90
CASTROL MULTIDRIVE 80W90
CEPSA TRANSMISIONES EP 90
CEPSA TRANSMISIONES EP MULTIG. 85W-140
CEPSA TRANSMISIONES EP MULTIGRADO 80W-90
ERTOIL EP CAMBIOS Y DIFERENCIALES SAE 90
ERTOIL EP MULT. CAMBIOS Y DIFERENCIALES 80W-90
CHEVRON RPM UNIVERSAL GEAR LUBRICANT SAE 80W-90
GEARTEX EP-B 85W-90
GEARTEX EP-C 85W-140
MULTIGEAR 80W-90
CALTEX HYPOID LD SAE 85W-90
CALTEX HYPOID LD SAE 90
GEAR S 80W90
GEAR S 85W140
TOR SUPER GEAR OIL 80W90
AGIP ROTRA MP 85W-140
AGIP ROTRA TRUCK GEAR 85W-140
ROTRA MP 80W-90
ROTRA TRUCK GEAR 80W-90
ESSO GEAR OIL GX-D 85W-90
ESSO GEAR OIL TDL 80W-90
MOBILUBE HD-A 85W-90
MOBILUBE S 80W-90
FALCON SUPER MP GEAR OIL 85W/140 GL-5
AKCELA GEAR 135H EP (SAE 80W90)
AKROS EP 90 SAE 80W90
09 / 2005
1.55.3
Continued
FUCHS PETROLUB AG, MANNHEIM/D
GENOL GMBH & CO., WIEN/A
GINOUVES GEORGES SA, LA FARLEDE/F
GREAT WALL LUBE OIL CO., BEIJING/CHINA
GRUPA LOTOS SA, GDANSK/PL
GULF OIL INTERNATIONAL, PITTSBURG/USA
HAFA, PARIS/F
HANDEL MIJ NOVIOL B.V., NIJMEGEN/NL
HUILES BERLIET S.A., SAINT PRIEST/F
IGOL FRANCE SA, AMIENS/F
JOHN DEERE, WATERLOO/USA
KOMPRESSOL-OEL VERKAUFS GMBH, KLN/D
KRAFFT S.A., ANDOAIN/E
KUWAIT PETROLEUM R&T B.V., EUROPOORT RT/NL
LIQUI MOLY GMBH, ULM/D
MAROIL S.R.L. CONC. BARDAHL MANU. CO.,ALTOPASCIO/I
MAZIVA ZAGREB D.O.O, ZAGREB/HR
MEGUIN GMBH & CO. KG MINERALOELWERKE, SAARLOUIS/D
MILLERS OILS LIMITED, BRIGHOUSE/GB
MINERALL-RAFFIN. DOLLBERGEN, UETZE-DOLLBERGEN/D
MODRICA OIL REFINERY, MODRICA/BIH
MOL-LUB LTD., ALMASFUZITO/H
MORRIS LUBRICANTS, SHREWSBURY/GB
MOTUL SA, AUBERVILLIERS CEDEX/F
NEW PROCESS AG, TBACH/CH
NOVA STILMOIL SPA, MODENA/I
OEL-BRACK AG, HUNZENSCHWIL/CH
OEST, GEORG MINERALLWERK, FREUDENSTADT/D
OMV AG, SCHWECHAT/A
OMV AG, SCHWECHAT/A
OMV AG, SCHWECHAT/A
ORLY INTERNATIONAL G.I.E., VIEUX-THANN/F
1.55.4

AMBRA HYPOIDE 140 SAE 85W140
ARBOR TRW 140 (SAE 85W140)
TUTELA W140/M-DA SAE 85W140
TITAN GEAR HYP SAE 90
TITAN SUPERGEAR MC 80W-90
GENOL GEAR-SYN 80W-90
GENOL HYPOLUBE 80W-90
YORK 793 SAE 80W90
YORK 793 SAE 85W140
GREATWALL 85W/90 GL-5
LOTOS TITANIS GL-5 SAE 80W/90
GULF GEAR DB 85W 90
HYPOID PL SAE 80W-90
KENDALL NS-MP GEAR LUBE SAE 80W-90
RTO HD 80W-90
RTO LONGEVIA P ECO 80W-140
GEAR M 80W90
HYPOID B SAE85W90
GL-5 GEAR LUBRICANT (80W90)
KOMPRESSOL-HYPOID EW SAE 80W-90
HIDROIL EP SAE 80W-90
Q8 AUTO 12 SAE 80W-90
Q8 AXLE OIL XG SAE 80W-140
Q8 GEAR OIL XG SAE 80W-90
Q8 T 55 SAE 80W-90
Q8 T 55 SAE 85W-140
Q8 T 55 SAE 90
Q8 T 65 SAE 75W-90
Q8 TRANS XGS SAE 75W-90
HYPOID GETRIEBEL GL 5 SAE 80W-90
HYPOID GETRIEBEL GL 5 SAE 90W
HYPOID GETRIEBEL TDL SAE 80W-90
BARDAHL T&D OIL 80W 90
INA HIPENOL GTL DB 90
INA HIPENOL GTL HD 80W-90
INA HIPENOL TDL 80W-90
MEGOL HYPOID-GETRIEBEOEL GL 5 SAE 80W-90
MEGOL HYPOID-GETRIEBEOEL TDL SAE 80W-90
SYNTRAN II/MILLERS TRX 80W/90
PENNASOL HYPOID-GETRIEBEOEL GL 5 SAE 80W90
PENNASOL HYPOID-GETRIEBEOEL GL 5 SAE 90
PENNASOL LONGLIFE GEAR GL 5 SAE 80W90
PENNASOL LONGLIFE GEAR GL 5 SAE 90
HIPOIDNO ULJE B SAE 80W90
HIPOIDNO ULJE B SAE 90
MOL HYKOMOL K 85W-90
MOL HYKOMOL KZ 80W-90
MORRIS EP 80W/90
MORRIS EP 85W/140
MOTUL TRANS MB 85W-90
HD GEAROIL SAE 90
GEARING PLUS 80W90
MIDLAND SUPER M 5 80W-90
MIDLAND SUPER M 5 85W90
OEST MEHRZWECK-GETRIEBEL FE SAE 80W-90
OEST MEHRZWECK-GETRIEBEL SPEZIAL SAE 85W-140
OMV GEAR OIL B SAE 85W-90
OMV GEAR OIL XD-5 SAE 80W-90
OMV UNIGEAR SAE 80W-90
ORLY AURIGA EP SAE 85W140
09 / 2005
Continued

PAKELO MOTOR OIL S.R.L, SAN BONIFACIO (VR)/I
PANOLIN AG, MADETSWIL/CH
PETRO-CANADA LUBRICANTS, MISSISSAUGA/CDN
PETROGAL S.A., LISBOA/P
PETROL OFISI A.S, MASLAK-ISTANBUL-TURKEY/TR
PRISTA OIL AD, ROUSSE/BG
PT PERTAMINA (PERSERO), JAKARTA/RI
RAFINERIA NAFTY JEDLICZE SA, JEDLICZE/PL
RAVENSBERGER SCHMIERSTOFFVERTRIEB GMBH, WERTHER/D
REPSOL LUBRICANTES, MADRID/E
S.A.E.L., MADRID/E
SHARJAH NATIONAL LUBE OIL CO. LTD., SHARJAH/UAE
SHELL ASEOL AG, BERN 5/CH
SHELL BRASIL, BARRA DA TIJUCA - RIO DE JANEIRO/BR
SHELL INTERNATIONAL PETROLEUM COMP LTD, LONDON/GB
SRS SCHMIERSTOFF VERTRIEB GMBH, SALZBERGEN/D
STATOIL LUBRICANTS, STOCKHOLM/S
STRUB + CO AG, REIDEN/CH
SUOMEN PETROOLI OY, HAMINA/FIN
SYNECO SPA, SAN GIULIANO MILANESE/I
TEDEX PRODUCTION SP.Z.O.O., TOMASZOW MAZOWIECKI/PL
TEXACO BRASIL S.A., RIO DE JANEIRO/BR
TOTAL LUBRIFIANTS S.A., PARIS/F
09 / 2005
ORLY LYRA EP
PAKELO GEAR OIL EP GL-5 SAE 80W/90
PAKELO GLOBAL GEAR CBS SAE 75W/90
PAKELO GLOBAL GEAR DLS SAE 85W/140
PAKELO GLOBAL GEAR SA SAE 80W/90
PAKELO GLOBAL MULTIGEAR CBS
PAKELO GLOBAL MULTIGEAR CBS DLS
PAKELO GLOBAL MULTIGEAR SA SAE 80W/140
PANOLIN SUPER DUTY 80W/90
PANOLIN SUPER DUTY 90
PANOLIN TOPGEAR 80W/90
TRAXON 80W-90
TRAXON 85W-140
GALP TRANSOIL HP 80W90
GALP TRANSVEX TDL 85W140
PO UNI. KEBAN EP MAN 80W/90
PRISTA EP 85W140
PRISTA EP 90
RORED HD-A SAE80W-90
RORED HD-A SAE90
HIPOL EXTRA GL-5 80W-90
HIPOL SUPER GL-5 80W-90
RAVENOL HYP. EPX GETR.L 85W-140 GL5
RAVENOL HYPOID EPX GETR.-OEL 80W-90 GL 5
RAVENOL HYPOID EPX GETRIEBE-OEL SAE 90 GL-5
RAVENOL SLG SPEC. LKW GETR.L 80W90
CARTAGO EP SAE 90
CARTAGO EP SAE 80W90
GULF MULTIPURPOSE GEAR LUBRICANT 85W-90
SHARLU MP GEAR LUBE 80W/90 (GL-5)
SHARLU MP GEAR LUBE 85W/140(GL-5)
ASEOL TOPRESS 320
ASEOL TOPRESS 80W-90
SHELL SPIRAX A 90
SHELL SPIRAX AX 80W-90
SHELL SPIRAX AX 90
SHELL SPIRAX MB 90
SHELL SPIRAX MX 80W-90
SHELL SPIRAX ST 80W-140
WINTERSHALL GETRIEBEFLUID SML 80W-90
WINTERSHALL WIOLIN HYPOID-GETRIEBEL 80W-90
WINTERSHALL WIOLIN HYPOID-GETRIEBEL 90
GEARWAY G5 80W-90
GEARWAY G5 85W-140
STRUB MULTIGEAR SGO 80W-90
TEBOIL HYPOID SAE 80W-140
AMPLEX 80W90
AMPLEX 85W140
TEDEX SUPER GEAR OIL (3343ML) SAE 80W90
MULTIGEAR EP SAE 90
ANTAR EPR 90
ANTAR EPR 80W-90
ANTAR UNIVERSAL FE 80W-140
FINA PONTONIC A 80W-140
FINA PONTONIC MDL 80W-90
FINA PONTONIC MP 80W-90
TOTAL EP B 80W-90
TOTAL EP B 85W-90
1.55.5
Continued
UNIL S.A., SAUMUR CEDEX/F
VALVOLINE EUROPE, DORDRECHT/NL
VEEDOL INTERNATIONAL, PANGBOURNE READING/GB
YACCO, ST PIERRE LES ELBEUF/F
ZELLER + GMELIN GMBH & CO., EISLINGEN/D
ZEPPELIN BAUMASCHINEN GMBH, GARCHING/D
ZF FRIEDRICHSHAFEN AG, FRIEDRICHSHAFEN/D
1.55.6

TOTAL EP-B 85W-140
TOTAL TRANSMISSION MDL 80W-90
TOTAL TRANSMISSION RS FE 80W-140
TRANSELF TYPE B 80W-90
TRANSELF TYPE B 90
TRANSELF UNIVERSAL FE 80W-140
UNIL OPAL GEAR ZF 80W90
HIGH PERFORMANCE GEAR OIL GL-5 90
VALVOLINE STX GEAR OIL GL-5 80W-140
VEEDOL MULTIGEAR B SAE 90
VEEDOL MULTIGEAR C SAE 85W-140
BVX C 100 80W-90
DIVINOL GEAR OIL STO SAE 80W-90
DIVINOL HYPOID-GETRIEBEL SAE 85W-140
DIVINOL SYNTHOGEAR SAE 75W-90
ZEPPELIN SPEZIALGETRIEBEL GL-4/GL-5 80W-90
ZF-ECOFLUID X
09 / 2005
Continued
Lubricant class 05B

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

HAFA, PARIS/F
OMV AG, SCHWECHAT/A
S.A.E.L., MADRID/E
AGIP HLX, SAE 75W-90

AGIP ROTRA TRUCK GEAR S, SAE 75W-90
AVIA SYNTOGEAR FE 75W-90 EP
BP ENERGEAR SHX 75W90
ENERGEAR SHX-M SAE 75W-90
MOTOREX UNISYNT TX
CASTROL DYNADRIVE PLUS 75W90
CASTROL SAF-XO SAE 75W-90
SAF-XT
CEPSA TRANSMISIONES EP FE+LD 75W-90
MULTIGEAR S 75W-90
TOR UNIGEAR 75W90 LD
ROTRA LSX 75W-90
MOBILUBE 1 SHC 75W-90
TITAN CYTRAC HSY SAE 75W-90
YORK 896
EUROGEAR SAE 75W-90
RTO LONGEVIA PXD ECO 75W-90
SYNTHEGEAR SAE75W90
MEGOL GETRIEBEOEL TRUCK-SYNTH SAE 75W-90
SYNTRAN FE/MILLERS TRX SYNTH 75W/90
MOTUL GEAR SYNT TDL 75W-90
GEAROIL SYNTH
OEST SYNTH GETRIEBEL SAE 75W-90
OMV UNIGEAR S SAE 75W-90
PAKELO GLOBAL MULTIGEAR TS SAE 75W/90
PANOLIN SUPER DUTY SYNTH 75W/90
GULF SYTHETIC GEAR LUBRICANT 75W-90
SHELL SPIRAX ASX 75W-90
WINTERSHALL GETRIEBEFLUID BOS
VULCOGEAR SYNT SGX 75W-90
ANTAR EPS 75W-90
FINA PONTONIC FDL 75W-90
TOTAL TRANSMISSION SYN FE 75W-90
TRANSELF SYNTHESE FE 75W-90
SYNPOWER GEAR OIL TDL 75W-90
VALVOLINE SYNPOWER STX GL-5 75W-140
VEEDOL SAF 66
BVX 1000
09 / 2005
1.55.7
Continued
Lubricant class 05C

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

ARAL AG, BOCHUM/D
BAYWA AG, MNCHEN/D
ENGEN PETROLEUM LTD., CAPE TOWN/ZA
HAFA, PARIS/F
OMV AG, SCHWECHAT/A
S.A.E.L., MADRID/E
ADDINOL GETRIEBEL GH 80W-90 LS

ADDINOL GETRIEBEL GH 85W-90 LS
ARAL GETRIEBEOL HYP LS 90
AVIA HYPOID 90 LS
AVIA HYPOID 90 LS, 85W-90
BAYWA GETRIEBEL HYPOID LS 90
GETRIEBEL LS 85W90
BP ENERGEAR LIMSLIP 90
FRONTOL GETRIEBEL LS 90
MOTOREX GEAR OIL UNIVERSAL LS 80W/90
CALPAM GEAR OIL LS 90
CASTROL HYPOY LS 90
CASTROL LSX
GEARTEX LS 80W-90
GEARTEX LS 85W-90
CALTEX GEAR OIL ZF SAE 80W-90
CALTEX GEAR OIL ZF SAE 85W-140
CALTEX GEAR OIL ZF SAE 90
GEAR T ( 90 )
GEAR T (80W90)
TOR SUPER GEAR OIL LS 80W90
ENGEN GEARLUBE EP 90 LS - SAE 80W-90
AGIP ROTRA MP/S 85W-90
ESSO GEAR OIL LSA 85W-90
MOBILUBE LS 85W-90
AKCELA AXLEPOWER (80W90)
AMBRA AXF 80W90
AMBRA STF (80W90)
TITAN GEAR LS 90
HYPOID PA SAE 80W-90
RTO EP 90 GL
HYPOID BPA SAE90
GL-5 GEAR LUBRICANT WITH LS ADDITIVE (85W140)
KOMPRESSOL-HYPOID LS SAE 90
Q8 T 45 SAE 90
HYPOID GETRIEBEL GL 5 SAE 85W-90 LS
INA HIPENOL GTL LS 90
MEGOL HYPOID-GETRIEBEOEL GL 5 SAE 85W-90 LS
PENNASOL SPERRDIFFERENTIAL HYPOID GETRIEBEOEL LS90
MOL HYKOMOL LS 85W-90
GEARING WONDER LS SAE 85W90
OEST GETRIEBEL HYPOID LS 90
OMV GEAR OIL LS SAE 85W-90
ORLY TUCANA LS
PAKELO UNIVERSAL GEAR EP/LS SAE 85W/140
PAKELO UNIVERSAL GEAR EP/LS SAE 80W/90
PANOLIN SUPER DUTY LS 90
GALP LS 90
RAVENOL SPERRDIFF.-GETR.-OEL LS 90
CS EP AUTOBLOCANTE SAE 85W140
GULF LS REAR AXLE OIL 80W-90
ASEOL TOPRESS LS 85W-90
SHELL SPIRAX A LS 85W-140
SHELL SPIRAX A LS 90
WINTERSHALL WIOLIN RSH
GEARTEX LS 85W140
ANTAR BLS 90
FINA PONTONIC LS 80W-90
TOTAL TRANSMISSION DA 80W-90
TRANSELF BLS 90
UNIL OPAL GEAR AB-EP SAE 85W90
VEEDOL MULTIGEAR LS SAE 90
BVX LS 200
ZEPPELIN SPEZIALGETRIEBEL GL-5 LS 90
1.55.8
09 / 2005
Continued
Lubricant class 05D

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

AGIP HLZ, SAE 75W-140

BP ENERGEAR SHX S 75W140
BP ENERGEAR SHX-ZR 75W-140
CASTROL SAF-X SAE 75W-140
CASTROL SAF-XJ SAE 75W-140
CASTROL SAF-XLS SAE 75W-90
MOBIL GEARLUBE VS 500
WINTERSHALL GETRIEBEFLUID BMS PLUS
FINA PONTONIC MLX 75W-140
TOTAL TRANSMISSION LS 75W-140
VEEDOL SAF 22
VEEDOL SAF 44
09 / 2005
1.55.9
Continued
Lubricant class 05E

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

CNH, BURR RIDGE/USA
OMV AG, SCHWECHAT/A
KOMATSU WBL 20W40

CASE TRANSAXLE FLUID, SAE 80W-140
MOBILFLUID 2040
TITAN UTTO ZF SAE 20W-40
INA TRANSHIDROL ZF 20W-40
OMV AUSTROMATIC ZF SAE 20W-40
PAKELO UTTO FLUID 4D SAE 20W/40
VULCOTRAC UTTO SAE 20W-40
1.55.10
09 / 2005
Continued
Lubricant class 05F

Universal Tractor Transmission Oil (UTTO)
Manufacturer (05F)
Trade name (05F)
76 LUBRICANTS (CONOCOPHILLIPS COMP.), HOUSTON/USA

ARAL AG, BOCHUM/D
ENGEN PETROLEUM LTD., CAPE TOWN/ZA
KENDALL MOTOR OIL (CONOCOPHILLIPS C.), HOUSTON/USA
OMV AG, SCHWECHAT/A
76 HYDRAULIC/TRACTOR FLUID
ARAL FLUID HGS 10W-30
AVIA HYDROFLUID DLZ
BP OLEX GO 4926
BP TERRAC SUPER TRANSMISSION 10W-30
BP TERRAC SUPER TRANSMISSION CVT 10W-30
BP TRACTRAN TF 10
MOTOREX POLYFARM 304
CASTROL AGRI TRANS PLUS 10W-30
CASTROL AGRI TRANS PLUS CVT 10W-30
CASTROL KOMATSU UTTO 10W-30
TEXTRAN TDH
TEXTRAN TDH PREMIUM
ENGEN AGRIFLUID
ESSO TORQUE FLUID 56
MOBIL AGRIFLUID 424
MOBILFLUID 424
MOBILFLUID 426
AMBRA MULTI G
TITAN UTTO J20C
YORK 676 SAE 10W30
TICMA FLUID MU SAE80W
KENDALL HYKEN 052
Q8 T 2000
Q8 T 2200
MIDLAND TOU
OMV AUSTROMATIC IGB SAE 10W-30
PAKELO UTTO FLUID 4D SAE 10W/30
PANOLIN JD 303
GALP TRALUB 807S
RAVENOL UTTO
AGRO ORION SAE 10W30
ASEOL MULTITRAC 85W
SHELL DONAX TD 10W-30
SHELL DONAX TD 5W-30
WINTERSHALL HYDROFLUID N
09 / 2005
1.55.11
Continued
Lubricant class 05G

Universal construction-machinery oil
Manufacturer (05G)
Trade name (05G)
CATERPILLAR INC., PEORIA/USA

JOHN DEERE, MANNHEIM/D
CATERPILLAR MULTIPURPOSE TRACTOR OIL (MTO) 10W-30

JOHN DEERE HY-GARD
ZF-POWERFLUID
1.55.12
09 / 2005
Off-Road Driveline Technology

and Axle Systems
Hydrostatic and mechanical drives

and electric drive systems
Product groups
List of lubricants TE-ML 07

Lubricant classes for
service fills (1)
Alternative lubricant classes for

service fills (1)
07B / 07D / 07E
---
07C / 07E
07D
07A / 07C / 07E
07D
Powershift transmissions
AVG (2)
HL
Mobile mixer drives
Common oil circuit for transmissionx
and hydrostatic systemx
P3200
PLM 7, PLM 9
Mobile mixer drives
Separate oil circuits for transmissionx
and hydrostatic systemx
P3301, P4300, P5300, P6300,
P7300
PK5300, PK6500, PK7500
Transmissions for lifting equipment
RME, RMT
Swing drives
DR
07A / 07E
---
07D / 07E
Mineral oil-based
Hydraulic oil:
- DIN 51524-02 (HLP) and
- ISO VG 46 / 68
---
(1) Refer to the following pages for approved commercial products and low temperature limits.
(2) For AVGs directly mounted on ZF axles, use gear oils in accordance with TE-ML 05 for the common oil circuit of
the transmission and axle
A lithium saponified multipurpose grease of NLGI class 2 which is mixable with mineral oil is to be used at greasing points
(grease code KP2K-30 in acc. with DIN 51825 or ISO-L-XCCHB2 in accordance with ISO 6743-9).
Additives of any kind added later to the oil change the oil in a manner that is unpredictable, and they are therefore not
permitted. No liability of any kind will be accepted by ZF for any damage resulting from the use of such additives.
Note low-temperature limits on page 2!
The list of lubricants TE-ML 07, Edition 01.04.2005 replaces all

previous editions. The current list can be requested from any ZF
after-sales service center or accessed on the Internet under
www.zf.com.
09 / 2005
ZF Passau GmbH
ZF Friedrichshafen AG
D-94030 Passau
D-88038 Friedrichshafenx
phone: + 49 7541 77 7181
fax:
+ 49 7541 77 7319
1.56.1
Continued
ZF Friedrichshafen AG / List of lubricants TE-ML 07, edition 01.041
Low temperatures limits

Use at outside temperatures above (3)
Lubricant
classes
07A
viscosity grades
- SAE 75W-90, 75W-140

- SAE 80W-85, 80W-90,
80W-140
Powershift transmissions;
Mobile mixer drives with common
oil circuit;x
(with pump)
---
- SAE 85W-90, 85W-140, 90
Mobile mixer drives with separate

oil circuit;
Transmissions for lifting
equipment; Swing drives;
(without pump)
-40C
-26C
-12C
07C, 07D
- SAE 5W-30, 5W-40
-35C
-40C
07E
- SAE 75W-80, ISO VG 46

(only 07E)
-35C
-40C
07B, 07C, 07D
- SAE 10W-30, 10W-40
-30C
-35C
07B, 07C, 07D
- SAE 15W-30, 15W-40
-25C
-30C
07D
- SAE 20W-20
-20C
-25C
07B
- SAE 20W-40
-20C
---
07D
- SAE 30
-5C
-10C
Hydraulic oil
- ISO VG 46
---
-10C
- ISO VG 68
---
-5C
(3) An even warm-up phase is needed in order to reach the minimum oil temperature required for starting the drive unit
(mentioned low temperature limit). At outside temperatures below -5C, a warm-up phase of at least 10 minutes is
required, irrespective of the viscosity grade used.
1.56.2
09 / 2005
Continued
Lubricant class 07A

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

ARAL AG, BOCHUM/D
ARAL AG, BOCHUM/D
ARAL AG, BOCHUM/D
ARAL AG, BOCHUM/D
ARMORINE S.A., LANESTER CEDEX/F
BAYWA AG, MNCHEN/D
BAYWA AG, MNCHEN/D
BEIJING TONGYI PETROLEUM CH. CO. LTD., BEIJING/CN

ADDINOL GETRIEBEL GX 80 W 90 ML
AGIP ROTRA TRUCK GEAR S, SAE 75W-90
AUTOL HYPOID-GETRIEBEL SAE 80W-90
ARAL GETRIEBEOL EP PLUS 80W-90
ARAL GETRIEBEOL HYP 85W-90
ARAL GETRIEBEL HYP SAE 85W-140
ARAL GETRIEBEL SNA-C SAE 75W-90
PM 90
AVIA HYPOID 90 EP
AVIA SYNTOGEAR FE 75W-90 EP
AVIA SYNTOGEAR FE 80W-90
BAYWA HYPOID GETRIEBEL 85W-90
BAYWA SUPER 8090 MC
XIECHENG 85W-90 GEAR OIL
HYPOID-GETRIEBEL 90
BP ENERGEAR DL 80W-90
BP ENERGEAR HT 80W-90
BP ENERGEAR HYPO 90
ENERGEAR HT 85W140
ENERGEAR SHX-M SAE 75W-90
FRONTOL GETRIEBEL FE SAE 80W-90
FRONTOL HYPOID GETRIEBEL B SAE 85W-140
FRONTOL HYPOID GETRIEBEL B SAE 90
MOTOREX PENTA TL
MOTOREX UNISYNT TX
CALPAM MULTI GEAR OIL FE 80W90
CALPAM SUPER GEAR OIL 85W90 GL 5
CASTROL AF-STO 85W140
CASTROL AGRI GEAR GL5 90
CASTROL AGRI GEAR ULTRA
CASTROL DYNADRIVE 80W-90
CASTROL DYNADRIVE PLUS 75W90
CASTROL EPX 85W-140
CASTROL EPX 90
CASTROL EPX M 90
CASTROL MULTIDRIVE 80W90
CEPSA TRANSMISIONES EP 90
CEPSA TRANSMISIONES EP FE+LD 75W-90
CEPSA TRANSMISIONES EP MULTIG. 85W-140
CEPSA TRANSMISIONES EP MULTIGRADO 80W-90
ERTOIL EP CAMBIOS Y DIFERENCIALES SAE 90
GEARTEX EP-B 85W-90
09 / 2005
1.56.3
Continued
COGNIS DEUTSCHLAND GMBH, DSSELDORF/D
GREAT WALL LUBE OIL CO., BEIJING/CHINA
GRUPA LOTOS SA, GDANSK/PL
GULF OIL INTERNATIONAL, PITTSBURG/USA
HAFA, PARIS/F
HAFA, PARIS/F
MAROIL S.R.L. CONC. BARDAHL MANU. CO.,ALTOPASCIO/I
1.56.4

GEARTEX EP-C 85W-140
MULTIGEAR 80W-90
MULTIGEAR S 75W-90
CALTEX HYPOID LD SAE 85W-90
CALTEX HYPOID LD SAE 90
COGNIS EMGARD UAF 4209, SAE 75W-90
GEAR S 80W90
GEAR S 85W140
TOR SUPER GEAR OIL 80W90
TOR UNIGEAR 75W90 LD
AGIP ROTRA MP 85W-140
AGIP ROTRA TRUCK GEAR 85W-140
ROTRA LSX 75W-90
ROTRA MP 80W-90
ROTRA TRUCK GEAR 80W-90
ESSO GEAR OIL GX-D 85W-90
MOBILUBE 1 SHC 75W-90
MOBILUBE HD-A 85W-90
MOBILUBE S 80W-90
AKROS EP 90 SAE 80W90
FUCHS TITAN CYTRAC SL SAE 75W-90
TITAN CYTRAC HSY SAE 75W-90
TITAN GEAR HYP SAE 90
TITAN SUPERGEAR MC 80W-90
GENOL GEAR-SYN 80W-90
GENOL HYPOLUBE 80W-90
YORK 793 SAE 80W90
YORK 793 SAE 85W140
YORK 896
GREATWALL 85W/90 GL-5
LOTOS TITANIS GL-5 SAE 80W/90
GULF GEAR DB 85W 90
EUROGEAR SAE 75W-90
HYPOID PL SAE 80W-90
KENDALL NS-MP GEAR LUBE SAE 80W-90
RTO HD 80W-90
RTO LONGEVIA PXD ECO 75W-90
GEAR M 80W90
HYPOID B SAE85W90
SYNTHEGEAR SAE75W90
KOMPRESSOL-HYPOID EW SAE 80W-90
HIDROIL EP SAE 80W-90
Q8 AUTO 12 SAE 80W-90
Q8 AXLE OIL XG SAE 80W-140
Q8 GEAR OIL XG SAE 80W-90
Q8 T 55 SAE 80W-90
Q8 T 55 SAE 85W-140
Q8 T 55 SAE 90
Q8 T 65 SAE 75W-90
Q8 TRANS XGS SAE 75W-90
HYPOID GETRIEBEL GL 5 SAE 90W
HYPOID GETRIEBEL TDL SAE 80W-90
BARDAHL T&D OIL 80W 90
INA HIPENOL GTL DB 90
09 / 2005
Continued

OMV AG, SCHWECHAT/A
OMV AG, SCHWECHAT/A
OMV AG, SCHWECHAT/A
OMV AG, SCHWECHAT/A
OMV AG, SCHWECHAT/A
PETROL OFISI A.S, MASLAK-ISTANBUL-TURKEY/TR
09 / 2005

INA HIPENOL TDL 80W-90
MEGOL GETRIEBEOEL TRUCK-SYNTH SAE 75W-90
MEGOL HYPOID-GETRIEBEOEL TDL SAE 80W-90
SYNTRAN FE/MILLERS TRX SYNTH 75W/90
SYNTRAN II/MILLERS TRX 80W/90
PENNASOL HYPOID-GETRIEBEOEL GL 5 SAE 90
PENNASOL LONGLIFE GEAR GL 5 SAE 90
HIPOIDNO ULJE B SAE 80W90
HIPOIDNO ULJE B SAE 90
MOL HYKOMOL K 85W-90
MOL HYKOMOL KZ 80W-90
MORRIS EP 80W/90
MORRIS EP 85W/140
MOTUL GEAR SYNT TDL 75W-90
MOTUL TRANS MB 85W-90
GEAROIL SYNTH
HD GEAROIL SAE 90
GEARING PLUS 80W90
MIDLAND SUPER M 5 80W-90
MIDLAND SUPER M 5 85W90
OEST MEHRZWECK-GETRIEBEL FE SAE 80W-90
OEST SYNTH GETRIEBEL SAE 75W-90
OMV GEAR OIL B SAE 85W-90
OMV GEAR OIL BSX SAE 75W-90
OMV GEAR OIL XD-5 SAE 80W-90
OMV UNIGEAR S SAE 75W-90
OMV UNIGEAR SAE 80W-90
ORLY AURIGA EP SAE 85W140
ORLY LYRA EP
PAKELO GLOBAL GEAR CBS SAE 75W/90
PAKELO GLOBAL MULTIGEAR CBS
PAKELO GLOBAL MULTIGEAR CBS DLS
PAKELO GLOBAL MULTIGEAR SA SAE 80W/140
PAKELO GLOBAL MULTIGEAR TS SAE 75W/90
PANOLIN SUPER DUTY 90
PANOLIN SUPER DUTY SYNTH 75W/90
PANOLIN TOPGEAR 80W/90
TRAXON 80W-90
TRAXON 85W-140
PO UNI. KEBAN EP MAN 80W/90
PRISTA EP 85W140
PRISTA EP 90
RORED HD-A SAE90
HIPOL EXTRA GL-5 80W-90
RAVENOL GETR.OEL 75W-90 VSG VOLLSYNTH.
1.56.5
Continued
S.A.E.L., MADRID/E
S.A.E.L., MADRID/E
SHELL BRASIL, BARRA DA TIJUCA - RIO DE JANEIRO/BR
TEDEX PRODUCTION SP.Z.O.O., TOMASZOW MAZOWIECKI/PL
1.56.6

RAVENOL HYP. EPX GETR.L 85W-140 GL5
RAVENOL HYPOID EPX GETR.-OEL 80W-90 GL 5
RAVENOL HYPOID EPX GETRIEBE-OEL SAE 90 GL-5
RAVENOL SLG SPEC. LKW GETR.L 80W90
CARTAGO EP SAE 90
GULF MULTIPURPOSE GEAR LUBRICANT 85W-90
GULF SYTHETIC GEAR LUBRICANT 75W-90
SHARLU MP GEAR LUBE 80W/90 (GL-5)
SHARLU MP GEAR LUBE 85W/140(GL-5)
ASEOL TOPRESS 320
SHELL SPIRAX A 90
SHELL SPIRAX ASX 75W-90
SHELL SPIRAX AX 90
SHELL SPIRAX MB 90
SHELL SPIRAX MX 80W-90
SHELL SPIRAX ST 80W-140
WINTERSHALL GETRIEBEFLUID AFS
WINTERSHALL GETRIEBEFLUID SML 80W-90
WINTERSHALL WIOLIN HYPOID-GETRIEBEL 90
GEARWAY G5 80W-90
GEARWAY G5 85W-140
STRUB MULTIGEAR SGO 80W-90
VULCOGEAR SYNT SGX 75W-90
AMPLEX 80W90
AMPLEX 85W140
TEDEX SUPER GEAR OIL (3343ML) SAE 80W90
MULTIGEAR EP SAE 90
ANTAR EPR 90
ANTAR EPR 80W-90
ANTAR EPS 75W-90
FINA PONTONIC A 80W-140
FINA PONTONIC FDL 75W-90
FINA PONTONIC MDL 80W-90
TOTAL EP B 80W-90
TOTAL EP B 85W-90
TOTAL EP-B 85W-140
TOTAL TRANSMISSION BM 75W-90
TOTAL TRANSMISSION MDL 80W-90
TOTAL TRANSMISSION SYN FE 75W-90
TRANSELF BM 75W-90
TRANSELF SYNTHESE FE 75W-90
TRANSELF TYPE B 80W-90
TRANSELF TYPE B 90
UNIL OPAL GEAR ZF 80W90
HIGH PERFORMANCE GEAR OIL GL-5 90
SYNPOWER GEAR OIL TDL 75W-90
VEEDOL MULTIGEAR B SAE 90
VEEDOL MULTIGEAR C SAE 85W-140
BVX 1000
BVX C 100 80W-90
09 / 2005
Continued
09 / 2005

DIVINOL GEAR OIL STO SAE 80W-90
DIVINOL HYPOID-GETRIEBEL SAE 85W-140
DIVINOL SYNTHOGEAR SAE 75W-90
ZEPPELIN SPEZIALGETRIEBEL GL-4/GL-5 80W-90
ZF-ECOFLUID X
1.56.7
Continued
Lubricant class 07B

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

ARAL AG, BOCHUM/D
ARAL AG, BOCHUM/D
BAYWA AG, MNCHEN/D
BAYWA AG, MNCHEN/D
HAFA, PARIS/F
HAFA, PARIS/F
INA MAZIVA RIJEKA, RIJEKA/HR
MAGNA INDUSTRIAL CO. LIMITED, HONG KONG/HK
OMV AG, SCHWECHAT/A
ADDINOL SUPER TRAKTOR MU 1045 SAE 10W-40

AUTOL AGROTECH SAE 10W-30
ARAL SUPER TRAKTORAL 10W-40
ARAL SUPER TRAKTORAL SAE 10W-30
TRACTAVIA FE 10W-40
TRACTAVIA SPEZIAL 10W-30
BAYWA SUPER 2000 CD-MC 10W-30
BAYWA SUPER MULTISYN SL 10W-40
BLASOL STOU 10W40
BP TERRAC SUPER UNIVERSAL 10W-40
BP TERRAC UNIVERSAL 15W-30
BP TERRAC UNIVERSAL 15W-40
MOTOREX FARMER TRAC
CASTROL AGRI MP 15W-30
CASTROL AGRI MP 15W-40
CASTROL AGRI MP PLUS 10W-30
CASTROL AGRI MP PLUS 10W-40
CEPSA AGRO PLUS 15W-40
ERTOIL MULTI AGRO 15W-40
MULTITEX PREMIUM 10W-40
SUPER UNIVERSAL TRACTOR OIL PREMIUM 10W-30
CALTEX SUPER TRACTOR SAE 15W-40
CALTEX SUPER TRACTOR SAE 20W-40
MAXITRACT 15W40
VICAM TP 10W40
MULTITRAC 15W30
ESSO UNIFARM 10W-30
ESSO UNIFARM 15W-40
MOBIL AGRI EXTRA 10W-40
MOBIL AGRI SUPER 10W-30
MOBIL AGRI SUPER 15W-40
AKCELA MULTI TRACTOR (SAE 10W40)
AKCELA SUPER UNIVERSAL (SAE 10W30)
AKCELA SUPER UNIVERSAL (SAE 15W40)
AKROS MULTI VT SAE 10W30
AKROS UNIVERSAL SAE 10W30
AKROS UNIVERSAL SAE 15W40
AMBRA UNIVERSAL SAE 10W30
AMBRA UNIVERSAL SAE 15W40
AMBRA VT SPECIAL (10W40)
ARBOR UNIVERSAL (SAE 15W40)
TITAN HYDRAMOT 10W-40 MC
TITAN HYDRAMOT MC 10W-30
GENOL TRAC-SYN 1040
YORK 743 10W40
POLYMAT SAE 10W-40
SUPER TUT SAE 15W-40
KENDALL MULTIFARM SAE 15W-30
AGRI MU SUPER 10W40
INA AGRINA 15W-30
STOU 15W40
Q8 T 1000 D SAE 10W-30
Q8 T 1000 D SAE 15W-30
Q8 T 1000 SAE 10W-30
Q8 T 1000 SAE 15W-30
OMEGA 603 SAE15W40
MEGOL SUPER TRAKTORENOEL STOU SAE 10W-30
PENNASOL SUPER TRACTOR UNIVERSALOEL STOU 10W30
PENNASOL SUPER TRACTOR UNIVERSALOEL STOU 15W30
SUPER VERSITRAC
MF LUBE+ AGRILUBE UNIVERSAL 10W30
MIDLAND STOU
OMV AUSTROTRAC SAE 10W-40
ORLY APOLLO SAE 15W-40
ORLY STOU LUNA
PAKELO STOU FLUID SAE 15W/40
1.56.8
09 / 2005
Continued

TAMOIL PETROLI S.P.A., MILANO/I
09 / 2005
PANOLIN STOU 10W/30

PANOLIN STOU 15W/30
GALP UNIAGRO
RAVENOL SUTO SAE 15W-30
AGRO CERES STOU SAE 15W40
ASEOL MULTITRAC SUPER 10W-30
SHELL HARVELLA T 10W-30
SHELL HARVELLA T 15W-40
SHELL HARVELLA TX 10W-40
WINTERSHALL PRIMANOL 10W-30
WINTERSHALL PRIMANOL 10W-40
SUPER TRACTOROEL UNI.10W-30 (STOU)
MULTITRACTOR STOU 15W40
SUPER TRACTOR SAE 15W/40
ANTAR AGRIA GR4 SAE 10W-40
ANTAR AGRIA SUPER FM SAE 15W-40
FINA SUPER UNIVERSAL OIL MF SAE 10W-40
FINA SUPER UNIVERSAL OIL SAE 15W-30
FINA SUPER UNIVERSAL OIL SAE 15W-40
TOTAL MULTAGRI MAX SAE 10W-40
TOTAL MULTAGRI MS SAE 15W-40
TOTAL MULTAGRI SUPER 10W-30
TOTAL MULTAGRI SUPER 15W-40
TOTAL MULTAGRI SUPER SAE 15W-30
TRACTORELF ST3 SAE 15W-30
XANTHOS 10W40
VALVOLINE STOU 10W-30
1.56.9
Continued
Lubricant class 07C

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

ARAL AG, BOCHUM/D
SUN OIL COMPANY (BELGIUM) N.V., AARTSELAAR/B
ADDINOL SUPER STAR MX 1547 SAE 15W-40

ARAL MULTITURBORAL SAE 15W-40
AVIA MULTI CFE PLUS 10W-40
AVILUB MULTI HDC-B 15W40
BLASOL MHP 10W40
BLASOL MHP 15W40
BP VANELLUS C6 GLOBAL PLUS SAE 10W-40
ECONO VERITAS HDE SAE 10W-40
CEPSA DIESEL TURBO SHPD 15W-40
CEPSA SUPER MULTIGRADO SHPD 15W-40
CEPSA ULTRA SHPD 15W-40
CHEVRON DELO 400 MULTIGRADE SAE 15W-40
YORK 645 SAE 15W40
YORK 740 SAE 15W40
KOMPRESSOL-ULTRALUB C SAE 15W-40
SUPERMULTIGRADO D 15W40
Q8 T 500 SAE 15W-40
Q8 T 710 SAE 15W-40
TOURING HIGH TECH DIESELSPEZIALOIL SAE 15W-40
MEGOL MOTORENOEL HD-C3 SAE 15W-40
ORION SUPER PLUS 15W40
PAKELO GOLDEN D/G SAE 15W/40
PAKELO PKO HD SUPER 4 SAE 15W/40
RAVENOL FORMEL DIESEL SUPER 15W-40
RAVENOL TURBO-C HD-C 15W-40
SUPERTURBO DIESEL SAE 15W40
ASEOL PERLA 15W-40
SHELL RIMULA X 15W-40
WINTERSHALL MULTI REKORD 15W-40
WINTERSHALL MULTI REKORD TOP, SAE 15W-40
SUPER MULTI TURBO 15W-40
FORZA SAE 15W40
VEEDOL DIESELSTAR
1.56.10
09 / 2005
Continued
Lubricant class 07D

Engine oil (API CD/CE/CF-4/CF/CG-4/CH-4/CI-4/SF/SG/SH/SJ/SL or ACEA-categories A/B/E)
Product groups in accordance with page 1
SAE viscosity grades
Powershift transmissions
Swing drives
20W-20 / 30 / 5W-30 / 5W-40 / 10W-30 / 10W-40 /

15W-30 / 15W-40
Mobile mixer drives
10W-40 / 15W-40
Note:
All mineral oil-based gear oils which satisfy the above specifications may be used.
09 / 2005
1.56.11
Continued
Lubricant class 07E

Biodegradable lubricant in accordance to Environmental labels RAL-UZ 79 (Blauer Engel),
VAMIL-regeling
Viscosity grade: SAE 75W-80
Manufacturer (07E)
Trade name (07E)
PANOLIN BIOFLUID ZFH
Only swing drives:
Biodegradable lubricant in accordance to Environmental labels RAL-UZ 79 (Blauer Engel),

VAMIL-regeling, Swedish standard 15 54 34
Viscosity grade: ISO VG 46x
Manufacturer
Trade name
PANOLIN HLP SYNTH 46
Instructions on the use of biodegradable lubricants:

The oil manufacturer`s change-over directives included in the product description are to be observed when change-over
to biodegradable lubricants is effected.
1.56.12
09 / 2005
Service Manual
SUBGROUP - INDEX
Section
Group
Type
Special tools general
2.01.1
A 309 LI 20221A 311 LI 20222A 312 LI 12363A 314 LI 2001A 316 LI 2001A 316 LI-IND 2001R 313 LI 27752R 317 LI 18161-
Special tools for diesel engines
2.03.1
Special tools for hydraulic systems
2.05.1
Special tools for electric systems
2.06.1
Special tools for gears
2.07.1
A 309 LI 20221A 311 LI 20222A 312 LI 12363A 314 LI 2001A 316 LI 2001A 316 LI-IND 20012.1
MJFCIFSS
Service Manual
R 313 LI 27752R 317 LI 18161Special tools for axles
2.08.1
A 309 LI 20221A 311 LI 20222A 312 LI 12363A 314 LI 2001A 316 LI 2001A 316 LI-IND 2001-
Assembly tools for hydraulic cylinders
2.12.1
Mounting device for piston rod bearings
2.13.1
Slotted nut wrench for slewing gear
2.14.1
Mounting device for slewing gear
2.15.1
Mounting device for travel gear
2.16.1
R 313 LI 27752R 317 LI 18161-
2.2
MJFCIFSS
Service Manual

for maintenance and repair
Picture
No.
Designation
Size
ID no.
Machi
ne
1
2
Measuring neck
NW 10
NW 12
7002404
7008688
all
types
Pressure gauge connection
R 1/2"
7002436
all
types
Pressure gauge direct

connection
R 1/2"
7002435
all
types
High-pressure hose
length
7002437
all
types
7002475
10
11
12
13
14
Screw coupling assembly, complete
M10X1
M12X1.5
M14X1.5
M16X1.5
R 1/4"
copyright by
MJFCIFSS
5005180
7402580
5004002
7361345
7362579
Application
all
types
2.01.1
Picture
Service Manual
No.
15
Designation
Size
Pressure gauge
16
17
0-1.6 bar
8042577
0-1.6 bar
*
8042578
7361288
19
5002867
20
0-250
bar *
7361285
21
0-400
bar *
7500002
22
0-600
bar *
5002866
30.1
30.2
30.3
30.4
30.5
30.6
Differential pressure
measuring kit, consisting of:
Machi
ne
all
types
5002865
18
30
2.01.2
ID no.
10288229
Measuring of operating
pressures of one or more
hydraulic circuits.
* glycerine dampened
all
types
10288155
1 manual measuring
device 3010
Application
Measuring of difference p between the pump

and the LS pressure.
10288152
1 data cable
10288154
2 measuring cables
0-600
bar
2 pressure sensors
10288153
10288151
1 power adapter
7025273
30.7
30.8
Vehicle connecting cable

not included in delivery!
Pressure sensor
Pressure sensor
33
Fitting
4901372
34
Measuring neck with

metal cap
7002404
35
Union nut
4774002
36
Cutting ring
4774001
copyright by
MJFCIFSS
see sensors on
page 7
6140626 01
6140647 01
all
types
Service Manual
Picture
No.
Designation
Size
ID no.
Machi
ne
Application
44
Measuring adapter
8504231
all
types
Measuring of current at
pump regulation
45
Adapter
9956422
all
types
Measuring of the inductive pickup B12 from 3-pin

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

solenoid valves
60
Piezzo speed
A 2106
10286429
all
types
Measuring of engine
speed via pulse frequency of injection line
62
Ornel speed meter
HT 460
7006974
all
types
Measuring of speed with

reflective strips
63
Shimpo speed meter
DT 205
7364284
64
Strips
614063201
copyright by
MJFCIFSS
with no. 63
2.01.3
Picture
Service Manual
No.
Designation
Size
Chauvin
Arnoux
ID no.
65
Multimeter with digital

display
70
Thermometer
non-contact
(infrared)
72
Thermometer with probe and sensor (magnetic)
80
Hand pump
8145666
82
Sampling valve for oil

samples, alternative to
hand pump 80
7019068
84
Mineral oil analysis kit *
GTH
1150
no. 1
Machi
ne
Application
10018500
all
types
Measuring of voltage,
current and resistance in
electric components and
valves
10024185
all
types
Monitoring of temperature of a medium / outside

temperature of a unit
all
types
Sampling of oil for analysis
all
types
1 oil sample
7020372
8145660
85
10029626
86
7018368
6 oil samples
87
7018369
12 oil samples
4 oil samples
*Analyses carried out by WAER

CHECK Germany, lab report in
German
88
89
2.01.4
Bio oil analysis kit *
no. 3
*Analyses carried out by WAER

CHECK Germany, lab report in
German
copyright by
MJFCIFSS
7026817
7026088
all
types
1 oil sample
6 oil samples
Service Manual
Picture
No.
Designation
Size
ID no.
Machi
ne
Application
90
REFCO vacuum pump
RD-4
7027552
all
types
Maintenance and repair

of a/c system
91
ITE filling hose, blue
1,500
mm
7027553
all
types
See item 90
92
ITE filling hose, yellow
1,500
mm
7027554
93
ITE filling hose, red
1,500
mm
7027555
94
ITE HGV coupling
253a
7027556
See item 90
95
ITE HGV coupling
254 a
7027557
all
types
96
4-valve test fittings
M4WS5
C
7027558
all
types
Maintenance and repair

of a/c system
100
101
102
Dismantling tool
M37X1
M42X1.5
M48X1.5
9583459
9583521
9583522
all
types
Dismantling of grapple
bolts
copyright by
MJFCIFSS
2.01.5
Picture
Service Manual
No.
Designation
105
Universal Passfix puller
120
Size
ID no.
Machi
ne
Application
9584738
all
types
Removal of Passfix bolts
Diagnostic instrument
5010474
all
types
Diagnostics of D5 WS auxiliary heating
121
Adapter cable
9614382
For connection to cable

harness in right bracket
122
Adapter cable
10025620
For direct plugging to the

heating device
130
Testing tool for cooling

system
7029179
all
types
Pressurisation of engine
cooling system (leakage
test)
140
Torque wrench
10045464
all
types
For tightening the hose

clamps
150
Hand pump with pressure gauge
10454803
all
types
For leakage test of backpressure line at particle

filter installation
M42X1.5
M48X1.5
M58X1.5
4-20 Nm
Scope of delivery of the Litronic measuring system

Depending on the requirements, there might be a need for various additional adapters and cables,
which must be ordered separately.
Item
Sensors
OEM pressure sensor, measuring range 0 - 1000 bar, output 0 - 20 mA
6*
6140 624 01
3*
6140 625 01
2.01.6
ID no.
copyright by
MJFCIFSS
1001 8329
Service Manual
Item
Sensors
ID no.
OEM pressure sensor, measuring range -1 to +6 bar, output 4 - 20 mA (LWE)
MINIMESS direct connection pressure sensor, 1620 screws
6*
6140 626 01
MINIMESS direct connection pressure sensor, 1620 screws, angled by 90
3*
6140 647 01
Pt 100 temperature sensor, measuring range -50 C to +200 C
1*
6140 627 01
10
MINIMESS p / t coupling, screw series 1620, G 1/4"
1*
6140 628 01
11
MINIMESS P / T coupling, screw coupling 1620, M10 x 1.5
1*
1004 1274
12
RE 4 10 measuring turbine, measuring range 1 to 10 l/min
1*
5010 031
13
RE 3 75 measuring turbine, measuring range 7.5 to 75 l/min
1*
6410 629 01
14
0*
6140 630 01
15
2*
5009 492
16
DS 03 speed sensor, measuring range 1 to 9999 rpm
1*
6140 631 01
17
Spare reflector foil kit
1*
6140 632 01
18
Magnet holder, for DS 03 speed sensor
1*
6140 633 01
19
Inductive sensor for speed measurement
1*
6140 634 01
Item
Accessory
20
Transport case for RE 3 measuring turbine
1*
6140 635 01
21
MK 12 measuring cable for the connection of the sensors, length 6 m
12*
6140 636 01
22
4*
6140 637 01
23
1*
6140 638 01
24
Power supply cable for connection to the on-board power system, length 6 m
1*
6140 639 01
25
Power supply cable for connection to the on-board power system, length 12 m
0*
6140 640 01
26
DPU 411 thermal printer with power adapter
0*
6140 641 01
27
Thermal paper rolls for DPU 411
0*
6140 642 01
28
Centronics data cable, length 2 m (for DPU 411)
0*
6140 643 01
29
RS 232 data cable, length 2 m (for connection to PC)
1*
9684 327
30
AK 12 adapter cable (for speed measurement with GLR testing instrument)
1*
6140 648 01
31
Litronic Service Program, German version (for DOS operating system)
0*
6140 646 01
32
Evaluation software (d / e / f) on CD-ROM (for Windows, 16 bit)
1*
6004 401
33
Evaluation software (d / e / f) on CD-ROM (for Windows, 32 bit)
34
Measuring adapter for current measurement A 309 - R 317 Litronic
1*
8504 231
36
Y-adapter for current measuring Junior Timer plug
1*
9956 436
37
3-to-2 pin plug adapter
1*
9956 422
1002 7591
5718 886 08
ID no.
* number of units for recommended basic equipment
copyright by
MJFCIFSS
2.01.7
2.01.8
Service Manual
copyright by
MJFCIFSS
Service Manual

for the maintenance and adjustment of DEUTZ diesel engines
Picture
no.
Designation
Size
1a
Compression pressure
tester
1b
Diagram sheets for

item 1a
Connecting piece for

compression pressure
tester
Nozzle tester
10
V-belt measuring instrument
14
Torx too kit
ID no.
8008782
100
Units
Krikit
Machi
ne
Application
all
types
Measurement of compression pressure
7019856
all
types
Insert at the position of the

injection valve
7361236
all
types
Testing of injection nozzles
7019872
all
types
for measurement of V-belt

tension
7014716
all
types
10012817
copyright by
MJFCIFSS
2.03.1
Picture
no.
22
2.03.2
Service Manual
Designation
Size
Torx insert key kits for

(long design)
ID no.
Machi
ne
E 14
7019851
all
types
23
E 18
7021668
24
E 20
7019852
WS 15
7019853
all
types
25
Socket for injection

nozzle (long design)
(union nut)
30
Torque wrench
7019854
all
types
32
Insert key
1/4
7019855
A 312 R 317
35
Turning key
7021680
A 312 R 317
copyright by
MJFCIFSS
Application
Service Manual
Picture
no.
Designation
Size
ID no.
Machi
ne
40
Mounting device for regulating rod
7021677
all
types
50
Mounting tool for

coolant thermostat
7019861
A 312 R 317
54
Piston ring mounting

pliers
7009319
all
types
60
Dismantling tool
(hooks) for crank shaft
seals (front and rear)
7019858
A 312 R 317
64
Mounting tool for crank

shaft seals, front (fan
side)
7021676
A 312 R 317
copyright by
MJFCIFSS
Application
2.03.3
Picture
2.03.4
no.
Service Manual
Designation
Size
ID no.
Machi
ne
66

shaft seal, rear (flywheel side)
7021675
A 312 R 317
68

shaft seal (rear)
7019859
A 309 /
A 311/
R 313
70

shaft seal (front)
10294728
A 309 /
A 311 /
R 313
75
Claw wrench for injection lines
10294729
A 309 /
A 311 /
R 313
80
Valve seal clamp
10294730
all
types
WS 17
copyright by
MJFCIFSS
Application
Service Manual
Picture
no.
Designation
Size
ID no.
Machi
ne
85
Turning key (multitooth) for injection

pump
10294731
A 309 /
A 311/
R 313
90
Wheelspin device
10294732
A 309 /
A 311 /
R 313
95
Wheelspin device
10294733
A 309 /
A 311 /
R 313
100
Adjusting bolt for MAG

shafts
10294734
A 309 /
A 311 /
R 313
105
Removing tool for injection nozzle, in conjunction with tool no.

115
10294735
A 309 /
A 311 /
R 313
copyright by
MJFCIFSS
Application
2.03.5
Picture
2.03.6
no.
Service Manual
Designation
Size
ID no.
Machi
ne
110
Special key for injection line
10294736
A 309 /
A 311 /
R 313
115
Removal tool for injection nozzle
8008803
all
types
120
Indicator for dial disc
8008789
all
types
copyright by
MJFCIFSS
Application
Service Manual

Picture
No.
Order no.
Model
SW 17
9359414
all types
SW 19
WS 19
9210371
To adjust primary and secondary pressure-relief

valves in the control valve
block
7009315
all types
To secure the adjusting

screws on the hydraulik aggregates
short
long
SW 10
WS 10
SW 13
SW 13 l
SW 17
SW 19
SW 19 l
30
Mounting sleeve
See chapter 2.12
all types
To assemble the O-ring

and stepseal ring on hydraulic cylinder pistons, variable-displacement pump
pistons and variable dispacement motor regulating
pistons
40
Expanding sleeve
See chapter 2.12
all types
for application, see also

tool no. 40
50
Piston wrench
See chapter 2.12
all types
10
Desciption
Size
Special wrench for

pressure -relief valves
11
20
Safety cap
short
long
21
22
23
24
25
7023492
7615515
7380629
7009316
7009317
Application
Details for manufact. see

page 2.12-01
A 309 LI - R 317 LI
copyright by
MJFCIFSS
2.05.1
Picture
No.
60
Service Manual
Desciption
Size
Piston wrench
SW
WS
61
Order no.
Model
Application
0541333
all types
To remove and tighten piston nuts
9245656
all types
To remove and install damper pins on hydraulic cylinders with damper on

piston/rod side.
all types
To dismantle the piston rod

bearing from the hydraulic
cylinder
See chapter 2.12
62
63
64
70
80
2.05.2
Socket wrench for

threaded bushing
SW 41
Mounting tool for piston rod bearings
M16
9951120
M20
9959261
M24
9959262
WS 41
90
Filling device, complete with adapter and filling hose
W24,3
2x1/14
3,0m
W24.3
2x1/14
3.0m
8145359
all types
To check and refill diaphragm and piston type accumulators
110
Rod
M6
9288234
A 900C
A 904C
Used to remove and install

piston of pressure balance
on LSC - control valve
block
120
Allen key
9922975
all types
To remove and install the

check valves in connection
K (with radiator bypass valve)
A 309 LI - R 317 LI
copyright by
MJFCIFSS
Service Manual
Picture
No.
Desciption
Size
Order no.
Model
Application
135
Wrench
10
mm
10114826
A 900C
A 904C
To remove the check valve

123 (LUDV system)
140
Clamping device for

spool
20
mm
10017281
all types
To clamp the spool during

disassembly/reassembly
25
mm
10017282
32
mm
10017283
25
mm
22
mm
45
mm
25
mm
9951457
all types
To assemble the Glyd-ring

and scraper ring on the
plunger piston of the hydraulic LIKUFIX coupling
00A7.
300
7405073
all types
To retain content of hydraulic tank during repair

work on the hydraulic system
160
Montagehlse
161
162
163
180
Vacuum pump complete, consisting of:

pump no. 180, vacuum
regulation valve no.
181 with seal, hose
with filter no. 187
181
Vacuum regulation
valve complete:
184
185
186
9951508
9966421
951458
10097130
Tank fitting, consisting

of:
GE 165 fitting
Cone reducing coupling 16/85
Straight nipple
7002240
7407155
7024875
A 309 LI - R 317 LI
copyright by
MJFCIFSS
2.05.3
2.05.4
Service Manual
A 309 LI - R 317 LI
copyright by
MJFCIFSS
Service Manual
copyright by
MJFCIFSS
2.06.1
Picture
2.06.2
No.
Service Manual
Desciption
Size
Order no.
Model
10
To crimp contacts for MATE-NLOK 1.5mm2 leads
7367025
all types
12
To crimp contacts for MATE-NLOK 2.5mm2 connectors
7366314
all types
15
Extraction tool to remove crimped

contacts from MATE-N-LOK connectors
7366655
all types
20
Socket contact for 1.5 mm2 wires

for MATE-N-LOCK connectors
6202619
all types
21
Pin contact for 1.5 mm2 wires for

MATE-N-LOCK connectors
6202620
22
Socket contact for 2.5 mm2 wires

for MATE-N-LOCK connectors
6202591
23
Pin contact for 2.5 mm2 wires fo

MATE-N-LOCK connectors
6202592
28
Hand-held tool to crimp contacts

(according to MIL-C5015,
VG952234, VG 955342)
7367086
29
Crimp turret to crimp contacts

DEUTSCH-type connectors with
special tool no. 28
7409779
30
Tool to crimp contacts of

DEUTSCH - type connectors
8503647
copyright by
MJFCIFSS
all types
all types
all types
Application
Service Manual
Picture
No.
32
Desciption
Size
Extraction tool to remove crimped contacts from DEUTSCHtype connectors
33
34
35
36
37
38
Pin contact for wires of

DT connectors
Socket contact for wires of DT connectors
39
Stopfen / Plug / Bouchon
55
Extraction tool for

WAGO connectors
60
Order no.
Model
Size 4
8503633
all types
Size 8
Size 12
Size 16
Size 20
8503632
8145674
8145673
8503630
0,81,0
1,02,0
2,03,0
7368251
0,81,0
1,02,0
2,03,0
7368252
7368406
Application
all types
6905271
7368405
6905272
7368253
777-310
7022773
all types
IC extraction tool
8042630
61
IC mounting tool
8042629
all types
70
Ergocrimp pliers
6004391
copyright by
MJFCIFSS
all types
To crimp contacts for wires

of JPT (Tyco) connectors
2.06.3
Picture
No.
Service Manual
Desciption
Size
Order no.
Ergocrimp matrix
72
0.5-2.5
mm2
10016253
73
0.5-2.5
mm2
10016255
74
0.5-2.5
mm2
10016256
Model
all types
Application
To crimp contacts for leads
Junior Power Timer Nr./no.
927777-3 / 927779-3 /
927846-2
Junior power Timer/EDS
Nr./no. 929938-3 double
spring contact no.
929940-3
flat adapter no. 963745-1 /
963746-1
80
Extraction tool
7415334
all types
To remove crimped contacts from JPT (Tyco) connectors
90
Crimp plier
10016251
all types
To crimp littlefuse contacts

for leads of JPT (Tyco)
connectors, see also no.
92.
92
Ergocrimp matrix
10016252
all types
In connection with no. 90

and used to crimp contacts
for leads
0.5 mm2
-3.32
mm2
receptacle no. 913053/

913065 / 913066 / 913067
/ 913069 / 913079
Double spring contact no.
913071 / 913072
2.06.4
copyright by
MJFCIFSS
Service Manual

for the maintenance and repair of gear systems
Picture
No.
Equip
ment
Description
Size
ID no.
10
Slotted nut wrench for

slewing gear mechanism
SAT
225
9202820
all
types
20
Mounting device
SAT
225
9202825
A 309 R 317
30
Mounting device
FAT
350/022
FAT
350/032
9981445
Rmachines
Tool used to dismantle and

mount the multi-disc brake
of the FAT slewing gear
mechanism (drawing, see
page 2.16-01)
35
Mounting device for

slide ring seals
FAT
350/022
FAT
350/032
8503594
Rmachines
For the mounting of slip

ring seals in FAT travel
gear systems
copyright by
MJFCIFSS
Application
Releasing and tightening of
slotted nuts in drive/slewing gear mechanisms (SAT
drawing, see page 2.1401)
2.07.1
2.07.2
Service Manual
copyright by
MJFCIFSS
Service Manual
Special tools for axles

for the maintenance and repair of axles
10
11
Collet chuck for axles

Chuck tip
7009536
all
types
Used to top in and top out

the snap ring into/from the
planetary gear of the axles
Used to loosen and tighten

slotted nuts in planetary
gears / axles.
5 mm
8145768
6 mm
8145769
AP/APL
745/
755
7013102
A 314 /
A 316
21
AP
745 TR*
AP
755 TR*
7021789
A 314 /
A 316
22
AP
755 HD
APL
755 HD
7014452
A 316
Industry
AP/APL
745
APL
755
7013101
A 314 /
A 316
31
AP
745 TR*
AP
755 TR*
7029469
A 314 /
A 316
32
AP/APL
755 HD
7013920
AP/APL
745 TR*
APL
755
7024975
A 316
Industry
A 314 /
A 316
12
20
30
35
Chuck tip

axles
Centring disc
Centring ring
copyright by
MJFCIFSS
In conjunction with tool no.

20-22

30
2.08.1
Service Manual
40
Mounting tool
AP/APL
745
AP
745 TR*
7024127
A 314
A 314
Used to insert the cassette

seal ring in the hub / axles.
APL
755
42
AP
755 TR*
7024974
A 316
44
APL
755 HD
7024973
46
AP
755 HD
7029525
A 316
Industry
A 316
Industry
AP/APL
745
APL
755
7019632
AP/APL
755 HD
7024131
A 316
Industry
M
16 x 1.5
7019556
A 314 /
A 316
Used to measure the pad

wear at the ZP axles.
A 309 /
A 312
Used to measure the pad

wear at the
multi-disc brake
A 316
Used to loosen and tighten

the slotted nuts in the planetary housing / hub carrier
50
Slip bushing, 2-part
51
2.08.2
60
Measuring screw for

pad wear
65
Measuring tool for pad

wear
70

axles
MS-E
3060
MT-E
3060
A 314
A 316
10346444
copyright by
MJFCIFSS
Used to mount the brake

piston into the hollow
wheel.
Service Manual
75
Gripping piece
MS-E
3060
10354109
A 316
78
Removal insert
MS-E
3060
7011520
A 316
80
Removing tool
MS-E
3060
7026311
A 316
Used to remove the outer

bearing race from the joint
housing.
90
85
Removing tool
MS-E
3060
10353377
A 316
Used to pull the shaft seal

ring and the bushing from
the axle housing and the
joint housing.
90
90
Counter piece
MS-E
3060
7026310
A 316
copyright by
MJFCIFSS
Used to remove the inner

bearing race from the joint
housing.
78
2.08.3
Service Manual
95
Mounting tool
MS-E
3060
7011527
A 316
Used to insert the outer bearing race in the joint housing.
100
Mounting tool
MS-E
3060
10353378
A 316
103
Handle
MS-E
3060
7011518
Used to insert shaft seal

rings / bushings in the axle
housing and the joint housing.
103
* = Drum brake
2.08.4
copyright by
MJFCIFSS
Service Manual

Assembly wrenches for pistons of hydraulic cylinders WN 4121

1 Assembly wrenches for pistons of hydraulic cylinders WN 4121
Fig. 1
Assembly tool (bore for mounting bolt a)
ID no.
Square
9131359
52
38
75
200
10
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
15
210
1/2
0542336
120
100
140
240
12
152
240
1/2
0540947
124
100
150
240
12
15
240
1/2
0541379
145
125
170
280
11
15
280
3/4
0540966
160
135
185
280
12
10
20
280
3/4
0529897
165
140
190
280
12
10
20
280
3/4
Tab. 1
List of assembly wrenches (all dimensions in mm)
Note!
The dimensions of the pistons and assembly wrenches and the ID numbers can be looked up in
Lidos (* and # correspond to one wrench each)!
copyright by
MJFCIFSS
2.12.1
Service Manual
Assembly wrenches for piston nuts
2 Assembly wrenches for piston nuts
Fig. 2
Assembly wrenches for piston nuts
Size of piston nut

ID no.
*WS hex.
WS
paral.
M30X1.5 - 7006469
41
50
M42X1.5 - 7010163
M50X2 - 4129202
60
55
70
M50X2 - 9166795
9921132
1/2
9211967
65
**
1/2
9211967
1/2
9921132
1/2
9921123
1/2
9921123
M56X2 - 9921260
80
1/2
9921124
M60X2 - 4129203
80
1/2
9921124
M65X2 - 9247441
85
1/2
9921133
M68X2 - 9129554
90
1/2
9921124
M76X2 - 9970448
100
3/4
9921125
M85X3 - 9142472
110
3/4
9921125
M95X3 - 9101411
120
3/4
9921126
M100X3 - 9950036
130
3/4
9951123
M110X3 - 9129653 / 9112934
149
3/4
9921127
M120X3 - 9143685
165
3/4
9921128
M130X3 - 9125066
180
3/4
9921129
M150X3 - 9144654
210
3/4
9921131
M170X3 - 5008571
230
3/4
9921134
Tab. 2
List of piston nuts
* width over flats / ** conventional grooved socket spanner
2.12.2
**
1/2
62
M42X1.5 - 9113734
ID no.
**
50
M33 X1.5 - 9226916
M42X1.5 - 9970088
Square
44
M32X1.5 - 7010262
M36X1.5 - 9875702
Slotted nut
copyright by
MJFCIFSS
Service Manual

Assembly wrenches for WN 4122 piston rod bearings
3 Assembly wrenches for WN 4122 piston rod bearings
Fig. 3
ID no.
Assembly wrenches for piston rod bearings

a
Square
0541665
76
0541666
87,5
62
95
72
110
210
15
70
1/2
210
10
15
70
1/2
0541063
92
75
115
210
12
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
10
15
95
1/2
0541667
125
98
150
240
12
10
15
98
1/2
0529894
135
110
160
260
12
15
105
1/2
0540948
140
120
160
260
12
15
110
1/2
0541661
145
120
170
280
12
10
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
20
120
3/4
Tab. 3
List of assembly wrenches
copyright by
MJFCIFSS
2.12.3
Service Manual
Assembly wrenches for version 5100 pistons
4 Assembly wrenches for version 5100 pistons
Fig. 4
Assembly wrenches for version 5100 pistons
Size of piston nut
*WS hex.
a
for mounting bolts
M120X3
175
220
3/4
9584641
M140X3
190
240
3/4
9581705
Tab. 4
WS
square
ID no.
* width over flats
4.1
Assembly wrenches for pistons
Fig. 5
ID no.
Square
9249886
250
204
310
600
14
30
28
30
175
3/4
9249741
260
176
330
600
19
36
35
40
180
3/4
9243215
280
206
354
650
19
36
35
40
190
3/4
Tab. 5
2.12.4
Assembly wrenches for pistons
copyright by
MJFCIFSS
Service Manual

Mounting and expanding sleeves
4.2
Assembly wrenches with hex nut for pistons
Fig. 6
Assembly wrenches with hex nut for pistons
mm
mm
mm
mm
Piston
largest
mm
mm
mm
mm
Piston
smallest
*SW 6-KT
4-KT
9600751
80
3/4
170
110
140
160
525
15
85
3/4
170
115
140
160
9602239
9600418
525
15
90
3/4
170
120
150
160
525
15
9597668
100
3/4
170
130
160
180
525
15
9600928
110
3/4
170
160
190
200
525
15
9600769
120
3/4
174
170
200
200
525
15
ID no.
Tab. 6
* width over flats
5 Mounting and expanding sleeves

Piston
990 mounting sleeve

ID no.
991 expanding sleeve

ID no.
32
9136418
9136416
32
9113100
9113099
38
9143279
9143280
40
9196902
9136417
40
9580414
9580413
45
9136419
9136417
50
9288953
9288954
63
9170510
9170512
65
9177541
9177540
70
9110556
9110402
80
9227165
9227166
copyright by
MJFCIFSS
2.12.5
Service Manual
Tab. 7
2.12.6
Piston
990 mounting sleeve

ID no.
991 expanding sleeve

ID no.
85
9998618
9110404
85
9115710
9115708
90
9227161
9227162
98
9289130
9289131
100
9998626
9110405
105
9951984
9951983
106
9583670
9583671
110
9170509
9170511
110
9960483
9960502
115
9998625
9110406
120
9998778
9110407
125
9227163
9227164
125
9960484
9960503
130
9998624
9110408
135
9285578
9285579
140
9998623
9110409
150
9998622
9110410
160
9998621
9110411
170
9107931
9110412
180
9998619
9110413
180
9107932
9110413
190
9907684
9907701
190
9280862
9280863
200
9107933
9110414
List of mounting and expanding sleeves
copyright by
MJFCIFSS
Service Manual

Mounting sleeves used to insert pistons into cylinders
Tab. 8
Piston
950 mounting sleeve

ID no.
65
9177543
80
9231749
90
9248893
90
9248894
100
9248895
110
9248897
120
9248898
130
9248899
140
9177541
140
9952180
160
9248909
190
9281241
210
9281240
250
9951147
260
9284918
950 mounting sleeves
Note!
The mounting sleeve 950 is required to restore the shape of the expanded sealing elements to suit
the inside diameter of the cylinder (calibration).
Mounting sleeves used to mount the piston rod bearings on the piston rods
Tab. 9
Piston rod
960 mounting sleeve

ID no.
90
9282761
105
9287177
140
9926806
960 mounting sleeves
Note!
The 960 mounting sleeve is required in order to prevent damage to sealing and guide elements.
copyright by
MJFCIFSS
2.12.7
Service Manual
2.12.8
copyright by
MJFCIFSS
Service Manual

Tool used to dismantle piston rod bearings in hydraulic cylinders

1 Tool used to dismantle piston rod bearings in hydraulic cylinders
Fig. 1
Mounting device
Thread in
flange ring
Thread in
bearing head
M1
Thread of
mounting driver
M2
Length of
mounting driver
L
ID -no.
M12
M16
M10
250
9951120
M16
M20
M12
270
9959261
M20
M24X2
M16
290
9959262
Tab. 1
Mounting devices sizes for various flange ring threads
copyright by
MJFCIFSS
2.13.1
Service Manual
Tool used to dismantle piston rod bearings in hydraulic cylinders
2.13.2
copyright by
MJFCIFSS
Service Manual

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

1 Tool used to remove the slotted nut in the slewing gear mechanism
Fig. 1
Tab. 1
Slotted nut wrench for Sat 225

Slewing gear type
ID number
SAT 225
9202820
ID numbers of slottet nut wrenches
copyright by
MJFCIFSS
2.14.1
Service Manual
Tool used to remove the slotted nut in the slewing gear mechanism
Fig. 2
Technical drawing of slotted nut wrench
SAT
225
90
40
30
55
71.5+0.2
77
100
95
3.8
80
35
30
40
56
7.8
Tab. 2
Dimensions
Material: 42 CrMo 4 hardened to 800 - 950 N/mm2
2.14.2
copyright by
MJFCIFSS
Service Manual

Tool used to dismantle and mount the multi-disc brake of the slewing gear mechanism SAT 225
Fig. 1
Mounting device of slewing gear mechanisms
Size
SAT 225
268
40
12
10
10
16
100
117
ID no.
9202825
Tab. 1
List of mounting device sizes
copyright by
MJFCIFSS
2.15.1
2.15.2
Service Manual
copyright by
MJFCIFSS
Service Manual

Tool used to dismantle and mount the multi-disc brake of the FAT 350 travel gear mechanism
Fig. 1
Tab. 1
Technical drawing of mounting device

Size
FAT 350
022 / 032
238
205
100
108
40
18
16
15
ID no.
9981445
Dimensions of mounting device (in mm)
copyright by
MJFCIFSS
2.16.1
2.16.2
Service Manual
copyright by
MJFCIFSS
Service Manual
SUBGROUP - INDEX
Section
Group
Type
Technical data
3.09.1
A 309 LI 20221-
Technical data
3.11.1
A 311 LI 20222-
Technical data
3.12.1
A 312 LI 12363-
Technical data
3.13.1
R 313 LI 27752-
Technical data
3.14.1
A 314 LI 2001-
Technical data
3.16.1
A 316 LI 2001A 316 LI-IND 2001-
Technical data
3.17.1
R 317 LI 18161-
Inspection and maintenance schedule
3.29.1
A 309 LI 20221A 311 LI 20222-
3.32.1
A 312 LI 12363A 314 LI 2001A 316 LI 2001A 316 LI-IND 2001-
3.38.1
R 313 LI 27752R 317 LI 18161-
3.1
MJFCIFSS
Service Manual
3.2
MJFCIFSS
Service Manual
Technical data
A 309 Litronic
Technical data
1 A 309 Litronic
Type 717
Typ
Valid from serial number
717
20221
717
29269
General
20221
29269
Weight of basic machine with 2-point support
9,05
Weight of backhoe bucket attachment (2-point support)
10,82
Overall length (with blade support)
mm
4230
Overall width
mm
2550
Overall height without attacment
mm
3110
Rear reach from centre/slewing radius
mm
1600 / 1600
Ground clearance
mm
320
Break-out force at tooth
KN
44,8 / 68,5
Max. drawing pull (in offroad gear and max. operating

pressure)
KN
71,1
Drive motor
Type
Power at rated speed according to DIN ISO 9249
KW
Rated speed
min
Max. torque
Nm
Oil volume in engine (filling quantity at oil change with filter)
-1
Oil quality/oil viscosity and oil change intervals

Fuel tank capacity
Additional information
Hydraulic system
Hydraulic pump
Typ
Design
Drive power of pump with power control (min. power)
KW
Max. flow
l/min
Hydraulic oil volume (oil change with filter)
Hydraulic oil and filter change intervals
20221
29269
BF 4 M 1012
63 (86 PS)
2000
352 10
bei1300-1500 min-1
15,5
see groups 1.50 and

3.29
215
see group 4.02
20221
29269
A 8 VO 55
axial piston swash

plate double pump
53
212
ca.200
see groups 1.50 and

3.29
Control valve block
Typ
M8/NG 20
Rotary connection 7 x
Typ
DDF 720
A 309 LI 20221copyright by
MJFCIFSS
3.09.1
Technical data
Service Manual
A 309 Litronic
Hydraulic system
20221
29269
Typ
815.006
Boom cylinder (adjustable and gooseneck equipment)

piston / rod
mm
115 / 70
Stick cylinder with adjustable attachment piston / rod
mm
90 / 60
Bucket cylinder piston / rod
mm
80 / 50
Swivel cylinder
mm
90 / 50
Support cylinder with outrigger - blade support piston / rod
mm
110 / 50
Regulating cylinder with boom attachment piston / rod
mm
125 / 70
Additional cylinder
see group 7.31
Hydraulic pump / pilot control
Typ
Gear pump
Max. flow / pilot control
l/min
22
Hydraulic pump / brake system - swivel bearing and AS1
Typ
Gear pump
max. flow rate through flow distributor
l/min
53
Constant current for brake I residual current for swivel

bearing and AS1
l/min
Hydraulic pump / fan drive (cooling)
Typ
Max. flow / fan drive (cooling)

Pilot control unit / working attachment / slewing gear
51
Gear pump
l/min
50
Typ
VG - 7 - 4
Pilot control unit / travel drive
VG - 7 - 1
Pilot control unit / support
VG - 7 - 2
see group 6. / 7.
20221
29269
24
Elektrical system
Operating voltage
Battery capacity
Ah
2 x 92 (in series)
Alternator voltage / current
V/A
28 / 55
Starter
V / KW
24 / 4,0
20221
29269

Gearbox
Typ
SAT 225 / 220
Oil motor
Typ
FMF 45
Max. slewing speed
min-1
9,0
Oil volume in gearbox
4,4
see groups 1.50

and 3.29
wet multi-disc brake

(negative)
see group 9.10
20221
29269

Slewing gear brake
Typ
Transmission
Gearbox
Typ
2 HL 70
2 HL 270
Oil motor
Typ
DMVA 108
3.09.2
MJFCIFSS
Service Manual
Technical data
A 309 Litronic
Transmission
Travel speed in creeper / offroad / on-road gear
km/h

Parking brake
Typ
Axles
20221
29269
2,5 / 5,0 / 20,0
3,3
3,0
1.50 u. 3.29

(negative)
see group 11.08
group 11.20
20221
29269
Steering axle
Typ
212
Rigid axle
Typ
112
Oil volume in steering axle housing
7,3
Oil volume in steering axle wheel hub
2 x 0,8
Oil volume in rigid axle housing
8,0
Oil volume in rigid axle wheel hub
2 x 2,1
Oil volume in axle housing of steered rigid axle (4-wheel

steering)
7,3
Oil volume in wheel hub of steered rigid axle (4-wheel

steering)
2 x 2,0
see groups 1.50

and 3.29

Steering axle working brake
Typ
disc brake
Rigid axle working brake
Typ
disc brake
(positive)
see groups
12.02 / 12.03 / 12.05
9.00 - 20
500 / 45 - 20
see group 12.54
20221
29269
Brake type
Tyres
Zoll
Steering
Hydraulic pump
Typ
Gear pump
Flow
l/min
39
Steering / steering valve
Typ
Servostat 2 /
LAGS 200
LAGS 200
see group 13.20/

13.22
see group 13.22
20221
29269
Gear pump
2,0
see group 15.05
Brake system
Hydraulic pump
Typ
Max. flow
l/min
MJFCIFSS
3.09.3
Technical data
Service Manual
A 309 Litronic
3.09.4
MJFCIFSS
Service Manual
Technical data
A 311 Litronic
Technical data
1 A 311 Litronic
Type 718
Typ
718
20222
718
29170
General
20222
29170
10,03
11,99
mm
4370
Overall width
mm
2550
mm
3110
mm
1750 / 1750
Ground clearance
mm
320
KN
49,9 / 77,5

pressure)
KN
71,1
Drive motor
Type
KW
Rated speed
min
Max. torque
Nm
-1

Fuel tank capacity
Hydraulic system
Hydraulic pump
Typ
Design
KW
Max. flow
l/min
20222
29170
BF 4 M 1012
67 (91 PS)
2000
371 10
at 1300-1500 min-1
15,5
see groups 1.50 and

3.29
215
see group 4.02
20222
29170
A 8 VO 55
axial piston swash

plate double pump
57
212
ca.200
see groups 1.50 and

3.29
Control valve block
Typ
M8/NG 20
Typ
DDF 720
MJFCIFSS
3.11.1
Technical data
Service Manual
A 311 Litronic
Hydraulic system
20222
29170
Typ
815.006

piston / rod
mm
125 / 70
mm
100 / 70
mm
90 / 60
Swivel cylinder
mm
90 / 50
mm
110 / 50
mm
125 / 70
Additional cylinder
see group 7.33
Typ
Gear pump
l/min
22
Hydraulic pump / brake system - swivel bearing and AS1
Typ
Gear pump
max. flow rate through flow distributor
l/min
53
Constant current for brake I residual current for swivel

bearing and AS1
l/min
Typ

51
Gear pump
l/min
50
Typ
VG - 7 - 4
VG - 7 - 1
VG - 7 - 2
see group 6. / 7.
20222
29170
24
Elektrical system
Operating voltage
Battery capacity
Ah
2 x 92 (in series)
V/A
28 / 55
Starter
V / KW
24 / 4,0
20222
29170

Gearbox
Typ
SAT 225 / 220
Oil motor
Typ
FMF 45
Max. slewing speed
min-1
9,0
4,4
see groups 1.50

and 3.29

(negative)
see group 9.10
20222
29170

Slewing gear brake
Typ
Transmission
Gearbox
Typ
2 HL 70
2 HL 270
Oil motor
Typ
DMVA 108
3.11.2
MJFCIFSS
Service Manual
Technical data
A 311 Litronic
Transmission
km/h

Parking brake
Typ
Axles
20222
29170
2,5 / 5,0 / 20,0
3,3
3,0
1.50 and 3.29

(negative)
see group 11.08
group 11.20
20222
29170
Steering axle
Typ
262 LD
Rigid axle
Typ
162 LD
7,3
2 x 0,8
8,0
2 x 2,1
Oil volume in axle housing of steered rigid axle (4-wheel

steering)
7,3
Oil volume in wheel hub of steered rigid axle (4-wheel

steering)
2 x 2,0
see groups 1.50

and 3.29

Typ
disc brake
Typ
disc brake
(positive)
see groups
12.05 / 12.10 / 12.11
9.00 - 20
500 / 45 - 20
see group 12.54
20222
29170
Brake type
Tyres
Zoll
Steering
Hydraulic pump
Typ
Gear pump
Flow
l/min
39
Typ
Servostat 2 /
LAGS 200
LAGS 200
see group 13.20/

13.22
see group 13.22
20222
29170
Gear pump
2,0
see group 15.05
Brake system
Hydraulic pump
Typ
Max. flow
l/min
MJFCIFSS
3.11.3
Technical data
Service Manual
A 311 Litronic
3.11.4
MJFCIFSS
Service Manual
Technical data
A 312 Litronic
Technical data
1 A 312 Litronic
Type 719
Typ
719
12363
719
29898
General
12363
29898
13,0
12,5 - 13,5
mm
4150
Overall width
mm
2500
mm
3100
mm
1900 / 1900
Ground clearance
mm
360
KN
64,5 / 79,1

pressure)
KN
87
Drive motor
12363
Type
KW
Rated speed
min-1
Max. torque
Nm

Fuel tank capacity
Hydraulic system
Hydraulic pump
Typ
Design
Max. flow
l/min
29898
BF 4 M 1013 E
74 (100 PS)
1800
422 10
at 1400 min-1
15,5
see groups 1.50 and

3.32
215
see group 4.04
12363
29898
LMV 130
axial piston swash

plate pump
234
ca.300
see groups 1.50 and

3.32
Control valve block
Typ
M7/NG 20
Typ
DDF 720
Typ
815.006
MJFCIFSS
3.12.1
Technical data
Service Manual
A 312 Litronic
Hydraulic system
12363
29898

piston / rod
mm
100 / 70
mm
110 / 70
mm
90 / 70
mm
120 / 70 - 90 / 50
mm
140 / 80
see group 7.34
Gear pump
32
Additional cylinder
Hydraulic pump / Brake system - Servo control
Typ
l/min
Flow devider K (Brake) / R (Servo control)
30
Hydraulic pump
Typ
Gear pump
Typ
Gear pump
l/min
50
Typ
VG - 7 - 4
VG - 7 - 1
VG - 7 - 2
see group 6. / 7.
12363
29898
Elektrical system
Operating voltage
24
Battery capacity
Ah
2 x 92 (in series)
V/A
28 / 55
Starter
V / KW
24 / 4,8
12363
29898
Typ
SAT 225 / 228
Oil motor
Typ
FMF 45
Max. slewing speed
min-1
9,0
4,5
see groups 1.50

and 3.32

(negative)
see group 9.10
12363
29898

Gearbox

Slewing gear brake
Typ
Transmission
Gearbox
Typ
2 HL 70
2 HL 270
Oil motor
Typ
DMVA 108
km/h
2,5 / 5,0 / 20,0
3,3
3,0
1.50 and 3.32
3.12.2
MJFCIFSS
Service Manual
Technical data
A 312 Litronic
Transmission
12363
29898

(negative)
see group 11.08
group 11.20
12363
29898
Typ
262 / 51
Rigid axle
Typ
162 / 51
8,2
2 x 3,0
10,5 (at disc brake)
2 x 0,7 (2,0 l at disc

brake)
see groups 1.50

and 3.32
Parking brake
Typ
Axles
Steering axle

Typ
disc brake
Typ
drum brake (option

disc brake)
(positive)
see groups
12.20 / 12.21 / 12.23
10.00 - 20
18.00 - 19,5
600 / 40 - 22,5
see group 12.54
12363
29898
Brake type
Tyres
Zoll
Steering
Hydraulic pump
Typ
Gear pump
Flow
l/min
44
Typ
Servostat 2 /
LAGS 200
LAGS 200
see group 13.20/

13.22
see group 13.22
12363
29898
Brake system
Hydraulic pump
Typ
Gear pump
Max. flow
l/min
2,0
see group 15.05
MJFCIFSS
3.12.3
Technical data
Service Manual
A 312 Litronic
3.12.4
MJFCIFSS
Service Manual
Technical data
R 313 Litronic
Technical data
1 R 313 Litronic
Type 636
Valid from serial number 27752
R 313 Litronic
Type 636
General
Weight of backhoe bucket attachment and 600 mm base plates
Overall length
mm
4095
Overall width (500-750 mm base plates)
mm
2500-2750
Overall height without attachment
mm
2925
mm
2215
Ground clearance
mm
435
Max. break-out force at tooth
kN
111.3 / 79.2
Max. drawing pull (in off-road gear and max. operating pressure)
kN
151
Drive motor
15.3 (16.4*)
R 313 Litronic
Type 636
Type
BF 4 M 2012 C
kW
73 (99 HP)
Rated speed
rpm
1800
Max. torque
Nm
422 10
at 1500 rpm

Total tank capacity
14,0
see groups 1.50 and
3.38
approx. 230
see group 4.03
Hydraulic system
R 313 Litronic
Type 636
Hydraulic pump
Type
Design
DPVO 165
Axial piston swash plate pump
kW
Drive power of pump with power control (max. power)
kW
73
Max. flow
l/min
297
R 313 LI 27752copyright by
MJFCIFSS
29
approx. 350
see groups 1.50 and
3.38
3.13.1
Technical data
Service Manual
R 313 Litronic
Hydraulic system
R 313 Litronic
Type 636
Control valve block
Type
M7/NG 20-16
Rotary connection 5x
Type
DDF 520
Type
815.001
Boom cylinder (adjustable and gooseneck equipment) piston / rod
mm
110 / 70
mm
115 / 70
mm
90 / 60
Cylinder with blade support piston / rod
mm
130 / 90
mm
140 / 80
Type
Gear pump
l/min
36
Type
Gear pump
l/min
39
Type
VG - 7 - 4
Type
5 TH 6 NR
see group 6
Electrical system
R 313 Li
Type 636
Operating voltage
Battery capacity
Ah
V/A
28 / 55
Starter
V / kW
24 / 4.8
2 x 92 (in series)
R 313 Li
Type 636
Gearbox
Type
SAT 225 / 218
Oil motor
Type
FMF 45
Max. slewing speed
rpm
9.0

Slewing gear brake
5.2
see groups 1.50 and
3.38
Type
3.13.2
24
Wet multi-disc brake

(negative)
see group 9.10
MJFCIFSS
Service Manual
Technical data
R 313 Litronic
Travel gear
R 313 Litronic
Type 636
Gearbox
Type
FAT 350
Oil motor
Type
A6 VE 55
Travel speed in standard / fast travel mode
km/h
2.4 / 5.0

Travel brake
3.0
see groups 1.50 and
3.38
Type
Multi-disc brake
see group
11.62
or 11.67
Drive
R 313 Litronic
Type 636
Drive
bar
Running rollers
Type/
number of
rollers
D4 L / 2 X 7
D4 L
Support rollers
Type/
number of
rollers
D4 L / 2 X 2
Number of base plates / chains
Units
46
Base plate width
mm
500/ 600/
750
Specific pressure on ground (max.)
N/cm2
4.6(4.9*) / 3.9(4.2*)/
3.2(3.4*)
see group 12
* in machines with blade
MJFCIFSS
3.13.3
Technical data
Service Manual
R 313 Litronic
3.13.4
MJFCIFSS
Service Manual
Technical data
A 314 Litronic
Technical data
1 A 314 Litronic
Type 635
Typ
635
2001
General
2001
11,4
13,4 - 15,2
mm
4235
Overall width
mm
2500
mm
3107
mm
2030 / 2030
Ground clearance
mm
348
KN
66,1 / 72,9

pressure)
KN
87
Drive motor
2001
Type
BF 4 M 1013 EC
KW
Rated speed
min
Max. torque
Nm
80 (109 PS)
-1
1800
460 10
at 1400 min-1
15,5
see groups 1.50 and
3.32
Fuel tank capacity
290
see group 4.05
Hydraulic system
2001
Hydraulic pump
Typ
Design
LMV 130
axial piston swash
plate pump
Max. flow
l/min
234
ca.250
see groups 1.50 and
3.32
Control valve block
Typ
M7/NG 20
Typ
DDF 720
Typ
815.006
MJFCIFSS
3.14.1
Technical data
Service Manual
A 314 Litronic
Hydraulic system
2001

piston / rod
mm
110 / 70
mm
115 / 75
mm
100 / 70
mm
120 / 70 - 90 / 50
mm
140 / 80
Additional cylinder
see group 7.35
Typ
l/min
Gear pump
32
2
30
Hydraulic pump
Typ
Gear pump
Typ
Gear pump
l/min
45
Typ
VG - 7 - 4
VG - 7 - 1
VG - 7 - 2
see group 6. / 7.
Elektrical system
2001
Operating voltage
24
Battery capacity
Ah
2 x 92 (in series)
V/A
28 / 55
Starter
V / KW
24 / 4,8
2001
Gearbox
Typ
SAT 225 / 218
Oil motor
Typ
FMF 45
Max. slewing speed
min-1
9,0
4,4
see groups 1.50

and 3.32
Slewing gear brake
Typ

(negative)
see group 9.10
Transmission
2001
Gearbox
Typ
2 HL 100
Oil motor
Typ
LMV 108
km/h
2,5 / 5,0 / 20,0
3.14.2
3,3
1.50 and 3.32
MJFCIFSS
Service Manual
Technical data
A 314 Litronic
Transmission
2001
Parking brake
Typ

(negative)
see group 11.10
Axles
2001
Steering axle
Typ
APL - B 745
Rigid axle
Typ
AP - B 745 TR
7,5
2 x 0,7
9,0 ( 10,0 l at disc

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

brake)
see groups 1.50

and 3.32
Typ
disc brake
Typ
drum brake (option

disc brake)
Brake type
(positive)
see groups
12.28 / 12.29 / 12.31
Tyres
Zoll
10.00 - 20
18.00 - 19,5
600 / 40 - 22,5
see group 12.54
Steering
2001
Hydraulic pump
Typ
Flow
l/min
44
Typ
Servostat 2 /
LAGS 200
Gear pump
see group 13.20/

13.22
Brake system
2001
Hydraulic pump
Typ
Max. flow
l/min
Gear pump
2,0
see group 15.05
MJFCIFSS
3.14.3
Technical data
Service Manual
A 314 Litronic
3.14.4
MJFCIFSS
Service Manual
Technical data
A 316 Litronic
Technical data
1 A 316 Litronic
Type 715 / 716
Typ
715
2001
716
2001
715
28061
716
28062
General
2001
2001
28061
28062
12,4
14,9
12,4
14,9
15,0 16,7
18,9 21,0
15,0 16,7
18,9 21,0
mm
4235
Overall width
mm
2500
mm
3125
mm
2230 / 2230
Ground clearance
mm
390
KN
66,8 / 90

pressure)
KN
90
Drive motor
2001
Type
BF 4 M 1013 EC
86 (115 PS)
1800
497 10
at 1350 min-1
15,5
see groups 1.50 and

3.32
KW
Rated speed
min
Max. torque
Nm
-1

Fuel tank capacity
2001
28061
28062
290
see group 4.05
Hydraulic system
2001
Hydraulic pump
Typ
Design
2001
28062
LMV 150
axial piston swash
plate pump
Max. flow
l/min
270
ca.290
see groups 1.50 and
3.32
Control valve block
Typ
M7/NG 20
Typ
DDF 720
A 316 LI 2001A 316 LI-IND 2001-
28061
copyright by
MJFCIFSS
3.16.1
Technical data
Service Manual
A 316 Litronic
Hydraulic system
2001
2001
28061
28062
Typ
815.006

piston / rod
mm
120 / 70
mm
mm
100 / 70
mm
120 / 70 - 90 / 50
mm
140 / 80
Additional cylinder
120 / 80
110 / 70
120 /
80
110 /
70
see group 7.36
Typ
Gear pump
l/min
32
30
Typ
Gear pump
l/min
45
Typ
VG - 7 - 4
VG - 7 - 1

VG - 7 - 2
see group 6. / 7.
Elektrical system
2001
28061
28062
Operating voltage
24
Battery capacity
Ah
2 x 92 (in series)
V/A
28 / 55
Starter
V / KW
24 / 4,8
2001
28061
28062
28061
28062

Gearbox
Typ
SAT 225 / 218
Oil motor
Typ
FMF 45
Max. slewing speed
min-1
9,0
4,4
see groups 1.50

and 3.32
Slewing gear brake
Typ

(negative)
see group 9.10
Transmission
2001
Gearbox
Typ
2001
2 HL 100
2 HL 290
Oil motor
Typ
LMV 100
DMVA 108
km/h
2,5 / 5,0 / 20,0
3,3
3,0
1.50 and 3.32
3.16.2
copyright by
MJFCIFSS
A 316 LI 2001A 316 LI-IND 2001-
Service Manual
Technical data
A 316 Litronic
Transmission
2001
Parking brake
Typ
2001
28061
28062

(negative)
see group 11.10
group 11.20
Axles
2001
2001
28061
28062
Steering axle
Typ
APL-B
755
APL-B
755 HD
MS-E 3060
Rigid axle
Typ
AP-B
755 TR
AP-B
755 HD
MT-E 3060
9,0 (10 l
at disc
brake)
10,0
12,5
2 x 1,0
(2,0 l at
disc brake)
2,0
2,5
9,0
9,5
2 x 2,0
2,5
see groups 1.50

and 3.32
Typ
Typ
Brake type
disc brake
drum brake (option
disc brake)
disc brake
=
disc brake
(positive)
see
groups
12.36 /
12.37 /
12.39
Tyres
Zoll
see
groups
12.41 /
12.42 /
12.44
=
see groups
12.46 / 12.47 /
12.48
10.00 - 20
18.00 - 19,5
600 / 40 - 22,5
=
=
see group 12.54
=
=
Steering
2001
2001
28061
28062
Hydraulic pump
Typ
Gear pump
Flow
l/min
44
Typ
Servostat 2 /
LAGZ 190
LAGZ 190
see group 13.20/

13.24
see group 13.24
Brake system
2001
28061
Hydraulic pump
A 316 LI 2001A 316 LI-IND 2001-
Typ
copyright by
MJFCIFSS
2001
Gear pump
28062
=
3.16.3
Technical data
Service Manual
A 316 Litronic
Brake system
2001
Max. flow
l/min
3.16.4
copyright by
MJFCIFSS
2001
28061
28062
2,0
see group 15.05
A 316 LI 2001A 316 LI-IND 2001-
Service Manual
Technical data
R 317 Litronic
Technical data
1 R 317 Litronic
Type 970/ 362
Valid from serial number 18161
General
R 317 Li
Type 970
R 317
Type 362
Weight of backhoe bucket attachment and 600 mm track pad
17,6
18,7
Overall length
mm
3975
5010
Overall width (500-750mm track pad)
mm
2500.2750
mm
2995
mm
2450
Ground clearance
mm
470
KN
100,6 / 125,7
Max. drawing pull (in offroad gear and max. operating pressure)
KN
151
R 317 Li
Type 970
R 317
Type 362
BF 4 M 1013 EC
86 (115 HP)
Drive motor
Type
kW
-1
Rated speed
min
1800
Max. torque
Nm
491 10
at 1400 min-1
15,5
see group 1.50

and 3.38

Fuel tank capacity
Hydraulic system
Hydraulic pump
Type
Design
290
see group 4.05
R 317 Li
Type 970
R 317
Type 362
DPVO 165
axial piston
swash plate
pump
kW
29
Drive power of pump with power control (max. power)
kW
73
Max. flow
l/min
297
approx. 290
see group 1.50

and 3.38
M7/NG 20-16

Control valve block
Type
MJFCIFSS
3.17.1
Technical data
Service Manual
R 317 Litronic
Hydraulic system
R 317 Li
Type 970
R 317
Type 362
Rotary connection 5-way
Type
DDF 520
Rotary connection 1-way
Type
815.001
Boom cylinder (adjustable and gooseneck equipment) piston /

rod
mm
125 / 70
mm
130 / 80
mm
120 / 80
mm
140 / 80
Type
Gear pump
l/min
36
Type
Gear pump
l/min
43
Type
VG - 7 - 4
Type
5 TH 6 NR
see group 6. / 7.
R 317 Li
Type 970
R 317 Li
Type 362
Electrical system
Operating voltage
24
Battery capacity
Ah
2 x 92 (in series)
V/A
28 / 55
Starter
V / kW
24 / 4,8
R 317 Li
Type 970
R 317 Li
Type 362

Gearbox
Type
SAT 225 / 218
Oil motor
Type
FMF 45
Max. slewing speed
min-1
9.0
4,4
see groups 1.50

and 3.38
Wet multi-disc
brake (negative)
see group 9.10
R 317 Li
Type 970
R 317 Li
Type 362

Slewing gear brake
Type
Travel gear
Gearbox
Type
F40 / FAT 350
FAT 350
Oil motor
Type
A6 VE 55
Travel speed max on slow speed / on fast speed
km/h
1,8 / 6,0
4,5
see groups 1.50

and 3.38
3.17.2
MJFCIFSS
Service Manual
Technical data
R 317 Litronic
Travel gear
Parking brake
Type
Translation
R 317 Li
Type 970
R 317 Li
Type 362
multi-disc brake
see group
11.60 / 11.62
11.65 / 11.67
11.62 /
11.67
R 317 Li
Type 970
R 317 Li
Type 362
B 60 L
Track
bar
Track roller
Type/
Qty
B 60 L / 2 x 7
D6KL 2 x 9
Carier roller
Type/
Qty
B 60 L / 2 x 2
B 60 L / 2 x 3
Quantity of track pads
piece
44
55
Track pad width
mm
500 / 600 / 750 /

900 / 1000
600/ 900 /
1000
Ground pressure
n/cm2
5,0 / 4,3 / 3,5 / 2,7

/ 2,4
3,5 / 2,4 / 2,1
see group 12
MJFCIFSS
3.17.3
Technical data
Service Manual
R 317 Litronic
3.17.4
MJFCIFSS
Service Manual

A 309 Litronic / A 311 Litronic

1 A 309 Litronic / A 311 Litronic
A 309:Typ 717 from serial number 20221
A 311:Typ 718 from serial number. 20222
Customer:
................................
Serial no.:
................................
Type:
................................
Operating hours:
................................
Date:
.............................
Caution!
Careful maintenance can only be carried out when the machine is clean. In particular, visual inspections, such as for cracks, can only be made on a clean machine.
Clean the machine before starting any maintenance work (see also the chapter Maintaining the
machine safely, subheadings Cleaning and Checking for cracks).
Note!
The daily maintenance tasks, which the machine operator has to carry out, include a function check
of the brakes (swing gear, operating and parking brake), steering and the electrical and hydraulic
systems.
Additionally, a visual check must be made for leaks on the engine, hydraulic system, transmission
and axles.
Maintenance /
inspection at
operating hours
WORK TO BE CARRIED OUT

A 309 / A 311 Litronic
By maintenance personnel
(machine operator)
By authorized expert personnel
First and only interval

Repeat interval
Special interval every 250 hours
Note

Repeat interval
DIESEL ENGINE
Check oil level and oil pressure in engine
Check coolant level and coolant temperature
Check air filter via maintenance indicator
Check and drain water separator on fuel filter
Drain off water and sediment on fuel tank
copyright by
MJFCIFSS
3.29.1
Service Manual

Maintenance /
inspection at
operating hours

(machine operator)

Repeat interval
Note

Repeat interval
Empty dust collector on air filter (shorten or extend interval as necessary)

Check and clean cooler, pressure relief valve, coolant hose, fan
Replace lube oil filter cartridge
Replace engine oil
1)
Check oil, cooling and fuel system for leaks and condition
Replace water filter cartridge (at least 1 x annually)
Check and adjust throttle control
Check anti-corrosion fluid / antifreeze in coolant (replace coolant every
2 years)
Check condition and tension of the V-belt (using a testing device at operating
temperature). (Replace every 2 years)
Check / adjust valve clearance
Check engine console and oil sump mounts, clamps etc.
Check flexible fuel leak oil line
(change at least every 2 years)
Check intake system and exhaust system for leaks and for condition
Replace fuel fine filter cartridge (or as necessary)
4)
Replace fuel prefilter cartridge (or as necessary)
4)
Replace main element of air filter (according to maintenance indicator / annually)

Replace safety element of air filter (every third change of main element / annually)
Never
clean!
Check clean air line (during filter maintenance)

Check / adjust injection valves every 3000 hrs. (if performance diminishes)
HYDRAULIC SYSTEM
Check oil level in hydraulic tank
Clean magnetic rod in return filter (daily during first 300 hrs.)
Replace filter element in return filter (first time at 500 hrs.)
Replace filter unit on servo oil unit
Check mounting of components
3.29.2
copyright by
MJFCIFSS
2)
Service Manual

Maintenance /
inspection at
operating hours

(machine operator)

Repeat interval
Note

Repeat interval
Clean hydraulic oil cooler (and as necessary)

Drain off water in hydraulic tank
(when using environmentally friendly fluids, max. 0.1 % part of water permissible, insert bypass filter, take oil sample)
Check hydraulic system for leaks and function
Check / adjust servo, primary and secondary pressures
Replace hydraulic oil in tank (or optimize interval with oil analysis)
2), 3)
Replace breather filters on hydraulic tank
2)
ELECTRICAL SYSTEM
Check indicator lights and displays when turning on
Check lighting
Check acid concentration and level and cable terminals and pole ends on batteries as well as all plug connections
Spray slip rings on rotary connection (if present) with Cramolin contact spray
Check function of entire system and components
SWING GEAR
Check oil level and look for leaks
Check function and action of swing gear brake
Check mounting of gear and oil motor
Replace gear oil (first time at 500 hrs.)
SWING RING
Renew lubrication on gear
Renew lubrication on swing race
Check mounting screws for tight seating and entry of swing gear pinion
TRANSMISSION
Check function of gear shift and parking brake
copyright by
MJFCIFSS
3.29.3
Service Manual

Maintenance /
inspection at
operating hours

(machine operator)

Repeat interval

Repeat interval
Check mounting of transmission, oil motor and drive shafts

AXLES
Check oil level and for leaks, check wheel lugs for tight seating.
Check mounting tightness of axles
Lubricate steering knuckle bearing (weekly / monthly, depending on application)
Replace oil of differential and planetary gear, front and rear (first time at
500 hrs.)
Check wear on multi-disk brake (1 x annually or as necessary)
STEERING
Check for leaks and function
Check mounting tightness of components and steering parts
OSCILLATING AXLE SUPPORT
Check for leaks and function
Check mounting tightness of cylinders
BRAKE SYSTEM
Check system for leaks
Check function and action
Check accumulator and brake pressure as well as control switch
OPERATORS CAB + HEATER
Check / refill washing fluid in windshield washer system container
Check function of heater (before start of winter)
Check heating system for leaks
Check door and window hinges as well as locks
3.29.4
copyright by
MJFCIFSS
Note
Service Manual

Maintenance /
inspection at
operating hours

(machine operator)

Repeat interval
Note

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

Check cover hinges, quick connections and gas cylinders on hoods
Point out appropriate use of attachment
Have machine lubricated according to lubrication schedule by the machine operator and point out any operating errors.
HYDRAULIC QUICK CHANGE ADAPTER
Check function of visual and acoustic warning devices
Check extended position of locking pins visually
copyright by
MJFCIFSS
3.29.5
Service Manual

Maintenance /
inspection at
operating hours

(machine operator)

Repeat interval
Note

Repeat interval
Check condition of hydraulic hoses and of wiring harness

Lubricate locking pins
Clean strainer
MECHANICAL QUICK CHANGE ADAPTER
Tab. 1-1
1
2
3
4
Engine oil change intervals can be shortened depending on temperature, fuel and oil quality.
Observe shortened maintenance intervals in dust intensive application.
When using environmentally friendly hydraulic fluids, the maintenance interval is to be determined by regular analysis.
Shorten the maintenance interval depending on application (e.g. dust intensive application, barrel refuelling).
Comments / defects
Date:
3.29.6
......................................
...
Mechanic: ......................................... Customer: .........................................
copyright by
MJFCIFSS
Service Manual

A 312 Litronic - A 316 Litronic

1 A 312 Litronic - A 316 Litronic
A 312: type 719, starting with serial no. 12363
A 314: type 635, starting with serial no. 2001
A 316: type 715 / 716, starting with serial no. 2001
Customer:
................................
Serial no.:
................................
Machine type:
................................
Operating hours:
................................
Date:
.............................
Caution!
Careful maintenance is only possible, if the machine is clean. Especially visual inspections, e.g. for
cracks can only be carried out properly on a clean machine.
Therefore clean the machine thoroughly before starting any maintenance work (see also chapter
1.10 "Save maintenance of machine", subchapters "Cleaning" and "Crack inspection").
Note!
The daily maintenance tasks of the machine operator include a functional test of the brakes (slewing
gear brake, working brake, parking brake), steering, electrical and hydraulic system.
Also to be carried out are a daily visual inspection of the motor, hydraulic system, gearbox and axles
for leakage.
Maintenance/
inspection at
operating hours

A 312 - A 316 Litronic
by maintenance personnel
(machine operator)
by authorised specialist technician
Initial and single interval

Repeat interval
Special interval: every 250 hours

Repeat interval
Note
DIESEL ENGINE
Check motor oil level and oil pressure
Check coolant level and temperature
Check air filter (maintenance indicator)
Check and drain water separator at the fuel filter
Drain water at fuel tank with bottom settlings
Empty dust collecting container at air filter (shorten or extend interval, if necessary)
copyright by
MJFCIFSS
3.32.1
Service Manual

Maintenance/
inspection at
operating hours

(machine operator)

Repeat interval

Repeat interval
Note
Check and clean cooler, pressure relief valve, coolant hose and fan
Replace lubricating oil filter cartridge
Change engine oil
1)
Check oil, coolant and fuel systems for leakage

Replace water filter cartridge (at least 1 x every 12 months)
Check and adjust speed adjustment
Check corrosion inhibitor and antifreeze agent in coolant (change coolant every 2 years)
Check condition and tension of V-belt; check at operating temperature; use
gauge; replace every two years
Check / adjust valve play (first time after 500 operating hours)
Check motor brackets and oil pan, hose clips etc.
Check flexible fuel leak-oil line
(replace latest every 2 years)
Check intake and exhaust systems for general condition and leaks
Clean or replace the cartridge of the fuel prefilter or Separ prefilter (depending
on filter type); if necessary, clean or replace at shorter intervals
4)
Replace cartridge of the fuel fine filter (shorten interval, if necessary)
4)
Replace air filter main element (based on maintenance indicator / annually)

Replace air filter safety element (at every 3rd replacement of the main element
/ annually)
Check clean air line (during maintenance of filters)
Check / adjust injection nozzles (every 3000 operating hours or in the event of
loss of performance)
HYDRAULIC SYSTEM
Clean magnetic rod in return filter (daily during first 300 operating hours)
Replace return filter cartridge (first time after 500 operating hours)
Replace filter cartridge in control oil unit
Check components for proper mounting
3.32.2
copyright by
MJFCIFSS
2)
Service Manual

Maintenance/
inspection at
operating hours

(machine operator)

Repeat interval

Repeat interval
Note
Clean hydraulic oil cooler (shorten interval, if necessary)

Drain water from hydraulic tank
(max. permissible water content for environmentally friendly fluids: 0.1 %; insert bypass filter, take oil sample)
Check hydraulic system for leakage; complete functional test
Change hydraulic oil in tank (optimise interval by carrying out oil analyses)
2), 3)
Replace breather filter on hydraulic tank
2)
ELECTRICAL SYSTEM
Check indicator lights and indicating devices upon start-up
Check lighting
Check acid density and level, wire terminals and terminal ports of the batteries,
and all the plug connections
Spray slip rights of the slewing gear connection with Cramolin contact spray
Carry out functional tests of entire unit and all components
SLEWING GEAR MECHANISM
Check oil level; check system for leakage
Carry out functional test of slewing gear brake
Check gearbox and oil motor for proper mounting
Change gear oil (first time after 500 operating hours)
SLEWING RING
Replace lubricant of the gearing
Replace lubricant of the ball race
Check mounting bolts for press fit; slewing gear pining meshing
TRANSMISSION
Check oil level; check system for leakage
copyright by
MJFCIFSS
3.32.3
Service Manual

Maintenance/
inspection at
operating hours

(machine operator)

Repeat interval

Repeat interval
Carry out functional test of power shift mechanism and parking brake
Check gearbox, oil motor and joint shafts for proper mounting
Change gear oil (first time after 500 operating hours)
AXLES
Check oil level; check for leaks; check wheel lugs for proper fit
Check axles for proper mounting
Lubricate oscillating axle bearing (weekly or monthly, depending on use)
Lubricate steering knuckle bearing (weekly or monthly, depending on use)
Change oil in axle housing and planetary drives (front and rear) (first time after
500 operating hours)
Check multi-disc brake for wear (1 x every 12 months; shorten interval, if necessary)
STEERING
Check system for leakage; complete functional test
Check components and steering system parts for proper mounting
OSCILLATING AXLE SUPPORT
Check system for leakage; complete functional test
Check cylinders for proper mounting
BRAKE SYSTEM
Check system for tightness
Carry out functional test
Check pressure of accumulator and brakes; check test switches
OPERATOR'S CAB + HEATING
Check / add detergent solution in windscreen washer tank
Carry out functional test of heating system (before start of winter season)
3.32.4
copyright by
MJFCIFSS
Note
Service Manual

Maintenance/
inspection at
operating hours

(machine operator)

Repeat interval

Repeat interval
Note
Check heating system for leakage

Check water inlet valve for contamination, and clean, if necessary; carry out
functional test of valve
AIR-CONDITIONING SYSTEM
Regularly switch on air-conditioning system (at least 1 x every 14 days)
Check condenser for contamination; blow clean, if necessary
Check compressor mounting bolts and drive belts
Check dryer-collector unit (humidity, fill level, condition); replace, if necessary;
replace at least every two years
Clean fresh air filter; clean at least once every month; clean once every week
when operation generates lots of dust
Replace fresh air filter; where operation produces lots of dust, replace more often
Check air condition: proper mounting, hose connections and electric contacts;
check at least once every year
UNDERCARRIAGE + UPPERCARRIAGE + WORKING ATTACHMENTS
Lubricate bearing points of working attachments
Inspect teeth for wear
Lubricate bearing points on undercarriage
Lubricate daily when required due to type of use and/or shift operation
Check counter weight and tank for proper mounting
Check lines and screwed connections for proper fit
Check panelling hinges, quick fasteners and gas pressure springs of the caps
Instruct operators in the proper use of the equipment
Instruct the operator in how the machine must be lubricated according to the
lubricating chart and make him aware of potential operator errors
copyright by
MJFCIFSS
3.32.5
Service Manual

Maintenance/
inspection at
operating hours

(machine operator)

Repeat interval

Repeat interval
Note

Carry out a functional test of the visual and acoustic warning systems
Carry out a visual inspection of the extended locking bolts
Check hydraulic hoses and wire harness
Lubricate locking bolts
Clean mesh filters inside the screwed connections of the hydraulic hoses
Carry out a visual inspection of the extended locking bolts
Lubricate locking bolts
Tab. 1
Note:
1 The intervals for the change of the motor oil might have to be shortened, depending on the actual temperature, fuel
and oil quality.
2 In the case of applications with excessive dust generation, observe shortened maintenance intervals, see group 1.50.
3 For environmentally friendly hydraulic fluids, adjust the maintenance interval on the basis of regular analyses, see
group 1.50.
4 The maintenance intervals might have to be shortened, depending on the operating conditions (e.g. generation of
dust, barrel fuelling).
Comments / defects
Date:
3.32.6
.........................................
copyright by
MJFCIFSS
Service Manual

R 313 Litronic / R 317 Litronic

1 R 313 Litronic / R 317 Litronic
Customer:
................................
Serial no.:
................................
Type:
................................
Operating hours:
................................
Date:
.............................
Caution!
Careful maintenance can only be carried out when the machine is clean. In particular, visual inspections, such as for cracks, can only be made on a clean machine.
Clean the machine before starting any maintenance work (see also the chapter Maintaining the
machine safely, subheadings Cleaning and Checking for cracks).
Note!
The daily maintenance tasks, which the machine operator has to carry out, include a function check
of the brakes (swing gear, operating and parking brake), electrical and hydraulic systems.
Additionally, a visual check must be made for leaks on the engine, hydraulic system, transmission
and axles.
Maintenance /
inspection at
operating hours

(machine operator)

Repeat interval
Note

Repeat interval
DIESEL ENGINE
Check oil level and oil pressure in engine
Check coolant level and coolant temperature
Check air filter via maintenance indicator
Check and drain water separator on fuel filter
Drain off water and sediment on fuel tank
Empty dust collector on air filter (shorten or extend interval as necessary)
copyright by
MJFCIFSS
3.38.1
Service Manual

Maintenance /
inspection at
operating hours

(machine operator)

Repeat interval
Note

Repeat interval
Check and clean cooler, pressure relief valve, coolant hose, fan
Check condition of V-belt
Replace lube oil filter cartridge
Replace engine oil
1)
Check oil, cooling and fuel system for leaks and condition
Replace water filter cartridge (at least 1 x annually)
Check and adjust throttle control
Check engine bracket, oil pan mounting and clamps
Check anti-corrosion fluid / antifreeze in coolant (replace coolant every
2 years)
Check / adjust valve clearance, Renew valve bonnet seal
Check fuel leakage oil line
(replace at least every 2 years)
Check intake system and exhaust system for leaks and for condition
Check glow plugs, change if necessary
Replace fuel fine filter cartridge (or as necessary)
4)
Replace fuel prefilter cartridge (or as necessary)
4)
Replace main element of air filter (according to maintenance indicator / annually)

Replace safety element of air filter (every third change of main element / annually)
Never
clean!
Check clean air line (during filter maintenance)

Replace adjust injection valve (every 3000 operating hours)
HYDRAULIC SYSTEM
Clean magnetic rod in return filter (daily during first 300 hrs.)
Replace filter element in return filter (first time at 500 hrs.)
Replace filter unit on servo oil unit
Check mounting of components
3.38.2
copyright by
MJFCIFSS
2)
Service Manual

Maintenance /
inspection at
operating hours

(machine operator)

Repeat interval
Note

Repeat interval
Clean hydraulic oil cooler (and as necessary)

Drain off water in hydraulic tank
(when using environmentally friendly fluids, max. 0.1 % part of water permissible, insert bypass filter, take oil sample)
Check hydraulic system for leaks and function
Check / adjust servo, primary and secondary pressures
Replace hydraulic oil in tank (or optimize interval with oil analysis)
2), 3)
Replace breather filters on hydraulic tank
2)
ELECTRICAL SYSTEM
Check indicator lights and displays when turning on
Check lighting
Check acid concentration and level and wire terminals and pole ends on batteries and all plug connections
Spray slip rings on rotary connection (if present) with Cramolin contact spray
Check function of entire system and components
SWING GEAR
Check function and action of swing gear brake
SWING RING
Check mounting screws for tight seating and entry of swing gear pinion
TRAVEL GEAR
Check function and effectiveness of travel brake
copyright by
MJFCIFSS
3.38.3
Service Manual

Maintenance /
inspection at
operating hours

(machine operator)

Repeat interval

Repeat interval
TRACK COMPONENTS
Check chain tension visually, retension if necessary
Clean chain (after completion of work)
Check mounting of track pads and sprockets
Clean and grease sliding surfaces of tensioning device
Check for leaks on idlers, carrier and track rollers
OPERATORS CAB + HEATER
Check / refill washing fluid in windshield washer system container
Check function of heater (before start of winter)
Check heating system for leaks
Check water inlet valve for function and dirt, clean if necessary
AIR CONDITIONING SYSTEM
Turn on air conditioning system regularly (at least 1 x every 14 days)
Check condenser for contamination, blow out if necessary
Check mounting screws and compressor drive belt
Check dryer collector unit (moisture, fill and condition), replace if required (at
least every 2 years)
Clean fresh air filter (at least 1 x monthly, weekly for dust intensive use)
Replace fresh air filter (shorten change interval for dust intensive use)
Check mounting of air conditioning system, hose connections and electrical
contacts (at least 1 x annually)
UNDERCARRIAGE + UPPERCARRIAGE + ATTACHMENTS
Visually check wear condition of teeth
Lubrication of bearing points
(depending on application, daily in mult-shift operation)
3.38.4
copyright by
MJFCIFSS
Note
Service Manual

Maintenance /
inspection at
operating hours

(machine operator)

Repeat interval
Note

Repeat interval
Check mounting tightness of counterweight and tank

Check line and screw connections for tight seating
Check cover hinges, quick connections and gas cylinders on hoods
Point out appropriate use of attachment
Have machine lubricated according to lubrication schedule by the machine
operator and point out any operating errors.
Check function of visual and acoustic warning devices
Check condition of hydraulic hoses and of wiring harness
Clean strainer
Tab. 1-1
1
2
3
4
Engine oil change intervals can be shortened depending on temperature, fuel and oil quality.
Observe shortened maintenance intervals in dust intensive application.
When using environmentally friendly hydraulic fluids, the maintenance interval is to be determined by regular analysis.
Shorten the maintenance interval depending on application (e.g. dust intensive application, barrel refuelling).
Comments / defects
copyright by
MJFCIFSS
3.38.5
Service Manual

Date:
3.38.6
......................................
...
copyright by
MJFCIFSS
Service Manual
SUBGROUP - INDEX
Section
Group
Type
Technical data of diesel engines
4.02.1
A 309 LI 20221A 311 LI 20222-
4.03.1
R 313 LI 27752-
4.04.1
A 312 LI 12363-
4.05.1
A 314 LI 2001A 316 LI 2001A 316 LI-IND 2001R 317 LI 18161-
4.1
MJFCIFSS
Service Manual
4.2
MJFCIFSS
Service Manual

Engine type: BF 4 M 2012

1 Engine type: BF 4 M 2012
Installation in machines / from serial no.:
Power according to DIN / ISO 9249
Max. torque (max. engine speed)
A 309-Li / 20221
A 311-Li / 20222
kW
63
67
PS
86
91
Nm
352
371
A 309-Li / 20221
A 311-Li / 20222
Operating data
Design
4-cylinder - turbo
Operating method
4-stroke direct injection
Bore
mm
101
Stroke
mm
126
Displacement
cm
4040
Firing sequence
1-3-4-2
Compression ratio
19 : 1
Combustion pressure at starting speed
bar
30-38
Firing interval
kW
180
Weight (dry)
kg
360
Direction of rotation (seen from flywheel)
left
Flywheel housing
SAE 4
Cooling system
Recirculation cooling
Speed range
A 309-Li / 20221
A 311-Li / 20222
2000
2000
Rated speed
min-1
High idle rpm
min-1
Low idle rpm
min
-1
Lowest operating speed
min-1
1000
-1
1500
Speed at max, engine speed
min
Settings
Inlet valve play (cold)
Outlet valve play (cold)
Begin of delivery
+40
2100 +50
+100
850 +100
2100
850
A 309-Li / 20221
mm
A 311-Li / 20222
0,30
mm
0,50
CA before
TDC
see type plate
copyright by
MJFCIFSS
4.02.1
Service Manual
Engine type: BF 4 M 2012

Filling volumes (approx. values)
A 309-Li / 20221
Lubricating oil in standard oil pan
A 311-Li / 20222
max. 8,5 / min. 7,0
Lubricating oil system (filter / cooler / channels)
10,0
Filling volumes (for oil change with filter replacement)
15,5
Cooling liquid including coolant
15,5 (Engine alone 9,3)
Operating data
A 309-Li / 20221
A 311-Li / 20222
Coolant temperature
110 max.
Thermostat opening temperature
87 -103
Pressure in cooling system
bar
min. 1.4 in engine at operating temperature

(coolant temperature > 110C), measured at
coolant pump outlet (connection to heating)
at nominal engine speed
Lubricating oil temperature
max. 140
Min. lubricating oil pressure
Injection nozzles
DLLA 151PV3 190588
Injection pressure of injection nozzles:

new
at end of service life (3000 operating hours)
220 +8
at least 198 +8
bar
bar
Max. engine inclination towards right or left
right 45 / left 35
Max. engine inclination towards front or rear
30
Engine wear parts
A 309-Li / 20221
A 311-Li / 20222
Fuel filter
1 unit
10 m prefilter
Fuel filter
1 unit
3 m fine filter
Oil filter
1 units
Air filter
1 unit
1 unit
Main element
Safety element
V-belt
2 unit
8PK 1850 NDIN 7867

8PK 1850 NDIN 7867
Safety device: oil pressure sensor
1 unit
B16 Response pressure: 0.5 bar
Coolant temperature sensor
1 unit
B2 Response temp. 100 3C
Coolant level sensor
1 unit
B3
For order numbers, see respective spare parts list and service packs
Antifreeze agent /
mixing ratio
Min. temperature for

protection
Water content
Antifreeze content
-37C
50%
50%
Note!
Do not exceed an antifreeze concentration of 60%, as this tends to lead to reduced protection and
cooling effect!
4.02.2
copyright by
MJFCIFSS
Service Manual

Engine Type: BF 4 M 2012 C

1 Engine Type: BF 4 M 2012 C
R 313-Li / 27752
kW
PS
99
Speed at max. (engine speed)
Nm
422 (1500 rpm)
Operating data
73
R 313-Li / 27752
Design
4-cylinder turbo, intercooled
Type
Bore
mm
101
Boom
mm
126
Displacement
cm3
4038
Firing sequence
1-3-4-2
Compression ratio
19 : 1
bar
Firing interval
kW
180
Weight (dry)
kg
380
30 - 38
left
Flywheel housing
SAE 4
Cooling system
Recirculation cooling
Speed range
R 313-Li / 27752
Rated speed
rpm
1800
High idle rpm
rpm
1900 +40
Low idle rpm
rpm
850 +100
rpm
1000
Speed at max. torque
rpm
1500
Settings
R 313-Li / 27752
mm
0.30
mm
0.50
CA before
TDC
see type plate
Begin of delivery
copyright by
MJFCIFSS
4.03.1
Service Manual

R 313-Li / 27752
max. 8.5 / min. 7.0
Lubricating oil system (filter / cooler / channels)
10.0
14.0
15.5 (motor only: 9.3)
Operating data
R 313-Li / 27752
Coolant temperature
110 max.
Opening temperature of Thermostat (control range)
87 - 103
Pressure in cooling system
bar
min. 1.4 in engine at operating temperature (coolant

temperature > 110C),
measured at coolant pump
outlet (connection to heating)
at nominal engine speed
Lubricating oil temperature
max. 140
bar
at approx. 900 rpm 0.8 bar

(oil temp. 120 C)
Injection nozzles
DLLA 151PV3 190588

New
after 3000 operating hours
220 +8
min. 198 +8
bar
bar
Max. engine inclination to
right 45 / left 35
Max. engine inclination towards front or rear
30
Engine wear parts, V-belts and safety devices
R 313-Li / 27752
Fuel filter
Coarse filter 10 m
Fuel filter
Fine filter 3 m
Oil filter
Air filter
1
1
V-belt
8PK 1850 NDIN 7867
B 16 response pressure: 0.5

bar
B2 response temperature
100 3C
B3
Main element
Safety element
Antifreeze agent /
mixing ratio
4.03.2
Antifreeze content
Water content
Antifreeze content
-37C
50%
50%
copyright by
MJFCIFSS
Service Manual

Note!
cooling effect!
copyright by
MJFCIFSS
4.03.3
Service Manual
4.03.4
copyright by
MJFCIFSS
Service Manual

Engine type: BF 4 M 1013 E

1 Engine type: BF 4 M 1013 E
A 312-Li / 12363
kW
74
HP
100.7
Nm
422
Operating data
A 312-Li / 12363
Design
4-cylinder - turbo
Type
Bore
mm
108
Stroke
mm
130
Displacement
4764
cm
Firing sequence
1-3-4-2
Compression ratio
17.5 : 1
bar
30 - 38
Firing interval
kW
180
Weight (dry)
kg
430 (according to DIN 70020 - A)
left
Flywheel housing
SAE 4
Cooling system
liquid-cooled
Speed range
A 312-Li / 12363
Rated speed
rpm
1800
High idle rpm
rpm
1900 +30
Low idle rpm
rpm
850 +100
rpm
1000
rpm
1400
Settings
A 312-Li / 12363
mm
0.30
mm
0.50
CA before
TDC
Preset by manufacturer and specified on type

plate
Begin of delivery
copyright by
MJFCIFSS
4.04.1
Service Manual
Engine type: BF 4 M 1013 E

A 312-Li / 12363
11
approx. 15.5
approx. 19 (7.2 l in engine + 11.5 l in radiator

and lines)
Operating data
A 312-Li / 12363
Max. lubricating oil temperature
130 (in oil pan)
bar
0.8 (at oil temperature of 120 C)
Safety valve of lubricating oil pump
bar
5.25 - 6.75

new
bar
bar
250 +12
245 +12
30
Max. engine inclination towards fan / flywheel
30
A 312-Li / 12363
Fuel filter
Coarse filter 10 m
Fuel filter
Fine filter 3 m
Oil filter
Air filter
1
1
Main element
Safety element
V-belt
1
1
10 x 874
10x1050
B 16 response pressure: 0.5 bar
B2 response temperature 100 3C
B3
Antifreeze agent /
mixing ratio
Antifreeze content
Water content
Antifreeze content
-37C
50%
50%
Note!
cooling effect!
4.04.2
copyright by
MJFCIFSS
Service Manual

Tightening torques / oversize levels
2 Tightening torques / oversize levels

Installation in models / serial no.:
A 312-Li / 12363
Screw tightening torque:

Screwed connections
Tightening instructions
Cylinder head
General notes
1. stage
Pre-tighten with 50 Nm
2. stage
130 Nm
3. stage
90 degrees
According to tightening sequence
Pre-tighten with 30-40 Nm
Apply a little oil to the screw

thread and head surface
Screw for V-belt pulley

1. retightening angle
60 degrees
2. retightening angle
60 degrees
Flywheel
1. stage
60 degrees
2. stage
60 degrees
Oversize levels / limit values


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

Annular groove
Double-tapered groove
Height of 1st ring groove
mm
2.0 + 0.1
+ 0.08
Height of oil ring groove
mm
3.5 + 0.04
+ 0.02
1. stage
- (double-tapered groove)
mm
0.17
Axial play of piston ring

1. Limit of play of compression ring
Limit of play of compression ring
copyright by
MJFCIFSS
4.04.3
Service Manual

Limit of play of grooved piston ring
mm
0.10
Piston ring gap
4.04.4
Limit value of 1st compression ring
mm
max. 0.8
Limit value of 2nd compression ring
mm
max. 2.5
Limit value of grooved piston ring
mm
max. 1.5
copyright by
MJFCIFSS
General notes
Service Manual

Engine type: BF 4 M 1013 EC

1 Engine type: BF 4 M 1013 EC
A 314-Li / 2001
A 316-Li / 2001
R 317 Li / 18161
86
kW
82
PS
109
115
Nm
458
491
A 314-Li / 2001
A 316-Li / 2001
R 317 Li / 18161
Operating data
Design
4-cylinder turbo, intercooled
Type
Bore

mm
108
Stroke
mm
130
Displacement
cm3
4767
Firing sequence
1-3-4-2
Compression ratio
17.5 : 1
bar
30 - 38
Firing interval
kW
180
Weight (dry)
kg
430 (according to DIN 70020 - A)
left
Flywheel housing
SAE 4
Cooling system
liquid-cooled
Speed range
A 316-Li / 2001
R 317 Li / 18161
A 314-Li / 2001
Rated speed
min-1
High idle rpm
min
-1
1900 +30
Low idle rpm
min-1
850 +100
min-1
1000
min-1
1400
Settings
1800
A 316-Li / 2001
R 317 Li / 18161
A 314-Li / 2001
mm
0,30
mm
0,50
CA before
TDC
Preset by manufacturer and specified on type

plate
Begin of delivery
copyright by
MJFCIFSS
4.05.1
Service Manual
Engine type: BF 4 M 1013 EC
A 316-Li / 2001
R 317 Li / 18161
A 314-Li / 2001
11
approx. 15,5
approx. 25 (13.5 l in engine + 11.5 l in radiator

and lines)
Operating data
A 316-Li / 2001
R 317 Li / 18161
A 314-Li / 2001
Max. lubricating oil temperature
125 (in oil pan)
bar
0.8 (at oil temperature of 120 C)
Safety valve of lubricating oil pump
bar
5.25 - 6.75

new
bar
bar
250 +12
245 +12
30
Max. engine inclination towards fan / flywheel
30
A 316-Li / 2001
R 317 Li / 18161
A 314-Li / 2001
Fuel filter
Coarse filter 10 m
Fuel filter
Fine filter 3 m
Oil filter
Air filter
1
1
Main element
Safety element
V-belt
1
1
10 x 874
10x1050
B 16 response pressure: 0.5 bar
B2 response temperature 100 3C
B3
Antifreeze agent /
mixing ratio
Antifreeze content
Water content
Antifreeze content
-37C
50%
50%
Note!
cooling effect!
4.05.2
copyright by
MJFCIFSS
Service Manual

2 Tightening torques / oversize levels

A 314-Li / 2001
A 316-Li / 2001
R 317-Li / 18161
Installation in models / serial no.:
Screw tightening torque:

Screwed connections
Cylinder head
General notes
1st stage
2nd stage
130 Nm
3rd stage
90 degrees
According to tightening sequence
Pre-tighten with 30-40 Nm

Screw for V-belt pulley

1st retightening angle
60 degrees
2nd retightening angle
60 degrees
Flywheel
1st stage
60 degrees
2nd stage
60 degrees


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

Annular groove
Double-tapered groove
Height of 1st ring groove
mm
2.0 + 0.1
+ 0.08
Height of oil ring groove
mm
3.5 + 0.04
+ 0.02
copyright by
MJFCIFSS
4.05.3
Service Manual

Axial play of piston ring

Limit of play of 1st compression ring
1st stage
- (double-tapered groove)
Limit of play of compression ring
mm
0.17
Limit of play of grooved piston ring
mm
0.10
Piston ring gap
4.05.4
Limit value of 1st compression ring
mm
max. 0.8
Limit value of 2nd compression ring
mm
max. 2.5
Limit value of grooved piston ring
mm
max. 1.5
copyright by
MJFCIFSS
General notes
Service Manual
SUBGROUP - INDEX
Section
Group
Type
Coupling
5.05.1
A 309 LI 20221A 311 LI 20222-
Clutch
5.10.1
A 312 LI 12363A 314 LI 2001A 316 LI 2001A 316 LI-IND 2001R 317 LI 18161-
5.1
MJFCIFSS
Service Manual
5.2
MJFCIFSS
Service Manual
Coupling
Function
Coupling
1 Function
The flexible coupling (torsion dampers) are installed between the diesel engine and the variable displacement pump and dampens torque impacts in the event of load changes.
It is a permanent coupling and thus transmits the motor torque directly and continuously to the pump.
Decoupling is not possible.
Fig. 1
Coupling built into motor
copyright by
MJFCIFSS
5.05.1
Coupling
Service Manual
Design and function of coupling
2 Design and function of coupling

The flexible element 4 of the coupling 1 is fixed with screws to the flywheel 10 of the diesel engine.
The four metal segments 3 of the internally toothed hub 2 are connected to the drive shaft of the double variable displacement pump 20.
The segments 3 are aligned in a circle and mesh in the tooth spaces of the specially formed flexible
element 4, thus positively connecting the coupling sections with each other, allowing for limited flexibility.
The power from the diesel engine is applied to the double variable displacement pump 20 through
the flywheel 10, the mounting bolts 7, the flexible element 4, the segments 3 and the hub 2 to the
pump's drive shaft 20.
Torque impacts upon start-up of the diesel engine and load fluctuations are thus compensated, as
the flexible element is deformed at the moment of impact and subsequently released.
Rotational vibration from the engine is also significantly dampened so that the pump 20 is only marginally affected.
Fig. 2
5.05.2
Fitting position of the coupling1
Coupling, complete (torsion damper)
10
Flywheel
2
3
Hub
Segment
11
20
Engine intermediate housing

Double variable-displacement pump
4
5
Flexible element
Allen head screw
22
24
Retaining washer
Hex head screw
Allen head screw
copyright by
MJFCIFSS
Service Manual
Coupling
Installation and dismantling of the coupling
3 Installation and dismantling of the coupling

3.1
Dismantling
Secure the variable-displacement pump 20 using a rope.
Remove the Allen head screws 24 and the washers 22.
Remove the flange-mounted double variable displacement pump 20 from the intermediate housing 11 of the diesel engine and pull it together with the hub 2 from the flexible element 4.
Note!
Before dismantling the coupling 1, note the position of the hub 2 at the drive shaft of the double variable displacement pump 20 and of the flexible element 4 at the flywheel 10.
Remove the Allen head screws 5.
Pull the hub 2 from the drive shaft of the variable displacement pump 20.
Remove the hex head screws 7 and disconnect the flexible element 4 from the flywheel 10.
3.2
Installation
Caution!
Screws that are tightened with less than the prescribed torque might become loose and can seriously damage the coupling. Always tighten all screws with a torque wrench and apply the prescribed
torque!
Grease the drive shaft of the double variable displacement pump 20 with LIEBHERR CTK special
lubricant, see group 1.50.
Push the hub 2 onto the spline mesh section to the collar of the pump drive shaft (for correct position, see Fig. 3).
Tighten the attachment screw 5 (tightening torque 70 Nm).
Place the flexible element 4 in the correct position, see Fig. 3, onto the flywheel 10.
Tighten the Allen screws 7 (tightening torque 50 Nm).
Check the flexible element 4 for concentricity at outer edge (tolerance = 0.1 mm).
Check the surface of the flexible element 4 for side-to-side wobble (tolerance = 0.05 mm).
Push the drive shaft of the double variable displacement pump 20 with the mounted hub 2 into the
flexible element 4 and position it on the engine intermediate housing 11.
Insert and tighten the hex head screws 24 with retaining washers 22 (tightening torque 68 Nm).
7
Coupling, complete (torsion damper)
10
Flywheel
Hub
11
Engine intermediate housing
Segment
20
4
5
Flexible element
Allen head screw
22
24
Retaining washer
Hex head screw
Allen head and hex head screw
copyright by
MJFCIFSS
5.05.3
Coupling
Service Manual
Fig. 3
5.05.4
Sectional drawing showing position and alignment of the coupling
copyright by
MJFCIFSS
Service Manual
Clutch
Design and function of coupling
Clutch
1 Design and function of coupling
see Fig. 1 and Fig. 2
The flexible coupling (torsion dampers) 5 is mounted between the diesel engine and the variable-displacement pump. It dampens impacts caused by torque and load changes.
It is a permanent coupling and thus transmits the motor torque directly and continuously to the pump.
Decoupling is not possible.
Disk 5.1 is connected with bolts to the flywheel C of the diesel engine. The hub 5.2 is guided axially
by circular disks 5.3 that are riveted onto hub 5.2.
The hub 5.2 can be moved radically on disk 5.1. Eight pressure springs 5.4 mounted on the reference
circle provide a non-positive flexible connection between the disks 5.3 and the hub 5.2.
The drive shaft 10.10 of the variable-displacement pump 10 is connected by means a spline mesh to
the hub 5.2 of the torsion damper 5 (positive connection).
The transmission of power from the diesel engine to the pump 10 consists of the flywheel C, the
mounting bolts 7, the disk 5.1, the pressure springs 5.4, the hub 5.2 with the disks 5.3 and the drive
shaft 10.10 of the pump 10.
Torque impacts upon start-up of the diesel engine and load fluctuations are thus compensated, as
the pressure springs 5.4 are compressed at the moment of impact and subsequently released.
The rotational vibration from the engine is also significantly dampened so that the pump 10 is only
marginally affected.
copyright by
MJFCIFSS
5.10.1
Clutch
Service Manual
Fig. 1
Installation position of coupling 5 (a = A 312 - 316, b = R 313 / R 317)
Coupling (torsion damper)
80
Holder
7
10
Allen head / hex head screw

Variable-displacement pump
81
Allen head screw
11
12
Allen head screw

Allen head / hex head screw
C
D
Flywheel
Intermediate housing / engine
2 Installation and dismantling of the coupling

(see Fig. 2 on page4)
2.1
Dismantling
Secure the variable-displacement pump 10 using a rope.
Remove the screws 11 and 81.
Remove the hex retaining washers 12.
Disconnect the flange connection between the variable-displacement pump 10 and the intermediate housing B of the diesel engine, and pull the pump from the coupling 5.
Note and mark the installation position of the coupling 5.
Remove the mounting bolts 7.
Remove the coupling 5 from the flywheel C of the diesel engine.
5.10.2
copyright by
MJFCIFSS
Service Manual
Clutch
2.2
Installation
Note!
Note!
Incorrect installation might destroy the coupling 5 due to insufficient engagement of the spine mesh
of the hub 5.2 and the drive shaft 10.10 of the pump.
Check position A of the installed coupling (see sectional drawing, see Fig. 2).
Mount the coupling 5 in its correct installation position, see Fig. 2, on the flywheel C.
Screws that are tightened with less than the prescribed torque might become loose and can seriously damage the coupling.
Tighten all screws with the prescribed torque, using a torque spanner!
Tighten Allen screws 7 (tightening torque 46 Nm).
Check the hub 5.2 for concentricity at outer edge (tolerance = 0.1 mm).
Check the surface of the coupling 5 for side-to-side wobble (tolerance = 0.05 mm).
Apply a little Liebherr CTK special paste onto the spine mesh of the pump drive shaft and the hub
5.2, see group 1.50.
Slide the drive shaft 10.10 of the pump into the hub 5.2 and mount the pump 10 on the intermediate housing D.
Screw in the Allen head screws 11 / 81 with the retaining washer 12 and the Allen head screws
81 with the retaining washer 12 and the holder 80, see Fig. 2, (tightening torque 46 Nm).
copyright by
MJFCIFSS
5.10.3
Clutch
Service Manual
Fig. 2
5
5.1
5.10.4
Sectional drawing showing position and alignment of the coupling

Coupling (torsion damper)
Washer
11
12
Allen head screw

Retaining washer
81
Allen head screw
5.2
Hub
5.3
Washers
5.4
Pressure spring
Correct position and alignment of the

coupling
Allen head screw
Incorrect position and alignment of the

coupling
copyright by
MJFCIFSS
Service Manual
Clutch
10
10.10
C
D
Pump drive shaft
copyright by
MJFCIFSS
Flywheel / engine
Intermediate housing / engine
5.10.5
Clutch
Service Manual
5.10.6
copyright by
MJFCIFSS
Service Manual
SUBGROUP - INDEX
Section
Group
Type
Adjustment protocol
6.09.1
A 309 LI 20221-27109
Adjustment protocol
6.09.11
A 309 LI 27110-
Adjustment protocol
6.11.1
A 311 LI 20222-27111
Adjustment protocol
6.11.11
A 311 LI 27112-
Adjustment protocol
6.12.1
A 312 LI 12363-
Adjustment protocol
6.13.1
R 313 LI 27752-
Adjustment protocol
6.14.1
A 314 LI 2001-
Adjustment protocol
6.16.1
A 316 LI 2001A 316 LI-IND 2001-
Adjustment protocol
6.17.1
R 317 LI 18161-
LSC system
6.20.1
Design of hydraulic system
6.22.1
A 309 LI 20221A 311 LI 20222-
Layout of hydraulic system
6.24.1
6.27.1
R 313 LI 27752R 317 LI 18161-
Adjustment guidelines for hydraulic system
6.30.1
A 309 LI 20221A 311 LI 20222-
6.34.1
A 312 LI 12363A 314 LI 2001A 316 LI 20016.1
MJFCIFSS
Service Manual
6.37.1
R 317 LI 18161-
Hydraulic system
6.40.1
A 309 LI 20221-23502
A 311 LI 20222-23506
Hydraulic system
6.40.11
A 309 LI 23503-27109
A 311 LI 23507-27111
Hydraulic system
6.40.21
A 309 LI 27110A 311 LI 27112-
Hydraulic system
6.42.1
A 312 LI 12363-13288
Hydraulic system
6.42.13
A 312 LI 13289-29897
Hydraulic system
6.42.21
A 312 LI 29898-
Hydraulic system
6.43.1
R 313 LI 27752-
Hydraulic system
6.44.1
A 314 LI 2001-11146
A 316 LI 2001-11151
A 316 LI-IND 2001-11151
Hydraulic system
6.44.13
A 314 LI 11147-13103
A 316 LI 11152-13104
A 316 LI-IND 11152-13104
Hydraulic unit
6.44.21
A 314 LI 13104A 316 LI 13105-28060

A 316 LI-IND 13105-28060
Hydraulic unit
6.44.31
A 316 LI 28061A 316 LI-IND 28061-
Hydraulic unit
6.47.1
R 317 LI 18161-21204
Hydraulic unit
6.47.11
R 317 LI 21205-
6.2
MJFCIFSS
Service Manual
Adjustment protocol
A 309 Litronic from 20221
Adjustment protocol
1 A 309 Litronic from 20221
Date:
.........................................
Mechanic:
.........................................
Customer:
Type:
.........................................
Series no.:
.........................................
Operating hours: .....................................
Checks
Measuring
point
Specified
value
1.
Operating conditions - warming up
1.1
Oil temperature
min. 50 +10C
1.2
Regulating rpm
2000 min-1
1.3
Max. speed
2100 +50min-1
1.4
Min. speed
770 +50min-1
2.
Pilot pressure
Test point 49
32
Actual
value
Possible
Setting.
.....................................
....
View
Comment
Set measure at valve 51.
bar
A 309 LI 20221-27109
copyright by
MJFCIFSS
6.09.1
Adjustment protocol
Service Manual
Checks
3.
Horsepower control
3.1
at speed level 1 (low idle

rpm)
3.2
3.3
6.09.2
Measuring
point
Specified
value
Actual
value
Possible
Setting.
using adapter cable at Y50.
Measuring
point 59
( X3 )
Current
850 +25 mA
Control pressure LR
30 1 bar
View
Comment
at power test
Remove plug of Y50. Set valve to
emergency setting. (Remove cotter
pin and actuate lever.)
Current
<50mA
Control pressure LR
1 bar
(tank pressure)
Checking regulating pressure for emergency operation
Measuring
point 59
30 1 bar
A 309 LI 20221-27109
copyright by
MJFCIFSS
Service Manual
Adjustment protocol
Checks
4.
Checking
Function Y51
4.1
Current
200 - > 900 mA
via speed steps
or flow reduction kit
5.
Checking
Flow reduction of pump
P1
5.1
Value X
Measuring
point
Specified
value
Actual
value
Possible
Setting.
View
Comment
Take measure using adapter cable
at Y51.
Measuring
point 57
( X1)
Pressure: see
Diagram
up to pump no. 20194344
9,3 0.2 mm
starting with pump no.

20194345
12,4 0.2 mm
A 309 LI 20221-27109
copyright by
MJFCIFSS
6.09.3
Adjustment protocol
Service Manual
Checks
Measuring
point
Specified
value
6.
Begin of hydraulic regulation of double variabledisplacement

Pump
(basic setting)
Measuring
point 40/41
6.1
Pump P1
Primary pressure relief valve 120
(extend bucket cylinder)
reduce below begin of regulation, turn in until
actuating pressure at 43 rises to 10 bar
50 2 bar
Actual
value
Possible
Setting.
View
Comment
Speed - low (about 1,200 min-1)
Y50 / Y51 not active
Y50 in emergency position (30 bar
at measuring point 59)
Adjust using screw 1 on pump regulator
10 bar
(for auxiliary control block,

AHS ) valve 122 is in charge
6.2
Pump P2
(retract support cylinder)
actuating pressure at 44 at
50 2 bar
10 bar
Re-connect plug on Y 50 and Y51.

Return Y50 to normal position
6.09.4
A 309 LI 20221-27109
copyright by
MJFCIFSS
Service Manual
Adjustment protocol
Checks
7.
Checking power of the

diesel engine
(power test)
Note:
Perform this check only
when necessary (e.g.
when you detect reduced
engine performance.
Measuring
point
Specified
value
Actual
value
Possible
Setting.
View
Comment
High idle rpm
Measuring
point 41
max. fan speed

2150 min-1 approx.
Pull out plug (I = 0 mA).
Disconnect Y50
and/or launch menu power
test on your laptop
Reduce primary relief valve 120 / 121 (retract stick
cylinder) below test pressure. Turn back in until you
reach test pressure again.
Be careful not to lower diesel engine speed below rated speed. (Check diesel
speed at B12).
Pump at Qmax
Control chamber
( < 50mA)
100 bar
(each pump)
2000 +10min-1
Measuring
points 41 and
44
= tank pressure
A 309 LI 20221-27109
copyright by
MJFCIFSS
6.09.5
Adjustment protocol
Service Manual
Checks
8.
Secondary pressure
Primary pressure relief valve 120 /
121 screwed in
Measuring
point
Specified
value
Actual
value
Possible
Setting.
View
Comment
Measuring
point 40
at upper idle speed
8.1
Operational functions
- extend adjusting cylinder
380 +20 bar
Valve 129
- retract adjusting cylinder
380 +20 bar
Valve 130
- extend control cylinder
380 +20 bar
Valve 131
- retract control cylinder
380 +20 bar
Valve 132
- extend bucket cylinder
380 +20 bar
Valve 133
- retract bucket cylinder
380 +20 bar
Valve 134
Measuring
point 41
8.2
6.09.6
- retract stick cylinder
380 +20 bar
Valve 127
- extend stick cylinder
380 +20 bar
Valve 128
Travel function
Measuring
point 41
- Travel forward
380 +20 bar
Valve 214
- Travel reverse
380 +20 bar
Valve 215
A 309 LI 20221-27109
copyright by
MJFCIFSS
Service Manual
Adjustment protocol
Checks
9.
10.
Measuring
point
Specified
value
Primary pressure / high

pressure
Measuring
point 40
Primary relief valve 120

Retracting bucket cylinder
350 +10 bar
(with accessory kit AHS11

/ AHS 12
via hammer starting function; see kit
group 16.)
Measuring
point 40

Retracting support cylinder
350 +10 bar
Primary pressure / low

pressure
Measuring
point 45
110 +20 bar
Actual
value
Possible
Setting.
View
Comment
High idle rpm
350 +10 bar

Measuring
point 41
High idle rpm
Extending swivel cylinder
A 309 LI 20221-27109
copyright by
MJFCIFSS
6.09.7
Adjustment protocol
Service Manual
Checks
11.
Slewing gear function

secondary pressure
11.1
Turning
11.2
Actual
value
Possible
Setting.
View
Comment
Measuring
points
197/198
Turning right
197
200 +10 bar
Valve 191
(high pressure setting)
Lock nut 1
Adjusting screw 2
Turning left
198
200 +10 bar
Valve 192
Lock nut 1
Adjusting screw 2
198
70 5 bar
Valve 192
(low pressure setting)
Lock nut 3
Adjusting screw 4
197
70 5bar
Valve 191
Lock nut 3
Adjusting screw 4
Slowing down
Turning right
Turning left
6.09.8
Measuring
point
Specified
value
A 309 LI 20221-27109
copyright by
MJFCIFSS
Service Manual
Adjustment protocol
Checks
12.
Travel motor
12.1
Regulation
Begin of regulation
End of regulation
12.2
Measuring
point
Specified
value
Actual
value
Possible
Setting.
View
Comment
Adjusting screw 213.1
on travel motor 210
Measuring
point
40 / M
240 bar
340 bar
Output speed
(speed)
Standard machine
1500 25 min-1
Speeder machine
1930 25 min-1
on drive shaft, measured during onroad gear

Qmin stop screw 212.1
Checking measurement
Y
Standard machine
23.8 mm
Speeder machine
26.0 mm
A 309 LI 20221-27109
copyright by
MJFCIFSS
6.09.9
Adjustment protocol
Service Manual
Checks
13.
Measuring
point
Specified
value
Lowering speed
of equipment
4 seconds approx.
Checking measurement Z
of stop screw 162
5 mm
14.
Hydrostatic fan drive
14.1
Checking the fan speed

Check speed while diesel
engine runs at rated
speed. Disconnect Y352.
Actual
value
Possible
Setting.
View
Comment
2150 +50min-1
Hydraulic oil temperature >

should be 50C when checking fan speed.
Danger!
Moving fan blades can cause serious injury to fingers and hands.
Before working near the fan, switch off the engine.
6.09.10
A 309 LI 20221-27109
copyright by
MJFCIFSS
Service Manual
Adjustment protocol
A 309 Litronic from 27110 (applicable from software version 5.12)
Adjustment protocol
2 A 309 Litronic from 27110 (applicable from software version 5.12)
Date:
.........................................
Mechanic:
.........................................
Customer:
.........................................
Type:
.........................................
Series no.:
.........................................
Operating
hours:
.........................................
Checks
Measuring point
Specified value
1.
Operating conditions warming up
1.1
Oil temperature
min. 50 +10C
1.2
1.2.1
1.2.2
Regulating rpm
during work
with servo OFF (on-road
travel)
1800 rpm
1950 rpm
1.3
1.3.1
1.3.2
1.4
Max. speed
during work
travel)
Min. speed
2.
Pilot pressure
Actual
value
Possible
Setting.
View
Comment
1950 +40 rpm

2100 +50 rpm
770 +50 rpm

Measuring
point 49
32 1 bar
3.
Horsepower control
3.1

rpm)
3.2
3.3
Measuring
point 59
( X3 )
Current
850 +25 mA
Control pressure LR
30 1 bar
at power test
Current
<50mA
Control pressure LR
1 bar
(tank pressure)
Measuring
point 59
30 1 bar
Remove plug of Y50.

Set valve to emergency setting.
(Remove cotter pin and actuate lever.)
Diagram, see page 12.
MJFCIFSS
6.09.11
Adjustment protocol
Service Manual
Checks
4.
Checking
function Y51
4.1
Current
200 - > 900 mA
via speed steps
5.
Checking
flow reduction of pump
P1
5.1
Value X
6.09.12
Measuring point
Specified value
Actual
value
Possible
Setting.
View
Comment
at Y51.
Measuring
point 57
( X1)
Pressure: see
diagram
12,4 0.2 mm
MJFCIFSS
Service Manual
Adjustment protocol
Checks
Measuring point
Specified value
6.
Begin of hydraulic regulation of double variable-displacement

Pump
(basic setting)
Measuring
point 40/41
6.1
Pump P1
Primary pressure relief
valve 120
actuating pressure at 43
rises to 10 bar
50 2 bar
Actual
value
Possible
Setting.
View
Comment
Speed - low (about 1,200 rpm)
10 bar

6.2
Pump P2
valve 121
50 2 bar
10 bar

MJFCIFSS
6.09.13
Adjustment protocol
Service Manual
Checks
7.

diesel engine
(power test)
Note:
engine performance.
Measuring point
Specified value
Actual
value
Possible
Setting.
View
Comment
High idle rpm
Measuring
point 40/41
max. fan speed

2150 rpm approx.
Disconnect Y50
and/or launch menu power test on your laptop
cylinder) below test pressure. Turn back in until
you reach test pressure
again. Be careful not to lower diesel engine speed
below rated speed.
(Check diesel speed at
B12).
Pump at Qmax.
Control chamber
6.09.14
( < 50mA)
100 bar
(each pump)
1800 +10rpm
Measuring
point 43/44
= tank
pressure
MJFCIFSS
Service Manual
Adjustment protocol
Checks
8.
Secondary pressure
valve 120 /
121 screwed in
Measuring point
Specified value
Actual
value
Possible
Setting.
View
Comment
Measuring
point 40
at upper idle speed
8.1
380 +20 bar
Valve 129
380 +20 bar*
Valve 130
380 +20 bar
Valve 131
380 +20 bar
Valve 132
380 +20 bar
Valve 133
380 +20 bar
Valve 134
Measuring
point 41
380 +20 bar
Valve 127
380 +20 bar
Valve 128
* adjustment to 240 bar + 1
revolution of adjusting screw = 380
bar
MJFCIFSS
6.09.15
Adjustment protocol
Service Manual
Checks
8.2
9.
6.09.16
Measuring point
Specified value
Actual
value
Possible
Setting.
View
Comment
Travel function
Measuring
point 41
- Travel forward
380 +20 bar
Valve 214
- Travel reverse
380 +20 bar
Valve 215

pressure
Measuring
point 40
High idle rpm

350 +10 bar

/ AHS 12
group 16.)
Measuring
point 40

350 +10 bar
350 +10 bar

Measuring
point 41
MJFCIFSS
Service Manual
Adjustment protocol
Checks
10.
Measuring point
Specified value

pressure
Measuring
point 45
110 +20 bar
Actual
value
Possible
Setting.
View
Comment
High idle rpm
MJFCIFSS
6.09.17
Adjustment protocol
Service Manual
Checks
11.

secondary pressure
11.1
Turning
11.2
Actual
value
Possible
Setting.
View
Comment
Measuring
points
197/198
Turning right
197
200 +10 bar
Valve 191
Lock nut 1
Adjusting screw 2
Turning left
198
200 +10 bar
Valve 192
Lock nut 1
Adjusting screw 2
198
70 5 bar
Valve 192
Lock nut 3
Adjusting screw 4
197
70 5bar
Valve 191
Lock nut 3
Adjusting screw 4
Slowing down
Turning right
Turning left
6.09.18
Measuring point
Specified value
MJFCIFSS
Service Manual
Adjustment protocol
Checks
12.
Travel motor
12.1
Regulation
Begin of regulation
End of regulation
12.2
Measuring point
Specified value
Actual
value
Possible
Setting.
View
Comment
on travel motor 210
Measuring
point
40 / M
240 bar
340 bar
Output speed
(speed)
Standard machine
1500 25 rpm
Speeder machine
1930 25 rpm

Y
13.
Standard machine
23.8 mm
Speeder machine
26.0 mm
Lowering speed
of equipment
4 seconds approx.
of stop screw 162
5 mm
MJFCIFSS
6.09.19
Adjustment protocol
Service Manual
Checks
14.
14.1

Measuring point
Specified value
Actual
value
Possible
Setting.
View
Comment
2150 +50rpm
Hydraulic oil temperature

> should be 50C when
checking fan speed.
Danger!
Before working near the fan, switch off the engine (observe afterrun).
6.09.20
MJFCIFSS
Service Manual
Adjustment protocol
Adjustment protocol
Date:
.........................................
Mechanic:
.........................................
Customer:
.........................................
Type:
.........................................
Series no.:
.........................................
Operating
hours:
.........................................
Checks
Measuring
point
Specified
value
1.
Operating conditions - warming up
1.1
Oil temperature
min. 50 +10C
1.2
Regulating rpm
2000 min-1
1.3
Max. speed
2100 +50min-1
1.4
Min. speed
770 +50min-1
2.
Pilot pressure
Measuring
point 49
Actual
value
Possible
Setting.
View
Comment
32 1 bar
A 311 LI 20222-27111
copyright by
MJFCIFSS
6.11.1
Adjustment protocol
Service Manual
Checks
3.
Horsepower control
3.1

rpm)
3.2
3.3
6.11.2
Measuring
point
Specified
value
Actual
value
Possible
Setting.
Measuring
point 59
( X3 )
Current
850 +25 mA
Control pressure LR
30 1 bar
View
Comment
at power test
Current
<50mA
Control pressure LR
12 bar
(tank pressure)
Measuring
point 59
30 1 bar
Remove plug of Y50.

A 311 LI 20222-27111
copyright by
MJFCIFSS
Service Manual
Adjustment protocol
Checks
4.
Checking
Function Y51
4.1
Current
200 - > 900 mA
via speed steps
5.
Checking
Flow reduction of pump
P1
5.1
Value X
Measuring
point
Specified
value
Actual
value
Possible
Setting.
View
Comment
atY51.
Measuring
point 57
( X1)
Pressure: see
Diagram
up to pump no. 20194344
8,8 0.2 mm
starting with pump no.

20194345
11,8 0.2 mm
A 311 LI 20222-27111
copyright by
MJFCIFSS
6.11.3
Adjustment protocol
Service Manual
Checks
Measuring
point
Specified
value
6.
Begin of hydraulic regulation of double variabledisplacement

Pump
(basic setting)
Measuring
point 40/41
6.1
Pump P1
actuating pressure at 43 rises to 10 bar
60 2 bar
Actual
value
Possible
Setting.
View
Comment
Speed - low (about 1,200 min-1)
10 bar

6.2
Pump P2
602 bar
10 bar

6.11.4
A 311 LI 20222-27111
copyright by
MJFCIFSS
Service Manual
Adjustment protocol
Checks
7.

diesel engine
(power test)
Note:
engine performance.
Measuring
point
Specified
value
Actual
value
Possible
Setting.
View
Comment
High idle rpm
Measuring
point 41
max. fan speed

2150 min-1 approx.
Disconnect Y50
and/or launch menu power
test on your laptop
cylinder) below test pressure. Turn back in until you
reach test pressure again.
Be careful not to lower diesel engine speed below rated speed. (Check diesel
speed at B12).
Pump at Qmax
Control chamber
( < 50mA)
110 bar
(each pump)
2000 +10min-1
Measuring
points 41 and
44
= tank pressure
A 311 LI 20222-27111
copyright by
MJFCIFSS
6.11.5
Adjustment protocol
Service Manual
Checks
8.
Secondary pressure
Primary pressure relief valve 120 /
121 screwed in
Measuring
point
Specified
value
Actual
value
Possible
Setting.
View
Comment
Measuring
point 40
at upper idle speed
8.1
380 +20 bar
Valve 129
380 +20 bar
Valve 130
- retract boom cylinder
380 +20 bar
Valve 131
- extend boom cylinder
380 +20 bar
Valve 132
380 +20 bar
Valve 133
380 +20 bar
Valve 134
Measuring
point 41
8.2
6.11.6
380 +20 bar
Valve 127
380 +20 bar
Valve 128
Travel function
Measuring
point 41
- Travel forward
380 +20 bar
- Travel reverse
380 +20 bar
Valve 214
Valve 215
A 311 LI 20222-27111
copyright by
MJFCIFSS
Service Manual
Adjustment protocol
Checks
9.
10.
Measuring
point
Specified
value

pressure
Measuring
point 40

350 +10 bar

/ AHS 12
group 16.)
Measuring
point 40

350 +10 bar

pressure
Measuring
point 45
110 +20 bar
Actual
value
Possible
Setting.
View
Comment
High idle rpm
350 +10 bar

Measuring
point 41
High idle rpm
A 311 LI 20222-27111
copyright by
MJFCIFSS
6.11.7
Adjustment protocol
Service Manual
Checks
11.

secondary pressure
11.1
Turning
11.2
Actual
value
Possible
Setting.
View
Comment
Measuring
points
197/198
Turning right
197
200 +10 bar
Valve 191
Lock nut 1
Adjusting screw 2
Turning left
198
200 +10 bar
Valve 192
Lock nut 1
Adjusting screw 2
198
70 5 bar
Valve 192
Lock nut 3
Adjusting screw 4
197
70 5bar
Valve 191
Lock nut 3
Adjusting screw 4
Slowing down
Turning right
Turning left
6.11.8
Measuring
point
Specified
value
A 311 LI 20222-27111
copyright by
MJFCIFSS
Service Manual
Adjustment protocol
Checks
Measuring
point
Specified
value
12.
Travel motor
12.1
Regulation
Measuring
point
40 / M
Begin of regulation
240 bar
End of regulation
340 bar
12.2
Actual
value
Possible
Setting.
View
Comment
on travel motor 210
Output speed
(speed)
Standard machine
1500 25 min-1
Speeder machine
1930 25 min-1

Y
13.
Standard machine
23.8 mm
Speeder machine
26.0 mm
Lowering speed
of equipment
4 seconds approx.
of stop screw 162
5 mm
A 311 LI 20222-27111
copyright by
MJFCIFSS
6.11.9
Adjustment protocol
Service Manual
Checks
14.
14.1

Measuring
point
Specified
value
Actual
value
Possible
Setting.
View
Comment
2150 +50min-1
Hydraulic oil temperature >

should be 50C when checking fan speed.
Danger!
6.11.10
A 311 LI 20222-27111
copyright by
MJFCIFSS
Service Manual
Adjustment protocol
Adjustment protocol
2 A 311 Litronic from 27112 (applicable from software version 5.12)
Date:
.........................................
Mechanic:
.........................................
Customer:
.........................................
Type:
.........................................
Series no.:
.........................................
Operating
hours:
.........................................
Checks
Measuring point
Specified value
1.
1.1
Oil temperature
min. 50 +10C
1.2
1.2.1
1.2.2
Regulating rpm
during work
travel)
1800 rpm
1950 rpm
1.3
1.3.1
1.3.2
1.4
Max. speed
during work
travel)
Min. speed
2.
Pilot pressure
Actual
value
Possible
Setting.
View
Comment
1950 +40 rpm

2100 +50 rpm
770 +50 rpm

Measuring
point 49
32 1 bar
3.
Horsepower control
3.1

rpm)
3.2
3.3
Measuring
point 59
( X3 )
Current
850 +25 mA
Control pressure LR
30 1 bar
at power test
Current
<50mA
Control pressure LR
1 bar
(tank pressure)
Measuring
point 59
30 1 bar
Remove plug of Y50.

Diagram, see page 12.
MJFCIFSS
6.11.11
Adjustment protocol
Service Manual
Checks
4.
Checking
function Y51
4.1
Current
200 - > 900 mA
via speed steps
5.
Checking
flow reduction of pump
P1
5.1
Value X
6.11.12
Measuring point
Specified value
Actual
value
Possible
Setting.
View
Comment
at Y51.
Measuring
point 57
( X1)
Pressure: see
diagram
11,8 0.2 mm
MJFCIFSS
Service Manual
Adjustment protocol
Checks
Measuring point
Specified value
6.
Begin of hydraulic regulation of double variable-displacement

Pump
(basic setting)
Measuring
point 40/41
6.1
Pump P1
valve 120
rises to 10 bar
60 2 bar
Actual
value
Possible
Setting.
View
Comment
Speed - low (about 1,200 rpm)
10 bar

6.2
Pump P2
valve 121
60 2 bar
10 bar

MJFCIFSS
6.11.13
Adjustment protocol
Service Manual
Checks
7.

diesel engine
(power test)
Note:
engine performance.
Measuring point
Specified value
Actual
value
Possible
Setting.
View
Comment
High idle rpm
Measuring
point 40/41
max. fan speed

2150 rpm approx.
Disconnect Y50
and/or launch menu power test on your laptop
cylinder) below test pressure. Turn back in until
you reach test pressure
again. Be careful not to lower diesel engine speed
below rated speed.
(Check diesel speed at
B12).
Pump at Qmax.
Control chamber
6.11.14
( < 50mA)
120 bar
(each pump)
1800 +10rpm
Measuring
point 43/44
= tank
pressure
MJFCIFSS
Service Manual
Adjustment protocol
Checks
8.
Secondary pressure
valve 120 /
121 screwed in
Measuring point
Specified value
Actual
value
Possible
Setting.
View
Comment
Measuring
point 40
at upper idle speed
8.1
380 +20 bar
Valve 129
380 +20 bar*
Valve 130
380 +20 bar
Valve 131
380 +20 bar
Valve 132
380 +20 bar
Valve 133
380 +20 bar
Valve 134
Measuring
point 41
380 +20 bar
Valve 127
380 +20 bar
Valve 128
* adjustment to 240 bar + 1
revolution of adjusting screw = 380
bar
MJFCIFSS
6.11.15
Adjustment protocol
Service Manual
Checks
8.2
9.
6.11.16
Measuring point
Specified value
Actual
value
Possible
Setting.
View
Comment
Travel function
Measuring
point 41
- Travel forward
380 +20 bar
Valve 214
- Travel reverse
380 +20 bar
Valve 215

pressure
Measuring
point 40
High idle rpm

350 +10 bar

/ AHS 12
group 16.)
Measuring
point 40

350 +10 bar
350 +10 bar

Measuring
point 41
MJFCIFSS
Service Manual
Adjustment protocol
Checks
10.
Measuring point
Specified value

pressure
Measuring
point 45
110 +20 bar
Actual
value
Possible
Setting.
View
Comment
High idle rpm
MJFCIFSS
6.11.17
Adjustment protocol
Service Manual
Checks
11.

secondary pressure
11.1
Turning
11.2
Actual
value
Possible
Setting.
View
Comment
Measuring
points
197/198
Turning right
197
200 +10 bar
Valve 191
Lock nut 1
Adjusting screw 2
Turning left
198
200 +10 bar
Valve 192
Lock nut 1
Adjusting screw 2
198
70 5 bar
Valve 192
Lock nut 3
Adjusting screw 4
197
70 5bar
Valve 191
Lock nut 3
Adjusting screw 4
Slowing down
Turning right
Turning left
6.11.18
Measuring point
Specified value
MJFCIFSS
Service Manual
Adjustment protocol
Checks
12.
Travel motor
12.1
Regulation
Begin of regulation
End of regulation
12.2
Measuring point
Specified value
Actual
value
Possible
Setting.
View
Comment
on travel motor 210
Measuring
point
40 / M
240 bar
340 bar
Output speed
(speed)
Standard machine
1500 25 rpm
Speeder machine
1930 25 rpm

Y
13.
Standard machine
23.8 mm
Speeder machine
26.0 mm
Lowering speed
of equipment
4 seconds approx.
of stop screw 162
5 mm
MJFCIFSS
6.11.19
Adjustment protocol
Service Manual
Checks
14.
14.1

Measuring point
Specified value
Actual
value
Possible
Setting.
View
Comment
2150 +50rpm

> should be 50C when
checking fan speed.
Danger!
Before working near the fan, switch off the engine (observe afterrun).
6.11.20
MJFCIFSS
Service Manual
Adjustment protocol
Adjustment protocol
Date:
.........................................
Mechanic:
.........................................
Customer:
.........................................
Typ:
.........................................
Serial-No:
.........................................
Operating
hours:
.........................................
Checks
Measuring
point
Specified
value
1.
Warm up equipment
1.1
Oil temperature
min. 50 +10C
1.2
Regulating rpm
1800 min-1
1.3
Max. speed
1910 +50min-1
1.4
Min. speed
770 +50min-1
2.
Pilot pressure
Measuring
point 49
32 1 bar
3.
Horsepower control
3.1
at rpm step 9
(speed max.rpm)
Measuring
point 59
Current
(until software 1.5)
Control pressure
Current
(from software 1.6)
Actual
value
Possible
setting
View
Comment
Adjusting at valve 51
using adapter cable at Y50
560 +30 mA
11 +2 bar
600 +30 mA
13 +3 bar
Control pressure
Remove plug at Y50.
+2 bar
3.2
Control pressure at
Power test
20
3.3
Checking regulating pressure during

emergency operation
Measuring
point 59
3,2 0,5 bar
MJFCIFSS
6.12.1
Adjustment protocol
Service Manual
Checks
Measuring
point
Specified
value
4.
Checking
Fine control functionY51
Measuring
point 57
4.1
Fine control min.

(Q.max)
100 < 280 mA
0.8 bar approx.(Tank

pressure)
4.2
Fine control min. to

Fine control max.
280.>.640 mA
(dim. cross-section)
Pressure: see
diagram
5.
Begin of hydraulic
regulation of variable
displacement pump
Measuring
point 41
5.1
(basic setting)
until software 1.5
65 2 bar
from software 1.6
50 2 bar
Actual
value
Possible
setting
View
Comment
Using adapter cable at Y51
Select low speed (appr.1200 min-1

Disconnect plug connection at Y50
/ Y51. Adjust setting at screw
23.2.1 of pump.
Set secondary relief valve

262 (extend bucket cylinder) below begin of regulation.Screw in again until
starts to go down.
p at 59 = tankpressure
Re-connect Y50.
6.12.2
MJFCIFSS
Service Manual
Adjustment protocol
Checks
6.
Measuring
point
Specified
value
Actual
value
Adjusting pressure difference ( p)

with function extend bucket cylinder
Measuring
point 41 / 45
23 +1 bar
Reduce or set pressure at

valve 262 at 100-120 bar
at Measuring point 41 MP.
p at 57 = tank pressure
Adjustment
up to 500 operating hours
24 +1 bar
Possible
setting
View
Comment
max. rpm (step 9), button p not
active (Y51 disconnected). Take
readings between MP and LS. Adjust at screw 23.5.1 of pump.
Re-connect plug at Y51.

7.
Checking power of diesel engine (power test)

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

Max. fan speed
2230 min-1 approx.
Measuring
point 41
110 bar
1800 +10min-1
< 10 bar
* Both functions are necessary to get the

max.pump flow.
MJFCIFSS
6.12.3
Adjustment protocol
Service Manual
Checks
Measuring
point
Specified
value
8.
Primary pressure
(safety valve)
Measuring
point 41
8.1
Main relief valve 105
400 +20 bar
Actual
value
Possible
setting
View
Comment

262 above adjustment
pressure 105 and extend
bucket cylinder.
Raise pressure at pressure
cut-off valve 104 until
pressure gauge does
not go up any more.
(response pressure 105)
9.
Secondary pressure
flow cut-off pressure at
104 raised
(not on block).
Measuring
point 45
high idle rpm
9.1 Working functions
6.12.4
-Extend boom cylinder
380 +20 bar
Valve 221
-Retract boom cylinder
380 +20 bar
Valve 222
-Retract stick cylinder
380 +20 bar
Valve 241
-Extend stick cylinder
380 +20 bar
Valve 242
-Retract bucket cylinder
380 +20 bar
Valve 261
-Extend bucket cylinder
+20
380
bar
Valve 262
MJFCIFSS
Service Manual
Adjustment protocol
Checks
9.2
Measuring
point
Specified
value
Actual
value
Possible
setting
View
Comment
Travel function
Measuring
point 45
-Travel forward
380 +20 bar
Valve 176
-Travel reverse
380 +20 bar
Valve 177
10.
Operating pressure p
10.1
Pressure cut-off
Measuring
point 41
max. rpm (step 9)

Valve 104
350 +10 bar
MJFCIFSS
6.12.5
Adjustment protocol
Service Manual
Checks
11.
11.2
Actual
value
Possible
setting
View
Comment
Slewing gear functions

Measuring
point 137/138
Pressure setting at valve 125, see

fig. on page 7, raised.
Turning right
137
250 +10 bar
Valve 135
(High pressure setting)
Lock nut 1
Adjusting screw 2
Turning left
138
250 +10 bar
Valve 134
Lock nut 1
Adjusting screw 2
Secondary pressure
11.1
Measuring
point
Specified
value
Turning
Slowing down, braking

Turning right
138
90 5 bar
Valve 134
(Low pressure setting)
Lock nut 3
Adjusting screw 4
Turning left
137
90 5bar
Valve 135
Lock nut 3
Adjusting screw 4
Valves 134 / 135
6.12.6
MJFCIFSS
Service Manual
Adjustment protocol
Checks
12.

Primary pressure
Measuring
point
Specified
value
Actual
value
Possible
setting
Measuring
point 137 / 138
Turning left or
right
200 5 bar
13.
Travel motor
13.1
Regulation
Measuring
point 45 / M
Begin of regulation
240 bar
End of regulation
320 bar
View
Comment
Carry out settings on valve 125

on travel motor
MJFCIFSS
6.12.7
Adjustment protocol
Service Manual
Checks
13.2
Measuring
point
Specified
value
Actual
value
Possible
setting
Output speed
(speed)
Measured on drive shaft, during

on-road gear
Standard machine
1850 25 min-1
Speeder machine
2780 25 min-1
Checking measurement Y
16,0 mm
14.
14.1
Checking fan speed

View
Comment
Spool 160
2230 50 min-1

should be > 50 C during
check.
Danger!
Moving fan blades are a severe hazard to fingers and hands.
Be sure to switch off the engine when working near the fan.
6.12.8
MJFCIFSS
Service Manual
Adjustment protocol
R 313 Litronic from 27752
Adjustment protocol
1 R 313 Litronic from 27752
Date:
.........................................
Mechanic:
.........................................
Cust.:
.........................................
Type:
.........................................
Serial no.:
.........................................
Operating
hours:
.........................................
Checks
Measuring
point
Specified
value
1.
Warm up equipment
1.1
Oil temperature
min. 50 +10C
1.2
Regulating rpm
1780 rpm
1.3
Max. speed
1900 +30rpm
1.4
Min. speed
770 +50rpm
2.
Pilot pressure
Measuring
point 49
Actual
value
Possible
setting
View
Comment
Set at valve 51.
32 1bar
3.
Horsepower control
3.1
at speed step 9
(high idle rpm)
3.2
3.3
Current
Control pressure
580 +30 mA
7 +2 bar
Control pressure during

power test
10+2 bar
Check of regulating pressure during emergency

operation
Measure at Y50 using the adapter

cable.
Measuring
point 59
Remove the plug from Y50.

Set valve to emergency position
(remove cotter pin and tilt lever).
Measuring
point 59
2.0 0.5bar
copyright by
MJFCIFSS
6.13.1
Adjustment protocol
Service Manual
Checks
Measuring
point
Specified
value
4.
Check of
Y51 function
Measuring
point 57
4.1
SF min /(Q.max.)
100 < 300 mA
max. 0.8 bar

(tank
pressure)
4.2
SF min. to SF.max.
(300 > 760 mA)
(Q.reduction)
5.
Hydraulic begin of regulation of variable displacement

pump (basic setting)
Set the secondary relief
valve 262
to a value below begin of
regulation; turn in again
until the actuating pressure
at 44 starts to drop.
Actual
value
Possible
setting
View
Comment
Measure using adapter cable at
Y51.
Pressure: see
diagram
Measuring
point 41
Speed - low ( approx. 1200 rpm)

Y 50 / Y 51 disconnected.
Adjust at screw 8 of the pump regulator.
50 2bar
Re-connect the plug to Y50.
6.13.2
copyright by
MJFCIFSS
Service Manual
Adjustment protocol
Checks
6.
Adjustment of the differential pressure ( -p)

Extend bucket cylinder
with function.
Lower pressure setting or
adjust the valve 262 to
100-120 bar at measuring
point 41 -MP.
P at 57 = tank pressure
Measuring
point
Specified
value
Actual
value
Possible
setting
View
Comment
Maximum speed step (step 9).
Button -p disabled (Y51 disconnected). Read value between MP
and LS. Adjust at the screw 2 at the
pump.
Measuring
point
41 / 45
19 +1 bar
Adjustment
up to 500
operating
hours
20 +1 bar
Re-connect plug to Y51.

7.
Checking diesel engine

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

Max. fan speed
approx. 1500 rpm
Measuring
point 41
110 bar
1800 +10rpm
<10 bar
copyright by
MJFCIFSS
6.13.3
Adjustment protocol
Service Manual
Checks
8.
Primary pressure
Safety valve 105
Measuring
point
Specified
value
Actual
value
Possible
setting
Measuring
point 41
400 +20 bar
Set the secondary pressure-relief valves 262 to a value above the adjustment
pressure of 105 and extend the bucket cylinder.
Turn up the pressure cutoff 104 until the value
shown at the pressure gauge stops to increase
(response pressure 105).
6.13.4
copyright by
MJFCIFSS
View
Comment
Service Manual
Adjustment protocol
Checks
9.
Secondary pressure
Pressure cut-off 104 screwed in (not to block)
9.1
Measuring
point
Specified
value
Actual
value
Possible
setting
High idle speed
Measuring
point 45
- Extend boom cylinder
380 +20 bar
380
+20
bar
- Retract stick cylinder
380
+20
bar
380 +20 bar

+20
380
380 +20 bar
View
Comment
Valve 221
Valve 222
Valve 241
Valve 242
bar
Valve 261
Valve 262
copyright by
MJFCIFSS
6.13.5
Adjustment protocol
Service Manual
Checks
9.2
10.
6.13.6
Measuring
point
Specified
value
Actual
value
Possible
setting
View
Comment
Travel functions
Measuring
point 45
Disconnect the line 210 to the brake.
Forward travel, left
380 +20 bar
Valve 211
Reverse travel, left
380 +20 bar
Valve 212
Forward travel, right
380 +20 bar
Valve 213
Reverse travel, right
380 +20 bar
Valve 214
Measuring
point 41
Maximum speed step (step 9)

Valve 104
(pressure cut-off)
350 +10 bar
copyright by
MJFCIFSS
Service Manual
Adjustment protocol
Checks
11.

Secondary pressure
11.1
Swivelling back
11.2
Measuring
point
Specified
value
Actual
value
Possible
setting
View
Comment
Valve 125 screwed in
Measuring
points
137/138
Turning right
137
250 +10 bar
Valve 134
(high-pressure setting)
Lock nut 1
Adjusting screw 2
Turning left
138
250 +10 bar
Valve 135
(high-pressure setting)
Lock nut 1
Adjusting screw 2
Turning right
138
90 5bar
Valve 135
(low-pressure setting)
Lock nut 3
Adjusting screw 4
Turning left
137
90 5bar
Valve 134
(low-pressure setting)
Lock nut 3
Adjusting screw 4
Slowing down
copyright by
MJFCIFSS
6.13.7
Adjustment protocol
Service Manual
Checks
12.
6.13.8

Primary pressure
Measuring
point
Specified
value
Actual
value
Possible
setting
Adjust settings at valve 125.
Measuring
point
137 / 138
Turning left or right
230 +10 bar
at Y451
100%
580 mA
50%
540 mA
0%
500 mA
View
Comment
copyright by
MJFCIFSS
Service Manual
Adjustment protocol
Checks
13.
Regulating travel motor
13.1
Speed
13.2
13.3
Measuring
point
Specified
value
Actual
value
Possible
setting
View
Comment
Measured at tumbler wheel (output
speed of gearbox) at stroke stop
160.1, 160.2, 180.1, 180.2
Screw .3
Normal travel
15 1 rpm
15.0 mm
Fast travel mode (activated with switch S21, hare

symbol)
45 1 rpm
Straight-ahead travel with

same speed at both sides.
45 rpm
Qmin stop screw Vmin
Qmin stop Vmin
copyright by
MJFCIFSS
6.13.9
Adjustment protocol
Service Manual
Checks
14.
14.1
Measuring
point
Specified
value
Actual
value
Possible
setting

Check the speed while the
diesel engine runs at rated
speed and Y347 is disconnected.
1500+ 50rpm
During the fan speed

check, the hydraulic oil
temperature should be >
50 C.
Danger!
6.13.10
copyright by
MJFCIFSS
View
Comment
Service Manual
Adjustment protocol
Adjustment protocol
Date:
.........................................
Mechanic:
.........................................
Customer:
.........................................
Typ:
.........................................
Serial-No:
.........................................
Operating
hours:
.........................................
Checks
Measuring
point
Specified
value
1.
Warm up equipment
1.1
Oil temperature
min. 50 +10C
1.2
Regulating rpm
1800 min-1
1.3
Max. speed
1900 +30min-1
1.4
Min. speed
770 +50min-1
2.
Pilot pressure
Measuring
point 49
32 1 bar
3.
Horsepower control
3.1
at speed level 9
(high idle rpm)
Current
Control pressure
Current
(from software 1.6)
Actual
value
Possible
setting
View
Comment
Measuring
point 59
560 +30 mA
11 +2 bar
600 +30 mA
13 +3 bar
Control pressure
Remove plug at Y50.
+2 bar
3.2
Control pressure at
Power test
20
3.3

emergency operation
Measuring
point 59
3,2 0,5 bar
MJFCIFSS
6.14.1
Adjustment protocol
Service Manual
Checks
Measuring
point
Specified
value
4.
Checking
Measuring
point 57
4.1
Fine control min.

(Q.max)
100 < 280 mA
0.8 bar approx. (Tank

pressure)
4.2

Fine control max.
280.>.640 mA
Pressure: see
diagram
5.
Begin of hydraulic
displacement pump
Measuring
point 41
5.1
(basic setting)
until software 1.5
65 2 bar
from software 1.6
50 2 bar
Actual
value
Possible
setting
View
Comment

23.2.1 of pump.

starts to go down.
Re-connect Y50.
6.14.2
MJFCIFSS
Service Manual
Adjustment protocol
Checks
6.
Measuring
point
Specified
value
Actual
value

Measuring
point 41 / 45
23 +1 bar

Adjustment
24 +1 bar
Possible
setting
View
Comment

7.

Note:
speed.
Difference between
44.
high idle rpm

Max. fan speed
1600 min-1 approx.
Measuring
point 41
130 bar
1800 +10min-1
< 10 bar

max.pump flow.
MJFCIFSS
6.14.3
Adjustment protocol
Service Manual
Checks
8.
Primary pressure
(safety valve)
8.1
Measuring
point
Specified
value
Actual
value
Possible
setting
View
Comment
Measuring
point 41
400 +20 bar

bucket cylinder.
pressure gauge does
not go up any more.
9.
Secondary pressure
104 raised
(not on block).
9.1
Working functions
380
bar
380
+20
bar
380 +20 bar
380
+20
bar
380
+20
bar
380
+20
bar

high idle rpm
Valve 221
+20
6.14.4
Measuring
point 45
Valve 222
Valve 241
Valve 242
Valve 261
Valve 262
MJFCIFSS
Service Manual
Adjustment protocol
Checks
9.2
Measuring
point
Specified
value
Actual
value
Possible
setting
View
Comment
Travel function
Measuring
point 45
-Travel forward
380 +20 bar
Valve 176
-Travel reverse
380 +20 bar
Valve 177
10.
10.1
Pressure cut-off
Measuring
point 41
max. rpm (step 9)

Valve 104
350 +10 bar
MJFCIFSS
6.14.5
Adjustment protocol
Service Manual
Checks
11.
11.1
Actual
value
Possible
setting
View
Comment

Secondary pressure
Measuring
point 137/138

Turning
137
250 +10 bar
Valve 135
Lock nut 1
Adjusting screw 2
138
250 +10 bar
Valve 134
Lock nut 1
Adjusting screw 2
Turning right
138
120 5 bar
Valve 134
Lock nut 3
Adjusting screw 4
Turning left
137
120 5bar
Valve 135
Lock nut 3
Adjusting screw 4
Turning right
Turning left
11.2
Measuring
point
Specified
value
from Serial no.

2001
from Serial no.

11147
Valves 134 / 135
6.14.6
MJFCIFSS
Service Manual
Adjustment protocol
Checks
12.

Primary pressure
Measuring
point
Specified
value
Actual
value
Possible
setting
Measuring
point 137 / 138
Turning left or
right
230 10 bar
13.
Travel motor
13.1
Regulation
Measuring
point 45 / M
Begin of regulation
240 bar
End of regulation
320 bar
View
Comment

on travel motor
MJFCIFSS
6.14.7
Adjustment protocol
Service Manual
Checks
13.2
Measuring
point
Specified
value
Actual
value
Possible
setting
Output speed
(speed)

on-road gear
Standard machine
1780 25 min-1
Speeder machine
2670 25 min-1
16,7 mm
14.
14.1
Checking fan speed

View
Comment
Spool 160
1600 50 min-1

check.
Danger!
6.14.8
MJFCIFSS
Service Manual
Adjustment protocol
Adjustment protocol
Date:
.........................................
Mechanic:
.........................................
Customer:
.........................................
Typ:
.........................................
Serial-No:
.........................................
Operating
hours:
.........................................
Checks
Measuring
point
Specified
value
1.
Warm up equipment
1.1
Oil temperature
min. 50 +10C
1.2
Regulating rpm
1800 min-1
1.3
Max. speed
1900 +30min-1
1.4
Min. speed
770 +50min-1
2.
Pilot pressure
Measuring
point 49
32 1 bar
3.
Horsepower control
3.1
at speed level 9
(high idle rpm)
Current
Control pressure
Current
(from software 1.6)
Actual
value
Possible
setting
View
Comment
Measuring
point 59
560 +30 mA
11 +2 bar
600 +30 mA
13 +3 bar
Control pressure
3.2
Control pressure at
Power test
20
3.3

emergency operation
Measuring
point 59
3,2 0,5 bar
A 316 LI 2001A 316 LI-IND 2001-
Remove plug at Y50.

+2 bar
copyright by
MJFCIFSS
6.16.1
Adjustment protocol
Service Manual
Checks
Measuring
point
Specified
value
4.
Checking
Measuring
point 57
4.1
Fine control min.

(Q.max)
100 < 280 mA
0.8 bar approx. (Tank

pressure)
4.2

Fine control max.
280.>.640 mA
Pressure: see
diagram
5.
Begin of hydraulic
displacement pump
Measuring
point 41
5.1
(basic setting)
until software 1.5
65 2 bar
from software 1.6
50 2 bar
Actual
value
Possible
setting
View
Comment

23.2.1 of pump.

starts to go down.
Re-connect Y50.
6.16.2
copyright by
MJFCIFSS
A 316 LI 2001A 316 LI-IND 2001-
Service Manual
Adjustment protocol
Checks
6.
Measuring
point
Specified
value
Actual
value

Measuring
point 41 / 45
23 +1 bar

Adjustment
24 +1 bar
Possible
setting
View
Comment

7.

Note:
speed.
Difference between
44.
high idle rpm

Max. fan speed
1600 min-1 approx.
Measuring
point 41
130 bar
1800 +10min-1
< 10 bar

max.pump flow.
A 316 LI 2001A 316 LI-IND 2001-
copyright by
MJFCIFSS
6.16.3
Adjustment protocol
Service Manual
Checks
8.
Primary pressure
(safety valve)
8.1
Measuring
point
Specified
value
Actual
value
Possible
setting
View
Comment
Measuring
point 41
400 +20 bar

bucket cylinder.
pressure gauge does
not go up any more.
9.
Secondary pressure
104 raised
(not on block).
9.1
Working functions
high idle rpm
380 +20 bar
Valve 221
380 +20 bar

80 +20 bar*
Valve 222
*(only industrial equipment)
380 +20 bar
Valve 241
380 +20 bar
Valve 242
380 +20 bar
Valve 261
380 +20 bar
Valve 262

6.16.4
Measuring
point 45
copyright by
MJFCIFSS
A 316 LI 2001A 316 LI-IND 2001-
Service Manual
Adjustment protocol
Checks
9.2
Measuring
point
Specified
value
Actual
value
Possible
setting
View
Comment
Travel function
Measuring
point 45
-Travel forward
380 +20 bar
Valve 176
-Travel reverse
380 +20 bar
Valve 177
10.
Measuring
point 41
max. rpm (step 9)

Valve 104
10.1
Pressure cut-off
350 +10 bar
A 316 LI 2001A 316 LI-IND 2001-
copyright by
MJFCIFSS
6.16.5
Adjustment protocol
Service Manual
Checks
11.
Actual
value
Possible
setting
Measuring
point 137/138

137
250 +10 bar
Valve 135
Lock nut 1
Adjusting screw 2
138
250 +10 bar
Valve 134
Lock nut 1
Adjusting screw 2
Turning right
138
120 5 bar
Valve 134
Lock nut 3
Adjusting screw 4
Turning left
137
120 5bar
Valve 135
Lock nut 3
Adjusting screw 4
Turning
Turning right
Turning left

11.2
View
Comment

Secondary pressure
11.1
Measuring
point
Specified
value
from Serial no.

2001
from Serial no.

11152
Valves 134 / 135
6.16.6
copyright by
MJFCIFSS
A 316 LI 2001A 316 LI-IND 2001-
Service Manual
Adjustment protocol
Checks
12.

Primary pressure
Measuring
point
Specified
value
Possible
setting
Measuring
point 137 / 138
Turning left or
right
230 10 bar
13.
Travel motor
13.1
Regulation
Measuring
point 45 / M2
Begin of regulation
240 bar
End of regulation
320 bar
A 316 LI 2001A 316 LI-IND 2001-
Actual
value
View
Comment

on travel motor
copyright by
MJFCIFSS
6.16.7
Adjustment protocol
Service Manual
Checks
13.2
Measuring
point
Specified
value
Actual
value
Possible
setting
Output speed
(speed)

on-road gear
Standard machine
until SNo. 28060
from SNo. 28061
1860 25 min-1
1680 25 min-1
Speeder machine
until SNo. 28060
from SNo. 28061
2790 25 min-1
2520 25 min-1
16,7 mm
14.
14.1
Checking fan speed

View
Comment
Spool 160
1600 50 min-1

check.
Danger!
6.16.8
copyright by
MJFCIFSS
A 316 LI 2001A 316 LI-IND 2001-
Service Manual
Adjustment protocol
Adjustment protocol
1 R 317 Litronic from 18161
Date:
.........................................
Mechanic:
.........................................
Customer:
.........................................
.........................................
Serial number:
.........................................
Operating
hours:
.........................................
Actual
value
Checks
Possible
setting
View
Comment
1.
1.1
Oil temperature
min. 50 +10C
1.2
Regulating rpm
1800 min-1
1.3
Max. speed
1900 +30min-1
1.4
Min. speed
770 +50min-1
2.
Pilot pressure
Measuring point
49
32 1 bar
3.
Horsepower control
Measuring point
59
3.1
at speed level 1
(low idle rpm)
3.2
3.3
Current
Control pressure
500+30 mA
6+2 bar
Control pressure
on Power test
10 +2 bar
Checking regulating pressure during emergency

operation
Measuring point
59
2.0 0.5 bar
MJFCIFSS
Remove plug of Y50.

(Remove cotter pin and actuate
lever.)
6.17.1
Adjustment protocol
Service Manual

Actual
value
Checks
4.
Checking SF function
Y51
Measuring point
57
4.1
SF min.(Q. max)
100 < 300 mA
Tank pressure
0.8 bar approx.
4.2
SF min. to SF max.
300 < 760 mA
Pressure: see
diagram
5.
Begin of hydraulic
displacement pump
(basic setting)
Measuring point
41

starts to go down.
50 +2 bar
Possible
setting
View
Comment
Take measure using adapter cable at Y51.
Select low speed (appr.1200 min1)
Disconnect plug connection at

Y50 / Y51. Adjust setting at screw
23.2.1 of pump.
Re-connect Y50.
6.17.2
MJFCIFSS
Service Manual
Adjustment protocol
Actual
value
Checks
6.

Possible
setting
Measuring point
41 / 45
19+1 bar
until 500 hrs.
20+1 bar
View
Comment
readings between MP and LS. Adjust at screw 2 of pump.

Checking power of diesel engine
(power test)
Note:
Carry out this check only
when you suspect the
motor runs at reduced power.
stick cylinder) and 262
below test pressure. Raise again until you reach
test pressure again.The
rpm of the diesel engine
must never drop below
rated speed. (Read rpm
on screen.)
Difference between
44.
high idle rpm

max. fan speed
1600 min-1 approx.
Pull out plug (I = 0 mA)
Measuring point
41
110 bar
1800 +10min-1
< 10 bar
MJFCIFSS
6.17.3
Adjustment protocol
Service Manual

Actual
value
Checks
8.
Primary pressure
bucket cylinder.
Raise pressure at pressure cut-off valve 104 until
pressure gauge does
not go up any more.
9.
Secondary pressure
Pressure cut-off 104
screwed in (not on block).
9.1
Working functions
6.17.4
Possible
setting
Measuring point
41
400+20 bar
View
Comment
P
Measuring point
45
high idle rpm
380 +20 bar
Valve 221
380 +20 bar
Valve 222
380 +20 bar
Valve 241
380 +20 bar
Valve 242
380 +20 bar
Valve 261
380 +20 bar
Valve 262
MJFCIFSS
Service Manual
Adjustment protocol
Actual
value
Checks
9.2
10.
Possible
setting
View
Comment
Travel functions
Measuring point
45
disconnect brake hose 210
-Travel left forward
380 +20 bar
Valve 211
-Travel left reverse
380 +20 bar
Valve 212
-Travel right reverse
380 +20 bar
Valve 213
-Travel right forward
380 +20 bar
Valve 214
(pressure cut-off)
Measuring point
41
350 +10 bar
max RPM ( step 9)

Valve 104
MJFCIFSS
6.17.5
Adjustment protocol
Service Manual

Actual
value
Checks
11.

Secondary pressure
11.1
Turning
11.2
6.17.6
Possible
setting
View
Comment
Measuring points
137/138
Valve125 raised.
Turning right
137
250 +10 bar
Valve 134
Lock nut 1
Adjusting screw 2
Turning left
138
250 +10 bar
Valve 135
Lock nut 1
Adjusting screw 2
Turning right
138
120 5 bar
Valve 135
Lock nut 3
Adjusting screw 4
Turning left
137
120 5bar
Valve 134
Lock nut 3
Adjusting screw 4
MJFCIFSS
Service Manual
Adjustment protocol
Actual
value
Checks
12.

Primary pressure
Turning left or right
13.
Travel motor
13.1
Slow travel speed
Possible
setting
Measuring point
137 / 138
View
Comment
230 +10 bar
measured on turas
Hoist limit screw .3 on
160.1, 160.2, 180.1, 180.2
Normal Travel
151 min-1
Control measurement Y
15 mm
MJFCIFSS
6.17.7
Adjustment protocol
Service Manual

Actual
value
Checks
13.2
Fast travel speed

(with switch S21)
14.
14.1
Checking fan speed

Possible
setting
View
Comment
Q-min screw Vmin
45 1 min-1
1600 +50 min-1

> should be 50 C during
check.
Danger!
Be sure to switch off motor when working near the fan.
6.17.8
MJFCIFSS
Service Manual
LSC system
Basic principle - general description of functions
LSC system
1 Basic principle - general description of functions
1.1
Introduction
The LIEBHERR hydraulic excavator generation of the A 312 - R 317 Litronic series is equipped with
the LSC hydraulic control system (Liebherr synchronous control).
It allows operators to work much faster and much more precisely, thanks to easier and simpler overall
handling of the machine.
The biggest advantage of the LSC system is, however, that handling and operation can be adapted
much better to prevailing working conditions.
The speed of the working movement is determined by the displacement of the control lever / pilot control valve, not by the load pressure.
Other advantages of the LSC system:
Several consumers can be handled simultaneously, without any problems, independently of load
pressure and even with saturation deficits.
The LSC system will adapt flow rates to the requirements of the various consumers.
Pressures are adapted to the consumer with the highest load.
Economic operation matched to actual application of the machine
1.2
Design of LSC system

Control elements:
Load-sensing control
LUDV system
On-board electronics
Horsepower and on-demand flow control
Note!
For detailed information on the design of components mentioned above, please refer to the respective subgroups in the service manual.
1.3
Functional description of LSC system

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

The amount of oil supplied by the pump is adjusted by means of the flow regulator. A gauge orifice
(opening at the spool) generates a pressure difference which corresponds to the spring force ( p)
set at the regulator.
Flow cross-section
The cross-section of the flow supplied by the pump and fed through the spool to the consumers can
copyright by
MJFCIFSS
6.20.1
LSC system
Service Manual
LUDV system
be controlled by actuating the pilot-control lever. It determines the control pressure, which is proportional to the travel of the lever.
In other words:
Short travel of lever / pedal at the pilot control valve = low control pressure at the spool = small
flow cross-section = low speed of consumer.
Long travel of lever / pedal at the pilot control valve = high control pressure at the spool = large
flow cross-section = high speed of consumer.
Flow rate
The applicable law of hydrodynamics tells us that there is a relation between the volumes flowing through the spool, the aperture of the orifice and the corresponding difference in pressure:
High p value = high flow rate

Low p value = low flow rate
Values for
p are pre-set at the pump, i.e. the volume depends on the cross-section.
The on-board electronics make it possible to use a proportional solenoid valve (Y51) to lower p
continuously and to adapt the speed of working movements to prevailing work conditions and consumer requirements.
2 LUDV system
As part of the load-sensing system, the LUDV system is connected to a spool (gauge orifice) of the
respective consumer, and a subsequent pressure balance. The load pressure of each consumer (LS
signal) is measured at the pressure channel leading to the consumer. The highest measured load
pressure is signalled by the pressure balance of the working pump.
The p value generated by the pressure spring of the LS regulator (located near the working pump)
is used as a reference p value for the system.
p1 = p2 corresponds to p1 =
proportional to cross-section A2.
p2; the flow Qv1 is proportional to cross-section A1, and Qv2 is
The flow generated by the pump at the gauge orifice cross-sections A1 and A2 is proportional to these cross-sections. The p values at the gauge orifices ( p1 and p2) are equal, due to the applied
pressure, see Fig. 1.
If several consumers are in use and the flow from the pump Q is not sufficient to saturate the gauge
orifice cross-sections, p1 and p2 are reduced. Due to the status signal p2 indicating the highest
load pressure and acting on all pressure balances, the flow distribution remains unaffected by the
load pressure and is determined by the operation of the controls.
6.20.2
copyright by
MJFCIFSS
Service Manual
LSC system
LUDV system
Fig. 1
Principle of LUDV system
A1
Gauge orifice (spool 1)
p1
Pressure in front of pressure balance 1
A2
Dw 1
Gauge orifice (spool 2)

Pressure balance of spool 1)
p2
Pp
Pressure in front of pressure balance 2

Pump pressure
Dw 2
Pressure balance of spool 2)
p1
Pressure difference between Pp and p1
F1
F2
External force applied to consumer 1

External force applied to consumer 2
p2
p3
Pressure difference between Pp and p2

Pressure difference between p1 and p1
FR
Flow regulator
PQ
Pump flow volume
p1
Load pressure at consumer 1
Qv1
Flow rate at consumer 1
p2
Load pressure at consumer 2
Qv2
Flow rate at consumer 2
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6.20.3
LSC system
Service Manual
Horsepower control by means of proportional solenoid valve Y50
2.1
Proportional split of flow volumes

Example: if a consumer 1 is operated with the required flow rate Q1 = 50 l/min, the oil volume is controlled on the basis of the requirements and made available by the variable capacity pump. If a second consumer 2 with a required flow rate Q2 = 100 l/min is added, the maximum pump flow rate
Qmax = 200 l /min is split at a ratio of 200 : 250 = 0.8 onto the two consumers. This means that consumer 1 receives only Q1 = 120 l/min, while consumer 2 receives only Q2 = 80 l/min.
2.2
Performance split
Performance split means the ratio between pump capacity, on the one hand, and useful and lost performance on the other.
The performance of the pump is equal to the flow rate Q of the pump multiplied by the highest consumer pressure (load pressure + p).
Loss in performance might be caused by volumes required by other consumers, multiplied by the corresponding differential pressure ( p at the highest load pressure).
A higher loss of performance arises when a consumer is operated with a pressure cut-off valve.
2.3
Intelligent electronics
Purpose of electronics:
Switching functions
Displaying and managing important operational data
Monitoring units and safety devices
Displaying error and operational status messages
Controlling functions and processes
Regulation and control according to current operation
Proportional solenoid valves Y50 and Y51
3 Horsepower control by means of proportional solenoid valve Y50

3.1
Regulation of hydraulic performance steps

Horsepower control is effected by means of the spring on the performance regulator of the pump and
the current at valve Y50.
3.2
Speed preselection by means of the potentiometer R75:

By turning the potentiometer R75, located at the control console, 9 speed levels for the diesel engine
can be preselected.
ECO: Levels 1- 8 = speed levels for various applications in the most ecologically efficient range
POWER: Level 9 = Max. engine speed
6.20.4
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MJFCIFSS
Service Manual
LSC system
Horsepower control by means of proportional solenoid valve Y50
Fig. 2
21
Horsepower control in LSC system

Powertrain (variable-displacement pump) 235
Boom cylinder
23.2 Performance regulator (A 312 - 316)

25
Performance regulator (R 317)
R75 Potentiometer for speed adjustment

U16 Excavator control (BST)
220
Y50
Spool
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MJFCIFSS
Proportional valve (LR)
6.20.5
LSC system
Service Manual
On-demand flow control

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

Machines with a load-sensing hydraulic circuit are equipped with on-demand flow control to control
pump flows. As a result, the powertrain of the working pump supplies only the amount of oil needed
by the consumers. This prevents any unnecessary circulation and throttle losses.
4.1
Functional description of the on-demand flow control

(see Fig. 4, page 8)
If all the spools (220 - 260) are in neutral position (no control oil to spools 220 - 260), the pump supplies only the oil required for stand-by operation. The flow regulator pivots the pump back to the stop
Q min. (stand-by operation = QRest at circulation pressure).
Actuation of a spool (gauge orifice opens) reduces the normal ( p) between the pump and the consumer. This difference in pressure effects a shifting of the flow regulator 23.5/26 due to the pre-set
pressure spring (pump pressure is reduced).
The flow through the bores in the spool 220 / 260 is comparable with the flow through a gauge orifice.
With increasing flow rates to the consumer, the pressure difference at the gauge orifice also increases.
The balance is established when the pressure difference in the spool reaches the value
at the LS regulator (pump pressure - consumer pressure in LS line).
p pre-set
The flow cross-section of each spool is dimensioned in such a way that the pressure drop is equal to
the value p(LS) pre-set at the regulator when the desired nominal flow rate has been reached while
the spool is fully open.
If the spool 220 - 260 is shifted back to an interim position, the aperture of the gauge orifice is reduced
in size, and the pressure difference p(LS) is achieved with a smaller oil volume. The pump has a
tendency to maintain a constant pressure difference at all times and therefore pivots back to its initial
position.
If several consumers are actuated at the same time, the amount of oil required exceeds the max. capacity of the pump. The value p(LS) drops, but remains the same for all consumers, so that all flow
rates are reduced by the same factor.
4.2
4.2.1
Flow regulation by means of proportional solenoid valve Y51

Working speed and fine control
The proportional valve Y51 is pressurised with pilot control pressure (pst) counteracting according to
the pre-set % value by means of the BST of the spring force (LS) 23.5/26 through pMLS . As a result,
p is reduced.
As a result, the pressure difference
a smaller volume of oil.
p is smaller, and the pump can maintain the reduced
The pump pivots only to the point where the pre-set flow rate at the pump outlet is reached.
6.20.6
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MJFCIFSS
p with
Service Manual
LSC system
On-demand flow control
Fig. 3
Flow regulation in the LSC system
21
Powertrain (variable-displacement pump) R76 Potentiometer / fine adjustment
23.5 Flow regulator (A 312 - 316)
S382 Activating switch fine control adjustment
4.2.2
26
Flow regulator (R 317)
B33
Sensor (kit)
Y51
Proportional valve LS ( p reduction)
Adapting flow reduction to working conditions

Reducing pumping capacity:
I Ls < 300 mA = pMLS = 0 bar (tank pressure)
p = basic setting
Note!
The working speeds can immediately be tested by means of the joysticks.
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MJFCIFSS
6.20.7
LSC system
Service Manual
Hydraulic diagram
5 Hydraulic diagram
Fig. 4
6.20.8
Hydraulic schematic: a = Pump pivots out, b = pump pivots back
Hydraulic tank
105
Primary pressure relief valve
21
Powertrain
220
Spool
21.1 Adjusting device

23.5 LS regulator
224
235
Pressure balance
Consumer
100
Control valve block
260
Spool
102
Pressure balance / minimum flow
264
Pressure balance
103
104
Pressure balance / remaining flow

Pressure cut-off valve
275
to consumer (bucket cylinder)
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Service Manual
LSC system
Hydraulic diagram
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MJFCIFSS
6.20.9
LSC system
Service Manual
Hydraulic diagram
6.20.10
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Service Manual
LSC system
Hydraulic diagram
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MJFCIFSS
6.20.11
LSC system
Service Manual
Hydraulic diagram
6.20.12
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MJFCIFSS
Service Manual

Tank arrangement

1 Tank arrangement
Fig. 1
11
1.1
1.1.1
Hydraulic tank
11
From turbo charger / diesel engine
2
3
Breather filter
Stop cock
12
B8
Check valve
Hydraulic oil temperature transducer
4
5
Return filter
Integrated bypass valve
B285 Hydraulic oil temperature transducer(fan control)
Hydraulic tank
Purpose:
1.1.2
Hydraulic tank with filters and other components
Takes up all hydraulic oils from the entire equipment

Separates inlet and return sections. Baffle oil with baffle plates on the inside.
Supplies purified oil to hydraulic pumps.
Reservoir for return oil, with return filters.
Preload of oil volume to prevent cavitation by pressure (0.5 0.7 bar) from the turbo charger 11
of the diesel engine through the check valve 12
Filter units:
Return filter 4 with two-stage glass-fibre filter element and bypass valve 5 (integrated in return filter)
Breather filter 2
Filter elements:
Return filter element for commissioning (factory-installed) 10
Return filter element for cleaning of circuit (after oil change / pump failure) 5
Return filter element for normal operation, two-stage20 / 5 ,
for use in dusty environments single-stage 10
Breather filter 2 complete, for normal operation 7 ,
for use in dusty environments 2
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6.22.1
Service Manual
Hydraulic pumps
1.1.3
Maintenance:
Oil analyses
Changing hydraulic oil
Replacing return filter element and breather filter
Draining tank
see maintenance regulations in group 3
2 Hydraulic pumps
Fig. 2
Double variable-displacement pump and gear pumps
20 Double variable-displacement pump 32 Gear pump for steering

30 Gear pump for fan drive
33 Gear pump for pilot control
31 Gear pump for low-pressure circuit
and brake system
2.1
2.1.1
Double variable-displacement pump 20

Powered by:
Diesel engine
Via torsion dampers (flexible coupling)
2.1.2
Design:
Axial piston inclined axle
2.1.3
Classification:
Axial piston drive system with inclined axle
6.22.2
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Service Manual

Hydraulic pumps
Hydromechanic adjusting unit

Regulating unit
Technical data and description of functions:
see double variable-displacement pump in group 7.02
2.2
2.2.1
Gear pumps 30 - 33
Pump 30 for hydraulic fan drive:
Powered by diesel engine via gear system of the double variable-displacement pump 20
Supply of hydraulic fan drive
For flow rate, see "Technical data" in group 3
2.2.2
Pump 31 for brake system and low-pressure circuit:
Powered by diesel engine (direct)

With flow distributor
Preferred volume flow for brake system (connection K)
Supply of offset boom bearing and grapple rotator
with remaining volume flow (connection R)
2.2.3
Pump 32 for steering:

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

Powered via gear pump 32 (flange-connected)
Supply of control oil unit
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6.22.3
Service Manual
Pilot control
3 Pilot control
Fig. 3
Pilot control units on operator's platform and control oil unit
A
B
Control oil unit from start of series

Control oil unit from serial no. ()
86
87
Pilot control unit 2x, for kit

Positioning brake / slewing gear
Hydraulic tank
Y3
Solenoid valve of servo safety shut-down
50
80
Control oil unit

Pilot control unit 4x, left
Y24
Y50
Solenoid valve / creeper gear

Proportional solenoid valve / power control
81
84
Pilot control unit 4x, right

Pilot control unit 1x, for travel drive
Y51 Proportional solenoid valve / flow reduction P1

Y330 Solenoid valve reset pump P2
85
Pilot control unit 2x, for support
Y371 Solenoid valve / oscillating axle support
() Solenoid valve removed without replacement in A 309 machines from serial no. 26291 and A 311
machines from serial no. 26086, see also service information 07-11-37/2005
3.1
Purpose:
Hydraulic control of all operational and travel motions of the machine by means of hand and/or
foot-operated controls (pilot control valves / joystick etc.)
3.2
Design and function:

Pressure generated by separate gear pump 33, see Fig. 2
Control oil unit 50 regulates, monitors, filters, stores and distributes control oil and pressure.
6.22.4
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20
Service Manual

Arrangement of control valve block
3.3
Solenoid valve Y3 for shutdown of the pilot control pressure to the pilot control units
Solenoid valve Y24 for the control of the travel motor / creeper mode
Solenoid valve Y330 used to reset Qmin of pumps P2 during travel ;Note, see Fig. 3
Solenoid valve Y371for oscillating axle support
Pilot control valves 80 - 86 with regulating characteristics for comfortable operation:
Pilot control unit 80 and 81 with joystick to operate slewing gear and attachments.
Pilot control unit84 with foot pedal for the operation of the travel drive system
Pilot control unit85 with lever to operate outrigger / blade support
Pilot control unit 86 with foot pedal to operate supplementary attachment (kit)
Control lines leading from the pilot control units to the control caps of the respective spools.
Maintenance:
Replacing filter elements (control oil filter in control oil unit)
For description, see maintenance regulations in group 3.
4 Arrangement of control valve block
Fig. 4
Compact control valve block (high-pressure circuit) and auxiliary control valve block (lowpressure circuit)
100
Compact control block (high pressure)
107
Spool / bucket cylinder
101
102
Spool / slewing gear

Spool / stick cylinder
108
109
Spool / travel motor

Spool / combined boom cylinder /
stick cylinder
103
Spool / support cylinder
110
105
Spool / regulating cylinder
112
Auxiliary control valve block (low pressure)

106
Spool / boom cylinder
113
Spool / grapple rotator
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6.22.5
Service Manual
Oil rotary connection
4.1
Design of the compact control valve block 100:

Possibility to flange-mount more sections, e.g. another kit axle
Pressure control by means of screwed-in pressure relief valves (primary and secondary valves
with suction function)
Suction valves for chassis
Stroke limitation of spools
For description of functions, see group 7.50
5 Oil rotary connection
Fig. 5
260
5.1
Oil rotary connections located in the pivot point of the upper/undercarriage

Oil rotary connection for high pressure
7x
262
Oil rotary connection for low pressure

6x
Purpose:
Leads through hydraulic oil from uppercarriage to undercarriage and vice versa
5.2
Design:
Oil rotary connection 260 for high pressure
Travel drive system,
Outrigger and blade support
Steering
Leak oil
Oil rotary connection 262 for low pressure
Brake system
Gear shifting
Creeper gear
Oscillating axle support
For description, see groups 7.76 and 7.78.
6.22.6
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Service Manual

Consumers and attachments
6 Consumers and attachments
Fig. 6
64
Hydraulic cylinder for uppercarriage

locking mechanism (*)
210
Regulating travel motor DMVA
160-250
Hydraulic cylinder for attachment

and support
225
Transmission
190
Slewing gear motor FMF
(*) installed as standard in A 309 machines from serial no. 26392 and A 311 machines from serial no.
26396
6.1
Purpose:
Conversion of hydraulic energy into mechanical energy
6.2
6.2.1
Classification:
Cylinder 64 - 250
Hydraulic device for the transmission of pushing and/or pulling forces in linear motion with limited
stroke.
6.2.2
Oil motor 190 / 210

Hydraulic device for the transmission of torque in a rotary motion.
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MJFCIFSS
6.22.7
Service Manual
Hydraulic cylinder
7 Hydraulic cylinder
Fig. 7
7.1
Arrangement of consumers and working attachments
64
Hydraulic cylinder / uppercarriage locking 230

mechanism
160
170
Boom cylinder
Stick cylinder
180
Bucket cylinder
240
250
Support cylinder
Swivel cylinder
Regulating cylinder
Design:
Single-side cylinder
Mechanical return
Differential cylinder
No end-of-travel cushioning
With end-of-travel cushioning, one-end / two-end
7.2
Functional description
7.3
Classification:
Single-side cylinder as:
hydraulic cylinder 64 for the locking of the uppercarriage during on-road travel and transport.
Differential cylinder as:
Boom cylinder 160 actuates basic boom, with end-of-travel cushioning on the piston side.
Stick cylinder 170 moving the stick, with cushioning at both ends.
Bucket cylinder 180 moving the bucket, with end-of-travel cushioning on piston side.
Support cylinder 230 moving outrigger and/or blade support, no end-of-travel cushioning
Swivel cylinder 240 for the adjustment of the offset boom bearing, no end-of-travel cushioning
Regulating cylinder 250 operating the hydraulic outrigger adjusting device, no end-of-travel cushioning
6.22.8
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Service Manual

Slewing gear motor
8 Slewing gear motor
Fig. 8
190
8.1
Slewing gear motor mounted in slewing gear mechanism

195
Slewing gear motor FMF
Slewing gear mechanism SAT 225
Purpose:
Slewing gear motor 190driving the slewing gear mechanism
Slewing gear mechanism 195 rotating the uppercarriage
9 Travel motor
Fig. 9
210
Travel motor, flange-mounted to transmission

225
Travel motor DMVA
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Transmission 2 HL 70 / 2 HL 270
6.22.9
Service Manual
Hydraulic oil cooler
9.1
Purpose:
Travel motor 210 driving the transmissions
Transmission 225 for the travel of the machine
10
Fig. 10
10.1
13
Oil motor / radiator fan
B2
14
Pressure relief valve / fan motor
B285 Hydraulic oil temperature transducer (fan control)
15
30
Coarse filter / fan motor

Gear pump / cooling
Y352 Proportional solenoid valve / fan
Hydraulic oil temperature transducer (fan control)
Design:
Two-part cooling unit, consisting of an oil cooler for hydraulic oil (bottom), and an engine cooler
for coolant / diesel engine (top)
Hydrostatic fan drive, controlled by the hydraulic and coolant temperature, with high air flow rate
Fan speed is controlled electronically, relative to temperature, through the proportional solenoid
valve Y352
For a detailed description of the cooling unit, see group 7.20.
6.22.10
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Service Manual

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6.22.11
Service Manual
6.22.12
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Service Manual

Hydraulic tank

1 Hydraulic tank
Fig. 1
1.1
Hydraulic tank
Hydraulic tank
2
3
Breather filter
Stop cock
5 Safety check valve

K Oil level sight glass
Return filter
Purpose

Supplies purified and cooled oil to the hydraulic pumps.
Provides reservoir for return oil, with return filters.
Preloads oil to prevent cavitation.
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MJFCIFSS
6.24.1
Service Manual
Hydraulic tank
1.2
Design
Fig. 2
1
Section drawing of hydraulic tank
Hydraulic tank
A Return side
Breather filter
3
4
Stop cock
Return filter
C Drain valve (collection area)

D Drain valve (suction side)
Safety check valve
K Oil level sight glass
Suction side
Classification:
Return side A with return filter 4
Suction side C with suction pipe, stop cock 3
Filter units:
Return filter 4 with 2-stage fibre glass -filter element and safety check valve- 5
Filter elements:
for intake (initial equipment) 10
for normal use 2-stage 20 05 , for use in dusty environments 10
Breather filter: for normal use 7 , for use in dusty environments 2
1.3
Maintenance
Check of oil level through the oil level sighting glass K

Replacement of filter elements in return and breather filter
Drainage of the tank through the drain valves C and D
see inspection and maintenance schedule in group 3
Note!
For a detailed description of the hydraulic tank, see group 19.
6.24.2
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Service Manual

Hydraulic pumps
2 Hydraulic pumps
2.1
Variable-displacement pump 20
Fig. 3
20 Variable-displacement pump
23 Regulating unit
Purpose:
Supply of all consumers with high pressure oil
Powered by:
Diesel engine
Design:
Axial piston powertrain
Adjustable unit with swash plate
Regulating unit 23 with performance regulator GLR and LS regulator
see variable-displacement pump in group 7.05
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6.24.3
Service Manual
Hydraulic pumps
2.2
Gear pumps
Fig. 4
Gear pumps 30, 31 and 32
31 Steering pump
30 Pump for fan drive/radiator fan
32 Pump for brake and pilot control system
Pump 30 for fan drive/radiator fan

Driven by variable-displacement pump 20
Supply of oil motor/fan drive, see 4.
For flow rate, see technical data in group 3
Pump 31 for steering:
Powered by diesel engine (flange-mounted)
Supply of Servostat, see group 13.20
For flow rate see technical data in group 3
Pump 32 for brake and pilot control system:
Powered by diesel engine (flange-mounted)
Distribution of flow volume from the pump 32 by means of integrated flow distributor
Constant flow K: Supply of braking system, see group 15.10
Residual flow: Supply of control oil unit, see group 7.42
6.24.4
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Service Manual

Compact control block
3 Compact control block
Fig. 5
3.1
Compact control block 100
Purpose:
Distribution of the requested pump flow volumes to the consumers
3.2
Design:
Compact control block 100
Integrated LUDV control
Input section
5 spools with one pressure balance each for LUDV-control
Flange-mounting option for additional sections, e.g. auxiliary way valve for accessory kits
with suction function) for attachment
Stroke limitation of the spool
For a description of the functions, see group 7.60
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6.24.5
Service Manual
4 Hydraulic oil cooler

4.1
Purpose
Cooling of return oil
Cooled by motor-driven fan
Fig. 6
13
4.2
design of hydraulic oil cooling system
14
13
Blower motor
Y352 Proportional solenoid valve
Pressure-relief valve
Design
Three-part cooling unit, consisting of an oil cooler 6 for hydraulic oil (centre), and an coolant cooler
for the diesel engine (bottom)
Temperature-controlled cooling by means of annual fans.
The fans are driven by a blower motor 13 with the pressure-relief valve 14 and the proportional
valve Y352.
6.24.6
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Service Manual


5.1
Purpose
Transfer of hydraulic oil from the uppercarriage to the undercarriage and vice versa.
5.2
Design

Travel drive, outrigger and blade support, steering and leak oil
Braking system, gear shifting, creeper gear system, oscillating axle support
For a detailed description, see groups 7.76 and 7.78.
Fig. 7
320

Rotary connection for high pressure
322
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MJFCIFSS
Rotary connection for low pressure
6.24.7
Service Manual
Consumers / working attachments
6 Consumers / working attachments
Fig. 8
6.1
130
170
Slewing gear motor

Travel motor
255
275
Stick cylinder
Bucket cylinder
235
Boom cylinder
295
Support cylinder
Function and classification

Conversion of hydraulic energy into mechanical energy
stroke, see 6.2.
Hydraulic device for the transmission of torque in a rotary motion, see 6.3.
6.2
Cylinder
Design:
without end-of-travel cushioning
with single-side or double-side end-of-travel cushioning
For a description of the functions, see group 7.30
6.24.8
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Service Manual

Pilot control
Classification:
Boom cylinder 235 moving the basic boom, with single-side end-of-travel cushioning.
Stick cylinder 255 moving the bucket stick, with cushioning at both ends.
Bucket cylinder 275 moving the bucket, with single-side end-of-travel cushioning.
Support cylinder 295 moving the outrigger and/or blade support, no end-of-travel cushioning
6.3
Oil motor
Design:
Axial piston swash plate
constant (with constant oil flow consumption)
regulated (with variable oil flow consumption)
For a description of the functions: see groups 7.24, 7.26 and 7.27
Classification:
Slewing gear motor 130 with integrated control to drive the uppercarriage by means of the slewing
gear mechanism constant flow consumption
Travel motor 170 to drive the vehicle wheels through the transmission regulated by the travel
brake valve 190
7 Pilot control
7.1
Purpose
Hydraulic control of all working and travel motions of the machine by means of hand and/or footoperated controls (pilot control units, / actuators, etc.)
7.2
Design and function
Fig. 9
Control oil unit and pilot control units on the operator's platform
50 Control oil unit

80 Pilot control unit for stick and rotary movement
85 Pilot control unit / support

86 Pilot control unit for accessory kits
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6.24.9
Service Manual
Hydraulic control
81 Pilot control unit for boom and bucket move- 87 Pedal for positioning brake
ment
84 Pilot control unit for chassis
Pressure generated by separate gear pump 32, see 2.2
Control oil unit 50 regulates, monitors, filters, stores and distributes control oil at the required pilot
pressure
Proportional solenoid for the control of the variable-displacement pump 20
Solenoid valves
for the shut-down of the pilot control pressure
for the control of the creeper gear and oscillating axle support
for the provision of the pilot control pressure for additional excavator functions (e.g. gear shifting
and speed adjustment of the diesel engine)
For a detailed description, see group 7.42 .
Pilot control units 80 - 86 with regulating characteristic for easy excavator operation
Pilot control units 80 and 81 with joystick used to operate the slewing gear and the attachments, see group 7.45
Pilot control unit 84 with pedal, used to control the chassis, see group 7.49
Pilot control unit 85 with lever, used to control the support, see group 7.48
Pilot control unit 86 with pedal, used to control the accessory kits, see group 7.47
Pedal for positioning brake 87
Control lines leading from the pilot control units to the control caps of the respective spools
7.3
Maintenance
For a detailed description, see inspection and maintenance schedule in group 3
8 Hydraulic control
The LIEBHERR hydraulic excavator generation of the A 312 - R 317 Litronic series is equipped with
the LSC -hydraulic control system (Liebherr synchronous control).
It allows operators to work much faster and much more precisely, thanks to easier and simpler overall
handling of the machine.
The biggest advantage of the LSC system is, however, that handling and operation can be adapted
much better to prevailing working conditions.
The speed of the working movement is determined by the displacement of the control lever / pilot control valve, not by the load pressure.
Other advantages of the LSC system:
Several consumers can be handled simultaneously, without any problems, independently of load
pressure and even with saturation deficits.
The LSC system will adapt flow rates to the requirements of the various consumers.
Pressures are adapted to the consumer with the highest load.
Economic operation matched to actual application of the machine
For a detailed description of the principle, design and function, see group 6.20
6.24.10
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MJFCIFSS
Service Manual

Tank arrangement

1 Tank arrangement
Fig. 1
11
1.1
1.1.1
Hydraulic tank
50
Control oil unit
Breather filter
B8
Temperature transducer / hydraulic oil
Stop cock
Return filter
B285 Temperature transducer / hydraulic oil (fan control)

K
Sight glasses for hydraulic oil level
Integrated bypass valve
Hydraulic tank
Purpose:
1.1.2
Hydraulic tank with filters and other components

Supplies purified oil to hydraulic pumps.
Reservoir for return oil, with return filters.
Preloads oil to prevent cavitation.
Filter units:
Return filter 4 with two-stage glass-fibre filter element and bypass valve 5 (integrated in return filter)
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MJFCIFSS
6.27.1
Service Manual
Hydraulic pumps
Breather filter 2
1.1.3
Filter elements:
Return filter element for commissioning (factory-installed) 10
Return filter element for cleaning of circuit (after oil change / pump failure) 5
Return filter element for normal operation, two-stage 20 / 5 ,
for use in dusty environments single-stage 10
Breather filter 2 complete, for normal operation 7 ,
for use in dusty environments 2
1.1.4
Maintenance:
Changing hydraulic oil

Replacing return filter element and breather filter
Draining tank
see maintenance regulations in group 3
2 Hydraulic pumps
Fig. 2
Variable-displacement pump with integrated or flange-connected gear pumps
31 Gear pump for fan drive
30 Gear pump for pilot control system
6.27.2
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Service Manual

Pilot control
2.1
2.1.1
Powered by:
diesel engine
2.1.2
Design:
Axial piston swash plate
2.1.3
Classification:
Axial piston drive system with swash plate
Hydromechanical adjusting unit
Regulating unit
see variable-displacement pump in group 7.05
2.2
2.2.1
Gear pumps 30 / 31:

Pump 30 for pilot control:
Driven by variable-displacement pump 20 (built in)
Supply of control oil unit
2.2.2
Pump 31 for hydraulic fan drive:

Powered by variable-displacement pump (flange-connected)
Supply of hydraulic fan drive
3 Pilot control
Fig. 3
Control oil unit 50 and view of pilot control units on operator's platform
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MJFCIFSS
6.27.3
Service Manual
Pilot control
50
Control oil unit
Y3
Solenoid valve / servo shutdown
80
Pilot control unit 4x, left
Y7
Solenoid valve slewing gear brake
81
Pilot control unit 4x, right
Y24
Solenoid valve / fast travel gear shifting
82
Pilot control unit 1x, for travel drive,

left
Pilot control unit 1x, for travel drive,
right
Y50
Y51
Proportional solenoid valve / flow reduction
83
86
3.1
Pilot control unit 2x, for accessory kit
Purpose:
Hydraulic control of all operational and travel motions of the machine by means of hand and/or
foot-operated controls (pilot control valves / joystick etc.)
3.2
Design and function:

Pressure generated by separate gear pump 30, see Fig. 2
Control oil unit 50 regulates, monitors, filters, stores and distributes control oil and pressure.
Solenoid valve Y3 for shutdown of pilot control pressure
Solenoid valve Y7 for the control of slewing gear brake
Solenoid valve Y24 for the control of fast travel gear shifting
Proportional solenoid valves Y50 / Y51 for the control of the variable-displacement pump 20
Pilot control valves 80 - 86 with regulating characteristics for comfortable operation:
Pilot control unit 80 and 81 with joystick to operate slewing gear and attachments.
Pilot control unit 82 with foot pedal for the operation of the travel drive system, left
Pilot control unit 83 with foot pedal for the operation of the travel drive system, right
Pilot control unit 86 with foot pedal to operate supplementary attachment (kit)
Control lines leading from the pilot control units to the control caps of the respective spools
3.3
Maintenance
For description, see maintenance regulations in group 3.
6.27.4
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Service Manual

Arrangement of control valve block
4 Arrangement of control valve block
Fig. 4
4.1
Compact control valve block 100
100
120
Compact control valve block

220
240

160
180
Spool for travel, right

Spool for travel, left
260
Design of the compact control valve block 100:
Integrated LUDV control

Input section
5 spools
1 auxiliary axle with spool for slewing gear
one pressure balance for each spool, used for LUDV control
Possibility to flange-mount more sections, e.g. another kit axle
with suction function)
Bleeder valves of control lids
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MJFCIFSS
6.27.5
Service Manual
Fig. 5
195
5.1
Oil rotary connections located in the pivot point of the upper/undercarriage
Oil rotary connection for high pressure

5x
196
Oil rotary connection for low pressure

1x
Purpose:
feeds hydraulic oil from the uppercarriage to the undercarriage and vice versa
5.2
Design:
Travel drive left forward / reverse
Travel drive right forward / reverse
Leak oil
Fast travel gear shifting
For a description, see groups 7.75 and 7.77.
6.27.6
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Service Manual

6 Consumers and attachments
6.1
Fig. 6
235-275
Hydraulic cylinder for attachment
200
Travel motor, A6VE, left
130
FMF slewing gear motor
201
Travel motor, A6VE right
Purpose:
Convert hydraulic energy to mechanical energy
6.2
6.2.1
Classification:
Cylinders 235 / 255 / 275
stroke.
6.2.2
Oil motors 130 / 200 / 201

Hydraulic device for the transmission of torque in a rotary motion.
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MJFCIFSS
6.27.7
Service Manual
Hydraulic cylinder
7 Hydraulic cylinder
Fig. 7
235
255
7.1
Arrangement of consumers and working attachments
275
Boom cylinder
Stick cylinder
Bucket cylinder
Design:
with end-of-travel cushioning, one-end / two-end
7.2
For description of functions of the cylinders, see group 7.30.
7.3
Classification:
Boom cylinder 235 actuates basic boom, with end-of-travel cushioning on the piston side.
Stick cylinder 255 moving the stick, with cushioning at both ends.
Bucket cylinder 275 moving the bucket, with end-of-travel cushioning on piston side.
6.27.8
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Service Manual

Slewing gear motor
8 Slewing gear motor
Fig. 8
130
8.1
Slewing gear motor mounted in slewing gear mechanism
156
FMF slewing gear motor
Slewing gear mechanism SAT 225
Purpose:
Slewing gear motor 130 driving the slewing gear mechanism
Slewing gear mechanism 156 rotating the uppercarriage
Travel motor
Fig. 9
Travel motors, installed in the travel gears 216 of the undercarriage
200
Travel motor, left
201
Travel motor, right
216
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MJFCIFSS
Travel gear
6.27.9
Service Manual
9.1
Purpose
Travel motors 200 / 201 driving the travel gear 216
Travel gear 216 drives the tumbler wheels and chains
10
10.1

Purpose
Cooling of return oil
Cooled by motor-driven fan
Fig. 10
13
6
13
10.2
Design of hydraulic oil cooling system

14

Blower motor
Design
Three-part cooling unit, consisting of an oil cooler 6 for hydraulic oil (centre), and an coolant cooler
for the diesel engine (bottom)
Temperature-controlled cooling by means of annual fans.
The fans are driven by a blower motor 13 with the pressure-relief valve 14 and the proportional
valve Y352.
6.27.10
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MJFCIFSS
Service Manual

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MJFCIFSS
6.27.11
Service Manual
6.27.12
copyright by
MJFCIFSS
Service Manual

Arrangement of measuring points

Caution!
For maintenance work on the hydraulic unit, the undercarriage and the uppercarriage of the machine must be accessed. This poses a great danger for mechanics.
During all adjustment and setting procedures, strictly adhere to the general safety instructions laid
down in group 1.10.
Adjustment and setting by skilled and well trained personnel only.
1 Arrangement of measuring points
Fig. 1
40
41
43
44
45
49
57
59
197
198
Measuring points at variable-displacement pump LPV 20, control valve block 50 and control oil unit 100
Measuring point for high pressure of pump 1 at the control valve block 100 (connection M1)
Measuring point for high pressure of pump 2 at the control valve block 100 (connection M2)
Measuring point for the control chamber pressure at the pump P1
Measuring point for the control chamber pressure at the pump P2
Measuring point for low pressure at the flow distributor connection R of the gear pump 31 for
the offset boom bearing and AS1
Measuring point for the pilot pressure at the control oil unit 50 (connection M)
Measuring point for the flow reduction control pressure (connection X1) at the pump 20
Measuring point for the power control pressure (connection X3) at the pump 20
Measuring point for the slewing gear working pressure at the slewing gear motor 190 (connection MA for turning right)
Measuring point for the slewing gear working pressure at the slewing gear motor 190 (connection MB, turning left)
Note
If a AHS 1, AHS 11 or AHS 12 attachment kit is installed, the measuring point 40 for the high pressure from the pump 1 is located at the auxiliary control valve block.
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MJFCIFSS
6.30.1
Service Manual
Measuring instruments / adjusting tools
2 Measuring instruments / adjusting tools

2.1
Measuring instruments
You need the following measuring instruments and tools o check and/or adjust the hydraulic equipment:
MS measuring system tool, tool no. 40
For pilot pressure:
For high pressure:
> Pressure sensor 0 - 60 bar

For actuating pressure:
plus measuring cable and accessories for the measuring of speed and temperature
Alternative:
Speed measurement:
>Speed counter, tool no. 60 / 62
Temperature measurement: >Thermometer, tool no. 70 / 72
For pilot pressure:
> Pressure gauge 0 - 60 bar
For high pressure:
Note!
For the adjustment of valves and units, use commercially available high-quality tools, for instance:
ring spanners, open end spanners and Allen keys.
Secure adjusting screws against tampering and unintentional interference:
Use lead seal wire.
Use safety caps (see tools no. 20 - 25 in group 2.05).
2.2
Instructions for adjustment / pre-conditions

Note!
During the warranty period, only LIEBHERR agents and mechanics may modify settings of valves and units.
2.2.1
Prior to checking and adjusting the settings of the hydraulic system, ensure
that the following conditions are fulfilled:
The operating temperature of the hydraulic unit (measured in the tank) must be minimum 50C.
The pressure gauges must be glycerine-filled and have an indicating accuracy of below 1% relative to the scale end value.
When measuring or adjusting an actuated spool of the control valve block, ensure that the piston
is fully lifted at maximum control pressure (maximum piston stroke).
6.30.2
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Service Manual

Checking and adjusting pilot pressure
Note!
In the event of hydraulic failures, follow the instructions in the adjustment protocol in the
prescribed sequence.
The required minimum oil temperature can be obtained by actuating the 'close bucket' command while the pressure at the secondary pressure relief valve 133 is lowered (close bucket /
grapple).
All valves must be secured against unauthorized readjustment by safety caps.
3 Checking and adjusting pilot pressure
Fig. 2
Control oil unit located at the hydraulic tank
49 Measuring connection
51 Pressure relief valve / pilot control
50 Control oil unit

Connect the pressure gauge (0-60 bar) to the measuring point 49.
Run the engine at maximum speed.
Compare the displayed pressure with the prescribed pressure (see adjustment protocol).
If necessary, adjust the setting of the pressure relief valve 51.
Proceed as follows: Remove the safety cap. Loosen the lock nut (WS 13). Use an Allen key (WS
4) to turn the adjusting screw.
Turn clockwise (cw)
increase pressure
Turn counter-clockwise (ccw)
reduce pressure
Secure the adjusting screw 51 with the lock nut and replace the safety cap.
Disconnect the pressure sensor or gauge and seal the measuring point 49.
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MJFCIFSS
6.30.3
Service Manual
Checking the proportional solenoid valve Y50
4 Checking the proportional solenoid valve Y50

Start the machine.
Using a suitable adapter (tool no. 44 in group 2.01), measure the current at the valve Y50.
Based on the chart, determine the required pressure and compare with the actual pressure at the
measuring point 59.
Fig. 3
50
Control oil unit
Y50
59
Measuring point LR (power control)
Current OK
Pressure OK
=> Everything OK
Current OK
Pressure not
OK
=> Replace proportional solenoid valve.
Current not
OK
Pressure not
OK
=> Search for fault in the electrical system and the horsepower control
Note!
The characteristic of the solenoid valve Y50 cannot be adjusted.
4.1
Adjusting the regulating pressure for emergency operation

Switch off machine.
Remove the plug from the proportional solenoid valve Y50, see Fig. 3,.
Remove the cotter pin and tilt the lever.
Start the machine.
Compare the pressure values to those in the adjustment protocol and adjust, if necessary.
Proceed as follows: Remove the lock nut and turn the insert by hand.
Turn clockwise (cw)
=
increase pressure
6.30.4
reduce pressure
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Service Manual

Re-set the lever to its initial position.
Insert the cotter pin.
Disconnect the pressure sensor or gauge and seal the measuring point 59.

Start the machine.
Adjust the current to the proportional solenoid 51 by means of the speed step switch (positions 1
- 6) or the flow reduction (kit).
Using a suitable adapter (tool no. 44 in group 2.01), measure the current at valve Y51.
measuring point 57.
Fig. 4
50
Control oil unit
57
Measuring point LS (flow reduction)
Y51
Current OK
Current OK
Pressure OK
Pressure not
OK
=> Everything OK
Current not
OK
Pressure not
OK
=> Search for fault in the electrical system.
Note!
The characteristic of the solenoid valve Y51 cannot be adjusted.
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MJFCIFSS
6.30.5
Service Manual
Checking of flow reduction of pump P1
6 Checking of flow reduction of pump P1

Note:
The flow reduction of pump P1 works only properly, if the threaded stud 73 is properly inserted. The
stud is factory-set and secured.
Incorrect stud position results in incorrect flow reduction and malfunction of the pump.
If the threaded stud 73 is screwed in too far, the powertrain cannot reach the maximum pivoting angle, i.e. flow reduction remains active even if there is no pressure at the proportional
solenoid valve Y51.
If the threaded stud 73 is screwed out too much, flow reduction is not possible, even when
the proportional solenoid valve is activated Y51 (i.e. correct current and pressure at the valve).
6.1
Check measurement at the adjusting screw for flow reduction:

Remove the safety cap 75 of the threaded stud 73.
Using a calliper gauge, measure distance X between the upper edge of the threaded stud 73 and
the upper edge of the screw plug 72 and compare with the prescribed value in the adjustment protocol.
If necessary, loosen the lock nut 74 and adjust the distance X . Tighten the lock nut 74 and mount
a new safety cap 75.
R
Fig. 5
72
73
6.30.6
Adjusting screw for flow reduction of pump P1

74
75
Screw plug
Threaded stud
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MJFCIFSS
Seal-Lock collar nut

Safety cap
Service Manual

Checking and adjusting the variable-displacement pumps
7 Checking and adjusting the variable-displacement pumps
Fig. 6
1
Adjusting screw of begin of regulation P1
Adjusting screw of begin of regulation P2
Lock nut / adjustment Y50 (basic setting / 59

emergency operation)
20
40
7.1
Measuring connections and valves
Measuring point for high pressure from

pump 1 at the control valve block 100
(connection M1)
43
Measuring point for the control chamber

pressure at the pump P1
44
Measuring point for the control chamber

50
Control oil unit

X1
20
Measuring point for the power control

pressure (connection X3) at the pump 20
120
121
Primary pressure relief valve for pump P1

Y50
Y51
Hydraulic begin of regulation (basic setting)

To check the begin of the hydraulic regulation, determine the point from which the pump is regulated
from Q max to Q min.
Connect pressure sensors or gauges (0-60 bar) to the measuring points 57 and 59.
Disconnect the plugs at the proportional solenoid valves Y50 and Y51.
Measure the pressure at the measuring points 57 and 59
(Measuring point 57 = tank pressure).
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MJFCIFSS
6.30.7
Service Manual

Remove the cotter pin from the lever at Y50 and tilt it (emergency position).
The pressure at the measuring point 59 must correspond to the prescribed value (see emergency
pressure in adjustment protocol).
If required, adjust the emergency pressure value at the nut 3.
Connect pressure sensors or gauges (0-600 bar) to the measuring points 40 / 41 (control valve
block 100).
Connect pressure sensors or gauges (0-600 bar) to the measuring points 43 / 44 (p control chamber
variable-displacement pump P1 / P2).
of
Start the engine.

Run the diesel engine at low speed (level 2 / 3, approx. 1200 rpm).
7.1.1
Checking and adjustment of the pump P1

Fully extend the bucket or grapple cylinder.
Press the pilot control unit to the stop.
Lower the pressure at the primary pressure relief valve 120 to a value below the begin of regulation (p pump = p valve) and (p control chamber = p tank).
Slowly screw in the primary pressure relief valve 120 until the pressure at the measuring point 43
(p control chamber) begins to rise (5 - 10 bar).
Compare the pressure indicated at the measuring point 40 with the prescribed value (see basic
begin of pressure regulation in adjustment protocol).
If the value does not correspond to the prescribed pressure value, adjust the begin of regulation as
described below.
Set the primary press relief valve 120 to the basic begin of regulation (see adjustment protocol).
Turn in the adjusting screw 1 at the pump P1 until p control chamber = ptank.
Carefully screw out the adjusting screw 1 until p control chamber is about 5 - 10 bar below p pump pressure.
Secure the adjusting screw 1 with a lock nut.

Check again the begin of regulation by reducing and increasing the pressure with the primary relief
valve 120as described above.
7.1.2
Checking and adjustment of the pump P2

Fully extend the support cylinder.
Lower the pressure at the primary pressure relief valve 121 to a value below the begin of regulation (p pump = p valve) and (p control chamber = p tank).
Slowly screw in the primary pressure relief valve 121 until the pressure at the measuring point 44
(p control chamber) begins to rise (5 - 10 bar).
Compare the pressure indicated at the measuring point 41 with the prescribed value (see basic
begin of pressure regulation in adjustment protocol).
If the value does not correspond to the prescribed pressure value, adjust the begin of regulation as
described below.
Set the primary press relief valve 121 to the basic begin of regulation (see adjustment protocol).
6.30.8
copyright by
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Service Manual

Turn in the adjusting screw 2 at the pump P1 until p control chamber = ptank.
Carefully screw out the adjusting screw 2 until p control chamber is about 5 - 10 bar below p pump pressure.
Secure the adjusting screw 2 with a lock nut.

Check again the begin of regulation by reducing and increasing the pressure with the primary relief
valve 121as described above.
Connect the plugs to the proportional solenoid valves Y50 / Y51.
Return the lever of Y50 to its normal position (i.e. upwards) and secure it with the cotter pin.
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MJFCIFSS
6.30.9
Service Manual
Checking output power of the diesel engine (power test)
8 Checking output power of the diesel engine (power test)

This test is only required, if the power output of the diesel engine is reduced.
8.1
Principle
The power input of the pump can be calculated with the following formula:
If the pump is maintained at maximum pivoting angle, the power input of the powertrain is determined
solely by the pressure (see adjustment protocol). This pressure value has been measured individually
for each model and size of attachment, whereby secondary consumers have also been taken into
consideration.
Fig. 7
20

A8VO
Measuring point for high pressure of
(connection M1)
120
121
41

(connection M2)
Y50
43
Measuring point for the control chamber Y51 Proportional solenoid valve / flow reduction
Measuring point for the control chamber Y352 Proportional solenoid valve of radiator fan
40
44
50
6.30.10
Pump, control oil unit, control valve block and cooling unit
Control oil unit
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Service Manual

8.2
Proceed as follows:
Connect the pressure sensor or gauge (0-600 bar) to the measuring point 41 (control valve block
100).
Connect a pressure sensor or pressure gauge (0-600 bar) to the measuring point 43 (pump P1)
and the measuring point 44 (pump P2).
Connect the speed counter (tool no. 60 in group 2.01) via B12 and LMS to the engine, using a
measuring adapter (tool no. 45 /46), if necessary.
Start the machine.
Run the engine at maximum speed (level 9*).
Lower the pressure at the primary pressure relief valve 120 / 121 (extending stick cylinder), (see
Fig. 7 page 10) to a value below the test pressure (see adjustment protocol).
Note:
In machines equipped with kit AHS, the valve 120 is located at the auxiliary control valve block. The
bore of valve 120 in the compact block 100 is sealed.
Disconnect the plug at the solenoid valve Y 352 (fan).
Disconnect Y50 or activate the power test menu at the laptop.
Fully extend the stick or bucket cylinder.
Press the pilot control units to the stop.
Increase the pressure until the pressure at the measuring point 41 reaches the prescribed pressure (see adjustment protocol).
Note!
The pressure sensors at the measuring points 43 and 44 may only indicate the tank pressure, i.e.
the pumps must be set to Qmax.
Note down the speed at the speed counter or the LMS measuring device or laptop.
Speed
> Regulating
rpm
=> Diesel engine output OK
Speed
< Regulating
rpm
=> Diesel engine output not OK
* from software version V5.12, only the speed level 8 is reached when the servo steering is switched
on (through S35).
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6.30.11
Service Manual
Checking and adjusting the secondary pressure
9 Checking and adjusting the secondary pressure

9.1
Fig. 8
100
Control valve block with measuring connections and valves
40
Measuring point (pump P1)
127
41
Measuring point (pump P2)
128
100
129
120
Primary pressure relief valve of pump P1
130
Secondary relief valve / retracting regulating cylinder
121
Primary pressure relief valve of pump P2
131
Secondary relief valve / retracting boom

cylinder
Secondary relief valve / extending boom
cylinder
132
133
134
Secondary relief valve / retracting stick

cylinder
Secondary relief valve / retracting stick
cylinder
Secondary relief valve / extending stick
cylinder
Secondary relief valve / retracting bucket

cylinder
Secondary relief valve / extending bucket
cylinder
The output of the diesel engine and the hydraulic pump must correspond to the values prescribed
in the adjustment protocol.
Connect the pressure sensor or gauge (0-600 bar) to the measuring point 41.
Start the machine.
Run the engine at maximum speed (level 9).
Fully extend the stick cylinder.
Press the pilot control units to the stop.
Increase the pressure at the primary pressure relief valves 120 and 121 to a value above the adjusting value of the secondary pressure relief valves (see adjustment protocol), (turn in valves).
Extend or retract the respective cylinder.
6.30.12
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Service Manual

Checking and adjusting the secondary pressure
Compare the indicated pressure with the prescribed pressure (see adjustment protocol).
If necessary, adjust the setting of the pressure relief valves 127 - 134.
To do this, remove the safety cap and loosen the lock nut (WS 19). Using an Allen key (WS 4),turn
the adjusting screw.
Turn clockwise (cw)
= increase pressure
= reduce pressure
Note!
The prescribed secondary pressure at valve 130 (retracting regulating cylinder) cannot be reached
from serial no. 27110. The correct adjustment of the valve 130 is to be completed as described below.
Adjust the pressure at the valve 130 to 240 bar.
Turn the adjusting screw of the valve 130 by 1 full revolution. The prescribed secondary pressure
is reached, see adjustment protocol.
Secure the adjusting screws of the valves 127 - 134 with lock nuts and replace the safety caps.
9.2
Travel functions
Fig. 9
210
Travel motor with valves

Travel motor DMVA
214
Secondary relief valve / forward travel
215
Secondary relief valve / reverse travel

Preselect on-road gear.
Apply the working brake (locking device engaged).
Operate the travel motor 210 and move forward and back.
Turn the secondary pressure relief valves 214 and 215 until the prescribed pressure is reached.
To do this, remove the safety caps and loosen the lock nut (WS 19). Using an Allen key (WS 6),
turn the adjusting screw.
Turn clockwise (cw)
increase pressure
reduce pressure
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MJFCIFSS
6.30.13
Service Manual
Checking and adjusting the primary pressure (operating pressure).

Adjust the primary pressure control valves 120 and 121 to the prescribed value, see description
below in section 10.
10
Checking and adjusting the primary pressure (operating pressure).

Connect pressure sensors or gauges (0-600 bar) to the measuring points 40 / 41 (control valve
block 100, (see Fig. 8 page 12)).
Start the machine.
Run the engine at maximum speed (level 9*).
Fully extend the bucket cylinder.
Compare the pressure indicated at the measuring point 40 with the prescribed pressure (see adjustment protocol).
Turn the primary pressure relief valve 120 until the prescribed pressure is reached.
Turn clockwise (cw)
=
=
increase pressure
reduce pressure
Fully extend the support cylinder.

Compare the pressure indicated at the measuring point 41 with the prescribed pressure (see adjustment protocol).
Turn clockwise (cw)
increase pressure
reduce pressure
Disconnect the pressure sensor or gauge and seal the measuring points 40 / 41.
* from software version V5.12, only the speed level 8 is reached when the servo steering is switched
on (through S35).
6.30.14
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Service Manual
Checking and adjusting the primary pressure for the offset boom bearing and the kit (low pressure)
11 Checking and adjusting the primary pressure for the offset boom
bearing and the kit (low pressure)
Fig. 10
31
45
Low pressure control block and diesel engine with working and auxiliary pumps
Gear pump / brake and attachment kit AS 110

with flow distributor
Measuring point for low pressure
123
Low pressure control valve block

Pressure relief valve for low pressure
Start the machine.
Fully extend the swivel cylinder.
To do this, remove the safety cap and loosen the lock nut (WS 19). Using an Allen key (WS 4),turn
the adjusting screw.
Turn clockwise (cw)
increase pressure
reduce pressure
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MJFCIFSS
6.30.15
Service Manual
Checking and adjusting secondary pressure for slewing gear
12
Fig. 11
12.1
Slewing gear motor with measuring points and 2-stage valves
190
Slewing gear motor
197
Measuring point, turning right
191
192
Secondary pressure relief valve, turning right

Secondary pressure relief valve, turning left
198
Measuring point, turning left
Start-up pressure settings

Danger!
Uncontrolled rotating movement of the uppercarriage during adjusting work can lead to serious injury or damage to the equipment. Prior to carrying out any adjustment work:
Apply the slewing gear brake.
Lock the uppercarriage against undercarriage, using the locking mechanism.
Anchor the equipment to the ground.
Cordon off the machine and the danger zone (swivel range) against unauthorized access.
Connect the pressure sensor or gauge (0-600 bar) to the measuring points 197 / 198.
Block the uppercarriage (maximum pressure is not be reached when the uppercarriage is rotated).
Start the machine.
Turn the slewing with full load to the right.
If required, check the maximum control pressure at the oil motor connection XA.
Compare the pressure indicated at the measuring point 197 with the prescribed high pressure
(swivelling to right, see adjustment protocol).
Turn clockwise (cw)
=
=
increase pressure
reduce pressure
Turn the slewing with full load to the left.

6.30.16
copyright by
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Service Manual

If required, check the maximum control pressure at the oil motor connection XB.
Compare the pressure indicated at the measuring point 198 with the prescribed high pressure
(swivelling to left, see adjustment protocol).
12.2
Turn clockwise (cw)
increase pressure
reduce pressure
Setting brake pressure

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

Compare the pressure indicated at the measuring point 197 with the prescribed low pressure (braking left, see adjustment protocol).
If necessary, loosen the lock nut 3 and adjust the pressure relief valve 191 using the adjusting
screw 4.
Turn clockwise (cw)
=
=
increase pressure
reduce pressure
Re-connect the hose connections to XA and XB.
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6.30.17
Service Manual
Checking travel motor 210
13
Fig. 12
13.1
Control valve block and travel motor
3.35
Screw plug at measuring point M
40
4.14
Qmin stop
100
Measuring point for working pressure of

pump P1
Control valve block
4.28
Safety cap
210
Travel motor DMVA
Setting begin of regulation (end of regulation), see Fig. 12 and see Fig. 13
Danger!
Uncontrolled travel movement (brakes not properly applied!) can lead to serious injury or damage!
Press the attachment into the soil.
Extend all supports and immobilize the machine.
Cordon off the machine and the danger zone against unauthorised access.
Prior to carrying out any measurements or adjustments to the travel motor, ensure that the drive
system is shut down.
Connect the pressure sensor or gauge (0-600 bar) to the measuring point 40 (control valve block
100 right).
Remove the screw plug from the measuring point M located at to the left at the rear of the housing.
Attach the screw coupling M10X1 (tool no 10 in group 2.01, with extension, is required) and connect the pressure sensor (see Fig. 12).
Select (on-road gear)
Run the machine against the applied brake (on-road gear). Press the pedal slowly and carefully
down to rev up the travel motor. High pressure builds up at the measuring point 40.
Below the begin of regulation for the engine A, no pressure may be building up at the measuring
6.30.18
copyright by
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Service Manual

connection M, i.e. the oil motor is at minimum pivot angle.
Fig. 13
Regulating characteristic of the travel motor with begin and end of regulation
A Begin of regulation
B End of regulation
p Operating pressure
M Measuring point at the travel motor
Q Engine flow consumption

41 Measuring point at the control valve block
Continue to rev up the engine to the maximum speed. Keep your eyes on both pressure sensors
(at measuring points 40 and M).
From the begin of regulation A the pressure at the measuring connection M must continue to
increase (to about 1/2 high pressure value), i.e. the oil motor is adjusted towards the max. pivot
angle.
As soon as the high pressure (at measuring point 40) reaches the value of the end of regulation
B, the value measured at point M rises to the high pressure value, i.e. the pressures at measuring points 40 and M are identical (see Fig. 13).
If the pressure value for the end of regulation B does not correspond to the prescribed value, turn the
adjusting screw 4.14, (see Fig. 12 page 18).
To do this, release the adjusting screw 4.14. Using an Allen key (WS 8), turn the screw until end of
regulation B is correct.
Turn in
increase end of regulation
Turn out
decrease end of regulation
Note!
The begin of regulation A cannot be adjusted separately.
After adjusting the end of regulation B, secure the adjusting screw 4.14 with the lock nut.
Remove both pressure sensors and the screw coupling. Seal both measuring points M / 40.
copyright by
MJFCIFSS
6.30.19
Service Manual
Adjusting of max. output speed / max. travel speed
14 Adjusting of max. output speed / max. travel speed

Note:
The maximum speed is fixed by the manufacturer by means of the maximum pivot angle of the travel
motor (measurement Y, see adjustment protocol) and may not be adjusted.
Fig. 14
Qmin stop at the travel motor
210 Travel motor DMVA

3.14 Qmin stop screw
3.17 Lock nut

3.37 Safety cap
Danger!
To measure the drive shaft speed, attach a reflecting strip onto the universal joint shaft and hold the
speed counter in an appropriate position to the strip.
Rotating wheels or universal joint shafts can lead to serious injury when touched or when loose clothing is caught by them.
Only access the area below the undercarriage, if the travel motor is shut down.
Mount the speed counter in the appropriate position, using auxiliary equipment (magnetic brackets, etc.).
Prior to carrying out any measurements or adjustments to the travel motor, ensure that the drive
system is shut down.
To check the maximum travel speed of the machine, check the position of the screw 3.14 (measurement Y serves as guide value) and adjust it, if necessary.
Remove the safety cap 3.37.
Measure the distance Y between the upper edge of the adjusting screw 3.14 and the lock nut 3.17
and compare with the value in the adjustment protocol.
If necessary, adjust distance Y by loosening the lock nut 3.17 and turning the screw.
Tighten the lock nut 3.17.
Replace the safety cap 3.37.
A more accurate adjustment of the maximum pivot angle can be achieved by adjusting the speed of
the universal joint shaft.
Jack up the machine.
6.30.20
copyright by
MJFCIFSS
Service Manual

Operate the travel motor in on-road gear at full speed.
Apply reflecting strips (tool no. 64 in group 2.01) at the universal joint shaft.
Measure the maximum speed of a universal joint shaft (connection between gear system and axle) using the HT 460 speed counter (tool no 62 / 63 in group 2.01) and compare with the prescribed
speed in the adjustment protocol.
If the measured speed does not correspond to the prescribed speed, proceed as follows:
Loosen the lock nut 3.17.
Turn the adjusting screw 3.14 in the respective direction.
The measured drive shaft speed must correspond to the prescribed value.
Turn in
reduce speed
Turn out
increase speed
Tighten the lock nut 3.17.

copyright by
MJFCIFSS
6.30.21
Service Manual
Checking and adjusting the lowering speed of the attachment
15
Checking and adjusting the lowering speed of the attachment

The lowering speed of the attachment is limited by means of the stroke of the spool 106 of the boom
cylinder with the adjusting screw / stroke limitation 162.
The system is factory-set (for optimised lowering speed, see adjustment protocol).
To check and adjust the lowering speed, proceed as described below.
Danger!
To measuring the lowering time, the attachment must be lowered at maximum speed to the ground.
There is a serious risk of injury and damage to the equipment, if the bucket hits the ground.
This test thus requires fast response by the machine operator, who must stop the movement before
the bucket hits the ground.
Fig. 15
100
106
Stroke limitation of the boom cylinder spool

162
163

Stop screw of stroke limitation

Lock nut
Start the machine.

Extend the attachment.
Fully extend the boom cylinder.
Fully retract the boom cylinder.
Using a stopwatch, measure the time until the bucket touches the ground.
Compare the measured time with the prescribed time (see adjustment protocol).
If the measured time does not correspond to the prescribed time, proceed as follows:
Loosen the lock nut 163.
Turn the adjusting screw 162 and repeat the test until the measured time corresponds to the
prescribed time.
Turn in
Turn out
=
=
Prolong lowering time

Shorten lowering time
Tighten the lock nut 163.
6.30.22
copyright by
MJFCIFSS
Service Manual

Checking fan control
16 Checking fan control
Fig. 16
13
16.1
Hydraulic radiator fan located near the diesel engine

Fan motor
Checking fan speed

Danger!
The fan speed to be measured depends on the current temperature of coolant and hydraulic oil and
the air condition.
A simple way of checking the fan speed and thus the hydraulic circuit (pump / oil motor) is to disconnect the electric supply at the proportional solenoid valve Y352. This results in maximum fan speed.
To check the fan speed, ensure that the temperature of the hydraulic oil is > 50 C.
Measure the hydraulic oil temperature.
If the temperature of the hydraulic oil is too low, heat it up.
Disconnect the cable at the proportional solenoid valve Y352 at the fan motor 13 (Fig. 16).
To measure the speed with the speed counter (tool no. 62 / 63 in group 2.01), apply a reflective
strip to one of the fan blades.
Start the motor.
Run the motor at maximum speed.
Measure the maximum fan speed.
Compare the measured fan speed with the prescribed speed (see adjustment protocol).
Note!
The fan speed cannot be adjusted. The pressure is factory-set by the manufacturer and may not be
changed. The above measurement serves only to establish proper functioning. If the measurement
indicates that there is a substantial difference between the actual and the specified value, check the
hydraulic circuit for faults.
copyright by
MJFCIFSS
6.30.23
Service Manual
Checking fan control
6.30.24
copyright by
MJFCIFSS
Service Manual

Pressure check

1 Pressure check
1.1
Fig. 1
Layout of measuring points, part 1
20
41
Measuring point for high pressure
at the control block 100 (MP connection)
50
57
Control oil unit

Measuring point LS pressure
at the control oil unit 50 (MLS connection)
44
Measuring point for actuating pressure

at the pump 20 (MA connection)
59
Measuring point LR pressure

at the control oil unit 50 (MLR connection)
45
Measuring point for LS pressure

at the pump 20 (LS connection)
Measuring point for pilot pressure
at the control oil unit 50 (M1 connection)
100
Control valve block
49
copyright by
MJFCIFSS
6.34.1
Service Manual
Pressure check
Fig. 2
137
1.2
1.2.1
Layout of measuring points, part 2

Measuring point for slewing gear working 138
pressure at the slewing gear motor 130
(MA connection / pivot right)
Measuring point for slewing gear working

pressure at the slewing gear motor 130
(MB connection / pivot left)
Measuring instruments / adjusting tools / safety of adjusting screws

The following measuring tools from group 2.01 are required for the checking and adjustment of the
hydraulic system:
High-pressure measuring lines
Tools no. 7 or 8
For pilot pressure measurement:
Pressure gauge 0 - 60 bar, tool no. 19
For high pressure measurement:
For actuating pressure measurement:
For differential pressure p measurement:
Differential pressure gauge no. 30
For speed measurement:
Tool no. 60/62/63
For temperature measurement:
Tool no. 70
Alternatively, the following measuring tool can be used:
LMS measuring system, tool no. 40
For pilot pressure measurement:
Pressure sensor 0 - 60 bar
For high pressure measurement:
For actuating pressure measurement:
plus measuring cables and accessories for the measuring of speed and temperature
6.34.2
copyright by
MJFCIFSS
Service Manual

1.2.2
Adjusting tools:
All adjustments to the valves / units can be made with conventional ring spanners, open-end wrenches and Allen keys.
1.2.3
Securing of the adjusting screws:

To protect the adjusting screws against tampering and unintentional maladjustment, they must be secured (depending on the model):
with lead seal wire
with safety caps, see "Special tools" in group no 2.05
1.3

Before you start checking / adjusting the hydraulic system, be sure the following conditions
are fulfilled:
Measure the operating temperature of the hydraulic unit (minimum 50 C) in the tank.
The pressure gauge is glycerine-damped with an indication accuracy of less than 1%.
The valves must be secured with lead seal wire / caps to prevent tampering.
Remember that during the guarantee period only representatives of LIEBHERR may modify settings of valves and units.
Fig. 3
49
Measuring point
50
Control oil unit
51
Adjusting screw
Connect the pressure sensor or gauge (60 bar) to the measuring point 49.
Operate the diesel engine at the rated speed.
Compare the pressure indicated at the pressure gauge with the prescribed pressure (see adjustment protocol).
If necessary, adjust the setting of pressure relief valve 51.
Loosen the lock nut (WS 13).
copyright by
MJFCIFSS
6.34.3
Service Manual
Adjustments at the working pump

Increasing the pressure
Turn the adjusting screw 51 clockwise, using an Allen key (WS 4).
The pressure is increased.
Reducing the pressure
Turn the adjusting screw 51 anticlockwise, using an Allen key (WS 4).
The pressure is reduced.
After the pressure settings have been adjusted, lock the adjusting screw 51.
Replace the protective cap.
Remove the pressure gauge and seal the measuring point.
3 Adjustments at the working pump

3.1
Checking and adjustment of the hydraulic begin of regulation of pump 20

(basic settings)
Fig. 4
6.34.4
Adjustment of the pump 20
copyright by
MJFCIFSS
Service Manual

20
262
Secondary pressure relief valve
23.2.1 Adjusting screw

41
Measuring point
Y24
Y50
Solenoid valve
Solenoid valve
44
Y51
Solenoid valve
Measuring point
The settings of the hydraulic begin of regulation must be adjusted at minimum pump rate. Before adjusting the settings, the pressure must be adjusted, so that the performance regulator = tank pressure.
Disconnect the plug at the proportional solenoid valve LR (Y50 at the control oil unit 50).
Connect the pressure sensor or gauge (0 - 600 bar) to the measuring point 41 (control valve
block 100).
Connect the pressure sensor or gauge (0 - 600 bar) to the measuring point 44 (pump 20).
Lower the adjusting pressure at the secondary pressure-relief valve 262 to the begin of regulation
(see adjustment protocol).
Run the diesel engine at a speed of approx. 1000 rpm.
Note!
If the adjusting pressure cannot be reduced to a value below the begin of regulation (residual pump
volume too high), set the engine speed to the lower idle speed.
Extending bucket cylinder
Turn out the secondary pressure-relief valve 262 and slowly turn it in again, while observing the
pump pressure at the measuring point 44.
At the prescribed begin of regulation (see adjustment protocol), the actuating pressure (=
pump press) at the measuring point 44 must begin to drop.
If necessary, adjust the control valve settings.
Adjust the begin of regulation to a later point
Turn the adjusting screw 23.2.1 (WS 5) clockwise.
Pressure is increased = later begin of regulation
Adjust the begin of regulation to an earlier point
Turn the adjusting screw 23.2.1 (WS 5) anticlockwise.
Pressure is reduced = earlier begin of regulation
Note!
If the begin of regulation is adjusted correctly for minimum output, the pump's begin of regulation is
correct across the entire performance regulating pressure range (GLR).
After completion of the adjustment, lock and secure the adjusting screw 23.2.1.
After checking or adjusting the regulating valves, adjust the secondary pressure-relief valve 262
to the previous value, see section 6.
Reconnect the solenoid valves Y50/Y51 to the control oil unit, see Fig. 4.
copyright by
MJFCIFSS
6.34.5
Service Manual
3.2
Checking and adjusting the differential pressure ( p) between the pump pressure and the LS pressure
Fig. 5
Adjustment of the working pump, part 1
1
2
Measuring cable
Pressure sensor
41
45
Measuring neck
23.5.1Adjusting screw
4
5
Measuring point
Differential pressure measuring instrument
262
Measuring point
Measuring point
Disconnect the plug at the proportional solenoid valve Y51 at the control oil unit 50, see Fig. 1.
Run the diesel engine at maximum speed.
Adjust the adjusting screw of the secondary pressure-relief valve 262 (set pressure to approx.
100 - 120 bar so that oil can flow through the valve 262 ).
If a pressure gauge ID no. 7025376 is used, calibrate the two pressure sensors ID no. 614062401:
For this purpose, connect the differential pressure measuring instrument (connection P1/P2) through two pressure sensors (600 bar) and the measuring necks ID no. 4901372 and 7002404 at
the measuring point 41 of the control block 100.
Extend the bucket cylinder to the stop.
Calibrate the devices at a pressure of approx. 100 - 120 bar.
Connect the pressure sensor at connection P2 to the measuring point 45 and measure the differential pressure p between the measuring points 41 and 45, and compare them with the prescribed value (see adjustment protocol).
6.34.6
copyright by
MJFCIFSS
Service Manual

Note!
If you want to use the LMS measuring system, ensure that you have two pressure sensors (600 bar)
with an indication tolerance of 0.3 bar ready.
Fig. 6
Adjustment of the working pump, part 2
20
23.5
Load sensing regulator
If necessary, adjust the differential pressure setting pat flow regulator 23.5 of the variabledisplacement pump.
Increasing the differential pressure
Turn the adjusting screw 23.5.1 with the Allen key (WS 4) clockwise.
Reducing the differential pressure
Turn the adjusting screw23.5.1 with the Allen key (WS 4) anticlockwise.
After adjustment of the pressure settings, lock the adjusting screw 23.5.1.
Readjust the secondary pressure-relief valve 262.
Note!
To check the dynamic behaviour of the settings, the differential pressure p can be checked again
while the extended attachment is slowly lifted. The pressure measured in this process may not differ
significantly from the pressure of the static measurement (difference maximum 1.0 bar).
copyright by
MJFCIFSS
6.34.7
Service Manual
Checking the output power of the diesel engine (power test)
4 Checking the output power of the diesel engine (power test)

4.1
Principle
The hydraulic output available at the outlet of the pump is measured.
For this purpose, the pump is moved to its maximum pivot angle and the working pressure is slowly
increased in order to push the engine to the rated speed.
Fig. 7
4.2
Output check of the diesel engine
41
242
Measuring point
262
H307
S382
Indicator light
Fine control switch
Procedure
Connect the pressure sensor or gauge (0 - 600 bar) to the measuring point 41, see Fig. 7.
Connect the pressure sensor or gauge (0 - 600 bar) to the measuring point 44 at the pump 20,
see Fig. 4.
Power the solenoid valve Y50, using a laptop and the relevant software and accessories (24 V).
If this is not possible, power the solenoid valve Y50 with 24 V through an electrical plug connection in its vicinity, e.g. through valve Y24.
To do this, remove the plug at the solenoid valve Y50, disconnect the plug from the solenoid
valve Y24 and connect this plug to the solenoid valve Y50. Actuate the switch S21 (creeper gear)
and remove the plug at the fan motor Y352 (motor runs at maximum speed).
Lower the adjusting pressure at the secondary pressure-relief valve 242 and 262* (axle/stick and
bucket cylinder) to approx. 100 bar.
Run the diesel engine at its upper idle speed. Switch off the fine regulation by means of the switch
S382 in the joystick , see Fig. 7, (indicator light H307 is off).
Extend the stick and bucket cylinder*
6.34.8
copyright by
MJFCIFSS
Service Manual

Checking the output power of the diesel engine (power test)
Note!
During the build-up of the high pressure, closely monitor the control chamber pressure at the
measuring point 44 of the pump. Ensure that there is no significant pressure difference ( 10 bar)
to the measuring point 41 (no regulation of the pumps).
Turn in the primary pressure control valve 242 and 262* until the prescribed value is reached (see
adjustment protocol), while checking the speed.
The output of the diesel engine is correct, if the speed does not drop below the rated speed
(1800 rpm) at the preset value.
After completion of the diesel engine output check, reset the secondary pressure-relief valves 242
and 262 to the prescribed value, see section 6.
It is necessary to complete both movements and turn both secondary pressure-relief valves, in order to ensure that
the entire pump flow volume is fed through the system.
copyright by
MJFCIFSS
6.34.9
Service Manual
Adjusting pressure relief and cut-off valves
5 Adjusting pressure relief and cut-off valves
Fig. 8
5.1
Measuring points and valves at the pump and control block
20
41
Measuring point MP
177
221
Reverse travel
Extending boom cylinder
45
Measuring point MLS
222
Retracting boom cylinder
100
Control valve block
241
Retracting stick cylinder
104
105

242
261
Extending stick cylinder

170
Travel motor LMV / DMVA
262
Extending bucket cylinder
176
Forward travel
A 316 to 28060
A 316 from 28061
Checking/adjusting the safety valve 105

Connect the pressure sensors / gauges to the measuring points 41 (control block 100) and 41
(variable displacement pump).
6.34.10
copyright by
MJFCIFSS
Service Manual

Run the diesel engine at its upper idle speed (fine regulation disabled tank pressure at measuring point 57, see Fig. 1).
Extend the bucket / grapple cylinder to the stop.
Increase the pressure cut-off value 104 by turning in the valve (up to max. 440 bar, or until secondary pressure-relief valve 262 responds, plus 1/2 turn).
Increase the pressure at the secondary pressure-relief valve 262 until the safety valve 105 responds, but only up to max. 440 bar at the measuring point 41.
Compare the pressure value with the prescribed pressure of the primary pressure-relief valve 105
and adjust, if necessary.

Turn the adjusting screw clockwise, using an Allen key (WS 6).
Turn the adjusting screw anticlockwise, using an Allen key (WS 6).
After completion of the adjustment, secure the stop screw with a lock nut.
5.2
Checking/adjusting the secondary pressure-relief valves 176 / 177, 221 - 262

Adjust the secondary relief valve 262 to the prescribed value.
After completion of the adjustment, secure the stop screw with a lock nut.
Check the other secondary pressure-relief valves 176, 177, 221, 222,241,242 and 261 by moving
the respective devices to the stop. Adjust the settings, if required (measuring point 45).

5.3
Adjusting the operating pressure (pressure cut-off valve 104)

Set the operating pressure at the cut-off valve 104 to the prescribed value (measuring point 45).
copyright by
MJFCIFSS
6.34.11
Service Manual
Checking and adjusting the secondary pressure for the slewing gear
Fig. 9
6.34.12
TC valve and slewing gear motor with pressure-relief valves, sample diagram
copyright by
MJFCIFSS
Service Manual

Checking and adjusting the secondary pressure for the slewing gear
6.1
Relationship between the secondary protection and the control pressure for
swivelling
II
III
Relationship between high pressure and the control pressure for swivelling
Relationship between the motor flow consumption (speed) and the control
pressure for swivelling
Secondary setting, minimum value (braking)
2
3
Secondary setting (starting)

Primary setting (operating pressure)
125
TC valve
130
Slewing gear motor
125.1
125.2
Valve body
Lock nut
134
135
Secondary pressure-relief valve

128
Shuttle valve
137
Measuring point
128.2
Screw fitting
138
Measuring point
Adjustment of the start-up pressure, Fig. 9

Danger!
Uppercarriage may execute uncontrolled rotary movements,
posing a hazard to mechanics and equipment.
Lock the uppercarriage against the undercarriage, using locking bolts.
Connect the pressure sensor to the measuring points 137 / 138.
Block the uppercarriage (maximum pressure cannot be reached if the uppercarriage is rotating).
Turn in the valve body at the TC valve 125.1 until p primary is higher than the pressure at the secondary relief valve (complete about 2 turns).
Start the machine.
Run the diesel engine at its upper idle speed.
Press the pilot control unit for "turning left" to the stop.
Compare the pressure with that in the adjustment protocol (measuring point 138).
If necessary, remove the locknut 1 and adjust the settings of the pressure-relief valve 135 with
the adjusting screw 2
Press the pilot control unit for "turning right" to the stop.
6.2
Adjusting the brake pressure Fig. 9

Disconnect and dummy both hose connections with X and Y
Press the pilot control unit for "turning left" to the stop.
copyright by
MJFCIFSS
6.34.13
Service Manual
Checking the travel motor 170

Press the pilot control unit fort "turning right" to the stop (measuring point 137).
Re-connect the hose connections to X and Y
6.3
Adjusting the settings of the TC valve 125, Fig. 9.

Turn back as many turns as turned previously.
Turn the valve body 125.1 of the TC valve to adjust the pressure to that prescribed in the adjustment protocol.
7 Checking the travel motor 170

7.1
Adjustment of the begin of regulation (end of regulation)
Fig. 10
20
Checking the travel motor, part 1

45
Measuring point
Condition: The outputs of the diesel engine and the hydraulic pump must correspond to the
prescribed values (see adjusting protocols and hydraulic pump settings in group 7.05).
Connect the pressure sensor/gauge to the measuring point 45 (pump 20), see Fig. 10.
M
M2
Screw in the screw coupling assembly M10x1 (tool no. 10 in group 2.01, with extension, if required) and connect a pressure gauge / sensor.
Jack up the machine and run the travel motor in on-road gear at full speed (operate pilot control
unit). Take all necessary safety precautions.
6.34.14
copyright by
MJFCIFSS
Service Manual

Fig. 11
3.14
Threaded stud Qmin. (A 312 and A

316*)
170.26 Begin of regulation / adjusting screw

(A 314/316)
4.14
Begin of regulation / adjusting screw

(A 312 and A 316*)
Measuring connection (A 312 and A

316*)
M2
Measuring connection (A 314/316)
170
Travel motor
170.17 Threaded stud Qmin (A 314/316)
in A 316 to 28060
in A 316 from 28061
Operate the brake pedal to slowly apply the working brake (4-wheel brake). High pressure builds
up at the measuring point 45.
At values below the motor begin of regulation (see values in the adjustment protocol on pages
7.26-03/7.27-03) there may be no pressure at the measuring connections M or M2, i.e. the oil
motor must be set to its minimum pivot angle.
Continue to accelerate the motor to its max. speed. Keep your eyes on the two pressure gauges
(at measuring points 45 and M2).
copyright by
MJFCIFSS
6.34.15
Service Manual

From the moment of begin of regulation M, the pressure at the measuring connection M2 must
continue to rise (to about 1/2 high pressure value). The oil motor is adjusted towards the max.
pivot angle.
When the high pressure (at the measuring point 45) reaches the value of the end of regulation
(see pages 7.26-03/7.27-03) the pressure measured at measuring point M/M2 increases suddenly to the high pressure value, so that the pressure values at the measuring points 45 and
M/M2 are the same, Fig. 12.
Fig. 12
160.1

160.2
Stroke limitation 1
Stroke limitation 2
160.1.1 Adjusting screw of the stroke limitation 1 160.2.1 Adjusting screw of the stroke limitation 2
160.1.2 Lock nut of the stroke limitation 1
160.2.2 Lock nut of the stroke limitation 2
If the pressure value for the begin of regulation does not correspond to the prescribed value,
it can be adjusted by means of the adjusting screw 4.14/170.26, see Fig. 11.
Release the adjusting screw 4.14/170.26.
Increasing the end of regulation
Turn in the adjusting screw.
6.34.16
copyright by
MJFCIFSS
Service Manual

The end of regulation is increased.
Reducing the end of regulation

Turn out the adjusting screw.
The end of regulation is reduced.
After adjustment of the end of regulation, remove both pressure gauges and the screw coupling
and seal both measuring points.
7.2
Adjustment of the minimum pivot angle

The minimum pivot angle is set by the threaded stud 3.14/170.17, see Fig. 11. The angle is factoryset by the manufacturer and may not be changed.
The correct position of the threaded stud 3.14/170.17 can be used as a reference value after measuring of the dimensions X, Fig. 11 and comparison with the adjustment protocol.
7.3
Adjustment of the maximum output speed/maximum travel speed

The maximum output speed of the oil motor is determined by the minimum flow consumption of the
oil motor (Qmin) and the maximum flow rate of the spool/chassis 160.
Note!
The max. flow rate is factory-set by the manufacturer by means of the stroke limitation of spool 160
(value Y - see adjustment protocol or group 7.60) and may only be adjusted in exceptional circumstances.
If the max. travel speed of the vehicle is unsatisfactory, the setting can be modified, provided that the
measured maximum speed of the universal joint shaft (connection of transmission and axles) does
not correspond to the specified value (see adjustment protocol).
Adjustment of the maximum output speed:
Jack up the vehicle and run it in on-road gear (pilot control valve at full throttle).
Measure the maximum speed of one joint shaft, using the HT 460 speed meter (for tool, see
page 2.01.07) and compare with the prescribed speed (in adjustment protocol).
At fully actuated pilot control unit, remove the cap nut of the chassis control axle 160 of the control
valve block 100.
Loosen the lock nut .2 of the stroke limitation 160.1/160.2.
Reducing the speed:
Turn the adjusting screw .1 in.
The speed is reduced.
Increasing the speed:
Turn adjusting screw .1 out.
The speed is increased.
Repeat the adjustment on the other side of the spool 160 (forward and reverse travel).
After adjustment of the speed, secure the adjusting screws 160.1/160.2 and replace the cap nuts.
copyright by
MJFCIFSS
6.34.17
Service Manual
Checking the fan control system
8 Checking the fan control system
Fig. 13
13
8.1
Fan motor with proportional solenoid valve

Y352
Fan motor
Proportional solenoid valve

Danger!
Moving fan blades might cause serious injury to fingers and hands.
Shut down the engine.
Do not reach into the fan operating range until the fan blades have come to a standstill.
The fan speed to be measured depends on the current temperature of coolant and hydraulic oil and
the air condition.
A simple way of checking the fan speed and thus the hydraulic circuit (pump / oil motor) is to disconnect the electric supply to the proportional solenoid valve Y347 (max. fan speed).
The temperature of the hydraulic oil must be > 50 C (see adjustment protocol).
To check the fan speed with the speed counter (tool no. 62 / 63), apply a reflective strip to one of
the fan blades.
Introduce the pressure measuring connection into the cooling circuit (not within scope of delivery).
Connect a pressure sensor.
Note!
6.34.18
copyright by
MJFCIFSS
Service Manual


1 Arrangement of measuring points
Fig. 1
41
44
45
49
57
59
137
138
Measuring points at variable-displacement pump DPVO 20, the control valve block 50,
the control oil unit 100 and the slewing gear motor 130
Measuring point for high pressure at control valve block 100 (connection MP)
Measuring point for control chamber pressure at pump20 (connection MA)
Measuring point for LS pressure at pump 20 (connection X2)
Measuring point for pilot pressure at control oil unit 50 (connection M1)
Measuring point - LS pressure at control oil unit 50 (connection MLS)
Measuring point - LR pressure at control oil unit 50 (connection MLR)
Measuring point for slewing-gear working pressure at slewing gear motor130 (connection MA
turn right)
Measuring point for slewing-gear working pressure at slewing gear motor130 (connection MB
turn left)
2 Measuring instruments / adjusting tools / safety of adjusting

screws
2.1
To check and/or adjust the hydraulic unit, you need the following measuring equipment and tools:
copyright by
MJFCIFSS
6.37.1
Service Manual
Measuring instruments / adjusting tools / safety of adjusting screws

Differential pressure gauge / kit 0 - 600
bar
Tool in group 2.01
Speed measurement
Temperature measurement
Speed counter
Thermometer
No. 60 or 62
No. 70
Alternative:
LMS measuring system, tool no. 40
For pilot pressure:
> Pressure sensor 0 -60 bar
For high pressure:
plus measuring cables and accessories for the measuring of speed and temperature
Note!
If the differential pressure gauge for measuring
sure gauges (examples):
p is not available, use one of the following pres-
Note!
For the adjustment of valves and units, use commercially available high-quality tools, for instance:
ring spanners, open end spanners and Allen keys.
Always secure the adjusting screws against tampering and unintentional modification:
Apply lead seal wire.
Use safety caps (see tools no. 20 - 25).
2.2

Note!
During the warranty period, only LIEBHERR agents and mechanics may modify settings of
valves and units.
2.2.1
Prior to checking and adjusting the settings of the hydraulic system, ensure
that the following conditions are fulfilled:
The operating temperature of the hydraulic unit (measured in the tank) must be at least 50C.
The pressure gauges must be glycerine-filled and have an indicating accuracy of below 1% relative to the scale end value.
When measuring or adjusting an actuated spool of the control valve block, ensure that the piston
is fully lifted at maximum control pressure (maximum piston stroke).
Note!
In the event of a hydraulic failure, follow the instructions in the adjustment protocol in the
prescribed sequence.
The required minimum oil temperature can be obtained by actuating the 'close bucket' command while the pressure at the secondary pressure relief valve 262 is lowered, (see Fig. 8,
page 9).
All valves must be secured against unauthorized readjustment by safety caps.
6.37.2
copyright by
MJFCIFSS
Service Manual

Fig. 2
Control oil unit with valve and measuring connection
49 Measuring connection - control pressure

50 Control oil unit
51 Pressure relief valve / pilot control
Run machine at maximum engine speed.
Compare the displayed pressure with the prescribed pressure (see adjustment protocol).
If necessary, adjust the setting of the pressure relief valve 51.
Proceed as follows: Remove the safety cap. Loosen the lock nut (WS 13). Use an Allen key (WS
4) to turn the adjusting screw.
Turn clockwise (cw)
= increase pressure
= reduce pressure
Secure the adjusting screw 51 with the lock nut and replace the safety cap.
Remove the pressure sensor / gauge and seal the measuring point 49.

Connect the pressure sensor or gauge (0-60 bar) to the measuring point 59(see Fig. 3, page 4).
Start the machine.
Using a suitable adapter (tool no. 44 in group 2.01), measure the current at the valve Y50.
measuring point 59.
copyright by
MJFCIFSS
6.37.3
Service Manual
Fig. 3
50
Control oil unit
59
Measuring point MLR (power control)
Y50
Current OK
Current OK
Pressure OK
Pressure not
OK
=> everything OK
Current not
OK
Pressure not
OK
=> Search for fault in the electrical system and the horsepower control
Note!
The characteristic of the solenoid valve cannot be adjusted.
4.1
Adjusting the regulating pressure for emergency operation

Switch off machine.
Remove the plug from the proportional solenoid valve Y 50.
Remove the cotter pin.
Actuate the lever.
Start the machine.
Preselect the maximum engine speed.
Compare the pressure values to those in the adjustment protocol and adjust, if necessary.
Proceed as follows: Remove the locknut and turn the insert by hand.
Turn clockwise (cw)
=
increase pressure
=
reduce pressure
Reset the lever to its initial position.
Insert the cotter pin.
Remove the pressure sensor and seal the measuring point 59.
6.37.4
copyright by
MJFCIFSS
Service Manual


Start the machine and run it at maximum engine speed.
Change the current to the proportional solenoid valve Y51 by turning the potentiometer for fine
adjustment (R76).
Using a suitable adapter (tool no. 44 in group 2.01), measure the current at valve Y51.
measuring point 57.
Fig. 4
50
Control oil unit
Y51
57
Measuring point MLS (flow reduction)
Current OK
Current OK
Pressure OK
Pressure not
OK
=> everything OK
Current not
OK
Pressure not
OK
=> Search for fault in the electrical system.
Note!
The characteristic of the solenoid valve cannot be adjusted.
copyright by
MJFCIFSS
6.37.5
Service Manual
Checking and adjusting the variable-displacement pump
6 Checking and adjusting the variable-displacement pump
Fig. 5
8
57
20
Variable displacement pump DPVO
59
41
Measuring point for high pressure at con- 100

trol valve block 100 (connection MP)
44
Measuring point for control chamber pres- Y50

sure at pump20 (connection MA)
Control oil unit
Y51

50
6.1
Measuring connections and valves

Measuring point for flow reduction / control pressure (connection MLS)
Measuring point for the power control /
pressure (connection MLR)
Hydraulic begin of regulation (basic setting)

To check the begin of the hydraulic regulation, determine the point from which the pump is regulated
from Q max to Q min and adjust it, if necessary.
Disconnect plugs on proportional solenoid valves Y50 and Y51. Measure pressure at measuring
points 57 (MLS) and 59 (MLR). Target = tank pressure.
Connect the pressure sensor to the measuring point 41 (p pump - control block100).
Connect the pressure sensor to the measuring point 44 (p control chamber - variable-displacement
pump20).
Run the diesel engine at low speed (approx. 1200 rpm).
Fully close the bucket / grapple.
Screw out the secondary pressure relief valve 262 to a position below the begin of regulation (p
pump pressure = p control chamber).
Carefully screw in the secondary relief valve 262 until p control chamber is about 5 - 10 bar below p
pump pressure.
6.37.6
copyright by
MJFCIFSS
Service Manual

Compare the pressure at the measuring point 41 (p pump pressure ) with the values in adjustment
protocol.
If necessary, adjust the settings using the regulating valve .
Proceed as follows:
Start the machine.
Run the diesel engine at low speed (approx. 1200 rpm).
To do this, set the secondary pressure relief valve 262 (measuring point 41) to the nominal value
for begin of regulation (see adjustment protocol).
Turn in the adjusting screw 8 until p pump pressure = p control chamber.
Carefully turn out the adjusting screw until p control chamber is about 5 - 10 bar below p pump pressure.
Secure the screw with a lock nut.
Check the begin of regulation again: Reduce and increase the pressure by means of the secondary relief valve 262.
Connect the plug to the proportional solenoid valve Y50 / Y51.
6.2
Checking and adjusting the differential pressure (

pressure and the LS pressure
Before adjusting the differential pressure
control Y50.
- p) between the pump
-p, check the begin of regulation and the horsepower
Note!
As the tolerance for the differential pressure -p is very small (+1 bar), use measuring instruments
with suitable accuracy. As such measuring instruments do not always determine the precise pressure value, always first test and recalibrate the pressure sensors (for detailed instructions, see operating manual of your measuring device). Connect both pressure sensors to the same pressure
source (100 - 110 bar). The difference between the indicated values should not exceed 0.5 bar. In
the event of a greater difference, adjust the sensors using a calibration device (if possible), or replace them.
6.2.1
Calibration of pressure sensors
Fig. 6
Diagram of calibration
Measuring instrument
Pressure sensor
Control valve block
Measuring cable
copyright by
MJFCIFSS
6.37.7
Service Manual

C
D
6.2.2
P1
P2
Measuring neck (ID no. 4901372)

Measuring point 41
Adjusting differential pressure
Fig. 7
Measuring connection
-p
Measuring connections and valves at the hydraulic pump 20, the control oil unit 50 and
the control valve block100
-p
57
Adjusting screw
20
41
Measuring point for high pressure at con- 100

trol valve block 100 (connection MP)
44
Measuring point for control chamber pres- Y50

sure at pump20 (connection MA)
45
Measuring point for LS pressure at pump

20
Control oil unit
Y51
50
59
Measuring point for flow reduction / control pressure (connection MLS)

Measuring point for the power control /
pressure (connection MLR)
Disconnect the plug connection from the proportional solenoid valve Y51 (see Fig. 5) and check
the pressure at the measuring point 57 (nominal pressure = tank pressure).
Connect the pressure sensor to the measuring points 41 (p pump) and 45 (p LS) (see Fig. 7).
Start the machine.
Reduce the secondary relief valve 262 to the specified value.
Check the pressure difference.
If necessary, adjust the differential pressure setting -p at flow regulator 2 of variable-displacement pump 20.
6.37.8
Turn clockwise (cw)
= increase differential pressure -p
= reduce differential pressure
copyright by
MJFCIFSS
-p
Service Manual

Secure the adjusting screw with a lock nut.
Reconnect the plug at the proportional solenoid valve Y 51.
7 Checking output power of the diesel engine (power test)

7.1
Principle
The power input of the pump can be calculated with the following formula:
If the pump is maintained at maximum pivot angle, the power input of the powertrain is determined
solely by the pressure (see adjustment protocol). This pressure value has been measured individually
for each model and size of attachment, whereby secondary consumers have also been taken into
consideration.
Fig. 8
20

242
A8VO
262
pump 2 at control valve block 100 (connection MP)
41
7.2
Proportional solenoid valve / cooling and measuring points at the variable-displacement

pump and the control valve block
44
Measuring point for control chamber

pressure at pump20 (connection MA)
100
Secondary pressure relief valve for extending stick cylinder

Secondary pressure relief valve for extending bucket cylinder
Y352 Proportional solenoid valve / radiator fan
Proceed as follows:
Disconnect the plug at the solenoid valve Y 352 (fan) (see Fig. 8).
copyright by
MJFCIFSS
6.37.9
Service Manual

Connect the pressure sensor (0-600 bar) to the measuring point 41 (p pump) (see Fig. 8).
Connect the pressure sensor (0-600 bar) to the measuring point 44 (p LS) (see Fig. 8).
Connect the speed counter.
Start the machine.
Run the engine at maximum speed (check maximum speed).
R76 not actuated (fine adjustment disabled)
Fully extend the stick cylinder and close the bucket.
Lower the pressure at the secondary pressure relief valve 242 (extend stick cylinder - Fig. 9) and
262 (extend bucket cylinder - Fig. 9) below the test pressure in the adjustment protocol.
Start the power test program at the laptop.
Increase the pressure until the pressure indicated at the measuring point 41 reaches the prescribed pressure (see adjustment protocol).
Control chamber pressure, pressure difference< 10 bar, pump pressure (10 bar max.)
Read motor speed at speed counter.
Speed
> Regulating
rpm
=> Diesel engine output OK
Speed
< Regulating
rpm
=> Diesel engine output not OK
8 Adjusting pressure relief and cut-off valves
Fig. 9
6.37.10
Pump 20, control valve block 100 and travel motor 200/201 with measuring connections
and valves
20
212
Secondary pressure relief valve / reverse

travel, left
41
Measuring point(pump pressure)
213
Secondary pressure relief valve / forward

travel, right
45
Measuring point (LS pressure)
214
100
221
Secondary pressure relief valve / reverse

travel, right
Extend boom cylinder
copyright by
MJFCIFSS
Service Manual

104
105

Safety valve
222
241
Retract boom cylinder

Retract stick cylinder
200
201
Travel motor, left

Travel motor, right
242
261
Extend stick cylinder

Retract bucket cylinder
210
211
Brake hose
262
Secondary pressure relief valve / forward
travel, left
Note!
All measurements must be completed at maximum engine speed. Check the secondary pressure
relief valves at the measuring point 45 (p LS). Check the pressure cut-off valve 104 and the safety
valve 105 at the measuring point 41 (p pump).
8.1
8.1.1
Checking and adjusting the secondary pressure relief valves

Secondary pressure relief valves for the attachment
Method I (including adjustment of valve 105):
Connect pressure sensors to the measuring point 41 (p pump) and to the measuring point 45 (p LS).
Start the machine.
Check tank pressure at the measuring point 57 (MLS - see Fig. 7).
Increase the pressure cut-off value 104 by turning it in (up to max. 440 bar, or until secondary relief
valve 262 responds, plus 1/2 turn).
Increase pressure at secondary relief valve 262 until safety valve 105 responds, but only up to
440 bar max. at measuring point 41 (p pump).
If necessary, set the safety valve 105 (measuring point 41 - p pump) to the correct value.
Adjust the secondary relief valve 262 (measuring point 45 p LS).
Secure the secondary relief valve 262 with a lock nut.
Activate the remaining secondary relief valves by moving the associated attachments to the stop,
and adjust the settings, if necessary (measuring point 45 p LS).
Check the valves of the travel motorsee 8.1.2.
Adjust the operating pressure at pressure cut-off valve 104 (measuring point 41 p pump).see 8.2
Secure all valves with lock nuts.
Remove the pressure sensors and seal the measuring points.
8.1.2
Secondary pressure relief valve for the travel motor

Danger!
During the measuring procedure, cordon off the danger zone around the machine and ensure that
no persons enter it!
copyright by
MJFCIFSS
6.37.11
Service Manual

Remove the cover from the longitudinal member.
Remove the hose 210 to the travel gear and seal the connection (this is required in order to travel
against the applied brake).
Operate one travel motor after the other in both directions.
Check the pressure at the valves 211 - 214, compare it with the prescribed pressure (see adjustment protocol) (measuring point 45 p LS) and adjust it, if necessary.
Secure the valves with lock nuts.
Reconnect the hose 210 to the travel gear system.
Mount the cover onto the longitudinal member.
8.2
Adjustment of the operating pressure (pressure cut-off valve 104)

Connect the pressure sensor to the measuring point 41 (p pump).
Start the machine.
Adjust the operating pressure (see adjustment protocol) at the pressure cut-off valve 104 .
Adjust pressure cut-off valve 104 .
Remove the pressure sensor and seal the measuring point.
Key to slewing gear adjustment, see Fig. 10
125
TC valve
135
125.1
Valve body
135.1
2-stage pressure relief valve for turning

left
Lock nut
125.2
128
Lock nut
Shuttle valve
135.2
135.3
Adjusting screw for start-up pressure

Lock nut
128.2
Union nut / screw connection
135.4
Adjusting screw for brake pressure
130
Slewing gear motor
137
Measuring point for turning left
134
2-stage pressure relief valve for turning 138

right
134.1
134.2
Lock nut
Adjusting screw for start-up pressure
134.3
134.4
Lock nut
Adjusting screw for brake pressure
XA
XB
Measuring point for turning right
Control pressure connection, turn left

Control pressure connection, turn right
: Relationship between the secondary protection and the control pressure for
swivelling
II : Relationship between high pressure and the control pressure for swivelling
III : Relationship between the motor flow consumption (speed) and the control pressure for swivelling
1 : Secondary setting, minimum value (braking)
2 : Secondary setting (starting)
6.37.12
copyright by
MJFCIFSS
Service Manual

Checking / adjusting the secondary pressure for the slewing gear
3 : Primary setting (operating pressure)
9 Checking / adjusting the secondary pressure for the slewing gear
Fig. 10
Slewing gear motor with pressure relief valves, and TC valve, with sample diagram
copyright by
MJFCIFSS
6.37.13
Service Manual
Checking / adjusting the secondary pressure for the slewing gear
9.1
Adjustment of the start-up pressure, Fig. 10

Danger!
Uppercarriage may execute uncontrolled rotary movements,
posing a hazard to mechanics and equipment.
Lock the uppercarriage against the undercarriage, using locking bolts.
Connect the pressure sensor to the measuring points 137 / 138.
Block the uppercarriage (maximum pressure cannot be reached when the uppercarriage is rotated).
Turn in the valve body at the TC valve 125.1 until p primary is higher than the pressure at the secondary relief valve (complete 2 turns approx.).
Start the machine.
Press the pilot control unit for 'turn left' to the stop.
If necessary, loosen the lock nut 1 and adjust the pressure relief valve 135 with the adjusting
screw 2.
Press the pilot control unit for 'turn right' to the stop.
screw 2.
9.2
Adjusting the brake pressure Fig. 10

Disconnect and seal both hose connections to XA and XB.
Press the pilot control unit for 'turn left' to the stop.
screw 4.
Press pilot control unit 'turn right' to the stop (measuring point 137).
screw 4.
Re-connect the hose connections to XA and XB.
9.3
Adjusting TC valve 125. Fig. 10

Turn out the valve body 125.1 to its initial position (i.e. turn in by the same number of rotations as
used previously to turn it in).
Turn the valve body 125.1 of the TC valve to adjust the pressure to that in the adjustment protocol.
6.37.14
copyright by
MJFCIFSS
Service Manual

Adjustment of the output speed of the travel drive system
10 Adjustment of the output speed of the travel drive system
Fig. 11
Spool 160/180 for chassis
160
Spool / chassis right
180
Spool / chassis left
160.1
160.2
Stroke limitation
Stroke limitation
180.1
180.2
Stroke limitation
Stroke limitation
160.3
160.4
Adjusting screw
Lock nut
180.3
180.4
Adjusting screw
Lock nut
Note!
The max. speed is factory-set by means of the spool stroke limitation (value Y - see adjustment protocol) and may only be adjusted in exceptional circumstances.
If there is a problem with the maximum travel speed of the machine, the setting can be modified, provided that the maximum speed measured at the tumbler wheel does not correspond to the value in
the adjustment protocol.
Lift one side of the chassis, using the attachment, and run the respective travel drive at normal
speed (S21 not actuated).
Measure the maximum speed of the tumbler wheel and compare with the prescribed value in the
adjustment protocol.
Danger!
During the measuring procedure, cordon off the danger zone around the operated crawler and
ensure that no persons enter it!
Remove the cap nut at the control axle of travel gear 160/180 of control valve block 100.
Remove the lock nut .4 of the stroke limitation and turn the adjusting screw .3 as required.
copyright by
MJFCIFSS
6.37.15
Service Manual
Adjustment of the maximum speed (Qmin stop / fast travel)

Turn in
= reduce speed
Turn out
= increase speed
Repeat the adjustment on the other side of the spool (travelling forward and reverse).
Check adjustment of the speed.
The measured tumbler wheel speed must correspond to the prescribed value.
Secure adjusting screws .3 of stroke limitation 160.1 / 160.2 / 180.1 / 180.2 with lock nuts.
Replace the cap nuts.
11
Adjustment of the maximum speed (Qmin stop / fast travel)

Note:
The maximum speed of the travel drive can be achieved by setting the unit into fast travel mode by
actuating the switch S21. In this mode, the regulating motor is set to Qmin.
If the factory-set maximum speed cannot be reached, check the oil motor settings:
Run the diesel motor at maximum speed.
Lift one side of the chassis with the attachment.
Actuate the switch S21.
Run lifted travel drive in fast travel mode.
Compare the actual speed of the tumbler wheel with the nominal speed specified in the adjustment protocol.
If the actual speed is below the nominal speed, adjust the Qmin stop screw of the respective regulating motor as follows:
Danger!
Before making any adjustments to the travel motor, ensure that the chain is not moving. Cordon off
the danger zone around the operated crawler and ensure that no persons enter it!
Fig. 12
Travel motor with travel gear system in longitudinal member and Qmin stop Vmin
Remove the cover from the longitudinal member.

Release the Qmin stop screw of the travel motor.
Release the lock nut.
Turn the stop screw.
6.37.16
copyright by
MJFCIFSS
Service Manual

Turn in
= reduce speed
Turn out
= increase speed
Note:
When adjusting the maximum speed of the travel gear system, also check the synchronisation of
the two travel motors (tracking). Adjust the two oil motors to the speed of the lower one.
Secure the stop screw with a lock nut.
Mount the cover onto the longitudinal member.
12 Checking the fan control system
Fig. 13
13
14
12.1
Oil motor and proportional solenoid valve / fan control with pressure relief valve
Oil motor radiator fan

Y352 Proportional solenoid valve / radiator fan

Danger!
Moving fan blades might cause serious injury to fingers and hands.
The fan speed to be measured depends on the current temperature of the coolant and the hydraulic
oil.
A simple way of checking the fan speed and thus the hydraulic circuit (pump / oil motor) is to disconnect the electric supply to the proportional solenoid valve Y347 (max. fan speed).
The temperature of the hydraulic oil must be > 50 C (see adjustment protocol).
To check the fan speed with the speed counter (tool no. 62 / 63), apply a reflective strip to the fan
blade.
copyright by
MJFCIFSS
6.37.17
Service Manual

Start the motor.
Note!
6.37.18
copyright by
MJFCIFSS
Service Manual
Hydraulic system
A 309 from 20221 / A 311 from 20222
Hydraulic system
1 A 309 from 20221 / A 311 from 20222
Note!
For a detailed description of the design and construction of the hydraulic system and the various
main components see group 6.20.
Items
see
group
Items
see
group
Hydraulic tank
19.08
134
Secondary pressure relief valve /

bucket cylinder B7
Breather filter
19.08
135
Suction valve travel motor A8
7.50
Stop cock
136
Suction valve travel motor B8
7.50
Return filter
19.08
150
Check valve
7.50
Bypass valve/return filter (pressure)
19.08
151
Load-holing valve
7.50
Oil cooler
152
Check valve
7.50
10
Cylinder / speed adjustment
153
Check valve 0.5 bar
7.50
11
from turbocharger / engine
154
Preload valve 5.5 bar
7.50
12
Check valve 0.2 bar
155
Restrictor valve
13
160
Boom cylinder
7.30
14
Pressure relief l valve fan motor
161
Pipe-fracture safety
16.04
15
Coarse filter
162
Stroke limitation / spool for lifting
20
Double variable-displacem. pump
7.02
170
Stick cylinder
7.30
21
Powertrain P1
7.02
171
Restrictor check valve
7.90
22
Powertrain P2
7.02
180
Bucket cylinder
7.30
23
Regulating unit P1 + P2
7.02
181
Shut-off device / grapple operation
18.35
24
Adjustment
7.02
182
Lines leading to grapple cylinder
25
Spool
7.02
183
26
Nozzle
7.02
190
Slewing gear motor / powertrain
7.24
27
Differential piston
7.02
191
Pressure-relief l valve / turn right A
7.24
28
Opposed piston / flow reduction
7.02
192
Pressure-relief l valve / turn left B
7.24
29
Actuation device
7.02
193
Suction valve
7.24
30
Gear pump / fan drive
195
Slewing gear brake
9.20
31
Pump/low-pressure circuit- brake
196
9.10
32
Gear pump / steering with

Pressure-relief l valve
197
Measuring point 'turn left'
7.24
33
Gear pump / pilot control
198
Measuring point 'turn right'
7.24
40
Measuring point pump P1
210
Regulating travel motor / powertrain
7.27
41
211
Powertrain
7.27
43
Measuring point / actuating pressure for regulation P1
212
Control piston
7.27
A 309 LI 20221-23502
A 311 LI 20222-23506
copyright by
MJFCIFSS
7.90
6.40.1
Hydraulic system
Service Manual
A 309 from 20221 / A 311 from 20222

Items
see
group
Items
see
group
44
213
Spool
7.27
49
Measuring point / pilot pressure
214
Secondary pressure-relief l valve /

chassis forward A
7.27
50
Control oil unit
7.40
215

chassis reverse B
7.27
51
7.40
216
Shuttle valve
7.27
52
Pressure filter
7.40
217* Brake valve, two-end
7.27
53
Check valve
7.40
218
Brake piston
7.27
54
Accumulator
7.40
219
Check valve
7.27
57
Measuring point servo pressure

(LS)
Flow reduction P1
220
7.27
59

(LR)
Power control
225
Transmission
11.08
75
Check valve P2 - reset
230
Support cylinder
7.30
76
Shuttle valve / compound circuit
231
Double load-holding valve / blade

support
7.86
80
Pilot control valve left 4 x
7.45
241
to Double load-holding valve /

swivel cylinder, see 6.40.9
7.82
81
Pilot control valve right 4 x
7.45
250
Regulating cylinder
7.30
84
Pilot control valve 1 x / chassis
7.49
251
Double-load back-pressure valve
7.82
85
Pilot control valve 2 x / support
7.48
260
7.78
86
Pilot control valve 2 x / adjustable

boom
7.47
262
7.76
87
9.25
300
Line leading to oscillating axles

support
14.10
88
Manifold / collecting pipe
301
Line leading to gear shifting
11.08
100
7.50
302
Line leading to servostat / steering
13.10
101
7.50
303
Line leading to compact block

Brake system
15.10
102
7.50
S21
Switch / creeper gear
8.09/8.20
103
7.50
S35
Switch / pilot control
8.09/8.20
105
7.50
S63
Switch / changeover
Bucket swivel bearing
8.09/8.20
106
7.50
S75
Switch / oscillating axle support
8.09/8.20
107
7.50
S263 Switch / travel direction
8.09/8.20
108
7.50
U16
Excavator control BST
8.09/8.20
109
Spool, compound boom cylinder /

stick cylinder
7.50
Y3
Solenoid valve / pilot control
8.09/8.20
110
to control valve block, low pressure
7.62
Y24
8.09/8.20
120
Primary pressure relief valve pump

P1
7.50
Y50

Power control
8.09/8.20
6.40.2
copyright by
MJFCIFSS
A 309 LI 20221-23502
A 311 LI 20222-23506
Service Manual
Hydraulic system
A 309 from 20221 / A 311 from 20222
Items
see
group
Items
see
group
121

P2
7.50
Y51
Proportional solenoid valve / flow

reduction P1
8.09/8.20
127
Secondary pressure relief valve,

stick cylinder A2
7.50
Y62
Solenoid valve / travel direction
8.09/8.20
128

stick cylinder B2
7.50
Y63
8.09/8.20
129

control cylinder A5
7.50
Y262 Solenoid valve: bucket cylinder /

swivel bearing
8.09/8.20
130

control cylinder B5
7.50
Y330 Solenoid valve / flow reduction P2
8.09/8.20
131

boom cylinder A6
7.50
8.09/8.20
132

boom cylinder B6
7.50
Y358 Proportional solenoid valve / speed

adjustment
8.09/8.20
133

bucket cylinder A7
7.50
Y371 Solenoid valve / oscillating axle

support
8.09/8.20
A 309 LI 20221-23502
A 311 LI 20222-23506
copyright by
MJFCIFSS
6.40.3
Hydraulic system
Service Manual
A 309 from 20221 / A 311 from 20222
6.40.4
copyright by
MJFCIFSS
A 309 LI 20221-23502
A 311 LI 20222-23506
Service Manual
Hydraulic system
Hydraulic system 3 (low-pressure circuit)
21
Fig. 1
Items
see
group
Items
see
group
to hydraulic tank
159
Restrictor
7.56
31
from gear pump / low-pressure circuit: brake
240
Swivel cylinder
7.30
45
Measuring point: low pressure
241
Double load-holding valve
7.82
50
from Control oil unit
260
Oil motor / grapple rotator
110
Compact control valve block, lowpressure circuit
7.56
261
Pressure relief valve
111
Input section
7.56
262
112
Spool / swivel bearing
7.56
S5L Push button: 'turn grapple left'
8.09/8.20
113
7.56
S5R Push button: 'turn grapple right'
8.09/8.20
123
7.56
S19
Button / grapple rotator
8.09/8.20
124
Pressure balance / LS - control
7.56
Y22
Solenoid valve / turn left
8.09/8.20
156
Check valve
7.56
Y23
Solenoid valve / turn right
8.09/8.20
A 309 LI 20221-23502
A 311 LI 20222-23506
copyright by
MJF C I F S S
6.40.9
Hydraulic system
Service Manual

Items
157
see
group
Adjustment restrictor / oil quantity,
rotator
6.40.10
7.62
Items
see
group
Y262 fromSolenoid valve bucket swivel

bearing
copyright by
MJF C I F S S
8.09/8.20
A 309 LI 20221-23502
A 311 LI 20222-23506
Service Manual
Hydraulic system
Key to diagrams I and II (high pressure circuit)
Hydraulic system
3 Key to diagrams I and II (high pressure circuit)
Note!
main components see group 6.20.
Items
see
group
Items
see
group
Hydraulic tank
19.08
136
Breather filter
19.08
150
Check valve
7.50
Stop cock
151
Load-holing valve
7.50
Return filter
19.08
152
Check valve
7.50
Bypass valve/return filter (pressure)
19.08
153
Check valve 0.5 bar
7.50
Oil cooler
154
7.50
10
155
Restrictor valve
11
156
Shuttle valve Swing left (i)
12
Check valve 0.2 bar
157
Shuttle valve Swing right (i)
13
158
Shuttle valve compound stick cylinder (i)
14
Pressure relief l valve fan motor
160
Boom cylinder
7.30
15
Coarse filter
161
Pipe-fracture safety
16.04
20
Double variable-displacem. pump
7.02
162
21
Powertrain P1
7.02
170
Stick cylinder
7.30
22
Powertrain P2
7.02
180
Bucket cylinder
7.30
23
7.02
181
18.35
24
Adjustment
7.02
182
Lines leading to grapple cylinder
25
Spool
7.02
183
26
Nozzle
7.02
190
7.24
27
Differential piston
7.02
191
Pressure-relief l valve / turn right A
7.24
28
Opposed piston / flow reduction
7.02
192
Pressure-relief l valve / turn left B
7.24
29
Actuation device
7.02
193
Suction valve
7.24
30
195
Slewing gear brake
9.20
31
Pump/low-pressure circuit- brake
196
9.10
32
Gear pump / steering with

Pressure-relief l valve
197
7.24
33
198
7.24
40
210
7.27
41
211
Powertrain
7.27
43
212
Control piston
7.27
A 309 LI 23503-27109
A 311 LI 23507-27111
copyright by
MJFCIFSS
7.90
6.40.11
Hydraulic system
Service Manual

Items
see
group
Items
see
group
44
213
Spool
7.27
49
214

chassis forward A
7.27
50
Control oil unit
7.40
215

chassis reverse B
7.27
51
7.40
216
Shuttle valve
7.27
52
Pressure filter
7.40
217
Brake valve, two-end
7.27
53
Check valve
7.40
218
Brake piston
7.27
54
Accumulator
7.40
219
Check valve
7.27
57

(LS)
Flow reduction P1
220
7.27
59

(LR)
Power control
225
Transmission
11.08
75
230
Support cylinder
7.30
76
Shuttle valve / compound circuit
231
Double load-holding valve / blade

support
7.86
80
Pilot control valve left 4 x
7.45
241
to Double load-holding valve /

swivel cylinder, see 6.40.9
7.82
81
Pilot control valve right 4 x
7.45
250
Regulating cylinder
7.30
84
7.49
251
7.82
85
7.48
260
7.78
86
Pilot control valve 2 x / adjustable

boom
7.47
262
7.76
87
9.25
300
Line leading to oscillating axles

support
14.10
88
301
Line leading to gear shifting
11.08
100
7.50
302
Line leading to servostat / steering
13.10
101
7.50
303
Line leading to compact block

Brake system
15.10
102
7.50
103
7.50
S21
8.09/8.20
105
7.50
S35
8.09/8.20
106
7.50
S63
Switch / changeover
Bucket swivel bearing
8.09/8.20
107
7.50
S75
8.09/8.20
108
7.50
8.09/8.20
109
Spool, compound boom cylinder /

stick cylinder
7.50
U16
8.09/8.20
110
to control valve block, low pressure
7.62
Y3
8.09/8.20
120

P1
7.50
Y24
8.09/8.20
6.40.12
copyright by
MJFCIFSS
A 309 LI 23503-27109
A 311 LI 23507-27111
Service Manual
Hydraulic system
Items
see
group
Items
see
group
121

P2
7.50
Y50

Power control
8.09/8.20
127

stick cylinder A2
7.50
Y51

reduction P1
8.09/8.20
128

stick cylinder B2
7.50
Y62
8.09/8.20
129

control cylinder A5
7.50
Y63
8.09/8.20
130

control cylinder B5
7.50
Y262 Solenoid valve: bucket cylinder /

swivel bearing
8.09/8.20
131

boom cylinder A6
7.50
Y330 Solenoid valve / flow reduction P2
8.09/8.20
132

boom cylinder B6
7.50
8.09/8.20
133

bucket cylinder A7
7.50

adjustment
8.09/8.20
134

bucket cylinder B7
7.50

support
8.09/8.20
135

(i)
1.02
A 309 LI 23503-27109
A 311 LI 23507-27111
Brand, see group
copyright by
MJFCIFSS
6.40.13
Hydraulic system
Service Manual
6.40.14
copyright by
MJFCIFSS
A 309 LI 23503-27109
A 311 LI 23507-27111
Service Manual
Hydraulic system
4 Hydraulic system 3 (low-pressure circuit)
Fig. 2
Items
see
group
Items
see
group
to hydraulic tank
159
Restrictor
7.56
31
from gear pump / low-pressure circuit: brake
240
Swivel cylinder
7.30
45
Measuring point: low pressure
241
7.82
50
from Control oil unit
260
110
Compact control valve block, lowpressure circuit
7.56
261
111
Input section
7.56
262
112
Spool / swivel bearing
7.56
S5L
Push button: 'turn grapple left'
113
7.56
8.09/8.20
123
7.56
S19
8.09/8.20
124
7.56
Y22
8.09/8.20
156
Check valve
7.56
Y23
8.09/8.20
157
Adjustment restrictor / oil quantity,

rotator
7.62
Y262 fromSolenoid valve bucket swivel

bearing
A 309 LI 23503-27109
A 311 LI 23507-27111
copyright by
MJFCIFSS
8.09/8.20
8.09/8.20
6.40.19
Hydraulic system
Service Manual
6.40.20
copyright by
MJFCIFSS
A 309 LI 23503-27109
A 311 LI 23507-27111
Service Manual
Hydraulic system
Hydraulic system
5 Key to diagrams I and II
(high pressure circuit)
Note!
For a description of the design of the hydraulic system with main components, see group 6.22
Items
A 309 LI 27110A 311 LI 27112-
see
group
Hydraulic tank
Breather filter
19.08
Stop cock
19.08
Return filter
Bypass valve / return filter (pressure)
19.08
Oil cooler
19.08
10
11
from turbo charger / diesel engine
12
Check valve 0.2 bar
13
14
15
Coarse filter
20
21
Powertrain P1
7.02
22
Powertrain P2
7.02
23
7.02
24
Adjusting device
7.02
25
Spool
7.02
26
Nozzle
7.02
27
Differential piston
7.02
28
Opposed piston / flow limitation
7.02
29
Actuation device
7.02
30
7.02
31
Gear pump / low-pressure circuit - brake
32
Gear pump / steering with pressure-relief valve
33
40
Measuring point P1
41
Measuring point P2
43
Measuring point actuating pressure for regulation P1
44
Measuring point actuating pressure for regulation P2
46
Measuring point actuation valve 166 (k)
copyright by
MJFCIFSS
6.40.21
Hydraulic system
Service Manual

Items
6.40.22
see
group
47
Measuring point actuation valve 165 (k)
49
50
Control oil unit
7.40
51
7.40
52
Pressure filter
7.40
53
Check valve
7.40
54
Accumulator
7.40
57
Measuring point servo pressure (LS) flow reduction P1
59
Measuring point servo pressure (LR) / power control
64
Hydraulic cylinder / uppercarriage locking mechanism (m)
75
76
Shuttle valve / combined shifting
80
Pilot control unit, left 4 x
7.45
81
Pilot control unit, right 4 x
7.45
84
7.49
85
Pilot control unit 2 x / support
7.48
86
Pilot control valve 2 x / adjustable boom
7.47
87
9.20
88
100
7.50
101
Slewing gear spool
7.50
102
Stick cylinder spool
7.50
103
Support cylinder spool
7.50
105
Spool / regulating cylinder (k)
7.50
106
Spool / boom cylinder (k)
7.50
107
7.50
108
7.50
109
Spool / combined boom cylinder / stick cylinder (k)
7.50
110
to control valve block / low pressure
7.56
120
Prim. pressure relief valve pump P1
7.50
121
Prim. pressure relief valve pump P2
7.50
127
Secondary pressure-relief valve, stick cylinder A2
7.50
128
Secondary pressure-relief valve, stick cylinder B2
7.50
129
Secondary pressure-relief valve, regulating cylinder A5
7.50
130
Secondary pressure-relief valve, regulating cylinder B5
7.50
131
Secondary pressure-relief valve, boom cylinder A6
7.50
132
Secondary pressure-relief valve, boom cylinder B6
7.50
133
Secondary pressure-relief valve, bucket cylinder A7
134
Secondary pressure-relief valve, bucket cylinder B7
135
136
copyright by
MJFCIFSS
7.50
A 309 LI 27110A 311 LI 27112-
Service Manual
Hydraulic system
Items
A 309 LI 27110A 311 LI 27112-
see
group
150
Check valve
151
Load holding valve
7.50
152
Check valve
7.50
153
Check valve 0.5 bar
7.50
154
7.50
155
Restrictor valve
156
Shuttle valve turning left 0.8 mm
157
Shuttle valve turning right 0.8 mm
158
Shuttle valve retracting stick cylinder 0.8 mm (k)
160
Boom cylinder
7.30
161
Pipe fracture safety valve
16.04
162
165
3/2-way valve / priority switching (k)
166
Pressure reduction valve / decoupling (k)
167
Measuring point actuation valve 165 0.6 mm (k)
168
Shuttle valve extending boom cylinder 0.8 mm (k)
169
Shuttle valve retracting boom cylinder 0.8 mm (k)
170
Stick cylinder
7.30
171
Restrictor check valve (k)
7.90
7.30
180
Bucket cylinder
181
182
Lines to grapple cylinder
183
7.90
190
7.24
191
Pressure-relief valve / turn right A
7.24
192
Pressure-relief valve / turn left B
7.24
193
Suction valve
7.24
195
Slewing gear brake
9.20
196
9.10
197
7.24
198
7.24
210
7.27
211
Powertrain
7.27
212
Control piston
7.27
213
Spool
7.27
214
Secondary pressure-relief valve / chassis forward A
7.27
215
Secondary pressure-relief valve / chassis reverse B
7.27
216
Shuttle valve
7.27
217
Two-end brake valve
7.27
218
Brake piston
7.27
219
Check valve
7.27
copyright by
MJFCIFSS
6.40.23
Hydraulic system
Service Manual

Items
6.40.24
see
group
220
7.27
225
Transmission
11.08/11.20
230
Support cylinder
7.30
231
Double load-holding valve / blade support
7.83
241
to double load-holding valve / swivel cylinder, see page 6.40.19
7.82
250
Regulating cylinder
7.30
251
Load holding valve
7.85
260
7.78
262
7.76
300
Line to oscillating axle support
14.10
301
Line to gear switching unit
11.08/11.20
302
Line to Servostat / steering
13.10
303
Line to compact block brake system
15.10
S21
8.09/8.20/8.22
S354 Switch / pilot control
8.09/8.20/8.22
S63
Solenoid valve / switchover bucket offset boom bearing
8.09/8.20/8.22
S75
8.09/8.20/8.22
8.09/8.20/8.22
U16
8.09/8.20/8.22
Y3
8.09/8.20/8.22
Y24
8.09/8.20/8.22
Y50
8.09/8.20/8.22
Y50
Proportional solenoid valve / flow reduction P1
8.09/8.20/8.22
Y62
8.09/8.20/8.22
Y63
8.09/8.20/8.22
Y262 Solenoid valve: bucket cylinder / swivel bearing
8.09/8.20/8.22
8.09/8.20/8.22
Y358 Proportional solenoid valve / speed adjustment
8.09/8.20/8.22
8.09/8.20/8.22
(k),(l)(m)change mark, see also
1.02
copyright by
MJFCIFSS
A 309 LI 27110A 311 LI 27112-
Service Manual
Hydraulic system
6 Hydraulic system 3 (low-pressure circuit)
Fig. 3
Item
see
group
Item
see
group
to hydraulic tank
159
Restrictor
7.56
31
from gear pump / low-pressure circuit - brake
240
Swivel cylinder
7.30
45
Low pressure measuring point
241
7.82
50
from control oil unit
260
110
Compact control block low pressure

circuit
7.56
261
111
Input section
7.56
262
112
7.56
S5L
Push button: 'turn grapple left'
113
7.56
8.09/8.20
123
Prim. pressure relief valve
7.56
S19
8.09/8.20
124
7.56
Y22
8.09/8.20
156
Check valve
7.56
Y23
8.09/8.20
157
Adjustment restrictor / oil volume

rotator
Y262 from solenoid valve changeover

bucket cylinder - swivel bearing
8.09/8.20
A 309 LI 27110A 311 LI 27112-
copyright by
MJFCIFSS
8.09/8.20
6.40.29
Hydraulic system
Service Manual
6.40.30
copyright by
MJFCIFSS
A 309 LI 27110A 311 LI 27112-
Service Manual
Hydraulic system
Main components and key to diagrams I and II
Hydraulic system
1 Main components and key to diagrams I and II
Fig. 1
Hydraulic tank and hydraulic pumps
Hydraulic tank
31
Steering pump
20
30
Hydraulic variable- displacement pump

Cooling fan pump
32
50
Brake and control oil pump

Control oil unit
Fig. 2
Pilot control units
80
Pilot control unit for stick and rotary

movement
85
Pilot control unit for outrigger and blade

support
81
Pilot control unit for boom and bucket

movement
86
Pilot control unit for working movement of

auxiliary attachments (hydraulic boom
adjustment, hydraulic hammer, etc.)
84
Pilot control unit for travel movement
87
Pedal for positioning brake
A 312 LI 12363-13288
copyright by
MJFCIFSS
6.42.1
Hydraulic system
Service Manual
Fig. 3
130
Slewing gear motor
255
Stick cylinder
170
Travel motor
275
Bucket cylinder
235
Boom cylinder
275
Support cylinder
Fig. 4
320
6.42.2
Consumer
Rotary connections
Rotary connection 7x for high-pressure oil 322
Rotary connection 6x for low-pressure oil
A 312 LI 12363-13288
copyright by
MJFCIFSS
Service Manual
Hydraulic system
Fig. 5
100
Control valve block
280
Spool for support cylinder
160
220
Spool for travel

Spool for boom cylinder
120
540
Slewing gear control axle

Control axle for grapple rotation
240
Spool for stick cylinder
41-284 Valves, etc. see next page
260
Spool for bucket cylinder
A 312 LI 12363-13288
copyright by
MJFCIFSS
6.42.3
Hydraulic system
Service Manual
6.42.4
Item
Designation
Group
Item
Designation
Group
Hydraulic tank
176
Secondary pressure-relief valve /

forward travel
Breather filter
177

reverse travel
Stop cock
185
Transmission
11.08
Return filter
190
Travel brake valve, complete
7.82
Bypass valve / return line
192
Brake piston
Oil cooler
193
Check valve 3.5 bar
7.59
194
Check valve
7.59
195
Changeover valve
196
Check valves
13
Pressure-relief valve / cooling
220
14
221

extending
20
222

retracting
21
Powertrain
224
Pressure balance
21.1
Adjusting unit, complete
227
23
Regulating valve
233
Distribution block
23.2
Performance regulator
235
Boom cylinder
23.5
LS regulator
237
Stop cock (in models without item

238)
23.6
Changeover valve
238
Pipe fracture safety valve (kit)
16.04
28
Check valve
240
7.59
29
Restrictor
241

retracting
30
Gear pump / cooling
242

extending
31
Gear pump / steering
244
Pressure balance
32
Gear pump / brake, pilot control
247
41
Measuring point MP
255
Stick cylinder
7.30
44
Measuring point / actuating pressure P
260
7.59
45
Measuring point LS
261

retracting
49
Measuring point / pilot control
262

extending
50
Control oil unit
264
Pressure balance
51
275
Bucket cylinder
52
Pressure filter
277
Shut-off device for grapple operation
53
Check valve
278
54
Accumulator
279

only with attachment/quickchange adapter
7.90
57
Measuring point Servo pressure

p-lowering
280
7.59
59

powercontrol
281
Plug / dummy cartridge
80
Pilot control unit, left 4x-
7.45
284
Pressure balance
81
Pilot control unit, right 4x-
7.45
295
Support cylinder
7.30
84
Pilot control unit 1x -/ travel
7.49
297
Double lowering brake valve, see

page 6.42-09 and 6.42-10
7.86
7.14
7.42
7.59
7.30
7.30
A 312 LI 12363-13288
copyright by
MJFCIFSS
Service Manual
Hydraulic system
Item
Designation
Group
85
Pilot control unit 2x,- support
7.48
87
Valve / positioning brake
88
Collecting pipe P/T
100
Compact control block 5x-
102
Pressure balance minimum flow
402
to oscillating axle support
14.10
103
Pressure balance remaining flow
403
to gear switching device (HBGV)
11.08/
11.30
104
540
16.44
105
Primary pressure-relief valve
541
Secondary relief valve / turn right
107
Shuttle valve
542
Secondary relief valve / turn left
109
LS central nozzle
544
Pressure balance
111
Check valve
550
120
551
122
Input pressure balance
552
123
Check valve / load-holding valve
S5
8.10/8.30
125
TC valve with additional pressure

level
S7
Switch / safety switch
8.10/8.30
126
Orifice 0.9 mm
S19
Switch / grapple rotator
8.10/8.30
127
S21
8.10/8.30
128
Changeover valve
S263
Switch / travelling direction
8.10/8.30
130
Slewing gear motor, complete
S35
8.10/8.30
132
Powertrain
S75
Switch / oscillating axle automatic
8.10/8.30
133
Suction valves
U16
BST excavator control system
8.10/8.30
134
pressure-relief valve with additional pressure stage
Y3
Solenoid valve / servo release
7.42
136
pressure-relief valve with additional pressure stage
Y22
Solenoid valve / turn grapple left
16.44
137
Y23
Solenoid valve / turn grapple right
16.44
138
Y24
7.42
155
Slewing gear brake
9.20
Y50
Proportional solenoid valve/LR
7.42
156
9.10
Y51
Solenoid valve/LS
7.42
160
Travel gear spool
7.59
Y62
Solenoid valve / forward travel
161
Suction valve
Y63
Solenoid valve / reverse travel
162
Suction valve
Y352
Proportional solenoid valve / oil

cooling
164
Pressure balance
Y358
Proportional valve / engine speed
167
Y371
Solenoid valve / oscillating axle

support
170
Travel motor, complete
172
Powertrain
173
Control cylinder / regulating unit
174
Spool / regulating unit
7.59
7.59
7.24
Item
Designation
Group
320
7.78
322
7.76
400
to brake system
15.10
401
to steering
13.10
16.44
7.42
7.27
A 312 LI 12363-13288
copyright by
MJFCIFSS
6.42.5
Hydraulic system
Service Manual
Fig. 6
6.42.6
Hydraulic system 1
copyright by
MJF C I F S S
Service Manual
Hydraulic system
Fig. 7
Hydraulic system 2
copyright by
MJF C I F S S
6.42.7
Hydraulic system
Service Manual
Fig. 8
100/A1 from control valve block connection A1 297
Double lowering brake valve, see also

group valves 7.86
100/B1 from control valve block connection B1 320
Rotary connection
295
6.42.8
Support option 2-point outriggers
Support cylinder
A 312 LI 12363-13288
copyright by
MJFCIFSS
Service Manual
Hydraulic system
Fig. 9

group valves 7.86

295
Support cylinder
Rotary connection
Fig. 10
Support option 2-point blade front or rear
A 312 LI 12363-13288
copyright by
MJFCIFSS
6.42.9
Hydraulic system
Service Manual

100/A1 from control valve block connection A1 S206
Push button / individual control of left

outrigger
100/B1 from control valve block connection B1 S207
Push button / individual control of right

outrigger
295
Support cylinder
S335
Push button / individual control of blade
297

group valves 7.86
Y56
Solenoid valve / individual control of

blade
320
Rotary connection
Y217
Solenoid valve / individual control of left

outrigger
325
Slip ring / rotary connection
Y218

right outrigger
Fig. 11
6.42.10
Support option 4-point front blade / rear outriggers with individual control

outrigger

outrigger
295
Support cylinder
S335
297

group valves 7.86
Y56

blade
A 312 LI 12363-13288
copyright by
MJFCIFSS
Service Manual
Hydraulic system
320
Rotary connection
Y217
325
Y218
A 312 LI 12363-13288
copyright by
MJFCIFSS

outrigger
right outrigger
6.42.11
Hydraulic system
Service Manual
6.42.12
A 312 LI 12363-13288
copyright by
MJFCIFSS
Service Manual
Hydraulic system
Key to diagrams I and II
Hydraulic system
Note!
main components, see group 6.24.
Key to diagram I
Items
see
group
Hydraulic tank
2
3
Items
see
group
80
Pilot control unit, left 4x
7.45
Breather filter
81
Pilot control unit, right 4x
7.45
Stop cock
84
Pilot control unit 1x / travelling
7.49
Return filter
85
Pilot control unit 2x / support
7.48
87
Oil cooler
88P
Manifold pressure
13
88T
Collecting pipe return line
14
100
from / to control valve block
7.60
15
Coarse filter (d)
155
to slewing gear brake
9.20
20
21
Powertrain
19.10
170
Travel motor
322
to rotary connection 6x
7.76
21.1 Control cylinder
400
to brake system
15.10
23
Regulating valve
401
to steering system
13.10
23.2 Performance regulator
402
14.10
23.5 LS regulator
403
to gear shifting
11.08
23.6 Shuttle valve
S7
Safety switch
8.10/8.30
28
Check valve
S21
8.10/8.30
29
Restrictor
S35
8.10/8.30
30
S75
8.10/8.30
31
8.10/8.30
32
U16
8.10/8.30
44
Measuring point actuating pressure
Y3
Solenoid valve servo release
8.10/8.30
45
Measuring point / LS pressure
Y24
8.10/8.30
49
Measuring point / pilot pressure M1
Y50
Proportional solenoid valve LR
8.10/8.30
50
Control oil unit
Y51
Proportional solenoid valve LS control
8.10/8.30
51
Y62
8.10/8.30
52
Pressure filter
Y63
8.10/8.30
53
Check valve

control
7.05
7.42
A 312 LI 13289-29897
copyright by
MJFCIFSS
8.10/8.30
6.42.13
Hydraulic system
Service Manual

Items
see
group
Items
see
group
54
Accumulator
Y358 Proportional solenoid valve / motor

speed
8.10/8.30
57

-p reduction

support
8.10/8.30
59
Measuring point servo pressure LR
Index to wiring diagram II

Items
6.42.14
see
group
to hydraulic tank
to oil cooler
Check valve 3.5 bar
7.60
7.60
20
from the variable-displacement pump
7.05
23
to regulating valve
41
Measuring point MP
80
from pilot control unit, left 4x
7.45
81
from pilot control unit, right 4x
7.45
85
from pilot control valve / support
7.48
87
from valve / positioning brake
88P
from manifold P
88T
to collecting pipe T
100
Compact control block 5x
102
103
104
105
107
Shuttle valve (e)
109
LS central nozzle
120
122
123
Check valve (e)
125
TC valve with additional pressure stage (e)
126
Restrictor 1.5 mm
127
128
Shuttle valve
129
Restrictor ( 0.6 mm) (e)
130
132
Powertrain
133
Suction valve
134
Pressure-relief valve with additional pressure stage
135
7.60
7.80
7.24
A 312 LI 13289-29897
copyright by
MJFCIFSS
Service Manual
Hydraulic system
Items
see
group
137
138
155
Slewing gear brake
9.20
156
9.10
160
Spool / chassis
7.60
161
Suction valve / reverse travel
162
Suction valve / forward travel
164
Pressure balance, directly controlled
167
170
Travel motor
172
Powertrain
173
174
176
Secondary relief valve / forward
177
Secondary relief valve / reverse
7.27
185
Transmission
11.08
190
7.27
192
Brake piston
193
194
Check valve
195
Shuttle valve
196
Check valves
220
221
Secondary pressure-relief valve / extending
222
Secondary pressure-relief valve / retracting
224
Pressure balance, pilot-controlled (e)
227
233
Distribution block
7.60
235
Boom cylinder
237
Stop cock (devices without item 238)
238
Pipe-fracture safety system (kit)
240
241
242
244
247
7.30
7.60
255
Stick cylinder
7.30
260
7.60
261
262
264
A 312 LI 13289-29897
copyright by
MJFCIFSS
6.42.15
Hydraulic system
Service Manual

Items
see
group
275
Bucket cylinder
277
Shut-off device for

grapple operation
278
Lines leading to grapple
279

(QC only)
280
281
284
295
Support cylinder
297
320
7.78
322
7.76
540
16.44
541
Secondary relief valve / turning right
542
Secondary relief valve / turning left
544
550
551
552
7.30
7.60
7.30
S5L Push button / grapple rotator, left
8.10/8.30
S5R Push button / grapple rotator, right
8.10/8.30
S19
8.10/8.30
Y22
Solenoid valve / grapple rotation left
16.44
Y23
Solenoid valve / grapple rotation right
16.44
Y24
from solenoid valve / creeper gear
7.42
Y62
from solenoid valve / forward travel
8.10/8.30
Y63
from solenoid valve / reverse travel
8.10/8.30
(d)/(e), see changes in group 1.02
6.42.16
A 312 LI 13289-29897
copyright by
MJFCIFSS
Service Manual
Hydraulic system
Hydraulic system
Note!
Index to wiring diagram I

Item
see
group
Hydraulic tank
Item
see
group
64
Cylinder / uppercarriage locking

mechanism (m)
Breather filter
80
Pilot control unit, left 4 way
7.45
Stop cock
81
Pilot control unit, right 4 way
7.45
Return filter
84
Pilot control unit, travel 1 way
7.49
85
Pilot control unit 2 x, support
7.48
Oil cooler
87
13
88P
Manifold pressure
14
88T
15
Coarse filter
100
7.60
20
155
9.20
21
Powertrain
170
from travel engine
322
to rotary connection 6 way
7.76
23
19.10
7.05
400
to brake system
15.10
23.2 Power regulator
401
to steering
13.10
23.5 LS regulator
402
14.10
23.6 Shuttle valve
403
to gear switching unit
11.10
28
Check valve
S7
Safety switch
8.10/8.32
29
Restrictor
S21
8.10/8.32
30
S35
8.10/8.32
31
S75
8.10/8.32
32
8.10/8.32
44
Measuring point / actuating pressure
U16
8.10/8.32
45
Y3
8.10/8.32
49
Y24
8.10/8.32
50
Control oil unit
Y50

Power control
8.10/8.32
51
Y51
8.10/8.32
52
Pressure filter
Y62
8.10/8.32
Regulating valve
7.42
MJFCIFSS
6.42.21
Hydraulic system
Service Manual

Item
see
group
Item
see
group
53
Check valve
Y63
54
Accumulator

control
8.10/8.32
57
Measuring point / servo pressure

-p reduction

speed
8.10/8.32
59

Power control

support
8.10/8.32
8.10/8.32

Item
see
group
Item
see
group
to hydraulic tank
192
Brake piston
to hydraulic tank
193
Check valve 3.5 bar
7.60
194
Check valve
7.60
195
Shuttle valve
20
from variable-displacement pump
7.05
196
Check valves
23
to regulating valve
220
41
Measuring point MP
221

extending
80
7.45
222

retracting
81
from pilot control unit, right 4 way
7.45
224
Pressure balance, pilot-controlled
85
7.48
227
87
233
Distribution block
88P
from manifold P
235
Boom cylinder
88T
237

238)
100
Compact control block 5 x
238
102
240
103
241

retracting
104
242

extending
105
244
107
Shuttle valve
247
109
LS central nozzle
255
Stick cylinder
7.30
120
260
7.60
122
261

retracting
123
Check valve
262

extending
125

stage
264
6.42.22
7.60
7.80
7.60
7.30
7.60
MJFCIFSS
Service Manual
Hydraulic system
Item
see
group
Item
see
group
126
Restrictor ( 1.5 mm)
275
Bucket cylinder
127
277
Shut-off device for

grapple operation
128
Shuttle valve
278
129
279

(QC only)
130
280
132
Powertrain
281
133
Suction valve
284
134
Pressure relief valve with additional

pressure stage
295
Support cylinder
135

pressure stage
297
137
320
Rotary connection 7 way
7.78
138
322
7.76
155
Slewing gear brake
9.20
540
16.44
156
9.10
541
160
Travel gear spool
7.60
542
161
544
162
550
164
551
167
552
170
Travel motor
S5L
Push button / grapple rotator, left
172
Powertrain
8.10/8.32
173
S19
8.10/8.32
174
Y22
16.44
176

forward travel
Y23
Solenoid valve / grapple rotation

right
16.44
177

reverse travel
Y24
7.42
185
Transmission
11.20
Y62
8.10/8.32
190
7.27
Y63
8.10/8.32
7.24
7.27
7.30
7.60
7.30
8.10/8.32
(m), see changes in group 1.02
MJFCIFSS
6.42.23
Hydraulic system
Service Manual
6.42.24
MJFCIFSS
Service Manual
Hydraulic system
Hydraulic system
Note!
Items
see
group
Items
see
group
Hydraulic tank
19.10
155
Slewing gear brake
9.20
Breather filter
19.10
156
9.10
Stop cock
160
7.60
Return filter
19.10
161
Suction valve A1, forward
7.60
19.10
162
Suction valve B1, reverse
7.60
Oil cooler
164
7.60
Check valve 3.5 bar
7.60
167
7.60
7.60
180
7.60
10
181
Suction valve A2, forward
7.60
13
182
Suction valve B2, reverse
7.60
14
184
7.60
15
195
7.77
20
7.15
196
7.75
21
Powertrain
7.15
200
Travel motor, left
7.28
22
Control cylinder
7.15
201
Travel motor, right
7.28
23
Measuring cylinder
7.15
202
Adjusting device
7.28
24
Angular lever
7.15
203
Shifting piston, oil motor adjustment
7.28
25
7.15
205
Brake valve
7.28
26
Flow regulator
7.15
206
Shuttle valve
7.28
27
Shuttle valve
7.15
207
2-way valve / brake control pressure
7.28
28
Check valve
7.15
208
Pressure reduction valve / brake

pressure
7.28
29
Restrictor
7.15
211

chassis, forward left
7.28
30
212

chassis, reverse left
7.28
31
213

chassis, forward right
7.28
41
Measuring point MP
(control valve block)
214

chassis, reverse right
7.28
44

(variable-displacement pump)
215
Travel brake
11.67
45
Measuring point LS
216
Travel gear
11.62
MJFCIFSS
6.43.1
Hydraulic system
Service Manual
see
group
Items
49
Measuring point control pressure

M1
50
Control oil unit
51
see
group
Items
220
7.60
7.42
221
Secondary pressure-relief valve A3

/ extend
7.60
7.42
222
Secondary pressure-relief valve B3

/ retract
7.60
52
Pressure filter
7.42
224
7.60
53
Check valve
7.42
227
7.60
54
Accumulator
7.42
233
Distribution block
57

(MLS)
-p reduction
235
Boom cylinder
59

(MLR)
Power control
237
Stop cock (machines without item

238)
80
Pilot control unit, left 4x
7.45
238
81
Pilot control unit, right 4x
7.45
240
7.60
82
Pilot control valve 4x / travel
7.46
241

/ retract
7.60
88P
Manifold pressure
242

extend
7.60
88T
244
7.60
100
7.60
247
7.60
102
7.60
255
Stick cylinder
7.30
103
7.60
257
104
7.60
260
7.60
105
7.60
261

/ retract
7.60
106
Shift valve regulating motor Qmin
7.60
262

/ extend
7.60
107
Shuttle valve
7.60
264
7.60
108
LS main orifice
7.60
275
Bucket cylinder
7.30
109
Shuttle valve
7.60
277
Shut-off device for

grapple operation
120
7.60
278
122
7.60
278
Grapple cylinder
123
Check valve
7.60
279

(with QC only)
125
Restrictor 1.8 mm
7.80
B335 Pressure switch / slewing gear
8.17/8.38
126
Shuttle valve 0.8 mm / 0.8 mm
7.80
S17
Switch / slewing gear brake
8.17/8.38
127
7.60
S21
8.17/8.38
128
Restrictor 1.2 mm
7.60
U16
8.17/8.38
130
Slewing gear motor
7.24
Y3
8.17/8.38
6.43.2
7.30
7.90
MJFCIFSS
Service Manual
Items
Hydraulic system
see
group
Items
see
group
132
Powertrain
7.24
Y7
8.17/8.38
133
Suction valve
7.24
Y24
Solenoid valve / fast travel
8.17/8.38
134
Pressure-relief valve with additional pressure level, right B
7.24
Y50

Power control
8.17/8.38
135
Pressure-relief valve with additional pressure level, left A
7.24
Y51
8.17/8.38
137
Measuring point / turn right

control
8.17/8.38
138
Measuring point / turn left

adjustment
8.17/8.38
Y451 Proportional solenoid valve / slewing gear
8.17/8.38
MJFCIFSS
6.43.3
Hydraulic system
6.43.4
Service Manual
MJFCIFSS
Service Manual
Hydraulic system
Hydraulic system
1 Main components and key to diagrams I and II
Fig. 1
Hydraulic tank and hydraulic pumps
Hydraulic tank
31
Steering pump
20
30
Hydraulic variable displacement pump

Cooling fan pump
32
50
Brake and control oil pump

Control oil unit
Fig. 2
Pilot control units
80
Pilot control unit for stick and rotary

movement
85
Pilot control unit for outrigger and blade

support
81
Pilot control unit for boom and bucket

movement
86
84
Pilot control unit for travel movement
87
Pilot control unit for working movement of

auxiliary attachments (hydraulic boom
adjustment, hydraulic hammer, etc.)
Pedal for positioning brake
copyright by
MJFCIFSS
6.44.1
Hydraulic system
Service Manual
Fig. 3
130
170
Slewing gear motor

Travel motor
255
275
Stick cylinder
Bucket cylinder
235
Boom cylinder
275
Support cylinder
Fig. 4
320
6.44.2
Consumer
Rotary connections
Rotary connection 7x for high-pressure oil 322
copyright by
MJFCIFSS
Rotary connection 6x for low-pressure oil
Service Manual
Hydraulic system
Fig. 5
100
Control valve block with
280
Spool for support cylinder
160
220
Spool for travel

Spool for boom cylinder
120
540
Slewing gear control axle

Control axle for grapple rotation
240
Spool for stick cylinder
41-284 Valves, etc. see next page
260
Spool for bucket cylinder
copyright by
MJFCIFSS
6.44.3
Hydraulic system
Service Manual
6.44.4
Item
Designation
group
Item
Designation
Hydraulic tank
176

forward travel
Breather filter
177

reverse travel
Stop cock
185
Transmission
11.08
Return filter
190
7.82
Bypass valve / return line
192
Brake piston
Oil cooler
193
Check valve 3.5 bar
7.59
194
check valve
7.59
195
Changeover valve
196
Check valves
13
Pressure-relief valve / cooling
220
14
221

extending
20
222

retracting
21
Powertrain
224
Pressure balance
21.1
Adjusting unit, complete
227
23
Regulating valve
233
Distribution block
23.2
235
Boom cylinder
23.5
LS regulator
237

238)
7.14
group
7.59
7.30
23.6
Changeover valve
238
16.04
28
check valve
240
7.59
29
Restrictor
241

retracting
30
Gear pump / cooling
242

extending
31
244
Pressure balance
32
247
41
Measuring point MP
255
Stick cylinder
7.30
44
Measuring point / actuating pressure P
260
7.59
45
Measuring point LS
261

retracting
49
Measuring point / pilot control
262

extending
50
Control oil unit
264
Pressure balance
51
275
Bucket cylinder
52
Pressure filter
277
53
check valve
278
54
Accumulator
279

only with attachment/quickchange adapter
7.90
57

p-lowering
280
7.59
59

powercontrol
281
80
Pilot control unit, left 4x-
7.45
284
Pressure balance
81
Pilot control unit, right 4x-
7.45
295
Support cylinders
7.30
84
Pilot control unit 1x -/ travel
7.49
297
Double lowering brake valve, see

page 6.42-09 and 6.42-10
7.86
7.42
copyright by
MJFCIFSS
7.30
Service Manual
Hydraulic system
Item
Designation
group
85
Pilot control unit 2x,- support
7.48
87
88
Collecting pipe P/T
100
Compact control block 5x-
102
Pressure balance minimum flow
402
14.10
103
Pressure balance remaining flow
403
to gear switching device (HBGV)
11.08/
11.30
104
540
16.44
105
541
107
Shuttle valve
542
109
LS central nozzle
544
Pressure balance
111
check valve
550
120
551
122
552
123
Check valve / load-holding valve
S5
8.10/8.30
125

level
S7
Switch / safety switch
8.10/8.30
126
Orifice 0.9 mm
S19
8.10/8.30
127
S21
8.10/8.30
128
Changeover valve
S263
8.10/8.30
130
S35
8.10/8.30
132
Powertrain
S75
8.10/8.30
133
Suction valves
U16
8.10/8.30
134
Pressure relief valve with additional pressure stage
Y3
7.42
136
Y22
Solenoid valve / turn grapple left
16.44
137
Y23
Solenoid valve / turn grapple right
16.44
138
Y24
7.42
155
Slewing gear brake
9.20
Y50
Proportional solenoid valve/LR
7.42
156
9.10
Y51
Solenoid valve/LS
7.42
160
Travel gear spool
7.59
Y62
161
Suction valve
Y63
162
Suction valve
Y352
Proportional solenoid valve / oil

cooling
164
Pressure balance
Y358
Proportional valve / engine speed
167
Y371

support
170
172
Powertrain
173
174
7.59
7.59
7.24
Item
Designation
group
320
7.78
322
7.76
400
to brake system
15.10
401
to steering
13.10
16.44
7.42
7.27
copyright by
MJFCIFSS
6.44.5
Hydraulic system
Service Manual
Fig. 6
6.44.6
Hydraulic system 1
copyright by
MJF C I F S S
Service Manual
Hydraulic system
Fig. 7
Hydraulic system 2
copyright by
MJF C I F S S
6.44.7
Hydraulic system
Service Manual
Fig. 8

group valves 7.86
Rotary connection
295
6.44.8
Support cylinder
copyright by
MJFCIFSS
Service Manual
Hydraulic system
Fig. 9

group valves 7.86

295
Support cylinder
Rotary connection
Fig. 10
Support option 2-point blade front or rear
copyright by
MJFCIFSS
6.44.9
Hydraulic system
Service Manual


outrigger

outrigger
295
Support cylinder
S335
297

group valves 7.86
Y56

blade
320
Rotary connection
Y217

outrigger
325
Y218

right outrigger
Fig. 11
6.44.10
Support option 4-point front blade / rear outriggers with individual control

outrigger

outrigger
295
Support cylinder
S335
297

group valves 7.86
Y56
copyright by
MJFCIFSS

blade
Service Manual
Hydraulic system
320
Rotary connection
Y217
325
Y218
copyright by
MJFCIFSS

outrigger
right outrigger
6.44.11
Hydraulic system
Service Manual
6.44.12
copyright by
MJFCIFSS
Service Manual
Hydraulic system
Hydraulic system
Note!
Key to diagram I
Items
see
group
Hydraulic tank
Items
see
group
59
Measuring point servo pressure LR
Breather filter
80
Pilot control valve, left 4x
7.45
Stop cock
81
Pilot control valve, right 4x
7.45
Return filter
84
Pilot control valve 1 x / travelling
7.49
85
7.48
Oil cooler
87
11
from turbo charger / diesel engine
88P
Manifold pressure
12
Check valve 0.2 bar
88T
13
100
7.60
14
155
9.25
15
Coarse filter (d)
170
from travel motor
20
322
to rotary connection 6x
7.76
21
Powertrain
400
to brake system
15.10
401
to steering system
13.10
23
19.10
7.14
Regulating valve
402
14.10
403
to gear shifting
11.10
23.5 LS regulator
S7
Safety switch
8.10/8.30
23.6 Shuttle valve
S21
8.10/8.30
28
Check valve
S354 Switch / pilot control
8.10/8.30
29
Restrictor
S75
8.10/8.30
30
8.10/8.30
31
Gear pump / steering (f)
U16
8.10/8.30
32
Y3
8.10/8.30
44
Y24
8.10/8.30
45
Y50
Proportional solenoid valve / LS

control
8.10/8.30
49
Y51
8.10/8.30
50
Control oil unit
Y62
8.10/8.30
51
Y63
8.10/8.30
A 314 LI 11147-13103
A 316 LI 11152-13104
A 316 LI-IND 11152-13104
7.42
copyright by
MJFCIFSS
6.44.13
Hydraulic system
Service Manual

Items
see
group
Items
see
group
52
Pressure filter

control
8.10/8.30
53
Check valve

speed
8.10/8.30
54
Accumulator

support
8.10/8.30
57

-p reduction
Key to diagram II
Items
1
6.44.14
see
group
to hydraulic tank
to oil cooler
Check valve 3.5 bar
7.60
7.60
20
from the variable-displacement pump
7.05
23
to regulating valve
41
Measuring point MP
80
from pilot control unit, left 4x
7.45
81
from pilot control unit, right 4x
7.45
85
7.48
87
88P
from manifold P
88T
100
102
103
104
105
107
Shuttle valve (e)
109
LS central nozzle
120
122
123
Check valve (e)
125
TC valve with additional pressure stage (e)
126
Restrictor 1.5 mm
127
128
Shuttle valve
129
130
132
Powertrain
7.60
copyright by
MJFCIFSS
7.80
7.24
A 314 LI 11147-13103
A 316 LI 11152-13104
A 316 LI-IND 11152-13104
Service Manual
Hydraulic system
Items
see
group
133
Suction valve
134
135
137
138
155
Slewing gear brake
9.20
156
9.10
7.60
160
Spool / chassis
161
162
164
167
170
Travel motor
172
Powertrain
173
174
176
Secondary relief valve / forward travel
177
Secondary relief valve/ reverse travel
185
Transmission
11.08
190
7.27
192
Brake piston
193
194
Check valve
195
Shuttle valve
196
Check valves
220
221
222
7.27
7.60
224
Pressure balance, pilot-controlled (e)
227
233
Distribution block
235
Boom cylinder
237
Stop cock (devices without item 238)
238
240
241
242
244
247
255
Stick cylinder
7.30
260
7.60
A 314 LI 11147-13103
A 316 LI 11152-13104
A 316 LI-IND 11152-13104
7.30
7.60
copyright by
MJFCIFSS
6.44.15
Hydraulic system
Service Manual

Items
see
group
261
262
264
275
Bucket cylinder
277
278
279
Restrictor check valve (only SW)
280
281
284
295
Support cylinder
297
320
7.78
322
7.76
540
16.44
541
542
544
550
551
552
7.30
7.60
7.30
8.10/8.30
8.10/8.30
S19
8.10/8.30
Y22
16.44
Y23
16.44
Y24
7.42
Y62
8.10/8.30
Y63
8.10/8.30
(d)/(e), see changes in group 1.02
6.44.16
copyright by
MJFCIFSS
A 314 LI 11147-13103
A 316 LI 11152-13104
A 316 LI-IND 11152-13104
Service Manual
Hydraulic unit
Hydraulic unit
Note!

Item
see
group
Hydraulic tank
2
3
Item
see
group
59

Power control
Breather filter
80
7.45
Stop cock
81
7.45
Return filter
84
7.49
85
7.48
Oil cooler
87
11
88P
Manifold pressure
12
Check valve 0.2 bar
88T
13
100
7.60
14
155
9.20
15
Coarse filter (d)
170
from travel engine
20
322
7.76
21
Powertrain
19.10
7.14
400
to brake system
15.10
401
to steering
13.10
23
402
14.10
403
11.10
23.5 LS regulator
S7
Safety switch
8.10/8.30
23.6 Shuttle valve
S21
8.10/8.30
28
Check valve
S35
8.10/8.30
29
Restrictor
S75
8.10/8.30
30
31
Gear pump / steering (f)
U16
8.10/8.30
32
Y3
8.10/8.30
44
Y24
8.10/8.30
45
Y50

Power control
8.10/8.30
49
Y51
8.10/8.30
50
Control oil unit
Y62
8.10/8.30
51
Y63
8.10/8.30
52
Pressure filter

control
Regulating valve
A 314 LI 13104A 316 LI 13105-28060

A 316 LI-IND 13105-28060
7.42
copyright by
MJFCIFSS
8.10/8.30
8.10/8.30
6.44.21
Hydraulic unit
Item
Service Manual
see
group
Item
see
group
53
Check valve

speed
8.10/8.30
54
Accumulator

support
8.10/8.30
57

-p reduction

Item
see
group
to hydraulic tank
to hydraulic tank
Check valve 3.5 bar
7.60
20
23
41
80
81
Item
see
group
192
Brake piston
193
194
Check valve
7.60
195
Shuttle valve
7.14
196
Check valves
to regulating valve
220
Measuring point MP
221

extending
7.45
222

retracting
7.45
224
Pressure balance, pilot-controlled(e)
85
7.48
227
87
233
Distribution block
88P
from manifold P
235
Boom cylinder
88T
237

238)
100
238
102
240
103
241

retracting
104
242

extending
105
244
107
Shuttle valve (e)
247
109
LS central nozzle
255
Stick cylinder
7.30
120
260
7.60
122
261

retracting
123
Check valve (e)
262

extending
125

stage (e)
264
126
275
Bucket cylinder
6.44.22
7.60
7.80
copyright by
MJFCIFSS
7.59
7.30
7.60
7.30
A 314 LI 13104A 316 LI 13105-28060
A 316 LI-IND 13105-28060
Service Manual
Item
Hydraulic unit
see
group
Item
see
group
127
277
Shut-off device for

grapple operation
128
Shuttle valve
278
129
279

(QC only)
130
280
132
Powertrain
281
133
Suction valve
284
134

pressure stage
295
Support cylinder
135

pressure stage
297
137
320
7.78
138
322
7.76
155
Slewing gear brake
9.20
540
16.44
156
9.10
541
160
Travel gear spool
7.60
542
161
544
162
550
164
551
167
552
170
Travel motor
172
173
7.24
7.60
7.30
8.10/8.30
Powertrain
8.10/8.30
S19
8.10/8.30
174
Y22
16.44
176

forward travel
Y23

right
16.44
177

reverse travel
Y24
7.42
185
Transmission
11.10
Y62
8.10/8.30
190
7.26
Y63
8.10/8.30
7.26
(d)/(e)/(f), see changes in group 1.02
A 314 LI 13104A 316 LI 13105-28060

A 316 LI-IND 13105-28060
copyright by
MJFCIFSS
6.44.23
Hydraulic unit
6.44.24
Service Manual
copyright by
MJFCIFSS
A 314 LI 13104A 316 LI 13105-28060

A 316 LI-IND 13105-28060
Service Manual
Hydraulic unit
Hydraulic unit
Note!

Item
see
group
Hydraulic tank
Item
see
group
59

Power control
Breather filter
64
Cylinder / uppercarriage locking

mechanism (m)
Stop cock
80
7.45
Return filter
81
7.45
84
7.49
Oil cooler
85
7.48
11
87
19.10
12
Check valve 0.2 bar
88P
Manifold pressure
13
88T
14
100
7.60
15
Coarse filter
155
9.20
20
170
from travel engine
21
Powertrain
7.05
322
7.76
400
to brake system
15.10
23
401
to steering
13.10
402
14.10
23.5 LS regulator
403
11.10
23.6 Shuttle valve
S7
Safety switch
8.10/8.32
28
Check valve
S21
8.10/8.32
29
Restrictor
S35
8.10/8.32
Regulating valve
30
S75
31
8.10/8.32
32
U16
8.10/8.32
44
Y3
8.10/8.32
45
Y24
8.10/8.32
49
Y50

Power control
8.10/8.32
50
Control oil unit
Y51
8.10/8.32
51
Y62
8.10/8.32
52
Pressure filter
Y63
8.10/8.32
A 316 LI 28061A 316 LI-IND 28061-
7.42
copyright by
MJFCIFSS
8.10/8.32
6.44.31
Hydraulic unit
Item
Service Manual
see
group
Item
see
group
53
Check valve

control
54
Accumulator

speed
57

-p reduction
Y371 Solenoid valve / osc. axle support
8.10/8.32
8.10/8.32

Item
see
group
to hydraulic tank
to hydraulic tank
Check valve 3.5 bar
7.60
20
23
41
80
Item
see
group
192
Brake piston
193
194
Check valve
7.60
195
Shuttle valve
7.14
196
Check valves
to regulating valve
220
Measuring point MP
221

extending
7.45
222

retracting
7.59
81
7.45
224
85
7.48
227
87
233
Distribution block
88P
from manifold P
235
Boom cylinder
88T
237

238)
100
238
102
240
103
241

retracting
104
242

extending
105
244
107
Shuttle valve
247
109
LS central nozzle
255
Stick cylinder
7.30
120
260
7.60
122
261

retracting
123
Check valve
262

extending
125

stage
264
126
275
Bucket cylinder
6.44.32
7.60
7.80
copyright by
MJFCIFSS
7.30
7.60
7.30
A 316 LI 28061A 316 LI-IND 28061-
Service Manual
Item
Hydraulic unit
see
group
Item
see
group
127
277
Shut-off device for

grapple operation
128
Shuttle valve
278
129
279

(QC only)
130
280
132
Powertrain
281
133
Suction valve
284
134

pressure stage
295
Support cylinder
135

pressure stage
297
137
320
7.78
138
322
7.76
155
Slewing gear brake
9.20
540
16.44
156
9.10
541
160
Travel gear spool
7.60
542
161
544
162
550
164
551
167
552
170
Travel motor
S5L
Push button / grapple rotator, left
172
Powertrain
8.10/8.32
173
S19
8.10/8.32
174
Y22
16.44
176

forward travel
Y23

right
16.44
177

reverse travel
Y24
7.42
185
Transmission
11.20(n)
Y62
8.10/8.32
190
7.27(n)
Y63
8.10/8.32
7.24
7.27(n)
7.60
7.30
8.10/8.32
(m)/(n), see changes in group 1.02
A 316 LI 28061A 316 LI-IND 28061-
copyright by
MJFCIFSS
6.44.33
Hydraulic unit
6.44.34
Service Manual
copyright by
MJFCIFSS
A 316 LI 28061A 316 LI-IND 28061-
Service Manual
Hydraulic unit
Hydraulic unit
Note!
Item
see
group
Item
see
group
Hydraulic tank
19.10
137
Breather filter
19.10
138
Stop cock
155
Slewing gear brake
9.20
Return filter
19.10
156
9.10
19.10
160
7.60
Oil cooler
161
Suction valve A1 / forward
7.60
Check valve 3.5 bar
7.60
162
Suction valve B1 / reverse
7.60
7.60
164
7.60
10
167
7.60
11
180
7.60
12
Check valve 0.2 bar
181
7.60
13
182
7.60
14
184
7.60
15
195
7.77
20
7.16
196
7.75
21
Powertrain
7.16
200
Travel motor, left
7.28
22
Control cylinder
7.16
201
Travel motor, right
7.28
23
Measuring cylinder
7.16
202
Adjustment
7.28
24
Elbow lever
7.16
203
7.28
25
7.16
205
Brake valve
7.28
26
Flow regulator
7.16
206
Shuttle valve
7.28
27
Shuttle valve
7.16
207
7.28
28
Check valve
7.16
208

pressure
7.28
29
Restrictor
7.16
211

7.28
30
212

7.28
31
213

7.28
41
Measuring point MP
214

7.28
R 317 LI 18161-21204
copyright by
MJFCIFSS
6.47.1
Hydraulic unit
Service Manual
see
group
Item
see
group
Item
44

215
Travel brake
11.65
45
Measuring point LS
216
Travel gear
11.60
49
Measuring point / control pressure

M1
220
7.60
50
Control oil unit
7.43
221
Secondary relief valve A3 / extending
7.60
51
7.43
222
Secondary relief valve / retracting
7.60
52
Pressure filter
7.43
224
7.60
53
Check valve
7.43
227
7.60
7.43
54
Accumulator
233
Distribution block
57

(MLS)
-p reduction
235
Boom cylinder
59

(MLR)
Power control
237

238)
80
7.45
238
81
7.45
240
7.60
82
Pilot control unit, travel, left 2 x
7.46
241
Secondary relief valve A5 / retracting
7.60
83
Pilot control unit, travel, right 2 x
7.46
242
Secondary relief valve B5 / extending
7.60
84
Pilot control unit, travel 1 x
244
7.60
85
247
7.60
88P
Manifold pressure
255
Stick cylinder
7.30
88T
257
100
Compact control valve block 5 x
7.60
260
7.60
102
7.60
261
7.60
103
7.60
262
7.60
104
7.60
264
7.60
105
7.60
275
Bucket cylinder
7.30
106
Shift valve Qmax. variable displacement motor
7.60
277
Shut-off device for

grapple operation
107
Shuttle valve
7.60
278
108
LS mainmain orifice
7.60
278
Grapple cylinder
109
Shuttle valve
7.60
279

(QC only)
120
7.60
122
7.60
6.47.2
7.30
7.90
R 317 LI 18161-21204
copyright by
MJFCIFSS
Service Manual
Item
Hydraulic unit
see
group
Item
see
group
123
Check valve
7.60
S17
Switch slewing gear brake
8.17/8.40
125

level
7.80
S21
8.17/8.40
126
7.80
U16
8.17/8.40
127
7.60
Y3
8.17/8.40
128
Shuttle valve
7.60
Y7
8.17/8.40
129
7.80
Y24
8.17/8.40
130
Slewing gear motor
7.24
Y50

Power control
8.17/8.40
132
Powertrain
7.24
Y51
8.17/8.40
133
Suction valve
7.24

control
8.17/8.40
134

pressure level, r B
7.24

adjustment
8.17/8.40
135

pressure level, l A
7.24
R 317 LI 18161-21204
copyright by
MJFCIFSS
6.47.3
Hydraulic unit
6.47.4
Service Manual
R 317 LI 18161-21204
copyright by
MJFCIFSS
Service Manual
Hydraulic unit
Hydraulic unit
Note!
Item
see
group
Item
see
group
Hydraulic tank
19.10
137
Breather filter
19.10
138
Stop cock
155
Slewing gear brake
9.20
Return filter
19.10
156
9.10
19.10
160
7.60
Oil cooler
161
7.60
Check valve 3.5 bar
7.60
162
7.60
7.60
164
7.60
10
167
7.60
11
180
7.60
12
Check valve 0.2 bar
181
7.60
13
182
7.60
14
184
7.60
15
195
7.77
20
7.16
196
7.75
21
Powertrain
7.16
200
Travel motor, left
7.28
22
Control cylinder
7.16
201
Travel motor, right
7.28
23
Measuring cylinder
7.16
202
Adjustment
7.28
24
Elbow lever
7.16
203
7.28
25
7.16
205
Brake valve
7.28
26
Flow regulator
7.16
206
Shuttle valve
7.28
27
Shuttle valve
7.16
207
7.28
28
Check valve
7.16
208

pressure
7.28
29
Restrictor
7.16
211

7.28
30
212

7.28
31
213

7.28
41
Measuring point MP
214

7.28
MJFCIFSS
6.47.11
Hydraulic unit
Service Manual
see
group
Item
see
group
Item
44

215
Travel brake
11.65
45
Measuring point LS
216
Travel gear
11.60
49

M1
220
7.60
50
Control oil unit
7.43
221
Secondary relief valve A3 / extending
7.60
51
7.43
222
Secondary relief valve / retracting
7.60
52
Pressure filter
7.43
224
7.60
53
Check valve
7.43
227
7.60
7.43
54
Accumulator
233
Distribution block
57

(MLS)
-p reduction
235
Boom cylinder
59

(MLR)
Power control
237

238)
80
7.45
238
81
7.45
240
7.60
82
Pilot control unit, travel, left 4 x
7.46:11
241
7.60
84
Pilot control unit, travel 1 x
242
7.60
85
244
7.60
88P
Manifold pressure
247
7.60
88T
255
Stick cylinder
7.30
100
7.60
257
102
7.60
260
7.60
103
7.60
261
7.60
104
7.60
262
7.60
105
7.60
264
7.60
106
Shift valve Qmax. variable displacement motor
7.60
275
Bucket cylinder
7.30
107
Shuttle valve
7.60
277
Shut-off device for

grapple operation
108
LS mainmain orifice
7.60
278
109
Shuttle valve
7.60
278
Grapple cylinder
120
7.60
279

(QC only)
122
7.60
6.47.12
7.30
7.90
MJFCIFSS
Service Manual
Hydraulic unit
see
group
Item
see
group
Item
123
Check valve
7.60
125

level
7.80
S17
8.17/8.40
126
7.80
S21
8.17/8.40
127
7.60
U16
8.17/8.40
128
Shuttle valve
7.60
Y3
8.17/8.40
129
7.80
Y7
8.17/8.40
130
Slewing gear motor
7.24
Y24
8.17/8.40
132
Powertrain
7.24
Y50

Power control
8.17/8.40
133
Suction valve
7.24
Y51
8.17/8.40
134

pressure level, r B
7.24

control
8.17/8.40
135

pressure level, l A
7.24

adjustment
8.17/8.40
MJFCIFSS
6.47.13
Hydraulic unit
6.47.14
Service Manual
MJFCIFSS
Service Manual
SUBGROUP - INDEX
Section
Group
Type
Hydraulic pumps - dismantling,

installation and initial operation
7.01.1
A 309 LI 20221A 311 LI 20222A 312 LI 12363A 314 LI 2001A 316 LI 2001A 316 LI-IND 2001R 317 LI 18161-
Double variable-displacement pump A8VO
7.02.1
A 309 LI 20221A 311 LI 20222-
LPV variable displacement pump
7.05.1
DPVO variable displacement pump
7.10.1
R 317 LI 18161-
DPVO variable-displacement pump
7.15.1
R 313 LI 27752-
Cooling unit
7.20.1
FMF hydraulic fixed displacement motor
7.24.1
A 314 LI 2001-11146
A 316 LI 2001-11151
A 316 LI-IND 2001-11151
7.24.11
7.1
MJFCIFSS
Service Manual
LMV regulating motor
7.26.1
A 314 LI 2001A 316 LI 2001-28060

A 316 LI-IND 2001-28060
DMVA regulating motor
7.27.1
A 309 LI 20221A 311 LI 20222A 312 LI 12363A 316 LI 28061A 316 LI-IND 28061-
Regulating motor A6VE
7.28.1
R 313 LI 27752R 317 LI 18161-
Hydraulic cylinder
7.30.1
Hydraulic cylinder
7.34.1
A 312 LI 12363-
Hydraulic cylinder
7.35.1
A 314 LI 2001-
Hydraulic cylinder
7.36.1
A 316 LI 2001A 316 LI-IND 2001-
Control oil and regulation unit
7.40.1
A 309 LI 20221A 311 LI 20222-
7.42.1
A 312 LI 12363A 314 LI 2001A 316 LI 2001A 316 LI-IND 2001R 313 LI 27752R 317 LI 18161-
Pilot control unit 4 x
7.45.1
Pilot control unit 2 way for travel gear drive
7.46.1
R 317 LI 18161-
7.2
MJFCIFSS
Service Manual
SUBGROUP - INDEX
Section
Group
Type
Pilot control unit 4x
7.46.11
R 313 LI 27752R 317 LI 21205-
Pilot control valve 2 x
7.47.1
7.48.1
7.49.1
7.50.1
A 309 LI 20221A 311 LI 20222-
LSC control block
7.60.1
7.75.1
R 313 LI 27752R 317 LI 18161-
7.3
MJFCIFSS
Service Manual
7.76.1
7.77.1
R 313 LI 27752R 317 LI 18161-
7.78.1
TC valve
7.80.1
7.4
MJFCIFSS
Service Manual
Hydraulic pumps - dismantling, installation and initial

Variable-displacement pump / double variable-displacement pump 20 / working hydraulics
Hydraulic pumps - dismantling, installation and

initial operation
Note!
For a clean and nearly oil-free assembly and disassembly of the hydraulic pumps, we recommend
the use of a vacuum pump (tool no. 180 - 187 in group 2.05).
This pump can also be used as a compressor with a controlled low pressure of 300 - 500 mbar for
ventilating the equipment.
See also service information no. 06 - 03 - 22 / 2003
1 Variable-displacement pump / double variable-displacement pump

20 / working hydraulics
see Fig. 1
1.1
Dismantling
Close stop cock on hydraulic tank.
Disconnect the suction and pressure lines from the pump 20 and 30/31 and collect the hydraulic
oil in a suitable container.
Dismantle the hydraulic pump 20.
1.2
Installation
Apply CTK special paste to the gearing of the pump 20 (see group 1.50).
Insert the hydraulic pump 20 into the clutch and place it on the intermediate housing/motor.
Screw in the mounting bolts and tighten them with the prescribed tightening torque, see also group
5.05 / 5.10.
Carefully clean all pipes and hoses and inspect them for damage.
Connect the pipes and hoses to the pumps 20 / 30, as shown in the hydraulic diagram.
Disconnect the leak oil line T1 from the pump 20.
Fill the pump hosing through the open leak oil connection.
Before starting the machine, fill the hydraulic tank to the upper fill level mark.
Open the stop cock on the hydraulic tank.
Check the screw fittings and lines for tightness.
Make the suction hose air-tight. (Re-tighten connection and/or pipe clamps.)
copyright by
MJFCIFSS
7.01.1
Service Manual
Gear pumps
Fig. 1
Variable-displacement pump / double variable-displacement pump and gear pumps
20 Double variable-displacement pump (A 309 - 30 Gear pump

A 311)
20 Variable-displacement pump (A 312 - R 317) 31 Gear pump
T1 Leak oil connection
2 Gear pumps
2.0.1
In models A 309 - A 311311, see Fig. 1 and Fig. 2

Gear pump 30 for hydraulic fan drive
Gear pump 31 for brake system and low-pressure circuit
Gear pump 32 for steering
Gear pump 33 for pilot control system
2.0.2
In models A 312 - A 316, see Fig. 1 and Fig. 2

Gear pump 31 - steering
Gear pump 32 for brake and pilot control system
2.0.3
In model R 317, see Fig. 1

Gear pump 30 for pilot control system
7.01.2
copyright by
MJFCIFSS
Service Manual

Gear pumps
Fig. 2
Variable-displacement pump / double variable-displacement pump and gear pumps
20 Double variable-displacement pump A 309 - 31 Gear pump with flow distributor

A 311
20 Variable-displacement pump (A 312 - A 316) 32 Gear pump
30 Gear pump
2.1
33 Gear pump
Dismantling
Close stop cock on hydraulic tank.
Place suitable oil pan under hydraulic pumps.
Disconnect hoses / lines at pumps. Collect hydraulic oil.
Remove hydraulic pumps.
2.2
Installation
Install hydraulic pumps.
Connect all hoses / lines at pumps.
Before starting the system, fill the hydraulic tank all the way to full mark at the top. Open the stop
cock.
Check the screw fittings and lines for tightness.
copyright by
MJFCIFSS
7.01.3
Service Manual
First operation after replacement of pumps

Note!
Gear pumps do not require filling. To bleed the gear pumps 30, 31, 32 and 33:
Loosen the screwed connections of the respective pressures hoses.
Bleed the pump with the diesel engine at low idle speed
until the oil runs out of the pressure connection (liquid, not oil foam).
Re-tighten the connections. Check for tightness.
3 First operation after replacement of pumps

and/or after use of a vacuum pump. See start-up of pumps.
Run diesel engine for about 10 seconds using starter, but do not start the engine yet.
Start diesel engine. Let run for about 7 minutes at low idle speed.
Check oil level in hydraulic tank. Fill up, if necessary.
Loosen leak oil line at variable-displacement pump, but do not disconnect.
Bleed pump with diesel engine at low idle speed
until oil runs out of the leak connection (collect escaping oil).
Re-tighten leak oil line (not necessary with gear pumps).
Run hydraulic system at full power. Run hydraulic oil to a working temperature of at least 50C.
Check settings of system's pressure relief valves.
When pressures increases, remember to reduce engine speed.
Also check electrical signals and settings, if necessary. See adjustment protocol and adjustment guideline, group 6.
Check system for tightness.
7.01.4
copyright by
MJFCIFSS
Service Manual

Function

1 Function
Pump 21 supplies the following consumers:

Chassis, bucket cylinder, boom cylinder, stick cylinder (total)
Pump 22 supplies the following consumers:
Slewing gear, stick cylinder, support system
The volumetric delivery of the pump is determined by the pivot angle of the respective powertrains.
At the begin of regulation, each pump is set to Qmax (maximum flow). The control piston adjusts the
cylinders to a smaller pivot angle. By operating the power regulator (LR regulator). the hydraulic control of the control piston can be adjusted.
In a similar manner, the flow volume of pump P1 can be adjusted by means of the flow limitation.
Fig. 1
Variable-displacement pump A8VO
20
Double variable-displacement
pump, complete
22
Pump P2
21
Pump P1
30
copyright by
MJFCIFSS
7.02.1
Service Manual
Function
7.02.2
copyright by
MJFCIFSS
Service Manual

General information
2 General information
Equipment
from serial number
A 309 Litronic
20221
A 311 Litronic
20222
A8VO 55
A8VO 55
2000 min-1
2000 min-1
Drive power of diesel engine

(nominal power) = Pmax
63 kW
67kW
Max. input power of the pumps
59 kW
63 kW
106 l/min
20 l/min
106 l/min
20 l/min
13.5 kW
15.7 kW
60 2 bar
70 2 bar
Begin of regulation P1 / P2
290 bar
300 bar
Gear pump 30 / fan drive
40 l/min
40 l/min
Check measurement X (stroke limitation,

flow reduction)
12.4 mm
11.8 mm
Flow from solenoid

valve Y50
Flow from solenoid

valve Y50
850 + 25 mA
850 + 25 mA
0 mA
0 mA
Control pressure from

solenoid valve Y50
Control pressure from

solenoid valve Y50
P max.
0 +1 bar
0 +1 bar
P emergency operation
30+2 bar
30+2 bar
Type of pump
Input speed
Volumetric delivery per pump

max.
min.
Hydraulic output per pump
(basic operation)
Begin of regulation (basic operation)
Check measurement Y (threaded stud 56 /

Qmax stop)
Settings and comparative values
I max
I emergency operation
Tab. 1
Technical data
copyright by
MJFCIFSS
7.02.3
Service Manual
Description
3 Description
The double variable-displacement pump consists of the following main components:
Pump housing 1
Regulator housing 40
Actuation housing 60
Actuation device 70
Pump flange 98 for gear pump / fan drive
The double variable-displacement pump A8VO is flange-connected to the diesel engine.
The powertrains of the pumps P1 and P2 consisting of an input pinion, cylinder and piston are adjustable by means of the control pistons and necks.
The regulator housing 40 with the integrated control piston is mounted to the rear of the pump housing
1. The actuation housing 60 with spool and regulating springs for the regulation and adjustment of
the pump output is mounted on the regulator housing 40. The actuation housing 60 carries the actuation device 70 with the differential pistons of the power regulator and the spool with springs for the
flow reduction of pump P1.
The gear pump for the cooling system is attached to flange 98.
Fig. 2
7.02.4
Elements of the pump A8VO
copyright by
MJFCIFSS
Service Manual

Description
1
40
Pump housing
Regulator housing
70
78
Actuation device
Stroke limitation / flow limitation
60
65
Actuation housing
98
Flange for gear pump
from / to hydraulic tank
28
Spool / flow limitation
13
to oil motor / fan drive
29
Actuation device, complete
20
30
Gear pump / cooling
21
Double variable-displacement pump,

complete
Powertrain P1
43

pump 1
22
Powertrain P2
44
23
Pump regulator / actuation housing, com- 57

plete

pump 2
Measuring point MR / flow reduction control pressure
24
Pump adjustment
59
Measuring point LR / power control pressure
25
Spool
100
to control valve block
26
Nozzle
Y50
from proportional solenoid valve / power

control
27
Differential piston
Y51
from proportional solenoid valve / flow

limitation
Fig. 3
1
Hydraulic diagram of A8VO
copyright by
MJFCIFSS
7.02.5
Service Manual
Functional description of double variable-displacement pump
4 Functional description of double variable-displacement pump

4.1
Powertrain 21/ 22
The input pinions 2 and 3 are installed on tapered roller bearings 8 / 9 / 10 in the pump housing. The
input/drive shaft 2 with spline mesh is driven directly by the diesel engine to which it is connected with
a flexible coupling. The input pinion 3 and the gear 91 are driven through the helical gearing in opposite direction of rotation. The gear 91 or the input pinion 3 respectively drive the input pinion 95 of the
gear pump / cooling or the input pinion 100, (see Fig. 7 page 14) (in opposite direction). The tapered
roller bearing is preloaded with the slotted nuts 11 screwed into the input pinions 2 / 3.
The cylinders 30 are set in motion by the conical pistons 33 connected to the input pinions 2 / 3. The
centre pegs 31 act as axial and radial guide devices for the cylinders 30. The spherical heads of the
centre pegs 31 and the conical piston 33 are borne by the spherical caps of the input pinions 2 / 3
and are secured with the screws 36 to the return plate 35.
Each cylinder 30 rotates in radial direction on the control lens 38 with spherical sliding and sealing
face. The control lens 38 is moved in vertical direction by the control piston 41 and the attached control neck 49. By placing the cylinder 30 into an incline position to the pinion axis (by means of regulating system), the piston stroke in cylinder 30 is adjusted. At each revolution of the cylinder 30, the
seven pistons 33 complete a double stroke motion. The actual volumetric delivery (piston stroke x
piston surface) depends on the number of strokes per minute.
When not pressurised, the disc springs 32 press the cylinder 30 against the control lens 38. When
the pressure increases, the hydraulic forces support the spring force, so that a sufficiently thick lubricating layer is maintained between the cylinder 30 and the control lens 38 and oil leakage is minimal,
even at high pressures between the above components. The spherical heads of the piston 30 and
the centre peg 31 , and the tapered roller bearings 8 - 10 are lubricated through the axial bores in the
piston, centre peg and input pinion.
The control lens 38 separates the pressure side from the suction side of the powertrain. The spherical
surface of the control lens 38 is equipped with radially aligned kidney-shaped grooves through which
the cylinder 30 is supplied through the joint suction connection (suction side) with oil from the tank.
Another set of kidney-shaped grooves ensure that the pressure oil from cylinder 30 is fed to the respective pressure connection A1 (for pump P1) or A2 (for pump P2).
The radial shaft seal ring 5 in the locking ring 4 seals the gap between the drive shaft 2 and the housing 1.
7.02.6
Pump housing
38
Control lens
Input pinion / drive shaft
40
Regulator housing
Input pinion
41
Control piston, siehe Fig. 6
Locking ring
49
Control neck, siehe Fig. 6
5
8
Radial shaft seal ring

Tapered roller bearing
90
91
Stub shaft
Gear
92
Cylindrical roller bearing
10
94
Cover
11
Slotted nut
95
Gear
30
31
Cylinder
Centre peg
96
97
Deep groove ball bearing

32
33
Disc springs
Conical piston
98
A1
Flange
Pressure connection of pump P1
34
35
Piston ring
Return plate
A2
S
Pressure connection of pump P2

joint suction connection P1/P2
36
Oval head screw
Profile of inclined axle
copyright by
MJFCIFSS
Service Manual

Fig. 4
Powertrain of the pump A8VO
copyright by
MJFCIFSS
7.02.7
Service Manual
4.1.1
Min. and max. pivot angle of the pump

The maximum pivot angle max of the pump powertrain is determined by the threaded stud 56 in the
regulator housing 40. In Qmax position, the hex head screw 52 of the control piston 41 touches the
threaded stud 56. The position of the threaded stud 56 is factory-set and may not be modified.
Dimension Y of max is used for checking purposes only, (see page 3).
The minimum pivot angle min of the powertrain is determined by the stop of the piston 51 in the regulator housing 40 and cannot be modified.
Fig. 5
7.02.8
Minimum and maximum stop of the pump
40
Regulator housing
55
Allen head screw
41
Control piston
56
Threaded stud / Qmax stop
51
Piston
57
52
54
Hex head screw

Cover
58
Safety cap
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MJFCIFSS
Service Manual

Pump regulation
5 Pump regulation
5.1
Introduction
The double variable-displacement pump consists of two individually controlled pumps installed in a
joint housing. Each pump is regulated independently from the other according to its performance characteristic.
5.2
Performance regulator LA, siehe Fig. 6

The performance regulator 25 is designed to adjust the flow rates of the pump in relation to the operating pressure, in line with the performance curve of the diesel engine. The pump performance is
thus regulated along a hyperbolic characteristic. The pump delivers larger volumes at low pressure
and smaller volumes at high pressures. The hyperbolic performance characteristic is approximated
by means of the regulating springs 44 and 45/46.
The operating pressure acts on the small measuring surface of the differential piston 80. The resulting
force of this piston 80 is then applied through the stud 81 and the externally adjustable spring force
(through the treaded stud 65) against the spring force of the regulating springs 44/45/46.
When the pump is not pressurised, the powertrain is held by the regulating springs 44/45/46 at a maximum pivot angle. At a pressure below the maximum output of the pump (before begin of regulation),
the pressure oil acts on the small piston surface (annular surface Fk ) of the control piston 41. As a
result, the mechanical connection of the control piston 41 to the control lens 38 through the control
neck 49 pushes the power train to its maximum pivot angle. The large control piston surface Fg is
thereby connected to the tank side.
5.2.1
Begin of pump regulation

If the total hydraulic forces exceed the spring force of the regulating springs 44/45/46, the spool 25 is
moved and high pressure oil flows from the small piston surface through the nozzle 26 to the large
piston surface of the control piston 41. The resulting increased force pushes the control piston 41
against the regulating springs 44/45/46. The control piston 41 thus regulates the powertrain in the
direction of a smaller pivot angle, and thus towards Qmin.
5.2.2
Performance override by means of control pressure

The external control pressure is fed through connection X3 onto the large measuring surface of the
diffrential piston 80. The control pressure is created and controlled by the proportional solenoid valve
Y50 located at the control oil unit 50, in proportion to the current fed to the valve by the U16 excavator
control system. The force resulting from the high pressure and the additional control pressure acts
on the spool 25 and, through the pushrod 81, also onto the regulating springs 44/45/46. The set output (i.e. max. output) of the pump isthereby adjusted to a lower value. This mechanism allows for a
number of performance settings, (see Fig. 8 page 14) or (see Fig. 9 page 15). The total of the two
pump outputs corresponds to the maximum available drive power.
5.2.3
Hydraulic stroke limitation of pump P1

By means of the hydraulic stroke limitation, the volumetric delivery of the pump P1 can be adjusted
or limited stepleessly across the entire adjusting range from Qmax to Qmin. The desired volumetric
delivery is determined by the control pressure from the proportional solenoid valve Y51 of the control
oil unit through the connection X1 onto the piston 78. The hydraulic stroke limitation is overridden by
the power regulator, which means that, below the power regulator characteristic, the volumetric delivery is adjusted in line with the control pressure. If the set flow volume or the operating pressure exceeds the pump characteristic, the power regulator overrides the settings and controls the volumetric
delivery along the performance characteristic.
When pressure is applied to the piston 78, the control bushing 79 is moved towards the spool 25, so
that the spool 25 is pressed through the differential piston 80 and the pin 81 into its switching position.
copyright by
MJFCIFSS
7.02.9
Service Manual
Pump regulation
As a result, the powertrain is moved in direction Qmin = smaller volumetric delivery. The volumetric
delivery is proportional to the control pressure fed t connection X1. The basic setting is determined
by the pressure spring 77 with the threaded stud 73.
25 Spool
60 Actuation housing
26 Nozzle
61 Measuring connection / begin of regulation (

M10x1)
38 Control lens
40 Regulator housing
63 Spring bushing
64 Pressure spring ( 16.2 mm)
41 Control piston
42 Spring plate
65 Threaded stud (begin of regulation)

66 Seal-Lock collar nut
43 Spring plate
67 Safety cap
44 Pressure spring ( 30.4 mm, regulating

spring)
spring)
70 Actuation device
71 Actuation housing

spring)
72 Screw plug
47 Spring plate
49 Control neck
73 Threaded stud
50 Threaded stud
51 Piston
75 Safety cap
76 Spring plate
52 Hex head screw

54 Cover
77 Pressure spring
78 Control piston
55 Allen head screw
79 Control bushing
56 Threaded stud / Qmax stop

80 Spool
81 Pin
58 Safety cap
84 Screw plug (M12x1.5)
59 Screw plug M (M12x1.5)
X1 Control pressure connection MR (M14x1.5)

X3 Control pressure connection LR (M14x1.5)
7.02.10
copyright by
MJFCIFSS
Service Manual

Pump regulation
Fig. 6
Sectional drawing of power regulator LA
copyright by
MJFCIFSS
7.02.11
Service Manual
Adjustment of the variable-displacement pump A8VO
6 Adjustment of the variable-displacement pump A8VO

6.1
Adjustment of the hydraulic begin of regulation and the stroke limitation / flow
reduction
Note!
The procedure to adjust the pump settings is described in group 6 "Adjustment protocol" and
"Adjustment guidelines".
1
2
Housing
Input pinion / drive shaft
55
56
Allen head screw

Threaded stud / Qmax stop
3
4
Input pinion
Locking ring
57
58

Safety cap
5
6

O-ring
59
60
Screw plug (M12x1.5)

Actuation housing
Snap ring
61
Measuring connection / begin of regulation ( M10x1)
8
9

63
64
Spring bushing
Pressure spring ( 16.2 mm)
10
11

Slotted nut
65
70
Threaded stud / begin of regulation

Actuation device
25
Spool
71
Actuation housing
26
30
Restrictor
Cylinder
72
73
Screw plug
Threaded stud
31
32
Centre peg
Disc spring
74
75

Safety cap
33
35
Conical piston
Return plate
76
77
Spring plate
Pressure spring
38
Control lens
78
Control piston
40
41
Regulator housing
Control piston
79
80
Control bushing
Spool
42
Spring plate
81
Pin
43
Spring plate
82
Screw plug (M12x1.5)
44
Pressure spring ( 30.4 mm, regulating

spring)
84
Threaded stud
45

spring)
spring)
85
86
Safety cap
47
49
Spring plate
Control neck
100
101
Stub shaft
Gear
50
Threaded stud
102
51
Piston
103
Cover
52
Hex head screw
R1 Bleeding connection
54
Cover
R2 Oil drain screw
46
7.02.12
copyright by
MJFCIFSS
Service Manual

Sectional drawing of the double variable-displacement pump A8VO
7 Sectional drawing of the double variable-displacement pump

A8VO
copyright by
MJFCIFSS
7.02.13
Service Manual
Regulating characteristic for A 309

Fig. 7
8 Regulating characteristic for A 309
Fig. 8
7.02.14
Performance characteristics of the pumps P1 / P2
copyright by
MJFCIFSS
Service Manual

9 Regulating characteristic for A 311
Fig. 9
Performance characteristics of the pumps P1 / P2
copyright by
MJFCIFSS
7.02.15
Service Manual
7.02.16
copyright by
MJFCIFSS
Service Manual

Purpose

1 Purpose
The LPV variable displacement pump is of the axial piston swash-plate type. Powertrain and gear
pump are powered by the diesel engine via the flexible coupling (torsion damper).
The variable displacement pump regulates its output according to actual requirements and, thus, provides the hydraulic pressure / volume required by the hydraulic system.
The volumetric delivery of the pump is determined by the pivot angle of the swivel yoke. The angle
can be changed / controlled by the regulating cylinder. Regulation is effected by the flow regulator
(LS regulator ) and/or performance regulator.
Fig. 1
copyright by
MJFCIFSS
7.05.1
Service Manual
General information
Machine
from serial number
A 312
Litronic
12363
A 314
Litronic
2001
A 316
Litronic
2001
Pump type
Input speed
LPV 130
LPV 130
LPV 150
1800 rpm
1800 rpm
1800 rpm

(rated power)
74 kW
80 kW
86 kW
Volumetric delivery max.

min.
234 l/min
30 l/min
234 l/min
30 l/min
270 l/min
30 l/min
Hydraulic performance (basic performance)
30 kW
23 kW (*)
30 kW
23 kW (*)
27 kW
35 kW (*)
Begin of regulation (with basic settings)
65 2 bar
50 2 bar(*)
65 2 bar
50 2 bar(*)
65 2 bar
50 2 bar(*)
Begin of regulation (at rated output of the diesel

engine)
155 bar
165 bar
155 bar
Control oil pump / radiator fan
45 l/min
45 l/min
45 l/min
Check measurement X (Q min. stop)
16.3 mm
16.3 mm
16.3 mm
Current from solenoid valve Y50, see adjustment protocols in group 6

For parameters and reference values, see adjustment protocol in group 6.
Tab. 1
Technical data
(*) from software version 1.6
7.05.2
copyright by
MJFCIFSS
Service Manual

Description
3 Description
The variable displacement pump consists of three main components:
Mounting plate 11
Connecting flange 13
Powertrain 1
The LPV variable displacement pump is flanged to the diesel engine with connection flange 13.
Powertrain 1 / 21* consists of drive shaft, cylinder and piston. It can be adjusted / regulated by means
of the swivel yoke.
The pump regulation 23 consisting of the performance regulator (LR regulator) 23.2 and the flow regulator (LS regulator) 23.5 is mounted to the housing of the powertrain and connected through the
pump adjustment 5 with a lever to the swivel yoke.
The performance regulator 23.2 controls the pump via the performance curve (performance chart,
see Fig. 13, see Fig. 14 and Fig. 15).
The load-sensing regulator 23.5 is used to regulate the required oil volume by adjusting the pressure
difference p.
Gear pump 8 / 30* (pilot control) is screwed to mounting plate 11 and driven via the drive shaft of the
variable displacement pump.
The min. flow rate of the pump is pre-set by means of a stop screw.
Fig. 2
1
LPV components
Powertrain (21*)
13
Connecting flange
Regulating valve
Pump regulation
23*
Gear pump(30*)
23.2* Performance regulator
11
Mounting plate
23.5* Load sensing regulator
* items in hydraulic diagram
copyright by
MJFCIFSS
7.05.3
Service Manual
Description
Fig. 3
7.05.4
LPV hydraulic diagram
to hydraulic tank
23.6 Shuttle valve
3
20
from stop cock / tank

LPV pump unit
28
29
from check valve

Restrictor
21
Powertrain
30
21.1 Control piston

23
Regulating valve
44
45


23.5 LS regulator
50
100

copyright by
MJFCIFSS
Service Manual

4 Functional description
4.1
Powertrain, see Fig. 11

The drive shaft 1.10 is borne in the mounting plate 11 and the mounting flange 13 with needle bearings 11.3 and a roller bearing 13.3. It drives the cylinder 1.11 and the nine pistons 1.9 via the gearing.
The clutch sleeve 11.31 conveys some of the driving power to the flange-mounted gear pump 8 (pilot
control).
Bearing of pistons 1.9 is arranged with slippers. The sliding disc 1.15 holds them on to the swivel yoke
with the help of return plate 1.14 and return ball 1.13.
Hydrostatic bearing by means of bores in piston 1.9 and slippers reduces high surface pressure between the rotating slippers and sliding disc 1.15
When there is no pressure, pressure springs 1.16 press cylinder 1.11 and return ball 1.13 against
pilot plate 1.12. As soon as the pressure rises, the hydraulic forces add to the spring force so that an
oil film is maintained, and the amount of leak oil is small.
The leak oil will grease all the moving parts of the powertrain and is then lead on to the tank.
For every rotary motion of the cylinder 1.11, the pistons 1.9 execute a double stroke. The length of
the stroke depends on the inclination of swivel yoke 1.2. The rotary bearing of the swivel yoke is arranged via flanges 12 and the roller bearing 12.34. The rotary motion of the swivel yoke 1.2 is effected
as the swivel yoke 1.2 engages with the control piston 5.10 at each axial movement of the swivel yoke
1.2.
The volumetric delivery of the pump per each interval of time is determined by the piston capacity
(piston diameter x stroke) and the speed of drive shaft 1.10.
Pilot plate 1.12 separates the pressure side from the suction side of the powertrain. Pilot plate 1.12
has a kidney-shaped slit for suction, and a three-part slit for pressure.
4.2
Adjustment and control of the pump, see Fig. 11

There is a mechanical connection between swivel yoke 1.2 and control piston 5.10. The swivel yoke
is in engagement (via the neck) with sliding block 5.30 on control piston 5.10. The axial motion of control piston 5.10, and, thus, the rotary motion (change of pivot angle) of swivel yoke 1.2, is caused by
an actuating pressure controlled by regulating valve 23.
In stand-by mode (i.e. all pilot control valves in neutral position), the pump supplies only min. flows
(about 30 l/min - pre-set by stop screw at the factory).
The pivoting motion of the pump is initiated by actuation of one or more consumers (via pilot control
valves). It is the actuating pressure acting on the larger piston face plus the mechanical force of pressure spring 5.14 that effect the adjustment.
Adjustment of the powertrain to a certain pivot angle depends on the following:
Requirements pre-set (speed of consumers via displacement of lever / pedal at pilot control valve)
Desired flow rate (e.g. when the volume is to be reduced)
Working pressure (performance curve, see Fig. 13 applies from the beginning of basic regulation)
see Fig. 14 and Fig. 15.
The pivoting back of the pump is effected by the regulating unit of the pump, see 5.
copyright by
MJFCIFSS
7.05.5
Service Manual
Pump regulation
5 Pump regulation
5.1
5.1.1
Performance regulator 23.2 with regulating piston 23.2.7, see Fig. 4

Horsepower control
Pump high pressure (PHD) acts continuously on the small face s of control piston 5.10, via shuttle
valve 23.6 and internal bores in valve housing 23 and the control cylinder.
High pressure from the pump also acts on the central groove of regulating piston 2.7 via shuttle valve
23.6 and LS regulator 23.5.
High pressure from the pump also acts on the space behind rod 2.33 via bores in housing 23 and
lid 2.35.
The resulting pressure is transmitted via spring plate 2.19 and push rod 2.4 to piston 2.7.
At low pump pressure (below begin of regulation), spring 2.13 shifts piston 2.7 to the right, and edge
S2 opens. That way, PHD (pump high pressure) acts via open control spool edge S2 on the large
face S2 of control piston 5.10.
Both faces S and s of control piston 5.10 are now connected to the same pump pressure so that
piston 5.10 is now moved towards Qmax (max. pivot angel of pump).
If the pump pressure increases and the resulting force becomes greater than the preload force of
pressure spring 2.13, spool 2.7 is moved to the left, edge S closes and edge S opens so that oil
can flow from large piston face S back to the tank (begin of regulation).
Control piston 5.10 is pushed to the left so that the pivot angle of the pump becomes smaller. The
motion of control piston 5.10 is transmitted via lever 2.6 and return piston 2.5 to regulating spring 2.11
so that preloading of spring 2.11 increases. If control piston 5.10 is shifted even further to the left,
regulating spring 2.12 is preloaded as well.
The pivot angle of the pump will be reduced until a balance is re-established between preloads of
pressure spring 2.13, regulating springs 2.11 and 2.12 and the pump high-pressure force transmitted
by rod 2.33.
Over the entire range of control, each high-pressure value of the pump corresponds to a certain position of the control piston so that spool 2.7 is in a state of balance (control edges S1 and S2
closed).
Regulating springs 2.11 and 2.12 define the regulating characteristics of the pump. The springs have
been designed to get the regulating characteristics as close as possible to the theoretical curve at
constant performance (= hyperbole).
The beginning of preloading regulating springs 2.12 corresponds to the pump angle at which the slope of the regulating characteristics changes.
Preloading of regulating spring 2.13 determines the begin of regulation.
The max. pivot angle is determined by the final position of control piston 5.10 in the control cylinder
and cannot be adjusted.
The min. pivot angle is determined by the setting of Qmin stop screw 5.13.
7.05.6
copyright by
MJFCIFSS
Service Manual

Pump regulation
Fig. 4
23
Sectional drawing of performance regulator 23.2

2.19 Spring plate
Regulating valve
2.33 Rod
2.4
2.5
Pressure rod
Return piston
2.35 Lid
23.5 Load-sensing regulator
2.6
Lever
23.6 Shuttle valve
2.7 Regulating piston

2.11 Regulating spring
5.10 Control piston

5.13 Adjusting screw
2.12 Regulating spring

2.13 Pressure spring / begin of regulation
5.24 Hex nut

44
copyright by
MJFCIFSS
7.05.7
Service Manual
Pump regulation
5.1.2
Stage for performance change
Fig. 5
21
21.1
Pump regulation
Powertrain
Control cylinder
GLR
LS
Connection from LR control oil unit

Connection from LS control oil unit
ST
Connection from LS control block
This stage allows to hydraulically adjust the pump regulation characteristics during operation.
As soon as a pressure is connected to chamber "B" (see Fig. 4) via the regulator connection "GLR",
a force is generated at the spool 2.7 which is proportional to pressure "GLR" and which shifts the
spool towards "pump to Qmax". A new balance at the spool can only be established if the pressure
from the pump increases. The higher the GLR pressure, the higher the pump pressure at begin of
regulation.
The pump regulation continues as described in 5.1 , page 6. However, the regulation characteristics
in the P-Q diagram are shifted towards a higher pressure (i.e. higher performance) in order to attain
a value that is proportional to the GLR pressure.
The connection "GLR" receives the output pressure of the performance-regulating solenoid valve
Y50 (LR valve).
7.05.8
copyright by
MJFCIFSS
Service Manual

Pump regulation
5.2
5.2.1
Load-sensing regulator 23.5

Regulation of pressure difference
P LS
This regulator adapts the flow rate of the pump to the flow consumption of the consumers to be fed.
The load-sensing regulator 23.5 is installed together with the performance regulator 23.2 at the control cylinder 21.1.
Piston .7 connects the channel leading to the control pistons either with tank pressure T (edge S4
open and pump pivots to Qmin), or with pump high pressure PHD (edge S3 open and pump pivots to
Qmax.).
The preload force of springs .13 and .14 (value for P setting) and the force resulting from the pressure in chamber PLS, acting on the working face of piston .8, shift piston .7 to Qmax.
The hydraulic force resulting from the pump high pressure acting on the working face of piston .9
shifts piston .7 towards Qmin.
In the neutral position of the piston, the three forces are in balance. That means, regulating piston .7
regulates so that a constant pressure difference ( P) is maintained between both chambers LS and
PHD which corresponds to the preload of springs .13 and .14.
And the pressure difference does not depend on the current working pressure and flow rate of the
pump.
Fig. 6
Sectional drawing: load-sensing regulator 23.5
21.1
Control cylinder
23.8
Piston
23.2
23.9
Piston
23.5
23.6
Load-sensing regulator
Shuttle valve
23.13
2.314
Regulating spring
Regulating spring
23.7
Spool
44
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7.05.9
Service Manual
Pump regulation
5.2.2
Limitation of max. pump flow rate ( P reduction)

By preselecting a certain working attachment, e.g. a hydraulic hammer, a possible flow reduction is
preset at the switch S241 and the excavator control U16 is activated (both devices are installed in the
right console). As a result, the chamber PST of the LS regulator 23.5 is pressurised through the regulating solenoid valve Y51. This results in an additional pressure force on the piston .7 that acts against
the preload force of the regulating springs 2.11 and 2.13.
That means, the pressure difference
a smaller amount of oil.
P is smaller, and the pump can maintain the reduced
The pump pivots only to the point where the pre-set flow rate at the pump inlet is reached.
Fig. 7
7.05.10
Diagram: variable displacement pump
21
Powertrain
21.1 Adjustment
23.5 LS regulator
23.6 Shuttle valve
23
Regulating valve
30
44
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Service Manual

Pump regulation
5.3
Fine control and/or flow reduction via
Fig. 8
p reduction
Hydraulic diagram: flow reduction
21
Powertrain
235
Boom cylinder
21.1
Control cylinder
240
23.5
LS regulator
120 Spool / slewing gear
255
260
Stick cylinder
130
Slewing gear motor
275
Bucket cylinder
160
Spool / chassis
280
170
Travel motor
295
Support cylinder
220
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7.05.11
Service Manual
Adjustment of LPV variable displacement pump (LR - LS)
6 Adjustment of LPV variable displacement pump (LR - LS)

6.1
Fig. 9
Min. and max. pivot angle of the variable displacement pump
5.10
Spring plate
5.29
Safety cap
5.13
5.24
Pressure spring
Hex nut
5.32
Sleeve
The max. pivot angle of the powertrain of the pump is determined by the non-adjustable dead stop
(collar 5.32) of control piston 5.10 in the control cylinder. That means, it cannot be adjusted from the
outside.
The min. pivot angle of the powertrain is determined by the stop of control piston 5.10. It can be adjusted by means of adjusting screw 5.13 (with lock nut 5.24). It has been pre-set at the factory to guarantee sufficient cooling and lubrication of the powertrain.
The min. pivot angle should not be changed under normal circumstances (adjusting screw 5.13 is secured against tampering by lock nut 5.24 and safety cap 5.29).
7.05.12
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Service Manual

Adjustment of LPV variable displacement pump (LR - LS)
6.2
Adjustment of differential pressure

of the working pump
p (LS) and begin of hydraulic regulation
The procedure to adjust the differential pressure and begin of regulation of pump 20 is described in
group 6 "Adjustment protocol" and "Adjustment guideline".
Fig. 10
Adjusting begin of regulation Prb and pressure difference

screw 23.2.1 and 23.5.1
p(LS) by means of adjusting
23.2.1 Adjusting screw of performance regula- 23.5.1 Adjusting screw of load-sensing regulator
tor
23.2.2 Lock nut
23.5.2 Lock nut
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7.05.13
Service Manual
Sectional drawing: pump regulation 23
7 Sectional drawing: pump regulation 23

Key re. sectional drawing, see Fig. 11
2.1
2.2
7.05.14
Adjusting screw
Lock nut
23.2
23.5
Load-sensing regulator
2.4
Pressure rod
23.6
Shuttle check valve
2.5
2.6
Return piston
Lever
44
5.1
Measuring point MA
Adjusting screw
2.7
Spool
5.2
Lock nut
2.8
Control sleeve
5.5
Screwed connection
2.9
Spring plate
5.6
Control sleeve
2.10
Spring plate
5.7
Spool
2.11
2.12
Regulating spring
Regulating spring
5.8
5.9
Piston
Piston
2.13
2.14
Pressure spring / begin of regulation

Spacer
5.10
2.11
Spring plate
Spring plate
2.15
2.16
O-ring
O-ring
5.13
5.14
Pressure spring
Pressure spring
2.18
Guide sleeve
5.15
O-ring
2.19
2.20
Spring plate
Lid
5.16
5.17
O-ring
Guide sleeve
2.21
2.33
Allen head screw

Rod
5.22
6.1
O-ring
Valve insert
2.34
2.35
O-ring
Lid
6.2
6.3
Sleeve
Ball
2.36
Allen head screw
6.4
O-ring
23
Regulating valve
6.5
O-ring
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Service Manual

Sectional drawing: pump regulation 23
Fig. 11
Sectional drawing: Pump regulation
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7.05.15
Service Manual
Sectional drawing of the complete LPV pump
8 Sectional drawing of the complete LPV pump

1.0
1.1
Powertrain
Pump casing
5.14
5.24
Pressure spring
Hex nut
1.2
Swivel yoke
5.25
Allen head screw
1.9
1.10
Piston slipper
Drive shaft
5.30
11
Sliding block
End plate
1.11
Cylinder
11.3
Cylindrical needle bearing
1.12
Pilot plate
11.31
Clutch sleeve
1.13
Return ball
12
Flange
1.14
Return plate
12.34
1.15
Sliding disc
13
Connecting flange
1.16
5.
Pressure spring
Adjustment (21.1*)
13.3
13.4

5.10
5.11
Control piston
Lid
23*
23.2*
Regulating valve
5.12
5.13
Lid
Stop screw / Qmin
23.5*
44*
LS regulator
7.05.16
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Service Manual

Sectional drawing of the complete LPV pump
Fig. 12
Sectional drawing of LPV variable displacement pump
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MJFCIFSS
7.05.17
Service Manual
LPV 130 pump performance diagram
9 LPV 130 pump performance diagram
Fig. 13
Performance diagram of the LPV 130 variable-displacement pump in A 312 Litronic machines
Hyperbola for rated power
Power
S -1.5
to software version 1.5
(*)Qn is the rated flow rate (=volume at PO(LS)) of the respective spool
7.05.18
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Service Manual

LPV 130 pump performance diagram
Fig. 14
Power
S -1.5
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MJFCIFSS
7.05.19
Service Manual
LPV 150 pump performance diagrams
10
LPV 150 pump performance diagrams
Fig. 15
H
P
S -1.5

Power
7.05.20
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Service Manual

Purpose

1 Purpose
The DPVO variable displacement pump is of the axial piston swash-plate type. Powertrain and integrated pilot-control gear pump are powered by the diesel engine via the flexible coupling (torsion
damper).
The variable displacement pump regulates its flow rate according to current requirements (load sensing principle) and supplies the required quantities of oil to the various consumers , (lifting / bucket /
stick / travel / support / slewing gear / pivot grapple).
The volumetric delivery of the pump is determined by the pivot angle of the swivel yoke. The swivel
yoke is adjusted by means of the control cylinder. Regulation of the regulating cylinder is effected by
the flow regulator (LS regulator ) and/or performance regulator (LR regulator).
Fig. 1
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7.10.1
Service Manual
Purpose
7.10.2
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Service Manual

General information
Equipment
from serial number
R 317 Litronic
18161
Type of pump
DPVO 165
Input speed
1800 min-1

86 kW
Volumetric delivery
max.
min.
297 l/min
40 l/min

29 kW
50 2 bar
Control oil pump / pilot control
36 l/min
Test value X (Q min. stop)
15.6 mm

Flow from solenoid valve Y50
P min.
180 +10 mA
P max
500 +13 mA

Flow from solenoid valve Y50
P min.
1,5 +1 bar
P max
6 +3 bar
Tab. 1
Technical data
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MJFCIFSS
7.10.3
Service Manual
Description
3 Description
The variable displacement pump consists of the following main components:
Mounting plate 1
Connecting flange 2
Powertrain21
Pump casing 40
The DPVO variable displacement pump is flanged to the diesel engine with connection flange 2.
The powertrain consists of drive shaft, cylinder and piston. It can be adjusted by means of the swivel
yoke.
Regulator housing 6 sits on pump casing 40. Performance regulator 25 (for regulating and adjusting
pump performance) is mounted in regulator housing 6. It obtains feedback concerning the current pivot angle by means of a pin.
Flow regulator 26 sits right on mounting plate 26. It controls flows and the adjustment of differential
pressure p.
Gear pump 30 (pilot control) sits on mounting plate 1. It is driven by means of an internal drive shaft.
There is an opening in the mounting plate for the installation of an additional gear pump, if required.
Fig. 2
7.10.4
Components of the DPVO
Mounting plate
40
Pump casing
Connecting flange
44
Measuring point pSK (control chamber

pressure)
Qmin stop screw
A1
Pressure connection
6
25
Regulator housing
Performance regulator (LR)
AX
T
Pressure connection locked up

Leak oil connection
26
Flow regulator (LS)
FE
Pressure connection of servo oil pump
27
Shuttle valve
X2
Connection LS-pressure
28
Check valve (12 Nm)
X3
Connection to servo oil unit
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Service Manual

Description
29
30
Fig. 3
Restrictor
Gear pump
X4
Connection
25
26
Flow regulator
p -subsidence
Hydraulic schematic: DPVO
1
3
to hydraulic tank
Pressure spring /
27
Shuttle valve
10
28
Check valve
15
Connecting pin (swivel yoke)
29
Restrictor
16
20
Return piston
DPVO pump unit
30
44

21
22
Powertrain
Control piston
45
50

from / to control oil unit
23
Measuring cylinder
100
24
Lever (rocker)
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7.10.5
Service Manual
Functional description of variable displacement pump
4 Functional description of variable displacement pump

4.1
Powertrain 21, see Fig. 10

Bearing of drive shaft 5 in mounting plates 1 and mounting flange 2 is arranged by way of cylindrical
roller bearing 8 and sliding bearing 10. The shaft drives cylinder 16 and the nine pistons with slipper
19 via the gearing. The toothing on the drive shaft, in addition, drives flange-mounted gear pump 30
(pilot control).
Sliding disc 31 holds pistons 19 (with slippers) on swivel yoke 7, with the help of return plate 34 and
return ball 33.
Hydrostatic bearing by means of bores in pistons 19 reduces high surface pressure between the rotating slippers and sliding disc 31.
When there is no pressure, pressure springs 35 / 36 press cylinder 16 and return ball 33 against pilot
plate 17. As soon as the pressure rises, the hydraulic forces add to the spring force so that an oil film
is maintained, and the amount of leak oil is small.
The leak oil will grease all the moving parts of the powertrain, and is then lead on to the tank.
For every rotary motion of cylinder 16, pistons 19 execute a double stroke. The length of the stroke
depends on the angle of swivel yoke 7. Rotary bearing of the swivel yoke is arranged by way of roller
bearing 14. The rotary motion of swivel yoke 7 is effected by means of a connection between control
piston 22 and connecting link 37 at every axial motion of the piston.
The volumetric delivery of the pump per each interval of time is determined by the piston capacity
(piston diameter x stroke) and the speed of drive shaft 5.
Pilot plate 17 separates the pressure side from the suction side of the powertrain. Pilot plate 17 has
a kidney-shaped opening on the suction side, and three smaller kidney-shaped openings on the pressure side.
Fig. 4
7.10.6
Section: powertrain
16 Cylinder
17 Pilot plate
33 Return ball
34 Return plate
18 Pin
35 Spring
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Service Manual

Functional description of variable displacement pump
19 Piston
4.1.1
35 Spring
Adjusting the pivot angle of the pump

Connecting link 37 provides a mechanical connection between swivel yoke 7 and control piston 22.
The connecting link engages into the opening on control piston 22. It is secured by means of pin 12
and roll pin 11. The axial motion of control piston 22 (and thus the rotary motion, i.e. the change of
the angle of swivel yoke 7) is determined by way of the performance regulator and/or flow regulator.
The LS signal generated by the consumer moves the flow regulator into the actuating position so that
pump pressure can reach the control chamber - the pump pivots. The pump will pivot back as soon
as the control chamber is connected to the tank by the flow regulator (no LS signal) or by the performance regulator (output too high).
In standby mode (i.e. all pilot control valves in neutral position), the pump delivers only min. flows
(about 40 l/min - pre-set in the factory by means of stop screw 3).
4.1.2

The max. pivot angle of the powertrain of the pump is determined by the dead stop (collar 39) of control piston 22 in the control cylinder. The stop cannot be adjusted.
The min. pivot angle of the powertrain is determined by stop screw 3 (with locknut 38). It has been
pre-set at the factory. It is recommended not to tamper with that angle under normal circumstances.
Fig. 5
3
Adjusting the swivel yoke

22 Control piston
stop screw Q-min
7 Swivel yoke
11 roll pin
37 Connecting link
38 Locknut
12 Pin
39 Collar
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7.10.7
Service Manual
Pump regulation
5 Pump regulation
5.1
Performance regulator 25 (LR) hyperbolic regulator

The purpose of the performance regulator is to adapt the flow rates from the pump with respect to the
pump pressure (decreasing output) to the performance curve of the diesel engine. That means, regulation of the pump performance is effected along a hyperbolic line. The pump delivers larger volumes at low pressure and smaller volumes at high pressures. The basic setting of regulating spring 10
/11 corresponds to the mechanical beginning of basic regulation. It can be switched up to load limit
control via control pressure pMLR at connection X3.
Pressure springs 10 / 11 switch piston 17 to the right against lever 24. This will open control edge S1,
and the control chamber of control cylinder 22 will receive pump pressure pP. The pump will pivot to
Qmax. The return piston has a mechanical connection with the swivel yoke in connecting pin 15.
5.1.1

As soon as operating pressure pP in the system rises to the value of begin of regulation, the force
exercised on lever 24 at measuring cylinder 23 goes up as well. Control piston 17 is moved against
spring 10 and thus opens the connection between control chamber (SK) and tank (T) with the help
of control edge S2. The pump pivots back. The pump pivoting back effects an axial movement of return piston 16 against pressure spring 3 by means of connecting pin 15 with the bearing pin of the
swivel yoke. This leads to the line of force of measuring cylinder 23 against lever 24 being shifted in
the direction of the fulcrum. The force exercised by lever 24 on piston 17 decreases so that pressure
spring 10 moves piston 17 back into its neutral position. The connection between control chamber
(SK) and tank (T) is interrupted. The pump remains on a constant flow rate that corresponds (with
the pP still prevailing) to a constant decrease of performance.
5.1.2
Pivoting of the pump (at pressures below begin of regulation)

As soon as operating pressure pP drops in the system, the force exercised by piston 23 on lever 24
will go down. Spring 10 will move piston 17 against lever 24. The connection via control edge S1
pump pressure (P) in control chamber (SK) will be opened. The pump will go to a larger pivot angle.
The pivoting motion of the pump will move return piston 16 in the direction of screw plug 1. Measuring
cylinder 23 will be pushed away by lever 24. The resulting force of lever 24 exercised on piston 17
goes up, i.e. there is a balance again, and piston 17 moves to closing position (S1 and S2 closed).
Fig. 6
7.10.8
View: control edges S1 and S2
10
Spring
pP
Pump pressure
11
Spring
SK
Control chamber pressure
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Service Manual

Pump regulation
17
Control piston
Tank pressure
Sectional drawing: performance regulator 25
Fig. 7
1
Plug
12
Bushing
2
3
Threaded stud
Pressure spring
13
14
Spring plate
Ball
4
5
O-ring
O-ring
15
16

Return piston
Regulator housing
17
Spool
7
8
Sealing nut
Adjusting screw
23
24
Piston with slipper (measuring cylinder)

Lever
9
10
Plug
Pressure spring (begin of regulation)
pP
SK
Pump pressure
11
Pressure spring
Tank pressure
Note!
Tightening torques: Screw plug 1 / 9 = 35 Nm; sealing nut 7 = 18 Nm.
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7.10.9
Service Manual
Pump regulation
5.2
Flow regulator 26 (LS regulator)

The purpose of flow regulator 26 is to adapt the flow rates of the pump to the requirements of the
consumers.
Flow regulator 26 is mounted on mounting plate 1. The regulator consists of piston 15 switching the
connection between control chamber and tank or pump pressure, and pressure spring 4, being adjusted using adjusting screw 2 (adjustment p).
Basic setting p can be reduced using control pressurepMLS at connectionX4 of the pump. This
will, at the same time, reduce the flow rate of the pump.
Reduction of flow rates /
p reduction/ SF
Flow regulator 26 on mounting plate 1 , connection X4 for
Fig. 8
p-reduction
Mounting plate
15
Control piston
Regulating screw
26
Flow regulator
Nut
pP
Pump pressure
X4
Control pressure
Spring (Adjusting
Sealnut
p)
Note!
Screw down flow regulator 26 all the way to stop. Tighten with 5 Nm max.
Sealing nut 9 = 8 Nm; nut 3 = 120 Nm.
7.10.10
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p -subsidence
Service Manual

Pump regulation
5.3
5.3.1
P LS
Standby
As soon as all the consumers are closed, the flow from the pump will build up a backpressure in channel pP. Feedback concerning backpressure will be sent to piston 8. As soon as the pressure exceeds
the forces of springs 4/14, control edge S2 will open. The powertrain will go on pivoting back until the
spring and pressure forces at regulating piston 15 cancel out each other or the powertrain attains
Qmin.
Shifting piston 15 is pushed to the right by pressure spring 4. Control edge S1 opens, pump pressure
gets into the control chamber, the pump goes to a large pivot angle, and the flow rate goes up.
5.3.2
Pivoting out
Pressure building up at connection pLS (operation of a consumer) will increase the sum of forces acting on the spring side of piston 15, and piston 15 will switch right. Control edge S1 opens, pump pressure gets into the control chamber, the pump goes to a large pivot angle, and the flow rate goes up.
The backpressure pP caused by the increasing volumes coming from the pump will now increase
pressure against piston 8. As soon as it reaches the value set at spring 4, shifting piston 15 will go
back to the left again until control edge S1 closes. The control chamber does not receive pP any more, but is not relieved to tank either (thanks to control edge S2 which is still closed). That means, the
flow rate from the pump levels out at a constant value.
5.3.3
Pivoting back
As soon as pressure pP acting on piston 8 exceeds a value made up of pLS (consumer pressure)
plus spring force, piston 15 will go to the left, control edge S1 will close, control edge S2 will open,
and the control chamber of the regulating cylinder will be connected to the tank for relief. The pump
pivots back.
Fig. 9
Sectional drawing: load-sensing regulator
1
2
Plug
Adjusting screw
12
13
Backing ring
O-ring
Nut
Pressure spring(adjustment
14
Pressure spring
Piston
15
pP
Spool
Pump pressure
5
6
7
Bushing
Bushing
pLS LS-Druck
pMLS p-Reduction
8
9
Piston
Sealing nut
S1
Control edge pump pressure
S2
Control edge tank pressure
10
Backing ring
SK
p)
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7.10.11
Service Manual
Adjustment of DPVO variable displacement pump

11
O-ring
Tank pressure
6 Adjustment of DPVO variable displacement pump

6.1
Adjustment of differential pressure
p LS and begin of hydraulic regulation
Note!
The procedure to adjust the differential pressure and begin of regulation of the pump is described
in group 6 "Adjustment protocol" and "Adjustment guideline".
7.10.12
1
2
Mounting plate
Connecting flange
17
18
Pilot plate
Locking pin (against tampering)
Stop screw
19
Piston with slipper
4
5
Locking ring
Drive shaft
22
30
Control piston
Gear pump
6
7
Regulator housing
Swivel yoke
31
32
Sliding disc
Set of discs
8
9

O-ring
33
34
Return ball
Return plate
10
Sliding bearing
35
Pressure spring
11
12
Roll pin
Pin
36
37
Pressure spring
Connecting link
13
14
O-ring
38
39
Hex nut
Stop sleeve
15
16
Pin
Cylinder with bushing
40
Pump casing
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Service Manual

Fig. 10
Sectional drawing: DPVO
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7.10.13
Service Manual
Regulating characteristics
7 Regulating characteristics
Fig. 11
7.10.14
Performance curve: DPVO 165
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Service Manual

Design

1 Design
The DPVO variable-displacement pump is of the axial piston swash-plate type. The powertrain and
the integrated pilot-control gear pump as well as the attached gear pump for the fan control are powered by the diesel engine via the flexible coupling (torsion damper).
The variable-displacement pump regulates its flow rate according to current requirements (load sensing principle) and supplies the required quantities of oil to the various consumers, (lifting / bucket /
stick / travel / support / slewing gear / pivot grapple).
The variable displacement pump consists of the following main components:
Powertrain 21
Pump casing 40
Mounting plate 46
Connecting flange 47
Regulator housing 49
The DPVO variable displacement pump is flange-mounted to the diesel engine with the connecting
flange 47.
The powertrain consists of drive shaft, cylinder and piston. It can be adjusted by means of the swivel
yoke.
The regulator housing 49 in mounted to the pump casing 40. The performance regulator 25 (for regulating and adjusting the pump performance) is screw-mounted in the regulator housing 49. It obtains feedback concerning the current pivot angle by means of a pin.
The flow regulator 26 used to adjust the flow and the differential pressure
to the regulator housing 49.
p is also screw-mounted
The gear pump 30 (pilot control) is integrated into the mounting plate 46, while the gear pump 31 (fan
control) is flange-mounted to the mounting plate 46. Both pumps are driven through the powertrain.
copyright by
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7.15.1
Service Manual
Design
Fig. 1
7.15.2
Components of the DPVO
25
Performance regulator (LR)
48
Qmin stop screw
26
27
Flow regulator (LS)

Shuttle valve
49
Regulator housing
28
29
Check valve
Restrictor
A1
AX
Pressure connection
Pressure connection sealed
30
31

Gear pump / fan control
FE
S
Pressure connection of control oil pump

Suction connection
40
Pump casing
Leak oil connection
44
Measuring point pSK (control chamber

pressure)
X2
46
Mounting plate
X3
Connection of control oil unit LR
47
Connecting flange
X4
Connection
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-p reduction
Service Manual

Technical data
2 Technical data
Machine
from serial number
R 313 Litronic
27752
Pump type
DPVO 165
Input speed
1800 rpm

73 kW
Volumetric delivery
max.
min.
297 l/min
40 l/min

29 kW
50 2 bar
Control oil pump / pilot control
36 l/min
Control oil pump / fan control
39 l/min
Check measurement X (Q min. stop)
15.0 mm
Settings and comparative values:

Flow from solenoid valve
Y50
P min.
180+10 mA
P max.
580+30 mA

Control pressure from solenoid valve Y50
P min.
1.5 +1 bar
P max.
7 +2 bar
Tab. 1
Technical data
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7.15.3
Service Manual
Technical data
Fig. 2
7.15.4
Hydraulic diagram of DPVO
to hydraulic tank
25
26
Flow regulator
4
10
Pressure spring / p
27
28
Shuttle valve
Check valve
13
15
to oil motor / fan drive

29
30
Restrictor
16
20
Return piston
DPVO pump unit
31
44
Gear pump / fan control

21
Powertrain
45
22
23
Control piston
Measuring cylinder
50
100
from/to control oil unit

24
Lever (rocker)
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Service Manual

3.1
Powertrain 21, see Fig. 9

The drive shaft 5 is borne in the mounting plate 46 and the mounting flange 47 with a cylindrical roller
bearing 8 and a sliding bearing 10. The shaft drives the cylinder 16 and the nine pistons with slipper
19 via the gearing. The toothing on the drive shaft drives the integrated and flange-mounted gear
pump 30/31.
The pistons 19 with slippers are held by means of the return plate 34 and the return ball 33 on the
swivel yoke 7 with the sliding disc 31.
The hydrostatic bearing by means of bores in the pistons 19 reduces the high surface pressure between the rotating slippers and the sliding disc 31.
If there is no pressure, the pressure springs 35 / 36 press the cylinder 16 and the return ball 33
against the pilot plate 17. As soon as the pressure rises, the hydraulic forces add to the spring force
so that an oil film is maintained, while the amount of leak oil is small.
The leak oil lubricates all the moving parts of the powertrain, and is then fed to the tank.
For every rotary motion of the cylinder 16, the pistons 19 execute a double stroke. The length of the
stroke depends on the inclination of swivel yoke 7. The swivel yoke is borne on the roller bearing 14
and can be tilted. The rotary motion of the swivel yoke 7 is effected by means of a connection between the control piston 22 and the connecting link 37 at every axial motion of the piston.
The volumetric delivery of the pump per time interval is determined by the piston capacity (piston diameter x stroke) and the speed of drive shaft 5.
The pilot plate 17 separates the pressure side from the suction side of the powertrain. Pilot plate 17
has a kidney-shaped opening on the suction side, and three smaller kidney-shaped openings on the
pressure side.
Fig. 3
Section of powertrain
16
Cylinder
33
Return ball
17
Pilot plate
34
Return plate
18
Pin
35
Pressure spring
copyright by
MJFCIFSS
7.15.5
Service Manual
19
3.1.1
36
Piston
Pressure spring
Adjusting the pivot angle of the pump, see Fig. 9

The connecting link 37 provides a mechanical connection between the swivel yoke 7 and the control
piston 22. The connecting link engages in the opening on the control piston 22. It is secured by means
of the pin 12 and the roll pin 11. The axial motion of the control piston 22 (and thus the swivelling
motion, i.e. the change of the angle of swivel yoke 7) is determined by way of the performance regulator and/or flow regulator.
The LS signal generated by the consumer moves the flow regulator into the actuating position so that
the pump pressure can reach the control chamber. As a result, the pump is swivelled out. The pump
pivots back as soon as the control chamber is connected by the flow regulator (no LS signal) or by
the performance regulator (output too high) to the tank.
In stand-by mode (i.e. all pilot control valves in neutral position), the pump supplies only minimum
flows, (see Tab. 1 on page3).
3.1.2
Min. and max. pivoting angle of the pump

The max. pivot angle of the powertrain of the pump is determined by the dead stop (collar 39) of the
control piston 22 in the control cylinder. The stop cannot be adjusted.
The min. pivot angle of the powertrain is determined by the stop screw 48 (with lock nut 38). It is factory-set. It is recommended not to tamper with these angle settings.
Fig. 4
7.15.6
Adjusting the swivel yoke
Swivel yoke
37
Connecting link
11
Roll pin
38
Lock nut
12
Pin
39
Sleeve
22
Control piston
48
Qmin stop screw
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Service Manual

Pump regulation
4 Pump regulation
4.1
Performance regulator 25 (LR) hyperbolic regulator

The purpose of the performance regulator is to adapt the flow rates from the pump with respect to the
pump pressure (decreasing output) to the performance curve of the diesel engine. As a result, the
pump performance is regulated along a hyperbolic line. The pump delivers larger volumes at low
pressure and smaller volumes at high pressures. The basic setting of the regulating spring 90 /91 corresponds to the mechanical begin of basic regulation. It can be switched up to load limit control via
the control pressure pMLR at the connection X3.
The pressure springs 90 / 91 push the spool 97 to the right against the lever 24. This opens the control
edge S1; the control chamber of the control cylinder 22 receives pump pressure pP. The pump pivots
to Qmax. The return piston 16 has a mechanical connection with the swivel yoke in the connecting
pin 15.
4.1.1

When the working pressure pP in the system rises to the value of the begin of regulation, the force
from the measuring cylinder 23 to the lever 24 is increased. The spool 97 is shifted against the pressure spring 90 and opens, through the control edge S2, the connection from the control chamber (SK)
to the tank (T). The pump pivots back. The pump pivoting back results in an axial movement of the
return piston 96 against the pressure spring 83 by means of the connecting pin 95 with the bearing
pin of the swivel yoke. As a consequence, the line of force of the measuring cylinder 98 against the
lever 99 is shifted in the direction of the fulcrum. The force exercised by the lever 94 onto the spool
97 is reduced so that the pressure spring 90 moves the spool 97 back into its neutral position. The
connection between the control chamber (SK) and the tank (T) is closed. The pump remains at a constant flow rate, which results in a constant drop in performance (at the prevailing pP).
4.1.2
Pivoting of the pump (at pressures below the begin of regulation)

As soon as the operating pressure pP in the system drops, the force exercised by the piston 98 onto
the lever 99 is reduced. The spring 90 shifts the spoon 97 against the lever 99. The connection through the control edge S1 pump pressure (P) in the control chamber (SK) is opened. The pump is
set to a larger pivot angle. The pivoting motion of the pump moves the return piston 96 in the direction
of the screw plug 81. The measuring cylinder 23 is pushed away from the fulcrum by the lever 99.
The resulting force applied by the lever 99 onto the spool 97 is increased, i.e. an equilibrium is reestablished, and the piston 97 is moved to its closing position (S1 and S2 closed).
Fig. 5
Control edges S1 and S2
10
Pressure spring
pP
Pump pressure
11
Pressure spring
SK
17
Spool
Tank pressure
copyright by
MJFCIFSS
7.15.7
Service Manual
Pump regulation
Fig. 6
Sectional drawing of performance regulator 25
26
49
Flow regulator, complete

Regulator housing
91
92
Pressure spring
Bushing
81
82
Screw plug
Threaded stud
93
94
Spring plate
Ball
83
84
Pressure spring
O-ring
95
96

Return piston
85
O-ring
97
Spool
86
87
Regulator housing
Sealing nut
98
99
Piston with slipper (measuring cylinder)

Lever
88
89
Adjusting screw
Screw plug
pP
SK
Working pressure
90
Tank pressure
Note!
Tightening torques: Screw plug 81 / 89 = 35 Nm; sealing nut 87 = 18 Nm.
7.15.8
copyright by
MJFCIFSS
Service Manual

Pump regulation
4.2
Flow regulator 26 (LS regulator)

The flow regulator 26 is used to adapt the flow rates of the pump to the requirements of the consumers.
The flow regulator 26 is screw-mounted to the mounting plate 49. It consists of the following main
components: 3-piece piston 63/64/65 and pressure spring 59 with adjusting screw 52.
The spool 62 is held in its controlling position by the equilibrium of the pressures (pP, pLS) and the
spring force of the pressure spring 59. When the pressure forces change, the control chamber is connected with the tank, or the pump pressure is applied to the control cylinder. The spring force of the
pressure spring 59 and thus the setting of p can be adjusted / set by turning the adjusting screw 52.
Fig. 7
Flow regulator, inserted in regulator housing
26
49
Flow regulator, complete

Regulator housing
62
63
Spool
Piston
51
52
Screw plug
Adjusting screw
64
65
Control sleeve
Piston
56
Sealing nut
73
O-ring with backing ring
58
Lock nut
Pp
Pump pressure
59
Pressure spring (adjustment
60
Pressure spring
Return channel
61
Seal
X2
Connection control block-LS
X4
Connection T to tank
p)
pLS LS pressure
Note!
Screw down the flow regulator 26 all the way to stop. Tighten it with 5 Nm max.
Sealing nut 56 = 8 Nm; nut 58 = 120 Nm.
copyright by
MJFCIFSS
7.15.9
Service Manual
Pump regulation
4.3
4.3.1
P LS
Stand-by
When all consumers are closed, the flow from the pump builds up a backpressure in channel pP. The
backpressure acts on the piston 63. If the pressure exceeds the forces of the pressure springs 59/60,
the control edge S2 is opened, i.e. the connection between SK and T is opened. The powertrain is
swivelled back until the spring forces and the pressure forces on the spool 62 are balanced, or until
the powertrain is set to Qmin.
4.3.2
Pivoting out
The spool 62 is pushed to the right by the pressure spring 59. The control edge S1 is opened, and
the pump pressure pP is applied to the channel SK to the control chamber of the pump. The pump
swivels to the large swivel angle and the pumped volume is increased.
The pressure building up at the connection pLS (by means of operation of a consumer) increases the
sum of the forces acting on the spring side of the spool 62, so that the spool 62 is switched to the
right. The control edge S1 is opened.
The pump pressure pP is applied through the channel SK to the control camber / control piston.
The pump swivels to the large swivel angle.
The pumped volume increases.
The backpressure pP caused by the increasing pump volume is built up and acts on the piston 63.
As soon as it reaches the value set at the pressure spring 59, the spool 62 is moved to the left again
until the control edge S1 closes. The pressure pP ceases to act on the control chamber of the control
piston, but is not released to the tank or the channel T (as the control edge S2 is still closed). As a
result, the powertrain is fixed and the flow rate from the pump is levelled out at a constant value.
4.3.3
Pivoting back
If the pump pressure pP at the spool 62 exceeds the total value in pLS (consumer pressure at X2)
and the spring force of the pressure spring 59,
the spool 62 is pushed to the left,

the control edge S1 is closed,
the control edge S2 is opened, and
the spool is relieved through SK to the tank.
The pump pivots back.
Fig. 8
7.15.10
Control edges S1 and S2 at the flow regulator
51
Screw plug
68
Backing ring
52
Adjusting screw
72
Backing ring
56
58
Sealing nut
Nut
73
O-ring
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MJFCIFSS
Service Manual

59
60
Pressure spring (adjustment

Pressure spring
62
63
64
65
p)
pP
pLS
Working pressure
LS pressure
Spool
Piston
S1
S2
Pump pressure control edge

Tank pressure control edge
Bushing
Piston
SK
T

Tank pressure
66
Bushing
X2
Connection at regulator housing
67
O-ring
X4
Connection at regulator housing
5 Adjustment of DPVO variable displacement pump

5.1
Adjustment of the differential pressure

lation
p LS and begin of the hydraulic regu-
Note!
The procedure to adjust the differential pressure and begin of regulation of the pump is described
in group 6 "Adjustment protocol" and "Adjustment guideline".
Locking ring
22
Control piston
5
6
Drive shaft
Regulator housing
30
31
Gear pump
Sliding disc
7
8
Swivel yoke
32
33
Set of discs
Return ball
O-ring
34
Return plate
10
11
Sliding bearing
Roll pin
35
36
Pressure spring
Pressure spring
12
Pin
37
Connecting link
13
O-ring
38
Hex nut
14
15

Pin
39
40
Stop sleeve
Pump casing
16
46
Mounting plate
17
Pilot plate
47
Connecting flange
18
Locking pin (against tampering)
48
Stop screw
19
Piston with slipper
100
Flange with O-ring
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MJFCIFSS
7.15.11
Service Manual
Fig. 9
7.15.12
Sectional drawing of DPVO
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MJFCIFSS
Service Manual

6 Regulating characteristics
Fig. 10
Performance curve of DPVO 165
copyright by
MJFCIFSS
7.15.13
Service Manual
7.15.14
copyright by
MJFCIFSS
Service Manual
Cooling unit
Function and design
Cooling unit
1 Function and design
Cooling of the hydraulic oil, the coolant and the intercooling air of the diesel engine.
The speed of the hydrostatically driven annular fan RL is controlled according to the cooling requirements (i.e. based on the coolant and hydraulic oil temperature).
The flow rate of the hydraulic oil is not controlled. The flow rate of the engine coolant is however thermostat-controlled.
Fig. 1
Cooling unit, e.g. in three parts
6
13

Blower motor
FS
H
Finger guard
Air scoop
14
LLK
MWK
Intercooling air cooler / engine

Water cooler (coolant) / engine
RL
Y352
Annular fan
copyright by
MJFCIFSS
7.20.1
Cooling unit
Service Manual
Function and design
1.1
Cooling elements
The cooling unit consists of 2 or 3 cooling elements (depending on model):
In models A 309 - A 312, the cooler 6 for the hydraulic oil and the cooler 7 for the diesel engine
coolant are mounted in a shared frame equipped with the necessary air baffle plates.
In models A 314 - A 316 / R 313 / R 317, the cooler 6 for the hydraulic oil, the cooler for the engine
coolant and the cooler for the intercooling air are mounted in a shared frame equipped with the
necessary air ducting plates.
The annular fan required to produce the air flow (equipped with 8 fan blades as standard) is positioned in the opening of the air duct frame.
The annular fan is driven by the gear oil motor 13. The oil motor speed required to produce the necessary air flow is automatically controlled by the BST through the proportional solenoid valve Y352
at the fan motor and the necessary signals from the temperature sensors at the diesel engine and
the hydraulic tank.
The blower motor 13 is protected with the pressure-relief valve 14, on the proportional solenoid valve
Y352, . The pressure relief valve 14 is integrated into the radiator fan circuit and is factory-set.
1.2
Fan control
The hydrostatic fan drive is controlled by the hydraulic oil temperature B285 and the coolant temperature B2. The fan speed is controlled electronically, relative to the temperature, through the proportional solenoid valve Y352.
Between the above minimum and maximum values, the current of the BST to the solenoid valve Y352
is nearly linear, i.e. each temperature between these two limit points corresponds to a specific current
and pressure between min. and max., resulting in a specific fan speed.
Note!
If Y352 is disconnected, the fan switches to nnot
Diagrams of the hydraulic fan control, see 2.2.
Current from
BST
Valve position
Y352
Fan speed
Imax
Largest opening
nmin
60 - 80 C oil temperature and

90 - 100 C coolant temperature
Imax - Imin
Medium opening
nmin - nmax
80 C oil temperature and

100 C coolant temperature
Imin
Smallest opening
nmax
Temperature
60 C oil temperature and
90 C coolant temperature
7.20.2
copyright by
MJFCIFSS
Service Manual
Cooling unit
Function and design
Fig. 2
Components of the fan control system
Hydraulic tank
30

(A 309-316)
13
14
Oil motor / fan drive

Proportional pressure-relief valve
31
B2
Gear pump / fan drive (R 313 / R 317)

Temperature transducer / coolant
15
Coarse filter fan motor
B285 Temperature transducer / hydraulic oil
20
Variable-displacement pump / double

variable-displacement pump
Y352 Proportional solenoid valve / fan control
copyright by
MJFCIFSS
7.20.3
Cooling unit
Service Manual
Function of the fan control
2 Function of the fan control

The speed of the blower motor is controlled with the solenoid valve Y352. Depending on the oil and
coolant temperature, the BST adjusts the current to the solenoid valve Y352 thus opening and closing
it . The more the solenoid valve Y352 is opened, the less hydraulic oil flows to the blower motor 13
and the lower the fan speed.
If the temperature of the hydraulic oil in the tank and/or coolant in the engine is equal to or below the
lower limit value T 285 (min.) or T 2 (min.) respectively, the output current to the solenoid valve Y347
of the BST (U16) is I Y352 (max.).
In this case, the pressure at the proportional solenoid valve Y352 is reduced to a low value. This has
the effect that the speed of the fan is reduced to the minimum working speed n fan (min.). Surplus oil
from pump 31 is returned back to tank through the pressure relief valve 14.
If the temperatures increase from minimum to maximum limit value T 285 (max.) or T 2 (max.) respectively, the current at the solenoid valve Y352 drops continuously .
The pressure in the fan drive system corresponds now to the upper nominal value. Nearly all oil from
the pump 31 flows to the fan motor 13. The speed of the fan reaches its upper nominal value nfan
(max.).
Between the above minimum and maximum values, the current of the BST (U16) to the solenoid valve Y352 is nearly linear, i.e. each temperature between these two limit points corresponds to a specific current I and pressure p between min. and max., resulting in a specific fan speed (see diagrams).
In emergency mode, i.e. in the event of a failure of the control system (I = 0 mA), the oil pressure in
the hydraulic fan drive reaches the maximum value p(max.) set for the pressure relief valve 14, resulting in maximum speed of the fan n fan (max.).
Fig. 3
7.20.4
Cooling unit and fan circuit
Layout from start of series
Layout from change in series
1
6
Hydraulic tank
31
100
Gear pump (in R 313 / R 317)

from compact control block connection K
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MJFCIFSS
Service Manual
Cooling unit
7
9
2.1
B2
Temperature transducer / coolant
B285 Temperature transducer / hydraulic oil
Cooler for motor coolant

Annular fan
13
Blower motor
MK
Engine coolant circuit
14
U16
15
Coarse filter (from serial no. 13104)
30
Gear pump (in A 309 - A 316)
Maintenance
Maintenance is limited to inspection and cleaning of the cooling unit fins.
After a repair on the hydraulic components (defective pump, etc.), the coarse filter 15 in the fan circuit
must be inspected for contamination and replaced, if necessary.
copyright by
MJFCIFSS
7.20.5
Cooling unit
Service Manual
2.2
2.2.1
Diagrams
Diagram of model A 309/ A 311
Fig. 4
Y352
p
7.20.6
Temperature current and current speed and pressure

to proportional solenoid valve
Pressure in cooling circuit
T
n
Temperature of medium (oil, coolant)

Speed of annular fan
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MJFCIFSS
Service Manual
Cooling unit
2.2.2
Diagram of model A 312
Fig. 5
Temperatures current and current speed and pressure
Y352
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MJFCIFSS
7.20.7
Cooling unit
Service Manual
2.2.3
Diagram of model R 313
Fig. 6
7.20.8
Y352
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MJFCIFSS
Service Manual
Cooling unit
2.2.4
Diagram of model A 314 - R 317
Fig. 7
Y352
Note!
Speed during emergency operation (failure of Y352):
Inot = 0 mA = nmax
p not a the pressure-relief valve 14 = pmax
copyright by
MJFCIFSS
7.20.9
Cooling unit
Service Manual
7.20.10
copyright by
MJFCIFSS
Service Manual

Function

1 Function
The FMF hydraulic fixed displacement motor is of the built-in type. Its purpose is to drive the slewing
gear mechanism of the machine.
The axial piston motor is of the swash plate design and sits on the slewing gear mechanism of the
machine.
Fig. 1
copyright by
MJFCIFSS
7.24.1
Service Manual
General information and tightening torques
2 General information and tightening torques

Machines from serial number

Type of oil motor
FMF 45
45 cm3/rev
Oil flow consumption

Max. leak oil at max. working pressure
Tab. 1
6 l/min
Technical data
Allen head screws 14
118 Nm
Screw plug / leak-oil connection S

Pressure relief valve 134 / 135
68 Nm
100-120 Nm
Screw plug / suction valve 133.1

Measuring connection 137 / 138
250 Nm
27 Nm
Note!
For the adjustment of the valves 134 / 135: see adjustment protocol and adjustment guideline in
group 6.
7.24.2
copyright by
MJFCIFSS
Service Manual

Design
3 Design
Axial-piston oil motors are energy converters characterised by the axial alignment of the pistons in
the cylinder.
The oil motor 130 consists of two main components:
Motor housing 12 with powertrain 132
Mounting plate 13 with suction valves 133 and pressure relief valves 134 / 135
Furthermore, there are the measuring connections 137 / 138 at the top of the mounting plate 13.
The powertrain pistons 132 with slippers rotate on the swash plate. The inclined arrangement of the
slide faces is responsible for the stroke of the pistons in the cylinder and, thus, the constant oil flow
consumption of the oil motor.
The force resulting from hydraulic pressure and piston areas generates the required torque on the
output shaft.
Fig. 2
FMF fixed displacement motor
12
Housing
134
13
Mounting plate
135
130
Oil motor, complete
137
Measuring connection MA
132
Powertrain, complete
138
Measuring connection MB
133
Suction valve
copyright by
MJFCIFSS

7.24.3
Service Manual
4.1
Functioning of the oil motor, see Fig. 3 and see Fig. 4

The housing 12 contains 9 pistons 5 that are arranged in a circle, parallel to output shaft 3. They run
in cylinder 4, which is geared with output shaft 3.
The piston ends are designed as ball joints and sit in the slippers 5.1. They are held by the return ball
8 and the return plate 7 on the fixed inclined eccentric disc 6.
The hydrostatic bearing arrangement of the slippers 5.1 on thrust washer 6 (by means of bores in
piston 5 and slippers 5.1) reduces the otherwise high friction between the slippers and the eccentric
disc to a minimum.
When there is no pressure, the pressure springs 8.1 built into the return ball 8 press the cylinder 4
against the disc cam 9. When the pressure increases, the cylinder 4 and the pilot plate 9 are balanced by hydraulic forces in such a way that the oil film at the control surface is maintained at all times,
even under high loads, and the amount of leak oil is reduced to a minimum. Some of the leak oil is
used to lubricate the moving parts of the powertrain and guided externally back to the tank.
If pressure oil is supplied to the operating connections A or B, the respective four pistons 5 are pressurised through the kidney-shaped slots in the pilot plate 9. Another group of four pistons 5 displaces
the unpressurised oil through the kidney-shaped slots in the pilot plate 9 and connection B or A to
the tank. A ninth piston is situated in the area of the dead centre, i.e. at the point of return of motion.
The oil acting on the four pistons on the pressure side generates a certain force determined by the
pressure and the piston area. This force acts through the piston 5 and the slipper 5.1 on the eccentric
disc 6.
The radial component of the above force (together with the limb of the cylinder acting as a lever arm)
generates a torque, which is transmitted onto the cylinder 4 and the output shaft 3.
The torque can be influenced only by the applied oil pressure, i.e. high pressure = high torque. The
two-way pressurisation of the oil motor (connection A or B) results in a change of direction of the
torque at drive shaft 3 (left or right-hand rotation).
With every rotary motion of cylinder 4, the pistons 5 complete a double stroke. The stroke of the pistons corresponds to the inclination of the eccentric disc 6 and determines the volume of oil consumed.
As the oil flow consumption remains constant at all times, it is the travel / output speed of the oil motor
that is changed accordingly via the spool when the oil supply changes.
7.24.4
copyright by
MJFCIFSS
Service Manual

Fig. 3
Sectional drawing of fixed displacement motor
Roller bearing
15
Locking ring
3
4
Output shaft
Cylinder
16
17

O-ring
5
5.1
Piston
Slipper
18
19
O-ring
O-ring
6
7
Eccentric disc
Return plate
22
23
Snap ring
Snap ring
Return ball
26
Needle bearing
8.1
Pressure spring
27
Shim
Pilot plate
28
Shim
10
Locking pin
29
Shim
12
Housing
30
Shim (supplied only with repair set /

locking ring
13
Mounting plate
134
Pressure relief valve B with additional

pressure
stage
13.21
Screw plug
135

pressure
stage
14
Allen head screw
copyright by
MJFCIFSS
7.24.5
Service Manual
4.2
4.2.1
Functioning of valves on the mounting plate, see Fig. 4

Suction valves 133
The suction valves (acting as check valves) ensure that the oil motor is always properly filled (no cavitation e.g. when relief valves blow off or in the event of leaks). If a vacuum occurs at the connection
A or B the cone 133.10 is pushed against the force of the spring 133.14 from its seat, and oil can flow
from the connection S to the suction side A or B. This prevents cavitation in the oil motor.
4.2.2
Pressure relief valves with additional pressure level 134 and 135
These valves limit the high pressure that may arise at main connections A and B with respect to the
control pressure at connections XAB.
Pressure control
If the pressure increases in the slewing gear circuit in undesirable ways, damage would occur at the
weakest point, e.g. screwed connections or hydraulic hoses.
In order to prevent this, the system is equipped with a pre-determined breaking point. The increasing
working pressure in the slewing gear circuit acts on a pressure relief valve. It limits the maximum
pressure in the slewing gear circuit and its connection to a pre-set value.
As high flows result in pressure on the pressure-relief valves, the machine is equipped with indirectly
acting (pilot-controlled) pressure-relief valves. In these valves, a pressure-relief valve is installed as
a pilot control valve to actuate a second, larger valve.
The applied pressure (in A or B respectively) acts on the front face of the piston (main cone) .19 and
through a small bore also on the reverse side of the piston .19, closing it. Simultaneously, the pilot
control cone .20 is pressurised. The pressure spring .23 pushes the pilot control cone .20 into its closing position (static status). The pressure springs .24 and .31 serve as return devices.
As soon as the pressure in the consumer circuit attains a value exceeding the set value of pressure
and adjusting spring .23, pilot control cone .20 is lifted from its seat, and some oil can penetrate into
the return channel.
As the diameter of the boreholes in the bushing .19 differs from that of the valve insert .18, a differential pressure is built up between the front side and the rear side of the piston .19. As a result of
this pressure difference, the piston .19 is shifted against the pressure spring .23, and a substantial
amount of oil flows off to the non-pressurised return side 5 or the opposite side.
Additional pressure level

If the pilot control valve for the actuation of the slewing gear is not actuated, the connection XAB is
relieved.
Stage 1 (low pressure = braking pressure - see adjustment protocol of hydraulic system)
Connection XAB is connected to the tank: Pressure spring .23 has a lower pre-loading force.
The pressure limitation of the relief valve 134 / 135 is set to the low value (level 1).
When the pilot control unit for the slewing gear actuation is activated, the pilot control pressure is applied the piston .12 through the connection XAB respectively, the internal boreholes in the mounting
plate 13 and the boreholes and the annular gap in the valve 134 / 135.
Level 2 (higher pressure = pivoting pressure - see adjustment protocol of hydraulic system)
Pressure spring .23 is pre-loaded a bit more by shifting piston .12, ball .21 and spring plate .11, so
that there is a higher blow-off pressure.
The pressure limitation of the relief valve 134 / 135 is set to the high value (level 2).
Adjustment of the relief valves 134 / 135 with additional pressure level: see adjustment protocol and
adjustment guideline in group 6.
7.24.6
copyright by
MJFCIFSS
Service Manual

Fig. 4
Sectional drawing of mounting plate
13
Mounting plate
134.19 Piston
14
Allen head screw
134.20 Cone
133
Check valve / suction valve
133.10 Cone
134.21 Ball
134.22 O-ring
133.11 Screw plug

133.14 Pressure spring

133.17 O-ring
134.25 O-ring
134
Pressure relief valve / turn right A with

additional pressure stage
134.26 Backing ring
134.11 Spring plate

134.12 Piston
134.28 O-ring
134.29 O-ring
134.13 Nut
134.14 Bushing*
134.30 O-ring
134.15 Bushing
134.98 Seal kit
134.16 Nut
135
134.17 Bushing*
137
Pressure relief valve / turn left B with

additional
pressure level items .10 - 0.98, see 134
Measuring point MA / turn right
134.18 Valve seat
138
Measuring point MB / turn left
134.27 O-ring
* one piece (roller bearing)
copyright by
MJFCIFSS
7.24.7
Service Manual
Maintenance and repairs
5 Maintenance and repairs

Note!
Liebherr oil motors do not require any maintenance whatsoever. For sealing and repair jobs, please
refer to separate repair instructions "Liebherr FMF fixed displacement oil motors".
5.1
Sealing jobs on valves on mounting valve

Replacement of O-ring 133.17 or spring 133.14 on the suction valves 133:
Remove the screw plug 133.11 complete with the measuring connection 137 / 138. Remove the cone
133.10, the spring 133.14 and the O-ring 133.17.
Check the cones 133.10 for free movement. Place the new spring or O-ring in the valve, and reassemble it.
When installing the valve, tighten the screw plug 133.11 with the measuring connection 137 / 138
(tightening torque: 250 Nm).
Sealing jobs on the pressure relief valves 134 and 135

To seal the valves, use the seal kit .93.
For this purpose, remove and/or dismantle the valve 134 / 135 completely, as needed.
Check whether the parts are in proper working order and can be reused.
Note!
After having replaced the defective sealing element, reassemble it and insert it (tightening torque
between 100 and 120 Nm).
After the replacement of the O-rings .22, .27, .29, the response pressures of the valve must be readjusted. See adjustment guideline and protocol in group 6.
7.24.8
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MJFCIFSS
Service Manual

Function

6 Function
The FMF hydraulic fixed displacement motor is of the built-in type. Its purpose is to drive the slewing
gear mechanism of the machine.
The axial piston motor is of the swash plate design and sits on the slewing gear mechanism of the
machine.
Fig. 5
copyright by
MJFCIFSS
7.24.11
Service Manual
General information and tightening torques
7 General information and tightening torques

Machines from serial number
Type of oil motor
FMF 45
45 cm3/rev
Oil flow consumption

Max. leak oil at max. working pressure
Tab. 2
6 l/min
Technical data
118 Nm
Screw plug / leak-oil connection S

Pressure relief valve 134 / 135
68 Nm
100-120 Nm
Screw plug / suction valve 133.1

Measuring connection 137 / 138
250 Nm
27 Nm
Note!
For the adjustment of the valves 134 / 135: see adjustment protocol and adjustment guideline in
group 6.
7.24.12
copyright by
MJFCIFSS
Service Manual

Design
8 Design
Axial-piston oil motors are energy converters characterised by the axial alignment of the pistons in
the cylinder.
The oil motor 130 consists of two main components:
Motor housing 12 with powertrain 132
Mounting plate 13 with suction valves 133 and pressure relief valves 134 / 135
Furthermore, there are the measuring connections 137 / 138 at the top of the mounting plate 13.
The powertrain pistons 132 with slippers rotate on the swash plate. The inclined arrangement of the
slide faces is responsible for the stroke of the pistons in the cylinder and, thus, the constant oil flow
consumption of the oil motor.
The force resulting from hydraulic pressure and piston areas generates the required torque on the
output shaft.
Fig. 6
FMF fixed displacement motor
12
Housing
134
13
Mounting plate
135
130
Oil motor, complete
137
Measuring connection MA
132
133
Powertrain, complete
Suction valve
138
Measuring connection MB
copyright by
MJFCIFSS
7.24.13
Service Manual
9.1
Functioning of the oil motor, see Fig. 7 and see Fig. 8

The housing 12 contains 9 pistons 5 that are arranged in a circle, parallel to output shaft 3. They run
in cylinder 4, which is geared with output shaft 3.
The piston ends are designed as ball joints and sit in the slippers 5.1. They are held by the return ball
8 and the return plate 7 on the fixed inclined eccentric disc 6.
The hydrostatic bearing arrangement of the slippers 5.1 on thrust washer 6 (by means of bores in
piston 5 and slippers 5.1) reduces the otherwise high friction between the slippers and the eccentric
disc to a minimum.
When there is no pressure, the pressure springs 8.1 built into the return ball 8 press the cylinder 4
against the disc cam 9. When the pressure increases, the cylinder 4 and the pilot plate 9 are balanced by hydraulic forces in such a way that the oil film at the control surface is maintained at all times,
If pressure oil is supplied to the operating connections A or B, the respective four pistons 5 are pressurised through the kidney-shaped slots in the pilot plate 9. Another group of four pistons 5 displaces
the unpressurised oil through the kidney-shaped slots in the pilot plate 9 and connection B or A to
the tank. A ninth piston is situated in the area of the dead centre, i.e. at the point of return of motion.
The oil acting on the four pistons on the pressure side generates a certain force determined by the
pressure and the piston area. This force acts through the piston 5 and the slipper 5.1 on the eccentric
disc 6.
The radial component of the above force (together with the limb of the cylinder acting as a lever arm)
generates a torque, which is transmitted onto the cylinder 4 and the output shaft 3.
The torque can be influenced only by the applied oil pressure, i.e. high pressure = high torque. The
two-way pressurisation of the oil motor (connection A or B) results in a change of direction of the
torque at drive shaft 3 (left or right-hand rotation).
With every rotary motion of cylinder 4, the pistons 5 complete a double stroke. The stroke of the pistons corresponds to the inclination of the eccentric disc 6 and determines the volume of oil consumed.
As the oil flow consumption remains constant at all times, it is the travel / output speed of the oil motor
that is changed accordingly via the spool when the oil supply changes.
7.24.14
copyright by
MJFCIFSS
Service Manual

Fig. 7
Sectional drawing of fixed displacement motor
2
3
Roller bearing
Output shaft
15
16
Locking ring
Cylinder
17
O-ring
5
5.1
Piston
Slipper
18
19
O-ring
O-ring
6
7
Eccentric disc
Return plate
22
23
Snap ring
Snap ring
Return ball
26
Needle bearing
8.1
Pressure spring
27
Shim
Pilot plate
28
Shim
10
12
Locking pin
Housing
29
30
Shim
Shim (supplied only with repair set /
locking ring
13
Mounting plate
134

pressure
stage
13.21
Screw plug
135
14
Allen head screw
137

pressure
stage
Measuring point MA / pivot right
138
Measuring point MA / turn left
copyright by
MJFCIFSS
7.24.15
Service Manual
9.2
9.2.1
Functioning of valves on the mounting plate, see Fig. 8

Suction valves 133
The suction valves (acting as check valves) ensure that the oil motor is always properly filled (no cavitation e.g. when relief valves blow off or in the event of leaks). If a vacuum occurs at the connection
A or B the cone 133.10 is pushed against the force of the spring 133.14 from its seat, and oil can flow
from the connection S to the suction side A or B. This prevents cavitation in the oil motor.
9.2.2
Pressure relief valves with additional pressure level 134 and 135
These valves limit the high pressure that may arise at main connections A and B with respect to the
control pressure at connections XA / XB.
Pressure control
If the pressure increases in the slewing gear circuit in undesirable ways, damage would occur at the
weakest point, e.g. screwed connections or hydraulic hoses.
In order to prevent this, the system is equipped with a pre-determined breaking point. The increasing
working pressure in the slewing gear circuit acts on a pressure relief valve. It limits the maximum
pressure in the slewing gear circuit and its connection to a pre-set value.
As high flows result in pressure on the pressure-relief valves, the machine is equipped with indirectly
acting (pilot-controlled) pressure-relief valves. In these valves, a pressure-relief valve is installed as
a pilot control valve to actuate a second, larger valve.
The applied pressure (in A or B respectively) acts on the front face of the piston (main cone) .19 and
through a small bore also on the reverse side of the piston .19, closing it. Simultaneously, the pilot
control cone .20 is pressurised. The pressure spring .23 pushes the pilot control cone .20 into its closing position (static status). The pressure springs .24 and .31 serve as return devices.
As soon as the pressure in the consumer circuit attains a value exceeding the set value of pressure
and adjusting spring .23, pilot control cone .20 is lifted from its seat, and some oil can penetrate into
the return channel.
As the diameter of the boreholes in the bushing .19 differs from that of the valve insert .18, a differential pressure is built up between the front side and the rear side of the piston .19. As a result of
this pressure difference, the piston .19 is shifted against the pressure spring .23, and a substantial
amount of oil flows off to the non-pressurised return side 5 or the opposite side.
Additional pressure level

If the pilot control valve for the actuation of the slewing gear is not actuated, the connection XA / XB
is relieved.
Stage 1 (low pressure = braking pressure - see adjustment protocol of hydraulic system)
Connection XA and/or XB is connected to the tank. Pressure spring .23 has a lower pre-loading force.
The pressure limitation of the relief valve 134 / 135 is set to the low value (level 1).
When the pilot control unit for the slewing gear actuation is activated, the pilot control pressure is applied the piston .12 through the connection XA or XB respectively, the internal boreholes in the mounting plate 13 and the boreholes and the annular gap in the valve 134 / 135.
Level 2 (higher pressure = pivoting pressure - see adjustment protocol of hydraulic system)
Pressure spring .23 is pre-loaded a bit more by shifting piston .12, ball .21 and spring plate .11, so
that there is a higher blow-off pressure.
The pressure limitation of the relief valve 134 / 135 is set to the high value (level 2).
Adjustment of the relief valves 134 / 135 with additional pressure level: see adjustment protocol and
adjustment guideline in group 6.
7.24.16
copyright by
MJFCIFSS
Service Manual

Fig. 8
13
14
Sectional drawing of mounting plate

134.19 Piston
134.20 Cone
Mounting plate
Allen head screw
133
Check valve / suction valve
133.10 Cone
134.21 Ball
134.22 O-ring
133.11 Screw plug

133.17 O-ring

134.25 O-ring
134
Pressure relief valve / turn right A with

additional
pressure stage
134.26 Backing ring
134.11 Spring plate
134.28 O-ring
134.12 Piston
134.13 Nut
134.29 O-ring
134.30 O-ring
134.14 Bushing*
134.15 Bushing

134.98 Seal kit
134.16 Nut
135
Pressure relief valve / turn left B with

additional
pressure stage, items .10 - 98, see 134
134.17 Bushing*
137
Measuring point MA / turn right
134.18 Valve seat
138
Measuring point MB / turn left
134.27 O-ring
* one piece (roller bearing)
copyright by
MJFCIFSS
7.24.17
Service Manual

Note!
Liebherr oil motors do not require any maintenance whatsoever. For sealing and repair jobs, please
refer to separate repair instructions "Liebherr FMF fixed displacement oil motors".
10.1
Sealing jobs on valves on mounting valve

Replacement of O-ring 133.17 or spring 133.14 on the suction valves 133:
Remove the screw plug 133.11 complete with the measuring connection 137 / 138. Remove the cone
133.10, the spring 133.14 and the O-ring 133.17.
Check the cones 133.10 for free movement. Place the new spring or O-ring in the valve, and reassemble it.
When installing the valve, tighten the screw plug 133.11 with the measuring connection 137 / 138
(tightening torque: 250 Nm).
Sealing jobs on the pressure relief valves 134 and 135

To seal the valves, use the seal kit .93.
For this purpose, remove and/or dismantle the valve 134 / 135 completely, as needed.
Check whether the parts are in proper working order and can be reused.
Note!
After having replaced the defective sealing element, reassemble it and insert it (tightening torque
between 100 and 120 Nm).
After the replacement of the O-rings .22, .27, .29, the response pressures of the valve must be readjusted. See adjustment guideline and protocol in group 6.
7.24.18
copyright by
MJFCIFSS
Service Manual

Function

1 Function
The axial-piston oil motor is of the swash-plate type. It is flange-mounted to the transmission of the
machine.
The flow from the variable-displacement pump is fed through brake valve "Connection A or B" to the
oil motor and acts on the pistons of the powertrain. The pistons (moving in the axial direction inside
the cylinder of the powertrain) act on the cylinder and drive shaft and generate a certain torque.
The regulating and adjusting unit adjusts the pivot angle to the flow consumption of the oil motor (depending on the operating pressure).
The variable flow consumption of the oil motor determines the torque and speed of the drive shaft.
Both values are in inverse ratio, i.e.:
Large flow consumption
large torque, low rpm, low speed
Small flow consumption
small torque, high rpm, high speed
Fig. 1
copyright by
MJFCIFSS
7.26.1
Service Manual
General information
Machine
from serial number
Design
Oil motor
Unit
A 314-Li
2001
N
A 314-Li
2001
Speeder
A 316-Li
2001
N
A 316-Li
2001
Speeder
Type
LMV 100
LMV 100
LMV 100
LMV 140
Max. oil flow consumption
cm3/rev
100
100
100
140
Oil flow consumption min.
cm3/rev
49
49
49
49
bar
240
240
240
240
Begin of regulation (1)

End of regulation
Max. admissible amount of
leak oil
bar
320
320
320
320
l/min
8,0
8,0
8,0
8,0
mm
11.0
11.0
11.8
14.0
rpm
178025
267025
186025
279025
86
115
82
105
380+20
380+20
380+20
380+20
Adjustable settings of oil motor

A
Regulation end of oil motor

Min. pivot angle
Measure X (standard value),
see Fig. 4
Drive shaft speed
(jacked up)
Travel pressure (2)
Secondary pressure-relief valves
Tab. 1
bar
Technical data
(1) This value is only for orientation. It actually depends on the setting of end of regulation and the
min. pivot angle Qmin. to be attained.
It is not necessary to set the beginning of regulation. However, you can measure this value when you
check the end-of-regulation value. See group 6.34.
(2) This value depends on the friction factors in the gearbox and axles of the machine. Remember, it
is a standard given only for orientation. Tolerances of up to 20 bar are possible.
Execute checks and adjustments of values A, B and C as described in group 6.34.
7.26.2
copyright by
MJFCIFSS
Service Manual

Design
3 Design
The LMV regulating motor consists of the following main components:
Mounting plate 100
Travel motor 170 with drive shaft
Regulating unit 173
Spool / regulating unit 174
Travel brake valve 190
The travel motor consists of the motor housing with integrated drive shaft, swivel yoke, regulating and
adjusting unit. The mounting plate 100 carries the secondary pressure-relief valves 176 / 177.
The control cylinder 173 and the spool 174 sit directly on the travel motor 170.
The brake valve 190, acting in both travel directions, is mounted directly on the mounting plate 100.
Fig. 2
Design of LMV regulating motor
100
Mounting plate
176
170
173

Control cylinder
177
190

Brake valve, complete
174
Spool
copyright by
MJFCIFSS
7.26.3
Service Manual
4.1
Functioning of powertrain, see Fig. 3

The housing 2 contains 9 pistons 77.1 that are arranged in a circle, parallel to the drive shaft 95.
They run in axial arrangement in cylinder 75, which is in gear with the drive shaft 95. The piston ends
are designed as ball joints and sit in the slippers 77.2. They are held in place by the swivel yoke 84
(swash plate) by the return ball 78.1 and the return plate 78.2.
The hydrostatic bearing arrangement of the slippers 77.2 on the sliding disc 85 in the swivel yoke 84
(by means of bores in the piston 77.1 and the slippers 77.2) reduces the otherwise high friction between the slippers and the sliding disc to a minimum.
When there is no pressure, the cylinder 75 is pressed by the pressure springs 78.2 in the return ball
78.1 against the pilot plate 79. When the pressure increases, the cylinder 75 and the pilot plate 79
are balanced by hydraulic forces in such a way that the oil film at the control surface is maintained at
all times, even under high loads, and the amount of leak oil is reduced to a minimum. Some of the
leak oil is used to lubricate the moving parts of the powertrain and guided externally back to the tank.
If pressure oil is supplied to the operating connection "A or B", pressure is applied to four pistons
through kidney-shaped slots in the pilot plate 79. Another four pistons press the non-energised oil
through the kidney-shaped openings in the piston plate 79 through the connection "A or B" and the
brake valve 190 (see Fig. 2) to the tank. A ninth piston is situated in the area of the dead centre, i.e.
at the point of return of motion.
The oil acting on the four pistons on the pressure side will generate a certain force resulting from pressure and piston area. This force acts through the piston 77.1 and the slipper 77.2 on the swivel yoke
84. The radial component of the above force (together with the limb of the cylinder acting as a lever
arm) generates a torque, which is transmitted to the cylinder 75 and the drive shaft 95.
For every rotary motion of cylinder 75, the pistons execute one stroke. That stroke corresponds to
the inclination of swivel yoke 84 and determines the amount of oil consumed. The stroke of the pistons can be modified by changes to the angle of the swivel yoke. Speed and torque will follow and
adjust to the resulting pressure. Changing the side of the oil motor that bears the pressure (connection A or B) will lead to a change of direction of the torque and drive shaft (right or left-hand rotation
= travel forward or reverse, respectively).
The drive shaft 95 is borne with the roller bearings 32 and 33 in the mounting plate 100 and the mounting flange 98.
The gap between the housing 2 and the drive shaft 95 is sealed with the shaft seal 35 and O-ring 36
in the locking ring 97. The seal 15 seals off the contact faces of the mounting flange 98 and the housing 2 to the outside.
7.26.4
copyright by
MJFCIFSS
Service Manual

Fig. 3
Sectional drawing: travel motor / powertrain 170
Housing
75
5
12
Adjusting device
Flange
77.1 Piston (172*)

77.2 Slipper
15
18
Seal
O-ring
78.1 Return ball with pressure spring

78.2 Return plate
20
21
Allen head screw

Retaining washer
79
84
Pilot plate
Swivel yoke
25
Allen head screw
85
Sliding disc
29
Allen head screw
87
Actuation device (174*)
32
95
Drive shaft
33
97
Locking ring
Mounting flange
Cylinder (172*)
34
98
35
36

O-ring
100 Mounting plate

170* Travel engine
40
Snap ring
172* Powertrain
41
Snap ring
173* Regulating unit / control cylinder (see Fig.

5)
44
Shim ring
174* Regulating unit / spool (see Fig. 6)
70
Spacer ring
copyright by
MJFCIFSS
7.26.5
Service Manual
Fig. 4
4.2
4.2.1
Sectional drawing of the regulating unit of the regulating motor, actuating device and control cylinder
Functioning of the regulating unit (control cylinder), see Fig. 5

System is without pressure; or high pressure below begin of regulation
When the system is without pressure, the pressure spring 14 holds the control piston 10 in the control
cylinder 173 in the direction of Qmin. The pressure oil from the respective high pressure side A or B
respectively, acts on the small piston surface (spring side) of the control piston 10 through the check
valves 3 and the internal bores in the mounting plate 100, Fig. 7. The swivel yoke 84 is switched to
small pivot angle (Qmin.) = large output speed; low oil flow consumption - low speed. This happens
via the control neck with sliding block 30 that engages with the control piston 10. The travel of the
control piston 10 in the direction of min. pivot angle is limited by the stop screw 13.
4.2.2
High-pressure value above begin of regulation

High-pressure oil is fed through the control piston and the restrictor 20 to the large surface of the control piston 10. Due to the larger size of the effective piston surface, the control piston 10 moves the
control neck with sliding block 30 of the swivel yoke 84 in the direction of the large swivel angle =
smaller output speed; high oil flow consumption - high torque. The maximum pivot angle is limited by
the guide ring 19 (dead stop). The hydraulic connection between the spool and the control piston is
locked after a relative movement of control piston 10, and the adjustment procedure comes to an end.
This happens thanks to the mechanical connection between the control piston 10 and the regulating
spring .24, via the lever .25 (see Fig. 6). If high pressure attains the value in question (end of regula-
7.26.6
copyright by
MJFCIFSS
Service Manual

tion), the regulating motor is at max. pivot angle.

If the high pressure drops, the large surface of the control piston 10 is relieved and the powertrain is
adjusted with the control piston 15 to a smaller swivel angle.
Fig. 5
Sectional drawing of the regulating unit / control cylinder 173
10
Control piston
21
Allen head screw
11
12
Lid
Lid
22
23
O-ring
Backing ring
13
Stop screw
25
Seal ring
14
Pressure spring
26
O-ring
15
Lock nut
27
Guide bushing
16
17
Protective cap
O-ring
28
30
Circlip
Sliding block
18
Backing ring
84
Swivel yoke
copyright by
MJFCIFSS
7.26.7
Service Manual
19
Guide ring
20
Restrictor
173* Regulating unit / control cylinder
4.3
4.3.1
Functioning of the regulating unit (actuation device 87), see Fig. 5 / Fig. 6
System is without pressure; or high pressure below begin of regulation
The pressure oil of the relevant high pressure side A or B acts on the spool .11 (measuring cylinder
.43) of the actuation device 87, via connection G of the flanged-mounted brake valve and the internal
bores in the mounting plate 100.
If the high pressure value is below the begin of regulation set at the adjusting screw .41, the spring
.19 pushes the spool .11 through the guide rod .13 against the right stop in the direction of the shim
.21. The large piston surface of the control piston is relieved and the powertrain is set to Q min through
the control piston 10.
4.3.2
High-pressure value above begin of regulation

If the high pressure value rises above the pressure value for begin of regulation, the spool .11 is moved against the guide rod .13 and the adjusting spring .19. As soon as the control edge of the spool
.11 opens, high pressure oil flows through the restrictor 20 to the large surface of the control piston
10. The control piston 10 pushes the swivel yoke 84 towards the larger pivot angles.
The mechanical connection between the control piston and the regulating spring .24 through the lever
.25 has the effect that regulating spring .24 is preloaded to a higher degree during adjustment. That
means, the spool .11 is pushed into closing position after a relative movement of the control piston,
and the adjustment procedure comes to an end. If high pressure attains the value in question (end of
regulation), the regulating motor is at max. pivot angle.
As soon as the high pressure goes down again, below begin of regulation, the spring force of the regulating spring .24 is higher again than the hydraulic force at the spool .11. That means, the powertrain is switched to a smaller pivot angle.
4.3.3
Creeper gear mode

With the push button S21 on the right control desk and the solenoid valve Y24 (see hydraulic system,
group 6) in the control oil unit, it is possible to maintain the oil motor constantly at max. pivot angle
(creeper gear mode).
When the button S21 is pushed, the pilot pressure is guided through the control connection "X" to
the spool .11, which is then shifted against the pressure springs .19 and .24. That means, the high
pressure is applied and immediately acts on the large face of the control piston (independent of regulation settings) so that the oil motor is switched to a large pivot angle.
The machine has a great tractive power.
4.3.4
Protecting the oil motor, see Fig. 7

The two pilot-controlled pressure-relief valves .1 on the mounting plate 100 provide secondary protection for the oil motor against reaction forces from the outside and, thus, excess pressure.
7.26.8
copyright by
MJFCIFSS
Service Manual

Fig. 6
Sectional drawing of regulating unit / actuation device 87
.01
.10
Screw
Regulating valve (housing)
.24
.25
Regulation spring
Lever
.11
.12
Spool
Spring plate
.26
.27
Lock nut
Plug
.13
Guide rod
.28
Screw plug
.14
.15
Lid
Control sleeve
.29
.34
Guide
Snap ring
.16
.17
Guide
Lid
.35
.39
Axle
Allen head screw
.18
.19
Guide sleeve
.41
.42
Adjusting screw
Ball
.20
Seal
.43
Measuring cylinder
.21
Shim
.45
Snap ring
.22
Spring plate
.46
Pin
.23
Seal ring
copyright by
MJFCIFSS
7.26.9
Service Manual
Fig. 7
7.26.10
Sectional drawing of mounting plate 100
.1
Secondary relief valve (176* travel forward)
.13
O-ring
.1
.14
O-ring
.3
Secondary relief valve (177* travel forward)

Check valve (175*)
15
Allen head screw
.4
Screw plug
172* Powertrain
.10
Mounting plate
A/B
copyright by
MJFCIFSS
Bores (high pressure from control

valve block)
Service Manual

Maintenance and inspection
0.12 Screw plug
Bores (high pressure from shuttle

valve 195 in brake valve
5 Maintenance and inspection

5.1
Maintenance and repair works on oil motor

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

Disconnect the hose L leading from the connection T1 of the oil motor to the lower rotary connection and seal the connection.
Apply the machine brakes, and pressurise the oil motor to the maximum high pressure.
Collect leak oil from the oil motor, in a suitable and sufficiently large container, using the hose L.
Determine how much leak oil has been collected and compare this volume to the max. admissible
value, (see Technical data on page 2).
Oil motors producing too much leak oil should be replaced.
Re-connect the hose L.
copyright by
MJFCIFSS
7.26.11
Service Manual
Secondary pressure-relief valves 1 (176* / 177*)
Fig. 8
Leak oil connection T1 at the oil motor
6 Secondary pressure-relief valves 1 (176* / 177*)

6.1
Function
The secondary pressure-relief valves 1 are of the cartridge type and screwed directly into the mounting plate of the regulating motor. They put a limit on the pressure between the oil motor and the control valve block when the spools are closed (secondary function).
The high pressure in the oil motor acts on the pressure-relief valve. It limits the maximum pressure
in the consumer and its connection to the pre-set value. As high flows result in pressure on the pressure valves of the hydraulic unit, the machine is equipped with indirectly responding (pilot-controlled)
pressure-relief valves. In these valves, a direct-acting pressure-relief valve is installed acting as a pilot control valve to actuate a second, larger valve.
6.2
Function of pressure-relief valve, see Fig. 9

The pressure (P) built up in the consumer circuit acts on the front face of the main piston .2 and, through the bore A, also on the rear face of the main piston .2. At the same time, the pressure acts also
on the pilot control cone .5.
The pressure springs .3 and .6 push the main piston .2 and the pilot control cone .5 into their closing
positions (static status).
As soon as the pressure in the oil motor reaches a value above the adjusting value for the pressure
and adjusting spring .6 (due to external forces acting on the powertrain), the pilot control cone .5 is
lifted from its seat and a little oil is released into the return channel (T1).
Due to the different cross-sections of the bores A in the main piston .2 and B in the valve insert .4
respectively, there is a pressure difference between the front and the spring side of the main piston
.2. As a result of this pressure difference, the main piston .2 is shifted against the pressure springs
.3, and a substantial amount of oil flows off to the non-pressurised return side (T2).
The pressure in the system drops, and the main piston .2 is again pushed against the sealing edge
at the front part of the housing .1. Furthermore, the adjusting spring .6 pushes the pilot control cone
.5 against the valve insert .4, i.e. the connection between pressurised side and return side (T1/T2) is
closed.
7.26.12
copyright by
MJFCIFSS
Service Manual

Exploded view / sectional drawing
Exploded view / sectional drawing
Fig. 9
Exploded view and sectional drawing of secondary pressure-relief valve 1 (176* / 177*)
Valve
.24
O-ring
.1
Housing (rolled up)
.25
O-ring
.1.1
.1.2
Housing - front part

Housing - back part
.26
.27
O-ring
O-ring
.2
Main piston
.28
Backing ring
.3
.4
Pressure spring
Valve insert
.7
.8
Adjusting screw
Lock nut
.5
.6
Pilot control cone

Pressure spring
.10
999
Protective cover
O-ring (seal kit)
A
B
Bore / main cone

Bore / valve insert
T1
T2
Outlet pilot control cone

Outlet main cone
High pressure
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MJFCIFSS
7.26.13
Service Manual
Brake valve
8 Brake valve
8.1
Function
The travel brake valve is flanged to the mounting plate of the regulating travel motor 170*. During
downhill travel or deceleration of the machine, it prevents insufficient filling and over-speeding of the
regulating travel motor.
Insufficient filling (cavitation) can become a problem when the speed of the oil motor exceeds the
speed corresponding to the oil flowing in from the control block due to some sort of external drive (via
axles and gearbox). In such a case, brake valve 190* restricts the return flow going back to the tank.
The drive is thus slowed down hydraulically while overspeeding of the oil motor is prevented.
8.2
8.2.1
Functioning of brake valve

Function of brake valve 190* during travel
High-pressure oil flows through the connection A / B, the check valve 210 - 230 (196*) and the connection A / B to the mounting plate 100 where it acts on the powertrain of the oil motor 170*.
The return oil from the oil motor flows via the connection A / B back to the brake valve. The check
valve 210 - 230 (196*) closes so that the brake piston 20 (192*) (in closing position) is throttled via
the ring gap (reduced diameter) at the end of the pistons and the shuttle valve 50 / 140 (193*) and is,
thus, slowly shifted against the pressure spring 170. The brake piston opens, and the return oil can
flow via the opening check valve 200 / 220 / 250 (194*) connection B to the return side (tank) of the
control valve block.
8.2.2
Braking function
During downhill travel or deceleration, the operating pressure (high pressure) goes down. That
means, the pressure at the brake piston 20 (192*) drops as well. Pressure spring 170 pushes the brake piston 20 (192*) into braking position.
The connection of the return oil from the oil motor from connection B / A to connection B / A is restricted, i.e. the oil flow (and, thus, the speed of the oil motor) is reduced.
The small bores in the cone 230 let a small amount of oil flow directly to the return side in advance,
and, thus, prevent a jerky slowdown, especially when the oil is cold.
7.26.14
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Service Manual

Brake valve
Fig. 10
Sectional drawing of brake valve 190*
10
20
Housing
Brake piston
230
250
Valve cone
Screw plug
30
Pin
300
Shuttle check valve
40
50
Valve seat
Valve seat
310
999
Screw plug
O-ring (seal kit)
70
100
Spring plate
Screw plug
190* Brake valve
110
140
Screw plug
Restrictor bolt
192* Brake piston

193* Shuttle valve
170
Pressure spring
194* Check valve
200
210
Cone
Guide
195* Shuttle valve

196* Check valve
220
Pressure spring
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MJFCIFSS
7.26.15
Service Manual
Brake valve
Fig. 11
Exploded view of brake valve
10
20
Housing
Brake piston
210
220
Guide
Pressure spring
30
40
Pin
Valve seat
230
250
Valve cone
Screw plug
50
70
Valve seat
Spring plate
300
310
Shuttle check valve

Screw plug
100
Screw plug
420
Screw plug
110
Screw plug
480
Hex nut
140
Restrictor bolt
490
Mounting bolt
170
200
Pressure spring
Cone
999
O-ring (seal kit)
7.26.16
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Service Manual

Design of hydraulic 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 regulating and adjusting unit.
The mounting plate features a brake valve working in both directions of travel. The mounting plate is
also equipped with the secondary pressure-relief valves and the suction valves.
The flow volume of the variable displacement pump is fed through connections A or B to the travel
motor and acts on the piston of the powertrain. The pistons (moving in the axial direction inside the
cylinder of the powertrain) act on the cylinder and drive shaft and generate a certain torque.
The regulating and adjusting unit built into the mounting plate adjusts the pivot angle to the flow consumption of the oil motor (= flow consumption of the travel motor).
The variable flow consumption of the travel motor determines the torque and speed of the drive shaft.
High flow consumption Qmax = high torque = low speed of travel motor
Low flow consumption Qmax = low torque = high speed of travel motor
The brake valve integrated into the mounting plate restricts the return flow to the control valve block
or the tank respectively, while the pressure in the feed line is reduced, thus slowing down the drive.
This approach prevents overspeeding of the travel motor when travelling down a slope and consequent cavitation.
Fig. 1
DMVA travel motor
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MJFCIFSS
7.27.1
Service Manual
Technical data
2 Technical data
Machine
A 312 Litronic /
from serial number
A 309 Litronic /
A 311 Litronic
20221
Oil motor
DMVA 108
DMVA 108
12363
106.5
cm3/rev
106.5 cm3/rev

Standard machine
Speeder
52.3 cm3/rev
38.5 cm3/rev
48.8 cm3/rev
48.8 cm3/rev
Begin of regulation (high pressure)
240 bar
240 bar
End of regulation (high pressure)
340 bar
340 bar
Max. pivot angle
22
22
Min. pivot angle
10,8
10,8
Max. permissible leak oil volume
7 l/min
7 l/min
240 bar
240 bar

A
Begin of regulation of the oil motor

at the adjusting screw
Qmin. pivot angle

Dimension X of the stop screw 35
(guide value)
Standard machine
Speeder
23.8 mm
26 mm
14.8 mm
-
Drive shaft speed

Standard machine
Speeder
1500 rpm (25 rpm)

1930 rpm (25 rpm)
1850 rpm (25 rpm)

2780 rpm (25 rpm)
High pressure
115 bar
115 bar
380+20 bar
380+20 bar
D
Tab. 1
7.27.2
Technical data of the travel motor for machines A 309 Litronic to A 312 Litronic
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Service Manual

Technical data
Machine
A 316 Litronic
from serial number
28061
Oil motor
DMVA 165
165 cm3/rev
94 cm3/rev
Begin of regulation (high pressure)
190 bar
End of regulation (high pressure)
250 bar
Max. pivot angle
22
Min. pivot angle
10,8
Max. permissible leak oil volume
7 l/min

A
Begin of regulation of the oil motor

at the adjusting screw
Qmin. pivot angle

Dimension X of the stop screw 35
(guide value)
Standard machine
Speeder
21 mm
-
Drive shaft speed
1680 rpm (25 rpm)
Adjusting screw 92 for stroke limitation of the control axle 160 (dimension Y)
16.7 mm
12.9 mm*
115 bar
190 bar
High pressure
D
Tab. 2
380+20 bar
Technical data of the travel motor for model A 316 Litronic
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MJFCIFSS
7.27.3
Service Manual
Design
3 Design
The travel motor consists of the following main components:
Powertrain 172
Mounting plate 30
Regulator 174
80
172
The housing 80 is screwed to the mounting plate 30. The mounting plate contains the secondary
pressure-relief valves, the control and regulating unit and the brake valve acting in both directions of
travel.
Fig. 2
7.27.4
Design of the travel motor
30
Mounting plate
172
Complete powertrain
60
Regulator, complete
176
80
Housing
177
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Service Manual

Functional description of the travel motor
4 Functional description of the travel motor

see also sectional drawing on page 7.27.21
4.1
Function of powertrain
The housing 80 encloses the powertrain 172 with the drive shaft 4, cylinder 3, piston 2 with slipper,
etc. Parallel to the drive shaft 4, there are nine pistons 2 arranged in a circle. They run in axial arrangement in the cylinder 3, which is in gear with drive shaft 4. The bottom ends of the pistons are designed as ball joints and sit in slippers. They are held on the swivel yoke 9 by the return ball 6 and the
return plate 7 (swash plate).
The hydrostatic bearing of the slipper on the sliding disc 8 of the swivel yoke 9 (through bores in the
piston 2 and the slippers) reduces the high surface pressure between the slipper and the swivel yoke
9 to a minimum.
When there is no pressure, the cylinder 3 is pressed by the pressure springs 13 in the return ball 6
against the pilot plate 5. When the pressure increases, the cylinder 3 and the pilot plate 5 are balanced by hydraulic forces in such a way that the oil film at the control surface is maintained at all times,
If pressure oil is supplied to the operating connections A or B, the respective four pistons are pressurised through the kidney-shaped slots in the pilot plate 5. Another four pistons press the non-energised oil through the kidney-shaped openings in the piston plate 5 through the connection A or B to
the tank. A ninth piston is situated in the area of the dead centre, i.e. at the point of return from the
pressure to the suction phase.
The oil acting on the four pistons on the pressure side will generate a certain force resulting from pressure and piston area. This force acts via the pistons 2 with slippers onto the swivel yoke 9.
The radial component of the above force (together with the section of the cylinder acting as a lever
arm) generates a torque which is transmitted onto the cylinder 3 and the drive shaft 4. Changing the
side of the travel motor (connection A or B) results in a change of direction of the torque at the drive
shaft 4 (clockwise or anticlockwise rotation respectively).
For every rotary motion of the cylinder 3, the pistons execute a double stroke. This stroke corresponds to the inclination of the swivel yoke 9 and determines the amount of oil consumed Q.
4.2
Function of the regulating unit

The sectional drawing shows the following regulating positions of the travel motor:
The powertrain 172 (swivel yoke 9) is already set to a maximum swivel angle. The working pressure
acts on the large piston surface of the spool 173 (minimum pressure: pressure at end of regulation),
(see table on page 2 or 3, depending on machine model).
The regulating piston 174 is in regulating position, i.e. the flow from the high pressure side through
the check valve 52 to the large piston surface of the spool 173 and the flow from the large piston surface of the spool 173 to the tank side are blocked. The maximum swivel angle is determined by the
stop of the spool 173 at the guide bushing 33. The motor remains in this position, until the high pressure drops below the pressure value at the end of regulation.
Within the regulated range, the travel motor can reach any position that corresponds to a working
pressure of between Qmax and Qmin. If the working pressure drops below the value at the begin of
regulation, the spool 173 touches the stop screw 35, i.e. the travel motor's flow consumption capacity
is lowest at high drive shaft speed, high speed and low drawing pull.
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MJFCIFSS
7.27.5
Service Manual
Fig. 3
Sectional drawing at the begin of regulation (spool)
32 Mounting plate
38 Lock nut
33 Guide bushing
42 Bolt
34 Connecting link
50 Measuring connection of the actuating pressure M
35 Stop screw
4.3
Function prior to the begin of regulation

The pressure oil from the respective high pressure side A or B respectively, acts on the piston ring
surface of the spool 173 through the check valves 52 and the internal bores in the mounting plate 32.
The swivel yoke 9 is kept at a small swivel angle by the connecting link 34. The minimum swivel angle
is limited by the stop screw 35, (see Fig. 3, page 6).
The working pressure acts on the spool 174 through the check valves 52. The spool 174 is held by
the preloaded adjusting spring 68 in its blocking position so that the flow from the high pressure side
through the check valve 52 to the large piston surface of the spool 173 is blocked. The flow from the
large piston surface of the spool 173 to the tank side is opened. The travel motor remains in this position, until the working pressure rises above the pressure value at the begin of regulation, (see table
on page 2 or 3, depending on machine model).
4.4
Function from begin of regulation

The spool 174 is held in the regulating position by the adjusting spring 68 and the return spring 69 (+
the working pressure acting on the shuttle check valve 195). Regulating position of the spool 174
spring force of the return spring 69 + force resulting from the working pressure on the surface difference = spring force of the adjusting spring 68.
If the existing working pressure rises above the value at the begin of regulation, it acts on the surface
difference D - d, (see Fig. 5, page 7) of the spool 174, pushing it against the adjusting spring 68.
The edge of the control spool 174 opens the oil flow to the large piston surface of the spool 173. The
surface difference of the spool 173 generates the necessary actuating force to swivel the powertrain
in direction Qmax. As a result, the powertrain is swivelled to a large swivel angle. The push rod 67
acts as a sensing device and relieves the return spring 69, so that the force ratio between the adjusting spring 68 + return spring 69 differs from the working pressure. As a result, the spool 174 returns
to its regulating position (= closed position) and the actuating procedure is completed, (see Fig. 4,
page 7).
At the respective working pressure (end of regulation) the powertrain is set again to the maximum
swivel angle.
7.27.6
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Service Manual

Fig. 4
Sectional drawing of the regulator
61
Bushing
69
Pressure spring (regulating spring)
62
63
Bushing
Spring plate
72
174
Ball
Spool
64
65
Adjusting screw
Spring plate
A
B
High pressure through valve 52

Pressure to control piston 173
66
Spring plate
High pressure through valve 195
67
68
Push rod
Pressure spring (adjusting spring)
to tank
Fig. 5
Magnified view of the surface difference (detail Z)
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MJFCIFSS
7.27.7
Service Manual
4.5
Protection
The two pilot-controlled pressure-relief valves 176 / 177 protect the travel motor against overpressure
(secondary protection).
The suction valves (check valves) 194 prevent cavitation when the secondary pressure-relief valves
176 / 177 respond.
Fig. 6
52
173
4.6
Arrangement of the valves for pressure protection

176/177
194
Check valve
Control piston

Check valve
Creeper gear mode

The travel motor is kept at a maximum swivel angle (creeper gear mode) with the switch S21 (standard equipment) on the control console and the solenoid valve Y24 located on the control oil unit.
When the switch S21 is actuated, the pilot control pressure from the solenoid valve Y24 acts through
the control connection "X" onto the spool 174, which is then pushed against the pressure spring 68.
As a result, the high pressure immediately acts on the large surface of the control piston 173 (independent of regulation settings) so that the travel motor is switched to a maximum pivot angle. The oil
motor remains set to high consumption flow and the fine control of the powertrain is improved.
7.27.8
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Service Manual

4.7
Functioning of brake valve

When a travel motion of the machine is initiated, the working pressure that is being built up acts through the restrictor bolt 193 (restrictor check valve) onto the brake piston 192 and pushes it against
the pressure spring 48. As a result, the flow is opened on the return side A or B so that the oil is displaced to the tank.
If the pressure in the feed line A or B drops, be it as a result of a steering movement or a change in
load, for example during travel down a slope, the pressure in the spring chamber is reduced through
the restrictor bolt 193. The brake piston 192 is put into braking position by the pressure spring 48,
whereby the equilibrium of forces between the high pressure at the brake piston 192 and the pressure
spring 48 determines the automatic brake function. Irregular braking of the travel motor is prevented
by the check valves 196 with bypass bores, see page 7.27.21.
Fig. 7
Arrangement of the valves for the brake function
45 Valve seat
52
Check valve
46 Spring plate
192
Piston
47 Cover
193
Restrictor bolt
48 Pressure spring
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MJFCIFSS
7.27.9
Service Manual

Note!
Liebherr oil motors do not require any maintenance whatsoever.
repair instructions for DMVA regulating motors.
6 Checking and adjusting the travel motor

Danger!
For inspection, adjustment and repair work, it is necessary to access the undercarriage.
This can be dangerous for technicians. There is a risk of serious injury or even death from rotating
wheels and shafts, or if the machine begins to move.
Extend the supports.
Place the attachment onto the ground and lift the undercarriage from the ground, if necessary.
Apply the parking brake.
Note!
This travel motor has been pre-set by the manufacturer and its settings should not be changed.
6.1
Checking and adjusting the begin of regulation of the travel motor

The checking and adjustment of the begin of regulation of the travel motor is described in detail in
group 6 "Adjustment protocols and guidelines".
6.2
Checking and adjusting of the maximum output speed / maximum travel speed
(setting C)
Note!
The maximum output speed of the travel motor is determined by the minimum flow consumption of
the oil motor and the maximum volumetric delivery of the pump.
The maximum speed is factory-set by the manufacturer and may not be changed.
In models A 309 and 311, the minimum flow consumption of the oil motor is only determined by the
Qmin stop screw 35.
In models A 312 316, the minimum flow consumption of the oil motor is determined by the Qmin
stop screw 35 and the maximum flow rate at the spool (stroke limitation) for travel.
If the maximum travel speed of the vehicle is unsatisfactory, the setting can be adjusted. To determine the current actual value, measure the dimension Y of the stop screw 35 (in A 309 Li and A311 Li
models), or the stroke limitation of the travel spool (in A 312- 316 Li models).
To determine the maximum travel speed accurately, measure the speed of the universal joint shaft
(connection of gear system and axle) using a HT 460 speed meter (for tools, see group 2.01.3).
Settings (see tables on pages 2 and 3).
7.27.10
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Service Manual

Checking and adjusting the travel motor
6.3
Checking and adjusting the minimum pivot angle (setting B)

The minimum pivot angle, i.e. the minimum flow consumption is determined by the stop screw 35.
The angle is factory-set by the manufacturer and should not be changed.
To check the position of the stop screw 35 in the mounting plate 32, use dimension X (between the
stop screw 35 and the lock nut 38) as a guide value (see tables on pages 2 and 3, depending on
machine model).
Fig. 8
6.4
Setting value of Qmin stop screw
32 Mounting plate
38 Lock nut
35 Stop screw
51 Protective cap
Checking travel motor for leakage

Disconnect the leak oil hose to connection T1 and seal the hose.
Screw a matching hose section to connection T1 on the travel motor and place the other end of
the hose in a suitable oil collection container.
Press the brake pedal to the stop and apply the maximum pressure to the travel motor (maximum
high pressure).
Measure the volume of leaked oil and compare it with the permissible volume, (see Tab. 2, page 3).
If there is excessive leakage, replace the oil motor.
Remove the hose section and reconnect the leak oil hose to connection T1.
Fig. 9
Connection T1 for the leakage check of the travel motor
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MJFCIFSS
7.27.11
Service Manual
Hydraulic diagram of the travel motor
7 Hydraulic diagram of the travel motor
7.27.12
34
Connecting link
177
Secondary pressure-relief valve, reverse
35
Stop screw
190
52
67
Check valve
Push rod
192
193
Brake piston
Restrictor bolt
68
194
Check valve
69
195
Shuttle valve
170
172

Complete powertrain
196
X
Check valve
Connection for control pressure from solenoid valve Y24
173
Control piston
T1
Leak oil connection
174
Spool
Pressure/return line connection, reverse
176
Secondary pressure-relief valve, forward
Pressure/return line connection, forward
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Service Manual

Fig. 10
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MJFCIFSS
7.27.13
Service Manual
8 DMVA regulating motor

Item
7.27.14
Item
172
Complete powertrain
44
Bolt
Piston with slipper
45
Valve seat
46
Spring plate
Drive shaft
47
Cover
Pilot plate
48
Pressure spring
Return ball
49
O-ring
Return plate
50
Screw cap (measuring point M)
Sliding disc
51
Safety cap
Swivel yoke
52
Check valve
10
Locking ring
173
Control piston
11
Bolt
176
12
Bolt
177
13
Pressure spring
192
Piston
14
193
Restrictor bolt
15
194
Check valve
16
195
Shuttle valve
17
196
Check valve
18
O-ring
19
Snap ring
60
Regulator, complete
20
Snap ring
61
Bushing
21
Allen head screw
62
Bushing
22
Roll pin
63
Spring plate
80
Housing
64
Adjusting screw
82
O-ring
65
Spring plate
83
Cylinder pin
66
Spring plate
67
Push rod
30
Connecting plate, complete
68
31
Screw plug
69
32
Mounting plate
70
Lock nut
33
Guide bushing
71
Circlip
34
Connecting link
72
Ball
35
Stop screw
73
O-ring
36
Backing ring
74
O-ring
37
O-ring
75
Allen head screw
38
Lock nut
76
Protective cap
39
Allen head screw
77
Lead seal
40
Allen head screw
78
Disc
41
Jacket ring
79
Allen head screw
42
Bolt
81
Cylinder pin
43
Roll pin
174
Spool
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Function

1 Function
The axial piston oil motor of the inclined axle type is inserted into the travel gear of the crawler excavator (plug-in motor).
The travel motor propels the travel gear and, through the tumbler wheel, the chain.
The flow from the variable-displacement pump is fed through brake valve "Connection A or B" to the
oil motor and acts on the pistons of the powertrain. The pistons (moving in axial direction inside the
cylinder of the powertrain) act on the cylinder and drive shaft and generate an input torque.
The regulating and adjusting unit adjusts the pivot angle to the flow consumption of the oil motor (depending on the operating pressure).
The variable flow consumption of the oil motor determines the torque and speed of the drive shaft.
Large flow consumption = large torque, low rpm, low speed
Small flow consumption = small torque, high rpm, high speed
The travel motor can be adjusted by the operator to its minimum pivot angle (electrohydraulic adjustment) (fast travel).
.
Fig. 1
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MJFCIFSS
7.28.1
Service Manual
Function
7.28.2
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Service Manual

Function
1.1
Technical data
Equipment
from serial number
Unit
R 313 / R 317
27752 / 18161
Regulating motor
Type
A6VE
cm3
54.8
Max. torque
Nm
349
Operating pressure
bar
350
l/min
Check measurement X.
Qmin Stop 8
Qmax Stop 11
mm
mm
approx.15.5
approx.15.5
Brake release pressure
bar
approx. 30
Secondary pressure relief valves 211-214
bar
380 +20
Max. leak oil

Tab. 1
Technical data and settings
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7.28.3
Service Manual
Description
2 Description
The regulating motor 200/201 consists of two main components:
Motor housing2
End plate 20
The regulating motor consist of the motor housing 2 with integrated powertrain 1. At the left and right
side of the travel motor housing 2, the stop screws 8 (Qmin) and 11 (Qmax) are mounted.
The motor housing 2 is equipped with a flange-mounted end plate 20. The end plate 20 includes the
powertrain adjusting device 202.
The brake valve 205, double stop valve 209 and the secondary pressure relief valves 211-214 are
screwed into the end plate 20.
Fig. 2
7.28.4
Design of regulating motor
Motor housing
211
Secondary pressure relief valve, powertrain, forward left
Stop screw (Qmin)
212
Secondary pressure relief valve, powertrain,reverse left
11
Stop screw (Qmax)
213
Secondary pressure relief valve, powertrain, forward right
20
End plate
214
Secondary pressure relief valve, powertrain, reverse right
200
201
Travel motor, left

Travel motor, right
A
B
Pressure/return line connection

209
Double stop valve
T1
Leak oil connection
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Service Manual

Description
Fig. 3
Hydraulic diagram of regulating motors
50
208
Pressure reduction valve / brake pressure
100
209
Double stop valve
106
Shift valve / Qmax Regulating motors
211
Secondary pressure relief valve, powertrain, forward left
195
212
196
213
Secondary pressure relief valve, powertrain,reverse left

Secondary pressure relief valve, powertrain, forward right
200
Travel motor, left
214
201
Travel motor, right
215
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Secondary pressure relief valve, powertrain, reverse right

Travel brake
7.28.5
Service Manual
Description
7.28.6
202
203
Powertrain adjusting device

Shifting piston / powertrain adjusting
device
216
S21
Travel gear
Switch (fast travel)
205
206
Brake valve
Shuttle valve
Y24
Solenoid valve (fast travel)
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see Fig. 3 and see Fig. 4
3.1
Powertrain
The pressure oil from the hydraulic pump is fed through the pressure connection A or B respectively
and through a kidney-shaped orifice in the control lens 13 to the cylinder 12.
Three bores of the cylinder 12 are connected to the pressure side of the control lens 13, and three
bores are connected with the return side. One bore is located at the dead centre, i.e. between the
pressure and suction phase.
The conical pistons 15 moving in axial direction inside the cylinder 12 are sealed by means two piston
rings each. By applying oil under pressure onto the three piston surfaces, a radial force is created at
the pistons 15, in turn generating a output torque at the perimeter of the drive shaft 1 .
In idle mode, and during start-up, the cylinder 12 is pressed by the pressure spring 17 mounted on
the centre peg 14 against the control lens 13. When the pressure increases, the cylinder 12 is balanced in such a way that the oil film at the control surface of the cylinder 12 and the control lens 13 is
maintained at all times, even under high loads, and the amount of leak oil is reduced to a minimum.
The leak oil lubricates the centre peg 14, the pistons 15 and the tapered roller bearings39 of the drive
shaft.
3.2
Adjustment
The oil motor can only be operated in two powertrain positions (on-off control).
3.2.1
Operation
Switch S21 for fast travel is not actuated.
The operating pressure at the high pressure side A or B is applied through the internal bores and the
shuttle valve 206 in the end plate 20, the spool 24 and the restriction pin 30 onto the surface Fg of
the spool 21. The powertrain is set by the control piston 21 and the control neck 22 to a large pivot
angle (Qmax) = large oil volume consumption = high tractive power.
3.2.2
Fast travel
Switch S21 for fast travel is actuated.
The solenoid valve Y24 connected to the switch S21 is powered. As a result, the control oil of the
control oil unit flows through Y24, the shift valve 106 (in the control valve block), the rotary connection
196,(see Fig. 3 on page 5) and connection X of the end plate 20 and acts on the spool 24.
The spool 24 is pressed against the pressure spring 25. The operating pressure is applied through
the opening edge of the control spool 24 and the control bushing 23 onto the piston surface Fk of the
control piston 21, while the surface Fg is relieved by the spool 24 to the tank.
The control piston 21, through the control neck 22, moves the cylinder 12 to a small pivot angle position = small oil volume consumption = high speed = low tractive power.
The maximum and minimum pivot angles are set by means of the stop screws 11 and 8 respectively.
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7.28.7
Service Manual
Sectional drawings of the regulating motor
4 Sectional drawings of the regulating motor
Fig. 4
7.28.8
Sectional drawing of the regulating motor
Powertrain with drive shaft
12
Cylinder
Motor housing
13
Control lens
Snap ring
14
Centre peg
15
Piston
5
6
Back-up washer
O-ring
16
17
Tuning disc (S = 3.50 4.00 mm)

Pressure spring
7
8
O-ring
Stop screw (Qmin)
18
19
Return plate
Oval head screw
9
10

O-ring
20
39
End plate
11
Stop screw (Qmax)
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Service Manual

20
End plate
36
Screw plug
21
22
Control piston
Control neck
37
202
Double pull-off plug

Adjusting device
23
Control bushing
203
Shifting piston (powertrain adjustment)
24
Spool
205
Brake valve
25
Pressure spring
206
Shuttle valve
26
27
Screw plug
Restriction screw
208
209
Pressure reduction valve

Double stop valve
28
Restriction screw
211
30
Restriction pin
212
Secondary pressure relief valve, chassis,

forward left
reverse left
32
Screw plug
213

forward right
34
Cylinder pin
214

reverse right
35
Double pull-off plug
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MJFCIFSS
7.28.9
Service Manual
Fig. 5
7.28.10
Sectional drawing of adjusting device
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MJFCIFSS
Service Manual

Inspection, maintenance and adjustment
5 Inspection, maintenance and adjustment

5.1
Maintenance and repair works on oil motor

Note!
Hydraulic regulating motors are maintenance-free!
This hydraulic regulating motor has been pre-set by the manufacturer and must not be changed.
If you detect disturbances in connection with the motor, inspect the secondary protection system.
Proceed according to the adjustment guideline and protocol, see group 6.
repair instructions "A6VE regulating motor".
Danger!
Danger areas: undercarriage - crushing hazard for mechanics, if machine unintentionally starts rolling or if the chassis is moved.
Park the machine on a level surface.
If parked on a slope or off the road, secure the machine.
Block the chassis by applying the parking brake.
Place attachments on the ground.
Contact operating personnel.
5.2
Check oil motor for leakage

Disconnect hose L leading from the connection T1 of the oil motor to the rotary connection at the
T-piece. Remove the hose and seal the open connection at the T-piece.
Disconnect and seal the line 210 to the brake.
Pressurise the regulating motor with maximum high pressure.
Collect leak oil from the oil motor, using the hose L and a suitable and sufficiently large container.
Determine how much leak oil you actually collected and compare to the max. admissible value.
(see Technical data and settings on page 3)
Oil motors producing too much leak oil should be replaced.
After completed measurement, reconnect the hoses L and 210.
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MJFCIFSS
7.28.11
Service Manual
Inspection, maintenance and adjustment
Fig. 6
210
7.28.12
Leak oil check at the regulating motor

Brake hose from the oil motor to the multi- L
disc brake
T1
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Leak oil line

Leak oil connection at oil motor
Service Manual

Double stop valve 209
6 Double stop valve 209
Fig. 7
6.1
Double stop valve 209
Valve cone
20
Housing / mounting plate
2
3
Pressure spring
Valve seat
209
Double stop valve, complete
Valve cone
5
6
Pressure spring
Screw plug
B
R

return line from brake valve
11
O-ring
from/to powertrain and pressure control
Blocking functions, see Fig. 7 and see Fig. 8

As soon as pressure is applied to the operating connection A or B , the valve cone 1 closes the connection to the respective other operating connection B or A. The oil returning from the brake valve
205 opens the valve cone 1, i.e. the oil can flow through the respective connection A or B to the control valve block. The valve thus prevents a short circuit.
As soon as pressure is applied onto the operating connection A or B, the valve cone 4 opens the
connection to the powertrain. The oil returning from the powertrain closes the valve cone 4, and thus
the direct connection to A or B respectively. The oil is thus fed through the brake valve 205 and is
restricted (slowed down).
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7.28.13
Service Manual
Brake valve 205
7 Brake valve 205
Fig. 8
7.1
Sectional drawing of brake valve 205
1
2
Brake piston
Screw plug
6
10
Restriction screw
Restriction pin
Pressure spring
11
O-ring
4
5
Washer
Restriction screw
205
209

Double stop valve
Opening of brake piston (travel), see Fig. 8

The pressure oil from the pressurised side A or B flows via the double stop valve 209 to the control
lens of the travel motor and also acts on the brake valve 205. At the same time, the pressure at the
control is built up progressively at the control surface of the brake piston 1 through the edge of the
control spool S1 or S2 and the restriction screw 5/6. The brake piston 1 is pressed against the pressure spring 3, opening a connection between A or B and S.
The oil can now drain off through the respective return line (tank). The brake valve is now in normal
travel operation position.
7.2
Closing or brake piston (hydraulic braking)

If the pressure at connection A or B drops (e.g. when travelling downhill), the spring 3 presses the
brake piston 1 towards its brake position. The oil flow between A or B and S is gradually restricted,
preventing cavitation or overspeeding of the travel motor. When the travel movement is halted, the
pressure spring 3 pushes the brake piston 1 into its neutral position, thus immediately closing the connection from A or B to S.
7.28.14
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Service Manual

Pressure reduction valve (brake pressure) 208
8 Pressure reduction valve (brake pressure) 208
Fig. 9
8.1
Sectional drawing of the pressure reduction valve for brake pressure 208
12
Screw plug
15
Pressure spring
13
Control bushing
16
O-ring
14
Spool
17
Disc
Releasing of multi-disc brake, see Fig. 9

When the travel motor is pressurised through connection A or B, a high pressure P is built up through
the shuttle valve 206 at the pressure reduction valve 208. The piston 14 is moved, so that the high
pressure is fed via the edge of control spool S3 (limited by pressure spring 15) to connection Bre and
the hose, releasing the multi-disc clutch, (see Technical data and settings on page 3).
If the high pressure P (travel operation) is increased at connection A or B, the control bushing 13 is
pressed against the pressure spring 15. The control bushing thereby seals off the connection T to the
tank. The brake pressure (Bre) in the spring chamber of the pressure spring 15 is added to the spring
pressure. The applied high pressure P, the surface ratio of the control bushing 13 and the interaction
between the spring force and the brake pressure ensure a constant brake release pressure at the
control edge of the spool S3.
If there is no pressure at connection A or B, the spring 15 presses the piston 14 and the control bushing into their normal position. The release pressure at the connection Bre is thus released directly
via connection T and the internal restrictor to the tank.
The release pressure is created by the pressure reduction valve 208. This prevents inadvertent release of the multi-disc brake when the machine is standing still or is travelling.
copyright by
MJFCIFSS
7.28.15
Service Manual
Pressure relief valve with suction function 211 - 214
9 Pressure relief valve with suction function 211 - 214

9.1
Function and design

The secondary pressure relief valves 211 - 214 are of the cartridge type and screwed directly into the
mounting plate of the regulating motor. They put a limit on the pressure between the oil motor and
the control valve block when the spools are closed (secondary function).
In the event of an undesirable pressure rise in the circuit of an attachment, it is the weakest point of
the circuit that would normally break, e.g. screwed connections or hydraulic hoses. In order to prevent
this, machines are equipped with a pre-determined breaking point. The pressure increase in the hydraulic system acts on a built-in pressure relief valve. It limits the maximum pressure in the consumer
and its connection to the pre-set value. As the pressure valves in the hydraulic system must be able
to cater for great flows of oil, our machines are equipped with indirect (pilot-controlled) pressure relief
valves for reasons of manufacture and better functioning. In these valves, a pressure relief valve is
installed that works directly as a pilot control valve to actuate a second, larger valve.
9.2
The pressure (P) applied in the circuit of the consumer acts on the front face of main cone 1 and, at
the same time, through the bore a on the rear face of the main piston 1. The pressure is also applied
simultaneously to the pilot control cone 2.
The pressure springs 9 and 3 push the main cone 1 and the pilot control cone 2 into their closing positions (static status).
As soon as the pressure in the oil motor reaches a value above the adjusting value for the pressure
and adjusting spring 3 (due to external forces acting on the powertrain), the pilot control cone 2 is
lifted from its seat and a little oil is released into the return channel (T1).
Due to the different cross-sections of the bores a in the main piston 1 and b in the rear section of the
housing 4, a pressure difference between front and rear side of the main piston 1 is created. The pressure difference results in the main piston 1 being shifted against the pressure springs 9 so that a great
amount of oil can drain off to the non-pressurised return side (T2).
The pressure in the system drops, and the main piston 1 is again pushed against the sealing edge at
the front part of the housing 8. The adjusting spring 3 pushes the pilot control cone 2 against the rear
section of the housing 4, i.e. the connection between the pressurised side and the return side (T1/T2)
is closed.
9.3
Suction:
If there is a vacuum at the high pressure connection A or B, the higher pressure of the low pressure
circuit acts on the ring face of the main cone 1. This resulting pressure difference affects the entire
surface of the main cone 1 and lifts it against the force of the pressure springs 9 from its seat, so that
the required oil volume can flow through A orB the respective side of the consumer.
7.28.16
copyright by
MJFCIFSS
Service Manual

Fig. 10
1
Sectional drawing of the pressure relief valve 211 - 214

6
Main cone
Adjusting screw
Pilot control cone
Lock nut
Pressure spring
Housing (front section)
4
5
Housing (rear section)

Protective cap
9
10
Pressure spring
O-ring
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MJFCIFSS
7.28.17
Service Manual
7.28.18
copyright by
MJFCIFSS
Service Manual
Hydraulic cylinder
Function
Hydraulic cylinder
1 Function
The LIEBHERR hydraulic cylinders are primarily used as working cylinders for the movement of attachments. Due to their design, they are classified as differential cylinders.
When hydraulic oil is fed to the piston side, the cylinder is extended; when oil is fed to the piston rod
side, the cylinder retracts.
The maximum forces of the cylinder depend on the size and shape of the effective surfaces
Extending
Retracting
Piston surface
Piston ring surface
and the max. admissible operating pressure, which is greater during extending than retracting. The
speed of the cylinder extending or retracting depends on the amount of oil fed per interval of time,
and on the surface. It is reciprocally proportional to the force, so that it is higher at retracting than at
extending.
LIEBHERR offers hydraulic cylinders for various fields of application that differ in stroke (length of extension), diameter (power) and cushioning system (end-of-travel cushioning).
Our machines are equipped with hydraulic cylinders with and without end-of-travel cushioning.
Note!
As the machines feature a great range of seals, guides, pistons and cushioning equipment, it was
not possible to cover all components in detail in the service manual. For details, please refer to the
ET spare parts catalogue and the delivery documents.
Fig. 1
Hydraulic cylinder
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MJFCIFSS
7.30.1
Hydraulic cylinder
Service Manual
Description
2 Description
Hydraulic cylinders consist basically of a cylinder tube 10 with welded cylinder base and bearing bore,
a screwed-in piston rod bearing 13 (acting as cylinder head) and a piston rod 8 with bearing bore and
screwed-in piston 12.
To seal off the pressure chambers to the inside and outside, the cylinder is equipped with O-rings and
backing rings, as well as Glyd-Rimseal rings and Stepseal seal rings in the piston 12 and the piston
rod bearing 13. The scraper ring in the piston rod bearing 13 protects the piston rod 8 against dirt.
The guide rings on the piston 12 and in the piston rod bearing 13 guide the piston rod.
For a detailed description of the sealing elements of the piston 12 and the piston rod bearing 13, see
Fig. 3.
For further details concerning the piston see Fig. 16, the end-of-travel cushioning see Fig. 17 and the
stroke reductionsee Fig. 18.
Fig. 2
7.30.2
Exploded view of a hydraulic cylinder with various piston, cushioning and stroke shortening options.
Bushing
2
3
Sleeve (stroke reduction as optional

25
extra)
Piston (stroke reduction as optional extra) 31
20
Piston nut
32
Cushioning sleeve
Piston rod
33
Disc
Cushioning sleeve
34
Cushioning pin
10
Cylinder
35
Threaded bushing
12
Piston
60
Retaining washer
13
Piston rod bearing
65
Allen head screw
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MJFCIFSS
Hex head screw

Circlip
Screw
Service Manual
Hydraulic cylinder
Description
15
Fig. 3
2.1
Radial seal ring
Sealing elements at the piston 12 and the piston rod bearing 13
9
12
Cushioning sleeve
Piston
125
126
Backing ring
Piston guide ring
13
25
Piston rod bearing

Ring
131
132
Guide ring
Backing ring
91
O-ring
133
O-ring
92
121
Seal ring
Piston guide ring
134
135
Scraper ring
O-ring
122
Turcon-Glyd ring
136
Rimseal ring (secondary protection)
123
O-ring
137
O-ring
124
O-ring
138
Turcon Stepseal (primary protection)
Cylinder variants, see Fig. 17 / Fig. 18

The uncushioned hydraulic cylinder (type I) is used mainly with supports and with certain (less frequently used) cylinders for working attachments such as grapple and regulating cylinders, etc. and
for on-road travel.
Cushioned hydraulic cylinders can be equipped with one-side and two-side end-of-travel cushioning.
See type II (one-side) and/or type III and type IV (two-side).
Depending on the application, cylinders might be used in conjunction with stroke reduction. The stro-
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MJFCIFSS
7.30.3
Hydraulic cylinder
Service Manual
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
3.1.1
One-side end-of-travel cushioning

Extending piston rod 8
The hydraulic oil coming from the control valve block flows through the piston-side connection of the
cylinder 10 and acts on the piston 12. The piston rod is driven out and displaces the oil on the rod
side back through the control valve block to the tank.
Shortly before the end of the stroke is reached, the cushioning sleeve 9 is inserted into the cushioning
bore of the piston rod bearing 13.
When the cushioning sleeve 9 is introduced into the bore, the flow cross-section of the displaced oil
is reduced. The oil is fed from the hydraulic cylinder back to the control valve block. This happens
with the help of three splines sitting around the circumference of the sleeve 9.
The extending motion of the piston rod is slowed down, i.e. cushioned, thanks to the strong restriction
of the return oil flow.
3.1.2
Retracting piston rod 8

The hydraulic oil coming from the control valve block flows through the connection into piston rod bearing 13 and pushes against the front face of the cushioning sleeve 9 through the ring gap between
the cushioning sleeve 9 and the piston rod 8 and/or the piston rod bearing 13. Through the radial bores and the splines in the cushioning sleeve 9, the oil acts on the piston 12.
The piston rod retracts and displaces the oil on the piston side through the connection bore and the
control valve block back to the tank.
Fig. 4
7.30.4
Sectional drawing of the hydraulic cylinder
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Service Manual
Hydraulic cylinder
3.2
3.2.1
Two-side end-of-travel cushioning, see Fig. 5

Extending piston rod 8
The hydraulic oil coming from the control valve block flows through the connection into the piston side
of the cylinder and acts on the cushioning pin 31 and the piston 12 via the longitudinal slots.
The piston rod 8 is extended (see 3.1, page 4).
3.2.2
Retracting piston rod 8

The hydraulic oil coming from the control valve block flows through the connection into the piston rod
bearing 13 and acts on the front face of the cushioning sleeve 9 through the ring gap between the
cushioning sleeve 9 and the piston rod 8. The oil acts on the piston 12 through the radial bores and
splines in the cushioning sleeve 9.
The piston rod retracts and displaces the oil on the piston side back to the tank. Shortly before the
end of the stroke, the cushioning pin 31 is inserted into the base of the cylinder 10. When the cushioning sleeve 32 enters the cushioning bore, the flow cross-section of the displaced oil is reduced. The
oil flows through two longitudinal slots arranged along the circumference of the sleeve 32 and/or the
pin 34 from the hydraulic cylinder back to the control block.
The retracting motion of the piston rod is slowed down i.e. cushioned, thanks to the strong restriction
of the return oil flow.
Fig. 5
Partial section of end-of-travel cushioning device
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MJFCIFSS
7.30.5
Hydraulic cylinder
Service Manual
Removal and installation of hydraulic cylinders
4 Removal and installation of hydraulic cylinders

Caution!
The dismantling and installation of a cylinder requires lifting gear such as a crane and additional personnel.
When the cylinder is placed in its bearings, there is a risk of serious injury to hands and other limbs
that might become caught and crushed between the cylinder and other equipment parts. To prevent
accidents, the following precautionary measures must be taken:
Drive the vehicle onto level and firm ground. Place the attachments and the support on the
ground. Ensure that the cylinder is stopped in a suitable position for removal and installation.
Switch off the diesel engine. Relieve the hydraulic pressure from pressure lines. To do this,
switch on the ignition and the pilot control system and actuate the pilot control units several times
to the stop.
Relieve the preload of hydraulic tank by loosening the breather filter at the tank.
Secure the hydraulic cylinder by attaching it to lifting tackle. Secure other loose equipment, if necessary.
4.1
Dismantling
Disconnect the flange connections of the hydraulic hoses. Collect the escaping oil in a suitable
container.
If necessary, unscrew and remove the connection block with the pressure line from the piston rod
bearing and the cylinder base.
Seal the lines and hoses with cover plates, screw caps, plugs etc.
Sealing work on the machine

Release and drive out the bearing pin connecting the piston rod eye to the equipment. Pull out
stuck bolts using a special removal tool.
Complete dismantling
Release and drive out both bearing pins from the piston rod and the cylinder tube. Pull out stuck
bolts using a special removal tool.
4.2
Installation
Using lifting tackle, place the hydraulic cylinder into the bearing block so that the bearing bores in
the cylinder base and in the attachment component are aligned to each other.
Slightly grease the bearing pin and drive/pull it in.
Secure both bearing pins.
Bleed hydraulic cylinder, see 4.3.
Move the attachments / support to check their functions and tightness of the cylinder and the hydraulic connections.
7.30.6
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Service Manual
Hydraulic cylinder
Removal and installation of hydraulic cylinders
4.3
4.3.1
Bleeding cylinder after repair

Bleeding cylinder without bleeder bores
Caution!
After a repair of the cylinder, there is air trapped in the closed chamber. In connection with oil and
high pressure, this could result in explosive ignition ("diesel effect").
This poses a serious risk to persons and property. Therefore complete the following steps:
When bleeding the cylinder, never extend/retract it to the stop (to prevent maximum pressure
build-up).
When connecting the pressure lines and tightening the screw connections, ensure that they are
air-tight.
To accomplish this, connect the hose on the piston side. Completely extend cylinder slowly and
carefully, at low idle rpm, so that the air on the rod side can escape completely from the cylinder.
Collect escaping oil in a suitable container.
When the cylinder is fully retracted, connect the line to the piston rod.
Extend and retract the cylinder several times slowly and carefully, at low idle rpm, so that the remaining air in the cylinder can escape towards the tank.
Re-tighten all the lines. Check the screw connections of the flanges for correct torque.
4.3.2
Bleeding of cylinders with integrated bleeder plug, see Fig. 6

Caution!
The cylinder is under pressure.
When you loosen and unscrew the plug 11, it is possible that residual pressure in the line pushes
out the plug with great force, which can result in serious injury.
Therefore carefully loosen the plug and release the oil pressure (collect oil in suitable container).
Unscrew the plug 11. (New versions of this design have separate bleeder valves to which an oil
discharge hose can be connected.)
Insert a mini measuring connection with an oil discharge hose into the bleeder bore and keep a
suitable collecting container ready.
Completely extend the cylinder slowly and carefully at low idle rpm.
A mixture of air and oil escapes through the hose into the container.
Remove the mini measuring connection.
Be sure to properly replace plug after bleeding (torque: 40 Nm).
Fig. 6
Bleeder screw at the hydraulic cylinder
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MJFCIFSS
7.30.7
Hydraulic cylinder
Service Manual
Replacing seals
5 Replacing seals
Fig. 7
5.1
Partial section of the hydraulic cylinder
Piston nut
33
Disc
8
9
Piston rod
Cushioning sleeve
121
122
Piston guide ring

Turcon-Glyd ring
12
13
Piston
Piston rod bearing
123
124
O-ring
O-ring
20
Hex head screw
125
Backing ring
25
Snap ring
126
Piston guide ring
Dismantling
Note!
To disassemble and assemble the piston nut 4 and the piston 12, you need great force. Inadvertent
rotation of the piston rod 8 can lead to damage to the chromium surface finish. To prevent this, complete the following steps:
Lock the piston rod 8 using a suitable clamping or anti-torsion device.
Avoid damaging the surface of the piston rod.
Unscrew the hex head screw 20 with washer 33. Pull the piston rod bearing 13 together with the
piston rod 8 and the piston 12 from the cylinder.
Place the piston rod on a suitable and clean surface to prevent damage.
Remove the piston guide rings 121.
Remove the snap ring 25. Unscrew the piston nut 4 (if any).
Attach a piston spanner and other special tools (see group 2.05) to the piston 12 . Remove the
piston from the piston rod 8.
Hydraulic cylinders with end-of-travel cushioning: Remove the cushioning sleeve 9.
Remove the piston rod bearing 13 from the piston rod 8.
Remove all sealing elements from the piston, the piston rod bearing and the cushioning system.
7.30.8
copyright by
MJFCIFSS
Service Manual
Hydraulic cylinder
Replacing seals
5.2
5.2.1
Assembly of sealing and guide elements on the piston

Installation in piston rod bearing
Carefully remove all dirt, dust, chips and other foreign matter from the parts.
Check all parts for suitability for reuse.
Parts that show damage to the piston rod such as dents and grooves must be replaced.
Treat the seal housings with Castrol-Tarp corrosion inhibitor (40g tube - ID no. 830005).
Apply a little oil to the O-ring 135 / 137 and insert it in the piston rod bearing 13. Apply a little oil
to the seal rings 136 and 138 and insert them into the piston rod bearing 13, see Fig. 10 and Fig.
11.
.
Note!
Ensure that the seal rings 136 and 138 are installed in the correct position and direction (see flow
direction of pressurised oil). Pay attention to the different features of the various seals:
Turcon - Rimseal 136 (dark grey or turquoise) secondary- flexible - like rubber
Turcon - Stepseal 138 (light grey) primary, see Fig. 10
Fig. 8
Pressing seal and scraper ring into kidney shape ring for assembly
13
135
Piston rod bearing

O-ring
137
138
136
Rimseal Ring (secondary protection)
O-ring
Turcon Stepseal (primary protection)
Press Stepseal / Rimseal into kidney shape, avoiding kinking.

Place the pressed Stepseal / Rimseal over the O-ring 135 / 137 and press it into the groove, in the
direction of the arrow, see Fig. 10.
Compress and place the scraper ring 134 in the same fashion and insert it in its correct position,
see Fig. 10.
5.2.2
Installing the piston rod bearing

Caution!
For certain piston guide designs, (see Fig. 9, page 10) use a mounting sleeve c (in the ET catalogue,
included with no. 960) for the installation of the piston guide bearing 13.
If this installation aid is not used, the sealing elements in the piston rod bearing 13 get damaged.
Screw the mounting sleeve c to the piston rod 8.
Slide the piston rod bearing 13 over the mounting sleeve c onto the piston rod 8.
Remove the mounting sleeve c.
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MJFCIFSS
7.30.9
Hydraulic cylinder
Service Manual
Replacing seals
Fig. 9
c
Mount the piston rod bearing using the mounting sleeve for special piston rod shapes
Mounting sleeve, see tools in group 2.01 / 8
2.12
13
Piston rod
Piston rod bearing
Slide the cushioning sleeve 9 (not required for hydraulic cylinders without end-of-travel cushioning) onto the piston rod 8.
7.30.10
copyright by
MJFCIFSS
Service Manual
Hydraulic cylinder
Replacing seals
Note!
Distinguishing features of the seal rings 136 / 138. The various shapes of the Rimseal 136 are
shown here in comparison to the Stepseal 138 ring (see Fig. 10).
Fig. 10
5.2.3
Distinguishing features of seal rings
136
Rimseal ring
Flange - inclined
138
Stepseal ring
Flange - straight
Colour
Rimseal
Stepseal
136 =>
138 =>
dark grey - polished or turquoise (new)

light grey - matt
Elasticity
Rimseal
Stepseal
136 =>
138 =>
flexible
rigid
Shape
Rimseal
Stepseal
136 =>
138 =>
flange inclined
flange straight
Mounting to piston
Note!
The Turcon-Glyd ring 122 must be expanded before mounting and then returned to its normal shape, as it can otherwise not be slid over the outer edge and into the groove.
To facilitate installation, we recommend to heat the Turcon-Glyd ring 122 in a water or oil bath
(approx. 60C).
Apply a little oil to the O-ring 125 and the Turcon-Glyd ring 122 and place them onto the piston 12,
using the mounting sleeve b and the expanding sleeve b (for special tools, see group 2.05).
After installation, return the Turcon-Glyd ring 122 to its original shape, using the piston tightening
strap.
Insert the first backing ring 125, the O-ring 124 and the second backing ring into the piston 12.
Apply Castrol Tarp to the internal piston chamber.
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MJFCIFSS
7.30.11
Hydraulic cylinder
Service Manual
Mounting of the cylinder after replacement of the seals
Fig. 11
Mounting of sealing and guide elements to the piston, using the mounting sleeve a and
expanding sleeve b
a
b
Mounting sleeve
Expanding sleeve
121
122
Piston guide ring

Turcon-Glyd ring
9
12
Cushioning sleeve
Piston
123
124
O-ring
O-ring
13
Piston rod bearing
125
Backing ring
6 Mounting of the cylinder after replacement of the seals

6.1
Mounting of the piston and the piston nut onto the piston rod
Carefully clean all contact and thread faces between the piston rod, the piston and the piston nut.
Apply a thin layer of Gleitmo 800 lubricant (ID no. 8300004) to both sides (see fuels and lubricants
group 1.50).
Note!
If components are mounted without having been treated with lubricant, the turning distance prescribed according to factory standard 4121 cannot be achieved.
As the parts tend to become jammed (seizing), it is also not possible to remove the component at a
later stage.
Apply Gleitmo 800 lubricant (ID no. 8300004) to all components.
Screw the piston 12 onto the piston rod 8.
Attach a piston wrench or special tool (see group 2.05) to the piston 12.
7.30.12
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MJFCIFSS
Service Manual
Hydraulic cylinder
Note!
Mount the piston and the piston nut following the instruction in the factory standard 4121 B in group
1.22.
The drawing number and the date of assembly are engraved on the cylinder. The factory standard
4121-095 is specified in the hydraulic cylinder list, see group 7.31 7.37. This information is engraved on all newly manufactured pistons.
Tighten the piston 12 to the piston rod 8 according to the installation instructions, see group 1.22.
Remove the piston wrench.
Screw the piston nut 4 onto the piston rod 8.
Tighten the piston nut 4 to the piston rod, using a suitable piston nut wrench and following the installation instructions, see group 1.22.
Remove the piston nut wrench.
Secure the piston nut 4 with a snap ring 25 (drill new hole, if necessary).
6.2
Mounting the cushioning sleeve 32

Cylinder with two-side end-of-travel cushioning, see Fig. 12
Clean the thread of the screw 31 (remove all grease).
Apply Loctite no. 270 to the thread of the screw 31. Apply Gleitmo 800 to the shank.
Secure the sleeve 32 with the screw 31 to the piston rod 8 (torque: 130 Nm).
Fig. 12
Mounting the piston-side cushioning sleeve
Piston rod
121
Piston guide ring
31
32
Screw
Cushioning sleeve
126
Piston guide ring
copyright by
MJFCIFSS
7.30.13
Hydraulic cylinder
Service Manual
6.3
Mounting the piston rod in the cylinder tube

Place the inside piston guide straps 121 (hard) and the outside straps 126 (soft) on the piston 12.
Note:
For perfect piston assembly, we offer special calibrating sleeves (mounting sleeves, see group
2.05, 2.12 for a number of piston sizes.
Place the piston tightening strap and/or the mounting sleeve on the piston 12. Gently tighten the
guide rings 121 and 126 to the piston.
Push the piston rod 8 (complete with piston 12) carefully into the cylinder 10.
Remove the piston tightening strap and/or mounting sleeve.
6.4
Mounting the piston rod bearing 8 (plug-in type)
Fig. 13
Installation of piston rod bearing
10
13
Cylinder tube
Piston rod bearing
33
132
Disc
Backing ring
20
Screw
133
O-ring
Mount the slightly oiled O-ring 133 and the backing ring 132. Observe the installation position of the
backing 132 and the O-ring 133 (concave).
Push the piston rod bearing 13 into the cylinder 10. Observe the positions of the hydraulic connections.
Screw in the hex head screw or socket screw 20 (with washer 33, if any).
6.5
Mounting the piston rod bearing 8 (screw-in type)

Attach the assembly wrench (special tool group 2.12) to the piston rod bearing 13.
Note!
Mount the piston and the piston nut following the instruction in the factory standard 4122 B in group
1.22.
The factory standard 4122-017 is specified in the hydraulic cylinder list, see group 7.34 7.36. This
information is engraved on all newly manufactured pistons.
Tighten the piston rod bearing13 in the cylinder tube 10, following the instructions, see group
1.24.
7.30.14
copyright by
MJFCIFSS
Service Manual
Hydraulic cylinder
Piston rod bearing types
Fig. 14
8
10
Assembly wrenches for screw-type piston rod bearings
13
Piston rod
Cylinder tube
Piston rod bearing
7 Piston rod bearing types
Fig. 15
Piston rod bearing types
Piston rod bearing 13, plug-in type
Piston rod bearing 13, screw-in type
copyright by
MJFCIFSS
7.30.15
Hydraulic cylinder
Service Manual
Piston types on hydraulic cylinders
8 Piston types on hydraulic cylinders
Fig. 16
7.30.16
Piston types 12
Piston 12 secured with piston nut
Piston 12 with integrated piston nut
copyright by
MJFCIFSS
Service Manual
Hydraulic cylinder
End-of-travel cushioning
9 End-of-travel cushioning
Fig. 17
Options for end-of-travel cushioning and stroke reduction
Option I
Option II

one-side end-of-travel cushioning
Option III
two-side end-of-travel cushioning

(old)
Option IV
two-side end-of-travel cushioning

(new)
Cushioning sleeve
34
Cushioning pin
31
Screw
35
Threaded bushing
copyright by
MJFCIFSS
7.30.17
Hydraulic cylinder
Service Manual
Stroke reduction
32
10
Cushioning sleeve
Stroke reduction
Fig. 18
7.30.18
Cylinder with stroke reduction
Option G
Stroke reduction with sleeve 2
Option H
Stroke reduction with piston 3
copyright by
MJFCIFSS
Service Manual
Hydraulic cylinder
Hydraulic cylinder
Drawing no.
Installed as
Stroke
eff.
Fitting
length
(in equipment)
(mm)
(mm)
(mm)
(mm)
WN 4121
No.
Boom cylinder at
29 441 1047
adjustable attachment
100
70
895
1410
091
29 441 1047
Gooseneck boom
100
70
875
1430
091
Stick cylinder at
29 748 1000
110
75
1050
1590
091
29 748 1000
Gooseneck boom
110
75
1050
1590
091
29 524 4049
Bucket cylinder
90
60
900
1340
073
140
80
700
1140
171
Regulating cylinder at
29 447 1040
hydraulic boom adjustment

grapple cylinder at
29 128 1000
clamshell grab
70
50
350
710
(*)
29 679 1040
Multiple tine grab
70
50
155
485
(*)
Support cylinder at
29 187 1000
outrigger support
120
70
455
855
091
29 530 1049
Blade support
90
50
205
515
075
29 530 2049
Blade support
90
50
205
515
075
Boom, horizontally adjus29 513 5000
Adjustable attachment
110
60
640
1040
091
29 513 5000
Gooseneck boom
110
60
640
1040
091
Diameter of piston
Piston rod diameter
Working tolerance of hydraulic cylinder:

H8
at cylinder diameter
f7
at piston rod diameter
with stroke reduction
Factory standard no. 4121 / see also page 7.30.09
Simple piston installation, see also page 7.30.09
copyright by
MJFCIFSS
7.34.1
Hydraulic cylinder
7.34.2
Service Manual
copyright by
MJFCIFSS
Service Manual
Hydraulic cylinder
Hydraulic cylinder
Drawing no.
Installed as
Stroke
eff.
Fitting
length
(in equipment)
(mm)
(mm)
(mm)
(mm)
WN 4121
No.
Boom cylinder at
29 443 1040
110
70
895
1410
091
29 443 1048
Gooseneck boom
110
70
895
1410
091
29 441 1049
Gooseneck boom
100
70
895
1410
091
Stick cylinder at
29 761 1000
Adjustable attachment
115
75
1050
1590
091
29 761 2000
Gooseneck boom
115
75
1050
1590
091
29 523 1049
Gooseneck boom
110
70
1050
1565
091
29 524 1049
Bucket cylinder
90
60
900
1340
073
29 524 4049
Bucket cylinder
90
60
900
1340
073
140
80
700
1140
171
29 447 1049

Grapple cylinder at
29 128 1000
clamshell grab
70
50
350
710
(*)
29 679 1040
Multiple tine grab
70
50
155
485
(*)
Support cylinder at
29 187 1000
outrigger support
120
70
455
855
091
29 530 1049
Blade support
90
50
205
515
075
29 530 2049
Blade support
90
50
205
515
075
Diameter of piston
Piston rod diameter

H8
f7
copyright by
MJFCIFSS
7.35.1
Hydraulic cylinder
7.35.2
Service Manual
copyright by
MJFCIFSS
Service Manual
Hydraulic cylinder
Hydraulic cylinder
Drawing no.
Installed as
Stroke
eff.
Fitting
length
(in equipment)
(mm)
(mm)
(mm)
(mm)
WN 4121
No.
Boom cylinder at
29 680 1048
120
70
895
1420
091
29 615 1040
Industrial gooseneck boom
120
70
895
1420
091
Stick cylinder at
29 497 1040
adjustable and gooseneck
120
80
970
1500
121
29 749 1000
adjustable and gooseneck
120
80
970
1515
112
29 443 1040
Industrial gooseneck boom
110
70
895
1410
091
29 441 7040
Bucket cylinder
100
70
895
1410
091
140
80
700
1140
171
29 447 1040

Grapple cylinder at
29 128 1000
clamshell grab
70
50
350
710
(*)
29 679 1040
Multiple tine grab
70
50
155
485
(*)
Support cylinder at
29 187 1000
outrigger support
120
70
455
855
091
29 530 1049
Blade support
90
50
205
515
075
29 530 2049
Blade support
90
50
205
515
075
Diameter of piston
Piston rod diameter

H8
f7
copyright by
MJFCIFSS
7.36.1
Hydraulic cylinder
7.36.2
Service Manual
copyright by
MJFCIFSS
Service Manual

Function

1 Function
The control oil unit generates the servo pressure for the pilot control and the regulating pressures for
the working pumps.
It also generates the control pressures for the actuation of the oscillating axle support and the multidisc brake of the slewing gear.
Fig. 1
Control oil unit
copyright by
MJFCIFSS
7.40.1
Service Manual
Design
2 Design
The control oil unit 50 consists of a housing block with integrated oil channels and screwed-in valves.
The pressure-relief valve 51 is screwed into the front part of this block. the measuring point 49 for the
control pressure is also accessible from the front.
The solenoid valves Y3, Y24 and Y371 are inserted from the top into the unit. The pressure accumulator 54 is mounted at the top of the unit and secured with screws. The pressure filter 52 is screwed
in from the base. The control oil block also features an integrated check valve 53.
To the side of the unit 50, the proportional solenoid valves Y50 and Y51 are flange-mounted to the
control oil unit and are connected hydraulically.
Up to the change in the series (from serial no. 27110/27112, see below), a switching solenoid valve
Y330 is flange-mounted to the solenoid valve Y51 and hydraulically connected.
Fig. 2
49
7.40.2
Control oil unit with control and regulating valves, pressure-reduction valve, pressure accumulator and measuring point
50
Measuring point for control pres- Y3

sure
Y24
51
52
Pressure filter
Y50
Y51
53
Check valve
Y330 Solenoid valve / reset pump P2

(to serial no. 27109/27111,
see also service information 07-11-37/2005)
54
Accumulator

Solenoid valve / creeper gear switching
Proportional solenoid valve / LS control
copyright by
MJFCIFSS
Service Manual

3.1
Generation of servo pressure

The control oil unit is supplied with oil via the connection P from the gear pump / pilot control system.
The unit contains a pressure relief valve 51 of the cartridge type that is screwed into the unit. It limits
the control pressure to a certain value (see adjustment protocols, group 6).
The oil flows through the filter 52 and the check valve 53 to the accumulator 54.
The accumulator 54 allows for a small number of control operations - after the diesel engine has been
switched off or when the gear pump fails.
The connection P1 in the circuit is located behind the filter 52. It provides control pressure to the regulating unit of the working pumps.
3.2
Function of switching solenoid valves

Through internal pressure channels in the control oil unit, the pressure oil also acts on the switching
solenoid valves Y3, Y24 and Y371.
The flange-mounted switching solenoid valve Y330 is connected through the connection PHD to the
high-pressure line (from the pump P1) of the control block.
When switched, the solenoid valves Y3, Y24 and Y371 provide control pressure to the outlets A1, A2
and A3. In neutral position, the outlets are connected to the tank.
Through the connection A1, the solenoid valve Y3 releases control pressure to the pilot control units.
Through connection A2, the solenoid valve Y24 acts on the circuit for the control for creeper gear
switching.
Through the connection A3, the solenoid valve Y371 controls the oscillating axle support.
Through the connection A4, the solenoid valve Y330 controls the reset of the pump during travel
(omitted from serial no. 27110/27112).
3.3
Function of the proportional solenoid valves Y50 / Y51

The proportional solenoid valves Y50 and Y51 are pressurised through internal pressure channels in
the control oil unit.
The proportional solenoid valves for power control or flow limitation in the working pumps of the control oil unit are used to build up a pressure at their output, which is determined by the actual solenoid
current.
The outlet "LR" of the solenoid valve Y50 is connected to the connection "X3", which is the pressure
connection to the spool of the working pumps.
The proportional solenoid valve Y51 regulates the control pressure LS, which determines the limitation of the pivot angle of the working pump P1. This pressure also acts on the connection X1 of the
pump regulator and reduces the spool stroke through opposed piston of the pump P1. This results in
a reduction of the maximum pump flow rate.
copyright by
MJFCIFSS
7.40.3
Service Manual
Characteristics of the proportional solenoid valves Y50 and Y51
Fig. 3
Regulating diagram for Y50 / Y51
The regulation characteristic illustrates the interrelation between the input current (I) of the regulating
solenoids and the regulating pressure (p) at outlets LR or LS.
The effect of the pressures p at the outlet LR or p at the outlet LS on the power settings and/or the
limitation of the pivot angle of the respective working pumps is described in group 7.
The regulation characteristic of a proportional solenoid valve can be checked by measuring a few
pressure values at the outlet LR (or LS respectively) and comparing them with the solenoid current
Y50 or Y51).
7.40.4
copyright by
MJFCIFSS
Service Manual

Emergency position of the proportional solenoid valve Y50
4 Emergency position of the proportional solenoid valve Y50

In order to prevent that the control current affects the system when operated in emergency position,
disconnect the plug 1 to the proportional solenoid valve Y50.
By removing the cotter pin 2 and tilting the lever 3 into a horizontal position, the solenoid valve Y50
can be brought into a pre-defined emergency position.
4.1
Adjustment of the emergency position

Set the regulating pressure to the desired fixed value by proceeding as follows:
Connect pressure sensor to the measuring point 59.
While the engine is running and the lever 3 is in a horizontal position, remove the lock nut 5 and
turn the adjusting screw 4 until the desired pressure is obtained.
Re-tighten the locknut 5, holding the adjusting screw 4 in its position and re-check the pressure
settings.
Fig. 4
5
Normal position a and emergency position b of the regulating solenoid valve Y50
1
2
Adapter
Cotter pin
5
50
Lock nut
Control oil unit
Lever
Y50
Proportional solenoid valve / performance control
Adjusting nut
Y51
copyright by
MJFCIFSS
7.40.5
Service Manual
Emergency position of the proportional solenoid valve Y50
7.40.6
copyright by
MJFCIFSS
Service Manual

Purpose

1 Purpose
The control oil and regulation unit generates the servo pressure for the pilot control and the regulating
pressures for the working pumps.
This unit also provides the control pressures for the operation of the oscillating axle support and the
creeper gear system of the regulating travel motor (in wheel machines)
and for the operation of the multi-disc brake of the slewing gear or the fast travel gear respectively of
the regulating travel motors (in track machines)
Fig. 1
copyright by
MJFCIFSS
7.42.1
Service Manual
Description
2 Description
The control oil unit 50 consists primarily of an aluminium block. At its front, it is equipped with a pressure relief valve 51 of the cartridge type that is screwed into the block.
At the top of the unit, the solenoid valves Y3, Y7 and Y66 are integrated into the block. The measuring
points 49, 57, 59 and the accumulator are also secured with screw connections to the top of the unit.
At its base of the block, the proportional solenoid valves Y50 and Y51 and the pressure filter 52 are
screwed in. The control oil block also features an integrated check valve 53.
2.1

The stationary measuring points 49, 57 and 59 are designed to measure the pressures in the control
oil unit.
Measuring point 49
At this point, the current pilot pressure of the entire pilot control system is measured. See instructions
on checking pressures in main group 6.
Measuring point 57
At this point, the control pressure for p-reduction, which is generated by the solenoid valve Y51 is
measured. See flow reduction in group 16.20.
Measuring point 59
The control pressure for the power regulation generated by the solenoid valve Y50 is measured here,
see also the basic values and power adjustments in the groups "Adjusting protocols" 6. and
"Pump description" 7.05.
7.42.2
copyright by
MJFCIFSS
Service Manual

Description
Fig. 2
Control oil unit with control and regulating valves, pressure-reduction valve, pressure accumulator and measuring points
49
50
Measuring point for control pressure

57
59
Measuring point ( p reduction)

Measuring point (power control)
51
52
Pressure filter
Y3
Y7

Solenoid valve / slewing gear brake (track
machines only)
53
Check valve
Y24
Solenoid valve / creeper gear clutch

(wheel machines only)
Solenoid valve / fast travel clutch (track
machines only)
54
Accumulator
Y50
55
56
Dummy plate
Dummy plate
Y51 Proportional solenoid valve / LS control

(wheel machines only)
copyright by
MJFCIFSS
7.42.3
Service Manual
3.1
Generation of servo pressure

The control oil unit is fed via connection P with the flow from the gear pump. The unit contains a pressure relief valve 51 of the cartridge type that is screwed into the unit. It limits the control pressure to
a certain value (see adjustment protocol).
The oil flows through the filter 52 and the check valve 53 to the accumulator 54. The accumulator 54
allows for a limited number of control operations after the diesel engine is switched off, or in the event
of a gear pump failure.
The connection P1 is located after the filter 52 . It provides control pressure to the regulating unit of
the working pumps.
3.2
Function of switching solenoid valves

Through pressure channels in the control oil unit, the pressure oil acts also on the switching solenoid
valves Y3, Y7 and Y66 and on the regulating solenoid valves Y50 and Y51.
When engaged, the solenoid valves Y3, Y24 and Y7 provide control pressure to the outlets A1, A2
and A3. In neutral position, the outlets are connected to the tank.
Through the connection A1, the solenoid valve Y3 releases control pressure to the pilot control units.
Through connection A2, the solenoid valve Y24 acts on the circuit for the control of the creeper
speed.
The solenoid valve Y7 / Y371 controls the multi-disc brake in the slewing gear or oscillating axle support through the outletA3.
3.3
Proportional solenoid valves Y50 / Y51

The proportional solenoid valves for power control or flow limitation in the working pumps of the control oil unit are used to build up a pressure at their output, which is determined by the actual solenoid
current.
The outlet LR of the solenoid valve Y50 is connected to the connection GLR, which is the pressure connection for the power control of the working pumps.
The proportional solenoid valve Y51 regulates the control pressure p(LS), which determines the limitation of the pivot angle of the working pump. This pressure line is also linked to the connection pst
of the pump regulator. Through the LS regulator, it reduces the pre-set pLS ( p reduction) and,
thus, limits the maximum pump flow. This pressure is therefore referred to in the other groups of this
manual as p ( Pred).
7.42.4
copyright by
MJFCIFSS
Service Manual

Characteristics of the proportional solenoid valves Y50 and Y51
4 Characteristics of the proportional solenoid valves Y50 and Y51
Fig. 3
Regulation diagram
a = Y50 (A 900 C); Y51 (A 900 C / A 904 C)

b = Y50 (A 904 C)
The regulation characteristics illustrate the interrelation between input current (I) of the regulating solenoid valves and the regulating pressure (p) at the outlets LR or LS respectively.
The effect of the pressures p (GLR) at outlet LR or p ( Pred) at outlet LS on the power settings and/
or the limitation of the pivot angle of the respective working pumps is described in group 7.
The regulation characteristics of a proportional solenoid valve can be checked by measuring a number of pressure values at outlet LR (or LS) relative to the solenoid current ILR in Y50
(or Iev in Y51).
The measurement and subsequent adjustment of the currents ILR and IEV to fixed values can be
completed with sufficient accuracy by means of the display menus (see group 8.71).
copyright by
MJFCIFSS
7.42.5
Service Manual
Emergency position of the proportional solenoid valves Y50 / Y51
5 Emergency position of the proportional solenoid valves Y50 / Y51

By removing the pin 2 and tilting the lever 3 into a horizontal position, the solenoid valves Y50 and
Y51 can be brought into a pre-defined emergency position.
During operation in emergency position, the connection plug 1 at the proportional solenoid valve must
be unplugged in order to prevent interference by the control current.
5.1
Adjustment of the emergency position

Set the regulating pressure to the desired fixed value by proceeding as follows:
Connect a pressure sensor to the measuring point 59 or 57.
While the engine is running and the lever 3 is in a horizontal position, remove the lock nut 5 and
turn the adjusting screw 4 until the desired pressure is obtained.
Re-tighten the lock nut 5, holding the adjusting screw 4 in its position and re-check the pressure
settings.
Fig. 4
7.42.6
Emergency position of the regulating solenoid valves Y50 and Y51
1
2
Adapter
Cotter pin
57
59
Measuring point (rp reduction)

Measuring point (power control)
3
4
Lever
Adjusting nut
Y50
Lock nut
Y51
Proportional solenoid valve / LS control
copyright by
MJFCIFSS
Service Manual

Design

1 Design
The two pilot control valves with joystick, (to the left and right of the operator's seat) control the working functions of lifting, stick movements, bucket cylinder movements and turning of the uppercarriage.
There are four regulating pistons 12 (pressure control valves) inserted in an axial position in the housing 10, complete with pressure, return and control connections. The regulating piston 12 is operated
by means of the joystick 1 with universal joint 16 and the switching disc 18.
The joystick 1 can be moved freely in any direction. With each movement, it presses against one or
several spring-loaded pushrods, which then switch the disc 18 attached to the joystick. The regulating
piston 12 located under the disc is operated by means of the regulating spring (see Fig. 4) and the
reset spring (see Fig. 4), so that a connection is established from the pressure channel P to the outlet
1 / 2 / 3 / 4.
The bellows 31 protects universal joint, pushrods, guide bushing etc. against dirt.
Fig. 1
Diagram of the pilot control unit with joystick and other components
Joystick
16
Universal joint
10
Housing / pilot control unit
18
Switching disc
12
Regulating piston
31
Bellows
copyright by
MJFCIFSS
7.45.1
Service Manual
see Fig. 4
The pilot control valve is of the pressure regulating type. That means, regulating piston 12 of the pilot
control valve builds up pressure on the discharge side, between pilot control valve and control valve
block, and is, thus, shifted, against the pressure from pressure spring 25.
When the joystick 1 is moved, the switching disc 18 pushes the pushrod 98.1 down, and the regulating spring 25 shifts the regulating piston 12. The control oil flows through the radial and axial boreholes in the regulating piston 12 from the pressure channel P through connection 1 or 2 , and from
the control line to one of the control connections at the control valve block.
As the spools in the control valve block are pressurised, a set pressure that is proportional to the predefined lever travel (see Fig. 2) is built up. The pressure acts on the face of the regulating piston 12
and shifts it against the regulating spring 25 until the connection with channel P is blocked.
Depending on the position of the joystick 1 and the stroke travel of the pushrod 98.1, a preset pilot
pressure is established, which shifts the spool 12 proportionally to the pressure increase. At a set
pressure (corresponding to the end of the fine-control phase of the spool), the pushrod 98.1 moves
the regulating piston 12 downwards. At this point, maximum control pressure is applied to the spool.
3 Repairs
3.1
Dismantling of the regulating unit

Pull up the bellows 31.
Loosen the locknut 21. Remove the sleeve 20 with the joystick components 1 / 2.
Remove the nut 17 and the switch disc 18. Remove the universal joint 16 from the housing 10.
Remove the protective covers 98.5 and the lid 32. Pull the pushrod 98.1 complete with the bushing
98.2 from the housing 10.
Press the pushrod 98.1 out of the bushing 98.2.
Remove the O-ring 98.4 and the PDF seal 98.3 from the bushing 98.2.
Press the regulating piston 12 with the pressure springs 25 and 28 as well as the spring plate 15
with disc 23 from the plate 10, pushing it upwards.
Remove the disc 23* from the spring plate 15 .
Pull out the regulating piston 12. Remove the pressure spring 25 with the washers 49 / 50.
3.2
Assembly of the regulating unit

Prior to assembling the unit, clean all parts and check whether they are fit for re-use.
49 / 50
25
15
12
Mount the disc 23* .

Insert the spring plate 15 with the preassembled regulating piston 12 and the pressure spring 25
into the housing 10 and the bushing 13.
Insert a new O-ring 98.4 and PDF seal 98.3 into the bushing 98.2.
Insert the pushrod 98.1 and install the bushing 98.2 with the pushrod 98.1 into the housing 10.
7.45.2
copyright by
MJFCIFSS
Service Manual

Repairs
Replace the lid 32 and the protective cover 98.5. Screw in the universal joint 16 (torque: 20 Nm).
Screw in the switch disc 18 complete with the nut 17. Adjust pilot control unit to zero position.
Screw the sleeve 20 with the joystick 1 into the nut 17 and then tighten the nut 21, ensuring that
the joystick 1 is in the correct position.
Pull the bellows 31 down over disc 30.
* New model II does not contain disc 23, see Fig. 3.
3.3
Pilot control valve adjustment in zero position, see Fig. 4

The switch disc 18 and the pushrod 98.1 must be set and installed in such a way that there is no play
between them when the pilot control valve is not actuated.
To adjust: loosen the nut 17. Turn the switch disc 18 until all four pushrods are in zero position, and
there is no more play between switch disc 18. and the four pushrods 98.1. When finished, re-tighten
nut 17.
Fig. 2
Diagram: c = control pressure in bar, d = lever displacement in angular degrees
Built into the machine

A 309 - R 317
copyright by
MJFCIFSS
Point a
Point b
5.8 -0.3 bar
24.3 bar
7.45.3
Service Manual
Exploded view
4 Exploded view
7.45.4
Fig. 3
Pilot control valve model I until May 2004, model II from June 2004
10
12
Housing
Regulating piston
98.2
98.3
Bushing
PDF seal
13
15
Bushing (press-fitted)
Spring plate
98.4
98.5
O-ring
Protective cap
16
17
Universal joint
Hex nut
140
150
Plate
Bellows
18
Switching disc
160
Sleeve
23
25
Disc
166
171
Nut
Handle section
28
Pressure spring (return spring)
172
Handle section
30
Plate
173
Sensor surface
32
Cover
177
Dummy cap
49
Washer
192
Wire harness
50
Washer
80
Wire grommet
S5L/S5R button / grapple rotator
81
Bushing
S63
98
Repair kit
S263
98.1
Pushrod
S382
copyright by
MJFCIFSS
Switch / travel direction
Service Manual

Sectional drawing
5 Sectional drawing
Fig. 4
Sectional drawing of the pilot control unit
copyright by
MJFCIFSS
7.45.5
Service Manual
Sectional drawing
7.45.6
140
142
Plate
Retaining washer
B19R* Sensor transducer / right

B19L* Sensor transducer / left
144
146
Spacer sleeve
Allen head screw
S5R*
S5L*
150
Bellows
160
166
Sleeve
Hex head screw
S263* Switch / travel direction

S382* Switch / fine adjustment (A 312 - R 317)
170
171
Handle
Handle section
X15-2* Plug connection, 2-pin

X80*
Plug connection, 3-pin
172
173
Handle section
Sensor surface
X81*
X342* Plug connection / 3-pin
177
Dummy cap
X909* Plug connection, 2-pin
Push button / turn grapple right

Push button / turn grapple left
190
Sheet metal screw
191
Allen head screw
192
193
Wire harness
Adapter

X1049 Plug connection, 3-pin
200
201
Sheet metal screw

Small parts kit
202
Pressure spring
copyright by
MJFCIFSS
Installation according to machine type

and serial number, see electrical system
of basic machine, group 8.
Service Manual

Sectional drawing
Fig. 5
Pilot control valve, right, with electrical components
Fig. 6
Pilot control valve, left, with electrical components
copyright by
MJFCIFSS
7.45.7
Service Manual
Sectional drawing
7.45.8
copyright by
MJFCIFSS
Service Manual

Description

1 Description
The travel gear operation is controlled by means of the pilot control unit with two pedals located in
front of the operator seat and integrated into the pedal plate/base of the operator's cab.
There are two regulating pistons 12 (pressure control valves) inserted in an axial position in the housing 10, complete with pressure, return and control connections. The regulating pistons 12 are operated by means of the pedal plate 2 that are equipped with the axle 24.
The two pedals plates 2 / 3 can be moved forward and backward, thus actuating a spring-loaded
pushrod via a threaded stud. This actuates the regulating piston 12 (with regulation spring and return
spring) located below the above assembly, which is now opened towards the pressure channel P,
outlet 1/2.
The unit is equipped with a cover protecting the pushrod, guide bushing etc. against dirt.
Fig. 1
Pilot control unit 2x for travel left/right with functional diagram
copyright by
MJFCIFSS
7.46.1
Service Manual
Description of functions
2 Description of functions
see Fig. 3 / Fig. 4
The pilot control unit is of the pressure regulating type. That means, regulating piston 12 of the pilot
control unit builds up pressure on the discharge side, between pilot control unit and control unit block,
and is, thus, shifted, against the pressure from pressure spring 25.
When the pedal plate 2 is pressed down, a threaded stud 2.3 pushes the pushrod 13 down, so that
the regulating spring 25 shifts the regulating piston 12. The control oil flows through the radial and
axial boreholes in the regulating piston 12 from the pressure channel P through connection 1 or 2,
see Fig. 4 and the control line to one of the control connections at the control valve block.
and shifts it against the regulating spring 25 until the connection with channel P is blocked.
Depending on the position of the pedal 2/3 and the stroke travel of the pushrod 13,a preset pilot pressure is established, which shifts the spool 12 proportionally to the pressure increase. At a set pressure (corresponding to the end of the fine-control phase of the spool 12), the pushrod 13 moves the
regulating piston downwards. At this point, maximum control pressure is applied to the spool 12.
There is a valve insert 20 (shuttle valve) in the housing 10 between the control connections. If the
pilot control unit is operated in such a way that control pressure is fed through a pressure connection
the control valve bloc, the control oil system pressurises the shuttle valve 20. The ball 45 in the valve
20 closes the connection to the other control line, so that the applied pressure is available at connection 7 for other control functions (connection 7 is temporarily closed).
3 Repairs
3.1

Release the disc 47.
Press out the axle 24 and remove the pedal plate 2.
Remove the protective covers 30 and the screws 46 and remove the retaining plate 29.
Pull the pushrod 13 with the bushing 14 from the housing 10.
Press the pushrod 13 out of the bushing 14.
Remove the O-ring 38 and the PDF seal 40 from the bushing 14.
Press the regulating piston 12 with the pressure springs 25 and 26 as well as the spring plate 15
with disc 23 from the plate 10, pushing it up from underneath.
Remove the disc 23 from the spring plate 15.
Pull the regulating piston 12 from the unit.
Remove the pressure spring 25 with the washers 49 / 50.
3.2
Assembly of the regulating unit

Place the washers 41 / 42, the pressure spring 25 and the spring plate 15 on the regulating piston
12. Mount the disc 23.
7.46.2
copyright by
MJFCIFSS
Service Manual

Repairs
Insert the spring plate 15 with the preassembled regulating piston 12 and the pressure spring 25
/ 26 into the housing 10 and the bushing 10.2.
Insert a new O-ring 38 and PDF seal 37 in the bushing 14.
Insert the pushrod 13 and install the bushing 14 with pushrod 13 in the housing 10.
Place the retaining plate 29 with the pedal 2 onto the unit and secure it with the screws 46.
Mount the protective covers 98.5.
Position the pedal 2 in the bearing, push in the axle 24 and spring-mount the disc 47.
Adjustment of pilot control unit
3.3
Adjustment of pilot control unit to zero position

The pilot control unit should be adjusted in such a way that the maximum control pressure can be
reached in the extreme position (stop), and the pedal can be operated in a comfortable and ergonomic position.
Remove the cover 2.2 from the pedal 2.1.
Loosen the lock nut 2.4 and turn the threaded stud 2.3 (see Fig. 1) until the pedals reach their new
neutral / limit positions and fulfil the above requirements.
Install a measuring point to measure the control pressure between the connection 1 / 2 and the
connection at the respective spool / control valve block.
After completed adjustment, tighten the lock nut 2.4 and replace the cover 2.2 on the pedal 2.1.
3.4
Check of shuttle valves 20

The valve insert 20 is secured with Loctite. Heat it and remove it from the housing, using an Allen
key. Be careful not to lose the ball 45.
Check valve for dirt and damage.
Install the ball 45. Insert the seal ring 40 and the valve insert 20. Apply Loctite 572 to the valve
insert and screw it in completely (torque: 10 Nm).
.
Fig. 2
Diagram: Control pressure relative to pedal travel

Diagram to the left: from start of series - diagram to the right: from serial no. 18915
copyright by
MJFCIFSS
7.46.3
Service Manual
Exploded view and sectional drawing
4 Exploded view and sectional drawing
7.46.4
Pilot control unit, complete
33
Screw plug
2
2.1
Pedal, complete
Pedal
36
37
Seal plug
PDF seal
2.2
Cover
38
O-ring
2.3
Threaded stud
40
Sealing ring
2.4
Hex nut
41
Washer
2.5
10R
Bushing
Housing right
42
45
Washer
Ball
10L
Housing left
46
Hex nut
10.2
12
Pressed-in bushing
Regulating piston
47
50
Disc
Screw plug
13
14
Pushrod
Bushing
51
Sealing ring
15
20
Spring plate
Valve insert
998
Repair kit, consisting of
23
Disc
998.1
Pushrod (item 13)
25
26

998.2
998.3
Bushing (item 14)

PDF seal (item 37)
29
30
Retaining plate
Cap
998.4
998.5
O-ring (item 38)

Protective cover (cap)
copyright by
MJFCIFSS
Service Manual

Fig. 3
Exploded view of the pilot control units for the right and left travel gear drives
copyright by
MJFCIFSS
7.46.5
Service Manual
7.46.6
33
Screw plug
2
2.1
Pedal, complete
Pedal
36
37
Seal plug
PDF seal
2.2
Cover
38
O-ring
2.3
Threaded stud
40
Sealing ring
2.4
Hex nut
41
Washer
2.5
10R
Bushing
Housing right
42
45
Washer
Ball
10L
10.2
Housing left
Pressed-in bushing
46
47
Hex nut
Disc
12
13
Regulating piston
Pushrod
50
51
Screw plug
Sealing ring
14
Bushing
15
20
Spring plate
Valve insert
998
Repair kit, consisting of
23
25
Disc
998.1
998.2
Pushrod (item 13)

Bushing (item 14)
26
998.3
PDF seal (item 37)
29
Retaining plate
998.4
O-ring (item 38)
30
Cap
998.5
Protective cover (cap)
copyright by
MJFCIFSS
Service Manual

Fig. 4
Sectional drawing of a pilot control unit for the travel gear
copyright by
MJFCIFSS
7.46.7
Service Manual
7.46.8
copyright by
MJFCIFSS
Service Manual

Design

for travel gear drive
5 Design
The travel gear operation is controlled by means of the pilot control unit with two pedals located in
front of the operator seat and integrated into the pedal plate/base of the operator's cab.
There are two regulating pistons 16 (pressure control valves) inserted in an axial position in the housing 3, complete with pressure, return and control connections. The regulating pistons 16 are operated by means of two pedals 20 / 25.
The two pedals 20 / 25 can be moved forward and backward, thus pushing the spring-loaded pushrod
8 with the switch disc 6 and the threaded stud 18. As a result, the regulating piston 16 is actuated by
the regulation spring 11.1 and the return spring 11.1, so that it is in open position (connection P - control connection 19).
The pushrod, guide bushing, etc. are protected against dirt with a bellows 5.
Fig. 5
Pilot control unit 4x 82 for travel left/right with functional diagram
copyright by
MJFCIFSS
7.46.11
Service Manual
see Fig. 8 / Fig. 9
The pilot control unit is of the pressure regulating type. That means, regulating piston 16 of the pilot
control unit builds up pressure on the discharge side, between pilot control unit and control valve
block, and is, thus, shifted, against the pressure from pressure springs 11.
When the pedal 20/25 is pressed down, a threaded stud 18 pushes the pushrod 8 down, and the regulating spring 25 shifts the regulating piston 16. The control oil flows through the radial and axial
boreholes in the regulating piston 16 from the pressure channel P through connection 1, 2, 3 or 4,
see Fig. 9 and the control line to one of the control connections at the control valve block.
and shifts it against the regulating spring 11.1 until the connection with channel P is blocked.
Depending on the position of the switch disc 5 and the stroke travel of the pushrod 8, a preset pilot
pressure is established, which shifts the spool 16 proportionally to the pressure increase. At a set
pressure (corresponding to the end of the fine-control phase of the spool), the pushrod 8 moves the
spool downwards. At this point, maximum control pressure is applied to the spool 12.
With each actuation of the pedal 20/25, the threaded stud 18 pushes the pushrod 12 down. Simultaneously, the control oil below the pushrod 12 (fed through the check valve 14) is pressurised and
flows through the nozzle 15 to the parallel-mounted pushrod 12. The restriction ensures that the control flow flowing off dampens the pedal movement.
The housing 3 of the pilot control units is equipped with the shuttle valves 17 mounted between the
control connections. If the pilot control unit is operated in such a way that control pressure is fed through a pressure connection the control valve block, the control oil system pressurises the shuttle
valve 17. The ball 45 in the valve 17 closes the connection to the other control line, so that the applied
pressure is available at connection 7 for other control functions (connection 7 is temporarily closed).
7 Repairs
7.1

Remove the screws 26 and fold the pedals 20 / 25 up.
Remove the screws 41 and remove the base 27 / 28 with the pedal 20 / 25.
Remove the bellows 5.
Note!
The regulating unit 10 and the pushrod 12 are preloaded by the spring.
When dismantling and mount the devices, work at a clean workplace and proceed with the necessary caution.
The regulating unit can only be ordered as a complete item.
Remove the threaded studs 7.4 and pull out the pins 7.2, using the M4 screw.
Loosen the screws 7.3 and remove the plate 7.
Pull the hollow rod 9 with the pushrod 8 from the housing 3.
Pull/push the regulating unit 10 with the spring set 11 from the housing 3.
7.46.12
copyright by
MJFCIFSS
Service Manual

Repairs
7.2
Installation of regulating unit

Push the regulating unit 10 with the spring set 11 into the housing 3.
Push the hollow rod 9 with the pushrod 8 into the housing 3.
Position the plate 7 and secure it with the screws 7.3.
Check the pushrod for free movement.
Insert the switch disc 6 into the bearing of the plate 7 and push in the pins 7.2.
Secure the pins 7.2 with the threaded studs 7.4.
Adjustment of pilot control unit, see 7.3
Place the base 27 / 28 together with the pedal 20 / 25 onto the switch disc 6 and secure it with the
screws 41 (with retaining washers 42).
Fold the pedal 20 / 25 down and screw in the screws 26, holding the pedal 20 / 25 in the desired
position.
7.3
Adjustment of pilot control unit to zero position

Remove the cover 2.2 from the pedal 2.1.
Loosen the lock nut 2.4 and turn the threaded stud 2.3 (see Fig. 5) until the pedals reach their new
neutral / limit positions and fulfil the above requirements.
Install a measuring point to measure the control pressure between the connection 1 / 2 and the
connection at the respective spool / control valve block.
After completed adjustment, tighten the lock nut 2.4 and replace the cover 2.2 on the pedal 2.1.
7.4
Check of shuttle valves 20

The valve insert 20 is secured with Loctite. Heat it and remove it from the housing, using an Allen
key. Be careful not to loose the ball 45.
Install the ball 45. Insert the seal ring 40 and the valve insert 20. Apply Loctite 572 to the valve
insert and screw it in completely (torque: 10 Nm).
.
Fig. 6
Diagram: Control pressure relative to pedal travel
copyright by
MJFCIFSS
7.46.13
Service Manual
8 Exploded view and sectional drawing
Fig. 7
7.46.14
Exploded view of pilot control unit operation
2
20

Left pedal
30
31
Pin
Washer
25
26
Right pedal
Allen head screw
32
41
Cotter pin
Allen head screw
27
Base
42
Retaining washer
28
Base
copyright by
MJFCIFSS
Service Manual

Fig. 8
Exploded view of pilot control unit
12
Pushrod
Bellows
13
Return spring
Switch disc
14
Check valve
7
7.1
Plate, complete
Bearing block
15
16
Nozzle set
Regulating piston
7.2
Allen head screw
17
Shuttle valve
7.3
Pin
18
Threaded stud
7.4
Threaded stud
8
9
Pushrod
Hollow rod
10
11
Regulating unit
Spring set
copyright by
MJFCIFSS
7.46.15
Service Manual
Fig. 9
7.46.16
Sectional drawing of the pilot control unit
Switch disc
7
7.1
Plate, complete
Bearing block
11.1
11.2
Regulation spring
Return spring
7.2
Allen head screw
12
Pushrod
7.3
Pin
13
Return spring
7.4
8
Threaded stud
Pushrod
15
16
Nozzle set
Regulating piston
9
10
Hollow rod
Regulating unit
17
18
Shuttle valve
Threaded stud
11
Spring set
19
Control connection
copyright by
MJFCIFSS
Service Manual

Description

1 Description
The two pilot control valves with foot pedals, in front of the operator's seat to the left, in the running
plate of the base of the operator's platform, control the operations of the accessory kit.
There are two regulating pistons 12 (pressure control valves), sitting in an axial position in
housing 1, complete with pressure, return and control connections. There are two pedals 2 and 3 on
top, to actuate regulating piston 12.
The two pedals 2 / 3 can be pressed down, and then actuate a spring-loaded pushrod via a threaded
stud. This actuates regulating piston 12 underneath (with regulation spring and return spring) and,
thus, opens it towards pressure channel P, outlet 1/2.
There is a cover to protect pushrod, guide bushing etc. against dirt.
Fig. 1
Pilot control valve 2 x with hydraulic diagram
copyright by
MJFCIFSS
7.47.1
Service Manual
see Fig. 3 / Fig. 4
When pedals 2 and/or 3 are actuated, threaded stud 47 presses pushrod 98.1 down and shifts regulating piston 12 via regulating spring 25. The radial and axial bores in regulating piston 12 let control
oil from pressure channel P enter into connection 1 or 2 (see Fig. 4) and the control line to flow to one
of the control connections on the additional axle of the control valve block.
Pressurising the spools in the control block will build up a certain pressure which is proportional to
the pre-defined displacement of the lever (see Fig. 2). The pressure acts on the face of regulating
piston 12 and shifts it against regulating spring 25 until the connection with channel P is interrupted.
Depending on how pedal 2/3 is positioned, and what the stroke of pushrod 98.1 is, there will be a
certain pilot pressure, which will shift the spool proportionally. At a certain pressure (which corresponds to the end of the fine control phase of the spool), pushrod 98.1 will move regulating piston 12
down directly. At this point, the spool will receive the max. control pressure.
1
3 Repair
3.1
Dismantling the regulating unit

Lift pedal 2 / 3
Remove protective covers 98.5. Remove screws 46. Remove bearing pillow block 10 complete
with pedals
2 / 3.
Pull pushrod 98.1 with bushing 98.2 from housing 1.
Press pushrod 98.1 out of bushing 98.2.
Remove O-ring 98.4 and PDF seal 98.3 from bushing 98.2.
Press regulating piston 12 complete out of bearing pillow block 10 (from below), complete with
pressure springs 25 and 26 and spring plate 15 with disc 23.
Remove disc 23 from spring plate 15.
Pull out regulating piston 12.
Remove pressure spring 25 with washers 49 / 50.
3.2
Installing the regulating unit

Before installation, be sure to clean all parts and check whether they are fit for re-use.
7.47.2
copyright by
MJFCIFSS
Service Manual

Repair
Place washers 49 / 50, pressure spring 25 and spring plate 15 on regulating piston 12. Place
disc 23.
Push spring plate 15 into housing 1 and bushing 16, complete with pre-installed regulating piston
12 and pressure spring 25 / 26.
Install new O-ring 98.4 and PDF seal 98.3 in bushing 98.2.
Insert pushrod 98.1. Install bushing 98.2 complete with pushrod 98.1 in housing 1.
Bearing pillow block 10 complete with pedals 2 / 3. Screw in screws 46.
Install protective covers 98.5.
Adjusting pilot control valve
3.3
Pilot control valve adjustment in zero position

The pilot control valve should be adjusted in such a way that the max. control pressure can be reached in the extreme position (stop), and pedals 2 / 3 can be operated in a comfortable and ergonomic
position.
To adjust: Loosen lock nut 48. Turn stud 47 (see Fig. 1) until the pedals reach their new neutral / end
positions and fulfil the conditions as mentioned above.
Install a measuring point to measure the control pressure between connection 1 / 2 and the connection at the spool / control valve block in question.
3.4
Checking shuttle valve 20

Valve insert 20 has been installed using Loctite. Heat, and remove completely from housing, using
an Allen key. Be careful with ball 45.
Install ball 45. Install seal 40. Apply Loctite 572 to valve insert 20 and screw in completely
(torque: 10 Nm).
.
Fig. 2
Diagram: c = control pressure in bar, d = Pushrod displacement in mm
A 309 - R 317 Litronic
copyright by
MJFCIFSS
Point a
Point b
5.8 -0.3 bar
24.3 bar
7.47.3
Service Manual
Exploded view
4 Exploded view
Fig. 3
7.47.4
Exploded drawing: pilot control valve
Housing
40
Seal ring
2
2.1
Pedal to the left

Bushing
41
42
Washer
Washer
Pedal to the right
45
Ball
3.1
10
Bushing
Bearing pillow block
46
47
Hex nut
Threaded stud
11
12
Pin
Regulating piston
48
50
Hex nut
Screw plug
13
15
Bushing (pressed in)

Spring plate
51
52
Seal ring
Snap ring
16
Bushing
98
Repair kit
20
Valve insert
98.1 Pushrod
23
25
Washer
98.2 Bushing
98.3 PDF seal
26
98.4 O-ring
33
Screw plug
98.5 Protective cover
copyright by
MJFCIFSS
Service Manual

Sectional drawing
5 Sectional drawing
Fig. 4
Sectional drawing
copyright by
MJFCIFSS
7.47.5
Service Manual
Sectional drawing
7.47.6
copyright by
MJFCIFSS
Service Manual

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
copyright by
MJFCIFSS
7.48.1
Service Manual
Upon actuation, lever 64 and tipping switch 3 act on threaded stud 18, which presses pushrod 98.1
down and, at the same time, shifts regulating 12 via regulating spring 25. The radial and axial bore in
regulating piston 12 lets control oil flow from pressure channel P via connection 1 or 2 and the control
line to one of the control connections of the control valve block.
Pressurising the spools in the control block will build up a certain pressure which is proportional to
the pre-defined displacement of the lever (see Fig. 2). The pressure acts on the face of regulating
piston 12 and shifts it against regulating spring 25 until the connection with channel P is interrupted.
3 Repair
3.1

Loosen hex nut 68. Unscrew lever 64 complete from tipping switch 3.
Remove bellows 66. Remove screws from connecting link 90. Remove connection link.
Remove threaded stud or Allen head screw 20.
This will release axle 24.
Press out axle 24. Lift and take out complete tipping switch 3.
Remove protective covers 98.5.
Remove Allen head screw 21.
Lift and take out cover plate 29.
Pull pushrod 98.1 with bushing 98.2 from housing 70.
Press pushrod 98.1 out of bushing 98.2.
Remove O-ring 98.4 and PDF seal 98.3 from bushing 98.2.
Press complete regulating piston 12 out of the housing (from below), complete with pressure
springs 25 and 28 and spring plate 15 with disc 23.
Remove split disc 23 from spring plate 15 .
Pull out regulating piston 12. Remove pressure spring 25 with washers 49 / 50.
3.2

Place washers 49 / 50, pressure spring 25 and spring plate 15 on regulating piston 12. Place split
disc 23.
Push spring plate 15 into housing 70 (bushing), complete with pre-installed regulating piston 12
and pressure spring 25 and pressure spring 28.
Place plate 29. Screw in screws 21.
Place protective covers 98.5.
7.48.2
copyright by
MJFCIFSS
Service Manual

Repair
Place tipping switch 3. Press in axle 24.
Re-tighten threaded stud / Allen head screw 20.
Screw lever 64 complete. to tipping switch 3. Re-tighten hex nut 68.
Adjusting pilot control valve
3.3
Pilot control valve adjustment in zero position

Stud 18 and pushrod 98.1 must be set and installed in such a way that there is no play between them
when the pilot control valve is not actuated.
Loosen lock nut 17. Turn stud 18 until both pushrods 98.1 are in zero position and there is no more
play between screw 18 and pushrod 98.1.
.
Fig. 2
Diagram: c = control pressure in bar, d = lever displacement in angular degree
A 309 - A 316 Litronic und A 309 - R 317 Litronic TCD
copyright by
MJFCIFSS
Point a
Point b
5.8 -0.3 bar
24.3 bar
7.48.3
Service Manual
Exploded view
4 Exploded view
Fig. 3
7.48.4
3
12
Tipping switch
Regulating piston
52
54
Shim
Shim
15
17
Spring plate
Hex nut
64
65
Lever
Handle
18
Threaded stud
66
Bellows
20
21
Allen head screw

Allen head screw
68
70
Hex nut
Housing
23
24
Split disc
Axle
71
90

Connecting link
25
98
Repair kit
28
98.1
Pushrod
29
Cover plate
98.2
Bushing
49
50
Washer
Washer
98.3
98.4
PDF seal
O-ring
51*
Shim
98.5
Protective cover
Omitted in A 309 - 312 machines from

start of series
in A 314 - 316 machines from serial no.
11500
and A 309 - R 317 Litronic TCD machines from start of series
copyright by
MJFCIFSS
Service Manual

Sectional drawing
5 Sectional drawing
Fig. 4
Sectional drawing: pilot control valve
copyright by
MJFCIFSS
7.48.5
Service Manual
Sectional drawing
7.48.6
copyright by
MJFCIFSS
Service Manual

Description

1 Description
The operator controls the operations of the chassis by means of a foot pedal, to the right, in front of
his seat, in the running plate of the base of the operator's platform. It actuates the pilot control valve.
There is a regulating piston 12 (pressure control valve), sitting in an axial position in housing 6, complete with pressure, return and control connections. There is a second pedal 2 on top to actuate regulating piston 12. This pedal (that can be pressed down) pushes down on a spring-loaded pushrod.
This actuates regulating piston 12 underneath (with regulating spring 25 and return spring) and, thus,
opens it towards pressure channel P (outlet A).
Fig. 1
Pilot control valve 1x with hydraulic diagram
copyright by
MJFCIFSS
7.49.1
Service Manual
Fig. 3 / Fig. 4
Actuation of pedal 2 will push pushrod 98.1 down. At the same time, it will shift regulating piston 12
by means of regulating spring 25. The radial and axial bores in regulating piston 12 let control oil from
pressure channel P penetrate into connection 1 and the control line, to flow on to solenoid valve 'travel forward / reverse' and to the control connections on control valve block 6.
Pressurising spool 12 in housing 6 will build up a certain pressure which is proportional to the predefined displacement of the lever (Fig. 2). The pressure acts on the face of regulating piston 12 and
shifts it against regulating spring 25 until the connection with channel P is interrupted.
Depending on how pedal 2 is positioned, and what the stroke of pushrod 98.1 is, there will be a certain
pilot pressure, shifting spool 12 proportionally. At a certain pressure (which corresponds to the end
of the fine control phase of the spool), pushrod 98.1 will move regulating piston 12 down directly. At
this point, the spool will receive the max. control pressure.
3 Repair
3.1

Remove hex head screws 86.
Remove protective cover 98.5. Remove plate 1 complete with pedal 2.
Pull pushrod 98.1 with bushing 98.2 from housing 6. Press pushrod 98.1 out of bushing 98.2. Remove O-ring 98.4 and PDF seal 98.3 from bushing 98.2.
Press regulating piston 12 out of housing 6 (from below), complete with pressure springs 25 and
26 and spring plate 15 with disc 23.
Remove split disc 23 from spring plate 15.
Pull out regulating piston 12. Remove pressure spring 25 with washers 37 / 38.
3.2

Place washers 37 / 38, pressure spring 25 and spring plate 15 on regulating piston 12. Place split
disc 23.
Push spring plate 15 into housing 6 and bushing 17, complete with pre-installed regulating piston
12 and pressure spring 25 and pressure spring 26.
Place plate 1 in one piece. Screw in screws 86 complete with washers 85.
Screw in pin 7 with retaining washer 9. Secure with cotter pin 11 (see Fig. 3).
Place protective cover 98.5. Check pilot control valve for correct operation.
7.49.2
copyright by
MJFCIFSS
Service Manual

Repair
Fig. 2
Diagram: c = control pressure in bar, d = lever displacement in angular degree
A 309 - A 316
copyright by
MJFCIFSS
Point a
Point b
6.5 bar
25 bar
7.49.3
Service Manual
Repair
3.3
Exploded view
Fig. 3
1
2
Plate
Pedal
26
37

Washer
6
7
Housing
Pin
38
39*
Washer
Shim ring
Washer
85
Retaining washer
11
12
Cotter pin
Regulating piston
86
98
Hex head screw

Repair kit
15
17
Spring plate
98.1 Pushrod
98.2 Bushing
23
25
Washer
98.3 PDF seal

98.4 O-ring
26
98.5 Protective cover

*
7.49.4
copyright by
MJFCIFSS
Omitted in A 309 - 312 machines from

start of series
in A 314 - 316 machines from serial no.
11500.
Service Manual

Repair
3.4
Sectional drawing
Fig. 4
Sectional drawing: pilot control valve
Housing
37
12
15
Regulating piston
Spring plate
38
Washer
98.1 Pushrod
17
Bushing (press-fitted)
98.2 Bushing
23
Disc
98.3 PDF seal
25
98.4 O-ring
26
98.5 Protective cap
copyright by
MJFCIFSS
Washer
7.49.5
Service Manual
Repair
7.49.6
copyright by
MJFCIFSS
Service Manual

Function

1 Function
The devices of the compact excavator models A 309 / A 311 are equipped with a built-in compact
control valve block. The compact control valve blocks are designed specifically to suit the relevant
task.
Each control valve block contains 8 spools for working and travel functions, and the associated pressure-relief and suction valves. The geometry of the spools and the mounted regulating spring has
been designed and adapted specifically to match the characteristics of the individual consumer.
The control valve block is designed as a restrictor control element.
Fig. 1
copyright by
MJFCIFSS
7.50.1
Service Manual
Technical data
2 Technical data
Contained in:
Type
A 309 Litronic
717
Series
A 311 Litronic
718
M8-1384-00 8M8-16
Spool
Unit
101
Slewing
gear
Ext.
Retr.
102
Stick
cylinder
Ext.
Retr.
103
Support
cylinder
Ext.
Retr.
105
Regulating
cylinder
Ext.
Retr.
106
Boom cylinder
107
Bucket cylinder
Ext.
Ext.
Retr.
Retr.
Nominal block
width
mm
20
20
20
20
20
20
Consumer connection
inch
3/4
3/4
3/4
3/4
3/4
1/2
piston rod
mm
20
20
20
20
20
20
Piston stroke
mm
9.0
9.0
9.0
9.0
9.0
9.0
9.0
9.0
9.0
9.0
9.0
9.0
p1bar 0.5 mm*
bar
7.0
7.0
7.0
7.0
7.0
7.0
7.0
7.0
7.0
7.0
7.0
7.0
p2bar 0.5 mm*
bar
24
24
24
24
24
24
24
24
24
24
24
24
Leak oil max.

at load pressure
at oil temperature
cm /min
bar
C
60
150
50
60
150
50
Unit
108
Travel motor
109
Total
Boom /
stick
cylinder
Spool
Ext.
Retr.
Ext.
60
150
50
Retr.
Nominal block
width
mm
20
20
Consumer connection
inch
3/4
3/4
piston rod
mm
20
20
Piston stroke
mm
9.0
9.0
8.0
p1bar 0.5 mm*
bar
7.0
7.0
17
17
p2bar 0.5 mm*
bar
24
24
24
24
Leak oil max.

at load pressure
at oil temperature
cm3/min
bar
C
Tab. 1
60
150
50
60
150
50
8.0
60
150
50
Technical data
* p1 = Control pressure at begin of regulation (fine-control phase)

p2 = Control pressure in final position of spool
7.50.2
copyright by
MJFCIFSS
60
150
50
60
150
50
Service Manual

Description
3 Description
3.1
Design of the control valve block

see Fig. 4
The compact control valve block 100 consists of a compact cast element.
The cast element contains the following components:
Spool 101-109 with spring pack 25
Primary pressure-relief valve 120 (P1)
Primary pressure-relief valve 121 (P2)
Secondary pressure-relief valves 127/128, 131/132, 133/134
Suction valves 135/136
Load-holding valves 151
Check valves 152
Restrictor valve 155
The block contains the control axles 101 - 109, which are adjusted to suit the respective function.
Each control axle 101 - 109 contains a spool with spring pack, a control lid 13 at the top (long design)
and a control lid 12 at the bottom (short design). The adjusting screw 162 (lowering speed of attachment) is integrated into the control lid 13 of the control axle 106 of the boom cylinder.
The secondary pressure-relief valves 127 - 134 are screwed in parallel to the control axles 101 - 107.
The control axle 108 of the travel motor includes the two suction valves 135 / 136, which are screwed
in one on each side.
The measuring connections for the measuring points 40 (pump P1) and 41 (pump P2) are also screwed into the control valve block 100.
The load-holding valves 151, check valves152 and the restrictor valve 155 are screwed into the block
100 at the connection side. There are two additional load-holding valves 151 screwed in at the rear
of the block. The check valve 153 and the preload valve154 are integrated into a separate block,
which is flange-mounted to the compact control valve block 100.
copyright by
MJFCIFSS
7.50.3
Service Manual
Description
7.50.4
10
Plate
127
30
Allen head screw
128
40
Measuring point P1
129
41
Measuring point P2
130
100
131

Secondary pressure-relief valve, boom
cylinder A6
101
Slewing gear spool
132

cylinder B6
102
133
Secondary pressure-relief valve, bucket

cylinder A7
103
134

cylinder B7
105
106
Regulating cylinder spool

Boom cylinder spool
135
136
Suction valve, travel motor A8

Suction valve, travel motor B8
107
Bucket cylinder spool
150
Check valve
108
109
Travel motor spool

Combined boom cylinder /
stick cylinder spool
151
152
Load-holding valve
Check valve
111
120
Auxiliary block
Prim. pressure-relief valve pump P1
153
154
Check valve 0.5 bar

Check valve 5.5 bar
121
162
Stroke limitation adjusting screw
copyright by
MJFCIFSS
Secondary pressure-relief valve, stick

cylinder A2
cylinder B2
Service Manual

Description
Fig. 2
Control valve block - front and rear view
copyright by
MJFCIFSS
7.50.5
Service Manual
Description
1
to tank
127

cylinder A2
to oil cooler
128
10
Plate
129
20
from pump
130

cylinder B2
40
Measuring point P1
131

cylinder A6
41
Measuring point P2
132

cylinder B6
100
133

cylinder A7
101
Slewing gear spool
134
102
135

cylinder B7
103
136
105
106

Boom cylinder spool
150
151
Check valve
Load-holding valve
107
108

Travel motor spool
152
153
Check valve
Check valve 0.5 bar
109
154
111
Combined boom cylinder /

stick cylinder spool
Auxiliary block
155
Restrictor valve
120
162
Adjusting screw
121

* marked with P2 at control valve block
** marked with P1 at control valve block
7.50.6
copyright by
MJFCIFSS
Service Manual

Description
Fig. 3
Diagram of control valve block
copyright by
MJFCIFSS
7.50.7
Service Manual
Description
7.50.8
10
12
Plate
Control lid, bottom
105
106

Boom cylinder spool
13
14
Control lid, top

Control lid with stroke limitation (for
lowering of boom)
107
108

Travel motor spool
23
Spring pack, complete
109
Combined boom / stick cylinder spool
24
25

111
120
Auxiliary block
26
27

121
Regulating spring (various characteristics) 127

cylinder A2
28
Spring plate
128

cylinder B2
29
Lock washer
129
30
Allen head screw
130

31
Allen head screw
131

cylinder A6
32
Washer
132
33
O-ring
133

cylinder B6
cylinder A7
34
O-ring
134

cylinder B7
40
41
Measuring point for pump P1

Measuring point for pump P2
135
135
Suction valve, travel A8

Suction valve, travel B8
49
50
Bushing
Threaded stud
150
151
Check valve
Load-holding valve
51
52
Hex nut
Washer
152
153
Check valve
Check valve 0.5 bar
100
101

Slewing gear spool
154
155

Restrictor valve
102
162
Adjusting screw
103
copyright by
MJFCIFSS
Service Manual

Description
Fig. 4
Design of the control valve block 100
copyright by
MJFCIFSS
7.50.9
Service Manual
see Fig. 5
4.1
Sectional drawing of control axles

In neutral position, the lines from the pumps to the consumers, and from the consumers to the tank
are closed.
The flow from the pump P1 applies pressure onto the connection P2. The oil flows virtually pressurefree through the spool 108 (travel motor), the spool 107 (bucket), the spool 106 (boom cylinder), the
spool 105 (regulating cylinder) and the spool 109 (combined boom/stick) to the tank channel in the
block 100.
The flow from the pump P2 applies pressure onto the connection P1. The oil flows virtually pressurefree through the spool 101 (slewing gear), the spool 102 (stick), the spool 103 (support) and the spool
109 (combined boom/stick) to the tank channel in the block 100.
All return oil flows are fed through the internal tank channels in the control valve block and via the
check valves 153 (connection K) to the hydraulic oil cooler. In the event of increased backpressure
(cold oil), the oil flows through the check valve 154 and the connection T to the hydraulic tank, bypassing the oil cooler (protective function).
4.2
Working position of the control axles

When a spool is moved from its neutral position, the connection P to VA/VB from the pump channel
to the consumer connection is opened through fine control grooves, while the flow through the pump
channel to the tank channel (free passage) is restricted.
The pump pressure increases until the pressure applied to the consumer connection (load pressure)
is reached.
Each axle is equipped with a screwed-in load-holding valve 151,retaining the load pressure in the
consumer until the pump pressure has reached the level of the load pressure.
When the pump pressure has reached the level of the load pressure, oil begins to flow to the consumer, and the cylinder or oil motor is set in motion.
When the spool 101 - 108 is actuated further, the connection from the pump channel to the tank channel is closed, and the connection from the consumer to the tank channel is opened, so that the return
oil can flow to the tank channel. This design ensures that the entire oil flow from the pump is available
to the consumer(s).
The adjusting displacement of the spool is determined by the existing control pressure at the connections a1 - a8 or b1 - b8 and the pre-set spring force of the spring pack.
The control pressure can be continuously adjusted, in proportion to the level motion of the respective
pilot control device.
The pistons of the control block are equipped with a negative control edge overlap and fine control
grooves. These components ensure that the oil flow to the consumers, and thus all working and travel
movements, can be controlled in small and accurate steps.
Approx. 30% of the piston stroke goes to control edge overlap, while approx. 50% are assigned to
the fine control range, and approx. 20% constitute the residual stroke for the complete opening of the
orifice cross-section.
The fine control grooves adjusted to the characteristics of the hydraulic pilot control devices allow for
optimised fine control properties.
The spring pack 25 installed at the upper end of the spool resets the spool to its neutral position when
there is no control pressure.
7.50.10
copyright by
MJFCIFSS
Service Manual

The internal leakage of a consumer connection under pressure is influenced by the length of the overlap and the play between the housing and the piston. For maximum permissible leakage volumes,
(see "Technical data", page 2).
For optimum bleeding of the control oil circuit, there is a hydraulic connection through the flushing
grooves (restrictor) between the control caps and the upper or lower tank channel of the control valve
block. This connection is only open, if the spools 101 - 109 are in neutral position.
4.3
Control lid
The control lids 12/13/14 are located at the base and top of the spools 101 to 109 and secured to the
compact block 100. The control oil required for the actuation of the spool is fed through the control
connection a / b of the control lids12/13/14.
Thanks to its customised spring characteristic, the regulating spring 27 installed at the upper end of
the spools, acts as a regulating element and returns the spool to its neutral position.
4.4
4.4.1
Combined shifting and priorities

Combined shifting of boom and stick cylinder
The oil flow from both pumps P1 and P2 applies pressure to the connections P2 and P1 at the control
valve block 100. The oil flows virtually pressure-free through all spools 101 - 109 to the tank.
If the spool 106 (boom cylinder) is pressurised through connection a6 with control oil, while the combined spool 109 actuates connection b4, the combined spool 109 opens the connection to the pump
side P1 so that the double pumped oil volume is available when the boom cylinder is extended.
If the spool 102 (stick cylinder) is pressurised through connection a2 / b2, while the combined spool
109 actuates connection a4, the combined spool 109 opens the connection to the pump side P1 so
that the double pumped oil volume is available when the stick cylinder is extended and retracted.
If no other consumers are actuated, the boom and stick cylinder can now be operated with maximum
pump volume. As soon as another consumer is actuated, one of the pumps P1 and P2 is not available
any more, depending on the position of the spools. The boom and stick cylinders are now only supplied by one pump.
4.4.2
Shifting priorities
If several consumers are operated simultaneously, the slewing gear axle 101 is first supplied with oil
by the pump P2 due to the position of the spools in the control block. These two axles have thus priority over the other control axles.
If the control axle 101 is not actuated, the oil flow is available to the other control axles.
The control axle 102 (stick cylinder) is also given priority. The oil flow from the pump P2 is fed through
the connections E1 and E2 and the restrictor valve 155 and continuously supplies the control axle
102 with hydraulic oil. This means that the stick cylinder is always operational, even when other consumers are actuated.
copyright by
MJFCIFSS
7.50.11
Service Manual
7.50.12
12
Control lid, bottom
13
14
Control lid, top

108
Control lid with stroke limitation 109
107
23
Spring pack
127
Secondary pressure-relief valve, stick cylinder A2
24
Spring pack
128
Secondary pressure-relief valve, stick cylinder B2
26
Spring pack
129
Sec. pressure-relief valve, regulating cylinder A5
27
28
Regulating spring (various cha- 130

racteristics)
Spring plate
131
Secondary pressure-relief valve, regulating cylinder

B5
Secondary pressure-relief valve, boom cylinder A6
29
30
Lock washer
Allen head screw
132
133
Secondary pressure-relief valve, boom cylinder B6

Secondary pressure-relief valve, bucket cylinder A7
31
Allen head screw
134
Secondary pressure-relief valve, bucket cylinder B7
32
33
Washer
O-ring
135
136

100
101

Slewing gear spool
150
151
Check valve
Load-holding valve
111
102
Auxiliary block
152
157
Check valve
O-ring
103
158
Cone / load-holding valve
105
106

Boom cylinder spool
159
Pressure spring / load-holding valve

Travel motor spool
copyright by
MJFCIFSS
Service Manual

Fig. 5
Sectional drawings of working axles 1,2,3,5,6,7 and 8
Free passage
Pressure channel, pump side
VA/VB channel, consumer side
copyright by
MJFCIFSS
Return channel, tank side
7.50.13
Service Manual
4.5
Cooler and tank preload valves 153 / 154

The compact control block is equipped with central cooler and tank connections. The return lines are
preloaded by the pressure springs of the check valves 153 / 154. The resulting back pressure at the
outlet guarantees sufficient inflow in the event of negative external loads (boom down, uphill travel
etc.), thus preventing cavitation.
The volumes required for back-feeding are usually available from the volumes displaced by the consumer.
The priority of the return flow of the oil through the cooler is implemented by means of different preloads of the valves with different pressure springs 153 (0.5 bar for tank preload) and 154 (5.5 bar for
cooler protection). When the volume flow becomes greater and/or the oil viscosity is increased as the
oil is cold, the resistance in the cooling circuit increases, and the additional oil volume or the volume
not to be discharged by the cooler is directly fed to the tank.
The valves are maintenance-free.
In the event of malfunction, proceed as follows:
Disconnect the hose lines from connection T / K.
Unscrew the connecting pieces 17/18 of the valves 153 / 154 from the housing and inspect the
valve cones 6 for contamination. If necessary, complete a function test of the valve.
Note!
When dismantling both valves 153 / 154, do not confuse the two pressure springs 7/8.
To reinstall the parts, complete the above steps in reverse order.
7.50.14
5
6
Valve seat
Valve cone
32
33
Washer
O-ring
7
8
Pressure spring (0.5 bar)

Shim
55
56
Reducer
O-ring
Pressure spring (5.5 bar)
57
Pressure spring
11
12
Valve seat
Control lid, bottom
58
59
Pressure spring
Spring plate
13
17
Control lid, top

Connecting piece
60
61
Valve cone
Valve seat
18
Connecting piece
100
19
Allen head screw
109
Combined boom / stick spool
20
O-ring
111
Auxiliary block
21
22
Backing ring
O-ring
152
153
Check valve
Check valve (0.5 bar)
25
154
31
Allen head screw
155
Restrictor valve, complete
E2
External pressure connection (inlet)
P1
Pressure channel pump 1
F1
Free passage P1
P2
Pressure channel pump 2
F2
Free passage P2
Suction connection
Return connection, oil cooler side
Return channel, tank side
copyright by
MJFCIFSS
Service Manual

Fig. 6
Control axle 4 with auxiliary block and integrated cooler and tank preload valves
copyright by
MJFCIFSS
7.50.15
Service Manual
Primary and secondary pressure-relief valves
5 Primary and secondary pressure-relief valves

5.1
Primary pressure-relief valve 120 / 121 (pump safety valve)

The primary pressure-relief valves mounted on the side of the control block limit the pressure between the pump and the control block (working and operating pressure).
The pressure-relief valves 120 / 121 are of the cartridge type and inserted directly into control valve
block 100. The raising system pressure in the hydraulic unit acts on the indirectly acting (pilot-controlled) valve. In these valves, a direct-acting pressure-relief valve (with valve cone and seat) acts as
the pilot-control valve, generating a pulse that actuates the second, larger valve.
The preload of the valve spring determines the opening pressure and can be adjusted by means of
the adjusting screw located on the outside of the unit.
5.2
Secondary pressure-relief and feeder valves 127 - 134

The secondary pressure-relief valves127-134 limit the pressure between the attachments and the
control block when the spools are closed (secondary function). The design and function of these valves is identical with that of the primary pressure-relief valves.
The pressure settings are however significantly higher than those of the primary pressure-relief valves.
The secondary pressure-relief valves also act as feeder valves. Differences in the flow rates of the
oil to and from the working cylinders result in a vacuum. This might occur for instance when the stick
cylinder is extended with a long stick, due to external pulling loads. In order to prevent this, the valves
connect the return side with the corresponding low-pressure side so that additional oil can be taken
in.
5.3
5.3.1
Pressure limitation
The pressure (P) built up in the consumer circuit acts on the front face of the main cone 3 and, through
the bore D1, also on the rear surface of the main cone 3. At the same time, the pressure acts also on
the pilot control cone 4. The springs 8 / 9 and 5 push the main cone 3 and the pilot control cone 4 into
their closing positions (static status).
As soon as the pressure in the consumer circuit exceeds the pre-set pressure of the pressure and
adjusting spring 5, the pilot control cone 4 is lifted from its seat, and some oil can flow into the return
channel.
Due to the different cross-sections of the bores D1 in the main cone 3 and D2 in the valve insert 2,
there is a pressure difference between the front and the spring side of the main cone 3.
As a result of this pressure difference, the main cone 3 is shifted against the pressure springs 8 / 9,
and a substantial amount of oil flows off to the non-pressurised return side T.
5.3.2
Feed
If there is a vacuum in a working circuit, the higher pressure in the hydraulic tank is applied through
the bore T of the housing 1 onto the ring face of the main cone 3. As a result of the pressure difference
across the effective surface of the main cone 3, the main cone is pressed against the force of the
pressure springs 8 / 9 so that the required amount of oil can flow through the bore T to the respective
side of the consumer.
7.50.16
copyright by
MJFCIFSS
Service Manual

Primary and secondary pressure-relief valves
Fig. 7
Primary and secondary pressure-relief valves 120-134
Housing
Pressure spring
Valve insert
10
Protective cap
3
4
Main cone
Pilot control cone
11
12
Piston seal
O-ring
5
6
Pressure spring
Adjusting screw
13
14
O-ring
Backing ring
Lock nut
15
O-ring
Pressure spring
16
O-ring
copyright by
MJFCIFSS
7.50.17
Service Manual
6 Suction valves 135/136

The suction valves (i.e. feeder valves / check valves) are mainly used in conjunction with rotating consumers.
The risk of insufficient oil, i.e. cavitation, in oil motors is greatest when there are delays in the operation of the machine (downhill travel). When decelerating, the oil motor of the drive system runs idle.
The pressure peaks due to the high moment of inertia during downhill travel result in activation of the
brake valves while the spools are blocked.
From a certain inclination, the speed of the motor (and, thus, the oil volume to be fed) is no longer
determined by the aperture of the inlet orifice of the spool, but depends on the load and the grade
resistance.
The feeder valve provides the required volume of oil to the working connection in order to prevent
cavitation.
6.1
6.1.1
Closing position:
The high pressure in channel A/B is applied through the bore D to the spring side of the main cone
3, pressing the cone against the sealing edge of the valve insert 1, so that the valve 135 / 136 / 181
/ 182 is closed towards the consumer side.
6.1.2
Suction:
If there is a vacuum in the working circuit, the higher pressure in the hydraulic tank acts through the
bore T of the valve insert 1 onto the ring face of the main cone 3.
As a result of the pressure difference across the effective surface of the main cone 3, the main cone
is pressed against the force of the pressure spring 8 so that the required amount of oil can flow through the bore T to the respective side of the consumer A / B.
7.50.18
copyright by
MJFCIFSS
Service Manual

Fig. 8
1
3
Valve insert
Main cone
33
34
O-ring
Backing ring
6
8
Screw
Pressure spring
35
37
O-ring
O-ring
31
Piston seal
copyright by
MJFCIFSS
7.50.19
Service Manual
Repairs to control valve block
7 Repairs to control valve block

Caution!
Before carrying out any repairs on the control valve block, release the preload pressures at the tank
and servo system.
Switch off the diesel engine.
Proceed as follows: Unscrew the breather filter on the hydraulic tank with 1 turn (slow de-pressurisation).
Release backpressures.
Turn ignition key into contact position.
Actuate all pilot control devices in all possible directions.
7.1
Leaks on the outside

If there are leaks on control valve block, replace the seals on the screwed connections, SAE flanges,
caps and valves.
7.1.1
Spool
Disconnect the relevant control line.
Remove the Allen head screws 30. Remove the control lid 12 or 13/14.
Lift off the spring pack 23/24/25/26 and pull the respective spool101 - 109 from the housing.
Note!
If you wish remove more than one spool at a time, do not confuse them and ensure they are reinstalled in their original bores (observe markings, etc.).
In spare spools, the axle marking A1 - A8 is engraved on the front side opposite the spring and on
the shaft of the spring pack.
Prior to installing the spools, check the O-rings 33 in the housing for damage (spool lid seals). Also
check the spools for damage or defects (scores in surface).
Install the parts by completing the above steps in reverse order. Insert the spool with care to avoid
jamming. Do not use force.
7.2
Dismantling of spools 101 to 109

Caution!
Before dismantling control lines: relieve pressure from hydraulic circuit.
The lid 12/13/14 is spring-loaded.
Risk of injury from propelled spring pack
Dismantle the respective control line.
Remove the screws 30.
Remove the lid 12/13 with the O-ring 33.
Pull the spool 101 to 109 from the control valve block 100.
Remove the spring pack 26.
7.50.20
copyright by
MJFCIFSS
Service Manual

7.3
Installation of spools
Important information for installation / replacement of pistons:
The various spools are matched to suit the specific requirements of the respective operational
functions (boom, stick etc.) and cannot be interchanged with each other for that reason.
If you want to remove several spools at a time, reinstall them in their original bores.
Usually, the bores in the control valve blocks are made for perfect fit. If this is the case with all the
bores in the block, the type plate of the block shows end number "000". 'Perfect fit' indicates that
the bores have 0 m tolerance. This means that spools supplied for replacement usually have
a tolerance of 8-10 m, and the amount of leak oil is within the normal range.
Zero-tolerance bores are marked with punched code 0. Replacement with spools as specified in
the ET spare parts catalogue is possible.
If one or several bores of the control block do not meet the zero tolerance standard, the actual
tolerance is indicated on the type plate. To find out which bore is meant, remove the top lid of the
spool in question.
The marking indicating the tolerance of the bore (10 = 10) is located at the front face of the control
block. In this case, it is not possible to replace the spool with a part from the spare parts catalogue,
and the spool must be specially made to fit the tolerance.
When ordering spare spools, please quote all information on the type plate, see also service information no. 1-14-52 / 2000.
Ensure that the spool is installed in the correct position.
Choose a matching spool and grease it lightly.
Carefully insert it into the control valve block 100.
Place the spring pack 26 on the spool.
Place the lid 12/13/14 complete with the O-ring 33 onto the control block100 and secure it with the
screws 30.
copyright by
MJFCIFSS
7.50.21
Service Manual
Auxiliary control axles
8 Auxiliary control axles

8.1
Function
The auxiliary element for the accessory kit AHS 12 is flange-mounted to the control block 100. It allows for the activation of additional working movements (hammers, scrap shear, etc.).
The control axles of the auxiliary control block includes the spool with actuation elements (control lid,
spring pack) required for the relevant function, and all associated secondary protection elements.
Fig. 9
7.50.22
Accessory kit AHS 12
copyright by
MJFCIFSS
Service Manual

Description
9 Description
The auxiliary control valve block 115 consists of a compact cast element.
The cast element contains the following components:
Spool 116
Primary protection 120
Pressure-relief valve143, 144
Check valve 152
The auxiliary control axle 115 is flange-mounted to the mounting plate 10 of the control block 100.
The threaded stud 47 is screwed into the auxiliary control block 115,inserted through the bores of the
mounting plate 10 and secured with the nut 51.
The bushing 49 is inserted into the auxiliary block and used to secure it to the mounting plate 10.
The O-rings 34 seal the hydraulic connections between the mounting plate 10 and the auxiliary block
115.
Fig. 10
Auxiliary axle AHS 115
Note!
When attaching an auxiliary control axle 115, ensure that it is not equipped with a primary protection
120 provided by the manufacturer.
Remove the primary protection 120 from the control block 100 by turning it from the bore.
Remove the dummy plug 48 from the auxiliary control axle 115.
Insert the primary protection 120 in the axle 115 and screw it in.
Insert the dummy plug 48 in the axle 100 and screw it in.
copyright by
MJFCIFSS
7.50.23
Service Manual
Fig. 11
10
Hydraulic diagram of the auxiliary axle AHS 12
100
115

Auxiliary control valve block
120
143

Secondary pressure-relief valve with additional pressure stage
116
Spool / kit AHS 12
144
The design and function of the auxiliary axle AHS corresponds to that of the working axles, (see "Design of the control valve block", page 3) and see page 3.
7.50.24
copyright by
MJFCIFSS
Service Manual

Fig. 12
Sectional drawing of auxiliary axle AHS 12
12
13
Control lid, bottom

Control lid, top
115
116
Auxiliary control valve block (low pressure)

Spool AHS12
24
143
Secondary pressure-relief valve with additional pressure stage, hydraulic hammer A9
27
Regulation spring
144
Secondary pressure-relief valve, kit AHS B9
28
Spring plate
151
Load-holding valve
29
31
Lock washer
Allen head screw
152
157
Check valve
O-ring
32
Washer
158
33
O-ring
159
copyright by
MJFCIFSS
7.50.25
Service Manual
Pressure and feeder valves 143 (2-step at AHS for hammer)
11

The pilot-controlled pressure-relief valve 143 of the consumer connection is of the cartridge type and
inserted directly into control valve block 100. The valve has an additional hydraulic pressure stage
and can therefore be used for two different pressure ranges. It limits the pressure between the pump,
the control valve block and the working attachment (stage 1 - primary function - hammer operation)
or between the working attachments and the control block when the spool is closed (stage 2 - secondary function - regulating cylinder protection).
If the pressure increases in the circuit of an attachment in undesirable ways, destruction would occur
at the weakest point, e.g. screwed connections or hydraulic hoses.
In order to prevent that, we provide a sort of pre-determined breaking point. In our scenario, the pressure rising in the hydraulic system acts on a certain type of integrated hydraulic device. This element
is referred to as a pressure-relief valve. It limits the maximum pressure in the consumer and its connections to a pre-set value.
As the pressure valves in the hydraulic system must be able to cater for great flows of oil, our machines are equipped with indirect (pilot-controlled) pressure-relief valves for reasons of manufacture and
better functioning. In these valves, a direct-acting pressure-relief valve acts as the pilot-control valve,
generating a pulse that actuates the second, larger valve.
The pressure-relief valve 143 also serves as a feeder valve. Differences in the flow rates of the oil to
and from the working cylinders result in a vacuum. This might occur for instance when the regulating
cylinder is extended due to external pulling loads. In such a case, the speed of the consumer would
not be controlled by means of the gauge orifice diameter, but based on the loads and via the outlet
edge of the spool.
In order to prevent this, the valves connect the return side with the corresponding low-pressure side
so that additional oil can be taken in.
Fig. 13
7.50.26
Pressure and feeder valve 143
copyright by
MJFCIFSS
Service Manual

11.1
11.1.1
Pressure limitation
the pilot control cone 15.
The springs 7 and 18 push the main cone 5 and the pilot control cone 15 into their closing positions
(static status).
As soon as the pressure in the consumer circuit exceeds the preset pressure of the pressure and
channel. Due to the different cross-sections of the bores D1 in the bushing 6 and the ring face D2 in
the valve insert 2, a pressure difference is built up between the front and rear sides of main cone 5.
As a result of this pressure difference, the main cone 5 is shifted against the pressure springs 7, and
a substantial amount of oil flows off to the non-pressurised return side T.
11.1.2
Additional pressure stage

Stage 1 (low pressure - protection of hydraulic hammer) connection X is connected to
the tank. Pre-loading of pressure spring 18 is lower.
Stage 2 (higher pressure - protection of regulating cylinder) connection X receives pilot
pressure. The pressure spring 18 is pre-loaded via the shifting piston 9 and
the piston 8 to a higher degree, which results in a higher blow-off pressure.
11.1.3
Feed
pressure springs 7 so that the required amount of oil can flow through the bore T to the respective
side of the consumer.
Fig. 14
Sectional drawing: pressure and feeder valve 143
copyright by
MJFCIFSS
7.50.27
Service Manual
7.50.28
copyright by
MJFCIFSS
Service Manual
LSC control block

Function
LSC control block

1 Function
The A 312 - R 317 Litronic machines are equipped with an LSC control system.
The control unit consists of a compact control valve block with LUDV system. The control block contains five spools (working and travel functions) with the corresponding valves.
There is a separate control block segment for the slewing gear drive.
Fig. 1
Example: LSC control block of model A 312 - 316
copyright by
MJFCIFSS
7.60.1
LSC control block
Service Manual
General data of A 312 - A 316 Litronic control block
2 General data of A 312 - A 316 Litronic control block

Contained in:
Type
Construction
A 312 Litronic
719
A 314 Litronic
635
A 316 Litronic
715 / 716
from sn.12363 M7-1442-20

from sn.16275 M7-1442-31
from sn. 2001 M7-1340-20

from sn.11820 M7-1340-22
from sn.11814 M7-1340-23
from sn.16215 M7-1340-31
from sn. 2001 M7-1340-20

from sn.11822 M7-1340-22
from sn.12741 M7-1340-23
from sn.16141 M7-1340-31
Industry
from sn. 2001 M7-1341-20

from sn.11823 M7-1341-22
from sn.12845 M7-1341-23
from sn.16286 M7-1341-31
Speeder
from sn.12363 M7-1443-20

from sn.15864 M7-1443-31
Spool
Unit
220
Boom
cylinder
Ext.
Retr.
from sn. 2001 M7-1433-20

from sn.12734 M7-1433-21
from sn.15964 M7-1433-31
240
Stick
cylinder
Ext.
Retr.
260
Bucket
cylinder
Ext.
from sn. 2001 M7-1433-20

from sn.12734 M7-1433-21
from sn.15964 M7-1433-31
160
Travel
motor
Retr.
280
Support
cylinder
Ext.
120
Slewing gear
Retr.
Nominal block
width
mm
20
20
20
20
20
20
Consumer connection A/B
()
3/4
3/4
3/4
3/4
3/4
1/2
piston rod
mm
25
25
25
Piston stroke
mm
9.0
9.0
9.0
9.0
9.0
9.0
9.0
9.0
9.0
9.0
Setting value Y*
A 312 - A 316
A 312 - A 316
mm
17.4
14.0
17.2
13.6
17.3
14.5
17.5
14.3
15.9
13.2
16.0
13.0
16.7
12.9
15.8
13.0
15.5
13.0
16.3
12.3
p1bar 0.5 mm**
bar
7.0
7.0
7.0
7.0
7.0
7.0
7.0
7.0
7.0
7.0
p2bar 0.5 mm***
bar
20.6
20.6
20.6
20.6
20.6
20.6
20.6
20.6
20.6
20.6
Qn (A)/Qn(B)
A 312
A 312 Speeder
A 314
A 316
314/316 Speeder
A 316 Industry
l/min
l/min
l/min
l/min
l/min
l/min
220
220
220
220
220
300
90
90
90
90
90
70
220
220
220
220
220
300
150
150
150
150
150
110
180
180
180
180
180
225
100
100
100
100
100
175
120
200
120
120
200
150
75
75
75
75
75
220
65
65
65
65
65
190
120
120
120
120
120
120
Restr. check valve

at connection a / b
mm
Leak oil max.

at load pressure
at oil temperature
cm3/min
bar
C
Tab. 1
#
7.60.2
25
25
0.8#
0.8
60
150
50
60
150
50
60
150
50
0.8
0.8
60
150
50
60
150
50
60
150
50
Technical data
from index 23 = diameter 0.6 mm
sn. = Serial number
copyright by
MJFCIFSS
25
Service Manual
LSC control block

General data of R 313 / R 317 Litronic control block
Machine A 312 from serial no. 11367, A 314 from serial no. r.12814, A 316 from serial no.
12741, A 316 Ind. 12846
3 General data of R 313 / R 317 Litronic control block

Contained in:
Type
R 313 Litronic
790
standard model
Spool
R 317 Litronic
790
from sn. 27752 M7-1748-30

Unit
220
Boom
cylinder
Ext.
Retr.
from sn. 18161 M7-1466-31
240
Stick
cylinder
Ext.
Retr.
260
Bucket
cylinder
Ext.
mm
Consumer connection A/B
()
piston rod
mm
Piston stroke
mm
9.0
9.0
9.0
9.0
9.0
Setting value Y*
R 313 / R 317
mm
14.0
13.6
14.5
14.3
p1bar 0.5 mm**
bar
7.0
7.0
7.0
7.0
p2bar 0.5 mm***
bar
20.6
20.6
20.6
Qn (A)/Qn(B)
R 313
R 317
l/min
195
220
85
90
0.6
0.6
Leak oil max.

at load pressure
at oil temperature
Tab. 2
mm
cm3/min
bar
C
180
Drive
motor
120
Slewing gear
Retr.
Nominal block
width
Restrictor check
valve at connection
a/b
160
Drive
motor
20
20
20
20
20
20
3/4
3/4
3/4
3/4
3/4
1/2
25
25
25
25
25
25
9.0
9.0
9.0
9.0
13.2
13.0
14.5
14.5
12.3
7.0
7.0
7.0
7.0
7.0
20.6
20.6
20.6
20.6
20.6
20.6
250
220
150
150
210
180
90
100
125
125
125
125
140
120
0.8
0.8
0.8
0.8
0.8
60
150
50
60
150
50
60
150
50
60
150
50
60
150
50
60
150
50
Technical data
The setting value Y serves as reference value
**
p1 = control pressure at begin of regulation
***
p2 = control pressure in final position
Qn A/ Qn B = nominal flow rate at outlet A / B at
copyright by
MJFCIFSS
p = nominal value
7.60.3
LSC control block
Service Manual
General data of R 313 / R 317 Litronic control block
7.60.4
copyright by
MJFCIFSS
Service Manual
LSC control block

Design of A 312 - A 316 control block
4 Design of A 312 - A 316 control block

4.1
Elements of control valve block, (see Fig. 2, page 7)

Input section:
Connection P for oil pump flow
Connection K for return flow to hydraulic oil cooler
Connection MP for pump pressure
Connections MLS and LS2 for external load signal
Connection LS with shuttle 107 for load signal line to pump flow regulator
Check valve 7 (3.5 bar) in block for return backpressure
Preload valve 8 (7 bar) in block for return as cooler bypass valve
Minimum-flow pressure balance 102 (flow controller) for the stabilisation of the load pressure and
relief of the LS line
Pressure balance / remaining flow 103 (unloading valve) for a fast and direct response in the system
Pressure cut-off valve 104 as a limiting valve for the working pressure
Primary pressure-relief valve 105 to protect the system
Control and distribution area:

Operating connections A1 - A5 and B1 - B5 for supply and return flows of consumers
Connection T for return oil to hydraulic tank1
The control caps of the various axles with stroke limitation of spools 160 / 220 / 240 / 260 and 280;
control pressure connections a1 - a5 and b1 - b5, and regulating and return spring 132
Spool 160 / 220 / 240 / 260 and 280 for the working movements of travel drive, boom, stick, bucket
and support
Secondary pressure-relief valve 221 / 222 / 241 / 242 and 261 / 262 to protect the consumer circuit
in closed condition.
Suction valves 161 and 162 to prevent cavitation in the travel drive system
Pressure balance 164 / 224 / 244 / 264 and 284 for LS signal message re. compensation of the
various axles
Restrictor check valves 127 / 167 / 227 and 247 for the fine control of the spools 120 / 160 / 220
and 240
The auxiliary control axle is equipped with the following components as standard: slewing gear
spool 120, inlet pressure balance 122, check valve 123 and restrictor check valves 127, see 17.1
Note!
Additional elements with spools serving as auxiliary equipment can be flange-mounted to the compact block.
copyright by
MJFCIFSS
7.60.5
LSC control block
Service Manual
4.2
7.60.6
Control block for A 312 - 316 and components

7
8

Preload valve (7.0 bar)
167
220

100
102

221
222

103
224
Pressure balance (pilot-controlled)
104
227
105
240
106
Shift valve / Qmax regulating motor
241
107
Shuttle valve
242
108
Restrictor (LS central nozzle)
244
Pressure balance
109
110

Mounting plate
247
260

111
120
Allen head screw

261
262

122
123
Inlet pressure balance

Check valve
264
280
Pressure balance
Spool / support
127
281
Screw plug / dummy cartridge
134
135
Control lid
Allen head screw
284
334
Pressure balance
Control lid
140
160
Screw plug
369
373
Screw plug
Screw plug
161
162
Suction valve
Suction valve
810
811
Mounting plate
Allen head screw
164
Pressure balance
copyright by
MJFCIFSS
Service Manual
LSC control block

Fig. 2
Control valve block for A 312 - A 316 - front and rear view
copyright by
MJFCIFSS
7.60.7
LSC control block
Service Manual
7.60.8
164
Pressure balance (directly controlled)
8
41

Measuring point MP
167
220

45
Measuring point LS
221
Secondary pressure-relief valve / extend
100
222
Secondary pressure-relief valve / retract
102
Pressure balance / minimum flow (flow

controller)
224
Pressure balance (direct / pilot-controlled*)
103
Pressure balance (remaining flow control- 227

ler)
104
240
105
106

Shift valve / Qmax Regulating motor
241
242

107
Shuttle valve
244
108
109

247
260

120
122

Inlet pressure balance (supply pressure
balance)
261
262

123
Check valve
264
127
160

Spool / travel drive
280
281

Suction valve
161
162
Suction valve
Suction valve
284
from index 31, see Tab. 2, pilot-controlled

(directly controlled pressure balance: see
items 244 / 264)
copyright by
MJFCIFSS
Service Manual
LSC control block

Fig. 3
Hydraulic diagram of LSC control block for A 312 - A 316
copyright by
MJFCIFSS
7.60.9
LSC control block
Service Manual
Fig. 4
7.60.10
Exploded view of control block for A 312 - 316
100
169
Screw plug
102
103
Pressure balance / minimum flow (LS outlet)

Residual flow pressure balance (unloading
valve)
170
171

104
105

172
220
Screw plug
Spool / boom
110
111
End plate
Allen head screw
221
222
Spring plate
120
Control axle / slewing gear
223
Pressure spring
130
O-ring
224
Piston / pressure balance (pilot-controlled)
131
Spring plate
225
Screw plug
132
134
Regulation spring
Control lid
227
240

Spool / stick
135
Allen head screw
242
140
Screw plug
244
160
247
Piston / pressure balance (directly

controlled)
162
164
Suction valve
260
Piston / pressure balance (directly controlled) 262
165
Spring / pressure balance
264
copyright by
MJFCIFSS
Spool / bucket
controlled)
Service Manual
LSC control block

Design of R 317 control block
166
280
O-ring
Spool / support
167
281
Screw plug
168
Screw plug
284

controlled)
5 Design of R 317 control block

5.1
Elements of control valve block, (see Fig. 5, page 13)

Input section:
Connection P for oil pump flow
Connection K for return flow to hydraulic oil cooler
Connection MP for pump pressure
Connections MLS and LS2 for external load signal
Connection LS with shuttle 107 for load signal line to pump's flow regulator
Check valve 7 (3.5 bar) in block for return backpressure
Preload valve 8 (7 bar) in block for return as cooler bypass valve
Minimum-flow pressure balance 102 (flow controller) for the stabilisation of the load pressure and
relief of the LS line
Pressure balance / remaining flow 103 (unloading valve) for a fast and direct response in the system
Pressure cut-off valve 104 as a limiting valve for the working pressure
Primary pressure-relief valve 105 to protect the system
Control and distribution area:
Operating connections A1 - A5 and B1 - B5 for supply and return flows of consumers
Connection T for return oil to hydraulic tank1
The control caps of the various axles with stroke limitation of spools 160 / 180 / 220 / 240 and 260;
control pressure connections a1 - a5 and b1 - b5, and regulating and return spring 132
Spool 160 / 180 / 220 / 240 and 260 for the working movements of travel drive, boom, stick, bucket
and support
Secondary pressure-relief valve 221 / 222 / 241 / 242 and 261 / 262 to protect the consumer circuit
in closed condition.
Suction valves 161 /181 and 162 / 182 to prevent cavitation in the travel drive system
Pressure balance 164 / 184 / 224 / 244 and 264 for LS signal message re. compensation of the
various axles
Restrictor check valves 167 / 187 / 227 and 247 for the fine control of the spools 160 / 180 / 220
and 240
Shift valve 106 for Qmax shifting of the regulating travel motors
The auxiliary control axle is equipped with the following components as standard: slewing gear
spool 120, inlet pressure balance 122, check valve 123 and restrictor check valves 127, see 17.1
Note!
Additional elements with spools serving as auxiliary equipment can be flange-mounted to the compact block.
copyright by
MJFCIFSS
7.60.11
LSC control block
Service Manual
5.2
7.60.12
Control block R 317 and components

7
8

180
181

Suction valve
100
102

182
184
Suction valve
Pressure balance
103
187
104
220
105
221
106
222
107
Shuttle valve
224
108
227
109
110

Mounting plate
240
241

111
120
Allen head screw

242
244

Pressure balance
122
123
Inlet pressure balance

Check valve
247
260

127
261
134
135
Control lid
Allen head screw
262
264

Pressure balance
140
160
Screw plug
334
369
Control lid
Screw plug
161
162
Suction valve
Suction valve
373
810
Screw plug
Mounting plate
164
Pressure balance
811
Allen head screw
167
copyright by
MJFCIFSS
Service Manual
LSC control block

Fig. 5
Control valve block for R 317 - front and rear view
copyright by
MJFCIFSS
7.60.13
LSC control block
Service Manual
7.60.14
167
8
41

Measuring point MP
180
181

Suction valve
45
Measuring point LS
182
Suction valve
100
184
102

controller)
187
103
Pressure balance (remaining flow control- 220

ler)
104
221
105
106

222
224

107
Shuttle valve
227
108
109

240
241

120
122

Inlet pressure balance (supply pressure
balance)
242
244

123
Check valve
247
127
160

260
261

161
162
Suction valve
Suction valve
262
264

164
copyright by
MJFCIFSS
Service Manual
LSC control block

Fig. 6
Hydraulic diagram of LSC control valve block for R 317
copyright by
MJFCIFSS
7.60.15
LSC control block
Service Manual
Fig. 7
7.60.16
Exploded view of control valve block for R 317
100
170
102
103
Pressure balance / minimum flow (LS outlet)

171
Residual flow pressure balance (unloading valve) 172

Screw plug
104
180
105
110

End plate
182
184
Suction valve
controlled)
111
Allen head screw
187
120
130

O-ring
220
221
Spool / boom
Spring plate
131
Spring plate
222
132
Regulation spring
223
Pressure spring
134
Control lid
224
135
Allen head screw
225
Piston / pressure balance (pilot-controlled)

Screw plug
140
Screw plug
227
160
240
Spool / stick
162
Suction valve
242
164
Piston / pressure balance (directly controlled)
244

controlled)
165
Spring / pressure balance
247
166
O-ring
260
Spool / bucket
copyright by
MJFCIFSS
Service Manual
LSC control block

Functional description (short description)
167
262
168
Screw plug
264

controlled)
169
Screw plug
6 Functional description (short description)

(see Fig. 3, page 9) and (see Fig. 6, page 15)
6.1
Neutral position
All spools 160 / 180 / 220 / 240 / 260 and 280 are maintained in a neutral position by means of regulating and return springs 132. The connection between pump connection and consumer is closed.
The connection between consumer and tank is closed.
Pressure balances 164 / 184 / 224 / 244 / 264 and 284 are in a neutral position (connections are
closed).
Pressure balance / remaining flow 103 is open. The pre-set flushing volume is pumped from the variable displacement pump through 103 to the tank.
6.2
6.2.1
Working position, (see Fig. 16, page 29)

One spool in working position
Connection between sections P and P' opens, oil flows.
The respective pressure balance 164/184/224/244/264/284 is pressurised and opened, while all
other balances remain closed.
When the spool is in its working position, oil flows through the pressure balances to the flow regulator.
The pressure in the pump is increased and exceeds the load-holding function. As a consequence,
the consumer is supplied oil.
Pressure balance 103 closes, and the flow from the pump is now available to the consumer.
6.2.2
Several spools in working position, see figure 4

Connection between sections P and P' opens, oil flows.
Pressure balances 164 to 284 are pressurised and shifted in the direction of the spring side (in proportion to the LS pressure), i.e. the consumer with the highest load pressure determines the LS pressure. The pressure balances 164 to 284 of each spool always switch to the same pressure difference
( -p), even at different load pressures.
The pump is pivoted according to the oil requirements of the various consumers.
The oil is fed via the control edge of the respective pressure balance and load-holding valves 170172 to section PA or PB, to the consumer connection A1 - A5 or B1 - B5 and to the consumer.
The remaining flow pressure balance 103 closes. The flow from the pump is now available to the consumer.
Decisive advantages of the LSC control:
The pump delivers only the oil required for the individual consumers.
The speeds of the consumers are determined only by the pre-selected pilot pressure on the spool.
It remains constant, irrespective of the load pressure of the consumer in question.
copyright by
MJFCIFSS
7.60.17
LSC control block
Service Manual
Functional description (short description)
Fig. 8
View of compact control block from the left with sectional drawing of the a control axle
100
222
Secondary pressure-relief valve / boom
104
224
105
Prim. pressure-relief valve
240
Spool / stick
160
161
Spool / chassis right / travel drive

Suction valve
241
242

Pressure-relief valve / stick
162
164
Suction valve
244
260

Spool / bucket
180
Spool / chassis left (R 317 only)
261
181
Suction valve
262
Pressure-relief valve / bucket
182
Suction valve
264
184
280
Spool / support (A only)
220
Spool / boom
284
221

*
7.60.18
copyright by
MJFCIFSS
only in A machines/R machines
Service Manual
LSC control block

Input section / input element
7 Input section / input element

Description
The input element contains the central system functions such as the check valve 7 (cooler valve),
check valve 8 (tank valve), primary pressure control (valve 105), LS pressure relief (cut-off valve
104), residual flow pressure balance 103, minimum-flow pressure balance 102 and LS central nozzle
108.
Fig. 9
Exploded drawing of the input element
Cone
105
Pressure spring
106
Shift valve / Qmax - Travel motor (R

317 only)
3
4
O-ring
Screw plug
107
108
Shuttle valve
LS central nozzle ( 1.6 mm)
Shim
109
Pressure spring
210
Valve seat
7
8
Check valve (cooler)

Check valve (tank)
211
219
Restrictor bolt
Valve seat
100
Compact block
275
Screw plug
102
Pressure balance / minimum flow (flow controller)

valve)
221
Spring plate
222
Pressure spring
103
104
copyright by
MJFCIFSS
7.60.19
LSC control block
Service Manual
Fig. 10
7.1
Hydraulic diagram: input section - control valve block
6
7
to oil cooler
100
102
Compact block
controller)
Check valve (7 bar)
103
Residual flow pressure balance (unloading valve)
20
26

to LS regulator
104
105

41
45
Measuring point MP
Measuring point LS
107
108
Shuttle valve
LS central nozzle
Cooler and tank preload valves 7 / 8, (see Fig. 11, page 21)
The compact control block is equipped with cooler and tank connections. The return lines are preloaded with the pressure springs 2 / 6 of the check valves 7/8. The resulting back pressure at the outlet
guarantees sufficient inflow in the event of negative external loads (boom down, uphill travel etc.),
thus preventing cavitation.
The volumes required for back-feeding are usually available from the volumes displaced by the consumer.
The priority of the return flow of the oil through the cooler is implemented by means of different preloads of the valves with different pressure springs 2 (3.5 bar for tank preload) and 6 (7 bar for cooler
protection). With increasing volumetric flow, the resistance in the cooler line increases, and the additional volume of oil is fed directly to the tank after valve 8 has opened.
The valves do not require maintenance. In the event of a malfunction, the valve can be removed with
the screw plug, the pressure springs 2 / 6 and the cone 1 from the housing 100 for inspection (contamination, defect), testing and replacement. If there is leakage at the outside, mount a new O-ring 3.
Note!
When installing/removing the valves 7 and 8, ensure that the correct pressure springs 2 / 6 and
shims 5 are mounted.
7.60.20
copyright by
MJFCIFSS
Service Manual
LSC control block

Fig. 11
Sectional drawing of inlet elements in the oil return section
1
2
Cone
Pressure spring
8
25
Preload valve, complete (7.0 bar)

Screw coupling / measuring point MP
O-ring
100
Compact block
Screw plug
105
Shim
Connection to oil cooler
6
7
Pressure spring
Check valve, complete (3.5 bar)
P
MP
connection / pump pressure

Measuring connection / pump pressure
Tank channel
copyright by
MJFCIFSS
7.60.21
LSC control block
Service Manual
7.2
Minimum flow pressure balance / input pressure balance 102, see Fig. 12 and
Fig. 13
The valve 102 (which is screwed into the block 100 from the bottom) allows a small amount of oil (approx. 0.7 l/min.) to flow continuously from the LS line to the tank. This ensures that sudden pressure
increases in the LS line caused by impacts are eliminated. The valve 102 also ensure that the LS line
is relieved to the tank if the consumers are not actuated (neutral position of spools).
The 2-way flow limitation valve consists of an orifice and a pressure balance with regulating piston.
The pressure balance keeps the pressure decrease p constant, so that the volume of outliving oil
is also kept constant, irrespective of the LS pressure. The ratio p is determined by the selected
cross-section of the orifice (spool).
The valve cannot be adjusted and is maintenance-free. In the event of a malfunction, the valve can
be removed from the housing and dismantled for inspection (contamination, spring break) or replacement. In the event external leakage, mount a new seal kit.
7.3
Remaining flow pressure balance 103, see Fig. 12 and Fig. 13

In standby mode, there is a continuous flow volume Qmin of approx. 30 l/min. When consumers are
not in operation, the p ration of the valve and the additional tank preload generate a standby pressure at the pump connection MP. In this mode, the system pressure is thus approx. 35 bar (R 317-Li).
The standby pressure pushes the piston 103 through the integrated channels against the spring 322.
Simultaneously, the LS channel is relieved through the valve 102 to the tank. As a result, a connection
between the pressure side P and the tank side T is established, and the pre-set volume of oil flows
off. The valve ensures that, in the event of idle run, there is still a minimum volume flow of Qmin at
standby pressure to the tank. There is thus a certain loss of power in this mode, in line with the volume
flow.
As soon as a consumer is actuated, the load pressure of the consumer is applied to spool 103. The
pressure and spring force displace the piston 103 proportionally to the requested volume, thus reducing the outlet cross-section of the orifice in the direction of the tank.
If the total amount of the consumer volumes is smaller than Qmin, the volume allotted through the
gauge orifice is fed to the consumers first, due to the lower p ration of the spool. The remaining
differential quantity (Qmin - total of consumer volume) continues to flow via the adjusted control edge
to tank.
As soon as the requested volumes exceed Qmin at one or more spool(s) (i.e. total of consumer volumes greater than Qmin), the valve 103 is closed completely, shutting off the connection to the tank
side.
Above this volume, the system works with the variable displacement pump according to the "closed
centre" and adjust the requested volumes by means of the LS regulator. As long as the performance
requested by the diameter of the gauge-orifice (at the spool) and the highest load pressure is below
the pre-set power curve, the LS regulator maintains the set p ratio at a constant level.
As soon as the system falls below this point, a saturation deficit occurs. The LS regulator of the pump
is unable to maintain the set p ratio via the gauge orifices. The pump cannot build up the required
pressure at it has already reached its maximum pivot angle. The LS regulator is disabled, and the
pump delivers the highest obtainable volume given the prevailing load pressure.
The valve cannot be adjusted and is maintenance-free. In the event of a malfunction, the valve 103
can be checked for contamination or defects and replaced, if necessary, by unscrewing the screw
plug 275 and removing the parts 321 and 322 from the housing.
7.60.22
copyright by
MJFCIFSS
Service Manual
LSC control block

Fig. 12
Sectional drawing of the inlet element "residual pressure balance and pressure cut-off"
100
Compact block
211
Restrictor bolt
102

controller)
For details, see Fig. 13
275
Screw plug
103
Piston/pressure balance (unloading valve) 321
104
322
Pressure spring
105
LS
107
Shuttle valve
LS signal from the consumer with the

highest load
Pump pressure
108
LS central nozzle
Tank channel
copyright by
MJFCIFSS
Spring plate
7.60.23
LSC control block
Service Manual

The diagram of the inlet element with external shuttle valve 107 is only valid for A 312 units to serial
no. 16275, A 314 units to serial no. 16214 and A 316 units to serial no. 16141.
Fig. 13
100
102
7.60.24
Sectional drawing of the inlet element "residual pressure balance and external shuttle valve"
16
103
Compact block
Minimum flow pressure balance, complete
Valve insert/pressure balance
104
Backing ring/pressure balance

valve)
2
3
Piston/pressure balance
Pressure spring/pressure balance
107
108
Shuttle valve
LS central nozzle
Screw plug/pressure balance
211
Restrictor bolt
14
O-ring/pressure balance
321
Spring plate
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MJFCIFSS
Service Manual
LSC control block

15
7.4
322
O-ring/pressure balance
Pressure spring
Primary pressure-relief valve 105 (pump safety valve), see Fig. 12

The primary pressure-relief valve protects the pump against excessive pressure in the event of failure
of the secondary pressure-relief valve and cut-off valve. As it is supposed to respond only in the event
of an emergency, its pressure setting is significantly higher than that of the cut-off valve and system
pressure.
This valve is identical as regards function and design with the secondary pressure-relief valves of the
control axles for boom, stick and bucket, see Fig. 27.
7.5
LS shuttle valve 107, see Fig. 12 and Fig. 13

The orifices of LS shuttle 107 limit the volumetric flow to the LS regulator of the pump. The propagation of abrupt pressure peaks to the regulator and resulting power peaks of the pump are prevented
in the LS line, thanks to the interrelation between the various orifices and capacities. The pulsating
of the hose and/or the compressibility of the oil volume smoothens out pressure peaks. This prevents
aggressive or unwanted responses of the pump to sudden peaks, ensuring stable operating behaviour.
In the event of malfunction, the valve 107 can be removed by screwing off the valve seal 210/219 and
pulling out the double-sided cone 211 so that the valve can be inspected for damage or contamination
and replaced, if necessary (observe correct installation position of double-sided cone).
7.6
LS central nozzle 108, see Fig. 12 and Fig. 13

The LS central nozzle acts as restrictor and dampener at the LS oil inlet in the input element. When
the pressure cut-off valve 104 is actuated, the restrictor lowers the p ratio, and the cut-off valve can
be used to reduce the pump volume through the pump flow regulator.
The central nozzle 108 restricts the volume flowing off through the pressure cut-off line. This is particularly important where several consumers are run to their limit and the fully opened pressure balances feed oil into the LS line.
copyright by
MJFCIFSS
7.60.25
LSC control block
Service Manual
7.7
Pressure cut-off valve 104

The LS pressure cut-off valve 104 acts as a pressure controller. As soon as the pre-set pressure is
reached, it reduces the volumetric delivery of the pump to Qmin. This function has priority over the
pump's power and flow regulation systems. As soon as the pressure cut-off valve is actuated, loadsensing and/or power regulation are disabled.
Once a consumer reaches its max. permissible operating pressure, the cut-off valve is actuated, relieving the LS signal behind the LS main nozzle in the control valve block to the tank. The LS signal
to the pump cannot increase any further, and the pump regulates the flow in such a way that a maximum pump pressure of LS + is built up in the pump channel.
Thanks to the pressure cut-off valve, there is still a certain pump flow volume available in the power
control system.
The valve 104 thus prevents that consumers connected in parallel are stopped as soon as one or
more are run at their maximum limit.
The valve must be regularly inspected and readjusted, if necessary (see maintenance schedule).
Fig. 14
7.60.26
Valve insert
11
Backing ring
Adjusting screw
12
Backing ring
Spring plate
13
Backing ring
6
7
Pressure spring
Washer
14
15
O-ring
O-ring
Lock nut
16
O-ring
10
Circlip
104
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MJFCIFSS
Service Manual
LSC control block

Control and distribution area
8 Control and distribution area

8.1
Control axles, see Fig. 15 and Fig. 16

Each control axle is equipped with the necessary spool and actuation devices (control lid, regulating
springs), a pressure balance and the respective control and high-pressure connections with secondary protection.
8.2
Spools 160, 180, 220, 240, 260

The geometry of the spools and their orifices have been designed and adapted specially to match the
characteristics of the individual consumer. The control of the consumer in the LUDV system is independent of the load pressure. At a constant p, the volumetric flow rate is adjusted by modifying the
cross-section of the gauge orifice and via the stroke of the spool. The maximum volumetric flow rate
to the consumer is thus determined by the maximum possible cross-section.
In the event of malfunction, check the spools 160 to 280. To do this, remove the upper control lid 134,
pull out the spool and check it for damage, contamination, etc. If necessary replace it.
8.3
Dismantling of spools 160 to 260

Caution!
Before dismantling control lines: relieve pressure from hydraulic circuit.
Lid 134 is spring-loaded.
Risk of injury
Dismantle the respective control line.
Remove the screws 135.
Remove the lid 134 with O-ring 130.
Pull the spools 160 to 280 from the control valve block 100.
Remove the pressure spring 132 and the spring plate 131.
8.4
Installation of spools
Important information for installation / replacement of pistons:
The individual spools are matched to the specific requirements of their operational functions
(boom, stick, etc.) and are not interchangeable.
If you wish to remove more than one spool at a time, make sure they are re-installed in their original bores.
Usually, the bores in the control valve blocks are made for perfect fit. If this is the case with all the
bores in the block, the type plate of the block shows end number "000". 'Perfect fit' indicates that
the bores have 0 m tolerance. This means that the spools supplied for replacement usually
have a tolerance range of 8-10 m, and that the amount of leak oil is within the standard tolerance
range.
Zero-tolerance bores are marked with steel stamping numeral 0. Replacement with spools as specified in the ET spare parts catalogue is possible.
If one or several bores of the control block do not meet the zero tolerance standard, the actual
tolerance is indicated on the type plate. To find out the bores to which this applied, remove the top
lid 134 of the spool in question.
copyright by
MJFCIFSS
7.60.27
LSC control block
Service Manual

The tolerance is indicated on the front face /control lid of the control block (e.g. 10 = 10 m). In
this case, it is not possible to replace the spool with a part from the spare parts catalogue, and the
spool must be specially made to fit the tolerance.
When ordering spare spools, please quote all information on the type plate, see also service information no. 1-14-52 / 2000.
Ensure that the spool is installed in the correct position.
Apply a little oil to the fitting spool and carefully insert it into the control valve block 100.
Place the spring plate131 and the pressure spring132 onto the spool.
Insert the O-ring 130 and place the lid 134 on the control valve block 100 and secure them with
the screws 135.
Fig. 15
7.60.28
Control axles with regulating springs and control lid at the control valve block
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MJFCIFSS
Service Manual
LSC control block

Fig. 16
Control axles of the compact control valve block (left) and travel gear (right)
100
134

Control lid
221/222
224

160
161/162

Suction valves chassis right
227
240

Spool / stick
164
241/242
167
244**
170
247
172
180

260
261/262
Spool / bucket
181/182* Suction valves chassis left
264**
184*
280
Spool / support
187*
281
Screw plugs only with section

support
220
Spool / boom
284**
copyright by
MJFCIFSS
7.60.29
LSC control block
Service Manual
Control lid 134

*
**
in R machines only
Sectional drawing, (see Fig. 19, page 32)
9 Control lid 134
Fig. 17
Control lid 134
1
2
Cap nut
O-ring
167
167
Restrictor check valve / travel drive (A)

Restrictor check valve / travel right (R)
3
4
Lock nut
Adjusting screw / stroke limitation
187
227
Restrictor check valve / travel left (L)

Restrictor check valve / boom
134
Control lid
247
Restrictor check valve / stick
140
Screw plug
Setting value of stroke limitation
The control lid 134 is located on both sides of the spools 120 to 260 and is fixed to the compact block
100. The control oil required for the actuation of the spool is fed through the control connection a / b
of the control lid 134.
Some of the control axles have a shuttle dampening function (restrictor check valve 167 / 187 / 227
/ 247) in the inlet area of the control connection. They restrict the flow of the oil displaced by the spool
in the opposite control lid, thus reducing the shifting speed of the spool. This results in a smooth start
of the motion of the consumer, as well as good handling and fine-control.
The consumer movement is damped by the restrictor check valve 167 / 187 / 227 / 247 in the opposite
control lid. The oil enters the control lid (e.g. at connection a) through the opening valve seat. The oil
displaced by the spool (e.g. through connection b) closes the valve seat so that the control oil displaced must flow through the orifice of the valve. The cross-section of the orifice (and thus the shifting
speed) are adjusted to suit the characteristics of the individual consumer. The restriction of the flow
in the outlet to T ensures that both abrupt actuation and sudden pressure relief are effectively dampened.
The control lid is also equipped with a stroke limitation 4 for the spool, so that the maximum speed of
the consumer can be limited.
The relevant setting are factory set (by supplier/manufacturer) and may not be changed. The adjusting screws 4 are secured with the lock nuts 3 and protected against damage by the cap nut 1.
For rough adjustment, check the setting value Y. The fine adjustment of the absolute maximum vo-
7.60.30
copyright by
MJFCIFSS
Service Manual
LSC control block

Control lid 134
lume to a consumer must be carried out with a flow meter on the outlet of the control block.
The flushing grooves a of the spools 160 to 260 form a connection between the tank and control lid
134. Together with the tank preload of the control valve block, they ensure a continuous flow of oil
when the pilot control valve is not actuated. The flushing volume is thus available for the preheating
of the control oil circuit.
Fig. 18
Sectional drawing of control lid134
1
2
Cap nut
O-ring
167
180

Spool / chassis left*
3
4
Lock nut
187
220
Restrictor check valve*

Spool / boom
Shuttle
227
Orifice
240
Spool / stick
100
Control valve block
247
130
131
O-ring
Spring plate
260
280
Spool / bucket
Spool / support
132
Regulation spring
134
Control lid
Flushing groove
160
a1-a5
Control pressure connections, bottom
160
Spool / chassis right*
b1-b5
Control pressure connections, top
in R machines only
copyright by
MJFCIFSS
7.60.31
LSC control block
Service Manual
Directly controlled pressure balances 164 / 184* / 244 / 264 / 284
10

The required flow is controlled by means of the cross-section of the opening of the respective spool
shaft and the LS pressure at the pump regulator.
The effect of differing load pressures in the consumers is compensated by the pressure balances
connected to each spool axle and used in each control valve block.
The LUDV pressure balances 164 -284 with the pressure spring 165 of each section is situated
downstream of the gauge orifice of the spool.
The pressure balance reports the pressure of the consumer with the highest load to the pump regulator. The pressure balance then compensates the pressure difference between load pressure and
pump pressure in all consumers with a lower load.
When in neutral position, the spool blocks the connection between the pump and the channel p (see
Fig. 22). In this position, the pressure in the channel p and behind the load-holding valves is relieved
through the piston play to nearly tank level. The consumer connections are blocked by the spool in
the housing. The consumer is thus located between two oil columns.
Fig. 19
7.60.32
Directly controlled pressure balance (front view and sectional drawing)

Shown here: pressure balance 164
164
Pressure balance
166
O-ring
165
Pressure spring
167
Screw plug
in R machines only
copyright by
MJFCIFSS
Service Manual
LSC control block

10.1
High pressure
As soon as the spool is shifted, the supply orifice of the spool opens the connection between the
pump connection p and the channel p. The pressure built up in this section shifts the pressure balance and also acts through the internal channels in the pressure balance on the rear of the loadholding valves.
The consumer pressure pc of the connection A acts via the channels in the spool and is available at
the front of the left-hand load-holding valve. When the pump pressure p is increased above the consumer pressure pc, the load-holding valve is opened. The connection between the pump and the
consumer is now established and initiates the movement. The displaced oil flows through the outlet
orifice back to the tank. The secondary pressure-relief valves remain closed as long as the pressure
in the consumer connection is below the pre-set pressure value.
Fig. 20
Pressure balance in high-pressure position
pc high = LS signal to pump regulator
10.2
Consumer with highest load is actuated

In the event of individual movements, or if the load pressure of the consumers pc is the highest within
the system, the pressure balance is fully opened. The channel p is connected to the consumer connection pc, without pressure drop.
The consumer pressure is transferred through the pressure balance bores to the spring chamber of
the pressure balance and subsequently to the LS line. The LS signal is transmitted to the flow regulator (LS regulator) of the variable displacement pump, and also to the spring chambers of the other
LUDV pressure balances, which then block the load pressures of the other consumers against the
LS line.
As the LS signal is constantly regenerated by the load-holding valves, the consumer connections remain closed until the required working pressure is reached. This prevents sudden pressure drops in
the event of negative (i.e. pulling) loads.
copyright by
MJFCIFSS
7.60.33
LSC control block
Service Manual
10.3
10.3.1
Low pressure
Load-sensing regulation
In the saturated area, the LUDV system operates as a pure load-sensing regulation system. The
speed of the consumer is controlled independently of the load pressure, by means of the cross-section of the gauge orifice (spool).
When several movements overlap, the load pressure of the consumer with the highest pressure is
applied through the central LS line to the spring chambers of the other LUDV pressure balances. The
resulting pressure in the channel p of this section is determined by the highest reported LS pressure
(p = LS + spring force). The LUDV pressure balances automatically regulate the pressure p of the
various axles by restricting the flow cross-sections to the consumer channels to the same value. As
pressure p in the P channel of the block is the same everywhere, p is the same at all gauge orifices. As a consequence, the consumer speed is independent of the difference between the load
pressures. As the pressure balance spring end is pressurised according to the highest load signal, it
cannot open completely. As the pressure balance is only partly open, an additional pressure difference is built up, which is based on the actual load.
Fig. 21
Pressure balance in low-pressure position
d = LS = pc high
e = pc low
p = LS pressure (approx.)
F = spring chamber
R = regulating orifice
10.3.2
LUDV function
The LUDV system works even in the event of a saturation deficit. In such a case, the oil volume requested by means of the sum of the open gauge-orifice cross-sections at the existing p exceeds
the maximum flow rate of the pump within the boundaries of the power control. The LS regulator of
the pump is no longer in a position to build up the set p by means of further pivoting the variable
displacement pump. Pressure p set at the regulator collapses.
In this status, the LUDV system maintains the p at the same level across all open gauge orifices.
This ensures that the consumer(s) with the highest pressure is/are not shut down in the event of a
saturation deficit. Instead, the speeds of all actuated consumers is reduced in proportion to the respective open cross-sections.
7.60.34
copyright by
MJFCIFSS
Service Manual
LSC control block

When all the pressure balances are in balance,

the LS system pressure is the same in all the spring chambers of the pressure balances
the pressure p in front of the gauge orifices or the pressure balances of the section with the lower
load corresponds to the LS pressure of the consumer with the highest load
p inlet orifice = ppump - p
The pat the inlet orifices of all consumers is always the same. In the event of a saturation deficit,
the p is reduced but again remains the same in all consumers.
The pressure differences p inlet orifices between p and each individual consumer pressure pc are
regulated and automatically levelled by adapting the opening cross-section, so that the volumetric
flows are split proportionally.
10.3.3
Negative load
Speed control of the consumers via the aperture of the inlet orifice is not possible with negative (pulling) loads. In such a case, the consumer is controlled in relation to the actual load, via the outlet orifices.
Fig. 22
Pressure balance in position "spool closed"
a
b
no LS signal
LS signal
100
Control valve block
160
164
copyright by
MJFCIFSS
Spool / travel
Piston
7.60.35
LSC control block
Service Manual
Pilot-controlled pressure balance 224
11

The pilot-controlled pressure balance 224 fulfils the same purposes as the directly controlled pressure balance in the LUDV system. Its function therefore corresponds to the basic functions of the directly controlled pressure balances, (see 10, page 32).
11.1
Additional properties of the pressure balances 224:

Finer and more precise regulation behaviour thanks to the pilot control pistons 1 with pressure
springs 2 incorporated in the pressure balance.
The fast-responding pilot control pistons control the pressure signal from the high-load to the low-load
consumers.
Fig. 23
7.60.36
Pilot-controlled pressure balance (front view and sectional drawing)
1
2
Pilot control piston

Pressure spring
165
166
Pressure spring
O-ring
3
4
Spring plate
Spring plate
168
224
Screw plug
copyright by
MJFCIFSS
Service Manual
LSC control block

11.1.1
Low pressure section:

The pilot control piston 1 is in its initial position, i.e. it connects the current LS pressure of the consumer with the highest load pressure to the spring side of the pressure balance. The pressure balance
regulates the pump pressure of the consumer with the lower load pressure to the LS pressure of the
consumer.
Fig. 24
Pressure balance in low-pressure position (LS signal from consumer with highest load
pressure)
Spring chamber
2
100
Pressure spring
Control valve block
R
pch
Regulating orifice
High pressure (LS)
220
Spool
pcl
Low pressure
224
Pressure balance
copyright by
MJFCIFSS
7.60.37
LSC control block
Service Manual
11.1.2
High pressure section:

The pilot control piston 1 is shifted against pressure spring 2, thus relieving the spring side of the pressure balance main piston. At the same time, the consumer with the highest load pressure is connected to the LS pressure, which in turn acts on the LS controller of the working pump.
7.60.38
Fig. 25
Pressure balance in high-pressure position (pc high = LS signal to pump regulator)
Fig. 26
Pressure balance in position "spool closed"
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Service Manual
LSC control block

Pressure-relief and feeder valves
12 Pressure-relief and feeder valves

see Fig. 27
The pilot-controlled pressure-relief valves 105 / 221 - 262 of the various consumer connections are
all of the cartridge type and screwed directly into the control valve block 100. They limit the pressure
between the pump, the control block and the working attachments and/or between the working attachments and the control block when the spools are closed (secondary function).
If the pressure in the working attachment circuit exceeds the maximum permissible limit, it activates
the built-in pressure-relief valve. the valve limits the maximum pressure in the consumer and the respective connection to the pre-set value.
As high flows result in pressure on the pressure valves of the hydraulic unit, the machine is equipped
with pilot-controlled pressure-relief valves. In these valves, a direct-acting pressure-relief valve acts
as the pilot-control valve, generating a pulse that actuates the second, larger valve.
The pressure-relief valves also act as feeder valves. Differences in the flow rates of the oil to and from
the working cylinders result in a vacuum. This might occur for instance when the stick cylinder is extended with a long stick, due to external pulling loads. In such a case, the speed of the consumer
would not be controlled by means of the gauge orifice diameter, but based on the loads and via the
outlet edge of the spool.
12.1
12.1.1
Pressure limitation
the pilot control cone 4. The springs 8 / 9 and 5 push the main cone 3 and the pilot control cone 4 into
their closing positions (static status).
As soon as the pressure in the consumer circuit reaches a value that is above the set value of pressure and adjusting spring 5, the pilot control cone 4 is lifted from its seat and some oil enters the return
channel T through the ring gap between the housing and the main cone 3.
Due to the different cross-sections of the bores D1 in the main cone 3 and D2 in the valve insert 2,
there is a pressure difference between the front and the spring side of the main cone 3.
As a result of this pressure difference, the main cone 3 is shifted against the pressure springs 8 / 9,
and a substantial amount of oil flows off to the non-pressurised return side T.
12.1.2
Feed
pressure springs 8 / 9 so that the required amount of oil can flow through the bore T and the connection P to the respective side of the consumer.
copyright by
MJFCIFSS
7.60.39
LSC control block
Service Manual
Pressure-relief and feeder valves
Fig. 27
7.60.40
Pressure and feeder valve 105 / 221 - 262
Housing
Valve insert
10
Safety cap
3
4
Main cone
Pilot control cone
11
12
Piston seal
O-ring
Pressure spring
13
O-ring
Adjusting screw
14
Backing ring
Lock nut
15
O-ring
Pressure spring
16
O-ring
copyright by
MJFCIFSS
Pressure spring
Service Manual
LSC control block

Feeder valves 161 / 162 / 181 / 182
13 Feeder valves 161 / 162 / 181 / 182

see Fig. 28
Feeder valves (i.e. suction valves / check valves) are mainly used in conjunction with rotating consumers.
The risk of insufficient oil, i.e. cavitation, in oil motors is greatest when there are delays in the operation of the machine (downhill travel). When decelerating, the oil motor of the drive system runs idle.
The pressure peaks due to the high moment of inertia during downhill travel result in activation of the
brake valves while the spools are blocked.
From a certain inclination, the speed of the motor (and, thus, the oil volume to be fed) is no longer
determined by the aperture of the inlet orifice of the spool, but depends on the load and the grade
resistance.
The feeder valve provides the required volume of oil to the working connection in order to prevent
cavitation.
13.1
13.1.1
Closing position:
The high pressure in channel A/B is applied through the bore D to the spring side of the main cone
3, pressing the cone against the sealing edge of the valve insert 1, so that the valve 161 / 162 / 181
/ 182 is closed towards the consumer side.
13.1.2
Suction:
If there is a vacuum in the working circuit, the higher pressure in the hydraulic tank acts through the
bore T of the valve insert 1 onto the ring face of the main cone 3.
As a result of the pressure difference across the effective surface of the main cone 3, the main cone
is pressed against the force of the pressure spring 8 so that the required amount of oil can flow through the bore T to the respective side of the consumer A / B.
copyright by
MJFCIFSS
7.60.41
LSC control block
Service Manual
Feeder valves 161 / 162 / 181 / 182
Fig. 28
7.60.42
Feeder valves 161 / 162 / 181 / 182
1
3
Valve insert
Main cone
33
34
O-ring
Backing ring
6
8
Screw
Pressure spring
35
37
O-ring
O-ring
31
Piston seal
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Service Manual
LSC control block

Shift valve for Qmin shifting (fast run) of the regulating motor 106 (in R models only)
14 Shift valve for Qmin shifting (fast run) of the regulating motor 106
(in R models only)
The 3/2-way shift valve 106 integrated into the control valve block controls the working pressure of
the travel motor and thus the Qmin / Qmax shifting of the regulating travel motors 200/201.
If fast travel of the excavator is pre-selected with the switch S21 (on the right control console, see
electric equipment) (regulating motor to Qmin), the switching from Qmax to Qmin and vice versa is
determined by the working pressure in the travel gear circuit (travel pressure).
Travel pressure 0 bar - 300 bar = regulating motor can be run at normal and fast speed (Qmax./
Qmin.).
Travel pressure > 310 bar = regulating motor is automatically set to Qmax (low speed).
Travel pressure <130 bar = Resetting pressure from Qmax. (low speed = normal travel) to Qmin.(high
speed = fast travel).
14.1
Function
The valve 106 in neutral position feeds the control oil from the control oil unit 50 connection A2 (solenoid valve Y24) through connection c to connection d and a line to connection X of the regulating
motors 200/201.
The maximum control pressure acts on the travel motors and pushes the powertrain to the minimum
pivot angle (Qmin.= fast speed), see also functional description in group 7.28).
If the travel pressure is increased (>310 bar), the shifting piston 6 is pressed against the pressure
spring 4 and the connection between c - d is blocked, while the pressure at the connection X of the
regulating motors 200/201 is released through connection d -L to the tank. As a consequence, the oil
motor switches to Qmax = low speed, despite the pre-set fast speed.
If the travel pressure drops to the level or the switching point (<130 bar) of the valve or below, the
pressure spring 4 pushes the shifting piston 6 to its neutral position (connecting lines c - d) and the
regulating motors are switched again to Qmin (fast travel).
copyright by
MJFCIFSS
7.60.43
LSC control block
Service Manual
Shift valve for Qmin shifting (fast run) of the regulating motor 106 (in R models only)
Fig. 29
14.2
Sectional drawing of shifting valve (Qmin shifting)
1
2
Connecting piece
Bushing
11
17
O-ring
Backing ring
Piston guide
18
O-ring
4
5
Pressure spring
Spring plate
50
100
from the control oil unit

6
7
Shifting piston
Piston
106
200
Shift valve, complete

from/to travel motor left
Threaded stud
201
from/to travel motor right
Repairs
In the event of malfunction, the valve 106 can be screwed out and inspection for damage and contamination.
7.60.44
copyright by
MJFCIFSS
Service Manual
LSC control block

15 Repairs to control valve block

Caution!
Before carrying out any repairs on the control valve block, release the preload pressures at the tank
and servo system.
Proceed as follows: Unscrew the breather filter on the hydraulic tank with 1 turn (slow de-pressurisation).
Release backpressures.
Turn ignition key into contact position.
Actuate all pilot control devices in all possible directions.
15.1

If there are leaks on the control valve block, replace the seals on the screwed connections, SAE flanges, caps and valves.
15.2
Spool
Remove the control line (collect escaping oil).
Remove the Allen head screws 135. Remove the control lid 134.
Remove the pressure spring 132 with spring plate 131 and pull the spool from the housing.
Note!
If you wish to remove more than one spool at a time, do not confuse them and ensure they are reinstalled in their original bores (observe markings, etc.).
In spare spools, the axle marking A1 - A5 is engraved on the front side opposite the spring and on
the shaft of the spring pack. Note (see table 8.4, page 27)
Prior to installing the spools, check the O-rings in the housing for damage (spool lid seals). Also
check the spools for damage or defects (scores in surface).
Install the parts by completing the above steps in reverse order. Insert the spool with care to avoid
jamming. Do not use force.
15.3
Pressure balances and valves

To repair pressure balances and valves, they must be removed from the housing.
To access the suction valves 161 / 162 / 181 / 182 and the secondary pressure-relief valves 221 262, screw the respective load-holding valve 170 - 172 from the housing.
When installing the valves, check the outer seal rings.
Do not use seal rings that are damaged. Avoid twisting and warping. Fit seals tightly.
Use correct torques to tighten the auxiliary axles, valves and screwed connections.
copyright by
MJFCIFSS
7.60.45
LSC control block
Service Manual
Maintenance
15.4
Tightening torques for the valves and screw plugs of control valve block 100
Pressure balance 102
15.5
120 Nm
Nozzle 271
6.5 Nm
25 Nm
Check valve 274
3.5 Nm
Pressure-relief valve105
120 Nm
Screw plug 275
30 Nm
LS central nozzle 108
8 Nm
Screw plug 276
60 Nm
Restrictor check valve 109

Allen head screw 111
10 Nm
70 Nm
Screw plug 278

10 Nm
70 Nm
10.5 Nm
10.5 Nm
Screw plug 140
20 Nm
Valve 341
20 Nm
Restrictor check valve 167/187/227/247

Screw plug 168/169
20 Nm
200 Nm
Screw plug 369

Screw plug 373
90 Nm
120 Nm
Load-holding valve 172
100 Nm
Screw plug 475
30 Nm
Suction valves 161/162/181/182

Valve seat 210/219
100 Nm
120 Nm
Screw plug 476

Screw plug 490
60 Nm
3.5 Nm
Pressure-relief valves 221 - 262

Check valve 233/234
100 Nm
10 Nm
Screw plug 811
55 Nm
Installation instructions
The contact surface must be absolutely even.

Tighten the mounting bolts evenly, in a cross-wise pattern.
Ensure that all contact faces of the SAE connections are clean.
Pipes and hose lines must be properly laid, without any twists, warps, or tension.
Observe the prescribed tightening torques for mounting bolts, screwed connections etc. (See also
group 1.20 torques of screws, bolts, screw-in studs)
16 Maintenance
Regularly inspect the control valve block for leaks. Regularly check the pressure cut-off valve 104
and the secondary pressure-relief valves 221 - 262 for correct settings (see maintenance instructions). To test the secondary pressure-relief valves, increase the set value of the pressure cut-off valve 104 to a value above the expected peak (see adjustment protocol and guidelines for the hydraulic
system, group 6).
7.60.46
copyright by
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Service Manual
LSC control block

17 Auxiliary control axles

17.1
Slewing gear element, see Fig. 31

Components of the element:
Connections A01 and B01 for slewing-gear supply and return flows
Connection LSDR for load signal to right-hand control block side
Connection DRDA for pressure line to TC valve 125, see also group 7.80
Spool 120 for working movements of the uppercarriage (turning left and right)
Input pressure balance 122 for priority shifting
Check valve 123, preventing any effects on the slewing gear from simultaneously operated consumers with a higher load pressure
Control lid 334 of the axle, limiting the stroke of the spool 120, and featuring the control pressure
connections a01 and b01 as well as the regulating and return spring 332
Restrictor check valves 127 for the fine-control of the spool 120
Fig. 30
17.2
Hydraulic diagram of slewing gear element 120 with TC valve 125

Always observe the safety notes, (see 15, page 45).

Replace the seal rings of flanges, lids and valves. Replace all screw plugs that are no longer tight.
Spool
Disconnect the relevant control line.
Remove the control lid 334 (caution: the lid 334 is spring-loaded.)
Remove the pressure spring 332 and pull the spool 120 from the housing.
Install the parts by completing the above steps in reverse order.
Valves
To repair valves, remove them from the housing. If necessary, replace them with spare parts from the
ET catalogue.
copyright by
MJFCIFSS
7.60.47
LSC control block
Service Manual
Fig. 31
7.60.48
Slewing gear segment
100
120

Spool / slewing gear segment
332
333
Pressure spring
Washer
122
Inlet/supply pressure balance
334
Control lid
123
125
Check valve
TC valve
335
365
Allen head screw

Pressure spring
126
127

369
371
Screw plug
Pressure spring
128
129
Shuttle valve
372
373
O-ring
Screw plug
130
Nozzle ( 0.9 mm)
475
Screw plug
131
132
Nozzle ( 1.5 mm)

Cone
810
811
End plate
Allen head screw
330
331
O-ring
Spring plate
999
Seal kit
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Service Manual
LSC control block

17.3
17.3.1
Functional description of slewing gear spool

Priority of slewing gear
In a single-circuit LUDV system, all consumers are arranged in parallel and supplied by a single working pump. In the LUDV system, the slewing gear is always given priority. It can be controlled independently of all the other consumers.
The question of priorities arises whenever the system must work with a deficit in saturation and the
LUDV system automatically influences the speed of movements with respect to the degree of the actual saturation deficit.
Assigning first priority to the slewing gear became necessary because most operators do not like it
when the speed is automatically influenced by other movements. Automatic acceleration caused as
a result of the LUDV principle is also considered unacceptable.
The priority of the slewing gear during combined movements is ensured by the following measures:
The module is the only consumer in the system working with a 2-way pressure balance in the supply
flow to the gauge orifice. The pressure balance for the section located in front of the gauge orifice
compares the load pressure LS slewing gear and the setting of the pressure balance spring with the
pressure p at the gauge orifice. The p gauge orifice is maintained at a constant level (corresponding to the applied spring force), allowing for speed control that is independent of the load pressure.
The volume can only be increased or reduced, and the speed thus only changed by manipulating the
gauge orifice.
17.3.2
Attachment section is consumer with highest load pressure

The check valve in the LS line between the module and the system ensures that the control of the
slewing gear is not influenced by consumers with higher loads running at the same time.
The difference between the pump pressure psystem and the working pressure p of the slewing gear
element is always controlled and regulated by the preceding pressure balance, even when consumer
pressures fluctuate significantly. The regulating cross-section of the pressure balance has been chosen to allow for quick responses in cases of great differences between psystem and p slewing gear and
is increased/opened with decreasing pressure differences.
The volumes supplied by the pump and not taken up by the slewing gear are distributed proportionally
to the other active consumers according to the LUDV principle.
17.3.3
Slewing gear section is consumer with highest load

The LSslewing gear is reported to the LS line of the compact control block (via the check valve) to have
the highest pressure in the system. Its pressure acts on the rear of the LUDV pressure balances and
the p regulator of the variable displacement pump. The volumes supplied by the pump and not taken up by the slewing gear are distributed proportionally to the other active consumers according to
the LUDV principle.
17.3.4
Slewing gear torque control

In order to achieve sensitive acceleration of the slewing gear, a torque control (pressure control) is
required.
During acceleration from standstill, the slewing gear requires only a small amount of oil. With pure LS
control, this amount however generates the maximum load pressure in the slewing gear, resulting in
maximum rotary acceleration. Any precise speed that is independent of the load pressure (via 2-way
supply pressure balance 360) is thereby overridden by a torque control.
The directly controlled torque control valve 125* allows the operator to continuously control the admissible pslewing gear with respect to pcontrol pressure and, thus, the available torque. The corresponding operating pressure is generated in proportion to the control pressure, i.e. in proportion to the
angle of the pilot control valve. The operator can thus control the rotary acceleration by means of the
angle of the pilot control valve. This approach allows for very sensitive means of accelerating the rotary motion.
copyright by
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7.60.49
LSC control block
Service Manual
17.3.5
Loss-free acceleration
The torque control valve 125 is mounted separately to the hydraulic tank. It is integrated into the LS
line of the module of the pressure balance. This design ensures that the slewing gear is supplied with
the quantity of oil required to build up the necessary working pressure. As soon as the pre-set pslewing gear is reached, the preceding pressure balance reduces the flow, and only supplies the amount
necessary to maintain the pressure. The acceleration of the slewing gear works thus without any losses. The maximum admissible acceleration pressure at the torque control valve 125 is about 30 bar
below the upper setting of the 2-step slewing gear valves in the oil motor. The secondary valves
therefore do not respond, so that loss is prevented. Thanks to the torque control, the quantities supplied to the slewing gear motor increase when pslewing gear drops until the required pressure according to the pre-set p pressure spring is obtained through the gauge orifice.
17.3.6
Deceleration of the slewing gear

The slewing gear is slowed down by means of the outlet orifices of the spool leading to the tank, and
the pressure-relief valves leading to the motor. The minimum possible deceleration is determined by
the lower pressure setting of the 2-step slewing-gear pressure valves. They have been tuned to a
lower level in order to provide for smooth deceleration. Again, the following rule applies: when pcontrol
pressure increases, the additional pressure stage of the secondary cartridge is increased continuously
to the maximum admissible value.
Both values can be adjusted independently by controlling the admissible acceleration pressure via
the torque control valve and the deceleration by means of the brake valves at the motor.
If the spool is in neutral position, the slewing gear is hydraulically fixed by means of the locked consumer connections A and B.
The valve 125 is factory-set and cannot be adjusted. Should modifications become necessary, proceed as laid down in the adjustment protocol and guideline; see group 6.
In the event of a malfunction, the valve can be removed from the housing and dismantled for inspection (contamination, spring break) or replacement.
7.60.50
copyright by
MJFCIFSS
Service Manual
LSC control block

Fig. 32
Sectional drawing of slewing-gear element
120
122
Spool / slewing-gear segment

Inlet/supply pressure balance
372
373
O-ring
Screw plug
127
130

Nozzle ( 0.9 mm)
475
D1
Screw plug
Supply gauge orifice p-A01 or p-B01
131
132
Nozzle ( 1.5 mm)

Cone (load-holding function)
D2
pV
Outlet orifice A01 - T or B01 - T

Consumer pressure
334
Control lid
pM
Pressure in front of gauge orifice
365
Pressure spring
a01/b0 Control oil connection
369
Screw plug
A01
Consumer connection
371
Pressure spring
B01
Consumer connection
copyright by
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7.60.51
LSC control block
Service Manual
7.60.52
copyright by
MJFCIFSS
Service Manual
LSC control block

Kit elements for auxiliary control axles
18 Kit elements for auxiliary control axles
Fig. 33
Auxiliary control axles AS1, AHS 1, AHS 11 and AHS 12
copyright by
MJFCIFSS
7.60.53
LSC control block
Service Manual
LSC auxiliary control axles
19

M7 - 205
Product
Secondary valve
with additional
pressure stage
2 axles
(AHS 1 + AHS 11)
AS1
AHS 1
AHS11
AHS 12
540
Grapple rotator
500
Boom
adjusting device
510
Hydraulic hammer
500 and 510

All auxiliary attachments
Extend
Extend
Contained in:
left
Nom. block width

Consumer connection
M7 - 205
Secondary valve
without additional
pressure stage
Unit
Spool
for
M7 - 205
SX/14-1X
right
Retract
Retract
()
14
(G3/4)
20
(SAE /4)
20
(SAE 3/4)
20
(SAE 3/4)
piston rod
mm
18
25
25
25
Piston stroke
mm
11
11
11
11
11
Setting value Y
A 312 - R 317
mm
15.6
15.6
17.4
14.7(^)
17.4
14.7(^
17.4
14.7(^)
17.4
14.7(^)
p1 0.5 *
bar
2.0
2.0
7.0
7.0
7.0
7.0
p2
0.5 **
bar
23.4
23.4
20.6
20.6
20.6
20.6
Qn (A)/Qn (B)***
l/min
30
30
200
200
200
200*
Restr. check valves

at connection a
at connection b
mm
mm
Max. leak oil

at load pressure
at oil temperature
Tab. 3
1.0
1.0
1.0
1.0
60
150
50
60
150
50
cm3/min
bar
C
see AHS 1 / AHS

11
see AHS 1 / AHS

11
List of LSC auxiliary control axles
= when connecting to a horizontal boom movement device, the flow rate must be reduced at both
sides by turning in the stop screw to Y = 15mm (top) and Y = 12 mm (bottom).
# = when connecting to a regulating cylinder / hydraulic boom adjusting device, reduce the flow rate
to the piston rod side to 140 l/min by turning the stop screw by 270 degrees = 0.7 mm. This reduces
dimension Y to 13.5 mm.
(^)= valid for models A 312 - A 316 from serial no. 13225 and model R 317 from serial no. 18161
Magnet Y22 / Y23
12 Nm
Pressure-relief valve 501 / 502 100 Nm

/ 511 / 512
Seal-lock collar nut 31
38 Nm
Pressure balance 504 / 514

70 Nm
110 Nm
Restrictor check valve 507/517 20 Nm

Pressure-relief valve 541 542 90 Nm
10 Nm
Screw plug 172
100 Nm
p1 = control pressure at begin of regulation

**p2 = control pressure in final position
***Qn (A) / Qn (B) = nominal flow rate at outlet A / Bat
7.60.54
copyright by
MJFCIFSS
p = nominal value
160 Nm
55 Nm
at AS1
Service Manual
LSC control block

19.1
Auxiliary control valve block for accessory kit AS 1

The auxiliary element 540 consists of the accessory kit AS1 for working movements by the grapple
rotator, swivelling ditch cleaning bucket, quick change adapter or Likufix system and is flange-mounted to the control valve block adjacent to the slewing gear element. The above devices for movements are supplied with oil by the main working pump.
The individual segment is equipped with an electromagnetic-hydraulic control of the spool. The proportional control of the spool is designed as an ON-OFF switching system.
The control pressure at the connection a / b is only fed to the spring chamber of the spool 540 after
the solenoids Y22 / Y23 have been switched. The spool is then fully switched over. The pressure balance 544 fulfils the same purpose as the other pressure balances in compact block 100.
Adjust the stroke limitation of the spool according to the instructions in group 16.40.
The design and settings of the secondary protection correspond to group 16.40.
Fig. 34
Auxiliary axle at AS1
540
Spool / auxiliary control block AS1
810
End plate
541
811
Allen head screw
542
Y22
544
Pressure balance
Y23
copyright by
MJFCIFSS
7.60.55
LSC control block
Service Manual
Fig. 35
7.60.56
Auxiliary control axle AS1
540
Spool / AS 1
544
Pressure balance
541
542

Y22
Y23

copyright by
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Service Manual
LSC control block

Fig. 36
27
Sectional drawing of auxiliary control axle AS1

541
28
Pressure spring / L
542
29
30
Screw plug
O-ring
544
810
Pressure balance
End plate
31
32

811
Y22
Allen head screw

33
Pressure spring
Y23
540
Spool / auxiliary control block AS1
copyright by
MJFCIFSS
7.60.57
LSC control block
Service Manual
19.2
Kit elements (kits AHS 1, AHS 11 and AHS 12)

For additional functions, e.g. accessory kits AHS1, AHS11 and AHS 12, more auxiliary axles can be
flange-mounted to the left-hand side of the compact control block.
Each control axle (auxiliary control block) is equipped with the spool and actuating devices (control
load, control springs) required for the relevant function, a pressure balance and all required connections with secondary protection. It is connected hydraulically through the pressure, return and LS
channels with the series block 100. The flange faces of the channels are sealed with O-rings.
The geometry of the spools and their orifices has been designed and adapted specifically to match
the characteristics of the individual consumer. The control of the consumer in the LUDV system is
independent of the load pressure. At a constant p, the volumetric flow rate is generated by modifying the cross-section of the gauge orifice and via the stroke of the spool. The maximum volumetric
flow rate to the consumer is thus determined by the maximum possible cross-section.
To retrofit one or more auxiliary axles, remove the end plate 110 or 810 and mount the new axle between the block 100 and the plate 110 / 810.
19.3
Auxiliary control valve block for accessory kit AHS 1

The design of the individual segment for the working movement 'hydraulic adjustment of boom' etc.
corresponds to that of the boom, stick and bucket axles of the compact block.
For a description of its functions and settings, see group 16.48.
19.4

The design of the individual segment for the working movement 'hydraulic hammer' corresponds to
that of the boom, stick and bucket axles of the compact block. Only the function 'actuate hydraulic
hammer' has a 2-step secondary pressure-relief valve.
19.5

The design of the individual segment for the working movement 'hydraulic adjustment of boom hydraulic hammer / hydraulic adjustment of boom telescopic demolition stick / scrap shear / concrete
crusher / sorting grapple', etc. corresponds to that of the boom, stick and bucket axles of the compact
block.
Only the function 'actuate hydraulic hammer' has a 2-step secondary pressure-relief valve.
7.60.58
copyright by
MJFCIFSS
Service Manual
LSC control block

100
510
Spool / hydraulic hammer, etc.
500
511
Secondary pressure-relief valve /extend

cylinder, 2-step
501
512

cylinder
502
514
Pressure balance
504
Pressure balance
517
507
520
Accessory kit AHS 12 consisting of

Auxiliary axles AHS 1 and AHS 11
copyright by
MJFCIFSS
7.60.59
LSC control block
Service Manual
Fig. 37
7.60.60
Auxiliary control axles for AHS 1, AHS 11 and AHS 12
copyright by
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Service Manual
LSC control block

Fig. 38
Auxiliary axles AHS 1, AHS 11 and AHS 12
copyright by
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7.60.61
LSC control block
Service Manual
Fig. 39
Auxiliary control axles, left = AHS 1, right = AHS 11
15
Control lid
122
Allen head screw*
20
Allen head screw
500
Spool / segment AHS 1
27
28
Cone
Pressure spring
501
502
Pressure and feeder valve, 1-step

29
34
Screw plug
O-ring
504
507
Pressure balance
70
O-ring
510
Spool / segment AHS 11
71
Screw plug
511
72
Pressure spring
512
90
Spring plate
514
Pressure balance
91
100
Pressure spring
Compact block
517
520

AHS 12
110
End plate
999
Seal kit
* various lengths (depend on the number of auxiliary elements)
7.60.62
copyright by
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Service Manual
LSC control block

Pressure and feeder valves 511 (2-step at AHS 11)
20 Pressure and feeder valves 511 (2-step at AHS 11)

see Fig. 41
The pilot-controlled pressure-relief valve 511 of the consumer connection is of the cartridge type and
inserted directly into control valve block 510. The valve has an additional hydraulic pressure stage
and can therefore be used for two different pressure ranges. It limits the pressure between the pump,
the control valve block and the working attachment (stage 1 - primary function - hammer operation)
or between the working attachments and the control block when the spool is closed (stage 2 - secondary function - regulating cylinder protection).
If the pressure in the circuit of a working attachment rises, it begins to act on the built-in hydraulic
device. This element is referred to as a pressure relief valve. It limits the maximum pressure in the
consumer and its connections to a pre-set value.
As high flows result in pressure on the pressure valves of the hydraulic unit, the machine is equipped
with indirectly responding (pilot-controlled) pressure-relief valves. In these valves, a direct-acting
pressure-relief valve acts as the pilot-control valve, generating a pulse that actuates the second, larger valve.
The pressure-relief valve 511 also serves as a feeder valve. Differences in the flow rates of the oil to
and from the working cylinders result in a vacuum. This might occur for instance when the regulating
cylinder is extended due to external pulling loads. In such a case, the speed of the consumer would
not be controlled by means of the gauge orifice diameter, but based on the loads and via the outlet
edge of the spool.
Fig. 40
Pressure and feeder valve 511 (2-step)
copyright by
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7.60.63
LSC control block
Service Manual
20.1
20.1.1
Pressure limitation
The pressure P built up in the consumer circuit acts on the front face of the main cone 5 and, through
the pilot control cone 15.
The springs 7 and 18 push the main cone 5 and the pilot control cone 15 into their closing positions
(static status).
As soon as the pressure in the consumer circuit exceeds the pre-set pressure of the pressure and
channel. Due to the different cross-sections of the bores D1 in the bushing 6 and the ring face D2 in
the valve insert 2, a pressure difference is built up between the front and rear sides of the main cone
5.
As a result of this pressure difference, the main cone 5 is shifted against the pressure springs 7, and
a substantial amount of oil flows off to the non-pressurised return side T.
20.1.2
Additional pressure stage

Stage 1 (low pressure - protection of hydraulic hammer) connection X is connected to
the tank. Pre-loading of pressure spring 18 is lower.
Stage 2 (higher pressure - protection of regulating cylinder) connection X is pressurised with pilot
pressure. The pressure spring 18 is pre-loaded via the shifting piston 9 and
the piston 8 to a higher degree, which results in a higher blow-off pressure.
20.1.3
Feed
pressure springs 7 so that the required amount of oil can flow through the bore T and connection P
to the respective side of the consumer.
Fig. 41
7.60.64
Sectional drawing of pressure and feeder valve 511
copyright by
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Service Manual
LSC control block

Fig. 42
Pressure and feeder valve with additional pressure stage (2-step)
Housing
27
O-ring
2
3
Valve insert
Adjusting screw
28
30
O-ring
Backing ring
4
5
Screw
Main cone
31
32
Piston seal
O-ring
Bushing
33
O-ring
7
8
Pressure spring
Piston
34
35
Backing ring
O-ring
9
10
Shifting piston
Lock nut
37
511
O-ring
Pressure-relief valve, 2-step, complete
11
15
Lock nut
Pilot control cone
999
D1
Seal kit
Bore
18
Pressure spring
D2
Ring face
21
Shim
Connection for control pressure
copyright by
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7.60.65
LSC control block
Service Manual
7.60.66
copyright by
MJFCIFSS
Service Manual
Design
1 Design
The rotary connection is situated at the fulcrum between uppercarriage and undercarriage. It connects the hydraulic system of the uppercarriage with the units situated on the undercarriage.
The stator 2 is mounted above the stator of the 5x rotary connection (high pressure) to the undercarriage.
The rotor 1 is mounted above the rotor of the 5x rotary connection (high pressure) to the uppercarriage.
The connection at the top is connected through the radial and axial bore in the stator 2 and the lines
leading downwards.
The two V seals 21 seal the rotary connection to the outside.
Fig. 1
Rotary connection
copyright by
MJFCIFSS
7.75.1
Service Manual
Connection and hydraulic link
2 Connection and hydraulic link

Connection A
Regulating travel motors

Supply from the solenoid valve Y24 to the regulating motor connection X
3 Sealing of the 1x rotary connection, see Fig. 3 and Fig. 4

To carry out sealing work, the rotary connection 30 can remain mounted in the rotary connection 20.
Disconnect the hydraulic line from the top of the screw fitting 40.
If necessary, remove the hex head screw 26 and remove the driver 25.
Remove the nut 4 (secured with Loctite).
Remove the rotor 1 from the stator 2.
Remove the V-seals 12 from the nut 4 and the stator 2.
Remove the thrust washers 3 and the Quad rings 11 from the rotor 1.
Mount new Quad rings 11 and thrust washers 3 in the rotor 1.
Remount the V-seals 12 onto the stator 2 and the nut 4.
Secure the driver 25 using the hex head screw 26 and the retaining washer 27 to the rotary connection 20.
Place the rotor 1 from the stator 2.
Carefully remove all oil and grease from the thread of the stator 2 and the nut 4.
Apply Loctite 270 to both parts.
Mount the nut 4 and tighten it (tightening torque 30Nm).
Connect the hydraulic line at the screw fitting 40 of the rotary connection 30.
7.75.2
copyright by
MJFCIFSS
Service Manual
Sealing of the 1x rotary connection, see Fig. 3 and Fig. 4
Fig. 2
1
2
Installation and dismantling of the rotary connection

20
25
Rotor
Stator
Rotary connection 5x, complete

Driver
Thrust washer
26
Allen head screw
Nut
27
Retaining washer
11
Quad ring
30
12
V seal
40
Screw connection with screw fitting
copyright by
MJFCIFSS
7.75.3
Service Manual
Exploded view
4 Exploded view
Fig. 3
7.75.4
Exploded view of the rotary connection
Rotor
11
Quad ring
2
3
Stator
Thrust washer
12
999
V seal
Seal kit
Nut
copyright by
MJFCIFSS
Service Manual
Sectional drawing
5 Sectional drawing
Fig. 4
Sectional drawing of the rotary connection
copyright by
MJFCIFSS
7.75.5
Service Manual
Sectional drawing
7.75.6
copyright by
MJFCIFSS
Service Manual
Design
1 Design
The stator 2, the pipe coupling 4 and the flange 5 with the connections 1-6 are connected to the undercarriage via the stator of the 7 x rotary connection (high pressure). The rotor 1 with the connections 1-6 is fixed to the uppercarriage through the rotor of the 7 x rotary connection (high pressure).
There are bores leading from line connections 1-6 of the uppercarriage to the annular chambers.
They are sealed by the rotor seal 22 in the rotor 1.
Every annular chamber is connected through a radial and axial bore in the stator 2 to the pipe coupling 4 and the connections of the flange 5.
The two V-seals 21 prevent dirt penetrating the assembly.
The lid 3 secures the rotor 1 in axial direction and also serves as an additional protection against dirt.
Fig. 1
Rotary connection
copyright by
MJFCIFSS
7.76.1
Service Manual
Connections and hydraulic connections
2 Connections and hydraulic connections

Connection 1
Brake system / working brake

Supply from the foot brake valve (compact brake block), connection B1, to the
multi-disk brakes of the front axle
Connection 2
Transmission
Supply from brake and HBGV switch block (connection A) to shift lo
ok / gearbox connection P1 (travel in 2nd gear)
Connection 3
Transmission
Supply from brake and HBGV switch block (connection B) to shift lo
ok / gearbox connection P2 (travel in 1st gear)
Connection 4
Oscillating axle support

Supply from solenoid valve Y66 to the support cylinders, connection St
Connection 5
Brake system / working brake

Supply from the foot brake valve (compact brake block), connection B2, to the
multi-disc brakes and/or drum brakes of the rear axle
Connection 6
Regulating travel motor / creeper gear mode

Supply from solenoid valve Y24 to regulator / regulating motor connection X
3 Removal and installation

3.1
Dismantling of 6 x rotary connection for sealing work, see Fig. 2

Mark the bottom of the hydraulic lines leading to the rotary connection and disconnect them.
Remove the hollow screw 6 and pull off the flange 5. Be careful with the seal washer 7.
Mark the top of the hydraulic lines leading to the rotary connection and disconnect them.
Remove the Allen head screws 32 with the retaining washer 33 and remove the driver 30.
Remove the nut 29 and the retaining washers 28. Pull the rotary connection 25 from the rotary
connection 40.
3.2
Installation of the 6 x rotary connection after sealing work, see Fig. 2

Insert the complete rotary connection 25 into the rotary connection 40 and replace the cover 44.
Secure the nuts 29 complete with the washers 28 to the screws 27.
Place the driver 30 on the rotary connection 40 and secure it with the Allen head screws 32 and
washer 33.
Place the seal washer 7 in the flange 5. Put the flange 5 on the pipe coupling 4 of the rotary connection. Pay attention to the locking pin in the coupling 4, and the bore in the seal washer 7 and
the flange 5.
Insert and tighten the hollow screw 6 with the tooth lock washer 9 (torque: 50 Nm).
Connect all the hydraulic lines to the completed rotary connection. Pay attention to markings you
made before.
7.76.2
copyright by
MJFCIFSS
Service Manual
Removal and installation
Fig. 2
4
Installation and dismantling of the rotary connection

28
Pipe coupling
Retaining washer
Flange
29
Hex nut
6
7
Hollow screw
Seal washer
30
32
Driver
Allen head screw
Tooth lock washer
33
Retaining washer
25
27

Allen head screw
40
44

Lid
copyright by
MJFCIFSS
7.76.3
Service Manual
Exploded view of previous design
4 Exploded view of previous design
Fig. 3
7.76.4
Exploded view of rotary connection
Rotor
Tooth lock washer
Stator
11
Allen head screw
Lid
12
Allen head screw
Pipe coupling
13
Lock washer
5
6
Flange
Hollow screw
21
22
V seal
Rotor seal
7
8
Seal washer
Thrust washer
25
999
Rotary connection
Seal kit
copyright by
MJFCIFSS
Service Manual
Sectional drawing of previous design
5 Sectional drawing of previous design
Fig. 4
copyright by
MJFCIFSS
7.76.5
Service Manual
Exploded view of new design
6 Exploded view of new design
Fig. 5
7.76.6
1
2
Rotor
Stator
9
11
Tooth lock washer

Allen head screw
3
4
Lid
Pipe coupling
12
13
Allen head screw

Lock washer
Flange
21
V seal
Hollow screw
22
Rotor seal
Seal washer
25
Rotary connection
Thrust washer
999
A
Seal kit
modified design from 08 / 2002
copyright by
MJFCIFSS
Service Manual
Sectional drawing of modified design
7 Sectional drawing of modified design
Fig. 6
copyright by
MJFCIFSS
7.76.7
Service Manual
Sectional drawing of modified design
7.76.8
copyright by
MJFCIFSS
Service Manual
Design
1 Design
The stator is on the undercarriage. The rotor is held in the axial direction by the lid, which, at the same
time, provides additional protection against dirt. The driving pin locks the rotor with the uppercarriage.
There are cast channels leading from line connections 0 - 4 in the rotor to the annular chambers. Special seal rings (seal kit) seal them off against each other. Every annular chamber is connected to its
individual connection 0 - 4 in the stator via a radial and axial bore.
The two outer seal rings (seal kit) seal off the rotor to the outside.
The rotary connection does not need any maintenance.
Fig. 1
Rotary connection
copyright by
MJFCIFSS
7.77.1
Service Manual

Connection 0
Leak oil
Return of the leak oil from the travel motor to the transmission
Connection 1
Connection 2
Travel motor, right

Supply from the control block connection B1 to the travel motor (right, reverse
motion)
Travel motor, left
Connection 3
Supply from the control block connection B2 to the travel motor (left, reverse
motion)
Travel motor, left
Supply from the control block connection A2 to the travel motor (left, forward
motion)
Connection 4
Travel motor, right

Supply from the control block connection A1 to the travel motor (right, forward
motion)

3.1

Remove all lines and parts that might obstruct the disassembly.
Mark the hydraulic lines leading to bottom of the rotary connections 1 and 20 and disconnect them
(collect escaping oil in a suitable container).
Remove the L-piece 25 from the pressure line 24.
Mark the hydraulic lines leading to the top of the rotary connections 1 and 20 and remove them.
Remove the hex head screws 42 with the retaining washers 43.
Carefully pull the rotary connection 20 from the rotary connection 1.
Remove the hex head screws 17 with the retaining washer 18 and remove the driver 19.
Remove the nuts 34 from the hex head screws 32 and lift off the washer 33.
Pull the rotary connection 1 from the undercarriage 50.
3.2
Installation of the 5x rotary connection after sealing work, see Fig. 2

Insert the rotary connection 1 into the undercarriage.
Screw the nuts 34 with the retaining washers 33 onto the hex head screws 32 and tighten them.
Slide the rotary connection 20 into the rotary connection 1.
Screw the hex head screws 42 with the retaining washers 43 into the cover 3 and the rotary connection 20.
Secure the driver 19 to the uppercarriage, using the hex head screws 17 with the washers 18.
Re-connect the hydraulic lines to the rotary connections 1 and 20 (top and bottom). Pay attention
to the markings you made before.
Re-install all other lines and parts you may have removed before.
7.77.2
copyright by
MJFCIFSS
Service Manual
Fig. 2
Installation position of rotary connection
32
Hex head screw
17
18
Hex head screw

Retaining washer
33
34
Retaining washer
Hex nut
19
Driver
41
Allen head screw
20
42
Hex head screw
22
Screw connection
43
Retaining washer
23
Screw connection
44
Retaining washer
24
25
Pressure line
Fitting
50
Undercarriage
copyright by
MJFCIFSS
7.77.3
Service Manual
Exploded view
4 Exploded view
Fig. 3
7.77.4
Cover
11
Rotor
4
5
Screw plug
Retaining washer
15
16*
Felt washer
Screw plug
Hex head screw
98
Seal kit - consisting of 8 seals:

1 felt washer, 2 outer seals top / bottom, 5
inside seals
10
Stator
The type of screw plug has changed

during the production of the series.
copyright by
MJFCIFSS
Service Manual
Sectional drawing
5 Sectional drawing
Fig. 4
copyright by
MJFCIFSS
7.77.5
Service Manual
Sectional drawing
7.77.6
copyright by
MJFCIFSS
Service Manual
Design
1 Design
The stator is on the undercarriage. The rotor is held in the axial direction by the lid, which, at the same
time, provides additional protection against dirt. The driving pin locks the rotor with the uppercarriage.
There are cast channels leading from line connections 0 - 6 in the rotor to the annular chambers. Special seal rings (seal kit) seal them off against each other. Every annular chamber is connected to its
individual connection 0 - 6 in the stator via a radial and axial bore.
The two outer seal rings (seal kit) seal off the rotor to the outside.
The rotary connection does not need any maintenance.
Fig. 1
Rotary connection

2.1
Model A 309 - A 311 Litronic

Connection 0
Leak oil
Recycling of leak oil from travel motor and auxiliary gearbox
copyright by
MJFCIFSS
7.78.1
Service Manual

Connection 1
Travel motor
Supply from control block connection A8 to travel motor (reverse)
Connection 2
Support cylinders
Supply from control block connection A3 to support cylinders (retract)
Connection 3
Travel motor
Supply from control block connection B8 to travel motor (forward)
Connection 4
Support cylinders
Supply from control block connection B3 to support cylinders (extend)
Connection 5
Steering
Supply from Servostat to steering cylinder (travel, right)
Connection 6
Steering
Supply from Servostat to steering cylinder (travel, left)
2.2
Model A 312 - A 316 Litronic

Connection 0
Leak oil
Connection 1
Recycling of leak oil from travel motor and auxiliary gearbox

Travel motor
Supply from control block connection A2 to travel motor (reverse)
Connection 2
Support cylinders
Supply from control block connection B1 to support cylinders (retract)
Connection 3
Travel motor
Supply from control block connection B2 to travel motor (forward)
Connection 4
Support cylinders
Supply from control block connection A1 to support cylinders (extend)
Connection 5
Steering
Connection 6
Supply from Servostat to steering cylinder (travel, right)

Steering
Supply from Servostat to steering cylinder (travel, left)
7.78.2
copyright by
MJFCIFSS
Service Manual

3.1

Remove all lines and parts that might obstruct the disassembly.
Mark the hydraulic lines leading to rotary connections 10 and 115 and disconnect them.
Remove the hollow screw 117 and the tooth lock washer 118.
Remove the flange 116 with the seal 117.
Remove the Allen head screws 27 with the retaining washer 26 and remove the driver 25.
Remove the nuts 122 and the washer 121.
Pull the rotary connection 115 from the rotary connection 10.
Unscrew the hex head screw 12. Lift the rotary connection 10 from the undercarriage 125.
3.2
Installation of the 7x rotary connection after sealing work, see Fig. 2

Place the rotary connection 10 in the undercarriage, engage the driving pin in the driver 19 and
tighten the screws 12.
Secure the driver 25 using the hex head screws 27 and the retaining washers 26 to the rotary connection 10.
Insert the complete rotary connection 115 into the rotary connection 10 and replace the lid 3.
Secure the nuts 122 complete with the washers 1 21 to the screws 120.
Place the driver 25 on the rotary connection 10 and secure it with the Allen head screws 27 and
washers 26.
Secure the flange 116 and the seal 117 with the hollow screw 119 (with tooth lock washer 118)
on the rotary connection 115. Observe correct position.
Re-connect the hydraulic lines to the rotary connections 10 and 115 (top and bottom). Pay attention to marks you made earlier.
Re-install all other lines and parts you may have removed before.
copyright by
MJFCIFSS
7.78.3
Service Manual
Fig. 2
7.78.4
Installation position of rotary connection
Lid
115
10
12

Hex head screw
116
117
Flange
Seal
17
Hex head screw
118
Tooth lock washer
18
19
Retaining washer
Driver
119
120
Hollow screw
Allen head screw
26
27
Retaining washer
Allen head screw
121
122
Retaining washer
Hex nut
125
Undercarriage
copyright by
MJFCIFSS
Service Manual
Exploded view
4 Exploded view
Fig. 3
Lid
11
Rotor
4
5
Screw plug
Screw plug
12
13
Hex head screw

Stator
6
7
Retaining washer
Hex head screw
15*
16#
Felt washer
Screw plug
10
Rotary connection
98
Seal kit - consists of 9 seals:

1 felt washer, 2 outer seals top / bottom, 7
inside seals
version in models A 309 - A 312 from start *

of series production
in machine model A 314 from serial no.
9972
9701
In models A 309 - A 312 from start of

series production
9972
9701
Version in models A 309 - A 311 from start #

of series production
in machine model A 312 - 316 from serial
no. 17250
In models A 309 - A 311 from start of

series production
in machine model A 312 - 316 from serial
no. 17250
copyright by
MJFCIFSS
7.78.5
Service Manual
Sectional drawing
5 Sectional drawing
Fig. 4
7.78.6
copyright by
MJFCIFSS
Service Manual
TC valve
Purpose
TC valve
1 Purpose
The directly controlled 2-stage torque control valve allows the operator to continuously control the admissible operating pressure in the slewing gear, with respect to the control pressure and, thus, the
available torque. The corresponding operating pressure is generated in a proportional relation to the
control pressure, i.e. the angle of the pilot control valve. That way, the operator can control the rotary
acceleration via the angle of the pilot control valve and, thus, benefit from a very sensitive means of
accelerating the rotary motion.
For reasons of better accessibility, the torque control valve is situated on the outside of the slewing
gear section, in the area of the hydraulic tank. It is connected to the pressure balances LS line of the
slewing gear circuit via pressure lines.
The max. admissible acceleration pressure has been pre-set on the torque control valve by the manufacturer. In order to prevent actuation of the secondary valves - and the resulting losses - the highest set value of the 2-step slewing-gear pressure valves in the oil motor is about 30 bar above the set
value of the TC valve.
2.1
Pressure limitation in step 1

Pressure spring 6 is pre-loaded via guide 4 and valve body 2 and presses valve cone 8 against the
sealing edge in valve insert 3 via spring sleeve 7. In its static condition (closed position), the cone
blocks the connection between pressure side P and tank side T.
As soon as the pressure in pressure connection P attains a value above the pre-set value of pressure
spring 6, valve cone 8 will be lifted from its seat and allow oil to enter the return channel. The oil will
continue to flow until the pressure goes down again, back to the pre-set value. That is when the force
of the spring will push valve cone 8 back into its closed position.
2.2
Pressure limitation in step 2 (actuation of the slewing gear)

When actuating and turning the slewing gear to the left or right, the pre-selected control pressure is
guided to connection Pst via a shuttle check valve. Control oil flows to pilot control piston 9 via shuttle
valve 11. Pilot control piston 9 acts on piston 5 and, thus, compresses pressure spring 6. That way,
pre-loaded pressure spring 6 is set under higher pressure so that valve cone 8 stays longer in its
closed position, i.e. even under higher operating pressure.
That means, proportional to the control pressure added in connection Pst, a certain operating pressure is attained in connection P. (The ratio of 1:11 between control pressure and operating pressure
is determined by the piston area of pilot control valve 9.)
Shuttle valve 11 (sitting in connection Pst) throttles the control oil and, thus, prevents a jerky control
behaviour of the TC valve when the control pressure goes down again.
Restrictors 12 and 13, sitting in pressure connection P leading to valve cone 8 and the by-pass channel leading to tank connection T, respectively, also improve the fine-control and regulating behaviour
of the valve.
copyright by
MJFCIFSS
7.80.1
TC valve
Service Manual
2.3
Setting the valve

The valve has a pre-determined fixed setting. Should modifications become necessary, proceed according to adjustment protocol and guideline; see group 6.
In the event of disturbances, it is possible to check the valve for dirt and/or a broken spring: remove
and dismantle; if necessary, replace completely. In the event of leaks, use new seal elements. See
ET spare parts list.
2.4
Repair
In the event of leaks, use seal kit 40.
How to proceed: Loosen locknut 10.
Screw out valve body. Pull out piston 5.
Install new seals on piston 5 and valve body 2.
If necessary, it is also possible to dismantle valve insert 3 complete with piston 4 to check valve cone
8 for dirt and/or damage (scorings, broken spring etc.).
Re-assemble valve according to sectional drawing (see Fig. 2).
Valve insert 3: use torque = 25 Nm.
Valve body 2 / adjusting screw: use torque = 25 Nm.
Locknut 10: use torque = 40 Nm.
Restrictor 12: use torque = 8 Nm.
Restrictor 13: use torque = 6.5 Nm.
Screw plug 22: use torque = 30 Nm.
Fig. 1
TC valve and hydraulic schematic
Valve body
11 Shuttle valve
Valve cone
12 Restrictor
13 Restrictor
10 Lock nut
7.80.2
copyright by
MJFCIFSS
Service Manual
TC valve
Sectional drawing
3 Sectional drawing
Fig. 2
Sectional drawing and hydraulic schematic of TC valve
1
2
Housing
Valve body
11
12
Shuttle valve 1.2 / 0.3 mm

Restrictor 1.5 mm
3
4
Valve insert
Piston guide
13
14
Restrictor 0.9 mm
Stroke stop
5
6
Piston
Pressure spring
16
17
O-ring
Backing ring
Spring sleeve
19
Backing ring
Valve cone
20
O-ring
22
Screw plug
10
Hex nut
29
O-ring
copyright by
MJFCIFSS
7.80.3
TC valve
Service Manual
Sectional drawing
7.80.4
copyright by
MJFCIFSS
Service Manual
SUBGROUP - INDEX
Section
Group
Type
Component arrangement
8.09.1
A 309 LI 20221A 311 LI 20222-
8.10.1
8.17.1
R 313 LI 27752R 317 LI 18161-
Electrical system
8.20.9
A 309 LI 20221A 311 LI 20222-
Electrical system
8.22.9
A 309 LI 29269A 311 LI 29270-
Electrical system
8.30.1
Electrical system
8.32.1
Electrical system
8.33.1
A 312 LI 29898A 316 LI 28061-
Electrical system
8.34.1
A 312 LI 31253A 316 LI 31134R 317 LI 31140-
Electrical system
8.38.1
R 313 LI 27752-
Electrical system
8.40.8
R 317 LI 18161-
8.1
MJFCIFSS
Service Manual
Electric kits
8.45.1
8.70.1
Slip ring rotary connection
8.80.1
Directory of electric kits
8.100.1
8.2
MJFCIFSS
Service Manual
Control elements
1 Control elements
1.1
Overview of operator's cab
Fig. 1
Operator's cab as seen from the operator
A126
Printed circuit board (autocheck)
S5
B19L
Sensor transducer / left pilot control

unit
S8-S218 Switches, see Fig. 19
B19R
Sensor transducer / right pilot control S18-S422 Switches, see Fig. 17

unit
B40
Sensor transducer / travel
B290
B291
Sensor transducer left (kit)

Sensor transducer right (kit)
S32
S44
Indicator switch, horn

Hazard light switch
E8
Cigarette lighter
H7-H336 Indicator lights see Fig. 17
S63
S75
H9
Horn
S263
Switch / offset boom bearing

Switch / oscillating axle locking
device
H10
P6-P50
Buzzer
Displays / clock see Fig. 17
S439L
S439R
Switch button / split blade left

Switch button / split blade right
A 309 LI 20221A 311 LI 20222-
copyright by
MJFCIFSS
Push button / turn grapple
8.09.1
Service Manual
A125 printed circuit board

R75
Potentiometer speed see Fig. 17
S*
Switches for various kits
S1
Pre-heating and start switch
U16
2 A125 printed circuit board
Fig. 2
A125 printed circuit board installed at the left control console behind the function box
A 125
printed circuit board potentiometer
K63-K386 Relays on the distribution board (fig. 1-23)
Fig. 3
S7
Safety switch
Heating
A125 printed circuit board potentiometer
H301
BST indicator light
X837
Plug connection / 8-pin
P1
Potentiometer flow limitation (P1)
X838
P2
X838-1 Plug connection / 9-pin (service)
P3
S1
X834
Code switch
X838-3 Plug connection CAN bus / 2-pin

X839 Screw terminal / 3-pin
X835
X973
Power socket (12V)
X836 Plug connection / 4-pin
8.09.2
copyright by
MJFCIFSS
A 309 LI 20221A 311 LI 20222-
Service Manual
E50 safety and power switch cabinet
3 E50 safety and power switch cabinet
Fig. 4
E50
Fig. 5
Component arrangement in E50 safety cabinet on the hydraulic tank

A127
safety and power switch cabinet
printed circuit board - power (fig. 1-5)
A127 printed circuit board - power
Termina1 5Plus after ignition
F302
terminal 19Pre-heating
F303
Terminal 30EPermanent plus (input)

Terminal 30APermanent plus (output)
F332 Fuse M1, Y12 (25 A)

F-A to F-HFuse / option
Terminal 31Ground
Kl6-1
Relay / terminal 50
Terminal 50Engine start
K288
Relay / terminal 15
BTKP Refuelling pump (kit)
K302
Relay / pre-heating 15
F300
F301
A 309 LI 20221A 311 LI 20222-
Fuses terminal 15, terminal 30, B3, S44

(7.5 A)
Fuse Y29 (7.5 A)
Fuse terminal 15, terminal 30 (50 A) K-A to K-ERelay / option

Fuse K302, R60 (70 A)
copyright by
MJFCIFSS
8.09.3
Service Manual
Sensors / transducers
4 Sensors / transducers
Fig. 6
Fuel level sensor B1 (mounted on the fuel tank)
Fig. 7
Diesel engine, output side
B2
B7
Temperature sensor / engine coolant

Vacuum switch / air filter
Y12
Y29
Solenoid valve / excess fuel for starting

Solenoid valve / engine shut-down
B232 Temperature switch / excess fuel for starting
8.09.4
copyright by
MJFCIFSS
A 309 LI 20221A 311 LI 20222-
Service Manual
Fig. 8
Coolant level sensor B3 (mounted on coolant / expansion tank)
Fig. 9
Hydraulic tank, bottom
B8
Switch / hydraulic oil temperature (indicator light)
B285
Transducer / hydraulic oil temperature

(fan control)
HBGV block mounted on hydraulic tank (engine side)
Fig. 10
A
HBGV block mounted on hydraulic tank (engine side)

B
HBGV block at unit

A 309 from serial no. 29269,
A 311 from serial no. 29170
Pressure switch / Parking brake
Y55
Solenoid valve / first gear
Y6
Solenoid valve / parking brake
Y60
Y55
B10
A 309 LI 20221A 311 LI 20222-
HBGV block at unit

A 309 to serial no. 29268,
A 311 to serial no. 29169
copyright by
MJFCIFSS
8.09.5
Service Manual
Fig. 11
Engine, seen from rear
B12 Transducer / engine speed
Fig. 12
B16
Compact brake block located under the operator's cab
B20 Pressure switch / accumulator pressure

B60 Pressure switch / brake light
Fig. 13
8.09.6
Switch / engine oil pressure
B266
Proximity switch / oscillating axle automatic
S4
Switch / horn
Boom cylinder with pressure switch, overload warning system B21 (kit)
copyright by
MJFCIFSS
A 309 LI 20221A 311 LI 20222-
Service Manual
Fuses
Fig. 14
Water sensor B289 (located near fuel prefilter)
5 Fuses
Fig. 15
Component arrangement on control console, front right
F304-F339Fuses (fig. 1-16)
Fig. 16
A 309 LI 20221A 311 LI 20222-
P5
Operating hour meter
Fuses in the control console, front right
F304
15 A
External fuse / ignition switch
F305
15 A
Interior lights / cigarette lighter / clock
F306
15 A
Reserve
F312
7.5 A
Indicators
copyright by
MJFCIFSS
8.09.7
Service Manual
Fuses
8.09.8
F313
F314
5A
3A
Brake light
Safety lever
F315
F316
15 A
7.5 A
Excavator control
Sensor control / console
F318
F319
20 A
15 A
Heating / air-conditioning system (kit - terminal 30)

F320
15 A
Reserve
F321
15 A
Reserve
F322
7.5 A
Voltage transformer
F325
7.5 A
Parking brake / travel
F326
15 A
Fast travel / quick change adapter
F327
15 A
Reserve
F328
F329
15 A
5A
Reserve
Servo control
F330
F331
7.5 A
15 A
AHS / AS1
Reserve
F336
F337
15 A
15 A
External fuse for lighting

Support / solenoid
F338
15 A
Horn
F339
20 A
A/c condenser (kit)
copyright by
MJFCIFSS
A 309 LI 20221A 311 LI 20222-
Service Manual
Overview of control console
6 Overview of control console
Fig. 17
Control console A (front right)
Indicating elements:
P6
Dial indicator / coolant temperature
P7
Dial indicator / fuel reserve
P50
Clock
Indicator lights:
H7
Engine oil pressure
H167
Forward travel
H11
Pre-heating
H168
Reverse travel
H12
H13
Battery charging
Air filter contamination
H175
H176
Engine overheating
Oscillating axle automatic
H15
H186
Offset boom bearing
A 309 LI 20221A 311 LI 20222-
copyright by
MJFCIFSS
8.09.9
Service Manual

H16
H18
Overload warning system*

Coolant level
H26
H196
Quick change adapter*

Scrap shear / sorting grapple*
H19
H20
Indicator
Parking brake
H311
H336
Oscillating axle locking mechanism

Water in fuel filter
H23
Accumulator pressure
S241
S335
Hydraulic hammer
Blade support
* kit
Switches, potentiometers
R75
S18
Speed adjustment
S19
Grapple rotator*
S343
Individual control of split blade sections ()
S21
Creeper gear travel
S360
Acknowledgement of quick change adapter

buzzer*
S42
1st gear switching
S422
Radio mute mode
S47
* kit
Fig. 18
Control console B (front centre)
S1
S16

Parking brake
S92
S93
S20
Idle automatic
S284 Heating-a/c system blower (4 speeds)
S35
S74
Switch / servo control

Immobiliser*
S318 A/c system*

S398 Reversing switch
Rotary potentiometer / air distribution

Rotary potentiometer for heating-a/c
system
* kit
() This switch has been removed without replacement, see service information 08-08-06/2006
8.09.10
copyright by
MJFCIFSS
A 309 LI 20221A 311 LI 20222-
Service Manual
Fig. 19
Control console C (rear right)
E8
Cigarette lighter
S22
Work headlights, front, front

roof light*
F307-F343Fuses, see Fig. 20

S8
Beacon*
S22-1
S61
Rear roof light*

Travel light
S11
Windscreen washer system
S218
Roof window wiper*
S14
Windscreen wiper
* kit
Fig. 20
Fuses and relays, control console, rear right
F307
F308
7.5A Parking light / tail light

7.5A Right parking light / tail light
F309
7.5A Travel light, left
F310
F311
7.5A Travel light, right

15 A Windscreen wiper / washing system
F317
F323
7.5A Beacon*
15 A Work headlight, attachment*
F324
15 A Work headlight, roof*
F343
7.5A Roof window wiper*
K414
Relay interval control device*
* kit
A 309 LI 20221A 311 LI 20222-
copyright by
MJFCIFSS
8.09.11
Service Manual
Battery and battery main switch
Fig. 21
Left control console with auxiliary switches and indicator lights for 4-wheel steering
H191
Indicator light / 4-wheel steering*
S309
Rotary switch / 4-wheel steering
H192
Indicator light / dog walk steering
7 Battery and battery main switch
Fig. 22
Battery compartment in uppercarriage, front right
F359 Fuse permanent ground clock (3 A)

G2
8.09.12
S9
Battery main switch
Batteries
copyright by
MJFCIFSS
A 309 LI 20221A 311 LI 20222-
Service Manual
Generator / starter
8 Generator / starter
Fig. 23
G1
Diesel engine, radiator side

Alternator
M1
Starter
9 Distribution board
Fig. 24
A 309 LI 20221A 311 LI 20222-
Distribution board with relays and buzzer, located at the control console, rear right
copyright by
MJFCIFSS
8.09.13
Service Manual
Distribution board
H27
Warning buzzer
K375
Relay / kit*
K63
K250
Relay / indicator
Relay / oscillating axle support
K386
K445
Relay / safety switch

Relay / travel 4-wheel steering*
K251
Relay / hand brake (light)
Terminal 15Plus after ignition / permanent plus
K252
Relay / servo hand brake (buzzer)
Terminal 30Plus after ignition / permanent plus
K315
Relay / brake light
K370
Relay / terminal 15 servo
Ground
* kit
Fig. 25
Distribution board with plug connection located at the control console, rear right
X10
X11
Housing recess* 2-pin

X958
X959

X12
X960
X27
X28

X961
X962

X29
X963
X952
X964
X953
X965
X954
X955

X966
X967

X956
X957

X1106 Housing recess* 4-pin
*Recesses for plugs
8.09.14
copyright by
MJFCIFSS
A 309 LI 20221A 311 LI 20222-
Service Manual
Seat heating
10 Seat heating
Fig. 26
Seat heating switch S389 at the front of the operator seat
11 Solenoid valves
Fig. 27
Control oil unit with solenoid valves (located on the engine side of the hydraulic tank)
Y3
Solenoid valve / pilot control pressure Y51
Y24
Y50
Proportional solenoid valve / power

control
A 309 LI 20221A 311 LI 20222-
Proportional solenoid valve / flow limitation
Y330 Solenoid valve / pump regulation

removed on machine A 309 from Sno 26291
and A 311 from Sno 27086
copyright by
MJFCIFSS
8.09.15
Service Manual
Solenoid valves
Fig. 28
Low-pressure control valve block AS1 and valve block for travel / offset boom bearing (located at fuel tank)
Y22
Y23
Solenoid valve / grapple rotator

Y62
Solenoid valve / travel forward
Fig. 29
Outrigger bearing at rear of undercarriage
et
Y217 Solenoid valve / left outrigger
8.09.16
Y63 Solenoid valve / grapple rotator

Y262 Solenoid valve / switchover bucket offset
boom bearing
Y218 Solenoid valve / right outrigger
copyright by
MJFCIFSS
A 309 LI 20221A 311 LI 20222-
Service Manual
Solenoid valves
Fig. 30
Y268
Auxiliary solenoid valve below the control valve block

Solenoid valve / changeover
AHS pilot control
Y299
Solenoid valve / AHS* additional pressure level
* kit
Fig. 31
Proportional solenoid valve / fan control Y352 (located on the oil motor / fan)
Fig. 32
Proportional solenoid valve / motor speed adjustment Y358 (located on the hydraulic
tank)
A 309 LI 20221A 311 LI 20222-
copyright by
MJFCIFSS
8.09.17
Service Manual
Solenoid valves
8.09.18
copyright by
MJFCIFSS
A 309 LI 20221A 311 LI 20222-
Service Manual
Control elements
1 Control elements
1.1
Overview of operator's platform
Fig. 1
Operator's platform seen from the operator
A126
S1
B19L
Sensor transducer / left pilot control

unit
S5
B19R
Sensor transducer / right pilot control S8-S218 Switches, see Fig. 25

unit
B40
Sensor transducer / travel
B290
B291
Sensor transducer left (kit)

Sensor transducer right (kit)

S32
Indicator switch, horn
E8
Cigarette lighter
S44
Hazard light switch
H7-H336 Indicator lights see Fig. 21

H9
Horn
S63
S75

Switch / oscillating axle locking
device
H10
Buzzer
S263
P6-P50
Displays / clock see Fig. 21
S382
Switch fine adjustment ON / OFF
copyright by
MJF C I F S S
8.10.1
Service Manual

R75
R76
Potentiometer speed see Fig. 21

Potentiometer / fine adjustment
S*
U16

Fig. 2
Installation of the printed circuit board A125 in the housing behind the left control console
in machine model A 312 from serial no. 20432, A 314 units to serial no. 20333 and A 316
units to serial no. 20339.
A 125
Printed circuit board potentiometer
Safety switch
Heating
Fig. 3
Installation of the printed circuit board A125 without housing behind the left control console (function box must be removed)
in machine model A 312 from serial no. 20433, A 314 units from serial no. 20334 and A
316 units from serial no. 20340.
A 125

S7
8.10.2
S7
C
Heating
Function box
Safety switch
copyright by
MJF C I F S S
Service Manual
Fig. 4
Printed circuit board potentiometerA125in machine model A 312 from serial no. 20432, A
314 units to serial no. 20333 and A 316 units to serial no. 20339.
Fig. 5
Printed circuit board potentiometerA125in machine model A 312 from serial no. 20433, A
314 units to serial no. 20334 and A 316 units to serial no. 20340.
H301
BST indicator light
X837
P1
X838
P2
P3


S1
Code switch
V156-4 Blocking diode kit
X839
X834
X835

X973 Power socket (12V)

X974-4 Diode plug, 2-pin (kit)
X836
copyright by
MJF C I F S S
Screw terminal / 3-pin
8.10.3
Service Manual
Fig. 6
8.10.4
Installation of the fuse box and solenoid valves at the hydraulic tank
A127 Printed circuit board / power, see Fig. 7
Y63
E50
Safety and power switch cabinet
Y62
Y268 Solenoid valve changeover adjusting

equipment / hammer (kit)
Y299 Solenoid valve pressure reduction (kit)
Fig. 7
Printed circuit board / powerA127
KL15
Plus after ignition
F302
KL19
Pre-heating
F303
Fuses terminal 15, terminal 30, B3, S44

(7.5 A)
Fuse Y29 (7.5 A)
KL30E
Permanent plus (input)
F332
Fuse M1, Y12 (25 A)
KL30A
KL31
Permanent plus (output)

Ground
F-A to F-HFuse / option

K16-1
Relay / terminal 50
copyright by
MJF C I F S S
Service Manual
KL50
BTKP
Engine start
Refuelling pump (kit)
K288
K302
F300
Fuse terminal 15, terminal 30

(50 A)
K-A to K-ERelay / option
F301
Fuse K302, R60 (70 A)
Relay / terminal 15
Relay / pre-heating 15
Fig. 8
Fig. 9
B2
M1
copyright by
MJF C I F S S
Starter
8.10.5
Service Manual
Fig. 10
Fig. 11
B7
Fig. 12
B8
8.10.6
Y12
Y29

Switch / hydraulic oil temperature (indica- B285 Transducer / hydraulic oil temperature
tor light)
(fan control)
copyright by
MJF C I F S S
Service Manual
Fig. 13
HBGV block for 2 HL 70/100 in models A 312 to 29897 and A 316 to 28060 located at the
basic boom bearing block
B10
Pressure switch / parking brake
Y6
Fig. 14
Y55
Fig. 15
Solenoid valve / 1st gear
HBGV block for 2 HL 270/290 in models A 312 to 29898 and A 316 to 28061 located at
the basic boom bearing block
Y60
Solenoid valve / 2nd gear
B16
Y55
copyright by
MJF C I F S S
8.10.7
Service Manual
Fig. 16
Compact brake block located under the operator's cab

8.10.8
B266
S4
Switch / horn
Fig. 17
Fig. 18
Water sensor B289 (located near fuel prefilter)
copyright by
MJF C I F S S
Service Manual
Fuses
5 Fuses
Fig. 19
Component arrangement on control console, front right
F304-F339 Fuses,
Fig. 20
P5
F304
15 A
F305
F306
15 A
15 A

Reserve
F312
7.5 A
Indicators
F313
5A
Brake light
F314
F315
3A
15 A
Safety lever
Excavator control
F316
7.5 A
F318
F319
20 A
15 A

F320
F321
15 A
15 A
Reserve
Reserve
F322
7.5 A
Voltage transformer
F325
7.5 A
Parking brake / travel
F326
15 A
F327
F328
15 A
15 A
Reserve
Reserve
copyright by
MJF C I F S S
8.10.9
Service Manual

F329
5A
Servo control
F330
7.5 A
AHS / AS1
F331
F336
15 A
15 A
Reserve
F337
15 A
Support / solenoid
F338
15 A
Horn
F339
20 A
A/c condenser (kit)
Fig. 21
8.10.10
Control console A (front right) in model A 312 to serial no. 20432, A 314 units to serial no.
20333 and A 316 units to serial no. 20339.
copyright by
MJF C I F S S
Service Manual
Fig. 22
Control console A (front right) in model A 312 from serial no. 20433, A 314 units from serial no. 20334 and A 316 units from serial no. 20340.
P6
P7
Fuel level indicator
P50
Clock
Indicator lights:
H7
H11
Engine oil pressure

Pre-heating
H167
H168
Forward travel
Reverse travel
H12
H13
Battery charging
Air filter contamination
H175
H176
Engine overheating
Oscillating axle automatic
H15
H186
Offset boom bearing
H16
H26
copyright by
MJF C I F S S
8.10.11
Service Manual

H18
H19
Coolant level
Indicator
H196
H311
Scrap shear / sorting grapple*

Oscillating axle locking mechanism
H20
H23
Parking brake
Accumulator pressure
H307
H336
Fine adjustment (delta P)

Water in fuel filter
S241
Hydraulic hammer
* kit
Switches, potentiometers
R75
Speed adjustment
S18
S335
Blade support
S19
Grapple rotator*
S343
Individual control of split blade sections
S21
Creeper gear travel
S360
Acknowledgement of quick change adapter

buzzer*
S42
1st gear switching
S422
Radio mute mode
S47
* kit
Fig. 23
8.10.12
Control console B (front centre) in model A 312 to serial no. 20432, A 314 units to serial
no. 20333 and A 316 units to serial no. 20339.
copyright by
MJF C I F S S
Service Manual
Fig. 24
Control console B (front centre) in model A 312 to serial no. 20433, A 314 units from serial
no. 20334 and A 316 units from serial no. 20340.
S16
Parking brake
S93
S20
S35
Idle automatic

S318 A/c system*
S74
Immobiliser*
S92

system
* kit
Fig. 25
E8
Cigarette lighter
S22*

roof light
F307-F343 Fuses, see Fig. 26
S22-1
Rear roof light
S8*
S61
Travel light
Beacon
copyright by
MJF C I F S S
8.10.13
Service Manual

S11
S14
* Kit

Windscreen wiper
S90 #
S218*
Interval switch / windscreen wiper

Roof window wiper
# only in models A 312 to serial no. 20432, A 314 units to serial no. 20333 and A 316 units to serial no. 20339.
Fig. 26
Fuses and relays, control console, rear right
F307
7.5A
Parking light / tail light
F308
F309
7.5A
7.5A
Right parking light / tail light

Travel light, left
F310
F311
7.5A
15 A
Travel light, right

Windscreen wiper / washing system
F317*
F323*
7.5A
15 A
Beacon
Work light / attachment
F324*
15 A
Work headlight, roof
F343*
K414
7.5A
Roof window wiper

* kit
Fig. 27
e
8.10.14
E4
Travel light, right
G2
Batteries
E15
E23
Parking light, right

Indicator light, front right
S9
Battery main switch
copyright by
MJF C I F S S
Service Manual
Generator / starter
8 Generator / starter
Fig. 28
G1
Diesel engine, radiator side

Alternator
M1
Starter
Fig. 29
H27
Warning buzzer
K375
Relay / kit*
K63
Relay / indicator
K386
copyright by
MJF C I F S S
8.10.15
Service Manual
Distribution board
K250
K251
Relay / oscillating axle support

K392# Relay / industrial shut-off*

KL15 Plus after ignition / permanent plus
K252
K315
Relay / servo hand brake (buzzer)

Relay / brake light
KL30
A
K370
* Kit
Fig. 30
Plus after ignition / permanent plus

Ground
# only in models A 312 to serial no. 27113
X10
X958
X11
X12

X959
X960

X27
X961
X28
X29

X962
X963

X952
X953

X964
X965

X954
X966
X955
X967
X956
X957
*Recesses for plugs
8.10.16
copyright by
MJF C I F S S
Service Manual
Additional switches
10 Additional switches
Fig. 31
Switch for release of the windscreen wiper S283 (located in the front right position on the
operator's cab frame)
Fig. 32
Switch of air cushioning and seat heating at the front of the operator seat
S388
S389
Switch air cushioning
copyright by
MJF C I F S S
Switch / seat heating
8.10.17
Service Manual
Solenoid valves
11
Solenoid valves
Fig. 33
Y3
Solenoid valve / pilot control pressure
Y24
Y50
Fig. 34
Y22
8.10.18
Control oil unit with solenoid valves (located on the engine side of the hydraulic tank)
Y51

Compact control block with auxiliary control axle for AS1 kit
Solenoid valve / grapple rotator left
Y23
copyright by
MJF C I F S S
Solenoid valve / grapple rotator right
Service Manual
Solenoid valves
Fig. 35
Outrigger bearing at rear of undercarriage
Y217 Solenoid valve / left outrigger *
Fig. 36
Y218 Solenoid valve / right outrigger *
Junction box and solenoid valve in undercarriage (seen from the bottom)
S272 Junction box
Y56
Solenoid valve / blade *
* for outrigger individual control resp. front blade with outrigger individual control.
copyright by
MJF C I F S S
8.10.19
Service Manual
Solenoid valves
8.10.20
Fig. 37
Fig. 38
Proportional solenoid valve / motor speed adjustment Y358 (located on the hydraulic
tank)
copyright by
MJF C I F S S
Service Manual
Control elements
1 Control elements
1.1
Overview of operator's cab
Fig. 1
Operator's cab seen from the operator
A126
B19L

P6-P50 Displays / clock siehe Fig. 15
Sensor transducer / left pilot control unit R75
Potentiometer / speed siehe Fig. 15
B19R
Sensor transducer / right pilot control

unit
Sensor transducer / pilot control unit
Travel left
R76
S1
B40R

Travel right
S5
B290

Kit left
S8-S218Switch siehe Fig. 17
B291

Kit right
S17-S382 Switchsiehe Fig. 15
E8
Cigarette lighter
S20-S398 Switch siehe Fig. 16
B40L
H7-H307Indicator lamps siehe Fig. 15

H9
Horn
R 313 LI 27752R 317 LI 18161-
S382
S*
copyright by
MJFCIFSS
Switch fine adjustment ON / OFF

8.17.1
Service Manual

H10
U16
Buzzer
Fig. 2
A125 printed circuit board installed at the left control console behind the function box
A 125
K370-K386 Relay on distribution boardsiehe Fig. 20
Fig. 3
8.17.2
S7
C
Safety switch
Heating
A125 printed circuit board potentiometer
copyright by
MJFCIFSS
R 313 LI 27752R 317 LI 18161-
Service Manual
H301
BST indicator light
X837
P1
P2


P3
S1

Code switch

X834
X839
Screw terminal / 3-pin
X835
X836

X973
Power socket (12V)
Fig. 4
Component arrangement in E50 safety cabinet on the hydraulic tank

A127 printed circuit board / powersiehe Fig. 5
Fig. 5
R 313 LI 27752R 317 LI 18161-
Y299 Solenoid valve / AHS 11 kit
A127 printed circuit board / power
copyright by
MJFCIFSS
8.17.3
Service Manual
KL15
Plus after ignition
KL19 Pre-heating
KL30E Permanent plus (input)
F302
Fuses KL 15, KL 30, B3, S44 (7.5 A)
F303
F332
Fuse Y29 (7.5 A)

Fuse M1, Y12 (25 A)
KL30A Permanent plus (output)
F_A - F_M Fuse / optional
KL31
Ground
K16-1 Relay / terminal 50
KL50
Engine start
K288
BTKP Refuelling pump (kit)

F300 Fuse KL15, KL 30
F301
Relay / terminal 15
K302 Relay / pre-heating 15

K_A - K_E Relay / optional
Fuse K302, R60
Fig. 6
Fig. 7
Engine output side
B2
8.17.4
M1
copyright by
MJFCIFSS
Starter
R 313 LI 27752R 317 LI 18161-
Service Manual
Fig. 8
Fig. 9
B7
R 313 LI 27752R 317 LI 18161-
Y12
Vacuum switch / air filter (located at the
suction pipe between the air filter and the
engine)
copyright by
MJFCIFSS

(located on the housing / speed adjusting
device)
8.17.5
Service Manual
Fig. 10
B8
Switch / hydraulic oil temperature (indica- B285 Transducer / hydraulic oil temperature
tor light)
(fan control)
Fig. 11

B16 Switch / engine oil pressure
8.17.6
G1
R60
copyright by
MJFCIFSS
Three-phase regulator
Pin-type glow plugs (located at the
engine)
R 313 LI 27752R 317 LI 18161-
Service Manual
Fuses
Fig. 12
5 Fuses
Fig. 13
F304-F339Fuses siehe Fig. 14
Fig. 14
P5
F304
F305
15 A
15 A

F306
F314
15 A
3 A
Reserve
Safety lever
F315
F316
15 A
7,5 A
Excavator control
R 313 LI 27752R 317 LI 18161-
copyright by
MJFCIFSS
8.17.7
Service Manual
Fuses
8.17.8
F318
20 A
Heating / air-conditioning system (kit - terminal

30)
Heating / air-conditioning system (kit - terminal
15)
F319
15 A
F320
F321
15 A
15 A
F322
7,5 A
F326
F327
15 A
15 A

Reserve
F328
F329
15 A
5 A
Reserve
Servo control
F330
F331
7,5 A
15 A
AHS / AS
Reserve
F336
15 A
F338
F339
15 A
20 A
Horn
A/c condenser (kit)
Reserve
Reserve
Voltage transformer
copyright by
MJFCIFSS
R 313 LI 27752R 317 LI 18161-
Service Manual
Fig. 15
Control console A (front right)
P6
P7
Indicator lights:
H7
Engine oil pressure
R 313 LI 27752R 317 LI 18161-
P50
Clock
Dial indicator fuel reserve
H18
Coolant level
copyright by
MJFCIFSS
8.17.9
Service Manual

H11 Pre-heating
H12 Battery charging
H26 Quick change adapter*

H175 Engine overheating
H13 Air filter contamination

H15 Hydraulic oil temperature
H196 Scrap shear / sorting grapple*

H307 Fine adjustment ( p)
H16 Overload warning system*

* kit
Operation / switches, potentiometers
R75 Speed adjustment
S47
S17
S18
Slewing gear brake

S19
Grapple rotator*
S241 Hydraulic hammer

S360 Acknowledgement of quick change adapter
buzzer*
S382 Activation fine control adjustment
S21
Fast travel
* kit
Fig. 16
S20
Control console B (front centre)

Idle automatic
S74
Immobiliser*
S318 A/c system*
S92
S93

system
* kit
8.17.10
copyright by
MJFCIFSS
R 313 LI 27752R 317 LI 18161-
Service Manual
Fig. 17
E8

S22

roof light*
F307-F343Fuses siehe Fig. 18
S22-1
Rear roof light*
S8
S11
Beacon*
S61
S218
Travel light
Roof window wiper*
S14
Windscreen wiper
Cigarette lighter
* kit
Fig. 18
Fuses and relays, control console, rear
F307
F308
7.5 A
7.5 A
Parking light / tail light

Right parking light / tail light
F309
F310
7.5 A
7.5 A
Travel light, left

Travel light, right
F311
15 A
Windscreen wiper / washing system
F317
F323
7.5 A
15 A
Beacon*
Work headlight, attachment*
F324
15 A
Work headlight, roof*
F343
7.5 A
Roof window wiper*
K414
* kit
R 313 LI 27752R 317 LI 18161-
copyright by
MJFCIFSS
8.17.11
Service Manual
Fig. 19
G2

S9
Batteries
Battery main switch
Fig. 20
H27
Warning buzzer
K386
K370
K375
Relay / KL 15 servo
Relay / kit*
KL15 / KL 30Plus after ignition / permanent plus

C
Ground
* kit
8.17.12
copyright by
MJFCIFSS
R 313 LI 27752R 317 LI 18161-
Service Manual
Distribution board
Fig. 21
X10
X11
X12
X27


X28
X29







*Recesses for plugs
R 313 LI 27752R 317 LI 18161-
copyright by
MJFCIFSS
8.17.13
Service Manual
Seat heating
9 Seat heating
Fig. 22
10
Solenoid valves
Fig. 23
8.17.14
Seat heating switch S389 at the front of the operator seat
Control oil unit (located at the rear of the hydraulic tank)
Y3
Solenoid valve / pilot control pressure
Y50
Y7
Solenoid valve / slewing gear brake
Y51
Y24
copyright by
MJFCIFSS

R 313 LI 27752R 317 LI 18161-
Service Manual
Solenoid valves
Fig. 24
Y22
Additional control valve block AS1
Y23
Fig. 25
Fig. 26
Proportional solenoid valve / motor speed Y358 (located at the separating panel of the
control valve block console)
R 313 LI 27752R 317 LI 18161-
copyright by
MJFCIFSS
8.17.15
Service Manual
Solenoid valves
8.17.16
copyright by
MJFCIFSS
R 313 LI 27752R 317 LI 18161-
Service Manual
Electrical system
Electrical system
Item
Description
Step
Place / layout
A3
A125
A126
Radio (optional)
Potentiometer board
Operator's cab, back

Left bracket
Right bracket
A127
Printed circuit board: power
A134
A1017
Control: 4-wheel steering

Printed circuit board: quick-change adapter
8
26/34
4/10/13/
21a/21b/
24/33/34/
36/38/40/
1a/1b/1c/
2/3
12
38
B1
B2
B3
B7
B8
B10
B12
B16
B19L
B19R
B20
Transducer/fuel level - with plug

Temperature sensor for motor coolant
Transducer/motor coolant - with plug
Switch / hydraulic oil temperature
Transducer / motor speed
Switch / motor oil pressure
Sensor transducer - pilot control valve, left
Sensor transducer - pilot control valve, right
Pressure switch / accumulator pressure
17
20
21a
21a
21a
13
27
21a
28
28
21a
B21
Pressure switch UL
36
B26
B40
B50L
B50R
B60
Proximity switch / quick-change adapter

Proximity switch / pilot pressure valve: travel
Loudspeaker, left
Loudspeaker, right
Pressure switch / brake light
38
28
8
8
9
B232
B248H
B248V
B266
B285
B289
B290
B291
Temperature switch / excess fuel for starting

Sensor for rear axle alignment
Sensor for front axle alignment
Transducer hydraulic oil temperature / fan control
Water sensor in fuel tank
Proximity switch / kit pedal
1a
12
12
33
29
21a
34
34
Fuel tank
Motor, top fan side
Engine compartment
Suction pipe - air filter
HBGV block
Flywheel housing / motor
Motor housing
Joystick, left
Joystick, right
Brake block beneath operator's platform
Boom cylinder section piston side
Quick-change adapter
Travelling pedal
Cab, rear left
Cab, rear right
Motor
Rear axle housing
Front axle housing
Lower brake pedal
Tank
Preliminary fuel filter
Operators platform
Operators platform
E1
E2
E3
E4
E7
E8
E9
E15
work headlight for attachments

Front roof light
Travel light, left
Travel light, right
Roof-mounted light
Cigarette lighter
Beacon
5
5
6
6
8
8
37
6
Attachment
Front cab roof
Revolving deck, front
Cab
Bracket, rear right
Cab, top
Revolving deck, front right
A 309 LI 20221A 311 LI 20222-
copyright by
MJFCIFSS
Electric cabinet at hydraulic tank

below operator's platform
Distribution board
8.20.1
Electrical system
Service Manual
Item
Description
Step
Place / layout
E16
E17
E18
E19
E20
E21
E22
E23
E24
Parking light, left

Tail light, right
Tail light, left
Brake light, right
Brake light, left
Direction indicator, front left
Direction indicator, rear left
Direction indicator, front right
Direction indicator, rear right
6
6
6
6
6
4
4
4
4
E50
Electric cabinet
E150
Rear roof light, with plug
1a/1b/1c/
2/3/40
5
Revolving deck, front left

Revolving deck, rear right
Revolving deck, rear left
Revolving deck, backside,
to the right
Hydraulic tank
F_A
F_B
F_C
F_D
F_E
F_F
F_G
F_H
F_I
F_K
F_L
F_M
F_N
FRes
F20/
F300
F19/
F301
F22/
F302
F303
F304
F305
F306
F307
Fuse optional
Fuse optional
Fuse optional
Fuse optional
Fuse optional
Fuse optional
Fuse optional
Fuse optional
Fuse optional
Fuse optional
Fuse optional
Fuse optional
Fuse optional
Fuse, reserve
Fuse A127 class 30 to class 15
_A
_A
_A
_A
_A
_A
_A
_A
_A
_A
_A
_A
70 A
_A
50A
1b
1b
1b
1b
1b
1b
1b
1b
1b
1b
1b
1b
1a
14
1a
A127, hydraulic tank

Right bracket
Fuse A127 K302, R60
70A
Fuse A127 class 15, class 30, S44
7.5A
1b
Fuse A127, Y29

Fuse S1
Fuse E7, E8, P50
Fuse X10
Fuse E16, E17, P6, P7, P50
7.5A
15A
15A
15A
7.5A
3
1a
8
16
6
F308
Fuse E15, E18
7.5A
F309
Fuse E3
7.5A
F310
Fuse E4
7.5A
F311
Fuse M3, M4
15A
F312
F313
Fuse S44, E21, E22, E23, E24

Fuse E19, E20
7.5A
5A
4
9

Right bracket
Right bracket
Right bracket
Bracket, backside, to the
right
right
right
right
right
Right bracket
Right bracket
8.20.2
copyright by
MJFCIFSS
Cab roof, rear
A 309 LI 20221A 311 LI 20222-
Service Manual
Electrical system
Item
Description
Step
Place / layout
F314
F315
F316
F317
Fuse S7
Fuse BST (excavator control)
Fuse: servo control
Fuse: beacon
3A
15A
7.5A
7.5A
14
23
28
37
F318
F319
F320
F321
F322
F323
Fuse: heating / air condition, class 30

Fuse: heating / air condition, class 15
Fuse X11
Fuse X12
Fuse T1
Fuse E1
20A
15A
15A
15A
7.5A
15A
30c
30c
16
16
8
5
F324
Fuse S22 - E2, S22-1 - E150
15A
F325
F326
F327
F328
F329
F330
F331
F332
F336
F337
F338
F339
F343
F356
F357
F359
Fuse S16, K251

Fuse S21 - Y24, S42 - Y55
Fuse X27
Fuse X28
Fuse S35
Fuse: kits
Fuse X29
Fuse A127, M1, Y12
Fuse S61
Fuse: support
Fuse H9, seat heating
Fuse: a/c condenser
Fuse: roof window wiper
Fuse: 4-wheel steering, class 15
Fuse: permanent ground - clock
7.5A
15A
15A
15A
5A
7.5A
15A
25A
20A
15A
10A
20A
7.5A
10A
2A
3A
13
11
16
16
15
16
16
1a
6
35
4
30c
7
1b
1b
42
Right bracket
Right bracket
Right bracket
right
Right bracket
Right bracket
Right bracket
Right bracket
Right bracket
right
right
Right bracket
Right bracket
Right bracket
Right bracket
Right bracket
Right bracket
Right bracket
Right bracket
Right bracket
Right bracket
Right bracket
Right bracket
Battery box
G1
G2
alternator
batteries
1a
1a
diesel engine
Battery box
H7
H9
H10
H11
H12
H13
H15
H16
H18
H19
H20
H23
H26
H27
H167
Indicator light: motor oil pressure

horn
Warning buzzer
Indicator light: pre-heat
Indicator light: charge
Indicator light: air filter dirty
Indicator light: hydraulic oil temperature
Indicator light: overload warning (kit)
Indicator light: coolant level
Indicator light: direction indicator
Indicator light: parking brake
Indicator light: accumulator pressure
Indicator light: quick-change adapter
warning buzzer
Indicator light: travel forward
21a
4
21b
2
21b
21a
21a
36
21a
4
13
21a
38
13
10
Right bracket
Right bracket
Right bracket
Right bracket
Right bracket
Right bracket
Right bracket
Right bracket
Right bracket
Right bracket
Right bracket
Right bracket
Right bracket
Right bracket
A 309 LI 20221A 311 LI 20222-
copyright by
MJFCIFSS
8.20.3
Electrical system
Service Manual
Item
Description
Step
Place / layout
H168
H175
H176
H186
H191
H192
H196
H301
H311
H336
HRes
Indicator light: travel reverse

Indicator light: motor overheating
Indicator light: oscillating-axle locking device
Indicator light: swivel bearing
Indicator light: 4-wheel steering
Indicator light: dog-walk steering mode
Indicator light: sorting grapple
Indicator light: error BST
Indicator light: oscillating axle locked
Indicator light: water in fuel filter
Indicator light: reserve
10
21a
33
40
12
12
34
26
33
21a
40
Right bracket
Right bracket
Right bracket
Right bracket
Left bracket
Left bracket
Right bracket
A125, left bracket
Right bracket
Right bracket
Right bracket
K_A
K_B
K_C
K_D
K_E
K16-1
K16-2
K63
K250
K251
K252
K288
K302
K315
K364
Relay optional
Relay optional
Relay optional
Relay optional
Relay optional
Relay terminal 50
Relay, disconnected
Relay: direction indicator
Relay: oscillating axle automatic
Relay: hand brake (indicator light H20)
Relay servo - hand brake (buzzer)
Relay, terminal 15
Relay: pre-heat
Relay: brake light
Relay to A1017
1c
1c
1c
1c
1c
1a
1a
4
33
13
13
3
2
9
38
K370
K375
K386
K393
K403
K405
K414
K445
Relay KL15, servo

Relay kit - quantity
Relay, safety switch S7
Relay, air-spring seat
Relay: heating
Relay: heating
Relay: intermittent windscreen wiper
Relay: travel shut-off 4-wheel steering
15
34
14
31
30a
30b
7
10

Right bracket
Right bracket
Right bracket
Right bracket
Right bracket
board
Right bracket
Operator's platform, back
Right bracket
Operators platform
Right bracket
M1
M3
M4
M60
M65
M68
M70
M71
M72
Starter
Motor: windscreen washer system
Motor: windscreen wiper with plug
Windscreen washer system: roof (optional)
blower motor
Windscreen washer system: roof (optional)
Motor: air-spring seat
Servo motor water valve
Servo motor: air diffusion
1a
7
7
7
30b
7
31
30a
30a
Diesel engine
Cab, back
Windscreen
Cab, top
Cab, top
Operators platform
8.20.4
copyright by
MJFCIFSS
A 309 LI 20221A 311 LI 20222-
Service Manual
Electrical system
Item
Description
Step
Place / layout
M73
Servo motor: air diffusion
30a
P1
P2
P3
P5
P6
P7
P50
Potentiometer flow limitation 1

Display: operating hour meter
Display: motor temperature
Display: fuel level
Display: clock
26
26
26
19
20
17
18
Left bracket
Left bracket
Left bracket
Right bracket, bottom
Right bracket
Right bracket
Right bracket
R60
R75
R78-1
R78-2
RS232
Pin-type glow plug, with plug

Potentiometer: speed
seat heating
seat heating
Laptop interface
2
22
32
32
26
diesel engine
Right bracket
Operators platform
Operators platform
Left bracket
S1
S1
S4
S5L
S5M
S5R
S7
S8

Code switch A125
Switch: horn H9
Push button 'turn grapple left' Y22
Push button, centre (no function)
Push button 'turn grapple right' Y23
safety switch
Switch: beacon
1a
26
4
25
25
25
14
37
S9
S11
battery main switch

Switch: windscreen washer system M3
42
7
S14
Switch: windscreen wiper M4
S16
S18
S19
S20
S21
S22
Switch: parking brake Y6

Switch: overload warning system (optional)
Switch: grapple rotator Y22, Y23
Switch: sensor control
Switch: creeper gear Y24
Switch: work headlight E1 / roof light E2
13
36
25
28
11
5
S22-1
Switch: auxiliary headlight / roof light
S32
S35
S42
S44
S47
S61
Switch: direction indicator / horn

Switch: servo
Switch. first gear Y55
Switch: hazard light
Switch: Bucket quick-change adapter (optional)
Switch: lighting installation
4
15
11
4
38
6
S63
S75
S92
Switch: swivel bearing

Switch: oscillating axle locking device Y371
Potentiometer: air diffusion
40
33
30a
Right bracket
Left bracket
Cab floor plate
Pilot control valve, left
Left bracket
right
Battery compartment
right
right
Right bracket
Right bracket
Right bracket
Right bracket
Right bracket
right
right
steering column
Right bracket
Right bracket
Right bracket
Right bracket
right
Pilot control valve right
Right bracket
Right bracket
A 309 LI 20221A 311 LI 20222-
copyright by
MJFCIFSS
8.20.5
Electrical system
Service Manual
Item
Description
Step
Place / layout
S93
S218
S241
S263
S272
S283
S284
S309
S343
S360
S388
S389
S398
S422
S439L
S439R
Potentiometer: heating / air condition

Switch: roof window wiper (optional)
Switch: accessory kit AHS 11 / AHS 12 (optional)
Switch: travel direction
Junction box undercarriage
Switch: windscreen wiper release
Switch: four-step blower
Rotary switch: 4-wheel steering
Switch: individual control, back
Switch: Mute switch for buzzer UL
Switch: air-spring seat
Switch: seat heating
Reversing switch / air diffusion
Switch: mute switch for radio
Push button: split blade, left
Push button: split blade, right
30a
7
34
10
12/35
7
30b
12
35
38
31
32
30a
8
35
35
Right bracket
Bracket, backside
Right bracket
Undercarriage
windscreen
Right bracket
Left bracket
Right bracket
Right bracket
operator seat
operator seat
Right bracket
Right bracket
Pilot control valve: support
T1
Voltage transformer / radio
Left bracket
U16
Right bracket
V155
V156-2
V156-4
V171
Blocking diode: oscillating axle

Blocking diode H311 - S75
Diode input quantity
Blocking diode: buzzer
2/15(I)/
20-23/2629/34
33
33
34
13
Right bracket
Right bracket
Right bracket
Right bracket
X10
X11
X12
X27
X28
X29
X65
X66
X67-1
X67-2
X90
X196
X197
X230
X262
X262-1
X262-3
X262-4
X262-5
X262-6
X301
X304
Plug connection distribution board / 2-pin

Plug connection to voltage transformer / 2-pin
Plug connection to voltage transformer / 2-pin
Plug connection A3 power supply / 8-pin
Plug connection: heating fan motor
B40 plug connection / 3-pin
Plug connection: wire harness quick-change adapter, 8-pin
Plug connection: wire harness, 12-pin
Plug connection: wire harness, console, 6-pin
16
16
16
16
16
16
8
8
8
8
30b
28
33
10/13
38
38
38
38
38
38
35
35
Right bracket
Right bracket
Right bracket
Right bracket
Right bracket
Right bracket
Right bracket
Right bracket
Operator's platform, left
Operators platform
Travelling pedal
Brake pedal
Right bracket
Right bracket
Bearing block
stick
Revolving deck
Right bracket
8.20.6
copyright by
MJFCIFSS
A 309 LI 20221A 311 LI 20222-
Service Manual
Electrical system
Item
Description
Step
Place / layout
X404
X406
X407
X410
X411
X412
X413
X550
X834
X835
X836
X837
X838
X838-1
X838-2
X838-3
X839
X842-1
X842-2
X842-3
X856
Plug connection: work headlight / 4-pin

Plug connection: transducer fuel reserve / 3-pin
Plug connection: revolving deck UL 2-pin
Plug-type connection distribution board / 2-pin
Plug connection: switch S32 / 6-pin
Plug connection to A 125 / 2-pin
Plug connection CAN - bus connection, 2-pin
Screw terminal on A125 / 3-pin
Climate plug connection / 15-pin
Plug connection: console, ignition switch / 2-pin
Plug connection: blocking diode / 2-pin
Plug connection to BST excavator control / 40-pin
Revolving deck
Revolving deck
Revolving deck
Right bracket
Right bracket
Right bracket
Right bracket
steering column
Left bracket
Left bracket
Left bracket
Left bracket
Left bracket
Left bracket
Left bracket
Left bracket
Left bracket
Right bracket
Right bracket
Right bracket
Right bracket
X857
X859
X860
X861
X862
X863
X924-1
X924-2
X950

Plug connection: console display autocheck / 21-pin
X951
Plug connection: console display autocheck / 21-pin
X952
Plug connection: revolving deck - BST excavator control / 21pin
X953
Plug connection: revolving deck - distribution board / 21-pin
X954
Plug connection: revolving deck - BST excavator control / 21pin
X955
Plug connection: revolving deck - distribution board / 15-pin
5
17
36
38
38
38
38
4
26
26
26
26/34
26
26
26
26
34
30c
30c
33
2/15(I)/
20-23/2629/34
21a/2223/26/28/
34
30a/30b
30a
30a
30a
30a/30b
34
34
4/10/13/
21a/33/
36/38/40
4/10/13/
21b/34/
38/40
10-15/25/
30c/33/
34/40
1/4-6/12/
13/17/
21a/36/42
2/12/20/
22/26/27/
29
1a/3/4/35/
38
A 309 LI 20221A 311 LI 20222-
copyright by
MJFCIFSS
Right bracket

Right bracket
Right bracket
Right bracket
Right bracket
Right bracket
Right bracket
8.20.7
Electrical system
Service Manual
Item
Description
Step
Place / layout
X956
Plug connection: BST excavator control - distribution board /

21-pin
Right bracket
X957
Plug connection: switch - distribution board / 21-pin
X958
Plug connection: switch - distribution board / 21-pin
X959
Plug connection: fuse - distribution board / 21-pin
X960
X961
Plug connection: operator's platform - distribution board / 21pin

Plug connection: display - distribution board / 21-pin
X962
X963
X964
X965
X966
Plug connection: BST excavator control - distribution board /

21-pin
Plug connection A 125 - distribution board / 21-pin
2/15(I)/
20-23/26/
28/34/43
8/11/20/
22/25/34/
35/
18/28/34/
35/36/38/
43
15/30c/
35/40
4/6/9/21a/
28/33/34
2/6/13/17/
20/21a/
21b/33
4/10/13/
14/21b/
28/34/38/
40
6/8/9/11/
13-16/23/
24/28/35
1a/3/4/13/
14/16/28/
33/43
26/34
X967
X967-1
X967-2
X968-1
X968-2
X971
X972
X973
X974-2
X974-4
X1046
X1047
X1048
X1049
X1090
X1104
X1106
X1117
X1118

Plug connection: wire harness - connection / 1-pin
Plug connection: wire harness - connection / 1-pin
Plug connection: quantity 2 / 1-pin
Plug connection: quantity 3 / 1-pin
Plug connection: seat adjustment / 2-pin
Plug connection: seat heating / 2-pin
Power socket, 12V
Plug connection B19L / 3-pin
Plug connection: B19R / 3-pin
Plug connection / -pin
Plug connection: 4-wheel steering, 6-pin
Plug connection: blocking diode, 2-pin
8.20.8
copyright by
MJFCIFSS
8/10/12/
14/25/28/
32/34/43
5/6/8/37
45
43
34
34
31
32
8
33
34
10/25
28
40
28
12
35
14/15
12/14/43
13
Right bracket
Right bracket
Right bracket
Right bracket
Right bracket
Right bracket
Right bracket
Right bracket
Right bracket
Right bracket
Right bracket
Right bracket
Right bracket
Operators platform
Operators platform
Left bracket
Right bracket
Cab, right
Left bracket
Right bracket
Right bracket
Right bracket
Right bracket
A 309 LI 20221A 311 LI 20222-
Service Manual
Electrical system
Item
Description
Step
Place / layout
Y3
Y6
Y12
Y20
Y22
Y23
Y24
Y28-1
Y28-2
Y29
Y50
Y51
Y55
Y56
Y62
Y63
Y217
Y218
Y229-1
Y229-2
Y262
Y268
Y294-1
Y294-2
Y299
Y330
Y352
Y358
Y371
Solenoid valve: pilot pressure

Solenoid valve: parking brake
Solenoid valve: excess fuel for starting
magnetic clutch / a/c compressor
Solenoid valve: creeper gear
Solenoid valve: quick-change adapter
Solenoid valve: quick-change adapter
Solenoid valve: motor shut-down
Proportional solenoid valve: power control
Proportional solenoid valve: flow limitation
Solenoid valve: first gear
Solenoid valve: blade
Solenoid valve: travel forward
Solenoid valve: travel reverse
Solenoid valve: outrigger, rear left
Solenoid valve: outrigger, rear right
Solenoid valve: dog-walk steering mode
Solenoid valve: 4-wheel steering
Solenoid valve: bucket swivel bearing
Solenoid valve: flow reduction, AHS
Solenoid valve: flow reduction, AHS
Solenoid valve: pump regulation
Proportional solenoid valve: fan control
Proportional solenoid valve: motor speed with plug
Solenoid valve: oscillating axle support
15
13
1a
30c
25
25
11
38
38
3
26
26
11
35
10
10
35
35
12
12
40
34
12
12
34
15
29
22
33
control oil unit

HBGV block
Regulator: motor
diesel engine
control valve block
control valve block
control oil unit
Regulating rod: motor
control oil unit
control oil unit
HBGV block
Undercarriage
Hydraulic tank
Hydraulic tank
Undercarriage
Undercarriage
Undercarriage
Undercarriage
Fuel tank
Hydraulic tank
Hydraulic tank
control oil unit
Fan / radiator
Bulkhead
control oil unit
A 309 LI 20221A 311 LI 20222-
copyright by
MJFCIFSS
8.20.9
Electrical system
Service Manual
1a Power supply, board A127
8.20.10
copyright by
MJFCIFSS
A 309 LI 20221A 311 LI 20222-
Service Manual
Electrical system
1b Power supply, board A127 / fuses
A 309 LI 20221A 311 LI 20222-
copyright by
MJFCIFSS
8.20.11
Electrical system
Service Manual
1c Power supply, board A 127 / relay
8.20.12
copyright by
MJFCIFSS
A 309 LI 20221A 311 LI 20222-
Service Manual
Electrical system
2 Pre-heating
A 309 LI 20221A 311 LI 20222-
copyright by
MJFCIFSS
8.20.13
Electrical system
Service Manual
3 Motor shut-down
8.20.14
copyright by
MJFCIFSS
A 309 LI 20221A 311 LI 20222-
Service Manual
Electrical system
4 Direction indicator system / horn
A 309 LI 20221A 311 LI 20222-
copyright by
MJFCIFSS
8.20.15
Electrical system
Service Manual
5 Work headlight
8.20.16
copyright by
MJFCIFSS
A 309 LI 20221A 311 LI 20222-
Service Manual
Electrical system
6 Lighting installation
A 309 LI 20221A 311 LI 20222-
copyright by
MJFCIFSS
8.20.17
Electrical system
Service Manual
7 Windscreen wiper / washer systems
8.20.18
copyright by
MJFCIFSS
A 309 LI 20221A 311 LI 20222-
Service Manual
Electrical system
8 Interior lights, radio
A 309 LI 20221A 311 LI 20222-
copyright by
MJFCIFSS
8.20.19
Electrical system
Service Manual
9 Brake light
8.20.20
copyright by
MJFCIFSS
A 309 LI 20221A 311 LI 20222-
Service Manual
Electrical system
10 Travel direction switch
A 309 LI 20221A 311 LI 20222-
copyright by
MJFCIFSS
8.20.21
Electrical system
Service Manual
11 Creeper gear first gear
8.20.22
copyright by
MJFCIFSS
A 309 LI 20221A 311 LI 20222-
Service Manual
Electrical system
12 Optional 4-wheel steering
A 309 LI 20221A 311 LI 20222-
copyright by
MJFCIFSS
8.20.23
Electrical system
Service Manual
13 Parking brake
8.20.24
copyright by
MJFCIFSS
A 309 LI 20221A 311 LI 20222-
Service Manual
Electrical system
14 Safety switch
A 309 LI 20221A 311 LI 20222-
copyright by
MJFCIFSS
8.20.25
Electrical system
Service Manual
15 Servo
8.20.26
copyright by
MJFCIFSS
A 309 LI 20221A 311 LI 20222-
Service Manual
Electrical system
16 Power supply / socket
A 309 LI 20221A 311 LI 20222-
copyright by
MJFCIFSS
8.20.27
Electrical system
17 Fuel gauge
8.20.28
Service Manual
18 Clock
copyright by
MJFCIFSS
19 Hour meter
A 309 LI 20221A 311 LI 20222-
Service Manual
Electrical system
20 Motor temperature
A 309 LI 20221A 311 LI 20222-
copyright by
MJFCIFSS
8.20.29
Electrical system
Service Manual
21a Indicator lights
8.20.30
copyright by
MJFCIFSS
A 309 LI 20221A 311 LI 20222-
Service Manual
Electrical system
21b Autocheck / main warning buzzer / charge indicator
A 309 LI 20221A 311 LI 20222-
copyright by
MJFCIFSS
8.20.31
Electrical system
Service Manual
22 Speed adjustment
8.20.32
copyright by
MJFCIFSS
A 309 LI 20221A 311 LI 20222-
Service Manual
Electrical system
23 BST excavator-control power supply
A 309 LI 20221A 311 LI 20222-
copyright by
MJFCIFSS
8.20.33
Electrical system
Service Manual
25 Optional: AS I
8.20.34
copyright by
MJFCIFSS
A 309 LI 20221A 311 LI 20222-
Service Manual
Electrical system
26 Regulating valves
A 309 LI 20221A 311 LI 20222-
copyright by
MJFCIFSS
8.20.35
Electrical system
Service Manual
27 Speed sensor
8.20.36
copyright by
MJFCIFSS
A 309 LI 20221A 311 LI 20222-
Service Manual
Electrical system
28 Sensor control
A 309 LI 20221A 311 LI 20222-
copyright by
MJFCIFSS
8.20.37
Electrical system
Service Manual
29 Fan control
8.20.38
copyright by
MJFCIFSS
A 309 LI 20221A 311 LI 20222-
Service Manual
Electrical system
30a Heating
A 309 LI 20221A 311 LI 20222-
copyright by
MJFCIFSS
8.20.39
Electrical system
Service Manual
30b Heating
8.20.40
copyright by
MJFCIFSS
A 309 LI 20221A 311 LI 20222-
Service Manual
Electrical system
30c Heating
A 309 LI 20221A 311 LI 20222-
copyright by
MJFCIFSS
8.20.41
Electrical system
Service Manual
31 Electrical set adjustment - seat made by Isringhausen
8.20.42
copyright by
MJFCIFSS
A 309 LI 20221A 311 LI 20222-
Service Manual
Electrical system
32 Seat heating - seat made by Isringhausen
A 309 LI 20221A 311 LI 20222-
copyright by
MJFCIFSS
8.20.43
Electrical system
Service Manual
33 Automatic oscillating axle locking device
8.20.44
copyright by
MJFCIFSS
A 309 LI 20221A 311 LI 20222-
Service Manual
Electrical system
34 Optional AHS11 / AHS12
A 309 LI 20221A 311 LI 20222-
copyright by
MJFCIFSS
8.20.45
Electrical system
Service Manual
35 Optional blade / individual control outrigger
8.20.46
copyright by
MJFCIFSS
A 309 LI 20221A 311 LI 20222-
Service Manual
Electrical system
36 Optional overload warning system
A 309 LI 20221A 311 LI 20222-
copyright by
MJFCIFSS
8.20.47
Electrical system
Service Manual
37 Optional beacon
8.20.48
copyright by
MJFCIFSS
A 309 LI 20221A 311 LI 20222-
Service Manual
Electrical system
38 Optional bucket quick-change adapter
A 309 LI 20221A 311 LI 20222-
copyright by
MJFCIFSS
8.20.49
Electrical system
Service Manual
40 Swivel bearing
8.20.50
copyright by
MJFCIFSS
A 309 LI 20221A 311 LI 20222-
Service Manual
Electrical system
42 Ground
A 309 LI 20221A 311 LI 20222-
copyright by
MJFCIFSS
8.20.51
Electrical system
Service Manual
43 Ground
8.20.52
copyright by
MJFCIFSS
A 309 LI 20221A 311 LI 20222-
Service Manual
Electrical system
44 Ground
A 309 LI 20221A 311 LI 20222-
copyright by
MJFCIFSS
8.20.53
Electrical system
Service Manual
45 Class 30 / class 15
8.20.54
copyright by
MJFCIFSS
A 309 LI 20221A 311 LI 20222-
Service Manual
Electrical system
Electrical system
Item
Description
Step
Location / arrangement
A3
A125
A126
Radio (optional)
Potentiometer board
Operator's cab, rear

Left console
Right console
A127
Printed circuit board / power
A134
A1017
Control: 4-wheel steering

Printed circuit board / quick-change adapter
8
26/34
4/10/13/
21a/21b/
24/33/36/
38/40/
1a/1b/1c/
2/3
12
38
B1
B2
B3
B7
B8
B12
B16
B19L
B19R
B20
Transducer / fuel level, with plug

Temperature sensor / motor coolant
Transducer / motor coolant, with plug
Sensor transducer / left pilot control unit
Sensor transducer / right pilot control unit
17
20
21a
21a
21a
27
21a
28
28
21a
B21
Pressure switch / overload
36
B26
B33
B40
B50L
B50R
B60

Pressure switch / accessory kit
Proximity switch / pilot pressure valve, travel
Loudspeaker, left
Loudspeaker, right
38
34
28
8
8
9
B232
B248H
B248V
B266
B285
B289
Temperature switch / excess fuel for starting

Sensor for rear axle alignment
Sensor for front axle alignment
Water sensor in fuel tank
1a
12
12
33
29
21a
Fuel tank
Motor, top fan side
Engine compartment
Suction pipe / air filter
Motor housing
Left joystick
Right joystick
Near control valve block
Travelling pedal
Cab, rear left
Cab, rear right
Engine
Rear axle housing
Front axle housing
Lower brake pedal
Tank
Preliminary fuel filter
E1
E2
E3
E4
E7
E8
E9
E15
E16
E17

Front roof light
Travel light, left
Travel light, right
Roof-mounted light
Cigarette lighter
Beacon
Parking light, left
Tail light, right
5
5
6
6
8
8
37
6
6
6
Attachment
Front cab roof
Cab
Right console, rear
Cab, top
A 309 LI 29269A 311 LI 29270-
copyright by
MJFCIFSS

Below operator's platform
Distribution board
8.22.1
Electrical system
Service Manual
Item
Description
Step
E18
E19
E20
E21
E22
E23
E24
E50
Tail light, left

Brake light, right
Brake light, left
Indicator light, front left
Indicator light, rear left
Indicator light, rear right
Electric cabinet

Hydraulic tank
E150
Rear roof light, rear, with plug
6
6
6
4
4
4
4
1a/1b/1c/
2/3/40
5
F_A
F_B
F_C
F_D
F_E
F_F
F_G
F_H
F_I
F_K
F_L
F_M
F_N
FRes
F20/
F300
F19/
F301
F22/
F302
F303
F304
F305
F306
F307
F308
F309
F310
F311
F312
F313
F314
F315
F316
F317
F318
F319
F320
Fuse optional
Fuse optional
Fuse optional
Fuse optional
Fuse optional
Fuse optional
Fuse optional
Fuse optional
Fuse optional
Fuse optional
Fuse optional
Fuse optional
Fuse optional
Fuse, reserve
Fuse A127 terminal 30 to terminal 15
_A
_A
_A
_A
_A
_A
_A
_A
_A
_A
_A
_A
70 A
_A
50A
1b
1b
1b
1b
1b
1b
1b
1b
1b
1b
1b
1b
1a
14
1a

Right console
Fuse A127 K302, R60
50A
Fuse A127 terminal 15, terminal 30, S44
7.5A
1b
Fuse A127, Y29

Fuse S1
Fuse E7, E8, P50
Fuse X10
Fuse E16, E17, P6, P7, P50
Fuse E15, E18
Fuse E3
Fuse E4
Fuse M3, M4
Fuse S44, E21, E22, E23, E24
Fuse E19, E20
Fuse S7
Fuse BST
Fuse servo control
Fuse beacon
Fuse heating / air conditioning, terminal 30
Fuse X11
7.5A
15A
15A
15A
7.5A
7.5A
7.5A
7.5A
15A
7.5A
5A
3A
15A
7.5A
7.5A
20A
15A
15A
3
1a
8
16
6
6
6
6
7
4
9
14
23
28
37
30c
30c
16

Right console
Right console
Right console
Right console, rear
Right console, rear
Right console, rear
Right console, rear
Right console, rear
Right console
Right console
Right console
Right console
Right console
Right console, rear
Right console
Right console
Right console
8.22.2
copyright by
MJFCIFSS
Rear cab roof
A 309 LI 29269A 311 LI 29270-
Service Manual
Item
Description
F321
F322
F323
F324
F325
F326
F327
F328
F329
F330
F331
F332
F336
F337
F338
F339
F343
F356
F357
F359
Fuse X12
Fuse T1
Fuse E1
Fuse S22 - E2, S22-1 - E150
Fuse S16, K251
Fuse S21 - Y24, S42 - Y55
Fuse X27
Fuse X28
Fuse S35
Fuse kits
Fuse X29
Fuse A127, M1, Y12
Fuse S61
Fuse support
Fuse a/c condenser
Fuse roof window wiper
Fuse: permanent ground - clock
G1
G2
H7
H9
H10
H11
H12
H13
H15
H16
H18
H19
H20
H23
H26
H27
H167
H168
H175
H176
H186
H191
H192
H196
H301
H311
Electrical system
Step
16
8
5
5
13
11
16
16
15
16
16
1a
6
35
4
30c
7
1b
1b
42
Right console
Right console
Right console, rear
Right console, rear
Right console
Right console
Right console
Right console
Right console
Right console
Right console
Right console
Right console
Right console
Right console
Right console
Battery box
Alternator
Batteries
1a
1a
Diesel engine
Battery box
Indicator light / motor oil pressure

Horn
Warning buzzer
Indicator light / pre-heating
Indicator light / charging
Indicator light / air filter contamination
Indicator light / hydraulic oil temperature
Indicator light / overload warning (kit)
Indicator light / coolant level
Indicator light / indicator
Indicator light / parking brake
Indicator light / accumulator pressure
Indicator light / quick-change adapter
Warning buzzer
Indicator light / forward travel
Indicator light / reverse travel
Indicator light / motor overheating
Indicator light / oscillating-axle locking device
Indicator light / swivel bearing
Indicator light: 4-wheel steering
Indicator light: dog-walk steering mode
Indicator light / sorting grapple
Indicator light / error BST
Indicator light / oscillating axle locked
21a
4
21b
2
21b
21a
21a
36
21a
4
13
21a
38
13
10
10
21a
33
40
12
12
34
26
33
Right console
Right console
Right console
Right console
Right console
Right console
Right console
Right console
Right console
Right console
Right console
Right console
Right console
Right console
Right console
Right console
Right console
Right console
Left console
Left console
Right console
A125, left console
Right console
A 309 LI 29269A 311 LI 29270-
15A
7.5A
15A
15A
7.5A
15A
15A
15A
5A
7.5A
15A
25A
20A
15A
10A
20A
7.5A
10A
2A
3A
copyright by
MJFCIFSS
8.22.3
Electrical system
Service Manual
Item
Description
Step
H336
HRes
Indicator light: water in fuel filter

Indicator light: reserve
21a
40
Right console
Right console
K_A
K_B
K_C
K_D
K_E
K16-1
K16-2
K63
K250
K251
K288
K302
K315
K364
Relay, optional
Relay, optional
Relay, optional
Relay, optional
Relay, optional
Relay terminal 50
Relay, disconnected
Relay / direction indicator
Relay / oscillating axle automatic
Relay / hand brake (indicator light H20)
Relay terminal 15
Relay / pre-heating
Relay brake light
Relay to A1017
1c
1c
1c
1c
1c
1a
1a
4
33
13
3
2
9
38
K370
K375
K386
K393
K403
K405
K414
K445
K466
Relay terminal 15, servo

Relay / kit, quantity
Relay / safety switch S7
Relay / air-spring seat
Relay / heating
Relay / heating
Relay / windscreen wiper interval
Relay: travel shut-off 4-wheel steering
Relay horn H9
15
34
14
31
30a
30b
7
10
4

Right console
Right console
Right console
Right console
board
Right console
Operator's platform, rear
Right console
Operator's platform
Right console
Right console
M1
M3
M4
M60
M65
M68
M70
M71
M72
M73
Starter
Motor / windscreen washer system
Motor / windscreen wiper with plug
Windscreen washer system / roof (optional)
Blower motor
Motor / air-spring seat
Servo motor / water valve
Servo motor / air distribution
1a
7
7
7
30b
7
31
30a
30a
30a
Diesel engine
Windscreen
Cab, top
Cab, top
Operator's platform
P1
P2
P3
P5
P6
P7
P50
Potentiometer / flow limitation 1

Display / operating hour meter
Display / motor temperature
Indicator / fuel level
Display / clock
26
26
26
19
20
17
18
Left console
Left console
Left console
Right console, bottom
Right console
Right console
Right console
R60
Diesel engine
8.22.4
copyright by
MJFCIFSS
A 309 LI 29269A 311 LI 29270-
Service Manual
Electrical system
Item
Description
Step
R75
R78-1
R78-2
RS232
Potentiometer / speed
Seat heating
Seat heating
Laptop interface
22
32
32
26
Right console
Operator's platform
Operator's platform
Left console
S1
S1
S4
S5L
S5M
S5R
S7
S8
S9
S11
S14
S16
S18
S19
S20
S21
S22
S22-1
S32
S35
S42
S44
S47
S61
S63
S75
S92
S93
S218
S241
S263
S272
S283
S284
S309
S360
S388
S389
S398
S422
S439L
S439R

Code switch A125
Switch / horn H9
Push button / turning grapple to the left, Y22
Push button / turning grapple to the right, Y23
Safety switch
Switch / beacon
Battery main switch
Switch / windscreen washer system M3
Switch / windscreen wipers M4
Switch / parking brake Y6
Switch / overload warning system (optional)
Switch / grapple rotator Y22, Y23
Switch / sensor control
Switch / creeper gear Y24
Switch / work light E1 / roof light E2
Switch / auxiliary headlight / roof light
Switch / direction indicator / horn
Switch servo
Switch / first gear Y55
Switch / hazard light
Switch / bucket quick-change adapter (optional)
Switch / lighting installation
Switch / swivel bearing
Switch / oscillating axle locking device Y371
Potentiometer / air distribution
Potentiometer / heating / air condition
Switch / roof window wiper (optional)
Switch / accessory kit AHS 11 / AHS 12 (optional)
Junction box, undercarriage
Switch / windscreen wiper release
Switch / four-step blower
Rotary switch: 4-wheel steering
Switch / mute switch for overload buzzer
Switch / air-spring seat
Reversing switch / air distribution
Switch / mute switch for radio
Push button: split blade, left
Push button: split blade, right
1a
26
4
25
4,25
25
14
37
42
7
7
13
36
25
28
11
5
5
4
15
11
4
38
6
40
33
30a
30a
7
34
10
12/35
7
30b
12
38
31
32
30a
8
35
35
Right console
Left console
Cab floor plate
Left pilot control unit
Left console
Right console, rear
Battery compartment
Right console, rear
Right console, rear
Right console
Right console
Right console
Right console
Right console
Right console, rear
Right console, rear
Steering column
Right console
Right console
Right console
Right console
Right console, rear
Right pilot control unit
Right console
Right console
Right console
Right console, rear
Right console
Undercarriage
Windscreen
Right console
Left console
Right console
Operator seat
Operator seat
Right console
Right console
A 309 LI 29269A 311 LI 29270-
copyright by
MJFCIFSS
8.22.5
Electrical system
Service Manual
Item
Description
Step
T1
Left console
U16
Right console
V155
V156-2
V156-4
V171
V181
V182
Blocking diode / oscillating axle

Diode / input quantity
Blocking diode: buzzer
Amplifier magnet Y22
Amplifier magnet Y23
2/15/2023/26-29/
34
33
33
34
13
25
25
Right console
Right console
Right console
Right console
Right console, rear
Right console, rear
X10
X11
X12
X27
X28
X29
X65
X66
X67-1
X67-2
X90
X196
X197
X230
X262
X262-1
X262-3
X262-4
X262-5
X262-6
X301
X304
X404
X406
X407
X410
X411
X412
X413
X550
X834
X835
X836
X837
X838
X838-1
X838-2

Plug connection on voltage transformer / 2-pin
Plug connection / heating fan motor
Plug connection B40 / 3-pin
Plug connection wire harness quick-change adapter / 8-pin
Plug connection: wire harness, 12-pin
Plug connection wire harness, console / 6-pin
Plug connection work headlight / 4-pin
Plug connection transducer fuel reserve / 3-pin
Plug connection revolving deck overload / 2-pin
Plug connection switch S32 / 6-pin
16
16
16
16
16
16
8
8
8
8
30b
28
33
10/13
38
38
38
38
38
38
35
35
5
17
36
38
38
38
38
4
26
26
26
26/34
26
26
26
Right console
Right console
Right console
Right console
Right console
Right console
Right console
Right console
Operator's platform
Travelling pedal
Brake pedal
Right console
Right console
Bearing block
Stick
Revolving deck
Right console
Revolving deck
Revolving deck
Revolving deck
Right console
Right console
Right console
Right console
Steering column
Left console
Left console
Left console
Left console
Left console
Left console
Left console
8.22.6
copyright by
MJFCIFSS
A 309 LI 29269A 311 LI 29270-
Service Manual
Electrical system
Item
Description
Step
X838-3
X839
X842-1
X842-2
X842-3
X856
Plug connection CAN - bus / 2-pin

Plug connection air-conditioning / 15-pin
Plug connection console, ignition switch / 2-pin
Plug connection blocking diode / 2-pin
Left console
Left console
Right console
Right console
Right console
Right console
X857
X859
X860
X861
X862
X863
X924-1
X924-2
X950

Plug connection console display autocheck / 21-pin
X951
X952
Plug connection revolving deck BST excavator control / 21pin
X953
Plug connection revolving deck distribution board / 21-pin
X954
X955
X956
Plug connection BST excavator control distribution board /

21-pin
X957
Plug connection switch distribution board / 21-pin
X958
X959
Plug connection fuse distribution board / 21-pin
X960
Plug connection operator's platform distribution board / 21pin

Plug connection display distribution board / 21-pin
26
34
30c
30c
33
2/15/2023/26-29/
34
21a/2223/26/28/
34
30a/30b
30a
30a
30a
30a/30b
34
34
4/10/13/
21a/33/
36/38/40
4/10/13/
21b/34/
38/40
10-15/25/
30c/33/
34/40
1/4-6/12/
13/17/
21a/36/42
2/12/20/
22/26/27/
29
1a/3/4/35/
38
2/15 /2023/26/28/
34/43
8/11/20/
22/25/34/
35/
18/28/34/
35/36/38/
43
15/30c/
35/40
4/6/9/21a/
28/33/34
2/6/13/17/
20/21a/
21b/33
X961
A 309 LI 29269A 311 LI 29270-
copyright by
MJFCIFSS
Right console
Right console
Right console
Right console
Right console
Right console
Right console
Right console
Right console
Right console
Right console
Right console
Right console
8.22.7
Electrical system
Service Manual
Item
Description
Step
X962
Right console
X963
X964
X965
X966

21-pin
Plug connection A 125 distribution board / 21-pin
4/10/13/
14/21b/
28/34/38/
40
6/8/9/11/
13-16/23/
24/28/35
1a/3/4/13/
14/16/28/
33/43
26/34
X967
X967-1
X967-2
X968-1
X968-2
X971
X972
X973
X974-2
X974-4
X1046
X1047
X1048
X1049
X1090
X1104
X1106
X1117
X1118
Y3
Y12
Y20
Y22
Y23
Y24
Y28-1
Y28-2
Y29
Y50
Y51
Y55
Y60
Y56
Y62
8.22.8
Right console
Right console
Right console
Right console

Plug connection wire harness connection / 1-pin
Plug connection quantity 2 / 1-pin
Plug connection seat adjustment / 2-pin
Plug connection seat heating / 2-pin
Power socket, 12V
Plug connection B19R / 3-pin
Plug connection / -pin
Plug connection: 4-wheel steering, 6-pin
Plug connection: blocking diode, 2-pin
8/10/12/
14/25/28/
32/34/43
5/6/8/37
45
43
34
34
31
32
8
33
34
10/25
28
4/40
28
12
35
14/15
12/14/43
13
Right console
Right console
Right console
Operator's platform
Operator's platform
Left console
Right console
Cab, right
Left console
Right console
Right console
Right console
Right console
Solenoid valve / pilot pressure

Magnetic clutch / a/c compressor
Solenoid valve / quick change adapter
Solenoid valve / blade
15
1a
30c
25
25
11
38
38
3
26
26
11
11
35
10
Control oil unit

Regulator / motor
Diesel engine
Control valve block
Control valve block
Control oil unit
Regulating rod / motor
Control oil unit
Control oil unit
HBGV block
HBGV block
Undercarriage
Hydraulic tank
copyright by
MJFCIFSS
A 309 LI 29269A 311 LI 29270-
Service Manual
Electrical system
Item
Description
Step
Y63
Y217
Y218
Y229-1
Y229-2
Y262
Y268
Y294-1
Y294-2
Y299
Y352
Y358
Y371
Y451

Solenoid valve / outrigger, rear left
Solenoid valve / outrigger, rear right
Solenoid valve: dog-walk steering mode
Solenoid valve: bucket swivel bearing
Solenoid valve / flow reduction, AHS
Proportional solenoid valve / fan control
Proportional solenoid valve / motor speed with plug
Solenoid valve/oscillating axle support
Solenoid valve / combined lifting of boom
10
35
35
12
12
40
34
12
12
34
29
22
33
34
Hydraulic tank
Undercarriage
Undercarriage
Undercarriage
Undercarriage
Fuel tank
Near control oil unit
Fan / radiator
Bulkhead
A 309 LI 29269A 311 LI 29270-
copyright by
MJFCIFSS
8.22.9
Electrical system
Service Manual
1a power supply, board A127
8.22.10
copyright by
MJFCIFSS
A 309 LI 29269A 311 LI 29270-
Service Manual
Electrical system
1b power supply, board A127 / fuses
A 309 LI 29269A 311 LI 29270-
copyright by
MJFCIFSS
8.22.11
Electrical system
Service Manual
1c power supply, board A 127 / relay
8.22.12
copyright by
MJFCIFSS
A 309 LI 29269A 311 LI 29270-
Service Manual
Electrical system
2 Pre-heating
A 309 LI 29269A 311 LI 29270-
copyright by
MJFCIFSS
8.22.13
Electrical system
Service Manual
3 Motor shut-down
8.22.14
copyright by
MJFCIFSS
A 309 LI 29269A 311 LI 29270-
Service Manual
Electrical system
A 309 LI 29269A 311 LI 29270-
copyright by
MJFCIFSS
8.22.15
Electrical system
Service Manual
5 Work headlight
8.22.16
copyright by
MJFCIFSS
A 309 LI 29269A 311 LI 29270-
Service Manual
Electrical system
A 309 LI 29269A 311 LI 29270-
copyright by
MJFCIFSS
8.22.17
Electrical system
Service Manual
8.22.18
copyright by
MJFCIFSS
A 309 LI 29269A 311 LI 29270-
Service Manual
Electrical system
A 309 LI 29269A 311 LI 29270-
copyright by
MJFCIFSS
8.22.19
Electrical system
Service Manual
9 Brake light
8.22.20
copyright by
MJFCIFSS
A 309 LI 29269A 311 LI 29270-
Service Manual
Electrical system
A 309 LI 29269A 311 LI 29270-
copyright by
MJFCIFSS
8.22.21
Electrical system
Service Manual
11 Creeper gear first gear
8.22.22
copyright by
MJFCIFSS
A 309 LI 29269A 311 LI 29270-
Service Manual
Electrical system
12 Optional 4-wheel steering
A 309 LI 29269A 311 LI 29270-
copyright by
MJFCIFSS
8.22.23
Electrical system
Service Manual
13 Parking brake
8.22.24
copyright by
MJFCIFSS
A 309 LI 29269A 311 LI 29270-
Service Manual
Electrical system
14 Safety switch
A 309 LI 29269A 311 LI 29270-
copyright by
MJFCIFSS
8.22.25
Electrical system
Service Manual
15 Servo
8.22.26
copyright by
MJFCIFSS
A 309 LI 29269A 311 LI 29270-
Service Manual
Electrical system
A 309 LI 29269A 311 LI 29270-
copyright by
MJFCIFSS
8.22.27
Electrical system
17 Fuel gauge
8.22.28
Service Manual
18 Clock
copyright by
MJFCIFSS
19 Hour meter
A 309 LI 29269A 311 LI 29270-
Service Manual
Electrical system
A 309 LI 29269A 311 LI 29270-
copyright by
MJFCIFSS
8.22.29
Electrical system
Service Manual
8.22.30
copyright by
MJFCIFSS
A 309 LI 29269A 311 LI 29270-
Service Manual
Electrical system
A 309 LI 29269A 311 LI 29270-
copyright by
MJFCIFSS
8.22.31
Electrical system
Service Manual
22 Speed adjustment
8.22.32
copyright by
MJFCIFSS
A 309 LI 29269A 311 LI 29270-
Service Manual
Electrical system
A 309 LI 29269A 311 LI 29270-
copyright by
MJFCIFSS
8.22.33
Electrical system
Service Manual
25 Optional AS I
8.22.34
copyright by
MJFCIFSS
A 309 LI 29269A 311 LI 29270-
Service Manual
Electrical system
A 309 LI 29269A 311 LI 29270-
copyright by
MJFCIFSS
8.22.35
Electrical system
Service Manual
27 Speed sensor
8.22.36
copyright by
MJFCIFSS
A 309 LI 29269A 311 LI 29270-
Service Manual
Electrical system
28 Sensor control
A 309 LI 29269A 311 LI 29270-
copyright by
MJFCIFSS
8.22.37
Electrical system
Service Manual
29 Fan control
8.22.38
copyright by
MJFCIFSS
A 309 LI 29269A 311 LI 29270-
Service Manual
Electrical system
30a Heating
A 309 LI 29269A 311 LI 29270-
copyright by
MJFCIFSS
8.22.39
Electrical system
Service Manual
30b Heating
8.22.40
copyright by
MJFCIFSS
A 309 LI 29269A 311 LI 29270-
Service Manual
Electrical system
30c Heating
A 309 LI 29269A 311 LI 29270-
copyright by
MJFCIFSS
8.22.41
Electrical system
Service Manual
31 Electrical set adjustment / seat made by Isringhausen
8.22.42
copyright by
MJFCIFSS
A 309 LI 29269A 311 LI 29270-
Service Manual
Electrical system
32 Seat heating / seat made by Isringhausen
A 309 LI 29269A 311 LI 29270-
copyright by
MJFCIFSS
8.22.43
Electrical system
Service Manual
8.22.44
copyright by
MJFCIFSS
A 309 LI 29269A 311 LI 29270-
Service Manual
Electrical system
A 309 LI 29269A 311 LI 29270-
copyright by
MJFCIFSS
8.22.45
Electrical system
Service Manual
8.22.46
copyright by
MJFCIFSS
A 309 LI 29269A 311 LI 29270-
Service Manual
Electrical system
A 309 LI 29269A 311 LI 29270-
copyright by
MJFCIFSS
8.22.47
Electrical system
Service Manual
37 Optional beacon
8.22.48
copyright by
MJFCIFSS
A 309 LI 29269A 311 LI 29270-
Service Manual
Electrical system
A 309 LI 29269A 311 LI 29270-
copyright by
MJFCIFSS
8.22.49
Electrical system
Service Manual
40 Swivel bearing
8.22.50
copyright by
MJFCIFSS
A 309 LI 29269A 311 LI 29270-
Service Manual
Electrical system
42 Ground
A 309 LI 29269A 311 LI 29270-
copyright by
MJFCIFSS
8.22.51
Electrical system
Service Manual
43 Ground
8.22.52
copyright by
MJFCIFSS
A 309 LI 29269A 311 LI 29270-
Service Manual
Electrical system
44 Ground
A 309 LI 29269A 311 LI 29270-
copyright by
MJFCIFSS
8.22.53
Electrical system
Service Manual
45 Terminal 30 / terminal 15
8.22.54
copyright by
MJFCIFSS
A 309 LI 29269A 311 LI 29270-
Service Manual
Electrical system
Electrical system
Item
Description
Step
Location/arrangement
A3
A125
A126
Radio (optional)
Potentiometer board

Left bracket
Right bracket
A127
A1017
Printed circuit board / quick change adapter
8
26/34
4/10/13/
21a/21b/
24/33/34/
36/38/40/
41
1a/1b/1c/
2/3
38
B1
B2
B3
B7
B8
B10
B12
B16
B19L
B19R
B20

17
20
21a
21a
21a
13
27
21a
28
28
21a
B21
36
B26
B40
B50L
B50R
B60

Loudspeaker, left
Loudspeaker, right
38
28
8
8
9
B204
B266
B285
B290
B291
Proximity switch / industrial shut-down

39
33
29
34
34
Fuel tank
Motor, top fan side
Engine compartment
HBGV block
Motor housing
Left joystick
Right joystick
Quick change adapter
Travelling pedal
Cab, rear left
Cab, rear right
Attachment
Lower brake pedal
Hydraulic tank
Operator's platform
Operator's platform
E1
E2
E3
E4
E7
E8
E9
E15
E16
E17

Front roof light
Travel light, left
Travel light, right
Roof-mounted light
Cigarette lighter
Beacon
Parking light, left
Tail light, right
5
5
6
6
8
8
37
6
6
6
Attachment
Front cab roof
Cab
Right bracket, rear
Cab, top
copyright by
MJFCIFSS

Distribution board
8.30.1
Electrical system
Service Manual
Item
Description
Step
E18
E19
E20
E21
E22
E23
E24
E50
Tail light, left

Brake light, right
Brake light, left
Electric cabinet

Hydraulic tank
E150
6
6
6
4
4
4
4
1a/1b/1c/
2/3/40
5
F_A
F_B
F_C
F_D
F_E
F_F
F_G
F_H
F_I
F_K
F_L
F_M
F_N
FRes
F20/
F300
F19/
F301
F22/
F302
F303
F304
F305
F306
F307
F308
F309
F310
F311
F312
F313
F314
F315
F316
F317
F318
F319
F320
Fuse optional
Fuse optional
Fuse optional
Fuse optional
Fuse optional
Fuse optional
Fuse optional
Fuse optional
Fuse optional
Fuse optional
Fuse optional
Fuse optional
Fuse optional
Fuse, reserve
_A
_A
_A
_A
_A
_A
_A
_A
_A
_A
_A
_A
70 A
_A
50A
1b
1b
1b
1b
1b
1b
1b
1b
1b
1b
1b
1b
1a
14
1a

Right bracket
Fuse A127 K302, R60
50A
7.5A
1b
Fuse A127, Y29

Fuse S1
Fuse E7, E8, P50
Fuse X10
Fuse E16, E17, P6, P7, P50
Fuse E15, E18
Fuse E3
Fuse E4
Fuse M3, M4
Fuse S44, E21, E22, E23, E24
Fuse E19, E20
Fuse S7
Fuse BST
Fuse servo control
Fuse beacon
Fuse X11
7.5A
15A
15A
15A
7.5A
7.5A
7.5A
7.5A
15A
7.5A
5A
3A
15A
7.5A
7.5A
20A
15A
15A
3
1a
8
16
6
6
6
6
7
4
9
14
23
28
37
30c
30c
16

Right bracket
Right bracket
Right bracket
Right bracket, rear
Right bracket, rear
Right bracket, rear
Right bracket, rear
Right bracket, rear
Right bracket
Right bracket
Right bracket
Right bracket
Right bracket
Right bracket, rear
Right bracket
Right bracket
Right bracket
8.30.2
copyright by
MJFCIFSS
Rear cab roof
Service Manual
Item
Description
F321
F322
F323
F324
F325
F326
F327
F328
F329
F330
F331
F332
F336
F337
F338
F339
F343
Fuse X12
Fuse T1
Fuse E1
Fuse S22 - E2, S22-1 - E150
Fuse S16, K251
Fuse S21 - Y24, S42 - Y55
Fuse X27
Fuse X28
Fuse S35
Fuse kits
Fuse X29
Fuse A127, M1, Y12
Fuse S61
Fuse support
Fuse a/c condenser
G1
G2
Electrical system
Step
16
8
5
5
13
11
16
16
15
24
16
1a
6
35
4
30c
7b
Right bracket
Right bracket
Right bracket, rear
Right bracket, rear
Right bracket
Right bracket
Right bracket
Right bracket
Right bracket
Right bracket
Right bracket
Right bracket
Right bracket
Right bracket
Right bracket
Right bracket
Alternator
Batteries
1a
1a
Diesel engine
Battery box
H7
H9
H10
H11
H12
H13
H15
H16
H18
H19
H20
H23
H26
H27
H167
H168
H175
H176
H186
H196
H301
H307
H311

Horn
Warning buzzer
Warning buzzer
Indicator lamp / delta P
21a
4
21b
2
21b
21a
21a
36
21a
4
13
21a
38
13
10
10
21a
33
40
34
26
24
33
Right bracket
Right bracket
Right bracket
Right bracket
Right bracket
Right bracket
Right bracket
Right bracket
Right bracket
Right bracket
Right bracket
Right bracket
Right bracket
Right bracket
Right bracket
Right bracket
Right bracket
Right bracket
Right bracket
A125, left bracket
Right bracket
Right bracket
K_A
K_B
K_C
Relay, optional
Relay, optional
Relay, optional
1c
1c
1c

15A
7.5A
15A
15A
7.5A
15A
15A
15A
5A
7.5A
15A
25A
20A
15A
10A
20A
7.5A
copyright by
MJFCIFSS
8.30.3
Electrical system
Service Manual
Item
Description
Step
K_D
K_E
K16-1
K16-2
K63
K250
K251
K252
K288
K302
K315
K364
Relay, optional
Relay, optional
Relay, terminal 50
Relay, disconnected
Relay servo / hand brake (buzzer)
Relay, terminal 15
Relay / pre-heating
Relay brake light
Relay to A1017
1c
1c
1a
1a
4
33
13
13
3
2
9
38
K370
K375
K386
K392
K393
K403
K405
K414

Relay / optional industry shutt off
Relay / heating
Relay / heating
15
34
14
39
31
30a
30b
7

Right bracket
Right bracket
Right bracket
Right bracket
Right bracket
board
Right bracket
Right bracket
Right bracket
Operator's platform
M1
M3
M4
M60
M65
M68
M70
M71
M72
M73
Starter
Blower motor
1a
7
7
7b
30b
7
31
30a
30a
30a
Diesel engine
Windscreen
Cab, top
Cab, top
Operator's platform
P1
P2
P3
P5
P6
P7
P50

Display / clock
26
26
26
19
20
17
18
A125, left bracket

A125, left bracket
A125, left bracket
Right bracket
Right bracket
Right bracket
R60
R75
R76
R78-1
R78 -2
RS232

Seat heating
Seat heating
Laptop interface
2
22
24
32
32
26
Diesel engine
Right bracket
Right bracket
Operator's platform
Operator's platform
Left bracket
8.30.4
copyright by
MJFCIFSS
Service Manual
Electrical system
Item
Description
Step
S1
S1
S4
S5L
S5R
S7
S8
S9
S11
S14
S16
S18
S19
S20
S21
S22
S22-1
S32
S35
S42
S44
S45
S46
S47
S61
S63
S75
S90
S92
S93
S204
S205
S206
S207
S216
S218
S241
S263
S272
S283
S284
S335
S360
S382
S388
S389
S398

Code switch A125
Switch / horn H9
Safety switch
Switch / beacon
Battery main switch
Switch servo
Switch / priotity (optional)
Switch / magnet system (optional)
Intervall switch / windshield wiper
Switch / outrigger, front left
Switch / outrigger, front right
Switch / outrigger, rear left
Switch / outrigger, rear right
Push button / bypass
Switch / blade (optional)
Switch / fine adjustment ON / OFF
1a
26
4
25
25
14
37
42
7
7
13
36
25
28
11
5
5
4
15
12
4
34
41
38
6
40
33
7a
30a
30a
35
35
35
35
39
7b
34
10
35
7
30b
35
38
24
31
32
30a
Right bracket
A125, left bracket
Cab floor plate
Left bracket
Right bracket, rear
Battery compartment
Right bracket, rear
Right bracket, rear
Right bracket
Right bracket
Right bracket
Right bracket
Right bracket
Right bracket, rear
Right bracket, rear
Steering column
Right bracket
Right bracket
Right bracket
Right bracket
Right bracket
Right bracket
Right bracket, rear
Right bracket
Cab right
Right bracket
Right bracket
Right bracket
Right bracket
Right bracket
Right bracket
Right bracket
Right bracket, rear
Right bracket
Undercarriage
Windscreen
Right bracket
Right bracket
Right bracket
Right bracket
Operator seat
Operator seat
Right bracket
copyright by
MJFCIFSS
8.30.5
Electrical system
Service Manual
Item
Description
Step
T1
Left bracket
U16
Right bracket
V155
V156-1
V156-2
V156-3
V156-4

Blocking diode H307 - BST
Blocking diode S14-S90
2/20-24/
26-29/34/
41
33
24
33
7a
34
Right bracket
Right bracket
Right bracket
Right bracket
Right bracket
X10
X11
X12
X15-2
X27
X28
X29
X65
X66
X67-1
X67-2
X80
X81
X90
X196
X197
X230
X262
X262-1
X262-3
X262-4
X262-5
X262-6
X301
X304
X327
X342
X404
X406
X407
X410
X411
X412
X413
X550
X771
X834
X835

Plug connection wire harness, 12-pin
Plug connection wire harness / revolving deck
16
16
16
25
16
16
16
8
8
8
8
28
28
30b
28
33
10/13
38
38
38
38
38
38
35
35
39
10
5
17
36
38
38
38
38
4
35
26
26
Right bracket
Right bracket
Right bracket
Left bracket
Right bracket
Right bracket
Right bracket
Right bracket
Right bracket
Pilot control valve, right
Operator's platform
Travelling pedal
Brake pedal
Right bracket
Right bracket
Bearing block
Stick
Revolving deck
Right bracket
Basic boom bearing block
Left bracket
Revolving deck
Revolving deck X
Revolving deck
Right bracket
Right bracket
Right bracket
Right bracket
Steering column
Right bracket
Left bracket
Left bracket
8.30.6
copyright by
MJFCIFSS
Service Manual
Electrical system
Item
Description
Step
X836
X837
X838
X838-1
X838-2
X838-3
X839
X842-1
X842-2
X842-3
X856

Left bracket
Left bracket
Left bracket
Left bracket
Left bracket
Left bracket
Left bracket
Right bracket
Right bracket
Right bracket
Right bracket
X857
X859
X860
X861
X862
X863
X909
X924-1
X924-2
X950

Plug connection fine control / 2-pin
X951
X952
X953
X954

26
26/34
26
26
26
26
34
30c
30c
33
2/20-24/
26-29/34
21a/2224/26/28/
34
30a/30b
30a
30a
30a
30a/30b
30a/30b
34
34
4/10/13/
21a/33/
36/38/40/
41
4/10/13/
21b/34/
38/40/41
10-13/15/
25/30c/
33/34
1/4-6/9/
13/17/
21a/36/42
2/20/22/
26/27/29
1a/3/4/38/
39
2/20-24/
28/34/41/
43
8/11/12/
20/22/25/
34/35
18/28/34/
35/36/38/
39/41/43
10/24/30c
X955
X956

21-pin
X957
X958
X959
copyright by
MJFCIFSS
Right bracket
Right bracket
Right bracket
Right bracket
Right bracket
Right bracket
Right bracket
Right bracket
Right bracket
Right bracket
Right bracket
8.30.7
Electrical system
Service Manual
Item
Description
Step
X960
Right bracket
X961
X962
X963
X964
X965
X966

21-pin
4/6/9/21a/
28/33/34/
40
2/6/13/17/
20/21a/
21b/24/33
4/10/13/
14/21b/
28/34/38/
40/41
6/8/9/11/
13/14/16/
23/24/28/
35
1a/3/4/13/
14/28/33/
43
26/34
X967
X967-1
X967-2
X968-1
X968-2
X971
X972
X973
X974-1
X974-2
X974-3
X974-4
Y3
Y6
Y12
Y20
Y22
Y23
Y24
Y28-1
Y28-2
Y29
Y50
Y51
Y55
Y56
Y62
8.30.8
Right bracket
Right bracket
Right bracket
Right bracket
Right bracket
Right bracket

Power socket, 12V
8/14/24/
25/28/32/
34/43
5/6/8/37
45
43
34
34
31
32
8
24
33
7a
34
Right bracket
Right bracket
Right bracket
Operator's platform
Operator's platform
Left bracket
Right bracket
Right bracket
Right bracket
Cab, right

15
13
1a
30c
25
25
11
38
38
3
26
26
11
35
10
Control oil unit

HBGV block
Regulator / motor
Diesel engine
Control valve block
Control valve block
Control oil unit
Control oil unit
Control oil unit
HBGV block
Undercarriage
Hydraulic tank
copyright by
MJFCIFSS
Service Manual
Electrical system
Item
Description
Step
Y63
Y212
Y215
Y216
Y217
Y218
Y268
Y299
Y352
Y358
Y371

Solenoid valve / industrial shut-down
Solenoid valve / outrigger, front left
Solenoid valve / outrigger, front right
10
39
35
35
35
35
34
34
29
22
33
Hydraulic tank
Uppercarriage
Undercarriage
Undercarriage
Undercarriage
Undercarriage
Hydraulic tank
Hydraulic tank
Fan / radiator
Control valve block panel
Control oil unit
copyright by
MJFCIFSS
8.30.9
Electrical system
Service Manual
8.30.10
copyright by
MJFCIFSS
Service Manual
Electrical system
copyright by
MJFCIFSS
8.30.11
Electrical system
Service Manual
8.30.12
copyright by
MJFCIFSS
Service Manual
Electrical system
2 Pre-heating
copyright by
MJFCIFSS
8.30.13
Electrical system
Service Manual
3 Motor shut-down
8.30.14
copyright by
MJFCIFSS
Service Manual
Electrical system
copyright by
MJFCIFSS
8.30.15
Electrical system
Service Manual
5 Work headlight
8.30.16
copyright by
MJFCIFSS
Service Manual
Electrical system
copyright by
MJFCIFSS
8.30.17
Electrical system
Service Manual
7a Windscreen wiper / washer systems
8.30.18
copyright by
MJFCIFSS
only A 314 / 316 from 2001
Service Manual
Electrical system
7b Windscreen wiper/washer systems A 312 from 12363/A 314/316 from 12736
copyright by
MJFCIFSS
8.30.19
Electrical system
Service Manual
8.30.20
copyright by
MJFCIFSS
Service Manual
Electrical system
9 Brake light
copyright by
MJFCIFSS
8.30.21
Electrical system
Service Manual
8.30.22
copyright by
MJFCIFSS
Service Manual
Electrical system
11 Creeper speed
copyright by
MJFCIFSS
8.30.23
Electrical system
12
8.30.24
Service Manual
1st gear
copyright by
MJFCIFSS
Service Manual
Electrical system
13 Parking brake
copyright by
MJFCIFSS
8.30.25
Electrical system
Service Manual
14 Safety switch
8.30.26
copyright by
MJFCIFSS
Service Manual
Electrical system
15 Servo
copyright by
MJFCIFSS
8.30.27
Electrical system
Service Manual
8.30.28
copyright by
MJFCIFSS
Service Manual
Fuel gauge
Electrical system
18 Clock
copyright by
MJFCIFSS
19 Hour meter
8.30.29
Electrical system
Service Manual
8.30.30
copyright by
MJFCIFSS
Service Manual
Electrical system
copyright by
MJFCIFSS
8.30.31
Electrical system
Service Manual
8.30.32
copyright by
MJFCIFSS
Service Manual
Electrical system
22 Speed adjustment
copyright by
MJFCIFSS
8.30.33
Electrical system
Service Manual
8.30.34
copyright by
MJFCIFSS
Service Manual
Electrical system
24 Fine control
copyright by
MJFCIFSS
8.30.35
Electrical system
Service Manual
25 Optional AS I
8.30.36
copyright by
MJFCIFSS
Service Manual
Electrical system
copyright by
MJFCIFSS
8.30.37
Electrical system
Service Manual
27 Speed sensor
8.30.38
copyright by
MJFCIFSS
Service Manual
Electrical system
28 Sensor control
copyright by
MJFCIFSS
8.30.39
Electrical system
Service Manual
29 Fan control
8.30.40
copyright by
MJFCIFSS
Service Manual
Electrical system
30a Heating
copyright by
MJFCIFSS
8.30.41
Electrical system
Service Manual
30b Heating
8.30.42
copyright by
MJFCIFSS
Service Manual
Electrical system
30c Heating
copyright by
MJFCIFSS
8.30.43
Electrical system
Service Manual
8.30.44
copyright by
MJFCIFSS
Service Manual
Electrical system
copyright by
MJFCIFSS
8.30.45
Electrical system
Service Manual
8.30.46
copyright by
MJFCIFSS
Service Manual
Electrical system
copyright by
MJFCIFSS
8.30.47
Electrical system
Service Manual
8.30.48
copyright by
MJFCIFSS
Service Manual
Electrical system
copyright by
MJFCIFSS
8.30.49
Electrical system
Service Manual
37 Optional beacon
8.30.50
copyright by
MJFCIFSS
Service Manual
Electrical system
copyright by
MJFCIFSS
8.30.51
Electrical system
Service Manual
39 Optional industrial shut-down
8.30.52
copyright by
MJFCIFSS
Service Manual
Electrical system
40 Reserve
copyright by
MJFCIFSS
8.30.53
Electrical system
Service Manual
41 Optional magnet system
8.30.54
copyright by
MJFCIFSS
Service Manual
Electrical system
42 Ground
copyright by
MJFCIFSS
8.30.55
Electrical system
Service Manual
43 Ground
8.30.56
copyright by
MJFCIFSS
Service Manual
Electrical system
44 Ground
copyright by
MJFCIFSS
8.30.57
Electrical system
Service Manual
8.30.58
copyright by
MJFCIFSS
Service Manual
Electrical system
Electrical system
Item
Description
Step
A3
A125
A126
Radio (optional)
Potentiometer board

Left bracket
Right bracket
A127
A1017
Printed circuit board / quick change adapter
8
26/34
4/10/13/
21a/21b/
24/33/34/
36/38/40/
41/47
1a/1b/1c/
2/3
38
B1
B2
B3
B7
B8
B10
B12
B16
B19L
B19R
B20

17
20
21a/47
21a/47
21a/47
13
27
21a
28
28
21a/47
B21
36
B26
B40
B50L
B50R
B60

Loudspeaker, left
Loudspeaker, right
38
28
8
8
9
B204
B266
B285
B290
B291
Proximity switch / industrial shut-down

39
33
29
34
34
Fuel tank
Motor, top fan side
Engine compartment
HBGV block
Motor housing
Left joystick
Right joystick
Travelling pedal
Cab, rear left
Cab, rear right
Attachment
Lower brake pedal
Hydraulic tank
Operator's platform
Operator's platform
E1
E2
E2L
E2R
E3
E4
E7
E8
E9
E15

Front roof light
Front roof light left
Front roof light right
Travel light, left
Travel light, right
Roof-mounted light
Cigarette lighter
Beacon
5,46
5
46
46
6
6
8
8
37
6
Attachment
Front cab roof
Front cab roof
Front cab roof
Cab
Right bracket, rear
Cab, top
copyright by
MJFCIFSS

Distribution board
8.32.1
Electrical system
Service Manual
Item
Description
Step
E16
E17
E18
E19
E20
E21
E22
E23
E24
E50
Parking light, left

Tail light, right
Tail light, left
Brake light, right
Brake light, left
Electric cabinet

Hydraulic tank
E150
6
6
6
6
6
4
4
4
4
1a/1b/1c/
2/3/40
5
F_A
F_B
F_C
F_D
F_E
F_F
F_G
F_H
F_I
F_K
F_L
F_M
F_N
FRes
F20/
F300
F19/
F301
F22/
F302
F303
F304
F305
F306
F307
F308
F309
F310
F311
F312
F313
F314
F315
F316
F317
F318
Fuse optional
Fuse optional
Fuse optional
Fuse optional
Fuse optional
Fuse optional
Fuse optional
Fuse optional
Fuse optional
Fuse optional
Fuse optional
Fuse optional
Fuse optional
Fuse, reserve
_A
_A
_A
_A
_A
_A
_A
_A
_A
_A
_A
_A
70 A
_A
50A
1b
1b
1b
1b
1b
1b
1b
1b
1b
1b
1b
1b
1a
14
1a

Right bracket
Fuse A127 K302, R60
50A
7.5A
1b
Fuse A127, Y29

Fuse S1
Fuse E7, E8, P50
Fuse X10
Fuse E16, E17, P6, P7, P50
Fuse E15, E18
Fuse E3
Fuse E4
Fuse M3, M4
Fuse S44, E21, E22, E23, E24
Fuse E19, E20
Fuse S7
Fuse BST
Fuse servo control
Fuse beacon
7.5A
15A
15A
15A
7.5A
7.5A
7.5A
7.5A
15A
7.5A
5A
3A
15A
7.5A
7.5A
20A
3
1a
8
16
6
6
6
6
7
4
9
14
23
28
37
30c

Right bracket
Right bracket
Right bracket
Right bracket, rear
Right bracket, rear
Right bracket, rear
Right bracket, rear
Right bracket, rear
Right bracket
Right bracket
Right bracket
Right bracket
Right bracket
Right bracket, rear
Right bracket
8.32.2
copyright by
MJFCIFSS
Rear cab roof
Service Manual
Electrical system
Item
Description
F319
F320
F321
F322
F323
F324
F325
F326
F327
F328
F329
F330
F331
F332
F336
F337
F338
F339
F343

Fuse X11
Fuse X12
Fuse T1
Fuse E1
Fuse S22 - E2, S22-1 - E150
Fuse S16, K251
Fuse S21 - Y24, S42 - Y55
Fuse X27
Fuse X28
Fuse S35
Fuse kits
Fuse X29
Fuse A127, M1, Y12
Fuse S61
Fuse support
Fuse a/c condenser
Step
30c
16
16
8
5, 46
5, 46
13
11
16
16
15
24
16
1a
6
35
4
30c
7
Right bracket
Right bracket
Right bracket
Right bracket
Right bracket, rear
Right bracket, rear
Right bracket
Right bracket
Right bracket
Right bracket
Right bracket
Right bracket
Right bracket
Right bracket
Right bracket
Right bracket
Right bracket
Right bracket
G1
G2
Alternator
Batteries
1a
1a
Diesel engine
Battery box
H7
H9
H10
H11
H12
H13
H15
H16
H18
H19
H20
H23
H26
H27
H167
H168
H175
H176
H186
H196
H301
H307
H311
H336

Horn
Warning buzzer
Warning buzzer
Warning lamp / water in fuel filter
21a
4
21b
2
21b
21a/47
21a/47
36
21a/47
4
13
21a/47
38
13
10
10
21a/47
33
40
34
26
24
33
33
Right bracket
Right bracket
Right bracket
Right bracket
Right bracket
Right bracket
Right bracket
Right bracket
Right bracket
Right bracket
Right bracket
Right bracket
Right bracket
Right bracket
Right bracket
Right bracket
Right bracket
Right bracket
Right bracket
A125, left bracket
Right bracket
Right bracket
Right bracket
15A
15A
15A
7.5A
15A
15A
7.5A
15A
15A
15A
5A
7.5A
15A
25A
20A
15A
10A
20A
7.5A
copyright by
MJFCIFSS
8.32.3
Electrical system
Service Manual
Item
Description
Step
K_A
K_B
K_C
K_D
K_E
K16-1
K16-2
K63
K250
K251
K252
K288
K302
K315
K364
Relay, optional
Relay, optional
Relay, optional
Relay, optional
Relay, optional
Relay, terminal 50
Relay, disconnected
Relay servo / hand brake (buzzer)
Relay, terminal 15
Relay / pre-heating
Relay brake light
Relay to A1017
1c
1c
1c
1c
1c
1a
1a
4
33
13
13
3
2
9
38
K370
K375
K386
K393
K403
K405
K414
K447
K448
K449

Relay / heating
Relay / heating
Relay / Front roof light
Relay / Rear roof light
Relay / Front work light
15
34
14
31
30a
30b
7
46
46
46

Right bracket
Right bracket
Right bracket
Right bracket
Right bracket
board
Right bracket
Right bracket
Operator's platform
M1
M3
M4
M60
M65
M68
M70
M71
M72
M73
Starter
Blower motor
1a
7
7
7
30b
7
31
30a
30a
30a
Diesel engine
Windscreen
Cab, top
Cab, top
Operator's platform
P1
P2
P3
P5
P6
P7
P50

Display / clock
26
26
26
19
20
17
18
A125, left bracket

A125, left bracket
A125, left bracket
Right bracket
Right bracket
Right bracket
R60
R75

2
22
Diesel engine
Right bracket
8.32.4
copyright by
MJFCIFSS
Service Manual
Electrical system
Item
Description
Step
R76
R78-1
R78 -2
RS232

Seat heating
Seat heating
Laptop interface
24
32
32
26
Right bracket
Operator's platform
Operator's platform
Left bracket
S1
S1
S4
S5L
S5M
S5R
S7
S8
S9
S11
S14
S16
S18
S19
S20
S21
S22
S22-1
S32
S35
S42
S44
S46
S47
S61
S63
S75
S92
S93
S204
S205
S206
S207
S216
S218
S241
S263
S272
S283
S284
S335
S360
S382

Code switch A125
Switch / horn H9
Safety switch
Switch / beacon
Battery main switch
Switch servo
Switch / outrigger, front left
Switch / outrigger, front right
Switch / outrigger, rear left
Switch / outrigger, rear right
Push button / bypass
Switch / blade (optional)
1a
26
4
25
25
25
14
37
42
7
7
13
36
25
28
11
5, 46
5, 46
4
15
12
4
41
38
6
40
33
30a
30a
35
35
35
35
39
7
34
10
35
7
30b
35
38
24
Right bracket
A125, left bracket
Cab floor plate
Left bracket
Right bracket, rear
Battery compartment
Right bracket, rear
Right bracket, rear
Right bracket
Right bracket
Right bracket
Right bracket
Right bracket
Right bracket, rear
Right bracket, rear
Steering column
Right bracket
Right bracket
Right bracket
Right bracket
Right bracket
Right bracket, rear
Right bracket
Right bracket
Right bracket
Right bracket
Right bracket
Right bracket
Right bracket
Right bracket
Right bracket, rear
Right bracket
Undercarriage
Windscreen
Right bracket
Right bracket
Right bracket
Right bracket
copyright by
MJFCIFSS
8.32.5
Electrical system
Service Manual
Item
Description
Step
S388
S389
S398
S422

31
32
30a
8
Operator seat
Operator seat
Right bracket
Right bracket
T1
Left bracket
U16
Right bracket
V155
V156-1
V156-2
V156-4

2/20-24/
26-29/34/
41
33
24
33
34
Right bracket
Right bracket
Right bracket
Right bracket
X10
X11
X12
X27
X28
X29
X65
X66
X67-1
X67-2
X90
X196
X197
X230
X262
X262-1
X262-3
X262-4
X262-5
X262-6
X301
X304
X327
X404
X406
X407
X410
X411
X412
X413
X550
X771
X834
X835

Plug connection wire harness, 12-pin
Plug connection wire harness / revolving deck
16
16
16
16
16
16
8
8
8
8
30b
28
33
10/13
38
38
38
38
38
38
35
35
39
5
17
36
38
38
38
38
4
35
26
26
Right bracket
Right bracket
Right bracket
Right bracket
Right bracket
Right bracket
Right bracket
Right bracket
Operator's platform
Travelling pedal
Brake pedal
Right bracket
Right bracket
Bearing block
Stick
Revolving deck
Right bracket
Revolving deck
Revolving deck X
Revolving deck
Right bracket
Right bracket
Right bracket
Right bracket
Steering column
Right bracket
Left bracket
Left bracket
8.32.6
copyright by
MJFCIFSS
Service Manual
Electrical system
Item
Description
Step
X836
X837
X838
X838-1
X838-2
X838-3
X839
X842-1
X842-2
X842-3
X856

Left bracket
Left bracket
Left bracket
Left bracket
Left bracket
Left bracket
Left bracket
Right bracket
Right bracket
Right bracket
Right bracket
X857
X859
X860
X861
X862
X863
X924-1
X924-2
X950

X951
X952
X953
X954

26
26/34
26
26
26
26
34
30c
30c
33
2/20-24/
26-29/34
21a/2224/26/28/
34/47
30a/30b
30a
30a
30a
30a/30b
34
34
4/10/13/
21a/33/
36/38/40/
41/47
4/10/13/
21b/34/
38/40/41
10-13/15/
25/30c/
33/34
1/4-6/9/
13/17/
21a/36/
42/47
2/20/22/
26/27/29
1a/3/4/38/
39
2/20-24/
28/34/41/
43
8/11/12/
20/22/25/
34/35
18/28/34/
35/36/38/
39/41/43
10/24/30c
X955
X956

21-pin
X957
X958
X959
copyright by
MJFCIFSS
Right bracket
Right bracket
Right bracket
Right bracket
Right bracket
Right bracket
Right bracket
Right bracket
Right bracket
Right bracket
Right bracket
8.32.7
Electrical system
Service Manual
Item
Description
Step
X960
Right bracket
X961
X962
X963
X964
X965
X966

21-pin
4/6/9/21a/
28/33/34/
47
2/6/13/17/
20/21a/
21b/24/
33/47
4/10/13/
14/21b/
28/34/38/
40/41
6/8/9/11/
13/14/16/
23/24/28/
35
1a/3/4/13/
14/28/33/
43
26/34
X967
X967-1
X967-2
X968-1
X968-2
X971
X972
X973
X974-1
X974-2
X974-4
X1046
X1047
X1048
X1049
X1116
Y3
Y6
Y12
Y20
Y22
Y23
Y24
Y28-1
Y28-2
Y29
8.32.8
Right bracket
Right bracket
Right bracket
Right bracket
Right bracket

Power socket, 12V
8/14/24/
25/28/32/
34/43
5/6/8/37/
46
45
43
34
34
31
32
8
24
33
34
24/25
28
10
28
15

Right bracket
Right bracket
Operator's platform
Operator's platform
Left bracket
Right bracket
Right bracket
Cab, right
Left bracket
Right bracket

15
13
1a
30c
25
25
11
38
38
3
Control oil unit

HBGV block
Regulator / motor
Diesel engine
Control valve block
Control valve block
Control oil unit
copyright by
MJFCIFSS
Right bracket
Right bracket
Service Manual
Electrical system
Item
Description
Step
Y50
Y51
Y55
Y56
Y62
Y63
Y212
Y215
Y216
Y217
Y218
Y268
Y299
Y352
Y358
Y371

Solenoid valve / outrigger, front left
Solenoid valve / outrigger, front right
26
26
11
35
10
10
39
35
35
35
35
34
34
29
22
33
Control oil unit

Control oil unit
HBGV block
Undercarriage
Hydraulic tank
Hydraulic tank
Uppercarriage
Undercarriage
Undercarriage
Undercarriage
Undercarriage
Hydraulic tank
Hydraulic tank
Fan / radiator
Control oil unit
copyright by
MJFCIFSS
8.32.9
Electrical system
Service Manual
8.32.10
copyright by
MJFCIFSS
Service Manual
Electrical system
copyright by
MJFCIFSS
8.32.11
Electrical system
Service Manual
8.32.12
copyright by
MJFCIFSS
Service Manual
Electrical system
2 Pre-heating
copyright by
MJFCIFSS
8.32.13
Electrical system
Service Manual
3 Motor shut-down
8.32.14
copyright by
MJFCIFSS
Service Manual
Electrical system
copyright by
MJFCIFSS
8.32.15
Electrical system
Service Manual
5 Work headlight
(on machine A312 from 20330, A 314 from 20334, A 316 from 20340 until 25765
A 316 from 25766, see page 8.32.58
8.32.16
copyright by
MJFCIFSS
Service Manual
Electrical system
copyright by
MJFCIFSS
8.32.17
Electrical system
Service Manual
8.32.18
copyright by
MJFCIFSS
Service Manual
Electrical system
copyright by
MJFCIFSS
8.32.19
Electrical system
Service Manual
9 Brake light
8.32.20
copyright by
MJFCIFSS
Service Manual
Electrical system
copyright by
MJFCIFSS
8.32.21
Electrical system
Service Manual
11 Creeper speed
8.32.22
copyright by
MJFCIFSS
Service Manual
12
Electrical system
1st gear
copyright by
MJFCIFSS
8.32.23
Electrical system
Service Manual
13 Parking brake
8.32.24
copyright by
MJFCIFSS
Service Manual
Electrical system
14 Safety switch
copyright by
MJFCIFSS
8.32.25
Electrical system
Service Manual
15 Servo
8.32.26
copyright by
MJFCIFSS
Service Manual
Electrical system
copyright by
MJFCIFSS
8.32.27
Electrical system
17 Fuel gauge
8.32.28
Service Manual
18 Clock
copyright by
MJFCIFSS
19 Hour meter
Service Manual
Electrical system
copyright by
MJFCIFSS
8.32.29
Electrical system
Service Manual

(on machine A 312 until 27112, A 314 until 27114, A 316 until 27118, A 316 Ind. until 27383
new version , see page 8.32.59
8.32.30
copyright by
MJFCIFSS
Service Manual
Electrical system
copyright by
MJFCIFSS
8.32.31
Electrical system
Service Manual
22 Speed adjustment
8.32.32
copyright by
MJFCIFSS
Service Manual
Electrical system
copyright by
MJFCIFSS
8.32.33
Electrical system
Service Manual
24 Fine control
8.32.34
copyright by
MJFCIFSS
Service Manual
Electrical system
25 Optional AS I
copyright by
MJFCIFSS
8.32.35
Electrical system
Service Manual
8.32.36
copyright by
MJFCIFSS
Service Manual
Electrical system
27 Speed sensor
copyright by
MJFCIFSS
8.32.37
Electrical system
Service Manual
28 Sensor control
(on machine A 312 until 27112, A 314 until 27114, A 316 until 27118, A 316 Ind. until 27383
new version , see page 8.32.60
8.32.38
copyright by
MJFCIFSS
Service Manual
Electrical system
29 Fan control
copyright by
MJFCIFSS
8.32.39
Electrical system
Service Manual
30a Heating
8.32.40
copyright by
MJFCIFSS
Service Manual
Electrical system
30b Heating
copyright by
MJFCIFSS
8.32.41
Electrical system
Service Manual
30c Heating
8.32.42
copyright by
MJFCIFSS
Service Manual
Electrical system
copyright by
MJFCIFSS
8.32.43
Electrical system
Service Manual
8.32.44
copyright by
MJFCIFSS
Service Manual
Electrical system
copyright by
MJFCIFSS
8.32.45
Electrical system
Service Manual
8.32.46
copyright by
MJFCIFSS
Service Manual
Electrical system
copyright by
MJFCIFSS
8.32.47
Electrical system
Service Manual
8.32.48
copyright by
MJFCIFSS
Service Manual
Electrical system
37 Optional beacon
copyright by
MJFCIFSS
8.32.49
Electrical system
Service Manual
8.32.50
copyright by
MJFCIFSS
Service Manual
Electrical system
copyright by
MJFCIFSS
8.32.51
Electrical system
Service Manual
40 Reserve
8.32.52
copyright by
MJFCIFSS
Service Manual
Electrical system
copyright by
MJFCIFSS
8.32.53
Electrical system
Service Manual
42 Ground
8.32.54
copyright by
MJFCIFSS
Service Manual
Electrical system
43 Ground
copyright by
MJFCIFSS
8.32.55
Electrical system
Service Manual
44 Ground
8.32.56
copyright by
MJFCIFSS
Service Manual
Electrical system
copyright by
MJFCIFSS
8.32.57
Electrical system
Service Manual
46 (5) Work headlight

(on machine A 316 from 25766)
8.32.58
copyright by
MJFCIFSS
Service Manual
Electrical system
47 (21a) Indicator lights

(on A 312 from 27113, A 314 from 27115, A 316 from 27119, A 316 Ind. from 27384)
copyright by
MJFCIFSS
8.32.59
Electrical system
Service Manual
48 (28) Sensor control

(on A 312 from 27113, A 314 from 27115, A 316 from 27119, A 316 Ind. from 27384)
8.32.60
copyright by
MJFCIFSS
Service Manual
Electrical system
Electrical system
Item
Description
Step
A3
A 125
A 126
Radio (optional)
Potentiometer board
Operator's cab, back

Left bracket
Right bracket
A 127
A 1017
Printed circuit board/quick change adapter
8
26/34
4/10/13/
21a/21b/
24/33/34/
36/38/40/
41
1a/1b/1c/
2/3
38
B1
B2
B3
B7
B8
B12
B16
B19L
B19R
B21
Transducer/fuel level - with plug

Transducer / motor coolant - with plug
17
20
21a
21a
21a
27
21a
28
28
36
B26
B40L
B40R
B50L
B50R
B285
B290
B291

Proximity switch / pilot control unit, left, travel
Proximity switch / pilot control unit, right, travel
Loudspeaker, left
Loudspeaker, right
38
28
28
8
8
29
34
34
E1
E2
E3
E4
E7
E8
E9
E15
E16
E50

Front roof light
Travel light, left
Travel light, right
Roof-mounted light
Cigarette lighter
Beacon
Parking light, left
Electric cabinet
Attachment
Front cab roof
Cab
Bracket, rear, right
Cab, top
Hydraulic tank
E150
5
5
6
6
8
8
37
6
6
1a/1b/1c/
2/3
5
F_A
F_B
F_C
F_D
Fuse optional
Fuse optional
Fuse optional
Fuse optional
1b
1b
1b
1b

_A
_A
_A
_A
MJFCIFSS
Hydraulic tank
Distribution board
Fuel tank
Motor
Expansion tank
Flywheel housing
Motor housing
Left joystick
Right joystick
Boom cylinder / piston
side
Travelling pedal, left
Travelling pedal, right
Cab, rear left
Cab, rear right
Hydraulic tank
Operators platform
Operators platform
Rear cab roof
8.40.1
Electrical system
Service Manual
Item
Description
Step
F_E
F_F
F_G
F_H
F_I
F_K
F_L
F_M
F_N
FRes
F20/
F300
F19/
F301
F22/
F302
F303
F304
F305
F306
F307
F308
F309
F310
F311
F314
F315
F316
F317
F318
F319
F320
F321
F322
F323
F324
F326
F327
F328
F329
F330
F331
F332
F336
F337
F338
F339
F343
Fuse optional
Fuse optional
Fuse optional
Fuse optional
Fuse optional
Fuse optional
Fuse optional
Fuse optional
Fuse optional
Fuse, reserve
_A
_A
_A
_A
_A
_A
_A
_A
70 A
_A
50A
1b
1b
1b
1b
1b
1b
1b
1b
1a
14
1a

Right bracket
Fuse A127 K302, R60
70A
Fuse A127 terminal 15, terminal 30, B3, S44
7.5A
1b
Fuse A127, Y29

Fuse S1
Fuse E7, E8, P50
Fuse X10
Fuse E16, E17, P6, P7, P50
Fuse E15, E18
Fuse E3
Fuse E4
Fuse M4
Fuse S7
Fuse BST
Fuse servo control
Fuse servo control
Fuse X11
Fuse X12
Fuse T1
Fuse E1
Fuse S22 - E2, S22-1 - E150
Fuse S21 - Y24
Fuse X27
Fuse X28
Fuse servo
Fuse kits
Fuse X29
Fuse A127, M1, Y12
Fuse S61
Fuse support
Fuse a/c condenser
7.5A
15A
15A
15A
7.5A
7.5A
7.5A
7.5A
15A
3A
15A
7.5A
7.5A
20A
15A
15A
15A
7.5A
15A
15A
15A
15A
15A
5A
15A
15A
25A
20A
15A
15A
20A
7.5A
3
1a
8
16
6
6
6
6
7
14
23
28
37
30c
30c
16
16
8
5
5
11
16
16
15
24
16
1a
6
35
4
30c
7

Right bracket, front
Hydraulic tank
8.40.2
MJFCIFSS
Service Manual
Electrical system
Item
Description
Step
G1
G2
Alternator
Batteries
1a
1a
Diesel engine
Battery box
H7
H9
H10
H11
H12
H13
H15
H16
H18
H26
H27
H175
H196
H301
H307

Horn
Warning buzzer
Warning buzzer
21a
4
21b
2
21b
21a
21a
36
21a
38
13
21a
34
26
24
Right bracket
Right bracket
Right bracket
Right bracket
Right bracket
Right bracket
Right bracket
Right bracket
Right bracket
Right bracket
Right bracket
Right bracket
A125, left bracket
Right bracket
K_A
K_B
K_C
K_D
K_E
K16-1
K16-2
K288
K302
K364
Relay, optional
Relay, optional
Relay, optional
Relay, optional
Relay, optional
Relay, terminal 50
Relay, disconnected
Relay, terminal 15
Relay / pre-heating
Relay to A1017
1c
1c
1c
1c
1c
1a
1a
3
2
38
K370
K375
K386
K393
K403
K405
K414
Relay / fine control, grapple rotation

Relay / kit - quantity
Relay / heating
Relay / heating
15
34
14
31
30a
30b
7

board
Right bracket
Right bracket
Operators platform
M1
M3
M4
M60
M65
M68
M70
M71
M72
M73
Starter
Blower motor
1a
7
7
7
30b
7
31
30a
30a
30a
Diesel engine
Windscreen
Cab, top
Cab, top
Operators platform
MJFCIFSS
8.40.3
Electrical system
Service Manual
Item
Description
Step
P1
P2
P3
P5
P6
P7
P50

Display / clock
26
26
26
19
20
17
18
Left bracket
Left bracket
Left bracket
Left bracket, bottom
Right bracket
Right bracket
Right bracket
R60
R75
R76
R78-1
R78-2
RS232

Seat heating
Seat heating
Laptop interface
2
22
24
32
32
26
Diesel engine
Right bracket
Right bracket
Operators platform
Operators platform
Left bracket
S1
S1
S4
S5L
S5M
S5R
S7
S8
S9
S11
S14
S17
S18
S19
S20
S21
S22
S22-1
S46
S47
S61
S92
S93
S218
S241
S283
S284
S360
S382
S388
S389
S398
Ignition switch
Code switch A125
Switch / horn H9
Push button/turning grapple to the left, Y22
Safety switch
Switch / beacon
Battery main switch
Switch / slewing gear brake Y7
Switch / rapid gear Y24
Push button / muting overload buzzer (optional)
1a
26
4
25
25
25
14
37
42
7
7
15
36
25
28
11
5
5
41
38
6
30a
30a
7
34
7
30b
38
24
31
32
30a
Right bracket
Left bracket
Cab floor plate
Left bracket
Right bracket, rear
Battery compartment
Right bracket, rear
Right bracket, rear
Right bracket
Right bracket
Right bracket
Right bracket
Right bracket
Right bracket, rear
Right bracket, rear
Right bracket
Right bracket
Right bracket, rear
Right bracket
Right bracket
Right bracket, rear
Right bracket, rear
Windscreen, bottom
Right bracket
Right bracket
Operator seat
Operator seat
Right bracket
8.40.4
MJFCIFSS
Service Manual
Electrical system
Item
Description
Step
S422
Right bracket
T1
Right bracket
U16
Right bracket
V155
V156-1
V156-2
V156-4

2/20/2629/34/41
33
24
33
34
Right bracket
Right bracket
Right bracket
Right bracket
X10
X11
X12
X27
X28
X29
X65
X66
X67-1
X67-2
X90
X196
X197
X230
X262
X262-1
X262-3
X262-4
X262-5
X262-6
X304
X404
X406
X407
X410
X411
X412
X413
X550
X771
X834
X835
X836
X837
X838
X838-1
X838-2

Plug connection / wire harness quick-change adapter / 8-pin
Plug connection wire harness revolving deck / 2-pin
16
16
16
16
16
16
8
8
8
8
30b
28
33
10/13
38
38
38
38
38
38
35
5
17
36
38
38
38
38
4
35
26
26
26
26/34
26
26
26
Right bracket
Right bracket
Right bracket
Right bracket
Right bracket
Right bracket
Right bracket
Right bracket
Operators platform
Travelling pedal
Travelling pedal
Right bracket
Right bracket
Bearing block
Stick
Right bracket
Revolving deck
Revolving deck
Revolving deck
Right bracket
Right bracket
Right bracket
Right bracket
Steering column
Right bracket
Left bracket
Left bracket
Left bracket
Left bracket
Left bracket
Left bracket
Left bracket
MJFCIFSS
8.40.5
Electrical system
Service Manual
Item
Description
Step
X838-3
X839
X842-1
X842-2
X842-3
X856
Plug connection to A 125 / CAN bus / 2-pin

Left bracket
Left bracket
Right bracket
Right bracket
Right bracket
Right bracket
X857
X859
X860
X861
X862
X863
X902
X924-1
X924-2
X950

X951
X952
Plug connection revolving deck - BST excavator control / 21pin
X953
Plug connection revolving deck - distribution board / 21-pin
X954
Plug connection revolving deck - BST excavator control / 21pin

Plug connection revolving deck - distribution board / 15-pin
26
34
30c
30c
33
2/20/24/
26-29/38/
41
21a/2224/26/28/
34
30a/30b
30a
30a
30a
30a/30b
4/6/42
34
34
4/10/13/
21a/24/
33/36/38/
40/41
4/10/13/
21b/34/
38/40/41
10-13/15/
25/30c/
33/34
4-6/9/13/
17/21a/
36/42
2/20/22/
26/27/29
1a/3/4/38/
39
2/20-24/
28/34/41/
43
8/11/12/
15/20/22/
25/34/35
18/28/34/
35/36/38/
39/41/43
10/24/30c
4/6/9/21a/
28/33/34
2/6/13/17/
20/21a/
21b/24/33
X955
X956

21-pin
X957
X958
X959
X960

Plug connection / display distribution board / 21-pin
X961
8.40.6
Right bracket
Right bracket
Right bracket
Right bracket
Right bracket
Right bracket
Right bracket
Right bracket
Right bracket
Right bracket
Right bracket
Right bracket
Right bracket
MJFCIFSS
Service Manual
Electrical system
Item
Description
Step
X962
Right bracket
X963
X964
X965
X966

21-pin
4/10/13/
14/21b/
34/38/40/
41
6/8/9/11/
13/14/16/
23/24/28/
35
1a/3/4/13/
15/28/33/
43
26/34
X967
X967-1
X967-2
X968-1
X968-2
X971
X972
X973
X974-1
X974-2
X974-3
X974-4
X1046
X1047
X1048
X1049
X1115
X1116
Y3
Y7
Y12
Y20
Y22
Y23
Y24
Y28-1
Y28-2
Y29
Y50
Y51
Y268
Y299
Y352
Right bracket
Right bracket
Right bracket

Power socket, 12V
Plug connection slewing gear brake / 2-pin
Plug connection slewing gear brake / 2-pin
8/14/24/
25/28/32/
34/43
5/6/8/37
45
43
34
34
31
32
8
24
33
7
34
24,25
28
10
28
15
15
Right bracket
Right bracket
Right bracket
Operators platform
Operators platform
Left bracket
Right bracket
Right bracket
Cab, right
Cab, right
Left bracket
Right bracket

Solenoid valve / slewing gear brake
Magnetic valve / a/c compressor
15
15
1a
30c
25
25
11
38
38
3
26
26
34
34
29
Control oil unit

Control oil unit
Regulator / motor
Diesel engine
Control valve block
Control valve block
Control oil unit
Control oil unit
Control oil unit
Hydraulic tank
Hydraulic tank
Fan / radiator
MJFCIFSS
Right bracket
8.40.7
Electrical system
Service Manual
Item
Description
Step
Y358
22
8.40.8
MJFCIFSS
Service Manual
Electrical system
MJFCIFSS
8.40.9
Electrical system
Service Manual
8.40.10
MJFCIFSS
Service Manual
Electrical system
MJFCIFSS
8.40.11
Electrical system
Service Manual
2 Pre-heating
8.40.12
MJFCIFSS
Service Manual
Electrical system
3 Motor shut-down
MJFCIFSS
8.40.13
Electrical system
Service Manual
8.40.14
MJFCIFSS
Service Manual
Electrical system
5 Work headlight
MJFCIFSS
8.40.15
Electrical system
Service Manual
8.40.16
MJFCIFSS
Service Manual
Electrical system
MJFCIFSS
8.40.17
Electrical system
Service Manual
8.40.18
MJFCIFSS
Service Manual
Electrical system
9 Brake light
MJFCIFSS
8.40.19
Electrical system
Service Manual
8.40.20
MJFCIFSS
Service Manual
Electrical system
11 Rapid gear
MJFCIFSS
8.40.21
Electrical system
Service Manual
12 1st gear
8.40.22
MJFCIFSS
Service Manual
Electrical system
13 Parking brake
MJFCIFSS
8.40.23
Electrical system
Service Manual
14 Safety switch
8.40.24
MJFCIFSS
Service Manual
Electrical system
15 Servo swing gear brake
MJFCIFSS
8.40.25
Electrical system
Service Manual
8.40.26
MJFCIFSS
Service Manual
17 Fuel gauge
Electrical system
18 Clock
MJFCIFSS
19 Hour meter
8.40.27
Electrical system
Service Manual
8.40.28
MJFCIFSS
Service Manual
Electrical system
MJFCIFSS
8.40.29
Electrical system
Service Manual
8.40.30
MJFCIFSS
Service Manual
Electrical system
22 Speed adjustment
MJFCIFSS
8.40.31
Electrical system
Service Manual
23 Excavator-control power supply
8.40.32
MJFCIFSS
Service Manual
Electrical system
24 Excavator-control power supply
MJFCIFSS
8.40.33
Electrical system
Service Manual
25 Optional AS I
8.40.34
MJFCIFSS
Service Manual
Electrical system
MJFCIFSS
8.40.35
Electrical system
Service Manual
27 Speed sensor
8.40.36
MJFCIFSS
Service Manual
Electrical system
28 Sensor control up to serial number 21204
MJFCIFSS
8.40.37
Electrical system
Service Manual
28 Sensor control from serial number 21205
8.40.38
MJFCIFSS
Service Manual
Electrical system
29 Fan control
MJFCIFSS
8.40.39
Electrical system
Service Manual
30a Heating
8.40.40
MJFCIFSS
Service Manual
Electrical system
30b Heating
MJFCIFSS
8.40.41
Electrical system
Service Manual
30c Heating
8.40.42
MJFCIFSS
Service Manual
Electrical system
MJFCIFSS
8.40.43
Electrical system
Service Manual
8.40.44
MJFCIFSS
Service Manual
Electrical system
MJFCIFSS
8.40.45
Electrical system
Service Manual
8.40.46
MJFCIFSS
Service Manual
Electrical system
MJFCIFSS
8.40.47
Electrical system
Service Manual
8.40.48
MJFCIFSS
Service Manual
Electrical system
37 Optional beacon
MJFCIFSS
8.40.49
Electrical system
Service Manual
8.40.50
MJFCIFSS
Service Manual
Electrical system
MJFCIFSS
8.40.51
Electrical system
Service Manual
40 Reserve
8.40.52
MJFCIFSS
Service Manual
Electrical system
MJFCIFSS
8.40.53
Electrical system
Service Manual
42 Ground
8.40.54
MJFCIFSS
Service Manual
Electrical system
43 Ground
MJFCIFSS
8.40.55
Electrical system
Service Manual
44 Ground
8.40.56
MJFCIFSS
Service Manual
Electrical system
MJFCIFSS
8.40.57
Electrical system
8.40.58
Service Manual
MJFCIFSS
Service Manual
Electric kits
List of kits
Electric kits
8.45A 309 LI 20221-A 311 LI 20222-A 312 LI 12363-A 314 LI 2001-A 316 LI 2001-A 316 LI-IND 2001-R 317 LI 18161-
1 List of kits
Step
Kit
Page
50
51
51
51
52-1
52-2
53
54
55-1
55-2
55-3
56
57
58
59
60
61
62
63
64 a - c
65
66-1
66-2
67
68
69
70
71
72
73
74
75
76
77
78-1
78-2
79
80
81
82
83/1
List of electric units

Changeover blade - outrigger/individual control
AHS 11
AHS 12
AHS 12 & PRIO
Refuelling pump
Refuelling pump
Hydraulic operator's cab elevation (lift frame)
Overload warning system
Magnet system control
Industrial shut-off
Radio system
Beacon
Motor stop (emergency-stop)
Immobiliser
Travel alarm
Industrial quick change adapter
Air-conditioning system
Auxiliary headlight equipment
Accessory kit changeover valve
Back-up alarm
Fuel pre-heating
Auxiliary heater
Power socket
Stroke limitation at hydraulic boom adjusting device
Individual control (blade)
License plate light
Central lubrication system
Emergency drain
Stroke limitation (basic boom)
Accessory kit changeover valve fine regulation switch
Stroke limitation (boom and stick)
AS1 actuating device in handle, left and right
Kit quantity switchable
Inclinometer illumination
Krger stroke limitation part 1
8.45.3
8.45.19
8.45.21
8.45.23
8.45.25
8.45.27
8.45.29
8.45.31
8.45.33
8.45.35
8.45.37
8.45.39
8.45.41
8.45.43
8.45.45
8.45.47
8.45.49
8.45.51
8.45.53
8.45.55
8.45.57 - 8.45.59
8.65.61
8.45.63
8.45.65
8.45.67
8.45.69
8.45.71
8.45.73
8.45.75
8.56.77
8.45.79
8.45.81
8.45.83
8.45.85
8.45.87
8.45.89
8.45.91
8.45.93
8.45.95
8.45.97
8.45.99
8.45.101
A 309 LI - R 317 LI
copyright by
MJF C I F S S
8.45.1
Electric kits
Service Manual
List of kits
Step
Kit
Page
83/2
84/1
84/2
84/3
85
86/1
86/2
87
88
89
90
91
92
93
94
95
96
97/1
97/2
97/3
98
99
100
101
102
103
104
105
106
107
108
109
110
111
Krger stroke limitation part 2

Changeover bucket tilt circuit / AHS
Puritech particle filter
Mower rake accessory kit
Mower rake accessory kit
Trailer coupling
Joystick control
Visual and acoustic back-up warning
Bucket cylinder shut-off
Special installation kit bore gun carriage
Individual blade control
Telescopic support blade
Actua tion valve spool with pushbutton
Timed motor stop
Turn grapple with right rocker button
Auxiliary indicators
Auxiliary lamps
Auxiliary lamps
Travel direction switch in left handle
Horn operation through push buttons
Changeover Fuchs control
Outrigger monitoring system
Reversible fan
Automatic oscillating axle locking device
Travel alarm new
Accessory kit changeover valve, new
Stroke limitation boom and stick
AS1 actuator in left and right handle A 312 - R 317
Changeover bucket tilt circuit A 309 / 311
Kit for reduction of engine speed during work
power reduction
Slider section operation through push buttons
Turn grapple with right rocker button
Individual blade / outrigger control
Flow distributor
emi-automatic central lubrication system
Stick cylinder shut-down
Automatic shut-down mechanism at the gooseneck boom
Puritech particle filter
AS1 accessory kit with 3 buttons - handle
Xenon light
8.45.103
8.45.105
8.45.107
8.45.109
8.45.111
8.45.113
8.45.115
8.45.117
8.45.119
8.45.121
8.45.123
8.45.125
8.45.127
8.45.129
8.45.131
8.45.133
8.45.135
8.45.137
8.45.139
8.45.141
8.45.143
8.45.145
8.45.147
8.45.149
8.45.151
8.45.153
8.45.155
8.45.157
8.45.159
8.45.161
8.45.163
8.45.165
8.45.167
8.45.169
112
113
114
115
116
117
118
119
120
121
8.45.2
8.45.171
8.45.173
8.45.175
8.45.177
8.45.179
8.45.181
8.45.183
8.45.185
8.45.187
8.45.189
A 309 LI - R 317 LI
copyright by
MJF C I F S S
Service Manual
Electric kits
Key to accessory kit diagrams
2 Key to accessory kit diagrams

Item
Description
Step
A3
A123
A125
Radio
Printed circuit board
PCB potentiometers
Left console
Left console
Left console
A126
PCB / autocheck
A127
A133
A1017
A1202

Printed circuit board / frequency conversion
8*, 57
88
26*,51,81,84,
110,115
21*,54,55,68,81,
89,97,103
1*,51,52,59,60,69,70,
71,95,100
85,119
38*,54,62
67
B10
B19
B21
B26
B33
B36
B40
B50
B51-1
B204
B213
B214
B233
B290
B291
B294
B295
B306

Handle sensor / sensor control
Pressure switch / overload warning system
Proximity switch quick-change adapter
Pressure switch pst for AHS section
Pressure switch/travel alarm
Proximity switch / travel pedal
Loudspeaker
Piston detector
Proximity switch / industrial stick
Proximity switch / boom shut-down
Proximity switch / bucket cylinder movement
Proximity switch / adjusting pedal left
Proximity switch / adjusting pedal, right
Pressure switch a/c compressor
Heating thermostat
Particle filter temperature sensor
13*,68
25*, 120
36*,54,118
38*,62
84,110
61,104
28*,51,81
8*,57
75
39*,56,117
79,108
72,77,79,108
90
34*,51,81,100,101
34*,51,81
64b
64b
85,119
HBGV block
Boom cylinder
Quick change adapt. head
Operator's platform / front
Cab
Industrial stick
Stick
At stick
A/c compressor
Operator's platform, base
Particle filter
5*,16*,65
5*,65
121
121
6*,65,74,97
6*,74,97
37*,58
6,*74,97
6*,74,97
6*,74,97
6*,74,97
6*,74,97
6*,74,97
4*,97
4*,97
Attachment
Front cab roof
Uppercarriage, front
Uppercarriage, front
Front cab roof
Cab roof
Cab roof
Weight, right
Weight, left
Weight, left
E1
E2
E2L
E2R
E3
E4
E9
E15
E16
E17
E18
E19
E20
E21
E22

Auxiliary headlight / front of roof
Work light, front left
Work light, front right with plug
Headlight uppercarriage left
Headlight uppercarriage, right
Beacon
Parking light, left
Rear light, right
Tail light, left
Brake light, right
Brake light, left
A 309 LI - R 317 LI
copyright by
MJF C I F S S
Right console
Hydraulic tank
Left console
Right console, rear
Near fuel tank
8.45.3
Electric kits
Service Manual

Item
Description
Step
E23
E24
E30
E50
E150
E150L
E150R
E163
E164
E167
E169
E170
E171
E172
E172
E173
E174

D5W5 auxiliary heater
Power and safety switch cabinet
Roof light
Working light, rear left
Work light, front right with plug
License plate light
Illumination
Beacon for back-up warning
Position light, front right in indicator
Position light, front left in indicator
Outline light, right
Outline light, left
License plate light
Auxiliary indicator, right
Auxiliary indicator, left
F20/F300
F319
F320
A127
E15, E18
Fuse A 127 auxiliary heating
Fuse A 127 auxiliary heating
Fuse A 127 timer, water vent.
Fuse A127 refuelling pump
Fuse A127 terminal 30 to termin. 15
Fuse
Fuse A127, Y29
Fuse A127 S1
Fuse X10
Fuse E16, E17
Fuse E15, E18
Fuse E3
Fuse E4
Fuse S44,E21 - E24
Fuse S7
Fuse sensor control
Fuse E9
Fuse heating / air conditioning terminal 30
Fuse heating /air cond. terminal 15
Fuse X11 / X12
F321
F322
F323
F324
F325
F326
Fuse X12
Fuse T1
Fuse E1
Fuse E2, E150
Fuse S16, S263
Fuse Y24, Y55, Y371, QC adapter
15.0 A
15.0 A
10.0 A
10.0 A
7.5 A
15.0 A
F20
F34
F35
F36
F216
F300
F301
F303
F304
F306
F307
F308
F309
F310
F312
F314
F316
F317
F318
8.45.4
4*,97
4*,97
70
1to3*,70,85,119
5*,65
121
121
74
80
89
97
97
97
97
74,
97
97

Weight, left
Hydraulic tank
Hydraulic tank
Rear cab roof
Uppercarriage, rear
Uppercarriage, rear
Cap, rear
Right console, front
Cap, top right
Revolving deck, right
Revolving deck, left
Uppercarriage, right
Uppercarriage, left
Uppercarriage, rear
Uppercarriage, front right
Uppercarriage, front left
50.0 A
2.0 A
25.0 A
15.0 A
7.5 A
20.0 A
70.0 A
15.0 A
7.5 A
15.0 A
15.0 A
7.5 A
7.5 A
7.5 A
7.5 A
7.5 A
15.0 A
7.5 A
7.5 A
20.0 A
1a*,95
95
70
70
70
52
1*,59,60
110
3*,59,60,95
1*,57,60
16*,60
6*,74,82,97
6*,74,97
6*,74,97
6*,74,97
4*,97
14*,60,111
28*,51,54,62,81
37*,58
30c*,64c
Left console
Left console
Near hydraulic tank
Near hydraulic tank
Near hydraulic tank
Near hydraulic tank
Near hydraulic tank
Right control desk, rear
Near hydraulic tank
Right console, rear
Right console, rear
Right console, rear
Right console, rear
Right console
Cab
3.0 A
15.0 A
30c*,64c
16*,55,61,67,69,75,
83,84,87,91,101,102,
104,116
16*,84,
8*,57
5*,65
5*,65
13*,68,89,95
11*,62,103

Right console, rear
Right console, rear
A 309 LI - R 317 LI
copyright by
MJF C I F S S
Service Manual
Electric kits
Item
Description
Step
F327
F329
F330
F331
Fuse industrial stick

Fuse industrial stick
Fuse kits
Fuse X29
15.0 A
15.0 A
15.0 A
15.0 A
F332
F336
F337
Fuse A127 M1, Y12

Fuse S61
Fuse kits
25.0 A
20.0 A
15.0 A
F338
F339
F340
F342
F344
F345
F346
F347
F348
F349
F351
F364
Fuse capacitor motors

Fuse A 127 Thermoline
Fuse terminal 15 A 127
Fuse terminal 15 A 127
Fuse Xenon roof light
Fuse Xenon headlight, left
Fuse Xenon headlight, front right
Fuse Xenon headlight, rear left
Fuse Xenon headlight, rear right
Fuse (F_H)
Fuse control (F_G)
20.0 A
20.0 A
15.0 A
15.0 A
7.5 A
15.0 A
15.0 A
15.0 A
15.0 A
15.0 A
3A
15.0 A
G1
G2
Alternator
battery
H9
H10
H16
H19
H26
H27
Horn
Warning buzzer overload warning system
Indicator light / overload warning system
Warning buzzer
H33
H90
H158
H159
H167
H168
H176
H183
H196
H249
H293
H293
H298
H299
H311
Back-up alarm travel warning

Indicator light / change of direction of fan
Indicator light / Fuchs control ON
Indicator light / stroke limitation ON
Indicator lamp / oscillating axle automatic
Buzzer / back-up alarm
Indicator light / bypass ON
Indicator light / operator's cab
Warning light/exhaust backpressure
Warning buzzer/exhaust backpressure
Indicator lamp / oscillating axle locked
16*,63
15*,53,111
24*,51,81,84,98
16*,66,72,77,78,
79,84,86,88,90,91,
94,100,105,106,
108,112,117,118
1*,60
6*,74,97
35*,50,55,56,73,
92,93,114
4*,82,97,99
30c*,64c
69
71
76
121
121
121
121
121
85,119
100
1a*, 67
1a*, 70
4*,97,99
21b*,54
36*,54,118
4*,97
38*,62,63
13*,62,63,72,77,
79,108,111
61,104
102
100
83
10*,68,89
10*,68,89
33*,92,103
68,89
34*,51,84,107,110
79,108
53
53
85,119
85,119
103
A 309 LI - R 317 LI
copyright by
MJF C I F S S

Hydraulic tank
Near hydraulic tank
Near hydraulic tank
Near hydraulic tank
Near hydraulic tank
Printed circuit board A127
Diesel engine
Battery box
Right console
Right console
Right control desk
Right control desk
Right control desk
Right console
Hydraulic tank, top
Right control desk
Right control console
Right control desk
Right control desk
Right console
Cap, top left
Right control desk
Right control desk, centre
Right control desk
Right control desk
Right console
8.45.5
Electric kits
Service Manual

Item
H315
H322
H323
H324
H328
H329
H343
H344
K1
K2
K30
K33
K63
K229
K250
K251
K261
K288
K333-1
K333-2
K334
K358
K359
K360
K362
K364
K368
K369
K370
K375
K375
K386
K392
K402
K403
K404
K405
K407-1
K407-2
K414
K436
K437
K438
K439
K455
K464
K467
8.45.6
Description
Step
Warning light shut-down bridged

Warning light/changeover
Indicator light / lateral adjustment
Indicator light / shut-down active
Indicator light / mower rake operation
Warning light / outriggers not retracted
Indicator light / flow distributor
113,118
84,110
78,105,107
82
90
78,86
101
115
Relay / preliminary shut-off Krger electronics

Relay / shut-off Krger electronics
Relay/refuelling pump control circuit
Relay / Thermoline A127
Relay / changeover (K_B)
Relay / parking brake
Relay / solen. valve actuation in case of bypass
Relay / terminal 15 at A127
Relay / boom shut-off
Relay / heating ON A127
Relay / water circuit ON A127
Relay / heater fan ON A127
Relay fan control
Relay / quick change valves A1017
Relay / terminal 15 A127
Relay / terminal 15 A127
Relay / fine regulation, grapple
Relay / changeover hammer / pile driver
Relay / signal flow reduction AHS
Relay for industrial shut-off
Relay / heating
Relay / heating
Relay / capacitor motors
Relay / blower switch
Relay / travel warning mute
Time relay / traction-delayed travel warning 10s.
Step relay (autom. reset)
Relay / signal flow reduction drilling slide
Step relay / mower rake operation
Relay / drop-out delayed
Relay/changeover switch
Relay / oscillating axle release
Step relay / flow distributor operation
83
83
52
69
4*,97
79,95,100
33*,103
13*,68,89,95
13*,68,83,95
3*,59,95
72,77
72,77
72,77
70,87
70,87
70,87
89
38*,62
1*,60
1*,60
15*,66,78,105,111
34*,51,81,84,107,110
84,91,115
14*,60,111
56
64b
30a*,64a
64b
30b*,64b
61,104
61,104
7*,79,108
91
91
78,86
95
106
103
115
Right console
Right console
Right console
in control box / Krger
Near fuel tank
Near hydraulic tank
Near hydraulic tank
A127
Right console, rear
Right console, rear
Right console, rear
Near hydraulic tank
Distribution board
Distribution board
Distribution board
Near hydraulic tank
Near hydraulic tank
Near hydraulic tank
Left console
Right console, rear
Near hydraulic tank
Near hydraulic tank
Right console, rear
Right console, rear
Right console, rear
Right console, rear
Right console, rear
Right console, rear
Right console, rear
Distribution board
Distribution board
Distribution board
Distribution board
Distribution board
Distribution board
Distribution board
Distribution board
A 309 LI - R 317 LI
copyright by
MJF C I F S S
Service Manual
Electric kits
Item
Description
Step
K471
K473
KT20
KT21
Relay inversion signal servo OFF

Relay shutdown attachment
Time relay / fan afterrun
Time relay / direction of rotation switching
M1
M6
M52
M53
M71
M72
M73
M74-1
M74-2
M74-3
Starter
Refuelling pump
Coolant pump
Fuel metering pump
Fan motor / condenser
1a*/60
52
70
87
30a*, 64a
30a*, 64a
30a*, 64a
64b
64b
64b
Engine
Near fuel tank
Near heating
Near heating
Condenser blower
Condenser blower
Condenser blower
P1
P5-1
P5-2
P5-3
P6
Potentiometer / flow reduction A125

Operating hour meter / idle run
Operating hour meter / partial load
Operating hour meter / full load
26*, 51,84
67
67
67
82
Left console, bottom

Near fuel tank
Near fuel tank
Near fuel tank
Right control desk
R8
R70
R71
Thermoline
rotary potentiometer
rotary potentiometer
S1
S4
S5L
S5R
S5M
S6L
Ignition switch
Horn switch
Push button, centre, optional
Push button / magnet unit, grapple operation,
joystick
control, horn activation, oscillating axle release
Push button / magnet unit, grapple operation,
joystick
control, horn activation
Push button / bridging of horn shut-off
Safety switch
Switch / beacon
Battery main switch
Parking brake switch
Switch/overload warning system
S6R
S6R
S7
S8
S9
S16
S18
S19
S22
S22-1
S25
S32
111
118
102
102
69
83
83
Auxiliary headlight switch

Auxiliary roof headlight switch
Switch/refuelling pump ON
Steering column switch
1a*, 57,60
4*,97,99
25*,62,80,96,109,120
25*,62,80,96,109,120
120
55,61,80,88,94,99,
103,104,109,112,113
, 115
55,61,80,88,94,99,
103,104,109,112,
113,115
79
14*,60,111
37*,58
42*,70
13*,62
36*,54,62,118
25*,80,96,109,113,
120
5*,65
5*,65
52
97,99
A 309 LI - R 317 LI
copyright by
MJF C I F S S
Distribution board
Distribution board
Near weight
Near weight
Near fuel tank

At basic boom
At boom
Right control desk
Cab floor plate
Keyboard of right console
Battery compartment
Right control desk
Near fuel tank
Steering column
8.45.7
Electric kits
Service Manual

Item
Description
Step
S35
S44
S45
S46
S47
S47-1
S47-2
S59
S61
S74
S75
S78
S84-1
S92
S93
S124
S160
S204
S205
S206
S207
S213
S216
S232
S241
S247
S249
S263
S269
S270
S272
Switch servo
Hazard warning lights switch
Switch/priority
Switch/control magnet system
Key switch/activate quick change adapter
Key switch/activate quick change adapter
Key/activate quick change adapter
Switch/refuelling pump OFF
Code key for immobiliser
Switch/oscillating axle locking device
Push button / emergency drain
Push button / central lubrication with plug
Rotary switch / air-conditioning, heating
Switch / activation of mower rack operation
Switch / change of direction of rotation
Switch/front left outrigger support
Switch/front right outrigger support
Switch/rear left outrigger support
Switch/rear right outrigger support
Switch/fuel pre-heating
Switch/industrial shut-down
Digital timer/auxiliary heating
Switch AHS 11 / AHS 12
Key switch / Fuchs control
Key switch / boom shut-off with plug
Switch in slip ring
Switch in slip ring
Slip-ring case
S284
S291
S291
S313
S318
S321
S335
S335-1
S335-2
S341
S343
S356
S360
S361
S379
S380
Switch / blower (4 speeds)

Push button / bridging boom shut-off with plug
Push button / bridging boom shut-off with plug
Switch / emergency-stop
Switch a/c system
Switch / activate joystick steering
Switch / changeover blade - outrigger
Switch / front blade
Switch / rear blade
Float switch / refuelling pump
Switch / individual control, back
Switch / changeover valve with plug
Switch / acknowledgement QC buzzer
Switch / hydr. operator's cab elevation
Switch/releasing key kits
Switch / mower rake activation
8.45.8
15*,53,111
4*,97
51,81
41*,55
38*,62
63
63
52
6*,74,82,97
60
33*,103
76
75,116
30a*,64a
30a*,64a
78,86,113
102
35*,50
35*,50
35*,50
35*,50
69
39*,56,117
70
51,81,84,107,110
100
72,79,83,108,118
10*,68,89,98
68,89
68,89
35*,50,73,92,93,
101,114
30b*,64b
72,77,108
79,83
77
30b*,64b
88
35*,73,92,114
73
73
52
92,114
66,78,105,106,107
38*,62
53
94,101,112
78,86
Right console
Right control desk
Right control desk
Right control desk
Right control desk
Right control desk
Near fuel tank
Right console, rear
Right console
Right console
Right console
Right control desk
Right control desk
Right control desk
Right control desk
Right control desk
Right control desk
Right control desk
Right control desk
Right control desk
Right control desk
Right control desk
left control desk
Right control desk
Right control desk
rotary connection
rotary connection
Undercarriage
Right control desk
Right control desk
Right control desk
Right control desk
Right control desk
Right control desk
Right control desk
Near fuel tank
Right control desk
Right console, rear
Right control desk
Right console, rear
Right console
Right control desk
A 309 LI - R 317 LI
copyright by
MJF C I F S S
Service Manual
Electric kits
Item
S382
S384
S398
S405
S406
S419
S423
S424
S439L
S439R
S442
S443L
S443R
S451
S452
S457
S464
Description
Step
Switch / fine regulation OFF
24*,78,79,96,98
Switch / operating hour meter

Reversing switch / heating
Switch / changeover
Switch / kit quantity changeover
Switch / trailer coupling
Key switch / bridging shut-off
Push button / continuous operation AHS
Push button / support pilot control unit
Switch / changeover blade UP/DOWN - ON/
OFF
Push button / telescope blade, left rear
Push button / telescope blade, right rear
Bypass switch stick cylinder
Switch / rotating grapple with rocker button
Rocker button / magnet unit ON/OFF
Switch activation / flow distributor
82
30a*,64a
84,110
81
87
90
91
92
92,114
93

or right control desk
Near fuel tank
Right control desk
Right console
Right console
Right console
Right console
Right console
Right console
93
93
96,113
96
55
115

In handle, right
Right console
Right console
Right console
T1
T4

Voltage transformer / 12V / 20 A
8*,57
71
U4-1
U7
U13
U16

Switching system / magnet unit
Electronic box / auto-scan
75,116
55
60
2*,20to29*,51,55,81,
84,110,111,115
V11
V35
V154
V155
V156-2
V156-3
V156-4
LED on A1017
Diode on A126
Blocking diode / QC warning
blocking diode
blocking diode
blocking diode
Blocking diode A125
V163-1
V163-2
V172-1
V172-2
V166
V168
V169
V173
V177
V178-1
V178-2
V179
Blocking diode / QC signal

Boom shut-off signal
Blocking diode / signal Y428 - Y217
blocking diode
decay diode
blocking diode
Blocking diode BTKP
Blocking diode signal flow distributor
Blocking diode signal Servo-S7
Blocking diode signal actuation Y465
62
55
63
33*,103
33*,103
62
34*,51,81,84,
110,115
72,77
72,77
93
93
81
59,95
84
52
115
111
111
118
A 309 LI - R 317 LI
copyright by
MJF C I F S S
Left console
Near fuel tank
Near fuel tank
Operator's cab, front
Right console, rear
Right console, rear

Right console
Left console
Left console
Right console, rear
Right console
Right console
Right console
Right console
Right console
A 127
A 125
Near fuel tank
Right console
Right console
Right console
Right console
8.45.9
Electric kits
Service Manual

Item
Description
Step
V180
V181
V182
Blocking diode signal actuation H16

Amplifier actuation grapple turning left
Amplifier actuation grapple turning right
X10
X11

Plug connection on distribution board / 2-pin
X12
X15
X15-2
X20
X27
X29

Terminal for kit / 2-pin
X65
X66
X67-1
X67-2
X74
Plug connection T1 / 2-pin

Plug connection T1 / 2-pin
Plug connection loudspeaker / 8-pin
Plug connection S6 / 3-pin
X74-1
X95
X98
X99
X100
X101
X133-1
X143-1
X204
X206
X207
X217
X230
X262
X262-1
X296
X297
X301
Plug connection magnet unit CS / 1-pin

Plug connection to S232, 4-pin
Plug connection to M53, 2-pin
Plug connection to M52 / 2-pin
Plug connection to B51-1 / 2-pin
Plug connection to U4-1 / 4-pin
Plug connection to buzzer / 2-pin
Plug connection to B36, 2-pin
Plug connection on A1100, 3-pin
Plug connection to quick change adapter, 8-pin
Plug connection on bearing block, 8-pin
Plug connection left handle / 1-pin
Plug connection left handle / 1-pin
Plug connection on slip ring, 12-pin
X304
X312
X313
X314
X324-1
X324-2
Plug con. to S204, S205, S206, S207, 6-pin

Plug connection to electr. buzzer / 2-pin
8.45.10
118
120
120
Right console
Right console
Right console
16*,60
16*,55,61,67,69,75,
83,87,91,101,104,
116
16*,84
88
62,80,96,109,113
1b*,85,119
16*,63
16*,66,72,77,78,79,
84,86,88,90,91,94,
100,105,106,108,
110, 112,117,118
8*,57
8*,57
8*,57
8*,57
55,61,79,80,96,99,
103,108,109,112,
113,115
55
70
70
70
70
70
75
75,116
61,104
61,104
61,104
55
10*,13*,98
38*,63
38*,62,63
80,109
80,109
35*,50,73,87,92,93,
101,114
35*,50,73,92,93,114
68,89
68,89
68,89
61,68,89,104
61,104
Right console
Right console
Right console
Right joystick
Left console
Right console, rear
Right console, rear
Left console
Left console
Cab
Cab
Right console
Right console
Left console
Auxiliary heating
Auxiliary heating
Auxiliary heating
Auxiliary heating
Near fuel tank
Left console
Right console
Right console
Operator's cab, front
Left console
Attachment
Bearing block
Rotary connection
Right console, rear
Rotary connection
Rotary connection
Revolving deck
Revolving deck
Revolving deck
A 309 LI - R 317 LI
copyright by
MJF C I F S S
Service Manual
Electric kits
Item
X327
X342
X358
X358-1
Description
Step
X550
X689
X738
X771
X798
X821
X822
X829
X837

Plug connection to travel selection switch, 3-pin
Plug connection under operator's platform / 2pin
Plug connection to Y354 and Y355 / 2-pin
Plug connection to R70, 4-pin
Plug connection to revolving deck CS / 2-pin
Plug connection to revolving deck CS / 2-pin
Plug connection power supply A1017 / 2-pin
Plug connection A1017 / 4-pin
Plug connection to Y307 / 3-pin
Plug connection to S321 / 3-pin
Plug connection to A123 / 5-pin
Plug connection to S47 / 5-pin
Plug connection / warning system blocking diode
Plug connection
Plug connection blocking diodes / 6-pin
Plug connection Thermoline
X839
Plug connection / screw terminal on A125 / 3-pin
X358-2
X370
X374
X378
X379
X381
X358-1
X382
X382-1
X382-2
X404
X407
X408
X410
X411
X412
X412
X413
X413
X414
X446
X447
X842-1
X842-2
X842-3
X856

Plug connection BST wire harness / 40-pin
X857
Plug connection: BST excavator control / 24-pin
X859
X860

39*,56,117
68,89
66
78,105,106
78,105,106
55
83
83
83
83
83
83
83
83
5*,65
36*,54,94,112,118
94,112
38*,62,94
38*,62
38*,62
88
38*,62,63,
88
88
63
63
4*,97,99
70,83
69
35*,50,73,93, 101
62
53
53
53
26*,51,81,84,
110,115
34*,51,81,84,
110,115
30c*,64c
64c,70
103
2*,20to29*,55,84,110
,115
21to29*,51,81,84,
110,115
30*,64a/b
30a*,64a
A 309 LI - R 317 LI
copyright by
MJF C I F S S
Industrial stick
Right console
Revolving deck
Operator's platform
Fuel tank
Near attachment
Right control console, rear
At basic boom
Near attachment
At basic boom
Near attachment
Near attachment
Attachment
Right console, rear
Right console, rear
Right console, rear
Right console, rear
Right console, rear
Right console, rear
Right console, rear
Right console
Right console
Right console
Right console
Near fuel tank
Left console
Right console, rear
Right console, rear
Right console
Right console
Right console
Right console
Right console
8.45.11
Electric kits
Service Manual

Item
X861
X862
X863
X864
X891-1
X891-2
X902
X909
X914
X915
X924-2
X950
Description
Step

Plug connection at valve Y360 / 2-pin
Plug connection to stick, 2-pin
Plug connection to H300 warning light / 3-pin
Plug connection to wire harness P5 / 6-pin
Plug connection on A1202 / 16-pin
Plug connection autocheck / 21-pin
30a*,64a
30a*,64a
30*,64a/b
64c
63
63
74
100
67
67
34*,51,81
4*,10*,13*,21a*,54,6
2,68,89,97,103
4*,10*,13*,21b*,51,5
4, 55,62,68,81,89,98
10 to
13*,51,64c,68,80,84,
89,95,96,103,107,10
9,110, 111,113, 120
1until 6*,54,74,82,97,
110,118
110
1*to4*,56,60,62,63,
64c,67,74,92,97,114
2*,20until24*,55,56,8
1, 98, 111
8*,11*,50,51,62,73,
80,81,84,92,93,96,
107,109,110,113,
114, 115,120
18*,28*,50,
51,54,55,56,62,73,81
,84,92,93,107,
110,114, 118
10*;24*,30*,64c,68,8
9,92,98,103,111, 114
4*,6*,9*,51,
74,81,97,99
2*,6*,13*,62,74,82,97
,103
4*,10*,13*,51,55,68,
81,89,95,97,98,111
6*,8*,9*,
50,51,54,55,56,60 to
63, 66 to 69, 72 to
75,77, 78,79, 81 to
84, 86,87,88, 90 to
95,97,98,100,
101,104,105,106,
108,110,111,112,
114, 116,117,118

Attachment
Attachment
Lighting, front right
Left console
Near fuel tank
Near fuel tank
Auxiliary pedal, right
Right console
X951
Plug connection autocheck / 21-pin
X952
X953
X954
X955

X956
X957
X958
X959
X960
X961
X962
X963
8.45.12
Right console
Right console, rear
Right console, rear

Right console, rear
Right console, rear
Right console, rear
Right console, rear
Right console, rear
Right console, rear

Right console, rear
Right console, rear
Right console, rear
Right console, rear
A 309 LI - R 317 LI
copyright by
MJF C I F S S
Service Manual
Electric kits
Item
Description
Step
X964
Right console, rear
X965
X966
Plug connection BST- CS A125 / 21-pin

Plug connection A125 wire harness / 21-pin
X967
1*,3*,4*,60,64c,97,99
103,111
26*,34*,84,110, 115
8*,14*,51,57,60,62,
80,81,84,96,98,109,
111,113,115,120
5*,6*,57,58,
65,74,82,97
34*,81,84,110,115
34*,81,84,110,115
81
8*,57
103
34*,81,84,110, 115
84
69
69
78,105,106
70
72, 77,79,108
72, 77,79,108
72, 77,79,108
79,108
79,108
79,108
71
89
76
76
76
76
116
59,95
59,95
83
83
83
84,110
84,110
85,119
85,119
24*,25*,55,78,80,
98,107,109,120
80,98,109
10*,55,61,80,98,98,
103,104,112,115
55,98
78,86
78,86
X968-1
X968-2
X968-3
X973
X974-2
X974-4
X974-5
X979
X982
X983
X987
X988-1
X988-2
X988-3
X988-4
X988-5
X988-6
X989
X993
X998
X999-1
X999-2
X999-3
X998
X1006
X1011
X1017
X1018
X1019
X1028
X1029
X1040
X1041
X1046
Plug connection A125 CS / 1-pin

Power socket, 12V
Plug connection adapter CS / 1-pin
Plug connection switch CS / 2-pin
Plug connection auxiliary heating CS / 8-pin
Socket 12V / 20 A / 12-pin
Plug connection beacon / 2-pin
Plug connection, A 127 /1-pin
Plug terminal / 1-pin
Plug connection decay diode / 3-pin
Plug connection to Y237/Y238 / 4-pin
Plug connection to S405 and H322 / 4-pin
Plug connection solenoid valves / 4-pin
Plug connection to display unit / 3-pin
Plug connection for temperature sensor / 2-pin
X1046-1
X1048
Plug handle extension / 6-pin

X1046-1
X1050
X1051
Plug to handle switch / 3-pin

Plug connection adapter switch CS / 3-pin
A 309 LI - R 317 LI
copyright by
MJF C I F S S
Right console, rear

Right console, rear
Right console, rear
Left console
A125
Revolving deck
Revolving deck
Right console, rear
Near operator's cab
Right console
Right console
Right console
Right console
Right console
Right console
Left console
Uppercarriage, rear
Left console
Left console
Left console
Near hydraulic tank
Near A127
Near A127
Near hydraulic tank
Near hydraulic tank
Near hydraulic tank
Electric box E50
Electric box E50
Left console
Right handle
Right handle
Right handle
Right handle
Right handle
8.45.13
Electric kits
Service Manual

Item
Description
X1052
X1053
X1060
X1061
X1062
X1070-1
X1070-2
X1104
X1106
X1117
X1132
X1138
X1179
X1186
X1190
X1198
X1210
X1213
X1215
X1218
X1224
X1226
X1234
X1235
X1240
X1241
Plug connection mower rake drive CS / 4-pin

Plug connection slip ring CS / 1-pin
Plug connection switch / 3-pin
Plug connection solenoid valve / 2-pin
Plug connection power supply / 4-pin
Plug connection 4-wheel steering / 6-pin
Plug connection extension bridging / 3-pin
Plug connection A127 - refuelling pump / 2-pin
Plug connection to display unit / 3-pin
Plug connection float switch / 2-pin
Plug connection for temperature sensor / 2-pin
Plug connection delta p / 3-pin
Plug connection decay diode / 2-pin
Plug connection warning light / 2-pin
Plug connection warning light / 2-pin
Plug connection pressure switch / 3-pin
Plug connection switch CS flow distributor / 2pin
Plug connection CS solenoid valve / 2-pin
Plug connection switch CS flow distributor / 1pin
Plug connection CS diode / 2-pin
Plug connection switch / 3-pin
X1242
X1243
X1244
X1245
X1246
X1251
X1253
X1254
X1255
X1260
X1261
X1262
X1263
X1265
Y3
Y6
Y12
Y20
Y22
8.45.14
Step

Coupling/air-conditioning system
78,86
87
90
90
90
91
91
92,93,114
111
111
79,108
52
96,113
74,97
52
97
78
100
101
101
84
106
102
102
115
115
Right handle
Distribution board
Near upper carriage Y409
Bearing block
Near hydraulic tank
Near hydraulic tank
Right control desk
Right control desk
Right control desk
Left control desk
Near hydraulic tank
Engine compar., left rear
Near fuel tank
Right control desk
Distribution board
Solenoid valves
Distribution board
Distribution board
Right control desk
Right control desk
115
115
Right control desk

Right control desk
115
106
106
116
117
117
117
118
118
118
118
120
Right control desk

Solenoid valves
Solenoid valves
Right control desk
Right control desk
Right control desk
Right control desk
Right control desk
Right control desk
Right control desk
Right control desk
Right control desk
111
13*,60
1a*,60
30c*,64c
25*,80,96,109,
113,120
Control oil unit

HBGV block
Diesel engine regulator
Engine compartment
Control valve block
A 309 LI - R 317 LI
copyright by
MJF C I F S S
Service Manual
Electric kits
Item
Y23
Y28-1
Y28-2
Y29
Y56
Y62
Y63
Y204
Y212
Y212-1
Y215
Y216
Y217
Y218
Y236-1
Y236-2
Y236-3
Y236-4
Y237
Y238
Y238
Y268
Y295
Y299
Y307
Y330
Y332
Y341
Y354
Y355
Y356
Y357
Y357
Y360
Y363
Y365
Y366
Y371
Y385-1
Y385-2
Y405
Y406
Y406
Description
Step
25*,80,96,109,
113,120
38*,62
38*,62
3*,59,60,95
35*,50,73,92,114
10*,68,89
10*,68,89
76
39*,56,117
118
35*,50
35*,50
35*,50,73,92,93,114
35*,50,73,92,93,114
100
100
100
100
72,77,79,83,108,118
72,79,108
83
34*,51,84,107,110
55,115
34*,51,84,107,110
88
111
66,78,105,106
53
83
Control valve block

Solenoid valve / changeover outrigger - blade
Solenoid valve / emergency discharge
Solenoid valve/industrial shut-down
Solenoid valve blocking stick lowering
Solenoid valve / front left outrigger support
Solenoid valve / front right outrigger support
Solenoid valve / rear left outrigger support
Solenoid valve / rear right outrigger support
Solenoid valve/changeover
Solenoid valve / boom shut-off
Solenoid valve/stroke limitation
Solenoid valve/stick shut-down
Solenoid valve / grapple hammer
Solenoid valve / magnet unit
Solenoid valve / changeover pressure limitation
Proportional solenoid valve/steering
Solenoid valve / pump regulation
Solenoid valve / changeover valve
Solenoid valve / lift frame
Solenoid valve / pressure limitation pst / boom
cylinder extension bridged
Solenoid valve / pressure limitation pst / boom
cylinder extension
Solenoid valve / fan stop
Solenoid valve/priority circuit
Solenoid valve / change of direction of rotation
Solenoid valve / industrial quick change adapter
Solenoid valve/retracting
Solenoid valve / cylinder retraction
Solenoid valve / cylinder extension / hammer
Solenoid valve/changeover bucket cylinder AHS
Solenoid valve/changeover bucket cylinder AHS
Solenoid valve / mower rack forward
Solenoid valve / mower rack, reverse
Solenoid valve / trailer coupling OPEN/
CLOSED
A 309 LI - R 317 LI
copyright by
MJF C I F S S
Engine regulating rod
Undercarriage
Hydraulic tank
Hydraulic tank
Lift frame base
Industrial stick
Industrial stick
Undercarriage
Undercarriage
Undercarriage
Undercarriage
Near hydraulic tank
Near hydraulic tank
Near hydraulic tank
Near hydraulic tank
Near hydraulic tank
Control oil unit
Attachment
Behind cab
Near hydraulic tank
83
Near hydraulic tank
102
51
102
63
101
94,101,112
94,101,112
33*,103
84,110
Near weight
Near hydraulic tank
Near weight
Industrial stick
Behind cab
Hydraulic tank
Hydraulic tank
Control oil unit
Behind cab
84,110
Behind cab
78,86
86
87
Control valve block

Control valve block
Uppercarriage, rear
8.45.15
Electric kits
Service Manual

Item
Description
Y409
Y410
Y428
Y443
Y444
Y451
Y452
Y453
Y454
Y456
Y465
Item
Designation
be
beige
bl
blue
br
brown
ge
yellow
gn
green
gr
grey
rt
red
sw
black
vi
purple
ws
white
Tab. 1
Step
Solenoid valve / tilt cylinder shut-off

Solenoid valve / continuous operation AHS
Solenoid valve / changeover UP/DOWN - telescope OUT/IN
Pipe fracture safety stop valve / regulating cylinder extending
Pipe fracture safety stop valve / regulating cylinder retracting
Solenoid valve AHS actuation
Sol. valve control press. changeover / piston
side
Sol. valve control press. changeover / piston
side
Solenoid valve changeover control lines
Block solenoid valve / boom lowering
Designation (examples)
BTKP
Refuelling pump
GND
Ground
KLxx
Terminal number
KL15
Terminal 15
KL19
Terminal 19
KL30
Terminal 30
KL50
Terminal 50
M5/M6/M8
M5/M6/M8 earth conductor screw
8.45.16
Near hydraulic tank

Near hydraulic tank
Undercarriage
106
106
84,110
115
106

106
106
118

Cable colours
Item
Tab. 2
90
91
92
Terminal designation
A 309 LI - R 317 LI
copyright by
MJF C I F S S
Service Manual
Electric kits
A 309 LI - R 317 LI
copyright by
MJF C I F S S
8.45.17
Electric kits
Service Manual

Step 50
Item
Designation
F337
Fuse
S204
S205
S206
S207
Switch / front left outrigger support

Switch / front right outrigger support
Switch / rear left outrigger support
Switch / rear right outrigger support
S272**
Slip-ring case
S335
Blade support switch
X301
X304
X771
X957**
X958**
X963**

Y 56
Y215
Y216
Y217
Y218
Solenoid valve blade support

Solenoid valve / front left outrigger support
Solenoid valve / front right outrigger support
15 A
Fuse box in control console,

front right
** in basic machine
8.45.18
A 309 LI - R 317 LI
copyright by
MJF C I F S S
Service Manual
Electric kits
50 A 312 Litronic / 314 Litronic / A 316 Litronic

UMSCHALTUNG SCHILD / PRATZE
EINZELSTEUERUNG 4PKT
EINZELSTEUERUNG 2PKT
DOZER BLADE / OUTRIGGER CHANGEOVER
4PT. OUTRIGGER INDIVIDUAL

CONTROL
2PT. OUTRIGGER INDIVIDUAL

CONTROL
COMMUTATION DE LAME DE NIVELAGE / BRAS STABILISATEUR
COMMANDE UNIQUE 4POINTS
COMMANDE UNIQUE 2POINTS
A 309 LI - R 317 LI
copyright by
MJF C I F S S
8.45.19
Electric kits
Service Manual

Step 51
Location /
arrangement
Item
Designation
A125**
A126**
Compact potentiometer PCB

Autocheck PCB
B40**
B290**
B291**
Proximity switch / travel pedal right

Proximity switch / adjusting pedal right
F316**
F330**
Fuse / indicator instruments / overload warning system /

sensor control
ASH/AS1 fuse / fine adjustment
H196
K375
P1**
Flow reduction potentiometer
S45
S241
Prio switch (not installed)

Switch AHS 12
U16
Electronic box BST
V156-4
X837**
X839**
X857**
X924-2**
X951**
X952**
X956**
X957**
X958**
X960**
X962**
X963**
X966**
X974-4
Blocking diode
Plug connection, 8-pin / / A125 left console
Screw terminal, 3-pin / / kit PCB
Plug connection, 24-pin / / BST
Plug connection, 3-pin / / accessory kit pedal
Plug connection, 21-pin / / autocheck
Plug connection, 21-pin / / revolving deck CS distribution board
Plug connection, 21-pin / / CS BST distribution board
Plug connection, 21-pin / / console switch distribution board
Plug connection, 21-pin / / platform CS distribution board
Plug connection, 21-pin / / console ignition key distribution board
Plug connection, 21-pin / / CS AI 25 distribution board
Plug connection, 2-pin / / / CS AI 25 diode plug
Y299
Solenoid valve pressure control
15A
15 A
** in basic machine
8.45.20
A 309 LI - R 317 LI
copyright by
MJF C I F S S
Service Manual
Electric kits
51
A 312 Litronic / 314 Litronic / A 316 Litronic

AHS11
AHS11
AHS11
A 309 LI - R 317 LI
copyright by
MJF C I F S S
8.45.21
Electric kits
Service Manual

Step 51
Location /
arrangement
Item
Designation
A125**
A126**
Compact potentiometer board

Autocheck PCB
B40**
B290**
B291**
Proximity switch right travel pedal

F316**
F330**
Fuse / indicator instruments / overload warning system / sensor control

ASH/ AS1 fuse / fine adjustment
H196
K375
P1**
S45
S241

Switch AHS 12
U16
Electronic box BST
V156-4
X837**
X839**
X857**
X924-2**
X951**
X952**
X956**
X957**
X958**
X960**
X962**
X963**
X966**
X974-4
Blocking diode
Plug connection, 8-pin / A125 left console
Screw terminal, 3-pin / kit PCB
Plug connection, 24-pin / BST
Plug connection, 3-pin / accessory kit pedal
Plug connection, 21-pin / autocheck
Plug connection, 21-pin / revolving deck CS distribution board
Plug connection, 21-pin / CS BST distribution board
Plug connection, 21-pin / console switch distribution board
Plug connection, 21-pin / platform CS distribution board
Plug connection, 21-pin / console ignition key distribution board
Plug connection, 21-pin / CS AI 25 distribution board
Plug connection, 2-pin / CS AI 25 diode plug
Y299
Solenoid valve pressure control
15.0 A
15.0 A
** in basic machine
8.45.22
A 309 LI - R 317 LI
copyright by
MJF C I F S S
Service Manual
Electric kits
51

AHS12
AHS12
AHS12
A 309 LI - R 317 LI
copyright by
MJF C I F S S
8.45.23
Electric kits
Service Manual

Step 51
Location /
arrangement
Item
Designation
A125**
A126**
Compact potentiometer board

Autocheck PCB
B40**
B290**
B291**
Proximity switch / travel pedal right

F316**
F330**
Fuse / indicator instruments / overload warning system

/ sensor control
ASH/AS1 fuse / fine adjustment
H196
K375
P1**
S45
S241

Switch AHS 12
U16
Electronic box BST
V156-4
Blocking diode
X837**
X839**
X857**
X924-2**
X951**
X952**
X956**
X957**
X958**
X960**
X962**
X963**
X966**
X974-4
Plug connection, 8-pin / A125 left console

Screw terminal, 3-pin / kit PCB
Plug connection, 3-pin / accessory kit pedal
Plug connection, 21-pin / platform CS distribution board
Plug connection, 21-pin / console ignition key distribution board
Plug connection, 21-pin / CS A125 distribution board
Plug connection, 2-pin / CS A125 diode plug
Y268
Y299
Y357
Solenoid valve / grapple / hammer

Solenoid valve / pressure control
Solenoid valve / priority circuit
15.0 A
15.0 A
** in basic machine
8.45.24
A 309 LI - R 317 LI
copyright by
MJF C I F S S
Service Manual
Electric kits
51

AHS12 & PRIO
AHS12 & PRIO
AHS12 & PRIO
A 309 LI - R 317 LI
copyright by
MJF C I F S S
8.45.25
Electric kits
Service Manual

Step 52/1
Item
Designation
A 127**
F216
Fuse / refuelling pump
K30
Relay / refuelling pump
M6
Refuelling pump
S25
S59
S341
Switch / refuelling pump ON

Switch / refuelling pump OFF
20.0 A
** in basic diagram
8.45.26
A 309 LI - R 317 LI
copyright by
MJF C I F S S
Service Manual
Electric kits
52/1
A 309 Litronic - R 317 Litronic

BETANKUNGSPUMPE
REFUELLING PUMP
PUMPE DE REMPL.
A 309 LI - R 317 LI
copyright by
MJF C I F S S
8.45.27
Electric kits
Service Manual

Step 52/2
Item
Designation
A 127**
F216
Fuse / refuelling pump
K30
Relay / refuelling pump
M6
Refuelling pump
S25
S59
S341
Switch / refuelling pump ON

Switch / refuelling pump OFF
V173
Blocking diode BTKP
X7
X1138
X1190
Plug connection on A127 (F_L)

Plug connection, 2-pin / A127 refuelling pump
Plug connection, 2-pin / float switch
15.0 A
** in basic diagram
8.45.28
A 309 LI - R 317 LI
copyright by
MJF C I F S S
Service Manual
Electric kits
52/2
A 309 Litronic - R 317 Litronic

BETANKUNGSPUMPE
REFUELLING PUMP
PUMPE DE REMPL.
A 309 LI - R 317 LI
copyright by
MJF C I F S S
8.45.29
Electric kits
Service Manual

Step 53
Location /
arrangement
Item
Designation
F329**
Servo switch fuse
H293
S35**
S361
Switch / front left outrigger support

Switch / hydraulic cab elevation
X821**
X822**
X829**
Plug connection, 21-pin / console (switch) distribution board

Y341
Solenoid valve / cab lift frame UP and DOWN
15.0 A
** in basic diagram
8.45.30
A 309 LI - R 317 LI
copyright by
MJF C I F S S
Service Manual
Electric kits
53
A 316 Litronic (IND)

HYDRAULISCHE FAHRERHAUSERHHUNG
HYDRAULIC CAB ELEVATION
HYDR.P.CONTRE POIDS DEMONTABLE
A 309 LI - R 317 LI
copyright by
MJF C I F S S
8.45.31
Electric kits
Service Manual

Step 54
Location /
arrangement
Item
Designation
A 126**
Autocheck PCB
B21
Pressure switch / overload warning system
H10
H16
Buzzer / overload warning system

Indicator light / overload warning system
S18
S20**
Switch / overload warning system

X407**
Plug connection, 2-pin / revolving deck CS overload warning system

Plug connection, 21-pin / A 126
Plug connection, 21-pin / A 126
X950**
X951**
X953**
X958**
** in basic diagram
8.45.32
A 309 LI - R 317 LI
copyright by
MJF C I F S S
Service Manual
Electric kits
54
A 312 Litronic / A 314 Litronic / A 316 Litronic / A 316 (IND)

BERLASTWARNEINRICHTUNG
OVERLOAD WARNING SYSTEM
AVERITISSEUR DE SUCHARGE
A 309 LI - R 317 LI
copyright by
MJF C I F S S
8.45.33
Electric kits
Service Manual

Step 55/1
Item
Designation
A 126**
Autocheck PCB
F337
Fuse
S6L
S46
Button / magnet system

Switch / magnet system
U7
U16**
Switching system / magnet system

Electronic box BST
X11**
X963**
Plug connection, 2-pin / magnet system CS distribution

board
Plug connection, 2-pin / magnet system CS, handle / button
Plug connection, 2-pin / magnet system CS
Plug connection, 2-pin / magnet system CS, solenoid valve CS
Plug connection, 40-pin / CS BST
Plug connection, 21-pin / console switch distribution
board
Plug connection, 21-pin / console indicator distribution
board
Plug connection, 21-pin / fuse distribution board
Y295**
X74
X74-1
X217
X370
X856**
X950**
X951**
X956**
X958**
X962**
15.0 A
Fuse box in control console, front right
** in basic diagram
8.45.34
A 309 LI - R 317 LI
copyright by
MJF C I F S S
Service Manual
Electric kits
55/1

STEUERUNG MAGNETANLAGE
MAGNET SYSTEM CONTROL
CONTROLE DE MONTAGE PLATEAU MAGNETIQUE
A 309 LI - R 317 LI
copyright by
MJF C I F S S
8.45.35
Electric kits
Service Manual

Step 55/2
Item
Designation
A 126**
Autocheck PCB
F337
Fuse
S6L
S46

U7
U16**
Switching system / magnet system

Electronic box BST
X11**
X963**
Plug connection, 2-pin / magnet system CS distribution

board
board
board
Y295**
X74
X74-1
X217
X370
X856**
X950**
X951**
X956**
X958**
X962**
15.0 A
** in basic diagram
8.45.36
A 309 LI - R 317 LI
copyright by
MJF C I F S S
Service Manual
Electric kits
55/2

A 309 LI - R 317 LI
copyright by
MJF C I F S S
8.45.37
Electric kits
Service Manual

Step 55/3
Item
Designation
A 126**
Autocheck PCB
F337**
Fuse
S6L
S46

U7
U16**
Switching system / magnet unit

Electronic box BST
X74
X963**

board
board
Y295
X74-1
X217
X370
X856**
X950**
X951**
X956**
X958**
X962**
15.0 A
** in basic diagram
8.45.38
A 309 LI - R 317 LI
copyright by
MJF C I F S S
Service Manual
Electric kits
55/3

A 309 LI - R 317 LI
copyright by
MJF C I F S S
8.45.39
Electric kits
Service Manual

Step 56
Item
Designation
B204
Proximity switch
F337
Fuse
K392
Relay for industrial shut-shut-down
S216
Switch/industrial shut-down
X955**
X958**
X963**

Y212
15.0 A
** in basic diagram
8.45.40
A 309 LI - R 317 LI
copyright by
MJF C I F S S
Service Manual
Electric kits
56

INDUSTRIEABSCHALTUNG
IND. SHUTDOWN
INTERRUPTION IND.ELEVABLE
A 309 LI - R 317 LI
copyright by
MJF C I F S S
8.45.41
Electric kits
Service Manual

Step 57
Item
Designation
A3**
Radio
B50**
Loudspeaker
F304**
F322**
Fuse S1
Fuse T1
S1**
Start and pre-heating switch
T1**
Voltage transformer
X65**
X66**
X67-1**
X67-2**
X963**
X966**
X967**
X973**
Plug connection, 2-pin / T1 / 24 V

Plug connection, 2-pin / T1 / 12 V
Plug connection, 8-pin / A3 power supply
Plug connection, 8-pin, A3 loudspeaker
Plug connection, 21-pin / distribution board
Power socket
15.0 A
15.0 A
** in basic diagram
8.45.42
A 309 LI - R 317 LI
copyright by
MJF C I F S S
Service Manual
Electric kits
57

RADIO
RADIO
RADIO
A 309 LI - R 317 LI
copyright by
MJF C I F S S
8.45.43
Electric kits
Service Manual

Step 58
Item
Designation
E9
Beacon
Location /
arrangement
F317**
Fuse
Working light / beacon
7.5 A
S8
Switch / beacon
X967**
X993
Plug connection, 21-pin / console indicator distribution board

Plug connection, 2-pin / console indicator distribution board
** in basic diagram
8.45.44
A 309 LI - R 317 LI
copyright by
MJF C I F S S
Service Manual
Electric kits
58

RUNDUMKENNLEUCHTE
BEACON
GIROPHARE
A 309 LI - R 317 LI
copyright by
MJF C I F S S
8.45.45
Electric kits
Service Manual

Step 59
Item
Designation
A 127**
F300**
F303**
Fuse A127 / terminal 30 to terminal 15

Fuse A127, Y29
K288**
Relay 15 A127
S313
Switch / engine shut-down
V168
Decay diode
X1006
X1011
Plug terminal, 1-pin

Plug connection decay diode, 3-pin
Y29**
Solenoid valve / engine stop
50.0 A
7.5 A
** see basic diagram of electrical system
8.45.46
A 309 LI - R 317 LI
copyright by
MJF C I F S S
Service Manual
Electric kits
59

MOTORSTOP
ENGINE STOP
ARRET MOTEUR
A 309 LI - R 317 LI
copyright by
MJF C I F S S
8.45.47
Electric kits
Service Manual

Step 60
Item
Designation
A127**
F300**
F303**
F304**
F306**
F314**
F332**
Fuse terminal 30 to terminal 15

Fuse Y29 B3
External fuse S1
Fuse X10
Fuse S7
Fuse M1, Y12
K368**
K369**
K386**
Relay of terminal 50
Relay of terminal 15
M1**
Starter
S1**
S7**
S74
Start switch / right console

Safety switch / left console
Code key for immobiliser
U13
Electronic box / auto-scan
X10**
X955**
X963**
X964**
X966**

Plug connection, 15-pin / revolving deck CS distribution
board
Plug connection, 21-pin, fuse distribution board
Plug connection, 21-pin, fuse distribution board
Plug connection, 21-pin, A 125 distribution board
Y6**
Y12**
Y29**

Solenoid valve / cold-start aid
Solenoid valve / engine stop
50.0 A
7.5 A
15.0 A
15.0 A
15.0 A
25.0 A
** in basic diagram
8.45.48
A 309 LI - R 317 LI
copyright by
MJF C I F S S
Service Manual
Electric kits
60

WEGFAHRSPERRE
IMMOBILISER
ANTIVOL DE DEMARRAGE
A 309 LI - R 317 LI
copyright by
MJF C I F S S
8.45.49
Electric kits
Service Manual

Step 61
Item
Designation
B36
Pressure switch
F320**
Fuse X11 / X12
H33
Back-up alarm
K407-1
K407-2

Time relay, delayed travel warning 10 sec.
S6L
S6R
Push button / grapple pilot control right

Push button / grapple pilot control right
X11**
X74
X204
X206
X207
X324-1
X324-2
X963**

Plug connection, 3-pin / cable with button
Plug connection, 2-pin / to buzzer H33
Plug connection, 2-pin / to pressure switch B36
15.0 A
** in basic diagram
8.45.50
A 309 LI - R 317 LI
copyright by
MJF C I F S S
Service Manual
Electric kits
61

FAHRWARNEINRICHTUNG
TRAVEL ALARM
AVERTISSEUR DE MARCHE
A 309 LI - R 317 LI
copyright by
MJF C I F S S
8.45.51
Electric kits
Service Manual

Step 62
Item
Designation
A1017
B26
Proximity switch / bucket quick-change adapter
F316**
F326**
Fuse sensor / sensor control / console

Fuse creeper gear / 1st gear / oscillating axle /S
H26
H27**

Buzzer
K364
Relay / quick-change adapter valves
S18
S47
S360

Key switch
Buzzer acknowledgement
V156-3
Quick-change adapter blocking diode
X15-2**
X262
X262-1
X262-3
X262-4
X262-5
X262-6
X410
X411
X412
X413
X798
X955**
X957**
X958**
X961**
X963**
X966**
Plug connection, 3-pin / to S5

Plug connection, 8-pin / to quick-change adapter
Plug connection, 8-pin / on bearing block
Plug connection, 8-pin / on stick
Plug connection, 2-pin / on valve Y28-1
Plug connection, 2-pin / on valve Y28-1
Plug connection, 2-pin / on B26
Plug connection A 1017 power supply
Plug connection key switch
Plug connection A 1017 - AS1 button
Plug connection, 4-pin, quick-change warning
Plug connection, 3 pin / blocking diode
Y28-1
Y28-2
Solenoid valve / quick-change adapter

** in basic diagram
8.45.52
A 309 LI - R 317 LI
copyright by
MJF C I F S S
Service Manual
Electric kits
62
A 312 Litronic / A 314 Litronic / A 316 Litronic

SCHNELLWECHSLER
QUICK-CHANGE ADAPTER
ADAPTEUR A CHANGEMENT RAPIDE
A 309 LI - R 317 LI
copyright by
MJF C I F S S
8.45.53
Electric kits
Service Manual

Step 63
Item
Designation
F327**
Fuse / industrial stick quick-change adapter
H26
H27**
Quick-change indicator light

Quick-change warning buzzer
S47-1
S47-2
Key switch / activate quick-change adapter

Key switch / activate quick-change adapter
V154
Blocking diode / quick-change warning system
X262
X262-1
X413
X446
X447
X8911
X891-2
X955
X963**

Plug connection, 8-pin / bearing block
Plug connection, 5-pin / S47-1/2
Plug connection to blocking diode / quick-change warning system
Plug connection, 2-pin / on valve Y360
Plug connection, 2-pin / on stick
Y360
15.0 A
** in basic diagram
8.45.54
A 309 LI - R 317 LI
copyright by
MJF C I F S S
Service Manual
Electric kits
63

INDUSTRIESCHNELLWECHSLER
IND. QUICK-CHANGE ADAPTER
ADAPT. RAPIDE INDUSTRIE
A 309 LI - R 317 LI
copyright by
MJF C I F S S
8.45.55
Electric kits
Service Manual

Step 64
Item
Designation
B294
B295
Pressure switch / a/c compressor

Heating thermostat
F318**
F319**
F339**
Fuse heating/air-conditioning system Kl30

Fuse heating/air-conditioning system terminal
15
K402
K403**
K404
K405
Relay / heating
Relay / heating
Relay / capacitor motors
Relay / blower switch
M65**
M71**
M72**
M73**
M74-1
M74-2
M74-3
Blower motor
Servo motor / eversing - air distribution
S92**
S93**
S284**
S318
S398**

Potentiometer / heating / air conditioning system
Switch a/c system
Reversing switch / heating
X842-1**
X842-2**
X859**
X860**
X861**
X862**
X863**
X864
X952**
X955**
X959**
X964**

Y20
Solenoid valve / a/c coupling
20.0 A
3.0 A
20.0 A
** in basic diagram
8.45.56
A 309 LI - R 317 LI
copyright by
MJF C I F S S
Service Manual
Electric kits
64a Air-conditioning system
A 309 LI - R 317 LI
copyright by
MJF C I F S S
8.45.57
Electric kits
Service Manual
64b Air-conditioning system
8.45.58
A 309 LI - R 317 LI
copyright by
MJF C I F S S
Service Manual
Electric kits
64c Air-conditioning system
A 309 LI - R 317 LI
copyright by
MJF C I F S S
8.45.59
Electric kits
Service Manual

Step 65
Item
Designation
E1**
E2**
E 150**
Working light / attachment

Auxiliary headlight (roof) / front
Auxiliary headlight (roof) / rear
F323**
F324**
Fuse
Fuse
S22**
S22-1**
Switch / auxiliary headlight

Switch / auxiliary headlight
X404**
X967**

15.0 A
15.0 A
** in basic diagram
8.45.60
A 309 LI - R 317 LI
copyright by
MJF C I F S S
Service Manual
Electric kits
65

ZUSATZSCHEINWERFER
AUXILIARY HEADLIGHT
PROJECTEURS SUPPLEMENTAIRES
A 309 LI - R 317 LI
copyright by
MJF C I F S S
8.45.61
Electric kits
Service Manual

Step 66/1
Item
Designation
F331**
Fuse
K370
S356
Relay servo
Switch / changeover valve
X29
X358
X963

Y332
15.0 A
** in basic diagram
8.45.62
A 309 LI - R 317 LI
copyright by
MJF C I F S S
Service Manual
Electric kits
66/1

ANBAUSATZ UMSCHALTSCHIEBER
CHANGEOVER VALVE ACCESSORY KIT
ENSEMBLE DE MONTAGE
A 309 LI - R 317 LI
copyright by
MJF C I F S S
8.45.63
Electric kits
Service Manual

Step 66/2
Item
Designation
F331**
Fuse
K455
Relay / changeover valve UP, horizontal
S356
X29
X358-1
X358-2
X963**
X983
X1226

Plug connection, 2-pin / under operator's platform
Plug connection, 2-pin / fuel tank
Plug connection, 2-pin / magnet system
Y332
Y443
Y444

Check valve / boon cylinder pipe fracture safety valve
Check valve / boon cylinder pipe fracture safety valve
15.0 A
** in basic diagram
8.45.64
A 309 LI - R 317 LI
copyright by
MJF C I F S S
Service Manual
Electric kits
66/2

ENSEMBLE DE MONTAGE
A 309 LI - R 317 LI
copyright by
MJF C I F S S
8.45.65
Electric kits
Service Manual

Step 67
Item
Designation
A1202
Frequency switching board
F320**
Fuse X11 / X12
G1**
Alternator
P5-1
P5-2
P5-3
Operating hour meter / idle run

Operating hour meter / partial load
Operating hour meter / full load
S384
Switch / operating hour meter
X11**
X914
X915
X955**
X963**

Plug connection, 6-pin, operating our meter CS
Plug connection, 16-pin / on A 1202
15.0 A
** in basic diagram
8.45.66
A 309 LI - R 317 LI
copyright by
MJF C I F S S
Service Manual
Electric kits
67

BETRIEBSSTUNDENZHLER
HOUR COUNTER
COMPTEUR HORAIRE
A 309 LI - R 317 LI
copyright by
MJF C I F S S
8.45.67
Electric kits
Service Manual

Step 68
Item
Designation
A 126**
Autocheck PCB
F325**
Fuse S16, S263 (7.5 A)
H167**
H168**
H183

Electronic buzzer
K251**
S263
S269
S270
Pilot control unit switch, right

Switch in slip ring
Switch in slip ring
X312
X313
X314
X324-1
X342**
X950**
X951**
X952**
X959**
X962**
X963**
Plug connection, 12-pin / slip ring

Plug connection, 12-pin / slip ring
Plug connection, 2-pin / electronic buzzer
Plug connection, 2-pin / electronic buzzer
Plug connection, 3-pin / travel switch
Plug connection, 21-pin / revolving deck CS BST
board
Y62**
Y63**
Solenoid valve, forward travel

Solenoid valve, reverse travel
** in basic diagram
8.45.68
A 309 LI - R 317 LI
copyright by
MJF C I F S S
Service Manual
Electric kits
68

RCKFAHRWARNEINRICHTUNG
BACK-UP WARNING DEVICE
AVERTISSEUR DE MARCHE ARRIERE
A 309 LI - R 317 LI
copyright by
MJF C I F S S
8.45.69
Electric kits
Service Manual

Step 69
Item
Designation
A 127**
F320**
F340
Fuse X11
Fuse Thermoline
K33
Relay Thermoline
R8
Thermoline
S237
Switch / fuel pre-heating
X11**
X738
X963**
X979
X982

Plug connection, 2-pin / Thermoline
Plug connection / distribution board
Plug connection, 2-pin / switch CS
15.0 A
15.0 A
** in basic diagram
8.45.70
A 309 LI - R 317 LI
copyright by
MJF C I F S S
Service Manual
Electric kits
69

KRAFTSTOFFVORWRMUNG
FUEL PREHEATER
PRECHAUFFE DE CARBURANT
A 309 LI - R 317 LI
copyright by
MJF C I F S S
8.45.71
Electric kits
Service Manual

Step 70
8.45.72
Item
Designation
A127
E30
E50
D5WS auxiliary heating

Power cabinet and fuse cabinet
F34
F35
F36
Fuse / auxiliary heater to ground

Fuse / auxiliary heater control unit
Fuse / auxiliary heater timer, water valve, heating
G2
Battery
K358
K359
K360
Relay heating ON
Relay water circuit ON
Relay / heater fan ON
M52
M53
Water pump
Fuel metering pump
S9
S232
Battery main switch

Digital timer
X95
X98
X99
X100
X101
X689
X842-2
X987

Plug connection, 2-pin / to fuel metering pump
Plug connection, 2-pin / to water recirculation pump
Plug connection, 2-pin / to water recirculation pump
Plug connection, 8-pin / to auxiliary heater control device
Plug connection, 6-pin / blocking diodes
Plug connection, 2-pin / heater - auxiliary heater
Plug connection, 8-pin / auxiliary heater
25.0 A
15.0 A
15.0 A
A 309 LI - R 317 LI
copyright by
MJF C I F S S
Service Manual
Electric kits
70

STANDHEIZUNG D5WS
AUXILIARY HEATER
CHAUFFAGE SUPPLEMENT SUPPLEMENTAIRE A L'ARRET
A 309 LI - R 317 LI
copyright by
MJF C I F S S
8.45.73
Electric kits
Service Manual

Step 71
8.45.74
Item
Designation
A127
F342
Fuse terminal 15
T4
Voltage transformer
X989
Power socket 12V / 20 A / 2-pin
15.0 A
A 309 LI - R 317 LI
copyright by
MJF C I F S S
Service Manual
Electric kits
71

STECKDOSE 12V 20A
SOCKET 12V 20A
PRISE 12V 20A
A 309 LI - R 317 LI
copyright by
MJF C I F S S
8.45.75
Electric kits
Service Manual

Step 72
8.45.76
Item
Designation
B214
F331
Fuse X29
H27
Buzzer / quick-change adapter / boom shut-down
K333-1
K333-2
K334
Relay / boom shut-down

S249
S291
Key switch with plug / boom shut-down

Push button with plug / override boom shut-down
V163-1
V163-2

Blocking diode / signal boom shut-down
X29
X963
X988-1
X988-2
X988-3

Plug connection, 8-pin / boom shut-down CS
Y237
Y238
Solenoid valve / boom shut-down

15.0 A
A 309 LI - R 317 LI
copyright by
MJF C I F S S
Service Manual
Electric kits
72

HUBBEGRENZUNG
STROKE LIMITER
LIMITEUR DE COURSE DE LEVAGE
A 309 LI - R 317 LI
copyright by
MJF C I F S S
8.45.77
Electric kits
Service Manual

Step 73
8.45.78
Item
Designation
F337
Fuse
S272
S335
S335-1
S335-2
Slip-ring case
Switch front blade
Switch / rear blade
X301
X304
X771
X957
X958
X963
Plug connection, 12-pin / slip rig distribution board

Plug connection, 6-pin / console right
Y56
Y217
Y218
Solenoid valve / blade support, front

Solenoid valve / outrigger support, rear left
Solenoid valve / outrigger support, rear right
15.0 A
A 309 LI - R 317 LI
copyright by
MJF C I F S S
Service Manual
Electric kits
73

EINZELSTEUERUNG SCHILD / SCHILD
BLADE / BLADE INDIVIDUAL CONTROL
COMMANDE UNIQUE LAME / LAME
A 309 LI - R 317 LI
copyright by
MJF C I F S S
8.45.79
Electric kits
Service Manual

Step 74
8.45.80
Item
Designation
F307
F308
F309
F310
F336
Fuse E16, E17

Fuse E15, E18
Fuse E3
Fuse E4
Fuse S61
E4
E15
E18
E163

Tail light, left
License plate light
S61
X902
X953
X963
X967
Plug connection, 6-pin / lighting system

7.5 A
7.5 A
7.5 A
7.5 A
20.0 A
A 309 LI - R 317 LI
copyright by
MJF C I F S S
Service Manual
Electric kits
74

KENNZEICHENLEUCHTE
LAMP
ECLAIREAGE DE LA PLAQUE D'IMMATRICULATION
A 309 LI - R 317 LI
copyright by
MJF C I F S S
8.45.81
Electric kits
Service Manual

Step 75
8.45.82
Item
Designation
B51-1
Piston detector
F320
Fuse X11
S84-1
Push button with plug / central lubrication
U4-1
X11
X133-1
X143-1
X963
X998

Plug connection, 2-pin / piston detector
Plug connection, 4-pin / central lubrication system
15.0 A
A 309 LI - R 317 LI
copyright by
MJF C I F S S
Service Manual
Electric kits
75

ZENTRALSCHMIERANLAGE
CENTRAL LUBRICATION SYSTEM
DISP. DE GRAISSAGE CENTRALISE
A 309 LI - R 317 LI
copyright by
MJF C I F S S
8.45.83
Electric kits
Service Manual

Step 76
8.45.84
Item
Designation
F344
Fuse / emergency lowering
S78
Push button / emergency lowering
X999-1
X999-2
X999-3
Plug connection, 2-pin / fuse - switch

Plug connection, 2-pin / fuse - switch
Plug connection, 1-pin / switch - solenoid valve
Y204
Solenoid valve / emergency lowering
7.5 A
A 309 LI - R 317 LI
copyright by
MJF C I F S S
Service Manual
Electric kits
76

NOTABLASS
EMERCENCY LOWERING
DESCENTE SECOURS
A 309 LI - R 317 LI
copyright by
MJF C I F S S
8.45.85
Electric kits
Service Manual

Step 77
8.45.86
Item
Designation
B214
F331
Fuse X29
H27
Quick-change adapter buzzer / boom shut-down
K333-1
K333-1
K334

S249
S291
Key switch / boom shut-down

V163-1
V163-2

Blocking diode / signal boom shut-down
X29
X963
X988-1
X988-2
X988-3

Y237
15.0 A
A 309 LI - R 317 LI
copyright by
MJF C I F S S
Service Manual
Electric kits
77

HUBBEGRENZUNG SCHWENKARM
STROKE LIMITER BASIC BOOM
LIMITEUR DE COURSE FLECHE DE BASE
A 309 LI - R 317 LI
copyright by
MJF C I F S S
8.45.87
Electric kits
Service Manual

Step 78/1
8.45.88
Item
Designation
F331
Fuse X29
H323
K370
Relay servo
S356
X29
X358-1
X358-2
X963
X983

Plug connection, 2-pin / fuel tank
Y332
15.0 A
A 309 LI - R 317 LI
copyright by
MJF C I F S S
Service Manual
Electric kits
78/1

ENSEMBLE DE MONTAGE TIROIR D'INVERSION
A 309 LI - R 317 LI
copyright by
MJF C I F S S
8.45.89
Electric kits
Service Manual

Step 78/2
8.45.90
Item
Designation
F330
Fuse kits
H307
Indicator light / delta P
R76
S382
U16
V156-1
Blocking diode H307 BST
X856
X857
X909
X956
X959
X961
X963
X966
X974-1
Plug connection, 40-pin / BST wire harness

Plug connection, 21-pin / A125 wire harness
Plug connection, 2-pin / blocking diode
15.0 A
A 309 LI - R 317 LI
copyright by
MJF C I F S S
Service Manual
Electric kits
78/2

ANBAUSATZ UMSCHALTSCHIEBER / FEINREGELUNG
CHANGEOVER VALVE / FINE ADJUSTMENT
ENSEMBLE DE MONTAGE TIROIR D'INVERSION / REGLAGE
A 309 LI - R 317 LI
copyright by
MJF C I F S S
8.45.91
Electric kits
Service Manual

Step 79
8.45.92
Item
Designation
B213
B214
Proximity switch boom shut-down at stick

Proximity switch boom shut-down at bearing block
F331
Fuse X29
H27
H249
Buzzer / quick-change adapter / boom shut-down

Indicator light / override ON
K414
S6R
S249
Push button override boom shut-down in right pilot control unit

Key switch with plug / boom shut-down ON
X29
X74
X963
X988-1
X988-2
X988-3
X988-4
X988-5
X988-6

Plug connection, 3-pin handle right
Plug connection, 4-pin / to B214
Y237
Y238
Solenoid valve boom shut-down / stick

Solenoid valve boom shut-down / boom
15.0 A
A 309 LI - R 317 LI
copyright by
MJF C I F S S
Service Manual
Electric kits
79

HUBBEGRENZUNG HUB UND STIEL
STROKE LIMITER AND STICK
LIMITEUR DE COURSE LEVAGE ET BALANCIER
A 309 LI - R 317 LI
copyright by
MJF C I F S S
8.45.93
Electric kits
Service Manual

Step 80
8.45.94
Item
Designation
S5L
S5R
S6L
S6R
S19
Push button / left grapple rotator, left pilot control unit

Push button / right grapple rotator, left pilot control unit
Push button / left grapple rotator, right pilot control unit
Push button / right grapple rotator, right pilot control unit
Switch / grapple rotator, right console
X15-2
X296
X297
X952
X957
X966
Plug connection, 3-pin / left handle

Plug connection, 3-pin / handle right
Y22
Y23
Solenoid valve / left grapple rotator

Solenoid valve / right grapple rotator
A 309 LI - R 317 LI
copyright by
MJF C I F S S
Service Manual
Electric kits
80

BETTIGUNG AS1 IM GRIFF LINKS UND RECHTS
GRAPPLE CONTROL IN LEFT AND RIGHT JOYSTICK
CDE. AS DANS LE MANIPULATEUR GAUCHE ET DROITE
A 309 LI - R 317 LI
copyright by
MJF C I F S S
8.45.95
Electric kits
Service Manual

Step 81
Item
Designation
A125**
A126**
PCB potentiometers
PCB / autocheck
Left console
Right console
B40**
B290**
B291**
Proximity switch / travel pedal

Base plate
Base plate
Base plate
F316**
F330**
Fuse / indicator instruments / overload warning

Fuse kits
K375**
S45
S241**
S406

Switch / kit quantity changeover
Right controle
Right controle
Right console
U16**
Electronic box BST
Right console
V156-4**
V166
Blocking diode A125

Diode with plug
A125
A 125
X837**
X839**
X857**
X924-2**
X951**
X956**
X957**
X958**
X960**
X962**
X963**
X966**
X968-1**
X968-2**
X974-4**

Plug connection, 3-pin / screw terminal on A125
Plug connection, 3-pin / B291
Plug connection, 2-pin / A125 CS
Left console
Right console, rear
Right console, rear
Right console, rear
Right console, rear
Right console, rear
Right console, rear
Right console, rear
Right console, rear
Right console, rear
A125
A125
15.0 A
15.0 A

** item from basic diagram
8.45.96
A 309 LI - R 317 LI
copyright by
MJF C I F S S
Service Manual
Electric kits
81

BAUSATZMENGE UMSCHALTBAR
SWITCHABLE FLOW REDUCTION
REDUCTION DE DEBIT
A 309 LI - R 317 LI
copyright by
MJF C I F S S
8.45.97
Electric kits
Service Manual

Step 82
Item
Designation
F307**
F336**
Fuse E16, E17

Fuse S61
H324
Right control console,

front
P6**
Right controle
S61**
Right console, rear
X953**
X961**
X963**
X967**

Right console, rear

Right console, rear
Right console, rear
Right console, rear
7.5 A
20.0 A
Right console, rear

8.45.98
A 309 LI - R 317 LI
copyright by
MJF C I F S S
Service Manual
Electric kits
82
A 312 Litronic / A 314 Litronic / A 316 Litronic (IND)

BELEUCHTUNG NEIGUNGSMESSER
ILLUMINATION INCLINOMETER
ECLAIRAGE NIVEAU ELECTRONIQUEB
A 309 LI - R 317 LI
copyright by
MJF C I F S S
8.45.99
Electric kits
Service Manual

Step 83/1
Item
Designation
F320**
Fuse X11 / X12
H159
Indicator light / stroke limitation ON
K261
Relay / solenoid valve actuation in case of override
Right console, rear
S249
S291
Key switch / boom shut-down with plug

Right controle, rear

X11**
X374
X378
X379
X689
X963
X1017
X1018
X1019
Plug connection, 2-pin / on distribution board

Plug connection, 2-pin / to Y354 and Y355
Plug connection, 4-pin / to Y237 - Y238
Right console
Right console
Right console, rear
Near hydraulic tank
Near hydraulic tank
Near hydraulic tank
Y237
Y238
Y354

Solenoid valve / stick shut-down
Solenoid valve / pressure limitation pst / boom cylinder
extension override
Solenoid valve / pressure limitation pst / boom cylinder
extension
Near hydraulic tank

Near hydraulic tank
Near hydraulic tank
Y355
15.0 A
Near hydraulic tank
8.45.100
A 309 LI - R 317 LI
copyright by
MJF C I F S S
Service Manual
Electric kits
83/1 A 312 Litronic / A 314 Litronic / A 316 Litronic (IND)

HUBBEGRENZUNG KRGER
KRUEGER STROKE LIMITER
LIMITEUR DE COURSE ELECTRIQUE
A 309 LI - R 317 LI
copyright by
MJF C I F S S
8.45.101
Electric kits
Service Manual

Step 83/2
8.45.102
Item
Designation
A
B
Krueger indicating instrument

Krueger control box
K1
K2
Relay / preliminary shut-down Krger electronics

Relay / shut-down Krger electronics

R70
R71
Rotary potentiometer
Rotary potentiometer
At basic boom
At boom
X379
X381
X358-1
X382
X382-1
X382-2

Plug connection, 4-pin / to R70

At basic boom
At basic boom
At boom
At boom
At boom
A 309 LI - R 317 LI
copyright by
MJF C I F S S
Service Manual
Electric kits
83/2

HUBBEGRENZUNG KRGER
KRUEGER STROKE LIMITIER
LIMITEUR DE COURSE ELECTRIQUE
A 309 LI - R 317 LI
copyright by
MJF C I F S S
8.45.103
Electric kits
Service Manual

Step 84/1
Item
Designation
A125**
PCB potentiometers
Left console
F330**
F331**
Fuse kits
Fuse X29
H322
Warning light / changeover

DOWN
P1**
Potentiometer / flow reduction A125
S241**
S405

Switch / changeover
Right controle
Right console
V156-4**
V169
Blocking diode A125

Blocking diode
A125
A 125
X29**
X837**
X839**
X952**
X957**
X958**
X963**
X974-4**
X1028
X1029

Plug connection, 8-pin / A125
Plug connection, 4-pin / to S405 and H322
Plug connection, 4-pin / solenoid valves
Right console, rear

Right console, rear
Right console, rear
Right console, rear
Right console, rear
Y385-1
Y385-2
Solenoid valve / changeover bucket cylinder - AHS

Behind cab
Behind cab
15.0 A
15.0 A

8.45.104
A 309 LI - R 317 LI
copyright by
MJF C I F S S
Service Manual
Electric kits

UMSCHALTUNG LFFELKIPPKREIS / AHS
SWITCHING SYSTEM BUCKET / AHS
COMMUTATEUR GODET CURAGE / AHS
A 309 LI - R 317 LI
copyright by
MJF C I F S S
8.45.105
Electric kits
Service Manual

Step 84/2
Item
Designation
A125**
PCB potentiometers
Left console
B33
F320**
F321**
F330**
F331**
Fuse X11 / X12

Fuse X12
Fuse kits
Fuse X29
H322
K375**
Right console, rear
S241**
S405

Switch / changeover
Right controle
Right console
U16**
Right console, rear
V156-4
Blocking diode A125
A125
X12**
X29**
X837**
X839**
X856**
X857**
X957**
X958**
X963**
X965**
X966**
X968-1**
X968-2**
X974-4**
X1028
X1029
X1224

Plug connection, 21-pin / BST- CS A125
Plug connection, 3-pin / pressure switch
Right console
Right console, rear
Right console
Right console
Right console, rear
Right console, rear
Right console, rear
Right console, rear
Right console, rear
Distribution board
Y268**
Y299**
Y385-1
Y385-2

Near hydraulic tank

Near hydraulic tank
Behind cab
Behind cab
15.0 A
15.0 A
15.0 A
15.0 A

8.45.106
A 309 LI - R 317 LI
copyright by
MJF C I F S S
Service Manual
Electric kits
84/2

A 309 LI - R 317 LI
copyright by
MJF C I F S S
8.45.107
Electric kits
Service Manual

Step 84/3
8.45.108
Item
Designation
A125**
A133
PCB potentiometers
Left console
Left console
B33
F321**
F330**
Fuse X12
to kits fuse
H196**
H322

Right control desk

K375**
Right console, rear
S19**
S241**
S405
to switch / grapple rotator Y22, Y23

Switch / changeover

Right control desk
Right console
U16**
Right console, rear
V156-4
V169
Blocking diode A125

Blocking diode
A125
A 125
X12**
X29**
X837**
X839**
X856**
X857**
X952**
X957**
X958**
X963**
X965**
X966**
X967**
X968-1
X968-2
X974-4
X1028
X1029
X1224
Y268
Y299
Y385-1
Y385-2
Y451

Right console
Right console, rear
Right console
Right console
Right console, rear
Right console, rear
Right console, rear
Right console, rear
Right console, rear
Right console, rear
Right console, rear
Distribution board
Near hydraulic tank
Near hydraulic tank
Behind cab
Behind cab
Near hydraulic tank
15.0 A
15.0 A

A 309 LI - R 317 LI
copyright by
MJF C I F S S
Service Manual
Electric kits
84/3 A 309 Litronic / A 311 Litronic

A 309 LI - R 317 LI
copyright by
MJF C I F S S
8.45.109
Electric kits
Service Manual

Step 85
Item
Designation
A133
Left console
B306
Particle filter
E50
Hydraulic tank
F351
Fuse (F_H)
H298
H299
Warning light / exhaust backpressure

Warning buzzer / exhaust backpressure

X20
X1040
X1041
Terminal for kit, 2-pin

Plug connection, 3-pin / to display unit
Plug connection, 2-pin / for temperature sensor

Electric box E50
Electric box E50
3A
Near hydraulic tank
8.45.110
A 309 LI - R 317 LI
copyright by
MJF C I F S S
Service Manual
Electric kits
85

PARTICLE FILTER PURITECH
FILTRE DE PARTICULES PURITECH
PARTICLE FILTER PURITECH
A 309 LI - R 317 LI
copyright by
MJF C I F S S
8.45.111
Electric kits
Service Manual

Step 86/1
Item
Designation
F331**
Fuse X29
S124
S380

Switch / mower rake activation
Right controle
Right controle
X29**
X963**
X1050
X1051
X1052

Plug connection, 3-pin / adapter switch CS
Plug connection, 4-pin / mower rake drive CS
Right console, rear

Right console, rear
Right handle
Right handle
Right handle
Y405
Y406
Solenoid valve with plug / mower rack forward

Solenoid valve with plug / mower rack reverse
15.0 A
8.45.112
A 309 LI - R 317 LI
copyright by
MJF C I F S S
Service Manual
Electric kits

ANBAUSATZ MAHKORB
MOWER RAKE
GODET FAUCARDEUR
A 309 LI - R 317 LI
copyright by
MJF C I F S S
8.45.113
Electric kits
Service Manual

Step 86/2
Item
Designation
A1017
to quick-change adapter board
Right console, rear
F331**
Fuse X29
H329
Indicator light / mower rake operation
Right console
K438
Step relay / mower rake operation
Distribution board
S5L**
S5R**
S19**
S124
S241**
S380

to switch AHS 11 / AHS 12
Override switch stick cylinder

Right controle
Right controle
In handle, right
X29**
X412**
X952**
X957**
X963**
X966**
X1046**
X1050
X1052

to plug connection distribution board / 2-pin
Plug connection, 4-pin / mower rake drive CS
Right console, rear

Right console, rear
Right console, rear
Right console, rear
Right console, rear
Right console, rear
Left console
Right handle
Right handle
Y22**
Y23**
Y405

Solenoid valve with plug / mower rack forward
Control valve block

Control valve block
Mower rake
15.0 A
8.45.114
A 309 LI - R 317 LI
copyright by
MJF C I F S S
Service Manual
Electric kits

ANBAUSATZ MAHKORB
MOWER RAKE
GODET FAUCARDEUR
A 309 LI - R 317 LI
copyright by
MJF C I F S S
8.45.115
Electric kits
Service Manual

Step 87
Item
Designation
F320
Fuse X11 / X12
S272
S419
Slip-ring case
Switch / trailer coupling
Undercarriages
Right console
X11
X301
X963

Plug connection, 12-pin / on slip ring
Right console
Rotary connection
Right console, rear
X1053
Plug connection, 1-pin / slip ring CS
Distribution board
Y406
Solenoid valve / trailer coupling OPEN/CLOSED
Uppercarriage, rear
15.0 A
8.45.116
A 309 LI - R 317 LI
copyright by
MJF C I F S S
Service Manual
Electric kits
87

ANHANGEKUPPLUNG
TRAILER COUPLING
D'ATTELAGE
A 309 LI - R 317 LI
copyright by
MJF C I F S S
8.45.117
Electric kits
Service Manual

Step 88
Item
Designation
A123
Left console
F331**
Fuse X29
S6L
S6R
S321
Push button / joystick control

Push button / joystick control
Switch / activate joystick steering

Right controle
X15
X29**
X412
X413
X414

Plug connection, 3-pin / to Y307
Plug connection, 5-pin / to A123
Right joystick
Right console, rear
Right console, rear
Right console, rear
Right console, rear
Y307
Proportional solenoid valve / steering
15.0 A
8.45.118
A 309 LI - R 317 LI
copyright by
MJF C I F S S
Service Manual
Electric kits
88

JOY-STICK LENKUNG
JOYSTICK CONTROL
COMMAND DU VOLANT DE DIRECTION
A 309 LI - R 317 LI
copyright by
MJF C I F S S
8.45.119
Electric kits
Service Manual

Step 89
Item
Designation
A126**
PCB / autocheck
Right console
B10**
to pressure switch / parking brake
HBGV block
E167
Beacon for back-up warning
Cap, top right
F325**
Fuse S16, S263
H167**
H168**
H183

Buzzer / back-up alarm
Right controle
Right controle
Cap, top left
K251**
Right console, rear
S263**
S269
S270

Switch in slip ring
Switch in slip ring

Rotary connection
Rotary connection
X312
X313
X314
X324-1
X342
X950**
X951**
X952**
X959**
X962**
X963**
X993

Plug connection, 2-pin / to electr. buzzer
Plug connection, 3-pin / to travel selection switch
Plug connection, 2-pin / beacon
Rotary connection
Rotary connection
Revolving deck
Revolving deck
Right console
Right console
Right console
Right console, rear
Right console, rear
Right console, rear
Right console, rear
Uppercarriage, rear
Y62**
Y63**

Hydraulic tank
Hydraulic tank
7.5 A
8.45.120
A 309 LI - R 317 LI
copyright by
MJF C I F S S
Service Manual
Electric kits
89

RCKFAHRWARNEINRICHTUNG OPTISCH UND AKUSTISCH
BACK-UP WARNING DEVICE
AVERTISSEUR DE MARCHE ARRIERE
A 309 LI - R 317 LI
copyright by
MJF C I F S S
8.45.121
Electric kits
Service Manual

Step 90
Item
Designation
B233
Proximity switch / bucket cylinder movement
At stick
F331**
Fuse X29
H328
Indicator light / shut-down active
S423
Key switch / shut-down override
Right console
X29**
X963**

Right console, rear

Right console, rear
X1060
X1061
X1062
Plug connection, 3-pin / switch


Uppercarriage
Bearing block
Y409
Solenoid valve / tilt cylinder shut-down
Near hydraulic tank
15.0 A
8.45.122
A 309 LI - R 317 LI
copyright by
MJF C I F S S
Service Manual
Electric kits
90 A 312 Li / A 314 Li / A 316 Li (IND) / R 317 Li

ABSCHALTUNG LFFELKIPPZYLINDER
A 309 LI - R 317 LI
copyright by
MJF C I F S S
8.45.123
Electric kits
Service Manual

Step 91
Item
Designation
F320**
F331**
Fuse X11 / X12

Fuse X29
K375**
K436
K437

Step relay (atom. reset)
Relay / signal flow reduction drilling slide
Right console, rear

Distribution board
Distribution board
S424
Push button / continuous operation AHS
Right console
X11**
X29**
X957**
X963**
X966**
X1070-1
X1070-2

Plug connection, 2-pin / solenoid valve
Right console
Right console, rear
Right console, rear
Right console, rear
Right console, rear
Near hydraulic tank
Near hydraulic tank
Y410
Solenoid valve / continuous operation AHS
Near hydraulic tank
15.0 A
15.0 A

8.45.124
A 309 LI - R 317 LI
copyright by
MJF C I F S S
Service Manual
Electric kits
91

ANBAUSATZ BOHRLAFETTE
DRILLING SLIDE ACCESSORY KIT
EQUIPEMENT COMPLEMENTAIRE AFFUT
A 309 LI - R 317 LI
copyright by
MJF C I F S S
8.45.125
Electric kits
Service Manual

Step 92
Item
Designation
F337**
Fuse kits
S272**
S335**
S343
S439R
Slip-ring case
Switch / preselection changeover blade - outrigger
Switch / individual control, back
S439R
X301**
X304**
X955**
X957**
X958**
X959**
X963**
X1104

Plug connection, 6-pin / to S04, S205, S206, S207
Rotary connection
Right console, rear
Right console, rear
Right console, rear
Right console, rear
Right console, rear
Right console, rear
Right controle
Y56**
Y217**
Y218**
Solenoid valve / changeover outrigger - blade

Undercarriages
Undercarriages
Undercarriages
15.0 A

Undercarriages
Right controle
Right controle
Pilot control valve / support
8.45.126
A 309 LI - R 317 LI
copyright by
MJF C I F S S
Service Manual
Electric kits
92

SCHILD EINZELSTEUERUNG
OPTION LAME DE NIVELAGE/BRAS STABILISATEUR
OPTION DOZER BLADE/OUTRIGGER INDIVIDUAL CONTROL
A 309 LI - R 317 LI
copyright by
MJF C I F S S
8.45.127
Electric kits
Service Manual

Step 93
Item
Designation
F337**
Fuse kits
S7**
S272**
S443L
S443R
to safety switch
Slip-ring case
Push button / telescope blade, left rear
Push button / telescope blade, right rear
Left console
Undercarriages
V172-1
V172-2

Right console
Right console
X301**
X304**
X771**
X957**
X958**
X963**
X1104

Plug connection, 6-pin / to S04, S205, S206, S207
Rotary connection
Right console, rear
Left console
Right console, rear
Right console, rear
Right console, rear
Right controle
Y217**
Y218**
Y428

Solenoid valve / changeover UP/DOWN - telescope
OUT/IN
Undercarriages
Undercarriages
Undercarriages
15.0 A
8.45.128
A 309 LI - R 317 LI
copyright by
MJF C I F S S
Service Manual
Electric kits
93

TELESCOPIC SUPPORT BLADE
A 309 LI - R 317 LI
copyright by
MJF C I F S S
8.45.129
Electric kits
Service Manual

Step 94
Item
Designation
F331**
Fuse X29
S6L
S6R
S379
Push button / activation horizontal adjustment

Switch / release of push button for horizontal adjustment
(right handle)

Right console
X29**
X407**
X408
X410**
X963**

Plug connection: 2-pin, / reolving deck CS
Plug connection, 2-pin / to revolving deck CS
Plug connection, 2-pin / power supply A1017
Right console, rear

Right console, rear
Right console, rear
Y365
Y366

Hydraulic tank
Hydraulic tank
15.0 A
8.45.130
A 309 LI - R 317 LI
copyright by
MJF C I F S S
Service Manual
Electric kits
94
A 312 Litronic / A 314 Litronic / A 316 Litronic / R 317 Litronic

BETTIGUNG SCHIEBERSEKTION BER TASTER
ACTUATION VALVE SPOOL WITH PUSH BUTTON
COMMANDE TIROIR DE DISTRIDUTION AVEC BOUTON POUSSOIR
A 309 LI - R 317 LI
copyright by
MJF C I F S S
8.45.131
Electric kits
Service Manual

Step 95
Item
Designation
A127**
Hydraulic tank
F20/
F300**
F303**
F325**
Fuse terminal 30 to terminal 15
50.0 A
A127 hydraulic tank
Fuse A127, Y29

Fuse S16, S263
7.5 A
7.5 A
Near hydraulic tank

K251**
K288**
K439

Relay / terminal 15 at A127
Relay / drop-out delayed
Right console, rear

Near hydraulic tank
Distribution board
V168
Decay diode
A 127
X952**
X962**
X963**
X1006
X1011

Plug terminal, 1-pin
Plug connection, 3-pin / decay diode
Right console, rear

Right console, rear
Right console, rear
Near A127
Near A127
Y29**
Engine block regulating

rod
8.45.132
A 309 LI - R 317 LI
copyright by
MJF C I F S S
Service Manual
Electric kits
95
A 312 Li / A 314 Li / A 316 Li (IND) / R 317 Li

MOTORSTOP ZEITGESTEUERT
ENGINE STOP WITH TIMER
ARRET MOTEUR AUTOMATIQUE
A 309 LI - R 317 LI
copyright by
MJF C I F S S
8.45.133
Electric kits
Service Manual

Step 96
Item
Designation
A1017**
Right console, rear
S5L**
S5R**
S19**
S45
S241**
S382**
S451
S452

to priority switch
to switch AHS 11 / AHS 12
Rocker button / rotating grapple

Right controle
Right controle
Right controle
Right console
X15-2**
X74**
X952**
X957**
X966**
X1179

Plug connection, 3-pin / S6
Left console
Right console
Right console, rear
Right console, rear
Right console, rear
Y22**
Y23**

Control valve block

Control valve block

Z=
8.45.134
switch S382 in rocker button design with indicator light

due to change of the switch from the left pilot control unit (rocker button design, see
step 24 in basic machine diagram) to the right control desk.
A 309 LI - R 317 LI
copyright by
MJF C I F S S
Service Manual
Electric kits
96

GREIFER DREHEN BER RECHTEN WIPPTASTER
GRAPPLE ROTATOR
MECHANISME DE ROTATION
A 309 LI - R 317 LI
copyright by
MJF C I F S S
8.45.135
Electric kits
Service Manual

Step 97/1
Item
Designation
A126**
PCB / autocheck
Right console
E21**
E22**
E23
E24
E173
E174

Auxiliary indicator, right
Auxiliary indicator, left

Weight, left
Weight, left
Uppercarriage, front right
Uppercarriage, front left
F302**
F312**
F338**
to fuse S44
Fuse S44,E21 - E24
H9**
H19**
Horn
Right console
Right controle
K63**
Near hydraulic tank
M70**
to motor / air-spring seat
Operator's platform
S4**
S32
S44**
S389**
Horn switch
Hazard warning lights switch
to switch seat heating
Cab floor plate

Steering column
Right console
Operator seat
X550**
X950**
X951**
X953**
X955**
X960**
X962**
X964**
Plug connection
Right console
Right console
Right console
Right console, rear
Right console, rear
Right console, rear
Right console, rear
Right console, rear
7.5 A
7.5 A
20.0 A
A127
Right console
8.45.136
A 309 LI - R 317 LI
copyright by
MJF C I F S S
Service Manual
Electric kits
97/1 A 309 Li / A 311 Li / A 312 Li / A 314 Li / A 316 Li (IND)

ZUSATZ - BLINKLEUCHTEN / BLINKANLAGE, HUPE
INDICATORS, HORN
CLINGOTANTS, AVERTISSEUR
A 309 LI - R 317 LI
copyright by
MJF C I F S S
8.45.137
Electric kits
Service Manual

Step 97/2
Item
Designation
E3**
E4**
E15**
E16**
E17**
E18**
E19**
E20**
E23**
E171
E172
Headlight uppercarriage, left

Parking light, left
Rear light, right
Tail light, left
Brake light, right
Brake light, left
to indicator light, front right
Outline light, left
Front cab roof

Cab roof
Weight, right
Weight, left
Uppercarriage, left
F307**
F308**
F309**
F310**
F336**
Fuse E16, E17

Fuse E15, E18
Fuse E3
Fuse E4
Fuse S61
K315**
to relay / brake light
Right console, rear
P6**
to indicator / engine temperature
Right controle
S61**
Right console, rear
X953**
X960**
X961**
X963**
X967**
X1186**

X1198**
Right console, rear

Right console, rear
Right console, rear
Right console, rear
Right console, rear
Engine compartment, left
rear
7.5 A
7.5 A
7.5 A
7.5 A
20.0 A
Right console, rear

Right console, rear
Right console, rear
Right console, rear
8.45.138
A 309 LI - R 317 LI
copyright by
MJF C I F S S
Service Manual
Electric kits
97/2

ZUSATZ - LEUCHTEN / LICHTANLAGE
LIGHTING SYSTEM
ECLAIRAGE
A 309 LI - R 317 LI
copyright by
MJF C I F S S
8.45.139
Electric kits
Service Manual

Step 97/3
Item
Designation
E3**
E4**
E15**
E16**
E17**
E18**
E169
E170
E171
E172
Headlight uppercarriage left

Parking light, left
Rear light, right
Tail light, left
Position light, front right in indicator
Position light, front left in indicator
Outline light, left
Front cab roof

Cab roof
Revolving deck, right
Revolving deck, left
Uppercarriage, left
F20**
F307**
F308**
F309**
F310**
F336**
to fuse terminal 30
Fuse E16, E17
Fuse E15, E18
Fuse E3
Fuse E4
Fuse S61
P6**
to indicator / engine temperature
Right controle
S61**
Right console, rear
X953**
X960**
X961**
X963**
X967**

Right console, rear

Right console, rear
Right console, rear
Right console, rear
Right console, rear
7.5 A
7.5 A
7.5 A
7.5 A
7.5 A
20.0 A
A127
Right console, rear
Right console, rear
Right console, rear
Right console, rear
8.45.140
A 309 LI - R 317 LI
copyright by
MJF C I F S S
Service Manual
Electric kits
97/3

ZUSATZ - LEUCHTEN / LICHTANLAGE
LIGHTING SYSTEM
ECLAIRAGE
A 309 LI - R 317 LI
copyright by
MJF C I F S S
8.45.141
Electric kits
Service Manual

Step 98
Item
Designation
F330**
Fuse kits
S16**
S263**
S382**
to parking brake switch


Right controle
U16**
Right controle
X230**
X951**
X956**
X959**
X962**
X963**
X966**
X1046**
X1046-1
X1048**
X1046-1
Plug connection, 3-pin / on A1100

Plug handle extension, 6-pin
Plug to handle switch, 3-pin
Left console
Right console
Right console, rear
Right console, rear
Right console, rear
Right console, rear
Right console, rear
Left console
Right handle
Right handle
Right handle
15.0 A
8.45.142
A 309 LI - R 317 LI
copyright by
MJF C I F S S
Service Manual
Electric kits
98

SCHALTER FAHRTRICHTUNG IM LINKEN GRIFF
TRAVEL DIRECTION SELECTION IN LEFT JOYSTICK
INTTERRUPTEUR SENS DE MARCHE AU MANIPULATEUR GAUCHE
A 309 LI - R 317 LI
copyright by
MJF C I F S S
8.45.143
Electric kits
Service Manual

Step 99
Item
Designation
F338**
Fuse S4, seat heating
F338**
Fuse S4, seat heating
H9**
Horn
Right console
S4**
S6L
S6R
S32
Horn switch
Push button / horn activation
Push button / horn activation
Cab floor plate

Steering column
X74
X550**
X960**
X964**
X1048**

Plug connection
Right console
Right console
Right console, rear
Right console, rear
Right handle
10.0 A
at 309-311
15.0 A
at 312-316

8.45.144
A 309 LI - R 317 LI
copyright by
MJF C I F S S
Service Manual
Electric kits
99
A 309 Li / A 311 Li / A 312 Li / A 314 Li / A 316 Li

BETTIGUNG HUPE BER TASTER
HORN ACTUATION WITH PUSH BUTTON
COMMANDE AVERTISSEUR AVEC BOUTON POUSSOIR
A 309 LI - R 317 LI
copyright by
MJF C I F S S
8.45.145
Electric kits
Service Manual

Step 100
Item
Designation
A127**
Hydraulic tank
F331**
F364
Fuse X29
Fuse
H158
Indicator light / Fuchs control ON
K229
Relay / changeover (K_B)
A127
S247
Key switch / Fuchs control
Right controle
X29**
X963**

Right console, rear

Right console, rear
X1213
Plug connection, 2-pin / decay diode
Y236-1
Y236-2
Y236-3
Y236-4


15.0 A
15.0 A

8.45.146
A 309 LI - R 317 LI
copyright by
MJF C I F S S
Service Manual
Electric kits
100 A 312 Li / A 314 Li / A 316 Li (IND) / R 317 Li

UMSCHALTUNG FUCHS-STEUERUNG
SWITCHING FUCHS SERVO CONTROLS
COMMUTATION COMMANDE FUCHS
A 309 LI - R 317 LI
copyright by
MJF C I F S S
8.45.147
Electric kits
Service Manual

Step 101
Item
Designation
B290**
F320**
Fuse X11 / X12
H343
Warning light / outriggers not retracted
S272**
Slip-ring case
Undercarriages
X11**
X301**
X771**
X963**
X1215
X1218

Plug connection, 2-pin / warning light
Plug connection, 3-pin / warning light
Right console
Rotary connection
Left console
Right console, rear
15.0 A
8.45.148
A 309 LI - R 317 LI
copyright by
MJF C I F S S
Service Manual
Electric kits
101 A 312 Li / A 314 Li / A 316 Li (IND)

PRATZENKONTROLLE
OUTRIGGER CONTROL
BRAS STABO OSATEIRS DE CONTROL
A 309 LI - R 317 LI
copyright by
MJF C I F S S
8.45.149
Electric kits
Service Manual

Step 102
Item
Designation
F320**
Fuse X11 / X12
H90
Indicator light / change of direction of fan
Right console
KT20
KT21
Time relay / fan afterrun

Time relay / direction of rotation switching
Distribution board
Distribution board
S160
Switch / change of direction of rotation
Right console
X11**
X963**
X1234
X1235

Plug connection, 4-pin / magnet unit CS
Right console
Right console, rear
Right console
Behind cab
Y356
Y357
Solenoid valve / fan stop

Solenoid valve / change of direction of rotation
Counter weight
Counter weight
15.0 A
8.45.150
A 309 LI - R 317 LI
copyright by
MJF C I F S S
Service Manual
Electric kits
102 A 309 Li / A 311 Li / A 312 Li / A 314 Li / A 316 Li IND / R 317 Li

LFTERANTRIEB REVERSIERBAR
REVERSIBLE FAN DRIVE
ENTRAINEMENT DU VENTILATEUR REVERSIBLE
A 309 LI - R 317 LI
copyright by
MJF C I F S S
8.45.151
Electric kits
Service Manual

Step 103
Item
Designation
A126**
PCB / autocheck
Right console
F326**
H176**
H311**
Indicator lamp / oscillating axle automatic

Indicator lamp / oscillating axle locked
Right console
Right console
K250**
K464

Relay / oscillating axle release
Distribution board
S6L
S7**
S35**
S75**
Push buttons magnet unit, grapple activation, joystick

steering, horn actuation, oscillating axle release
Push buttons magnet unit, grapple activation, joystick
steering, horn actuation
to safety switch
to servo switch
Switch / oscillating axle locking device

Right console
V155**
V156-2**
Blocking diode
Blocking diode
Left console
Left console
X74**
X842-3**
X950**
X952**
X959**
X961**
X964**
X974-2**
X1048**

Right console
Right console
Right console
Right console, rear
Right console, rear
Right console, rear
Right console, rear
Right handle
Y371**
Control oil unit
S6R
15.0 A

8.45.152
A 309 LI - R 317 LI
copyright by
MJF C I F S S
Service Manual
Electric kits
103 A 309 Li / A 311 Li / A 312 Li / A 314 Li / A 316 Li (IND)

AUTOMATISCHE PENDELACHSVERRIEGELUNG
AUTOM. OSCILLATING AXLE LOCK
VERROUILLAGE AUTOMATIQUE DU PONT OSCILLANT
A 309 LI - R 317 LI
copyright by
MJF C I F S S
8.45.153
Electric kits
Service Manual

Step 104
Item
Designation
B36
F320**
Pressure switch
Fuse X11
H33
Back-up alarm
Right console
K407-1
K407-2

Time relay / delayed travel warning
Distribution board
Distribution board
S6L
Push button / right pilot control device travel warning
X11**
X204
X206
X207
X324-1
X324-2
X963**
X1048**

Plug connection, 12-pin, CS console, ignition switch
Right console
Right console, rear
Right console
Right console, rear
Hood
Revolving deck
Right console, rear
Right console
15.0 A

** in basic machine
8.45.154
A 309 LI - R 317 LI
copyright by
MJF C I F S S
Service Manual
Electric kits
104 A 309 - A 316 Li

FAHRWARNEINRICHTUNG
TRAVEL ALARM
AVERTISSEUR DE MARCHE
A 309 LI - R 317 LI
copyright by
MJF C I F S S
8.45.155
Electric kits
Service Manual

Step 105
Item
Designation
F331**
Fuse
H323
Right console
K370**
Relay servo
Right console, rear
S356
Right console
X29**
X358-1
X358-2
X963**
X983**
X1046

Right console, rear

Fuel tank
Right console, rear
Right console, rear
Right console, rear
Y332**
Attachments
15.0 A
8.45.156
A 309 LI - R 317 LI
copyright by
MJF C I F S S
Service Manual
Electric kits
105 A 309 - A 316 Li

TIROIR DIVERSION
A 309 LI - R 317 LI
copyright by
MJF C I F S S
8.45.157
Electric kits
Service Manual
Step 106
Item
Designation
F331**
K455
Relay / changeover valve UP, horizontal
Right console, rear
S356
Right console
X29**
X358-1
X358-2
X963**
X983**
X1226
X1245
X1246

Right console, rear

Fuel tank
Right console, rear
Right console, rear
Hydraulic tank
Hydraulic tank
Y332
Y443

Solenoid valve control pressure changeover / piston side
Solenoid valve control pressure changeover / rod side
Solenoid valve changeover control line at regulating cylinder
Slewing boom
Hydraulic tank
Y444
Y453
Y454
Y456
15.0 A
Hydraulic tank
Hydraulic tank
8.45.158
A 309 LI - R 317 LI
copyright by
MJF C I F S S
Service Manual
Electric kits
106 A 312 - R 317 Li

TIROIR DIVERSION
A 309 LI - R 317 LI
copyright by
MJF C I F S S
8.45.159
Electric kits
Service Manual
Step 107
Item
Designation
F330**
Fuse
H196
H323

Right console
Right console
K375**
Right console, rear
S241
S356
Switch AHS 12
Right console
Right console
X952**
X957**
X958**
X1046

Right console, rear

Right console, rear
Right console, rear
Y268**
Y299**
Solenoid valve changeover

Solenoid valve / additional pressure stage
Hydraulic tank
Hydraulic tank
15.0 A
8.45.160
A 309 LI - R 317 LI
copyright by
MJF C I F S S
Service Manual
Electric kits
107 A 312 - R 317 Li

TIROIR DIVERSION
A 309 LI - R 317 LI
copyright by
MJF C I F S S
8.45.161
Electric kits
Service Manual
Step 108
Item
Designation
B213
B214
Proximity switch boom shut-down at stick

Proximity switch boom shut-down at bearing block
Attachments
Attachments
F331**
H27
H249
Quick-change adapter buzzer / boom shut-down

Indicator light / override ON

K414
Right console, rear
S249
S291
Key switch boom shut-down ON

Button boom shut-down override / left pilot control unit
Right console
Right console
X29**
X74
X963**
X988-1
X988-2
X988-3
X988-4
X988-5
X988-6
X1132

Plug connection, 8-pin / boom shut-down
Plug connection, 4-pin / boom shut-down
Plug connection, 3-pin / to B214
Plug connection, 3-pin / extension
Right console, rear

Right console, rear
Revolving deck
Attachments
Right console, rear
Right console, rear
Right console, rear
Attachments
Left console, rear
Y237
Y238
Solenoid valve / stick shut-down

Hydraulic tank
Hydraulic tank
15.0 A
8.45.162
A 309 LI - R 317 LI
copyright by
MJF C I F S S
Service Manual
Electric kits
108 A 312 - R 317 Li

HUBBEGRENZUNG HUB UND STIEL
STROKE LIMITER AND STICK
LIMITEUR DE COURSE LEVAGE ET BALNCIER
A 309 LI - R 317 LI
copyright by
MJF C I F S S
8.45.163
Electric kits
Service Manual
Step 109
Item
Designation
A1017**
Right console, rear
S5L**
S5R**
S6L
S6R
S19**


X15-2**
X74
X952**
X957**
X966**
X1046
X1046-1
X1048

Plug connection, 6-pin / handle extension
Left console
Right console
Right console, rear
Right console, rear
Right console, rear
Left control console
Left control console
Y22**
Y23**

Control valve block

Control valve block
8.45.164
A 309 LI - R 317 LI
copyright by
MJF C I F S S
Service Manual
Electric kits
109 A 312 - R 317 Li

BETTIGUNG AS1 IM GRIFF LINKS UND RECHTS
GRAPPLE CONTROL IN LEFT AND RIGHT JOYSTICK
CDE. AS 1 DANS MANIPULATEUR GUAUGE ET DROITE
A 309 LI - R 317 LI
copyright by
MJF C I F S S
8.45.165
Electric kits
Service Manual
Step 110
Item
Designation
A125**
PCB potentiometers
Left console
B33
F330**
F331**
to fuse
Fuse X29
H322
K375**
Right console, rear
S19**
S241**
S405
to switch AS 1
Switch / changeover
Right controle
Right controle
Right console
U16**
Right console, rear
V156-4
Blocking diode A125
A125
X29**
X837**
X839**
X856**
X857**
X952**
X953**
X954**
X957**
X958**
X963**
X965**
X966**
X968-1**
X968-2**
X974-4**
X1028
X1029

Right console, rear

Right console
Right console
Right console, rear
Right console, rear
Right console, rear
Right console, rear
Right console, rear
Right console, rear
Right console, rear
Right console, rear
Y268**
Y299**
Y385-1
Y385-2
Y451

Near hydraulic tank

Near hydraulic tank
Behind cab
Behind cab
Behind cab
15.0 A
15.0 A

8.45.166
A 309 LI - R 317 LI
copyright by
MJF C I F S S
Service Manual
Electric kits
110

A 309 LI - R 317 LI
copyright by
MJF C I F S S
8.45.167
Electric kits
Service Manual
Step 111
Item
Designation
F314**
F329**
FRes**
Fuse S7
Fuse S35
Fuse, reserve
H27**
Warning buzzer
K370**
K386**
K471
Relay terminal 15 servo

Relay inversion signal servo OFF
Right console, rear

Right console, rear
Right console, rear
S7**
S35**
Safety switch
Switch servo shut-down
Left console
Right controle
U16**
Right console, rear
V178-1
V178-2

Right console, rear

Right console, rear
X952**
X956**
X959**
X962**
X963**
X964**
X966**
X1106
X1117

Plug connection, 4-pin / power supply
Plug connection, 6-pin / 4-wheel steering
Right console, rear

Right console, rear
Right console, rear
Right console, rear
Right console, rear
Right console, rear
Right console, rear
Y3**
Y330**

Solenoid valve / pump regulation
(not required during series)
Control oil unit

Control oil unit
3.0 A
5.0 A

8.45.168
A 309 LI - R 317 LI
copyright by
MJF C I F S S
Service Manual
Electric kits
111

BAUSATZ ABSENKUNG MOTORDREHZAHL BEIM ARBEITEN / LEISTUNGSREDZIERUNG
KIT LOWERING ENGINE RPM DURING WORK / POWER REDUCTION
KIT REDUCTION DE PUISSNANCE
A 309 LI - R 317 LI
copyright by
MJF C I F S S
8.45.169
Electric kits
Service Manual
Step 112
Item
Designation
F331**
Fuse X29
S6L
S6R
S379

Switch / release of push button for horizontal adjustment
(right handle)

Right console
X29**
X74**
X407**
X408
X963**
X1048**

Plug connection, 3-pin / button
Right console, rear

Right console, rear
Right console, rear
Right handle
Y365
Y366

Hydraulic tank
Hydraulic tank
15.0 A
8.45.170
A 309 LI - R 317 LI
copyright by
MJF C I F S S
Service Manual
Electric kits
112 A 312 Litronic / A 314 Litronic / A 316 Litronic / R 317 Litronic

BETTIGUNG SCHIEBERSEKTION BER TASTER
VALVE SPOOL ACTUATION WITH PUSH BUTTON
COMMANDE TIROIR DE DISTRIDUTION AVEC BOUTON POUSSOIR
A 309 LI - R 317 LI
copyright by
MJF C I F S S
8.45.171
Electric kits
Service Manual
Step 113
Item
Designation
A1017**
Right console, rear
S6L**
S6R**
S19**
S124
S241**
S451

to switch accessory kit AHS
Rocker button / rotating grapple

Right console
Right console
X952**
X957**
X966**
X1046
X1048
X1179

Right console, rear

Right console, rear
Right console, rear
Y22**
Y23**

Control valve block

Control valve block
8.45.172
A 309 LI - R 317 LI
copyright by
MJF C I F S S
Service Manual
Electric kits
113 A 312 Litronic / A 314 Litronic / A 316 Litronic (IND)

GREIFER DREHEN BER RECHTEN WIPPTASTER
GRAPPLE ROTATOR
MECHANISME DE ROTATION
A 309 LI - R 317 LI
copyright by
MJF C I F S S
8.45.173
Electric kits
Service Manual
Step 114
Item
Designation
F337**
Fuse
S272**
S124
S343
S439L
S439R
Slip-ring case
Switch individual control, back, optional
Undercarriages
X301
X304
X955
X957
X958
X959
X963
X1104
Plug connection, 12-pin / slip rig distribution board

Plug connection, 4-pin / console right

Y56
Y217
Y218
Solenoid valve / blade support, front

Solenoid valve / outrigger support, rear left
Solenoid valve / outrigger support, rear right
Undercarriages
Support cylinders
Support cylinders
15.0 A
8.45.174
A 309 LI - R 317 LI
copyright by
MJF C I F S S
Service Manual
Electric kits
114 A 309 / A 311 Litronic

SCHILDEINZELSTEUERUNG PRATZE
INDIVIDUAL BLADE CONTROL OUTRIGGER
COMMANDE UNIQUE LAME / STABILISATEUR
A 309 LI - R 317 LI
copyright by
MJF C I F S S
8.45.175
Electric kits
Service Manual
Step 115
Item
Designation
A125**
PCB potentiometers
Near hydraulic tank
H344
Indicator light / flow distributor
K375**
K467

Step relay / flow distributor operation
Right console, rear

Right console, rear
S6L
S6R
S464
Left button
Right button
Switch activation / flow distributor operation

Right console
U16**
Right console, rear
V156-4
V177

Blocking diode signal flow reduction / flow distributor
Right console, rear

Right console, rear
X74
X837**
X839**
X856**
X857**
X957**
X965**
X966**
X968-1**
X968-2**
X974-4**
X1048
X1240
X1241
X1242
X1243
X1244

Plug connection, 2-pin / CS flow distributor
Plug connection, 2-pin / CS solenoid valve
Plug connection, 1-pin / CS flow distributor
Plug connection, 2-pin / CS diode
Right console, rear

Right console
Right console
Right console, rear
Right console, rear
Right console, rear
Near hydraulic tank
Near hydraulic tank
Near hydraulic tank
Near hydraulic tank
Near hydraulic tank
Near hydraulic tank
Counter weight
Y295
Y452
Solenoid valve flow distributor

Solenoid valve changeover AHS actuation
Counter weight
Fuel tank
8.45.176
A 309 LI - R 317 LI
copyright by
MJF C I F S S
Service Manual
Electric kits
115 A 309 / A 311 Litronic

MENGENTEILER
FLOW DISTRIBUTOR
DIVISEUR DE DEBIT
A 309 LI - R 317 LI
copyright by
MJF C I F S S
8.45.177
Electric kits
Service Manual
Step 116
Item
Designation
F320**
Fuse X11
S84-1
Push button with plug / central lubrication
U4-1
X11**
X143-1
X963**
X998
X1251

Plug connection, 4-pin / central lubrication system
Plug connection, 4-pin / CS switch
15.0 A
8.45.178
A 309 LI - R 317 LI
copyright by
MJF C I F S S
Service Manual
Electric kits
116 A 309 - R 317 Litronic

ZENTRALSCHMIERANLAGE SEMIAUTOMATISCH
SEMIAUTOMATIC CENTRAL LUBRICATION SYSTEM
DISP. DE GRAISSAGE CENRALISE SEMIAUTOMATIQUE
A 309 LI - R 317 LI
copyright by
MJF C I F S S
8.45.179
Electric kits
Service Manual
Step 117
Item
Designation
B204
Proximity switch stick cylinder shut-down
At stick
F331**
Fuse X29
S216
Button stick cylinder shut-down override
Right console
X29**
X327
X963**
X1254
X1255

Plug connection, 3-pin / button
Right console, rear

Attachments
Right console, rear
Y212
Solenoid valve shut-down stick cylinder
Near hydraulic tank
15.0 A
8.45.180
A 309 LI - R 317 LI
copyright by
MJF C I F S S
Service Manual
Electric kits
117 A 309 - A 311 Litronic

STIELZYLINDERABSCHALTUNG
STICK CYLINDER SHUT-DOWN
ARRET PILOTAGE VERIN BALANCIER
A 309 LI - R 317 LI
copyright by
MJF C I F S S
8.45.181
Electric kits
Service Manual
Step 118
Item
Designation
B21**
Boom cylinder bearing
F331**
Fuse
H16**
H20**
H315
Warning light overload warning system

to indicator light parking brake
Warning light shut-down override
Right console
Right console
Right console
K473
Relay shutdown attachment
Distribution board
S18
S396

Key switch shut-down override
Right console
Right console
V179
V180
Blocking dialog signal / flow distributor control to override

Blocking diode signal / H16 actuation to ground
Left console
Left console
X29**
X407
X953**
X958**
X963**
X1253
X1260
X1261
X1262
X1263

Right console
Right console
Right console
Right console, rear
Right console, rear
Right console, rear
Right console, rear
Right console, rear
Right console, rear
Right console, rear
Y212-1
Y237
Y465
Solenoid valve blocking stick lowering

Solenoid valve blocking stick lifting
Solenoid valve blocking lower boom
Hydraulic tank
Hydraulic tank
Hydraulic tank
15.0 A
8.45.182
A 309 LI - R 317 LI
copyright by
MJF C I F S S
Service Manual
Electric kits
118 A 312 - R 317 Litronic

AUTOMATISCHE ABSCHALTEINRICHTUNG BEI MONOAUSLEGER
AUTOMATIC SHUT-DOWN
INTERRUPTION AUTOMATIQUE
A 309 LI - R 317 LI
copyright by
MJF C I F S S
8.45.183
Electric kits
Service Manual
Step 119
Item
Designation
A133
Left console
B306
Particle filter
E50
Hydraulic tank
F351
Fuse (F_H)
H298
H299
Warning light / exhaust backpressure

Warning buzzer / exhaust backpressure

X20
X1040
X1041
Terminal for kit


Electric box E50
Electric box E50
3A
Electric box E50
8.45.184
A 309 LI - R 317 LI
copyright by
MJF C I F S S
Service Manual
Electric kits
119 A 309 - A 316 Litronic

ARTICLEFILTER PURITECH
FILTRE DE PARTICULES PURITECH
PURITECH PARTICLE FILTER
A 309 LI - R 317 LI
copyright by
MJF C I F S S
8.45.185
Electric kits
Service Manual
Step 120
Item
Designation
A1017
Right control desk
B19L
Sensor transducer
S5L
S5M
S5R
S19
Push button / grapple rotator left

Push button / central option
Push button / grapple rotator right

Right control desk
V181
V182
Amplifier actuation grapple rotation left

Amplifier actuation grapple rotation right

X952
X957
X966
X1046
X1047
X1265


Left control desk
Y22
Y23
Solenoid valve grapple rotator left

Solenoid valve grapple rotator right
Hydraulic tank
Hydraulic tank
8.45.186
A 309 LI - R 317 LI
copyright by
MJF C I F S S
Service Manual
Electric kits
120 A 309 - A 316 Litronic

AS1 / GRIFF MIT 3 TASTEN
AS1 / JOYSTICK WITH 3 SWITCHES
AS1 / MANIPULATEUR AVEC 3 INTERRUPTEURS
A 309 LI - R 317 LI
copyright by
MJF C I F S S
8.45.187
Electric kits
Service Manual
Step 121
8.45.188
Item
Designation
E2L
E2R
E2R2
E150L
E150R
E150R2
Work light, left

Work light, right
Plug connection
Work light, rear left
Work light, rear right
Plug connection
Attachments
Attachments
Attachments
Roof
Roof
Roof
F345
F346
F347
F348
F349
Fuse Xenon roof light

Fuse Xenon headlight front left
Fuse Xenon headlight front right
Fuse Xenon headlight rear left
Fuse Xenon headlight rear right

K420
K421
K422
K423
Relay for Xenon headlight front left

Relay for Xenon headlight front right
Relay for Xenon headlight rear left
Relay for Xenon headlight rear right

MP-E50
Ground bolt in E50 box to A127
Electric box E50
OPT1
Terminal 30 bolt in E50 box to A127
Electric box E50
X1012
X1013/1
X1013/2
X1013/3
X1013/4
X1013/5
X1013/6
X1013/7
X1013/8
X1013/9
X1013/10
X1013/11
X1013/12
Plug connection cab revolving deck / 4-pin

Terminal 4-pin / power supply terminal 30
Terminal 4-pin / power supply terminal 30
Terminal 4-pin / actuation for E2
Terminal 4-pin / actuation for E150
Terminal 4-pin / power supply E2 L
Terminal 4-pin / power supply E2 R
Terminal 4-pin / power supply E150 L
Terminal 4-pin / power supply E150 R
Terminal 4-pin / ground E2
Terminal 4-pin / ground E150
Terminal 4-pin / ground supply
Terminal 4-pin / ground supply
Revolving deck
Revolving deck
Revolving deck
Revolving deck
Revolving deck
Revolving deck
Revolving deck
Revolving deck
Revolving deck
Revolving deck
Revolving deck
Revolving deck
Revolving deck
A 309 LI - R 317 LI
copyright by
MJF C I F S S
Service Manual
Electric kits
121 A 309 - A 316 Litronic

XENON - SCHEINWERFER
XENON HEADLIGHTS
PHARES - XENON
A 309 LI - R 317 LI
copyright by
MJF C I F S S
8.45.189
Electric kits
Service Manual
8.45.190
A 309 LI - R 317 LI
copyright by
MJF C I F S S
Service Manual

Function

1 Function
The LIEBHERR hydraulic excavator generation of the Litronic series is equipped with an electrical
BST excavator control system and the associated units and elements.
The BST (U16) excavator control system controls the diesel engine, the hydraulic pump, the monitoring function as well as the storage of the error codes.
The BST control performs the following functions for the control of the machine:
Pre-heating control of the diesel engine
Recording and control of the diesel engine speed
Recording of the nominal value of the diesel engine speed
Electrohydraulic speed adjustment
Sensor control / idle automatic
Warm-up phase of diesel engine
Control of hydraulic fan
Horsepower control
Limitation of pump delivery volume
Monitoring of system sensors and actuators
Saving of error messages generated by the monitoring function of the system sensors
Fig. 1
20

Eprom (program version (V1.2 - V5......)
U16
copyright by
MJFCIFSS
Excavator control system
8.70.1
Service Manual
Description
2 Description
The BST (U16) is installed in the right console on the operator's platform.
The outputs and inputs of the BST are connected to the following components:
Control console (push button, indicator lights and plug-in board)
B2 Transducer / coolant temperature
B3 Switch / coolant level
B8 Transducer / hydraulic oil temperature
B16 Transducer / engine oil pressure
B285Transducer / hydraulic oil temperature (fan control)
Y50 Proportional solenoid valve / power control
Y51 Prop. valve / volume control
Y352 Proportional valve of hydraulic fan control
Y358 Prop. valve hydraulic speed adjustment
The listed items are installed in the diesel engine, the radiator, the right console, the hydraulic and
fuel tanks as well as the control oil unit, see Fig. 2.
8.70.2
A127
printed circuit board / power
R76
B2
Temperature sensor / engine coolant U16
B3
Transducer / coolant level
B8
B12
Transducer / engine speed
Y51

limitation
B16
Y352
B285
Transducer / hydraulic oil temperature (fan control)
Y358
Proportional solenoid valve / fan

control
Proportional solenoid valve / engine
speed
R75
Potentiometer for speed adjustment

(A 312 - R 317 only)
X10-X967 Plug connections between U16

and the individual components
Y50
control
copyright by
MJFCIFSS
Service Manual

Description
Fig. 2
Connections of BST
copyright by
MJFCIFSS
8.70.3
Service Manual
The BST controls or monitors the following functions, (see "Connections of BST", page 3).
3.1
Pre-heating control of the diesel engine

The glow-plug indicator light H11 and the glow-plug relay K302 are controlled by the coolant temperature sensor (B2).
During the pre-heating time, the glow-plug relay K302 is actuated and the glow-plug indicator light
H11 is on.
Pre-heating time:
Coolant temperature tK > 0C = 6 sec.
Coolant temperature tK < 0C = 6 sec. + 0.3 x tK
Example:
Coolant temperature tK = - 20C
6 sec. + 20 x 0.3
6 sec. + 6 sec. = 12 sec.
The pre-heating time is followed by the switch-off time. During the switch-off time, the relay K302
drops off and the indicator light H11 is off.
Switch-off time:
Coolant temperature < 0C = 18 sec.
Coolant temperature > 0C = 16 sec. + 0.3 x tK
Example:
6 sec. + 20 x 0.3
6 sec. + 6 sec. = 12 sec.
The switch-off time is followed by the post glow time. During the post glow time, the relay K302 is
actuated.
Post glow time:

Coolant temperature tK < 0C = 99 sec. + 4 x tK
Example:
99 sec. + 20 x 4
99 sec. + 80 sec. = 179 sec.
Coolant temperature tK > 0C = 99 sec.- 1.6 x tK

99 sec. + 20 x 1.6
3.2
99 sec. + 32 sec. = 67 sec. 1 min
Warm-up phase of the diesel engine

The warm-up phase of the diesel engine is controlled on the basis of the measured diesel engine
coolant temperature (B2). If the coolant temperature at the start is < 20C, the BST requires minimum
speed step 3. During this period, the operator can however select a higher speed step.
The warm-up phase of the diesel engine is terminated as soon as the coolant temperature is> 0C or
when the set maximum phase time (3 minutes) has lapsed.
8.70.4
copyright by
MJFCIFSS
Service Manual

Fig. 3
3.3
Components of the pre-heating control system
A127
H11
Pre-heating indicator light
B2
K302
Pre-heating relay
Recording and control of the diesel engine speed

The speed sensor B12 at the diesel engine transmits the actual diesel engine speed as a frequency
value to the BST.
With the potentiometer R75, located at the control console, the diesel engine speed can be set by the
operator to 9 different speed steps.
With certain working functions, the speed is automatically controlled by the BST, see 3.4 and 3.5.
The speed steps can be displayed in the service menu on a laptop.
The diesel engine speed is adjusted through the Bowden cable and the speed adjusting lever by the
35 electrical proportional solenoid valve Y358 and the hydraulically connected control cylinder 10,
see Fig. 4.
Each speed step is assigned a specific speed, which in turn corresponds to a specific frequency or
current respectively.
3.3.1
Speed steps of models A 309 - A 311:

Speed
step
Speed
(without load)
Frequency
Current from
BST version 5.11
860 rpm
1849 Hz
400 mA
1010 rpm
2162 - 2182 Hz
425 mA
1170 rpm
2506 - 2526 Hz
450 mA
1330 rpm
2850 - 2870 Hz
475 mA
1490 rpm
3194 - 3214 Hz
520 mA
1650 rpm
3538 - 3558 Hz
565 mA
1810 rpm
3882 - 3902 Hz
625 mA
copyright by
MJFCIFSS
8.70.5
Service Manual
3.3.2
3.4
Speed
step
Speed
(without load)
Frequency
Current from
BST version 5.11
1950 rpm
4226 - 4246 Hz
685 mA
2120rpm
4558 Hz
820 mA
Speed steps of models A 312 - R 317:

Speed
step
Speed
(without load)
Frequency
Current to
BST version 1.2
Current from
BST version 1.3
860 rpm
1849 Hz
350 mA
400 mA
1050 rpm
2220 - 2268 Hz
380 mA
425 mA
1220 rpm
2613 - 2633 Hz
410 mA
450 mA
1360 rpm
2914 - 2934 Hz
440 mA
475 mA
1500 rpm
3215 - 3235 Hz
490 mA
520 mA
1630 rpm
3495 - 3515 Hz
540 mA
565 mA
1750 rpm
3753 - 3773 Hz
600 mA
625 mA
1840 rpm
3946 - 3966 Hz
670 mA
685 mA
1925 rpm
4128 Hz
780 mA
820 mA
Speed adjustment / working mode (only valid for A 309 / A 311, from software
version 5.12)
In the above models, the regulating speed and thus the upper idle speed (speed without load) are
lowered during work by means of the switch S35 (servo ON). When the switch S35 is in this position,
the automatic engine speed adjustment cannot exceed speed step 8.
This means that the maximum speed of the diesel engine = upper idle speed, and the maximum regulating speed (see 3.8.1 / 3.8.2 and adjustment protocols in group 6) can only be reached, if the
switch S35 is in position "servo OFF".
3.5
Speed adjustment / magnet system

The switch S46 of the magnet system affects the speed step of the diesel engine through the electrohydraulic speed adjustment as follows:
Magnet system off:
Speed can be selected with R75
Magnet system on:
Speed step 8
8.70.6
copyright by
MJFCIFSS
Service Manual

Fig. 4
3.6
Speed adjustment
10
35
Regulating cylinder / engine speed

Speed adjusting lever
B12
S46
Transducer / engine speed

Magnet system switch (only in A 316
industrial model)
50
Bowden cable
R75
Y358
Potentiometer / speed adjustment

speed
Control of hydraulic fan

The hydrostatic fan drive is controlled by the hydraulic oil temperature B285, the coolant temperature
B2 and the air-conditioning system. The fan speed is controlled electronically, relative to the temperature, through the proportional solenoid valve Y352.
Design and function of the fan control system, see group 7.20
copyright by
MJFCIFSS
8.70.7
Service Manual
Fig. 5
B2
B285
3.7
Components of the fan control system

Y352
Proportional solenoid valve / fan

control
Transducer / hydraulic oil temperature/ fan control
Sensor control (idle automatic)

The function can be activated with the sensor control switch S20.
Sensors in the joystick and the foot pedals:
Capacitive handle sensor in right joystick B19R
Capacitive handle sensor in left joystick B19L
Inductive proximity switch in foot pedal (travel) B40 (only in A models)
Inductive proximity switch in right pedal (travel) B40R (only in R models)
Inductive proximity switch in left pedal (travel) B40L (only in R models)
Inductive proximity switch in right pedal (attachment kit) B291
Inductive proximity switch in left pedal (attachment kit) B290
These sensors are used to adjust the speed for travel, the slewing gear, the attachment and the kit
to a preset speed step defined by means of the nominal speed potentiometer R75, when the hydraulic
circuits are activated and provided that the sensor control is switched on.
While the magnet system is switched on, the sensor control is disabled.
8.70.8
copyright by
MJFCIFSS
Service Manual

Fig. 6
3.8
Components of the sensor control
in A models
B290
B19R
Capacitive right handle sensor
B291
B19L
B40
Capacitive left handle sensor

Inductive proximity switch in foot pedal
(travel)
S20
R75
Sensor control switch

B40R

(travel)
in R machines only
B40L

(travel)
Inductive proximity switch in left foot

pedal (kit)
Inductive proximity switch in right foot
pedal (kit)
Horsepower control / power control

The power is controlled with a digital PID regulator. The current values of the PID regulator are used
to control the current fed to the proportional solenoid valve Y50.
The solenoid valve Y50 located at the control oil unit controls the oil flow and thus the control pressure
to the regulating valve of the variable-displacement / double variable-displacement pump.
Depending on the speed step and the actual load of the diesel engine, the horsepower control adjusts
the preset regulating rpm.
copyright by
MJFCIFSS
8.70.9
Service Manual
The regulating speed can be adjusted in the service menu.
The following parameters are required for the pump performance control (in CAN mode):
Number of teeth (to determine the speed in rpm)
Regulating speed values of steps 1 to 9
3.8.1
3.8.2
3.9
Regulating speeds in model A 309 / 311

Speed
step
Speed
(without load)
Regulating rpm
Reduction
860 rpm
940 rpm
0 rpm
1050 rpm
940 rpm
100 rpm
1220 rpm
920 rpm
300 rpm
1360 rpm
1010 rpm
350 rpm
1500 rpm
1200 rpm
300 rpm
1630 rpm
1360 rpm
270 rpm
1750 rpm
1500 rpm
250 rpm
1940 rpm
1640 rpm
200 rpm
2120 rpm
1780 rpm
145 rpm
Speed steps of models A 312 - R 317:

Speed
step
Speed
(without load)
Regulating rpm
Reduction
860 rpm
940 rpm
0 rpm
1010 rpm
940 rpm
70 rpm
1170 rpm
1000 rpm
170 rpm
1330 rpm
1060 rpm
170 rpm
1490 rpm
1320 rpm
170 rpm
1650 rpm
1480 rpm
170 rpm
1810 rpm
1640 rpm
170 rpm
1950 rpm
1780 rpm
170 rpm
1925 rpm
1755 rpm
170 rpm
Limitation of pump delivery volume

Certain work, such as the production of a fine subgrade, and certain attachments such as hammers,
pile drivers, etc. requires specific volumetric settings, that are lower than those produced during normal machine operation. Otherwise, the precision work cannot be completed and the attachments
cannot be operated properly.
The reduction of the pump flow volumes can be controlled by means of two different signals:
for all working movements (chassis, slewing gear and equipment)
by means of the switch S382 and the fine adjust potentiometer R76 (only available in model A 312
- R 317)
For additional movements only (e.g. hydraulic hammer kit AHS11)
by means of the switch S241, the proximity switch B291 and the potentiometer P1, P2 or P3.
The volumetric flow generated by the BST is fed to the proportional solenoid valve Y51. The solenoid
valve Y51 reduces the control pressure to the AS regulator of the pump relative to the actual flow rate,
thus reducing p in the pump circuit.
8.70.10
copyright by
MJF C I F S S
Service Manual

3.9.1
Low flow rate
small
p reduction
normal
High flow rate
large
p reduction
low
p in system
p in system
maximum pump flow rate

minimum pump flow rate
Fine adjustment (for A 312 - R 317 only)

The fine adjustment function is activated/deactivated by means of the switch S382. When the fine
adjustment function is on, the indicator light H307 is also on.
The pump flow rate can be steplessly adjusted by means of the potentiometer R76.
Note!
Fine adjustment is only available in model A 312 R 317.
3.9.2
Flow reduction through kit

The pump flow rate can be further reduced by activating the respective limitation function with the
inductive proximity switch B291 and adjusting the flow rate with the potentiometer P1 / P2 / P3.
For a description of the function and settings of the flow reduction, see flow reduction in group 16.19
or 16.20 respectively.
copyright by
MJF C I F S S
8.70.11
Service Manual
Fig. 7
8.70.12
Components of the fine adjustment / flow reduction system
A125
Potentiometer board
R76

(A 312 - R 317 only)
B291
Inductive proximity switch in right foot

pedal (kit)
S241
Switch AHS 11 / AHS 12 accessory kit
H307
Indicator light p - reduction

(A 312 - R 317 only)
S382
Fine adjustment switch

(A 312 - R 317 only)
P1
Flow limitation potentiometer
Y50

control
P2
Y51

limitation
P3
copyright by
MJFCIFSS
Service Manual

3.10
Monitoring of system sensors and actuators

The sensors and actuators of the BST excavator control system are continuously monitored. In the
event of a fault or failure, the respective fault signals are recognised and stored.
3.10.1
Plug connection X838-1 (service interface)

It is possible to connect a laptop to the interface X838-1 on the printed circuit board A125 to read the
fault messages in the form of fault codes from the system,(see 3.11, page 14).
The interface can also be used by authorised personnel (service staff) to check and adjust the parameters of the excavator control system.
3.10.2
Indicator light H301

The indicator light H301 installed near the printed circuit board A125 indicates whether a fault or error
occurred in the excavator control system.
Light off = no fault/error
Light flashing = minor faults/errors
Light continuously on = serious faults/errors
Fig. 8
Printed circuit board A125 with service interface and fault indicator light
A125
Potentiometer board
X838-1 Plug connection, 9-pin

service interface
H301
Indicator light/ fault/error in BST
copyright by
MJFCIFSS
8.70.13
Service Manual
3.11
Monitoring function of system sensors and actuators

The following sensors and actuators are monitored by the BST excavator control system. In the event
of a fault or failure, the respective fault messages are generated and stored.
In the event of an input or output error, the status LEDs (BST-MAIN, H1 earth contact-H4) and the
fault indicator light H301 are actuated (continuously on or flashing).
If there are not fault messages, the status LEDs H1, H2, H3, H4 of the BST flash in sequence (clockwise).
Error code
Sensor / actuator
Cause / switching status
Error LED
Status LED
007
Cooling water temperature sensor
Short to earth
continuous
008
Short to plus
continuous
009
Wire break
continuous
Response to fault:
- The time of the pre-heating control is set to the maximum values.
- The fan control output is actuated with lmin (max. fan speed)
013
Hydraulic oil temperature sensor
Short to earth
continuous
014
Short to plus
continuous
009
Wire break
continuous
Response to fault:
- The fan control output is actuated with lmin (max. fan speed)
8.70.14
022
Diesel engine speed sensor
Short to earth
continuous
023
Short to plus
continuous
024
Wire break
continuous
027
LR1 amplifier
Wire fault
continuous
036
Delta-P1 amplifier
Wire fault
continuous
039
HDV amplifier
Wire fault
continuous
045
LST amplifier
Wire fault
continuous
066
067
Speed adjustment potentiometer

Fine adjustment potentiometer
Wire fault
Wire fault
continuous
flashing
422
423
Left handle sensor

Left handle sensor
Short to plus
Wire fault
flashing
flashing
445
446
Right handle sensor

Right handle sensor
Short to plus
Wire fault
flashing
flashing
501
Engine oil pressure switch
Switch actuated
continuous
502
Coolant level switch
Switch actuated
flashing
503
Coolant temperature switch
Switch actuated
flashing
copyright by
MJFCIFSS
Service Manual

Error code
Sensor / actuator
Cause / switching status
Error LED
Status LED
Error code 503 is currently deduced from the temperature sensor signal (coolant
temperature) (switching point 105 C.)
505
Hydraulic oil temperature switch
Switch actuated
511
Supply voltage + UB
Overvoltage >30V
513
Fan switch
Switch actuated
copyright by
MJFCIFSS
flashing
flashing
8.70.15
Service Manual
8.70.16
copyright by
MJFCIFSS
Service Manual

Function

1 Function
Machines with electrical equipment in the undercarriage (e.g. pressure switches, solenoid valves,
angle sensors, etc.) must be equipped with a special rotary connection for electrical power from the
uppercarriage to the undercarriage.
This slip ring rotary connection is screw-mounted to the 6x oil rotary connection.
Depending on the requirements regarding the rotary connection, a varying number of slip rings/contact brackets and microswitches are installed.
Fig. 1
copyright by
MJFCIFSS
8.80.1
Service Manual
Design
2 Design
The base flange 3, adapter ring 1 and the associated slip rings 6/9/10 are fixed to the stator of the oil
rotary connection and thus permanently fixed to the undercarriage.
The bearing washer 2 with the contact bracket holder 14, the shim 3 and the contact bracket 11/12
is fixed to the rotor of the oil rotary connection, and thus permanently fixed to the uppercarriage.
The bearing between the stationary base flange 3 and the rotating bearing disk 2 consists of deep
groove ball bearings 25.
The slip rings 6/9/10 is equipped with the microswitch attachment 19 and the angle sensor 39 of the
swivel angle limitation (optional).
The hood 4 and the hood pipe 7 with the O-ring 24 protect the slip ring against physical impact and
contamination.
Fig. 2
8.80.2
Slip ring rotary connection in uppercarriage
copyright by
MJFCIFSS
Service Manual

Design
Fig. 3
Exploded view of slip ring rotary connection
Adapter ring
23
Forcing screw
2
3
Bearing washer (base plate)

Base flange
24
25
O-ring
Hood, glued to hood pipe 7
26
Lock washer
5
6
Ring
Slip ring
27
28
Snap ring
Snap ring
7
8
Hood pipe
Threaded cable gland
29
30
Lock washer
Hex nut
9
10
Insulating ferrule
Slip ring
31
32
Holding plate of potentiometer

Notch ring
11
Contact bracket, gold-plated
33
Washer with chamfer
12
Contact bracket, nickel-plated
35
Hexagon cap nut
13
Shim
37
Washer
14
15
Contact bracket holder

Cover plate
39
42
Angle gauge (optional)

Pipe
17
18
Threaded rod
Threaded rod
43
45

Threaded rod
19
Threaded rod
50
Hex nut
22
Microswitch attachment
55
Hex nut
copyright by
MJFCIFSS
8.80.3
Service Manual
The current is fed from the uppercarriage to the undercarriage and vice versa through the electrical
lines that are connected to the contact brackets 11/12 and the slip rings 6/9/10 respectively.
All contact brackets 11/12 are permanently pressed against the associated slip rings 6/9/10, irrespective of the position of the uppercarriage to the undercarriage, thus providing an electrical connection
between the units in the uppercarriage and the undercarriage.
Note!
The cable assignment of the individual slip rings/contact brackets is shown in the wiring diagram in
group 8 and the diagram below.
8.80.4
copyright by
MJFCIFSS
Service Manual

Maintenance
4 Maintenance
Caution!
The slip ring body is easily damaged by humidity, as an oxidant layer might form on the conducting
surfaces, impairing the conductivity. As a result, the electrically powered units located in the undercarriage are not supplied with sufficient power. This can lead to malfunctions.
Regularly apply Cramolin contact spray to the slip ring contact surface (see inspection and
maintenance schedule of group 3.), see also group 1.50.
Hold the nut 35 and loosen the hexagon nut 30.
Remove the hood 4 with the hood pipe.
Remove oxidation from the slip ring body.
Remove damaged (corroded) fork terminals.
Spray Cramolin contact spray onto the slip ring contact surfaces.
Mount the hood 4 with the hood pipe and secure it with the nuts 30 (hold nuts 35).
Fig. 4
4.1
Electrical connections
4
30
Hood
Hex nut
35
Hex nut
X301
Plug connection slip ring / 12-pin
Adjustment of the angle sensor 39 (optional)

Note!
For a detailed description of the angle sensor 39 settings, see the respective kit.
copyright by
MJFCIFSS
8.80.5
Service Manual
Maintenance
8.80.6
1
2
Adapter ring
Bearing washer (base plate)
23
24
Forcing screw
O-ring
3
4
Base flange
Hood with hood pipe
25
26

Lock washer
Ring
27
Snap ring
6
8
Slip ring
28
29
Snap ring
Lock washer
Insulating ferrule
30
Hex nut
10
Slip ring
31
Holding plate of potentiometer
11
32
Notch ring
12
33
Washer with chamfer
13
Shim
35
Hexagon cap nut
14
15
Contact bracket holder

Cover plate
37
39
Washer
Angle sensor (optional)
16
17
Back-up washer
Threaded rod
42
44
Brass pipe
Brass pipe
18
20
Threaded rod
FGR pipe
45
46
Threaded rod
Washer
21
Countersunk screw
55
Hex nut
22
Microswitch attachment
copyright by
MJFCIFSS
Service Manual

Maintenance
Fig. 5
Sectional drawing of slip ring
copyright by
MJFCIFSS
8.80.7
Service Manual
Maintenance
Fig. 6
40
Contact pin
11
12

41
43
Plug
34
Flat adapter
Fig. 7
8.80.8
Section A-A Slip ring rotary connection
Section B-B Slip ring rotary connection
copyright by
MJFCIFSS
Service Manual
Directory of electric kits

Chapter
Group
Type
Blockage 2nd gear
8.101
A 312 - A 316
Function travel left / SF function right
8.102
A 312 - A 316
Travel alarm system
8.103
A 312 - A 316
Blade support front / rear
8.104
A 312 - A 316
Dozer blade with 4-point support
8.105
A 312 - A 316
AHS12 with tool control
8.106
A 312 - A 316
Changeover high lateral in left handle
8.107
A 312 - A 316
Changeover high lateral in left handle
8.108
A 312 - A 316
Turning grapple in handle left and right
8.109
A 312 - A 316
Stroke limitation boom and stick

Bridging button in left handle
8.110
A 312 - A 316
Mower rake
8.111
A 312 - A 316
Auxiliary heating
8.112
A 312 - A 316
copyright by
MJF C I F S S
8.100.1
Service Manual
8.100.2
copyright by
MJF C I F S S
LIEBHERR HYDRAULIKBAGGER GMBH
PROJEKT:
103281525_2_bs_hoch_seitl_im_linken_griff
/4.A6
/5.A3
PROJEKT:
-F330.A
-F331.A
-F330.E
-F331.E
/5.F4
-F337.E
/3.C8
PROJEKT:
-MP/VP.X3
PROJEKT:
/2.E6
A126
PROJEKT:
/2.E6
/2.E6
PROJEKT:
PROJEKT:
Service Manual
SUBGROUP - INDEX
Section
Group
Type
9.10.1
Slewing gear brake
9.20.1
Slewing gear brake
9.24.1
R 313 LI 27752R 317 LI 18161-
9.1
MJF C I F S S
Service Manual
9.2
MJF C I F S S
Service Manual

Function and design

The slewing gear mechanism, through the attached output shaft and the internally toothed slewing
ring, moves the uppercarriage against the undercarriage of the machine.
The two-stage planetary gear is driven by the FMF hydraulic oil motor to which it is connected with a
flange.
The wet multi-disc brake integrated into the gearbox acts directly onto the gear drive. The brake is
designed as a spring applied brake and is released hydraulically, i.e. when the brake system is not
pressurised, the discs are pressed together by the pressure springs, so that the brake is mechanically
applied.
The pinion of the slewing gear mechanism is encased in a nearly tight housing containing a grease
reserve for the gear greasing of the slewing ring.
If regularly greased according to the maintenance schedule, the reserve is sufficiently topped up to
adequately lubricate the parts.
Fig. 1
Slewing gear mechanism with oil tank
13
Oil tank
110
17
Pinion / output shaft
155
Lubrication line / lubrication system
26
Grease cap
960
Brake discs / multi-disc brake
97
Oil motor / slewing gear motor
copyright by
MJF C I F S S
9.10.1
Service Manual
Technical data
2 Technical data
Machine
from serial number
A 309 - A 311
Litronic
20221
Gearbox type
Sat 225 / 240
A 312
Litronic
12363
SAT 225 /
228
R 317
Litronic
18161
SAT 225 / 218
21720 min-1
Max. drive speed

Max. output torque
5600 Nm
Gear ratio
1: 31.7
Weight (approx.)
130 kg
4.5 l
Oil quality
API - GL - 5
Oil viscosity
(with positioning brake
actuated with foot pedal)
SAE 80 W 90 / SAE 90 W
(SAE 90 LS)
Brake
Hydraulically released multi-disc brake
Min. release pressure
20 bar
Max. release pressure
33 bar
Tab. 1
A 314 - A
316 Litronic
2001
R 313
Litronic
27752
Technical data
Settings and tightening torques, to be observed for installation:

A)
Checking measurement of the sun gear 5

(to upper edge of the gearbox)
93.5+0.5mm
B)
Friction torque of tapered roller bearing 57 / 58
20-25 Nm
C)
Tightening torque of Allen head screws 60
49 Nm
D)
190 Nm
E)
Tightening torque of hex head screws 62
195 Nm
F)
117 Nm
G)
280 Nm
Tab. 2
9.10.2
Settings and tightening torques
copyright by
MJF C I F S S
Service Manual

Function of slewing gear
3 Function of slewing gear

see Fig. 6
The input torque is transferred from the hydraulic oil motor 97 to the sun gear 5. Through the planetary gears 10 and the planetary carrier 15, the sun gear 5 drives the sun gear 6 at the oil motor speed
geared down by planetary stage I.
Through the planetary gears 11 and the planetary carrier 16, the sun gear 6 drives the output shaft
17 at the oil motor speed geared down by planetary stage II.
The total speed reduction is based on the gearing down of both planetary stages.
As the output speed is reduced, the output torque is increased accordingly.
3.1
Function of lubricating system
Fig. 2
Output pinion / slewing ring lubrication system at slewing ear
Housing
150
Lubricant hose
26
146
Grease cap
Distribution block
153
Lubrication nipple
The grease cap 26 on the housing 2 covers the pinion of the drive shaft all the way to the connection
of the slewing ring. The cap 26 is filled with grease through the lubrication nipple 153 of the distribution block 146 of the lubrication system and the lubricant line 150. Every time the uppercarriage is
rotated, grease is applied to the gearing of pinion and slewing ring.
copyright by
MJF C I F S S
9.10.3
Service Manual
Maintenance
4 Maintenance
4.1
Maintenance of the gearbox

The gearbox must be serviced regularly at the intervals laid down in the maintenance instructions for
group 3. The regular maintenance work includes a check of the oil level, inspection for leakage and
check of the gearbox and oil motor for proper mounting. The gear oil must be replaced at prescribed
intervals.
4.2
Maintenance of the lubricating system

The grease packing in the grease cap is replaced or replenished automatically at defined intervals
from the central lubrication system, see maintenance instructions for group 3.
5 Installation and dismantling of the slewing gear mechanism

see Fig. 3
Fig. 3
9.10.4
Gear oil tank with oil drain valve

Fit bore of the slewing gear in the upper carriage
1
13
Hydraulic tank
Oil tank
119
135
Slewing gear
Valve
110
Slewing gear
136
Protective cover
115
Allen head screw
138
Oil drain hose (included in the machine

toolbox)
copyright by
MJF C I F S S
Service Manual

Repair of the gear system
118
5.1
Uppercarriage
Dismantling, see Fig. 3

Place assembly onto the floor.
Release the tank pressure.
Before you start dismantling, release all pressure from the control oil and brake lines.
Remove the protective cap 136 of the drain valve 135.
Connect the oil drain hose 138 (included in the machine toolbox) through the access bore of the
revolving deck onto the drain valve 135 and drain the gear oil into a suitable container.
Remove the oil drain hose 138 and replace the protective cap of drain valve 135.
Remove the parts and hydraulic lines that impede the dismantling of the gearbox.
Disconnect all leak oil, lubrication and brake lines at the oil motor and gearbox.
Remove the screws 115 and lift the gearbox from the uppercarriage, using suitable lifting tackle.
5.2
Installation, (see Fig. 3 on page4)

Apply anti-corrosion grease (Optimol Paste White ID no. 8500307) to the area around the lower
centring device and the centring surface of the gearbox in the revolving deck (see Fig. 3).
Observe correct position for oil discharge.
Lift the gearbox into the uppercarriage.
Insert the screws 115 and tighten them with the prescribed torque.
Connect the leak oil, lubrication and pressure lines to the gearbox and oil motor.
Remove the lid of the oil tank 13 and fill the tank with the correct oil product (see lubricant table
for group 1) until the "Max." mark at the tank is reached.
Close the oil tank 13.
Check the gearbox for leakage and complete a function test.
Check the pinion engagement in the slewing ring.
Add grease through the lubrication nipple 153.
Replace or replenish grease packing of the slewing ring.
Check lubrication of gearing.
6 Repair of the gear system

The repair procedures are described in the separate repair manual
"SAT 225 - 350".
7 Sealing gearbox
7.1
Sealing of drive motor section

The work described below can be completed while the gearbox is mounted.
copyright by
MJF C I F S S
9.10.5
Service Manual
Sealing gearbox
Remove all lines that impede access to the gearbox.
The leak oil and control lines at the oil motor may remain connected.
Remove the screws 62 and lift the oil motor from the gearbox.
Remove the O-ring 98.
Prior to the installation, clean all parts to be reused and inspect them carefully for damage.
Apply a little grease or oil to the O-ring 98 before installing it.
Insert the O-ring 98 into the groove of the oil motor 97.
Place the oil motor 97 in the gearbox.
Insert the screws 62 and tighten them with the prescribed tightening torque, see Tab. 2.
Fig. 4
62
97
Oil motor with seals and fixture attaching it to the slewing gear mechanism
98
115
Hex head screw

Oil motor
O-ring
Allen head screw
For installation, observe the tightening torques E and G, (see Tab. 2 on page2).
7.2
Sealing of the multi-disc brake

For detailed instructions regarding the above sealing work, refer to chapter "Repair of brake" in group
9.20 "Slewing gear brake".
7.3
Sealing of output area in the gearbox

To seal the output side of the gearbox (radial shaft seal rings and Nilos ring), it is necessary to fully
dismantle the gearbox. For repair instructions, see document "SAT 225 - 350".
9.10.6
copyright by
MJF C I F S S
Service Manual

Exploded view of the gearbox
8 Exploded view of the gearbox

2
5
Output shaft
Sun gear
60
61
Allen head screw

Allen head screw
Sun gear
62
Hex head screw
10
11
Planetary gear
Planetary gear
63
64
Allen head screw

Retaining washer
15
Planetary carrier
65
Retaining washer
16
Planetary carrier
66
Retaining washer
17
Output shaft
70
Snap ring
20
Sun wheel
71
Snap ring
25
Brake housing
73
Snap ring
26
30
Grease cap
Annular piston
82
83
O-ring
O-ring
31
35
Locking ring
Thrust plate
84
86
O-ring
Fitting
36
37
Inner disc
Outer disc
88
89
Lip seal
Lip seal
40
Disc carrier
90
43
Pressure spring
91
Nilos ring
44
Pressure spring
92
Screw-in stud
45
46
Stop washer
Stop washer
93
94
Fitting
Plug
47
49
Slotted nut
Washer
98
900
Screw-in stud
Repair kit / brake
57
910
Seal kit / swing drive
58
960
Brake disc set
copyright by
MJF C I F S S
9.10.7
Service Manual
Fig. 5
9.10.8
copyright by
MJF C I F S S
Service Manual

Sectional drawing of the gearbox
9 Sectional drawing of the gearbox

2
Output shaft
60
Allen head screw
Sun gear
61
Allen head screw
Sun gear
62
Hex head screw
10
11
Planetary gear
Planetary gear
63
64
Allen head screw

Retaining washer
15
Planetary carrier
65
Retaining washer
16
Planetary carrier
66
Retaining washer
17
20
Output shaft
Sun wheel
70
71
Snap ring
Snap ring
25
Brake housing
73
Snap ring
26
30
Grease cap
Annular piston
82
83
O-ring
O-ring
31
35
Locking ring
Thrust plate
84
86
O-ring
Fitting
36
37
Inner disc
Outer disc
88
89
Lip seal
Lip seal
40
Disc carrier
90
43
44
Pressure spring
Pressure spring
91
92
Nilos ring
Screw-in stud
45
46
Stop washer
Stop washer
93
94
Fitting
Plug
47
49
Slotted nut
Washer
98
900
Screw-in stud
Repair kit / brake
57
910
Seal kit / swing drive
58
960
Brake disc set
Observe the settings and tightening torques A - F for the installation, (see Tab. 2 on page2).
copyright by
MJF C I F S S
9.10.9
Service Manual
Sectional drawing
10
Sectional drawing
Fig. 6
9.10.10
Sectional drawing of slewing gear mechanism
copyright by
MJF C I F S S
Service Manual
Slewing gear brake

Design of the slewing gear brake
Slewing gear brake

1 Design of the slewing gear brake
The slewing gear brake is designed as a holding and parking brake. Thanks to the progressive control
characteristics of the brake valve, the brake can also be used as a positioning brake for the continuous
slowing down of the uppercarriage. This results of course in increased wear of the multi-disc brake. It
is therefore recommended to slow down the uppercarriage by means of counter-pressurisation.
1.1
Multi-disc brake
The brake is integrated into the slewing gear mechanism and is applied to the gear drive.
It consists of a hydraulically operated wet multi-disc brake. The brake discs 36 / 37 are mechanically
pressed together by the preload of the pressure springs 43 / 44. They are released when the annular
piston 30 is pressurised with pilot control pressure.
1.2
Brake valve 87
The brake valve 87 with the pedal is located to the left of the steering column in the operator's cab.
87
50
88P
25
As the pressure in the chamber K is built up gradually through the brake valve 87 and the collecting
pipe 88T to the tank, the brake is mechanically closed.
Fig. 1
Brake valve in the operator's cab and multi-disc brake in the slewing gear
25
Brake housing/slewing gear brake
43
Pressure spring
30
Annular piston
44
Pressure spring
36
37
Inner disc
Outer disc
87
K
Brake valve with pedal and retainer

Pressure chamber / opening pressure
copyright by
MJF C I F S S
9.20.1
Slewing gear brake
Service Manual
Design of the slewing gear brake
Fig. 2
9.20.2
Components of the slewing gear brake system
50
Control oil unit
88T
Collecting pipe / return oil
87
88P
Brake valve
Distributor / pilot control oil
195
196
Slewing gear brake

copyright by
MJF C I F S S
Service Manual
Slewing gear brake

Function of slewing gear brake system
2 Function of slewing gear brake system

(see 3 on page4) and (see Fig. 2 on page2)
When the brake valve 87 is in neutral position, the pilot control oil flows from the control oil unit 50,
connection A1 and the distributor 88P through the brake valve 87 and the brake connection BR in
the chamber in front of the annular piston 30 of the slewing gear brake. The opening pressure (corresponding to the pilot control pressure) pushes the annular piston 30 upwards against the pressure
springs 43 / 44. This force cancels out the pressure force applied to the brake discs 36/37, so that
the brake is released.
When the pedal of the brake valve 87 is actuated, the line between connection SP of the valve 87
and the connection BR of the slewing gear brake is closed, relative to the pedal travel. When the pedal is pressed down further, the piston in the brake valve 87 opens the line between the connection
BR of the multi-disc brake via the connection T and the collecting pipe 88T to the tank.
The pressure springs 43 / 44 shift the annular piston 30 against the disc pack 36/37. The resulting
pressure force generates the desired braking torque, reducing the rotational speed of the uppercarriage (outlet), i.e. the brake is being closed.
At the end of the pedal travel, the pedal of the brake valve 87 engages in the retainer, so that the
brake remains in the brake position (parking brake).
By reducing the pressure on the pedal of the brake valve or by releasing the retainer with the foot,
the piston in the brake valve 87 slides back into its neutral position, connecting the pressure chamber
K of the brake with the connection A1 of the control oil unit 50, and the brake is released.
Due to the spring force effect, the multi-disc brake has also a safety function:
When the diesel engine is off, and the accumulator of the pilot control circuit is empty (no pilot control
pressure / release pressure), the slewing gear brake is applied automatically. This occurs for example
in the event of a failure of the diesel engine during working operation, or if there is a fault in the pilot
control pressure circuit / pilot control components.
1*
20*
Hydraulic tank
Variable displacement pump
50*
87
Control oil unit

Brake valve
25
30
Brake housing/Slewing gear brake

Annular piston
88P
88T
Distributor / pilot control oil

Collecting pipe / return oil
30*
36
Gear pump / servo control

Inner disc
195
196
Multi-disc brake
37
Outer disc
197
Pedal with return spring and retainer
43
44
Pressure spring
Pressure spring
S7
Y3
Current from safety switch

49
Measuring point pilot / opening pressure
* item of the hydraulic system
copyright by
MJF C I F S S
9.20.3
Slewing gear brake
Service Manual
Hydraulic diagram
3 Hydraulic diagram
9.20.4
copyright by
MJF C I F S S
Service Manual
Slewing gear brake

Repair of brake
4 Repair of brake
Caution!
To repair the brake, the hydraulic circuit and the spring-loaded components must be accessed.
This can lead to serious injury from escaping oil or crushing.
Position the machine on firm and level ground.
Lower the attachment to the ground. This is particularly important, if the machine is standing on
a slope.
Press down the pedal of the brake valve 87, so that it engages.
Release the tank preload.
Depressurise the pilot control/brake system.
4.1
Sealing of brake and replacement of brake discs

Load noises or insufficient brake effect indicate that the brake lining surfaces are worn.
Replace the brake discs without delay.
Note!
We recommend replacing the entire disc pack. The brake can be repaired without dismantling the
gear.
4.1.1
Dismantling of oil motor and the brake housing 25

Remove the mounting bolts of the oil motor and pull the oil motor with the flange-connected hydraulic lines from the gearbox.
Disconnect the brake line from the brake connection at the gear.
Remove the entire brake housing 25 from the sun wheel 20
copyright by
MJF C I F S S
9.20.5
Slewing gear brake
Service Manual
Repair of brake
Fig. 3
4.1.2
Sectional drawing of the brake housing
20
Sun wheel / gear
66
Retaining washer
25
61
Brake housing/Slewing gear brake

Allen head screw
83
O-ring
Dismantling of the brake housing 25

Caution!
The locking ring 31 and the annular piston 30 are spring-loaded.
Improper opening of the brake housing 25 might result in injury from impact and crushing.
Open the brake housing 25 using the matching mounting device.
Proceed as follows:
Place the mounting tool 200 (special tool, see group 2.07) onto the brake housing 25 and push
the annular piston 30 down, using the two screws M16X120 or M16X140 respectively. Ensure that
the force is applied uniformly.
Remove the snap ring 73.
Release the screws uniformly and remove the device 200.
Remove the entire brake piston 30.
Remove the pressure springs 43 / 44, the O-ring 82 and the lip seal 88 from the brake housing 25.
Push the locking ring 31 from the annular piston 30 and remove the lip seal 89.
Remove the front thrust plate 35, the brake discs 36 / 37 and the rear thrust plate 35 from the sun
wheel 20.
4.1.3
Installation of the brake housing 25

see Fig. 5
Mount the lower thrust plate 35 in the sun wheel 20.
9.20.6
copyright by
MJF C I F S S
Service Manual
Slewing gear brake

Repair of brake
Insert the outer and inner discs 37 / 36 one after the other into the gearing of the sun wheel 20
and the disc carrier 40. To do this, proceed as follows:
Outer disc - inner disc - outer disc, etc.
Mount the front thrust plate 35 on the last outer disc.
Apply a little grease to the lip seal 89 and insert it into the locking ring 31.
Apply a little grease to the lip seal 88 and insert it into the brake housing 25.
Apply a little grease to the O-ring 82 and mount it on the brake housing 25.
Press the locking ring 31 into the annular piston 30.
Insert the pressure springs 43 /44 and push the annular piston 30 onto the brake housing 25, applying uniform pressure.
Using the mounting device 200, push the annular piston 30 down.
Top in the snap ring 73 (ensure proper seat).
Release the screws uniformly and remove the mounting device 200.
4.1.4
Mounting of the brake housing 25 and slewing gear motor

Apply a little grease to the new O-ring 83 and insert it in the groove of the brake housing 25.
Insert the complete brake housing 25 into the sun wheel 20 and secure it with the screws 61 and
the washers 66.
Apply a little grease onto the O-ring and insert it in the groove of the oil motor.
Insert the complete oil motor into the gearbox and secure it to the brake housing 25 using the
mounting bolts.
Observe tightening torques (see "General information" for group "Slewing gear mechanism").
Connect the line between the brake valve and the brake connection BR to the gearbox.
Test brake function, (see Function of slewing gear brake system on page 3).
20
Sun wheel / gear
61
25
66
Retaining washer
30
31
Annular piston
Locking ring
73
82
Snap ring
O-ring
35
36
Thrust plate
Inner disc
83
86
O-ring
Screw plug
Allen head screw
37
Outer disc
88
Lip seal
40
Disc carrier
89
Lip seal
43
Pressure spring
92
Plug
44
Pressure spring
200
Mounting device (special tool)
copyright by
MJF C I F S S
9.20.7
Slewing gear brake
Service Manual
Repair of brake
9.20.8
Fig. 4
Sealing and repair kit of the slewing gear brake
Fig. 5
Sectional drawing of the brake housing with mounting tool, rotated by 90
copyright by
MJF C I F S S
Service Manual
Slewing gear brake

Design
Slewing gear brake

The mechanical slewing gear brake is designed as a holding and parking brake. The slowing down
of the uppercarriage is achieved by means of hydraulic counter-pressurisation.
Caution!
When the slewing gear brake is applied, its drive is blocked. When the brake is applied during a
rotating motion, the components of the slewing gear circuit and drive system are exposed to excessive load and might be damaged.
Therefore apply the slewing gear brake only when the uppercarriage is standing still.
1 Design
1.1
Multi-disc brake
The brake is integrated into the slewing gear mechanism and acts on the gear drive.
It consists of a hydraulically operated wet multi-disc brake. The brake discs 36 / 37 are mechanically
pressed together by the preload of the pressure springs 43 / 44. They are released when the annular
piston 30 is pressurised with pilot control pressure.
1.2
Solenoid valve Y7
The solenoid valve Y7 is integrated into the control oil unit 50.
In neutral position, the solenoid valve Y7 connects the chamber K through the port A3 to the tank
(brake applied).
In working position, the solenoid valve connects the chamber K through port A3 to the pilot pressure
oil system (brake released). As a result, the annular piston 30 is pressed by hydraulic forces against
the pressure springs 43/44.
Fig. 1
Slewing gear brake in slewing gear mechanism and solenoid valve at the control oil unit
25
44
Pressure spring
30
Annular piston
50
Control oil unit
36
Inner disc
Pressure chamber / opening pressure
37
43
Outer disc
Pressure spring
Y7
copyright by
MJF C I F S S
9.24.1
Slewing gear brake
Service Manual
Design
1.3
Switch S17
The switch S17 is used to control the slewing gear function (apply-release) through the solenoid valve Y7 :
Switch down = indicator light in switch S17 on = Y7 in idle position = brake applied
Switch up = indicator light in switch S17 off = Y7 powered = brake released
Fig. 2
9.24.2
Components of the slewing gear brake system
Hydraulic tank
195
Slewing gear brake
50
Control oil unit
196
87
Brake valve positioning brake (optional) S17

Y7
copyright by
MJF C I F S S

Service Manual
Slewing gear brake

Design
copyright by
MJF C I F S S
9.24.3
Slewing gear brake
Service Manual
Design
1.4
1.4.1
Function of slewing gear brake system

Standard brake system (switch S7)
(see Fig. 1, page 1) and (see Fig. 3, page 7)
When the switch S17 is in neutral position, the solenoid valve Y7 is powered. The solenoid valve Y7
is switched during flow-through. As a result, pilot control oil from the control oil unit 50 flows through
the connection A3 and the brake connection P into the room in front of the annular piston 30 of the
slewing gear brake. The opening pressure (corresponding to the pilot control pressure) pushes the
annular piston 30 upwards against the pressure springs 43 / 44. This force cancels out the pressure
force applied to the brake discs, so that the brake is released.
If the switch S17 is actuated, the solenoid valve Y7 is now powered and the valve is switched to its
neutral position. As a result, the connection P of the multi-disc brake is connected through the connection A3 and the solenoid valve Y7with the tank.
The pressure springs 43 / 44 shift the annular piston 30 against the disc pack 36/37, producing the
prescribed torque by means of the maximum pressure force. The excavator is now blocked (parking
brake applied).
Due to the spring force effect, the slewing gear brake has also a safety function:
When the diesel engine is off, and the accumulator of the pilot control circuit is empty (no pilot control
pressure / release pressure), the slewing gear brake is applied automatically. This occurs for example
in the event of a failure of the diesel engine during working operation, or if there is a fault in the pilot
control pressure circuit / pilot control components.
1.4.2
Optional brake system (positioning brake through brake valve 87)

For special applications, LIEBHERR offers the "Positioning brake" kit as a slewing gear brake option. In this case, the brake described in section 1.4.1 (with S17 and Y7) is blocked,, i.e. the connection A3 is sealed and the switch S17 at the control desk is deactivated.
The brake valve 87,(see Fig. 2, page 2) that is now in operation controls the positioning, holding and
parking brake of the slewing gear.
For details regarding the design, function and hydraulic diagram are described in detail in group 9.20.
9.24.4
1
25
Hydraulic tank
Brake housing
195
196
Slewing gear brake

29
30
36
Annular piston
Inner disc
F337
S17
Fuse slewing gear brake 15 A

37
Outer disc
X958
43
Pressure spring
X963
44
Pressure spring
X1115
49
Measuring point pilot control / opening

pressure
X1116
50
Control oil unit
Y7
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MJF C I F S S
Service Manual
Slewing gear brake

Hydraulic diagram
2 Hydraulic diagram
copyright by
MJF C I F S S
9.24.5
Slewing gear brake
Service Manual
Repair of brake
3 Repair of brake
Caution!
To repair the brake, the hydraulic circuit and the spring-loaded components must be accessed.
This can lead to serious injury from escaping oil or crushing.
Position the machine on firm and level ground.
Lower the attachment to the ground. This is particularly important, if the machine is standing on
a slope.
Actuate the switch S17 (apply brake).
Depressurise the pilot control/brake system.
3.1
Sealing of brake and replacement of brake discs

Load noises or insufficient brake effect indicate that the brake lining surfaces are worn.
Replace the brake discs without delay.
Note!
We recommend replacing the entire disc pack. The brake can be repaired without dismantling the
gear.
3.1.1
Dismantling of oil motor and the brake housing 25

Remove the mounting bolts of the oil motor and pull the oil motor with the flange-connected hydraulic lines from the gearbox.
Disconnect the brake line from the brake connection at the gear.
Remove the entire brake housing 25 from the sun wheel 20
9.24.6
copyright by
MJF C I F S S
Service Manual
Slewing gear brake

Repair of brake
Fig. 3
3.1.2
Sectional drawing of the brake housing
20
Sun wheel / gear
66
Retaining washer
25
61

Allen head screw
83
O-ring
Dismantling of the brake housing 25

Caution!
The locking ring 31 and the annular piston 30 are spring-loaded.
Improper opening of the brake housing 25 might result in injury from impact and crushing.
Open the brake housing 25 using the matching mounting device.
Proceed as follows:
Place the mounting tool 200 (special tool, see group 2.07) onto the brake housing 25 and push
the annular piston 30 down, using the two screws M16X120 or M16X140 respectively. Ensure that
the force is applied uniformly.
Remove the snap ring 73.
Release the screws uniformly and remove the device 200.
Remove the entire brake piston 30.
Remove the pressure springs 43 / 44, the O-ring 82 and the lip seal 88 with the backing rings from
the brake housing 25.
Push the locking ring 31 from the annular piston 30 and remove the lip seal 89 with the backing
ring.
Remove the front thrust plate 35, the brake discs 36 / 37 and the rear thrust plate 35 from the sun
wheel 20.
3.1.3
Installation of the brake housing 25

see Fig. 5
copyright by
MJF C I F S S
9.24.7
Slewing gear brake
Service Manual
Repair of brake
Mount the lower thrust plate 35 in the sun wheel 20.
Insert the outer and inner discs 37 / 36 one after the other into the gearing of the sun wheel 20
and the disc carrier 40. To do this, proceed as follows:
Outer disc - inner disc - outer disc, etc.
Mount the front thrust plate 35 on the last outer disc.
Apply a little grease to the lip seal 89 and insert it with backing rings into the locking ring 31.
Apply a little grease to the lip seal 88 and insert it with backing rings into the brake housing 25.
Apply a little grease to the O-ring 82 and mount it on the brake housing 25.
Press the locking ring 31 into the annular piston 30.
Insert the pressure springs 43 /44 and push the annular piston 30 onto the brake housing 25.
Using the mounting device, push the annular piston 30 down, applying the force uniformly around
its circumference.
Top in the snap ring 73 (ensure proper seat).
Remove the mounting device.
3.1.4
Mounting of the brake housing 25 and slewing gear motor

Apply a little grease to the new O-ring 83 and insert it in the groove of the brake housing 25.
Insert the complete brake housing 25 into the sun wheel 20 and secure it with the screws 61 and
the washer 66.
Apply a little grease to the O-ring and insert it into the groove of the oil motor.
Insert the complete oil motor into the gearbox and secure it to the brake housing 25 using the
mounting bolts.
Observe tightening torques (see "General information" for group "Slewing gear mechanism").
Connect the lines between the control oil unit connection A3 and the brake connection P.
Test brake function, (see "Function of slewing gear brake system", page 4)
9.24.8
20
25
Sun wheel / gear

61
66
Allen head screw

Retaining washer
30
Annular piston
73
Snap ring
31
35
Locking ring
Thrust plate
82
83
O-ring
O-ring
36
Inner disc
86
Screw plug
37
Outer disc
88
Lip seal
40
Disc carrier
89
Lip seal
43
44
Pressure spring
Pressure spring
92
200
Plug
Mounting device
copyright by
MJF C I F S S
Service Manual
Slewing gear brake

Repair of brake
Fig. 4
Sealing and repair kit of the slewing gear brake
Fig. 5
Sectional drawing of the brake housing with mounting tool, rotated by 90
copyright by
MJF C I F S S
9.24.9
Slewing gear brake
Service Manual
Repair of brake
9.24.10
copyright by
MJF C I F S S
Service Manual
SUBGROUP - INDEX
Section
Group
Type
Slewing ring
10.10.1
10.1
MJF C I F S S
Service Manual
1.2
MJF C I F S S
Service Manual
Slewing ring
Design
Slewing ring
1 Design
The slewing ring is used as a connecting and bearing element between the undercarriage and the
uppercarriage.
The slewing ring consists of a single-row axial rolling bearing with a large diameter.
It consists of an outer race and a geared inner race. For the bearing and connection of the races,
large balls are located between the two precision bearing elements. Sealing lips protect the ball bearing against dirt.
To turn the uppercarriage, the slewing gear mechanism engages with the involute teething of the inner race of the slewing ring.
Fig. 1
Location of the slewing ring in the undercarriage
copyright by
MJF C I F S S
10.10.1
Slewing ring
Service Manual
Technical data
2 Technical data
Machine
from serial number
A 309-Li
20221
A 311-Li
20222
A 312-Li
12363
Factory play
0.5 mm
0.5 mm
0.5 mm
Max. play
1.5 mm
1.5 mm
1.5 mm
Tooth backlash
1.4 mm
1.4 mm
1.4 mm
Tilting play
Weight of uppercarriage
with offset boom bearing
kg
5540
6030
6300
With attachment
kg
6600 - 6800
7400 - 7600
8560 - 8620
M 16
M 16
M 16
280 Nm
280 Nm
280 Nm
R 313-Li
27752
A 314-Li
2001
A 316-Li
2001
Factory play
0.5 mm
0.5 mm
0.5 mm
Max. play
1.5 mm
1.5 mm
1.5 mm
Tooth backlash
1.4 mm
1.4 mm
1.4 mm
Tightening torques
Mounting bolts
Quality 10.9
Machine
from serial number
Tilting play
Without attachment
kg
6400
6950
7800
With attachment
kg
8500 - 8600
8950 - 10750
10370 - 12070
13020 - 15120*
Tightening torques
Mounting bolts
M 20
M 20
M 20
Quality 10.9
560 Nm
560 Nm
560 Nm
Machine
from serial number
R 317-Li
18161
Tilting play
Factory play
0.5 mm
Max. play
1.5 mm
Tooth backlash
1.4 mm
with offset boom bearing
kg
7800
With attachment
kg
10370 - 12070
Tightening torques
Mounting bolts
M 20
Quality 10.9
Tab. 1
560 Nm
Technical data
* in A 316 Industry
10.10.2
copyright by
MJF C I F S S
Service Manual
Slewing ring
Fig. 2
Sectional drawing of the slewing ring
Outer race
Upper sealing lip
2
3
Inner race
Ball
5
6
Lower sealing lip

Connecting bore for lubrication line
During work with the machine, the slewing gear must withstand changing torques and great forces
from the upper carriage. These forces and stresses are transferred through the outer race 1 attached
to the uppercarriage and the ball 3 onto the toothed inner race 2 mounted on the undercarriage.
The sealing lips 4 and 5 prevent dirt and dust penetrating the ball bearing.
The ball races are lubricated through central lubrication lines attached to the outer race of the slewing
ring. The gearing of the inner race and the drive pinion are lubricated by a grease packing on the slewing gear pinion, see also group 9.
The grease in the ball race and the grease packing is automatically renewed by activating the central
lubrication system at regular intervals, see also maintenance instructions for group 3.
copyright by
MJF C I F S S
10.10.3
Slewing ring
Service Manual
Measuring of clearance
4 Measuring of clearance
Fig. 3
4.1
4.1.1
Measuring of tilting play a and tooth backlash b (tooth impression in lead sheet)
Tilting play measurement

Factory tilting play
Maximum play of a new installed bearingsee Tab. 1).
4.1.2
Maximum tilting play

Maximum permissible play in the uppercarriage bearing (wear limit). Slewing rings can normally be
operated until the maximum tilting play is reached. If there bearing shows signs of premature stiffness, replace the slewing ring. Exceeding of the maximum play impairs the operational reliability and
safety of the machine.
The slewing ring must be regularly inspected and checked for stiffness.
4.1.3
Measuring procedure:
The tilting play is measured using a dial gauge and a magnetic-base holder.
Caution!
To attach the magnetic-base holder and/or to measure the tilting play, the technician must access
the danger area between the uppercarriage and the undercarriage. In the event of incorrect machine operation, there is a risk of serious injury from crushing.
Before accessing the danger area of the machine, ensure that the unit is standing on level and firm
ground.
Apply the parking brake.
Place the attachment on the ground.
Move the uppercarriage into a suitable position.
Mount the dial gauge in a position that is in line with the attachment on the slewing gear (see Fig.
3).
Note!
In order to prevent incorrect or inaccurate measurements, ensure that the magnetic-base holder is
properly secured in its position.
Before mounting the holder, carefully clean the respective area.
10.10.4
copyright by
MJF C I F S S
Service Manual
Slewing ring
Dismantling
Fill the bucket of the machine, lift it above ground level and extend it as far as possible away from
the machine.
Secure the machine in this position (establish visual/audible contact with the machine operator).
Set the dial gauge to zero (initial value).
Lift machine with attachment slightly (i.e. front wheels are slightly elevated from the ground).
Secure the machine again in this position.
Read measured value at the gauge.
The difference between the two measured values corresponds to the tilting play of the slewing ring.
In order to detect any differences in play along the ring, repeat the above measurement at various
swivel angles of the uppercarriage.
4.2
4.2.1
Measuring of tooth backlash

Tooth backlash
corresponds to the tooth backlash occurring for various reasons when a new bearing is combined
with a new pinion.
4.2.2
Measuring procedure:
The tooth backlash is measured with a lead sheet of approx. 10 mm in width, 120 mm in length and
2 mm in thickness.
Park the machine on level ground and release the uppercarriage locking mechanism and the slewing gear brake.
Fully extend the attachment and lift it by approx. 1 metre from the ground.
Insert the lead strip horizontally between the slewing gear pinion and the slewing ring so that it is
placed on the centre of a tooth and swivel the uppercarriage slightly by manually moving the end
of the attachment.
Determine the tooth backlash as described in the example below:
Tooth face A
Tooth face B
Tooth backlash
1.00 mm
+ 0.40 mm
1.40 mm
5 Dismantling
Danger!
For the work described below, always comply with all applicable safety instructions!
Do not stand under the suspended uppercarriage!
To replacing the slewing ring, the uppercarriage must be lifted from the undercarriage.
Ensure that a crane/excavator with sufficiently dimensioned lifting tackle, cables and attachments
is available to lift off the uppercarriage.
Place the uppercarriage on a level and firm surface and remove the supports, if necessary. Secure
the undercarriage against rolling by inserting wheel chocks.
Fully extend the bucket, stick and boom cylinder and fully retract the stick and the bucket.
copyright by
MJF C I F S S
10.10.5
Slewing ring
Service Manual
Installation
Retract the regulating cylinder so that the bottom edge of the attachment and the bottom edge of
the uppercarriage are aligned to each other (level bearing surface on which the parts can be
placed).
Mark, disconnect and seal the lines at the top of the oil rotary connections.
Collect any escaping oil, using suitable oil pans.
Remove the driver of the oil rotary connections.
If necessary, disconnect the lubrication line.
Attach lifting tackle, cables, shackles etc. to the lifting eyes and mounting points at the top of the
basic boom to secure the uppercarriage see Fig. 5.
Remove the outer mounting bolts 30 and washers 40 between the slewing ring and the uppercarriage.
Carefully lift the uppercarriage with the crane above the rotary connections and place it to the side
of the undercarriage.
Remove the mounting bolts 5 with washers 6 connecting the slewing ring to the undercarriage.
Caution!
Deformation or stress results in damage to the slewing ring.
Always transport and store the slewing rings in horizontal position.
Avoid impacts and stress when installing the ring.
Lift the slewing ring from the undercarriage and place in onto a suitable surface.
6 Installation
Caution!
Screw connections that are unable to bear the occurring forces, due to elongation of or damage to
the screws, can cause serious damage to components such as slewing rings, uppercarriages and
undercarriages. Such breaks can also injure persons standing nearby.
For safety reasons, all screws must thus be replaced with new ones when the slewing ring is replaced.
When mounting the slewing ring, always use new screws.
Carefully remove all dirt and other irregularities from the slewing ring bearing surface and the ring
itself.
Place the complete slewing ring onto the undercarriage, observing correct alignment, see Fig. 4.
The slewing gear pinion must be properly engaged in the gearing and the passages must be aligned to the threads in the uppercarriage.
Insert the mounting bolts 5 with washers 4 and tighten crosswise and at 90 angles, using a torque
wrench (see Tab. 1 on page 2).
Check slewing ring for free movement.
Lift the complete uppercarriage including attachment and carefully position it on the slewing ring.
Caution!
Incorrect installation of the slewing ring might result in excessive load on the ball races and the balls.
Before positioning the uppercarriage, rotate the outer race of the slewing ring to the correct position (see Fig. 4).
10.10.6
copyright by
MJF C I F S S
Service Manual
Slewing ring
Installation
Insert the mounting bolts 30 with washers 40 and tighten crosswise and at 90 angles according
to the torque table, using a torque wrench.
Lower lifting tackle and remove it from the machine.
Connect the oil lines to the rotary connections, observing the marks.
Mount the driver of the oil rotary connections.
Connect the lubrication lines and lubricate the ball race from the central lubrication system.
Start the diesel engine, check all functions of the undercarriage and inspect lines for leakage.
Renew the grease packing of the slewing gear pinion, lubricate the gearing by rotating the uppercarriage or by means of the central lubrication system. Check all parts for proper lubrication.
Inspect slewing ring for proper functioning and measure play (see Fig. 3).
Note!
When installing a new slewing ring, remove all grease from the grease cap (housing enclosing the
slewing gear pinion) and clean it carefully. Proceed with filling the grease cap with brake-in grease
conforming to DIN 51350.
Recommended product: Liebherr Universalfett 9900
Fig. 4
Correct alignment and position of the slewing ring
Hex head screw
Plug
Washer
Travel and main working direction
30
Hex head screw
Mark of non-hardened zone
40
Washer
Note!
Mark S (non-hardened zone = areas outside the hardened bearing race) at the end face of the slewing ring tooth and the plug A at the outer race must be at an angle of 90 to the main working direction.
copyright by
MJF C I F S S
10.10.7
Slewing ring
Service Manual
Installation
Fig. 5
10.10.8
Correct attachment of lifting tackle for the lifting of the uppercarriage
copyright by
MJF C I F S S
Service Manual
SUBGROUP - INDEX
Section
Group
Type
2 HL 70 transmission
11.08.1
A 309 LI 20221-29268
A 311 LI 20222-29169
A 312 LI 12363-29897
11.10.1
A 314 LI 2001A 316 LI 2001-28060

A 316 LI-IND 2001-28060
2 HL 270 / 290 transmission
11.20.1
HBGV block for 2 HL 70 / 100
11.30.1
A 309 LI 20221-29268
A 311 LI 20222-29169
A 312 LI 12363-29897
A 314 LI 2001A 316 LI 2001-28060
A 316 LI-IND 2001-28060
11.32.1
Travel gear F40
11.60.1
R 317 LI 18161-23449
FAT 350 travel gear system
11.62.1
R 313 LI 27752R 317 LI 23450-
Travel brake
11.65.1
R 317 LI 18161-23449
Travel brake
11.67.1
R 313 LI 27752R 317 LI 23450-
11.1
MJF C I F S S
Service Manual
11.2
MJF C I F S S
Service Manual
Function
1 Function
The 2 HL 70 transmission is attached to the undercarriage. It distributes the drive force from the flange-connected engine through the drive shafts to the input axles.
The transmission is designed as a 2-speed powershift transmission. The on-road gear is switched
automatically, while the off-road gear must be manually selected.
The input system, shift lock and the output elements are attached to the gearbox.
Fig. 1
copyright by
MJF C I F S S
11.08.1
Service Manual
Technical data
2 Technical data
Machine
from serial number
A 309Li / A 311 Li
20221 / 20222
A 309 / 311 Li
Speeder
A 312 Li
12363
A 312 Li
Speeder
2 HL 70
2 HL 70
Max. drive power (*)
50 kW
50 kW
Max. input torque (*)
394 Nm
394 Nm
Max. input speed (*)
2500 rpm
2500 rpm
5.00
1.29
5.00
1.29
110 kg
110 kg
Gearbox type
Gear ratio
1st gear
2nd gear
Weight
Oil viscosity
Operating temperature
Short-time max.
2.3 l
2.3 l
SAE 20 W-20 or
SAE 10 W-30
SAE 20 W-20 or
SAE 10 W-30
80 - 110
120
80 - 110
120
32 l/min
approx. 30 l/min
32 l/min
approx. 30 l/min
Hydraulic control
Max. control oil level of gear pump 32
Residual flow R from flow distributor
Pilot pressure of hydraulic unit and release pressure of multi-disc brake / coupling
Pressure-relief valve 51
32 1 bar
32 1 bar
approx. 32 bar
approx. 32 bar
7 - 15 bar
7 - 15 bar
Shifting pressure of pressure switch B10
25 2.5 bar
25 2.5 bar
Shift lock pump pressure (pressure-relief valve 74)

at max. input speed
at shift speed
6 - 7 bar
2.0 - 2.6 bar
6 - 7 bar
2.0 - 2.6 bar
Switching speed
(drive shaft / oil motor)
800 100 rpm(+)
800 100 rpm(+)
Switching speed
(drive shaft / universal joint)
620 80 rpm (+)
620 80 rpm (+)
Measuring points 49, 65, 103, 104

Brake backpressure
(Measuring point 65)
Shift lock on-road gear/off-road gear
Tab. 1
Technical data
((*)
maximum permissible value

modified push button
(+) at oil temperature 80C
The switching range results from the tolerance orifice 77
( ) with
11.08.2
copyright by
MJF C I F S S
min /
max from pump 71.
Service Manual
Design
3 Design
see Fig. 2
The 2 HL 100 transmission is designed as a powershift transmission with a planetary and a spur gear.
The powershift transmission of the planetary drive consists of a rotating multi-disc clutch and a multidisc brake mounted in a housing attached at the top of the planetary drive. Both the clutch and the
brake are applied mechanically by spring force (disc springs) and hydraulically released (control pressure).
When in on-road gear, the multi-disc brake is hydraulically released, and the multi-disc clutch is mechanically engaged. In off-road gear, control pressure is applied to the clutch, which is thus disengaged, and the brake is applied by means of the spring force.
The transmission is driven by an axial piston regulating motor with brake valve. For a description of
the complete hydraulic system, the regulating motor and the brake valve, see groups 6 and 7.
The machine is equipped with a release mechanism for towing in the event of an emergency. This
mechanism allows for the simultaneous hydraulic release of the multi-disc brake and the multi-disc
clutch by means of a piston that can be accessed from the outside, so that there is no power transmission between the input and the output end. When disengaged, the parking brake is disabled.
The shut-off mechanism thus acts as the auxiliary release device required by law for the parking brake, as it is activated in the event of a power failure and/or missing release pressure.
The hydraulic shift lock of the transmission protects the regulating motor against overspeeding when
the gear is shifted from on-road to off-road. It is operated by the flow produced to pressurize a spool
through a gear pump driven by the transmission. Depending on the machine speed, the spool is set
to neutral or working position respectively, i.e. the preselected off-road speed cannot be chosen when
the vehicle is driven at high speed.
During the gear shifting, the multi-disc brake or clutch is supplied with oil so that it is released and is
kept in this position by a constant control pressure.
The spur gear transmission section is equipped with an oil reservoir from where oil is sucked by the
gear pump. Bearings, shafts and gears are lubricated with gear oil from the oil sump (splash and centrifugal lubrication). The moving clutch parts are supplied with lubricating oil fed through lubrication
channel.
copyright by
MJF C I F S S
11.08.3
Service Manual
Design
3.1
Design of transmission
Fig. 2
11.08.4
1
2
Connecting flange / regulating motor

Disc springs
7
8
Release mechanism
Shift lock
Rotary-type pump for shift lock and lubrication
Spur drive
Multi-disc clutch
Multi-disc brake
Input
Planetary drive
Output
copyright by
MJF C I F S S
Service Manual
Fig. 3 and Fig. 4
4.1
4.1.1
Summary
Parking
Multi-disc brake 87 and multi-disc clutch 93
applied by disc springs 90 / 91
Power circuit interrupted (ignition off)
4.1.2
Braking
Switch S16 operated
4.1.3

On-road gear
Switch S42 not operated
4.1.4
Brake 87 (outside) released by control pressure,

clutch 93 engaged by disc springs 91
Off-road gear
Switch S42 operated
4.2
4.2.1
Brake 87 (outside) applied by disc springs 90,

clutch 93 (inside) opened by control
pressure
Function of parking brake

Diesel engine off:
No control pressure from the control oil unit 50.
Multi-disc brake 87 and multi-disc clutch 93 (1st gear) engaged by disc springs 90 / 91.
4.2.2
Diesel engine on:
4.2.3
Switch S16 in brake position (LED on).

Brake valve Y6 in neutral position, and thus no pressure at connection A - P - B and brake 87.
Pressure switch B10 closed, indicator light H20 on
The machine cannot be started.
Braking machine when in motion:

Incorrect operation, see 6.4:
Switch S16 in brake position (integrated lamp on).
Brake valve in neutral position.
Pressure in the piston chamber of the multi-disc brake 87 is released via the shift lock 70, connection B, switching the piston 75 connection P1, rotary connection 322, HBGV block 60 connection
A, shift valve Y55 and brake valve Y6 to the backpressure valve 63.
Slow closing of the brake by piston with preloaded pressure spring of the accumulator 102, restrictor effect of the valve 100 and preload of the valve 63.
copyright by
MJF C I F S S
11.08.5
Service Manual
Preload is gradually reduced to zero.
The multi-disc clutch 93 is released via the shift lock 70 connection P2 and the HBGV block connection B T to the accumulator.
4.3
4.3.1
Gear function and power flow

On-road gear / 2nd gear (no preselection with switch S42):
Multi-disc brake 87 is released.
Multi-disc clutch 93 is closed.
The sun gear 83 and the hollow gear 86 are driven simultaneously through the engaged clutch 93
and the drive shaft 82 by the oil motor 210.
There is therefore no speed reduction by the planetary drive. The planetary carrier 85 drives the
helical gear 97 via the sliding sleeve 95 and the jaw clutch 96.
The larger helical gear 98 meshing with the gear 97 rotates at a lower speed (speed reduction)
and drives the axles, and thus the drive wheel of the machine, via the drive flange 99 and the flange-connected universal joint shafts.
4.3.2
Off-road gear / 1st gear (preselection with switch S42):

Multi-disc brake 87 is applied.
Multi-disc clutch 93 is disengaged.
The sun gear 83 is propelled through the drive shaft 82 by the oil motor 210. The planetary gears
84 roll on the stationary hollow gear 86 (due to applied multi-disc brake 87).
The planetary carrier 85 drives the helical gear 97 via the sliding sleeve 95 and the jaw clutch 96.
The second speed reduction of the planetary drive / spur drive results in a high reducing gear ratio,
(see Technical data on page 2).
4.4
4.4.1
Function of shift lock

General
The shift lock 70 protects the gear system and the hydraulic motor against excessive speed, which
might occur when the drive changes from on-road to off-road gear while travelling at relatively high
speeds. It does however not protect the system against excessive speed during deceleration. If the
input speed and thus the drive speed are above the set shifting-down point, gear switching from onroad to off-road speed is not possible. The preselected off-road gear is only released by the shift lock
70 when the shifting-down point is reached. If the input speed is below the shifting-down point, the
machine is automatically shifted to the selected off-road gear. The on-road gear can be chosen at
any speed.
4.4.2
Normal position of shift lock

The rotary-type pump / gear pump 71 driven by the gear input shaft sucks oil from the gear sump
through the internal bores and the suction filter 71.2. It produces an oil pressure, which is determined
by the input speed (output speed of the oil motor) and corresponds to the pressure at the orifice 77
for the lubricating oil supply of the gear system. A part of the oil is used to lubricate the gear system,
while the rest moves the shifting piston 75, or is returned by the pressure-relief valve 74 to the suction
side.
The pump flow, the lubricating oil orifice 77 and the characteristic of the pressure spring in the shifting
piston 75 are adjusted in such away that, at input speeds below the shifting-down point, the backpressure at the orifice 77 and the resulting piston force are smaller than the spring force.
11.08.6
copyright by
MJF C I F S S
Service Manual
When the piston is in this position (neutral position), oil flow from P1 B or from P2 K is possible so
that the machine can be switched to on-road or off-road speed.
If the off-road gear is chosen, the shifting piston 75 remains in neutral position, as the shifting pressure K and the spring force are higher than the pump pressure.
It is thus possible to shift the machine up to on-road gear.
4.4.3
Leakage check valve 72

If off-road gear is preselected, the leak oil from the shifting piston 75 and the check valve 73 (at pressure side P2) is fed through the leakage check valve 72 through connection P1 to the tank. The valve
72 also blocks the control pressure to the multi-disc brake 87 when the machine is driven in on-road
or off-road gear.
4.4.4
Shuttle check valve 73

If the off-road gear is preselected, the shuttle check valve 73 blocks the flow from connection P2 to
P1. If the machine is in on-road gear and moves at a speed above the shifting-down point, it blocks
the flow from connection P1 to P2.
4.4.5
The pressure-relief valve 74 protects the lubricating pump 71 against pressures above 6 to 8 bar. It
only opens, if the machine is moving above the shifting-down point, i.e. the pressure required to operate the shifting piston 75 is determined by the backpressure at the orifice 77 for the lubricating oil
supply.
4.4.6
Shifting piston 75
The shifting piston 75 acts as the actual shift lock. The flow, which is given by the input speed of the
gear system, and the resulting backpressure at the orifice 77 determines the position of the shifting
piston 75.
Low speed low flow low backpressure
shifted from on-road gear to off-road gear.
shifting piston in neutral position
machine can be
High speed high flow high backpressure shifting piston in working position machine can only
be shifted to on-road gear shifting to off-road gear locked.
4.4.7
Check valve 76
The check valve 76 feeds the oil that is replaced when the shifting piston 75 is moved through P2 to
the tank.
copyright by
MJF C I F S S
11.08.7
Service Manual
4.5
Diagram of gearbox / hydraulic circuit
Fig. 3
a
11.08.8
Diagram of transmission and shift lock

Output
72
Leakage check valve
Shut-off mechanism
73
Shuttle check valve
e
B
Oil supply transmission

to multi-disc brake
74
75
Shifting piston
Release mechanism
76
Check valve
EB
Bleeder / multi-disc brake
77
Orifice
EK
EL
Bleeder / multi-disc clutch

Bleeder / release mechanism
80
87
Transmission
Multi-disc brake
Measuring point on-road gear
90
Disc springs
K
L
to multi-disc clutch
Measuring point pump pressure
91
93
Disc springs
Multi-disc clutch
M
P1
Measuring point off-road gear

from HBGV block
95
100
Piston / release mechanism

P2
60
from HBGV block

from HBGV block
101
102

Accumulator
70
Shift lock
106
Shift valve
71
Lubricating oil pump
210
71.2
Suction filter (maintenance-free)
copyright by
MJF C I F S S
Service Manual
Positions of the shift lock 70
5 Positions of the shift lock 70

5.1
Machine in on-road gear (2nd gear)

Input speed
Control oil
to
connection
Function / shift lock
Function /
transmission
Gear pump 71 delivers a specific

oil volume
Shift speed travel

motor
(> 700 - 900 rpm)
Drive shaft
(> 540 - 700 rpm)
Pump pressure Pp max. 7.0 bar

Shifting piston 75 in working position
P1
Shifting pressure Sp over shuttle

check valve 73
Via external line to
multi-disc brake. Brake
released
Valves 72 and 73 block the connection to point K.

Point K is connected via the
check valve 76 and connection
P2 to the tank.
Multi-disc clutch
closed. Gear ratio planetary drive =
1: 1
(2nd gear)
If the machine is in on-road gear and the speeds are above the shifting-down point, an increased
pump pressure is applied to the shifting piston 75. The piston is pressed against the pressure spring
and moved into working position.
If the operator now preselects the off-road gear, the pressure applied to the shift lock 70 changes
from connection P1 to connection P2. The shuttle check valve 73 continues to release the pressure
to connection B so that shifting down is not possible. The machine remains in on-road gear.
Only when the speed is reduced to below the shifting-down point (reduction of travel speed), the
spring presses the piston 75 into its neutral position, i.e. the machine can now be set to off-road gear.
70
79
Oil supply / transmission
71
71.2 Suction filter (maintenance-free)
B
K
Connection to multi-disc brake

Connection to multi-disc clutch
72
Leakage check valve
P1
from HBGV block
73
Shuttle check valve
P2
from HBGV block
74
75
Shifting piston
Pp
S
Pump pressure
Suction chamber / pump
76
Check valve
Sp
Shifting pressure
77
78
Orifice
Connection of lubricating oil supply
Return / tank
Shift lock
copyright by
MJF C I F S S
11.08.9
Service Manual
Fig. 4
11.08.10
Hydraulic diagram and sectional drawing of the transmission during travel in on-road gear
at high speed
copyright by
MJF C I F S S
Service Manual
5.2
Travel in on-road gear

On-road gear (1st gear) preselected with switch S42
Input speed
Control oil
to
connection
Shift speed
Travel motor
(> 700 - 900 rpm)
Universal joint shaft
(> 540 - 700 rpm)
Function /
transmission
Gear pump 71 delivers a specific oil volume

Pump pressure Pp max. 7.0
bar
Spool 75 in working position
P2
Shifting pressure Sp over the

shifting piston 75 and the
shuttle check valve 73; valve
73 also blocks connection to
P1.
released

check valve 72 and connection P1 to the tank.
Multi-disc clutch
closed. Gear ratio planetary drive =
1: 1
(2nd gear)
Shifting-down to 1st
gear not possible;
shifting down only possible when the input
speed is below 800
rpm
70
78
71
79
B

72
Leakage check valve
73
Shuttle check valve
P1
from HBGV block
74
P2
from HBGV block
75
76
Shifting piston
Check valve
Pp
S
Pump pressure
77
Orifice
Sp
Shifting pressure
Shift lock
copyright by
MJF C I F S S
11.08.11
Service Manual
Fig. 5
11.08.12
off-road gear preselected
copyright by
MJF C I F S S
Service Manual
5.3
Off-road gear (1st gear) preselected with switch S42

Input speed
Control oil
to
connection
Shift speed
Travel motor
(< 700 - 900 rpm)
(< 540 - 700 rpm)
Function /
transmission

Pump pressure Pp low
Shifting piston 75 in neutral
position
P2
Shifting pressure Sp over

shifting piston 75 (open edge
of control spool)

multi-disc brake.
Clutch released
Gear ratio of planetary
drive = 1 : 3.87 (1st gear)
Valve 72 blocks the connection to point B.
Point B is connected via the
shifting piston 75 (open control edge) and connection P1
to the tank.
Multi-disc brake depressurised, brake applied
70
Shift lock
79
71
to multi-disc brake

72
Leakage check valve
K
P1
from HBGV block
73
74
Shuttle check valve

P2
Pp
from HBGV block

Pump pressure
75
Shifting piston
76
Check valve
Sp
Shifting pressure
77
Orifice
Return / tank
78
to lubricating oil supply
copyright by
MJF C I F S S
11.08.13
Service Manual
Fig. 6
11.08.14
Hydraulic diagram and sectional drawing of the transmission during travel in off-road gear
copyright by
MJF C I F S S
Service Manual
Operation of the machine
6 Operation of the machine

Fig. 7 or Fig. 8
6.1
Driving and gear shifting

After gear preselection and subsequent preselection of the travel direction, the vehicle can be set into
motion by pressurising the oil motor.
6.2
Preselection of gear
The on-road gear is automatically selected.
The 1st gear / off-road gear is preselected with the switch S42 located on the right console beside
the operator's seat, see Fig. 7 or Fig. 8.
Actuate the switch S42:
The off-road gear (1st gear) is preselected.
The indicator lamp in the switch S42 is on.
The solenoid valve Y55, Fig. 14, is powered and thus in working position.
The gear is automatically shifted from on-road to off-road, based on the speed through the hydraulic/
mechanical shift lock 70. In other words, the shift is not completed immediately when the switch is
operated.
6.3
Preselection of travel direction

Preselect the travel direction at the preselection switch S263 located in the right pilot control unit, see
Fig. 7 or Fig. 8.
The indicator lights H167 or H168 respectively indicate the preselected travel direction. They are integrated into the right control desk, see Fig. 7 or Fig. 8.
Press the preselection switch S263 down:
The indicator light H167 (forward) is on.
If the pilot control unit 84, Fig. 7 or Fig. 8, is actuated, the machine travels forward.
Press the preselection switch S263 up:
The indicator light H168 (reverse) is on.
If the pilot control unit 84, Fig. 7 or Fig. 8, is actuated, the machine travels backwards.
Reversing (i.e. switching from forward to reverse motion and back) is possible in both gears.
6.4
Brakes
Caution!
The parking brake is designed in such a way that it cannot be operated during work.
Otherwise, the machine would be damaged.
During work, use only the working brake.
Engage the locking device 23 of the working brake (pedal 22 to the right of the steering column),
see Fig. 7 or Fig. 8.
copyright by
MJF C I F S S
11.08.15
Service Manual

By applying the parking brake (multi-disc brake 87) with the switch S16, Fig. 7 or Fig. 8, the machine
is secured against inadvertent rolling-off when parked.
By applying the parking brake, the opened pressure switch B10, Fig. 14 automatically disconnects
the electric mass and connection to the solenoid valves for the travel direction preselection, so that
the machine cannot be moved when the brake is applied (see also electrical system).
the brake is applied.
The indicator light H20 is on.
The pressure switch B10 is released.
Note!
The brake is designed as a parking brake and may only be applied when the machine is standing
still.
When parking on slopes, we recommend securing the vehicle with wedges, in addition to the parking brake.
6.5
Parking the machine

Turn the ignition key of the machine to position 0 and remove it.
The clutch 87 (brake) and 93 (1st gear) is automatically engaged.
Fig. 7
11.08.16
Switch and indicator light of the models A 312 to serial no. 20329
copyright by
MJF C I F S S
Service Manual
Fig. 8
Switch and indicator light of the models A 309 from serial no. 20221 and A 311 machines
from serial no. 20222 and A 312 machines from serial no. 20330
22
23
Foot pedal / working brake

Foot pedal retainer
H168
S16

Switch / parking brake
84*
Travel pilot control unit
S42
Switch 1st gear
H20
H167
Indicator light of parking brake

S263
Items of hydraulic unit
copyright by
MJF C I F S S
11.08.17
Service Manual
Towing of the machine
7 Towing of the machine

Caution!
The towing of the machine is a dangerous manoeuvre with a risk of injury to the driver and damage
to the machine. The machine may only be towed if absolutely necessary, e.g. to carry out repairs at
a suitable location or workshop.
When towing the machine, please note:
max. towing speed = 5 km/h
max. towing distance = 10 km
7.1
Towing of machine with running diesel engine

Before towing the machine, ensure that pilot control oil is fed to the transmission, so that the parking brake is released.
Set the switch S16 to its neutral position.
The parking brake is released.
The indicator light H20 is off.
If there is no battery voltage or if the electrical system fails:
Turn in the T-handle screw S at the HBGV block 60, Fig. 9.
The brake valve Y6 is set to working position.
7.2
Towing of machine when diesel engine is off

Caution!
The parking brake is disabled while the machine is being towed. When the diesel engine is shut
down, the working brake can still perform a few braking manoeuvres, even if the brake accumulator
is filled.
When the diesel engine is off, the machine can only be steered with the emergency steering system
(steering wheel is stiff).
The machine may only be towed away from the danger zone but not any further!
Disconnect the gear drive and brake from the output.
Danger!
Emergency activation requires access to the undercarriage of the machine. There is a risk of serious
injury or even death to the technician, if the machine begins to move.
Park the machine on a level surface and secure it with chucks against rolling away.
Access the area of the undercarriage only when the machine is shut down and properly secured
in its position.
Adhere to the accident prevention regulations issued by the German Ground Construction Trade
Association (Tiefbau-Berufsgenossenschaft) for powertrains and earth-moving equipment.
Before actuating the release mechanism (piston 95), ensure that the clutch chambers are properly
bled.
Bleed the clutch chambers of the parking brake, gear shifting mechanism and the release mechanism as follows:
11.08.18
copyright by
MJF C I F S S
Service Manual
Maintenance
Release the bleeders EB, EK and EL of the multi-disc brake / multi-disc clutch and the release
mechanism. Bleed the clutch chambers, see 9.3 and Fig. 12 by actuating the parking brake and
the gear shifting mechanism (clutch chambers are filled with oil). Collect escaping oil.
When bubble-free oil escapes, seal the bleeders.
Turn the piston 95 of the release mechanism quickly to the stop, using an Allen key (size 12), Fig.
9,.
The multi-disc brake 87 and the multi-disc clutch 93 are hydraulically released.
The oil motor is disconnected from the drive system.
Fig. 9
Bottom view of HBGV block and gear system release mechanism
60
80
HBGV block
Gearbox (bottom view)
95
Piston / release mechanism
S
Y6
T-handle screw / emergency activation

Brake valve
8 Maintenance
Danger!
Maintenance requires access to the undercarriage of the machine. There is a risk of serious injury
or even death to the technician, if the machine begins to move.
Park the machine on level ground.
Secure it against uncontrolled movement.
Only carry out maintenance work on the gearbox, if the machine is fully shut down and properly
secured.
Association (Tiefbau-Berufsgenossenschaft) for powertrains and earth-moving equipment.
The service life and operating time of the gearbox depend primarily on regular and careful maintenance and servicing of the unit. It is therefore important that the following instructions are strictly followed.
copyright by
MJF C I F S S
11.08.19
Service Manual
Maintenance
8.1
Oil level check

Check the oil level at the intervals laid down in the inspection and maintenance schedule, see group
3.
Wait 5 minutes and then carry out a oil level check:
Carefully remove the screw plug at the check and filling opening 2 at the gearbox 80 and check
the oil level.
If the oil reaches the lower edge of the opening , it is not necessary to add oil.
If the oil level is below the lower edge of the opening , add oil of the prescribed viscosity to
the lower edge of the opening.
8.2
Oil change
Change the oil at the intervals laid down in the inspection and maintenance schedule.
When the gearbox is warm (30 - 40C), switch off the engine and wait for 5 minutes. Then change
the oil:
Remove the oil discharge screw 1.
Drain the oil from the gearbox 80 into the provided container.
Screw in the oil discharge screw 1 (ensure that the seal ring is positioned properly).
Remove the screw plug at the check and filling opening 2 at the gearbox 80.
Add oil of the prescribed viscosity until it reaches the lower edge of the check and refill bore 2.
Screw in the screw 2 of the gearbox 80 (ensure that the seal ring is positioned properly).
Fig. 10
1
Maintenance tasks to be carried out on the gearbox 80

2
Oil drain screw
Oil check and filling opening screw
A check of the gear shifting and parking brake function must be carried out in the course of the maintenance work.
In the event of malfunctions or failures, check the pressures in the gear system as described below.
8.3
Check of gearbox
Note!
The inspection must be carried out while the machine is at operating temperature and the diesel
engine running at high idle speed.
11.08.20
copyright by
MJF C I F S S
Service Manual
Maintenance
8.3.1
Checking the release pressure of the clutch, see Fig. 11

Connect the pressure sensor (0-40 bar) to the measuring point 103 (multi-disc brake / connection
B) or the measuring point 104 (multi-disc clutch / connection K).
Preselect on-road or off-road gear and check release pressure, (see Technical data on page 2).
A release pressure below the nominal pressure is possibly caused by a defect in the shift lock 70.
If the pressure is too low, check and adjust the pressure of the pilot system.
After adjustment of the pressure, remove the pressure sensor and seal the measuring point(s).
8.3.2
Checking the backpressure of the brake, see Fig. 11

Connect the pressure sensor (0-40 bar) to the measuring point 65.
Apply the brake with the switch S16 and measure the pressure at the measuring point 65, (see
Technical data on page 2).
To adjust the backpressure to the nominal value, turn the adjusting screw of the backpressure valve
63 (located opposite the two solenoid valves Y6 and Y55).
To do this, remove the protective cap from the valve 63, loosen the lock nut and turn the adjusting
screw, until the prescribed value is reached.
Turn in
Turn out
= Increase pressure
= Reduce pressure
After the pressure has been adjusted, tighten the sealing nut and replace the protective cap.
Fig. 11
Measuring points at the transmission and HBGV block
Connection of multi-disc brake
65
Backpressure measuring point
Connection of multi-disc clutch
80
Gearbox
60
63
HBGV block
Backpressure valve
103
104
Measuring point
Measuring point
copyright by
MJF C I F S S
11.08.21
Service Manual
Dismantling, repair and installation of the gearbox
9 Dismantling, repair and installation of the gearbox

9.1
Dismantling of the gearbox for repair work

Danger!
The dismantling and installation of the gearbox requires access to the undercarriage of the machine.
There is a risk of death to the technician, as limbs could become crushed.
The gearbox may only be dismantled or installed if the machine is properly secured.
Depressurise the hydraulic system. Always refer to the safety instructions in group 1.10.
Disconnect and seal the hydraulic line to the oil motor and the gearbox (collect any escaping oil)
and seal the lines.
Remove the hex nuts 7 and remove the universal joint shafts 3 from the gearbox 80.
In order to remove all nuts 7, it might be necessary to lift the undercarriage 9, so that the universal
joint shafts 3 can be rotated by turning the wheels.
Secure the gearbox 80 with suitable lifting tackle.
Remove the hex head screws 54 with the washers 52.
Remove the hex head screw 60 with the washer 62.
Disconnect the gearbox 80 and the angle bracket 40 from the undercarriage 9 and pull it from the
undercarriage 9.
Remove the hex head screws 44 and disconnect the angle bracket 40 from the gearbox 80.
Remove the hex head screws 22.
If necessary, heat the screws 22 (secured with locking agent).
Insert the oil motor 210 from the gearbox 80.
9.2
Repair of the rigid axle

Note!
For detailed repair instructions for the transmission, refer to the separate "Repair manual for 2 HL
70 ZP gearbox".
9.3
Installation of the gearbox after repairs

Apply sealant to the flange surface of the gearbox 80 and the oil motor 210.
Insert the oil motor 210 into the gearbox 80.
Treat the threads of the hex head screws 22 with Omnifit 100 and tighten the hex head screws 22
(tightening torque 195 Nm).
Position the angle bracket 40 in the correct position on the gearbox 80.
Tighten the hex head screws 44 (torque 79 Nm).
11.08.22
copyright by
MJF C I F S S
Service Manual
Place the gearbox 80 with the angle bracket 40 in the undercarriage 9, using suitable lifting gear.
Secure the angle bracket 40 to the undercarriage 8, using the hex head screws 54 and the washers 52 (torque 560 Nm).
Secure the gearbox 80 to the undercarriage 8, using the hex head screws 60 and the washers 62
(torque 430 Nm).
Secure the universal joint shaft 3 with the hex head screws 7 to the output flanges of the gearbox
80.
Connect all hydraulic lines of the gearbox 80 and the oil motor 210.
Remove the protective cap from the bleeders EB/EK/EL,Fig. 12, and connect a suitable hose.
Release the bleeders of the multi-disc brake / multi-disc clutch and the release mechanism and
repeatedly actuate the parking brake and the gear shifting mechanism to bleed the clutch chambers (clutch chambers are filled with oil). Collect escaping oil.
When bubble-free oil escapes, seal the bleeders and replace the protective caps.
Fig. 12
Top view of bleeder of the gearbox (without protective cap)
EB
EK
EL
copyright by
MJF C I F S S
Bleeder / release mechanism
11.08.23
Service Manual
Fig. 13
11.08.24
Undercarriage with transmission
52
Retaining washer
Hex nut
54
Hex head screw
9
22
Undercarriage
Hex head screw
60
62
Retaining washer
Hex head screw
40
44
Angle bracket
Hex head screw
80
210
Transmission, complete
Oil motor with brake valve
copyright by
MJF C I F S S
Service Manual
Components and layout
10 Components and layout
Fig. 14
Main components of the transmission control and the parking brake
32
49
Gear pump
80
210
50
Control oil unit
B10 Pressure switch
60
64
HBGV block
Accumulator
P
R
Control pressure connection

Residual flow from flow distributor / gear
pump
65
70

Shift lock
Y6
Y55
Brake valve
Shift valve
copyright by
MJF C I F S S
Transmission
11.08.25
Service Manual
Hydraulic release mechanism and hydraulic accumulator
11
Fig. 15
11.08.26
Sectional drawing and diagram of hydraulic release mechanism
copyright by
MJF C I F S S
Service Manual
70
87
from/to shift lock

from/to multi-disc brake
103
104
Measuring point / brake B

Measuring point / clutch K
93
95
from/to multi-disc clutch

Piston / hydraulic release mechanism
105
106
Safety valve
Shift valve
100
107
Bleeder (EB) / multi-disc brake
101
102

Accumulator
107
210
Bleeder (EL) / release mechanism

Regulating motor
copyright by
MJF C I F S S
11.08.27
Service Manual
11.08.28
Check valve, complete

consisting of assemblies 1- 17
Drive housing (81/95*)
10
Multi-disc brake (87/89/90*)
11
Planetary drive (85/86*)
Drive (82*)
12
Spur drive (97*)
4
5
Housing (80/102*)
Housing (80/102*)
13
14
Spur drive (97*)

Shift lock (70*)
6
7
Oil lines
Clutch (91/92/93/94*)
15
16
Shift lock (70*)

Output (98/99*)
8
9
Clutch (91/92/93/94*)
17
Output (98/99*)
Items in sectional drawing on page

11.08.35
copyright by
MJF C I F S S
Service Manual
Exploded view of gearbox components
12 Exploded view of gearbox components

12.1
Gearbox 0 complete, drive housing 1/2 and housing 4/5
Fig. 16
Exploded view of gear housing based on spare parts list
copyright by
MJF C I F S S
11.08.29
Service Manual
12.2
Clutch 7/8 and multi-disc brake 9/10
Fig. 17
11.08.30
Exploded view of the clutch and the multi-disc brake based on spare parts list
copyright by
MJF C I F S S
Service Manual
12.3
Drive 3, planetary drive 11 and spur drive 12/13
Fig. 18
Exploded views of the drive, planetary drive and spur drive based on spare parts list
copyright by
MJF C I F S S
11.08.31
Service Manual
12.4
Oil lines 6 and shift lock 14/15
Fig. 19
11.08.32
Exploded views of oil lines and shift lock based on spare parts list
copyright by
MJF C I F S S
Service Manual
12.5
Gear drive 16/17
Fig. 20
Exploded views of output end based on spare parts list
copyright by
MJF C I F S S
11.08.33
Service Manual

1
2
Hydraulic tank (*)

Breather filter (*)
86
87
Hollow gear
Multi-disc brake (6 inner discs)
3
4
Stop cock (*)

Return filter (*)
89
90
Piston
Disc springs
Bypass valve / return line (*)
91
Disc springs
20
21
Variable displacement pump (*)

Powertrain
92
93
Piston
Multi-disc clutch
30
Gear pump / cooling (*)
94
Thrust plate
31
Steering pump
95
Piston
32
Pump for pilot control (*)
96
Screw plug
49
Measuring point / pilot pressure (*)
97
Helical gear
50
Control oil unit / pilot control (*)
98
Helical gear
51
52
Pressure-relief valve (*)

Pressure filter (*)
99
103
Output flange
53
54
Check valve (*)

Accumulator (*)
104
210

Regulating motor (*)
60
63
HBGV block
Backpressure-limiting valve
322
400
Rotary connection 6x (*)

to compact brake block
64
Accumulator
65
A126
66
Measuring point / backpressure and

release pressure
Check valve
B10
from/to autocheck printed circuit board

(X)
Pressure switch / parking brake (X)
70
71
Shift lock, complete

Gear pump
H20
K251
Indicator light of parking brake (X)

Relay / parking brake (X)
71.2
Suction filter
S16
Push button / parking brake (X)
72
73
Leakage check valve

Shuttle check valve
S42
Y3
Push button / off-road gear (X)

Solenoid valve / pilot control (*)
74
75
Pressure-relief valve (6-8 bar)

Shifting piston
Y6
Y24
Solenoid valve / parking brake (X)

Solenoid valve / creeper gear (*)
76
77
Check valve
Orifice
Y50
Y50
Solenoid valve / power control (X)

80
Transmission
Y55
Solenoid valve / 1st gear (X)
81
82
Connecting flange
Drive shaft
Y62
Y63
Solenoid valve / forward travel (X)

Solenoid valve / reverse travel (X)
85
Planetary carrier
Y371
Solenoid valve / oscillating axle (*)
* = Items in hydraulic diagram of group 6

X = Items in electrical diagram of group 8
O = built into housing connection
11.08.34
copyright by
MJF C I F S S
Service Manual
Function
1 Function
The 2 HL 100 transmission is attached to the undercarriage. It distributes the drive force from the flange-connected engine through the drive shafts to the input axles.
Fig. 1
copyright by
MJF C I F S S
11.10.1
Service Manual
Technical data
2 Technical data
Machine
from serial number
A 314 Li
2001
A 314 Li
Speeder
A 316 Li
2001
A 314 Li
Speeder
Gearbox type
2 HL 100
2 HL 100
110 kW
110 kW
770 Nm
770 Nm
4500 rpm
4500 rpm
5.35
1.39
5.35
1.39
125 kg
125 kg
Gear ratio
1st gear
2nd gear
Weight
Oil viscosity
Operating temperature
Short-time max.
3.3 l
3.3 l
SAE 20 W-20 or
SAE 10 W-30
SAE 20 W-20 or
SAE 10 W-30
80 - 110
120
80 - 110
120
32 l/min
approx. 30 l/min
32 l/min
approx. 30 l/min
Hydraulic control
Max. control oil level of gear pump 32
Residual flow R from flow distributor
32 1 bar
32 1 bar
approx. 32 bar
approx. 32 bar
12.5 bar
12.5 bar
26.5 bar
25 2.5 bar ()
26.5 bar
25 2.5 bar ()
6 - 8 bar
2.0 - 2.6 bar
6 - 8 bar
2.0 - 2.6 bar
Switching speed
580 - 950 rpm (+)
580 - 950 rpm (+)
Switching speed
415 - 680 rpm (+)
415 - 680 rpm (+)
Measuring points 49, 65, 103, 104

Brake backpressure
(Measuring point 65)
Shift lock pump pressure (pressure-relief valve 74)
at max. input speed
at shift speed
Tab. 1
Technical data
(*)
maximum permissible value

modified pressure switch
(+) at oil temperature 80C
The switching range results from the tolerance orifice 77
( ) with
11.10.2
copyright by
MJF C I F S S
min /
max from pump 71.
Service Manual
Design
3 Design
see Fig. 2
The 2 HL 100 transmission is designed as a powershift transmission with a planetary and a spur gear.
The powershift transmission of the planetary drive consists of a rotating multi-disc clutch and a multidisc brake mounted in a housing attached to the top of the planetary drive. Both the clutch and the
brake are applied mechanically by spring force (disc springs) and hydraulically released (control pressure).
When in on-road gear, the multi-disc brake is hydraulically released, and the multi-disc clutch is mechanically engaged. In off-road gear, control pressure is applied to the clutch, which is thus disengaged, and the brake is applied by means of the spring force.
A shut-off mechanism is installed between the planetary drive and the spur gear. This jaw clutch is
operated by means of a lever attached to the gearbox. The lever is equipped with a locking mechanism. In OFF position, it interrupts the power transmission between input and output. When disengaged, the parking brake is disabled.
The shut-off mechanism thus acts as the auxiliary release device required by law for the parking brake, as it is activated in the event of a power failure and/or missing release pressure.
The hydraulic shift lock of the transmission protects the regulating motor against overspeeding when
the gear is shifted from on-road to off-road. It is operated by the flow produced to pressurize a spool
through a gear pump driven by the transmission. Depending on the machine speed, the spool is set
to neutral or working position respectively, i.e. the preselected off-road speed cannot be chosen when
the vehicle is driven at high speed.
During the gear shifting, the multi-disc brake or clutch is supplied with oil so that it is released and is
kept in this position by a constant control pressure.
gear pump. Bearings, shafts and gears are lubricated with gear oil from the oil sump (splash and centrifugal lubrication). The moving clutch parts are supplied with lubricating oil fed through the lubrication channel.
copyright by
MJF C I F S S
11.10.3
Service Manual
Design
3.1
Fig. 2
11.10.4
Control pressure rotary-type pump
2
3
Shifting pressure accumulator

Multi-disc clutch
9
10
Spur gear drive

Disc springs
4
5
Multi-disc brake
Planetary drive
11
a
Restrictor valve
Input
Shut-off mechanism
Output
Shift lock
copyright by
MJF C I F S S
Service Manual
Fig. 3 and Fig. 4
4.1
4.1.1
Summary description
Parking
4.1.2
Braking
Switch S16 operated
4.1.3

On-road gear
4.1.4
Brake 87 (outside) released by control pressure,

Off-road gear
Switch S42 operated
4.2
4.2.1
Brake 87 (outside) applied by disc springs 90,

clutch 93 (inside) opened by control
pressure

Diesel engine off:
4.2.2
Diesel engine on:
4.2.3
Switch S16 in brake position (LED on).

Brake valve Y6 in neutral position, and thus no pressure at connection A - P - B and brake 87.
Pressure switch B10 closed, indicator light H20 on.
Braking machine when in motion

Incorrect operation, see 6.4:
Switch S16 in brake position (integrated lamp on).
Brake valve in neutral position.
Pressure in the piston chamber of the multi-disc brake 87 is released via the shift lock 70, connection B, switching piston 75 connection P1, rotary connection 322, HBGV block 60 connection A,
shift valve 62 and brake valve 61 to backpressure valve 63.
Slow closing of the brake by piston with preloaded pressure spring of accumulator 102, restrictor
effect of valve 100 and preload of valve 63.
copyright by
MJF C I F S S
11.10.5
Service Manual
Preload is gradually reduced to zero.
Multi-disc clutch 93 is released via shift lock 70 connection P2 and HBGV block connection B T
to the accumulator.
4.3
4.3.1

Multi-disc clutch 93 is engaged.
The sun gear 83 and the hollow gear 86 are driven simultaneously through the engaged clutch 93
and the drive shaft 82 by the oil motor 210.
There is therefore no speed reduction by the planetary drive. The planetary carrier 85 drives the
helical gear 97 via the sliding sleeve 95 and the jaw clutch 96.
4.3.2

The sun gear 83 is propelled through the drive shaft 82 by the oil motor 210. The planetary gears
84 roll on the stationary hollow gear 86 (due to applied multi-disc brake 87).
The planetary carrier 85 drives the helical gear 97 via the sliding sleeve 95 and the jaw clutch 96.
The second speed reduction of the planetary drive / spur drive results in a high reducing gear ratio,
(see Technical data on page 2).
4.4
4.4.1

General
might occur when the driver changes from on-road to off-road gear while travelling at relatively high
speeds. It does however not protect the system against excessive speed during deceleration. If the
input speed and thus the drive speed are above the set shifting-down point, gear switching from onroad to off-road speed is not possible. The preselected off-road gear is only released by the shift lock
70 when the shifting-down point is reached. If the input speed is below the shifting-down point, the
machine is automatically shifted to the selected off-road gear. The on-road gear can be chosen at
any speed.
4.4.2

side.
11.10.6
copyright by
MJF C I F S S
Service Manual
When the piston is in this position (neutral position), oil flow from P1 B or from P2 K is possible so
If the off-road gear is chosen, the shifting piston 75 remains in neutral position, as the shifting pressure P2 and the spring force are higher than the pump pressure.
4.4.3

If off-road gear is preselected, the leak oil from the shifting piston 75 and the check valve 73 (at pressure side P2) is fed through the leakage check valve 72 through connection P1 to the tank. The valve
or off-road gear.
4.4.4

If the off-road gear is preselected, the shuttle check valve 73 blocks the flow from connection P2 to
P1. If the machine is in on-road gear and moves at a speed above the shifting-down point, it blocks
the flow from connection P1 to P2.
4.4.5
The pressure-relief valve 74 protects the lubricating pump 71 against pressures above 6 to 8 bar. It
only opens, if the machine is moving above the shifting-down point, i.e. the pressure required to operate the shifting piston 75 is determined by the backpressure at the orifice 77 for the lubricating oil
supply.
4.4.6
Shifting piston 75
piston 75.
machine can be
4.4.7
Check valve 76
The check valve 76 feeds the oil that is replaced when the shifting piston 75 is moved through P2 to
the tank.
copyright by
MJF C I F S S
11.10.7
Service Manual
4.5
Diagram of gear system / hydraulic circuit
Fig. 3
11.10.8
Diagram of transmission and shift lock
Output
60
from HBGV block
b
d
Shut-off mechanism
Oil supply transmission control
70
71
Shift lock
e
B
Oil supply transmission

to multi-disc brake
71.2
72

Leakage check valve
Leak oil control circuit
73
Shuttle check valve
J
K

74
75
Shifting piston
L
M

76
77
Check valve
Orifice
P1
from HBGV block
80
Transmission
P2
S
from HBGV block

87
93
Multi-disc brake
Multi-disc clutch
100
101
102
210
Accumulator
copyright by
MJF C I F S S
Service Manual

5.1

Input speed
Control oil
to
connection
Function /
transmission

oil volume
800 rpm to
max. rpm

check valve 73
P1

released
Valves 72 and 73 block the connection to point K

check valve 76 and connection
P2 to the tank
Multi-disc clutch engaged. Gear ratio planetary drive = 1: 1 (2nd

gear)
pump pressure is applied to the shifting piston 75. The piston is pressed against the pressure spring
and moved into working position.
from connection P1 to connection P2. The shuttle check valve 73 continues to release the pressure
to connection B so that shifting down is not possible. The machine remains in on-road gear.
70
79
71
B
K

72
73
Leakage check valve

Shuttle check valve
P1
P2
from HBGV block

from HBGV block
74
Pp
Pump pressure
75
Shifting piston
76
Check valve
Sp
Shifting pressure
77
78
Orifice
Return / tank
Shift lock
copyright by
MJF C I F S S
11.10.9
Service Manual
Fig. 4
11.10.10
at high speed
copyright by
MJF C I F S S
Service Manual
5.2

Input speed
Control oil
to
connection
Function /
transmission
800 rpm to
max. rpm

bar
P2

P1
released

check valve 72 and connection P1 to the tank
Multi-disc clutch engaged. Gear ratio planetary drive =

1:
1 (2nd gear)
Shifting-down to 1st
gear not possible;
Shifting down only possible when the input
speed is below 800
rpm
70
Shift lock
78
71
79
72
Leakage check valve
73
74
Shuttle check valve

P1
P2
from HBGV block

from HBGV block
75
76
Shifting piston
Check valve
Pp
S
Pump pressure
77
Orifice
Sp
Shifting pressure
copyright by
MJF C I F S S
11.10.11
Service Manual
Fig. 5
11.10.12
copyright by
MJF C I F S S
Service Manual
5.3

Input speed
Control oil
to
connection
Function /
transmission
0-800 rpm

position
P2

of control spool)

multi-disc brake.
Clutch released
Valve 72 blocks the connection to point B
shifting piston 75 (open control edge) and connection P1
to the tank
Multi-disc brake depressurised, brake applied
70
Shift lock
79
71
to multi-disc brake

72
Leakage check valve
K
P1
from HBGV block
73
74
Shuttle check valve

P2
Pp
from HBGV block

Pump pressure
75
76
Shifting piston
Check valve
S
Sp

Shifting pressure
77
Orifice
Return / tank
78
copyright by
MJF C I F S S
11.10.13
Service Manual
Fig. 6
11.10.14
copyright by
MJF C I F S S
Service Manual

Fig. 7 or Fig. 8
6.1

6.2
the operator's seat, see Fig. 7 or Fig. 8.
operated.
6.3

Preselect the travel direction at the preselection switch S263 located in the right pilot control unit, see
Fig. 7 or Fig. 8.
The indicator lights H167 or H168 respectively indicate the preselected travel direction. They are integrated into the right control desk, see Fig. 7 or Fig. 8.
the indicator light H167 (forward) is on.
If the pilot control unit 84, Fig. 7 or Fig. 8, is actuated, the machine travels forward.
the indicator light H168 (reverse) is on.
If the pilot control unit 84, Fig. 7 or Fig. 8, is actuated, the machine travels backward.
6.4
Brakes
Caution!
Engage the locking device 23 of the working brake (pedal 22 to the right of the steering column),
see Fig. 7 or Fig. 8.
copyright by
MJF C I F S S
11.10.15
Service Manual

By applying the parking brake (multi-disc brake 87) with the switch S16 Fig. 7 or Fig. 8, the machine
is secured against inadvertent rolling-off when parked.
By applying the parking brake, the opened pressure switch B10 Fig. 13 automatically disconnects the
electric mass and connection to the solenoid valves for the travel direction preselection, so that the
machine cannot be moved when the brake is applied (see also electrical system).
The pressure switch B10 is released.
Note!
still.
6.5
Parking the machine

The clutch 87 (brake) and 93 (1st gear) is automatically engaged.
Fig. 7
11.10.16
Switch and indicator light of the models A 314 to serial no. 20333 and A 316 to serial no.
20339
copyright by
MJF C I F S S
Service Manual
Fig. 8
Switch and indicator light of the models A 314 from serial no. 20334 and A 316 machines
from serial no. 20340
22
23

Foot pedal retainer
H168
S16

84*
S42
Switch 1st gear
H20
H167

S263
copyright by
MJF C I F S S
11.10.17
Service Manual

Caution!
7.1

If there is no battery voltage or if the electrical system fails:
Turn in the T-handle screw S at the HBGV block 60, Fig. 9.
The brake valve Y6 is set to working position.
The machine is set to the selected gear.
7.2

Caution!
The parking brake is disabled while the machine is being towed. When the diesel engine is shut
down, the working brake can still perform a few braking manoeuvres, even if the brake accumulator
is filled.
Disconnect the gear drive and brake from the output.
Danger!
Park the machine on a level surface and secure it with chucks against rolling away.
in its position.
Association (Tiefbau-Berufsgenossenschaft) for the powertrains and earth-moving equipment.
Remove the hex head screws 109, Fig. 9.
Turn the lever 108 of the gear-shift fork to position OFF (in direction of arrow).
Secure the lever 108 with the hex head screw 109 in its turned position.
11.10.18
copyright by
MJF C I F S S
Service Manual
Maintenance
Fig. 9
Bottom view of HBGV block and gear system
60
HBGV block
109
Hex head screw / locking device
80
Gearbox (bottom view)
108
Lever / Gear-shift fork / emergency acti- Y6

vation
Brake valve
8 Maintenance
Danger!
secured.
Always adhere to the safety instructions in group 1.10 "Safe maintenance of machine".
8.1
Oil level check

3.
Wait 5 minutes and then carry out a oil level check:
Carefully remove the screw plug at the check and filling opening 2 at the gearbox 80 and check
the oil level.
copyright by
MJF C I F S S
11.10.19
Service Manual
Maintenance
If the oil level is below the lower edge of the opening
8.2
, add oil of the prescribed viscosity to
Oil change
the oil:
Remove the oil discharge screw 1.
Screw in the oil discharge screw 1 (ensure that the seal ring is positioned properly).
Remove the screw plug at the check and filling opening 2 at the gearbox 80.
Screw in the screw 2 of the gearbox 80 (ensure that the seal ring is positioned properly).
Fig. 10
1
Maintenance tasks to be carried out on the transmission 80

2
Oil drain screw
Oil check and filling opening screw
A check of the gear shifting and parking brake function must be carried out in the course of the maintenance work.
In the event of malfunctions or failures, check the pressures in the gear system as described below.
8.3
Check of gearbox
Note!
8.3.1
Checking the release pressure of the clutch, see Fig. 11

Connect the pressure sensor (0-60 bar) to the measuring point 103 (multi-disc brake / connection
B) or the measuring point 104 (multi-disc clutch / connection K).
Preselect on-road or off-road gear and check release pressure, (see Technical data on page 2).
A release pressure below the nominal pressure is possibly caused by a defect in the shift lock 70.
If the pressure is too low, check and adjust the pressure of the pilot system.
After adjustment of the pressure, remove the pressure sensor and seal the measuring point(s).
11.10.20
copyright by
MJF C I F S S
Service Manual
Maintenance
8.3.2
Checking the backpressure of the brake, see Fig. 11

Apply the brake with the switch S16 and measure the pressure at the measuring point 65, (see
Technical data on page 2).
To adjust the backpressure to the nominal value, turn the adjusting screw of the backpressure valve
63 (located opposite the two solenoid valves Y6 and Y55).
To do this, remove the protective cap from valve 63, loosen the lock nut and turn the adjusting
screw, until the prescribed value is reached.
Turn in
= Increase pressure
Turn out
= Reduce pressure
After the pressure has been adjusted, tighten the sealing nut and replace the protective cap.
Fig. 11
Measuring points at the transmission and HBGV block
Connection of multi-disc brake
65
Measuring point of backpressure
Connection of multi-disc clutch
103
Measuring point / coupling pressure of

multi-disc brake
60
HBGV block
104
Measuring point / coupling pressure of

multi-disc clutch
63
Backpressure valve
copyright by
MJF C I F S S
11.10.21
Service Manual
9 Dismantling, repair and installation of the gearbox

9.1
Dismantling of the gearbox for repair work

Danger!
Disconnect and seal the hydraulic line to the oil motor and the gearbox (collect any escaping oil)
and seal the lines.
Remove the hex nuts 7 and remove the universal joint shafts 3 from the gearbox 80.
In order to remove all nuts 7, it might be necessary to lift the undercarriage 9, so that the universal
joint shafts 3 can be rotated by turning the wheels.
Remove the gearbox 80 with the plate 5 from the undercarriage 9.
Remove the plate 5 from the gearbox 80.
Remove the nuts 17 complete with the washers 18 and pull the oil motor 210 from the gearbox
80.
9.2

Note!
For detailed repair instructions for the transmission, refer to the separate "Repair manual for 2 HL
100 ZP gearbox".
9.3
Installation of the gearbox after repairs

Tighten the nuts 17 with the washers 18 (tightening torque 79 Nm).
Place the plate 5 on the gearbox 80.
Apply Omnifit 100 to the thread of the hex head screws 12, insert them with the washers 13 into
the gearbox 80 and tighten them (tightening torque 430 Nm).
Place the gearbox 80 with the plate 5 in the undercarriage 9, using suitable lifting gear.
11.10.22
copyright by
MJF C I F S S
Service Manual
Apply Omnifit 100 to the thread of the hex head screws 11 and secure the plate 5 with the gearbox
80 using the hex head screws 11 and the washers 13 to the undercarriage 8 (tightening torque
560 Nm).
Secure the universal joint shaft 3 with the hex head screws 7 to the output flanges of the gearbox
80.
Connect all hydraulic lines to the gearbox 80 and the oil motor 210 and bleed the system by repeatedly actuating the parking brake and the gear shift lever.
Fig. 12
Undercarriage with transmission
13
Washer
Plate
17
Hex nut
Hex nut
18
Washer
9
11
Undercarriage
Hex head screw
80
210
Oil motor with brake valve
12
Hex head screw
copyright by
MJF C I F S S
11.10.23
Service Manual
10
Fig. 13
11.10.24
Main components of the transmission control and the parking brake
32
Gear pump
80
Transmission
49
210
50
Control oil unit
B10
Pressure switch
60
HBGV block
64
Accumulator
Connection for control pressure to HBGV

block
Residual flow from flow distributor / gear
pump
65
70

Shift lock
Y6
Y55
Brake valve
Shift valve

consisting of assemblies 1- 11
1
2

Drive (82/101*)
7
8
Planetary drive (83/84/85/86*)

Shut-down mechanism (95/96*)
Housing
Spur drive (97*)
Oil line
10
Shift lock (70*)
Clutch (91/92/93*)
11
Output (98/99*)

*
Items in sectional drawing on page

11.10.33
copyright by
MJF C I F S S
Service Manual
11 Exploded view of gearbox components

11.1
Gearbox 0 complete, drive housing 1 and input 2
Fig. 14
Exploded view of gear drive system based on spare parts list
copyright by
MJF C I F S S
11.10.25
Service Manual
11.2
Gear housing 3 and oil lines 4
Fig. 15
11.10.26
Exploded view of gear housing based on spare parts list
copyright by
MJF C I F S S
Service Manual
11.3
Multi-disc clutch 5 and multi-disc brake 6
Fig. 16
Exploded views of the multi-disc clutch and multi-disc brake based on the spare parts list
copyright by
MJF C I F S S
11.10.27
Service Manual
11.4
Planetary drive 7, gear shut-down mechanism 8 and spur drive 9
Fig. 17
11.10.28
Exploded views of the planetary drive, shut-down mechanism and spur drive based on
spare parts list
copyright by
MJF C I F S S
Service Manual
11.5
Shift lock 10 and gear output 11
Fig. 18
Exploded view of the shift lock and the output based on spare parts list
copyright by
MJF C I F S S
11.10.29
Service Manual

1
2
Hydraulic tank (*)

Breather filter (*)
85
86
Planetary carrier
Hollow gear
3
4
Stop cock (*)

Return filter (*)
87
89
Multi-disc brake (5 inner discs)

Piston
Bypass valve / return line (*)
90
Disc springs
20
21
Variable displacement pump (*)

Powertrain
91
92
Disc springs
Piston
30
Gear pump / pilot control (*)
93
Multi-disc clutch (10 inner discs)
31
Steering pump
94
Inner disc carrier
32
Brake system pump
95
Sliding sleeve
49
96
Jaw clutch
50
97
Helical gear
51
52
Pressure-relief valve (*)

Pressure filter (*)
98
99
Helical gear
Output flange
53
Check valve (*)
100
54
Accumulator (*)
101
Restrictor check valve (orifice 1.2

mm) O
Restrictor check valve (orifice 0.8
mm) O
57
Measuring point
102
Accumulator
59
63
Measuring point
103
104

64
65
Accumulator
Measuring point / backpressure and
release pressure
210
322

66
Check valve
400
70
A126
71
Gear pump
B10
from/to autocheck printed circuit board

(X)
Pressure switch / parking brake (X)
71.2
72
Suction filter
Leakage check valve
H20
K251

Relay / parking brake (X)
73
74
Shuttle check valve

S16
S42

75
Shifting piston
Y3
Solenoid valve / pilot control (*)
76
77
Check valve
Orifice
Y6
Y24
Solenoid valve / parking brake (X)

Solenoid valve / creeper gear (*)
80
Transmission
Y50
81
Connecting flange
Y51

Solenoid valve / -p reduction (X)
82
Drive shaft
Y55
Solenoid valve / 1st gear (X)
83
Sun gear
Y62
Solenoid valve / forward travel (X)
84
Planetary gear
Y63
Solenoid valve / reverse travel (X)
Y371
Solenoid valve / oscillating axle (*)
= Items in hydraulic diagram of group 6

O = built into housing connection
11.10.30
copyright by
MJF C I F S S
Service Manual

Function

1 Function
The 2 HL 270 / 290 transmission is attached to the undercarriage. It distributes the drive force from
the flange-connected regulating travel motor through the drive shafts to the input axles.
Fig. 1
copyright by
MJF C I F S S
11.20.1
Service Manual
Technical data
2 Technical data
Machine
from serial number
A 309 Li / A 311 Li
29269 / 29170
A 312 Li
29898
A 316 Li
28061
Gearbox type
2 HL 270
2 HL 270
2 HL 290
110 kW
110 kW
110 kW
Input torque at P max.
650 Nm
650 Nm
650 Nm
770 Nm
770 Nm
950 Nm
3500 rpm
3500 rpm
3500 rpm
4,87
1,20
4,87
1,20
4,87
1,20
135 kg
135 kg
135 kg
3.0 l
3.0 l
3.0 l
SAE 20 W -20
or SAE 10 W-30
SAE 20 W-20 or
SAE 10 W-30
SAE 20 W-20 or
SAE 10 W-30
33
22 l/min
32
30 l/min
32
30 l/min
Gear ratio
1. gear
2. gear
Weight
Oil viscosity
Hydraulic control
Max. control oil level of gear pump /
flow distributor
pressure-relief valve 51
32 1 bar
32 1 bar
32 1 bar
approx. 32 bar
approx. 32 bar
approx. 32 bar
6 - 8 bar
2.0 - 2.6 bar
6 - 8 bar
2.0 - 2.6 bar
6 - 8 bar
2.0 - 2.6 bar
Switching speed
800 100 rpm
800 100 rpm
800 100 rpm
Switching speed
667 70 rpm
667 70 rpm
667 70 rpm
Measuring points 49, 63, MB, MK

Shift lock pump pressure (pressurerelief valve 74)
at max. input speed
at shift speed
Tab. 1
Technical data
(*) maximum permissible value
11.20.2
copyright by
MJF C I F S S
Service Manual

Design
3 Design
see Fig. 2
The 2 HL 270 / 290 transmission is designed as a powershift transmission with a planetary and a spur
gear. The powershift transmission of the planetary drive consists of a rotating multi-disc clutch and a
multi-disc brake mounted in a housing attached at the top of the planetary drive. Both the clutch and
the brake are applied by spring force (disc springs) and hydraulically released (control pressure).
When in on-road gear, the multi-disc brake is hydraulically released, and the multi-disc clutch is mechanically engaged. In off-road gear, control pressure is applied to the multi-disc clutch, which is thus
disengaged, and the multi-disc brake is applied by means of the spring force and the hydraulic pressure.
The hydraulic shift lock mounted on the gearbox prevents shifting down at high speeds. It is operated
by the flow produced to pressurize a spool through a gear pump driven by the transmission. Depending on the machine speed, the spool is set to neutral or working position respectively, i.e. the preselected off-road speed cannot be chosen when the vehicle is driven at high speed.
During gear shifting, the multi-disc brake or clutch is supplied with oil from the control valve block so
that it is released and is kept in this position by a constant control pressure.
Excessive speeding of the gear and oil motor in overrun conditions (rolling down a slope) is not prevented by the shift lock, but by the brake valve that is flange-mounted to the oil motor.
gear pump. Bearings, shafts and gears are lubricated with gear oil from the oil sump (splash and centrifugal lubrication). The moving clutch parts are supplied with lubricating oil fed through the lubrication channel.
The emergency activation device is designed to disrupt the power transmission between input and
output in the event of failure of the control pressure or if there is a defect at the oil motor / hydraulic
circuit. This is necessary to allow for the machine to be towed in such a situation. For this purpose,
press grease into the lubrication nipple at the emergency activation device, using a standard grease
gun (included in machine toolbox) until the grease escapes at the pressure relief valve of the emergency activation device. The two pistons of the multi-disc brake and clutch are now released so that
the output shaft can be rotated freely and towing is possible.
copyright by
MJF C I F S S
11.20.3
Service Manual
Design
3.1
Fig. 2
11.20.4
Transmission 2 HL 270/290
Disc springs
Output flange
2
3
Drive shaft
Multi-disc brake
9
10
Output flange
4
5
Multi-disc clutch
Planetary drive
11
a
Shift lock
Input
Output
Spur gear drive
copyright by
MJF C I F S S
Service Manual

See also diagram on page 11.20.31.
4.1
Parking
4.2
Braking
Switch S16 operated
4.3
On-road gear
Brake 87 released by control pressure,
closed
4.4
Off-road gear
Switch S42 operated
4.5
Multi-disc brake 87 (outer) and multi-disc clutch

93 (inner)
Brake 87 applied by disc springs 90,

clutch 93 opened by control
pressure

Diesel engine off:
Diesel engine on:
Switch S16 in brake position (indicator light in switch on).
Brake valve Y60 in neutral position, and thus no pressure at connection P - B .
4.5.1
Braking the machine when in travel motion (emergency braking)

The parking brake can also be used for dynamic braking. The braking power is thereby enhanced by
the brake effect of the hydrostatic drive.
copyright by
MJF C I F S S
11.20.5
Service Manual
Caution!
The braking force cannot be controlled by the operator!
This method of braking may thus only be used in an emergency, e.g. in the event of failure of the
working brake.
4.6
4.6.1

Multi-disc clutch 93 is engaged.
The planetary carrier 85 and the hollow gear 86 are driven simultaneously through the engaged
clutch 93 and the drive shaft 82 by the oil motor 210.
There is therefore no speed reduction by the planetary drive. The planetary carrier 85 propels the
spur gear 99.
The larger spur gear 99 meshing with the planetary carrier 85 rotates at a lower speed (speed reduction) and drives the axles, and thus the drive wheel of the machine, via the drive flange 100
and the flange-connected universal joint shafts.
4.6.2

The planetary gears 84 are propelled through the drive shaft 82 by the oil motor 210. The planetary gears 84 roll on the stationary hollow gear 86 (due to applied multi-disc brake 87).
The planetary carrier 85 propels the helical gear 99.
The larger helical gear 99 meshing with the planetary carrier 85 rotates at a lower speed (speed
reduction) and drives the axles, and thus the drive wheels of the machine, via the drive flange 100
and the flange-connected universal joint shafts.
The second speed reduction of the planetary drive / spur drive results in a high reducing gear ratio.
4.7

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

If off-road gear is preselected, the leak oil from the shifting piston 75 and the check valve 73 (at pressure side K) is fed through the leakage check valve 72 through connection B to the tank. The valve
or off-road gear.
4.7.2

If the off-road gear is preselected, the shuttle check valve 73 blocks the flow from connection K to B.
If the machine is in on-road gear and moves at a speed above the shifting-down point, it blocks the
flow from connection B to K.
11.20.6
copyright by
MJF C I F S S
Service Manual

4.7.3
The pressure-relief valve 74 protects the lubricating pump 71 against pressures above 6 to 8 bar. The
pressure required to move the shifting piston 75 is determined by the backpressure at the orifice 77
for the lubricating oil supply.
4.7.4
Shifting piston 75
piston 75.
machine can be
4.7.5
Check valve 76
The check valve 76 feeds the oil that is replaced when the shifting piston 75 is moved through K to
the tank.
4.8

side.
When the piston is in this position (neutral position), oil flow from B B or from K K is possible so
If the off-road gear is chosen, the shifting piston 75 remains in neutral position, as the shifting pressure K and the spring force are higher than the pump pressure.
copyright by
MJF C I F S S
11.20.7
Service Manual
4.9
Diagram of gearbox / hydraulic circuit

Items in transmission diagram, (see Fig. 3 on page9)
11.20.8
Output
Lubrication nipple / emergency activation
Planetary drive
Bleeder / emergency activation
Spur gear drive
Pressure relief valve / emergency activation
Emergency activation
60
Valve block
B/B/B to multi-disc brake
61
Valve plunger
EB
62
Pressure valve
EK
63
Measuring point / opening pressure
J
K/K/K to multi-disc clutch
70
71
Shift lock
L
M

71.2
72

Leakage check valve
MB
MK
Measuring point multi-disc brake

Measuring point multi-disk clutch
73
74
Shuttle check valve

+P
75
Shifting piston
S
T

to tank
76
77
Check valve
Orifice
Y55
Solenoid / 1st gear
80
87
Multi-disc brake
Y60
Solenoid / 2nd gear
93
101
Multi-disc clutch
Accumulator
102
210
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MJF C I F S S
Service Manual

Fig. 3
Diagram of transmission and shift lock (shifting position = 2nd gear)
copyright by
MJF C I F S S
11.20.9
Service Manual

5.1
Input speed
Control oil
to
connection
Function /
transmission

oil volume
800 rpm to
max. speed

B

check valve 73
released
Valves 72 and 73 block the connection to point K.

check valve 76 and connection K
to the tank.
70
71

gear)
79
B

from HBGV block
to multi-disc brake
72
73
Leakage check valve

Shuttle check valve
K
K
to HBGV block
from multi-disc clutch
74
75
Shifting piston
Pp
S
Pump pressure
76
77
Check valve
Orifice
Sp
T
Shifting pressure
Return / tank
78
Shift lock
pump pressure is applied to the shifting piston 75. The shifting piston is thus pressed against the pressure spring into working position.
from connection B to connection K. The shuttle check valve 73 continues to release the pressure to
connection B so that shifting down is not possible. The machine remains in on-road gear.
11.20.10
copyright by
MJF C I F S S
Service Manual

Fig. 4
at high speed
copyright by
MJF C I F S S
11.20.11
Service Manual
5.2

Input speed
Control oil
to
connection
Function /
transmission
800 rpm to
max. speed

bar
K

B.
released

check valve 72 and connection B to the tank.

gear)
Shifting down to 1st
gear not possible.
shifting down only possible when the input
speed is below 800
rpm
70
71
11.20.12
78
79


72
Leakage check valve
B
B
to HBGV block
to multi-disc brake
73
74
Shuttle check valve

K
K
from HBGV block

from multi-disc clutch
75
Shifting piston
Pp
Pump pressure
76
77
Check valve
Orifice
S
Sp

Shifting pressure
Shift lock
copyright by
MJF C I F S S
Service Manual

Fig. 5
copyright by
MJF C I F S S
11.20.13
Service Manual
5.3
Input speed
Control oil
to
connection
0-800 min-1
Function /
transmission

position
K

of control spool)

multi-disc brake.
Clutch released
Valve 72 blocks the connection to point B.
shifting piston 75 (open control edge) and connection B to
the tank.
70
11.20.14
Multi-disc brake not

pressurised
Brake applied
79
71
B
B
to HBGV block
from multi-disc brake
72
Leakage check valve
from HBGV block
73
74
Shuttle check valve

K
Pp
Pump pressure
75
76
Shifting piston
Check valve
S
Sp

Shifting pressure
77
Orifice
Return / tank
78
Shift lock
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MJF C I F S S
Service Manual

Fig. 6
copyright by
MJF C I F S S
11.20.15
Service Manual

Fig. 7
6.1

6.2
the operator's seat, Fig. 7.
operated.
6.3

Preselect the travel direction at the preselection switch S263 located in the right pilot control unit, Fig.
7.
The indicator lights H167 or H168 respectively indicate the preselected travel direction. They are integrated into the right control desk, Fig. 7.
The indicator light H167 (forward) is on.
When the pilot control unit 84, Fig. 7, is actuated the machine travels forward.
The indicator light H168 (reverse) is on.
When the pilot control unit 84, Fig. 7, is actuated, the machine travels backward.
6.4
Brakes
Caution!
Actuate the pedal 22 of the working brake (to the right of the steering column) until the brake is
fully applied (foot pedal 22 engages in the locking device 23,, Fig. 7).
11.20.16
copyright by
MJF C I F S S
Service Manual

By applying the parking brake (multi-disc brake 87 and clutch 93) with switch S16, the machine is
secured against inadvertent rolling-off when parked, Fig. 7.
The indicator light in the switch S16 is on.
By applying the parking brake, the electric mass, and connection to the solenoid valves for the travel
direction preselection are disconnected, so that the machine cannot be moved when the brake is applied (see also electrical system).
Note!
still.
6.5
Parking the machine

The multi-disc packs 87 and 93 are closed automatically.
Fig. 7
Switches and indicator lights
22
H168
23
84*
Foot pedal retainer

S16
S42

Switch 1st gear
H20
S263
H167
copyright by
MJF C I F S S
11.20.17
Service Manual
Caution!
To tow the machine, use a suitably dimensioned rod.
Never use a cable or rope.
7.1

If there is no battery power or in the event of an electric failure, activate the emergency mode at the
double solenoid valve Y60/Y55:
Turn in the T-handle screw 67 at the double solenoid valve Y60/Y55. The valve plunger is pressed
into its open position.
The brake is released and the machine is in 2nd gear.
Fig. 8
60
67
11.20.18
Valve block
Valve block, complete
Y55
Y60
copyright by
MJF C I F S S

Solenoid valve / 2nd gear parking brake
Service Manual

7.2

In this case, there is no pilot control oil at the valve block 60 required to release the parking brake.
Danger!
With the subsequent emergency activation for towing, the parking brake is temporarily disabled.
Before accessing the danger area and the area of the undercarriage, secure the wheels with
chucks.
in its position.
Disconnect the solenoid valves Y6 / Y55 to disable gear switching when the emergency activation is on.
Fig. 9
7.2.1
Transmission with emergency activation of the gearbox
Switch on emergency activation

Using the grease gun (included in machine toolbox), press normal grease into the lubrication nipple 1 until it escapes at the pressure relief valve 3.
The machine can now be towed away, see 7.2.
copyright by
MJF C I F S S
11.20.19
Service Manual
Maintenance
Caution!
When the diesel engine is shut down, the working brake can still perform a few braking manoeuvres,
even if the brake accumulator is filled.
Vor
Before setting the gearbox back to normal mode (after towing) deactivate the emergency activation!
Do not lubricate the lubrication nipple 3, Fig. 9, of the emergency activation.
7.2.2
Deactivating emergency activation

Open the bleeder 4 of the emergency activation.
If the gear can be shifted, switch it to on-road gear (S16 not actuated - S42 not actuated).
The indicator light in the switch S16 / S42 and the indicator light H20 are off.
If the gearbox is dismantled, apply pilot control pressure to the connection B at the gearbox.
Close the bleeder 4.
Release the pressure supply at connection B or actuate S16.
The multi-disc brake and the multi-disc clutch are now again operational.
8 Maintenance
Danger!
secured.
8.1
Oil level check

3.
Carefully clean and remove the screw plug at the check and filling opening 10 at the gearbox 80
and check the oil level.
If the oil level is below the lower edge of the opening , add oil of the prescribed viscosity to
11.20.20
copyright by
MJF C I F S S
Service Manual

Maintenance
8.2
Oil change
the oil:
Carefully clean and remove the screw plug from the oil discharge bore 9 and the control and refill
bore 10 at the gearbox 80.
Clean the screw plug of the oil discharge bore 9 and its sealing surfaces.
Screw in the plug screw at the gearbox 80 (ensure that the seal ring is properly positioned) and
tighten it.
Clean the screw plug of the check and refill bore 10 and the sealing surfaces.
Screw in the plug screw at the gearbox 80 (ensure that the seal ring is properly positioned) and
tighten it.
Fig. 10
Oil discharge bore, oil check and filling opening
80 Transmission, complete
Oil discharge bore
10 Oil check and filling opening
copyright by
MJF C I F S S
11.20.21
Service Manual
Maintenance
8.3
Check of gearbox
Fig. 11
Measuring points at the gearbox and valve block
60
62

Pressure valve
70
80
Shift lock
63
MB
MK
Measuring connection for multi-disc brake

Measuring connection for multi-disc clutch
Note!
8.3.1
Checking the release pressure of the discs, see Fig. 11

Connect the pressure sensor (0-60 bar) to the measuring point 63 of the valve block 60.
Start the engine.
Check the opening pressure, (see Technical data on page 2).
After adjustment, remove the pressure sensors and seal the measuring points.
8.3.2
Checking the opening pressure in the piston chamber / multi-disc brake and
multi-disc clutch, see Fig. 11
Connect the pressure transducer (0-60 bar) to the measuring points MB and MK .
Release the parking brake with the switch S16 and measure the pressure at the measuring point
MB, comparing it with the prescribed value, (see Technical data on page 2).
1. Select the gear with the switch S42 and measure the pressure at the measuring point MK, comparing it with the prescribed value (see Technical data on page 2).
If the prescribed pressure is not reached, it must be assumed that there is a fault in the switch
fusing system.
If the pressure is OK, remove the pressure sensor.
11.20.22
copyright by
MJF C I F S S
Service Manual

Installation, dismantling and repair
9 Installation, dismantling and repair

Danger!
9.1
In models A 309 - A 312
Fig. 12
12
9.1.1
Dismantling and installation of the gearbox in models A 309 - A 312

60
Hex head screw
13
Hex nut
62
Washer
40
44
Angle bracket
Hex head screw
80
210
Gearbox, complete
Oil motor / travel drive
52
Washer
EB
Bleeder connection B
54
Hex head screw
EK
Bleeder connection K
Dismantling of the gearbox

Lift the undercarriage using suitable lifting gear or propping it up on the outrigger/blade support.
Drain off gear oil, see 8.2.
copyright by
MJF C I F S S
11.20.23
Service Manual
Note!
To disconnect the universal joint shafts, the output shaft of the gearbox 80 must be cranked.
Lift the undercarriage at the front and back (wheels off the ground).
Release the parking brake with switch S16 (indicator light H20 and LED in switch are off).
If there is no opening pressure: Switch on emergency activation, see 8.3.1
Remove the hex nuts 13 and remove the universal joint shafts 12 from the output flanges.
By cranking the wheels of the machine, screw connections at the universal joint shaft flange connection that are normally not accessible become accessible.
Apply the parking brake with switch S16 (indicator light H20 and indicator light in the switch S16
are on).
Switch off the engine.
Disconnect and seal all hydraulic lines from the gearbox 80 and the oil motor 210 (collect escaping
oil).
Secure the gearbox with suitable supports 80.
Remove the gearbox 80 and the angle console 40 from the gearbox 80.
Pull the oil motor 210 from the gearbox 80.
9.1.2
Repairs
Note!
For detailed repair instructions for the axle, refer to the separate "Repair manual for 2 HL 250 / 270
/ 290 transmission".
9.1.3
Installation of the gearbox

Screw in the hex head screws 22 and tighten them (torque 280 Nm).
Position the angle bracket 40 in the correct position on the gearbox 80.
Tighten the hex head screws 44 (torque 79 Nm).
Insert the gearbox 80 with the angle bracket 40 into the undercarriage, using suitable lifting gear.
Secure the angle bracket 40 to the undercarriage, using the hex head screws 54 and the washers
52 (torque 560 Nm).
Secure the gearbox 80 to the undercarriage, using the hex head screws 60 and the washers 62
(torque 430 Nm).
Mount the universal joint shafts 12 to the output flanges of the gearbox 80 and tighten the hex nuts
13.
If the emergency activation is on, deactivate it, see section 7.2.2.
11.20.24
copyright by
MJF C I F S S
Service Manual

Connect all hydraulic lines of the gearbox 80 and the oil motor 210.
Release the parking brake with the switch S16 (indicator light H20 and indicator light in the switch
S16 are off).
Caution!
Overspeeding of the gearbox without sufficient oil can damage the gear system.
Before starting the machine, check the oil level, see 8.1, and add oil, if necessary.
Check all screw connections at the gearbox and the oil motor for leakage.
Carefully bleed the gearbox 80, see 10.
9.2
In models A 314 - A 316
Fig. 13
9.2.1
Dismantling and installation of the gearbox in models A 314 - A 316
12
19
Hex head screw
13
Hex nut
24
Washer
14
15
Plate
Washer
26
80
Nut
Gearbox, complete
16
17
Hex head screw

Rubber pads
210
EB
Oil motor / travel drive

Bleeder connection B
18
Washer
EK
Bleeder connection K
Dismantling of the gearbox

Lift undercarriage using the outrigger support system
copyright by
MJF C I F S S
11.20.25
Service Manual

Drain off gear oil.
Note!
To disconnect the universal joint shafts, the output shaft of the gearbox 80 must be cranked.
Lift the undercarriage at the front and back (wheels off the ground).
Release the parking brake with switch S16 (indicator light H20 and indicator light in switch are
off).
If there is no opening pressure: Switch on emergency activation, see 7.2.1
Remove the hex nuts 13 and remove the universal joint shafts 12 from the output flanges.
Apply the parking brake with switch S16 (indicator light H20 and indicator light in the switch S16
are on).
Switch off the engine. Release the pressure from the system.
Disconnect and seal all hydraulic lines from the gearbox 80 and the oil motor 210 (collect escaping
oil).
Secure the gearbox with suitable supports 80.
Remove the mounting bolts 19 (secured with Omnit; heat, if necessary).
Remove the washers 18 and the rubber pads 17.
Remove the gearbox 80 with plate 14 from the undercarriage.
Remove the mounting bolts 16 (secured with Omnit; heat, if necessary).
Remove the washers 15.
Remove the plate 14 from the gearbox 80.
Remove the nuts 26 and the washers 24.
Pull the oil motor 210 from the gearbox 80.
9.2.2
Repairs
Note!
For detailed repair instructions for the axle, refer to the separate "Repair manual for 2 HL 250 / 270
/ 290 transmission".
9.2.3
Installation of the gearbox

Mount the nuts 26 with the washers 24.
Apply a tightening torque of 280 Nm.
Place the plate 14 on the gearbox 80.
Apply Omnit 100 to the mounting bolts 16 and screw them in with the washer 15.
Drive the rubber pads 17 from the top and bottom into the boreholes of the plate 14.
Insert the gearbox 80 with plate 14 into the undercarriage.
Apply Omnit 100 to the mounting bolts 19 and screw them in with the washer 18.
11.20.26
copyright by
MJF C I F S S
Service Manual

Bleeding of gearbox
Start the diesel engine.
Release the parking brake with the switch S16 (indicator light H20 and indicator light in the switch
S16 are off).
Mount the universal joint shafts 12 to the output flanges of the gearbox 80 and tighten the hex nuts
13.
If the emergency activation is on, deactivate it, see section 7.2.2.
Caution!
Overspeeding of the gearbox without sufficient oil can damage the gear system.
Before starting the machine, check the oil level, see 8.1, and add oil, if necessary.
Check all screw connections at the gearbox and the oil motor for leakage.
Carefully bleed the gearbox.
10 Bleeding of gearbox
Fig. 14
4
Gearbox bleeder
EB
Bleeder for multi-disc brake
EK
Bleeder for multi-disc clutch

In models A 309 - A 312:
Remove the protective cap of the bleeder EB. Place one end of a transparent bleeder hose for the
hydraulic oil in a suitable collecting vessel. Connect the other end to the bleeder nozzle EB.
Open the bleeder EB.
In model A 316:
Remove the protective cap of the bleeder EB. Place one end of a high pressure hose for the hy-
copyright by
MJF C I F S S
11.20.27
Service Manual
Bleeding of gearbox
draulic oil in a suitable collecting vessel. Connect the other end to the bleeder nozzle EB.
Release the parking brake with switch S16, (see Fig. 7 on page17), (brake connection pressurised).
If a new gearbox has been installed, also open bleeder 4 (no oil escaping here).
This approach ensures that the emergency activation is in its initial position.
Release the multi-disc brake for approx. 20 sec.
Close both bleeders 4 and EB (in model A 316, remove the high pressure hose).
In models A 309 - A 312:
Remove the protective cap of the bleeder EK. Place one end of a transparent bleeder hose for the
hydraulic oil in a suitable collecting vessel. Connect the other end to the bleeder nozzle EK.
Open the bleeder EK.
In model A 316:
Remove the protective cap of the bleeder EK. Place one end of a high pressure hose for the hydraulic oil in a suitable collecting vessel. Connect the other end to the bleeder nozzle EK.
Switch the machine to off-road gear, using switch S42, (see Fig. 7 on page17), (clutch connection
pressurised).
Release the multi-disc clutch for approx. 20 sec.
Close the bleeder EK (in model A 316, remove the high pressure hose).
Continue the bleeding procedure (at least 2 more times) until there is no air left in the chambers
of the multi-disc brake and the multi-disc clutch.
There must be no visible air bubbles in the oil when completing the last the bleeding procedure.
When shifting the gear from off-road to on-road (1st to 2nd gear) at low engine speed, the travel
drive must not become blocked.
After completion of the bleeding procedure, close the bleeders EB and EK (in model A 316, remove the high pressure hose) and replace the protective caps.
11.20.28
copyright by
MJF C I F S S
Service Manual

11 Component arrangement
Fig. 15
Diesel engines with gear pumps and control oil unit of the various models
32
Gear pump pilot control / brake unit with flow dis- 49

tributor (residual flow for pilot control)
33
Fig. 16
50

Control oil unit
Valve block in the uppercarriage with solenoid valves and measuring point
60
Valve block
Y6
62
63
Pressure valve
Y55
Solenoid / 1st gear
copyright by
MJF C I F S S
11.20.29
Service Manual
1
Hydraulic tank
90
Disc springs / multi-disc clutch
91
Piston / multi-disc clutch fixed
92
Piston / multi-disc clutch rotating
93
Multi-disc clutch
20
Double variable-displacement pump (*) 94

A 309 - A 311
Variable-displacement pump (*) A 312 - 95
A 316
20
Pressure spring
32
Gear pump / pilot control and

brake (*)
96
Piston / emergency activation
33
49
Gear pump / pilot control (*)

97
98
Counterpart / emergency activation

Bolt / emergency activation
50
51

Pressure relief valve / pilot control
99
100
Spur gear
Output flange
60
61

Shifting piston
101
102
Accumulator
62
Pressure valve
210
63
67

Emergency activation / shifting to 1st
gear
322
70
71

Gear pump
EB
EK
Bleeder / brake B
Bleeder / clutch K
71.2
Suction filter
MB
72
73
Leakage check valve

Shuttle check valve
MK
H20

74
75

Shifting piston
S16
S42

76
77
Check valve
Orifice
Y55
Y60
Solenoid / 1st gear (X)

Solenoid / 2nd gear (X)
80
81
Connecting flange
Connections:
82
Drive shaft
B, B, B Pressure oil supply of multi-disc brake
84
85
Planetary gear
Planetary carrier
K/K/K Pressure oil supply to multi-disc clutch

J, M
Measuring connections
86
Hollow gear
P, Pp
Pressure from control oil pump
87
Multi-disc brake
S, Sp
Suction connection (lubricating pressure)
88
Piston / multi-disc brake
Return connection
89
Disc springs / multi-disc brake
= Items in hydraulic diagram of group 6
11.20.30
Inner disc carrier
copyright by
MJF C I F S S
Service Manual

Function

1 Function
Machines with 2 HL 70 / 100 powershift transmissions are equipped with a transmission control system as standard.
(HBGV block = hand brake and gear shift valve block)
The HBGV block has the following functions:
The solenoid valve Y6 (shifting piston 20 with solenoid part 120see Fig. 2) integrated in the HBGV
block 60 controls the parking brake in the transmission.
The solenoid valve Y55 (shifting piston 30 with solenoid part 20 - see Fig. 2) integrated in the
HBGV block 60 controls the off-road gear clutch in the transmission.
The pressure-relief valve 63 (backpressure valve) integrated in the HBGV block 60 prevents the
parking braking being suddenly applied, e.g. when the brake is closed, or in the event of a power
failure.
The flange-connected pressure switch B10 mounted to the HBGV block 60 disables the travel direction control when the brake is closed, thus protecting the parking brake against an overload.
The flange-connected hydraulic accumulator 64 mounted to the HBGV block 60 protects the hydraulic circuit of the transmission control against pressure fluctuations, thus preventing disruptions
in the travelling movement of the machine. It also delays the (instant) closing of the multi-disc clutches in the event of an emergency braking manoeuvre.
Fig. 1
Hydraulic diagram and HBGV block 60
60
HBGV block
66
63
B10* Pressure switch
64
65
Hydraulic accumulator
Measuring point
Y55* Solenoid valve / 1st gear

Y6* Solenoid valve / parking brake
Check valve
* items in electrical / hydraulic diagram
copyright by
MJF C I F S S
11.30.1
Service Manual
Fig. 1 and Fig. 2
The HBGV block is pressurised with control pressure (from the control oil unit 50) via the check valve
66 (Fig. 2) and connection P. The control or backpressure can be measured at measuring point M of
the HBGV block.
The block is linked through the connections A / B and hydraulic lines to the shift lock of the distributor
gear. The oil from the piston chambers of the gearbox is fed through connection T to the hydraulic
tank.
2.1
Neutral position
If the switches S16 and S42 in the control console are not actuated, both solenoid valves Y6 and Y55
are in neutral position, i.e. the multi-disc brake and the multi-disc clutch are not pressurised and thus
closed by the disc springs. The gearbox is blocked.
2.2
Control of multi-disc brake (parking brake)

When setting the switch S16 to its opening position, the solenoid valve Y6 is powered and opens.
The pilot control oil flows through the solenoid valve Y55 and connection A to the shift lock/gear. The
multi-disc brake is released, while the multi-disc clutch remains closed. The machine is in 2nd gear.
When setting the switch S16 to its closing position, the solenoid valve Y6 is not powered and thus
closes. The pilot control oil flow is blocked. The oil from the piston chamber of the multi-disc brake is
fed via the shift lock/gear and connection A, solenoid valve Y55, solenoid valve Y6 and backpressure
valve 63 to the tank. The multi-disc brake is closed by the disc springs.
2.3
Control of the multi-disc clutch (gear clutch for 1st gear)

When the switch S42 is set to 1st gear position (= off-road gear), the solenoid valve Y55 is powered
and set to its changeover position. The pilot control oil flows through the already switched solenoid
valve Y6 and connection B to the shift lock/gear.
At the required shift speed (monitored by the shift lock), the multi-disc clutch is opened. At the same
time, the multi-disc brake is closed, as the piston chamber of the brake is depressurised via connections A and T to the tank. The machine is in 1st gear.
When setting the switch S16 to its reset position, the solenoid valve Y55 is not powered and thus returns to its initial position. The pilot control oil flows through the already switched solenoid valve Y6
and connection A to the shift lock/gear.
In this process, the multi-disc brake is released as the brake piston is pressurised with control pressure. The multi-disc clutch is thereby closed as the clutch chamber is depressurised via connection
B, solenoid valve Y5 and connection T to the tank. The machine is in 2nd gear.
2.4
Emergency activation of the multi-disc brake

To tow the machine, the parking brake must be released.
If this cannot be done in the normal way, as the electrical system is dead despite running diesel engine and correct pilot pressure (i.e. Y6 not powered), the solenoid valve Y6 can be operated manually
by turning the T-handle screw of the device 70 clockwise.
11.30.2
copyright by
MJF C I F S S
Service Manual

Fig. 2
10
Sectional drawing of the HBGV block

110
Housing
Magnetic tube
20
Piston
120
Magnetic coil
30
40
Piston
Spring plate
130
160
Protective cover
Collar nut
50
60
Screw plug
Adjusting screw
170
180
Ball
Nozzle
63
190
Protective cover
70
Manual emergency locking mechanism
260
Knurled nut
80
Pushrod
999
Seal kit
90
Pressure spring
Y6
100
Pressure spring
Y55
copyright by
MJF C I F S S
11.30.3
Service Manual
2.5
Testing and adjustment of the backpressure-limiting valve 63
Fig. 3
View and sectional drawing of HBGV block (key see Fig. 1 and Fig. 2)
Remove the cover cap at the measuring point 65 and connect a pressure sensor (0-60 bar).
Start the diesel engine and observe the pressure sensor.
Set the switch S16 to open or push the safety lever S7 down.
The buzzer is off.
Set the switch S16 to close or push the safety lever S7 up.
The parking brake is applied.
The buzzer sounds (unless the safety lever S7 has been actuated when the switch S35 was
pressed).
The opening pressure (pilot control pressure) gradually drops to the value of the required backpressure (see chapter "General information" for group 11.10).
If the backpressure does not reach the prescribed value:
Remove the cover cap 190.
Loosen the collar nut 160.
Turn the adjusting screw 60 at the backpressure-relief valve 63 until the actual pressure corresponds to the nominal pressure.
Turn adjusting screw 60 in.
= Increase pressure
Turn adjusting screw 60 out.
= Reduce pressure
After the pressure has been adjusted, tighten the collar nut 160 and replace the cover cap 190.
2.6
Inspection of the hydraulic tank 64

Remove the cover cap at the measuring point 65 and connect the pressure sensor.
Start the diesel engine and observe the pressure sensor.
Testing procedure with activation of the switch S16 or operation of the safety lever S7, see 2.5.
If the hydraulic tank 64 works properly, the opening pressure gradually drops to the backpressure as
regulated by valve 63. The pressure then remains at this level for a certain period of time. If the opening pressure suddenly drops to a value near 0 bar when the brake is applied, the hydraulic tank 64
is defective and must be replaced.
11.30.4
copyright by
MJF C I F S S
Service Manual

Function and design

Machines with 2 HL 270/290 powershift transmissions are equipped with a HBGV block as standard.
(HBGV block = hand brake and gear shift valve block)
The HBGV block mounted to the basic boom bearing block of the revolving deck or to the hydraulic
tank has the following functions:
Y60
67
Control of the transmission in off-road gear by means of the solenoid valve Y55.
The pressure-relief valve 62 installed in the HGBV block 60 protects the gearbox against damage
from excessive or insufficient control pressure.
Fig. 1
Design of the HBGV block
60
HBGV block
Y60
62
Connection to brake / on-road gear

2nd gear
63
Measuring point
Connection to clutch / off-road gear

1st gear
67
Y55
T-handle for emergency operation

P
T
Connection to pilot control pressure

Tank connection
copyright by
MJF C I F S S
11.32.1
Service Manual
The HBGV block is pressurised with pilot control pressure by the gear pump / pilot control system
through the connection P (at control oil unit 50). The control pressure at the HBGV block can be
measured at the measuring point 63 (M).
The block is linked through the connections K / B and hydraulic lines to the shift lock of the load-holding transmission. The oil from the piston chambers of the gearbox is fed through connection T to the
hydraulic tank.
2.1
Neutral position
If the switches S16 and S42 are not actuated, the solenoid valves Y55/Y60 are not powered. The
piston 61 is thus in neutral position and the multi-disc brake (B) and the multi-disc clutch (K) of the
gearbox are not pressurised and thus applied/engaged by disc springs. The parking brake is applied
and the gear is locked.
2.2
Control of multi-disc brake (parking brake)

Set the switch S16 to opening position to power the solenoid valve Y60. The piston 61 is shifted to
position a. The pilot control oil flows through the piston 61 connection B (shift locking) the piston
chamber of the multi-disc brake in the gearbox. The multi-disc brake is released, while th e multi-disc
clutch remains closed. The machine is in 2nd gear.
Set the switch S16 to closing position to shut off the power supply to the solenoid valve Y60. The
piston 61 is shifted to its neutral position. The pilot control oil flow is blocked. The oil from the piston
chamber of the multi-disc brake is fed through the shift lock / gearbox and the connection K, at the
piston 61 to the tank (T). The multi-disc brake is closed by the disc springs.
2.3
Control of the multi-disc clutch (gear clutch for 1st gear)

When the switch S42 is set to 1st gear position (= off-road gear), the solenoid valve Y55 is powered
and the piston 61 is shifted to position b. The pilot control oil flows through the already switched solenoid valve Y60, connection K to the shift lock/gear. The solenoid valve Y60 is not powered.
At the required shift speed (monitored by the shift lock), the multi-disc clutch is opened by the pilot
control pressure at the connection K. At the same time, the multi-disc brake is applied, as the piston
chamber of the brake is depressurised via connections B and T to the tank. The machine is thus in
1st gear.
Set the switch S42 to reset position to shut off the power supply to the solenoid valve Y55. The piston
61 is shifted to its neutral position. The pilot control oil flows over the piston 61 and the connection B
to the shift lock/gear.
In this process, the multi-disc brake is released as the brake piston is pressurised with control pressure. The multi-disc clutch is thereby closed as the clutch chamber is depressurised via connection
K, the piston 61 and THE connection T to the tank. The machine is thus in 2nd gear.
11.32.2
copyright by
MJF C I F S S
Service Manual

Fig. 2
Functional diagram
1
50
to hydraulic tank
322
S16
60
61
HBGV block
Piston
S42
Y55
Switch / off-road gear

62
Y60
63
Measuring point (M)
Connection to brake / on-road gear
64
Piston
Connection to clutch / off-road gear
66
67
Pressure spring
P
T
Connection to pilot control pressure

Tank connection
185
Transmission
copyright by
MJF C I F S S
11.32.3
Service Manual
Fig. 3
11.32.4
Sectional drawing of the HBGV block
60
61
HBGV block
Piston / shift valve
67
68

Spring plate
62
Y55
64
66
Piston / pressure-relief valve

Pressure spring
Y60
copyright by
MJF C I F S S
Service Manual

3 Pressure-relief valve 62
Fig. 4
3.1
Pressure relief valve in HBGV block
Function
The pressure relief valve 62 inserted in the HBGV block 60 protects the gearbox from damage
caused by insufficient or excessive control pressure. It ensures that no pressure < 26 bar is applied
to the gear shifting valve, so that the parking brake is applied.
At an existing control pressure of > 32 bar, this pressure is reduced by the integrated pressure reduction function to 32 bar.
3.2
Testing of pressure relief valve 62

Remove the cover cap at the measuring point 63 and connect the pressure sensor.
Start the diesel motor and observe the pressure sensor.
Release and reapply the parking brake.
This can be done with switch S16 (buzzer signal) or by turning the safety lever upwards (no
buzzer signal). The opening pressure (pilot control pressure) should then gradually drop to the
value of the required pressure (see chapter "General information" for group 11.20).
Note!
The pressure relief valve 62 is fixed by the spring pressure force 66 and cannot be adjusted.
3.3
Emergency activation of the multi-disc brake (machine in 2nd gear)

If the brake cannot be released due to a fault in the electrical system, despite running diesel engine
and correct pilot pressure (i.e. Y60 not powered), the solenoid valve Y60 can be operated manually.
To tow the machine, the parking brake must be released.
Turn in the T-handle 67 of the solenoid valve Y60, see Fig. 4.
The piston 61 is mechanically moved so that the multi-disc brake is pressurised with pilot control pressure through the connection B.
The machine can now be removed from the danger area.
copyright by
MJF C I F S S
11.32.5
Service Manual
11.32.6
copyright by
MJF C I F S S
Service Manual
Travel gear F40

Function
Travel gear F40

1 Function
The three-stage planetary gear is driven by the A 6VE hydraulic oil motor.
It propels the tumbler wheel attached to the gearbox and the crawler chain.
The wet multi-disc brake integrated into the gearbox acts directly onto the gear drive.
The brake is designed as a spring applied brake and is released hydraulically, i.e. when the brake
system is not pressurised, the discs are pressed together by the pressure springs, so that the brake
is mechanically applied.
Fig. 1
Travel gear F40
copyright by
MJF C I F S S
11.60.1
Travel gear F40
Service Manual
General information
Equipment
from serial number
R 317-Li
18161
Gearbox type
Input speed
Output speed
F40 - 110
max. (fast travel)
5479 min-1
min. (normal travel)
1713 min-1
max. (fast travel)
49.6 min-1
15.5 min-1
Max. output torque
40,000 Nm
Max. brake torque
420 Nm
Gear ratio
1: 110.38
Weight (approx.)
228 kg
4.5 l
Oil quality
API - GL - 5
Oil viscosity
SAE 90 W
SAE 80 W 90
SAE 90 LS
Brake
Min. brake release pressure
18 bar
33 bar
Settings and tightening torques, to be observed for

installation:
A)
Tightening torque for hex head screws 5
195 Nm
B)
620 Nm
C)
300 Nm
D)
300 Nm
E)
Tightening torque for nut 260
9000 Nm
F)
G)
46 Nm
H)
Tightening torque of screw plug 900
35 Nm
I)
Stroke of brake piston 30
3.2 mm
5.0 mm
new
Wear limit
resulting in a maximum permissible wear of
the entire disc pack of
Items A - D (see Fig. 2) Items E - H (see Fig. 6) Items I (see Fig. 8)

Tab. 1
11.60.2
34 Nm
Technical data, settings and tightening torques
copyright by
MJF C I F S S
1.8 mm
Service Manual
Travel gear F40

(see "Sectional drawing of the travel gear system", page 9)
The output torque of the hydraulic oil motor 3 is transmitted through the spline mesh of the brake 990
and the pinion 100 to the planetary stage I (positive coupling).
The pinion 100 thereby propels the planetary gear and thus the planetary carrier 10 and the pinion
(sun gear) 90 positively connected to the planetary carrier at the speed reduced by the planetary stage I.
The pinion (sun gear) 90 simultaneously propels the planetary gear and the planetary carrier 20 as
well as the pinion (sun gear) 80 positively connected to the planetary carrier 20 at the speed reduced
by the planetary stage II.
The pinion (sun gear) 80 propels the planetary gears of the planetary carrier 30 and thus the hollow
gear 40 (positive coupling) at the speed reduced by the planetary stage III .
The total speed reduction is the sum of the reductions of the three planetary stages.
4 Maintenance
4.1

The gearbox must be regularly serviced at the intervals laid down in the maintenance instructions in
group 3. Regular maintenance includes a check of the oil level, inspection for leakage and of the gearbox, oil motor and tumbler wheel for proper mounting.
The gear oil must be changed at the prescribed intervals.
To change the oil, follow the instructions below (see "Installation and dismantling of the travel
gear system", page 4) or refer to the operating manual.
The travel gear brake must also be inspected and tested at the prescribed intervals laid down in the
maintenance instructions in group 3.
copyright by
MJF C I F S S
11.60.3
Travel gear F40
Service Manual
Installation and dismantling of the travel gear system
5 Installation and dismantling of the travel gear system
Fig. 2
Attachment of the travel gear with tumbler wheel and oil motor to the longitudinal member
Longitudinal member
Hex head screw
2
3
Travel gear
Oil motor
8
9
Hex head screw

Cover
Tumbler wheel
11
Hex head screw
5
6
Hex head screw

Washer
12
Washer
Danger!
To dismantle and install the gearbox, the crawler chain must be dismantled, and the hydraulic and
brake systems of the machine must be interfered with, whereby the danger zone of the machine
must be accessed.
Before dismantling or installing the gearbox:
Park the machine on a level and firm surface.
If parked on a slope, secure the machine properly.
Release all pressure from the hydraulic system and the brake.
5.1
Dismantling
see Fig. 2 and see 5.2
Turn the gearbox until the screw plug at the front 900 is at the lowest point (position A).
The second screw plug 900 is in position 9.30 o'clock.
Place a suitable oil collecting container under the gearbox.
Remove both screw plugs 900.
11.60.4
copyright by
MJF C I F S S
Service Manual
Travel gear F40

Drain the gear oil from the gearbox into the container.
Insert both screw plugs 900; for tightening torque, (see Tab. 1, page 2)
Remove the oil collecting container.
Release the chain and remove it, see also group 12.70.
Remove the hex head screws 8 and disconnect the tumbler wheel 4 from the gearbox 2.
Remove the hex head screws 11 and lift off the cover 9 with the washers 12.
Prior to dismantling the gearbox, release all pressure from the pressure, leak oil and brake lines.
Disconnect the pressure, leak oil, lubricating and brake lines at the oil motor 3 (seal openings).
7

Mark or write down installation position of the gearbox 2.
Remove the hex head screws 5 and the washers 6, and lift the gearbox 2 from the undercarriage.
Fig. 3
5.2
Oil drain position A and oil filling and checking position B
Installation
see Fig. 2, see 5.2, see Fig. 4
Before installing the gearbox, ensure that it is in the correct position.
Place the gearbox into the gearbox bearing of the longitudinal member.
5
Check the O-ring 15 at the oil motor 3 and replace it, if necessary. New O-rings must be slightly
lubricated before they are placed onto the oil motor 3.
Place the oil motor 3 with brake valve in the gearbox 2.
Insert and tighten the hex head screws 7; for tightening torque, see Table 1, page 2.
Connect the brake, leak oil and hydraulic lines to the oil motor.
Mount the cover 9 and tighten the hex head screws 11 with washers 12.
For tightening torque, see Table 1, page 2.
copyright by
MJF C I F S S
11.60.5
Travel gear F40
Service Manual
Sealing of gearbox
Turn the gearbox 2so that one of the screw plugs 900 is in horizontal position (position B), (see
5.2, page 5).
Remove the upper screw plug 900.
Add gear oil (for recommended products, see Table 1, page 2) until the level reaches the lower
edge of the bore in the gearbox 2.
Close both screw plugs 900; for tightening torque, (see Tab. 1, page 2).
Mount the tumbler wheel 4 onto the gearbox 2 and secure it; for tightening torque, see Table 1,
page 2.
Tighten the hex head screws 8.
Mount the chain, see group 12.70.
6 Sealing of gearbox
Fig. 4
2
3
Seal between the oil motor and the gearbox

7
15
Travel gear
Oil motor
Hex head screw

O-ring
Note!
11.60.6
copyright by
MJF C I F S S
Service Manual
Travel gear F40

Sealing of gearbox
Please note:
Apply a little oil or grease to all sealing elements to facilitate installation.
6.1
Sealing of travel motor section

Turn the gearbox until the screw plug at the front 900 is at the lowest point (position A), (see 5.2,
page 5).
Insert both screw plugs 900; for tightening torque, (see Tab. 1, page 2).
Disconnect the pressure, leak oil, lubricating and brake lines at the oil motor3 (seal openings).
Remove the hex head screws 7 and pull the oil motor 3 from the gearbox 2 .
Replace the O-ring 15 of the oil motor3.
Mount the cover 9 and tighten the hex head screws 11 with washers 12; for tightening
torque, see Table 1, page 2.
6.2
Sealing of travel brake and replacement of brake discs

Note!
To carry out sealing and repair work on the travel brake, the travel gear does not have to be dismantled. It is however necessary to remove the oil motor from the gearbox, see 6.1.
For detailed instructions for the sealing and repair of the travel brake, refer to the repair manual
F40-110, chapter 'Brake'.
6.3
Replacement of the slide ring seal

Note!
To replace the slide ring seal, you must first dismantle the gearbox, (see "", page 4).
For detailed instructions for the sealing and repair of the travel brake, refer to the repair manual
F40-110, chapter "Wheel hub and bearing".
copyright by
MJF C I F S S
11.60.7
Travel gear F40
Service Manual
Exploded view of the travel gear system
7 Exploded view of the travel gear system
Fig. 5
11.60.8
Exploded view of the travel gear system
Oil motor
220
7
10
Hex head screw

Planetary carrier (planetary stage I)
260
290
Nut
Slide ring seal
15
O-ring
310
Shim
20
30
Planetary carrier (planetary stage II)

Planetary carrier (planetary stage III)
320
550
Adjusting ring
Circlip
40
50
Hollow gear
Cover
600
800
O-ring
Allen head screw
80
Pinion
810
O-ring
copyright by
MJF C I F S S
Service Manual
Travel gear F40

Sectional drawing of the travel gear system
90
100
Pinion
Pinion
840
850
Allen head screw

O-ring
200
210
Suspension tube
Hub
900
990
Screw plug
Brake see Fig. 7 and see Fig. 8
8 Sectional drawing of the travel gear system
Fig. 6
Travel gear system
Note!
Observe settings and tightening torques B, F, G, H for the maintenance and repair of the travel gear
system, see Table 1, page 2.
copyright by
MJF C I F S S
11.60.9
Travel gear F40
Service Manual
Exploded view of the travel brake
9 Exploded view of the travel brake
Fig. 7
11.60.10
Exploded view of the travel brake
10
Carrier
90
Outer disc (steel)
20
30
Hub
Piston
100
110
Inner disc (sinter)

Snap ring
40
50
Cover
Pressure spring
140
150
Backing ring
O-ring
60
70
Pressure spring
Seal
160
170
Backing ring
O-ring
80
Seal
180
Backing ring
copyright by
MJF C I F S S
Service Manual
Travel gear F40

Sectional view of the travel brake
10 Sectional view of the travel brake
Fig. 8
Travel brake in gearbox
Note!
For setting I for the maintenance and repair of the travel brake, see Table 1, page 2.
copyright by
MJF C I F S S
11.60.11
Travel gear F40
Service Manual
11.60.12
copyright by
MJF C I F S S
Service Manual

Design

1 Design
The three-stage planetary gear is driven by the A 6VE hydraulic oil motor.
It propels the tumbler wheel attached to the gearbox and the crawler chain.
The wet multi-disc brake integrated into the gearbox acts directly onto the gear drive.
The brake is designed as a spring applied brake and is released hydraulically, i.e. when the brake
system is not pressurised, the discs are pressed together by the pressure springs, so that the brake
is mechanically applied.
Fig. 1
FAT travel gear system
copyright by
MJF C I F S S
11.62.1
Service Manual
Technical data
2 Technical data
Machine
from serial number
R 313-Li / R 317-Li
27752 / 23450
Gearbox type
Input speed
FAT 350 P062

max. (fast travel)
5479 rpm

Output speed
1713 rpm
max. (fast travel)
49.6 rpm
15.5 rpm
Max. output torque
35,000 Nm
Max. brake torque
420 Nm
Gear ratio
1: 113
Weight (approx.)
180 kg
4.1 l
Oil quality
API - GL - 5
Oil viscosity
SAE 90 W
SAE 80 W 90
SAE 90 LS
Brake
18 bar
33 bar
Settings and tightening torques, to be observed for installation:

A) Check dimension for the installation of the oil motor
102
93.5+1 Nm
B)
Check dimension for the axial play at the wheel end

(from end of drive shaft 35 to flange face of the
lid 40
3.5 + 1 mm
C)
Friction torque of ball bearing 11
100 Nm
D)
Tightening torque for threaded stud 1.4
69 Nm*
46 Nm**
E)
Tightening torque for Allen head screws 46
F)
Tightening torque of screw plug 48
90 Nm
G)
560 Nm
H)
280 Nm
I)
560 Nm
K0) Tightening torque for hex head screws 109
117 Nm
Items A - F (see Fig. 5 on page9) and items G - K (see Fig. 2 on page4)

Tab. 1

* secured with Loctite 242
** secured with Loctite 272
11.62.2
copyright by
MJF C I F S S
Service Manual

(see Sectional drawing of the travel gear system on page 9)
The output torque of the hydraulic oil motor 96 is transmitted through the spline mesh of the disc carrier 55 and the drive shaft 35 to the planetary stage I (positive coupling).
The drive shaft 35, through the planetary gears 32, drives the planetary carrier 30 and thus the sun
gear 25 that is positively connected to the planetary carrier 25 at the speed of the oil motor as reduced
by the planetary stage I.
Simultaneously, the sun gear 25, through the planetary gears 22, drives the planetary carrier 20 and
thus the sun gear 15 that is positively connected to the planetary carrier 20 at the speed of the planetary stage I as reduced by stage I.
The sun gear 15, through the planetary gears 5 of the connected carrier 1, drives the hollow gear 10
that is positively connected, at the speed of the planetary stage III as reduced by stage II.
The total speed reduction is the sum of the reductions of the three planetary stages.
4 Maintenance
4.1

The gearbox must be regularly serviced at the intervals laid down in the maintenance instructions in
group 3. Regular maintenance includes a check of the oil level, inspection for leakage and of the gearbox, oil motor and tumbler wheel for proper mounting.
The gear oil must be changed at the prescribed intervals.
To change the oil, follow the instructions below see Fig. 3 or refer to the operating manual.
The travel gear brake must also be inspected and tested at the prescribed intervals laid down in the
maintenance instructions in group 3.
copyright by
MJF C I F S S
11.62.3
Service Manual
5 Installation and dismantling of the travel gear system
Fig. 2
Attachment of the travel gear with tumbler wheel and oil motor to the longitudinal member
100
101
Longitudinal member
Travel gear
106
107
Hex head screw

Hex head screw
102
103
Oil motor
Tumbler wheel
108
109
Lid
Hex head screw
104
Hex head screw
110
Washer
105
Washer
Danger!
To dismantle and install the gearbox, the crawler chain must be dismantled, and the hydraulic and
brake systems of the machine must be interfered with, whereby the danger zone of the machine
must be accessed.
Before dismantling or installing the gearbox:
If parked on a slope, secure the machine properly.
Release all pressure from the hydraulic system and the brake.
5.1
Dismantling
see Fig. 2 and see 5.2
Turn the gear until the screw plug at the front 48 (A) is at the lowest point.
The second screw plug 48 (K/E) is in position 2 o'clock.
11.62.4
copyright by
MJF C I F S S
Service Manual

Insert both screw plugs 48; for tightening torque, (see Tab. 1 on page2).
Remove the oil collecting container.
Release the chain and remove it, see also group 12.70.
Remove the hex head screws 107 and disconnect the tumbler wheel 103 from the gearbox 101.
Disconnect the pressure, leak oil, lubricating and brake lines at the oil motor 102 (seal openings).
Remove the hex head screws and the oil motor 102 together with the brake valve from the gearbox 101 .
Mark or write down installation position of the gearbox 101.
Remove the hex head screws 104 and the washers 105, and lift the gearbox 101 from the undercarriage.
Fig. 3
5.2
Gear positions for oil discharge, refilling and inspection
48 Screw plug
A Oil discharge bore
K Inspection bore
Oil filling bore
Installation
see Fig. 2, see Fig. 4
Caution!
the screws, can result in serious damage of components such as longitudinal members, gearboxes
and chains. Such breaks can also injure persons standing nearby.
For safety reasons, all screws must thus be replaced with new ones when the gearbox and the
tumbler wheel are replaced.
When mounting the gearbox and the tumbler wheel, always use new screws.
Before installing the gearbox, ensure that it is in the correct position.
copyright by
MJF C I F S S
11.62.5
Service Manual
Sealing gearbox
Place the gearbox into the gearbox bearing of the longitudinal member.
Insert and tighten the hex head screws 104 with washers 105; for tightening torque, see Table 1,
page 2.
Check the O-ring 112 at the oil motor 102 and replace it, if necessary. New O-rings 112 must be
slightly lubricated before they are placed onto the oil motor 102.
Place the oil motor 102 with brake valve in the gearbox 101.
Mount the cover 108 and tighten the hex head screws 109 with washers 110.
For tightening torque, see Table 1, page 2.
Turn the gearbox 101 so that one of the screw plugs 48 is in horizontal position, (see 5.2 on
page5).
The second screw plug 48 is in position 2 o'clock.
Remove the upper screw plug 48 (K/E).
Add gear oil (for recommended products, see Table 1, page 2) until the level reaches the lower
edge of the bore in the gearbox 101.
Close both screw plugs 48; for tightening torque, (see Tab. 1 on page2).
Mount the tumbler wheel 103 onto the gearbox 101 and secure it; for tightening torque, see
Table 1, page 2.
Tighten the hex head screws 107.
Mount the chain, see group 12.70.
6 Sealing gearbox
Fig. 4
Seal between the oil motor and the gearbox
101
Travel gear
106
Hex head screw
102
Oil motor
112
O-ring
Note!
11.62.6
copyright by
MJF C I F S S
Service Manual

Sealing gearbox
Before you start assembly, please note:
Apply a little oil or grease to all sealing elements to facilitate installation.
6.1
Sealing of travel motor section

Turn the gear until the screw plug at the front 48 (A), (see 5.1 on page4), is at the lowest point
(position 6 o'clock).
The second screw plug 48 (K/E) is in position 2 o'clock.
Insert both screw plugs 48; for tightening torque, (see Tab. 1 on page2).
Disconnect the pressure, leak oil, lubricating and brake lines from the oil motor 103 (seal openings).
Remove the screws 106 and pull the oil motor 102 from the gearbox 101 .
Replace the O-ring 112 of the oil motor 102.
Insert and tighten the screws 106; for tightening torque, see Table 1, page 2.
Mount the cover 108 and tighten the hex head screws 109 with washers 110; for tightening torques, Table 1, page 2.
6.2

Note!
To carry out sealing and repair work on the travel brake, the travel gear does not have to be dismantled. It is however necessary to remove the oil motor from the gearbox, see 6.1.
For instructions regarding sealing and repair work, refer to the FAT 350 P repair manual.
6.3
Replacement of slide ring seal

Note!
To replace the slide ring seal, you must first dismantle the gearbox, (see on page 4).
For detailed instructions regarding the sealing and repair of the travel brake, refer to the FAT 350 P
repair manual, chapter 'Sealing work at the connected carrier'.
copyright by
MJF C I F S S
11.62.7
Service Manual
Sealing gearbox
1
Connected carrier (planetary stage III)
41
Stop washer
1.2
1.3
Seal plug
Taper pin
42
45
L-ring
O-ring
1.4
Threaded stud
46
Allen head screw
Snap ring
48
Screw plug
Stop washer
50
Thrust plate
5
6
Planetary gear
Snap ring
51
52
Inner disc
Outer disc
7
10
Seal plug
Sun wheel
55
56
Disc carrier
Lip seal
11
15
Ball
Sun gear
57
60
Lip seal
Annular piston
20
Planetary carrier (planetary stage II)
61
Pressure spring (large)
21
22
Stop washer
Planetary gear
62
63
Pressure spring (small)

Locking ring
23
25
Snap ring
Sun gear
64
70
Snap ring
Slip ring seal
30
Planetary carrier (planetary stage I)
71
O-ring
31
Stop washer
72
Grooved pin
32
Planetary gear
75
Shroud ring
33
35
Snap ring
Drive shaft
76
95
Circlip
Planetary carrier
36
38
Circlip
Ball cage
102
106
Oil motor
Hex head screw
40
Lid
112
O-ring
Note!
Observe settings and tightening torques A, B, C, D, E, F, and H for the maintenance and repair of
the travel gear system, see Table 1, page 2.
11.62.8
copyright by
MJF C I F S S
Service Manual

7 Sectional drawing of the travel gear system
Fig. 5
Travel gear system
copyright by
MJF C I F S S
11.62.9
Service Manual
11.62.10
copyright by
MJF C I F S S
Service Manual
Travel brake
Function
Travel brake
1 Function
The travel brake is a wet multi-disc brake that is hydraulically released and installed in each travel
gear system. It acts on the gear output.
To apply the brake, the pressure to the brake connection of the travel gear system 216 is blocked by
the solenoid valve / travel brake valve 205. In the event of a failure of the hydraulic unit, there is no
pressure available to open the travel brake 215, so that it remains applied.
In both cases, pressure springs connected to a brake piston push against the brake discs and thus
mechanically apply the brake (static brake function).
The brake acts as a spring-applied brake with a safety function in the event of malfunction of the machine.
The machine is equipped with a second brake system for the travel oil motor. The travel brake valve
205 flange-mounted to the oil motor 200 / 201 acts as a dynamic brake on the hydraulic gearbox drive.
For a description of the travel brake valves 205, see group 7.90 hydraulic components).
Fig. 1
Components of the hydraulic system and brake
82
83
Pilot control unit, travel left

Pilot control unit, travel right
200
201
Travel motor, left

Travel motor, right
100
160

205
215
Brake valve
Travel brake
180
216
Travel gear
copyright by
MJF C I F S S
11.65.1
Travel brake
Service Manual
Design, (see Fig. 1, page 1)
2 Design, (see Fig. 1, page 1)

2.1
Pilot control units 82 / 83

The pilot control units 82 /83 equipped with pedal ensure that the control oil flows to the spools 160
/ 180 in the control valve block 100. Depending on the pedal travel, high pressure is established in
the lines to the travel motors 200 / 201.
2.2
Travel motor 200 / 2001

The axial piston oil motor is designed as a plug-in motor for installation into the travel gear system
216. It is positively connected to the planetary drive and the travel gear multi-disc brake 215 in the
gearbox.
2.3
Brake valve 205

Each travel motor 200 /201 is equipped with a flange-mounted brake valve. The brake piston in brake
valve 205 acts on the hydraulic return line of the travel motor and prevents overspeeding of the oil
motor when the machine is travelling downhill.
The brake valves 205with the respective pressure pA or pB also produce the release pressure required to release the multi-disc brake. Through the connection Bre of the brake valve 205 and the
hose line 210, the release pressure also acts on the brake piston of the travel brake.
2.4
Multi-disc travel brake 215

The brake discs are integrated into the travel gearbox. Pressure springs connected to the brake piston press the inner and outer discs against each other. The high friction blocks the travel gear.
3 Function of the brake system

3.1
System depressurised
The travelling pedals 82 / 83 are not actuated, or there is a fault in the high pressure circuit.
The pressure springs 50 / 60 push in the brake piston 30, which in turn presses the outer discs 100
(steel discs) against the inner discs 90 (sinter discs). The surface pressure between the discs, combined with the high friction factor of the sinter discs, ensures maximum brake force.
The outer disc 100 is positively connected through gearing to the brake hub 20, which is also positively connected through gearing to the suspension tube A and the planetary carrier B of the gearbox.
The inner disc 90 is positively connected through gearing to the carrier 10, which is positively connected through gearing to the drive shaft C of the oil motor 200 / 201.
The friction between the disc surfaces pressed against each other by the pressure springs 50/60
block the drive and thus stop the machine.
3.2
Travel motor pressurised / release pressure reached

If one of the two travelling pedals 82/83 is pressed down, the oil motor 200 / 201 is pressurised by
the working pump with hydraulic oil. The pressure is thereby proportional to the pedal travel. The
11.65.2
copyright by
MJF C I F S S
Service Manual
Travel brake
Function of the brake system
pressure-reducing valve 208 converts the high pressure into release pressure for the multi-disc brake
215. The release pressure acts on piston 30, which is pressed against the springs 50/60 so that the
spring force onto the brake discs is reduced.
From the minimum release pressure (see also technical data in group 11.60), the pressure springs
50/60 are pressed together, so that the brake discs 90/100 are not in contact and the brake is released.
Fig. 2
10
20

110
140
Carrier
Hub
Snap ring
Backing ring
30
Piston
150
O-ring
40
50
Cover
Pressure spring
160
170
Backing ring
O-ring
60
70
Pressure spring
Seal
180
A
Backing ring
Suspension tube
80
90
Seal
Outer disc
B
C
Planetary carrier stage III

Drive shaft / oil motor
100
Inner disc
Input pinion / gearbox
copyright by
MJF C I F S S
11.65.3
Travel brake
Service Manual
11.65.4
1
160
to hydraulic tank
from / to spool travel right
212
213

180
195
from / to spool travel left

214
215

Travel brake
196
216
Travel gear
200
201
Travel motor, left

Travel motor, right
Y24
from solenoid valve / fast travel
202
Adjusting device
203
Bre
Connection for brake control pressure/release

pressure
205
206
Brake valve
Shuttle valve
MA
MB
Measuring point for travel high pressure

207
2-way shift valve
Connection for high pressure, reverse travel
208
Leak oil connection
210

pressure
Brake line
Connection for high pressure, forward travel
211
Connection for control pressure/fast travel
copyright by
MJF C I F S S
Service Manual
Travel brake
Fig. 3
Travel motors with brake valve and travel brake in travel gearbox
copyright by
MJF C I F S S
11.65.5
Travel brake
Service Manual
Repair of the travel brake

Note!
The brake system is filled with oil from the hydraulic unit, see group 1.50.
When the oil in the hydraulic tank is replaced with a different product (e.g. environmentally friendly
hydraulic fluid), the oil in the brake system must also be replaced. This means that the oil in the brake
system and associated lines must be drained.
Note!
Under special circumstances, e.g. when the machine is to be towed, and there is no release pressure, the brake can be released by dismantling the oil motor and turning in the two M8 x 20 screws.
4 Repair of the travel brake

Caution!
Prior to any inspection or adjustment work on the machine, take all safety and accident prevention
measures required to protect the technician, see also the accident prevention regulations issued by
the German Ground Construction Trade Association (Tiefbau-Berufsgenossenschaft).
4.1

To carry out sealing and repair work on the travel brake, the travel gear does not have to be dismantled from the undercarriage. It is however necessary to remove the oil motor from the gearbox.
Follow the instructions in chapter "Sealing of oil motor" in group 11.60.
For detailed instruction for sealing and repair work, refer to the repair manual F40-110.
11.65.6
copyright by
MJF C I F S S
Service Manual
Travel brake
Function
Travel brake
1 Function
The travel brake is a wet multi-disc brake that is hydraulically released and installed in each travel
gear system. It acts on the gear output.
To apply the brake, the pressure to the brake connection of the travel gear system 216 is blocked by
the solenoid valve / travel brake valve 205. In the event of a failure of the hydraulic unit, there is no
pressure available to open the travel brake 215, so that it remains applied.
In both cases, pressure springs connected to a brake piston push against the brake discs and thus
mechanically apply the brake (static brake function).
The brake acts as a spring-applied brake with a safety function in the event of malfunction of the machine.
The machine is equipped with a second brake system for the travel oil motor. The travel brake valve
205 flange-mounted to the oil motor 200 / 201 acts as a dynamic brake on the hydraulic gearbox drive.
For a description of the travel brake valves 205, see group 7.28 hydraulic components).
Fig. 1
82
100
Components of the hydraulic system and brake

200
201

Travel motor, left

Travel motor, right
160
205
Travel brake valve
180
215
Travel brake
216
Travel gear
copyright by
MJF C I F S S
11.67.1
Travel brake
Service Manual
Design, (see Fig. 1, page 1)
2 Design, (see Fig. 1, page 1)

2.1
Pilot control unit 82

When the pilot control unit 82 with pedals is actuated, control oil is fed to the travel gear spools 160
/ 180 in the control valve block 100. Depending on the pedal travel, high pressure is established in
the lines to the travel motors 200 / 201.
2.2
Travel motor 200 / 201

The axial piston oil motor is designed as a plug-in motor for installation into the travel gear system
216. It is positively connected to the planetary drive and the travel gear multi-disc brake 215 in the
gearbox 216.
2.3
Brake valve 205

Each travel motor 200 /201 is equipped with a flange-mounted brake valve. The brake piston in brake
valve 205 acts on the hydraulic return line of the travel motor and prevents overspeeding of the oil
motor when the machine is travelling downhill.
The brake valves 205 with the respective pressure pA or pB also produce the release pressure required to release the multi-disc brake. Through the connection Bre of the brake valve 205 and the
hose line 210, the release pressure also acts on the brake piston of the travel brake.
2.4
Multi-disc travel brake 215

The brake discs are integrated into the travel gearbox. Pressure springs act on the annular piston,
pressing the inner and outer discs against each other. The resulting high friction blocks the travel gear.

3.1
System depressurised
The travelling pedals 82 / 83 are not actuated, or there is a fault in the high pressure circuit.
The pressure springs 61 / 62 press against the annular piston 60. The piston in turn presses the outer
discs 52 (steel discs) against the inner discs 51 (sinter discs). The surface pressure between the
discs, combined with the high friction factor of the sinter discs, ensures maximum brake force.
The outer disc 52 gearing ensures that it is positively connected to the connected carrier 1.
The inner disc 51 is equipped with a gear and positively connected to the disc carrier 55, which in
turn is positively linked through its gear with the drive shaft 35.
The friction between the disc surfaces pressed against each other by the pressure springs 61/62
block the drive and thus stop the machine.
3.2
Travel motor pressurised / release pressure reached

If one of the two travelling pedals 82/83 is pressed down, the oil motor 200 / 201 is pressurised by
the working pump with hydraulic oil. The pressure is thereby proportional to the pedal travel. The
11.67.2
copyright by
MJF C I F S S
Service Manual
Travel brake
pressure reducing valve 208 converts the existing high pressure into the release pressure for the multi-disc brake 215. The release pressure acts on the annular piston 60 against the force of the pressure
springs 61 / 62, which means that the pressure force applied onto the brake discs is reduced.
As soon as the minimum release pressure (see also technical data in group 11.60) is reached, the
pressure springs 61/62 are pressed together, so that the brake discs 51/52 are not in contact and the
brake is released.
Fig. 2
1
2
Connected carrier (planetary stage III)

Snap ring
55
56
Disc carrier
Lip seal
7
15
Seal plug
Sun gear (planetary stage III)
57
60
Lip seal
Annular piston
35
Drive shaft
61
Pressure spring (large)
36
50
Circlip
Thrust plate
62
63
Pressure spring (small)

Locking ring
51
Inner disc
64
Snap ring
52
Outer disc
pBre Brake connection
copyright by
MJF C I F S S
11.67.3
Travel brake
Service Manual
11.67.4
1
160
to hydraulic tank
from / to spool travel right
212
213

180
195
from / to spool travel left

214
215

Travel brake
196
216
Travel gear
200
201
Travel motor, left

Travel motor, right
Y24
from solenoid valve / fast travel
202
Adjusting device
203
Bre
Connection for brake control pressure/release

pressure
205
206
Brake valve
Shuttle valve
MA
MB

207
2-way shift valve
Connection for high pressure, reverse travel
208
Leak oil connection
210

pressure
Brake line
Connection for high pressure, forward travel
211
Connection for control pressure/fast travel
copyright by
MJF C I F S S
Service Manual
Travel brake
Fig. 3
Travel motors with brake valve and travel brake in travel gearbox
copyright by
MJF C I F S S
11.67.5
Travel brake
Service Manual
Repair of the travel brake

Note!
system and associated lines must be drained.
Note!
Under special circumstances, e.g. when the machine is to be towed, and there is no release pressure, the brake can be released by dismantling the oil motor and turning in the two M8 x 20 screws.
4 Repair of the travel brake

Caution!
4.1

To carry out sealing and repair work on the travel brake, the travel gear does not have to be dismantled from the undercarriage. It is however necessary to remove the oil motor from the gearbox.
Follow the instructions in chapter "Sealing of oil motor" in group 11.60.
For detailed instruction for sealing and repair work, refer to the repair manual F350-110.
11.67.6
copyright by
MJF C I F S S
Service Manual
SUBGROUP - INDEX
Section
Group
Type
Steering axle 212 with multi-disc brake
12.02.1
A 309 LI 20221-
Rigid axle 112 with multi-disc brake
12.03.1
A 309 LI 20221-
Differential for the axles 112 / 212 / 162 / 262
12.05.1
A 309 LI 20221A 311 LI 20222-
Steering axle 262 LD with multi-disc brake
12.10.1
A 311 LI 20222-
Rigid axle 162LD with multi-disc brake
12.11.1
A 311 LI 20222-
Steering axle
12.20.1
A 312 LI 12363-
Rigid axle
12.21.1
A 312 LI 12363-
Differential for 162 / 262 axles
12.23.1
A 312 LI 12363-
APL - B 745 steering axle with multi-disc brake 12.28.1
A 314 LI 2001-
AP - B 745 rigid axle with drum brake
12.29.1
A 314 LI 2001-
AP - B 745 rigid axle
12.30.1
A 314 LI 2001-
Differential for AP / APL - B 745 axles
12.31.1
A 314 LI 2001-
APL - B 755 steering axle with multi-disc brake 12.36.1
A 316 LI 2001-28060
12.37.1
A 316 LI 2001-28060
12.39.1
A 316 LI 2001-28060
APL - B 755 HD steering axle

with multi-disc brake
12.41.1
A 316 LI-IND 2001-28060
AP - B 755 rigid axle with multi-disc brake
12.42.1
A 316 LI-IND 2001-28060
Differential for AP / APL - B 755 HD axles
12.44.1
A 316 LI-IND 2001-28060
MS - E 3060 steering axle
12.46.1
A 316 LI 28061A 316 LI-IND 28061-
12.1
MJF C I F S S
Service Manual
MT - E 3060 rigid axle
12.47.1
A 316 LI 28061A 316 LI-IND 28061-
MS/MT - E 3060 drive unit and differential
12.48.1
A 316 LI 28061A 316 LI-IND 28061-
Tyres and spacer rings
12.54.1
Chassis / drive
12.60.1
R 313 LI 27752R 317 LI 18161-
Technical data / tightening torques
12.62.1
R 313 LI 27752-
12.64.1
R 317 LI 18161-
Wear of chassis parts
12.66.1
R 313 LI 27752R 317 LI 18161-
D4L wear limits
12.67.1
R 313 LI 27752-
Wear limits - B60
12.69.1
R 317 LI 18161-
Chain
12.72.1
R 313 LI 27752R 317 LI 18161-
Tensioning unit
12.75.1
R 313 LI 27752R 317 LI 18161-
Idler
12.78.1
R 313 LI 27752R 317 LI 18161-
Running roller
12.81.1
R 313 LI 27752R 317 LI 18161-
Support roller
12.84.1
R 313 LI 27752R 317 LI 18161-
Slide ring seal
12.86.1
R 313 LI 27752R 317 LI 18161-
12.2
MJF C I F S S
Service Manual

Function

1 Function
The steering axle transfers the axle load of the machine onto the drive wheels. The axle consists of
the following main components: Differential and two axle shafts with brake as well as two joint housings with output system.
The differential transmits 50% of the output power of the transmission via the universal joint shafts to
the planetary drives of the wheel hubs.
The axle housing contains the differential as well as the hydraulically operated wet multi-disc brake.
It is applied when the brake pedal (working brake) is operated and the brake is pressurised with brake
oil. For a detailed description of the brake system, see group 15.10.
The steering cylinder (synchronised speed cylinder) attached to the differential of the steering axle
moves the wheels through the joint housings (steering knuckles) between the two stop positions. For
a detailed description of the steering cylinder, see group 13.33.
The steering cylinder is mounted directly on the undercarriage (oscillating bearing). This design compensates for uneven surfaces so that all wheels of the vehicle are always in contact with the ground.
During digging operation, the oscillating movement of the steering axles can be blocked by means of
the two swing axle support cylinders attached to the undercarriage, see group 14.10.
Fig. 1
Steering axle 212
copyright by
MJF C I F S S
12.02.1
Service Manual
General information
Equipment
Unit model
Serial number
A 309-Li
717
20221
Axle type
212 / 440
Design
Planetary steering axle
Total gear ratio

Standard
Speeder
A 309-Li
717
21648
212 / 567
13.71
13.71
Brake
Oil volume in axle

Differential and axle shaft
Planetary drive
(filling level at the check screws is binding)
7.3 l
0.8 l per side
Oil quality/viscosity
API - GL 5 / SAE 90 LS
Settings and tightening torques to be observed for installation:

A
Friction torque of the joint housing bearing 322 / 327
30 -60 Nm
10 -30 Nm
Friction torque of the wheel bearing 329
Torque for the hex head screws 301
122 Nm
15 Nm
Torque for the hex head screw 304
283 Nm
140 Nm
Torque for the wheel lugs 338
460 Nm
Torque for the countersunk screws 340
50 Nm
Torque for the nuts 343
1st stage
2nd stage
120 Nm
255 -285 Nm
Distance B of the adjusting screw 345 to the lock nut
Limit gap of the brake discs 401 (gap S)
4.5 mm
Torque for the readjusting screws 402
5 -7 Nm
Checking of the multi-disc brakes:

High pressure test, max. value
There may be no visible pressure drop after 3 minutes.
Tolerance between the left and the right steering stop
0.6 - 0.7 mm
Torque for the Allen head screw 1 at the cylinder 4,

see also group "Steering".
116 - 128 Nm
Torque of the spherical end sections of the piston rod /

cylinder 4 , see also group "Steering"
240 - 270 Nm
Torque for the joint tie rod 5 at the cylinder,

298 - 328 Nm
Torque for the slotted nut 6 at the joint tie rods,

260 - 290 Nm
38 1 mm
50 bar
Items A - D / F - K (see Fig. 6), items E, M (see Fig. 8) Pos. L (see Fig. 2), items P - S (see Fig. 9)
Tab. 1
12.02.2
copyright by
MJF C I F S S
Service Manual

General information
secured with Loctite 242
2.1
Tyre pressure
The tyre pressure depends on the tyre size, tyre ply rating and brand. For details, see overview of
tyres in group 12.46.
copyright by
MJF C I F S S
12.02.3
Service Manual
(see Fig. 6 on page 11)
The input torque of the transmission is transmitted through the drive shaft to the output flange of the
differential. A bevel pinion and crown wheel transfer the torque via the differential case to the differential spider with balancing and axle shaft gears, which is borne in the cage.
The respective axle shaft gear transfers the torque (increased by the differential translation with pinion and crown wheel) to the joint 311 meshing with the axle shaft gear.
The end section of the joint 311 meshes with the planetary gears 336. These roll off on the stationary
crown gear 333. This results in a high speed reduction and thus increased power transmission onto
the planetary housing 341. The planetary housing 341 propels the wheel hub 331 and the wheel
stud330, thus driving the vehicle wheels with the respective power and speed (based on the total gear
ratio).
4 Maintenance of the axle

The axle must be serviced regularly at the intervals laid down in the service manual. All maintenance
work must be completed according to the instructions in the operating manual.
Inspect the brake once every 12 months for damage and wear. During the annual inspection, or
if any of the following problems occur:
Reduced braking force
Reduced brake pressure
Changes in the oil level in the planetary drive
Unusual braking noises
inspect the multi-disc brake for damage and wear.
4.1
Inspection of the brake for disc wear (see Fig. 2 on page 5)

Remove the two oil filling screws 326 (one screw at the front and one screw at the rear).
Apply the brake by pressing down the brake pedal.
Insert a feeler gauge (tool no. 64 in group 2.08) through the oil filling bore B to measure the gap
"S" between the brake disc.
The gap "S" may not be greater than 4.5 mm.
If the gap is narrower (i.e. the feeler gauge cannot be inserted), replace all discs.
12.02.4
copyright by
MJF C I F S S
Service Manual

Maintenance of the axle
Fig. 2
Inspection of brake discs for wear
copyright by
MJF C I F S S
12.02.5
Service Manual
Dismantling, repair and installation of the steering axle
5 Dismantling, repair and installation of the steering axle

5.1
Dismantling of the steering axle for repair work, (see Fig. 3 on page 7)
Danger!
Prior to dismantling the steering axle, take all necessary safety measures to protect persons and
machinery. Always comply with the safety instructions in the operating manual and the accident prevention regulations issued by the German Ground Construction Trade Association (Tiefbau-Berufsgenossenschaft).
Block the wheels of the rigid axle 623 with chocks.
If required, lift the front section of the undercarriage 620 and remove the vehicle wheels 622 from
the steering axle.
Disconnect the hydraulic lines to the steering cylinder and the brake line to the multi-disc brakes
and seal the line openings (collect escaping oil).
Loosen the hex nuts 611 and remove the universal joint shaft 610.
Lift and secure the undercarriage 620.
Secure the steering axle 621 with suitable lifting tackle.
Remove the hex head screws 608 and remove the bracket 603 and the bushings 602. Lower the
steering axle 621 and pull it from the undercarriage.
5.2
Repairs on the steering axle

Note!
For detailed repair instructions for the axle, refer to the separate Repair manual for Dana 212 axles.
5.3
Installation of the steering axle after repair, (see Fig. 3 on page 7)

Place the steering axle 621 in the undercarriage 620, using suitable lifting gear.
Check the oscillating axle bearing for proper functioning (i.e. reusability of thrust bushings 602).
Place the old or new thrust bushings 602 and brackets 603 on the steering axle 621 and secure
the steering axle 621 to the undercarriage, using the hex head screws 608.
Lubricate the oscillating axle bearing at the lubrication nipple 604.
Attach the universal joint shaft 610 with the nuts 611 to the differential of the steering axle 621.
Connect the brake lines to the multi-disc brake and bleed the brake (see group 15.10).
Connect the hydraulic lines to the steering cylinder and bleed the steering system (see group
13.20).
Mount the vehicle wheels 622 .
Lower the undercarriage and remove the chocks.
Tighten the wheel lugs 338 with the prescribed torque, see table 1.
12.02.6
copyright by
MJF C I F S S
Service Manual

Fig. 3
338
5.4
Dismantling and installation of the steering axle

608
Wheel lug
Hex head screw
601
Intermediate bushing
610
602
603
Thrust bushing
Bracket
611
620
Hex nut
Undercarriage
604
605
Conical lubrication nipple

Plug
621
622
Steering axle
Vehicle wheels
623
Rigid axle
Dismantling and installation of the axle for the inspection/replacement of the

brake discs
Note!
For instructions on how to replace the brake discs 401 / 410 or how to seal the brake, also refer to
the repair manual for Dana 212.
5.4.1
Dismantling, (see Fig. 4 on page 8)

Dismantle the entire axle and remove it from the undercarriage,, (see 5.1 on page 6).
Place the axle onto a suitable surface. Remove the screw plugs 108 and 326 and drain the oil from
the axle shaft 303 and the differential 103.
Replace the screw plugs 108 and 326.
Release the steering linkage 605 from the joint housing 322 / 327.
Loosen the screws 304 (with washers 305) and carefully remove the axle shaft 303 from the differen-
copyright by
MJF C I F S S
12.02.7
Service Manual

tial 103. Remove the O-ring 101.
Remove the brake and counter discs 401 / 410 from the gearing of the joint 311.
5.4.2
Installation, (see Fig. 4 on page 8)

Apply a little oil to the new brake and counter discs 401 / 410 and install them in alternating sequence,
beginning with a counter disc 410, onto the joint 311 and install the axle shaft 303.
Note!
When installing the discs, ensure that the oil guide bores in the discs are properly aligned. Ensure
that the connection to the oil filling and check bore (outer missing tooth) is not blocked when the
counter disc 410 is mounted.
Insert a new O-ring 101 into the differential 103. Observe proper alignment. Place the axle shaft 303
onto the differential 103 and secure it with the screws 304 (with washers 305). Observe the tightening
torque for the screws 304,(see Tab. 1 on page 2).
Attach and secure the steering linkage 605 to the joint housing 322 / 327, see group13.33 Steering
cylinder.
Remove the screw plugs107 and 326 and add oil of the prescribed grade through the threaded bore
of the screw plug 107, until the oil level reaches the lower edge of the bore for screw plug 326. Insert
screw plugs 107 (with O-ring 106) and 326.
Secure the axle to the undercarriage, (see 5.3 on page 6).
Fig. 4
12.02.8
Dismantling and assembly of parts for the replacement of the brake discs
copyright by
MJF C I F S S
Service Manual

Output end of the steering axle
6 Output end of the steering axle
Fig. 5
Output end of the steering axle (assembly 30)
Hex nut
27
Right joint housing
2
3
Screw
Axle shaft
28
29
Sealing ring
Hex head screw
30
Wheel stud
5
6
Washer
31
32
Wheel hub
O-ring
Sealing ring
33
Crown gear
34
Hollow gear carrier
Snap ring
35
Snap ring
10
O-ring
36
Planetary gear
11
Joint
37
Roller bearing
12
13
Thrust bushing
Bushing
38
40
Wheel lug
Countersunk screw
14
Screw
41
Planetary housing
15
Cover
42
Stud
16
Plug
43
Nut
17
44
Snap ring
18
Upper steering knuckle bolt
45
Adjusting screw
19
20
Lower steering knuckle bolt

Sealing ring
49
50
Locking plate
Snap ring
21
22
Joint
Left joint housing
57
59
Shim (S = 0.15 / 0.20 / 0.50)

Repair kit for planetary housing
copyright by
MJF C I F S S
12.02.9
Service Manual

23
25
Sealing ring
Magnetic plug
66
67
Repair kit for left joint housing

Repair kit for right joint housing
26
Plug
75
76
Washer
Washer
301
Hex nut
328
Sealing ring
302
303
Screw
Axle shaft
329
330

Wheel stud
306
331
Wheel hub
307
Sealing ring
332
O-ring
308
309

Snap ring
333
334
Crown gear
Hollow gear carrier
310
O-ring
335
Snap ring
311
312
Joint
Thrust bushing
336
337
Planetary gear
Bearing
313
314
Bushing
Screw
338
340
Wheel lug
Countersunk screw
315
316
Cover
Plug
341
342
Planetary housing
Stud
317
343
Nut
318
319

344
345
Snap ring
Adjusting screw
320
321
Sealing ring
Joint
349
350
Locking plate
Snap ring
322
323
Left joint housing

Sealing ring
357
375
Shim (S = 0.15 / 0.20 / 0.50)

Washer (centring ring)
326
Plug
376
Washer (lock washer)
327
Right joint housing
Note!
Observe the tightening torques A, B, C, D, F, G, H, I, K for the maintenance and repair of the axles
(see Fig. 6, page 11) and table 1, page 2.
12.02.10
copyright by
MJF C I F S S
Service Manual

Fig. 6
copyright by
MJF C I F S S
12.02.11
Service Manual
Steering axle brake
7 Steering axle brake
Fig. 7
1
12.02.12
Working brake (assembly 40)

Brake disc
Anti-extrusion ring
Adjusting screw
O-ring
3
4
Spring
Piston
10
11
Counter disc
Bleeder screw
5
6
Spring
Anti-extrusion ring
12
13
Plug
Pin
O-ring
14
Piston repair kit
101
O-ring
402
Adjusting screw
102
103
Intermediate cover
Housing / differential
403
404
Spring
Piston
204
205

Shaft nut
405
406
Spring
Anti-extrusion ring
207
Allen head screw
407
O-ring
303
304
Axle shaft
Hex head screw
408
409
Anti-extrusion ring
O-ring
305
311
Washer
Joint
410
411
Counter disc
Bleeder screw
325
Screw plug
412
Plug
326
Screw plug
413
Pin
401
Brake disc
copyright by
MJF C I F S S
Service Manual

Steering axle brake
Fig. 8
Multi-disc brake in axle shaft
Note!
Observe tightening torques E and M for the repair of the axles, see table 1, page 2.
copyright by
MJF C I F S S
12.02.13
Service Manual
Steering cylinder of the steering axle
8 Steering cylinder of the steering axle
Fig. 9
Steering cylinder in differential (assembly 50)
Allen head screw
Slotted nut
Steering cylinder, complete, see group 13.33 Steering

cylinder
Joint tie rod, complete
Cotter pin
10 Differential, complete
Note!
Observe tightening torques P - S for the repair of the axles, see table 1, page 2.
12.02.14
copyright by
MJF C I F S S
Service Manual

Function

1 Function
The rigid axle transfers the axle load of the machine onto the drive wheels. The axle consists of the
following main components: Differential and two output shafts with axle shaft and brake.
the planetary drives.
The axle shafts contain the hydraulically operated wet multi-disc brake, which is located near the connection of the differential. The brake is applied when the brake pedal (working brake) is operated and
the brake is pressurised with brake oil.
For a detailed description of the brake system, see group 15.10.
Fig. 1
Rigid axle 112
copyright by
MJF C I F S S
12.03.1
Service Manual
Function
12.03.2
copyright by
MJF C I F S S
Service Manual

General information
Equipment
Unit model
Serial number
A 309-Li
717
20221
Axle type
112 / 209
Design
Planetary rigid axle
Total gear ratio

Standard
Speeder
Planetary drive
13.71
13.71
6.0
Brake
Oil volume in axle

Planetary drive
8.0 l
2.1 l per side

A
283 Nm
460 Nm
50 Nm
Limit gap of the brake discs 401 (gap S)
4.5 mm
Torque for the adjusting screws 402
5 - 7 Nm
Multi-disc brakes:
10 -30 Nm
1st stage
2nd stage
120 Nm
255 - 285 Nm
50 bar
Items A / C / D / E (see Fig. 6), item F (see Fig. 2), items B and G (see Fig. 8)
Tab. 1

2.1
Tyre pressure
copyright by
MJF C I F S S
12.03.3
Service Manual
3.1
Power flow in the rigid axle, (see Fig. 6 on page 11)

The output torque of the transmission is transmitted through the universal joint shaft to the input flange of the differential. A bevel pinion and crown wheel transfer the torque via the differential housing
to the balancing and axle shaft gears borne in the cage.
The respective axle shaft gear transfers the torque (increased by the differential translation with pinion and crown wheel) to the axle shaft 327 meshing with the axle shaft gear.
The end section of the axle shaft 326 meshes with the planetary gears 317. These roll off on the stationary crown gear 313. This results in a great speed reduction and thus increased power transmission onto the planetary housing 323. The planetary housing 323 propels the wheel hub 309 and the
wheel stud 308, thus driving the vehicle wheels with the respective power and speed (based on the
total gear ratio).

Inspect the brake once every 12 months for damage and wear. During the annual inspection, or if
following problems occur:
inspect the multi-disc brake for damage and wear.
4.1
Checking of discs for wear

Remove the two oil filling screws 304 (one screw at the front and one screw at the rear).
Apply the brake by pressing down the brake pedal.
Insert a feeler gauge (tool no. 64 in group 2.08 List of tools) through the oil filling bore B to measure the gap "S" between the brake disc.
The gap S may not be greater than 4.5 mm.
If the gap is narrower (i.e. the feeler gauge cannot be inserted), replace all discs.
12.03.4
copyright by
MJF C I F S S
Service Manual

Fig. 2
Inspection of brake discs for wear
copyright by
MJF C I F S S
12.03.5
Service Manual
Dismantling, repair and installation of the rigid axle
5 Dismantling, repair and installation of the rigid axle

5.1
Dismantling of the rigid axle for repair work, (see Fig. 3 on page 7)
Danger!
Prior to dismantling the rigid axle, take all necessary safety measures to protect persons and machinery. Always comply with the safety instructions in the operating manual and the accident prevention regulations issued by the German Ground Construction Trade Association (TiefbauBerufsgenossenschaft).
Block the wheels of the steering axle 604 with chocks.
the rigid axle 604.
Disconnect and seal the brake line to the multi-disc brakes (collect any escaping oil).
Lift the undercarriage 600 and secure the rigid axle 604 with suitable lifting tackle.
625
5.2
600

Note!
For detailed repair instructions for the axle, refer to the separate Repair manual for Dana planetary rigid axles 112.
5.3
Installation of the rigid axle after repair, (see Fig. 3 on page 7)

Place the rigid axle 604 in the undercarriage 600, using suitable lifting gear.
Secure the rigid axle 604 with the plate 630, the hex head screws 620 (with washer 622) and hex
head screw 625 / hex lock nut 625 to the undercarriage 600.
Attach the universal joint shaft 611 with the nuts 615 to the differential of the rigid axle 604.
Mount the vehicle wheels 603.
Lower the undercarriage 600 and remove the chocks.
Tighten the wheel lugs 319 with the prescribed torque, Tab. 1 page 3.
12.03.6
copyright by
MJF C I F S S
Service Manual

Fig. 3
5.4
Dismantling and installation of the rigid axle
319
Wheel lug
611
332
Washer
615
Hex nut
600
602
Undercarriage
Steering axle
620
622
Hex head screw

Washer
603
604
Vehicle wheels
Rigid axle
625
630
Hex nut / lock nut

Plate
Dismantling and installation of the axle for the inspection/replacement of the

brake discs, (see Fig. 4 on page 8)
Note!
For instructions on how to replace the brake discs 401 / 410 or how to seal the brake, also refer to
the repair manual for Dana planetary rigid axle 112.
Dismantle the entire axle and remove it from the undercarriage, see 5.1.
5.4.1
Dismantling, see Fig. 4

Place the axle onto a suitable surface. Remove the screw plugs 108 und 304 and drain the oil from
the axle shaft 301 and the differential 103. Insert and tighten the screw plugs 108 and 304.
Remove the screws 303 and carefully lift the axle shaft 301 from the differential 103. Remove the Oring 101.
Remove the brake and counter discs 401 / 410 from the gearing of the axle shaft 327.
copyright by
MJF C I F S S
12.03.7
Service Manual
5.4.2
Installation, see Fig. 4

Apply a little oil to the new brake and counter discs 401 / 410 and install them in alternating sequence,
beginning with a counter disc 410, onto the shaft 327 and install the axle shaft 301.
Note!
that the connection to the oil filling and check bore is not blocked when the counter disc 410 is mounted.
Insert a new O-ring 101 into the differential 103. Observe proper alignment. Place the axle shaft 301
onto the differential 103 and secure it with the screws 303 (with washers 302). Observe the tightening
torque for the screws 303, see Tab. 1 page 3.
Remove the screw plugs107 and 304 and add oil of the prescribed grade through the threaded bore
of the screw plug 107, until the oil level reaches the lower edge of the bore for screw plug 304.
Replace the screw plugs 107 and304.
Fig. 4
12.03.8
Dismantling and assembly of parts for the replacement of the brake discs
101
O-ring
303
Hex head screw
103
107
Differential housing
Screw plug
304
327
Screw plug
Axle shaft
108
Screw plug
401
Brake disc
301
302
Axle shaft
Washer
410
Counter disc
copyright by
MJF C I F S S
Service Manual

Output end of the rigid axle
6 Output end of the rigid axle
Fig. 5
Output end of rigid axle (assembly 30)
1
2
Axle shaft
Washer
16
17
Snap ring
Planetary gear
3
4
Hex head screw

Screw plug
18
19
Roller bearing
Wheel lug
5
6
Screw plug
Sealing ring
20
22
Sealing ring
Countersunk screw
Wheel stud
23
Planetary housing
Wheel hub
24
Nut
10
O-ring
25
Stud
11
12

Snap ring
26
27
Thrust washer
Axle shaft
13
14
Crown gear
Hollow gear carrier
30
31

15
Locking plate
32
copyright by
MJF C I F S S
12.03.9
Service Manual
301
304
Axle shaft
Screw plug
317
318
Planetary gear
Roller bearing
306
308
Sealing ring
Wheel stud
319
320
Wheel lug
Sealing ring
309
Wheel hub
322
Countersunk screw
310
O-ring
323
Planetary housing
311
324
Nut
312
Snap ring
325
Stud
313
Crown gear
326
Thrust washer
314
Hollow gear carrier
327
Axle shaft
315
Locking plate
331
316
Snap ring
332
Note!
Observe the prescribed settings and torques A, C, D, E for maintenance and repair of the axles,
(see Fig. 6 on page 11) and (see Tab. 1 on page 3).
12.03.10
copyright by
MJF C I F S S
Service Manual

Fig. 6
copyright by
MJF C I F S S
12.03.11
Service Manual
Brake of the rigid axle
7 Brake of the rigid axle
Fig. 7
12.03.12
1
2
Brake disc
Adjusting screw
8
9
Anti-extrusion ring
O-ring
Spring
10
Counter disc
4
5
Piston
Spring
11
12
Bleeder screw
Plug
6
7
Anti-extrusion ring
O-ring
13
14
Pin
Piston repair kit
101
102
O-ring
Intermediate cover
401
402
Brake disc
Adjusting screw
103
201
Housing / differential
403
404
Spring
Piston
225
Shaft nut
405
Spring
226
Allen head screw
406
Anti-extrusion ring
301
Axle shaft
407
O-ring
302
303
Washer
Hex head screw
408
409
Anti-extrusion ring
O-ring
304
Screw plug
410
Counter disc
305
Screw plug
411
Bleeder screw
327
Axle shaft
412
413
Plug
Pin
copyright by
MJF C I F S S
Service Manual

Fig. 8
Multi-disc brake in axle shaft
Note!
Observe the tightening torques B and G for the repair of the axles, see Tab. 1 page 3.
copyright by
MJF C I F S S
12.03.13
Service Manual
12.03.14
copyright by
MJF C I F S S
Service Manual

Function

1 Function
The differential is built into the axle housing of steering and rigid axles. It transmits the output power
of the transmission to the planetary drives, adjusting the speed and torque by means of bevel pinions
and the crown wheel.
When negotiating bends, the differential also compensates the different forces and speeds of the planetary outputs and thus the vehicle wheels.
Fig. 1
Differential of he steering and rigid axle
copyright by
MJF C I F S S
12.05.1

Function
12.05.2
copyright by
MJF C I F S S
Service Manual
Service Manual

General information
Equipment
Unit model
Serial number
A 309 /311 Li
718 / 719
20221
Axle type
112 / 212 and 162 / 262
Gear ratio
14 : 32
Settings, to be observed for installation:

A Setting value of the crown wheel kits 203
/ 212
B Tooth backlash of the crown wheel kit 203
/ 212
C Bearing preload of the differential bearing 201
/ 204
213
E
Torque for the hex heads screws 206 / 207

respectively
or 211 / 226
/ 210
G Torque for the hex head screws 217

H Torque for the nut 218
I
/ 223
Dimension on the shaft circumference of he bevel gears 203 /

212 (e.g. 118) and on the front
end of the bevel gear 203 /
212 as marked (e.g. +1)
0.18 - 0.23 mm
1 - 4 Nm
120 - 170 Ncm
24 - 26 Nm
128 - 142 Nm
145 Nm
280 - 310 Nm
Torque for the shaft nut 219
500 Nm
Items A - I (see Fig. 3 on page 7) und (see Fig. 5 on page 11)

Tab. 1
Note!
The differential can only be dismantled, installed and repaired together with the respective axle.
Please also refer to the separate repair manual
'Dana axles 112 / 212 / 162 LD / 262 LD'.
Position on steering axle
Position on rigid axle
copyright by
MJF C I F S S
12.05.3
Service Manual
General information
12.05.4
Assembly 10
Assembly 20
1
2
O-ring
Intermediate cover
1
2
O-ring
Shim 0.15 / 0.20 / 0.40 / 0.50
Housing
Bevel gear with crown wheel kit
4
5
Cover
Bleeder
4
5

Shaft nut
6
7
O-ring
Plug
6
7
Allen head screw

Allen head screw
Magnetic plug
Hex head screw
9
10
Thrust washer
Differential gear shaft wheel
Assembly 60
1 Intermediate bushing
11
12
Pin
Snap ring
2
3
Stop bushing
Bracket
13
14
Thrust washer
Balancing shaft gears
15
5
6
Plug
Bracket, complete
16
17

Shim 0.10 / 0.15 / 0.20 / 0.30
18
19
Spacer ring
Shaft nut
20
21
Sealing ring
Protective plate
22
Flange
23
24
Nut
Snap ring
25
Repair kit for differential
copyright by
MJF C I F S S
Service Manual

Differential of the steering axle
Fig. 2
Exploded view of the differential (assemblies 10 and 20)

and the oscillating axle bearing (assembly 60)
copyright by
MJF C I F S S
12.05.5
Service Manual
101
O-ring
211
Pin
102
103
Intermediate cover
Housing
212
213
Snap ring
Thrust washer
104
Cover
214
105
106
Bleeder
Sealing ring
215
216
107
108
Plug
Magnetic plug
217
218
Shim 0.10 / 0.15 / 0.20 / 0.30

Spacer ring
201
O-ring
219
Shaft nut
202
203
Shim 0.15 / 0.20 / 0.40 / 0.50

220
221
Sealing ring
Protective plate
204
205

Shaft nut
222
223
Flange
Nut
206
207
Allen head screw

Allen head screw
224
314
Snap ring
Axle shaft
208
Hex head screw
334
Axle shaft
209
210
Thrust washer
349
Screw plug
Note!
Observe settings and torques A, B, C, D, E, F, G, H, I, K, and Tab. 1 page 3.
12.05.6
copyright by
MJF C I F S S
Service Manual

4 Differential of the steering axle
Fig. 3
Sectional drawing of the differential of the steering axle
copyright by
MJF C I F S S
12.05.7
Service Manual
12.05.8
Assembly 10
1
O-ring
Assembly 20
1
2
3
Intermediate cover
Housing
2
3
Axle shaft wheel
Cover
Pin
Bleeder
Snap ring
Plug
Snap ring
Magnetic plug
Thrust washer
Snap ring
Thrust washer
10
Hex head screw
11
12
Allen head screw

13
14
Shim 0.10 / 0.15 / 0.20
15
16
Shim 0.20 / 0.40 / 0.50

O-ring
17
Hex head screw
18
19
Nut
Shaft nut
20
21
Sealing ring
Protective plate
22
23
Cover
Spacer ring
24
O-ring
25
26
Shaft nut
Allen head screw
27
28
Flange
copyright by
MJF C I F S S
Service Manual

Differential of the rigid axle
5 Differential of the rigid axle
Fig. 4
Differential (assemblies 10 and 20)
copyright by
MJF C I F S S
12.05.9
Service Manual
101
O-ring
212
102
103
Intermediate cover
Housing
213
214

Shim 0.10 / 0.15 / 0.20
104
Cover
215
Shim 0.20 / 0.40 / 0.50
105
Bleeder
216
O-ring
107
Plug
217
Hex head screw
108
109
Magnetic plug
Snap ring
218
219
Nut
Shaft nut
201
202

220
221
Sealing ring
Protective plate
203
Axle shaft wheel
222
Cover
204
205
Pin
Snap ring
223
224
Spacer ring
O-ring
206
207
Snap ring
Thrust washer
225
226
Shaft nut
Allen head screw
208
209

Thrust washer
227
304
Flange
Screw plug
210
Hex head screw
319
Axle shaft
211
Allen head screw
320
Axle shaft
Note!
Observe settings and torques A, B, C, D, E, F, G, H, I, (see Fig. 5 on page 11) and Tab. 1 page 3.
12.05.10
copyright by
MJF C I F S S
Service Manual

Fig. 5
Sectional drawing
copyright by
MJF C I F S S
12.05.11

12.05.12
copyright by
MJF C I F S S
Service Manual
Service Manual

Function

1 Function
The steering axle transfers the axle load of the machine onto the drive wheels. The axle consists of
the following main components: Differential and two joint housing with axle shaft, output system and
brake.
the planetary drives.
The joint housing contains the output / wheel hub as well as the hydraulically operated wet multi-disc
brake. The brake is applied when the brake pedal (working brake) is operated and the brake is pressurised with brake oil. For a detailed description of the brake system, see group 15.10.
The steering cylinder (synchronised speed cylinder) built into the differential of the steering axle
The steering cylinder is mounted directly on the undercarriage (oscillating bearing). This design compensates uneven surfaces so that all wheels of the vehicle are always in contact with the ground.
Fig. 1
Steering axle 262 LD
copyright by
MJF C I F S S
12.10.1
Service Manual
General information and settings
2 General information and settings

Equipment
Unit model
Serial number
A 311-Li
718
20222
Axle type
262 / 056
Design
Total gear ratio

Standard
Speeder
13.71
13.71
Brake
Oil volume in axle

Planetary drive
7.3 l
2.0 l per side

A
Friction torque of the joint housing bearing 327 / 328
30 - 60 Nm
10 - 30 Nm
Torque for the hex nuts 303
283 Nm
140 Nm
20 Nm
60 - 70 Nm
Setting value B for the stop screw 332 at the joint housing
327/ 328see also group 'Steering'.
148 Nm
460 Nm
1st stage
2nd stage
120 Nm
255 - 285 Nm
40 - 50 Nm
200 Nm
Torque for the adjusting screw 412
5 - 7 Nm
Torque for the adjusting screw 414
10 - 15 Nm
Dimension X of the disc pack 415 / 416

(see Fig. 3 on page 6)
Testing of multi-disc brakes

128 Nm
(new)
Wear limit
Items A - P (see Fig. 8 on page 13), item Q (see Fig. 3 on page 6)
12.10.2
36.2 1 mm
copyright by
MJF C I F S S
21.0 mm
19.2 mm
50 bar
Service Manual

General information and settings
Equipment
Unit model
Serial number
A 311-Li
718
20222
Tolerance between the left and the right steering stop
0.6 - 0.7 mm
Torque for the Allen head screw 1 at the cylinder 4,

see also group 'Steering'.
116 - 128 Nm
Torque of the spherical end sections of the piston rod /

cylinder 4 , see also group 'Steering'
240 - 270 Nm
Torque for the nut at the joint tie rod 5,

298 - 328 Nm
Torque for the slotted nut 6 / joint tie rods5,

260 - 290 Nm
Items T - W (see Fig. 7 on page 11)

Tab. 1

2.1
Tyre pressure
copyright by
MJF C I F S S
12.10.3
Service Manual
3.1
Power flow in the steering axle, (see Tab. 1 on page 3)

The output torque of the transmission is transmitted through the universal joint shaft to the input flange of the differential. A bevel pinion and crown wheel transfer the torque via the differential housing
to the balancing and axle shaft gears borne in the cage.
The respective axle shaft gear transfers the torque (increased by the differential translation with pinion and crown wheel) to the joint 315 meshing with the axle shaft gear.
315
and the
344

The testing of the multi-disc brake is an integral part of the maintenance; for detailed instructions, see
also chapter 'Brakes' in group 15.10.
Also carry out a wear check of the brake discs 416, if any of the
To do this, the axle does not have to be removed from the undercarriage.
Remove the wheels from the steering axle and drain off the oil of the planetary output gear by opening
the plug screw 307.
Dismantle the discs for inspection as shown in the diagram below.
Note
For extensive dismantling and installation work concerning the multi-disc brake, we recommend referring to the repair manual for Dana planetary steering axles 262 LD.
12.10.4
copyright by
MJF C I F S S
Service Manual

Fig. 2
Dismantling of the wheel hub for inspection and/or replacement of the brake discs
301
Axle shaft
347
Nut
307
327
Screw plug
Right joint housing
348
349
Planetary housing
Countersunk screw
328
336
Left joint housing

Locking plate
353
354
Centring ring
Lock washer
337-339Hollow wheel, complete

340
O-ring
404
415
O-ring
Counter disc
341
Wheel hub
416
Brake disc
342
343
Sealing ring
417
419
Cover
Screw
345
Wheel lug
copyright by
MJF C I F S S
12.10.5
Service Manual
4.1
Checking of discs for wear

Remove the brake discs 416 and counter discs 415 from the brake housing (joint housing 327/328
and cover 417).
Place discs in correct sequence one onto the other and check dimension X:
For nominal dimension X in new brake discs, (see Tab. 1 on page 3).
For limit dimension X in used discs, (see Tab. 1 on page 3).
If the limit value is reached or even exceeded, replace discs 415 / 416.
Fig. 3
Dimension X for brake disc wear check
Note!
that the connection to the oil filling and check bore (outer missing tooth) is not blocked when the
counter disc 415 is mounted.

5.1
Dismantling of the steering axle for repair work

Danger!
Block the wheels of the rigid axle 623 with chocks.
the steering axle.
Lift the undercarriage 620 and secure the steering axle 621 with suitable lifting tackle.
Remove the hex head screws 608 and remove the bracket 603 and the bushings 602. Lower the
steering axle 621 and pull it from the undercarriage.
12.10.6
copyright by
MJF C I F S S
Service Manual

5.2
Repairs to the steering axle

Note!
For detailed repair instructions for the axle, refer to the separate Repair manual for Dana 262 LD
axles.
5.3
Installation of the steering axle

Place the steering axle 621 in the undercarriage 620, using suitable lifting gear.
Check the oscillating axle bearing for proper functioning (i.e. reusability of stop bushings 602).
Place the old or new stop bushings 602 and brackets 603 on the steering axle 621 and secure the
steering axle 621 to the undercarriage, using the hex head screws 608.
Lubricate the oscillating axle bearing at the lubrication nipple 605.
Attach the universal joint shaft 610 with new self-locking nuts 611 to the differential of the steering
axle 621.
13.20).
Tighten the wheel lugs 345 with the prescribed torque, see Tab. 1.
Fig. 4
Installation of the steering wheel in the undercarriage
copyright by
MJF C I F S S
12.10.7
Service Manual

345
Wheel lug
608
Hex head screw
354
Centring ring
610
601
611
Hex nut
602
603
Thrust bushing
Bracket
620
621
Undercarriage
Steering axle
604
622
Vehicle wheels
605
Plug
623
Rigid axle
6 Output end of the steering axle
Fig. 5
12.10.8
Output end of the steering axle (assembly 30)
Axle shaft
30
Screw
31
Nut
3
4
Hex nut
Hex head screw
32
33
Adjusting screw
Bearing
Washer
34
Planetary gear
7
8
Plug
Magnetic plug
35
36
Snap ring
Locking plate
9
10
Snap ring
Snap ring
37
38
Hollow gear carrier

Crown gear
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MJF C I F S S
Service Manual

11
12

Sealing ring
39
40
Snap ring
O-ring
13
14
O-ring
41
42
Wheel hub
Sealing ring
15
16
Joint
Sealing ring
43
44

Wheel stud
17
Thrust bushing
45
Wheel lug
18
Screw
46
Stud
20
Plug
47
Nut
21
48
Planetary housing
22
49
Countersunk screw
23
Shim (S = 0.15 / 0.20 / 0.50)
50
24
26
Sealing ring
Bushing
51
56
Magnetic plug
Nut
27
28
Right joint housing

Left joint housing
57
60
Stud
Repair kit for left joint housing
29
Joint
61
Repair kit for right joint housing
copyright by
MJF C I F S S
12.10.9
Service Manual
Steering axle brake
7 Steering axle brake
Fig. 6
1
Plug
12
Adjusting screw
2
3
Bleeder screw
Pin
13
14
Spring
Adjusting screw
4
5
O-ring
O-ring
15
16
Counter disc
Brake disc
Outer anti-extrusion ring
17
Cover
Piston
19
Screw
Inner O-ring
20
Screw plug
9
10
Inner anti-extrusion ring

Counter disc
21
22
Sealing ring
Screw
11
12.10.10
Spring
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MJF C I F S S
Service Manual

8 Steering cylinder of the steering axle
Fig. 7
Steering cylinder in differential (assembly 50)
1
4
Allen head screw

Steering cylinder, complete, see group 13.33 Steering cylinder
6
7
Slotted nut
Cotter pin
Joint tie rod, complete
10
Differential, complete
Note!
Observe torques T - W for repairs of the axle, Tab. 1 page 3.
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MJF C I F S S
12.10.11
Service Manual

301
302
Axle shaft
Screw
339
340
Snap ring
O-ring
303
307
Hex nut
Plug
341
342
Wheel hub
Sealing ring
309
Snap ring
343
310
311
Snap ring 40
344
345
Wheel stud
Wheel lug
312
Sealing ring
346
Stud
313
347
Nut
314
O-ring
348
Planetary housing
315
Joint
349
Countersunk screw
316
Sealing ring
401
Plug
317
318
Thrust bushing
Screw
402
403
Bleeder screw
Pin
320
321
Plug
404
405
O-ring
O-ring
322
323

Shim (S = 0.15 / 0.20 / 0.50)
406
407

Piston
324
Sealing ring
408
Inner O-ring
326
327
Bushing
Right joint housing
409
410

Counter disc
328
329
Left joint housing

Joint
411
412
Spring
Adjusting screw
330
331

Nut
413
414
Spring
Adjusting screw
332
Adjusting screw
415
Counter disc
333
334
Bearing
Planetary gear
416
417
Brake disc
Cover
335
336
Snap ring
Locking plate
419
420
Screw
Screw plug
337
Hollow gear carrier
421
Sealing ring
338
Crown gear
Note!
View A of sectional drawing is turned by 90.
Observe prescribed settings and torques A - P for maintenance and repair of the axles, (see Fig. 8
on page 13) and Tab. 1 page 3.
12.10.12
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MJF C I F S S
Service Manual

Fig. 8
Output system and working brake of the steering axle
copyright by
MJF C I F S S
12.10.13
Service Manual
12.10.14
copyright by
MJF C I F S S
Service Manual

Function

1 Function
The rigid axle transfers the axle load of the machine onto the drive wheels. The axle consists of the
following main components: Differential and two axle shafts with drive system and brake.
The differential transmits 50% of the output power of the transmission via the universal joint shafts
to the planetary drives of the wheel hubs.
The axle shaft contains the output / wheel hub as well as the hydraulically operated wet multi-disc
brake. It is pressurised and applied when the brake pedal (working brake) is operated. For a more
detailed description of the brake system, see group 15.10.
Fig. 1
Rigid axle 162 LD
copyright by
MJF C I F S S
12.11.1
Service Manual
Function
12.11.2
copyright by
MJF C I F S S
Service Manual

General information
Equipment
Unit model
Serial number
A 311-Li
718
20222
Axle type
162 / 056
Design
Total gear ratio

Standard
Speeder
13.71
13.71
Brake
Oil volume in axle

Planetary drive
8.0 l
2.1 l per side

A
283 Nm
460 Nm
200 Nm
9 - 10 Nm
5 - 7 Nm
10 - 15 Nm
Dimension X of the disc pack 421 / 422 (new)

(see Fig. 3 page 6)
Wear limit
Checking of the multi-disc brakes:

10 - 30 Nm
40 - 50 Nm
1st stage
2nd stage
120 Nm
255 - 285 Nm
219 - 242 Nm
21 mm
19.2 mm
50 bar
Items A - K (see Fig. 7 page 13), item L (see Fig. 3 page 6)

Tab. 1

2.1
Tyre pressure
copyright by
MJF C I F S S
12.11.3
Service Manual
3.1
Power flow in the rigid axle, (see Fig. 7 page 13)

The output torque of the transmission is transmitted through the universal joint shaft to the input flange of the differential. A bevel pinion and crown wheel transfer the torque via the differential case to
the differential spider with balancing and axle shaft gears, which is borne in the cage.
The respective axle shaft gear transfers the torque (increased by the differential translation with pinion and crown wheel) to the axle shaft 326 meshing with the axle shaft gear.
The end section of the axle shaft 326 meshes with the planetary gears 315. These roll off on the stationary crown gear 311. This results in a high speed reduction and thus increased power transmission
onto the planetary housing 320. The planetary housing 320 propels the wheel hub 325 and the wheel
stud307, thus driving the vehicle wheels with the respective power and speed (based on the total gear
ratio).

Also carry out a wear check of the brake discs 422, if any of the
To do this, the axle does not have to be removed from the undercarriage.
Remove the wheels from the rigid axle and drain off the oil of the planetary output gear by opening
the plug screw 318.
Dismantle the discs for inspection as shown in the diagram below.
Note
For extensive dismantling and installation work concerning the multi-disc brake, we recommend referring to the repair manual for Dana planetary rigid axles 162 LD.
12.11.4
copyright by
MJF C I F S S
Service Manual

Fig. 2
Dismantling of the wheel hub for inspection and/or replacement of the brake discs
301
Axle shaft
324
306
308
Sealing ring
Wheel lug
325
331
Wheel hub
Centring ring
309
O-ring
332
Lock washer
406
408
Cover
O-ring
310-312Hollow wheel, complete

313
Locking plate
318
Screw plug
421
Counter disc
319
Countersunk screw
422
Brake disc
320
321
Planetary housing
Thrust washer
423
425
Cover
Screw
322
Nut
copyright by
MJF C I F S S
12.11.5
Service Manual
4.1
Checking of discs for wear (see Fig. 2 page 5)
422
Place discs in correct sequence one onto the other and check dimension X:
For nominal dimension X in new brake discs, (see Tab. 1 page 3)
For limit dimension X in used discs, (see Tab. 1 page 3)
If the limit value is reached or even exceeded, replace the discs 421 / 422.
Fig. 3
406/423
Dimension X for brake disc wear check
Note!
that the connection to the oil filling and check bore is not blocked when the counter disc 421 is mounted.
12.11.6
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MJF C I F S S
Service Manual


5.1
Dismantling of the rigid axle for repair work, see Fig. 4

Danger!
Lift the undercarriage 600 at the front and secure the wheels of the rigid axle 604 using chocks.
If required, remove the wheels 603 from the rigid axle 604.
Loosen the hex head screws 615 and remove the universal joint shaft 611.
Remove the hex nuts 625 and the hex head screws 620 with the washer 622. Lower the rigid axle
604 and pull it from the undercarriage 600.
5.2

Note!
For detailed repair instructions for the axle, refer to the separate Repair manual for Dana 162 LD
axles.
5.3
Installation of the rigid axle after repair, see Fig. 4

Secure the rigid axle 604 with the plate 630, the hex head screws 620 (with washer 622) and hex
head screw 625 / hex lock nut 625 to the undercarriage 600.
Attach the universal joint shaft 611 with the screws 615 to the differential of the rigid axle 604.
Lower the undercarriage 600 and remove the chocks.
Tighten the wheel lugs 308 with the prescribed torque, see Tab. 1.
copyright by
MJF C I F S S
12.11.7
Service Manual
Fig. 4
12.11.8
Dismantling and installation of the rigid axle
308
Wheel lug
611
332
Lock washer
615
Hex nut
600
602
Undercarriage
Steering axle
620
622
Hex head screw

Washer
603
604
Vehicle wheels
Rigid axle
625
630
Hex nut
Plate
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MJF C I F S S
Service Manual

Sectional drawing of the rigid axle
6 Sectional drawing of the rigid axle
Fig. 5
Output end of rigid axle (assembly 30)
1
2
Axle shaft
Hex head screw
18
19
Plug
Countersunk screw
3
4
Washer
Screw plug
20
21
Planetary housing
Thrust washer
Screw plug
22
Wheel lug
Sealing ring
23
Stud
Wheel stud
24
8
9
Wheel lug
O-ring
25
26
Wheel hub
Axle shaft
10
Snap ring
27
11
Crown gear
28
Stud
12
13
Hollow gear carrier

Locking plate
29
30
Hex nut
Sealing ring
14
Snap ring
31
Centring ring
15
16
Planetary gear
Bearing
32
Lock washer
copyright by
MJF C I F S S
12.11.9
Service Manual
7 Brake of the rigid axle
Fig. 6
12.11.10
1
2
O-ring
Sealing ring
14
15
Spring washer
Hex head screw
3
4
Screw plug
Plug
16
17
Counter disc
Spring
Bleeder screw
19
Spring
6
7
Cover
Pin
20
21
Adjusting screw
Counter disc
8
9
O-ring
O-ring
22
23
Brake disc
Cover
10
25
Screw
11
Piston
26
Screw
12
Inner O-ring
27
Magnetic plug
13
copyright by
MJF C I F S S
Service Manual

copyright by
MJF C I F S S
12.11.11
Service Manual
102
103
Intermediate cover
329
330
Hex nut
Sealing ring
301
302
Axle shaft
Hex head screw
331
332
Centring ring
Lock washer
303
Washer
401
O-ring
306
307
Sealing ring
Wheel stud
404
405
Plug
Bleeder screw
308
Wheel lug
406
Cover
309
O-ring
407
Pin
310
Snap ring
408
O-ring
311
312
Crown gear
Hollow gear carrier
409
410
O-ring
313
Locking plate
411
Piston
314
315
Snap ring
Planetary gear
412
413
Inner O-ring
316
318
Bearing
Plug
414
415
Spring washer
Hex head screw
319
Countersunk screw
416
Counter disc
320
321
Planetary housing
Thrust washer
417
418
Spring
Adjusting screw
322
323
Nut
Stud
419
420
Spring
Adjusting screw
324
325

Wheel hub
421
422
Counter disc
Brake disc
326
Axle shaft
423
Cover
328
Stud
425
Hex head screw
Note!
12.11.12
A-K
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MJF C I F S S
Service Manual

Fig. 7
Output system and working brake of the rigid axle
copyright by
MJF C I F S S
12.11.13
Service Manual
12.11.14
copyright by
MJF C I F S S
Service Manual
Steering axle
Function
Steering axle
1 Function
The axle housing of the steering axle, which transfers the axle load of the machine to the drive
wheels, is equipped with a built-in differential mounted between the axle supports of the steering axle.
the planetary drives of the double output.
For a detailed description of the differential, see group 12.23.
The planetary housing contains the planetary drive as well as the hydraulically operated wet multidisc brake. It is applied when the brake pedal (working brake) is operated and the brake is pressurised with brake oil.
The steering cylinder (synchronised speed cylinder) attached to the differential of the steering axle
moves the wheels through the joint housings (steering knuckles) between the two stop positions.
For a description of the steering system and the steering cylinder, see group 13.10/13.32.
the two swing axle support cylinders attached to the undercarriage.
For a detailed description of the oscillating axle support, see group 14.10 .
Fig. 1
Steering axle 262
copyright by
MJF C I F S S
12.20.1
Steering axle
Service Manual
Function
12.20.2
copyright by
MJF C I F S S
Service Manual
Steering axle
Technical data
2 Technical data
Series
Machine
Machine model
Serial number
Litronic
A 312
719
12363
Litronic
A 312
719
14296
Axle type
262/51
262/53
Design
Ratio wheel hub input : total input
17.5
Brake

8,2 l
Oil volume in axle

Wheel hub
3,0 l

API-GL-5/SAE 90 LS

A
Friction torque of the joint bearing 3.26 and 3.27
B Friction torque of the wheel bearing hub 3.47
30 - 60 Nm
10 - 30 Nm
C Tightening torque of the screws 3.18
140 Nm
D Tightening torque of the countersunk screws 3.37
50 Nm
initial
120 Nm
final
285 Nm
Tightening torque of the nuts 3.18

Tightening torque of the wheel lugs 3.44
460 Nm
G Tightening torque of the nuts 3.5
122 Nm
H Tightening torque of the screws 3.6
15 Nm
148 Nm
Tightening torque of the nuts 3.28
K Tightening torque of the slotted nuts/tie rod 5.1
260 - 290 Nm
116 - 128 Nm
Tightening torque of 5.3
M Tightening torque of the tie rod 5.1 at the piston rod
240 - 270 Nm
N Tolerance between the left and the right steering stop
0,6 - 0,7 Nm
O Tightening torque of the Allen head screws 4.11

P
Check of multi-disc brakes:
53 Nm
50 bar

No visible pressure drop after 3 minutes
Q Disc wear, see Maintenance of the axle", page 4
Disc pack 4.9/4.10
Dimension X (new)
44.85 !0.75 mm
Dimension X (worn)
40.3 mm
For items A - H, O, P and Q, see see Fig. 7

Tab. 1
2.1
Technical data
Tyre pressure
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MJF C I F S S
12.20.3
Steering axle
Service Manual
3.1
Power flow in the steering axle

The input torque of the transmission is transmitted through the universal joint shaft to the output flange of the differential. A bevel pinion and crown wheel transfer the torque via the differential case to
the differential spider with balancing and axle shaft gears, which is borne in the cage, see Fig. 7.
The respective axle shaft gear transfers the torque (increased by the differential translation with pinion and crown wheel) to the double joint drive shaft 14 meshing with the axle shaft gear.
The geared joint 3.14 (double joint drive shaft) drive the planetary gears 3.31. These roll off on the
stationary gear 3.32. This results in a great speed reduction and associated power transmission to
the rotating planetary housing 3.36.
The planetary housing drives the vehicle wheels through the wheel hub 3.47 and the wheel lugs
3.45 with the respective force and speed (based on the overall gear ratio).

Danger!
For maintenance work on the axles, the undercarriage of the machine must be accessed. This poses a great danger for mechanics.
The axle must be inspected for oil level, leakage and proper fixture regularly at preset intervals, see
inspection and maintenance schedule in group 3. Regularly check the wheel lugs 3.44 for the correct
tightening torque, (see Tab. 1, page 3).
The steering knuckle bearing must be regularly lubricated through the lubrication nipple 3.21, while
the oscillating axle support bearing must be lubricated through the nipple 124, see Fig. 3 (apply 2 grease gun strokes). For intervals, see the inspection and maintenance schedule.
The lubricating oil must be changed at preset intervals laid down in the inspection and maintenance
schedule. As part of the maintenance work, measure the wear of the disc brake, see Fig. 2. The testing of the multi-disc brake is an integral part of the maintenance; for detailed instructions, see also
chapter 'Brakes' in group 15.10.
12.20.4
copyright by
MJF C I F S S
Service Manual
Steering axle
Fig. 2
8.1

3.47 Wheel hub
Plug
3.2 Seal ring

3.32 Gear
4.9 Brake discs

4.10 Counter discs
3.36 Planetary housing
Nominal dimension/limit dimension
3.37 Countersunk screw

If the braking force is reduced or if you hear unusual noises, check the brake discs 4.9 for wear
of the lining.
To do this, drain the oil in the planetary drives (wheel hubs).
Remove the countersunk screws 3.37, pull off the planetary housing 3.36 and pull the brake
discs 4.9 with the counter discs 4.10 from the gear 3.32 (observe sequence of disc for replacement!).
Check the dimension X of the complete disc pack using a calliper gauge:
nominal dimension X at the new brake discs = 44.850.75 mm
Limit dimension X at used discs = 40.3 mm
If the limit dimension is reached or exceeded, replace all brake discs 4.9 and counter discs
4.10.
Note!
When inserting the disc pack, ensure that the discs are in the correct sequence (oil bores must be
positioned so that they are aligned in axial direction with the plug 3.1 and vertically to each other.
Place the planetary housing 3.36 onto the wheel hub 3.47 and tighten the screws 3.37 (tightening
torque 50 Nm).
Turn the wheel until the oil level mark is in horizontal position, and add oil, see (see Tab. 1, page
3) (or operating manual) through the check screw 3.1, until it reaches the lower edge of the bore.
copyright by
MJF C I F S S
12.20.5
Steering axle
Service Manual
5 Dismantling of the steering axle for repair work

Danger!
The dismantling and installation of the steering axle requires access to the undercarriage of the machine. There is a risk of death to the technician, as limbs could become crushed.
Secure the lifted undercarriage with suitable props.
Depressurise the hydraulic system.
Always adhere to the safety instructions in group 1.10 and the accident prevention regulations
issued by the German Ground Construction Trade Association (Tiefbau-Berufsgenossenschaft)
Fig. 3
Dismantling and installing the steering axle
110
Steering axle
123
Bracket
111
Rigid axle
124
Lubrication nipple
112
Vehicle wheels
125
Plug
115
127
Screw
116
Hex head screw
130
Undercarriage
If required, remove the wheels 112 from the steering axle.

Block the wheels of the rigid axle 111 with chocks. Lift the undercarriage 130 and secure the
12.20.6
copyright by
MJF C I F S S
Service Manual
Steering axle
steering axle 110 with suitable lifting tackle.
Remove the hex head screw 127 and lower the steering axle 110 together with the holder 123.
6 Repairs to the steering axle

For detailed repair instructions for the axle, refer to the separate repair manual for Dana 262 axles.
7 Installation of the steering axle

Place the steering axle 110 in the undercarriage, using suitable lifting gear.
Check the steering axle bearing for proper functioning (i.e. reusability of stop bushings 6).
Secure the steering axle 110 together with the holder 123 to the undercarriage 130, using the
screw 127.
Apply lubricant to the lubrication nipple 124 and then place the plug 125 onto the nipple.
Secure the universal joint shaft 115 with the hex head screws 116 to the differential of the steering axle 110.
Connect the hydraulic lines to the steering cylinder and bleed the steering system. For detailed
instructions, see group 13.10/13.20/13.32.
copyright by
MJF C I F S S
12.20.7
Steering axle
Service Manual
Exploded view of the steering axle
8 Exploded view of the steering axle
Fig. 4
12.20.8
Output
1
3
Differential, see group 12.23

Output, complete
3.26 Joint housing

3.27 Joint housing
3.1
Plug
3.28 Nut
3.2
Seal ring
3.29 Stop screw
3.3
Disc
3.30 Bearing
3.4
3.5
Hex head screw

Nut
3.31 Planetary gear

3.32 Gear
3.6
3.7
Screw
Outer race
3.33 Hollow gear carrier

3.34 Control oil unit
3.8
Snap ring
3.35 Bearing
3.9
Snap ring
3.36 Planetary housing
3.10 Deep groove ball bearing
3.37 Countersunk screw
3.11 Seal ring

3.12 Intermediate bushing
3.38 Nut
3.39 Locking plate
3.13 O-ring
3.40 Stud
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MJF C I F S S
Service Manual
Steering axle
3.14 Joint
3.15 Seal ring
3.41 Snap ring

3.42 Bearing
3.16 Bearing
3.43 O-ring
3.17 Steering knuckle bolt
3.44 Nut
3.18 Screw
3.19 Cover
3.45 Wheel stud

3.47 Wheel hub
3.20 Plug
3.48 Seal ring
3.21 Conical lubrication nipple
3.49 Magnetic plug
3.22 Shim ring
3.52 Centring ring
3.23 Dust sealing ring

3.24 Spacer ring
3.53 Lock washer

3.54 Spacer ring
3.25 Steering knuckle bolt
Fig. 5
Brake
3.26 Joint shaft, left / output
4.11 Allen head screw
3.27 Joint shaft, right / output

3.32 Gear
4.12 Brake disc

4.13 Spring
3.33 Hollow gear carrier, see Fig. 4

4
Brake, complete

4.16 Pin
4.1
Bleeder screw
4.17 O-ring
4.2
Plug
4.18 Seal ring
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MJF C I F S S
12.20.9
Steering axle
Service Manual

4.8
4.9
4.19 Screw plug

4.20 Piston repair kit
Ring
Brake disc
4.10 Counter disc
Fig. 6
12.20.10
Steering cylinder
Differential, complete, see page 12.23-05 5.2
5
5.1
Steering cylinder, complete

Joint tie rod
5.3
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MJF C I F S S
Cylinder
Allen head screw
Service Manual
Steering axle
Sectional drawing of steering axle
9 Sectional drawing of steering axle
Fig. 7
Steering axle with disc brake
copyright by
MJF C I F S S
12.20.11
Steering axle
Service Manual

1
3.31
Planetary gear
3
3.1
Output, complete
Plug
3.32
3.33
Gear
Hollow gear carrier
3.2
Seal ring
3.34
Axle shaft
3.3
Disc
3.35
Bearing
3.4
Hex head screw
3.36
Planetary housing
3.5
3.6
Nut
Screw
3.37
3.38
Countersunk screw
Nut
3.7
3.8
Outer race
Snap ring
3.39
3.40
Locking plate
Stud
3.9
3.10
Snap ring
3.41
3.42
Snap ring
Bearing
3.11
Seal ring
3.43
O-ring
3.12
3.13
O-ring
3.44
3.45
Nut
Wheel stud
3.14
3.15
Joint
Seal ring
3.47
3.48
Wheel hub
Seal ring
3.16
Bearing
3.49
Magnetic plug
3.17
Steering knuckle bolt
3.52
Disc
3.18
Screw
3.53
Spacer ring
3.19
3.20
Cover
Plug
4.1
4.2
Bleeder screw
Plug
3.21
3.22

Shim ring
4.8
4.9
Ring
Brake disc
3.23
Dust sealing ring
4.10
Counter disc
3.24
3.25
Spacer ring
Steering knuckle bolt
4.11
4.12
Allen head screw

Brake disc
3.26
3.27
Joint housing
Joint housing
4.14
4.17
Adjusting screw
O-ring
3.28
3.29
Nut
Stop screw
4.20
Piston repair kit
3.30
Joint housing
Note!
For settings and torques A, B, C, D, E, F, G, H, O, P, Q for the maintenance and repair of the axle,
see Fig. 7 and Technical data", page 3.
12.20.12
copyright by
MJF C I F S S
Service Manual
Rigid axle
Function
Rigid axle
1 Function
The rigid axle is permanently screwed to the undercarriage.
The axle housing of the rigid axle, which transfers the axle load of the machine to the drive wheels,
is equipped with a built-in differential mounted between the axle supports of the axle. The differential
transmits 50% of the output power of the transmission via the axle shafts to the planetary drives of
the output units. For a detailed description of the differential, see group 12.23.
The output unit contains the planetary output as well as the hydraulically operated wet multi-disc brake. It is applied when the brake pedal (working brake) is operated and the brake is pressurised with
brake oil. For a detailed description of the brake system, see group 15.10.
Fig. 1
Rigid axle 162
copyright by
MJF C I F S S
12.21.1
Rigid axle
Service Manual
Technical data
2 Technical data
Series
Machine
Machine model
Serial number
Litronic
A 312
719
12363
Axle type
162/55
Design
Ratio wheel hug input : total input
17.5/6.0
Brake
West multi-disc brake
Oil volume in axle
Axle support/
differential/wheel hub
total 10.5. l

API-GL-5/SAE 90 LS

A Friction torque of the wheel bearing (cover 3.10
130 - 180 Nm
B Tightening torque for the Allen head screws 3.8
220 - 240 Nm
C Tightening torque for the wheel lugs 3.13
460 Nm
D Tightening torque for the hex head screws 3.28
280 - 310 Nm
Tightening torque for the readjusting screws 4.4
10 - 15 Nm
Tightening torque for the readjusting screws 4.10
5 - 7 Nm
G Check of multi-disc brakes:

50 bar
No visible pressure drop after 3 minutes

H Disc wear, see Maintenance of the axle", page 3
Disc pack 4.1/4.2
Dimension X (new)
44.85 !0.75 mm
Dimension X (worn)
40.3 mm
For items A - F and H, see see Fig. 6

Tab. 1
2.1
Technical data
Tyre pressure
12.21.2
copyright by
MJF C I F S S
Service Manual
Rigid axle
3.1
Power flow in the rigid axle

See also sectional drawing Fig. 6 and drawing on page 12.23-11.
The input torque of the transmission is transmitted through the universal joint shaft to the output flange of the differential. A bevel gear and crown wheel transfer the torque via the differential housing to
the differential spider with balancing and axle shaft gears, which is borne in the differential housing.
The respective axle shaft gear transfers the torque (increased by the differential translation with pinion and crown wheel) to the axle shaft meshing with the axle shaft gear.
The geared axle shaft 3.19 drives the planetary gears 3.14. These roll off on the stationary gear
3.18. This results in a great speed reduction and associated power transmission to the rotating cover
3.10 (planetary housing).
The COVER drives the vehicle wheels through the wheel hub 3.2 and the wheel lugs 3.12 with the
respective force and speed (based on the overall gear ratio).
Danger!
inspection and maintenance schedule in group 3. Regularly check the wheel lugs 3.13 for the correct
tightening torque, (see Tab. 1 on page 2).
schedule.
Fig. 2
copyright by
MJF C I F S S
12.21.3
Rigid axle
Service Manual
Dismantling of the rigid axle for repair work

8.2
Wheel hub
3.28 Hex head screw
3.4
3.9
Magnetic plug
Spring washer
4.1
4.2
Brake discs
Counter discs
Nominal dimension/limit dimension
3.10 Cover
3.20 Axle shaft
If the braking force is reduced or if you hear unusual noises, check the brake discs 4.1 for wear
of the lining.
For this purpose, drain the oil from the planetary gear through the magnetic plug 3.4.
Remove the hex head screws 3.28 and lift of the cover 3.10 together with the wheel hub 3.2.
Pull the brake discs 4.1 with the counter discs 4.2 from the axle shaft 3.20 (observe sequence of
discs for possible replacement!).
Check the nominal dimension X of the complete disc pack using a calliper gauge:
nominal dimension X at the new brake discs = 44.850.75 mm
Limit dimension X at used discs = 40.3 mm
If the limit dimension is reached or exceeded, replace all brake discs 4.9 and counter discs
4.10.
Note!
When inserting the disc pack in the cover 3.10, ensure that the discs are in the correct sequence.
Place the cover 3.10 with the wheel hub 3.2 on the axle shaft 3.20 and screw in the screws 3.28
with the spring washers 3.9 (tightening torque 280 - 310 Nm).
Add prescribed oil (see Tyre pressure", page 2 (or operating manual) at the oil filling opening
(plug 3.5, see Fig. 4)) until it reached the lower edge of the bore.
.
5 Dismantling of the rigid axle for repair work
Danger!
The dismantling and installation of the rigid axle requires access to the undercarriage of the machine. There is a risk of death to the technician, as limbs could become crushed.
12.21.4
copyright by
MJF C I F S S
Service Manual
Rigid axle
Fig. 3
Dismantling and installing the rigid axle
110
111
Steering axle
Rigid axle
117
127
Hex nut
Hex head screw
112
115
Vehicle wheels
128
129
Nut
Washer
116
Hex head screw
130
Undercarriage
If required, remove the vehicle wheels 112 from the rigid axle.
Block the wheels of the steering axle 110 with chocks. Lift the undercarriage 130 and secure the
rigid axle 111 with suitable lifting tackle.
Remove the hex head nuts 128 and the screws 127 and then remove the rigid axle 111 from the
undercarriage 130.
6 Repair of the rigid axle

For detailed repair instructions for the axle, refer to the separate repair manual for Dana 162 axles.
copyright by
MJF C I F S S
12.21.5
Rigid axle
Service Manual
Installation of the rigid axle
7 Installation of the rigid axle

Place the rigid axle 111 below the undercarriage and lift it.
Secure the rigid axle with the hex head screws 127 and the nuts 128 to the undercarriage (tightening torque 560 Nm); lock the nuts 128.
Secure the universal joint shaft 115 with the hex head screws 116 to the differential of the rigid
axle 111.
12.21.6
copyright by
MJF C I F S S
Service Manual
Rigid axle
Exploded view of the rigid axle
8 Exploded view of the rigid axle
Fig. 4
Output
1
3

Output, complete
3.16 Bearing
3.17 Snap ring
3.1
Planetary housing
3.18 Gear
3.2
3.3
Wheel hub
Bearing
3.19 Axle shaft

3.20 Axle shaft
3.4
Magnetic plug
3.21 Hex head screw
3.5
Plug
3.22 Washer
3.6
3.7
O-ring
3.23 Pin
3.24 Seal ring
3.8
Allen head screw
3.25 Plug washer
3.9 Spring washer

3.10 Cover
3.26 Plug
3.27 Bleeder screw
3.11 Seal ring
3.28 Hex head screw
3.12 Wheel stud
3.29 Thrust washer
3.13 Wheel lug
3.33 Centring ring
3.14 Planetary gear
3.34 Lock washer
copyright by
MJF C I F S S
12.21.7
Rigid axle
Service Manual

3.15 Washer
Fig. 5
12.21.8
Brake
3.10 Cover, see Fig. 4
4.6
Piston
4
4.1
Brake, complete
Brake disc
4.7
4.8
O-ring
Ring
4.2
4.3
Counter disc
Ring
4.9 Spring
4.4
4.5
Adjusting screw
Spring
4.11 O-ring
copyright by
MJF C I F S S
Service Manual
Rigid axle
Fig. 6
Rigid axle with multi-disc brake
copyright by
MJF C I F S S
12.21.9
Rigid axle
Service Manual

3
Output, complete
3.22
Washer
3.1
3.2
Planetary housing
Wheel hub
3.23
3.24
Pin
Seal ring
3.3
Bearing
3.25
Screw plug
3.4
Magnetic plug
3.26
Plug
3.5
Plug
3.27
Bleeder screw
3.6
3.7
O-ring
3.28
3.29
Hex head screw

Thrust washer
3.8
3.9
Allen head screw

Spring washer
3.33
3.34
Centring ring
Lock ring
3.10
3.11
Cover
Seal ring
4
4.1
Brake, complete
Brake disc
3.12
Wheel stud
4.2
Counter disc
3.13
3.14
Nut
Planetary gear
4.3
4.4
Ring
Adjusting screw
3.15
3.16
Washer
Bearing
4.5
4.6
Spring
Piston
3.17
Snap ring
4.7
O-ring
3.18
Gear
4.8
Ring
3.19
Axle shaft
4.9
Spring
3.20
3.21
Axle shaft
Hex head screw
4.10
4.11
Adjusting screw
O-ring
Note!
For settings and torques A, B, C, D, E, F, H for the maintenance and repair of the axle, see Fig. 6
and (see Tab. 1 on page 2).
12.21.10
copyright by
MJF C I F S S
Service Manual

Function

1 Function
The differential is built into the axle housing of steering and rigid axles. It transmits the output power
of the transmission to the planetary drives, adjusting the speed and torque by means of bevel pinions
and the crown wheel.
When negotiating bends, the differential also compensates the different forces and speeds of the planetary outputs and thus the vehicle wheels.
Fig. 1
Differential of the steering and rigid axle
copyright by
MJF C I F S S
12.23.1
Service Manual
Function
12.23.2
copyright by
MJF C I F S S
Service Manual

Technical data
2 Technical data
Machine
Machine model
Serial number
A 312 Li
719
12363
Axle type
162/51 and 262/51
Gear ratio
12 : 35
Settings to be observed for installation:

A Setting value of the crown wheel kits 203
/212
/ 212

(through nut 205 / 225 )
Torque for the hex heads screws 206 / 207

respectively
0.13 - 0.18 mm
/ 204
D Rolling resistance of the input pinion bearing 213

216
(increase or reduce shim thickness
by 0.01 mm)
E
Dimension on the shaft circumference of he bevel gears 203

/
212 (e.g. 118) and on the front
/
end of the bevel gear 203
212 as marked (e.g. +1)
or 211 / 226
/ 210
1 - 4 Nm
120 - 170 Ncm

(+ / -) 60 Ncm
24 - 26 Nm
128 - 142 Nm
G Torque for the hex head screws 217
90 - 100 Nm
H Torque for the nut 218
280 - 310 Nm
/ 223
Torque for the shaft nut 219
500 - 570 Nm
Items A - I (see Fig. 3 on page7) and (see Fig. 5 on page11)

Tab. 1
Note!
"162 / 262 Dana axles"
Position on steering axle
Position on rigid axle
copyright by
MJF C I F S S
12.23.3
Service Manual
Exploded view of the differential of the steering axle
12.23.4

Assembly 10
1
O-ring
Assembly 20
1
O-ring
Intermediate cover
Shim 0.15 / 0.20 / 0.40 / 0.50 mm
3
4
Housing
Lid
3
4

Bleeder
Shaft nut
Seal ring
Allen head screw
Plug
Allen head screw
Magnetic plug
Hex head screw
Thrust washer
Assembly 60
10
11

Pin
1
2
Thrust bushing
12
13
Snap ring
Thrust washer
3
4
Support bracket
14
15
Balancing shaft gear

Plug
16
Bracket, complete
17
18
Shim 0.10 / 0.15 / 0.20 / 0.30 mm

Spacer ring
19
20
Shaft nut
Seal ring
21
22
Protective plate
Flange
23
Nut
24
25
Snap ring
copyright by
MJF C I F S S
Service Manual

Fig. 2
Exploded view of the differential (assemblies 10 and 20)

and the oscillating axle bearing (assembly 60)
copyright by
MJF C I F S S
12.23.5
Service Manual
4 Exploded view of the differential of the steering axle

101
O-ring
211
Pin
102
103
Intermediate cover
Housing
212
213
Snap ring
Thrust washer
104
Lid
214
105
Bleeder
215
106
Seal ring
216
107
108
Plug
Magnetic plug
217
218
Shim 0.10 / 0.15 / 0.20 / 0.30 mm

Spacer ring
201
O-ring
219
Shaft nut
202
203
Shim 0.15 / 0.20 / 0.40 / 0.50 mm

220
221
Seal ring
Protective plate
204
205

Shaft nut
222
223
Flange
Nut
206
207
Allen head screw

Allen head screw
224
314
Snap ring
Axle shaft
208
Hex head screw
334
Axle shaft
209
210
Thrust washer
349
Screw plug
Note!
Observe settings and torques A, B, C, D, E, F, H, I and Table 1, page 3.
12.23.6
copyright by
MJF C I F S S
Service Manual

Fig. 3
Sectional drawing of the differential of the steering axle
copyright by
MJF C I F S S
12.23.7
Service Manual
Exploded view of the differential of the rigid axle
12.23.8

Assembly 10
1
O-ring
Assembly 20
1
Intermediate cover
3
4
Housing
Lid
3
4
Axle shaft wheel

Pin
Bleeder
Snap ring
Plug
Snap ring
Magnetic plug
Thrust washer
Snap ring
Thrust washer
10
11
Hex head screw

Allen head screw
12
13

14
15
Shim 0.10 / 0.15 / 0.20 mm

Shim 0.20 / 0.40 / 0.50 mm
16
O-ring
17
18
Hex head screw

Nut
19
20
Shaft nut
Seal ring
21
22
Protective plate
Lid
23
Spacer ring
24
25
O-ring
Shaft nut
26
27
Allen head screw

Flange
28
copyright by
MJF C I F S S
Service Manual

Fig. 4
Differential (assemblies 10 and 20)
copyright by
MJF C I F S S
12.23.9
Service Manual
Sectional drawing of the differential of the rigid axle
6 Sectional drawing of the differential of the rigid axle

101
O-ring
212
102
Intermediate cover
213
103
Housing
214
Shim 0.10 / 0.15 / 0.20 mm
104
Lid
215
Shim 0.15 / 0.20 / 0.40 / 0.50 mm
105
107
Bleeder
Plug
216
217
O-ring
Hex head screw
108
109
Magnetic plug
Snap ring
218
219
Nut
Shaft nut
201
220
Seal ring
202
203
Axle shaft wheel
221
222
Protective plate
Lid
204
205
Pin
Snap ring
223
224
Spacer ring
O-ring
206
207
Snap ring
Thrust washer
225
226
Shaft nut
Allen head screw
208
227
Flange
209
210
Thrust washer
Hex head screw
304
319
Screw plug
Axle shaft
211
Allen head screw
320
Axle shaft
Note!
Observe settings and torques A, B, C, D, E, F, G, H, I, (see Fig. 5 on page11) and Table 1, page 3.
12.23.10
copyright by
MJF C I F S S
Service Manual

Fig. 5
copyright by
MJF C I F S S
12.23.11
Service Manual
12.23.12
copyright by
MJF C I F S S
Service Manual
APL - B 745 steering axle with multi-disc brake

Function

1 Function
wheels, is equipped with a built-in differential.
Due to the technical design combining a high planetary gear ratio in the wheel hub with a small bevel
gear ratio in the differential, the differential is very compact, providing for great ground clearance.
The wheel hub contains the planetary drive as well as the hydraulically operated wet multi-disc brake.
It is pressurised and applied when the brake pedal (working brake) is operated. For a more detailed
description of the brake system, see group 15.10.
Fig. 1
APL - B 745 steering axle
copyright by
MJF C I F S S
12.28.1

Function
12.28.2
copyright by
MJF C I F S S
Service Manual
Service Manual

Technical data
2 Technical data
Machine
Machine model
Serial number
A 314 Litronic
635
2001
Axle type
A 314 Litronic
635
11308
APL - B 745
Design
Gear ratio
Standard
Speeder
17,52
17,52
Brake
16,62
16,62
Oil volume in axle

Axle housing
Planetary drive
7.5 l
0.7 l per side

A
End play of the double joint drive shaft 20
0.3 - 0.6 mm
Clearance of the disc pack 83 / 84 (piston stroke)

new
at max. wear
2.5 - 2.9 mm
5.0 mm
Rolling resistance of the joint housing bearing 35
40 - 50 Nm
Rolling resistance of the wheel bearing 61/64 (new)
8 - 12 Nm
Torque for the slotted nut 32
280 Nm
11 Nm
Torque for the Allen head screws 103
32 Nm
420 Nm
Tightening torque of the slotted nut / tie rods,

see steering cylinder
300 Nm
1550 + 500 Nm
Multi-disc brakes:
Max. pressure drop after 5 min.
Low pressure test
Visible pressure drop after 15 seconds is not permissible
120 bar
3 bar
5 bar
Items A - K, (see Fig. 7, page 11)

Tab. 1
2.1
Technical data
Tyre pressure
copyright by
MJF C I F S S
12.28.3
Service Manual
3.1
Power flow in the steering axle, (see Fig. 7, page 11)

The sun gear shaft 91, which is connected through the disc carrier 92 to the double joint drive shaft
20, drives the planetary gears 95. These roll off on the stationary hollow gear 68. This results in a
great speed reduction and associated power transmission to the rotating planetary carrier 94. The
planetary carrier 94 drives the vehicle wheels through the wheel studs 104 with the respective force
and speed (based on the overall gear ratio).

Danger!
The axle must be serviced at the intervals laid down in the inspection and maintenance schedule, see
group 3. Regularly check the wheel lugs 107 for the correct tightening torque, (see Tab. 1, page 3).
The oscillating axle bearing of the steering knuckle bearing must be lubricated and lubricating oil must
be changed at fixed intervals laid down in the inspection and maintenance schedule.
also chapter "Brakes" in group 15.10.
The manufacturer also prescribes an annual inspection of the disc lining for wear, see Fig. 2.
The above check must be carried out annually, or if one of the following problems arise:
Changes in the oil level in the wheel hub
Measuring of brake lining wear

Turn the wheel hub until the small screw plug M16 is at the top.
Apply working brake to the stop.
Remove the screw plug and screw in the measuring plug M16 (tool ID no. 7019556) to the stop;
tighten it with 10 Nm.
Measure and write down distance X from the screw head to the plane recess at the planetary
carrier, see Fig. 2.
Release the brake, turn the measuring screw further in and tighten it again with 10 Nm. Measure
and write down the dimension Y from the screw head to the p plane recess at the planetary carrier.
Calculate the difference between the two measurements "X" "Y". This value corresponds to
the piston stroke.
12.28.4
copyright by
MJF C I F S S
Service Manual

Note!
Limit value for piston stroke with wear = 5.0 mm
If the actual value exceeds the permissible limit value, replace the entire brake disc pack.
Fig. 2
A = screw plug M 16; B = measuring screw M 16

5.1

Danger!
Loosen the hex head screw 6 and remove the universal joint shaft 13 (old bearing).
Remove the hex head screws 6, the retaining washers 14 and the plate 7 (new bearing).
Drive out the pin 8 (do not damage the washer 9) and lower the steering axle 4.
copyright by
MJF C I F S S
12.28.5
Service Manual
5.2

Note!
For detailed repair instructions for the axle, refer to the separate "Repair manual for APL-B 745
ZP axles".
5.3

Insert the steering axle 4 into the undercarriage 5, using suitable lifting tackle. Insert the washers
9 and drive in pin 8.
Loosen the hex head screw 6 and screw in the universal joint shaft 13 (old bearing).
Secure the plate 7 using the hex head screws 6 and the retaining washers 14 (new bearing).
Lubricate the steering axle bearing at the lubrication nipple 10.
Secure the universal joint shaft 3 with the screws 2 to the differential of the steering axle 4.
13.20).
Tighten the wheel lugs with the prescribed torque, see Tab. 1.
Fig. 3
12.28.6
Undercarriage with axles
Vehicle wheels
Bolt
2
3
Hex head screw

Joint shaft
9
10
Spacer
Lubrication nipple
Steering axle
11
Lock nut
Undercarriage
12
Rigid axle
copyright by
MJF C I F S S
Service Manual

6
7
13
14
Hex head screw

Plate
Disc
Retaining washer
Fig. 4
Steering axle (assembly 17)
.10
Axle housing
.290
Stub shaft
.30
Axle housing
.330
Snap ring
.40
Bearing bushing
.340
Bushing
.50
.90
Washer (S = 0.5 - 2.0mm)

Roller bearing
.350
.550

Left tie rod
.100
.120
Roller bearing
O-ring
.560
.600
Right tie rod

Axial joint
.130
.140
Hex head screw

Disc
.605
.610
Bellows
Right ball joint, complete
.150
Fit bolt
.611
Left ball joint, complete
.240
.250
Screw plug
Screw plug
.620
.630
Clamp
Slotted nut
.260
O-ring
.640
Cotter pin
copyright by
MJF C I F S S
12.28.7
Service Manual
Fig. 5
.10
12.28.8
Joint housing (assembly 18)

Left joint housing
.130
Lubrication nipple
.10
Right joint housing
.150
Bushing
.10
.50
Slotted nut
Roller bearing
.160
.170

Universal joint
.80
.90
Sealing cap
O-ring
.200
.270
Snap ring
Plug
.100
Washer (S = 1.2 - 2.0mm)
.390
Bleeder valve
.114
.120
Bearing pin
Hex head screw
.480
.500
Stop washer (S = 2.0 - 6.0 mm)

Stop screw
copyright by
MJF C I F S S
Service Manual

Fig. 6
Output (assembly 19)
.10
.30

Roller bearing
.290
.300
End washer
Snap ring
.40
.50
Ring (S = 14.0 - 15.0 mm)

Roller bearing
.320
.340
Thrust washer
Sun gear shaft
.80
Hub
.350
Disc carrier
.90
.120
O-ring
Plug
.360
.370
Snap ring
Snap ring
.130
.140
O-ring
Junk ring
.390
.400
Planetary carrier
Planetary gear
.150
.160
Snap ring
Hollow gear
.410
.420
Roller bearing
Junk ring
.200
Piston
.430
Snap ring
.210
.214
Lip seal
Backing ring
.480
.490
Thrust washer (S = 2.0 3.0 mm)

O-ring
.220
.230
Lip seal
Backing ring
.500
.510
Screw plug (oil drainage)

Allen head screw
.232
.238
Backing washer
Pressure spring
.540
.550
Wheel stud
Lock washer
.248
Lock nut
.560
Centring ring
.256
.258
Hex head screw

Spring sleeve
.570
.620
Wheel lug
Screw plug (measuring bore)
.270
Outer disc (S = 2.0 3.0 mm)
.630
O-ring
.280
Inner disc
copyright by
MJF C I F S S
12.28.9
Service Manual

Item
ZP figure
no.
Description
Item
ZP figure
no.
Description
17010
Axle housing
76
19230
Backing ring
17340
Bushing
77
19232
Back-up washer
17350
78
19258
Spring sleeve
10
18160
79
19238
Pressure spring
20
18170
Double joint drive

shaft
81
19256
Hex head screw
31
18010
Right joint housing
82
19248
Lock nut
32
18010
Slotted nut
83
19270
Outer disc
35
18050
Roller bearing
84
19280
Inner disc
37
18080
Sealing cap
85
19290
End washer
38
18090
O-ring
86
19150
Snap ring
39
18100
Washer
87
19320
Thrust washer
40
18114
Bearing pin
91
19340
Sun gear shaft
41
18120
Hex head screw
92
19350
Disc carrier
42
18130
Lubrication nipple
93
19300
Snap ring
43
18150
Bushing
94
19390
Planetary carrier
44
18114
Bearing pin
95
19400
Planetary gear
45
18390
Bleeder valve
96
19410
Roller bearing
60
19010
97
19420
Junk ring
61
19030
Roller bearing
98
19430
Snap ring
62
19080
Hub
99
19480
Thrust washer
63
19090
O-ring
103
19510
Allen head screw
64
19050
Roller bearing
104
19540
Wheel stud
65
19130
O-ring
105
19550
Lock washer
66
19140
Junk ring
106
19560
Centring ring
68
19160
Hollow gear
107
19570
Wheel lug
71
19040
Ring
108
19370
Snap ring
72
19200
Piston
109
19360
Snap ring
73
19210
Lip seal
110
17330
Snap ring
74
19214
Backing ring
111
17290
Stub shaft
75
19220
Lip seal
Note!
Observe settings and torques A, B, C, D, E, F, G, H, I, K, see Fig. 7 and Table 1, page 3.
12.28.10
copyright by
MJF C I F S S
Service Manual

Fig. 7
Sectional drawing of steering axle(see Fig. 7, page 11)
copyright by
MJF C I F S S
12.28.11

12.28.12
copyright by
MJF C I F S S
Service Manual
Service Manual

Function

1 Function
is equipped with a built-in differential.
The wheel hub contains the planetary drive as well as the hydraulically operated drum brake. It is
applied when the brake pedal (working brake) is operated and the brake is pressurised with brake oil.
Fig. 1
copyright by
MJF C I F S S
12.29.1
Service Manual
Technical data
2 Technical data
Machine
Machine model
Serial number
A 314 Li
635
2001
Axle type
A 314 Li
635
11308
AP-B 745
Design
Gear ratio
Standard
Speeder
17,52
17,52
Brake
16,62
16,62
Drum brake
Oil volume in axle

Axle housing and planetary drive
10.4 l

A
End play of the stub shaft 7 with sun gear shaft 91
0.4 - 2.0 mm

(without sealing element)
8 - 12 Nm
560 Nm
79 Nm
Torque for the Allen head screws 27/28
280 Nm
Torque for the hex nut 31
1400 + 200 Nm
Torque for the self locking screw 87
69 Nm
33 Nm
420 Nm
Check of drum brakes 20:

Residual lining thickness of the brake system (glued) min.
2 mm
Items A, B, D- K (see Fig. 6, page 9) and item C (see Fig. 2, page 4)

Tab. 1
2.0.1
Technical data
Tyre pressure
12.29.2
copyright by
MJF C I F S S
Service Manual

3.1
Power flow in the rigid axle, see Fig. 6

The respective axle shaft gear transfers the torque (increased by the differential translation with pinion and crown wheel) to the stub shaft 7 meshing with the axle shaft gear.
The sun gear shaft 91, which is connected through the sleeve 8 to the stub shaft 7, drives the planetary gears 95. These roll off on the stationary hollow gear 68. This results in a great speed reduction
and associated power transmission to the rotating planetary carrier 94. The planetary carrier drives
the vehicle wheels through the wheel studs 104 with the respective force and speed (based on the
overall gear ratio).

Danger!
The axle must be services at the intervals laid down in the inspection and maintenance schedule, see
group 3. Regularly check the wheel lugs 107 for the correct tightening torque, (see Tab. 1, page 2).
The lubricating oil must be changed at fixed intervals laid down in the inspection and maintenance
schedule.
The testing of the drum brake is an integral part of the maintenance; for detailed instructions, see also
chapter "Brakes" in group 15.10.

5.1

Danger!
Lift the undercarriage at the rear and secure the wheels of the steering axle 6 using chocks.
Disconnect the brake lines of the drum brake and seal the line openings.
Loosen the hex head screws 8 and remove the universal joint shaft 5 from the differential of the
copyright by
MJF C I F S S
12.29.3
Service Manual

rigid axle.
Secure the rigid axle 2 with suitable lifting tackle.
Remove the hex head nuts 3 and the screws 4 and then remove the rigid axle 2 from the undercarriage 9.
5.2

Note!
For detailed repair instructions for the axle, refer to the separate "Repair manual for AP-B 745 ZP
axles with drum brakes".
5.3

Install the rigid axle 2 in the undercarriage 9, using lifting gear and secure with the hex head
screws 4 and the nuts 3 to the undercarriage 9; lock the nuts 3.
Secure the universal joint shaft 5 with the hex head screws 2 to the differential of the rigid axle 2.
Connect the brake lines to the drum brake and bleed the brake (see group 15.10).
Fig. 2
12.29.4
Vehicle wheels
Steering axle
2
3
Rigid axle
Hex nut
7
8
Hex nut
Hex head screw
Hex head screw
Undercarriage
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MJF C I F S S
Service Manual

Drive shaft
Fig. 3
Axle housing, group 17
17010 Axle housing part I
17150 Fit bolt
17030 Axle housing part II
17240 Screw plug
17050 Washer (S = 0.10 - 2.0mm)
17250 Screw plug
17090 Roller bearing

17260 O-ring
17290 Stub shaft
17120 O-ring
17130 Hex head screw
17690 Sleeve
17700 Snap ring
17140 Disc
copyright by
MJF C I F S S
12.29.5
Service Manual
Fig. 4
12.29.6
Hub carrier, group 22 and drum brake, group 2 (1 = old) and (400 = new)
Brake (old)
350
Locking plate
10
50
Brake drum
Adapter
370
400
Tension spring
Brake (new)
60
Brake disc
410
Adapter
70
80
Bolt
Disc spring
420
430
Wheel cylinder
Allen head screw
90
Disc
440
Disc
100
Hex nut
510
Hub carrier
120
170
Countersunk screw
Wheel cylinder
510
570
Slotted nut
Allen head screw
180
Lock washer
580
Allen head screw
190
270
Hex head screw

Brake pad
590
610
O-ring
Retainer plate
340
Bolt
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MJF C I F S S
Service Manual

Fig. 5
Hub carrier and output of the wheel bearings or the planetary gear, group 19
10
410
Roller bearing
30
40
Roller bearing
Ring (S = 14.0 - 15.2 mm)
420
430
Junk ring
Snap ring
50
Roller bearing
480
Thrust washer (S = 1.5 5.0 mm)
80
Hub
490
O-ring
90
O-ring
500
Screw plug
160
184
Hollow gear
Locking plate
510
540
Allen head screw

Wheel stud
190
Self locking screw
550
Lock washer
340
Sun gear shaft
560
Centring ring
390
Planetary carrier
570
Wheel lug
400
Planetary gear
copyright by
MJF C I F S S
12.29.7
Service Manual
Item
ZP figure
no.
Description
Item
Group 17
ZP figure
no.
Description
Group 19
17010
Axle housing part I
17030
Axle housing part II
17290
Stub shaft
17690
Sleeve
17700
10
61
30
Roller bearing
62
80
Hub
63
90
O-ring
Snap ring
64
50
Roller bearing
Group 2
60
68
160
Hollow gear
10
Brake
71
40
Ring
11
10
Brake drum
86
184
Locking plate
12
40
Brake disc
87
190
Self locking screw
17
170
Wheel cylinder
91
340
Sun gear shaft
18
180
Lock washer
94
390
Planetary carrier
19
190
Hex head screw
95
400
Planetary gear
20
270
Brake pad
96
410
Roller bearing
21
340
Pin
97
420
Junk ring
22
350
Locking plate
98
430
Snap ring
23
370
Tension spring
99
480
Thrust washer
101
490
O-ring
102
500
Screw plug
Group 22
27
570 / 2 430
Allen head screw
28
580 / 2 430
Allen head screw
103
510
Allen head screw
30
10
Hub carrier
104
540
Wheel stud
31
10
Slotted nut
105
550
Lock washer
33
110
Retainer plate
106
560
Centring ring
37
90
O-ring
107
570
Wheel lug
Note!
Observe the setting values and tightening torques A, B, D, E, F, G, H, I, K , see Fig. 6 ,
and see Tab. 1.
12.29.8
copyright by
MJF C I F S S
Service Manual

Fig. 6
Sectional drawing of rigid sleeve
copyright by
MJF C I F S S
12.29.9
Service Manual
12.29.10
copyright by
MJF C I F S S
Service Manual

Function

1 Function
The axle housing of the rigid axle, which transfers the axle load of the vehicle to the drive wheels, is
equipped with a built-in differential.
The differential transfers 50% of the output power of the transmission via the universal joint shafts to
the planetary drives of the wheel hubs. For a detailed description of the differential, see group 12.31.
The wheel hub contains the planetary drive as well as the hydraulically operated multi-disc brake. It
is applied when the brake pedal (working brake) is operated and the brake is pressurised with brake
oil. For a detailed description of the brake system, see group 15.10.
x
Fig. 1
copyright by
MJF C I F S S
12.30.1
Service Manual
Technical data
2 Technical data
Series
Machine
Machine model
Serial number
Litronic
A 314
635
2001
Axle type
Litronic
A 314
635
11308
AP-B 745
Design
Gear ratio
Standard
17.52
16.62
Speeder
17.52
16.62
Brake
Multi-disc brake
Oil volume in the axle - axle housing + 2 planetary gears
11,6 l
Planetary output
approx. 0.8 l per side
API-GL-5/SAE 90 LS

A End play of the stub shaft 7 with sun gear shaft 91
0.4 - 2.0 mm
B Clearance of the disc pack 83 / 84 (piston stroke)

new
at max. wear
C Rolling resistance of the wheel bearing 61 (new)
2.5 - 2.9 mm
5.0 mm
8 - 12 Nm
1550+500 Nm
D Torque for the slotted nut 31

E
Tightening torque for the Allen head screws 32
280 Nm
Tightening torque for the lock nuts 82
11 Nm
G Tightening torque for the Allen head screws 103
32 Nm
H Tightening torque for the wheel lugs 107
420 Nm
560 Nm
Tightening torque for the nuts 3.18
K Check of multi-disc brakes:

120 bar
3 bar
Low pressure test
5 bar

For items A - H, seesee Fig. 7
Item I, see Fig. 3
Tab. 1
2.1
Technical data
Tyre pressure
12.30.2
copyright by
MJF C I F S S
Service Manual

3.1
Power flow in the rigid axle

See also sectional drawing Fig. 7 and drawing on page 12.31-09.
The sun gear 91, which is connected through the disc carrier 92 to the stub shaft 7, drives the planetary gears 95. These roll off on the stationary hollow gear 68. This results in a great speed reduction and associated power transmission to the rotating planetary carrier 94. The planetary carrier
drives the vehicle wheels through the wheel studs 104 with the respective force and speed (based
on the overall gear ratio).

Danger!
inspection and maintenance schedule in group 3. Regularly check the wheel lugs 107 for the correct
tightening torque, (see Tab. 1 on page 2).
schedule.
The manufacturer also prescribes regular inspections of the disc lining for wear.
Fig. 2
copyright by
MJF C I F S S
12.30.3
Service Manual

1
M16 screw plug
M16 measuring screw
This check should be carried out annually or if any of the following occur:
or unusual brake noises

Turn the wheel hub until the small M16 screw plug is at the top, see Fig. 2.
Remove the screw plug and screw in the M16 measuring plug (tool ID no. 7019556) to the stop;
Release the brake, screw measuring screw in further and tighten it again with 10 Nm.
Measure and write down distance Y from the screw head to the plane recess at the planetary
Calculate the difference between the two measurements X and Y. This value corresponds to the piston stroke.
If the permissible limit value is exceeded, replace all brake discs.
5 Dismantling of the rigid axle for repair work

Danger!
issued by the German Ground Construction Trade Association (Tiefbau-Berufsgenossenschaft).
12.30.4
copyright by
MJF C I F S S
Service Manual

Fig. 3
Dismantling and installing the rigid axle
110
111
Steering axle
Rigid axle
127
128
Hex head screw

Nut
112
Vehicle wheels
129
Washer
115
130
Undercarriage
117
Hex head screw
Loosen the hex nuts and hex head screws 117 and remove the universal joint shaft 115 from the
differential of the rigid axle.
Block the wheels of the steering axle 110 with chocks.
Secure the rigid axle with suitable lifting tackle.
Remove the hex head nuts 128, the washers 129 and the screws 127 and then remove the rigid
axle 111 from the undercarriage 130.
6 Repair of the rigid axle

axles with multi-disc brakes" .
copyright by
MJF C I F S S
12.30.5
Service Manual
Installation of the rigid axle after repairs
7 Installation of the rigid axle after repairs

Place the rigid axle 111 with lifting gear under the undercarriage and secure it with the hex head
screws 127 and the nuts 128 and washers 129 to the undercarriage (tightening torque I, see (see
Tab. 1 on page 2)).
Secure the universal joint shaft 115 with the hex head screws 117 to the differential of the rigid
axle 111.
Connect the brake lines to the multi-disc brake and bleed the brake (see description in group
15.10).
12.30.6
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MJF C I F S S
Service Manual

Axle housing
8 Axle housing
Fig. 4
Axle housing
17 010 Axle housing part I
17 140 Washer
17 030 Axle housing part II
17 150 Fit bolt
17 050 Washer (s=0.50 - 2.0 mm)

17 090 Roller bearing
17 240 Screw plug

17 250 Screw plug

17 120 O-ring
17 260 O-ring
17 290 Stub shaft
17 130 Hex head screw
copyright by
MJF C I F S S
12.30.7
Service Manual
Hub carrier
9 Hub carrier
Fig. 5
12.30.8
Hub carrier
22 010 Hub carrier complete with

22 010 Slotted nut
22 090 O-ring
22 110 Retainer plate
22 050 Washer
22 070 Allen head screw
22 160 Bleeder valve
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MJF C I F S S
Service Manual

Output
10 Output
Fig. 6
Output
19 010 Radial shaft seal ring
22 290 End washer

19 040 Ring (14.0 - 15.0 mm)
22 300 Snap ring

22 320 Thrust washer

19 080 Hub
22 340 Sun gear shaft

22 350 Disc carrier
19 090 O-ring
19 120 Plug
22 370 Snap ring

22 390 Planetary carrier
19 130 O-ring
22 400 Planetary gear
19 140 Junk ring
22 410 Cylindrical roller bearing
19 150 Snap ring
22 420 Junk ring
19 160 Hollow gear

19 200 Piston
22 430 Snap ring

22 480 Thrust washer (s=2.0 - 3.0 mm)
19 210 Lip seal
22 490 O-ring
19 214 Ring
19 230 Backing ring
22 500 Screw plug (oil drainage)

19 232 Back-up washer
22 540 Wheel stud
copyright by
MJF C I F S S
12.30.9
Service Manual
Output
19 238 Pressure spring
22 550 Lock washer
19 248 Lock nut
22 560 Centring ring

19 258 Spring sleeve
22 570 Wheel lug

22 620 Screw plug (measuring screw)
19 270 Outer disc (s=2.0 - 3 mm)
22 630 O-ring
19 280 Inner disc
Fig. 7
12.30.10
Rigid axle with multi-disc brake
copyright by
MJF C I F S S
Service Manual

Output
Item
1
ZP figure
no.
Designation
Item
ZP figure
no.
Designation
17 010
Axle housing part I
79
19 238
Pressure spring
17 030
Axle housing part I
81
19 256
Allen head screw
17 290
Stub shaft
82
19 248
Lock nut
29
22 050
Washer
83
19 270
Outer disc
30
22 010
Hub carrier
84
19 280
Inner disc
31
22 010
Slotted nut
85
19 290
End washer
32
22 070
Allen head screw
86
19 150
Snap ring
33
22 110
Retainer plate
87
19 320
Thrust washer
36
22 160
Bleeder valve
91
19 340
Sun gear shaft
37
22 090
O-ring
92
19 350
Disc carrier
60
19 010
93
19 300
Snap ring
61
19 030
Roller bearing
94
19 390
Planetary carrier
62
19 080
Hub
95
19 400
Planetary gear
63
19 090
O-ring
96
19 410
Roller bearing
64
19 050
Roller bearing
97
19 420
Junk ring
65
19 130
O-ring
98
19 430
Snap ring
66
19 140
Junk ring
99
19 480
Thrust washer
68
19 160
Hollow gear
101
19 490
O-ring
71
19 040
Ring
102
19 500
Screw plug
72
19 200
Piston
103
19 510
Allen head screw
73
19 210
Lip seal
104
19 540
Wheel stud
74
19 214
Ring
105
19 550
Lock washer
76
19 230
Backing ring
106
19 560
Centring ring
77
19 232
Back-up washer
107
19 570
Wheel lug
78
19 258
Spring sleeve
108
19 370
Snap ring
Note!
Observe settings and tightening torques A, B, C, D, E, F, G, H, see also Fig. 7 and (see Tab. 1 on
page 2).
copyright by
MJF C I F S S
12.30.11
Service Manual
Output
12.30.12
copyright by
MJF C I F S S
Service Manual

Function

1 Function
The differential is built into the axle housing of the steering and rigid axle. They transmit the output
power of the transmission to the planetary drives of the wheel hubs, adjusting the speed and torque
by means of bevel pinions and the crown wheel.
The differential also acts as an equalising device when the vehicle is negotiating a corner. If the mechanical connection from the transmission via the universal joint shafts, the differential, the stub
shafts and the planetary drives to the vehicle wheel were rigid, such steering manoeuvres would result in great strain on the axle and excessive tyre wear.
The differential balances out these forces. The torque input from the input flange to the bevel gear,
crown wheel and differential cage, and from there to the balancing axles mounted in the differential
cage ensures that the four balancing bevel gears attached to the balancing axles mesh with the two
axle shaft gears.
As a result, there is a relative shift in direction of rotation between the two stub shafts meshing with
the axle shaft gears, i.e. one stub shaft rotates clockwise, while the other rotates anticlockwise, or the
two stub shafts rotate at different rates.
The balancing movement has however a negative effect on the traction of the machine when driving
off-road over surfaces with different grip. On loose ground, ice or snow, only one wheel per axle might
properly grip the surface.
At the request of the customer, the machine can be equipped with a limit slip differential, which at
least partly eliminates this problem.
Fig. 1
Differential of steering and rigid axle
copyright by
MJF C I F S S
12.31.1
Service Manual
Technical data
2 Technical data
Machine
Machine model
Serial number
A 314 Litronic
635
2001
Axle type
BK
Gear ratio
2.92
This differential is not available as a complete unit. The component parts of the differentials for the
steering and the rear axle are identical.
A Setting value of the crown wheel kit 20
(etched onto the end side of

the pinion 20.1)
0.15 - 0.25 mm
0.18 - 0.23 mm (Speeder)
C Bearing preload of the differential bearing 3 / 4
1 - 4 Nm
D Rolling resistance of the driving pinion bearing 16/19
1 - 2 Nm
430 Nm
Torque for the hex head screws 6 and the fit bolt 7
410 Nm
145 Nm
Items A - G (see Fig. 5)

Tab. 1
Technical data
Note!
"AP / APL - B 745 ZP axles".
12.31.2
copyright by
MJF C I F S S
Service Manual

Exploded view of the differential
3 Exploded view of the differential
Fig. 2
10
Input (assembly 16)

210
Input flange
50
Bevel gear kit (crown wheel and bevel

pinion)
Washer (S = 1.0 - 1.5 mm)
220
Valance
80
110

Ring (S = 11.6 - 12.38 mm)
270
290
Washer
Hex nut
160
310
Locking plate
190
copyright by
MJF C I F S S
12.31.3
Service Manual
Fig. 3
12.31.4
Differential (assembly 73)
10
Crown wheel
720
Differential spider
570
640
Differential cage
Axle shaft gear
800
850
Allen head screw

Washer
650
670
Thrust washer
860
870
Connex heavy-duty spring pin

Roll pin S
680
Thrust washer
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MJF C I F S S
Service Manual

Axle housing of steering and rigid axle
4 Axle housing of steering and rigid axle
Fig. 4
Axle housing of steering and rigid axle (assembly 17)
.10
Axle housing I
.240
Screw plug
.30
.40
Axle housing II
Bearing bushing
.250
.260
Screw plug
Seal
.50
.90
Washer (S = 0.1 - 2.0 mm)

Roller bearing
.290
.330
Stub shaft
O-ring
.100
Roller bearing
.340
Bearing bushing
.120
O-ring
.350
Seal ring
.130
Hex head screw
.690
Bearing bushing
.140
.150
Washer
Fit bolt
.700
Seal ring
copyright by
MJF C I F S S
12.31.5
Service Manual
Sectional drawing of the differential
5 Sectional drawing of the differential

Item
ZP figure
no.
Designation
Item
ZP figure
no.
1.1
17010
Axle housing I
16
16160
1.2
17030
Axle housing II
17
16110
Ring
2.1
17050
Washer
18
16050
Adjusting disc
2.2
17050
Washer
19
16080
17090
20.1
16010
Bevel pinion
17100
20.2
16010
Crown wheel
17120
O-ring
21
73850
Washer
17130
Hex head screw
22
73800
Allen head screw
17150
Fit bolt
23.1
73570
Differential cage I
17140
Washer
23.2
73570
Differential cage II
17290
Stub shaft
24
73650
Thrust washer
10
16310
Locking plate
25
73640
Axle shaft gear
11
16290
Hex nut
26
73720
Differential spider
12
16270
Washer
27
73680
Thrust washer
13
16210
Input flange
28
73670
Balancing gear
14
16220
Valance
29
73870
Roll pin "S"
15
16190
30
73860
Heavy-duty roll pin

"Connex"
Designation
Note!
Observe settings and torques A, B, C, D, E, F, G, , see Fig. 5 and Table 1, page 2.
12.31.6
copyright by
MJF C I F S S
Service Manual

Fig. 5
copyright by
MJF C I F S S
12.31.7
Service Manual
12.31.8
copyright by
MJF C I F S S
Service Manual

Function

1 Function
Fig. 1
copyright by
MJF C I F S S
12.36.1

Function
12.36.2
copyright by
MJF C I F S S
Service Manual
Service Manual

Technical data
2 Technical data
Machine
Machine model
Serial number
A 316 Litronic
715
2001
Axle type
APL - B 755
Design
Gear ratio
Standard
Speeder
17.52
17.52
Brake
Oil volume in axle

Axle housing
Planetary drive
9.0 l
2.0 l per side

A
End play of the double joint drive shaft 20
0.3 - 0.6 mm

new
at max. wear
3.1 - 3.5 mm
5.0 mm
40 - 50 Nm
8 - 12 Nm
280 Nm
11 Nm
55 Nm
420 Nm

see steering
300 Nm
1400 + 500 Nm
Multi-disc brakes:
Low pressure test
150 bar
3 bar
1 - 5 bar
Items A - K ((see Fig. 7 on page11))

Tab. 1
2.0.1
Technical data
Tyre pressure
copyright by
MJF C I F S S
12.36.3
Service Manual
3.1
Power flow in the steering axle, (see Fig. 7 on page11)

Danger!
The axle must be regularly serviced according to the intervals laid down in the service or operating
manual. Regularly check the wheel lugs 107 for the correct tightening torque, (see Tab. 1 on page3).
be changed at fixed intervals laid down in the maintenance instructions.

Turn wheel hub until the small screw plug M16 is at the top, see Fig. 2.
Measure and write down distance Y from the screw head to the plane recess of the planetary
carrier.
Calculate the difference between the two measurements "X" "Y" . This value corresponds
12.36.4
copyright by
MJF C I F S S
Service Manual

to the piston stroke.
Note!
Fig. 2

5.1

Danger!
Remove the hex head screws 6 and the plate 7 (new bearing).
copyright by
MJF C I F S S
12.36.5
Service Manual
5.2

Note!
ZP axles".
5.3

Insert the steering axle 4 in the undercarriage 5, using suitable lifting tackle. Insert the washers 9
and drive in pin 8.
Secure the pin 8 with the washer 13 and the screws 6 (old), or with the plate 7 and the screws 6
with retaining washers 14 (new).
13.20).
Fig. 3
12.36.6
Vehicle wheels
Pin
2
3
Hex head screw

Joint shaft
9
10
Spacer
Lubrication nipple
4
5
Steering axle
Undercarriage
11
12
Lock nut
Rigid axle
copyright by
MJF C I F S S
Service Manual

6
7
13
14
Hex head screw

Plate
Washer
Retaining washer
Fig. 4
.10
.30
Axle housing
Axle housing
.260
.290
O-ring
Stub shaft
0.40
Bearing bushing
.330
Snap ring
.50
Washer (S = 1.05 - 2.0 mm)
.340
Bushing
.90
Roller bearing
.350
.100
.120
Roller bearing
O-ring
.600
.605
Axial joint
Bellows
.130
Hex head screw
.610
Right ball joint, complete
.140
Washer
.611
Left ball joint, complete
.150
Fit bolt
.620
Clamp
.240
.250
Screw plug
Screw plug
.630
.640
Slotted nut
Cotter pin
copyright by
MJF C I F S S
12.36.7
Service Manual
Fig. 5
.10
12.36.8

Left joint housing
.130
Lubrication nipple
.10
Right joint housing
.150
Bushing
.10
.50
Slotted nut
Roller bearing
.160
.170

Universal joint
.80
.90
Sealing cap
O-ring
.200
.270
Snap ring
Plug
.100
Washer (S = 0.6 - 2.0 mm)
.390
Bleeder valve
.114
.120
Bearing pin
Hex head screw
.500
Stop screw
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MJF C I F S S
Service Manual

Fig. 6
.10
.290
End washer
.30
.40
Roller bearing
Ring (S = 14.0 - 15.2 mm)
.300
.320
Snap ring
Thrust washer
.50
.80
Roller bearing
Hub
.340
.350
Sun gear shaft

Disc carrier
.90
O-ring
.360
Snap ring
.120
.130
Plug
O-ring
.370
0.390
Snap ring
Planetary carrier
.140
.150
Junk ring
Snap ring
.400
.410
Planetary gear
Roller bearing
.160
.200
Hollow gear
Piston
.420
.430
Junk ring
Snap ring
.210
Lip seal
.480
Thrust washer (S = 1.5 - 3.0 mm)
.214
.220
Backing ring
Lip seal
.490
.500
O-ring
.230
.232
Backing ring
Back-up washer
.510
.540
Allen head screw

Wheel stud
.238
Pressure spring
.550
Lock washer
.248
Lock nut
.560
Centring ring
.256
Hex head screw
.570
Wheel lug
.258
.270
Spring sleeve
Outer disc (S = 2.0 - 3.0 mm)
.620
.630

O-ring
.280
Inner disc
copyright by
MJF C I F S S
12.36.9
Service Manual

Item
ZP figure
no.
Designation
Item
ZP figure
no.
Designation
17010
Axle housing
76
19230
Backing ring
17340
Bushing
77
19232
Back-up washer
17350
78
19258
Spring sleeve
10
18160
79
19240
Hex head screw
20
18170
Double joint drive

shaft
81
19254
Hex head screw
31
18010
Right joint housing
82
19248
Lock nut
32
18010
Slotted nut
83
19270
Outer disc
35
18050
Roller bearing
84
19280
Inner disc
37
18080
Sealing cap
85
19290
End washer
38
18090
O-ring
86
19150
Snap ring
39
18100
Washer
87
19320
Thrust washer
41
18120
Hex head screw
91
19340
Sun gear shaft
42
18130
Lubrication nipple
92
19350
Disc carrier
43
18150
Bushing
93
19300
Snap ring
44
18114
Bearing pin
94
19390
Planetary carrier
45
18390
Bleeder valve
95
19400
Planetary gear
60
19010
96
19410
Roller bearing
61
19030
Roller bearing
97
19420
Junk ring
62
19080
Hub
98
19430
Snap ring
63
19090
O-ring
99
19480
Thrust washer
64
19050
Roller bearing
103
19510
Allen head screw
65
19130
O-ring
104
19540
Wheel stud
66
19140
Junk ring
105
19550
Lock washer
68
19160
Hollow gear
106
19560
Centring ring
71
19040
Ring
107
19570
Wheel lug
72
19200
Piston
108
19370
Snap ring
73
19210
Lip seal
109
19360
Snap ring
74
19214
Backing ring
110
17330
Snap ring
75
19220
Lip seal
111
17290
Stub shaft
Note!
12.36.10
copyright by
MJF C I F S S
Service Manual

Fig. 7
copyright by
MJF C I F S S
12.36.11

12.36.12
copyright by
MJF C I F S S
Service Manual
Service Manual

Function

1 Function
The wheel hub contains the planetary drive as well as the hydraulically operated drum brake. It is
applied when the brake pedal (working brake) is operated and the brake is pressurised with brake oil.
Fig. 1
2 Technical data
Machine
Machine model
Serial number
A 316 Li:
715
2001
Axle type
AP-B 755 TR
copyright by
MJF C I F S S
12.37.1
Service Manual
Technical data
Machine
Machine model
Serial number
A 316 Li:
715
2001
Design
Gear ratio
Standard
Speeder
17,52
17,52
Brake
Drum brake
Oil volume in axle

Axle housing
Planetary drive
9.0 l
1.0 l per side

A
Rolling resistance of the wheel bearing 61 / 64 (new)

560 Nm
79 Nm
Torque for the Allen head screws 27/28
Torque for the self locking screw 87
69 Nm
33 Nm
420 Nm
Check of drum brakes 20:

Residual lining thickness of the brake system (glued) min.
0.4 - 2.0 mm
8 - 12 Nm
280 Nm
1400 + 200 Nm
2 mm
Items A, B, D- K (see Fig. 6 on page9) and item C (see Fig. 2 on page4)

Tab. 1
2.1
Technical data
Tyre pressure
12.37.2
copyright by
MJF C I F S S
Service Manual

3.1
Power transfer in the rigid axle, see Fig. 6

The sun gear shaft 91, which is connected through the sleeve 8 to the stub shaft 7, drives the planetary gears 95. These roll off on the stationary hollow gear 68. This results in a great speed reduction
and associated power transmission to the rotating planetary carrier 94. The planetary carrier drives
the vehicle wheels through the wheel studs 104 with the respective force and speed (based on the
overall gear ratio).

Danger!
group 3. Regularly check the wheel lugs 107 for the correct tightening torque, (see Tab. 1 on page2).
schedule.
The testing of the drum brake is an integral part of the maintenance; for detailed instructions, see also
chapter "Brakes" in group 15.10.

5.1

Danger!
rigid axle.
copyright by
MJF C I F S S
12.37.3
Service Manual

5.2

Note!
axles with drum brakes".
5.3

Install the rigid axle 2 in the undercarriage 9, using lifting gear and secure it with the hex head
Fig. 2
12.37.4
1
2
Vehicle wheels
Rigid axle
6
7
Steering axle
Hex nut
3
4
Hex nut
Hex head screw
8
9
Hex head screw

Undercarriage
copyright by
MJF C I F S S
Service Manual


Fig. 3

17150 Fit bolt

17240 Screw plug
17050 Washer (S = 0.10 - 2.0 mm)

17250 Screw plug

17260 O-ring

17120 O-ring
17290 Stub shaft

17690 Sleeve
17700 Snap ring
17140 Washer
copyright by
MJF C I F S S
12.37.5
Service Manual
Fig. 4
12.37.6
Hub carrier, group 22 and drum brake, group 2 (1 = old) and (400 = new)
Brake (old)
350
Locking plate
10
50
Brake drum
Adapter
370
400
Tension spring
Brake (new)
60
Brake disc
410
Adapter
70
Pin
420
Wheel cylinder
80
Disc springs
430
Allen head screw
90
Washer
440
Washer
100
Hex nut
510
Hub carrier
120
170
Countersunk screw
Wheel cylinder
510
570
Slotted nut
Allen head screw
180
Lock washer
580
Allen head screw
190
Hex head screw
590
O-ring
270
Brake pad
610
Retainer plate
340
Pin
copyright by
MJF C I F S S
Service Manual

Fig. 5
Hub carrier and output of the wheel bearings or the planetary gear, group 19
10
30

Roller bearing
410
420
Roller bearing
Junk ring
40
Ring (S = 3.4 - 5.0 mm)
430
Snap ring
50
80
Roller bearing
Hub
480
490

O-ring
90
160
O-ring
Hollow gear
500
510
Screw plug
Allen head screw
184
190
Locking plate
Self-locking screw
540
550
Wheel stud
Lock washer
340
Sun gear shaft
560
Centring ring
390
400
Planetary carrier
Planetary gear
570
Wheel lug
copyright by
MJF C I F S S
12.37.7
Service Manual
Item
ZP figure
no.
Designation
Item
Group 17
1
ZP figure
no.
Designation
Group 19
17010
Axle housing part I
60
10
17030
61
30
Roller bearing
17290
Stub shaft
62
80
Hub
17690
Sleeve
63
90
O-ring
17700
Snap ring
64
50
Roller bearing
68
160
Hollow gear
Group 2
10
Brake
71
40
Ring
11
10
Brake drum
86
184
Locking plate
12
40
Brake disc
87
190
Self locking screw
17
170
Wheel cylinder
91
340
Sun gear shaft
18
180
Lock washer
94
390
Planetary carrier
19
190
Hex head screw
95
400
Planetary gear
20
270
Brake pad
96
410
Roller bearing
21
340
Pin
97
420
Junk ring
22
350
Locking plate
98
430
Snap ring
23
370
Tension spring
99
480
Thrust washer
101
490
O-ring
27
570 / 2 430
Allen head screw
102
500
Screw plug
28
580 / 2 430
Allen head screw
103
510
Allen head screw
30
10
Hub carrier
104
540
Wheel stud
31
10
Slotted nut
105
550
Lock washer
33
110
Retainer plate
106
560
Centring ring
37
90
O-ring
107
570
Wheel lug
Group 22
Note!
Observe the setting values and tightening torques A, B, D, E, F, G, H, I, K , see Fig. 6 and (see Tab.
1 on page 2).
12.37.8
copyright by
MJF C I F S S
Service Manual

Fig. 6
copyright by
MJF C I F S S
12.37.9
Service Manual
12.37.10
copyright by
MJF C I F S S
Service Manual

Function

1 Function
axle shaft gears.
Fig. 1
Differential of steering and rigid axle
copyright by
MJF C I F S S
12.39.1
Service Manual
Technical data
2 Technical data
Machine
Machine model
Serial number
A 316 Litronic
715 / 716
2001
Axle type
BK
Gear ratio
3,18

the pinion 20.1)
0.15 - 0.2 mm
0.18 - 0.23 mm (speeder)
1 - 4 Nm
1 - 2 Nm
550 Nm
390 Nm
145 Nm

Tab. 1
Technical data
Note!
"AP / APL - B 755 ZP axles".
12.39.2
copyright by
MJF C I F S S
Service Manual

Fig. 2
10
Input (assembly 16)

210
Input flange
50

pinion)
Washer (S = 0.7 - 1.5 mm)
220
Valance
80
110

Ring (S = 10.97 - 11.36 mm)
270
290
Washer (S = 10.94 - 12.38 mm)

Hex nut
160
310
Locking plate
190
copyright by
MJF C I F S S
12.39.3
Service Manual
Fig. 3
12.39.4
10
Crown wheel
720
Differential spider
570
640
Differential cage
Axle shaft gear
800
850
Allen head screw

Washer
650
670
Thrust washer
860
870

Roll pin S
680
Thrust washer
copyright by
MJF C I F S S
Service Manual

Fig. 4
.10
Axle housing I
.240
Screw plug
.30
Axle housing II
.250
Screw plug
.40
.50
Bearing bushing
Washer (S = 0.1 - 2.0 mm)
.260
.290
Seal
Stub shaft
.90
Roller bearing
.330
O-ring
.100
Roller bearing
.340
Bearing bushing
.120
.130
O-ring
Hex head screw
.350
.690
Seal ring
Bearing bushing
.140
Washer
.700
Seal ring
.150
Fit bolt
copyright by
MJF C I F S S
12.39.5
Service Manual

Item
ZP figure
no.
Designation
Item
ZP figure
no.
1.1
17010
Axle housing I
16
16170
1.2
17030
Axle housing II
17
16110
Bushing
2.1
17050
Washer
18
16050
Adjusting disc
2.2
17050
Washer
19
16070
17090
20.1
16010
Bevel pinion
17100
20.2
16010
Crown wheel
17120
O-ring
21
73850
Washer
17130
Hex head screw
22
73800
Allen head screw
17150
Fit bolt
23.1
73570
Differential cage I
17140
Washer
23.2
73570
17290
Stub shaft
24
73650
Thrust washer
10
16310
Locking plate
25
73640
Axle shaft gear
11
16290
Hex nut
26
73720
Balancing axle
12
16270
Washer
27
73680
Thrust washer
13
16210
Input flange
28
73670
Balancing gear
14
16220
Valance
29
73870
Roll pin "S"
15
16190
30
73860
Heavy-duty roll pin

"Connex"
Designation
Note!
12.39.6
copyright by
MJF C I F S S
Service Manual

Fig. 5
copyright by
MJF C I F S S
12.39.7
Service Manual
12.39.8
copyright by
MJF C I F S S
Service Manual
APL - B 755 HD steering axle with multi-disc brake

Function

1 Function
Fig. 1
copyright by
MJF C I F S S
12.41.1

Function
12.41.2
copyright by
MJF C I F S S
Service Manual
Service Manual

Technical data
2 Technical data
Machine
Machine model
Serial number
A 316 Litronic Industry

716
2001
Axle type
APL-B 755 HD
Design
Gear ratio
Standard
Speeder
17.72
-
Brake
Oil volume in axle

Axle housing
Planetary drive
9.0 l
2.0 l per side

A
End play of the double joint shaft 20 with sun gear shaft
91

new
at max. wear
2.4 - 2.8 mm
4.5 mm
40 - 50 Nm
Rolling resistance of the wheel bearing 61 (new)

(without sealing elements)
10 - 15 Nm
410 Nm
11 Nm
0.4 - 0.6 mm
1200 - 1400 Nm
120 Nm
86 Nm
570 Nm

see steering cylinder, group 16.34
L
Multi-disc brakes:
Low pressure test
340 - 360 Nm
120 bar
3 bar
1 - 5 bar
Items A - L ((see Fig. 7 on page12))

Tab. 1
2.0.1
Technical data
Tyre pressure
copyright by
MJF C I F S S
12.41.3
Service Manual
3.1
Power flow in the steering axle, (see Fig. 7 on page12)

Danger!

carrier.
12.41.4
copyright by
MJF C I F S S
Service Manual

Note!
Fig. 2

5.1

Danger!
Remove the hex head screws 6 and the plate 7 (new bearing).
copyright by
MJF C I F S S
12.41.5
Service Manual
5.2

Note!
ZP axles".
5.3
Installation of the steering axle after repair work

Insert the steering axle 4 in the undercarriage 5, using suitable lifting tackle. Insert the washers 9
and drive in the pin 8.
Secure the pin 8 with the washer 13 and the screws 6 (old), or with the plate 7 and the screws 6
with retaining washers 14 (new).
13.20).
Fig. 3
12.41.6
Vehicle wheels
Pin
Hex head screw
Spacer
Joint shaft
10
Lubrication nipple
Steering axle
11
Lock nut
Undercarriage
12
Rigid axle
copyright by
MJF C I F S S
Service Manual

6
7
13
14
Hex head screw

Plate
Washer
Retaining washer
Fig. 4
.10
Axle housing part I
.260
O-ring
.30
.40

Bearing bushing
.290
.330
Stub shaft
Snap ring
.50
Washer (S = 0.15 - 2.0 mm)
.340
Bushing
.90
Roller bearing
.350
.100
Roller bearing
.600
Axial joint
.120
.130
O-ring
Hex head screw
.605
.610
Bellows
Right tie rod, complete
.140
Washer
.611
Left tie rod, complete
.150
.240
Fit bolt
Screw plug
.620
.630
Clamp
Slotted nut
.250
Screw plug
.640
Cotter pin
copyright by
MJF C I F S S
12.41.7
Service Manual
Fig. 5
.30
12.41.8
.10
Left joint housing, with slotted nut
.130
Lubrication nipple
.20
.30
Right joint housing, with slotted nut

Plug
.150
.160
Bushing
.50
Roller bearing
.170
Universal joint
.80
Sealing cap
.390
Bleeder valve
.90
O-ring
.480
Washer (S = 1.9 - 3.0 mm)
.100
.114
Washer (S = 0.6 - 2.0 mm)

Bearing pin
.490
.500
Pipe
Stop screw
.120
Hex head screw
.510
Separate slotted nut
copyright by
MJF C I F S S
Service Manual

Fig. 6
.10
.290
End washer
.30
.40
Roller bearing
Ring (S = 26.0 - 27.0 mm)
.300
.310
Snap ring
Locking plate
.80
.90
Hub
O-ring
.320
.326
Thrust washer
Allen head screw
.100
.120
Hollow gear carrier

Plug
.340
.344
Sun gear shaft

O-ring
.130
O-ring
.350
Disc carrier
.144
Backing ring
.380
Snap ring
.154
Backing ring
.390
Planetary carrier
.200
.210
Piston
Lip seal
.392
.400

Planetary gear
.214
Backing ring
.410
Roller bearing
.230
Backing ring
.412
Washer
.232
Back-up washer
.420
Junk ring
.236
.238
Spring sleeve
Pressure spring
.430
.480
Snap ring
Thrust washer (1.5 - 3.0 mm)
.244
Circlip
.500
copyright by
MJF C I F S S
12.41.9
Service Manual

.246
.248
Hex head screw

Lock nut
.510
.540
Allen head screw

Wheel stud
.256
.270
Hex head screw

.550
.560
Lock washer
Centring ring
.280
Inner disc
.570
Wheel lug
Item
ZP figure
no.
Designation
Item
ZP figure
no.
Designation
17010
Axle housing
76
19230
Backing ring
17290
Stub shaft
77
19232
Back-up washer
17330
Snap ring
78
19258
Spring sleeve
17340
Bushing
79
19240
Pressure spring
17350
80
19244
Circlip
10
18160
81
19246
Hex head screw
11
18150
Bushing
82
19248
Lock nut
20
18170
Double joint drive

shaft
83
19270
Outer disc
31
18010
Right joint housing
84
19280
Inner disc
18020
Left joint housing
85
19290
End washer
32
12.41.10
18010
Slotted nut
86
19150
Snap ring
18510
87
19320
Thrust washer
35
18050
Roller bearing
88
19326
Allen head screw
37
18080
Sealing cap
89
19330
Shim
38
18090
O-ring
90
19336
Snap ring
39
18100
Washer
91
19340
Sun gear shaft
40
18114
Bearing pin
92
19350
Disc carrier
41
18120
Hex head screw
93
19380
Snap ring
42
18130
Lubrication nipple
94
19390
Planetary carrier
45
18390
Bleeder valve
95
19400
Planetary gear
60
19010
96
19410
Roller bearing
61
19030
Roller bearing
97
19412
Circlip
62
19080
Hub
98
19420
Snap ring
63
19090
O-ring
99
19430
Thrust washer
65
19130
O-ring
100
19480
Thrust washer
66
19144
Backing ring
101
19392
Screw plug
67
19154
Backing ring
102
19500
Screw plug
68
19100
Hollow gear carrier
103
19510
Allen head screw
71
19040
Bushing
104
19540
Wheel stud
72
19200
Piston
105
19550
Lock washer
73
19210
Lip seal
106
19560
Centring ring
74
19214
Backing ring
107
19570
Wheel lug
copyright by
MJF C I F S S
Service Manual

Note!
copyright by
MJF C I F S S
12.41.11

Fig. 7
12.41.12
copyright by
MJF C I F S S
Service Manual
Service Manual

Function

1 Function
The wheel hub contains the planetary output drive as well as the hydraulically operated multi-disc
brake. It is applied when the brake pedal (working brake) is operated and the brake is pressurised
with brake oil.
Fig. 1
copyright by
MJF C I F S S
12.42.1
Service Manual
Technical data
2 Technical data
Machine
Machine model
Serial number
A 316 Li:
716
2001
Axle type
AP-B 755 HD
Design
Gear ratio
Standard
Speeder
17.72
-
Brake
Multi-disc brake
Oil volume in axle

Axle housing
Planetary drive
10.0 l
2.0 l per side

A

new
at max. wear
Rolling resistance of the wheel bearing 61 (new)

(without sealing elements)
0.4 - 2.0 mm
2.4 - 2.8 mm
4.5 mm
10 - 15 Nm
Tightening torque for the nuts 3
Tightening torque for the slotted nut 32
280 Nm
Tightening torque for the lock nuts 82
11 Nm
86 Nm
Tightening torque for the wheel lugs 107
570 Nm

Low pressure test
120 bar
3 bar
5 bar
560 Nm
1200 - 1400 Nm
Items A, B, C, E, K (see Fig. 7 on page11) and item D (see Fig. 3 on page5)

Tab. 1
2.1
Technical data
Tyre pressure
12.42.2
copyright by
MJF C I F S S
Service Manual

3.1
Power transfer in the rigid axle, see Fig. 7

The sun gear shaft 91, which is connected through the disc carrier 92 to the stub shaft 7, drives the
planetary gears 95. These roll off on the stationary hollow gear 68. This results in a great speed reduction and associated power transmission to the rotating planetary carrier 94. The planetary carrier
drives the vehicle wheels through the wheel studs 104 with the respective force and speed (based
on the overall gear ratio).

Danger!

carrier.
copyright by
MJF C I F S S
12.42.3
Service Manual

Note!
Fig. 2

5.1

Danger!
issued by the German Ground Construction Trade Association (Tiefbau-Berufsgenossenschaft).
rigid axle.
12.42.4
copyright by
MJF C I F S S
Service Manual

5.2

Note!
axles with multi-disc brakes".
5.3

Install the rigid axle 2 in the undercarriage 9, using lifting gear and secure with the hex head
Fig. 3
Vehicle wheels
Steering axle
Rigid axle
Hex nut
Hex nut
Hex head screw
4
5
Hex head screw

Undercarriage
copyright by
MJF C I F S S
12.42.5
Service Manual
Fig. 4
12.42.6
17150 Fit bolt

17050 Washer (S = 0.15 - 2.0 mm)
17240 Screw plug

17250 Screw plug
17260 O-ring
17290 Stub shaft
17120 O-ring
17690 Sleeve

17140 Washer
17700 Snap ring
copyright by
MJF C I F S S
Service Manual

Fig. 5
Hub carrier
10
Hub carrier complete with slotted nut
110
Retainer plate
70
90
Allen head screw

O-ring
160
330
Bleeder valve
copyright by
MJF C I F S S
12.42.7
Service Manual
Fig. 6
12.42.8
Output of planetary gear group 19
.10
.300
Snap ring
.30
.40
Roller bearing
Ring (S = 26.0 - 27.0 mm)
.310
.320
Locking plate
Thrust washer
.80
.90
Hub
O-ring
.340
.344
Sun gear shaft

O-ring
.100
Hollow gear carrier
.350
Disc carrier
.120
Plug
.380
Snap ring
.130
O-ring
.390
Planetary carrier
.144
.154
Backing ring
Backing ring
.392
.400

Planetary gear
.200
.210
Piston
Lip seal
.410
.412
Roller bearing
Washer
.214
Backing ring
.420
Junk ring
.230
Backing ring
.430
Snap ring
.232
Back-up washer
.480
.238
Pressure spring
.500
.244
Circlip
.510
Allen head screw
copyright by
MJF C I F S S
Service Manual

.248
.256
Lock nut
Hex head screw
.540
.550
Wheel stud
Lock washer
.270
.280

Inner disc
.560
.570
Centring ring
Wheel lug
.290
End washer
copyright by
MJF C I F S S
12.42.9
Service Manual

Item
ZP figure
no.
17010
17030
17290
Designation
Item
ZP figure
no.
Designation
Axle housing part I
80
19244
Circlip
81
19246
Hex head screw
Stub shaft
82
19248
Lock nut
17330
Snap ring
83
19270
Outer disc
17340
Bushing
84
19280
Inner disc
17350
85
19290
End washer
30
22010
Hub carrier
86
19150
Snap ring
22330
87
19320
Thrust washer
33
22070
Allen head screw
88
19326
Allen head screw
34
22110
Retainer plate
89
19330
Shim
36
22160
Bleeder valve
90
19336
Snap ring
37
19090
O-ring
91
19340
Sun gear shaft
60
19010
92
19350
Disc carrier
61
19030
Roller bearing
93
19380
Snap ring
62
19080
Hub
94
19390
Planetary carrier
63
19090
O-ring
95
19400
Planetary gear
65
19130
O-ring
96
19410
Roller bearing
66
19144
Backing ring
97
19412
Circlip
67
19154
Backing ring
98
19420
Snap ring
68
19160
Hollow gear carrier
99
19430
Thrust washer
71
19040
Bushing
100
19480
Thrust washer
72
19200
Piston
101
19392
Screw plug
73
19210
Lip seal
102
19500
Screw plug
74
19214
Backing ring
103
19510
Allen head screw
76
19230
Backing ring
104
19540
Wheel stud
77
19232
Back-up washer
105
19550
Lock washer
78
19258
Spring sleeve
106
19560
Centring ring
79
19240
Pressure spring
107
19570
Wheel lug
Note!
Observe the setting values and tightening torques A, B, D, E, F, G, H, I, K , see Fig. 7 and (see Tab.
1 on page 2).
12.42.10
copyright by
MJF C I F S S
Service Manual

Fig. 7
copyright by
MJF C I F S S
12.42.11
Service Manual
12.42.12
copyright by
MJF C I F S S
Service Manual

Function

1 Function
axle shaft gears.
Fig. 1
Differential
copyright by
MJF C I F S S
12.44.1
Service Manual
Technical data
2 Technical data
Machine
Machine model
Serial number
A 316 Litronic
716
2001
Axle type
BK
Gear ratio
3.18

the pinion 20.1)
0.15 - 0.2 mm
0.18 - 0.23 mm (Speeder)
1 - 4 Nm
1 - 2 Nm
550 Nm
390 Nm
145 Nm

Tab. 1
Technical data
Note!
"AP / APL - B 755 HD ZP axles".
12.44.2
copyright by
MJF C I F S S
Service Manual

Fig. 2
10
Input (assembly 16)

210
Input flange
50

pinion)
Washer (S = 0.7 - 1.5 mm)
220
Valance
80
110
Roller bearing
Ring (S = 10.94 - 12.38 mm)
270
290
Washer
Hex head screw
160
Roller bearing
310
Locking plate
190
copyright by
MJF C I F S S
12.44.3
Service Manual
Fig. 3
12.44.4
10
Crown wheel
720
Differential spider
570
640
Differential cage
Axle shaft gear
800
850
Allen head screw

Washer
650
670
Thrust washer
860
870

Roll pin S
680
Thrust washer
copyright by
MJF C I F S S
Service Manual

Fig. 4
.10
Axle housing I
.240
Screw plug
.30
Axle housing II
.250
Screw plug
.40
.50
Bearing bushing
Washer (S = 0.1 - 2.0 mm)
.260
.260
Seal
Stub shaft
.90
Roller bearing
.330
O-ring
.100
Roller bearing
.340
Bearing bushing
.120
O-ring
.350
Seal ring
.130
.140
Hex head screw

Washer
.690
.700
Bearing bushing
Seal ring
.150
Fit bolt
copyright by
MJF C I F S S
12.44.5
Service Manual

Item
ZP figure
no.
Designation
Item
ZP figure
no.
1.1
17010
Axle housing I
16
16170
1.2
17030
Axle housing II
17
16110
Bushing
2.1
17050
Washer
18
16050
Adjusting disc
2.2
17050
Washer
19
16070
17090
20.1
16010
Bevel pinion
17100
20.2
16010
Crown wheel
17120
O-ring
21
73850
Washer
17130
Hex head screw
22
73800
Allen head screw
17150
Fit bolt
23.1
73570
Differential cage I
17140
Washer
23.2
73570
Designation
17290
Stub shaft
24
73650
Thrust washer
10
16310
Locking plate
25
73640
Axle shaft gear
11
16290
Hex nut
26
73720
Balancing axle
12
16270
Washer
27
73680
Thrust washer
13
16210
Input flange
28
73670
Balancing gear
14
16220
Valance
29
73870
Roll pin "S"
15
16190
30
73860
Heavy-duty roll pin

"Connex"
Note!
12.44.6
copyright by
MJF C I F S S
Service Manual

Fig. 5
copyright by
MJF C I F S S
12.44.7
Service Manual
12.44.8
copyright by
MJF C I F S S
Service Manual

Function

1 Function
wheels, is equipped with a built-in drive / differential.
gear ratio in the differential, the drive unit is very compact, providing for great ground clearance.
The brake is applied when the brake pedal (working brake) is operated and the brake is pressurised
with brake oil.
The steering cylinder (synchronised speed cylinder) built into the axle drive housing of the steering
axle moves the wheels through the joint housings (steering knuckles) between the two stop positions.
For a detailed description of the steering cylinder, see group 13.34.
Fig. 1
copyright by
MJF C I F S S
12.46.1
Service Manual
Function
12.46.2
copyright by
MJF C I F S S
Service Manual

Technical data
2 Technical data
Machine
Machine model
Serial number
A 316 Li
715 / 716
28061 / 28062
Axle type
MS-E 3060
Design
Gear ratio
16,00
Brake
Oil volume in axle

Axle housing
Planetary drive
9.5 l
2.5 l per side

A*
Axial play of double joint drive shaft 35
0.3 - 0.6 mm
B*

new
at max. wear
1.2 - 1.8 mm
6.0 mm
C*
Rolling resistance of joint housing bearing 68
40 - 50 Nm
D*
Rolling resistance of wheel bearing 99
8 - 12 Nm
E*
Tightening torque of slotted nut 54
F*
280 Nm
G*
11 Nm
H*
55 Nm
I*
Tightening torque of wheel lugs 108
460 Nm
K*

Max. pressure drop after 5 minutes
Low pressure test
Visible pressure drop after 5 minutes is not permissible
100 bar
3 bar
5 bar

see steering
1400 + 200 Nm
100 Nm
* Items A - K, see Fig. 10

Tab. 1
Technical data
Tyre pressure
copyright by
MJF C I F S S
12.46.3
Service Manual
Description
3 Description
The steering axle screw-mounted to the undercarriage consists of the following main components:
Drive unit 1, differential 2 in axle drive housing
Axle housing 3
Joint housing 4 with axle drive housing
Output 5
Steering 6
Fig. 2
12.46.4
Design of steering axle
1
2
Input
Differential
6
7
Steering
Oil discharge / oil filling opening / planetary
drive
3
4
Axle housing with axle drive housing

Joint housing
8
9
Oil filling control bore / axle housing

Oil discharge / axle housing
Output
copyright by
MJF C I F S S
Service Manual

Description
3.1
Design of drive unit 1 and differential 2
Fig. 3
Design of drive unit/differential
10
Crown wheel
20
Allen head screw
11
Pinion
21
Washer
12
Roller bearing
22
Differential cage
13
Disc (S=0.70-1.50mm)
23
Thrust washer
14
15
Roller bearing
Ring (S=10.94-12.38mm)
24
25
Axle shaft gear

16
26
Thrust washer
17
Protective plate
27
Balancing axle
18
Input flange
28
Heavy-duty roll pin
19
Hex nut with washer
29
Roll pin
Note!
copyright by
MJF C I F S S
12.46.5
Service Manual
Description
3.2
Layout of the axle housing 3
Fig. 4
12.46.6
Design of axle housing
30
31
Axle housing
Axle drive housing
42
43
Hex nut
Axial joint
32
Clamping bush
44
Slotted nut
33
34
Bushing
45
46
Tie rod (right)

Ball joint
35
36
Double joint drive shaft (complete)

Yoke
47
48
Hex nut
Axial joint
37
38
Joint yoke
Double yoke
49
110
Hex head screw

O-ring
39
Joint yoke (sun gear shaft)
111
Washers
40
41
Tie rod (left)

Ball joint
112
Roller bearing
copyright by
MJF C I F S S
Service Manual

Description
3.3
Design of the joint housing 4
Fig. 5
Design of joint housing
30
Axle housing
59
Lubrication nipple
39
50
Joint yoke (sun gear shaft)

Joint housing (complete)
60
61
Hex head screw

Washer (S=0.60-2.00mm)
51
Snap ring
62
Bearing pin
52
53
Thrust washer
Thrust washer
63
64
Lubrication nipple
Plug
54
Slotted nut
65
Bleeder
55
O-ring
66
Bushing
56
57
Sealing cap
O-ring
67
68

Roller bearing
58
Bearing pin
69
Hex head screw
copyright by
MJF C I F S S
12.46.7
Service Manual
Description
3.4
Design of output unit 5
Fig. 6
12.46.8
Design of the output unit
50
Joint housing
88
Backing ring
70
71
Planetary carrier
Screw plug
89
90
Piston
Pressure spring
72
O-ring
91
Pressure spring
74
75
Allen head screw

Circlip
92
93
Spring sleeve
Hex head screw
76
Planetary gear
94
Disc carrier
77
Washer
95
O-ring
78
80
Roller bearing
Snap ring
96
97
Inner disc
Outer disc
81
Thrust washer (S = -1.50-3.00mm)
98
O-ring
82
83
O-ring
Hollow gear
99
100
Roller bearing
Spacer bushing
84
Cylinder pin
101
Hub
85
Backing ring
103
86
Lip seal
104
Allen head screw
87
Lip seal
105
Wheel stud
copyright by
MJF C I F S S
Service Manual

4.1
Power flow in the steering axle, see Fig. 10

drive system. A bevel pinion and crown wheel transfer the torque via the differential case/differential
to the differential spider with balancing and axle shaft gears, which is borne in the cage.
The sun gear 39 drives the planetary gears 76. These roll off on the stationary hollow gear 83. This
leads to a high speed reduction and thus a high torque transmission to the planetary carrier 70. The
planetary carrier 70, via the wheel studs 105, drives the vehicle wheels with the resulting torque and
speed (resulting from the overall gear ratio).
copyright by
MJF C I F S S
12.46.9
Service Manual

Danger!
For maintenance work on the axles, the undercarriage of the machine must be accessed, which poses a great danger for mechanics.
manual. Regularly check the wheel lugs 108 for the correct tightening torque, (see Tab. 1, page 3).
The manufacturer also prescribes an annual inspection of the disc lining for wear, (see Fig. 8, page
11).
Fig. 7
Wear assessment

Caution!
Escaping oil, due to a pressure build-up in the drive unit, can drive out the plug screw, causing injury.
Slowly screw out the screw plug to 12 o'clock position.
Turn the output (wheel hub) until the screw plug 71 is in its top position (12 o'clock).
12.46.10
copyright by
MJF C I F S S
Service Manual

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
3
Measuring bore ( 10 mm)

Dial gauge with magnetic stand
83
89
70
71
Planetary carrier
Screw plug
Oil filling / oil discharge bore
96/97 Disc pack

X
Piston travel
copyright by
MJF C I F S S
Hollow gear
Piston
12.46.11
Service Manual

6.1

Danger!
Lift the undercarriage 5 and secure the steering axle 4 with suitable lifting tackle.
Remove the hex head screws 6 and remove the plate 7. Drive out the bolt 8 and lower the steering
axle 4.
6.2

Note!
For detailed repair instructions for the axle, refer to the separate Repair manual for ZF axles MSE 3050/3060/3070.
6.3

Install the steering axle 4 in the undercarriage, using lifting gear, and drive in the pin 8.
Secure pin 8 with the plate 7 and the screws 6.
Secure the universal joint shaft 3 with the screws 2 to the output flange / output of the steering
axle 4.
13.20).
12.46.12
copyright by
MJF C I F S S
Service Manual

Fig. 9
1
2
Vehicle wheels
Hex head screw
6
7
Hex head screw

Plate
Joint shaft
Pin
Steering axle
10
Lubrication nipple
Undercarriage
11
Lock nut
copyright by
MJF C I F S S
12.46.13
Service Manual

30
36
Axle housing
Yoke
78
82
Roller bearing
O-ring
37
38
Joint yoke
Double yoke
83
85
Hollow gear
Backing ring
39
Joint shaft (sun gear shaft)
86
Lip seal
50
51
Joint housing
Snap ring
87
88
Lip seal
Backing ring
52
Thrust washer
89
Piston
53
Thrust washer
90
Pressure spring
54
Slotted nut
91
Pressure spring
56
Sealing cap
92
Spring sleeve
57
O-ring
93
Hex head screw
58
59
Bearing pin
Lubrication nipple
94
95
Disc carrier
O-ring
60
61
Hex head screw

Washer (S=0.60-2.00mm)
96
97
Inner disc
Outer disc
62
63
Bearing pin
Lubrication nipple
99
100
Roller bearing
Spacer bushing
65
Bleeder
101
Hub
66
67
Bushing
103
104

Allen head screw
68
70
Roller bearing
Planetary carrier
105
106
Wheel stud
Lock washer
74
75
Allen head screw

Circlip
107
108
Centring ring
Wheel lug
76
Planetary gear
Note!
12.46.14
copyright by
MJF C I F S S
Service Manual

Fig. 10
copyright by
MJF C I F S S
12.46.15
Service Manual
12.46.16
copyright by
MJF C I F S S
Service Manual

Function

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
copyright by
MJF C I F S S
12.47.1
Service Manual
Function
12.47.2
copyright by
MJF C I F S S
Service Manual

Technical data
2 Technical data
Machine
Machine model
Serial number
A 316 Li
715 / 716
28061 / 28062
Axle type
MT-E 3060
Design
Gear ratio
Standard
Brake
16,00
Oil volume in axle (filling level at the check

screws is binding)
Axle housing
Planetary drive
Oil quality
12.5 l
2.5 l per side

A*
End play of the stub shaft 36
B*
Clearance of the disc pack 96/97(piston

stroke)
0.4 - 0.6 mm
new
at max. wear
0.7 - 1.3 mm
6.0 mm at 6 discs
6.5 mm at 7 discs
C*
Rolling resistance of the wheel hub 99
D*
E*
280 Nm
F*
8 Nm
G*
55 Nm
H*
460 Nm
I*

Max. pressure drop after 5 minutes
Low pressure test
Visible pressure drop after 5 minutes is not permissible
100 bar
3 bar
5 bar
8 - 12 Nm
1400 +600 Nm
* Items A - H (see Fig. 10)

Tab. 1
Technical data
Tyre pressure
copyright by
MJF C I F S S
12.47.3
Service Manual
Description
3 Description
The rigid axle screw-mounted to the undercarriage consists of the following main components:
Drive unit 1, differential 2 in axle drive housing
Axle housing 3
Hub carrier 4
Drive unit 5
Fig. 2
12.47.4
Design of rigid axle
Input
Output
Differential
Oil discharge / oil filling opening / planetary

drive
Axle housing with axle drive housing
Oil filling control bore / axle housing
Hub carrier
Oil discharge / axle housing
copyright by
MJF C I F S S
Service Manual

Description
3.1
Design of drive unit 1 and differential 2
Fig. 3
Design of the drive unit
10
11
Crown wheel
Pinion
20
21
Allen head screw

Washer
12
13
Roller bearing
Disc (S=0.70-1.50mm)
22
23
Differential cage
Thrust washer
14
15
Roller bearing
Ring (S=10.94-12.38mm)
24
25
Axle shaft gear

16
26
Thrust washer
17
18
Protective plate
Input flange
27
28
Balancing axle
Heavy-duty roll pin
19
Hex nut with washer
29
Roll pin
Note!
copyright by
MJF C I F S S
12.47.5
Service Manual
Description
3.2
Layout of the axle housing 3
Fig. 4
12.47.6
Design of axle housing
30
Axle housing
34
Washer (S = 0.10 - 2.0mm)
31
Axle drive housing
35
O-ring
32
33
Hex head screw

Roller bearing
36
37
Stub shaft
Washer
copyright by
MJF C I F S S
Service Manual

Description
3.3
Design of hub carrier 4
Fig. 5
Design of hub carrier
30
50
Axle housing
Hub carrier
54
55
Slotted nut
O-ring
51
Sun gear shaft
56
Washer
52
53
Bleeder
Plug
57
Hex head screw
copyright by
MJF C I F S S
12.47.7
Service Manual
Description
3.4
Design of output unit 5
Fig. 6
12.47.8
Design of the output unit
50
Joint housing
88
Backing ring
70
71
Planetary carrier
Screw plug
89
90
Piston
Pressure spring
72
O-ring
91
Pressure spring
74
75
Allen head screw

Circlip
92
93
Spring sleeve
Hex head screw
76
Planetary gear
94
Disc carrier
77
Washer
95
O-ring
78
80
Roller bearing
Snap ring
96
97
Inner disc
Outer disc
81
Thrust washer (S = -1.50-3.00mm)
98
O-ring
82
83
O-ring
Hollow gear
99
100
Roller bearing
Spacer bushing
84
Cylinder pin
101
Hub
85
Backing ring
103
86
Lip seal
104
Allen head screw
87
Backing ring
105
Wheel stud
copyright by
MJF C I F S S
Service Manual

4.1
Power flow in the rigid axle, see Fig. 10

drive system. A bevel pinion and crown wheel transfer the torque via the differential case to the differential spider with balancing and axle shaft gears, which is borne in the cage.
The sun gear 51 drives the planetary gears 76. These roll off on the stationary hollow gear 83. This
leads to a high speed reduction and thus a high torque transmission to the planetary carrier 70. The
planetary carrier 70, via the wheel studs 105, drives the vehicle wheels with the resulting torque and
speed (resulting from the overall gear ratio).
copyright by
MJF C I F S S
12.47.9
Service Manual

Danger!
manual. Regularly check the wheel lugs 108 for the correct tightening torque, (see Tab. 1, page 3).
schedule.
The manufacturer also prescribes an annual inspection of the disc lining for wear, (see Fig. 8, page
11).
Fig. 7
Wear assessment

Caution!
Escaping oil, due to a pressure build-up in the drive unit, can drive out the plug screw, causing injury.
Slowly screw out the screw plug to 12 o'clock position.
Turn the output (wheel hub) until the screw plug 71 is in its top position (12 o'clock).
12.47.10
copyright by
MJF C I F S S
Service Manual

Carefully loosen the screw plug 71 and remove it.
The internal measuring bore 2 becomes visible.
Turn the output unit until the measuring bore 2 is in the 9 o'clock position.
Attach the dial gauge with magnetic stand and extension to the output unit, see Fig. 8.
Insert the dial gauge 3 through the oil discharge bore and the measuring bore 2 and position it at
the piston 89.
If the brake is not applied, the piston is pushed by the return spring force onto the hollow gear.
Apply pressure to the brakes and measure the piston travel X with the dial gauge. Write down the
measured value.
Mount a new O-ring on the screw plug 1 and insert it.
.
Note!
Piston travel with new discs = 0.7 1.3 mm.
Limit value for piston travel with wear at 6 discs = 6.0 mm.
Limit value for piston travel with wear at 7 discs = 6.5 mm.
Fig. 8
Wear measurement at the disc pack
Measuring bore ( 10 mm)
83
3
70
Dial gauge with magnetic stand

Planetary carrier
89
Piston
96/97 Disc pack
71
Screw plug
Oil filling/ oil discharge bore
copyright by
MJF C I F S S
Hollow gear
Piston travel
12.47.11
Service Manual

6.1

Danger!
Lift the undercarriage 5 at the rear and secure the wheels of the steering axle using chocks.
If required, remove the vehicle wheels 1 from the rigid axle .
Loosen the hex nuts 9 and remove the hex head screws 7. Lift the rigid axle 8 from the undercarriage 5.
6.2

Note!
For detailed repair instructions for the axle, refer to the separate "Repair manual for ZF axles MTE 3050/3060/3070".
6.3
Installation of the rigid axle after repair work

Screw in the hex head screw 7 and tighten it with the prescribed torque.
Secure the universal joint shaft 3 with the screws 2 to the output flange / drive of the rigid axle 8.
12.47.12
copyright by
MJF C I F S S
Service Manual

Fig. 9
Vehicle wheels
Undercarriage
2
3
Hex head screw

Joint shaft
6
7
Washer
Hex head screw
Lock nut
Rigid axle
copyright by
MJF C I F S S
12.47.13
Service Manual

6
30
Screw plug
Axle housing
87
88
Lip seal
Backing ring
36
50
Stub shaft
Hub carrier
89
90
Piston
Pressure spring
51
Sun gear shaft
91
Pressure spring
54
55
Slotted nut
O-ring
92
93
Spring sleeve
Hex head screw
56
Sealing cap
94
Disc carrier
57
Hex head screw
95
O-ring
70
Planetary carrier
96
Inner disc
74
Allen head screw
97
Outer disc
75
Circlip
99
Roller bearing
76
77
Planetary gear
Washer
100
101
Spacer bushing
Hub
78
80
Roller bearing
Snap ring
103
104

Allen head screw
82
83
O-ring
Hollow gear
105
106
Wheel stud
Lock washer
85
Backing ring
107
Centring ring
86
Lip seal
108
Wheel lug
Note!
Observe settings and torques A, B, C, D, E, F, G, H, I, see Fig. 10 and Table 1, page 3.
12.47.14
copyright by
MJF C I F S S
Service Manual

Fig. 10
copyright by
MJF C I F S S
12.47.15
Service Manual
12.47.16
copyright by
MJF C I F S S
Service Manual

Function

1 Function
The drive unit and differential are integrated into the axle housing of the steering and rigid axle. They
transmit the output power of the transmission to the planetary drives of the wheel hubs, adjusting the
speed and torque by means of bevel pinions and the crown wheel.
axle shaft gears.
Fig. 1
Differential
copyright by
MJF C I F S S
12.48.1
Service Manual
Function
12.48.2
copyright by
MJF C I F S S
Service Manual

Technical data
2 Technical data
Machine
Machine model
Serial number
A 316 Li
715 / 716
28061 / 28062
Axle type
MT-MS
Gear ratio
3,18
A Setting value of the crown wheel kit 10/11

the pinion 11)
B Tooth backlash of the crown wheel kit 10/11
0.12 - 0.24 mm
1 - 4 Nm
1 - 2 Nm
600 Nm
Tightening torque for the hex head screws 49
390 Nm
145 Nm
Items A - G
Tab. 1
Technical data
copyright by
MJF C I F S S
12.48.3
Service Manual
Description
3 Description
The differential 2 is inserted into the axle drive housing 31. The drive 1 is also integrated into the axle
drive housing. The axle housings 3 with the yoke / stub shaft connecting the output end to the input
end are screwed to the left and right to the axle drive housing with the hex head screws 49.
12.48.4
1
2
Input
Differential
21
22
Washer
Differential cage
Axle housing
23
Thrust washer
10
11
Crown wheel
Pinion
24
25
Axle shaft gear

12
13
Roller bearing
Disc (S=0.70-1.50mm)
26
27
Thrust washer
Balancing axle
14
Roller bearing
28
Heavy-duty roll pin
15
Ring (S=10.94-12.38mm)
29
Roll pin
16
31
Axle drive housing
17
18
Protective plate
Input flange
32
33
O-ring
Washer
19
Hexagon nut with washer
34
Roller bearing
20
Allen head screw
49
Hex head screw
copyright by
MJF C I F S S
Service Manual

Description
3.1
Design of differential
Fig. 2
Design of differential
copyright by
MJF C I F S S
12.48.5
Service Manual
Dismantling, repair and installation of the differential
4 Dismantling, repair and installation of the differential

Danger!
The dismantling and installation of the differential requires access to the undercarriage of the machine. There is a risk of death to the technician, as limbs could become crushed. For the dismantling
and installation see also group 12.46 for the steering axle and group 12.47 for the rigid axle.
4.1
Repair of differential
Note!
"ZF axles MT/MS-E 3050/3060/3070".
10
Crown wheel
23
Thrust washer
11
Pinion
24
Axle shaft gear
12
13
Roller bearing
Disc (S=0.70-1.50mm)
25
26

Thrust washer
14
15
Roller bearing
Ring (S=10.94-12.38mm)
27
28
Balancing axle
Heavy-duty roll pin
16
29
Roll pin
17
18
Protective plate
Output flange
30
31
Axle housing
Axle drive housing
19
20
Hexagon nut with washer

Allen head screw
32
33
O-ring
Washer
21
22
Washer
Differential cage
34
49
Roller bearing
Hex head screws
Note!
Observe settings and torques A, B, C, D, E, F, G, and Table 1, page 3.
12.48.6
copyright by
MJF C I F S S
Service Manual

Fig. 3
copyright by
MJF C I F S S
12.48.7
Service Manual
12.48.8
copyright by
MJF C I F S S
Service Manual

A 309 and A 311 Litronic

1 A 309 and A 311 Litronic
1.1

Type: 717
Size
Tyre
type
Producer
PR
Pressure
[bar]
Spacer
rings
9.00-20
Amor Gard
Nokia
14
7,50
MH 2
9.00-20
8 NB 38
Mitas
14
7,50
MH 3
500/45-20
4 Wide tire
Alliance
6,0
PR
Pressure
[bar]
Spacer
rings
Tab. 1
1.2
Tyres and spacer rings 309

Type: 718
Size
Tyre
type
Producer
9.00-20
Amor Gard
Nokia
14
7,50
MH 2
9.00-20
8 NB 38
Mitas
14
7,50
MH 3
500/45-20
4 Wide tire
Alliance
6,00
Tab. 2
copyright by
MJF C I F S S
12.54.1
Service Manual
A 312 and A 314 Litronic
2 A 312 and A 314 Litronic

2.1

Types: 719
Size
Tyre
type
Producer
PR
Pressure
[bar]
Spacer
rings
10.00-20
8 Titan
Continental
16
9,00
10.00-20
8 E 91-2
Dunlop
16
7,50
MH 3
10.00-20
8 Fast-Grip
Bridgestone
14
7,00
MH 2
10.00-20
8 Amor Gard
Nokia
16
9,00
MH 2
10.00-20
8 NB 38
Mitas
16
7,50
MH 3
18.00-19,5
4XTF
Michelin
7,00
600/40 - 22,5
4 HDI 331
Alliance
6,00
600/40 22,5
4 TR 12
Mitas
6.0
Tab. 3
2.2

Type 635
Size
Tyre
type
Producer
PR
Pressure
[bar]
Spacer
rings
10.00-20
8 E 91-2
Dunlop
16
7,50
MH 2
10.00-20
8 Fast-Grip
Bridgestone
14
7,00
MH 2
10.00-20
8 Amor Gard
Nokia
16
9,00
MH 2
10.00-20
8 NB 38
Mitas
16
7,50
MH 3
10.00-20
8 R 20 XL
Michelin
7,75
18.00-19,5
4XTF
Michelin
16
7,00
600/40 - 22,5
4 HDI 331
Alliance
6,00
600/40 - 22,5
4 TR 12
Mitas
6,00
Tab. 4
12.54.2
copyright by
MJF C I F S S
Service Manual

A 316 Litronic
3 A 316 Litronic
3.1

Type: 715
Size
Tyre
type
Producer
PR
Pressure
[bar]
Spacer
rings
10.00-20
8 Titan
Continental
16
9,00
10.00-20
8 E 91-2
Dunlop
16
7,50
MH 3
10.00-20
8 Fast-Grip
Bridgestone
14
7,00
MH 2
10.00-20
8 Amor Gard
Nokia
16
9,00
MH 2
10.00-20
8 NB 38
Mitas
16
7,50
MH 3
10.00-20
8 Gumasol
Euromaster
MH 4
18.00-19,5
4XTF
Michelin
7,00
600/40 - 22,5
4 HDI 331
Alliance
6,00
600/40 - 22,5
4 TR 12
Mitas
6,00
Size
Tyre
type
Producer
PR
Pressure
[bar]
Spacer
rings
10.00-20
8 NB 38
Mitas
16
7,50
MH 3
10.00-20
8 Gumasol
Euromaster
MH 4
Size
Tyre
type
Producer
PR
Pressure
[bar]
Spacer
rings
10.00-20
8 Titan
Continental
16
7,75
MH4
10.00-20
8 E 91-2
Dunlop
16
7,50
MH 2
10.00-20
8 XL
Michelin
16
7,75
10.00-20
8 NB 38
Mitas
16
7,50
MH 4
Type: 716
Type: 715 / 716 EW
Tab. 5
Tyres and spacer rings 316Broad tire
copyright by
MJF C I F S S
12.54.3
Service Manual
A 316 Litronic
12.54.4
copyright by
MJF C I F S S
Service Manual
Chassis / drive
Design
Chassis / drive
1 Design
The chassis / drive consist of three main components:
The chain 40 with chain link 41 and base plate 45
Tensioning unit 66 with grease tensioner 3, pressure spring 67 and idler 2
Running roller 38
Support roller 39
Chassis drive with travel gear 65 and tumbler wheel 63
Fig. 1
2
Design
45 Base plate
Idler
3 Grease tensioner
38 Running roller
62 Longitudinal member
63 Tumbler wheel
39 Support roller
65 Travel gear
40 Chain
66 Tensioning unit, complete
41 Chain link
67 Spring
copyright by
MJF C I F S S
12.60.1
Chassis / drive
Service Manual
Chain 40
2 Chain 40
2.1
Dismantling, mounting and repairing chain 40

For detailed instructions, see group 12.72.
3 Tensioning unit with idler 2

3.1
Design of tensioning unit and idler 2

See groups 12.75 and 12.78.
3.2
Dismantling and mounting tensioning unit and idler 2

Dismantle the chain 40 (see group 12.72).
Dismantling and mounting tensioning unit (see group 12.75)
Dismantling and installing idler (see group 12.78)
4 Running roller 38
4.1
Design of running roller 38

See group 12.81.
4.2
Dismantling idler 38
Release or remove the chain 40 (see group 12.72).
Remove the screws 54see Fig. 2.
Remove the idler 38 from the longitudinal member 62.
Dismantling and mounting idler (see group 12.81)
4.3
Design of running roller 38

Caution!
the screws, can cause serious damage of components such as longitudinal members, running rollers and chains. Such breaks can also injure persons standing nearby.
For safety reasons, all screws must thus be replaced with new ones when the running rollers are
replaced.
When mounting running rollers, always use new screws.
Mount the running roller 38 on the longitudinal member 62 and tighten the screws 54see Fig. 2.(for
tightening torque, see group 12).
Mount the chain 40 (see group 12.72).
12.60.2
copyright by
MJF C I F S S
Service Manual
Chassis / drive
Support roller 39
5 Support roller 39
5.1
Design of support roller 39

See group 12.84.
5.2
Dismantling of support roller

Release the chain 40 (see group 12.72).
Push the chain 40 upwards by inserting a piece of timber between the upper edge of the longitudinal member and the chain.
Remove the screws 56see Fig. 2.
Remove the support roller 39 from the longitudinal member 62.
Dismantling and installing support roller (see group 12.84)
5.3
Mounting support roller

Place the support roller 39 onto the bearing block of the longitudinal member 62.
Insert the screws 56, see Fig. 2with the retaining washers and tighten them.
Remove the piece of timber.
Tighten the chain (see group 12.72).
6 Chassis drive
6.1
Design and function of travel gear 65

See groups 11.60 / 11.62.
6.2
Dismantling and mounting travel gear 65

See groups 11.60 / 11.62.
7 Maintenance of chassis parts

During operation, the chassis parts must be regularly inspected at the prescribed maintenance intervals, see inspection and maintenance schedule of main group 3.
Clean the chain 40 at the end of the shift.
The chain tension must be checked every day (every 8 to 10 operating hours), see also group
12.72.
The fixture of the base plates 45 and tumbler wheels 63 must be examined every week (every 50
operating hours), see group 12.72.
The fixture of the travel gear 65, the oil motor and the running and support rollers 38 / 39 must be
checked every 500 operating hours by examining the tightening torque of the fastening bolts, see
groups 12.62, 12.64.
copyright by
MJF C I F S S
12.60.3
Chassis / drive
Service Manual
Maintenance of chassis parts

The sliding surface of the tensioning unit (on sliding pieces and longitudinal members) must be
cleaned and lubricated every 500 operating hours.
The travel gear 65, the oil motor and the running and support rollers 38 / 39 must be checked every
500 operating hours for leakage.
12.60.4
1
2
Undercarriage
Idler
54 Hex head screw

56 Hex head screw
3
4
Grease tensioner
Lid
59 Lubrication nipple
60 Extension
Lid
61 USIT ring
Locking mechanism
Hex head screw
63 Tumbler wheel
8 Hex head screw

30 Regulating motor
65 Travel drive
66 Tensioning unit
31 Hex head screw

35 O-ring
67 Spring
68 Spring plate
38 Running roller
70 Lid
39 Support roller
40 Chain
71 Hex head screw

72 Hose
41 Chain link
42 End bolt
73 Hose
74 Hose
43 End bushing
75 Allen head screw
45 Base plate
49 Spacer ring
76 Flange halves
77 Hose
50 Allen head screw

51 Square nut
78 Hose
79 Rectangular ring
copyright by
MJF C I F S S
Service Manual
Chassis / drive
Fig. 2
Chassis parts
copyright by
MJF C I F S S
12.60.5
Chassis / drive
Service Manual
12.60.6
copyright by
MJF C I F S S
Service Manual

Machine
Type
valid from serial no.
R 313
636
27752
Chain
Type
Number of segments
D4 L
46
Base plate
Type
Model
Width / spec. weight on ground (15 t / 16 t * usable weight)
Base plate screws

Thread
Tightening torques
Three-step
D4 L
500 mm / 4.6 N / cm
4.9 N / cm *
600 mm / 3.9 N / cm
4.2 N / cm *
750 mm / 3.2 N / cm
3.4 N / cm *
5/8-18 UNF X16
180 20 Nm + 120
Travel gear
Type
Number per chain
Tightening torque for mounting screws
FAT 350
1
560 Nm
Tumbler wheel
Number per chain
1
560 Nm
Running roller
Type
Number per chain
D4 L
7
280 Nm
Support roller
Type
Number per chain
Tightening torques of mounting screws and bolts
D4 L
2
280 Nm
Lubrication nipple (extension)

Number per chain
Torque
Tab. 1
1
170 Nm
Technical data
copyright by
MJF C I F S S
12.62.1
12.62.2
Service Manual
copyright by
MJF C I F S S
Service Manual

Machine
Type
valid from serial no.
R 317
970
18161
R 317
362
18161
Chain
Type
Number of segments
B 60 L
44
B 60 L
55
Three-step
B 60 L
500 mm / 5.0 N / cm
600 mm / 4.3 N / cm
750 mm / 3.5 N / cm
900 mm / 2.7 N / cm
1000 mm / 2.4 N / cm
Three-step
B 60 L
600 mm / 3.5 N / cm
900 mm / 2.4 N / cm
1000 mm / 2.1 N / cm
M 20 x 1.5
740 - 840 Nm
M 20 x 1.5
740 - 840 Nm
FAT 350
1
560 Nm
FAT 350
1
560 Nm
Tumbler wheel
Number per chain
1
560 Nm
1
560 Nm
Running roller
Type
Number per chain
B 60
7
280 Nm
D6 KL
9
280 Nm
Support roller
Type
Number per chain
B 60 L
2
280 Nm
B 60 L
3
280 Nm
1
170 Nm
1
170 Nm
Base plate
type
Type
Width / specific base plate load (with hydr. boom
adjusting device, 17t usable weight)
Base plate screws

Thread
Tightening torques
Travel gear
Type
Number per chain
Lubrication nipple (extension)

Number per chain
Tab. 1
Technical Data
copyright by
MJF C I F S S
12.64.1
12.64.2
Service Manual
copyright by
MJF C I F S S
Service Manual

Introduction

1 Introduction
Chassis parts are subject to wear from movement, loads and contact between parts.
Improper driving and manoeuvring (e.g. sudden turning, uneven loads, incorrect crossing of obstacles) results in significantly increased wear.
It is therefore important that the excavators are operated according to the following basic rules:
Note!
For travel over long distances, the drive system of the excavator must be at the rear.
When working in longitudinal direction using the backhoe bucket, e.g. in connection with channel
digging, move the excavator in reverse direction and work across the idler.
For pipe laying work, the drive unit must be at the rear of the excavator.
When working with the front shovel or the backhoe bucket, ensure that the excavator is not elevated or tipped with a high centre of gravity.
Worn chassis parts such as chain links, running rollers, idlers, support rollers, tumbler wheels, base
plates, etc. must be replaced with new parts as soon as the specified wear limit is reached, see group
12.67, 12.69.
1.1
Wear of bolts and bushings

Internal wear of bushings and bolts leads to an increased chain pitch. As a result, the drive wheel and
the bushings fail to engage properly, so that there is increased wear at the inner and outer surfaces
of the bushings as well as at the engaging surfaces of the drive wheels.
The effect of internal wear can be considerably reduced by turning the bolts and bushings by 180
degrees.
The time at which the bolts and bushings are to be turned must be determined as described below.
It cannot be determined based on the operating hours of the machine.
Measuring of chain pitch: measure the chain pitch across at least 4 chain links. Repeat this
measurement at different intervals on the chain. Divide the average measured value by 4. The
result corresponds to the wear per bolt and bore.
If the wear is less than approx. 3 mm, turn the bushings and bolts.
If the wear exceeds approx. 5 mm, replace the bushings and bolts.
Measuring of bushings: they may not be worn by more than 3 to 3.5 mm at the outer wear limit.
In order to establish the degree of wear and thus the need for replacement, it is necessary to regularly
and accurately measure the chassis parts.
Note!
Prior to measuring, carefully clean the chassis parts or measuring points. Repeat the measurements at various locations, e.g. at the tumbler wheel, or on various parts, e.g. on the chain. Always
base your assessment on the maximum wear measured. The degree of wear is calculated by comparing the measured dimension (actual value) with the corresponding dimension of the new part
(nominal value), see wear limits, group 12.67, 12.69..
copyright by
MJF C I F S S
12.66.1
Service Manual
Chain links
Example:
Hn
= height of new part
= 126 mm
Hv
H
= wear limit of part

= actual height (measured
height)
= 116 mm
= 120 mm
Degree of wear:
Fig. 1
Calculation of the degree of wear
2 Chain links
Fig. 2
Measurement with depth gauge or ruler of bearing surface wear on chain link between
the chain bearing surface and the base plate pad.
3 Chain bolts
Fig. 3
12.66.2
Measurement of inner wear of bolts and bushings using a ruler. The measurement is carried out on the tight chain and across 4 chain links.
copyright by
MJF C I F S S
Service Manual

Chain bushing
4 Chain bushing
Fig. 4
Measurement with calliper gauge of outer wear of chain bushing at point of maximum
wear.
5 Base plate
Fig. 5
Measurement with depth gauge or ruler of ridge wear at base plate.
6 Idler
Fig. 6
Measurement with depth gauge of wearing surface wear of idler.
copyright by
MJF C I F S S
12.66.3
Service Manual
Running roller
7 Running roller
Fig. 7
Measurement with calliper gauge or outside calliper of wearing surface wear of running
roller.
8 Support roller
Fig. 8
12.66.4
Measurement with calliper gauge or outside calliper of wearing surface wear of support
roller.
copyright by
MJF C I F S S
Service Manual
D4L wear limits
D4L wear limits

New
Tumbler wheel
Wear limit
Zv
to
tip of gear
Chain link
Chain bolt
Hn
Hv
96.0
90.0
Ln
Lv
686.8
698.8
Dn
Dv
Chain bushing
normal impact
54.2
46.3
high impact
48.9
New
copyright by
MJF C I F S S
Wear limit
12.67.1
D4L wear limits
Service Manual
Base plate
Idler
Running roller
Support roller
12.67.2
copyright by
MJF C I F S S
Hn
Hv
25
12.5
Hn
Hv
17
23.5
Dn
Dv
138
126
Dn
Dv
120
110
Service Manual
Wear limits - B60
Wear limits - B60

New
Tumbler wheel
Wear limit
Zv
to
Tip of gear
Chain link
Chain bolt
Chain bushing
Tab. 1
Hn
Hv
105
98
Ln
Lv
761
774
Dn
Dv
59
54
Wear limits
copyright by
MJF C I F S S
12.69.1
Wear limits - B60
Service Manual
Base plate
Idler
Running roller
Support roller
12.69.2
copyright by
MJF C I F S S
New
Wear limit
Hn
Hv
28
12.5
Hn
Hv
20
25
Dn
Dv
154
141
Dn
Dv
120
107
Service Manual
Chain
Dismantling complete chain
Chain
1 Dismantling complete chain
Danger!
When dismantling the chain, there is a risk of the chain suddenly becoming slack, which can result
in injury. There is a risk of injury from escaping grease when the chain is handled incorrectly when
being released.
To remove the chain, the longitudinal member must be lifted over the attachment, see Fig. 1. Persons working near the chain are thus exposed to a serious risk of injury when the member is dropped or inadvertently lowered.
Never reach under the suspended longitudinal member.
Keep your head away from the opening of the longitudinal member when releasing the chain.
Never loosen or tighten the screws by hand, always use a suitable tool.
Always wear protective goggles and gloves.
Always observe the instructions below.
Place the excavator on a firm level ground. Move the chain until the end bolt 42, see Fig. 3 is located in the lower third of the drive train. Place the wedge under the unit.
The end bolts 42 differ from normal bolts in that they feature a larger or smaller recess and bevelled front edges, (see Fig. 4 on page3).
Fig. 1
1.1
Lifting longitudinal member using the attachment
Releasing chain, see Fig. 2

Before releasing the chain, carefully clean the chassis, in particular the area around the chain end
bolts and the cover 4 on the longitudinal member.
Remove all objects jammed in the chain (if necessary, move the chain back and fore).
Remove the screws 8 and then remove the cap 4 from the longitudinal member.
Turn the lubrication nipple 59 only by a few turns on the extension 60 (WS 27) (do not screw it out
fully) so that the grease escapes at the release groove N (longitudinal groove, see Fig. 2). Press
the chain towards the longitudinal member between the support rollers.
After the chain has been released, immediately turn in and tighten the lubrication nipple 59 complete with the extension 60 (tightening torque 170 Nm).
copyright by
MJF C I F S S
12.72.1
Chain
Service Manual
Dismantling complete chain
Fig. 2
4
8
Screw plug with release groove and lubrication nipple

60 Lubrication nipple extension (WS 27)
Lid (access to lubrication nipple)

Hex head screw
59 Lubrication nipple (WS 22)
1.2
N Release groove
Opening and removing chain

Note!
Press the thumb screw from the inside of the chain outwards. Push out the grooved end bolts (inwards or outwards).
Push out the end bolts, (see 3 on page6).
Roll off the chains in the direction of travel.
If required, you can now remove the idler with tensioning unit from the longitudinal member, see
group 12.78.
Lift the excavator and pull off the chain.
12.72.2
copyright by
MJF C I F S S
Service Manual
Chain
Mounting chain
Fig. 3
Direction of travel for chain dismantling
A Roll-off direction
42 End bolt
Direction of travel
Fig. 4
Lid
End bolt
N Grooved end bolt
R Thumb end bolt
2 Mounting chain
Before mounting the chain, inspect the fixture of the chassis components, see also maintenance
instructions for the chassis, group 12.70
Position the excavator on the rolled-out chain and secure it with chocks.
Place the chain over the idler and the support roller, using a rope or cable and a pulling device
(vehicle, etc.).
Observe the direction of travel of the chain and the position of the base plates, see Fig. 5.
Insert the end bushing rings 43. Connect the chain links and push in the end bolt 42 from the outside, (see 3 on page6).
Screw in the lubrication nipple 59 with the extension 60 and the UNIT seal ring at the grease tensioner and tighten the chain with the grease gun.
copyright by
MJF C I F S S
12.72.3
Chain
Service Manual
Mounting chain
Note!
The chain is tensioned correctly, if there is a dip of approx. 15 to 22 mm between the two support
rollers, (see Fig. 7 on page5)!
Fig. 5
Direction of travel of the chain
Fig. 6
Chain tensioning with manual level grease gun
80 Manual grease gun
Lid
82 Nozzle pipe
60 Extension
2.1
Checking chain tension

Release the chain by moving fore and back.
Place the measuring rod 90 onto the section between the support rollers.
12.72.4
copyright by
MJF C I F S S
Service Manual
Chain
Mounting chain
Measure the distance X between the measuring rod lower edge and the base plate.
There must be a dip of approx. 15 to 20 mm between the support rollers.
If necessary, tension the chain.
Alternative measurement:
Measure the distance Y1 between the upper edge of the longitudinal member and the lower edge
of the chain link beside the support roller.
Measure the distance Y2 between the upper edge of the longitudinal member and the lower edge
of the chain link at the centre between the support rollers.
Calculate the actual dip: Deduct dimension Y2 from Y1.
Fig. 7
2.2
Chain dip of correction tensioned chain
Insufficiently tensioned chain
B
90
Correctly tensioned chain

Measuring rod
Y1-Y2 Chain dip
Chain dip
Tensioning chain
As the chassis is exposed to normal wear, the chain tension must be regularly checked and redesigned, if necessary.
Remove the lid 4 from the longitudinal member of the undercarriage.
Screw the nozzle pipe 82 from the hand grease gun 80.
Connect the nozzle pipe 82 through the opening in the longitudinal member with the lubrication
nipple 59 of the grease tensioner, (see Fig. 6 on page4).
Fill in grease until the chain is sufficiently tensioned.
Check chain tension, see Fig. 7.
copyright by
MJF C I F S S
12.72.5
Chain
Service Manual
Dismantling and mounting end bolt when replacing chain
3 Dismantling and mounting end bolt when replacing chain

Danger!
There is a risk of injury when the hardened end bolt 42 is driven out or in with the sledge hammer,
as metal might break off!
When driving the end bolt out or in, always were protective goggles!
Complete the process with a bolt press, (see Fig. 8 on page7), or other suitable tool.
Note!
Push thumb bolts from the inside of the chain towards the outside, (see Fig. 8 on page7). If available, drive them out with a suitable device.
The groove bolts can be driven out from the outside to the inside or vice versa! Always secure the
chain link when driving out the bolts!
Drive or push out the end bolt 42.
Remove the seal / spacer rings and the chain bushing.
3.1
Mounting end bolt

Place the seal / spacer rings and the chain bushing in the end links of the chain and bring the chain
ends together.
Insert the end bolt 42 from the outside of the chain and press it in, using a bolt press.
12.72.6
copyright by
MJF C I F S S
Service Manual
Chain
Replacing damaged base plates
Fig. 8
Bolt press for the dismantling and mounting end bolt
4 Replacing damaged base plates

Caution!
Bent or loose base plates can lead to serious consequential damage to the adjacent base plates
and the track chain.
Regularly service the chain. For instructions, see maintenance instructions for the chassis in
group 12.60.
Replace damaged base plates!
Loosen the mounting screws 50 and remove all damaged base plates.
Clean the support face at the chain link and mount a new base plate.
Tighten the mounting screws 50 crosswise and with the correct torque, using a torque spanner
(see Fig. 9 on page8) (see group 12.57).
copyright by
MJF C I F S S
12.72.7
Chain
Service Manual
Repair of damaged chain
Fig. 9
Replacement of damaged base plates
1-4
Tightening of base plate screws
50
Hex head screw for base plate
51
Base plate nut
5 Repair of damaged chain

5.1
Dismantling of torn chain link

Using a blow torch, cut through the damaged chain link and place the chain on the ground.
With the blow torch, cut off the bushings and bolts at the damaged chain link at the indicated
points, see Fig. 10.
Remove cut chain pieces.
Fig. 10
Torch cuts through damaged chain
44 Complete side chain link

12.72.8
C Fraction point at chain link

D Torch cuts at chain link
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MJF C I F S S
Service Manual
Chain
5.2
Preparation for insertion of new chain link

Torch-cut the front side of the bushing 43 and grind it to a smooth finish (E).
Weld in the bolt stump K at the centre, using a blow torch and drive it out with a hammer (back it
with the hammer G).
Fig. 11
Preparation for insertion of new chain link
43 Bushing
G Backing with hammer
H Direction of bolt drive-out
K Bolt stub
Grinding chain link to a plane surface
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MJF C I F S S
Burn in hole, using a blow torch
12.72.9
Chain
Service Manual
5.3
Insertion of new chain link

Connect the compressed chain link 46 with the spacer ring 49 and one end bolt 42 to the chain
link 48.
Press in the end bolt 42.
Mount the chain.
Insert two spacer rings 49 into the chain link 46 and connect them with the end bolt 44.
Close the chain by pressing in the end bolt 42.
Mount the base plate, (see Fig. 9 on page8).
Fig. 12
Insertion of new chain link
42 End bolt
12.72.10
47 Drive-in direction of thumb end bolt
43 End bushing

46 New chain link
49 Spacer ring
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MJF C I F S S
Service Manual
Tensioning unit
Dismantling complete tensioning unit
Tensioning unit
1 Dismantling complete tensioning unit
Remove the covers 4 and 5 from the longitudinal member 62see Fig. 2 of the undercarriage.
Caution
The spring 67 of the tensioning unit applies a great force through the spring plate 68 onto the locking
mechanism 6. Loosening the screws 7 while the spring is prestressed can cause damage to the locking mechanism.
Never loosen the screws 7 while the spring plate 68 is being supported by the locking mechanisms.
Place the nozzle tube of the manual grease gun onto the lubrication nipple 59 of the grease tensioner 3.
Press in grease (over-tensioning chain) until the spring plate 68 is lifted from the locking mechanisms 6.
Remove the mounting bolts 7 and the locking mechanisms 6.
Remove the grease gun from the lubrication nipple 59.
Release and dismantle the chain (see group 12.72).
Pull the idler 2 with the grease tensioner 3, the spring plate 68 and the spring 67 from the longitudinal member 62.
copyright by
MJF C I F S S
12.75.1
Tensioning unit
Service Manual
Dismantling grease tensioner
Fig. 1
2
3
Assembling tensioning unit and idler

14 Backing ring
Idler, complete
Grease tensioner
10 Piston
11 Housing
60 Extension
61 USIT ring
12 Lip seal
67 Spring
13 Scraper ring
68 Spring plate
2 Dismantling grease tensioner

Dismantle the grease tensioner only, if this is necessary for repair, etc.
Screw off the extensions with the lubrication nipple and pull the piston 10 from the cylinder 11.
Remove the lip seal 12 from the piston 10.
Remove the scraper ring 13 from the cylinder 11.
3 Mounting grease tensioner

Place the new lip seal 12, new scraper ring 13 and piston 10 in the cylinder 11.
Screw in the extension 60 with the lubrication nipple 59 together with the new USIT ring 61.
12.75.2
copyright by
MJF C I F S S
Service Manual
Tensioning unit
Mounting complete tensioning unit
4 Mounting complete tensioning unit

Insert the spring 67 into the longitudinal member 62 and centre it on the pipe section.
Insert the spring plate 68 into the sliding rails of the longitudinal member 62. The centring device
at the spring plate 68 must thereby be inserted into the spring 67.
Insert the idler 2 with the grease tensioner 3 into the rail of the longitudinal member 62.
Mount and tighten the chain (see group 12.72).
Preload the spring 67 by pressing grease into the grease tensioner 3 until the spring plate has
passed the opening 5 and the locking mechanisms 6 can be mounted.
Note!
Ensure that the machined surface of the locking mechanism 6 faces the idler 2. The machined surface is marked with an arrow.
Insert the locking mechanisms 6 and secure them with the screws 7 (tightening torque for screws
7 = 107 Nm).
Remove the grease gun from the lubrication nipple 59.
Danger!
When releasing the chain, there is a risk of injury from escaping grease.
Keep your head away from the opening of the longitudinal member when releasing the chain.
Never loosen or tighten the screws by hand, always use a suitable tool.
Always wear protective goggles and gloves.
Loosen the extension 60 with the lubrication nipple and let the grease escape until the correct
chain tension is reached, see group 12.72.
Screw in the extension 60 with the lubrication nipple and tighten it (torque = 170 Nm).
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MJF C I F S S
12.75.3
Tensioning unit
Service Manual
Fig. 2
12.75.4
Tensioning unit with idler
2
3
Idler
Grease tensioner
7 Hex head screw

59 Lubrication nipple (with extension)
4
5
Lid
Lid
67 Spring
Locking mechanism
68 Spring plate
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MJF C I F S S
Service Manual
Tensioning unit
Fig. 3
Sectional drawing of tensioning unit
4
5
Lid
Lid
13 Scraper
6
7
Locking mechanism
Hex head screw
60 USIT ring
10 Piston
11 Housing
67 Spring
68 Spring plate
12 Compact seal
Machine
Type
Serial number
R 313
636
27752
R 317
362 / 790
18161
Piston 10
(mm)
Free length
Lo
(mm)
Preloaded
length
L1 (mm)
Preload force
kN
Spring travel
L
(mm)
S
(mm)
80
423
354
85
45
38
100
442
372
140
56
49
Tab. 1
Technical data of tensioning unit
copyright by
MJF C I F S S
12.75.5
Tensioning unit
Service Manual
12.75.6
copyright by
MJF C I F S S
Service Manual
Idler
Dismantling idler
Idler
1 Dismantling idler
Remove the tensioning unit with the idler from the longitudinal member in the undercarriage (see
group 12.75), proceeding as follows:
Disconnect the idler 11 with the two sliding pieces 7 from the housing 14.
2 Dismantling
Remove the screw cap 3 and drain off the oil.
Drive out the roll pins 8 and remove the sliding pieces 7 and the O-rings 6 from the axle 1. Pull the
axle 1 from the idler 11.
Remove the slide ring seal halves 5 from the idler 11 and the sliding pieces 7.
Push out the bearing bushings 2 from the idler 11.
3 Installation
Press the bearing bushings 2 into the idler 11. Insert the slide ring seal halves 5 into the idler 11
and the sliding pieces 7 (see group 12.71).
Note:
The slide rings must be ground in pairs. Do not confuse them!
Place the O-ring 6 and a sliding piece 7 on the axle 1 and drive in the roll pin 8.
Insert the axle1 in the idler 11 and place the second O-ring 6 and sliding piece 7 on the axle 1.
Drive in the second roll pin 8.
Fill the idler with oil (adhere to filling instructions).
4 Mounting idler
Secure the sliding pieces 7 with the hex head screws 12 to the housing 14 and tighten the screws
with the correct torque.
Insert the tensioning unit with the idler from the longitudinal member in the undercarriage (see
group 12.75).
5 Filling instructions
Turn the idler until the oil filling opening is aligned vertically. Fill in SAE 40 motor oil until the centre
chamber is full.
Apply compressed air to the centre chamber, to press the oil into the side chambers.
Turn the idler 11 until the oil filling opening is at a 45 degree angle to the perpendicular. Add oil
until it escapes through the opening 15. Apply Loctite to the screw plug 3 and screw it in together
copyright by
MJF C I F S S
12.78.1
Idler
Service Manual
Filling instructions
with the O-ring 4, (see Fig. 3, page 3).
Filling volumne:~0.300 - 0,330 kg of SAE 40
Fig. 1
1
12.78.2
Sectional drawing of the idler
Axle
Roll pin
Trapezoid ring
Bearing bushing
3
4
Screw plug
O-ring
10 Slide ring
11 Idler
5
6
Slide ring seal

O-ring
12 Hex head screw

13 Washer
Sliding piece
14 Housing
copyright by
MJF C I F S S
Service Manual
Idler
Fig. 2
Exploded view of the idler
Fig. 3
Filling position of the idler
15 Oil level
copyright by
MJF C I F S S
12.78.3
Idler
Service Manual
12.78.4
copyright by
MJF C I F S S
Service Manual
Running roller
Dismantling
Running roller
1 Dismantling
Remove the screw cap 5 and drain off the oil.
Drive out the roll pin 8 on both sides of the running roller axle 10 and remove the end piece 7 from
the axle. Remove the slide ring seal halves 9 from the running roller body 1 and the end piece 7.
Remove the O-ring 11 from the running roller axle. Pull the running roller axle 10 from the running
roller body and drive out the roll pin 8. Push the running roller bushings 4 from the running roller
body.
2 Assembly
Push the running roller bushings 4 into the running roller body.
Insert the running roller axle 10 into the running roller body and place the seals 11 into the grooves
of the running roller axle.
Place the slide seal ring halves 9 into the running roller body and insert the end piece 7, (see group
12.71).
Mount the end piece 7 on the running roller axle 10 and secure it with the roll pin 8.
Check axial play (movability). Drive in the running roller with compressed air at approx. 6 bar and
check for leakage.
Turn the roller until the oil filling opening is aligned vertically. Fill in SAE 40 motor oil until the centre
chamber is full.
Using compressed air, pressurize the centre chamber to press the oil into the side chambers.
Turn the running roller 1 until the oil filling opening is at a 45 degree angle to the perpendicular.
Add oil until it escapes through the opening 15.
Apply Loctite to the screw plug 5 and tighten it.
Filling volume: ~0.270kg of SAE 40
Fig. 1
Filling position of running roller
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MJF C I F S S
12.81.1
Running roller
Service Manual
12.81.2
Fig. 2
Exploded view of running roller
Fig. 3
Sectional drawing of running roller
1
4
Running roller body

Running roller bushing
9 Slide ring seal

10 Running roller axle
5
6
Screw plug
Sealing ring
11 O-ring
12 Trapezoid ring
End piece
13 Slide ring
Roll pin
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MJF C I F S S
Service Manual
Support roller
Dismantling
Support roller
1 Dismantling
Remove the screw plug 6 and drain the oil.
Place the support roller with the end cap10 (cap11 facing upwards) in the vice.
Remove the screws 1 and then remove the cap 11. Remove the O-ring 2.
Remove the Allen head screws 3 and the remove the retaining washer 4.
Pull the support roller body 12 with the bushings 5 and 8 and the slip ring seal 9 from the axle 7.
Remove the seal 9 from the support roller body 12 and lift off the cap 10.
Press the bearing bushing 5 and the bushing 8 from the support roller body 12.
Note!
The axle 7 press-mounted into the end cap 10 and cannot be dismantled.
2 Installation
Press the bearing bushing 5 and the bushing 8 into the support roller body 12.
Mount the seal 9 in the end cap and the support roller body 12.
Place and secure the support roller body 12 on the axle 7.
Secure the retaining washer 4 with the Allen head screws 3 on the axle 7.
Mount the O-ring 2 to the cap 11.
Press the cap 11 into the support roller body 12 and secure it with the screws 1.
Check axial play. Apply compressed air at approx. 6 bar to the support roller and check it for leakage.
Fill oil into the support roller, observing the filling instructions below.
Ensure that the oil fill opening is at the top and in vertical position. Fill in SAE 40 engine oil until
the centre chamber is full.
Pressurise the centre chamber with compressed air to press the oil into the lateral chambers.
Turn the support roller body 12 until the oil fill opening is at an angle of 45 degrees to the perpendicular. Fill in more oil until the oil escapes at point 15, (see Fig. 1, page 2).
Replace the screw plug 6 and seal it with Loctite.
Filling volume: ~0.20kg SAE 40
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MJF C I F S S
12.84.1
Support roller
Service Manual
Fig. 1
Filling position of support roller
15 Oil level
For the items in fig. 2 and 3, page 3.
12.84.2
Screw
Axles
2
3
O-ring
Allen head screw
8
9
Bushing
Seal
Stop washer
10 End cap
5
6
Bearing bushing
Screw plug
11 Cover
12 Support roller body
copyright by
MJF C I F S S
Service Manual
Support roller
Fig. 2
Exploded view of the support roller
Fig. 3
Sectional drawing of support roller
copyright by
MJF C I F S S
12.84.3
Support roller
Service Manual
12.84.4
copyright by
MJF C I F S S
Service Manual
Slide ring seal

Design
Slide ring seal

1 Design
The slide ring seal is used to seal chassis parts with a long service life and that are exposed to heavy
loads.
Slide ring seals consists of a pairs of slide rings and seal rings (trapezoid rings), see Fig. 2.
2 Installation instructions for slide ring seals

Note!
Seal rings are high-precision parts made in chilled hard iron. They are easily damaged by impact.
Therefore avoid impacts and shocks to the slide rings.
Do not remove the seals from the original packaging until you are ready to install them. Protect
the fine-machined slide faces 1 against damage and contamination. Always install seals in pairs
(as packaged).
Check the seal retaining parts to ensure that they are free of dirt.
All edges of the seating hole must be rounded or bevelled. Ensure that there are not burrs, (see
Fig. 2 on page2).
Prior to assembling the seal rings, apply a thin film of oil to the slide faces 1, using a lint-free cloth.
Ensure that the trapezoid rings 3 and their seats are not contaminated with oil.
To facilitate this, apply a little spirit solution (spirit / water 1:1) to the bore hole 7 and to the trapezoid ring 3.
Before assembling the seal halves, wait until the spirit/water mixture has evaporated and the parts
are completely dry. If necessary, clean with compressed air.
Note!
We advise you not to use a thick piece of string or a rope for the installation of the slip ring seals.
Press the slip ring seal into the borehole 7. Ensure that the trapezoid ring is properly positioned
in the chamber radius 5 and that the slide face 1 is aligned parallel to the housing face 8.
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MJF C I F S S
12.86.1
Slide ring seal
Service Manual
Installation instructions for slide ring seals
Fig. 1
Trapezoid ring
Fig. 2
12.86.2
Slide ring seal
Sectional drawing of slide ring seal
Slide ring
Correctly installed slide ring seal
Sliding face
Chamber radius
2
3
Slide face cone

Trapezoid ring
6
7
Installation bevel
Borehole diameter
Slide ring
Housing face
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MJF C I F S S
Service Manual
SUBGROUP - INDEX
Section
Group
Type
Operating pressures of the steering system
13.05.1
Hydraulic steering system
13.10.1
Servostat
13.20.1
A 309 LI 20221-21648
A 311 LI 20222-21648
A 312 LI 12363-19111
A 314 LI 2001-19111
A 316 LI 2001-24954
A 316 LI-IND 2001-24954
Steering valve
13.22.1
A 309 LI 21649A 311 LI 21649A 312 LI 19112A 314 LI 19112-
Steering valve
13.24.1
A 316 LI 24955A 316 LI-IND 24955-
Steering cylinders
13.32.1
A 309 LI 20221A 311 LI 20222A 312 LI 12363-
Steering cylinders
13.34.1
A 314 LI 2001A 316 LI 2001A 316 LI-IND 2001-
4-wheel steering
13.50.1
A 309 LI 20221A 311 LI 20222-
13.1
MJF C I F S S
Service Manual
13.2
MJF C I F S S
Service Manual

General information

Machine
Series
A 309/311
Litronic
A 312/314
Litronic
A 316
Litronic
l/min
39
44
44
Adjustment pressure at pressure-relief valve 88

at flow rate 15 - 20 l/min
bar
230 +15
230+15
230+15
Adjustment pressure at primary pressure-relief valve 29

in Servostat
bar
180 +10
180 +10
180 10

in steering valve
bar
180 +10
180 +10
195 10
Secondary pressure relief valve 44

in Servostat
bar
240 10
240 10
240 10

in steering valve
bar
240 10
240 10
250 10
Unit
Gear pump 31 / 32:
Max. oil flow to steering pump 31/32
Adjustment pressures
Tab. 1
Technical data of machine series
Machine
4-wheel steering kit
A 309/A 311
Unit
Gear pump 32
Max. oil flow to steering pump 32
l/min
39
Adjustment pressure at pressure-relief valve 88

at flow rate 15 - 20 l/min
bar
230 +15
Adjustment pressure at primary pressure-relief valve 29 in Servostat
bar
210 +10

in steering valve
bar
210 +10

in Servostat
bar
260 10

in steering valve
bar
260 10
Adjustment pressures
Tab. 2
Technical data of 4-wheel steering system
copyright by
MJF C I F S S
13.05.1
Service Manual
General information
13.05.2
copyright by
MJF C I F S S
Service Manual

Function

1 Function
Fig. 1
2 Description
2.1
Steering pump 31 / 32, see Fig. 2

31 / 32
The pump takes up hydraulic oil from the tank 1 and transfers it to the steering valve / Servostat 84.
The gear pump 31 / 32 is secured by the pressure relief valve 88.
2.2
Steering valve 84, see Fig. 2

The steering valve 84 is located at the base of the steering column a and is connected to the steering
wheel in the operator's cab.
It contains the valve actuators (way valve), the safety valves (primary and secondary pressure relief)
and the hand pump for emergency operation.
copyright by
MJF C I F S S
13.10.1
Service Manual
Description
Fig. 2
Gear pump with pressure relief valve and steering column with Servostat / steering valve
31 Gear pump / steering system (A312 - 316)
84 Steering valve
32 Gear pump / steering system (A309/311)
88 Pressure relief valve

A 309 / 311 from start of series
A 312 - 316 from serial no. 20241
a
2.3
Steering column
Rotary connection 85, see Fig. 3

The seven-fold oil rotary connection 85 is a special connection for hydraulic oil between the uppercarriage and the undercarriage and is located at the centre of the slewing ring.
Pressure oil is fed from the Servostat / steering valve 84 through the rotary connection 85 to the steering cylinder 86, while return oil flows from the steering cylinder 86 through the steering valve 84 to
the tank.
2.4
Steering cylinder 86, see Fig. 3

The steering cylinder is integrated into the front axle (steering axle) differential.
The steering cylinder 86 is pressurised with pressure oil by the Servostat / steering valve 84 so that
the connected joint housings (steering knuckles) are moved every time the piston rod is moved in axial direction, adjusting the steering angle of the wheels.
13.10.2
copyright by
MJF C I F S S
Service Manual

Function of the steering system
Fig. 3
Rotary connection and steering cylinder
85 Rotary connection 7 x
86 Steering cylinder
3 Function of the steering system

The gear pump 31 takes up oil from the tank 1 and transfers it to the Servostat / steering valve 84
port P. When the valve actuator in the Servostat / steering valve 84 is in neutral position (neutral position of the steering wheel), oil flows through port T back to the tank1.
When the steering wheel is turned to the left or right, pressure oil flows from the Servostat / steering
valve 84 port L or port R and the rotary connection 85 to the corresponding side of steering cylinder
86. The hand pump (metering pump) built into the Servostat / steering valve 84 is used for metering.
The return oil flows from the steering cylinder 86 through the non-pressurised side back to the tank 1.
The built-in hand pump of the Servostat 84 can also be used to pressurise the steering cylinder 86 in
the event of a failure of the gear pump 32 (emergency steering).
By pressurising the steering cylinder 86, the piston with the piston rod is moved in the corresponding
direction, thus rotating the joint housing (steering knuckles) so that the axle is steered.
The integrated primary and secondary pressure relief valves of the Servostat / steering valve 84 protect the entire steering system against excess pressure.
To protect the gear pump 31/32, especially when cold oil is used, it is equipped with a pressure relief
valve 88.
3.1
Pressure check and adjustment of the steering system
3.2
Pressure check and adjustment of the pressure relief valve 88 at the gear
pump 31 / 32, see Fig. 4
Remove the cover cap at the measuring point 83 and connect the pressure sensor or pressure
gauge (600 bar).
Heat the hydraulic system to operating temperature.
Start and run the diesel engine at its lower idle speed (level 1).
copyright by
MJF C I F S S
13.10.3
Service Manual

Measure and write down the actual position of the valve adjusting screw.
Move the vehicle wheels to the outer steering position.
Slowly turn the steering wheel against the resistance.
Measure the pressure at the pressure sensor and compare it with the prescribed pressure (see
group 13.05).
Loosen the lock nut at the valve 88.
Turn out the adjusting screw of the valve 88 until the pressure drops at the measuring point 83
(valve 5/29 closes, the flow noises at the valve 5/29 cease, while there are now flow noises at the
valve 88).
Turn in the adjusting screw of the valve 88 until the pressure reaches the prescribed value (valve
88 closes, the flow noises at the valve 88 cease, while there are now flow noises at the valve 5/29).
If the prescribed pressure (see group 13.05) is not reached, check the primary pressure relief
valve 29 / 5 and the secondary pressure relief valves 44 / shock valve 6 in the Servostat / steering valve 84, see 3.3.
If the prescribed pressure (see group 13.05) is reached, turn in the adjusting screw of the valve
88 by 180 degrees.
Tighten the lock nut at the valve 88.
Remove the pressure sensor or gauge 83 and mount the cover cap.
3.3
Inspection of the primary pressure relief valve 29 / 5 in the Servostat / steering

valve 84
Note!
The pressure relief valve 88 has been added to the machine A 312 - 316 as an additional safety
valve of the pump 31/32, see Fig. 2.
In machines with valve 88, the primary pressure relief valve 29 / 5 has already been checked
before the pressure relief valve 88 is checked and adjusted.
For machines without valve 88, proceed as follows:
Remove the cover cap at the measuring point 83 and connect the pressure sensor or pressure
gauge (600 bar).
Heat the hydraulic system to operating temperature.
Start and run the diesel engine at its lower idle speed (level 1).
Move the vehicle wheels to the outer steering positions (right and left).
Slowly turn the steering wheel against the resistance.
Measure the pressure at the pressure sensor and compare it with the prescribed pressure (see
group 13.05.
If the pressure is not reached at only one of the steering positions (left/right), it is likely that the
secondary pressure relief valves 44 / the shock valve 6 are faulty, see 3.4.
If the pressure is not reached in both steering positions, it is likely that the primary pressure
relief valve 29 / 5 is faulty.
Replace the primary cartridge 29 / 5 (cartridge is not adjustable), see group 13.20 / 13.22.
After installation of the new cartridge, check the steering system again for correct settings.
Remove the pressure sensor or gauge 83 and mount the cover cap.
13.10.4
copyright by
MJF C I F S S
Service Manual

Fig. 4
5
Servostat / steering valve with primary pressure relief valve
Primary pressure relief valve in the steering

valve 84
83 Measuring point for steering pressure

84 Servostat A / steering valve B
88 Pressure relief valve / pump
29
copyright by
MJF C I F S S
13.10.5
Service Manual
3.4
Check of the secondary pressure relief valves 44 / shock valve 6 in the Servostat / steering valve 84
Note!
The secondary pressure relief valves 44 / shock valves 6 (safety valves) are factory-set and cannot
be tested or adjusted. In the event of a defect or malfunction, repair it by following the instructions
for the Servostat / steering valve 84 (see groups 13.20 and 13.22).
Fig. 5
6
Secondary pressure relief valves in the Servostat and shock valves in the steering valve
Shock valve in the steering valve 84
84 Servostat A / steering valve B
44 Secondary pressure relief valve in the Servostat 84
1
5
Hydraulic tank (*)

Primary pressure relief valve in the
steering valve 84
85
86
6
29
Shock valve in the steering valve 84

87
Primary pressure relief valve in the Ser- 88
vostat 84
31
Steering pump A 312 - 316 (*)
32
44
Steering pump A 309 / 311 (*)

Secondary pressure relief valve in the
Servostat 84
L
R
Preload valve 3 bar (only in A 316)

A 309 / 311 from start of series
A 312 - 316 from serial no. 20241
Operating connection, turning left
Operating connection, turning right
83
Measuring point for steering
Pressure connection
84 A
Servostat
84 B1
LAGS steering valve

(A 309 from 20221
A 311 from 20222
A 312 and A 314 from 19112),
see group 13.22
T
F
Return channel
Direction of travel
84 B2
LAGZ steering valve

(A 316 from 17171),see group 13.24
* items in the hydraulic diagram of group 6.
13.10.6
Rotary connection (320*)

Steering cylinder
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MJF C I F S S
Service Manual

Fig. 6
Diagram of the steering system with Servostat 84 A
copyright by
MJF C I F S S
13.10.7
Service Manual
Fig. 7
13.10.8
Diagram of the steering system with steering valves 84/B1, 84/B2 and pressure relief valve 88
copyright by
MJF C I F S S
Service Manual
Servostat
Function
Servostat
1 Function
The Servostat serves as a hydraulic power assisted steering with hydrostatic transmission to the
steered wheels. With this system, there is thus no need for a mechanical connection between the
steering wheel and the steering linkage.
In the event of failure of the steering pump, the machine can be steered manually to some extent, i.e.
to be towed away.
Fig. 1
Servostat
copyright by
MJF C I F S S
13.20.1
Servostat
Service Manual
General information
Equipment
from serial number
A 309 Li
20221
A 311 Li
20222
A 312 Li
18161
Manufacturer model
Servostat 2
Type no.
8474955194
Valve settings:
Pressure relief valve 29 (primary pressure)
Safety valves 44 (secondary pressure)
Pump rate of the hydraulic pump 82
18010 bar
24010 bar
18010 bar
24010 bar
18010 bar
24010 bar
18010 bar
24010 bar
39 l/min
39 l/min
44 l/min
44 l/min
44 l/min
Setting value for the spool (19.2)
2.3 0.01mm
End play of the joint shaft (10)
0.03 mm
Breakaway torque of the steering shaft(56)
max. 8 Nm
Torque for the screws (1)
32 3 Nm
Torque for the

pressure relief valve (29)
30 3 Nm
Torque for the filter insert (43)
12 3 Nm
13.20.2
A 316-Li
2001
18010 bar
24010 bar
Settings and torques for the installation of the Servostat
Tab. 1
A 314 Li
2001
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MJF C I F S S
Service Manual
Servostat
Description
3 Description
The Servostat consists of:
Component
Explanation
Metering pump 8
consisting of stators 8.1 and 8.2; it delivers when turning in clockwise or anticlockwise direction.
Spool 19.2
adjusted in axial direction
Hose safety
valve 44
limits the oil pressure that might occur in the lines L and
R to the operating cylinder (secondary pressure)
Short circuit valve 23
the hand pump can suck up oil from the return line, if
the steering is operated without hydraulic assistance
Suction valve 36
helps prevent cavitation in the steering system
TV check
valve 31
located in the pressure connection, preventing the taking in

of air in the event of a pressure line break
limits the delivery pressure of the motor-driven pump to the

required maximum value (primary pressure)
Stop valve 22
prevents that the wheels are automatically returned

to their initial position when the spool is in the steering end position,
and also
reduces pressure peaks in the piston interior
Tab. 2
3.1
Component parts of the Servostat
Metering pump
The rotor 8.2 of the metering pump 8 is driven by the joint shaft 10 and is connected through the steering shaft 56 with the steering wheel. It has one tooth less than the stator, so that there is always a
tooth space when the rotor is rotated.
Opposite the tooth space (also known as the chamber) the tool of the rotor fits into the internal tooth
of the stator. When the rotor is turned, the other teeth and chambers thus form extended suction zones and narrowed pressure zones. The centre of the rotor thereby completes a planetary movement.
This movement is in the opposite direction to the rotation of the steering shaft and its angular speed
is 6 times higher. The suction and pressure zones revolve around the rotor at the speed of the planetary movement.
The required synchronous distribution control is achieved by the rotary movement of the spool.
3.2
Steering valve
The steering valve consists of the steering housing 19.1 and the spool19.2, which is located inside
the housing and can be rotated and moved in axial direction. Its barrel surface is equipped with control groves aligned in radial and axial direction. These grooves match channels in the valve bore of
the housing.
When the steering wheel is turned, the steering shafts transfers the movement via the centring spring
and the joint shaft to the metering pump 8. The spool is connected to the pump motor through the
joint shaft. The centring spring on the other hand allows for relative rotation between the steering
shaft and the spool, which is used to adjust the spool in axial direction by means of the steep-pitch
thread.
The axial motion of the spool results in an increase of the operating pressure and the changing of
direction of the oil flow. The radial motion of the spool ensures synchronous distribution control of the
copyright by
MJF C I F S S
13.20.3
Servostat
Service Manual
metering pump.
4.1
Neutral position of the steering valve

If the steering wheel is not turned, the spool 19.2 is in neutral position. This allows for the flow generated by the pressure oil pump to exit the pressure channel P through the left and right return channels T1 and T2 and to return from there to the oil tank. The oil in the other channels and the hand
pump is not affected by this. The control channels for the operating cylinders L and R are of a closed
design and do not feature a connection to the distributing grooves HP1 and HP2. The built-in safety
valves 44 prevent excessive pressure peaks in the steering system, which might occur as a result of
sudden impacts and loads during machine travel.
4.2
Valve in operating position

When the steering wheel is turned, the joint shaft 10 is moved through the steering shaft 56 and the
centring spring 52. Its gearing meshes with the internal rotor of the hand pump which then moves with
the shaft. The oil pressure required in the cylinder to steer the wheels acts against the rotating movement of the rotor 8.2. As a result, the steering angle of the steering shaft becomes greater than that
of the rotor 8.2 and of the spool 19.2. The spool is only rotated relative to the steering shaft if there
is a simultaneous axial movement. This is achieved by means of a driving pin in conjunction with a
coupling designed as a steep-pitch thread between the spool and the stop bushing.
When the spool is moved inside the housing in axial direction to the left (turning of the steering wheel
in anticlockwise direction), the distribution groves HP1 of the spool are opened. The oil flows from
connection P through the pressurised internal chamber and the distribution grooves HP1. As the distribution control rotates, there are at any one time 3 distributing grooves of the spool connected to 3
distributing channels in the housing, which lead to the suction zone of the hand pump. From the pressure zone of the hand pump, the oil flows also through 3 assigned distributing channels to 3 distributing grooves HP2 and the annular groove L and from there to the operating cylinder. When the
channel T1 is opened, the left side of the operating cylinder is connected with the return line T.
To steer the vehicle through a right bend the steering wheel is turned in clockwise direction, and the
valve piston is moved to the right. The following channels are thereby connected with each other.
P
HP1 to R
The oil downstream from the hand pump flows to the operating cylinder
L to T2
The oil expelled by the operating cylinder flows into the return channel
When steering without the assistance of the pressure oil from the motor-driven pump, e.g. when the
vehicle is being towed, the operator must generate the oil pressure necessary for steering by operating the hand pump. This means that considerably more force is required to turn the steering wheel
than is normally necessary when the steering is assisted by the pump 82.
When the machine is standing still, it is nearly impossible for one person to apply this force, so that
emergency steering is virtually impossible.
5 Inspection
13.20.4
copyright by
MJF C I F S S
Service Manual
Servostat
Inspection
Danger!
To check the steering, the technician must enter the undercarriage.
To prevent serious injury or even death,
secure the machine against inadvertent or unauthorised switching on.
Note!
During a steering system check, all screw connections and lines of the hydrostatic steering system
must be checked for leakage, and all steering components must be inspected for proper fixture.
Check the Servostat, hydraulic lines and the steering cylinder for leakage
Seal leaks and retighten lines, if necessary
Inspect the piston rod of the steering cylinder for damage or wear
The piston rod must be covered in a thin film of oil
The steering cylinder is sealed
Drops forming on the steering cylinder
Seal the steering cylinder
5.1
Bleeding of the steering system

After the hydraulic steering circuit has been opened to remove or install a component or as a result
of a fault, the steering system must be bled.
Proceed as follows:
Start the machine.
Move the steering wheel several times from one stop to the other.
Test drive the vehicle on a cordoned-off area.
Please note that the use of oils that tend to foam may lead to malfunction, as such oils tend to keep
air trapped so that the system cannot be properly bled.
5.2
Installation and dismantling of the Servostat

Note!
Before dismantling the Servostat, take all measures necessary to secure and block the machine
(see safety instructions in group 1.10).
Label the hydraulic lines of the Servostat, disconnect them and seal the openings (collect escaping oil).
Remove the M8 mounting bolts from the Servostat and the steering column and lift the Servostat
from the base plate (if necessary, secure the loose steering column).
copyright by
MJF C I F S S
13.20.5
Servostat
Service Manual
Inspection
Note!
In order to ensure proper functioning of the Servostat as part of the steering system, ensure that all
components of the system and all lines are kept clean at all times, especially during installation. To
prevent foreign bodies and dirt from entering the steering oil circuit, do not remove the plugs sealing
the lines to the Servostat, oil pump, operating cylinder, valves, etc. until they are finally reconnected.
Carefully deburr and clean all line ends and screw connections.
Apply grease (with lithium or calcium complex) to the missing tooth area and mount the Servostat
on the shaft 2 of the steering column.
Secure the Servostat and the steering column 1 to the base plate, using the four M8 hex head
screws (with washers) (torque: 25 Nm).
Connect the hydraulic lines to the Servostat (observe marks).
L = Pressure side of the operating cylinder when steering wheel is turned anticlockwise
P = Pressure line (pump)
R = Pressure side of the operating cylinder when steering wheel is turned clockwise
T = Return line (to tank)
13.20.6
copyright by
MJF C I F S S
Service Manual
Servostat
Inspection
5.3
Commissioning of the steering system

In order to prevent dirt particles in the lines entering the pressure relief valve when the system is operated for the first time, we recommend to let the steering system run for a few minutes at various engine speeds, without actually turning the steering wheel, allowing the oil to flush the system.
Then turn the steering wheel several times to the right and to the left without reaching the steering
lock, while the engine is run at a medium speed (until the operating temperature is reached). We recommend removing and separately cleaning the filter cartridge 43 (torque 12 Nm). Bleed the steering
system, (see 5.1, page 5).
5.4
Troubleshooting
In the event of malfunction, first check the oil level in the tank while the engine is running and add oil,
if necessary. When oil is added to the hydraulic system, there is always a risk of contamination with
dirt particles. In order to prevent malfunctions caused by dirt in the system, always pay particularly
attention to cleanliness when filling oil into the system.
copyright by
MJF C I F S S
13.20.7
Servostat
Service Manual
Inspection
13.20.8
Hex head screw
35.1 O-ring
2
3
Cover
Spacer
36
Suction valve
36.1 Seal washer
3.1
Washer
36.2 Cover plate
O-ring
37.1 Plug
Rotor kit (metering pump)
38
Pressure spring
8.1
8.2
Stator
Rotor
43
44
Filter
Safety valve
9
10
Cover plate
Joint shaft
44.4 Valve seat

44.5 Valve seat
19
Housing / valve plunger
19.1 Steering housing
44.7 Tapered plug

50.1 Stop bushing
19.2 Spool
51
21
22
51.1 Spacer plate

52
Spring carrier with centring spring
O-ring
Plug
Flat spring

22.4 Stop / pressure relief valve
55
56
Coupler
Steering shaft
23.1 Valve cone
57
Driving pin
23.2 Seal washer
59
Axial needle bearing
23.3 Cover plate
60
Washer

23.5 Valve guide
61
Backing ring
61.1 O-ring
29
30

O-ring
62
69
Spacer ring
ID tag
31
TV check valve
70
Grooved drive stud
34
35
Plug
O-ring
76
79
O-ring
Flange
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MJF C I F S S
Service Manual
Servostat
Exploded view
6 Exploded view
Fig. 2
Exploded drawing of the Servostat
copyright by
MJF C I F S S
13.20.9
Servostat
Service Manual
Exploded view
13.20.10
Rotor kit (metering pump)
29
8.1
8.2
Stator
Rotor
31
36
TV check valve
Suction valve
10
Joint shaft
44
Safety valve
19
Housing / valve plunger
19.1 Steering housing
52
56
Spring carrier with centring spring

Steering column
19.2 Spool
22
Plug
81
82
Hydraulic tank (1*)

Pump (32*)
85
Oil rotary connection (320*)
22.4 Stop / pressure relief valve

23
Stop valve
86
Steering cylinder
copyright by
MJF C I F S S
Service Manual
Servostat
Sectional drawing of the Servostat
7 Sectional drawing of the Servostat
Fig. 3
Sectional drawing and hydraulic diagram of the Servostat
copyright by
MJF C I F S S
13.20.11
Servostat
Service Manual
Exploded view of the steering column
8 Exploded view of the steering column
Fig. 4
13.20.12
Exploded view of the adjustable steering column for Servostat
1
2
Steering column
Shaft
16
17
Hex nut
Lock washer
3
4
Universal joint
Allen head screw
18
20
Hex head screw

Washer
5
6
Hex nut
Pin
21
22
Roll pin
Washer
Hex nut
23
Hex nut
8
9
Absorber
Rotating pin
24
25
Oval head screw

Base plate
10
Washer
30
Pedal (old version)
11
Hex nut
31
Washer
15
Top plate
40
Pedal (new version)
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MJF C I F S S
Service Manual
Steering valve
Function
Steering valve
1 Function
The steering valve serves as a hydraulic power assisted steering with hydrostatic transmission to the
steered wheels. It does away with a mechanical connection from the steering wheel to the steering
linkage and the steering knuckles of the steering axle.
In servo mode, the steering valve works with a rotor kit.
to be towed away.
The size for servo operation is based on the total size of the rotor kit and has been chosen in such a
way that the wheels can be moved from one stop to the other with 3 to 5 full turns of the steering
wheel.
Fig. 1
Steering valve
copyright by
MJF C I F S S
13.22.1
Steering valve
Service Manual
General information
Machine
from serial number
A 309 Li / A 311Li
20221 / 20222
A 312 / A 314
19112
Steering mode
2-wheel steering
4-wheel steering
2-wheel steering
Steering mode
Manufacturer model
Steering valve
LAGS 200/20
Steering valve
LAGS 200/20
Steering valve
LAGS 200/20
Max. flow rate
50 l/min
Valve settings:
Pressure-relief valve 5 (primary pressure)
Shock valve 6 (secondary pressure)
180+10 bar
240 10 bar
210+10 bar
260 10 bar
180+10 bar
240 10 bar
39 l/min
39 l/min
44 l/min
Pump rate of the hydraulic pump 31 / 32

Flow rate in servo operation
Flow rate in emergency operation
Pressure fluid temperature range
Tab. 1
50 l/min
200
cm3/rev
20
cm3/rev
-20 to +80 C
200
cm3/rev
200 cm3/rev
20
cm3/rev
20 cm3/rev
-20 to +80 C
-20 to +80 C
Technical data
3 Design
The steering valve consists of:
Component
Explanation
Spool 1
The spool is moved in radial direction when the steering wheel

is turned.
Control sleeve 2
The control sleeve is moved in radial and axial direction when

the steering wheel is turned. Barrel surface with radially and
axially aligned control grooves.
Rotor kit 3
In normal mode and emergency mode, the rotor kit 3 feeds

the hydraulic oil to the steering cylinders.
The valve limits the delivery pressure of the motor-driven

pump to the required maximum value (primary pressure).
Shock valves 6
The shock valves limit the oil pressure that might occur in the
lines L and R to the operating cylinder (secondary pressure).
Suction valve 7/8
This valve helps prevent cavitation in the steering system.
Check valve 9
This valve prevents impacts to the steering wheel in the event

of excessive external forces.
Housing 24
All parts of the steering valve are encased in the housing.
Tab. 2
Component parts of the steering valve
13.22.2
copyright by
MJF C I F S S
Service Manual
Steering valve
Design
Fig. 2
1
2
Design of steering valve, diagram

7
8
Spool
Control sleeve
Suction valve
Suction valve
Rotor kit
Check valve
5
6
Shock valve
24
Valve housing
copyright by
MJF C I F S S
13.22.3
Steering valve
Service Manual
Function
4 Function
see Fig. 3
4.1
Servo operation
Through the steering column, the spool 1 of the steering valve is rotated relatively to the steering sleeve 2. As a consequence, a number of matching channels are opened between the spool 1 and the
control sleeve 2. The hydraulic oil then acts on the rotor kit 3, putting it into motion. From the rotor kit
3, the hydraulic oil flows to the steering cylinder. The rotation of the two rotors acts on the sleeve 2,
which rotates together with the piston 1.
The check valve 9 prevents impacts to the steering wheel by excessive external steering forces.
The size of the opened channels depends on the turning speed of the steering wheel and the steering
pressure. If the steering movement is halted, the spool 1 comes to a standstill, while the oil still flowing
through the open channels to the rotor make the rotor and the sleeve 2 rotate further.
4.2
Neutral position
By turning the steering wheel, the channel is closed. The rotor and the steering cylinder are now in
the desired position. The centring spring 4 aligns the spool 1 and the sleeve 2 and keeps them in
neutral position. If the steering wheel is not turned, the line between the pump connection P and the
tank connection T is opened and the pump volume flow is fed to the tank at virtually no pressure. In
neutral position, the connections L and R are closed.
The system pressure in the steering cycle is limited by the pressure-relief valve 5.
The two shock valves 6 shut off the connections L and R to the steering cylinder. If one of the shock
valves 6 is opened, the escaping oil is fed through the suction valve 7/8 to the opposite side, or the
leaked oil is sucked from the tank.
4.3
Emergency operation
In the event of a failure of the gear pump (steering pump), the steering valve acts as a hand pump.
If necessary, hydraulic oil can sucked through the suction valve 8 from the tank line, whereby the
check valve 9 prevents that air is being sucked in through the pump connection P.
13.22.4
copyright by
MJF C I F S S
Service Manual
Steering valve
Cross-section of steering valve
5 Cross-section of steering valve
Fig. 3
Sectional drawing of the steering valve
Spool
14
Spacer bolt
2
3
Control sleeve
Rotor kit
15
16
Hex head screw

Cover
Centring spring
19
Thrust washer
5
6
pressure-relief valve
Shock valve
20
21
Drive shaft
Rotor gear
Suction valve
23
Needle roller
Suction valve
24
Valve housing
Check valve
copyright by
MJF C I F S S
13.22.5
Steering valve
Service Manual
Installation and dismantling of the steering valve
6 Installation and dismantling of the steering valve

see Fig. 5
6.1
Dismantling of the steering valve

Label the hydraulic lines of the steering valve, disconnect them and seal the openings (collect escaping oil).
Remove the mounting bolts M10 from the steering valve and the steering column and lift the steering valve from the base plate (if necessary, secure the loose steering column).
6.2
Installation of the steering valve

Apply grease (with lithium or calcium complex) to the missing tooth area of the spool 1.
Mount the steering valve onto the shaft 2 of the steering column.
Secure the steering valve and the steering column 1 to the base plate, using the four M10 hex
head screws (with washers) (torque: 46 Nm).
Connect the hydraulic lines to the steering valve (observe marks).
7 Repair of the steering valve

Note!
In the event of malfunction or failure of the steering valve, it may not be repaired but must be replaced for safety reasons.
Replace the defective steering valve with a new one.
Leakage repair:
Use the seal kit 999 and seal the steering valve according to the separate instructions "Dismantling and assembly for seal change".
8 Commissioning of the steering system

During commissioning, dirt particles in the line system might enter the pressure-relief valve.
Let oil flow through the system for a few minutes without turning the steering wheel, and while
changing the speed of the diesel engine.
lock, while the engine is run at a medium speed (until operating temperature is reached).
Bleed the steering system.
13.22.6
copyright by
MJF C I F S S
Service Manual
Steering valve
Troubleshooting
8.1

Caution!
Air locked in the steering circuit and the steering system components can impair steering.
As a consequence, unintended steering movements might occur, posing a risk to operator and machine.
To prevent this, bleed the system as described below:
Move the steering wheel several times from one stop to the other.
Test-drive the vehicle on a cordoned-off area.
9 Troubleshooting
In the event of malfunction, first check the oil level in the tank while the engine is running and add
oil, if necessary.
When oil is added to the hydraulic system, there is always a risk of contamination with dirt particles.
Therefore add hydraulic oil through the return filter.
10 Exploded view of the steering valve
Fig. 4
Exploded view of steering valve
copyright by
MJF C I F S S
13.22.7
Steering valve
Service Manual
11
Spool
14
Spacer bolt
Control sleeve
15
Hex head screw
Rotor kit
16
Cover
4
5
Centring spring
19
20
Thrust washer
Drive shaft
Shock valve
21
Rotor gear
7
8
Suction valve
Suction valve
23
24
Needle roller
Valve housing
Check valve
999
Seal kit
Fig. 5
13.22.8
Exploded view of steering column
Steering column
16
Hex nut
2
3
Shaft
Universal joint
17
18
Lock washer
Hex head screw
4
5
Allen head screw

Hex nut
20
21
Washer
Roll pin
Bolt
22
Washer
copyright by
MJF C I F S S
Service Manual
Steering valve
7
8
Hex nut
Absorber
23
24
Hex nut
Oval head screw
9
10
Rotating pin
Washer
25
30
Base plate
Pedal
11
15
Hex nut
Top plate
31
40
Washer
Pedal
copyright by
MJF C I F S S
13.22.9
Steering valve
Service Manual
13.22.10
copyright by
MJF C I F S S
Service Manual
Steering valve
Function
Steering valve
1 Function
The steering valve serves as a hydraulic power assisted steering with hydrostatic transmission to the
steered wheels. It does away with a mechanical connection from the steering wheel to the steering
linkage and the steering knuckles of the steering axle.
In servo operation, the steering valve works with two rotor kits. In emergency mode, one rotor kit is
switched off.
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
copyright by
MJF C I F S S
13.24.1
Steering valve
Service Manual
General information
Machine
from serial number
A 900 C-Li
14675-18087
Manufacturer model
A 904 C
16000
LAGZ 190 / 60 steering valve
Max. flow rate
50 l/min
Valve settings:
Pressure-relief valve 5 (primary pressure)
Shock valve 6 (secondary pressure)
Pump rate of the hydraulic pump 31
180 + 8 bar
240 + 10 bar
40 l/min
Settings and torques for the installation of the steering valve

Flow rate in servo operation
190 cm3/rev
Flow rate in emergency operation
60 cm3/revs
Pressure fluid temperature range
-20 to +80 C
Tab. 1
13.24.2
Technical data
copyright by
MJF C I F S S
Service Manual
Steering valve
Description
3 Description
The steering valve consists of:
Component
Description
Spool 1
The piston is moved in radial direction when the steering

wheel is turned.
Control sleeve 2
The control sleeve is moved in radial and axial direction when

the steering wheel is turned. Barrel surface with radially and
axially aligned control grooves.
Rotor kits 3/10
In servo mode, the rotor kits 3/10 feed the hydraulic oil to the
steering cylinders; in emergency mode, only the rotary kit 3.
feeds oil.
The valve limits the delivery pressure of the motor-driven

pump to the required maximum pressure (primary pressure).
Shock valves 6
The shock valves limit the oil pressure that might occur in the
lines L and R to the operating cylinder (secondary pressure).
Suction valve 7/8
This valve helps prevent cavitation in the steering system.
Check valve 9
This valve prevents impacts to the steering wheel in the event

of excessive external forces.
Changing piston 12
The piston switches off the rotor kit 10 in the event of an emergency
Housing 24
All parts of the steering valve are encased in the housing.
Tab. 2
3.1
Component parts of the steering valve
Control valve
The control valve consists of the spool 1 and the control sleeve 2, which is located inside the spool
and can be rotated and moved in axial direction. Its barrel surface is equipped with control grooves
aligned in radial and axial direction. These grooves match channels in the valve bore of the housing.
copyright by
MJF C I F S S
13.24.3
Steering valve
Service Manual
Fig. 2
Design of the steering valve
1
2
Spool
Control sleeve
9
10
Check valve
Rotor kit 2
3
5
Rotor kit 1
11
12
Changeover housing
Changing piston
Shock valve
13
Pressure spring
7
8
Suction valve
Suction valve
24
Valve housing
see Fig. 3
4.1
Servo operation
Through the steering column, the spool 1 of the steering valve is rotated relatively to the steering sleeve 2. As a consequence, a number of channels are opened between the spool 1 and the sleeve 2.
The hydraulic oil then acts on the rotor kits 3 and 10, putting them into motion. From the rotor kits,
the hydraulic oil flows to the steering cylinder. The rotation of the two rotors acts on the sleeve, which
rotates together with the piston 1.
The size of the opened channels depends on the turning speed of the steering wheel. If the steering
movement is halted, the spool 1 comes to a standstill, while the oil still flowing through the open channels to the rotor let the rotor and thus the sleeve 2 rotate further.
4.2
Neutral position
By turning the steering wheel, the channels are closed. The rotor and thus the steering cylinder remain in the desired position. The centring spring 4 thereby moves and then secures the spool 1 and
the sleeve 2 in their neutral position. While the steering wheel is not operated, the line between port
(P) and the tank connection (T) is open and the pump flow is fed at very low pressure to the tank. In
neutral position, the connections L and R are closed.
13.24.4
copyright by
MJF C I F S S
Service Manual
Steering valve
The system pressure in the steering cycle is limited by the pressure relief valve 5.
The two shock valves 6 shut off the connections L and R to the steering cylinder. If one of the shock
valves is opened, the escaping oil is fed through the suction valve 7/8 to the opposite side or the leaked oil is sucked from the tank respectively.
4.3
Emergency operation
In the event of a failure of the hydraulic pump, the steering valve acts as a hand pump. In such a case,
the supply pressure (control pressure for the changing pistons) drops to zero. The spring 13 moves
the changing piston 12 into its initial position so that the chambers of the rotor kit 10 are connected
to the chamber. Simultaneously, the connection between the rotor kits is blocked. The volumetric displacement of the steering unit is thus reduced by the volume of the rotor kit 10. The rotor kit 3 determines the volumetric displacement during normal operation.
If necessary, hydraulic oil is sucked through the suction valve 8 from the tank line, whereby the check
valve 9 prevents that air is being sucked in through the pump connection (P). In normal operation,
the valve 9 prevents impacts to the steering wheel by excessive external steering forces.
5 Sectional drawing of the steering valve
copyright by
MJF C I F S S
13.24.5
Steering valve
Service Manual

Fig. 3
Spool
13
Pressure spring
2
3
Control sleeve
Rotor kit 1
14
15
Spacer bolt
Hex head screw
Centring spring
16
Cover
17
Rotor gear 2
Shock valve
18
Washer
Suction valve
19
Thrust washer
Suction valve
20
Drive shaft
9
10
Check valve
Rotor kit 2
21
22
Rotor gear 1
Splined shaft
11
Changeover housing
23
Needle roller
12
Changing piston
24
Valve housing
6 Installation and dismantling of the steering valve

Note!
For safety reasons, replace the valve if you experience any problems in relation to the steering valve. Leakage can be sealed with a seal kit 999 available from LIEBHERR.
6.1
Dismantling of the steering valve

Note!
Before dismantling the steering valve, take all measures necessary to secure and block the machine
(see group 1).
Label the hydraulic lines of the steering valve, disconnect them and seal the openings (collect escaping oil).
Remove the M10 mounting bolts from the steering valve and the steering column and lift the steering valve from the base plate (if necessary, secure the loose steering column).
6.2
Installation of the steering valve, see Fig. 5

Note!
In order to ensure proper functioning of the steering valve and the entire steering system, ensure
that all components of the system and all lines are kept clean. To prevent foreign bodies and dirt
from entering the steering oil circuit, do not remove the plugs sealing the lines to the steering valve,
oil pump, operating cylinder, valves, etc. until they are finally reconnected. Carefully deburr and
clean all line ends and screw connections.
Apply grease (with lithium or calcium complex) to the missing tooth area and mount the steering
valve on the shaft 2 of the steering column.
Secure the steering valve and the steering column 1 to the base plate, using the four M10 hex
head screws (with washers) (torque: 46 Nm).
13.24.6
copyright by
MJF C I F S S
Service Manual
Steering valve
Connect the hydraulic lines to the steering valve (observe marks).
copyright by
MJF C I F S S
13.24.7
Steering valve
Service Manual
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.
lock, while the engine is run at a medium speed (until the operating temperature is reached). Bleed
the steering system.
6.4

Start the diesel engine and operate the steering several times by turning the wheels from one end
position to the other.
Test drive the vehicle on a cordoned-off off-road area.
Subsequently bleed the steering system by turning the steering wheel several times moving the
wheels from one stop position to the other while the engine is on. Please note that the use of oils that
tend to foam may lead to malfunction, as such oils tend to keep air trapped so that the system cannot
be properly bled.
6.5
Troubleshooting
In the event of malfunction, first check the oil level in the tank while the engine is running and add oil,
if necessary. When oil is added to the hydraulic system, there is always a risk of contamination with
dirt particles. In order to prevent malfunctions caused by dirt in the system, always pay particularly
attention to cleanliness when filling oil into the system.
13.24.8
copyright by
MJF C I F S S
Service Manual
Steering valve
Exploded view of the steering valve
7 Exploded view of the steering valve
Fig. 4
Exploded drawing of the steering valve
Spool
14
Spacer bolt
2
3
Control sleeve
Rotor kit 1
15
16
Hex head screw

Cover
Centring spring
17
Rotor gear 2
18
Washer
Shock valve
19
Thrust washer
7
8
Suction valve
Suction valve
20
21
Drive shaft
Rotor gear 1
Check valve
22
Splined shaft
10
Rotor kit 2
23
Needle roller
11
12
Changeover housing
Changing piston
24
999
Valve housing
Seal kit
13
Pressure spring
copyright by
MJF C I F S S
13.24.9
Steering valve
Service Manual
Exploded view of the steering valve
7.1
Fig. 5
13.24.10
Exploded view of the adjustable steering column for Servostat
1
2
Steering column
Shaft
16
17
Hex nut
Lock washer
3
4
Universal joint
Allen head screw
18
20
Hex head screw

Washer
5
6
Hex nut
Pin
21
22
Roll pin
Washer
Hex nut
23
Hex nut
8
9
Absorber
Rotating pin
24
25
Oval head screw

Base plate
10
11
Washer
Hex nut
30
31
Pedal
Washer
15
Top plate
40
Pedal
copyright by
MJF C I F S S
Service Manual
Steering cylinders
Design and function
Steering cylinders
1 Design and function
see Fig. 4
The steering cylinder is integrated into the cast housing of the differential of the steering axle.
The steering cylinder is of the synchronous cylinder design (i.e. cylinder with piston rods on both sides).
The two rod ends are connected by joint tie rods and ball joints to the joint housings (steering knuckles). The piston rod with the attached piston moves in axial direction, thereby moving the steering
knuckles from one steering stop to the other.
The connections L and R of the Servostat / steering valve of the steering system are linked through
hydraulic hoses and the oil rotary connection to the left or right connection of the steering cylinder
respectively, see also steering system, group 13.
Fig. 1
Steering cylinder on the steering axle
copyright by
MJF C I F S S
13.32.1
Steering cylinders
Service Manual
Replacement of the steering cylinder sealing elements
2 Replacement of the steering cylinder sealing elements

Note!
The sealing elements can be replaced without removing the steering axle or the differential. The figures below are sections from the sectional drawing (see Fig. 4).
Please also refer to the separate repair manual "Dana axles 112 / 212" or "Dana axles 162 / 262".
Danger!
To dismantle and mount the steering cylinder while the steering axle is built in, you must access the
undercarriage of the machine. There is a risk of death to the technician, as limbs could become
crushed.
Lift the undercarriage and secure the lifted undercarriage with suitable props.
Association (Tiefbau-Berufsgenossenschaft).
2.1
Dismantling of steering system and removing steering cylinder from the differential
see Fig. 2
Unlock and remove the slotted nuts 5.22.
Disconnect the joint tie rods 5.20 with the ball joints from the joint housing 3.26 / 3.27.
Heat up the joint tie rods 5.20 at the piston rod 5.5 (secured with Loctite) and screw them from the
piston rod 5.5.
Complete the following steps, if necessary, for example for the complete replacement of the steering
cylinder 5.3:
Remove the mounting screws between the steering cylinder 5.3 and the differential and pull the
steering cylinder 5.3 from the differential, see also groups 12.02, 12.10, 12.20.
Note!
It is possible to reseal the built-in steering cylinder by proceeding as described below:
2.2
Dismantling of steering cylinder

see Fig. 3
Remove the snap ring 5.1.
Push the cylinder head 5.2 inwards and push the circlip 5.4 from the recess, using a pin and moving the circlip over the bore at the cylinder 5.3.
Pull the cylinder head 5.2 and the piston rod 5.5 together with the piston and the sealing elements
5.6 - 5.13 from the cylinder 5.3.
Remove the sealing elements from the piston 5.5.
Remove the seals 5.6 - 5.8 from the cylinder 5.3.
13.32.2
copyright by
MJF C I F S S
Service Manual
Steering cylinders
Fig. 2
Steering cylinder with steering system on the steering axle
3.26
Left joint housing
5.22
Slotted nut
5.3
Cylinder
5.23
Cotter pin
5.5
5.20
Piston rod
Joint tie rod
5.24
Guard ring
Fig. 3
Section of the sectional drawing of the steering cylinder
5.1
Snap ring
5.8
Scraper ring
5.2
5.3
Cylinder head
Cylinder
5.9
5.10
Seal ring
Guide ring
5.4
Circlip
5.11
Guide ring
5.5
Piston rod with piston
5.12
O-ring
copyright by
MJF C I F S S
13.32.3
Steering cylinders
Service Manual

5.6
5.7
2.3
5.13
Seal ring
Backing ring
Seal ring
Mounting of steering cylinder

see Fig. 3
Carefully clean all parts and remove all foreign objects.
Check all parts for damage. Reuse only undamaged parts.
If the piston rod is irreparably damaged (impact damage, ridges), replace it.
Do not use tools with sharp edges.
Before mounting components and sealing elements, treat them with hydraulic oil.
Place/insert all sealing elements in the correct sequence (see Fig. 4) on/in the piston 5.5, cylinder
5.3 and cylinder head 5.2.
When inserting the seal and backing rings, ensure that they are in the correct position, see Fig. 4.
Place the guide piece (special tool according to repair instructions) on the piston rod 5.5 and drive
the piston rod 5.5 with piston and sealing elements into the cylinder 5.3 until the piston is inserted
by approx. 100 mm into the cylinder 5.3 (use a mallet, if required).
Place the guide piece on the cylinder side of the piston rod 5.1.
Slide the cylinder head 5.2 onto the piston rod 5.5 and push it into the cylinder 5.3 until it is flush
with the cylinder edge.
Insert the circlip 5.4 and ensure that the grooves of the cylinder 5.3 are aligned correctly.
Using a screwdriver or lever, push the cylinder head 5.2 back to the stop at the circlip 5.4.
Insert the snap ring 5.1.
2.4
Mounting of steering system

see Fig. 2
Apply Loctite 242 to the thread of the tie rod 5.20.
Screw the tie rod 5.20 to the stop into the piston rod 5.5 (tightening torque = 350 Nm). Ensure that
the heads are facing in the same direction.
Check the guard ring 5.24 of the ball joint for proper seat.
Insert the tie rods 5.20 with the ball joints in the joint housing 3.26 / 3.27.
Screw on the slotted nut 5.22 (tightening torque 260 - 290 Nm).
Secure the slotted nuts 5.22 with the cotter pins 5.23.
Note!
If the wheels must be realigned, please follow the instructions in the separate repair manual "112 /
212 Dana axles" or "162 / 262 Dana axles".
13.32.4
K
5.1
Piston seal
Snap ring
Z
5.8
Cylinder head seal

Scraper ring
5.2
5.3
Cylinder head
Cylinder
5.9
5.10
Seal ring
Guide ring
copyright by
MJF C I F S S
Service Manual
Steering cylinders
Sectional drawing of the steering cylinder
5.4
5.5
Circlip
5.11
5.12
Guide ring
O-ring
5.6
Seal ring
5.13
Seal ring
5.7
Backing ring
3 Sectional drawing of the steering cylinder
Fig. 4
copyright by
MJF C I F S S
13.32.5
Steering cylinders
Service Manual
13.32.6
copyright by
MJF C I F S S
Service Manual
Steering cylinders
Design and function
Steering cylinders
see Fig. 5
The steering cylinder is integrated into the differential of the steering axle.
The cylinder 1 and the two piston rod guides 4 and 20 are mounted in the cast housing of the axle
housing.
The steering cylinder is of the synchronous cylinder design (i.e. cylinder with piston rods on both sides).
The two rod ends are connected by the tie rods 24 and the ball joints to the joint housings 30 (steering
knuckles). The piston rod 8 with the attached piston 9 moves in axial direction, thereby moving the
steering knuckles from one steering stop to the other.
The connections L and R of the Servostat / steering valve of the steering system are linked via hydraulic hoses and the oil rotary connection to the left or right connection of the steering cylinder respectively, see also steering system, group 13.
Fig. 1
copyright by
MJF C I F S S
13.34.1
Steering cylinders
Service Manual
2 Replacement of the steering cylinder sealing elements

Note!
The sealing elements can be replaced without removing the steering axle or the differential. The figures below are sections from the sectional drawing (see Fig. 5).
Please also refer to the separate repair manual "APL-B 745 / APL-B 755 ZP planetary axles".
Danger!
To dismantle and mount the steering cylinder while the steering axle is built in, you must access the
undercarriage of the machine. There is a risk of death to the technician, as limbs could become
crushed.
Lift the undercarriage and secure the lifted undercarriage with suitable props.
Association (Tiefbau-Berufsgenossenschaft).
2.1
Dismantling
Fig. 2
Cylinder
23
Axial joints
Piston rod
24
Tie rod
17
Washers
26
Stop ring
20
Guide
28
Slotted nut
21
Hex head screw
31
Axle housing
Unlock and remove the slotted nuts 28.

Disconnect the tie rods 24 with ball joints from the joint housings.
Move the stop ring 26 along the piston rod 8.
Warm up the connection of the right tie rod 24 to the piston rod (secured with Loctite).
13.34.2
copyright by
MJF C I F S S
Service Manual
Steering cylinders
Disconnect the axial joints 23 from the piston rod 8.
Remove the stop ring 26.
Pull the guide 20 from the axle housing 31 and the piston rod 8 (hold washers 17).
Pull the piston rod 8 from the cylinder 1.
Remove the sealing elements from the piston 9 and the piston rod guides 4 and 20 (see Fig. 5).
If required, pull the cylinder 1 and the guide 4 from the axle housing.
Check the O-rings 2, 3 and 5 and reuse, if possible.
2.2
Installation, see Fig. 5
Fig. 3
Section of the sectional drawing of the steering cylinder
Cylinder
Guide
Carefully clean all parts and remove all foreign objects.

Check all parts for damage. Reuse only undamaged parts.
If the piston rod is irreparably damaged (impact damage, ridges), replace them.
Do not use tools with sharp edges.
Before mounting components and sealing elements, treat them with hydraulic oil.
Mount all sealing elements in the correct sequence (see Fig. 4) on the cylinder 1, in the guides 4 and
20 and on the piston 9.
Insert the guide 4 and the cylinder 1 in the axle housing 31.
Mount the complete piston rod 8, using a piston tightening strap or a special slip bushing.
Place all previously removed washers 17 in the guide 20, using grease as an adhesive.
Note!
For new cylinders or guides 4 and 20, first determine the number of washers required (see repair
manual "APL-B 745 / APL-B 755 ZP planetary axles").
copyright by
MJF C I F S S
13.34.3
Steering cylinders
Service Manual
Exploded view
Mount the guide 20 and secure it with the screws 21 (tightening torque 190 Nm).
Apply a little grease onto the stop ring 26 and the O-ring 27 and slide them onto the piston rod 8.
Note!
The thickness of the stop ring 26 determines the steering angle. The permissible maximum steering
angle of the wheel is prescribed by the manufacturer and may not be exceeded.
If the wheels must be realigned, please follow the instructions in the separate repair manual "APLB 745 / APL-B 755 ZP planetary axles".
Screw the complete tie rod 24 with the axial joint 23 (thread treated with Loctite 242) into the piston
rod 8 to the stop (ensure that the heads are facing in the same direction).
Tighten the axial joints 23 (torque = 350 Nm)
Insert the tie rods 24 with the ball joints in the joint housings 30 and secure them with the slotted
nuts 28 (tightening torque 300 Nm).
Secure the slotted nuts 28 with the cotter pins 29.
3 Exploded view
Fig. 4
13.34.4
Exploded drawing of the steering valve
copyright by
MJF C I F S S
Service Manual
Steering cylinders
Sectional drawing
10
Cylinder
400
Stop ring
30
70
O-ring
Guide
460
550
O-ring
Tie rod (left)
80
O-ring
560
Tie rod (right)
150
Scraper ring
600
Axial joint
160
Lip seal
605
Bellows
170
240

Seal ring
610
611
Right ball joint

Left ball joint
250
280
Scraper
Washer
620
630
Clamp
Slotted nut
320
350
Guide
Hex head screw
640
700
Cotter pin
Axle housing
4 Sectional drawing
Fig. 5
Sectional drawing of the steering cylinder and the axial joint
copyright by
MJF C I F S S
13.34.5
Steering cylinders
Service Manual
Sectional drawing
13.34.6
Item
ET item
10
2
4
Designation
Item
ET item
Designation
Cylinder
21
350
Hex head screw
30
O-ring
23
600
Axial joint
70
Guide
24
550
Right tie rod
80
O-ring
560
Left tie rod
250
Scraper ring
610
Right ball joint
160
Lip seal
611
Left ball joint
170
Piston rod
620
Clamp
25
180
Piston
26
400
Stop ring
15
240
Sealing ring
27
460
O-ring
16
150
Scraper
28
17
280
Washer, of various thickness
29
20
320
Guide
copyright by
MJF C I F S S
Right /left joint housing

700
Axle housing
Service Manual
4-wheel steering
Function
4-wheel steering
1 Function
Four-wheel steering allows you to use and manoeuvre the machine in confined spaces.
In order to access loading bays with ease, the steering can be switched over to crab steer mode. In
this mode, the wheels of the rear axle are moved in the same direction (i.e. parallel) to those of the
front axle.
Fig. 1
Steered front and rear axle wheels with 4-wheel steering valve
copyright by
MJF C I F S S
13.50.1
4-wheel steering
Service Manual
Description
2 Description
2.1
Steering pump 32
The hydraulic pump 32 is a gear pump and is flange-mounted to the diesel engine.
The pump sucks hydraulic oil from the tank and feeds it through the steering valve 92 and the steering
valve 84 to the respective side of the steering cylinder.
For additional protection, the pump 32 is equipped with the flange-mounted pressure-relief valve 88.
2.2
Steering valve 84
The steering valve 84 is located at the base of the steering column and is connected to the steering
wheel in the operator's cab.
It contains the valve actuators (way valve), the safety valves (primary and secondary pressure relief)
and the hand pump for emergency operation.
The oil is pumped from the pump 32 through the pressure port P to the steering valve. When the steering wheel is turned, the working connection L or R, through the rotary connection 260, pressurises
the respective components in the undercarriage, including the shift valve 94 and the steering cylinder
86-1/ 86-2,. For details, see the description of functions of the various components. The return oil
flows through the tank connection T back to the tank.
Fig. 2
a
Gear pump, steering column and steering valve

84 Steering valve
Steering column
32 Gear pump / steering
2.3
88 Pressure-relief valve
Steering valve 92 for centring

The steering valve 92 located below the operator's cab base plate ensure that the wheels are automatically reset to their neutral position (centred) before a different steering mode is selected.
The 6/3-way valve is an electro hydraulic valve containing the solenoids Y294-1 and Y294-2. The
main valve is operated through a pilot control valve pressurised with control pressure.
The steering control A134 powers the respective solenoids Y294-1 and Y294-2. The wheels are the
automatically moved by steering pump to their neutral position.
13.50.2
copyright by
MJF C I F S S
Service Manual
4-wheel steering
Description
2.4
Shift valve 94 for the switching between steering modes

The steering cylinder 86-1 / 86-2 is operated via the shift valve 94 equipped with the solenoids Y2291 and Y229-2 and mounted in the undercarriage.
The steering control A134 powers the respective solenoids Y229-1 and Y229-2. The steering cylinders 86-1 and 86-2 are then pressurised with hydraulic oil, and the wheels are turned parallel to each
other or in opposite directions respectively.
2.5
Load-holding valve 98
The load-holding valve 98 protects the rear axle against pressure peaks that might occur when external forces interfere with the system. The vehicle meets the TUEV requirements for travel on public
roads.
Fig. 3
2.6
6/3-way shift valve in upper carriage and 4/3-way shift valve and load-holding valve in undercarriage
92
6/3-way shift valve (wheel centring)
Y229-1 Solenoid shift valve for crab steer mode
94
4/3-way shift valve (changeover)
Y229-2 Solenoid shift valve for 4-wheel steering
98
Load-holding valve
Y294-1 Solenoid shift valve for wheel centring

Rotary connection 260

The seven-fold oil rotary connection is a special connection for hydraulic oil between the uppercarriage and the undercarriage and is located at the centre of the slewing ring.
2.7
Steering cylinders 86-1 / 86-2

The steering cylinders 86-1/86-2 are integrated into the differential of the front and rear axles.
They are actuated with pressure oil from the steering valve 84, so that the steering knuckles are moved with every axial movement of the piston rod to which they are connected. As a result, the steering
angle of the vehicle wheels is changed.
copyright by
MJF C I F S S
13.50.3
4-wheel steering
Service Manual
Description
Fig. 4
86-1
86-2
2.8
Rotary connection, slip ring rotary connection and steering cylinders

260
265
Front axle steering cylinder

Rear axle steering cylinder
Slip ring rotary connection 9x
Electronic control system A 134

The components of the 4-wheel steering system are controlled and monitored by the steering system
A134 in the electronic box, (see 7, page 26).
When switching from one steering mode to another, the box A134 controls the centring of the wheels
(return to neutral position).
Fig. 5
2.9
Electronic steering system A134, mounted to the revolving desk below the operator's cab
Rotary switch S309 and indicator lights H191 / 192

The steering mode can be preselected by means of the rotary switch S309 located in the left control
console.
The indicator lights H191 / H192 indicate the selected mode to the machine operator.
13.50.4
copyright by
MJF C I F S S
Service Manual
4-wheel steering
Operation of the 4-wheel steering
Fig. 6
Rotary switch and indicator lights
H191
Indicator light / 4-wheel steering
H192
Crab steer indicator light
S309
Selection switch for 2-wheel/4-wheel/

crab steer mode
3 Operation of the 4-wheel steering

Apart from standard 2-wheel steering, machine is equipped with two additional steering modes.
Steering mode
Characteristics
2-wheel steering
Front axle steering.

Steering movement when turning to left=Front axle left
Steering movement when turning to right=Front axle right
Rear axle steering is blocked.
4-wheel steering
When the steering wheel is turned, the front and rear

wheels are moved in opposite directions.
= Rear axle right
= Rear axle left
The turning circle is smaller.
Crab steer mode
When the steering wheel is turned, the front and rear

wheels are moved in the same direction, i.e. parallel.
= Rear axle left
= Rear axle right
The machine can now move sideward.
Tab. 3-1
Characteristics and advantages of the available steering modes
copyright by
MJF C I F S S
13.50.5
4-wheel steering
Service Manual
3.1
Switching to desired steering mode (steering mode preselection)

Danger!
For safety reasons, the steering modes "4-wheel" and "crab steer" may not be used when travelling
on public roads.
When travelling on public roads, use only 2-wheel steering.
3.1.1
Start conditions for steering mode preselection

To switch to a particular steering mode, ensure that the following conditions are fulfilled:
Diesel engine is running.
The travelling direction switch S263 is in neutral position 0.
The lever of the safety switch S7 is pushed down.
The servo steering switch S35 is on.
Note!
To switch from one steering mode to another, the wheels of both axles must be aligned to their
neutral position (centred). This can be done with suitable manoeuvres carried out by the operator.
Alternatively, the machine can align the wheels automatically one after the other. If the machine
is placed on uneven ground, this might however not be possible.
If necessary, relieve the axles, using the supports or the attachment.
If the machine is switched to a different steering mode while the start conditions, see 3.1.1 are not
met, the command is ignored and the buzzer H27(at the rear of the right control console) is activated
for short period. The machine remains in its current steering mode. If the start conditions are subsequently met, the preselection switch S309 must be actuated again in order to start the changeover
procedure.
Normally, the rear axle is aligned first, while the front wheels are trailing. The machine subsequently
aligns the front wheels (monitored with proximity switches B248-H / B248-V)
When switching from 4-wheel steering or crab steer mode to 2-wheel steering, the front axle is not
aligned separately.
3.1.2
Switching to 4-wheel steering

Ensure that the above start conditions are met.
Turn the switch S309 to position 1.
The machine cannot be moved (travel lock).
A audible warning signal is issued, and the indicator light H191 flashes while the wheels are
being aligned. When this process is completed, the indicator light is permanently on.
4-wheel steering is now enabled, and the travel lock is released.
3.1.3
Switching to crab steering

A audible warning signal is issued, and the indicator light H192 flashes while the wheels are
being aligned. When this process is completed, the indicator light is permanently on.
crab steer mode is now enabled, and the travel lock is released.
3.1.4
Switching to 2-wheel steering

13.50.6
copyright by
MJF C I F S S
Service Manual
4-wheel steering
A audible warning signal is issued, and the two indicator lights H191 and H192 are flashing
while the wheels are being aligned. When this process is completed, the light is off.
2-wheel steering is now enabled, and the travel lock is released.
Note!
If one of the above start conditions is interfered with while the steering is being switched over,
the changeover process is aborted.
This results in an error and is indicated by the alternating flashing of the two indicator lights H191
and H192. In this status, the travel lock is released, and the steering is reset to 2-wheel steering.
The desired steering mode can be selected again after the start conditions are met.
Caution!
In the event of an error, the steering angle of the rear axle might not correspond to the selected steering mode. This might result in unexpected movements of the machine.
Therefore, turn the switch S309 to position 0 and restart the changeover procedure.
Fig. 7
Operator's cab with safety switch, servo switch, travelling direction switch, preselection
switch and steering mode indicator lights
H191 Indicator light / 4-wheel steering
S35
H192 Indicator light / crab steer mode

S7
Safety switch with lever

S309 Selection switch for 4-wheel/crab steer
mode
copyright by
MJF C I F S S
13.50.7
4-wheel steering
Service Manual
4 Function of the steering system

Note!
In the following chapter, the steering functions are described for steering to the right. They apply
accordingly to steering to the left.
For information regarding the settings of the pressure-relief valves of the steering system, refer to
group 13.10.
The function of the steering valve 84 is described in group 13.22.
4.1
Neutral position
Steering wheel not turned, switch S309 in position 0
Shift valves 92 and 94 in neutral position
The oil is fed by the gear pump 32 through the valve 92 connection P-T and the steering valve 84
connection P-T and flows back to the tank 1.
13.50.8
from/to tank
A134
31
Gear pump / low-pressure circuit +

brake
B248-H Proximity switch rear axle
32
B248-V Proximity switch front axle
33
Gear pump / steering with pressurerelief valve

MP2
Ground connection
50
83

Measuring point for steering pressure
S309
U16
Selection switch / 4-wheel steering

84
86-1
Steering valve
Y229-1 Solenoid shift valve for crab steering

4-wheel steering control
86-2
88P
88T
Distributor
Collecting pipe
92
94
6/3-way shift valve

4/3-way shift valve
98
Load-holding valve
260
265
copyright by
MJF C I F S S
Service Manual
4-wheel steering
Fig. 8
4-wheel steering in neutral position
copyright by
MJF C I F S S
13.50.9
4-wheel steering
Service Manual
4.2
2-wheel steering
Steering wheel turned to right, switch S309 in position 0
Shift valves 92 and 94 in neutral position
The oil is fed by the gear pump 32 through the valve 92 connection P-T, the steering valve 84 connection P- R, the shift valve 92 connection A (blocked), the rotary connection 260 connection 5, and
the shift valve 94 connection T-P to the right port of the steering cylinder 86-1.
The wheels of the front axle are moved to the right, and the vehicle travels to the right.
The return oil flows from the left side of the steering cylinder 86-1 through the rotary connection 260
connection 6 and the steering valve 84 connection L - T to the tank 1.
The wheels of the rear axle are not steered.
1
from/to tank
A134
31

brake

MP2
S309
Ground connection
32
33
50
13.50.10
83
U16
84
86-1
Steering valve

86-2
88P

Distributor

88T
92
Collecting pipe
6/3-way shift valve
94
4/3-way shift valve
98
260
Load-holding valve
265
copyright by
MJF C I F S S
Service Manual
4-wheel steering
Fig. 9
2-wheel steering
copyright by
MJF C I F S S
13.50.11
4-wheel steering
Service Manual
4.3
4-wheel steering
The shift valve 92 is in neutral position. The solenoid valve Y229-2 is powered (shift valve 94
in working position I), the indicator light H191 is on.
The oil is fed by the gear pump 32 through the valve 92 connection P-T, the steering valve 84 connection P- R, the shift valve 92 connection A (blocked), the rotary connection 260 connection 5, the
shift valve 94 connection T-B and the load-holding valve 98 connection V1-C1 to the right port of the
steering cylinder 86-2.
The wheels of the rear axle are moved to the left.
The built up pressure opens the stop valve of the load-holding valve 98.
The displaced oil from the left side of the steering cylinder 86-2 is fed through the load-holding valve
98 connection C2- V2, and the valve 94 connection A-P, pressurising the right connection of the steering cylinder 86-1.
The wheels of the front axle are moved to the right, and the vehicle travels to the right.
1
31
32
33
50
13.50.12
from/to tank
brake
A134 4-wheel steering control

MP2
S309
Ground connection
83
U16
84
86-1
Steering valve

86-2
88P

Distributor

88T
92
Collecting pipe
6/3-way shift valve
94
4/3-way shift valve
98
260
Load-holding valve
265
copyright by
MJF C I F S S
Service Manual
4-wheel steering
Fig. 10
4-wheel steering
copyright by
MJF C I F S S
13.50.13
4-wheel steering
Service Manual
4.4
Crab steering
The steering valve 92 is in neutral position and the shift valve 94 is in working position II.
The indicator lamp H192 is on.
The oil is fed by the gear pump 32 through the valve 92 connection P-T, the steering valve 84 connection P- R, the shift valve 92 connection A (blocked), the rotary connection 260 connection 5, the
shift valve 94 connection T-B and the load-holding valve 98 connection V2-C2 to the left port of the
steering cylinder 86-2.
The wheels of the rear axle are moved to the right.
The displaced oil from the right side of the steering cylinder 86-2 is fed through the valve 98 connection C1- V1, and the valve 94 connection B-P, pressurising the right connection of the steering cylinder 86-1. The wheels of the front axle are moved to the right, and the vehicle travels to the right.
1
31
32
13.50.14
from/to tank
brake
A134 4-wheel steering control

33
50

MP2
S309
83
84

Steering valve
U16
86-1
86-2
88P

Distributor

88T
92
Collecting pipe
6/3-way shift valve
94
4/3-way shift valve
98
260
Load-holding valve
265
copyright by
MJF C I F S S
Ground connection
Service Manual
4-wheel steering
Fig. 11
Crab steering
copyright by
MJF C I F S S
13.50.15
4-wheel steering
Service Manual
4.5
4.5.1
Reset (centring) of wheels prior to switching to a different steering mode

Centring from 2-wheel steering mode after steering to the right
The steering wheel is not turned.
The start conditions, (see 3.1.1, page 6), are met.
The proximity switch B248-V sends a signal to A134 (steering cylinder 86-1 not in neutral position).
The solenoid Y294-2 is powered through the steering control system A134.
The shift valve 92 is in working position II and the shift valve 94 is in neutral position.
The oil is fed by the gear pump 32 through the valve 92 connection P-B and the rotary connection
260 connection 6 and flows to the left port of the steering cylinder 86-1.
The wheels of the front axle are aligned for forward travel (centre position).
The return oil from the right side of the steering cylinder 86-1 flows through the valve 94 connection
P-T, the rotary connection 260 connection 5 and the valve 92 connection A-T1 back to the tank 1.
from/to tank
A134
31

brake
32
13.50.16
33
MP2
Ground connection
50
83

S309
U16

84
86-1
Steering valve

86-2
88P
88T
Distributor
Collecting pipe
92
94
6/3-way shift valve

4/3-way shift valve
98
260
Load-holding valve
265
copyright by
MJF C I F S S
Service Manual
4-wheel steering
Fig. 12
Centring from 2-wheel steering mode
copyright by
MJF C I F S S
13.50.17
4-wheel steering
Service Manual
4.5.2

The proximity switches B248-H and B248-V send a signal to A134 (steering cylinders 86-1 and
86-2 not in neutral position).
The solenoids Y229-2 and Y294-2 are powered through the steering control system A134.
The shift valve 92 is in working position II and the shift valve 94 is in working position.I.
The displaced oil from the right side of the steering cylinder 86-1 is fed through the valve 94 connection P-A, and the valve 98 connection V2 - C2, pressurising the left connection of the steering cylinder
86-2.
C1 - V1, valve 94 connection B-T, the rotary connection 260 connection 5 and the valve 92 connection
A-T1 back to the tank 1.
The wheels of the rear axle are aligned for forward travel (centre position).
The proximity switch B248-H sends a signal to A134 (steering cylinder 86-2 is in neutral position).
The solenoid Y229-2 is not powered through the steering control system A134.
The shift valve 94 is set to its neutral position.
P-T, the rotary connection 260 connection 5 and the valve 92 connection A - T1 back to the tank 1.
from/to tank
A134
31

brake
32
13.50.18
33
MP2
Ground connection
50
83

S309
U16

84
86-1
Steering valve

86-2

88P
Distributor
88T
Collecting pipe
92
94
6/3-way shift valve

4/3-way shift valve
98
Load-holding valve
260
265
copyright by
MJF C I F S S
Service Manual
4-wheel steering
Fig. 13
copyright by
MJF C I F S S
13.50.19
4-wheel steering
Service Manual
4.5.3
Centring from crab steering mode after steering to the right

The proximity switches B248-H and B248-V send a signal to A134 (steering cylinders 86-1 and
86-2 not in neutral position).
The solenoids Y229-1 and Y294-2 are powered through the steering control system A134.
The shift valve 92 is in working position II and the shift valve 94 is in working position II.
The displaced oil from the right side of the steering cylinder 86-1 is fed through the valve 94 connection P-B, and the valve 98 connection V1 - C1, pressurising the right connection of the steering cylinder 86-2.
The return oil from the left side of the steering cylinder 86-2 flows through the valve 98 connection
C2 - V2, valve 94 connection A-T, the rotary connection 260 connection 5 and the valve 92 connection
A - T1 back to the tank 1.
The wheels of the rear axle are aligned for forward travel (centre position).
The proximity switch B248-H sends a signal to A134 (steering cylinder 86-2 is in neutral position).
The solenoid Y229-1 is not powered through the steering control system A134.
The shift valve 94 is set to its neutral position.
P-T, the rotary connection 260 connection 5 and the valve 92 connection A - T1 back to the tank 1.
from/to tank
A134
31

brake
32
13.50.20
33
MP2
Ground connection
50
83

S309
U16

84
86-1
Steering valve

86-2

88P
Distributor
88T
Collecting pipe
92
94
6/3-way shift valve

4/3-way shift valve
98
Load-holding valve
260
265
copyright by
MJF C I F S S
Service Manual
4-wheel steering
Fig. 14
Centring of wheels from crab steer mode
copyright by
MJF C I F S S
13.50.21
4-wheel steering
Service Manual
Components and hydraulic lines

Note!
For details regarding the pressure settings of the steering system, refer to group 13.10.
5 Components and hydraulic lines
Fig. 15
13.50.22
Components in uppercarrige
Hydraulic tank
88T
Collecting pipe
32
Gear pump
92
6/3-way shift valve (wheel centring)
83
260
Rotary connection
84
Steering valve
Y294-1 Solenoid
88P
Distributor
Y294-2 Magnet
copyright by
MJF C I F S S
Service Manual
4-wheel steering
Fig. 16
Components in undercarriage
86-1
Front steering cylinder
260
Rotary connection
86-2
Rear steering cylinder
265
94
4/3-way shift valve (steering changeover)
Y294-1 Solenoid
98
Load-holding valve
Y294-2 Solenoid
copyright by
MJF C I F S S
13.50.23
4-wheel steering
Service Manual
Electrical system
6 Electrical system
Fig. 17
13.50.24
Electrical components in uppercarriage
A127
KS
A134
F356

Fuse / 4-wheel steering, terminal 15
S309 Selection switch / 4-wheel steering

X1117 Plug connection / 4-wheel steering, 6pin
Wire harness of potentiometer board

A125
F357
Fuse / 4-wheel steering, terminal 30
H191
H192

copyright by
MJF C I F S S
Service Manual
4-wheel steering
Electrical system
Fig. 18
265
Electrical components in undercarriage
Y294-1 Solenoid / crab steer mode
Y229-2 Solenoid / 4-wheel steering
S272
Junction box / undercarriage
copyright by
MJF C I F S S
13.50.25
4-wheel steering
Service Manual
Block diagram of 4-wheel steering
7 Block diagram of 4-wheel steering
Fig. 19
13.50.26
Block diagram
A134
K370
A125
Potentiometer board
K445
Relay / travel shut-off /4-wheel steering
A126
A127
Printed circuit board (auto check)

MP V
S35
Ground connection / distribution board

Servo switch
S263
S272
Junction box / undercarriage
F314
Fuse S7
S309
F356
F357
Fuse / 4-wheel steering, terminal 15 RS232 Laptop interface

Fuse / 4-wheel steering, terminal 30 Y229-1 Solenoid shift valve for crab steering
H27
H191
Warning buzzer

H191
K252

Relay / servo
copyright by
MJF C I F S S
Service Manual
4-wheel steering
Fault messages
Note!
For a detailed wiring diagram, refer to step 12 and the respective electrical system diagram in group
8.20.
8 Fault messages
8.1
No response when the selection switch S309 is actuated; a short audible signal is issued
Start conditions for the changeover of the steering are not fulfilled, (see 3.1.1, page 6).
Fulfil the start conditions, activate the selection switch S309 again and set it to the desired steering
mode. Wait, until the changeover process is completed.
8.2
The indicator lights H191 / H192 flash alternately, and the warning buzzer H27
issues signals at short intervals
The changeover process has been aborted, possibly due to non-compliance with the start conditions, (see 3.1.1, page 6): S35 is off, S7 is in top position, S263 is set to V/R, ignition is off
Fulfil the start conditions, activate the selection switch S309 again and set it to the desired steering
mode. Wait until the changeover process is completed.
8.3
One of the two indicator lights H191 / H192 flashes or both flash together.
The wheels of the axles are moving:
centre contact of the rear axle not found, i.e. wire break or proximity switch B248-H defective
The wheels of the front axle are moving, while the wheels of the rear axle are standing still.:
centre contact of the front axle not found, i.e. wire break or proximity switch B248-V defective
The wheels of both axles are at the right or left steering stop
Solenoid Y294-1 or Y294-2 defective, or wire break
8.4
The wheels of the rear axle are not being aligned.

The wheels of the front axle are moving from one side to the other, and the wheels of the rear
axle are not in centre position
Solenoid Y229-1 or Y229-2 defective, or wire break
8.5
4-wheel steering activated, indicator light H191 not on, or crab steer mode activated; indicator light H1921 not on
Switch off ignition for approx. 3 seconds, and restart the engine.
Both lights must be on for 1 second (lamp check).
If the lights are not on:
Indicator lightH191 / H192 defective, or wire break
copyright by
MJF C I F S S
13.50.27
4-wheel steering
Service Manual
Fault messages
13.50.28
copyright by
MJF C I F S S
Service Manual
SUBGROUP - INDEX
Section
Group
Type
Oscillating axle support with automatic control 14.10.1
Support cylinders
14.20.1
14.1
MJF C I F S S
Service Manual
14.2
MJF C I F S S
Service Manual
Oscillating axle support with automatic control

Function

1 Function
The oscillating axle support is a hydraulic locking mechanism designed to eliminate the oscillating
motion of the steering axle.
During work, the oscillating steering axle is blocked with two support cylinders in order to improve the
stability of the machine.
When these cylinders are pressurised with control from the pilot system through a solenoid valve and
the rotary connection, the two stop valves (hydraulically controlled check valves) are opened. The
piston in the cylinder can thus follow the oscillating motion of the axle.
Fig. 1
Support cylinder attached to the undercarriage
copyright by
MJF C I F S S
14.10.1
Service Manual
Design of the oscillating axle support mechanism
2 Design of the oscillating axle support mechanism

2.1
Support cylinder 1, (see Fig. 2 on page2) / Fig. 7

The support cylinders 1 with screwed-in stop valve 5 are located to the right and left above the steering axle on the undercarriage.
The plunger pistons in the cylinders 2 block and release the oscillating motion of the steering axle.
When in blocking position (solenoid valve Y371 is not powered), the stop valves 5 close the cylinder
chambers, i.e. the piston 2 is positioned between the axle and the oil column in the cylinder chamber.
When the stop valves 5 are open (solenoid valve Y371 is powered), the cylinder chambers are connected to each other, i.e. the pistons follow the oscillating motion of the steering axle.
The cylinders are continuously fed with a little oil (1 to 2 l/min) by the pilot system through the restrictor (0.5 mm) in the unlocking piston of the stop valve 5 in the cylinder chamber.
To prevent the steering axle from oscillating when the supports are engaged (compression by air content in oil), the connecting line between the two cylinders 1 is equipped with restrictors 20, the check
valve 11 and the accumulator 24.
The check valve 11 produces a return pressure to the tank and thus to the pressure accumulator 24
to minimum 6 bar.
This means that the unloaded piston is continuously pressed against the axle as long as the oscillating axle is locked.
The cylinder 1 and the associated lines must be inspected for proper connection and leakage at the
prescribed intervals, see maintenance instructions in group 3.
Fig. 2
14.10.2
Undercarriage with support cylinders and main components
Support cylinder, complete
Piston
10 Undercarriage
copyright by
MJF C I F S S
Stop valve
Service Manual

Design of the oscillating axle support mechanism
2.2
Rotary connections 320 / 322

The six-fold oil rotary connection 322 is mounted on the seven-fold rotary connection 320 (high-pressure connection). Control oil is fed from the solenoid valve Y371 through the oil rotary connection 322
to the stop valve 5 of the support cylinders.
2.3
Solenoid valve Y371

The solenoid valve Y371 is integrated into the control oil unit 50 of the pilot control system. It consists
of a hydraulic 3/2 way valve with electric actuator.
When in working position, the solenoid valve Y371 is open, allowing control oil to flow to the stop valves 5. In neutral position, it blocks the control oil flow and thereby relieves the stop valve 5 to the tank.
Fig. 3
Control oil unit and rotary connection
50
Control oil unit
320
Rotary connection 7 x for high pressure
A Control oil unit for model A 309 / 311 from

start of series
B Control oil unit for model A 309 / 311 from
change of series, see hydraulic unit
322 Rotary connection 6 x for low pressure (*) C Control oil unit for model A 312 - 316
Y371 Solenoid valve for oscillating axle support
copyright by
MJF C I F S S
14.10.3
Service Manual
Operation of oscillating axle support
Fig. 4
Operator's platform with rotary switches, proximity switches and indicator lights
B266
Proximity switch of oscillating axle automa- S7

tic
H176
Indicator light of automatic support
H311
S75
Switch safety lever

Rotary switch of oscillating axle support
3 Operation of oscillating axle support

3.1
Releasing oscillating axle locking system

The safety lever S7 is turned down.
The indicator lights H176 and H311 are off.
Note!
For safety reasons, the oscillating axle cannot be released if there is a certain load on the axle (high
load forces due to loads attached at right angles to the travel direction).
Before the oscillating axle locking system is released, swivel the uppercarriage into travel direction or otherwise change the kinematics of the equipment.
Operating status:
14.10.4
copyright by
MJF C I F S S
Service Manual

Operation of oscillating axle support
Oscillating axle is released (oscillating freely).

Low stability
Only for travel operation without load or with load aligned in travel direction
3.2
Locking oscillating axle

Operating status:
The oscillating axle is permanently locked.
High stability
for travel with load
Preferred mode for excavator operation
3.3
Oscillating axle support automatic

Danger!
If the oscillating axle automatic is on (rotary switch S75 in position A),
the oscillating axle is automatically released when the working brake is released. This results in a
lower stability.
If a load is taken up and the uppercarriage is swivelled, the machine might tip over.
This can result in serious injury or even death to the machine operator or the person in charge of
attaching loads.
Prior to taking up a load, switch off the oscillating axle automatic and permanently lock the oscillating axle (rotary switch S75 in position I).
Only then travel with the machine with attached load (e.g. filled digging tool, load suspended on
safety hook).
Turn the switch S75 to position A.
Operating status:
The oscillating axle is locked while the working brake is applied.
This results in higher stability.
When the working brake is released, the oscillating axle is oscillating freely.
This results in reduced stability.
Suitable for operation with frequent changes between travel and excavator operation (travel without load, or load swivelled in travel direction)
copyright by
MJF C I F S S
14.10.5
Service Manual
Function of the oscillating axle support mechanism
4 Function of the oscillating axle support mechanism

4.1
4.1.1
Oscillating function
Permanent
When the rotary switch S75 is turned to position 0 (indicator light H311 is off), the solenoid valve Y371
is powered and moved to working position.
The control connection St at the stop valve 5 is pressurised with pilot control pressure through the
solenoid valve Y371 and the rotary connection 322.
The valve cone of the stop valve 5 is lifted from the seat so that the two support cylinders are connected to each other through the connection P at the cylinder 1 and the connected lines. The oscillating axle is opened.
4.1.2
Automatic
By turning the rotary switch S75 to position A (indicator light H176 on) and releasing the working
brake, the solenoid valve Y371 is powered and moved into its working position.
The control connection St at the stop valve 5 is pressurised with pilot control pressure through the
The valve cone of the stop valve 5 is lifted from its seat so that the two support cylinders are connected to each other. As a consequence, the oscillating axle is released.
If the working brake (wheel brake) is applied, the solenoid valve Y371 is not powered (due to signal
from proximity switch B266 - Fig. 4), i.e. the solenoid valve Y371) returns to its neutral position, thus
locking the oscillating axle see 4.2.2.
4.2
4.2.1
Support function
Permanent
When the rotary switch S75 is turned to position 0 (indicator light H311 is on, the solenoid valve Y371
is not powered and moved to neutral position.
The pressure is released to the tank from the control connection St at the stop valve 5 through the
4.2.2
Automatic
By turning the rotary switch S75 to position A (indicator light H176 on) and applying the working
brake, the solenoid valve Y371 is deactivated (not powered) and moved into its neutral position.
The pressure is released to the tank from the control connection St at the stop valve 5 through the
If the working brake (wheel brake) is released, the solenoid valve Y371 is automatically powered (due
to signal from proximity switch B266 - Fig. 4), i.e. the solenoid valve Y371 returns to its neutral position, thus releasing the oscillating axle see 4.2.2.
5 Bleeding of the system

As the cylinders are permanently flushed with control oil (operating mode "oscillating axle unlocked"),
14.10.6
copyright by
MJF C I F S S
Service Manual

Bleeding of the system
the system is automatically bled. Separate bleeding is thus not necessary.

After a repair, first fill the cylinder 1 with oil.
Then insert the stop valve 5,
connect the lines,
and turn the switch S75 (see Fig. 4) to position 0 (oscillating axle unlocked).
Let the diesel engine idle for some time (minimum 5 minutes) to let oil flow through the stop valve
(flushing).
Complete a functional test, (see 6 on page8).
Fig. 5
Hydraulic connections with oscillating axle support
Cylinder
24
Accumulator
5
11
Stop valve
Check valve
320
322
20
Restrictor
copyright by
MJF C I F S S
14.10.7
Service Manual
Functional test
6 Functional test
Ensure that the front axle is unlocked (switch S75 in position 0 - Fig. 4), support the machine with
its working attachment and lift one wheel of the front axle from the ground.
Lock the axle (switch S75 in position I) and apply a load.
Check whether there is any play between the piston 2 of the support cylinder without load 1 and
the oscillating bridge (visual inspection).
The loaded piston 2 of the support cylinder may not move inwards.
If necessary, repeat the bleeding process,(see 5 on page6).
If required, check the valve cone in the stop valve 5.
Complete the above functional test on both support cylinders 1.
Fig. 6
14.10.8
Functional test of the locked oscillating axle
copyright by
MJF C I F S S
Service Manual

Functional test
copyright by
MJF C I F S S
14.10.9
Service Manual
Hydraulic diagram
7 Hydraulic diagram
14.10.10
1
2
Cylinder
Piston
H176
H311
Indicator light of oscillating axle automatic

Stop valve
K250
11
Check valve
6 bar preload
S35
20
S75
Rotary switch of the automatic oscillating

axle Oscillating axle support
24
32
Diaphragm accumulator
V155 Blocking diode S75-K250
Gear pump / brake and pilot control V156-2 Blocking diode S75-H311
unit (312 316)
33
Gear pump/pilot control unit (309311)
X197
49
50

Control oil unit
X842-3 Plug connection A1001 - B266 / 2-pin

X856 Plug connection to BST / 40-pin
170
302
Leak oil line from travel motor

Line to steering system (309-311)
X857
X950
Plug connection to BST / 24-pin

Plug connection indicator check / 21-pin
320
X952
Plug connection revolving deck BST / 21-pin
322
X956
Plug connection BST distributor / 21-pin
400
Line to brake system (312-316)
X957
Plug connection switch distributor / 21-pin
A126
B266

Proximity switch / brake pedal
X958
X960
Plug connection switch distributor / 21-pin

Plug connection operator's platform distributor / 21-pin
C
D
X961
X963
Plug connection indicator distributor / 21-pin

Plug connection fuse distributor / 21-pin
F316
Version in models A 309 / A 311

Version in models A 312 to serial
no. 20329 / A 314 to serial no.
20333 /
Fuse servo steering / 15 A
X964
Plug connection fuse distributor / 21-pin
F326
F329
Fuse S75 / 15 A
Fuse S35 / 5 A
X974-2 Plug connection blocking diode / 2-pin

in models A 309 and A 311
copyright by
MJF C I F S S
in models A 312 to serial no. 20329

A 314 to serial no. 20333 and
Service Manual

Hydraulic diagram
Fig. 7
Diagram of electric and hydraulic system for automatic oscillating axle support
copyright by
MJF C I F S S
14.10.11

Hydraulic diagram
14.10.12
copyright by
MJF C I F S S
Service Manual
Service Manual
Support cylinders
Design
Support cylinders
1 Design
The support cylinders are attached to the right and left on the undercarriage above the steering axle.
They are designed as single-acting cylinders (plunger cylinders).
The steering and oscillating axle touches the curved front face of the two pistons 2. When the machine is in working position, it is supported by the pistons 2, which are resting on oil columns in the cylinder 1.
To release the axle so that it can oscillate, the stop valves 5 (hydraulically operated check valves)
screwed into the cylinder base are opened, so that the pistons 2 can follow the oscillating motion of
the axle.
Fig. 1
Main components of support cylinder
Cylinder
Piston
copyright by
MJF C I F S S
Stop valve
14.20.1
Support cylinders
Service Manual
Function of support cylinder
2 Function of support cylinder

see Fig. 6
In the cylinder 1, the piston 2 is axially guided by means of the two guide rings 15.
The cylinder is sealed by means of a Turcon-Stepseal ring 12. It is protected against penetrating dirt
with a special scraper ring 10.
The stop valve 5 is pressurised with pilot pressure through the connection St in the cylinder 1 and
depressurised to the tank.
When the valve 5 is in locking position, the valve cone 31 is closed, so that the piston 2 is blocked in
its position by the oil in the cylinder chamber.
When the valve 5 is opened, the oil escapes through the valve 5 and the line connected to port P from
the cylinder chamber, as soon as the piston 2 is moved in axial direction. The oil then flows into the
support cylinder on the other side of the undercarriage.
Fig. 2
14.20.2
Exploded view of the support cylinder 1
1
2
Cylinder
Piston
13
15
O-ring
Guide ring
5
10
Stop valve
Special scraper ring
801
999
Corrosion inhibitor Tarp

Seal kit
12
Turcon-Stepseal ring
copyright by
MJF C I F S S
Service Manual
Support cylinders
Function of the stop valve
3 Function of the stop valve

3.1
Blocking position
The control oil connection ST is not under pressure. The release piston 11 is pressed upwards by the
pressure spring 16. The hydraulic pressure produced in the cylinder chamber as the oscillating axle
presses against the plunger of the support cylinder presses the valve cone 31 upwards. The cone
thereby fully closes the connection P to the other support cylinder. The ball 18 closes the connection
P ST.
3.2
Release position
The release piston 11 is pressurised through the solenoid valve Y371 (see group 14.10), and the connection St with pilot control pressure. As a result, it is pushed down against the valve cone 31.
When the cylinder is fully or nearly load-free, the valve cone 31 is lifted slightly from its seat. When
the cylinder carries a load (e.g. due to a load that is suspended at right angles to the travel direction
of the machine), the valve cone 31 is only lifted from its seat by the release piston 11 after the load
pressure on the respective support cylinder is below 420 bar.
When there is some oscillating motion by the steering axle, the oil can escape from the cylinder chamber through the valve cone 31 and connection P and/or then flows into the support cylinder at the
other side of the undercarriage.
A little pilot control oil flows through the restrictor 14, the check valve 17 / 18 and the bore C into the
connecting line and thus continuously refills the pressure accumulator of the system.
Fig. 3
Sectional drawing of the stop valve
copyright by
MJF C I F S S
14.20.3
Support cylinders
Service Manual
Maintenance
5
Stop valve, complete
24
Backing ring
11
14
Release piston
Restrictor
26
27
O-ring
O-ring
16
Pressure spring
31
Valve cone
17
Pressure spring
32
Spring plate
18
Ball
33
Pressure spring
21
22
Connector screw
O-ring
34
35
Snap ring
Valve housing
23
O-ring
4 Maintenance
The regular maintenance of the support cylinder includes a visual inspection of the cylinder for leakage and proper mounting at predefined intervals, see maintenance instructions in group 3.
14.20.4
copyright by
MJF C I F S S
Service Manual
Support cylinders
Installation and dismantling of support cylinder
5 Installation and dismantling of support cylinder

5.1
Dismantling
Slightly lift the undercarriage with the attachment so that the steering axle is oscillating freely.
Disconnect and seal the hydraulic lines of the support cylinder 1.
Loosen the mounting bolts 22 and remove the support cylinder from the undercarriage.
5.2
Installation
Place the support cylinder 1 against the undercarriage 10 and secure it with the hex head screw
30 (with washers 29) to the undercarriage.
Align it properly (tightening torque for the screws 30 = 960 Nm)
Connect the hydraulic lines to the cylinders.
Flush the oscillating axle support mechanism so that it is automatically bled, and complete a functional test, see group 14.10.
Fig. 4
1
10
Installation of the support cylinders to the undercarriage

29
30
Support cylinder
Undercarriage
copyright by
MJF C I F S S
Washer
Hex head screw
14.20.5
Support cylinders
Service Manual
Sealing the support cylinders
6 Sealing the support cylinders

Note!
To seal the support cylinder, you need a "Support cylinder seal kit" and a "Stop valve seal kit".
Do not use pointed or sharp-edged tools to dismantle or mount the sealing elements.
To seal the support cylinders, proceed as follows:
6.1
Dismantling of the support cylinder

Remove the entire support cylinder from the undercarriage, see Fig. 4.
Screw the stop valve 5 from the cylinder 1.
If required, remove the backing ring 24 and the O-rings 23 and 27.
Push the piston 2 from the cylinder and inspect it for damage and scoring.
Remove the scraper ring 10, the Turcon-Stepseal ring 12 and the O-ring 13 from the cylinder 1.
6.2
Installation of the support cylinder

Clean all parts carefully and remove all foreign particles.
Inspect all components and sealing elements for damage. Reuse only undamaged parts.
Apply Tarp corrosion inhibitors 801 (see group 1.50) to the gap between the guide ring 15 and the
scraper ring 10.
Before mounting them, wet all parts with hydraulic oil.
Insert the O-ring 13 into the groove of the cylinder 1.
Note!
When squeezing the Turcon-Stepseal ring 12, avoid kinking.
Squeeze the new Turcon-Stepseal ring 12, see Fig. 5.
Insert the Turcon-Stepseal ring 12 into the cylinder 1, ensuring that it is in the correct position, see
detail Z, (see Fig. 6, page 9).
Expand the Turcon ring 12 in the cylinder 1 and place it on the inserted O-ring 13.
14.20.6
copyright by
MJF C I F S S
Service Manual
Support cylinders
Sealing the support cylinders
Fig. 5
1
Correct installation of the Turcon-Stepseal ring

12 Turcon-Stepseal ring
Cylinder
13 O-ring
Insert the new scraper ring 10, see detail Z(see Fig. 6, page 9).
Carefully push the piston 2 into the cylinder 1.
Place the O-rings 23 / 26 and the backing ring 24 onto the stop valve 5.
If required, replace the O-rings 22 and 27 after removing the connecting screw 21 (torque 160
Nm).
Screw the compete stop valve 5 into the cylinder 1 (torque 300 Nm)
Mount the support cylinder 1 onto the undercarriage, complete a functional test and connect the
lines to the stop valve and the support cylinder.
Complete a leakage and function test of the stop valve, see group 14.10.
copyright by
MJF C I F S S
14.20.7
Support cylinders
Service Manual
Sectional drawing
7 Sectional drawing
14.20.8
1
2
Cylinder
Piston
21
22
Connector screw
O-ring
Stop valve
23
O-ring
10
11
Special scraper ring

Release piston
24
26
Backing ring
O-ring
12
Turcon-Stepseal ring
27
O-ring
13
O-ring
31
Valve cone
14
Restrictor
32
Spring plate
15
Guide ring
33
Pressure spring
16
Pressure spring
34
Snap ring
17
18
Pressure spring
Ball
35
Valve housing
copyright by
MJF C I F S S
Service Manual
Support cylinders
Sectional drawing
Fig. 6
Sectional drawing of the support cylinder and the stop valve
copyright by
MJF C I F S S
14.20.9
Support cylinders
Service Manual
Sectional drawing
14.20.10
copyright by
MJF C I F S S
Service Manual
SUBGROUP - INDEX
Section
Group
Type
Operating pressures of the brake system
15.05.1
Hydraulic brake system
15.10.1
Compact brake block
15.20.1
15.1
MJF C I F S S
Service Manual
15.2
MJF C I F S S
Service Manual

General information

Machine
Series
Einheit
A 309 Litronic
from
20221
A 311
Litronic
from
20222
A 312 - 316
Litronic
from
2001
Gear pump 31 / 32
Brake oil max.
l/min
bar
125 5
125 5
Shut-off pressure
bar
150 5
Switching range
bar
20 +15
20 +15

abate
rise
bar
100 5
125 5
100 5
125 5
Accumulator charging valve 5

in compact brake block 4
Switch-on pressure
150
Brake system
Brake pressure in front and
rear brake circuits (measuring point 25 /
26)
bar
bar
Rated flow
cm3
700
700
Filling pressure (nitrogen)
bar
40
40
Max. permissible pressure
bar
180
180
50+5
55 +5
75 +10
Accumulators 14 and 15
Tab. 1
Technical data
Einheit
A 316
Litronic
from 28061
l/min
Switch-on pressure
bar
150 5
Shut-off pressure
bar
185 5
Switching range
bar
35 +15
Machine
Series
Gear pump 31 / 32
Brake oil max.
Accumulator charging valve 5
in compact brake block 4
copyright by
MJF C I F S S
15.05.1
Service Manual
General information
Machine
Series
Einheit

abate
bar
A 316
Litronic
from 28061
100 5
125 5
rise
Brake system
Brake pressure in front and
rear brake circuits (measuring point 25 /
26)
bar
75 +10
bar
cm3
1000
Accumulators 14 and 15
Rated flow
15.05.2
Filling pressure (nitrogen)
bar
45
Max. permissible pressure
bar
200
copyright by
MJF C I F S S
Service Manual

Function

1 Function
The LIEBHERR hydraulic excavators are equipped with hydraulic dual-circuit brake systems. This
working brake is charged by the gear pump 31/32 and the accumulator charging valve in the compact
brake block 4. The charge pressure is then available at the brake valve of the working brake, which
is also integrated in the compact brake block.
When the pedal 11 is pressed down, the brake valve pressurises the brake circuit of the steering axle
(multi-disc brakes 20) and the rigid axle (multi-disc and drum brakes 21/22).
At maximum operation, the retainer of the brake pedal 11 is locked. The brake is now fully applied.
This is the only brake function (parking brake) that may be used during work.
Fig. 1
Compact brake block
22
Drum brake, rear
11
31
Gear pump with flow distributor
20
Multi-disc brake, front
32
Gear pump with flow distributor
copyright by
MJF C I F S S
15.10.1
Service Manual
Design of brake system

21
H23
Multi-disc brake, rear
Indicator light / accumulator charging

pressure
2 Design of brake system

2.1
Gear pump 31 / 32:

The gear pump 31/32 with the flow distributor is driven directly by the diesel engine. It takes up hydraulic oil from the tank and feeds a constant oil volume of approx. 2 litres to the connection K to the
compact brake block 4.
Fig. 2
4
Gear pumps flange-mounted to the diesel engine

31 Gear pump with flow distributor for low-pressure circuit and brake system (A309/311)
27 Measuring point / accumulator pressure
2.2
32 Gear pump with flow distributor for pilot control and brake system (A312-316)
K Connection for constant flow of the flow distributor
Compact brake block 4, see Fig. 3 and Fig. 5

The accumulator charging valve 5, the double check valve 9 and the brake valve 10 are integrated
into the compact brake block 4.
The accumulator charging valve 5 keeps the pressure in the system with the accumulators 14 and 15
at a predefined level.
When the charging pressure / shut-off pressure (see operating pressures, group 15.05) is reached,
the valve 5 with the pressure balance 6 and the pressure regulator 7, see Fig. 10 automatically feed
the flow from the gear pump 31 / 32 back to the tank 1 or lowers the constant flow rate to the level of
the additional pressure to the connected brake accumulators 14 and 15.
This charging/accumulator pressure is then available at the brake valve 10. The brake valve 10 is
mechanically shifted via the linkage when the brake pedal 11 is operated. As a consequence, the brake pressure, which is proportional to the pedal travel, is fed through the connections B1 and B2 on
the compact brake block 4 and the rotary connection 322 to the brakes of the axles, so that the brakes
15.10.2
copyright by
MJF C I F S S
Service Manual

Design of brake system
are applied.
If there is sufficient accumulator pressure, the pressure switch B20 opens an electrical circuit when
a predefined value is reached (see operating pressures group, 15.05). The indicator light H23 on the
control desk is switched off, see Fig. 1. This indicates that the brake system is ready for operation.
When the brake is actuated, the pressure switch B60 acts as a brake light switch and closes the electrical circuit when a predefined value is reached (see operating pressures, group 15.05), so that the
brake lights of the machine are switched on.
The proximity switch B266 for the oscillating axle automatic is installed near the linkage of the brake
pedal 11 and the brake valve 10 (see also description in group 14).
2.3
Accumulator
The accumulators 14 and 15 - located below the operator's platform and near the compact brake
block 4 - fulfil an important safety function. In the event of a failure of the pump 31 / 32, or if the diesel
engine is off, the machine can be brought to a halt by the accumulated pressure.
Fig. 3
Compact brake block with pressure accumulator below the operator's platform
14
Brake accumulator of the brake circuit of

the steering axle
Accumulator charging valve
15
Brake accumulator of the brake circuit of

the rigid axle
Pressure balance
10
Brake valve
11
Brake pedal
12
Locking lever (for brake working position) B266 Proximity switch / oscillating axle automatic
copyright by
MJF C I F S S
15.10.3
Service Manual
2.4
Multi-disc brakes 20 and 21, or drum brake 22 respectively, (see Fig. 4, page 4)
The axles of the various machines are equipped with brakes of the same or of different types. The
steering axle is always equipped with a multi-disc brake. The rigid axle of the machine might feature
a multi-disc brake or a drum brake.
When the brake is applied with the brake pedal 11, the brake pistons and cylinders of the brakes 20
/ 21 / 22 in the axles are pressurised with oil through the brake valve 10.
When the multi-disc brakes are pressed together, or when the brake pads are pressed against the
drum, the resulting friction slows down the vehicle.
Fig. 4
Multi-disc brake 20/21 and drum brake 22

see Fig. 5 and Fig. 10.
3.1
System not pressurised, or switch-on pressure reached

The gear pump 31/32 with flow distributor feeds the hydraulic oil through connection K directly to
the compact brake block 4 connection P. The hydraulic oil flows via the internal channels, the check
valve 8 and the connections S1/S2 into the connected brake accumulators 14 and 15. The pressure
in the accumulator circuit is thus increased.
The accumulator charge pressure is applied through the check valve 8 to the pilot control piston 135
of the pressure regulator and through the channels in the housing and the edges of the piston 72 to
the two front faces of the pressure balance 6. The pump 31 / 32 feeds the accumulator circuit through
the double check valve 9 until the force resulting from the charging pressure exceeds the preload
force of the adjusting spring 51.
3.2
System charged, shut-off pressure reached

The piston 72 pushes against the spring 51, shuts off the supply from the connection P to the springfacing surface of the pressure balance 6 and also relieves this surface to the connection T. The pressure balance 6 is shifted towards the pressure spring 56 and opens the P channel to the tank through
connection N.
That means, the pump flow flows at low
-p through accumulator charging valve 5 to the tank.
The check valve 8 closes. The pilot control piston 135 stabilises the shut-off function, as it has a larger
effective surface than the spool 72.
15.10.4
copyright by
MJF C I F S S
Service Manual

When the working brake is operated, or if there is internal leakage at the accumulator charging valve,
the accumulator charge pressure drops from its maximum level (shut-off pressure) to its minimum
level (switch-on pressure). The spring force of the adjusting spring 51 now exceeds the force of the
pilot 135. As a result, pressure regulator 7 is reset to its initial position so that connection "T" is closed
and connection "P" is opened towards the accumulator circuit and pressure balance 6 (spring side).
The pressure balance closes connection "P-N". The system is again charged.
The switching pressure difference / switching range (see operating pressures, group 15.05) between
the switch-on and the shut-off pressure results from the surface difference of the pilot control piston
135 and spool 72.
3.3
Applying working brake

By pressing down the brake pedal 11 (located to the right in the operator's cab), see Fig. 1, the linkage
attached to the pedal presses down regulation springs 57 and 58. The brake piston 64 is moved inwards, so that the force applied to the pedal actuates the build-up of a proportional hydraulic brake
pressure in the first brake circuit. The brake pressure of the first brake circuit shifts the brake piston
63 with the same force that is applied to the brake piston 64.
After a short stroke, the pin 81 pushes the brake piston 63 against the pressure spring 52
As the pistons 63 and 64 are moved from their neutral position inwards against the pressure springs
52/53, the lines from connections B1 and B2 to connection T are closed first by means of the control
edges. Subsequently, the accumulator pressure is applied through connections B1 and B2 and the
rotary connection 322 to the multi-disc brakes 20 / 21/22 of the axle. As a consequence, the brakes
are applied.
If the force applied onto the pedal is constant, the brake pistons 63 and 64 are set in a control position,
keeping the brake pressure constant, i.e. the supply from the respective accumulator circuit and the
outlet to the tank are closed.
If the force applied onto the pedal is reduced, the control edges of brake pistons 63 / 64 open the
connection to the tank, so that the brake pressure is reduced until an equilibrium of forces is established above and below the pistons 63 / 64.
When the brake pedal 11 and the brake piston 63 / 64 return to their initial position, the brakes 20 /
21 / 22 are released to the tank.
copyright by
MJF C I F S S
15.10.5
Service Manual
15.10.6
4
6
Compact brake block

Pressure balance
38
50
Piston/pressure balance
Pressure spring / pilot control piston
7
8
Pressure regulator
Check valve
51
52
Pressure spring / accumulator pressure

Pressure spring / brake piston return
Double check valve
53
Pressure spring / brake piston return
10
11
Foot brake valve

Foot brake pedal with housing
56
57
Pressure spring / pressure balance

Pressure spring / brake pressure
14
Brake accumulator / front brake circuit
58
15
Brake accumulator / rear brake circuit
63
Brake piston
20
Multi-disc brake / steering axle
64
Brake piston
21
Multi-disc brake / rigid axle
72
Spool
22
Drum brake / rigid axle
81
Pin
25
26
Measuring point / front brake pressure

Measuring point / rear brake pressure
102
131
Threaded bolt
Sleeve
27
31
Measuring point / accumulator pressure 132

Gear pump / low pressure relay and
135
brake system (A 309/311)
Bushing
32
Gear pump / pilot control and brake

system (A 312- 316)
322
Rotary connection
copyright by
MJF C I F S S
Service Manual

Fig. 5
Sectional drawing of the compact brake block with hydraulic lines
copyright by
MJF C I F S S
15.10.7
Service Manual
Bleeding of the brake system
Note!
system must be drained through the bleeder screws at the wheels. Minimum drain volume: 0.5 l per
axle. The accumulators might have to be charged several times by repeated starting of the diesel engine.
Note!
Do not drain the oil while the engine is on, as the accumulators are otherwise not emptied.
4 Bleeding of the brake system

Caution!
After the brake circuit has been opened for repair work, the piston chamber/cylinder in the axles and
the line to the brake must be bled.
Fig. 6
Different location of bleeder valve in models A 309 and A 311 - 316.

A
B Dust cap
Bleeder valve
Start diesel engine and let it run for approx. 2 minutes.

Remove the dust cap B from the bleeder valve A and connect the bleeder hose.
Immerse the other hose end into a glass container half filled with hydraulic oil.
Open the bleeder valve A.
Press down brake pedal and lock in place, if necessary.
Close bleeder valve A again.
Repeat this procedure (opening valve, operating brake, closing valve) until the oil flowing out is
not foaming.
Disconnect the bleeder hose and replace the dust cap B on bleeder valve A again.
15.10.8
copyright by
MJF C I F S S
Service Manual

Inspection and adjustment of the brake system settings
5 Inspection and adjustment of the brake system settings

5.1
Important adjustment notes

Note!
Please note that all work on the brake system must be carried out by technicians who are authorised
by LIEBHERR.
The pressure adjustments must be made at operating temperature of the hydraulic oil.
To adjust the pressure, use only glycerine damped pressure sensors with an accuracy of at least
1% of the scale full scale value.
Caution!
5.2
Layout of measuring points 25, 26 and 27

Note!
The location of the measuring points 25 and 26 in the undercarriage is similar to that shown for model A 312.
Fig. 7
5.2.1
Measuring points for the brake pressure in the undercarriage and measuring point of the
accumulator pressure at the connection K of the flow distributor.
25
Measuring point / front brake pressure
26
Measuring point / rear brake pressure
27
Measuring point / accumulator pressure
Measuring point 25
Used to check the brake pressure in the front brake circuit.
copyright by
MJF C I F S S
15.10.9
Service Manual
5.2.2
Measuring point 26
Used to check the brake pressure in the rear brake circuit.
5.2.3
Measuring point 27 at the flow distributor of the pump 31/32, (see Fig. 7, page
9)
Used to check the switch-on and the shut-off pressure, the accumulator pressure and the switching
pressure of the pressure switch B20.
5.3
Checking of the switch-on and the shut-off pressure of the accumulator charging valve 5, and of the switching pressure of the pressure switch B20.
Fig. 8
Compact brake block 4 below the operator's platform
Compact brake block
74
Adjusting screw
16
17
Fork head
Lock nut
75
102
Lock nut
Threaded bolt
18
Bolt
B20
Connect the 0-600 bar pressure sensor to measuring point 27 and check the following values:
5.3.1
Switch-on and shut-off pressure of the charging valve 5

Start the diesel engine and recharge the unit.
The pressure at the measuring point 27 must rise all the way to the shut-off value specified.
See operating pressures, group 15.05.
The accumulator valve 5 is now switched, so that the system is depressurised at the measuring
point 27.
Repeatedly press down foot brake pedal 11 (see Fig. 3, page 3) until the system is recharged or
the switch-on pressure is reached.
The pressure at measuring point 27 rises again to the level of the shut-off pressure.
To check the switch-on pressure, remove pressure switch B20, mount a M10 X 1 screw coupling assembly and connect a 0-600 bar pressure sensor.
If required, loosen the lock nut 75 and adjust the switch-on and switch-off pressures to the prescribed value by turning the adjusting screw 74 (see operating pressures, group 15.05).
15.10.10
Turn in
= Increase pressure
Turn out
= Reduce pressure
copyright by
MJF C I F S S
Service Manual

5.3.2
Switching pressure of pressure switch B20

Connect pressure sensor to measuring point 27.
Shut down the diesel engine, leave the ignition on and reduce the brake pressure by repeatedly
operating the foot pedal.
The indicator light H23, (see Fig. 1, page 1) in the control desk is on.
Connect the pressure sensor to the measuring point 27.
Start the diesel engine and observe the pressure sensor and the indicator light H23. When the
prescribed switching pressure is reached (see operating pressures, group 15.05), the indicator
light H23 must switch off.
If defective, replace the pressure switch B20.
5.4
Checking brake pressure of working brake
Fig. 9
Brake pedal and operating linkage of the brake valve at the compact brake block
Compact brake block
17
Lock nut
11
12
Foot brake pedal

Locking lever
18
29
Bolt
Stop screw, rear
13
Stop screw, front
102
Threaded bolt
16
Fork head
Connect pressure sensor (0 - -600 bar) to measuring points 25 and 26, see Fig. 7.
Start the diesel engine. Press down the foot brake pedal 11 and lock it.
The actual brake pressure, as shown at the pressure sensor, must correspond to the respective value in the list of operating pressures, see group 15.05.
To adjust the brake pressure, modify the linkage length as follows:

12
Adjust stop screw 13 so that there is only minimum play between the locked pedal and the upper
edge of the screw.
While the pedal 11 is engaged, loosen the lock nut 17 and turn the threaded rod 102 so that the
pressure measured at the measuring points 25 and 26, Fig. 7 corresponds to the prescribed pressure.
Re-tighten the lock nut 17.
copyright by
MJF C I F S S
15.10.11
Service Manual

Disengage the pedal 11.
Unlock and drive out the pin 18 ( 10 mm) inserted between the fork head 16 and the pedal lever,
and insert a 9 mm pin (drill bore, if necessary).
Loosen and adjust the stop screw 29 until there is no play between the fork head 16 and the inserted pin.
Secure the stop screw 29 with a lock nut.
Remove the 9 mm adjusting pin and re-insert and lock the original 10 mm pin 18.
The threaded rod is now correctly pre-stressed (1 mm).
After the adjustment is completed, check whether the measuring points 25 and 26 remain without
pressure when the pedal 11 is not pressed.
If required, readjust the position of stop screw 29.
5.4.1
Checking of the brake accumulators 14 and 15, (see Fig. 3, page 3)

Connect pressure sensor (0-600 bar) to the measuring point 27 (see Fig. 7, page 9).
Connect pressure sensor (0-600 bar) to the measuring points 25 and 26, see Fig. 7.
Start the diesel engine. Charge the system all the way up to shut-off pressure.
Shut down the diesel engine and slowly press down foot brake pedal 11 Fig. 3 - at least ten times,
with short intervals.
Having done that 10 x, the brake pressure at measuring points 25 and 26 Fig. 7 should not
drop below 50 bar filling pressure.
If it happens anyway, there is most probably a problem with accumulators 14 / 15. Release the
pressure from the system and install new accumulators.
Remove the pressure sensor, and seal the measuring points 25, 26 and 27.
15.10.12
Hydraulic tank
28
Diesel engine
Compact brake block
31
32
Gear pump / low pressure circuit and

brake (A309-311)
Gear pump / pilot control and brake
system (A312-316)
6
7
Pressure balance
Pressure regulator
38
51
Piston
Check valve
57
58
10
Shuttle check valve / double check

valve
Foot brake valve
63
Brake piston
11
Brake pedal
64
Brake piston
14
Brake accumulator / front brake circuit
72
Spool
15
Brake accumulator / rear brake circuit
135
20
21
Multi-disc brake / steering axle

Multi-disc brake / rigid axle
322
B20
Pressure switch / accumulator charge
pressure
22
25
Drum brake / rigid axle

Measuring point / front brake circuit
B60
E19

Right brake light
26
Measuring point / rear brake circuit
E20
Left brake light
27
Measuring point / accumulator charge

pressure
H23
Indicator light / accumulator charging

pressure
copyright by
MJF C I F S S
Service Manual

Hydraulic diagram
6 Hydraulic diagram
Fig. 10
copyright by
MJF C I F S S
15.10.13
Service Manual
Hydraulic diagram
15.10.14
copyright by
MJF C I F S S
Service Manual
Compact brake block

Design
Compact brake block

1 Design
The compact brake block 4 includes the accumulator charging valve 5 and the brake valve 10. Other
components required for its proper functioning are connected via hydraulic lines of hoses to the block
4.
The brake valve 10 is actuated mechanically with a brake pedal via elbow levers and threaded bolts.
When the brake is operated, it pressurises the multi-disc or drum brakes of the axles through two different brake circuit containing oil, which is taken from the respective accumulator circuits.
Fig. 1
Compact brake block 4
copyright by
MJF C I F S S
15.20.1
Compact brake block
Service Manual
Functional description of the accumulator charging valve 5
2 Functional description of the accumulator charging valve 5

The accumulator charging valve 5 or the pressure shut-off valve ensures that the pressure in the brake accumulator is kept at the preset level. This is achieved by means of a switching logic where the
brake system is recharged to the shut-off pressure level when the pressure drops below the switchon level.
2.1
Charging pressure at the accumulator charging valve 5

During the charging process, the constant oil flow from the gear pump flows from the connection P
to the check valve 8 and the double check valve 9 to the accumulator circuit. Simultaneously, the oil
acts on the piston 38 of the pressure balance 6 and the spool 72 on the spring side of the pressure
balance 6. As a result, the oil flow to the return side (connection N) is blocked, until the pump pressure is greater than the spring pressure at the pressure regulator 7 across the surface of the pilot
control piston 135.
The pilot control piston 135 shifts the spool 72 against the adjusting spring 51. The spring prevents
that the pump pressure P acts on the spring side surface of the piston 38 and thus relieves the spring
chamber of the pressure balance 6 to the tank T. The piston 38 is now shifted, and the oil is fed from
the connection P via the connection N to the tank 1. The check valve 8 closes. The resulting force
of the accumulator pressure acting on the adjusting spring 51 stabilises the shut-down function.
The charging process is completed, and the pump flow can now flow through the charging valve at a
relatively low -p.
2.2
Shifting pressure difference (shifting range)

The shifting pressure difference is the result of the difference surfaces at the pilot control pistons 135
and the spool 72. The upper switching point (shut-off pressure) is reached, when the T edge (line to
T) is opened; the lower switching point is however only reached, when the P edge (line to P is opened).
If the pressure in the accumulator circuit drops below the lower switching point (switch-on point) the
spool 72 is pushed by the pressure spring 51 into its basic position. As a result, pressure is applied
to the spring side face of the pressure balance 6. The piston 38 blocks the connection P-N and the
gear pump 33 pumps the oil again into the accumulator circuit.
15.20.2
copyright by
MJF C I F S S
Service Manual
Compact brake block

Connections at the compact brake block
3 Connections at the compact brake block
Fig. 2
Views W, X, Y, and Z of the compact brake block
Connections:
Connection P
from pump
Connection N and T to tank

Connection B1
to multi-disc brake / steering axle
Connection B2
Connection DS1
to multi-disc brake or drum brake / rigid axle

Pressure switch / brake light (B60*)
Connection DS2
Pressure switch / accumulator pressure (B20*)
* item in electrical diagram
copyright by
MJF C I F S S
15.20.3
Compact brake block
Service Manual
Connections at the compact brake block
Fig. 3
to hydraulic tank
31
from gear pump with flow distributor (A 309311)
Compact brake block
32
from gear pump with flow distributor (A 312316
5
6

Pressure balance, complete
38
51
Piston / pressure balance

Pressure regulator
57
Check valve
58
Double check valve
63
Brake piston
10
11

Brake pedal
64
72
Brake piston
Spool
14
to brake accumulator / steering axle 88

circuit
to brake accumulator / rigid axle cir- 135
cuit
to brake cylinders / steering axle with 999
multi-disc brake
15
20
21
15.20.4
Hydraulic diagram of compact brake block
to brake cylinders / rigid axle with

multi-disc brake
copyright by
MJF C I F S S
to collecting pipe
Seal kit, complete, consisting of
bellows, radial shaft seal ring and various
backing and O-rings
Service Manual
Compact brake block

Sectional drawing
22
27
to brake cylinders / rigid axle with

drum brake
Measuring point / accumulator pres- B60 Pressure switch / brake light*
sure
4 Sectional drawing
In A 312 Li from 12363, A 314 Li from 2001, A 316 Li from 2001
Fig. 4
Sectional drawing of compact brake block from start of series production
copyright by
MJF C I F S S
15.20.5
Compact brake block
Service Manual
Sectional drawing
Fig. 5
15.20.6
Exploded view of compact brake block from start of series production
Compact brake block
64
Brake piston
5
6

66
72
Screw plug
Spool
77
Screw plug
Pressure control element, complete

Check valve
78
Snap ring
Double check valve
81
Pin
10
Foot brake valve, complete
102
Threaded bolt
14
Spring plate
112
Screw plug
15
22
Washer
Washer
130
131
Valve insert, complete

Sleeve
24
31
Pipe
Spring plate
132
133
Bushing
Sleeve
38
Piston
134
Check valve
39
49
Spring plate
Pressure spring
135
141

Pressure switch
50
51
Pressure spring
Pressure spring
142
144
Seal ring
Pressure switch
52
53
Pressure spring
Pressure spring
163
165
Reducer
Screw plug
56
Pressure spring
166
Reducer
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MJF C I F S S
Service Manual
Compact brake block

Sectional drawing
57
58
Pressure spring
Pressure spring
999
B20
Seal kit, complete

Pressure switch / accumulator pressure*
63
Brake piston
B60
*
Pressure switch / brake light*

Item in electric diagram
5 Sectional drawing
In A 309 Li from 20221, A 309 Li from 20221, A 312 Li from 18335, A 314 Li from 18337,
A 316 Li from 18339, A 316 Li Ind. 18374
Fig. 6
Sectional drawing of compact brake block from start of series production
copyright by
MJF C I F S S
15.20.7
Compact brake block
Service Manual
Sectional drawing
15.20.8
copyright by
MJF C I F S S
Service Manual
SUBGROUP - INDEX
Section
Group
Type
Pipe fracture safety valve for boom cylinders
16.04.1
Pipe fracture safety valve for stick cylinder
16.06.1

for regulating cylinder
16.10.1
16.12.1
Hydraulic quick change adapter
16.16.1
Flow reduction
16.19.1
A 309 LI 20221A 311 LI 20222-
16.1
MJF C I F S S
Service Manual
Flow reduction
16.20.1
LIKUFIX Hydraulic Coupling System
16.24.1
Hydraulic hammers
16.30.1
Accessory kit AS1
16.44.1
Accessory kit AHS 1
16.48.1
16.52.1
16.54.1
A 309 LI 20221A 311 LI 20222-
16.56.1
16.2
MJF C I F S S
Service Manual
SUBGROUP - INDEX
Section
Group
Type
Accessory kit AHS 11 / AHS 12

with Tool Control
16.57.1
Accessory kit AHS 12 with changeover valve
16.58.1
Individual control
16.60.1
A 312 LI
A 314 LI
A 316 LI
A 316 LI-IND
Kit for control switch-over
16.62.1
A 309 LI 20221-23701
A 311 LI 20222-23253
16.62.21
A 309 LI 23702A 311 LI 23254-
16.64.1
Dozer blade
16.66.1
Hydraulic cab elevation system
16.70.1
Speeder kit
16.74.1
A 312 LI 12363A 314 LI 2001A 316 LI 2001A 316 LI-IND 200116.3
MJF C I F S S
Service Manual
Generator drive accessory kit
16.86.1
16.4
MJF C I F S S
A 316 LI-IND 2001-
Service Manual

Function

1 Function
The pipe fracture safety valve is installed directly at the pressure connection of the boom cylinder
(piston side).
The pipe fracture safety valve works independently of the load, pressure and adjusting pressure. It
protects the entire equipment against damage from pipe fracture.
The pipe fracture safety valve consists of a housing, a control piston (stop valve), the pilot piston required for actuation and a check valve (bypass of stop valve). The pressure-relief valve in the housing
is responsible for secondary protection.
In the event of a line break, the valve prevents uncontrolled lowering of equipment and/or the lifted
load. The pipe fracture safety valve blocks the corresponding cylinder connection when the control
pressure connection is not pressurised (without any leak oil).
Fig. 1
Pipe fracture safety valves at the boom cylinder (example of A 312 - R 317 model)
copyright by
MJF C I F S S
16.04.1
Service Manual
Sectional drawing, see Fig. 2, hydraulic diagrams, see Fig. 7 and Fig. 8.
2.1
Extending cylinder 160 / 235

The hydraulic oil flows now from the control block 100 connection A3 / A6 to the valve 238 connection
V2. The sleeves 12 and 42 (check valves) are shifted, and the pressure oil pressurises the piston side
of the cylinder through connection C2. The cylinder 160/235 is extended.
The return oil from the rod side flows through the connection B3 / A6 of the control block 100 to the
tank. When the working movement is completed, the check valve 8 closes again. The return line is
blocked, i.e. the load is held without any leak oil.
2.2
Pressure control
The secondary pressure control is based on the application of pressure onto the cone 29.7 through
the filter insert 30. In the event of pressure peaks, the cone 29.7 is shifted against the preloaded pressure spring 29.6, which results in a relief of the piston side. The oil escapes partly through the restrictor check valve 23, see Fig. 2 and Fig. 8 and pressurises, at the same time, the piston 3, which
then shifts the piston 7(see Fig. 2 on page3). More oil flows from the piston side through the open
valve 7 and the connection V2 to the control block 100 and the secondary pressure-relief valve 131/
221 (boom cylinder 160/235 extending). The valve 131 / 221 opens to allow the oil to flow back to the
tank.
2.3
Retracting cylinder 160 / 235

The pilot pressure at the control valve block 100, connection b3/b6, used to actuate the pilot control
piston 106/220 for working movement "Lowering attachment", pressurises at the same time the restrictor check valve 23 and the pilot piston 3 through connection Pil.
The pilot 3 presses against valve plunger 7.7 and, thus, shifts it against the pressure spring 7.5. After
a short stroke, the sleeve 42 finds purchase on valve guide 7.1, and the leak oil free shut-off device
is opened.
The hydraulic oil flows now from the control block 100 connection B3 to the rod-side connection V2.
The cylinder 160/235 is retracted.
The oil from the piston room flows via connections C2 and V2 to the control valve block, and from
there back to the hydraulic tank. Simultaneously, oil is fed from the variable-displacement pump through the respective connection in the control block to the rod side of the cylinder 160/235.
Key of sectional drawing, see Fig. 2
16.04.2
O-ring
14
Spring guide
Slide ring
15
O-ring
Pilot piston
16
Backing ring
Housing
17
Screw plug with O-ring
5
7

Pilot control piston, complete
19
23

7.1
Valve guide
27
Protective cap
7.2
7.3
Adjusting screw
Protective cap
29
Pressure-relief valve, complete
29.1 Valve guide
copyright by
MJF C I F S S
Service Manual

Sectional drawing
7.4
7.5
Seal ring
Pressure spring

29.3 Lock nut
7.6
7.7
Valve cone
Valve plunger
29.4 Spring guide

29.5 Seal ring
7.8
8
O-ring

29.7 Valve cone
8.1
Valve guide
30
Filter cartridge
8.2
9
Cone
O-ring
31
40
Screw plug with seal ring

Slide ring
10
11
Slide ring
O-ring
41
42
O-ring
Valve seat (sleeve)
12
Valve seat (sleeve)
43
Pressure spring
13
Pressure spring
44
Spring guide
3 Sectional drawing
Fig. 2
Sectional drawing of pipe fracture safety valve
copyright by
MJF C I F S S
16.04.3
Service Manual
Repair and sealing of valve 238
4 Repair and sealing of valve 238

.
Danger!
Defective valves can pose a serious risk to persons and property in the danger area.
For safety reasons, it is forbidden to repair pipe fracture safety valves.
Always replace pipe fracture safety valves with all associated parts, and install only new valves
supplied and preset by the manufacturer.
Return defective valves to the manufacturer, indicating the problem or damage you have observed.
4.1
Sealing work
In the event of external leakage of the valves, the valves may only be resealed, if this work does not
require the dismantling or the valve.
To reseal the valve, use only the seal kit provided by the manufacturer.
4.2
Assembly and dismantling of the pipe fracture safety valves

Danger!
The dismantling, installation or sealing of the valves requires workers to access the danger area of
the machine. This bears risks for the mechanic, as equipment might move uncontrolled when a valve/hydraulic circuit is opened.
Never open the hydraulic circuit of the pipe fracture safety valves while the circuit is pressurised.
Place the unloaded attachment on the ground (piston side of the cylinder must be fully depressurised)
Depressurise the pipe fracture safety valve(s) by actuating the pilot control device for lifting and
lowering to the stop and holding it in this position while the diesel engine is off (ignition and pilot
control system on).
After the hydraulic circuit of the valves 238 is opened, certain problems might occur caused by air in
the control circuit. The circuit must therefore be bled (collect escaping oil), see 4.3.
4.3
Bleeding of pipe fracture safety valve 238, see Fig. 3

If the measuring neck 52 is not available: Remove the screw plug from the connections Pil and T.
Screw the M12x1.5 screw coupling (tool no. 11 from group 2.01) into the bores.
Remove the protective cap from the measuring neck 52 at the connections Pil and T.
Install the Minimess high pressure hose between the connection Pil and connection T.
Start the engine.
Actuate the boom cylinder to retract it (keep pilot control unit pushed forward).
The control circuit is bled.
Lower the unloaded attachment onto flat and firm ground.
Release the tank pressure and the load-holding valve(s) by actuating the pilot control device for
control system on).
16.04.4
copyright by
MJF C I F S S
Service Manual

Remove the measuring hose and screw coupling.
Screw in the screw plug 13 at the connections Pil and T.
Fig. 3
52
Screw coupling for the bleeding of the hydraulic circuit and the pipe fracture safety valve
238
Screw coupling
copyright by
MJF C I F S S
16.04.5
Service Manual
Inspection and testing of pipe fracture valves
5 Inspection and testing of pipe fracture valves

Danger!
The inspection and testing of the pipe fracture safety valves require access to the danger area of
the machine. There is a risk to life and limb for mechanics from uncontrolled machine movements.
Only carry out inspections, if the machine is fully shut down and properly secured.
Before opening the hydraulic circuit release all pressure from the hydraulic system.
Valves 238 have been pre-set by the manufacturer. The setting cannot be changed and is secured
by means of a lead seal. Missing seals / protective caps are proof that the original settings have
been tampered with.
The readjustment of the pipe fracture safety valve settings is not permitted for safety reasons.
Should a subsequent inspection reveal that the settings are incorrect, remove the defective valves and replace them with new valves preset by the manufacturer.
5.1
Pressure check, see Fig. 4

Switch off the engine. Release the pressure from the valve.
Remove the plug 5 at the connection E and drain the pressure oil through the bleeding connection
52 and a measuring hose (collect escaping oil).
Insert the measuring connection 52 (1/4" tool, ID no. 7362579) into the connection E of the two
valves 238. In machines that are equipped with an overload warning system, insert the connection
only in the valve 238 of the left boom cylinder.
Instead of a measuring connection 52, you may connect a measuring hose and a measuring Tpiece to the bleeding connection 52, see group 2.01. Items 33, 34, 35, 36.
Remove the cap from the measuring point 40 / 41 (at the control block 100) and connect a Minimess hose between the measuring points 40 / 41 and 52 (in connection E).
Connect a pressure sensor (600 bar) with measuring connection (1.5 - 2.5 m) to the other measuring connection 52 of the valve 258 (connection E).
Turn the secondary pressure-relief valve 131/221 (spool 106/220) to extend the boom cylinder to
minimum 150 bar.
Reduce the pressure, so that the oil can flow through connection V2 of valve 238.
Fully pressurise the bucket and grapple cylinder to reach maximum pressure.
Turn in the secondary pressure valve 133/262 (spool 107/260) for extending the bucket cylinder,
(increase the pressure above the prescribed adjusting pressure of the valve = 410 + 10 bar).
Slowly turn in the pressure cut-off valve 104 (A 312- R 317) or the primary pressure-relief valve
120/122 (A 309 - A 311) and listen for pressure sounds.
When the secondary pressure-relief valve 29, (see Fig. 2 on page3), opens, a hissing sound
is audible.
16.04.6
copyright by
MJF C I F S S
Service Manual

The pressure indicated at the measuring point 52 must correspond to the prescribed adjusting
pressure of the valve.
If the prescribed adjusting pressure is not reached in the above test, replace the entire pipe fracture safety valve.
Remove the hose line.
Readjust the secondary pressure-relief valve, see adjustment protocol in group 6, and remove the
pressure gauge.
Fig. 4
Measuring points at the pipe fracture safety valves and at the respective pressure-relief
valves at the control blocks
40
Measuring point P1 (A 309 - A 311)
122
Primary pressure-relief valve (A 309/

311 with AHS)
41
Measuring point MP (A 312 - R 317)
131
52
Measuring neck
133
100
220
Secondary pressure-relief valve / extending boom cylinder

Secondary pressure-relief valve / extending bucket cylinder
Boom cylinder spool ( 312 - 317)
104
Pressure cut-off valve (A 312 - R 317)
221
copyright by
MJF C I F S S
16.04.7
Service Manual
5.2
106
107

238
260
120
Primary pressure-relief valve (A 309/ 311) 262

Bucket cylinder spool ( 312 - 317)
Check for leakage

In principle, there should be no leak oil at the pipe fracture safety valves. New valves might however
show some leakage, caused by internal drop leakage, so that the pressure might drop slightly within
the first 10 seconds. Subsequently, the leakage gap is sealed and leakage is prevented.
Fully extend the attachment with attached load.
Note!
For this test, the attached load may not exceed half of the maximum load capacity.
The load may not be greater than half the maximum load capacity
At operating temperature (approx. 50C), fully lift the attachment and hold it in this position.
The load may not drop by more than 100 mm within the first 10 seconds (according to ISO 8643).
If the drop is greater, there is a problem with the hydraulic unit or the valve. Inspect the valve to locate
and identify the problem.
Danger!
The inspection of the valves requires access to the danger area of the machine. This bears risks for
the mechanic, as equipment might move uncontrolled when a valve/hydraulic circuit is opened.
Extend the attachment so that the valve can be accessed.
Lift the attachment slightly (by approx. 20 cm).
Switch off the diesel engine and release the tank pressure.
Place an oil pan under the valve to collect the leak oil.
Remove the line to the high pressure connection V2, (see Fig. 4 on page7).
Measure the leak oil escaping at the valve.
If the leak oil volume exceeds 5 cm3 within 5 minutes, it is likely that the valve seat has been damaged.
In this case, replace the valve, (see 4.2 on page4).
16.04.8
50
to control oil unit
160
Boom cylinder
52
88T
Bleeding and measuring connection

Collecting pipe
235
238
Boom cylinder
100
Control valve block
copyright by
MJF C I F S S
Service Manual

Hydraulic connections and links
6 Hydraulic connections and links

6.1
Models A 309 - A 311
Fig. 5
Hydraulic connections and lines in models A 309 - 311
copyright by
MJF C I F S S
16.04.9

6.2
Models A 312 - R 317
Fig. 6
16.04.10
Hydraulic connections and lines in models A 312 R 317
copyright by
MJF C I F S S
Service Manual
Service Manual

copyright by
MJF C I F S S
16.04.11
Service Manual
Components of hydraulic diagram, see Fig. 7
16.04.12
to hydraulic tank
130
to slewing gear motor
to hydraulic oil cooler
131
20
132

cylinder
40
Measuring point P1
160
Boom cylinder
50
to control oil unit
162
Stroke limitation / boom cylinder
52
238
81/1 from right pilot control unit / connection 1

(lowering attachment)
238.7
Control piston

(lifting attachment)
100 Control valve block
238.8
Check valve
106
238.29 Pressure-relief valve

238.30 Filter
238.23 Restrictor check valve
copyright by
MJF C I F S S
Service Manual

Hydraulic diagram of pipe fracture safety system
7 Hydraulic diagram of pipe fracture safety system

7.1
Models A 309 - A 311
Fig. 7
Diagram of the hydraulic system of the pipe fracture safety system for the boom cylinder,
models A 309 - A 311
copyright by
MJF C I F S S
16.04.13
Service Manual
Components of hydraulic diagram, see Fig. 8

1
to hydraulic tank
221
222

cylinder
20
224
Pressure balance
23
to pump regulator
227
41
50
Measuring point MP
to control oil unit
235
238
Boom cylinder
52
238.7
Control piston

(lowering attachment)
238.8
Check valve

(lifting attachment)
100
238.29 Pressure-relief valve
220
16.04.14
Control valve block
238.30 Filter
copyright by
MJF C I F S S
Service Manual

7.2
Models A 312 - R 317
Fig. 8
Diagram of the hydraulic system of the pipe fracture safety system for the boom cylinder,
models A 312 - R 317
copyright by
MJF C I F S S
16.04.15

16.04.16
copyright by
MJF C I F S S
Service Manual
Service Manual

Function

1 Function
The pipe fracture safety valve is installed directly at the pressure connection of the stick cylinder (piston and rod side).
The pipe fracture safety valve works independently of the load, pressure and adjusting pressure. It is
used to protect the stick cylinder and the attached bucket stick with equipment against damage from
a pipe fracture.
The pipe fracture safety valve consists of a housing, a control piston (stop valve), the pilot piston required for actuation and a check valve (bypass of stop valve). The pressure-relief valve in the housing
is responsible for secondary protection.
In the event of a line break, the valve prevents uncontrolled lowering of equipment and/or the lifted
load. The pipe fracture safety valve blocks the corresponding cylinder connection when the control
pressure connection is not pressurised (without any leak oil).
Fig. 1
The pipe fracture safety valve at the stick cylinder (example of pipe fracture safety at both
ends)
copyright by
MJF C I F S S
16.06.1
Service Manual
Sectional drawing, see Fig. 2, hydraulic diagrams see Fig. 7 and Fig. 8 and Fig. 9.
2.1
2.1.1
Single-side pipe fracture safety valve (A 309 - R 317)

Extending cylinder 170 / 255
The pilot pressure at the control block 100 connection b2/b5 used to actuate the spool 102/240 for
working movement "extending stick cylinder" applies pressure to the pilot piston 3 of the rod-side valve 258. This pressure is applied through the connection Pil and the restrictor check valve 23.
is opened.
The hydraulic oil flows from the control block 100 connection B2/B5 to the piston-side connection of
the cylinder 170/255. The return oil from the piston side flows through the connections C2 and V2 of
the open valve 258 and the connection A2/A5 of the control block 100 to the tank (in A 309/311, the
oil also flows through the restrictor check valve 171). The cylinder 255 is extended. When the working
movement is completed, the check valve 8 closes again. The return line is blocked, i.e. the load is
held without any leak oil.
2.1.2
Pressure control
the filter insert 30. In the event of pressure peaks, the cone 29.7 is shifted against the preloaded pressure spring 29.6, which results in a relief of the piston rod side. The oil escapes partly through the
restrictor check valve 23, see Fig. 7 and Fig. 8 and pressurises, at the same time, the piston 3, which
then shifts the piston 7(see Fig. 2 on page5). More oil flows from the piston rod side through the open
valve 7 and the connections C2 and V2 to the control block 100 and the secondary pressure-relief
valve 127/241 (stick cylinder 170/255 retracting). The valve 127 / 241 opens to allow the oil to flow
back to the tank.
2.1.3
Retracting cylinder 170 / 255

The pilot control pressure at the control pressure 100 connection a2/a5 acts on the spool 102/240 for
the working movement "retracting stick cylinder".
The hydraulic oil flows from the control block 100 connection A2/A5 (in A309/311: also through the
restrictor check valve 171) to the rod-side valve 258 connection V2. The sleeves 12 and 42 (check
valves) are shifted, and the pressure oil pressurises the piston side of the cylinder through connection
C2.
The return oil from the piston side flows through the connection B2/B5 of the control block 100 to the
tank. The cylinder 170 / 255 is retracting. When the working movement is completed, the check valve
8 closes again. The return line is blocked, i.e. the load is held without any leak oil.
2.2
2.2.1
Double-side pipe fracture safety valve (A 312 - R 317 only)

Extending cylinder 255
The pilot pressure at the control block 100 connection b5 used to actuate the spool 240 for working
movement "extending stick cylinder" applies pressure to the pilot piston 3 of the rod-side valve 258.
This pressure is applied through the connection Pil and the restrictor check valve 23.
16.06.2
copyright by
MJF C I F S S
Service Manual

is opened.
The hydraulic oil now flows from the control block 100 connection B5 to the piston-side valve 258
connection V2. The sleeves 12 and 42 (check valves) are shifted, and the pressure oil pressurises
the piston side of the cylinder through connection C2. The cylinder 255 is extended.
The return oil from the piston side flows through the connections C2 and V2 of the open valve 258
and the connection A5 of the control block 100 to the tank. When the working movement is completed, the check valve 8 closes again. The return line is blocked, i.e. the load is held without any leak oil.
2.2.2
Pipe fracture safety valve at piston side

the filter insert 30. In the event of pressure peaks, the cone 29.7 is shifted against the preloaded pressure spring 29.6, which results in a relief of the piston side. The oil escapes partly through the restrictor check valve 23(see Fig. 8 on page14) and pressurises, at the same time, the piston 3, which
then shifts the piston 7(see Fig. 2 on page5).
In a next step, more oil from the cylinder piston side flows via V2 to the control valve block 100 and
the secondary relief valves 242 (stick cylinder 255 extending). The valve 242 opens to allow the oil
to flow back to the tank.
2.2.3
Retracting cylinder 255

The pilot pressure at the control block 100 connection a5 used to actuate the spool 240 for working
movement "retracting stick cylinder" applies pressure to the pilot piston 3 of the piston-side valve 258.
This pressure is applied through the connection Pil and the restrictor check valve 23.
is opened.
The hydraulic oil now flows from the control block 100 connection A5 to the piston-side valve 258
connection V2. The sleeves 12 and 42 (check valves) are shifted, and the pressure oil pressurises
the piston side of the cylinder through connection C2. The cylinder 255 is retracted.
The return oil from the piston side flows through the connections C2 and V2 of the open valve 258
and the connection B5 of the control block 100 to the tank. When the working movement is completed, the check valve 8 closes again. The return line is blocked, i.e. the load is held without any leak oil.
2.2.4
Pipe fracture safety valve at rod side

the filter insert 30. In the event of pressure peaks, the cone 29.7 is shifted against the preloaded pressure spring 29.6, which results in a relief of the piston side. The oil escapes partly through the restrictor check valve 23(see Fig. 8 on page14) and pressurises, at the same time, the piston 3, which
then shifts the piston 7(see Fig. 2 on page5).
More oil from the rod side flows through V2 to the control block 100 and the secondary pressure-relief
valves 241 (retracting stick cylinder 255) or the secondary pressure-relief valve 241 (retracting stick
cylinder 255). The valve 241 opens to allow the oil to flow back to the tank.
copyright by
MJF C I F S S
16.06.3
Service Manual
Key of sectional drawing, see Fig. 2
16.06.4
O-ring
14
Spring guide
2
3
Slide ring
Pilot piston
15
16
O-ring
Backing ring
Housing
17
19
Pilot control piston, complete
27
Protective cap
7.1
7.2
Valve guide
Adjusting screw
29
29.1 Valve guide
7.3
Protective cap
7.4
7.5
Seal ring
Pressure spring
29.3 Lock nut

29.4 Spring guide
7.6
Valve cone
29.5 Seal ring
7.7
7.8
Valve plunger
O-ring

29.7 Valve cone
8
8.1

Valve guide
30
31
Filter cartridge
Screw plug with seal ring
8.2
Cone
40
Slide ring
9
10
O-ring
Slide ring
41
42
O-ring
Valve seat (sleeve)
11
12
O-ring
Valve seat (sleeve)
43
44
Pressure spring
Spring guide
13
Pressure spring
copyright by
MJF C I F S S
Service Manual

Sectional drawing
3 Sectional drawing
Fig. 2
Sectional drawing of pipe fracture safety valve
copyright by
MJF C I F S S
16.06.5
Service Manual
4 Repair and sealing of valve 258

.
Danger!
For safety reasons, it is forbidden to repair pipe fracture safety valves.
Always replace pipe fracture safety valves with all associated parts, and install only new valves
supplied and preset by the manufacturer.
4.1
Sealing work
In the event of external leakage of the valves, the valves may only be resealed, if this work does not
require the dismantling of the valve.
4.2
Assembly and dismantling of the pipe fracture safety valves

Danger!
Never open the hydraulic circuit of the pipe fracture safety valves while the circuit is pressurised.
Place the unloaded attachment on the ground (piston side of the cylinder must be fully depressurised)
Depressurise the pipe fracture safety valve(s) by actuating the pilot control device for lifting and
control system on).
After the hydraulic circuit of the valves 258 is been opened, certain problems might occur caused by
air in the control circuit. The circuit must therefore be bled (collect escaping oil), see 4.3.
4.3
Bleeding of pipe fracture safety valve 258, see Fig. 3

Release the tank pressure and the load-holding valves by actuating the pilot control device for lowering to the stop and holding it in this position while the diesel engine is off (ignition and pilot
control system on).
16.06.6
copyright by
MJF C I F S S
Service Manual

Screw in the screw plug 13 at the connections Pil and T.
Fig. 3
Screw coupling for the bleeding of the hydraulic circuit and the pipe fracture safety valve
52
Screw coupling
255
Stick cylinder
170
Stick cylinder
258
copyright by
MJF C I F S S
16.06.7
Service Manual
5 Inspection and testing of pipe fracture valves

Danger!
The inspection and testing of the pipe fracture safety valves require access to the danger area of
the machine. There is a risk to life and limb for mechanics from uncontrolled machine movements.
Valves 258 have been pre-set by the manufacturer. The setting cannot be changed and is secured
by means of a lead seal. Missing seals / protective caps are proof that the original settings have
been tampered with.
Should a subsequent inspection reveal that the settings are incorrect, remove the defective valves and replace them with new valve preset by the manufacturer.
5.1
Pressure check, see Fig. 4

Switch off the engine. Release the pressure from the valve.
Remove the plug 5 at the connection E and drain the pressure oil through the bleeding connection
52 and a measuring hose (collect escaping oil).
Measuring connection 52 (1/4", tool ID no. 7362579) in the connection E of the two valves 258,
instead of a additional measuring connection 52, you may connect a measuring hose and a
measuring T-piece to the bleeding connection 52, see group 2.01. Items 33, 34, 35, 36.
Remove the cap from the measuring point 40 / 41 (at the control block 100) and connect a Minimess hose between the measuring points 40 / 41 and 52 (in connection E).
Connect a pressure sensor (600 bar) with measuring connection (1.5 - 2.5 m) to the other measuring connection 52 of the valve 258 (connection E).
Turn out the secondary pressure-relief valve 127 /128 or 241/242 (spool 102/240) for the stick cylinder by minimum 150 bar.
Reduce the pressure, so that the oil can flow through the connection V2 of the valve 258.
Fully pressurise the bucket and grapple cylinder to reach high pressure.
Turn in the secondary pressure valve 133/262 (spool 107/260) for extending the bucket cylinder,
(increase the pressure above the prescribed adjusting pressure of the valve = 410 + 10 bar).
Slowly turn in the pressure cut-off valve 104 (A 312- R 317) or the primary pressure-relief valve
120/122 (A 309 - A 311) and listen for pressure sounds.
When the secondary pressure-relief valve 29, (see Fig. 2 on page5), opens, a hissing sound
is audible.
The pressure indicated at the measuring point 52 must correspond to the prescribed adjusting
pressure of the valve.
16.06.8
copyright by
MJF C I F S S
Service Manual

If the prescribed adjusting pressure is not reached in the above test, replace the entire pipe fracture safety valve.
Remove the hose line.
Readjust the secondary pressure-relief valve, see adjustment protocol in group 6, and remove the
pressure gauge.
Fig. 4
A
A
Measuring points at the pipe fracture safety valves and at the respective pressure-relief
valves at the control blocks
Pipe fracture safety valve, single side (A 127

309 - R 317)
Pipe fracture safety valve, double side 128
(A 312 - R 317)
Secondary pressure-relief valve / extending stick cylinder

Screw plug
133
40
41

170
240
Stick cylinder
Spool of stick cylinder (312 - 317)
52
Measuring neck
241
100
242
104
Pressure cut-off valve (A 312 - R 317)
255
Secondary pressure-relief valve / retracting stick cylinder

Stick cylinder
102
107
Spool of stick cylinder (A 309 - 311)

Bucket cylinder spool (A 309 - 311)
258
260

Bucket cylinder spool (312 - 317)
120
Primary pressure-relief valve (A 309 A 262

311)
Primary pressure-relief valve (A 309/
311 with AHS)
122
copyright by
MJF C I F S S
16.06.9
Service Manual

6.1
Single-side pipe fracture safety valve, models A 309 - A 311
Fig. 5
16.06.10
Hydraulic connections and lines in models A 309 - 311
52
Bleeding connection / Minimess
170
Stick cylinder
88T
100
Collecting pipe
258
copyright by
MJF C I F S S
Service Manual

6.2
Single-side and double-side pipe fracture safety valve, models A 312 - R 317
Fig. 6
Hydraulic connections and lines in models A 312 R 317
copyright by
MJF C I F S S
16.06.11
Service Manual
Components in hydraulic diagram, see Fig. 7 and Fig. 8 and Fig. 9

1
Hydraulic tank
170
Stick cylinder
6
20

171
240
Restrictor check valve / stick cylinder

23
to pump regulator
241
Secondary pressure-relief valve / retracting stick cylinder
41
242
41
244
Pressure balance
50
Screw coupling (install for measurement)
247
52
Measuring and bleeding connection
255
Stick cylinder
80/1
from left pilot control unit / connection 1 258

(retracting stick cylinder)
from left pilot control unit / connection 3 258.7
(extending stick cylinder)
80/3
16.06.12

Control piston
100
102
Control valve block

258.8 Check valve

127
Secondary pressure-relief valve / retrac- 258.29 Pressure-relief valve

ting stick cylinder
128
Secondary pressure-relief valve / exten- 258.30 Filter

ding stick cylinder
130
to slewing gear motor
copyright by
MJF C I F S S
Service Manual

7 Hydraulic diagram of pipe fracture safety system

7.1
Single-side pipe fracture safety valve, models A 309 - A 311
Fig. 7
Diagram of the hydraulic system of the pipe fracture safety system for the stick cylinder,
models A 309 - A 311
copyright by
MJF C I F S S
16.06.13
Service Manual
7.2
Single-side pipe fracture safety valve, models A 312 - R 317
Fig. 8
16.06.14
copyright by
MJF C I F S S
Service Manual

7.3
Double-side pipe fracture safety valve, models A 312 - R 317
Fig. 9
copyright by
MJF C I F S S
16.06.15
Service Manual
16.06.16
copyright by
MJF C I F S S
Service Manual
Pipe fracture safety valve for regulating cylinder

Function

for regulating cylinder
1 Function
The two load-holding valves used as pipe fracture safety valves are installed directly at the pressure
connections of the regulating cylinder.
In the event of a pipe break, the valves prevent uncontrolled lowering of the equipment and/or the
attached load. The pipe fracture safety valves block the corresponding cylinder connection when the
control pressure connection is not pressurised (without leak oil).
The load-holding valve described here is outlet pressure compensated, i.e. the pressure limitation
and actuation function is independent of the load pressure at the outlet connection V2.
The load-holding valve consists of a housing, a control piston (stop valve), the pilot piston required
for actuation and a check valve (bypass of stop valve).
Fig. 1
Pipe fracture safety valve at the regulating cylinder
copyright by
MJF C I F S S
16.10.1
Service Manual
see sectional drawing on page 3 and hydraulic diagram on page 11.
2.1

The pilot control pressure at the auxiliary control block 500 connection b6 used to operate the spool
500 for working movement "extending regulating cylinder" also pressurises the pilot piston 50 of the
load-holding valve 517 (piston rod side) through the connection Pil, the filter 60 and the nozzle 61.
The pilot piston 50 in the valve 517 presses against the valve plunger 51 and pushes it against the
pressure spring 54. After a short stroke, the sleeve 57 finds purchase on valve guide 52, and the leak
oil free shut-off device is opened.
The hydraulic oil now flows from the auxiliary control block 500 connection B6 to the valve 516 connection V2. The sleeves 57 is shifted, and pressure oil pressurises the piston side of the cylinder through connection C2. The cylinder 515 is extended.
The oil in the piston rod chamber flows through the open valve 517 connections C2 and V2 to the
spool 500 and from there back to the hydraulic tank.
When the working movement is completed, the sleeve 57 is closed (check valve). The return line is
blocked, i.e. the load is held without any leak oil. When the working movement "extending regulating
cylinder" is completed, the control pressure at the connection Pil drops and the valve 517 is also
closed without leak oil..
2.2

The pilot control pressure at the auxiliary control block 500 connection a6 used to operate the spool
500 for working movement "retracting regulating cylinder" also pressurises the pilot piston 50 of the
load-holding valve 516 (piston side) through the connection Pil, the filter 60 and the nozzle 61.
The pilot piston 50 in the valve 516 presses against the valve plunger 51 and pushes it against the
pressure spring 54. After a short stroke, the sleeve 57 finds purchase on valve guide 52, and the leak
oil free shut-off device is opened.
The hydraulic oil now flows from the auxiliary control block 500 connection A6 to the valve 517 connection V2. The sleeves 57 is shifted, and pressure oil pressurises the piston side of the cylinder through connection C2. The cylinder 515 is retracted.
The oil in the piston chamber flows through the open valve 516 connections C2 and V2 to the spool
500 and from there back to the hydraulic tank.
When the working movement is completed, the sleeve 57 is closed (check valve). The return line is
blocked, i.e. the load is held without any leak oil. When the working movement "retracting regulating
cylinder" is completed, the control pressure drops and the valve 516 is closed without leak oil.
2.3
Pressure control
The secondary pressure control is based on the application of high pressure on the valve plunger 51,
which pushes against the adjustable pressure spring 54. In the event of pressure peaks, the valve
plunger 51 is shifted against the preloaded pressure spring 54, thus opening the connection for the
oil from the cylinder chamber to the connection V2. The oil can flow to the auxiliary control block 500
and secondary pressure-relief valve 501 (retracting regulating cylinder 515), or the secondary pressure-relief valve 502 (extending regulating cylinder 515). The valve 501 / 502 opens to allow the oil
to flow back to the tank. The pressure peak in the cylinder chamber are reduced.
16.10.2
copyright by
MJF C I F S S
Service Manual

Fig. 2
Sectional drawing of the load-holding valve
Housing
35
Backing ring
Slide ring
36
Seal washer
O-ring
41
O-ring
5
6
O-ring
Screw plug
42
50
O-ring
Pilot piston
Screw plug
51
Valve plunger
O-ring
52
Valve guide
10
Backing ring
53
Valve cone
11
12
Screw plug
O-ring
54
55
Pressure spring
Adjusting screw
13
Screw plug
56
Protective cap
14
O-ring
57
Valve seat (sleeve)
21
USIT ring
58
Pressure spring
30
Slide ring
59
Spring guide
32
Slide ring
60
Filter
33
34
O-ring
O-ring
61
Nozzle ( 0.6 mm)
copyright by
MJF C I F S S
16.10.3
Service Manual
Repair and sealing of valve 516 / 517
3 Repair and sealing of valve 516 / 517

.
Danger!
For safety reasons, it is forbidden to repair load-holding valves.
Always replace load-holding valves with all associated parts, and install only new valves supplied and preset by the manufacturer.
3.1
Sealing work
In the event of external leakage of the valves, the valves may only be resealed, provided that this
does not require the dismantling of the valve.
3.2
Mounting and dismantling of the pipe fracture safety valves

Danger!
Never open the hydraulic circuit of the load-holding valves while the circuit is pressurised.
Place the unloaded attachment on the ground (piston side of the cylinder must be fully depressurised).
Depressurise the load-holding valve(s) by actuating the pilot control device for lifting and lowering
to the stop and holding it in this position while the diesel engine is off (ignition and pilot control
system on).
After the hydraulic circuit of the valves 516/517 is opened, certain problems might occur caused by
air in the control circuit. The circuit must therefore be bled (collect escaping oil), see 3.3.
3.3
Bleeding of the load-holding valve 516 / 517, see Fig. 3

Release the tank pressure and the load-holding valve(s) by actuating the pilot control device for
lifting and lowering to the stop and holding it in this position while the diesel engine is off (ignition
and pilot control system on).
16.10.4
copyright by
MJF C I F S S
Service Manual

Repair and sealing of valve 516 / 517
Screw in the screw plug at the connections Pil and T.
Fig. 3
Screw coupling for the bleeding of the hydraulic circuit and the load-holding valve
52
Screw coupling
516
Load holding valve
515
Regulating cylinder
517
Load-holding valve
copyright by
MJF C I F S S
16.10.5
Service Manual
Testing of load-holding valve(s)
4 Testing of load-holding valve(s)

Danger!
The inspection and testing of the load-holding valves require access to the danger area of the machine. There is a risk to life and limb for mechanics from uncontrolled machine movements.
The valves 516 / 517 have been pre-set by the manufacturer. The settings cannot be changed and
are secured by means of lead seals. Missing seals / protective caps are proof that the original settings have been tampered with.
Should a subsequent inspection reveal that the settings are incorrect, remove the defective valves and replace them with new valve preset by the manufacturer.
4.1
Pressure check
Due to the high adjustment pressure, it is not possible to check the pressure.
16.10.6
copyright by
MJF C I F S S
Service Manual

Fig. 4
1
Exploded view from ET list

500
Hydraulic tank
from auxiliary control valve block (low

pressure)
52
Screw coupling at connection Pil and T
515
Regulating cylinder
86
from auxiliary pilot control unit
516
517
Load-holding valve, piston side

Load-holding side, piston rod side
copyright by
MJF C I F S S
16.10.7
Service Manual
Components in hydraulic diagram, see Fig. 5
16.10.8
to hydraulic tank
86
from auxiliary pilot control unit
6
20
to oil cooler
100
104
Control valve block

23
to pump regulator
500
Auxiliary control axle with spool for regulating cylinder
41
Measuring point MP for pump pressure
501
Secondary pressure-relief valve / retracting regulating cylinder
48
Bleeding opening for connection Pil and T 502
Secondary pressure-relief valve / extending regulating cylinder
49
Pressure balance
50
Retrofitted measuring point for load pres- 504

sure at connection E
Pilot piston
515
51
Valve plunger / main valve
54
57
Pressure spring
Sleeve / check valve
60
61
Filter
Nozzle
Regulating cylinder
516
517
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MJF C I F S S
Service Manual

Hydraulic diagram
6 Hydraulic diagram
Fig. 5
Hydraulic diagram of pipe fracture safety valve, regulating cylinder
copyright by
MJF C I F S S
16.10.9

Hydraulic diagram
16.10.10
copyright by
MJF C I F S S
Service Manual
Service Manual

Function

1 Function
Machines used for lifting loads (lifting, transporting and lowering loads attached to the machine with
lifting tackle such as chains, cables, etc.) where personnel other than the machine operator are required to attach and release the loads, are subject to certain safety regulations laid down in the European standard EN 474-5. Lifting operations also include lifting and lowering of pipelines, shaft rings
and vessels.
Fig. 1
Equipment options of the overload warning system
Overload warning system with pipe-fracture safety, e.g. in model A 309 / 311
Overload warning system with pipe-fracture safety, e.g. in model A 312 - R 317
copyright by
MJF C I F S S
Overload warning system with pipe-fracture safety, e.g. in model A 312 - R 317
16.12.1
Service Manual
Function
Danger!
The machine may only be used for lifting operations, if it is equipped with the necessary safety devices and when these devices are in proper working order, see 1.1.
The overload warning system disables the machine as soon as a set load moment is exceeded. The
operator is thereby informed of the cause of the shut-down. When operating the machine to lift
loads, always adhere to the relevant safety and accident prevention regulations.
If the warning system is disabled or its signals (buzzer sound and indicator light) are ignored, there
is a risk of serious injury or even death to the machine operator.
A copy of the load lift chart must be available in the operator's cab.
Before carrying out any lifting operation, always enable the overload warning system.
At the start of each shift, test the overload warning system:
Fully extend the boom cylinder (max. operating pressure is built up)
A visual and acoustic warning signal must be emitted.
As soon as the warning symbol for load moment is on, reduce the reach of the boom.
Machines used to lift loads must undergo an annual load test, (see 1.4 on page3).
Defective machines may not be used to lift loads.
The unit must be repaired by specialist technicians and tested according to the testing and adjustment guidelines.
1.1
Safety devices for load lifting operation

Lifting tackle:
safe attachment of a load
Lift hooks attached to the machine instead of a digging bucket, or safety hooks welded to the digging bucket are deemed safe.
Overload warning system:
If the actual load reaches or exceeds the permissible load according to the load lift chart, the overload warning system must generate a visual and audible alarm signal to the machine operator.
Pipe fracture safety valve:
This valve is flange-mounted to the boom cylinder connection on the piston side. The pipe fracture
safety valve must conform to the requirements laid down in ISO 8643.
1.2
General
If the maximum permissible load is reached or exceeded, the overload warning system notifies
the machine operator with a warning light H16 located on the control console (see Fig. 2) and an
audible signal from the buzzer H10.
As a rule, only loads with a known weight might be lifted, so that the suitability of the machine for
the task can be determined by means of the load lift chart.
The load lift values in the chart correspond to max. 75% of the tip load or 87% of the hydraulic
lifting power according to ISO 10567
In machines equipped with a backhoe bucket attachment (including bucket cylinder, change lever
and connecting link), the values are applicable to the tip of the stick. If the oscillating axle is closed,
and the machine is standing on a level ground, the load can be swivelled by 360.
If the bucket cylinder, change lever and connecting link are removed, the values are increased by
the values that apply to the above parts of equipment.
If a quick change adapter is used, the values are reduced by the 110 kg for SWA 33 and 190 kg
for SWA 48.
16.12.2
copyright by
MJF C I F S S
Service Manual

Function
For industrial equipment, the values at the lift hook apply, and loads can be swivelled by 360 if
the oscillating axle is closed and the machine is standing on firm and level ground.
The load values also depend on any attached tools, such as grapples, etc.
1.3
Start-up
The overload warning system may only be used in connection with the lifting of loads.
Activate the warning system with the switch S18 (see Fig. 2).
Before the initial start-up of the warning system, adjust it according to the instructions in the adjustment guidelines.
All moving parts of the warning system must be regularly inspected for unobstructed movement
and lubricated.
1.4
Load test
Proceed as described below:
Determine the test load by multiplying the load-bearing capacity according to the table for swivelled loads (no support) or traverse extension by factor 1.33 and adding 150 kg. Attach a test
load to the machine at the prescribed extension (see table), taking into account any other attached
bucket or tool (grapple, etc.).
Carefully swivel the uppercarriage with the attached load (suspended to just above the ground)
by 360.
Ensure that the machine does not tip over. One wheel or a section of the track might be lifted off
the ground.
The warning system must be triggered.
The settings of the warning system must be inspected at least once every year by a specialist
technician and adjusted according to the adjustment protocol and guidelines.
Note!
Deactivate the overload warning system when working with a digging bucket, as the great force
used for such operations would constantly trigger the overload warning system.
Press the switch S18.
Overload warning system is deactivated.
LED in the switch is off.
copyright by
MJF C I F S S
16.12.3
Service Manual
Design and function
Fig. 2
Switch and indicator light in the front right control console
H16Indicator light
S360 Switch / buzzer acknowledgement
S18 Switch / overload warning system

The switch S18 is located in the control console.
The indicator light in the switch is off.
Overload warning system is activated.
A constant pressure switch B21 with measuring point 66 is located at the pipe fracture safety valve
or directly at the boom cylinder 160/235.
When the maximum load-bearing capacity is reached , i.e. load pressure in the boom cylinder =
switching pressure, e.g. 141 bar - (punched into the plate B), (see Fig. 4 on page7).
The pressure switch B21 makes electrical contact to the indicator light H16 and the buzzer
H10.
The indicator light H16 is on (visual signal).
The buzzer H10 emits an acoustic signal.
The switching pressure is set at the pressure switch B21 and depends on the machine model.
16.12.4
copyright by
MJF C I F S S
Service Manual

Overload warning system with hydraulic connections
3 Overload warning system with hydraulic connections
Fig. 3
Installation of an overload warning system at the boom cylinders
52
238
160
235
Boom cylinder
Boom cylinder
B21 Pressure switch

(*)
Switching pressure (machine-specific)
4 Setting instructions
Remove the cover cap at the measuring connection 52 and connect a pressure sensor/gauge in
such a way that the dial is visible from the operator's cab.
Switch on the warning system by actuating the switch S18.
Open the stop cock (if any) between the warning system and the boom cylinder connection.
Move the boom cylinder 160/235 to it upper stop to check whether the warning system's pressure
switch B21 is working properly (indicator light H16 and buzzer H10, see Fig. 2, on).
Carefully actuate the right pilot control unit (extending boom cylinder) to establish the prescribed
switching pressure (embossed in the plate B of the switch B21), see Fig. 4. The value embossed
at the pressure switch is binding.
copyright by
MJF C I F S S
16.12.5
Service Manual
Setting instructions
4.1
Example:
Machine
Attachment*
A 309
A 311
A 312
R 313
A 314
A 316
and
A 316
Ind.
317
169-5
178-5
141-5
161-5
141-5
145-5
175-5
138-5
146-5
150-5
with gooseneck boom
with gooseneck boom

(with 2-point or blade support)
with gooseneck boom

(with 2-point/4-point or blade
support)
with gooseneck boom

(horizontally adjustable)
Pressures in bar
with hydraulic
boom adjustment
with hydraulic
boom adjustment (with 2-point
or blade support)
132-5
with hydraulic boom adjustment

(vertical and horizontal)
with hydraulic boom adjustment
(with 4-point or
blade and outrigger support)
167-5
177-5
159-5
147-5
145-5
147-5
150-5
170-5
Note!
* This table contains only examples of standard machines. For other situations, refer to the pressure
tables for the respective machine model or contact our technical department.
For machines with retrofitted overload warning system:
The switching pressure is indicated in the enclosed installation drawing (pressure table) and embossed in the plate B, arrow see Fig. 4.
If the warning system fails to emit a signal when the prescribed limit pressure is reached, the switching pressure can be corrected at the respective pressure switch B21:
Remove the cap K (if any).
Loosen the self-locking screw SS of the pressure switch B21.
Turn the adjusting screw ES with a suitable screwdriver to adjust the switching pressure:
Turn clockwise
Increase switching pressure
Turn anticlockwise
Reduce switching pressure
Secure the adjusting screw ES with the self-locking screw SS .
Replace the cap K (if any).
If the warning system is only triggered at a higher pressure, the switching point (pressure) must be
adjusted again. A lower switching pressure is permissible.
16.12.6
copyright by
MJF C I F S S
Service Manual

Fig. 4
B21
Pressure switch with adjusting device and pressure indication
Pressure switch
Plate (with switching pressure*)
K
ES
Protective cap
Adjusting screw / switching point
SS
Self-locking screw
(*)
Switching pressure (machine-specific)
copyright by
MJF C I F S S
16.12.7
Service Manual
16.12.8
66
H16
Indicator light
100
100
A5 control block / connection

B5 control block / connection
S18
S20

to sensor control switch
160
Boom cylinder (A 309/A 311)
X407
161
Pipe fracture safety valve (A 309/A 311) X950

233
Distribution block / boom cylinder
X951
235
238
Boom cylinder (A 312 - R 317)

Pipe fracture safety valve (A 312 - R
317)
X953
X958

A126
B21

Constant pressure switch
Electrical system / basic machine
H10
Buzzer
Electrical system / kit
copyright by
MJF C I F S S
Service Manual

Hydraulic and electric diagram
5 Hydraulic and electric diagram
Fig. 5
Hydraulic and electric diagram of the overload warning system
copyright by
MJF C I F S S
16.12.9
Service Manual
Hydraulic and electric diagram
16.12.10
copyright by
MJF C I F S S
Service Manual

Function

1 Function
If several different attachments are to be used in short sequence, we recommend using a hydraulic
quick change adapter, as this helps to reduce the set-up time for the bucket.
The relevant parts are available as an accessory kit. It contains all mechanical, hydraulic and electrical components for the operation of the equipment.
The locking and release function of the quick change adapter are operated through the hydraulic circuit for the grapple rotator (AS1).
Note!
For the safe operation of the attached working tools, always adhere to the instructions in the separate operating and maintenance manual for hydraulic/mechanical quick change adapters.
Fig. 1
copyright by
MJF C I F S S
16.16.1
Service Manual
Design of quick change adapter
2 Design of quick change adapter

see Fig. 2
The hydraulic quick change adapter consists of the following main components:
Quick change unit 10
Locking unit 20
Cylinder 30
Covering parts 50
Securing flaps 60
Low pressure block 110 or auxiliary control axle 540
Solenoid valves Y28-1,Y28-2
Control elements S5L/S5R, S19, S47, see Fig. 4 and associated wire harnesses
To secure the adapters when closed, they are equipped with two single-acting solenoid valves Y281 and Y28.2 in connections at the piston and the piston rod ends of the locking cylinder.
The quick change adapter is operated through the AS1 (grapple rotator).
In models A 309 - A 311: screw-mounted to the fuel tank above the spool 113 of the low pressure
block 110 (offset boom bearing / grapple rotator).
For pressure protection, a pressure-relief valve 123 is screwed into the low pressure block 110 and
set to 110 bar; for details, see adjustment protocol for the hydraulic unit, group 6.09 / 6.11.
In models A 312 - R 317: flange-mounted above the auxiliary control axle 540 to the slewing gear
axle 120 of the control block 100.
For pressure protection, the pressure-relief valves 541/542 are screwed into the auxiliary control
block 540 and set to 120 bar; for details, see the instructions for settings and check of the "AS1" accessory kit or the tilting bucket, group 16.44.
To protect the locking unit 20 against dirt or damage, the system is equipped with covering parts 50.
16.16.2
copyright by
MJF C I F S S
Service Manual

Fig. 2
Main components and drive system of the hydraulic quick change adapter
10
123
20
50
Locking unit
Covering parts
540
541
Spool of hydraulic drive

Secondary relief valve / retracting cylinder
100
542
110
Low pressure block
Y22
Secondary relief valve / extending cylinder

Solenoid valve / locking adapter
113
Spool of hydraulic drive
Y23
Solenoid valve / releasing adapter
copyright by
MJF C I F S S
16.16.3
Service Manual
Fig. 3
10
16.16.4
Design of hydraulic quick change adapter

100
Heavy-duty roll pin
20
Locking unit
B26
Proximity switch with plug
30
Hydraulic cylinder
Y28-1
2/2-way valve
50
60
Covering parts
Securing flap
Y28-2
2/2-way valve
copyright by
MJF C I F S S
Service Manual

see Fig. 10
3.1
Working position quick change adapter locked

To attach a working tool (bucket, etc.), actuate the switch S19 and the button S47 together with the
push button S5L (indicator lights in the switches are on).
Press the left push button S5L - in the left joystick 80 to power the solenoid valve Y22, the button S47
and the solenoids Y28-1/Y28-2 (via A 1017). As long as S5L remains pushed down, S47 can be released (holding function).
The oil of the gear or working pump flows from the low pressure block 100 connection B2 , or from
the auxiliary control axle 540 connection B02 through the strainer 33 to the way valve Y28-2 in flowthrough position. The oil applies pressure to the piston side of the locking cylinder 24 via the connection B-B. The return oil from the piston rod side flows through the way valve Y28-1 connection A-A
and connection A2 /A02 of the block 110/540 to the tank.
The cylinder 30 is extended, pressing the two locking bolts 21 outwards (through levers). The tool is
now bolted to the quick change unit 10. When the left push button S5L is released, the power supply
to the solenoids Y28-1/Y28-2 is discontinued and the way valves are switched to blocking position.
The blocking valves Y28-1/Y28-2 protect the locking mechanism against release by inadvertent operation of the push button S5R. Actuate the switch S19 (indicator light in the switch is off).
In the event of inadvertent retraction of the locking bolts 21, for whatever reason, the proximity switch
B26 is triggered and an electrical signal is sent to the buzzer H10 and the indicator light H26 (locking
bolts retracted). The machine operator is thus made aware by an acoustic and a visual signal of the
imminent danger. In the event of such a signal, work must be immediately interrupted and the problem must be rectified.
3.2
Changing position quick change adapter released

To remove a working tool (bucket, etc.), actuate the switch S19 and the button S47 together with the
push button S5R (indicator lights in the switches are on).
Press the right push button S5R - in the right joystick 80 to power the solenoid valve Y23, the button
S47 and the solenoids Y28-1/Y28-2 (via A 1017). As long as S5R remains pushed down, S47 can be
released (holding function).
The oil of the gear or working pump flows from the low pressure block 100 connection A2 , or from
the auxiliary control axle 540 connection A02 through the strainer 33 to the way valve Y28-1 in flowthrough position. The oil applies pressure to the piston rod side of the locking cylinder 21 via the connection A-A. The return oil from the piston side flows through the way valve Y28-2 connection B-B
and connection B2 /B02 of the block 110/540 to the tank.
The cylinder 30 is retracted, pulling with it the pins 21, so that the attached tool is released.
When the pins 21 are retracted, the proximity switch B26 is activated. The buzzer H10 and the indicator light H26 are activated, indicating that the quick change adapter is released.
Release the right push button S5R. Attach a new tool, or deactivate the switch S19 (indicator light in
the switch is off).
Note!
For load-lifting work without digging bucket, the pins of the quick change adapter must be retracted.
The buzzer H10 can be set to mute by means of S360.
copyright by
MJF C I F S S
16.16.5
Service Manual
Operation of the quick change adapter
4 Operation of the quick change adapter
Fig. 4
80
S19
Switch / quick change adapter
H26
S5L
Indicator light / quick change adapter

Push button / locking quick change
adapter
Push button / releasing quick change
adapter
S47
S360
Switch / quick change adapter

Switch / buzzer acknowledgement
S5R
4.1
Control elements
Switch S19
S19
Press the switch.
The auxiliary equipment is activated.
The indicator lamp in the switch is on.
Press the switch again.
The auxiliary equipment is deactivated.
The indicator lamp in the switch is off.
16.16.6
copyright by
MJF C I F S S
Service Manual

Operation of the quick change adapter
4.2
Button S47
Press the button S47 to activate the quick change adapter. The lock pin can now be operated.
Press and hold the button, until the button S5L/S5R is actuated (holding function activated).
The quick change adapter is activated.
The indicator light in the button S47 is on.
To change the direction of movement of the lock pin, press and hold the button S47 again.
4.3
Button S5L / S5R

Actuate the push buttons S5L and S5R to lock and unlock the tool.
Press and hold the buttonS5R.
The lock pins are retracted, releasing the tool.
The indicator light H26 is on and the buzzer H10 emits a warning sound.
Press and hold the buttonS5L.
The lock pins are extended.
The indicator light H26 is off and the buzzer H10 is switched off.
4.4
Indicator light H26

The indicator light H26 shows the current operating status of the quick change adapter:
The quick change adapter is released / the lock pins are retracted.
The buzzer H10 emits a warning sound.
The quick change adapter is locked / the lock pins are fully extended.
The buzzer H10 is off.
4.5
Switch S360 (buzzer acknowledgement)

In machines with built-in and activated overload warning system, the warning signal of the buzzer
H10 can be set to mute with switch S360 to prevent unnecessary distraction.
The buzzer H10 is off.
The buzzer H10 only emits a warning signal after the lock pins have been extended again.
copyright by
MJF C I F S S
16.16.7
Service Manual
Maintenance instructions
5 Maintenance instructions
The filter disc 35 must be regularly inspected for dirt and cleaned, if necessary. The inspection interval depends on the frequency of use of the quick change adapter but may not exceed 2000 operating
hours.
In the process of this inspection, also check the pins, levers and bearings of the quick change adapter
for wear. Replace any damaged parts.
Remove the screws 51 and then remove the cap 50 from the quick change adapter.
Remove the screw connections and hydraulic hoses at the piston rod and the piston sides of the
hydraulic cylinder 30.
Unscrew the external support body 36, using a suitable tool (e.g. a thumb tack).
Remove and inspect the filter disc 35 and clean or replace it, if necessary.
Place the filter disc 35 onto the inner internal support body 34 and mount the external support
body 36.
Connect the screw connections and hydraulic hoses at the hydraulic cylinder 30.
Secure the lid 50 to the quick change adapter, using the screws 51.
Fig. 5
16.16.8
Cleaning mesh filter
30
Cylinder
36
External support body
34
35
Internal support body

Filter disc
50
51
Lid / covering parts

Hex head screw
copyright by
MJF C I F S S
Service Manual

Adjustment of the proximity switch B26 settings
6 Adjustment of the proximity switch B26 settings

In the event of a malfunction of the warning system, check the distance of the proximity switch B26
to the lock pin 21 and adjust it, if necessary.
Retract the lock pin 21.
Turn in the proximity switch B26 to the stop at the pin 21.
Turn back the switch B26 by one full revolution = distance of 1 mm (tolerance 0.3 mm is permissible).
Tighten the lock nut 90 again.
After this adjustment, carry out a functional test of the switch B26 by extending and retracting the
lock pins 21.
Fig. 6
21
90
Locking unit with proximity switch
B26
Lock pin
Lock nut
copyright by
MJF C I F S S
Proximity switch
16.16.9
Service Manual
Sealing elements bearing head / piston
7 Sealing elements bearing head / piston
Fig. 7
r
16.16.10
Sealing kit bearing head / piston
36
Bearing head
75
Piston rod bearing
70
71
Double scraper ring

O-ring
76
77
Piston guide ring

O-ring
72
O-ring
78
Turcon AQ seal
73
Backing ring
998
Seal kit / piston
74
Seal ring (Zurcon-L-Cup)
999
Seal kit / bearing head / piston
copyright by
MJF C I F S S
Service Manual

Exploded view of quick change adapter
8 Exploded view of quick change adapter
Fig. 8
Exploded view of quick change adapter
20
Locking unit
33
Filter disc
21
Pin
36
Bearing head
22
Left lever
38
Hex nut
23
24
Right lever
Pin
39
40
Retaining washer
Piston rod
25
26
Heavy-duty roll pin

Heavy-duty roll pin
41
42
Piston
Screw plug
30
Cylinder
Parts are secured with Loctite 243
copyright by
MJF C I F S S
16.16.11
Service Manual
Hydraulic diagrams with electrical components
9 Hydraulic diagrams with electrical components

9.1
Quick change adapter in models A 309 - A 311

1
16.16.12
A1017 Printed circuit board / quick change

adapter
to hydraulic tank
10
Quick change unit
B26
Proximity switch
20
Locking unit
H10
Warning buzzer
21
Lock pin
H26
Indicator light
30
Cylinder
K364
Quick change relay
31
from gear pump / low pressure

Residual flow distributor
S5L
Push button/auxiliary activation left, or

locking quick change adapter
33
Filter disc
S5R
45
Low pressure measuring point
S19
Push button/auxiliary activation right, or

releasing quick change adapter
Switch / auxiliary activation
80
110

Low pressure control block
S47
S360
Push button
111
Input section
X262
Plug connections,
see electric diagrams
112
X411
113
Spool grapple rotator / quick change

adapter
X412
Plug connection,
Plug connection,
123
X413
Plug connection,
156
157
Check valve
Adjustment restrictor / oil volume
Y22
Y23
Solenoid / locking adapter

Solenoid / releasing adapter
158
Shuttle valve
Y28-1
Y28-2
Solenoid / seat valve rod side

Solenoid / seat valve piston side
copyright by
MJF C I F S S
Service Manual

Fig. 9
Hydraulic diagram with electric components, models A 309 - A 311
copyright by
MJF C I F S S
16.16.13
Service Manual
9.2
Quick change adapter in models A 312 - R 317

10
16.16.14
20
Locking unit

adapter
B26
Proximity switch
21
Lock pin
H10
Quick change unit
Warning buzzer
30
Cylinder
H26
Indicator light
33
Filter disc
K364
Quick change relay
80
S5L
88P
from pressure manifold
S5R
Push button/auxiliary activation left, or

locking quick change adapter
Push button/auxiliary activation right, or
releasing quick change adapter
S19
88T
to collecting pipe return line
120
540

S47
Spool of hydraulic drive grapple rotator / S360
quick change adapter
Push button
541
Secondary pressure-relief valve / retrac- X262

ting cylinder
Plug connections,
542
Secondary pressure-relief valve, exten- X411

ding cylinder
Plug connection,
544
Pressure balance
X412
Plug connection,
X413
Y22
Plug connection,
Solenoid / locking adapter
Y23
Solenoid / releasing adapter
Y28-1
Y28-2

copyright by
MJF C I F S S
Switch / auxiliary activation
Service Manual

Fig. 10
Hydraulic diagram with electric components, models A 312 - R 317
copyright by
MJF C I F S S
16.16.15
Service Manual
Electrical system
10
Electrical system
Fig. 11
11
Exploded view of electrical system

adapter
X262-4
B26
Proximity switch of quick change adapter
X262-5
H26
Indicator light quick change adapter
X262-6 Plug-type connection at B26 / 3-pin
S47
Push button / quick change adapter
X798
S360 Switch / buzzer acknowledgement

X262-1 Plug connection / 8-pin
Y28-1
Y28-2
Solenoid / seat valve

X262-3 Plug connection / 8-pin
100
101
Cable harness of revolving deck

Cable harness of quick change adapter
Electric diagram of hydraulic quick change adapter

For the electrical diagrams of the hydraulic quick change adapter, please refer to the electrical documentation of the attachments and basic machine of the respective model in group 8.
16.16.16
copyright by
MJF C I F S S
Service Manual
Flow reduction
Function
Flow reduction
1 Function
Certain attachments such as hammers, etc. require specific flow rates and volumes that are lower
than those generated normally by the machine. Otherwise, these attachments might not work properly.
The flow reduction can be easily adjusted by the operating personnel to suit any connected attachment.
With the AHS 12 accessory kit, preset flow reductions can be activated.
Fig. 1
Attachments such as hydraulic hammers, sorting grapples, and various auxiliary cylinders
Note!
The flow reduction must conform to the maximum permissible oil volume as specified by the manufacturer of the attachment (e.g. hydraulic hammer).
Factory-set AHS 12 accessories are configured for a maximum oil flow for hammers of approx. 65
l/min.
copyright by
MJF C I F S S
16.19.1
Flow reduction
Service Manual
Function
2 Function
Fig. 2
Operator's cab with printed circuit board, pilot control device, switch kit, proportional solenoid valve and pump regulator
21
Pump P1
A125 Potentiometer board
50
70
Control oil unit

Actuation device / pump regulator
B290 Proximity switch / flow reduction

S241 Switch / AHS 12 kit
78
integrated spool/stroke limitation
Y51
86
Pilot control device / kit
The desired or required oil flow volume is determined by the current fed to the proportional solenoid
valve Y51 and the proportional actuation pressure to the spool 78 of the actuation device 70 of the
variable-displacement pump P1. It determines the flow reduction (stroke limitation of pump P1), resulting from the additional force applied to the spool of the pump regulator.
The solenoid current (in mA) from BST (U16) to the proportional solenoid valve Y51 is preset at the
respective potentiometer P1 / P2 / P3 and determines the proportional control pressure at the outlet
LS of the proportional solenoid valve Y51.
The start signal for the flow reduction is preselected by the operator by means of the switch S241
(position 2) and the process is initiated with the proximity switch B290.
The pump P1 is pivoted to a smaller angle (irrespective of the working pressure of the pump), see
also group 7.02, stroke limitation in Service Manual 1 - 7. As a result, the oil flow volume to the attachment is reduced.
16.19.2
copyright by
MJF C I F S S
Service Manual
Flow reduction
Adjustment of pump flow volume
3 Adjustment of pump flow volume

3.1
Diagram for the determination of the required control pressure
Fig. 3
Diagram for the adjustment of the desired pump flow rate
QP1 Pump flow rate pump P1
PY51 Control pressure from valve Y51 to pump

connection X1
copyright by
MJF C I F S S
16.19.3
Flow reduction
Service Manual
3.2
Example of calculation of the control current/control pressure by means of the

diagram
For its HM 190 model, the hammer manufacturer Krupp specifies an oil flow rate between 50 and
90 l/min, see also group 16.30.
Based on these specifications, the maximum permissible flow volume of pump P1 must be set to a
reduced pump flow.
The corresponding current to the proportional solenoid valve Y51 or the corresponding control pressure from the solenoid valve Y51 to the pump P1 respectively are indicated in the diagram with an
arrow.
In the above case, based on a required oil flow rate of 75 l/min, a current of 0.41 A (410 mA) / control
pressure of approx. 14.5 bar is required in an A 309 / A 311 model.
The control pressure is thereby the determining setting. The current value must be regarded as a guide value only.
3.3
Measurement and adjustment of the reduced pump flow rate

Note!
In order to achieve correct values, check the basic settings of the machine (for settings and values, see adjustment protocol).
To accurately adjust the flow reduction to the required value, the operator must measure the oil flow
at the consumer, using a measuring turbine and suitable gauge (LMS system).
An initial adjustment (rough adjustment) can be made without any need for dismantling, based on
the flow diagram and guide values (see Fig. 3, page 3) and by following the instructions below.
Fig. 4
50
Y51
Operator's cab with pilot control device/kit, potentiometer board and control oil unit with
proportional solenoid valve / flow reduction
K
Console
Control oil unit

16.19.4
copyright by
MJF C I F S S
Clamping mechanism
Service Manual
Flow reduction
The printed circuit board A125 is located behind the left control console and can be accessed as follows:
Move the operator seat to the front stop position.
Release the clamping mechanism S at the console K.
Remove the console K from the operator's cab.
3.3.1
Adjustment procedure
Fig. 5
Adjustment of the control pressure from the proportional solenoid valve to the pump by
means of the adjusting screw of the potentiometer
Measuring point for control pressure at the pump

P1
Potentiometer / flow volume 1
20
21

Pump P1
P2
P3
57
Measuring point / servo pressure flow reduction

Set the switch S241 to position 2 (hammer icon is illuminated).
Press the pedal of the pilot control device 86 (hammer operation),see Fig. 4, to the stop.
Using a screwdriver, turn the adjusting screw of the potentiometer P1 / P2 / P3 until the pressure
value measured at the measuring point 57 corresponds to the value determined from the diagram
(see Fig. 3, page 3).
After adjustment, remove the pressure sensor and seal the measuring point.
Mount the console K and readjust the position of the operator seat.
Note!
If the adjustment of the flow rate is completed with a measuring turbine, there is no need to refer to
the diagram, (see Fig. 3, page 3), as any adjustment made to the potentiometer can be directly observed at the turbine.
Prior to adjusting the flow reduction with a measuring turbine, ensure that the basic machine settings are OK.
copyright by
MJF C I F S S
16.19.5
Flow reduction
Service Manual
16.19.6
copyright by
MJF C I F S S
Service Manual
Flow reduction
Function
Flow reduction
1 Function
Certain attachments such as hammers, pile drivers, etc. require specific flow values that are lower
than those generated under normal operating conditions. Otherwise, these attachments might not
work properly. This means that the maximum pump flow rate must be reduced.
Operating personnel should be in a position to easily and efficiently adjust the flow to the level required for the attachment.
The accessory kits AHS 11 / AHS 12, see group 16.48 or 16.50, allow for the reduction of the flow
rate of the machine, so that it can be used together with various attachments.
D
Fig. 1
Attachments such as hydraulic hammer, sorting grapple and additional consumer
copyright by
MJF C I F S S
16.20.1
Flow reduction
Service Manual
General description and function of the flow reduction
2 General description and function of the flow reduction

2.1
Flow reduction
The flow to the consumer is calculated on the basis of the maximum oil volume that can be fed to the
consumer at the chosen settings.
The flow reduction is achieved by reducing the spring force at the LS regulator.
To do this, a control pressure must be built up that acts against the spring force. The pressure results
in a reduction of the normal spring force (for pressure, see adjustment protocol in group 6). The flow
reduction is thus based on the following principle:
-p.
Flow rate Q in l/min = cross-section A of the restrictor (spool opening) x
Regular
The
-p (= 23+1 bar) maximum flow rate.
-p is reduced by means of the proportional valve Y51 that is part of the control oil unit 50.
The necessary control pressure of for example 23 - 16 bar = 7 bar determines the residual flow volume of the pump
In machines that are equipped with the AHS 11 or AHS 12 accessory kit, a pressure and flow reduction can be achieved, see also group 16.48 and 16.50.
By setting the switch S241, at the control desk, to the positions 0 / 1 / 2 the pressure and/or flow rate
are reduced.
The flow reduction is actuated by means of the signal to the relays K375 and U16. The excavator
control U16 then powers the solenoid valve Y51 with a defined current, which is adjusted at the respective potentiometer P1 / P2 / P3.
The settings of the potentiometer P1 / P2 / P3 (located on the printed circuit board A125) can be adjusted as follows:
3 Adjustment of flow reduction settings

Note!
In order to ensure correct adjustment, first check the basic settings of the machine, see adjustment
protocol or guidelines in group 6.)
Also check the settings of the stroke limitation of the spool / auxiliary axle (dimension Y), see group
7.60.
To accurately adjust the flow reduction to the required value, the operator must measure the oil flow
at the consumer, using a measuring turbine and suitable gauge (LMS system).
An initial adjustment (rough adjustment) can be made without any need for dismantling, based on
the flow diagram and guide values (see Fig. 5, page 6) and by following the instructions below.
The values in the table are average values of a series of measurements. They might deviate slightly
from machine to machine, i.e. the average value pMLS in the table 0.5 bar (or 5%) applies.
The flow rates prescribed by the manufacturers of the working tools (hydraulic hammer, etc.) are
compiled in a diagram in group 16.30, where you can also determine the control pressure at the
measuring point MLS that corresponds to the required flow rate.
16.20.2
copyright by
MJF C I F S S
Service Manual
Flow reduction
Adjustment of flow reduction settings
3.1
3.1.1
Position of the printed circuit board A 125 with potentiometers P1/P2/P3

in models A 312 to 20432, A 314 to 20333 and A 316 to 20339
Fig. 2
50
57
Control oil unit


B291 Proximity switch / sensor control
86
Cover/electric cabinet
EK Electric cabinet
S241 Switch AHS 11 / AHS 12 accessory kit
Y51
The printed circuit board A125 is located in the electric cabinet behind the left control console and
can be accessed as follows:
Remove the screws and lift the cover D from the electric cabinet EK.
copyright by
MJF C I F S S
16.20.3
Flow reduction
Service Manual
3.1.2
In models A 309 / A 311 and R 317 from start of series, A 312 from 20433, A 314
from 20334 and A 316 from 20340
Fig. 3
50
Control oil unit
A125
Potentiometer board
57
B291
Proximity switch / sensor control
86
K
S
Console / function box

Clamping mechanism
S241
Y51
Switch AHS 11 / AHS 12 accessory kit

3.2
Adjustment procedure, see Fig. 2, see Fig. 3 and Fig. 4

Set the switch S241 to position 2 (hammer icon is illuminated).
Press the pedal of the pilot control device 86 (hammer operation),see Fig. 2, to the stop.
Using a screwdriver, turn the adjusting screw of the potentiometer P1 / P2 / P3 until the pressure
value measured at the measuring point 57 corresponds to the value determined from the diagram
(see Fig. 5, page 6).
16.20.4
copyright by
MJF C I F S S
Service Manual
Flow reduction
After adjustment, remove the pressure sensor and seal the measuring point.
Mount the console K and readjust the position of the operator seat.
Fig. 4
Adjustment of the desired flow rate by means of a potentiometer
Note!
If the adjustment of the flow rate is completed with a measuring turbine, there is no need to refer to
the diagram, (see Fig. 5, page 6), as any adjustment made to the potentiometer can be directly observed at the turbine.
Prior to adjusting the flow reduction with a measuring turbine, ensure that the basic machine settings are OK.
copyright by
MJF C I F S S
16.20.5
Flow reduction
Service Manual
Diagram for flow reduction in A 312 R 317 (Y51)
4 Diagram for flow reduction in A 312 R 317 (Y51)
Fig. 5
4.1
Diagram for flow reduction for hammer operation with A 312 R 317
Example for the determination of the control pressure for a HM350 hydraulic
hammer from diagram
For its HM 350 model, the hammer manufacturer Krupp specifies an oil flow rate between 60 and
100 l/min, see also group 16.30.
Based on these specifications, the maximum permissible flow volume of the pump must be set to a
reduced pump flow.
To determine the control pressure of the proportional solenoid valve Y51 follow the arrow in the diagram.
In the above example, where the required oil flow is 80 l/min (average value) in model A 312 - A 316,
the control pressure is approx. 16.5 bar.
16.20.6
copyright by
MJF C I F S S
Service Manual

Task

1 Task
The newly developed LIKUFIX hydraulic coupling system allows for the automatic coupling of hydraulic lines together with the hydraulic quick change adapter. The operator therefore does not have to
connect or disconnect the hydraulic lines of working tools.
System requirements for hydraulic excavators:
Original Liebherr quick change adapter SWA
Recommended kits in AHS 11/12 basic unit (required for the operation of hammers, sorting grapple, shears, etc.)
AHS lines mounted to basic boom and AHS boom.
Mountable working tools:
Ditch cleaning bucket 2x45, 2x50 swivelling
Clamshell grab / multiple tine grab
Sorting grapple
Hydraulic hammer
Shear
Plate vibrator
etc.
Fig. 1
LIKUFIX coupling system
copyright by
MJF C I F S S
16.24.1
Service Manual
Design of LIKUFIX hydraulic coupling system
2 Design of LIKUFIX hydraulic coupling system
Fig. 2
2.1
16.24.2
LIKUFIX coupling system with attachments
Protective cover at the quick change adapter 4
Protective cover at the working tool
LIKUFIX hydraulic coupling at quick change

adapter
LIKUFIX hydraulic coupling at the working

tool
Alternative hydraulic coupling at the working
tool
Design of the LIKUFIX coupling system mounted to quick change adapter 33 /

48
copyright by
MJF C I F S S
Service Manual

Fig. 3
2.1.1
LIKUFIX 33 / 48 accessory kit
Design, see Fig. 4

The coupling housing 10 is secured with the Allen head screws 21/22 to the quick change adapter.
The coupling sleeves 60/70 are inserted into the coupling housing, and are secured by means of the
retaining plates 80 or tie-down devices 90/100 and the Allen head screws 81.
The fixture includes a locking plate 110 preventing inadvertent turning of the union nuts of the hydraulic hoses. The guide bushings 50 are press-mounted into the housing 10 and ensure proper
alignment of the coupling to the counterpart at the attachment.
The protective cover 30 protects the LIKUFIX hydraulic coupling system against dirt and damage
from impacts. When the coupling is not in use, or when attachments without mating plates are used,
it is inserted into the guides provided at the coupling housing 10.
copyright by
MJF C I F S S
16.24.3
Service Manual
2.2
Exploded drawing of LIKUFIX mounted to quick change adapter
Fig. 4
16.24.4
LIKUFIX mounted to quick change adapter
10
Coupling housing
80
Retaining plate
21
Allen head screw
81
Allen head screw
22
Allen head screw
82
Retaining washer
30
Protective cover
90
Tie-down device
50
Guide bushing
100
Tie-down device
60
70
Coupling sleeve
Coupling sleeve
110
Locking plate
copyright by
MJF C I F S S
Service Manual

2.3
Design of LIKUFIX coupling system mounted to the attachments
Fig. 5
2.3.1
LIKUFIX mounted to attachment
Design, see Fig. 6

The coupling system can be mounted onto various attachments.
The coupling plugs 10/20 see Fig. 5 are inserted into the coupling housing 10 and then secured with
the holders 80/90 and Allen head screws 81, see Fig. 4.
The plungers 50 are inserted in to the housing see Fig. 4 of the attachment and secured with screws.
They are used to compensate the applied operating pressure in the coupling system, ensuring that
the two coupling housings 10 are pressed against each other with increasing force when the pressure
is increased.
The pressure springs 40 are secured with the Allen head screws 41/42 to the coupling housing 10.
Thanks to this floating bearing, the pressure springs 40 compensate strains that might occur during
the coupling procedure.
The guide bolts 20 are secured with the Allen head screws 21 to the connection side of the housing
10. They ensure proper alignment of the coupling halves during the coupling procedure. During coupling, the guide bolts 20 are inserted into the guide bushings 50, see Fig. 4 at the quick change side
of the housing. They also prevent the housing 10 from being shifted horizontally.
The protective cover 30 protects the LIKUFIX hydraulic coupling system against dirt and damage
from impacts. When the coupling system is not in use, the cover is placed on the guide bolts 20 at
the coupling housing 10.
copyright by
MJF C I F S S
16.24.5
Service Manual
2.4
Exploded drawing of LIKUFIX mounted to an attachment
Fig. 6
16.24.6
LIKUFIX for attachments
10
Coupling housing
80
Retaining plate
20
21
Guide bolt
Allen head screw
81
82
Allen head screw

Washer
30
40
Protective cover
Pressure spring
90
91
Tie-down device
Allen head screw
41
42
Allen head screw

Allen head screw
92
100
Retaining washer
Tie-down device
50
Plunger
copyright by
MJF C I F S S
Service Manual

2.5
Assembly drawing of LIKUFIX
Fig. 7
The attachment-specific LIKUFIX 33 / 48 accessory kit 20 is inserted into the housing 10

and secured with screws
10 LIKUFIX 48 for digging bucket

11 Hex head screw
41 Hex head screw

42 Retaining washer
12 Retaining washer
20 LIKUFIX (accessory kit)
43 Washer
80 Stop
30 Protective cover
40 Cover
81 Allen head screw

90 Plug
copyright by
MJF C I F S S
16.24.7
Service Manual
Function of LIKUFIX hydraulic coupling system
3 Function of LIKUFIX hydraulic coupling system

3.1
Description of functions, see Fig. 20

The basic function of the LIKUFIX hydraulic coupling system corresponds to that of the hydraulic
quick change adapter, see group 16.18.
3.1.1
Check valves Y 376-1 / Y 376-2

Die Sperrventile sind in den Hydraulikkreislauf des Anbausatzes AS1 installiert. They block off the
oil flow channels when the attachment is removed. Beim Bettigen des Schnellwechslers ber Drucktaste S5R/S5L werden die Magnetventile Y376-1 und Y376-2 bestromt und sperren den ldurchfluss
zu den Anschlssen E und D am LIKUFIX. Der lkreislauf beim Koppeln bzw.Entkoppeln ist somit
drucklos.Nicht Bestromt sind sie geffnet, so dass das l zu den Anschlssen E und D gelangen
kann.
T
Fig. 8
A Working line (high pressure)
Y376-1 solenoid valve rotating grab right
B Working line (high pressure)

E Hydraulic line rotating grab left
Y376-2 solenoid valve rotating grab left
16.24.8
Check valves mounted on boom
Hydraulic line rotating grab right
copyright by
MJF C I F S S
Service Manual

3.1.2
Relief valves Y 387-1 / Y 387-2

The relief valves are integrated into the high-pressure lines of the AHS 11/AHS 12 accessory kit.
They ensure that the pressure lines can be opened to the tank so that the pressure is released when
the LIKUFIX coupling system is disconnected. By pressing the S5R/S5L button of the quick change
adapter, the solenoid valves Y 387-1 and Y 387-2 are powered, opening the fluid flow so that the fluid
pressure in line A or B is released through the restrictor 40 to the tank.
3.1.3
Inspection of relief valves

Disconnect attachment.
Press left and/or right AHS pedal.
Quick change mechanism is operated.
Pressure is released through valves Y387-1 or 387-2 respectively (hissing noise).
Watch high-pressure hoses A and B for pulsating movements.
Note!
When the S5L or S5R button is activated, all 6 solenoid valves Y 28-1/Y28-2 (quick change adapter activation) Y376-1,Y376-2 (check valves) and Y 387-1, Y 387-2 (relief valves) are powered
in parallel.
Fig. 9
In models manufactured before 08/2003, the relief valves Y387-1/Y387-2 are mounted at
the tank 1.
40
Restrictor
X262-3 Plug connection
Y376-1 Check valves

Y376-2 Check valves
copyright by
MJF C I F S S
16.24.9
Service Manual
Fig. 10
16.24.10
In models manufactured after 08/2003, the relief valves Y387-1/Y387-2 are mounted at
the control valve block 100.
40
Restrictor
X262-3 Plug connection
100
Control valve block - connections
Y387-1 Relief valve

Y387-2 Relief valve
copyright by
MJF C I F S S
Service Manual

3.2
Function of the plunger cylinders 50
Fig. 11
3.2.1
Hydraulic connections of the plunger cylinders at the attachment and changeover

valve
10
Coupling plug
60
Changeover valve
20
Coupling plug
90
Mount plug
50
Plunger cylinder
Control of the plunger cylinders 50

The plunger cylinders 50 are controlled and operated through the working line A (in other attachments: through working lines A and B). The operating pressure built up in the couplings repels the
coupled plates from each other. The plunger cylinders counteract this force. For rotating grab attachments, the force of the spring plate package 50 is sufficient, see Fig. 12. If a high-pressure circuit is
used, the plungers must be operated in addition to the spring plate kit.
The disc springs 50, see Fig. 12 mounted in the plunger ensure that the coupling plates 10 are properly held together by applying pressure provided by the working line A .
The correct number of disc springs 50, combined with the required pressure from line A produce the
required counterforce.
The surfaces are calculated in such a way that the coupling plates are pressed together.
While the coupling is closed, the plates are thus pressed against each other and cannot be separated
by the applied working pressure in the couplings 10/20.
Note!
The additional control of the plunger cylinders 50 is only required for certain attachments. In plunger
cylinders with a low working pressure, mount plug 90. When using couplings E and D (rotating grab),
we recommend filling the plunger cylinders 50 to one third with oil.
copyright by
MJF C I F S S
16.24.11
Service Manual
3.3
Exploded drawing of plunger
Fig. 12
16.24.12
Plunger (X = observe correct alignment and position of disc springs).
10
Plunger cylinder
31
Circlip
11
O-ring
50
Disc spring
12
20
Scraper ring
Piston
990
991
Mounting sleeve for Glyd ring

Expanding sleeve for Glyd ring
21
Turcon-Glyd ring
992
22
O-ring
993
Mounting sleeve (insertion aid for piston

into cylinder)
Mounting sleeve for scraper ring
30
Thrust plate
999
Cylinder seal kit
copyright by
MJF C I F S S
Service Manual

Fig. 13
A = decoupled; B = coupled (offset due to conversion of radial movement of the quick

change adapter linear movement of the coupling plate).
High pressure hose from A or B
Disc spring pack
copyright by
MJF C I F S S
Plunger cylinder
16.24.13
Service Manual
Coupling sleeves / coupling plugs
4 Coupling sleeves / coupling plugs

4.1
Coupling/decoupling, see Fig. 14 to see Fig. 17

When connecting the coupling sleeves and plugs together, the plug 10/20 can be inserted into the
sleeve 60/70 until it touches the collar. In the process, valve 10.4 of the coupling plug is pushed inward by valve 60.2 of the coupling sleeve 60/70.
As soon as the coupling housing is closed, and the coupling plug 10/20 is fully inserted into the coupling sleeve 60/70, the oil flow channel through the coupling is opened, allowing for oil flow to the
consumer and/or the tank. The O-rings 60.11 and 60.12 act as seals for the valve 60.2.
When decoupling the system, the housings 10.1/60.1 are decoupled. The valves 10.4/60.6 are closed
by the pressure springs 60.4/60.8 . The flow channel is thus blocked, so that no fluid can escape. The
dust cover 60.7 at the coupling sleeve 60/70 prevents dirt and dust penetrating the decoupled device.
The O-rings 60.11/12/13 at the coupling sleeve 60/70 act as seals for the valve 60.2 so that no oil
can escape. The profile ring 10.3 at the coupling plug 10/20 also protects the valve 10.4 against dirt
and dust and provide a seal for the valve, similar to the O-rings 10.7and 10.8.
Fig. 14
10
20
16.24.14
Coupling plug and coupling sleeve
60
70
Coupling plug M24X1,5

Coupling plug M36X2
copyright by
MJF C I F S S
Coupling sleeve M24X1,5

Coupling sleeve M36X2
Service Manual

4.2
Sectional drawing of coupling sleeves / plugs
Fig. 15
10
.4
A = coupling open; B = coupling closed
60
.2
Coupling plug M24X1,5

Valve
Coupling sleeve M24X1,5

Valve
.6
Spring
.4
Spring
20
Coupling plug M36X2
.6
Valve cover
.7
Dust cover
.8
Spring
70
copyright by
MJF C I F S S
16.24.15
Service Manual
Fig. 16
16.24.16
Sectional drawing of coupling sleeve
60
Coupling sleeve M24X1.5
.7
Dust cover
70
.1

Housing
.8
.9
Spring
Adapter
.2
.3
Valve
Valve seat
.10
.11
Retainer
O-ring
.4
.5
Spring
Guide
.12
.13
O-ring
O-ring
.6
Valve cover
copyright by
MJF C I F S S
Service Manual

Fig. 17
Sectional drawing of coupling plug
10
20
Coupling plug M24X1.5

.4
.5
Valve
Valve seat
.1
.2
Plug housing
Adapter
.6
.7
Spring
O-ring
.3
Profile ring
.8
O-ring
Note!
O-ring 8 might become dislodged and flushed away during coupling procedures. If this O-ring is
found on the surface of the coupling plug:
Remove the O-ring.
The O-ring acts only as a seal to prevent oil leakage during the replacement of the profile
rings .3.
copyright by
MJF C I F S S
16.24.17
Service Manual
Mounting and dismantling of working tools
5 Mounting and dismantling of working tools

Note!
The LIKUFIX quick change adapter is operated as described in group 16.15 Hydraulic quick
change adapter.
Please observe the following additional instructions:
Before mounting the equipment, remove the protective covers of the quick change adapter and
the working tool.
Keep the coupling housings 3 and 4 clean at all times.
Before mounting the attachment, inspect the coupling parts for contamination and dirt. If necessary, brush off dirt and dust, and clean the coupling parts and sealing faces with a clean cloth and
oil. The coupling parts are treated with Gleitmo 900 spray at the factory. This protective treatment
should be repeated when necessary.
Slowly connect or disconnect the hydraulic couplings to/from the respective attachment.
Tilt the quick change adapter at the attachment so that the coupling plates can easily be connected due to the weight of the working tool.
Extend locking bolt.
If the plates cannot be easily connected to each other, check whether a foreign object (stone, etc.)
is jammed between the parts. If this is the case, clean the coupling parts to prevent damage by
subsequent coupling.
Adjust the oil level and pressure to the attached tool.
After completion of the work, and especially before transport, mount the protective covers.
Fig. 18
16.24.18
LIKUFIX during coupling
Coupling housing upper section at the

quick change adapter
copyright by
MJF C I F S S
Coupling housing lower part at the attachment e.g. grapple
Service Manual

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.
copyright by
MJF C I F S S
16.24.19
Service Manual
Hydraulic and electric units
7 Hydraulic and electric units

Key to hydraulic diagram
3
LIKUFIX part at quick change adapter
540
LIKUFIX part at attachment
541
Secondary relief valve / rotation right
10/20
40
Coupling plug
Restrictor
542
544
Secondary relief valve / rotation left

Pressure balance
60/70
Coupling sleeve
550
80
Pilot control valve left
S5L
Push button / grapple rotator left
88P
Manifold P
S5R
Push button / grapple rotator right
88T
110
Collecting pipe T
Low pressure-control valve block
S19
Y22

Solenoid valve / Grapple rotation left
113
Spool grapple rotator
Y23
Solenoid valve / Grapple rotation right
120
Y28-1

156
Check valve
Y28-2
157
158
Adjusting restrictor
Two way check valve
Y376-1 Check valve on base side

Y376-2 Check valve on boom side
515
517
Hydraulic hammer
Additional consumer
Y387-1 Relief valve

Y387-2 Relief valve
10*
Hydraulic quick change device (kit)

see group 16.15
Key to electric diagram

B26
Proximity switch of quick change adapter

X262-1 Plug-type connection, 8-pin or 3-pin
X263-3 Plug-type connection / 2-pin

X452-2 Plug-type connection to SV Y376-2

Y28-1 Solenoid valve of quick change device
X262-4 Plug-type connection at valve 28-1/2pin

X262-5 Plug-type connection at valve Y28-2/2pin
X262-6 Plug-type connection at B26 / 3-pin
Y28-2
Y376-2 Check valve grapple rotator cycle

Y387-1 Solenoid valve for LIKUFIX relief

Y387-2 Solenoid valve for LIKUFIX relief
X452-1 Plug-type connection to SV Y376-1
Y376-1 Check valve grapple rotator cycle
A B26 als ffner

B B26 als Schlieer
C Option mit Sure Seal-Stecker B26 als Schlieer
16.24.20
Solenoid valve of quick change device
copyright by
MJF C I F S S
Service Manual

Fig. 20
Hydraulic diagram of LIKUFIX
copyright by
MJF C I F S S
16.24.21
Service Manual
Fig. 21
16.24.22
Electric diagram of LIKUFIX
copyright by
MJF C I F S S
Service Manual

Connection options for LIKUFIX system
8 Connection options for LIKUFIX system
Fig. 22
Universal interface for member / attachment
A Actuation of P1(G1)
Optional switching of control
View: in driving direction, right side
A Actuation of P2(G2)
Operator's cab
C Hammer return line

D Actuation of D1
c
d
In wheel models
In track models
x
y
View: against driving direction, from front

View: in driving direction, from rear
Actuation of D2
Left
Right
Coupling
Actuation
D2
Function
Rotate grab to left
Lock quick change adapter
G2
P2
Close pressure (AHS) circuit of grab/shear
Coupling
Actuation
D1
copyright by
MJF C I F S S
Function
Rotate grab to right
Release quick change adapter
G1
P1
Open pressure (AHS) circuit of hammer advance

line
grab/shear
16.24.23
Service Manual

Left
Coupling
Right
Actuation
Function
Coupling
Actuation
Function
Hammer return line/ leak oil
The following principle applies: Movement to the right = pressure in right line, and vice versa
Left
Coupling
Right
Actuation
Function
Coupling
Actuation
Function
G1
Open pressure (AHS) circuit of hammer advance

line grab/shear
P1
With optional "switching of AHS control with bucket function" kit.

B
G2
Close pressure (AHS) circuit

of grab/shear
P2
Note!
The hammer advance line can be placed to the right (P1) or the left (P2) side.
By default, the hammer return line is positioned to the right, with the option to position it to the left.
16.24.24
copyright by
MJF C I F S S
Service Manual

Fig. 23
Hydraulic diagrams for the various attachments
copyright by
MJF C I F S S
16.24.25
Service Manual
Maintenance and cleaning
Fig. 24
Hydraulic diagrams for the various attachments
Supply line to plunger
Mill, pile driver, plate vibrator without rotator

and separator (2 directions of rotation)
Grab, concrete pulverizer, shear, sorting

grapple
Hydraulic hammer without swivel bearing

(mill 1 direction of rotation)
Vibrator plate with rotator,

Hydraulic hammer with swivel bearing
Ditch cleaning bucket, tilting bucket, compactor, spreader (no need for additional
hydraulic pressure at the disk springs)
9 Maintenance and cleaning

The LIKUFIX hydraulic coupling system is virtually maintenance-free.
We recommend regular cleaning of the system and lubrication of the guide elements with
Gleitmo 900.
This treatment prevents caking of dirt and icing up in winter.
With regular cleaning, the seals of the system have a long service life.
16.24.26
copyright by
MJF C I F S S
Service Manual

Troubleshooting
10 Troubleshooting
10.1
Coupling system leaking

:
Note!
After decoupling, the parts might be covered in a thin film of oil. This is normal and does not indicate
a leak. In the event of substantial leakage, check the system to find the defective coupling. There is
an increased risk of leakage at older coupling plugs and after prolonged operation.
Replace seals and the coupling will regain their original state.
10.2
Foreign object in coupling sleeve:

The coupling sleeve is mounted into the quick change adapter housing, see Fig. 16:
Shut down engine.
Examine coupling sleeves to see whether a foreign object is caught in them.
Carefully remove the object, push in the dust cover .7 using a screwdriver and flush out the object.
If the object cannot be removed, replace the coupling.
Note!
Always shut down the engine before removing a foreign object!
When pushing the dust covers .7 into the coupling sleeves, oil might escape.
Place a suitable receptacle under the sleeves.
10.3
Leakage at coupling sleeve:

Complete a visual inspection of the coupling:
Place oil pan under the leakage to collect the leak oil.
Disconnect LIKUFIX system.
Clean coupling plates.
Pressurise one circuit after the next.
Caution!
Risk of damage to eyes from escaping oil when the couplings are pressurised.
Keep a safe distance from the coupling system.
Complete a visual inspection of all couplings,.
If oil escapes under pressure from the gap between the dust cover .7 and the valve .2, the coupling is likely to be leaking.
Check the seal ring in valve .2 for damage. Also check whether a foreign object has been jammed in the coupling.
Complete a visual inspection of the inside of the coupling:
Push in the dust cover .7, using a screwdriver.
copyright by
MJF C I F S S
16.24.27
Service Manual
Troubleshooting
If the leak cannot be rectified, replace the coupling.
Note!
If there is no visible leakage at the coupling sleeves, the coupling plugs must be examined.
10.4
Leakage at coupling plug:

If oil escapes at the sleeves, while no pressure is applied, so that the oil slowly drips from the sleeve,
the problem is likely caused by a leaking coupling plug.
Note!
In the event of a leak at the coupling plug, the escaping oil see Fig. 25 tends to distribute itself in the
entire front section of the coupling sleeve. During the coupling process, the oil is squirted by the leaking coupling plug into the spring space, so that drops form at the decoupled sleeve.
Fig. 25
10.5
Oil-filled section of the coupling sleeve
Identification of the leaking coupling plug:

Remove all oil and grease from the coupling plates (use brake cleaner).
Connect attachment.
Pressurise all lines.
Immediately decouple the device.
Check coupling plates.
Oil film around the coupling sleeve of the leaking plug
Replace seal ring at defective coupling plug
16.24.28
copyright by
MJF C I F S S
Service Manual

Instructions for the replacement of the coupling plug seal
11 Instructions for the replacement of the coupling plug seal

Using a screwdriver, press valves 4 down, one after the other, and examine the profile ring 3 for
wear and tear. If necessary, replace the profile ring as described below.
Fig. 26
Instructions for the seal replacement
Fig. 27
Instructions for the seal replacement
Using a screwdriver, push valve 4 of the coupling plug 10/20 down (approx. 2 cm) and remove the
defective profile ring 3 with a pointed implement. Squeeze new seal ring 3 and place it on the valve
with the open side facing down.
Push valve 4 down into the groove, place the screwdriver onto the centre of the valve surface and
remove your hand.
Let seal ring 3 expand in the groove, using the thumb to control the movement. Remove the screwdriver.
Check whether the valve 4 can be moved up.
If this is not the case, readjust the seal ring 3 by pressing it in further until valve 4 can be moved.
copyright by
MJF C I F S S
16.24.29
Service Manual
Instructions for the replacement of the coupling plug seal
16.24.30
copyright by
MJF C I F S S
Service Manual
Hydraulic hammers
Function
Hydraulic hammers
1 Function
The hydraulic hammer is used in connection with road works, demolition tasks and in quarries for the
compaction, opening, breaking up or crushing of mineral material. A hammer can be connected to
any LIEBHERR hydraulic excavator. Ensure however that the hydraulic output of the hammer (pressure and oil flow volume) is within the range of the actual output capacity of the excavator. For details,
see data sheets 16.30-03 to 16.30-14
m
Fig. 1
Hydraulic hammers
copyright by
MJF C I F S S
16.30.1
Hydraulic hammers
Service Manual
Operating and maintenance instructions
2 Operating and maintenance instructions

Note!
When using a hammer, there is an ever present risk of a dusty environment, which might affect the
hydraulic oil in the excavator, so that it might be contaminated more than normal. This in turn can
cause excessive wear of components of the hydraulic unit (in particular of the pump parts).
When using a hydraulic hammer with a LIEBHERR excavator, LIEBHERR requests the operator to
adhere to the following instructions:
Change the hydraulic oil every 500 operating hours.
Replace the standard cartridge in the return filter/ hydraulic tank (20 / 5 m) with a 10 m cartridge.
This fine filter cartridge (10 m) must be replaced every 500 operating hours.
the breather filter / hydraulic tank (7 m*) must be replaced with a 2 m fine filter.
This fine filter cartridge (2 m) must be replaced each time the hydraulic oil is changed (i.e. every
500 operating hours).
When changing the hydraulic oil, clean the hydraulic tank and drain off the oil from all hydraulic
cylinders.
After refilling of the system, insert a the cleaning cartridge (5 m) in the return filter, which must
be replaced after 50 operating hours by a fine filter cartridge (10 m).
Regularly check the hydraulic oil for contamination (laboratory oil analysis).
Hineri
Note!
* From approx. Sept. 2005 all machines have been equipped with the 2 m fine filter as standard.
In machines purchased after this date, there is thus no need to replace the filter cartridge when first
using the hammer attachment.
3 Equipment supplied by hammer manufacturers

Note!
The following equipment is offered by hammer manufacturers. Please note that the respective supplier is responsible for service, warranty, etc.
Equipment available from hammer manufacturers:
Hydraulic hammer
Tool (e.g. chisel)
Device retainer / connecting part for excavator
Parts available from LIEBHERR:
Accessory kit for the attachment of hydraulic hammers to basic machines (e.g. AHS 11 / AHS 12)
Lines for the hydraulic hammers at the basic boom, standard boom and adjustable gooseneck
boom
Lines for hydraulic hammers at the bucket stick
Functional description and diagram with pressure settings for the accessory kits AHS 11 and AHS 12.
The following tables list the hammer models recommended by LIEBHERR for use with its excavator
models.
16.30.2
copyright by
MJF C I F S S
Service Manual
Hydraulic hammers
ATLAS - COPCO hydraulic hammers
4 ATLAS - COPCO hydraulic hammers

4.1
SB and TEX
Type
Product
SB
450
Tex
400 H
Tex
600 H
Tex
700 H
Unit
Effective weight (1)
kg
419
412
665
715
Oil flow
l/min
50-100
50-100
52-105
55-120
Operating pressure / hammer
bar
150
150
150
140
Adjustment pressure of machine

see AHS 11 / AHS 12
bar
170
170
170
170
right
NB
NB
left
A 309 Litronic
A 311 Litronic
A 312
Return (2)
Attachable to machine types:
A 314
A 316
R 317
Tab. 1
Technical data
1)
2)
including standard chisel and suspension kit

seen from operator seat
NB
no details in brochure
copyright by
MJF C I F S S
16.30.3
Hydraulic hammers
Service Manual
ATLAS - COPCO hydraulic hammers
4.2
MB (former Krupp HM)

Previous
type
Product
HM
190
New
type
Product
Unit
HM
350
HM
580
MB
500
MB
800
kg
300
535
830
Oil flow
l/min
50-90
60-100
70-120
bar
130
160
170
Adjustment pressure
of machine
see AHS 11 / AHS 12
bar
150
180
190
right
right
right
A 309 Litronic
A 311 Litronic
A 312 Litronic
Return (2)
Tab. 2
16.30.4
A 314 Litronic
A 316 Litronic
R 317 Litronic
Technical data
1)
2)
copyright by
MJF C I F S S
Service Manual
Hydraulic hammers
EURORAM hydraulic hammers
EURORAM hydraulic hammers

Type
Product
Unit
RM
90
RM
115
kg
625
875
Oil flow
l/min
60-95
85 - 115
bar
145
160

see AHS 11 / AHS 12
bar
170
180
NB
NB
Return (2)
A 309 Litronic
A 311 Litronic
A 312 Litronic
A 314 Litronic
A 316 Litronic
R 317 Litronic
Tab. 3
Technical data
1)
2)
NB

copyright by
MJF C I F S S
16.30.5
Hydraulic hammers
Service Manual
FRD hydraulic hammers
FRD hydraulic hammers

Type
Product
Unit
HB
10G
HB
15G
kg
785
1100
Oil flow
l/min
70-90
90-120
bar
160
170

see AHS 11 / AHS 12
bar
180
190
right
right
Return (2)
A 309 Litronic
A 311 Litronic
A 312 Litronic
A 314 Litronic
A 316 Litronic
R 317 Litronic
Tab. 4
16.30.6
Technical data
1)
2)
copyright by
MJF C I F S S
Service Manual
Hydraulic hammers
INDECO hydraulic hammers
INDECO hydraulic hammers

Type
Product
Unit
MES
1200
MEST
1500
MES
1750
kg
600
780
950
Oil flow
l/min
60-90
80-125
85-115
bar
120
130
130

see AHS 11 / AHS 12
bar
140
150
150
right
right
right
A 314 Litronic
A 316 Litronic
R 317 Litronic
Return (2)
A 309 Litronic
A 311 Litronic
A 312 Litronic
Tab. 5
Technical data
1)
2)
copyright by
MJF C I F S S
16.30.7
Hydraulic hammers
Service Manual
NPK hydraulic hammers
8 NPK hydraulic hammers

Type
Product
Unit
H4
XE
kg
565
Oil flow
l/min
50-80
Operating pressure /
hammer
bar
110
Adjustment pressure of machine,

see AHS 11 / AHS
12
bar
130
Return (2)
right

A 309 Litronic
A 311 Litronic
A 312 Litronic
A 314 Litronic
A 316 Litronic
R 317 Litronic
Tab. 6
16.30.8
Technical data
1)
2)
copyright by
MJF C I F S S
Service Manual
Hydraulic hammers
RAMMER hydraulic hammers
9 RAMMER hydraulic hammers

Type
Product
S25
S26 N
S29C/
E64/
Unit
kg
425
540
820
1000
Oil flow
l/min
50-150
60-135
60-120
70-130
Operating pressure
/ hammer
bar
180
175
200
190
Adjustment pressure of machine, see

AHS 11 / AHS 12
bar
200
205
220
220
left
left
left
left
A 309 Litronic
A 311 Litronic
A 312 Litronic
A 314 Litronic
A 316 Litronic
R 317 Litronic
Return (2)
Tab. 7
Technical data
1)
2)

copyright by
MJF C I F S S
16.30.9
Hydraulic hammers
Service Manual
Ingersoll hydraulic hammers
10 Ingersoll hydraulic hammers

Type
Product
130
270 C
Unit
kg
370
695
Oil flow
l/min
70-110
90-130
bar
170
110
Adjustment pressure
of machine
see AHS 11 / AHS 12
bar
190
130
left
left
Return (2)
A 309 Litronic
A 311 Litronic
A 312 Litronic
A 314 Litronic
A 316 Litronic
R 317 Litronic
Tab. 8
Technical data
1)
2)
16.30.10

copyright by
MJF C I F S S
Service Manual
Hydraulic hammers
TABE and Stanley hydraulic hammers
11 TABE and Stanley hydraulic hammers

Producer
Type
Product
Tabe
AGB
370
Stanley
MB
875
Unit
kg
390
875
Oil flow
l/min
65-80
80-115
bar
130
125
Adjustment pressure
of machine
see AHS 11 / AHS 12
bar
150
160
NB
right
Return (2)
A 309 Litronic
A 311 Litronic
A 312 Litronic
A 314 Litronic
A 316 Litronic
R 317 Litronic
Tab. 9
Technical data
1)
2)

NB
copyright by
MJF C I F S S
16.30.11
Hydraulic hammers
Service Manual
WIMMER hydraulic hammers
12 WIMMER hydraulic hammers

Type
Product
W 440
W 550
Unit
kg
600
1150
Oil flowl/min
l/min
60-100
70-130
bar
130
135
Adjustment pressure
of machine
see AHS 11 / AHS 12
bar
150
180
left
left
A 309 Litronic
A 311 Litronic
A 312 Litronic
A 314 Litronic
A 316 Litronic
R 317 Litronic
Return (2)
Tab. 10
Technical data
1)
2)
16.30.12

copyright by
MJF C I F S S
Service Manual
Accessory kit AS1

Function
Accessory kit AS1

1 Function
Auxiliary attachments that can be connected to the hydraulic excavator often require special components, hydraulic lines and hoses for control and drive purposes.
These parts have been combined in accessory kits. As there is a wide range of different auxiliary attachments for excavators, we offer a number of different accessory kits to suit the equipment.
The accessory kit AS1 described below is needed when the following attachments are to be used
with the excavator:
Examples:
A Hydraulic grapple rotator
B Ditch cleaning bucket, with swivel hydraulics
C Hydraulic quick-change adapter
Fig. 1
Attachments for AS1
copyright by
MJF C I F S S
16.44.1
Accessory kit AS1
Service Manual
General information
Attachments and associated pressure relief valve
Secondary pressure relief valve 541 / 542
(This valve limits the operating pressure and, thus, the operating
pressure at measuring point 45) at the auxiliary control axle 540
120 +10 bar
Primary pressure relief valves 551 / 552

(primary protection for oil motor 550 / grapple rotator)
100 +10 bar
Secondary pressure relief valves 562/563

(secondary protection for cylinder 560 / tilting bucket, old model)
500 20 bar

(secondary protection for cylinder 560 / tilting bucket, new model)
350 20 bar

(Allen head screws) of auxiliary axle 540
55 Nm
Max. flow rate at spool 540

via limitation of stroke of spool
30 l/min
Stroke limitation of spool 540

Measure Y of the stop screw 540.1
Tab. 1
16.44.2
Pressure limit (in bar)
Technical data
copyright by
MJF C I F S S
17.0 mm
17.0 mm
Service Manual
Accessory kit AS1

Description of design and operation
3 Description of design and operation

The kit AS1 enables the operator to move the grapple to the right and left or to swivel the tilting bucket
into the desired position. To do this, the switch S19 must be pressed and the two buttons S5L/S5R
in the left pilot control unit 80 must be actuated. Push the buttons S5L/S5R to lock and release the
attachment by means of the hydraulic quick-change adapter.
These additional functions are controlled by means of the auxiliary axle 540 attached to the slewing
gear element 120. The auxiliary axle controls the flow rate between the working pump and the connected consumer.
Fig. 2
80
Control devices of AS1

S5L Button for actuation of grapple / bucket /
quick-change adapter
S5R Button for actuation of grapple / bucket /

quick-change adapter
S19
copyright by
MJF C I F S S
Switch / preselection / kit AS1
16.44.3
Accessory kit AS1
Service Manual
Functioning of the accessory kit
Fig. 3
Auxiliary control axle AS1 flange-mounted to the slewing gear axle of the compact block
100
540
Control valve block

Spool / AS1
542
Y22
Pressure-relief valve connection B02

541
Pressure-relief valve connection A02
Y23
4 Functioning of the accessory kit

see Fig. 7
4.1
Neutral position, see Fig. 7

The solenoids Y22 / Y23 are not powered. There is no pressure applied to the spool 540, and the
control lines leading to the tank are relieved. The variable displacement pump 20 is in stand-by position and/or is available to other consumers.
4.2
Pressurisation of consumers 550, 560, 570

Actuate the push button S19 (on the control desk, to the right) to switch on the electrical system of
the accessory kit. The integrated indicator light in the switch S19 is on.
Press the left button S5L or the right button S5R in the joystick of the left pilot control unit 80 to power
the solenoid Y22 or Y23 of the auxiliary control axle and to shift the spool 540 with maximum control
pressure into the working position ("black/white switching").
The pump 20 swivels to the cross-section pre-set at the spool 540, provided that the set volume is
greater than the volume Qmin of the pump. The oil flows from the control block 100 through the slewing gear axle 120 and the auxiliary control axle 540 connection "A02" or "B02" to the connected
consumer.
16.44.4
copyright by
MJF C I F S S
Service Manual
Accessory kit AS1

Pressure check and adjustment
4.2.1
Oil circuit with grapple

Oil from the connection "A02" or "B02" of the auxiliary control axle 540 flows to the oil motor 550 of
the grapple rotator for right/left rotation. The oil motor 550 turns the grapple attached by means of a
slewing ring to the right or to the left.
To increase the torque at the grapple rotator, a second a oil motor 550 is installed.
The return oil from the oil motor 550 flows through the connection "B02" or "A02" or the auxiliary
control axle 540 to the control block 100.
The double-acting pressure relief valve 551 secures the oil motor 550. If the solenoids Y22 / Y23 of
the auxiliary control axle 540 are switched to their neutral position during a rotary motion, the oil motor
acts as a pump. The resulting excess pressure in the line L or R is released through the pressurerelief valve 551/552.
4.2.2
Oil circuit with tilting bucket

Oil from the connection "A02" for swivelling to the right or "B02" for swivelling to the left of the auxiliary control axle 540 flows through the double check valve 561 connection "V1-C1" or "V2 - C2" to
the cylinder 560 (piston or rod side).
Pressure is built up, opening the hydraulic double check valve 561 towards the return side. The cylinder 560 is extended or retracted and the bucket is turned into the desired horizontal position by
means of a special mechanism.
The return oil from the cylinder 560 flows through the open double check valve 561 connection "C2V2" or "C1-V1" and the connection "B02" or "A02" of the auxiliary control axle 540 to the control
block 100.
The pressure-relief valves 541 / 542 integrated into the auxiliary control axle 540 limit the pressure
at the tilting bucket.
In machines with attached tilting bucket, the pressure is controlled by means of the secondary pressure-relief valves 562 / 563 in the double check valve 561.
4.2.3
Oil circuit with quick-change adapter

Oil from the connection "A02" for the retracting (releasing) of the locking cylinder 570 or "B02" for
the extending (locking) of the locking cylinder 570 in the auxiliary control axle 540 flows through the
solenoid valves Y28-1 / Y28-2 to the cylinder 570 (piston or rod side respectively).
The seat valves are protected against dirt by the filters 572.
The return oil from the cylinder 570 flows through the powered seat valve Y28-1 / Y28-2 and the connection "B02 or A02" in the auxiliary control axle 540 to the control block 100.
The pressure-relief valves 541 / 542 integrated into the auxiliary control axle 540 limit the pressure
at the quick-change adapter.
5 Pressure check and adjustment

5.1
Important adjustment notes

Pressure settings at operating temperature and engine speed step 8.
Use suitable pressure sensors and gauges.
During the warranty period, only employees and agents of LIEBHERR are allowed to carry out
adjustment works.
The pressure-relief valves must be equipped with protective caps.
copyright by
MJF C I F S S
16.44.5
Accessory kit AS1
Service Manual
5.2
Checking of the pressure-relief valves 541 / 542

Remove the protective cap at the measuring point 45.
Connect a measuring sensor / gauge (600 bar).
Close the stop cocks and remove and pressure connections (seal).
541 /542
Proceed as follows: Loosen the lock nut. Use a WS 6 Allen key to turn the adjusting screw.
Turn screw in
Increase pressure
Turn screw out
Reduce pressure
When the adjustment is completed, re-tighten lock nut.
Fig. 4
16.44.6
Measuring point for LS pressure, control block and auxiliary control axle with secondary
pressure-relief valves .
20
540
Auxiliary control axle / AS1
45
100
Measuring point LS
Control valve block
541
542
copyright by
MJF C I F S S
Service Manual
Accessory kit AS1

5.3
Inspecting double-acting primary pressure relief valve 551 / 552

(not applicable for tilting bucket and quick-change adapter)
Remove the protective cap at the measuring point 45.
Connect a measuring sensor / gauge (600 bar).
Lock grapple rotator. Actuate the solenoid Y22 / Y23 on both sides.
Compare the pressure at the pressure sensor with the prescribed pressure, see Tab. 1.
Note!
The secondary pressure relief valves 551 / 552 are factory-set and can be checked for correct pressure settings only at considerable expense.
If required, adjust the pressure by inserting or removing washers between the pressure spring
and the screw cap in the pressure-relief valve 551 / 552. Alternatively, replace the entire valve.
Fig. 5
A
B
Oil motor with shock valves and tilting bucket with twin/double check valve
561
562
Shock valve
Shock valve
Double check valve

Pressure-relief valve, swivelling to left
for old tilting bucket models
563
Pressure-relief valve, swivelling to right
D
550
for new tilting bucket models

565
566
Double check valve

Pressure-relief valve, swivelling to left
551
Pressure-relief valve / turning left
567
Pressure-relief valve, swivelling to right
552
Pressure-relief valve / turning right
copyright by
MJF C I F S S
16.44.7
Accessory kit AS1
Service Manual
5.4
Inspection of the secondary pressure relief valves 562 / 563 / 566 / 567
(only in AS1 kit for tilting bucket)
Note!
The tilting bucket design has been improved during the production of the series. The stop valve (twin
check valve 561 has been changed to a double check valve 565.
The secondary pressure relief valves 562 / 563 / 566 / 567, see Fig. 5 are factory-set and can be
checked for correct pressure settings only at considerable expense.
Inspection must be limited to the condition of the pressure springs of the relief valves 562 / 563 /
566 / 567 (setting and break).
Caution!
Risk of injury to eyes and hands from preload of the spring in the valves 562 / 563 / 566 / 567.
In type C units, carefully screw out the screw at the valve 562 / 563 and remove the cover.
In type D units, carefully remove the screw plug of the valve 566 / 567.
Check the valve for damage.
Reassemble the valve 561 / 565. If required, replace the entire valve.
5.5
Adjusting the flow of the spool 540

(rotating speed of grapple)
Fig. 6
16.44.8
Compact control block, auxiliary control axle AS1 with stroke limitation of the spool
100
Control valve block
540.1
Stroke limitation of spool, top
540
Auxiliary control axle
540.2
.1
Stroke limitation spool, bottom

Stop screw
.2
Stop screw
copyright by
MJF C I F S S
Service Manual
Accessory kit AS1

The speed of the grapple is determined by the max. oil volume flowing at spool 540.
The value has been pre-set at the factory (stroke limitation 540.1 or 540.2) and should not be tampered with.
Measure Y serves as a reference value for the prescribed setting.see Tab. 1
For certain applications, it is possible to change the flow rate and, thus, the rotating speed of the
grapple. To do this, turn the stop screw 1.
Turning out the stop screw .1 /stroke limitation
to increase the speed.
Turning in the stop screw .1 /stroke limitation
to reduce the speed. (Possible only to a certain degree because pump's Q.min volume play a
certain role as well.)
When the desired speed is set, secure the stop screws .1 with the lock nut .2.
copyright by
MJF C I F S S
16.44.9
Accessory kit AS1
Service Manual
5.6
5.6.1
5.6.2
5.6.3
16.44.10
Hydraulic unit AS1 (basic diagram)

1
6
to hydraulic tank
120
540

Spool / AS1
20
23
Pump regulator (A 312-316)
541
542
Pressure-relief valve connection A02

Pressure-relief valve connection B02
26
Pump regulator (R 317)
544
Pressure balance
41
Measuring point MP
S5L
Press push button
45
Measuring point LS
S5R Press push button
50
S19
Switch / kit AS1
88
P from distribution block
Y22
Solenoid valve
88
Y23
Solenoid valve
100
Control valve block
Hydraulic system - turning grapple attachment

550
Oil motor
552
551
Pressure-relief valve / turning right
Pressure-relief valve / turning left
Hydraulic system tilting bucket attachment

560
Cylinder / swivelling bucket
563
Pressure-relief valve, rod side
561
562
Double check valve

Pressure-relief valve, piston side
564
Restrictor
Hydraulic system quick-change adapter

570
571
Locking cylinder
Seat valve
572
Filter disc
Y28-1
Y28-2
copyright by
MJF C I F S S

Service Manual
Accessory kit AS1

Fig. 7
Hydraulic diagram of the AS1 kit
copyright by
MJF C I F S S
16.44.11
Accessory kit AS1
Service Manual
Electrical system
6 Electrical system
For electric diagrams of the AS1 kit, please refer to the electrical system of the basic machines A 312
- A 316 and R 317.
16.44.12
copyright by
MJF C I F S S
Service Manual
Accessory kit AHS 1

Function
Accessory kit AHS 1

1 Function
Auxiliary attachments that can be connected to the machine often require special components, hydraulic lines and hoses for control and drive purposes.
These parts have been combined in accessory kits. As there is a wide range of different auxiliary attachments for machines, we offer a number of different accessory kits to suit the equipment.
The accessory kit AHS 1 described here allows for the following functions when an auxiliary attachment is connected to the machine:
Auxiliary control axle without pressure and flow reduction of the high-pressure connections:
e.g. fir attachment of a hydraulic boom adjustment unit
Fig. 1
Auxiliary cylinder, e.g. regulating cylinder A for hydraulic boom adjustment unit
copyright by
MJF C I F S S
16.48.1
Accessory kit AHS 1
Service Manual
General information
Attachments and associated pressure-relief
valves
(this valve limits the LS pressure and thus the
operating pressure at the control block 100)
(for cylinder 515)
(in the auxiliary control axle 500)
Piston 500
Dimension Y of stop screw 500.1
for the retraction of the cylinder
for the extension of the cylinder
16.48.2
primary
secondary
350 +10 bar

380 +20 bar
16.3 mm (from serial no. 14517 = 14.7 mm)

For more information on the auxiliary axle AHS1,

see 7.60.55.
Tab. 1
Technical data
copyright by
MJF C I F S S
Service Manual
Accessory kit AHS 1

Operation
3 Operation
The accessory kit AHS 1 enables the operator to operate the working attachment (consumer) for hydraulic boom adjustment.
Note!
To ensure proper use and functioning of the accessory kit AHS 1, the connected units must be operated according to the instructions in this manual:
Danger!
When the regulating cylinder is retracted and the attachment is in a particular position, the digging
bucket might reach the operator's cab, posing a serious risk to the operator and the machine.
Fig. 2
Operator's platform with pilot control unit 86 for the kit
Operation of the boom regulating cylinder

Press down the right pedal of the pilot control unit 86.
The boom regulating cylinder is extended, i.e. the attachment is moved upwards.
Press down the left pedal of the pilot control unit 86.
The boom regulating cylinder is retracted, i.e. the attachment is moved down.
copyright by
MJF C I F S S
16.48.3
Accessory kit AHS 1
Service Manual

4.1
Important adjustment notes:

Heat the hydraulic oil to operating temperature.
To adjust the pressure, use suitable pressure sensors/gauges.
Note!
Please note that, during the warranty period, all work on the valves must be carried out by LIEBHERR technicians. The pressure-relief valves must be protected against unauthorised manipulation
with safety caps.
Fig. 3
120
16.48.4
Variable displacement pumps with measuring point LS and compact control valve block
with measuring point MP and auxiliary axle AHS1.
20
Variable displacement pump (LPV or

DPVO)
104
41
Measuring point MP for pump pressure
500
Auxiliary control axle with spool for auxiliary cylinder (regulating cylinder)
45
Measuring point LS for LS pressure
501
100
Control valve block
502

regulating cylinder
regulating cylinder
copyright by
MJF C I F S S
Service Manual
Accessory kit AHS 1

4.2
Checking and adjustment of the secondary pressure relief valve 501 / 502 at
the auxiliary control axle 500
Connect the pressure sensor/gauge to measuring points 41 and45, see Fig. 3.
Extend and retract the cylinder 517 to the stop by pressing the right and left pedal.
Screw in the pressure cut-off valve 104.
The pressure must be above the adjustment pressure of the secondary pressure relief valves
501 / 502.
Check the adjustment pressure of the secondary pressure-relief valves 501 / 502.
Turn the adjusting screw at the secondary pressure relief valve 501 / 502 until the pressure sensor/gauge at the measuring point 45 indicates the nominal pressure, Table 1, page 2.
4.3
Adjustment of the pressure cut-off valve 104

Extend the bucket cylinder to the stop
Turn out the adjusting screw of the pressure cut-off valve 104 until the prescribed nominal pressure,see Tab. 1, is indicated at the pressure/gauge at the measuring point 41.
Remove the pressure sensor / gauge and seal the measuring point 41 / 45.
4.4
Adjustment of the stoke limitation of the spool 500
Fig. 4
Stroke limitation of the spool 500
100
1.1
Stop screw
500
1.2
Lock nut
1.3
Safety cap
500.1 Stroke limitation / retract regulating cylinder

500.2 Stroke limitation / extend regulating cylinder
copyright by
MJF C I F S S
16.48.5
Accessory kit AHS 1
Service Manual

Note!
The stroke of the spool 500 for maximum oil flow is factory-set by means of the stroke limiters 500.1
/ 500.2 and should not be modified.
The dimension Y, see Tab. 1 serves as a reference value for the prescribed settings. If dimension
Y does not correspond to the prescribed value, adjust the stroke limiter as follows:
Turn the stop screw 1.1 until dimension Y is reached.
Re-tighten the lock nut 1.2.
16.48.6
copyright by
MJF C I F S S
Service Manual
Accessory kit AHS 1

Fig. 5
Hydraulic connections of AHS 1 kit
Hydraulic tank
500
50
501
86
Pilot control unit 2x, with pedal
502
88P
Distributor
88T
Collecting pipe
B290 Proximity switch / sensor control (kit)
100
104

copyright by
MJF C I F S S
Spool of auxiliary cylinder(e.g. regulating

cylinder)
Secondary pressure relief valve / cylinder
515 retracting
Secondary pressure relief valve / extend
cylinder 515
16.48.7
Accessory kit AHS 1
Service Manual
Hydraulic system
6 Hydraulic system
16.48.8
1
6

to oil cooler
100
104

20
500
23
Regulating valve
501
Secondary pressure relief valve / cylinder

515 retracting
30
502

cylinder 515
41
45
Measuring point MP
Measuring point LS
504
507
Pressure balance
50
515
Regulating cylinder / hydr. boom adjusting

device
86
88P

Distributor
516
517

88T
Collecting pipe
copyright by
MJF C I F S S
Service Manual
Accessory kit AHS 1

Hydraulic system
copyright by
MJF C I F S S
16.48.9
Accessory kit AHS 1
Service Manual
Hydraulic system
16.48.10
copyright by
MJF C I F S S
Service Manual

Function

1 Function
The AHS 11 accessory kit described below enables operators to use an auxiliary attachment and to
supply it through an auxiliary control axle.
Auxiliary control axle located beside the main control valve block with pressure and flow reduction
for a high-pressure connection:
used for example in connection with the attachment of a hydraulic hammer.
Auxiliary control axle without pressure and flow reduction of the two high-pressure connections:
used for example in connection with the attachment of a sorting grapple, a horizontally movable boom or an offset boom bearing
Fig. 1
Auxiliary attachments available for basic machine (examples)
A Hydraulic hammer
B Sorting grapple
copyright by
MJF C I F S S
16.52.1
Service Manual
General information
valves
(This valve limits the LS pressure) in control valve
block 100

primary
secondary
350 +10 bar
Secondary pressure-relief valve with additional

pressure stage 511
Stage 1
(hydraulic hammer 535)
Stage 2
(extend cylinder 537)
(in the auxiliary axle 510)
200 +10 bar (*)

380 +20 bar (**)
380 +20 bar
Secondary pressure-relief valves 522

for the retraction of the cylinder537
Piston 510 dimension Y of stop screw 510.1
17.4 mm (15 mm***)

from serial no. 14517 = 14.7 (11.5 mm***)
16.3 mm (12 mm***)
from serial no. 14517 = 14.7 (11.0 mm***)
Return flow - backpressure
(*)
Oil flow rate required for hammer operation
(*)
Factory settings
Current at proportional solenoid valve Y51
640 mA (*)
Control pressure at the pump P1

via proportional solenoid valve Y51
17+1 bar (*)
Tab. 1
Technical data
(*) Always observe the instructions and specifications of the hammer manufacturer, see also group
16.30.
(**) In machines with the auxiliary attachments "45 offset boom bearing" or "horizontal boom
movement", the secondary pressure-relief valve 537 controlling the flow at the piston side of the cylinder 512 is set to 200 bar and acts as a primary pressure relief valve.
(***) In machines with the auxiliary attachments "45 offset boom bearing" or "horizontal boom
movement", the flow volume of the auxiliary control axle 510 for the cylinder 537 is reduced by
means of the stroke limitation 510.1 / 510.2.
16.52.2
copyright by
MJF C I F S S
Service Manual

Function and operation
3 Function and operation

The accessory kit AHS 11 enables the operator to control an auxiliary attachment (consumer) by
means of the auxiliary pilot control unit 86 and to reduce the pressure and oil flow by operating the
switch S241.
Note!
To ensure proper use and functioning of the accessory kit AHS 11, the connected units must be
operated according to the instructions in this manual:
Fig. 2
86
Operator's cab with pilot control device, switch and indicator lamp for the accessory kit
H196 Sorting grapple indicator lamp
Pilot control device of kit
S241 Switch AHS11

Actuate the switch S241 to preselect the desired attachment and thus activate the required pressure
and flow reduction by means of the solenoid valve Y299.
Operation of the sorting grapple:
Set the switch S241 to position 1.
Unreduced flow rate and maximum permissible pressure (stage 2) on the sorting grapple cylinder (via spool 510).
Sorting grapple cylinder is extended, and the sorting gripper is closed.
Sorting grapple cylinder is retracted, and the sorting gripper is opened.
copyright by
MJF C I F S S
16.52.3
Service Manual

Operation of the hydraulic hammer:
The indicator lamp H196 is not on.
Reduced flow rate and lower pressure (stage 1) on the hydraulic hammer (via spool 510).
Left pedal of the pilot control unit 86 (no function assigned in connection with hydraulic hammer; for sorting grapple, etc.: no pressure or flow reduction at connection A6).
Hydraulic hammer is pressurised.
16.52.4
copyright by
MJF C I F S S
Service Manual


4.1

Note!
with safety caps.
Fig. 3
120
with measuring point MP and auxiliary axle AHS11
20
Variable displacement pump (LPV

or DPVO)
104
41
Measuring point MP for pump pres- 510

sure
Auxiliary control axle AHS 11 with spool
45
Measuring point LS for LS pressure 511

pressure stage / extending cylinder 537 or hammer
100
512
Secondary pressure relief valve / retracting

cylinder 537 or pile driver
copyright by
MJF C I F S S
16.52.5
Service Manual
Fig. 4
4.2
10
Adjusting screw
15
Lock nut
11
12
Adjusting screw
Shifting piston
30
33
Bushing
Valve seat
13
Piston
511
Secondary pressure-relief valve, complete
14
Lock nut
Checking and adjustment of the secondary pressure relief valve 511

Connect the pressure sensor/gauge to measuring points 41 and 45.
The pressure must be above the adjustment pressure of the secondary pressure relief valve
511.
Disconnect the control line from the additional pressure stage of the pressure relief valve 511.
Seal the control hose but keep the pressure-relief valve connection open (risk of pressure buildup by leak oil at the control pressure connection X -).
Disconnect the pressure line from the hammer and seal it.
Only required, if a hydraulic hammer is to be attached.
4.2.1
Adjustment of pressure stage 2 (higher pressure level)

Loosen the lock nut 15 and block the shifting piston 12 by screwing in the adjusting screw 11.
Press down the right pedal to pressurise the hydraulic hammer 535 with maximum permissible
pressure or to extend the cylinder537 to its stop.
Loosen the lock nut 14 and turn the adjusting screw 10 at the pressure-relief valve 511 until the
pressure sensor indicates the nominal pressure for stage 2, see Table 1, page 2, is indicated at
the pressure sensor/gauge at the measuring point 45.
Re-tighten lock nut 14.
Reset the system to pressure stage 1.
4.2.2
Adjustment of pressure stage 1 (lower pressure level)

Pressurise the hydraulic hammer 535 to the limit value.
Turn the adjusting screw 11 at the pressure-relief valve 511 until the pressure sensor/gauge
16.52.6
copyright by
MJF C I F S S
Service Manual

(measuring point 45) indicates the nominal pressure, see Tab. 1.
Reconnect the control line to the connection X.
4.3
Fig. 5
20
Auxiliary control axle AHS 11 with secondary pressure-relief valves 511 and 512
Variable displacement pump (LPV 104
or DPVO)
sure
41
45
100
Control valve block
512

pressure stage / extend cylinder 537 or hammer
Fully retract the cylinder 537 to the stop by pressing down the left pedal.
Turn the adjusting screw at the secondary pressure-relief valve 512 until the pressure sensor/gauge at the measuring point 45 indicates the nominal pressure, Table 1, page 2.
4.4
Adjustment of the pressure cut-off valve 104

Turn out the adjusting screw of the pressure cut-off valve 104 until the prescribed nominal pres-
copyright by
MJF C I F S S
16.52.7
Service Manual

sure,see Tab. 1, is indicated at the pressure/gauge at the measuring point 41.
4.5
Fig. 6
100

510 Hydraulic hammer/cylinder spool

510.1 Stroke limitation / cylinder retraction
1.1
Stop screw
1.2
1.3
Lock nut
Safety cap
510.2 Stroke limitation / hydraulic hammer / cylinder extension

Note!
The stroke of the spool 510 for maximum oil flow is factory-set by means of the stroke limiters 510.1
16.52.8
copyright by
MJF C I F S S
Service Manual

Fig. 7
Hydraulic connections AHS 11
copyright by
MJF C I F S S
16.52.9
Service Manual
Hydraulic system
6 Hydraulic system
16.52.10
510
to oil cooler
511
20
512
23
Regulating valve
514
Pressure balance
30
Gear pump / cooling
517
41
Measuring point MP
535
Hydraulic hammer
45
Measuring point LS
536
Pile driver
50
537
Cylinder (auxiliary device)
86
88P

Distributor
538 Stop cock

88T
100
Collecting pipe

Y62 Solenoid valve / travel
104

Y299 Solenoid valve / secondary pressure hammer
copyright by
MJF C I F S S
Spool / hydraulic hammer / cylinder / pile

driver
hydraulic hammer 535 cylinder 537
cylinder 537
Service Manual

Hydraulic system
copyright by
MJF C I F S S
16.52.11
Service Manual
Electrical system
7 Electrical system
The electrical diagram of the AHS 11 accessory kit is shown in section 34 of groups 8.20 / 8.30 / 8.32
/ 8.40, electrical equipment of basic machine.
16.52.12
copyright by
MJF C I F S S
Service Manual

Function

1 Function
The AHS 12 accessory kit described below enables operators to use two different auxiliary attachments and to supply them through two separate control axles:
one control axle in the main control valve block without pressure and flow reduction of the highpressure connections:
used for example in connection with the attachment of a hydraulic boom adjusting device
(vertical), a horizontally adjustable boom or an offset boom bearing
one auxiliary control axle at the main control valve block with pressure and flow reduction of a
high-pressure connection:
the auxiliary control axles without pressure and flow reduction of both high-pressure connections:
used for example in connection with the attachment of a sorting grapple, a concrete crusher.
As both functions are controlled with the same pilot control device (pedal), they cannot be operated
simultaneously.
Fig. 1
A Hydraulic boom adjusting device

B Hydraulic hammer
C Sorting grapple
copyright by
MJF C I F S S
16.54.1
Service Manual
General information
valves
Primary pressure-relief valve 122
(valve limiting the working pressure of the pump
P1 at the measuring point 40) in the control valve
block 100
pressure stage 511
Stage 1
Stage 2
for the retracting of cylinder537

primary
secondary
350 +10 bar
150 +10 bar (*)

380 +20 bar
380 +20 bar
(200 bar **)
640 mA

23+1 bar
Tab. 1
Technical data
(*) Always observe the instructions and specifications of the hammer manufacturer, see also group
16.30.
(**) In machines with the auxiliary attachments "45 offset boom bearing" or "horizontal boom adjustment", the secondary valve 515 controlling the flow at the piston side of the cylinder 537is set to 200
bar and acts as a primary pressure-relief valve.
16.54.2
copyright by
MJF C I F S S
Service Manual

3 Function and operation

The accessory kit AHS 12 allows the machine operator to control the connected auxiliary attachments (consumers) by means of the auxiliary pilot control device 86.
The desired consumers and the required pressure and flow reduction can be preselected by means
of switch S241.
Note!
Danger!
Fig. 2
86
S241 Switch AHS12

and flow reduction by means of the solenoid valve Y268 and Y299.
Set switch S241 to position 0 (not actuated)
The LED in the switch is off.
Unreduced flow rate and maximum permissible pressure on the boom regulating cylinder (via
spool 106).
copyright by
MJF C I F S S
16.54.3
Service Manual

Press right pedal to the stop.
Press left pedal to the stop.
The LED in the switch is off.
Unreduced flow rate and maximum permissible pressure on the sorting grapple cylinder (via
spool 510).
Press left pedal to the stop.
The LED in the switch is on.
Reduced flow rate and lower pressure on the hydraulic hammer (via spool 510).
Combined shifting for lowering and lifting of boom.
Left pedal (no function).
Note:
When the switch S241 is in position 2 ("hydraulic hammer" position), the pressure-relief valve 511
(with additional pressure stage) is set to the reduced pressure value. The pressure relief valve 511
for the pressure stage 1 must be set to the maximum permissible working pressure for the hammer
(specified by the hammer manufacturer), (see "Technical data", page 2).
The potentiometer P1/P2 /P3 must be set to the permissible oil volume as specified by the hammer
manufacturer, see also group 16.19, flow reduction.

4.1

Note!
with lead seal wire or safety caps.
16.54.4
copyright by
MJF C I F S S
Service Manual

Fig. 3
120
Compact control block with auxiliary axle AHS12
40
Measuring point for pump pressure
510
Hydraulic hammer/cylinder spool
100
511
Activate the secondary pressure-relief

valve of the hydraulic hammer / extend
cylinder
122
Primary pressure-relief valve P1
512

cylinder
Fig. 4
Secondary pressure-relief valve 511 with additional pressure stage
10
Adjusting screw
15
Lock nut
11
Adjusting screw
30
Bushing
12
Shifting piston
33
Valve seat
13
Piston
511
14
Lock nut
Secondary pressure-relief valve, complete

copyright by
MJF C I F S S
16.54.5
Service Manual
4.2

Connect the pressure sensor/gauge to measuring point 40.
Turn in the primary relief valve 122.
The pressure must be above the adjustment pressure of the secondary pressure-relief valve
511 / 512.
4.2.1
Adjustment of pressure stage 2 (higher pressure level)

Press down the right pedal to pressurise the hydraulic hammer 535 or the cylinder 537 with the
maximum permissible pressure.
pressure sensor indicates the nominal pressure for stage 2, Table 1, page 2.
4.2.2
Adjustment of pressure stage 1 (lower pressure level)

Press down the right pedal to pressurise the hydraulic hammer 535 or the cylinder537 with the
maximum permissible pressure.
Turn the adjusting screw 11 at the pressure-relief valve 511 until the pressure sensor/gauge
(measuring point 40) indicates the nominal pressure, see Tab. 1.
4.3
Fig. 5
16.54.6
Auxiliary axle AHS 12 with primary and secondary pressure-relief valves
copyright by
MJF C I F S S
Service Manual

Flow reduction of pump P1
40
Measuring point for AHS 12 working pres- 510

sure
100
Control valve block
511
122
Primary pressure-relief valve P1
512

Activate the secondary pressure-relief
valve of the hydraulic hammer / extend
cylinder
cylinder
Fully retract the cylinder 537 to the stop by pressing down the left pedal.
Turn the adjusting screw at the secondary pressure-relief valve 512 until the pressure sensor indicates the nominal pressure, Table 1, page 2.
4.4
Adjustment of primary pressure-relief valve 122, see Fig. 5

Move the bucket cylinder to the stop and adjust the primary pressure-relief valve 122 to the required pressure (measured at measuring point 40) by turning the adjusting screw, see Tab. 1.
5 Flow reduction of pump P1

The flow reduction function is implemented in conjunction with the potentiometers P1 - P3 on the printed circuit board A125 by means of the excavator control system U16 and the solenoid valve Y51,
see group 16.19.
Men
Fig. 6
The printed circuit board with the potentiometers is located behind the left control console
P1
P2
P3

copyright by
MJF C I F S S
16.54.7
Service Manual
Adjustment of flow reduction

Note!
The flow reduction options are used to allocate preset reduced pump flow volumes to the connected
attachment (e.g. hydraulic hammer).
The flow reduction is set by the technician at the potentiometers P1 - P3 on the board A125.
.
Fig. 7
Potentiometer board, switch and pilot control device for kit in operator's cab
Proportional solenoid valve for flow reduction at the control oil unit
Measuring point for control pressure/flow reduction of pump P1
20
21
Pump P1
S241 Kit switch
50
Control oil unit
Y51
57
Measuring point for flow reduction

reduction
Console
86
Clamping mechanism
6 Adjustment of flow reduction

For detailed instructions on how to adjust the various flow reductions, refer to group16.19, flow reduction.
16.54.8
copyright by
MJF C I F S S
Service Manual

Fig. 8
copyright by
MJF C I F S S
16.54.9
Service Manual
Hydraulic system
8 Hydraulic system
1
20
to tank
109
120

Dummy cartridge / screw plug
40
Measuring point P1
121
Primary pressure-relief valve pump P2
41
50
Measuring point P2
122
150

Check valve
76
Shuttle valve of combined shifting of stick 151
78
Shuttle valve of combined shifting of

boom
152
Check valve
86
Pilot control unit two-fold, with pedal
250
Regulating cylinder / hydr. boom adjusting

device
88P
88T
Distributor
Collecting pipe
251
510

Auxiliary spool AHS 12
100
511
101
Slewing gear spool
512

cylinder 517 or hammer
Secondary pressure relief valve / retract
cylinder 537
102
535
Hydraulic hammer
103
105

537
Sorting grapple cylinder
106
107
Boom cylinder spool

S241 AHS 12 switch

Y268 Solenoid valve / changeover cylinder hammer
108
Travel motor spool
Y299 Solenoid valve / pressure limitation of

hammer / combined shifting to lower
boom
marked with P2 at the control valve block
** marked with P1 at the control valve block
16.54.10
copyright by
MJF C I F S S
Load-holding valve
Service Manual

Hydraulic system
copyright by
MJF C I F S S
16.54.11
Service Manual
Electrical system
9 Electrical system
The electrical diagram of the AHS 12 accessory kit is shown in section 34 of group 8.20, electrical
equipment of basic machine.
16.54.12
copyright by
MJF C I F S S
Service Manual

Function

1 Function
The AHS 12 accessory kit described below enables operators to use two different auxiliary attachments and to supply them through two separate auxiliary control axles:
first auxiliary control axle, located at the main control valve block without pressure and flow reduction for the high-pressure connections:
(vertical), a horizontally adjustable boom or an offset boom bearing
second auxiliary control axle without pressure/flow reduction for a high-pressure connection:
second auxiliary control axle without pressure/flow reduction for both high-pressure connections:
used for example in connection with the attachment of a sorting grapple, a concrete crusher.
As both functions are controlled with the same pilot control unit (pedals), they cannot be operated
simultaneously.
Fig. 1
C Sorting grapple
B Hydraulic hammer
copyright by
MJF C I F S S
16.56.1
Service Manual
General information
valves
block 100

primary
secondary
350 +10 bar

380 +20 bar

for regulating cylinder 525 extension and retraction
pressure stage 511
Stage 1
Stage 2
180 +10 bar (*)

380 +20 bar
380 +20 bar
200 bar (**)

for the retraction of the cylinder537

17.4 mm (15 mm***)
from serial no. 14517 =14.7 mm (12 mm***)
16.3 mm (12 mm***)
from serial no. 14517 =14.7 mm (10.5 mm***)
Return flow - backpressure
(*)
Oil flow rate required for hammer operation
(*)
Factory settings
640 mA (*)

17+1 bar (*)
Tab. 1
Technical data
(*)
Always observe the instructions and specifications of the hammer manufacturer, see also
group 16.30.
(**)
In machines with the auxiliary attachments "45 offset boom bearing" or "horizontal boom
movement", the secondary pressure-relief valve 512 controlling the flow at the piston side of
the cylinder 537 is set to 200 bar and acts as a primary pressure relief valve.
(***) In machines with the auxiliary attachments "45 offset boom bearing" or "horizontal boom
movement", the flow volume of the auxiliary control axle 510 for the cylinder 537 is reduced
by means of the stroke limitation 510.1 / 510.2.
16.56.2
copyright by
MJF C I F S S
Service Manual

Operation
3 Operation
The accessory kit AHS 12 allows the machine operator to control the connected auxiliary attachments (consumers) by means of the auxiliary pilot control unit 86.
of switch S241.
Note!
Danger!
Fig. 2
86
Operator's cab with pilot control unit, switch and indicator lamp for the accessory kit
Pilot control unit of kit
S241 Switch AHS12

and flow reduction by means of the solenoid valves Y268 and Y299.
copyright by
MJF C I F S S
16.56.3
Service Manual
Operation
Set the switch S241 to position 0 (not actuated).
spool 500).
Unreduced flow rate and maximum permissible pressure (stage 2) on the sorting grapple cylinder (via spool 510).
The indicator lam in the switch is on.
Reduced flow rate and lower pressure (stage 1) on the hydraulic hammer (via spool 510).
Left pedal of the pilot control unit 86 (no function assigned in connection with hydraulic hammer; for sorting grapple, etc.: no pressure or flow reduction at connection B7).
16.56.4
copyright by
MJF C I F S S
Service Manual


4.1

Note!
with safety caps.
Fig. 3
120
with measuring point MP and auxiliary axles AHS12
20

or DPVO)
500
41

sure
Secondary pressure relief valve / extend cylinder 525
45
100
510
Secondary pressure relief valve / retract cylinder

525
104
511

512

copyright by
MJF C I F S S
16.56.5
Service Manual
Fig. 4
4.2
10
11
Adjusting screw
Adjusting screw
15
30
Lock nut
Bushing
12
13
Shifting piston
Piston
33
511
Valve seat
Secondary pressure-relief valve,complete
14
Lock nut

Connect the pressure sensor/gauge to measuring points 41 and 45.
The pressure must be above the adjustment pressure of the secondary pressure relief valve
511.
4.2.1
Adjustment of pressure stage 2 (higher pressure stage)

Press down the right pedal to pressurise the cylinder 537.
pressure sensor/gauge indicates the nominal pressure for stage 2, see Table 1, page 2.
4.2.2
Adjustment of pressure stage 1 (lower pressure stage)

Pressurise the hydraulic hammer 535 to the limit value.
pressure sensor/gauge indicates the nominal pressure for stage 1, see Table 1, page 2.
Re-tighten lock nut 15.
16.56.6
copyright by
MJF C I F S S
Service Manual

4.3
Checking and adjustment of the secondary pressure relief valve 501 / 502 / 512
Fig. 5
Variable displacement pumps and auxiliary axles AHS 12 (AHS1 and AHS 11) with secondary pressure-relief valves
20

or DPVO)
500
41

sure
Secondary pressure relief valve / extend cylinder 525
45
Secondary pressure relief valve / retract cylinder

525
100
Control valve block
510
104
511

512
Move the cylinders 525 and 537 to the stop.

Check the adjustment pressure of the secondary pressure-relief valves 501 / 502 / 512.
Turn the adjusting screw at the secondary pressure relief valve 501 / 502 / 512 until the pressure
sensor/gauge at the measuring point 45 indicates the nominal pressure, see Table 1, page 2.
copyright by
MJF C I F S S
16.56.7
Service Manual
4.4
Adjustment of the pressure cut-off valve 104 (see Fig. 5, page 7)

Turn out the adjusting screw of the pressure cut-off valve 104 until the prescribed nominal pressure,see Tab. 1, is indicated at the pressure/gauge at the measuring point 41.
4.5
Adjustment of the stroke limiter of the spools 500 and 510
Fig. 6
100
Stroke limiter of the spool 500 and 510

500 Spool / regulating cylinder

500.1 Stroke limitation / retract regulating cylinder
1.1
Stop screw
1.2
1.3
Lock nut
Safety cap
500.2 Stroke limitation / extend regulating cylinder

510 Hydraulic hammer/cylinder spool
510.1 Stroke limitation / cylinder retraction
510.2 Stroke limitation / hydraulic hammer / cylinder extension
Note!
The stroke of the spool 500 / 510 for maximum oil flow is factory-set by means of the stroke limiters
500.1 / 500.2 / 510.1 / 510.2 and should not be modified.
16.56.8
copyright by
MJF C I F S S
Service Manual

Fig. 7
Hydraulic tank
B290
50
86
Control oil unit

Pilot control unit 2x, with pedals
B291 Proximity switch / sensor control

X924-1 Plug connection, 3x
88P
Distributor
X924-2 Plug connection, 3x
88T
Collecting pipe
Y62
Solenoid valve / travel
100
500

Y63
Y268
510
Spool / hydraulic hammer / cylinder /

pile driver
Y299

Solenoid valve / changeover regulating
cylinder - hammer
Solenoid valve / secondary pressure
hammer
511
Secondary pressure relief valve with

additional pressure stage / hydr. hammer - cyl.
copyright by
MJF C I F S S
Proximity switch / sensor control
16.56.9
Service Manual
Hydraulic system
6 Hydraulic system
1
Hydraulic tank
510

driver
to oil cooler
511
Secondary pressure-relief valve with additional pressure stage / retract hydraulic

hammer 535 cylinder 537
20
512
23
Regulating valve
514

cylinder 537
Pressure balance
30
Gear pump / cooling
517
41
Measuring point MP
525
Regulating cylinder
45
Measuring point LS
526
Load-holding valve (piston side)
50
527
Load-holding valve (rod side)
86
535
Hydraulic hammer
88P
88T
Distributor
Collecting pipe
536
537
Pile driver
100
104

538 Stop cock

500
501

regulating cylinder 525

S241 AHS 12 switch
Pressure balance

Y268 Solenoid valve / changeover regulating
cylinder - hammer
502
504
507
Y62
16.56.10
copyright by
MJF C I F S S
Service Manual

Hydraulic system
copyright by
MJF C I F S S
16.56.11
Service Manual
Electrical system
7 Electrical system
The electrical diagram of the AHS 12 accessory kit is shown in section 34 of groups 8.20 / 8.30 / 8.32
/ 8.40, electrical equipment of basic machine.
16.56.12
copyright by
MJF C I F S S
Service Manual
Accessory kit AHS 11 / AHS 12 with Tool Control

Function
Accessory kit AHS 11 / AHS 12

with Tool Control
1 Function
The accessory kits AHS 11 and AHS 12 described below are required for the installation of the following auxiliary attachments to a machine:
Hydraulic hammer
Telescopic demolition stick
Scrap shear
Concrete crusher
Sorting grapple
Fig. 1
Machine with adjusting equipment and sorting grapple and hydraulic hammer

B Hydraulic hammer
C Sorting grapple
copyright by
MJF C I F S S
16.57.1
Service Manual
General information
Attachments and associated pressure relief
valve
(this valve limits the LS pressure and thus the
operating pressure at the measuring point 41 in
the control block 100)
Low-pressure (basic settings)
High pressure (proportional valve Y414 with max.
current)
primary
secondary
350 +10 bar
100 +10 bar

380 +20 bar
Flow rate at the outlet A / B

Extending:
Retracting:
200 l/min
200 l/min

Piston 510 dimension Y of stop screw 510.1
14.2 mm
14.2 mm
Tab. 1
16.57.2
Technical data
copyright by
MJF C I F S S
Service Manual

Design
3 Design
The accessory kit includes the following components:
Pilot control unit 86
Auxiliary control axle 500 (only with AHS 12)
Auxiliary control axle 510 with pressure relief valves 511 (bottom) and 512 (top)
Proportional valve Y414 for the pressure limitation of the control axle of the hydraulic hammer
Proportional valve Y463 / Y464 for the flow limitation of the control axle of the hydraulic hammer
The auxiliary control axle 500/ 510 are flange-connected to the control valve block 100. The proportional solenoid valve Y414 is screw-mounted to the hydraulic tank 1 below the solenoid valve for forward/reverse travel. The two proportional solenoid valves Y463 / Y464 are mounted near the control
block.
The switch S241 for flow limitation and the control of the Tool Control A156 (ESX) are integrated into
the control desk (front right).
The keyboard unit A155 is mounted above the control desk (front right), see Fig. 5.
The pilot control unit 86 is equipped with pedals for the control of the attachment and is mounted in
the front left section of the operator's cab.
The solenoid valve Y268 used to change over from the boom adjustment to hammer operation is located at the tank.
Fig. 2
Hydraulic unit AHS 12 with Tool Control
Hydraulic tank
Y62
86
Y62
copyright by
MJF C I F S S
16.57.3
Service Manual
100
Control valve block

cylinder / hammer
Y414 Prop. valve pressure reduction
500
Auxiliary control axle regulating cylinder
510
511
Auxiliary control axle / hydraulic hammer Y463 Prop. valve / flow reduction
Pressure relief valve with additional pres- Y464 Prop. valve / flow reduction
sure stage
512
The accessory kits AHS 11 / AHS 12 allow the operator to work with two completely different attachments (consumers) using a single kit type:
Standard consumer, not requiring pressure and/or flow reduction
One consumer requiring pressure and/or flow reduction
Note!
To ensure proper use and functioning of the accessory kit AHS 12 / AHS 11, the connected units
must be operated according to the instructions in this manual:
Incorrect pressure or flow reduction settings may result in damage to the attachment (e.g. hydraulic
hammer or reduced tool performance (e.g. mill).
The pressure and flow reduction settings must be made at service level 2/3.
Adjustment of pressure and flow reduction settings, see 6.
16.57.4
copyright by
MJF C I F S S
Service Manual

4.1
Functional description of proportional pressure relief valve Y414

This valve allows you to steplessly adjust the system pressure to be restricted, in proportion to an
electric nominal value. At nominal value 0 or in the event of a power failure, the minimum pressure is
established.
To adjust the system pressure (high pressure), enter the required nominal value in the ESX control
system. The solenoid coil 14 is subsequently powered with the set nominal current.
The proportional solenoid valve converts the current into a mechanical force, moving the armature
bar and with it the valve cone 16. The valve cone 16 is pressed against the valve seat 15, blocking
the flow between connection P and T1. If the hydraulic pressure acting on the valve cone 16 exceeds
the magnetic force, the valve cone opens the connection to the tank, thus limiting the pressure.
Fig. 3
Sectional drawing of proportional pressure relief valve Y414
14
Magnetic coil
15
Valve seat
16
copyright by
MJF C I F S S
Valve cone
16.57.5
Service Manual
4.2
Functional description of secondary pressure relief valve 511 / 512

The pressure P built up in the consumer circuit acts on the front face of the main cone 5 and, through
the bore B1, also on the rear surface of the main cone 5.
The main cone 5 and the pilot control cone 4 are kept in a position that closes the valve, due to the
surface difference between B3 and B4 that are exposed to the same pressure P.
The springs 11 and 3 are used to adjust the main cone 5 and the pilot control cone 4.
As soon as the pressure in the consumer circuit reaches a value exceeding the set value of the pressure and adjusting spring 3, the pilot control cone 4 is lifted from its seat, and some oil can penetrate
through the valve Y414 connection (T1) to the tank.
Due to the different diameters of the bore B1 in the bushing 12 and the ring face B2 in the adjusting
screw 6, a pressure difference is built up between the front side and the rear side of the main cone
5. As a result, the main cone 5 is lifted, opening the connection T to the tank. Any excess pressure
is thus released to the tank (secondary relief).
4.2.1
Proportional pressure control

In order to achieve proportional pressure control, the pressure (P) in the consumer circuit is controlled
by valve Y414 via the connection Y in the pressure relief valve 511 / 512.
The minimum and maximum pressure settings (as set in the menu) are controlled relative to the current (which in turn is controlled by the ESX), (see "", page 10).
The later valve Y414 is opened via T1, when the operating pressure increases. When the valve Y414
opens the connection to T1, the pressure of the column in the pressure relief valve is reduced in proportion to the actual current through the valve. The main cone 5 is thus lifted from its seat and the oil
flow channel P - T is opened. The pressure set in the menu is established.
16.57.6
Adjusting screw
12
Bushing
Lock nut
14
Magnetic coil
Pressure spring
15
Valve seat
4
5
Pilot control cone

Main cone
16
511
Valve cone
Screw plug
512
Housing
Y414 Prop. solenoid valve
11
Pressure spring
copyright by
MJF C I F S S
Service Manual

Fig. 4
Function of pressure control system
copyright by
MJF C I F S S
16.57.7
Service Manual
Fig. 5
86
Pilot control unit and menu display on the screen

A155 Tool Control keyboard
16.57.8
S241 Switch AHS12
copyright by
MJF C I F S S
Service Manual

Operation
5 Operation
5.1
Operating working tool

spool 500).
Tool Control is disabled (pressure and flow reduction are not possible).
Operating the sorting grapple or hydraulic hammer:
Tool Control is enabled (pressure and flow reduction are possible)
Select the desired working tool on the screen, (see 5.2, page 9) e.g. for sorting grapple cylinder
(through spool 510).
The pressure and flow settings made by the LIEBHERR/dealer technician and the chosen
name of the working tool are shown in the Tool Control screen.
The sorting grapple cylinder is extended at the set speed and pressure, i.e. the sorting grapple
closes.
The sorting grapple cylinder is retracted at the set speed and pressure, i.e. the sorting grapple
opens.
5.2
Selecting working tools on the Tool Control screen A155

see Fig. 5
The horizontal arrow on the screen indicates the currently active option (working tool) and the currently applied settings in %, see Fig. 6.
In the example shown here, option 1 is active.
Move the cursor (black frame) to another preset option (no. 1 to 10) and press the Menu button to
activate it.
Press the arrow buttons UP and/or DOWN.
The black frame indicates the selected option.
Press the Menu button.
Your selection is confirmed.
The arrow moves to the selected number, and the option is activated (here: option 3).
The working tool can be operated at reduced oil pressure / reduced flow rate.
copyright by
MJF C I F S S
16.57.9
Service Manual
Operation
Note!
On request, LIEBHERR and the customer service department shall label the options with the name
of the associated tool, e.g. "hammer" or "grapple".
The working tool can only be operated by means of Tool Control. If you wish to operate a working
tool without reduction, select the option with maximum values (EV1, EV2 and EV6 at 100 % level).
Fig. 6
16.57.10
Keyboard unit A155 with "Tool Control" screen
EV1 Oil volume 1

EV1 Oil volume 2
F2
F3
DOWN arrow button

UP arrow button
EV2 Pressure
F4
"Menu" button
copyright by
MJF C I F S S
Service Manual


6.1

To adjust the pressure, use suitable pressure sensors.
Note!
Please note that, during the warranty period, all work on the valves must be carried out by LIEBHERR technicians. The pressure relief valves must be protected against unauthorised manipulation
with lead seal wire or safety caps.
6.2
Adjustment of the pressure reduction system (low pressure)

Connect the pressure sensor to the measuring point 45, see Fig. 7.
Remove the 4 screws at the rear of the keyboard unit A155 and remove the lid of the housing.
Pull the cable with the interface X1252, see Fig. 11, from the housing.
Insert the service plug at the interface provided X1252.
Select speed step 8.
In menu "Option 1", set EV6 to 0%.
Operate the left pedal 86.
Check the low pressure at the measuring point 45 (basic settings), see Tab. 1.
If the prescribed pressure is not reached, adjust the secondary pressure-relief valve512:
Turn the adjusting screw clockwise, using an Allen key:
the pressure is increased.
Turn the adjusting screw anticlockwise, using an Allen key:
the pressure is reduced.
Operate the right pedal 86 and check the pressure at the measuring point 45.
If the prescribed pressure is not reached, adjust the secondary pressure-relief valve511:
Turn the adjusting screw clockwise, using an Allen key:
Turn the adjusting screw anticlockwise, using an Allen key:
Operate the right pedal 86 and check the pressure at the measuring point 45.
Compare the pressures:
they must correspond.
copyright by
MJF C I F S S
16.57.11
Service Manual
Fig. 7
6.3
Adjusting points and operation
20
Variable-displacement pump LPV /

DPVO
104
41
45
Measuring point MP
Measuring point LS
500
510

86
511
100
512

additional pressure level /
hammer / additional consumer
additional pressure level
Adjustment of pressure reduction system (high pressure)

Set the pressure cut-off valve 104 to 400 bar.
Connect a pressure sensor to the measuring point 45, see Fig. 7.
In menu "opt.1", set EV6 to 100%.
Operate left or right pedal.
Check the high pressure, see Tab. 1, at the measuring point 45.
If the prescribed high pressure is not reached:
Turn the adjusting screw 20 at the proportional valve Y414 until the prescribed high pressure is
reached.
Turn the adjusting screw 20 clockwise, using an Allen key:
16.57.12
copyright by
MJF C I F S S
Service Manual

Turn the adjusting screw 20 anticlockwise, using an Allen key:
Compare the high pressure values of the right and the left foot pedal.
the two measured pressures must be identical.
Disconnect the service plug.
Place the cable with the interface X1252 in the housing of the keyboard unit A155.
Mount the lid and tighten the screws (first tighten right bottom screw in the internal clip).
Fig. 8
1
20
Foot pedal in the operator's cab and proportional solenoid valve attached to the hydraulic
tank
86
Y414 Prop. solenoid valve
Hydraulic tank
Adjusting screw
copyright by
MJF C I F S S
16.57.13
Service Manual
6.4
Adjustment of the pressure cut-off valve 104, see Fig. 7

Run engine at step 8.
Connect a pressure sensor to the measuring point 41.
Move the bucket cylinder to the stop and adjust the pressure cut-off valve 104 to the required pressure (see Tab. 1, page 2) by turning the adjusting screw.
6.5
Fig. 9
100
500

500.1 Stroke limitation / retracting regulating cylinder
1.1
1.2
Stop screw
Lock nut
1.3
Safety cap
500.2 Stroke limitation / extending regulating cylinder

510
Spool / hydraulic hammer/cylinder spool
510.1 Stroke limitation / retracting cylinder

510.2 Stroke limitation / hydraulic hammer / extending cylinder
The stroke of the spool 510 for maximum oil flow is factory set by means of the stroke limitation 510.1
The dimension Y, (see Tab. 1, page 2) serves as a reference value for the prescribed settings. If dimension Y does not correspond to the prescribed value, adjust the stroke limiter as follows:
Remove the protective cap 1.3, loosen the lock nut 1.2 and turn the stop screw 1.1 until dimension
Y is reached.
Tighten the lock nut 1.2 and mount the safety cap 1.3.
16.57.14
copyright by
MJF C I F S S
Service Manual

copyright by
MJF C I F S S
16.57.15
Service Manual
Hydraulic diagram
7 Hydraulic diagram
Items in hydraulic diagram, (see Fig. 10, page 17)
1
6
514
517
Pressure balance
20
525
Regulating cylinder
23
41
Pump regulator
Measuring point MP
526
527
Load holding valve

Load holding valve
45
Measuring point LS
535
Hydraulic hammer
50
536
Pile driver
86
537
Shear
88P
Distributor
538
Stop cock
88T
90
Collecting pipe
Shuttle valve
535
536
Hydraulic hammer
Pile driver
100
104

537
538
Shear
Stop cock
500
501
Auxiliary spool / regulating cylinder

Secondary pressure relief valve / retrac- A155
ting cylinder 525
502
Secondary pressure relief valve / exten- A156

ding cylinder 537
504
507
Pressure balance
S241
Y268
AHS 11 / AHS 12 switch

Solenoid valve changeover auxiliary
axle 500/ 501
510
Auxiliary spool / hammer or additional

consumer
Y414
Prop.solenoid valve / pressure limitation
511

additional pressure level /
additional pressure level / additional
consumer
Y463
Prop.solenoid valve flow reduction hammer control axle
Y464
Prop.solenoid valve flow reduction hammer control axle
512
16.57.16
to tank
to oil cooler
copyright by
MJF C I F S S
Keyboard unit
ESX control
Service Manual

Hydraulic diagram
Fig. 10
Hydraulic diagram of AHS 11 with Tool Control
copyright by
MJF C I F S S
16.57.17
Service Manual
Electrical system
8 Electrical system
Fig. 11
Electrical system of AHS 12 accessory kit with Tool Control
A155
Keyboard unit / display with plug

X1 and X3
X974-4 Plug
A156
S241
ESX control unit with plug X1

Switch AHS12
X1252 CanBus interface

Y268 Solenoid valve / changeover auxiliary
axle 500/ 501
X11
Plug
Y299
Plug connection to solenoid valve
X414
X463
Plug
Plug
Y414
Y463
Prop.solenoid valve / pressure limitation

Prop.solenoid valve / flow limitation
Hammer control axle
X464
Plug
Y464
Prop.solenoid valve / flow limitation

Hammer control axle
The electric diagram of the accessory kit is included in group 8.106.
16.57.18
copyright by
MJF C I F S S
Service Manual

Function

1 Function
These parts have been combined in accessory kits. As there is a wide range of different auxiliary attachments available for machines, we offer a number of different accessory kits to suit the equipment.
The accessory kit AHS 12 with changeover valve accessory kit described below enables operators
to use three different auxiliary attachments and to supply them through two separate auxiliary control
axles:
first auxiliary control axle, located beside the main control valve block without pressure and flow
reduction for the high-pressure connections:
(vertical) and a horizontally adjustable boom.
second auxiliary control axle without pressure/flow reduction for a high-pressure connection:
second auxiliary control axle without pressure/flow reduction for both high-pressure connections:
used for example in connection with the attachment of a sorting grapple, a concrete crusher,
etc.
one solenoid valve for the changeover of the high-pressure connections of the first auxiliary control axle from vertically to horizontally adjustable boom
As all functions are controlled with the same pilot control device (pedal), they cannot be operated simultaneously.
copyright by
MJF C I F S S
16.58.1
Service Manual
General information
Fig. 1
Application options with kit AHS12 with changeover valve
A Cylinder for hydr. boom adjustment (vertical) C Example: Hydraulic hammer

B Cylinder for hydr. boom adjustment (horizon- C Example: Sorting grapple
tal)
valves
block 100
for regulating cylinder 525 / 545 extension and retraction
Tab. 1

primary
secondary
350 +10 bar

380 +20 bar

Technical data
Note!
The settings for the valves of the AHS 12 accessory kit are documented in detail in group 16.56.
16.58.2
copyright by
MJF C I F S S
Service Manual

Operation
3 Operation
The accessory kit AHS 12 with changeover valve allows for the operation of working attachments
(consumers) used for the vertical and horizontal adjustment of the boom as well as of other connected auxiliary attachments, by means of the auxiliary pilot control unit 86.
of switch S241.
In addition, it is possible to preselect the direction of movement of the boom (up/down, left/right) by
means of switch S356.
Note!
For a detailed description of the functions and operation of the AHS 12 kit, refer to group 16.56.
To ensure proper use and functioning of the accessory kit AHS 12 with changeover valve, the connected units must be operated according to the instructions in this manual:
Fig. 2
86
S241 Switch AHS12
S356 Switch/changeover valve

Actuate switches S241 and S356 to preselect the desired attachment and activate it through the solenoid valve Y332.
Operation of the boom regulating cylinder 252 (vertical):
copyright by
MJF C I F S S
16.58.3
Service Manual
Operation
spool 500).
Operation of the boom regulating cylinder 545 (horizontal):
The indicator in the switch is off.
Switch S356 is actuated.
spool 500).
The regulating cylinder (vertical) 545 is retracted, i.e. the boom is swivelled to the right.
The regulating cylinder (vertical) 545 is extended, i.e. the boom is swivelled to the left.
16.58.4
copyright by
MJF C I F S S
Service Manual

Function
4 Function
4.1

Set switch S241 to position 0 (not actuated).
The solenoid valve Y332 is in neutral position.
4.1.1
Extending
By pressing down the right pedal of the pilot control unit 86, the control oil is fed from connection 1
through the solenoid valve Y268 connection P1-A1 to the auxiliary control axle 500 connection b6.
The spool 500 feeds high-pressure oil from the working pump 20 through connection B6 and the solenoid valve Y332 connection A2 - B2 and the load-holding valve 526 connection V2-C2 to the piston
side of the regulating cylinder 525.
The control oil is then fed through the T-piece at the connection b6 and the solenoid valve Y444 connection T-A to the load-holding valve 527 connection Pil. The valve 527 is opened, releasing return
oil from the piston rod side of the cylinder 525 through connection C2-V2 of the valve 527, connection
B1-A1 of the solenoid valve Y332, connection A6 of the control valve block 100 and the spool 500 to
the tank. The cylinder is extended, moving the attachment upwards.
4.1.2
Retracting
By pressing down the left pedal of the pilot control unit 86, the control oil is fed from connection 2
through the solenoid valve Y268 connection P2-B1 to the auxiliary control axle 500 connection a6.
The spool 500 feeds high-pressure oil from the working pump 20 through connection A6 and the solenoid valve Y332 connection A1 - B1 and the load-holding valve 527 connection V2-C2 to the piston
rod side of the regulating cylinder 525.
The control oil is then fed through the T-piece at the connection a6 and the solenoid valve Y443 connection T-A to the load-holding valve 526 connection Pil. The valve 526 is opened, releasing return
oil from the piston side of the cylinder 525 through connection C2-V2 of the valve 526, connection
B2-A2 of the solenoid valve Y332, connection B6 of the control valve block 100 and the spool 500 to
the tank. The cylinder is retracted, moving the attachment downwards.
4.2

Set switch S356 to ON (active).
The solenoid valve Y332 is in working position.
4.2.1
Extending
By pressing down the left pedal of the pilot control unit 86, the control oil is fed from connection 2
through the solenoid valve Y268 connection P2-B1 to the auxiliary control axle 500 connection a6.
The spool 500 feeds high-pressure oil from the working pump 20 through connection A6 and the solenoid valve Y332 connection A1 - C1 and the load-holding valve 546 connection V2-C2 to the piston
side of the regulating cylinder 545.
Control oil is fed through an internal line with restrictor to a stop valve in the load-holding valve 546
located at the piston rod side. The valve 546 is opened, releasing return oil from the piston rod side
of the cylinder 545 through connection C1-V1 of the valve 546, connection C2-A2 of the solenoid valve Y332, connection B6 of the control valve block 100 and the spool 500 to the tank. The cylinder is
copyright by
MJF C I F S S
16.58.5
Service Manual
Function
extended, moving the attachment to the left.
4.2.2
Retracting
By pressing down the right pedal of the pilot control unit 86, the control oil is fed from connection 1
through the solenoid valve Y268 connection P1-A1 to the auxiliary control axle 500 connection b6.
The spool 500 feeds high-pressure oil from the working pump 20 through connection B6 and the solenoid valve Y332 connection A2 - C2 and the double load-holding valve 546 connection V1-C1 to
the piston side of the regulating cylinder 545.
Control oil is fed through an internal line with restrictor to a stop valve in the load-holding valve 546
located at the piston side. The valve 546 is opened, releasing return oil from the piston side of the
cylinder 545 through connection C2-V2 of the valve 546, connection C1-A1 of the solenoid valve
Y332, connection A6 of the control valve block 100 and the spool 500 to the tank. The cylinder is retracted, moving the attachment to the right.
4.3
Stop function of solenoid valves Y443 and Y444

To prevent that the attachment is inadvertently extended or lowered, the solenoid valves Y443 and
Y444 have been installed. They act as stop valves in the hydraulic circuit of the regulating cylinder
525.
If the switch S356 is activated (indicator lamp in switch is on), the two solenoid valves Y443 and Y444
are switched from neutral to blocking position.
The connections Pil of the load-holding valves 526 and 527 are thus opened through the valves Y443
and Y444 connection A-P to the tank. This prevents internal pressure build-up at the control piston
of the load-holding valves 526 and 527.
16.58.6
copyright by
MJF C I F S S
Service Manual


Note!
For a detailed description of testing procedures and pressure adjustments, see AHS 12, group
16.56.
copyright by
MJF C I F S S
16.58.7
Service Manual

6.1
Boom regulating cylinder without stop valves (early machines of series)
Fig. 3
Hydraulic lines of the kit with changeover valve and without hydraulic stop valves
Key to diagrams on pages 16.62.08 and 16.62.09

546
16.58.8
Hydraulic tank
545
255
Stick cylinder 7
546
500
525
Regulating cylinder (vertical movement)
Y332 Solenoid valve / changeover valve
526
527

Y443 Stop valve for cylinder retracting

Y444 Stop valve for cylinder extending
copyright by
MJF C I F S S
Regulating cylinder (horizontal movement)

Service Manual

6.2
Boom regulating cylinder with stop valve (later machines of series)
Fig. 4
Hydraulic lines of the kit with changeover valve and with hydraulic stop valves
copyright by
MJF C I F S S
16.58.9
Service Manual
Hydraulic system
7 Hydraulic system
1
20

514
517
Pressure balance
23
Regulating valve
525
Regulating cylinder
41
45
Measuring point MP
Measuring point LS
526
527

50
535
Hydraulic hammer
86
536
Pile driver
88P
Distributor
537
88T
Collecting pipe
538
Stop cock
100
545
Regulating cylinder (horizontal movement)
104
500

546
501
Secondary pressure-relief valve / retrac- S241 Switch / changeover regulating cylinder ting reg. cyl. 525 / extending reg. cyl. 545
hydraulic hammer
Secondary pressure-relief valve / exten- S356 Switch / changeover of boom adjustment
ding reg. cyl. 525 / retracting reg. cyl. 545
horizontal - vertical
502
504
Pressure balance

cylinder - hammer
507
510

driver

Y332 Solenoid valve / changeover valve
511

hydraulic hammer cylinder 535 cylinder
537
512
Secondary pressure relief valve / cylinder Y444 Stop valve for cylinder extending
537 retracting
Y443 Stop valve for cylinder retracing
16.58.10
copyright by
MJF C I F S S
The valve is not built into all machines

(subsequently added to machine equipment).
Service Manual

Hydraulic system
Fig. 5
Hydraulic diagram of the changeover valve kit
copyright by
MJF C I F S S
16.58.11
Service Manual
Electrical system
8 Electrical system
Step 66 / 78#
Item
F331**
K455
S356
X29**
X358-1
X358-2
X963**
X983
X1226
Y332
Y443
Y444
16.58.12
Description
Fuse kits
Relay/changeover switch
Switch/changeover valve
Stop valve/ regulating cylinder extending
Stop valve/ regulating cylinder retracting
copyright by
MJF C I F S S
15.0 A

Right control desk
Right console, rear
Fuel tank
Right console, rear
Right console, rear
Basic boom
Hydraulic tank
Hydraulic tank
Service Manual

Electrical system
** in basic diagram
# For other options of kit layout changeover
valve, see group 8.45.
copyright by
MJF C I F S S
The item is not built into all machines

(subsequently added to machine equipment).
16.58.13
Service Manual
Electrical kit step 66 / 78
9 Electrical kit step 66 / 78
Fig. 6
16.58.14
Electrical kit for changeover valve, see also step 66 / 78 in group 8.45, electrical kits.
copyright by
MJF C I F S S
Service Manual
Individual control
Function
Individual control
1 Function
On request, the machine can be equipped with individual control system for the 2-point or 4-point outrigger support.
This allows for the separate control of each support leg, so that the machine can be brought into a
horizontal position even on a slope or on uneven ground. The pressure in the individual support cylinders is thereby controlled by means of the "outrigger support" function.
Fig. 1
Hydraulic excavator with 4-point outrigger support
copyright by
MJF C I F S S
16.60.1
Individual control
Service Manual
Design
2 Design
The kit for individual control consists of a number of operating elements, solenoid valves and hydraulic and electrical connections.
The operator can select the respective individual control systems by means of switches S204 - S207.
This switch is integrated into the right-hand control console in the operator's cab. The pilot control unit
85 with which the extension and retraction of the outrigger support is controlled is also installed in this
console.
The support cylinder 295 is controlled by means of the solenoid valves Y215 - Y218 located in the
undercarriage. The electrical connections from the uppercarriage to the undercarriage are fed through the rotary connection 325. The rotary connection 325 is installed on the 6x rotary connection
322 with which all models are equipped.
The two rotary connections 320 (high pressure) and 322 (low pressure) are connected to each other
with screws and attached to a bracket mounted in the undercarriage.
The junction box S272 is mounted in the undercarriage. From this point, all electrical lines of the system in the undercarriage are supplied.
The support cylinder 295 with attached double lowering brake valves 297 are secured with bolts to
the steel structure of the undercarriage.
Fig. 2
85
16.60.2
Pilot control unit and switch for individual outrigger control
Pilot control unit
S204
Individual control system switch
S205
S206
S207
copyright by
MJF C I F S S
Service Manual
Individual control
Design
Fig. 3
Rotary connections, slip ring connection and solenoid valves in the undercarriage
320
Rotary connection (high pressure)
Y215
Solenoid valve
Individual control of front left outrigger
322
Rotary connection (low pressure)
Y216
Solenoid valve
Individual control of front right outrigger
325
Y217
Solenoid valve
Individual control of rear left outrigger
Solenoid valve
Individual control of rear right outrigger
Y218
copyright by
MJF C I F S S
16.60.3
Individual control
Service Manual
see Fig. 4 and see Fig. 5
When in neutral position, the solenoid valves Y215 - Y218 close the pressure connection B; as a result, the oil flow from the pump through the spool 280 and the rotating connection 320 to the support
cylinders 295 is thus blocked.
By pressing the respective switch S204 - S207, the desired outrigger foot can be selected. When
pressed, the indicator light in the respective button S204 -S207 is on.
The solenoid valves Y215- Y218 are powered through the switches S204 - S207 via the slip ring rotary connection 325.
If the lever of the pilot control unit 85 located in the right control console is now moved forward or
back, oil flows from the pump and the spool 280 through the connections 2/ 4 of the 7x rotary connection 320 and the solenoid valves Y215 - Y218 to the support cylinders 295 in the undercarriage.
The solenoid valves that have not been actuated seal the other cylinders so that no oil is fed to them.
The pressure generated in this process opens the flange-mounted double lowering brake valve 297.
The respective support cylinder 295 is now retracted or extended. The return oil from the piston or
rod side of the cylinder flows through the valve 297 back to the tank.
The valve 297 seals the extending support cylinder against the spool 280.
100
16.60.4
S206
Switch / individual outrigger control, left
100
A1 from control valve block connection

A1
B1 from control valve block B1
S207
Switch / individual outrigger control,

right
295
Support cylinder
Y217
Solenoid valve
297
Double lowering brake valve
Y218
Solenoid valve
320
325
copyright by
MJF C I F S S
Service Manual
Individual control
Fig. 4
Hydraulic diagram of support option with 2-point support and individual control
copyright by
MJF C I F S S
16.60.5
Individual control
Service Manual
16.60.6
100
A1 from control valve block connection

A1
S205
Switch / individual control of front right

outrigger
100
B1 from control valve block B1
S206
295
Support cylinder
S207
Switch / individual control of rear left

outrigger
Switch / individual control of rear right
outrigger
297
Y215
Solenoid valve
320
Y216
Solenoid valve
325
Y217
Solenoid valve
S204
Switch / individual control of front left

outrigger
Y218
Solenoid valve
copyright by
MJF C I F S S
Service Manual
Individual control
Fig. 5
Hydraulic diagram of support option with 4-point support and individual control
copyright by
MJF C I F S S
16.60.7
Individual control
Service Manual
Fig. 6
16.60.8
Electrical system of individual control
F337
S204
Fuse (15 A) (front control console)

X771
X957

S205
S206

X958
X963

S207
Y61
S272
Junction box
Y215

(without function with individual control)
Solenoid valve
S335
Changeover switch
Y216
(without function with individual control)
X301
Y217
Solenoid valve
X304
Y218
Solenoid valve
copyright by
MJF C I F S S
Solenoid valve
Service Manual
Individual control
Electric diagram of individual control system
4 Electric diagram of individual control system
copyright by
MJF C I F S S
16.60.9
Individual control
Service Manual
Electric diagram of individual control system
16.60.10
copyright by
MJF C I F S S
Service Manual

Function

A 309 up to serial no. 23701
A 311 up to serial no. 23253
1 Function
This kit allows the operator to control the auxiliary attachment with the foot pedal or with the joystick.
To install the kit, a number of units, hydraulic lines and hoses required for the switch-over of the control are required.
These parts are included in the switch-over of control kit.
Fig. 1
Pilot control units for bucket movement and kit
81 Pilot control unit for boom and bucket move- 86 Pilot control unit with pedals
ment with joystick
e
Tilt bucket inwards
Tilt bucket outwards
m Operate hydraulic hammer / close sorting

grapple
n Open sorting grapple
after switch-over:
after switch-over:
Operate hydraulic hammer / close sorting

grapple
m Tilt bucket inwards
Open sorting grapple
copyright by
MJF C I F S S
16.62.1
Service Manual
Operation
2 Operation
Caution!
Always take into account that operating procedures might change after a switch-over. Ensure that
all operating staff are familiar with the operating behaviour of the machine after switch-over and that
the respective instructions are included in the manual. Attach a warning sign at a clearly visible location at the machine.
Fig. 2
81
86
Operator's cab with pilot control devices, switches and indicator lamps for the switch-over
kit
Pilot control unit with joystick
Pilot control unit with pedals
H196
H322
Sorting grapple indicator lamp

Indicator light / control switch-over
S241
Switch AHS12
S405
Key switch / control switch-over
Using the switch S241 and the key switch S405, preselect the operating method for the attachment
and activate it by means of the solenoid valves Y268 and Y385-1 / Y385-2.
2.1
Operation of bucket cylinder 180 and boom regulating cylinder 525:

Set the key switch S405 to position A or B (switch-over not possible)
spool 105).
Push the joystick of the pilot control unit 81 to the right.
The bucket cylinder is retracted, i.e. the bucket is tilted outwards
16.62.2
copyright by
MJF C I F S S
Service Manual

Operation
Push the joystick of the pilot control unit 81 to the left.
The bucket cylinder is extended, i.e. the bucket is tilted inwards
2.2
Operation of bucket cylinder 180 and shears / sorting grapple 537 (standard):
Set the key switch S405 to position A.
spool 510).
The cylinder of the sorting grapple / shears is extended (sorting grapple / shears closed)
The cylinder of the sorting grapple / shears is retracted (sorting grapple / shears opened)
2.3
Operation of bucket cylinder 180 and shears / sorting grapple 537 (after
switch-over):
The indicator light at the switch is not on (as shown in section 2.2)
Set the key switch S405 to position B
spool 510).
copyright by
MJF C I F S S
16.62.3
Service Manual
Operation
2.4
Operation of bucket cylinder 180 and hydraulic hammer 535 (standard):

The indicator light H196 at the switch is not on (as shown in section 2.5)
Set the key switch S405 to position A
The hydraulic hammer is pressurised.
no function assigned
2.5
Operation of bucket cylinder 180 and hydraulic hammer 535 (after switchover):
16.62.4
copyright by
MJF C I F S S
Service Manual

Function of switch-over / control
3 Function of switch-over / control

Note!
For the regular functions of the accessory kit AHS 12 that can be activated with switch S241, please
refer to group 16.54.
3.1
Operation of sorting grapple / shears and hydraulic hammer with pilot control
unit 86 (pedals)
Operation of bucket cylinder with pilot control unit 81 (joystick)
The solenoid valves Y385-1 / Y385-2 are in neutral position.
3.1.1
Extending/ pressurising hammer

When the right pedal of the pilot control unit 86 is pressed down, control oil is fed from connection 1
through the solenoid valve Y268 connection P1-A2 and through the solenoid valve Y385-1 connection 3-4 to the auxiliary control axle 510 connection a9. The spool 510 feeds high-pressure oil from
the working pump 20 through the connection A9 to the hydraulic hammer 535 or the piston side of
the cylinder 537 respectively.
The hydraulic hammer / the cylinder is extended, moving the attachment.
When the joystick of the pilot control unit 81 is pushed to the left, control oil is fed from connection 4
through the solenoid valve Y262 connection P2-B1 and through the solenoid valve Y385-1 connection 2-1 to the control valve block 100 connection a7. The spool 107 feeds high-pressure oil from the
working pump 20 through the connection A7 to the piston side of the bucket cylinder 180.
The cylinder is extended; the bucket is tilted inwards.
3.1.2
Retracting
When the left pedal of the pilot control unit 86 is pressed down, control oil from connection 2 is fed
through the solenoid valve Y268 connection P2-B2, the solenoid valve Y299 connection P2-B2 and
the solenoid valve Y385-2 connection 3-4 to the auxiliary control axle 510 connection b9. The spool
510 feeds high-pressure oil from the working pump 20 through the connection B9 to the rod side of
the cylinder 537.
The cylinder is retracted, moving the attachment.
through the solenoid valve Y262 connection P1-A1 and through the solenoid valve Y385-2 connection 2-1 to the control valve block 100 connection b7. The spool 107 feeds high-pressure oil from the
working pump 20 through the connection B7 to the rod side of the bucket cylinder 180.
The cylinder is retracted; the bucket is tilted outwards.
copyright by
MJF C I F S S
16.62.5
Service Manual
3.2
device 81 (joystick)
Operation of bucket cylinder with pilot control unit 86 (pedals)
Set the key switch S405 to position B.
The solenoid valves Y385-1 / Y385-2 are in working position.
3.2.1

through the solenoid valve Y262 connection P2-B1 and through the solenoid valve Y385-1 connection 2-4 to the auxiliary control axle 510 connection a9. The spool 510 feeds high-pressure oil from
The hydraulic hammer 535 / the cylinder 537 is extended, moving the attachment.
the working pump 20 through eh connection A7 to the piston side of the bucket cylinder 180.
3.2.2
Retracting
When the joystick of the pilot control unit 81 is pushed to the right, control oil is fed from connection
2 through the solenoid valve Y262 connection P1-A1 and through the solenoid valve Y385-2 connection 2-4 to the auxiliary control axle 510 connection b9. The spool 510 feeds high-pressure oil from
the working pump 20 through the connection B9 to the rod side of the cylinder 537.
the solenoid valve Y385-2 connection 3-1 to the control valve block 100 connection b7. The spool
the bucket cylinder 180.
3.3
Pressure reduction at auxiliary control valve block, and combined shifting

when boom is lowered
When the switch S241 is in this position, the control oil line from the control oil unit 50 / P1 to the
pressure boost cartridge of the valve 511 and through the solenoid valve Y299 connection B1/A2 is
blocked, and the line from the valve 511 through the solenoid valve Y299 connection A2-T to the tank
is relieved. As a result, the pressure for the hydraulic hammer is reduced.
When the switch S241 is in position 2, the control oil line from the control line to the connection b6
(function "lower boom") through the solenoid valve Y299 connection A1/P1, the shuttle valve 78 and
the line to the control valve block 100 connection b4 is established. The spool 109 is moved, allowing
for the combined shifting of booms.
In this case, the control oil line from the pilot control unit 86 connection 2 through the solenoid valve
Y268 connection P2-B2, the solenoid valve Y299 connection P2-B2 and the solenoid valve Y385-2
16.62.6
copyright by
MJF C I F S S
Service Manual

connection 3-1 to the control valve block 100 connection b7 is blocked.

This has a negative effect on the control of the machine (S405 in position B), as the bucket cylinder
can now only be extended but not retracted.

Note!
For a description of the valve and stroke limiter settings in auxiliary axle AHS 12, refer to group
16.54.
copyright by
MJF C I F S S
16.62.7
Service Manual
Components and hydraulic lines A 309 up to serial no. 23701 and A 311 up to serial no. 23253

A 309 up to serial no. 23701 and A 311 up to serial no. 23253
Fig. 3
16.62.8
Hydraulic connections of control switch-over kit
Hydraulic tank
B33
Pressure switch flow reduction
50
78
Control oil unit

Y22
Y23

79
Shuttle valve / pressure switch
Y62
81
Y63
Solenoid valve / travel reverse
86
Y262
Solenoid valve / switch-over bucket offset boom bearing
100
Y268

cylinder - hammer
copyright by
MJF C I F S S
Service Manual

Components and hydraulic lines A 309 up to serial no. 23701 and A 311 up to serial no. 23253
105
106
Boom cylinder spool
107
109
510
511

additional pressure stage / retract hydr.
hammer cyl.
Fig. 4
Y299

hammer
Y385-1 Solenoid valve changeover bucket cyl. AHS
copyright by
MJF C I F S S
16.62.9
Service Manual
Hydraulic diagram of the kit
6 Hydraulic diagram of the kit

546
to hydraulic tank
510
Spool / hydraulic hammer /

cylinder
20
from double variable-displacement

pump
511

extend hydraulic hammer 535 cylinder
537
40
Measuring point P1
512

cylinder 537
50
535
Hydraulic hammer
78
537
Cylinder (auxiliary activation, e.g. sorting

grapple)
79
Shuttle valve / pressure switch B33
81
Pilot control unit 4x, with joystick
B33
86
88P

Distributor
S63
S241

Switch / changeover regulating cylinder
- hydraulic hammer
88T
Collecting pipe
S263
100
105

S405
Y62

106
107
Boom cylinder spool

Y63
Y262

109
Y268

cylinder - hammer
122
Y299
180
Bucket cylinder
250
Regulating cylinder
251
16.62.10

hammer
Y385-1 Solenoid valve / changeover bucket cyl.
- AHS
- AHS
copyright by
MJF C I F S S
Service Manual

Hydraulic diagram of the kit
copyright by
MJF C I F S S
16.62.11
Service Manual
Electrical system
7 Electrical system
B33
H322
Warning light / switch-over
S405
Switch / changeover
Right console
X12**
X29**
X957**
X1029
X1224

Plug connection to B33 / 3-pin
Right console
Right console, rear
Right console, rear
Distribution board
Y385-1
Y385-2
Solenoid valve / changeover bucket cylinder- AHS

Near fuel tank

Near fuel tank
** position from basic diagram
16.62.12
copyright by
MJF C I F S S
Service Manual

Electrical system
Fig. 5
Electrical system of switch-over control kit
copyright by
MJF C I F S S
16.62.13
Service Manual
Electrical system
Step 84/2#
Item
Description
A125**
PCB potentiometers
Left console
B33
F321**
F330**
F331**
Fuse X12
Fuse kits
Fuse X29
H322
K375**
Right console, rear
S241**
S405

Switch / changeover
Right control desk

Right console
U16**
Right console, rear
V156-4
Blocking diode A125
A125
X12**
X29**
X837**
X839**
X856**
X857**
X957**
X958**
X963**
X965**
X966**
X968-1**
X968-2**
X974-4**
X1028
X1029
X1224

Plug connection BST excavator control / 24-pin
Right console
Right console, rear
Right console
Right console
Right console, rear
Right console, rear
Right console, rear
Right console, rear
Right console, rear
Distribution board
Y268**
Y299**
Y385-1
Y385-2
to solenoid valve / grapple hammer

to solenoid valve secondary pressure hammer
Near hydraulic tank

Near hydraulic tank
Behind cab
Behind cab
15.0 A
15.0 A
15.0 A

# see also electric kits in group 8.45
16.62.14
copyright by
MJF C I F S S

Service Manual

Electrical system
copyright by
MJF C I F S S
16.62.15
Service Manual
Electrical system
16.62.16
copyright by
MJF C I F S S
Service Manual

Function

8 Function
Fig. 6
ment with joystick
e
Tilt bucket inwards

grapple
after switch-over:
after switch-over:
Operate hydraulic hammer / close sorting

grapple
copyright by
MJF C I F S S
16.62.21
Service Manual
Operation
9 Operation
Caution!
Fig. 7
kit
81
H196
86
H322
S241
S405
Switch AHS12
9.1

spool 105).
16.62.22
copyright by
MJF C I F S S
Service Manual

Operation
9.2
spool 510).
9.3
switch-over):
The indicator light in the switch is not on (as shown in section 9.2)
spool 510).
copyright by
MJF C I F S S
16.62.23
Service Manual
Operation
9.4

The indicator light H196 is not on (as shown in section 9.5)
9.5
16.62.24
copyright by
MJF C I F S S
Service Manual


Note!
For the regularly functions of the accessory kit AHS 12 that can be activated with switch S241, please refer to group 16.54.
10.1
unit 86 (pedals)
10.1.1

through the solenoid valve Y262 connection P2-B1 and through the solenoid valve Y385-1 connection 2-1 to the control valve block 100 connection a7. The spool 107 feeds high-pressure oil from the
10.1.2
Retracting
the solenoid valve Y385-2 connection 3-4 to the auxiliary control axle 510 connection b9. The spool
the cylinder 537.
through the solenoid valve Y262 connection P1-A1 and through the solenoid valve Y385-2 connection 2-1 to the control valve block 100 connection b7. The spool 107 feeds high-pressure oil from the
working pump 20 through the connection B7 to the rod side of the bucket cylinder 180.
copyright by
MJF C I F S S
16.62.25
Service Manual
10.2
Set the switch S241 to position 1 or 2.
10.2.1
Extending / pressurising hammer

through the solenoid valve Y262 connection P2-B1 and through the solenoid valve Y385-1 connection 2-4 to the auxiliary control axle 510 connection a9. The spool 510 feeds high-pressure oil from
the working pump 20 through the connection A7 to the piston side of the bucket cylinder 180.
10.2.2
Retracting
2 through the solenoid valve Y262 connection P1-A1 and through the solenoid valve Y385-2 connection 2-4 to the auxiliary control axle 510 connection b9. The spool 510 feeds high-pressure oil from
the working pump 20 through the connection B9 to the rod side of the cylinder 537.
the bucket cylinder 180.
10.3

pressure boost cartridge of the valve 511 and through the solenoid valve Y299 connection B1/A2 is
blocked, and the line from the valve 511 through the solenoid valve Y299 connection A2-T to the tank
is relieved. As a result, the pressure for the hydraulic hammer is reduced.
When the switch S241 is in position 2, the control oil line from the control line to the connection b6
(function "lower boom") through the solenoid valve Y299 connection A1/P1, the shuttle valve 78 and
the line to the control valve block 100 connection b4 is established. The spool 109 is moved, allowing
for the combined shifting of booms.
16.62.26
copyright by
MJF C I F S S
Service Manual


Note!
16.54.
copyright by
MJF C I F S S
16.62.27
Service Manual
Components and hydraulic lines A 309 from serial no. 23702 and A 311 from serial no. 23254
12

A 309 from serial no. 23702 and A 311 from serial no. 23254
Fig. 8
16.62.28
copyright by
MJF C I F S S
Service Manual

Components and hydraulic lines A 309 from serial no. 23702 and A 311 from serial no. 23254
Hydraulic tank
B33
50
78
Control oil unit

Y22
Y23

79
Shuttle valve / pressure switch
Y62
81
Y63
86
Y262
100
Y268

cylinder - hammer
105
Y299

hammer
106
Boom cylinder spool
107
109

Y451 Solenoid valve switch-over buzzer /
boom
510
511

additional pressure stage / retract hydr.
hammer cyl.
copyright by
MJF C I F S S
16.62.29
Service Manual
Hydraulic system
Fig. 9
13
Hydraulic system
546
to hydraulic tank
510

cylinder
20
from double variable-displacement

pump
511

537
40
Measuring point P1
512

cylinder 537
50
535
Hydraulic hammer
78
537

grapple)
79
Shuttle valve / pressure switch B33
81
86

B33
S63

88P
Distributor
S241

- hydraulic hammer
88T
100
Collecting pipe
S263
S405

105
106

Boom cylinder spool
Y62
Y63

107
Y262
109
Y268
122
Y299

cylinder - hammer
hammer
180
Bucket cylinder

- AHS
250
Regulating cylinder
251

- AHS
Y451 Solenoid valve switch-over buzzer /
boom
16.62.30
copyright by
MJF C I F S S
Service Manual

Hydraulic system
copyright by
MJF C I F S S
16.62.31
Service Manual
Electrical system
14
Electrical system
B33
H322
K375**
Relay / signal flow reduction kit AHS
Right console, rear
S405
Switch / changeover
Right console
X12**
X29**
X952**
Right console
Right console, rear
Right console, rear
X957**
X1029
X1224

Plug connection revolving deck BST excavator control /
21-pin
Right console, rear

Distribution board
Y268
Y299
Y385-1
Y385-2
Y451
Solenoid valve / changeover adjustable boom - hammer

Solenoid valve / additional pressure stage
Solenoid valve switch-over buzzer / lower boom

Near fuel tank
Near fuel tank
16.62.32
copyright by
MJF C I F S S
Service Manual

Electrical system
Fig. 10
copyright by
MJF C I F S S
16.62.33
Service Manual
Electrical system
Step 84/2#
Item
Description
A125**
PCB potentiometers
Left console
B33
F321**
F330**
F331**
Fuse X12
Fuse kits
Fuse X29
H196**
H322


K375**
Right console, rear
S19/5**
S241**
S405
to switch AS1
Switch / changeover
Right control desk

Right control desk
Right console
U16**
V156-4

Blocking diode A125
Right console, rear

A125
X12**
X29**
X837**
X839**
X856**
X857**
X957**
X958**
X963**
X965**
X966**
X968-1**
X968-2**
X974-4**
X1028
X1029
X1224

Plug connection BST excavator control / 24-pin
Right console
Right console, rear
Right console
Right console
Right console, rear
Right console, rear
Right console, rear
Right console, rear
Right console, rear
Distribution board
Y268**
Y299**
Y385-1
Y385-2
Y451
to solenoid valve / grapple hammer

to solenoid valve / pressure reduction
Solenoid valve switch-over buzzer / boom

at fuel tank
at fuel tank
15.0 A
15.0 A
15.0 A

16.62.34
copyright by
MJF C I F S S

Service Manual

Electrical system
copyright by
MJF C I F S S
16.62.35
Service Manual
Electrical system
16.62.36
copyright by
MJF C I F S S
Service Manual

Function

1 Function
Fig. 1
ment with joystick
e
Tilt bucket inwards

grapple
after switch-over:
e Operate hydraulic hammer / close sorting
grapple
after switch-over:
copyright by
MJF C I F S S
16.64.1
Service Manual
Operation
2 Operation
Caution!
Fig. 2
81
86
kit
H196
H322

S241
Switch AHS12
S405
2.1

spool 500).
16.64.2
copyright by
MJF C I F S S
Service Manual

Operation
2.2
spool 510).
2.3
switch-over):
The indicator light in the switch is not on (as shown in section 2.2)
spool 510).
copyright by
MJF C I F S S
16.64.3
Service Manual
Operation
2.4

The indicator light H196 is not on (as shown in section 2.5)
2.5
16.64.4
copyright by
MJF C I F S S
Service Manual


Note!
For the regular functions of the accessory kit AHS 12 that can be activated with switch S241, please
refer to group 16.56.
3.1
unit 86 (pedals)
3.1.1

through the solenoid valve Y385-2 connection 2-1 to the control valve block 100 connection b4. The
spool 260 feeds high-pressure oil from the working pump 20 through the connection B4 to the piston
side of the bucket cylinder 275.
3.1.2
Retracting
When the left pedal of the pilot control unit 86 is pressed down, control oil is fed from connection 2
through the solenoid valve Y268 connection P2-B2 and through the solenoid valve Y385-2 connection 3-4 to the auxiliary control axle 510 connection b7. The spool 510 feeds high-pressure oil from
the working pump 20 through the connection B7 to the rod side of the cylinder 537 or the pile driver
537 respectively.
The cylinder is retracted, moving the attachment, or operating the pile driver.
through the solenoid valve Y385-1 connection 2-1 to the control valve block 100 connection a4. The
spool 260 feeds high-pressure oil from the working pump 20 through the connection A4 to the rod
side of the bucket cylinder 275.
copyright by
MJF C I F S S
16.64.5
Service Manual
3.2
3.2.1

through the solenoid valve Y385-1 connection 2-4 to the auxiliary control axle 510 connection a7. The
spool 510 feeds high-pressure oil from the working pump 20 through the connection A7 to the hydraulic hammer 535 or the piston side of the cylinder 537 respectively.
through the solenoid valve Y268 connection P1-A2 and through the solenoid valve Y385-1 connection 3-1 to the control valve block 100 connection a4. The spool 260 feeds high-pressure oil from the
3.2.2
Retraction of attachment/pressurisation of pile driver

4 through the solenoid valve Y385-2 connection 2-4 to the auxiliary control axle 510 connection b7.
The spool 510 feeds high-pressure oil from the working pump 20 through the connection B7 to the
rod side of the cylinder 537.
The cylinder is retracted, moving the attachment, or operating the pile driver.
the bucket cylinder 275. The cylinder is retracted; the bucket is tilted outwards.
3.3

pressure boost cartridge of the valve 511 and through the solenoid valve Y299 connection P-A is blocked, and the line from the valve 511 through the solenoid valve Y299 connection A-T to the tank is
relieved. As a result, the pressure for the hydraulic hammer is reduced.

Note!
16.56.
16.64.6
copyright by
MJF C I F S S
Service Manual

Fig. 3
1
50
Hydraulic tank
Control oil unit
Y62
Y63

81
Y268

cylinder - hammer
86
Y299
Solenoid valve / secondary pressure hammer
100
260
510
511

additional pressure stage / extend
hydr. hammer cyl.
copyright by
MJF C I F S S
16.64.7
Service Manual
Hydraulic system
6 Hydraulic system
1
to hydraulic tank
512
Retracting secondary pressure relief

valve / cylinder 537
20
514
Pressure balance
41
45
Measuring point MP
Measuring point LS
517
525

Regulating cylinder
50
81

526
527
Load-holding valve
Load-holding valve
86
535
Hydraulic hammer
88P
Distributor
537

grapple)
88T
100
Collecting pipe
B33
S63

104
S241
260
S263

- hydraulic hammer
275
Bucket cylinder
S405
500
Spool / regulating cylinder /

Y62
cylinder
Secondary pressure-relief valve / retract Y63
501
502
504

extend regulating cylinder 525
Pressure balance
Y268
507
Y299
510

cylinder
537

- AHS
- AHS
511
16.64.8
Y262

copyright by
MJF C I F S S

cylinder - hammer
hammer
Service Manual

Hydraulic system
copyright by
MJF C I F S S
16.64.9
Service Manual
Electrical system
7 Electrical system
B33
H322
S405
Switch / switch-over
Right console
X12**
X29**
X957**
X1029
X1224

Right console
Right console, rear
Right console, rear
Distribution board
Y385-1
Y385-2
Y451

Solenoid valve switch-over buzzer / boom
Near fuel tank

Near fuel tank
Near fuel tank
16.64.10
copyright by
MJF C I F S S
Service Manual

Electrical system
Fig. 4
copyright by
MJF C I F S S
16.64.11
Service Manual
Electrical system
Step 84/1#
Item
Description
A125**
PCB potentiometers
Left console
F330**
F331**
Fuse kits
Fuse X29
H322
P1**
S241**
S405

Switch / changeover
Right control desk

Right console
U16**
Right console, rear
V156-4
V169
Blocking diode A125

Blocking diode
A125
A125
X29**
X837**
X839**
X952**
X957**
X958**
X963**
X974-4**
X1028
X1029

Right console, rear

Right console
Right console, rear
Right console, rear
Right console, rear
Y385-1
Y385-2

Behind cab
Behind cab
15.0 A
15.0 A


16.64.12
copyright by
MJF C I F S S
Service Manual

Electrical system
copyright by
MJF C I F S S
16.64.13
Service Manual
Electrical system
16.64.14
copyright by
MJF C I F S S
Service Manual
Dozer blade
Function
Dozer blade
1 Function
Machines with 2-point or 4-point support can be equipped with an optional dozer blade.
This blade is designed only for the purpose of grading work and may not be used as a support device.
It can only be attached at the front, if no support or outrigger is mounted at that position.
Lowering the dozer blade does not improve the stability of the machine, and does therefore not increase its load capacity.
Fig. 1
4-point outrigger support with dozer blade at the undercarriage
copyright by
MJF C I F S S
16.66.1
Dozer blade
Service Manual
Technical data
2 Technical data
Machine
A 312 - A 316 Li
Adjusting pressure at the

pressure-relief valve 304
Tab. 1
240 5 bar
Adjusting pressure for the dozer blade cylinder
3 Design
The dozer blade equipped with these devices (cylinder, beam, etc.) is designed exclusively for grading work. The pressure at the piston side in the cylinder is limited by the additional pressure-relief
valve 304.
To actuate the dozer blade, the hydraulic cylinder 395 is pressurised through the oil circuit of the support cylinder.
The support cylinder is switched over from working movement to dozer blade operation by means of
the 6-way solenoid valve Y56 in the undercarriage.
The hydraulically releasable check valve 302 is installed in the hydraulic circuit at the rod side. It secures the dozer blade against inadvertent lowering if there is a leakage.
4 Description of functions, Fig. 9 and Fig. 10

4.1
Outrigger support
When the pilot control unit 85 (Fig. 2) is moved forward or back, the spool / support is pressurised
with control oil.
The hydraulic oil flows from the pump through the control block 100 the connection A1, the rotary
connection 320 and the solenoid valve Y56 connection A2 - B2 or A1 - B1 to the double lowering
brake valves 297 and the support cylinders 295. Depending on whether the oil reaches the rod or the
piston side of the cylinder, the outrigger support is retracted or extended.
4.2
Working movement of the dozer blade

By actuating the additional switch S335 located in the right control console, the solenoid valve Y56
is powered and the support cylinder 295 changes over from working movement to dozer blade 395.
4.2.1

When the pilot control unit 85 (Fig. 2) is pushed forward, oil flows from the control block 100 connection A1 through the rotary connection 320 to the solenoid valve Y56 connection A1 - C1. From connection C1, the oil flows through the hydraulically releasable check valve 302 connection V1 - C1 to
the piston side of the dozer blade cylinder 395.
High pressure is built up, opening the hydraulically releasable check valve 302.
The cylinder 395 is extended and pushes the dozer blade down. The return oil from the rod side flows
through the open check valve 302 connection C2 - V2, the solenoid valve Y56 connection C2 - A2,
the rotary connection 320 and the control block 100 connection B1 back to the tank.
16.66.2
copyright by
MJF C I F S S
Service Manual
Dozer blade
Operation of dozer blade
4.2.2

When the pilot control unit 85 (Fig. 2) is pushed back, oil flows from the control block 100 connection
B1 through the rotary connection 320 to the solenoid valve Y56 connection A2 - C2. From connection
C1, the oil flows through the hydraulically releasable check valve 302 connection V2 - C2 to the rod
side of the dozer blade cylinder 395.
The cylinder 395 is retracted and lifts the dozer blade up. The return oil from the piston side flows
through the check valve 302 connection C1 - V1, the solenoid valve Y56 connection C1 - A1, the rotary connection 320 and the control block 100 connection A1 back to the tank.
5 Operation of dozer blade

Select the dozer blade by means of switch S335.
The indicator light in the switch is on.
Push the pilot control unit 85 forward (a):
the dozer blade is lowered
Push the pilot control unit 85 back (b):
the dozer blade is lifted
Fig. 2
Pilot control unit and switch for the dozer blade located in the right control console
Lowering dozer blade
85
Lifting dozer blade
S335 Switch / dozer blade
copyright by
MJF C I F S S
16.66.3
Dozer blade
Service Manual
Operation of dozer blade
Fig. 3
16.66.4
Hydraulic unit / dozer blade
302
Hydraulically releasable check valve
325
304
395
Dozer blade cylinder
320
Y56
Solenoid valve 6x
copyright by
MJF C I F S S
Service Manual
Dozer blade
Exploded view / sectional drawing of Y56
6 Exploded view / sectional drawing of Y56
Fig. 4
Exploded view of solenoid valve Y56
Fig. 5
Sectional drawing of solenoid valve Y56
1
2
3
Way valve 6x
10
Pressure reducing valve (switching pressure 11
reduction)
Way valve / magnet
12
Allen head screw
A1/A2 Connection / control valve block
Allen head screw
B1/B2 Connection / support cylinder
Allen head screw
C1/C2 Connection / dozer blade cylinder
copyright by
MJF C I F S S
Lock washer
Lock washer
O-ring
16.66.5
Dozer blade
Service Manual
Testing of pressure-relief valve 304
7 Testing of pressure-relief valve 304

Danger!
To adjust the pressure-relief valve, it is necessary to access the undercarriage of the machine. There is a risk of death to the technician, as he could be crushed under the machine.
Access the danger area only when the machine is shut down and properly secured in its position.
Always refer to the safety instructions in group 1.10.
Fig. 6
Pressure-relief valve and measuring point at the control block
41
Measuring point
100
A1/B1 from control valve block
304
Remove the cap from the measuring point 41 at the control block 100 and connect the pressure
sensor.
Carefully fully extend the dozer blade (lower it to firm ground).
Read the pressure at the measuring point 41.
Caution!
The pressure at the piston side in the cylinder 395 is limited by the pressure-relief valve 304.
Excessive pressure applied for the extending of the cylinder 395 can lead to damage to the blade
and the undercarriage.
The indicated pressure may not exceed the prescribed limit pressure, see Tab. 1.
If required, adjust the valve 304 to the correct pressure.
Remove the protective cap 21.
Loosen the lock nut and adjust the settings by turning the adjusting screw 19.
Turn adjusting screw 19 out.
Pressure is reduced
Turn adjusting screw 19 in.
Pressure is increased
After adjustment, secure the adjusting screw with the lock nut.
16.66.6
copyright by
MJF C I F S S
Service Manual
Dozer blade
Sectional drawing of hydraulically releasable check valve 302
Fig. 7
Sectional drawing of pressure-relief valve
19
Adjusting screw
21
Protective cover
304
8 Sectional drawing of hydraulically releasable check valve 302
Fig. 8
Sectional drawing of check valve
Housing
Screw plug
Valve insert
Pressure spring
Control piston
Seal ring
4
6
Pushrod
Valve cone
999
Seal kit
copyright by
MJF C I F S S
16.66.7
Dozer blade
Service Manual
Hydraulic diagram
9 Hydraulic diagram
9.1
at 2-point undercarriage, model A 316
Fig. 9
16.66.8
Hydraulic diagram of dozer blade with 2-point support
100
from compact control block
320
295
Support cylinder / outriggers
325
297
395
Dozer blade cylinder
302
S335 Switch / changeover blade - outrigger
304
Y56
copyright by
MJF C I F S S
Solenoid valve 6x
Service Manual
Dozer blade
Hydraulic diagram
9.2
at 4-point undercarriage, model A 316
Fig. 10
Hydraulic diagram of dozer blade with 4-point support
100
295
from compact control block

Support cylinder / outriggers
320
325
297
302
Double stop valve

395 Dozer blade cylinder

S335 Switch / changeover blade - outrigger
304
Y56
copyright by
MJF C I F S S
Solenoid valve 6x
16.66.9
Dozer blade
Service Manual
Electrical system
10
Electrical system
Fig. 11
F337
16.66.10
Electrical system in upper and undercarriage

Fuse (15 A)
X771
S272
Junction box
X957
S335
Switch / dozer blade - outrigger
X958
X301
X963
X304
Y56
Solenoid valve 6x
copyright by
MJF C I F S S
Service Manual
Dozer blade
Electrical diagram
11 Electrical diagram
Fig. 12
Electrical diagram of switchover system blade - outrigger, see basic diagram step 35
copyright by
MJF C I F S S
16.66.11
Dozer blade
Service Manual
Electrical diagram
16.66.12
copyright by
MJF C I F S S
Service Manual

Function

1 Function
The hydraulic operator's cab elevation kit has been developed specifically for machines that are used
mainly in industrial operations such as timber, bulk and scrap movement and loading.
The operator can adjust the elevation above ground of the cab, in order to have the best possible
view during operation (eye level more than 4.5 m above ground).
Danger!
When working on the elevated cab, operators and technicians are exposed to a high risk of injury.
When the cab is elevated, the machine may only be used on level ground free of obstacles, so that
the stability of the machine is not in any way compromised.
Lift or lower the cab only when the machine is standing still.
Ensure that no persons are standing in the operating range of the cab elevation system.
Fig. 1
Hydraulic operator's cab elevation
copyright by
MJF C I F S S
16.70.1
Service Manual
Technical data
2 Technical data
Machine:
Type:
Serial number:
A 316 Litronic Industry

716
2001
Volumetric flow rates

at rated speed (1800 rpm) of the diesel engine
270 l/min
Flow volume / spool connection A

Flow volume / spool connection B
Setting value Y (bottom)
Setting value Y (top)
14 l/min
32 l/min
16 mm
17 mm
Setting values of the valves

Secondary pressure-relief valve 601
for working pressure of cab elevation system
These valves act as primary valves (measuring point 41).
100+10 bar
Secondary pressure-relief valve 602

for working pressure of cab elevation system
These valves act as primary valves (measuring point 41).
150+10 bar
Tab. 1
Technical data
Caution!
An incorrectly set proximity switch of the stick shut-down can lead to injury to the operator and damage to the operator's cab.
Adjust the proximity switch of the stick cylinder shut-down so that the stick with grapple cannot
damage the cab when the latter is at its maximum height, the boom is fully extended and the cab
lift frame is adjusted horizontally.
Prior to commissioning of the hydraulic cab elevation system, read the operating manual and the
safety instructions for group 1.10.
The cab elevation system should only be operated when the diesel engine is running at its nominal
speed.
16.70.2
copyright by
MJF C I F S S
Service Manual

Design
3 Design
Fig. 2 - 4
The hydraulic operator's cab elevation consists of the following main components:
Cab lift frame 70 - 78
Pilot control unit of cab elevation system 90
Additional control block 600
Cylinder for cab elevation 615
Restrictor check valve / pipe fracture safety valve 619
Hydraulic accumulator 620
Block ball valve of emergency lowering system in the operator's cab 621 (from serial no. 2001)
Block ball valve of emergency lowering system behind the operator's cab 622 (from serial no.
2001)
Load holding / lowering brake valve 623
Solenoid valve of emergency lowering system Y204 (from serial no. 12390)
Switch of emergency lowering system S78 (from serial no. 12390)
To lift / lower the operator's cab, the hydraulic cylinders 615 are pressurised, so that the cab is lifted
on the lift frame.
The oil flow required for this is produced by the variable-displacement pump 20 driven directly by the
diesel engine. The oil flow to the cylinders 615 is controlled with the pilot control unit 90 and the additional control block 600.
Other valves (pressure-relief valves 601 and 602, load holding / lowering brake valve 623) are designed to enhance the safety of the operator and the machine.
The restrictor check valves 619 built into the cylinders 615 prevent sudden lowering of the cab in the
event of a pipe break.
Fig. 2
Cab lift frame
70 Support
72 Beam
76 Left strut
78 Carrier
74 Right strut
copyright by
MJF C I F S S
16.70.3
Service Manual
Design
Fig. 3
16.70.4
Pilot control of hydraulic cab elevation system
Hydraulic tank
100
80
Pilot control valve left / stick
600
90
Pilot control unit of cab elevation system
623
Additional control block / operator's cab

adjustment
Load holding / lowering brake valve
copyright by
MJF C I F S S
Service Manual

Design
Fig. 4
Components of the hydraulic operator's cab elevation
20
619
Restrictor check valve / pipe fracture

safety valve
100
600

Additional control block
620
623
615
Cylinder
copyright by
MJF C I F S S
16.70.5
Service Manual
Design
Fig. 5
100
600
3.1
623

Control devices in operator's cab
Fig. 6
90
16.70.6
Installation position of the additional control block and the load holding / lowering brake
valve
Control devices in the left control console for the hydraulic cab elevation system
S78
copyright by
MJF C I F S S
Button for emergency lowering (from

serial no. 12390, see Fig. 9)
Service Manual

Design
Fig. 7
Installation position of the accumulator, restrictor check valves and cylinders in the support
615
Cylinder for cab elevation system
619

safety valve
620
copyright by
MJF C I F S S
16.70.7
Service Manual
4.1
Neutral position
The pilot control unit 90 is not actuated, and the spool 600 is in its neutral position. The variable-displacement pump 20 driven directly by the diesel engine takes up the hydraulic oil from the tank 1 and
is fed to the control block 100 in stand-by mode. In this operating state, the system pressure is set to
approx. 30 to 35 bar and acts on the spool 600.
4.2
Lifting operator's cab (extending cylinder 615)

If the pilot control unit 90 in the left console is pushed back, the spool in the additional control block
600 is switched through the line b03. Oil flows from the variable-displacement pump 20 over the control edge of the piston and pressurises the pressure balance. The pressure balance is switched, so
that the oil can flow through the spool, the line B03, the load holding / lowering brake valve 623 and
the restrictor check valve / pipe fracture safety valve 619 to the piston side of the cylinder 615. The
variable-displacement pump 20 is swivelled according to the oil requirements (actuation of the pilot
control unit). The return oil from the rod side flows through the line A03 of the control block 100 to the
hydraulic tank 1.
The operator's cab is lifted as long as the pilot control unit 90 is actuated, or until the maximum height
is reached.
4.3
Lowering operator's cab (retracting cylinder 615)

If the pilot control unit 90 in the left console is pushed forward, the spool in the additional control block
600 is switched through the line a03 and the load holding / lowering brake valve 623 is opened. Oil
flows over the control edge of the spool and pressurises the pressure balance. The pressure balance
is switched, so that the oil flows through the spool and the line A03, to the rod side of the cylinder
615. The variable-displacement pump 20 is swivelled according to the oil requirements (actuation of
the pilot control unit). The oil from the piston side flows through the orifice of the restrictor check valve
/ pipe break safety valve 619 through the open load holding / lowering brake valve 623, the line B03,
the spool and the control block 100 to the hydraulic tank 1.
The operator's cab is lowered as long as the pilot control unit 90 is actuated or until the lower limit
position is reached.
4.4
Emergency operation
In the event of a failure of the diesel engine or the control system of the adjustable operator's cab, it
can be lowered manually.
There are three methods of emergency lowering:
16.70.8
copyright by
MJF C I F S S
Service Manual

4.4.1
Emergency lowering system from serial no. 2001, see Fig. 8

In the event of a failure of the diesel engine or the hydraulic system, the operator's cab can be lowered
by means of the emergency lowering system (block ball valve 621 and 622). With the emergency lowering system, the operator's cab is lowered by operating the lever of the block ball valve 621 in the
bottom right corner or with the lever of the block ball valve 622 located at the rear of the lift frame
support. The piston side of the cylinder 615 is connected to the hydraulic tank 1, and the cab is lowered.
Fig. 8
Emergency lowering system from serial no. 2001
Hydraulic tank
621
Block ball valve of emergency lowering

system in operator's cab
88P
Distributor of control block
622

system at support
88T
Collecting pipe / tank
Caution!
When the block ball valve is opened, the cab can still be lifted, but will automatically be lowered
again. Such uncontrolled movement can cause injury to the operator or damage to the cab. To prevent this, complete the following steps:
After lowering the cab, always return the lever of the block ball valve 621 / 622 to its initial position.
copyright by
MJF C I F S S
16.70.9
Service Manual
4.4.2
Emergency lowering system from serial no. 12390, see Fig. 9

In the event of a failure of the diesel engine or the hydraulic system, the operator's cab can be lowered
by means of the emergency lowering system (button S78, solenoid valve Y204). The cab can be lowered by pressing the button S78 located in the left control console in the operator's cab. It can also
be lowered by a person standing beside the machine by actuating the emergency valve Y204 at the
support of the lift frame. Screw in the handle A of the emergency valve Y204 until the cab is fully lowered, see Fig. 9.
Fig. 9
Emergency lowering system from serial no. 12390
Hydraulic tank
S78
90
Y204 Solenoid valve / emergency lowering

system
Button / emergency lowering system
Caution!
When the block ball valve is opened, the cab can still be lifted, but will automatically be lowered
again. Such uncontrolled movements can cause injury to the operator or damage to the cab. To prevent this, complete the following steps:
After lowering the cab, return the handle A of the solenoid valve Y204 to its initial position.
16.70.10
copyright by
MJF C I F S S
Service Manual

Fig. 10
Y204
A
Installation position of the emergency valve at the support

system
Handle of mechanical emergency
lowering system
Connection from the cylinders 615
to hydraulic tank
copyright by
MJF C I F S S
16.70.11
Service Manual

Danger!
Repair work requires access to the danger area of the elevated cab. There is a risk of death to the
technician, as limbs could become crushed.
If at all possible, carry out all repair and maintenance work on the operator's cab, the lift frame
and the hydraulic system when the cab is lowered. If this is not possible, proceed as follows:
Secure the lift frame to prevent lowering of the cab, using suitable propping material and supports.
Please note that all works on the valves must be carried out by technicians who are authorised by
LIEBHERR.
The pressure adjustments must be made at operating temperature of the hydraulic oil and at the
rated speed.
5.1
Fig. 11
Installation of additional control block
41
Measuring point MP
600.2 Adjusting screw (size 6 Allen key)
100
601
Pressure-relief valve / lowering cab
602
Pressure-relief valve / lifting cab
600 Additional control block

600.1 Lock nut (WS 22)
16.70.12
copyright by
MJF C I F S S
Service Manual

5.2
5.2.1
Settings of additional control block 600

Adjustment of the stroke limitation of the spool
Remove the control lines at the bottom and top at connection a03 / b03 (SW 19) and seal them.
Loosen the lock nuts 600.1.
Turn in the adjusting screws 600.2 using an Allen key (size 6) until dimension Y is reached (upper
edge of lock nut / connection to upper edge of adjusting screw), (see Tab. 1 on page 2).
Re-tighten lock nuts 600.1.
Mount the control lines a03 / b03 at the top and bottom.
5.2.2
Testing and adjustment of the pressure-relief valves 601/602

Connect the pressure sensor/gauge (600 bar) to the measuring point 41.
Extend the cylinder 615 to the stop.
Check the pressure and if necessary adjust it as follows:
Remove the protective caps of the pressure-relief valves 602.
Release the lock nuts (WS 17) at the pressure-relief valves 602.
Extend the cylinder 615 to the stop.
Turn the adjusting screw with the Allen key (size 5) until the prescribed pressure is shown at the
pressure gauge / sensor, (see Tab. 1 on page2).
Adjust the pressure for the retraction of the cylinder 615 at the valve 601.
When the adjustment is completed, re-tighten the lock nuts.
Mount the protective caps.
Fig. 12
Sectional drawing of the additional control valve
600
601
600.1
Lock nut (WS 22)
602
600.2
Adjusting screw (size 6 Allen key)
604
Pressure balance
copyright by
MJF C I F S S
16.70.13
Service Manual
Hydraulic unit of the operator's cab elevation
6 Hydraulic unit of the operator's cab elevation
16.70.14
1
6
Hydraulic tank
to oil cooler
600
601

20
602
23
30
Regulating valve / pump

Gear pump / cooling
604
615
Pressure balance
Cylinder for cab elevation system
41
Measuring point / pump pressure
618
45
619

safety valve
50
80

620
Pilot control valve, left slewing gear / stick 621
88P
Distributor of control block
622
88T
90
Collecting pipe / tank

623
T16

Connection to hydraulic tank
100
S78
Button for emergency lowering system

(from serial no. 12390)
104
Y204 Solenoid valve of emergency lowering

system (from serial no. 12390)
copyright by
MJF C I F S S
system (in operator's cab from serial no.
2001)
system (at the rear of support, from serial
no. 2001)
Service Manual

Hydraulic unit of the operator's cab elevation
Fig. 13
Hydraulic diagram of cab elevation system
copyright by
MJF C I F S S
16.70.15
Service Manual
Electrical system of hydraulic operator's cab elevation system
7 Electrical system of hydraulic operator's cab elevation system
Fig. 14
A127
F344
16.70.16
Electrical system of the hydraulic operator's cab elevation system from serial no. 12390
Fuse emergency lowering system

KL 31 Earth connection terminal
S78
Emergency cab lowering system symbol
Y78
X9
Plug connection on board A127
copyright by
MJF C I F S S
Service Manual

Fig. 15
Electrical system of the hydraulic operator's cab elevation system from serial no. 12390
F344
Fuse emergency lowering system
S78
Y204

system

copyright by
MJF C I F S S
16.70.17
Service Manual
16.70.18
copyright by
MJF C I F S S
Service Manual
Speeder kit
Function of Speeder kit
Speeder kit
1 Function of Speeder kit
On request, the Liebherr models A 312 - 316 Litronic are available as Speeder models. These models
can travel at considerably higher travel speeds.
2 Design
2.1
170 Travel motor
Fig. 1
Travel motor
3.14 Threaded stud (A 314 / 316)

17
Threaded stud (A 312)
170
Travel motor
The minimum pivot angle is set by the threaded stud 17/3.14.

The angle is factory-set by the manufacturer and may not be changed.
The correct position of the threaded stud 17/3.14 in the housing can be determined by checking
dimension X,
see Fig. 1 and pages 7.26.2 and 7.27.2 / 7.27.3 (standard value).
copyright by
MJF C I F S S
16.74.1
Speeder kit
Service Manual
Design
2.2
Control block 100 with control axle 160 chassis
Fig. 2
100
160.2
Control block with control axle

160.1.2 Lock nut
Control valve block

Stroke limitation
In Speeder models, a machine-specific control block 100 is equipped with a control axle 160 that has
been designed specifically for higher travel speeds (for control block no., see type plate and group
7.60).
If there is a problem with the max. travel speed of the machine, the setting can be modified, if the
actual max. speed of the universal joint shaft (connection between - gearbox and axles) is not in line
with the value stated in the adjustment protocol (see group 6.
2.3
Adjustment of max. output speed / max. travel speed

Danger!
The inspection and testing of universal joint shaft speed require access to the undercarriage of the
machine. There is a risk of serious injury or even death to the technician, if the machine begins to
move.
Extend the supports.
Place the attachment on the ground and lift the undercarriage from the ground, if necessary.
Note!
The maximum flow volume is factory-set by the stroke limitation of the spool 160
(dimension Y, see also adjustment protocol in group 6 and the control block in group 7.60) and
may not be changed.
In the event of an exceptional case where correction is required, proceed as follows:
Jack up the vehicle and run it in on-road gear (pilot control unit at full throttle).
16.74.2
copyright by
MJF C I F S S
Service Manual
Speeder kit
Design
Measure the maximum speed of a joint shaft with a HT 460 speedometer (tool group 2.01) and
compare with the prescribed speed, see adjustment protocol or pages 7.26.2 / 7.27.2 / 7.27.3.
At fully actuated pilot control unit, remove the cap nut of the chassis control axle 160 of the control
valve block 100.
Reduce the universal joint shaft speed.
Turn the adjusting screw .1 in.
The speed is reduced.
Increase the universal joint shaft speed.
Turn adjusting screw .1 out.
The speed is increased.
Note!
If the speed does not increase despite turning in the adjusting screw 1, the spool is not fully actuated.
Check the prescribed pilot control pressure at the control caps of the control axle 160 and eliminate the error, if required (e.g. restrictor check valve defective).
Repeat the adjustment on the other side of the spool 160 (forward and reverse travel).
After adjustment of the correct speed, secure the adjusting screws 160.1/160.2 with the lock
nuts .2 (hold adjusting screw .1 firm).
Replace the cap nuts.
Fig. 3
160.1 Stroke limitation
.1
Adjusting screw
160.2 Stroke limitation
.2
Lock nut
copyright by
MJF C I F S S
16.74.3
Speeder kit
Service Manual
Design
16.74.4
copyright by
MJF C I F S S
Service Manual

Function

1 Function
The generator drive accessory kit includes all main components required for the operation of a magnet system.
Magnet systems are used in conjunction with the conventional load lifting magnet tool to take up, load
and sort ferromagnetic parts, i.e. all iron parts up to a certain alloy content.
The A 316 industrial mobile excavator thereby serves as a support and energy supply unit. The generator is driven hydraulically. The hydraulic energy of a gear pump drives the oil motor, which in turn
propels the AC generator. The electrical energy is used to generate a magnetic field at the load lifting
magnet.
The necessary components are added to the installed accessory kit by LIEBHERR, your dealer or
the supplier of the generator unit.
Fig. 1
400
A 316 machine with generator and load lifting magnet

Generator with hydraulic drive unit
402
copyright by
MJF C I F S S
Load lifting magnet
16.86.1
Service Manual
Technical data
2 Technical data
Description
Generator
10 kW
from serial no.
2001
Generator
10 kW
from serial no.
18429
1841
2008
28
28
l/min.
51,5
56,2
min-1
3000 + 50
3150 + 50
16
16
7 - 15
7 - 15
bar
bar
15
190
15
190+5
bar
35
Gear pump 36:

Drive speed
rpm
3
Volumetric delivery
cm
Flow rate
Axial piston - fixed-displacement motor 430:
Output speed
Flow consumption
cm
Pressure balance 413:

-p
Solenoid pressure relief valve Y295:
Minimum pressure
Maximum pressure
Restrictor check valve 417:
Back pressure
Tab. 1
Data of the components
3 Design and function of the generator drive system

3.1
3.1.1
Arrangement of the units to serial no. 18428 (old model)

Gear pump 36, (see Fig. 3, page 4)
The gear pump 36 is driven directly by the diesel engine and feeds hydraulic oil to the connection A
of the pressure relief valve 411 and through the connection A-A of the solenoid valve 410 to the oil
motor 430.
3.1.2
Generator 400 and oil motor 430, (see Fig. 3, page 4)

The generator 400 and the oil motor 430 are mounted on the bearing block 408 in the uppercarriage.
This block is located behind the operator's cab or the lift frame respectively (in models with elevated
operator's cab).
The axial piston oil motor 430 propels the generator 400 via a flexible coupling.
3.1.3
Pressure balance 413

The pressure balance 413 is used to control the flow rate to the oil motor 430. The pressure balance
413 is screwed into the housing body 410.
The fixed orifice (gauge orifice) 415 generates a pressure difference ( -p), which can be controlled
by means of the pressure balance 413 . The volume flow from the pump 36 to the oil motor 430 is
proportional to the adjusted value -p. The drive speed resulting from the actual volume flow to the
oil motor 430 is relevant for the adjustment of the -p value, (see Tab. 1, page 2).
16.86.2
copyright by
MJF C I F S S
Service Manual

Design and function of the generator drive system
3.1.4
Solenoid pressure relief valve Y295

The solenoid pressure relief valve Y295 is used as a 2-stage pressure relief valve for the regulation
of the working pressure at the oil motor 430. The valve Y295 is screwed into the housing body 411.
If the valve Y295 is activated (powered) by means of the switch S46 , the solenoid Y295 switches the
piston to the higher pressure level (maximum pressure, see Tab. 1). The pump flow volume is fed to
the oil motor at the set working pressure.
If the valve Y295 is deactivated by means of the switch S46 (power off), the solenoid Y295 switches
the piston in the valve to the lower pressure level (minimum pressure, see Tab. 1). As a result, the oil
from the gear pump 36 flows through the valve Y295 and the housing 411 / control valve block 420
to the tank 1.
3.1.5
Check valve 416 and restrictor check valve 417

The check valve 416 allows for the take-up of oil and prevents cavitation in the oil motor during the
afterrun of the generator 400 when the generator drive is switched off 430.
417
Fig. 2
, (see Tab. 1, page 2)
Pump, pressure balance, pressure relief valve and oil motor of the generator drive system
36
Gear pump
417
400
Generator
418
Measuring point / working pressure
408
413
Bearing block
Pressure balance
419
430
Measuring point / return pressure

Axial piston - oil motor
416
Check valve
Y295
Solenoid pressure relief valve
copyright by
MJF C I F S S
16.86.3
Service Manual
3.2
3.2.1
Arrangement of the units from serial no. 18429 (new model)

Gear pump 36, generator 400 and oil motor 430.
The gear pump 36 is driven directly by the diesel engine and feeds hydraulic oil to the connection P
- A in the control block 420 to the oil motor 430.
The design and functions of the components 400 and 430 correspond to those described above, see
3.1.2.
3.2.2
Control valve block 420

The control block 420 installed between the pump 36 and the oil motor 430 includes a pressure balance 413 and the solenoid pressure relief valve Y295.
The design and functions of the components 413 and Y295 correspond to those described above,
see 3.1.3.
.
Fig. 3
16.86.4
Pump, control block and oil motor of the generator drive system
36
Gear pump
418
400
408
Generator
Bearing block
420
430
Control valve block

Oil motor
413
Pressure balance
Y294
copyright by
MJF C I F S S
Service Manual

3.3
Switch S46 magnet system (for both versions)

The generator drive and the magnet system are switched on and off with the switch S46 located in
the right front control console.
When then generator drive is switched off, the solenoid pressure relief valve Y295 is set to the lower
pressure level (minimum pressure,see Tab. 1). After the magnet system is switched on, the device is
automatically switched as follows:
The motor speed is increased to minimum level 8.
The sensor control / idle automatic is disabled.
The solenoid pressure relief valve Y295 is set to the higher pressure level (maximum pressure,see
Tab. 1).
3.4
S6L push button of magnet system (for both versions)

The load lifting magnet is activated and deactivated with the left push button S6L in the right joystick.
Press the push button S6L.
The magnet is activated.
Press the push button S6L again.
The magnet is deactivated.
Fig. 4
S6L
3.5
Switches and push buttons of the magnet system
S46
Push button of magnet
Switch to activate magnet system
Switch S457 (in special customised models only)

At the request of the customer, the magnet system can be controlled by means of the rocker switch
S457 in the left joystick. The switch S382 in the left joystick is included as standard in the right control
condole and is used for fine adjustment, (see Fig. 5, page 6)
The load lifting magnet is activated and deactivated with the rocker switch S457 in the left joystick.
Press the rocker switch S457 up.
The magnet is activated.
Press the rocker switch S457 down.
copyright by
MJF C I F S S
16.86.5
Service Manual
The magnet is deactivated.
Fig. 5
S46
S382
Switches, rocker switch/load lifting magnet and switch/fine control in special version
S457
Magnet system switch

Fine control switch
Magnet system rocker switch
4 Setting instructions
The following instructions apply to both versions of the control!
Note!
Before checking and adjusting the pressure and the input speed of the oil motor / generator drive,
ensure that the unit has reached an operating temperature of at least 50C.
For operating pressures, flow rates and speed, see section "2. Technical data".
4.1
Adjustment of solenoid pressure relief vale Y295, see Fig. 6

Write down the current position of the adjusting restrictor (sleeve) of the restrictor check valve 417.
Close the restrictor check valve 417 by turning in the adjusting restrictor (in old generator drive
model), see Fig. 6.
Disconnect the pressure line from the A to the oil motor 430, (see Fig. 11, page 13) and seal the
pressure line with a screw plug / plug (in new generator drive model).
Activate the generator drive by actuating the switch S46.
The system is set to pressure level II (high pressure level).
The current pressure is indicated at the measuring point 418.
If required, adjust the maximum pressure to the prescribed value, (see Tab. 1, page 2) by turning
the adjusting screw 5 at the pressure relief valve Y295:
Remove the cap nut 5 (WS 13).
Loosen the lock nut 7 (WS 13) at the pressure relief valve Y295.
Turn in the adjusting screw 6 (wrench size 7) = increase pressure; turn out the adjusting screw 6
16.86.6
copyright by
MJF C I F S S
Service Manual

= reduce pressure.
Note!
It is not necessary to adjust the minimum pressure.
Do not turn the Allen adjusting screw 6.
After the adjustment is completed, tighten the lock nut 7.
Adjustment of old generator drive system:
Open and readjust the restrictor check valve 417, see Fig. 2, see Tab. 1.
Adjustment of new generator drive system:
Deactivate the generator drive system.
Remove the screw / plug and the pressure line from the connection P to the oil motor 430.
Remove the pressure sensor / gauge.
Fig. 6
4.2
Pressure relief valve and measuring point for the adjustment of the pressure settings in
different installation models
Model with old generator drive system
Model with new generator drive system
Cap nut
417
6
7
Adjusting screw
Lock nut
418
430

Oil motor
400
Generator
Y295
Adjustment of the pressure balance 413

The volume flow from the pump 36 to the oil motor 430 is determined by the pressure balance 413.
The necessary drive speed of the generator results from the volume determined by the pressure balance (volume results from the cross-section of the fixed restrictor 415 and the adjustable spring of
the volume distributor) and the flow consumption 430.
The prescribed drive speed of the oil motor 430 = drive speed of the generator 400 can be adjusted
by measuring the speed at the coupling and turning the adjusting screw 2 at the pressure balance 413.
copyright by
MJF C I F S S
16.86.7
Service Manual
Caution!
The rotating coupling and generator shaft might cause serious injury to hands and fingers.
Before removing the guard 403 , switch off the generator drive system and take the necessary safety
measures by establishing visual or audible contact with the operator.
Deactivate the magnet system with the switch S46.
Remove the guard 403.
Apply reflecting strips to the rubber element of the coupling 404, see Fig. 7.
Measure the drive speed of the generator 400 using a suitable speed meter or LMS system.
If required, adjust the speed by means of the adjusting screw 2:
Turn in the screw 2 = increase drive speed; turn out the screw 2 = reduce drive speed.
After the adjustment is completed, tighten the lock nut 3.
Deactivate the generator drive by actuating the switch S46.
Fig. 7
4.3
Application of the measuring strip to the coupling 4 and adjusting screw at the pressure
balance 412
Model with old generator drive system
Model with new generator drive system
Adjusting screw
403
Guard
Lock nut
404
Coupling
400
Generator
413
Pressure balance
Adjustment of the restrictor check valve 417

The return back pressure of the oil from the oil motor 430 must be adjusted at the restrictor check
valve 417 as follows:
Write down the current position of the adjusting restrictor (sleeve) of the restrictor check valve 417.
16.86.8
copyright by
MJF C I F S S
Service Manual

Hydraulic unit of the generator drive system (old model)
Adjust the restrictor check valve 417 by turning the adjusting restrictor in such a way that the
prescribed back pressure is reached at the measuring point 419, (see Tab. 1, page 2).
Deactivate the generator drive by actuating the switch S46.
Remove the pressure sensor / gauge.
5 Hydraulic unit of the generator drive system (old model)
Fig. 8
Hydraulic connections of the generator drive (old model)
Hydraulic tank
416
Check valve
36
400
Gear pump
Generator
417
418

410
411
Housing body / pressure balance

Housing body / pressure-relief valve
419
430

413
Pressure balance
Y295
415
Restrictor
copyright by
MJF C I F S S
16.86.9
Service Manual
Hydraulic diagram of the generator drive system (old version)
6 Hydraulic diagram of the generator drive system (old version)

Item
see
group
Hydraulic tank
31
32
Gear pump / brake and pilot control

unit
36
400
Item
see
group
414
13.10
415
15.12
6.24/6.27
416
Check valve
Gear pump
417
Generator
418
410
Housing body / pressure balance
419
411
Housing body / pressure-relief

valve
430
413
Pressure balance
Y295 Solenoid pressure relief valve
16.86.10
copyright by
MJF C I F S S
Service Manual

Fig. 9
copyright by
MJF C I F S S
16.86.11
Service Manual
Sectional drawing of the control valve block 420 (new generator drive system)
7 Sectional drawing of the control valve block 420

(new generator drive system)
Fig. 10
16.86.12
Control block with pressure balance, solenoid pressure relief valve and restrictors
Adjusting screw (internal hex head 5

mm)
423
Check valve
Lock nut (WS 17)
424
Cap nut
425
413
Y295 Solenoid pressure-relief valve
420
copyright by
MJF C I F S S
Service Manual

Hydraulic unit of the generator drive system (new version)
8 Hydraulic unit of the generator drive system (new version)
Fig. 11
Hydraulic connections of the generator drive (new model)
1
36
Hydraulic tank
Gear pump
420
425
Control valve block

Minimess damping line (length 600 mm,
function-relevant)
400
Generator
430
433
Oil motor
Spacer*
413
418
Pressure balance
Measuring point
434
Y295
Pipe seal*
(only for installations without generator)
copyright by
MJF C I F S S
16.86.13
Service Manual
Hydraulic diagram of the generator drive system (new version)
9 Hydraulic diagram of the generator drive system (new version)

Item
see
group
Hydraulic tank
31
32
Gear pump / brake and pilot control

unit
36
400
Item
see
group
423
Check valve
13.10
424
15.12
425
Gear pump
430
Generator
433
Spacer*
413
Pressure balance
434
Pipe seal*
418
Measuring point
Y295 Solenoid valve
420

*
16.86.14
only for installations without generator
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MJF C I F S S
Service Manual

Fig. 12
copyright by
MJF C I F S S
16.86.15
Service Manual
Electrical system of the generator drive
10
Fig. 13
16.86.16
Different versions of the electrical system / generator drive
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MJF C I F S S
Service Manual

Fig. 14
Versions "load lifting magnet actuation in the left joystick"
S6R
Push button, not assigned
X90
Plug connection (heating), 2-pin
S6L
S46
Push button magnet system ON / OFF

Switch to activate magnet system
X217
X370

S382
Fine control switch
X958
S457
U7
Rocker switch magnet unit ON/OFF

Magnet unit switching unit

X1047 Plug connection (B19L), 3-pin
X15-2
X74
X1048-1Plug connection, 6-pin
X74-1
Y295
X80
Plug connection (B19L), 3-pin
Solenoid valve
Note!
For the electrical diagrams of the accessory kit, see group 8.45, sectional drawing 55.
copyright by
MJF C I F S S
16.86.17
Service Manual
16.86.18
copyright by
MJF C I F S S
Service Manual
SUBGROUP - INDEX
Section
Group
Type
Passfix bolts
18.15.1
A 309 LI 20221A 311 LI 20222-
18.1
MJF C I F S S
Service Manual
1.2
MJF C I F S S
Service Manual
Passfix bolts
Function
Passfix bolts
1 Function
Certain bearings of the attachments of the compact excavator models A 309 and A 311 are equipped
with Passfix bolts. They reduce wear at the bearing points.
Fig. 1
Passfix bolts A / B at the attachment
A General bearing points with Passfix bolts
B Main bearing points

Machine model A 309 from serial no. 20221
and model A 311 from serial no. 20222
with Passfix bolts.
Machine model A 309 from serial no. 27369
and model A 311 from serial no. 27373
with tab/locking nut bolts.
copyright by
MJF C I F S S
18.15.1
Passfix bolts
Service Manual
Design
2 Design
Fig. 2
Parts of the Passfix bolt
1
2
Bolt
Clamping bush
Clamping washer
4
5
Nordlock retaining washer

Clamping screw
The clamping bushes 2 are pressed with the clamping screws 1 and the clamping washers 3 onto the
cone-shaped bolt ends 1. The cone-shaped and slit clamping bushes 2 are thereby expanded and
thus pressed against the wall of the bearing bore. This effectively prevents play between the bearing
bore at the fixed bearing.
To ensure a long service life and best operation, the attachment and cylinder bearings must be properly installed, (see 4.2, page 4), and regularly inspected (check of tightening torque).
3 Maintenance
Check the clamping screws after approx. 50 operating hours after the first start-up of the attachment. Check the torque (400 Nm) and retighten, if necessary.
Subsequently, check the tightening torque every 500 operating hours.
18.15.2
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MJF C I F S S
Service Manual
Passfix bolts
Dismantling and mounting of Passfix bolts
4 Dismantling and mounting of Passfix bolts

4.1
Dismantling
Fig. 3
6
7
Removal tool and dismantling procedure A and B

8
Adapter
Removing tool
Removal screw
Remove the clamping screw 5, the retaining washer 4 and the clamping washer 3 at both sides.
Insert the removal tool 7 included in the machine toolbox (see also tool group 2.01) into the clamping bush 2 using the adapter 6, if necessary (depending on the size of the clamping bush 2).
Turn the removal screw 8 to the stop.
Tighten the removal screw 8 by holding the removal tool 7 with a suitable spanner so that the bolt
1 and the clamping bush 2 are tensioned (A).
Tap the head of the removal screw 8 with a hammer (B).
The clamping bush 2 should become loose.
If the clamping bush 2 is not loose, tighten the removal screw 8 further and tap it again with a hammer.
Repeat the procedure at the other side.
copyright by
MJF C I F S S
18.15.3
Passfix bolts
Service Manual
Dismantling and mounting of Passfix bolts
4.2
Mounting
Note!
For assembly, the bore near the clamping bush 2, the clamping bush and the conical surface of the
bolt 1 must be free of any grease or oil.
Fig. 4
Alignment of the Passfix bolts during mounting
1
2
Bolt
Clamping bush
4
5
Nordlock retaining washer

Clamping screw
Clamping washer
Bearing bore / fixed bearing
Insert the bolt 1 into the attachment and bearing and align it evenly.
Insert clamping bushes 2 at both sides.
The bolt must be centred.
If aligned correctly, there is a gap of 5 to 7 mm between the bush edge and the outer edge of
the bolt.
If the distance is < 5 mm or > 7 mm, the bolt is not correctly aligned and its position must be
adjusted.
Note!
Insert the clamping bush 2 in such a way that the slots in the bush are at the bottom (to prevent
corrosion).
Mount the clamping screw 5, the retaining washer 4 and the clamping washer 3.
Tighten the clamping screws 5 at both sides by hand. Ensure that the bolt 1 remains properly cantered.
The clamping bushes 2 must be tensioned.
Using a torque spanner, tighten the clamping screws 5 one after the other
(tightening torque 400 Nm).
18.15.4
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Service Manual
SUBGROUP - INDEX
Section
Group
Type
Tank arrangement
19.10.1
19.1
MJFCIFSS
Service Manual
1.2
MJFCIFSS
Service Manual
Tank arrangement
Function
Tank arrangement
1 Function
The hydraulic and fuel tanks are installed in the uppercarriage of the machine and serve as reserve
tanks for the fuel and the hydraulic oil.
The hydraulic and fuel tank are two separate components.
The fuel tank is mounted on the right side of the uppercarriage. For the design of the fuel tank, see
also Design of fuel tank", page 10.
The hydraulic tank is mounted on the left side of the uppercarriage. For the design and function of
the hydraulic tank, see also Design and function of the hydraulic tank", page 2.
The design and function of the return filter protection system integrated into the hydraulic tank are
described in chapter Hydraulic oil return filter 4", page 7.
Fig. 1
Tank arrangement
Fuel tank
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MJFCIFSS
Hydraulic tank
19.10.1
Tank arrangement
Service Manual
Design and function of the hydraulic tank
2 Design and function of the hydraulic tank

2.1
Hydraulic tank
See also Fig. 3, Fig. 4 and Fig. 5.
The hydraulic tank contains hydraulic oil used in the machine.
The separating and baffle plates inside the tank baffle the oil inside the tank when the excavator is
moving and separate the tank into different sections:
The suction room A, from where the baffled and foam-free oil is taken up by the hydraulic pumps
through the connection and the stop cock 3.
The return, collection and baffling section B, in which all return and leak oil is collected through
the connections T1 - T21, TL and TV.
(When a generator is attached, the respective oil pump sucks oil through the pipe E from the suction
room A)
The oil level in the tank is indicted by the two oil level gauges 50 (O/U or Maximum/Minimum). The
correct oil level is indicated when the excavator is in a horizontal position:
after all working cylinders have been retracted and the oil level does not exceed the upper limit
mark (O or Maximum) and
after all working cylinders have been extended and the oil level does not drop below the lower oil
level mark (U or Minimum).
Drain off condensate and oil (for oil change) through the two oil drain pieces C. Observe the prescribed intervals in the maintenance instructions. Dispose of the drained condensate (contaminated with
oil) and the spent oil according to the statutory requirements.
The large opening with lid D allows for proper access to the inside of the tank for cleaning purposes.
When adding or changing oil, always pour it through the return filter 4, which is accessible after the
lid has been opened 4.1, see Fig. 6.
The hydraulic tank is preloaded by the turbo charger of the diesel engine through the preload valve
45 ( 0.2 bar).
For repair work on the hydraulic pumps, the stop cock 3 mounted on the suction connection of the
tank can be closed, so that no oil from the tank can flow to the pumps.
The hydraulic tank is equipped with two screwed-in oil temperature sensors.
The hydraulic oil temperature sensor B8 is triggered when the oil temperature reaches 95 100 C and issues a negative signal to the indicator light H15, warning the driver.
Switch off the engine, identify the problem (radiator dirty?) and eliminate it.
High or low oil temperatures change the resistance value of the hydraulic oil temperature
sensor B285, which the issues a signal to the excavator control system U16 that controls the fan
of the engine and oil cooling system, see also assembly 8.70.
19.10.2
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MJFCIFSS
Service Manual
Tank arrangement
2.2
Breather filter 2
Fig. 2
Hydraulic tank with filter
Hydraulic tank, complete
Breather filter
Return filter, complete
The breather filter 2 mounted on the top of the hydraulic tank 1 protects the tank against overpressure or underpressure that might otherwise occur due to the constantly changing oil volume during
operation.
If a low pressure value of 0.03 bar is reached, air enters the system through the breather part of the
filter. Due to its spring preload, the breather part generates a tank lead pressure of 1.0 bar. If the tank
pressure rises above this value, the valve is opened to release the excessive air pressure.
The filter element has a mesh size of 7 m (for machines operated in dusty environments, use 2 m
filter element) and prevents that dirt enters the tank when it is bled.
The filter must be changed regularly, see maintenance schedule.
copyright by
MJFCIFSS
19.10.3
Tank arrangement
Service Manual
Fig. 3
19.10.4
Hydraulic tank, connections part 1
Breather filter
Suction pipe for generator drive
3
4
Stop cock
T4
T8
Return line from control valve block

Radiator return line
Check valve
T11
Suction chamber
T15
Return line / leak oil variable-displacement pump

Return line / control oil unit connection T
Return and collecting chamber
TL
Return line / control oil unit connection TL
Cleaning opening
TV
Return line / control oil unit connection TV
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MJFCIFSS
Service Manual
Tank arrangement
Fig. 4
Hydraulic tank, connections part 2
C
T1
Drainage and oil discharge piece

T9
Return line / pipe fracture safety valves of T10
boom cylinder
Return line / attachment kit AS1

Return line / solenoid valve - travel
T1'

stick cylinder
Return line / hydraulic hammer
T1''

reg. cylinder
Return line / leak oil variable-displaceT17
ment pump
Reserve
T2
T7
Return line / collecting pipe operator's

platform
Return line / speed adjustment
T3
Return line / leak oil rotary connection
T18
Return line / TC valve
T5
T6
Return line / brake system

Return line / steering system
T20
T21
Return line / HBGV block

Reserve
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MJFCIFSS
19.10.5
Tank arrangement
Service Manual
Fig. 5
19.10.6
copyright by
MJFCIFSS
Service Manual
Tank arrangement
2.3
85
Lid
1/45
1/46
Check valve (tank lead pressure)

Reducing piece
86
87
Seal
Washer
1/50
Hose from turbo charger
88
Hex head screw
2
2/36
Breather filter, complete

Seal ring
97
98
Reduction fitting
Drain valve
2/37
2/38
Adapter
Breather filter
99
100
Seal ring
Seal ring
Stop cock, complete
200
Air filter
3/100
Suction pipe
B7
3/101
Seal ring
B8
Transducer / hydraulic oil temperature
3/102
3/103
Hex head screw

Retaining washer
B285
E50
Oil temperature sensor / fan control

Power and fuse cabinet
Y3
4/41
Return filter, see Fig. 6
Y24
4/42
Retaining washer
Y50
4/43
Hex head screw
Y51
4/45
Fibreglass cartridge
Y62
Proportional solenoid valve / power control LR

Proportional solenoid valve / flow limitation LS
4/46
10
Protective cylinder
Mounting bolt / tank
Y63
Y358

speed
50
Oil level sight glass
Y371
Solenoid valve / oscillating axle support
51
Measuring coupling (for tank pressure

or LMS temperature measurement)
Hydraulic oil return filter 4

see Fig. 6
The hydraulic tank is equipped with a magnet return filter 4 that is easily accessible, see also Fig. 6.
To remove abrasion debris and dirt from the return oil of the attachments, it is fed through a two-stage
filter cartridge 4.20 (mesh size 20/5 m). For machines operated in dusty environments, use cartridges of mesh size 10 m.
The standard filter cartridge consists of 2 segments. The lower segment has a mesh size of 20 m,
while the upper segment has a mesh size of 5 m. The filter fleece is made of fibreglass and is folded
a sinusoidal shape. The fibreglass fleece is reinforced with a wire mesh. It is also supported by the
perforated sheet metal cylinder along its circumference that helps the filter withstand the high radial
forces that occur when large volumes of oil flow through it.
The return oil flows from the centre outwards through the fleece. Suspended particles and abrasion
debris is removed from the oil and collects in the filter fleece.
The magnetic rod 4.8 removes all suspended metal particles from the oil. These particles then collect
around the rod, held in place by magnetic force. The filter cartridge is protected by a bypass valve 5
in the receptacle 4.6. In the event of malfunction of the filter, which can occur if extremely cold oil is
fed through or if the filter is blocked by dirt (filter surface of approx. 17000 cm2 blocked by dirt particles), there is a risk of backpressure in the filter chamber. If this pressure exceeds the opening pressure of 3 bar (determined by the spring force of the pressure spring 5.1), the closing angle 5.2 is
shifted so that unfiltered oil escapes upwards through the protective cylinder 1.2 with bore to the suction section.
copyright by
MJFCIFSS
19.10.7
Tank arrangement
Service Manual
Maintenance
3 Maintenance
3.1
Maintenance tasks on hydraulic tank

See also maintenance instructions of group 3.
Note!
Modern standard maintenance procedures always include regular oil analyses in order to determine
whether the hydraulic oil must be changed. Check the oil with an oil analysis kit, see group 2.01,
and change it, if indicated. Otherwise, adhere to the prescribed oil change intervals in the maintenance instructions group 3..
For machines operated in extremely dusty environments, shorten the maintenance intervals.
Warning!
Risk of injury from pressurised hydraulic oil.
Before carrying out any maintenance or repair work on the hydraulic tank or the hydraulic system, shut down the diesel engine and carefully release the pressure from the hydraulic tank by
opening the breather filter 2.38.
The magnetic rod 4.5 must be cleaned regularly according to the maintenance schedule. In new excavators, clean the rod daily to remove metal abrasion particles.
Regularly change the filter cartridge 4.20, see maintenance instructions group 3. (Never reuse filter
cartridges).
To change the cartridge, remove the screws 4.43.
Remove the lid with handle 4.1 together with the receptacle 4.6.
Clean the magnetic rod 4.8 with a soft clean cloth.
To replace the filter cartridge 4.20, remove the old cartridge with the bracket and dispose of it according to the statutory regulations.
When inserting the new filter cartridge, ensure that the seal rings 4.21 and 4.22 are properly installed. Insert the filter cartridge 4.20 with the seal ring 4.21 in the tank connection (bottom end),
see sectional drawing Fig. 6.
Replace the lid with handle 4.1 and tighten the screws 4.43 (with the washers 4.42).
After completion of the maintenance or repair work, tighten the breather filter 2.38.
Start the diesel engine and test the hydraulic functions.
19.10.8
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MJFCIFSS
Service Manual
Tank arrangement
Maintenance
Fig. 6
1
1.1
Return filter
4.7
4.8

Tank connection
Roll pin
Magnetic rod
1.2
Protective cylinder
4.20 Fibreglass filter cartridge
4
4.1

Lid with handle
4.21 O-ring
4.22 O-ring
4.2
4.3
Flat gasket
Roll pin
4.42 Retaining washer

4.43 Hex head screw
4.4
4.5
Spacer tube
Rod
5
5.1
Check/bypass valve, complete

Pressure spring
4.6
Receptacle
5.2
Valve sleeve
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MJFCIFSS
19.10.9
Tank arrangement
Service Manual
Design of fuel tank
4 Design of fuel tank
3
1
Fig. 7
19.10.10
Design of fuel tank
Supply line to filter unit
40
Water drain valve
Fuel tank, complete
41
Seal ring
Return line from injection pump
46
Transducer fuel level (B1)
4
11
Internal lines
Mounting bolts
48
49
Hex head screw

Retaining washer
21
Tank lid
60
TC valve / slewing gear
22
Strainer
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MJFCIFSS
Service Manual
Tank arrangement
Design of fuel tank
4.1
Fuel tank
The fuel tank 2 is the fuel reservoir of the diesel engine.
The fuel is fed through a line in the tank, leading from the bottom of the tank upwards and then through the filter unit to the injection system of the engine. From the injection system, the fuel flows
through an internal line and down to the fuel tank.
To refuel the machine, open the tank lid 21 and add fuel through the strainer 22.
The fuel level in the tank 2 is monitored by a fuel level transducer 46 (B1) that sends and electric signal (resistance value) to the fuel level indicator P7 in the control panel of the operator's cab.
Condensate collecting in the tank must be drained off at prescribed intervals, see maintenance instructions group 3. This is done with the drain valve 40 located at the bottom of the tank.
If necessary, the tank can also be emptied that way, by removing the valve 40 and the seal cap 21.
4.2
Tubular-type sensor
The tubular-type sensor B1 consists of a vertical tube in which 7 magnetic floats are placed one on
top of the other. These floats are held at defined distances to each other and switch different reed
contacts that correspond to specified fuel levels.
Due to fuel in the tube and the physical properties of the currently switched contacts (parallel circuit
with resistors), switching points with different resistance values are achieved (see values in Fig. 8).
The resistance values thus vary, depending on whether the tank is full, half empty or empty, and the
respective level is indicated by the fuel level indicator P7 and converted into analog values in the display field.
copyright by
MJFCIFSS
19.10.11
Tank arrangement
Service Manual
Design of fuel tank
4.2.1
Tubular-type sensor for model A 309 / 311 to serial no. 31389,

Fig. 8
19.10.12
Switching points of tubular-type sensor
O-ring
3rd switching point (5/8 full; 29 Ohm)
Magnet
4th switching point (1/2 full; 35 Ohm)
Adjusting ring, secured with screw
4
5
1st switching point (full; 19 Ohm)

2nd switching point (3/4 full; 25 Ohm)
9
10

7th switching point (reserve; 70 Ohm)
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MJFCIFSS
Service Manual
Tank arrangement
Design of fuel tank
4.2.2
Tubular-type sensor for model A 309 / 311 from serial no. 31390, model A 312
from 31399
Fig. 9
1
2
O-ring
Magnet
7
8

10
11
copyright by
MJFCIFSS
19.10.13
Tank arrangement
Service Manual
Design of fuel tank
4.2.3
Tubular-type sensor for models A 314, A 316 and R 317 to serial no. 31402
Fig. 10
19.10.14
O-ring
2
3
Magnet
7
8

4
5

9
10

copyright by
MJFCIFSS
Service Manual
Tank arrangement
Design of fuel tank
4.2.4
Tubular-type sensor for models A 314, A 316 and R 317 from serial no. 31403
Fig. 11
1

7
O-ring
Magnet
10
11
copyright by
MJFCIFSS
19.10.15
Tank arrangement
Service Manual
Design of fuel tank
19.10.16
copyright by
MJFCIFSS
Service Manual
SUBGROUP - INDEX
Section
Group
Type
Heating / air-conditioning system
17.30.1
17.1
MJF C I F S S
Service Manual
1.2
MJF C I F S S
Service Manual
Technical data
Page
17.30.3
Design and function
Page
17.30.5
Cooling circuit diagram
Page
17.30.8
Heating/air-conditioning circuit
Page
17.30.9
Operation of air-conditioning system
Page 17.30.11
Page 17.30.14
Maintenance
Page 17.30.18
Fault diagnosis
17.30Page 17.30.27
copyright by
MJF C I F S S
17.30.1
Service Manual
Notes
1 Notes
17.30.2
copyright by
MJF C I F S S
Service Manual

Technical data
2 Technical data
Device
Series
A 309 - R 317
Litronic
Complete air-conditioning system

Manufacturer
Wlfle GmbH
Type
R134a/air
Rated voltage
24 V DC
Refrigerant
R134a
Coolant oil
PAG
Air conditioning unit:

Rated voltage
24 V
Max. air circulation rate
1050 m3/h (blower on)
Cooling performance
4,7 kW
Heating performance
9.0 kW
Blower steps
Max. current consumption
13.5 A
Compressor unit:
Rated voltage
24 V
Max. air circulation rate
1500 m3/h
Heating performance
10.5 kW
Blower steps
Max. current consumption
12 A
Compressor:
Type
Seltec TM - 15 HD
Rated voltage
24 V
Max. speed
6000 rpm
Flow rate
147 cm3
Direction of rotation
rotating clockwise or anticlockwise
Refrigerant
R134a
Oil
ZXL 100 PG (PAG oil)
Filling volume
150 cm3
Weight without oil
7 kg
Max. power consumption
48 W
Filter dryer:
Capacity
0.7 l
Filter effect
up to particle size >6 m
Water absorption in drying cartridge
16 g
Weight
1 kg
Leak test
35 bar
Bursting strength test
130 bar
Max. leak rate
5 g R134a/year
Refrigerant:
Type
R134a
Filling volume
1 000 g serial machine*

1 800 g operator's cab elevation*
The following parameters are crucial: ambient air temperature, operating pressure and filling level in sight glass.
copyright by
MJF C I F S S
17.30.3
Service Manual
Purpose
3 Purpose
The air-conditioning system is designed to help increase or reduce the temperature and air humidity
in the operator's cab. The adjustment must be made independently from the actual ambient conditions.
4 Mode of operation
Fig. 1
M74-1
Air-conditioning system, part 1
Refrigeration compressor
M74-1 Fan motor
Fluid tank
M74-2 Fan motor
4
6
Dryer insert
Sight glass
M74-3 Fan motor

Y20
Electromagnetic clutch
B294
Pressure switch
The compressor 1 compresses the gaseous R134a refrigerant. In this process, the refrigerant is heated while being liquefied before it flows through the condenser 2 (heat exchanger). The heat is extracted from the refrigerator flowing through the condenser 2 by the air flow from the cooler blower
M74-1/M74-2/M74-3.
The liquefied coolant flows into the liquid tank 3 and then through the dryer insert 4 and the sight
glass 6 to the expansion valve 7 (relief valve). The pressurised coolant is depressurised by means
of the expansion valve.
Due to the pressure drop, the refrigerant evaporates and extracts heat from the air in the operator's
cab through the fins of the evaporator 8. The fan M65 blows cold air through the outlets back into the
operator's cab. This results in a lower room temperature.
The unit is also used to heat the cab during cold weather. The turning knob S284 allows for the adjustment of the heating performance at 4 levels.
17.30.4
copyright by
MJF C I F S S
Service Manual

Design and function
Fig. 2
M74-1
Air-conditioning system, part 2
7
8
Expansion valve
Evaporator
M65
M72
Evaporator blower
Servo motor
14
Heat exchanger for heating
M74
Condenser blower

See also Fig. 3.
The air-conditioning system consists of 3 main components that are connected to each other with hoses:
The a/c compressor 1 with electromagnetic clutch Y20 is powered by the diesel engine through
V-belts and is located near the diesel engine / the fan side.
The high-pressure area of the unit is located near the roof behind the operator's cab and consists
of a condenser 2, liquid tank 3 with dryer insert 4, sight glass 6 and pressure switch B294, see
also figure on page 17.50-11 and Fig. 13. The fan motors M74-1, M74-1, M74-3 remove the heat
from the unit.
The low-pressure area of the unit is located inside the operator's cab, below the seat and consists
of a combined heating/air-conditioning unit. The combined heating/air-conditioning unit includes
the evaporator 8, the heat exchanger of the heating system 14 and the expansion valve 7. The
evaporator 8 and the heat exchanger of the heating system 14 (water) are combined in a battery
unit. The cooling water of the diesel engine is fed through hoses to the heat exchanger and forms
a separate circuit. The thermostat B295 protects the evaporator 8 against icing. If the thermostat
is triggered:
the magnetic clutch of the compressor 1 is switched off,
the condenser blower M74 is stopped and
the evaporator blower M65 remains on.
5.1
Cooling compressor 1
The cooling compressor 1 compresses the coolant in the circuit.
5.2
Condenser 2
In the air-filled fin condenser 2 the heat in the circuit is dissipated into the ambient air and the gase-
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MJF C I F S S
17.30.5
Service Manual
Design and function

ous refrigerant becomes liquid under pressure.
5.3
Liquid tank 3
The condenser 2 is located behind the liquid tank 3 where the liquid refrigerant is collected. This
ensures that only liquid refrigerant without air bubbles reaches the expansion valve 7.
5.4
Dryer insert 4
Due to its chemical properties, the R134a refrigerant can only absorb very little water.
At evaporation temperatures below 0C, any residual water is normally eliminated in the form of ice
at the valve, leading to unit failure.
High humidity in the system can also cause corrosion.
To prevent drying agent from entering the circuit, a number of sieves or filters are installed at the outlet end of the dryer 4. They remove contaminants such as acidic substances and dirt particles.
The design of the solid body insert allows for efficient multi-layer drying.
5.5
Sight glass 6
During operation, the liquid refrigerant must flow through the sight glass 6 in front of the expansion
valve 7 without any visible air bubbles.
5.6
Expansion valve 7
The expansion valve 7 acts as a thermostatic pressure-relief valve.
5.7
Evaporator 8
The evaporator 8 consists of an air-filled fan air cooling unit. The warm air is moved through the fins
of the evaporator 8, so that heat dissipates through the fins and pipe walls to the refrigerant. The refrigerant evaporates and thus becomes gaseous.
5.8
Safety devices
When the maximum pressure is reached at the high-pressure side, the pressure switch B294, see
electrical diagrams Fig. 15, Fig. 16 and Fig. 17, the cooling compressor 1 are switched off through
the electromagnetic clutch Y20. This feature is designed to prevent damage to the machine.
5.9
Lubricants
The lubricant in the compressor 1 reduces friction and wear. It also facilitates heat dissipation and
reduces leakage, noise and the transportation of abrasive particles.
Due to the rotary movement of the compressor 1, the oil used as a lubricant for the compressor is
transferred into the refrigerant circuit.
The oil in the refrigeration system should amount to approx. 10% of the refrigeration volume. To reach
this level, it might be necessary to add oil.
17.30.6
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MJF C I F S S
Service Manual

Design and function
5.10
Refrigerant
The system is filled with R134a. As the coolant circuit of the air-conditioning system is not completely
closed (reason: flexible connecting hoses from the compressor to the condenser and evaporator),
there might be a need to add refrigerant from time to time.
Within the circuit, the refrigerant constantly changes its physical state:
in the evaporator, it changes from liquid to gaseous,
in the condenser, it changes from gaseous to liquid.
The refrigerant must meet a number of requirements. It must for example have a small vapour volume
and a low condensation pressure.
5.11
Repair work
For repair work on components in the cooling circuit, the R134a refrigerant must be drained off into
a suitable container, see Evacuating system and leakage check", page 16. The refrigerant can be
cleaned and reconditioned by the refrigerant manufacturer. If you have access to an a/c service unit,
see also Fig. 9, you can recycle the refrigerant safely.
5.12
Leak test
Before carrying out a pressure and leak test, we recommend filling refrigerant vapour at a pressure of 1 bar and then to increase the pressure to the prescribed test pressure of 35 bar by adding
dry nitrogen. Please ensure that the nitrogen used to pressurise the system is fed to the system
through a reduction valve on the gas bottle.
A drop in pressure indicates that there is a leak.
There are various methods to locate the leak.
A simple method consists of applying foam to the pipelines and devices in question, or immersing
them in water. Alternatively, leaks can be detected with chemical or electrical methods.
Electronic leak detectors can find leaks of as little as 1 g/year.
copyright by
MJF C I F S S
17.30.7
Service Manual
Design and function
Fig. 3
17.30.8
Diagram of the cooling circuit of the air-conditioning system
1
2
A/c compressor
Condenser
9
Temperature sensor
B294 Pressure switch
Liquid tank
B295 Electr. thermostat
4
6
Dryer insert
Sight glass
M65 Blower motor

M74 Fan motor
7
8
Expansion valve
Evaporator
Y20
copyright by
MJF C I F S S
Magnetic clutch
Service Manual

Design and function
Fig. 4
Heating/air-conditioning circuit
13
Heating/ air-conditioning unit, complete
M65 Blower motor
14
19

Water valve
M71 Servo motor / water valve
copyright by
MJF C I F S S
17.30.9
Service Manual
Design and function
Fig. 5
17.30.10
A/c system circuit
A/c compressor
14
2
3
Condenser
Liquid tank
B294
B295
Pressure switch
Electr. thermostat
Dryer insert
M65
Blower motor
Sight glass
M74-1 Fan motor
Expansion valve
M74-2 Fan motor
Evaporator
M74-3 Fan motor
13
Heating/ air-conditioning unit
copyright by
MJF C I F S S
Service Manual

6 Operation of air-conditioning system

The air-conditioning system is designed for cooling, heating and fan operation.
The cooled or heated air flows through the outlets to the left and right behind the operator's seat and
through the openings below the seat and near the windscreen into the operator's cab.
Fig. 6
Air outlet
Fig. 7
Control elements of the air-conditioning system
S92
Rotary potentiometer for air distribution

control
S318
Air-conditioning switch
S93
Rotary potentiometer for heating/airconditioning control
S398
Switch for the assignment of the blower

motor (change of direction of air flow
from rear to front)
S284
Switch for blower level 1 4/

warm cold
copyright by
MJF C I F S S
17.30.11
Service Manual
Fig. 8
6.1
Control and actuating elements of the air-conditioning system
B295
Electr. thermostat with temperature sen- K405

sor
K402
K403
Relay for heating

Relay for heating
K404
Relay of condenser motors M74-1 to

M74-3
M71
M73
Relay for blower switch S284

Servo motor for the reversal of the air
distribution system
A/c operation
For air-conditioning operation, the supply of diesel engine coolant must be discontinued by closing
the water valve 19 by means of the rotary potentiometer S93 and the servo motor M71.
Start the diesel engine and then switch on the air-conditioning system with the switch S318, Fig. 7.
In order to prevent unnecessary heating up of the cold air through the windscreen, we recommend
closing the outlet at the control console.
Adjust the cold air temperature in the operator's cab with the rotary potentiometer S93 (thermostat
controller), Fig. 7.
The rotary potentiometer S92 and the servo motor M72 allow for the stepless adjustment of the a/c
air distribution in the cab.
6.2
Heating operation
The water flow through the heat exchanger 14 can be adjusted by means of the rotary
potentiometer S93, Fig. 7, and the servo motor M71.
Setting maximum heating output:
Turn the turning knob to the right stop.
Max. heat level
Switching off heating:
Turn the turning knob to the left stop.
No neat
17.30.12
copyright by
MJF C I F S S
Service Manual

The air-conditioning system can be used at any time in the year to dehumidify the air in the cab. It
can also be operated for that purpose together with the heating
The rotary potentiometer S92 and the servo motor M72 allow for the stepless adjustment of the heating air distribution in the cab.
6.3
Fan operation
Close the water supply with of the rotary potentiometer S93, Fig. 7.
The heated/air-conditioned air volume supplied to the cab can be adjusted by means of the rocker
switch S284 for the heater fan (4 speeds).
Actuate the reversing switch S398 to change the direction of rotation of the fan motor by means of
the servo motor M73 so the heated/conditioned air is supplied through the outlet at the windscreen
rather than through the outlets at the back of the operator's cab.
Note!
For care and maintenance instructions for the air-conditioning system and instruction on the handling of the refrigerant, see chapter Maintenance", page 18.
6.4
Air-conditioning system service device

This device has been designed for the evacuation, recycling (cleaning, drying) and collecting of refrigerant in suitable containers (see page 16).
Fig. 9
Air-conditioning system service device
Note!
For operating instructions, see the manual issued by the manufacturer.
copyright by
MJF C I F S S
17.30.13
Service Manual
7 Installation instructions
7.1
Compressor
New refrigeration compressors are filled with 150 cm3 of PAG-TL and nitrogen (N2).
To distribute the oil in the compressor, rotate it a number of times up and down before installing it.
Secure the compressor in such a way that the housing is not under stress.
Remove the plastic cover from the low-pressure side of the compressor and carefully release the
nitrogen!
Caution!
The special oil in the compressor might react with moisture contained in the air. When installing the
compressor, ensure that the individual components remain sealed for as long as possible! Ensure
that all components have the same temperature!
Do not let compressor oil escape from the unit!
7.2
Filter dryer
The filter dryer, which is also referred to as the collection dryer, consists of a collector, a dryer and a
filter unit as well as a sight glass. It is of compact design.
New dryers are clean, dry and sealed air-tight.
8 Handling of refrigerant
If the refrigeration circuit is opened, refrigerant escapes in liquid or gaseous form. The higher the
pressure in the system, the more refrigerant escapes.
Caution!
Refrigerant can cause serious injury to eyes and other parts of the body from frostbite!
Wear protective goggles!
Evaporating refrigerant can result in very low temperatures, which can cause localised frostbite!
Avoid skin contact with liquid refrigerant!
Refrigerants are good solvents for grease and oil. When in contact with the skin, they remove the
protective film, causing damage to the skin!
Wear suitable protective gloves!
Danger!
All refrigerants, with the exception of R11 and R113, displace oxygen in the atmosphere. Risk of
suffocation!
Handle refrigerants only in well-ventilated rooms!
R 134a is heavier than air.
Do not handle refrigerants when standing in a pit.
Refrigerants are flammable and can be set on fire by glowing cigarette ash. The substances released by combustion are toxic and must not be inhaled!
Do not smoke when handling refrigerants!
17.30.14
copyright by
MJF C I F S S
Service Manual

Handling of refrigerant
Warning! Misuse of refrigerant!

Refrigerants have a narcotic effect and displace oxygen. Therefore do not inhale refrigerant vapours!
Misuse of the substance can be fatal!
Refrigeration systems are under pressure!
The liquid or gaseous refrigerant in the refrigeration unit is under pressure. This fact must be taken
into consideration when carrying out repair work on the system.
Immediately seals any leaks on the refrigeration unit!
Leaks do not only reduce the output rate of the unit, but might also cause dangerously high concentrations of gaseous refrigerant in the air.
During filling and repair work, do not let refrigerant escape into the ambient air, but collect it
in a special recycling container!
If refrigerant escapes from the unit in a closed room, a high concentration of the substance in the air
might be built up, endangering the health and safety of people due to the narcotic effect of the substance. Before carrying out any repair work on refrigeration systems, collect the refrigerant in the recycling container where it can be safely stored. After completion of the repair work and reconditioning
of the refrigerant, it can be returned to the system. Alternatively, it can be returned to the supplier.
Handle refrigerants only in well-ventilated rooms!
To prevent the risk of high concentrations of refrigerant in a room, always ensure proper ventilation.
Under certain circumstances, it might not be sufficient to open doors and windows, and it might be
necessary to operate an extractor system that extracts the air near the point where the refrigerant
escapes or at floor level.
In the event of a sudden rise in refrigerant concentration in the air (e.g. after a pipeline rupture), immediately leave the room and only enter it after it has been properly ventilated!
All refrigerants, with the exception of R11 and R113 pose a special risk to the health and safety of
persons as they displace the oxygen in the air (risk of suffocation).
If there is a risk of high refrigerant concentrations in the air, use respiratory equipment with
separate oxygen supply!
Filter masks with A-type filters (for solvents) do not provide sufficient protection and may only be used
in rooms where the refrigerant concentration in the air does not exceed 0.5 vol. % (see respiratory
protection sheet). As refrigerant vapours are heavier than air, there is a particular risk of high concentrations in pits and shafts. If you are not sure whether there is dangerous amount of refrigerant in the
ambient air, use respiratory equipment with oxygen supply that is independent of the ambient air!
Welding and soldering work on the refrigeration unit must be carried out in well-ventilated
rooms!
When refrigerant is combusted in the flame of the soldering iron or the arc of the welding machine,
toxic substance are released that must not be inhaled!
Before carrying out any welding or soldering work on the refrigeration unit, drain the refrigerant from the respective section of the unit and remove all residue by blowing out the lines
and components with air or nitrogen!
The substances produced when refrigerant is exposed to heat are not only toxic but also highly corrosive, causing damage to pipelines and other unit parts. In the case of chlorinated refrigerants, the
decomposition products include hydrogen chloride, hydrogen fluoride and elementary chlorine. Under certain circumstances, highly toxic phosgene might be produced! When halogenated fluorocarbons are burnt, hydrogen fluoride might be produced.
copyright by
MJF C I F S S
17.30.15
Service Manual
An acrid smell indicates that the refrigerant is decomposing due to overheating.
Immediately leave the room, air it or wear a filter mask / respiratory filter B (acidic gases)!
Please note that the dangerous decomposition products listed above are already in the air when the
acrid smell occurs. Do not inhale these substances, as they can cause serious damage to the respiratory passages, the lung and other organs. The decomposition products are effectively removed by
a filter mask with respiratory filter B (acidic gases). Always observe the user instructions of the filter!
8.1
First aid
In the event of contact with eyes or mucous membranes, rinse the affected are with plenty of
water and consult an ophthalmologist.
In the event of contact with skin, remove all contaminated clothing and rinse the affected area
with plenty of water.
After inhalation of highly concentrated refrigerant vapours, remove the casualty to fresh air
and keep at rest. Consult doctor. In the event of respiratory difficulties, administer oxygen. In case
of respiratory arrest, resuscitate the casualty.
8.1.1
Instructions for doctor

The inhalation of refrigerant vapours can cause drowsiness or unconsciousness. Refrigerants sensitise the heart against the effect of catecholamine, thus prohibiting the administration of adrenaline
and similar substances. After inhalation of refrigerant decomposition products, there is an increased
risk of lung oedema even after a prolonged latency period.
Ensure that your refrigerant is suitable for the refrigeration unit you wish to operate. For this purpose,
carefully read the instruction signs on the various air-conditioning system components (compressor,
dryer housing, etc.). The filling valves, pressure gauge battery and vacuum pump may only be used
to add R134A/PAG (polyalkylene glycol oils) to air-conditioning systems. Refilling of refrigerant oil is
normally only necessary in units that contain more than 2 kg of refrigerant.
Caution!
Do not mix the above substances with other refrigerant or oils as this could damage the air-conditioning system.
Before connecting the quick-release couplings, ensure that the valves of the test pressure gauges
are fully closed (turn pressure gauge valves clockwise). The centre fitting connection for the vacuum
pump or filling bottle is thus closed.
10
Evacuating system and leakage check

Connect the filling hoses to the quick-release couplings.
Open both filling hoses.
Run the vacuum pump for approx. 30 minutes to remove the refrigerant from the system.
The pressure indicated at the blue pressure gauge (low-pressure gauge) is gradually reduced
to 1 bar.
Use a high-performance pump.
Close the pressure gauge valve and check whether the pressure changes.
If the pressure remains constant, there are no major leaks.
17.30.16
copyright by
MJF C I F S S
Service Manual

Filling of unit with refrigerant
Disconnect the pump and connect the refrigerant bottle. Open the bottle valve and the red pressure gauge valve (high-pressure side) so that a small amount of refrigerant (approx. 100 g) can
flow into the system (weigh the amount, if possible).
Check all connections for leakage, using a leak detector (suitable for R134a) or a leak detection
spray.
Fig. 10
1
Filling hoses and dryer container

2
Low-pressure line (blue)
High-pressure line (red)
11 Filling of unit with refrigerant

Note!
To fill the unit with refrigerant, use only bottles with one or two connections and a riser pipe.
11.1
Filling of liquid refrigerant when engine is off

Bottles equipped with one connection must be placed upside down for liquid filling.
To measure the filled amount of liquid, weigh the bottle before and after the filling process.
Close the pressure gauge valve and connect the refrigerant bottle (yellow hose).
Open the high-pressure valve (red).
Wait until the pressure indicated at the gauge is constant.
Close the red tap and place the bottle in an upright position.
Before switching on the system, close the high-pressure gauge valve (red).
copyright by
MJF C I F S S
17.30.17
Service Manual
Maintenance
11.2
Filling of gaseous refrigerant when engine is on

The filling process must be completed with the addition of gaseous refrigerant while the compressor is running.
The refrigerant must thereby be added in gaseous form through the open low-pressure gauge valve (blue).
During the filling process, continuously weigh the refrigerant bottle.
The filling process is completed when refrigerant flows through the sight glass of the dryer and
does not contain gas bubbles.
Close the low-pressure gauge valve (blue).
Check the unit for leakage and proper operation and disconnect the filling devices.
12 Maintenance
Important:
The air-conditioning system should be switched on at least once every 3 months in order to lubricate rotating parts and prevent seizing of the compressor.
The air-conditioning system must be serviced every year, preferably at the beginning of the hot
season, by a specialist workshop. All services must be recorded in line with our warranty policy.
The following maintenance tasks must be carried out at the beginning, middle and end of the cooling
period:
Check the V-belt tension and compressor fixture.
Check the refrigerant level in the system.
When the engine is on, the refrigerant must flow without air bubbles through the sight glass of the
liquid tank (dryer).
Fig. 11
1
Sight glass
2
Floating ball (white)
Indicator bead
The refrigerant level is OK, if the floating ball is visible at the top of the sight glass.
The refrigerant level is too low, if the floating ball is visible at the bottom of the sight glass.
In this case, contact the customer service or identify the cause and eliminate it. Subsequently add
refrigerant to the correct level.
After the engine has been switched off, the liquid level in the tank should drop slightly in order to prevent overfilling of the unit.
The indicator bead in the sight glass indicates the moisture content of the drying agent 4.
indicator bead: blue = agent is dry
The collector-dryer unit 3/4 is in proper working order.
indicator bead: pink = agent is moist
The collector-dryer unit must be replaced.
17.30.18
copyright by
MJF C I F S S
Service Manual

Cleaning of the compressor
The dryer tank should be replaced at each service, or at least every 2 years, as moisture in the agent
and the formation of acids can damage the air-conditioning system.
The dryer is installed in the compressor unit, see also Fig. 1.
13 Cleaning of the compressor

The fins of the compressor must be cleaned with great care and without undue pressure, as they
might otherwise be bent and damaged, preventing air flow through the compressor.
The annual inspection at your service workshop should be carried out at the beginning of the cooling
period and must be recorded in a service log.
copyright by
MJF C I F S S
17.30.19
Service Manual
Air condition components
14 Air condition components
Fig. 12
13
17.30.20
A/c compressor 1 with bracket and V-belt tensioning device
A/c compressor
B294
Pressure switch
Condenser
B295
Electr. thermostat
Liquid tank
K402
Relay for heating
4
6
Dryer insert
Sight glass
K403
K404
Relay for heating

Relay for motors M74
Evaporator
K405
Relay for blower
13
Heating/ air-conditioning unit
M65
Blower motor
14
B294

Pressure switch
M72
M73
Air distribution servo motor

Reversing servo motor
copyright by
MJF C I F S S
Service Manual

Fig. 13
13
2
3/4
Condenser with dryer, sight glass and pressure switch

6
B294
Condenser
Dryer
copyright by
MJF C I F S S
Sight glass
Pressure switch
17.30.21
Service Manual
Fig. 14
13
17.30.22
Units of the air-conditioning system
8
14
Evaporator
Heat exchanger
K404
K405
Relay for motors M74

Relay for blower
B295
K402
Thermostat
Relay for heating
M65
M72
Blower motor
K403
Relay for heating
M73
copyright by
MJF C I F S S
Service Manual

Electrical diagrams
15 Electrical diagrams
B294
B295
Pressure switch of a/c compressor

Thermostat of heating
F318**
F319**
Fuse (20 A) of heating/air-conditioning system terminal 30

Fuse (3 A) of heating/air-conditioning system terminal 15
F339**
Fuse (20 A) of condenser motors
K402
Relay for heating
K403**
Relay for heating
K404
Relay for condenser motors
K405
Relay for blower switch
M65**
M71**
Blower motor
Water valve servo motor
M72**
M703**

M74-1
Condenser fan motor
M74-2
M74-3
Condenser fan motor

Condenser fan motor
S92**
Air distribution potentiometer
S93**
S284**
Heating/air-conditioning potentiometer
Blower switch (4 speeds)
S318
Air-conditioning switch
S398**
Air distribution reversing switch
X842-1** Plug connection, 15-pin

X842-2** Plug connection, 2-pin
X859**
X860**
X861**
X862**
X863**

X864
X952**
X955**
X959**
X964**
Y20
Solenoid valve / a/c clutch
** in basic diagram
copyright by
MJF C I F S S
17.30.23
Service Manual
Electrical diagrams
Fig. 15
17.30.24
copyright by
MJF C I F S S
Service Manual

Electrical diagrams
Fig. 16
copyright by
MJF C I F S S
17.30.25
Service Manual
Electrical diagrams
Fig. 17
17.30.26
copyright by
MJF C I F S S
Service Manual

Troubleshooting
16 Troubleshooting
Fault
Cause
Remedy
A/c system
fails to cool
Faulty electrical connections
Check the connections of the magnetic clutch, switches, relays, temperature sensors and control unit.
Air temperature sensor

defective*
Replace.
Icing protection temperature transducer defective*
Replace B295 (electrical thermostat only).
Rotary potentiometer defective
Replace S93 (electrical thermostat only).
Relay defective
Replace K404.
Fuse defective
Replace F318/F319.
Compressor shut down after exceeding of max. operating pressure
Clean compressor. Carry out function test of condenser blower F339.
Filter dryer blocked*
Exchange filter dryer.
Excessive refrigerant in
the system*
Extract refrigerant.
Compressor shut down after pressure dropped below min. operating

pressure
Check system for leaks; add refrigerant, if necessary.
Compressor magnetic
clutch defective
Replace coil Y20.
V-belt broken
Replace V-belt.
Evaporator iced, check

electrical control unit*
Adjust icing protection limit temperature settings of

the thermostat (only with mechanical thermostat).
System cools
only for a
short time
Tab. 1
Troubleshooting
copyright by
MJF C I F S S
17.30.27
Service Manual
Troubleshooting
Fault
Cause
Remedy
Cooling effect insufficient
Insufficient air flow rate
Clean fins in front of the evaporator and condenser.
Insufficient refrigerant in
system*
Add refrigerant until it is visible without bubbles in the

sight glass.
Expansion valve blocked*
Clean or replace expansion valve.
Expansion valve iced

over, excessive moisture
in system*
Filter dryer moisture indicator red. Replace filter dryer.
Filter dryer partly blocked

(indicated by ice on the
dryer)*
Exchange filter dryer.
Air in refrigerant circuit at

increased pressure values, bubbles visible in
sight glass*
Evacuate and refill system.
Ball bearing of compressor worn*
Replace ball bearing.
Magnetic clutch defective*
Replace magnetic clutch Y20.
Insufficient oil in
compressor*
Refill oil.
V-belt worn
Replace V-belt.
V-belt loose
Tighten V-belt.
Loud noise
from
compressor
Whistling
noise from Vbelt
Tab. 1
*
17.30.28
Troubleshooting
The tasks marked with an asterisk must be carried out by a specialist refrigeration technician!
copyright by
MJF C I F S S

Liebherr A309li - 307li - SERVICE MANUAL

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Liebherr A309li - 307li - SERVICE MANUAL

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Service Manual

Tightening torques WN 4037

Tightening torques for screw connections

Assembly instruction for cylinder (WN 4121B)

Assembly instruction for cylinder (WN 4122B)

Fuels, lubricants and other consumables

Lubricant list TE-ML 05

Lubricant list TE-ML 07

Modified measuring connections

A 314 Li: 11820

Spool for slewing gear

A 316 Li: 11822

Spool for chassis

Modified pressure balance 244 for stick

A 314 Li: 12814

Additional control line from control valve block

Modified fan cycle

A 312 Li: 13289

Installation of coarse filter 15 in the pressure

A 314 Li: 13104

Various modifications to control valve

A 312 Li: 16275

A 316 Li: 13105

A 314 Li: 16215

Modified TC valve 125

Gear pump of steering system with integrated

Modified electrical system

New pilot control unit for travel working

A 312 Li: 20330

R 317 Li: 21205

The two individual pilot control units 2x are

Optimised control of control valve block

Optimisation of fine control

A 309 Li: 23503

A 309 Li: 27110

See also service information 07-11-37/2005

Speed reduction when working at 1950

A 309 Li: 27110

The solenoid valve Y330 at the control oil unit

Hydraulic slewing ring locking mechanism

Changeover to travel operation

A 309 Li: 26392

2 General Safety instructions

Crushing and burn prevention

3 Crushing and burn prevention

4 Fire and explosion prevention

5 Transporting the machine safely

Bringing the machine safely into service

6 Bringing the machine safely into service

7 Starting the machine safely

8 Shutting down the machine safely

9 Towing the machine safely

10 Working with the machine safely

Working with the machine safely

Safe application in material handling operation (especially when handling timber)

Safe application of machines with tower elevation

Additional notes for machines with fixed operators cab elevation

Working with the machine safely

Protection from vibrations

11 Safe installation and removal of attachment parts

Safe removal and installation of attachment pins

Safe maintenance of the machine

Safe maintenance of the machine